JLG 600AJ Service and Maintenance Manual

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Service and Maintenance Manual
Model
600AJ
PVC 2001
31215031
October 10, 2019 - Rev A
AS/NZS
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SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
INTRODUCTION
AGENERAL
This section contains general safety precautions which must be observed during maintenance of the Mobile Elevating Work Platform (MEWP). It is of utmost importance that mainte­nance personnel pay strict attention to these warnings and pr
ecautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure the machine is safe to operate.
MODIFICATION OR ALTERATION OF A MOBIL E ELEVATI NG WORK P LATF ORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFAC TURER.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These pre­cautions are, for the most part, t ing hydraulic and larger machine component parts.
Your safety, and that of others, is the first consideration when e
ngaging in 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 an unstable position. When raising a portion of the equip­ment, ensure adequate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL ITY OF THE OWNER/OPERATOR.
hose that apply when servic-
-
B HYDRAULIC SYSTEM SAFETY
It should be noted the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to discon­necting or removing any portion of the system.
CMAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
• USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, REPLACEMENT PARTS OR COMPONENTS MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC­TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
URE AT ALL OTHER TIMES.
SEC
• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER­FORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT­TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL­ANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
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BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER­FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.
• ALWAYS DISCONNECT BATTERY DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL­VENTS.
31215031 A-1
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INTRODUCTION
Original Issue A - October 10, 2019
REVISON LOG
A-2 31215031
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TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.10 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.11 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Metric Fastener Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
31215031 i
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TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
DO NOT Do the Following When Welding on JLG Equipment:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires And Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hub-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Spindle-Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Output Planet Gear Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Spindle - Brake Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Integral Brake Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.4 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.6 Steer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.7 Chassis Tilt Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.9 Transport Position Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.10 Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.11 Drive/Steer – Boom Function Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.12 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.13 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
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3.14 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Roll, Leak And Brake Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Main Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Hub-Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.15 Swing Hub Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.16 Swing Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Procedure For Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.17 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.18 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.19 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.20 Deutz D2.9 L4 (T4F) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Change Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.21 Deutz D2011 (T4i) Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Clean Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.22 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.23 Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.24 Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.25 Bio Fuel In Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3.26 Ford Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.27 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
SECTION 4 - BOOM & PLATFORM
4.1 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Platform Load Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Ground Control Keyswitch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 Function Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.5 SkyGuard Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.6 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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4.7 Rotator and Slave Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8 Main Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.9 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Replace Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.10 Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.11 Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.12 Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.13 Jib Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.14 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.15 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Testing Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Testing Actuator for Internal Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.16 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.17 Platform Load Sensing System- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.18 Skyguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.19 Bolt-on External Fall Arrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
. . . . . . . . . . . . . . . . . . . 4-42
iv 31215031
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SECTION NO. TITLE PAGE NO.
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.1 Lubricating O-rings In The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Systems With Double Acting Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Systems With Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder. . . . . . . . . . . . . . . . . . 5-3
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cylinders With Dual Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Upright Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Upright Level Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Tower Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Tower Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tower Telescope Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Hydraulic Cylinder repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Tower Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Upright Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Tower Boom Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Platform Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.6 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Inspect Parts For Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Placing Pump Back Into Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
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5.7 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Ports and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Remove and Install FNR and NFPE Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Remove and Install FNR and NFPE Control Orifices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Shaft Seal and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.8 Hydraulic Component Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5.9 Main Valve Block Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Upper (Main) Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
2-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
4-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.10 Platform Valve Block Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Platform Level Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Platform Level Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Articulating Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.11 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.5 MSSO (Machine Safety System Override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.6 LSS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Testing & Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6.7 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
vi 31215031
Page 11
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
7.3 Applying Silicone Dielectric Compound Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Micro-Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mini Fit Jr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Mini Fit Sr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Carling Switch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Telematics-Ready (TCU) Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.9 Wiring Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.10 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
31215031 vii
Page 12
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2. Axle Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Axle Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . 3-6
3-5. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . 3-7
3-6. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 3-9
3-8. Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-9. Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-10. Steering Installation (7ft/2.1m Wide Machines) - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-11. Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-12. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-13. Torque Hub Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-14. Output Carrier Disassemb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-15. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-16. Hub Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-17. Spindle Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-18. Torque Hub Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-19. Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-20. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-21. Seal Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-22. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-24. Disconnecting Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-25. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-26. Removing Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-27. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-28. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-29. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-30. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-31. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-32. Cylinder Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-33. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-34. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-35. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-36. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-37. Servo Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-38. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-39. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-40. Shaft and Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-41. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-42. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-43. Valve Plate and Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-44. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-45. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-46. Plugs and Fittings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-47. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-48. Steer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-49. Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-50. Motor and Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3-51. Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3-52. Hub Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
. . . . . . . . . . . . . . . . . . 3-36
viii 31215031
Page 13
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
3-53. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-54. Swing Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-55. Swing Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-56. Swing Bearing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-57. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-58. Swing Bearing Tolerance Measurement Location & Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3-59. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3-60. Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-61. Rotary Coupling - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-62. Rotary Coupling - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-63. Rotary Coupling Port Location - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3-64. Rotary Coupling Port Location - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-65. Generator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-66. Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-67. Blow Out Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-68. Generator Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-69. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-70. Deutz D2.9 L4 (T4F) Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-71. Deutz D2.9 L4 (T4F) Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3-72. Deutz 2.9 T4F Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-73. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-74. Deutz D2011 (T4i) Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-75. Deutz D2011 (T4i) Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-76. Deutz Dipstick Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3-77. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3-78. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3-79. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3-80. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3-81. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-82. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3-83. EMR 2 Engine Plug Pin Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3-84. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-85. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3-86. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-87. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-88. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
3-89. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3-90. Ford Engine Installation Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-91. Ford Engine Installation Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3-92. Ford Engine Installation Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
3-93. Ford Engine Installation Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
3-94. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
4-1. Location of Components Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3. Rotator and Leveling Cylinder Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3. Rotator and Leveling Cylinder Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4. Main Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-5. Main Boom Assembly Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-6. Tower Upright Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Tower Boom Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-8. Tower Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-9. Tower Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-10. Tower Boom Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-11. Jib Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-12. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-13. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-14. Actuator Bleed Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
. . . . . . . . . . . . . . . . . . . . . . 4-18
31215031 ix
Page 14
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
4-15. Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-16. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
5-1. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. Hydraulic Cylinder Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Telescope and Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4. Leveling Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-5. Plunger Valve Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-6. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-7. Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-8. Tower Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-9. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-10. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-11. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-12. Upright Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-13. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-14. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-15. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-16. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-17. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-18. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-19. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-20. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-21. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-22. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-23. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-24. Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-25. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-26. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-27. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-28. Main Boom Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-29. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-30. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-31. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-32. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-33. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-34. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-35. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-36. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-37. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-38. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-39. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-40. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-41. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-42. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-43. Main Boom Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-44. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-45. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-46. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-47. Wear Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-48. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-49. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-50. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-51. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-52. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-53. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-54. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-55. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
x 31215031
Page 15
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
5-56. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-57. Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-58. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-59. Tower Boom Telescope Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-60. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-61. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-62. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-63. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-64. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-65. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-66. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-67. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-68. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-69. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-70. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-71. Platform Level (Slave) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5-71. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-72. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-73. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-74. Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-75. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-76. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-77. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-78. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-79. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-80. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-81. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-82. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-83. Hydrolock Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-84. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-85. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-86. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-87. Removing Spanner Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-88. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-89. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-90. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-91. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-92. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-93. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-94. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-95. Piston Seal and Wear Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-96. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-97. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-98. Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-99. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-100. Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-101. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-102. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-103. Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-104. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-105. Charge Pump Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-106. Main Control Valve - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-107. Main Control Valve - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-108. Location of Components - Platform Control Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-109. 2-Wheel Steer (2WS) Hydraulic Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-110. 2-Wheel Steer (2WS) Hydraulic Schematic 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-111. 4-Wheel Steer (4WS) Hydraulic Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
31215031 xi
Page 16
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
5-112. 4-Wheel Steer (4WS) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-113. 2-Wheel Drive (2WD) Hydraulic Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5-114. 2-Wheel Drive (2WD) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5-115. 4-Wheel Drive (4WD) Hydraulic Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
5-116. 4-Wheel Drive (4WD) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. ADE Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-3. Analyzer Flow Chart Software Version P6.30 - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-4. Analyzer Flow Chart Software Version P6.30 - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-5. Analyzer Flow Chart Software Version P6.30 - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-6. Analyzer Flow Chart Software Version P6.30 - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-7. Analyzer Flow Chart Software Version P6.30 - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-8. Analyzer Flow Chart Software Version P6.30 - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-9. Analyzer Flow Chart Software Version P6.30 - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-10. Control Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6-11. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
6-12. Ground Control Module Pin Connections 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
6-13. Ground Control Module Pin Connections 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-14. Platform Control Module Pin Connections 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
6-15. Platform Control Module Pin Connections 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6-16. Platform Control Module (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-10. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-18. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-19. Telematics Gateway Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-20. Telematics Gateway Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-21. Electrical Components 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-22. Electrical Components 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-23. Platform Console Box SkyGuard - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-24. Platform Console Box SkyGuard - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-25. Platform Console Box with SkyGuard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-26. Platform Valve Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-27. Main Boom Harness without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-28. Main Boom Harness with Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-29. Tower Boom Cable Harness without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-30. Tower Boom Cable Harness with Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7-31. Main Valve Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7-32. Main Valve Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7-33. Main Valve Harness (China Market). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-34. Deutz D2011 (T4i) Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7-35. Deutz D2011 (T4i) Engine Harness - Sheet 1 of 2 (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7-36. Deutz D2011 (T4i) Engine Harness - Sheet 2 of 2 (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
. . . . . . . . . . . . . . . . . . 7-25
xii 31215031
Page 17
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
7-37. Deutz TD2.9L4 (T4F) Engine harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-38. Ford Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7-39. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L,
MSG425 Engines - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-40. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L,
MSG425 Engines - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7-41. Electrical Schematic - Sheet 1 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-42. Electrical Schematic - Sheet 2 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-43. Electrical Schematic - Sheet 3 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-44. Electrical Schematic - Sheet 4 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-45. Electrical Schematic - Sheet 5 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7-46. Electrical Schematic - Sheet 6 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-47. Electrical Schematic - Sheet 7 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
7-48. Electrical Schematic - Sheet 8 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
7-49. Electrical Schematic - Sheet 9 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
7-50. Electrical Schematic - Sheet 10 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
7-51. Electrical Schematic - Sheet 11 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
7-52. Electrical Schematic - Sheet 12 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
7-53. Electrical Schematic - Sheet 13 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7-54. Electrical Schematic - Sheet 14 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7-55. Electrical Schematic - Sheet 15 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-56. Electrical Schematic - Sheet 16 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7-57. Electrical Schematic - Sheet 17 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7-58. Electrical Schematic - Sheet 18 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
31215031 xiii
Page 18
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Deutz TD 2.9L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3 Ford DF 2.5L, MSG 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Mobilfluid 424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5 Mobile DTE 10 Excel 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-6 Quintolubric 888-46 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-7 Mobil EAL 224H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-8 Mobil EAL H 46 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-9 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-10 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-11 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-3 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-4 No Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-7 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-8 Drive Mode Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-9 Coupling Port Information Table - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-10 Coupling Port Information Table - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-11 Engine Fault Codes (Deutz Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
3-12 Fault Code Cross Reference List (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3-13 CAN to DTC Cross Reference (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-2 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
5-1 Hydraulic Pump Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-2 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-3 Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-4 Machine Configuration Programming Information (Software Version P6.30) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-5 Machine Configuration Programming Settings (Software Version P6.30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-6 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-8 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-9 SkyGlazier Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-10 Pipe Rack Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-11 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6-12 Fault Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
xvi 31215031
Page 19
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Page 20
SECTION 1. SPECIFICATIONS
SECTION 1 - SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS
Machine Specifications
Maximum Work Load (Capacity) - ANSI
Un r es t ri c te d : 500 lb (227 kg)
Maximum Work Load (Capacity) - CE & Australia
Un r es t ri c te d : 500 lb (230 kg)
Maximum Operating Slope ANSI/CE/AUS - 4°
China - 5°
7ft Chassis - ANSI /AUS - 3°
7ft Chassis - China- 5°
Maximum Travel Grade, Stowed Position (Gradeability)
2W D 4W D
Maximum Travel Grade, Stowed Position (Side Slope)
Turning Radius - (Outside)
2W S 4W S
ANSI/CE/AUS - 4°
China - 5°
7ft Chassis - ANSI /AUS - 3°
7ft Chassis - China- 5°
17 ft. 8 in. (5.38 m) 11 ft. 8 in. (3.56 m)
30% 45%
1.2 DIMENSIONAL DATA
Machine Dimensional Data
Machine Height (Stowed) 8 ft. 5 in. (2.57 m)
Machine Length (Stowed) 29 ft. (8.80 m)
Machine Width (by tire size) 355/55D-625 41/18LLx22.5X625 (turf)
Wheelbase 8 ft. 2 in. (2.49 m)
Ground Clearance 11.7 in. (0.29 m)
Platform Height 60 ft. 7 in. (18.47 m)
Horizontal Reach 39 ft. 9 in. (12.10 m)
Tai l S wi n g 0 in. (0 m)
98 in. (2.49 m)
100 in. (2.54 m)
Turning Radius - (Outside
2W S 4W S
Turning Radius - (Inside)
2W S 4W S
Turning Radius - (Inside) 7 ft Chassis
2W S 4W S
Maximum Tire Load: 12,500 lb (5670 kg)
Ground Bearing Pressure
60 0 A J
600AJ - 7 ft Chassis
Maximum Drive Speed 4.25 MPH (6.84 KM/hr.)
Gross Machine Weight (Approximate) 2W S 4W S 7 f t C ha s si s
) 7 ft Chassis
16 ft. 6 in. (5.03 m)
11 ft. 2 in. (3.4 m)
11 ft. 5 in. (3.48 m)
5 ft. 6 in. (1.68 m)
12 ft. 2 in. (3.71 m)
5 ft. 7 in. (1.7 m)
77 psi (5.5 kg/cm2)
94 psi (6.6 kg/cm
22,240 lb (10,088 kg) 22,740 lb (10,315 kg) 24,000 lb (10,886 kg)
2
)
31215031 1-1
Page 21
SECTION 1 - SPECIFICATIONS
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1.3 CAPACITIES
Fuel Tank 30 Gallons (113.6 L)
Hydraulic Oil Tank 30.6 Gallons (115.8 L)
Hydraulic System (Including Tank) 40 Gallons (151.4 L)
Tor q ue H ub, D r iv e
Engine Crankcase D eu t z D 2 01 1 L0 4 D eu t z T D 2 . 9 L
Swing Hub, Drive 32 ounces (0.9L)
*Torque hubs should be one half full of lubricant.
