2-414
CYLINDER
ACTING
LINE, WORKING
w\
MISCELLANEOUS
SINGLE
ROTATING SHAFT
CYLINDER - DOUBLE
ACTING
DIFFERENTIAL
LINE, PILOT
MANUAL
LINE, DRAIN
-e
ENCLOSURE
NON-DIFFERENTIAL
<=L
i------------1
i
i________i
CONNECTOR
VALVES
LINE, FLEXIBLE
(HI
PUSH BUTTON
RESERVOIR
VENTED
CHECK
LINES JOINING
LINES PASSING
i____i
PUSH-PULL LEVER
ON-OFF
h
SHUT-OFF)
DIRECTION OF FLOW
(MANUAL
PRESSURIZED
ii
PEDAL OR TREADLE
LINE TO RESERVOIR ABOVE
FLUID LEVEL
PRESSURE RELIEF
PRESSURE GAUGE
CH
MECHANICAL
LINE
TO
MANIFOLD
VENTED
FLOW CONTROL,
ADJUSTABLE - NONCOMPENSATED
DETENT
FLOW CONTROL
ADJUSTABLE
(TEMPERATURE AND
PRESSURE
COMPENSATED)
PLUG OR PLUGGED
CONNECTION
RESTRICTION. FIXED PRESSURE
COMPENSATED
q=C
SOLENOID,SINGLE WINDING
REVERSING MOTOR
SINGLE,
VARIABLE
DISPLACEMENT
MOTOR, VARIABLE
DISPLACEMENT,
REVERSIBLE
?!
HEATER
it
@k
COOLER
HE
ACTUATORS
MOTOR,
FIXED
DISPLACEMENT
NON-REVERSIBLE
in
SINGLE,
FIXED
DISPLACEMENT
MOTOR, FIXED
DISPLACEMENT
REVERSIBLE
RESTRICTION, VARIABLE
PUMPS
ACCUMULATOR, SPRING
LOADED
INTERNAL SUPPLY
--C
TWO POSITION IN
TRANSITION
TEMPERATURE
CONTROLLER
SHE
ft
-o-
6.
7.
If the pressure reading is greater than or less than 3300 psi (22,753.5
kPa/227.53 bar), install an alien wrench into the adjustment in RV2
and turn the adjustment clockwise to increase the pressure or 1.
counterclockwise to decrease.
Remove the alien wrench from the adjustment in RV2 and install the 2.
cap. Recheck the pressure reading.
3.
8.
9.
Install an alien wrench into the adjustment in valve RV1. Turn the
4.
adjustment counterclockwise approximately 1 1/2 turns.
CAUTION
5.
6.
2.
3.
If the pressure gauge reading is greater than or less than 800 psi
(5516 kPa/55.1 6 bar), install an alien wrench into the adjustment in
RDV1 and turn the adjustment clockwise to increase pressure or
counterclockwise to reduce pressure until the gauge reads 800 psi
(5516 kPa/
55.16
bar).
Drain the control accumulator using the valve knob in M5. Close the
7.
valve knob. Install a test fitting in M5 port TP2.
Remove the alien wrench from the adjustment in RDV1 and install the
cap. Recheck the pressure reading on the gauge to ensure a reading
Install a 0 to 5000 psi (0 to 34,475 kPa/0 to 344.75 bar) pressure
of 800 psi (5516 kPa/
gauge into the test fitting in port TP2 of M5.
55.16
bar).
Start the engine and set the throttle at FUlsL. Observe the gauge, 8.
pressure should level off at 3000 psi (20,685 kPa/206.85 bar).
1.
7.
2.
Start the engine and position the throttle to the MID position. Observe
the pressure gauge for a reading of 250 psi (1723.75 kPa/17.23 bar).
3.
4.
If the pressure reading on the gauge is greater than or les? than 250 4.
psi (1 723.75 kPa/17.23), loosen and remove the cap on the cartridge
valve in port RV. Install an alien wrench into the adjustment in valve
RV and turn the adjustment clockwise to increase the pressure or
counterclockwise to decrease the pressure until the pressure gauge
reads 250 psi (1 723.75 kPa/1 7.23 bar).
Shut down the engine and remove the pressure gauge from the M17
valve body. Install the cap on the cartridge valve in port RV.
Setting the Flow Control Valve.
Shut down the engine and remove the pressure gauge from the M17
valve body.
POR ADJUSTMENT.
The pressure override (POR) adjustment will now be set on the front
hoist pump (P3), the rear hoist pump (P1), and the boom hoist pump
(P2). The front and rear hoist brake pedals will be applied while
hoisting up to set the POR on pumps P1 and P3. To set the POR on
the boom hoist pump, P2, the solenoid coil on the boom hoist brake
release solenoid must be removed.
1.
WARNING
2.
Start the engine and position the throttle to the FULL position. Observe
the pressure gauge for a reading of 215 psi (1482.4 kPa.14.82 bar).
2.
3.
Loosen the jam nut on the POR adjustment which is on the opposite
end of the hoses which install to the POR.
CAUTION
WHEN CHECKING OR SETTING HOIST POR
SETTING, DO NOT PUSH THE HRC FORWARD,
PULL BACK ON THE HRC FOR AN ACCURATE
READING.
3.
If the pressure reading on the gauge is greater than or less than 215
psi (1482.4 kPa/14.82 bar), move the adjustment on the flow control
valve clockwise to increase the pressure or counterclockwise to
decrease the pressure until the pressure gauge reads 215 psi (1482.4
kPa/ 14.82 bar).
4.
Start the engine and position the throttle to FULL. Place one foot on
the rear hoist brake pedal on the cab floor and pull back on the rear
hoist HRC. Observe the pressure gauge in M3-R for a reading of 5000
psi (34,475 kPa/
344.75
bar).
2-4-5
0339
1.
2.
5.
Tighten the jam nut on the POR adjustment and observe the gauge to ensure a reading of 5000 psi
(34,475 kPa/344.75 bar).
7.
CAUTION
CAUTION
6.
motor.
Boom Hoist POR Setting.
4. Start the engine and position the throttle to FULL. Observe the pressure gauge in the B line of the boom hoist
circuit for a reading of 5500 psi (37,922.5 kPa/379.22 bar).
ACCURATE READING.
3.
1.
2.
3.
4.
NOTE
The POR must be adjusted with the
engine running at full throttle, the
solenoid coil on the boom hoist
brake release valve removed, and
the boom hoist HRC pulled back to
boom up.
Tighten the jam nut on the POR adjustment and observe the gauge to ensure a reading of 5000 psi
(34,475 kPa/344.75 bar).
5.
2-4-7
Tighten the jam nut on the POR adjustment and observe the gauge to ensure a reading of 5500 psi
(37,922.5 kPa/379.22 bar.
Shut down the engine and remove the gauge from
the B line of the boom hoist circuit.
8.
Install the solenoid coil to the boom hoist brake release valve using the nut.
1.
2.
3.
CAUTION
ENSURE THE MATING SURFACES
OF THE VALVE BODIES ARE
CLEAN.
4.
5.
Remove the plug (11) from port R2. Install the orifice 5.
plug (12) into the inner bore of port R2. Install the
plug (11) into port R2.
Install the orifice plug (10), connector (9), 90 degree
6.
fitting (8), and the pressure switch (7) into port TP11.
6.
7.
8.
7.
9.
8.
9.
2.
3.
4.
5.
6.
a.
body (1).
Inspect all fittings and internal components for damaged threads, burrs, and scratches. b.
Lubricate
and install a new O-ring (30) and a new
backup ring (29) into the outer
groove of the valve spacer
Replace all damaged components.
(27).
ASSEMBLY.
