choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
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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-
-
BHYDRAULIC 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
-
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.
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get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
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
FuelDiesel
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 RPM1000
Low RPM1800
High RPM2500
Alternator60 Amp, belt drive
Battery950 Cold Cranking Amps,
Fuel Consu mption0.65 GPH (2.46 LPH)
Horsepower49
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)
1-231215031
Page 22
SECTION 1 - SPECIFICATIONS
SizeIN355/55D 62536x14-20FA
Load R angeG*
Ply Rating14N/A
Tire PressureFoam-FilledSolid-Boss
* Load Capacity - 11,800 lb (4404 kg) - Static
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1.5TIRES
1.6TORQUE REQUIREMENTS
DescriptionTor que V alue ( Dry )
Bearing To Chassis190 ft-lb (260 Nm)50/600*
Bearing To Turntable190 ft-lb (260 Nm)50/600*
Wire R ope15 ft- lb (20 Nm)150
Wheel Lugs170 ft- lb (231 Nm)150
Engine Mounting Bolts165 ft-lb (231 Nm)A/R
Engine Manifold Mounting Bolts30 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
312150311-3
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 Gravity0.877
Pour Point, Max
-40° F (-40° C)
Flash Point, Min.
330° F (166° C)
Viscosit y
at 40° C33 cSt
at 100° C6.6 cSt
at 100° F169 SUS
at 212° F48 SUS
cp at -20° F6,200
Viscosity Index140
Table 1-6. Quintolubric 888-46 Specs
TypeSynthetic Fire Resistant Biodegradable
Density
0.92 g/cm
3
Pour Point<-30° C (<-22° F)
Flash Point300° C (572° F)
Fire Point360° 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 Index190
Table 1-7. Mobil EAL 224H
TypeSynthetic Biodegradable
ISO Viscosity Grade32/46
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)
Weight7.64 lb. per gal.
(0.9 kg per liter)
Viscosit y
at 40° C37 cSt
at 100° C8.4 cSt
Viscosity Index 213
NOTE:Must be stored above 32° F (14° C)
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1.7HYDRAULIC 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° C2700
at 40° C55 cSt
at 100° C9.3 cSt
Viscosity Index152
1-431215031
10W30
29.0
7.35
-46° F (-43° C)
442° F (228° C)
Page 24
Table 1-8. Mobil EAL H 46 Specs
TypeSynthetic Biodegradable
ISO Viscosity Grade46
Density0.874 @ 15° C (59° F)
Pour Point-49° F (-45°C)
Flash Point500° F (260° C)
Operating Temp.-29 to 93° C (-20 to 200 ° F)
Weight7.64 lb/gal
(0.9 kg/L)
Viscosit y
at 40° C48.8 cSt
at 100° C7.8 cSt
Viscos ity I ndex145
Table 1-9. Mobil EAL 46 Specs
TypeSynthetic Biodegradable
ISO Viscosity Grade46
Density0.93 @ 15° C (59° F)
Pour Point-27° F (-33° C)
Flash Point568° F (298° C)
Operating Temp.-29 to 93° C (-20 to 200° F)
Viscosity
at 40° C43.3 cSt
at 100° C7.7 cSt
Viscosity Index149
Table 1-10. Exxon Univis HVI 26 Specs
Specific Gravity32.1
Pour Point-76° F (-60° C)
Flash Point217° F (103° C)
Viscosit y
at 40° C25.8 cSt
at 100° C9.3 cSt
Viscosity Index376
NOTE:Mobil/Exxon recommends this oil be checked on a yearly basis for
viscosity.
SECTION 1 - SPECIFICATIONS
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1.8CRITICAL 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.
ComponentsLBS.KG.
Tire and Wheel (Standard Foam
Filled)
Engine
Counte rweight
Platform
355/55D345440200
Deutz D20111222554
Deutz TD2.9L1250567
Ford 873396
600AJ61002767
Narrow Frame80503651
30x4815168
30x6016575
36x7219990
36x96230105
312150311-5
Page 25
Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011
SECTION 1 - SPECIFICATIONS
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1-631215031
Page 26
Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9
SECTION 1 - SPECIFICATIONS
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312150311-7
Page 27
Figure 1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425
SECTION 1 - SPECIFICATIONS
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1-831215031
Page 28
SECTION 1 - SPECIFICATIONS
Table 1-11. Lubrication Specifications.
