JLG 600AJ Service and Maintenance Manual

/

Go to Discount-Equipment.com to order your parts

Service and Maintenance Manual

Model

600AJ

PVC 2001

31215031

October 10, 2019 - Rev A

AS/NZS

Discount-Equipment.com is your online resource for quality parts

Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101

Need parts?

& equipment.

Click on this link: http://www.discount-equipm

ent.com/category/5443-parts/ and

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.

We sell worldwide for the br

Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,

Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,

Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,

Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,

Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-

Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,

Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,

Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,

ands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,

Rol-Air, Small Line, Wanco, Yanmar

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

Go to Discount-Equipment.com to order your parts

INTRODUCTION

AGENERAL

This section contains general safety precautions which must
be observed during maintenance of the Mobile Elevating
Work Platform (MEWP). It is of utmost importance that mainte­nance personnel pay strict attention to these warnings and
pr

ecautions to avoid possible injury to themselves or others,
or damage to the equipment. A maintenance program must
be followed to ensure the machine is safe to operate.

MODIFICATION OR ALTERATION OF A MOBIL E ELEVATI NG WORK P LATF ORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFAC
TURER.

The specific precautions to be observed during maintenance
are inserted at the appropriate point in the manual. These pre­cautions are, for the most part, t
ing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when
e

ngaging in maintenance of equipment. Always be conscious
of weight. Never attempt to move heavy parts without the aid
of a mechanical device. Do not allow heavy objects to rest in
an unstable position. When raising a portion of the equip­ment, ensure adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL
ITY OF THE OWNER/OPERATOR.

hose that apply when servic-

-

B HYDRAULIC SYSTEM SAFETY

It should be noted the machines hydraulic systems operate at
extremely high potentially dangerous pressures. Every effort
should be made to relieve any system pressure prior to discon­necting or removing any portion of the system.

CMAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.

• USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT
ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED,
REPLACEMENT PARTS OR COMPONENTS MUST BE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC­TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND

URE AT ALL OTHER TIMES.

SEC

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER­FORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT­TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
MACHINE AND IN SERVICE MANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL­ANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

-

BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER­FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
POWER CONTROLS.

• ALWAYS DISCONNECT BATTERY DURING REPLACEMENT OF
ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL­VENTS.

31215031 A-1

INTRODUCTION

Go to Discount-Equipment.com to order your parts

Original Issue A - October 10, 2019

REVISON LOG

A-2 31215031

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

SECTION 1 - SPECIFICATIONS

1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.8 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.9 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.10 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.11 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Metric Fastener Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

31215031 i

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

DO NOT Do the Following When Welding on JLG Equipment:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires And Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Hub-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Spindle-Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Output Planet Gear Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Spindle - Brake Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Integral Brake Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.4 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.6 Steer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.7 Chassis Tilt Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.9 Transport Position Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.10 Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.11 Drive/Steer – Boom Function Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.12 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.13 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

ii 31215031

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

3.14 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Roll, Leak And Brake Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Main Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Hub-Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3.15 Swing Hub Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3.16 Swing Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Procedure For Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3.17 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3.18 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

3.19 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3.20 Deutz D2.9 L4 (T4F) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Change Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

3.21 Deutz D2011 (T4i) Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Clean Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

3.22 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3.23 Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3.24 Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

3.25 Bio Fuel In Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

3.26 Ford Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

3.27 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124

SECTION 4 - BOOM & PLATFORM

4.1 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Platform Load Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 Ground Control Keyswitch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.4 Function Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.5 SkyGuard Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.6 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

31215031 iii

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

4.7 Rotator and Slave Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.8 Main Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.9 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Replace Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.10 Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.11 Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.12 Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4.13 Jib Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.14 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.15 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Testing Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Testing Actuator for Internal Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4.16 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

4.17 Platform Load Sensing System- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

4.18 Skyguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

4.19 Bolt-on External Fall Arrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

. . . . . . . . . . . . . . . . . . . 4-42

iv 31215031

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.1 Lubricating O-rings In The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spray Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Systems With Double Acting Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Systems With Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder. . . . . . . . . . . . . . . . . . 5-3

Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cylinders With Dual Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Main Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Upright Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Upright Level Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Tower Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Tower Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Tower Telescope Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5 Hydraulic Cylinder repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Tower Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Upright Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Tower Boom Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Platform Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5.6 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Inspect Parts For Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Placing Pump Back Into Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

31215031 v

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

5.7 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Ports and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Remove and Install FNR and NFPE Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Remove and Install FNR and NFPE Control Orifices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Shaft Seal and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5.8 Hydraulic Component Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

5.9 Main Valve Block Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Upper (Main) Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

2-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

4-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

5.10 Platform Valve Block Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Platform Level Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Platform Level Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Articulating Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

5.11 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

SECTION 6 - JLG CONTROL SYSTEM

6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Connect JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.2 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6.5 MSSO (Machine Safety System Override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6.6 LSS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Testing & Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

6.7 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

vi 31215031

TABLE OF CONTENTS

Go to Discount-Equipment.com to order your parts

SECTION NO. TITLE PAGE NO.

7.3 Applying Silicone Dielectric Compound Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.4 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Micro-Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Mini Fit Jr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Mini Fit Sr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Carling Switch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.7 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Telematics-Ready (TCU) Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.8 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7.9 Wiring Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7.10 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

31215031 vii

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-2. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3-1. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2. Axle Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Axle Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . 3-6

3-5. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . 3-7

3-6. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . 3-8

3-7. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 3-9

3-8. Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-9. Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-10. Steering Installation (7ft/2.1m Wide Machines) - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-11. Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-12. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-13. Torque Hub Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-14. Output Carrier Disassemb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-15. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-16. Hub Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-17. Spindle Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-18. Torque Hub Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-19. Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-20. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-21. Seal Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-22. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-24. Disconnecting Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-25. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-26. Removing Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-27. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-28. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-29. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-30. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-31. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-32. Cylinder Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-33. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-34. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-35. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-36. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-37. Servo Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-38. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-39. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-40. Shaft and Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-41. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-42. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-43. Valve Plate and Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-44. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-45. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-46. Plugs and Fittings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-47. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-48. Steer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-49. Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-50. Motor and Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-51. Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-52. Hub Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

. . . . . . . . . . . . . . . . . . 3-36

viii 31215031

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

3-53. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-54. Swing Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-55. Swing Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-56. Swing Bearing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3-57. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-58. Swing Bearing Tolerance Measurement Location & Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-59. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3-60. Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

3-61. Rotary Coupling - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

3-62. Rotary Coupling - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

3-63. Rotary Coupling Port Location - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

3-64. Rotary Coupling Port Location - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3-65. Generator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-66. Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-67. Blow Out Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-68. Generator Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3-69. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

3-70. Deutz D2.9 L4 (T4F) Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

3-71. Deutz D2.9 L4 (T4F) Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3-72. Deutz 2.9 T4F Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3-73. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3-74. Deutz D2011 (T4i) Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

3-75. Deutz D2011 (T4i) Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

3-76. Deutz Dipstick Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

3-77. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

3-78. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

3-79. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

3-80. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

3-81. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

3-82. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

3-83. EMR 2 Engine Plug Pin Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

3-84. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

3-85. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

3-86. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

3-87. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3-88. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

3-89. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

3-90. Ford Engine Installation Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

3-91. Ford Engine Installation Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

3-92. Ford Engine Installation Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3-93. Ford Engine Installation Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110

3-94. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124

4-1. Location of Components Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-3. Rotator and Leveling Cylinder Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3. Rotator and Leveling Cylinder Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-4. Main Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-5. Main Boom Assembly Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-6. Tower Upright Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Tower Boom Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-8. Tower Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-9. Tower Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-10. Tower Boom Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-11. Jib Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-12. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-13. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

4-14. Actuator Bleed Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

. . . . . . . . . . . . . . . . . . . . . . 4-18

31215031 ix

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

4-15. Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-16. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

5-1. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Hydraulic Cylinder Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-3. Telescope and Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4. Leveling Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-5. Plunger Valve Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-6. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-7. Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-8. Tower Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-9. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-10. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-11. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-12. Upright Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-13. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-14. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-15. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-16. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-17. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-18. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-19. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-20. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-21. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-22. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-23. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-24. Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-25. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-26. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-27. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-28. Main Boom Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-29. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-30. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-31. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-32. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-33. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-34. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-35. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-36. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-37. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-38. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-39. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-40. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-41. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-42. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-43. Main Boom Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-44. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-45. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-46. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-47. Wear Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-48. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-49. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-50. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-51. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-52. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-53. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-54. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-55. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

x 31215031

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

5-56. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-57. Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-58. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-59. Tower Boom Telescope Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-60. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-61. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-62. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-63. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-64. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-65. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-66. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-67. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-68. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-69. Seating Tapered Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-70. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-71. Platform Level (Slave) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-71. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-72. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-73. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-74. Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-75. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

5-76. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

5-77. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

5-78. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

5-79. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-80. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-81. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-82. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-83. Hydrolock Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-84. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-85. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-86. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-87. Removing Spanner Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-88. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-89. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5-90. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-91. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-92. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-93. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-94. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-95. Piston Seal and Wear Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-96. Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-97. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-98. Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-99. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-100. Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

5-101. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5-102. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5-103. Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5-104. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-105. Charge Pump Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5-106. Main Control Valve - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

5-107. Main Control Valve - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

5-108. Location of Components - Platform Control Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

5-109. 2-Wheel Steer (2WS) Hydraulic Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

5-110. 2-Wheel Steer (2WS) Hydraulic Schematic 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

5-111. 4-Wheel Steer (4WS) Hydraulic Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

31215031 xi

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

5-112. 4-Wheel Steer (4WS) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

5-113. 2-Wheel Drive (2WD) Hydraulic Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

5-114. 2-Wheel Drive (2WD) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

5-115. 4-Wheel Drive (4WD) Hydraulic Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

5-116. 4-Wheel Drive (4WD) Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. ADE Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-3. Analyzer Flow Chart Software Version P6.30 - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-4. Analyzer Flow Chart Software Version P6.30 - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5. Analyzer Flow Chart Software Version P6.30 - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-6. Analyzer Flow Chart Software Version P6.30 - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-7. Analyzer Flow Chart Software Version P6.30 - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-8. Analyzer Flow Chart Software Version P6.30 - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-9. Analyzer Flow Chart Software Version P6.30 - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-10. Control Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6-11. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

6-12. Ground Control Module Pin Connections 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

6-13. Ground Control Module Pin Connections 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

6-14. Platform Control Module Pin Connections 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68

6-15. Platform Control Module Pin Connections 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69

6-16. Platform Control Module (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-10. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-18. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-19. Telematics Gateway Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-20. Telematics Gateway Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-21. Electrical Components 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-22. Electrical Components 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-23. Platform Console Box SkyGuard - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-24. Platform Console Box SkyGuard - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-25. Platform Console Box with SkyGuard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-26. Platform Valve Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-27. Main Boom Harness without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-28. Main Boom Harness with Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-29. Tower Boom Cable Harness without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7-30. Tower Boom Cable Harness with Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7-31. Main Valve Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7-32. Main Valve Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-33. Main Valve Harness (China Market). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-34. Deutz D2011 (T4i) Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7-35. Deutz D2011 (T4i) Engine Harness - Sheet 1 of 2 (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7-36. Deutz D2011 (T4i) Engine Harness - Sheet 2 of 2 (China Market) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

. . . . . . . . . . . . . . . . . . 7-25

xii 31215031

LIST OF FIGURES

Go to Discount-Equipment.com to order your parts

FIGURE NO. TITLE PAGE NO.

7-37. Deutz TD2.9L4 (T4F) Engine harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-38. Ford Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7-39. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L, 

MSG425 Engines - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7-40. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L, 

MSG425 Engines - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-41. Electrical Schematic - Sheet 1 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-42. Electrical Schematic - Sheet 2 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-43. Electrical Schematic - Sheet 3 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

7-44. Electrical Schematic - Sheet 4 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-45. Electrical Schematic - Sheet 5 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

7-46. Electrical Schematic - Sheet 6 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-47. Electrical Schematic - Sheet 7 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-48. Electrical Schematic - Sheet 8 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

7-49. Electrical Schematic - Sheet 9 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

7-50. Electrical Schematic - Sheet 10 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

7-51. Electrical Schematic - Sheet 11 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

7-52. Electrical Schematic - Sheet 12 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

7-53. Electrical Schematic - Sheet 13 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

7-54. Electrical Schematic - Sheet 14 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

7-55. Electrical Schematic - Sheet 15 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

7-56. Electrical Schematic - Sheet 16 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

7-57. Electrical Schematic - Sheet 17 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

7-58. Electrical Schematic - Sheet 18 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

31215031 xiii

LIST OF TABLES

Go to Discount-Equipment.com to order your parts

TABLE NO. TITLE PAGE NO.

1-1 Deutz TD 2.9L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Ford DF 2.5L, MSG 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 Mobilfluid 424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-5 Mobile DTE 10 Excel 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-6 Quintolubric 888-46 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-7 Mobil EAL 224H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-8 Mobil EAL H 46 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-9 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-10 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-11 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-3 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-4 No Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-7 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-8 Drive Mode Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-9 Coupling Port Information Table - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-10 Coupling Port Information Table - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-11 Engine Fault Codes (Deutz Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

3-12 Fault Code Cross Reference List (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

3-13 CAN to DTC Cross Reference (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117

4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-2 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

5-1 Hydraulic Pump Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-2 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-2 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-3 Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-4 Machine Configuration Programming Information (Software Version P6.30) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-5 Machine Configuration Programming Settings (Software Version P6.30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6-6 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

6-8 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

6-9 SkyGlazier Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6-10 Pipe Rack Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6-11 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

6-12 Fault Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

xvi 31215031

Discount-Equipment.com is your online resource for quality parts

Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101

Need parts?

& equipment.

Click on this link: http://www.discount-equipm

ent.com/category/5443-parts/ and

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.

We sell worldwide for the br

Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,

Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,

Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,

Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,

Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-

Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,

Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,

Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,

ands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,

Rol-Air, Small Line, Wanco, Yanmar

SECTION 1. SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SECTION 1 - SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Machine Specifications

Maximum Work Load (Capacity) - ANSI

Un r es t ri c te d : 500 lb (227 kg)

Maximum Work Load (Capacity) - CE & Australia

Un r es t ri c te d : 500 lb (230 kg)

Maximum Operating Slope ANSI/CE/AUS - 4°

China - 5°

7ft Chassis - ANSI /AUS - 3°

7ft Chassis - China- 5°

Maximum Travel Grade, Stowed Position
(Gradeability)

2W D 
4W D

Maximum Travel Grade, Stowed Position
(Side Slope)

Turning Radius - (Outside)

2W S 
4W S

ANSI/CE/AUS - 4°

China - 5°

7ft Chassis - ANSI /AUS - 3°

7ft Chassis - China- 5°

17 ft. 8 in. (5.38 m)
11 ft. 8 in. (3.56 m)

30%
45%

1.2 DIMENSIONAL DATA

Machine Dimensional Data

Machine Height (Stowed) 8 ft. 5 in. (2.57 m)

Machine Length (Stowed) 29 ft. (8.80 m)

Machine Width (by tire size)
355/55D-625
41/18LLx22.5X625 (turf)

Wheelbase 8 ft. 2 in. (2.49 m)

Ground Clearance 11.7 in. (0.29 m)

Platform Height 60 ft. 7 in. (18.47 m)

Horizontal Reach 39 ft. 9 in. (12.10 m)

Tai l S wi n g 0 in. (0 m)

98 in. (2.49 m)

100 in. (2.54 m)

Turning Radius - (Outside

2W S 
4W S

Turning Radius - (Inside)

2W S 
4W S

Turning Radius - (Inside) 7 ft Chassis

2W S 
4W S

Maximum Tire Load: 12,500 lb (5670 kg)

Ground Bearing Pressure



60 0 A J

600AJ - 7 ft Chassis

Maximum Drive Speed 4.25 MPH (6.84 KM/hr.)