(27) into the port with the
c.
(27).
NOTE
d. Repeat this procedure for the four remaining
ports,
1. Install all plugs into the M3 valve body as marked during removal.
14. Install the orifice plug (25) into the inner bore of port . Install
CV1 the valve cartridge (24) into port CV1.
2.
15.
Install the hot oil shuttle valve (23) into port PSH1.
3.
16.
4.
17.
5.
18.
2-4-8
6.
19.
7.
20.
8.
Install the test fitting (44) into port PS and the fitting
21.
(45) into port D on the hoist port valve (37). Install the
MAINTENANCE
REMOVAL
1.
2.
4.
DISASSEMBLY.
NOTE
3.
1.
2.
5.
6.
Remove the fitting (6) from port P2 and the fitting (6)
from port P1.
7.
8.
9.
2-4-10
2-4-9
Energized
Low Speed
High Speed
Freefall
None
SV1
SV2, SV3
Solenoids
Deenergized
Pressurized
Poppet Valves
Vented
V2, V3, V4
V2.V3.V5
*V1.V4.V5
V1,V5
V1.V4
V2, V3
MAINTENANCE
REMOVAL.
the
1.
hoist
Disconnect
cable
from
block.
the
hook
Re
move the cable
from the hoist.
NOTE
.J
'/
T
h
e
m
a
i
n
t
e
n
a
n
c
e
p
r
o
c
e
d
u
r
e
f
o
r
t
h
e
f
r
o
n
t
a
n
d
r
e
a
r
h
o
i
s
t
s
i
s
i
d
e
n
t
i
c
a
l
.
2.
3.
4.
5.
6.
Disconnect the pawl by removing the cotter key and the pin from
the spring loaded cylinder. Disconnect the rotation indicator
4.
transmitter by removing the two bolts and lockwashers.
Remove the caliper assembly from the arm on the hoist frame by
5.
referring to Front and Rear Hoist Brake - REMOVAL, steps 3 thru
8, in this Section.
Loosen and remove the 24 bolts and flat washers that attach the
Lift off the hydraulic motor and place it on a flat work bench with
the valve assembly end pointing upward.
Loosen and remove the six bolts and flat washers that attach the
hoist valve assembly to the hydraulic motor.
Tag and disconnect all hydraulic hoses and tubes on the hoist 6.
valve assembly. Discard the O-rings in the two large'tubes.
Remove the hose on the hydraulic accumulator.
7.
Attach a suitable lifting device to the valve assembly and lift the
valve assembly straight up to remove it. Discard all O-rings.
Plug all open ports and cap all hoses and tubes.
contamination.
CAUTION
8.
9.
7.
Tag and remove all the solenoid coils from the valve bodies by 11. Rotate the hoist drum 1 80 degrees using a suitable
lifting device
so the brake disc is facing upward.
removing the nuts on the end of the solenoid and pulling the
solenoid coils straight out.
12. Loosen
and remove the four bolts that secure the
8.
9.
Loosen and remove the two bolts and flat washers from each of the
NOTE
The hoist weighs approxiamtely 4000 pounds
(1818 kg).
10.
13. Attach
disc.
Circuit Used In
M10R
M13
Distribution
M16
Swivel
M17
Horsepower
Limiter
M19
M20
M21
Reservoir Return
MAINTENANCE
M1
VALVE
BODY.
Removal
.
1.
Dischar
ge
the
control
accumul
ator by
turning
the
manual
rotary
valve
knob on
the
control
accumul
ator
valve
body
counterc
lockwise
until
pressure
is
relieved.
CAUTIO
N
D
U
R
I
N
G
R
E
M
O
V
A
L
O
F
A
N
Y
C
O
M
P
O
N
E
N
T
S
O
R
A
F
T
E
R
B
R
E
A
K
I
N
G
A
N
Y
C
O
N
N
E
C
T
I
O
N
S
,
A
L
L
lines that
attach to
the
P
O
R
T
S
valve
body.
Plug
ports
and cap
all
hoses.
3.
S
H
O
U
L
D
B
E
P
L
U
4.
G
G
E
D
O
R
C
A
P
P
E
D
.
2.
Tag and
disconne 5.
ct
all
hydraulic
all
open
A
N
D
H
O
S
E
S
M1
Loosen
and
remove
the jam
nut that
secures
the
solenoid
coil
to
the valve
cartridge
in port
SV. Pull
the
solenoid
coil
off
the
cartridge.
Loosen
and
remove
the three
nuts and
washers
that
attach
M1
to
the
bracket
on
the
rear
of
the
upperstr
ucture.
Remove
M1 from
the
upperstr 5.
ucture
and
place on
a clean
workben
ch
for
disasse
mbly.
Disasse
mbly.
1.
Loosen
6.
and
remove
the
straight
fittings
(9) from
ports C,
E, H, A,
and D.
2.
Remove
the
connecto
r (7) from
port G.
3.
Remove
the
test
Clean all
the parts
in
a
suitable
solvent.
2.
Submerg
e
the
valve
body in
a
suitable
solvent
and
agitate
gently to
flush
any
contami
nants
from
within
the
block.
Remove
from port
and the
plug
(12) from
port PS.
4.
Remove
the
90
degree
fitting
(11) from
port
T
and the
check
valve
cartridge
(1
0)
from port
CV.
Remove
the plug
(2) from
port R.
Remove
the recessed
orifice
plug (3)
from
within
port R.
Cleanin
g
and
Inspecti
on.
1.
fitting (8)
TP
Loosen
and
remove
the
connect
or
(4)
from port
B
and
the valve
cartridge
(5) from
port SV.
the
2.
block
and
blow dry
with air.
3.
or
(5)
3.
scratche
or
contami
nants.
into
port SV.
thread
burrs,
and
cartridge
body for
damage,
(4)
into port
valve
the
valve
4.
connect
the
all ports
s,
the
Inspect
on
Install
:*
Inspect
all
fittings,
plugs,
valves,
and
Install
the
check
valve
cartridge
(10) into
port CV
and the
90
degree
fitting
(11) into
port T.
switches
for
4.
Install
thread
the plug
damage.
(1
2)
into port
5.
Replace
all
defective
compon
ents.
Assemb
ly.
1.
PS and
the test
fitting (8)
into port
TP.
5.
Install
the
orifice
plug (3)
6.
within
the
recesse
d area
of port
R. Install
the plug
(2) into
port R.
Install the
connect
or
(7)
into port
G.
Install the
straight
fittings
(9)
into
ports
E, H, A,
and
D.
Installat
ion.
1.
2.
Install the
M1 valve
body to
the
bracket
on
the
rear of
the
upperstr
ucture
using
the three
3.
washers
and
nuts.
Install
the
solenoid
coil
to
the
valve
cartridge
in port
SV.
Install
the jam
nut that
secures
the coil.
Install all
hydrauli
c
marked
during
removal.
M1 Valve Body
lines
to M1 as
7.
maintenance instructions
refer to M3/M4 Valve Bo- s
in Section 7 - HOISTS.
i VALVE BODY.
moval.
2.
the
1.
Remove
Inspectall
portsonthevalvebodyforthrea
ddamage, burrs, scratches,
or contaminants.
Inspect all fittings, plugs,
valves,
and
switches
for
thread damage.
Replace
all
defective
components.
Assembly.
Install all plugs to the valve
body (2).
(I)
(II)
3.
Install
the
control
8.
accumulator assembly into
the valve body (2).
4.
5.
6.
18
-
..
2.
3.
M5 Valve Body
Install all hoses to the M5 valve body as
marked during removal.
Close the accumulator drain valve.
0330
M6 VALVE BODY.
Removal.
1.