KEYSPECIFICATIONS
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
EOEngine (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.
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1.9OPERATOR 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.
312150311-9
• 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
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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.
1-1031215031
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
.
312150311-11
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.
1-1231215031
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.
312150311-13
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.
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
312150311-15
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
SizeTPIBolt 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
InSq InLBI N - L B [N.m]IN - LB [N.m]I N - L B [N.m]
4400.11200.00604
480.11200.00661
6320.13800.00909
400.13800.01015
8320.16400.01400
360.16400.014741320435
10240.19000.017501580607
320.19000.020001800688
1/4200.25000.031828601431612915
280.25000.036432801641914817
InSq InLBFT-LB [N.m]FT-LB [N.m]F T - L B [N.m]
5/16180.31250.05244720253520252025
240.31250.05805220253525352025
3/8160.37500.07757000456040553550
240.37500.08787900507045603550
7/16140.43750.10639550709565905070
200.43750.1187107008011070956080
1/2130.50000.1419127501051459513080110
200.50000.15991440012016511015090120
9/16120.56250.182016400155210140190115155
180.56250.203018250170230155210130175
5/8110.62500.226020350210285190260160220
180.62500.256023000240325215290180245
3/4100.75000.334030100375510340460280380
160.75000.373033600420570380515315430
7/890.87500.462041600605825545740455620
140.87500.509045800670910600815500680
181.00000.60605150086011707701045645875
121.00000.663059700995135589512157451015
1 1/871.12500.76306870012901755116015809651310
121.12500.856077000144519651300177010851475
1 1/471.25000.969087200181524701635222513651855
121.25001.073096600201527401810246015102055
1 3/861.37501.1550104000238532452145291517852430
121.37501.3150118100270536802435331020302760
1 1/261.50001.4050126500316543052845387023703225
121.50001.5800142200355548353200435026653625
Torque
(Loctite® 262
Vibra-TITE
™
K=0.15
™
or
131)
NOTES:1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
1-1631215031
Page 36
SECTION 1 - SPECIFICATIONS
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SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
SizeTPIBolt Dia
InSq InLBIN - L B [N.m]IN - LB [N.m]I N - L B [N.m]
4400.11200.0060438070.8
480.11200.0066142080.9
6320.13800.00909580141.5
400.13800.01015610141.6
8320.16400.01400900252.8
360.16400.01474940262.9
10240.19000.017501120364.1
320.19000.020001285424.7
1/4200.25000.03182020869.7809
280.25000.036423209911.19511
InSq InLBF T- LB [N.m]FT-LB [N.m]F T- LB [N.m]
5/16180.31250.05243340152014191520
240.31250.05803700152015211520
3/8160.37500.07754940253525342534
240.37500.08785600304028382534
7/16140.43750.10636800405540543548
200.43750.11877550456044604054
1/2130.50000.14199050659060825575
200.50000.1599107007510071976588
9/16120.56250.182011600901208711880109
180.56250.2030129501051459713290122
5/8110.62500.226014400130175120163115156
180.62500.256016300145195136185125170
3/4100.75000.334021300225305213290200272
160.75000.373023800255345238324225306
7/890.87500.462029400365495343466320435
140.87500.509032400400545378514355483
181.00000.606038600545740515700480653
121.00000.663042200600815563765530721
1 1/871.12500.763042300675920635863595809
121.12500.8560475007551025713969670911
1 1/471.25000.969053800955130089712198401142
121.25001.0730596001055143599313519301265
1 3/861.37501.155064100125017001175159811001496
121.37501.315073000142019301338182012551707
1 1/261.50001.405078000166022601560212214651992
121.50001.580087700186525351754238516452237
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 FASTENERS5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
312150311-17
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*
SizeTPIBolt Dia
InSq InLBI N - L B [N.m]I N - L B [N.m]I N - L B [N.m]
4400.11200.00604
480.11200.00661
6320.13800.00909
400.13800.01015
8320.16400.01400
360.16400.014741320374
10240.19000.017501580516
320.19000.020001800587
1/4200.25000.031828601221411413
280.25000.036432801391613115
InSq InLBF T- LB [N.m]FT-LB [N.m]F T- LB [N.m]
5/16180.31250.05244720202520252025
240.31250.05805220253520252025
3/8160.37500.07757000355035503550
240.37500.08787900405540553550
7/16140.43750.10639550608055755070
200.43750.118710700659060806080
1/2130.50000.141912750901208511580110
200.50000.1599144001001359513090120
9/16120.56250.182016400130175125170115155
180.56250.203018250145195135185130175
5/8110.62500.226020350180245170230160220