Gross Machine Weight (Approximate)
2W S 
4W S 
7 f t C ha s si s

) 7 ft Chassis

16 ft. 6 in. (5.03 m)

11 ft. 2 in. (3.4 m)

11 ft. 5 in. (3.48 m)

5 ft. 6 in. (1.68 m)

12 ft. 2 in. (3.71 m)

5 ft. 7 in. (1.7 m)

77 psi (5.5 kg/cm2)

94 psi (6.6 kg/cm

22,240 lb (10,088 kg)
22,740 lb (10,315 kg)
24,000 lb (10,886 kg)

2

)

31215031 1-1

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1.3 CAPACITIES

Fuel Tank 30 Gallons (113.6 L)

Hydraulic Oil Tank 30.6 Gallons (115.8 L)

Hydraulic System (Including Tank) 40 Gallons (151.4 L)

Tor q ue H ub, D r iv e

Engine Crankcase
D eu t z D 2 01 1 L0 4
D eu t z T D 2 . 9 L

Swing Hub, Drive 32 ounces (0.9L)

*Torque hubs should be one half full of lubricant.

*

20 ounces (0.6L)

11 quarts (10.5 L)

2.4 Gallon (8.9 L) w/Filter

1.4 ENGINE DATA

Table 1-1. Deutz TD 2.9L Specifications

Fuel Ultra Low Sulfur Diesel (15 ppm)

Output 67 hp (50 kW)

Tor q u e 173 ft.lbs. (234 Nm) @ 1800rpm

Oil Capacity (Crankcase) 2.4 Gallon (8.9 L) w/Filter

Cooli ng Syst em 3.3 Gallon (12.5 L)

Low RPM 1200 ±50 rpm

High RPM 2600 ±50 rpm

Alternator 95 Amp

Fuel Co nsump tion 0.65 GPH (2.46 LPH)

Table 1-3. Ford DF 2.5L, MSG 425

Fuel Gasoline/LP Gas

Oil Capacity 7 qt (6.6 L)

Coola nt Capa city 0 . 63 G al l on ( 2. 4 L)

Low RPM 1000 ±50 rpm

High RPM 3200 ±50 rpm

Alternator 150 Amp

Starter 64.4 Amp @ 3574 rpm

Fan Rat io 1:3

Fuel Consum ption
G as o li n e
LP

Max Output (Power)
G as o li n e
LP

Max Output (Torque)
G as o li n e
LP

142 ft. lbs. (192 Nm) @ 2400 RPM
145 ft. lbs. (197 Nm) @ 2400 RPM

1 GPH (3.79 LPH)

5.34 lb/h(2.42 Kg/h)

84HP @3200
80HP @3200

Fuel Diesel

Oil Capacity
Co o li n g S y st e m
Cr a nk c as e 
Tot a l C ap a ci t y

Idle RPM 1000

Low RPM 1800

High RPM 2500

Alternator 60 Amp, belt drive

Battery 950 Cold Cranking Amps,

Fuel Consu mption 0.65 GPH (2.46 LPH)

Horsepower 49

Table 1-2. Deutz D2011L04

11 Quarts (10.5 L) w/Filter

20

5 Minutes Reserve Capacity, 12 VDC

5 Quarts (4.5 L)

16 Quarts (15 L)

1-2 31215031

SECTION 1 - SPECIFICATIONS

Size IN355/55D 625 36x14-20FA

Load R ange G *

Ply Rating 14 N/A

Tire Pressure Foam-Filled Solid-Boss

* Load Capacity - 11,800 lb (4404 kg) - Static

Go to Discount-Equipment.com to order your parts

1.5 TIRES

1.6 TORQUE REQUIREMENTS

Description Tor que V alue ( Dry )

Bearing To Chassis 190 ft-lb (260 Nm) 50/600*

Bearing To Turntable 190 ft-lb (260 Nm) 50/600*

Wire R ope 15 ft- lb (20 Nm) 150

Wheel Lugs 170 ft- lb (231 Nm) 150

Engine Mounting Bolts 165 ft-lb (231 Nm) A/R

Engine Manifold Mounting Bolts 30 ft-lb (42 Nm) A/R

*Check swing bearing bolts after first 50 hours of operation and every 600 hours
thereafter. (See Swing Bearing in Section 3.)

Interval

Hours

31215031 1-3

SECTION 1 - SPECIFICATIONS

Hydraulic System Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° F to + 180° F (-18° C to +83° C) 10W

+0° F to + 210° F (-18° C to +99° C) 10W-20, 10W-30

+50° F to + 210° F (+10° C to +99° C) 20W-20

Table 1-5. Mobile DTE 10 Excel 32

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max

-40° F (-40° C)

Flash Point, Min.

330° F (166° C)

Viscosit y

at 40° C 33 cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 212° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

Table 1-6. Quintolubric 888-46 Specs

Type Synthetic Fire Resistant Biodegradable

Density

0.92 g/cm

3

Pour Point <-30° C (<-22° F)

Flash Point 300° C (572° F)

Fire Point 360° C (680° F)

Auto Ignition Temperature >450° C (842° F)

Viscosit y

at 0° C (32° F) 320 cSt

at 20° C (68° F) 109 cSt

at 40° C (104° F) 47.5 cSt

at 100° C (212° F) 9.5 cSt

Viscosity Index 190

Table 1-7. Mobil EAL 224H

Type Synthetic Biodegradable

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max - 25° F (-3 2° C)

Flash Point, Min. 428° F (220° C)

Operating Temp. 0 to 180° F (-17 to 162° C)

Weight 7.64 lb. per gal.

(0.9 kg per liter)

Viscosit y

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

NOTE: Must be stored above 32° F (14° C)

Go to Discount-Equipment.com to order your parts

1.7 HYDRAULIC OIL

NOTE: Hydraulic oils must have anti-wear qualities at least to API

Service Classification GL-3, and sufficient chemical stabil­ity for mobile hydraulic system service. JLG Industries rec­ommends standard UTTO which has an SAE viscosity
index of 152.

NOTE: When temperatures remain below 20° F (-7° C), JLG Indus-

tries recommends the use of Premium Hydraulic Fluid.

NOTE: Aside from JLG recommendations, it is not advisable to

mix oils of different brands or types. They may not contain
required additives or be of comparable viscosities. If use of
hydraulic oil other than standard UTTO is desired, contact
JLG Industries for proper recommendations.

Table 1-4. Mobilfluid 424

SAE Grade

Gravity, API

Density, lb/Gal. 60° F

Pour Point , Max

Flash Point, Min.

Viscosity

Brookfield, cP at -18° C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

1-4 31215031

10W30

29.0

7.35

-46° F (-43° C)

442° F (228° C)

Table 1-8. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Density 0.874 @ 15° C (59° F)

Pour Point -49° F (-45°C)

Flash Point 500° F (260° C)

Operating Temp. -29 to 93° C (-20 to 200 ° F)

Weight 7.64 lb/gal

(0.9 kg/L)

Viscosit y

at 40° C 48.8 cSt

at 100° C 7.8 cSt

Viscos ity I ndex 145

Table 1-9. Mobil EAL 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Density 0.93 @ 15° C (59° F)

Pour Point -27° F (-33° C)

Flash Point 568° F (298° C)

Operating Temp. -29 to 93° C (-20 to 200° F)

Viscosity

at 40° C 43.3 cSt

at 100° C 7.7 cSt

Viscosity Index 149

Table 1-10. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76° F (-60° C)

Flash Point 217° F (103° C)

Viscosit y

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends this oil be checked on a yearly basis for

viscosity.

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1.8 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR
SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT
MODIFY THE MEWP IN ANY WAY TO AFFECT STABILITY.

Components LBS. KG.

Tire and Wheel (Standard Foam
Filled)

Engine

Counte rweight

Platform

355/55D345 440 200

Deutz D2011 1222 554

Deutz TD2.9L 1250 567

Ford 873 396

600AJ 6100 2767

Narrow Frame 8050 3651

30x48 151 68

30x60 165 75

36x72 199 90

36x96 230 105

31215031 1-5

Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1-6 31215031

Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

31215031 1-7

Figure 1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1-8 31215031

SECTION 1 - SPECIFICATIONS

Table 1-11. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).

Excellent water resistance and adhesive qualities, and being of extreme
pressure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or

MIL-Spec MIL-L-2105

HO Hydraulic Oil. Refer Section 1.7, Hydraulic Oil.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API

CC/ CD cl ass , M IL-L- 21 04 B/M IL- L-2 104 C.

Go to Discount-Equipment.com to order your parts

1.9 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 1-1.,

Figure 1-2. and Figure 1-3.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR­MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.

2. Wheel Bearings (If equipped)

•Lube Point(s) - Repack

• Capacity - A/R

•Lube - MPG

• Interval - Every 2 years or 1200 hours of operation.

3. S

wing Drive Hub

1. Swing Bearing

• Lube Point(s) - 1 Grease Fittings

• Capacity - A/R

•Lube - MPG

• Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access. Apply grease and rotate in 90
degree intervals until bearing is completely lubricated.

31215031 1-9

• Lube Point(s) - Level/Fill Plug

• Capacity - 43 oz. (1.3 L)

•Lube - 90w80 Gear Oil

• Interval - Check level every 3 months or 150 hrs of opera­tion; change every 2 years or 1200 hours of operation.

SECTION 1 - SPECIFICATIONS

NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION

Go to Discount-Equipment.com to order your parts

4. Wheel Drive Hub

• Lube Point(s) - Level/Fill Plug

• Capacity - 20 oz. (0.6 L)

•Lube - EPGL

• Interval - Check level every 3 months or 150 hrs of opera­tion; change every 2 years or 1200 hours of operation.

5. Hydraulic Return Filter

6. Hydraulic Charge Filter

• Interval - Change after first 50 hrs. and every 6 months or
300 hrs. thereafter, or as shown by Condition Indicator.

7. Hy

draulic Tank

Lube Point(s) - Fill Cap

• Lube Point (s) - Fill Cap

• Capacity: 
Tank - 30.6 gal. (115.8 L);
System - 40 gal. (151.4 L);

•Lube - HO

• Interval - Check Level daily; Change every 2 years or 1200
hours of operation.

• Interval - Change after first 50 hrs. and every 6 months or
300 hrs. thereafter or as shown by Condition Indicator.

1-10 31215031

SECTION 1 - SPECIFICATIONS

MINIMUM OIL
LEVEL

MAXIMUM OIL
LEVEL

Go to Discount-Equipment.com to order your parts

8. A. Oil Change w/Filter - Deutz 2011

• Lube Point(s) - Fill Cap/Spin-on Element

• Capacity - 11 Quarts Crankcase; 5 Quarts Cooler

•Lube - EO

• Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accordance with
engine manual.

B. Oil Change w/Filter - Deutz D2.9

• Lube Point(s) - Fill Cap/Spin-on Element

• Capacity - 9.6 Quarts (9.0 L) Crankcase and Filter

•Lube - EO

• Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

.

31215031 1-11

SECTION 1 - SPECIFICATIONS

MAE18190

Go to Discount-Equipment.com to order your parts

9. Oil Change w/Filter - Ford

• Lube Point(s) - Fill Cap/Spin-on Element

• Interval - Every 3 months or 300 hours of operation
Comments - Check level daily/Change in accordance with
engine manual.

. Fuel Filter - Deutz

10. A

(On Engine)

B. Fuel Filter - Deutz TD2.9 (On Turntable)

• Lube Point(s) - Replaceable Element

• Interval - Change in accordance with engine manual

C. Fuel Filter - Deutz TD2.9 (On Engine)

• On Engine:
Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation.

• Lube Point(s) - Replaceable Element
Interval - Change in accordance with engine manual.

1-12 31215031

SECTION 1 - SPECIFICATIONS

MAE16880

FUEL FILTER

MAE17720

Go to Discount-Equipment.com to order your parts

11. A. Fuel Filter - Ford (On Engine)



B. Air Filter - Deutz D2.9

• Lube Point(s) - Replaceable Element

• Interval - Every 6 months or 300 hours of operation or as
shown by condition indicator.

C. Air Filter - Ford

• Lube Point(s) - Replaceable Element

• Interval - Every 6 months or 300 hours of operation.

12. A. Air Filter (Deutz 2011)

• Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator.

• Lube Point(s) - Replaceable Element

• Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator.

31215031 1-13

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1.10 THREAD LOCKING COMPOUND

JLG PN

0100011

1001095650

0100019
0100071

NOTE: Loct ite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.