*
20 ounces (0.6L)
11 quarts (10.5 L)
2.4 Gallon (8.9 L) w/Filter
1.4 ENGINE DATA
Table 1-1. Deutz TD 2.9L Specifications
Fuel Ultra Low Sulfur Diesel (15 ppm)
Output 67 hp (50 kW)
Tor q u e 173 ft.lbs. (234 Nm) @ 1800rpm
Oil Capacity (Crankcase) 2.4 Gallon (8.9 L) w/Filter
Cooli ng Syst em 3.3 Gallon (12.5 L)
Low RPM 1200 ±50 rpm
High RPM 2600 ±50 rpm
Alternator 95 Amp
Fuel Co nsump tion 0.65 GPH (2.46 LPH)
Table 1-3. Ford DF 2.5L, MSG 425
Fuel Gasoline/LP Gas
Oil Capacity 7 qt (6.6 L)
Coola nt Capa city 0 . 63 G al l on ( 2. 4 L)
Low RPM 1000 ±50 rpm
High RPM 3200 ±50 rpm
Alternator 150 Amp
Starter 64.4 Amp @ 3574 rpm
Fan Rat io 1:3
Fuel Consum ption G as o li n e LP
Max Output (Power) G as o li n e LP
Max Output (Torque) G as o li n e LP
142 ft. lbs. (192 Nm) @ 2400 RPM 145 ft. lbs. (197 Nm) @ 2400 RPM
1 GPH (3.79 LPH)
5.34 lb/h(2.42 Kg/h)
84HP @3200 80HP @3200
Fuel Diesel
Oil Capacity Co o li n g S y st e m Cr a nk c as e Tot a l C ap a ci t y
Idle RPM 1000
Low RPM 1800
High RPM 2500
Alternator 60 Amp, belt drive
Battery 950 Cold Cranking Amps,
Fuel Consu mption 0.65 GPH (2.46 LPH)
Horsepower 49
Table 1-2. Deutz D2011L04
11 Quarts (10.5 L) w/Filter
20
5 Minutes Reserve Capacity, 12 VDC
5 Quarts (4.5 L)
16 Quarts (15 L)
1-2 31215031
Page 22
SECTION 1 - SPECIFICATIONS
Size IN355/55D 625 36x14-20FA
Load R ange G *
Ply Rating 14 N/A
Tire Pressure Foam-Filled Solid-Boss
* Load Capacity - 11,800 lb (4404 kg) - Static
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1.5 TIRES
1.6 TORQUE REQUIREMENTS
Description Tor que V alue ( Dry )
Bearing To Chassis 190 ft-lb (260 Nm) 50/600*
Bearing To Turntable 190 ft-lb (260 Nm) 50/600*
Wire R ope 15 ft- lb (20 Nm) 150
Wheel Lugs 170 ft- lb (231 Nm) 150
Engine Mounting Bolts 165 ft-lb (231 Nm) A/R
Engine Manifold Mounting Bolts 30 ft-lb (42 Nm) A/R
*Check swing bearing bolts after first 50 hours of operation and every 600 hours thereafter. (See Swing Bearing in Section 3.)
Interval
Hours
31215031 1-3
Page 23
SECTION 1 - SPECIFICATIONS
Hydraulic System Operating
Temperature Range
S.A.E. Viscosity
Grade
+0° F to + 180° F (-18° C to +83° C) 10W
+0° F to + 210° F (-18° C to +99° C) 10W-20, 10W-30
+50° F to + 210° F (+10° C to +99° C) 20W-20
Table 1-5. Mobile DTE 10 Excel 32
ISO Viscosity Grade #32
Specific Gravity 0.877
Pour Point, Max
-40° F (-40° C)
Flash Point, Min.
330° F (166° C)
Viscosit y
at 40° C 33 cSt
at 100° C 6.6 cSt
at 100° F 169 SUS
at 212° F 48 SUS
cp at -20° F 6,200
Viscosity Index 140
Table 1-6. Quintolubric 888-46 Specs
Type Synthetic Fire Resistant Biodegradable
Density
0.92 g/cm
3
Pour Point <-30° C (<-22° F)
Flash Point 300° C (572° F)
Fire Point 360° C (680° F)
Auto Ignition Temperature >450° C (842° F)
Viscosit y
at 0° C (32° F) 320 cSt
at 20° C (68° F) 109 cSt
at 40° C (104° F) 47.5 cSt
at 100° C (212° F) 9.5 cSt
Viscosity Index 190
Table 1-7. Mobil EAL 224H
Type Synthetic Biodegradable
ISO Viscosity Grade 32/46
Specific Gravity .922
Pour Point, Max - 25° F (-3 2° C)
Flash Point, Min. 428° F (220° C)
Operating Temp. 0 to 180° F (-17 to 162° C)
Weight 7.64 lb. per gal.
(0.9 kg per liter)
Viscosit y
at 40° C 37 cSt
at 100° C 8.4 cSt
Viscosity Index 213
NOTE: Must be stored above 32° F (14° C)
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1.7 HYDRAULIC OIL
NOTE: Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stabil­ity for mobile hydraulic system service. JLG Industries rec­ommends standard UTTO which has an SAE viscosity index of 152.
NOTE: When temperatures remain below 20° F (-7° C), JLG Indus-
tries recommends the use of Premium Hydraulic Fluid.
NOTE: Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types. They may not contain required additives or be of comparable viscosities. If use of hydraulic oil other than standard UTTO is desired, contact JLG Industries for proper recommendations.
Table 1-4. Mobilfluid 424
SAE Grade
Gravity, API
Density, lb/Gal. 60° F
Pour Point , Max
Flash Point, Min.
Viscosity
Brookfield, cP at -18° C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
1-4 31215031
10W30
29.0
7.35
-46° F (-43° C)
442° F (228° C)
Page 24
Table 1-8. Mobil EAL H 46 Specs
Type Synthetic Biodegradable
ISO Viscosity Grade 46
Density 0.874 @ 15° C (59° F)
Pour Point -49° F (-45°C)
Flash Point 500° F (260° C)
Operating Temp. -29 to 93° C (-20 to 200 ° F)
Weight 7.64 lb/gal
(0.9 kg/L)
Viscosit y
at 40° C 48.8 cSt
at 100° C 7.8 cSt
Viscos ity I ndex 145
Table 1-9. Mobil EAL 46 Specs
Type Synthetic Biodegradable
ISO Viscosity Grade 46
Density 0.93 @ 15° C (59° F)
Pour Point -27° F (-33° C)
Flash Point 568° F (298° C)
Operating Temp. -29 to 93° C (-20 to 200° F)
Viscosity
at 40° C 43.3 cSt
at 100° C 7.7 cSt
Viscosity Index 149
Table 1-10. Exxon Univis HVI 26 Specs
Specific Gravity 32.1
Pour Point -76° F (-60° C)
Flash Point 217° F (103° C)
Viscosit y
at 40° C 25.8 cSt
at 100° C 9.3 cSt
Viscosity Index 376
NOTE: Mobil/Exxon recommends this oil be checked on a yearly basis for
viscosity.
SECTION 1 - SPECIFICATIONS
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1.8 CRITICAL STABILITY WEIGHTS
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY THE MEWP IN ANY WAY TO AFFECT STABILITY.
Components LBS. KG.
Tire and Wheel (Standard Foam Filled)
Engine
Counte rweight
Platform
355/55D345 440 200
Deutz D2011 1222 554
Deutz TD2.9L 1250 567
Ford 873 396
600AJ 6100 2767
Narrow Frame 8050 3651
30x48 151 68
30x60 165 75
36x72 199 90
36x96 230 105
31215031 1-5
Page 25
Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011
SECTION 1 - SPECIFICATIONS
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1-6 31215031
Page 26
Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9
SECTION 1 - SPECIFICATIONS
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31215031 1-7
Page 27
Figure 1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425
SECTION 1 - SPECIFICATIONS
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1-8 31215031
Page 28
SECTION 1 - SPECIFICATIONS
Table 1-11. Lubrication Specifications.
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. Refer Section 1.7, Hydraulic Oil.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API
CC/ CD cl ass , M IL-L- 21 04 B/M IL- L-2 104 C.
1.9 OPERATOR MAINTENANCE
NOTE: The following numbers correspond to those in Figure 1-1.,
Figure 1-2. and Figure 1-3.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR­MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.
2. Wheel Bearings (If equipped)
•Lube Point(s) - Repack
• Capacity - A/R
•Lube - MPG
• Interval - Every 2 years or 1200 hours of operation.
3. S
wing Drive Hub
1. Swing Bearing
• Lube Point(s) - 1 Grease Fittings
• Capacity - A/R
•Lube - MPG
• Interval - Every 3 months or 150 hrs of operation Comments - Remote Access. Apply grease and rotate in 90 degree intervals until bearing is completely lubricated.
31215031 1-9
• Lube Point(s) - Level/Fill Plug
• Capacity - 43 oz. (1.3 L)
•Lube - 90w80 Gear Oil
• Interval - Check level every 3 months or 150 hrs of opera­tion; change every 2 years or 1200 hours of operation.
Page 29
SECTION 1 - SPECIFICATIONS
NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION
4. Wheel Drive Hub
• Lube Point(s) - Level/Fill Plug
• Capacity - 20 oz. (0.6 L)
•Lube - EPGL
• Interval - Check level every 3 months or 150 hrs of opera­tion; change every 2 years or 1200 hours of operation.
5. Hydraulic Return Filter
6. Hydraulic Charge Filter
• Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter, or as shown by Condition Indicator.
7. Hy
draulic Tank
Lube Point(s) - Fill Cap
• Lube Point (s) - Fill Cap
• Capacity: Tank - 30.6 gal. (115.8 L); System - 40 gal. (151.4 L);
•Lube - HO
• Interval - Check Level daily; Change every 2 years or 1200 hours of operation.
• Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as shown by Condition Indicator.
1-10 31215031
Page 30
SECTION 1 - SPECIFICATIONS
MINIMUM OIL LEVEL
MAXIMUM OIL LEVEL
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8. A. Oil Change w/Filter - Deutz 2011
• Lube Point(s) - Fill Cap/Spin-on Element
• Capacity - 11 Quarts Crankcase; 5 Quarts Cooler
•Lube - EO
• Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual.
B. Oil Change w/Filter - Deutz D2.9
• Lube Point(s) - Fill Cap/Spin-on Element
• Capacity - 9.6 Quarts (9.0 L) Crankcase and Filter
•Lube - EO
• Interval - Every Year or 600 hours of operation Comments - Check level daily/Change in accordance with engine manual
.
31215031 1-11
Page 31
SECTION 1 - SPECIFICATIONS
MAE18190
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9. Oil Change w/Filter - Ford
• Lube Point(s) - Fill Cap/Spin-on Element
• Interval - Every 3 months or 300 hours of operation Comments - Check level daily/Change in accordance with engine manual.
. Fuel Filter - Deutz
10. A
(On Engine)
B. Fuel Filter - Deutz TD2.9 (On Turntable)
• Lube Point(s) - Replaceable Element
• Interval - Change in accordance with engine manual
C. Fuel Filter - Deutz TD2.9 (On Engine)
• On Engine: Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation.
• Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual.
1-12 31215031
Page 32
SECTION 1 - SPECIFICATIONS
MAE16880
FUEL FILTER
MAE17720
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11. A. Fuel Filter - Ford (On Engine)
B. Air Filter - Deutz D2.9
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or as shown by condition indicator.
C. Air Filter - Ford
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation.
12. A. Air Filter (Deutz 2011)
• Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator.
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator.
31215031 1-13
Page 33
SECTION 1 - SPECIFICATIONS
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1.10 THREAD LOCKING COMPOUND
JLG PN
0100011
1001095650
0100019 0100071
NOTE: Loct ite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
Loctite
242 243 271 262
®
ND Industries Description
Vibra-TITE™121 Vibra-TITE™122 Vibra-TITE™140 Vibra-TITE™131
Medium Strength (Blue) Medium Strength (Blue)
High Strength (Red)
Medium - High Strength (Red)
1-14 31215031
Page 34
SECTION 1 - SPECIFICATIONS
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1.11 TORQUE CHARTS
SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
T o r q u e
Tensile
Size TPI Bolt Dia
In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB F T - L B [N.m] F T - L B [N.m] FT - L B [N.m] FT - L B [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
Stress
Area
Clamp
Load
T o r q u e
(Dry)
T o r q u e
Lubricated
(Loctite® 242
271
Vibra-TITE
111 or 140)
or
or
T o r q u e
(Loctite® 262
Vibra-TITE
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
31215031 1-15
Page 35
SECTION 1 - SPECIFICATIONS
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SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
T o r q u e
Size TPI Bolt Dia
Tensile
Stress Area
Clamp
Load
Torque
( D r y o r L o c t i t e ® 2 6 3 )
K=0.20
(Loctite® 242
Vibra-TITE
or 271™ or
1 1 1 or 1 4 0 )
K=0.18
In Sq In LB I N - L B [N.m] IN - LB [N.m] I N - L B [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] F T - L B [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
Torque
(Loctite® 262
Vibra-TITE
K=0.15
or
131)
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
1-16 31215031
Page 36
SECTION 1 - SPECIFICATIONS
SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Size TPI Bolt Dia
In Sq In LB IN - L B [N.m] IN - LB [N.m] I N - L B [N.m]
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
In Sq In LB F T- LB [N.m] FT-LB [N.m] F T- LB [N.m]
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
Tensile
Stress Area
Clamp
Load
Torque
(Dry)
K=0.17
(Loctite® 242
Vibra-TITE
T o r q u e
or 271™ or
111 or 140)
K=0.16
Torque
(Loctite® 262
Vibra-TITE
K=0.15
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
31215031 1-17
Page 37
SECTION 1 - SPECIFICATIONS
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SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Size TPI Bolt Dia
In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB F T- LB [N.m] FT-LB [N.m] F T- LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
Tensile
Stress Area
Clamp
Load
Torque
( D r y o r L o c t i t e ® 2 6 3 )
K=0.17
(Loctite® 242
Vibra-TITE
T o r q u e
or 271™ or
111 or 140)
K=0.16
300 410 280 380
Torque
(Loctite® 262
Vibra-TITE
K=0.15
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
1-18 31215031
Page 38
SECTION 1 - SPECIFICATIONS
SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SOCKET HEAD CAP SCREWS
Size TPI Bolt Dia
In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB F T- LB [N.m] FT-LB [N.m] FT -L B [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
Tensile
Stress Area
Clamp
Load See
Note 4
Torque
(Dry) K=0.17
(Loctite® 242
Vibra-TITE
T o r q u e
or 271™ or
111 or 140) or
Precoat® 85 K=0.16
300 415 280 380
Torque
(Loctite® 262
Vibra-TITE
K=0.15
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2.
ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * AS
SEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
31215031 1-19
Page 39
SECTION 1 - SPECIFICATIONS
SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
SOCKET HEAD CAP SCREWS
Size TPI Bolt Dia
In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB F T- LB [N.m] FT-LB [N.m] F T-L B [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
Tensile
Stress Area
Clamp
Load See
Note 4
Torque
(Dry) K=0.17
(Loctite® 242
Vibra-TITE
T o r q u e
or 271™ or
111 or 140) or
Precoat® 85 K=0.16
300 415 280 380
Torque
(Loctite® 262
Vibra-TITE
K=0.15
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2.
ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
1-20 31215031
Page 40
SECTION 1 - SPECIFICATIONS
Metric Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
(Dry or Loctite®
)
263
Torque (Lube)
Size Pitch
Tensile
Stress Area
Clamp
Load See
Note 4
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154 16 2 157 68.3 219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290
T o r q u e
(Loctite® 262
or
271
Vibra-TITE
or
131)
(Loctite® 242
Vibra-TITE
T o r q u e
271
or
111 or
141)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL
TESTING IS REQUIRED.
31215031 1-21
Page 41
SECTION 1 - SPECIFICATIONS
Metric Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
T o r q u e
Size Pitch
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25 23 19 8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150 16 2 157 97.8 315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395
Tensile
Stress Area
Sq mm KN [N.m] [N.m] [N.m]
Clamp Load
See Note 4
Torque
(Dry or Loctite® 263
K=0.20
(Lube or Loctite® 242
)
or 271
Vibra-TITE
K=0.18
111 or 140)
or
T o r q u e
(Loctite® 262
Vibra-TITE
K=0.15
or
131)
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
1-22 31215031
Page 42
Metric Fastener Torque Chart (Continued)
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Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Size Pitch
3 0.5 5.03
3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 7 1 28.90 8 1.25 36.60
10 1.5 58.00 12 1.75 84.30 14 2 115 16 2 157 18 2.5 192 20 2.5 245 22 2.5 303 24 3 353 27 3 459 30 3.5 561 33 3.5 694 36 4 817 42 4.5 1120
Tensile
Stress Area
Sq mm KN [N.m] [N.m] [N.m]
Clamp Load
See Note 4
2.19 1.1 1.1 1.0
2.95 1.8 1.7 1.5
3.82 2.6 2.4 2.3
6.18 5.3 4.9 4.6
8.74 9 8.4 7.9
12.6 15 14 13
15.9 22 20 19
25.2 43 40 38
36.7 75 70 66
50.0 119 110 105
68.3 186 175 165
83.5 256 240 225
106.5 362 340 320
132.0 494 465 435
153.5 627 590 555
199.5 916 860 810
244.0 1245 1170 1100
302.0 1694 1595 1495
355.5 2176 2050 1920
487.0 3477 3275 3070
Torque
(Dry or Loctite® 263
K=0.17
Torque
(Lube or Loctite® 242
)
Vibra-TITE
271
K=0.16
SECTION 1 - SPECIFICATIONS
or
111 or 140)
or
T o r q u e
(Loctite® 262
Vibra-TITE
K=0.15
131)
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL
TESTING IS REQUIRED.
31215031 1-23
Page 43
SECTION 1 - SPECIFICATIONS
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Metric Fastener Torque Chart (Continued)
Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
T o r q u e
Size Pitch
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150 16 2 157 97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 222.0 905 850 800 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395
Tensile
Stress Area
Sq mm KN [N.m] [N.m] [N.m]
Clamp
Load See
Note 4
Torque
(Dry or Loctite® 263
K=0.17
(Lube or Loctite® 242
)
or 271
Vibra-TITE
K=0.18
111 or 140)
or
T o r q u e
(Loctite® 262
Vibra-TITE
K=0.15
or
131)
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
1-24 31215031
Page 44
SECTION 2. GENERAL
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SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been com­pleted before placing the machine into service. With proper
e, maintenance, and inspections performed per JLG's rec-
car ommendations, and with any and all discrepancies corrected, this product will be fit for continued use.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The follow­ing table outlines periodic machine inspections and mainte­nance recommended by JLG Industries, Inc. Consult your
al, regional, or local regulations for further requirements
nation for Mobile Elevating Work Platforms. Frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine before use daily or at each change of operator. Reference the Operation and Safety Man­ual for Pre-Start Inspection procedures. The Operation and
afety Manual must be read and understood in its entirety
S before performing the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent Inspection
The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Indus­tries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.
items requiring inspection. Reference appropriate areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection
The Annual Machine Inspection must be performed on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries recom­mends this task be performed by a Factory-Trained Service
echnician. JLG Industries, Inc. recognizes a Factory-Trained
T Service Technician as a person who has successfully com­pleted the JLG Service Training School for the subject JLG
oduct model. Reference the machine Service and Mainte-
pr nance Manual and appropriate JLG inspection form for perfor­mance of this inspection.
Reference the JLG Annual Machine Inspection Form and
nspection and Preventive Maintenance Schedule for items
I requiring inspection. Reference appropriate areas of this man­ual for servicing and maintenance procedures.
For the purpose of receiving saf important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of current machine ownership.
ety-related bulletins, it is
Preventive Maintenance
In conjunction with specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experi­ence, has successfully demonstrated the ability and profi­ciency to service, repair, and maintain the subject JLG product
.
model
Reference the Preventive Maintenance Schedule and appro­priate areas of this manual for servicing and maintenance pro­cedures. Frequency of service and maintenance must be
ncreased as environment, severity and frequency of usage
i requires.
The Pre-Delivery Inspection and Frequent Inspection proce­dures are performed in the same manner, but at different
s. The Pre-Delivery Inspection shall be performed prior to
time each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. Fre­quency of this inspection must be increased as environment,
erity and frequency of usage requires.
sev
Reference the JLG Pre-Delivery and Frequent Inspection Form
d Inspection and Preventive Maintenance Schedule for
an
31215031 2-1
Page 45
SECTION 2 - GENERAL
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Table 2-1. Inspection and Maintenance
Type Frequency
Pre-Start
Inspection
Pre-Delivery
tion
Inspec
Frequent
Inspection
Annual Machine
Inspection
Preventive
Maintenance
In service for 3 months or 150 hours, whichever
out of service for a period of more than 3 months; or
Annually, no later than 13 months from date of
Prior to use each day; or
at each Operator change.
Prior to each sale, lease, or
rental delivery.
comes first; or
purchased used.
prior inspection.
At intervals as specified in S ervice and Mainte-
nance Manual.
2.2 SERVICE AND GUIDELINES
General
Following information is provided to assist you in using servic­ing and maintenance procedures in this manual.
Safety and Workmanship
Your safety, and that of others, is the first consideration in maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without aid of a mechani­cal device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising a portion of the equipment.
Cleanliness
Primary
Responsibility
User or Operator User or Operator Operation and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic
Owner, Dealer, or User Qualified JLG Mechanic
Owner, Dealer, or User
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
3. Clean and inspect all parts during servicing or mainte­nance. Ensure all passages and openings are unob­structed. Cover all parts to keep them clean. Make sure all parts are clean before they are installed. New parts should remain in their containers until ready to be used.
Service
Qualification
Factory-Trained Service
Technician
(Recommended)
Reference
Service and Maintenance Manual nd applicable JLG inspection form.
a
Service and Maintenance Manual
and applicable JLG inspection form.
Service and Maintenance Manual nd applicable JLG inspection form.
a
Components Removal and Installation
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.
2. Sho
uld it be necessary to remove a component on an angle, keep in mind the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and component becomes less than 90 degrees.
1. The most important single item in preserving the long service life of a machine is to keep dirt and contamina­tion out of vital components. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a schedule to function properly.
y time air, fuel, or oil lines are disconnected, clean
2. An 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 contamination.
3. If a part resists removal, check to see if all nuts, bolts, cables, brackets, wiring, etc., have been removed and no adjacent parts are interfering.
2-2 31215031
Page 46
SECTION 2 - GENERAL
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Component Disassembly and Reassembly
When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to ensure nothing is overlooked. Do not make any adjustments, other than those recommended, without obtain­ing proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use a molybdenum disul­fide base compound or equivalent to lubricate the mating sur­face.
Bearings
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,
t do not spin the bearing.
bu
2. Discard bearings if races and balls (or rollers) are pitted, scored, or burned.
f bearing is found to be serviceable, apply a light coat of
3. I oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until ready to install.
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.
2. Unless
specific torque requirements are given within the text, use standard torque values on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Section 1.11,Torque Charts)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, and their receptacles, when disconnecting or removing them from the unit. This ensures correct reinstallation.
Hydraulic System
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.
2. Disa
ssemble and reassemble parts on clean work sur­face. Clean all metal parts with non-flammable cleaning solvent. Lubricate components as needed to aid assem­bly.
Lubrication
Service applicable components with the amount, type, and grade of lubricant recommended in this manual at the speci­fied intervals. When recommended lubricants are not avail­able, consult your local supplier for an equivalent that meets
ceeds the specifications listed.
or ex
Battery
Clean battery using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corro­sion compound.
Gaskets
Check holes in gaskets align with openings in mating parts. If it is necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the correct location. Blank gaskets can cause serious system damage.
Lubrication and Servicing
Components and assemblies requiring lubrication and servic­ing are shown in the Lubrication Chart in Section 1.
Bolt Usage and Torque Application
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1. Always use new replacement hardware when installing locking fasteners. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.
31215031 2-3
Page 47
SECTION 2 - GENERAL
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2.3 LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is contamina­tion. Contaminants can enter the system by using inade­quate hydraulic oil; allowing moisture, grease, filings, sealing components, sand, or other contaminants to enter during maintenance; or allowing the pump to cav­itate due to insufficient system warm-up or leaks in pump supply (suction) lines.
2. De
sign and manufacturing tolerances of component working parts are very close. The smallest amount of dirt or other contamination entering a system can cause wear or damage to components and faulty operation. Take every precaution to keep hydraulic oil clean ­including reserve oil in storage. Check, clean, and replace hydraulic system filters as at intervals specified in the Lubrication Chart in Section 1. Always examine fil­ters for metal particles.
3. Cloudy oils mits organic growth and causes oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or types. They may not contain required additives or be of com­parable viscosities. Good grade mineral oils, with viscos­ities suited to ambient temperatures in which the machine is operating, are recommended for use.
NOTE: Metal particles may appear in oil or filters of new machines
due to wear-in of meshing components.
indicate high moisture content which per-
Hydraulic Oil
1. Refer to Section 1 for viscosity ranges.
Changing Hydraulic Oil
3. I
nspect all hydraulic components, lines, fittings, etc. while unit is shut down. Perform a functional check of each system before placing machine back in service.
Lubrication Specifications
Specified lubricants, as recommended by component manu­facturers, are always the best choice. However, multi-purpose
eases usually have qualities which meet a variety of single
gr purpose grease requirements. Should any questions arise regarding use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explana­tion of lubricant key designations in the Lubrication Chart.
2.4 CYLINDER DRIFT
Theory
When a hydraulic cylinder is supporting a load, cylinder drift may occur as a result of any of the circumstances below:
• Normal leakage of load holding valves or malfunction of load holding valves. See Cylinder Leakage Test and Table 2- 2, Cylinder Drift below for evaluation.
• Damaged or worn piston seals.
• Normal thermal expansion or contraction of the hydraulic oil within cylinders (See Cylinder Thermal Drift below).
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.
Thermal expansion or contraction of oil in hydraulic cylinders
a normal occurrence and does not result in oil leaking out of
is the cylinder or leaking internally from one cylinder chamber to the other. Thermal expansion or contraction is the tendency for materials to change size in response to a change in temperature.
Cylinder Leakage Test
Cylinder oil must be at stabilized ambient temperature before beginning this test.
Measure drift at cylinder rod with a calibrated dial indicator.
1. Filter elements must be changed after first 50 hours of operation and every 300 hours (unless specified other­wise) thereafter. If it is necessary to change the oil, use only oils meeting or exceeding specifications in this manual. If unable to obtain same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Do not mix petroleum and synthetic base oils.
2. Keep
hydraulic oil clean. If oil must be poured from orig­inal container into another, clean all possible contami­nants from service container. Always clean filter mesh element and replace cartridge any time oil is changed.
In an area free of obstructions, cylinder must have load applied and appropriately positioned to detect drift.
Cylinder leakage is acceptable if
it passes this test.
2-4 31215031
Page 48
Table 2-2. Cylinder Drift
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Cylinder Bore
Diameter
inches mm inches mm
3 76.2 0.026 0.66
3.5 89 0.019 0.48
4 101.6 0.015 0.38
5 127 0.009 0.22
6 152.4 0.006 0.15
7 177.8 0.005 0.13
8 203.2 0.004 0.10
9 228.6 0.003 0.08
NOTE: T
his information is based on 6 drops per minute cylinder
leakage.
Max. Acceptable Drift
in 10 Minutes
Cylinder Thermal Drift
The oil in all hydraulic cylinders will expand or contract due to thermal effects over time and may result in changes to the boom and/or platform position while the machine is station­ary. These effects occur as the cylinder oil changes tempera­ture, usually from a higher oil temperature as it cools and approaches the ambient air temperature. Results of these effects are related to several factors including cylinder length and change in temperature over the time the cylinder remains stationary.
2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES
Filament wound bearings.
1. Pinned joints should be disassembled and inspected if the following occurs:
a. Excessive sloppiness in joints.
b. Noise originating from joint during operation.
SECTION 2 - GENERAL
4. Re-assembly of pinned joints using filament wound bearings:
a. Housing should be blown out to remove all dirt and
debris. Bearings and bearing housings must be free of all contamination.
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).
c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear­ing during installation and operation.
2.6 WELDING ON JLG EQUIPMENT
NOTE: This instruction applies to repairs, or modifications to the
machine and to welding performed from the machine on an external structure, or component,
Do the Following When Welding on JLG Equipment:
• Disconnect battery.
• Disconnect moment pin connection (where fitted)
• Ground only to structure being welded.
DO NOT Do the Following When Welding on JLG Equipment:
• Ground on frame and weld on any other area than chassis.
• Ground on turntable and weld on any other area than turn-
table.
• Ground on platform/support and weld on any other area
than platform/support.
• Ground on a specific boom section and weld on any other
area than that specific boom section.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
valves, electrical wiring, or hoses to be between grounding position and welded area.
2. Filament wound bearings should be replaced if any of the following is observed:
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
d. Debris embedded in liner surface.
3. Pins should be replaced if any of the following is
observed (Clean pin before inspection):
a. Detectable bearing area wear.
b. Flaking, peeling, scoring, or scratches on pin surface.
c. Rusting of pin in bearing area.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN COMPO­NENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.).