2-4-86
4.
5.
1.
2.
3.
4.
3.
4.
5.
4.
Assembly.
P2.
1.
2.
2-4-88
1.
2.
2487
Valve
Body
Tem
perat
ure
Swit
ch
Cartr
idge
Valve
Cartr
idge
Valve
Cartr
idge
Valve
90
Degr
ee
Fittin
g
Tem
perat
ure
Swit
ch
Cartr
idge
Valve
90
Degr
ee
Fittin
g 90
Degr
ee
Fittin
g
Tem
perat
ure
Swit
ch
Scre
w
Slide
r
Valve
Sprin
g
MgM
4.
5.
M6 Valve Body
Lubri
rotary
cate
valve
and
knob
install
on
new
the
Ocontr
rings
ol
to the
accu
tubes
mulat
that
or
attach
valve
to
body
M6.
count
ercloc
Instal
kwise
l
all
until
hoses
press
and
ure is
tubes
reliev
to the
ed.
M6
valve
body
as
mark
ed
durin
g
remo
val.
M7
VALV
E
BOD
Y.
Rem
oval.
1.
0342
Disch
arge
the
contr
ol
accu
mulat
or by
turnin
g the
manu
al
CAUT
ION
D
U
R
I
N
G
R
E
M
O
V
A
L
O
F
A
N
Y
C
O
M
P
O
N
R
T
S
E
N
T
S
A
N
D
O
R
A
F
T
E
R
B
R
E
A
K
I
N
G
A
N
Y
C
O
N
N
E
C
T
I
O
N
S
, 2.
A
L
L
P
O
H
O
S
E
S
S
H
O
U
L
D
B
E
P
L
U
G
G
E
D
O
R
C
A
P
P
E
D
.
Tag
and
remo
ve all
hoses
and
tubes
that
conne
ct to
the
M7
valve
body.
Plug
all
open
ports
and
cap
all
hoses
.
3.
Loos
en
and
remo
ve the
three
bolts,
nuts,
and
flatwash
ers
that
secur
e M7
to the
cab
floor.
Remo
ve
valve
body
M7
and
place
it on a
clean
workb
ench
for
disas
sembly.
Disas
semb
ly.
NOTE
A
s
e
a
c
h
c
o
m
p
o
n
e
n
t
i
s
r
e
m
o
v
e
d
f
r
o
m
t
h
e
v
a
l
v
e
b
o
d
y
,
i
t
m
u
s
t
b
e
t
a
g
g
e
d
w
i
t
h
t
h
e
n
u
m
b
e
r
/
l
e
t
t
e
r
o
f
t
h
e
p
o
r
t
t
h
a
t
t
h
e
c
o
m
p
o
n
e
n
t
w
a
s
r
e
m
o
v
e
d
f
r
o
m
.
T
h
i
s
w
i
l
l
b
e
t
h
e
o
n
l
y
m
e 1.
a
n
s
o
f
i
d
e
n
t
i
f
y
i
n
g
t
h
2.
e
c
o
m
p
o
n
e
n
t
s
d
u 3.
r
i
n
g
a
s
s
e
m
b
l
y
.
Loos
en
and
remo
vethe
90
degre
e
fitting
(2) in
portT
3 and
the
straig
ht
fitting
(3)
from
port
P3.
Rem
ove
the
fitting
s (4)
from
ports
PS3,
PS4,
PS6,
PS7,
PS9,
and
PS10.
Loos
en
and
remo
ve the
check
valve
cartri
dges
(5)
from
port
CV1
and
CV2.
4.
5.
6.
7.
Loos
en
and
remo
ve the
straig
ht
fitting
s (6)
from
port
E21,
A21,
C11,
D11,
D21,
A11,
C21, 8.
and
E11.
Rem
ove
the
cartri
dge
valve
plugs
(7)
from
ports
SV1
and
SV2.
Loos
en
and
remo
vethe
flow
valve
s (8)
from
ports
FV1
and
FV2.
Remo
vethe
straig
ht
fitting
s (9)
from
ports
T1,
T2,
A2,
E2,
D2,
A1,
C2,
D1,
C1,
E1,
P2,
and
P1.
Rem
ove
all
remai
ning
plugs
from
the
valve
body
(1).
Clea
ning
and
Inspe
blow
ction
dry
with
.
1.
air.
Clean
3.
all the
parts
in
suitab
le
solve
nt.
2.
Subm
erge
the
valve
body
in
4.
Inspe
ct all
suita
fitting
ble
s,
solve
plugs
nt
and
valve
agitat
s,
and
gentl
y
Inspe
ct all
ports
on
the
manif
old
block
for
threa
d
dama
ge,
burrs,
scrat
ches,
or
conta
mina
nts.
switc
to
hes
flush
for
any
threa
conta
mina
dama
nts
ge.
from
within
5.
Repl
the
block.
ace
Rem
ove
all
the
block
and
defect
ive
comp
onent
s.
Asse
mbly.
NOTE
A
l
l
c
o
m
p
o
n
e
n
t
s
m
u
s
t
b
e
i
n
s
t
a
l
l
e
d
t
o
t
h
e
i
r
c
o
r
r
e
c
t
p
o
r
t
s
a
s
m
a
r
k
e
d
d
u
r
i
n
g
d
i
s
a
s
s
e
m
b
l
y
.
C
a
p
a
l
l
f
i
t
t
i
n
g
s
ports
T2,
T1,
A2,
E2,
D2,
A1,
C2,
D1,
C1,
E1,
t
o
P2,
and
p
r 3.
e
v
e
n
t
c
o
n 4.
t
a
m
i
n
a
t
i
o
n
.
1.
Install
all
plugs
into
the
valve
body
(1).
P1.
Install
the
flow
valve
s (8)
into
ports
FV1
and
FV2.
Install
the
cartri
dge
valve
plugs
(7)
into
ports
SV1
and
SV2.
5.
Instal
l
the
straig
ht
fitting
s (6)
into
2.
Install
ports
the
E21,
straig
A21,
ht
C11,
fitting
D11,
s (9)
D21,
into
A11,
C21,
and
El 1.
6.
Instal
l the
check
valve
cartri
dges
(5)
into
ports
CV1
and
CV2.
7.
Install
the
straight 8.
fittings (4) into ports
PS3, PS4, PS6, PS7,
PS9, and PS10.
0366
M8 VALVE BODY.
Removal.
1.
manual
valve
knob
control
NOTE
rotary
on
the
accumulator
valve
body
counterclockwise until
pressure is relieved.
CAUTION
DURING
REMOV
AL
OF
ANY
COMPO
NENTS
OR
AFTER
BREAKI
NG ANY
CONNECTIO
NS, ALL
PORTS
AND
HOSES
SHOULD
BE
PLUGGE
D
OR
CAPPED
.
2.
Disassembly.
3.
4.
As each
compon
ent
is
removed
from the
valve
body, it
must be
tagged
with the
number/lette
r of the
port that
the
compon
ent was
removed
from.
This will
be
the
only
means
of
identifyi
ng
compon
ents
during
assembly.
Loosen and remove
the straight fittings (2)
in ports PS4, PS6, and
PS7. Remove the
cartridge valve (3) in
port RDV.
Remove the 90
degree fittings (4) from
ports T2, P3, G, and F.
Loosen and remove
the test fitting (5) from
port P2.
Loosen
and
removethe
straight
fittings (6) from ports
F1,
G1,
and
T.
Remove the swivel tee
5.
6.
1.
2.
Submerge
suitable solvent.
body
solvent
in
the
a
and
gently to
valve
suitable
agitate 1.
any
flush
contaminants
within
the
from
block. 2.
4.
It is recommended
3.
that all O-rings be
replaced.
