Manual de Servicio P9K1-1812

MODEL HTC-867511
BOOK No.
SERIAL No. P9K1-1 8 12
CRANE SERIAL NUMBER

The cra ne serial number is on the crane rating manual which is located inside the operato r's
cabo The serial number should always be furnished when ordering parts for the crane or w hen
corresponding with the distributor or factory concerning the crane . Providing the serial
number is the only w ay of ensuring the correct parts and /or info rm atio n can be furnis hed.
In the event the serial number plate is not readable, a number is stamped on the u pp er revo lving
trame which can be used to identify the crane. On lattice cranes t his number is l o cated o n the
ri ght hand boom foot mounting lug. On hydraulic cranes the number is stamped just below the
bo om hoist cylinder mounting lugs.
Ll r~-B e l t Cansuucnnn Eqlll pmént Comp any F00056

07\TE U/ 1 6 /l 1
PAGE 1
ORDE R NO.- P9XP006 MODEL - HTC - ü675XP 11 SERIl\L NO. - P9Kl-l!312
n TST R I BUTOR: M7\QUTNAS O TES El.,S.7\.. DE C.V. S7\.LE S ORDER: 0 211:11 2

ENGI NE : TRANSMI SSI ON:
MOOF:I. C7\.T Cl3 EURO MODEl.- ZF };'>-AS-2302
S/N J7\M007 2 0 S/N- 00544163
OPF.RATION SF.BU769~ OPERATTON- NONE
P7\.RTS SEBP4420
7\F.M: BOOK- C-70 - 2
O/M BOOK- 1] 5807/.4 10 VTDEO- DVD-CR
7\DD EN DUMS - NONE
TECH BULLETINS - NONE
MJSCP.T,LI\NF.OUS - HOTST ROPE CAUTTON
SH CODE DESCRIPTTON SM ConF. DESCRJPTTON

SM01 RUBBER TIRE LOWER SMO] RUBBER TTRE LOWER
SMOI - 0 01-006.00 BOOM REST, R & T SM01-022-00S.00 U-JO TN T TNST7\I.T.7\T TON

SM01-002 - 012.00 FRONT l\XLE, RECON (FlJ T.L ROUND YOKE S)
SMOI-002-01'l.OO FRONT WHF.ET. & BRi'\KE SM01-024-01 S .00 REAR AXLES, RECON
DRUM, R & J SMOJ-02~-016.00 ANT T J.OCK BRAKTNG SYSTF.M ,
SMOI-003-010.00 BR7\.KE, RECON TROU BT.ESHOOTTNG
SM01-OOJ-014 .00 7\DJUSTING THE BRAKES SMOJ -02 '1- 000. 00 PNf~ UM7\TTC S YSTEM A TR To r NE
SMO 1 - 003-019.00 AUTOM7\TTC STJ7\.CK 7\DJUSTF.RS TDENTIFTCAT TON CODE
SMOI-004-014.00 FRONT AXT,F.S & 7\TR SMOI-027 - 0Lfl.OO FRON1' J\T R RR7\KE CHI\MRF:R,
SUSPENSJON, R & T RF.CON
SM01-00S-027.00 TROURT.ESHOOTTNG SHEPP7\.RD SMOI-027-0& 2. 00 7\.T H DI{YER, R & r
STEERING GEJ\I{S SMOI-027 - 06 :L OO J\I R DRYF:R. RECON
SMO]-00S- OJ2.00 STEERJNG MTTF.R BOXF.S, R&T SMOI-OZ'/ - O'Jl.OO FRONT Al R RRI\KE C HJ\MBER,
SM01-00S-OJ3.00 STEERTNG GFJ\RS, R !. T R& T (W / AUT O ST.J\CK 7\DJUST J
SMO] -00~ - () J 4. 00 STF.F.RJNG COT.UMN, R & T SMOI-O Z·I - O'J2.00 DUI\I, 7\.IR BRAKE CIIJ\MBER,
SM01-00~-OJ~.00 STEERING COLUMN, RF.CON R & 1
SM01-00S-0Tl.00 STEERTNG GEJ\RS, RF.CON SM01-0/,"-106.00 CJ\GING DU7\T. J\TR BRAKE
S1'101-006-036.00 FRONT WHEEL AT.TGNMF.NT & CHAMBERS
STEER LIN~AGE ADJUSTMF.NT SMOI-0 /' 7-11 ·1.00 DUl\L AJR B RJ\K 1-: CH7\MBF.n,
SMOI-Ol 0-02').00 POWF'.R STF.F.RTNG PUMP, RF.CN RF.CON
SMOI-O ]Ü-04 2.00 POWER STEERING PUMP, R&T SM01-0/,·I-146.00 ClIRR J ER A1 R SY ST EM
SH OI - 016 - 002.00 HEJ\TE:R CORE & I\/C COMPONENTS, R & 1
EVI\.PORATOR co rr., R & 1 SM01 - 02!l-002.00 REJ\R WHE I:;L HUR & BRJ\KE
SHOI-Oln-0~6.00 TRANSM TSSION 7\ND DRUM, R & T
CLUTCH, R & 1 SM01-029 - 0 J O.00 RFJ\R 7\XT.F:S AN D J\r R
SMO]-01U-OS7.00 TRANSMI SS TON, RECON SUSPE NS ION, R & 1
( Zf" ASTRONIC TI) SMOI-OJ9-00J_00 HYDRAUl .TC SYS1'F.M C I.EI\.NrNG
SMOI - 019-0 J 4.00 TR7\NSMTSSI0N SHTFT SMOI - OJ 9-00S.00 HYDRJ\IJT, TC RF. S t-:I'WOlR
CONTROT., R & 1 F' r L n : R A SSY, HI-:CON
SMOI-020-002.00 SUSPENDED BRAKE PF.D7\T. , SMO 1-039-000 . (lO HY¡)RAUT:r C JU:SI-:RVOI R
RF.CON F TT.1'F.R, R & T
SH O] - O? O- Oll.OO SUSPENDED BR7\KE SM0 1 - 0 4 ]-001. 00 SOLENO I D VJ\t.VES, GENF.RI\[.
PEDAL V7\.LVE, R & T RF:CON O [ 1' .1ON
SMO] -O;'>;:> -004.00 U-JOINT INST7\I.Ll\TlON SM01-04J -OOJ .OO OU'l'R r GGF. R SOLI':NOTD V7\.I.VE
(H7\LF ROUND YOKES) STI\CK, R ~:C ON
SMOJ-O "lJ-004.00 4 - WJ\Y SOI.I-:NOJO VAT.vF.,RECN
D7\T E U/16/11
P7\CE 2
ORDE R NO.- P9XP006 MODEL - HTC-86~5XP 11 SERIAL NO. - P9KI-IU12
$M CODE DE s crUPTION SM CODE DESCRTPTION

SMO l RUBBL H TI RE LOWER SM01 RUBBER TIRE LOWF:R
SMOI-043-04S.00 OUTRIC,GER DTRECTION7\L SMOI-077 - 00ü.OO STARTF.R, R & 1

CONTROL VA},VE, R & I SMOI-077-021.00 R7\DT7\TOR, CHARGF.D 7\IR 1\ND
SMOI-04]-04 ',.OO STH OUTRIGGER OTRF.CTTONAJ" HYDRAUT.IC OTL COOLER, R&I
CONTROT. V7\T,vE, R & T SMOI-077-033.00 7\T,TERNATOR, R & T
SMOI - 0 4 J-04B.00 OUTRTGGER FUNCTTON (W/7\IR CONDTTIONING)
CONTROl, VAl.VE, R & I SMOI-079-063. DO T,OWF.R HYD COMPONENTS, RI>. T
SM0 1 -044 - 0JJ.00 STH OUTRIGGER 1.0CK VALVE (SUenON, PRESS. & RETURN)
C7\RTRTDGE . R & T SMOl-OHl-Ol4.00 HYDRAUT .TC GF.7\R PUKP, RP.CN
SM0 1 - 0H -() 2', .00 OUTRTGGER LOCK VALVE (MUT.T I SECT TON - ';T EEL )
C7\RTRIDGE, R&I ANO RECON SMOI-0~31-040.00 HYORAULIC PUKP . R & I
SHO ] - O"' S- 04U.OO ROTTOM OUTRIGGER FlE7\M (T7\NOUM 4-SECT fON)
CYT. I NOER, RECON SMOI-OHI-04S.00 R7\DI7\TOR F 7\N MOTOR, R & 1
S MOI-04~i-049.00 T Ol' OUTRIGGER BF.7\M SMOI - 081-046.00 HYD GFJ\R PUMP/MOTOR, RF.CN
CYT. INOER, RECON (PGP/PGM620 SERI E S)
SMOI - 04',-OS9.00 OUTRIGGER FlEAM ASSY, R&I SMOI-081-051.00 HYOR7\ULIC P UKP , R & T
SMOI-04S-060.00 OUTRTGGER BEAM (O. R. /PTCK & CARRY)
CYT.INDER, R & I
SM01 - 04G-0:l4.00 J7\CK CYLINDER, RECON SM03 UPPER FR7\MF. & M7\0 1Y
SM01-()4 6-04 ".00 J7\CK CYT.TNDF.R, R & T
r SMO 1 -04 G-04 H. 00 JACK CYT.INDER,
$MOl-04 6-049.00 FTF"fH OUTRIGGER JI\CK
RECON SM03-00 1 - 0 ', S. 00 U PPER RF.VOT,VING F RJ\ME 7\ND
·,'URNT7\BLE Rf,I\H 1 NG, H lO r
CYT.TNOER, R & T SM03-010 - 02S.00 COU NTERWEI GHT H g MOV7\ L
SMO ) - 04"-Oll.00 REL IEF VI\T.VE, RECON CYJ.I NDI;:R , RECON
SHOI-041-0JfLOO PTCK & CARRY M'I\NTFOT,D SM03-010-03fl.00 COUN·J.'ERWF.T CIIT Rr-:HOV I\T.
fH.OCK, TT.l.USTRATEO CONT RO To V7\T.VF. , R ~ T
SMOI - 04H-O H . OO ROTATTNG JOTNT, RECON SM03-010-047.00 COUNTF.RWF.T GIIT rU":MOV7\T.
(S-WAY) CYLTNDER, R & 1
SMOI-04U-049.00 ROT7\TTNG JOINT, R & 1
SMO 1-OSO-004 .00 OTT, COOT.ER l\SSEMBT.Y, R& I SH04 VERTIC7\T. S H7\ITS
SMO 1 - OSO-OO~;. 00 OTT. COOT.F.R HYDR7\UT. TC *********************T********** *~*~*~*~ **
MOTOR, R & T SH04-010-0 :U.OO SWTNG REDUCTJ ON UNT'f

SMO ] - OSO-Ol ~'- 00 HYDRAUT.TC OTT. COOT,ER W/RR7\KF. , Rt:CON
7\CCUMUL7\TOR, R & 1 SM04 - ()1 0-038.00 SWTNG REDUCTI ON UN LT I\NO
SMOI-OSO-Ol6.00 OH . COOLER HYOR7\ULIC FlR7\KE . R & T
F7\N MOTOR. RECON
SHOI-066-0J4.00 Fl7\TTERY, R & 1 SM05 HORTZONT7\l. SH1\FTS
SMOI-OG9-009.00 TTRES & RTMS, R & 1
SMOI-0-1l-004.00 RF:PATR OF COMPONF.;NTS M7\DE SHOS - 006-0?S.00 WINCH. RF". ON
OF FIBROUS COMPOSTTE M7\TT. SH05-006-0 26. 00 w I NCII. TROUHI.ESHO(Y1"TNG
SMOI-07l - () lJ.OO ENGINE HOUSING. R & T ( B R7\D EN CH;.> 10 MOOF.T. )
SM01-()'f ] - 00;'>.00 F:T.F.CTRON re G7\UGES, SMO'l-006 - 0Jü.00 WTN CH 7\S S f:MFIT.Y. R 1> T
TROUR1.ESHOOT ING SMOS-O l U-0 03. 00 WI NClI ROl.U:R. RECON
SMO] - {P 6-0 !>H.00 COlJLECT OR RING, H. & 1
SMOI - 076 -06J.00 COUJECT OR RTNG, RE CON
(34 RING)
KEYSHEET
Link-Belt
CONSTRUCTIO N EOUIPMENT
SM KEYSHEET AND GENERAL INFORMATION
D7\TE 8 /1 6/1 L
PAGE )
ORDER NO.- P9XP006 MODEL - HTC-8675XP 11 SERIAL NO. - P9Kl - 1812
SM CODE DESCRIPTION SM CODE DESCRIPTION

SM06 UPPER ENGINE SM07 UPPER HYDRAULICS & AIR
SM06-000-009.00 THROTTLE TREADLE, R & I SM07-008-122.00 WINCH COUNTERBALANCE

SM06-02 5 -0 22 .00 HEATER CORE & A/C EVAP VAl,VE. RECON
COIL, ILLUSTRATED SM07-000-13 2 .00 CONTROL VALVES. RECON
SM06-0 25- 023.00 UPPER CAE A/C EVAP COIL & (BOOM HOIST/TELE/WIN H)
HEATER CORE, R & I SM07-008-152.00 WINCH COUNTERBAI~CE
SM06-025-026.00 DIESEL COOLANT HEATER, VALVE. R & I
TROUBLESHOOTING & RECON SM07 -008- Pd. 00 SWING BRAKE PEDAL
SM06-075-07fl.00 DTESEl. COOT.ANT HEATER, R& T VAl.VE, R & T
SM06-04 -¡-000.00 ELECTRICAL SYSTEM WlRE SMO -J-001:l - l~4. 00 WINCH CONTROL VAl.VE, RH
IDENTIFICATION CODE SM07-000-1 55 .00 SWING CONTROL VALVE, R&T