Loctite

242
243
271
262

®

™

™

™

™

ND Industries Description

Vibra-TITE™121
Vibra-TITE™122
Vibra-TITE™140
Vibra-TITE™131

Medium Strength (Blue)
Medium Strength (Blue)

High Strength (Red)

Medium - High Strength (Red)

1-14 31215031

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

1.11 TORQUE CHARTS

SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

T o r q u e

Tensile

Size TPI Bolt Dia

In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB F T - L B [N.m] F T - L B [N.m] FT - L B [N.m] FT - L B [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Stress

Area

Clamp

Load

T o r q u e

(Dry)

T o r q u e

Lubricated

(Loctite® 242

271

Vibra-TITE

111 or 140)

™

or

™

or

™

T o r q u e

(Loctite® 262

Vibra-TITE

™

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

31215031 1-15

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

T o r q u e

Size TPI Bolt Dia

Tensile

Stress Area

Clamp

Load

Torque

( D r y o r L o c t i t e ® 2 6 3 )

K=0.20

(Loctite® 242

Vibra-TITE

™

or 271™ or

™

1 1 1 or 1 4 0 )

K=0.18

In Sq In LB I N - L B [N.m] IN - LB [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 43 5

10 24 0.1900 0.01750 1580 60 7

32 0.1900 0.02000 1800 68 8

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] F T - L B [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 262

Vibra-TITE

™

K=0.15

™

or

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

1-16 31215031

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] IN - LB [N.m] I N - L B [N.m]

4 40 0.1120 0.00604 380 7 0.8

48 0.1120 0.00661 420 8 0.9

6 32 0.1380 0.00909 580 14 1.5

40 0.1380 0.01015 610 14 1.6

8 32 0.1640 0.01400 900 25 2.8

36 0.1640 0.01474 940 26 2.9

10 24 0.1900 0.01750 1120 36 4.1

32 0.1900 0.02000 1285 42 4.7

1/4 20 0.2500 0.0318 2020 86 9.7 80 9

28 0.2500 0.0364 2320 99 11.1 95 11

In Sq In LB F T- LB [N.m] FT-LB [N.m] F T- LB [N.m]

5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20

24 0.3125 0.0580 3700 15 20 15 21 15 20

3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34

24 0.3750 0.0878 5600 30 40 28 38 25 34

7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48

20 0.4375 0.1187 7550 45 60 44 60 40 54

1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75

20 0.5000 0.1599 10700 75 100 71 97 65 88

9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109

18 0.5625 0.2030 12950 105 145 97 132 90 122

5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156

18 0.6250 0.2560 16300 145 195 136 185 125 170

3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272

16 0.7500 0.3730 23800 255 345 238 324 225 306

7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435

14 0.8750 0.5090 32400 400 545 378 514 355 483

1 8 1.0000 0.6060 38600 545 740 515 700 480 653

12 1.0000 0.6630 42200 600 815 563 765 530 721

1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809

12 1.1250 0.8560 47500 755 1025 713 969 670 911

1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142

12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265

1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496

12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707

1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992

12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

Tensile

Stress Area

Clamp

Load

Torque

(Dry)

K=0.17

(Loctite® 242

Vibra-TITE

T o r q u e

™

or 271™ or

™

111 or 140)

K=0.16

Torque

(Loctite® 262

Vibra-TITE

™

K=0.15

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

31215031 1-17

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Size TPI Bolt Dia

In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 37 4

10 24 0.1900 0.01750 1580 51 6

32 0.1900 0.02000 1800 58 7

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB F T- LB [N.m] FT-LB [N.m] F T- LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile

Stress Area

Clamp

Load

Torque

( D r y o r L o c t i t e ® 2 6 3 )

K=0.17

(Loctite® 242

Vibra-TITE

T o r q u e

™

or 271™ or

™

111 or 140)

K=0.16

300 410 280 380

Torque

(Loctite® 262

Vibra-TITE

™

K=0.15

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

1-18 31215031

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAP SCREWS

Size TPI Bolt Dia

In Sq In LB IN - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB F T- LB [N.m] FT-LB [N.m] FT -L B [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile

Stress Area

Clamp

Load See

Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

T o r q u e

™

or 271™ or

™

111 or 140) or

Precoat® 85 K=0.16

300 415 280 380

Torque

(Loctite® 262

Vibra-TITE

™

K=0.15

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2.

ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * AS

SEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. 
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

31215031 1-19

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS

Size TPI Bolt Dia

In Sq In LB I N - L B [N.m] I N - L B [N.m] I N - L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB F T- LB [N.m] FT-LB [N.m] F T-L B [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile

Stress Area

Clamp

Load See

Note 4

Torque

(Dry) K=0.17

(Loctite® 242

Vibra-TITE

T o r q u e

™

or 271™ or

™

111 or 140) or

Precoat® 85 K=0.16

300 415 280 380

Torque

(Loctite® 262

Vibra-TITE

™

K=0.15

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2.

ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. 
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-20 31215031

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Torque

(Dry or Loctite®

™

)

263

Torque (Lube)

Size Pitch

Tensile

Stress Area

Clamp

Load See

Note 4

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

T o r q u e

(Loctite® 262

™

or

271

Vibra-TITE

™

™

or

131)

(Loctite® 242

Vibra-TITE

T o r q u e

™

™

271

or

™

111 or

141)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. 
IF HIGHER LOAD IS REQUIRED, ADDITIONAL

TESTING IS REQUIRED.

31215031 1-21

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS,

CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

T o r q u e

Size Pitch

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27

10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

Tensile

Stress Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

K=0.20

(Lube or Loctite® 242

™

)

or 271

Vibra-TITE

K=0.18

™

™

111 or 140)

or

™

T o r q u e

(Loctite® 262

Vibra-TITE

™

K=0.15

™

or

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-22 31215031

Metric Fastener Torque Chart (Continued)

Go to Discount-Equipment.com to order your parts

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Size Pitch

3 0.5 5.03

3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10
7 1 28.90
8 1.25 36.60

10 1.5 58.00
12 1.75 84.30
14 2 115
16 2 157
18 2.5 192
20 2.5 245
22 2.5 303
24 3 353
27 3 459
30 3.5 561
33 3.5 694
36 4 817
42 4.5 1120

Tensile

Stress Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

2.19 1.1 1.1 1.0

2.95 1.8 1.7 1.5

3.82 2.6 2.4 2.3

6.18 5.3 4.9 4.6

8.74 9 8.4 7.9

12.6 15 14 13

15.9 22 20 19

25.2 43 40 38

36.7 75 70 66

50.0 119 110 105

68.3 186 175 165

83.5 256 240 225

106.5 362 340 320

132.0 494 465 435

153.5 627 590 555

199.5 916 860 810

244.0 1245 1170 1100

302.0 1694 1595 1495

355.5 2176 2050 1920

487.0 3477 3275 3070

Torque

(Dry or Loctite® 263

K=0.17

Torque

(Lube or Loctite® 242

™

)

Vibra-TITE

271

™

K=0.16

SECTION 1 - SPECIFICATIONS

™

™

or

111 or 140)

or

T o r q u e

(Loctite® 262

Vibra-TITE

™

K=0.15

131)

™

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. 
IF HIGHER LOAD IS REQUIRED, ADDITIONAL

TESTING IS REQUIRED.

31215031 1-23

SECTION 1 - SPECIFICATIONS

Go to Discount-Equipment.com to order your parts

Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,

CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*

T o r q u e

Size Pitch

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

Tensile

Stress Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp

Load See

Note 4

Torque

(Dry or Loctite® 263

K=0.17

(Lube or Loctite® 242

™

)

or 271

Vibra-TITE

K=0.18

™

™

111 or 140)

or

™

T o r q u e

(Loctite® 262

Vibra-TITE

™

K=0.15

™

or

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. 
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-24 31215031

SECTION 2. GENERAL

Go to Discount-Equipment.com to order your parts

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND
MAINTENANCE

General

This section provides the necessary information needed by
those personnel that are responsible to place the machine in
operation readiness and maintain its safe operating condition.
For maximum service life and safe operation, ensure that all
the necessary inspections and maintenance have been com­pleted before placing the machine into service. With proper

e, maintenance, and inspections performed per JLG's rec-

car
ommendations, and with any and all discrepancies corrected,
this product will be fit for continued use.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive
inspection and preventive maintenance program. The follow­ing table outlines periodic machine inspections and mainte­nance recommended by JLG Industries, Inc. Consult your

al, regional, or local regulations for further requirements

nation
for Mobile Elevating Work Platforms. Frequency of inspections
and maintenance must be increased as environment, severity
and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a
Pre-Start Inspection of the machine before use daily or at each
change of operator. Reference the Operation and Safety Man­ual for Pre-Start Inspection procedures. The Operation and

afety Manual must be read and understood in its entirety

S
before performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus­tries, Inc. recognizes a qualified JLG equipment mechanic as a
person who, by possession of a recognized degree, certificate,
extensive knowledge, training, or experience, has successfully
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.

items requiring inspection. Reference appropriate areas of this
manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed on an
annual basis, no later than thirteen (13) months from the date
of the prior Annual Machine Inspection. JLG Industries recom­mends this task be performed by a Factory-Trained Service

echnician. JLG Industries, Inc. recognizes a Factory-Trained

T
Service Technician as a person who has successfully com­pleted the JLG Service Training School for the subject JLG

oduct model. Reference the machine Service and Mainte-

pr
nance Manual and appropriate JLG inspection form for perfor­mance of this inspection.

Reference the JLG Annual Machine Inspection Form and

nspection and Preventive Maintenance Schedule for items

I
requiring inspection. Reference appropriate areas of this man­ual for servicing and maintenance procedures.

For the purpose of receiving saf
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of current
machine ownership.

ety-related bulletins, it is

Preventive Maintenance

In conjunction with specified inspections, maintenance shall
be performed by a qualified JLG equipment mechanic. JLG
Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized
degree, certificate, extensive knowledge, training, or experi­ence, has successfully demonstrated the ability and profi­ciency to service, repair, and maintain the subject JLG product

.

model

Reference the Preventive Maintenance Schedule and appro­priate areas of this manual for servicing and maintenance pro­cedures. Frequency of service and maintenance must be

ncreased as environment, severity and frequency of usage

i
requires.

The Pre-Delivery Inspection and Frequent Inspection proce­dures are performed in the same manner, but at different

s. The Pre-Delivery Inspection shall be performed prior to

time
each sale, lease, or rental delivery. The Frequent Inspection
shall be accomplished for each machine in service for 3
months or 150 hours (whichever comes first); out of service for
a period of more than 3 months; or when purchased used. Fre­quency of this inspection must be increased as environment,

erity and frequency of usage requires.

sev

Reference the JLG Pre-Delivery and Frequent Inspection Form

d Inspection and Preventive Maintenance Schedule for

an

31215031 2-1

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start

Inspection

Pre-Delivery

tion

Inspec

Frequent

Inspection

Annual Machine

Inspection

Preventive

Maintenance

In service for 3 months or 150 hours, whichever

out of service for a period of more than 3 months; or

Annually, no later than 13 months from date of

Prior to use each day; or

at each Operator change.

Prior to each sale, lease, or

rental delivery.

comes first; or

purchased used.

prior inspection.

At intervals as specified in S ervice and Mainte-

nance Manual.

2.2 SERVICE AND GUIDELINES

General

Following information is provided to assist you in using servic­ing and maintenance procedures in this manual.

Safety and Workmanship

Your safety, and that of others, is the first consideration in
maintenance of equipment. Always be conscious of weight.
Never attempt to move heavy parts without aid of a mechani­cal device. Do not allow heavy objects to rest in an unstable
position. Ensure adequate support is provided when raising a
portion of the equipment.

Cleanliness

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or User Qualified JLG Mechanic

Owner, Dealer, or User Qualified JLG Mechanic

Owner, Dealer, or User

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

3. Clean and inspect all parts during servicing or mainte­nance. Ensure all passages and openings are unob­structed. Cover all parts to keep them clean. Make sure
all parts are clean before they are installed. New parts
should remain in their containers until ready to be used.

Service

Qualification

Factory-Trained Service

Technician

(Recommended)

Reference

Service and Maintenance Manual
nd applicable JLG inspection form.

a

Service and Maintenance Manual

and applicable JLG inspection form.

Service and Maintenance Manual
nd applicable JLG inspection form.

a

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.

2. Sho

uld it be necessary to remove a component on an
angle, keep in mind the capacity of an eyebolt or similar
bracket lessens, as the angle between the supporting
structure and component becomes less than 90
degrees.

1. The most important single item in preserving the long
service life of a machine is to keep dirt and contamina­tion out of vital components. Shields, covers, seals, and
filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a
schedule to function properly.

y time air, fuel, or oil lines are disconnected, clean

2. An
adjacent areas as well as the openings and fittings them­selves. As soon as a line or component is disconnected,
cap or cover all openings to prevent contamination.

3. If a part resists removal, check to see if all nuts, bolts,
cables, brackets, wiring, etc., have been removed and no
adjacent parts are interfering.

2-2 31215031

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete
the procedural steps in sequence. Do not partially disassemble
or assemble one part, then start on another. Always recheck
your work to ensure nothing is overlooked. Do not make any
adjustments, other than those recommended, without obtain­ing proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use a molybdenum disul­fide base compound or equivalent to lubricate the mating sur­face.

Bearings

1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol­vent and allow to drip dry. Compressed air can be used,

t do not spin the bearing.

bu

2. Discard bearings if races and balls (or rollers) are pitted,
scored, or burned.

f bearing is found to be serviceable, apply a light coat of

3. I
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until ready to install.

4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or
bore, apply pressure to the outer race. If the bearing is to
be installed on a shaft, apply pressure to the inner race.

2. Unless

specific torque requirements are given within the
text, use standard torque values on heat-treated bolts,
studs, and steel nuts, in accordance with recommended
shop practices. (See Section 1.11,Torque Charts)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, and
their receptacles, when disconnecting or removing them from
the unit. This ensures correct reinstallation.

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.

2. Disa

ssemble and reassemble parts on clean work sur­face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components as needed to aid assem­bly.

Lubrication

Service applicable components with the amount, type, and
grade of lubricant recommended in this manual at the speci­fied intervals. When recommended lubricants are not avail­able, consult your local supplier for an equivalent that meets

ceeds the specifications listed.

or ex

Battery

Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro­sion compound.

Gaskets

Check holes in gaskets align with openings in mating parts. If
it is necessary to hand-fabricate a gasket, use gasket material
or stock of equivalent material and thickness. Be sure to cut
holes in the correct location. Blank gaskets can cause serious
system damage.

Lubrication and Servicing

Components and assemblies requiring lubrication and servic­ing are shown in the Lubrication Chart in Section 1.

Bolt Usage and Torque Application

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

1. Always use new replacement hardware when installing
locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.

31215031 2-3

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamina­tion. Contaminants can enter the system by using inade­quate hydraulic oil; allowing moisture, grease, filings,
sealing components, sand, or other contaminants to
enter during maintenance; or allowing the pump to cav­itate due to insufficient system warm-up or leaks in
pump supply (suction) lines.

2. De

sign and manufacturing tolerances of component
working parts are very close. The smallest amount of dirt
or other contamination entering a system can cause
wear or damage to components and faulty operation.
Take every precaution to keep hydraulic oil clean ­including reserve oil in storage. Check, clean, and
replace hydraulic system filters as at intervals specified
in the Lubrication Chart in Section 1. Always examine fil­ters for metal particles.

3. Cloudy oils
mits organic growth and causes oxidation or corrosion.
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types.
They may not contain required additives or be of com­parable viscosities. Good grade mineral oils, with viscos­ities suited to ambient temperatures in which the
machine is operating, are recommended for use.

NOTE: Metal particles may appear in oil or filters of new machines

due to wear-in of meshing components.

indicate high moisture content which per-

Hydraulic Oil

1. Refer to Section 1 for viscosity ranges.

Changing Hydraulic Oil

3. I

nspect all hydraulic components, lines, fittings, etc.
while unit is shut down. Perform a functional check of
each system before placing machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by component manu­facturers, are always the best choice. However, multi-purpose

eases usually have qualities which meet a variety of single

gr
purpose grease requirements. Should any questions arise
regarding use of greases in maintenance stock, consult your
local supplier for evaluation. Refer to Section 1 for an explana­tion of lubricant key designations in the Lubrication Chart.

