JLG H800AJ PVC 2001 Service & Maintenance Manual (31215043) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG H800AJ PVC 2001 Service & Maintenance Manual (31215043) – PDF DOWNLOAD
31215043_A_H800AJ_JLG Service English...................................................................................................................................................................................................................................................... 1
Section A. Introduction - Maintenance Safety Precautions............................................................................................................................................................................................................................... 3
A General.......................................................................................................................................................................................................................................................................... 3
B Hydraulic System Safety.......................................................................................................................................................................................................................................................... 3
C Maintenance...................................................................................................................................................................................................................................................................... 4
Table of Contents...................................................................................................................................................................................................................................................................... 7
List of Figures........................................................................................................................................................................................................................................................................ 15
List of Tables......................................................................................................................................................................................................................................................................... 22
Section 1. Specifications.............................................................................................................................................................................................................................................................. 25
1.1 Operating Specifications....................................................................................................................................................................................................................................................... 25
1.2 Tires.......................................................................................................................................................................................................................................................................... 25
1.3 Capacities..................................................................................................................................................................................................................................................................... 25
1.4 Engine Data.................................................................................................................................................................................................................................................................... 25
1.5 Hydraulic Oil.................................................................................................................................................................................................................................................................. 26
1.6 Critical Stability Weights..................................................................................................................................................................................................................................................... 27
1.7 Maintenance and Lubrication.................................................................................................................................................................................................................................................... 29
1. Swing Bearing - Internal Ball Bearing....................................................................................................................................................................................................................................... 29
2. Wheel Drive Hub............................................................................................................................................................................................................................................................. 29
3. Oil Change w/Filter......................................................................................................................................................................................................................................................... 29
4. Fuel Filter/Water Separator................................................................................................................................................................................................................................................. 30
5. Fuel Strainer............................................................................................................................................................................................................................................................... 30
6. Radiator.................................................................................................................................................................................................................................................................... 30
7. Swing Drive Hub............................................................................................................................................................................................................................................................. 30
8. Hydraulic Return Filter..................................................................................................................................................................................................................................................... 31
9. Hydraulic Charge Filter..................................................................................................................................................................................................................................................... 31
10. Hydraulic Tank............................................................................................................................................................................................................................................................. 31
11. Air Filter................................................................................................................................................................................................................................................................. 31
1.8 ThreadLocking Compound......................................................................................................................................................................................................................................................... 32
1.9 Torque Charts.................................................................................................................................................................................................................................................................. 33
SAE Fastener Torque Chart...................................................................................................................................................................................................................................................... 33
SAE Fastener Torque Chart (Continued).......................................................................................................................................................................................................................................... 34
SAE Fastener Torque Chart (Continued).......................................................................................................................................................................................................................................... 35
SAE Fastener Torque Chart (Continued).......................................................................................................................................................................................................................................... 36
SAE Fastener Torque Chart (Continued).......................................................................................................................................................................................................................................... 37
SAE Fastener Torque Chart (Continued).......................................................................................................................................................................................................................................... 38
Metric Fastener Torque Chart................................................................................................................................................................................................................................................... 39
Metric Fastener Torque Chart (Continued)....................................................................................................................................................................................................................................... 40
Metric Fastener Torque Chart (Continued)....................................................................................................................................................................................................................................... 41
Metric Fastener Torque Chart (Continued)....................................................................................................................................................................................................................................... 42
Section 2. General..................................................................................................................................................................................................................................................................... 43
2.1 Machine Preparation, Inspection, and Maintenance............................................................................................................................................................................................................................... 43
General........................................................................................................................................................................................................................................................................ 43
Preparation, Inspection, and Maintenance....................................................................................................................................................................................................................................... 43
Pre-Start Inspection........................................................................................................................................................................................................................................................... 43
Pre-Delivery Inspection and Frequent Inspection................................................................................................................................................................................................................................ 43
Annual Machine Inspection...................................................................................................................................................................................................................................................... 43
Preventive Maintenance......................................................................................................................................................................................................................................................... 43
2.2 Service and Guidelines......................................................................................................................................................................................................................................................... 44
General........................................................................................................................................................................................................................................................................ 44
The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.............................................................................................................................. 44
Safety and Workmanship......................................................................................................................................................................................................................................................... 44
Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in ................. 44
Cleanliness.................................................................................................................................................................................................................................................................... 44
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................. 44
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........................... 44
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................. 44
Components Removal and Installation............................................................................................................................................................................................................................................ 44
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........................................... 44
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......................................... 44
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........................................................................................................... 44
Component Disassembly and Reassembly........................................................................................................................................................................................................................................... 45
Pressure-Fit Parts............................................................................................................................................................................................................................................................. 45
When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface................................................................................................................................................ 45
Bearings....................................................................................................................................................................................................................................................................... 45
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....................................................................... 45
2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned...................................................................................................................................................................................... 45
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............................................................................................. 45
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....................................... 45
Gaskets........................................................................................................................................................................................................................................................................ 45
Bolt Usage and Torque Application.............................................................................................................................................................................................................................................. 45
1. 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 to engage and hold the part properly. When replacing bolts, use only t................. 45
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 Section 1.)........................................ 45
Hydraulic Lines and Electrical Wiring.......................................................................................................................................................................................................................................... 45
Hydraulic System............................................................................................................................................................................................................................................................... 45
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.................................................................................................................................... 45
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................................................................................................... 45
Lubrication.................................................................................................................................................................................................................................................................... 46
Battery........................................................................................................................................................................................................................................................................ 46
Lubrication and Servicing...................................................................................................................................................................................................................................................... 46
2.3 Lubrication and Information.................................................................................................................................................................................................................................................... 46
Hydraulic System............................................................................................................................................................................................................................................................... 46
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................. 46
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................. 46
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.............................................................. 46
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................. 46
Hydraulic Oil.................................................................................................................................................................................................................................................................. 46
1. Refer to Section 1 for recommendations for viscosity ranges............................................................................................................................................................................................................. 46
2. JLG recommends Standard UTTO fluid which has an SAE viscosity of 10W and a viscosity index of 140....................................................................................................................................................................... 46
Changing Hydraulic Oil......................................................................................................................................................................................................................................................... 46
1. Filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain t................. 46
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................. 46
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........................ 46
Lubrication Specifications..................................................................................................................................................................................................................................................... 46
Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regardin................. 46
2.4 Cylinder Drift................................................................................................................................................................................................................................................................. 47
Theory......................................................................................................................................................................................................................................................................... 47
When a hydraulic cylinder is supporting a load, cylinder drift may occur as a result of any of the circumstances below:.................................................................................................................................................... 47
The first two circumstances may result in cylinder movement due to oil leaking out of the cylinder externally or by leaking back to tank or due to oil leaking internally from one cylinder chamber to the other........................................................... 47
Thermal expansion or contraction of oil in hydraulic cylinders is a normal occurrence and does not result in oil leaking out of the cylinder or leaking internally from one cylinder chamber to the other. Thermal expansion or contraction is the tendenc................. 47
Cylinder Leakage Test.......................................................................................................................................................................................................................................................... 47
Cylinder oil must be at stabilized ambient temperature before beginning this test.......................................................................................................................................................................................... 47
Measure drift at cylinder rod with a calibrated dial indicator............................................................................................................................................................................................................. 47
In an area free of obstructions, cylinder must have load applied and appropriately positioned to detect drift.............................................................................................................................................................. 47
Cylinder leakage is acceptable if it passes this test...................................................................................................................................................................................................................... 47
Cylinder Thermal Drift......................................................................................................................................................................................................................................................... 47
2.5 Pins and Composite Bearing Repair Guidelines................................................................................................................................................................................................................................... 48
1. Pinned joints should be disassembled and inspected if the following occurs:................................................................................................................................................................................................. 48
a. Excessive sloppiness in joints.......................................................................................................................................................................................................................................... 48
b. Noise originating from the joint during operation....................................................................................................................................................................................................................... 48
2. Filament wound bearings should be replaced if any of the following is observed:............................................................................................................................................................................................. 48
a. Frayed or separated fibers on the liner surface......................................................................................................................................................................................................................... 48
b. Cracked or damaged liner backing........................................................................................................................................................................................................................................ 48
c. Bearings that have moved or spun in their housing....................................................................................................................................................................................................................... 48
d. Debris embedded in liner surface........................................................................................................................................................................................................................................ 48
3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):........................................................................................................................................................... 48
a. Detectable wear in the bearing area..................................................................................................................................................................................................................................... 48
b. Flaking, pealing, scoring, or scratches on the pin surface.............................................................................................................................................................................................................. 48
c. Rusting of the pin in the bearing area.................................................................................................................................................................................................................................. 48
4. Re-assembly of pinned joints using filament wound bearings.................................................................................................................................................................................................................. 48
a. Housing should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination............................................................................................................................................... 48
b. Bearing / pins should be cleaned with a solvent to remove all grease and oil filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins)......................................................................... 48
c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation and operation........................................................................................................................... 48
2.6 Welding on JLG Equipment....................................................................................................................................................................................................................................................... 48
Do the Following When Welding on JLG Equipment................................................................................................................................................................................................................................. 48
DO NOT Do the Following When Welding on JLG Equipment.......................................................................................................................................................................................................................... 48
Section 3. Chassis & Turntable......................................................................................................................................................................................................................................................... 55
3.1 Tires & Wheels................................................................................................................................................................................................................................................................. 55
Tire Damage.................................................................................................................................................................................................................................................................... 55
Tire Replacement............................................................................................................................................................................................................................................................... 55
Wheel Replacement.............................................................................................................................................................................................................................................................. 55
Wheel Installation............................................................................................................................................................................................................................................................. 55
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts............................................................................................................................................................................ 55
2. Tighten nuts in the following sequence:................................................................................................................................................................................................................................. 55
3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart............................................................................................................................................ 55
4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation...................................................................................................................... 56
3.2 Powertrain Operating Modes..................................................................................................................................................................................................................................................... 56
Hybrid Mode.................................................................................................................................................................................................................................................................... 56
Electric Mode.................................................................................................................................................................................................................................................................. 56
Switching Between Modes on the Fly............................................................................................................................................................................................................................................. 56
Idle Reduction Stop Start...................................................................................................................................................................................................................................................... 57
3.3 Drive Orientation System....................................................................................................................................................................................................................................................... 58
3.4 Oscillating Axle System........................................................................................................................................................................................................................................................ 58
3.5 Lockout Cylinder Bleeding...................................................................................................................................................................................................................................................... 59
1. Start the engine............................................................................................................................................................................................................................................................ 59
2. Position the turntable to the normal stowed position........................................................................................................................................................................................................................ 59
3. Attach clear tubing to bleeder valve nipple................................................................................................................................................................................................................................. 59
4. Position a small bucket/bottle in front of the lockout cylinder bleeder valve and insert clear tubing....................................................................................................................................................................... 59
5. Using a 3/8” wrench, loosen the bleeder valve, turning counterclockwise slowly. Bleed air from the top of lockout cylinder. Capture hydraulic oil until a steady unbroken stream of hydraulic oil is viewed. Tighten/close the bleeder valve while st....................... 59
6. Locate the bleeder valve on the opposite side lockout cylinder. Repeat the process.......................................................................................................................................................................................... 59
1. Oscillating Axle............................................................................................................................................................................................................................................................ 60
2. Fixed Axle.................................................................................................................................................................................................................................................................. 60
3. Axle Lockout Cylinder....................................................................................................................................................................................................................................................... 60
4. Keeper Pin.................................................................................................................................................................................................................................................................. 60
5. Axle Pivot Pin.............................................................................................................................................................................................................................................................. 60
6. Shim........................................................................................................................................................................................................................................................................ 60
7. Stop Plate.................................................................................................................................................................................................................................................................. 60
8. Washer...................................................................................................................................................................................................................................................................... 60
9. Bushing..................................................................................................................................................................................................................................................................... 60
10. Bolt....................................................................................................................................................................................................................................................................... 60
11. Shim....................................................................................................................................................................................................................................................................... 60
1. Drive Spindle............................................................................................................................................................................................................................................................... 61
2. Steer Cylinder.............................................................................................................................................................................................................................................................. 61
3. Tie Rod..................................................................................................................................................................................................................................................................... 61
4. Kingpin..................................................................................................................................................................................................................................................................... 61
5. Bolt........................................................................................................................................................................................................................................................................ 61
6. Thrust Washer............................................................................................................................................................................................................................................................... 61
7. Composite Bearing........................................................................................................................................................................................................................................................... 61
8. Thrust Washer............................................................................................................................................................................................................................................................... 61
9. Retaining Plate............................................................................................................................................................................................................................................................. 61
10. Keeper PIN................................................................................................................................................................................................................................................................. 61
11. Cylinder Pivot Pin......................................................................................................................................................................................................................................................... 61
12. Cylinder Pivot Pin......................................................................................................................................................................................................................................................... 61
3.6 Oscillating Axle Lockout Test.................................................................................................................................................................................................................................................. 62
1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left front wheel........................................................................................................................................................................................ 62
2. From platform control station, activate machine hydraulic system............................................................................................................................................................................................................ 62
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/ TORQUE SELECT control switches to their respective LOW positions.............................................................................................................................................................. 62
4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block....................................................................................................................................... 62
5. Carefully activate SWING control lever and position boom over right side of machine......................................................................................................................................................................................... 62
6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.......................................................................................................................................................... 62
7. Have an assistant check to see that left front wheel remains locked in position off of ground............................................................................................................................................................................... 62
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 ..................... 62
9. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel..................................................................................................................................................................................... 62
10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.............................................................................................................................................. 62
11. Carefully activate SWING control lever and position boom over left side of machine......................................................................................................................................................................................... 62
12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.......................................................................................................................................................... 62
13. Have an assistant check to see that right front wheel remains locked in position off of ground............................................................................................................................................................................. 62
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..................... 62
15. If lockout cylinders do not function properly, have trained personnel correct the malfunction prior to any further operation............................................................................................................................................... 62
1. Axle Lockout Cylinder....................................................................................................................................................................................................................................................... 63
2. Flow Drive Valve............................................................................................................................................................................................................................................................ 63
3. Swivel...................................................................................................................................................................................................................................................................... 63
4. Drive Motor................................................................................................................................................................................................................................................................. 63
5. Drive Hub................................................................................................................................................................................................................................................................... 63
3.7 Drive System................................................................................................................................................................................................................................................................... 64
3.8 Drive Hub (Torque)............................................................................................................................................................................................................................................................. 65
Removal........................................................................................................................................................................................................................................................................ 65
1. Place machine on the firm level surface................................................................................................................................................................................................................................. 65
2. Remove and cap all hydraulic hoses from the drive motor assembly........................................................................................................................................................................................................ 65
3. Disconnect the electrical connections from the drive motor assembly..................................................................................................................................................................................................... 65
4. Use suitable lifting device to support the drive hub assembly .......................................................................................................................................................................................................... 65
5. Remove bolts attached drive hub to the frame............................................................................................................................................................................................................................ 65
6. Remove the drive hub assembly from machine and place in a clean work area............................................................................................................................................................................................... 65
Installation................................................................................................................................................................................................................................................................... 65
1. Use suitable lifting device to support the drive hub assembly........................................................................................................................................................................................................... 65
2. Install the drive hub to the machine.................................................................................................................................................................................................................................... 65
3. Use the eight bolts and attach the drive hub to the machine. Tighten the bolts to torque 190 ft.lbs. (260 Nm)........................................................................................................................................................... 65
4. Reconnect electrical connections to the drive motor..................................................................................................................................................................................................................... 65
5. Install previously removed hydraulic hoses to drive motor............................................................................................................................................................................................................... 65
3.9 Drive Hub...................................................................................................................................................................................................................................................................... 66
Assembly/Disassembly........................................................................................................................................................................................................................................................... 66
3.10 Drive brake................................................................................................................................................................................................................................................................... 66
3.11 Drive Motor................................................................................................................................................................................................................................................................... 66
Removal........................................................................................................................................................................................................................................................................ 66
1. Place machine on the firm level surface................................................................................................................................................................................................................................. 66
2. Disconnect the battery power and all electrical connections from the drive motor........................................................................................................................................................................................ 66
3. Use suitable lifting device to support the drive motor.................................................................................................................................................................................................................. 66
4. Remove two bolts attached drive motor to the drive hub.................................................................................................................................................................................................................. 66
5. Remove the motor from machine and place in a clean work area............................................................................................................................................................................................................ 66
6. Clean the motor for dirt. Remove rust or corrosion from coupling shaft.................................................................................................................................................................................................. 66
Installation................................................................................................................................................................................................................................................................... 66
1. Use suitable lifting device to support the drive motor.................................................................................................................................................................................................................. 66
2. Install the drive motor to the machine.................................................................................................................................................................................................................................. 66
3. Make sure that the pump shaft is properly aligned....................................................................................................................................................................................................................... 66
4. Use the two bolts and attach the drive motor to the drive hub........................................................................................................................................................................................................... 66
5. Reconnect all electrical connections to the drive motor................................................................................................................................................................................................................. 66
6. Start the machine and check the motor for proper functioning............................................................................................................................................................................................................ 66
Description.................................................................................................................................................................................................................................................................... 67
Shaft Seal Replacement......................................................................................................................................................................................................................................................... 67
Removal.................................................................................................................................................................................................................................................................... 67
1. Remove the snap ring (1) retaining the shaft seal and support washer................................................................................................................................................................................................ 67
1. Snap Ring........................................................................................................................................................................................................................................................... 67
2. Support Washer...................................................................................................................................................................................................................................................... 67
3. Shaft Seal.......................................................................................................................................................................................................................................................... 67
2. Remove the support washer (2)................................................................................................................................................................................................................................... 67
3. Carefully pry out the shaft seal (3). To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal........................... 67
4. Discard the seal................................................................................................................................................................................................................................................ 67
inspect the components..................................................................................................................................................................................................................................................... 67
installation............................................................................................................................................................................................................................................................... 67
1. Cover the shaft splines with an installation sleeve to protect the shaft seal during installation................................................................................................................................................................... 67
2. Install a new shaft seal with the cupped side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal................................................................................................... 67
3. Install seal support washer......................................................................................................................................................................................................................................... 67
4. Install snap ring................................................................................................................................................................................................................................................... 67
5. Remove the installation sleeve...................................................................................................................................................................................................................................... 67
Loop Flushing Valve............................................................................................................................................................................................................................................................ 68
Removal.................................................................................................................................................................................................................................................................... 68
1. Using a 11/16 in internal hex wrench remove plug (1) and (2)........................................................................................................................................................................................................ 68
1. Plug................................................................................................................................................................................................................................................................ 68
2. Plug................................................................................................................................................................................................................................................................ 68
3. Plug................................................................................................................................................................................................................................................................ 68
4. O-ring.............................................................................................................................................................................................................................................................. 68
5. O-ring.............................................................................................................................................................................................................................................................. 68
6. O-ring.............................................................................................................................................................................................................................................................. 68
7. Spring.............................................................................................................................................................................................................................................................. 68
8. Spring.............................................................................................................................................................................................................................................................. 68
9. Spring.............................................................................................................................................................................................................................................................. 68
10. Washer............................................................................................................................................................................................................................................................. 68
11. Washer............................................................................................................................................................................................................................................................. 68
12. Shift Spool........................................................................................................................................................................................................................................................ 68
13. Orifice Poppet..................................................................................................................................................................................................................................................... 68
2. Using a 1/4 in hex wrench remove plug (3)....................................................................................................................................................................................................................... 68
3. Remove O-rings (4, 5, and 6).................................................................................................................................................................................................................................... 68
4. Using pliers, remove centering springs (7, 8, and 9)............................................................................................................................................................................................................ 68
5. Remove spring retaining washers (10 and 11)..................................................................................................................................................................................................................... 68
6. Remove shift spool (12)......................................................................................................................................................................................................................................... 68
7. Remove orifice poppet (13)...................................................................................................................................................................................................................................... 68
inspect the components..................................................................................................................................................................................................................................................... 68
installation............................................................................................................................................................................................................................................................... 68
1. Install orifice poppet (13)......................................................................................................................................................................................................................................... 68
2. Install shift spool (12)............................................................................................................................................................................................................................................ 68
3. Install spring retaining washers onto springs (10 and 11)........................................................................................................................................................................................................... 68
4. Carefully install centering springs (7, 8, and 9)................................................................................................................................................................................................................... 68
5. Install new O-rings (6, 4, and 5)................................................................................................................................................................................................................................... 68
6. Using a 1/4 in hex wrench torque plug (3) to 20 ft.lbs. (27 Nm)..................................................................................................................................................................................................... 68
7. Using a 11/16 in internal hex, torque plugs (2 and 1) to 27 ft.lbs. (37 Nm)......................................................................................................................................................................................... 68
Troubleshooting................................................................................................................................................................................................................................................................ 69
Disassembly.................................................................................................................................................................................................................................................................... 70
1. Plug.................................................................................................................................................................................................................................................................... 70
2. Plug.................................................................................................................................................................................................................................................................... 70
3. Plug.................................................................................................................................................................................................................................................................... 70
4. O-ring.................................................................................................................................................................................................................................................................. 70
5. O-ring.................................................................................................................................................................................................................................................................. 70
6. O-ring.................................................................................................................................................................................................................................................................. 70
7. Spring.................................................................................................................................................................................................................................................................. 70
8. Spring.................................................................................................................................................................................................................................................................. 70
9. Spring.................................................................................................................................................................................................................................................................. 70
10. Washer................................................................................................................................................................................................................................................................. 70
11. Washer................................................................................................................................................................................................................................................................. 70
12. Shift Spool............................................................................................................................................................................................................................................................ 70
13. Orifice Poppet......................................................................................................................................................................................................................................................... 70
1. Using a 11/16 in wrench remove plug (1) and (2)..................................................................................................................................................................................................................... 70
2. Using a 5/8 in hex wrench remove plug (3)........................................................................................................................................................................................................................... 70
3. Remove O-rings (4, 5, and 6)........................................................................................................................................................................................................................................ 70
4. Using pliers, remove centering springs (7, 8, and 9)................................................................................................................................................................................................................ 70
5. Remove spring retaining washers (10 and 11)......................................................................................................................................................................................................................... 70
6. Remove shift spool (12)............................................................................................................................................................................................................................................. 70
7. Remove orifice poppet (13).......................................................................................................................................................................................................................................... 70
14. Lock Nut............................................................................................................................................................................................................................................................... 70
15. O-ring Plug............................................................................................................................................................................................................................................................ 70
16. Control Line Plug...................................................................................................................................................................................................................................................... 70
17. Control Line Plug...................................................................................................................................................................................................................................................... 70
18. Cavity Plug............................................................................................................................................................................................................................................................ 70
19. Drain Plug............................................................................................................................................................................................................................................................. 70
20. Drain Plug............................................................................................................................................................................................................................................................. 70
21. Work Port Plug......................................................................................................................................................................................................................................................... 70
8. Remove all fittings from the unit. Discard any O-rings on the fittings.............................................................................................................................................................................................. 70
9. Using an 11/16 inch hex wrench, loosen the speed sensor lock nut (14) if equipped. Then remove the speed sensor using a Vi inch hex wrench. Units without speed sensor have an O-ring plug (15) installed in that location; remove it with a Va inch in............. 70
10. Using a 1/4 inch 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..................................................................... 70
11. Using a 5/16 inch internal hex wrench, remove drain plugs (19, 20). Discard O-rings................................................................................................................................................................................ 70
12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O- rings................................................................................................................................................. 70
22. Screw.................................................................................................................................................................................................................................................................. 71
23. Endcap................................................................................................................................................................................................................................................................. 71
24. O-ring................................................................................................................................................................................................................................................................. 71
13. Using an 8 mm internal hex wrench, remove the endCapscrews (22).................................................................................................................................................................................................... 71
14. Remove the endcap (23). Remove O-ring (24) from the housing or endcap. When the end Capscrews are removed, pressure from the servo spring will cause the endcap to bind on the shaft. Press down on the portion of the endcap covering the servo pisto............. 71
25. Valve Plate............................................................................................................................................................................................................................................................ 71
26. Endcap................................................................................................................................................................................................................................................................. 71
27. O-ring................................................................................................................................................................................................................................................................. 71
28. O-ring................................................................................................................................................................................................................................................................. 71
29. Angle Stop............................................................................................................................................................................................................................................................. 71
30. Servo Spring........................................................................................................................................................................................................................................................... 71
15. Remove the valve plate (25) and timing pin (26) from the endcap. Each displacement has a unique valve plate. For identification, the last two digits of the valve plate part number are stamped on its surface..................................................... 71
16. Remove and discard the O-rings (27 and 28)......................................................................................................................................................................................................................... 71
17. Remove the rear shaft bearing (29) from the endcap with a bearing puller. The bearing may be difficult to remove with a puller. Try this as an alternative: Pack the bearing cavity with heavy grease. After the shaft is removed, insert it into the ............. 71
18. Remove minimum angle stop (29) and servo spring (30) from the housing.............................................................................................................................................................................................. 72
31. Cylinder Kit Assembly.................................................................................................................................................................................................................................................. 72
19. Turn the housing on its side and remove the cylinder kit assembly (31). Set the assembly aside, being careful not to scratch the running surface................................................................................................................... 72
32. Snap Ring.............................................................................................................................................................................................................................................................. 72
33. Support Washer......................................................................................................................................................................................................................................................... 72
34. Shaft Seal............................................................................................................................................................................................................................................................. 72
20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34). Discard the seal. To avoid damaging the shaft during seal removal. Install ............. 72
35. Inner Snap Ring........................................................................................................................................................................................................................................................ 72
36. Snap Ring.............................................................................................................................................................................................................................................................. 72
37. Bearing................................................................................................................................................................................................................................................................ 72
38. Shaft.................................................................................................................................................................................................................................................................. 72
21. Remove the inner snap ring (35) and the shaft / bearing assembly................................................................................................................................................................................................... 72
22. Remove the snap-ring (36) retaining the shaft front bearing. Pull the bearing (37) off of the shaft (38)........................................................................................................................................................... 72
39. Swashplate............................................................................................................................................................................................................................................................. 73
40. Servo Piston........................................................................................................................................................................................................................................................... 73
41. Piston Seal............................................................................................................................................................................................................................................................ 73
42. O-ring................................................................................................................................................................................................................................................................. 73
43. Journal Bearings....................................................................................................................................................................................................................................................... 73