SM07-008-1 5 6.00 BOOM HOIST/TELESCOPE
SM07 UPPER HYD~ULICS & AIR CONTROL VALVE. R & I
~~~*~************************************* SM07-010-006.00 BOOM TEI,ESCOPE ELEcrRONIC
SMO"¡-001-0 2 7.00 PILOT CONTROL FOOT CONTROL, R & 1
ACCUMULATOR, R & I SM07-018-001.00 HYDRAULIC TUBE FITTIN GS
SMO"¡-002-033.00 SOLENOID/RELIEF VAI,VE,
RECON SM17 HYDRAULIC BOOM
SMO "¡-OOJ-006.00 SOLENOID VALVES, RECON
(GENERAl, PROCEDURE) SM17-001-05J.OO HYORAUJ.TC ROOM TNSPEC"rrON
SMO-¡-003-011.00 DlRECTIONAL REI,IEF VALVE. (FORMED BOOM SEcrIONS)
RECON (BOOM HOIST/TELE) SM17-001-06ü.OO BOOM, R & I
SM07 - 004-0Jl.00 UPPER HYDRAUI.IC COMP, R&I (41-127' LATCHING BOOM)
(UPPER CAE FLOOR) SM17-001-069.00 4-SEcrION BOOM, RECON
SM07-004-033.00 UPPER HYDRAULIC COMP, R&I (41-127' I.ATCHING BOOM)
(TWO WINCH PLUMBING) SM17-00 2 -054.00 BOOM TELE COUNTERBALJ\N C~:
SM07-004-060.00 UPPER HYD COMPONENTS, R&I VALVE, R & I
(UPPER FRAME) SM17-002-055.00 BOOM TELESCOPE CYI,INDER,
SM07-006-034.00 SWING MOTOR, RECON RECONDITION
SM07 - 006-095.00 WINCH MOTOR, RECON SM17-002-059.00 TELESCOPE CYL INDER I,ENGiIl
(T.TNDE) RF'.ET., RECON
SMO-¡-006-109.00 WINCH MOTOR, R & 1 SM1-¡-002-066.00 BOOM I.ATCHING/PINNI NCi
SM07-006-124.00 SWING MOTOR, R & I CYl.INDER, R & I
(W/NEEDLE VALVE) SM1"J-00 2 -068.00 TELESCOPE CYLINDER
SMO"J-008-0J 2 .00 CONTROL VALVE, RECON LENGTH REEI.. R & T
(MODEL V20) SM17-002-069.00 ROOM LATCHING CYLINDER,
SM07-008-037.00 PRESSURE REDUCTNG VALVE, RECON
RECON SM17-002-070.00 LATCHING BOOM TELESCOPE
SM07-001l-107.00 DUAL AXIS CONTROLLER SYSTEM, TROUBLESHOOT ING
VALVE, RECON SM17-00 2 -071.00 BOOM TELESCOPE CYLIN DER ,
SM07-008-112.00 PRESSURE REDUCING CAI,IBRATION
VAl.VE, RECON SM17-002-0'lO.OO ROOM TET.ESCOPF. CYT.T NTIP.R
SM07-008 - 116.00 DUAL AXIS CONTROLLER MECHANISM, RECON
VALVE. R & I SM1 7-003-01.3.00 BOOM HOTST CYI,INDER, ItECN
SM07-008-11B.00 SWING BRJ\KE PEDAL SM17-003-039.00 BOOM HOIST CYLINDER, R&l
VAl.VE, RECON
KEYSHEET
Dl\T E n/ló/ll
PJ\GE Ij
OIU)E R NO. - P')XP006 MODEL - HTC-8675XP 11 SERIAL NO. - P,)KI - IU12
SM COOE OESCRIPTION SH COOE OESCRIPTION

SM1 7 HYDRAULIC BOOM
SH17-003-040.00 BOOM HOIST COUNTERBAI.ANCE

V7\J.VF: , R " T
SH]7 -009-004.00 FTVE SHEl\VF: HEAD
M7\CI-ITNERY, RECON
SMlü SPECIl\L l\TTACHMENTS
SH10 - 0 00-001 .00 Cl\PSCRRW TORQUES

SH1I1-000- 002.00 BEJ\RING, GEAR , SHl\FI', "
HOUSING INSPECTION
SH18 - 000-003.00 CRl\NE SYSTEM SCHEHATICS
SHI8 - 007-006.00 REELING ORUH, R & I
SMI8-007-007.00 REET.ING DRUH, RECON
SH18-013-00].00 l\IR CONOITIONTNG SERVTCE
PRECl\UTIONS
SH18-0lB - 004.00 l\/C COHPRESSOR, RECON
SM18-0lll - 013.00 7\/C COMPRESSOR, R " I
(UPPER)
SH1 8-01 8-014.00 7\/C HYDRAUT.TC DRTVF.
MOTOR, R , I (UPPER)
SM]fl-01U-01 ~) . OO l\/C HYDRAULTC ORIVE
MOTOR, RECON (UPPER)

SH1B-OlO- 021.00 l\/ C COHPRESSOR, R , I
(Cl\RRTER)
KE YSHH T
Service Manual 0104 SM01-001-006.00
8. Remove the boom rest assembly from the crane.
Boom Rest, R & I 9. If further disassembly of the boom rest is required,
This procedure covers the removal and installation of proceed with Steps a thru c as needed.
the boom rest. If boom rest extensions are used, see a. Remove the nylon pads (3) from the locator
SM Keysheet 01 -001 for additional information. caps (2) by removing the screws (4).
b. Remove the locator caps (2) by removing the
Removal capscrews, washers, and locknuts (5).
c. Using an auxiliary lifting device, separate the
1. Lower, detach, and secure load, as required.
pivot assembly (6) and cross tube assembly
2. Stabilize the crane for service as follows:
(8) by removing the cotter pins (11) and pin
a. Park the crane out of the way on a firm and level
(12) .
surface.
b. Engage the park brake and/or properly block Note: The pivot assembly weighs approxi
the tires. mately 180 lb (82kg) and the cross tube as
c. Engage the swing park brake or travel swing sembly weighs approximately 75 lb (3 4kg) .
lock, as requíred.
d. Level the crane on fully extended outriggers. 10. If boom rest is to removed for an extended per iod
e. Fully retract and lower the boom over the rear of time, adequately support the boom.
of the carrier.
3. Shutdown the engine and disengage the main hy
Cleaning And Inspection
draulic pump.
A WARNING
A WARNING
Solvents and cleaning solutions can be
Solvents and cleaning solutions can be hazardous. Serious personal injury may
hazardous. Serious personal injury may result from misuse of these products. Read
result from misuse of these products. Read and follow all the manufacturer's
and follow all the manufacturer's recommendations concerning solvents and
recommendations concerning solvents and cleaning solutions.
cleaning solutions.
1. AII components should be thoroughly cleaned wit h
4. Thoroughly clean area to be disassembled with an an approved cleaning solvent, air drled, and care
approved cleaning solvent. Allow the area to air fully inspected.
lRj
dry. 2. AII Loctite , Permatex '''· , or other sealant residue
should be removed from threads of hardware and
Refer to Figure 1.
the mounting surfaces of parts that are going to be
5. Remove the engine housing (1). See SM Keysheet
reused. Prior to applying new thread locking com
Area 01-071 for the correct procedure.
pounds or sealants, clean threads and surfaces
6. Support the boom rest assembly with an auxiliary
with Loctite® 7070 Cleaner to ensure best perfor
lifting device.
mance of products.
Note: The boom rest assembly weighs approxi 3. Thoroughly inspect all related parts for damage,
mately 350 lb (159kg). wear, fatigue ar stress fractures, and carrosion.
Repair or replace as required.
7. Remove the cotter pins (10) and pins (9) which se 4. In the event of severe defects, contact factory per
cure the cross tube assembly (8) to the carrier sonnel for directions whether to repair or replace
frame (7). any majar component.
1 uf 4
S M01-001-006.00 0104 Service Manual
, .
li
. -.-.--. f "
12
1. Engine Housing 5. Capscrews, Washers, & Locknuts 9. Pins

2. Locator Caps 6. Pivot Assembly 10. CoMer Pin s
3. Nylon Pads 7. Carrier Fram e 11 . CoMer Pins
4. Screws 8. Cross Tube Assembly 12. Pin
Figure 1
Boom Rest
2 of 4
Service Manual 0104 SM01-001-006. 00
Installation b. Install the locator caps (2) on the pivot assem
bly (6) and secure with the capscrews, wash
ers, and locknuts (5).
A WARNING
Lubricants, sealants, joint and thread locking 2.
c. Position the nylon pads (3) on the locator caps
(2) and install the screws (4).
Using an auxiliary lifting device, align boom rest as
compounds, etc. can be hazardous. Serious sembly to the carrier frame (7).
personal injury may result from misuse of
these products. Read and follow all Note: The boom rest assembly weighs approxi
manufacturer's recommendations concerning mately 350 lb (159kg).
these products.
3. Install the pins (9) and cotter pins (10) which se
cure the cross tube assembly (8) to the carrier
Refer to Figure 1. frame (7). Bend cotter pins (10) only slightly.
1. If assembly of the boom rest is required, proceed 4. Install the engine housing (1). See SM Keysheet
with Steps a thru c as needed. Area 01 -071 for the correct procedure.
a. Using an auxiliary lifting device, position the 5. Complete the installation by testing the boom rest
pivot assembly (6) to the cross tu be assembly for proper alignment. The boom should rest evenly
(8) and install the pin (12) and cotter pins (11). on the pads. Adjust as required.
Bend cotter pins (11) only slightly.
Note: The pivot assembly weighs approxi

mately 180 lb (82kg) and the cross tu be as
sembly weighs approximately 75 lb (34kg).
3 of 4
SM 01-001-006.00 0104 Service Manual
aorn
Service Manual 0700 SM1-2-1 2 .0
If parts are hard to dísassemble and assemble , do not

Front Steer Axle, use a hammer unless it has a soft face , do not force
Recondition parts together, they must be free to turn and not bínd.
It is a good practice when disassemblíng comple x

This procedure covers the recondition of the front components to lay the parts out in the order that they
steer axle. For removal and installation procedures, were disassembled. Keeping the parts in thís order
see SM Keysheet Area 1 -4. during disassembly, cleaning , and ínspectíon will aid ín
the assembly process.
The following pages are taken directly from Dana ~
Spicer" Service Manual AXSM-0037 dated March
1992. Axle models 12F3/F4, 13F3/F5, 18F3, 20F4,
22T2/T5 , and 24T2/T5 are covered by this information.
Pay particular attention to Section 1 of this procedure to
A WARNING
correctly identify the specific axle being serviced. hazardous. Serious personal injury may
Proper identification of the axle is crucial lo obtain the result from misuse of these products. Read
correct information to follow from the charted and follow all the manufacturer's
specifications included in this procedure.
recommendations concerning solvents a nd
Based on the specific application of this axle, Link-Belt cleaning solutions.
literature wlll supersede any discrepancies in
operation, lubrication, maíntenance, or service,
Thoroughly clean the exterior surface of the axle before
ímplied by the axle manufacturero Any concerns
beginning the disassembly process.
regarding such inconsistencies should be reviewed
wíth a Link-Belt distríbutor.
1 of 26
SM 1-2-12.0 0700 Service IM anual
The description, testing procedures, and information regarding this Eaton product. This manual
specifications contained in this service publication is intended to be used as a supplement to such
were current at the time of printing. information.
Eaton Corporation reserves the right to discontinue or Any reference to brand names in this publication is
modify its models and/or procedures and to change made simply as an example of the types of tools and
specifications at any time without notice and without materials recommended for use and, as such, should
incurring obligation. not be considered as an endorsement. Equivalents, if
available, may be used.
The recommendations of the vehicle manufacturer
should be considered as the primary source of service
2 of 26
Section 1: Generallnformation
Axle Identification
Parts Nomenclature
Section 2: Periodic Service

Inspection Inspection (Cont'd)
Recommendations and Intervals Caster
Knuckle Vertical Play Inspection Toe Setting
Knuckle Pin Fit Inspection
Tie Rod Inspection Maintenance / Adjustment
Wheel Bearing Inspection Knuckle Vertical Play Adjustment
Wheel Alignment Inspection Wheel Bearing Adjustment
Camber Steering Stop Adjustment
Section 3: Axle Overhaul

Removal / Disassembly Component Repair/Replacement
Steering Knuckle Disassembly Tie Rod End Replacement
Knuckle Pin Removal Ackermann or Steering Arm
Replacement
Cleaning Knuckle Pin Bushing and Seal
Replacement
Installation / Assembly
Steering Knuckle Assembly
Final Assembly
Fastener Torque Specilications
30126
PARTS IDENTIFICATION/NOMENCLATURE General

Information
The service procedures and specificatlons Basic instructions are the same unless
in this publication cover six basic Eaton specified otherwise.
Steer Axles. Their design is common with
major differences in the beam type and For Eaton Brake service information, refer
capacity. Refer to chart below. to EB-3i Service Manual for EB and ES-i50
Brakes or ES-32 Service Manual for ES and
ES-i65, EB-i80 Brakes.
Eaton® Steer Axle Models and Specifications

EFA-12F3/F4 EFA-13F3/ F5 EFA-18F3 EFA-20F4 EFA-22T2fT5 EFA-24T2fT5
Nominal Load 12,000- 12,000- 18,000 lb 16,000 - 20,000 lb 22,000 lb
Ratings 13,200 lb 13,200 lb (8 163kg) 20,000 lb (9070kg) (9977kg)
(5433- (5433- (7257
5987kg) 5987kg) 9072kg)
I Beam Forged Steel Forged Steel Forged Steel Forged Steel Tubular Tubular
i Type I-Beam I-Beam I-Beam I-Beam Beam Beam
Beam F3 -3 .50" F3 -3 .50" 3.50" 350" T2 -1.50 " T2 -1.50"

Drop (89mm) (89mm) (8 9mm) (89mm) (38mm) (38mm)
F4 -350" F5 -5.00" T5 -5 .12" T5 -5.12"
(89mm) (127mm) (130mm) (130mm)
Eaton EB-150' EB-150 EB-165 EB-165 EB-165 EB-165

Standard Brake (15" x 4 ") (15" x 4") (16.5" x 6") (16.5" x 6") (16.5" x 6") (16.5" x 6")
Model & Size (381 x 102mm) (381 x 102mm) (419x 152mm) (419 x 152mm) (419x 152mm) (419x 152mm)
\ - Note EB-,165 Brake is optional on ':FA-12F4 Steer Axle.
Wheel Alignment: For specifications , refer to vehicle manufacturer's instructions.
Axl e Identification
The Model and Par! Numbers are stamped Number describes the axle specifications.
on a plate that is attached to the front of the If difficulty is experienced in parts
axle beam. The Serial Number is stamped replacement identification, furnish Model
in the beam. The Serial Number is used No. and Serial No. only.
by Eaton for control purposes, The Model
Ste er Axle Idenfification Piafe

••,., .• __'.•·.•·.·.""..·.•.......·.·.w.•. w.,,''''''''''''''''.•...........................................................""......."".........................................................................._ \
¡Eat.on· ¡
l,'~~~;,~~:::~~~;~~~:~,:"~:,,l~};,«;-.:l,t~
I I . Par! No. (if shown
EFA 12 F4 XXXXX on pi ate) is the

identi¡ication number
C"" CmoO "",
Nominal Load Capacity

I~
Beam Type
T Design
Level
Axle Assembly
Identification No.
used by vehicle
manufacturero
F - Forged
I-Beam
T - Tubular
Beam
4 of 26
Service Manual 0700 SM1-2- 12.0
General PARTS IDENTIFICATION/NOMENCLATURE
Information
Eaton EFA-12F3/F4, 13F3/F5 Steer Axles
CAPSCREW LUBE FITTING JI

WASHER ~~ I ~-~--~STEERINGARM
KNUCKLE CAP ~ (l. 1 I - "1 GREASE SEAL
i l ' / ¡SHIMS
GASKET ~~:tL \KEY (" ~/ - - AXLE BEAM
BUSHING ~ ~<l.p I ~ ",.,,,
'T~
~ IINUT~""0'."
I
conER PIN _'

STEERING ~ ~ n _ ,,_-~_ J /ORAW KEY
ARM NUT ~" ~ ti) ~II ~® '<::¡,/
COTTER PIN ~ ~ ~/1 ~"'THRUST BEARING
ACKERMANN ~ '{- /~ GREASE SEAL
~ or' / /
ARM NUT ," " "«(', STOP SCREW COTTER PIN
STEERING KNUCKLE- )-.;: ),' ~ JAI\i1 NUT g /
" NUT /.P' CLA~P CROSS
KEYWASHER -~" ~ ~ "0!1 ¿SCREW -TUBE
~/'x:J KNUCKLE . KEY/ ~ ~, TIE ROO
BEA~,,,~'N tlk ~~~~ ~/ e, G~_~~~MP

AOJUSTING
NUT
"
COTTER
~ ~
~ BUSHING
U
PIN $ ~ GASKET
WASHER/¡¡ ~ KNUCKLE CAP
/~~
CAPSCREW LUBE FITTING TIE ROO
ENO
50126
PARTS IDENTIFICATION/NOMENCLATURE General

Informafion
Eaton EFA-1 BF3, 20F4, 22T2/T5, 24T2 /T5 Steer Ax/es
LUBE FITTING - - - -""- \~KEY

~ ----- STEERING ARM BALL STUO
CAPSCREW - ~",,-, \. ------STEERING ARM

WASHER ~ \ ,;., ®-
~-
NUT COTTER
~~ '~ ' ~
CAP ~, ~i I \
lN
KNUCKLE
BUSHING
CO TTER PIN
NÓ!.
•
~
• •
I
1"
1
UPPER GREASE SEAr
SHIMS~ $
' NUT-Q;¡
I
,
$
/
~
: -
*EFA-18F3
---EFA-20F4
AXLE BEAM
STEER I NG I '; , '-"' :jr! .;. " ORAW KEY

ARM NUT " ,;" ~ ; ~' " ~
COTTER PIN / " ",_ '. , . ~ _ J / ~~~~-- T'H~ST BEARING
A C KERMANN ________
ARM NUT ~
() " ,".
'J"
- "''.,:';/
. :/JAM NUT
i\ ~--
LOWER GREASE SEAL
COTTER PIN
' jl:' '(.... . STOP NUT /"
STEERING KNUCKLE- ,' .,: ',~ " -. SCREW \ // CL~AP
" O" WASHER- ./' ~ .~ 7RE/
~ _ _ ~~~~S
-~ /~ ~ ~ ~
~-~_
~
~ARM -
.
NUT
BEARING
AOJUSTING
KNUCKLE
PIN
~
A
,
BUSHING I TIE ROO
NUT WASHER--.. f~ KNUCKLE CAP CLAMP
CAPSCREW--
¡ I
V LUBE FITTING
TIE ROO
ENO
*Tubu/ar Ax/e Beams for EFA-22T2/T5, 24T2 /T5
o
EFA-22T2 /T5
6 " x 5/ 8"
o
EFA-24T2 /T5
6-3 / 8"x 13/ 16" BEAM
Tube Tube EXTENSION
6 of 26
INSPECTION
Inspection Recommendations and Intervals

General Recommendations
The following procedures are consistent with ind ustry practice and are recommended as general guidelines for
periodic service. Use manufacturer's instructions as a primary guide .
Intervals of inspection or service are recommended for general or average vehicle use. It may be appropriate to
increase frequency of intervals depending on vehicle service.
General Inspection Wheel Bearings and Knuckle Thru st

Bearings
Perform a thorough visual inspection for proper
assembly, broken parts, looseness each time vehicle is Inspect wheel and knuckle thrust bearings for damage
lubricated. Make certain spring to axle beam mounting or wear each time hub/ drum is removed or steering
nuts and steering connection fasteners are secure. knuckle repaired.
Wheel Alignment Lubrication

Follow manufacturer's instructions for inteNal s of Pressure-Fitting Grease - Heavy-duty, multipurpose
inspecting wheel alignment. However, if excessive lithium base (#2 grade). Do not mix with sodium base
steering effort , vehicle wander, or uneven and grease.
excessive tire wear is evident, then check wheel
alignment (see page 12). Knuckle Pins, Thrust Bearings, Tie Rad Ends -
Pressure lubricate every 25,000 miles (40 OOOkm) . Use
Steering Axle Stops grease specified above. Knuckles or tie rod ends
without grease fittings are permanently lubricated .
No specific interval is recommended. However, if
steering turning radius is insufficient or excessive , Wheel Bearings - Refer to vehicle manufacturer's
adjust stops . Refer to manufacturer's instructions . recommendations for grease or oil and frequency
lubrication . Generally, lubricate at each brake overhau l
Tie Rod Ends or when hub/drum is removed for service.
Inspect each time axle is lubricated . Check for seal General Procedure far Grease Lubricated Wheel
damage , worn ba ll socket, or loose fasteners. Bearings - Thoroughly clean bearings, spindle, hub
cap, and hub cavity. Parts may be washed in a suitable
Knuckle Thrust Bearings commercial solvent. Be certain parts are free of
moisture or other contaminants.
Adjust knuckle vertical play each time knuckle pin is
removed for service, at axle overhaul, or when Fill wheel hub with grease to inside diameter of bearing
excessive knuckle vertical movement is noted. cups. Fill hub cap. Grease bearing eones by forcing
grease between rollers, eones , and cage .
Knuckle Pins
General Procedures far Oil Lubricate d Wheel
Inspect pin fit in bushings when pin is removed for Bearings - Fill hub (or wheel) to oillevelline on hLl b
service, at axle overhaul, or when looseness IS noted . cap.
7 of 26
SM1 -2-12.0 0700 Service Manual
INSPECTION
Inspection Preliminary Steps 2. Jack vehicle until steering axle wheels are raised
from the ground. Suppart raised vehicle with
Prior to performing inspections, the following safety stands.
preliminary steps should be accomplished :
1. Set parking brake and block drive wheels to A. WARNING: Never work under a
prevent vehicle movement.
. . vehicle supported only by a jack.
Knuckle Vertical Play Inspection
Reference
dial indicator
on knuckle cap
1. Pry knuckle
downward
1. Mount dial indicatar on axle beam . Reference the 4. Lower the front axle to obtain dial indicatar reading.
knuckle cap . If reading exceeds 0.040 " (1 .02mm), inspect thrust
2. Pry steering knuckle downward . bearings. Replace if necessary and adjust. Refer
3 . Zero the dial indicatar. to page 17 far overhaul procedures.
SPECIAL NOTE : Inspection procedures above assume axle is assembled and

installed in vehicle with tire and wheels. Checking knuckle vertical play during axle
assembly requires different procedure. See page 23.
8 o f 26
INSPECTION
Knuckle Pin Fit Inspection

Upper Bushing Inspection
1. Mount a dial indicator on the axle as shown in
photo. Reference upper part of knuckle.
2. Move top of wheel in and out with a push/pull

motion. Have assistant mon itor the d ial indicator.
3. Readings in excess of 0.015" (O.38mm )
the need fo r bushing replacement.
Lower Bushing Inspection

1. Mount dial indicator on the axle . Reference the
lower Ackermann Arm socket of the steering
knuckle.
2. Move bottom of wheel in and out with a push/ pull
motion. Have assistant read dial indicator.
3. Dial indicator readings in excess of 0.015"
(O.38mm) indicate that the lower bushing should
be replaced.
Reference di al
indicator on
knuckle
9 of 26
SM1 -2-12.0 0700 Service ,M anual
INSPECTION
Upper Bushing Torque Deflection . ' .,,::.:::::~
Test
1. Mount a dial indicator to axle referencing the upper
Refer~ri~-' ,~_~
knuckle steering arm socket area. dial indicator .
2. Apply foot brake . Try to roll wheel forwards and I~
backwards (fore and aft) (with brake applied) and
note deflection.
3. Readings in excess of 0.015" (O.38mm) indicate
that top bushing should be replaced.
Lower Bushing Torque Deflection

Test
1. Mount dial indicator to reference the lower bushing
area.
2. Apply foot brake. Try to rol! wheel forwards and
backwards (fore and aft) (with brake applied) and
note deflection .
3 . Readings in excess of 0.015" (O.3Bmm) indicate
that lower bushing should be replaced .
Tie Rod Inspection

1. Shake the cross tube. Movement or looseness, 3. Sal! and socket torque (exclusive of boot resist
between the tape red shaft of the bal! and the cross ance) should be 5 inch-pounds (O.6Nm) or more
tube socket members, indicate that tie rod end as on disconnected tie rod end assemblies . Replace
sembly should be replaced. assemblies that test less than 5 inch-pounds
2 . The threaded portion of both tie rod ends must be (O.6Nm). Loose assemblies will adversely affect
inserted completely in the cross tu be split. This is steering performance. They may prevent adjust
essential for adequate clamping. Replace compo ment of the steering assembly to vehicle manufac
nents if this fit cannot be obtained (see page 19). turer's recommended alignment specifications.
10 of 26
INSPECTION
Wheel Bearing Inspection NOTE: Bearings normally fail after they have I¡ved their
expected life. Premature wear or fatigue can be
1. Remove bearings. Clean bearings , spindle, hub
caused by improper installation, incorrect adjustment,
cap, and hub cavity with a suitable commercial
or lack of lubrication.
solvent .
2. Inspect cups, rollers, and eones for wear or As a guide for inspecting bearing condition, the three
damage. The photographs in this section of the photographs below illustrate various stages of wear.
manual can be used as a guide to inspect the
bearings.
Break-in (uneven wear). High mileage (normal wear). Bearing failure (damag ed).
This cup displays an uneven wear This bearing cup is evenly worn in This cup has been badly bruised
pattern typical in low mileage with a manner common for advanced by hard metal particles in the lubri
light or moderate loads. It is mileage with normal loading. It is cant. If reused, it would probably
caused by the bearing preload ap lightly pitted because of contami begin spalling or flaking within a
plied during assembly and will nants in the lubricant and would be short time. It should be replaced.
gradually become more even as replaced before it reached an ad
mileage increases. If not otherwise vanced stage.
damaged, parts showing this wear
pattern can be reused.
Typical Bearing Failures
Normal Wear and Pitting Pitted and Spalled

The slight defects on the cup surfaces and cone rollers Surface Fatigue Failure
are indications 01 normal wear. However, upon closer This bearing is in the advanced stages or corros ion or
inspection you will note three or lour pits starting on the etching. Heavy pitting and spalling has occurred .
cupo Under continued operation, this bearing would Corrosion damage is usually caused by water or other
not last. contaminants in the lube.
11 of 26
INSPECTION
Typical Bearing Failures (cont'd)
Chipped and Spalled Surface Fatigue Failure Pitted and Spalled

This bearing shows damage at the extreme end of the Surface Fatigue Failure
roller and cup contact surface . Metal surfaces of the This bearing is in an advanced stage of pitting and
ro llers are chipping and spalling, and it is also spalling.
occurring on the cupo
Wheel Alignment Inspection

Correct wheel alignment is important. It promotes Use vehicle manufacturer's instructions as a primary
longer tire wear, ease of handling, and minimizes strain source of information to inspect wheel alignment and
on steering components and axle components. make adjustments. For general guidelines , use the
following data.
Camber is the vertical tilt of the wheel as viewed from POSITIVE

the front of the truck. ..,:: •. CAMBER VERTICAL .<~. NEGATIVE
.... ,. :.. ... CAMBER
"Positive " camber is an outward tilt of the wheel at the ,,,L~' VERTICAL CENTERLlNE
¡~•:.~.i.:;.¡~:I;~:~=l
topo
"Negative" camber is an inward tilt of the wheel at the

1l'TrENTERUNE ....
~.;:.~:,¡'¡~..::.:•R.~': ~.: ¡.:,1~; :.'~ : ~ .-:}::.:::::-~:::::j~~~
~ ~:.;' ~. _
:t:(.,,:
...
to po
A CAUTION: Eaton expressly prohibits

bending ofaxle beams (hot or cold) to
.:.:...
.:::.....: ..
.. .. .•.:.:
'• '.. ..t.. t =... ". :. ..:':::....:\.:
. ' \.,......:. .
.:.:..
.: :.."..
J~:,:,:, : .?:: .~: :.: : :

.:.. :::
....'..•....:..... :" : :::
change camber or for any other purpose. CAMBER ILLUSTRATIONS
12 of 26
INSPECTION
Caster
Caster is the fore and aft tilt (toward front or rear of Caster is adjusted by adding or removing taper
ve hiele) of the steering knuekle pin as viewed from the wedges between the springs and axle beam mounting
side of the vehiele. pad.
"Positive " easter is the tllt of the top of the knuekle pin The easter angle is generally more positive with power
toward the rear of the vehi ele. steering , sinee the power-assist overeomes
exeessive steering effort. This enables the vehiele to
"Negative" easter is the tilt of the top of the knuekle pin exhibit maximum straight ahead steering stability.
toward the front of the vehiele.
NOTE: Ineorreet easter adjustment may affeet steering SPECIAL NOTE: Caster should be
effort or stability. It has a negligible affeet on tire wear. adjusted to specifications recommended
A easter angle more positive than speeified may re sult by the vehicle manufacturero
in exeessive steering effort. An angle less positive may
result in vehiele wander or poor steering return to
eenter.
Caster angle is determined by the installed position of

A CAUTION: Eaton expressly prohibits
twisting ofaxle beam for caster adjustment
the steer axle.
or any straightening purposes.
• FRONT OF VEHICLE
(LEFT SIDE)
NEGATIVE
VERTI CAL .. .. ~ : r-~ POSITIVE CASTER "~:. ,~-- . --
CENTERLlNE ""~ CASTER :...;v.. . VERTI CAL
, ~,./--"/~IL~~~~~R LlNE
CASTER ILLUSTRATIONS
13 of 26
INSPECTION
Toe Setting
Toe setting represents the different distan ces between condition . With an initial toe-in setting, a desirable "O"
front and rear of the tires (measured at the vertical toe-in can be achieved when the vehicle is in motion.
centerline of the tires).
Incorrect toe setting, whether toed-in or toed-out,
Toe-in is obtained when the tire rear distance is can have a significant affect on tire wear. Toe setting is
greater than the tire front distance . adjusted by lengthening or shortening cross tube.
Toe-out is present when the tire front distance is

greater than the tire rear distance. SPECIAL NOTE: Toe setting should be
adjusted according to the vehicle manu
A toe-in adjustment is usually specified. As the
wheels roll forward, the tires tend towards a toe-out
facturer's recommendation.
FRONTVIEW
TOE-IN - Tire ¡ront distance

is less than tire rear dislance
(measured al tire vert ical centerline)
FRONTVIEW
TOE-OUT - Tire ¡ront distance

is greater than tire rear distance
(measured at tire vertical centerline)
TOE SETTING ILLUSTRATIONS
14 of 26
MAINTENANCE / ADJUSTMENT
Knuckle Vertical Play Adjustment Specifications:

NOTE: For measuring vertical play with knuckle Adjust when vertical play exceeds 0.040 " (1.02mm).
assembled, refer to page 8. If adjustment is
necessary, disassemble knuckle, adjust end play, and Adjust to 0.002 to 0.012 " (0.051 to 0.305mm).
reassemble following instructions in the Overhaul
Adjust by removing or installing shims between axle
Section of the manual .
beam and upper part of knuckle .
NOTES:
15 of 26
MAINTENANCE/ADJUSTMENT
Wheel Bearing Adjustment

1. Spin the wheel and tighten adjusting nut to 100 ft lb slot with cotter pin hole.
(136Nm) to seat the bearing . 5. Repeat rotation of wheel in both directions. Wheel
2. Back off nut one full turno should rotate freely. Bearing end play should be
3. Spin the wheel and tighten adjusting nut to 50 ft lb 0.001 to 0.010" (0.025 to 0.250mm) .
(68Nm). 6. With adjustment complete , insta" cotter pino
4. Back off adjusting nut 1/6 to 1/4 turn to align nut
FORWARD
f STEER AXlE BEAM
~-~--
DEGREE OF
STEERING ANGLE
STEERING STOP ADJUSTMENT

(EACH END OFAXLE)
Steering Stop Adjustment

1. Check vehicle manufacturer's manual to deter
mine correct steering stop angle.
2. Check steering angle with alignment turntable set.
3. If adjustment is required, loosen jam nut and turn
stop screw as necessary.
4. Af1er adjustment, tighten stop screw n ut to torque
shown in adjacent photo.
NOTE: Adjust power steering unit so that power assist

0
sto ps approximately 3 ar 1/8" (3. 175mm) befare
reaching the steering stop screws .
ALL MODELS
90-120 ft lb
(122-163Nm) o
16 of 26
REMOVAL / DISASSEMBLY
Overhaul Preliminary Steps

Prior to performing overhaul procedures, the following 2. Jack vehicle until steering axle wheels are raised
prelimínary steps should be accomplished. from the ground. Support raised vehicle with
1. Set parking brake and block drive wheels to safety stands.
prevent vehicle movement.
A.
WARNING: Never work under a
. . vehicle supported only by a jack.
Steering Knuckle Disassembly

1. Back off slack adjuster to return brake shoes to the
released position and clear of drum .
2. Remove hub cap from wheel then remove cotter
pin, nut, washer, and outer bearing cone
assembly.
3. Remove wheel and hub assembly.
4. Disconnect air (or hydraulic) line from the brake
assembly.
NOTE: Do not allow contamination of hydraulic fluid.
5. Remove brake assembly.

6. To disconnect tie rod end from Ackermann Arm,
remove cotter pín and slotted nut.
7. Disconnect tie rod end using suitable tool (pickle
fork, see photo) .
A CAUTION: Do not use heat on any

parts or fasteners.
8. Disconnect drag link from steering arm by

removing cotter pin and slotted nut.
Disconnect tie rod en d

using suitable tool
(pickle fork)
17 of 26
REMOVAL / DISASSEMBLY
Knuckle Pin Removal
Remove
knuckle
Orive out
knuckle pin
1. Remove capscrews and lockwashers to remove 3. Orive knuckle pin out with hammer and brass dríft.
knuckle caps.
Remove
knuckle
1. Remove nut. .
4. Remove steer knuckle from axle beam .

Remove nut from draw key, then drive key out 5. Discard thrust bearíng .
using a hammer and brass drift.
A WARNING: Never use steel hammer

or tool to strike hardened metal parts
18 of 26
COMPONENT REPAIR / REPLACEMENT
Cleaning
After disassembly and befare attempting inspection,
clean parts as follows :
WARNING: Gasoline is not an
1. Wash steel parts with ground or po lished surfaces acceptable cleaning solvent.
in suitable cleaning solven\. Rinse thoroughly to
remove cleaning solution . Dry parts with clean 2. Wire brush or steam-clean castings , forgings,
rags. and other rough -surface parts that are suscepti
ble to accumulation of mud, road dirt, salt, etc .
Tie Rod End Replacement CORRECT ASSEMBLV

The threaded portion of
1. Disconnect tie rod end (see page 17).
~
both tie rod ends must
2. Loosen clamp nut and unscrew tie rod end. be completely inserted
3. Install new tie rod end. Thread end into cross tube in cross tube split.
~
past the tube split (see drawing).
4. Attach rod end to Ackermann Arm . Tighten to
carrect torque (see illustration below). Install
cotter pino INCORRECT ASSEMBLV
5 . Adjust toe-in (see page 14) . Tighten cross tube Threaded end not
clamp screw to correct torque (45-60 ft lb, completely inserted
61-81Nm). in spli\.
6. NOTE: On tie rods with rotating clamp, position
clamp with fastener away from beam .
T/E ROD INSTALLAT/ON
Ackermann or Steering Arm Replacement

1. Disconnect tie rod end from Ackermann Arm (or 4. Install new key in slot p rovided in Ackermann Arm
drag link from steering arm). (or steering arm) .
2. Remove cotter pin and nut from arm at knuckle 5. Install nut and tighten to carrect torque (see photos
end . below). Install cotter pino
3. Drive arm out of knuckle using suitable brass drift
and hammer.
6. Reconnect tie rod ends . Install nut and tighten to
A CAUTION: Do not use heat on com
ponents to facilitate removal of arm.
correct tarque (see photo). Install cotter pin o
MODELS 12F, 13F

350-490 ft Ib*
(475-664Nm)
MODELS 18F, 20F, 22T, 24T
775- 1,050 ft Ib*
(1051-1424Nm)
MODELS 12F, 13F

350-490ft lb (475-664Nm)*
775-1,050 ft lb (1 051-1 424Nm) *
* Tarque to minimum, then continue tightening to align Verify that torque does not exceed maximum .
cotter pin hole . repl ace nut.
19 of 26
Knuckle Pin Bushing and Seal Replacement

Remove Grease Sea/s. I MPORTANT: For proper removal and installation of
knuckle pin bushings and seals, use Eaton Installation
NOTE: Early model steer axles were equipped with an Tool part number 700291.
upper seal only. Later models use two seals (upper
and lower). Eaton Parts Kits with both seals are WARNING: During removal and
avaitable. It is recommended that both seals be used
when replacing seals or bushings. A
installation procedures, never
1. Remove grease seals from knuckle arms using . . use steel hammer or tool to
suitable tool. strike hardened metal parts.
Remove Knuck/e Pin Bushings.
2. Orive bushings out of knuckles using suitable
plloted drift (or Eaton Installation Tool, part number
700291) .
Orive out bushing

(using suitable
piloted drift)
/nstall Knuck/e Pin Bushings.
SPECIAL NOTE: When installing bush

ings, position seam in areas marked "X"
3. Remove all foreign material from knuckle pin are as
of steering knuckle and axle beam. (see drawing page 21).
4. Wire brush machined surfaces taking care not to
damage them. Clean knuckle pin bores.
NOTE: Some Eaton bushings require reaming after
installation . Follow directions provided with bushings.
Refer to Parts Books for correct part numbers of
reamable bushings.
5. Use same method (Step 6) to insta" both upper

and lower bushings. To facilitate installation, lightly
lubricate outside diameter of bushings.
20 of 26

/nstall Knuck/e Pin Bushings (cont'd). /nstall Grease Sea/s.
6. To install bushings, first hand start bushing in bore. 7. Install new seal, using suitable pilot drift or sim ilar
Then, using suitable piloted drift (or Eaton device that will not damage seal as it is installe d.
Installation Tool 700291), drive bushings in until
they are properly located (see drawing below). NOTE: When installing grease seal, be sure li p Is
pointing toward center of knuckle (see illustration).
This is essential for correct seal operation.
Hand start
bushing in bore
BUSHING SEAM
LOCATE IN
EITHER AREA
MARKED "X"
BUSHING LOCATION
MODEL 12F, 13F ... 0.25" (6.35mm)
MODEL 18F, 20F, 22T, 24T ... 0.100" (2.54mm)
BUSHING TO KNUCKLE
SURFACE
* POSITION SEAL
LlPS TOWARD BEAM
GREASE SEALS*
INSTALL FLUSH WITH UPPER SEAL
K~UCKLE SURFA~
BUSHING LOCATION
MODEL 12F, 13F ... 0.25" (6.35mm)
O
MODEL 18F, 20F, 22T, 24T ... 0.100" (2.54mm)
BUSHING TO KNUCKLE :;
SURFACE ~ Ltt~~ LOWERSEA L
21 of 26
S M 1-2-12.0 0700 Service Manual
INSTALLATION / ASSEMBLY
Steering Knuckle Assembly
Install shim
or shims
NOTE: Replace knuckle pin if pin finish is damaged . 4. Wedge up steering knuckle and fill gap (at knuckle
Always replace pin and bush ings when either are upper end) with shim or shims. Th is is a
faulty. preadjustment of knuckle vertical play.
1. Lightly lubricate the thrust bearing areas of the

steering knuckle, the axle end , and the kn uckle pin
bore of the axle beam. Also pack dimples in
bus hing bores with grease.
Start knuckle
pin installation .
by hand .
Position thrust
bearing with
sealup 5. Position knuckle pin with flat aligned with draw key
hole and start installing pin by hand .
Positlon thrust bearing on knuckle w ith seal facing

up.
Mount this assembly on axle beam .
22 of 26
Steering Knuckle Assembly (cont'd)
Reference dial indicator

. ·. Install .. at top of knuckle pin
. knuckle pin
6. Install pin in knuckle and axle beam from the top . If 7, To check vertical play, center steering compo
necessary, tap pin in place using hammer and nents ,
brass dritt. 8, Mount dial indicator to flange and reference top of
knuckle pin , Zera dial indicator,
NOTE: At this point in reassembly, check knuckle
vertical play and adjust if necessary (see Step 7
through 10) ,
9. Simulate axle loading with a jack (see photo) and

note dial indicator reading,
10, Knuckle vertical play should be 0 ,002 to 0 ,012 "
(0.051 lo 0,305mm), Add or remove shims as
necessary to obtain correct end play,
23 of 26
Align draw key hole

with knuckle pin flat. GALL MODELS
30-45 ft lb .,.,;.:':.:. lI>-~:."\,,
(41-61Nm
~
. ,.
. . ... :.'....
~"T" ..,."
, .
$
11 . Wi th adjustment comp lete, check draw key 13. Ins tall d raw key nut and tighten to correct torque
opening and pin flat alignment (see drawing). (see pho to above). Reseat key and reto rque nut.

Apply silicone rubber
gasket compound*
Install new draw key. Seat draw key with a hammer

and puncho
14. Apply silicone rubber gasket compound* to
knuck le cap mounting su rface (Models 18F, 20F,
22T, 24T see photo) . Use gasket on Model 12F, 13F
axle.
* NOTE: Do not apply excessive silicone compound

which cou ld block grease path for knuckle pin bushing .
24 of 26
Service Manual 0700 SM1-2-1 2.0
Install cap
"OALL MODELS
" 165-230ft lb
(224~312Nm)
15. Install capscrews and lockwashers to secure cap. 17. Attach drag link to steering armo Install and torque
nut to 165-230ft lb (224-312Nm). Also see NOTE
below. Install cotter pin o
.
O
. ... .
(30-38Nm)
. '
22-28 ft lb (AII Models)

.
e
18. Attach tie rod end to Ackermann Arm. Install and
torque (see photo). Install cotter pino
G
NOTE: Torque nut to range minimum, then tighten
further to align cotter pin hole. Check to make su re
torque does not exceed range maximum. If it does , use
a new nut.
16. Tighten capscrews to correct to rque (see photo) .
O
Final Assembly
NOTE: The following instructions are general. For 2. Lubricate wheel bearings.
specific details, refer to manufacturer 's instructions. 3. Install wheel/hub/drum assembly.
4. Adjust wheel bearings.
1. Insta" brake assembly and connect air lines.
25 of 26
Fa stener Torque Specifications

Specifications are the sam e for all axles
except where specified otherwise.
Steering Arm Sal!
Stud Nut
165-230 tt lb
(224-3 12Nm)
Kn uckle Cap Draw Key

Capscrew Nut
22-28 tt lb 30 - 45 tt lb
(30 - 38Nm) (4 1- 61Nm)
Steering and
Ackermann Arm
Nuts
12F, 13FAxle
350 - 490 tt lb
(47 5- 664Nm) Stop Screw
18F, 20F, 22T, 24T Axle Nut
775 - 1,050 tt lb 90-120 tt lb
(1051 - 1424Nm) (122 - 163Nm)
Cross Tube
Clamp Screw Nut
Wheel Searing 45 - 60 tt lb
Adjustment (61 - 81Nm)
(see page 16) Tie Rod End
Nut
165-230 tt lb
(224-312Nm)
Knuckle Cap
Capscrew
22-28 tt lb
(30 - 38Nm)
* NOTE : Torq ue nut to th e range minimum ,

then tighten lurther to align cotter pin hale.
Check torqu e to make sure it doesn 't
exceed ran ge maxim um. If it does, use
a new nut.
260126
Service Manual 0307 SM01-002-015 .0
15
1. Capscrew 5. Thrust Washer* 9. Bearing Cup 13. Bearong Cane

2. Hub Cap 6. Gasket 10. Wheel Hub 14. Seal
3. Adjusting Nut* 7. Bearing Cane 11. Lug 15. Spindle
4. Catter Pin* 8. Brake Drum 12. Bearing Cup
* Adjusting nut arrangement may va ry from illustratian . See Figure 2.
Figure 1
Front Wheel And Brake Drum
Front Wheel & Brake Drum,

R& I A WARNING
This procedure covers the removal and installation of
Brake Lining Fiber Warning
the front wheel hub and brake drum. Older brake linings may contain asbestos
fibers, a cancer and lung disease haza rd .
Removal Brake linings manufactured today contain
1. Lower, detach, and secure load, as required. non-asbestos fibers, whose long-term
2. Stabilize the crane for service as follows : effects to health are unknown. Use caution
a. Park the crane, out of the way, on a firm and when handling either asbestos or
level surface. non-asbestos materials used in brake
b. Engage the par k brake. linings. Refer to OSHA regulations for proper
c. Engage the swing park brake or travel swing handling of these materials. Material Safety
lock, as required. Data Sheets (MSDS) regarding brake lining
d. Level the crane on fully extended outriggers. materials can be obtained from your lo cal
e. Position/support the boom, as required. distributor.
3. Shutdown the engine and disengage the main
hydraulic pump, as equipped. 4. Remove the tire and rim assembly from the wheel.
Refer to SM Keysheet Area 01 -069 for correct
procedure .
1 of 6
8
Style 1 Style 2
1. Jam Nut 3. Lockwash er 5. Sp in dle 7. Adjusting Nul
2. Relainer Washer 4. Adjusting Nul 6. Thrust Washer 8. Co tter Pin
Figure 2
Wheel Bearing Adjustment Arrangements
Refer to Figure 2.
A WARNING 11 . After oil has thoroughly drained from wheel hub:
a , Style 1: Remove jam nut (1), retainer washer
Solvents and cleaning solutions can be (2) , lockwasher (3) , and adjusting nut (4) from
hazardous. Serious personal injury may spindle (5),
resu lt from misuse of these products. Read
b, Style 2: Remove cotter pin (8), adjusting nut
and follow all the manufacturer's
(7) , and thrust washer (6) from spindle (5) ,
reco mmendations concerning solvents and
cleaning solutions. Refer to Figure 1,
12 , Slowly remove wheel hub (10) from the spindle
5 , Thoroughly clean area to be disassembled with an (15), The bearing cone (7) is loose and may be
approved cleaning solvent. Allow area to air dry. removed ahead of the wheel hub (10) . Use care
6, Back off the brake shoes from the inner diameter of not to damage bearing cones (7,13), wheel hub
the brake drum by using the adjustment screw on (10), seal (14) or spindle (15),
the slack adjuster. Refer to SM Keysheet Area
01 -003 for more detailed information on brake
adjustment and slack adjusters . CAUTION
Refer to Figure 1, Removing some types of seals from the wheel
7. Support the brake drum (8) with an appropriate hub may cause permanent damage to the
lifting device remove it from the wheel hub (10) by seal. Reusing a damaged seal will eventually
pu ll ing it off the lugs (11) . It may be necessary to cause the failure of the wheel bearings. Do
strike the inner rim of the brake drum (8) with a soft not install a damaged sea!.
lace hammer to break it free of the wheel hub (10),
8, Place a suitable container under the wheel hub 13, To remove the bearing con e (13) from the wheel
(10) , Remove capscrews (1) securing hub cap (2) hub (10), the seal (14) must first be removed. Refer
to the wheel hub (10), Remove hub cap (2) . Drain to Figure 3 through Figure 5 to identify the style of
the oil Irom the wheel hub (10), seal (14) used,
9. Remove the gasket (6) from wheel hub (10) and 14 , Remove seal (14) and bearing cones (7,13) from
hub cap (2) . Properly sto re or dispose of used oil. wheel hub (10) , If equipped , remove the axle ring
10, Us ing an auxiliary lifting device , adequately (6 ,Figure 5) from the spindle (15) , using a ball peen
support wheel hub (10), hammer, Do not cut through the axle ring as
damage to the spindle (15) may result.
15 , Remove bearing cups (9,12) from the wheel hub
(10), as required ,
2016
Cleaning And Inspection 2 3 4
A WARNING
hazardous. Serious personal injury may
result from misuse of these products. Read
recommendations concerning solvents and
cleaning solutions.
1. AII components should be thoroughly cleaned with

an approved cleaning solvent, air dried , and
carefully inspected. Be sure that all foreign Deflector Ring 6 5
material is removed from the bearings and inner Flush With Shoulder Face
cavity of the wheel hubo
2 . Clean the shoulder of the axle spindle with a wire 1. Wheel Hub 4. Seal
brush . AII Loctite®, Permatex.:;) , or other sealant 2. Bearin g Cup - Inner 5. Deflector Rlng
residue should be removed from threads of 3. Bea ring Co ne - Inner 6. Spindle Shoulder
hardware and parts thatare going to be reused . AII Figure 3
gasket material should be removed from the Two Piece Seal (Stemco ® Guardian ®)
spindle and wheel hubo
3 . Carefully inspect all components for damage,
wear, fatigue or stress fractures corrosion, deep Refer to Figure 1.
scratches, cracks , and scuffed metal. Remove any 1. Install bearing cups (9,12) , as required.
burrs or sharp edges with a fine file, hone, emery 2 . Install the seal (14) using one of the followmg
cloth , or crocus cloth. Replace any damaged com procedures:
ponent, as required .
Two Piece Seal Installation
4. Replace bearing cones and cups as a matched set
only. Note: Do not install the seal into the bore of the
5. Replacement of the seal is recommended. wheel hubo
6. In the event of severe defects, contact factory
personnel for directions whether to repair or Refer to Figure 3.
replace any major component. a . Apply a thin coat of Permatex'" No. 2 sealant to
the spindle shoulder (6) used to mount the
Insta Ilatio n deflector ring (5) portion of the seal (4). Be
sure to coat the entire circumference to ensu re
Multiple types of seals have be en used in the wheel an oil tight seal.
hubs, depending on crane model and lubrication type . b. Separate the seal (4) from the deflector ring (5)
Figure 3 through Figure 5 illustrate three different and apply a light coat of clean lubricant to the
types used. Refer to the appropriate Figure and related lip of the seal (4) and inner diameter of the
installation instructions for specific seal installation deflector ring (5). Refer to th e Operator ' s
procedure . Manual for the correct type of lubricant to use.
C. Reassemble the seal (4) and deflector ring (5)
and manually rotate the parts to ensure the
A WARNING
Lubricants, sealants, joint and thread locking
seal (4) is properly seated in the deflector ring
(5) .
d. Place the seal (4) and deflector ring (5)
compounds, etc . can be hazardous. Serious assembly on spindle shoulder (6) so the words
personal injury may result from misuse of "OIL BEARING SIDE" can be read . A slight
these products. Read and follow all step on inside diameter of deflector ri ng (5) will
manufacturer's recommendations concerning allow it to be placed by hand , approximately
these products. 0 .12 in (3mm) , onto spindle shoulder (6) .
3 of 6
Seal Fully Seated

2 3 4 In Wheel Hub
4
Seal Fully Seated ~-'
In Wheel Hub
Axle Ring Flush
With Shoulder Face
1. Wheel Hub 4. Seal
1. Wheel Hub 3. Bearin g Gone - Inner 2. Bearing Gup - Inner 5. Sp indle Shoulder
2. Bearing Gup - Inner 4. Seal 3. Bearing Gone - Inner 6. Ax le Ring
Figure 4 Figure 5
I Dne Pi ece Seal One Piece Seal With Axle Ring
Note: To ensure proper installation of the seal

One Piece Seal Installation
and deflector ring a seal driver must be used.
The installation tool should only contact the Refer to Figure 4 or Figure 5 .
defl ector ring and not apply any force to a. Prelubricate the bearing cone (3) by packing it
surfa ces of the seal. When properly installed, with grease or dipping it in the proper oil type
th e deflector ring should be flush and square lubricant. Refer to the Operator's Manual to
with the face of the spindle shoulder. determine the correct type of lubricant to use.
e. Using the proper seal installation tool , carefully b . Lay wheel hub (1) on a flat surface with the
drive the deflector ring (5) evenly onto the bearing cup (2) facing up.
spindle shoulder (6) . Wip e away any excess c. Place the bearing cone (3) into bearing cup (2).
d. Applya thin coat of Permatex't' No. 2 sealant to
sealant.
f. Oip bearing cone (3) in clean oil and place it on the outer diameter of the seal (4). Be sure to
the spind le untíl it is seated against the spindle coat the entire circumference to ensure an oil
shoulder (6) . Use care not to get oil on brake tight seaL
e. Position the seal (4) in tlle bore of the wheel
linings. Refer to the Operator's Manual for
hub (1). Align tlle proper installation tool on the
correct type of oil.
seal (4) wit h handle in vert ical position and
strike the tool sharply to start the seal (4) into
the bore. Orive the seal (4) into bore unlil il
CAUTION complelely bottoms out in Ihe bore. Check
Do not push the wheel hub anta the seal by clearance between bearing co ne (3) and seal
ha nd . Uneven installation of the wheel hub (4). Al least 1/32 " (O.8mm) is required.
may cause misalignment of the seal causing
Refer 10 Figure 5.
leakage and /or damage to the seal. The wheel
f. If equipped wilh an axle ring (6). apply a thin
h ub will be seated onto the seal as the
coat of Permatex® No. 2 sealanl lO Ihe spindle
adjusting nut is tightened. shoulder (5). Be sure to coat the entire circum
ference lO ensure an oi l lighl seal.
g . Do not seat the wheel hub (1) against the seal
by hand . The wheel hub will be seated using
the adjusting nut in the installation steps to
follow.
4 of 6
g. Place axle ring (6) on the spindle shoulder (5).
Align proper installation tool on the axle ring (6)
and strike the tool sharply to start the axle ring
CAUTION
(6) into the spindle shoulder (5). Continue to Do not tighten adjusting nut to align dowel p in
tap the installation tool until tool contacts the hole to the lockwasher. This can preload the
spindle shoulder (5). Rotate the tool and tap bearing and cause premature bearing fa ilure .
several times to assure complete bottoming 11 the dowel pin and the hole in the lockwasher
out of tool and proper position ofaxle ring (6). are misaligned, remove the lockwasher, turn
h. The axle ring (6) should be flush with the face of in over, and reinstall it. If parts are still
the spindle shoulder (5). misaligned, loosen the adjusting nut just
enough for alignment.
CAUTION e. Installlockwasher (3) on spindle (5) . Ensure

that dowel pin on nut (4) is properly seated in
Do not seat the seal by hand. Uneven
lockwasher (3).
installation of the wheel hub may cause
f. Install retainer washer (2) and Jam nut (1).
misalignment 01 the seal causing leakage
Torque jam nut (1) to 100-150 ft lb
and/or damage to the seal. The seal will be
(136-203Nm).
seated as the adjusting nut is tightened.
g. Secure the jam nut (1) by bending retainer
washer (2) over two of the flat hex surface of
Refer to Figure 1. the jam nut (1).
3. Using an appropriate lifting device, carefully place
wheel hub (10) on the spindle (15) and slide it back Style 2 Installation And Adjustment
until the seal (14), wheel hub (10) and shoulder of a Install thrust washer (6) and adjusting nut (7).
the spindle (15) just make contact. Torque adjusting nut (7) to 100 ft lb (136Nm)
4. Prelubricate the bearing cone (7) by packing it with while rotating wheel hub (6 , Figure 1) to seat
grease or dipping it in the proper oil type lubrican!. the bearing cone.
Refer to the Operator's Manual to determine the b. Back off the adjusting nut (7) one full turno
correct type of lubricant to use. C. Spin the wheel hub (6, Figure 1) again and
5. Place the bearing cone (7) in the bearing cup (9) torque the adjusting nut (7) to 50 ft lb (68Nm).
within the wheel hub (10). d . Back off adjusting nut (7), 1/6 to 1/4 turn , to
6. Use one of the two following procedures to install allow wheel hub (6, Figure 1) to turn freely.
the adjusting nut on the spindle. Refer to Figure 2 Install cotter pin (8) .
to determine which procedure is applicable. Refer to Figure 1.
7. Verify that wheel hub (10) end play is 0.001 -0.005
Style 1 Installation And Adjustment
in (O.0025-0.0127mm) using a dial indicator. If
a. Install adjusting nut (4) onto spindle (5) with
reading does not fall into acceptable range, rep eat
dowel pin on adjusting nut (4) facing out. Tor
previous steps.
que nut (4) to 100 ft lb (136Nm) while rotating
8. Install gasket (6) and hub cap (2) . Install and
wheel hub (6, Figure 1) to seat the bearing
evenly tighten capscrews (1) to secure hub cap (2)
cone.
to wheel hub (10).
b . Loosen the adjusting nut (4) one full turn o
9. If an oil typelubricant is used to lubricate the wheel
c . Spin the wheel hub (6, Figure 1) again and
bearings , fill wheel hub (10) with oil. Refer to the
torque the adjusting nut (4) to 50 ft lb (68Nm).
Operator 's Manual for correct type and procedure .
d . Loosen the adjusting nut (4) 1/3 to 1/2 turn
Do not overfill.
maximum.
10. Properly adjust the front brakes . Refer to SM
Keysheet Area 01-003 for the correct procedure.
11. Install tire and rim assembly. Refer to SM Keysheet
Area 01 -069 for correct procedure.
12. Complete the installation by testing all relate d
functions of the front wheel and brakes for proper
operation. A general inspection of components
and systems in the areas adjacent to the repair
should also be performed to ensure related
damage or wear is not present.
5 of 6
6 of 6
Service Manual 0509 SM01-003-01 0. 00
If parts are hard to disassemble and assemble, do not

Brakes, Recondition use a hammer unless it has a soft face, do not force
(Dana®/Spicer® ES & ES Models) parts together, they must be free to operate an d not
bind.
This procedu re covers the recondition of the carrier It is a good practice when disassembling complex
wheel brakes. components to lay the parts out in the order that they
were disassembled. Keeping the parts in this order
The following pages are taken directly from the service
during disassembly, cleanin g, and inspection wllI aid in
literature produced by the axle manufacturero Multiple
brake models are covered by this information . Pay
particular attention to Section 1 of this procedure to
correctly identify the specific brake model being
serviced. Proper identification of the brakes is crucial
to obtain the correct information to follow from the
A WARNING
charted specifications included in this procedure . hazardous. Serious personal injury may
Based on the specific application of the brakes used on
the axle, Link-Belt literature will supersede any
discrepancies in operation, lubrication, maintenance,
cleaning solutions.
or service , implied by the brake manufacturero Any
concerns regarding such inconsistencies should be
reviewed with a Link - Belt distributor. Thoroughly clean the exterior surface of the axle , with
an approved solvent, to prevent contamination from
entering it befare beginning the disassembly process
1 of 56
Tab le of Contents
Section 1: General Information
Foreword ' , , , , , , , , , , , , , , , , , , , . ... ... ... ..... .. . .. . ... .. ..... . .. ' , , , . . , , , , , , . . , , , , . , .. . , . , , 5
How to Use this Manual. ,' o,. " " •• • " ••• " , • 5 • •••• , • ••••• •• " ••• • • •• ,., • • • ••• • • , •• "", • •• , •• ••• • ,
Lining Material Warning 'o •• ,., •• ,.,., • • ".,'., 6 ••••••• , ••• •• •• • , • •• •• , • • • ••••• " • ••• ••• ••• ••••••• • ,
Model Coverage "",., .. ' , , ' , , . , . , .... , .... . . ' . , , . .. . . . , , . ... . . . .... .. . ... .. . . . ..... ..... . , . 7
Parts Nomenclature , , , , , , ' , , ' , , , , , , . , , ..... , , . , . . , . , . , ..... , , . . .. ... . . . .. . . .. .. .. , 9
Model ES - 165-7 and EB-165-7Interchangeability .. . , . . .. ,., . . . . . , . ... . . .. , ..... .... ... .... ,. .. 13
EB Roller and ES Cam Interchangeability . , , , , ' , , . , , , . , , , .. . . .. .. . . .. , ... . . . . , .. 13 o •• , , , • • o • •••••• o .
Sectio n 2: Periodic Service

Maintenance And Adjustment . , , . , , , . , , , , . , . . , , , , . . , . , . .. . .. , .. . . . ........ . . , , , , ... . . ..... , ..... . " 16
Brake Maintenance Preliminary Steps "o" • • •• "" • • • ',' • •• •• ,., • ••• ", • • • ,.,., •• • , •••• • '.'" •• • ". 16
Brake AdJustment-Manual Slack Adjuster ' o , ' . , . , • • • • • , ' • • • , . , . , • • , . , . , • • • , • • • • • • • • • , • • • • • , . , • • • " , 16
Brake Adjustment-Automatic Slack Adjuster , , . . , . , .. , .... .. , . , . . . . , , .... . . , .. , , . .. , . , . . .. ' .. , . . . , " 17
Brake Operation Check " " " " " , .. ,.".,".' ... ... . ,., . ', ., . . . . ", . . .. ,., . . .. . ,.,' ... . ,., . . " .. , 19
Lubrication ' o . ,.,.,."" " " •• , . " • • , • • , ••• •• • •• •• , . " •• "" •• • "", • • • ,.,., • • • ,., • •• •• ", . , • • • " 19
Periodi c Inspections ., .... , .. . . .... . . . ' .. .. . . .... . , .. , . .. , , , , , . , , , , , . . . , . , ... . . , . , . , .. . , . , . . . . . 19
Service Intervals .... , .. ' , ' . ... ... .. ... . . .. .. . ... . . . , , . , .. , , , . , . .. , , , , . . . , .... , . . . . . . . 19
Section 3 : Removal /Disassembly
Drum Removal ' , , , , , , , , . , , . , , , . , .. , , , , . . . ..... . .. . . . .. ... , ........ . .......... ...... ... .. , . .. , . , 'o 21
Shoe Removal ,,'o,.,., •• •• ', ,' o. , •• , • • • , •••••••••••• • ,., • • ,.,., • • ••• •••• • •••• , •• • • ,., •••••• • " , 22
Slack Adjuster Removal , , . . . ' , , , . .. ' . , , .. . .. ' .. .... , ... .. . , ... . ........ ............... .. ... o . 30
Camshaft Removal o" •• ,., •• ,." ••• ,., • • ,., •• •• ••••• • • ,., •• • , • • •••••••••••••••••• • •• ••• • • • ••• •••• 30
Air Chamber Bracket Removal " " , ' . . . , ..... . . . ... ..... .... .. . .. ...... .. , ..... .... .... . . , . ... . , ... 30
Spider Removal , , , . , , , . , , . , . , . , , , ... , .. . ... , .. .... ... .. , , , . .. , , , , .... .... . .. . . . .. .. . . . .. .. . . . . o , 31
Dustshield Removal "" " .... '", .. "" .. , . ....... , .. . ,., . ...... .. . . . . , . .. . . . . , . . . ...... . .. . ,." , 31
Cleaning Brake Parts "'o, •• • • ", •• '" •••• , ••• • ••• ' • ••• • , • •••• •••• ••••••• , • • ••• , • • ••• • •• • •• • • • • ',, 31
Section 4: Inspection
Drum Inspection " " " " . . ,." . . . ,."' . '"., .. ,., . . . " ., ... '" . . .. ',." . . , ... , .. ' " " ' .. ', ... , , ,, 33
Drum Turning /R eboring " " " " . . . ",' . . ',' . . . '"'. ' "., . .. . ,., ... . ", . .. , ..... . ...... , . . . .. ,' . . ,, 33
Shoe and Lining Inspection , , , , , , , , , , ... , , , . , .. , . , .... , , , .... , , , . . . ' . , , ... .. , , , .. . . , , . , . . ' . . 34
Camshaft Radial Play Inspection " " " ' . ',.,' . .. ,., .. '" . , .. "" , .. ,,, .... ..... . ... ',,' .. ... ,,' . .. , 36
Camshaft Inspection , , , o , """ . "" . "."' • • ",' •• ,." , •• "" •• • '" ••••• ",,' •• • ,.,' ••• ,., •• '.,, 36
Camshaft Bushing and Seal Inspection o •• • • • •••• ' • • •• • ,." •• , . , •• ••• •• • •• • , •••• , •• ' , . " ' ••• ,.", . ,, 36
Spider Inspection 'o, •• ,. , .". , ••••••• • • ••• •••• ••• ••• •••• •• , • •• •••• •••• ••• ••••• •• ,."., •• '"", . " 37
Air Chamber Bracket Inspection ' .. . .. . . ...... . . ... ... ... .. ... .. . ... ",' . . ,.",' . . ""., ..... ",." 37
Air Chamber Inspection , .. , . , . , , . .. . . ... ... ... ... . ... ... .. ..... .......... . , . , . ... , . , , , . . , , , , , , .. . , 38
Slack Adjuster Inspection o ••• ,. ,. ", . " " ' •• ' . ,., •• , •• ••• , ••• , • • " • ••• • • • • ••• • •••• •••• •• • ••••• •• ,, 38
Sectioll 5: Repair/Replacement
Camshaft Bushing And Grease Seal Replacement o •••••• ••• • '" •• , •• , • • • " " , • •• •• • ••• • • •••••• •• • • , . 39
Brake Lining Replacement 'o"", •• ,.,.,.".",' • • ,. ', • • • , ••• • •• ,., • •• ••• " •• '",." •• •••• • • • , •• , 39
Secti on 6: Installation/Assembly
Spider Installation " " " " " . " ... , . . ',,' . . ,., '. ' . . , , , , . . , , , ... .. , . , , , ....... , . . ... , ' , . . . . , , ., 41
Dustshield Installation (Two Piece) ,' .. ',' . ...... . . . . , . ' .. ", . . . , .... . .. '",' ... ",' .. ', .. .. , , " 41
Dustshield Installation (One Piece) ,' ... ,., . . ,., . . ... , ' . . . ,., .... ,., . . ' . ... , . . ,." .. .. .. , . ,' .. .. '", 42
Air Chamber Bracket Installation o ••••• • , •••• • • • • ••••• •••• ", ••• , ••• • • • ••••••• • •• , ••• • ,." ••••• •• ", 43
Camshaft Installation " " " " ' . , .... ,., .. "., .. " . . , . .. "" .. . '" .................. . ..... . .... ', , . 44
Cam Head Washer And Slack Adjuster Installation " " , ... ,.", .. , .. . ....... , . . . , ........ . " .... " " , 45
Shoe and Lining Installation "' o , . """ . ""."".", • • "" •• "", •• ••• ", • • ,., •• , •• •• , •• • •• ",, . , 46
Specification Chart . , . , . , , ... ' ........ , . , , , . , .. ' .. , . . , , , , , .. , . , , , .. , , , . , .. .... , , . . , ..... ... . , , . " 54
1Di QÓ
Service Manual 0509 SM01 -003-010. 00
List of IIlustrations
Figure 1 Brake Model Identification . .. . .... . . .. .. . .... . . . ..... . . ........ .. . .... .... . .... 8
Figure 2 Brake Part Nomenclature, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Figure 3 Brake Model Part Nomenclature . . . . . . . . . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
Figure 4 Brake Model Part Nomenclature, Continued . . . . . ........ ............. 11
Figure 5 Brake Model Part Nomenclature, Continued .. . .... . . . . . . . . . ... .. . . . .. . .. . . ..... . . . ....... 12
Figure 6 EB Roller and ES Cam Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 7 Parts Identilication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 8 Parts Identilication, Continued ..... . . . . ... . ............. ... .. .... ......... .... . . .. 15
Figure 9 Crane Maintenance Support ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 10 Brake Chamber Measurement , At Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 11 Brake Chamber Measurement , 80 psi Applied .... . . ......... ..... .. ..... 17
Figure 12 Brake Chamber Measurement , Manually Applied . ... . .. .. . . ........ .. .... . . .. . 17
Figure 13 Automatic Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 14 Slack Adjuster Adjustment . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 15 Roller Retainer Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 16 Upper Cam Roller and Pin Removal . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . .. . 23
Figure 17 ES-1 65-7D,F,L Shoe Removal. .... .... .. . .... ....... . . . ....... .......... ...... 24
Figure 18 Shoe Removal .. ....... . ... ........... .. ..... . . ........ ... ....... ... ... . .. . . . . . . . .... 24
Figure 19 Cast Spider With Horse Collar ........ . . . ... ..... . ...... . . ... .. ... .. ...... . .... ....... . .. 24
Figure 20 Shoe Return Spring Removal ...... .. .. . . . . . ... .. .... . . .. ... . . .... ...... .. . ...... .. . . . .. 25
Figure 21 Lower Shoe Removal ........ ... .. . . . .. . . . . . .. .. .... .. ... . . ..... .. ....... .. . . . . .. .... . 25
Figure 22 Retainer Loop Removal. ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26
Figure 23 Roller and Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 24 Return Spring Removal .. ......... .................. . ....... ...... .. . .. ... .............. 26
Figure 25 Retaining Ring and Washer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 26 Capscrew Removal ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27
Figure 27 Anchor Pin Removal ............ . . . . . ........ . ........ .. .... ... . ........ ... . . . . . . . .. 27
Figure 28 Anchor Pin Bushing Removal ................ . ... .. ... .. . ...... . . . . . . ..... . . 27
Figure 29 Retaining Ring and Washer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28
Figure 30 Capscrew Removal ............. . . .. . .. ......... . . .. .. , . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 31 Anchor Pin Removal ... . . .... . . . .. ............. .. . ... ... ... ....... .. .... ... .... .... . . .. 28
Figure 32 Shoe Removal .. ...... ..... . . . .... . . ......... . ..... . .. ..... ..... ..... . . .. ... . ....... 28
Figure 33 Anchor Pin Bushing Removal ...... . ..... .. . ............. . ... . .. . . . . . . ... . ..... 29
Figure 34 Groove Pin Removal .. ... .......... ... ......... . ..... . . . . ...... . . ........... .. 29
Figure 35 Slack Adjuster Removal .... ....... .. ...... ........ ..................... 30
Figure 36 Automatic Slack Adjuster ....... ......... . .. . ......... . . . ..... . .. . ... . .... .... .. . .... ... 30
Figure 37 Spider Mounting Hardware Removal ... . .. . .. . ........ .. .... . . .. .. . ... . ... ...... .. . ...... 31
Figure 38 Dustshield Mounting Hardware Removal . ...... . .... ... ... . . ... ... . ...... . . ........ . .. 31
Figure 39 Dustshield Torques-AII EB/ES-1 65-5/6/7/8 L Models ... . . ......... . ... ............ . . . .. 31
Figure 40 Drum Inspection ......... ... . . .... .. ... .. ... ..... ..... . . .... . .. .. .. . ... . ... . , , . . .. . 33
Figure 41 Shoe and Lining Inspection . . . . . . . . . . .. . . . . . . ..... . .. ... . ... . ..... . . . ....... , ... . . 34
Figure 42 Brake and Lining Blocks ...... . ... ..... .. ... . .. ......... . ...... . ... . ....... ... . ... . .. . .. 35
Figure 43 Camshaft Radial Play Inspection .. ... .... .... . . . ........ .... . ... . . ..... . . . . . . .. .... 36
Figure 44 Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ... .. 36
Figure 45 Spider Inspection ... . . ....... ....... . , . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 37
Figure 46 Air Chamber Bracket Inspection . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 47 Air Chamber Inspection .............. . . . . . . .... . ........ .. .... . .............. ... 38
Figure 48 Slack Adjuster Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 49 Air Chamber Bracket Bushing Installation .... ... .. . ..... .. . ... .. ...... .. . . ......... 39
Figure 50 Camshaft Grease Seal Installation ................ . . . . . .... . .... . . . . . ....... .. ... .. 40
Figure 51 Installing Spider Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 52 Dustshield Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 41
Figure 53 Designed Interference Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 41
Figure 54 Dustshield Attaching Screw Locations . . .... ...... ... . . ....... . ..... . .... ... ......... . . 42
30156
Figure 55 Dustshield Attaching Screw Locations .... ....... ... . .. ..... . ......... ... ....... .. ... . ... 42
Fi gure 56 Air Chamber Bracket Mounting Hardware ............ . . ..... . . ..... . . ...... .. . ..... . .. . .. 43
Figure 57 Camshaft Instaliation .. .... .............................. .. .. . ..... . , .. ...... .... .. " ... 44
Figure 58 Cam Head Washer Instaliation ....... " , . . ....... . . . .. , ...... , ... " ....... . . .. " . .... , .. 44
Figure 59 Cam Installation - ES-165-5/6/7D,L .. .. ..... ... , .. . , .. ", .... ... " . .... " .', .. ... , .... 44
Figure 60 Shim Washer and Snap Ring Instaliation ., ... ,., .... , ... .. . . . '".,. " ", .. " .", ... . .. ',. 45
Figure 61 Slack Adjuster End Play Check, , .... .... .. . , , . , , , .. , , .... , . . , , , .... . . , , .. , , , .. , .. , , , . , ., 45
Figure 62 Slack Adjuster Lubrication and Adjustment .... " " ... " ...... " . . . ..... , .. " . " " ", .. . " 45
Figure 63 Shoe Web Lubrication .. , ....... ... ....... , . . . , . , ' .. .... , , .. , . .. . .. , , .. .... ...... . , , . , .. 47
Figure 64 Shoe Retaining Spring Instaliation .. . . , ........ ,., .. " .. ,." "" . . . ,. " .. . .. ... , ... , . ,.,. 47
Figure 65 Shoe Return Spring and Rolier Instaliation ..... , , .. ... , ... . , . ... , , . ..... ... . .... . , , .... . ,. 47
Figure 66 Upper and Lower Shoe Positioning ...... ... ............ "." ... "., ... .. .. . " ... . , ... ... 48
Figure 67 Shoe Return Spring Installation ... . " .. , .... , ..... ,. ,., ... ... .. , .. ..... , '., ..... , . . ..... 48
Figure 68 Upper and Lower Shoe Positioning , .. , .. , . , , , .... , , , ........ , , .. , ....... , ... ... .. , . ..... . 49
Figure 69 Shoe Return Spring Instaliation , .... . .. " , .. , .......... , . . , ... . ....... " . ..... . . , ...... . 49
Figur e 70 Rolier Retainer Instaliation .,., ... , ' . . " , ... " . ........ ..... .. . .... " ... , .. ",. , . . .. . ",. 50
Figure 71 Shoe Return Spring Instaliation .. " ..... ... , . ... .. ,. , .. , .... , . . .. . , . , . ..... .. " ., ..... .. 50
Figure 72 Retainer Instaliation ....... , .. ... , ... , , , . , ... , ...... , .... , ... ...... , , . .... ... , , ......... 50
Figure 73 Anchor Pin Bushing Instaliation ., ........ " .. .... ... , .. ..... , .. ... " .. . ... ,., ........ ... 51
Figure 74 Lower Shoe and Anchor Pin Installation.. , , , . .. , .... , . , . , . , ... , , . . .. . .... , , .. .... , .. . .. , .. 51
Figu re 75 Upper Shoe and Anchor Pin Instaliation .. . " .. . .. .. ""." .. " ........ . . .... . . ........ , .. 51
Figure 76 Capscrew Installation ............... , .... , ............... .. , .. , ... , ... , ... . " ... , ...... 51
Figure 77 Shoe Return Spring Instaliation .. , . . .. , . . . ........ , ' .. ...... . ..... , ' ........ , ., ...... ... 52
Figure 78 Roller Retainer Installation ..... ... . ..... , . . ...... . , ..... ..... . , . . "" .. ..... ,." . .. . " .. 52
Fi gure 79 Rolier and Retainer Instaliation ... , ... .. " .. , . ... .. ... ... .. . ............... " .... , ... " . . 52
Figure 80 Retalner Instaliation ...... ... .......... , . , . . .... , , .. , . . .. . , ... , ... . . . ... .. , ........ , , ... 52
Figure 81 Groove Pin Installation .... .. ......... , .. , . ..... , .. , .... . , ... .. .. . ..... , .. , ....... " .... 53
Fi gu re 82 Spider Anchor Pin Bushing Instaliation .......... "., ., .. " , . . , ... .. , ..... ,' . . , .... " , .... 53
Figure 83 Shoe Anchor Pin Bushing Instaliation . ........ " .. , ...... , ..... . .... .... . . ... ...... ...... 53
Fig ure 84 Lower Shoe Positionin g . . ..... . , .... . , ...... . .. , , ...... , . ...... . , .... , . , . . . . . . .. 54
Figu re 85 Upper Shoe Positioning .. . .. . ...... . . ', . ... . ... ..... , .. , ..... " ........ , ...... , . ... .... 54
Figure 86 Upper Shoe Instaliation ... ....... ... ,., ... . .. . .... ,." ... , . ... , ...... , ......... , . . ..... 54
Fi gure 87 Lower Shoe and Anchor Pin Installation , .. .. , .. , .. , . . .... ..... , . .. , .... , ., ...... . . ...... . 54
List 01 Tables
Table 1 Brake Models and Specilications . ... , ..... . .. ... .... . .... , ... . .... ,. , . ..... .... .. . .... ,.. 7
Table 2 Distance Range ............... . ........ , . . .. , ................. .. ... . ..... . . . . .. .... . ,. 16
Table 3 Stroke Values ........ . ..... , .. . ... ..... . , ....... . ........ ,. ... . ..... , , . . . . . . . . . .. 17
Table 4 Lubrication Intervals . . . .. . ... , ... .. ............. , . .... , ......... . .. ......... ...... 19
Table 5 Shoe Removal Procedure Index ....... , . .... . .... , ...... ... .. ... . . , ... , . ... . .... , . . , . . .. 22
Ta ble 6 Brake Shoe Maximum Diameters ... , .. , . . . , .. . , . ......... , .... ..... . . .... .. .. . . , ... . .... 34
Table 7 Clevis Pin Hole Centerline ... ........ ..... .. , .... . ..... " , ..... ... . ... ...... . .. .. ... . . .. 38
Table 8 Camshaft Bushing Installation Specilications .. . , , . .... .... ....... . . , . ......... , ..... . . . . .. 39
40156
Section 1: General Information How to Use this Manual
Foreword 1. Arrangement. This manual is arranged in seven

sections: General Information , Periodic Service ,
This publication is intended to act as a source of Removal/Disassembly, Inspection, Repair/Re
maintenance information to those involved in servicing placement, Installation/Assembly, and Specifi ca
brakes . tions. General page layout, including se ction and
parag raph headings , indention levels , and Figure
and Table designator information, is shown on
Pages 2 thru 4.
2 . Table of Contents. The Table of Contents lists all
section headings and primary paragraph head
ings in this publication.
3. Illustrations and Tables. IlIustrations and tables are
included to help make the text of this publication
clear. See the List of IlIustrations and List ofTables
following the Table of Contents.
4 . Specification Chart. A tabulation of all measure
ment specifications is provided at the back of this
publication.
5 of 56
SM0 1 -003-010.00 0509 Service Manual
OANGER A
AVOIO CREATING OUST
POSSIBLE CANCER ANO LUNG OISEASE HAZARO
CAUTIONARV INFORMATION
1. AVOIO CREATING OUST Compressed air or dry
A Oanger
brushing must never be used for cleaning brake
assemblies or the work area.
Brake Lining Fiber Warning 2. WORKERS OOING BRAKE WORK MUST TAKE
STEPS TO MINIMIZE EXPOSURE TO AIRBORNE
Older brake linings may contain asbestos BRAKE LlNING PARTICLES . Proper procedures to
fibers, a cancer and lung disease hazard. reduce exposure include working in a well venti
Brake li nings manufactured today contain lated area, segregation of areas where brakework
non-asbestos fibers, whose long-term is done, use of local filtered ventilation systems or
effects to health are unknown. Use caution use olenclosed cells with liltered vacuums. Respi
when handling either asbestos or rators approved by the Mine Salety and Health Ad
non -asbestos materials used in brake ministration (MSHA) or Nationallnstitutefor Occu
linings. Refer to OSHA regulations for proper pational Safety and Health (NIOSH) should be
handling of these materials. Material Safety worn at all times during brake servicing .
Data Sheets (MSDS) regarding brake lining 3. Workers must wash before eating , drinking or
materials can be obtained from your local smoking ; showerafter working , and should not
distributor. wear work clothes home. Work clothes should be
vacuumed and laundered separately without
shaking .
Lining Material Warning 4. OSHA Regu lations regarding testing , disposal of
While current manufacturers no longer offer asbestos waste and methods of reducing exposure for as
bestos are set forth in 29Code 01 Federal Regula
b rake linings, the long-term effects of some non -as
tions §191 0.001. These Regu lations provide valu
bestos fi bers have not been determined . Current
able information which can be utilized to reduce ex
OS HA Regulations cover exposure levels to some
posure to airborne particles .
com ponen ts of non-asbestos linings, but not all. The
5. Material safety data sheets on this product, as re
I lI owing pre cautions must be used when handling quired by OSHA, are avai lable fr om your distribu
these mate rials . tor.
6 of 56
Service Manual 0509 SM01 -003-010.00
Model Coverage
The service procedures and specifications in this
publication cover the brake models listed in Table 1.
The basic instructions cover all 15, 16.5, and 18 inch
brake types and sizes , unless specified otherwise. A
breakdown of brake model identification is provided in
Figure 1.
Size Config u ration
Model Applications
in. mm Shoe Spider Anchor
EB-150-4L 15.0 x 4 381 x 102 Fabricated Fabricated SAP Steer Axles
EB-165-50 16.5 x 5 419 x 127 Fabricated Cast SAP Steer or Orive Ax les
EB-165-5L 16.5 x 5 419 x 127 Fabricated Fabricated SAP Steer or Orive Axles
EB-165-60 16.5 x 6 419 x 152 Fabricated Cast SAP Steer or Orive Axles
EB-165-70 16.5 x 7 419 x 178 Fabricated Cast SAP Steer or Orive Axles
EB-165-7F 16.5 x 7 419 x 178 Fabricated Forged SAP Trailer Axles
EB-165-80 16.5 x 8.63 419 x 219 Fabricated Cast SAP Orive Axles
EB-165-8L 16.5 x 8.63 419 x 219 Fabricated Fabricated SAP Orive Axles
EB-180-7R 18.0 x 7 457 x 178 Cast Heavy Cast SAP On/OH Hwy. Orive Axles
ES-150-4L 15 .0 x 4 381 x 102 Fabricated Fabricated SAP Steer Axles
ES-150-40 15.0 x 4 381 x 102 Fabricated Cast SAP Steer Axles
ES-150-60 15.0 x 6 381 x 152 Fabricated Cast SAP Steer or Orive Axles
ES-150 - 80 15 .0 x 8.63 381 x 219 Fabricated Cast SAP Orive Axles
ES-150-8F 15.0 x 8.63 381 x 219 Fabricated Forged SAP Trailer Axles
ES-165-50 16.5 x 5 419x127 Fabricated Cast SAP Steer or Orive Axles
ES-165-5L 16.5 x 5 419x 127 Fabricated Fabricated SAP Steer or Orive Axles
ES-165-6L 16.5 x 6 419 x 152 Fabricated Fabricated SAP Steer or Orive Axles
165 XL Cast 16.5 x 6 419 x 152 Cast Cast OAP Steer Axle Transit
ES-165-7F 16.5 x 7 419 x 178 Fabricated Forged SAP Trailer Axles
ES-165-7H 16.5 x 7 419 x 178 Cast Heavy Cast OAP On/OH Hwy. Orive Axles
ES-165-7L 16.5 x 7 419 x 178 Fabricated Fabricated SAP Steer or Orive Axles
ES-165-7M 16.5 x 7 419 x 178 Fabricated Heavy Cast OAP On/ OH Hwy. Orive Axles
ES-165-8L 16.5 x 8.63 419 x 219 Fabricated Fabricated SAP Orive Axles
ES-165-80 16.5 x 8.63 419 x 219 Fabricated Cast SAP Orive Axles
ES-165-8F 16.5 x 8.63 419 x 219 Fabricated Forged SAP Trailer Axles
ES-165-8L 16.5 x 8.63 419 x 219 Fabricated Forged SAP Trailer Axles
165 XL Cast 16.5x10 419 x 254 Cast Cast OAP Orive Transit
Table 1 Brake Models And Specifications
7 of 56
S M01 -003-010.00 0509 Service Manual
ES-150-8D
service~
B - Standard Brake
r-L
Configuration
Example: L = Fabricated Shoe
Fabricated Spider
Single Anchor Pin (SAP)
S - Extended Service Brake
Drum DiameteF--------.J Shoe Size

Example : 150 = 15 in (381 mm) Example: 8 = 8.63 in (219mm)
Brake Options
Drum Diameter Configuration
150 = 15 in (381mm) L = Fabricated Shoe / Fabricated Spider / SAP
165 = 16 . 5 in (419mm) O = Fabricated Shoe / Cast Spider / SAP
180 = 18 in (457 mm) F = Fabricated Shoe / Forged Spider / SAP
M = Fabricated Shoe / Heavy Cast Spider / DAP
Shoe Size H = Cast Shoe / Heavy Cast Spider / DAP
4 = 4 in (102mm) R = Cast Shoe / Heavy Cast Spider / SAP
5 = 5 in (127mm)
6 = 6 in (152mm) SAP = Single Anchor Pin
7 = 7 in (178mm) DAP = Double Anchor Pin
8 = 8.63 in (219mm)
10 =10 in (254mm)
Figu re 1
Brake Model Identification
8 of 56
Parts Nomenclature
General parts nomenclature lor brake models are nomenclature lor specific brake models are provided in
identilied in Figure 2. Variations in shoe hold - down Figure 3 and Figure 4.
springs and guides are also identilied . Specilic parts
Shoe Hold-Down Spring and Guide Variation
ES-150-4L O!d Slyle New Slyle
Standard Nut
Shoe Hold - Down Spring , ShOB Guide and hos
Hol d - Down Spnng
Camshaft
Retainer
Snap Ring
~/ Slaek Adjuster o
Shoe
@ ~nner Wash er . Spacer
/ / Camshaft Slabilizer Nut
Camshaft
Shim /
@ Bushing B k
/ rae et
I
Washer ;0 c:> Assembly
Camshaft
Shoe Spacer No! flequired
(Mus! be Removed for ew Sty fe Ho ld Down
Slaek Grease \ ID
Bushing
Adjuster Seal Grease
I
»
Seal Dustshield
«> O/ /
Shoe Return /
Cam Roll er
\
Dustshield Serew _ ~ Spnng <lO
Cam Roller Color-Blue
~ , .
p.p. . ~ :
(l
Shoe Assembly
~"" ~ Nut
___ o • ~
Shoe Assem bly : :
• o"
" ~.............. ~Shaft

• Shoe Relainer
Spring Spider
Color-Blue Assembly*
Spring
* Shoe Hold - Down Spring and Guide Variation
ES-150-4D Camshaft Camshaft

Shim Relainer
Shoe ~s\embIY B k 1 Wash~ ';) / Snap Ring
(N
•
• o " Inspeetion
.
' . ' Hole Plug

rae e
Assembly
Grease
Seal ~
\ ©
fJ
Shoe Return
Spnng--
'.
1~
.' Loek Washer Nut
----------- \
DO>
I
o~(.) '"
/ \Q) .• / ' Slaek Adjuster
'. Adjuster Inner Washer
Slaek
Camshaft Bushing
Color-Red Q)' \
~ Grease Fitting
Cast Camshaft Bushing
Spider~
Grease Seal
Dustshield
<;f.
<IP" ----- Retainer
Roller
Spring
Color-Gray *,r-lk
~
I
Shoe Assem bly
Figure 2
Brake Part Nomenclature, General
90156
ES- 150-60 Camshaft
Camshaft Retainer
Steer Brake Shoe Assembly Shim Snap Ring
\ Washer ';}/
.. .. . ~a\'@
~ . '.. .
Slack
AdJuster Q
Camshaft ~.
BuShln g "", ~ Slack AdJuster
Roller
Bracket ~o\ Inner Washer
Retalner_____ ~ tS>---
Assempl~ Grease Seal
Shoe Shoe Return
Retainer Springs \ \ spring'-..... ' Camshaft a o
Color-Orange ~ . J " .- Grease Fitting
O
BUShln~~ •
Grease
Spider ~ CJ Seal
(Stamped Steel)
Cam Head Washer _ _ a

tl Shoe Return
camShaft~ ............ Spring
~ Color-Red
~
~-""""'R etalner
.
~"
I
Shoe Assembly
Camshaft
ES -150-80 and Shim Camshaft
ES -150-8F Orive Shoe Assembly Camshaft

Bushing
~was~
00 @
~---S~~~I~~g
\
\
& Trailer Brake @
i)f,:- ~:'"~,;¡:;~7'"""
Bracket •
J1!.
Shoe Roller
A"'I"~
Retainer Springs 6) /
~" Retainer
Color-Orange ____ o . ' Seal
o -- Grease Fitting
Spider
(Stamped Ste~
()~--
a I ~ C;u~~~aft 9
Grease
Cam Head Washer ~ Seal
Forged Spider
~ ri' --- Retain er /
Color- White
Shoe Assembly
Figure 3
Brake Model Part Nomenclature
100156
EB-165-5D Cam Roller and Pin for

EB-165 and EB-180 Brakes
EB-165-5L Two- Piece Roller and Pin
EB-165-6D
EB-165-6F Shoe Assembly_ Camshaft
EB-165-7D Shoe
EB-165-7F
EB-165-7L
Retainer Springs~
Color- Orange \t -t
Spid er ___ ~'A"':::::::='"
(Stamped Steel)
Camshaft
~
Bushing
and Pin Cast Spider

Note : Cast spiders are tap ped
and require 4 bolts and lock
Shoe Retu rn Spring
washers to attach air
chamber bracke t assembly.
Cast Spider
" Wlth Horse
ES-165-5D ~ Collar
ES-165-5L
ES-165-6D Sh,, @
Retalnlng Spnngs -~ Camshaft
Camshaft
Retainer
ES-165-6F Color-Orange ~ Shim Snap Rlng
ES-165-7D Cam Head Washer - Washer ~
Grease \ ' iQ) ';)
ES-165-7F Seal ~~
ES-165-7L b~~ Slack Adjuster
Shoe \{ ~C ams ha ft Slack Adjuster
Bushing Inner Washer
Return Spring - --- .'
O'
Grease Fitting
Camshaft Bushing Cast
G,,,,, S", Spid"
Forged
STd~
~
Shoe Assembly
Figure 4
Brake Model Part Nomenclature, Continued
11 of 56
SM 01 -003-010.00 0509 Service Manual
ES -165-7M Camshaft
Retainer
HEAVY-DUTY Snap Ring Snap R~
BRAKE Fabricated
Shoe Assembly Washer
\
Slack Adjuster ~ ti
ES -165 - 7H "'"
""' ' . . " " "'a C)
Bracket
""~ ~~ Camshaft
Shim Washer
~
. Assembly J'.
S EVER E OUTY Anchor Pln . " "" " Inspectlon

Hole Plug
/
~
~- Slack Adjuster Inner Washer
BRAKE ~ \
Washer ______ tt- Retalner / ~<il'-.... Grease Seal
Snap Rlng ______ ~ ~ • Camshaft Bushmg
~ \ • •....A '"
~ Roller ~ or ______
Grease Fitting
~ r" <il
\
G
Bol!
Cast Shoe Return Spnng Cast ~ '" Bracket Lockwasher
Color - Orange SPlder", " " Camshaft Bushlng
Nut ___ .. GreaseSeal
Anchor Pln " - - - Dustshleld Cast Spider H version

Bushlng ----~ ~ \ Shoe Return
Roller Dowel Pin Bushlng
~ "'-
\ - - Spring
Camshaft _ Washer Color- Yellow ~/
Snap Ring,- Camshaft ROllerc~.
Washer- () C) <f.~ and Pin 't? ' • .'
A nchor P·In ~6)'-...

.. "- Retainer 69-=:-
~
Bushing
Anchor Pin
Washer ~ .... '. ' Roller
1:)_______
C) _____ Washer
___ \) cY" .' ' . •
Snap Ring_~ / . Snap Ring
Note: Cast spiders are tapped
Fabricated and require 4 bolts and lockwashers to attach
Shoe Assembly air chamber bracket assembly.
ES -180-7R
Camshaft Camshaft
Camshaft Sh·
. 1m Retainer
Bushlng W h
~
Shoe Assembly rease as er ____ Snap Ring
Inspection \'- ~ ';)
\ Hole Plug
Bracket Seal
~
Lockwa~r Bo~ ~
Assemb ly \ SI ac k Ad luster
·
~
• ® ()
~~ Slack Adjuster
• Inner Washer
and Pin
Shoe ~
Retalner Spring _ _ ~
Color - Orange
Spider -
(Stamped Ste~~ Dustshield
Camshaft ~hoeReturn
Spnng
Camshaft Roller ~ 6) \ Color- Green
and Pin ~
Shoe Assembly
Figu re 5
Bra ke Model Part Nomenclature, Continued
12 of 56
Model ES-165 and ES-165
Interchangeability
ES Roller , ES Ca m
Brake parts for the Extended Service Brake (Model
ES -165) are unique and must not be intermixed with 1,
Standard Brake parts (Model EB-165) unless other
wise instructed . These parts consist of the camshaft,
camshaft washer, return spring , cam rOller, and shoe/
-+
lining assembly. Any attempt to operate the brake with
other than its intended parts may result in unsatisfacto I
Normal
ry performance. Contact
"On- Road" Repair: If a crane should need "On Pattern
Road " repair and ES Brake hardware is not available, it
is possible to retrofit the brake with Standard Brake Figure 6
parts in order to return the crane to service. These ES Roller And ES Cam Contact Pattern
parts consist of the Standard shoe/ lining assembly,
cam roller, pin , and return spring. The retaining springs
and camshaft with cam washer will work in this situa
tion and do not need to be replaced.
ES Roller and ES CAM Interchangeability

EB Roller and ES Cam Interchangeability. The EB RolI
er and the ES Cam are compatible and can be used to
gether. Figure 6 illustrates the proper fit of an EB Roller
to an ES Cam. As shown, the contact pattern is at two
points and the two parts will function satisfactorily with
this fit.
Note: The ES Roller and ES Cam are not compatible

and should not be used together.
13 of 56
Brake model parts identification far shoes, return
springs , spiders, and camshafts are identified in
Figure 7.
AII EB-165 Models ES-150-D,F ES/EB-150-4L ES-165-D,L,F

Old New
~
\
Shoe Shoe
~ Shoe with Spring Shoe without
with Tab without Tab Attaching Lugs Spring Attaching
Lugs
Note: Shoe with tab cannot be
used on lightweight brakes
ES-165-7M ES-165-7H EB-180-7R
Double Anchor Pin Double Anchor Pin Single Anchor Pin

With Cam Roller
and Anchor Pin
Bushings
Hig h And Low Mount Shoes Shoe Return Spring
Color-Coded By Application
AII EB-165 Models

Blue .. ES-150-4UEB-150-4L
White . ES-150-8D,8F
Red ....... Use with "High-Mount"
Shoes (AII EB-165)
Black ..... Use with "Low- Mount"
Shoes (AII EB - 165)
Grey ES-165-5D,5L, 6D,6L
70,7L ,7F,8D,8L,8 F
Yellow ..... ES-165-7M
"High - Mount" "Low-Mount"
Orange ... ES-165-7H
Shoe Shoe Green .. .. . EB-180-7R
Red . . . . ES-150-6D
ES-165-5D,5L,6D,6L ,7D,7L
Figure 7
Parts Identification
140156
Brake Spiders
Lightweight Stamped Spider Cast Spider
Single Anchor Pin Single Anchor Pin
~~/ (·
~
Spider Part No,
Locatlon
(,c'-n
-~~'J
¡(-.
j ~ O' ('~
,))
" í -" "
ffD
~;:; " ~
o?! -'
l' ,
~O#O
\~ ¿:"c~
/; CJ
Air Chamber ~O~~ -!

Bracket Flange ":§.j ""'0 S-:~:'
'~.
- () Bracket Flange Shape lor ' -
~ (_, Shape lor Cast Spider e
Stamped Spider Spider Part No,
Location
Cast Spider Reduced Envelope Steer Brake

Double Anchor Pin Cast Spider
Spider Part No, Single Anchor Pin
Location
Spider Part No,
[QJ
Location
Air Chamber
Bracket Flange
6n Air Chamber
Bracket Flange
Shape lor Shape lor
Cas t Spider
Cast Spider o
Stamped Spider ES/EB-150-4L Reduced Envelope Drive Brake
Cast Spider
Single Anchor Pin
Splder Part No,
[15J
~
~' 0
'1
Location / I ,
.' " ., , , ) . _. roi
"l,
, :~ , /,~ '~ ;--........ \
:'::1.
"
! ".
, "
~1~ .-;~r·;:i-:·:.
"'''1''
(~-::_·;I:i
Air Chamber
Bracket Flange
Shape lor
ES/EB-150-4L
Air Chamber
Bracket Flange
Shape lor
)0r "¡ , O
o
\ ~ :' r , ,':/
" ,;~
,7,
..
;, '~'-' . Cast Spider Splder Part No ', K
Locatlon
B
Camshafts
Cam Head for EB-165 and
EB-180 Brakes
Cam Head for ES-165 and

ES-150 Reduced Envelope Brakes Camshaft Part No,
Location
Figure 8
Parts Identification, Continued
15 of 56
Section 2: Periodic Service Brake Adjustment- Manual Slack Adjuster
Note: An assistant is required to make a brake ad

Maintenance and Adjustment justment.
Due to the importance of a well-maintained brake sys
tem, the inspections and maintenance listed below
must be accomplished by commercial crane operators
at the intervals suggested. Since driver technique and
A WARNING
Block all wheels before beginning adjustment
crane use affect the rate of brake component wear, it
procedure.
may be appropriate to increase the frequency of the fol
lowing inspections to fit individual needs based upon
To determine whether brakes require adjustment, ap
past experience.
ply stroke is measured and compared to the maximum
Brake Maintenance Preliminary Steps value for the air chamber size in use on the crane.
1. Perform "Brake Maintenance Preliminary Steps"
Prior to performing any maintenance requiring removal
described earlier.
of the tire and wheel, the following preliminary steps
2. With air chamber push rod fully retracted, measure
must be taken to ensure your safety. Refer to Figure 9.
distance from face of air chamber to centerline 01
clevis pin hole. Refer to Figure 10. If the measure
ment is not within ranges shown in Table 2, reposi
tion clevis. Remeasure the distance and repeat un
til within range. Record exact measured distance
as dimension "f:\'.
Distance: Clevis Pin Hole

Centerline to Air Chamber Face
AII brakes (except Mack 2-5/8 ± 1/ 16 inch
and Trailer Axle) (66.7± 1.59mm)
Mack Brakes 4-3/8 ± 1/16 inch
(111 . 1± 1.59mm)
Trailer Axle Brakes 6-1 /2 ± 1/8inch
Support On (165.1 ± 3. 175mm)
Jack Stands
01 Adequate Table 2 Distance Range
Capacity
Block Wheels
Fig ure 9
Crane Maintenance Support ---- A
1. Set parking brake and block wheels to prevent

crane movement.
2. Raise drive axlewith ajack and support on suitable
stands.
A WARNING
Do not work under a crane supported only by
Measure This
a jack.
OiSlance With
Chamb er "Al Rest ",
3. Ca ge spring-type brake chamber. See SM Key Oimension'A"
sheet Area 01 -027 for the correct procedure.
Figure 1O
Brake Chamber Measurement, At Rest
160156
3. Apply and hold an 80 psi (552kPa) brake applica 5. Take "f'\' dimension exactly as before. Take "B"
tion, and again measure from face 01 air chamber measurement using a lever to move slack adjuster
to clevis pin centerline. Reler to Figure 11. Record as shown until the shoes contact drum. Reler to
distance as dimension "B". Figure 12. The result 01 "B" minus "f'\' is brake free
stroke. Adjust Iree stroke to within range specified
in Table 3.
--- 8
1I
Measure This Distance
at 80 psi (552kPa)
Dimension "B "
Figure 11
Brake Chamber Measurement, Air Applied
Measure with
Brake "Applied "
4. Subtract dimension "f'\' Irom " B ". The difference is Using Lever,
applied stroke. Compare applied stroke to maxi Dimension "B"
mum value in Table 3. II applied stroke equals or
exceeds maximum applied stroke shown, adjust Figure 12
brakes. II less than the maximum, no adjustment is Brake Chamber Measurement, Manually Applíed
required and you may perlorm Brake Operation
Check. 6. To adjust free stroke, depress locking sleeve on
slack adjuster adjustment nut and turn in direction
80-90 psi (552-620kPa) required . Recheck Iree stroke to ve rify it is within
Air Maximum Desired range . Make sure sleeve is "Iocked " when adjust
Chamber Applied Free
Size Stroke Stroke
ment is completed.
7. Verify that brakes are not dragging by spinning
Type 30 inch - Long Stroke 2.5 in (64mm) 3/8 to 5/8 in
(70 lo 15mm)
wheels by hand or tapping drum lightly with a ham
Type 30 inch - Stan dard 2 in (51mm ) (Without Drag) mer and listening lor a sharp ringing sound.
Type 24 inch - Standard 1- 3/4 in (44mm) 8 . Perform Brake Operation Check, to verily proper
Type 24 inch - (w/2 - 112 in 2 in (51mm)
operation of brakes before releasing crane lor ser
extended slroke) vice .
Type 24 inch 2.5 in (64mm)
(w/3 inch extended stroke)
Type 20 and 16 inch 1-3/4 in (44mm) 3/8 to 1/2 in

(10 lo 12mm)
Type 12 inch 1 -3/4 in (44mm) 3/8 to 1/2 in

(10 lo 12mm)
Table 3 Stroke Values
NOTE: If adjustment is necessary, brakes are ad

justed to achieve proper free stroke. The difference
between free stroke and applied stroke is merely
the method used to move the slack adjuster from
rest. Applied stroke uses an 80 psi (552kPa) brake
application; free stroke is measured using a lever to
move the slack adjuster until the brake shoes con
tact the drum. If applied stroke exceeded the maxi
mum and adjustment is necessary, adjust the
brakes as described in Steps 5 through 8.
17 of 56
Brake Adjustment-Automatic Slack
Adjuster
Adjustment of automatic slack adjusters is only
required with the initial installation of the brake
chamber or following brake shoe replacement. They
are not designed to function like manual slack
adjusters or intended to be manually operated once
they are unable to maintain the brake adjustment
automatically. Automatic slack adjusters should not be
manually adjusted in an effort to correct excessive
pushrod stroke, because this condition indicates that a
problem exists with the automatic adjuster, with the
installation of the adjuster, or with related brake
components . Replacement of the automatic slack
adjuster or other brake components may be
necessary. Refer to the Automatic Slack Adjusters in
SM Keysheet Area 01 - 003 or 01-025 lor proper
installation and complete adjustment procedure .
Figure 13
Typical Automatic Slack Adjuster
A WARNING
Do not make manual adjustments of an
automatic slack adjuster once it can no longer
automatically adjust the brakes. Manual
adjustment DOES NOT fix the underlying
wheel end adjustment. As soon as possible,
have the crane inspected by a qualified
technician or consult your distributor to locate
and fix the actual brake problem.
18 0156
Brake Operation Check

Note: An assistant is required to make a thorough 4. Orive crane at low speeds in a safe area and make
brake operation check. several brake applications to verify safe operation
and absenceof pulling , grabbing , or noise . lf anyof
1. Apply brakes to 80 psi (552kPa) and hold. Check these are noted , investigate and repair prior to re
all air line fittings and air chambers for leakage. leasing crane for service .
2. Apply and release brakes while observing opera
tion of slack adjusters on each axle. As brakes are
applied and released, slack adjusters should move
in unison visually.
CAUTION
3. Investigate source and make corrections for any Do not release a crane for service if any bra ke
discrepancies found in Steps 1 and 2. discrepancy, no matter how minor, is evide nt.
Lubrication
When servicing brakes or replacing components, lubricate per guidelines listed in Lubrication Table below.
Lubricate the following components with grease specified in table:
o One-piece Roller -Iubricate shoe roller recess .
o Two-piece Roller-Iubricate shoe roller 1.0.
o Roller and anchor pin recesses of each shoe on ES & EO 150-4L models
Do Not Lubricate The Following:
o Cam head surface or related parts that contact cam head surface. For efficient operation, the cam head surface
must rema in free of oil, grease or other contaminants .
Note: When lubricating the camshaft bracket, lubricate until grease comes out at the slack adjuster en d. The
seal is installed at this end with the air side in so that grease purges out.
CAUTION
Do not use moly-disulfide loaded grease or oil because this may shorten service life.
Note: In no case should the lubrication interval exceed the published intervals in Table 4.
Component Lubrication Interval Type of Lubricant

Standard Every 50,000 miles or every 3 months Standard Chassis Grease
LMS-Low Lube Every 250,000 miles or once a year* Mobilith SHC-460 Synthetic
LMS-Lube Free None* Mobilith SHC-PM Synthetic

Table 4 Lubrication Intervals
Note: The Dana LMS-Low Lube brake uses a special " button head" grease fitting. This helps identify the
system as an LMS Brake Package and also indicates that system should be lubricated with an approved syn·
thetic lubricant.
The Dana LMS-Lube Free brake is lubricated at the factory with Mobilith SHC-PM synthetic grease and
does not require lubrication at service intervals. There is no grease fitting on the LMS lube free compo nents.
Slack Adjuster Lubrication: Pressure Lubricate according to manufacturer's instructions
19 of 56
SM01-003-010.00 0509 Service Manual
Period ic I nspections Service Intervals
The component inspections discussed below are gen Brake Reline
eral in nature. More detailed component inspections
are normally done at overhaul. For more specilic A brake reline should be done any time the lining
guidelines, reler to the appropriate inspection instruc thickness or condition indicates the need.
tions in Brake Overhaul.
Camshaft Radial Play
Visual Inspection Camshaft radial play should be checked with a dial
A thorough visual inspection lor brake wear, loose indicator any time the brake shoes have been removed
fasteners, broken parts and/or obvious damage from the crane to assess the condition 01 the camshaft
should be made each time the brake is being serviced bushings. Reler to Camshaft Inspection.
or the wheel and drum have been removed . In no case
should the visual inspection interval exceed 3
Camshaft Axial Play
months of service. Camshaft axial play should be checked any time the
camshaft or slack adjuster has been removed Irom the
Lining Inspection crane. Reler to the axial play instructions in Slack
A visual check 01 lining thickness and condition should Adjuster Installation, starting with Step 6 .
be made each time the crane is being serviced in the
maintenance shop . In no case should the lining
Brake Overhaul
thickness/condition inspection interval exceed 3 A complete brake overhaul lollowing the instructions in
months of service . the service manual should be accomplished at every
third brake reline.
Brake Adjustment
Lubrication
Brake Adjustment should be checked (and
adju ste d if necessary) WEEKLY or any time applied See Periodic Service/Lubrication lor detailed lube
stroke exceeds the maximums shown in Periodic instructions and intervals .
Maintenance: Brake Adjustment Manual Slack
Adjuste r.
Brake Operation Check

A complete operation check of the braking system
should be made following the instructions in Brake
Operation Check, after any brake service. In no case
should the operation check interval exceed 3
months of service.
20 of 56
Section 3: Drum Removal
1. Perform "Brake Maintenance Preliminary
Removal/Disassembly Steps".
2 . While depressing locking sleeve , back off slack ad
A complete brake overhaul consists of: juster adjusment nut on manual slack adj usters.
• complete disassembly Refer to Figure 14. Continue turning until shoes
are fully returned to released position and clear of
• cleaning drum. On automatic slack adjusters, follow
• inspection man ufactu rer's instru ctions.
• repair and replacement of components Note: With outboard mounted drums go to Step 6.
• assembly
• brake operation check
Detailed instructions for each of these steps are listed

on the following pages in the order in which they would
normally be encountered during a typical brake
overhaul.
A WARNING
The long term effects 01 non - asbestos fibers,
have not been determined. Therefore,
precautions should be used when handling
these materials. See General Information
Lining Material Warning .
Figure 14
Slack Adjuster Adjustment
3. On drive axles, remove stud nuts and axle shafts . If

used, remove lockwashers and taper dowels. If
necessary, loosen dowels by holding a brass drift
in the center of the shaft head and striking it a sharp
blow with a hammer. On trailer and steer axles , re
move hub cap .
A WARNING
Do not strike the axle shaft f1ange with a
hammer. Do not use chisels or wedges to
loosen shaft or dowels.
4. Remove axle spindle nut(s) and washer.

5. While rocking drum, pull outboard enough to allow
removal of outer wheel bearing.
6. Remove drum by pulling out board while rockin g
from side to side . If shoes are not clear of drum, re
turn to Step 2 above.
CAUTION
11 difficulty is found on removal, do not f orce
drum. Excessive pulling force may damage
brake components.
21 of 56
Shoe Removal
Table 5 provides an index lO Ihe local ion 01 shoe
removal procedures. Locale Ihe brake model under
service and idenlify Ihe page where Ihe appropriale
shoe removal procedures are localed.
Model Page Number Model Page Number

EB-150-4D 23 ES-150-4D 23
EB-150-4F 23 ES-150-4F 23
EB-150-4L 25 ES-150-4L 25
EB-150-6D 23 ES-150-6D 23
EB-150-6F 23 ES-150-6F 23
EB-150-6L 23 ES-150-6L 23
EB-150-BD 23 ES-150-BD 23
EB-150-BF 23 ES-150-BF 23
EB-150-BL 23 ES-150-BL 23
EB-165-5D 23 ES-165-5D 23
EB-165-5F 23 ES-165 -5 F 23
EB-165-5L 23 ES-165-5L 23
EB-165-6D 23 ES-165-6D 23
EB - 165-6F 23 ES-165-6F 23
EB-165-6L 23 ES - 165-6L 23
EB-165-7D 23 ES-165-7D 23
EB-165-7F 23 ES-165-7F 23
ES-165-lH 2B
EB-165-7L 23 ES-165-7L 23
ES-165-7M 26
EB-165-BD 21 ES-165-BD 23
EB-165-BF 21 ES-165-BF 23
EB-165-BL 21 ES-165-BL 23
EB-1 BO-7R 23
Table 5 Shoe Removal Procedure Index
220156
Note: The following procedures are divided into
sections, identified by brake model numbers.
A WARNING
The long term effects of non -asbestos fib ers,
Shoe Removal: have not been determined. Therefore,
EB models (except EB-150-4L) /ES-165-5D,L precautions should be used when handl ing
/ES-165-6D,L /ES-165-7D,F,L /ES-150-8D,F these materials. See General Information
/ES-150-6D /ES-165-8D,F,L Lining Material Warning.
1. Perform steps in Removal/Disassembly: Drum

3. Using a large screwdriver or lever, lift upper shoe to
Removal.
stretch return spring as shown in Figure 16.
2. ES-165-5,6,7,8,D,L,F, /ES-150-8D,F & 6D
ONLY: Pry roller retainer coiled loops out of both
shoe web holes as shown in Figure 15. Pivot roller
retainer to swing loops clear of shoe webs.
Note: EB models do not have roller retainers .
Remove Roller and Pin, Then

Repeat lar Lower Shoe.
For ES Brakes, See Note Below
Figure 16
Upper Cam Roller and Pin Removal
Pivot Retainer to
Swing Loops Clear
4. Remove upper cam roller and pino
01 Shoe Web
Note: ES-165-5,6,7,8D,L,F, /ES-150-8D,F & 6D
ONLY: Remove roller and roller retainer as a unit.
5. Repeat Steps 2 through 4 to remove lower shoe

roller and pino
Note: Dana recommends the use of a suitable

brake tool when removing rollers and return
springs.
Figure 15
Roller Retainer Removal
23 of 56
6. Push cam end of both shoes toward cam and un 7. Rotate both shoes around anchor pin and remove
hook shoe return spring . Remove and discard from crane. Refer to Figure 18.
spring .
Note: To remove return spring, position a lever 8. Clean and inspect remaining parts as outlined in
or suitable tool with notch to engage spring rod. removal/disassembly section of this manual.
Refer to Figure 17. Apply downward force to
stretch spring, allowing removal of upper
sp ring hook. Remove and discard spring.
Stretch Using Suitable

Tool Positioned
As Shown
Rotate Both Shoes

Around Anchor
Pin and Lift OH
Brake Shoes
Figu re 17 Figure 18
ES- 165-7D,L,F Shoe Removal Shoe Removal
Note: ES-165-5,6,7L,D /ES-150-6D steer

axle brakes may use two return springs with a
horse collar or dual spring post as shown in
Figure 18a. To remove return springs, position
a lever or suitable tool with notch to engage
spring. Refer to Figure 17. Apply downward
force to stretch upper spring, allowing removal
01 upper spring hook. Remove and discard. Re
peat procedure for lower spring.
Cast Spider With

Horse Collar
Figure 19
Cast Spider With Horse Collar
24 of 56
Service Manual 0509 SM01 -003-010 .00
Shoe Removal:
ES-150-4L and EB-150-4L A WARNING
1. Perform steps in Removal/Disassembly: Drum The long term effects 01 non-asbestos fibers ,
Removal. have not been determined. The refore,
2. Using a large screwdriver or lever, lift upper shoe to precautions should be used when handling
stretch return spring. these materials. See General In1ormation
3. Remove upper roller. Lining Material Warning.
4. Repeat Steps 2 through 3 to remove lower roller.
5. Stretch shoe return spring and unhook it from up
per shoe web.
Reler to Figure 20.
Unhook
Retainlng
Spring
Shoe Return
Spring
Figure 20 Figure 21
Shoe Return Spring Removal Lower Shoe Removal
6. Rotate shoe downward and turn to allow disen

gagement 01 shoe retaining spring from lower shoe
web. Reler to Figure 21.
7. Rotate upper shoe upward and remove shoe and
shoe retaining spring.
8. Clean and inspect remaining brake parts as out
lined in Removal/Disassembly section 01 this
manual.
25 of 56
Shoe Removal: 4. Using a lever or large screwdriver, lift upper shoe lo
ES-165-7M remove roller and relainer as a unit. Reler lo
Figure 23.
A WARNING
The long term effects of non- asbestos fibers,
have not been determined. Therefore, Litt Upper Shoe
precautions should be used when handling to Stretch Spring
Lining Material Warning.
1. Perlorm sleps necessary far drum removal. See

Removal/Disassembly-Drum Removal.
2. Remove cap screws and dusIshield, if applicable.
3. Pry roller relainer coiled loops oul 01 bolh shoe web
holes as shown in Figure 22. Pivol roller relainer lo
swing loops clear 01 shoe webs.
Remove Roller and Retainer, Then

Repeat lor Lower Shoe
Figure 23
Roller and Retainer Removal
5. Repeal Sleps 3 and 4 lo remove lower roller and re

lainer assembly.
6. To remove relurn spring, posilion a lever or suilable
1001 wilh a nolch lo engage spring rod. Refer 10
Figure 20. Apply downward force lO slrelch spring ,
allowing removal of upper spring hook. Remove
and discard spring.
Stretch Spring
Using Suitable
Tool Positioned
As Shown
Figure 24
Figure 22 Return Spring Removal
Retain er Loop Removal
260156
ES-165-7M, Continued 9 . To remove upper and lower shoes, remove anchor
pins with a brass drift or a mallet. Refer to
7. Remove retaining ring and washer from drum side Figure 27.
of both anchor pins. Refer to Figure 25.
Remove ól] ~ ])
»
Retaining
Rings and
Washers .. O;) ~
Orive Out
Anchor Pins
O O O O.
00
Figure 27
Figure 25 Anchor Pin Removal
Retaining Ring and Washer Removal
Note: Inspect anchor pin and bushings. If pi n was

seized or bushing is grooved or worn beyond
0.031" (0.79mm) , replace pin and bushing . Always
replace pins and bushings with brake reline .
8. To allow removal of anchor pins, cut lock wire and

remove capscrews from spider. Refer to Figure 26. 10. If any noted conditions are found , drive out old an
chor pin bushings from spider. Refer to Figure 28 .
Cu t Lockwire
and Remove
Capscrews
Orive Out Bushings

.0 o o o with a Suitable Driver
Figure 26
Capscrew Removal Figure 28
Anchor Pin Bushing Removal

lined in Removal /Disassembly section of this
manual.
27 of 56
Shoe Removal: 5. Remove upper anchor pin with a brass drift or a
ES-1 65-7H malle!. Refer to Figure 31 .
A WARNING
... .....:.:.:..::!.
The long term effects of non- asbestos fibers,
ha ve not been determined. Therefore,
Li ning Material Warning. Orive Out
Anchor Pin
1. Perform steps necessary for drum removal, see
Removal /Disassembly - Drum Removal.
2. Remove cap screws and dustshield , if applicable. o O 00
3. Remove retaining ring and washer from drum side
of each anchor pino Refer to Figure 29. Figure 31
Anchor Pin Removal
6. Rotate upper shoe around cam end, disengage

:o' ' .Q ~ .? . . roller end from cam, then unhook return spring
from shoe and remove upper shoe. Refer to
Figure 32. Discard return spring.
Remove
Retalnlng
@@_--:
..
Rings and
Washers
~ ®_... -----;-'-1
o o o o
Figure 29
Retain ing Ring and Washer Removal
4. To allow removal of anchor pin , cut lock wire and Rotate Upper
Shoe Around
remove capscrews from spider. Refer to Figure 30. Cam End
Oísengage Shoe
End From Cam ...
Cut Lockwire Then Unhook
and Remove Return Spring
Capscrews and Remove Shoe
0 0 .0 o
Figure 30
Capscrew Removal
Figure 32
Shoe Removal
28 of 56
7. Remove lower anchor pin to remove lower shoe. 9. Do not remove roUer from the brake shoe , unless :
the roller does not roll freely, there are flat spots on
Note: Inspect anchor pin and bushings. 11 pin was the roller, or there is more than 0.025 inch (0 .6mm)
seized or bushing is grooved or worn beyond 0.031 play between the roller and pino If removal of roller
inch (O. 79mm), replace pin and bushing. Always re is necessary, use a steel punch to drive out the
place pins and bushings with brake reline. groove pin, then push the pin out of the shoe. Ois
card roller and pin o Refer to Figure 34 .
8. Orive out the old anchor pin bushings from brake
shoe and spider with a suitable driver. Refer to
Figure 33.
Orive Out
Bushings with
Suitabl e Driver
Figure 34
Groove Pin Removal

lined in Removal / Disassembly section 01 this
manual.
Orive Out Bushings

with a Suitable Driver
Figure 33
Anchor Pin Bushing Removal
290156
Sla ck Adjuster Removal 4. Note orientation of slack adJuster with reference to
push rod before removal to assure assembly is in
1. Remove cotter pin and clevis pin from air chamber
proper orientation. Remove slack adjuster with a
push rod clevis.
suita ble puller.
2. While depressing locking sleeve, turn adjuster nut
until slack adjuster is clear 01 air chamber push rod
clevis . Refer to Figure 35 .
Note: If automatic slack adjusters are used,
CAUTION
(Fig u re 36), refer to SM Keysheet Area 01-003 for Do not hammer on slack adjuster to remove!
com p lete instructions. Damage to slack adjuster and/or camshaft
splines may result.
Camshaft Removal
1. Perlorm a ll steps for drum , s hoe, and slack adjust
er remova l as outlined in Removal / Disassembly
section .
2. Grasp camshaft head and pull camshaft outboard
to remove.
Air Chamber Bracket Removal

.
t' lo Remove
~,
Rotate Adjus ter
Until Slack
Adju ster is
A DANGER
To prevent personal injury, be sure to "cage"
- ~
Clear of Clevis
spring before removing spring brake type air
///" /1 \ components. Refer to SM Keysheet Area
01-027 for complete instructions.
Figu re 35
Slack Adjuster Removal
3. Remove snap ring and outer shim washer(s) Irom 1. Perform all steps for drum, shoe, slack adjuster
camshaft. and camshaft removal as outlined in Removal /
Disassembly section.
2 . Disconnect chamber air line.
3. Remove the attaching nuts (bolts on bra kes with
cast spider) and pull the air chamber bracket away
from the spider.
Note: On 16.5 inch (42mm) diameter brakes, with

stamped spiders, the air chamber bracket-to-spi
der studs are press fit into the spider. Their removal
is not required to remove the air chamber bracket.
On ES & EB 150-4L a stabilizing nut has to be re

moved. The bracket-to-spider studs are pressed
Fig ure 36 to fit into the air chamber bracket flange . Their re
Auto matic Slack Adjuster moval is not required to remove the air chamber
bracket.
300156
Spider Removal Dustshield Removal
1. Perform all steps for drum and shoe removal as Note: On ES-165-7H,M Brakes, the dustshield is
outlined in Removal/Disassembly section. removed before shoes and anchor pins are re
2. Remove spider-to-axle attachment nuts and moved.
bolts. Refer to Figure 37.
3. Remove Spider. 1. If applicable, remove screws and retaining clip.
Remove all screws attaching dustshield to spider
(4-6 screws depending on model). Refer to
Figure 38.
2. Remove dustshield.
Remove AII
Mounting 60lts
and Nuts
Figure 37 Figure 38
Spider Mounting Hardware Removal Dustshield Mounting Hardware Removal
Figure 39
Dustshield Torques-AII ES/EB-165-5/6/7/SL
Models
31 of 56
Clean ing Brake Parts
A WARNING
The long term effects 01 non-asbestos 1ibers,
have not been determined. There10re,
these materials. Do not use compressed air to
blow from interior 01 drums. Brake lining dust,
when inhaled, can be injurious to health. See
Generalln10rmation Lining Material Warning.
After removing the brake parts to be serviced, the

following clea ning procedures should be followed:
• Wire brush all parts exposed to mud, road dirt, and

salt , includlng spider, air chamber bracket,
dustshields, and exterior of drum .
CAUTION
A layer 01 oxidation and dirt on the outside 01 a
brake drum acts as an insulator and may
hlnd er normal heat dissipation . Remove
excessive deposits by wire brushing .
• Use a vacuum cleaner lo remove brake dust from

drums . Wipe interior of drums with a greaseless
solvent to remove any spilled oil.
32 of 56
Section 4: Inspection Drum Turning/Reboring
Dana does nol recommend the turning or reboring 01
Drum Inspection brake drums. The reduction 01 wall thickness red uces
Clean all remaining brake parts thoroughly with a suit the amount 01 thermal energy that can be absorbed by
able shop solvent. Wipe dry with a clean , lint-Iree the drum during braking. Also, the decrease in wall
cloth . thickness increases the amount 01 dellection lor the
same input load. 60th 01 these are undesirable II
Note: This information is general in nature. For drums are relaced or oversized , the new diameter
specific brake drum inspection guidelines, refer to MUST NOT exceed the maximum diameter marked on
the drum manufacturer's instructions. the drum during ils service lile.
1. Check lor cracks , heat-checks, glazing, groov
ing , run-out and out-ol-round . Reler lO
Figure 40. Cracked drums must be replaced.
Drums which are glazed , grooved, out-ol -round ,
etc., may be returned 10 service il they can be re
paired withoul exceeding manulacturer's maxi
mum diameler or run-out specilicalions .
Check lar Cracks

Heat Checks, Glazing
and Grooving
Figure 40
Drum Inspection
2. Check drum diameter. Replace drum il it exceeds

maximum diameler stamped in drum.
A WARNING
Under no circumstances should drum be used
if it exceeds manufacturer's recommended
maximum diameter or run-out specification.
Maximum specifications are stamped or cast
onto the brake drum.
33 of 56
Shoe and Lining Inspection 4. Check the linings and replace with Dana OEM
grade shoe and lining assembly if contaminated,
1. Check shoes for bent or cracked webs, or table , cracked, or worn to less than 1/ 4 inch (6.4mm)
broken welds,loose rivets or elongated rivet holes. thickness at any point (see instructions below) or
Refer to Figure 36. If any arefound , replace with 3/ 16 inch (4 .5mm) for EB/ ES 150-4L.
Dana OEM grade lining and shoe assemblies.
Note: To eliminate premature Lining Replacement
use a Brake Lining Wear Gauge to accurately mea
sure lining thickness. This tool is available through
Check Table and Web lor Cracks and Ben ds
your distributor as 3A 22684.
Important: For use

with air actuated cam
brakes where mini
mum allowable lining
thickness is 1/4 in
(6.4mm).
Check Both End s
lor Wear and (Note: Do not use for
Elongation strip linings on
15 x 4 brakes
See Table 6lor or similar brakes.)
Specilications
An chor Roll er
Pin Ends 1. With the brake
End s not applied ,
place the tip of
Figure 41 the gauge be
Shoe A nd Lining Inspection
tween the two
lining blocks, be
2. Check anchor pin and cam roller contact areas in tween the top of
shoe webs for elongation or wear. Replace shoe if the shoe table and
diameter exceeds the following specifications. drum . Use the
Anchor Pin gauge to scrape
Roller End away any mud, rust, or other contaminants
Brake Model End
that could interfere with proper lining mea
Inch mm Inch mm surement.
I Al! EB, AII ES-1 65 , 2. Remove the gauge from the brake.
0.836 21 1400 35
I ES- 150-80,F & 60
3. With the crane's brakes applied , try to put the
ES - 165-7M 0.744 18 1.280 32 gauge between the two lining blocks and the top of
Table 6 Brake Shoe Maximum Diameters the shoe table. Note "hook"of gauge allows inser
tion around worn drum lip. If the tip of the gauge
3. ES - 165-7H only: Anchor pin bushings are will not fit between the brake drum and the top of
mounted in these brake shoes . Refer to Inspec the shoe table, the lining is worn below 5/ 16 inch
tion-Spider Inspection (Double Anchor Pin)for in (Bmm) and will need to be replaced.
stru ction s. 4 . If the tip of the gauge fits between the brake drum
and the shoe table , the lining is not worn below 1/4
Note: Two-piece roller and pin are mounted in inch (6.4mm) at this time.
brake shoes for 7H model brake. Do not remove 5. Because brake shoes can wear at different rates,
roller and roller pin unless: the roller does not roll check both shoes on each brake and all brakes on
freely, there are flat spots on the rollers or there is the crane.
more than 0.025 inch (6.4mm) play between roller
and pin o Replace roller and pin if these conditions
are 10u nd.
34 of 56
Service Manual 0509 SM01 -003-01 0 .00
Shoe and Lining Inspection (Continued)
Standard Production ES brakes use different shoe and

A WARNING
The long term effects 01 non - asbestos fibers,
lining assemblies than those used for the ES mod els. have not been determined. There1ore,
Secause of thes e part differences, normal wear of precautions should be used when handling
either creates a unique lining wear pattern . these materials. See General In10 rmation
New AII EB New 150-80,F & 60

(Stand ard Production) 165-70,L&F
(Extended Service)
• When the ES Standard Production linings • When the ES Extended Service linings require
require replacem ent due to normal wear. they replacement due to norm al wear, the lining
will have a tapered shape as shown below. The thlckness will be uniform all along its leng th.
lining will be thinner at the center 01 shoe than
at the cam or anchor pin end .
Wearable
Minimum
Thickness
At Any Point At Any Point
0.25 inch (6.4mm) 025 inch (6.4mm)
Worn AII EB-165 Worn 150-40, 150-80,F & 60

(Standard Production) ES - 165-70,L& F
(Extended Service)
Wearable
At Any Point
0.1875 inch (4.8mm)
Worn AII EB-150 -4L Worn AII ES-150-4L

(Stand ard Production) (Extended Service)
Figure 42
Brake and Lining Blocks
35 of 56
S M 01 -003-010.00 0509 Service Manual
Cam shaft Radial Play Inspection Camshaft Inspection
Camshaft redial play should be checked any lime the 1. Refer lo Figure 44. Check spline end for cracks,
brake shoes have been removed from the crane. Refer worn or deformed splines. Replace as necessary,
to Figure 38. 2, Check camshaft bushing journals for wear and
corrosion . Replace camshaft if it shows visible
1. Mount a suitable dial indicator with plunger refer wear or if roughness is felt in journal areas.
encing cam head at roller contact area.
3 . Inspect camshaft head for brinelling, cracking or
2. Zero dial indicator.
flat spots . Replace camshaft if a ridge can be felt
3 . Move cam head up and down and note maximum
between worn areas and cam head surface.
reading .
If More Than 0.035 " Check for Cracks, Wear -------.,~~~

(O.91mm), Replace or Deformed Splines
Bushings and
Recheck
Check for Wear,

Roughness and
Corrosion
Check for Wear,

Move CamShaft,
Cracks and
Note Maxi mum _ - ! -_ _
Flat Spots
Deflection
Figure 43 Figure 44
Camshaft Radial Play Inspection Camshaft Inspection
4. If play exceeds 0.035 inch (0.91 mm), rebush air Camshaft Bushing and Seal
chamber bracket. See Repair/ Replacement
Cam shaft Bushing and Grease Seal Replace Inspection
ment o
Note: Steer and drive axle camshaft bushings and
Note: Fo r Trailer Axle Brakes, rebush spider and /or seals are mounted in the air chamber bracket as
replace support bushing assembly at slack adjust sembly.
ero See Repair/Replacement-Camshaft Bushing
1. Check bushing for deterioration or wear. Inner sur
and Grease Seal Replacement.
face must be smooth. If surface is rough or abra
5. After rebushing , recheck radial play. If still exces sive, replace bushing, see Repair/Replacement
sive, replace camshaft. - Camshaft Bushing and Grease Seal Replace
ment.
2. Inspect grease seals . Replace if seallip is nicked,
cut or distorted. See Repair/Replacement
Camshaft Bushing and Grease Seal Replace
mento
36 of 56
Spider inspection Air Chamber Bracket Inspection
Single Anchor Pin 1. Check lor a bent, broken, or cracked arm and
1. Check visually lor cracks around mounting bolt cracked welds. Reler to Figure 41. Replace brack
holes , in cam area and around anchor pin o Reler to et il any are evident.
Figure 40. Replace spider il any are lound . 2. Check mounting studs (or bolts) lor looseness ,
2. Check anchor pino II loose or grooved more than damaged threads, or a bent condition. Replace
0.031 inch (O. 79mm) below original surface, re mounting stud il any 01 these conditions are evi
place spider assembly. dent.
Note: Anchor pins are not replaceable on single an
chor pin brake spiders.
3. On EB/ES 150-4L check anchor pin retaining nut
torque reler to the last page 01 this manual lor cur
rent torque values.
Check for Cracks
Lightweight Check Bushings

Flange and Seals
Check Welds Check lar Bending

Loase Anchor Pin or Cracks
Figure 45 Figure 46
Spider Inspection Air Chamber Bracket Inspection
Note: ES and ES-150-4L R.H. brakes use a R.H.

thread anchor pin retaining nut. L.H. brakes use a
L.H. thread nut. Ensure that nut is being turned in
proper direction when checking retaining nut
torques.
CAUTION
If Anchor pin turns while checking retaining
nut torque, the spider assembly must be
replaced .
Double Anchor Pin

1. Check visually lor cracks around mounting bolt
holes and cam and anchor pin areas. Replace spi
der il any are lound.
2. Check anchor pin and bushings lor wear, grooves
and Iree movement 01 pino II pin is seized, or worn
or grooved beyond 0 .031 inch (O. 79mm) , replace
pin and bushing. Reler to Shoe Removal and
Installation Sections lor procedure .
Note: Replace pins and bushings at each brake re

line.
3701 56
SMO -003-010.00 0509 Service Manual
Air Chamber Inspection 3. If a new air ehamber is installed, insure that cut-off
push rod does not projeet too far into elevis. Míni
mum elearanee: elevis eenterline to push rod end
should be 7/8 inch (22.2 mm).
WARNING 4 . Check clevis pín for cracks and wear.
To prevent personal injury, be sure to "cage"
spring befo re removing spring - brake type air Slack Adjuster Inspection
chamber. Refer to SM Keysheet Area 01 -027
Note: This information is general in nature. For spe
for compl ete procedure
cific manual or automatic slack adjuster inspection
guidelines, refer to the manufacturer's instructions.
Note: This info rmation is general in nature. For spe
1. Check clevis pin bushing for eracks and wear. Re
cific air chamb er inspection guidelines, refer to SM
fer to Figure 48. Replace as necessary.
Keysheet Area 0 1 - 027 for specific instructions.
1. Check for air leaks, cracked housing, bent push
roel , loose clamp ring , clogged vent holes, or loose
air fitting. Repair or replace as required.
2 . If air chamber is repaired or replaced, check dis
tance fr om clevis pin hole centerline-to-air cham
ber face . Refer to Figure 47 and Table 7 for manu
al slack adjusters. For automatic slack adjusters
refer to SM Keysheet Area 01-003 for instructions.
f Figure 48
Slack Adjuster Inspection
See
Table 7
2. Check splines for ehipped teeth and deformation.
Replaee slaek adjuster if neeessary.
3. Depress locking sleeve and turn slaek adjuster ad
justment nut with a wrench at least one turn in each
direetion . If binding is present or if excessive force
is required to rotate, replace the slack adjuster.
Figure 47
Air Chamber Inspection A WARNING
If any of those conditions are found, the slack
Distance: Clevis Pin Hole Centerline To Air adjuster should be replaced. Do not attempt
Chamber Face to repair a faulty slack adjuster.
AII brakes (except Maek 2-5/8 ± 1/16 ineh

and Trai ler Axle) (66.7 ±1 .59mm)
Maek Brakes 4-3/8 ± 1/16 ineh
(111.1 ± 1.59mm)
Trailer Axle Brakes 6-1 /2 ± 1/8 ineh
(165. 1 ± 3. 175mm)
Table 7 Clevis Pin Hole Centerline
38 of 56
Camshaft Bushing And Grease Seal Brake Model At Cam Head
At Slack
Adjuster
Replacement
EB-150L,
Note: Routinely replace lower-cost items such as EB-1650,L,F &
springs, seals, bushings, and heavily-worn but un Non - metallic Non-metallic
ES-1650, L,F,
broken parts since the damage caused, should ES-150L,O,F
these components fail, is far in excess of their costo
ES-165M,H &
Bronze Non-metallie
1. Remove air ehamber braeket, see Removal/Dis EB-180
assembly-Air Chamber Bracket Removal. Installation Reeessed Reeessed
2. Orive out old bushings and grease seals with asuit Spees : (A11 9/32 ineh 22/32 ineh
able driver. exeept Trailer (7. 1mm) from (17.5mm ) from
3. Clean and inspeet air ehamber braeket, see In Axle) tube end. tube end
spection-Air Chamber Bracket Inspection.
Trailer Axle Flush with inner reeess shoulder
4 . Install new bushings in air ehamber braeket (Orive
Spider Bushings at eaeh end of spider (to allow
and Steer Axles) with a suitable piloted driver. For space for the seals)
identifieation and installation speeifieations , refer
to Figure 44 and Table 8. Note: Non-metallie bushings are labeled . Install
these bushings w/labeled ends faeing eaeh other.
Table 8 Camshaft Bushing Installation
At Cam Head End,
Specifications
Recess Bushing
9/32 in ch (7. 1mm)
Note: The LMS Low Maintenance Systems uses a
bronze bushing at the cam head (with the exception
of the LMS 15 x 4 brakes.)
5. Install new grease seals with a suitable piloted driv

er so seals are flush with end of air ehamber braek
et tube . Refer to Figure 50 .
CAUTION
Seals must be installed as indicated so that lip
AII Brakes, Except Trailer Axles side (with spring) 01 both seals faces towa rd
slack adjuster end of bracket. Improperly
~ oriented seals may allow grease to exit

camshaft head end 01 air chamber bracket
and contaminate lining material.
At Sl ack Adjuster
End, Recess Bushin g
22/32 in ch (17. 5mm)
I
C3j
Figure 49
Air Chamber Bracket Bushing Installation
39 of 56
Brake Lining Replacement
Link-Belt® does not recommend the relining of used
brake shoes . Due to the critical nature of this
component, Link - Belt® suggests replacement of
entire brake shoe assembly when linings become worn
to minimum thickness. Refer to Figure 42 far minimum
allowable brake lining thickness .
..
Llp Slde of Both Seals
Must Face Toward
1
Slack Adiuster End of
Bracket
Figure 50
Cam shaft Grease Seal Installation
40 of 56
3. Reposition dustshield as required to allow a uni
Section 6: form space of 1/ 8 inch (3.2mm) all along parallel
Installation/ Assembly mating edges. Refer to Figure 48.
4 . Torque attaching screws to proper torque ; see
Spider Installation Specifications charLO
Note: For ES/EB-150-4L distinct right-hand and

left-hand spider assemblies are used on this
Ensure Uni!orm
brake. Although similar in appearance, differences
1/8 inch (3m m) Gap
exist in anchor pin and retaining nut threads-L.H.
brake uses L.H . threads and R.H . brake uses R.H.
threads.
1. Verify the available spider is serviceable , see In

spection - Spider Inspection .
2. Verify that available spider is correct part number
for ax le being serviced .
3. Position spider on axle flange and install attaching
a)
bolts and nuts .
Note: Use hardened washer under bolt heads.
4. Sequentially torque nuts according to manufactur

Figure 52
er's specifications , Refer to Figure 47.0 Dustshield Spacing
Note: For EB/ ES -150 - 4L, a desig ned interf erence

fit at upper dustshield to air chamber bracket area
may cause the need to deform upper dustsh ield by
hand slightly to allow upper dustshield half to align
properly with the lower half. Refer to Figure 49 .
Figure 51
Installing Spider Mounting Hardware
Dustshield Installation (Two Piece)

Figure 53
Note: On ES-165-7H, M Brakes, the dustshield is
Designed Interference Fit
installed after shoes and anchor pins are installed,
see Installation/Assembly - Shoe Installation.
1. Place both dustshield into position against spider.

Install all attaching screws finger tight.
2. Install reta ining clip and screws , if applicable.
41 of 56
Dustshield Installation (One Piece)
1. Position dustshield against spider and install
screws finger tight.
2 . Torque attaching screws to proper torque; see
Specifications Chart and Figure 54.0
Figure 54
Dustshield Attaching Screw Locations
Figu re 55
Dustsh ield Attaching Screw Locations
42 of 56
Air Chamber Bracket Installation Air Chamber Bracket Installation:
1. Verily that available air chamber bracket is service
EB/ES-150-4L
able, see Inspection-Air Chamber Bracket In 1. Verily that available air chamber bracket is service
spection. able . Reler to RemovallDisassembly-Air
2. On stamped steel spider, orient bracket to align Chamber Bracket Removal.
mounting studs with holes in brackeL 2. Orient bracket to align stabilizing screw with slot in
3. Position bracket against spider and install lock spider and mounting studs with holes in spider.
washers and nuts. 3. Position bracket against spider and install lock
4. Torque stud nuts to proper torque; see Specifica washers and barrel (or standard) nuts on mounting
tions charLO bolts. Refer to Figure 51.
5. On cast spider orient bracket to align bracket holes
with tapped holes in spider. Note: Two brake shoe hold-down spring designs
are used on the Model 150 Brakes, see General In
6. Position bracket against spider and install bolts
formation- Parts Nomenclature.
and lockwashers.
7. Torque bolts to proper torque; see Specifications
charLO
8. II air chamber was removed, install chamber and
CAUTION
tighten nuts to correct torque; see Specifications Barrel nuts used in EB-150 brakes must be
retained. Failure to reinstall may cause shoe
chartO twist, excessive noise or improper brake
performance.
4. Torque barrel (or standard) nuts to proper torque,
see Specifications chart.O
5. Install plain washer, lockwasher, and nut on stab i
lizing screw.
6. Torque nut to proper torque , see Specifications
charLO
Figure 56
Air Chamber Bracket Mounting Hardware
4301 56
Camshaft Installation
1. Ve rify that available camshaft is serviceable and is
the correct part for the application, see Inspec
e SPIDER
Cast Spider: Position
Cam Head Washer
Under Cam Head With
tion-Camshaft Inspection
Note: Camshaft mounting and related parts vary
with Brake Models. Be sure to follow instructions
for special p-arts when installing camshafts.
O\j301dS
03dl<'llflS
CJ
"CAST SPIOER" Arrew
Pointing Toward Center
01 Spider.
Note For ES-150-80 & 60:

Position Cam Head Washer
~
Under Cam Head With
"CAST SPIOER" Arrew
CAUTION Pointing Away From Center
01 Spider.
Ensurethe camshaft being installed is correct
for the application. ~
CJ Stamped Spider: Position
2. To ensure that camshaft being installed is correct STAMPED
Cam Head Washer
SPIDER
for the application, rotate camshaft in the direction Under Cam Head With
of air chamber push rod extension and check that
th e ro ller starts to ride up on the convex side of the
cam head. Refer to Figure 57.
3 . Apply a thin film of chassis grease on inside of cam
O
830ldS
"STAMPEO SPIOER" Arrew
Pointing Toward Center
01 Spider.
stl aft bushings and seals, and on spline area of

camshaft.
V
Figure 58
Cam Head Washer Installation
CAUTION
00 notgrease cam head surface. For efficient
operation. thís surface must remain free of oíl, Note: For ES-165-5/6/70,L steer axle brakes us
grease or other contaminants. ing the horse collar spring retention system, posi
tion the cam head washer with the "STAMPEO SPI
4. Carefully slip camshaft into mounting position. OER" arrow pointing towards the center of the spi
Note: For ES- 165-7M, H,F insta 11 flat washer adja der. The horse collar should be placed over the cam
cent to cam head before installing camshaft. On tube first then the ES washer and fínally the cam.
ES -165- 5/6/7,80, L Brakes, camshafts use a spe
cial washer between the cam head and spider. It is
important that thís washer be installed correctly.
Reter to Figure 58.
Figure 59
Toward Push Rod Ride up On Convex Cam Installation - ES-165-5/6/70,L
Extension .. Side 01 Cam Head
Figure 57
Camshaft Installation
44 of 56
Service Manual 0509 SM01-003- 0 1 0.00
Note: For ES -165 - 5/6/7D,L steer axle brakes us 5. Install camshaft shim washers and snap ringo Re
ing the horse collar spring retention system, posi fer to Figure 60 . Check and adjust camshaft axial
tion the cam head washer with the "STAMPED SPI play (see step 6).
DER" arrow pointing towards the center of the spi Note: Camshaft axial play must be chec ked before
der. The horse collar should be placed over the cam camshaft installation is complete. Follow instruc
tube first then the ES washer and finally the cam. tions below.
Cam Head Washer And Slack 6. Mount a suitable dial indicator with plunger refer
Adjuster Installation encing end of cam head. Refer to Fig ure 61.
7. Pull inboard on slack adjuster end of cam to take
1. Verify that slack adjuster is serviceable, see In up end play.
spection - Slack Adjuster Inspection. 8. Zero dial indicator.
2. Install slack adjuster inner washer on camshaft. 9. Push outboard on slack adjuster end of cam and
Washer is identified by its 0.060 inch (1.5mm) thick note maximum reading. If necessary, ad d or clelete
ness and larger hole (see Figure 60). camshaft shim washer to obtain end play between
0 .005-0.025 inch (O.13-0.65mm) wit h slack ad
juster centered between air chamber bracket and
snap ring groove.
10. Pressure lubricate slack adjuster accorclin g to
manufacturer's instructions. Pressure lubricate air
chamber bracket until grease flows out of slack ad
juster end of tube . Refer to Figure 62.
CAUTION
Grease should not flow out end of t ube toward
cam head. If it does, seal is defective and
Shim Washers must be replaced.
'1
I
Figure 60
Shim Washer and Snap Ring Installation CAUTION
Do not replace existing grease fitting with a
3. Apply a thin film of chassis grease to slack adjuster
pressure relief type. Only standard
splines.
non-vented fittings areto be used with spring
4. Install slack adjuster on camshaft in the same posi
loaded lip seals.
tion as noted before removal.
Rotate Adjuster Nut Until

Slack Adjuster Is Aligned
With Clevis Hole.
Figure 61 ---~
Slack Adjuster End Play Check
Figure 62
Slack Adjuster Lubrication Adjustment
45 of 56
SM01 -003-010.00 0509 Se,rvice Manual
11 , Verify that air chamber face-to -clevis centerline 13, I nstall clevis pin and cotter pin,
dimension is correct, see Inspection-Air Cham
ber Inspection. Ensure that clevis lock nut is se Shoe and Lining Installation
curely tightened ,
An index to the location of shoe installation procedures
12 , While depressing locking sleeve, rotate adjusting
is provided in Table 9, Locate the brake model under
nut as required until appropriate hole in slack ad
service to identify the location of the appropriate shoe
juster is aligned with hole in airo Refer to Figure 62,
installation procedures ,
M odel Page Number Model Page Number

EB-150- 4D 49 ES - 150-4D 49
EB - 150-4F 49 ES-150-4F 49
EB-150-4L 47 ES - 150-4L 47
EB- 150-6D 49 ES-150-6D 48

EB -150-6F 49 ES - 150-6F 48
EB-150 -6L 49 ES-150-6L 48
EB-150-8D 49 ES-150-8D 48
EB- 150-8F 49 ES - 150-8F 48
EB - 150-8L 49 ES-150-8L 48
EB-165-5D 49 ES - 165-5D 49
EB-165-5F 49 ES-165-5F 49
EB-165-5L 49 ES - 165-5L 49
EB -165-6D 49 ES-165-6D 49
EB -165-6F 49 ES - 165-6F 49
EB- 165-6L 49 ES-165-6L 49
EB-165-7D 49 ES-165-7D 49
EB -165-7F 49 ES - 165 -7F 49
ES -165-7H 53
EB- 165-7L 49 ES-165-7L 49
ES - 165-7M 51
EB-165-8D 49 ES - 165 -8D 49

EB-165-8F 49 ES-165-8F 49
EB-165-8L 49 ES-165-8L 49
EB -180-7R 49
Table 9 Shoe Installation Procedure Index
46 of 56
Shoe and Lining Installation:
EB/ES-150-4L Hook Spring
1. Verify that spider, camshaft, air chamber bracket, Into Shoe
and slack adjuster are serviceable and properly Web Hole
installed .
Anch or Pin
Recess
~~\\
",~¡ I, ~
Use Onlya
Light Film 01
l'
Specilied
Grease Figure 64
Shoe Retaining Spring Installation
\
Roller Recess
6. Stretch spring to allow positioning of lower shoe
web against anchor pin o
Figure 63 7. Rotate lower shoe into position on spider.
Shoe Web Lubrication 8 . Hook end of a new shoe return spring in lower sll oe
web hole. Using a screwdriver for assistance ,
stretch shoe return spring to hook it in upper shoe
Note: See General Information-Parts Nomencla web hole . Refer to Figure 65.
ture for shoe hold-down spring variations. 9 . Using a large screwdriver or lever with tip , stret ch
shoe return spring to allow insertion of a new cam
2. Apply a thin film of grease to cam roller and anchor roller on upper shoe web.
pin recesses of each shoe web. Refer to Figure 63 . 10. Install a new cam roller on lower shoeweb in same
manner.
CAUTION
Use only grease conforming to NLGI grade
#1, high-temperature, waterproof.
3. Position upper shoe and lining web on anchor pin

and rotate down. Continue rotation until shoe is
held in place by shoe holddown spring.
4 . Hook one end of a new shoe retaining spring into
hole in upper shoe web so coillays across anchor
pino Refer to Figure 64.
5. Hook opposite end of spring into hole on lower
shoe web.
Figure 65
Shoe Return Spring and Roller Installation
47 of 56
SM01 - 003 - 01 0.00 0509 Service Manual
Shoe and Lining Installation: With Retainer Springs
ES-150-BD,F And 6D Installed. Position Upper
And Lower Shoes
Note: The f ollowing procedures are divided into
1. See Inspection & Repair/Replacement to verify
that spid er camshaft, bracket, and slack adjuster
are serviceable and properly installed.
2. During shoe installation, lubricate:
• Shoe roller recess-one-piece roller.
CAUTION
Use only g rease conforming to NLGI grade
Do not Lubrícate:
• Cam head surface. For efficient operation, this Figure 66
surface must remain free of oil, grease or other Upper and Lower Shoe Positioning
contaminants.
3. Position upper shoe on anchor pin and cam . Stretch Spring Using
4. Install retaining springs by butting bottom shoe Suitable Tool As Shown
against anchor pin and top shoe . Install spring
hooks in holes on webs. (Be sure hooks are fully
engaged befo re rotating lower shoe around an
chor pin.)
5. Position upper and lower shoes around anchor
CAUTION
When the retaining spring passes the anchor
pin, the shoes may close very rapidly.
A WARNING
The long term eflects of non-asbestos fibers,
have not been determined. Therefore, Figure 67
precautions should be used when handling Shoe Return Spring Installation
Liníng Material Warning.
6. The shoes may close rapidly when the return

spring hook passes the center of the anchor pin
(watch fingers.) Install a new shoe return spring .
On ES-150-6D install new return springs be
tween spring post and shoe with spring hooks to
ward s the cam . Refer to Figure 67.
Note: A lever or spring tool may be required to as

5ist in hooki ng shoe return spring.
48 of 56
Shoe and Lining Installation: Wilh Relainer Springs
AII EB (Except EB-150-4L) And Inslalled, Position Upper
And Lower Shoes
ES-165 -5/6/7/8D,F,l Around Anchor Pin
Note: The following procedures are divided into

that spider camshaft, bracket, and slack adjuster
are serviceable and properly instalied.
• Shoe roller recess-one-piece roller.

• Roller I.D.-two-piece roller.
CAUTION
Use only grease conforming to NlGI grade
Figure 68
Upper and lower Shoe Positioning
Do not lubricate:
• Cam head surface. For efficient operation, this
surface must remain free of oil, grease , or other
contaminants.
ES-165-D,L,F Only:
3. Hook ends of new retainer springs into holes in Stretch Spring Using
both shoe tables, hooks pointing out. Suitable Tool As Shown
4. Position upper and lower shoes around anchor
A WARNING
The long term effects of non - asbestos fibers,
lining Material Warning.
5. Install a new shoe return spring. Refer to

Figure 69.
Figure 69
Note: A lever or spring tool may be required to Shoe Return Spring Installation
assist in hooking shoe return spring.
49 of 56
6. For ES-165 5/6/7/80,L,F, ES-150-80, F & 60 8. For ES-165 5/6/7/80,L,F, ES-150-80, F & 60
only: Assemble roller retainer on ends of roller as only: Position assembly in roller recess as shown.
shown in Figure 70. Squeeze loops and swing retainer into position to
snap loops into web holes . Refer to Figure 72 .
Verify that both retainer loops are engaged in web
holes before proceeding .
Figure 70
Roller Retainer Installation Install Retainer
Loops In Shoe
Web Holes
7. Using a lever or large screwdriver, stretch shoe re
turn spring to allow insertion of new pin and roller, Figure 72
(or roller and retainer assembly) on the lower shoe Retainer Installation
web. Refer to Figure 71 .
9. Repeat process on upper shoe.
Note: 11 drums are oversized, use oversize rollers,
see In spection-Drum Inspection. Note: For all ES Models a roller retainer is not used.
Stretch
Return Spring ,
Install Roller
And Retainer
Figure 71
Shoe Return Spring Installation
50 of 56
Service Manual 0509 SM01 -003-010. 0 0
ES-165-7M
A WARNING
The long term effects of non-asbestos fibers,
these materials . See General Information
Position Lower Shoe On Spid er And Ins tall
that spider camshaft , bracket, and slack adjuster Anchor Pi n, Washers And Retain in g Rings
are servi ceable and properly installed.
2. During shoe installation , lubricate : Figure 74
• Shoe roller recess . Lower Shoe and Anchor Pin Installation
• Anchor pin - light film of grease.
6. Place upper shoe in mounting position on spider,
and install upper anchor pin, washers, and retain
CAUTION ing rings. Refer to Figure 69.
#1, high - temperature, waterproof. Place Upper Shoe On Spid er And Install
Anchor Pin, Washers And Retainin g
Rings
Do Not Lubricate:
• Cam head surface . For efficient operation , this
surface must remain free of oil, grease, or other
contaminants.
3 . After driving out old anchor pin bushings from spi
der, see RemovallDisassembly - Shoe Remov
al, press new an chor pin bushings in spider, align
ing slot in bushing with tapped holes in spider. Re
fer to Figure 67.
4. Lubricate all anchor pins during installation (see Figure 75
Step 2) Upper Shoe and Anchor Pin Installation
7. Install cap screws in spider to secure anchor pins .

Tighten to proper torque (see Specifications
chart) , then lock wire. Refer to Figure 70. 0
Install Cap screws

Slot In And Lockwire ~
Position Bushing s ()mn ....-----'----"'.~
To Align Spid er ----'--~
(í1ImD ......
Screw Hole With
Bushing Slo t
Figure 73 o o o G
Anchor Pin Bushing Installation
Figure 76
5. Place the lower shoe in mounting position on spi Ca pscrew Installation
der, and install lower anchor pin, washers , and re
taining rings. Refer to Figure 68.
51 of 56
SM0 1-003-010.00 0509 Service Manual
B. Install shoe return spring. Refer to Figure 77.
Note: A lever may be required to assist in hooking

return spring.
Stretch
Return Spring,
Install Roller
Stretch Spring,
Using Suitable
Tool Positioned
Figure 79
As Shown
Roller and Retainer Installation
11. Position roller and retainer in shoe recess as

Figure 77 shown in Figure 79, Squeeze loops and swing re
Shoe Return Spring Installation tainer into position to snap loops in shoe web
holes. Refer to Figure 80. Verify that both retainer
Note: If drums are oversized, see Inspection loops are engaged in web holes before proceed
Drum Inspection. ing.
12. Repeat process on upper shoe.
9. Ass emble roller retainer on ends of roller as shown
below. Refer to Figure 78.
Install Retainer
On Roller
Install Retainer
Loops In Shoe
Web Holes
Figure 78
Roller Reta iner Installation Figure 80
Retainer Installation
10. Using a lever or large screwdriver, stretch shoe re
turn spring to allow installation of new roller and re 13. Install dustshield. Secure with capscrews, Tighten
tain er assembly on lower shoe web. Refer to screws to correct torque, see Specifications
Fig ure 79. chart.O
52 of 56
ES-165-7H Secure Roller Pin
Wilh Groove Pin
A WARNING
The long term effects of non - asbestos fibers,
that spider, camshaft, bracket, and slack adjuster Figure 81
are serviceable and properly installed . Groove Pin Installation
• Roller inside diameter.
• Anchor pin-light film of grease.
CAUTION
Do Not Lubricate: Sial In

Position Bu shing Bushlng
• Cam head surface. For efficient operation, this
To Align Spider
surface must remain free of oil, grease, or other Screw Hale With
contaminants Bushing Slot
Note: If rollers were removed, replace with new

OEM rollers and pins.
Figure 82
3. Lubricate roller inside diameter (see Step 2), prior
Spider Anchor Pin Bushing Installation
to installation. Assemble roller and pin to shoe and
secure with groove pino Stake casting area around
groove pino Refer to Figure 81.
4. After driving out old anchor pin bushings from spi 6)
der, see Removal/Disassembly-Shoe Removal, / Press Bushing
press new anchor pin bushings in spider, aligning In Shoe
slots in bushing with tapered holes in spider. Refer
to Figure 82.
5. Press anchor pin bushings in brake shoes. Refer
to Figure 83.
6. Lubricate all anchor pins prior to installation (see
Step 2).
7. Place the lower shoe in position on the spider, and
install lower anchor pin, washers, and retaining
rings. Refer to Figure 84. Figure 83
Shoe Anchor Pin Bushing Installation
53 of 56
Complete Installation 01 Upper Shoe
Figure 84 Figure 86
Lower Shoe Positioning Upper Shoe Installation
8. Connecl a new return spring to lower shoe. 10. Complete the inslallalion of upper shoe and inslall
9. Position upper shoe for inslallalion on spider (par anchor pin, washers , and retaining rings. Refer lo
tially inslalled wilh shoe end disengaged from Figure 86.
cam), then connecl return spring lO upper shoe. 11. Install cap screws in spider to secure anchor pins.
Refer to Figure 85. Tighlen screws lO proper lorque , see Specifica
lions chart, then lock wire . Refer to Figure 87.0
Install Capscrews
In Spider And
Affix Lockwire
Position Upper Shoe On Spider, Connect

Return Sprin g (With Shoe End Dlseng aged
From Cam)
Figure 85 Figure 87
Upper Shoe Positioning Lower Shoe and Anchor Pin Installation
12. Install duslshield. Secure wilh cap screws. Tighl

en screws to correcl lorque , see Specifications
charLO
54 of 56
Specification Chart
Fastener Torque Specifications
AII ES/ES 165, 150-4D, 150-8D, F & 6D
Torque
Fastener
English Metric
Oustshield Retaining Clip Screws 48-60 in lb 5-7Nm
Oustshield to Spider Screws 150-180inlb 16.9-20.3Nm
Air Chamber Bracket to Steel Slamped Spider Nuts 65-85 ft lb 88-115Nm
Air Chamber Bracke t to Cast Spider Bolts 65-85 ft lb 88-115Nm
Air Chamber Mounting Nuts (7/16" - 20 Nuts) 35-40 ft lb 48-54Nm
Air Chambe r Mounting Nuts (5/8 " -18 NulS) 110-1 15 ft lb 149-156Nm
Anchor Pin Cap Screw (ES-165-7H, 7M) 120-150inlb 13.6 -16.9Nm
EB/ES -150-4L
Torque
Fastener
English Metríc
Ouslshield Attaching Screws 11-16 ft lb 15-22Nm
Air Cham ber Bracket Nuts 55-65 ft lb 75 -88Nm
Stabilizing Screw Nut 23-27 ft lb 31-37Nm
Anchor Pin Reinforcement Nuts 35 -40ftlb 47 - 54Nm
Anchor Pin Relaining Nul 475-525 ft lb 644 -71 2Nm

Shoe Hold - Oown Spring Screws 6-9 ft lb 8-12Nm
Key Dimensional Specifications

Minimum Lining Thickness (See Shoe & Lining Inspection)
EB/ ES-150-4L 3/16 inch (4.76mm) or 1/16 inch (1.59mm) from rivet head s
EB/ES-165 1/4 inch (6.4mm) or 1/ 16 inch (4.76mm) from ovel heads
Camshaft End Play (Axia l) 0.005-0.025 inch (O. 13-0.65mm)
Camshaft Radial Play 0.035 inch (0.91mm) maximum
Air Chamber Face to Clevis Pin Cen terline (Trailer Axle Brakes) 61/2:<::1/8 inch (165. 10:<::3. 175mm)
Air Chamber Face to Clevis Pin Cenlerline (Orive Axle Brakes) 25/8:<::1/16 inch (66.7:<::1 .59mm)
Wheel Bearing End Play 0.001 -0.005 inch (0.025 - O. 125mm)
Air Chamber/Applied & Free Stroke

Maximum Air Chamber Size Maximum Desired Applied Stroke Free Stroke
30 inch (762.0mm) 2 inch (50.8mm)
3/8 inch to 5/8 inch
30 inch (762. 0mm) Long Slroke 2.5 inch (63.5mm)
55 of 56
56 of 56
Chamber Maximum Allowable Free Distance From Face 01 Air
-
Size Applied Stroke Stroket Chamber To Centerline 01
Clevis Pin o
in cm in cm A
9 1.38 3.49 0.62 0.16
12 1.38 3.49 0.62 0. 16

16 1.75 4.44 0.62 0. 16
20 1.75 4.44 0.62 0.16
24 1.75 4.44 0.62 0.16
*24L 2.00 5.08 0.62 0. 16
**24L 2.50 6.35 0.62 0.16
30 2.00 5.08 0.62 0.16 Measure Dlstan ce "A"
With Air Chamber At
30L 2.50 6.35 0.62 0.16 Res!. (Zero Pressure)
36 2.25 5.71 0.62 0.16 Figure 2

Measuring "Distance 1:\' - Chamber At Rest
* Type 24 w/2.5 in (6.35cm) extended stroke
** Type 24 w/3.0 in (7.62cm) extended stroke Note: Cranes equipped with automatic sla ck ad
1 Tolerance far the free stroke values shown are: justers do not require periodic adjustment. Adjust
+ 0.125 (0.317cm) far Rockwell Axles
- 0.125 (0.317 cm) far Eaton Axles ment of automatic slack adjusters is only required
with the initial installation of the brake cha m ber or
1 2 3 following brake shoe replacement. They are notde
signed to function like manual slack adjusters or in
~p~
tended to be manually operated once they are un
able to maintain the brake adjustment auto matícal
Iy. Automatíc slack adjusters should not be manu
ally adjusted in an effort to correct excessíve push
llllllllL
~} l rod stroke, beca use this condition indícates that a
~ problem exists with the automatic adjuster, with the
V ~
V \\
components. Replacement of the automatíc slack
O )
adjuster or other brake components may be neces
sary. Refer to the Automatic S/ack Adjusters in SM
Keysheet Area 01 - 003 or 01 - 025 for proper instal
lation and complete adjustment procedure .
6 5 4
1.
2.
3.
Identification Number
Push Rod Clevis
Clevis Pin
4.
5.
6.
Slack Adjuster
Pu sh Rod
Air Chamber
A WARNING
Figure 1 GG1891- A
Brake Adjustment Data
automaticaliy adjust the brakes. Ma nual
adjustment DO ES NOT fix the underlying
wheel end adjustment. As soon as possible ,
Adjusting The Brakes have the crane inspected by a qua lified
"S" Cam & "P" ,"a", & "T" Series technician or consult your distributor to locate
To determine if the brakes require adjustment, applied
stroke is measured and compared to the maximum This SM Code includes the following procedures:
value listed on the Chart in Figure 1 . - Adjustment Inspection
- Adjusting The Brakes
- Brake Test
1 af 6
SM01 -003-014.00 0509 Service IManual
Distance From Face 01 Air Distance From Face 01 Air

Chamber To Centerline 01 Chamber To Centerline 01
Clevis Pin Clevis Pino
----- B
Apply Brake With A

Measure Distance "B" With Lever And Measure
Air Chamber Pressurized. Dislance "B".
(80 psi [552kPa] minimum)
Figure 3 Figure 4
Measuring Applied Stroke - Pressurized Measuring "Free Stroke" - Lever Applied
4. Once the push rod clevis (2) is properly adjusted,

Adjustment Inspection measure the exact distance from the face of the air
1. Level the crane on outriggers , disengage the park chamber (6) to the centerline of the clevis pin (3)
b rake and shutdown the engine. hole while the push rod (5) is fully retracted. Re
cord this measurement as "Distance P\'.
5. Apply and hold a minimum of 80 psi (522kPa)
A DANGER brake application, and again measure the distance
from the face of the air chamber (6) to the center
Do not attempt to remove, disassemble, line of the clevis pin (3) hole. Refer to Figure 3. Re
inspect or adjust the dual air brake chamber cord this measurement as "Distance B".
befo re cagi ng the power spring. If proper 6. Subtract "Distance 14.' from "Distance B". The dif
directions are not followed, the chamber and ference is called the "Applied Stroke".
its internal parts could rapidly and forcefully 7 . Compare the applied stroke tothe maximum value
explode. Th is may result in severe personal shown on the Chart in Figure 1. If the applied
injury or death. Always cage the power spring stroke equals or exceeds the maximum applied
before attem pting any brake or air chamber stroke shown, adjust the brakes using the proce
adjustment or repair. If any doubt exists as to dure to follow. If the applied stroke is less than the
whether a potential safety hazard exists, maximum value shown, no adjustment is required.
contact yo ur nearest distributor before
repairs are attempted. Adjusting The Brakes
Brake adjustments should only be done after an
2 . Cage the power springs ofthe dual air brake cham
adjustment inspection is performed per the procedure
bers. See SM Keysheet Area 01-027 for the cor
outlined above. Brake adjustment is based on the
rect procedure.
" Free Stroke" of the air brake chamber. "Applied
Refer to Figure 1. Stroke" is used in the inspection process. The
3. With the air chamber push rod (5) fully retracted, difference between "Free Stroke" and "Applied Stroke"
measu rethe distancefrom theface ofthe air cham is merely the method used to move the slack adjuster
ber (6) to the centerline of the clevis pin (3) hole. from rest. Applied stroke uses an 80 psi (522kPa)
Refer to Figure 2. This distance should be 2.62 in brake application; free stroke is measured using a lever
(6.65cm) ± 0.06 in (O. 15cm). Disconnect and ad to move the slack adjuster until the brake shoes
j ust the push rod clevis (2) as required. contact the brake drum .
2 of 6
chamber. They are not designed to function like
ct 01 Slack Adjuster
manual slack adjusters or intended to be manually
operated once they are unable to maintain the brake
adjustment automatically. Automatic slack adjusters
should not be manually adjusted in an effort to correct
excessive push rod stroke, because this condition
indicates that a problem exists with the automatic
adjuster, with the installation of the adjuster, or with
related brake components . Replacement of the
ct
01 -
automatic slack adjuster or other brake components Push
may be necessary. Refer to the Automatic SJack Rod
Adjusters in SM Keysheet Area 01-003 for proper
installation and complete adjustment procedure.
1. Level the crane on outriggers, disengage the park

~-- Mounting
brake and shutdown the engine.
Surface
A DANGER
Do not attempt to remove, disassemble,
Figure 5
Orientation Of Slack Adjuster To Brake Cha m ber
inspect or adjust the dual air brake chamber 4. Reler to Figure 6 for cranes with manual slack ad
before caging the power spring . If proper justers or to Figure 7 lor cranes with automatic
directions are not followed, the chamber and slack adjusters .
its internal parts could rapidly and forcefully a. Cranes with manual slack adjusters:
explode. This may result in severe personal Depress the locking sleeve (2) and turn the ad
injury or death. Always cage the power spring juster pawl (3) on the slack adjuster (1) until a
before attempting any brake or air chamber drag is lelt when rotating the wheel.
adjustment or repair. If any doubt exists as to
whether a potential safety hazard exists, b. Cranes with automatic slack adjusters:
contact your nearest distributor before Use a screwdriver to pry the releas e pin up , if
repairs are attempted. equipped , and disengage the adjusting pawl.
Rotate the manual adjusting pawl until a drag
2. Cage the power springs of the dual air brake cham is lelt when rotating the wheel.
bers . See SM Keysheet Area 01 -027 for the cor
rect procedure.
Refer to Figu re 1. A CAUTION
3 . With the air chamber push rod (5) fully retracted, Disengage the release pin before attempting
measure the distance from the face of the air cham to adjust the brakes, if equipped. Failure to
ber (6) to the centerline of the clevis pin (3) hale . disengage the release pin may result in
Refer to Figure 2. This distance should be 2.62 in damage to the slack adjuster. Use a sc rew
(6.65cm) ± 0.06 in (O.15cm). Disconnect and ad driverto pry the release pin up before rotating