2.4 CYLINDER DRIFT

Theory

When a hydraulic cylinder is supporting a load, cylinder drift
may occur as a result of any of the circumstances below:

• Normal leakage of load holding valves or malfunction of
load holding valves. See Cylinder Leakage Test and 
Table 2- 2, Cylinder Drift below for evaluation.

• Damaged or worn piston seals.

• Normal thermal expansion or contraction of the hydraulic
oil within cylinders (See Cylinder Thermal Drift below).

The first two circumstances may result in cylinder movement
due to oil leaking out of the cylinder externally or by leaking
back to tank or due to oil leaking internally from one cylinder
chamber to the other.

Thermal expansion or contraction of oil in hydraulic cylinders

a normal occurrence and does not result in oil leaking out of

is
the cylinder or leaking internally from one cylinder chamber
to the other. Thermal expansion or contraction is the tendency
for materials to change size in response to a change in 
temperature.

Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature
before beginning this test.

Measure drift at cylinder rod with a calibrated dial indicator.

1. Filter elements must be changed after first 50 hours of
operation and every 300 hours (unless specified other­wise) thereafter. If it is necessary to change the oil, use
only oils meeting or exceeding specifications in this
manual. If unable to obtain same type of oil supplied
with the machine, consult local supplier for assistance in
selecting the proper equivalent. Do not mix petroleum
and synthetic base oils.

2. Keep

hydraulic oil clean. If oil must be poured from orig­inal container into another, clean all possible contami­nants from service container. Always clean filter mesh
element and replace cartridge any time oil is changed.

In an area free of obstructions, cylinder must have load
applied and appropriately positioned to detect drift.

Cylinder leakage is acceptable if

it passes this test.

2-4 31215031

Table 2-2. Cylinder Drift

Go to Discount-Equipment.com to order your parts

Cylinder Bore

Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

8 203.2 0.004 0.10

9 228.6 0.003 0.08

NOTE: T

his information is based on 6 drops per minute cylinder

leakage.

Max. Acceptable Drift

in 10 Minutes

Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station­ary. These effects occur as the cylinder oil changes tempera­ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these
effects are related to several factors including cylinder length
and change in temperature over the time the cylinder remains
stationary.

2.5 PINS AND COMPOSITE BEARING REPAIR
GUIDELINES

Filament wound bearings.

1. Pinned joints should be disassembled and inspected if
the following occurs:

a. Excessive sloppiness in joints.

b. Noise originating from joint during operation.

SECTION 2 - GENERAL

4. Re-assembly of pinned joints using filament wound
bearings:

a. Housing should be blown out to remove all dirt and

debris. Bearings and bearing housings must be free
of all contamination.

b. Bearing / pins should be cleaned with a solvent to

remove all grease and oil. Filament wound bearing
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).

c. Pins should be inspected to ensure it is free of burrs,

nicks, and scratches which would damage the bear­ing during installation and operation.

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to the

machine and to welding performed from the machine on
an external structure, or component,

Do the Following When Welding on JLG Equipment:

• Disconnect battery.

• Disconnect moment pin connection (where fitted)

• Ground only to structure being welded.

DO NOT Do the Following When Welding on JLG
Equipment:

• Ground on frame and weld on any other area than chassis.

• Ground on turntable and weld on any other area than turn-

table.

• Ground on platform/support and weld on any other area

than platform/support.

• Ground on a specific boom section and weld on any other

area than that specific boom section.

• Allow pins, wear pads, wire ropes, bearings, gearing, seals,

valves, electrical wiring, or hoses to be between grounding
position and welded area.

2. Filament wound bearings should be replaced if any of
the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their housing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is

observed (Clean pin before inspection):

a. Detectable bearing area wear.

b. Flaking, peeling, scoring, or scratches on pin surface.

c. Rusting of pin in bearing area.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN COMPO­NENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
RING, BOOM WIRE ROPES ETC.).

31215031 2-5

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Delivery

or Frequent

Inspection

Boom Assembly

Boom Weldments 1,2,4 1,2,4

Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wea r Pa ds 1,2 1,2

Covers or Shi elds 1,2 1,2

Extend/Retract Chain or Cable Systems 1,2,3 1,2,3

Boom Assembly

Platform Assembly

Platform 1,2

Railing 1 1,2

Gate 1,5 1,5

Floor 1 1,2

Rotator 5, 9, 15 5, 9, 15

Lanyard Anchorage Point 1,2,10

Turntable Assembly

Swing Bearing 1,2,14 1,2,3,13,14

Oil Coupling 9 9

Swing D rive Syste m 11 11

Tur nt ab l e L oc k 1,2,5 1,2,5

Hood, Hood Props, Hood Latches 5

Chassis Assembly

Tires 16,17,18 16,17,18

Wheel Nuts/Bolts 15 15

Wheel Bearings 14, 24 14, 24

Oscillating Axle/Lockout Cylinder Systems 5,8

Extendable Axle Systems 5,8 5,8

Steer Components 1,2 1,2

Spindle Thrust Bearing/Washers 1,2

Drive Hubs 11 11

1

2

Inspection

Annual

(Yearly)

14

1,2,10

1,2,5

3

2-6 31215031

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Delivery

or Frequent

Inspection

Functions/Controls

Platform Controls 5, 6 6

Ground Controls 5, 6 6

Function Control Locks, Guards, or Detents 1, 5 5

Foots witch 5 5

Emergency Stop Switches (Ground & Platform) 5 5

Function Limit or Cutout Switch Systems 5 5

Drive Brakes 5 5

Swing Br akes 5 5

Auxiliar y Power 5

Power Syste m

Engine Idle, Throttle, and RPM 3 3

Engine Fluids (Oil, Coolant, Fuel) 9, 11 11

Air/Fuel Filter 1, 7 7

Exhaust System 1, 9 9

Batteries 1, 9 19

Battery Fluid 11 11

Battery Charger 5 5

Fuel Reservoir, Cap, and Breather 1, 2, 5

Hydraulic/Electric System

Hydraulic Pumps 1,2,9 1,2,9

Hydraulic Cylinders 1, 2, 7, 9 1,2,9

Cylinder Attachment Pins and Pin Retainers 1,2, 9 1,2

Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12

Hydraulic Reservoir, Cap, and Breather 1, 2, 5, 9 1,5

Hydraulic Filter 1, 7, 9 7

Hydraulic Flui d 7,11 7,11

Electrical Connections 1, 20 20

Instruments, Gauges, Switches, Lights, Horn 1

General

Operation and Safety Manuals in Storage Box 21 21

ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI and ANSI Export ONLY) 21 21

Capacity Decals Installed, Secure, Legible 21 21

All Decals/Placards Installed, Secure, Legible 21 21

1

2

Inspection

Annual
(Yearly)

5

1,5

5,23

3

31215031 2-7

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

All Fasteners, Pins, Shields, and Covers 1,2 1,2

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21, 22

Paint and Appearance 7 7

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footn otes:

1

Pr i or t o e a ch s al e , l e as e , o r de l iv e r y

2

In service for 3 months or 150 Hours; or Out of ser vice for 3 months or more; or Purchased used

3

Annually, no later than 13 months from the date of the prior inspection

Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authori
19 - Fully charged
20 - No loose connectio ns, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill

zed components

Pre-Delivery

or Frequent

Inspection

1

2

Annual

(Yearly)

Inspection

3

2-8 31215031






























































































!"
















 !"!





 

!

!"

!!

#

!



$!

%!%

#!

"#

 

!"

!!

! 



&



 !#!

$
 !"!

&'
&

!'


&





%"%


&
''
'&

%

!

"#

"""$%
"&  "

'"$'(

)













)

)

)









 

*"!"

$%







4150548-E

Go to Discount-Equipment.com to order your parts

SECTION 2 - GENERAL

31215031 2-9

Figure 2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz

-40

4150548-E

SECTION 2 - GENERAL

Go to Discount-Equipment.com to order your parts

Figure 2-2. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425

2-10 31215031

Discount-Equipment.com is your online resource for quality parts

Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101

Need parts?

& equipment.

Click on this link: http://www.discount-equipm

ent.com/category/5443-parts/ and

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.

We sell worldwide for the br

Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,

Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,

Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,

Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,

Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-

Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,

Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,

Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,

ands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,

Rol-Air, Small Line, Wanco, Yanmar

3.1 TIRES AND WHEELS

Figure 3-1. Wheel Lug Nut Tightening Sequence

Go to Discount-Equipment.com to order your parts

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

Tire Damage

For polyurethane foam filled tires, JLG Industries, Inc. recom­mends that when any of the following are discovered, mea­sures must be taken to remove the JLG product from service
immediately and arrangements must be made for replace­ment of the tire or tire assembly.

• Smooth, even cut through cord plies which exceeds
ches (7.5 cm) in total length.

3 in

• Tears or rips (ragged edges) in cord plies which

exceeds 1inch (2.5 cm) in any direction.

• Any punctures which exceed 1inch in diameter.

• Any damage to the bead area cords of the tire.

If a tire is damaged but within above criteria, it must be
inspected daily to ensure damage does not exceed allowable
criteria.

Tire Replacement

JLG recommends a replacement tire be the same size, ply, and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for part number of approved tires for a par­ticular machine model. If not using a JLG approved replace­ment tire, we recommend that replacement tires have the
following characteristics:

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
MATCHED TO THE CONE ANGLE OF THE WHEEL.

Tighten lug nuts to proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten fasteners. If you
do not have a torque wrench, tighten fasteners with a lug
wrench, then immediately have a service garage or dealer
tighten lug nuts to proper torque. Over-tightening will break
studs or permanently deform mounting stud holes in wheels.
The proper procedure for attaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence.

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the
or

iginal

• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do not

eplace a foam filled or ballast filled tire assembly with a pneu-

r
matic tire. Due to size variations between tire brands, both
tires on the same axle should be the same.

Wheel Replacement

Rims installed on each product model have been designed for
stability requirements which consist of track width and load
capacity. Size changes such as rim width, center piece loca­tion, larger or smaller diameter, etc., without written factory
recommendations, may result in unsafe stability conditions.

Wheel Installation

It is extremely important to apply and maintain proper wheel
mounting torque.

3. The tightening of the nuts should be done in stages. Fol­lowing the recommended sequence, tighten nuts per
wheel torque chart.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2n d Stage 3rd Stage

40 ft-lbs.

(55 Nm)

4. Whee

l nuts should be torqued after first 50 hours of
operation and after each wheel removal. Check torque
every 3 months or 150 hours of operation.

95 ft-lbs.

(130 Nm)

170 ft-lbs.

(230 Nm)

31215031 3-1

SECTION 3 - CHASSIS & TURNTABLE

MAE18170

BLEEDER VALVE

Go to Discount-Equipment.com to order your parts

3.2 OSCILLATING AXLE BLEEDING PROCEDURE AND
LOCKOUT TEST

Lockout Cylinder Bleeding

1. Position the turntable to the normal stowed position. In
this position the axle is free oscillate. Drive charge pres­sure will pass through the lock out valve built into the
swivel and down to the pilot section of the hold valves
on the cylinders. This will automatically purge the air
from the pilot section of the circuit.

2. Disc

3. L

4. Rep

5. Reconnect the brake wire connector on the brake valve.

onnect the brake wire connector on the brake valve

located under the drive pump.

ocate the bleeder on the lock out cylinders. Use a small
hose (gas hose, etc.) to direct the oil to a bucket. Do one
cylinder a time. Using a wrench open the bleeder a 1/4
turn. Have the operator in the platform just crake the
drive controller in reverse. This will activate the brake
valve sending charge pressure to the lock out cylinder.
make sure the bleeder is open enough to vent any air for
about 10 seconds. Close the bleeder while there is fluid
pressure at the bleeder.

eat the procedure for the other lockout cylinder.

2. From platform control station, start engine.

3. Place the Drive control lever to the forward position and

carefully drive machine up ascension ramp until left
front wheel is on top of block.

4. Car

5. W

6. Ha

7. Carefully activate Swing control lever and return boom

8. Place the 6 in. (15.2 cm) high block with ascension ramp

9. Place Drive control lever to Forward and carefully drive

10. W

11. Ha

12. Car

13. I

efully activate Swing control lever and position boom

over right side of machine.

ith boom over right side of machine, place Drive con­trol lever to Reverse and drive machine off of block and
ramp.

ve an assistant check to see that left front wheel

remains locked in position off of ground.

to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground, it may be necessary to activate Drive to release
cylinders.

in front of right front wheel.

machine up ascension ramp until right front wheel is on
top of block.

ith boom over left side of machine, place Drive control
lever to Reverse and drive machine off of block and
ramp.

ve an assistant check to see that right front wheel

remains locked in position off of ground.

efully activate Swing control lever and return boom
to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground, it may be necessary activate Drive to release cyl­inders.

f lockout cylinders do not function properly, have quali­fied personnel correct the malfunction prior to any fur­ther operation.

Oscillating Axle Lockout Test

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS­TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and centered

between drive wheels prior to beginning lockout cylinder
test.

1. Pla

ce a 6 in. (15.2 cm) high block with ascension ramp in

front of left front wheel.