23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever.................................................................................................................................................................... 73
24. Remove the servo piston (40). Remove the piston seal (41) and O-ring (42) from the servo piston. Discard the seal and O-ring....................................................................................................................................... 73
25. Remove the journal bearings (43) from the housing. If the bearings are to be reused, note the location and orientation of each bearing for reassembly.............................................................................................................. 73
44. Piston................................................................................................................................................................................................................................................................. 73
45. Slipper Retainer....................................................................................................................................................................................................................................................... 73
46. Cylinder Block......................................................................................................................................................................................................................................................... 73
47. Ball Guide............................................................................................................................................................................................................................................................. 73
48. Holddown Pins.......................................................................................................................................................................................................................................................... 73
49. Retaining Ring......................................................................................................................................................................................................................................................... 73
50. Block Spring Washer.................................................................................................................................................................................................................................................... 73
51. Spiral Retaining Ring.................................................................................................................................................................................................................................................. 73
52. Block Spring........................................................................................................................................................................................................................................................... 73
53. Inner Block Spring Washer.............................................................................................................................................................................................................................................. 73
26. Remove pistons (44) and slipper retainer (45) from the cylinder block (46). The pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number the pistons and bores for reassembly if they are to be reused........... 73
27. Remove the ball guide (47), hold-down pins (48), and retaining ring (49) from the cylinder block................................................................................................................................................................... 73
28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining r............. 74
Inspection..................................................................................................................................................................................................................................................................... 74
Piston..................................................................................................................................................................................................................................................................... 74
Slippers................................................................................................................................................................................................................................................................... 74
Cylinder Block............................................................................................................................................................................................................................................................. 74
Ball Guide and Slipper Retainer............................................................................................................................................................................................................................................ 75
Valve Plate................................................................................................................................................................................................................................................................ 75
Swashplate and Journal Bearings............................................................................................................................................................................................................................................ 75
Shaft Bearings............................................................................................................................................................................................................................................................. 76
Shaft...................................................................................................................................................................................................................................................................... 76
Servo Piston and Minimum Angle Stop........................................................................................................................................................................................................................................ 76
Loop Flushing Spool........................................................................................................................................................................................................................................................ 76
Assembly....................................................................................................................................................................................................................................................................... 76
1. Install new O-ring (1) and piston seal (2) to the servo piston (3). Install the piston seal over the O-ring. Installing the piston seal stretches it, making it difficult to install the servo piston in its bore. Allow 30 minutes for the seal to rel................. 76
1. O-ring.................................................................................................................................................................................................................................................................. 76
2. Piston Seal............................................................................................................................................................................................................................................................. 76
3. Servo Piston............................................................................................................................................................................................................................................................ 76
2. After piston seal has relaxed, lubricate and install servo piston into the housing bore. Align the piston with the ball socket facing the inside of the housing..................................................................................................... 76
3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (7) into the groove in t............. 77
4. Block Spring Washer..................................................................................................................................................................................................................................................... 77
5. Block Spring............................................................................................................................................................................................................................................................ 77
6. Outer Washer............................................................................................................................................................................................................................................................ 77
7. Spiral Retaining Ring................................................................................................................................................................................................................................................... 77
8. Retaining Ring.......................................................................................................................................................................................................................................................... 77
9. Holddown Pins........................................................................................................................................................................................................................................................... 77
10. Ball Guide............................................................................................................................................................................................................................................................. 77
11. Piston................................................................................................................................................................................................................................................................. 77
12. Slipper Retainer....................................................................................................................................................................................................................................................... 77
4. Turn the block over and install the retaining ring (8), hold-down pins (9), and ball guide (10) to the cylinder block............................................................................................................................................... 77
5. Install the pistons (11) to the slipper retainer (12). Install the piston/retainer assembly into the cylinder block. Ensure the concave surface of the retainer seats on the ball guide. If you're reusing the pistons, install them to the original bl............. 77
6. Install the journal bearings (13) into the housing seats. Use assembly grease to keep the bearings seated during assembly. Ensure the locating nubs drop into the cavities in the seats. If you're reusing the bearings, install them in the original l............. 77
13. Journal Bearings....................................................................................................................................................................................................................................................... 77
14. Swashplate............................................................................................................................................................................................................................................................. 77
7. Install the swashplate (14) into the housing. Tilt the swashplate and guide the servo lever ball into its socket in the servo piston rod. Ensure the swashplate seats into the journal bearings and moves freely. Lubricate the running surface of the ............. 77
8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) onto shaft.................................................................................................... 78
15. Front Shaft Bearing.................................................................................................................................................................................................................................................... 78
16. Shaft.................................................................................................................................................................................................................................................................. 78
17. Snap Ring.............................................................................................................................................................................................................................................................. 78
18. Snap Ring.............................................................................................................................................................................................................................................................. 78
9. While holding the swashplate in place, turn the housing on its side. Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18)........................................................................................ 78
10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the slippers facing the swashplate. Rock the shaft to align the block splines and slide the cylinder kit into place. Orient the motor w............. 78
19. Cylinder Kit........................................................................................................................................................................................................................................................... 78
11. Lubricate and install the servo spring (20), and minimum angle stop (21) into the housing bore..................................................................................................................................................................... 78
20. Servo Spring........................................................................................................................................................................................................................................................... 78
21. Minimum Angle Stop..................................................................................................................................................................................................................................................... 78
12. Press the rear shaft bearing (22) into the endcap. Install the bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface..................................................................................... 79
22. Rear Shaft Bearing..................................................................................................................................................................................................................................................... 79
23. Timing Pin............................................................................................................................................................................................................................................................. 79
24. Valve Plate............................................................................................................................................................................................................................................................ 79
13. Install timing pin (23) into its bore in the endcap. Install the pin with its groove facing toward or away from the shaft. Press the pin until the end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above endcap surface................................................... 79
14. Install the valve plate (24) onto the endcap. Install the valve plate with the yellow surface toward the cylinder block. Align the slot in the valve plate with the timing pin. Apply a liberal coat of assembly grease to the endcap side of the valv............. 79
15. Install the endcap (25) onto the housing with the endCapscrews (26). Check to ensure the endcap will properly seat onto the housing without interference. Improper assembly of the internal components may prevent the endcap from seating properly. E............. 79
25. Endcap................................................................................................................................................................................................................................................................. 79
26. Screw.................................................................................................................................................................................................................................................................. 79
16. Using an 8 mm internal hex wrench, tighten the endCapscrews. Tighten the screws in opposite corners slowly and evenly to compress the servo spring and properly seat the endcap. Torque end Capscrews 35-45 ft.lbs. (47-61 Nm)..................................... 79
17. Before installing the shaft seal, ensure the shaft turns smoothly with less than 120 in.lbs. (13.5 Nm) of force. If the shaft does not turn smoothly within the specified maximum force, disassemble and check the unit............................................ 79
18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with the cup side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. Install seal support washer (28)............. 80
27. Shaft Seal............................................................................................................................................................................................................................................................. 80
28. Seal Support Washer.................................................................................................................................................................................................................................................... 80
29. Snap Ring.............................................................................................................................................................................................................................................................. 80
19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation torques.......................................................................................................................................... 80
20. Install orifice poppet (30)........................................................................................................................................................................................................................................ 81
30. Orifice Poppet......................................................................................................................................................................................................................................................... 81
31. Shift Spool............................................................................................................................................................................................................................................................ 81
32. Spring................................................................................................................................................................................................................................................................. 81
33. Spring................................................................................................................................................................................................................................................................. 81
34. Spring................................................................................................................................................................................................................................................................. 81
35. Spring................................................................................................................................................................................................................................................................. 81
36. Spring................................................................................................................................................................................................................................................................. 81
37. O-ring................................................................................................................................................................................................................................................................. 81
38. O-ring................................................................................................................................................................................................................................................................. 81
39. O-ring................................................................................................................................................................................................................................................................. 81
40. Plug................................................................................................................................................................................................................................................................... 81
41. Plug................................................................................................................................................................................................................................................................... 81
42. Plug................................................................................................................................................................................................................................................................... 81
21. Install shift spool (31)........................................................................................................................................................................................................................................... 81
22. Install spring retaining washers onto springs (32 and 33).......................................................................................................................................................................................................... 81
23. Carefully install centering springs (34, 35, and 36)............................................................................................................................................................................................................... 81
24. Install new O-rings (37, 38, and 39)............................................................................................................................................................................................................................... 81
25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs. (27 Nm)....................................................................................................................................................................................................... 81
26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27 ft.lbs. (37 Nm)............................................................................................................................................................................................ 81
Initial Start-up Procedures.................................................................................................................................................................................................................................................... 81
1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into the reservoir. Never reuse hydraulic fluid........................................................................................................ 81
2. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks................................................................................................ 81
3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper most case drain port.............................................................................................................................................. 81
4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most case drain ports........................................................................................................................................................ 81
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge pressure gauge port of the pump to monitor system pressure during start up..................................................................................................................................... 81
6. While watching the pressure gauge, run the engine at the 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 n................. 81
7. Operate the hydraulic system for at least fifteen minutes under light load conditions................................................................................................................................................................................... 81
8. Check and adjust control settings as necessary after installation....................................................................................................................................................................................................... 81
9. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressure gauge port................................................................................................................................................................. 81
10. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The motor is now ready for operation.................................................................................................................................................... 81
2. Pin..................................................................................................................................................................................................................................................................... 82
3. Retaining Pin........................................................................................................................................................................................................................................................... 82
4. Swash Plate............................................................................................................................................................................................................................................................. 82
5. Gasket.................................................................................................................................................................................................................................................................. 82
6. Cylinder Block.......................................................................................................................................................................................................................................................... 82
7. Valve Plate............................................................................................................................................................................................................................................................. 82
8. Slipper Retainer........................................................................................................................................................................................................................................................ 82
9. Slipper Hold Pin........................................................................................................................................................................................................................................................ 82
10. Piston Assembly........................................................................................................................................................................................................................................................ 82
11. Retainer Slipper....................................................................................................................................................................................................................................................... 82
12. Retainer Hold Down..................................................................................................................................................................................................................................................... 82
13. Retaining Ring......................................................................................................................................................................................................................................................... 82
14. Spring................................................................................................................................................................................................................................................................. 82
15. Washer................................................................................................................................................................................................................................................................. 82
16. Retainer............................................................................................................................................................................................................................................................... 82
17. Shaft.................................................................................................................................................................................................................................................................. 82
18. Retaining Ring......................................................................................................................................................................................................................................................... 82
19. Screw.................................................................................................................................................................................................................................................................. 82
20. Bearing Needle......................................................................................................................................................................................................................................................... 82
21. Plug................................................................................................................................................................................................................................................................... 82
22. O-Ring................................................................................................................................................................................................................................................................. 82
23. Seat Spring............................................................................................................................................................................................................................................................ 82
24. Housing................................................................................................................................................................................................................................................................ 82
25. O-Ring................................................................................................................................................................................................................................................................. 82
26. Ring Seal.............................................................................................................................................................................................................................................................. 82
27. Piston................................................................................................................................................................................................................................................................. 82
28. Bearing................................................................................................................................................................................................................................................................ 82
29. Spring................................................................................................................................................................................................................................................................. 82
30. Seal Lip............................................................................................................................................................................................................................................................... 82
31. Washer................................................................................................................................................................................................................................................................. 82
2. Swing Motor............................................................................................................................................................................................................................................................. 83
3. Inner Race Bearing Bolt................................................................................................................................................................................................................................................. 83
4. Swing Bearing........................................................................................................................................................................................................................................................... 83
5. Outer Race Bearing Bolt................................................................................................................................................................................................................................................. 83
6. Turntable Lock Pin...................................................................................................................................................................................................................................................... 83
7. Grease Line............................................................................................................................................................................................................................................................. 83
8. Bolt.................................................................................................................................................................................................................................................................... 83
9. Jam Nut................................................................................................................................................................................................................................................................. 83
3.12 Swing Drive................................................................................................................................................................................................................................................................... 84
Roll, Leak And Brake Testing................................................................................................................................................................................................................................................... 84
Tightening and Torquing Bolts.................................................................................................................................................................................................................................................. 85
1. Tighten (but do not torque) bolt “A" until snug......................................................................................................................................................................................................................... 85
2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug...................................................................................................................................................................................... 85
3. Crisscross around the bolt circle and tighten remaining bolts........................................................................................................................................................................................................... 85
4. Now use a torque wrench to apply the specified torque to bolt “A”....................................................................................................................................................................................................... 85
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts............................................................................................................................................................. 85
Motor Control Valve Disassembly................................................................................................................................................................................................................................................ 86
1. Place unit on bench with the motor end up............................................................................................................................................................................................................................... 86
2. Remove O-ring Plug (1P) and drain the oil from the gearbox.............................................................................................................................................................................................................. 86
3. Remove Hydraulic Tubing Assembly (35) by loosening fittings on both ends of tube with a wrench.......................................................................................................................................................................... 86
4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32).................................................................................................................................................. 86
5. Remove O-ring Plugs (23) from Motor Control Valve (32).................................................................................................................................................................................................................. 86
6. Remove Motor Control Valve (32) from Motor (31) by removing the four Bolts (21) and washers (22)........................................................................................................................................................................ 86
7. Remove O-ring (99) between Motor Control Valve (32) and Motor (31). Discard O-ring...................................................................................................................................................................................... 86
Motor and Brake Disassembly.................................................................................................................................................................................................................................................... 87
1. With unit resting on bench with Motor (31) end up, loosen Hex Bolts (29) and remove Lift Lugs (28) from the Motor (31).................................................................................................................................................. 87
2. Pull Motor (31) straight up and remove Motor (31) from Brake Housing (6)................................................................................................................................................................................................ 87
3. Remove O-ring (26) from between Motor (31) and Brake Housing (6)........................................................................................................................................................................................................ 87
4. Insert and tighten the 0.250 – 20 UNC flat Socket Head Capscrews through the Pressure Plate (8M) and into the Brake Piston (8A) to compress the springs and relieve pressure on the Retaining Ring (8N)................................................................. 87
5. Using retaining ring pliers, remove Retaining Ring (8N) which holds the Brake Piston assembly in place.................................................................................................................................................................. 87
6. Lift Brake Piston Assembly (8A) out of the Brake Housing (6). If the Brake Piston assembly (8A) will not lift out, apply less than 50 psi air to the “brake port” to remove Brake Piston(8A). Remove the Inner (Rotor) (8J), Outer (Stator) Plates ..................... 87
7. Remove O-rings (8D, 8F) and Backup Rings (8E, 8H) from the Brake Housing (6). Discard O-rings and Backup Rings.......................................................................................................................................................... 87
8. Remove 0.250 – 20 UNC flat Socket Head Capscrews and lift the Pressure Plate (8M) from the Brake Piston (8A)............................................................................................................................................................ 87
9. Apply less than 50 psi (3.45 bar) air to the “brake port” to remove Brake Piston (8A)................................................................................................................................................................................... 87
10. Remove Springs (8L) from the Brake Piston (8A)......................................................................................................................................................................................................................... 87
Main Drive Disassembly......................................................................................................................................................................................................................................................... 88
11. Remove Sun Gear (8) with Retaining Ring (44) inside.................................................................................................................................................................................................................... 88
12. With the unit resting on the Output Shaft (Pinion) (1A), remove the Bolts (12) from the Brake Housing (6).............................................................................................................................................................. 88
13. Remove the Brake Housing (6) from the main assembly.................................................................................................................................................................................................................... 88
14. Remove O-ring (5A) from between Brake Housing (6) and Ring Gear (4).................................................................................................................................................................................................... 88
15. Remove Thrust Washer (11) from between Brake Housing (6) and Carrier Subassembly....................................................................................................................................................................................... 88
16. Remove Ring Gear (4) from Housing (1G)................................................................................................................................................................................................................................. 88
17. Remove O-ring (5) from between Ring Gear (4) and Housing (1G).......................................................................................................................................................................................................... 88
18. Remove Carrier Sub-Assembly............................................................................................................................................................................................................................................ 88
19. Remove Thrust Washer (11) from between Carrier Sub- Assembly and Internal Gear (2)..................................................................................................................................................................................... 88
20. Remove Internal Gear (2)............................................................................................................................................................................................................................................... 88
Hub-Shaft Disassembly.......................................................................................................................................................................................................................................................... 89
1. Using retaining ring pliers remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard..................................................................................................................................................................... 89
2. Remove Thrust Washer (1H)............................................................................................................................................................................................................................................... 89
3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G)..................................................................................................................................................... 89
4. Remove the Bearing Cone (1E) from the Housing (1G)...................................................................................................................................................................................................................... 89
5. Use a bearing puller to remove the Bearing Cone (1D) from the Shaft (1A)................................................................................................................................................................................................ 89
6. Bearing Cups (1C & 1F) will remain in Housing (1G)...................................................................................................................................................................................................................... 89
Carrier Disassembly............................................................................................................................................................................................................................................................ 90
1. Using a 3/16” punch drive the Roll Pin (3G) which holds the Planet Shaft (3E) in the Carrier (3A) down into the Planet Shaft (3E) until it bottoms...................................................................................................................... 90
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E)............................................................................................................................................ 90
3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A)......................................................................................................................................................................................... 90
4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F)...................................................................................................................................................................... 90
5. Repeat Steps 1 thru 4 for the remaining two Cluster Gears (3F).......................................................................................................................................................................................................... 90
Hub-Shaft Assembly............................................................................................................................................................................................................................................................. 91
1. Press Bearing Cup (1C) into Housing (1G) taking care to insure cup starts square with the bore of Hub (1G).............................................................................................................................................................. 91
2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing (1G)............................................................................................................................................................................................................. 91
3. Press or tap Seal (1B) Into the counterbore of Housing (1G) to the point where it becomes flush with the Housing (1G) face. Care should be taken to insure Seal (1B) is being correctly installed (smooth face up). Apply grease to the rubber portion ................. 91
4. Invert Hub (1G) and press Bearing Cup (1E) into counterbore of Housing (1G)............................................................................................................................................................................................. 91
5. Carefully lower Housing (1G) onto the Output Shaft (1A) until Bearing Cone (1D) contacts the Output Shaft (1A).......................................................................................................................................................... 91
6. Press on the small end of the Bearing Cone (1D), being careful not to contact the bearing cage, until the Bearing Cone (1D) seats on the shoulder of the Output Shaft (1A).............................................................................................. 91
7. Start the Bearing Cone (1F) onto the Output Shaft (1A).................................................................................................................................................................................................................. 91
8. Press or tap the Bearing Cone (1F) onto the Output Shaft (1A) until it is just seated in the Bearing Cup (1E). while rotating the Housing (G)........................................................................................................................... 91
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and against Bearing Cone (1F)........................................................................................................................................................................................ 91
10. Install Retaining Ring (1I) into the groove in the Output Shaft (1A). This Retaining Ring (1I) should never be reused in a repair or rebuild........................................................................................................................... 91
11. Tap the Retaining Ring (1I) with a soft metal punch to ensure that the Retaining Ring (1I) is completely seated in the groove of the Output Shaft (IA)................................................................................................................. 91
12. Install O-ring Plug (1P) and torque to 23 to 24 ft.lbs. (31 to 32 Nm).................................................................................................................................................................................................. 91
Carrier Assembly............................................................................................................................................................................................................................................................... 91
1. Apply a liberal Coat of grease to the bore of Cluster Gear (3F). This will enable the Needle Rollers (3C) to be held in place during assembly........................................................................................................................... 91
2. Install the first row of Needle Rollers (3C) into the bore of Cluster Gear (3F)......................................................................................................................................................................................... 91
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of the Needle Rollers (3C)..................................................................................................................................................................................... 91
4. Place second row of Needle Rollers (3C) into bore of Cluster Gear (3F) against Spacer (3D).............................................................................................................................................................................. 91
5. Place Carrier (3A) so that one of the roll pin holes is straight up..................................................................................................................................................................................................... 91
6. Start Planet Shaft (3E) through the hole in Carrier (3A). Using ample grease to hold it in position, slide one Thrust Washer (3B) over the Planet Shaft (3E) with the tang resting in the cast slot of the Carrier (3A)................................................. 91
7. With large end of Cluster Gear (3F) facing the roll pin hole in the Carrier, place the Cluster Gear into position in carrier (3A) and push Planet Shaft (3E) through the Cluster Gear (3F) without going all the way through............................................ 91
8. Slide the second Thrust Washer (3B) between the Cluster Gear (3F) and the Carrier (3A) with the tang of the washer located in the cast slot of the Carrier (3A). Finish sliding the Planet Shaft (3E) through the Thrust Washer (3B) and into the Carri................. 91
9. Position the non-chamfered side on the Planet Shaft (3E) roll pin hole so that it is in line with the hole in the Carrier (3A) using a 1/8” (3 mm) diameter punch....................................................................................................... 91
10. After using a 3/16” (5 mm) punch to align the two roll pin holes. Drive the Roll Pin (3G) through Carrier (3A) and into the Planet Shaft (3E) until the Roll Pin (3G) is flush with the bottom of the cast slot in the Carrier (3A) outside diameter................... 91
11. Repeat Steps 1 thru 10 for the remaining two Cluster Gears(3F)......................................................................................................................................................................................................... 91
Main Drive Assembly............................................................................................................................................................................................................................................................ 92
1. With the Hub Shaft Sub-Assembly resting on the Shaft (1A) install Internal Gear (2). The spline of the Internal Gear (2) bore will mesh with the spline of the Output Shaft (1A). This will be a tight fit.............................................................. 92
2. Inspect the location of the Internal Gear (2) on the Output Shaft (1A). The portion of the Output Shaft (1A) should protrude through the Internal Gear (2) bore......................................................................................................... 92
3. Install 4 Dowel Pins (13) into counterbore holes in Hub (IG)............................................................................................................................................................................................................ 92
4. Install Thrust Washer (11) in counterbore of Carrier Sub- Assembly (Small Cluster-Gear end) Use grease to hold in place................................................................................................................................................. 92
5. Place O-ring (5) into Hub counterbore. Use grease to hold O-ring in place............................................................................................................................................................................................... 92
6. Place Carrier Sub-Assembly on bench with the large end of Cluster Gears (3F) facing up with one at the 12 o'clock position. Find the punch marked tooth on each gear at the large end and locate at 12 o'clock (straight up) from each planet pin. Mark................. 92
7. With large shoulder side of Ring Gear (4) facing down, place Ring Gear (4) over (into mesh with) cluster gears (3F). Be sure that cluster gear timing marks (punch marks) remain in correct location during Ring Gear (4) installation. The side of the................. 92
8. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh with the Internal Gear (2). On the Ring Gear (4) locate the hole marked "X", or punch marked, over one of the marked counterbored holes (St................. 92
9. Install Thrust Washer (11) into the counterbore on the face of the carrier. Use grease to hold in place................................................................................................................................................................. 92
10. Place O-ring (5A) into counterbore or Brake Housing (6). Use grease to hold O-Ring in place............................................................................................................................................................................ 92
11. Install the Brake Housing (6), taking care to correctly align Pipe Plug (20) with those in the Hub (1G)................................................................................................................................................................ 92
12. Install Bolts (12) through the Brake Housing (6) into the Hub (1G) and torque to 23-27 ft. lbs. (31-37 Nm)............................................................................................................................................................. 92
13. With gearbox standing on the pinion end fill gearbox with 43 oz. of 80W90 gear Oil..................................................................................................................................................................................... 92
14. Install Retaining Ring (44) into the groove in the Sun Gear (8)........................................................................................................................................................................................................ 92
15. Install the Sun Gear (8) into mesh with the Planet Gears (3F).......................................................................................................................................................................................................... 92
16. Install Pipe Plug (20) into Brake Housing (6) torque to 23 to 24 ft. lbs. (31-32 Nm)................................................................................................................................................................................... 92
Motor and Brake Assembly....................................................................................................................................................................................................................................................... 93
1. Starting with a Stator (8K), alternately stack and install Stators (8K) into Lobes of Brake Housing (6) and Rotors (8J) (internal splines) onto splines of Sun Gear (8)................................................................................................. 93
2. Insert Brake Piston (8A) completely into Brake Housing (6) without O-rings (8D, 8F) and Backup Rings (8E, 8H) to check fit of brake. The Brake Piston (8A) should slide into Brake Housing (6) without being forced. If Brake Piston (8A) does not fit,................. 93
3. Grease O-rings (8D, 8F) and install smaller diameter O- Ring (8F) into smaller diameter O-Ring groove in Brake Housing (6) and install larger diameter O-Ring (8D) into larger diameter O-Ring groove in Brake Housing (6).............................................. 93
4. Insert smaller diameter Solid Backup Ring (8H) into smaller groove in Brake Housing (6) between O-Ring (8F) and side of groove towards Output Shaft (1A)................................................................................................................ 93
5. Insert larger diameter Solid Backup Ring (8E) into groove in Brake Housing (6) between O-Ring (8D) and side of groove towards Motor (31)................................................................................................................................ 93
6. Lightly grease cylinder walls of Brake Housing (6) and install Brake Piston (8A) into Brake Housing (6). If necessary, place T-134711 on top of brake and lightly tap until Brake Piston (8A) contacts brake disk stack................................................. 93
7. Insert 8 Springs (8L) into Brake Piston (8A) spring holes............................................................................................................................................................................................................... 93
8. Install Pressure Plate (8M) into Brake Housing (6) bore and onto top of Springs (8L).................................................................................................................................................................................... 93
9. Insert and tighten the 0.250 – 20 UNC Flat Head Capscrews through the Pressure Plate (8M) and into the Brake Piston (8A) to compress the springs. Tighten Socket Head Capscrews incrementally to evenly compress the Springs (8L)....................................... 93
10. Using retaining ring pliers, install large Retaining Ring (8N) into groove in Brake Housing (6) making sure that it is seated properly................................................................................................................................. 93
11. Remove the Flat Head Capscrews from the Brake Piston (8A) incrementally to release the tension of the springs slowly. Discard Flat Head Capscrews...................................................................................................................... 93
12. The Unit should undergo brake test refer instr uction on page 30....................................................................................................................................................................................................... 93
13. Grease and install the O-Ring (26) into the Motor (31) pilot........................................................................................................................................................................................................... 93
14. Install Motor (31) into the Brake Housing (6). Insure the motor valve mounting face is aligned with the radial brake release port in the Housing (1G).................................................................................................................. 93
15. Install Bolts (29) into Brake Housing (6) through Lifting Lugs (28) and Motor (31) flange. Torque bolts to 80-100 ft. lbs. (108-136 Nm)................................................................................................................................ 93
Motor Control Valve Assembly................................................................................................................................................................................................................................................... 94
1. Install O-Rings (99) into counterbore on Motor Valve face. Assemble the Motor control Valve (32) onto the Motor (31) with Bolt (21) and Lock Washers (22). Torque Bolts (21) to 18-20 ft. lbs. (23-26 Nm)............................................................... 94
2. Install Elbow Fittings (30) into Brake (6). Do not tighten jam nuts..................................................................................................................................................................................................... 94
3. Install Elbow Fittings (30) into Motor Control Valve (32). Do not tighten jam nuts...................................................................................................................................................................................... 94
4. Assemble Tube (35) into Elbow Fittings (30) and torque to 13-15 ft.lbs (18-20 Nm). Tighten the jam nuts on the Elbow Fittings (30) and torque to 13-15 ft.lbs. (18-20 Nm)............................................................................................... 94
5. Install one O-ring Plug (23) into Motor Control Valve (32) and torque to 18-20 ft. lbs. (23-26 Nm)...................................................................................................................................................................... 94
6. Pressure test brake, tube and control valve connections by applying 3000 psi (207 bar) pressure to the open port in the Motor Control Valve (32) and holding lor 1 minute. Check lor leaks al the control-valve-motor interface and the tube connection................. 94
3.13 Swing Motor...................................................................................................................................................................................................................................................................101
Disassembly and inspection.....................................................................................................................................................................................................................................................101
1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable....................................101
2. Scribe an alignment mark down and across the Torqmotor™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cov...................101
3. Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts...........................................................101
4. Remove end cover assembly (2) and seal ring (4). Discard seal ring......................................................................................................................................................................................................101
5. If the end cover (2) is equipped with shuttle valve components, remove the two previously loosened plugs (21)...........................................................................................................................................................103
6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing.................103
7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs................................................................................................................................................................................................103
8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinel.................103
9. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the sea.................104
10. Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set.................104
11. Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane c.................104
12. 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 perceptible lash (play) should be noted between mating spline parts. Remove and dis.................105
13. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers..........................................................................................................................105
14. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. Remove any key (12A), nut (12B.................105
15. Remove coupling shaft (12), by pushing on the 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 spline.................105
16. Remove and discard seal ring (4) from housing (18).....................................................................................................................................................................................................................106
17. Remove thrust bearing (15) and thrust washer (14) Inspect for wear, brinelling, corrosion and a full complement of retained rollers....................................................................................................................................106
18. Remove seal (16) and backup washer (17) from Small Frame, housing (18). Discard both...................................................................................................................................................................................106
19. Remove housing (18) from vise, invert it and remove and discard seal...................................................................................................................................................................................................106
20. A blind hole bearing or seal puller is required........................................................................................................................................................................................................................106
21. Inspect housing (18) assembly for cracks, the 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 the housing is de.................106
22. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be .................107
23. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they wer.................107
Assembly.......................................................................................................................................................................................................................................................................108
1. If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counte.................108
2. The Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press i...................109
3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore....................................................................................................................................................................................109
4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange..............................................................................................................................................110
5. On the Torqmotor™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqmotor™, into their respective counterbores in housing (18) if they were not assembled in procedure 2............................................110
6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqmotor™...............................................................................................................................................................................110
7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.....................................................................................................................................................................................110
8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings....................111
9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove........................................................................................................................................................111
10. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.............................................................................................................112
11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).............................................................................................................................................................................112
12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B)..............................................................................................................112
13. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines......................................................................................................112
14. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7)........................................................................................................................................113
15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set...........................................................................................................113
16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold......................................................................................................................................................................113
17. Assemble the commutator ring (6) over alignment studs onto the manifold................................................................................................................................................................................................113
18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up........................................................................................................113
19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The .................114
20. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components .................115
21. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so equipped............................................................................................................................................115
One Piece Stator Construction..................................................................................................................................................................................................................................................116
1. Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13. Be sure the seal ring is in place......................................................................................................116
2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.......................116
3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines............................................................................................................116
4. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.......................................................................................................................................................................116
5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance t.................116
6. Remove the two assembled bolts (1) if used to retain stator and wear plate..............................................................................................................................................................................................116
3.14 Swing Hub Installation........................................................................................................................................................................................................................................................117
Procedure For Setting Swing Gear Backlash......................................................................................................................................................................................................................................117
1. Place the machine on firm, level ground.................................................................................................................................................................................................................................117
2. Place shim between pinion and bearing at bearing high spot (shown below)................................................................................................................................................................................................117
3. Apply High Strength Threadlocking Compound and torque pivot bolt to 205 ft. lbs. (280 Nm) (shown below).................................................................................................................................................................117
4. Remove turntable lock pin...............................................................................................................................................................................................................................................117
5. Apply High Strength Threadlocking Compound and pre- torque swing drive mounting bolts to 30 ft. lbs. (40 Nm)............................................................................................................................................................117
6. Tighten jack bolt until pinion is completely snug against shim and bearing then loosen jack bolt........................................................................................................................................................................117
7. Apply High Strength Threadlocking Compound and torque jack bolt 50 ft. lbs. (68 Nm).....................................................................................................................................................................................117
8. Apply High Strength Threadlocking Compound and tighten jam nut..........................................................................................................................................................................................................117
9. Torque mounting bolts to 340 ft. lbs. (460 Nm)..........................................................................................................................................................................................................................118
10. Remove shim and discard................................................................................................................................................................................................................................................118
Swing Drive Lubrication........................................................................................................................................................................................................................................................118
3.15 Swing Hub Removal.............................................................................................................................................................................................................................................................118
1. Disconnect all wiring harness terminals connected to the swing motor........................................................................................................................................................................................................118
2. Gently loosen the set screw. Do not remove..................................................................................................................................................................................................................................118
3. Remove the pivot bolt using Allen Wrench....................................................................................................................................................................................................................................118
4. Remove the mounting bolts securing swing drive hub to the turntable.........................................................................................................................................................................................................118
5. Using the suitable lifting device, remove the swing drive hub from mounting plate without damaging the swing gear...........................................................................................................................................................118
6. Place swing drive hub in the clean area.....................................................................................................................................................................................................................................118
7. Refer to Section 3.12, Swing Drive for swing drive maintenance..............................................................................................................................................................................................................118
3.16 Swing Bearing.................................................................................................................................................................................................................................................................119
Turntable Bearing Mounting Bolt Condition Check................................................................................................................................................................................................................................119
1. Check the frame to bearing attach bolts as follows:.....................................................................................................................................................................................................................119
a. Elevate the fully extended main boom to horizontal. (See Figure 3-48.)..............................................................................................................................................................................................119
b. At the positions indicated on Figure 3-49. try to insert a 0.0015 in. feeler gauge between the bolt and hardened washer at the arrow indicated position.............................................................................................................119
c. Ensure that the 0.0015 in. feeler gauge will not penetrate under the bolt head to the bolt shank....................................................................................................................................................................119
d. Swing the turntable 90 degrees, and check some selected bolts at the new position...................................................................................................................................................................................119
e. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants................................................................................................................................................119
2. Check the turntable to bearing Attach bolts as follows:.................................................................................................................................................................................................................119
a. Elevate the fully retracted main boom to full elevation.............................................................................................................................................................................................................119
b. At the position indicated on Figure 3-47. try to insert the 0.0015 in. feeler gauge between the bolt head and hardened washer at the arrow indicated position.......................................................................................................119
c. Lower the boom to horizontal and fully extend the boom..............................................................................................................................................................................................................119