just the push rod clevis (2) as required. the manual adjusting pawl.
Note: When the clevis is installed properly, the

push rod will be perpendicular to the centerline
of the slack adjuster as well as the mounting
surface of the air chamber. Refer to Figure 5.
Orientation of the slack adjuster can be revised
by rotating the adjusting pawl on the slack ad
juster while the push rod clevis is disconnected.
3 of 6
1. Slack Ad iuster *
2. Locking Sleeve
3. Adiusting Pawl * Manual Slack adlusters are shown. Reler lO Figure 7 lar illustralion 01 automatic type slack adiuster.
Figure 6 GD0742- A ,GF1141 -A

Typical Air Brake Chambers With Manual Slack Adjusters
5. Back off the adjustment until no drag is felt when Refer to Figure 4, Record this measurement as
rotating the wheel and a free running clearance is "Distance B".
obtained between brake lining and drum . 8, Subtract "Distance P\' from "Distance B", The dif
ference is called the "Free Stroke".
Note: Free running clearance can be easily 9. Compare the free stroke .lo t,he value shown on the
checked by striking the brake drum with a metal Chart in Figure 1. Adjustas required, using thead
tool and listening for a sharp ringo A dull thud juster pawl (3).
indicates inadequate clearance. 10. Check that the locking sleeve (2,Figure 6) or re
lease pin (Figure 7) is fully engaged after adjust
6. Measurethe distance from the face ofthe air cham
ment is complete .
ber (6) to the centerline of the clevis pin (3) hole
11. If the power springs were caged for rear brake ad
while the push rod (5) is fully retracted, Record this
justment, uncage the power springs. See SM
measurement as "Distance P\',
Keysheet Area 01 -027 for the correct procedure.
7, Using a lever, apply and hold the brake so that the
12. Perform a brake test before releasing the crane for
brake shoes are contacting the brake drum, Again
service using the procedure to follow.
measure the distance from the face ofthe air cham
ber (6) to the centerline of the clevis pin (3) hole,
4 of 6
Manual
Adjusting
Pawl
c·
Pry Release Pin To

Disengage Pawl
Note: Automatic Slack adjusters are shown. Reler to Figure 6 lar illustration 01 manual type slack adjuster.
Figure 7
Typical Air Brake Chambers With Automatic Slack Adjusters
Brake Test Reler to Figure 5.

1. Start the engine and allow the air system pressure Note: When the brake is adjusted properly, the
to reach its normal operating range. push rod must be 90 ° to the centerline of the slack
2. Apply the park and carrier brakes and inspect all adjuster and 90 ° to the mounting surface of the
connections and chambers lor leaks using a soap spring brake with the brake applied.
solution. Repair as required.
3. Oisengage the par k brake. Applyand release the 4. Orive the crane at low speeds in a sale area and
carrier brakes while observing the operation 01 the make several brake applications to verily sale op
slack adjusters on each axle. As the brakes are op eration and lack 01 pulling, grabbin g or noise.
erated, the slack adjusters should move in unisono Make adjustments as necessary.
Adjust or repair as required.
5 of 6
SM,01-003-014.00 0509 Service Manual
6 of 6
Service Manual 0509 SM01-003-019.0'0
Automatic Slack Adjusters

This procedure covers the installation , operation, in operation, lubrication , maintenance, or service ,
maintenance , and troubleshooting of the automatic implied by the manufacturer. Any concerns regarding
slack adjusters . such inconsistencies should be reviewed with a
f
Lin k - Belt distributor.
The following pages are taken directly from Dana :
Spicer!5· Service Manual BRSM -022 dated February If parts are hard to disassemble and assemble, do not
1997. use a hammer unless it has a soft face, do not force
parts together, they must be free to turn and not bind.
Based on the specific application of the slack adjuster,
Link-Belt literature will supersede any discrepancies
1 of 16
The description and specifications contained in this Any reference to brand na me in this publication is
service publication are current at the time of printing. made as an example of the types of tools and materials
recommended for use and should not be considered
Eaton Corporation reserves the right to discontinue or an endorsement. Equivalents may be used.
modify its models and/or procedures and to change
specifications at any time without notice.
IMPORTANT NOTICE
Thls symbol is used throughout this WARNINGS: FAILURE TO FOLLOW

manual to cal l attention to procedures INDICATED PROCEDURES CREATES A
wh ere carelessness or failure to follow HIGH RISK OF PERSONAL INJURY TO
specific instructions may result in THE SERVICING TECHNICIAN.
persona l injury and/or component
Caution: Failure to follow indicated
damage.
procedures may cause component damage
or malfunction.
Departure from the instructions, choice 01

tools, materials, and recommended parts Note: Additional service inlormation not
mentioned in this publications may covered in the service procedures.
Jeopardize the personal safety 01 the Tip: Helpful removal and installation
service technician or vehicle operator. procedures to aid in the service 01 this unit.
Always use genuine Eaton replacement parts.
2 of 16
Service Manual 0509 SM01 -003-019.0 0
Contents
Important Notice .......................................... . .................... 2
Introduction ................................................................... 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Automatic Slack Adjuster Identification ........................ . ................. 5
Steer Axle Installations .................................... .. ................... 6
Drive Axle Installations ...................................... .. ................. 7
Trailer Axle Installations ...................................... . ................. 8
Installation Procedure .......................................................... 10
Slack Adjuster Maintenance-General ........................................... 14
Operational Check ............................................................. 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Manufactured By Haldex
3 af 16
Introduction/Operation
Introduction
Eaton automatic slack adjusters compensate for wear
in brake shoe línings caused by normal braking
operation . Upon brake application, the brake adjuster
assembly rotates , rotating the brake camshaft. The
camshaft moves the shoes into contact with the drum .
During brake application and release, the adjuster

mechanism rotates the camshaft slightly to maintain
the correct shoe-to-drum clearance.
O peration
The Eaton automatic slack adjuster is a clearance
sensing slack adjuster that maintains a nominal
distance or clearance between lining and drum. The
clearance notch in the rack corresponds to this normal
lining-to-drum clearance. (See Figure 1.)
When the brake applies :

The rack moves upward and rotates the
one-way clutch. The one-way clutch allows
slippage in this direction.
Brake application torque presses the
wormshaft against the coil spring . Wormshaft
movement releases the cone clutch. CONTROLARM
~ ANCHOR BRACKET
When the brake releas es:

The coil spring presses against the wormshaft ,
engaging the con e clutch.
The rack is pulled back to its original position in Figure 1 Components of the Slack Adjuster
the clearance notch.
Any lining wear causes the rack to turn the
locked one-way clutch while rotating the
wormshaft via the locked cone clutch.
The wormshaft rotates the wormwheel and
camshaft , adjusting the brakes .
4 of 16
Introduction/Operation
Automatic Slack Adjuster Identification
The serial and part numbers are stamped on the lacing
01 the automatic slack adjuster. The serial number is
used by Eaton lar control purposes. The model
number describes the automatic slack adjuster
specification.
MANUFACTURER
\ NUMBERS
Lo~ rj~~
:jM~/\.L
r~800 I
SERIAL PART
NUMBER NUMBER
5 of 16
Typical Applications
Steer Axle Installations
Figure 2 , Figure 3, Figure 4, and Figure 5 show typical Offset auto slack adjuster using bolt-on type
brackets lor automatic slack adjuster installations on bracket (See Figure 4) .
steer axles: Disc brake type installation (See Figure 5).
Straight auto slack adjuster using a
clamp-type bracket (See Figure 2). Refer to pages 10, 11, and 12 lar detailed installation
Offset auto slack adjuster using clamp-type procedures.
bracket (See Figure 3).
OFFSET
ARM
BOLT -ON
AUTOMATIC SLACK
ADJUSTER
BRACKET
Figure 4 Offset (Bolt-On Type Bracket) Installation
Figure 2 Straight (Clamp - Type Bracket) Installation
CLAMP- TYPE . _./
BRACKET
Figure 5 Oisc Brake Type Installation

Figure 3 Offset (Clamp - Type Bracket) Installatíon
6 of 16
Orive Axle Installations
Figure 6, Figure 7, Figure 8, and Figure 9 show typical • Straight auto slack adjuster using bolt-on type
brackets lor automatic slack adjuster installations on bracket (See Figure 8) .
drive axle brakes: • Disc brake application (See Figure 9) .
• Straight auto slack adjuster using a clamp-type
bracket (See Figure 6). Reler to pages 10, 11, and 12 lar detailed installation
• Offset auto slack adjuster using bolt-on bracket procedures .
(See Figure 7).
\II AIR
CHAMBER
AIR
\1
I
;/1/ .'. "/ " I O) CHAMBER

í
CLAMP- TYPE ¡"J/ :r 1I , ,~,

\ \
BRACKET ¡/ \ \,
lj/ I
\
\ ,
~Wr STRAIGHT
ARM
STRAIGHT
ARM
Figure 6 Straight (Clamp - Type) Installation Figure 8 Straight (Bolt-On Type Bracket) Installation
AIR
. CHAMBER
BOLT -ON
';>./ BRACKET--...:..,~
\"\t::r.
AIR
~
rl
CHAMBER
JI'
I .
\ .
l'
L
tr i STRAIGHT
ARM
1
. .../
(
Figure 7 Off3e1 (Boll-0n Type Bracket) In31allation Figure 9 Oisc Brake Type Installation
70116
Trailer Axle Installations
Figure 10 through Figure 13 show typical and
alternative brackets for automatic slack adjuster
installations on trailer installations,
Universal Anchor Bracket

Tip: The universal anchor bracket mounts to the "S"
cam bushing support bracket. Rockwell, Dana, and
Fruehauf brakes mount with two bolts, Position plate
on adjuster side of the "S" cam support. Added
bracket thickness requires the use of longer mounting
bolts, Eaton trailer axles manufactured after January
1993 have the anchor bracket as an integral part of the L ", / '
"S" cam shaft bushing support.
'1
- ~ / L5!!J
/ ' STRAIGHT
ARM
Refer to pages 10, 11, and 12 for detailed installation

procedures,
Figure 11 Alternative Bra c ket Type s
UNIVERSAL
AN C HO R
BRACKET
EATON
'\ ,, 11 MOUNTING HOlE
" '\..YK (PRE-1993)
_ r, ,,~'\J \
AUTOMATIC
/
' / '~7\i
ROC KWEll , , - - " \ ' \ ,
SLACK
DANA, AND FRUEHAUF
ADJUSTER AUTOMATI C
MOUNTING HOlES
SLA CK ADJU STER
Figure 10 12 -1 /4 " Brake Applic ation Figure 12 Universal Anc hor Bra cket
8 of 16
Anchor Stud Installation
STEP ONE STEP TWO STEP THREE
2ND
SECURE STUD
Figure 13 Anchor Stud Installation
9 of 16
s 01 -003-019.00 0509 Service Manual
Installation
Installation Procedure
Caution : The procedures shown in this section are
A applicable to vehicles originally equipped with Eaton

Automatic Slack Adjusters only, and mustnot be used
for aftermarket retrofit. Specific retrofit instructions
are provided with retrofit kits.
ANCHOR
BRACKET
Attach the Automatic Slack Adjuster
A WARNING : BlOCKWHEElSTO PREVENTVEHIClE

FROM ROlLlNG. CAGE SPRING BRAKES IF
INSTAllED.
1. Verify that the pushrod is fully retracted. Applyair

to release spring brake. If air is not available,
spring brake must be manually caged off.
2. Install anchor bracket loosely as shown. Do not
tighten anchor bracket fasteners. (See Figure 14.)
~Iote: Configuration of anchor bracket will vary

depending on axle. (See Axle Installations on page 6,
7, and 8.) Figure 14 Insta" the Anchor Bracket
3. Apply anti-seize type lubricant to the shaft

splines. Install tl1e slack adjuster onto the
camshaft with the adjusting hex pointing away
from the brake air chamber. Secure the slack
adjuster on tl1e camshaft. Follow procedures in the
applicable Eaton brake service manual for
checking and adjusting camshaft end play.
4. Rotate the 7/16" adjusting hex nut clockwise until
t he slack adjuster arm hole lines up with the clevis
1101e. (See Figure 15.)
5. Install clevis pino Do not install the clevis cotter pin
at this time. It will be necessary to remove the lOOSElY
clevis pin later to check installation.
ADJUST UNTll
HOlES ALlGN
Figure 15 Insta" Adjuster
10 of 16
I nstallation
Position the Control Arm
6. Rotate the control arm counterclockwise away
from adjustment hex towards the air chamber until
it comes to a definite internal stop. (See Figure 16.)
If necessary, use a plastic mallet to tap the control
arm into position.
Caution: Excessive positioning force may damage the
A control armo Most adjusters will be equipped with an

Installation Indicator. Indicator must fall within the
slot for proper installation. Incorrect con trol arm
position can cause tight or dragging brakes.
7. Tighten all control arm anchor bracket fastener(s).
Note: Make sure the control arm does not move from
its position while tightening the anchor bracket
fasteners.
Note: Steer axle applications only-a gap of 1/16"

should be maintained between the anchor bracket and
the control armo (Se e Figure 17.)
8. Adjust brakes by turning adjusting hex clockwise

until the lining contacts the drum. Then rotate the
adjusting hex counterclockwise 1/2 of a turno A Figure 16 Position Slack Adjuster
minimum of 13 ft lb is necessary to overcome the
clutch and a racheting sound will occur.
AIR
Final Inspection of the Automatic Slack C HAMBER
Adjuster
9. With full air pressure , release spring and service
brake. Verify that the installation indicator is within
the slol. Remove the clevis pino The clevis hole
and adjuster hole should remain in alignment. If
the air chamber clevis pulls into the air chamber,
repeat the installation procedure.
10. After final inspection , install the cotter pin into the
clevis pino Verify that applied stroke is within the
legal limits for the air chamber being used .
1/ 16"
GAP ,t '~
"0f'
~
~
Figure 17 Proper Anchor Bracket and Control Arm Gap
11 of 16
I nstallation
Adjust tlle Automatic Slack Adjuster Applied Stroke Adjustment
1. Apply and hold an 80-90 psi brake application.
Free Stroke Adjustment 2. Measure distance between face 01 air chamber
1 . With air chamber fully retracted, measure distance and clevis pin centerline. Record distance as
from lace of aír chamber to centerlíne 01 clevis pino dimension C.
Record exact measurement as dimension A. 3. Subtract dimension A from dimension C. The
2 . Use a lever to move the slack adjuster until brake difference is applied stroke. Compare applied
shoes contact the drum . stroke to maximum value in table below.
3 . Measure the distance between face of air chamber 4. 1I applied stoke equals or exceeds maximum
and centerline of clevis pin. Record distance as applied stroke shown, adjust brakes. II less than
dimension B. the maximum, no adjustment is required.
4. Subtract dimension A from dimension B. The
80-90 PSI Brake Application
difference is free stroke. Allowable free stroke is a
minimum 013/8" stroke. Air Chamber Type Maximum Applied Stroke
5. Remove lever and check that brakes are not
Type 36 " 2-1 /4"
dragging:
Spin wheel end assembly by hand Type 30" 2"
Tap drum lightly with a hammer, listening for a Type 24" 1-3/4"
sharp ringing sound
Type 24"
If brake drag is noted , back off slack adjuster and (with 2 - 1/2" 2"
recheck Iree stroke. extended stroke)
Type 20" and 16" 1-3/4"
Note A properly working automatic slack adjuster
does not require manual adjustment while in service. Type 12" 1-3/8"
Free Stroke = B minus A

Applied Stroke = e minus A
lb
I~· ~
1 - e
(80-90 PSI Br ake Application)
~~I:::::::I ::::::I:::::::I:::::::I:::::::I:::::::I::::::$I:::~::: I
Figure 18 Stroke Measurements
12 of 16
Installation
Brake Adjustment-Automatic Slack
Adjuster
chamber or following brake shoe replacement. They
are not designed to function like manual slack
adjusters or intended to be manually operated once
they are unable to maintain the brake adjustment
automatieally. Automatic slack adjusters should not be
manually adjusted in an effort to correet excessive
push rod stroke, because this condition indicates that
a problem exists with the automatic adjuster, with the
components . Replaeement of the automatie slack
adjuster or other brake components may be
necessary. Refer to the Automatic Slack Adjusters in
SM Keysheet Area 01 -003 or 01 -025 for prop er
installation and complete adjustment proeedure.
Figure 19
Typical Automatic Slack Adjuster
A WARNING
automatically adjust the brakes . Manual
adjustment DOES NOT fix the underlying
wheel end adjustment. As soon as possible,
have the crane inspected by a qualified
technician or consultyour distributor to locate
13 of 16
Maintenance
Slack Adjuster Maintenance-General Camshaft Bushings
Service Intervals Worn "S" cam bushings will increase pushrod travel.
Replace bushing if worn and at each reline .
Vis ual During normal chassis lubrication.
For detailed inspection procedure on foundation brake
Inspection components refer to Eaton service manual
Lubrication Every 50,000 miles Or 3 months, BRSM-0033.
which ever occurs first.
Adjustrn ent Only at installation and reline. Ad
juster should not require adjustment Accurate wheel bearing preload is necessary to
while in service. If adjustment is maintain proper alignment between the brake drum
needed, inspect adjuster and and brake shoes .
foundation brakes . For proper adjustment procedure Or specilications
refer to Eaton axle or brake service manuals and
Lubrication Technical Information Bulletin AXIB-9405 .
Use standard chassis lubricant. Checking Release Torque

Caution: Do not use moly-disulfide loaded grease or The following procedure verifies proper operation of
oi! because they may shorten automatic slack adjuster the automatic slack adjuster.
service life.
Place a torque wrench on the 7/16" adjusting hex . (See
Lubricate the automatic slack adjuster at the same time Figure 20.) Turn the torque wrench counterclockwise .
chassis is serviced . Do not use pressure-release The clutch should not slip at a torque less than 13 ft lb
grease fittings . (18Nm) . A racheting sound occurs when the clutch
slips. If clutch slips at a lesser torque, replace the
In no case should automatic slack adjuster lubrication adjuster.
interval exceed 3 months or 50,000 miles.
Inspection
RACHETING SOUND OCCURS
Inspect brake adjuster and anchor bracket for WHEN CLUTCH SLIPS
damage. Check that anchor bracket is tight and the
control arm is in the full release position.
Note: II automatic slack adjuster is equipped with

ind icator arrow, make sure the indicator is within the
slot wh en the brake is in the release position.
Maintaining proper brake adjustment and brake

balance cannot be accomplished by the brake
adj uster alone. The condition of foundation brake
components have a direct bearing on the effectiveness
of brake adjustment. Inspect foundation brake
co mponents periodically.
Brake Air Chambers

Check that brake air chamber mounting bolts are tight
and properly aligned to avoid interference between air
chamber pushrod and air chamber housing.
Verify that brake chamber pushrod length is equal on

Figure 20 Checking Release Torque
both brake chambers of the same axle.
14 of 16
Operational Check/Troubleshooting
Operational Check Troubleshooting
1. Measure the pushrod length (distance from the Tight or Dragging Brakes
face of air chamber to the centerline of the pushrod
clevis pin) when fully retracted , step 1. (Se e Check foundation brake component for:
Figure 21.) Control arm anchor bracket not positione d
2. Have an assistant make an 80 to 90 psi brake properly (Se e slack adjuster installation
application . Measure pushrod length again , step procedures.)
2. Brake chamber not fully releasing
3. Subtract the step 1 dimension from step 2. The - Spring brake not fully releasing
difference is the "applied stroke" . - Pushrod binding on chamber housing
4 . Verify that the applied stroke is less than the - Air supply not exhausting completely
maximum specified below. Out-of-round brake drums
80-90 PSI Brake Application Extreme differences in lining-to-drum
clearances between shoes on same wheel
Air Chamber Type Maximum Applied Stroke Improper wheel bearing adjustment
Type 36" 2 - 1/4" Broken shoe return spring
• Loose brake linings
Type 30 " 2"
Type 24 " 1-3/4" Excessive Chamber Pushrod Travel
Type 24" Loose, broken, or bent control arm anchor
(with 2 -1 /2" 2" bracket
extended stroke) • Worn camshaft bushings
Loose air chamber mounting
Type 20" and 16" 1-3/4"
Binding camshaft
Type 12" 1-3/8" • Worn clutch assembly (See Checking Release
Torque.)
Verify the correct installation of the control arm . If the
automatic slack adjuster does not maintain proper
applied stroke, it must be replaced.
'11~STEP1
RETRACTED
Figure 21 Measuring Pushrod Length
15 of 16
Additional Service Information
Additional parts and service information on these and related Eaton products may be found in the following
publications:
Service Manuals
15" x 4" Steer Axle Brakes (Models ES-150 and EB-150) .................... .. ...... BRSI\Jl-0033
16.5" and 18" Axle Brakes (Models ES-165, EB-165, and EB-180) ........... . . ...... BRSM-0033
Trailer Axles .............................................................. . ...... BRSM -0033
Parts Books
Automatic Slack Adjusters ............................................... . ......... BRIP-0073
Brake Models ES-150, EB-150, ES-165, EB-165, and EB-180 ... . ...... . ........... BRIP-0065
Trailer Axles ............................................................ .. ........ BRIP-0065
These publications may be ardered through Eaton publications arder system. An arder form may be obtained by
calling Eaton Roadranger® Service Suppart
160116
6. When pressure is fully relieved , close the drain
Front Axle & Air valves on the air system reservoir.
Suspension, R & I 7. Remove tire and rim assemblies. Refer to SM Key
sheet Area 01-069 for the correct procedure.
This procedure covers the removal and installation of 8. Label for assembly purposes and disconnect the
the front axles and air suspension , as an assembly and air lines from the brake chambers . Cap the air lines
as individual axles. For recondition procedure, see SM and open ports to prevent contamination.
Keysheet Area 01-002. 9. If required, label for assembly purposes and dis
connect the air lines from the air bags. Cap the air
General lines and open ports to prevent contamination .
1. Lower, detach, and secure load, as required. Removal 01 Single Axle

2 . Stabilize the crane for service as follows:
a. Park the crane , out of the way, on a firm and This procedure can be used for either of the front axles.
level surface. Components described pertain to the axle being
b. Engage the park brake and/or properly block removed unless otherwise stated . When using related
the tires. steps in conjunction with "Removal Of Front Axles And
c. Engage the swing park brake or travel swing Air Suspension AsAn Assembly", both sets ofcommon
lock, as required. components must be addressed .
d. Level the crane on fully extended outriggers. Refer to Figure 1.
e. Position/support the boom, as required. 1. To provide a maximum amount of clearance , raise
3. Shutdown the engine and disengage the main hy the axle not being removed to its extreme limit of
draulic pump, as equipped. travel and securely block .
2 . Remove the cotter pin and cage nut (9) from the
drag link (8) ball stud.
A WARNING
3. Using a ball stud removal tool, break the tapered fit
between the drag link (8) ball stud and steer arm
(7) . Swing the drag link (8) out of the way and se
cure.
4. Adequately support the axle (4) being removed
with a rollable jack of sufficient capacity. Secure
the axle (4) to the jack in a manner which w ill pre
cleaning solutions.
vent the axle (4) from rotating forward or backward
during removal.
4. Thoroughly clean the area to be disassembled with
an approved cleaning solvent to prevent conta Note: Each front axle weighs approximately
mination. Allow the area to air dry. 1,200 lb (544kg).
5. Disconnect the torque rods (6) from the axle (4) by
A WARNING removing the capscrews and washers (5) . Swing

the torque rods (6) out of the way and secure.
Air lines may contain high pressure. Opening
Refer to Figure 2.
lines and fittings before relieving air pressure
6. Remove the locknuts (9), washers (7), capscrews
may result in serious injury. Shutdown the
(1), washers (4) , adaptors (2,8), and spacers (6)
engine and drain the air system reservoir
from the axle mount brackets (3) and equalizer
before opening any line or fitting.
beams (5) .
5. Open the drain valve on the air system reservoirs to Refer to Figure 1.
bleed the air system pressure. 7. Lower and remove the axle (4) from under the
crane.
1 of 6
9.20"
(23. 37cm)
2
1. Ride Height Control Valves 5. Capscrews & Washers 9. Cage Nut & Cotter Pin
2. Adjustment Rods 6. Torque Rods la. Caps
3. Capscrews, Washers, & Locknuts 7. Steer Arms 11 . Capscrews & Washers
4. Axles 8. Drag Links 12. Shims
Figure 1
Front Axles & Air Sus ension Assembl
2 of 6
10 11 12 13 14
~ , ¿ ,.. -
)
22----;;
21
19 18 17
25
13. Suspension Arms 17. Shock Absorbers 21. Capscrews & Washers 25. Air Bags
14. Carrier Frame 18. Equalizer Beams 22. Caps
15. Washers & Locknuts 19. Capscrews & Washers 23. Washers & Lock nuts
16. Rear Front Axle 20. Front Front Axle 24. Washers & Jam Nuts
3 of 6
3 4 5 6 7 8 7. Carefully lower and remove the front axles and air
suspension assembly from under the crane .
8. If required , remove the air bags (25) from the sus
pension arms (13) by removing the locknuts and
washers (15).
9. If removal of the suspension arms (13) is required:
a . Secure the suspension arm (13) to an auxiliary
lifting device.
Note: Each suspension arm weighs approx

imately 110 lb (SOkg).
b. Remove the capscrews and washers (21) and

9 caps (22) securing the suspension arm (13) to
the equalizer beam (18).
1. Cap screws 6. Spacers c. Separate and remove the suspension arm (13)
2. Adaptors 7. Washers
3. Axle Mount Brackets 8. Adaptors
from the equalizer beam (18) .
4. Washers 9. Locknuts d . Repeat as required for removal of the other
5 Equalizer Beams suspension arm (13) .
Figure 2
Equalizer Beam Mount
Removal Of Front Axles And Air

Suspension As An Assembly
A WARNING
Refer to Figure 1. hazardous. Serious personal injury may
1. First, follow "Removal Of Single Axle ", Steps 2 result 1rom misuse 01 these products. Read
thru 5. and 101l0w all the manu1acturer's
2 . Disconnect the shock absorbers (17) from the sus
pension arms (13) by removing the capscrews and cleaning solutions.
washers (19). Swing the shock absorbers (17) out
of the way and secure. 1. AII components should be tharoughly cleaned with
3. Remove the capscrews , washers, and locknuts (3)
an approved cleaning sOlvent, air d ried and care
fully inspected.
and disconnect the adjustment rods (2) from the
2. AII Loctite®, Permatex®, or other sealant residue
carrier frame (14) . Swing the adjustment rods (2)
out of the way and secure .
4 . Remove the washers and locknuts (23) and wash
ers and jam nuts (24) securing the air bags (25) to
the carrier frame (14) .
Note: For assembly purposes, match mark the caps mance of products.
and su spension arms and label the position and 3. Discard all used locknuts and replace with new.
quantity 01 the shims. 4. Inspect the integrity of the air bags and lines. Re
pair or replace if required.
5. Remove the capscrews and washers (11) , caps 5. Inspect the integrity of the brake lines. Repair or
(10) , and shims (12). replace if required.
6. Adequately support the front axles and air suspen 6. In the event of severe defects, contact factory per
sion assembly with a rollable jack of sufficient ca sonnel for directions whether to repair or replace
pacity. any majar component.
Note: The 1ront axles and air suspension assem

bly weighs approximately 3,100 lb (1 406kg).
4 of 6
Installation Of Front Axles And Air 6. Align match marks and install caps (10) and caps
crews and washers (11). Torque capscrews (11)
Suspension As An Assembly to 250-285 ft lb (340-386Nm).
7. Align the air bags (25) to the carrier trame (14)
and secure by installing the washers and lockn uts
CAUTION (23) and washers and jam nuts (24) .
Do notapply excessive Loctite®to parts. Over 8. Align the adjustment rods (2) to the carrier trame
use of thread locking compound can cause (14) and install the capscrews, washers , and lock
working parts to stick and malfunction . Use nuts (3).
minimal amounts of Loctite® on working parts 9. Rotatetheadjustment rods (2 ), as required , toob
and wipe clean any excess. tain the dimension shown in Figure 1.
Refer to Fig ure 2.
10. Align the shock absorbers (17) to the suspension
A WARNING
Lubricants, sealants, joint, and thread locking
arms (13) and secure by installing the capscrews
and washers (19).
11. To complete the installation, follow "Single Ax le
compounds, etc. can be hazardous. Serious Installation " Steps 6 thru 13.
personal injury may result 1rom misuse of
these products. Read and foHow aH Single Axle Installation
manufacturer's recommendations concerning
Refer to Figure 1.
these products.
1. Adequately support the axle (4) being installed
with a rollable jack of sufficient capacity. Secure
Refer to Figure 1. the axle (4) to the jack in a manner which will pre
1. If installation of the suspension arms (13) is re vent the axle (4) from rotating forward or backward
quired: during installation .
a. Secure the suspension arm (13) to an auxiliary
lifting device. Note: Each front axle weighs approximately
1,200 lb (544kg).
Note: Each suspension arm weighs approx
imately 110 lb (50kg). 2. Position the axle (16 ,20) under the crane .
3. Carefully raise and align the axle (16 ,20) to the
b. Position the suspension arm (13) on the equal equalizer beam (18).
izer beam (18). Refer to Figure 2 .
c. Secure the suspension arm (13) to the equaliz 4. Install the spacers (6), adaptors (2,8) , washers
er beam (18) by installing caps (22) and cap (4), capscrews (1), washers (7), and lock nuts (9).
screws and washers (21).
Torque locknuts (9) to 210 - 240 ft lb
2. If required, install air bags (25) to the suspension (284 -325Nm) .
arms (13) and secure by installing the locknuts and
washers (15). Refer to Figure 1.
3. Adequately support the front axles and air suspen 5. Remove the blocking from the opposite axle (4) .
sion assembly with a rollable jack of sufficient ca 6. Carefully align an d connect the torque rods (6) to
pacity. the axle (4) by installing the capscrews and washers
(5) .
Note: The front axles and air suspension assem 7. Align the drag link (8) to the steer arm (7) an d se
bly weighs approximately 3,100 lb (1 406kg). cure by installing the cage nut and cotter pin (9).
4. Position the front axles and air suspension as Note: To prevent tire damage, bend the cotter pin
sembly under the crane. away from the tire.
5. Lift the front axles and air suspension assembly,
align the suspension arms (13), and install shims 8. Install the tire and rim assemblies on the axle (s).
(12). Refer to SM Keysheet Area 01-069 for the correct
procedure .
Note: Apply a light coat of Loctite® 242 to the 9. Properly align steering . See SM Keysheet Area
threads 01 the capscrews. 01-006 for correct procedure .
5 of 6
12. Start the engine and let idle for five minutes . In
A WARNING
spect air lines for leaks. Repair if needed.
13. Complete the installation by testing all related func
tions of the front axle(s), brakes, and air suspen
lines and fitting s befo re relieving air pressure sion for proper operation. Normal operation of all
may res ult in serious injury. Shutdown the air system components should be confirmed . A
engine and drain the air system reservoir general inspection of components and systems in
before working on any line or fitting . the areas adjacent to the repair should also be per
formed to ensure related damage or wear is not
10. If required, connect the air lines to the air bags . present.
11. Connect the air lines to the brake chambers .
6 of 6
Troubleshooting Sheppard Steering Gears
Operating Principies
The Sheppard Integral Power Steering Gear provides full-time hydraulic steering. Only enough manual effort to
overcome the torsion bar and turn the rotary valve is required.
Refer to Figure 1.
The actuating shaft is connected to the steering column and is centered within the rotary valve by a torsion bar. The
rotary valve shaft is threaded into the piston with ball threads and travels within the piston on steel balls. Rotatin g the
input shaft causes high pressure fluid to build up on one end of the piston . This higher pressure causes the piston to
move in the bore of the gear housing. The sector shaft is engaged to a rack gear machined into one side of the
piston. Piston rack movement causes sector shaft and pitman arm rotation. When steering shaft rotation stops, the
actuating valve returns to its neutral position. Relief valve plungers or adjustable stops are used in the bearing cap
and cylinder head . When the plungers are adjusted properly, they will unload the hydraulic system if the wheels are
in a full turn to either direction.
TOR SION BAR

ROTARY VALVE SHAFT BALL THREAD
CYLlNDER HEAD
BEARIN G CA P
RELlEF PLUNGER
PI STON RACE ACTUATIN G

SHAFT
Figure 1
When the engine is running there is constant low pressure oil flow through the steering gear. This constant oil flow
provides an instant response and absorbs road shock to help eliminate steering wheel " ki ck". Press ure is equal
throughout the steering gear. However, care should be used when towing or moving a crane where the engine or
hydraulic supply pump is not running.
Note: 11 sudden loss 01 pressure occurs during normal driving, the parts are designed tp provide mechanicat
back-up steering so that the crane may be sa1ely steered to the side 01 the road.
An optional integral pressure relief valve is available on some steering gears. This valve limits maximum steering
system relief pressure at the steering gear. This reduces system temperature by avoiding high pressure by-pass
and recirculation within the pump .
The Sheppard Integral Power Steering Gears have been designed to provide long service tife and simple se rvi ce
repair. The rack and sector shaft does require center point adjustment. The clearan ce between the cylinder bore
and piston is closely controlled , and a piston ring was added to better use the hydraulic oil supplied .
1 of 18
SM01 005-027.00 0408 Service Manual
on Flow Through The Steering Gear
Sectm Sh," ~ 'i , IA:~:b~Y Refer to Figure 2.
Here the steering gear is in the neutral ar non steering

position. Equallow pressure is being applied to both
Housln --:\
Q
: : '" . '; : í ::~~~:~ ends of the steering gear piston. The oil is circulating at
the back pressure only and provides a hydraulic cush
.;: ' ....
" ....... ~ • • • o' , • .
: ::; .... !!! ion far the steering gear. Al! oil is being circulated
", :" :, ,:¡.r.! through the steering gear and back to the reservoir to
:'i
:," help cool the system.
.. '
.: :'
::1
Cylinder Head Piston Inlet
Figure 2
Refer to Figure 3.
When the steering wheel is turned, the actuating valve

is opened in one direction , all pressurized oil is applied
to one end of the steering gear piston. This pressure
build up causes the piston to move in the steering gear.
The illustration shows all oil being distributed to the in

put end 01 the gear.
Figure 3
Refer to Figure 4.
IIlustration shows al! oil being distributed to the cylinder

head end of the gear.
Figure 4
When no input is applied through the steering wheel
the gear returns to the neutral ar non steering position.
Steering Gear Identification
Reler to Figure 5.
A number is cast into the steering gear housing and identilies the basic lamily the steering gear belongs to
Stamped letters and numbers on an exposed machined surlace 01 the housing (opposite the mounting surface)
identilies the gear serial number.
Steering Gear Model Translation Serial Number System

(Cast Into Housing) (Stamped On Housing)
M-100
~ f t Sedes Gea,
(Revision Level)
Model Number Alphabetically
Qº-
L~
C 15914
Month built:
Sheppard Releren ce only
A = January
B = February
C = March
' - - - Power Etc .
-2000
'---- Gear Size (Used Last
Two Numbers)
Represents:
(00) Year Built - 2000
(C) Month - March
(15914) Relerence only
Figure 5
Diagnosis & Troubleshooting

This section 01 this procedure is to help the technician troubleshoot steering complaints . Do Not Remove Steering
Gear From Crane. Used properly the section will assist you in completing a proper and less time consum ing diag
nosis and repair.
You will lind sub sections covering diagnosis , troubleshooting , delinitions, and terms lar complaints . To properly
repair the problem you must have a clear understanding 01 the driver's complaint. The glossary 01 terms and delini
tions will help communicate the problem correctly.
Locate the complaint in the troubleshooting section and complete all the necessary test as outlined in the proper
section 01 the procedure. Complete the troubleshooting checklíst and record your findings.
If after completing the diagnosis and repairs lound in the diagnosis and troubleshooting section 01 this procedure ,
you are unsure 01 your findings, contact the Field Service Department 01 the Sheppard Co , Inc. 01 Hanover, PA
U.SA at (800) 274-7437. When contacting the Sheppard Co., Inc. with a problem be sure to have yourcomplete d
troubleshooting checklist available.
30118
Do not remove the steeri ng gear until you have completed all troubleshooting procedures to diagnose your prob
lem . Remember the steering gear is only one part of a total system. To properly diagnose steering complaints it is
important to understand the complete steering system. Many factors outside of the steering system will affect steer
in g p erformance. Factors such as misalignment, looseness in front end components , and mismatched tires , to
name a few, will aHect steering.
A troubleshooting checklist is provided on page 17 of this procedure . This form can be photo copied. This checklist
will follow the diagnosis outline below.
General Diagnosis
Many times a steering gear is removed and disassembled needlessly because an orderly diagnostic procedure was
not lollowed .
A glossary 01 common terms is provided on pages 8 and 901 this procedure. This glossary is intended to help you
better understand the procedures and improve your ability to document and communicate the problem.
Begin your diagnosis using the lollowing outline as a guide:

1. Defin e the complaint:
a. Talk to and question the driver - Refer to the glossary to obtain a clear understanding 01 what the driver is
saving .
b . Orive the crane - II possible have the driver show you what he is experiencing. Orive the crane together to
duplicate the condition .
2. Perform a visual inspection 01 the crane:
a. Check tires for mismatch, improper inllation, or uneven wear patterns .

b . Check for poor loading practices - Special body or equipment installations should be checked for their
eHect on steering performance.
c. Check for suspension sagging or shifting - Out of line rear axles will tend to steer the front end 01 the crane.
d . Confirm proper Wheel Alignment And Steering Linkage Adjustment. See SM Keysheet Area 01-006 for
complete instructions.
3. Inspect mechanical components:
a. Check all fron! axle components for wear, looseness , or seizing.
b. Inspect steering column for drag - more than 10 in lb (1 . 13Nm) of drag measured with the column sus
pended at the angle of operation is excessive.
c. Check steering mounting to be sure it is tight. A steering gear that is shifting on the frame will effect steering
performance.
4. Check the hydraulic supply system:
a. Follow the procedures as outlined in the hydraulic diagnosis section of this procedure . Oil pressure and
Ilow must be within the crane manufacturer's specifications. See Operator's Manual for proper hydraulic
reliel settings .
b. Check Relief Plunger Settings And Axle Stop Adjustment. See SM Keysheet Area 01 -006.
40118
Hydraulic Diagnosis
The Sheppard integral power steering gear is a reactionary part 01 the power steering system. Reactionary meaning
that its operation is dependent on the proper supply 01 oil pressure and Ilow Irom the hydraulic supply pump.
When the steering wheel is turned , oil Ilow is applied to one end 01 the steering gear piston causing pressure to buil d.
This pressure causes the piston to move. As the piston moves it is displaced by a volume 01 oil under pressure. The
speed the piston moves is dependent on the amount 01 oil Ilow or,
Flow = Speed 01 steering.
Maximum system relief pressure limits the amount 01 steering gear output available to steer your specilic crane or,
Pressure = The amount 01 work the steering gear can do.
Keeping the basic lormula of "Flow = Speed 01 steering " and "Pressure = Work" in mind will help to diagnose steer
ing problems.
Oil pressure and flow requirements are set during the design 01 the steering system. When diagnosing steerin g
problems, oil pressure and flow must meet design specilications. Pressure and Ilow specilications vary. Check the
hydraulic pressure settings as olltlined in the Operator's Manual.
System back pressure and operating temperature must be considered dllring the diagnosis of the steering system.
High system back pressure will create heat.
High system oil temperatures reduce overall efficiency 01 the steering pump and steering gear.
Equipment Required
Various types of pressure and flow meters are available to diagnose power steering problems. A presSllre gauge
rated at 3,000 psi (20 685kPa) and a flow meter with a capacity 0110 gpm (37.8Lpm) are needed to check oil pres
sure and Ilow.
A shlltoff valve placed downstream lrom the pressure gauge allows the hydraulic supply pump to be isolated from
the gear to check pump reliel pressure. A simple thermometer placed in the reservoir will show system temp erature .
Figure 6
Pictured above is the Heavy Outy Power Steering Test Kit Part Number 3A 22668. This is an excellent tool for trouble
shooting power steering systems and can be ordered through your distributor.
This tester is a self contained, direct reading device to check system Ilow, pressure or both at the same time. It can
detect WOrn components, check Ilow and pressure control setting or monitor overall system performance.
5 of 18
Test Kit Benefits
Only one hos e connection is broken, either at the pump output or at the pressure input to the power steering gear
hous ing .
• Installs between pump and steering gear.
• ShutoH valve isolates pump from steering gear.
• Pr essure and flow can be read at the same time.
·0- 3, 000 psi (0- 20 685kPa) pressure gauge.
·1-10 gpm (3.8 -3 7.8Lpm) flow meter.
• Complete with hoses and standard swivel fitting.
Actu al Testing
Using a p ressure and flow test kit, proceed with the evaluation of the hydraulic system . Record your findings on the
troubleshooting checklist.
Note: AII test must be performed with the crane parked on a clean, dry, solid surface, with the engine running
and the full weight of the crane on the front wheels.
1. Make a copy of the troubleshooting test sheet.
2. Connect the pressure and flow tester in series with the pressure line of the pump.
3. Start the engine and check the system oillevel. Make sure the oil is flowing in the proper direction as indicated
by th e arrow on the flow meter.
A WARNING
Oil under pressure can penetrate the skin causing severe injury. Never use your hands to check for
leaks.
4. Place a thermometer in the reservoir.
S. Ru n engine at idle speed . Slowly close the shutoff valve until you have pressure reading of 1,000 psi (6895kPa)
Maintain lhis pressure until system temperature reaches 180°F (82 OC). Open the shutoff valve all the way
when the temperalure is 180° F (82 OC).
6. Check system backpressure:

Normal system back pressure will be between 0-100 psi (0-690kPa) wilh the engine idling and the steering
wheel stationary. Dual systems will normally read slighlly higher. Back pressure should be checked al normal
operat ing temperature.
7. Pump maximum relief pressure:

With the engine running at specified idle speed, slowly turn the shutoff valve until it is closed and read the pres
sure al which the pressure relief opens. (open lhe shutoff valve as quickly as possible to avoid heat buildup or
possible damage to the sleering pump.) This pressure reading should equal lhe maximum pump pressure
specified in lhe Operator's Manual. See Operalor 's Manual for correct pressure setting procedure.
6 of 18
A WARNING
Abad pressure relief valve may not relieve pump pressure. Closing the shutoff valve may cause severe
pump damage or high - pressure hoses to rupture. Watch The pressure gauge closely. If pressure
rises rapidly or goes above 2,000 psi (13 790kPa). STOP. Do not close the valve all the way.
Some steering pumps are not equipped with integral relief valves. Close the shutoff valve slowl y and
watch the pressure. If system pressure goes above 2,500 psi (17 238kPa) do not continue to cl ose the
shutoff valve. Pump damage or personal injury may result.
8. Flow Test :
• Measure oil flow under the following conditions . Record your findings on the troubleshooting checklist.
• Flow at idle with back pressure only.
• Flow at idle under a 1,500 psi (10 343kPa) load applied with the shutoff valve.
• Flow at governed rpm with back pressure only.
• Flow at governed rpm under a 1,500 psi (10 343kPa) load applied with the shutoff valve.
9. Aerated oil:
Visually check for air mixed with the oil in the steering system. The oil should be clear. Any signs 01 frothing
indicates air in the system and steering perlormance will be effected . Carefully check lor leakage on the suction
side 01 the steering pump. Drain, refill, and bleed the system. Follow the procedure lor setting reliel plungers in
Front Whee/ A/ignment And Steering Linkage Adjustment . See SM Keysheet Area 01-006.
Before any steering gear repairs are made complete the hydraulic supply evaluation and make any repairs .
Many times sleering gears have been repaired or replaced needlessly because a hydraulic supply sysl sm
evaluation had not been made.
Additional references to pressure and Ilow lesting will be made in the troubleshooting charts lound laler in this
procedure.
10. Dry park pressure and input effort:

Measure and record Ihe pressure required to steer the crane Irom lullleft to lull right while parked . Input effort is
measured at the steering wheel retaining nut. Use a dial type in lb (Nm) torque wrench to check static steering
input effort. Normal input efforl will be less than 100 in lb (11.3Nm).
Oil Flow and Pressure Recommendations

The Sheppard power steering gears are designed lO operate at a maximum pressure 01 2,175 psi (14 997kPa).
Each crane model specilies the maximum operating pressure at which Iheir various steering installation are to
be operated . Always reler to your Operator's Manual specilications lor the correct pump relief settings lor the
crane you are working on .
A WARNING
Do not increase the maximum operating pressure beyond the specifications found in the Operat or's
Manual. Serious damages may occur.
Oil Ilow and pressure Sheppard power steering gears are outlined in the table below by model number. Refer to the
Steering Gear /dentification section 01 this procedure to determine the model 01 steering gear you are working on .
7 of 18
SM01 - 005 - 027.00 0408 Service Manual
Steering Gears
D120P M90P : M100P M110P
Rated Pressure - Do Not Ex- 2,175 psi 2,175 psi 2,175 psi 2,175 psi
ceed Pressure Specified In The (14997kPa) (14997kPa) (14997kPa) (14997kPa)
Operator's Ma nual.
Minimum Pump Flow 5 .0 gpm 2 .5 gpm 3 .0 gpm 3.5 gpm
(Single) (18.9Lpm) (9.5Lpm) (11.4Lpm) (13.2Lpm)
Pump Flow Range 5.0-6.0 gpm 2.5-6.0 gpm 3.0-6.0 gpm 3.5-6.0 gpm
(Single) (18.9-22.lLpm) (9.5-22. lLpm) (11.4-22. lLpm) (13.2-22. lLpm)
Pump Flow Range 5 .0-6 .0 gpm 4.6-6.0 gpm 5 .1-6.0 gpm 5 .6-6.0 gpm
(Dual System ) (18.9-22. lLpm) (17.4-22. lLpm) (19.3-22. lLpm) (21.2-22. lLpm)
Ratio 23-1 18.9-1 18.9- 1 23-1
Output Shaft Diameter 2 .5 in (63.5mm) 2 .0 in (50.8mm) 2 .0 in (50.8mm) 2.25 in (57.2mm)
Befare any stee ring gear repairs are made complete the entire troubleshooting checklist provided in the procedure.
Many times steering gears are removed or replaced needlessly. Remember, once the steering gear is removed , no
fu rth er diagnosis can be made.
If yo u have completed the troubleshooting checklist and are unsure of your diag nosis contact your crane distributor,
or th e field service department of the R.H. Sheppard Co . Inc. of Hanover, PA U.S .A. at (800) 274- 7437.
Glossary
1. Back Pressure - Circulating pressure of the steering system .
2. Base Mounted Gear - The steering gear is mounted to the frame rail or bracket utilizing the mounting holes
opposite the sector shaft cover.
3. Bearing Cap - End cap of the steering gear that houses the actuating shaft (input shaft) and valve.
4. Bearing Cap Cover - Small cover on the end of the bearing cap of the steering gear. The bearing cap cover
houses the actuating shaft (input shaft) oil and salt sea!.
5 . Bleeder Screw - 1/8 in Allenlf.' screw located in the sector shaft bore of the steering gear.
6. Cavitation - Bubbles that form in the oil which keep the pump from supplying pressure and volume.
7. Contamination - Dirt or foreign material in a fluid .
8. Cylinder Bore - Long bore of the steering gear where the steering gear piston is housed .
9. Cylinder Head - The end cap of the steering gear bolted on the housing opposite the actuating shaft
(input shaft) end of the steering gear.
10. Displacem ent - The volume of fluid that can pass through a pump or cylinder in a single revolution stroke.
11 . End Cap - Also called the cylinder head. See Cylinder Head.
12. Feedback - A transfer energy from the output of a device to its input.
13 . Flow - The amount of fluid that pass es a certain point in a unit of time . The volume of flow is usually expressed
in either gallons per minute (gpm) or Liters per minute (Lpm) for liquids .
14. Fluid Flow - The stream or movement of a fluid, or the rate of its movement.
15. Master Gea r - Mechanically actuated steering gear in a dual system application. It is actuated by the steering
wheel through the yoke connection to the steering column.
8 af 18
16. Piston - Is found in the cylinder bore . Changes the hydraulic force to mechanical force in the steering gear.
17. Plunger - Relief valves in the steering gear to limit steering gear piston travel. Plungers are adjustable an d can
be either manual or automatic adjusting .
18. Pressure Relief Valve - Pressure relief valves integral to the steering gear limit system operating pressure .
Identified by a large hex nut on the side of the bearing cap . Remote relief valves serve
the same purpose . However, other hydraulic functions may also be incorporated into
their use .
19. Pump - A devise that converts mechanícal force and motíon ínto hydraulic fluid power.
20 . Rack Teeth - The area on the piston that engages the sector shaft teeth .
21. Recirculation Ball Thread - The area of the rotary valve on which the internal steel balls travel.
22 . Relief Valve - A pressure control valve used to limit system pressure.
23 . Rotary Valve - Internal valve in the bearing cap of the master steering gear. It is actuated by the steeri ng wheel
through the input shaft and yoke connection of the steering column .
24. Sector Shaft - The shaft the pitman arm is attached too
25. Sector Shaft Bore - Area of the steering gear that houses the sector shaft.
26. Slave Gear - Hydraulically actuated steering g ear in a dual system application .
27. Slave Post - Threaded openings in the cylinder head , bearing cap, and sector shaft bore to install the pressure
lines to operate the slave gear.
28. Tab Lock Retainer - Bolt assembly used to provide torque when installing the pitman arm. Uses alignment
tabs that fit into the pitman arm and restraining tabs to be locked into the head of the
retainer.
Troubleshooting Chart
Problem Probable Cause Remedy
Oil leaking at sector shaft. 1. Damaged sector shaft seal. 1. Replace sector shaft seal and
sector shaft if necessary.
Oilleaking at actuating (input) shaft. 1. Worn or damaged oil seal. 1. Replace actuating (input) shaft
seal.
Oil leaking at supply pump drive 1. Damaged oil seal. 1. Replace oil seal.
shaft . 2. Oil seal heat damaged. 2. Check operating temperature .
3. Loose or damaged bushing on 3. Repair pump per service in
pump shaft. structions. See SM Keysheet
Area 01 - 010 .
Lubricant milky or white in appear- 1. Water entry though reservoir 1. Clean vent system or replace
ance. venting system . cap assembly.
2. Flush system.
9 of 18
Oil forced out of reservoir or foam- 1. Clogged oil filter. 1. Change oil and oil filter.
ing . (Change more often).
2 . Air in system. 2. Bleed air from system and
check for air leak on suction side
of supply pump.
3. Relief plungers not adjusted 3 . Adjust relief plungers.
properly creating high operating See SM Keysheet Area 01-006 .
temperatures.
4. Air leak in suction side of supply 4. Refer to pump servicing instruc
pump . tions. See SM Keysheet Area
01-010.
5. Pump cavitation . 5. Check for restrictions in pump
supply.
6. Oil overheating. 6 . Check for restrictions in in steer
ing gear return.
Engine oil in power power steering 1. Faulty seal at pump drive shaft. 1. Repair pump.
reservoir (Gear driven pump). 2. Faulty seal at accessory shaft 2. Repair accessory drive.
driving supply pump .
Lubrication oil discolored. 1. Operating temperatures too 1. Check and correct cause of
high. overheating .
2. Change intervals too long. 2. Change oil more often.
3. Incorrect lubricant used . 3. Drain, flush and refill with rec
ommended fluid.
High operating temperatures. 1. Oil flow restriction . 1. Check back pressure.

2. Oil flow too high . 2. Check maximum oil flow.
No power steering on cold starting. 1. Hydraulic supply pump vanes 1. Increase engine speed momen
not extending. (Vane type pump tarily to extend vanes and start
only). pump action.
2. Usualiy does not happen often
and does not last long. Not a
cause foe pump repair or re
placement .
Excessive pump pressure with 1. Pinched oil return line causes 1. Relocate line .
steering gear in neutral position . high Back pressure.
2. Binding steering column 2. Repair steering column .
Wheel cuts restricted. 1. Relief plungers not adjusted 1. Adjust relief plungers .
properly.
10 of 18
Erratic steering or mechanical 1. Insufficient volume of oi\. 1. Reler to pump servicing instruc
steering only. tions.
2. Sticking pressure relief valve. 2. Replace reliel valve as required .
Hard steering . 1. Faulty supply pump. 1. Check pump flow.

2. Steering out 01 alignment. 2. Align Iront end .
3. High operating temperature. 3. Locate and correct cause 01
overheating.
Wheel turns hard in one or both 1. Bind in steering column. 1. Check column drago
directions . 2. Oirt or foreign matter trapped in 2. Check piston relief.
piston relief.
3. Bent or damaged king pins and 3. Repair or replace king pins and
tie rods. tie rods .
4. Front end load too great. 4. Lighten load .
5. Low oillevel in steering system . 5. Fill oil reservoir as required .
6. Air in system. 6. Bleed system and check lor
cause of airo
7. Caster degree incorrecto 7. Correct to specilications .
Wheel turns hard in one direction. 1. Metal or foreign material in reliel 1. Remove and clean relief valve
ball seat in piston. seats or replace damaged
parts.
No attempt to return to straight 1. No positive caster. 1. Set caster to 3° to 5° positive

ahead Irom turns (may also be hard caster.
steering complaint). 2. Steering gear mounting dis- 2. Shim mounting pads to correct
torted. piston to bore interfe rence .
Make sure correct bolt length is
used on the base mount gears .
3. Linkage ball sockets seized or 3. Check and repair or replace.
binding .
4. King pins seized or binding . 4. Repai r or replace .
5. Oil flow rate incorrect. 5. Check and correct supply
pump.
Oarting, wandering (oversteering) . 1. 011 Ilow too high. 1.

Supply pump not to specilica
tions.
2. Air trapped in steering gear. 2. Bleed system .
3. Looseness, worn front end 3. Check and repair as required .
parts .
4. Front end alignment not correct o 4. Align Iront end caster.
5. Overloading . 5. Reduce loads .
6. Rear axle not paralle\. 6. Check and repair as required.
7. Tight tie rod ends and drag link 7. Clleck rotational torque and re
sockets . place if necessary.
11 01 18
Excessive backlash/lreeplay. 1. Worn universal joint. 1. Replace universal joint.

2. Pitman arm ball worn "egg- 2 . Replace pitman arm assembly
shaped " (il equipped). where riveted ball is used.
3 . Loose bracket frame to bracket 3. Remove bracket, clean frame
or bracket to gear. and bracket. Check radius 01
frame making sure bracket is
not bearing on radius surface.
Check bracket for wear from be
ing loose . Replace bracket and
tighten to recommended
torque. If necessary, replace
bracket .
4. Rack on piston damaged . 4 . Replace steering gear.
5 . Oamaged sector shaft/splines. 5 . Replace steering gear.
6. Worn or damaged pitman arm 6. Replace pitman arm and sector
splines . shaft.
7. Universal joint yoke loose on ac 7. Repair or replace damaged
tuating shaft. parts.
Steering input not smooth. 1. Worn universal joint. 1. Check and replace universal
joint as required .
2. Lack of lubrication. 2. Lubricate per recommenda
tions in Operator's Manual.
3. Universal joint not phased prop- 3. Re- phase columns. *
erly.
4. Low oil flow. 4 . Idle speed too low. Orive belts
slipping. Supply pump not to
specifications.
5. Overload on front axle . 5. Verify front axle weight. 00 not
exceed rating 01 Iront axle .
6. Pump cavitation . 6 . Correct pump supply.
7. Overheating. 7. Correct cause of overheating.
Note: Universal joints are designed to operate best when the angle between the drive and driven shaft is a
maxim um of 20° - 25 ° . Angles greater than this may upset steering performance.
Important: Actuating shaft thread wear generally comes from improper lubrication or excessive manual
steeri ng. Manual steering results from low pump pressure, insufficient flow, or an overloaded front axle.
* To check phasing 01 the universal joints in the steering column , use an inch pound graduated dial type torque
wrench . With a socket on the steering wheel retaining nut, read the d ifference in the torque while steering Irom
fullleft to full rig ht . Variation of more than 15 in lb (1 . 7Nm) means improper phasing . Take the reading with the
crane stationary and the engine running at idle.
Phasing can usually be corrected by rotating the two- piece intermediate shaft one spline at a time until the
torque reading remains the same throughout the 360° rotation 01 the steering wheel.
12 of 18
Cleaning & Inspection
Cleaning
Cleanliness is important. Dirt and foreign material that gets into the steering system during repair operations can
cause damage or a possible steering malfunction at a later date. Due to the close tolerances between mating parts it
is best to have all parts at the same temperature for reassembly.
A WARNING
Solvents and cleaning solutions can be hazardous. Serious personal injury may result from misuse of
these products. Read and follow all the manufacturer's recommendations concerning solvents and
cleaning solutions.
Clean the machined parts individually to avoid damage caused by "bumping " together. Use clean solvent to wash
parts . Allow the parts to air dry. Nicks or burrs must be removed with a fine hand stone or crocus cloth befo re
assembly. Use clean lubricant to coat parts for assembly. AII hoses , lines , and reservoir should be cleaned before
reinstalling a repaired steering gear or after pump replacement. Replace the filter element or cartridge .
Inspection
Make a careful visual inspection of all steering gear parts. Replace worn parts as well as any parts that show signs of
stress or fatigue .
A DANGER
Steering gears that have been damaged in an accident must be replaced. Impact loads transmitted
through the front axle and steering linkage into the steering gear can stress parts to a point just short 01
failure . Further use is unsafe and the steering gear assembly and pitman arm must be replaced. Dis
torted pitman arms, twisted sector shafts, broken or cracked rack and pinion gear teeth are some signs
of impact damage. Broken or damaged mounting brackets must be replaced.
Steering gear parts inspection may show problems in other areas of the steering system. To avoid repeat problems
inspect all parts carefully. Listed below are the more common problems you may see during steering gear ins p ec
tion along with their possible cause . This information should be considered carefully when repairing low millage
cranes .
Problem Probable Cause

Parts Discolored (blue). 1. Operating temperatures too high .
2. Steering column binding.
3. Hydraulic supply pump malfunctioning .
Sector Shaft (Roller bearing wear). 1. Incorrect lubricant use.
2. Excessive temperature.
3. Overloading the axle.
4. Contaminated lubricant.
5. Impact damage.
Actuating Shaft (ball thread brinelled or dented). 1. Impact damage.
Thrust Bearings (broken or distorted). 1. Impact damage.
2. Incorrect repairs.
13 of 18
Problem Probable Cause
Piston Rings (cut , pinched, sheared , or worn). 1. Incorrect installation.
2. Incorrect assembly.
Actuating Shaft (thread wear) . 1. Incorrect lubricant use.
2. Overloading
3. I nsufficient operating pressure.
4. Insufficient oil flow.
5. Continued operation at high temperature.
Housing or Piston Scoring (see Note). 1. Foreign material entry.
2. Severe overloading.
3. Incorrect lubricant use.
4. Excessive temperature (over 250°F) .
5. Pump damaged.
Thrust Bearings (pitted, rough) . 1. Foreign material in system .
2. Excessive overloading .
Broken Housing 1. Accident damage.
Note: Minor scoring and scuffing of the piston and housing of the steering gear is normal. During op
eratioll at relatively high pressure and flow rates this minor scoring will not affect the safety or opera
tion of the steering gear. Minor scoring should be polished with a fine hand stone or crocus cloth.
CAUTION
The cylinder bore should never be honed or bored out. This will increase internal leakage.
14 of 18
Secondary (Slave) Gear
Return From Master To Reservoir
Reservoir For Pump
Steering Column
Main Steering Gear
Une From Pump
Une Number 1
Return Une
To Reservoir
o O
Une Number 2
Figure 7
15 of 18
Secondary (Slave) Gear
Return From Master To Reservoir
Reservoir For Pump
Return Line Main

Gear To Secon
dary Gear
Steering Column
Main Steering Gear
Line From Pump
Line Number 2
Return Line To Secondary

(Slave) Gear
Figure 8
TROUBLESHOOTING CHECKLlST
Befare proceeding with the following test, be sure to read the diagnosis and troubleshooting section of this manual.
Check all mechanical and external conditions befare hydraulic testing.
Date:
Servicing Dealer Location:
Customer Name:
Description of steering complaint:
Crane Model: Mileage Crane Serial Number _ _ _ __

Steering Gear Model: Serial No.
Slave Gear Model (if equipped): _ _ _ _ __ Serial No.
Pump Manufacturer: Front Axle Weighí _ _ _ __
Hydraulic Tests:
Do not remove the steering gear! Install a pressure and f10w tester in series with the pressure line ofthe pump as
outlined in the diagnosis and troubleshooting section.
Record the following infarmation :
Stabilized Oi! Temperature:

System backpressure @ Idle _ _ _ __ Backpressure @ full rpm _ _ _ __
Maximum system pressure (pump relief setting) psi
Flow @ Idle with backpressure only gpm
Flow @ full governed rpm backpressure only gpm
Flow @ Idle with 1500 psi load applied gpm
Flow @ full governed rpm with 1500 psi load applied gpm
Static Steer Pressure Right Turn psi Left Turn psi

Static Steer Input Right Turn In lb Left Turn In lb
If you are unsure of your diagnosis, contact Sheppard Field Service @ (800) 274-7437
17 of 18
180118
~ -\
.. / ,
\
1. Capscrew & Locknut 4. Mounting Plate

2. Capscrew & Washer 5. Steering Orive Shatts
3 Steering Miter Box
Figure 1
Steering Miter Box
4. Thoroughly clean area to be disassembled with an

Steering Miter Boxes, R & I approved cleaning solvent to prevent
This procedure covers the removal and installation of contamination . Allow the area to air dry.
the steering miter boxes. Refer to Figure 1.
5. Remove capscrews and locknuts (1) and retract
Removal steering drive shafts (5) from steering miter box (3).
1. Lower, detach, and secure load, as required. 6. Remove the capscrews and washers (2) .
2. Stabilize the crane for service as follows : 7. Remove steering miter box (3) from mounting plate
a. Park the crane out ofthe way on a firm and level (4) .
surface.
b. Engage the park brake and/or properly block Cleaning And Inspection
the tires .
c. Engage the swing park brake or travel swing
lock , as required.
d. Level the crane on fully extended outriggers.
A WARNING
e. Fully retract and lower the boom, as required.
hydraulic pump.
and follow all the manufactu re r's
A WARNING
Solvents and cleaning solutions can be 1.
cleaning solutions.
AII components should be thoroughly cleaned with

hazardous. Serious personal injury may an approved cleaning sOlvent, air dried , and
result from misuse of these products. Read carefully inspected.
cleaning solutions.
1 of 2
Installation
Correet Orientation Of
Steering Wheel With
The Tires Parrallel To
The Carrier Frame A. WARNING
(Tires Straight Ahead). Lubricants, sealants, joint and thread locking
compounds, etc. can be hazardous. Serious
these products. Read and follow all
these products.
Refer lo Figure 2.
Figure 2
1. Orienl sleering wheel lo Ihe slraighl ahead
Ste er ing Wheel Orientation
posilion . Be sure wheels are parallel lO the carrier
frame.
2. AII Loclile®, Permalex®, or olher sealant residue
should be removed from threads of hardware and Refer lo Figure 1.
the mounting surfaces of parts that are going to be 2. Properly posilion Ihe sleering miler box (3) lo
reused. Prior to applying new Ihread locking mounting plate (4) and install capscrews and
compounds or sealants, clean threads and washers (2).
surfaces with Loctite® 7070 Cleaner to ensure besl 3. Connecl sleering drive shafts (5) lo sleering miler
performance of products. box (3) and install capscrews and locknuts (1).
3. In the event of severe defecIs, conlacl factory 4. Check and adjusl the fronl wheel alignment. Refer
personnel for directions whether lo repair or to $M Keysheel Area 01 -006 for complete
replace any major component. procedure.
5. Complete the inslallation by lesting all related
lunclions 01 Ihe sleering system for proper
operation . Normal operalion of hydraulic, air, and
electrical syslems should be confirmed. A general
inspection of components and systems in the
areas adjacent to the repair should also be
perlormed lO ensure relaled damage or wear is nol
present.
2 of 2
:-: : :
Steering Gears, R & I :.' .

the master steering gear. Though there are two
steering gears , a master and a slave, removal and
installation is basically the same. For recondition
procedure, see SM Keysheet Area 01-005 .
Removal
1. Lower, detach, and secure load, as required.
Figure 1
2. Stabilize the crane for service as follows :
Alignment Tab On Friction Washer
Do Not Bend
surface.
b. Engage the park brake and/ar properly block
the tires. CAUTION
c. Engage the swing park brake ar travel swing
Be sure to bend the correct part when
lock , as required.
removing the pitman armo The pitman arm
friction washer has flat alignment tabs, while
the retainer lockwasher has bendable
restraining tabs. Do not bend the align ment
hydraulic pump.
tabs out of the pitman armo See Figure 1 and
Figure 2.
A WARNING
cleaning solutions.

approved cleaning solvent to prevent
contamination. Allow the area to air dry.
5. Remove any fenders or sheet metal as required to Figure 2
gain access to the steering assembly. Bending Open Restraining Tabs On
Refer to Figure 3. Lockwasher
6. Disconnect hydraulic lines (6) from steering gear
(3). Cap/plug the open parts and hydraulic hoses 9. Support tie rods (7,8) and remove cotter pins (5)
(6) to prevent excessive oilloss and contamination and castle nuts (4) .
of the system. 10. Using a ball stud removal tool, break tapered fit
connection between tie rods (7,8) and pitman arm
Note: The steering gear and pitman arm (9). Swing tie rods (7,8) out of the way and secure .
assembly weighs approximately 175 lb (80kg). 11. Remove bolts (14), c-clips (13), retainers (12) ,
and washers (11).
7. Adequately se cure and support the steering gear 12. Remove steering gear (3) assembly from crane .
(3) and pitman arm (9) assembly with an 13. If removal of pitman arm (9) is required, remove
appropriate lifting device. retainer, lockwasher, and friction washer (10).
8. Loosen capscrew and locknut (2) and disengage Remove pitman arm (9) from steering gear (3) ,
steering shaft (1) from the steering gear (3). using a wheel puller.
1 01 4
SM01 - 005-033.00 0408 Service Manual
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1. Steering Shaft 8. Tie Rod

2. Capscrew & Locknut 9. Pitman Arm - Steering Gear
3. Steering Gear 10. Retainer, Lock Washer, & Fricti on Washer
4. Cas tle Nut 11 . Washer
5. Cotter Pin 12. Retainer
6. Hydraulic Line 13. C-clip
7. Tie Rod 14. Bolt
Figure 3
Steering Gears
2 of 4
Align Timing Marks

On Master Steering /~
I¡ " \
Gear And Pitman Arm ~~~f(/

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/'
------- Align Timing Marks
On Slave Steering
Gear And Pitman Arm
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Master Steering Gear

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Slave Steering Gear
1. Steering Gear 2. Pitman Arm
Figure 4
Pitman Arm Installation
Cleaning And Inspection Insta lIation
A WARNING
A WARNING
Lubricants, sealants, joint and thread lo cking
hazardous. Serious personal injury may compounds, etc. can be hazardous. Serious
result from misuse of these products. Read personal injury may result from misuse 01
and follow all the manufacturer's these products. Read and follow all
recommendations concerning solvents and manufacturer's recommendations conce rn ing
cleaning solutions. these products.
1. AII components shou ld be thoroughly cleaned wíth

an approved cleaníng solvent, aír dríed , and Note: The steering gear weighs approximately
carefully ínspected . 150 lb (68kg).
2. AII Loctíte®, Permatex®, or other sealant residue
should be removed from threads of hardware and Reter lO Fígure 3 .
the mountíng surfaces of parts that are goíng to be 1. Adequately secure and support the steeríng gear
reused. Prior to applyíng new thread locking (3) wíth an appropríate líftíng devíce .
compounds or sealants , clean threads and 2 . Alígn sleeríng gear (3) to carríer trame.
surfaces with Loctíte® 7070 Cleaner 10 ensure best 3. Apply Loclíle® to threads of bolts (14) and ínslall
performance of products. washers (11) , retaíners (12), c-clíps (13) , ancJ
3. In the event of severe defects , conlacl faclory bolts (14). Torque bolts (14) lo 165 ft lb (224.0Nm)
personnel for direclíons whelher lo rep air Or 4. After all hardware has been torqued , bend all
replace any major componen\. relainers (12) as íllustrated ín Figure 5 .
3 ot 4
Note: During torque process, align best
applicable hole in castle nut with hole in ball
Bend AII
studs to allow for installation of cotter pino
Locking Tabs
Over Until They 12. Retorque castle nuts (4) to 120-170 ft lb
Contact Plate. (163-230Nm).
13. Install cotter pins (5); bend accordingly.
14. Engage steering shaft (1) with steering gear (3)
and tighten capscrew and locknut (2).
15. Align and install hydraulic lines (6) to steering gear
(3) .
16. Check hydraulic reservoir oil level. Add oil as
required. See Operator's Manual for correct type
1. Carrier Frame 4. Retaining Ring and procedure.
2. Locki ng Tab 01 Retainer 5. Washer 17. Start the engine and let idle for five minutes.
3. Capscrew Inspect the connections on the hydraulic lines for
Figure 5 leaks. Repair if needed.
Bending Locking Tabs 18. Install any fenders ar sheet metal that were
removed .
19. Start the engine and let idle for five minutes.
5. Install pitman arm (9) by aligning timing mark on
Inspect the hydraulic connections for leaks.
pitman arm (9) with timing mark on the sector shaft
Repair leaks as required.
of the steering gear (3) as shown in Figure 4.
lO
6. App ly anti-seize compound, Bostik ' Never Seize Note: The main hydraulic system must be
or eq uivalent, to threads of retainer and to both sufficiently bled before bleeding the steering
sides of lock washer.
gears.
Note: Do not use an impact wrench to tighten
20 . Bleed air from the steering system:
retainer. Tig hten and torque by hand only.
a. Start the engine and allow it to run at fast idle .
While the retainer is being installed, align and
b. Turn the steering wheel full right and full left
instal! the flat tabs on the friction washer into the
three or more times to bleed the steering
slots in the pitman armo
gears .
7. Secure pitman arm (9) to steering gear (3) with 21. Make necessary adjustments to steering linkage .
retain er, lockwasher, and friction washer (10). Refer to "Front Wheel Alignment and Steer Linkage
Hand torque retainer to 450 ft lb (61ONm). Adjustment " in SM Keysheet Area 01-006.
B. Ifth e bent tabs on the lockwasher do not align with 22. Complete the installation by testing all related
any of the slots of the retainer, continue tightening functions of the steering gear (3) far proper
until the first set aligns. Bend tab of lockwasher operation. Normal operation of hydraulic, air, and
into slot of retainer to secure retainer in place. electrical systems should be confirmed. A general
9, Apply anti-seize compound, Bostik<liJ Never Seize inspection of components and systems in the
or equivalent, to taper of tie rods (7,8). areas adjacent to the repair should also be
10. Align and install tie rods (7,8) to pitman arm (9). perfarmed to ensure related damage ar wear is not
11. Install and tarque castle nuts (4) to 120-170 ft lb present.
(1 63-230Nm). Hit the castle nuts (4) with a soft
fac e mallet several times to seat the taper fit
between the tie rods (7,8) and the pitman arm (9).
4 of 4
.~. _--
...- ~- -------"
1. Steering Column 3. Capscrew & Locknut 5. Mounting Plate

2. Capscrews. Washers. & Spacers 4. Steer Shaft 6. Miter Box*
* Orienlation 01 miter box may vary. Sleering column cover. il equipped. is removed lar clarity.
Figure 1
Steering Column

Steering Column, R & I draulic pump, as equipped.
This procedure covers the removal and installation of Refer to Figure 1.
the steering column . For recondition procedure, see 4. If equipped , remove the cover (not shown) from the
SM Keysheet Area 01-005 . steering column (1) .
5. Label far assembly purposes and disconnect all
Removal electrical connections from the steering column
1. Lower, detach, and secure the load, as required. (1) .
2. Stabilize the crane for service as foliows: 6. Remove the capscrews, washers, and spacers (2)
a. Park the crane, out of the way, on a firm and that secure the steering column (1) to the mounting
level surface with the tires paraliel to the carrier plate (5).
frame (straight ahead). 7. Remove the capscrew and locknut (3) securing the
b. Engage the park brake and/or properly block steering column (1) to the steer shaft (4).
the tires. 8. Lih up on the steering column (1) to separate the
c. Engage the swing park brake or travel swing steering column (1) from the steer shah (4) . Se
lock, as required . cure the steer shah (4) out of the way.
d. Level the crane on fuliy extended outriggers . 9 . Remove the steering column (1) from the crane.
e. Position/support the boom , as required.
1 of 2
2. AII Loctite®, Permatex®, ar other sealant residue
should be removed Irom threads 01 hardware and
the mounting surlaces 01 parts that are going to be
with Loctite® 7070 Cleaner to ensure best perlor
manee 01 products.
3. Thoroughly inspect all parts lar damage, wear, la
tigue or stress Iractures, and corrosion. Repair ar
replace as required.
4. Inspect the integrity 01 the electrical wiring that
supplies the steering column. Repair ar replace if
required.
5. In the event 01 severe delects , contact lactary per
sonnel lor directions whether to repair or replace
any major component.
Installation
A WARNING
these products.
Figure 2
Steering Co lumn Orientation Reler to Figure 1.
1. Connect the steer shaft (4) to the steering column
(1), and install the capscrew and locknut (3) .
Note: Ensure the tires parallel to the carrier
frame (straight ahead).
A WARNING 2. Position the steering column (1) to the mounting

plate (5), and install the spacers , washers, and
hazardous. Serious personal injury may capscrews (2). Reler to Figure 2 for the correct ori
result from misuse of these products. Read entation 01 the steering column .
and fo llow all the manufacturer's 3. Connect the electrical connections to the steering
recommen dations concerning solvents and column (1).
cleaning solutions. 4. Complete the installation by testing al! steering
lunctions lar proper operation . Normal operation
1. AII components should be thoroughly cleaned with 01 the electrical system should be conlirmed. A
an approved cleaning sOlvent, air dried, and care general inspection of the components and
fully inspected. systems in the areas adjacent to the repair should
also be performed to ensure related damage ar
wear is no! present.
5. If equipped , install the cover (not shown) on the
steering column (1) .
2 of 2
Service Manual 0109 SM01 -005-035. 0 0
12. Remove the screws (4 ,21) , washers (3 ,22) , and tilt
Steering Column, stops (2,23) from the steering column (10) .
Recondition 13. If necessary, remove the turn signal (32) from the
steering column (10) .
This procedure covers the recondition of the steering 14. If necessary,remove the ignition switch (2 8) Irom
column . For removal and installation procedures, the steering column (10).
see SM Keysheet Area 01-005 . a. Remove the capscrews (31) which secure the
switch cover (30) to the steering column (10) ;
Disassembly remove the switch cover (30).
b. Remove the jam nut (29) Irom the igniti on
It is a good practice when disassembling complex switch (28).
components to lay the parts out in the order that they c. Remove the ignition switch (2 8) Irom the steer
were disassembled . Keeping the parts in this order ing column (10).
during disassembly, cleaning , and inspection will aid in d. If necessary the lock cylinder within the ignition
the assembly process . switch (28) can be removed by releaslng the
lock cylinder using the access hole in the side
If parts are hard to disassemble and assemble, do not of the ignition switch (28).
use a hammer unless it has a soft face , do not force
parts together, they must be free to rotate/operate and Cleaning And Inspection
not bind .
A WARNING A WARNING
Solvents and cleaning solutions can be Solvents and cleaning solutions can be
hazardous. Serious personal injury may hazardous. Serious personal injury may
result from misuse of these products. Read result from misuse of these products. Read
and follow all the manufacturer's and follow all the manufacturer's
recommendations concerning solvents and recommendations concerning solvents and
cleaning solutions . cleaning solutions.
1. Thoroughly clean all metal parts with an appr oved

Refer to Figure 1. cleaning solven!. Place parts on a clean, lint Iree
1. Remove the bolts (34) and washers (35) securing surface and allow to air dry. Exercise every precau
the bracket (33) to the steering column (10). tion possible to keep all parts free of dust, dirt , or
Remove the bracket (33). any other foreign material during assem bly.
2 . Remove the cover (13), spring (12) , and contact 2. AII Loctite®, Permatex®, or other sealant residue
(11) from the steering column (10) . Be careful not should be removed from threads 01 hardware an d
to damage the horn brush (9) . the mounting surfaces of parts that are going to be
3. Remove the nut (14) from the cover (13). reused. Prior to applying new thread locking co m
4. Remove the upper cover (1) , lower cover (15) , and pounds or sealants, clean threads an d su rfac es
trough cover (27) Irom the steering column (10) . with Loctite® 7070 Cleaner to ensure best pe rfor
5. Remove the pin (25) securing the actuator (16) to mance of products .
the steering column (10) . 3. Carefully inspect all components lor damage,
6. Remove the spring (26) and actuator (16) . wear, fatigue or stress fractures, corrosion , deep
7. Loosen the locknut (17) , and remove the knob (18) scratches, cracks, and scuffed metal. Rem ove any
from the actuator (16) . Remove the locknut (17) . burrs or sharp edges with a line file , hone , emery
8. Remove the retaining rin g (7) and washer (6) from cloth , or crocus cloth . Replace any damaged com
the end of the rod and pawl assembly (20) . ponent , as required.
9. Remove the pawl (5) and spring (8) from the rod 4. AII "soft parts ", such as seals , gaskets , back up
and pawl assembly (20) . rings , and 0- rings , should be replaced .
10. Remove the pin (24) from the rod and pawl assem
5. In the event of severe defects , contact factory per
bly (20) . sonnel for directions whether to repair or replace
11. Remove the rod and pawl assembly (20) and any major componen!.
spring (19).
1 014
2
3
23
}11i
13
14
15
1. Upper Cover 10. Steering Column 19. Spring 28. Ignltion Switch
2. Tilt Stop 11. Contact 20. Rod & Pawl Assembly 29. Jam Nut
3 Washer 12. Spring 21. Screw 30. Switch Cove r
4. Screw 13. Cover 22. Washer 31. Capscrews
5 Pawl 14. Nut 23. Tilt Stop 32. Turn Signal
6. Wash er 15. Lower Cover 24. Pin 33. Bracket
7. Retaining Ring 16. Actuator 25. Pin 34 . Bolts
8 Spring 17. Locknut 26. Spring 35 Washers
9. Horn Brush 18. Knob 27 Trough Cover
Figure 1
Steering Column Assembly
2 of 4
27
31
35
32
34
Steering Column Assembly - Continued
3 of 4
Assembly 2. If removed, install the ignition switch (28) and turn
signal (32) in tlle steering column (10).
3. Install tlle till stops (2,23) , wasllers (3,22), and
A WARNING 4.
screws (4,21).
Position Ihe spring (19) on tlle rod and pawl as
sembly (20) .
Lu bricants, sealants, joint and thread locking
com pounds, etc. can be hazardous. Serious 5. Compress the spring (19) , and install Ihe rod and
pawl assembly (20) through Ihe steering column
(10). Allow the spring (19) to expand into position
with the steering column (10).
6. Install Ihe pin (24) in the rod and pawl assembly
these products.
(20).
7. Position the spring (8) on the pawl (5) .
Refer to Figure 1. 8. Compress the spring (8) , and install the pawl (5) on
1 . If necessary, install the ignition switch (28) in the the rod and pawl assembly (20). Allow tlle spring
steering column (10) . (8) to expand into position with tlle steering column
a. If removed , align the lock cylinder within the (10) .
ignition switch (28) . 9. Install the locknut (17) on the actuator (16).
b . Rotate the lock cylinde r until the retaining ring 10. Install the knob (18) on the actuator (16), and se
on the lock cylinder goes inside the barrel of cure by tightening the locknut (17) against il.
the ignition switch (28). PUSll and rotate until 11. Position the actuator (16) to the steering column
you hear or feel the retaining ring snap into (10), and install the spring (26) and pin (25).
place. 12. Install the trough cover (27) , lower cover (15), and
c . Insert the key into the ignition switch (28). upper cover (1) to the steering column (10) .
Rotate the key to the "START" position and try 13 . Install tlle contact (11) and spring (12) on the steer
to pull the lock cylinder out of the ignition ing column (10) and against tlle horn brush (9).
switch (28). (This verifies the lock cylinder is 14. Install the nut (14) in the cover (13), and tighten the
properly installed and snapped in place.) cover (13) onto the steering column (10) .
d . Turn the key to the "OFF " position; remove the 15. Position the bracket (33) to the steering column
key. (10), and install the washers (35) and bolts (34).
e. Make the electrical connection and install the 16. If the steering column is not to be immediately
ignition switch (28) in the steering column (10). installed on the crane, properly store to prevent
f. Install the jam nut (29) on the ignition switch damage and contamination.
(28) .
g. Align the switch cover (30) to the steering col
umn (10) .
h. Install the capscrews (31) which secure the
switch cover (30) to the steering column (10).
4 of 4
Steering Gears, draulic pump , as equipped .
Recondition
This document covers the recondition of the
Sheppard O-Series power steering gears. For
A WARNING
troubleshooting or removal and installation hazardous. Serious personal injury may
procedures, see SM Keysheet Area 01-005 or result from misuse of these products. Read
01-006. and follow all the manufactu rer's
Both master steering gears and slave steering gear cleaning solutions.
units are covered. However, some individual
procedures may only apply to one or the other type 4. Thoroughly clean the area to be disassembled with
units . an approved cleaning solvent to prevent conta
mination. Allow the area to air dry.
It is a good practice when disassembling hydraulic
components to lay the parts out in the order that they
were disassembled . Keeping the parts in this order
during disassembly, cleaning, and inspection will aid in
A WARNING
Hydraulic oil is under pressure and may be
hoto A sudden release of hot oil could cause
If parts are hard to disassemble and assemble , do not burns or other serious injury. Shutdown the
use a hammer unless it has a soft face, do not force engine and exhaust all trapped hydra ulic
parts together, they must be free to rotate/ operate and pressure from the system before removing
not bind.
any line or component.
The following procedures are covered: . . . . . .. page
5. Relieve the hydraulic system pressure as follows :
Pitman Arm Removal ..... .. . ..... . ....... . . . 1 a . Release any residual pressure in the hydraulic
Pitman Arm Installation .. . ...... . ............ 4 reservo ir by slowly loosening the filler/breather
Input Shaft Seal Replacement . . .... . . . ....... 5 cap, located on the top of the hydraulic
Sector Shaft Seal Replacement ..... . . . ... . ... 7 reservoir, until pressure is fully relieved .
End Cap Seal Replacement ... ...... . . . . . . . .. 11 b . Turn the ignition switch to " ON" , but DO NOT
Bearing Cap Seal Replacement . . . . . . . . . . . . . .. 12 START THE ENGINE. Move the function lock
out sw itch to the "OPERATE " position.
Pitman Arm Removal
c. Work the crane control levers and outrigger
The pitman arm may need removal on some cranes switch es back and forth several times .
before removing the steering gear. Proper technique in d. Rotate the steering wheel back and forth sev
removing the pitman arm will avoid damage to the eral times.
steering gear, pitman arm , and retainer. e. Turn the ignition switch to the " OFF" position .
1. Lower, detach , and secure the load, as required. 6. Drain any excess hydraulic oil remaining within the
2. Stabilize the crane for service as follows: steering gear into an appropriate container. Prop
a. Park the crane , out of the way, on a firm and erly store or dispose of the used oil.
level surface. 7. Cap/ plug any openings in the steering g ear and
b. Engage the park brake and/ or properly block thoroughly clean the exterior su rface to prevent
the tires. contamination from entering the unit.
c . Engage the swing park brake or travel swing
lock, as required .
d. Level the crane on fully extended outriggers .
e. Fully retract and position the boom , as re
quired.
1 of 14
SM01 -005-037.00 0510 Service ManuaJ
14
11
8 __
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15
16
7
5
4
3 "
( \~-
2
= 31
21
\ JII)) 32
- </22
-d~ 33
28
'{(P
25
24
23
1. Protective Cover 10. Seal Ring 18. Input Shaft Seal 26. Bearing Cap*
2. Retalning Ring 11 . Oir! Seal 19. Cover - Bearing Cap 27. Seal
3 Sector Shaft Cover 12. Boot 20. Salt Seal 28. Seal Ring
4. Seal 13. Pitman Arm 21. Relief Plunger 29. Piston
5. L-Seal 14. Retainer 22. O-ring 30. Housing
6. Seal 15. Relief Valve 23. Oir! Seal 31. Shaft Seal
7. Capscrews 16. Thrust Washer 24. Input Shaft 32. Sector Shaft
8. Relief Plunger 17. O-ring 25. Capscrews 33. Shaft Seal
9 End Cap'
" Note: Slave steering gear units do not utilize a bearing cap and input shaft. Slave steering gears have an end cap
on both ends of the unit.
Figure 1
Steerin Gear Assembl ical Master Gear Shown
2 of 14
10. To remove pitman arm with gear puller:
a. Use an impact wrench to remove the retai ner.
b. Place a steel block within the retainer cavity
and center it over the threaded hole in the enel
of the sector shaft.
c. Install the gear puller jaws under the pitman
arm, and center the gear puller jack screw on
the metal block .
d. Carefully tighten the jack screw of the gear
puller until the pitman arm disengages from
the sector shaft; remove the pitman armo
CAUTION
removing the pitman armo The pitman arm has
alignment tabs, while the retainer has
restraining tabs. Do not bend the alignment
tabs out of the pitman armo See Figure 2.
Figure 5
Lubricate The Face Of The Retainer
11 . To remove pitman arm with puller cup:

a. Lubricate the face of the retainer with clean
chassis lube.
Note: Lubricating the face of the retainer
will greatly ea se rotation of reta iner and fa
cilitate pitman arm removal.
8. Use a punch to bend the restraining tabs out of the

pitman arm retainer.
Or
.:..
Figure 6
Install Pitman Arm Puller Cu
3A 25241
Three Jaw Pitman Arm
b. Slide the puller cup over the pitman arm, as
Gear Puller Puller Cup shown . Be sure to center the access hole over
Figure 4 the hex socket in the retainer.
Special Tool Required To Remove Pitman Arm C. Insert the hex drive socket through the pull er
cup and ¡nto the retainer socket.
9. One of the special tools shown in Figure 4 will be
required to remove the pitman arm from the sector
shaft. Choose Step 10 or Step 11 depending on
tOO!.
3 of 14
A WARNING : :
The pitman arm will be extremely tight. Do not

use a ha mmer or apply heat to the armo
Damage to the pitman arm or sector shaft can
cause 1ailure and/or an accident at a later
date.
d. Use an impact wrench to back off the retainer.

The retainer will act as a jackscrew to disen Figure 8
gag e the pitman arm; remove the pitman arm o Alignment Tabs (Do Not Bend)
Pitman Arm Installation 4. Install the pitman arm retainer into the sector shaft,
taking care to align the tabs in the notches of the
Proper pitman arm installation is crucial to the safe armo
operation of the crane. Correct torque values are very 5. Tighten the retainer with hand tools and a torque
imp ortant l Always follow these procedures when wrench. Do not use an impact wrench. Torque re
installing the pitman armo Any time a pitman arm is tainer to value stamped on the face of the retainer.
found loase, replace the pitman arm and the sector
shafl . If the pitman arm is not installed as specified, it
ca n cause an accident.
1. Properly mount the steering gear on the carrier
frame . See SM Keysheet Area 01-005 for com
plete instructions.
------~=
ure 9
n Restraining Tabs With Retainer Slots
6. Check the alignment of the restraining tabs and re
tainer. If necessary continue torquing the retainer
beyond the specified value until at least two of the
notches in the retainer align with the restraining
tabs of the washer.
Figure 7
Sector Shaft Timing Marks A DANGER
Do not back off the torque on the retainer to
2. Install the pitman arm onta the sector shaft, taking align the restraining tabs. A loose pitman arm
care to align the timing marks. will become damaged and/or result in 105501
steering control. Continue to tighten the
Note: Timing marks may vary in alignment. See retainer to align the restraining tabs.
Steeríng Gears, R & /, in SM Keysheet Area
01-005 or 01 -006, to confirm exact orientation 7. Use a punch and hammer to bend the restraining
01 timing marks. tabs of the washer into the notches of the retainer.
3. Apply anti-seize compound to the threads of the

retairier and both sides of the restraining washer.
CAUTION
installing the pitman armo The pitman arm has
alignment tabs, while the retainer has
restraining tabs. Do not bend the alignment
tabs out 01 the pitman armo See Figure 8.
4 of 14
Input Shaft Seal Replacement 6. Drain any excess hydtaulic oil remaining wit hin th e
steering gear into an appropriate container. Prop
The input shaft seal of the master steering gear may be erly store or dispose of the used oil.
replaced while the steering gear is still installed on the 7. Cap/pilug any openings in the steering gear to pre
crane . vent contamination from entering the unit.
1. Lower, detach, and secure the load, as required. 8. Disconnect t,he steering shaft yoke from the input
2. Stabilize the crane for service as follows: shaft. See Steering Miter Box, R & I in SM Keyslleet
a. Park the crane, out of the way, on a firm and Area 01-005 or 01 -006 for further instructions.
level surface.
b. Engage the park brake and/or p roperly block
the tires.
lock, as required.
e. Fully retract and position the boom, as re
quired .
draulic pump, as equipped.
A WARNING The Bearing Cap Cover

hazardous. Serious personal injury may 9. Remove the capscrews which secure the bearing
result from misuse of these products. Read _cap cover over the input shaft. Remove just the
and follow al! the manufacturer's cover. The thrust washer should remain in place on
recommendations concerning solvents and the input sllaft.
cleaning solutions.
Note: The thrust washer may stick to the bear
ing cap cover. If it does, reinstall the thrust
washer over the input shaft and on top of the
an approved cleaning solvent to prevent conta
thrust bearing.
A WARNING
CAUTION
Do notturn the input shaft with the bearing cap
cover removed. Turning the shaft or mixing of
hot. A sud den release of hot oil could cause components may cause damage to the input
burns or other serious injury. Shutdown the shaft, rotary valve, thrust bearings, and/or
engine and exhaust al! trapped hydraulic bearing cap.
pressure from the system before removing
5. Relieve the hydraulic system pressure as follows:

a. Release any residual pressure in the hydraulic
reservoir by slowly loosening the filler/ breather
cap, located on the top of the hydraulic
reservoir, until pressure is fully relieved .
b. Turn the ignition switch to "ON", but DO NOT
STARTTHEENGINE. Movethefunction lock
out switch to the "OPERATE" position .
switch es back and forth several times. Figure 11
d. Rotate the steering wheel back and forth sev Remove Salt Seal From Bearing Ca p Cover
eral times.
e. Turn the ignition switch to the "OFF" position . 10. Remove the salt seal from the bearing cap caver.
5 of 14
SM01- 005-037.00 0510 Service Manual
Note: Make sure the lip of the seal faces up
when installing the input shaft sea 1. The garter
spring will be visible when properly installed.
14. Coat the outside diameter of the input shaft seal

with elean ehassis lube.
Figure 12
Remove 0 - ring Frorn Bearing· Cap Cover
11 . Remove the 0- ring from the inside boss of the

beari ng eap eover.
Figure 15
Install O-ring On Bearing Cap Cover
15. Install the o-ring on the inside boss of the bearing

cap eover. Make sure the o-ring is not twisted.
Figure 13
Remove The Input Shaft Seal
12. Using an appropriate sized socket or seal driver,

tap the input shaft seal (high pressure seal) out of
the bearing cap cover and discard it.
Figure 16
~F0J501 Install The New Salt Seal
16. Press the salt seal into the bearing cap cover until it
is flush with the face of the bearing cap cover.
Figure 14
Insta 11 The New Input Shaft Seal
13. Place the bearing cap cover face down on a elean

work surface . Install the input shaft seal in tlle
beari ng cap cover using a suitable size seal driver
and an arbor press.
6 of 14
a. Park the crane, out of the way, on a firm and
level surface.
b. Engage the park brake and/or properly block
the tires .
C . Engage the swing park brake or travel swing
lock, as required .
quired .
draulic pump , as equipped.
Figure 17
Apply Masking Tape To Input Shaft Splines
.A WARNI NG
17. Using masking tape or similar material , wrap the
splines on the input shaft to prevent damage to the
result from misuse of these produ cts. Read
shaft seal as the bearing cap cover is installed.
18. Lube the the o-ring and shaft seal with a light coat
recommendations concerning so lvents and
of grease.
cleaning solutions.
19. Install the bearing cap cover. Be sure to align the
small hole in the bearing cap cover with the relief
4. Thoroughly clean the area to be disassembled w ith
plunger.
20. Secure the bearing cap cover with capscrews.
Evenly tighten the capscrews in a criss-cross pat
tern o Torque the capscrews to 53-64 ft lb
(72-87Nm) .
21. Remove the masking tape from the input shaft .
22 . Install the steering shaft yoke to the input shaft .
.A WARNI NG
Hydraulic oil is under pressure an d may be
See Steering Míter Box, R & I in SM Keysheet Area hot. A sudden release of hot oíl could cause
01 -005 or 01 -006 for further instructions. burns or other serious injury. Shutdown the
23 . Check the hydraulic reservoir oil level. Add oil as engine and exhaust all trapped hydraulic
required. See the Operator's Manual for the pressure from the system before removing
correct type and procedure. any line or component.
24. Engage the main hydraulic pump, as equipped .
25. Start the engine and let idle for five minutes . 5 Relieve the hydraulic system pressure as follows :
Inspect the hydraulic connections for leaks . a. Release any residual pressure in th e hydra ulic
Repair leaks as required. reservoir by slowly loosening the filler/breather
26. Complete the installation by testing all related cap , located on the top of the hydraulic
functions of the steering gear for proper operation . reservoir, until pressure is fully relieved.
b. Turn the ignition switch to "ON ", but DO NOT
Sector Shaft Seal Replacement STARTTHE ENGINE. Movethe function lock
The sector shaft seal of the steering gear may be out switch to the "OPERATE" position .
replaced while the steering gear is still installed on the C. Work the crane control levers and outrigger
crane. However, the steering gear must be mounted in switch es back and forth several times.
such a manner that enough access and clearance is d. Rotate the steering wheel back and forth sev
available to remove the pitman arm and sector shaft. If eral times .
such access and clearance is not available, first e. Turn the ignition switch to the "OFP' posilion .
remove the steering gear from the crane. See SM
Keysheet Area 01-005 or 01-006 for complete 6. Drain any excess hydraulic oil remaining within th e
procedure . steering gear into an appropriate container. Pro p
erly store or dispose of the used oil.
1. Lower, detach , and secure the load , as required.
7. Cap/ plug any openings in the steering gear to pre
vent contamination from entering th e unit.
7 of 14
SM01-005-037.00 0510 Service Man'ual
8. Disconnect the steering shaft yoke from the input
shaft. See Steering Miter Box, R & I in SM Keysheet
Area 01 -005 or 01-006 for further instru ctions.
9. Remove the pitman armo See Pitman Arm Removal
found on Page 1 of this document.
Figure 19
Remove The Retaining Ring
14. Remove the retaining ring using a suitable pair of

retaining ring pliers.
15. Ifthe steering gear is still mounted on the crane,
install a slide hammer to the tapped hole used for
the pitman arm retainer.
10. Remove the rubber boot from the sector shaft and 11 the steering gear is removed 1rom the crane,
discard. Retaining ring may be equipped with a drive the cover and sector shaft out of the housing
protective cap. Pry the cap out of the housing from the opposite side.
bore. Take care to not damage the housing during
removal.
11 . Clean any RTV sealant from the retaining ring area.
12. Rem ove the adhesive plastic dust cover from the
back side of the housing, if equipped.
13. Carefully clean any paint or corrosion from the
housing to allow the cover to slide freely out of the
housin g.
A. WARNING
Take care when removing the retaining ring
Figure 20
Remove Cover And Sector Sha1t
from the steering gear housing. Spring
tension on the retaining ring can cause it to
slip off of the pliers, resulting in personal 16. Remove the sector shaft and cover from the steer
injury. Wear gloves and eye protection when ing gear housing.
removing the retaining ringo
Figure 21
Separate The Cover And Sector Shaft
17. Separate the cover from the sector shaft.
8 of 14
18. Inspect the sector shaft for corrosion or damage.
Replace the sector shaft if necessary.
,...,.,.,.,~--,~=,.,.,.,.,
Figure 24
Install Sector Shaft In Housing
Figure 22
Remove Excluder Seal From Cover
19. Remove the seals from the housing and cover us
ing a seal pick. Take care not to damage the seal
A DANGER
bore. Carefully pry the pressed-in excluder seal Sector shaft timing marks must be properly
from the cover. Remove the two-piece L-seal aligned. Failure to align marks will result in
from the housing. lack of steering and/or damage to steering
linkage. Properly align sector shaft timíng
marks.
22. Install the sector shaft into the housing takin g care
to align the timing mark on the sector shaft with th e
timing marks on the piston. It may be necessary to
tap on the sector shaft to properly seat it into the
housing.
Figure 23
Install Sector Shaft Seal In Cover & Housing
20. Install a new sector shaft seal in both the cover and
the housing . The sector shaft seals are two-piece
seals that must be bent to install them. Take care to
install the oil seal with the lip toward the inside 01
the gear. To properly seat the seal once it is in Figure 25
place, it may be necessary to work the seal with Install Sector Shaft Cover on Housing
your lingers or a blunt seal pick. When using a
blunt seal pick to seat the seal, push only on the
23. Install the sector shaft cover onto the steering gear
body 01 the seal and not on the seallip. Damage to
housing. Insure that the cover is fully seated. Light
the seal lip will cause an oil leak.
blows with a rubber mallet may be required to in
Note: Install the sector shaft seals so the lip stall the cover. Use only sufficient force to seat the
side of the seal faces the inside of the steering cover. Excessive force on the cover could damage
gear. the sector shaft cover or bearing , damaging t he
steering gear. The cover must be installed flush
21. Lubricate the seals with clean grease after installa with or below the snap ring groove in the housing.
tion .
9 of 14
Figure 26 Figure 27
Install Retaining Ring In Housing Install Excluder Seal
26, If equipped with an excluder seal, pack the seallip

with clean grease, Using a suitable size seal driver
A WARNING
Take care when installing the retaining ring in
and hammer, install the seal over the sector shaft
splines into the seal groove of the cover. Apply a
bead of grease over the excluder seal and slide the
the steering gear housing. Spring tension on
rubber boot over the sector shaft,
the retai ning ring can cause it to slip off 01 the
27. Install the steering shaft yoke to the input shaft,
pliers, resulting in personal injury. Wear
See Steering Miter Box, R & I in SM Keysheet Area
gloves and eye protection when removing the
01 -005 or 01 -006 for further instructions .
retaining ringo
28, Check the hydraulic reservoir oil leve!. Add oil as
required , See the Operator's Manual for the
2 4, Install the retaining ring to secure the cover,
correct type and procedure.
29. Engage the main hydraulic pump, as equipped.
A DANGER
30. Start the engine and let idle for five minutes,
Inspect the hydraulic connections for leaks,
Repair leaks as required,
Use care to be sure the retaining ring is 1ully
seated in the housing groove. An improperly 31, Complete the installation by testing all related
seated retaining ring can come out without functions of the steering gear for proper operation .
warning. Proper installation 01 the retaining
ring ensu res the steering gear unít wíll not
come apa rt duríng operation, resulting in loss
01 steering.
25 . tf equ ipped , installthe retaining ring protectivecov

er into the housing over the retaining ring by lightly
tapp ing on the outside diameter of the cover until it
bottoms in the bore. It may be necessary to tap on
the Mdy of the seal with a drift punch and hammer
to fully seat the protective cover, Retaining ring
protective covers must be flush or below the retaín
ing ring groove when properly installed .
10Of 1a
End Cap Seal Replacement 5. Relieve the hydraulic system pressure as follows:
The end cap seals of the steering gears may be reservoir by slowly loosening thefiller/breather
replaced while the steering gear is still installed on the cap, located on the top of the hyd rau lic
crane. However, the steering gear must be mounted in reservoir, untll pressure is fully relieved.
such a manner that enough access and clearance is b. Turn the ignition switch to "ON", b ut DO NOT
available to remove the end cap. If such access and START THE ENGINE. Move the functi on lock
clearance is not avaílable, first remove the steering out switch to the "OPERATE" position.
gear from the crane. See SM Keysheet Area 01-005
c. Work the crane control levers and outrigg er
for complete procedure. switch es back and forth several times.
1. Lower, detach, and secure the load, as required. d. Rotate the steering wheel back and fo rtl1 sev
2. Stabilize the crane for service as follows: eral times.
a. Park the crane, out of the way, on a firm and e. Turn the ignition switch to the "OFF" positi on .
level surface.
b. Engage the park brake and/or properly block 6. Drain any excess hydraulic oil remaining within the
the tires. steering gear into an appropriate containe r. Prop
c. Engage the swing park brake or travel swing erly store or dispose of the used oil.
lock, as required. 7. Cap/plug any openings in the steering gear to pre
d. Level the eran e on fully extended outriggers. vent contamination from entering the unit.
e. Fully retract and position the boom, as re Refer to Figure 1.
quired. 8. Place index marks on the end cap (9) and hou sin g
3. Shutdown the engine and disengage the main hy (30) to ensure proper alignment during assembly.
draulic pump, as equipped. 9. Remove the capscrews (7) from the end cap (9) us
ing a suitable size socket; remove the end cap (9).
.A WARNING
10. Remove the seal ring (10) and seal (6) from tll e end
cap (9) and discard.
11. Thoroughly clean all surfaces of the end cap (9)
with an approved solvent or cleaning solution; al
low it to air dry.
12. Applya light coat of clean grease to the new seal
ring (10) and seal (6).
13. Install the new seal ring (10) and seal (6) in tll e end
cleaning solutions.
cap (9).
14. Align the index marks placed on the end cap (9)
and housing (30) during disassembly.
15. Install the end cap (9) onto the housing (30), and
secure it with the capscrews (7). Tig hten the cap
screws (7) evenly in a criss-cross pattem . Torque
.A WARNING
the capscrews to 114-140 ft lb (154 -190Nm ).
16. Check the hydraulic reservoir oil level. Add oil as
required. See the Operator's lVIanual for t he
hoto A sud den release of hot oil could cause correct type and procedure.
burns or other serious injury. Shutdown the 17. Engage the main hydraulic pump, as equipped .
engine and exhaust all trapped hydraulic 18. Start the engine and let idle for five minutes .
pressure from the system before removing Inspect the hydraulic connections for leaks .
any line or component. Repair leaks as required.
19. Complete the installation by testing all related
functions of the steering gear for proper op eration .
11 of 14
Bearing Cap Seal Replacement c. Work the crane control levers and outrigger
switches back and forth several times.
The bearing cap seals of the steering gears may be
d. Rotate the steering wheel back and forth sev
replaced while the steering gear is still installed on the
eral times.
cran e. However, the steering gear must be mounted in
e. Turn the ignition switch to the "OFF" position.
such a manner that enough access and clearance is
6. Label for assembly purposes and disconnect the
availab le to rernove the bearing cap. If such access
hydraulic lines from the steering gear.
an d clearance is not available, first remove the steering
7. Drain any excess hydraulic oil remaining within the
gear fro m the crane. See SM Keysheet Area 01-005
steering gear into an appropriate container. Prop
far complete procedure.
erly store or dispose of the used oi!.
1. Lower, detach, and secure the load, as required. 8. Cap/plug any openings in the steering gear to pre
2. Stabilize the crane for service as follows: vent contamination from entering the unit.
a. Park the crane, out of the way, on a firm and 9 . Disconnect the steering shaft yoke from the input
level surface. shaft. See Steering Miter Box, R & I in SM Keysheet
b . Engage the park brake and/or properly block Area 01-005 or 01-006 for further instructions.
the tires.
Refer to Figure 1.
c. Eng age the swing park brake or travel swing
10. Place index marks on the bearing cap (26) and
lock, as required.
housing (30) to ensure proper alignment during
assembly.
11 . Remove the dirt seal (23) from the input shaft (24) .
qu ired.
12. Remove the capscrews (25) that secure the bear
ing cap (26) to the housing (30).
draulic pump, as equipped .
13. Rotate the input shaft (24) to move the bearing cap
(26) away from the housing (30) . Do not fully sep
A WARNING
arate the bearing cap (26) from the housing (30) .
14. Using a seal pick , remove the seal ring (28) and
seal (27) from the bearing cap (26) and discard.
hazardous. Serious personal injury may 15. Warm the new seal ring (28) in hot water to allow it
result from misuse of these products. Read to stretch easily.
and foll ow all the manufacturer's 16. Carefully stretch the seal ring (28) over the bearing
recomm endations concerning solvents and cap (26) assembly. Take care not to over-stretch
cleaning so lutions. the seal ring (28).
17. With the seal ring (28) over the bearing cap (26),
4. Th oroug hly clean the area to be disassembled with push the seal ring (28) into the groove of the bear
an approved cleaning solvent to prevent conta ing cap (26). Apply clean grease to hold the seal
mination. Allow the area to air dry. ring (28) in place.
18. Install the seal (27) in the smaller groove of the
bearing cap (26). Apply clean grease to hold the
A WARNING
seal (27) in place.
19. Remove the relief plunger (21) .
20. Remove the o-ring (22) from the relief plunger
hot. A su dden release of hot oil could cause (21) .
burns or other serious injury. Shutdown the 21. Coat the new o-ring (22) with clean grease, and
engine and exhaust all trapped hydraulic install it on the relief plunger (21).
pressure from the system before removing 22. Apply Loctite® 242 to the threads of the relief plun
any fine or component. ger (21), and install the relief plunger (21) back into
the bearing cap (26).
5. Relieve the hydraulic system pressure as follows : 23. Rotate the input shaft (24) to move the bearing cap
a . Release any residual pressure in the hydraulic (26) toward the housing (30), and align the index
reservoir by slowly loosening the filler/breather marks placed on the bearing cap (26) and housing
cap, located on the top of the hydraulic (30) during disassembly.
reservoir, until pressure is fully relieved. 24. Secure the bearing cap (26) in place with the cap
b. Tu rn the ignition switch to "ON", but DO NOT screws (25). Tighten capscrews (25) evenly in a
START THE ENGINE. Move the function lock criss-cross pattern . Torque the capscrews to
out switch to the "OPERATE" position. 114 - 140 ft lb (154 - 190Nm) .
12 of 14
25. Install the steering shaft yoke to the input shaft. 27. Engage the main hydraulic pump, as equipped.
See Steering Miter Box, R & I in SM Keysheet Area 28. Start tlle engine and let idle for five minutes .
01-005 or 01 -006 for further instructions . Inspect the hydraulic connections for leaks .
26. Check the hydraulic reservoir oil level. Add oil as Repair leaks as required.
required. See the Operator's Manual for the 29. Complete the installation by testing all related
correct type and procedure. functions of the steering gear for proper operation .
13 of 14
14 of 14
Front
4
2
2
3
1. Clamps 4. Straight Edge
1. Tire 3. Axle 2. Tie Rod 5. Tire
2. Stationary Obiect 3. Carrier Frame
Figure 1 Figure 2
Tire & Rim Alignment Wheel Alignment
5. If any of the tires (1) are misaligned, correct the

Front Wheel Alignment And problem before proceeding. See SM Keysheet
Steering Linkage Adjustment Area 01 -069 for the correct rim and tire installation
procedure.
6. Engage the park brake and fully retract the
This document includes the following procedures:
outrigger jacks and beams.
Wheel Alignment ......................... page 1
Linkage Adjustment .... . . ...... .. ........ page 2 Refer to Figure 2.
Axle Stop Adjustment ... . . ...... . . ........ page 3 7. Turn the steering wheel to align the left front tire (5)
parallel with the carrier frame (3). This can be done
Wheel Alignment by placing a straight edge (4) on the outside of the
Wheel alignment should be perfarmed on each axle tire and equalizing the distance at "A".
independently and then synchronized by adjusting the 8. Shutdown the engine and measure the distance
steering linkage. from the centerline of one tire (5) to the centerline of
the other. Make this measurement at the front and
1. Properly park the crane and level it on outriggers. rear of the tires, "B" and "C".
Move the air ride switch to the "Up" position and 9. Proper "toe-In" requires the distance at "B" to be
shutdown the engine. 0.60-0.98 in (15-25mm) less than the distance at
2. Check the air pressure in the tires far proper "C".
inflation. 1O. If adjustment is required, loosen the clamps (1) on
Refer to Figure 1. each end of the tie rod (2) and rotate the tie rod to
3. Check each front tire (1) for proper alignment and achieve the proper measurements at "B" and "C".
mounting to the axle (3). Place a stationary object Torque the tie rod clamps (1) to 45-55 ft lb
(2) on the floor beside the tire (1), and rotate the tire (62-74Nm).
(1) . 11. Roll the crane forward at least 50 ft (15m) and
4. Note any variation in the distance between the tire repeat Steps 7 thru 10 to check the adjustment.
(1) and stationary obJect (2) as the tire (1) is 12. Repeat Steps 7 thru11 to properly align the wheels
rotated. If the variation in distance exceeds 0.19 in of the second axle.
(5mm) , the tire (1) is misaligned.
1 of 4
2 3 4 5 6
66.74" (1.70m)
.- -- 32.63"
(O. 83m)
,
11 9 8 7 10 9 8
1. Mlter Gear Sox 5. Slave Steering Gear 9. Sal! Studs, Castle Nuts, & Cotter Pins
2. Steering Shatt 6. Pitman Arm 10. Steering Link
3. Capscrews & Locknuts 7. Draglinks 11. Pilman Arm
4. Master Steering Gear 8. Capscrews, Nuts, & Clamps
Figure 3
Steering Gears & Linkage
Linkage Adjustment Refer to Figure 3.

1. Level the crane on outriggers to ease access to the 7. Loosen the nuts and capscrews on the clamps (8)
steering linkage. Position the tires straight ahead on each end of the draglinks (7) .
8. Apply a light coating of anti-seize compound to
and shutdown the engine.
the tapers of the ball studs (9).
Refer to Figure 3. 9 . While holding the ball studs (9) stationary, rotate
2. Using a ball joint removal tool, disconnect the the draglinks (7) , as required, to make the
draglinks (7) from the pitman arms (6,11) by connection with the pitman arms (6 ,11) . (Be sure
removing the cotter pins and castle nuts from the the pitman arms (6 ,11) are positioned per the
ball studs (9) . dimensions shown in Figure 4 when the
3. Loosen the capscrew and locknut (3) and connections are made.)
disconnect the steering shaft (2) from the master 10. Install the castle nuts (9) on the ball studs (9) and
steering gear (4) . Allow the steering shaft (2) to torque the castle nuts (9) at each end of the
hang from the miter gear box (1) . draglinks (7) to 120-170ft lb (163-230Nm) .
4. Check the steering link (10) for proper length. 11 . Hit each ball stud (9) several times with a rubber
Adjust as required . See Figure 3 for correct mallet to ensure they are fully seated . Torque the
dimensiono castle nuts (9) again to 120-170 ft lb
Refer to Figure 4. (163-230Nm) .
5. Manually rotate both pitman arms (3 ,7). as
Note: During torque process, align best
required, so they are positioned per the
applicable hole in castle nut with hole in ball
dimensions shown.
stud to allow for installation of cotter pino
Refer to Figure 2.
6. Manually align the left front tire (5) , of both front
axles , parallel with the carrier frame (3). This can
be done by placing a straight edge (4) on the
outside of the tire and equalizing the distance at
"P\'.
2 of 4
2 3 4
Front
- -",..
Front
~- -
<IT:
_1 J
rcr;J,
-.oLJ._-_ - J
-'¡¡4-
0 .58 in 0.58 in
(14.7mm) (14.7mm)
1 Relief Plunger - Limits Left Turn s 5. Carrier Fra me
2. Master Steering Gear 6. Slave Steeri ng Gea r
3 Pitm an Arm 7. Pitman Arm
4. Relief Plunger - Limits Right Turns
Figure 4
Steering Gears & Linkage
12. Install the cotter pins (9) through the castle nuts Axle Stop Adjustment
(9).
This procedure is potentially very dangerous . It
Note: Bend the cotter pins away 1rom the tires to
requires no fewer th an three people to perform . One
prevent tire damage.
person to operate the steering, one person to make
adjustments , and one person to carefully watch so no
A WARNING
one gets hurt. The tire and rim assemblies must be
installed before setting the axle stops. See SM
Keysheet Area 01 -069 for the correct procedure .
A correctly assembled draglink will have an
equal amount 01 threads exposed at each ball
stud. Improper engagement 01 either ball 1. Properly align the front wheels and adjust the
steering linkage. See "Wheel Alignment " and
stud could result in steering 1ailure.
"Linkage Adjustment" in this document.
2. Position the wheels straight ahead and fully retra ct
13. Torque the nuts and capscrews (8) on each end of
the outriggers .
the draglinks (7) to 45-55 ft lb (62-74Nm). Be
sure to orient the clamps (8) so they will not hit Refer to Figure 6 .
anything as the draglinks (7) move back and forth . 3 . Loosen the jam nuts (not shown) and tighten all the
14. Once again, check the orientation of the front tires stop bolts (1) into the steering knuckles (2), as far
as described in Step 6 . as possible, on both axles.
15. Position the steering wheel in the carrier cab for Refer to Figure 4 .
straight ahead travel, as shown in Figure 5. 4. Rotate the relief plungers (1,4), on each end of the
16. Connect the steering shaft (2) to the Iront master master steering gear (2), all the way in until they
steering gear (4). Be sure to maintain the position bottom out.
of the steering wheel, pitman arm (11), and wheel
alignment.
17. Torque the capscrew and locknut (3) on each end
of the steering shaft (2) to 50-55 ft lb (68 -74Nm).
3 of 4
Correet Orientation Of
Steering Wheel With / '
/.'
The Tires Parrallel To
The Carrier Frame
(Tires StraightAhead).
., .
'8h~1
· : ~0.06in
/ (1.5mm)
1. Stop Bolts 3 Axle Stops

2. Steering Knuckl es
Fig ure 5 Figure 6

Steering Wheel Orientation Axle Stop Adjustment
8. With the crane on tires and the engine running ,
A DANGER
Use extreme eaution when operating the
turn the steering wheel clockwise, as far as
possible , until the tires or linkage approach contact
with the tires , steering linkages , fenders , brake
erane with someone under the earrier. The chambers , and any other possible obstructions .
hydraulie force behind the steering 9. Turn the steering wheel counterclockwise and
eomponents is eapable of killing or severely adjust the other relief plunger (1 , Figure 4) and
injuring anyone eaught in the steering linkage stop bolts (1 , Figure 6) in the same manner as in
or trapped behind a tire . Post a signalman to Steps 7 and 8.
wateh earefully to ensure the safety of the 10. With the eng ine at idle, check that the relief
person under the earrier. plungers are functioning by fully rotating the
steering wheel in one direction and holding . A
5 . With the crane on tires and the engine running, noticeable decline in the engine speed indicates
turn the steering wheel clockwise , as far as the steering knuckle (2) is contacting the axle stops
possible, until the tires or linkage approach contact (3) and that the relief plunger is backed off too faro
with the carrier frame , axle , linkage, tires , or any Adjust as required .
other obstruction . 11 . Repeat Step 10, steering the opposite direction , to
check the other relief plunger.
Note: Do not baek off the relief plunger beyond 12. With the crane on fully extended outriggers , the
flush with the boss on the steering gear or leak transmission in neutral , and the engine runnin g,
age may oeeur. steer fully left and then right , checking the
clearances between the tires , steering linkages ,
6. Slowly back off the relief plunger (4), while fenders , brake chambers, and any other possible
continuing to turn the steering wheel clockwise, obstructions . Make any adjustments as required .
until 0.50 in (13mm) clearance is maintained from Check for clearance between tires and all parts
the closest point of undesired contact. during fullleft and right turn positions .
Refer to Figure 6 . 13. Complete the alignment procedures by testing all
7 . Turn the stop bolts (1) on t he steering knuckles (2) related functions of both steer axles for proper
to wit hin 0 .06 in (1 .5mm) of the axle stops (3). operation. Normal operation of hydraulic, air, and
electrical systems should be confirmed . A general
performed to ensure related damage or wear is not
present.
4 of 4
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7
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16
17
Key* 7. Washer 13. Orive Gear
2. Plug** 8. Front Plate 14. Idler Gear
3. Washers 9. O-ring 15. Body
4. Capscrews 10. Back Up Gasket 16. O-ring
5. Retaining Ring* 11. Seal 17. Back Plate
6. Shaft Seal 12. Wear Plate
* Optional
** Location Varies Oepending On Pump Rotation. Left Hand (CCW) Rotation Shown.
Figure 1
Power Steering Pump Assembly
Refer to the following pages for specific procedures

Power Steering Pump, General Instructions ...................... Page 2
Recondition Pump Disassembly .................... . .. Page 2
Back Plate Disassembly ................ . .. Page 3
Back Plate Assembly ......... . ....... . . .. Page 6
This procedure covers the recondition of the power
Cleaning And Inspection .................. Page 4
steering pump. For removal and installation
Pump Assembly ......................... Page 6
procedures, see SM Keysheet Area 1-10.
Changing Input Rotation Of Pump ...... . ... Page 8
Test Procedures ................... . ..... Page 10
Troubleshooting ... , ............ . . . ...... Page 11
Wear Plate Identification ............. ,., .. Page 9
1 of 12
General Instructions
• Cleanliness is extremely important. CAUTION
• Drain the oil and clean the exterior of the pump Do not grip on any machined surfaces.
befare making repairs. Excessive force while clamping could result in
Wash all metal parts in clean approved solvent. misalignment and/or serious damage to
• Use filtered, moisture free compressed air to dry parts. Take extreme care not to mar or
the parts . Do not use paper towels or cloth. damage any machined surface. Do not clamp
• Always use new seals when reassembling the in any form of vise unless jaws are protected
pump . by a soft material.
• Lubricate all new rubber seals with petroleum jelly
prior to assembly. 5. Secure pump in a padded vise , shaft end up.
Torque all bolts over gasket joints, then repeat the 6. Remove capscrews (4) and washers (3).
torquing sequence to makeup for gasket com
pression.
Verify the accuracy of pump repairs on an auth
orized test stand befare returning it to service.
If parts are hard to disassemble and assemble, do
not use a hammer unless it has a soft face , do not
force parts together, they must be free to turn and
not bind.
components to lay the parts out in the arder that
they were disassembled. Keeping the parts in this
arder during disassembly, cleaning , and inspec
tion will aid in the assembly process.
Pump Disassembly
1. Drain any excess oil, remaining within the pump, 7. Remove pump from vise, hold pump in hands, and
into an appropriate container. Properly store or tap shaft with a plastic hammer or rawhide mallet to
dispose of the used oil. separate front plate (8) and back plate (17).
A WARNING
clea ning solutions.
2. Cap/plug any openings in the pump. Thoroughly

clean the exterior surface of the pump to prevent
contamination from entering it.
Refer to Figure 1.
3. Remove key (1) from drive gear (13), as equipped. 8. Remove o-ring (16) from back plate (17).
4. Index mark front plate (8), body (15) , and back 9. Remove idler gear (14) from body (15) .
plate (17) to aid in the assembly process.
JDf 1]
13. Remove retaining ring (5), if applicable, from front
of front plate (8) shaft seal area .
10. Separate body (15) from front plate (8) by tapping

drive gear (13) with a plastic hammer or rawhide
malle!. Remove drive gear (13).
14. Remove shaft seal (6) and washer (7) from front
plate (8) using a blunt punch from the back side .
Note: Removal of plug from front plate is not
necessary, unless damaged or a ro tation
change is required .
15. Remove plug (2) from front plate (8) , if required.
See " Changing Input Rotation of Pump " found
later in this document if change of pump rotation is
necessary.
Back Plate Disassembly

Note: Prior to removal, note orientation of spools to
cavity in back plate.
Refer to Figure 2.
For Relief Valve Style Back Plate :

Note: For assembly purposes, note position of 1. Remove relief valve (5) from back plate (1) .
open side of wear plate. 2. Remove o-ring (2), back up ring (3) , and o-ring
(4) .
11. Remove wear plate (12) and 0- ring (9) from front
plate (8). For Tandem Style Back Plate :
1. Remove capscrews (6) and cover plate (7).
2. Remove o-ring (8) from back plate (9) .
For Flow Divider Style Back Plate:

1. Remove relief valve (16) or relief plug (17), as
equipped , from back plate (12).
2. Remove o-ring (13), back up ring (14), and
o-ring (15).
3. Remove plug (10) and o-ring (11) .
4. Remove plug (18) , o-ring (19) , shims (20) , spring
(21 ), and spool (22) .
12. Using an o-ring tool, remove back up gasket (10)

and seal (11) from wear plate (12).
3 of 12
For Tandem Flow Oivider Style Back Plate : 3. Replace gear if shaft measures les s than
Note: Do not remove internal relief valve seat, 0.748 in (19mm) in bushing area. (One
located within back plate. Seat is installed with gear may be replaced separately; shafts
Loctite® to a predetermined depth. and gears are available as assemblies
only.)
1. Remove plug (23) , o-ring (24) , shim washers (25), 4. Inspect gear for scoring and excessive
spring (26), and poppet (27) from back plate (28). wear.
2. Remove plug (33), o-ring (32), shims (31), spring 5. Replace gear assembly if gear width is
(30) , and spool (29) from back plate (28). below dimensions in Table 1.
3. Remove plug (38) , o-ring (37), spring (36), sleeve 6. If edge of gear teeth are sharp, break edge
(35) , and o-rings (34) from back plate (28). with an emery cloth .
b. Front and Back Plate:
Cleaning And Inspection 1. Oil groove in bushings in front plate should
be in li ne with dowel pi n hales and 180 o
A WARNING
apart. The oil grooves in the back plate
bushings should be approximately 37 ° to
the pressure side .
hazardous. Serious personal injury may 2. Replace the front plate or back plate if the
result from misuse of these products. Read inner diameter of the bushings exceeds
an d follow all the manufacturer's 0.755 in (19 .2mm) . (Bushings are not
recommendations concerning solvents and available as separate items.)
cleaning solutions. 3. Bushings in front plate should be 0.126 in
(3 .20mm) aboye surface of front plate .
1. Thoroughly clean al! metal parts with an approved 4. Check for scor ing on fa ce of back plate .
cleaning solvent. Use filtered, moisture free Replace if wear exceeds 0.0015 in
compressed air to dry the parts. Do not use paper (O.038mm) .
towels or cloth. Exercise every precaution C. Body:
possible to keep al! parts free of dust, dirt, or any 1. Check gear pockets for excessive scoring
other foreign material during assembly. or wear.
2. Careful!y inspect al! components for damage, 2. Replace body if inner diameter of gear
wear, corrosion, deep scratches , and scuffed met pqckets excee9s 1.719 in (43.7mm).
al. Remove any burrs or sharp edges with an 3. Al! Loctite''!; , Permatex "lJ , or other sealant residue
emery cloth. Replace any damaged component should be removed from threads of hardware and
as required. Replace al! seals, o-rings, back up the mounting surfaces of parts that are going to be
gaskets, wear plates, and shaft seals. Use the fol reused . Prior to applying new thread locking
lowing guidelines to further inspect individual com compounds or sealants , clean threads and
ponents: surfaces with Loctite® 7070 Cleaner to ensure best
a. Orive Gear and Idler Gear: performance of products .
1. Check splined drive shaft for twisted or 4 . In the event of severe defects, contact factory
broken teeth, or check keyed drive shaft personnel for directions whether to repair or
for broken or chipped keyway, as replace any major component.
applicable .
2. Inspect both the drive gear and idler gear
shafts at bushing points and seal area for
rough surfaces and excessive wear.
40f 12
6 \
~' .
1,:
\ . i I
, ,)
Relief Valve Style Back Plate Tandem Style Back Plate

_ _ _ _ 10
i&------: 11
" . . . - - 12
:.='
35----,~ I
',1
34----1
21 ~
20
Poi
~
'-"
J. l r33
29
' 1 ,,,.,/
30
~ I 17
19---0
18--..; ~~
Úr dKir,-J...
; ~f
Flow Divider Style Back Plate Tandem Flow Divider Style Back Plate
1. Back Plate - Relief Valve 14. Back U p Ring 27 . Poppet
2. O -ring 15. 0 -ring 28 . Back Plate - Tandem Flow Divid er
3. Back Up Ring 16. Reli ef Valve* 29. Spool
4. O -ring 17. Relie f Plug* 30. Spring
5. Reli ef Valve 18. Plug 31. Shims
6 Capscrews 19. O - ring 32 . O-nng
7. Cover Pl ate 20. Shi ms 33 . Plug
8. O-ring 21. Spring 34 . O -rings
9. Back Plale - Tandem 22. Spool 35 . Sleeve
10. Plug 23. Plug 36 . Spring
11. O-ring 24.0 -ring 37. O -ring
12. Back Piafe - Flow Divider 25. Shim Washers 38. Plug
13 O- ring 26. Spring
* Back PI ate Uses Relief Valve Or Relief Plug, Not Both .
Figure 2
Various Back Plate Assemblies
5 011 2
Model Number 26001 26002 26003 26004 26005 26006 26007 26008 26009 26010 26011 26012 26013
Pump
Displacement
in 3 j r 0.40 0.50 0.58 06 0 .84 1.02 1.20 1 37 1.48 1.54 1.69 1.77 18
(cm 3 j r) (6.6) (8.2) (9.5) ( 10.8) (13.8) (16.7) (19. 7) (22.5) (24.3) (25. 2) (27.7) (29.0) (30.6)
Gear Width
in 0 .309 0 .384 0.44 1 05 10 0.636 0.762 0.888 1.014 1.107 1.140 1.266 1.330 1 392
(mm) (7.85) (9.75) (11.20) (12.95) (16.15) (1 9 .35) (22.56) (25.76) (28 12) (28.96) (32.16) (33.78) (35.36)
Table 1
Gear Width Specifications
Back Plate Assembly Pump Assembly

Refer to Figure 2. It is important that the relationship of the back plate ,
body, wear plate , and front plate is corree!. Note the
Lubricate all o-rings, back up rings, and spools with two half moon cavities in the body, The sma"er half
clean hydraulic oil pr ior to assembly. See Operator's moon port cavity must be o n the pressure side of the
Manual for correct type. pump, The side of the wear plate with m idsection cut
out, must be on the suction side of the pump. The
For Relief Valve Style Back Plate :
suction side of the back plate is always the side with the
1. Insta" o-ring (4), back up ring (3), and o-ring (2)
larger port boss,
on relief valve (5) .
2. Install relief valve (5) in back plate (1) and torque to
30-34 ft lb (41-46Nm).
For Tandem Style Back Plate:

A WARNING
1. Insta" o-ring (8) in back plate (9) . compounds, etc. can be hazardous. Serious
2 . Insta" cover plate (7) and capscrews (6). personal injury may result from misuse of
For Flow Divider Style Back Plate : these products. Read and follow al!
1. Insta" o-ring (11) on plug (10). manufacturer's recommendations concerning
2. Install plug (10) in back plate (12) . To rque plug (10) these products.
to 21 -24 ft lb (29-33Nm) .
3. Install o-ring (19) on plug (18) . 1. Lubricate all o-rings, seals, and gaskets with
4. Insta" spool (22), spring (21), shims (20), and plug petroleum jelly or hydraulic fluid prior to assembly,
(18). Torque plug (10) to 21 -24 ft lb (29-33Nm). See Operator's Manual for correct type .
5. Insta" 0- ring (15), back up ring (14), and o-ring Refer to Figure 1.
(13) on relief valve (16) or relief plug (17), as 2, Install plug (2) in front plate (8) , if required. See
equipped. "Changing Input Rotation of Pump " found later in
6. Install relief valve (16) or relief plug (17) , as this document if change of pump rotation is
equippe d , in back plate (12). Torque to 30-34 ft lb necessary.
(41-46Nm) .
For Tandem Flow Divider Style Back Plate:

1, Install o-ring (37) on plug (38) ,
2, Insta" o-rings (34) on sleeve (35).
3. Install sleeve (35) , spring (36), and plug (38) in
back plate (28). Torque plug (38) to 35-40 ft lb
(4 8-54Nm) ,
4, Install o-ring (32) on plug (33) ,
5. Insta" spool (29), spring (30), shims (31) , and plug
(33) in back plate (28) , Torque plug (33) to 21-24 ft
lb (29-33Nm) ,
6. Install o-ring (24) on plug (23),
7. Install poppet (27), spring (26), washe rs (25) , and
plug (23) in back plate (28), Torque plug (23) to
10-12 ft lb (14-16Nm),
3. Install o-ring (9) in groove of front plate (8).
60f 12
4. Apply a thin coat of petroleum jelly to both milled
gear pockets in body (15).
Note: The si de of the wear plate with the mid

section cut away, must be on the suction side 01
Note: The small half moon port cavity must be the pump.
on the pressure side (the plugged side of the 7. Place wear plate (12) assembly into gear pocket in
front plate) of the pump. body (15) with seal (11) si de facing front plate (8).
5. Position body (15) on front plate (8) with half moan
port cavities in body (15) facing away from front
plate (8). Align index marks placed on parts during
disassembly.
Note: The flat section or support in the middle

of the back up gasket must face away from the
wear plate.
8. Dip gears (13,14) into clean hydraulic oil. See
6. Install seal (11) and back up gasket (10) into wear Operator's Manual for correct type.
plate (12) with flat fa ce of back up gasket (10) away 9. Install gears (13,14) into pockets in body (15).
from wear plate (12).
7 of 12
17 . Install retaining ring (5) in front plate (8), if
applicable.
18. Install key (1) in keyed drive gear (13) shaft , if
applicable.
19. Manually rotate gears with a small wrench to
ensure parts are align ed and seated correctly for
smooth operation .
20 . Properly test pump for correct operation. Refer to
Figure 3 for correct testing procedures.
21 . If power steering pump is not to be immediately
installed on crane, plug all open ports to prevent
contamination and properly store.
Changing Input Rotation of Pump
10 . Install o-ring (16) in groove in back plate (17). CAUTION

Note: Ensure port orientation is correct before Do not grip on any machined surfaces.
in stalling back plate on body. Excessive force while clamping could result in
11. Align ind ex marks made during d isassembly and misalignment and/or serious damage to
guide back plate (17) over gears (13 ,14) until parts. Take extreme care not to mar or
dowel pins engage. damage any machined surface. Do not clamp
12 . Secure assembly together by installing washers in any form of vise unless jaws are protected
(3) and capscrews (4). Torque capscrews (4) by a soft material.
evenly in a criss-cross pattern to 25-28 ft lb
(34-38Nm). 1. Secure pump in a padded vise, shaft end up.
Refer to Figure 1.
2. Remove capscrews (4) and washers (3) .
Note: For assembly purposes, note orientation
of drive shaft through bearing in reference to
back plate.
3. Remove front plate (8).
Note: For assembly purposes, note orientation
of open side of wear plate .
4. Remove wear plate (12).
5. Switch drive gear (13) and idler gear (14) within
gear pockets. Do not flip idler gear (14) end for
end.
13 . Install washer (7) over drive gear (13) shaft into Note: Gear housing body and back plate do not
front plate (8) . require altering.
14. Liberally oil shaft seal (6) with c lean hydraulic fluid. 6. Install wear plate (12) over gears (13 ,14) into gear
See Operator's Manual for correct type. pockets with seal (11) and back up gasket (10)
15. Carefully install shaft seal (6) over drive gear (13) facing up.
shaft . Use care not to damage shaft seal (6) on 7. Thread a 3/8" UNC threaded bolt into plug (2)
sharp edges of shaft . cavity. Start with flngers, then place bolt head in
16. Place a 1 -5/16" 0.0 . sleeve over shaft and press vise and turn front plate (8) to engage threads .
in shaft seal (6) until flush with front surface of front Appro ximately 2-3 turns.
plate (8) . If retaining ring (5) is utilized, install shaft 8. Hold ing bolt in vise , tap front plate (8) with rubber
seal (6) just far enough to allow for retaining ring (5) hammer to disengage plug (2) .
installation.
8 of 12
11. Ensure bearing drain holes are free of debris.
12. Hold o-ring (9) in groove of front plate (8) witll
petroleum jelly.
13 . Position front plate (8) over drive gear (13) shaft
end, being careful not to damage shaft seal (6).
14. Install washers (3) and capscrews (4). Torque
capscrews (4) to 25-28 ft lb (34-38Nm).
15. Lubricate gears (13,14) and mating suriaces
through ports with clean hydraulic oil. See
Operator's Manual for correct type.
16. Manually rotate drive gear (13) to ensure pro per
assembly of components.
Wear Plate Identification
9. Remove plug (2) from bolt.
A product improvement has been made to the Model

26000 gear pump with a new designed wear plate . To
Note: L or R at bottom of cavity indicates rota identify the new wear plate , look for grooves placed in
tion direction. Left (counterclockwise) or right the seal side of the wear plate . Th is new wear plate
(clockwise) rotation describes the shaft rota enables better pressure clamping with aerated oil in
tion when viewed from the shaft end of the pumps 1.37 cubic inch or smaller. Aerated oil may
pump. occur during cold sta rt-up in a pplication s with long
suction lines or when the mouth of the ínlet line is
10. Install plug (2) in other casting and tap flush with
temporaríly exposed to airo
rubber hammer.
9 of 12
Mount Pump Connect

on to
Test Stand Fluid Supply
Each
II
I
Load Load Load
At
Intermittently Intermittently Intermittently
Zero
to 500 psi to 1,000 psi to 2,0 00 psi
Pressure
(3447kPa) (6895kPa) (13 790kPa)
Pump Remove Check

Ready for from for
Service Test Stand Leaks
Test Stand
Mount Pump Connect

on to
Crane Fluid Supply
Each
At 1/2 Speed At 1/2 Speed

~
At Full Speed
I I I
Load Load
At
Intermittently Intermittently
Zero
to 500 psi to 1,000 psi
Pressure
(3447kPa) (6895kPa)
Pump Check
Ready for for
Service Leaks
Installed on Crane
Figure 3
Test Procedures
10 of 12
Problem Possible Cause Correction
Cavitation a. Oil too heavy a. Change to proper viscosity.
b. Oil filter plugged b. Clean filter.
c. Suction line plugged or too small c. Clean line and check size of line.
Oil Heating a. Oil supply low a. Fill reservoir.
b. Contaminated oil b. Drain reservoir and refill with clean oil
C. Setting of relief valve too high or too low C. Set to correct pressure .
d. Oil in system too light d . Drain reservoir and refill with proper oil
Shaft Seal a. Worn shaft seal a. Replace shaft seal
Leakage b. Worn shaft in seal area b. Replace drive assembly.
C. Debris in shaft seal suction side drain holes C. Disassemble pump and inspect.
Foaming a. Low oil level a. Fill reservoir.

Oil b. Ai r leaking into suction line b. Tighten fittings.
C. Drain and fill reservoir with correct oil . See
C. Wrong kind of oil
Operator 's Manual for correct type .
Table 2
Troubleshooting
11 of 12
",. ".:". :
12 of 12
Power Steering Pump, R & I a. Relieve any residual pressure in the hydraulic
This procedure covers the removal and installation of reservoir by pushing the button on the
the power steering pump. For recondition procedure, pressure relief valve located on the hydraulic
see SM Keysheet Area 01-010. reservoir (if equipped), or slowly loosening the
filler/breather cap, located on the top of the
Removal hydraulic reservoir, until pressure is fully
relieved.
1. Lower, detach, and secure the load, as required.
START THE ENGINE. Move the function
lockout switch to the "OPERATE" position.
level surface.
switch es back and forth several times.
the tires.
d. Turn ignition switch to the "OFF" position.
6. Check that all control levers are in the neutral
lock, as required.
position and move the function lockout switch to
the "DISABLE" position.
e. Fully retract and position the boom, as
required.
hydraulic pump. A WARNING
A WARNING
lines and fittings before relieving air pressu re
7. Open the drain valves on the air system reservoirs
to bleed the air system pressure.
8. When pressure is fully relieved, close the drain
cleaning solutions.
valves on the air system reservoir.
4. Thoroughly clean the area to be disassembled with Note: The hydraulic reservoir capacity is 144 gal
an approved cleaning solvent to prevent (545L). The total hydraulic system capacity is 200 gal
contamination. Allow the area to air dry. (757L).
9. If available, mount a vacuum pump to the hydraulic

A WARNING reservoir. If a vacuum pump is not available, drain
the hydraulic reservoir. Properly store or dispose of
the hydraulic oil. See the Operator's Manual for the
hot. A sud den release of hot oil could cause
correct procedure.
burns or other serious injury. Shutdown the
engine and exhaust all trapped hydraulic Refer to Figure 1.
pressure from the system before removing 10. Label for assembly purposes and disconnect the
any line or component. hydraulic lines (4) from the power steering pump
(3). Cap/plug the open hydraulic ports and lines
(4) to prevent excessive oilloss and contamination
of the system.
11. Support power steering pump (3) and remove
capscrews and washers (2).
12. Remove power steering pump (3) from engine (1).
13. Remove gasket (not shown) from power steering
pump (3) and/or engine (1).
1 of 4
1Ií (1/
'.' -_ /
Ij, . , -
. ·111' ,'-- -
. .
---- '.
1
\
\
\
\
1. Engine 2. Capscrews & Washers 3. Power Steering Pump 4. Hydraulic Unes
Figure 1
Power Steering Pump
2 of 4
Cleaning And Inspection Installation
A WARNING
A WARNING
hazardous. Serious personal injury may compounds , etc. can be hazardous. Serious
result from misuse of these products. Read personal injury may result from misuse of
and follow all the manufacturer's these products. Read and foHow aH
recommendations concerning solvents and manufacturer's recommendations concerning
1. AII components should be thoroughly cleaned with Refer to Figure 1,

an approved cleaning solvent, air dried, and 1, Place a gasket (not shown) between the power
carefully inspected. steering pump (3) and engine (1) ,
2. AII Loctite®, Permatex®, or other sealant residue 2, Properly align the power steering pump (3) to the
should be removed from threads of hardware and engine (1),
the mounting surfaces of parts that are going to be 3, Install the capscrews and washers (2) , Torque
reused . Prior to applying new thread locking capscrews (2) to 30-40 ft lb (41-54Nm) ,
compounds Or sealants , clean threads and 4, Install the hydraulic lines (4) ,
surfaces with Loctite® 7070 Cleaner to ensure best 5 , If installed , remove the vacuum pump,
performance of products , 6 , Check the hydraulic reservoir oil leve!. Add oil as
3, Thoroughly inspect all parts for damage , wear, required , See the Operator's Manual for correct
fatigue or stress fractures , and corrosion, Repair type and procedure,
or replace as required , 7, Start the engine and let idle for live minutes,
4, AII "soft parts", such as seals, gaskets, back up Inspect the connections on the hydraul ic lines lor
rings , and o-rings, should be replaced, leaks, Repair il needed,
5. Inspect the integrity of the hydraulic lines that are 8, Complete the installation by testing all related
connected to the power steering pump , Repair or lunctions 01 the power steering pump lor proper
replace if required, operation , Normal operation 01 hyd ra ulic system
6 , In the event of severe defects , contact factory should be conlirmed, A general inspection 01
personnel for directions whether to repair or components and systems in the areas adjacent to
replace any major component ,
the repair should also be performed lO ensure
related damage or wear is not present.
3014
4 of 4
~
. . ,. --------
~ ,
;---'1;1. \ 1
I 2
l_ - - 3
.. I
~
t • '
13 12 11 10 9 8 7 6 5 4
1. Screws 6. Screw, Washer, & Lockn ut 10 Air Conditioner Hose - Inlet
2. Grille 7. Mounting Bracket 11 . Hose Clamps
3 Screws 8. Capscrews, Washers, & Locknu ts 12. Healer Hose - Oullet
4. Carrier Cab 9. Air Condi tioner Hose - Oullel 13, Heater Hose - Inlet
5. Hea ler Core& A/C Coil
Figure 1
Heater Core & Air Conditioner Coil Assembly

Heater Core & Air draulic pump, as equipped,
Conditioner Coil, R & I 4. Check that all controllevers are in the neutral posi
tion and move the fun ctio n lockou t switch to the
This procedure covers the removal and installation of "DI SABLE" position or the gate lock lever to the
the carrier cab heater core and air conditioner coil "STOP" position, as equipped,
assembly,
Removal
1, Lower, detach , and secure load , as req uired ,
A WARNING
2, Stabilize the crane for service as follows : Failure to allow engine, radiator, and heater
a. Park the crane out of the way on a firm and level core to suf1iciently cool could result in burns
surface. En gage the park brake , or other personal injury, Allow the engine,
b. Engage the swing park brake or travel swing radiator, and heater core to cool before
lock , as required . attempting removal procedure.
c. Level lile crane on fully extended outriggers,
d, Position/support lile boom , as requir ed,
1 of 4
12. Support heater core and A/C coil (5) and remove
A WARNING capscrews, washers, and locknuts (8).
13 . Remove screws (1 ,3) securing grille (2) and heater
Sol vents and cleaning solutions can be core and A/C coil (5) to carrier cab (4).
hazardous. Serious personal injury may 14. Remove screw, washer, and locknut (6) securing
result from misuse of these products. Read lilter to grille (2).
and follow all the manufacturer's 15. Remove heater core and A/C coil (5) Irom crane.
recommendations concerning solvents and 16. Allow excess coolant to drain Irom hoses (13 ,12)
cl eaning solutions. and heater core and A/C coil (5) into a suitable con
tainer. Properly store or dispose 01 used coolant.
approved cleaning solvent to prevent contamina Cleaning And Inspection
tion Irom entering the circuits . Allow the area to air
dry.
6. Disconnect electrical connections (not shown)
lrom heater core and A/C coil (5).
A WARNING
7. Ensure that the engine , radiator, and heater core Solvents and cleaning solutions can be
have sufficiently cooled . hazardous. Serious personal injury may
8. Close drain valves on heater hoses (13 ,12) located result from misuse of these products. Read
at engine oil cooler and water pump. and follow all the manufacturer's
cleaning solutions.
A WARNING
Refrigerants are under pressure and can be
an approved cleaning solvent , air dried, and care
hazardous. A sud den release of refrigerant lully inspected .
could cause chemical burns, frostbite, or 2. AII Loctite'F, Permatex ' , or other sealant residue
other serious injury. Shutdown the engine and should be removed Irom threads 01 hardware and
p roperly " reclaim" the refrigerant from the the mounting surlaces 01 parts that are going to be
system before removing any line or reused. Prior to applying new thread locking com
component. Read and follow all of the pounds or sealants, clean threads and surfaces
manufacturer's recommendations with Loctite ' 7070 Cleaner to ensure best perfor
concerning use and storage of refrigerants. mance 01 products .
3. Inspect the integrity 01 the hoses and electrical
9. See SM Keyslleet Area 18-018 lor precautions re connections that are connected to the heater core
garding air conditioning service . and A/C coi/. Repair or replace il required.
10. Label lor assembly purposes and disconnect air 4. Inspect the integrity 01 the weather stripping and
conditioner hoses (10,9) . Cap/plug the open ports loam baffling around the heater core and A/C coil.
and hoses (10,9) to prevent contamination 01 the Repair or replace il required.
syste m. 5. In the event 01 severe delects , contact lactory per
11 . Label lor assembly purposes and disconnect heat sonnel lor directions whether to repair or replace
er hoses (13,12) by removing hose clamps (11) . any major component.
Cap/plug the open ports and hoses (13,12) to pre
vent contamination 01 the system.
2014
I nstallation 6. Connect air conditioner hoses (10,9) to heater core
and A/C coil (5).
7. Connect electrical connections (not shown) to
A WARNING
heater core and A/C coil (5).
8. Open drain valves on heater hoses (13,12) located
Lubricants, sealants, joint and thread locking at engine oil cooler and water pump.
compounds, etc. can be hazardous. Serious 9. Check radiator coolant level. Fill as required. See
personal injury may result from misuse of Operator 's Manual for correct procedure.
these products. Read and follow all 10. Properly charge air conditioning system . See SM
manufacturer's recommendations concerning Keysheet Area 18-018 for precautions regarding
these products. air conditioning service.
11. Start the engine and let idle for five minutes. Oper
1. Position heater core and A/C coil (5) in the carrier ate the heater and air conditioner and inspect all
cab (4). the connections for leaks. Repair if needed.
2. Align heater core and A/C coil (5) with mounting 12. Complete the installation by testin g all related func
bracket (7) and secure it by installing capscrews, tions of the heater and air conditioner for proper
washers, and locknuts (8). operation. A general inspection of components
3. Install filter to grille (2) with screw, washer, and and systems in the areas adjacent to the repair
locknut (6) . should also be performed to ensure related dam
4. Position grille (2) to heater core and A/C coil (5) and age or wear is not present.
secure with screws (3 ,1) .
5. Connect heater hoses (13 ,12) and install hose
clamps (11).
3 of 4
jol4'
e
1/ i----'
/¡' )
1 2
1. Englne (Typical) 5. Capscrews, Washers, & Locknuts 8. Shims & Washers

2. Transmlssion 6. Capscrews & Washers 9. Oampeners
3. Capscrews & Locknuts 7. Capscrews, Washers, & Locknuts 10. Flywheel Housing
4. PTO Adaptar
Figure 1
Transmission Assembly
2. Stabilize the crane lor service as lollows:

Transmission And a. Park the crane, out 01 the way, on a firm and
Clutch, R & I level surface,
b. Shift the transmission to neutral.
This procedure covers the removal and installation 01 c, Engage the park brake and/or properly block
the transmission and clutch, For recondition the tires,
procedure, see SM Keysheet Area 01-018, d. Engage the swing park brake or travel swing
lock , as required.
Transmission Removal e. Level the crane on lully extended outriggers.
1. Lower, detach, and secure the load, as required , f. Position/support the boom, as required.
1 0122