Lubricate
new O-rings with clean
petroleum jelly.
All
compon
ents
must be
installed
to their
correct
ports as
marked
during
disasse
mbly.
Cap all
fittings
to
prevent
contami
nation.
Install all plugs to the
valve body (1).
Lubricate and install
new O-rings to the
mounting face of the
solenoid valve (10).
CAUTION
6.
DURING REMOVAL OF ANY COMPONENTS OR AFTER
BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES
SHOULD BE PLUGGED OR CAPPED.
Assembly.
NOTE
2.
Tag and remove all hoses that attach to the M17 valve body. Plug all open
ports and cap all fittings.
3.
Tag and remove the six solenoids on the valve cartridges by removing the
jam nut that secures each solenoid and pulling the solenoids straight off.
Ensure the solenoids are properly tagged to facilitate installation to their 1.
correct valves.
2.
4.
Loosen and remove the two nuts and washers that attach the M17 valve
body to the rear of the upperstructure. Remove M17 and place it on a clean
3.
workbench for disassembly.
Disassembly.
4.
1.
Tag and remove the pressure valves (2, 3, 4, and 5) from ports PV1, PV2,
PV3, and PV4.
5.
6.
Install the pressure valves (2, 3, 4, and 5) into ports PV1, PV2, PV3, and
PV4 as tagged during removal.
Installation.
1.
2.
Install the six solenoid coils to the appropriate cartridge valves as marked
during removal. Secure the solenoid coils to the valves using the six jam
nuts.
2.
Loosen and remove the straight fittings (8) from ports T and T1.
3.
Remove the cartridge valves (6) from ports SV1 thru SV6.
4.
Remove the reducing valve (7) from port RV and the 90 degree fitting (9)
from port P.
5.
Loosen and remove the four bolts (10) that attach the flow control valve (11) 3.
to the valve body (1). Remove the flow control valve (11). Discard the Orings.
6.
port RV.
NOTE
As each component is removed from the valve body, it
must be tagged with the number/letter of the port that the
component was removed from. This will be the only
means of identifying the components during assembly.
Install all hoses to the M17 valve body as marked during removal.
Remove all remaining plugs from the M17 valve body. Cleaning and
Inspection.
1.
2.
Submerge the valve bodies in a suitable solvent and agitate gently to flush
contaminates from the internal ports. Blow dry with filtered air.
3.
4.
Inspect the ports on the valve bodies for damaged threads, burrs,
scratches, and contaminates.
5.
Inspect all fittings and internal components for damaged threads, burrs, and
scratches.
2-4-104
1.
2.
Valve Body
Pressure Valve
3.
4.
Pressure Valve
Pressure Valve
5.
6.
7.
8.
9.
Pressure Valve
Cartridge Valve
10.
11.
Reducing Valve
Straight Fitting
90 Degree Fitting
Bolt
Flow Control Valve
BH
0341
38.
assemble them over the exposed ring, rotor, and vanes. Ensure the scribe
marks are in line.
NOTE
The cast-in arrows, located next to the socket head
screws, indicate the direction of rotation of the cartridge.
40.
Thread the two socket head screws (31) into the cartridge until snug (hand
tight).
NOTE
HI 4 HI
HI
HI 1
T2
Hold the cartridge assembly together to prevent movement and rotate it 180
degrees so the outlet support plate rests on a flat surface, and the wooden
board is upward. Remove the wooden board.
42.
39.
PG
Lubricate the exposed surface of the rotor and vanes with clean hydraulic
fluid. Locate the scribe mark on the inlet support plate (29) and flex side
plate (27). Hold the inlet support plate and flex side plate together and
Check the rotor (23) for bind by inserting the index finger through the shaft
opening of the inlet support plate (29). Hold the cartridge kit in a horizontal
shaft position and lift the rotor with the finger. The rotor should move freely
back and forth within the cartridge. If the rotor binds, open the kit, clean and
2-4-105
stone all possible areas of bind, then reassemble using the aforementioned 51. Install the rotor (8) onto the shaft (33). Insert the vanes (9) into the rotor
procedure. The rotor must move freely within the cartridge when assembled.
slots. Ensure the radius edges on the vanes (9) are toward the cam ring,
43.
Lubricate and install a new O-ring (17) and backup ring (1 6) onto the outlet
support plate (20).
52.
44. Lubricate and install a new 0-ring (19) and sealing ring (18) onto the outlet
53.
support plate (20).
45.
46.
Install the cartridge assembly onto the shaft (33) with the inlet plate facing
54.
towards the main section (3).
Install the mid section (2) to the main section (3) using the two bolts (15),
INSTALLATION.
Install the front cover (1) to the mid section (2) using the four bolts (14),
torque to 40 pounds-foot (5.5 kgm).
Attach a suitable lifting device to the pump, remove the pump from the vise.
Align the spline on the pump with the spline on the pump drive and carefully
slide the pump into the drive.
3.
Secure the pump to the drive using the two bolts and washers.
4.
Remove the caps from the fittings and hoses and attach the hoses to the
pump.
2-4-106
PRESSURE SETTINGS
DESCRIPTION
This subsection outlines procedures for adjusting several major
pressure settings within the hydraulic system. Test fittings have
been provided for easy installation of the proper pressure gauges.
It is recommended that these pressures be checked every six
months and adjusted as required for maximum machine efficiency.
CHARGE CIRCUIT.
The charge pressure will be set to 450 psi (3103 kPa/31.03 bar)
using a 0 to 1000 psi (0 to 6895 kPa/0 to 68.95 bar) pressure
gauge.
1.
2.
3.
Locate the charge relief valve on the charge filter assembly on the
rear of the upperstrucutre.
4.
5.
6.
Tighten the jam nut on the charge relief valve. Recheck the
3.
pressure reading on the gauge to ensure a reading of 450 psi
(3103 kPa/31.03 bar).
7.
Shut down the engine and remove the pressure gauge from Ml.
CONTROL CIRCUIT.
WARNING
2-4-107
Drain the control accumulator using the valve knob in M5. Close
the valve knob.
Loosen the nut on valve RV1. Install an alien wrench into the
adjustment in RV1 and turn the adjustment clockwise until it
bottoms out.
Loosen and remove the cap on the end of valve RV2. Install an
alien wrench into the adjustment in RV2 and turn the adjustment
counterclockwise 1 1 /2 turns.
4.
5.
4.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
(
6
)
a
n
d
t
h
e
s
w
i
v
e
l
t
e
M8 Valve Body
e
(
7
)
i
n
t
o
p
o
rt 5.
P
.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
s
(
6
)
i
n
t
o
p
o
rt
s
F
1
,
G
1
,
a
n
d
T
.
I
n
s
t
a
ll
t
h
e
t
e
s
t
fi
tt
i
n
g
(
5
)
i
n
t
o
p
o
rt
P
2
a
n
d
t
h
e
9
0
d
e
g
r
e
e
fi
tt
i
n
g
s
(
4
)
i
n
t
o
p
o
rt
s
G
,
F
,
T
2
,
a
n
d
P
3
.
6.
I
n
s
t
a
ll
t
h
e
c
a
rt
ri
d
g
e
v
a
l
v
e
(
3
)
i
n
t
o
p
o
rt
R
D
V
.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
s
(
M8 Valve Body
2
)
i
n
t
o
p
o
rt
s
P
S
4
,
P
S
6
,
a
n
d
P
S
7
.
I
n
s
t
a
ll
a
ti
o
n
.
1.