d. At the position indicated on Figure 3-49., try and insert the 0.0015 in. feeler gauge between the bolt head and hardened washer at the arrow indicated position.....................................................................................................119
Wear Tolerance.................................................................................................................................................................................................................................................................122
1. From the underside of the machine, at rear center, with the main boom fully elevated and fully retracted, and tower boom stowed, as shown in Figure 3-47., Swing Bearing Tolerance Boom Placement (Sheet 1 of 2), using a magnetic base dial indicator,.................122
2. At the same point, with the main boom at horizontal and fully extended, and the tower boom fully elevated and fully retracted as shown in Figure 3-48., Swing Bearing Tolerance Boom Placement (Sheet 2 of 2). Using a magnetic base dial indicator, me.................122
3. If a difference greater than 0.079 in. (2.00 mm) is determined, the swing bearing should be replaced....................................................................................................................................................................122
4. If a difference less than 0.079 in. (2.00 mm) is determined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following:...................................................................................122
a. Metal particles in the grease.......................................................................................................................................................................................................................................122
b. Increased drive power required......................................................................................................................................................................................................................................122
c. Noise...............................................................................................................................................................................................................................................................122
d. Rough rotation......................................................................................................................................................................................................................................................122
5. If bearing inspection shows no defects, reassemble and return to service................................................................................................................................................................................................122
Swing Bearing Replacement......................................................................................................................................................................................................................................................122
Removal....................................................................................................................................................................................................................................................................122
1. From Ground Control station, operate the boom adequately to provide access to frame opening to rotary coupling......................................................................................................................................................122
2. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible......................................................................................................................................................122
3. From inside turntable, remove mounting hardware which attach rotary coupling retaining yoke brackets to turntable...................................................................................................................................................122
4. Tag and disconnect the hydraulic lines from the fittings on the top of the rotary coupling. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports........................................................................122
5. Attach suitable overhead lifting equipment to the base of the turntable weldment....................................................................................................................................................................................122
6. Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable. This will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the turntable to the bearing inne.............122
7. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame- mounted components...................................................................................122
8. Carefully place the turntable on a suitably supported trestle.......................................................................................................................................................................................................123
9. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard .............123
Installation...............................................................................................................................................................................................................................................................123
1. Using suitable lifting equipment, carefully lower the swing bearing into position on the frame. Ensure the scribed line of the outer race of the bearing aligns with the scribed line on the frame. If a new swing bearing is used, ensure that the fil.............123
2. Apply a light coating of High Strength Threadlocking Compound to the new bearing bolts, and loosely install the bolts and washers through the frame and outer race of bearing.......................................................................................123
3. Refer to the Torque Sequence diagram as shown in Figure 3-52., Swing Bearing Torque Sequence. Clean any residue off the new bearing bolts, then apply a light coating of High Strength Threadlocking Compound and install the bolts and washers through.............123
4. Remove the lifting equipment from the bearing.......................................................................................................................................................................................................................123
5. Using suitable lifting equipment, carefully position the turntable assembly above the machine frame.................................................................................................................................................................123
6. Carefully lower the turntable onto the swing bearing, ensuring that the scribed line of the inner race of the bearing aligns with scribed line on the turntable. If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees f.............123
7. Clean any residue off the new bearing bolts, then apply a light coating of High Strength Threadlocking Compound and install the bolts and washers through the turntable and inner race of the bearing...............................................................123
8. Following the Torque Sequence diagram shown in Figure 3-52., Swing Bearing Torque Sequence, tighten the bolts to a torque of 190 ft. lbs. (260 Nm) w/Threadlocking Compound.........................................................................................123
9. Remove the lifting equipment........................................................................................................................................................................................................................................123
10. Install the rotary coupling retaining yoke brackets, apply a light coating of Medium Strength Threadlocking Compound to the attaching bolts and secure the yoke to the turntable with the mounting hardware........................................................123
11. Connect the hydraulic lines to the rotary coupling as tagged prior to removal......................................................................................................................................................................................123
12. At ground control station, use boom lift control to lower boom to stowed position..................................................................................................................................................................................123
13. Using all applicable safety precautions, activate the hydraulic system and check the swing system for proper and safe operation....................................................................................................................................123
Swing Bearing Torque Values....................................................................................................................................................................................................................................................123
1. Outer Race - 190 ft. lbs. (260 Nm) w/High Strength Threadlocking Compound...............................................................................................................................................................................................123
2. Inner Race - 190 ft. lbs. (260 Nm) w/High Strength Threadlocking Compound...............................................................................................................................................................................................123
3. See Swing Bearing Torquing Sequence.....................................................................................................................................................................................................................................123
3.17 Chassis Tilt Indicator System.................................................................................................................................................................................................................................................125
3.18 Rotary Coupling...............................................................................................................................................................................................................................................................126
1. If not already removed, remove the axle oscillation valve from the cylinder barrel. The spool of the valve protrudes into the barrel and will damage the spool and seals if left in place...................................................................................126
2. Remove snap ring (7) from end...............................................................................................................................................................................................................................................126
3. Remove thrust ring (6) from the same end....................................................................................................................................................................................................................................126
4. Remove center body (1) from housing (3).....................................................................................................................................................................................................................................126
5. Cut off old seals (2, 4, 5).................................................................................................................................................................................................................................................126
6. Remove proximity switch.....................................................................................................................................................................................................................................................126
7. Assemble lip seals (2) in direction shown in Figure 3-53., Rotary Coupling Seal Installation................................................................................................................................................................................126
8. Reassemble O-ring (4).......................................................................................................................................................................................................................................................126
9. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F (149° C)........................................................................................................................................................................................................126
10. Assemble cap seals over O-rings............................................................................................................................................................................................................................................126
11. Reinsert center body into housing (lube with hydraulic oil)................................................................................................................................................................................................................126
12. Replace thrust ring and snap ring..........................................................................................................................................................................................................................................126
13. Install proximity switch as shown in Figure 3-57...........................................................................................................................................................................................................................126
1. Center Body.................................................................................................................................................................................................................................................................127
2. Seal........................................................................................................................................................................................................................................................................127
3. Housing.....................................................................................................................................................................................................................................................................127
4. O-ring......................................................................................................................................................................................................................................................................127
5. Seal........................................................................................................................................................................................................................................................................127
6. Thrust Ring.................................................................................................................................................................................................................................................................127
7. Snap Ring...................................................................................................................................................................................................................................................................127
8. Valve Block (Axle Oscillation)..............................................................................................................................................................................................................................................127
9. O-ring......................................................................................................................................................................................................................................................................127
10. Proximity Switch...........................................................................................................................................................................................................................................................127
1. Medium Strength Threadlocking Compound......................................................................................................................................................................................................................................130
2. Bolt........................................................................................................................................................................................................................................................................130
3. Bolt........................................................................................................................................................................................................................................................................130
4. Bolt........................................................................................................................................................................................................................................................................130
5. Bracket.....................................................................................................................................................................................................................................................................130
6. Rotary Coupling.............................................................................................................................................................................................................................................................130
7. Spool.......................................................................................................................................................................................................................................................................130
8. Retaining Ring..............................................................................................................................................................................................................................................................130
9. Plug........................................................................................................................................................................................................................................................................130
10. Torque Lug.................................................................................................................................................................................................................................................................130
11. Ring.......................................................................................................................................................................................................................................................................130
12. Seal.......................................................................................................................................................................................................................................................................130
13. O-ring.....................................................................................................................................................................................................................................................................130
14. Bearing....................................................................................................................................................................................................................................................................130
15. Cap Seal...................................................................................................................................................................................................................................................................130
16. O-ring.....................................................................................................................................................................................................................................................................130
17. Valve......................................................................................................................................................................................................................................................................130
18. Check Valve................................................................................................................................................................................................................................................................130
19. Case.......................................................................................................................................................................................................................................................................130
20. Plunger Valve..............................................................................................................................................................................................................................................................130
21. Bolt.......................................................................................................................................................................................................................................................................130
22. Nut........................................................................................................................................................................................................................................................................130
23. Washer.....................................................................................................................................................................................................................................................................130
24. Bracket....................................................................................................................................................................................................................................................................130
25. Proximity Switch...........................................................................................................................................................................................................................................................130
3.19 Generator.....................................................................................................................................................................................................................................................................132
Maintenance Schedule...........................................................................................................................................................................................................................................................132
Every 250 Hours............................................................................................................................................................................................................................................................132
Every 500 hours............................................................................................................................................................................................................................................................132
Overload Protection............................................................................................................................................................................................................................................................133
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings.................................................................................................................................................................................................................133
inspecting brush position..................................................................................................................................................................................................................................................133
inspecting brushes.........................................................................................................................................................................................................................................................133
CLEANING SLIP RINGS........................................................................................................................................................................................................................................................133
Troubleshooting................................................................................................................................................................................................................................................................135
Generator Disassembly and Assembly.............................................................................................................................................................................................................................................136
1. Rotor...................................................................................................................................................................................................................................................................136
2. Stator Assembly.........................................................................................................................................................................................................................................................136
Disassembly................................................................................................................................................................................................................................................................136
1. Mark and disconnect all electrical leads, secure using cable ties...................................................................................................................................................................................................136
2. Remove brush holder assembly........................................................................................................................................................................................................................................136
3. Disassemble generator parts shown in Figure 3-59....................................................................................................................................................................................................................136
4. Clean all parts with approved solvent and dry with compressed air, If applicable....................................................................................................................................................................................136
5. Inspect all part for damage. Replace if necessary...................................................................................................................................................................................................................136
assembly...................................................................................................................................................................................................................................................................136
1. Assemble generator parts using torque values in table...............................................................................................................................................................................................................136
2. Reconnect all leads. Use cable ties to secure leads away from moving or hot parts...................................................................................................................................................................................136
Lead Connection List for Generator.............................................................................................................................................................................................................................................144
3.20 Cold Start System.............................................................................................................................................................................................................................................................150
Engine Warmup..................................................................................................................................................................................................................................................................150
3.21 Clutch Adapter Plate Installation.............................................................................................................................................................................................................................................150
1. Place the Clutch Adapter Plate against the engine flywheel and start all bolts approximately 1/2 to 1 turn..................................................................................................................................................................150
2. Using the pattern shown in Figure 3-71., Clutch Adapter Plate Torque Sequence, work back and forth around the pressure plate turning each bolt not more than 3 turns before turning the other bolts to a similar level......................................................150
3. Using the same torque pattern, torque each bolt to 16 ft.lbs. (22 Nm).......................................................................................................................................................................................................150
3.22 Clutch Kit & Release Shaft Installation.......................................................................................................................................................................................................................................151
Clutch Kit.....................................................................................................................................................................................................................................................................151
1. Apply blue Medium Strength Threadlocking Compound to all bolts and start all bolts ½ to 1 turn..........................................................................................................................................................................151
2. Center the clutch disc in the pressure plate using JLG PN 1001227898....................................................................................................................................................................................................151
3. Using an alternating star pattern (1-6) work around the pressure plate, turning each bolt no more than 3 turns before turning the other bolts to a similar level........................................................................................................151
4. Continue step 3 until the pressure plate contacts the adapter plate at all 6 bolt locations.............................................................................................................................................................................151
5. Using the same pattern, torque each bolt to 35 - 25 Nm..................................................................................................................................................................................................................151
Release Shaft..................................................................................................................................................................................................................................................................152
1. Insert shaft from the top of the IMG and through the opening on the side................................................................................................................................................................................................152
2. Align the shaft with the right side bore................................................................................................................................................................................................................................152
3. Insert shaft further into bearing bore at right.........................................................................................................................................................................................................................152
4. Install bronze bearings, retaining clip on one end and actuation lever on the other.....................................................................................................................................................................................152
3.23 Clutch Installation...........................................................................................................................................................................................................................................................153
1. Place the clutch against the adapter plate and start all retaining bolts approximately 1/2 turn.............................................................................................................................................................................153
2. Center the friction disk (clutch) in the pressure plate using the alignment tool............................................................................................................................................................................................153
3. Using the pattern shown in Figure 3-66., Clutch Plate Torque Sequence, work back and forth around the clutch turning each bolt not more than 3 turns before turning the other bolts to a similar level. Stop when the pressure plate contacts the flywh.....................153
4. Using the same torque pattern, torque each bolt to 22 ±3.5 ft.lbs. (30 ± 5 Nm)..............................................................................................................................................................................................153
3.24 Clutch Linear Actuator/Throwout Bearing Positioning installation Procedure....................................................................................................................................................................................................153
1. Install the adjustment bolt into the Clutch Gauge bracket, about halfway. The bolt will be adjusted later...................................................................................................................................................................153
2. Assemble Clutch Gauge bracket onto outboard side of flywheel housing using the 3 bolts and washers provide with the kit.....................................................................................................................................................153
3. Assemble Clutch Gauge onto the end of the bolt. Rotate Clutch Gauge and bolt until Gauge is contacting the clutch gauge bracket.............................................................................................................................................154
4. Lightly pull the clutch actuation lever arm toward the engine, until resistance is felt or it stops. This should not require excessive force................................................................................................................................154
5. Now that the Clutch Gauge has set the bolt head height, release the clutch actuation lever and carefully remove the Clutch Gauge off of the bolt head, but leave the bolt position where it was set by the Gauge............................................................154
6. Before the continuing, ensure the Linear actuator is in the fully extended position as shown below..........................................................................................................................................................................154
7. Pin the rear mounting hole of linear actuator to rear mounting bracket as shown by position 1 below. Three bolts in rear mounting bracket should be installed loosely to allow for movement of the bracket as shown by position 2 below.....................................154
8. Next using a wrench rotate the rear mounting bracket toward the engine until the lever arm makes contact with the bolt head as shown below. This requires some force to achieve, as it is compressing the pressure plate to set the full throwout beari.....................155
9. While the lever arm is still touching the bolt head from the previous step, assemble the linear actuator to the clutch actuation lever as shown below. Adjust rear linear actuator mounting bracket as needed to allow the pin hole to line up correctl.....................155
10. Remove the Clutch Gauge bracket from flywheel housing. Installation is now complete........................................................................................................................................................................................155
3.25 Counterweight.................................................................................................................................................................................................................................................................156
1. Tower Boom Assembly.........................................................................................................................................................................................................................................................160
2. Main Boom Assembly..........................................................................................................................................................................................................................................................160
3. Upright Cover...............................................................................................................................................................................................................................................................160
4. Upright Cover...............................................................................................................................................................................................................................................................160
5. Tower Fly Cover.............................................................................................................................................................................................................................................................160
6. Pad Rest....................................................................................................................................................................................................................................................................160
7. Pin.........................................................................................................................................................................................................................................................................160
8. Pin.........................................................................................................................................................................................................................................................................160
9. Pin.........................................................................................................................................................................................................................................................................160
10. Pin........................................................................................................................................................................................................................................................................160
11. Pin........................................................................................................................................................................................................................................................................160
12. Pin........................................................................................................................................................................................................................................................................160
13. Pin........................................................................................................................................................................................................................................................................160
14. Pin........................................................................................................................................................................................................................................................................160
15. Pin........................................................................................................................................................................................................................................................................160
16. Pin........................................................................................................................................................................................................................................................................160
17. Pin........................................................................................................................................................................................................................................................................160
18. Upright....................................................................................................................................................................................................................................................................160
19. Tower Boom Lift Cylinder Assembly..........................................................................................................................................................................................................................................160
20. Main Boom Lift Cylinder Assembly...........................................................................................................................................................................................................................................160
21. Platform Slave Level Cylinder Assembly.....................................................................................................................................................................................................................................160
22. Upright Level Cylinder Assembly............................................................................................................................................................................................................................................160
23. Master Cylinder Assembly...................................................................................................................................................................................................................................................160
24. Jib Assembly...............................................................................................................................................................................................................................................................160
25. Rotator Assembly...........................................................................................................................................................................................................................................................160
26. Jib Lift Cylinder Assembly.................................................................................................................................................................................................................................................160
1. Base Boom...................................................................................................................................................................................................................................................................161
2. Fly Boom....................................................................................................................................................................................................................................................................161
3. Telescope Cylinder Assembly.................................................................................................................................................................................................................................................161
4. Pin.........................................................................................................................................................................................................................................................................161
5. Pin.........................................................................................................................................................................................................................................................................161
6. Pin Keeper..................................................................................................................................................................................................................................................................161
7. Boom Rest Block.............................................................................................................................................................................................................................................................161
8. Wear Pad....................................................................................................................................................................................................................................................................161
9. Shim........................................................................................................................................................................................................................................................................161
10. Wear Pad...................................................................................................................................................................................................................................................................161
11. Shim.......................................................................................................................................................................................................................................................................161
12. Retaining Ring.............................................................................................................................................................................................................................................................161
13. Bushing....................................................................................................................................................................................................................................................................161
1. Base Boom...................................................................................................................................................................................................................................................................167
2. Fly Boom....................................................................................................................................................................................................................................................................167
3. Tower Telescope Cylinder Assembly...........................................................................................................................................................................................................................................167
4. Support.....................................................................................................................................................................................................................................................................167
5. Attach Block................................................................................................................................................................................................................................................................167
6. Shim........................................................................................................................................................................................................................................................................167
7. Bushing.....................................................................................................................................................................................................................................................................167
8. Wear Pad....................................................................................................................................................................................................................................................................167
9. Shim........................................................................................................................................................................................................................................................................167
10. Wear Pad...................................................................................................................................................................................................................................................................167
11. Shim.......................................................................................................................................................................................................................................................................167
12. Boom Rest Pad..............................................................................................................................................................................................................................................................167
Section 4. Boom & Platform.............................................................................................................................................................................................................................................................157
4.1 Boom Systems...................................................................................................................................................................................................................................................................157
Switch Systems.................................................................................................................................................................................................................................................................157
Above Elevation (Above Horizontal) Cutout System...............................................................................................................................................................................................................................157
Beyond Transport Position - Drive Speed Cutback System.........................................................................................................................................................................................................................157
Drive/Steer – Boom Function Interlock System (CE Only).........................................................................................................................................................................................................................157
Transport Position Interlock System (CE only)..................................................................................................................................................................................................................................157
Platform Control Enable System.................................................................................................................................................................................................................................................157
Function Speed Control System..................................................................................................................................................................................................................................................157
Platform.......................................................................................................................................................................................................................................................................158
Main Lift End Stroke Dampening System..........................................................................................................................................................................................................................................158
QuikStick Lift System..........................................................................................................................................................................................................................................................158
Tower Boom Sequence Valve System...............................................................................................................................................................................................................................................158
Upright Level Override System..................................................................................................................................................................................................................................................158
Ground Control Keyswitch System................................................................................................................................................................................................................................................158
1. UMS Sensor..............................................................................................................................................................................................................................................................159
2. Main Boom Angle Switch..................................................................................................................................................................................................................................................159
3. Tower Boom Angle Switch.................................................................................................................................................................................................................................................159
4. Tower Telescope Plunger Valve...........................................................................................................................................................................................................................................159
5. Tower Lift Plunger Valve................................................................................................................................................................................................................................................159
6. Proximity Switch........................................................................................................................................................................................................................................................159
7. Rotator Valve...........................................................................................................................................................................................................................................................159
8. Platform Control Valve..................................................................................................................................................................................................................................................159
4.2 Main Boom Assembly.............................................................................................................................................................................................................................................................162
Removal........................................................................................................................................................................................................................................................................162
1. Using a suitable lifting equipment, adequately support boom assembly weight along entire length.........................................................................................................................................................................162
2. Tag and disconnect hydraulic lines from telescope cylinder. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports................................................................................................................162
3. Using a suitable brass drift and hammer, remove hardware securing the main boom lift cylinder rod end pin to the base boom section. Remove the main boom lift cylinder pin from base boom. Retract the main boom lift cylinder by using the auxiliary p.................162
4. Remove the Master Cylinder as follows:..................................................................................................................................................................................................................................162
a. Using an adequate supporting device, support the master cylinder so it doesn’t fall when the retaining pins are removed.............................................................................................................................................162
b. Tag and disconnect hydraulic lines from Master Cylinder. Use a suitable container to collect any residual hydraulic fluid. Cap hydraulic lines and ports............................................................................................................162
c. Remove the bolt and keeper pin securing the master cylinder barrel end pin to the base boom section. Next, install a 3/8-16 UNC threaded lifting eye into the threaded hole of the pin and pull pin out.............................................................162
d. Remove the bolt and keeper pin securing the master cylinder rod end pin to the upright. Remove the pin..............................................................................................................................................................162
5. Remove the bolt and keeper pin securing the main boom to the upright. Using a suitable brass drift and hammer...........................................................................................................................................................162
6. Using all applicable safety precautions, carefully lift main boom assembly clear of upright and lower to ground or suitably supported work surface......................................................................................................................163
Disassembly....................................................................................................................................................................................................................................................................163
1. Remove hardware securing telescope cylinder to back end of the base boom section........................................................................................................................................................................................163
2. Remove hardware securing the powertrack to fly boom.....................................................................................................................................................................................................................163
3. Remove hardware which secures the wear pads to the base boom section; remove the wear pads from the top, sides and bottom of the base boom section......................................................................................................................163
4. Using suitable lifting device, remove fly boom assembly from base section...............................................................................................................................................................................................163
5. Using a suitable brass drift and hammer remove the telescope cylinder pin from fly boom section.........................................................................................................................................................................163
6. Pull the telescope cylinder partially from aft end of the fly boom section; secure the cylinder with a suitable sling and lifting device at approximately the center of gravity.........................................................................................163
7. Carefully remove the telescope cylinder and place telescope cylinder on a suitable trestle..............................................................................................................................................................................163
8. Remove hardware which secures the wear pads to the aft end of fly boom section; remove the wear pads from the top, sides and bottom of the fly boom section.............................................................................................................163
Inspection.....................................................................................................................................................................................................................................................................163
1. Inspect main boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as necessary.........................................................................................................................................................163
2. Inspect telescope cylinder attach point for scoring, tapering and ovality. Replace pins as necessary....................................................................................................................................................................163
3. Inspect main boom 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.................................................................................163
4. Inspect inner diameter of boom pivot bearing for scoring, distortion, wear, or other damage. Replace bearing as necessary...............................................................................................................................................163
5. Inspect all wear pads for excessive wear, or other damage...............................................................................................................................................................................................................163
6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary....................................................................................................................................................163
7. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary...............................................................................................................................163
Assembly.......................................................................................................................................................................................................................................................................163
1. Measure inside dimensions of the base section to determine the number of shims required for proper fit..................................................................................................................................................................163
2. Install side, top and bottom wear pads to the aft end of fly section; shim evenly to the measurements of the inside of base boom section................................................................................................................................163
3. Secure the sling and lifting device at the telescope cylinder’s approximate center of gravity, and lift the cylinder to the aft end of the fly boom section.............................................................................................................163
4. Slide telescope cylinder into the aft end of fly boom section. Align attachment holes in fly boom section with hole in rod end of telescope cylinder....................................................................................................................163
5. Install telescope cylinder pin and secure with mounting hardware........................................................................................................................................................................................................163
6. Secure the sling and lifting device at the fly boom assembly approximate center of gravity..............................................................................................................................................................................163
7. Slide fly boom assembly into the base boom section. Shim boom, if necessary, for a total of 1/32 inch (metric equivalent) clearance.....................................................................................................................................163
8. Install wear pads into the forward position of the base boom section. Shim boom, if necessary, for a total of 1/ 32 inch (metric equivalent) clearance..................................................................................................................163
9. Align the cylinder with the slots at aft end of base boom section, then secure cylinder with mounting hardware..........................................................................................................................................................163
Installation...................................................................................................................................................................................................................................................................164
1. Using all applicable safety precautions, carefully lift boom assembly to align the pivot holes in the boom with those of the upright....................................................................................................................................164
2. Using a suitable brass drift and hammer, install the pivot pin into the upright. Install the bolt and keeper pin securing the main boom pivot pin to the upright........................................................................................................164
3. Install the Master Cylinder as follows:.................................................................................................................................................................................................................................164
a. Using an adequate supporting device, align the master cylinder with the mounting holes on the boom and upright......................................................................................................................................................164
b. Install the master cylinder rod end pin. Install the bolt and keeper pin securing the master cylinder rod end pin to the upright....................................................................................................................................164
c. Install the barrel end retaining pin. Install the bolt and keeper pin securing the master cylinder barrel end pin to the base boom section..........................................................................................................................164
d. Connect hydraulic lines to the master cylinder as tagged during removal.............................................................................................................................................................................................164
4.3 Upright........................................................................................................................................................................................................................................................................165
Removal........................................................................................................................................................................................................................................................................165
1. Remove the main boom assembly. Refer to Section 4.6, UMS Troubleshooting And Diagnostic Trouble Codes (DTC).............................................................................................................................................................165
2. Tag and disconnect hydraulic lines to the main boom lift cylinder. Use a suitable container to collect any residual hydraulic fluid. Cap hydraulic lines and ports......................................................................................................165
3. Remove mounting hardware from main boom lift Cylinder barrel end. Using a suitable brass drift and hammer, remove pin (1) from Upright and remove Main Boom Lift Cylinder...............................................................................................165
4. Remove mounting hardware from master cylinder assembly barrel end. Using a suitable brass drift and hammer, remove pin (2) from upright and remove master cylinder assembly.............................................................................................165
4. Disconnect wiring harness to horizontal limit switch....................................................................................................................................................................................................................165
5. Disconnect the Upright Level Cylinder as follows:.......................................................................................................................................................................................................................165
a. Using a suitable lifting device, support the Upright................................................................................................................................................................................................................165
b. Remove mounting hardware securing hose bracket in upright, and remove the hose bracket..............................................................................................................................................................................165
c. Remove mounting hardware securing the upright level cylinder to the upright. Using a suitable brass drift and hammer, remove pin (3) from upright and disconnect the upright level cylinder from the upright........................................................165
6. Remove mounting hardware from the Upright Pivot Pin using a suitable brass drift and hammer. Remove pin (4) from tower boom assembly and remove the upright from the machine............................................................................................165
7. With upright removed, override tower telescope limit switch and extend the tower boom to gain access to the upright level cylinder rod end attach pin...................................................................................................................165
8. Tag and disconnect hydraulic lines to the upright lift cylinder. Use a suitable container to collect any residual hydraulic fluid. Cap hydraulic lines and ports........................................................................................................165
9. Using an overhead crane or suitable lifting device, support the upright lift cylinder, remove mounting hardware from the barrel end of the upright lift cylinder and remove the pin.....................................................................................165
10. Carefully remove the upright lift cylinder and place on a suitable work surface........................................................................................................................................................................................165
Installation...................................................................................................................................................................................................................................................................166
1. Using a suitable lifting device, carefully install the upright lift cylinder into place in the tower boom...............................................................................................................................................................166
2. Install the pin and mounting hardware at the barrel end of the upright lift cylinder....................................................................................................................................................................................166
3. Connect the hydraulic lines to the upright lift cylinder as tagged during removal.......................................................................................................................................................................................166
4. Override the tower telescope limit switch and retract the tower boom....................................................................................................................................................................................................166
5. Using an adequate lifting device, install the upright into position. Install pin (4) into the tower boom assembly and secure it in place with the mounting hardware.....................................................................................................166
6. Connect the Upright Level Cylinder as follows:..........................................................................................................................................................................................................................166
a. Align the holes in the cylinder and upright for pin (3), and install the pin into the upright and connect the upright level cylinder to the upright. Install the mounting hardware securing the pin.................................................................166
b. Install the hose bracket and secure in place with the mounting hardware.............................................................................................................................................................................................166
7. Connect the wiring harness to horizontal limit switch...................................................................................................................................................................................................................166
8. Align the holes in the main boom lift cylinder and upright for pin (1) and install the pin. Secure the pin in place with the mounting hardware..........................................................................................................................166
9. Align the holes in the master cylinder assembly and upright for pin #2 and install the pin. Secure the pin in place with the mounting hardware..........................................................................................................................166
10. Connect the hydraulic lines to the main boom lift cylinder as tagged during removal....................................................................................................................................................................................166
11. Install the main boom. Refer to Section 4.6, UMS Troubleshooting And Diagnostic Trouble Codes (DTC)....................................................................................................................................................................166
4.4 Tower Boom Assembly............................................................................................................................................................................................................................................................168
Removal........................................................................................................................................................................................................................................................................168
1. Remove the main boom assembly. Refer to Section 4.6, UMS Troubleshooting And Diagnostic Trouble Codes (DTC).............................................................................................................................................................168
2. Using an overhead crane or suitable lifting device, support the entire Tower Boom Assembly and separately support the tower lift cylinder...............................................................................................................................168
3. Remove mounting hardware from tower lift cylinder rod end. with a brass drift and hammer, remove the tower Lift cylinder Pin disconnecting the tower lift cylinder......................................................................................................168
4. Remove mounting hardware from the tower boom pivot pin. Using a suitable brass drift and hammer, remove pin (1) from turntable assembly.................................................................................................................................168
5. Using all applicable safety precautions, carefully lift the Tower Boom Assembly clear of turntable and lower to ground or a suitable supported work surface.............................................................................................................168
6. Remove mounting hardware from the upright leveling cylinder rod end. with a brass drift and hammer, remove the pin, disconnecting the upright cylinder. Remove with suitable lifting device.............................................................................168
7. Remove the Tower Fly as follows:........................................................................................................................................................................................................................................168
a. Mark all hoses and wiring harnesses at bracket on rear end of tower base boom for future assembly. Remove hoses and wiring from tower boom Powertrack...............................................................................................................168
b. Remove mounting hardware that secures the Powertrack to tower base boom and remove the Powertrack...................................................................................................................................................................168
c. Remove mounting hardware from tower boom telescope cylinder barrel and rod end......................................................................................................................................................................................168
d. Slide the telescope cylinder out of the base boom, support with an overhead crane or suitable lifting device........................................................................................................................................................168
e. Remove mounting hardware that secures the wear pads to the front of tower base boom section; Remove the wear pads from the top sides and bottom of the tower base boom..............................................................................................168
f. Using an overhead crane or suitable lifting device, remove the fly section..........................................................................................................................................................................................168
Inspection.....................................................................................................................................................................................................................................................................168
1. Inspect tower boom pivot pin for wear scoring, tapering, and ovality, or other damage. Replace pins as necessary........................................................................................................................................................168
2. Inspect tower boom pivot attach points for scoring, tapering, and ovality, or other damage. Replace pins as necessary...................................................................................................................................................168
3. Inspect inner diameter of tower boom pivot bearings for scoring, distortion, wear, or other damage......................................................................................................................................................................169
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..........................................................................................169
5. Inspect inner diameter of upright attach point bearings for scoring, distortion, wear, or other damage. Replace bearing as necessary....................................................................................................................................169
6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary....................................................................................................................................................169
7. Inspect structural units of tower boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.........................................................................................................................169
8. Inspect Powertrack for damage such as cracking, wear, or other damage. Replace links or assembly, as necessary..........................................................................................................................................................169
Assembly.......................................................................................................................................................................................................................................................................169
1. Measure inside dimensions of the tower base section to determine the number of shims required for proper fit............................................................................................................................................................169
2. Install side, top, bottom wear pads to the aft end of tower fly section; shim evenly to the measurements of the inside of the base boom section.........................................................................................................................169