3. Process and record any and all error messages
sto red in the transmission CPU (Central Pro
cessing Unit). See the crane Operator's Manual for
complete instructions.
4 . Shutdown the engine and disengage the main hy
5. Allow the engine and transmission to cool befo re
preceding further.
A WARNING
recommendations concerning solvents and 2
cleaning solutions. 1. Clutch Actuator 3. Air line
2. Transmission
an approved cleaning solvent to prevent conta Figure 2
Clutch Actuator Air Line
13. label for assembly purpose and disconnect the air
A WARNING
line (3) that is connected to the clutch actuator (1)
on the transmission (2). Plug/cap the air line and
open por! to prevent contamination .
7. Open the drain valves on the air system reservoirs

to bleed the air system pressure.
8 . When pressure is fully relieved, close the drain
valves on the air system reservoirs.
9. Remove the engine housing. See SM Keysheet
10. Remove any additional sheet metal , as required, to
access the engine and transmission.
Refer to Figure 1.
11. Disconnect the drive shafts from the transmission
(2) and PTO adaptor (4).
12. Remove the capscrews and locknuts (3) securing
the PTO adaptor (4) to the transmission (2) .
1. Actuator 3. Transmission
2. Air line
Figure 3
Transmission Actuator Air Line
14. label for assembly purpose and disconnect the air

line (2) that is connected to the actuator (1) on the
top of the transmission (3). Plug/cap the air line
and open port to prevent contamination.
2 of 22
1. Cable 3 Cable
2. Sen so r 4. Sensor Clutch Actuator 2. Bleed Plug
Figure 4 Figure 6
Speed Sensors Clutch Actuator Bleed Plug
15. Label for assembly purposes and disconnect the 17. Loosen the bleed plug (2) on the clutch actuator (1 )
cables (1 ,3) from the sensors (2,4) on the transmis to ensure all air pressure is relieved from the clutch
sion . actuator (1).
1. Nuts & Washers 3. Studs

1. Electrical Connector 2. Clutch Actuator 4. Transmissi on
2. Actuator
3 Tran smlssion Figure 7
Clutch Actuator
Figure 5
Transmission Actuator
18. Remove the nuts and washers (1) which secure the
clutch actuator (2) to the studs (3) on the transm is
16 . Label for assembly purposes and disconnect any
sion (4) ; remove the clutch actuator (2) .
wire harnesses from the electrical connectors (1)
on the actuator (2) on top the transmission (3) .
3 of 22
21, Using an auxiliary lifting device, support the trans
mission (2),
Note: The transmission weighs approximately

650 lb (295kg).
22, Remove the capscrews, washers, and locknuts (7)

and shims and washers (8).
23. Remove the capscrews and washers (6) that se
cure the transmission (2) to the flywheel housing
(10) .
CAUTION
Be sure the push rod has been removed from
the release fork inside the clutch bellhousing.
Failure to remove the push rod before
separating the transmission from the
1. Push Rod 2. Release Fork bellhousing may cause damage to parts
within. If not removed, the push rod may
Fig ure 8
prevent the transmission from disengaging
Push Rod And Release Fork
from the engine.
19, Disengage the push rod (1) from release fork (2) by
24, Pry the transmission (2) away from the engine (1)
pressing push rod (1) towards the release fork (2),
Remove the push rod (1). far enough to allow clearance between the trans
mission (2) input shaft and the flywheel housing
(10).
A DANGER
Do not attempt to remove and/or disassemble CAUTION
the transmission without first placing Keep the transmission in line with the engine
blocking under the flywheel housing to during removal. Do notallowtheweightofthe
support the engine. The engine could tilt/fall transmission to hang on the input shaft.
resulting in severe personal injury or death. Doing so could bend the clutch disc hub or
result in internal transmission damage.
Refer to Figure 1.
20. Using adequate blocking , support the engine (1) at 25 . Carefully lift the transmission (2) through the open
the flywheel housing (10). ing in the top of the carrier frame.
26. Remove the capscrews , washers, and locknuts (5)
Note: The engine weighs approximately 3,000 lb and dampeners (9), if required.
(1361kg).
4 of 22
1. Load Ring
2. Pressure Plale
3 Release Bearing
Figure 9
Release Bearing Removal
Clutch Removal
A WARNING
Some clutch parts may contain fibers of which
long-term effects on health are not yet
known. Even though late model clutch linings
do not contain asbestos, care must be taken
when working with fibrous materials of any
type. Use adequate ventilation and breathing
protection to avoid long term health
complications from breathing dust.
27. Unlatch the load ring (1),

28, Forcefully push release bearing (3) against pres
sure plate (2) (in direction indicated by arrow), The
load ring (1) will thereby widen, Tilt the release
bearing (3) and remove.
A
1. Relaining Boll 3. Pressure Plale
WARNING 2. Flywheel
Figure 10
During removal, the input alignment shaft tool
Pressure Plate Removal
must not be used to hold or support the clutch.
Such action could result in the pilot bearing 29, Remove two retaining bolts (1) from upper side of
being damaged or the clutch falling resulting clutch bell housing.
in injury to bystanders or damage to clutch
components. Securely fasten clutch to a
clutch trolley or other appropriate support.
5 of 22
SM 0 1-018-056.00 0408 Service Manual
1. Guide Pins 3. Retaining Bolts 1. Flywheel 3. Pressure Plate

2. Flywheel 2. Retaining Bolts
Figure 11 Figure 12
Gulde Pin Installation Pressure Plate Removal
30. Create two guide pins (1) by removing the heads 31. Loosen the retaining bolts (2) from the flywheel (1)
from long capscrews which have the same thread a few turns at a time to relieve the spring pressure
as the pressure plate retaining bolts (3). Install the on the pressure plate (3).
guide pins (1) into threaded holes of the flywheel
(2) . 2
CAUTION
Handle the pressure plate and cover
assembly carefully; do not drop. Doing so
can cause minor bends or kinks in the four
drive strap assemblies. Any bends or kinks
can reduce or eliminate the ability of the
pressure plate to retract into the clutch cover.
Failu re of the pressure plate to retract into the
cover will result in clutch drag due to
¡ncomplete clutch release.
Note: When removing pressure plate retaining

bolts, be sure to progressively loosen the bolts in a
criss-cross pattern to prevent binding within the
1. Guide Pins 3. Pressure Plate
clutch and ensure easy removal of the pressure
2. Flywheel
plate.
Figure 13
32. Once all spring pressure is relieved from the pres

sure plate (3) fully remove the retaining bolts and
I
separate the pressure plate (3) from the flywheel

(2). Use the guide pins (1) to suppart and stabilize
the pressure plate (3) far safe removal.
6 of 22
Figure 14 Figure 15
Thoroughly Clean AII Friction Surfaces Properly Inspect AII Parts To Be Reused
Cleaning
Inspection
A WARNING
If the clutch was removed after giving satisfactory ser
vice, no clutch inspection or diagnosis is required.
Continue with the inspection to ensure the best perfor
Follow all manufacturer's recommendations
concerning solvents and cleaning solutions. mance after installation. If, however, some clutch prob
Serious personal injury may result from lem had developed, inspection of the old parts could
misuse of these products. help to isolate the malfunction and allow its repair prior
to installation of new parts. Refer to the troubleshoot
1. AII components should be thoroughly cleaned with ing guidetoassist in the clutch inspection, problem de
an approved cleaning solvent, air dried, and care termination, and recommended correction.
fully inspected. To remove grease, oil, or dirt from 1. Thoroughly inspect all parts far damage, wear, fa
clutch friction surfaces use a brakejelectricalj tigue or stress fractures, and corrosion. Repair or
clutch cleaning solvent only. replace as required.
2. Inspect the integrity of the air lines that supply the
transmission. Repair or replace if required.
CAUTION 3. Inspect the integrity of the electrical wires and con
Do not disassemble the pressure plate nectors that supply the transmission. Repair ar re
assembly for cleaning. The assembly is place if required.
difficult to properly reassemble. 4. In the event of severe defects, contact factory per
sonnel for directions whether to repair or replace
2. Applya light lubricant to metal parts to prevent cor any major component.
rosion, but keep all oil and grease away from the
clutch lining and clutch friction surfaces. Use the following detailed criteria to inspect specific
3. AII Loctite®, Permatex®, or other sealant residue parts:
should be removed from threads of hardware and Clutch Release bearing
the mounting surfaces of parts that are going to be 1. Rotate the body housing while applying a load and
reused. feel for ball bearing roughness. Any degree of
roughness indicates a failed bearing which must
be replaced.
7 of 22
2. Inspect lor signs 01 excessive heat, inadequate lu
brication, or excessive clutch brake wear.
3. Inspect the release lork tip wear pads lar signs of
excessive wear, uneven loading, or lack of lubrica
tion.
4 . Check the locknut for adequate tightness against
the release bearing coupler.
5. Inspect the bore of the release bearing threaded
sleeve to see il the bushing is seated in its proper
location. Examine the bushing condition. Look for
signs of excessive side loading that would indicate
transmission misalignment.
Pressure Plate And Cover Assembly

STRAIGHT EDGE
4. Examine the drive strap assemblies lor bends or

kinks. Normal drive strap units form a smooth,
gently curving "8" shape when viewed from the
edge, with all laminations fitting tightly together.
Bent of kinked drive straps will show an area 01
tight radius bending next to the rivet or bolt attach
ments and/ar noticeable gaps between lamina
tions.
CAUTION
FEELER GAUGE
Do not use a clutch with damaged drive straps
as clutch release problems can result.
1. Inspect the pressure plate Iriction surface lor wear 5. Check the stamped steel cover mounting flange
by placing a straight edge across the width of the and sides lar distortion due to shipping damage or
Iriction lace. A gap in the worn area 01 0.030 inch incorrect installation. Pressure plate and cover as
(O. 75mm) or more indicates the pressure plate and semblies with this condition must be replaced.
cover assembly should be replaced.
2. If reusing the pressure plate and cover assembly
with a new disc, inspect the pressure plate lor war
page or uneven wear by placing a straight edge
across the entire diameter 01 the plate. Ifthe gap at
the inside wear diameter exceeds the gap at the
outside wear edge by 0.008 inch (0.20mm) , there is
excessive concave warpage and that pressure
plate and cover assembly should be replaced. No
measurable amount 01 convex warpage is allowed.
3 . Inspect the pressure plate lor heat damage such
as discoloration, surlace checking or cracks.
Slight discoloration or light checking is normal.
Oeep checking or cracks indicate the pressure
plate and cover assembly should be replaced.
8 of 22
Clutch Disc
PADDLE AR M
The clutch disc must be checked for wear or damage
and should also be closely examined for contamina
/
tion . Make sure that the dampening springs are not
loose in the hubo If the springs have any axial (back and
/ FEELER GAUGE
forth) movement, they are loose. Check the hub
splines for wear or damage and make sure that the hub
is firmly fastened to the disc o
3. Lay the clutch disc on a new pressure plate and

cover assembly or Ilywheel to check lor bent
paddle arms. Using a leeler gauge, check the gap
between the Iriction material pads and the pres
sure plate and cover assembly or Ilywheel lace .
The gap must not exceed 0.030 inch (0.75mm) .
1. Inspect the friction material for signs of excessive 4. Examine the clutch disc lor a bent hub by looking
wear or heat damage. Disc thickness should be lor unusually heavy Iriction material wear. This
checked with calipers or an outside micrometer. wear will appear at one point on the diameter 01 the
Minimum disc thickness. Iriction material on one side 01 the disco A second
a. 14 inch clutch : 0 .272 inch (6.90mm) heavy Iriction material wear area with a similar pat
b. 16 and 17 inch clutch: 0 .295 inch (7.50mm) tern will be present 180 degrees away on the oppo
2. Slide the clutch disc onto the transmission input site side 01 the clutch disc il the hub is bent.
shaft to look for evidence of sticking or binding 5. Check the clutch disc lor signs 01 driveline torsional
splines . Clean and correct source of interference vibration or shock loading damage such as broken
or replace clutch disc o sprin gs, cracked damper retainer plates, or dam
aged splines .
Clutch Environment
The environment in which the clutch operates is ex
tremely important to proper lunction. There are three
major points to the environment check. Theyare:
a. Alignment 01 the engine and transmission
b. Presence 01 oil leakage or loreign materials
c. Component condition
CAUTION
Alignment is extremely important to proper
clutch operation . Improper alignment can
result in incomplete clutch release,
transmission gear slippage , and/ or input
bearing failure.
90122
The basic instrument required to take readings for mis 3. Inspect the flywheel for excessive wear or heat
alignment is a dial indicator. Accuracy of the readings damage . Minor wear or damage can be corrected
is essential when identifying and correcting alignment by resurfacing the flywheel. The flywheel should
problems. AII surfaces must be clean before readings be resurfaced il any of the following conditions ex
are taken. its:
a. Heat Checking - Do not use the flywheel il
heat checking is evident after resurlacing .
A WARNING b. Metal Flow - Metal Ilow indicated that metal
has actually melted due to excessive heat.
When taking readings, rotate the engine by
c. Wear - Look lor any detectable step in the Ily
ha nd. DO NOT crank the engine with the
wheel surface caused by clutch contact.
starter. Remove spark plugs on gasoline
engines and release the compression on Note: For flywheel wear limits and resurfacing
diesel engines where possible. specifications, refer to the engine manufactur
er's guidelines. If the flywheel has been resur
1. Make a general inspection of the engine and deter faced, check to be certain the clutch mounting
mine if there are any oil or coolant leaks that could capscrew threaded holes are deep enough to
contaminate the clutch . Correct as required. allow the capscrews to be threaded in by hand
to a point deeper than is required to instal! the
pressure plate and cover assembly.
2. To perform the check, attach the dial indicator base

to the flywheel housing and place the indicator
pointer against the flywheel. Then, force the crank
shaft forward and rearward with a prybar. Measure 4. Measure the axial runout at the outer diameter 01
the endplay of the crankshaft and compare the re the flywheel. Secure the dial indicator base to the
sults to the engine manufacturer's specifications. engine flywheel housing near the outer edge and
Correct as required. place the dial indicator tip on the Ilywheel. Turn the
engine over by hand and observe the reading on
the dial indicator. Measure at lour places , 90 de
grees apart. Force flywheel rearward when taking
each measurement to take up crankshaft endplay.
Typical runout limits are :
a. 14 in clutch: 0.007 inch (O. 178mm) max
b. 16 in clutch: 0.008 inch (0.203mm) max
c . 17 in clutch: 0.009 inch (0.216mm) max
5. Check the engine manufacturer's specilications
and recommended corrective actions il runout is
excessive.
10 of 22
6. Measure the radial runout of the pilot bearing bore 9. Measure the housing pilot bore radial runout by at
with a dial indicator. Secure the dial indicator to the taching a dial indicator base to the flywheel. Posi
flywheel housing and position the pointer of the tion the gag e pointer against the housing pilot an d
dial indicator to contact the pilot bearing bore sur zero the gauge. Rotate the engine by hand . Mark
face. Turn the engine over by hand while observing the high and low points of the housing pilot as indi
the dial indicator. A typical runout limit is 0.005 inch cated by the dial indicator reading as the flywheel
(O. 12 7mm) turns .
7. Check the engine manufacturer's specifications
and recommended corrective actions if runout is The total radial runout is the difference between the
excessive . highest plus and minus readings. The typical max
8. Inspect the flywheel housing pilot bore for wear. imum limit is 0.008 inch (0.203mm). Refer to the
The 0 .25 inch (6. 35mm) pilot lip ofthe transmission engine manufacturer's specifications and recom
clutch housing can wear into the flywheel housing. mended corrective actions if runout exceeds spec
This can be caused by the transmission attaching ification .
bolts becoming loose (caused by road and engine
vibrations over a long period) or high mileage. Any
appreciable amount of wear on either housing will
cause misalignment.
Note: This wear will usually be in the area of the

3 to the 8 o'clock position. Refer to the engine
manufacturer's allowable wear limits.
11 of 22
RELEASE FORK
CO NTACT TIPS
RELEASE FORK
BUSHINGS
10. Measure the rear face axial runout by positioning INPUT SHAFT
SPLINES
the dial indicator pointer against the flange face of
the flywheel housing. Rotate the flywheel and re
14. Inspect the clutch release fork contact tips and
cord dimension at four places, each 90 degrees
bushing for excessive wear. Replace as neces
apart. Force the flywheel back to take up crank
sary.
shaft endplay prior to taking each measurement.
15. Inspect the input shaft for wear or damage of the
Rotate the engine by hand. Typical maximum al
splines , release bearing contact area, and pilot
lowable limit is 0.008 inch (O.203mm). Refer to the
bearing arbor. Service as necessary.
engine specifications and recommended correc
tive actions if runout exceeds specification. INPUT SHAFT
BEARING RETAINER
11. I nspect the clutch housing front pilot for excessive
wear in the same manner as was described for the /
flywheel housing. Wear in this area can result in
engine to transmission misalignment. Refer lo the
transmission manufacturer's specifications for al
lowable wear limits.
12. Check for wear or damage to the clutch housing
mounting flange . Replace clutch housing if re
quired.
13. Inspect the clutch release yoke cross shaft bush
ings for wear and lubrication. Replace as neces
sary.
INPUT SHAFT
16. If applicable, check the input shaft front bearing re

tainer for excessive clutch brake wear. Refer to the
transmission manufacturer's specifications and
recommended corrective actions.
17. Inspect for oil leaks that could contaminate the
clutch. Correct as required .
12 of 22
18. Used Ilywheels should be properly inspected lor 21. Clutch mounting holes should be checked to en
heat checks, warpage, scoring, or cracks as out sure that the threaded holes are deep enough to
lined in the Inspection Section. Flywheels having allow the clutch mounting capscrews to be
these conditions may need to be resurlaced or re threaded by hand to a point deeper that is required
placed depending on engine manulacturer's to install the clutch. Thread a mounting capscrew
specilications and recommended corrective mea into the hole to a depth equivalent to the thickness
sures. 01 the clutch cover. This check is to assure suffi
19. The inside and outside diameter 01 the clutch disc cient thread engagement. In addition, check to
wear pattern on the Ilywheel should be measured make sure the capscrew does not extend through
and compared to the new clutch disco II the new the flywheel enough to contact the engine hous
clutch disc lacings go beyond the current Ilywheel ing. Complete rotation 01 the Ilywheel may be nec
wear pattern, check to be certain that no wear step essary to assure there is no contact.
exists at the edge 01 the Ilywheel wear pattern. II a
wear step does exist, the Ilywheel must be resur
laced or replaced.
20. II no resurfacing is necessary, the Ilywheel lace
should be cleaned with emery paper to remove
traces 01 old Iriction material. For lurther cleaning,
reler to the cleaning section 01 this SI\/I code lor the
proper procedure.
Note: New flywheels usually have an anti- cor

rosion protection material applied to the sur
face. Refer to the cleaning section of this SM
code for the proper procedure.
INPUT SHAFT
SPLINES
22. Check spline prolile on input shaft lor wear and

damage. Smooth out any slight scratches on the
input shaft with emery boards or carborundum
blocks. Check the end 01 the input shaft at which
the pilot bearing is located. Smooth out slight
scratches with emery boards. II necessary, re
place pilot bearing
130122
Installation
A DANGER
Do not attempt to install and/or assemble the
tra nsmission without first placing blocking
under the flywheel housing to support the
engine. The engine could tilt/fall resulting in
severe personal injury or death.
1. After making all the proper inspections of the mat

ing components of the engine, clutch , and trans
mission , check that the flywheel and pilot bearing ,
on the end of the engine crankshaft, are correctly
installed , torqued , and lubricated. See engine
manufacturer's information for correct specifica
tions.
A WARNING
1. Pressure Plate
2. Clutch Disk
co mpounds, etc. can be hazardous. Serious
Figure 17
personal injury may result from misuse of Pressure Plate Removal
manufacturer's recommendations concerning 3. Place the pressure plate (1) and clutch disc (2) on a
these products . clutch dolly (3) or other appropriate lifting device.
O_O 1;2
, ,¡/' '. '-,
/ · ~ -í-¡-~
'-~/t ~ \ \¡Jrtyf;\~\ O
.¿/ "
)~o\~~)o ) FLYWHEEL
F
./~ THIS SIDb _
0/ /'Figure 18
.------\\~
Clutch Disc Orientation
4. Check to see that the clutch disc is correctly ori

ented . A stamping or label will identify which side
1. Guide Pin s 2. Flywheel
of the clutch disc should face the engine flywheel.
Fig ure 16
Install Guide Pins In Flywheel
2. Install the guide pins (1) in the upper holes of the

flywheel (2).
14 of 22
1. Guide Pins 3. Pressure Plate 1. Flywheel 3. Pressure Plate

2. Flywh eel 2. Retaining Bolts
Figure 19 Figure 20
Pressure Plate Installation Pressure Plate Removal
5. Carefully lift the pressure plate (3) and clutch disc 6. Apply Loctite® 242 to the threads of the retaining
into position and slide the pressure plate (3) onto bolts (2). Start the retaining bolts (2) into the fly
the guide pins (1) in the flywheel (2). wheel (1) a few turns at a time to gradually apply
spring pressure on the pressure plate (3) to hold
the clutch disc in place.
CAUTION
Handle the pressure plate and cover
assembly carefully; do not drop. Doing so
can cause minor bends or kinks in the four
drive strap assemblies. Any bends or kinks
can reduce or eliminate the ability of the
pressure plate to retract into the clutch cover.
Failure of the pressure plate to retract into the
cover will result in clutch drag due to
incomplete clutch release.
Note: When installing pressure plate retaining

bolts, be sure to progressively tighten the bolts in a
criss- cross pattern to prevent binding within the
clutch and ensure easy installation of the pressure
plate.
Figure 21
7. Remove the guide pins and install the last two re
taining bolts (1) into the flywheel (2). Begin to fully
tighten the retaining bolts (1) , a few turns at a time
to secure the pressure plate (3) .
15 of 22
1 5
II
8
I '
\ I
,,
o
10
6 2 1. Load Ring
Figure 22 Figure 24
Pressure Plate Torque Sequence Latch Load Ring
8. Continue tightening the retaining bolts in a criss 10. Check that the load ring (1) is in place and latched .
cross pattern using the sequence illustrated. The
final torque value is 55 ft lb (75Nm).
1. Release Bearing 2. Guide Tu be
Figure 25
1. Spline Guide Tool
Install Release Bearing
Figure 23
Spline Guide Tool Should Remove Easily 11 . Slide the release bearing (1) on to the transmission
guide tube (2).
9. Disengage the clutch trolly from the clutch as
sembly and remove the sp line guide tool (1) from Note: Do not grease the Teflon bushing of the re
the clutch disco lease bearing. If using new or replacement trans
mission, degrease the guide tube before in
stalling the release bearing .
16 of 22
Service Manual 0408 SM01-0118-056.0 0
1. Release Bearing 2 Release Fork
Figure 26 Figure 28
Engage Release Fork With Release Bearing Adequately Support Engine & Transmission
12. Engage the release lork (2) with the release bear 14. Ensure the engine is properly supported at the Ily
ing (1), as shown. wheel housing end of the engine .
Note: The clutch is automatically adjusted on the Note: The engine weighs approximately 3,000 lb
transmission input shaft during operation. (1361kg).
Reler to Figure 1.
15. II removed, loosely install the dampeners (9) and
capscrews, washers , and locknuts (5).
Note: Ensure that the release bearing load ring

(retainer clip) is in the closed position before
positioning the transmission to the flywheel
housing, see Figure :24.
16. Using an auxiliary lifting device, position the trans

mission (2) through the opening in the carrier
Irame.
Note: The transmission weighs approximately

650 lb (295kg).
1. Release Bearing 2. Shift Fork
Figure 27
Install Release Bearing
13. The shift lork components must rotate freely and

easily around their mounting point. The lateral
clearance 01 the rotary axis must not be too great.
The release bearing must slide easily over the input
shaft.
170122
Figure 29 Figure 30
Carefully Align Input Shaft & Clutch Splines Remove Inspection Cover
23. Remove Ihe mounling capscrews and clulch in

CAUTIION speclion cover from Ihe Iransmission housing.
Ca refully insert transmission input shaft into

clutch disc hubo Clutch disc or clutch bell
housing could be damaged. Do not use force
to push or knock input slnaft into hubo
17. Align Ihe inpul shaft on Ihe Iransmission lo Ihe

splines in Ihe clutch disc. Wilh the transmission in
neutral, genlly rolate the input shaft and carefully
slide the spline profile of the input shaft and clutch
disc hub inlo one another.
18. Once Ihe Iransmission input shaft has engaged
with Ihe pilol bearing in the flywheel, align Ihe en
gine lo Ihe Iransmission I)ell housing.
CAUTIION
Do not use the capscrews to seat the
transmission to the bell ilousing. Damage to
the input shaft, clutch, or other components
may result. The transmission must be Figure 31
properly seated before installing the Engage Load Ring With Release Bearing
capscrews.
24. Secure release bearing in load ring by using a
Refer lo Figure 1. levering 1001 (pry bar) lo press lower end of release
19. Apply a Ihin coaling of Loctile® 242 lo Ihe Ihreads fork lowards Iransmission. The upper end of Ihe
of the capscrews (6) . release fork Ihereby presses Ihe release bearing
20. Inslall Ihe capscrews and washers (6) lo secure lowards Ihe engine until il snaps inlo Ihe load ringo
Ihe transmission (2) to the flywheel housing (10).
Torque the capscrews (6) lo 55 ft lb (77Nm). NOTE: You must be able to feel and hear the load
21. Inslall Ihe capscrews , washers, and locknuts (7) ring snapping into place. By pressing the fork to
and shims and washers (B). Torque Ihe capscrews wards the engine, check that the connection has
(7) lo 200 ft lb (280Nm) . snapped in correctly.
22. Torque Ihe capscrews (5) lO 80-90 ft lb
(112-126Nm) .
18 of 22
Service Manual 0408 SM01 - ()18 - 056.00
Jl
1. Push Rod 2. Release Fork 1. Plston 2. Clutch Actu ator
Figure 32 Figure 34
Push Rod And Release Fork Compress Clutch Actuator Piston
25. Engage the push rod (1) with release fork (2) by in 27. Manually compress the piston (1) into the clulch
serting the ball end of the push rod (1) into the actuator (2) .
socket of the release fork (2) . Press the push rod
(1) towards the release fork .
2
2
1. Clutch Actuator 1. Clutch Actuator 2. Bleed Plug

2. Bleed Plug
Figure 33 Figure 35
Clutch Actuator Preparation Keep Piston Compressed, Tighten Bleed Plug
26 . Loosen Ihe bleed plug (2) on Ihe side of the clutch 28 . Keep the piston compressed in the clutch actualor
actuator (1). (1) and tighten the bleed plug (2) . Torque the bleed
plug (2) lo 16 ft lb (22Nm).
19 of 22
SM01 -018,-056.00 0408 Service Manual
Figure 38
1. NulS & Washers 'l. Push Rod
Install Inspection Cover
2. Cl ulch Acluator 5. Transmiss ion
3. Studs
32. Inslall lhe clulch inspeclion cover on lhe lransmis
Figure 36
sion housing. Torque lhe mounling ca pscrews lo
Clutch Actuator
17 ft lb (23Nm) .
29 . Pos ilion lhe clulch aclualor (2) on lhe lransmission
(5) while engaging lhe pw¡h rod (4) wilh lhe pislon
in lhe clulch aclualor (2).
30. Inslall lhe nuls and washers (1) which secure lhe
clulch aclualor (2) lo lhe studs (3) on lhe lransmis
si~n (5) . Torque lhe nuls (1) lo 17 ft lb (23Nm) .
2 3 4 5
1. Electrical Connector
2. Actuator
3. Transmission
1. Release Fork 3. Piston 5. ClulCh Actuator

Figure 39
2. Push Rod 4. Bleed Plug Transmission Actuator
Figure 37 33 . Connecl lhe wire harnesses lO lhe eleclrical con

Release Clutch Actuator Piston neclors (1) on lhe aclualor (2) on 10p lhe lransmis
sion (3) .
31 . Loosen lhe bleed plug (4) on lhe side 01 lhe clulch
aclualor (5) and allow lile pis Ion (3) lO exlend.
Check lo see lhal lhe push rod (2) is sealed cor
rectly in re lease lork (1) and pislon (3) . Torque lhe
bleed plug (6) lO 17 ft lb (23Nm) .
20 0122
1. Cable 3. Cable 1. Clutch Actuator 3. Alr Line

2. Sensor 4. Sensor 2. Transmlssion
Figure 40 Figure 42
Speed Sensors Clutch Actuator Air Line
34. Connect the cables (1,3) to the sensors (2,4) on the 36. Conneet the air line (3) to the cluteh actuator (1) on
Iransmission , as equipped . the transmission (2) .
Refer to Figure 1.
37. Secure the PTO adaptor (4) lo Ihe transmission (2)
by inslalling Ihe capscrews and loekn uts (3).
38. Conneel the drive shafts to Ihe transmission (2)
and PTO adaptor (4). See SM Keysheet Area
01 -022 for the correet procedure.
39. Install any sheet metal that was removed.
40. Install the engine housing. See SM Keysheet Area
01-071 for the correet procedure.
41. Check the transmission oil leve!. Add oil as re
quired. Refer to the Operator 's Manual for correet
type and proeedure.
Note: The clutch is self adjusting and requires no

manual adjustment.
42. Start the engine and check that all air and eleetrieal
funetions are operating normally. Road test the
crane to check for proper shift operation before re
1. Actuator 3. Transmission turning the erane to service.
2. Air Line
Figure 41
Transmission Actuator Air Line
35. Connect the air line (2) that is conneeled to the ae
tuator (1) on the top of the transmission (3).
21 of 22
SM01 -018:-056.00 0408 Service Manual
22 o f 22
Transmission, Recondition Safety Notice

Individuals who repair ZF transmissions are
This procedure covers the recondition of the ZF
responsible for their own wark safety. To avoid injury to
Astronic® transmlssion . Far removal and installation
personnel and damage to products, compliance must
procedures, see SM Keysheet Area 01 -18 .
be maintained with all safety regulations and legal
This procedure is intended far skilled personnel who requirements which apply to repair and maintenance
have been trained by ZF Friedrichshafen AG to carry work .
out maintenance and repair work on ZF products .
This document deals with the standard ZF product in Befare starting work, mechanics must familiarize
accordance with the state of development on the themselves with these regulations . Personnel required
date of issue. However, due to continuing to carry out repairs on ZF products must receive
development of the product, repair work might appropriate training in advance. It is the responsibility
of all companies to ensure that their repair staft are
require work practices and test or adjustment data
properly trained.
which are not contained in this manual. We therefore
recommend that work done on ZF products be
carried out only by skilled mechanics who have their
General InformaUon
practical and theoretical knowledge updated on a
Read this manual carefully befare starting any tests or
regular basis at our After-Sales Service training
repair work . Pictures, drawings , and components do
courses
not always represent the original object but are used to
Repair work, carried out at ZF service points, is illustrate working procedures. Pictures , drawings, and
cave red by warranty in accordance with the components are not to scale and no information about
prevailing contractual conditions. Damage resulting size and weight should be inferred (even within a
from work performed by non-ZF personnel in an complete illustration). Always follow the working steps
improper and unprofessional manner, together with as described in the tex!. After completion of repair work
added costs caused by such work , is excluded from and testing, skilled staft must satisfy themselves that
the contractual warranty agreement. This also the product is functioning correctly.
applies where genuine spares have not be used .
1 of 60
Table Of Contents
Safet y Notice ..................... . ........................ . ............... . ....... . ....... . ..... 1
General Information ............. .. ............... .. ........................................ . ..... 1
Environ mental Threats ...... .. ......... . " ................. . ......... . ... . ..... . ......... . ...... " 4
General Disassembly .......... . ............. .. ................... . .............................. , 4
Cleaning And Inspection ............................. . . . .............. . ............ . .. . ........... 5
General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Assem bly Torques . ........ . ...... . . . .......... . .. .. ..... . ........ . ............... . .... . ......... 6
Specia l Tools Avai'lable .. . ................... . ......... . .......................................... 7
Assem bly Torque Values And Adjustment Data ... . ............... . ............... .. . . ............ . 12
Preparatory Work .. . ... . .............. .. ............................. . . ......................... 16
With Transmission Swivel Stand ...... . .. . .. .. ... ... . . . . . . . . . . .. . ... . ....... . . . . . . . . .. . . . . . . . . .. . . 16

With out Tran sm ission Swivel Stand ... ..... . .. .. . . . . .. . . ... ... . . . . .... .... .. .. . . . .. .. . . .. . ... . .. . . 17
Clutch Actuator ...... . .... . .... . ....... ... ......... . .... .. ............. . ........................ 18
Removal . . . . .. . . .. ...... .. . . . .. . ... . . . . ... .. . .. . . . ... . . .... . . . ..... . . . ...... . . . . . ....... . ... . . . 18
Installatio n .. ... . ..... . . . .. ... .. . . .. . . . . ... . .. . ..... .. ..... .... . . . .... .. ... . . ... . . . .. . . . . ....... 19
Venting Clutch Actuator . . .... . . . . . . . ........ . . .. .. . . .. . .. ... . .. . .. . . . .. . .. . ........ . . .. . . .. ... . . 19
Output Flange . ....... . ......... . ............... . .............. . . ............... . .. . ............ . 20
Removal . ....... . . . .... . . . ... . . . ... . .. . . . .. ... .... . . . .... .. .. . .. .. . . . . .. . . . . . ... . . . . . . .. .. ..... 20
Installation . . . . .. . .. .. .. . . . . . .. . ... . . . . . . ... . .... .. . .. . . . .... . . .. . . . .. . . .. .. ... . ..... . .. ... . . .. . 20
Output Cover . ................. ... .............................. . . ............... . .. . .......... . 21
Removal . .. ..... . . ... . . . . . .. " .. .... . . .. ... ..... . .. . . .. .. .. . . .. ... . ... .. .. . . .. .. . . . .. . . . . .. .... 21
Installat ion .... .. .. .. .. . . ... . . .... ... . . . . . .. .. . . . ....... . . . ... . .... . . . .... . . .. .. . . .... . .. . .. . .. . 21
Range -Change Housing .. . ......... . ......... . ................... . . ........ . ...... . .. . ......... 23
Rem oval . .. . . .. ..... .. ... .. ..... .. ... . . . .. . ... . ... . .... . ... . .. . . . . .... .. . . .. . .. .. . . . . ... . . . .... 23
Installatio n .. .. . .. ... . ....... . .. . . .... . . . .. .. .. .... . . . . ..... . ... . . .. . .. .... . .. . ... ........ . ... .. 24
Range-Change Housing Di sassem bly . . ... .... . .. .. . . . . . . .. . . . .. . . .. . . . . ...... ... . . . . . .. . .. . . . ... 29
Ran ge - Change Housin g Asse mbly .. . . .. . . . . . . . . .. . .. . . . . . . . . . . . .. . . . . . . ...... . .. .. ... . .. . . . . . ... 29
Plan etary Carrier, Disassem bly ... . . . . . ..... .. . .. ............. . .. . .. . ...... .. .... . . . .. .. . . ... ... . . 30
Pl anetary Carri er, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Initi al Sun Gear Assembly .... . .. ... . . . . . . . . . ..... . ..... . ... . . . .... .. . . . .. . . . . . . ... . .... . . .. .... 31
Initial Pl anet Gea r Assem bly . . .. . .... . . . .. . .. . ... .. . ..... .. .. . . .. . .. ... . .. .. .... ........ .. .. .. . . 3 1
Initi al Planet Carrier Assembly . . . . . ... .. . .... .. . .. .... .. .. . .... ... . .. . .... .. . .. . . ... . . . . . ..... .. 32
Transmissio ns with intard er option only . ... . . . .. . ... .. . ... . . .... . . . . . . .. . .. . . .. ...... . . .. . . . . . . . . 32
Moving The Transmission Into A Horizontal Position .. . ........ . . . .............. ... . . ......... . . . . . 33
2 of 60
Service Manual 0504 SM01-()18-057.00
Transmission Actuator ........................................................................ . . . 34
Removal .......... . ........... ... . ... .. .. . .. .... .... .. . .. .. .. . . .. .. .. .. ... . .. . .. . .. . .. .. .. . . 34

Installation ....... ......... . . ..... 35
Disassembly 37
Assembly ..... .......... . ............... . . ...... . ...... . ................ . . .. . . 37
Programming The Transmission Actuator ....... . ........... .. . . . ......... .. ........... . ...... . .... 37
Moving The Transmission Into A Vertical Position .... . ................................. . .......... . 38
Clutch Release Mechanism ...... ................................................................ 39
Removal .... .... ... .... . . ................ . ....... .. . . . . . . . .. .... ...... .. ..... . .... . . . . 39
Installation .......... ...... ..... .. . ...... .. . .... . ................ ....... ..... . ..... . . ..... .... . 39
Connection Plate ........ .. .. . ............ . .. ... .... ........ ..................................... 40
Removal . . ........ . .. . ........ .. ....... . . .... .. ... ..... ... .... . .. .... . ........ .... . ... . 40
Shim Calculations .. .. . . ...... ... ..... . .. .... .. . ..... . ..... . ... .... . . . . .. . . . . .... ..... .... ... . .. 41
Installation ........ ... .. . .. .. ..... . . . ........... 42
Bell Housing ............ ... . . .... ... ..... . ....... . ....... . ...... . ....... . ........ ...... .. ... . ... 44
Removal ......... ... .. . ...... .. ....... .. ....... . .. .. . 44

Installation ..... .... ......... . ......... .. . . . . .. . . . . . ... . ...... . . . . ........ .. ....... .. ........ 45
Disassembly ... ... ...... .. ......... ......... ............... . ... . .... .. . . 46
Assembly ..... ... . .... . .. . . .. . .. ........ . .. .............. . ... . ......... . ... . . .... . . .... . . .. . 46
Shaft Pack ........... . ... . ............................ .. ........................................ 47
Removal 47
Installation 48
Shaft Pack, Recondition ............................... . ...... . ........... "...................... 50
Input Shaft Disassembly . 50

Synchronizer Disassembly .. . .... . ... ... . . . . ...... .. ...... . ..... . . . ..... . ..... . .. . ..... .... .. 51
Synchronizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . .. ............ . ..... . ..... . ... . ......... 53
Main Shaft Disassembly ..... . ... . 54
Main Shaft Assembly ...... . .... ... .. ... .... .. . . 55
Countershaft Disassembly ... .. ....... . . ............... . ...... . ....... . . . . ... . . ...... . .. 57
Countershaft Assembly ....... . ... ..... .. .... .. . .. ... . ........ . . .......... . 57
Gear Shift Shaft Disassembly .. . ......................... . ........... . ... . . ... ... ... . . 58
Gear Shift Shaft Assembly .... . .... . .. . . . .. ... .. . .. . .. . . .... .. . . . . 58
Main Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59
Disassembly 59
Assembly 60
3 of 60
SM01-018--057.00 0504 Service Manual
General Disassembly
CAUTIC)N
Transmission must NOT be hung on the input It is a good practice when disassembling complex
shaft NOR on the output flange. Individually, components to lay the parts out in the order that they
these points are not stru'cturally capable of were disassembled. Keeping the parts in this order
carrying the entire weight of the transmission. during disassembly, cleaning , and inspection will aid in
Mount the transmission on a proper stand to the assembly process.
avoid damaging the transmission.
use a hammer unless it has a soft face, do not force
In any cases of doubt, contact factory personnel for parts together, they must be free to rotate/operate and
directions. Whenever workinq on the transmission, not bind.
ensure complete cleanline:3s and professional
procedures. When dismantling and assembling the
transmission, use only the tools intended for this
pu rpose. Some special tools may be required. See
A WARNING
"Special Tools Avallable" found later in this document.
Parts held on with Loctite® can be loosened more result from misuse of these products. Read
effectively if warmed with a hot air blower. Do not use and follow all the manufacturer's
any device with an open flame or that reaches extreme recommendations concerning solvents and
tempe ratu res. cleaning solutions.
Environmental Threats 1. Drain any excess hydraulic oil, remaining within

the transmission, into an appropriate container.
Lubrtcants and cleaning agents must not be allowed to Properly store or dispose of the used oil.
enter the soil , ground water, or sewage system. 2. Cap/plug any openings in the transmission and
thoroughly clean the exterior surface to prevent
Ask your local environment agency for safety contamination from entering it. Pay particular
¡nformation on the relevant products and adhere
attention to the corners and angles of housings
to their requirements.
and covers when cleaning.
• Collect used oil in suitably large container. 3. Maintaining a clean environment throughout the
Dispose of used oil, dirty filters , lubricants and entire recondition procedure will help to ensure the
cleaning agents in accordance with environmen best results. Often, the internal components of the
tal protection guidelines. transmission are more likely to be exposed to con
taminants during the disassembly process than at
• When working with lubricants and cleaning
any other time. Work only on a clean site when dis
agents always refer to the manufacturer's in
assembling and assembling the transmission.
structions.
4 of 60
Cleaning And Inspection d. Shaft Seals : Always change shaft seals w ith
rough, torn, or hardened sealing lips . Sealing
contact surfaces must be totally clean and in
perfect condition .
A WARNING
e. Bearing: Should not exhibit any irregularities .
Replace if any signs of spalling , corrosion , dis
colo ration , material displacement, or abnor
mal wear exis!. If any damage exists that will
result from misuse of these products . Read
impair the cages ability to separate, retain , and
gu ide the rollers properly, the bearing should
be replaced. Always replace bearing cups
cleaning solutions.
when replacing tapered bearing eones.
1. Thoroughly clean all metal parts with an app roved 4. Carefully cover opened transmissions to prevent
cleaning solven!. Remove the remains of gaskets the entry of foreign matter.
from all sealing faces . Place parts on a clean , lint 5 . In the event of severe defects, contact factory per
free surface and allow to air dry. Exercise every sonnel for directions whether to repair or replace
precaution possible to keep all parts free of dust , any major componen!.
dirt, or any other foreign material during assembly.
2. AII Loctite®, Permatex@, or other sealant residue
mance of products.
3. Carefully inspect all components for damage, ex
cessive wear, fatigue or stress fractures, corrosion ,
deep scratches, cracks, and scuffed metal. Re
move any rough or sharp edges and burrs with an
oil stone , fine file, or hone. Replace any damaged
component , as required , using the following
guidelines:
a. Reusing Parts: Parts su eh as roller bearings,
multi-discs, thrust washers , etc. mu st be in
spected by a competent person who can de
cide whether or not they should be reused .
b. Reworking Parts : Rework may only be carried
out on the sealing contact surfaces using
plunge-cut grinding . Do not use an emery
cloth . Ensure that there are no signs of grind
ing traces or rifling from grinding. If rework is
needed on spacer washers, shims, etc., be
cause of clearance settings, ensure that the re
worked areas contain no face runout and have
the same surface quality.
c. Locking Plates, Seals, and Gaskets: Parts
which cannot be removed without being dam
aged must be replaced with new parts. AII
"soft parts", such as seals, gaskets, back up
rings, and o-rings, should be replaced. Re
place all rubber and polymer seals whenever
disassembling the transmission.
50f60
SM 0 1 -018·-057.00 0504 Service Manual
• Shaft seals with "compound steel and rubber
surrounds" should be treated on the outer edge
of the rubber surrounds as described for "rubber
surrounds".
• Duo shaft seals have two sealing lips. The
dust-proof sealing lip (X in Figure 1) must face
outwards .
• Fill the gap between the sealing lips so that it is
60 % filled with grease (use grease, e.g. pro
duced by Aral, such as Aralub HL2, or by DEA,
such as Spectron FO 20).
x • If possible, heat shaft seal bores to 104-122 ° F

(40-50 OC) to makes installation easier. Press in
the shaft seal with special tool or face plate level
to the relevant installation depth.
Figure 1
Duo Shaft Seal Retaining Agents : Retaining agents, such as Loctite
may only be used when specifically instructed . Always
comply with the manufacturer's directions for use
General Assembly when using retaining agents.
Find a clean site to asser,lble the transmission. Adjustment Specifications : During assembly, comply
Gaskets are installed without the use of sealing with all adjustment data, checking data, and tightening
compound or grease . When measuring torques specified .
silicon-coated gaskets, take care not to include the
silicon layer in the measurement. During assembly, Transmission Oil: After completing repai rs, fill the
comply with all adjustment data, checking data, and transmission with transmission oil. For the correct
tightening torques given in thl3 procedure. procedure and proper oil specification refer to the
crane 's Operator's Manual.
Bearings: If the bearings are pulled on while hot, they
should be heated up evenly (e.g. in heating cabinet).
The temperature should be approximately 185 ° F
(85 °C) and must not exceed 248°F (120°C). AII
A WARNING
bearings must be coated with transmission oil after Lubricants, sealants, joint and thread locking
assembly. compounds, etc. can be hazardous. Serious
Sealing : If a sealing agent is lo be used, comply with these products. Read and follow all
the manufacturer's directions for use. Apply a thin manufacturer's recommendations concerning
layer of sealing agent to the surfaces and spread these products.
evenly. Do not allow sealing agent to enter oil ducts
and bores. When working witl1 oil-carrying ducts and
bores, wipe off the sealing agent from the surfaces to
Assembly Torques
be sealed near apertures to ensure that no sealing
Tables located on Pages 12 thru 15 list the standard
agent penetrates the oil feeds when the surfaces are
torque values used to assemble the transmiss ion.
sealed .
Fasteners should be oiled before installation and
Shaft Seals: Consider the following information when tightened evenly in a criss cross pattern. Plugs and
installing shaft seals : fittings should also be oiled prior to installation. Any
torque values deviating from these tables are listed
• Apply a thin coat of sealing agent on outer edge specifically within the assembly procedure.
of shaft seals with "steel surround".
• Do not apply sealing agent to shaft seals with
"rubber surround ". Rather, apply a thin coat of
Vaseline® 8420 to the outer edge or wet with
common dish washing liquid .
6 of 60
Special Tools Available
Item IIlustration Part Number Description Qty Remarks
For lifting and handling of

3A 24274 Three Section Chain the transmission
assembly.
Installed on transmiss ion

2
·.CJ
-
-
/ ,/-:
'\
3A 24275 Lifting Lugs - M 10 2 housing to create secure
lifting points .
Installed on transmission
to allow vertical
3 3A 24276 Support 4
positioning of the unit
(Use instead of Item 15.)
Basic tool used wlth Item

4 3A 24278 Basic Tool - Puller 5 or Item 21 for pulling
bearings, shafts , etc.
Used for removing

tape red roller bearings
5 3A 24277 Gripper Insert
from countershafts in
conjunction with Item 4 .
Used for pulllng 10 ball

6 Extractor - For 10 ball roller bearings off
planetary carrier.
Used for pulling 11 ball

7 Extractor - For 11 ball roller bearings off
planetary carr ier.
7 of 60
SM01-018·-057.00 0504 Service Manual
Item IlIustration Part Number Description Qty Remarks
Used for removing the

8 3A 24281 Extractor inner bearing race on
planetary carrier.
~
9 3A 24282 Range change
Bracket 6
synchronizer assembly
&~0)
For securing reverse
10 3A 24283 Retaining Bolt 2
gear.
Used for holding and

11 3A 24284 Retaining Plate
I centering main shaft.
I
Used for setting selector
12 3A 24285 Setting Fixture
rails.
'.,
r
,/
~
/ 9"/ ':-/ "
13
&) 3A 24286 Bushing & Seal Tool 2
Used for fitting the
bushings and shaft seals
of the release fork.
Transmission Swivel
stand adaptor. Used in
3A 24289 conjunction with Item 15
14 Swivel Stand Adaptor
:~
(optional)
and in place of (Qty 4)
Item 3.
8 of 60
Used to hold the

transmission in
3A 24288 Transmission Swivel
15 conjunction with Item 14
(optional) Stand
and in place 01 (Oty 4)
Item 3.
For driving out dowel

16 3A 24290 Drift Key
pins
Used to simplily the

17 3A 24291 Assembly Plate assembly 01 the
synchronizers.
Used to simplily the

18 3A 24292 Tapered Sleeve 3 assembly 01 the
synchronizers.
Used to install pipe in

19 3A 24293 Pipe Driver
main shaft
W
For protecting input shaft
20 3A 24294 Protective Bushing during removal 01 shaft
ball bearing
Used to remove ball

21 3A 24295 Bearing Extractor bearings Irom input
shaft.
Used to center and install

spray pipe through the
bell housing.
22 3A 24296 Alignment Tool
(Alternatively a M4 stud
bolt and nut may be
used.)
90160
Used to center and install
23
/@ 3A 24297 Alignment Tool 1
spray pipe through the
bell housing .
(Alternatively a M8 stud
bolt and nut may be
used.)
Lifting and extracting

fixture for assembly and
disassembly of input
24 3A 24298 Pull Tube 1
shaft . Used in
conjunction with Item 25
.. and Item 26 .
I~
I A ~"
1¡)ll'V
1 ,. ,• .
Used to remove the input
-\j~)
25 3A 24299 Extraction Fixture 1 shaft in conjunction with
. r;~~
Item 24.
26 ~ · · (~ei
Ds:? r-L
3A 24300 Assembly Fixture 1
Lifting and extracting
fi xture for assembly and
d isassembly of shaft
pack. Used in
'--'
27
~)
~ \ ,; ;/-:
r-- I_ ~ ,
U -,
. ..
3A 24301 Seal Installation Tool 1
Used to install shaft seal
in release flange
28
l\a1 ) \ \
J
I
11
"~J.
! )r - 3A 24302 Seal Installation Tool 1
in output cover. Used in
29
\) 3A 24303
Spacer Ring
(for 105x125x12mm Seal)
1
in output cover. Used in
30 ,
~
' . .
n
~ ~~,~",,\,::/~§S<
..~,~ ",
",,~ ~ ,''' '

3A 24304
ISO 9141 Cable
Connection
1
Used in conjunction with
Item 31 EPD1
programming device .
1 O of 60
Item IIlustration Part Number Description Qty Remarks
EPD1 Programming Prog ram Plug In Card is

31 3A 24305
Device required, Item 36.
11 of 60
Torque Values - Metric Standard Pitch Thread
Class 8.8 Class 10.9 Class 12.9
Size
ft lb Nm ft lb Nm fl lb Nm
M4 2.1 2.8 3.0 4.1 3.5 4.8

M5 4.1 5.5 6.0 8.1 7.0 9.5
M6 7.0 9.5 10.3 14.0 12.2 16.5
M7 11 15 17 23 21 28
M8 17 23 25 34 29 40
M10 34 46 50 68 58 79
M12 58 79 85 115 100 135
M14 92 125 136 185 159 215
M16 144 195 206 280 243 330
M18 206 280 288 390 339 460
M20 288 390 413 560 479 650
M22 391 530 553 750 649 880
M24 494 670 708 960 811 1100
M27 737 1000 1032 1400 1217 1650
M30 996 1350 1401 1900 1659 2250
12 of 60
Service Manual 0504 SM01-C~18-057 .00
Torque Values - Metric Fine Pitch Thread

Class 8.8 Class 10.9 Class 12.9
Size
ft lb Nm ftlb Nm 11 lb Nm
M8xl 18 24 27 36 32 43
M9xl 27 36 39 53 46 62
Ml0xl 38 52 56 76 66 89
Ml0xl.25 36 49 53 72 62 84
M12xl .25 64 87 92 125 111 150
M12xl .5 61 83 88 120 107 145
M14xl .5 100 135 147 200 173 235
M16xl .5 151 205 221 300 265 360
M18xl .5 229 310 324 440 383 520
M18x2 214 290 310 420 361 490
M20xl.5 317 430 457 620 531 720
M22xl.5 428 580 605 820 708 960
M24xl.5 560 760 811 1100 922 1250
M24x2 538 730 774 1050 885 1200
M27xl.5 811 1100 1180 1600 1364 1850
M27x2 774 1050 1106 1500 1327 1800
M30xl.5 1143 1550 1622 2200 1881 2550
M30x2 1106 1500 1549 2100 1844 2500
130160
Torque Values - Steel Plugs Torque Values - Steel Unions

Material ()f Mating Hole Pipe O. D.
Thread Size ft lb Nm
Size Steel/Grey Cast Aluminium Alloy inches mm
ftlb Nm ft lb Nm 0.16 4 M8x1 16 22

0 .20 5 M8x1 16 22
M8x 1 15 20 7 10
0.23 6 M10x1 20 27
M10x1 20 27 13 17
0.31 8 M12x1.5 26 35
M12x 1.5 26 35 18 25
0.39 10 M14x1.5 27 37
M14x1.5 26 35 18 25
0.47 12 M16x1.5 33 45
M16x1.5 29 40 22 30
0.59 15 M18x1.5 37 50
M18x1.5 37 50 26 35
0 .70 18 M22x1.5 44 60
M20x1.5 41 55 33 45
0 .86 22 M26x1.5 66 90
M22x1.5 52 70 42 57
1.09 28 M30x1.5 96 130
M24x1.5 52 70 44 60
1.37 35 M38x1.5 103 140
M26x1.5 70 95 59 80
M27x2 59 80 52 70
M30x1.5 85 115 81 110
M 30x2 70 95 63 85
M33x2 88 120 81 110
M36x1.5 96 130 85 115
M38x1.5 103 140 88 120
M42x1.5 111 150 96 130
M42x2 107 145 92 125
M45x1.5 118 160 103 140
M45x2 111 150 96 130
M48x1.5 125 170 107 145
M48x2 118 160 100 135
M52x1.5 133 180 111 150
M60x2 144 195 122 165
M64x2 151 205 129 175
14 0160
Service Manual 0504 SM01-0·18-057.00
Assembly Torque Values
Torque Measurement
Description Remarks
ft lb Nm Device
Lightly oil plug before

Screw plug 44 60 Torque Wrench
installation
- --- - - - - -- - - - - - -. ¡-- -- - -
Lightly oil plug before
Screw plug 11 15 Torque Wrench
installation
_. . _. o ~ . __
- ' - -_.- - - - -- -. - - 1- " - - - t- - -
Li ghtly oi I bol! before
Hex bolt 88 120 Torque Wrench
ir:stallation
-- - .- - -- - -- - - - -- - -- -
Lightly oil bolt before
Hex bolt 37 50 Torque Wrench
installation
- - - - - --
Llghtly oil sensor's threads
Input sensor 33 45 Torque Wrench
before installation
Adjustment Data
Dimension Measurement
Description Remarks
Inch mm Device
Move tapered roller bearing

Setting end float of -1 .95 to + 1.95 into a neutral position (no
-0.05 to +0.05 Depth Gauge
countershaft thousandth clearance) and measure.
Use shim to set clearance.
r-- - -- .- - - -
Move tapered roller bear ing
Setting end float of -1 .95 to + 1.95 illto a neutral position (no
-0.05 to +0.05 Depth Gauge
countershaft thousandth clearance) and measure .
Use shim to set clearance.
- 1-- - - - -
End float of input Oto 4
Oto 0.10 Depth Gauge Use shim to set clearance.
shaft/connection plate thousandth
~.- -- - -- - -- - + --- - '-
End 1I0at of circlip on Oto 4
OtoO.10 Feeler Gauge Use circlip to set clearance .
input shaft thousandth
- -- -- 1- - -- - -- - ¡-- -- - - -- --
Output bearing end Oto 4
Oto 0.10 Depth Gauge Use shim to set clearance.
float thousandth
- - - ._-- - ~- - - -
End float of main 74 to 82
1.9 fa 2.1 Depth Gauge Use shim to set clearance.
shaft/sun gear thousandth
15 of 60
SM01-01 fl-057 .00 0504 Service Manual
Preparatory Work
A WARNING
Whenever repairs have been carried out, the
transmission must be placed on a test rig and
its function and seal integrity tested.
Note: This procedure contains descriptions of how

to disassemble and assemble transmissions with
and without using the transmission swivel stand;
Special Tools Item 15.
With Transmission Swivel Stand

1. Use the three section chain, Special Tool Item 1, to
raise and transport the transmission . The three
section chain is atlached to the lugs on the trans
mission .
2. Get oil collecting container ready.
3. Remove oil drain plugs and drain oil. Refer to the
Crane Operator's Manual for complete instruc
tions.
4. If available, se cure the swivel stand adaptor, Spe
cial Tool Item 14, to transmission swivel stand, Spe
cial Tool Item 15.
5. Secure the transmission to the swivel stand adap
toro
16 of 60
Without Transmission Swivel Stand

1. Place two wooden blocks on a piece of flal firm
ground .
2. Secure (2) M16x1 .5 lifting lugs lo Ihe range
change housing (see arrows). Attach cha in and
use a suilable lifting device lo lift Ihe Iransmission.
CAUTION
Do not use the lug on the range-change
housing for risk of housing breakage. One lug
is not strong enough for the entire weight of
the transmission.
3. Place Iransmission and clulch bell housing on Ihe

wooden blocks .
CAUTION
Transmission must not be placed on the input
shaft. Damage to input shaft, seals, and other
components may occur.
17 of 60
- Terminal
Clutch Actuator
I
-Terminal
Terminal
Wiring
Harness ~ Washer Hex Nut
.A>
~Push Rod
"
....
, ./ .' . y :- C over
.' ''''
..~. >. /.
- Release
Fork ~- Hex Bolt
Clutch Actuator 4. Remove hex nuts and washers and take off clutch
actuator.
Removal 5. Take complete push rod out of the release fork.
6. Measure and record the overall length of the push
1. Disconnect plug connection from transmission ac rod .
tuator and output speed sensor.
2. Remove wiring harness from cable terminals. NOTE: For removal and installation 01 release
3. Remove hex bolts and take off cover. fork, refer to Page 39.
18 of 60
- Terminal
Clutch Actuator
I
Vent Screw
Terminal
_J~~¿l¡~;~~\*~I~--- Terminal Jam Nut
Wiring 1 Hex Nut

Harness I ~ Washe r
)?) Stud
~I
Push Rod
/ .,,~
/ .. . .'- Cover
,/"
"-.. ,/'"
Release
Fork , - Hex Bolt
Installation
1. Check the overall length of the push rod, as re CAUTION
corded during removal ; adjust as required . Do not overtighten DI' severely bend the wiring
2. Tighten jam nut to 38 ft lb (52 Nm). harness. Avoid chafing points. Install the
3. Check that the studs in the clutch actuator are connectors with ample slack to avoid tension
properly installed. Studs should be tightened to 7 which could damage the wiring harness or
ft lb (10 Nm) . If damaged, change studs. unplug the connectors.
4. Insert push rod in recess in release fork.
5. When installing the clutch actuator, check connec 8. Inspect the in teg ri ty of the wiring harness and re
tions are in correct position and that push rod is place wires , connectors, or sheath ing as required .
seated correctly. 9. Connect the wiring harness to the transmission ter
6. Install the hex nuts and torque to 17 ft lb (23 Nm) . minals, output spee é sensor, and clutch actuator.
7. Install the cover with hex bolts: to rque to 17 ft lb
(23Nm) . Venting clutch actuator
1. To vent the clutch actuator, loosen vent screw.
2. If the seal on the ven1 screw is worn , rep lace seal .
3. Tighten vent screw to 16 ft lb (22Nm).
19 of 60
Installation
1. If worki ng with a transmission equipped with an in
tarder, ensure that the bolts are inserted in the out
put flange.
Output 2. Heat output flange to maximum temperature of
Flange 158 °F (70 °C) and slide onto spl ine of planetary
carrier until firmly seated .
\
.A. WARNING
Do not handle the output flange with your bare
hands. Heated output flange may cause
burns. Heavy gloves will be required to safely
and effectively handle the heated output
~ 801t*
flange.
3. Once the output flange has cooled down , install

the o-ring into groove between shaft and output
flange.
* Units with intarder feature only. 4. Install the disc using bolts and tighten to 88 ft lb
(120Nm).
Output Flange
Removal
1. Remove bolts and tak e off disco
2. Use commercially available three-arm wheel pull
er to remove output flang e and o-ring o
CAUTION
Use care not to damagt~ the output flange
during removal. Protect the output flange
from the arms of the wheEll puller if necessary.
20 of 60
Output Cover Output Cover
Note: The output cover is only used on transmis
Shim
\()()
sions which do not have an intarder.
Removal
1. Remove bolts and take off output cover.
2. Remove shim. Shaft Seal
3. Use appropriate tool to remove shaft seal to avoid
Bolt
damaging the output cover.
4. Remove bolts and take off auxiliary cover and gas
ket.
Installation
1. Coat the outer diameter 01 shaft seal with sealant.
See "General Assembly" on Page 6 lor the correct
type of sealant and procedures to follow.
2. Use the seal installation tool, Special Toolltem 28 ,
in conjunction with the spacer ring, Special Tool
Item 29, to press the shaft seal into the output cov
er until lirmly seated . Slightly grease the lip of the
shaft sea!.
3. Two measurements will be required to determine
the thickness 01 shims required to complete the Gasket
~rq
installation of the output cover:
• Measure the output cover between the sealing
J0
face and bearing seat to determine
Oimension "A" . Record Oimension "P\' in mm.
Bolt
• Measure from the ball bearing to the sealing face
~
01 range-change housing to determine
Oimension " B". Record Oimension "B" in mm.
Note: Shims are available in O.10mm incre

ments. Refer to the Crane Parts Manual for spe
cific part numbers.
A --
4. Refer to the example below which illustrates the Shaft
"A"-"B" calculation required:
Sample Calculation
Oimension "A" = 5.4mm
- Oimension "B" = 5.0mm Oepth I
Gauge Cover
Max Clearance = 0.4mm
End float tolerance 01 ball bearing: O fa 0.1 mm :3all
(Min End Float) O.4mm-O.Omm = O.4mm Bearln~ _

(Max End Float) 0.4mm-0.1mm = 0.3mm
Thickness of shim dimension = 0.3 fa 0.4mm B I

5. Select the appropriate shim using the measure Range-Change
ments taken Irom the specilic transmission parts Housing
being serviced and applying them to the "A"-"B"
calculation , as shown aboye.
21 0160
6. Coat sealing face of output cover with Loctite® 574,
Output Cover or equivalent. Be sure sealing faces are clean and
Shim "" \) \) 7.
free of oil and grease before applying the sealant.
Install the shim in the output cover and align the
output cover with the transmission housing.
8. Install the bolts through the output cover and tight
Shaft Seal en to 34 ft lb (46Nm).
Note: Be sure the range-change housing is prop

Bolt
erly installed before installing the auxiliary cover.
See Pages 24 thru 29 for complete instructions.
9. Once the range-change housing and plug have

been installed , clean sealing face of the range
change housing and auxiliary cover.
10. Align the new gasket and auxiliary cover with the
range-change housing.
11. Install the bolts through the auxiliary cover and
tighten to 58 ft lb (79Nm) .
Auxiliary
Cover
Gasket
22 of 60
Range-Change Housing Retaining
Plate O-rings Cylindrical
Removal Pin
I I King Pin
1. Position the transmission in vertical position with
~..=--- 6c L.....;..
output at topo Refer to Preparatory Work on Page e -e e _
16. I
2. Remove bolts, retaining plate, and king pino Take I
the o-rings off the king pino 80lt
3. Remove cylindrical pins and housing bolts. Use
the drift key, Special Toolltem 16, to drive out cylin
drical pins.
4. Secure lifting lugs to the output flange or planetary
Housing
carrier and attach chain.
80lt
5. Using an adequate lifting device, carefully raise the
complete range-change housing and set it down
on a clean, sturdy work surface.
6. Remove spray pipe.
7. Raise selector rails slightly and remove shift fork
and fulcrum pads.
8. Remove the sliding sleeve with synchronizer rings. Spray Pipe
Sliding Sleeve
A WARNING
Bushings and springs within the assembly will
Selector
Rail
Fulcrum
Pad
jump out when the synchronizer rings are
removed. Cover sliding sleeve with a cloth
prior to removal to prevent injury or lost parts.
9. Use two prybars to raise the plate and remove

clutch body.
10. Remove sleeve with circlip and shim.
Synchronlzer Rlng
Spring
Circlip
23 of 60
S M01-018--057.00 0504 Service Manual
Slraighl
Installation
Spacer
Blocks Edge 1. Snap circlip inlo sleeve and install Ihe sleeve on Ihe
Dimension
B1 main shaft .
2. Use Iwo seIs of spacer blocks and a straighl edge
lo set up a measuring plane. II is crucial Ihat the
spacer blocks are of exacl Ihickness to ensure an
accurale measuremenl .
3. Four measuremenls will be required lo delermine
Ihe Ihickness of shim required lo complete Ihe
inslallation of the oulpul cover:
• Measure from Ihe lop of Ihe slraighl edge lo Ihe
lop of Ihe circlip lo delermine Dimension "B1 '"
Record Dimension "B1" in mm.
• Measure from Ihe lop of Ihe slraighl edge lo the
seal ing face on the main housing lo delermine
Dimension "B2". Record Dimension "B2" in mm,
Sample Calculation
Dimension "B 2" = 95mm
- Dimension "B 1 " = 70mm
Dimension
Dimension "B" = 25mm
B2
Note: Also see Page 26 for dimensional views
of "B", "B 1 " and "B 2 "
Note : Shims are available ün O.10mm increments .

Refer to the Crane Parts Manual for specific part
numbers.
24 of 60
• Measure from the top of the straight edge to the
sealing fa ce on the range-change housing to Spacer Block
determine Dimension "Aj " . Dimension
Record Dimension "A j " in mm. Al
• Measure from the top of the straight edge to the Straight
top of the sun gear to determine Dimension "A2". Edge
Record Dimension "A 2" in mm.
Sample Calculation
Dimension "A 2" = 84.3mm
- Dimension ''A j '' = 55.1 mm
Dimension "A" = 29.2mm
Note: Also see Page 26 for dimensional views

of ''t\', "Al" and "A2 "
Dimension "A" minus Dimension "B" equals the

total clearance between sun gear and main shaft.
Maximum end clearance between the sun gear
and main shaft is specified as: 2mm Í 0.1 mm
Shim = Total Clearance-Max Clearance
Sample Calculation
Dimension "A" = 29.2mm
- Dimension "B" = 25.0mm
Total Clearance = 4.2mm
Maximum Allowable Clearance = 2.1mm

Total Clearance = 4.2mm
- Max Clearance = 2.1mm
Shim Thickness = 2.1 mm
25 of 60
Main Housi ng Straight Edge
Determining Dimension "B"
¡ -- - - - ¡ - - - - ' - - ! ---t.iooio
B ,.i
_ I r, I
_ J rl_~,--~-
- 1_ _\ I
i II
Main Housing
2sZL _ __
Straight Edge Sun Gear

Range Change
Housing
Determining Dimension "Pt t~;"

A 1
Range Change
Housing
26 of 60
Sliding Sleeve Sleeve Circlip
Shim
Plate Clutch Body Main Shaft
4. Install the shim on the main shaft.

5. Insert circlip in sleeve. Be sure the circlip is fully
seated in the groove of the sleeve.
6. Place the sleeve on the main shaft so the circlip is
seated on the shim.
7. Place the clutch body and plate in the range
change housing.
8. Insert the compression springs and bushings in
both synchronizer rings and use the brackets,
Special Tool Item 9, to secure the compression
springs and bushings, until the synchronizer rings
are fully installed.
9. Install the synchronizer rings in the sliding sleeve
and remove the brackets, Special Tool Item 9 .
10. Place the sliding sleeve with the synchronizer rings
Synchronizer Ring
bushings and compression springs on the clutch
body.
11. Check that the sealing faces on main housing and
range-change housing are clean and free of oil
and grease . Applya consistent bead of Loctite 574 Clutch Body -
to the sealing face of the main housing. Sleeve
Shim
1'
Spring
Circlip
27 of 60
Guide 12. Install the spray pipe, so the longer end of the offset
Range-Change Pin is facing range-change housing.
Housing 13. Install the fulcrum pads in the shift fork and position
Spray the shift fork correctly on the sliding sleeve and se
Pipe lector rail.
14. Install two M10 guide pins in the main housing and
another guide pin in the spray pipe .
15. Install two lifting lugs to output flange or planetary
carrier and attach chain.
16. Using an appropriate lifting device, carefully align
M10 the range-change housing with the guide pins in
Gu id e the main housing and the spray pipe.
Pins 17. Slowly lower the range-change housing into
place and guide the spray pipe into the bore of
Shift plug.
Fork 18. Remove the two M10 guide pins (1) from the main
housing.
Fulcrum
Pad
CAUTION
Professional work is essential when installing
the range-change housing and driving in the
cylindrical pins. There is a risk of breaking the
housing.
19. Align and tighten the plug to 11 ft lb (15Nm) .

20. Install the two cylindrical pins.
21. Screw in the housing bolts and tighten to 37 ft lb
(50Nm) .
22. Install new O-rings on the king pins .
23. Use the retaining plate to guide the king pin
through the range-change housing bore and into
the sh ift fork .
Note: If the king pins are inserted too far into the
range-change housing, the range-change
housing will have to be removed again.
24. Secure retaining plate with a bolt and tighten to

Retaining 17 ft lb (23Nm) .
Plate O-rings Cylindrical
Pin
I ~ King Pin
=- .;- -c-c-
Hous ing
Bolt
28 of 60
Range-Change Housing Disassembly
1. Remove output flange. Refer to Page 20 for com
plete i nstructions.
2. Remove output cover. Refer to Page 21 for com
plete instructions .
3. Remove all plugs and impulse sensors from
range-change housing . Remove the o-rings
from the plugs .
4. Use an extractor, Special Tool Item 6 or 7 , to take Extractor,
the ball bearing and range-change housing off Special Tool
Item 6 or 7
the planetary carrier.
5. Use a manual press to remove the ball bearing
from the range-change housing.
Range-Change Housing Assembly

1. Press the ball bearing into the range-change
housing (31 .010) .
2. Heat inner bearing race of ball bearing, to 248 ° F
(120 °C) maximum , and place complete range
change housing on planetary carrier until firmly
seated.
A WARNING
Do not han die the heated parts with your bare
hands. Heated parts may cause burns. Heavy
gloves will be required to safely and
effectively handle the heated parts.
Plug & Seal Ball Beari ng
3. Install new seals on the plugs. (small) -.......--..
4. Install the large plug and tighten to 44 ft lb (60Nm) .
5. Wait to install the small plug until after the range
change housing is installed on the main housing .
Final torque for the small plug is 11 ft lb (15Nm) .
Impulse
6. Install the Impulse sensors and tighten to 33 ft lb
Sensor
(45Nm) .
7. Install the output cover. Refer to Page 21 for com
plete instructions.
8. Install the output flange. Refer to Page 20 for com
plete instructions. Plug &
Seal
(Iarge)
Impulse Sensor
29 of 60
Planetary Carrier, Disassembly
Thrust Ring 1. On transmission equipped with intarder, remove
Ring Gear bolts and use two-arm extractor to pull off step
Carrier up gear.
2. Position the planetary carr ier sideways on ri ng
gear.
A WARNING
Removing the lock wire will allow the ring gear
carrier to disengage from the rest of the
Clutch Body assembly. Support the inner ring gear, while
removing the lock wire, to prevent it from
falling.
3. Remove lock wire using two small screwd ri vers.

4. Remove the ring gear carrier.
5. Remove the thrust ring from the ri ng gear.
6. Remove the retaining ring and take off the clutch
body.
0
7. Rotate the planetary carrierthrough 180 and drive
Step-Up the pins out of the planetary carr ier.
Gear* 8. Remove the planet gear sets and separate the
spacers and rollers from the planet gears .
9. Remove the sun gear.
10. Rotate the thrust washers 1/2 a tooth so that the
drive pins are released; remove drive pins
11. Pull the inner bearing race out of the carrier using
the extractor, Special Tool Item 8.
Thrust Sun
Washer Gear
Rollers
Thin
Spacer
~
Pi n Th in
Spacer
Th ick Planet
Spacers Gear
* On transmission equipped with intarder only.
30 of 60
Planetary Carrier, Assembly
Initial Sun Gear Assembly
1. Install the bottom drive pin in the sun gear.
2. Align the splines of the bottom thrust washer with
those 01 the sun gear. Slide the bottom thrust Top Thrust
washer onto the sun gear with the shorter offset Washer
lacing planet gears. Rotate and engage the bot
tom thrust washer with the bottom drive pino /SUOGear
~
3. Align the splines of the top thrust washer with those
of the sun gear. Slide the top thrust washer onto Top Orive
the sun gear with the shorter offset facing planet Pin
gears.
4. Install the top drive pin in the sun gear.
5. Rotate the top thrust washer upward and engage
the top thrust washer with the top drive pino -'o
/ Bottom
Orive Pin
Initial Planet Gear Assembly
If any one 01 the planet gears is damaged or worn to the

point 01 replacement, all planet gear sets must be
replaced.
1. Coat all rollers with clean transmission fluid. See
the Operator's Manual lor the correct type of fluid
to use.
2. Place one 01 the thin spacers in the planet gear and
Bottorn Thrust Washer
insert the rollers into planetary gear.
3. Insert thick spacer and again insert rollers in planet
gear.
4. Finally, fit one thin spacer.
5. This operation should be repeated for each plane
tary gear set.
31 0160
Initial Planet Carrier Assembly
Thrust Ring 1. Heat the inner bearing race to 248°F (120°C) maxi
Ring Gear mum and slide on planetary carrier until firmly
Carrier seated.
A WARNING
Do not han die the heated parts with bare
Clutch Body
2. Insert pre-assembled sun gear in planet carrier.
3. Hold the thrust washer upwards and engage the
pre-assembled planet gears with the sun gear.
4. Insert the pins through the planet gears. Use a
plastic hammer to carefully drive the pins flush with
the planet carrier.
5. Place the retaining ring in the planet carrier.
6. Position the clutch body on planet carrier and
install the retaining ring into the groove of the
Step-Up clutch body.
Gear* 7. Insert the thrust ring, ground side facing the outer
ring gear.
8. Install the ring gear, from output end of the assem
bly, and the ring gear carrier ,from input end.
9. Seat the ring gear carrier and ring gear so the lock
Thrust wire can be inserted in the groove of the ring gear,
using a small screwdriver. The lock wire must lie on
base of ring gear groove .
Transmissions with intarder option only

1. Install two M12 guide pins in the planet carrier.
2. Heat the step-up gear to 248-266°F
(120-130°C) and slide on planetary carrier until
firmly seated.
Sealing
Cap
A WARNING
Do not handle the heated parts with bare
Thrust Sun hands. Heated parts may cause burns. Heavy
Washer Gear gloves will be required to safely and
Rollers
Thin 3. Align the mounting holes with the M12 gu ide pins
Spacer and install the step-up gear with the offset side of
the step-up gear facing the output side of planet
Pin Thin
Spacer carrier.
4. Remove the two M 12 guide pins from the planet
carrier.
Thick Planet 5. Install the bolts which secure the step-up gear to
Spacers Gear the planet carrier and tighten to 100 ft lb (135Nm).
*On transmission equipped with intarder only.
32 of 60
Moving The Transmission Into A Reverse Reverse
Horizontal Position Idler Shaft Idler Shaft
The transmission should be moved to a horizontal

position, prior to installation of the range-change
housi ng assembly (planetary),
1, Replace both reverse idler shafts with a retaining
bolt, Special Tool Item 10, The retaining bolts will
secure the reverse gears,
2, Install the retaining plate, Special Tool Item 11, on
the main housing,
3. Arrange wooden blocks and an oil collecting con
tainer to accommodate the transmission once it is
positioned horizontally.
4. Secure two lifting lugs, Special Toolltem 2, onto the
main housing. Attach chains and use an appropri
ate lifting device to move transmission into horizon
tal positi on,
5. Any remaining transmission fluid may escape and Retaining
drain into the oil collecting container, Properly Retaining Plate
store or dispose of used oil. Bolt
6, Remove the lifting lugs. Retaining
7, For transmission actuator removal, refer to Page Bolt
Main
34. Housing
33 of 60
SM01-018J-057.00 0504 Service Manual
Transmission Actuator
Removal
Bolt Once the transmission actuator is removed, it will
require reprogramming to perform properly.
1. Remove breather or the elbow and adaptor from
the actuator, as equipped.
2. Remove the bolts which secure the actuator to the
transmission bell housing.
3. Separate the actuator from the bell hous ing.
4. Ensure that the rubber gaskets within the actuator
are removed or they may fal! into the bel! housing.
5. Remove the springs and detent pins from the bell
housing and actuator.
6. Replace the dowel pins only if damaged .
7. Remove the gasket and clean the sealing faces on
Detent Pin the bel! housing and actuator.
8. If the bell housing is removed, remove the bal! stud .
Ball St ud ---"<:';¿:"'--J~~
34 of 60
Installation
Ball Stud
AII other portions of the transmission should be
assembled before installing the actuator.
Reprogramming of the actuator will be required after it
is assembled.
1. Apply Loctite® 262 to the threads of the ball stud.
2. Install the ball stud in the bell housing and tighten
to 17 ft lb (23Nm).
3. Install setting fixture, Special Tool Item 12.
4. Use the lever to connect the open ends in relevant
selector rails. Turn input shaft, by hand, and use
lever to select gears.
5. Shift splitter group and range-change selector
rails towards output. Move center selector rail into
neutral position.
6. Remove the setting fixture and position a new gas
ket on the bell housing.
7. Shift pisto n rod (B ), on the actuator, into central
position (neutral). The correct position is reached
once slight resistance can be felt when pulling out
the piston rod (B).
8. Align the two other piston rods (A and C) to the
same position.
9. Selector gate (O) and piston rod (B ) must be
aligned.
10. Ensure that rubber gaskets are installed in the ac
tuator.
35 of 60
11. Install the piston guide , Special Tool Item 35, to
properly position the piston rods .
12. Install the springs and detent pins in the bell hous
ing .
13. Align the actuatar so the ball stud engages with the
selector gate and the piston rods (A, B, and C) en
gage in the selector rails.
14. Install the bolts and tighten evenly in a criss-cross
pattern to a final tarque value of 17 ft lb (23Nm).
15. Install the breather or the elbow and adaptor on the
actuator, as equipped. Tighten the adaptor to 13 ft
lb (18Nm) or the breather to 7 ft lb (10Nm).
16. Connect air line to the pressure limiting valve of the
transmission actuator.
17. Connect the wiring harness to the transmission ac
Piston Guide
tuator. Function testing , using the diagnosis de
vice , is not possible unless the wiring harness is
properly i nstalled .
Bolt
Spring
Detent Pin
Ball Stud ----:~.;.c:.....-k~~
36 of 60
Transmission Actuator Upper Tabs
Seclion Boll
Disassembly
1. Remove the bolts which secure the upper section
to the lower section.
2. Raise the upper section and carefully insert the
tabs of the upper section into the slots on the lower
section
3. Unplug the connectors from the upper section.
4. Remove the rubber gaskets from the lower section. Gasket
5. Remove the gasket from the sealing surfaces of the
upper and lower sections.
Assembly
1. Install the rubber gasket on the interior of the lower
section.
2. Align the gasket on lower section before installing Gasket
the connectors in the upper section.
3. Install the connectors in the upper section. Ensure
the connection is tighl.
4. Place the upper section on the lower section mak
ing sure that the gasket remains aligned.
5. Install the bolts and tighten to 7 ft lb (9.5Nm).
6. Install the rubber gaskets on the boltom of lower
section
Lower
Programming The Transmission Actuator Section
Gaskets
When the transmission actuator and/or the upper sec

tion are changed, customer-specific programming
and/ or parameter setting are required. The following
Special Tool Items are required to program the actua Upper
tor: Section
Special Tool
Item Description
34 Table Mode Adaptor

Connector
31 Programming Device
36 Plug In Cards
Lower
32 Testman Set
Section
33 Diagnosis Software
33 Diagnosis Software
When setting parameters, the EOL data is entered into Connector

the transmission actuator electronics using the
Testman Set and relevant software.
37 of 60
Moving The Transmission Into A
Vertical Position
1. Secure two lifting lugs, Special Tool Item 2, onto the
main housing. Use 2-3 shims to bridge the offset
to the centering diameter (see arrows) .
2. Arrange an oil collecting container to accommo
date the transmission once it is positioned vertical
IV·
3. Attach a chain and carefullv raise the transmission.
4. Install the supports, Special Tool Item 3, to the
housing.
5. Carefullv place the transmission in a vertical posi
tion bV standing it on the supports .
6. AnV remaining transmission fluid mav escape and
drain into the oil collecting container. Properlv
store or dispose of used oil.
Support
Ret aining
Plate
38 of 60
,'.:
, ~~>:
~
" r"':" ) ': "
. .: -:- " ..
.: :~<8
:-: -1, .
" -'lt
Shaft
Seal .':.: ¿ .....
Release
Fork
Release
Bearing
Shaft
Seal
Ball Cup
Bolt
Clutch Release Mechanism Installation

1. Assemble the release fork. Use the bushing and
Removal seal tool , Special Too l Item 13 , to install both the
1. Remove the bolts from the shaft. bushings an d shaft seals.
2. Take the release bearing and release fark off the in 2. Fill the shaft seals , between its sealing lips , w lth
put shaft. grease. Do not grease the bushings.
3. Slide the shaft out of the release fork. 3. Slide the shaft into the release fork. Take care not
4. Disassemble the release fork. Use appropriate to damage the shaft seals .
tool to remove shaft seals and bushings. Replace 4. Position the release bearing over the input shaft .
the ball cup if it is damaged or worn. Do not grease the face of the release beanng or the
mating surface of the pressure plate .
5. Grease the mounting surfaces , on the release fork,
far the release bearing with OLlSTA LONG-TIME
3Ep, ar equ ivalen!.
6. Engage the release fork with release bearing .
7. Secure the shaft using the bolts. Tighten the bolts
to 85 ft lb (115Nm) .
39 of 60
Pump
Cover Brake Shim
Spring
\ /
Detent
Pin
Dowel
Pin
A
Brake Outer Brake

Piston Discs
Bolt
Bolt
Release B
Flange
Connection Plate
Removal
1. Remove the bolts.
2. Use an appropriate tool to lift off connection plate
or use M8 disassembly thread (See arrows A & B) .
It is easier to lift off the connect ion plate when the
release flange is installed . This gives a lifting point
and will help prevent the connection plate from
twisting .
3 . Remove shims, detent pin , and sp ring .
4 . Remove bolts and lift off release flange .
5. Use appropriate tool to remove shaft seal from re
Release
lease flange.
Flange
6 . Remove brake cover from connection plate and re
move outer brake discs and inner brake discs.
7. Remove the brake piston . When removing the
grooved ring , note the o ri entation of the part to en
sure prope r i nstallation .
8. Replace the dowel pins only if defective .
9 . Remove the capscrews and washers.
10. Remove the pump cover, pump shaft, and rotor.
40 of 60
Shim Calculations 6. Measure the distance between the sealing lace 01

1. In arder to set the specilied countershaft end toler conneclion plate ancl mounling lace 01 shim Y:
ance 01 :±O.05mm, "zero clearance" must lirst be 8. g . dimension bl = 5.50mm
reached . Rotate inpul shaft back and lorth several
7. Determine thickness 01 sh ims X, Y, & Z:
limes lo lully seal the bearing 's tape red rollers on
the outer bearing races . Pump (shim Z):
2. Use a mandrel to place outer bearing races on la C 1 + C2 = C = shim Z
pered rollers (no clearance). 2.00mm +O.05mm = 2.05mm = shim Z
3. Use a sharp object lo check whether the bearing 's
tapered rollers can move . Zero clearance is Transmission Brake :
reached once the tapered rollers are secure but a1 +a 2 = a = shim X
there is no preload . 1.95mm +O.15mm = 2.10mm = shim X
4 . Measure distance between outer bearing race and
Input shaft (shim y) :
housing sealing lace :
b 1 - b 2 = b = shim Y
Countershaft
5.50mm - 3.90mm =, 1.60mm = shim Y
Pump e.g. dimension C 2 = 2.00mm
8. The lollowing tolerances should be noted when se
Trans . Brake e.g. dimension a2 = 1.95mm
lecting shims X, Y, & Z:
Input shaft e.g. dimension b2 = 3.90mm
Countershafts:
5. Measure the distance between the sealing laces 01 -O.05mm (Preload) lo +O.05mm (Clearance)
the connect ion plate and:
Input shaft :
Pump Cover e.g . dimension c1 = O.05mm Omm to O.10mm (Clearance)
Brake Cover e.g . dimension al = O.15mm The clearance is deducled Irom the shim
thickness.
41 0160
s 0 1-018,-057.00 0504 Service Manual
ShimZ
ShimX
Inner Brake Spring
\-
Detent
Pin
Dowel
Pin
A
Discs
Bolt
Bolt
Release B
Flange
Installation
1. Clean sealing faces on the connection plate, re
lease flange and main housing . AII threaded bores
in the bell housing must be clean and free of oil and
grease.
2. Install the rotor, pump shaft, and pump cover.
3. Evenly install the bolts and tighten to 7 ft lb (10Nm) .
4 . Install the grooved ring in the piston , referencing
the notes taken during removal to ensure proper
orientation .
5. Install the piston in the connection plate.
6. Install the outer brake discs and the inner brake
discs.
Release 7. Place the brake cover on connection plate sealing
Flange
face . Collar of brake cover faces the brake disc
pack .
8. If removed, install the dowel pins in the bell hous
ing.
9. For proper selection of shims X, Y, & Z, refer to
Page 41.
10. Place shims X & Z on outer bearing races . Do not
mix up the shims .
11. Slightly grease shim Y and place in connection
plate.
42 of 60
12. Apply sealant to the outer diameter of the shaft seal
and to the inner diameter of its mating bore in the
release flange. Refer to "General Assembly" in
structions on Page 6 for specific instructions on
seal installation .
13. Use the seal installation tool, Special Toolltem 27,
to press shaft seal into release flange until fully
seated . Sealing lip must face towards the inside of
the transmi ssion .
14. Apply a consistent bead of Loctite® 574 to the seal
ing face on the release flange.
15. Secure the release flange on connection plate us
ing bolts. Evenly tighten the bolts to 17 ft lb
(23Nm) .
16. Apply a consistent bead of Loctite® 574 to the seal
ing face of the connection plate.
17. Carefully guide the connection plate over the input
shaft and align the mounting holes with the bell Pump Connection
housing. Engage the drive tab on the pump with Drive Tab Plate
the groove in the countershaft before attempting to
seat the connect ion plate .
18 . Apply Loctite 241 to the bolts . Evenly tighten the
bolts to 3 7 ft lb (50Nm) .
Pump Drive
Groove
43 of 60
Bell Housing
Removal
Bell 1. Remove the plug or switch and pin, as equipped .
2. Remove the retaining rings from the input shaft and
ball bearing.
Fllter 3 . Remove the filter from the bell housing .
4. Place the protective bushing, Special Tool Item 20,
on the input shaft .
. ~ 5. Install the bearing extractor, Special Tool Item 21 ,
\
through the ring groove of the ball bearing .
Bolt 6. Secure the basic tool, Special Tool Item 4, to the
bearing extractor and remove the ball bearing from
the input shaft.
Main 7. Remove the bolts which secure the bell housing to
input
Hous ing the main housing .
Retaining Shaft
Rings 8. Drive out dowel pins using drift key, Special Tool
Item 16.
9 . Secure lifting lugs, Special Toolltem 2 , to bell hous
ing. Bridge any offset, using shims as required , to
Basic stabilize the center of gravity of the bell housing ,
Tool (See arrows).
Bearing 10. Attach the three section chain, Special Toolltem 1,
Extractor to the lifting lugs .
11 . Using an appropriate lifting device, carefully lift and
separate the the bell housing from the main hous
ing.
Bell
Housing
44 of 60
Installation
1. The sealing faces on bell housing and main hous
ing must be clean and free of dust, oil, and grease.
2. Apply a consistent bead of Three Bond® 1215 to
the sealing faces of the main housing and bell
housing .
3. Use alignment tools, Special Tool Items 22 and 23
(see arrows) to center the spray pipes and align
with the connections in the bell housing.
4. Carefully place the bell housing on the main hou
sing.
5. Check that the spray pipes are seated correctly in
the bell housing.
6. Insert dowel pins (do not yet drive in all the way)
and tighten bolts to 37 ft lb (50Nm) . Then drive in
dowel pins until fully seated.
7. Insert retaining ring in groove of ball bearing.
8. Use a heating mandrel to heat inner race of ball
bearing to approximately 176-194 oF (80- 90 oC).
A WARNING
::::::::::.":"-- - - - Extraction
9. Insert ball bearing until retaining ring is Iying on bell Fixture
housing . If necessary, drive the ball bearing in us
íng the outer diameter of the pull tube, Special Tool Pull
Item 24. Pull input shaft into ball bearing using the Tube
pull tube in conjunction with extraction fixture , Spe
cial Tool Item 25, and continue pulling until firmly
seated.
10. Remove the extraction fixture and pull tube.
11. Use a feeder gauge to measure the available thick
ness of the groove for the retaining ringo When se
lecting the retaining ring, the toleran ce allowed is
0.00- 0.10mm clearance.
12. Install the retaining ringo The retaining ring must lie
on base of input shaft groove.
13. Insert pin and install the switch or install the plug,
as equipped. Tighten the switch to 33 ft lb (45Nm)
or tighten the plug to 26 ft lb (35Nm).
14. Install the filter.
15. For instructions on how to install the connection
plate, see Page 42.
45 of 60
Bell Clamping Pins
HOUSing~
Outer Spaeer
Bearing Raees
Type Plate
Breather
Media ~ ,('.;f' ¡~
,,"" lO
~ ', ' -:: \

"----- Blind Rivet
~ \ /
! v-
Plug
Bolt
Disassembly Assembly
1. Remove the bolts and eover from the bell housing; 1. Press the outer bearing raees in the bell housing
remove breather media. until fully seated.
2. Remove the elamping pins and spaeer from the 2. Install aH plugs in the bell housing , as equipped .
bell housing. 3. If required , install the type plate using blind rivets .
3. If required, remove the blind rivets by drilling them 4. Install the elamping pins and spaeer in the bell
out; remove the type plate. housing.
4. Remove any plugs frorn the bell housing, as 5. Insert the breather media in the bell housing and
equipped. seeure with eover and bolts .
5. Remove the outer bearing raees from the bell
housing.
46 of 60
Shaft Pack
Input Shaft
Removal
1. Reler to Page 44 lor complete instructions on bell
housing removal.
2. Remove retaining bolt, Special Tool Item 10, and
slide reverse gears to the side.
3. Remove the two spray pipes .
4. Tilt the countershafts away Irom the input shaft and
remove Irom the main housing.
5. Place assembly lixture, Special Tool Item 26, over
the input shaft and slide the legs 01 the assembly
lixture, over the selector rails.
6. Pull tube, Special Toolltem 24, consists 01 two hal
ves, one pipe, and one threaded piece. On one
side, insert the lugs 01 the two halves into the
groove 01 the input shaft. On the other side, install
the threaded piece and pipe.
7. Install a Mi O lug bolt, Special Tool Item 2, onto Pull Tube
threaded piece. Assembly
8. Attach the three section chain, Special Toolltem 1, Fixture
onto the lug bolt.
9. Use an appropriate lifting device to raise the input Selector
shaft and main shaft, as an assembly, out 01 the Rails
main housing.
10. Slide the legs 01 the assembly lixture upwards and
remove lrom the selector rails. II working with a
16-speed main shaft, hold the sliding sleeve and
then remove the selector rails.
11. Clamp the main and input shaft in a vice with pro
tective jaws.
Main Shaft Main Shaft

10/12-Speed 16-Speed
:"
,- _-L'
Sliding
Sleeve
470160
SM 01-018·-057.00 0504 Service Manual
12. Move the sliding sleeve towards the output end of
the shaft to access the retaining ring o
13. Use the correct type of retaining ring pliers to pull
the ends of the retaining ring together. Lift the input
shaft off main shaft .
14. Remove the pull tube and legs of the assembly fix
ture from the input shaft.
15. Secure the guide plate portion of the assembly fix
ture to the input shaft with retaining ringo
16. For instructions on how to disassemble the input
shaft, refer to Page 50.
Installation
1. Place the guide plate portion of the assembly fix
ture, Special Tool Item 26, over the input shaft .
2. Install retaining ring o
3. Pull tube, Special Toolltem 24, consists of two hal
ves, one pipe , and one threaded piece. On one
side, insert the lugs of the two halves into the
groove of the input shaft. On the other side, insta"
_ Retaining the threaded piece and pipe .
Ring 4. Install a M 1O lug bolt, Special Too I Item 2, onto
threaded piece.
5. Attach the three section chain, Speeial Toolltem 1,
onto the lug bolt .
6. Use an appropriate lifting device to place the input
shaft on the main shaft.
Guide 7. Move the sliding sleeve towards the output end of
Plate the shaft to aceess the retaining ring on the input
shaft.
8. Use the correet type of retaining ring pliers to pul!
the ends of the retaining ring together. Set the in
put shaft on main shaft so the retaining ring en
gages with the groove in the main shaft.
CAUTION
Be sure the retaining ring engages with the
main shaft. If the retaining ring does not
properly engage with the main shaft the
Pull Tube transmission unit will ultimately fai!. Check
Assembly
Fixture for proper engagement of the retaining ring
before continuing assembly process.
9. Insert the preassembled selector rails into their

corresponding sl iding sleeves. If working with
16-speed model, hold the sliding sleeve up to en
gage the selector rail.
10. Insta" the legs of the assembly fixture and slide
over the selector rails .
11. Use an appropriate lifting device to place the input
shaft and main shaft assembly into the main hous
ing.
48 of 60
12. Insert the countershafts into the main housing and
engage the gear teeth so the timing mark on the
top gear is aligned with the narrow window in the
top gear of the input shaft (See arrows).
13. Engage the reverse gear of each countershaft with
its corrisponding intermediate gear.
14. Install the retaining bolts, Special Tool Item 10, to
secure the position of the reverse gears.
15. Select neutral (move sliding sleeves into neutral
position) and rotate through shaft pack once.
16. Install the spray pipes .
17 . For instructions on bell housing Installation, Refer
to Page 45 .
49 of 60
Split
Input Shaft
Axial Roller
Cage
Washer
Axial Needle
Cage
Axial Needle
Cage
Washer
Synchronizer
Shaft Pack, Recondition

Pin Input Shaft Disassembly
Input Shaft
1. Secure the input shaft in a vice with protectlve jaws .
2. Use a chisel to remove the retaining ring whlch se
cures the split rlng . The retaining ring will be de
stroyed durlng removal.
Thrust 3. Remove the split ring , washer, axial rolle r cage ,
Washer bearing race , washer, axial needle cage , hel ical
gear, axial needle cage , and washer from the input
shaft.
4. Remove retaining rings and separate the bearing
disc from the helical gear.
5. Remove the synchronizer from the input shaft .
6. For instructions on synchronizer disassembly, Re
fer to Page 51 .
7. If stlll installed , remove the retaining ring and guide
Counting plate from the input shaft.
Disc 8. Using an arbor press , remove the counting disc,
thrust washer, and helical gear from the input shaft.
9. Remove the pln from the input shaft.
50 of 60
Synchronizer Oisassembly Detent
Overdrive
1. Place synchronizer on a clean working surface Pin Spring
with the collar facing down. Synchronizer
F~ing
A WARNING
Pins and springs within the assembly will
jump out when the synchronizer rings are
removed. Cover sliding sleeve with a cloth
prior to removal to prevent injury or lost parts.
2. Cover the synchronizer assembly with a clean

cloth to capture springs and/or pins as the syn
chronizer ring is removed. Center
3. Push the pin through the sliding sleeve. Plate
4. Rotate the center plate through half a tooth and re
move the sliding sleeve.
5. If necessary, press the long pins and short pins out
of the synchronizer rings. Oirect Orive Tapered
Short
Synchronizer Sleeve
Pin
Synchronizer Assembly Ring
Locate the identification number on the synchronizer
rings to determine whether the assembly is "overdrive"
Synchronizer
or "direct drive". Refer to the chart below.
Ring
Overdrive Direct Drive
1328302014 1328302013
1328302086 1328302085 Detent
1328302 113 1328302 112 Pin
1. If removed, press the long pins and short pins into Sliding
Long Center
the synchronizer rings. Sleeve Plate
2. Place center plate on sliding sleeve and rotate Pin
through half a tooth.
3. The hole in the sliding sleeve must be flush with
one of the recesses in the center plate.
4. Insert the pin through sliding sleeve hole until firmly
seated. Direct Drive Overdrive
5. In each of the three holes of the synchronizer ring, I
insert one spring and one detent pin and secure ¡;Ir ~.
el
with tapered sleeves, Special Tool Item 18. .::-y-
..
-J -.r ¡
,-,
\
"--t
I "
.c- - )
-l.'..' s
51 of 60
6. Place synchronizer ring and subassembled sliding
sleeve and center plate on assembly plate, Special
Toolltem 17.
7. Put the synchronizer ring, with the assembly
sleeves installed, on the long pins of the other syn
chronizer ringo
8. Evenly press synchronizer rings together.
9. Remove the tapered sleeves while pressing down
on the synchronizer ringo
Assembly 10. Rotate synchronizer. Move synchronizer into cen
Plate tral position by lifting the center plate with the slid
ing sleeve and pressing down on the synchronizer
ringo
11. Check that the pin is properly located and has not
fallen out.
Tapered
Sleeves
52 of 60
Service Manual 0504 SM01-tJ18-057.00
Retaining
Input Shaft
Washer
Axial Needle
Cage
Axial Needle
Cage
Washer
Input Shaft Assembly Pin

Input Shaft
1. Secure the input shaft in a vice with protective jaws.
2. Install the pin in the input shaft.
3. Install the helical gear and thrust washer on the in
put shaft.
4. Install the counting disc on the input shaft. A clear
ance of up to 0.012 in (O.3mm) is permitted be
tween the pin and the counting disco
5. Install the guide plate portian of Special Tool Item
26 and secure with retaining ringo
0
6. Rotate the input shaft 180 and clamp it in a vice
with protective jaws.
7. Install the synchronizer, washer, and axial needle
cage on the input shaft.
8. Install the bearing disc and both retaining rings in
the helical gear.
9. Install the helical gear on the input shaft .
10. Install the axial needle cage, washer, bearing race
Retaining
with retaining ring, axial roller cage, washer, split
Ring
ring , and new retaining ring on the input shaft .
11. Se cure the retaining ring by peening it (3x1200).
12. For instructions on how to install the shaft pack Re
fer to Page 48 .
Guide
Plate
53 of 60
S M01 -018--057.00 0504 Service Manual
Retaining
HElieal Ring
Gear Washers
,
I \
I
Washer
Sliding
Washer
Sliding . Helieal
Sleeve Gear Oil
Washer Pipe
Retaining
Ring Main Shaft
Washers n I .()
l ~Cj0
SlIding . il
Sleeve
Washer
., '0
./ Q
\1;
'
'\
'r'
1
1
Shaft
Key
Oil
Pipe
16-Speed
Transmission
Shown Helieal
Gear
Main Shaft Disassembly

10 or 12-Spe'ed Shown
1. Secure the main shaft in a viee with protective jaws.
2. Remove the shaft key from the main shaft by using
a small screwdriver and pulling the shaft key down
ward , as shown.
3. Remove the sliding sleeve from the main shaft.
4. Remove the first splined washer by rotating it 1/2
tooth and sliding it off.
5. Remove the helieal gear.
6. Remove the washer and retaining ring from the he
lical gear.
7. Rotate the pair of washers 1/2 tooth and remove
from the main shaft.
8. Remove the next helieal gear.
Shaft Key - - -
9. Remove the washer and retaining ring from the he
lical gear.
54 of 60
Sliding
Sleeve
Washer
Helical
Gear
Retaining
Ring
Retaining
Ring Washers
011
Helical Pipe
Gear
Main Shaft
Washer ( "
Sliding
. I
Sleeve '!
1 Washer
Oil Shaft
Pipe Key
10 And 12-Speed
Transmission Helical
Shown Gear
10. Again , Rotate the next splined washer 1/2 tooth Main Shaft Assembly
and remove from the main shaft .
1. Secure the main shaft in a vice with protectlve jaws .
11 . Remove the center sliding sleeve .
2. Use the pipe driver, Special Tool Item 19, to install
12. Remove the remaining spl ined washers, helical
the oil pipe, located on the flush end of the main
gears , and sliding sleeves from the main shaft in
shaft, as required . The oil pipe should prot rude
the same manner, as before. The number of com
from the end of the main shaft by 0.55-0 58 in
ponents varies based on the number of speed
(14-15mm) .
ranges available to the transm ission . Refer to the
Figures on Page 54 or Page 55 , as equipped.
3. If working with the 1G-speed version , install the
sliding sleeve on the main shaft so the recess in
13 . Remove the retaining rings and separate the
spline faces the shaft key.
splined washers from the helical gears, as
4. Slide the was her onto the main shaft. Rotate the
equipped.
washer 1/2 tooth and lock with the shaft key. The
14. If either of the oil pipes are damaged, remove and
shaft key is located in the main shaft spline where
repair or replace, as required.
the blind hole is located .
55 of 60
10 or 12-SpeE!d Shown CAUTION

When installing the washers, within the helical
Main Shaft gears, be sure to locate the sharp side of the
washer (side which protrudes due to
stamping process) away from the retaining
ring o Early failure of retaining ring may occur
Washer if sharp side of washer rests on the retaining
ring o
5. Insert the splined washers in each af the helical

gears and install the retaining rings, as equipped.
6. Install the helical gear anta main shaft .
Shaft Key
7. Install the washer (s), as equipped, anta the main
shaft and ratate 1/2 taath and lack with the shaft
key.
8. If warking with the 16-speed versian , install the
next helical gear anta main shaft.
9. If working with the 16-speed versian, install the
washer anta the main shaft and ratate 1/2 taath
and lack with the shaft key.
10. Install the sliding sleeve anta main shaft .
11. Install the washer anta the main shaft and ratate
1/2 taath and lack with the shaft key.
12. Install the helical gear anta main shaft.
13. Install the washers anta the main shaft and ratate
14. Install the helical gear anta main shaft.
15. Install the washer anta the main shaft and ratate
16. Install the sliding sleeve anta main shaft with re
cess facing upwards. Align the recess an sliding
sleeve with the ane an the main shaft.
17. Snap the lug af the shaft key inta blind hale in the
end af the main shaft.
18. Install the ail pipe in the recessed end af the main
shaft.
19. Far installatian af the main shaft, Refer ta Page 48 .
56 af 60
Countershaft Disassembly
Inner Bearíng Races
1. Secure the countershaft In a vice with protective
jaws.
2. Using a gripper insert, Special Tool Item 5, and ba
sic pulling tool, Special Toolltem 4, remove the in
ner bearing races off each end of the countershaft,
as required.
3. Inspect the rollers of the inner bearing races for
damage; replace as required.
Note: The inner bearing races are the only service

able parts of the countershatt assemblies . Do not
dismantle the countershafts any further. If damage
to any other component of the countershaft exists,
the entire countershaft must be replaced.
Counter
shafts CJ
16-Speed Shown
Countershaft Assembly
1. Secure the countershaft in a vice with protective
jaws.
Inner Bearíng Races
Note: If new inner bearing races and tapered bear
ings are being installed, replace the outer bearing
races in the main housing, as well. Refer to Page 59.
2. Heat the inner bearing race to 248°F (120 OC) maxi

mum and slide onto countershaft until firmly
seated.
A WARNING
hands . Heated parts may cause burns. Heavy Counter
gloves will be required to safely and shafts
3. For instructíons on how to ínstall the countershafts , 10 or 12-Speed Shown

Refer to Page 48.
57 of 60
Sh ift
Gear Shift Shaft Disassembly
Forks . ~ 1. Label for assembly purposes the location of each
of the shift forks.
~
Shift
" ~.'
'. I
2.
3.
Unlock and remove the sh ift forks from the shaft.
Remove the interlock and shift finger from the
Fork Interlock
.~ . . \ shaft.
Gear Shift Shaft Assembly

1. Install the shift finger in the shaft.
2. Install the interlock on the shaft.
3. Snap the shift forks into their correct position in in
Shaft terlock.
4. For instructions on how to insta" the gear shift
Shift Finger shaft, Refer to Page 48.
16-Speed Transmission
Shift
Fork~
Interlock
Sh ift
Fork
.J:~~
\ ~~ \ \ Shah
~ . <y>- \
ir"
\iD \ \'
~J
Shift Finger
10 and 12-Speed Transmission
58 of 60
Reverse Gear Outer Bearing

Race
Main Housing
Disassembly
A WARNING
Do not handle the heated parts with your bare
1. If still installed, remove idler shafts. hands. Heated parts may cause burns. Heavy
2. Remove the reverse gears from the main housing. gloves will be required to safely and
3. Remove the needle bearing cages from the re effectively handle thEl heated parts.
verse gears.
4. Remove any plugs from the main housing. 8. Remove the dowel pins from the main housing only
5. Remove the outer bearing races from the main if they, or the main housing, is damaged. Using a
housing only if the tapered bearings and inner hot air blower, evenly heat the main housing to
bearing races are being replaced on the counter 194 ° F (90 OC) and drive the dowel pins straight out.
shafts . Do not twist the dowel pins, as they are removed ,
6. Remove the retaining ring which secures the roller or damage may occur to the main housing .
bearing.
7. Using a hot air blower, evenly heat the bore in the
main housing to approximately 212 °F (100 OC) and
carefully pull the roller bearing.
59 of 60
Roller
Bearing
Retaining
Main Housing
Plug
Needle Bearing
Cages
Reverse Gear Outer Bearing
Race
Assembly 2. If required , install the dowel pins in the main hou

sing. Using a hot air blower, evenly heat the main
Note : If new outer bearing mees are being installed, housing to 194°F (90 °C) and drive the dowel pins
replaee the inner bearing raees and tapered rollers straight in. Do not twist the dowel pins, as they are
on the eountershafts, as we.11. Refer to Page 57. installed, or damage may occur to the main hous
ing.
1. Using a hot air blower, evenly heat the bore in the 3 . Install the retaining ring in the main housing.
main housing to approximately 212°F (100°C) and 4 . Install the plugs in the main housing and tighten to
carefully install the roller bearing and outer bearing 44 ft lb (60Nm) .
races until fully seated. 5. For installation of the shaft pack, Refer to Page 48 .
A WAIRNING
effeetively handle the heated parts.
60 of 60
Service Manual 0504 SM01-0-19-034.00
7 6
1. Carrier Cab 3 Screws 5. Mounting Bracket 7. Wire Harness
2. Shift Control 4. Capscrew & Washer 6. Grommet
Figure 1
Transmission Shift Control Assembly

Transmission Shift Control, level surface .
R& I b. Engage the park brake and/or properly block
the tires.
This procedure covers the removal and installation of c. Engage the swing park brake or travel swing
the transmission shitt control. lock , as required.
3. Shuldown Ihe engine.
Removal 4. Check Ihal all controllevers are in the neutral posi
1. Lower, delach, and secure the load, as required. tion and move the function lockoul switch lo the
2. Stabilize Ihe crane for service as follows: "D ISABLE" position.
1 of 2
Refe r to Figure 1 . 4. Inspect the integrity of the wire harness that sup
5. Disconnect the wire harness (7) from the transmis plies the transmission shift control. Repair or re
sion harness. place if required.
6. Remove the capscrews and washers (4) and 5. In the event of severe defects , contact factory per
screws (3) securing the shift control (2) to the sonnel for directions whether to repair or replace
mounting bracket (5). any major component.
7. While lifting the shift conitrol (2), remove the grom
met (6) and guide the wire harness (7) through the Installation
opening in the carrier cab (1) and mounting brack
et (5) .
8 . Remove the shift control (2) from the crane.
9. If required , remove the grommet (6) from the wire
A WARNING
harness (7) . Lubricants, sealants, joint and thread locking
Cleaning And Inspection personal injury may result from misuse of
A WARNING
these products.
Refer to Figure 1.
hazardous . Serious personal injury may
1 . If removed, wrap the grommet (6) around the wire
harness (7).
2 . Guide the wire harness (7) through the opening in
the mounting bracket (5) and carrier cab (1) .
cleaning solutions.
3. Install the grommet (6) to seal the opening in the
carrier cab (1) floor.
4. Position the shift control (2) over the mounting
an approved cleaning solvent, air dried, and care
bracket (5), and secure by installing the screws (3)
fully inspected.
and capscrews and washers (4) .
2. AII Loctite®, Permatex®, ex other sealant residue
5 . Connect the wire harness (7) to the transmission
should be removed from i:hreads of hardware and
harness.
6 . Complete the installation by testing all related func
reused . Prior to applying new thread locking com
tions of the transmission shift control for proper op
eration. A general inspection of the components
wlth Loctite® 7070 Cleaner to ensure best perfor
and systems in the areas adjacent to the repair
mance of products.
should also be performed to ensure related dam
3. Thoroughly inspect all parts for damage, wear, fa
age or wear is not present.
tigue or stress fractures, and corrosion . Repair or
2 of 2
Service Manual 1100 SIVl1-20-2.0
2 3 4
5
6
38 7
37 8
9
36
10
35 11
12
34 13
14
15
16
33 17
18
32
19
31
20
30
21
29
22
28
27 23
26
25
24
1. Valve Body 11. O-ring 21. Fulcrum Pin 30 . Mounting Plate

2. Inlet/Exhaust Valve 12. Piston 22 Cotter Pin 31. Locknut
3. Retaining Ring 13. Piston 23 . Brake Pedal 32 . Stem Bolt
4. O-ring 14. O-ring 24. Cotter Pin 33 . Retainer
5. Piston 15. O-ring 25 . Roller 34. Spring Seat
6. O-ring 16. Seat Nut 26. Roller Pin 35 . Rubber Spring
7. Piston 17. Spring 27. Plunger 36 . Inlet/Exhaust Valve
8. O-ring 18. Spring Seat 28 . Capscrew 37. Spring
9. O-ring 19. Jam Nut 29. Lockwasher 38. Retaining Ring
10. Spring 20 . Pedal Stop
Figure 1
Brake Valve And Pedal Assembly
Suspended Brake Pedal, 2. Remove roller pin (26), roller (25) and cotter pin
(24) from the brake pedal (23).
Recondition 3. Remove capscrews (28), lockwashers (29) , plung
er (27) and mountinn plate (30) from valve body
This procedure covers the recondition of the sus (1 ).
pended brake pedal. For removal and installation pro 4. Remove jam nut (19) and pedal stop (20) from
cedure , see SM Area 1-20. mounting plate (30).
5. Remove retainer (33) and valve assembly from
Disassembly valve body (1).
1. Remove cotter pin (22) , fulcrum pin (21) and brake 6. Remove piston (5) from valve body (1).
pedal (23) from mounting plate (30). 7. Remove and discard o-rings (4,6,9,11,15).
1 of 2
8. RamovQ mtaining ring (3) and inlat!Qxhaust valvQ 1. Install inlat/axhaust valva (2) and mtaining ring (3)
(2) from piston (5). in pisto n (5) . Make sure that retaining ring (3) is
9 . Compress spring (10) by applying pressure on the firmly seated in groove in piston (5) .
spring seat (34) . 2. Install o-rings (4 ,6) on piston (5) .
10. Insert the blade of a screwdriver through the ex 3. Install piston (5) into valve body (1) .
haust port in piston (12) and into a slot in the piston 4. Install inlet/exhaust valve (36) and retaining ring
stem in piston (13) . Be very careful not to nick, (38) in piston (12). Make sure that retaining ring
scratch or mar the exhaust seat of the piston . (38) is firmly seated in groove in piston (12).
Note : Hold the spring in the compressed posi 5. Install o-rings (9,11,15) on piston (12) .
tlon by inserting a wire or screwdriver through Note: The larger diameter o-ring (15) must be
the rectangular opening in the piston (12) and installed in groove nearest the bottom of the
into the locking 9 roove in the piston (13). piston (12).
11 . Remove locknut (31) , spring seat (18), spring (17), 6. Install o-rings (8,14) on pistons (7,13).
seat nut (16), spring seat (34) and rubber spring 7. Clamp piston (13) in a soft 1aced vise and install
(35) . Discard rubber spring (35). rubber spring (35), spring seat (34) and seat nut
12. Remove pisto n (7), spring (37) and stem bolt (32). (16) .
13. Remove the screwdriver from the locking groove 8. Tighten seat nut (16) until the end ofthe piston (13)
and allow spring (10) to separate pistons (12 ,13). stem, and the seat nut (16) are flush.
A WAFlNING
Use care when removing the tool from the
CAUTION
Use care not to mar or damage the exhaust
locking groove, thus relieving the pressure on seat or the outer diameter of the piston.
the p iston return spring. Failureto use caution
could result in personal injury and/or damage 9. Install spring (37) and piston (7) into the top 01 pis
to co m ponents. ton (12) .
10. Install stem bolt (32) through bore 01 piston (7).
14. Remove and discard o-rings (8,14). 11. Install spring (10) and piston (13) into the bottom of
15. Remove retaining ring (38) from piston (12) and re piston (12).
move inlet/exhaust valve (36) . 12. Depress piston (13) against spring (10) untillock
ing groove is accessible through the rectangular
Note: Sorne models may be fitted with an ex
hole in the side of piston (12) . Insert a suitable tool
haust check valve. If so, remove the screws and
into the rectangular hole and in locking groove .
washe rs and discard diaphragm.
Release the pressure on piston (13).
13. Install spring (17), spring seat (18) and locknut
Cleaning and Inspection (31). Torque locknut (31) to 20-30 in-lb (2.2-4
Tho roughly clean all metal parts in an approved clean Nm) .
ing solution , inspect for damage, wear and corrosion. Note: To prevent stem bolt (32) from turning
Re place any defective parts as required. while installing locknut (31), engage a screw
driver blade into the slot in the head of the stem
bolt (32).
A WAFtNING 14. Install the valve assembly into valve body (1) .
15. Install retainer (33), making sure that the locking
concerning solvents and cleaning solutions. tabs on retainer (33) engage the boss on valve
Serious personal injury may result from body (1).
misuse of these products. 16. Install pedal stop (20), jam nut (19) and plunger
(27) to mounting plate (30).
17. Install mounting plate (30) , capscrews (28) and
Assembly lockwashers (29) to valve body (1).
Lubricate all o-rings, bores and mating surfaces with 18. Install roller (25), roller pin (26) and cotter pin (24)
lubric ant (Dow-Corning ® 55-M) or equivalent. Do to brake pedal (23).
not lubricate rubber spring (35). 19. Install brake pedal (23), fulcrum pin (21) and cotter
pin (22) to mounting plate (30) .
20f2
1. Suspended Brake Pedal Valve 3. Air Lines

2. Capscrews 4. Mounting Bracke t
Figure 1
Suspended Brake Pedal Valve
4. Check that all controllevers are in the neutral posi

Suspended Brake Pedal tion and move the lunction lockout switch to the
Valve, R & I "DI SABLE" position or the gate lock lever to the
"STOP" position, as equipped.
This procedure covers the removal and installation 01
the suspended brake pedal valve . For recondition
procedure, see SM Keysheet Area 01-020. A WARNING
Removal
1. Lower, detach, and secure the load, as required . may result in seriou:s injury. Shutdown the
2. Stabilize the crane lar service as lollows: engine and drain the air system reservoir
a. Park the crane, out 01 the way, on a lirm and befo re opening any liine or fitting.
level surface . Engage the park brake .
b. Engage the swing park brake or travel swing 5. Open the drain valves on the air system reservoirs
lock , as required. to bleed the air system pressure.
c. Level the crane on lully extended outriggers. 6. When pressure is lully relieved, close the drain
d. Position/suppart the boom , as required. valves on the air system reservoir.
draulic pump, as equipped. Reler to Figure 1.
7. Label lor assembly purposes and disconnect the
air lines (3) Irom the suspended brake pedal valve
(1) . Cap the open ports and air lines (3) to prevent
contamination of the system .
1 012
8. Support the suspended brake pedal valve (1), and Installation
remove the capscrews (2) securing the suspended
brake pedal valve (1) to U",e mounting bracket (4) .
9 . Remove the suspended brake pedal valve (1) from
the crane . A WARNING
Clea ning And Inspection compounds, etc. can be hazardous. Serious
A WABNING
these products.
hazardous. Serious pl~rsonal injury may
resu lt from misuse of these products. Read Note: If a new pedal valve is being installed, remove
and follow all the manufacturer's the plugs from the old pedal valve, apply Loctite®
reco mmendations conce,rning solvents and 242 to the threads of the plugs, and install them in
cleaning solutions. the corresponding locations in the new pedal valve.
1. Al! components should be thoroughly cleaned with Refer to Figure 1.

an approved cleaning soll/ent, air dried, and care 1. Apply Loctite® 242 to the threads of the capscrews
fully inspected. (2).
2 . AII Loctite®, Permatex®, or other sealant residue 2. Position the suspended brake pedal valve (1) to the
should be removed from threads of hardware and mounting bracket (4) , and install the capscrews
the mounting surfaces of parts that are going to be (2) .
reused. Prior to applying new thread locking com 3 . Connect the air lines (3) to the suspended brake
pounds or sealants , clean threads and surfaces pedal valve (1) .
with Loctite® 7070 Cleaner to ensure best perfor 4 . Apply a soap solution to the air line connections.
mance of products. 5. Engage the main hydraulic pump, as equipped .
3 . Thoroughly inspect all parts for damage, wear, fa 6. Start the engine and let idle for five minutes .
tigue or stress fractures, and corrosion. Repair or Inspect the air connections for leaks. Air leaks will
replace as required. form bubbles in the soap solution where leaks are
4. Inspect the integrity of the air lines that are con present. Repair leaks as required.
nected to the suspended brake pedal valve. Re 7 . Complete the installation by testing all related
pair or replace if required . functions of the suspended brake pedal valve for
5. In the event of severe defects , contact factory per proper operation . Normal operation of the air
sonnel for directions whether to repair or replace system should be confirmed . A general inspection
any major component. of the components and systems in the areas
adjacent to the repair should also be performed to
ensure related damage or wear is not present.
2 of 2
A- .::::
/ ~
I/eY
(I
~ o\
)
\o~
~
AoJ
/
u - joint Size Dimension ''/1:' Capscrew Size Initial Torque Final Torque
3 .34 inch 11 -14 ft lb 22-27 ft lb

2C 0.3125 inch
(84 .8mm) (15-19Nm) (30-37Nm)
3.81 inch 11 -14 ft lb 22-27 ft lb
3C 0 .3125 inch
(96.7mm) (15-19Nm) (30-37Nm)
4.50 inch 11-14ftlb 22-27ft lb
4C 0 .3125 inch
(114.3mm) (15-19Nrn) (30-37Nm)
4.78 inch 18-24 ft lb 37 -49 ft lb
5C 0.375 inch
(121.4mm) (24-32Nm) (50-66Nm)
5.84 inch 18-24ftlb 37-49ftlb
6C 0.375 inch
(148.3mm) (24-32Nm) (50-66Nm)
-
6.22 inch 32-38 ft lb 65- 75 ft lb
7C 0.4375 inch
(158mm) (43-52Nm) (88-102Nm)
6.22 inch 35-40 ft lb 70-80 ft lb
7C 0.500 inch
(158mm) (47-54Nm) (95-108Nm)
8.50 inch 32-38 ft lb 65- 75 ft lb
8C 0.4375 inch
(216mm) (43-52Nm) (88-102Nm)
8.50 inch 35-40 ft lb 70-80 ft lb
8C 0.500 inch
(216mm) (47-54Nm) (95-108Nm)
6.88 inch 55-60 ft lb 110-120ftlb
8.5C 0 .500 inch
(174.7mm) (75-81Nm) (149-163Nm)
8.63 inch 55-60 ft lb 110-120ftlb
9C 0 .500 inch
(219.2mm) (75-81Nm) (149-163Nm)
-
8.88 inch 115-120 ft lb 230-240 ft lb
10C 0 .625 inch
(225 .5mm) (156-163Nm) (312-32 Nm)
11.88 inch 115 -120 ft lb 230-240 ft lb
12C 0 .625 inch
(301.7mm) (156-163Nrn) (312-325Nm)
Figure 1
U-joint Sizes & Capscrew Torques
1 of 2
1. Yok e 3. Mating Surface 5. Cap screw 7. Lip

2. Key 4. Keyway 6. U-joi nt
Figure 2
U - joint Removal/I nstallation
Installation
Refer to Figure 2.
1. Clean all paint, dirt, rust, etc . off the mating sur
faces (2 ,3,4) ofthe u-joint (6) and yokes (1). Re
move any burrs or knicks that may interfere with
u - joint seating.
2. Assemble the u-joint (6) to the yoke (1). Seat the
u-joint keys (2) in the yoke keyways (4) . This fit
should be tight. Use a e-clamp or tap with a soft
hammer as required to seat the key in the keyway.
Do not use the capscrews (5) to seat the keys in the
keyway.
3. With the u-joint (6) and yoke (1) properly seated ,
install the capscrews (5) through the yoke and into
Figure 3 the u-joint. The capscrews must be clean and
U-joint Capscrew Torquin!J Sequence dry.
4 . Torquing the capscrews (5) is a two step process
u- Joint Installation Half that must be done in a triangulated sequence. Re
fer to Figure 3 for an illustration of the triangulated
Round Yokes sequence. Refer to Figure 1 for the capscrew
Referto Figure 1. torque for each u-joint and capscrew size. Apply
1. The procedures containecl in this SM are of a gen the initial torque to each capscrew in a triangulated
eral nature that apply to installing u - joints on all sequence followed by the final torque in that same
types of yokes . Yokes are occasionally referred to sequence.
as companion flanges. The initial and final torque 5. Thoroughly lubricate the u- joint (6) befare operat
values must be strictly adhered to o ing the crane.
2 . U-joints used on Link-E3elt construction equip
ment vary from size 2C through 12C . Each size is
designed to fit different diameter yokes. To deter
mine the size of a particular u - joint refer to the
chart in Figure 1.
2 of 2
5ervice Manual 1100 51\111-22-5.0
8 ----........
~
I r 4
6
@
1
5 ===::>-..- - - 8
7~'
I Q
11
10
12
13--
Patch- Lock Bolts* Non Patch-·Lock Bolts

Bolt Torque Bolt Torque
Series Series
Size ftlb Nm Size ftlb Nm
16N 5/ 16"-24 26-35 35-47 16N 3/8"-24 45-60 61-81
17N 3/8"-24 38-48 52-65 17N 1/2"-24 115-135 156-183
176N 3/8"-24 38-48 52-65 176N 1/2 "- 24 115-135 156-183
18N 3/8" - 24 38-48 52-65 18N 1/2" -24 115-135 156-183
• Patch-Lock bolts can be idenlified by the "PL:' stamped
on the bolt head .
1. End Cap 5. Bearing Journal 8. Retaining Plate 11. Mounting Flange

2. End Cap 6. Capscrews 9. Yoke 12. 12 Point Ca p screws
3. Spider 7. Ca p screws 10. C -clamp 13. Locking Tab
4. Bearing Journal
Figure 1
U-Joint Installation
1 of 2
SM1-22-5,.O 1100 Service Manual
u- Joint Install~ltion - Full 6. Align rQtaining platQ (8).
7. If used, align locking tab (13).
Round Yokes 8.
9.
Install capscrews (6,7).
If non Patch - Lock bolts are used, apply Loctite '~
The procedures contained in I:his SM are of a general #242 and torque capscrews (6,7) per Non Patch
nature that apply to installing u-joints on all types of Lock 60lts Chart in Figure 1. 6end up locking tabs
yokes. Yokes are occasionally referred to as compan if equipped.
ion flanges. 10. If Patch-Lock bolts are used, torque capscrews
(6,7) per Patch-Lock 60lts chart in Figure 1.
Always use new hardware when installing u-joints. 11. Place u - joint assembly into desired position and
install c-clamp (10) over spider (3) and onto
In stallation mounting flange (11). If used, align locking tab
(13) .
Refer to Figure 1. 12 . Install the 12 point capscrews (12).
1. Clean all paint, dirt, rust, etc. off the mating sur 13. If Patch-Lock bolts are used , torque capscrews
faces of the u-joint and yokes (9). Remove any (12) per Patch- Lock 60lts chart in Figure 1.
burrs or nicks that may interfere with u-joint as 14. If non Patch - Lock bolts are used , apply Loctite ':E;
sembly. 242 and torque capscrews (12) per Non Patch
2 . Remove end caps (1,2) from spider (3). Lock 60lts Chart in Figure 1. 6end up locking tabs
3. Slide one end of the spider (3) into bearing journal if equipped .
(4). 15 . Thoroughly lubricate the u-joint before operating
4. Sllde opposite end of the spider (3) into bearing the crane . See Operator's Manual for correct type
Journal (5). of grease and proper procedure.
5 . Center spider (3) and install end caps (1,2) .
Note: Make cerlain that the needle bearings re

main properly seated when end cap installation
begins.
2 of 2
Service Manual 1104 SM01-l024-015.00

Rear Axles, Recondition use a hammer unless it has a soft face, do not force
parts together, they mus! be free to turn and not bin d.
This procedure covers the recondition of Oana®
Spicer® drive axles , Series 0170, 0190, and 0590. It is a good practice when disassembling complex
For removal and installation procedures, see SM components to lay the parts out in the order that they
Keysheet Area 01-029. were disassembled . Keeping the parts in this order
during disassembly, cleaning, and inspection wlII aid in
The following pages are taken directly from the service
literature produced by the axle manufacturero Multiple
axle models are covered by this information . Pay
particular attention to the "General Information"
section on page 8 to correctly identify the specific axle
being serviced . Proper identification of the axle is
A WARNING
crucial to obtain the correct information . hazardous. Serious personal injury may
Based on the specific application of this axle , Link-Belt® and follow all the manufacturer's
literature will supersede any discrepancies in recommendations concerning solvents and
operation , lubrication, maintenance, or service, cleaning solutions.
implied by the axle manufacturer in this document. Any
reviewed with your Link-Belt® distributor. Thoroughly clean the exterior surface of the axle to
prevent contamination.
1 of 76
SM01 -024--015.00 1104 Service Manual
20176
Table Of Contents
Wheel Power
Divider
Page 17
Carrier
Page 27
~.),
~
Seals
page 55
Inter-Axle
Lockout
~page16
~
' '' ''-f!.{' B
.1'- . Differential
Carrier
I l' . P
)' 1" ',. ' age15
" '
Wheel Housing
() Differential
Lock
Page 50
Breather
page 57
Wheel Lubrication
End Seal Page 62
page 58
Output Shaft
& Rear Cover
Page 51
30176
SM01-024-·015.00 1104 Service Manual
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction ........ ... . . . ,.",." ...... " ...... . ........ . . ... , ........... . . " ...... . ... 8
Model Information ... ,' . .... .. , . ............... . . ,.,., . ... . .. " . ...... " , ., ..... " .. 8
Model Identification , ...... , . .... , ' ....... , . ................ . ...... " ....... , ' . , ..... ,'.. 9
Orive Axle ...... . , , , , . ...... .. , . , .. , . , . . ...................... , , . ....... , .. , , . ... , . . 9
Parts Identification ., . . , . . . ...... . ......... ........ ... ... .. ......... .. ....... . ....... . , .. 9
Axle Housing ... . .. , ......... . . ....... , .... ... , ....... , , ........ , ....... . , ....... . , . 9
Axle Shaft ...... ...... " . . . . . , ... . ... . . ..... . , ....... " .. ...... . ...... . . . ....... , . . 9
Ring Gear and Pinion ......... .. .... ..... .. .. . , . ..... "., .... . ,.,. . . ... .... ..... .. . . 1O
Inspection ........... ... , ... .............................................. ... , . . . . . . . . . . . . 11
Failure Analysis ... .. . ... ....... , , , ......... . .. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to Oiagnose a Failure . . , . ...... .. , . , ..... .. . . , . , . . . .. ..... .. ..... ........... , . . . 11
Oocument the F'roblem .. ... ..................... .. ....... .. ... ..... ....... . ... . 11
Make a Preliminary Investigation .. ... .... .. ...... ... ......... ...... . , .. ...... . . . 12
Prepare the Parts for Inspection ................. .. ...... ... ...... .. ....... ", . . .. . . . . . .. . 12
Find the Cause 01 the Failure ...... . ................. , . .. , . .. . . ... " .. . .... " . .. . 12
Correct the Cause of the Problem ........ . ....... . ....... , . .. ..... . , ....... ,' .. . . 12
Inspection .. . ...... ..... .. .... . .......... . , .... ... .... .......... , ...... . ", ...... " . .. . 13
Cleaning ..... . .......... , . ........ ...... .... ...... ....... , ......... " ....... .. .. , . 13
Axle Housing Inspection 13
Components Inspection 13
Primary Gearing Inspection ........ .. .. , ........... . ... .... ,......... .. ........ . . .... 13
Endplay Procedure ..... . , ..................... . . ... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Input Shaft Endplay Check (Forward Axle) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adju stmen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Output Shaft Endplay Check (Forward Axle) ..... ........... ... .... ... .. ........ . ...... 14
Adjustment .. , ...... , ... . . . . . ....... . ............... . . ....... ... ....... . , . . . . . . 14
Differential Carrier . . . .. . ........................................... . . . . . .................. 15
Oifferential Carrier - Parts ............................. .. , . .. , ...... . ", ... .... .. . . . .... . 15
Oifferential Carrier Removal - (Forward and Rear) ..... . .. . .. . .. , ... .. . . " ........ , . .. ..... . 15
Standard Differentials .............................. , . . .. , ........ , ... .... , . ....... .. 15
Oifferential Carrier Installation - (Forward and Rear) 16
40176
Inter-Axle Lockout ...................................................................... . 16
Inter -Axle Differential Loek .... . ..... . . .. . ..... . ... . .. .......... .. .. ..... . ... ..... . . . . 16
Disassembly ... . . .......... ... ... .. . .... . . . ... ..... . . .. ........ . . .... . ....... . ... . . 16
Assembly .. . . . ....... . . ...... . .............. . ................. . ................... . 16
Power Divider . .......................................................................... . 17
Power Divider - Parts Exploded View ...... . ...... . ...... ............ . ..... . ..... .. ..... . . 17
Power Divider Disassembly ................ ..... . .. ..... . ........................ . ...... . 18
Pump Disassembly ................ . ......... . ... .. . . .... .. .. . ......... . ...... .. ..... .. . 20
Lube Manifold Disassembly .................... . .. . .. .... . .. .. . ......... .. ............. . . 20
Lube Manifold Assembly ..................................................... . .......... . 21
Pump Assembly .............. .. ............ .. ........... ... ... . . . ..... .. ..... . . ... .. . . . 22
Power Divider Assembly 23
Carrier ... . . . . ................................ .. ................................. ..... . .. . 27
Carrier Disassembly - Forward Carrier . . .... .. .. .... .. ....... . ..... . ............. ... ...... 27
Drive Pinion ........................................... . ............................... . .. 29
Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Forward Axle Pinion - Parts Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rear Axle Pinion - Parts Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive Pinion Overhaul and Assembly - Forward and Rear Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wheel Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Wheel Differential - Parts Exploded View .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Wheel Differential Disassembly 40
Wheel Differential Assembly 42
Wheel Differential Installation 44
Ring Gear ......... . .................... . .... . .......................... , . . . . . . . . . . . . . . . . . 48
Tooth Contaet Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 48
New Gearing - Correet Pattern ... . .... . ....... . ..... . . .... . .. ................... 48
Used Gearing - Correet Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Contaet Pattern Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ring Gear Position (Baeklash) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 of 76
Wheel Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 50
Wheel Oifferential Lock - Parts Exploded View .. .. .. . . . . ...... .. . . ......... .... ..... . ... ... 50
Wheel Oifferential Lock Installation and Adjustment .... ... .. ....... . ........ . .. ...... . . . . . . 50
Output Shaft and Rear Gover ............ . ............. . ......... . ......................... 51
Housing and Output S~laft - Parts Exploded View ............... . . ........ . . . ....... . .. . 51
Output Shaft Removal ......... . ....... . .... . . . ... . . .. ....... . . . ......... . ........ . . 52
Output Shaft Overhaul and Assembly 53
Measure .. .. ..................... ... .. .. . ... ........ .. ....... .. ...... .. . '" ...... . .... . 54
Seals .......................................................................... .. . ... ... . 55
Seal Replacement 55
Guidelines for Reusing Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service Kit ............... .... .. . .... . . ...... . .. . .. . . .. ..................... ...... .. ... . 56
Housing Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Housing Breather Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wheel End Seal . . . .. .. . . .. . .. . . . . .. . . . . . .. .. . . . . .. .. .. . . .. . . ... . . . .. ... . .. . . . . . .. . .. . . . .. . 58
Wheel End Seal - Parts Exploded View ................. . ...... . .... . ... . . . ......... . . ... . 58
Wheel End Seal - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wheel End Seal Removal ... . .... . ........................ .. ....... .. . . .. ... .. . .... . . 58
Wheel End Seallnstallation ........ . . ...................... . . ........... ......... .. . . 58
Wheel Bearing Adjustment .. ......... . ........ . . .... ... .... . . . ....... . . ... . . .. .. ....... . . 59
Wheel Endplay ................................... .......... ... . .... . . .. . 61
Wheel Endplay Verification . . .. ........ .. .. . ................. .. .. .. ... . 61
Wheel Endplay Readjustment ..... .. . . .. . . ........ ... ....... . ......... .. ... . . 61
Wheel End Lubrication ..... .... . . .... . ....... . .......... .. . . .. ... .. .. ... .. .. ........... . 61
Wheel Ends with an Oil Fill Hole ... . .... . .. .. ...... . . ..... ... . . . .. . . . .... . . . . . . . . . ... . 61
Wheel Ends Without Oil Fill Hole .... .. ... .. .. . . .... .. . ....... . . .......... . ....... . ... . 62
Lubrication ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Approved Lubricants .. . ..................... . ....... .. .. . ... . . . . .... . ............. . .... . 62
Recommendations for Viscosity/Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lube Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Guidelines - Lube Change Intervals for Orive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 of 76
Lube Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 64
Fill .............................................................. ............. . ... 64
Front Axle .................................................... . ..... . ..... .. ... 64
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Stand pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .... .. ...... . .... 65
Final Check ..... . ..................................... . ................... . ............ 65
Proper Towing ............................................................................ 65
Without Wheel Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
With Wheel Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Theory of Operation ........................................................... . .......... 66
Power Divider Operation (Power Flow and Torque Distribution) ... . ...... . ....... . ....... . .. 66
With Lockout Released (Inter-Axle Differential is Operating) ........................... 66
With Lockout Engaged (Inter-Axle Differential is not Operating) . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Wheel Differential Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Control Systems for Differential Lock 68
Transmission Low-Range Interlock Control System .............................. . ..... 68
Direct Driver Controlled System ...................................................... 68
Wheel Differential Lock ................ .. ..... .. .......................... . ...... .. ..... . 69
Differential Lock Engaged ........................................................... 69
Differential Lock Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Differential Lock Engagement Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power Divider - Par1s Exploded View .................................................... . 71
Forward Axle Pinion - Par1s Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Rear Axle Pinion - Parts Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Wheel Differential Lock - Par1s Exploded View ... . ....... . .... . . ...... . . ..... . ..... .. ...... 73
Housing and Output Shaft - Parts Exploded View ........................ . ................ . 74
Fastener Torque Specifications ............................................................ 75
7 of 76
General I nformatiion Model Information
Introduction The following models are included in this publication:
This information is presented to aid in maintenance Heavy Tandems

and overhaul of Oana® tandem drive axles.
040-170 046-590HP
Instructions contained cover the models listed. Their
040-170(P) 050-170
design is similar, with primarily differences in load
capacity. Capacity variatons are achieved by 040-1700(P) 052-190P
combining basic differential carrier assemblies with 046-170 052-1900P
different axle housings, axle shafts and wheel
equipment. 046-170(P) 052-590P
The suffix letter "P" in the rnodel number indicates 046-1700(P) 060-190P
optionallube pump. The purnp is designed to provide 046-170H 060-590P
additionallubrication to the inter-axle differential and
related parts. 046-170H(P) 070-190P
046-1700H(P)
Model Listing
D 46-1 7 O D
-, - -
I
T T Options
O Dual Orive Forward Axle C - Controlled Traction
with Inter-Axle Oifferential O - Oifferential Lock
G - Single Rear Axle (Global) E High Entry Single
R - Dual Orive Rear Axle H - Heavy Wall
S - Single Rear Axle (~~.A.) I Integral Brake
L Limited-Slip
P - Lube Purnp
R - Retarder Ready
GAW Rating - - - - - - - - W - Wide- Track
x 1000 lb (N. America) "-"
x 1 Tn. (Europe) "."
Gear Type - - - - - - ' - - - Design Level

1 - Standard Single Reduction
2 - Dual Range
3 - Planetary Oouble Reduction L--_ _ Head Assembly Series
4 - Open
5 - Helical Reduction
8 of 76
Service Manual 1104 SM01-C)24-015.00
Model Identification
Drive Axle
4 5
3
CUST. PART~. Spice
o SPEC. SERIAL NO.

o 6
2
KlOEL PARTNO. RATIO
MADEIN:
7
1. Country Or Origin
2. Axle Model Identification
3. Specification number assigned to the axle built by Oana·"'. Identifies all component parts of the axle including special OEM require
ments such as yokes or flanges.
4. OEM Part Number Assigned To The Axle Build
5. Carrier Assembly Serial Number Assigned By The Manufacturing Plant
6. Axle Gear Ratio
7. Carrier Assembly Production Or Service Part Number
Parts Identification
Axle Housing Axle Shaft
1. 1.0. Tag
2. Axle Shatt Part Number
9 of 76
Ring Gear and Pinion
8 3
7
5 2
1. Part Number
2. Number ef Ring Gear Tee th
3. Manufacturing Number
4. Matching Gear Set Numbers
5. Number ef Pinien Teeth Note: Ring gear and drive
6. Date Cede
7. Indicates Genuine Spicer~ Parts pinion are matched parts and
8. Heat Cede must be replaced in sets.
10 of 76
Service Manual 1104 SM01 -0)24-015.0 0
Inspection How to Diagnose a Failure
Failure Analysis The following five steps are an effective approach to
good failure diagnostics.
Failure analysis is the process of determining the 1. Document the problem.
original cause of a component failure in order to keep it 2. Make a preliminary investigation.
from happening again. Too often, when a failed 3. Prepare the parts for inspection.
component is replaced without determining its cause, 4. Find the cause of the failure.
there will be a recurring failure. If a carrier housing is 5. Correct the cause of the problem.
opened, revealing a ring gear with a broken tooth, it is
not enough lO settle on the broken tooth as the cause Document the Problem
of Ihe carrier failure. Other parts of the carrier must be Here are some guidelines for starting to learn aboul a
examined. For a thorough understanding of the failure failure.
and possible insight into related problems, the • Talk to the operator of the crane .
technician needs to observe the overall condition of the
• Look at the service records.
crane.
• Find out when the crane was last serviced.
l\Jo one benefits when a failed component goes on the
Ask the following questions:
junk pile with the cause unknown. Nothing is more
• In what type of service is the crane being
disturbing to a customer than a repeat failure.
used?
Systematically analyzing a failure to prevent a repeat
• Has this particular failure occurred before?
occurrence assures quality service by avoiding
unnecessary downtime and further expense to the • How was the crane working prior to the fail
ure?
customer.
You need to be a good listener. Somelimes ,
The true cause of a failure can be better determined by
insignificant or unrelatecl symptoms can poinl to the
knowing what to look for, determining how a piece of
the equipment was running, and learning about cause of the failure.
previous problems. In the case of a rebuilt rear axle, Ask the following questions:
mismatched gears may have been installed. • Was the crane operating at normal tempera
The more successful shops prevent repeat equipment tu res?
failures by developing good failure analysis practices. • Were the gauges showing normal ranges of
Knowing how lO diagnose the cause of a premature operation?
failure is one of the prerequisites of a good • Was there any unusual noise or vibration?
heavy-equipmenllechnician. After listening , review the previous repair and
maintenance records. If there is more than one driver,
talk to all of them and compare their observalions for
consistency with the service and maintenance
records. Verify the chassis Vellicle Identification
Number (VIN) number from the vehicle identification
plate, as well as the mileage and hours on the crane.
11 of 76
Make a Preliminary Investigation Find the Cause 01 the Failure
These steps consist 01 eX"lernal inspections and Here begins the real challenge to determine the exact
observation s that will be valuable when combined with cause 01 the lailure. Keep in mind that there is no
the results 01 the parts examination . benelit to replacing a lailed part without determining
Look lor leaks, cracks, or other damage that the cause 01 the lailure For example, after examining a
can point to the cause 01 the lailure. lailed part and linding that the lailure is caused by a
• Make note 01 obvious leaks around plugs lack 01 lubrication, you must determine il there was an
and seals. A missing lill or drain plug would externalleak . Obviously, ilthere is an externalleak , just
be an obvious cause lor concern. replacing the lailed gear is not going to correct the
• Look lor cracks in the carrier housing (harder situation.
to see, but sometimes visible) . Another important consideration is to determine the
• Does the general mechanical condition 01 specilic type 01 lailure which can be a valuable indicator
the crane indicate proper maintenance or are lor the cause 01 lailure. The lollowing pages show
there signs 01 neglect? diHerent types 01 lailures and possible causes. Use this
• Are the tires in good condition and do the as a guide in determining types 01 lailures and to
sizes match? correct problems.
• II equipped with a torque-limiting device, is
it working properly? Correet the Cause 01 the Problem
During the preliminary investigation , write down Once the cause 01 the problem has been determined ,
anything out 01 the ordinary lor later relerence . Items reler to the appropriate service manual to perlorm the
that appear insignilicant now may take on more repairs .
importance when the subassemblies are torn down.
Prepare the Parts for Inspection

Alter the preliminary investigation , locate the lailure
and prepare the part lor examination. In carrier lailure
analysis , it may be necessary to disassemble the unit.
• When disassembling subassemblies and
parts , do not clean the parts immediately
since cleaning may destroy some 01 the evi
dence .
• When tearing down the drive axle, do it in the
recommended manner. Minimize any lurther
damage to the unit.
• Ask more questions when examining the in
terior 01 the carrier. Does the lubricant meet
the manulacturer specilications regarding
quality, quantity, and viscosity? As soon as
you have located the lailed part , take time to
analyze the data .
120176
Inspection Axle housing inspection and repairs are limited to the
following checks or repairs .
Cleaning • Visually inspect axle housing far cracks ,
nicks, and burrs on machined surfaces.
A WARNING
Gasoline is not an acceptable solvent
• Check carrier bolt holes and studs far fareign
•
material.
Replace damagecj fasteners . Look far loose
beca use of its extreme combustibility. It is studs ar cross threaded holes .
unsafe in the workshop environment. • Check all seals and gaskets.
1. Wash steel parts with ground or polished surfaces Note: Replace conventional gaskets with silicone
in solvent. There are many suitable commercial rubber gasket compound (included in many repair
solvents available. Kerosene and diesel fuel are kits). The compound provides a more effective seal
acceptable. against lube seepage and is easier to remove from
2. Wash castings or other rough parts in solvent or mating surfaces when replacing parts.
clean in hot solution tanks using mild alkali
solutions. Components Inspection
Note: If a hot solution tank is used, make sure Inspect all steel parts for:
parts are heated thoroughly before rinsing. • Notches, visible steps , or grooves ereated by
wear
3. Rinse thoroughly to remove all traces of the
• Pitting or cracking along gear contact lines
cleaning solution .
• Scuffing, deformation , or discolorations are
4. Dry parts immediately with clean rags.
signs of excessive heat in the axle and are
5. Oil parts .
usually related to low lubrication levels or im
• If parts are to be reused immediately: lightly proper lubrication practices.
oil.
• If parts are to be stored: coat with oil, wrap in In addition, inspect the following for damage:
corros ion resistant paper, and store in a • Differential gearing
clean, dry place . • Bearings for loose fit on drive pinion , pilot
bearing, and differential bearings
Axle Housing Inspection • AII fasteners far rounded heads, bends ,
cracks , or damaged threads
• Inspect machined surfaces of east or mallea
CAUTION ble parts . They must be free of nieks , burrs ,
Any damage which affects the alignment or eracks, scoring, and wear.
structural integrity of the housing requires • Look for elongation of drilled holes , wear on
housing replacement. Do not repair by surfaces machined far bearing fits , and nicks
bending or straightening. This process can or burrs in mating surfaces .
affectthe material's properties and cause itto
fail completely under load. Primary Gearing Inspection
Before reusing a primary gear set, inspeet teeth lor
signs of excessive wear. Check tooth contaet pattern
for evidenee of incorrect adjustment.
13 of 76
SM01 -024·-015.00 1104 Service Manual
Endplay Procedure Output Shaft Endplay Check (Forward
Input Shaft Endplay Check (Forward Axle) Axle)
1. Position dial indicator at yoke end 01 output shaft .
Note : Before disassembling the power divider, 2. Push in on output shaft and zero the dial indicator.
measure and record input shaft endplay. 3. Using a pry bar, move output shaft axially and
measure/record endplay.
1. Position dial indicator at yoke end 01 input shaft.
2. Push in on input shaft and zero the dial indicator.
3. Using a pry bar, move input shaft axially and
measure/record endplay.
Adjustment
Correct endplay for a new assembly is 0.001-0.005 in
(0.025-0. 127mm) . The maximum endplay for a used
Adjustment assembly is no more than 0.015 in (0.381mm) . If
endplay is incorrect, contact your Link - Belt®
Correct endplay lor a new assembly is 0 .001 -0.005 in distributor.
(0.025 - O. 127mm). See the "Power Divider Assembly"
section on Page 23 for proper endplay adjustment
procedure.
14 of 76
Differential Carrier
Differential Carrier - Parts
2
1. Carrier Fasteners
2. Carrier Assembly
3. Forward Axle Assembly
4. Rear Axle Assembly
Differential Carrier Removal - (Forward and Rear)

Note: The removal 01 the 10rward carrier does not 8. To remove axle shaft , remove axle stud nuts . (If
require disconnecting 01 the inter-axle driveline used , remove lockwashers and taper dowels.)
and removal 01 the output shaft yoke assembly as
most other Dana® tandems require.
CAlJTION
Do not strike the shaft head with a steel
Standard Differentials hammer. Do not use chisels or wedges to
loosen shaft or dowels.
A WARNING 9. Remove axle shafts.

Do not lie under carrier after 1asteners are
Note: Al! models in this publication use axle
removed. Use transmission jack to support
shafts with unequal lengths. Axle shafts may
differential carrier assembly prior to
also be location speci1ic with various wheel
loosening 1asteners.
equipment. Do not misplace axle shafts 1rom
their intended location. Identi1y left and right
1. Block the tires.
shafts 10r re1erence during reassembly.
2. Drain axle lubricant.
3. Rear Only: Disconnect inter- axle driveline. Note: 11 necessary, loosen dowels by holding a
4. Front Only: Disconnect main driveline. brass drift in the center 01 the shaft head and
5. Front Only: Disconnect differentiallockout air line. striking drift with a sharp blow with a hammer.
6. Disconnect lead wires to the selector switch and air
line at shift cylinder. 10. Remove capscrews, nuts, and lockwashers.
7. Remove axle shafts. 11. Remove differential carrier assembly.
15 of 76
Differential Carrier Installation Inter-Axle Lockout
(Forward and Rear) Inter-Axle Differential Lock
Note: Before installing carrier assembly, inspect
and thoroughly clean interior ofaxle housing using
an appropriate solvent and clean rag .
1. Apply Dana® approved fHV compound on axle

housing mating surface as shown in the
illustration. Completely remove all old gasket
material prior to applying new material.
Compound will set in 5 minutes. Install carrier
before compound sets or reapply.
1. Campressian Spring
2. Shift Fork Assembly
3. Pistan
4. O-ring
5. Pista n Caver
Disassembly
1. With the axle installed in crane, place differential
lock selector valve in the disengaged or unlocked
position.
2. Disconnect the differential lockout air line.
3. Remove the piston cover.
4. Remove the piston and 0- ring assembly with
pliers .
Note: To assist in installing complete differen
Note: In order to remove the shift fork and push rod
tial carrier use two pieces of threaded rod
parts, first remove the power divider cover. See the
(M16x1.5) threaded into carrier capscrew
"Power Divider" section.
holes. Rod should be approximately 6 in
(15.24cm) long. Use these to pilot the carrier
into the housing . Assembly
1. Assemble the o-ring onto the piston. Apply
2. Install carrier to housing , lock washers, silicone grease to the o-ring o
capscrews , and nuts. Torque to proper 2. Gently push the piston 0- ring assembly into the
specification. Torque to 250-290 ft lb lockout cylinder bore. Make sure the piston
(339-393Nm). assembly is pushed in all the way.
3. Install axle shafts and axle stud nuts. (If used , also 3. Install the piston cover. Tighten by hand and then
install lockwashers and tapered dowels .) torque from 50-75 ft lb (68-102Nm).
4. Add axle lubrican!. Fill to bottom of filler hole. 4. Connect the differential lock air line.
5. Rear Only: Connect inter-axle driveline , making 5. Cycle the lockout to make sure there are no leaks
sure all yokes are in phase . Lubricate u-joints . and the system is operating properly.
6. Front Only: Connect ma.in driveline, making sure
all yokes are in phase. Lubricate u-joints .
7. Front Only: Connect differentiallockout air line.
16 of 76
Power Divider
Power Divider - Parts Exploded View
~~
19 ~i 8
~ _~
20 21
~ / 22
'
27
~~~'~", 9,..
~d~~/
· 6~ ' '~.:'. (íl(J: 1516
"--~ 29 ~7~~/?
23
,",,,,)f'>
~
24
30
31 32
/
1_J ~C$(l;>
12 '
,;--- 11 /
336'---13
~ 34
~M36
'l: P' l{~~ ,1
37
38 ~
39
1, Output Shaft Nut 16, Pin 31 Input Cover