180.62500.256023000205280190260180245
3/4100.75000.334030100320435
160.75000.373033600355485335455315430
7/890.87500.462041600515700485660455620
140.87500.509045800570775535730500680
181.00000.606051500730995685930645875
121.00000.663059700845115079510807451015
1 1/871.12500.76306870010951490103014009651310
121.12500.856077000122516651155157010851475
1 1/471.25000.969087200154521001455198013651855
121.25001.073096600171023251610219015102055
1 3/861.37501.1550104000202527551905259017852430
121.37501.3150118100230031302165294520302760
1 1/261.50001.4050126500269036602530344023703225
121.50001.5800142200302041052845387026653625
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
300410280380
Torque
(Loctite® 262
Vibra-TITE
™
K=0.15
131)
™
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
1-1831215031
Page 38
SECTION 1 - SPECIFICATIONS
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SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SOCKET HEAD CAP SCREWS
SizeTPIBolt Dia
InSq InLBIN - L B [N.m]I N - L B [N.m]I N - L B [N.m]
4400.11200.00604
480.11200.00661
6320.13800.00909
400.13800.01015
8320.16400.01400
360.16400.01474
10240.19000.01750
320.19000.02000
1/4200.25000.031828601221411413
280.25000.036432801391613115
InSq InLBF T- LB [N.m]FT-LB [N.m]FT -L B [N.m]
5/16180.31250.05244720202520252025
240.31250.05805220253520252025
3/8160.37500.07757000355035503550
240.37500.08787900405540553550
7/16140.43750.10639550608055755070
200.43750.118710700659060806080
1/2130.50000.141912750901208511580110
200.50000.1599144001001359513090120
9/16120.56250.182016400130175125170115155
180.56250.203018250145195135185130175
5/8110.62500.226020350180245170230160220
180.62500.256023000205280190260180245
3/4100.75000.334030100320435
160.75000.373033600355485335455315430
7/890.87500.462041600515700485660455620
140.87500.509045800570775535730500680
181.00000.606051500730995685930645875
121.00000.663059700845115079510807451015
1 1/871.12500.76306870010951490103014009651310
121.12500.856077000122516651155157010851475
1 1/471.25000.969087200154521001455198013651855
121.25001.073096600171023251610219015102055
1 3/861.37501.1550104000202527551905259017852430
121.37501.3150118100230031302165294520302760
1 1/261.50001.4050126500269036602530344023703225
121.50001.5800142200302041052845387026653625
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
300415280380
Torque
(Loctite® 262
Vibra-TITE
™
K=0.15
131)
™
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
312150311-19
Page 39
SECTION 1 - SPECIFICATIONS
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SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
SOCKET HEAD CAP SCREWS
SizeTPIBolt Dia
InSq InLBI N - L B [N.m]I N - L B [N.m]I N - L B [N.m]
4400.11200.00604
480.11200.00661
6320.13800.00909
400.13800.01015
8320.16400.01400
360.16400.01474
10240.19000.01750
320.19000.02000
1/4200.25000.031828601221411413
280.25000.036432801391613115
InSq InLBF T- LB [N.m]FT-LB [N.m]F T-L B [N.m]
5/16180.31250.05244720202520252025
240.31250.05805220253520252025
3/8160.37500.07757000355035503550
240.37500.08787900405540553550
7/16140.43750.10639550608055755070
200.43750.118710700659060806080
1/2130.50000.141912750901208511580110
200.50000.1599144001001359513090120
9/16120.56250.182016400130175125170115155
180.56250.203018250145195135185130175
5/8110.62500.226020350180245170230160220
180.62500.256023000205280190260180245
3/4100.75000.334030100320435
160.75000.373033600355485335455315430
7/890.87500.462041600515700485660455620
140.87500.509045800570775535730500680
181.00000.606051500730995685930645875
121.00000.663059700845115079510807451015
1 1/871.12500.76306870010951490103014009651310
121.12500.856077000122516651155157010851475
1 1/471.25000.969087200154521001455198013651855
121.25001.073096600171023251610219015102055
1 3/861.37501.1550104000202527551905259017852430
121.37501.3150118100230031302165294520302760
1 1/261.50001.4050126500269036602530344023703225
121.50001.5800142200302041052845387026653625
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
300415280380
Torque
(Loctite® 262
Vibra-TITE
™
K=0.15
131)
™
or
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
1-2031215031
Page 40
SECTION 1 - SPECIFICATIONS
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Metric Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
312150311-21
Page 41
SECTION 1 - SPECIFICATIONS
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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*
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
1-2231215031
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
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
312150311-23
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,
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS5000059K