3. Align upright leveling cylinder with attach holes in tower fly boom. Using a soft head mallet, install the cylinder pin into tower fly boom and secure with mounting hardware...........................................................................................169
4. Secure the sling and lifting device at the tower fly boom assembly’s approximate center of gravity......................................................................................................................................................................169
5. Slide tower fly boom assembly into the tower base boom section, for a total of 1/32 inch (metric equivalent) clearance..................................................................................................................................................169
6. Install wear pads into the forward position of the tower base boom section. Shim boom, if necessary, for a total of 1/32 inch (metric equivalent) clearance.............................................................................................................169
7. Align the telescope cylinder with the slots at the aft end of tower base boom section, then secure cylinder with mounting hardware......................................................................................................................................169
8. Attach internal Powertrack to tower base boom at bottom only and extended out of boom that the Powertrack links are opened at top.......................................................................................................................................169
9. Attach hoses and wiring harnesses at front end of base boom and route thru the Powertrack. Secure hoses and wiring harnesses with hose brackets.........................................................................................................................169
10. Roll the Powertrack back into the base boom section and attach loose end of the Powertrack to the inside top of the fly boom section...................................................................................................................................169
Installation...................................................................................................................................................................................................................................................................169
1. Using a suitable lifting device, position boom assembly on turntable so that the pivot holes in both boom and turntable are aligned.....................................................................................................................................169
2. Install boom pivot pin, ensuring that location of hole in pin is aligned with attach point on turntable.................................................................................................................................................................169
3. If necessary, gently tap pin into position with soft headed mallet. Secure pin mounting hardware........................................................................................................................................................................169
4. Connect all wiring connectors to the correct connectors.................................................................................................................................................................................................................169
5. Connect all hydraulic lines of boom assembly............................................................................................................................................................................................................................169
6. Using all applicable safety precautions, operate lifting device in order to position boom lift cylinder so that holes in the cylinder rod end and boom structure are aligned. Insert the lift cylinder pin, ensuring that location of hole in pin is al.................169
7. Using all applicable safety precautions, operate from the lower controls and raise and extend boom fully, noting the performance of the extension cycle.................................................................................................................169
8. Retract and lower boom, noting the performance of the retraction cycle..................................................................................................................................................................................................169
Tower Out of Sync..............................................................................................................................................................................................................................................................170
1. The releveling valve (red knob on the oil tank PN: 4640866), this is a poppet valve that could be leaking fluid out of the closed loop. Manually opening the valve and flushing it can eliminate any contaminate on the seat. The seat could also be da.................170
2. A relief valve is located in the upright. This relief valve could be leaking backwards out of the loop. Replace the cartridge. They are pre-set.........................................................................................................................170
3. The counterbalance valve in the piston end of the upright level cylinder. There could be a leak path from the valve port to the pilot port. Replace the counterbalance valve............................................................................................170
4. The counterbalance valve in the rod end of the lower lift cylinder. There could be a leak path from the valve port to the pilot port. Replace the counterbalance valve..................................................................................................170
5. The packing on either the upright or lower cylinder can cause this. Do cylinder tests to determine if either cylinder needs new packing.................................................................................................................................170
1. The relief valve located in the upright (PN: 4640929). If this valve is set too low or has contaminate in it causing it to leak prematurely, when lifting down oil can pass through it causing the volume to grow between the cylinders. Flush the valv.................171
2. The counterbalance valve in the piston end of the upright level cylinder. There could be a leak path from the pilot port to the valve port. Replace the counterbalance valve............................................................................................171
3. The counterbalance valve in the rod end of the lower lift cylinder. There could be a leak path from the pilot port to the valve port. Replace the counterbalance valve..................................................................................................171
4. The packing on the lower lift cylinder can cause this. Do a cylinder test to check this out. Refer to Table 2-2, Cylinder Drift.........................................................................................................................................171
4.5 Upright Monitoring System (UMS)................................................................................................................................................................................................................................................172
Re-Synchronizing Upright.......................................................................................................................................................................................................................................................172
1. Turn the key switch to the ground control position......................................................................................................................................................................................................................172
2. Start the engine........................................................................................................................................................................................................................................................172
3. Pull and hold the red relevel knob located next to the main control valve. Refer to (See Figure 4-7.)...................................................................................................................................................................172
4. Raise the tower boom 6 feet (1.8 m).....................................................................................................................................................................................................................................172
5. Release the red relevel knob............................................................................................................................................................................................................................................172
6. Lower the tower boom fully and continue to hold down the switch to Tower Down for an additional 20 seconds..............................................................................................................................................................172
7. Repeat steps 3 thru 6 if necessary until the upright is 90° (vertical) relative to the chassis..........................................................................................................................................................................172
Calibration....................................................................................................................................................................................................................................................................174
1. Connect the JLG Hand-held analyzer to the original analyzer connection in the ground box................................................................................................................................................................................174
2. Pull out the emergency stop button at the ground control station and start the engine from the ground controls..........................................................................................................................................................174
3. To calibrate the Upright Monitoring System through the hand-held analyzer, you must be in access level 1. To advance to access level 1, scroll to the ACCESS LEVEL menu and press "ENTER". Using the arrows on the keypad, enter the password "33271" a.................174
4. Calibrate the upright monitoring system sensor by the following procedure:..............................................................................................................................................................................................174
a. In access level 1, scroll through the menu items until "CALIBRATIONS" is displayed on the second line of the analyzer screen. The screen will display the following:................................................................................................174
b. after pressing 'ENTER" one of the following screens will be displayed: Or...........................................................................................................................................................................................174
c. Scroll left to right through the above menu items until "UMS SENSOR" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key.............................................................................................................175
d. After selecting "UMS SENSOR", the following screen will appear:.....................................................................................................................................................................................................175
e. Press "ENTER" and the next screen will display the following, asking if the machine is on a level surface:..........................................................................................................................................................175
f. Verify the machine is level and press "ENTER". The screen will display the following, asking you to fully elevate the main boom:....................................................................................................................................175
g. After the main boom has been fully elevated, press "ENTER". The analyzer will display the following:................................................................................................................................................................176
h. With the aid of an assistant, pull and hold the red re- leveling knob on the hydraulic tank while lifting the tower boom. Raise the tower boom six (6) feet or two (2) meters. After elevating the tower the required distance, press “ENTER”. If t.................176
i. When viewing the above display, press “ENTER”. The screen will display the following:...............................................................................................................................................................................177
j. Lower the tower boom onto the boom stop. Continue to hold the tower boom down function for at least twenty (20) seconds WITHOUT RELEASING THE FUNCTION SWITCH. The calibration must recognize continuous activation of the tower down function switch f.............177
k. To correctly complete the calibration process, fully retract and fully lower the main boom. Once the machine is in the stowed position, turn off the machine and disconnect the analyzer............................................................................178
Calibration Faults.............................................................................................................................................................................................................................................................178
Function Check.................................................................................................................................................................................................................................................................178
1. Connect the hand-held analyzer at the ground control station using the four-pin connector...............................................................................................................................................................................178
2. Pull out the emergency stop button at the ground control station and turn the key switch to ground controls. Start the engine...........................................................................................................................................178
3. Advance to access level 1 by scrolling to the ACCESS LEVEL menu and press "ENTER" . Using the arrows on the keypad, enter the password "33271" and press "ENTER" .......................................................................................................178
4. Scroll through the top level menu until SERVICE MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will be displayed: Or.........................................................................................179
5. Scroll left to right through the above menu items until "TEST UMS?" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key..................................................................................................................179
6. The controller will now display the following: or, by pressing the up and down arrow keys:..............................................................................................................................................................................179
7. When the "YES" message is displayed, press the "ENTER" key to automatically perform a function test. Upon the function test, the system will activate the Upright Monitoring System, warning lights, and alarm. Verify that the alarm sounds, the boom .................179
8. From the ground controls, raise the tower boom several feet. Verify that the tower boom will not lower..................................................................................................................................................................180
9. To end the system test, press the Emergency Stop Switch (EMS) at the ground controls. Upon loss of power (pressing the EMS) to the system, the upright monitoring system will reset and all functionality will be restored to the machine...............................180
Service Mode/Tower Boom Retrieval..............................................................................................................................................................................................................................................180
1. Connect the hand-held analyzer at the ground control station using the four-pin connector...............................................................................................................................................................................180
2. Pull out the emergency stop button at the ground control station and turn the key switch to ground controls. Start the engine...........................................................................................................................................180
3. Advance to access level 1 by scrolling to the ACCESS LEVEL menu and press "ENTER" . Using the arrows on the keypad, enter the password "33271" and press "ENTER" .......................................................................................................180
4. Scroll through the top level menu until SERVICE MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will be displayed: Or.........................................................................................180
5. Scroll left to right through the above menu items until "TOWER LIFT DOWN?" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key...........................................................................................................181
6. The controller will now display the following:..........................................................................................................................................................................................................................181
7. Enter the service code "81075" and press the "ENTER" key. The controller display will now display the following, followed by: The flashing and scrolling messages will repeat until the "ENTER" key is pressed..........................................................181
8. When the "ENTER" key is pressed, the UMS will be disabled and the display will read:....................................................................................................................................................................................181
9. Before using tower lift down adhere to the following:...................................................................................................................................................................................................................182
10. When the platform has been safely lowered to the ground, exit the service mode by pressing the Emergency Stop Switch (EMS) at the ground controls. Upon loss of power (pressing the EMS) to the system, the upright monitoring system will reset and a.................182
4.6 UMS Troubleshooting And Diagnostic Trouble Codes (DTC).........................................................................................................................................................................................................................184
Backward Stability Concern DTC (2532)..........................................................................................................................................................................................................................................184
Forward Stability Concern DTC (2530)...........................................................................................................................................................................................................................................184
Out of Usable Range DTC (2531).................................................................................................................................................................................................................................................184
UMS Sensor Not Calibrated DTC (816)............................................................................................................................................................................................................................................184
UMS Sensor Faulted DTC (817)...................................................................................................................................................................................................................................................184
Calibration Faults.............................................................................................................................................................................................................................................................184
4.7 Platform.......................................................................................................................................................................................................................................................................185
Platform Valve Removal.........................................................................................................................................................................................................................................................185
1. Tag and disconnect the hydraulic lines from the platform control valve. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports....................................................................................................185
2. Remove hardware securing cover from the platform support. Remove cover..................................................................................................................................................................................................185
3. Remove hardware securing the mounting bracket to the platform support. Take out the mounting bracket along with platform control valve..................................................................................................................................185
4. Remove hardware securing the platform control valve to the mounting bracket. Remove platform control valve..............................................................................................................................................................185
Platform Valve Installation....................................................................................................................................................................................................................................................185
1. Install platform control valve onto the mounting bracket and secure using hardware......................................................................................................................................................................................185
2. Install the mounting bracket onto the platform support and secure using hardware........................................................................................................................................................................................185
3. Install cover onto the platform support securing hardware...............................................................................................................................................................................................................185
4. Remove tag and reconnect the hydraulic lines to the platform control valve..............................................................................................................................................................................................185
Platform Support Removal.......................................................................................................................................................................................................................................................186
1. Disconnect electrical cables from control console.......................................................................................................................................................................................................................186
2. Tag and disconnect the hydraulic lines from the rotator. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports...................................................................................................................186
3. Remove the bolts securing the platform to the platform support..........................................................................................................................................................................................................186
4. Using a suitable device, support the platform support...................................................................................................................................................................................................................186
5. Remove the bolts and locknuts securing the support to the rotator.......................................................................................................................................................................................................186
6. Using a suitable brass drift and hammer, remove the rotator shaft, remove the support from the rotator..................................................................................................................................................................186
Support Installation...........................................................................................................................................................................................................................................................187
1. Using a suitable device, support the platform support and position it on the rotator....................................................................................................................................................................................187
2. Install the rotator center bolt.........................................................................................................................................................................................................................................187
3. Apply Medium Strength Threadlocking Compound to the eight bolts and locknuts securing the support to the rotator and install the bolts and locknuts.....................................................................................................................187
4. Torque the nut on the rotator center bolt to 586 ft. lbs. (795 Nm). Torque the retaining bolts to 40 ft. lbs. (55 Nm)...................................................................................................................................................187
5. Position the platform on the platform support and install the bolts securing the platform to the platform support. Torque the bolts to 64 ft. lbs. (88 Nm)..............................................................................................................187
6. Remove tag and reconnect the hydraulic lines to the rotator.............................................................................................................................................................................................................187
7. Connect the electrical cables to the platform control console...........................................................................................................................................................................................................187
4.8 Bolt-on External Fall Arrest...................................................................................................................................................................................................................................................189
Inspection Before Use..........................................................................................................................................................................................................................................................189
Installation...................................................................................................................................................................................................................................................................189
1. Install the retaining hardware (bolts, nuts, and washers) and secure the brackets to the platform rail. Tighten the nuts but do not torque them yet.....................................................................................................................189
2. Attach the fall arrest cable to the right hand bracket Using the attaching bolt and nut. Orient the bolt as shown below. Do not tighten the nut so cable can still rotate...............................................................................................190
3. Install the Attachment Ring onto the cable..............................................................................................................................................................................................................................190
4. Without twisting the fall arrest cable, pull it thru the left hand bracket and mark the top of the swaged cable end. Install the fall arrest cable through the left hand bracket and secure it using the belleville washers, washer, retaining nut, and.................190
5. Use the two jam nuts to prevent the cable from rotating while the nut is tightened. Tighten the nut until the belleville washers are fully compressed and no gap is present at the outside diameter of the washers. Ensure the cable has not rotated du.................190
6. Tighten the first jam nut against the retaining nut to keep the nut from loosening. Tighten the remaining jam nut against the first jam nut.............................................................................................................................190
7. Torque the nuts and bolts securing the brackets to 15 ft.lbs. (20 Nm)...................................................................................................................................................................................................190
1. Belleville Washer.......................................................................................................................................................................................................................................................190
2. Washer..................................................................................................................................................................................................................................................................190
3. Hex Nut.................................................................................................................................................................................................................................................................190
4. Jam Nut.................................................................................................................................................................................................................................................................190
5. LH Bracket..............................................................................................................................................................................................................................................................190
6. Attachment Ring.........................................................................................................................................................................................................................................................190
7. Cable...................................................................................................................................................................................................................................................................190
8. RH Bracket..............................................................................................................................................................................................................................................................190
9. Decal...................................................................................................................................................................................................................................................................190
4.9 Articulating Jib...............................................................................................................................................................................................................................................................191
Removal........................................................................................................................................................................................................................................................................191
1. For platform/support removal see platform/support removal diagram. (See Section 4.7, Platform)..........................................................................................................................................................................191
2. Position the articulating jib boom level with the ground................................................................................................................................................................................................................191
3. Tag and disconnect hydraulic lines from level cylinder and lift cylinder. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports..................................................................................................191
4. Remove mounting hardware from slave cylinder pin (1). Using a suitable brass drift and hammer, remove the cylinder pin from articulating jib boom.......................................................................................................................191
5. Remove mounting hardware from articulating jib boom pivot pin (2). Using a suitable brass drift and hammer, remove the pivot pin from boom assembly.....................................................................................................................191
Disassembly....................................................................................................................................................................................................................................................................191
1. Remove mounting hardware from articulating jib boom pivot pins (3) and (4). Using a suitable brass drift and hammer, remove the pins from articulating jib boom pivot weldment..........................................................................................191
2. Remove mounting hardware from rotator support pins (5) and (6). Using a suitable brass drift and hammer, remove the pins from rotator support...........................................................................................................................191
3. Remove mounting hardware from lift cylinder pin (7). Using a suitable brass drift and hammer, remove the cylinder pin from articulating jib boom........................................................................................................................191
Inspection.....................................................................................................................................................................................................................................................................191
1. Inspect articulating fly boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as necessary.............................................................................................................................................191
2. Inspect articulating fly boom pivot attach points for scoring, tapering and ovality, or other damage. Replace pins as necessary.........................................................................................................................................191
3. Inspect inner diameter of articulating fly boom pivot bearings for scoring, distortion, wear, or other damage. Replace bearings as necessary............................................................................................................................191
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...........................................................................................192
5. Inspect inner diameter of rotator attach point bearings for scoring, distortion, wear, or other damage..................................................................................................................................................................192
6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary....................................................................................................................................................192
7. Inspect structural units of articulating jib boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary..............................................................................................................192
Assembly.......................................................................................................................................................................................................................................................................192
1. Align lift cylinder with attach holes in articulating jib boom. Using a soft head mallet, install cylinder pin (7) into articulating jib boom and secure with mounting hardware.........................................................................................192
2. Align bottom tubes with attach holes in articulating jib boom pivot weldment. Using a soft head mallet, install rotator support pin (3) into articulating jib boom pivot weldment and secure with mounting hardware.....................................................192
3. Align rotator support with attach hole in articulating jib boom. Using a soft head mallet, install rotator support pin (6) into articulating jib boom and secure with mounting hardware.................................................................................192
4. Align bottom tubes with attach holes in rotator support. Using a soft head mallet, install rotator support pin (5) into articulating jib boom and secure with mounting hardware.........................................................................................192
5. Align articulating jib boom with attach hole in articulating jib boom pivot weldment. Using a soft head mallet, install rotator support pin (4) into articulating jib boom and secure with mounting hardware............................................................192
Installation...................................................................................................................................................................................................................................................................192
1. Align articulating jib boom pivot weldment with holes in fly boom assembly. Using a soft head mallet, install pivot pin #2 into fly boom assembly and secure with mounting hardware.....................................................................................192
2. Align the platform (slave) leveling cylinder with holes in articulating jib boom pivot weldment. Using a soft head mallet, install platform (slave) leveling cylinder pin #1 into articulating jib boom pivot weldment and secure with mounting hardware................192
3. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to platform level cylinder and jib lift cylinder as tagged during removal....................................................................................................192
4.10 Rotator and Slave Cylinder....................................................................................................................................................................................................................................................193
Removal........................................................................................................................................................................................................................................................................193
1. Remove the Platform and Platform Support. (Section 4.7, Platform).......................................................................................................................................................................................................193
2. Extend the fly boom section out to gain access to the platform level cylinder pin.......................................................................................................................................................................................193
3. 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.....................................................................................................193
4. Supporting the rotator and jib assembly, remove hardware from pin #1. Using a suitable brass drift and hammer remove pin #1 from the jib assembly.......................................................................................................................193
5. Remove the hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2 from the jib assembly and remove the rotator....................................................................................................................................193
6. Supporting the platform level cylinder, remove the hardware from pin #3. Using a suitable brass drift and hammer remove pin #3 from the jib assembly....................................................................................................................193
7. Remove the hardware from pin #4. Using a suitable brass drift and hammer remove pin #4 from the fly boom. Remove the platform level cylinder............................................................................................................................193
Installation...................................................................................................................................................................................................................................................................193
1. Support the platform level cylinder. Using a soft head mallet install pin #4 to the fly boom. Install hardware securing pin #4..........................................................................................................................................193
2. Support the jib assembly. Using a soft head mallet install pin #3 to jib assembly. Install hardware securing pin #3.....................................................................................................................................................193
3. Support the rotator. Using a soft head mallet, install pin #2 to the jib assembly. Install hardware securing pin #2 and torque to 35 ft. lbs. (48 Nm)...................................................................................................................193
4. Using head mallet install pin #1 to jib assembly and install the rotator. Install hardware securing pin #1 and torque to 35 ft. lbs. (48 Nm)............................................................................................................................193
5. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to rotator and platform level cylinder as tagged during removal..............................................................................................................193
4.11 Sequence For Hose Replacement In The Tower Boom...............................................................................................................................................................................................................................194
1. Remove the tower boom front cover bolts, exposing the Powertrack............................................................................................................................................................................................................194
2. Remove bolts to disconnect the top bar of the Powertrack....................................................................................................................................................................................................................194
3. Pull the Powertrack out of base boom. (as far as hoses will allow)..........................................................................................................................................................................................................194
4. At left side rear of upright, remove access cover plate (4) bolts. (others if necessary)....................................................................................................................................................................................194
5. Remove access cover plate, (4) bolts, from bottom front of fly boom.........................................................................................................................................................................................................194
6. Cut cable ties that attach hose to be replaced..............................................................................................................................................................................................................................194
7. Disconnect hose that is to be replaced, and cap the male fitting............................................................................................................................................................................................................194
8. Attach the new hose to the end of the hose to be replaced...................................................................................................................................................................................................................194
9. Pull these lines thru the upright and out the bottom, then feed back into the fly boom......................................................................................................................................................................................194
10. At the Powertrack, in front of the tower boom, open the Powertrack links to expose the hose to be replaced.................................................................................................................................................................194
11. Pull hose to be replaced, attached to the new hose, thru the fly boom and thru the Powertrack links........................................................................................................................................................................194
12. Disconnect new hose from the replaced hose and connect to fitting where the damaged hose was connected.....................................................................................................................................................................194
13. Roll Powertrack back into base, and attach the top bar of the Powertrack (2) bolts to the inside top of the fly boom section...............................................................................................................................................194
14. Check for leaks and hardware tightened securely............................................................................................................................................................................................................................194
15. Replace access cover plates and front cover................................................................................................................................................................................................................................194
4.12 Limit Switches Adjustment.....................................................................................................................................................................................................................................................194
Main Boom Horizontal Limit Switch..............................................................................................................................................................................................................................................194
1. Place machine on level surface..........................................................................................................................................................................................................................................194
2. Raise main boom 5 to 10 degrees above horizontal. Limit switch should activate before this point........................................................................................................................................................................194
3. Lower main boom until limit switch resets. This should be 1 degree above to 4 degrees below horizontal. (See Figure 4-16.) for adjustments..............................................................................................................................194
Tower Boom Horizontal Limit Switch.............................................................................................................................................................................................................................................194
1. Place machine on level surface..........................................................................................................................................................................................................................................194
2. Raise Tower Boom 8 to 13 degrees above horizontal. The tower angle limit switch should activate at this point...........................................................................................................................................................194
3. Lower the tower boom until the limit switch resets. This should be 2 to 7 degrees below where the switch was activated. (See Figure 4-15. and Figure 4-16. for adjustments).............................................................................................194
4.13 Boom Valve Adjustment.........................................................................................................................................................................................................................................................198
1. Adjust the screws so the plunger on the valves has 0.250 in. (6.35 mm) travel remaining when the lower boom is fully raised and retracted...................................................................................................................................198
2. After the valves are adjusted, adjust the proximity switches to within 0.314 in. (8 mm) of their target. The LED’s on the proximity switches will light when the power is on and the switch is within 0.314 in. (8 mm) of the target. There is a prox.......................198
Tower Boom.....................................................................................................................................................................................................................................................................198
1. Shim up wear pads until 1/32 in. (0.8 mm) clearance to adjacent surface.................................................................................................................................................................................................198
2. When adjusting wear pads, removing or adding shims, bolt length must also be changed....................................................................................................................................................................................198
a. When adding shims, longer bolts must be used to ensure proper thread engagement in insert...........................................................................................................................................................................198
b. When shims are removed, shorter bolts must be used so bolt does not protrude from insert and come into contact with boom surface....................................................................................................................................198
Main Boom......................................................................................................................................................................................................................................................................198
1. Shim up wear pads to within 1/32 in. (0.8 mm) clearance between wear pad and adjacent surface...........................................................................................................................................................................198
2. Adjusting wear pads, removing or adding shims, bolt length must also be changed.........................................................................................................................................................................................198
a. When adding shims, longer bolts must be used to ensure proper thread engagement in insert...........................................................................................................................................................................198
b. When shims are removed, shorter bolts must be used so bolt does not protrude from insert and Sheaves and wire rope must be replaced as sets.........................................................................................................................198
4.14 Boom Cleanliness Guidelines...................................................................................................................................................................................................................................................199
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.....................199
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 .....................199
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......................199
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.............................................199
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.....................199
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......................................................199
4.15 Main Boom Powertrack..........................................................................................................................................................................................................................................................200
Removal........................................................................................................................................................................................................................................................................200
1. Disconnect wiring harness connectors located in tower upright...........................................................................................................................................................................................................200
2. Tag and disconnect hydraulic lines from connectors at boom assembly. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.......................................................................................................200
3. Remove hydraulic lines and electrical cables from Powertrack............................................................................................................................................................................................................200
4. Using suitable lifting equipment, adequately support Powertrack weight along entire length..............................................................................................................................................................................200
5. Remove hardware (1) securing the push tube on the fly boom section......................................................................................................................................................................................................200
6. Remove hardware(2) securing the push tube on the mid boom section.......................................................................................................................................................................................................200
7. With Powertrack supported and using all applicable safety precautions, remove hardware (3), (4) and (5) securing rail to the base boom section. Remove Powertrack from boom section.....................................................................................200
Installation...................................................................................................................................................................................................................................................................200
1. With powertrack supported and using all applicable safety precautions, install bolt(3), (4) and (5) securing rail to the base boom section..............................................................................................................................200
2. With adequate support and lifting device align, place mid boom push tube on the mid boom section to get access to install hardware (2)..................................................................................................................................200
3. Install bolt (1) securing the push tube on the fly boom section.........................................................................................................................................................................................................200
4. Connect hydraulic lines and electrical cables to Powertrack. Uncap all hydraulic lines and ports........................................................................................................................................................................200
5. Disconnect wiring harness connectors located in tower upright...........................................................................................................................................................................................................200
4.16 Powertrack Maintenance........................................................................................................................................................................................................................................................205
Flat Bar Removal...............................................................................................................................................................................................................................................................205
1. Use a small ¼” ratchet and a T-20 Torx bit. Remove the 8- 32 x 0.500 screws from both sides. (If the track also has a flat bar on the inside of the track instead of round bar/ poly, perform the same step to remove it.)..............................................205
Round Bar/Poly Bar Removal.....................................................................................................................................................................................................................................................205
1. Use a small ¼” ratchet with a T-25 Torx bit. Remove the 10-24 x 0.812 screw. (If the bar spins then grip the bar and poly tightly with a vise-grip).....................................................................................................................205
2. Lift up one end of the bar and slide the poly roller off................................................................................................................................................................................................................205
3. While gripping the bar tightly, remove the other 10-24 x 0.812 screw....................................................................................................................................................................................................206
Removing and Installing Links..................................................................................................................................................................................................................................................206
1. To remove the links, the rivets holding the links together must be removed. The following will show one way this can be done. Use a right angle die grinder with a ¼” ball double cut bur...............................................................................206
2. Insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled over part of the rivet falls off. Repeat this step for all rivets that must be removed...............................................................206
3. After grinding, it is sometimes necessary to use a center punch to punch out the rivet from the link....................................................................................................................................................................207
4. To install new links, extend the main moving end over the lower part of the track so the new connection point is in the curved part of the track. This will allow the round half-shears to be rotated in a way they will fit into the peanut-shaped cut.................207
5. Install the pin into the center hole, then slide the washer over the pin. Install the snap ring into the groove in the pin..............................................................................................................................................208
6. Install more pins, washers, and snap rings into all the links where a rivet was removed.................................................................................................................................................................................209
Installing a New Flat Bar......................................................................................................................................................................................................................................................209
1. While holding the flat bar, install new 8-32 x 0.500 self threading torx screws into both holes on each side of track...................................................................................................................................................209
Installing a New Round Bar/Poly Roller.........................................................................................................................................................................................................................................210
1. While tightly holding the round bar, install the new 10- 24 x 0.812 self threading torx screw. Next lift up the other end and slide a new poly roller on. Install another 10-24 x 0.812 screw on the other side.........................................................210
Replacing a Fixed End Bracket..................................................................................................................................................................................................................................................210
1. Remove the bracket by removing the center pin, washer, and snap ring. Install a new bracket then reinstall the pin, washer, and new snap ring. After installing the new bracket make sure that it rotates correctly.....................................................210
Replacing a Moving End Bracket.................................................................................................................................................................................................................................................211
1. Remove bracket by removing all pins, washers, and snap rings. Replace with a new bracket and reinstall the pins, washers, and new snap rings. After installing a new bracket make sure that it rotates correctly........................................................211
Replacing a One Piece Bracket..................................................................................................................................................................................................................................................211
1. Remove all pins, washers, and snap rings and slide the bracket off of the links.........................................................................................................................................................................................211
2. To install a new bracket, slide the bracket over the links and reinstall the pins, washers, and new snap rings. After installing the new bracket make sure that it rotates correctly....................................................................................212
4.17 Rotator Assembly..............................................................................................................................................................................................................................................................213
Theory of Operation............................................................................................................................................................................................................................................................213
Required Tools.................................................................................................................................................................................................................................................................213
1. Flashlight - helps examine timing marks, component failure and overall condition........................................................................................................................................................................................213
2. Felt Marker - match mark the timing marks and outline troubled areas....................................................................................................................................................................................................213
3. Allen wrench - removal of port plugs and set screws.....................................................................................................................................................................................................................213
4. Box knife - removal of seals............................................................................................................................................................................................................................................213
5. Seal tool - assembly and disassembly of seals and wear guides...........................................................................................................................................................................................................213
6. Pry bar - removal of endcap and manual rotation of shaft................................................................................................................................................................................................................213
7. Rubber mallet- removal and installation of shaft and piston sleeve assembly.............................................................................................................................................................................................213
8. Nylon drift - installation of piston sleeve.............................................................................................................................................................................................................................213
9. Endcap dowel pins - removal and installation of endcap (sold with Helac seal kit).......................................................................................................................................................................................213
Disassembly....................................................................................................................................................................................................................................................................216
1. Remove the Capscrews (113) over endcap lock pins (109)..................................................................................................................................................................................................................216
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16” (4.76mm).................................................................................................................................................216
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 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out the entire pin...........................................................................216
4. Install the endcap (4) removal tools provided with the Helac seal kit...................................................................................................................................................................................................216
5. Using a metal bar, or similar tool, unscrew the endcap (4) by turning it counterclockwise...............................................................................................................................................................................216
6. Remove the endcap (4) and set aside for later inspection................................................................................................................................................................................................................217
7. Remove the stop tube if equipped. The stop tube is an available option to limit the rotation of the actuator............................................................................................................................................................217
8. Every actuator has timing marks for proper engagement...................................................................................................................................................................................................................217
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....................................................................................................217
10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet.................................................................................................................................................................218
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)....................................................................218
12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged........................................................................................................................................................................218
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.........................................................................................................................218
14. Remove the o-ring (204) and backup ring (207) from endcap (4) and set aside for inspection.............................................................................................................................................................................218
15. Remove the wear guides (302) from the endcap (4) and shaft (2).........................................................................................................................................................................................................218
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...............................................................................................................................219
17. Remove the thrust washers (304), from the endcap (4) and shaft (2).....................................................................................................................................................................................................219
18. Remove the wiper seal (304.1) from its groove in the endcap (4) and shaft (2)..........................................................................................................................................................................................219
19. Remove the piston O.D. seal (202) from the piston......................................................................................................................................................................................................................219
20. Remove the piston I.D. seal (200). You may now proceed to the inspection process.......................................................................................................................................................................................219
Inspection.....................................................................................................................................................................................................................................................................220
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..................220
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” or 2.34 mm)................................................................................................220
3. Inspect the wear guide condition and measure thickness (not less than 0.123” or 3.12 mm)................................................................................................................................................................................220
Assembly.......................................................................................................................................................................................................................................................................220
1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal orientations.................................................................................................................................220
2. Install the thrust washer (304) onto shaft (2) and endcap (4)...........................................................................................................................................................................................................221
3. Install the wiper seal (304.1/green 0-ring) into the groove on the shaft (2) and endcap (4) around the outside edge of the thrust washer (304)..........................................................................................................................221
4. Using a seal tool install the main pressure seal (205) onto shaft (2) and endcap (4). Use the seal tool in a circular motion............................................................................................................................................221
5. Install the wear guide (302) on the endcap (4) and shaft (2)............................................................................................................................................................................................................221
6. Install the O-ring (204) and backup ring (207) into the inner seal groove on the endcap (4).............................................................................................................................................................................222
7. Install the inner T-seal (200) into the piston (3) using a circular motion. Install the outer T-seal (202) by stretching it around the groove in a circular motion. Each T-seal has 2 backup rings (see drawing for orientation). Beginning with the in.................222
8. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore..............................................................................................................................................222
9. 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.....................223
10. 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......................223
11. Install the shaft (2) into the piston (3). Be careful not to damage the seals. Do not engage the piston gear teeth yet.................................................................................................................................................223
12. 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........................223
13. 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...................................................................................................224
14. Install the stop tube onto the shaft end, if equipped. Stop tube is an available option to limit the rotation of an actuator...........................................................................................................................................224
15. Coat the threads on the end of the shaft with anti-seize grease to prevent galling.....................................................................................................................................................................................224
16. Install the 0-ring (204) and backup ring (207) into the inner seal groove on the endcap (4)............................................................................................................................................................................224
17. Thread the endcap (4) onto the shaft (2) end. Make sure the wear guide remains in place on the endcap as it is threaded into the housing (1)...........................................................................................................................224
18. Tighten the endcap (4). In most cases the original holes for the lock pins will line up................................................................................................................................................................................225
19. 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........................................................................................................225
20. Insert the set screws (113) over the lock pins. Tighten them to 25 in. lbs. (2.825 Nm).................................................................................................................................................................................225
Installing Counterbalance Valve................................................................................................................................................................................................................................................226
1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Medium Strength Threadlocking Compound.......................................................................................................................226
2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing.............................................................................................................................................................226
3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. Medium Strength Threadlocking Compound should be applied to the shank of the three bolts at the time of installation..............................................226
4. Torque the 1/4-inch 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-inch bolts 140 in.lbs. (15.8 Nm). Do not torque over 145 in.lbs. (16.3 Nm)....................................................................226
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...............................226
Greasing Thrust Washers........................................................................................................................................................................................................................................................227
1. After the actuator is assembled but before it is put into service, the thrust washer area must be packed with Lithium grease............................................................................................................................................227
2. There are two grease ports located on both the shaft flange and the endcap. They are plugged with Capscrews (113) or set screws. Remove the grease port screws from the shaft flange and endcap. (See exploded view)....................................................227
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 endcap. Insert the Cap.................227
Testing the Actuator...........................................................................................................................................................................................................................................................227
Testing the Actuator for Internal Leakage..................................................................................................................................................................................................................................227
Installation and Bleeding......................................................................................................................................................................................................................................................228
1. Connect a 3/16" inside diameter x 5/16" 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 can be.................228
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.................228
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..........................................................................228
4. Repeat steps 2 & 3. After the last 1/2 gallon is purged, close both bleed nipples before rotating away from the end position............................................................................................................................................228
4.18 Foot Switch Adjustment........................................................................................................................................................................................................................................................228
Troubleshooting................................................................................................................................................................................................................................................................229
1. Shaft rotates slowly or not at all......................................................................................................................................................................................................................................229
2. Operation is erratic or not responsive..................................................................................................................................................................................................................................229
3. Shaft will not fully rotate.............................................................................................................................................................................................................................................229
4. Selected position cannot be maintained..................................................................................................................................................................................................................................229
4.19 Skyguard......................................................................................................................................................................................................................................................................230
Operation......................................................................................................................................................................................................................................................................230
Function Test..................................................................................................................................................................................................................................................................230
SkyGuard Only..............................................................................................................................................................................................................................................................230