2, Output Yoke 17, Output Side Gear 32, Input Cover Capscrew
3. Output Seal 18, Pump 33, Bearing Cup & Cage
4, Output Shaft Bearing Snap Ring 19, Inter-Axle DiHerential 34, Input Seal
5, Outer Bearing Cup 20, Helica l Side Gear 35, Input Yoke
6, Outer Bearing Cone 21, Thrust Washer 36, Input Nut
7, Inner Bearing Cone 22. Lockout Sliding Clutch
37 Pistol1
8 Inner Bearing Cup 23, Shift Fork Spring
9, Output Shaft 24, Shift Fork Assembly 38 O-ril1g
10, Seal Manifold 25 ,V-ring 39 Pistoll Cover
11, Clamp 26, Input Shaft 40, Pinion Cover
12 Se al Manifold Feed Tube 27, Input Shaft 41, Input Cover Capscrew
13, Sump Screen 28, Input Shaft Bearing Cone 42, Input Cover
14, Output Side Gear Bearing Cup 29, Carrier Housing 43, Carrier Housing
15, Output Side Gear Bearing Cane 30, Lacking Capscrew 44. High Entry Input Shaft Assemb ly
17 of 76
SM01 -02L~-015.00 1104 Service Manual
Power Divider Disassembly
Use these instructions with the carrier assembly in or
out 01 the crane .
1. Disconnect the main driveline.
2. Disconnect the lockout airline.
3. Drain the axle lubricant into a clean oil pan.
4. Remove the input yoke Ilut and yoke.
/
/1
\ ____ 1
.....:---
CAUTION
During removal of the power divider cover, the
inter-axle differential (IAD), input shaft
assem bly or IAD shift system may fall from the
carrier if not careful. Use caution to prevent
,r--- injury or damage.
2 ~ 3
7. Remove the power divider cover assembly. Use
the tabs provided to Iree the cover Irom the carrier
assembly.
1 Round Tl p Chlsel
I 2. Machined Slol in Pinion
3. NulS Slaking Flange
CAUT~ON
Failure to de- stake the pinion nut will result in
damage to the drive pinion threads when
removed. The pinion nut should never be
reused, always replace with new.
8. For High Entry Applications Only:
5. To de-stake the nut , use a chisel or drift with a Remove the input shaft and gear assembly.
round tip o The flange 01 the nut must be pushed lar Proceed to Step 13.
enough outward so that the staked area will not
interlere with the input shaft threads when the nut
is removed . See diagrams below.
6. Remove the input sea!.
Note: Do not reuse the seals after disassembly.
9. Remove the input shaft, sliding clutch, shift lork ,