31215031 2-5
Page 49
SECTION 2 - GENERAL
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Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Pre-Delivery
or Frequent
Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wea r Pa ds 1,2 1,2
Covers or Shi elds 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Boom Assembly
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 1,5 1,5
Floor 1 1,2
Rotator 5, 9, 15 5, 9, 15
Lanyard Anchorage Point 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling 9 9
Swing D rive Syste m 11 11
Tur nt ab l e L oc k 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5
Chassis Assembly
Tires 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15
Wheel Bearings 14, 24 14, 24
Oscillating Axle/Lockout Cylinder Systems 5,8
Extendable Axle Systems 5,8 5,8
Steer Components 1,2 1,2
Spindle Thrust Bearing/Washers 1,2
Drive Hubs 11 11
1
2
Inspection
Annual
(Yearly)
14
1,2,10
1,2,5
3
2-6 31215031
Page 50
SECTION 2 - GENERAL
Go to Discount-Equipment.com to order your parts
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Pre-Delivery
or Frequent
Inspection
Functions/Controls
Platform Controls 5, 6 6
Ground Controls 5, 6 6
Function Control Locks, Guards, or Detents 1, 5 5
Foots witch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Drive Brakes 5 5
Swing Br akes 5 5
Auxiliar y Power 5
Power Syste m
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9, 11 11
Air/Fuel Filter 1, 7 7
Exhaust System 1, 9 9
Batteries 1, 9 19
Battery Fluid 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 1, 2, 5
Hydraulic/Electric System
Hydraulic Pumps 1,2,9 1,2,9
Hydraulic Cylinders 1, 2, 7, 9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,2, 9 1,2
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1, 2, 5, 9 1,5
Hydraulic Filter 1, 7, 9 7
Hydraulic Flui d 7,11 7,11
Electrical Connections 1, 20 20
Instruments, Gauges, Switches, Lights, Horn 1
General
Operation and Safety Manuals in Storage Box 21 21
ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI and ANSI Export ONLY) 21 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
1
2
Inspection
Annual (Yearly)
5
1,5
5,23
3
31215031 2-7
Page 51
SECTION 2 - GENERAL
Go to Discount-Equipment.com to order your parts
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footn otes:
1
Pr i or t o e a ch s al e , l e as e , o r de l iv e r y
2
In service for 3 months or 150 Hours; or Out of ser vice for 3 months or more; or Purchased used
3
Annually, no later than 13 months from the date of the prior inspection
Performance Codes: 1 - Check for proper and secure installation 2 - Visual inspection for damage, cracks, distortion or excessive wear 3 - Check for proper adjustment 4 - Check for cracked or broken welds 5 - Operates Properly 6 - Returns to neutral or "off" position when released 7 - Clean and free of debris 8 - Interlocks function properly 9 - Check for signs of leakage 10 - Decals installed and legible 11 - Check for proper fluid level 12 - Check for chafing and proper routing 13 - Check for proper tolerances 14 - Properly lubricated 15 - Torqued to proper specification 16 - No gouges, excessive wear, or cords showing 17 - Properly inflated and seated around rim 18 - Proper and authori 19 - Fully charged 20 - No loose connectio ns, corrosion, or abrasions 21 - Verify 22 - Perform 23 - Sealed Properly 24 - Drain, Clean, Refill
zed components
Pre-Delivery
or Frequent
Inspection
1
2
Annual
(Yearly)
Inspection
3
2-8 31215031
Page 52
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4150548-E
Go to Discount-Equipment.com to order your parts
SECTION 2 - GENERAL
31215031 2-9
Figure 2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz
Page 53
-40
4150548-E
SECTION 2 - GENERAL
Figure 2-2. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425
2-10 31215031
Page 54
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Page 55
3.1 TIRES AND WHEELS
Figure 3-1. Wheel Lug Nut Tightening Sequence
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3. CHASSIS & TURNTABLE
Tire Damage
For polyurethane foam filled tires, JLG Industries, Inc. recom­mends that when any of the following are discovered, mea­sures must be taken to remove the JLG product from service immediately and arrangements must be made for replace­ment of the tire or tire assembly.
• Smooth, even cut through cord plies which exceeds ches (7.5 cm) in total length.
3 in
• Tears or rips (ragged edges) in cord plies which
exceeds 1inch (2.5 cm) in any direction.
• Any punctures which exceed 1inch in diameter.
• Any damage to the bead area cords of the tire.
If a tire is damaged but within above criteria, it must be inspected daily to ensure damage does not exceed allowable criteria.
Tire Replacement
JLG recommends a replacement tire be the same size, ply, and brand as originally installed on the machine. Please refer to the JLG Parts Manual for part number of approved tires for a par­ticular machine model. If not using a JLG approved replace­ment tire, we recommend that replacement tires have the following characteristics:
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.
Tighten lug nuts to proper torque to prevent wheels from coming loose. Use a torque wrench to tighten fasteners. If you do not have a torque wrench, tighten fasteners with a lug wrench, then immediately have a service garage or dealer tighten lug nuts to proper torque. Over-tightening will break studs or permanently deform mounting stud holes in wheels. The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
2. Tighten nuts in the following sequence.
• Equal or greater ply/load rating and size of original
• Tire tread contact width equal or greater than original
• Wheel diameter, width, and offset dimensions equal to the or
iginal
• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not
eplace a foam filled or ballast filled tire assembly with a pneu-
r matic tire. Due to size variations between tire brands, both tires on the same axle should be the same.
Wheel Replacement
Rims installed on each product model have been designed for stability requirements which consist of track width and load capacity. Size changes such as rim width, center piece loca­tion, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe stability conditions.
Wheel Installation
It is extremely important to apply and maintain proper wheel mounting torque.
3. The tightening of the nuts should be done in stages. Fol­lowing the recommended sequence, tighten nuts per wheel torque chart.
Table 3-1. Wheel Torque Chart
TORQUE SEQUENCE
1st Stage 2n d Stage 3rd Stage
40 ft-lbs.
(55 Nm)
4. Whee
l 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.
95 ft-lbs.
(130 Nm)
170 ft-lbs.
(230 Nm)
31215031 3-1
Page 56
SECTION 3 - CHASSIS & TURNTABLE
MAE18170
BLEEDER VALVE
3.2 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST
Lockout Cylinder Bleeding
1. Position the turntable to the normal stowed position. In this position the axle is free oscillate. Drive charge pres­sure will pass through the lock out valve built into the swivel and down to the pilot section of the hold valves on the cylinders. This will automatically purge the air from the pilot section of the circuit.
2. Disc
3. L
4. Rep
5. Reconnect the brake wire connector on the brake valve.
onnect the brake wire connector on the brake valve
located under the drive pump.
ocate the bleeder on the lock out cylinders. Use a small hose (gas hose, etc.) to direct the oil to a bucket. Do one cylinder a time. Using a wrench open the bleeder a 1/4 turn. Have the operator in the platform just crake the drive controller in reverse. This will activate the brake valve sending charge pressure to the lock out cylinder. make sure the bleeder is open enough to vent any air for about 10 seconds. Close the bleeder while there is fluid pressure at the bleeder.
eat the procedure for the other lockout cylinder.
2. From platform control station, start engine.
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front wheel is on top of block.
4. Car
5. W
6. Ha
7. Carefully activate Swing control lever and return boom
8. Place the 6 in. (15.2 cm) high block with ascension ramp
9. Place Drive control lever to Forward and carefully drive
10. W
11. Ha
12. Car
13. I
efully activate Swing control lever and position boom
over right side of machine.
ith boom over right side of machine, place Drive con­trol lever to Reverse and drive machine off of block and ramp.
ve an assistant check to see that left front wheel
remains locked in position off of ground.
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 to activate Drive to release cylinders.
in front of right front wheel.
machine up ascension ramp until right front wheel is on top of block.
ith boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.
ve an assistant check to see that right front wheel
remains locked in position off of ground.
efully 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 Drive to release cyl­inders.
f lockout cylinders do not function properly, have quali­fied personnel correct the malfunction prior to any fur­ther operation.
Oscillating Axle Lockout Test
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS­TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder test.
1. Pla
ce a 6 in. (15.2 cm) high block with ascension ramp in
front of left front wheel.
3-2 31215031
Page 57
8FT/2.4M WIDE MACHINES
OSCILLATING
FIXED
13
12
15
14
OR
4
9
1
8
3
11
7
10
5
6
2
3
7FT/2.1M WIDE MACHINES
OSCILLATING
17
24
20
OR
19
25
26
27
FIXED
16
23
19
21
18
22
MAE1260
Figure 3-2. Axle Installation - Sheet 1 of 2
SECTION 3 - CHASSIS & TURNTABLE
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3-4 31215031
Page 58
Figure 3-3. Axle Installation - Sheet 2 of 2
1. Bolt
2. Bolt
3. Bearing
4. Axle Lockout Cylinder Assembly
5. Pin
6. Keeper Pin
7. Thrust washer
8. Axle Weldment
9. Flat washer
10. Thrust washer
11. Shim
12. Stop Plate
13. Capscrew
14. Shim
15. Shim
16. Axle Weldment
17. Bolt
18. Bolt
19. Bearing
20. Axle Lockout Cylinder Assembly
21. Pin
22. Keeper Pin
23. Thrust washer
24. Flat washer
25. Bolt
26. Stop Plate
27. Spacer
SECTION 3 - CHASSIS & TURNTABLE
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31215031 3-5
Page 59
14
7
11
3
15
4
10
9
1
16
5
5
17
12
4
9
15
1
13
1
10
8
15
2
6
15
10
1
10
18
27
28
20
33
30
28
18
27
20
34
21
33
31
18
28
24
33
47
46
39
40
43A
43
40
39
45
48
44
42
49
41
38
37
23
32
29
25
19
38
36
21
35
28
26
18
22
33
MAE1920
Figure 3-4. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 1 of 2
SECTION 3 - CHASSIS & TURNTABLE
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3-6 31215031
Page 60
Figure 3-5. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 2 of 2
1. Bolt
2. Steer Cylinder Assembly
3. Bolt
4. Bushing
5. Bushing
6. Pin
7. King Pin
8. Pin
9. Pin
10. Keeper Pin
11. Keeper Pin
12. Tie-Rod
13. Spindle
14. Spindle
15. Thurstwasher
16. Thurstwasher
17. Thurstwasher
18. Bolt
19. Bolt
20. Bushing
21. Bushing
22. Steer Cylinder Assembly
23. Hub assembly
24. Pin
25. King Pin
26. Pin
27. Pin
28. Keeper Pin
29. Keeper Pin
30. Tie-Rod
31. Spindle
32. Spindle
33. Thurstwasher
34. Thurstwasher
35. Thurstwasher
36. Bolt
37. Nut
38. Flat Washer
39. Cone Bearing
40. Cup Bearing
41. Bolt
42. Hub Cap
43. Hub 43 A.Wheel Stud
44. Nut
45. Cotter Pin
46. Seal
47. Adapter
48. Flat Washer
49. Lock Washer
SECTION 3 - CHASSIS & TURNTABLE
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31215031 3-7
Page 61
1
17
15
22
1
18
16
1
18
1
18 13
14
25
7
3
10
21
24
25
6
24
9
6
24
24
8
24
18
27
5
11
1
1
12
18
5
26
18
1
17
2
19
15
23
24
4
24
4
28
31
51
53
55
51
31
53
31
53
50
31
31
53
53
47
66
61
37
60
42
37
60
41A
41
63
43
33
65
39
52
29
30
30
29
56
59
49
54
32
35 60
62
36
60
35
53
46
31
60
40
60
60
57
44
34
38
61
48
53
45
36 64
31
20
MAE1930
58
Figure 3-6. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 1 of 2
SECTION 3 - CHASSIS & TURNTABLE
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3-8 31215031
Page 62
1. Bolt
2. Bolt
3. Screw
4. Bushing
5. Bushing
6. Bushing
7. Bushing
8. Steer Cylinder Assembly
9. Link
10. Pad
11. Pin
12. Pin
13. Pin
14. Pin
15. Pin
16. Pin
17. Pin
18. Keeper Pin
19. Keeper Pin
20. Tie-Rod
21. Shim
22. Spindle
23. Spindle
24. Thurstwasher
25. Thurstwasher
26. Thurstwasher
27. Thurstwasher
28. Pivot
29. Cone Bearing
30. Cup Bearing
31. Bolt
32. Bolt
33. Bolt
34. Screw
35. Bushing
36. Bushing
37. Bushing
38. Bushing
39. Cap Hub
40. Steer Cylinder Assembly
41. Hub 41 A. Wheel Stud
42. Link
43. Nut
44. Pad
45. Pin
46. Pin
47. Pin
48. Pin
49. Pin
50. Pin
51. Pin
52. Cotter Pin
53. Keeper Pin
54. Keeper Pin
55. Tie-Rod
56. Seal
57. Shim
58. Spindle
59. Spindle
60. Thurstwasher
61. Thurstwasher
62. Thurstwasher
63. Flatwasher
64. Thurstwasher
65. Lock Washer
66. Pivot
Figure 3-7. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 2 of 2
SECTION 3 - CHASSIS & TURNTABLE
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31215031 3-9
Page 63
Figure 3-8. Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3
FRONT AXLE
WITHOUT TOW
16
5
20
6
21
5
20
16
17
3
8
7
24
14
5
20
10
35
15
20
5
23
8
19
36
22
2
1
1
2
25
13
4
9
18
12
11
11A
26
29
5
20
16
28
30
20
5
16
7
33
27
5
20
15
27
34
REAR AXLE
10
35
14
20
5
7
31
32
MAE2070
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SECTION 3 - CHASSIS & TURNTABLE
3-10 31215031
Page 64
41
64
65
42
41
58
64
61
39
45
44
68
39
45
74
62
56
41
64
66
38
37
37
38
70
53
40
48
62
52
50
50A
41
73
46
59
73
65
73
66
46
73
55
64
41
49
71
54
43
51
43
54
67
69
58
41
64
60
72
47
72
41
57
64
FRONT AXLE
WITH TOW
MAE2130
Figure 3-9. Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3
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SECTION 3 - CHASSIS & TURNTABLE
31215031 3-11
Page 65
Figure 3-10. Steering Installation (7ft/2.1m Wide Machines) - Sheet 3 of 3
1. Cup Bearing
2. Cone Bearing
3. Thurstwasher
4. Bolt
5. Bolt
6. Bolt
7. Bushing
8. Bushing
9. Hub Cap
10. Steer Cylinder Assembly
11. Hub 11 A. Wheel Stud
12. Wheel Nut
13. Slotted Nut
14. Pin
15. Pin
16. Pin
17. King Pin
18. Cotter Pin
19. Cotter Pin
20. Keeper Pin
21. Tie-Rod
22. Seal
23. Spindle
24. Spindle
25. Flat Washer
26. Bolt
27. Bearing
28. King Pin
29. Keeper
30. Tie-Rod
31. Spindle
32. Spindle
33. Thurstwasher
34. Thurstwasher
35. Plug
36. Slotted Nut
37. Cup Bearing
38. Cone Bearing
39. Thurstwasher
40. Bolt
41. Bolt
42. Bolt
43. Screw
44. Bushing
45. Bushing
46. Bushing
47. Bushing
48. Hub Cap
49. Steer Cylinder Assembly
50. Hub 50 A. Wheel Stud
51. Pivot
52. Wheel Nut
53. Slotted Nut
54. Pad
55. Pin
56. Pin
57. Pin
58. Pin
59. Pin
60. Pin
61. King Pin
62. Cotter Pin
63. Link
64. Keeper Pin
65. Tie-Rod
66. Seal
67. Shim
68. Spindle
69. Spindle
70. Flat Washer
71. Thurstwasher
72. Thurstwasher
73. Flat Washer
SECTION 3 - CHASSIS & TURNTABLE
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Page 66
SECTION 3 - CHASSIS & TURNTABLE
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
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3.3 TORQUE HUB
Oil Information
1. TYPE – EP90 Use EP90 for normal applications. For applications where lubricant must meet special requirements, the O.E.M can recommend a suitable substitute.