I
n
s
t
a
ll
t
h
e
M
8
v
a
l
v
e
b
o
d
y
t
o
t
h
e
u
n
d
e
r
s
i
d
e
o
f
t
h
e
c
a
b
fl
o
o
r
u
s
i
n
g
t
h
e
t
h
r
e
e
b
o
lt
s
,
n
u
t
s
,
a
n
d
fl
a
t
w
a
s
h
e
r
s
.
2.
I
n
s
t
a
ll
t
h
e
f
o
u
r
e
l
e
c
tr
i
c
a
l
w 3.
ir
e
s
t
o
t
h
e
s
o
l
e
n
o
i
d
v
a
l
v
e
i
n
M
8
a
s
t
a
g
g
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
I
n
s
t
M8 Valve Body
a
ll
a
ll
h
o
s
e
s
a
n
d
t
u
b
e
s
t
o
t
h
e
M
8
v
a
l
v
e
b
o
d
y
a
n
d
t
h
e
s
o
l
e
n
o
i
d
v
a
l
v
e
a
s
t
a
g
g
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
M
1
0
V
A
L
V
E
B
O
D
I
E
S
.
F
o
r
m
a
i
n
t
e
n
a
n
c
e
i
n
s
tr
u
c
ti
o
n
s
r
e
f
e
r
t
o
B
r
a
k
e
V
a
l
v
e
B
o
d
y 1.
M
1
0
i
n
S
e
c
ti
o
n
7
-
H
O
I
S
T
S
.
M
1
3
V
A
L
V
E
B
O
D
Y
.
R
e
m
o
v
a
l
a
n
d
D
i
s
a
s
s
e
m
b
l
y.
D
i
s
c
h
a
r
g
e
t
h
e
c
M8 Valve Body
tr
tr
w
i
s
e
u
n
ti
l
p
r
e
s
s
u
r
e
i
s
r
e
li
e 2.
v
e
d
.
C
A
U
TI
O
N
DURI
NG
REM
OVA
L OF
ANY
COM
PON
ENT
S OR
AFT
ER
BRE
AKIN
G
ANY
CO
NNEC
TION
S,
ALL
POR
TS
AND
HOS
ES
SHO
ULD
BE
PLU
GGE
D OR
CAP
PED.
T
a
g
a
n
d
r
e
m
o
v
e
a
ll
h
o
s
e
s
a
n
d
t
u
b
M8 Valve Body
e
s
t
h
a
t
c
o
n
n
e
c 3.
t
t
o
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
.
P
l
u
g
a
ll
o
p
e
n
p
o
rt
s
a
n
d
c
a
p
a
ll
h
o
s
e
s
.
L
o
o
s
e
n
a
n
d
r
e
m
o
v
e
t
h
e
t
w
o
n
u
t
s
a
n
d
w
a
s
h
e
r
s
t
h
a
t
a
tt
a
c
h
t
h
e
M
1
3
v
a
l 4.
v
e
b
o
d
y
t
o
t
h
e
i
n
n
e
r
l
e
ft
s
i
d
e
o
f
t
h
e
u
p
p
e
r
s
tr
u
c
t
u
r
e
fr
a
m
e
.
R
e
m
o
v
e
M
1
3
a
n
d
p
l
a
c
e
it
o
n
a
c
l
e
a
n
w
o
r
M8 Valve Body
k
b
e
n
c
h
f
o
r
d
i
s
a
s
s
e
m
b
l
y
.
5.
T
a
g
a
n
d
r
e
m
o
v
e
a
ll
fi
1.
tt
i
n
g
s
a
n
d
p
l
u
g
s
i
n
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
.
C
l
e
a
n
i
n
g
a
n
d
I
n
s
p
e
c
ti
o
n
.
C
le
a
n
al
l
t
h
e
p
a
rt
s
in
a
s
ui
t
a
bl
e
s
ol
v
e
n
t.
2.
S
u
b
m
e
r
g
e
t
h
e
v
a
l
v
e
b
o
d
y
i
n
a
s
u
it
a
b
l
e
s
o
l
v
e
n
t
a
n
d
a
g
it
a
t
e
g
e
n
tl
y
t
o
fl
u
s
h
a
n
y
c
o
n
t
a
m
i
n
a
n
t
s
fr
o
m
w
it
h
i
n
t
h
e
b
l
o
M8 Valve Body
c
k
.
R
e
m
o
v
e
t
h
e
b
l
o
c
k
a
n
d
b
l
o
w
d
r
y
w
it
h
a
ir
.
3.
I
n
s
p
e
c
t
a
ll
p
o
rt
s
o
n
t
h
e
m
a
n
if
o
l
d
b
l
o
c
k
f
o
r
t
h
r
e
a
d
d
a
m
a
g
e
,
b
u
r
r
s
,
s
c
r
a
t
c
h
e
s
,
o
r
c
o
n
t
a
m
i
n
a
n
t
s
.
ll
4.
d
s
w
it
c
h
e
s
f
o
r
t
h
r
e
fi
tt 5.
i
n
g
s
,
p
l
u
g
s
,
v
a
l
v
e
R
e
pl
a
c
e
al
l
d
e
f
e
ct
iv
e
c
o
m
p
o
n
e
n
ts
.
s
,
a
A
s
s
M8 Valve Body
e 1.
m
b
l
y
a
n
d
I
n
s
t
a
ll
a
ti
o
n
.
N
O
T
E
I
n
s
t
a
ll
a
ll
p
l
u
g
s
a
n
d
fi
All
com
pone
nts
must
be
insta
lled
to
their
correct
ports
as
mark
ed
durin
g
disa
sse
mbly
. Cap
all
fittin
gs to
prev
ent
cont
amin
ation
.
tt
i
n
g
s
t
o
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
a
s
m
a
r
k
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
2.
I
n
s
t
a
ll
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
t
o
t
h
e
i
n
n
e
r
l
e
ft
s
i
d
e
o
f
t
h
e
u
p
p
e
r
s
tr
u
c
t
u
r
e
fr
a
m
e
u
s
i
n
g
t
h
e
t
w
o
n
u
t
s
a
n
d
w
a
s
M8 Valve Body
h
e 6
r
s VA
.
LV
3.
E
Install
BO
all
DY
ho
.
se
s
to
M1
3
as
tag
ge
d
dur
ing
re
mo
val
.
M1
F
o
r
m
a
i
n
t
e
n
a
n
c
e
i
n
s
tr
u
c
ti
o
n
s
r
e
f
e
r
t
o
S
W
I
V
E
L
i
n
S
e
c
ti
o
n
8
S
W
I
V
E
L
.
M
l
7
V
A
L
V
E
B
O
D
Y
.
R
e
m
o
v
a
l.
1.
D
i
s
c
h
a
r
g
e
t
h
e
c
o
n
tr
o
l
a
c
c
u
m
u
l
a
t
o
r
b
y
t
u
r
n
i
n
g
t
h
e
m
a
n
u
a
l
r
o
t
a
r
y
v
a
l
v
e
M8 Valve Body
k
n
o
b
o
n
t
h
e
c
o
n
tr
o
l
a
c
c
u
m
u
l
a
t
o
r
v
a
l
v
e
b
o
d
y
c
o
u
n
t
e
r
c
l
o
c
k
w
i
s
e
u
n
ti
l
p
r
e
s
s
u
r
e
i
s
r
e
li
e
v
e
d
.
2.
R
e
m
o
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
s
(4
)
fr
o
m
p
or
ts
S
V
1
M8 Valve Body
22.
Remove
all
remainin
g plugs
from the
M3 valve
body.
a 3.
n
d
S
V
3.
R
e
m
o
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
pl
u
g
s
(5
)
fr
o
m
p
or
ts
S
V
4,
P
V
1,
a
n
d
P
V
3.
4.