and spring as an assembly.
180176
10. Remove the thrust washer and helical side gear.
Locking Fastener
13. To replace the input bearing cup, back off the

bearing cage locking fastener.
11 . Remove the inter - axle differential assembly.
14. Input cage is threaded into the PDU cover, use the
proper tool to remove the cage from the cover.
15. Use a suitable bearing puller to replace the input
bearing cupo
12. Remove the output side gear and pump assembly.
19 of 76
Pump Disassembly
For output side gear and/or pump replacement, follow
the procedure below.
3. Remove pump from the output side gear.

4. Remove the output side gear bearing cup from the
carrier with the proper bearing puller tool.
Lube Manifold Disassembly

1. Disconnect the hose from the lube manifold.
1. Press
2. Press Tool
1. Remove the output side gear bearing cone , if

required.
2 . Remove the manifold assembly by prying it out

around the inner diameter.
Note: Once removed, the seal manifold assem

bly can not be reused. This component should
always be replaced with new. Use the same re
moval procedure for the output side gear seal
removal on the non- pump models.
2. Remove pump locking dowel pin from the hole in

the output side gear hub o
1. 8arbed Nipple
20 of 76
Service Manual 1104 SM01-0:24-015.00
Lube Manifold Assembly
1. Manifo ld Oil Inlet Hale
4. Fully press the manifold assembly into position .
Note: Use care when pressing the manifold as

sembly to avoid damaging the seals and barbed
nipple. Do not overpress plastic.
Note: For non- pump manifold installation, it is

important to line up the oil inlet path hole in the
manifold with the oil path opening in the carrier
manifold casting.
Barbed Nipple
1. Install the manifold assembly into the output side

gear bore in the carrier. Make sure the barbed
nipple is lined up with the opening in the carrier
casting .
2. Install tlle /lose clamp on the hose , push the hose
onto the barbed fitting and slide the clamp over the
barbed nipple.
5. Attach the suction screen to the end of the hose.

If the unit does not have a pump , go to the "Power
Divider Assembly" section on Page 23.
If the unit contains a pump , go to the "Pump Assembly "
section on Page 22.
3. Route the suction end of the hose through the

holes in the carrier casting to the bottom of the
carrier.
21 of 76
Pump Assembly
Use these instructions with tll e carrier assembly in or
out 01 the crane.
II the unit does not have a pump , go to the "Power
Divider Assembly" section on page 23 .
Note : Keep work area clean. Dirt is an abrasive and

will cause premature wear Clfthe otherwise service
able parts.
Note: For non- pump models, see Page 21 for out

put side gear seal manifold installation.
Note: Only service the power divider if the differen

tia! carrier is secured in a stand or while the axle is
still attached to the housin~l.
1. Insta" the pump into the output side gear so that
the pump shaft is facing toward the teeth end of the
CAUTION side gear.
During installation of power divider cover,

inter-axle differential (IAD), input shaft
assembly, or IAD shift system parts may fall
from the carrier if not calíeful. Use caution to
prevent injury or damage.
1. Machined Sl ol
2. Pin
2. Insta" the pump locking dowel pin into the hole in

the output side gear hub o Make sure the pin is lined
up with the machined slot in the pump body.
22 of 76
4. Install the inter-axle diHerential.
Note: Install in the same direction as removed.
1. Press
2. Press Tool
Power Divider Assembly

1. Install output side gear bearing cone and press
until fully seated. Use proper press tools.
2. Fully press the output side gear bearing cup into
the carrier sea!.
Note: When inserting the input shaft assembly

through the IAD components, turn the shaft as 5. Install the helical sidE) gear so that the clutch teeth
necessary to align the slot ofthe input shaft with are facing upward in the carrier.
the pump drive shaft. The keyway on the 6. Install helical side gear thrust washer.
threaded end of the input shaft is aligned with
the pump driver slot. This can be used as a visu
al aid during assembly.
a. If bushing removal is needed, the bushings

must exit from the thrust side of the helical side
gear.
3. Install the output side gear. Apply a thin layer of oil

to the output side gear boss before installing into
the seal.
Note: For non- pump models, fill bore of output

side gear models with synthetic grease.
23 of 76
1. Press
2. Sleeve
3 1sI Bushing (press lo shoulder)
4. Shoulder
5. Sleeve
6. 2nd Bushlng (recess 0.049-0.069 in p .25-1.75mm))
1. Press
b. Install bushings in helical side gear. Bushing 2. Press Tool
must be installed from the thrust side of the 3. Bearing
4. Inpul Shaft
helical side gear. See illustration above for
installation depth. 10. If removed , press the new input bearing cone in
7. Install helical side gear thrust washer. place until seated using the proper press sleeve or
bearing installer.
8. Install the v-ring seal to the sliding clutch.

11. For High Entry Applications Only:
Install shaft/gear assembly. Proceed to Step 13.
9. Install the sliding clutch so that the teeth are facíng

up.
240176
12. Assemble the sliding clutch, shift fork, and fork 14. Install input cover and capscrews. Torque to the
spnng to the input shaft and install assembly into proper specificatiolls. See the Torque Chart on
carrier. Make sure that the shift fork rod is piloted in page 75. Tighten fasteners in a criss cross pattern.
the carrler bore.
190 Cover
15. Install input shaft bearing adjuster, adjust inward

until snug against the bearing cone.
170 Cover
Note: Before installing input cover, inspect and

thoroughly clean mating surfaces using an ap
propriate solvent and clean rag.
13. Applya bead of Loctite® 518 to the carrier surface

as shown in the illustration.
Note: Completely remove all old gasket materi

al prior to applying new Loctite®. 16. Back off input bearing cage one notch and check
endplay. Endplay should be between
0.001-0.005 in (0.03--0. 13mm). Rotate cage in or
out to get proper setti:lg.
25 of 76
17. Line up cage slot with locking fastener. Turn in

input cage locking fastener and torque to the
proper specifications. See Torque Chart on page 21. Verify that the endplay is between 0.001-0.005 in
75 .
(0.03-0. 13mm). If not, readjust until the proper
specification is achieved.
1--- 1
/
I
18. Install input seal using proper installation tool.
1. Round Tipped Chisel 3

2. Nuls Slaking Flange
3. Machined Sial In Pinion
A WARNING
Failure to stake the pinion nut properly may
result in the nut coming loose during service.
The pinion nut should never be reused,
always replace with new.
19. Install yoke and slinger assembly.

20. Install input shaft flanged nut and torque to the CAUTION
proper specifications. See Torque Chart on Page The stake must be deep enough to enter the
75 . machined slot 01 the input sha1t.
Note: A torque multiplier is recommended. 11 22. Use a punch with a round tip to stake the pinion
difficulty achieving correct torque, torque the nuts flange into the machined slot in the pinion
nut with the wheels on the ground and with the shaft.
axle shaft installed .
26 of 76
Carrier
Carrier Disassembly - Forward
Carrier
For models having Ihe wheel differenlial lock oplion ,
refer lo Ihe following procedure. These parls musl be
removed firsl befare furlher disassembly 01 the wheel
differenlial can lake place.
4. Remove the shift lork and sliding clulch assembly.
Note: Do not disassemble the shift fork from the

sliding clutch unless parts are to be replaced.
To disassemble, use a pin punch to remove
spring pin from the fork leg. The sliding clutch
1. Far ease 01 service, mounl differenlial carrier in can now be removed from the fork .
head stand wilh Ihe differential lock lacing up.
-~
Iy
2. Remove Ihe Ihreaded cylinder cap.
5. Remove Ihe shift lork spring.
Note: Omit this step il' the ring gear is to be re

placed. If the ring gear is to be reused, check the
tooth contact pattern and ring gear backlash before
disassembling the carrier assembly. When check
ing the backlash, a yolte or helical gear must be
installed and torqued to the proper specification to
get an accurate reading. Best results are obtained
when tooth contact patterns are maintained in used
gearing.
3. Remove Ihe pislon push rod Irom Ihe shift lork.
27 01 76
S M01-024--015.00 1104 Service Manual
1. Threaded Bearing Cup

2. Adjustment Plate
6. Mount the differential carrier in a head stand with 8. Use a wheel differential bearing adjustment tool
the wheel differential facing upward . (Link-Belt® part number 3A 24442) to back offthe
threaded cups and remove.
7. Remove the carrier differential bearing cap

capscrews and bearing caps. 9. Use a chain hoist and the proper strap, lift the ring
gear and wheel differential assembly Irom the
Note: For easier disassembly, loosen but do carrier.
not remove the pinion nrut.
280176
Service Manual 1104 SM01-02~4-015.00
Drive Pinion
Pinion Removal
1. Slots
b . For 8190 disassembly, use the pry slots

provided at each end of the pilot web.
1. For D170 assembly, remove the pinion cover. Use
a flat chisel to remove the cover from the carrier.
1 Threaded Jack Holes

CAUTION
Failure to de-stake the pinion nut will result in
2. If a pilot web is used , remove the web capscrews . damage to the drive pinion threads when
a . For D190 disassembly, install a M1 O x 1.5 bolt removed.
in the threaded jack holes found in-between
the pilot web capscrews . 3. Befare the pinion nut can be loosened , yo u must
de-stake the nut from the slot of the pinion .
29 of 76
SM01-02tl-015.00 1104 Service Manual
1. Round Tipped Chisel 3

2. Machined Slol In Pinion
3. Nuts Staked Flange
\ .
4. To de-stake the nut, use a chisel or drift with a "'
round tipo The flange of tlle nut must be pushed far
enough outward so that the staked area will not
interfere with the pinion threads when the nut is 1. Press
removed . 7. Use the proper pressing tool to press the end ofthe
5 . Remove the pinion nut. pinion until free from the pinion bearings.
Note: The pinion nut snould never be reused,

8. Forward Axles Only: Remove the pinion spacer

and the helical gear.
Note: The bearing spacer will be reused or used

. \ as a starting point when resetting the pinion
4
\ . l ' bearing preload. Do not discard this part.
1\ \ I t
. '. , \
1. Carn er Assembly
2. Press
3. Pinion
4 Wood Block
6. Place carrier assembly into a press, place a 2 x 6 x 6 in

(5 x 15 x 15cm) wood block under the pinion. This will
ensure that when the pinion is pressed free from the
bearings the pinion will not be damaged .
3 0 of 76
Forward Axle Pinion - Parts Exploded View
r---------------
I
I
I
I
I
I
I
I
I
I
I
I
I
I
IL _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
8
9
~
1. Pinion Pilot Bearing 4. Pinion Bearing Gup - Inner 7. Pinion Bearing Gup - Outer
2. Pinion 5. Pinion Helical Gear 8. Pinion Bearing Gone - Outer
3. Pinion Bearing Gone - Inner 6. Pinion Bearing Spacer 9. Pinio n Nut
Rear Axle Pinion - Parts Exploded View
r---------------
I I
I 1 I 3
\ 4
1 Pinion Pilot Bearing 5 Pinion Bearing Spacer 8. Oil Seal

2. Pinion 6. Pinion Bearing Gup - Outer 9. Yoke
3. Pinion Bearing Gone - Inner 7 Pinion Bearing Gone - Outer 10. Pinion ,\Jut
4. Pinion Bearing Gup - Inner
31 of 76
Drive Pinion Overhaul and
Assembly - Forward and Rear
Carrier
The preload of the bearings on the drive pinion is
adjusted by a spacer between the inner and outer
bearing cones and the helical gear. The preload is
adjusted by changing the thickness of the spacer. A
thicker spacer will decrease the preload, a thinner
spacer will increase the bearing preload .
The following procedure covers both the lorward and
rear axle carrier overhaul an d assembly.
Note: See "Carrier Disassembly" on Page 27 for in

structions on pinion and yoke removal.
2. Remove the inner pinion bearing cone from the
pinion using a split-type puller. Use two
procedure steps to remove each bearing .
a. Mount the puller vertically to separate the
bearing from the pinion . This action will force
the puller halves behind the bearing race and
start moving the bearing from the pinion.
/
./
1. Ifthe model ofaxle uses a pilot bearing , removethe

bearing using a split-type puller. Use two
procedure steps to remove each bearing.
a. Mount the puller vertically to separate the
bearing from the pinion . This action will force
the puller halves behind the bearing race and
start moving the bearing Irom the pinion.
1. Press
b. Mount the puller horizontally to press the

bearing from the pinion.
b. Mount the puller horizontally to press the

bearing from the pinion.
32 0176
Service Manual 1104 SM01-0~!4-015.00
3. Use a press sleeve to install the inner bearirig cone c. If replacement 01 the output shaft side gear
and pilot bearing, if used, anta the pinion. Apply bearing cup is necessary, use either 01 the
pressure until the bottom of the cone touches the following methods :
shoulder of the pinion. Apply lubricant to the cone
01 the bearing. Weld: Place a weld bead around the inside 01
the cup , when the weld cools the cup will lall
Note : Use the correctly sized spacer. Do not out.
use shim stock or grind spacers. These practic
es can lead to loss of bearing preload and gear Hammer: Use slipper to get under the cup
or bearing failure. and with a hammer and drift from the back side
of carrier tap out bearing cup o
Note: To prevent bearing damage, use suitable
d . To install the outer bearing cup, place the
sleeve that only contacts the inner race of bear
carrier in a press with the top 01 the carrier
ing cone.
lacing
e. Place the cup in the bore , use a sleeve ar
bearing driver tool to press the cup until it is
lully seated . Use a leeler gage to make sure
the cup is fully seated.
Note: If a press is not available, use a

sleeve or bearing driver and a hammer to
install the cups.
4. II removed , install the inner and outer bearing cups

into the carrier.
a. To install the inner bearing cup , place the
carrier in a press with the bottom 01 the carrier
lacing up.
b. Place the cup in the bare, use a sleeve ar
bearing driver tool to press the cup until it is
lully seated. Use a leeler gage to make sure
the cup is lully seated.
330176
7. To align the splines 01 the helical gear to the pinion ,

use a old pinion nut with a metal ring welded to the
1. Large, Long Boss
top , thread onto the pinion. Then lift the pinion
5. For Forward Carriers Only: Install the helical with while aligning the two splined surfaces .
the larger boss side facing down in the carrier.
Align the helical gear between the inner and outer
bearing cups.
8. Install the pinion spacer.
Note: If you are using the same drive pinion,

use the same spacer that was originaJly
installed in the assembly. If the drive pinion is to
be replaced, the original spacer wiJl be used as
6. Pla ce the pinion on a 6 x 6 x 6 in (15 x 15 x 15cm) the starting point 01 adjustment.
block of wood and lower the carrier over the pinion .
3 4 of 76
/ 1
9. Install the outer bearing cone. 11. Align a 6 x 6 x 6 in (15 x 15 x 15cm) wood block
under the drive pinion, then lower the carrier and
pinion assembly into a press so that it is supported
by the block.
12. Remove the pinion nut.
10. Install a pinion nut finger tight. This will hold the
pinion in place while it is positioned into the press.
13. Place a press sleeve over the top of the outer

bearing cone. Use the press to apply 5 tons of
force. It is important to rotate the carrier slightly to
make sure that the rollers of the bearing are
properly seated.
35 of 76
14 . With 5 tons of force on the press, you should be 16. Run the nut down with an impact gun . The pinion
able to feel a small amount of drag from the bearing should still have the same slight drag that was
as you rotate the carrier. If the carrier turns with no obtained in the press.
drag at all , the pinion spacer thickness should be
decreased by using a thinner spacer. If the carrier
is hard to turn, the spacer thickness must be
increased.
17. Secure the carrier in a head stand, rotate carrier so

the pinion nut can be torqued .
15. Remove the carrier from the press and reinstall the
pinion nut.
3 6 of 76
1. Wedge
20 Use an "in lb" larque wrench and correcl socket lo
18. Install Ihe wedge between the carrier wall and the check the rolling tarque of the pinion. Read tarque
leeth of the helical gear. while rotating the assembly. Recard the rotaling
torque, not Ihe breakaway torque. Torque must be
Note: A torquing wedge can be made to hold between 20-50 in lb (2-5Nm) . If the tarque
the helical gear from turning while the nut is recorded is not wilhin Ihe specified torque, Ihe
torqued. pinion spacer musl be changed. Repeal Sleps 6
Ihru 16.
21 . Once the proper rolling tarque is aChieved , use a

punch wilh a round head lo slake Ihe nut collar inlo
Ihe sial in the pinion.
Note: Always use él new nut and coat threads

with Loctite® 277 if 110t pre-coated.
19. Torque Ihe nul lo 800-1 ,000 ft lb (1084-1 355Nm).
Note: If you are unable to torque the yoke nut

correctly, try torquing the nut with the wheels on
the ground and with the axle shafts installed.
370176
1----- 1
1 Round Tipped Chisel 3

2. Nuts Staked Flange 24. Use a dead blow mallet to seat the cover.
3. Machined Slot In Pinion
A WAFlNING
Failure to stake the pinion nut properly may
result in the nut coming loose during service.
The pinion nut should never be reused,
CAUTION
The stake must be deep enough to enter the
machined slot of the pinion.
25. If a pilot bearing web is used, lineup theweb tothe

locating sleeves and tap in place with a rubber
malle!.
22. For D170 assembly, install the pinion cover. Apply

a bead of Loctite® 518 sealant to the outer flange of
the cover.
26. Install capscrews and torque to the proper

specifications. See the torque chart on page 75.
23. Install the cover, makin() sure that the cover is
parallel to the carrier opening.
38 of 76
Wheel Differential
Wheel Differential - Parts Exploded 'V,iew
1. Threaded Bearing Adjustor - Flange Hall 7, Side Pinion

2. Bearing Cone - Flange Hall 8 DiHerential Spider
3. DiHerential Case - Flange Hall 9, DiHerential Case - Plain Hall
4. Ring Gear 10, DiHerential Case Wheel DiHerential Lock - Plain Hall
5, Ring Gear Bolt 11 , Bearing Cone - Plain Hall
6, Side Gear 12, Threaded Bearing Adj ustor - Plain Hall
390176
Wheel Differential Disassembly
Note: During the following procedures, place the
differential assembly on a rnalleable surface to pre
vent damage when removing components.
1. Remove the differential case capscrews.
3. Remove the side gears, side pinions, and

differential spider from the plain hall case.
4. Place a block under the plain hall, use a rubber
mallet to remove the ring gear.
5. Remove the bearing eones Irom the case halves
using suitable pullers.
1. Spider Arm Slots
2. Remove the flange hall differential case and

bearing assembly. Use a screwdriver at the spider
arm machined slots 01 the case to loasen the Ilange
Irom the ring gear.
400176
r--=-t'-_- _ __ _
6. Remove the bearing eones Irom the plain and b. Mount the puller horizontally to remove the
Ilange halves in two steps: cone.
a. Mount the puller vertically to split the bearing.
This action will start the bearing moving off the
differential case.
41 0176
4. Assemble the side pinions anta the wheel

diHerential spider. Apply a thin coat 01 oil to the
mating surfaces 01 the side pinion and diHerential
spider. Install the wheel diHerential nest on top 01
the side gear.
Wheel Differential Assembly

1. Press the new bearing con e on the plain hall and
Ilange hall bearing boss using the proper press
sleeve or bearing installation tool.
Note: To prevent bearing damage, use suitable

sleeve that only contacts the inner race of the 5. Install the Ilange hall side gear. Apply a thin coat 01
cone . A used bearing race would be a suitable oil to the mating surlaces.
tool. This tool should have a slit cut if the ID is
the same as the flange OO.
2. Place the plain hall side 01 the diHerential case on a 6. Install the ring gear. Align the capscrew hales.
malleable surlace.
3. Install the side gear. Apply a thin coat 01 oil to the
mating surfaces 01 the side gear and plain hall.
420176
7. Use a rubber mallet to seat the ring gear to the plain 9. Install the ring gear capscrews .
half.
10. Tighten the ring gear capscrews with an impact

8. Install the flange half of the case. Align the gun and then use a torque wrench to torque to the
capscrew holes. proper specifications . See the tarque chart on
Page 75.
43 of 76
Wheel Differential Installation
Note: To install the wheel differential assembly,
p roperly setup the gear pattern and set the differen
tial bearing preload. This will require the use of the
following tools or equivalent. These tools will allow
you to align the bearing adjuster assembly to the
carr ier. This tool (Link- Belt® part number 3A
24442) will also gage the adjustment for the differ
ential bearing preload and assist in setting the
backlash. Below you will find detailed instructions
explaining each procedure.
2. Connect the adjuster plates using the threaded

rod , washers , and nuts. Tighten the nuts on the
rod to hold the threaded cups in place. Carelully
lower the wheel differential and ring gear assembly
into the carrier.
No
Gap
1
2
Threaded Beanng Cup
Ad justm en t Plate
- ---- --
1. The bearing adjustment tool is made up 01 a
threaded rOd, two nuts, two washers, and two
3. Make sure there is no gap between the carrier
adjustment plates. Fit one adjustment plate to the
threads and the cup threads .
plain hall threaded cup o Fit the other adjustment
plate to the Ilange hall cup o The adjustment rings Note: There are two ways to make sure that the
will lit into slots 01 the threaded bearing cups threaded cups are seated properly. If there is a
stamped adjustment ring o misalignment, reinstall the differential assem
bly at a slightly different angle.
440176
-I-.....-++I'~- I t-H~ Parallel
7. Obtain two notches 01 preload by tightening the

plain hall adjustment plate two notches. Start with
the notch at the top, count two notches
counter-clockwise on the adjuster plate , turn the
4. Make sure that the bearings cage is parallel to the
adjuster plate so that the notch is lacing straight
edge of the threaded cup o
up.
5. Use a ratchet or breaker bar and a 1-1/4" deep

8. Use a rubber mallet to fully seat the threaded
wall socket to turn the Ilange hall threaded bearing
cup in until the ring gear contacts the pinion (zero bearing cups.
backlash). Back the cup out two notches of the
adjustment plate .
9. With a dial indicator, check the ring and pini on

1. Ditferential Case - Fl ange Half backlash . Set the backlash Irom 0.010-0.012 in
2. Ditferential Case - Pl ain Half (O.25-0.37mm) . This will give you room to adjust
6. Turn the plain half adjuster ring until there is zero the contact pattern , il necessary.
preload on the bearings. This is done by turning 10. Remove the adjuster plates and threaded rod
the adjuster plate clockwise until you leel the assembly.
threaded cup gain resistance . The threaded
bearing cup should only be slightly snugged to
achieve a zero preload condition.
450176
Note: If you ha ve too much backlash, move the
ring gear closer to the pinion. Count the number
of notches you back off the plain half threaded
cupo Each notch equals about 0.003 in
(O.08mm) of backlash.
Note: In order to maintain the differential bear

ing preload, you will need to turn the flange half
threaded cup the same amount in the same di
rection. If you need more backlash, reverse the
procedure.
11. Install the carrier differential bearing caps and
14. lVIeasure the ring gear total radial runout. Indicator
capscrews. Make certain there is no gap between
reading should not exceed 0.010 in (O.25mm).
the carrier cap and the carrier surface .
12 . Use an impact gun to snug all carrier cap 15. Measure the ring gear total backface runout.
fasteners. Indicator reading should not exceed 0.010 in
(O.25mm).
13 . Recheck the backlash .

For new gearing, the 16. Check the ring gear tooth pattern . Paint 5 or 6 ring
backlash should be between 0.008-0.018 in 0
gear teeth 180 apart on the ring gear.
(O.20-0.46mm) .
Note: For used gearing, the backlash should be

reset to what it was at ttle time of disassembly.
46 of 76
17. With the carrier mounted in a head stand, roll the 20. Use the correct socket and a breaker bar to rotate
carrier on its side. the differential. The differential should be hard to
turno Rotate the pinion until the ring gear rotates 3
ar 4 times in both directions. See "Ring Gear"
section on page 48 for descriptions of correct
pattern position lor new and used gearing.
Stake
Locations
18. Make a sling out 01 a strap and position around the

plain hall 01 the wheel differential.
1. Machined Sial
2 Bearing Adjuslmenl Ring
3. Round Head Punch
21. When contact pattern is correet. Use a punch with

a round head to stake the threaded bearing cups in
place. Stake the outer edge of the bearing
adjustment ring into the machined slots in the
carrier bearing bore on both sides. Must be staked
19. Connect the end 01 the strap to a hoist and apply at two locations. Rotate cup il necessary to provide
pressure to the sling.
surfaees lar staking.
470176
Ring Gear
Taath Cantact Pasman Adjustment
1 Face Width
2. Tooth Depth
3 Heel
4 Top Land
Used Gearing - Correct Pattern
5 Root
6 Toe Used gearing will not usually display the square , even
contact pattern lound in new gear sets. The gear will
Note: Rear axle gearing is shown in the following normally have a "pocket " at the heal end 01 the gear
instructions. Correcttooth Gontact patlerns and ad tooth . The more use a gear has had, the more the line
justments are the same for forward and rear axles. becomes the dominant characteristic 01 the pattern .
Adjust used gear sets to display the same contact
pattern observed belore disassembly. A correct
pattern is up oH the toe and centers evenly along the
lace width between the top land and root. Otherwise ,
the length and shape 01 the pattern are highly variable
and is considered acceptable as long as it does not run
oH the tooth at any point.
Contact Pattern Adjustment

If necessary, adjust the contact pattern by moving the
ring gear and drive pinion .
• Ring gear position controls the backlash.
This adjustment moves the contact pattern
along the face width 01 the gear tooth.
• Pinion position is determined by the size of
the pinion bearing cage shim pack. It con
trols contact on the tooth depth of the gear
New Gearing - Correct Pattern tooth.
0
Paint six ring gear teeth 180 apart with marking These adjustments are interrelated. As a result, they
compound and roll the gear to obtain a contact pattern. must be considered together even though the pattern
The correct pattern is slightly below center on the ring is altered by two distinct operations. When making
gear tooth with lengthwise contact up oH the toe. The adjustments, first adjust the pinion, then the backlash .
length 01 the pattern in an unloaded condition is Continue this sequence until the pattern is satisfactory.
approximately one-hall to two-thirds 01 the ring gear
tooth in most models and ratios .
The pattern could vary in length and should cover 1/2
tooth or more (lace width). The pattern should be
evenly centered between tooth top land and root and
should be up oH the tooth toe .
4 8 0176
Ring Gear Position (Backlash) Adjustment
II the gear pattern shows incorrect lace width contact,
change backlash by adjusting the ring gear.
If the pattern is concentrated at the heel (too lar up the

tooth) , move the ring gear toward the pinion lo
decrease backlash.
1. Loosen the bearing adjuster on the teeth side of
II the pattern is too close to the edge 01 the tooth toe, the ring gear several notches .
move the ring gear away from the pinion to increase 2. Tighten the opposite adjuster one notch
backlash. 3. Return to adjuster on teeth side 01 ring gear and
1. Loosen the bearing adjuster on the teeth side of tighten adjuster until it contacts the bearing cupo
the ring gear several notches. 4. Continue tightening the same adjuster 2 Or 3
2. Loosen the opposite adjuster one notch. notches and recheck backlash .
3. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cupo
4. Continue tightening the same adjuster 2 or 3
notches and recheck backlash .
49 of 76
Wheel Differential Lock
Wheel Differential Lock - Parts Exploded View
9~
'\
4
!
c
'(;"f;~
ti! '.
' 0"
8
1 Sliding Clutch 4. Pi stan & Rad 7. Washer
2. Spring 5. O-ring 8. Switch
3 Clutch Fark 6. Pistan Cover 9. Pin
Wheel Differential Lock Installation With differential carrier completely assembled and
adjusted, install differentiallock as lollows:
and Adjustment 1. II shift lork and sliding clutch are disassembled,
en gag e lork with the clutch hub and install spring
pin in the lork leg.
2. Position spring, shift lork and clutch in shift
opening of the carrier. Align pilot hole 01 shift lork
with the pilot hole 01 carrier.
3. Install push rod through shift lork , spring and
carrier pilot hole.
~ r1J I
4. Lubricate piston and o-ring with silicone grease .
f~< Install shift piston assembly into cylinder. Position

piston with small diameter hub toward closed end
i~
) 1 1
-1- ' --- ' II of cylinder.
5 . Install piston cover and torque to 50-75 ft lb
(68-102Nm).
6. Install selector switch and torque to 10-12 ft lb
(14-16Nm).
7. Check selector switch operation. Check switch
electrically with an ohmmeter. Switch should be
closed when clutches are engaged and open
when disengaged .
5 00176
Service Manual 1104 SM01 - 024 - 015.00
Output Shaft and Rear Cover
Housing and Output Shaft - Parts Exploded View
22
~
28
27
Output Shatt Nut 8. Inner Bearing Cup 15. Stud 22. Carrier Capscrew
2. Output Yoke 9. Output Shatt 16. Spindle Nut - Outer 23. Nut
3. Output Seal 10. Rear Cover 17. Locking Ring 24. Washer
4. Snap Ring 11. Rear Cover Capscrew 18. Spindle Nut - Inner 25. Stud
5. Outer Bearing Cup 12. Fill Plug 19. Axle Housing 26. Drain Plug
6 Outer Bearing Cone 13. Rear Cover Nut 20. Breather 27. Axle Shatt
7. Inner Bearing Cone 14. Washer 21. Breather Hose 28. Welded Rear Cover
51 of 76
Output Shaft Removal Note: It may be helpful to loosely reinstall the
yoke and shoulder nut giving the technician
Note: For forward axle rear covers that are remov more of an area to grip when removing the out
able the output shaft may be removed when the cov put shaft.
er is in or out of the axle assembly.
7. Remove the inner bearing cup from rear cover
1. Disconnect the inter-axle driveline at the forward assembly. This may be removed from inside the
axle rear cover position . axle housing when the carrier is removed, or by
2. Remove yoke nut (shoulder nut) . removal of the forward axle rear cover.
1. Yoke Puller Tool
3. Remove yoke from output shaft using appropriate

tool.
Note: A yoke puller tool may be made from the

center section of most gear puller tools, or may
be purchased from your tool distributor.
4. Remove oil seaL

5. Remove snap ringo
1. Press
8. Remove both inner and outer bearing from output

shaft.
Note: Components such as the inter-axle drive

line, yoke, oil seal, and output shaft assembly
should have been removed according to normal
service procedures. Removing the differential as
sembly from the axle housing is not necessary, but
would ease the removal process of the inner bear
ing cup from the cover bore.
9. Remove output shaft inner bearing cupo

a. Using a bearing puller tool , remove the inner
bearing cupo
b. Visually inspect the inner-machined bore
surface of the welded-on cover for nicks and
burrs . Repair if necessary.
1. Snap Ring 4. Inner Bearing Cup
2. Outer Bearing Cup 5. Rear Cover Assembly
3. Output Sh aft Assem bly 6. Output Seal
6. Remove output shaft ancl outer bearing cup as an

assembly.
5 2 0176
2. Apply pressure until tlle inner bearing cone
touches tlle Slloulder 01 the output shaft.
3. Apply pressure until the back 01 the outer bearing
cone touclles the back 01 the inner bearing.
Note: Axle housings with welded-on covers pro

cured through service will include the inner bearing
cup as part of the "service" axle housing assembly.
Go to Step 6 if the inner cup has already been
installed.
CAUTION
Add Loctite® adhesive to the inner bearing
surface of the housing and NOT to the bearing
race itself. If added to the race, excessive
adhesive could get on the surface of the outer
bearing race journal during installation and
cure the outer cap in place with excessive
pre-Ioad.
f---- 6
4. Lightly coat the output bore 01 the axle housing
cover with a 0.38 in (9.5mm) wide application 01
Loctite® 680 where the bore contacts the inner
bearing cupo Do not apply Loctite® outside 01 this
1. Press
2. Plate area- to the bearing rollers or outboard 01 the inner
3. Sleeve cup bore. Improper application 01 the Loctite®
4. Outer Bearing - Press 1st could loe k the rollers or cause excessive pre-Ioad .
5. Inner Beanng - Press 2nd 5. Using a sleeve and driver (hammer), install tlle
6. Output Shatt
7. Plate inner bearing cupo
6. Put the output shaft and bearing assembly into tlle
Output Shaft Overhaul and Assembly axle housing assembly.
7. Using a sleeve and driver (hammer), install tlle
outer bearing cup into tlle Ilousing assembly over
CAUTION the output sllaft bearing cone.
To prevent bearing damage, use a suitable 8. Using snap ring pliers, install tlle snap ring that
sleeve that only contacts the bearing race. lastens the outer bearing cup into tlle welded-on
cover assembly.
9. Check the endplay 01 the output shaft. New
Note : Lubricate the parts with gear lube during as assemblies should measure 0.001 -0.015 in
sembly. (O.03-0.38mm).
1. The output shaft bearings are assembled with both
bearing eones back to back. Use a press and a
sleeve to install one bearing at a time.
530176
14. Connect inter-axle driveline. Make sure driveline
is properly phased. Lubricate u-joints .
15. Add axle lubricant. Fill to bottom of filler hole.
Note: When axle has been disassembled or hous

ing, axle shafts or wheel equipment replaced,
check axle assembly for proper differential actions
before operating crane. Wheels must rotate freely
and independentiy.
16. Road test crane to bring axle lubricant up to

temperature . Recheck joints , drain and fill plugs
far leakage. Retighten as necessary.
Measure
Correct endplay for a new assembly is 0.001-0.015 in
(O.03-0. 38mm) , The maximum endplay far a used
assembly is no mare than 0.015 in (O. 38mm). If
endplay is incorrect, contact your Link-Belt®
distributar.
1, Install oil seai.
2. Install yoke.
1. Snap Rlng
2. Bearing Cup
3 Output Shaft Assembly
4. Inner Bearing Cup
5. Rear Cover Assembly
6. Output Seal
10. Bolted Rear Cover Only: If removed, install cover

and fasten with nuts , capscrews, and lock
washers. Tighten to proper torque specifications.
See the Tarque Chart on Page 75,
Note: Use Dana® approved RTV compound on

axle housing mating surface. Completely re
move ali old gasket material prior to applying
new material. Compound will set in 20 minutes.
Install axle housing cover and output shaft as
sembly befo re compound sets or reapply. 3. Install yoke nut. One of the following options may
be utilized:
11 . Install the output seai.
a. Install a new nut with the pre-applied thread
12. Install output yoke .
adhesive compound. Tighten the nut to the
Note: Use of a torque multiplier is recom specified tarque. See the Tarque Chart on
mended . page 75.
b . If a new nut with pre-applied thread adhesive
Note: If you can't get the correcttorque on yoke compound is unavailable, apply Loctite® 277
nut, try torquing the nut with the wheels on the or 271 to the nut along two threads, far at least
ground and with the axle shafts installed. two flats (120°) of the nut midway through the
thickness. Tighten the nut to the specified
13 . Install axle shafts and axle stud nuts. (If used, also torque. See the Tarque Chart on Page 75 .
install lock washers and taper dowels.)
54 of 76
Seals
Seal Replacement
Oana® strongly recommends using seal drivers when
installing new seals . Use Ihe proper driver to make
sure that the seal is square and installed to the proper
depth .
CAUTION
Oil seals can be easily damaged prior to
installation. Use care when handling the new
seal to prevent damage or contamination.
Leave the seal in its package until installation.
On new yokes, leave the protector on the yoke
until it is installed on the shaft to prevent
damage or contamination.
1. Inspect axle endplay al the yoke (see Page 14).

A WARNING
Service il beyond specilied limit. Due to the resiliency of the plastic driver,
hammer rebound may occur when the seal is
seated. Keep clear of the hammer rebound
path!
CAUTION
Do not use any silicone or permatex-type
bore sealant with this sea 1.
5. Remove the new seal Irom ils package and inslall

wilh Ihe proper driver. See "Service Kit " table on
Page 56 lar driver part number inlarmalion
6. Handle Ihe seal by its oulside diameler avoiding
any conlacl wilh Ihe seallips . Ouring inslallalion ,
use Ihe proper driver lo make sure Ihal Ihe seal is
mounled properly. Handle Ihe seal by ils oulsi de
2. Remove Ihe old yoke using appropriale 1001. A
diameler avoiding any conlact wilh the seal lips.
yoke puller 1001 may be made Irom Ihe center
Ouring installalion, use Ihe proper driver lO make
section 01 mosl gear puller lools, or may be
sure Ihal Ihe seal is mounted properly.
purchased Irom your local 1001 dislribular.
7. Use a rubber mallel lo drive Ihe seal 1001 in unlil Ihe
3. Remove seal. Use care when removing the old
Ilange bottoms on Ihe housing cover bore lace .
seal lo prevenl damage to Ihe housing seal bore.
The Ilange willlocate the seal al Ihe proper depth .
4. InspecI the seal bare area lor any damage (nicks ,
Use a rubber mallel lo drive Ihe seal 1001 in unl il the
gouges, carrosion). Carelully remove any slighl
Ilange bottoms on Ihe housing cover bore lace .
damage wilh a crocus cloth . Clean the bore area lo
The flange willlocate the seal at the proper depth .
remove any loose debris.
550176
Guidelines tor Reusing Yoke Note: Do not rework the yoke with abrasives such
as emery paper or crocus cloth. Clean the surface
of the yoke as necessary using chemical cleaners.
CAUTION Remove all trace 01 the chemicals 1rom the yoke a1
Do not use the yoke if it has any damage on ter cleaning.
the seal surface (nicks or scratches).
The surface of the yoke and the líps of the seal form a CAUTION
critical interface which retains the axle's lubricant while Do not use wear sleeves. Wear sleeves
sealing the axle from outsíde contaminants. The condi increase the yoke hub surface diameter and
tíon of the yoke hub's surface ís a very important factor cause premature seal wear and repeat seal
in determining seallife. 1ailure.
Carefully inspect the seal surface area of the yoke hub
for signs of wear and damage. Do not reuse the yoke
if there is noticeable wear, such as heavy grooving, be
yond normal polishing from the seal lips.
Service Kit
O-Input O-Output
Location
Tool
3A 22010 3A 22010
3A 24444
3A 24443 3A 24443
56 of 76
Housing Breather
Housing Breather Installation
Dana® has an axle breather Ihat consists of a fitting ,
~
=~-::=
hose , and clamp assembly. This breather design has
improved resistance to water ingeslion , clogging '. I ' '
caused by dirl, ice, or snow buildup around the base of , I , " .,
/ " . : l'
the breather. See installation instructions below (all
views from rear).
b . Plastic Only: Tighten until one thread is

showing.
1. Install fitting in breather hole .
4. Insert hose onto fitti r.g, long end down .
2. Tighten fitting finger tight.
\\; '"
, :) ~.......-, ......
-
11
'{
J 11
5. Push hose firmly agalnst fitting. Rotate hose to
3. Using a 3/4" wrench: point down.
a. MetalOnly: Rotate the fitting atleast 1/2 turn
until nipple points to rear.
57 of 76
Wheel End Seal Wheel End Seal - Overhaul
Wheel End Seal - Parts Exploded Wheel End Seal Removal
View
A WARNING
Never work under a crane supported by only a
jack. Always support crane with stands.
Block the wheels and make sure the crane will
not roll before releasing the brakes.
Note: Wheel end seals can be easily damaged dur

ing handling. Leave the seal in its package until
installation to prevent damage or contamination.
1. Remove outer bearing and wheel.

2. Remove oil seal.
3. Remove inner bearing.
CAUTION
Do not cut through the old wear sleeve.
Damage to the housing may result.
4 . Remove old wear sleeve (2-piece design only)

with a ball peen hammer and discard.
2 5. Inspect spindle journal and hub bore for scratches
or burrs. Recondition with an emery cloth as
required.
Note: Deep gouges can be repaired by filling

gouge with hardening gasket cement and
3 smoothing with emery cloth.
6. Clean hub cavity and bearing bores before

reassembly. Be sure to remove contaminants from
all reces ses and corners .
7. Clean bearings thoroughly with solvent and
examine for damage. Replace damaged or worn
bearings .
Note: Always use the seal installation tool spe

cified by the seal manufacturero Using an im
proper tool can distort or damage the seal and
cause premature seal failure.
1. Install ation Tool
2 Seal
3. Rear Hub Wheel End Seal Installation
1. Before installation, lubricate the following with the
same lubricant used in the axle sump.
• Inner bearing
• Wheel seal (follow the directions provided by
the seal supplier)
2 . Place seal on installation tool.
3. Orive seal with installation tool onto hub o
5 8 of 76
CAUTION
Never use an impact wrench to adjust wheel
A WARNING
Do not mix spindle nuts and lockwashers 1rom
bearings. A torque wrench is required to
assure that the nuts are properly tightened.
di11erent systems. Mixing spindle nuts and 7. Inslall the inner nut on the spindle . Tighten tlle
lockwashers can cause wheel separation. inner nut to 200 tt lb (271 Nm) while rotating the
wheel hub o
8. Back off the inner nut one full turno Rotate the
Note: The lockwasher 10r a 10ur-piece tang/dow
wheel hubo
el-type wheel nut system is thinner than the lock
washer10r a three-piece tang-type wheel nut sys
9 . Retighten the inner nut to 50 ft lb (68Nm) while
rotating the wheel hub o
tem and is not designed to bear against the inner
10. Back off the inner nut exactly 1/4 turn.
nut.
Note: This adjustrnent procedure allows the
1. Inspect the spindle and nut threads for corrosion
and clean thoroughly or replace as required . wheel to rotate 1reely with 0.001 -0.005 in
(O.025-0.127mm) endplay.
Note: Proper assembly and adjustment is not
11. Install the correct lockwasher for the wheel nut
possible i1 the spindle or nut threads are cor
roded. system being used.
2. Inspect the tang - type washer (if used). Replace

the washer the tangs are broken, cracked, or
damaged.
CAUTION
A wheel dolly is recommended during
installation to make sure that the wheel seal is
not damaged by the weight 01 the hub and
drum. Never support the hub on the spindle
with just the inner bearing and seal. This can
damagetheseal and cause premature1ailure. 1. Inner Nut
2. Dowel Pin
3. Dowel-type Lockwasher
3. Install the hub and drum on thespindlewith careto
4. Outer Nut
prevent damage or distortion to the wheel seal.
4. Completely fill the hub cavity between the inner Three - piece Dowel- type Lockwasher System
and outer bearing races with the same lubricant a. Install the dowel-type lockwasher on the
used in the axle sump. spindle .
5. Before installalion, lubricate Ihe outer bearing with
the same lubricant used in the axle sump.
CAUTION
Note: Lubricate only with clean axle lubricant 01 Never tighten the inner nut10r alignment. Th is
the same type used in the axle sump. Do not can preload the bearing and cause premature
pack the bearings with grease be10re installa 1ailure.
tion. Grease will prevent the proper circulation
ofaxle lubricant and may cause wheel seal1ail
ure. Note: 11 the dowel pin and washer are not
aligned, remove washer, turn it over an d rein
6. Install the outer bearing on the spindle. stall. If required, ~oosen the inner nut just
enough 10r alignment.
b. Install the outer nut on the spindle and tighten

to 350 ft lb (475Nm).
C. Verify endplay, see page 61.
59 of 76
1. Inner Nut
2. Dowel Pin
1. Inner Nut 3. Dowel-type Lockwasher
2. Tang-type Lockwasher 4. Tang-type Lockwasher
3. Outer Nut 5. Outer Nut
Three- piece Tang-type Lockwasher System Four- piece Tang/Dowel-type Lockwasher System
a. Install the tang-type lockwasher on the a. Install the dowel-type lockwasher on the
spindle. spindle.
CAUTION CAUTION
Never tighten the inner nut for alignment. This Nevertighten the inner nut for alignment. This
ca n preload the bearing and cause premature can preload the bearing and cause premature
failu re. failure.
b. Install the outer nut on the spindle and tighten

to 250 ft lb (339Nm). Note: If the dowel pin and washer are not
c. Verify endplay, see Page 61 . aligned, remove washer, turn it over and rein
d. After verifying endplay, secure wheel nuts by stall. If required, loosen the inner nut just
bending one of the locking washer tangs over enough for alignment.
the outer wheel nut and another tang over the
b. Install the tang-type lockwasher on the
inner wheel nut.
spindle.
e. Go to Step 12. c. Install the outer nut on the spindle and tighten
to 250 ft lb (339Nm) .
d. Verify endplay, see Page 61 .
e. After verifying endplay, secure the outer nut by
bending (180 o apart) two opposing tangs of
the locking washer over the outer nut.
12. Install the following :
• New gasket at axle shaft flange
• Axle shaft
• Axle flange nuts and tighten to specified
torque
13. Lubricate axle wheel ends.
60 of 76
Wheel Endplay 2. Loosen the inner nut to the next adjustment hole of
the dowel-type was ~ler (if used).
3 . Reassemble the washer and re-torque the outer
nut.
4. Verify endplay with a dial indicator.
Fine Tuning the Endplay - If, after performing t he
readjustment procedures, endplay is still not within the
0 .001-0.005 in (0.025-0. 127mm) range :
1 . Disassemble and inspect the components. If parts
are found to be defective, re place the defective
parts
2. Reassemble and repeat wheel bearing adjustment
procedure.
3. Verify endplay with a dial indicator.
Wheel Endplay Verification Wheel End Lubrieation

Verify that endplay meets specification using a dial
indicator. An indicator with 0 .001 in (0.03mm)
resolution is required . Wheel endplay is the free CAUTION
movement of the tire and wheel assembly along the Before operating the axle, the wheel hub
spindle axis. cavities and bearings must be lubricated to
Correct endplay is 0.001-0.005 in (0.025-0. 125mm) . prevent failure.
1. Attach a dial indicator with its magnetic base to the
hub or brake drum as shown below. When wheel ends are serviced, follow Dana's® wheel
2. Adjust the dial indicator so that its plunger or end lubrication procedure before operating the axle.
pointer is against the end of the spindle with its line Dana® axles may be equipped with either of two wheel
of action approximately paral!el to the axis of the end designs:
spindle. • Wheel ends with an oil fill hole .
3. Grasp the wheel assembly at the 3 o' clock and
• Wheel ends without an oil fill hole .
9 o'clock positions . Push the wheel assembly
in and out while oscillating it to seat the Wheel Ends with an Oil Fill Hole
bearings. Read bearing endplay as the total
indicator mbvement.
CAUTION
If endplay is not within specification,
readjustment is required.
Wheel Endplay Readjustment

Excessive Endplay - If end-play is greater than
0.005 in (O.127mm):
1. Remove the outer nut and pul! the lockwasher
1. Wheel End Oil Fill Hale
away from the inner nut, but not off the spindle.
2. Praper Lubricant Level
2. Tighten the inner nut to the next alignment hole of 3. Lubricant Flaw from Sump
the dowel-type washer (if used).
3 . Reassemble the washer and re-torque the outer 1. Rotate the wheel end hub until the oil till hole is up .
nut. 2. Remove the oil fill plug .
4. Verify endplay with a dial indicator. 3. Pour 112 pint ofaxle sump lubricant into each hub
through the wheel end fill hole.
Insufficient Endplay - If endplay is not present: 4. Install oil fill plug and tighten to specified torque .
1. Remove the outer nut and pul! the lockwasher
away from the inner nut, but not off the spindle.
61 of 76
1. With axle on level surface, lill housing with oil to bottom 01 plug 3. Oil will run into wheel end
2. Temperature sensor mounting hale 4. Oil will run into wheel end
Wheel Ends Without Oil Fill Hole Approved Lubricants

1 With axle level and wheel ends assembled, add
General - Gear lubrications acceptable under military
lubricant through filler hole in axle housing cover
specification (MILSPEC) MIL-L-21050 (Lubricating
until fluid is level with the bottom of filler hole.
Oils, Gear, Multipurpose) are approved for use in
2. Raise the right side of the axle 6 in (15.24cm) or
Oana® Orive Axles. The MIL-L-21050 specification
more . Hold axle in this position for one minute.
defines performance and viscosity requirements for
3 Lower the right side.
multigrade oils. It supersedes both MIL-L-2105B,
4. Raise the left side of the axle 6 in (15.24cm) or
MIL-L-2105C and cold weather specification
MIL- L-10324A. This specification applies to both
5. Lower the left side.
petroleum based and synthetic based gear lubricants if
6. With axle on a level surface, add lubricant through
they appear on the most current "Oualified Products
housing cover oil filler hole until fluid is level with the
List" (OPL-2105) for MIL-L-21050.
bottom of the hole.
Note: The use of separate oil additives and/or fric
Note: Axles without wheel end fill holes will require
tion modifiers are not approved in Dana® Drive
approximately 2.5 additional pints of lubricant to
Axles.
bring the lube level even with the bottom of fill hole.
Synthetic Based - Synthetic- based gear lubricants

Lubrication exhibit superior thermal and oxidation stability, and
generally degrade at a lower rate when compared to
General Lubrication Information petroleum-based lubricants. The performance
The ability of a drive axle to d'9liver quiet , trouble-free characteristics of these lubricants include extended
operation over a period of years is largely dependent change intervals, improved fu el economy, better
upon the use of good quality gear lubrication in the extreme temperature operation , reduced wear, and
correct quantity. The most satisfactory results can be cleaner component appearance. The family of Dana®
obtained by following the directions contained in this Roadranger® gear lubricants represents a premium
manual. quality synthetic lube which fully meets or exceeds the
requirements of MIL- L-21 050. These products,
The following lubrication instructions represent the
available in both 75W -90 and 80/W -140, have
most current recommendations from the Axle & Brake
demonstrated superior performance in comparison to
Oivision of Oana Corporation® at time of publication.
others qualified under the MILSPEC , as demonstrated
by extensive laboratory and field testing. For a
complete list of Roadranger® approved synthetic
lubricants contact your local Link-Belt® distributor.
Makeup Lube - Maximum amount of non-synthetic
makeup lube is 10%.
62 of 76
Recommendations tor Lube Change Intervals
Viscosity/Ambient Temperature This product combines th e latest manufacturin g and
part washing technology. When filled with an Dana(H',
The lollowing chart lists the various SAE Grades
approved synthetic lubricant at the factory, the initial
covered by MIL-L -2 105D and the associated
drain is not required.
ambient temperature range Irom each. Those SAE
grades shown with an asterisk (*) are available in the Change the lubricant within the first 5,000 miles of
Roadranger® family 01 synthetic gear lubricants . The operation when not using a Roadranger® approved
lowest ambient temperatures covered by this chart are synthetic lubricant in either a new axle or alter a carrier
_40 °F (-40 °C). Lubrication recommendations lor head replacement. Base subsequent lu bricant
those applications which consistently operate below changes on a combination 01 the lollowing chart and
this temperature rang e, must be obtained through your user assessment 01 the application and operatin g
local Link-Belt® distributor. environment.
Severe Service Lubrication Change Intervals -
Ambient Temperature Range Severe service applications are those where the crane
Grade oC consistently operates at or near its maximum GCW or
°F
GVW ratings , dusty or wet environments, or consistent
75W -40to - 15 -40 lO -26 operation on grades greater than 8%. For these
75W-90 -40 to 100 -40 lo 38
applications, the ON/OFF HIGHWAY portion of the
chart should be used . Typical applications are
75W-80 -40 to 80 -40 lO 21 construction, logging, mining , and reluse re moval .
75W-140 -40 and above -40 and above Note: Clean metallic particles from the ma gnetic
80W-90 -15 to 100 -26 lO 38 filler plug and drain plugs. Clean or repla ce the
breather yearly to avoid lube contamination due to
80W-140 - 15 and above - 26 and above water ingestion.
85W-140 10 and above - 12 and above
Guidelines - Lube Change Intervals tor Orive Axles
100,000 Yearly 40,000 Yearly

Dana® Approved Synthetic 250,000 3 Years 100,000 Yearly
63 of 76
SM 01 -024-0 15.00 1
1104 Service Manual
Lube Change Fill
Drain Front Axle
Drain when the lube is at normal operating With crane on level ground , remove the filler hole plug
temperature, 150-200 °F (65-93°C). It will run freely from the axle housing cover and fill the axle with
and minimize the time necessary to fully drain the axle, approved lubricant until level with the bottom of the
this insures the axle is flushed . hole.
Rear Axle
Unscrew the magnetic drain plug on the underside of
tlle axle housing and allow the lube to drain into a Remove the filler hole plug from the axle housing cover
suitable container. and fill the axle with the approved lubricant unti l level
with the bottom of the hole.
Note: Dispose of all used lubricants properly byfol If wheel ends were removed , follow instructions in
lowing disposal methods approved for mineral or wheel end servicing Page 58.
synthetic based oils.
Note: Always use the filler hole as the final refer
After initial oil change, inspect drain plug for large ence. if lube is level with the bottom of the hole, the
quantities of metal particles. These are signs of axle is properly filled.
damage or extreme wear in the axle. Clean the drain
Note: Lube fill capacities (see chart) are basic
plug and replace it after tlle lube has drained
guidelines and will vary based on the angle the axle
completely. Inspect breather for clogging or corrosion.
is installed in a particular chassis. Torquefill plug to
Clean or replace as necessary.
40-60 ft lb (54-82Nm) .
Note: The axle can be filled through the axle hous

ing breather hole. Fill until lube level is even with
the bottom of filler hole in axle housing rear cover.
1. With axle on level suriace, lill housing with oil to bottom 01

plug
2. Temperature sensor mounting hole
64 of 76
The chart gives standpipe recommendations lor
Horizontal Installation
cranes operating in consistently mountainous areas.
Note: Grades must be continuous or lengthy in na

ture. Monitor oil temperatures before installing
standpipes. Axles should operate atapproximately
100°F (38 °C) overambienttemperatureand notex
ceed 240°F (116°C).
1. Oil Filler Hale Final Check