3-2 31215031

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

Go to Discount-Equipment.com to order your parts

3-4 31215031

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

Go to Discount-Equipment.com to order your parts

31215031 3-5

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

Go to Discount-Equipment.com to order your parts

3-6 31215031

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

Go to Discount-Equipment.com to order your parts

31215031 3-7

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

Go to Discount-Equipment.com to order your parts

3-8 31215031

1. Bolt

2. Bolt

3. Screw

4. Bushing

5. Bushing

6. Bushing

7. Bushing

8. Steer Cylinder Assembly

9. Link

10. Pad

11. Pin

12. Pin

13. Pin

14. Pin

15. Pin

16. Pin

17. Pin

18. Keeper Pin

19. Keeper Pin

20. Tie-Rod

21. Shim

22. Spindle

23. Spindle

24. Thurstwasher

25. Thurstwasher

26. Thurstwasher

27. Thurstwasher

28. Pivot

29. Cone Bearing

30. Cup Bearing

31. Bolt

32. Bolt

33. Bolt

34. Screw

35. Bushing

36. Bushing

37. Bushing

38. Bushing

39. Cap Hub

40. Steer Cylinder Assembly

41. Hub
41 A. Wheel Stud

42. Link

43. Nut

44. Pad

45. Pin

46. Pin

47. Pin

48. Pin

49. Pin

50. Pin

51. Pin

52. Cotter Pin

53. Keeper Pin

54. Keeper Pin

55. Tie-Rod

56. Seal

57. Shim

58. Spindle

59. Spindle

60. Thurstwasher

61. Thurstwasher

62. Thurstwasher

63. Flatwasher

64. Thurstwasher

65. Lock Washer

66. Pivot

Figure 3-7. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

31215031 3-9

Figure 3-8. Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3

FRONT AXLE

WITHOUT TOW

16

5

20

6

21

5

20

16

17

3

8

7

24

14

5

20

10

35

15

20

5

23

8

19

36

22

2

1

1

2

25

13

4

9

18

12

11

11A

26

29

5

20

16

28

30

20

5

16

7

33

27

5

20

15

27

34

REAR AXLE

10

35

14

20

5

7

31

32

MAE2070

Go to Discount-Equipment.com to order your parts

SECTION 3 - CHASSIS & TURNTABLE

3-10 31215031

41

64

65

42

41

58

64

61

39

45

44

68

39

45

74

62

56

41

64

66

38

37

37

38

70

53

40

48

62

52

50

50A

41

73

46

59

73

65

73

66

46

73

55

64

41

49

71

54

43

51

43

54

67

69

58

41

64

60

72

47

72

41

57

64

FRONT AXLE

WITH TOW

MAE2130

Figure 3-9. Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3

Go to Discount-Equipment.com to order your parts

SECTION 3 - CHASSIS & TURNTABLE

31215031 3-11

Figure 3-10. Steering Installation (7ft/2.1m Wide Machines) - Sheet 3 of 3

1. Cup Bearing

2. Cone Bearing

3. Thurstwasher

4. Bolt

5. Bolt

6. Bolt

7. Bushing

8. Bushing

9. Hub Cap

10. Steer Cylinder Assembly

11. Hub
11 A. Wheel Stud

12. Wheel Nut

13. Slotted Nut

14. Pin

15. Pin

16. Pin

17. King Pin

18. Cotter Pin

19. Cotter Pin

20. Keeper Pin

21. Tie-Rod

22. Seal

23. Spindle

24. Spindle

25. Flat Washer

26. Bolt

27. Bearing

28. King Pin

29. Keeper

30. Tie-Rod

31. Spindle

32. Spindle

33. Thurstwasher

34. Thurstwasher

35. Plug

36. Slotted Nut

37. Cup Bearing

38. Cone Bearing

39. Thurstwasher

40. Bolt

41. Bolt

42. Bolt

43. Screw

44. Bushing

45. Bushing

46. Bushing

47. Bushing

48. Hub Cap

49. Steer Cylinder Assembly

50. Hub
50 A. Wheel Stud

51. Pivot

52. Wheel Nut

53. Slotted Nut

54. Pad

55. Pin

56. Pin

57. Pin

58. Pin

59. Pin

60. Pin

61. King Pin

62. Cotter Pin

63. Link

64. Keeper Pin

65. Tie-Rod

66. Seal

67. Shim

68. Spindle

69. Spindle

70. Flat Washer

71. Thurstwasher

72. Thurstwasher

73. Flat Washer

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3-12 31215031

SECTION 3 - CHASSIS & TURNTABLE





Go to Discount-Equipment.com to order your parts

3.3 TORQUE HUB

Oil Information

1. TYPE – EP90 
Use EP90 for normal applications. For applications
where lubricant must meet special requirements, the
O.E.M can recommend a suitable substitute.

2. OIL TEM
Continuous – 160° F (70° C) Intermittent – 200° F (95° C).

3. OIL CHANGE 
Initial – After 50 hours or 50,000 revolutions of opera­tion. Subsequent – After 1000 hours or (1) year, which­ever comes first.

NOTE: Higher temperatures make it necessary to change oil more

4. OIL FILL LEVEL AND VOLUME 
Unit mounted horizontal – half full. (See Diagram A.)
Approximate volume - 17 oz. (0.5 1tr).

PERATURE 

frequently.

Roll and Leak Testing

Always roll and leak test Torque-Hubs after assembly to make
sure that the unit’s gears and sealants are working properly.
The following information briefly outlines what to look for
when performing these tests.

ROLL TEST

Tightening and Torquing Bolts

USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN
BOLTS BEYOND THEIR TORQUE SPECIFICATION.
WRENCH TO TIGHTEN SHOULDER BOLTS. TIGHTEN ALL SHOULDER BOLTS BY
HAND.

1. Tighten (but do not torque) bolt ”A” until snug.

2. Go to opposite side of bolt circle and tighten bolt ”B”

until equally snug.

3. Continue around bolt circle and tighten remaining bolts.

4. Use a torque wrench to apply specified torque to bolt

”A”.

5. Continue around bolt circle and apply equal torque to
remaining bolts.

NEVER USE AN IMPACT

The roll test determines if the unit’s gears rotate freely and
properly. You should be able to rotate gears by applying a con­stant force to the roll checker. If you feel more drag in gears
only at certain points, gears are not rolling freely. Examine
them for improper installation or defects.

Some gear packages roll with mor
not be concerned if gears seem to roll hard as long as they roll
with consistency.

LEAK TEST

The purpose of a leak test is to make sure unit is air tight. You
can tell if your unit has a leak if pressure gauge test reading
starts to fall once you have pressurized the unit.

Leaks usually occur at the main seal or wherever O-rings or
gaskets are located. You can usually detect location of a leak
by brushing a soap and water solution around main seal and
where O-rings or gaskets meet unit exterior, then checking for
air bubbles. Replace part immediately if you detect a leak in a
seal, O-ring, or gasket.

e difficulty than others. Do

Figure 3-11. Bolt Tightening Sequence

31215031 3-13

























































































































1A. Spindle
1B. Seal
1C. Bearing
1D. Housing
1E. Ring Gear
1F. Bearing Nut
1G. Setscrew
1H. Wheel Stud
1K. Retaining Ring

1L. Spring
1M. Thrustwasher

2. Th r us t wa s h er
3A. Carrier
3B. Thrustwasher
3C. Needle Bearing
3E. Planet Shaft
3F. Planet Gear
4B. Thrustwasher

4C. Needle Bearing
4D. Thrust Spacer
4E. Planet Shaft
4F. Planet Gear
4G. Roll Pin
4H. Thrustwasher

5. R et a in i n g R i ng
6A. Cover Plate
6B. Disengage Cap

6C. Bolt
6D. Dowel Pin
6E. O-Ring
6F. Pipe Plug
6G. Retaining Ring

7. C ou p li n g
8A. Brake Piston
8B. Pressure Plate
8C. Retaining Ring

8D. O-Ring
8E. Backup Ring
8F. O-Ring
8H. Backup Ring
8J. Brake Rotor
8K. Brake Stator
8L. Brake Spring

9. I np u t Sh a ft

11. Sun Gear

12. Plug

15. I.D. Plate

16. Drive Screw

17. O-Ring

18. O-Ring

19. Countersunk Screw

20. Retaining Ring

21. Plug

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3-14 31215031

Figure 3-12. Torque Hub

SECTION 3 - CHASSIS & TURNTABLE



















Go to Discount-Equipment.com to order your parts

Main Disassembly

1. Perform Roll Check, Leak Check, and Brake Check if
applicable before disassembly.

ain oil from unit. Note condition and volume of oil.

2. Dr

3. Remove Retaining Ring (6G) by prying open end of

Retaining Ring out of groove in Ring Gear (1E) with a
screwdriver. Grasp loose end with pliers and pull out
Retaining Ring.

4. Remov

e Cover Subassembly (6).

NOTE: Carefully pressurize unit with air to pop cover off.

5. Remove Input Carrier Subassembly (3).

6. Remove Input Shaft (9).

7. Remove Second Stage Sun Gear (11).

8. Loosen and remove three Flat Head Bolts (19) that retain

Ring Gear (1E) to Housing (1G).

9. Lift Ring Gear (1E) off Housing (1D).

10. Remove O-ring (18) from Housing (1D.

Figure 3-13. Torque Hub Main Disassembly

31215031 3-15

SECTION 3 - CHASSIS & TURNTABLE



































Go to Discount-Equipment.com to order your parts

Output Carrier Disassembly

11. Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet
Shaft (4E) until it bottoms against Spindle (1A).

12. Gr

13. Dri

asp Roll Pin (4G) with needle nosed pliers or a hooked

tool and pull Planet Shaft (4E) out of Spindle (1A).

ve Roll Pin (4G) out of Planet Shaft (4E). Discard roll

pin.

14. Slide Planet Gear Subassembly (4) out of Spindle (1A).
Do not drop Needle Bearings (4C).

15. Remove four Thrust Washers (4B), 28 Needle Rollers (4C),
and Thrust Spacer (4D) from Second Stage Planet Gear
(4F).

16. Repeat Steps 12-15 for remaining Planet Gears (4F).

17. Remove Thrust Washer (4H) from Spindle (1A) counter-

bore.

Figure 3-14. Output Carrier Disassemb

Input Carrier Disassembly

1. Using a 1/8” diameter punch, drive Roll Pin (4G) in Planet
Shaft (3E) until it bottoms against Carrier (3A).

2. Usi

3. Using a 1/8” diameter punch, drive Roll Pin (4G) out of

4. Slide Planet Gear (3F) and two Thrust Washers (3B) out of

5. Remo

6. Repeat steps 1 through 5 for remaining planet gears.

3-16 31215031

ng a soft face hammer, tap Planet Shaft (3E) out of

Carrier (3A).

Planet Shaft (3E). Discard roll pin.

Carrier (3A).

ve 14 needle Bearings (3C) from bore of Planet

Gear (3F).

Figure 3-15. Input Carrier Disassembly

SECTION 3 - CHASSIS & TURNTABLE

















Go to Discount-Equipment.com to order your parts

Hub-Spindle Disassembly

1. Place unit on bench with Spindle (1A) end down.

2. Remove 2 Set Screws (1G) and Bearing Nut (1F).

NOTE: Holes in Bearing Nut (1F) for Set Screws (1G) are staked for

retention of Set Screws (1G). Clean holes before removing
Set Screws.

3. Remove “A” position Bearing Cone (1C) from Bearing
Cup (1C) in Hub (1D).

4. While supporting unit on Hub (1D) flange, press Spindle
(1A) out of Hub (1D).

5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q)
from Hub (1D) if applicable.

6. If necessary, press nine Studs (1H) out of Hub (1D).
Locate Hub (1D) on Seal (1B) end.

emove Seal (1B) from Hub (1D). Discard seal.

7. R

8. Remove “B” position Bearing Cone (1C) from Bearing

Cup (1C) in Hub (1D).

9. Remove “B” position Bearing Cone (1C) from Hub (1D).

10. Using a soft steel rod, knock both Bearing Cups (1C) out

of Hub (1D).

Figure 3-16. Hub Spindle Disassembly

31215031 3-17

SECTION 3 - CHASSIS & TURNTABLE



































Go to Discount-Equipment.com to order your parts

Spindle-Brake Disassembly

NOTE: Units with integral Input Brake (8) only.

COMPRESSED SPRINGS CAN FLY OUT AND CAUSE SEVERE EYE DAMAGE OR
OTHER INJURIES. WEAR EYE PROTECTION WHEN PERFORMING THESE PROCE
DURES.

1. Install two 1/4"-20 x 5/8" Flat Head Capscrews (22)
through Pressure Plate (8B) into Piston (8A). Tighten
incrementally until spring force is taken off Retaining
Ring (8C).

NOTE: Flat Head Capscrews (22) are for transit and service only

and are removed before shipping new units. They are
included in most brake repair kits.

2. Using retaining ring pliers, remove Retaining Ring (8C)
from groove in Spindle (1A).

3. Back Flat Head Capscrews (22) incrementally out of Piston
(8A) until spring force is relieved from Pressure Plate (8B).

Remove Flat Head Capscrews (22) and Pressure Plate (8B)
from brake cavity in Spindle (1A).

4. Remo

5. Using an air hose, slowly and carefully pressurize brake

-

6. Remo

7. R

8. Remove Coupling Subassembly (7) from brake cavity in

9. Remove Retaining Ring (1K) from internal groove using

10. Remo

11. Remove Plastic Plug (12) and Pipe Plug (21) from Spindle

ve Compression Springs (8L) from Piston (8A).

port in Spindle (1A) until Piston (8A) comes out of piston
bore of Spindle (1A). Pull Piston (8A) out of Spindle (1A)
by hand.

ve Backup Rings (8E and 8H) and O-rings (8D and

8F) from grooves in Piston (8A).

emove Rotors (8J) and Stators (8K) from brake cavity in

Spindle (1A).

Spindle (1A).

appropriate tool.

ve Spacer (1M) and Spring (1L) from bore of Cou-

pling (7).

(1A) if applicable.

Figure 3-17. Spindle Brake Disassembly

3-18 31215031

SECTION 3 - CHASSIS & TURNTABLE



















Go to Discount-Equipment.com to order your parts

Cover Disassembly

1. Remove O-Ring (17) from groove in Cover (6A).

2. Remove Thrust Washer (2) from Cover (6A) pockets.

3. Unscrew two Hex Head Bolts (6C) and remove Disen-

gage Cap (6B) from Cover (6A).

ull Disengage Rod (6D) out from Cover (6A).

4. P

5. Use appropriate tool to remove O-ring (6E) from internal

groove in Cover (6A).

6. Remov

e two O-Ring Pipe Plugs (6F) from Cover (6A).

Cover Assembly

1. Grease O-Ring (6E) and insert in internal groove in Cover
(6A).

2. Ass

3. Insert Disengage Rod (6D) in hole in Cover (6A) until it

NOTE: Disengage Rod can be inserted either end first.

4. Grease face of Thrust Washer (2) and place in Cover (6A).

5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should

emble Disengage Cap (6B) on Cover (6A) using two

Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs.

touches inside of Disengage Cap (6B).

Make sure tangs on washer seat into pockets in cover.

be hand tight.

Input Carrier Sub-Assembly

1. Apply a liberal coat of grease to bore of one Input Planet
Gear (3F).

2. Line in

NOTE: The last roller installed must be installed end wise. That is,

3. Set Carrier (3A) in an upright position.

4. Insert a Planet Shaft (3E) in planet shaft hole in end of

5. Plac

6. F

7. F

8. No

side of Planet Gear (3F) with 14 Needle Rollers

(3C).

the end of the last roller must be placed in between ends of
the two rollers which form the space, and then slid, parallel
to the other rollers, into place.

Carrier (3A) opposite splined end. End of planet shaft
that does NOT have the roll pin hole should be inserted
into carrier FIRST.

e one Thrust Washer (3B) on end of Planet Shaft (3E).
Make sure the flat faces towards inside of carrier and
make sure button fits in the pocket on inside of Carrier
(3A) towards the OD.

ollowing the thrust washer, place Planet Gear (3F) with

needle rollers, on Planet Shaft (3E).

ollowing the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align Thrust Washer
(3B) in same manner described in Step 5.

w insert Planet Shaft (3E) through opposite planet
shaft hole on Carrier (3A). Use an alignment punch or
similar tool to align roll pin holes on Carrier (3A) and
Planet Shaft (3E).

NOTE: Do not to hit Planet Gears (3F) when driving in Roll Pins

(4G).