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.
1-2431215031
Page 44
SECTION 2. GENERAL
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SECTION 2 - GENERAL
2.1MACHINE 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
312150312-1
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.
2.2SERVICE 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 OperatorUser or OperatorOperation and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic
Owner, Dealer, or UserQualified JLG Mechanic
Owner, Dealer, or User
Owner, Dealer, or UserQualified JLG MechanicService 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.
2-231215031
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.
312150312-3
Page 47
SECTION 2 - GENERAL
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2.3LUBRICATION 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.
2.4CYLINDER 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.
2-431215031
Page 48
Table 2-2. Cylinder Drift
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Cylinder Bore
Diameter
inchesmminchesmm
376.20.0260.66
3.5890.0190.48
4101.60.0150.38
51270.0090.22
6152.40.0060.15
7177.80.0050.13
8203.20.0040.10
9228.60.0030.08
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.
2.5PINS 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.
2.6WELDING 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
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.).
312150312-5
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 Weldments1,2,41,2,4
Hose/Cable Carrier Installations1,2,9,121,2,9,12
Pivot Pins and Pin Retainers1,21,2
Sheaves, Sheave Pins1,21,2
Bearings1,21,2
Wea r Pa ds1,21,2
Covers or Shi elds1,21,2
Extend/Retract Chain or Cable Systems1,2,31,2,3
Boom Assembly
Platform Assembly
Platform1,2
Railing11,2
Gate1,51,5
Floor11,2
Rotator5, 9, 155, 9, 15
Lanyard Anchorage Point1,2,10
Turntable Assembly
Swing Bearing1,2,141,2,3,13,14
Oil Coupling99
Swing D rive Syste m1111
Tur nt ab l e L oc k1,2,51,2,5
Hood, Hood Props, Hood Latches5
Chassis Assembly
Tires16,17,1816,17,18
Wheel Nuts/Bolts1515
Wheel Bearings14, 2414, 24
Oscillating Axle/Lockout Cylinder Systems5,8
Extendable Axle Systems5,85,8
Steer Components1,21,2
Spindle Thrust Bearing/Washers1,2
Drive Hubs1111
1
2
Inspection
Annual
(Yearly)
14
1,2,10
1,2,5
3
2-631215031
Page 50
SECTION 2 - GENERAL
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Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Pre-Delivery
or Frequent
Inspection
Functions/Controls
Platform Controls5, 66
Ground Controls5, 66
Function Control Locks, Guards, or Detents1, 55
Foots witch55
Emergency Stop Switches (Ground & Platform)55
Function Limit or Cutout Switch Systems55
Drive Brakes55
Swing Br akes55
Auxiliar y Power5
Power Syste m
Engine Idle, Throttle, and RPM33
Engine Fluids (Oil, Coolant, Fuel)9, 1111
Air/Fuel Filter1, 77
Exhaust System1, 99
Batteries1, 919
Battery Fluid1111
Battery Charger55
Fuel Reservoir, Cap, and Breather1, 2, 5
Hydraulic/Electric System
Hydraulic Pumps1,2,91,2,9
Hydraulic Cylinders1, 2, 7, 91,2,9
Cylinder Attachment Pins and Pin Retainers1,2, 91,2
Hydraulic Hoses, Lines, and Fittings1,2,9,121,2,9,12
Hydraulic Reservoir, Cap, and Breather1, 2, 5, 91,5
Hydraulic Filter1, 7, 97
Hydraulic Flui d7,117,11
Electrical Connections1, 2020
Instruments, Gauges, Switches, Lights, Horn1
General
Operation and Safety Manuals in Storage Box2121
ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI and ANSI Export ONLY)2121
Capacity Decals Installed, Secure, Legible2121
All Decals/Placards Installed, Secure, Legible2121
1
2
Inspection
Annual
(Yearly)
5
1,5
5,23
3
312150312-7
Page 51
SECTION 2 - GENERAL
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Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Annual Machine Inspection Due21
No Unauthorized Modifications or Additions2121
All Relevant Safety Publications Incorporated2121
General Structural Condition and Welds2,42,4
All Fasteners, Pins, Shields, and Covers1,21,2
Grease and Lubricate to Specifications2222
Function Test of All Systems2121, 22
Paint and Appearance77
Stamp Inspection Date on Frame22
Notify JLG of Machine Ownership22
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
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
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 Stage2n d Stage3rd 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)
312150313-1
Page 56
SECTION 3 - CHASSIS & TURNTABLE
MAE18170
BLEEDER VALVE
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3.2OSCILLATING 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.
3-231215031
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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3-431215031
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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312150313-5