2. Los! Oil Capaci!y
Prior to putting crane back into service, run the crane to
bring axle lube up to temperature. Check liller and
12° Installation drain plugs and axle joint lor leakage. Re-tighten to
specilications as necessary.
Proper Towing
Without Wheel DiHerential Lock
l.
2.
Oil Filler Hale
Los! Oil Capacily
A WARNING
Do not lift the front wheels (non-drive
wheels). This alters the oil's position in the
12° Installation with Standpipes drive axle, draining it away from the drive
pinion and its bearin~ls . If the pinion is rotated
under these conditions for any period of time,
bearings will overheat resulting in axle
damage or failure.
Lift the drive wheels completely off 01 the ground or

damage will occur.
1. Oil Filler Hale II it is impossible to lift the drive wheels , remove all axle
2. Los! Oil Capaci!y shafts to prevent gear rotation and cap the wheel hubs
to prevent loss 01 lubricant and a possible road hazard .
Standpipes See the lollowing section "With Wheel Oifferential
Orive axles are lubricated with oil drawn Irom a large Lock" lor removal procedure.
sump integral to the assembly. Most axle designs
attempt to position vital components such as pinion With Wheel Differential Lock
bearings in close proximity to this sump, keeping them Follow this procedure to remove all axle shafts
bathed in a generous supply 01 oil at all times. preventing gear rotation with the drive wheels and
When drive axles are installed at severe angles in crane possible lubrication damage:
chassis, the position 01 these components is changed 1. Engage the wheel diHerentiallock, indicator lighl is
relative to the oil sump. The same eHect is present on (move crane to verily engagemenl).
when the crane travels up a steep grade. Oil in the 2. Shift transmission inlo neutral.
sump remains level while the axle itsell tilts up or down. 3. Wilh crane stationary, release the air pressure on
This makes it possible lor bearings and gears located the wheel diHerential lock shift syslem and apply
well lorward in the assembly to "starve" lor lubrication the parking brake.
even though the axle is lilled to the base 01 the lill plug 4. Oisconnect the air supply and lilting at the shift
hole as recommended by the manulacturer. cylinder.
5. Remove the axle shafts.
Axles should be modilied with standpipes to raise lube
6. Inslall temporary cover on hub lo prevent
levels whenever chassis installation angles exceed 10°
conlamination enlering and also lo prevenl Ihe
and when the crane must negotiate continuous or
loss 01 lubrican!.
lengthy grades on a routine basis.
650176
SM01-02Ll-015.00 1104 Service Manual
~
2
1. Inpullorque
2 Lockoul disengaged
3. Forward axle lorque is lransmit1ed from th e helical side gear lhrough lhe pinion helica l gear, drive pinion, ring gear, wheel diHerenllal ,
and axle shafts.
4. Rear axle larque is lransmit1ed from lhe oulPul shaf1 side gear through lhe oulPul shaf1, inler-axle driveline, drive pinion, ring gear.
wh eel diHerenlial , and axle shafls.
5. Inpul torque (p ower flow) from lhe driveline is lran smit1ed lO lhe input shaf1 and lh e Inler-axle diHerential sp ider. The diHerential dis
lribules lorque equally lo bolh axles.
Theory 01 Operation With Lockout Released (Inter-Axle

Differential is Operating)
Power Divider Operation (Power
The inter-axle differential compensates lor minor
Flow and Torque Distribution) variations in speed between the two axles, the same
In operation, the power divider accepts torque from the way the wheel differential works between the two
driveline and distributes it equally to the two axles. wheels 01 a single drive axle. This unit also acts as a
This assembly is of the two-gear design consisting of central point in distribution 01 torque to the two axles.
an input shaft, inter-axle differential, output shaft, and The power divider also includes a driver-controlled ,
two constantmesh helical gears . air-operated lockout. When lockout is engaged , il
mechanically prevenls inler -axle differenliation lor
better performance under poor traction conditions .
66 of 76
Service Manual 1104 SM01 -0:24-015. 00
~
2
1. Input torque
2. Lockout engaged
3. Forward axle torque is transmitted from the helical side gear through the pinlon hellcal gear, drive pinion, ring gear, wheel dlfferential,
and axle shafts.
4. Rear axle torque is transmitted rrom the output shaft side gear through the output shaft, inter-axle driveline, drive pinion, ring gear,
wheel differential, and axle shafts.
5 Input torque (power rlow) from the driveline is transmitted directly to the helical side gear and the output shaft. A positive drive is
provided to both axles ror maximum traction under adverse road conditions.
With Lockout Engaged (Inter-Axle Lockout should only be engaged when both axles are
Differential is not Operating) rotating at the same speed. Operation shou Id be
limited to low-traction situations and should !)e
disengaged when normal traction returns. Failure to
CAUTION do so will result in poor tlandling and damage to the
Prolonged operation with the lockout axle components.
engaged can damage axle and driveline Note: Varied road surface conditions can result in
components. unequal torque distribution between the two axle
assemblies.
67 of 76
10
1. Cab - mounted Control Valve (Plunger In - valve Open)

2. Dry Air Supply Tank 80- 120 psi (55 1- 827kPa )
3 Airline - Prelerably Equalln Length
4. Power Suppl y
5. Fuse or circuit breaker
6. Ind icator Light Or Audible Sigllal
7 Wheel Differential Lock Indicator Switch (Part 0 1Ax le Assembly)
8. Rear Axle Wheel Differential Lock Air Shift Cylinder
9. Forward Rear Ax le Wheel Differential Lock Air Shift Cylinder
10. Quick Release Valve (Optional) - Localed On Frame Rail And Within 10 ft (3.05m) Of Tub ing From Control Valve
Wheel Differential Lock Operation Direct Driver Controlled System

The wheel differential lock is driver-controlled and The driver manually locks and unlocks the wheel
operated by a carrier mounted air-actuated shift unit. differential, using a cab-mounted electric switch (or
In operation, it positively locks the wheel differential to air valve) . The following description assumes the
provide improved traction under adverse road system includes a cab-mounted electric switch and a
conditions. solenoid valve as shown in the illustration. An air valve
may be substituted for these components .
Control Systems tor Differential Lock Operation is as follows:
Two systems may be used to control the differential 1. With control switch in the "unlock" position, the
lock operation. wheel differential functions normally.
2. When the control switch is placed in the "Iock"
Transmission Low- Range Interlock position, the air supply solenoid valve opens and
Control System air pressure activates the shift cylinder. The shift
fork is moved to engage the curvic clutches, which,
The wheel differential is locked manually with the in turn, lock the wheel differential.
transmission in Low-Range. It is unlocked by the 3. When the control switch is placed in the "unlock"
driver or unlocked when the transmission is shifted out position , air pressure supply to the shift cylinder is
of Low-Range . shut off and air pressure is released from the
Note: The interlock system is preferred for cranes cylinder. A compression spring moves the shift
equipped with an air-shiftl~d, Low-Range trans fork to disengage the curvic clutch and unlock the
mission. It is designed to ensure the differential wheel differential.
lock is not left engaged (and to prevent accidental
engagement) when transmission is in high range.
68 of 76
10
1. Sliding Clutch 6. Piston Cover

2. Spring 7. Washer
3. Clulch Fork 8. Switch
4. Pisto n & Rod 9. Pin
5. O-ring 10. Carrier
Wheel Differential Lock

6
The wheel diHerential lock is an optional feature. In 1. Spring Is Compressed
operation, it positively locks the wheel diHerential, to 2. Shitt Fork
provide improved traction under adverse road 3. Piston & Rod
4. Selector Switch
conditions.
5. Air Pressure Applled Engages Clutches
The diHerential lock is driver-controlled through an 6. Fixed Clulch Splined To DiHerential Case
7. Sliding Clutch Splined To Axle Shatt And Engaged With
electric switch or air valve mounted in the cabo The
Fixed Clutch
locking mechanism is air-operated to engage a
mechanical clutch and lock the wheel diHerential. It is
spring -operated to disengage the lock and permit the Differential Lock Engaged
wheel diHerential to function normally. Air pressure applied to the shift cylinder moves the
The wheel diHerential lock consists of three major piston, push rod, shift fork, and the sliding curvic clutch
assemblies. engages the fixed curvic clutch.
• Shift Cylinder Assembly: Operates a shift The sliding clutch is splined to the axle shaft. The fixed
fork and push rod assembly. clutch is splined to the diHerential case hubo Engaging
• Shift Fork and Push Rod Assembly: En the two clutches locks the wheel diHerential thus
gages and disengages the diHerential lock preventing wheel diHerential action.
curvic clutch assembly.
• Curvic Clutch Assembly: Consists of a slid
ing clutch splined to a axle shaft and a fixed
clutch which is splined to the diHerential case
hub o
The diHerential lock also includes a selector switch
(electric) which senses clutch engagement and sends
an electrical signal to a cab mounted indicator light (or
an audible signal device).
69 of 76
Differential Lock Disengaged
When air pressure at the shift cylinder is released, a
compression spring (mounted on the push rod) moves
the push rod, shift fork, and sliding clutch as an
assembly. The sliding clutch moves out of
engagement with the fixed clutch. The wheel
diHerential is unlocked and operates normally.
Differential Lock Engagement Indicator

DiHerential lock engagement is detected by a switch
(electric) mounted on the diHerential carrier. An
actuator, mounted in the piston cover, operates the
switch.
When the shift fork moves to engage the diHerential
lock, the push rod actuator moves away from the
switch, allows the switch to close and send an electrical
signal to turn on a cab-mounted indicator light (or an
audible signal).
6 7 When the shift fork moves to disengage the diHerential
lock, the compression spring also moves the push rod
1 Spring Is Decompressed
actuator to contact the switch. The switch is opened
2. Shift Fork
3 Piston & Rod and turns oH the cab-mounted indicator light (or the
4. Selector SWitch audible signal).
5. Alr Pressure Released Disengages Clutches
6. Fixed Clutch Splined To DiHerential Case
7. Sliding Clutch Splined To Axle Shaft
70 of 76
Parts IdenUfication
Power Divider - Parts Exploded View
1, Output Shaft Nut 16, Pin 31, Input Cover

2, Output Yoke 17, Output Side Gear 32, Input Cover Capserew
3, Output Seal 18, Pump 33, Bearing Cup & Cage
4, Output Shaft Bearing Snap Ring 19, Inter-Axle DiHeren al 34, Input Seal
5, Outer Bearing Cup 20, Helical Side Gear 35 , Input Yoke
6, Outer Bearing Cone 21 , Thrust Washer 36, Input Nut
7, Inner Bearing Cone 22, Loekout Sliding Clu eh
37 , Plston
8, Inner Bearing Cup 23, Shift Fork Spring
38, O-ring
9, Output Shaft 24 , Shift Fork Assembl
10 Seal Manilold V-rí ng 39, Piston Cover
25
11, Clamp 26 , Input Shaft 40, Pinion Cover
12, Seal Manilold Feed Tube 27, Input Shaft 41 Input Cover Capserew
13, Sump Sereen 28, Input Shaft Bearing one 42, Input Cover
14, Output Side Gear Bearing Cup 29 Carrier Housing 43, Carrier Housing
15, OulpUI Slde Gear Bearing Cone 30 Locking Capscrew 44, High Enlry Input Shaft Assembly
71 af 76
Forward Axle Pinion - Parts Exploded View
¡--------------- 2
I
I
I
I
I
I
I
I
I
I
I
I
I
I
IL _______________ _
1. Pinlon Pilot Bearing 4. Pinion Bearing Gup - Inner 7. Pinion Bearing Gup - Outer
2. Pinion 5. Pinion Helical Gear 8 Pinion Bearing Gone - Outer
3 Pinion Bearing Gone - Inner 6 Pinion Bearing Spacer 9. Pinion Nut
Rear Axle Pinion - Parts Exploded View
¡---------------~
I 1 I
I I
I I
I
I
I
I
I
I
I
I
I
I
I
IL _______________ _
1. Pinion Pilot Bearing 5. Pinion Bearing Spacer 8. Oil Seal

2. Plnion 6. Pinion Bearing Gup - Outer 9. Yoke
3. Pinion Bearing Gone - Inner 7. Pinion Bearing Gone - Outer 10. Pinion Nut
4. Pinion Bearing Gup - Inner
72 01 76
Wheel Differential Lock - Parts Exploded View
9~
3
l
8
1. Sliding Clutch 4. Pistan & Rad 7. Washer
2. Spring 5. O-ring 8. Switch
3. Clutch Fark 6. Pistan Caver 9. Pin
73 af 76
Housing and Output Shaft - Parts Exploded View
1. Oulpul Shaft Nut 8. Inner Bearing Cup 15. Slud 22. Carrier Capscrew
2. Output Yoke 9. Oulpul Shaft 16. Spindle Nut - Outer 23. Nut
3 Output Seal 10. Rear Cover 17. Locking Ring 24. Washer
4. Snap Ring 11. Rear Cover Capscrew 18. Spindle Nut - Inner 25. Slud
5. Outer Bearing Cup 12. Fill Plug 19. Axle Housing 26. Drain Plug
6. Ouler Bearing Cone 13. Rear Cover Nul 20 Brealher 27 . Axle Shaft
7. Inner Bearing Cone 14. Washer 21. Brea ther Hose 28 . Welded Rear Cover
74 of 76
Fastener Torque Specifications
Torque
Location
I Size
ftlb Nm
Input Cage Locking Bolt M8 x 1.0 x 30 -- -
IAD Shift End Cap 2.375 - 16 UN-2A 50-75 68-702

Power Divider Cover Capscrews M14 x 1.545 165-1 85 223-250
Input Shaft Nut M48 x 1.5 800-1,000 7 084 -7 355
·. @~fffb~f~t~?t,¡~I~r~·· M~~rlr~ ·.· . : . · . · :··.·:·:··· : · ..·.: .:.....:.;. :..:<::.: .,: :. . : :: · · n·:.·,' '. .,,··'·(
Front Pinion Helical Nut M48 x 1.5 800-1 ,000 7 084-7 355
Output Shaft Nut M42 x 1.5 800-1 ,000 7 084-7 355
Rear Pinion Nut M48 x 1.5 800 - 1,000 7 084 -7 355
Ring Gear, Differential Case Bolts M20 x 15 450-475 670-644
¡ ::Ct~rmr·::::·:o:.:::n..·.·:.-:·:: t :.·:.:.>· :: .«..', " :··) ·>U·(.<: ·····';·t'·:······:.:·:.,,·..('\,:,

Carrier Differential Bearing Cap M18 x 1.5 x 85 325-375 440-508
M16x15x85 250-290 338-393
Carrier To Housing Capscrews
M16x1.5x55 250-290 338-393
Carrier To Housing Nuts -- 250-290 338-393
Pilot Bearing Web M16x1 .5x70 225-275 305-372
Differential Lock Switch M14 x 1.5 100-150 735-203
Differential Lock End Cap 2.375 - 16 UN-2A 50 - 75 68-702
IHA~~¡r~ ·· · · L}···· · ··.: ..·· . ···· :···· ·,··:··· ·< ?:· } · · .·:.••···;···;-:. ::{,/ ·_C ·/:;.
M16x1.5x70 250-290 338-393
Rear Cover Capscrews
M16 x 1.5 x 55 250-290 338-393
Rear Cover Nuts -- 250 - 290 338 - 393
Magnetic Plug (Fill) 1 x 11. 5 NPTF 40-60 54-87
Drain Plug 0.750-14NPTF 40-60 54 -87
Housing Breather 0.375 - 18 NPTF 20-26 27-35
Temperature Sending Plug 0.500 - 20 NPTF 55-71 75-96
0.625 - 18 70 - 190 230-258
Axle Shaft To Wheel Hub Nut
0.750-16 285-345 386 - 468
Wheel Differential Lock Caps 2.37 - 16UN 2A 55-75 74-701
75 of 76
SM01-024-015.00 11 04 Service Manual
76 of 76
Frame and Cab Mount
Standard Frame Standard Cab
Premium Frame Premium Cab
Figure 1
Bendix® EC-60'" ABS/ATC Controllers (Standard & Premium Models)
Antilock Brake System Table 01 Contents

General System Information ............... . . 2
Troubleshooting Introduction ......... .. . . ... . ..... . ... . . . .... 2
Components ....... . . .. . . . .. ..... .. .. . .. .. . . 2
This procedure is general in nature and covers the
ECU Mounting .. .. ... ........ ...... .. . ... . ... 3
diagnostic and troubleshooting procedures far a wide
EC-60 'M Controller Hardware Configurations ... 3
variety of vehicles that employ antilock brake systems
EC_60 'M Controllers with PLC . ... . ..... ..... .. 4
(ABS) . The Bendix® EC-60 ". electronic controller is
EC-60 '" Controller Inpucs . . .. . ... . .. . . . .. ... , 4
the base component of the ABS system featured in this
ABS Off-Road Switch and Indicator Lamp . .... , 4
document.
EC-60 'W. Controller Outputs .... ...... ..... . ... 5
Note: Al! options and/or features covered in this Power-Up Sequence . . . . . ... .... , . ... .. .. . .. 6
document may not be available on al! cranes. So me ABS Operation .. .. . . . . . , . . . .. .... . , . ........ . 7
ot the diagnostic procedures and equipment may ATC Operation . . ........... . . , .. . . . ......... . 8
only be available to trained Bendix technicians. Dynamometer Test Mode ..... . ... .. ... . ...... . 9
Automatic Tire Size Calibration .. . . , . .. . ....... 10
The ABS function of the EC -60 ,M is designed to ABS Partial Sh utdown .. . .......... . .... . .... 10
optimize slip on all of the carrier's wheels. The System Reconfiguration . .. ................ . 11
EC-60 'M provides the crane with improved stability EC-60 Controller System Reconfiguration . . . 11
1M
and steerability during braking . The EC-60" will also Troubleshooting ...... . ....... . ............. 12
reduce crane stopping distance on most surfaces. General ......... . .. . . ... .. . ..... . . ... ...... 12
In addition to the ABS function , in some cases the Diagnostic Trouble Codes .......... . . ... ..... 13
EC - 60 1M can be configured to provide an automatic Using Hand-Held or PC ·-based Diagnostics .. . 16
traction control (ATC) feature. Bendix® ATC can Diagnostic Trouble Code Troubleshooting Index 18
improve traction during acceleration on adverse road Diagnostic Trouble Code Tests . .......... . .. .. 19
conditions. ATC can utilize engine tarque limiting Connectar and Harnesses ... ... . ....... . .. ... 32
and/or differential braking to improve the crane's Wiring . . . .. . ... . .. .. ..... . . . ... .. . . .. . . .... 36
traction. Wiring Schematics . . .. . . ....... ... . ... . ..... 39
Glossary .......... . .... ... . .... .... . .. ..... 45
Note: Many acronyms are used throughout this
procedure. A composite listing of acronyms used
in this document can be found in the glossary on
page 45.
1 of 50
Sensor
c~~:::g~g~1l
Figure 2 Figure 4
Bendíx® WS-24 TM Wheel Speed Sensors Power Une Without PLC Signal
...... ........_~ .;. :~ ',:: ..... .
Modulator Modulator
Figure 3 Figure 5
M-32 ™ and M32QR™ Modulators Power Une With PLC Signal
General System InfClrmation In addition to the ABS function, premium models of the
Introduction EC -60 ™ controller provide an Automatic Traction
Control (ATC) feature . Bendix® ATC can improve
Bend ix® EC-60 controllers are members of a family
W vehicle traction during acceleration , and lateral stability
of electronic Antilock Brakin~1 System (ABS) devices while driving through curves . ATC utilizes Engine
designed to help improve the braking characteristics of Torque Umitíng (ETL) where the ECU communicates
air braked vehicles - inclucling heavy and medium with the engine's controller and/or Oifferential
duty buses , trucks, and tractors . ABS controllers are Braking (OB) where individual wheel brake
als o known as Electroníc Control Units (ECUs) . applications are used to improve vehicle traction.
Bend ix® ABS uses wheel speed sensors, ABS Premium EC-60 TV
controllers have a drag torque
••
modulator valves, and an ECU to control either four or control feature which reduces driven-axle wheel slip
six wheels of a vehicle. By monitoring individual wheel (due to driveline inertia) by communicating with the
turning motion during braking , and adjusting' or engine's controller and increasing the engine torque.
pulsing the brake pressure at each wheel, the
EC-60 ™ controller is able ':0 optimize slip between Components
the ti re and the road surface. When excessive wheel
slip , or wheel lock-up, is detected , the EC-60 '" The EC-60 controller's ABS function utilizes the
1M
controller will activate the Pressure Mod ulator Valves to following components:
simulate a driver pumping the brakes . However, the • Bendix® WS-24 ™ wheel speed sensors (4 or 6,
EC-60 'M controller is able to pump the brakes on depending on ECU model and configuration).
individual wheels (or pairs of wheels), independently, Each sensor is installed with a Bendix® Sensor
and with greater speed and 2ccuracy than a driver. Clamping Sleeve
2 of 50
Cab
Standard
Frame
12 4 4 v v v v
Stand ard Cab

PLC Frame
12 4 4 v v v v v
Cab
Premium
Frame
12 4/6 4/5/6 v v v v v v v v
Premium Cab 24 4/6 4/5/6 v v v v v v v
Chart 1
EC-60"" Controllers Available
• Bendix® M-32 1M or M- 32QR ™ Pressure Modu Cab ECUs utilize connectors from the AMP MCP 2.8
lator Valves (4, 5, or 6 depending on ECU model product family.
and configuration) Frame ECUs
• Dash - mounted tractor ABS Indicator Lamp
• Service brake relay va lve Frame-mounted EC - 60 , . controllers may be
• Dash-mounted trailer ABS Indicator Lamp (u sed mounted on the vehicle frame , but only in locations
on all towing vehicles manufactured after March where they will not be subjected to direct tire spray.
1, 2001) ECU mounting bolts must be torqued to 66-80 in lb
(7.5-9Nm) .
• Optional blink code activation switch
• Optional ABS off - road swlÍtch. (Off - road fea
ture is not available on all models - See CAUTION
Cllart 1.)
The frame wire harness connectors must be
The EC-60 . . controller's ATC function utilizes the properly seated with the seals intact
following components: (undamaged). AII unused connector
terminals must be plugged with the
• Traction control valve (may be integral to the ser
appropriate sealing plugs. Failure to properly
vice brake relay valve or a stand-alone device) seat or seal the connectors could resu lt In
• Dash-mounted ATC status/indicator lamp moisture or corrosion damage to the
• J1939 serial communication to engine control connector terminals. ECUs damaged by
module moisture and/or corrosion are not covered
• Stop lamp switch input (may be provided using under the Bendix® warranty.
the ECU hardware input or J1939)
• Optional ATC off - road switch
Frame ECUs utilize Deutsch connectors .
ECU Mounting
EC-60 Contro"er Hardware
1M
Cab ECUs Configurations

Cab-mounted EC - 60 '" control lers are not protected Standard Models
against moisture, and must be mounted in an Standard model EC-60 ™ controllers support four
environmentally protected area . sensor/four modulator (4S/4M) applications. Certain
models support Power Line Carrier (PLC)
AII wire harness connectors must be properly seated . communications, with all models supporting 12 volt
The use of secondary locks is strongly recommended .
installations. See Chart 1 for more details .
Premium Models
CAUTION Premium model EC-60 TM controllers support
AII unused ECU connectors must be covered applications up to six sensor/six modulator (6S/6M)
and receive any necessary protection from installations with ATC and drag torque control. AII 12
moisture, etc. volt models support PLC . 24 volt models do not
support PLG. See Ghart 1 for more details.
3 of 50
EC- 60"" Controllers with PLC Bendix® WS-24'" Wheel Speed Sensors
Wheel speed data is provided to the EC-60 ™
Since March 1, 2001, all towing vehicles must have an controller Irom the WS-24 n.. wheel speed sensor (see
in- cab trailer ABS Indicator Lamp . Trailers transmit Figure 2) . Vehicles have an exciter ring (or "tone ring ")
the status 01 the trailer ABS over the power line (the as part 01 the wheel assembly, and as the wheel turns ,
blue wire 01 the J560 connector) to the tractor using a the teeth 01 the exciter ring pass the wheel speed
Power Line Carrier (PLC) signa!. See Figure 4 and sensor, generating an AC signal. The EC-60 '"
Figure 5. Typically the signal is broadcast by the trailer controller receives the AC signal, which varies in
ABS ECU. The application 01 PLC technology lor the voltage and Irequency as the wheel speed changes .
heavy vehicle industry is known as "PLC4Trucks" . The
Standard PLC EC-60 W controller and the Premium Vehicle axle conligurations and ATC features
EC -60 '~ controller (12 volt versions) support PLC determine the number 01 WS - 24 T" wheel speed
communications in accordance with SAE J2497. sensors that must be used . A vehicle with a single rear
axle requires lour wheel speed sensors . Vehicles with
Identifying an EC-60'" Controller with PLC two rear axles can utilize six wheel speed sensors lor
Refer to the inlormation panel on the ECU label to see il optimal ABS and ATC perlormance.
the controller provides PLC . Diagnostic Blink Code Switch
An oscilloscope can be used to measure or identify the A momentary switch that grounds the ABS Indicator
presence 01 a PLC signal on the power line. The PLC Lamp output is used to place the ECU into the
signal is an amplitude and Irequency modulated diagnostic blink code mode and is typically located on
signal. Oepending on the liltering and load on the the vehicle 's dash panel.
power line, the PLC signal amplitude can range lrom
5.0mVp-p to 7.0 Vp-p . Suggested oscilloscope
ABS Off- Road Switch and Indicator
settings are AC coupling , 1 vOlt/div, 100 f.1sec/div. The Lamp
signal should be measured at the ignition power input
01the EC-60 '" controller.
Note: An ABS trailer equipped with PLC, or a PLC

A WARNING
The ABS 011- road mode should not be used
diagnostic tool, must be connected to the vehicle in on normal, paved road surfaces because
order to generate a PLC signal on the power line. vehiclestability and steerability may be
affected. When the ECU is placed in the ABS
Alternatively, the part number shown on the ECU label o11-road mode, the ABS Indicator Lamp will
can be identified as a PLC or non-PLC model by flash constantly to notify the vehicle operator
calling the Bendix®TechTeam at 1- 800-AIR-BRAKE that the 011- road mode is active.
(1- 800-247-2725).
Premium EC-60'" controllers use a
EC-60 "" Controller Inputs dash-mounted switch to place the ECU into
the ABS o11-road mode. In some cases,
Battery and Ignition Inputs ECUs may also be put into the ABS 011- road
The ECU operates at a nominal supply voltage 01 12 or mode by one of the other vehicle control
24 vo lts , depending on the model 01 the ECU. The modules, using a J1939 message to the
battery input is connected through a 30 amp luse EC - 60 ..... controller.
directly to the battery.
(If you need to know if your EC-60 '"
The ignition input is applied by the ignition switch controller uses a J1939 message to operate
through a 5 amp luse. the lamp, e-mail ABS@bendix.com.
specifying the ECU part number, or call
Ground Input
1-800-AIR-BRAKE and speak to the
The EC-60 '" controller supports one ground input.
Bendix® TechTeam.)
See "Wiring Schematics" lound later in this document.
ABS Indicator Lamp Ground Input (Cab ECUs
Stop Lamp Switch (SLS)
Only) The Premium EC-60 .. controller monitors the vehicle
EC-60 "" cab ECUs require a second ground input stop lam p status . Certain vehicle lunctions , such as
(X1 - 12) lor the ABS indicator lamp. The X1 wire ATC and AII- Wheel Orive (AWO), use the status 01 the
harness connector contains an ABS indicator lamp stop lamp to know the driver's intention. This can be
interlock (X1 - 15), which shorts theABS ind icator lamp provided to the ECU via J1939 communications, or
circuit (X1-18) to ground il the connector is removed hardware input.
from the ECU.
401 50
EC-60™ Controller Outputs Indicator Lamp Control Using Serial
Communications Links
Bendix® M-32 '" and M-32QR 'v Pressure
As mentioned previously, depending on the vehicle
IVlodulator Valves (PMV) manufacturer, the dash indicator lamps (ABS, ATC,
The Bendix® M -32 " and M -32QR ' pressure and trailer ABS) may be controlled using serial
v
modulator valves (PMV) are operated by the EC _60 · communications links. In these cases, the EC-60 "
controller to modify driver applied air pressure to the controller will send a serial communications message
service brakes during ABS or ATC activation . (See over the J1939 or J1587 links indicating the required
''ABS Operation " and "ATC Operation" found later in status of the lamp(s) . Another vehicle control module
this document.) The PMV is an electro-pneumatic receives the message and controls the indicatar
control valve and is the last valve that air passes lamp(s).
through on its way to the brake chamber. The
modulator hold and release solenoids are activated to Retarder Relay Disable Output
precisely modify the brake pressure during an antilock The retarder relay disable output may be used to
braking event. The hold solenoid is normally open and control a retarder disable relay.
the release solenoid is normally closed.
When configured to use this output, the ECU will
Traction Control Valve (TCV) energize the retarder disable relay and inhibit the use of
Premium EC-60 " controllers will activate the TCV the retarder as needed.
during diHerential braking ATC events. The TCV may
SAE J1939 Serial Communications
be a separate valve or integrated into the rear axle relay
A Controller Area Network (CAN) data link (SAE J1939)
valve .
is provided far communication. This link is used for
ABS Indicator Lamp Control with Optional various functions , such as:
Diagnostic Blink Code Switch (Cab and Frame • To disable retarding devices during ABS opera
ECUs) tion
Cab and frame-mount EC-60 " controllers have • To request torque converter lock - up during ABS
internal circuitry to control the ABS Indicator Lamp on operation
the dash panel.
• To share information such as wheel speed and
The ABS Lamp IlIuminates: ECU status with other vehicle control modules
1. During power up (e.g. when the vehicle is started)
Premium EC-60 ,., controllers utilize the J1939 data
and turns off after the self test is completed, provid
link for ATC and drag tarque control functions
ing no Diagnostic Trouble Codes (DTCs) are
present. Trailer ABS Indicator Lamp Control
2. If the ECU is unplugged ar has no power. Certain models of the EC-60'~ controller activate a
3. When the ECU is placed into the ABS off-road trailer ABS Indicator Lamp (Iocated on the dash panel)
mode (the lamp flashes rapidly). that indicates the status of the trailer ABS unit on one,
4. To display blink codes far diagnostic purposes af ar mare trailers, or dollies . Typically, the EC-60 ,,,
ter the external diagnostic switch is activated. controller directly controls the trailer ABS Indicator
Lamp based on the information it receives from the
Certain models of the EC-60 " controller trailer ABS.
communicate with other vehicle control modules to
operate the ABS Indicator Lamp using serial Alternatively, some vehicles require the EC-60 "
communications. (If you need to know if your EC -60' v
controller to activate the trailer ABS Indicator Lamp by
controller uses serial communications to operate the communicating with other vehicle controllers using
lamp, e-mail ABS@bendix.com. specifying the ECU serial communications. (If you need to know if your
part number, or call1-800-AIR-BRAKE and speak to EC-60 '" controller uses a serial communications
the Bendix® TechTeam.) message to operate the lamp , e-mail
ABS@bendix .com, specifying the ECU part number, ar
call 1-800-AIR-BRAKE and speak to the Bendix®
TechTeam.)
5 of 50
ABS System ATe System

Power Appli cati on Power Application
Status Indicators Status Indicator
I I I I I ,
I
I
I
I I I .,
I ,
0.5 1.5 2.0 2.5 3.0 (se c. ) 0.5 1.5 2.0 2.5 3.0 (sec.)
Powered Vehicle ABS ON Engin e torqu e limiting ON
Indicator Light OFF and diHerential braking OFF
enabled
Trailer AB S
ON ON
Indicator Light
(PLC Delected)*
OFF I NoATC
OFF
Figure 7
Trailer ABS
Indicalor Lighl ON ATC Indicator Light Start Up Sequence
(PLC Nol Delected) OFF
Power-Up Sequence
'Some vehicle manulaclurers may illuminale the Irailer AB S
in dicator lamp at power-up regardless 01 whether a PLC sig
nal is detected lrom the tra il er or no!. Consult the ve hicle
manufacturer's documentation lor more delails.
A WARNING
The vehicle operator should veri1y proper
Figure 6 operation of all installed indicator lamps
ABS Dash Lights Start Up Sequence (ABS, ATC, and trailer ABS) when applying
ignition power and during vehicle operation.
SAE J1708/J1587 Serial Communications
An AE J1708 data link, implemented accarding to Lamps that do not illuminate as required when
SAE J1587 recommended practice, is available for ignition power is applied, or remain
diagn ostic purposes, as well as ECU status messages. illuminated after ignition power is applied,
indicate the need for maintenance.
ATC La mp Output/ATC Off-Road Switch Input
Premium ECUs control the ATC dash lamp,
ABS Indicator Lamp Operation
The ATC Lamp Illuminates: The ECU will illuminate the ABS Indicator Lamp far
1. Ouring power up (e.g . when the vehicle is started) approximately three seconds when ignition power is
and turns off after the self test is completed , provid applied, after which the lamp will extinguish if no
ing no diagnostic trouble codes are present. diagnostic trouble codes are detected.
2. When ATC is disabled for any reason ,
3 . Ouring an ATC event (the lamp will flash rapidly). The ECU will illuminate the ABS Indicatar Lamp
4 . When the ECU is placed in theATC off-road mode whenever full ABS operation is not available due to a
(the lamp will flash slowly at arate of 1,0 seconds diagnostic trouble codeo In most cases, partial ABS is
on , 1.5 seconds off). This notifies the vehicle oper still available.
atar that the off-road mode is active , ATC Status/lndicator Lamp Operation
Interaxle Oifferential Lock Control (AWO Transfer The ECU will illuminate the ATC lamp for approximately
Cese) 2.5 seconds when ignition power is applied , after
Premium ECUs can control the interaxle differential which the lamp will extinguish, if no diagnostic trouble
lock (AWO transfer case) . This is recommended on codes are detected.
AWO vehicles , but the ECU must be specially The ECU will illuminate the ATC Indicator Lamp
configured to provide this feature , E-mail to
whenever ATC is disabled due to a diagnostic trouble
ABS @bendix ,com for more details ,
code o
Trailer ABS Indicator Lamp Operation
Certain models of the ECU will control the Trailer ABS
Indicatar Lamp when a PLC signal (SAE J2497) from a
trailer ABS ECU is detected.
6 of 50
ABS Operation
Right Bendix® ABS uses wt'leel speed sensors, ABS
Right Steer Right Orive Additional modulator valves, and an ECU to control either four or
I I I I I six wheels of a vehicle. By monitoring individual wheel
turning motion during braking, and adjusting or
I I
pulsing the brake pressure at each wheel, the
EC -60 ,." controller is able to optimize slip between the
tire and the road surface. When excessive wheel slip ,
O or wheellock-up, is detected, the EC-60 '" controller
wíll actívate the Pressure lV1odulator Valves to simulate
a dríver pumping the bral<es . However, the EC-60 "
Left Steer Left Orive Left controller is able to pump the brakes on individual
Additional wheels (or pairs of wheels), independently, and with
Figure 8 greater speed and accuracy than a driver.
Vehicle Orientation (Typical) Steer Axle Control
Although both wheels of the steer axle have their own
ECU Con1iguration Test wheel speed sensor and pressure modulator valve, the
Within two seconds of the application of ignition power, EC -60 'M controller bler,ds the applied braking force
the ECU will perform a test to detect system between the two steering axle brakes. This Bendix®
configuration with regards to the number of wheel patented brake application control, called Mod ified
speed sensors and PMVs . This can be audibly Individual Regulation (MIFl) , is designed to help reduce
detected by a rapid cycling of the PMVs . (Note: The steering wheel pull during an ABS event on road
ECU will Mt perform the configuration test when wheel surfaces with poor traction (or areas of poor traction ,
speed sensors show that the vehicle is in motion.) e.g. asphalt road surfaces with patches of ice).
Pressure Modulator Valve Chuff Test Single Orive Axle Control (4x2 Vehicle)
After the performance of the configuration test, the For vehicles with a single rear drive axle (4x2) , the
EC-60 " controller will perform a Bendix® patented brakes are operated independently by the EC-60 "
PMV Chuff Test. The Chuff Test is an electrical and controller, based on the individual wheel behavior.
pneumatic PMV test that can assist maintenance Dual Orive Axle Control (4S/4M Con1iguration)
personnel in verifying proper PMV wiring and For vehicles with dual drive axles (6x4) usíng a 4S/4M
installation. configuration, one ABS modulator controls both
right-side rear wheels and the other modulator
With brake pressure applied , a properly installed PMV
controls both left-side mar wheels. Both wheels on
will perform one sharp audible exhaust of air by
each side receive equal brake pressure during an ABS
activating the hold solenoid twice and the release
stop. The rear wheel speed sensors must be installed
solenoid once. If the PMV is wired incorrectly, it will
on the axle with the lightest load.
produce two exhausts of air or none at all.
Dual Rear Axle Control (6S/6M Con1iguration)
The EC -60 'M controller will perform a PMV chuff test For vehicles with dual rear axles (6x4 , 6x2) using a
on all installed modulators in the following order: 6S/6M configuration, the rear wheels are controlled
• Steer Axle Right PMV independently. Therefore, brake application pressure
• Steer Axle Left PMV at each wheel ís adjusted according to the individual
• Orive Axle Right PMV wheel behavior on the road surface.
• Orive Axle Left PMV 6x2 Vehicles with 6S/5N1 Con1iguration
• Additional Axle Right PI\I1V 6x2 vehicles can utilize a 6S/5M configuration, with the
• Additional Axle Left PMV additíonal axle (a non-driven rear axle) having two
sensors, but only one Pressure Modulator Valve. In this
The pattern will then repeat itself. case, the PMV controls both wheels on the additional
axle. The additional axle wheels would receive equal
The ECU will not perform the PMV Chuff Test when
brake pressure. based on the wheel that is currently
wheel speed sensors show that the vehicle is in motion.
experiencing the most wheel slip .
7 of 50
SM 01 - 025 - 016.00 1206 Service M,anual
Normal Braking The vehicle operator activates the off-road function
During normal braking, brake pressure is delivered with a switch on the dash panel. A flashing ABS
through the ABS PMV and into the brake chamber. If Indicator Lamp indicates to the driver that the ABS
the ECU does not detect excessivewheel slip, it will not off-road function is engaged . To exit the ABS
activate ABS control, and the vehicle stops with normal off-road mode, depress and release the switch.
braking. AII-Wheel Orive (AWO) Vehicles
Retarder Brake System Control AWD vehicles with an engaged interaxle differential
On surfaces with low traction, application of the (steer axle to rear axle)/AWD transfer case may have
retarder can lead to high levels of wheel slip at the drive negative effects on ABS performance. Optimum ABS
axle wheels , which can adversely affect vehicle performance is achieved when the lockable
stability. differentials are disengaged, allowing individual wheel
control.
To avoid this, the EC-60'M controller switches off the
retarder as soon as a lock - up is detected at one (or Premium EC-60"" controllers can be programmed
more) of the drive axle wheels. specifically for this configuration to control the
differential lock/unlock solenoid in the AWD transfer
When the ECU is placed in the ABS off-road mode, it case. When programmed to do so, the ECU will
wi ll switch off the retarder only when ABS is active on a disengage the locked interaxle/AWD transfer case
steer axle wheel and a drive axle wheel. during an ABS event and reengage it once the ABS
Optional ABS Off-Road Mode event has ended.
On some road conditions, particularly when the driving
su rface is soft, the stopping distance with ABS may be ATe Operation
longer than without ABS. This can occur when a ATC Functional Overview
locked wheel on soft ground plows up the road surface Just as ABS improves vehicle stability during braking,
in front of the tire, changing the rolling friction value. ATC improves vehicle stability and traction during
Although vehicle stopping jistance with a locked vehicle acceleration . The EC-60'" controller ATC
wheel may be shorter than corresponding stopping function uses the same wheel speed information and
d istance with ABS control, vehicle steerability and modulator control as the ABS function . The EC-60 'M
stability is reduced. controller detects excessive drive wheel speed,
compares the speed of the front, non-driven wheels ,
Premium EC-60 '" controllers have an optional control
and reacts to help bring the wheel spin under control.
mode that more effectively accommodates these soft
The EC-60'M controller can be configured to use
road conditions to shorten stopping distance while
engine torque limiting and/or differential braking to
maintaining optimal vehicle steerability and stability.
control wheel spin . For optimal ATC performance, both
methods are recommended.
A WARNING
The ABS of1- road mode should not be used
ATC Lamp Operation
The ATC Lamp IIIuminates:
1. During power up (e.g. when the vehicle is started)
on normal, paved road sur1aces because and turns off after the self test is completed, provid
vehicle stability and steerability may be ing no diagnostic trouble codes are present.
redu ced. The f1ashing ABS Indicator Lamp 2. When ATC is disabled for any reason.
com municates the status 01 this mode to the 3. During an ATC event (the lamp will flash rapidly).
driver. When ATC is no longer active, the ATC active/indi
cator lamp turns off.
4. When the ECU is placed in the ATC off - road mode
The vehicle manufacturer should provide the optional (the lamp will flash at arate of 1.0 seconds on, 1.5
AB S off - road function onlyfor vehicles that operate on seconds off). This notifies the vehicle operator that
unpaved surfaces or that are used in off - road the off-road mode is active.
applications, and is responsible for insuring that
vehicles equipped with the ABS off-road function Oifferential Braking
meet all FMVSS-121 requirements and have Differential braking is automatically activated when
adequate operator indicators and instructions. drive wheel(s) on one side of the vehicle are spinning ,
which typically occur on asphalt road surfaces with
patches of ice. The traction system will then lightly
apply the brake to the drive wheel(s) that are spinning.
8 of 50
The vehicle differential will then drive the wheels on the 5. When certain diagnostic trouble code conditions
other side of the vehicle. are detected.
Differential braking is available at vehicle speeds up to Optional ATC Off-Road Mode

25 mph (40km/h) . In some road conditions, the vehicle operator may
desire additional drive wheel slip when ATC is active .
Disabling ATC Differential Braking The Premium EC-60" controller has an optional
ATC differential braking is disabled under the following control mode to permit this desired performance.
conditions :
1. During power up (e.g. when the vehicle is started), The vehicle operator can activate the off -road funct ion
until the ECU detects a service brake application . with a switch on the dash panel. Alternately, a J1939
2. If the ECU receives a J1939 message indicating message may be used to place the vehicle in this
that the vehicle is parked. mode. The ATC Indicator Lamp will flash continuallyto
3. When the dynamometer test mode is active. The confirm that the off-road ATC function is engaged .
dynamometer test mode is entered using the diag
nostic blink code switch or by using a diagnostic To exit the ATC off-road mode , depress and release
tool (such as Bendix® ACom 'M Diagnostics). the ATC off-road switch.
4. In response to a serial communications request Drag Torque Control Functional Overview
from a diagnostic tool. Premium EC-60 controllers have a feature referred
N
5. During brake torque limiting to avoid overheating to as drag torque control which reduces wheel slip on a
of the brakes. driven axle due to driveline inertia . This condition is
6. When certain diagnostic trouble code conditions addressed by increasing the engine torque to
are detected. overcome the inertia.
Engine Torque Limiting (ETL) with SmartATCTM
Drag torque control in creases vehicle stability on
Traction Control
low-traction road surfaces during down-shifting or
The EC-60 controller uses Engine Torque Limiting
W
retarder braking.
to control drive axle wheel slip. This is communicated
to the engine control module (using J1939), and is Dynamometer Test Mode
available at all vehicle speeds.
Bendix® SmartATCTM Traction Control
The EC-60 '~ controller has an additional feature
known as SmartATC '" traction control. SmartATC'M
.A WARNING
ATC must be disabled prior to conducting any
traction control monitors the accelerator pedal position
(using J1939) to help provide optimum traction and dynamometer testing. When the
vehicle stability. By knowing the driver's intention and Dynamometer Test Mode is enabled, ATC
adapting the target slip of the drive wheels to the brake control and engine control along with
driving situation, the SmartATC'" traction control drag torque control are turned off. This test
allows higher wheel slip when the accelerator pedal is mode is used to avoid torque reductio n or
applied above a preset level. torque increase and brake control activation
when the vehicle is operated on a
The target wheel slip is decreased when driving dynamometer for testing purpose.
through a curve for improved stability.
Disabling ATC Engine Control and SmartATCTM The Dynamometer Test Mode may be activated by
Traction Control pressing and releasing the diagnostic blink code
ATC Engine Control and SmartATC ™ traction control switch five times or by using a hand - held or
will be disabled under the following conditions: PC-based diagnostic tool.
1. In response to a serial communications request The Dynamometer Test Mode will remain active even if
from an off - board tool. power to the ECU is removed and re-applied. Press
2. At power""': up until the ECU detects a service brake and release the blink code switch three times , or use a
application . hand-held or PC-based diagnostic tool to exit the
3. If the ECU receives a J1939 message indicating test mode.
that the vehicle is parked.
4. If the dynamometer test mode is active. This may
be accomplished via an off-board tool or the diag
nostic blink code switch.
9 of 50
SM 01 - 025 - 016.0,0 1206 Service Manual
Auto matic Tire Size Calibration ABS Partial Shutdown
The ECU requires a precise rolling circumference ratio Depending which component the trouble code is
between steer axle and drive axle tires in order for ABS detected on, the ABS and ATC functions may be fully or
and ATC to perform in an optimal manner. For this partially disabled . Even with the ABS indicator lamp
reason, a learning process continuously takes place in on, the EC-60 'M controller may still provide ABS
which the precise ratio is calculated. This calculated function on wheels that are not affected . The EC-60 'M
value is stored in the ECU memory provided the controller should be serviced as soon as possible.
following conditions are met: Steer Axle ABS Modulator Diagnostic Trouble
1. Rolling -circumference ratio is within the permissi
Code
ble range .
ABS on the affected wheel is disabled . ABS and ATC
2. Vehicle speed is greater than approximately 12 mph
on all other wheels remains active.
(19kmlh) .
3. No acceleration or deceleration is taking place. Drive Axle/Additional Axle ABS Modulator
4. There are no active speed sensor diagnostic Diagnostic Trouble Code
trouble codes o ATC is disabled. ABS on theaffectedwheel isdisabled .
ABS on all other wheels remains active.
TI1e ECU is provided with a ratio value of 1.00 as a
Steer Axle Wheel Speed Sensor Diagnostic
default setting . If the automatic tire size alignment
Trouble Code
calculates a different value, this is used to overwrite the
The wheel with the diagnostic trouble code is still
original figure in the memory. This process adapts the
controlled by using input from the remaining wheel
ABS and ATC function to the vehicle.
speed sensor on the front axle . ABS remains active on
Acceptable Tire Sizes the rear wheels . ATC is disabled .
TI1e speed calculation for an exciter ring with 100 teeth
Drive Axle/Additional Axle Wheel Speed Sensor
is based on a default tire size of 510 revolutions per
Diagnostic Trouble Code
mile, This figure is based on the actual rolling
ATC is disabled. In a four sensor system , ABS on the
circumference of the tires, which varies with tire size,
affected wheel is disabled, but ABS on all other wheels
tire wear, tire pressure, vehicle loading, etc.
remains active.
The ABS response sensitivity is reduced when the
In a six sensor system, ABS remains active by using
actual rolling circumference is excessive on all wheels .
input from the remaining rear wheel speed sensor on
For a 100 tooth exciter ring , the minimum number of tire
the same side.
revolutions per mile is 426, and the maximum is 567.
The ECU will set diagnostic trouble codes ifthe number ATC Modulator Diagnostic Trouble Code
or revolutions are out of this range . ATC is disabled. ABS remains active ,
J1939 Communication Diagnostic Trouble Code
In addition , the size of the steer axle tires compared to
the drive axle tires also has to be within the ABS system ATC is disabled. ABS remains active .
design o To avoid diagnostic trouble codes , the ratio of ECU Diagnostic Trouble Code
the effective rolling circumference of the steer axle, ABS and ATC are disabled. The system reverts to
divided by the effective rolling circumference of the normal braking .
drive axle, must be between 0.85 to 1.15, Voltage Diagnostic Trouble Code
While voltage is out of range, ABS and ATC are
disabled. The system reverts to normal braking . When
the correct voltage level is restored, full ABS and ATC
function is available. Operating voltage range is 9.0 to
17.0 VDC.
10 of 50
System Reconfiguration Reconfiguring Premium ECUs
As with standard ECUs , the Premium EC-60 "
The EC-60 " controller is designed to allow the controller also carries out, independently from any
technician to change the default system settings reconfiguration being carried out by the technician, an
(chosen by the vehicle OEM) to provide additional or automatic check of the J1939 serial link and
customized features. When replacing an ECU, be sure communicate with other vehi cle modules. This
to use an equivalent Bendix® replacement part number in eludes checking for ATC and retarder disable relay
so that the standard default settings are provided . operation. In addition , premium EC-60 '" controllers
Depending on the model, the customizable features will determine the number of wheel speed sensors and
include ABS control settings , engine module PMVs installed and configure itself accordingly.
communication, etc . Many of these settings can be 6S/5M Configuration
reconfigured using a hand-held or PC-based Premium EC- 60 '> controllers will configure for 6S/5M
software, such as the Bendix® ACom 'v Diagnostics operation when a reconfiguration event is initiated and
program o the ECU detects that an additional axle PMV is w ired as
follows:
EC - 60 Th4 Controller System
Reconfiguration PMV Connector ECU Connector
Reconfiguring Standard ECUs Right Additional Axle
Hold
Reconfigurating an EC-60 ,., controller may be carried Hold
out by using the Blink Code Switch or by using a
Left Additional Axle
hand-held or PC-based diagnostic tool. Release
Release
Note: During the reconfiguration process, and in Right Additional Axle
Common
dependently from any reconfiguration being car Common
ried out by the technician, standard ECUs automati
cally check the J1939 serial link and communicate See 6S/5M System Schematics for details .
with other vehicle modules. In particular, if the seri Reconfiguration Using the Blink Code Switch
al link shows that the vehicle has a retarder device The reconfiguration event is the same for both
present, the ECU will configure itself to communi Standard and Premium ECUs With ignition power
cate with the retarder device for improved ABS per removed from the EC-60 ' w controller, depress the
formance . For example, if the ECU detects the pres blink code switch. After the ignition power is activated,
ence of a retarder disable relay during a reconfi depress and release the switch seven times to initiate a
guration, it will configure itself to control the relay to reconfig u ration event.
disable the retarding device as needed. Diagnostic Tool
A reconfiguration event may be initiated using a
hand-held or PC-based diagnostic tool to
communicate with the ECU over the SAE J1587
diagnostic link .
11 of 50
SM 0 1 -025 -016.00 1206 Service Manual
Troubleshooting 8. Use only genuine Bendix® replacement parts ,
components , and kits . Replacement hardware ,
General tubing , hose, fittings, etc. must be of equivalent
Safe Maintenance Practices size, type, and strength as original equipment and
be designed specifically for such applications an
systems.
A WARNING
Please read and follow these instructions to
9. Components with stripped threads or damaged
parts should be replaced rather than repaired. Do
not attempt repairs requiring machining or welding
avoid personal injury or death. unless specifically stated and approved by the ve
hicle and component manufacturero
When working on or around a vehicle, the following 10. Prior to returning the vehicle to service, make cer
general precautions should be observed at all times: tain all components and systems are resto red to
1. Park the vehicle on a level surface , apply the park their proper operating condition.
ing brakes , and always block the wheels. Always 11. For vehicles with Antilock Traction Control (ATC) ,
wear safety glasses . the ATC function must be disabled (ATC indicator
2. Stop the engine and remove ignition key when lamp should be ON) prior to performing any vehicle
working under or around the vehicle. When work maintenance where one or more wheels on a drive
ing in the engine compartment, the engine should axle are lifted off the ground and moving .
be shut off and the ignition key should be removed .
Where circumstances require that the engine be in Removing The EC-60"" Controller Assembly
operation , extreme caution should be used to pre 1. Turn vehicle ignition off.
vent personal injury resulting from contact with 2. Remove as much contamination as possible prior
moving , rotating, leaking, heated, or electrically to disconnecting air lines and electrical connec
charged components . tions.
3 . Do not attempt to install, remove, disassemble, or 3 . Note the EC-60 '" controller assembly mounting
assemble a component until you have read and position on the vehicle.
thoroughly understand the recommended proce 4. Oisconnect the electrical connectors from the
EC - 60 ™ controller.
dures. Use only the proper tools and observe all
precautions pertaining to use of those tools. 5. Remove and retain the mounting bolts that secure
the EC - 60 controller.
TU
4. If the work is being performed on the vehicle's air
brake system, or any auxiliary pressurized air sys Installing A New EC-60"" Controller
tem , make certain to drain the air pressure from all
reservoirs before beginning any work on the ve
hicle. Ifthe vehicle is equipped with an AO-IS '" air CAUTION
dryer system or a dryer reservoir module, be sure
When replacing the EC - 60 controller, verify
TM
to drain the purge reservoir.
that the unit you are installing has the correct
5. Following the vehicle manufacturer's recom
default settings. Failure to do so could result
mended procedures, deactivate the electrical sys
in a loss of features, such as ATC and PLC, or
tem in a manner that safely removes all electrical
noncompliance with U.S. regulations such as
power from the vehicle. FMVSS 121 . It is recommended to use only
6. Never exceed manufacturer's recommended
the correct replacement part number.
pressures.
However, most configuration settings can be
7. Never connect or disconnect a hose or line con
altered using the Bendix® ACom TM ABS
taining pressure; it may whip. Never remove a
Diagnostic Software program o
component or plug unless you are certain all sys
tem pressure has been depleted.
Verify correct operation of Ihe EC - 60 " conlroller
system and indicator lamps prior to putting the vehlcle
back inlo servic e. Towing vehicles manufactured after
March 1, 2001 must support Ihe Irailer ABS indicator
lamp located on the dash ,
12 of 50
For further information, contact either the vehicle
manufacturer, Bendix®, or your local authorized
Bendix® dealer.
1. Position and secure the EC -60 ™ controller in the
original mounting orientation using the mounting
bolts retained during removal. On frame- mount
ECUs, torque the mounting bolts to 66-80 in lb
(7.5-9Nm). For cab-mount units use no more
Located On Located Under
torque than is necessary to firmly secure the ECU or
Dash Panel Dash Panel
into position . Over-tightening the mounting hard
ware can cause damage to the EC-60 ™ control Figure 9
ler. Typical Vehicle Diagnostic Connector
2. Reconnect the electrical connectors to the Locations (J1708/J1587,J1939)
EC-60 '" controller.
3. Apply power and monitor the EC-60 '" controller
Blink Code Switch Activation
power - up sequence to verify proper system op
When activating the blink code switch:
eration.
1. Wait at least two seconds after "ignition on" . (Ex
See "Wiring" , found later in this document, for more cept when entering reconfiguration mode - see
information on wire harnesses . "System Reconfiguration" found earlier in this doc
ument.)
Diagnostic Trouble Codes 2. For the ECU to recognize that the switch is acti
The EC-60 'V controller contains self-testing vated "on ", the technieian must press for at least
diagnostic circuitry that continuously checks for the 0.1 seconds , but less than 5 seconds . (If the switch
normal operation of internal components and circuitry, is held for more than 5 seconds, the ECU will reg is
as well as external ABS components and wiring . ter a malfunctioning switch.)
3. Pauses between pressing the switch when a se
Active Diagnostic Trouble Codes
quence is required, (e.g. when changing mode)
When an erroneous system condition is detected, the
must not be longer than 2 seconds.
EC -60 controller:
W
4. After a pause of 3.5 seconds, the ECU will begin re
1. IIluminates the appropriate indicator lamp(s) and it
sponding with output information blinks. See
engages part or all of the ABS and ATC functions .
Figure 10 for an example.
2. Places the appropriate trouble code information in
the ECU memory. Blink Code Timing
3. Communicates the appropriate trouble code infor The ECU responds with a sequence of blink codeso
mation over the serial communications diagnostic The overall blink eode response from the ECU is ealled
link as required . Hand - held or PC - based diag a "message" . Eaeh message ineludes, depending on
nostic tools attach to the vehicle diagnostic con the mode selected by the teehnieian, a sequenee of
nector, typically located on or under the dash. one or more groups of blinks. Simply record the
number of blinks for eaeh sequence and then use the
Blink Codes
troubleshooting index for active or inactive trouble
Blink codes allow a technician to troubleshoot ABS
eodes and you will be direeted to the page that
problems without using a hand-held or PC-based
provides troubleshooting information.
diagnostic tool. Instead, informatíon about the ABS
system is communicated by the ECU using the ABS Note:
indicator lamp to display sequences of blinks. 1. Sequences of blinks illuminate the ABS indica
tor lamp for half a second, with half- s econd
Note: The ECU will not enter the diagnostic blink
pauses between them.
code mode it the wheel speed sensors show that
2. Pauses between blink code digits are 1.5 sec
the vehicle is in motion. If the ECU is in the d iagnos
onds.
tic blink code mode and then detects vehicle mo
3. Pauses between blink code messages are 2.5
tion, it will exit the blink code mode. seconds.
4. The lamp remains on for 5 seconds atthe end of
In addition, by operating the blink code switch as messages.
described in "Blink Code Switch Activation ", found
later in this document, one of the several diagnostic
modes can be entered.
13 of 50
s 01-025-016.00 1206 Service Manual
Time in Seconds
O 1.0 2.0 3.0 4 .0 5.0 6.0 7.0 8.0 9 .0 10.0 11.0 12.013.014.0 15.0 16.0 17.0 18.0 19.0 20.0
3.5 second
initial pause Lamp stays illuminated
lor 5 seconds showing
Switch
2 \1 2 !
1.5 second pause between digits
2 end 01 messages
Activation
Figure 10
Exampl e Of Blink Code Message
Once the ABS indicator lamp begins displaying a Diagnostic Modes

sequence of codes, it continues until all blink code To enter the various diagnostic modes:
messages have been displayed and then returns to the
normal operating mode . During this time, the ECU will No. 01 Times to
ignore any additional blink code switch activation . Press the Blink System Mode Entered
Code Switch
A1I trouble codes, with the exception of voltage and
J 1939 trouble codes, will remain in an active state for Active diagnostic trouble code
1
the remainder of the power cycle. retrieval
Voltage trouble codes will clear automatically when the Inactive diagnostic trouble code
2 retrieval
voltage returns within the required limits . AII ABS
functions will be re-engaged . Clear active diagnostic trouble
3
codes
J1939 trouble codes will clear automatically when
com munications are re-established . 4 System configuration check
Oiagnostic Modes 5 Dynamometer Test Mode
In ord er to communicate with the ECU, the controller
has several modes that the technician can select, 7* Reconfigure ECU
allowing information to be retrieved, or other ECU
* To enter the Reconfiguration Mode, the switch
funct ions to be accessed . must be held in before the application of ignition
power. Once the power is supplied, the switch is
released and then pressed seven times.
Chart 2
Oiagnostic Modes
14 of 50
Active Diagnostic Trouble Code Mode 1st Number System Power
For troubleshooting, typically the Active and Inactive
Diagnostic Trouble Retrieval Modes are used . The 1 12 Volts
technician presses the blink code switch once and the
2 24 Volts
ABS indicator lamp flashes a first group of two codes ,
and if there are more trouble codes recorded, this is 2nd Number Wheel Speed Sensors
followed by a second set of cOdes, etc. (See Page 18
for a directory of these codes .) AII active trouble codes 4 4 Sensors
may also be retrieved using a hand-held or 6 6 Sensors
PC-based diagnostic tool, such as the Bendix®
ACom ™ Diagnostics software. 3rd Number Pressure Modulator Valves
To clear active diagnostic trouble codes (as problems 4 4 Modulators

are fixed), simply clear (or "self-heal ") by removing
5 5 Modulators
and re-applying ignition power. The only exception is
for wheel speed sensor trouble codes , which clear 6 6 lVlodulators
when power is removed , re-applied, and the ECU
detects valid wheel speed from all wheel speed 4th Number ABS Configuration
sensors. Alternately, codes may be cleared by 1 4S/4M or 6S/6M
pressing the diagnostic blink code switch 3 times (to
enter the Clear Active Diagnostic Trouble Code Mode) 2 6S/4M
or by using a hand-held or PC-based diagnostictool.
3 6S/5M
Handheld or PC-based diagnostic tools are able to
clear wheel speed sensor trouble codes without the 5th Number Traction Control Configuration
vehicle being driven.
2 NoATC
Inactive Diagnostic Trouble Code Mode
The ECU stores past trouble codes and comments 3 ATC Engine Control Only
(such as configuration changes) in its memory. This
4 ATC Brake Control Only
record is commonly referred to as "event history" .
When an activetrouble code is cleared , the ECU stores 5 Full ATC (Engine Control & Brake
it in the event history memory as an inactive trouble Control)
codeo
6th Number Retarder Configuration
Using blink codes, the technician may review all
1 No Retarder
inactive trouble codes stored on the ECU. The ABS
indicator lamp will display inactive diagnostic blink 2 J1939 Retarder
codes when the diagnostic blink code switch is
depressed and released two times . 3 Retarder Relay
Inactive trouble cOdes , and event history, may be 4 J1939 Retarder, Retarder Relay
retrieved and cleared by using a hand-held or Chart 3
PC-based diagnostic tool, such as the Bendix® Diagnostic Modes
ACom ™ Diagnostics software.
Clearing Active Diagnostic Trouble Codes System Configuration Check Mode
The ECU will clear active trouble codes when the The ABS indicator lamp will display system
diagnostic blink code switch is depressed and configuration information when the diagnostic bli nk
released three times. code switch is depressed and released four times. The
lamp will blink out configuration information codes
using the following patterns. (See Chart 3). In this
mode the ECU tells the technician, by means af a
series of six blink codes, the type of ABS system that
the ECU has been set up to expect. For example, if the
fourth blink code is a three , the technician knows that a
6S/5M sensor/ modulator configuration has been set.
15 of 50
Oynam ometer Test Mode
Th e Dynamometer Test Mode is used to disable ATC
LEO lights illuminate
when needed (e.g. when performing any vehicle Oiagnostic Trouble Codes
maintenance where the wheels are lifted off the ground (10 locations in total)
and moving, including dyno testing). This mode is not
reset by power off, power on, cycling . Instead a
hand -held or PC-based diagnostic tool must be
Llsed to change the setting . Alternatively, depressing
and releasing the blink code switch three times will
cause the ECU to exit the blink code mode.
Reconfig ure ECU Mode Figure 11
Vehicle reconfiguration is carried out by using the The Bendix® Remate Diagnostic Unit (RDU""')
Reconfigure ECU Mode.
Note: To enter the Reconfiguration Mode, the blink How the Bendix® RDU ""' Operates
code switch must be held in before the application See Figure 9 for typical vehicle connector locations .
of ignition power. Once the power is supplied, the
switch is relea sed and then pressed seven times. When the RDU 'M tool is plugged into the diagnostic
connector, all the LEDs will illuminate, and the green
Hand -Held or PC-based Diagnostics LED will flash 4 times to indicate communications have
been established.
With Bendix Diagnostic Software, the trained
techn ician can read, diagnose, and clear trouble If the ABS ECU has no active Diagnostic Trouble
cOdes, as well as perform reconfiguration, using Codes , only the green LED will remain illuminated.
handheld or PC-based diagnostic tools. Bendix®
Remote Diagnostic Unit (RDU T~ ), Bendix® ACom T" If the ABS ECU has at least one active Diagnostic
Diagnostics software, or the ProLink tool are avallable Trouble Code the RDU '.' tool displays the first
to trained Bendix technicians and can be utilized to diagnostic trouble code by illuminating the red LEDs,
troubleshoot the EC-60 ABS system . indicating the malfunctioning ABS component and its
Bendix® ROU ""' (Remote Oiagnostic Unit) location on the vehicle. (See Figure 11 .) If there are
multiple diagnostic trouble codes on the ABS system,
The Bendix® RDU ""' tool provides the technician with a
the RDU ' tool will display one diagnostic trouble code
visual indication of Antilock Braking System (ABS)
first, then once that Diagnostic Trouble Code has been
com ponent Diagnostic Trouble Code (DTC)
repaired and cleared, the next code will be displayed.
information. The RDU '" tool is specifically designed
for use with Bendix® ABS systems and Bendix® makes Typical Combination Diagnostic Trouble Codes are:
no claims for its operation and/or usabllity with other • Right steer sensor • Left drive modulator
bran ds of ABS systems ,
• Left steer sensor • Right additional
Features of the Bendix® ROU""' Tool • Right drive sensor modulator
The RDU ",. tool attaches to the 9 pin diagnostic • Left drive sensor • Left additional
connector in the cab of the vehicle. An adapter cable
• Right additional sensor modulator
(Link-Belt® part number 3R 1891) is available ItO
• Left additional sensor • Traction modulator
conn ect the RDU ™ to vehicles with a 6-pin diagnostic
connector. (See Figure 11.) • Right steer modulator • ECU
• Left steer modulator • Engine serial
The RDU '" tool allows the technician to: • Right drive modulator communication
• Troubleshoot ABS system component problems • MOD red LED illuminated, shows the "Common"
using Diagnostic -rrouble Code reporting via connection of one or more modulators is shorted
LEDs. to battery or ground
• Reset Diagnostic Trouble Codes on Bendix® ABS • VLT (Flashing indicates either over- or under
ECUs by holding a magnet over the reset lin cen voltage condition)
ter of RDU' ~ tool for less than 6 seconds.
• Enter the Self - Configuration Mode used by Ben To pinpoint the root cause and to ensure the system
dix® ABS ECUs by holding a magnet over the diagnostic trouble code is properly corrected the first
reset area for greater than 6 seconds but less time, additional troubleshooting may be necessary.
than 30 seconds.
16 of 50
LEO Diagnostic Trouble Codes
LFT Left ECU - ABS Controller
RHT Right SEN Wheel Speed
ORV Orive Axle Sensor
AOO Additional MOO Pressure
STR Steer Axle Modulator
VLT Power TRC Traction Control
LEOs
Example: If the Oiagnostic
Green
Trouble Code is "Right
VLT
Steer Axle Sensor", the
Red
ROU ,'" unit will display one
SEN
green and three red LEOs
STR
RHT Figure 14
Figure 12 Bendix® ACom 1M Diagnostics
Diagnostic Trouble Codes
Bendix® RDU 1M Communication Problems
If the ABS ECU does not respond to the ROU tool's
'M
request for diagnostic trouble codes, the ROU 'o., tool

will illuminate each red LEO in a clockwise pattern. This
pattern indicates the loss of communication and will
continue until the ABS ECU responds and
communication has been established .
Possible sources of communication problems are:

1. A problem with the J1587 link at the in-cab off
Heavy Duty board diagnostic connector (9 or 6 Pin).
ProLink Multi Protocol MPSI PC Card 2. The ECU does not support PI0194.
Cartridge 3. No power is being supplied to the ECU and/or the
diagnostic connector.
Figure 13 4. The J1587 bus is overloaded with information and
Nexiq (MPSI) ProLink Tool the ROU w. can not arbitrate access.
5. A malfunctioning ROU ., tool.
Bendix® RDU 1M Reset Function Nexiq Bendix® Application Card
The magnetic reset switch is located in the center top of Nexiq provides a Bendix® application card for use with
the ROU tool. Activation requires a magnet with 30
1M the ProLink tool. It can also be used to diagnose the
1M
gauss minimum. EC_30 EC-17 '" , Gen 4 Gen 5 and MC-30 ""
,
'M
,
'M
,
ABS Controllers . For more information on the Bendix®

The reset operations are: application card visit www.bendix.com or
1. If the magnet is held over the switch for less than 6 www.nexiq.com, or contact your local authorized
seconds the "clear diagnostic trouble codes" com Link-Belt® distributor or Bendix® parts outlet.
mand is sent.
2. Ifthe magnet is held over the switch for more than 6 Bendix® ACom 1M Diagnostics 3.0 Software
seconds , but less than 30 seconds, the Bendix® Bendix® ACom Oiagnostics is a PC-based software
1M
ABS "self-configuration command" is sent. program and is designed to meet RP-1210 industry
standards . This software provides the technician with
Additionally, it is recommended at the end of any access to all the available ECU diagnostic information
inspection that the user switches off and restores the and configuration capability, including :
power to the ABS ECU, then check the ABS Indicator • ECU information
Lamp operation and ROU tool to see if they indicate
W
• Oiagnostic trouble codes and repair information
any remaining Oiagnostic Trouble Codeso • Configuration (ABS, ATC, and more)
• Wheel speed information
• Perform component tests
• Save and print information
17 0f 50
When using ACom 'M Oiagnostics software to diagnose 1st
the EC-60 ABS ECU, the computer's serial or Blink
parallel port needs to be connected to the vehicle's Troubleshooting Test Page
Code
diagnostic connector. Number
For more information on ACom .... Oiagnostics software 1 No faults (1 ,1) -
or RP1210 compliant tools, visit www.bendix.com or 2 Wheel Speed Sensors 19

contact your local authorized Link-Belt® distributor or
Bendix<B 1 parts outlet. 3 Wheel Speed Sensors 19
4 Wheel Speed Sensors 19
See Appendix A: J 1587 SIO and FMI codes and their
Bendix0 blink code equivalents. 5 Wheel Speed Sensors 19
6 Power Supply 25
Diag nostic Trouble Code Troubleshooting
Index 7 Pressure Modulator Valves 21
How to interpret the first digit of messages received 8 Pressure Modulator Valves 21
when Active or Inactive Oiagnostic Trouble Code Mode 21
9 Pressure Modulator Valves
is entered.
10 Pressure Modulator Valves 21
Note: For J1587 SID and FMI Codes and Their Ben
11 J1939 27
dix® B link Code Equivalents, see Appendix A.
12 Miscellaneous 30
13 ECU 28
18 Traction Control Valve 24
Example: For a message sequence of :
3,212,4
For the first sequence go to Page 19 and
for the second sequence go to page 30.
18 of 50
Diagnostic Trouble Code Tests
1st Blink Location

Code ,~" -" -'-" -'-" -"-'.'.,
2 Left Steer Axle Sensor

15
3 Right Steer Axle Sensor
4 Left Orive Axle Sensor
5 Right Orive Axle Sensor
14 Left Additional Axle Sensor
15 Right Additional Axle Sensor
I
2nd Diagnostic
Blink Trouble Code Repair Information
Code Description
Adjust sensor to contact exciter ringo Rotate wheel and verify a minimum of 0.25
VAC senSOr output at - 0.5 RPS. Verify condition of sensor head. Verify mounting
Excessive
1 of exciter ring and condition of teeth. Verify proper bearing endplay. Verify
Air Gap
condition and retention of clamping sleeve. Verify sensor lead routing and
clamping.
Output Low VAC sensor output at - 0.5 RPS. Verify condition of sensor head . Verify mounting
2
at Orive-oH of exciter ring and condition of teeth . Verify proper bearing endplay. Verify condition
and retention of clamping sleeve . Verify sensor lead routing and clamping .
Verify 1500 - 2500 oh ms across sensor leads . Verify no continuity between sensor
Open or leads and ground or voltage. Verify no continuity between sensor leads and other
3 Shorted sensors . Check for corroded/damaged wiring or connectors between the ECU and
the wheel speed sensor.
Adjust sensor to contact exciter ring. Rotate wheel and verify a minimum of 0.25
VAC sensor output at - 0.5 RPS. Verify condition of sensor head. Verify mounting
Loss of of exciter ring and condition of teeth. Verify proper bearing endplay. Verify
4
Sensor Signal condition and retention of clamping sleeve. Verify sensor lead routing and
clamping. Check for corroded/damaged wiring or connectors between the ECU
and the wheel speed sensor.
Verify mounting of exciter ring and condition of teeth . Verify proper bearing endplay.
Verify condition and retention of clamping sleeve . Verify sensor lead routing and
5 Wheel End
clamping . Check mechanical function of brake . Check for kinked or restricted air
lines .
VAC sensor output at - 0.5 RPS. Verify condition of sensor head. Verify mounting
Erratic Sensor of exciter ring and condition of teeth. Verify proper bearing endplay. Verify
6
Signal condition and retention of clamping sleeve . Verify sensor lead routing and
clamping. Check for corroded/damaged wiring or connectors between the ECU
and the wheel speed sensor.
Tire Size Verify correct tire size as desired . Verify proper tire inflation . Verify correct number
7
Calibration of exciter ring teeth .
Configuration ECU is configured for four sensors, but has detected the presence of additional
8
Error sensors . Verify sensor wiring and ECU configuration.
Troubleshooting Diagnostic Trouble Codes: Wheel Speed Sensors
19 of 50
Wheel Speed
Connector Pin
Sensor Location
X1 10 Right Orive Axle (+)

18 Way 11 Right Orive Axle (-)
5 Left Steer Axle (+)

.... .... .... 8 Left Steer Axle (-)
,. 13 10 , 7 4 I ,. 13 10 7 4 1 13 10 , 7 4
[] O • O ,O O O ,.O O O O 2O ,.O O O O O 11 Rigllt Steer Axle (+)
" I •O 5O O
•
s X2
O I "I I • O
2 17 8 5 2
lb 'b ". OOO

, , 3 18 Way
"O " 12O •O •O O 14
• •
" 15I 12O 9O 6O 3O Right Steer Axle (-)
3 15 12
I
I I OOO
15 Left Orive Axle (+)
X 1 X 2 X 3
18 Left Orive Axle (-)
X3 11 Left Additional Axle (+)

15 Way
14 Left Additional Axle (-)
(if Premium
ECU is 12 Right Additional Axle (+)
configured for
6sensors) 15 Right Additional Axle (-)
Cab - m ount ECU: Looking into the wire harness connector
Wheel Speed
Connector Pin
Sensor Location
3 Left Steer Axle (+)
X1 7 Left Steer Axle (-)

15 Way 4 Right Steer Axle (+)
8 Right Steer Axle (-)
I, .••••
, \]
oo~
11
.000000
10 , I 7
1 Left Orive Axle (+)
( 'o 'o '()O 'o 'o X2

2 Left Orive Axle (-)
X 1 X 2 X 3 18 Way 3 Right Orive Axle (+)
4 Rigllt Orive Axle (-)
X3 3 Left Additional Axle (+)

18 Way
4 Left Add itional Axle (-)
(if Premium
ECU is 5 Right Additional Axle (+)
configured for
6sensors) 6 Right Additional Axle (-)
Frame -mount ECU: Looking into the wire harness connector
Speed Sensor Repair Tests 3. Wheel speed sensor measurements should read :
1. Take all measurements at ECU harness connector
pins in order to check wire harness and sensor. Localion Measuremenl
Pro be the connector carefully so that the terminals Sensor 1500-25000hms

are not damaged. Sensor to voltage or ground Open Circuit (no continuity)
2 . Clear OTC after issue is corrected . The sensor
> 0.25 01 VAC sensor output at
OTC will remain until the power is cycled to the ABS Sensor output voltag e
- 0.5 revs/sec
ECU and vehicle is driven above 15 mph (24km/h)
or OTC was cleared using either the diagnostic
b!ink code switch or diagnostic tool.
20 of 50
1st Blink Location
81~li~~)J;;1~~~:~;14~'¿} 17
Code
7 Left Sleer Axle
8 Righl Sleer Axle
9 Left Drive Axle
7~;t~~;' C'>" }~~·~3~~,'~·} 16

10 Righl Drive Axle
16 Left Addilional Axle
17 Righl Addilional Axle
2nd Diagnostic
Code Description
Release
Verify no conlinuily belween PMV leads and ground . Verify 4.9 lO 5.5 ohms from
Solenoid
REL lO CMN & HLD lO CMN, and 9 .8 lO 11 ohms from REL lO HLD. Check far
Sharlened
corroded/damaged wiring or conneClors belween ECU and PMV
lO Ground
Release
Verify no conlinuily belween PMV leads and vollage. Verify 4.9 lO 5.5 ohms from
Solenoid
2 REL lO CMN & HLD lO CMN, and 9.8 lo 11 ohms from REL lO HLD. Check far
Shortened
corroded /damaged wiring ar conneClors belween ECU and PMV
lO Vollage
Release Verify 4.9 lO 5 .5 ohms from REL lO CMI\J & HLD lO CMN , and 9 .8 lo 11 ohms from
3 Solenoid REL lo HLD. Check for corroded/ damaged wiring or conneclars belween ECU an d
Open Circuil PMV
Hold
Verify no continuity belween PMV leads and ground. Verify 4.9 to 5.5 ohms from
Solenoid
4 REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. Check for
Shorlened
corroded/ damaged wiring or connectors between ECU and PMV
lO Ground
Hold
Verify no continuity between PMV leads and voltage. Verify 4.9 to 5 .5 ohms from
Solenoid
5 REL to CMN & HLD to CMN , and 9 .8 to 11 ohms from REL to HLD. Check for
Shortened
corroded/ damaged wiring ar connectors belween ECU and PMV
to Voltage
Hold Verify 4.9 lO 5.5 ohms from REL to CMN & HLD to CMN , and 9.8 to 11 ohms from
6 Solenoid REL to HLD. Check far corroded/ damaged wiring or connectars between Ihe ECU
Open Circuit and PMV
Verify 4.9 to 5 .5 ohms from REL lO CMN & HLD to CMN , and 9.8 to 11 ohms from
CMN Open
7 REL to HLD. Check for corroded /damaged wiring or connectors between the ECU
Circuit
and PMV
Configuralion A mis-match exists between the ECU configuration and the modulator installation
8
Errar and wiring. Verify PMV wiring and installation. Verify ECU configuration.
Troubleshooting Diagnostic Trouble Codes: Pressure Modulator Valves
21 of 50
S M01 - 025 - 016.00 1206 Service Manual
Connector Pin PMV Location
1 Left Steer Axle Hold
2 Left Steer Axle Release
3 Left Steer Axle Common
4 Right Steer Axle Hold
6 Right Steer Axle Common
X2 7 Right Steer Axle Release

18 Way 9 Right Orive Axle Common
, . ~
, . ~
, ,
•, ,
16 ; 1"
O "O "O ,O ,O ,O I "I
Il 1 13 1
I I " 10 Right Orive Axle Hold

I I I
, , , ,110
, ,
"O "O O O O O
11
"I O O
lO 11
OOI
lO
O O
11
OOO 13 Right Orive Axle Release

, 6
O "I " O O O O "I "IJ " U

18 J J
I I I "O 12 IJ 9 6 J
I I O 12 Left Orive Axle Common
x 1 x 2 X 3
16 Left Orive Axle Hold
17 Left Orive Axle Release
4 Left Additional Axle Hold
X3 6 Left Additional Axle Common
15 Way
(if Premium 7 Left Additional Axle Release
ECU is 9 Right Additional Axle Common
configured for
6 sensors) 10 Right Additional Axle Hold
13 Right Additional Axle Release
Cab-mount ECU: Looking into the wire harness connector
22 of 50
7 Left Steer Axle Hold
8 Left Steer Axle Release
13 Left Steer Axle Common
9 Right Steer Axle Hold
10 Right Steer Axle Release
X2 14 Right Steer Axle Common

18 Way 11 Left Orive Axle Hold
'o
, JI' , . , , , 12 Left Orive Axle Release
ooob~[ (~ ,~ ,~~~~
( 'o· • 'o, ' ,
15 Left Orive Axle Common

[9 'o '00 'o ) 'o 'D@ ' oo~
X 1 X 2 X 3
16 Right Orive Axle Common
17 Right Orive Axle Hold
18 Right Orive Axle Release
9 Left Additional Axle Hold
X3 10 Left Additional Axle Release
15 Way
(il Premium 15 Left Additional Axle Common
ECU is 16 Right Additional Axle Common
conligured lor t---+___- - - - - - - - - - - - - 1
6 sensors) 17 Righl Additional Axle Hold
18 Right Addilional Axle Release
Frame- mount ECU : Looking into the wire harness connector
Pressure Modulator Valve Repair Tests 2. Pressure modulator resislance should read
pins in order to check wire harness and PMV. Location Measurement
Probe the connector carelully so that the terminals Release lo Common 4.9 10 5.5 Ohms
are not damaged. Hold lo Common 4.9 lo 5.5 Ohms
Release lo Hold 9.8 lo 11.0 Ohms
CAUTION Release, Hold, Common
Open Circuit (no conllnuity)
to Vollage or Ground
When troubleshooting modulator trouble
codes, check inactive trouble codes and
event history for over-voltage or excessive
noise trouble codeso If one 01 these is found,
troubleshoot these trouble codes first before
the PMV.
230150
1 st Blink
Code
Location 18
18 Traction Control Valve
2nd Diagnostic
Code Description
TCV Solenoid Verify 7 to 19 ohms between TCV and TCV common. Verify no continuity between
Sllorted t TCV leads and ground. Check for corroded /damaged wiring or connectors
Ground between ECU and TCV.
TCV Solenoid Verify 7 to 19 ohms between TCV and TCV common. Verify no continuity between
2 Shorted to TCV leads and voltage. Check for corroded/damaged wiring or connectors
Voltage between ECU and TCV.
TCV Solenoid Verify 7 to 19 ohms between TCV and TCV common. Check for corroded /damaged
3
Open Circuit wiring or connectors between ECU and TCV.
TCV
The ECU is not configured for ATC, but has detected the presence of a TCV. Verify
4 Configuration
TCV wiring . Inspect for the presence of a TCV. Verify ECU configuration.
Error
Troubleshooting Diagnostic Trouble Codes: Traction Control Valves
.... Connector Pin Traction Control Test

I~ U
0 0 110010
10 7 " 1
"o "o "o b b b "o "o Ob b
~ , ,~
000010
11 ., 2
' o ''o "o b 'o 'o "o no b b b Traction Control Valve

7
I~ n 12 g f: 3 111 15 12 ? IS 3 15 ,~ !I 6 3
X1 Common
000000 000000 O O OOO
18 Way
X 1 X 2 X 3 8 Traction Control Valve
Cab- mount ECU: Looking into the wire harness connector
Connector Pin Traction Control Test

,. o o"o
~ O.00, o. o, o. [
o'] .O?? ? ?? J l .'? ... C: .C: ?, ??
" [1 7 Traction Control Valve
9 .? ,? .? .? ,C: .? J I .0
C: .? .C? .C) .C) .~ ]
.
'0 '0 '0 '0)
,
000000
• 1
0000.
. ]
X3
18 Way 13
Traction Control Valve
Common
Frame -mount ECU: Looking into the wire harness connector
Tractio n Control Valve Repair Tests 2. Traction Control Valve resistan ce should read:
pins in order to check wire harness and traction Location Measurement
control valve. Probe the connector carefully so that TCV to TCV Common 7 to 19 Ohms
the terminals are not damaged. Release. Hold. Common to
Open Circuit (no continuity)
Voltage or Ground
24 of 50
1st Blink Location

Code
6 Power Supply
2nd Diagnostic
Code Description
Measure battery voltage under load . Check vehicle battery and associated
Battery Voltage
1 components. Check for damaged wiring. Check lor damaged or corroded
Too Low
connectors and connections.
Measure battery voltage under load. Insure that battery voltage is correct lor the
Battery Voltage
2 model 01 ECU. Check vehicle battery and associated components. Check lar
Too High
damaged wiring. Check for damaged or corroded connectars and connections.
Battery Voltage Measure battery voltage under load. Check vehicle battery and associated
3 Too Low co mponents . Check lor damaged wiring. Check lar damaged or corroded
During ABS connectors and connections.
Measure battery voltage under load . Check condition 01 luse. Check vehicle
Battery Voltage
4 battery and associated components. Check lor damaged wiring . Check lor
Open Circuit
damaged ar corroded connectors and connections.
Measure ignition voltage under load . Check vehicle battery and associated
Ignition Voltage
5 components. Check for damaged wiring. Check for damaged or corroded
Too Low
connectors and connections. Check condition 01 luse .
Measure ignition voltage. Insure that ignition voltage is correct lor the model 01
Ignition Voltage
6 ECU. Check vehicle battery and associated components. Check lor damaged
Too High
wiring. Check lar damaged or corroded connectors and connections.
Ignition Voltage Measure ignition voltage under load. Check vehicle battery and associated
7 Too Low components . Check lor damaged wiring. Check lar damaged or carroded
During ABS connectors and connections.
Input Voltage
Has Excess ive Check alternatar output lor excessive noise. Check lar other devices causing
8
Noise excessive noise.
(Temporary)
Input Voltage
Check alternator output lor excessive noise. Check lar other devices causing
9 Has Excess ive
excessive noise.
Noise
Troubleshooting Diagnostic Trouble Codes: Power Supply
250150
~
Connector Pin Power Supply Test
, , ,
no
•
" "O O O • "O "O "O Ob b "O "O O O O
..O " O b b b 1 Ground
"O "O "O b b b
"D "I "O O O I 9 6 3
"O O O O O ?O
,.
'"O "O "O O O JO
~ ~
"O " O b b b X1
18 Way
3 Ignition
X 1 X 2 X 3 Battery
16

[e o 'o(6) bobooo [ "? .o?
, , ?, .? o, J 9 Ignition
•oo ob b'6'bo06
[~oo '60 1 '00 '0000 [ '6 '66 '6 '6b 1 X1
15 Way
14 Battery
x 1 x 2 x 3
15 Ground
Frame-mount ECU: Looking into the wire harness connector
Power Supply Tests 3, Check for damaged wiring, damaged or corroded

1. Take all measurements at ECU harness connector. connectors and connections,
2. Place a load (e,g, an 1157 stop lamp) across bat 4. Check condition of vehicle battery and associated
tery or ignition and ground connection, measure components, ground connection good and tight.
ignition and battery voltage with the load, Ignition 5. Check alternator output for excessive noise,
to Ground should measure between 9 to 17 VDC,
Battery to Ground should also measure between 9
to 17 VDC,
26 of 50
Service Manual 1206 SM01-025~016.0 0
1st Blink Location

Code
11 J1939
2nd Diagnostic
Code Description
Loss of communications between the EC-60 ' controller and other devices
connected to the J1939 link. Check for damaged ar reversed J1939 wiring.
1 J 1939 Serial Li n k
Check for carroded ar damaged connectors. Verify ECU Configuration. Check far
other devices inhibiting J1939 communications.
Loss of communications between the EC-60 " controller and other devices
connected to the J1939 link. Check for damaged ar reversed J1939 wiring.
2 J1939 Retarder Check far corroded or damaged connectars. Verify presence of retarder on the
J1939 link . Verify ECU Configuration. Check far other devices inhibiting J1939
comm u n ications .
Loss of communications between the EC-60 controller and the engine ECU
W
over the J1939 link . Check for damaged or reversed J1939 wiring . Check for
J1939 Engine
3 carroded ar damaged connectors . Verify presence of engine ECU on the J1939
Communications
link. Verify ECU Configuration . Check for other devices inhibiting J1939
communications.
Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications
... ' .
, , , . Connector Pin Power Supply Test
"O "O "O í ,b ,b "o "O '"o ,O ,O ,O "O '"O O ,O ,O
a
''o 'b "O , , , I
"O "O "O O O O
, , ,
"O " O O O O 7 J1939 Low
• OO
"O "
•
X
"O O O O
1
" " "
O O O OOO
X 2
"O " O b 'O b
X 3
Xi
18 Way
8 J1939 High

.1'0. ?? I ,?. ?????
" , " J. 000000),
. .o ,o • °o
) oo o
10 •o "o I ? ,? ? ,? ,? ,? j
000000
~o '0 0 él 00[ 1
00 '0 '0 '0 '0] Xi
2 J1939 Low
x 1 X , X 3
18 Way
6 J1939 High
Frame- mount ECU: Looking into the wire harness connector
J1939 Troubleshooting Tests 3. Check for corroded or damaged wiring connector

1. Take all measurements at ECU harness connector. problems such as (opens ar shorts to voltage or
2. Check for damaged ar reversed J1939 wiring. ground).
4. Check for other Ji939 devices which may be load
ing down (inhibiting) J1939 communication.
27 of 50
1 st Blink Location
Code
13 ECU
2nd Diagnostic
Cod e Description
2 ECU (10)
3 ECU (11)
4 ECU (12)
5 ECU (13)
6 ECU (14)
7 ECU (15)
ALL: Check for damaged or corroded connectors. Check for damaged wiring.
8 ECU (16) Clear trouble codeso If diagnostic trouble codes return, replace the ECU.
9 ECU (17)
10 ECU (18)
11 ECU (1A)
12 ECU (1 B)
13 ECU (80)
Trou bleshooting Diagnostic Trouble Codes: ECU
28 of 50
1st Blink Location