2. OIL TEM Continuous – 160° F (70° C) Intermittent – 200° F (95° C).
3. OIL CHANGE Initial – After 50 hours or 50,000 revolutions of opera­tion. Subsequent – After 1000 hours or (1) year, which­ever comes first.
NOTE: Higher temperatures make it necessary to change oil more
4. OIL FILL LEVEL AND VOLUME Unit mounted horizontal – half full. (See Diagram A.) Approximate volume - 17 oz. (0.5 1tr).
PERATURE
frequently.
Roll and Leak Testing
Always roll and leak test Torque-Hubs after assembly to make sure that the unit’s gears and sealants are working properly. The following information briefly outlines what to look for when performing these tests.
ROLL TEST
Tightening and Torquing Bolts
USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN BOLTS BEYOND THEIR TORQUE SPECIFICATION. WRENCH TO TIGHTEN SHOULDER BOLTS. TIGHTEN ALL SHOULDER BOLTS BY HAND.
1. Tighten (but do not torque) bolt ”A” until snug.
2. Go to opposite side of bolt circle and tighten bolt ”B”
until equally snug.
3. Continue around bolt circle and tighten remaining bolts.
4. Use a torque wrench to apply specified torque to bolt
”A”.
5. Continue around bolt circle and apply equal torque to remaining bolts.
NEVER USE AN IMPACT
The roll test determines if the unit’s gears rotate freely and properly. You should be able to rotate gears by applying a con­stant force to the roll checker. If you feel more drag in gears only at certain points, gears are not rolling freely. Examine them for improper installation or defects.
Some gear packages roll with mor not be concerned if gears seem to roll hard as long as they roll with consistency.
LEAK TEST
The purpose of a leak test is to make sure unit is air tight. You can tell if your unit has a leak if pressure gauge test reading starts to fall once you have pressurized the unit.
Leaks usually occur at the main seal or wherever O-rings or gaskets are located. You can usually detect location of a leak by brushing a soap and water solution around main seal and where O-rings or gaskets meet unit exterior, then checking for air bubbles. Replace part immediately if you detect a leak in a seal, O-ring, or gasket.
e difficulty than others. Do
Figure 3-11. Bolt Tightening Sequence
31215031 3-13
Page 67
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1A. Spindle 1B. Seal 1C. Bearing 1D. Housing 1E. Ring Gear 1F. Bearing Nut 1G. Setscrew 1H. Wheel Stud 1K. Retaining Ring
1L. Spring 1M. Thrustwasher
2. Th r us t wa s h er 3A. Carrier 3B. Thrustwasher 3C. Needle Bearing 3E. Planet Shaft 3F. Planet Gear 4B. Thrustwasher
4C. Needle Bearing 4D. Thrust Spacer 4E. Planet Shaft 4F. Planet Gear 4G. Roll Pin 4H. Thrustwasher
5. R et a in i n g R i ng 6A. Cover Plate 6B. Disengage Cap
6C. Bolt 6D. Dowel Pin 6E. O-Ring 6F. Pipe Plug 6G. Retaining Ring
7. C ou p li n g 8A. Brake Piston 8B. Pressure Plate 8C. Retaining Ring
8D. O-Ring 8E. Backup Ring 8F. O-Ring 8H. Backup Ring 8J. Brake Rotor 8K. Brake Stator 8L. Brake Spring
9. I np u t Sh a ft
11. Sun Gear
12. Plug
15. I.D. Plate
16. Drive Screw
17. O-Ring
18. O-Ring
19. Countersunk Screw
20. Retaining Ring
21. Plug
SECTION 3 - CHASSIS & TURNTABLE
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3-14 31215031
Figure 3-12. Torque Hub
Page 68
SECTION 3 - CHASSIS & TURNTABLE
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Main Disassembly
1. Perform Roll Check, Leak Check, and Brake Check if applicable before disassembly.
ain oil from unit. Note condition and volume of oil.
2. Dr
3. Remove Retaining Ring (6G) by prying open end of
Retaining Ring out of groove in Ring Gear (1E) with a screwdriver. Grasp loose end with pliers and pull out Retaining Ring.
4. Remov
e Cover Subassembly (6).
NOTE: Carefully pressurize unit with air to pop cover off.
5. Remove Input Carrier Subassembly (3).
6. Remove Input Shaft (9).
7. Remove Second Stage Sun Gear (11).
8. Loosen and remove three Flat Head Bolts (19) that retain
Ring Gear (1E) to Housing (1G).
9. Lift Ring Gear (1E) off Housing (1D).
10. Remove O-ring (18) from Housing (1D.
Figure 3-13. Torque Hub Main Disassembly
31215031 3-15
Page 69
SECTION 3 - CHASSIS & TURNTABLE
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Output Carrier Disassembly
11. Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet Shaft (4E) until it bottoms against Spindle (1A).
12. Gr
13. Dri
asp Roll Pin (4G) with needle nosed pliers or a hooked
tool and pull Planet Shaft (4E) out of Spindle (1A).
ve Roll Pin (4G) out of Planet Shaft (4E). Discard roll
pin.
14. Slide Planet Gear Subassembly (4) out of Spindle (1A). Do not drop Needle Bearings (4C).
15. Remove four Thrust Washers (4B), 28 Needle Rollers (4C), and Thrust Spacer (4D) from Second Stage Planet Gear (4F).
16. Repeat Steps 12-15 for remaining Planet Gears (4F).
17. Remove Thrust Washer (4H) from Spindle (1A) counter-
bore.
Figure 3-14. Output Carrier Disassemb
Input Carrier Disassembly
1. Using a 1/8” diameter punch, drive Roll Pin (4G) in Planet Shaft (3E) until it bottoms against Carrier (3A).
2. Usi
3. Using a 1/8” diameter punch, drive Roll Pin (4G) out of
4. Slide Planet Gear (3F) and two Thrust Washers (3B) out of
5. Remo
6. Repeat steps 1 through 5 for remaining planet gears.
3-16 31215031
ng a soft face hammer, tap Planet Shaft (3E) out of
Carrier (3A).
Planet Shaft (3E). Discard roll pin.
Carrier (3A).
ve 14 needle Bearings (3C) from bore of Planet
Gear (3F).
Figure 3-15. Input Carrier Disassembly
Page 70
SECTION 3 - CHASSIS & TURNTABLE
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Hub-Spindle Disassembly
1. Place unit on bench with Spindle (1A) end down.
2. Remove 2 Set Screws (1G) and Bearing Nut (1F).
NOTE: Holes in Bearing Nut (1F) for Set Screws (1G) are staked for
retention of Set Screws (1G). Clean holes before removing Set Screws.
3. Remove “A” position Bearing Cone (1C) from Bearing Cup (1C) in Hub (1D).
4. While supporting unit on Hub (1D) flange, press Spindle (1A) out of Hub (1D).
5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable.
6. If necessary, press nine Studs (1H) out of Hub (1D). Locate Hub (1D) on Seal (1B) end.
emove Seal (1B) from Hub (1D). Discard seal.
7. R
8. Remove “B” position Bearing Cone (1C) from Bearing
Cup (1C) in Hub (1D).
9. Remove “B” position Bearing Cone (1C) from Hub (1D).
10. Using a soft steel rod, knock both Bearing Cups (1C) out
of Hub (1D).
Figure 3-16. Hub Spindle Disassembly
31215031 3-17
Page 71
SECTION 3 - CHASSIS & TURNTABLE
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Spindle-Brake Disassembly
NOTE: Units with integral Input Brake (8) only.
COMPRESSED SPRINGS CAN FLY OUT AND CAUSE SEVERE EYE DAMAGE OR OTHER INJURIES. WEAR EYE PROTECTION WHEN PERFORMING THESE PROCE DURES.
1. Install two 1/4"-20 x 5/8" Flat Head Capscrews (22) through Pressure Plate (8B) into Piston (8A). Tighten incrementally until spring force is taken off Retaining Ring (8C).
NOTE: Flat Head Capscrews (22) are for transit and service only
and are removed before shipping new units. They are included in most brake repair kits.
2. Using retaining ring pliers, remove Retaining Ring (8C) from groove in Spindle (1A).
3. Back Flat Head Capscrews (22) incrementally out of Piston (8A) until spring force is relieved from Pressure Plate (8B).
Remove Flat Head Capscrews (22) and Pressure Plate (8B) from brake cavity in Spindle (1A).
4. Remo
5. Using an air hose, slowly and carefully pressurize brake
-
6. Remo
7. R
8. Remove Coupling Subassembly (7) from brake cavity in
9. Remove Retaining Ring (1K) from internal groove using
10. Remo
11. Remove Plastic Plug (12) and Pipe Plug (21) from Spindle
ve Compression Springs (8L) from Piston (8A).
port in Spindle (1A) until Piston (8A) comes out of piston bore of Spindle (1A). Pull Piston (8A) out of Spindle (1A) by hand.
ve Backup Rings (8E and 8H) and O-rings (8D and
8F) from grooves in Piston (8A).
emove Rotors (8J) and Stators (8K) from brake cavity in
Spindle (1A).
Spindle (1A).
appropriate tool.
ve Spacer (1M) and Spring (1L) from bore of Cou-
pling (7).
(1A) if applicable.
Figure 3-17. Spindle Brake Disassembly
3-18 31215031
Page 72
SECTION 3 - CHASSIS & TURNTABLE







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Cover Disassembly
1. Remove O-Ring (17) from groove in Cover (6A).
2. Remove Thrust Washer (2) from Cover (6A) pockets.
3. Unscrew two Hex Head Bolts (6C) and remove Disen-
gage Cap (6B) from Cover (6A).
ull Disengage Rod (6D) out from Cover (6A).
4. P
5. Use appropriate tool to remove O-ring (6E) from internal
groove in Cover (6A).
6. Remov
e two O-Ring Pipe Plugs (6F) from Cover (6A).
Cover Assembly
1. Grease O-Ring (6E) and insert in internal groove in Cover (6A).
2. Ass
3. Insert Disengage Rod (6D) in hole in Cover (6A) until it
NOTE: Disengage Rod can be inserted either end first.
4. Grease face of Thrust Washer (2) and place in Cover (6A).
5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should
emble Disengage Cap (6B) on Cover (6A) using two
Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs.
touches inside of Disengage Cap (6B).
Make sure tangs on washer seat into pockets in cover.
be hand tight.
Input Carrier Sub-Assembly
1. Apply a liberal coat of grease to bore of one Input Planet Gear (3F).
2. Line in
NOTE: The last roller installed must be installed end wise. That is,
3. Set Carrier (3A) in an upright position.
4. Insert a Planet Shaft (3E) in planet shaft hole in end of
5. Plac
6. F
7. F
8. No
side of Planet Gear (3F) with 14 Needle Rollers
(3C).
the end of the last roller must be placed in between ends of the two rollers which form the space, and then slid, parallel to the other rollers, into place.
Carrier (3A) opposite splined end. End of planet shaft that does NOT have the roll pin hole should be inserted into carrier FIRST.
e one Thrust Washer (3B) on end of Planet Shaft (3E). Make sure the flat faces towards inside of carrier and make sure button fits in the pocket on inside of Carrier (3A) towards the OD.
ollowing the thrust washer, place Planet Gear (3F) with
needle rollers, on Planet Shaft (3E).
ollowing the planet gear, place one more Thrust Washer (3B) onto Planet Shaft (3E). Align Thrust Washer (3B) in same manner described in Step 5.
w insert Planet Shaft (3E) through opposite planet shaft hole on Carrier (3A). Use an alignment punch or similar tool to align roll pin holes on Carrier (3A) and Planet Shaft (3E).
NOTE: Do not to hit Planet Gears (3F) when driving in Roll Pins
(4G).
9. Drive Roll Pin (4G) down into aligned roll pin holes. Pin should be flush with flat of carrier.
10. Repeat Steps 1-9 for installation of two remaining Planet Gears (3F).
NOTE: Some grease may need to be applied to the Thrust Washers
(3B) to hold them in place while installing the planet gears.
Output Planet Gear Sub-Assembly
Figure 3-18. Torque Hub Cover
31215031 3-19
1. Apply a liberal coat of grease to the bore of one Output
Planet Gear (4F).
2. Line inside of the Planet Gear (4F) with 14 Needle Rollers (4C).
NOTE: Last roller installed must be installed end wise. That is, the
end of the last roller must be placed in between the ends of the two rollers which form the space, and then slid, parallel to the other rollers, into place.
ace Spacer (4D) in bore of Output Planet (4F).
3. Pl
Page 73
SECTION 3 - CHASSIS & TURNTABLE
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4. Repeat Step 2 to put in second roll of Needle Rollers (4C).
ply grease to hold two Thrust Washers (4B) together
5. Ap and on Output Planet Gear (4F) counterbore. Do the same to the other side.
6. Repea
t Steps 1-5 to finish assembly of two remaining
Output Planet Gears (4F).