R
e
m
ov
e
th
e
va
lv
e
ca
rtr
id
g
e
pl
u
g
(6
)
fr
o
m
p
or
t
P
V
2.
5.
R
e
m
o
v
e
th
e
pr
e
s
s
ur
e
s
wi
tc
h
(7
),
9 6.
0
d
e
gr
e
e
fit
ti
n
g
(8
),
c
o
n
n
e
ct
or
(9
),
a
n
d
th
e
or
ifi
c
e
pl
u
g
(1
0)
fr
o
m
p
or
t
T
P
1
1.
R
e
m
o
v
e
th
e
pl
u
g
M8 Valve Body
(1
1)
fr
o
m
p
or
t
R
2.
R
e
m
o
v
e
th
e
or
ifi
c
e
pl
u
g
(1
2)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
R
2.
7.
R
e
m
o
v
e
th
e
pi
p
e
pl
u
g
(1
3)
fr
o
m
p
or
t
G
.
R
e
m
o
v
e
th
e
pl
u
g
(1
4)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
G
.
8.
R
e
m
o
v
et
h 9.
e
pi
p
e
pl
u
g(
1
3)
fr
o
m
p
or
tF
s.
R
e
m
o
v
et
h
e
pl
u
g
(1
4)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
F.
T
a
g
a
n
d
re
m
o
v
e
al
l
re
m
ai
ni
n
g
pl
u
g
s
in
th
e
M
4
v
al
v
e
b
o
d
y.
V
al
v
e
B
o
M8 Valve Body
d
y
M
3.
m.
Thi
s
will
be
the
only
mea
ns
of
iden
tifyi
ng
the
com
pon
ents
duri
ng
ass
emb
ly.
N
O
T
E
As
eac
h
com
pon
ent
is
rem
ove
d
fro
m
the
valv
e
bod
1.
y, it
mus
t be
tag
ged
with
the
nu
mber/
lette
r of
the
port
that
the
com
pon
ent
was
2.
rem
ove
d
fro
R
e
m
ov
e
th
e
tu
b
e
(1
5)
th
at
ru
ns
ov
er
th
e
fitt
in
g
in
p
or
t
F.
R
e
m
o
v
e
th
e
st
ra
ig
ht 3.
fit
ti
n
g
(1
6)
a
n
d
th
e
9
0
d
e
gr
e
e
fit
ti
n
g
(1
7)
th
at
th
e
tu
b
e
(1
5)
w
a
s
c
o
n
n
e
ct
e
d
to
.
R
e
m
ov
e
th
e
9
0
d
e
gr
e
e
fitt
in
g
(1
8)
fr
o
M8 Valve Body
4.
9)
fr
or
F.
or
ov
3.
th 5.
ch
ec
ov
va
th
lv
te
ca
st
rtr
fitt
id
in
(2
(1
0)
6.
fr
in
(2
1)
or
fr
6.
or
D.
7.
m
ov
e
th
e
9
0
d
e
gr
e
e
Lo
os
e
n
a
n
d
re
m
ov
e
th
e
sh
ut
tle
va
lv
e
(2
2)
fr
o
m
p
fitt
M8 Valve Body
or
t
S
H
V
1.
9.
m
o
v
e
th
e
or
ifi
pl
th
(2
5)
fr
al
th
ar
in
tri
er
or
(2
4)
of
fr
or
or
1.
C
V 10.
1.
L
o
o
s
e
n
a
n
d
re
R
e
m
ov
e
th
e
st
ra
ig
ht
fitt
in
g
(2
6)
fr
o
m
p
or
t
P
P
3.
11.
L
o
c
at
e
th
e
fa
c
e
of
th
e
v
al
v
e
b
o
d
y
(1
)
th
at
m
at
e
s
wi
th
th
e
M
4
v
al
v
e
b
o
d
y
(2
).
R
e
m
o
v
e
th
e
fi
v
e
c
ar
tri
d
g
e
v
al
v
e
s
fr
o
m
th
e
fi
v
e
la
rg
e
p
or
ts
a
s
fo
ll
o
w
s.
M8 Valve Body
a.
C
ar
ef
ul
ly
pr
y
o
ut
th
e
v
al
v
e
s
p
a
c
er
(2
7)
.
Di
s
c
ar
dt
h
e
O
ri
n
g
(2
8)
in
th
e
in
n
er
b
or
e
a
n
d
th
e
b
a
c
k
u
p
ri
n
g
(2
9)
a
n
d
O
ri
n
g
(3
0)
in
th
e
ci
rc
u
m
fe
re
nt
ia
l
c
h
a
n
n
el
of
th
e
v
al
b.
c.
m
v
ai
e
ni
n
s
g
p
p
or
a
ts.
c
er
12.
(2
L
7)
o
.
o
s
R
e
e
n
m
ov
a
e
n
th
e
d
va
re
lv
e
m
ca
o
rtr
id
v
g
e
e
p
th
o
e
p
p
b
et
ol
(3
1)
t
fr
(3
o
m
2)
th
th
e
at
p
or
at
t.
ta
c
R
h
e
e
p
e
s
at
th
thi
s
e
pr
lo
oc
e
c
d
at
ur
e
or
fo
pl
r
th
at
e
e
fo
ur
(3
re
M8 Valve Body
3)
to
th
e
v
al
v
e
b
o
d
y
(1
).
er
b
or
e
a
n
d
th
e
O
ri
n
g
(3
13.
R
e
m
o
v
e
a
n
d
di
s
c
ar
d
th
e
O
ri
n
g
(3
4)
fr
o
m
th
5)
fr
o
m
th
e
o
ut
er
gr
o
o
v
e
of
th
e
lo
c
at
or
pl
at
e
(3
3)
.
e 14.
in
L
n
o
o
s
e
n
a
n
d
re
m
o
v
e
th
e
fo
ur
b
ol
ts
(3
6)
th
at
at
ta
c
h
th
e
h
oi
st
p
or
t
v
al
v
e
(3
6)
a
n
d
th
e
t
w
o
fl
a
n
g
e
h
al
v
e
s
(3
8)
to
th
e
v
al
v
e
b
o
d
y
(1
).
Di
s
c
ar
d
th
e
O
ri
n
g
(3
9)
.
1
5.
R
e
m
o
M8 Valve Body
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
(4
0)
fr
o
m
p
or
t
S
V
o
n
th
e
h
oi
st
p
or
t
v
al
v
e
(3
7)
.
R
e
m
o
v
e
th
e
pr
e
s
s
ur
e
s
wi
tc
h
(4
1)
,
fit
ti
n
g
(4
2)
,
a
n
d
th
e
c
o
n
n
e
ct
or
(4
3)
fr
o
m
th
e
h
oi
st
p
or
t
v
al
v
n
e
th
(3
e
7)
h
.
oi
R
st
e
p
m
or
o
t
v
v
e
al
th
v
e
e
te
(3
st
7)
fit
.
ti
1
n
6.
g
R
e
(4
m
4)
ov
e
fr
th
o
e
te
m
st
p
fitt
in
or
g
t
(2
0)
P
fr
S
o
a
m
p
n
or
d
t
T
th
P
e
4.
fit
ti 17. R
n
e
g
(4
m
5)
fr
ov
o
m
e
p
or
th
t
D
e
o
M8 Valve Body
tu
ov
th
(4
6)
fitt
fr
in
(4
th
7)
fr
fitt
in
in
or
or
3.
3.
9.
8.
ov
th
re
lie
1.
R
e
f
m
ov
e
va
th
e
st
lv
ra
ig
ht
e
fitt
in
g
ca
(4
9)
fr
rtr
o
m
id
p
or
t
g
P
P
2.
e
V'
21. R
e
(4
m
ov
e
8)
th
e
fitt
fr
in
g
(2
o
1)
fr
m
o
m
p
p
or
t
D
or
4.