1. Operate the telescope out function, then activate SkyGuard sensor...................................................................................................................................................................................................230
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.............230
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify operation can be resumed................................................................................................................230
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure normal operation available..............................................................................................................................................................230
Soft touch only............................................................................................................................................................................................................................................................230
SkyGuard not selected in machine setup.....................................................................................................................................................................................................................................230
Diagnostics & Troubleshooting..................................................................................................................................................................................................................................................231
Fault Codes................................................................................................................................................................................................................................................................231
Section 5. Basic Hydraulic Information & Hydraulic Schematics..........................................................................................................................................................................................................................233
5.1 Lubricating O-Rings in the Hydraulic System....................................................................................................................................................................................................................................233
Cup and Brush..................................................................................................................................................................................................................................................................233
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............................................................................233
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..........................................................................................233
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..................................................................................................................................233
Dip Method.....................................................................................................................................................................................................................................................................234
1. Place the sponge inside the container and add hydraulic oil to the sponge until it is fully saturated...................................................................................................................................................................234
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.............................................................234
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....................................................................................234
Spray Method...................................................................................................................................................................................................................................................................234
1. Fill the spray bottle with hydraulic oil................................................................................................................................................................................................................................234
2. Hold the fitting over a suitable catch can..............................................................................................................................................................................................................................234
3. Spray the entire o-ring surface with a medium coat of oil...............................................................................................................................................................................................................234
Brush-on Method................................................................................................................................................................................................................................................................234
1. Fill the bottle with hydraulic oil......................................................................................................................................................................................................................................234
2. Using slight pressure to the body of the spray bottle, invert the bottle so the brush end is in the downward position...................................................................................................................................................234
3. Brush hydraulic oil on the entire o-ring, applying an even coat of oil..................................................................................................................................................................................................234
5.2 Hydraulic Connection Assembly and Torque Specification.........................................................................................................................................................................................................................235
Tapered Thread Types...........................................................................................................................................................................................................................................................235
Straight Thread Types, Tube and Hose Connections...............................................................................................................................................................................................................................235
Straight Thread Types, Port Connections........................................................................................................................................................................................................................................236
Flange Connection Types........................................................................................................................................................................................................................................................236
Tightening Methods.............................................................................................................................................................................................................................................................236
Assembly And Torque Specifications.............................................................................................................................................................................................................................................237
GENERAL TUBE TYPE FITTING ASSEMBLY INSTRUCTIONS............................................................................................................................................................................................................................237
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.................237
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.......................................................................................................237
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...............................................................................237
a. Avoid using dirty or oily rags when handling fittings...........................................................................................................................................................................................................237
b. If fittings are disassembled, they should be cleaned and inspected for damage. Replace fittings as necessary before re-installing...............................................................................................................................237
c. Sealing compounds should be applied where specified; however, care should be taken not to introduce sealant into the system.....................................................................................................................................237
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........................................................................................................237
e. Sealant should only be applied to the male threads..............................................................................................................................................................................................................237
f. Straight thread fittings do not require sealants. O- rings or washers are provided for sealing..................................................................................................................................................................237
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.................................237
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...........................................................................................237
4. Take care to identify the material of parts to apply the correct torque values......................................................................................................................................................................................237
a. Verify the material designation in the table headings...........................................................................................................................................................................................................237
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......................................237
5. To achieve the specified torque, the torque wrench is to be held perpendicular to the axis of rotation..............................................................................................................................................................237
6. Refer to the appropriate section in this manual for more specific instructions and procedures for each type of fitting connection...................................................................................................................................237
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.............................................................................................................................................................................................238
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs......................................................................................................................................................238
2. Apply a suitable thread sealant, such as High Strength Threadlocking Compound, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads are uncovered to prevent system contamination...........................................................238
3. Assemble connection hand tight..........................................................................................................................................................................................................................................238
4. Mark fittings, male and female..........................................................................................................................................................................................................................................238
5. Rotate male fitting the number of turns per Table 5-1, NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT procedure requirements......................................................................................................................................238
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections..............................................................................................................................................................................................239
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs......................................................................................................................................................239
2. Apply a suitable thread sealant, such as High Strength Threadlocking Compound, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads are uncovered to prevent system contamination...........................................................239
3. Assemble connection hand tight..........................................................................................................................................................................................................................................239
4. Mark fittings, male and female..........................................................................................................................................................................................................................................239
5. Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT procedure requirements......................................................................................................................................239
Assembly Instructions for 37° (JIC) Flare Fittings.............................................................................................................................................................................................................................240
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...........................240
2. Align tube to fitting and start threads by hand.........................................................................................................................................................................................................................240
3. Torque assembly to value listed in Table 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 ...................240
Assembly Instructions for 45° SAE Flare Fittings...............................................................................................................................................................................................................................244
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...........................244
2. Align tube to fitting...................................................................................................................................................................................................................................................244
3. Tighten fitting by hand until hand tight................................................................................................................................................................................................................................244
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings.....................................................................................................................................................................................................................246
1. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement)...................................................................................................................................................................246
2. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter......................................................................................................................246
3. Pre-lubricate the O-ring with Hydraulic Oil.............................................................................................................................................................................................................................246
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......................................................................................................................246
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................246
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).....................................................................................................................................................................................................248
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..........................................................................248
2. Lubricate thread and cone of fitting body or hardened pre-assembly tool, as well as the progressive ring and nut threads................................................................................................................................................248
3. Slip nut and progressive ring over tube, assuring that they are in the proper orientation...............................................................................................................................................................................248
4. Push the tube end into the coupling body................................................................................................................................................................................................................................248
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 Table 5-9, DIN 24°Cone (MBTL & MBTS) while using the Double Wrench Method. The tube must..................248
Assembly Instructions for Bulkhead (BH) Fittings...............................................................................................................................................................................................................................250
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................................................................................................................250
2. Remove the locknut from the bulkhead assembly...........................................................................................................................................................................................................................250
3. Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening......................................................................................................................................................................................250
4. Hand thread the locknut onto the bulkhead end of the fitting body.......................................................................................................................................................................................................250
5. Torque nut onto fitting per Table 5-10 and Table 5-11 while using the Double Wrench Method..............................................................................................................................................................................250
Assembly Instructions for O-Ring Boss (ORB) Fittings...............................................................................................................................................................................................................................254
1. Inspect components to ensure that male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.....................................................................................................................................................254
2. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement).......................................................................................................................................................................254
3. Pre-lubricate the O-ring with Hydraulic Oil.................................................................................................................................................................................................................................254
4. For Non-Adjustable and Plugs, thread the fitting by hand until contact......................................................................................................................................................................................................254
5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly..........................................................................................................................................................................................254
6. Torque the fitting or nut to value listed in Table 5-12 thru Table 5-17 while using the Double Wrench Method................................................................................................................................................................254
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...............................................................................................254
b. Torque values provided in Table 5-12 thru 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:.........................254
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port....................................................................................................................................................................254
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings................................................................................................................................................................................................................262
1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs.............................................................................................................................................262
2. If O-ring is not pre-installed, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions...................................................................................................................................262
3. Pre-lubricate the O-ring with Hydraulic Oil.................................................................................................................................................................................................................................262
4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact.............................................................................................................................................................................................262
5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly..........................................................................................................................................................................................262
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................................................................................................................262
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................................................................................................................................262
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.....................262
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port....................................................................................................................................................................262
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends........................................................................................................................................................................................................270
1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs.........................................................................................................................................270
2. If O-ring is not preinstalled, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions................................................................................................................................270
3. Pre-lubricate the O-ring with Hydraulic Oil.............................................................................................................................................................................................................................270
4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact.........................................................................................................................................................................................270
5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly......................................................................................................................................................................................270
6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method............................................................................................................................................................................270
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............................................................................................................................270
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:....................................270
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port................................................................................................................................................................270
Assembly instructions for Adjustable Port End (BSPP) Fittings..................................................................................................................................................................................................................272
1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs.........................................................................................................................................272
2. If O-ring is not preinstalled, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions................................................................................................................................272
3. Pre-lubricate the O-ring with Hydraulic Oil.............................................................................................................................................................................................................................272
4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact.........................................................................................................................................................................................272
5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly......................................................................................................................................................................................272
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............................................................................................................272
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................................................................................................................................272
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.................272
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port................................................................................................................................................................272
Assembly Instructions for Flange Connections: (FL61 and FL62)..................................................................................................................................................................................................................280
1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs..........................................................................................................................................................................280
2. See Figure for O-ring installation instructions.........................................................................................................................................................................................................................280
3. Pre-lubricate the O-ring with Hydraulic Oil.............................................................................................................................................................................................................................280
4. Position flange and clamp halves........................................................................................................................................................................................................................................280
5. Place lock washers on bolt and bolt through clamp halves................................................................................................................................................................................................................280
6. Tighten all bolts by hand...............................................................................................................................................................................................................................................280
7. Torque bolts in diagonal sequence in two or more increments to the torque listed on Table Table 5-31and Table 5-32......................................................................................................................................................280
Double Wrench Method...........................................................................................................................................................................................................................................................283
FFWR and TFFT Methods..........................................................................................................................................................................................................................................................284
FFWR (Flats from Wrench Resistance Method).................................................................................................................................................................................................................................284
1. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight condition....................................................................................................................................284
2. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter. See Figure B.1................................................................................................................................................284
3. Use the double wrench method per Appendix A, turn the swivel nut to tighten as shown in Figure B.1. The nut is to be rotated clockwise the number of hex flats as defined by the applicable Table in Section 5.0....................................................284
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 5-13..................................................................284
TFFT (Turns from Finger Tight Method)......................................................................................................................................................................................................................................284
1. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight condition....................................................................................................................................284
2. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter................................................................................................................................................................284
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...............................................................................284
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...................................................................................284
Adjustable Stud End Assembly...................................................................................................................................................................................................................................................284
1. Lubricate the o-ring with a light coat of hydraulic oil.................................................................................................................................................................................................................284
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............................................................................284
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............................................................................................284
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..............................................................................................................................284
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.................................................284
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...................................................................................284
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....................................................................284
O-ring Installation (Replacement)..............................................................................................................................................................................................................................................285
1. Inspect O-ring for tears or nicks. If any are found replace O-ring......................................................................................................................................................................................................285
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.......................................................................................................285
3. Use a thread protector when replacing O-rings on fittings...............................................................................................................................................................................................................285
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.....................................................................................................................285
5. Inspect O-ring for any visible nicks or tears. Replace if found.........................................................................................................................................................................................................285
5.3 Hydraulic cylinders........................................................................................................................................................................................................................................................286
Axle Lockout Cylinder......................................................................................................................................................................................................................................................286
Disassembly............................................................................................................................................................................................................................................................286
1. Open bleeder valve. Rotate rod and remove from barrel...........................................................................................................................................................................................................286
2. Remove wiper. Do not scratch barrel bore........................................................................................................................................................................................................................286
3. Remove two wear rings and rod seal from grooves of rod bore. Do not scratch barrel bore.........................................................................................................................................................................286
4. Remove counterbalance valve.....................................................................................................................................................................................................................................286
CLEANING AND INSPECTION................................................................................................................................................................................................................................................286
1. Inspect bore and rod for scoring, pitting, or excessive wear....................................................................................................................................................................................................286
2. Remove minor surface blemishes with wet sandpaper. Pitting requires replacement of barrel and rod...............................................................................................................................................................286
3. Clean all parts with approved solvent and dry with compressed air...............................................................................................................................................................................................286
assembly...............................................................................................................................................................................................................................................................286
1. Install two new wear rings and rod seal in rod bore grooves. Make sure they are not twisted.....................................................................................................................................................................286
2. Install new wiper in barrel.....................................................................................................................................................................................................................................286
3. Lubricate rod bore with clean hydraulic fluid...................................................................................................................................................................................................................286
4. Install rod in bore and push to top of the bore.................................................................................................................................................................................................................286
5. Install counterbalance valve. Torque to 22 ft.lbs. (30 Nm)......................................................................................................................................................................................................286
6. Bleed system....................................................................................................................................................................................................................................................286
1. Barrel..........................................................................................................................................................................................................................................................287
2. Rod.............................................................................................................................................................................................................................................................287
3. Wiper...........................................................................................................................................................................................................................................................287
4. Rod Seal........................................................................................................................................................................................................................................................287
5. Wear Ring.......................................................................................................................................................................................................................................................287
6. Counterbalance Valve............................................................................................................................................................................................................................................287
7. O-ring Plug.....................................................................................................................................................................................................................................................287
8. O-ring Plug.....................................................................................................................................................................................................................................................287
9. Bleeder Valve...................................................................................................................................................................................................................................................287
Slave Cylinder.............................................................................................................................................................................................................................................................288
Disassembly............................................................................................................................................................................................................................................................288
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................288
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................288
3. Remove cartridge valve and fittings from the cylinder port block. Discard o-rings...............................................................................................................................................................................288
4. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................288
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer capscrews, and remove capscrews from cylinder barrel...........................................................................288
6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................288
7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................288
1. Barrel..........................................................................................................................................................................................................................................................289
2. Rod.............................................................................................................................................................................................................................................................289
3. Head............................................................................................................................................................................................................................................................289
4. Wiper...........................................................................................................................................................................................................................................................289
5. Seal............................................................................................................................................................................................................................................................289
6. Wear Ring.......................................................................................................................................................................................................................................................289
7. O-Ring..........................................................................................................................................................................................................................................................289
8. Backup Ring.....................................................................................................................................................................................................................................................289
9. Piston..........................................................................................................................................................................................................................................................289
10. Seal...........................................................................................................................................................................................................................................................289
11. Lock Ring......................................................................................................................................................................................................................................................289
12. O-Ring.........................................................................................................................................................................................................................................................289
13. Backup Ring....................................................................................................................................................................................................................................................289
14. Spacer.........................................................................................................................................................................................................................................................289
15. Tapered Bushing................................................................................................................................................................................................................................................289
16. Cartridge valve................................................................................................................................................................................................................................................289
17. Cartridge valve................................................................................................................................................................................................................................................289
18. Bushing........................................................................................................................................................................................................................................................289
19. Bolt...........................................................................................................................................................................................................................................................289
20. Capscrewl......................................................................................................................................................................................................................................................289
21. O-Ring Plug....................................................................................................................................................................................................................................................289
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................290
9. Insert the capscrews in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrews until the bushing is loosen on the piston.........................................................................................290
10. Remove the bushing from the piston.........................................................................................................................................................................................................................290
11. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod........................................................................................................................................................................290
12. Remove and discard the piston o-rings, seal rings, and backup rings........................................................................................................................................................................................290
13. Remove piston spacer, if applicable, from the rod..........................................................................................................................................................................................................290
14. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the o-rings, backup rings, rod seals, and wiper seals.....................................................................................................................290
Cleaning and Inspection................................................................................................................................................................................................................................................290
1. Clean all parts thoroughly in an approved cleaning solvent......................................................................................................................................................................................................290
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.....................................................................................................290
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary................................................................................................................................................................................290
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary..................................................................................................................290
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...........................................................................................................................................290
6. Inspect threaded portion of piston for damage. Dress threads as necessary.......................................................................................................................................................................................290
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................290
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary............................................................................................................................................290
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.......................................................................................................................................................290
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..............................................................................................................................................290
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.............................................................................................................................................290
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...............................................................................................................................................................290
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced............................................................................................................................................290
c. Lubricate inside of steel bushing prior to bearing installation.............................................................................................................................................................................................290
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..........................................................................................................................................................................290
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..........................................................................................................................................291
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.............................................................................................................................................................................291
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary......................................................................................................................................................291
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...........................................................................................................................................................................291
Assembly...............................................................................................................................................................................................................................................................291
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................291
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................292
3. Place a new o-ring and backup seal in the applicable outside diameter groove of the cylinder head...............................................................................................................................................................292
4. Install washer ring onto rod, carefully install the head gland 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........................................................292
5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................292
6. Place a new o-ring and backup rings in the inner piston diameter groove.........................................................................................................................................................................................292
7. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................292
8. Thread piston onto rod until it abuts the spacer end and install the tapered bushing............................................................................................................................................................................292
9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston......................................................................................................292
10. Tighten the capscrews evenly and progressively in rotation.....................................................................................................................................................................................................292
11. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;..........................................................................................................292
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews................................................................................................................................................292
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews...........................................................................................................................................292
12. Rotate the capscrews evenly and progressively in rotation......................................................................................................................................................................................................293
13. Remove the cylinder rod from the holding fixture...............................................................................................................................................................................................................293
14. Place new hydrolock seal and guidelock 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).....................................................................293
15. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................293
16. 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........................................................293
17. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................293
18. Apply Medium Strength Threadlocking Compound to the socket head bolts and secure the cylinder head gland using the washer ring and bolts.......................................................................................................................293
19. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves................................................................................................293
20. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. Torque valve to 50-55 ft.lbs. (68-75 Nm)..........................................................................................293
Upright Level Cylinder.....................................................................................................................................................................................................................................................294
Jib Lift Cylinder..........................................................................................................................................................................................................................................................295
Disassembly............................................................................................................................................................................................................................................................295
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................295
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................295
3. Remove the counterbalance holding valve and fittings from the cylinder port block. Discard o-rings..............................................................................................................................................................295
4. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................295
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer capscrews, and remove capscrews from cylinder barrel...........................................................................295
6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................295
7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................295
1. Barrel..........................................................................................................................................................................................................................................................296
2. Rod.............................................................................................................................................................................................................................................................296
3. Head............................................................................................................................................................................................................................................................296
4. Wiper...........................................................................................................................................................................................................................................................296
5. Rod Seal........................................................................................................................................................................................................................................................296
6. Wear Ring.......................................................................................................................................................................................................................................................296
7. O-Ring..........................................................................................................................................................................................................................................................296
8. Backup Ring.....................................................................................................................................................................................................................................................296
9. Piston..........................................................................................................................................................................................................................................................296
10. Seal...........................................................................................................................................................................................................................................................296
11. Lock Ring......................................................................................................................................................................................................................................................296
12. O-Ring.........................................................................................................................................................................................................................................................296
13. Backup Ring....................................................................................................................................................................................................................................................296
14. Tapered Bushing................................................................................................................................................................................................................................................296
15. Capscrew.......................................................................................................................................................................................................................................................296
16. Capscrew.......................................................................................................................................................................................................................................................296
17. O-ring Plug....................................................................................................................................................................................................................................................296
18. O-ring Plug....................................................................................................................................................................................................................................................296
19. Spacer.........................................................................................................................................................................................................................................................296
20. Cartridge valve................................................................................................................................................................................................................................................296
21. Bushing........................................................................................................................................................................................................................................................296
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................297
9. Insert the capscrews in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrews until the bushing is loosen on the piston.........................................................................................297
10. Remove the bushing from the piston.........................................................................................................................................................................................................................297
11. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod........................................................................................................................................................................297
12. Remove and discard the piston o-rings, seal rings, and backup rings........................................................................................................................................................................................297
13. Remove piston spacer, if applicable, from the rod..........................................................................................................................................................................................................297
14. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the o-rings, backup rings, rod seals, and wiper seals.....................................................................................................................297
Cleaning and Inspection................................................................................................................................................................................................................................................297
1. Clean all parts thoroughly in an approved cleaning solvent......................................................................................................................................................................................................297
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.....................................................................................................297
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary................................................................................................................................................................................297
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary..................................................................................................................297
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...........................................................................................................................................297
6. Inspect threaded portion of piston for damage. Dress threads as necessary.......................................................................................................................................................................................297
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................297
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary............................................................................................................................................297
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.......................................................................................................................................................297
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..............................................................................................................................................297
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.............................................................................................................................................297
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...............................................................................................................................................................297
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced............................................................................................................................................297
c. Lubricate inside of steel bushing prior to bearing installation.............................................................................................................................................................................................297
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..........................................................................................................................................................................297
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..........................................................................................................................................298
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.............................................................................................................................................................................298
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary......................................................................................................................................................298
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...........................................................................................................................................................................298
Assembly...............................................................................................................................................................................................................................................................298
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................298
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................299
3. Place a new o-ring and backup seal in the applicable outside diameter groove of the cylinder head...............................................................................................................................................................299
4. Install washer ring onto rod, carefully install the head gland 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........................................................299
5. Carefully slide the piston spacer on the rod....................................................................................................................................................................................................................299
6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................299
7. Place a new o-ring and backup rings in the inner piston diameter groove.........................................................................................................................................................................................299
8. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................299
9. Thread piston onto rod until it abuts the spacer end and install the tapered bushing............................................................................................................................................................................299
10. Install the bolts in tapered bushing...........................................................................................................................................................................................................................299
11. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.....................................................................................................299
12. Tighten the capscrews evenly and progressively in rotation to 5 ft.lbs. (7 Nm).................................................................................................................................................................................299
13. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;..........................................................................................................299
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews................................................................................................................................................299
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews...........................................................................................................................................299
14. Rotate the capscrews evenly and progressively in rotation to 5 ft.lbs. (7 Nm)..................................................................................................................................................................................300
15. Remove the cylinder rod from the holding fixture...............................................................................................................................................................................................................300
16. Place new hydrolock seal and guidelock 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).....................................................................300
17. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................300
18. 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........................................................300
19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................300
20. Apply Medium Strength Threadlocking Compound to the socket head bolts and secure the cylinder head gland using the capscrews. Torque capscrews to 18 ft. lbs. (25 Nm)..........................................................................................300
21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves................................................................................................300
22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. Torque valves to 50-55 ft.lbs. (68-75 Nm).........................................................................................300
Main Boom Lift Cylinder....................................................................................................................................................................................................................................................301
Tower Boom Lift Cylinder...................................................................................................................................................................................................................................................302
Master Cylinder............................................................................................................................................................................................................................................................303
Disassembly............................................................................................................................................................................................................................................................303
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................303
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................303
3. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................303
4. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer capscrews, and remove capscrews from cylinder barrel...........................................................................303
5. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................303
6. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................303
1. Barrel..........................................................................................................................................................................................................................................................304
2. Rod.............................................................................................................................................................................................................................................................304
3. Head............................................................................................................................................................................................................................................................304
4. Wiper...........................................................................................................................................................................................................................................................304
5. Rod Seal........................................................................................................................................................................................................................................................304
6. Wear Ring.......................................................................................................................................................................................................................................................304
7. O-ring..........................................................................................................................................................................................................................................................304
8. Backup Ring.....................................................................................................................................................................................................................................................304
9. Piston..........................................................................................................................................................................................................................................................304
10. Wear Ring......................................................................................................................................................................................................................................................304
11. Lock Ring......................................................................................................................................................................................................................................................304
12. O-ring.........................................................................................................................................................................................................................................................304
13. Backup Ring....................................................................................................................................................................................................................................................304
14. Tube Spacer....................................................................................................................................................................................................................................................304
15. Tapered Bushing................................................................................................................................................................................................................................................304
16. Capscrew.......................................................................................................................................................................................................................................................304
17. Capscrew.......................................................................................................................................................................................................................................................304
18. Bushing........................................................................................................................................................................................................................................................304
19. Bushing........................................................................................................................................................................................................................................................304
20. Plug...........................................................................................................................................................................................................................................................304
7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................305
8. Insert the capscrews in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrews until the bushing is loosen on the piston.........................................................................................305
9. Remove the bushing from the piston..........................................................................................................................................................................................................................305
10. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod........................................................................................................................................................................305
11. Remove and discard the piston o-rings, seal rings, and backup rings........................................................................................................................................................................................305
12. Remove piston spacer from the rod..........................................................................................................................................................................................................................305
13. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the o-rings, backup rings, rod seals, and wiper seals.....................................................................................................................305
Cleaning and Inspection................................................................................................................................................................................................................................................305
1. Clean all parts thoroughly in an approved cleaning solvent......................................................................................................................................................................................................305
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.....................................................................................................305
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary................................................................................................................................................................................305
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary..................................................................................................................305
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...........................................................................................................................................305