Spindle - Brake Sub-Assembly
1. Place Spindle (1A) with flange side up.
2. Pla
3. Pla
4. Rep
5. Pla
6. I
7. I
8. I
9. I
10. I
11. I
12. Pla
13. U
14. I
15. Pla
16. U
NOTE: R
17. I
ce Stator (8K) in Spindle (1A) scallop cuts.
ce Rotor (8J) on top of Stator (8K).
eat steps 2 & 3 until there are a total of 9 Stators (8K)
and 8 Rotors (8J) installed.
ce Piston (8A) with smaller O.D. end facing up. Grease
two O-Rings and two Backup Rings.
nstall large Backup Ring (8E) in large-diameter groove at
bottom of Piston (8A).
nstall large O-Ring (8D) in large-diameter groove at bot-
tom of Piston (8A), on top of large Backup Ring (8E).
nstall small O-Ring (8F) in small-diameter groove near top of Piston (8A). Make sure O-Ring is seated on the bottom of the groove.
nstall small Backup Ring (8H) in small-diameter groove near top of Piston (8A), on top of small O-Ring (8F).
nsert Piston (8A) in Spindle (1A) until it contacts Stator (8K).
nsert appropriate number of Springs (8L), based on assembly print, into Piston (8A)counterbore.
ce Spring (1L) in Coupling (7) counterbore. Place Pres-
sure plate (1M) on top of Spring (1L).
se appropriate tool to install Retaining Ring (1K) in
retaining ring groove in coupling (7) counterbore.
nsert Coupling sub-Assembly (7) through Rotors (8J).
ce Pressure Plate (8B) on top of Springs (8L).
se two ¼ -20 x 0.625 flat head Capscrews (22) by bolt­ing Pressure Plate (8B) and Piston (8A) together or some other appropriate tools to install Retaining Ring on top of Pressure Plate (8B) until Retaining Ring (8C) is seated.
emove 2 Screws from units when done or brake will not
function.
nstall Pipe Plug (21) if applicable
Hub-Spindle Sub-Assembly
NOTE: Spray a light film of oil on all component parts during
assembly. Spray a generous amount of oil on bearings dur­ing installation.
ress Bearing Cup of part (1C), position "A", into Hub
1. P using pressing tool.
urn hub over and press Bearing Cup of part (1C), posi-
2. T tion "B", into hub using pressing tool.(T).
3. Plac
4. Greas
5. Plac
NOTE: Use enou
6. Se
7. I
8. Appl
NOTE: F
9. Using
10. Plac
11. Plac
12. I
e Bearing Cone of part (1C), into Bearing Cup of part
(1C), position "B".
e Seal (1B) lip and press seal into Hub (1D) using
appropriate tool until seal is flush with end of hub.(T).
e Hub (1D) into pressing base. Press nine Studs (1H)
into Hub.
gh pressure to press in studs. Don t use excessively
high pressure to press in studs or hub may crack.
t Spindle assembly (1A) on the bench with the flange down. Turn Hub (1D) over and lower onto Spindle (5). Install boot (21) if applicable.
nstall Bearing Cone of part (1C) into Bearing Cup, posi-
tion "A".
y Medium Strength Threadlocking Compound on Bearing Nut (1F) thread. Screw Nut (1F) on top of Bearing Cone of part (1C). Leave 0.003-0.005 inches end play to check the initial rolling torque with the unit tied down. Then torque Bearing Nut (1F) until rolling torque is 40 to 50 in-lbs greater than initial rolling torque. Using tool for the Bearing Nut.
inal torque is initial rolling torque plus 40-50 in-lb (4.5-5.6 Nm). For example, if initial rolling torque is 30 in-lb (3.3 Nm), final rolling torque is between 70-80 in-lb (7.9-9 Nm). Rotate hub as torque is applied to properly seat bearing. Be sure torque wrench is tangent to the Hub (1D) OD.
appropriate tool, install two Set Screws (1G) into Bearing Nut (1F) threaded holes. Make sure Set Screw is driven into the spindle thread. Tighten the set screws to damage the thread and stake the edge of the nut around the Set Screws (1G) so the nut will not loosen.
e Thrust Washer (4H) in counterbore of Spindle (1A).
e Planet Gear Sub-assembly (4) into Spindle (1A) through gap between two Studs (1H). Align the planet gear bore with one of the planet shaft holes on the spin­dle (1A) assembly using tool.
nsert a Planet Shaft (4E) into the planet shaft hole described in Step (11) on Spindle (1A). Insert end of planet shaft that does NOT have roll pin hole in Spindle FIRST.
3-20 31215031
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SECTION 3 - CHASSIS & TURNTABLE
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13. Insert Planet Shaft (4E) through first set of Thrust Wash­ers (4B), Planet gear, then second set of Washers (4B). Use an alignment punch or similar tool to align roll pin holes on Spindle (1A) and Planet Shaft (4E).
NOTE: Do not hit Planet Gears (4F) when driving in Roll Pins (4G).
14. Drive new Roll Pin (4G) in aligned roll pin holes. Pin should be flush with OD of spindle.
15. Repeat Steps (11-14) for installation of two remaining Planet Gears (4F).
Cover Sub-Assembly
1. Grease O-Ring (6E) and insert in internal groove in Cover (6A).
2. Assemble Disengage Cap (6B) on Cover (6A) using two Hex Head Bolts (6C). Torque bolts to 70-80 in-lb (7.9- 9 Nm).
3. Insert Disengage Rod (6D) in hole in Cover (6A) until it touches inside of Disengage Cap (6B).
NOTE: Disengage Rod can be inserted either end first.
4. Grease Face of Thrust Washer (2) and place in Cover (6A) making sure tangs on washer seat into pockets in cover.
5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should be hand tight.
9. Place Input Carrier Sub-Assembly (3A) on Output Sun Gear (11) splines. Drop Input Sun (10) in mesh with planet gears for specific ratios, if required. (No timing required).
rease O-Ring (17) and insert in groove in Cover Sub-
10. G Assembly (6).
nstall Cover Sub-Assembly (6) in Ring Gear (1E) counter-
11. I bore and install Retaining Ring (6G) in groove in Ring Gear (1E).
ttach ID Tag (15) on unit using Drive Screws (16).
12. A
13. Check disconnect, roll and air check unit, leak check
brake, and record release pressure.
nsert Plastic Plug (12) if applicable.
14. I
Integral Brake Check
1. Using appropriate fittings, connect hydraulic line from hand pump to brake port.
2. Chec
3. Bl
k brake is set by trying to rotate Input Shaft (9). This can be accomplished by installing an appropriate tool (any tool that can locate on splines of Input Coupling (7), such as a mating splined shaft) into Input Coupling (7).
eed brake. Increase hydraulic pressure gradually while trying to rotate input until brake just starts to release. Note this pressure. Make sure pressure falls into appro­priate range below.
Main Assembly
NOTE: All components should receive a generous amount of lubri-
cant oil as they are being assembled.
1. Place Hub-Spindle Sub-Assembly on bench.
2. Grease O-Ring (18) and place it in groove of Hub (1D).
3. Place Ring Gear (1E) on Hub (1D). Align three shipping
Capscrew Holes on Hub (1D) and Ring Gear (1E).
nstall three shipping Capscrews (19) in ring gear and
4. I hub. Torque to 15-20 ft-lb (20-27 Nm).
5. Place External Retaining Ring (5) over 13T spline to the retaining groove on Input Shaft (9).
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over Input
Shaft (9) first, then install External Retaining Ring (5).
6. Using appropriate tool to install Retaining Ring (20) in groove on Output Sun (11).
7. Place Input Shaft (9) spline end into mesh with Internal Coupling (7) splines.
8. With modified spline end facing up, place Output Gear (11) in mesh with planet gears from Hub-Spindle Sub­Assembly.
BRAKE
CODE
A 200-260 13.7-17.9 B 170-220 11.7-15.1 C 140-185 9.6-12.7 D 130-155 8.9-10.6 E 115-145 7.9-9.9
4. Increase pressure to 1,000 psi and hold for 30 seconds to check for leaks. Repair leaks if necessary.
NOTE: Make sure brake re-engages when pressure is released.
NOTE: When done, make sure Input Coupling (7) is centered in
Spindle (1A) to make installation of motor possible without release of brake.
JUST RELEASE
PRESSURE RANGE
PSI BAR
31215031 3-21
Page 75
1A. Spindle 1B. Lip Seal 1C. Tapered Bearing 1D. Housing 1E. Ring Gear 1F. Bearing Nut 1G. Setscrew 1H. Stud 1K. Retaining Ring 1L. Spring
1M. Thrust Washer 1Q. Seal Boot
2. Th r us t S pa ce r 3A. Carrier 3B. Thrust Washer 3C. Needle Bearing 3E. Planet Shaft 3F. Planet Gear 4B. Thrust Washer
4C. Needle Bearing 4D. Thrust Spacer 4E. Planet Shaft 4F. Planet Gear 4G. Roll Pin 4H. Thrust Washer
5. R et a in i n g R i ng 6A. Cover 6B. Disengage Cap
6C. Bolt 6D. Dowel Pin 6E. O-Ring 6F. Pipe Plug 6G. Retaining Ring
7. C ou p li n g 8A. Brake Piston 8B. Pressure Plate 8C. Retaining Ring
8D. O-Ring 8E. Backup Ring 8F. O-Ring 8H. Backup Ring 8J. Brake Rotor 8K. Brake Stator 8L. Spring
9. I np u t S h a ft
10. Sun Gear
11. Sun Gear
12. Plastic Plug
15. ID Plate
16. Drive Screw
17. O-Ring
18. O-Ring
19. Bolt
20. Retaining Ring 21
. O-Ring Plug
SECTION 3 - CHASSIS & TURNTABLE
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3-22 31215031
Figure 3-19. Hub Assembly
Page 76
SECTION 3 - CHASSIS & TURNTABLE
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Figure 3-20. Bearing Cup Pressing Tool
Figure 3-21. Seal Pressing Tool
31215031 3-23
Page 77
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-22. Bearing Cup Pressing Tool
Figure 3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear
3-24 31215031
Page 78
SECTION 3 - CHASSIS & TURNTABLE
 







 !
Bias spring
Servo piston
Swashplate
Output
Shaft
Piston
Slipper
Cylinder
Block
Endcap
Shaft Seal
Bearing
Minimum Angle Stop
Va l v
e plate
3.4 FREE WHEELING OPTION
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)
1. Chock wheels securely if not on flat level surface.
2. Disconnect both drive hubs by inverting disconnect
caps in center of hubs.
3. If equipped, move steer/tow selector valve to float (tow) position by pulling valve knob out.
Engage Drive Motors and Brakes (Normal Operation)
1. If equipped, move steer/tow valve to steer position by pushing valve knob in.
2. Connect both drive hubs by inverting disconnect cap in center of hub.
3. Remov
e chocks from wheels as required.
3.5 DRIVE MOTOR
Description
Drive motors are low to medium power, two-position axial pis­ton motors incorporating an integral servo piston. They are designed for operation in open and closed circuit applications. The standard control is a direct acting single line hydraulic control. The integral servo piston controls motor displace­ment.
Motors are spring biased to maximum displacement and
ydraulically shifted to minimum displacement. Minimum and
h maximum displacement can be set with fixed internal stops. The large diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing.
Figure 3-25. Drive Motor Cross Section
31215031 3-25
Figure 3-24. Disconnecting Drive Hubs
Page 79
SECTION 3 - CHASSIS & TURNTABLE
1
2
3
Figure 3-26. Removing Shaft Seal
1. Snap Ring 2. Support Washer 3. Shaft Seal
Shaft Seal Replacement
REMOVAL
1. Remove snap ring (1) retaining shaft seal, and support
washer.
2. Remove support washer (2).
INSPECTION
Inspect new seal, motor housing seal bore, and sealing area on shaft for rust, wear, and contamination. Polish shaft and clean housing if necessary.
INSTALLATION
1. Cover shaft splines with an installation sleeve to protect
shaft seal during installation.
2. Install new shaft seal with cupped side facing motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal.
3. Install seal support washer.
4. Install snap ring.
5. Remove installation sleeve.
3. Carefully pry out shaft seal (3).
NOTE: To avoid damaging shaft during removal, install a large
sheet metal screw in chuck of a slide hammer. Drive screw in seal surface and use slide hammer to pull seal.
4. Discard seal.
3-26 31215031
Page 80
SECTION 3 - CHASSIS & TURNTABLE
2
6
9
11
1
4
8
10
12
5
3
7
13
(37 Nm)
27 ft.lbs.
11/ 16 in
(37 Nm)
27 ft.lbs.
11/ 16 in
(27 Nm)
20 ft.lbs.
5/8 in
1. Plug
2. Plug
3. Plug
4. O-ring
5. O-ring
6. O-ring
7. Spring
8. Spring
9. Spring
10. Washer
11. Washer
12. Shift Spool
13. Orifice Poppet
Figure 3-27. Loop Flushing Spool
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Loop Flushing Valve
REMOVAL
1. Remove plug (1) and (2) using an 11/16 in internal hex
wrench.
INSPECTION
Inspect new O-rings and the sealing area for rust, wear, or con­tamination. Check springs and poppet for wear.
INSTALLATION
1. Install orifice poppet (13).
2. Install shift spool (12).
3. Install spring retaining washers on springs (10 and 11).
4. Carefully install centering springs (7, 8, and 9).
5. Install new O-rings (6, 4, and 5).
6. Torque plug (3) to 20 ft-lb (27 Nm) using an 1/4 in hex
wrench.
orque plugs (2 and 1) to 27 ft-lb (37 Nm) using an 11/16
7. T in internal hex.
2. Remove plug (3) using a 1/4 in hex wrench.
3. Remove O-rings (4, 5, and 6).
4. Remove centering springs (7, 8, and 9) using pliers.
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).
31215031 3-27
Page 81
SECTION 3 - CHASSIS & TURNTABLE
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Troubleshooting
Item Description Action
Check oil level in reservoir and oil supply to motor.
Insufficient hydraulic fluid could lead to cavitation that would cause sys­tem noise.
Table 3-2. Excessive Noise and/or Vibration
Fill reservoir to proper level. Ensure oil supply to motor is adequate and lines are unobstructed.
Check for air in system. Air trapped in system lines or motor could result in cavitation that would
cause system noise.
Inspect output shaft couplings. A loose or incorrect shaft coupling will produce vibrations that could result
in system noise.
Inspect output shaft alignment. Misaligned shafts create excessive frictional vibration that could result in
system noise.
Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead
to system noise.
Table 3-3. System Operating Hot
Item Description Action
Check oil level in reservoir and oil supply to pump.
Inspect heat exchanger, (if equipped).
Check system relief valves. If a system relief valve becomes unseated for an extended period of time or
Insufficient amount of hydraulic fluid will not meet system cooling demands.
If heat exchanger fails, or becomes obstructed, it may not meet system cooling demands.
fails for any other reason, system could become overhe ated.
Table 3-4. No Shift or Slow to Start
Ensure all system lines and components are purged of air.
En s ur e co r re c t c o up l in g is u se d an d th a t i t fi t s p r op e rl y on s h af t.
Ensure shafts are properly aligned.
Replace hydraulic oil with appropriate fluid for operating conditions.
Fill reservoir to proper level.
Ensure heat exchanger is receiving adequate air flow and is in good operat­ing condition. Repair or replace as necessary.
Repair or replace any malfunctioning relief valves as applicable and verify loads on machine are not excessive.
Item Description Action
Ch e ck s ig n al l i ne to s e rv o co n tr o l port.
Check correct supply and drain ori­fices are properly installed and not obstructed.
Obstructed or restricted flow through servo control signal lines could result in slow shift or no shift motor conditions.
Supply and drain orifices determine motor shift. The smaller the orifice, the longer the time it takes to shift the motor. Obstruction also increases shift times.
Ensure signal lines are not obstructed or restricted and signal pressure is adequate to shi ft motor.
Ensure proper control orifices are installed in motor and not obstructed. Clean or replace as necessary.
3-28 31215031
Page 82
Disassembly
5
3
7
13
2
6
9
11
1
4
8
10
12
1. Plug
2. Plug
3. Plug
4. O-ring
5. O-ring
6. O-ring
7. Spring
8. Spring
9. Spring
10. Washer
11. Washer
12. Shift Spool
13. Orifice Poppet
Figure 3-28. Loop Flushing Spool
15
20161619171821
14
14. Lock Nut
15. O-ring Plug
16. Control Line Plug
17. Control Line Plug
18. Cavity Plug
19. Drain Plug
20. Drain Plug
21. Work Port Plug
Figure 3-29. Plugs, Fittings, and Speed Sensor
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SECTION 3 - CHASSIS & TURNTABLE
NOTE: Removal of endcap voids warranty.
Coat all moving parts with a film of clean hydraulic oil dur­ing assembly. This ensures parts will be lubricated during start-up.
Replace all O-Rings and gaskets.