20.
M8 Valve Body
The valve bodies M3 and M4 are bolted together and then bolted
directly to the hoist motor. Three main internal ports A, B, and C
MAINTENANCE
REMOVAL.
4.
Tag and remove all hydraulic lines that attach to the M3 and M4
valve body. Plug all open ports and cap all
hoses.
Tag and remove the remaining electrical lines that run to the valve
body.
Attach a suitable lifting or supporting device to the valve body.
Loosen and remove the six bolts and washers that attach the valve
body to the hoist motor.
Remove the valve body from the hoist motor. Discard the O-rings.
Plug all open hoist motor ports.
8.
9.
CAUTION
TAG THE SOLENOID COILS WITH THE CORRECT
Tag and remove the three solenoid coils on the M4 valve body by
removing the nut that secures each solenoid coil to the valve body.
Pull the coils straight off the valve cartridges. Tag and remove the
solenoid coil from the hoist port valve.
SECTION 9
ELECTRICAL
SYSTEM
TABLE OF CONTENTS
Page
ELECTRICAL SYSTEM
Description ......................................................................................................................................................................................2-9-3
Maintenance.....................................................................................................................................................................................2-9-3
HOIST SPEED SELECT, FREEFALL, AND STATUS PANEL ELECTRICAL CIRCUITS........................................................................2-9-13
Description ....................................................................................................................................................................................2-9-13
LIST OF FIGURES
Title
Page
LIST OF TABLES
Title
Page
2-9-3
ELECTRICAL SYSTEM
DESCRIPTION
The crane electrical system is 24-volt consisting of an alternator and leadacid batteries series parallel connected. Four batteries are used and are
installed on the rear left side of the upperstructure. Two batteries are
connected in parallel to make two parallel sets of batteries for a higher
the upperstructure. The cover on the box must be removed to gain access
to the fuse.
ALTERNATOR.
For a location and primary functions of circuit breakers, fuses, and relays
see chart titled Electrical Component, Location, and Primary Function.
The batteries are the maintenance free type and are completely sealed
except for a small vent hole in the side of the battery. The vent hole allows
what small amount of gasses that are produced in the battery to escape. A
test indicator located on the top of the battery is used to determine if the
battery can be tested in case of a starting problem. For information
concerning the use of this indicator, refer to Delco-Remy Service Bulletin
1B-116 in the back of this Service Manual.
An electrical junction box located under the cab contains most of the of
relays and associated electrical components that control the electrical
functions. The box also provides the junction point between the cab
controls and the remainder of the crane.
There is one fuse in the electrical system. The fuse (F2) is located in a
conduit box located on the gantry hydraulic relief valve on rear left side of
MAINTENANCE
GENERAL.
____________
WARNING
WARNING
ENSURE THE BATTERIES ARE DISCONNECTED
BEFORE PERFORMING ANY MAINTENANCE ON AN
ELECTRICAL CIRCUIT WHICH IS NOT FUSED.
CAUTION
NEVER REPLACE ORIGINAL WIRING WITH WIRING OF A
SMALLER DIAMETER.
TROUBLESHOOTING.
To isolate electrical troubles, a multimeter should be used. The multimeter,
when used properly, can provide readings necessary for service personnel
to determine the following.
1.
2.
receptacle. Cut the wire as close to the pin as possible. After cutting the pin 3.
off, the wire will most likely be too short. Using a wire that is too short will
allow pressure to be applied to the pin and wire where they are crimped 4.
when the pin is inserted in the plug or receptacle. Add a short length of the
same size wire to the short wire by crimp splice or solder. Use heat
shrinkable tubing or other suitable material to insulate the splice.
5.
Removal.
1.
2.
3.
Connect all leads to the battery terminals, starting with the positive
terminals.
Tag and disconnect the electrical leads from the terminals on the
4.
alternator.
3.
Loosen the alternator attaching hardware and remove the belts from the 5.
alternator pulley.
6.
4.
Remove the attaching hardware from the belt tension adjusting bracket.
5.
Remove the nuts, washers, and bolt attaching the alternator to the
mounting bracket and remove the alternator.
1.
Installation.
1.
2.
Swing the upperstructure over the front or rear to gain access to the
underside of the engine compartment.
2.
Tag and disconnect all leads from the battery terminals, starting with the
negative terminals.
Installation.
ALTERNATOR.
1.
Position the alternator on the mounting bracket and secure with the bolt,
2.
washers, and nut. Do not tighten at this time.
Install the hardware attaching the alternator to the belt tension adjusting 3.
bracket.
4.
3.
4.
Refer to the Alternator Belt Tension and Attaching Hardware Torque Table 5.
for proper belt tension.
6.
5.
7.
BATTERIES.
8.
Remove the heat shrink tubing from the work light and horn connections,
tag and disconnect their connections.
9.
Remove the locknuts and washers from inside the cab electrical box.
Remove the locknut and washer from each end of the threaded J hooks.
Remove the strap, securing the batteries to the battery box weldment.
No. of Belts
LB-FT
60-70
GMC
KGM
8.29 - 9.78
Press with thumb in center of belt. Maximum deflection is 0.5 to 0.75- inch (13 - 19
mm).
Belt tension gauge pressure is 40 - 50 lbs. (18 - 23 kg).
Cummins
60-70
8.29 - 9.78
Cat
60-70
8.29 - 9.78
10. While removing the box, also feed the harness through the floor of
the operator's cab.
INSTRUMENTS. Removal.
1.
2.
1.
2.
Install the cab electrical box on the threaded studs and install the
washers and locknuts that secure the box in place.
3.
4.
3.
that
chord
1.
2.
..
6.
7.
1.
8.
Install the left arm console using the six screws that secure the
panel in place.
2.
3.
Tag and disconnect the electrical leads to the gauge; then tape the
lead ends.
Inspection.
con
Remove the hardware securing the gauge to the instrument panel, then remove
the gauge.
Engine Instrument Removal and Installation
5.
10.
Remove the screws securing the instrument panel to the right front corner of the
cab.
Installation.
9.
Apply a 25 pound (11 kg) force perpendicular to the belts, midway between the
driver and driven pulley.
Maximum deflection is 0.50 to 0.75 inch(13-19 mm) for the first check. Maintain later
adjustments at 0.875 inch (22 mm) deflection.
.,
Installation.
Connect the electrical leads as marked prior to removal.
Place the gauge into position on the panel and secure it with the
attaching hardware.
Position the cab instrument panel and secure the panel with the
screws.
Functional Check.
Start the engine and observe for proper functioning of the repaired
indicator. (Refer to Operator's Handbook). Troubleshoot further as
necessary, any system malfunction not corrected by repair or
replacement of the indicator or associated wiring.
3651
kJ
ELECTRICAL SWITCHES.
Removal.
Inspection.
1.
1.
3.
a.
b.
1.
2.
Position any switches that were removed from the panel and
secure them with the attaching hardware.
3.
Install the panels in place using the screws that were removed.
Functional Check.
Operate the switch as described in the Operator's Handbook.
Observe it for proper functioning in the applicable circuit. Continue
troubleshooting as necessary any system or circuit malfunction not
corrected by repair or replacement of the switch or associated
wiring.
7665
7666
2.
3.
Remove the nuts and washers securing the wiper arms; then
remove the wiper arms.
4.
5.
6.
1.
Install the motor and mounting bracket, mounting plate, and gasket
in position.
2.
4.
5.
6.