6. Inspect threaded portion of piston for damage. Dress threads as necessary.......................................................................................................................................................................................305
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................305
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary............................................................................................................................................305
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.......................................................................................................................................................305
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..............................................................................................................................................305
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.............................................................................................................................................305
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...............................................................................................................................................................305
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced............................................................................................................................................305
c. Lubricate inside of steel bushing prior to bearing installation.............................................................................................................................................................................................305
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..........................................................................................................................................................................305
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..........................................................................................................................................306
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.............................................................................................................................................................................306
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary......................................................................................................................................................306
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...........................................................................................................................................................................306
Assembly...............................................................................................................................................................................................................................................................306
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................306
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................307
3. Place a new o-ring and backup seal in the applicable outside diameter groove of the cylinder head...............................................................................................................................................................307
4. Install washer ring onto rod, carefully install the head gland 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........................................................307
5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................307
6. Place a new o-ring and backup rings in the inner piston diameter groove.........................................................................................................................................................................................307
7. Install piston spacer onto the cylinder rod.....................................................................................................................................................................................................................307
8. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................307
9. Thread piston onto rod until it abuts the spacer end and install the tapered bushing............................................................................................................................................................................307
10. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.....................................................................................................307
11. Tighten the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)...............................................................................................................................................................................307
12. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;..........................................................................................................307
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews................................................................................................................................................307
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews...........................................................................................................................................307
13. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)................................................................................................................................................................................308
14. Remove the cylinder rod from the holding fixture...............................................................................................................................................................................................................308
15. Place new hydrolock seal and guidelock 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).....................................................................308
16. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................308
17. 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........................................................308
18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................308
19. Apply Medium Strength Threadlocking Compound to the socket head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 35 ft.lbs. (50 Nm)...................................................................................308
Steer Cylinder.............................................................................................................................................................................................................................................................309
Disassembly............................................................................................................................................................................................................................................................309
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................309
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................309
3. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................309
4. Using a hook spanner, loosen the spanner nut retainer and remove spanner nut from cylinder barrel...............................................................................................................................................................309
5. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................309
6. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................309
1. Piston..........................................................................................................................................................................................................................................................310
2. Wear Ring.......................................................................................................................................................................................................................................................310
3. Seal............................................................................................................................................................................................................................................................310
4. Setscrew........................................................................................................................................................................................................................................................310
5. Rod.............................................................................................................................................................................................................................................................310
6. Barrel..........................................................................................................................................................................................................................................................310
7. Head............................................................................................................................................................................................................................................................310
8. O-ring..........................................................................................................................................................................................................................................................310
9. Backup Ring.....................................................................................................................................................................................................................................................310
10. C- Ring........................................................................................................................................................................................................................................................310
11. Spanner Nut....................................................................................................................................................................................................................................................310
12. Wiper Seal.....................................................................................................................................................................................................................................................310
13. Rod Seal.......................................................................................................................................................................................................................................................310
14. Bushing........................................................................................................................................................................................................................................................310
7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................311
8. Remove the setscrews from the piston........................................................................................................................................................................................................................311
9. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod.........................................................................................................................................................................311
10. Remove and discard the piston seal and wear rings..........................................................................................................................................................................................................311
11. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the o-ring, backup ring, c- ring, rod seal, and wiper seal................................................................................................................311
Cleaning and Inspection....................................................................................................................................................................................................................................................311
1. Clean all parts thoroughly in an approved cleaning solvent..........................................................................................................................................................................................................311
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.........................................................................................................311
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary....................................................................................................................................................................................311
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary......................................................................................................................311
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...............................................................................................................................................311
6. Inspect threaded portion of barrel for damage. Dress threads as necessary...........................................................................................................................................................................................311
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.........................................................................................................................................................311
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary................................................................................................................................................311
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary...........................................................................................................................................................311
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..................................................................................................................................................311
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.................................................................................................................................................311
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...................................................................................................................................................................311
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced................................................................................................................................................311
c. Lubricate inside of steel bushing prior to bearing installation.................................................................................................................................................................................................311
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..............................................................................................................................................................................311
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..............................................................................................................................................311
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.................................................................................................................................................................................311
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary..........................................................................................................................................................311
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...............................................................................................................................................................................311
Assembly...............................................................................................................................................................................................................................................................312
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................312
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................312
3. Place a new o-ring, backup ring and c-ring in the applicable outside diameter groove of the cylinder head.......................................................................................................................................................312
4. Install spanner nut onto rod. Carefully install the head gland 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........................................................312
5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................312
6. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................312
7. Install the setscrews on the piston.............................................................................................................................................................................................................................312
8. Remove the cylinder rod from the holding fixture................................................................................................................................................................................................................312
9. Place new seal and wear 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).....................................................................................313
10. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................313
11. 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........................................................313
12. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................313
13. Secure spanner nut into the cylinder barrel. Torque nut to 325-390 ft.lbs. (441-529 Nm)........................................................................................................................................................................313
14. 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, if applicable...................................................................................313
Main Boom Telescope Cylinder...............................................................................................................................................................................................................................................314
Disassembly............................................................................................................................................................................................................................................................314
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................314
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................314
3. Remove capscrews and valve assembly from the barrel end. Discard o-rings........................................................................................................................................................................................314
4. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................314
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer capscrews, and remove capscrews from cylinder barrel...........................................................................314
6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................314
7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................314
1. Barrel..........................................................................................................................................................................................................................................................315
2. Rod.............................................................................................................................................................................................................................................................315
3. Head............................................................................................................................................................................................................................................................315
4. Wiper Seal......................................................................................................................................................................................................................................................315
5. Rod Seal........................................................................................................................................................................................................................................................315
6. Wear Ring.......................................................................................................................................................................................................................................................315
7. O-ring..........................................................................................................................................................................................................................................................315
8. Backup Ring.....................................................................................................................................................................................................................................................315
9. Piston..........................................................................................................................................................................................................................................................315
10. Wear Ring......................................................................................................................................................................................................................................................315
11. Piston Seal....................................................................................................................................................................................................................................................315
12. Wear Ring......................................................................................................................................................................................................................................................315
13. O-ring.........................................................................................................................................................................................................................................................315
14. Backup Ring....................................................................................................................................................................................................................................................315
15. Spacer.........................................................................................................................................................................................................................................................315
16. Tapered Bushing................................................................................................................................................................................................................................................315
17. Plate..........................................................................................................................................................................................................................................................315
18. Wear Pad.......................................................................................................................................................................................................................................................315
19. Valve Assembly.................................................................................................................................................................................................................................................315
20. Capscrew.......................................................................................................................................................................................................................................................315
21. Capscrew.......................................................................................................................................................................................................................................................315
22. Capscrew.......................................................................................................................................................................................................................................................315
23. Capscrew.......................................................................................................................................................................................................................................................315
24. O-ring Plug....................................................................................................................................................................................................................................................315
25. O-ring Plug....................................................................................................................................................................................................................................................315
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................316
9. Insert the capscrews in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrews until the bushing is loosen on the piston.........................................................................................316
10. Remove the bushing from the piston.........................................................................................................................................................................................................................316
11. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod........................................................................................................................................................................316
12. Remove and discard the piston o-rings, seal rings, and backup rings........................................................................................................................................................................................316
13. Remove o-rings from piston spacer. Remove piston spacer from the rod.......................................................................................................................................................................................316
14. Remove capscrews to remove plate and wear pads.............................................................................................................................................................................................................316
15. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the o-rings, backup rings, rod seals, and wiper seals.....................................................................................................................316
Cleaning and Inspection................................................................................................................................................................................................................................................316
1. Clean all parts thoroughly in an approved cleaning solvent......................................................................................................................................................................................................316
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.....................................................................................................316
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary................................................................................................................................................................................316
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary..................................................................................................................316
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...........................................................................................................................................316
6. Inspect threaded portion of piston for damage. Dress threads as necessary.......................................................................................................................................................................................316
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................316
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary............................................................................................................................................316
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.......................................................................................................................................................316
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..............................................................................................................................................316
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.............................................................................................................................................316
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...............................................................................................................................................................316
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced............................................................................................................................................316
c. Lubricate inside of steel bushing prior to bearing installation.............................................................................................................................................................................................316
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..........................................................................................................................................................................316
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..........................................................................................................................................317
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.............................................................................................................................................................................317
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary......................................................................................................................................................317
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...........................................................................................................................................................................317
Assembly...............................................................................................................................................................................................................................................................317
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................317
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................318
3. Place a new o-ring and backup seal in the applicable outside diameter groove of the cylinder head...............................................................................................................................................................318
4. Install plate on to the rod. Use capscrews to attach wear pads on the plate.....................................................................................................................................................................................318
5. Carefully install the head gland 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......................................................................................318
6. Install o-rings inside grooves of the piston spacer. Carefully slide the spacer on the rod......................................................................................................................................................................318
7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................318
8. Place a new o-ring and backup rings in the inner piston diameter groove.........................................................................................................................................................................................318
9. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................318
10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing...........................................................................................................................................................................318
11. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.....................................................................................................318
12. Tighten the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)...............................................................................................................................................................................318
13. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;..........................................................................................................318
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews................................................................................................................................................318
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews...........................................................................................................................................318
14. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)................................................................................................................................................................................319
15. Remove the cylinder rod from the holding fixture...............................................................................................................................................................................................................319
16. Place new hydrolock seal and guidelock 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).....................................................................319
17. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................319
18. 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........................................................319
19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................319
20. Apply Medium Strength Threadlocking Compound to the socket head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 35 ft.lbs. (50 Nm)...................................................................................319
21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves................................................................................................319
22. Install the valve assembly. Torque capscrews to 10 ft.lbs. (13 Nm).............................................................................................................................................................................................319
Tower Boom Telescope Cylinder..............................................................................................................................................................................................................................................320
Disassembly............................................................................................................................................................................................................................................................320
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting..........................................................................................................................................................................320
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.......................................................................................................320
3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o- rings..............................................................................................................................................320
4. Place the cylinder barrel into a suitable holding fixture.......................................................................................................................................................................................................320
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer capscrews, and remove capscrews from cylinder barrel...........................................................................320
6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable..........................................................................................................................................................320
7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel............................................................................................................320
1. Barrel..........................................................................................................................................................................................................................................................321
2. Rod.............................................................................................................................................................................................................................................................321
3. Head............................................................................................................................................................................................................................................................321
4. Wiper...........................................................................................................................................................................................................................................................321
5. Rod Seal........................................................................................................................................................................................................................................................321
6. Wear Ring.......................................................................................................................................................................................................................................................321
7. O-ring..........................................................................................................................................................................................................................................................321
8. Backup Ring.....................................................................................................................................................................................................................................................321
9. Piston..........................................................................................................................................................................................................................................................321
10. Seal...........................................................................................................................................................................................................................................................321
11. Lock Ring......................................................................................................................................................................................................................................................321
12. O-ring.........................................................................................................................................................................................................................................................321
13. Backup Ring....................................................................................................................................................................................................................................................321
14. Tube Spacer....................................................................................................................................................................................................................................................321
15. Tapered Bushing................................................................................................................................................................................................................................................321
16. Support Pad....................................................................................................................................................................................................................................................321
17. Support Pad....................................................................................................................................................................................................................................................321
18. Target Plate...................................................................................................................................................................................................................................................321
19. Mount Plate....................................................................................................................................................................................................................................................321
20. Valve Assembly.................................................................................................................................................................................................................................................321
21. Bolt...........................................................................................................................................................................................................................................................321
22. Setscrew.......................................................................................................................................................................................................................................................321
23. Bolt...........................................................................................................................................................................................................................................................321
24. Capscrew.......................................................................................................................................................................................................................................................321
25. Capscrew.......................................................................................................................................................................................................................................................321
26. U Bolt.........................................................................................................................................................................................................................................................321
27. Nut............................................................................................................................................................................................................................................................321
28. Flatwasher.....................................................................................................................................................................................................................................................321
29. Plug...........................................................................................................................................................................................................................................................321
30. Plug...........................................................................................................................................................................................................................................................321
31. Plug...........................................................................................................................................................................................................................................................321
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible...................................................................................................................................322
9. Insert the capscrews in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrews until the bushing is loosen on the piston.........................................................................................322
10. Remove the bushing from the piston.........................................................................................................................................................................................................................322
11. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod........................................................................................................................................................................322
12. Remove and discard the piston o-rings, seal rings, and backup rings........................................................................................................................................................................................322
13. Remove setscrew from the piston spacer. Remove spacer from the rod.........................................................................................................................................................................................322
14. Remove the rod from the holding fixture. Remove capscrews, target plate and washer ring. Remove the cylinder head gland. Discard the o-rings, backup rings, rod seals, and wiper seals.....................................................................322
Cleaning and Inspection................................................................................................................................................................................................................................................322
1. Clean all parts thoroughly in an approved cleaning solvent......................................................................................................................................................................................................322
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.....................................................................................................322
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary................................................................................................................................................................................322
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary..................................................................................................................322
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary...........................................................................................................................................322
6. Inspect threaded portion of piston for damage. Dress threads as necessary.......................................................................................................................................................................................322
7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................322
8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary............................................................................................................................................322
9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.......................................................................................................................................................322
10. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary..............................................................................................................................................322
11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.............................................................................................................................................322
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation...............................................................................................................................................................322
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced............................................................................................................................................322
c. Lubricate inside of steel bushing prior to bearing installation.............................................................................................................................................................................................322
d. Using an arbor of the correct size, carefully press the bearing into steel bushing..........................................................................................................................................................................322
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent..........................................................................................................................................323
13. If applicable, inspect port block fittings and holding valve. Replace as necessary.............................................................................................................................................................................323
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary......................................................................................................................................................323
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary...........................................................................................................................................................................323
Assembly...............................................................................................................................................................................................................................................................323
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.................................................................................................................................................................323
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove................................................................................................324
3. Place a new o-ring and backup seal in the applicable outside diameter groove of the cylinder head...............................................................................................................................................................324
4. Install washer ring onto rod, carefully install the head gland 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........................................................324
5. Carefully slide the piston spacer on the rod. Install setscrew on the spacer....................................................................................................................................................................................324
6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible...........................................................................................................................................324
7. Place a new o-ring and backup rings in the inner piston diameter groove.........................................................................................................................................................................................324
8. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged..............................................................................................................................324
9. Thread piston onto rod until it abuts the spacer end and install the tapered bushing............................................................................................................................................................................324
10. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.....................................................................................................324
11. Tighten the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)...............................................................................................................................................................................324
12. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;..........................................................................................................324
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews................................................................................................................................................324
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews...........................................................................................................................................324
13. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm)................................................................................................................................................................................325
14. Remove the cylinder rod from the holding fixture...............................................................................................................................................................................................................325
15. Place new hydrolock seal and guidelock 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).....................................................................325
16. Position the cylinder barrel in a suitable holding fixture.....................................................................................................................................................................................................325
17. 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........................................................325
18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder................................................................................................................................................325
19. Apply Medium Strength Threadlocking Compound to the socket head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 55 ft.lbs. (75 Nm)...................................................................................325
20. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves................................................................................................325
21. Install the valve assembly. Torque capscrews to 24 ft.lbs. (33 Nm).............................................................................................................................................................................................325
5.4 Cylinder Removal And Installation..........................................................................................................................................................................................................................................326
Main Boom Telescope Cylinder Removal.......................................................................................................................................................................................................................................326
1. Place machine on a flat and level surface, with main boom in the horizontal position................................................................................................................................................................................326
2. Extend the boom to gain access to main fly boom telescope cylinder rod end pin......................................................................................................................................................................................326
3. Remove the hardware securing the telescope cylinder rod attach pin to the boom. Using a suitable brass drift, drive out the cylinder rod attach pin.................................................................................................................326
4. Using a suitable sling and lifting device, secure the platform end of the boom......................................................................................................................................................................................326
5. Place blocking under the main lift cylinder to prevent it from falling when the attaching hardware is removed.......................................................................................................................................................326
6. Remove the hardware securing the main lift cylinder rod attach pin to the boom. Using a suitable brass drift, drive out the cylinder rod attach pin.................................................................................................................326
7. Using auxiliary power from ground controls, retract the lift cylinder rod completely................................................................................................................................................................................327
8. Remove hardware securing cover plate on the rear of the main boom. Remove cover plate...............................................................................................................................................................................327
9. Remove mounting hardware securing the telescope cylinder barrel to the main base boom...............................................................................................................................................................................327
10. Using an external pump, extend the cylinder as far as the hydraulic lines will allow to enable a lifting device to be attached to the telescope cylinder...........................................................................................................327
11. Tag and disconnect hydraulic lines from telescope cylinder. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports...........................................................................................................327
12. Secure the telescope cylinder with a suitable sling and lifting device.............................................................................................................................................................................................327
13. Carefully remove the telescope cylinder from the main boom assembly and place in a suitable work area..............................................................................................................................................................327
Main Boom Telescope Cylinder Installation..................................................................................................................................................................................................................................328
1. Using suitable lifting equipment, carefully insert the cylinder into the boom assembly..............................................................................................................................................................................328
2. Carefully install main telescope cylinder rod pin through the fly boom and secure it with the retaining rings.......................................................................................................................................................328
3. Remove applicable hydraulic line and port caps and properly connect the hydraulic lines to the telescope cylinder. Ensure all hoses are correctly routed............................................................................................................328
4. Carefully install the telescope cylinder barrel end support into mounting block in base boom and secure with blocks and torque the bolts to 35 ft.lbs. (48 Nm). Use Medium Strength Threadlocking Compound on bolts. Shim as necessary..............................328
5. Remove the lifting device from the main telescope cylinder and retract the main telescope cylinder..................................................................................................................................................................328
6. Extend the main lift cylinder using the auxiliary control from the ground controls to align with rod end hole in main base boom.....................................................................................................................................328
7. Carefully insert the main lift cylinder rod end pin thro- ugh the base boom and install the mounting hardware.......................................................................................................................................................328
8. Using all applicable safety precautions, operate the boom functions. Check for proper operation and hydraulic leaks. Secure as necessary............................................................................................................................328
9. Check fluid level of hydraulic tank and adjust as necessary.........................................................................................................................................................................................................328
Main Lift Cylinder Removal.................................................................................................................................................................................................................................................329
1. Place the machine on a flat and level surface. Attach a suitable lifting device and sling, sufficient to lift the main boom assembly, to the approximate center of the main boom assembly...........................................................................329
2. Place blocking under the cylinder to prevent it from falling when the attaching hardware is removed.................................................................................................................................................................329
3. Remove the hardware securing the main lift cylinder rod attach pin to the boom. Using a suitable brass drift, drive out the cylinder rod attach pin.................................................................................................................329
4. Using auxiliary power from ground controls, retract the lift cylinder rod completely................................................................................................................................................................................329
5. Disconnect, cap, and tag the main boom lift cylinder hydraulic lines and ports......................................................................................................................................................................................329
6. Attach a suitable lifting device and sling to the main lift cylinder................................................................................................................................................................................................329
7. Remove hardware securing cover plate on the bottom of the upright. Remove cover plate...............................................................................................................................................................................329
8. Use a suitable brass drift and hammer to remove main lift cylinder barrel end pin from Upright......................................................................................................................................................................329
9. Using a suitable brass drift drive out the barrel end attach pin from the tower upright. Raise the main boom assembly with the lifting device and sling to allow enough space to remove the main lift cylinder from the upright top.................................329
10. Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area.....................................................................................................................................................329
11. Lower the boom assembly to the stowed position.....................................................................................................................................................................................................................329
Main Lift Cylinder Installation............................................................................................................................................................................................................................................330
1. Lift the main boom to allow enough space to lower the main boom lift cylinder to align with pin mounting holes of the tower fly boom and barrel end of main lift cylinder...........................................................................................330
2. Using a suitable brass drift, drive barrel end attach pin through the mounting holes in the lift cylinder and the tower fly boom. Secure in place with the pin and torque the bolts to 35 ft. lbs. (48 Nm). Use Medium Strength Threadlocking Compound .............330
3. Remove cylinder port plugs and hydraulic line caps and attach lines to cylinder ports as tagged during removal......................................................................................................................................................330
4. Using auxiliary power extend the cylinder rod until the attach pin hole aligns with those in the main boom..........................................................................................................................................................330
5. Using a suitable drift drive cylinder rod attach pin through the aligned holes, taking care to align the grooved pin holes. Secure the pin in place and torque the bolt to 285 ft. lbs. (388 Nm). Use Medium Strength Threadlocking Compound on bolts...............330
6. Remove lifting device and sling. Activate hydraulic system..........................................................................................................................................................................................................330
7. Using all applicable safety precautions, operate the boom functions. Check for proper operation and hydraulic leaks. Secure as necessary............................................................................................................................330
8. Check fluid level of hydraulic tank and adjust as necessary.........................................................................................................................................................................................................330
Upright Level Cylinder Removal.............................................................................................................................................................................................................................................331
1. Remove the Main Boom. Refer to Section 4.2, Main Boom Assembly......................................................................................................................................................................................................331
2. Tag and disconnect hydraulic lines to the main lift cylinder. Use suitable container to collect any residual hydraulic fluid. Cap hydraulic lines and ports.........................................................................................................331
3. Remove mounting hardware from the main boom lift cylinder barrel end. Use a suitable brass drift and hammer to remove main lift cylinder barrel end pin from Upright and remove main lift cylinder..................................................................331
4. Disconnect the Upright Level Cylinder as follows:...................................................................................................................................................................................................................331
a. Use a suitable lifting device to support the Upright............................................................................................................................................................................................................331
b. Remove mounting hardware securing the Upright Level Cylinder to the upright. Use a suitable brass drift and hammer to remove upright level cylinder barrel end pin from upright and disconnect the upright level cylinder from the Upright......................331
5. Before extending the tower boom, support the tower boom from the bottom.............................................................................................................................................................................................331
6. Extend the Tower Boom to get access to the Upright level cylinder rod end pin by using an external auxiliary pump...................................................................................................................................................331
7. Tag, disconnect and cap the hydraulic lines of the Upright level Cylinder barrel....................................................................................................................................................................................331
8. Attach a suitable lifting device to support the Upright Level Cylinder..............................................................................................................................................................................................331
9. Remove mounting hardware from the upright level cylinder rod end and remove the pin.................................................................................................................................................................................331
10. Remove the Upright Level Cylinder from the Tower Fly Boom. Place the Upright level Cylinder in a suitable work area................................................................................................................................................331
Upright Level Cylinder Installation........................................................................................................................................................................................................................................332
1. Put the leveling cylinder in position in the tower boom, align holes in the tower boom and leveling cylinder rod end................................................................................................................................................332
2. Secure the leveling cylinder rod end pin to tower boom and torque the bolts to 35 ft. lbs. (48 Nm). Use Medium Strength Threadlocking Compound on bolts.............................................................................................................332
3. Remove Cylinder Port plugs and hydraulic line caps. Properly attach lines to Cylinder ports as tagged during removal................................................................................................................................................332
4. Use all applicable safety precautions, operate the lifting device to move upright assembly into proper position.....................................................................................................................................................332
5. Align holes in upright and barrel end of level cylinder. Use a suitable rubber mallet to install level barrel end pin. Secure pin and torque the bolt 285 ft. lbs. (388 Nm). Medium Strength Threadlocking Compound on bolts........................................332
6. Install Main Lift Cylinder..........................................................................................................................................................................................................................................332
7. Install Main Boom. Refer to Main Boom installation..................................................................................................................................................................................................................332
8. Remove hydraulic line caps and attach all the hydraulic and electrical lines as tagged during removal...............................................................................................................................................................332
9. Use all applicable safety precautions, operate the boom functions. Check for proper operation and hydraulic leaks...................................................................................................................................................332
10. Check fluid level of hydraulic tank and add fluid, if required.....................................................................................................................................................................................................332
Tower Boom Lift Cylinder Removal...........................................................................................................................................................................................................................................332
1. Place machine on a flat and level surface. Place the main boom in a horizontal position with the telescope cylinder fully retracted. Place the tower boom in a fully elevated and fully retracted position..........................................................332
2. Support the main boom, upright and tower boom with adequate overhead crane..........................................................................................................................................................................................332
3. Adequately support the tower lift cylinder..........................................................................................................................................................................................................................332
4. Remove mounting hardware securing the lift cylinder rod pin to the tower boom. Using a suitable brass drift, drive out the tower lift cylinder rod attach pin.......................................................................................................332
5. Using all applicable safety precautions, operate auxiliary power, activate tower lift down and fully retract lift cylinder..........................................................................................................................................332
6. Tag, disconnect, and cap the tower lift cylinder hydraulic lines and ports..........................................................................................................................................................................................332
7. Remove mounting hardware securing the tower lift cylinder barrel pin to the turntable. Using a suitable brass drift, drive out the tower lift cylinder barrel pin...................................................................................................333
8. Carefully remove the tower lift cylinder from turntable. Place in a suitable work area..............................................................................................................................................................................333
Tower Boom Lift Cylinder Installation......................................................................................................................................................................................................................................333
1. Support the main boom and tower boom, place the tower lift cylinder on the turntable and align the holes. Install the cylinder barrel pin and torque the bolt to 285 ft. lbs. (388 Nm). Use Medium Strength Threadlocking Compound on bolts.........................333
2. Remove caps from cylinder hydraulic lines properly and install lines to cylinder as previously tagged...............................................................................................................................................................333
3. Using auxiliary power, activate tower lift function and extend cylinder rod until the cylinder rod bushing aligns with bushings on boom.............................................................................................................................333
4. Using an appropriate brass drift, drive the tower lift cylinder rod end attach pin through the aligned bushings. Secure pin and torque the bolt 35 ft. lbs. (48 Nm). Use Medium Strength Threadlocking Compound on bolts............................................333
5. Remove main boom support and lifting device supporting the upright..................................................................................................................................................................................................333
6. Using all applicable safety precautions, operate the boom functions. Check for proper operation and hydraulic leaks. Secure as necessary............................................................................................................................333
7. Check fluid level of hydraulic tank and add fluid, if required......................................................................................................................................................................................................333
Tower Telescope Cylinder Removal...........................................................................................................................................................................................................................................334
1. Place machine on flat and level surface.............................................................................................................................................................................................................................334
2. Remove the tower telescope cylinder rod end trunion hardware........................................................................................................................................................................................................334
3. Using an external pump, extend the tower telescope cylinder as far enough to attach the lifting device..............................................................................................................................................................334
4. Tag, disconnect and cap hydraulic hoses to Tower Telescope Cylinder. Plug cylinder ports. Remove the hoses..........................................................................................................................................................334
5. Properly secure the Tower Telescope Cylinder by using a suitable sling or support...................................................................................................................................................................................334
6. Remove the tower telescope cylinder barrel end trunion hardware.....................................................................................................................................................................................................334
7. Carefully remove the Tower Telescope Cylinder from the Boom. Place cylinder on a suitable work area.................................................................................................................................................................334
Tower Telescope Cylinder Installation......................................................................................................................................................................................................................................334
1. Slide the telescope cylinder into the boom, aligning the cylinder port block end with slotted holes in Base Boom....................................................................................................................................................334
2. Secure the telescope cylinder barrel end to the fly boom by using retaining plate and torque the bolts 35 ft. lbs. (48Nm). Use Medium Strength Threadlocking Compound on bolts......................................................................................334
3. Secure telescope cylinder rod end and torque the bolts to 35 ft. lbs. (48 Nm). Use Medium Strength Threadlocking Compound P/N 0100011 on bolts......................................................................................................................334
4. Remove caps and plugs from hydraulic lines and ports. Properly connect hydraulic lines to cylinder. Reinstall cover plate...........................................................................................................................................334
5. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary...........................................................................................................................334
6. Check fluid level of hydraulic tank and add fluid, if required......................................................................................................................................................................................................334
Master Cylinder Removal....................................................................................................................................................................................................................................................335
1. Tag and disconnect hydraulic lines to the main boom lift cylinder. Use a suitable container to collect any residual hydraulic fluid. Cap hydraulic lines and ports..................................................................................................335
2. Properly secure the master cylinder by using a suitable sling or support............................................................................................................................................................................................335
3. Remove the master cylinder pin retaining hardware. Using a suitable brass drift, remove the master cylinder pins from the rod and barrel ends.......................................................................................................................335