It is recommended to replace all O-rings. Lightly lubricate O-rings with clean petroleum jelly before assembly.
8. Remove all fittings from unit. Discard any O-rings on fit­tings.
9. Using an 11/16 inch hex wrench, loosen speed sensor
1. Using a 11/16 in wrench remove plug (1) and (2).
2. Using a 5/8 in hex wrench remove plug (3).
3. Remove O-rings (4, 5, and 6).
4. Using pliers, remove centering springs (7, 8, and 9).
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).
31215031 3-29
lock nut (14) if equipped. Remove 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 internal hex wrench.
sing a 1/4 inch internal hex wrench, remove control
10. U line plugs (16, 17). Discard O-rings. Using a 3 mm hex wrench, remove cavity plug (18, if equipped with two­line control) from X2 cavity.
11. Using a 5/16 inch internal hex wrench, remove drain plugs (19, 20). Discard O-rings.
12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O­rings.
Page 83
SECTION 3 - CHASSIS & TURNTABLE
24
22
23
22. Screw
23. End Cap
24. O-ring
Figure 3-30. End Cap
26
28
30
292725
25. Valve Plate
26. End Cap
27. O-ring
28. O-ring
29. Bearing
30. Servo Spring
Figure 3-31. Valve Plate & Rear Shaft Bearing
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13. Using an 8 mm internal hex wrench, remove endcap­screws (22).
14. Remove endcap (23). Remove O-ring (24) from housing or endcap. When endcap screws are removed, pressure from servo spring will cause endcap to bind on shaft. Press down on portion of endcap covering servo piston and hold endcap level while removing.
DO NOT SCRATCH VALVE PLATE SURFACE.
15. Remove valve plate (25) and timing pin (26) from 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.
emove and discard O-rings (27, 28).
16. R
17. Remove rear shaft bearing (29) from endcap with a bear-
ing puller. Bearing may be difficult to remove with a puller. Try this as an alternative: Pack bearing cavity with heavy grease. After shaft is removed, insert it into bear­ing cavity and tap lightly with a soft mallet on the splined end. The grease will force the bearing out. Use caution not to drive bearing past the rear shaft journal as bearing may become trapped on shaft and damaged.
18. Remo
ve minimum angle stop and servo spring (30) from
housing.
3-30 31215031
Page 84
19. Turn housing on its side and remove cylinder kit assem-
31
31. Cylinder Kit Assembly
Figure 3-32. Cylinder Kit
32. Snap Ring
33. Support Washer
34. Shaft Se al
Figure 3-33. Shaft Seal
32
33
34
35. Inner Snap Ring
36. Snap Ring
37. Bearing
38. Shaft
Figure 3-34. Shaft & Front Bearing
38
37
36
35
39. Swashplate
40. Servo Piston
41. Piston Seal
42. O-ring
43. Journal Bearin gs
Figure 3-35. Swash Plate & Servo Piston
41
42
40
Lift here
39
43
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bly (31). Set assembly aside. Do not to scratch running surface.
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Grooves on surface of cylinder kit identify its displacement:
Table 3-5. Displacement Identifiers
# of Grooves Frame L Frame K
1 25 38
2 30 45
3 35 - -
emove inner snap ring (35) and shaft/bearing assembly.
21. R
22. Remove snap-ring (36) retaining shaft front bearing. Pull
bearing (37) off shaft (38).
20. Turn housing over and remove snap ring (32) retaining
31215031 3-31
shaft seal and support washer. Remove support washer (33) and carefully pry out shaft seal (34). Discard seal. To avoid damaging shaft during seal removal, install a large sheet metal screw in chuck of slide hammer. Drive screw into seal surface and use slide hammer to pull seal.
23. Turn housing over and remove swashplate (39) by lifting on end opposite servo lever.
emove servo piston (40). Remove piston seal (41) and
24. R O-ring (42) from servo piston. Discard seal and O-ring.
25. Remove journal bearings (43) from housing. Note loca­tion and orientation of each bearing for reassembly.
Page 85
SECTION 3 - CHASSIS & TURNTABLE
44. Piston
45. Slipper Retainer
46. Cylinder Block
47. Ball Guide
48. Hold- down Pins
49. Retaining Ring
50. Block Spring Washer
51. Spiral Retaining Ring
52. Block Spring
53. Inner Block Spring Washer
Figure 3-36. Cylinder Kit Disassembly
51
50
52
53
46
49
48
47
45
44
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28. Turn block over. Using a press, apply pressure on block spring washer (50) to compress the block spring. Com­press spring enough to safely remove the spiral retain­ing ring (51). While maintaining pressure, unwind the spiral retaining ring (51). Carefully release pressure and remove outer block spring washer (50), block spring (52), and inner block spring washer (53) from cylinder block.
Inspection
After disassembly, wash all parts (including end-cap and hous­ing) thoroughly with clean solvent and allow to air dry. Blow out oil passages in housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any rework or resurfacing.
PISTON
Inspect pistons for damage and discoloration. Discolored pis­tons may indicate excessive heat; do not reuse.
SLIPPERS
Inspect slipper running surfaces. Replace piston assemblies with scored or excessively rounded slipper edges. Measure
26. Remove pistons (44) and slipper retainer (45) from cylin­der block (46).
Pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number pistons and bores for reassembly if they are to be reused.
27. Remo
NOTE: Most repairs do not require block spring removal. Perform
RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAIN TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE SPIRAL RETAINING RING. RELEASE PRES­SURE SLOWLY AFTER RETAINING RING IS REMOVED.
3-32 31215031
ve ball guide (47), hold-down pins (48), and retain-
ing ring (49) from cylinder block.
this procedure only if you suspect block spring problems.
-
slipper foot thickness. Replace piston assemblies with exces­sively worn slippers. Check slipper axial end-play. Replace pis­ton assemblies with excessive end-play.
Minimum slipper foot thickness and maximum axial end-play
re given in table below.
a
Table 3-6. Slipper Foot Thickness & End Play
Measurement L Frame K Frame
Slipper Foot Thickness 2.71 mm
(0.11 in.)
Piston/Slipper End Play 0.15 mm
4.07 mm (0.16 in.)
(0.006 in.)
Page 86
SECTION 3 - CHASSIS & TURNTABLE
A
Table 3-7. Cylinder Block Measurements
Measurement L25 L30 L35 K38 K45
Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness 0.002
(0.0000079)
0.002
(0.0000079)
0.002
(0.0000079)
0.002
(0.0000079)
0.002
(0.0000079)
Slipper retainer
Ball guide
3.83 mm [0.151 in] min.
0.025 mm
[0.001 in]
0.0076 mm
[0.00030 in] convex max
LV
25.8 mm [1.015 in]
24.6 mm [0.969 in]
KV
Thickness equality side to side:
0.05 mm [0.002 in]
0.0025 mm
[0.0001 in]
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CYLINDER BLOCK
Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements.
BALL GUIDE AND SLIPPER RETAINER
Inspect ball guide and slipper retainer for damage, discolor­ation, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat. Do not reuse.
SWASHPLATE AND JOURNAL BEARINGS
Inspect running face, servo ball-joint, and swashplate journal surfaces for damage or excessive wear. Some material transfer may appear on these surfaces and is acceptable if surface con­dition meets specifications shown. Measure swashplate thick­ness from journals running face. Replace swashplate if damaged or worn beyond minimum specification. Replace swashplate if difference in thickness from one side to the other exceeds specification.
VALVE PL ATE
Condition of the valve plate is critical to efficiency of the motor. Inspect valve plate surfaces carefully for excessive wear, grooves, or scratches. Replace or resurface grooved or scratched valve plates. Measure valve plate thickness and replace if worn beyond minimum specification. Valve plates may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce thickness below mini­mum specification.
Inspect journal bearings for damage or excessive wear.
31215031 3-33
Replace journal bearings if scratched, warped, or excessively worn. The polymer wear layer must be smooth and intact.
Page 87
SECTION 3 - CHASSIS & TURNTABLE
3
2
1
3
1. O-ring
2. Piston Seal
3. Servo Piston
Figure 3-37. Servo Piston
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SHAFT BEARINGS
Inspect bearings for excessive wear or contamination. Rotate bearings while feeling for uneven movement. Bearings should spin smoothly and freely. Replace bearings that appear worn or do not rotate smoothly.
SHAFT
Inspect motor shaft for damage or excessive wear on output and block splines. Inspect bearing surfaces and sealing sur­face. Replace shafts with damaged or excessively worn splines, bearing surfaces, or sealing surfaces.
SERVO PISTON AND MINIMUM ANGLE STOP
Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace if necessary.
Assembly
1. Install new O-ring (1) and piston seal (2) to servo piston (3). Install piston seal over O-ring.
Installing piston seal stretches it, making it difficult to
stall servo piston in its bore. Allow 30 minutes for seal
in to relax after installation. To speed up seal relaxation, compress seal by installing piston head in servo cavity in the end-cap and let it stand for at least five minutes.
LOOP FLUSHING SPOOL
Inspect loop flushing spool for cracks or damage. Replace if necessary.
3-34 31215031
2. After piston seal has relaxed, lubricate and install servo
piston in housing bore. Align piston with ball socket fac­ing inside of housing.
RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAIN­TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL SPIRAL RETAINING RING. RELEASE PRES­SURE SLOWLY AFTER RETAINING RING IS INSTALLED.
Page 88
SECTION 3 - CHASSIS & TURNTABLE
7
6
5
4
8
9
10
12
11
4. Block Spring Washer
5. Block Spring
6. Outer Washer
7. Spiral Retaining Ring
8. Retaining Ring
9. Hold-down Pins
10. Ball Guide
11. Piston
12. Slipper Retainer
Figure 3-38. Cylinder Kit Assembly
14
13
13
13. Journal Bearings
14. Swash Plate
Figure 3-39. Swash Plate and Journal Bearing
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3. Install inner block spring washer (4), block spring (5), and outer washer (6) in cylinder block. Using a press, compress block spring enough to expose retaining ring groove. Wind spiral retaining ring (7) in cylinder block groove.
nstall journal bearings (13) in housing seats. Use assem-
6. I bly grease to keep bearings seated during assembly. Ensure locating nubs drop into seat cavities. If reusing bearings, install in original location and orientation. Lubricate journal bearings.
nstall swashplate (14) in housing. Tilt swashplate and
7. I guide servo lever ball into its socket in the servo piston rod. Ensure swashplate seats into journal bearings and moves freely. Lubricate running surface of swashplate.
urn block over and install retaining ring (8), hold-down
4. T pins (9), and ball guide (10) to cylinder block.
5. Install pistons (11) to slipper retainer (12). Install piston/ retainer assembly in cylinder block. Ensure concave sur­face of retainer seats on ball guide. If reusing pistons, install them in original block bores. Lubricate pistons, slippers, retainer, and ball guide before assembly. Set cylinder kit aside on a clean surface until needed.
31215031 3-35
Page 89
SECTION 3 - CHASSIS & TURNTABLE
16
15
17
18
15. Front Shaft Bearing
16. Shaft
17. Snap Rin g
18. Snap Rin g
Figure 3-40. Shaft and Front Bearing
19
19. Cylinder Kit
Figure 3-41. Cylinder Kit Installation
20
21
20. Servo Spring
21. Minimum Angle Stop
Figure 3-42. Servo Spring and Minimum Angle Stop
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8. Press front shaft bearing (15) on shaft (16). Press bearing on shaft with lettering facing out. Lubricate bearing roll­ers. Install snap-ring (17) on shaft.
10. Verify swashplate and bearings are properly seated. Install cylinder kit (19) on shaft. Install with slippers fac­ing swashplate. Rock the shaft to align block splines and slide cylinder kit into place. Orient motor with shaft pointing downward and verify cylinder kit, swashplate, journal bearings, and servo piston are secure and prop­erly installed.
ubricate and install servo spring (20) and minimum
11. L angle stop (21) in housing bore.
9. While holding swashplate in place, turn housing on its side. Install the install shaft/bearing assembly into hous­ing from flange end. Install snap-ring (18).
3-36 31215031
Page 90
SECTION 3 - CHASSIS & TURNTABLE
23
23
22
24
3 mm
[0.12 in]
2 mm
[0.08 in]
23
22
22. Rear Shaft Bearing
23. Timing Pin
24. Valve Plate
Figure 3-43. Valve Plate and Rear Bearing
26
25
8 mm
(47-61 Nm)
35-45 ft.lbs.
25. End Cap
26. Screw
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12. Press rear shaft bearing (22) in endcap. Install bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface.
15. Install endcap (25) on housing with endcap screws (26). Ensure endcap will properly seat to housing without interference. Improper assembly of internal compo­nents may prevent endcap from seating properly. Ensure O-rings seat properly when installing endcap.
13. Install timing pin (23) into its bore in the endcap. Install pin with groove facing toward or away from shaft. Press pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above endcap surface.
14. Install valve plate (24) on endcap. Install valve plate with yellow surface toward cylinder block. Align slot in valve plate with timing pin. Apply a liberal coat of assembly grease to endcap side of valve plate to keep it in place during installation.
Figure 3-44. End Cap
16. Using an 8 mm internal hex wrench, tighten endcap-
screws. Tighten screws in opposite corners slowly and evenly to compress the servo spring and properly seat the endcap. Torque end capscrews 35-45 ft-lb (47-61 Nm).
efore installing shaft seal, ensure shaft turns smoothly
17. B with less than 120 in-lb (13.5 Nm) of force. If shaft does not turn smoothly within specified maximum force, dis­assemble and check unit.
18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with cup side facing motor. Press seal in housing until it bottoms out. Press evenly to avoid binding and damaging seal. Install seal support washer (28) and snap ring (29).
31215031 3-37
Page 91
SECTION 3 - CHASSIS & TURNTABLE
29
28
27
27. Shaft Seal
28. Seal Support Washer
29. Snap Ring
  
  
  
  
  
  

39
40
34
30
41
37
36
33
42
38
35
32
31
(27 Nm)
20 ft.lbs.
5/8 in
(37 Nm)
(37 Nm)
27 ft.lbs.
27 ft.lbs.
11/ 16 in
11/16 in
30. Orifice Poppet
31. Shift Spool
32. Washer
33. Washer
34. Spring
35. Spring
36. Spring
37. O-ring
38. O-ring
39. O-ring
40. Plug
41. Plug
42. Plug
Figure 3-47. Loop Flushing Spool
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Figure 3-45. Shaft Seal
19. Install remaining plugs and fittings to housing. Refer to
drawing below for wrench sizes and installation torques.
1. Install shift spool (31).
2. Install spring retaining washers on springs (32 and 33).
3. Carefully install centering springs (34, 35, and 36).
4. Install new O-rings (37, 38, and 39).
5. Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27
Nm).
sing a 11/16 in wrench, torque plugs (41 and 42) to 27
6. U ft-lb (37 Nm).
Initial Start-up Procedures
Follow this procedure when starting-up a new motor or when installing a motor that has been removed.