9. Drive Roll Pin (4G) down into aligned roll pin holes. Pin
should be flush with flat of carrier.

10. Repeat Steps 1-9 for installation of two remaining Planet
Gears (3F).

NOTE: Some grease may need to be applied to the Thrust Washers

(3B) to hold them in place while installing the planet gears.

Output Planet Gear Sub-Assembly

Figure 3-18. Torque Hub Cover

31215031 3-19

1. Apply a liberal coat of grease to the bore of one Output

Planet Gear (4F).

2. Line inside of the Planet Gear (4F) with 14 Needle Rollers
(4C).

NOTE: Last roller installed must be installed end wise. That is, the

end of the last roller must be placed in between the ends of
the two rollers which form the space, and then slid, parallel
to the other rollers, into place.

ace Spacer (4D) in bore of Output Planet (4F).

3. Pl

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

4. Repeat Step 2 to put in second roll of Needle Rollers (4C).

ply grease to hold two Thrust Washers (4B) together

5. Ap
and on Output Planet Gear (4F) counterbore. Do the
same to the other side.

6. Repea

t Steps 1-5 to finish assembly of two remaining

Output Planet Gears (4F).

Spindle - Brake Sub-Assembly

1. Place Spindle (1A) with flange side up.

2. Pla

3. Pla

4. Rep

5. Pla

6. I

7. I

8. I

9. I

10. I

11. I

12. Pla

13. U

14. I

15. Pla

16. U

NOTE: R

17. I

ce Stator (8K) in Spindle (1A) scallop cuts.

ce Rotor (8J) on top of Stator (8K).

eat steps 2 & 3 until there are a total of 9 Stators (8K)

and 8 Rotors (8J) installed.

ce Piston (8A) with smaller O.D. end facing up. Grease

two O-Rings and two Backup Rings.

nstall large Backup Ring (8E) in large-diameter groove at

bottom of Piston (8A).

nstall large O-Ring (8D) in large-diameter groove at bot-

tom of Piston (8A), on top of large Backup Ring (8E).

nstall small O-Ring (8F) in small-diameter groove near
top of Piston (8A). Make sure O-Ring is seated on the
bottom of the groove.

nstall small Backup Ring (8H) in small-diameter groove
near top of Piston (8A), on top of small O-Ring (8F).

nsert Piston (8A) in Spindle (1A) until it contacts Stator
(8K).

nsert appropriate number of Springs (8L), based on
assembly print, into Piston (8A)counterbore.

ce Spring (1L) in Coupling (7) counterbore. Place Pres-

sure plate (1M) on top of Spring (1L).

se appropriate tool to install Retaining Ring (1K) in

retaining ring groove in coupling (7) counterbore.

nsert Coupling sub-Assembly (7) through Rotors (8J).

ce Pressure Plate (8B) on top of Springs (8L).

se two ¼ -20 x 0.625 flat head Capscrews (22) by bolt­ing Pressure Plate (8B) and Piston (8A) together or some
other appropriate tools to install Retaining Ring on top
of Pressure Plate (8B) until Retaining Ring (8C) is seated.

emove 2 Screws from units when done or brake will not

function.

nstall Pipe Plug (21) if applicable

Hub-Spindle Sub-Assembly

NOTE: Spray a light film of oil on all component parts during

assembly. Spray a generous amount of oil on bearings dur­ing installation.

ress Bearing Cup of part (1C), position "A", into Hub

1. P
using pressing tool.

urn hub over and press Bearing Cup of part (1C), posi-

2. T
tion "B", into hub using pressing tool.(T).

3. Plac

4. Greas

5. Plac

NOTE: Use enou

6. Se

7. I

8. Appl

NOTE: F

9. Using

10. Plac

11. Plac

12. I

e Bearing Cone of part (1C), into Bearing Cup of part

(1C), position "B".

e Seal (1B) lip and press seal into Hub (1D) using

appropriate tool until seal is flush with end of hub.(T).

e Hub (1D) into pressing base. Press nine Studs (1H)

into Hub.

gh pressure to press in studs. Don t use excessively

high pressure to press in studs or hub may crack.

t Spindle assembly (1A) on the bench with the flange
down. Turn Hub (1D) over and lower onto Spindle (5).
Install boot (21) if applicable.

nstall Bearing Cone of part (1C) into Bearing Cup, posi-

tion "A".

y Medium Strength Threadlocking Compound on
Bearing Nut (1F) thread. Screw Nut (1F) on top of Bearing
Cone of part (1C). Leave 0.003-0.005 inches end play to
check the initial rolling torque with the unit tied down.
Then torque Bearing Nut (1F) until rolling torque is 40 to
50 in-lbs greater than initial rolling torque. Using tool for
the Bearing Nut.

inal torque is initial rolling torque plus 40-50 in-lb (4.5-5.6
Nm). For example, if initial rolling torque is 30 in-lb (3.3
Nm), final rolling torque is between 70-80 in-lb (7.9-9 Nm).
Rotate hub as torque is applied to properly seat bearing. Be
sure torque wrench is tangent to the Hub (1D) OD.

appropriate tool, install two Set Screws (1G) into
Bearing Nut (1F) threaded holes. Make sure Set Screw is
driven into the spindle thread. Tighten the set screws to
damage the thread and stake the edge of the nut
around the Set Screws (1G) so the nut will not loosen.

e Thrust Washer (4H) in counterbore of Spindle (1A).

e Planet Gear Sub-assembly (4) into Spindle (1A)
through gap between two Studs (1H). Align the planet
gear bore with one of the planet shaft holes on the spin­dle (1A) assembly using tool.

nsert a Planet Shaft (4E) into the planet shaft hole
described in Step (11) on Spindle (1A). Insert end of
planet shaft that does NOT have roll pin hole in Spindle
FIRST.

3-20 31215031

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

13. Insert Planet Shaft (4E) through first set of Thrust Wash­ers (4B), Planet gear, then second set of Washers (4B).
Use an alignment punch or similar tool to align roll pin
holes on Spindle (1A) and Planet Shaft (4E).

NOTE: Do not hit Planet Gears (4F) when driving in Roll Pins (4G).

14. Drive new Roll Pin (4G) in aligned roll pin holes. Pin
should be flush with OD of spindle.

15. Repeat Steps (11-14) for installation of two remaining
Planet Gears (4F).

Cover Sub-Assembly

1. Grease O-Ring (6E) and insert in internal groove in Cover
(6A).

2. Assemble Disengage Cap (6B) on Cover (6A) using two
Hex Head Bolts (6C). Torque bolts to 70-80 in-lb (7.9- 9
Nm).

3. Insert Disengage Rod (6D) in hole in Cover (6A) until it
touches inside of Disengage Cap (6B).

NOTE: Disengage Rod can be inserted either end first.

4. Grease Face of Thrust Washer (2) and place in Cover (6A)
making sure tangs on washer seat into pockets in cover.

5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should
be hand tight.

9. Place Input Carrier Sub-Assembly (3A) on Output Sun
Gear (11) splines. Drop Input Sun (10) in mesh with
planet gears for specific ratios, if required. (No timing
required).

rease O-Ring (17) and insert in groove in Cover Sub-

10. G
Assembly (6).

nstall Cover Sub-Assembly (6) in Ring Gear (1E) counter-

11. I
bore and install Retaining Ring (6G) in groove in Ring
Gear (1E).

ttach ID Tag (15) on unit using Drive Screws (16).

12. A

13. Check disconnect, roll and air check unit, leak check

brake, and record release pressure.

nsert Plastic Plug (12) if applicable.

14. I

Integral Brake Check

1. Using appropriate fittings, connect hydraulic line from
hand pump to brake port.

2. Chec

3. Bl

k brake is set by trying to rotate Input Shaft (9). This
can be accomplished by installing an appropriate tool
(any tool that can locate on splines of Input Coupling (7),
such as a mating splined shaft) into Input Coupling (7).

eed brake. Increase hydraulic pressure gradually while
trying to rotate input until brake just starts to release.
Note this pressure. Make sure pressure falls into appro­priate range below.

Main Assembly

NOTE: All components should receive a generous amount of lubri-

cant oil as they are being assembled.

1. Place Hub-Spindle Sub-Assembly on bench.

2. Grease O-Ring (18) and place it in groove of Hub (1D).

3. Place Ring Gear (1E) on Hub (1D). Align three shipping

Capscrew Holes on Hub (1D) and Ring Gear (1E).

nstall three shipping Capscrews (19) in ring gear and

4. I
hub. Torque to 15-20 ft-lb (20-27 Nm).

5. Place External Retaining Ring (5) over 13T spline to the
retaining groove on Input Shaft (9).

NOTE: For ratio 48:1, assemble Output Sun Gear (11) over Input

Shaft (9) first, then install External Retaining Ring (5).

6. Using appropriate tool to install Retaining Ring (20) in
groove on Output Sun (11).

7. Place Input Shaft (9) spline end into mesh with Internal
Coupling (7) splines.

8. With modified spline end facing up, place Output Gear
(11) in mesh with planet gears from Hub-Spindle Sub­Assembly.

BRAKE

CODE

A 200-260 13.7-17.9
B 170-220 11.7-15.1
C 140-185 9.6-12.7
D 130-155 8.9-10.6
E 115-145 7.9-9.9

4. Increase pressure to 1,000 psi and hold for 30 seconds to
check for leaks. Repair leaks if necessary.

NOTE: Make sure brake re-engages when pressure is released.

NOTE: When done, make sure Input Coupling (7) is centered in

Spindle (1A) to make installation of motor possible without
release of brake.

JUST RELEASE

PRESSURE RANGE

PSI BAR

31215031 3-21

1A. Spindle
1B. Lip Seal
1C. Tapered Bearing
1D. Housing
1E. Ring Gear
1F. Bearing Nut
1G. Setscrew
1H. Stud
1K. Retaining Ring
1L. Spring

1M. Thrust Washer
1Q. Seal Boot

2. Th r us t S pa ce r 
3A. Carrier
3B. Thrust Washer
3C. Needle Bearing
3E. Planet Shaft
3F. Planet Gear
4B. Thrust Washer

4C. Needle Bearing
4D. Thrust Spacer
4E. Planet Shaft
4F. Planet Gear
4G. Roll Pin
4H. Thrust Washer

5. R et a in i n g R i ng 
6A. Cover
6B. Disengage Cap

6C. Bolt
6D. Dowel Pin
6E. O-Ring
6F. Pipe Plug
6G. Retaining Ring

7. C ou p li n g
8A. Brake Piston
8B. Pressure Plate
8C. Retaining Ring

8D. O-Ring
8E. Backup Ring
8F. O-Ring
8H. Backup Ring
8J. Brake Rotor
8K. Brake Stator
8L. Spring

9. I np u t S h a ft 

10. Sun Gear

11. Sun Gear

12. Plastic Plug

15. ID Plate

16. Drive Screw

17. O-Ring

18. O-Ring

19. Bolt

20. Retaining Ring
21

. O-Ring Plug

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3-22 31215031

Figure 3-19. Hub Assembly

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

Figure 3-20. Bearing Cup Pressing Tool

Figure 3-21. Seal Pressing Tool

31215031 3-23

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

Figure 3-22. Bearing Cup Pressing Tool

Figure 3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear

3-24 31215031

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

Go to Discount-Equipment.com to order your parts

3.4 FREE WHEELING OPTION

Disengage Drive Motors and Brakes for Towing, etc.
(Free Wheel)

1. Chock wheels securely if not on flat level surface.

2. Disconnect both drive hubs by inverting disconnect

caps in center of hubs.

3. If equipped, move steer/tow selector valve to float (tow)
position by pulling valve knob out.

Engage Drive Motors and Brakes (Normal
Operation)

1. If equipped, move steer/tow valve to steer position by
pushing valve knob in.

2. Connect both drive hubs by inverting disconnect cap in
center of hub.

3. Remov

e chocks from wheels as required.

3.5 DRIVE MOTOR

Description

Drive motors are low to medium power, two-position axial pis­ton motors incorporating an integral servo piston. They are
designed for operation in open and closed circuit applications.
The standard control is a direct acting single line hydraulic
control. The integral servo piston controls motor displace­ment.

Motors are spring biased to maximum displacement and

ydraulically shifted to minimum displacement. Minimum and

h
maximum displacement can be set with fixed internal stops.
The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.

Figure 3-25. Drive Motor Cross Section

31215031 3-25

Figure 3-24. Disconnecting Drive Hubs

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

Figure 3-26. Removing Shaft Seal

1. Snap Ring 2. Support Washer 3. Shaft Seal

Go to Discount-Equipment.com to order your parts

Shaft Seal Replacement

REMOVAL

1. Remove snap ring (1) retaining shaft seal, and support

washer.

2. Remove support washer (2).

INSPECTION

Inspect new seal, motor housing seal bore, and sealing area on
shaft for rust, wear, and contamination. Polish shaft and clean
housing if necessary.

INSTALLATION

1. Cover shaft splines with an installation sleeve to protect

shaft seal during installation.

2. Install new shaft seal with cupped side facing motor.
Press seal into housing until it bottoms out. Press evenly
to avoid binding and damaging the seal.

3. Install seal support washer.

4. Install snap ring.

5. Remove installation sleeve.

3. Carefully pry out shaft seal (3).

NOTE: To avoid damaging shaft during removal, install a large

sheet metal screw in chuck of a slide hammer. Drive screw
in seal surface and use slide hammer to pull seal.

4. Discard seal.

3-26 31215031

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

Go to Discount-Equipment.com to order your parts

Loop Flushing Valve

REMOVAL

1. Remove plug (1) and (2) using an 11/16 in internal hex

wrench.

INSPECTION

Inspect new O-rings and the sealing area for rust, wear, or con­tamination. Check springs and poppet for wear.

INSTALLATION

1. Install orifice poppet (13).

2. Install shift spool (12).

3. Install spring retaining washers on springs (10 and 11).

4. Carefully install centering springs (7, 8, and 9).

5. Install new O-rings (6, 4, and 5).

6. Torque plug (3) to 20 ft-lb (27 Nm) using an 1/4 in hex

wrench.

orque plugs (2 and 1) to 27 ft-lb (37 Nm) using an 11/16

7. T
in internal hex.

2. Remove plug (3) using a 1/4 in hex wrench.

3. Remove O-rings (4, 5, and 6).

4. Remove centering springs (7, 8, and 9) using pliers.

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

31215031 3-27

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

Troubleshooting

Item Description Action

Check oil level in reservoir and oil
supply to motor.

Insufficient hydraulic fluid could lead to cavitation that would cause sys­tem noise.

Table 3-2. Excessive Noise and/or Vibration

Fill reservoir to proper level. Ensure oil supply to motor is adequate and
lines are unobstructed.

Check for air in system. Air trapped in system lines or motor could result in cavitation that would

cause system noise.