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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3-631215031
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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312150313-7
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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3-831215031
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
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
312150313-13
Page 67
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
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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3-1431215031
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
312150313-15
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.
3-1631215031
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
312150313-17
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
3-1831215031
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
312150313-19
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
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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.
3-2031215031
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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.
Figure 3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear
3-2431215031
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
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3.4FREE 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.
3.5DRIVE 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
312150313-25
Figure 3-24. Disconnecting Drive Hubs
Page 79
SECTION 3 - CHASSIS & TURNTABLE
1
2
3
Figure 3-26. Removing Shaft Seal
1. Snap Ring2. Support Washer3. Shaft Seal
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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.
3-2631215031
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).
312150313-27
Page 81
SECTION 3 - CHASSIS & TURNTABLE
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Troubleshooting
ItemDescriptionAction
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
ItemDescriptionAction
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.
ItemDescriptionAction
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.
3-2831215031
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).
312150313-29
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.
3-3031215031
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 GroovesFrame LFrame K
12538
23045
335- -
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
312150313-31
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.
3-3231215031
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
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.
312150313-33
Replace journal bearings if scratched, warped, or excessively
worn. The polymer wear layer must be smooth and intact.
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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.
3-3431215031
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.
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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.
312150313-35
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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).
3-3631215031
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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).
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).
312150313-37
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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,
3-3831215031
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.
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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.
3.6STEER 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
312150313-39
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SECTION 3 - CHASSIS & TURNTABLE
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3.7CHASSIS 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.)
3.9TRANSPORT 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
3.8DRIVE 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.
3-4031215031
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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 SpeedHigh – 2600 RPM3.8
Mid-EngineMid – 1800 RPM0.09
Max TorqueHigh – 2600 RPM1.3
Engine Speed
when Drive
Control is Activated
Approx. Max
Speed (MPH)
Out of
Tra ns po r t
Max SpeedHigh – 2600 RPM0.4
Mid-EngineMid– 1800 RPM0.4
Max TorqueHigh – 2600 RPM0.4
312150313-41
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.
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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