4. Carefully remove the master cylinder................................................................................................................................................................................................................................335
5. Clean and inspect the cylinder pins and retaining hardware for reuse. Replace if necessary..........................................................................................................................................................................335
Master Cylinder Installation...............................................................................................................................................................................................................................................335
1. Remove caps from the hydraulic hoses and attach hoses to the proper cylinder ports..................................................................................................................................................................................335
2. Use suitable slings or support to position the master cylinder in place. Align barrel end mounting holes with the holes in main boom................................................................................................................................335
3. Use suitable mallet and keeper to install the barrel end attach pin and torque the bolts to 35 ft. lbs. (48 Nm).....................................................................................................................................................335
4. Extend the master cylinder rod until the rod attach pin hole aligns with holes in the upright pivot. Use suitable mallet and keeper to install the rod end pin......................................................................................................335
5. Remove any support or sling used to lift the master cylinder........................................................................................................................................................................................................335
6. Use all applicable safety precautions, operate the boom functions...................................................................................................................................................................................................335
7. Check for proper operation and hydraulic leaks......................................................................................................................................................................................................................335
8. Check the fluid level of hydraulic tank. Fill the tank, if required.................................................................................................................................................................................................335
5.5 Pressure Setting Procedures................................................................................................................................................................................................................................................336
1. All applicable steps must be followed...................................................................................................................................................................................................................................336
2. Set up of the function pump.............................................................................................................................................................................................................................................336
3. Adjustments Made at the Main Valve Block................................................................................................................................................................................................................................336
4. Adjustments Made at the Platform Valve Block............................................................................................................................................................................................................................336
Set Up the Function Pump...................................................................................................................................................................................................................................................336
1. Set Stand by pressure or load sense pressure........................................................................................................................................................................................................................336
a. Install a low pressure gauge at port “MP” of the main valve block. A gauge capable of reading 400 psi (27.58 bar)...............................................................................................................................................336
b. Start the engine and let it idle. The gauge should be reading 400-440 psi (28-30 bar)...........................................................................................................................................................................336
c. To make an adjustment to this pressure, go to the engine compartment, locate the function pump. There are (2) adjustments at the top of the pump. They are located on the pump compensator which has (4) bolts mounting it to the pump. The stand by ad.........336
d. To adjust this, a 4 mm and 6 mm Allen wrench will be needed. The adjustment screw is facing the front of the pump, or toward the engine. First, using the 4 mm wrench, loosen the setscrew on the side of the compensator (facing you) which is in line.........336
e. Then using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclockwise to decrease. The pressure should read between 400-440 psi (27.58-30.34 bar).....................................................................................336
2. Set High pressure relief............................................................................................................................................................................................................................................336
a. Install a high pressure gauge at the “MP” port of the main valve block..........................................................................................................................................................................................336
b. Activate main boom telescope in. The gauge should read 2600-2700 psi (179-186 bar)..............................................................................................................................................................................336
c. To make an adjustment to this pressure, go back to the engine compartment to the function pump. The high pressure relief adjustment is the lower one of the (2) on the compensator. To adjust this, a 4 mm and 6 mm Allen wrench will be needed. The ad.........337
d. First, using the 4 mm wrench, loosen the setscrew on the side of the compensator (facing you) which is in line with the adjustment screw. This is a jam nut screw which holds the main adjustment from turning. Loosen it 1 turn................................337
e. Then using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclockwise to decrease. This is the maximum relief pressure for all functions governed by this pump........................................................................337
Adjustments Made at the Main Valve Block...................................................................................................................................................................................................................................337
main lift down.........................................................................................................................................................................................................................................................337
3. Install a high pressure gauge (3000 psi) into the external pressure tap at the tee fitting in port L.S of main control valve. Right side of manifold............................................................................................................337
4. Activate main boom lift down. The gauge should read 2100 psi (145 bar)..........................................................................................................................................................................................337
5. The adjustment cartridge is located to the right of port # T2. Turn clockwise to increase, counterclockwise to decrease.........................................................................................................................................337
Swing..................................................................................................................................................................................................................................................................337
1. Install a high pressure gauge at the “MP” port of the main valve block. Lock the turn-table lock pin............................................................................................................................................................337
2. Activate swing, the gauge should read 1400 psi (97 bar). The adjustment cartridge is located on the right side of the block, right above “MP”...................................................................................................................337
3. Turn clockwise to increase, and counterclockwise to decrease....................................................................................................................................................................................................337
2 Wheel Steer..........................................................................................................................................................................................................................................................337
1. Install a high pressure gauge at the “MS” port of the main valve block. Activate steer left or right. The gauge should read 1800 psi (124 bar) (2-wheel steer) both directions..................................................................................337
2. One relief cartridge is located on the right side of the block, above port “MS”. The other one is located on the left side next to port #15.....................................................................................................................337
3. Turn clockwise to increase, and counterclockwise to decrease....................................................................................................................................................................................................337
4 Wheel Steer..........................................................................................................................................................................................................................................................337
1. Install a high pressure gauge at the “MS” port of the main valve block..........................................................................................................................................................................................337
2. Activate front wheel steer left or right. One relief cartridge is located on the right side of the block, above port “MS”. The other one is located on the left side next to port #15.Turn clockwise to increase, counterclockwise to decrease..................337
3. Adjust 2350 psi (162 bar) front steer. Remove the coil from the front wheel steer directional valve.............................................................................................................................................................337
4. Activate 4 wheel steer. Adjust the rear wheel steer reliefs to 2250 psi (155 bar). Those reliefs are located on the both sides of the 4-wheel steer block bolted on the top of the main control valve...........................................................337
5. There must be a minimum of 100 psi difference between the front axle reliefs and rear axle reliefs..............................................................................................................................................................337
Tower Telescope Out....................................................................................................................................................................................................................................................337
1. Install a high pressure gauge at gauge port “M2” located on the right side of the valve block, at the bottom....................................................................................................................................................337
2. Activate tower telescope out, the gauge should read 2200 psi (152 bar). This can be done with the tower lift down or up. If the tower lift is up, you must run tower telescope out to the end of stroke.........................................................337
3. The tower telescope out relief valve is located on the left side, at the bottom next to port #2. Turn clockwise to increase, counterclockwise to decrease.......................................................................................................337
Adjustments Made at the Platform Valve Block...............................................................................................................................................................................................................................337
Platform level up......................................................................................................................................................................................................................................................337
1. Install a high pressure gauge at the gauge port “M1” of the platform valve. There is pressure trapped at this test port.........................................................................................................................................337
2. To release this Pressure, activate level down to the end of stroke (the pressure in the up side goes to 0). This will allow you to snap a gauge on at this port.................................................................................................337
3. Activate level up to the end of stroke, the gauge should read 2600-2700 psi (179-186 bar). The level up relief valve is located next to the port “M1”...........................................................................................................337
4. Turn clockwise to increase, and counterclockwise to decrease....................................................................................................................................................................................................337
Platform level DOWN....................................................................................................................................................................................................................................................338
1. Install a high pressure gauge at gauge port “M2”, of the Platform Valve.........................................................................................................................................................................................338
2. To get a gauge on this point activate level up to the end of stroke (the pressure in the down side will go to 0, allowing you to snap a gauge on)...............................................................................................................338
3. Activate level down to the end of stroke, reading 1800 psi. The level down relief valve is located next to Port “M2”............................................................................................................................................338
4. Turn clockwise to increase, counterclockwise to decrease........................................................................................................................................................................................................338
Articulating jib down..................................................................................................................................................................................................................................................338
1. Install a high pressure gauge at the gauge port “M3” of the platform valve......................................................................................................................................................................................338
2. Activate jib down, you should read 1500 psi (103 bar). The down relief valve is located next to port M3.........................................................................................................................................................338
3. Turn clockwise to increase, and counterclockwise to decrease....................................................................................................................................................................................................338
4 Wheel Steer (If Equipped)............................................................................................................................................................................................................................................338
1. At the platform console using the steer select switch activate “4 wheel steer”..................................................................................................................................................................................338
2. Install a pressure gauge in port "G" on the control valve.......................................................................................................................................................................................................338
3. With the aid of an assistant, activate steer left and right, adjust front steer relief valve to 2500 psi (172.4 bar). This pressure only affects the front axle.................................................................................................338
4. At the platform console using the steer select switch activate “crab” or “coordinated” steer....................................................................................................................................................................338
5. At the main control valve block disconnect the wire din connectors on the front steer valve. When steer is activated only the rear steer will work..............................................................................................................338
6. Install a pressure gauge in port "G" on the control valve.......................................................................................................................................................................................................338
7. With the aid of an assistant, activate steer left and right, adjust rear steer relief valve to 2500 psi (172 bar) Reading at the valve bank. 2500 psi (172 bar) will give you 2000 psi (138 bar) at the cylinders...............................................338
8. Re-connect the front steer din connectors at the valve bank.....................................................................................................................................................................................................338
5.6 Hydraulic Component Start-Up Procedures and Recommendations................................................................................................................................................................................................................339
5.7 Hydraulic drive pump pre-fill procedure....................................................................................................................................................................................................................................340
1. Fill the hydraulic reservoir............................................................................................................................................................................................................................................340
2. Determine if the hydraulic oil tank sight level gauge is higher than other hydraulic components.........................................................................................................................................................................340
a. Determine if the hydraulic oil tank sight level gauge is higher than the hydraulic drive pump assembly..............................................................................................................................................................340
b. Determine if the hydraulic oil tank sight level gauge is higher than all hydraulic hope loops and the routings between the hydraulic tanks and the hydraulic drive pump assembly....................................................................................340
c. If sight level gauge is the highest hydraulic oil level point, proceed to step 3....................................................................................................................................................................................340
d. if sight level gauge is NOT the highest oil level point, low pressure air may need to 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 these high s.............340
3. If the machine is to be equipped with a hydraulic oil cooler option.....................................................................................................................................................................................................340
a. Determine if there is hydraulic “tee” fittings installed at the hydraulic drive pump that has a “cap” fittings 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.........................340
b. Remove “cap” fitting................................................................................................................................................................................................................................................340
c. Fill hydraulic drive pump case with hydraulic oil...................................................................................................................................................................................................................340
d. Attach and torque “cap” fitting.....................................................................................................................................................................................................................................340
e. Pre-filling of hydraulic drive pump w/oil cooler option is complete. (Step #4 can be omitted at this point).........................................................................................................................................................340
4. If machine is NOT equipped with a hydraulic oil cooler option...........................................................................................................................................................................................................340
a. Locate a case access port on the hydraulic drive pump. Preferably one located on at or near the top or under sides of the pump......................................................................................................................................340
b. Using the proper wrench, Remove the O-ring plug to allow air to escape from the hydraulic drive pump case...........................................................................................................................................................340
c. Hydraulic oil will flow by gravity from the hydraulic tank to the drive pump........................................................................................................................................................................................340
d. The pump is full, when hydraulic oil starts to flow out of this port................................................................................................................................................................................................340
e. Install the O-ring plug and torque..................................................................................................................................................................................................................................340
5. Pre-filled of the hydraulic drive pump is complete......................................................................................................................................................................................................................340
5.8 Function Pump..............................................................................................................................................................................................................................................................341
Removal....................................................................................................................................................................................................................................................................341
1. Place machine on level surface and allow the engine and system fluids to cool.......................................................................................................................................................................................341
2. Properly relieve any pressure in hydraulic system...................................................................................................................................................................................................................341
3. Tag and disconnect the hydraulic lines and fittings from the function pump. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports........................................................................................341
4. Use a suitable device to support the function pump..................................................................................................................................................................................................................341
5. Remove two bolts and washers attaching the function pump to the drive pump. Remove function pump from the machine as shown..........................................................................................................................................341
6. Remove and discard o-ring, if applicable............................................................................................................................................................................................................................341
7. Place function pump in the clean work area..........................................................................................................................................................................................................................341
Installation...............................................................................................................................................................................................................................................................341
1. Use a suitable device to support the function pump..................................................................................................................................................................................................................341
2. If applicable, install the o-ring on to the function pump...........................................................................................................................................................................................................341
3. Align and install the function pump to the drive pump...............................................................................................................................................................................................................341
4. Secure function pump with two bolts and washers as shown. Apply Medium Strength Threadlocking Compound to the bolts before installation. Torque bolts to 85 ft. lbs. (116Nm)........................................................................................341
5. Remove tag and reconnect the hydraulic lines to the function pump...................................................................................................................................................................................................341
6. Reconnect the battery power and make sure for proper working of the function pump...................................................................................................................................................................................341
Initial Start-up Procedures................................................................................................................................................................................................................................................343
1. Install the pump on the engine. Ensure the pump shaft is properly aligned...........................................................................................................................................................................................343
2. Fill the main pump housing with clean hydraulic fluid. Pour filtered oil directly into the main most case drain port................................................................................................................................................343
3. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks............................................................................................343
4. To ensure the pump stays filled with oil, install the case drain line in the main most case drain port..............................................................................................................................................................343
5. Install a gauge at port M2 to monitor system pressure during start up...............................................................................................................................................................................................343
6. While watching the pressure gauge installed at M2, jog the engine or run at the 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. .............343
7. Operate the hydraulic system for at least fifteen minutes under light load conditions...............................................................................................................................................................................343
8. Check and adjust control settings as necessary after installation. Refer to Adjustments.............................................................................................................................................................................343
9. Shut down the engine and remove the pressure gauge. Replace plug at port M2.........................................................................................................................................................................................343
10. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The pump is now ready for operation.................................................................................................................................................343
Troubleshooting............................................................................................................................................................................................................................................................344
Shaft Seal Replacement.....................................................................................................................................................................................................................................................348
Removal................................................................................................................................................................................................................................................................348
1. Using the appropriate snap-ring pliers, remove the retaining ring (K010) from the housing.......................................................................................................................................................................348
2. Remove the shaft seal (K020) from the bore in the pump housing and discard. Avoid damaging the pump housing or shaft. Puncture the face of the seal with a packing hook, or use a slide-hammer type puller to remove the seal...................................348
Installation...........................................................................................................................................................................................................................................................348
1. Inspect the pump housing and new seal for damage. Inspect the sealing area on the shaft for rust, wear, or contamination. Polish the sealing area on the shaft if necessary.....................................................................................348
2. Lubricate the lip of the new shaft seal with clean hydraulic fluid. Place a protective sleeve over the shaft end to prevent damage to the seal during installation..............................................................................................348
3. Keeping the seal perpendicular to the shaft, press the new seal into the housing just far enough to clear the retaining ring groove. Install seal with the cupped side toward the shaft bearing. Do not damage the seal during installation.....................348
4. Using the appropriate snap ring pliers, install the seal retaining ring.........................................................................................................................................................................................348
5. Remove the installation sleeve..................................................................................................................................................................................................................................348
Control Assembly...........................................................................................................................................................................................................................................................348
1. Remove the four screws (C300) holding the control hou- sing onto the endcap.........................................................................................................................................................................................349
2. Remove the control and discard the three interface o- rings (C200)..................................................................................................................................................................................................349
3. Remove the Pressure Compensator set screw (C102), Pressure Compensator adjustment screw (C138), o-ring (C136), springs (C135, C134), and seat (C133). Discard the o-ring............................................................................................349
4. Remove the plug (C103), o-ring (C103A),and Pressure Compensator spool (C132) from the control housing; discard the o-ring. Note orientation of the spool for reassembly.............................................................................................349
5. Remove the plug (C107) and o-ring (C107A); discard the o-ring.......................................................................................................................................................................................................349
6. Remove the Load Sense set screw (C102), Load Sense adjustment screw (C118), o-ring (C116), backup rings (C117), springs (C114, C115), and seat (C113); discard the o-ring...........................................................................................349
7. Remove the plug (C106), o-ring (C106A), and Load Sense spool (C112) from the control housing; discard the o- ring. Note orientation of the spool for reassembly.....................................................................................................349
Inspection.............................................................................................................................................................................................................................................................349
1. Inspect the adjustment screws for wear at the tips and where they contact the springs; replace as necessary.....................................................................................................................................................349
2. Inspect the springs and spring guides for wear or damage; replace as necessary..................................................................................................................................................................................349
3. Carefully inspect the spools. Ensure the sealing lands are free of nicks and scratches. Check the ends that contact the spring guides for wear. Replace spools as necessary.....................................................................................349
4. Inspect the control housing for damage. Check the spool bores for excessive wear................................................................................................................................................................................349
5. Clean all parts and lubricate spools, springs, guides and new o-rings with clean hydraulic fluid................................................................................................................................................................349
Reassembly.............................................................................................................................................................................................................................................................349
1. Install the Pressure Compensator spool, spherical end first, into the Pressure Compensator bore. The Pressure Compensator spool is the shorter of the two. Using a new o-ring, install the plug (C103). Torque to 8-10 ft.lb. [11-14 Nm]........................349
2. Place the two Pressure Compensator springs onto the spring guide and install into the Pressure Compensator bore. Place a new o-ring onto the Pressure Compensator adjustment screw and thread it into the Pressure Compensator bore until flush, then m.........349
3. Install the Load Sense spool, spherical end first, into the Load Sense bore. The Load Sense spool is the longer of the two. Using a new o-ring, install the plug (C106). Torque to 8-10 ft.lb. [11-14 Nm].......................................................349
4. Place the two Load Sense springs onto the spring guide and install into the Load Sense bore. Place a new o-ring and backup rings onto the Load Sense adjustment sc- rew and thread it into the Load Sense bore until flush, then make another full turn.........349
5. Using a new o-ring, install the plug (C107). Torque to 8- 10 ft.lb. [11-14 Nm]..................................................................................................................................................................................349
6. Using petroleum jelly to retain them, install the three interface o-rings (C200) in the recesses on the control housing.........................................................................................................................................349
7. Install the control assembly onto the endcap using the four screws (C300). Torque to 11-13 ft.lb. [15-18 Nm]. Torque screws in a criss-cross pattern and re-torque the first screw to ensure proper torque retention............................................349
Plug and Fitting Sizes and Torques.........................................................................................................................................................................................................................................350
5.9 Drive Pump.................................................................................................................................................................................................................................................................351
Removal....................................................................................................................................................................................................................................................................351
1. Tag and disconnect the hydraulic lines and fittings from the drive pump. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports...........................................................................................351
2. Use a suitable device to support the drive pump.....................................................................................................................................................................................................................351
3. Remove two bolts and washers attaching the drive pump to the engine assembly. Remove drive pump from the machine as shown...........................................................................................................................................351
4. Remove and discard o-ring from the drive pump groove................................................................................................................................................................................................................351
5. Place drive pump in the clean work area.............................................................................................................................................................................................................................351
Installation...............................................................................................................................................................................................................................................................351
1. Use a suitable device to support the drive pump.....................................................................................................................................................................................................................351
2. Install the new o-ring in to the drive pump groove..................................................................................................................................................................................................................351
3. Align and install the drive pump to the engine assembly.............................................................................................................................................................................................................351
4. Secure drive pump with two bolts and washers as shown...............................................................................................................................................................................................................351
5. Torque bolt to 46-56 ft.lbs. (62-76 Nm).............................................................................................................................................................................................................................351
6. Remove tag and reconnect the hydraulic lines and fittings to the drive pump.........................................................................................................................................................................................351
Servo Controlled Piston Pump...............................................................................................................................................................................................................................................352
Disassembly............................................................................................................................................................................................................................................................352
1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the Capscrews up. Mark the relationship of the working ports (for assembly identification) to the servo control assembly with a scribe. Remove the fou.........352
2. Lift the charge pump adapter assembly straight up off endcover, shaft and gerotor. Gerotor may stay in adapter or on endcover...................................................................................................................................352
3. Remove o-ring from charge pump adapter..........................................................................................................................................................................................................................352
4. Remove outer gerotor ring from either the charge pump adapter or the inner gerotor ring.........................................................................................................................................................................352
5. Remove the inner gerotor ring and key from drive shaft or inner gerotor ring and coupler assembly from shaft....................................................................................................................................................352
6. Lift endcover straight up off shaft and housing. Remove valve plate from endcover or from rotating kit assembly, still in housing...............................................................................................................................352
7. From endcover, remove bypass valve or plug, and relief valve assemblies. Note: Mark the relief valve in relationship to the cavity it was removed, for reassembly purposes......................................................................................352
1. Remove housing gasket from housing or endcover..................................................................................................................................................................................................................352
2. With pump still in vise, remove the six Capscrews retaining the manual servo control assembly. Remove the control assembly and control housing gasket from the housing. Remove orifice plates, noting location for reassembly. Remove nut and lock wash.........352
3. To remove rotating kit assembly from housing, first remove pump from vise holding the rotating kit assembly in position. Lower pump so that the shaft end (flange end) is up. Set the rear of housing onto table with housing flat and rotating kit ass.........352
4. Remove swash plate from rotating kit assembly and servo piston follower from swashplate.........................................................................................................................................................................352
1. To remove servo piston assembly from housing, start with the four each Capscrews and washers retaining each cover plate.........................................................................................................................................353
2. In removing the cover plate from the servo piston bolt, remove jam nut, washer, and seal washer. Hold the servo piston bolt with hex key and unscrew cover plate off of bolt....................................................................................353
3. Remove servo piston assembly and seal sub-assemblies (two sets) from housing....................................................................................................................................................................................353
4. Remove retaining ring from the front of housing. Press the shaft, shaft seal or spacer, and washer from housing. Remove retaining ring, thrust washer, thrust bearing, second thrust washer, and second retaining ring from shaft...............................353
1. To remove cradle sub-assembly, remove the two Capscrews retaining cradle inside housing. Removing cradle subassembly from housing...............................................................................................................................353
2. Remove button head Capscrews (2 Qty.) to remove bushing from cradle.............................................................................................................................................................................................353
1. Remove all plugs from housing...................................................................................................................................................................................................................................353
2. Discard the shaft seal, gaskets, and o-rings from all assemblies. Replace with new seals upon reassembly........................................................................................................................................................353
Assembly...............................................................................................................................................................................................................................................................353
1. All parts should be cleaned and critical moving parts lubricated before reassembly..............................................................................................................................................................................353
2. If necessary, press new bearing in housing to dimension shown in Figure 5-113. with the numbered end of bearing outward.........................................................................................................................................353
3. Install the two new seal sub-assemblies into the servo piston cavity of housing.................................................................................................................................................................................353
4. Screw the cover plate onto the servo piston assembly. Install new cover plate gasket in place on housing. Install servo piston assembly and cover plate into servo piston bore in right side of housing (as shown in Figure 5-114. Retain cover plate w.........353
5. Install new seal washer, washer, and jam nut to servo piston bolt. Holding servo piston bolt with hex key wrench Torque jam nut (150 to 160 in.lbs) 17 to 18 Nm. Check the centering of servo piston assembly. Install new cover plate gasket and cover.........353
6. To assemble cradle sub-assembly, install bushing onto cradle retaining with button head Capscrews. Torque button head Capscrew 14 to 16 in.lbs (1.6 to 1.8 Nm)..................................................................................................354
7. Place cradle sub-assembly into housing making sure cradle is completely seated into housing. Retain cradle sub-assembly with two Capscrews. Torque Capscrews 20 to 24 ft.lbs (27 to 33 Nm)......................................................................354
8. To install shaft, place exterior retaining ring, thrust race, thrust bearing, second thrust race, and second retaining ring onto shaft. Position washer and shaft seal or spacer onto shaft.....................................................................354
9. Install shaft assembly into front of housing for units with spacer, retain with interior retaining ring and go on to step 10. For units with shaft seal. seat seal into position with seal driver and retain with interior retaining ring.......................354
10. Install servo piston follower onto swashplate dowel pin. Install swashplate carefully onto bushing (coat bushing surface with hydraulic oil), aligning servo piston follower with slot in servo piston assembly................................................354
11. To install rotating kit assembly, leave housing and shaft in the horizontal position. Holding swashplate into position with screw driver thru controller linkage passageway at the top of housing. place rotating kit assembly over shaft and into hou.........354
12. Install gasket on to housing...................................................................................................................................................................................................................................354
13. If necessary, press new bearing and roll pin in endcover to dimension shown in figure 1-3. Bearing installed with the numbered end outward. Roll pin installed with split oriented away from bearing...........................................................354
14. Install new o-ring on relief valves. Install relief valve in its original cavity in endcover that it was removed. Torque 100 to 110 ft.lbs (136 to 149 Nm).....................................................................................................354
15. Install new o-ring on bypass valve or plug. Install bypass valve or plug into endcover. Note: Make sure paddle of bypass valve is perpendicular to relief valve axis prior to installing or damage could result................................................354
16. Apply a small amount of petroleum jelly to the steel side of valve plate to hold in place for installation. Aligning the index pin, place the valve plate in position onto the endcover, with steel side against endcover......................................354
17. Install endcover assembly onto housing assembly. Make sure ports are positioned correctly, valve plate and gasket stay in place................................................................................................................................354
18. Install key and inner ring gerotor onto shaft or coupler assembly. Lubricate inner ring gerotor................................................................................................................................................................354
19. Insta ll o-ring and outer ring gerotor onto adapter plate. Lubricate both a-ring and outer ring to hold in position during assembly of adapter plate. Install adapter plate onto endcover. Make sure o-ring and gerotor ring stay in place.....................354
20. Retain endcover and adapter plate (when used) with four Capscrews, Torque 27 to 31 ft.lbs (37 to 42 Nm)........................................................................................................................................................354
21. Install control housing gasket onto housing. Install orifices into control assembly and retain in position with petroleum jelly. Position the feedback link at 90 degrees from control housing. Install manual servo control assembly onto housing mak.........354
22. Retain control assembly with six Capscrews, torque 40 to 48 in.lbs (4.5 to 5.4 Nm).............................................................................................................................................................................354
23. Install control arm onto control assembly input arm. Retain with lock washer and nut, torque 4 to 6 ft.lbs (5 to 8 Nm).........................................................................................................................................354
24. Install new o-rings on all plugs. Install plugs into housing. Torque 3/4 in. plug 21 to 24 ft.lbs (28 to 32 Nm). Torque 1-1/4 in. plug 40 to 45 ft.lbs (54 to 61 Nm)...........................................................................................354
25. Refer to “Start-up Procedure”..................................................................................................................................................................................................................................354
Charge Pump Adapter Assembly...............................................................................................................................................................................................................................................355
Disassembly............................................................................................................................................................................................................................................................355
1. Remove plug, shims, spring, and poppet from adapter assembly as shown in Figure 5-116...........................................................................................................................................................................355
assembly...............................................................................................................................................................................................................................................................355
1. If necessary, press new bearing or bushing in adapter assembly. The bearing to dimension shown in Figure 5- 115. with the numbered end of bearing outward and closest to mounting flange. The bushing is to be pressed flush to 0.254 mm [0.010 in.) re.........355
2. Install poppet. spring, shims, new o-ring on plug, and plug into adapter assembly. Torque plug 30 to 27 ft.lbs. (40.7 to 36.6 Nm)...............................................................................................................................355
1. Charge Pump Adapter.............................................................................................................................................................................................................................................355
2. Bearing.........................................................................................................................................................................................................................................................355
3. Bushing.........................................................................................................................................................................................................................................................355
4. Poppet..........................................................................................................................................................................................................................................................355
5. Spring..........................................................................................................................................................................................................................................................355
6. Shims...........................................................................................................................................................................................................................................................355
7. 0-ring..........................................................................................................................................................................................................................................................355
8. Plug............................................................................................................................................................................................................................................................355
Manual Servo Control Basic Assembly........................................................................................................................................................................................................................................356
Disassembly............................................................................................................................................................................................................................................................356
1. Remove wiper seal with screw driver. Remove set screw retaining input shaft and remove input shaft from control housing.........................................................................................................................................356
2. Remove set screw from plug retaining valve spool and remove plug................................................................................................................................................................................................356
3. Remove E-ring from pin retaining feedback link and valve spool. Remove pin. feedback link. valve spool, and bell crank from control housing.....................................................................................................................356
4. Compress spring and remove E-ring. spring retainer. spring. and second spring retainer from valve spool.........................................................................................................................................................356
5. Remove o-rings from plug and input shaft. Clean all parts and lubricate in prep for reassembly..................................................................................................................................................................356
assembly...............................................................................................................................................................................................................................................................356
1. Install spring retainer, spring. and second spring retainer onto spool. Compress spring with retainer and retain with E-ring onto valve spool...................................................................................................................356
2. Install valve spool into control housing making sure that metering notches on valve spool can be seen in the metering ports. Notches shown in Figure 5-117......................................................................................................356
3. Position bell crank in housing. Slide feedback link into position between clevis on valve spool. aligning holes, and install dowel pin retaining with E-ring....................................................................................................356
4. Install new o-ring onto input shaft. Hold bell crank in position with feedback link slot and align splined hole of bell crank with input shaft cavity. Install input shaft into control housing and bell crank..................................................356
5. Apply Medium Strength Threadlocking Compound or equivalent to set screw and install, retaining input shaft. Adjust set screw until it bottoms out on input shaft and back out one-quarter turn..................................................................356
6. Install wiper seal on input shaft as shown in Figure 5- 117. Install new o-ring onto plug. retaining valve spool, and install plug. Adjust plug until there is no play in the valve spool with input shaft held stationary. Lock in place with set scre.........356
1. Control Housing.................................................................................................................................................................................................................................................356
2. Plug............................................................................................................................................................................................................................................................356
3. 0-ring..........................................................................................................................................................................................................................................................356
4. Retaining Ring..................................................................................................................................................................................................................................................356
5. Spring Retainer.................................................................................................................................................................................................................................................356
6. Spool Centering Spring..........................................................................................................................................................................................................................................356
7. Valve Spool.....................................................................................................................................................................................................................................................356
8. Set Screw.......................................................................................................................................................................................................................................................356
9. Feedback Link...................................................................................................................................................................................................................................................356
10. Dowel Pin......................................................................................................................................................................................................................................................356
11. Retaining Ring.................................................................................................................................................................................................................................................356
12. Bell Crank.....................................................................................................................................................................................................................................................356
13. Set Screw......................................................................................................................................................................................................................................................356
14. Input Shaft....................................................................................................................................................................................................................................................356
15. 0-ri ng........................................................................................................................................................................................................................................................356
16. Wiper Seal.....................................................................................................................................................................................................................................................356
17. Head Pin.......................................................................................................................................................................................................................................................356
Manual Servo Control Assembly Options......................................................................................................................................................................................................................................357
Disassembly - Destroke Valve Assembly Option...........................................................................................................................................................................................................................357
1. Remove the two Capscrews and lock washers from manifold. Removing destroke valve assembly and two a- rings......................................................................................................................................................357
2. Remove destroke valve from manifold in order to remove o-rings and backup washers. Note: in order to remove destroke valve the solenoid may need to be removed from core first (not shown)......................................................................357
assembly - Destroke Valve Assembly Option..............................................................................................................................................................................................................................357
1. Install new o-rings and backup washers onto destroke valve......................................................................................................................................................................................................357
2. Install destroke valve into manifold by hand until top o- ring is met by manifold. Then wrench tighten to 25 ft.lbs. (34 Nm) max. Loosen Nut retaining coil to reposition if necessary and re-torque 4 to 5 ft.lbs. (5.4 to 7 Nm)...............................357
3. Lubricate the two o-rings and install onto manifold. Install destroke valve assembly onto control assembly. Retain with lock washers and Capscrews. Torque 2.2 to 2.6 ft.lbs. (3 to 3.5 Nm).....................................................................357
1. 0-ring..........................................................................................................................................................................................................................................................357
2. manifold........................................................................................................................................................................................................................................................357
3. Destroke Valve..................................................................................................................................................................................................................................................357
4. 0-ring..........................................................................................................................................................................................................................................................357
5. Backup Washer...................................................................................................................................................................................................................................................357
6. O-ring..........................................................................................................................................................................................................................................................357
7. Lock Washer.....................................................................................................................................................................................................................................................357
8. Capscrew........................................................................................................................................................................................................................................................357
9. O-ring..........................................................................................................................................................................................................................................................357
10. Neutral Lockout Adapter........................................................................................................................................................................................................................................357
11. Ball...........................................................................................................................................................................................................................................................357
12. O-ring.........................................................................................................................................................................................................................................................357
13. Pin............................................................................................................................................................................................................................................................357
14. Set Screw......................................................................................................................................................................................................................................................357
15. Neutral Lockout Switch.........................................................................................................................................................................................................................................357
16. Ball Plunger...................................................................................................................................................................................................................................................357
17. Nut Seal.......................................................................................................................................................................................................................................................357
Disassembly - Neutral Lockout Switch Assembly Option...................................................................................................................................................................................................................358
1. Loosen set screw in adapter and remove neutral lockout switch from adapter......................................................................................................................................................................................358
2. Remove neutral lockout adapter from control assembly............................................................................................................................................................................................................358
3. Remove pin, ball. and a-rings from adapter......................................................................................................................................................................................................................358
assembly - Neutral Lockout Switch Assembly Option......................................................................................................................................................................................................................358
1. Install new a-ring onto adapter and new o-ring onto pin.........................................................................................................................................................................................................358
2. Install ball and pin into adapter. Lubricate with petroleum jelly to hold in place during installation..........................................................................................................................................................358
3. Install adapter into control assembly. Torque 44 to 53 ft.lbs. (60 to 70 Nm)....................................................................................................................................................................................358
4. Apply Low Strength Threadlocking Compound or equivalent to threads of switch and install neutral lockout switch into adapter. The adjustment procedures for the switch are as follows...........................................................................358
a. Install switch, while moving control arm back and forth, until “detent” action is detected. Back out the switch until the “detent” action is very slight....................................................................................................358
b. Obtain a test light or use a multimeter. Attach the leads from the test light to the switch or the wiring connector.........................................................................................................................................358
c. Move the control arm out of the detent position. The test light will go on. Screw in the switch until the light goes off. Mark this as position “A”. See Figure 5-119. Move the control arm to the detent position and the test light should come b.........358
d. Leaving the control arm in the detent position, the light will remain on. Screw in the switch until the light goes off. Mark this position"B"...............................................................................................................358
e. Unscrew the switch one third of the distance between "B" and "A". Install and tighten the hex socket head set screw in one of the main quadrants of the hex of the switch adapter. See Figure 5-119. Torque set screw 2.3 to 2.8 in.lbs (3.2 to 3.8 Nm).....358
5. Test the switch by moving the control arm to the detent position, the light should be on. Move the control arm out of detent, the light should go off...........................................................................................................358
6. Remove test light and put servo control assembly into operation.................................................................................................................................................................................................358
Disassembly - Neutral Detent Option....................................................................................................................................................................................................................................358
1. Loosen seal nut and remove ball plunger from control housing....................................................................................................................................................................................................358
assembly- Neutral Detent Option........................................................................................................................................................................................................................................358
1. Install ball plunger into control housing until contact with bell crank detent is detected. After contact screw in 1/2 turn and retain with seal nut. Torque nut 10 to 22 ft.lbs. (14 to 30 Nm).................................................................358
Rotating Kit Assembly......................................................................................................................................................................................................................................................359
DISASSEMBLY............................................................................................................................................................................................................................................................359
1. Remove the nine piston assemblies, shoe retainer, and shoe retainer pivot from cylinder barrel..................................................................................................................................................................359
2. To inspect pins and spring caution should be taken in removing spring. The spring is highly compressed and the retaining ring should not be removed without compressing the spring safely.......................................................................359
assembly...............................................................................................................................................................................................................................................................359
1. To reassemble the rotating kit assembly complete the following: Compress the pin keeper and install in the spline of the cylinder barrel. Insta ll the three pins with head end to the inside of the barrel and position in the special grooves of the .........359
2. Install the washer, spring, and second washer into the cylinder barrel. Use the two 3/8 in. I. D. washers, nut, and 3/8 in. x 3-1/4 in. Capscrew to compress the spring and retain with retaining ring. Remove the nut. Capscrew, and the two washers...........359
3. Install the pivot onto the three pins, shoe retainer on the pivot, and piston assemblies thru the shoe retainer and into cylinder barrel. resting on shoe retainer..............................................................................................359
1. Piston assemblies...............................................................................................................................................................................................................................................359
2. Shoe Retainer...................................................................................................................................................................................................................................................359
3. Shoe Retainer Pivot.............................................................................................................................................................................................................................................359
4. Retainer........................................................................................................................................................................................................................................................359
5. Cylinder Barrel.................................................................................................................................................................................................................................................359
6. Pins............................................................................................................................................................................................................................................................359
7. Washer..........................................................................................................................................................................................................................................................359
8. Spring..........................................................................................................................................................................................................................................................359
9. Retaining Ring..................................................................................................................................................................................................................................................359
Fault- logic Trouble Shooting..............................................................................................................................................................................................................................................360
Recommended Gauge Locations............................................................................................................................................................................................................................................360
Diagram Action Step Comments...........................................................................................................................................................................................................................................364
1. Inspect External Control Linkage for:...........................................................................................................................................................................................................................364
a. Misadjusted or disconnected.................................................................................................................................................................................................................................364
b. Binding, bent or broken.....................................................................................................................................................................................................................................364
2. Inspect Control Valve for:......................................................................................................................................................................................................................................364