Inspect output shaft couplings. A loose or incorrect shaft coupling will produce vibrations that could result

in system noise.

Inspect output shaft alignment. Misaligned shafts create excessive frictional vibration that could result in

system noise.

Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead

to system noise.

Table 3-3. System Operating Hot

Item Description Action

Check oil level in reservoir and oil
supply to pump.

Inspect heat exchanger, (if
equipped).

Check system relief valves. If a system relief valve becomes unseated for an extended period of time or

Insufficient amount of hydraulic fluid will not meet system cooling
demands.

If heat exchanger fails, or becomes obstructed, it may not meet system
cooling demands.

fails for any other reason, system could become overhe ated.

Table 3-4. No Shift or Slow to Start

Ensure all system lines and components are purged of air.

En s ur e co r re c t c o up l in g is u se d an d th a t i t fi t s p r op e rl y on s h af t.

Ensure shafts are properly aligned.

Replace hydraulic oil with appropriate fluid for operating conditions.

Fill reservoir to proper level.

Ensure heat exchanger is receiving adequate air flow and is in good operat­ing condition. Repair or replace as necessary.

Repair or replace any malfunctioning relief valves as applicable and verify
loads on machine are not excessive.

Item Description Action

Ch e ck s ig n al l i ne to s e rv o co n tr o l
port.

Check correct supply and drain ori­fices are properly installed and not
obstructed.

Obstructed or restricted flow through servo control signal lines could
result in slow shift or no shift motor conditions.

Supply and drain orifices determine motor shift. The smaller the orifice,
the longer the time it takes to shift the motor. Obstruction also increases
shift times.

Ensure signal lines are not obstructed or restricted and signal pressure is
adequate to shi ft motor.

Ensure proper control orifices are installed in motor and not obstructed.
Clean or replace as necessary.

3-28 31215031

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

Go to Discount-Equipment.com to order your parts

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Removal of endcap voids warranty.



Coat all moving parts with a film of clean hydraulic oil dur­ing assembly. This ensures parts will be lubricated during
start-up.





Replace all O-Rings and gaskets.





It is recommended to replace all O-rings. Lightly lubricate
O-rings with clean petroleum jelly before assembly.



8. Remove all fittings from unit. Discard any O-rings on fit­tings.

9. Using an 11/16 inch hex wrench, loosen speed sensor

1. Using a 11/16 in wrench remove plug (1) and (2).

2. Using a 5/8 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

31215031 3-29

lock nut (14) if equipped. Remove speed sensor using a
Vi inch hex wrench. Units without speed sensor have an
O-ring plug (15) installed in that location; remove it with
a Va inch internal hex wrench.

sing a 1/4 inch internal hex wrench, remove control

10. U
line plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18, if equipped with two­line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard O­rings.

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

Go to Discount-Equipment.com to order your parts

13. Using an 8 mm internal hex wrench, remove endcap­screws (22).

14. Remove endcap (23). Remove O-ring (24) from housing
or endcap. When endcap screws are removed, pressure
from servo spring will cause endcap to bind on shaft.
Press down on portion of endcap covering servo piston
and hold endcap level while removing.

DO NOT SCRATCH VALVE PLATE SURFACE.

15. Remove valve plate (25) and timing pin (26) from end­cap. Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate part
number are stamped on its surface.

emove and discard O-rings (27, 28).

16. R

17. Remove rear shaft bearing (29) from endcap with a bear-

ing puller. Bearing may be difficult to remove with a
puller. Try this as an alternative: Pack bearing cavity with
heavy grease. After shaft is removed, insert it into bear­ing cavity and tap lightly with a soft mallet on the
splined end. The grease will force the bearing out. Use
caution not to drive bearing past the rear shaft journal as
bearing may become trapped on shaft and damaged.

18. Remo

ve minimum angle stop and servo spring (30) from

housing.

3-30 31215031

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

Go to Discount-Equipment.com to order your parts

bly (31). Set assembly aside. Do not to scratch running
surface.

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Grooves on surface of cylinder kit identify its displacement:

Table 3-5. Displacement Identifiers

# of Grooves Frame L Frame K

1 25 38

2 30 45

3 35 - -

emove inner snap ring (35) and shaft/bearing assembly.

21. R

22. Remove snap-ring (36) retaining shaft front bearing. Pull

bearing (37) off shaft (38).

20. Turn housing over and remove snap ring (32) retaining

31215031 3-31

shaft seal and support washer. Remove support washer
(33) and carefully pry out shaft seal (34). Discard seal. To
avoid damaging shaft during seal removal, install a large
sheet metal screw in chuck of slide hammer. Drive screw
into seal surface and use slide hammer to pull seal.

23. Turn housing over and remove swashplate (39) by lifting
on end opposite servo lever.

emove servo piston (40). Remove piston seal (41) and

24. R
O-ring (42) from servo piston. Discard seal and O-ring.

25. Remove journal bearings (43) from housing. Note loca­tion and orientation of each bearing for reassembly.

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

Go to Discount-Equipment.com to order your parts

28. Turn block over. Using a press, apply pressure on block
spring washer (50) to compress the block spring. Com­press spring enough to safely remove the spiral retain­ing ring (51). While maintaining pressure, unwind the
spiral retaining ring (51). Carefully release pressure and
remove outer block spring washer (50), block spring (52),
and inner block spring washer (53) from cylinder block.

Inspection

After disassembly, wash all parts (including end-cap and hous­ing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air.
Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or
resurfacing.

PISTON

Inspect pistons for damage and discoloration. Discolored pis­tons may indicate excessive heat; do not reuse.

SLIPPERS

Inspect slipper running surfaces. Replace piston assemblies
with scored or excessively rounded slipper edges. Measure

26. Remove pistons (44) and slipper retainer (45) from cylin­der block (46). 



Pistons are not selectively fitted, however units with
high hourly usage may develop wear patterns. Number
pistons and bores for reassembly if they are to be reused.

27. Remo

NOTE: Most repairs do not require block spring removal. Perform

RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES FORCE
OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAIN
TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE
BEFORE ATTEMPTING TO REMOVE SPIRAL RETAINING RING. RELEASE PRES­SURE SLOWLY AFTER RETAINING RING IS REMOVED.

3-32 31215031

ve ball guide (47), hold-down pins (48), and retain-

ing ring (49) from cylinder block.

this procedure only if you suspect block spring problems.

-

slipper foot thickness. Replace piston assemblies with exces­sively worn slippers. Check slipper axial end-play. Replace pis­ton assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end-play

re given in table below.

a

Table 3-6. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness 2.71 mm

(0.11 in.)

Piston/Slipper End Play 0.15 mm

4.07 mm
(0.16 in.)

(0.006 in.)

SECTION 3 - CHASSIS & TURNTABLE

A

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness 0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

Slipper retainer

Ball guide

3.83 mm [0.151 in] min.

0.025 mm

[0.001 in]

0.0076 mm

[0.00030 in]
convex max

LV

25.8 mm
[1.015 in]

24.6 mm
[0.969 in]

KV

Thickness equality
side to side:

0.05 mm [0.002 in]

0.0025 mm

[0.0001 in]

Go to Discount-Equipment.com to order your parts

CYLINDER BLOCK

Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface.
Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing
will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements.

BALL GUIDE AND SLIPPER RETAINER

Inspect ball guide and slipper retainer for damage, discolor­ation, or excessive wear. A discolored ball guide or slipper
retainer indicates excessive heat. Do not reuse.

SWASHPLATE AND JOURNAL BEARINGS

Inspect running face, servo ball-joint, and swashplate journal
surfaces for damage or excessive wear. Some material transfer
may appear on these surfaces and is acceptable if surface con­dition meets specifications shown. Measure swashplate thick­ness from journals running face. Replace swashplate if
damaged or worn beyond minimum specification. Replace
swashplate if difference in thickness from one side to the other
exceeds specification.

VALVE PL ATE

Condition of the valve plate is critical to efficiency of the
motor. Inspect valve plate surfaces carefully for excessive wear,
grooves, or scratches. Replace or resurface grooved or
scratched valve plates. Measure valve plate thickness and
replace if worn beyond minimum specification. Valve plates
may be resurfaced to specifications shown in the drawing,
provided resurfacing will not reduce thickness below mini­mum specification.

Inspect journal bearings for damage or excessive wear.

31215031 3-33

Replace journal bearings if scratched, warped, or excessively
worn. The polymer wear layer must be smooth and intact.

SECTION 3 - CHASSIS & TURNTABLE

3

2

1

3

1. O-ring

2. Piston Seal

3. Servo Piston

Figure 3-37. Servo Piston

Go to Discount-Equipment.com to order your parts

SHAFT BEARINGS

Inspect bearings for excessive wear or contamination. Rotate
bearings while feeling for uneven movement. Bearings should
spin smoothly and freely. Replace bearings that appear worn
or do not rotate smoothly.

SHAFT

Inspect motor shaft for damage or excessive wear on output
and block splines. Inspect bearing surfaces and sealing sur­face. Replace shafts with damaged or excessively worn splines,
bearing surfaces, or sealing surfaces.

SERVO PISTON AND MINIMUM ANGLE STOP

Inspect the minimum angle stop, servo piston head, and servo
piston ball-socket for damage or excessive wear. Replace if
necessary.

Assembly

1. Install new O-ring (1) and piston seal (2) to servo piston
(3). Install piston seal over O-ring.



Installing piston seal stretches it, making it difficult to

stall servo piston in its bore. Allow 30 minutes for seal

in
to relax after installation. To speed up seal relaxation,
compress seal by installing piston head in servo cavity in
the end-cap and let it stand for at least five minutes.

LOOP FLUSHING SPOOL

Inspect loop flushing spool for cracks or damage. Replace if
necessary.

3-34 31215031

2. After piston seal has relaxed, lubricate and install servo

piston in housing bore. Align piston with ball socket fac­ing inside of housing.

RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES ABOUT
80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAIN­TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE
BEFORE ATTEMPTING TO INSTALL SPIRAL RETAINING RING. RELEASE PRES­SURE SLOWLY AFTER RETAINING RING IS INSTALLED.

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

Go to Discount-Equipment.com to order your parts

3. Install inner block spring washer (4), block spring (5),
and outer washer (6) in cylinder block. Using a press,
compress block spring enough to expose retaining ring
groove. Wind spiral retaining ring (7) in cylinder block
groove.

nstall journal bearings (13) in housing seats. Use assem-

6. I
bly grease to keep bearings seated during assembly.
Ensure locating nubs drop into seat cavities. If reusing
bearings, install in original location and orientation.
Lubricate journal bearings.

nstall swashplate (14) in housing. Tilt swashplate and

7. I
guide servo lever ball into its socket in the servo piston
rod. Ensure swashplate seats into journal bearings and
moves freely. Lubricate running surface of swashplate.

urn block over and install retaining ring (8), hold-down

4. T
pins (9), and ball guide (10) to cylinder block.

5. Install pistons (11) to slipper retainer (12). Install piston/
retainer assembly in cylinder block. Ensure concave sur­face of retainer seats on ball guide. If reusing pistons,
install them in original block bores. Lubricate pistons,
slippers, retainer, and ball guide before assembly. Set
cylinder kit aside on a clean surface until needed.

31215031 3-35

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

Go to Discount-Equipment.com to order your parts

8. Press front shaft bearing (15) on shaft (16). Press bearing
on shaft with lettering facing out. Lubricate bearing roll­ers. Install snap-ring (17) on shaft.

10. Verify swashplate and bearings are properly seated.
Install cylinder kit (19) on shaft. Install with slippers fac­ing swashplate. Rock the shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,
journal bearings, and servo piston are secure and prop­erly installed.

ubricate and install servo spring (20) and minimum

11. L
angle stop (21) in housing bore.

9. While holding swashplate in place, turn housing on its
side. Install the install shaft/bearing assembly into hous­ing from flange end. Install snap-ring (18).

3-36 31215031

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

Go to Discount-Equipment.com to order your parts

12. Press rear shaft bearing (22) in endcap. Install bearing
with letters facing out. Press until bearing surface is 0.08
±0.01 in (2 ±0.25 mm) above endcap surface.

15. Install endcap (25) on housing with endcap screws (26).
Ensure endcap will properly seat to housing without
interference. Improper assembly of internal compo­nents may prevent endcap from seating properly.
Ensure O-rings seat properly when installing endcap.

13. Install timing pin (23) into its bore in the endcap. Install
pin with groove facing toward or away from shaft. Press
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
above endcap surface.

14. Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.

Figure 3-44. End Cap

16. Using an 8 mm internal hex wrench, tighten endcap-

screws. Tighten screws in opposite corners slowly and
evenly to compress the servo spring and properly seat
the endcap. Torque end capscrews 35-45 ft-lb (47-61
Nm).

efore installing shaft seal, ensure shaft turns smoothly

17. B
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, dis­assemble and check unit.

18. Cover shaft splines with an installation sleeve. Install a
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).

31215031 3-37

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

Go to Discount-Equipment.com to order your parts

Figure 3-45. Shaft Seal

19. Install remaining plugs and fittings to housing. Refer to

drawing below for wrench sizes and installation torques.

1. Install shift spool (31).

2. Install spring retaining washers on springs (32 and 33).

3. Carefully install centering springs (34, 35, and 36).

4. Install new O-rings (37, 38, and 39).

5. Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27

Nm).

sing a 11/16 in wrench, torque plugs (41 and 42) to 27

6. U
ft-lb (37 Nm).

Initial Start-up Procedures

Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.

Prior to installing the motor, inspect for damage incurred dur­ing shipping. Make certain all system components (reservoir,

3-38 31215031

Figure 3-46. Plugs and Fittings Installation

nstall orifice poppet (30).

20. I

hoses, valves, fittings, heat exchanger, etc.) are clean prior to
filling with fluid.

ill reservoir with recommended hydraulic fluid. Always

1. F
filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid.

ill inlet line leading from pump to reservoir. Check inlet

2. F
line for properly tightened fittings and be certain it is
free of restrictions and air leaks.

ill pump and motor housing with clean hydraulic fluid.

3. F
Pour filtered oil directly in upper most case drain port.

SECTION 3 - CHASSIS & TURNTABLE













Go to Discount-Equipment.com to order your parts

4. To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.

5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres­sure gauge port of pump to monitor system pressure
during start up.

6. While watching pressure gauge, run engine at lowest
possible speed until system pressure builds to normal
levels (minimum 160 psi [11 bar]). Once system pressure
is established, increase to full operating speed. If system
pressure is not maintained, shut down engine, deter­mine cause, and take corrective action.

7. Operate hydraulic system for at least fifteen minutes
under light load conditions.

8. Check and adjust control settings as necessary after
installation.

9. Shu

10. Check fluid level in reservoir. Add clean filtered fluid if

t down engine and remove pressure gauge. Replace

plug at charge pressure gauge port.

necessary. Motor is now ready for operation.