'
Component
Location
2-9-8
Function
Breaker panel
CB3 (5 AMP)
Breaker panel
CB4 (5 AMP)
Breaker panel
CB5 (5 AMP)
Breaker panel
Breaker panel
Breaker panel
Breaker panel
Breaker panel
CB10 (5 AMP)
Breaker panel
Breaker panel
Breaker panel
Breaker panel
CB14 (5 AMP)
Breaker panel
CB15 (5 AMP)
Breaker panel
CB16 (5 AMP)
Breaker panel
CB17 (5 AMP)
Breaker panel
CB18 (5 AMP)
Breaker panel
Component
Location
CB19
CB20
2-9-9
Function
CB21
CB22
Breaker panel
CB23
Breaker panel
CB30 (5 AMP)
Hydraulic tank electrical box 4x4
F2 (4 AMP)
K1
Starter
Is energized when the IGNITION switch is in the ON
portion and engine switch is depressed to START to
engage the starter through K1.
K2
Engine compartment
Is energized as described in K1 function, K2
completes the circuit to energize K1.
K4
Z)
2
K8
Component
Location
K9
Function
2-9-10
K11
K12
K13
K14
K19
K23
Hydraulic tank electrical box 4x4
Location
K29
Function
Is energized by a pressure switch (PS10-7 or PS9-7) to
prevent switching speed on the rear hoist when the hoist is
rotating.
v!)
K31
2-9-11
TK1
TK5
^TK6^)
TK7
SELECT
2-9-12
2-9-13
switch
through
pressure
switch PS1-3F to the coil of
K6. This prevents changing
from high to low speed while
rotating the hoist.
HOIST FREEFALL CIRCUIT.
The front hoist freefall circuit
will be described in this
description, the rear hoist is
identical with the exception of
the relay and solenoid
numbers. The five major
components within the freefall
circuit are the select switch,
relay K5, relay TK6, PS6-8,
and relay K30. The select
switch is spring return to the
center position and supplies
power to the freefall circuit.
Relay K5 is the freefall relay
which when deenergized
provides the circuit for
automatic
hoist
brake
operation. When relay K5 is
energized,
it's
contacts
energize the freefall indicator
light, TK6, various solenoid
valves, a holding circuit to
maintain K5 energized, and
provides a second source of
power to K4, bypassing the
charge and control pressure
switches. Relay TK6 allows
solenoid valve SV1-1 9F to be
energized. After one second,
the contacts of energized TK6
will open to deenergize SV1 19F. When the brake foot
pedal is depressed, pressure
switch PS6-8 is activated and
supplies power to either K30
or K5 coil depending on the
position of the select switch.
Relay K30 has two functions;
when deenergized it's contacts are part of the holding
circuit for K5, when energized
it's contacts open to break the
circuit to K5.
To enter freefall, position the
hoist brake switch to AUTO
and simultaneously depress
the freefall select switch to
FREE and depress the brake
foot pedal. Power is supplied
from the switch terminal,
s'
CJ
2-9-14
LA
2-9-15
2-9-16
2-9-17
2-9-18
2-9-19
0438-3
f
VALVE
BODIE
S
DESC
RIPTI
ON
T
h
e
r
e
a
r
e
s
e
v
e
r
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2-4-79
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VALVE
BODY
LOCATIO
N TABLE
Valve Body
Circuit Used In
M1
Charge
M3F
Front Hoist
M4F
Front Hoist
M3R
Rear
Hoist
Rear
Hoist
Physic
al
Locati
on
Situado
detrs de
la puerta
de
acceso
de
la
bomba
que est
en el lado
derecho
2-4-83
Control
de
la
estructur
a
superior.
El cuerpo
de
la
vlvula
de carga
est
asegurad
a a la
abrazade
ra
que
est
montada
en
la
parte
superior
de
la
unidad
de
bomba.
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
the front
hoist
frame
and the
Haggland
s motor
distributor
.
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
valve
body
M3F.
Located
on
the
right side
of
the
upperstru
cture and
secured
2-4-84
directly to
the
rear
hoist
frame
(middle
frame)
and
the
Haggland
s
motor
distributor
.
M4R
M5
M6
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
the valve
body
M4R.
Located
on
the
control
accumula
tor
and
the
accumula
tor
is
located
below the
pump
drive
on
the
tail
section of
the
upperstru
cture.
Located
on
the
left side
of
the
upperstru
cture
behind
the door
for
gaining
access to
the
oil
cooler
radiator.
The valve
body is
located
2-4-85
behind
the
radiator
and
is
mounted
on
the
bottom of
the
radiator
frame
mount.
M7
Control
Located under the operator's cab. The valve body is placed over a cutout in the cab
floor for routing hoses to the cab control lever, valve body.
M8
Control
Located under the operator's cab, the valve body routes control pressure to the
valve body M7 and the hoist brake pedals in the operator's cab.
M9
Cab Control
Lever
Located in the operator's cab between the operator's control levers. There are two if
the optional third drum hoist is used.
M10F
Located on the front hoist frame below valve bodies M3F and M4F on the right side
of the upperstructure.
2-4-86
2480
7548
Valve
Bodies
Locati
on
BRAKE ACCUMULATOR
REAR HOIST
BRAKE ACCUMULATOR
FRONT HOIST
VALVE BODY M4
BODY M10
VALVE BODY M3
VALVE BODY M4
VALVE BODY M3
^^CALIPER BRAKE
'it,.
6.
Clean all the parts in a suitable solvent. Blow dry with filtered air. Do not dry the bearing
by spinning with compressd air.
7.
2.
3.
4.
5.
Install the shaft end cap to the end of the shaft using the four bolts. Wrench tighten the
bolts.
8.
Install the two keys to the input end of the hydraulic motor.
9.
Slide the motor hub weldment block over the keys and onto the hydraulic motor using a
suitable lifting device.
assembly and the hydraulic motor. Lubricate and install new O-rings in the valve
assembly.
Inspect the machined surfaces of the shaft for scratches and burrs. Minor scratches may
be polished out using a crocus cloth.
6.
11. Apply Loctite to the six Grade 8 bolts used to mount the valve assembly.
1 2. Using a suitable lifting device, install the valve assembly to the hydraulic motor
using the six bolts and hardened flat washers. Torque the bolts to 1 70 pounds-foot (24
kgm).
ASSEMBLY.
NOTE
1 3. Attach a suitable lifting device to the hydraulic motor and install it to the hoist.
2.
Lubricate and install a new seal into the smaller diameter bore of the bearing block.
3.
Press the bearing block onto the splined shaft on the hoist drum.
4.
Install the remaining seal into the exposed bore of the bearing block.
5.
NOTE
Ensure the hoist is positioned so the hydraulic motor end is
pointing upward. Block, as necessary, to thoroughly support and
balance the hoist.
14. Apply Loctite 242 to the 24 Grade 8 bolts used to mount the hydraulic motor.
15.
Install the 24 bolts and flat washers that attach the hydraulic motor to the hoist drum.
Torque the bolts to 170 pounds-foot (24 kgm).
4
7438
1.
INSTALLATION.
5.
6.
2.
Lift and position the hoist into its mounting bracket on the upperstructure.
3.
Apply loctite to the four bolts that attach the hub bearing blocks to the hoist frame.
4.
Install the two hub bearing blocks to the hoist frame using the four bolts and flat
washers. Torque the bolts to
1 360 pounds-foot (188 kgm).
Install the rotation indicator transmitter using the two bolts and lockwashers.
Connect the pawl by installing the pin through the clevis on the spring loaded cylinder
and through the pawl. Install the cotter pin to the pin.
7.
8.
Lubricate and install new O-rings to the tubes that use split-flanges.
Connect the hydraulic tubes, using the split flanges, to their corresponding ports as
marked previously.