a. Plugged control orifice(s)..................................................................................................................................................................................................................................364
b. Damaged mounting gasket.....................................................................................................................................................................................................................................364
c. Misadjusted, damaged or broken neutral return spring........................................................................................................................................................................................................364
d. Broken control connector pin................................................................................................................................................................................................................................364
e. Faulty destroke valve (if used).............................................................................................................................................................................................................................364
f. Galled or stuck control spool...............................................................................................................................................................................................................................364
g. Neutral detent or lockout switch misadjusted (if used)......................................................................................................................................................................................................364
3. Inspect System Relief Valves for:...............................................................................................................................................................................................................................364
a. Improper pressure relief setting............................................................................................................................................................................................................................364
b. Damaged or broken spring....................................................................................................................................................................................................................................364
c. Valve held off seat.........................................................................................................................................................................................................................................364
d. Damaged valve seat..........................................................................................................................................................................................................................................364
4. Inspect Servo Piston for:.......................................................................................................................................................................................................................................364
a. Misadjusted, damaged or broken neutral return spring assembly...............................................................................................................................................................................................364
b. Galled or stuck servo piston................................................................................................................................................................................................................................364
c. Damaged or missing o-ring and/or backup ring................................................................................................................................................................................................................364
5. Check Oil Level in Reservoir:...................................................................................................................................................................................................................................364
a. Consult owner/operators manual for the proper type fluid and level..........................................................................................................................................................................................364
6. Inspect Heat Exchanger for:.....................................................................................................................................................................................................................................364
a. Obstructed air flow (air cooled)............................................................................................................................................................................................................................364
b. Obstructed water flow (water cooled)........................................................................................................................................................................................................................364
c. Improper plumbing (inlet to outlet).........................................................................................................................................................................................................................364
d. Obstructed fluid flow.......................................................................................................................................................................................................................................364
7. Inspect Heat Exchanger Bypass Valve for:........................................................................................................................................................................................................................364
a. Improper pressure adjustment................................................................................................................................................................................................................................364
b. Stuck or broken valve.......................................................................................................................................................................................................................................364
8. Inspect Bypass Valve for: {if used).............................................................................................................................................................................................................................364
a. Held in a partial or full open position.....................................................................................................................................................................................................................364
9. Inspect Inlet Screen or Filter for:.............................................................................................................................................................................................................................364
a. Plugged or clogged screen or filter element.................................................................................................................................................................................................................364
b. Obstructed inlet or outlet..................................................................................................................................................................................................................................364
c. Open inlet to charge pump...................................................................................................................................................................................................................................364
10. Check System Pressure:.........................................................................................................................................................................................................................................364
a. See Figure 5-121. for location of pressure gauge installation...............................................................................................................................................................................................364
b. Consult owner/operators manual for maximum system relief valve settings.....................................................................................................................................................................................364
11. Check Charge Pressure:.........................................................................................................................................................................................................................................364
a. See Figure 5-121. for location of charge pressure gauge installation........................................................................................................................................................................................364
b. Consult owner/operators manual for maximum charge relief valve settings.....................................................................................................................................................................................364
12. Inspect Charge Relief Valve for:...............................................................................................................................................................................................................................364
a. Improper charge relief pressure setting.....................................................................................................................................................................................................................364
b. Damaged or broken spring....................................................................................................................................................................................................................................364
c. Poppet valve held off seat..................................................................................................................................................................................................................................364
13. Inspect Motor for:.............................................................................................................................................................................................................................................364
a. Consult owner/operator manual for motor operation and trouble shooting......................................................................................................................................................................................364
14. Inspect Charge Pump for:.......................................................................................................................................................................................................................................364
a. Broken or missing drive key.................................................................................................................................................................................................................................364
b. Damaged or missing o-ring...................................................................................................................................................................................................................................364
c. Excessive gerotor clearance.................................................................................................................................................................................................................................364
d. Galled or broken gerotor set................................................................................................................................................................................................................................364
Start-up Procedure.........................................................................................................................................................................................................................................................365
1. After the transmission components have been properly installed, fill the servo pump housing at least half full with filtered system oil. Connect all hydraulic lines and check to be sure they are tight............................................................365
2. Install and adjust all control linkage..............................................................................................................................................................................................................................365
3. Fill the reservoir with an approved oil that has been filtered through a 10 micron filter. Refer to Eaton Hydraulics Technical Data sheet number 3-401 titled Hydraulic Fluid Recommendations.......................................................................365
4. Gasoline or L.P. engines: remove the coil wire and turn the engine over for 15 seconds. Diesel engines: shut off the fuel flow to the injectors and turn the engine over for 15 seconds.............................................................................365
5. Replace the coil wire or return the fuel flow to the injectors. Place the transmission unit in the neutral position, start the engine and run it at a low idle. The charge pump should immediately pick up oil and fill the system. If there is no indi.............365
6. After the system starts to show signs of fill, slowly move pump swashplate to a slight cam angle. Continue to operate system slowly with no load on motors until system responds fully..............................................................................365
7. Check fluid level in the reservoir and refill if necessary to the proper level with an approved filtered oil........................................................................................................................................................365
8. Check all line connections for leaks and tighten if necessary.......................................................................................................................................................................................................365
9. The machine is now ready to be put into operation...................................................................................................................................................................................................................365
10. Frequent filter changes are recommended for the first two changes after placing the machine back into operation. Change the first filter in 3-5 hours and the second at approximately 50 hours. Routinely scheduled filter changes are recommended for.............365
Section 6. JLG Control System..........................................................................................................................................................................................................................................................371
6.1 Introduction...................................................................................................................................................................................................................................................................371
6.2 JLG Control System Analyzer Kit Instructions...................................................................................................................................................................................................................................372
To Connect the JLG Control System Analyzer.....................................................................................................................................................................................................................................373
1. Connect the four pin end of the cable supplied with the analyzer, to the control module located in the platform box or at the HEC module and connect the remaining end of the cable to the analyzer.....................................................................373
2. Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on......................................................................................................................................373
Using the Analyzer.............................................................................................................................................................................................................................................................373
Changing the Access Level of the Hand Held Analyzer............................................................................................................................................................................................................................375
Adjusting Parameters Using the Hand Held Analyzer..............................................................................................................................................................................................................................376
Machine Setup..................................................................................................................................................................................................................................................................376
Level Vehicle Description......................................................................................................................................................................................................................................................377
Ground Control Console Display Gauge...........................................................................................................................................................................................................................................378
6.3 Platform Load Sensing System...................................................................................................................................................................................................................................................381
1. The Overload Visual Warning Indicator will flash at the selected control position (platform or ground)......................................................................................................................................................................381
2. The Platform and Ground Alarms will sound 5 seconds On, and 2 seconds Off...................................................................................................................................................................................................381
3. All normal movement will be prevented from the platform control position (optional - ground control functions may be prevented).............................................................................................................................................381
4. Further movement is permitted by:...........................................................................................................................................................................................................................................381
a. Removing the excess platform load until actual platform load is less than Rated Load....................................................................................................................................................................................381
b. Operation of the overriding emergency system (Auxiliary Power Unit).....................................................................................................................................................................................................381
c. By an authorized person at the ground control position (optional - ground control functions may be prevented)...........................................................................................................................................................381
a. LSS Sensor removal or replacement.......................................................................................................................................................................................................................................382
b. Addition or removal of certain platform mounted accessories. (Refer to Calibration).....................................................................................................................................................................................382
c. Platform is removed, replaced, repaired or shows evidence of impact.....................................................................................................................................................................................................382
Diagnostic Menu................................................................................................................................................................................................................................................................382
Calibration Procedure..........................................................................................................................................................................................................................................................383
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...............................................383
2. Plug the JLG Analyzer into the Machine at the Ground Station and enter Service Access Password 33271....................................................................................................................................................................383
3. The platform should be approximately level for calibration. Level the platform from ground control (if necessary) to within +/- 5°......................................................................................................................................383
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:..................................................................................................................................383
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:....................................................................................................................383
6. Press Enter . The Screen will read:.....................................................................................................................................................................................................................................383
7. Press ENTER . The analyzer screen will read:............................................................................................................................................................................................................................384
8. If the platform is empty, press ENTER . The screen will read:...........................................................................................................................................................................................................384
9. The control system will calculate the load cell readings and ensure it is greater than 130 lb (59 kg), but less than 575 lb(261 kg).....................................................................................................................................385
10. Press ENTER . The control system will ask for installed accessories. The screen will show the following:...............................................................................................................................................................385
11. Use the analyzer keys to select N for no or Y for yes. Press ENTER . The screen will read:.............................................................................................................................................................................385
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 6-4, SkyGlazier Capacity Reductions and Table 6-5, Pi.................386
13. Press ENTER . The following screen will be displayed for restricted capacity, which can be adjusted if necessary. Refer to Table 6-4, SkyGlazier Capacity Reductions and Table 6-5, Pipe Rack Capacity Reductions......................................................386
14. Press ENTER . If calibration is successful, the screen will read:......................................................................................................................................................................................................387
Testing & Evaluation...........................................................................................................................................................................................................................................................388
1. Connect the JLG Analyzer................................................................................................................................................................................................................................................388
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.................................................................388
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 .................388
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...........................................................................................................388
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.....................388
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.................388
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.................388
Troubleshooting................................................................................................................................................................................................................................................................389
6.4 Resetting The MSSO System......................................................................................................................................................................................................................................................390
1. Use the following procedure to reset the MSSO system........................................................................................................................................................................................................................390
2. Position the Platform/Ground select switch to the desired position..........................................................................................................................................................................................................390
3. Plug the analyzer into the connector coming from the ground control module or from the platform console.....................................................................................................................................................................390
4. Pull out the Emergency Stop switch..........................................................................................................................................................................................................................................390
5. The analyzer screen should read:............................................................................................................................................................................................................................................390
6. Use the arrow button to reach OPERATOR ACCESS. Press Enter .................................................................................................................................................................................................................390
7. Enter the Access Code 33271.................................................................................................................................................................................................................................................390
8. Use the right Arrow key to reach MENU: CALIBRATIONS. Press Enter ...........................................................................................................................................................................................................390
9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read:..................................................................................................................................................................................................390
10. Press ENTER ...............................................................................................................................................................................................................................................................390
11. Use the Down arrow to reach MSSO RESET.....................................................................................................................................................................................................................................390
12. Press Enter . The screen will read:........................................................................................................................................................................................................................................391
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.......................................................................................................................391
6.5 Machine Configuration Programming Information..................................................................................................................................................................................................................................392
6.6 Machine Personality Settings and Function Speeds...............................................................................................................................................................................................................................399
6.7 Machine Orientation When Setting Function Speeds...............................................................................................................................................................................................................................400
Test Notes.....................................................................................................................................................................................................................................................................401
1. Stop watch should be started with the function, not with the controller or switch.......................................................................................................................................................................................401
2. Drive test results reflect 15x19.5 or 18x19.5 tires, pneumatic or foam filled...........................................................................................................................................................................................401
3. All speed tests are run from the platform. These speeds do not reflect the ground control operation.....................................................................................................................................................................401
4. The platform speed knob control must be at full speed (turned clockwise completely).....................................................................................................................................................................................401
5. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100° F (38° C).............................................................................................................................................401
6. Some flow control functions may not work with the speed knob clicked into the creep position............................................................................................................................................................................401
6.8 CANbus Communications..........................................................................................................................................................................................................................................................423
6.9 Diagnostic Trouble Code Chart..................................................................................................................................................................................................................................................428
6.10 Diagnostic Trouble Code Chart- Additional Hec Faults..........................................................................................................................................................................................................................444
6.11 Diagnostic Trouble Code Chart - Hybrid UGM....................................................................................................................................................................................................................................464
Section 7. Basic Electrical Information & Electrical Schematics........................................................................................................................................................................................................................485
7.1 General........................................................................................................................................................................................................................................................................485
7.2 Multimeter Basics..............................................................................................................................................................................................................................................................485
Grounding......................................................................................................................................................................................................................................................................485
Backprobing....................................................................................................................................................................................................................................................................485
Min/Max........................................................................................................................................................................................................................................................................485
Polarity.......................................................................................................................................................................................................................................................................485
Scale..........................................................................................................................................................................................................................................................................485
Voltage Measurement............................................................................................................................................................................................................................................................485
Resistance Measurement.........................................................................................................................................................................................................................................................486
Continuity Measurement.........................................................................................................................................................................................................................................................486
Current Measurement............................................................................................................................................................................................................................................................487
7.3 Applying Silicone Dielectric Compound to Electrical Connections................................................................................................................................................................................................................487
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...............................................................................487
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.....................487
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only.....................................................................................................................................................487
Installation of Dielectric Grease..............................................................................................................................................................................................................................................488
1. Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors...............................................................................................................................................................488
2. Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals (fill it approximately ½ full; see example below)......................................................................................................488
3. Leave a thin layer of dielectric grease on the face of the connector....................................................................................................................................................................................................488
4. Assemble the connector system immediately to prevent moisture ingress or dust contamination.............................................................................................................................................................................488
AMP Mate-N-Lok.................................................................................................................................................................................................................................................................488
AMP Faston.....................................................................................................................................................................................................................................................................488
AMP Micro-Fit..................................................................................................................................................................................................................................................................488
AMP Mini Fit Jr................................................................................................................................................................................................................................................................488
Mini Fit Sr....................................................................................................................................................................................................................................................................489
DIN Connectors.................................................................................................................................................................................................................................................................489
Exceptions.....................................................................................................................................................................................................................................................................489
Enclosures.....................................................................................................................................................................................................................................................................489
Carling Switch Connectors......................................................................................................................................................................................................................................................489
7.4 AMP Connector..................................................................................................................................................................................................................................................................490
Applying Silicone Dielectric Compound to AMP Connectors........................................................................................................................................................................................................................490
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.................490
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape...............................................................................................................................................................................490
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it........................................................................................................................................................490
Assembly.......................................................................................................................................................................................................................................................................490
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7.)........................................................................................................................................................490
2. Pull back on the contact wire with a force of 1 or 2 lb to be sure the retention fingers are holding the contact (See Figure 7-7.)......................................................................................................................................490
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 7-8.)............................................................................................491
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.)..............................................................................................................................................................................491
Disassembly....................................................................................................................................................................................................................................................................492
5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs...............................................................................................................................................................492
6. Pry open the wedge lock to the open position............................................................................................................................................................................................................................492
7. 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.................................................................................................................................492
Wedge Lock.....................................................................................................................................................................................................................................................................492
Service - Voltage Reading......................................................................................................................................................................................................................................................492
7.5 Deutsch Connectors.............................................................................................................................................................................................................................................................494
DT/DTP Series Assembly.........................................................................................................................................................................................................................................................494
1. Grasp crimped contact about 25mm behind the contact barrel..............................................................................................................................................................................................................494
2. Hold connector with rear grommet facing you.............................................................................................................................................................................................................................494
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.......................................................................................................................................494
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...............................................................494
DT/DTP Series Disassembly......................................................................................................................................................................................................................................................494
5. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out...............................................................................................................................................................................494
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...........................................................................................................494
7. Hold the rear seal in place, as removing the contact may displace the seal..............................................................................................................................................................................................494
HD30/HDP20 Series Assembly.....................................................................................................................................................................................................................................................495
8. Grasp contact about 25mm behind the contact crimp barrel................................................................................................................................................................................................................495
9. Hold connector with rear grommet facing you.............................................................................................................................................................................................................................495
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..............................................................................................................................495
HD30/HDP20 Series Disassembly..................................................................................................................................................................................................................................................495
11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed...............................................................................................................................................................495
12. Slide tool along into the insert cavity until it engages contact and resistance is felt................................................................................................................................................................................495
13. Pull contact-wire assembly out of connector............................................................................................................................................................................................................................495
7.6 DC Power Systems...............................................................................................................................................................................................................................................................496
7.7 Hot Weather Operation..........................................................................................................................................................................................................................................................496
7.8 Cold Weather Operation.........................................................................................................................................................................................................................................................496
7.9 Disconnecting Battery Box Connectors...........................................................................................................................................................................................................................................497
1. Release CPA to pre-lock position. Pull up on the red tab on the cable end of the connector..................................................................................................................................................................................497
2. At same time press lock latch in pre lock area with finger or tool. Pull the connector up to the first notch................................................................................................................................................................497
3. Press lock latch in second area with finger or small tool. Using a screwdriver or similar device, press in on the tab to release the cable end of the connector from the box end of the connector...........................................................................497
4. At same time completely pull the cable end of the connector away from the box end of the connector to ensure no power will flow through it..................................................................................................................................497
7.10 Battery Pack..................................................................................................................................................................................................................................................................498
Reducing System Voltage........................................................................................................................................................................................................................................................498
1. Disconnect connector D..................................................................................................................................................................................................................................................498
2. Disconnect connector E..................................................................................................................................................................................................................................................498
3. Remove cover (1) using a 5/32 allen wrench..............................................................................................................................................................................................................................498
4. Disconnect connector C..................................................................................................................................................................................................................................................498
5. Disconnect connector B..................................................................................................................................................................................................................................................498
6. Disconnect the 84V hybrid round connector (1) located on each side of the machine.......................................................................................................................................................................................499
7. Perform the following checks to confirm system voltage has been sufficiently reduced:...................................................................................................................................................................................499
a. Check voltage between connectors D and E (on tank side of machine). This check should yield a result of 0V..........................................................................................................................................................499
b. Check voltage between connectors B and C (at front of machine). This check should yield a result of 12V- 13V........................................................................................................................................................499
Restoring System Voltage.......................................................................................................................................................................................................................................................499
Battery Pack Charging System...................................................................................................................................................................................................................................................500
1. The primary method of charging the battery pack is the diesel engine, which powers the Integrated Motor Generator (IMG) which in turn charges the battery stack. When the diesel engine is running, the Hybrid Electric Control system determines how a.................500
2. The second method to recharge the battery stack is the onboard battery chargers. The chargers are located on the turntable and work with a 120VAC or 240VAC external power source. The chargers are set up as primary and secondary chargers. Both char.................500
Long Term Storage Guidelines...................................................................................................................................................................................................................................................500
7.11 IMG Box.......................................................................................................................................................................................................................................................................516
1. Turn power off at the rotary disconnect and lock it out.....................................................................................................................................................................................................................516
2. Disconnect the IMG sensor cable.............................................................................................................................................................................................................................................516
Partially Isolating System Voltage.............................................................................................................................................................................................................................................516
1. Turn the Maintance disconnect switch to the “OFF” position..............................................................................................................................................................................................................516
2. Disconnect the B- cable, “D” keyed (Green)..............................................................................................................................................................................................................................516
3. Disconnect the B+ cable, “E” keyed (Orange).............................................................................................................................................................................................................................516
4. Disconnect the 84V hybrid harness (round connector) located on each battery box.........................................................................................................................................................................................517
5. Check the voltage at the IMG connectors and verify the reading = 0V.....................................................................................................................................................................................................517
7.12 IMG Controller................................................................................................................................................................................................................................................................517
Removal........................................................................................................................................................................................................................................................................517
1. Disconnect the “D” keyed connector......................................................................................................................................................................................................................................518
2. Disconnect the “E” keyed connector......................................................................................................................................................................................................................................518
3. Disconnect the 84V hybrid round connector (1) located on each side of the machine.......................................................................................................................................................................................518
4. Turn off the power at the maintenance disconnect switch.................................................................................................................................................................................................................518
5. Disconnect and completely remove the B- cable, “D” keyed (Green) from the IMG box.......................................................................................................................................................................................518
6. Disconnect and completely remove the B+ cable, “E” keyed (Orange) from the IMG box......................................................................................................................................................................................518
7. Remove the hood section that covers the IMG Box.........................................................................................................................................................................................................................519
8. Remove the front cover from the box.....................................................................................................................................................................................................................................519
9. Remove the left hand side cover from the box............................................................................................................................................................................................................................519
10. Remove the bolts that secure the IMG Box to the turntable side tray....................................................................................................................................................................................................519
11. Remove the plastic cover from the fuse holder..........................................................................................................................................................................................................................519
12. Tag and disconnect the Left Hand cable coming from the fuse............................................................................................................................................................................................................519
13. Remove the bolts securing the maintenance disconnect switch mounting bracket to the box. Pull the switch and bracket assembly away from the box........................................................................................................................520
14. Tag and disconnect the connection for the battery charger and the control harnesses from the IMG Controller............................................................................................................................................................520
15. Tag, disconnect, and remove the power cables from the connectors and controller for clearance..........................................................................................................................................................................520
16. Remove the allen screws that secure the IMG Controller to the box. Pull the box out enough to gain access to the retaining nuts at the back of the box.................................................................................................................520
17. Remove the IMG Controller..............................................................................................................................................................................................................................................520
Installation...................................................................................................................................................................................................................................................................521
1. Install the IMG Controller to the box using the allen screws and retaining nuts. If installing a new controller, make sure to remove the standoffs from the old controller for proper installation. Push the box back in place..........................................521
2. Install the power cables to the controller as tagged during removal. Torque all fasteners 9.5 to 11 ft. lbs. (13 to 15 Nm)..............................................................................................................................................521
3. Plug the connectors back into the controller as tagged during removal. Reconnect the harness for the battery charger....................................................................................................................................................521
4. Position the maintenance disconnect and bracket assembly in place and secure with the attaching bolts...................................................................................................................................................................521
5. Install the bolts that secure the IMG box to the turntable side tray....................................................................................................................................................................................................521
6. Install the power cable onto the fuse as tagged during removal..........................................................................................................................................................................................................521
7. Install the plastic cover back onto the fuse holder.....................................................................................................................................................................................................................522
8. Install the left side cover onto the box................................................................................................................................................................................................................................522
9. Install the front cover onto the box....................................................................................................................................................................................................................................522
10. Install the hood.......................................................................................................................................................................................................................................................522
11. Connect the B+ cable, “E” keyed (Orange) as tagged during removal......................................................................................................................................................................................................522
12. Connect the B- cable, “D” keyed (Green) as tagged during removal.......................................................................................................................................................................................................522
13. Turn the power on at the maintenance disconnect switch.................................................................................................................................................................................................................522
14. Connect the 84V hybrid round connector (1) located on each side of the machine.........................................................................................................................................................................................523
15. Connect connector E....................................................................................................................................................................................................................................................523
16. Disconnect connector D.................................................................................................................................................................................................................................................523
7.13 Hybrid Electric Controller....................................................................................................................................................................................................................................................530
7.14 Resolver/Converter............................................................................................................................................................................................................................................................530
7.15 State of Charge Device........................................................................................................................................................................................................................................................530
7.16 Battery Equalizer.............................................................................................................................................................................................................................................................530
7.17 Battery Chargers..............................................................................................................................................................................................................................................................531
Battery Charging...............................................................................................................................................................................................................................................................531
1. The battery charger AC input plug is located near the ground control console............................................................................................................................................................................................531
2. Connect the charger AC input plug to a grounded outlet using a 3 wire heavy duty extension cord.........................................................................................................................................................................531
3. After connecting the charger to an AC outlet at the start of the charging cycle, check the Charger Status and Battery Balance indicators on the Ground Control console..................................................................................................531
Ground Panel Indicators........................................................................................................................................................................................................................................................531
Battery Balance Indicator..................................................................................................................................................................................................................................................531
Charger Status.............................................................................................................................................................................................................................................................531
Indications on the Charger 3-LED Display.......................................................................................................................................................................................................................................532
Troubleshooting Instructions (Wall - Charge)...................................................................................................................................................................................................................................534
Instructions for using the Delta-Q QuiQ Programmer CTQuiQ Programming Kit......................................................................................................................................................................................................538
Installing QuiQ Programmer CT Software and Drivers.........................................................................................................................................................................................................................538
Connecting a QuiQ Charger to your Computer.....................................................................................................................................................................................................................................539
1. Disconnect AC power from the QuiQ charger...............................................................................................................................................................................................................................539
2. Disconnect the QuiQ charger from all batteries..........................................................................................................................................................................................................................539
3. Connect the Wire Assembly red clip to the charger positive wire (red)...................................................................................................................................................................................................539
4. Connect the Wire Assembly black clip to the charger negative wire (black)...............................................................................................................................................................................................539
5. Connect the Wire Assembly to the QuiQ USB Interface Module..............................................................................................................................................................................................................539
6. Connect the USB cable upstream end to an open USB port on your PC.......................................................................................................................................................................................................539
7. Connect the USB cable downstream end to the QuiQ USB Interface Module...................................................................................................................................................................................................539
8. Upon connection, Windows will detect the QuiQ USB Interface Module and install drivers for it. If Windows does not detect the QuiQ Module you will need to reinstall QuiQ Programmer CT. See section Installing QuiQ Programmer CT Software and Drivers.................540
9. Connect the QuiQ charger to AC power....................................................................................................................................................................................................................................540
Starting QuiQ Programmer CT....................................................................................................................................................................................................................................................540
Start Application in User Mode.............................................................................................................................................................................................................................................540
1. To start QuiQ Programmer CT, select Program/QuiQ Programmer CT/QuiQ Programmer CT from the Start Menu...............................................................................................................................................................540
2. If your installation has not been registered with a license key, starting the application in User Mode is the only option. First select the Dongle you wish to connect in the COM Setting dialog....................................................................540
3. Then, the QuiQ Programmer CT starts. If your installation has been registered with a license key, then upon starting the application the login dialog appears: Click on “Cancel” to start the application in User Mode..............................................540
4. The QuiQ Programmer CT interface will appear. The connection status area at the bottom of the window will indicate if the QuiQ USB Interface Module is properly connected to your PC and the QuiQ charger. If the connection area displays Status: No C.............540
Programming Delta-Q QuiQ and QuiQ-dci Chargers.................................................................................................................................................................................................................................541
View Charge Tracking Data with QuiQ Programmer CT..............................................................................................................................................................................................................................542
Selecting a Charge Profile.....................................................................................................................................................................................................................................................542
Identify the default profile...............................................................................................................................................................................................................................................542
1. Required supplies include an insulated wrench, eye protection and gloves............................................................................................................................................................................................542
2. Disconnect the AC power source from the charger, either from the wall outlet, or from the IEC320 connector on the charger...........................................................................................................................................542
3. Disconnect power from the batteries using the battery disconnect on the side of the machine.........................................................................................................................................................................542
4. Reconnect AC power..................................................................................................................................................................................................................................................542
5. For 11 seconds after the self-test, the charger will display its default charge profile. Profiles are indicated by the number of consecutive flashes followed by a pause (e.g. #2 = ). 5b. Charge profiles in the double digits will display in the sam.............542
6. After 11 seconds the red fault light will then blink................................................................................................................................................................................................................542
Select a new profile.......................................................................................................................................................................................................................................................543
1. Disconnect the AC power source from the charger, either from the wall outlet, or from the IEC320 connector on the charger...........................................................................................................................................543
2. Reconnect AC power..................................................................................................................................................................................................................................................543
3. Touch the positive lead to the positive terminal for 3 seconds (+/- 0.5 seconds), then remove the lead. You will see the next profile displayed on the charger's display. Repeat this step until you reach the desired charge profile...............................543
4. When the charger displays the desired charge profile, apply the positive lead to the positive battery terminal for 10 seconds. When the charge profile is locked, you will hear a click from the charger............................................................543
5. Disconnect AC power, wait for the LED indicator display to turn off, then reconnect AC power........................................................................................................................................................................543
6. Check the LED display to ensure that the desired charge profile is selected.........................................................................................................................................................................................543
7. Disconnect the charger from AC power and wait for the LED indicator display to turn off.............................................................................................................................................................................543
8. Reconnect the positive lead to the positive battery terminal........................................................................................................................................................................................................543
Battery Testing................................................................................................................................................................................................................................................................543
Procedure:.................................................................................................................................................................................................................................................................543
7.18 ClearSky™ / Telematics Gateway................................................................................................................................................................................................................................................543
7.19 Wiring Harness Connector Labels and Wiring Harnesses..........................................................................................................................................................................................................................554
Connector Labels...............................................................................................................................................................................................................................................................554
Component Labels...............................................................................................................................................................................................................................................................554
7.20 Electrical Schematics.........................................................................................................................................................................................................................................................659
SHEET 2: CONSOLE BOX...........................................................................................................................................................................................................................................................659
SHEET 3: PLATFORM VALVE........................................................................................................................................................................................................................................................659
SHEET 4: TURNTABLE.............................................................................................................................................................................................................................................................659
SHEET 5: HYDRAULICS & ENGINE...................................................................................................................................................................................................................................................659
SHEET 6: HYBRID/ELECTRIC & IMG CONTROLLERS.....................................................................................................................................................................................................................................659
SHEET 7: RESOLVER/CONVERTER & IMG..............................................................................................................................................................................................................................................659
SHEET 8: BATTERY BOXES.........................................................................................................................................................................................................................................................659
SHEET 9: OPTIONS...............................................................................................................................................................................................................................................................659
SHEET 10: GENERATOR............................................................................................................................................................................................................................................................659
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