3.6 STEER ADJUSTMENTS

NOTE: 2 Wheel Steering/2 Wheel Drive: Spindles do not stop on

cylinder stroke. Adjust steering stops as follows: Adjust item
#1 to achieve 44° inside turn angles. Steer full left and
adjust RH item #2 to contact axle. Steer full right and adjust
LH item #2 to contact axle.



2 Wheel Steering/Four Wheel Drive: Spindles do not stop
on cylinder stroke. Adjust steering stops as follows: Adjust
item #1 to achieve 39° inside turn angles. Steer full left and
adjust RH item #2 to contact axle. Steer full right and adjust
LH item #2 to contact axle.



Figure 3-48. Steer Adjustments

31215031 3-39

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3.7 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the turntable angle
with respect to level ground. The control system compares the
reading to a pre-set turntable tilt angle value. When the
machine is in transport position refer Transport Position Sens­ing System procedure for detail, it
speed until it tilts more than 8.0 degree, then the system will
limit the drive speed to maximum displacement mode (slow
drive speed).

However, when the machine is out of transport position and

e turntable tilts more than the pre-set value, the boom func-

th
tions can only run in creep speed mode and with the drive

ction disabled. The operator must return the machine into

fun
transport mode to continue drive the machine.

By factory default, the tilt sensor
is 4 degree, but it need to select between 4.0 degree, and 3.0
degree by JLG hand held Analyzer. By factory default, the tilt
sensor pre-set value for 660AJ (7 ft.) is 3 degree.

Previously, it could be selected by JLG hand held analyzer so

at the machine could drive at maximum displacement mode

th
(slow speed) when out of transport position and tilted beyond
pre-set turntable tilt angle value. By regulations, this will not
have allowed for ANSI or CE markets.

can travel at up to maximum

pre-set value for 660AJ (8 ft.)

3.9 TRANSPORT POSITION SENSING SYSTEM

The transport position sensing system consists of two limit
switches capable of recognizing position of the tower and
main boom. The tower elevation switch is activated when the
tower upright is raised 40 in. to 42 in. from stowed position
and reset when lowered 25 in. to 30 in. from activated position.
The main boom elevation switch is activated when the main
boom reaches 0 to 5 degree above horizontal and reset when
the main boom is lowered 4 to 9 degree below horizontal.

This system uses switches with "positive opening" contacts.
These swit
to be physically broken to the open position when the
machine is in the "unsafe" condition. When the machine is in
the "safe" condition, the switch must be allowed to return to
the closed state. This requires switch arm cams to be posi­tioned in a way that the switch arm is actuated while the
mac
while the machine is in the "safe" condition.

The position of the articulated ji
used to control the following systems:

1. Be

2. Dr

ches are used in a way that requires switch contacts

hine is in the "unsafe" condition and the switch arm is free

b not considered. This system

yond Transport - Drive Speed Cutback System

ive/Steer - Boom Function Interlock System

3.8 DRIVE ORIENTATION SYSTEM

The Drive Orientation System (DOS) is intended to indicate to
the operator conditions that could make the direction of
movement of the chassis different than the direction of move­ment of the drive/steer control handle.

The system indicates to the operator the need to match the

ack and white directional arrows on the platform control

bl
panel to the arrows on the chassis. The system uses a proximity
switch mounted on the hydraulic swivel, an indicator light and
a spring return override switch on the platform display panel.
The proximity switch trips when the turntable is swing +/- 45
degrees off center of the normal driving position. This occurs
roughly when the main boom is swing past a rear tire.

When the turntable is in the no
boom between the rear tires, no indications or interlocks are
made. When the machine is actively driving when the turnta­ble is swing past the switch point, the sy
drive/steer is released. When drive is initiated with the boom
swing past the switch point, the DOS indicator will flash, and
the drive/steer functions will be disabled. The operator must
engage the DOS override switch to enable Drive/steer (high
drive will remain disabled). When the DOS is enabled, the DOS
indicator will be illuminated continuously, and a 3-second
enable timer will be started and will continue for 3 seconds
after the end of the last drive/steer command. If the timer
expires, the DOS override switch must be re-engaged to
enable drive/steer.

rmal drive position with the

stem is ignored until

3.10 BEYOND TRANSPORT - DRIVE SPEED CUTBACK
SYSTEM

When the boom is positioned beyond the transport position
as described in Transport Position Sensing System, the drive
motors are automatically restricted to their maximum dis­placement position (slow speed). See the Tilt Indicator System

or interaction with the tilt sensor.

f

3.11 DRIVE/STEER – BOOM FUNCTION INTERLOCK
SYSTEM

The Drive/Steer - Boom Function Interlock System uses the
Transport Position Sensing System to sense when the boom is
out of the transport position. All controls are simultaneously
functional when the booms are within the transport position
as on the standard machine.

When the boom is beyond the transport position, the control
functions interlocked to prevent simultaneous operation of
any boom function with drive/steer. The first function set to be
operated while in this mode, becomes the master function set.
In other words, while operating drive/steer functions the
boom functions are inoperable. Likewise, while operating
boom functions drive/steer functions are not in operation.

3-40 31215031

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3.12 OSCILLATING AXLE SYSTEM

The oscillating front axle is attached to the frame by a pivot
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain.

The oscillating axle incorporates two lockout cylinders con­nected between the frame and the axle. The lockout cylinders

et axle oscillation when pilot pressure allows flow through the

l
axle cylinder holding valves.

When the turntable moved off center, as recognized by a cam
valve in the hydraulic swivel coupling, pilot pressure removed
from the axle cylinder holding valves and the cylinders are
locked.

When the turntable moved back to
have been locked, the cylinders may not fully release until
drive is actuated.

center after the cylinders

3.13 DRIVE SYSTEM

The drive system consists of one variable displacement closed
loop pump, four variable displacement piston motors, gear
reduction hubs, and a traction control manifold that includes
three flow dividers/combiners.

Drive speed is varied by a combination of drive pump dis­placement, engine & integrated motor/generator speed, and
motor displacement. Traction control is full-time and is pres­ent in all drive modes. There are three drive modes that can be
selected at the platform console. The functionality of the drive
system is dependent on the position of the boom (In Transport
or Out of Transport, refer toSection 3.9, Transport Position
Sensing System and Section 3.10, Beyond Transport - Drive
Speed Cutback System for a detailed description). The follow­ing table describes how the system works in each drive mode.

Table 3-8. Drive Mode Speeds

Drive

Boom

Position

In

Tra n sp o r t

Selection

(Toggle Switch

Location on the

Platform Console)

Max Speed High – 2600 RPM 3.8

Mid-Engine Mid – 1800 RPM 0.09

Max Torque High – 2600 RPM 1.3

Engine Speed

when Drive

Control is Activated

Approx. Max
Speed (MPH)

Out of

Tra ns po r t

Max Speed High – 2600 RPM 0.4

Mid-Engine Mid– 1800 RPM 0.4

Max Torque High – 2600 RPM 0.4

31215031 3-41

SECTION 3 - CHASSIS & TURNTABLE

Go to Discount-Equipment.com to order your parts

3.14 SWING DRIVE

Roll, Leak And Brake Testing

Torque-Hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the unit's
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing
these tests.

NOTE: The brake must be released before performing the roll test.

This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the 12
bolts into the piston through the end plate (See Brake Dis­assembly Procedure).

NOTE: Bolts

Roll Test

The purpose of the roll test is to determine if the unit's gears

e rotating freely and properly. You should be able to rotate

ar
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con­cerned if the gears in your unit seem to roll hard as long as
they r
Housing (6) and remove the test fixtures.

Leak Test (Main Unit)

The purpose of a leak test is to make sure the unit is air tight.
You can tell if your unit has a leak if the pressure gauge reading
on your air checker starts to fall after the unit has been pressur­ized and allowed to equalize. Leaks will most likely occur at the
pipe plugs, the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be detected by
brushing a soap and water solution around the main seal and
where the o-rings or gaskets meet on the exterior of the unit,
then checking for air bubbles. If a leak is detected in a seal, o­ring or gasket, the part must be replaced, and the unit
rechecked. Leak test at 10 psi (0.7 bar) for 20 minutes.

must be removed while performing brake release test.

oll with consistency. Release the pressure at the Brake

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure that the bolts are not tightened
beyond their specified torque.

The following steps describe how to tighten and torque bolts
or socket head capscrews in a bolt circle.

1. Tighten (but do not torque) bolt “A" until snug.

2. Go to the opposite side of the bolt circle and tighten bolt

“B” until equally snug.

3. Crisscross around the bolt circle and tighten remaining
bolts.

w use a torque wrench to apply the specified torque

4. No
to bolt “A”.

5. Using the same sequence, crisscross around the bolt cir­cle and apply an equal torque to the remaining bolts.

Brake Test

The brake test must be performed with the Motor removed
and the
Bolts through Brake Test Plate and torque to 80 - 100 ft. lbs.
(108-135 Nm). Install Roll Checking Tool (T-212731) and apply
210 psi (14 bar) to the o-ring port in the side of the Brake Hous­ing. The roll checking fixture should roll freely. Increase the
pressur

NOTE: Failure to perform this lest may result in damaged or inef-

Brake Test Plate (T-214404) installed. Install the Hex

e to 3000 psi (207 bar) and perform the Roll Test.

fective brake parts.

3-42 31215031

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

Go to Discount-Equipment.com to order your parts

Motor Control Valve Disassembly

NOTE: Refer to Figure 3-49.

1. Place unit on bench with the motor end up.

2. Remove O-ring Plug (1P) and drain the oil from the gear-

box.

3. Remov

e Hydraulic Tubing Assembly (35) by loosening

fittings on both ends of tube with a wrench.

4. Using a wrench, loosen jam nuts on Elbow Fittings (30)
and remove fittings from Brake (6) and Motor Control
Valve (32).

5. Remove O-ring Plugs (23) from Motor Control Valve (32).

6. Remove Motor Control Valve (32) from Motor (31) by

removing the four Bolts (21) and washers (22).

31215031 3-43

SECTION 3 - CHASSIS & TURNTABLE

6

8K

8J

8K

8K

8K

8J

8K

8J

8J

8L

26

31

28

29

8A

6. Brake Housing
8A. Brake Piston
8L. Spring
8J. Rotors
8K. Stator

26. O-ring

28. Lift Lug

29. Hex Bolt

31. Motor

Figure 3-50. Motor and Brake

Go to Discount-Equipment.com to order your parts

Motor and Brake Disassembly

NOTE: Refer to Figure 3-50.

1. With unit resting on bench with Motor (31) end up,
loosen Hex Bolts (29) and remove Lift Lugs (28) from the
Motor (31).

ull Motor (31) straight up and remove Motor (31) from

2. P
Brake Housing (6).

3. Remove O-ring (26) from between Motor (31) and Brake
Housing (6).

4. Remove the Springs (8L) from the piston.

5. Apply less than 50 psi (3.45 bar) air to the “brake port” to

remove Brake Piston (8A).

THE PISTON MAY MOVE QUICKLY. EYE PROTECTION SHOULD BE WORN DURING
THIS PROCEDURE.

6. Remove Rotors (8J) and Stators (8K) from Brake Housing
(6).

3-44 31215031

Main Drive Disassembly

44

8

20

12

6

11

5A

4

5

3F

11

2

13

1G

1A

Hub-Shaft
Subassembly

Carrier
Subassembly

1A. Output Shaft (Pinion)
1G. Housing

2. Internal Gear
3F. Carrier subassembly

4. Ring Gear

5. O-ring
5A. O-ring

6. Brake Housing

8. Sun Gear

11. Thrust Washer

12. Bolt

13. Dowel Pin

20. Pipe Plug

44. Ring

Figure 3-51. Main Drive Assembly

Go to Discount-Equipment.com to order your parts

NOTE: Refer to Figure 3-51.

SECTION 3 - CHASSIS & TURNTABLE

emove Thrust Washer (11) from between Brake Hous-

5. R
ing (6) and Carrier Subassembly.

6. Remove Ring Gear (4) from Housing (1G).

1. Remove Sun Gear (8) with Retaining Ring (44) inside.

2. With the unit resting on the Output Shaft (Pinion) (1A),

remove the Bolts (12) from the Brake Housing (6).

3. Remov

4. Remove O-ring (5A) from between Brake Housing (6)

e the Brake Housing (6) from the main assembly.

and Ring Gear (4).

7. Remove O-ring (5) from between Ring Gear (4) and
Housing (1G).

8. Remove Carrier Sub-Assembly.

9. Remove Thrust Washer (11) from between Carrier Sub-

Assembly and Internal Gear (2).

10. Remove Internal Gear (2).

31215031 3-45

SECTION 3 - CHASSIS & TURNTABLE

1A

1B

1D

1C

1G

1F

1E

1H

1I

1A. Output Shaft
1B. Lip Seal
1C. Bearing Cup
1D. Bearing Cone
1E. Bearing Cone

1F. Bearing Cup
1G. Housing
1H. Thrust Washer
1I. Retaining Ring

Figure 3-52. Hub Shaft

Go to Discount-Equipment.com to order your parts

Hub-Shaft Disassembly

NOTE: Refer to Figure 3-52.

1. Using retaining ring pliers remove Retaining Ring (1I)
from groove in Output Shaft (1A) and discard.

EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

2. Remove Thrust Washer (1H).

3. While supporting the Housing (1G) on the Output Shaft

(1A) end, press the Output Shaft (1A) out of the Housing
(1G).

NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by

the Bearing Cone (1D) during this step.

4. Remo

5. Use a bearing puller to remove the Bearing Cone (1D)

6. Bearing Cups (1C & 1F) will remain in Housing (1G).

ve the Bearing Cone (1E) from the Housing (1G).

from the Shaft (1A).

3-46 31215031

SECTION 3 - CHASSIS & TURNTABLE

3B

3B

3C

3D

3C

3F

3G

3E

3A

3A. Carrier
3B. Thrust Washers
3C. Needle Bearing
3D. Spacer

3E. Planet Shaft
3F. Cluster Gear
3G. Roll Pin

Figure 3-53. Carrier

Go to Discount-Equipment.com to order your parts

Carrier Disassembly

NOTE: Refer to Figure 3-53.

1. Using a 3/16” punch drive the Roll Pin (3G) which holds
the Planet Shaft (3E) in the Carrier (3A) down into the
Planet Shaft (3E) until it bottoms.

NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-

age to the carrier could occur when the Planet Shaft is
removed.

2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3D) from the Planet
Shaft (3E).

3. Slide the Planet Gear (3F), the two Thrust Washers (3B)
out of the Carrier (3A).

4. Remove both rows of Needle Bearings (3C) and the
Spacer (3D) from the bore of the Planet Gear (3F).

5. Repeat Steps 1 thru 4 for the remaining two Cluster
Gears (3F).

31215031 3-47