Prior to installing the motor, inspect for damage incurred dur­ing shipping. Make certain all system components (reservoir,
3-38 31215031
Figure 3-46. Plugs and Fittings Installation
nstall orifice poppet (30).
20. I
hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.
ill reservoir with recommended hydraulic fluid. Always
1. F filter fluid through a 10 micron filter when pouring into the reservoir. Never reuse hydraulic fluid.
ill inlet line leading from pump to reservoir. Check inlet
2. F line for properly tightened fittings and be certain it is free of restrictions and air leaks.
ill pump and motor housing with clean hydraulic fluid.
3. F Pour filtered oil directly in upper most case drain port.
Page 92
SECTION 3 - CHASSIS & TURNTABLE






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4. To ensure pump and motor stay filled with oil, install case drain lines in upper most case drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres­sure gauge port of pump to monitor system pressure during start up.
6. While watching pressure gauge, run engine at lowest possible speed until system pressure builds to normal levels (minimum 160 psi [11 bar]). Once system pressure is established, increase to full operating speed. If system pressure is not maintained, shut down engine, deter­mine cause, and take corrective action.
7. Operate hydraulic system for at least fifteen minutes under light load conditions.
8. Check and adjust control settings as necessary after installation.
9. Shu
10. Check fluid level in reservoir. Add clean filtered fluid if
t down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.
necessary. Motor is now ready for operation.
3.6 STEER ADJUSTMENTS
NOTE: 2 Wheel Steering/2 Wheel Drive: Spindles do not stop on
cylinder stroke. Adjust steering stops as follows: Adjust item #1 to achieve 44° inside turn angles. Steer full left and adjust RH item #2 to contact axle. Steer full right and adjust LH item #2 to contact axle.
2 Wheel Steering/Four Wheel Drive: Spindles do not stop on cylinder stroke. Adjust steering stops as follows: Adjust item #1 to achieve 39° inside turn angles. Steer full left and adjust RH item #2 to contact axle. Steer full right and adjust LH item #2 to contact axle.
Figure 3-48. Steer Adjustments
31215031 3-39
Page 93
SECTION 3 - CHASSIS & TURNTABLE
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3.7 CHASSIS TILT INDICATOR SYSTEM
The Chassis Tilt Indicator System measures the turntable angle with respect to level ground. The control system compares the reading to a pre-set turntable tilt angle value. When the machine is in transport position refer Transport Position Sens­ing System procedure for detail, it speed until it tilts more than 8.0 degree, then the system will limit the drive speed to maximum displacement mode (slow drive speed).
However, when the machine is out of transport position and
e turntable tilts more than the pre-set value, the boom func-
th tions can only run in creep speed mode and with the drive
ction disabled. The operator must return the machine into
fun transport mode to continue drive the machine.
By factory default, the tilt sensor is 4 degree, but it need to select between 4.0 degree, and 3.0 degree by JLG hand held Analyzer. By factory default, the tilt sensor pre-set value for 660AJ (7 ft.) is 3 degree.
Previously, it could be selected by JLG hand held analyzer so
at the machine could drive at maximum displacement mode
th (slow speed) when out of transport position and tilted beyond pre-set turntable tilt angle value. By regulations, this will not have allowed for ANSI or CE markets.
can travel at up to maximum
pre-set value for 660AJ (8 ft.)
3.9 TRANSPORT POSITION SENSING SYSTEM
The transport position sensing system consists of two limit switches capable of recognizing position of the tower and main boom. The tower elevation switch is activated when the tower upright is raised 40 in. to 42 in. from stowed position and reset when lowered 25 in. to 30 in. from activated position. The main boom elevation switch is activated when the main boom reaches 0 to 5 degree above horizontal and reset when the main boom is lowered 4 to 9 degree below horizontal.
This system uses switches with "positive opening" contacts. These swit to be physically broken to the open position when the machine is in the "unsafe" condition. When the machine is in the "safe" condition, the switch must be allowed to return to the closed state. This requires switch arm cams to be posi­tioned in a way that the switch arm is actuated while the mac while the machine is in the "safe" condition.
The position of the articulated ji used to control the following systems:
1. Be
2. Dr
ches are used in a way that requires switch contacts
hine is in the "unsafe" condition and the switch arm is free
b not considered. This system
yond Transport - Drive Speed Cutback System
ive/Steer - Boom Function Interlock System
3.8 DRIVE ORIENTATION SYSTEM
The Drive Orientation System (DOS) is intended to indicate to the operator conditions that could make the direction of movement of the chassis different than the direction of move­ment of the drive/steer control handle.
The system indicates to the operator the need to match the
ack and white directional arrows on the platform control
bl panel to the arrows on the chassis. The system uses a proximity switch mounted on the hydraulic swivel, an indicator light and a spring return override switch on the platform display panel. The proximity switch trips when the turntable is swing +/- 45 degrees off center of the normal driving position. This occurs roughly when the main boom is swing past a rear tire.
When the turntable is in the no boom between the rear tires, no indications or interlocks are made. When the machine is actively driving when the turnta­ble is swing past the switch point, the sy drive/steer is released. When drive is initiated with the boom swing past the switch point, the DOS indicator will flash, and the drive/steer functions will be disabled. The operator must engage the DOS override switch to enable Drive/steer (high drive will remain disabled). When the DOS is enabled, the DOS indicator will be illuminated continuously, and a 3-second enable timer will be started and will continue for 3 seconds after the end of the last drive/steer command. If the timer expires, the DOS override switch must be re-engaged to enable drive/steer.
rmal drive position with the
stem is ignored until
3.10 BEYOND TRANSPORT - DRIVE SPEED CUTBACK SYSTEM
When the boom is positioned beyond the transport position as described in Transport Position Sensing System, the drive motors are automatically restricted to their maximum dis­placement position (slow speed). See the Tilt Indicator System
or interaction with the tilt sensor.
f
3.11 DRIVE/STEER – BOOM FUNCTION INTERLOCK SYSTEM
The Drive/Steer - Boom Function Interlock System uses the Transport Position Sensing System to sense when the boom is out of the transport position. All controls are simultaneously functional when the booms are within the transport position as on the standard machine.
When the boom is beyond the transport position, the control functions interlocked to prevent simultaneous operation of any boom function with drive/steer. The first function set to be operated while in this mode, becomes the master function set. In other words, while operating drive/steer functions the boom functions are inoperable. Likewise, while operating boom functions drive/steer functions are not in operation.
3-40 31215031
Page 94
SECTION 3 - CHASSIS & TURNTABLE
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3.12 OSCILLATING AXLE SYSTEM
The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground when traveling on rough terrain.
The oscillating axle incorporates two lockout cylinders con­nected between the frame and the axle. The lockout cylinders
et axle oscillation when pilot pressure allows flow through the
l axle cylinder holding valves.
When the turntable moved off center, as recognized by a cam valve in the hydraulic swivel coupling, pilot pressure removed from the axle cylinder holding valves and the cylinders are locked.
When the turntable moved back to have been locked, the cylinders may not fully release until drive is actuated.
center after the cylinders
3.13 DRIVE SYSTEM
The drive system consists of one variable displacement closed loop pump, four variable displacement piston motors, gear reduction hubs, and a traction control manifold that includes three flow dividers/combiners.
Drive speed is varied by a combination of drive pump dis­placement, engine & integrated motor/generator speed, and motor displacement. Traction control is full-time and is pres­ent in all drive modes. There are three drive modes that can be selected at the platform console. The functionality of the drive system is dependent on the position of the boom (In Transport or Out of Transport, refer toSection 3.9, Transport Position Sensing System and Section 3.10, Beyond Transport - Drive Speed Cutback System for a detailed description). The follow­ing table describes how the system works in each drive mode.
Table 3-8. Drive Mode Speeds
Drive
Boom
Position
In
Tra n sp o r t
Selection
(Toggle Switch
Location on the
Platform Console)
Max Speed High – 2600 RPM 3.8
Mid-Engine Mid – 1800 RPM 0.09
Max Torque High – 2600 RPM 1.3
Engine Speed
when Drive
Control is Activated
Approx. Max Speed (MPH)
Out of
Tra ns po r t
Max Speed High – 2600 RPM 0.4
Mid-Engine Mid– 1800 RPM 0.4
Max Torque High – 2600 RPM 0.4
31215031 3-41
Page 95
SECTION 3 - CHASSIS & TURNTABLE
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3.14 SWING DRIVE
Roll, Leak And Brake Testing
Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using the Brake Leak Test procedure below or by tightening the 12 bolts into the piston through the end plate (See Brake Dis­assembly Procedure).
NOTE: Bolts
Roll Test
The purpose of the roll test is to determine if the unit's gears
e rotating freely and properly. You should be able to rotate
ar the gears in your unit by applying constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be con­cerned if the gears in your unit seem to roll hard as long as they r Housing (6) and remove the test fixtures.
Leak Test (Main Unit)
The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your air checker starts to fall after the unit has been pressur­ized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o-rings or gaskets meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, o­ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 minutes.
must be removed while performing brake release test.
oll with consistency. Release the pressure at the Brake
Tightening and Torquing Bolts
If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque.
The following steps describe how to tighten and torque bolts or socket head capscrews in a bolt circle.
1. Tighten (but do not torque) bolt “A" until snug.
2. Go to the opposite side of the bolt circle and tighten bolt
“B” until equally snug.
3. Crisscross around the bolt circle and tighten remaining bolts.
w use a torque wrench to apply the specified torque
4. No to bolt “A”.
5. Using the same sequence, crisscross around the bolt cir­cle and apply an equal torque to the remaining bolts.
Brake Test
The brake test must be performed with the Motor removed and the Bolts through Brake Test Plate and torque to 80 - 100 ft. lbs. (108-135 Nm). Install Roll Checking Tool (T-212731) and apply 210 psi (14 bar) to the o-ring port in the side of the Brake Hous­ing. The roll checking fixture should roll freely. Increase the pressur
NOTE: Failure to perform this lest may result in damaged or inef-
Brake Test Plate (T-214404) installed. Install the Hex
e to 3000 psi (207 bar) and perform the Roll Test.
fective brake parts.
3-42 31215031
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SECTION 3 - CHASSIS & TURNTABLE
31
1P
35
32
23
22
21
6
1P. O-ring Plug
6. Hydraulic Brake
21. Hex Bolt
22. Lockwasher
23. Plug
30. Elbow Fitting
31. Hydraulic Motor
32. Motor Control Valve
35. Hydraulic Tubing
Figure 3-49. Motor Control Valve
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Motor Control Valve Disassembly
NOTE: Refer to Figure 3-49.
1. Place unit on bench with the motor end up.
2. Remove O-ring Plug (1P) and drain the oil from the gear-
box.
3. Remov
e Hydraulic Tubing Assembly (35) by loosening
fittings on both ends of tube with a wrench.
4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32).
5. Remove O-ring Plugs (23) from Motor Control Valve (32).
6. Remove Motor Control Valve (32) from Motor (31) by
removing the four Bolts (21) and washers (22).
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Page 97
SECTION 3 - CHASSIS & TURNTABLE
6
8K
8J
8K
8K
8K
8J
8K
8J
8J
8L
26
31
28
29
8A
6. Brake Housing 8A. Brake Piston 8L. Spring 8J. Rotors 8K. Stator
26. O-ring
28. Lift Lug
29. Hex Bolt
31. Motor
Figure 3-50. Motor and Brake
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Motor and Brake Disassembly
NOTE: Refer to Figure 3-50.
1. With unit resting on bench with Motor (31) end up, loosen Hex Bolts (29) and remove Lift Lugs (28) from the Motor (31).
ull Motor (31) straight up and remove Motor (31) from
2. P Brake Housing (6).
3. Remove O-ring (26) from between Motor (31) and Brake Housing (6).
4. Remove the Springs (8L) from the piston.
5. Apply less than 50 psi (3.45 bar) air to the “brake port” to
remove Brake Piston (8A).
THE PISTON MAY MOVE QUICKLY. EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
6. Remove Rotors (8J) and Stators (8K) from Brake Housing (6).
3-44 31215031
Page 98
Main Drive Disassembly
44
8
20
12
6
11
5A
4
5
3F
11
2
13
1G
1A
Hub-Shaft Subassembly
Carrier Subassembly
1A. Output Shaft (Pinion) 1G. Housing
2. Internal Gear 3F. Carrier subassembly
4. Ring Gear
5. O-ring 5A. O-ring
6. Brake Housing
8. Sun Gear
11. Thrust Washer
12. Bolt
13. Dowel Pin
20. Pipe Plug
44. Ring
Figure 3-51. Main Drive Assembly
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NOTE: Refer to Figure 3-51.
SECTION 3 - CHASSIS & TURNTABLE
emove Thrust Washer (11) from between Brake Hous-
5. R ing (6) and Carrier Subassembly.
6. Remove Ring Gear (4) from Housing (1G).
1. Remove Sun Gear (8) with Retaining Ring (44) inside.
2. With the unit resting on the Output Shaft (Pinion) (1A),
remove the Bolts (12) from the Brake Housing (6).
3. Remov
4. Remove O-ring (5A) from between Brake Housing (6)
e the Brake Housing (6) from the main assembly.
and Ring Gear (4).
7. Remove O-ring (5) from between Ring Gear (4) and Housing (1G).
8. Remove Carrier Sub-Assembly.
9. Remove Thrust Washer (11) from between Carrier Sub-
Assembly and Internal Gear (2).
10. Remove Internal Gear (2).
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Page 99
SECTION 3 - CHASSIS & TURNTABLE
1A
1B
1D
1C
1G
1F
1E
1H
1I
1A. Output Shaft 1B. Lip Seal 1C. Bearing Cup 1D. Bearing Cone 1E. Bearing Cone
1F. Bearing Cup 1G. Housing 1H. Thrust Washer 1I. Retaining Ring
Figure 3-52. Hub Shaft
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Hub-Shaft Disassembly
NOTE: Refer to Figure 3-52.
1. Using retaining ring pliers remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard.
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
2. Remove Thrust Washer (1H).
3. While supporting the Housing (1G) on the Output Shaft
(1A) end, press the Output Shaft (1A) out of the Housing (1G).
NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by
the Bearing Cone (1D) during this step.
4. Remo
5. Use a bearing puller to remove the Bearing Cone (1D)
6. Bearing Cups (1C & 1F) will remain in Housing (1G).
ve the Bearing Cone (1E) from the Housing (1G).
from the Shaft (1A).
3-46 31215031
Page 100
SECTION 3 - CHASSIS & TURNTABLE
3B
3B
3C
3D
3C
3F
3G
3E
3A
3A. Carrier 3B. Thrust Washers 3C. Needle Bearing 3D. Spacer
3E. Planet Shaft 3F. Cluster Gear 3G. Roll Pin
Figure 3-53. Carrier
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Carrier Disassembly
NOTE: Refer to Figure 3-53.
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.
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-
age to the carrier could occur when the Planet Shaft is removed.
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).
3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).
4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F).
5. Repeat Steps 1 thru 4 for the remaining two Cluster Gears (3F).
31215031 3-47
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