Code
12 Miscellaneous
2nd Diagnostic
Code Description
ECU has not detected the presence 01 the stop lamp switch since ignition power
was applied (note that stop lamp switch input may be applied to the EC-60'"
controller using either hard wire input or J1939). Apply and release service brake.
Check lor brake switch input into ECU (see System Wiring Schematic) . With service
Stop Lamp
brake released, check lor presence 01 the stop lamp bu lb . With service brake
1 Switch Not
applied, verily system voltage is now present at the stop lamp switch input to the
Detected
ECU. Check lor damaged wiring between ECU , stop lamp switch, and bulb. Check
lor corroded or damaged connectors . Check lor damaged or reversed J1939
wiring . Check lor corroded or damaged connectors on J1939 link . Verily presence
01 engine ECU on the J1939 link . Verily ECU conliguration .
Apply and release service brake . Check lor brake switch input into ECU (see
System Wiring Schematic). With service brake released , check lor presence 01 the
stop lamp bulb . With service brake applied , verily system voltage is now present at
Stop Lamp the stop lamp switch input to the ECU. Check lor damaged wiring between ECU ,
2 Switch
stop lamp switch, and bulb. Check lor corroded or damaged connectors . Check lor
Delective
damaged or reversed J1939 wiring. Check lor corroded Or damaged connectors on
J1939 link. Verily presence 01 engine ECU on the J1939 link . Verily ECU
conliguration .
Dynamometer ECU has been placed in the Dynamometer Test Mode by either the diagnostic blink
3 code switch or a hand-held or PC-based diagnostic tool. ATC is disabled.
Test Mode
Retarder Relay Verify vehicle contains a retarder relay. Verily ECU conliguration. Check wiring
Open Circuit or between ECU and retarder relay. Verily no continuity between retarder disable
4
Shorted to output 01 EC-60 " controller and ground. Verily condition and wiring 01 the
Ground retarder relay.
Retarder Relay Check wiring between ECU and retarder relay. Verily no continuity between retarder
5 Circuit Shorted disable output 01 EC -60 ," controller and voltage . Verily condition and wiring 01 the
to Voltage retarder relay.
ABS Indicator Check operation 01 diagnostic blink code switch . Check wiring 01 diagnostic blink
6 Lamp Circuit code switch, ABS WL , and ABS WL relay (Irame ECUs only) . Verily ABS WL ground
Fault input (cab ECUs only).
PMV Commo Verily no continuity between the CMN 01 all PMVs , TCV, and DiH Lock Solenoid and
7 Shorted to ground. Check lor corroded/damaged wiring or connectors between the ECU and
Ground CMN 01 all PMVs, TCV, and DiH Lock Solenoid.
PMV Common Verify no continuity between the CMN 01 all PMVs , TCV, and DiH Lock Solenoid and
8 Shortedto voltage. Check lor corroded/damaged wiring or connectors between the ECU and
Voltage CMN 01 all PMVs, TCV, and DiH Lock Solenoid .
ATC Disabled
9 to Prevent ATC is temporarily disabled to prevent excessive heating 01 the loundation brakes.
Brake Fade
Tire Size Out 01
Verily correct tire size as desired. Verily proper tire inllation. Verily correct number
10 Range (Front
01 exciter ring teeth. Verily that the ECU has the proper tire size settings.
to Rear)
Troubleshooting Diagnostic Trouble Codes: Miscellaneous - Continued on page 30
290150
Wheel Speed
Sensors Sensors are reversed (Ieft to right) on one 01 the axles. Verily proper instaliation,
11
Reversed on connection, and wiring 01 the sensors.
an Axle
Oiff. Lock
Solenoid
Shorted to Verily no continuity between the Oiff Lock Solenoid and ground. Check lor
12
corroded/damaged wiring or connectors between the ECU and Oiff Lock Solenoid.
Ground or
Open Circuit
Oiff. Lock
Solenoid Verily no continuity between the Oiff Lock Solenoid and voltage. Check lor
13
Shorted to corroded/damaged wiring or connectors between the ECU and Oiff Lock Solenoid.
Voltage
Trou bleshooting Diagnostic Trouble Codes: Miscellaneous

4 TCV Common
9 Stop Lamp Switch
Xi 12 ABS WL Ground
18 Way 15 ABS WL Interlock
17 Retarder
18 ABSWL
,
"
O O "O b ',1 ,b
"
.
"I O O sO O O
'"
,
.
7
"O " O "O O O O
8 , ,
"O O "O O O O
,
•
,. .
7
" O "O O O O
, ,
O " O O O ,•
• ,
3 PMV Left Steer Axle Common

6 PI\i1V Right Steer Axle Common
•
, 8
'"I "I " • O O ~ 1>
'"O "O "I I • I ',f, 8
O " O 11.
6
X2
x 1 x 2 X 3
18 Way 9 PMV Right Orive Axle Common
12 PMV Left Orive Axle Common
2 Oiff Lock Solenoid
3 Diff Lock Solenoid Common
X3 PMV Left Additional Axle
15 Way 6
Common
PMV Right Additional Axle
9
Common
Cab -mount ECU: Looking into the wire harness connector
30 of 50
X1 10 Retarder
18 Way 12 ABSWL
5 Stop Lamp Switch
13 PMV Left Steer Axle Common
X2 14 PMV Right Steer Axle Common
18 Way
I'gb ~ ~ °(, ,?o [ [,0 ~ ~ ? ?? ~? b ,? ? ? b ~ 15 PMV Left Orive Axle Common
, o. o •
I ,?o ,?o ,,?• ,•? •,,? •? [ ,O,?,?,O~~J
oo • • • • 16 PMV Right Orive Axle Common
X , X , X 3
8 Oiff Lock Solenoid
13 TCV Common
14 Oiff Lock Solenoid Common
X3
15 Way PMV Left Additional Axle
15
Common
PMV Right Additional Axle
16
Common
Frame- mount ECU: Looking into the wire harness connector
Stop Lamp Switch Test Retarder Relay

1. With the service brake applied, measure the sys 1. Measure resistance between retarder disable out
v
tem voltage (9 to 17 VOC) stop lamp switch input to pul of EC-60 controller and voltage/ ground.
ECU.
Test Measurement
Test Measurement Retarder disable lo Vollage or
Open Circuit (no co ntinuity)
Stop Lamp Switch to Ground 9 to 17 VDC Ground
2. Apply and release service brake, does lamp exlin 2. Verify vehicle has relarder relay.
guish? 3. Verify proper wiring from ECU lo retarder relay.
3. Verify brake lamp switch is connected to ECU via PMV Commons
hard wire or J 1939. 1. Measure resistan ce between any common (PMV,
4. Wilh service brake released , check for presence of TCV, and Oiff) and vollage or ground .
stop lamp bulb.
Test Measurement
Dynamometer Test Mode (ATC Indicator Lamp
Continuously IlIuminated) Any PMV, TCV, or DiH Com
Open Circuit (no contin ulty)
mon to Vollage or Ground
1. Clear the dynamometer test mode by depressing
and releasing the blink code switch three times (or
use an off-board diagnostic tool). Differential Lock Solenoid
1. I\/Ieasure resistance between differentiallock sole
ABS Indicator Lamp
noid and voltage or ground.
1. Verify diagnostic blink code switch is open when
not activated. Test Measurement
DIH Lock Solenoid to Voltage
or Ground Open Circuit (no continuily)
31 of 50
X1 X2
Connectors Not Used
Figure 15
Standard Cab EC-60'" Controller
Conn ector and Harnesses Pin Designatíon Pin Designation
EC-60 "" Controller Wire Harness Connector Pin 1 PMV SA Left HLD 10 PMV DA Right HLD
Assign ments - Standard Cab 2 PMV SA Left REL 11 WSS SA Right (+ )
3 PMV SA Left CMN 12 PMV DA Left CMN

Connector Designation Number 01 Contacts
4 PMV SA Right HLD 13 PMV DA Right REL
Xl 17
5 WSS SA Left (+) 14 WSS SA Right (-)
X2 18
6 PMV SA Right CMN 15 WSS DA Left (+)
Note: Standard cab models utilize two AMP connectors lor
wi re harness connections. 7 PMV SA Right REL 16 PMV DA Left HLD
8 WSS SA Left (-) 17 PMV DA Left REL

Pin Designation Pin Designation 9 PMV DA Right CMN 18 WSS DA Left (-)
1 Ground 10 WSS DA Right (+) Standard Cab X2 Connector Pín Assignments

2 Trailer ABS WL 11 WSS DA Right (- )
3 Ignition 12 ABS WL Ground
4 Not Used 13 J1587 (B)
5 Not Used 14 J1587 (A)
6 Not Used 15 ABS WL Interlock
7 J1939 Low 16 Battery
8 J1939 High 17 Retarder
9 Not Used 18 ABSWL
Stllndard Cab Xl Connector Pin Assignments
32 af 50
X1 X2
Figure 16
Standard Frame EC-60 '" Controller
EC-60 '" Controller Wire Harness Connector Pin Pin Designation Pin Designation
Assignments - Standard Frame 1 WS S DA Leh (+) 10 PMV SA Rig ht REL
Connector Designation Number 01 Contacts 2 WSS DA Leh (- ) 11 PMV DA Leh HLD
Xl 15 3 WSS DA Right (+) 12 PMV DA Leh RE L
X2 18 4 WSS DA Righ t (- ) 13 PMV SA Leh CMN
Note : Standard Ira me models utilize two Deutsch connectors 5 No t Used 14 PMV SA Rig ht CMN
lor wire harness connections.
6 No t Used 15 PMV DA Left CMN
7 PMV SA Leh HLD 16 PMV DA Rig ht CMN
Pin Designation Pin Designation
8 PMV SA Leh RE L 17 PMV DA Right HLD
1 J1 587(B) 9 Ignition
9 PMV SA Rig ht H LD 18 PMV DA Righ t REL
2 J1 939 Low 10 Re tarder
Standard Frame X2 Connector Pin Assignments
3 WSS SA Leh (+) 11 Tra iler ABS WL
4 WSS SA Righ t (+) 12 ABS WL

5 J 1587 (A) 13 Not Used
6 J 1939 High 14 Ba ttery

7 WSS SA Leh (- ) 15 Groun d
8 WSS SA Rig ht (-) - --
Standard Frame X1 Connector Pin Assignments
33 of 50
X1 X2 X3
Connector Not Used
Figure 17
Premium Cab EC-60'" Controller
EC-60 "'" Controller Wire Harness Connector Pin Pin Designalion Pin Designation
Assig nments - Premium Cab
1 PMV SA Left HLD 10 PMV DA Right HLD
Connector Designation Number 01 Contacts 2 PMV SA Left REL 11 WSS SA Right (+)
Xl 17 3 PMV SA Left CMN 12 PMV DA Le ft CMN
X2 18 4 PMV SA Right HLD 13 PMV DA Right REL
X3 15 5 WSS SA Left (+) 14 WSS SA Right (-)
Note : Premium cab models utilize three AMP connectors lor 6 PMV SA Right CMN 15 WSS DA Left (+)
wire harness connections.
7 PMV SA Right REL 16 PMV DA Left HLD
8 WSS SA Left (- ) 17 PMV DA Left REL

9 PMV DA Right CMN 18 WSS DA Left (-)
1 Ground 10 WSS DA Right (+)
Premium Cab X2 Connector Pin Assignments
2 Trailer ABS WL 11 WSS DA Right (- )
3 Ignition 12 ABS WL Ground

4 TCV CMN 13 J1587(B)
1 ABS ORS 9 PMV AA Right CMN
5 TCV 14 J1587 (A)
2 Diff Lock SOL 1 10 PMV AA Right HLD
6 ATC Lamp/ATC ORS 15 ABS WL Interlock
3 Diff Lock SOL CMN1 11 WS S AA Left (+)
7 J1939 Low 16 Battery
4 PMV AA Left HLD 12 WSS AA Rig ht (+)
8 J1939 High 17 Retarder
5 Reserved 13 PMV AA Right REL
9 SLS 18 ABSWL
6 PMV AA Left CMN 14 WSS AA Left (- )
Premiu m Cab Xl Connector Pin Assignments
7 PMV AA Left REL 15 WSS AA Right (- )
8 Reserved - --
1 AWD vehicles only. (AW D Transfer Case)
Premium Cab X3 Connector Pin Assignments
340150
Connector Not Used
X1 X2
Figure 18
Premium Frame EC-60"" Controller
EC-60 Controller Wire Harness Connector Pin

1M Pin Designation Pin Designation
Assignments - Premium Frame PMV SA Right REL
1 WSS DA Le ft (+) 10
Connector Designation Number ot Contacts 2 WSS DA Le ft (-) 11 PMV DA Left HLD
Xl 15 3 WSS DA Right (+) 12 PMV DA Left REL
X2 18 4 WSS DA Right (-) 13 PMV SA Letl CMN
X3 18 5 SLS 14 PMV SA Right CMN
Note : Premium trame models utilize three Deutsch connec- 6 ABS ORS 15 PMV DA Left CMN
tors tor wire harness connections .
7 PMV SA Left HLD 16 PMV DA Righ! CivlN
8 PMV SA Left REL 17 PMV DA Righ! HLD

9 PMV SA Rlght HLD 18 PMV DA Right REL
1 J1587(B) 9 Ignition
Premium Frame X2 Connector Pin Assignments
2 J1939 Low 10 Retarder
3 WSS SA Left (+) 11 Trailer ABS WL

4 WSS SA Right (+) 12 ABSWL
1 Reserved 10 PMV AA Letl REL
5 J1587 (A) 13 ATC Lamp/ATC ORS
2 No! Used 11 Reserved
6 J1939 Hi gh 14 Battery
3 WSS AA Left (+) 12 Reserved
7 WSS SA Left (-) 15 Ground
4 WSS A Left (-) 13 TCV CMN
8 WSS SA Right (-) - --
5 WSS AA Right (+) 14 Ditl Lock SOL CMN l
Premium Frame Xl Connector Pin Assignments
6 WSS AA Right (-) 15 PMV AA Left CMN
7 TCV 16 PMV AA Right CMN
8 DiH Lock SO L 1 17 PMV AA Rlght HLD
9 PMV AA Left HLD 18 PMV AA Rig ht REL
1 AWD vehicles only. (AWD Transler Case)
Premium Frame X3 ConneClor Pín Assígnmenls
35 o f 50
SM 0 1 -025 - 016.00 1206 Service Manual
Wiring ABS Wiring Requirements
As a matter of good practice and to insure maximum
CAB EC U Wiring Harness Connectors
system robustness , always use the ma ximum size wire
The in -cab EC - 60 '" controllers are designed to
supported by the wire harness connectors for battery,
interface with AMP MCP 2.8 connectors as referenced ignition , ground, PMV, TCV, Interaxle Oifferential Lock,
in Chart 4. Follow all AMP requirements for the repair of
and indicator lamp circuits.
wir e harnesses.
AII sensor and serial communications circuits (J1587
AII wire harness connectors must be properly seated . and J1939) must use twisted pair wiring (one to two
Th e use of secondary locks is strongly advised. twists per inch) . See the appropriate SAE document
for additional details .
CAUTION
AII un used ECU connectors must be covered
and receive proper environmental protection.
A WARNING
AII wires must be carefully routed to avoid
contact with rotating elements. Wiring must
Frame ECU Wiring Harness Connectors be properly secured approximately every
Frame- mount EC-60 'M controllers are designed to 6-12 inches (15.24 -30.48cm) using UV
interface with Oeutsch connectors as referenced in stabilized, non-metallic hose clamps or
Chart 4 . bow-tie cable ties to prevent pinching,
binding, or fraying.
CAUTION It is recommended that wires be routed

straight out of a connector for a minimum of
Tlle f rame wire harness connectors must be 3 inches (7.62cm) before the wire is allowed to
properly seated with the seals intact bend.
(undamaged). AII unused connector
termi nals must be plugged with the Battery and ground wires should be kept to a
appropriate sealing plugs. Failure to properly minimum length.
seat or seal the connectors could result in
moisture or corrosion damage to the If convoluted tubing is used, its I.D. must
connector terminals. ECUs damaged by match the size 01 the wire bundle as closely as
moisture and/or corrosion are not covered possible.
under the Bendix® warranty. Secondary locks
must be snapped securely in place.
Follow all Deutsch requirements for the repair CAUTION

01 wire harnesses.
Wire harness lengths must be carelu"y
AII unused connector terminals must be selected 10r the vehicle. Harnesses that are
plu gged with the appropriate sealing plugs. too long increase the possibility 01 electrical
interlerence and wire damage. Excess
lengths 01 wire are not to be wound to 10rm
Frame ECU Connector Covers
coils, instead re- route, repair, or replace wire
Frame ECUs are provided with covers that must be
harness. Do not attempt to stretch harnesses
removed to permit connection of the vehicle wiring
that are too short, since mechanical strain can
harn ess . The cover can be removed by sliding the slide
result in wire breakage.
lock mechanism to the unlock position .
The covers provide strain relief and connector

protection of the vehicle wire harness and will accept
round convoluted conduit with an 1.0. of 19 mm .
36 of 50
ABS Connector Wire Terminal
Wire Terminal Termina l
Component Seal/Plug Lock Crimp Tool
In-Cab Controller ~,
Harness
17 Way AMP 927768-9
N/A
MCP 2.8 (X1) 1 - 2.5 mm 2
.\
1718091 -1 967634
X1 -12 & 18
.........>
In-Cab Controller
Harness ,:::@~)U~~~:{< N/A N/A
18 Way AMP .)'::.....
MCP 2.8 (X2) 968874
8-968974-1 2.5 - 4 mm 2
In-Cab Controller
Harness 'l\1t)J?<:~\ N/A N/A
15 Way AMP 968873
MCP 2.8 (X3) 8-968973-1 1.0 - 2.5 mm 2 539723-2
Frame Controller
Harness
15 Way
N/A N/A
0462 - 203 - 12XX
Deutsch (X1) OT16-15SA- K003 (Solid)
(or alternatively use
1062-12-01 )
Frame Controller 12AWG
Harness X1-14&15
18 Way
N/A N/A
Deutsch (X2) OT16-18SB-K004 ,:~~\\~\\\~m~",;
0462-201-16XX
Frame Controller (Solid)
Harness (or alternatively use a
15 Way stamped and formed N/A N/A
version: 1062 - 16 - 06)
Deutsch (X3) OT16-18SC-K004 16-18 AWG HOT -48-00
ABS Modulator
Harness
AMP Twist-Lock N/A N/A
(Bayonet) 1-967325-2 929975-1
ATC Modulator
Harness
AMP Twist-Lock N/A N/A
(Bayonet) 1-967325-3 929975-1
ABS Modulator
Harness
3 Pin Packard ~~,~
Metripack
280 Series 12040977 12077411 12034145 12155975
1M
WS-24 Wheel Speed Sensor Connectors
Packard GT Packard Metripack Oeulsch OTM06 Packard Metripack Packard Metripack Oeulsch OT04 Standard round
150 Series 150.2 Series Series 280 Series (Female) 280 Series (Male) Series two p ln
Chart 4
EC-60'" Controller Component Connectors (Bendix® Part Numbers Shown)
37 of 50
Brake Drum
Hub Assembly t:'.'-.

;L'» ~·,
'. ,
'\\',
Sensor
Clamping
Sleeve
Figure 19
Whee l S eed Sensor Installation
Wheel Speed Sensor Wiring Bendix® does nol recommend using standard
Roule sensor wiring coming oul of Ihe wheel ends lie-wraps to secure wiring harnesses direclly lO
away from moving brake componenls. Sensor wiring rubber air lines. This may cause premature wiring
needs lO be secured lo Ihe axle lo prevenl excess cable failure from the pressure exerted on the wiring when air
lenglh and wiring damage. II is required Ihal cable lies pressure is applied Ihrough Ihe air line. Non-melallic
be inslalled lo Ihe sensor wire wilhin 3 inches (76.2mm) hose clamps or bow-lie lie-wraps are preferred.
of Ihe sensor head lO provide slrain relief.
The use of grommels or olher suilable proleclion is
Following Ihe axle, Ihe sensor wires musl be attached required whenever Ihe cable musl pass through
along Ihe lenglh of Ihe service brake hoses using cable melallic frame members.
lies wilh ullraviolel proleclion and secured every 6-8
inches (152-203mm). Sufficienl "bul nol excessive" AII sensor wiring musl utilize Iwisled pair wire, wilh
cable lenglh musl be provided lO permil full approximalely one 10 Iwo Iwists per inch .
suspension Iravel and sleering axle movement. Inslall
II is recommended Ihal wires be rouled straighl oul of a
wires so Ihal Ihey cannol louch rolating elemenls such
conneclor for a minimum of 3 inches (7.62cm) before
as wheels, brake discs, or driveshafts. Radialion
the wire is allowed lo bend.
proteclion may be necessary in Ihe area of brake discs.
38 of 50
Wiring Schematics
Z
g~m '3~ U:: 9 ::<w
-' oZ-'
-,::<w
+ , + , I<..)a: I On:. :: Ua: I<..)a: + ; I
a: a: -' -' a: a: a: -' -' -' a: a: a: -' -' -' a: a: -' -'
00 00 000 000 <f) <f)<f) <f)<f)<f) <f) (J) (J) Vl
»> »>
oz ::<::<::<
"- "- "-
::<::<::<
"-<L a.
~~
~ ~
UlUl
Vl trl
~ ~
L
I ~r:IILU ¡
11.1'-l ~
X2
.",
, !
tllt X2
1 , 1, I : '
L, j, ,1 1I~
* 3 2 , _ * 321" *~ 2-'- * "32 , 1
iL,tr t[ ,1 ,
J
~I;' ~},j JI FDllr! f]
~ lID -'::- ¡ -o _
w ss
s rEER 5TEER
05:>
ORIVE ORIVE STEER STEE R AX l.E AX LE
AXL E AXLE AXLE AX LE RIGHT l EfT
RIGHT LEFT RIGHT LEr
PM V PMV PMV PMV
l
DRIVE AX.LE STEER AX.LE
-'") - -:?
IOPTIONAL)
RETAROER
RELAY ~ ---'f (r_r
_ __
(__ j:-\/ 'o -

ABS INOICATOR
I
TRAILER ABS
INOICATOR J LAMP
c -~ _J
1
+1 2V IGNITIO
1 + 12V BATTERY
* Pressure Modulator Valves

Connector Twist - Lock Packard
Common (CMN) Pin 2 Pin B
Hold (HLD) Pin 3 Pin C
Release (REL) Pin 1 Pin A
Figure 20
Standard Cab Wiring Schematic (4S/4M)
39 of 50
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Pin 3
Pin 1
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Figure 22
Premium Cab Wiring Schematic (6S/5M)
41 of 50
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LAMP
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+ 12V BATTERY
* Pressure Mod ulator Valves
1 Conne ctor Twist - Lock Packard
Common (CMN) Pin 2 Pin B
Hold (HLD) Pin 3 Pin C
Release (REL) Pin 1 Pin A
Figu re 23
Stan dard Frame Wiring Schematic (4S/4M)
42 01 50
M
X xM u
W
Ce cnU<c
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J 1939 1-11
J i 939 LO F "' --{)
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ctJ
J1587 A F
J 1587 B F= ---<>- r------'
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x x el
Figure 24
Premium Frame Wiring Schematic (6S/6M)
43 of 50
x ~
~- ,--
- re-
-<>- '" f=::::
f=::::
J1587 B
J1587 A
k>- f=:::: J1939 LO
¡v- f=:::: J 1939 HI
f=:::: BATTER Y
:o ~~
m »,:j
1Tr=t-I-------------~ F= RETARDER
~¡g~ • f=:::: GROUN D
~~ l'l1-~f---------,1
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+
<
el
F= IGNITION
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+
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f=:::: TRAiW\ ABS WL
m i>-----------' z f=:::: ABSW .
~
ffi ~--------_.
f=:::: ATC LAMP/ATC ORS
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rr
t=
F=
WSS S t
WSS SL
k>- t=
F=
WS S SR+
WS S SR
-~ '--
r-
k>- ¡:::::: PMV Sl HLD
f=:::: PMV Sl CMN
-1"" ~ PM V Sl P.EL
~ fe- t= PMV R LO
t== PMV SF1 GMN
["" t== PMV SR REL
k>- t= PMV DL HLD

F PM V DL GMN
T" F= PMV DL RB
k>- t=
F
PMV DP, HW
PMV DP, CMN
1" F PM V DR REL
k>-
-1"
t=
F=
WSS DL+
WSS DL
- ¡-k>- t= WSS DR+

F= WSS DR
t= SLS
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s:: o ~
F=
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-O" x x WL INTERLOCK
N N
ABS WL GND
,-
-f<>- = RESE RVED
= NDT USED
-f<>-
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=
F
RESEA VED
RESERVED
s :::::: TCV DA
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o.
e
= TCV DA CMN
ül t= DIFF
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== DIF F CMN
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r< l>
o ro
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o
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A ::::¡
o f=:::: NOT USED
5 o f=::::
z NOTUSED
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r
o F= NOT US ED
1<>-
t=
~m
PMV AA HLD
F=: PMV AA CMN
'---
f=::::
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x
w 1'5
Fig ure 25
Premium Frame Wiring Schematic (6S/5M)
44 of 50
Glossary IR - Independent Regulation. A control method in
which a wheel is controlled at optimum slip, a point
ABS - Antilock Brake System. where retardation and stability are maximized. The
ABS Event - Impending wheel lock situation that brake pressure that is best for the wheel in question is
causes the ABS controller to activate the modulator directed individually into each brake chamber.
valve(s). J1587 - The SAE heavy duty standard diagnostic data
ABS Indicator Light - An amber light which indicates link.
the operating status of an antilock system. When the J1708 - An SAE standard which defines the hardw re
indicator lamp is on, ABS is disabled and the vehicle and software protocol for implementing 9600 baud
reverts to normal brake operation. heavy vehicle data links. J1587 version of a J1708 data
Air Gap - Distance between the sensor and tone ringo link.
ASR - Automatic Slip Regulation. Another name for J1939 - A high speed 250,000 baud data link used for
traction control. communications between the ABS ECU engine,
ATC - Automatic Traction Control. An additional ABS transmission, and retarders.
function in which engine torque is controlled and MIR - Modified Independent Regulation. A method of
brakes are applied differentially to enhance vehicle controlling the opposite sides of a steer axl e du rin g
traction. ABS operation so that torque steer and stopplng
ATC Light - A light that indicates when traction control distance are minimized.
is operating. PLC - Power Line Carrier. The serial communication
Channel - A controlled wheel site. protocol used to communicate with the trailer over the
blue full time power wire.
CAN - Controller Area Network. J1939 is an SAE
version of the CAN link. PMV - Pressure ModulatorValve. An airvalvewhich is
used to vent or block air to the brake chambers to limit
Clear Codes - System to erase historical diagnostic
or reduce brake torque.
trouble codes from the ECU, from either the Diagnostic
Switch or from a hand-held diagnostic tool (only QR - Ouick Release. Ouick releasevalves all ow faster
repaired diagnostic trouble codes may be cleared). release of air from the brake chamber after a brak e
application. To balance the system, quick release
Configuration - The primary objective is to identify a
valves have hold off springs that produce higher crack
"normal" set of sensors and modulators for the
pressures (when the valves open).
Electronic Control Unit, so that it will identify future
missing sensors and modulators. Relay Valve - Increases the application speed of the
service brake. Installed near brakes with larger air
Diagnostic Connector - Diagnostic receptacle in
chambers (type 24 or 30). The treadle valve activates
vehicle cab for connection of J1587 hand-held or PC
the relay valve with an air signal. The relay valve then
based test equipment. The tester can initiate test
connects its supply port to its delivery ports. Equal
sequences, and can also read system parameters.
length air hose must connect the delivery ports of the
Diagnostic Switch - A switch used to activate blinks relay valve to the brake chambers.
codeso
Retarder Relay - A relay which is used to disable a
Differential Braking - Application of brake force to a retarder when ABS is triggered.
spinning wheel so that torque can be applied towheels
Sensor Clamping Sleeve - A beryllium coppersleeve
which are not slipping.
which has fingers cut into it. It is pressed between an
ECU - Electronic Control Unit. ABS sensor and mounting hole to hold the sensor in
DiagnosticTrouble Code - A condition that interferes place.
with the generation or transmission of response or Sto red Diagnostic Trouble Codes - A diagn ostic
control signals in the vehicle's ABS system that could trouble code that occurred.
lead to the functionality of the ABS system becoming
TCS - Traction Control System. Another namefor ATC
inoperable in whole or in part.
or ASR.
FMVSS-121 Federal Motor Vehicle Safety
Tone Ring - A ring that is usually pressed into a w heel
Standard which regulates air brake systems.
hub that has a series of teeth (usually 100) an d
provides actuation for the speed sensor. Note:
maximum run out is .008.
45 of 50
Bendix'" Blink Code
Sto FM I Equivalent(s)
General Diagnostic Trouble Code Description
(J1587) (J1587)
(1 st Digit) (2nd Digit)
1 1 Wheel Speed Sensor 2 1 SA Left WSS Excessive Air Gap
1 2 Wheel Speed Sensor 2 3 SA Left WSS Open or Shor1ed
1 7 Wheel Speed Sensor 2 5 SA Left WSS Wheel End
1 8 Wheel Speed Sensor 2 6 SA Left WSS Erratic Sensor Signal
1 10 Wheel Speed Sensor 2 4 SA Left WSS Loss 01 Sensor Signal
1 13 Wheel Speed Sensor 2 7 SA Left WSS Tire Size Calibration
1 14 Wheel Speed Sensor 2 2 SA Left WSS Output Low @ Drive- OH
2 1 Wheel Speed Sensor 3 1 SA Right WSS Excessive Air Gap
2 2 Wheel Speed Sensor 3 3 SA Right WSS Open or Shor1ed
2 7 Wheel Speed Sensor 3 5 SA Right WSS Wheel End
2 8 Wheel Speed Sensor 3 6 SA Right WSS Erratic Sensor Signal
2 10 Wheel Speed Sensor 3 4 SA Right WSS Loss 01 Sensor Signal
2 13 Wheel Speed Sensor 3 7 SA Right WSS Tire Size Calibration
2 14 Wheel Speed Sensor 3 2 SA Right WSS Output Low@ Orive-Off
3 1 Wheel Speed Sensor 4 1 DA Left WSS Excessive Air Gap
3 2 Wheel Speed Sensor 4 3 DA Left WSS Open or Shor1ed
"" 7 Wheel Speed Sensor 4 5 DA Left WSS Wheel End
3 8 Wheel Speed Sensor 4 6 DA Left WSS Erratic Sensor Signal
3 10 Wheel Speed Sensor 4 4 DA Left WSS Loss 01 Sensor Signal
3 13 Wheel Speed Sensor 4 7 DA Left WSS Tire Size Calibration
3 14 Wheel Speed Sensor 4 2 DA Left WSS Output Low @ Drive- Off
4 1 Wheel Speed Sensor 5 1 DA Right WSS Excessive Air Gap
4 2 Wheel Speed Sensor 5 3 DA Right WSS Open or Shor1ed
4 3 Wheel Speed Sensor 5 5 DA Right WSS Wheel End
4 8 Wheel Speed Sensor 5 6 DA Right WSS Erratic Sensor Signal
4 10 Wheel Speed Sensor 5 4 DA Right WSS Loss 01 Sensor Signal
4 13 Wheel Speed Sensor 5 7 DA Right WSS Tire Size Calibration
4 14 Wheel Speed Sensor 5 2 DA Right WSS Output Low @ Drive- Off
5 1 Wheel Speed Sensor 14 1 AA Left WSS Excessive Air Gap
5 2 Wheel Speed Sensor 14 3 AA Left WSS Open or Shor1ed
5 7 Wheel Speed Sensor 14 5 AA Left WSS Wheel End
5 8 Wheel Speed Sensor 14 6 AA Left WSS Erratic Sensor Signal
5 10 Wheel Speed Sensor 14 4 AA Left WSS Loss 01 Sensor Signal
5 13 Wheel Speed Sensor 14 7 AA Left WSS Tire Size Calibration
5 13 Wheel Speed Sensor 14 10 AA Left WSS Conliguration Error
5 14 Wheel Speed Sensor 14 2 AA Left WSS Output Low @ Drive-OH
J1587 SID and FMI Codes and Bendix® Blink Code Equivalents - Continued
46 of 50
Service Manual 1206 SM01-025- 0 16.00
Bendix'~Blink Code
SID FMI Equivalent(s)
(J1587) (J1587)
(1st Digit) (2nd Digit)
6 1 Wheel Speed Sensor 15 1 AA Right WSS Excessive Air Gap
6 2 Wheel Speed Sensor 15 3 AA Right WSS Open or Shorted
6 7 Wheel Speed Sensor 15 5 AA Right WSS Wheel End
6 8 Wheel Speed Sensor 15 6 AA Right WSS Erratic Sensor Signal
6 10 Wheel Speed Sensor 15 4 AA Right WSS Loss of Sensor Signal
6 13 Wheel Speed Sensor 15 7 AA Right WSS Tire Size Ca libration
6 13 Wheel Speed Sensor 15 10 AA Right WSS Configuration Error
6 14 Wheel Speed Sensor 15 2 AA Right WSS Output Low @ Drive-OH
7 5 Pressure Modulator Valve 7 7 SA Left PMV CMN Open Circuit
7 13 Pressure Modulator Valve 7 8 SA Left PMV Configuration Error
8 5 Pressure Modulator Valve 8 7 SA Right PMV CMN Open Circuit
8 13 Pressure Modulator Valve 8 8 SA Right PMV Configuration Error
9 5 Pressure Modulator Valve 9 7 DA Left PMV CMN Open Circuit
9 13 Pressure Modulator Valve 9 8 DA Left PMV Configuration Error
10 5 Pressure Modulator Valve 10 7 DA Right PMV CMN Open Circuit
10 13 Pressure Modulator Valve 10 8 DA Right PMV Configuration Error
11 5 Pressure Modulator Valve 16 7 AA Left PMV CMN Open Circuit
11 13 Pressure Modulator Valve 16 8 AA Left PMV Configuration Error
12 5 Pressure Modulator Valve 17 7 AA Right PMV CMN Open Circuit
12 13 Pressure Modulator Valve 17 8 AA Right PMV Configuration Error
13 2 Miscellaneous 12 4 Retarder Relay Open Circuit or Shorted to Ground
13 3 Miscellaneous 12 5 Retarder Relay Circuit Shorted to Voltage
17 14 Miscellaneous 12 3 Dynamometer Test Mode
17 14 Miscellaneous 12 9 ATC Disabled to Prevent Brake Fade
18 13 TCV 18 4 TCV Configuration Error
18 3 TCV 18 2 TCV Solenoid Shorted to Voltage
18 4 TCV 18 1 TCV Solenoid Shorted to Ground
18 5 TCV 18 3 TCV Solenoid Open Circuit
22 7 Miscellaneous 12 11 Wheel Speed Sensors Reversed on an Axle
23 2 Miscellaneous 12 6 ABS Warning Lamp Circuit
42 3 Pressure Modulator Valve 7 5 SA Left PMV HLD Solenoid Shorted to Voltage
42 4 Pressure Modulator Valve 7 4 SA Left PMV HLD Solenoid Shorted to Ground
42 5 Pressure Modulator Valve 7 6 SA Left PMV HLD Solenoid Open Circuit
43 3 Pressure Modulator Valve 8 5 SA Right PMV HLD Solenoid Shorted to Voltage
43 4 Pressure Modulator Valve 8 4 SA Right PMV HLD Solenoid Shorted to Ground
43 5 Pressure Modulator Valve 8 6 SA Right PMV HLD Solenoid Open Circuit
44 3 Pressure Modulator Valve 9 5 DA Left PMV HLD Solenoid Shorted to Voltage
J1587 SID and FMI Codes and Bendix® Blink Code Equivalents - Continued
47 ot 50
Bendix ' Blink Code
(J1587) (J1587) General Diagnostic Trouble Code Description
44 4 Pressure Modulalor Valve 9 4 DA Left PMV HLD Solenoid Shor1ed lo Ground

44 5 Pressure Modulalor Valve 9 6 DA Left PMV HLD Solenoid Open Circuil
45 3 Pressure Modulalor Valve 10 5 DA Righl PMV HLD Solenoid Shor1ed lo Vollage
45 4 Pressure Modulalor Valve 10 4 DA Righl PMV HLD Solenoid Shor1ed lo Ground
45 5 Pressure Modulalor Valve 10 6 DA Righl PMV HLD Solenoid Open Circuil

46 3 Pressure Modulalor Valve 16 5 AA Left PMV HLD Solenoid Shor1ed lo Vollage
46 4 Pressure Modulalor Valve 16 4 AA Left PMV HLD Solenoid Shor1ed lo Ground
46 5 Pressure Modulalor Valve 16 6 AA Left PMV HLD Solenoid Open Circuil

47 3 Pressure Modulalor Valve 17 5 AA Righl PMV HLD Shor1ed lo Vollage
47 4 Pressure Modulalor Valve 17 4 AA Righl PMV HLD Solenoid Shor1ed lo Ground
47 5 Pressure Modulalor Valve 17 6 AA Righl PMV HLD Solenoid Open Circuil
48 3 Pressure Modulalor Valve 7 2 SA Left PMV REL Shor1ed lo Vollage
48 4 Pressure Modulalor Valve 7 1 SA Left PMV REL Solenoid Shor1ed lo Ground
48 5 Pressure Modulalor Valve 7 3 SA Left PMV REL Solenoid Open Circuil
49 3 Pressure Modulalor Valve 8 2 SA Righl PMV REL Shor1ed lo Voltage
49 4 Pressure Modulalor Valve 8 1 SA Righl PMV REL Solenoid Shor1ed to Ground
49 5 Pressure Modulalor Valve 8 3 SA Righl PMV REL Solenoid Open Circuil
50 3 Pressure Modulalor Valve 9 2 DA Left PMV REL Shor1ed lO Voltage
50 4 Pressure Modulator Valve 9 1 DA Left PMV REL Solenoid Shor1ed lO Ground
50 5 Pressure Modulalor Valve 9 3 DA Left PMV REL Solenoid Op en Circuit
51 3 Pressure Modulator Valve 10 2 DA Right PMV REL Shor1ed to Vollage
51 4 Pressure Mod ulator Valve 10 1 DA Righl PMV REL Solenoid Shor1ed lo Ground
51 5 Pressure Modulator Valve 10 3 DA Righl PMV REL Solenoid Open Circuil
52 3 Pressure Modulator Valve 16 2 AA Left PMV REL Shor1ed to Voltage
52 4 Pressure Modulator Valve 16 1 AA Left PMV REL Solenoid Shor1ed to Ground
52 5 Pressure Modulator Valve 16 3 AA Left PMV REL Solenoid Open Circuil
53 3 Pressure Modulalor Valve 17 2 AA Right PMV REL Shor1ed lo Vollage
53 4 Pressure Modulalor Valve 17 1 AA Right PMV REL Solenoid Shor1ed lo Ground
53 5 Pressure Modulalor Valve 17 3 AA Right PMV REL Solenoid Open Circuil
55 2 Miscellaneous 12 2 Stop Lamp Switch Deleclive
55 7 Miscellaneous 12 1 SIOp Lamp Switch Nol Delecled
79 13 Miscellaneous 12 10 Tire Size Oul 01 Range (Fronl lo Rear)
93 3 Miscellaneous 12 8 PMVrrCV/Oiff Lock CMN Shor1ed lo Vollage
93 4 Miscellaneous 12 7 PMVrrCV/Diff Lock CMN Shor1ed lo Ground
102 3 Miscellaneous 12 13 Diff Lock Solenoid Shor1ed lO Vollage
102 5 Miscellaneous 12 12 Diff Lock Solenoid Shor1ed lO Ground or Open Circuil
231 2 J1939 11 3 J1939 Engine Communicalions
J1587 SlD and FMI Codes and Bendix® Blink Code Equivalents - Continued
48 of 50
Bendix" Blink Code
(J1587) (J1587)
231 12 J1939 11 1 J 1939 Serial Link
231 14 J1939 11 2 J1939 Retarder
251 2 Power Supply 6 8 Input Voltage Has Excessive Noise (Temp)
251 3 Power Supply 6 2 Battery Voltage Too High
25 1 3 Power Supply 6 6 Ignition Voltage Too High
251 4 Power Supply 6 1 Battery Voltage Too Low
251 4 Power Supply 6 3 Battery Voltage Too Low During ABS
251 4 Power Supply 6 5 Ignilion Vollage Too Low
251 4 Power Supply 6 7 Ignilion Vollage Too Low During ABS
251 5 Power Supply 6 4 Batlery Vollage Inpul Open Clrcuit
251 14 Power Supply 6 9 Input Voltage Has Excesslve Noise
254 2 ECU 13 4 ECU (12)
254 2 ECU 13 5 ECU (13)
254 12 ECU 13 2 ECU (10)
254 12 ECU 13 3 ECU (11 )
254 12 ECU 13 6 ECU (14)
254 12 ECU 13 7 ECU (15)
254 12 ECU 13 10 ECU (18)
254 12 ECU 13 11 ECU (lA)
254 12 ECU 13 12 ECU (lB)
254 12 ECU 13 13 ECU (80)
254 13 ECU 13 8 ECU (16)
254 13 ECU 13 9 ECU (17)
Appendix A
J1587 SID and FMI Codes and Bendix® Blink Code Equivalents
49 of 50
50 of 50
Pneumatic System Air Line
Line Sequence In Circui7
Identification Code
Category ~
In order to promote consistency and simplify trouble
shooting techniques, the air system of this crane uses
an "Identification Code" . The following inlormation
outlines the "Code" used to identify the air lines depic
) 2048 )
ted on the air system schematic and the physical la
beling of the lines in the crane's air system. A basic le
gend 01 pneumatic symbols can be lound on Page 4.
Character Representation
L
Example: Air line 204B indicates:
Circuit Designat,on
Category 2 (Engine & Transmission)

Each air line , in any given air line harness , is labeled Circuit 04 (Throttle Control)
with a string 01 characters made up 01 numbers and let 2nd Line In Circuit (A=1st , B=2nd , etc .)
terso The sequence of characters, when lully under
stood , will allow the positive identilication of an air line Figure 1
and its specilic use in the circuit. The identification Air Une Code Explanation
marking will only occur once on any given crane . Each
line has three basic identilying elements . Reler to 4. Category 4 Warning Devices: 400 Series numbers
Figure 1. are used to identily lines in circuits providing
operation 01 traHic or travel horns and alarms .
The lirst character of the code is a number which cor
5. Category 5 Equipment Control: 500 Seri es
responds to the category that generally fits its basic
numbers are used to identify wires in circuits
lunction.
con cerned with the operation and contr ol of
The second and third characters of the code corres functions such as brakes, axle contro ls, or
ponds to a number which has been specifically as hydraulic valves and motors; anything that is
signed to a given lunction within a category. See Cir unique to the crane .
cuit Designation Assignment List lound on page 2. 6. Category 6 Accessories : 600 series numbers are
used to identify lines in circuits concerned with the
The lourth character 01 the code is a letter which rep operation and control 01 operator accessory
resents the position, or sequence of the given air line equipment such as heaters, delrosters , windsh ield
within the circuit. Generally, the circuit starts at the wipers, etc.
power source and continues through the circuit related
components. A circuit interruption due to a tee , reliel
Circuit Designation
valve, etc., requires the assignment of a new letter lor The second and third character of each air line desig
each resulting line segmento nation corresponds to a two digit number which has
been specilically assigned to the lunction ofth e air line .
Category
Atable listing can be found on Page 2 which refer
The category of a given air line is delined by the lirst ences the meaning 01 numbers already assigned. Fu
character marked on the surlace of the air line. A single ture listings may include additional numbers assigned
digit number from 1 through 6 is used to define the six after the publication of this document.
basic categories as lollows:
1. Category 1 Primary Power: 100 series numbers are Air Une Location In The Circuit
used to identily lines which are used to provide the The fourth character of the code is a letter which rep
originating source 01 power to all circuits within the resents the position, or sequence 01 the given air line
air system. within the circuit. The letter assignment will begin at the
2. Category 2 Engine and Transmission Control: 200 power source and be assigned alphabetically for each
Series numbers are used to identifywires in circuits line segment in a circuit thereafter ; "AHfor the lirst lin e,
used in the operation and control 01 the engine and "B" for the second line, "C" lor the third line, and so on .
transmission . Refer to Figure 2 .
3. Category 3 Monitoring Circui!: 300 series numbers
are used to identily lines in circuits used in
Note: The Letters 1, O, Q, S, X, a 0<1 Z are not used and
monitoring crane operation . Circuits that contain
merely skipped within the sequence due to their
gauges or instrumentation are included in this
similarity to numbers.
category.
1 of 6
·- 141A - -
13 1A Pressure
Prolect Valve
112A Air Reservoir
. I
.- •I I
160A -
•
I
I
160C
1
I
•I
Orain
Valve I~II 130A
SuspenSlon
Conlrol Valve
160B
Inler-Axle
Conlrol Valve
I
1600
Air Ride
-1 : Seal
1.
1
I
:l LI
563A
I _~ 5638 -4-LLI
I r
550A
1
Fig ure 2
Typi cal Air Line Schematic
Circuit Designation Assignment List

Category 1 - Primary Power Circuits
Wire Number Description
101-109 Air Dryer
110-119 Reservoirs (Air Tanks)
120-124 Governor
125 - 129 Throttle Control
130-139 Service Brakes
140-144 Parking Brake (Emergency Brake)
145-149 Hydraulic Reservoir
150-154 Tire Inllation
155-159 Transmission
160- 164 Axle Differential Lockout
165-179 Remote Control
180-184 Winch 2-Speed
185 & Above Yet To Be Assigned
2016
Category 2 - Engine And Transmission Control Circuits
201-204 Throttle Control
205-209 Governor
210-214 Modulator
215-219 Clutch Brake
220-224 Range Control
225-239 Remote Shift (Automatic Transmission)
240-244 Remote Shift (Manual Transmission)
245-249 Remote Clutch
250-254 Turbo And EGR Controls
Category 3 - Monitoring Circuits

Category 4 - Warning Devices

Category 5 - Equipment Control Circuits

501-519 Service Brakes
520-529 Parking Brake (Emergency Brake)
530-534 Remote Steer
535-544 Remote Parking Brake (Emergency Brake)
545-549 Remote Service Brakes
550-554 Axle DiHerential Lockout
555-559 Winch 2-Speed
560-569 Air Ride Suspension
570-579 Rear Steer
580-589 2-Speed Axle/Auxiliary Transmission
Category 6 - Accessories Circuits

3 of 6
Pn eumatic Symbol Legend

Unes & Une Functions
Work ing Line (Solid Line)
Pilot Line (Long Dash) --------
Exhaust or Drain Line (Short Dash) --------
-.r
Electric Line c_
¡- ~
Enclosure, Case, Housing I
I
I
I
L- __ ~
Connector •
r:.
Flexible Lines - rJ
..'
Pluggecl Port, Plugged Test Station, -

Plugged Power Take Off (PTO)
" __ O
Fixed Restriction .--.
4
Variable Restriction .
-
-.
Fixed Restriction In Lines - -
4 4
Variable Restriction In Lines ~
Joining, Connected Lines
Passing, Non-Joining Lines

~
+
-+- t
~ -L + 1-r
Energy Source @f>--
Direction of Flow
---!>--
Left lo Righl Top lo Bottom + ----<J---
Righl lo Left
t
Bottom lo Top
Qui ck Disconnects
Without Checks - Connected 1
Without Checks - Disconnected --:-1 ~

With Checks - Connected .1 •.-+-'~-
With Checks - Disconnected -C) - I -I-:: '~

,....:... ...
With One Check - Connected .)
I
1 __
.-'-, j
W ith One Check - Disconnected -1_, I
aot 6
Pneumatic Symbol Legend - continued
Air Preparation Units
.
Filter/Separator With Manual Drain
Filter/Separator With . , .
Automatic Drain
Oil Removal Filter

With Manual Drain • I
-
I
Lubricator Without Drain
Lubricator With Manual Drain -
Air Dryer (Chemical Type)
á- --e
I
Air Line Pressure Regulators

(With Relief Feature) L_-, L_-,
Manual Pi lot
Adjusting Controlled
Combination Unit:
Air Line Filter,
-
..
" -~
."
~. _ . _
--'
t
Pressure Regulator,
Lubricator f. -j 1
With Pressure Gauge c
J . _- -
-
,- .,
Pneumatic Valves
Shut-off t--- '
Check I
•
Flow Control
~
.

Relief ,
I
h
~
.
2-Position ,2- Way
,-=-1 LI
2 - Position,3-Way Tr
L
, r.JJ 4
2-Position,4-Way
~ ,. ~
3-Position,4-Way
lill~ = LL
5 of 6
SM01 -027 -000.00 0808 Service Manual
Pneumatic Symbol Legend - continued

Valve Actuators
Actuator Basic Symbol r=J ~
Actuator With Detent (s)

,,-=[ L !-
I
-
One Position Two Position
Spring Actuated
·,r
Push Button Actuated ,---i
- -l _
Lever Actuated
1
Pedal Actuated
,~
Plu nger/Tracer Actuated , -~
-
Roller Actu ated

¡. '- -1 L
¡ ' L-[
Two Directional
•
One Directional
Solenoid Actuated
-=C
One Directional
I ~-:
Two Directional
Internal Pilot Actuated

Q
Remote Pilot Actuated - ~-Il ---r ~
Composite Actuated (Either/Or) ti, L One Directional Solenoid
Internal Pilot
Or
One Directional Solenoid

Composite Actuated (And/Or)
I l'l i Internal Pilot
And
Monitoring
(~ , (7) -1,';;:::;",
,c>r
Gages '- ~ 7'
Pressure Temperature Flow Meter
l
Pressure Switch
(E lectric/Adjustable)
- ~y '1 / I
Vv
6 of 6
Front Air Brake Chamber,

Recondition ~-- ~ -1
~~2
This SM Code includes the following procedures :
Air Brake Chamber, Recondition
- Diaphragm Replacement
Replacement of the diaphragm may be performed

with the air brake chamber installed on the axle. If ~~ :
the air brake chamber is to be completely
disassembled, first remove it from the axle. Refer to 5
SM Keysheet Area 1-27 for the correct procedure.
This procedure does not cover reconditioning of dual

air brake chambers, gene rally used on rear axle
brakes. See SM Keysheet Area 1-27 for caging and
reconditioning procedure for dual air brake chambers.
It is a good practice when disassembling comple x

. ---6
~.
~Y~
~
A.\."'.. . .
, ~~.¡'
~
were disassembled . Keeping the parts in this order 7
~ --
the assembly process .
If parts are hard to disassemble and assemble , do not

~8
parts together, they must be free to operate and not
bind . 1. Pressur e Ca p 5. Push Rod Assemb ly
2. Bolts & Nuts 6. Return Spri n g
Disassembly 3. Clamp Ring Asse mbl y 7. Cha mber Assem bly
4. Dia phrag m 8. Jam Nut
Figure 1
A WARNING
Air Brake Chamber Assembly
hazardous. Serious personal injury may Cleaning And Inspection

cleaning solutions . A WARNING
Solvents and cleaning solutions c an be
1. Thoroughly clean the exterior surface of the front
hazardous. Serious personal inju ry may
air brake chamber to prevent contamination from
entering it.
2. Place index marks on pressure cap (1) and cham
recommendations concerning solve nts and
ber assembly (7) . Aligning these marks will ensure
cleaning solutions.
proper orientation of the air line ports during as
sembly.
1. Thoroughly clean all metal parts with an approve d
3. Remove the bolts and nuts (2) from the clamp ring
cleaning solvent. Place parts on a clean , lint free
assembly (3) ; remove clamp ring assembly (3) .
surface and allow to air dry. Exercise every prec au
4. Separate the pressure cap (1) from the chamber
tion possible to keep all parts free of dust , dirt, or
assembly (7) and remove the diaphragm (4).
any other foreign material during assembly.
5. Remove clevis (not shown) and jam nut (8) from
the push rod assembly (5).
6. Remove the push rod assembly (5) and return
spring (6) from the chamber assembly (7).
1 of 4
2. Carefully inspect all componQnts for damage,
wear, fatigue or stress fractures , corrosion , deep
Diaphragm Replacement
scratches , cracks, and scuffed metal. Remove any 1. Lower, detach, and secure load, as required .
burrs or sharp edges with a fine file , hone, emery 2. Stabilize the crane for serviee as follows:
cloth, or crocus cloth. a. Park the erane, out of the way , on a firm and
3. The diaphragm should be replaced. level surfaee.
4. The clamp ring assembly should be replaced. b. Engage the park brake andjor properly block
5. In the event of severe defects, contact factory per the tires.
sonnel for directions whether to repair or replace c. Engage the swing park brake or travel swing
any major component. loek , as required.
d . Level the erane on fully extended outriggers.
Asse mbly e. Fully retraet and position the boom, as re
quired .
Install the return spring (6) on the push rod assem
3. Check that all eontrollevers are in the neutral posi
bly (5) and install the push rod assembly (5) in the
tion and move the funetion loekout switch to the
chamber assembly (7).
"DISABLE " position.
2. Install the jam nut (8) and clevis (not shown) on the
push rod assembly (5).
draulie pump.
3. Dust the lips of the diaphragm (4), the pressure
cap (1) , and chamber assembly (7) with talcum
powder.
4 . Install the diaphragm (4) over the push rod assem
bly (5) and onto the chamber assembly (7).
A WARNING
5. Carefully place the pressure cap (1) over the dia hazardous. Serious personal injury may
phragm (4 ) and align the marks made during dis result from misuse of these products. Read
assembly. Apply moderate pressure sufficient to and follow all the manufacturer's
allow the diaphragm (4) to slip into a firm seal with recommendations concerning solvents and
out wrinkling or bulging between the housings. cleaning solutions.
6. Install clamp ring assembly (3) . Install the bolts
and nuts (2) finger tight. 5. Thoroughly elean area to be disassembled with an
7 . Using a plastic or rubber mallet , tap the clamp ring approved eleaning solvent to prevent eontamina
assembly (3) around its eircumferenee while alter tion from entering the air eircuit. Allow the area to
nately tig htening the bolts and nuts (2) in 5 -10ft lb air dry.
(7 -1 4Nm) inerements, eonstantly eheeking the
alignment ofthe mating parts during this operation
will e nsure proper seating.
8. Tighten the bolts and nuts (2) to a final torque of
A WARNING
25 - 30 ft lb (34-41Nm). Be sure to replaee any
identification tags that may have been attaehed to
the clamp ring assembly (3) bolt.
9 . If fro nt air brake ehamber is not to be immediately
installed on crane , plug all open ports to prevent
eontamination and properly store . 6. Open the drain valve on the air system reservoirs to
bleed the air system pressure .
2 of 4
7. When the air pressure has been fully exhausted, 14. Carefully place the pressure cap (1) over the dia
close the drain valve on the air system reservoir. phragm (4) and align the marks make during dis
8. Place index marks on pressure cap (1) and cham assembly. Apply moderate pressure sufficient to
ber assembly (7). Aligning these marks during as allow the diaphragm (4) to slip into a firm seal with
sembly will ensure proper orientation of the air out wrinkling or bulging between the housings .
lines . 15. Install clamp ring assembly (3). Install the bolts
9. Remove bolts and nuts (2) which secure clamp and nuts (2) finger tight.
ring assembly (3); remove the clamp ring assem 16. Using a plastic or rubber mallet, tap the clamp ring
bly (3). assembly (3) around its circumference while alter
10. Remove the pressure cap (1) and diaphragm (4) nately tightening the bolts and nuts (2) in 5 -10ft lb
from the chamber assembly (7). (7 - 74Nm) increments , constantly checking the
11. Visually inspect the push rod assembly (5), return alignment of the mating parts during this operation
spring (6), and chamber assembly (7) for damage , will ensure proper seating.
wear, and corros ion . Replace any defective parts 17. Tighten the bolts and nuts (2) to a final torque of
as necessary. 25-30 ft lb (34-47Nm). Be sure to replace any
12 . Dust the lips of the diaphragm (4) , the pressure identification tags that may have been attached to
cap (1), and chamber assembly (7) with talcum the clamp ring assembly (3) bolt.
powder. 18. Start the engine and allow the air pressure to
13. Install the diaphragm (4) over the push rod assem achieve normal operation leve!.
bly (5) and onto the chamber assembly (7). 19. Apply the carrier brakes and inspect the air brake
chamber and fitting connections for leaks using a
soap solution . Repair leaks as necessary.
20. Test the brakes for proper operation before releas
ing the crane for service. See "Adjusting The
Brake" in SM Keysheet Area 1 - 3 for the correct
procedure.
3 of 4
----- - -
-----
4 of 4
Air Dryer, R & I
(Bendix)
the Bendix air dryer. For recondilion procedures , see
SM Area 01 -027.
Removal 6
1. Properly park the crane on a firm level surface. En-
gag e the park brake and shitt the transmission to 7
neutral. Shutdown the engine.
6-_~
A WARNING
lines and fitting s before relieving air pressure
engine and drain the air system reservoir(s)
2. Open Ihe drain valves on Ihe air system reser

voir(s) to bleed the air system pressure.
valves on the air syslem reservoir(s). 1. Air Dry er 5. El ectrical Connector
2. Ca rrier Frame 6. Studs
3 Mounhng Brackets 7. Locknuts & Washers
A WARNING
4. Air Lines
Note: Orienlation 01 air dryer and lines may va ry Irom illu st ratlon .
Figure 1
hazardous. Serious personal injury may Air Dryer
and follow al! the manufacturer's
recommendations concerning solvents and Cleaning And Inspection
cleaning solutions .

approved clea ning solvenllo prevent conlamina
A WARNING
tion from enlering the air circuils . Allow the area lO Solvents and cleaning solutions can be
air dry. hazardous. Serious personal injury may
Refer lO Figure 1. and follow al! the manufacturer' s
5. Unplug Ihe wire harness from Ihe electrical con recommendations concerning solvents a nd
neclor (5) on the air dryer (1) . cleaning solutions.
6 . Label, for assembly purposes, and disconnecl air
lines (4) from Ihe air dryer (1). 1. AII componenls should be Ihoroughly cleaned wilh
7. Cap air lines (4) and plug open ports on air dryer (1) an approved cleaning solvent, air dried , and care
to prevenl contaminalion . fully inspected.
2. AII Loclite®, Permalex®, or other sealanl residue
Note: The air dryer (1) weighs approximately should be removed from Ihreads of hardware and
30 lb (14 kg) . the mounting surfaces of parls Ihat are going lo be
reused . Prior lO applying new thread locki ng com
8. Remove locknuts and washers (7) from sluds (6)
pounds or sealanls , clean threads and surfaces
which atlach air dryer mounling brackels (3) lO car
with Loclite® 7070 Cleaner lo ensure besl perfor
rier frame (2) .
mance of products.
9. Remove air dryer (1) from crane.
1 of 2
S M01-027 -062.00 1006 Service Manual
3. Thoroughly inspect all parts for damage , wear, fa Installation
replace as required. Note: The air dryer (1) weighs approximately
4 . AII "soft parts" , such as seals , gaskets, back up 30 lb (14 kg).
rings , and o-rings, should be replaced.
5 . Inspect the integrity of the electrical wires and con Refer to Figure 1.
nectors that service the air dryer. Repair or replace 1. Align the air dryer mounting brackets (3) over studs
if required. (6) on carrier frame (2).
6 . Inspect the integrity of the air lines and fittings that 2. Installlocknuts and washers (7) used to secure the
supply the air dryer. Repair or replace if required . air dryer (1) to the carrier frame (2).
7. In the event of severe defects , contact factory per 3 . Remove plugs from air dryer (1) and caps from air
sonnel for directions whether to repair or replace lines (4) installed during removal and used to pre
any major component. vent contaminants from entering the system.
4 . Connect the air lines (4) to the air dryer (1).
5 . Plug the wire harness into the electrical connector
(5) on the air dryer (1).
6 . Applya soap solution to the air connections. Start
the engine and let idle for five minutes.
7. Inspect the air connections for leaks . Air leaks will
form bubbles in the soap solution where leaks are
present. Repair leaks as required .
functions of the air dryer for proper operation.
Normal operation of the air system and carrier
brakes systems should be confirmed. A general
inspection of the components and systems in the
present.
2 of 2
5. Remove the check valve (25) from the end cover
Air Dryer, Recondition (8).
(Bendix AD-9) 6. Remove the o-ring (26) from the check valve (25) .
7. Remove the screws (19) that secure the purge
This procedure covers the reconditioning and
valve housing (17) to the end cover (8).
troubleshooting of the Bendix AD-9 air dryers . For
8. Pull the purge valve housing (17) out of the end
removal and installation procedures , see SM
cover (8) .
Keysheet Area 01-027 .
9. Remove the o-rings (10,11,13) from the purge
If parts are hard to disassemble and assemble , do not valve housing (17).
force them, they must be free to operate and not bind . 10. Remove the shoulder bolt (21) from the bottom of
the purge valve housing (17) while securing the top
Disassembly of the purge valve piston (15) .
11. Remove the purge valve guide (20) and purge
It is a good practice when disassembling air
valve (18) from the purge valve housing (17).
components lO lay the parts oul in the order that they
12. Remove the purge valve piston (15) and return
were disassembled . Keeping Ihe parts in this order
spring (16) from the opposite end of the purge
during disassembly, cleaning and inspection will aid in
valve housing (17).
13. Remove the quad ring (14) from the purge valve
piston (15).
A WARNING
CAUTION
hazardous. Serious personal injury may Do not attempt to remove the heater and
result from misuse of these products. Read thermostat assembly from the purge va lve
and follow all the manufacturer's housing. Any attempt to remove the hea ter
recommendations concerning solvents and and thermostat assembly will damage it, a nd it
cleaning solutions. is not available as a service part. If the heater
and thermostat are defective, replace the
1. Plug all open ports and thoroughly clean the exleri entire purge valve housing .
or surface of the air dryer lo prevenl contamination
from entering il. 14. Remove the 10cknulS (6), capscrews (12), and
washers (7,9) thal secure the end cover (8) to the
outer housing (5). Remove the end cover (8).
CAUTION 15. Remove the o-ring (28).
Do not clamp any die cast aluminum 16. If necessary, remove the safely valve (27) from the
components in any form of clamping device. end cover (8).
Component damage may result. To secure
the end cover, install a pipe nipple in the Note: A substantial torque [up to 50 ft lb
supply port and clamp the nipple in a vise. (67.8Nm)] may be required to separate the de
siccant cartridge from the end cover.
2. Install a pipe nipple in the supply port, and clamp 17. Using a slrap or chain wrench positioned approx
the nipple in a vise.
imately 2-3 in (5.1-7.6cm) away from the end
Refer to Figure 1. cover (8), rotate the desiccant cartridge (30) coun
3. Remove the sleeve nut (1) and capscrew (3) secur terclockwise until il completely separates from Ihe
ing Ihe upper mounting slrap (2) and upper mount end cover (8). Remove the desiccant cartridge
ing bracket (4) from the outer housing (5). Remove (30) from the end cover (8) .
the upper mounting strap (2) and upper mounting 18. Remove Ihe o-ring (29).
bracket (4).
4. Remove the capscrews (22) and washers (23) se
curing the lower mounting brackel (24) lo the end
cover (8). Remove Ihe lower mounting bracket
(24).
1 of 14
~
y- 3
~
30 --_~
------ 4
29 - - 5
~ 6
28 - - -
-----c~ ___ 7
------1
~9
~ 10
~ ~~
~ 13
~ ~1 4
15
~ 16
~-- 17
• Not Used On AII Models

1. Sleeve Nut 9. Washers 17 . Purge Yalve Housing 24 . Lower Mounting Bracket
2. Upper Mounting Strap 10. O-ring 18 Purge Yalve 25. Check Yalve
3. Capscrew 11. O-ring* 19 Screws 26. O-ring
4. Upper Mounting Bracket 12. Capscrews 20. Purge Yalve Guide 27 . Safety Yalve
5. Outer Housing 13. O-nng 21. Shoulder Bolt 28. O-ring
6. Locknuts 14. Quad Ring 22 Capscrews 29. O-ring
7. Washers 15. Purge Yal ve Piston 23 . Washers 30. Desiccant Cartridge
8. End Cover 16. Return Spring
Figu re 1
Ai r Dryer
2 of 14
A WARNING
cleaning solutions.
1. Thoroughly clean all metal parts with an approved

cleaning solvent. Place parts on a clean lint free
surface and allow to air dry. Exercise every precau
tion possible to keep all parts free of dust, dirt or
any other foreign material eluring assembly.
the mounting surfaces of parts that are going to be Figure 2
reuseel. Prior to applying new thread locking com End Cover To Outer Housing Torque Pattern
with Loctite® 7070 Cleaner to ensure best perfor Assembly
mance of products.
3. Carefully inspect all components for elamage,
Lubricate all o-rings, o-ring grooves, and bores prior
wear, corrosion, deep scratches and scuHed met
to assembly.
al. Superficial corrosion and/or pitting on the exter
ior portion of the outer housing anel enel cap is ac Refer to Figure 1.
ceptable. Remove any burrs or sharp eelges with a 1. Install the quad ring (14) on the purge valve piston
fine file, hone, emery cloth or crocus cloth. (15).
4. Inspect the bores of the end cover and purge valve 2. Install the return spring (16) in the purge valve
housing for deep scuHing or gouges. housing (17).
5. Make certain all end cover and purge valve hous 3. Install the purge valve piston (15) in the center 01
ing passages are open and free of obstructions. the return spring (16).
6. Inspect the pipe threads in the end cover. Make 4. Position the purge valve guide (20) and purgevalve
certain they are clean and free of thread sealant. (18) on the shoulder bolt (21).
7. Inspect the purge valve housing bore and seats for
Note: The purge valve piston must be held from
excessive wear and scuHing.
rotating while the shoulder bolt is install ed .
8. Inspect the purge valve piston seat for excessive
wear. 5. Install the purge valve (18), purge valve guide (20),
9. Inspect all air line fittings for corrosion. Clean all and shoulder bolt (21) into the purge valve housing
thread sealant from the pipe threads. (17). Torque the shoulder bolt (21) to 60-90 in lb
10. Replace all "soft parts" such as o-rings. (7.08-10.62Nm).
11. Replace any damageel component as required. 6. Install the o-rings (10,11,13) on the purge valve
12. In the event of severe defects, contact factory per housing (17).
sonnel for directions whether to repair or replace 7. Install the purge valve housing (17) in the end cov
any major component. er (8), making certain to orient both parts such that
0
the connector is approximately 10 clockwise from
the supply port.
30114
Note: Start all three screws (19) by hand, then 15. If removed, install the safety valve (27) in the end
torq ue to 50-80 in lb (5.90-9.44Nm). cover (8).
16. Install the 0- ring (28) on the shoulder in the end
8. Secure the purge valve housing (17) to the end cover (8).
cover (8) by installing the screws (19). 17. Install the outer housing (5) over the desiccant
9. Install the 0- ring (26) on the check valve (25). cartridge (30), and align the holes.
10. Install the check valve (25) in the end cover (8). 18. Install the capscrews (12), washers (7,9), and lock
11. Install the o-ring (29) in the end cover (8). nuts (6).
12. Lightly lubricate the bottom of the desiccant cart 19. Position the lower mounting bracket (24) to the end
ridge (30) in the area that will contact the 0- ring cover (8), and install the capscrews (22) and wash
(29) and end cover (8). ers (23).
13. Install the desiccant cartridge (30) into the end cov 20. Torque the capscrews (12,23) to 270-385 in lb
er (8) until contact is made between it and the (31.86-45.43Nm) in the sequence shown in
o-ring (29). Figure 2.
14. Using a strap or chain wrench positioned approx 21. Position the upper mounting strap (2) and upper
imately 2-3 in (5.1-7.6cm) from the bottom ofthe mounting bracket (4) to the outer housing (5), and
desiccant cartridge (30), turn the desiccant cart install the capscrew (3) and sleeve nut (1). Torque
ridge (30) clockwise 180 o -225 o beyond the point the capscrew (3) to 80-120 in lb (9.44-14. 16Nm).
where initial contact is made between the desic
cant cartridge (30) and the o-ring (29). Torque
should not exceed 50 ft lb (67.8Nm).
4 of 14
Service Manual 0807 SM01 -027 -063.00
Troubleshooting Chart
SYMPTOMS CAUSE REMEDY
1. Dryer is constantly "cycling" or A. Excessive system leakage. A. 1I leakage is shown on gauges,
purging. Dryer purges Ire IMPORTANT: Note whether the test lor excessive service brake
quently (every 4 minutes or less air pressure loss is shown on system leakage. Allowable
while the crane is idling). the dash gauge. Pressure loss Leakage is 1 psi/min (6.9kPa/
shown on the dash gauge is min).
caused by service brake system
or component leakage. Pres
sure loss not shown on the
dash gauge is caused by sup
ply system or component leak
age.
Air pressure loss

';','-,',\' shown on dash
gauges: test all com
ponents, littings, and
lines in service brake
system Irom this point
down stream.
1I leakage is not shown on

gauges, test lor excessive sup
ply system leakage.
'*--------------
:.....:.;:-.
Air pressure loss not shown on
dash gauges: test all components,
littings, and lines in supply system
Irom this point lorward. ~----------------
Remove the drain valve in the

supply reservoir (wet tank), and
install an air gauge. Bulid the
system pressure, allow the air
dryer to purge, and observe the
air gauge. Pressure drop
should not exceed 1 pSi/min
(6. 9kPa/min). Perform test 1 - 6
in the order presented.
.. ,:\:.: ::;.:\.,,'-..~ .. t
; -:
5 of 14
Sym ptom 1 continued Cause A continued Remedy A continued
1. Test the fittings, hoses, lines,
and connections.
Applya soap solution to detect
excessive leakage. Tighten or
replace as needed, then repeat
the air dryer charge-purge
cycle , and observe the gauge
installed in the supply reservoir.
If leakage is within allowable
limits, remove the gauge Irom
the reservoir, and replace the
drain valve . If leakage is detec
ted , continue testing.
2. Test the accessories connec
ted to the supply reservoir.
Drain all air pressure Irom the
system, disconnect all air lines
leading to the accessories (Ian
clutch, wipers, air seats , etc.),
and plug the reservoir at a dis
connection point. Build air sys
tem pressure until the air dryer
purges, and observe the supply
reservoir gauge. If leakage is
not longer excessive , repair or
replace the leaking accessory.
II excessive leakage is detected ,
continue testing .
3. Test the governor for leakage.
Build the system pressure to the
governor cut-out, turn off en
gine, and apply a soap solution
to the governor exhaust port
and around the cap. Leakage
should not exceed 1 in (2 .54cm)
bubble in 5 seconds . Reduce
the system pressure to 80 psi
(552kPa) or less, and reapply
soap solution . Leakage should
not exceed 1 in (2.54cm)
bubble in 5 seconds . If excess
ive leakage is detected in either
test , repair or replace the gov
ernor.
6 of 14
Service Manual 0807 SM01-027 -063.00
Symptom 1 continued Cause A continued Remedy A continued
4. Test the compressor unloader
for leakage.
Drain all air pressure from the
system, and remove the gov
ernor from the compressor.
Temporarily plug the governor
unloader port or air line that is
mated with, or connected to,
the compressor. Build air sys
tem pressure until the air dryer
purges, then immediately shut
off the engine. Observe the
gauge in the supply reservoir. If
leakage is within limits, replace
the compressor unloader. Re
connect the governor to the
compressor (after removing the
plug installed for testing), and
retest while observing the sup
ply reservoir gauge. If excess
ive leakage is detected, contin
ue testing.
5. Test the air dryer purge valve
and outlet check valve.
Drain all air pressure from the
system, remove the control line
connection at the air dryer, and
plug the end of tlle air line lead
ing to the governor (not the air
dryer control port). Build sys
tem pressure to the governor
cut-out, and observe the air
gauge. If little or no pressure
drop is observed, replace the
air dryer check valve. If pres
sure drop continues, apply
soap solution to the air dryer
purge exhaust and purge con
trol port (where the control line
was removed). Leakage should
not exceed 1 in (2.54cm)
bubble in 5 seconds. If leakage
is excessive, repair or replace
the purge valve assembly.
7 of 14
Symptom 1 continued Cause A continued Remedy A continued
6. With a gauge installed at RES
port of governor, pressure
should not drop below "Cut-In "
pressure at the onset of the
compressor "Unloaded" cycle .
If pressure drops, check for
"kinks" or restrictions in the line
connected to the RES port. The
line connected to the RES port
on the governor must be the
same diameter, or preferably
larger than the line connected
to the unloader port on the gov
ernor.
B. Leaking purge valve housing B. With the supply port open to the
assembly and/or o-rings in end atmosphere, apply 120 psi
cover. (827kPa) at the control port.
Apply a soap solution to the
supply port and exhaust port.
Leakage should not exceed 1 in
(2.54cm) bubble in 5 seconds.
C. Holset "E" type compressor. C. Test the Holset "E" compressor
unloader system with feedback
line and check valve for proper
operation . Make certain the
Holset ECO N is not in use with
the drop - in version of the air
dryer. If so , remove and retest.
) ~ r",:,,'X..-) (~;,>~~::' ~;:~\.:':

1>/ /
Typical Drop - In Air Dryer End Cover

When installing a Bendix Drop
In air dryer, in a system
equipped with a Holset E or OE
compressor, remove the Holset
ECON valve, along with its feed
back and governor controlline.
~~,
'1J ~;)
";"~~;
8 of 14
2. Water in air reservoir. A. Oesiccant cartridge requires re- A. Replace desiccant cartridge.
placement due to excessive
contam inants .
B. Improper discharge line length B. The discharge line should be at
or material. Maximum air dryer least 12 ft (3.66m) and have an
inlet temperature is exceeded. inside diameter of no less than
1/2 in (1 .27cm) .
C. Air system charged from out- C. If the system must have outside
side air source (outside air not air fil! provision , outside air
passing through air dryer) . should pass through the air dry
ero This practice should be min
imized .
O. Air dryer not purging. D. Refer to Symptom 5.
E. Purge (air exhaust) time insuffi- E. Refer to Symptom 1, causes
cient due to excessive system and remedies .
leakage.
F. Excess ive air usage, duty cycle F. Charge C~cle Time
is too high . The air dryer is designed to
Note: Outy cycle is the ratio of provide clean , dry air for the
time the compressor spends brake system . When an air sys
building air to total engine run- tem is used to operate non
ning time . Air compressors are brake air accessories , it is ne
clesigned to build air up to 25% cessary to determine that dur
01 the time. Higher duty cycles ing normal, daily operation the
cause conditions that affect air compressor recovers Irom gov
brake charging system perlorm- ernor "c ut-in " to "cut-out" in
ance which may require addi- 90 seconds or less at engine
tional maintenance. RPM commensurate with nor
mal operation. II the recovery
time consistently exceeds this
limit, it may be necessary lO
"bypass" the air accessory re
sponsible lor the high air usage.
Purge C~cle Time -
During normal operation , the air
compressor must remain un
loaded lor a minimum 01 20
seconds lor standard or 30
seconds lor extended purge
models. These minimum purge
times are required to ensure
complete regeneration 01 the
desiccant material. 1I the purge
time is consistently less than the
minimum, an accessory bypass
system must be installed .
9 of 14
Symptom 2 continued
G. Air compressor discharge and/ G. Restricted Discharge Line -
or air d ryer inlet temperature is The discharge line should have
too high . an inside diameter of no less
than 1/2 in (1 .27cm). If more
than 1/16 in (O. 16cm) carbon
build up is found , replace the
discharge line.
Discharge Line Freeze - Up -
The discharge line must main
tain a constant slope down from
the compressor to the air dryer
inlet to avoid low points where
ice may form and block flow. If
ice blockages occur at the air
dryer inlet, insulation may be
added or a straight or 45 o fitting
can be used to replace the
standard 90 ° fitting. Shorter
discharge line lengths or insula
tion may be required in cold cli
mates.
InsuHicient Coolant Flow
Throuqh The Compressor -
Inspect the coolant lines and fit
tings for kinks and restrictions .
Replace as necessary. Verify
that the coolant lines go from
the engine block to the com
pressor and back to the water
pump. Repair as necessary.
Restricted Air Inlet (Not Enough
Air To The Compressorl -
Check the compressor air inlet
line for restrictions , brittleness ,
soft or sagging hose conditions,
etc . Repair as necessary.
Check the engine air filter, re
place if required.
Poorly Filtered Inlet Air (Poor Air
Quality To The Compressor -
Check for leaking, damaged , or
malfunctioning compressor air
inlet components (e.g. induction
line , fittings, gaskets, filter bod
ies, etc.). Repair the inlet com
ponents as needed. Note: Dirt
ingestion will damage the com
pressor.
If excessive oil is present in the
service reservoir, the com
pressor may be passing oil. Re
place the compressor.
10 of 14
Symptom 2 continued
H. The compressor is malfunction H. If excessive oil is present in the
ing. service reservoir, test the com
pressor and replace as re
quired.
1. Air by pass es the desiccant cart 1. If a Holset compressor is in
ridge. stalled, inspect the feedback
check valve for proper installa
tion and operation .
When replacing the desiccant
cartridge, make sure it is prop
erly installed and that the seal
ing rings are in place.
,'o ..::
:.. ~ : ;:\.:~'X.) t>,~ ·~'::: ~~:,,:.;;-~
. j>// -'
Typical Drop-In Air Dryer End Cover

J. Desiccant cartridge requires re J. Replace the desiccant cartridge.
placement.
3. Oil is present at air dryer purge A. Air brake charging system is A. Air dryers remove water and oil
exhaust or cartridge during functioning normally. from the air brake charging sys
maintenance . temo A small amount of oil is
normal. Check that regular
maintenance is being per
formed and that the amount of
oil in the air reservoirs is within
acceptable limits. Replace the
desiccant cartridge as requir ed.
4. The safety valve on the air dryer A. Restriction between the air dry- A. Determine if air is reaching the
is "popping off " or exhausting er and supply reservoir. supply reservoir. Inspect for
airo kinked tubing or hoses. Check
for undrilled or restricted hos e
or tubing fittings. Repair or re
place as required.
B. Air dryer safety valve is malfunc- B. Verify relief pressure is at re
tioning. commended specifications . Re
place as required .
C. Desiccant cartridge mainten C. Check the compressor for ex
ance is required . cessive oil passing and/or cor
rect installation. Repair or re
place compressor as required.
Replace desiccant cartridge.
D. Malfunctioning defective dis D. Test to determine if air is
charge check valve in end cov passing through the check
ero valve. Repair or replac e as re
quired.
11 of 14
Symptom 4 continued E. Excessive pressure pulsations E. Increase the volume in the dis
from the compressor. charge line by increasing dis
charge line length or diameter.
F Governor is malfunctioning. F. Test the governor for proper op-
Missing or restricted governor eration. Inspect the controlline
control line. leading from the governor un
loader port to the air dryer con
trol port.
5. Constant exhaust of air at air A. Air dryer purge valve is leaking A. With the compressor loaded ,
dryer purge valve exhaust. excessively. apply a soap solution on the
(Charge mode.) purge valve exhaust to test lor
excessive leakage. Repair
purge valve as required .
B. Compressor fails to unload B. Confirm failure to unload by in
(stop compressing air) and air creasing and decreasing engine
dryer purge exhaust makes a RPM and noting the chan ge in
"sputtering " or "popping " the rate 01 leakage and the in
sound. tensity 01 the accompanying
leakage sound . Repair or re-
place the compressor unloaders
as required .
C. Purge control line connected to C. Purge control line must be con
the reservoir or exhaust port 01 nected to the unloader port 01
governor. the governor.
D. Purge valve frozen open - mal- D. Test the heater and thermostat.
lunctioning heater and thermo- Shutdown the engine and allow
stat, wiring, or blown luse. the end cover to cool below
40°F (4 OC). Using an Ohm
meter, check the resistan ce
between the electrical pins in
the female connector. The res
istance should be 1.5-3 .0
ohms for a 12-volt and 6.8-9.0
ohms lor a 24-volt . Warm the
end cover to over 90 °F (32 oC)
and recheck the resistance .
The resistance should not ex
ceed 1,000 ohms. II the resist
ance values are within the
stated limits , the thermostat and
heater are operating properly. II
the resistan ce values are out
side the stated limits, replace
the purge valve housing (which
includes the thermostat and
heater) .
E. Excessive system leakage. E. Refer to Symptom 1.
F. Purge valve stays open - the F. Repair purge valve and hous
supply air leaks to control side. ing.
6 . Can not build system air pres- A. Inlet and outlet air connections A. Connect the compressor dis
sure. reversed. charge to the air dryer supply
port. Reconnect lines properly.
B. Check valve between air dryer B. Test the check valve for proper
and lirst reservoir. operation . Repair or replace as
required .
120114
Symptom 6 continued C. Kinked or blocked discharged C. Check to determine if air passes
line. through the discharge line.
Check for kinks, bends, excess
ive carbon deposits, or ice
blockage.
D. Excessive bends in the dis- D. The discharge line should be
charge line (water collects and constantly sloping from the
freezes) . compressor to the air dryer with
as few bends as possible.
E. Excessive pressure pulsations E. Increase the volume in the dis
F. Governor is malfunctioning. F. Test the governor for proper op-
Missing or restricted governor eration. Inspect the control line
control line. leading from the governor un
loader port to the air dryer con
trol port.
7. Air dryer does not purge or ex- A. Missing, broken, kinked, frozen, A. Inspect the controlline from the
haust air. plugged, or disconnected purge governor unloader port to the
control line. air dryer control port. Test to
determine air flows through the
purge control line when the
compressor is unloaded.
Check for undrllled fittings.
Check the compressor for ex
cessive oil passing and/or cor
rect installation. Repair or re-
place compressor as required.
Replace desiccant cartridge.
B. Faulty air dryer purge valve. B. Ensure air is reaching the purge
valve. Repair the purge valve.
C. Air dryer safety valve is malfunc- C. Verify relief pressure is at re
tioning. commended specifications. Re-
place as required.
D. Excessive pressure pulsations D. Increase the volume in the dis
8. Desiccant material is being ex- A. This symptom is almost always A. See remedies for Symptoms
pelled from the air dryer purge accompanied by one or more of 1-5.
valve exhaust (may look like the symptoms from Symptoms
whitish liquid, paste, or small 1 -5. Refer to the causes for
beads) or unsatisfactory desic- Symptoms 1 -5.
cant cartridge life.
B. Air dryer not securely mounted. B. Vibration should be held to a
(Excessive vibration.) minimum. Add bracket sup
ports or change tlle air dryer
mounting location.
C. Malfunctioning or saturated de- C. Replace the desiccant cartridge.
siccant cartridge.
D. Compressor passing excessive D. Check for proper compressor
oil. installation. If symptoms contin
ue, replace the compressor.
13 of 14
Symptom 8 continued E . Desiccant cartridge not as E. Check the torque on the desic
sembled properly to end cover. cant cartridge to end cover.
9 . "Pinging " noise excessive dur A. Defective check valve in end A. Replace the check valve.
ing compressor loaded cycle . cover.
B. Leaking turbo cutoff valve. B. Repair or replace the purge
valve assembly.
C. Leaking purge valve control pis- C. Repair or replace the purge
ton o-ring o valve assembly.
10. Constant seepage of air at the A. Detective check valve in end A. Replace the check valve .
air dryer purge valve exhaust cover.
(non-charging model o
B. Leaking turbo cutoff valve. B. Repair or replace the purge
valve assembly.
C. Leaking purge valve control pis- C. Repair or replace the purge
ton o-ring o valve assembly.
11.The air dryer purge piston A. Compressor fails to "unload". A. Faulty governor installation. No
cycles rapidly in the com air line from governor to com
pressor unloaded (non-com pressor or line is kinked or re
pressing) mode. stricted . Install or repair the air
line.
14 of 14
Front Air Brake Chamber, 2 3 4 5

R & I (W/Automatic Slack Adjuster)
front air brake chambers used on axles equipped with
automatic slack adjusters. For recondition procedure ,
see SM Keysheet Area 01-027. Please note that
exact orientation of parts may vary from
illustrations.
Removal 12---
1. Park the crane on a firm, level surface. Engage the
11
park brake and shift the transmission to neutral.
2. Level the crane on fully extended outriggers, re
lease the park brake, and shutdown the engine.
Note: If leveling the crane on outriggers is not
practical, the wheels may be blocked so that the
park brake can be released. 6
1. Slack Adjuster 7. Jam Nut
2. Camshaft 8. Clevis
A WARNING
3.
4.
5.
Anchor Bracke t
Brake Chamber
Air Llne
9. Pin
10 Nut
11. Chamber Bracket
Solvents and cleaning solutions can be 6. Nut 12. Adlusting Hex
Figure 1
Dual Air Brake Chamber
cleaning solutions. Cleaning And Inspection
approved cleaning solvent to prevent contamina
tion from entering the air circuits. Allow the area to
A WARNING
air dry.
result from misuse 01 these products. Rea d
A WARNING
and follow al! the manufacture r' s
cleaning solutions.
Iines and fittings before relieving air pressure
may result in serious injury. Shutdown the 1. AII components should be thoroughly cleaned with
engine and drain the air system reservo ir an approved cleaning sOlvent , air dried , and care
before opening any line or fitting. fully inspected.
R
2. AII Loctite , Permatex , or other sealant residue
4. Open the drain valve on the air system reservoirs to should be removed from threads of hardware and
bleed the air system pressure . parts that are going to be reused.
valves on the air system reservoirs. tigue, or stress fractures and corrosion. Repair or
Refer to Figure 1 . replace as required.
6. Disconnect the air line (5) from the brake chamber 4. AII "soft parts ", such as seals , gaskets, back up
(4). Cap/ plug the open port and air line (5) to pre rings , and o-rings, should be replaced .
vent contamination of the system. 5. Inspect the integrity of the air line that is connected
7. Remove the pin (9) which secures the clevis (8) to to the brake chamber being serviced. Repair or re
the slack adjuster (1). place if required.
8. Remove 1he nuts (10,6) which secure the brake 6. In the event of severe defects , contact factory per
chamber (4) to the chamber bracket (11); remove sonnel for directions whether to repair or replace
the brake chamber (4) from the crane. any major componen!.
1 of 4
Installation Indicator
Aligned With Slot
3
2 _ _ _ _- ----
10 9 8 7
1 Brake Chamber 6. Adjusting Hex
2 Nut 7. Clevis
3 Anchor Bracket 8. Jam Nut 10
4. Control Arm 9. Push Rod 1. Nut 6. Slack Adjuster
5 Slack Adjuster 10. Pin 2. Anchor Bracket 7. Clevis
3 Control Arm 8. Pin
Figure 2 4. Installation Indicator 9. Push Rod
Slack Ad'uster Installation 5. Adjusting Hex 10. Brake Chamber
Figure 3
Installation Control Arm Adjustment
The following installation procedure is applicable only
to cranes with brake assemblies originally equipped 4. Properly orient the anchor bracket (3) over the sec
with automatic slack adjusters. These instructions do ond mounting stud, of the brake chamber (4) , be
not apply to aftermarket automatic slack adjusters. fore loosely installing the upper nut (10). The
Please note that exact orientation of parts may vary slotted hole, of the anchor bracket (3), must be
from illustrations. positioned toward the camshaft (2).
1. Check that the cranes wheels are blocked, to pre Refer to Figure 2.
vent the crane from rOlling, or set the crane on out 5. Disengage the control arm (4), from the anchor
riggers. bracket (3) and rotate the adjusting hex (6), as re
Refer to Figure 1. quired, to align the hole in the slack adjuster (5)
2. Verify that the carrier brakes are fully released by with the clevis (7).
rotating the wheels and listening for any dragging 6. The push rod (9) should be perpendicular to the
of brake shoes. If necessary, rotate the adjusting centerline of the slack adjuster (5) (disregard any
hex (12) counterclockwise to release the brakes. offset in the lever arm), once the clevis (7) is pinned
to the slack adjuster (5). If required, loosen the jam
A WARNING
nut (8) and adjust the clevis (7) to achieve as close
to a 90 degree angle, as possible, between the
push rod (9) and the centerline of the slack adjust
co mpounds, etc. can be hazardous. Serious er (5). Tighten the jam nut (8).
personal injury may result from misuse of 7. Install the pin (10) through the clevis (7). However,
these products. Read and follow all do not install the cotter pin (not shown) th rough the
manufacturer's recommendations concerning pin (10). Later steps may requ ire th e removal of th e
these products. cotter pin.
3. Insert the mounting studs, of the brake chamber

(4), through the chamber bracket (11) and install
just the lower nut (6) using Loctite® 242.
l of a
Reler lo Figure 3. Reler to Figure 1.
12. Connect the air line (5) to the brake chamber (4).
13. Apply a soap solution to air line conneclions. Start
CAUTION the engine. Apply and release bolh the park brake
and the service brakes several times.
Excessive positioning force may damage the
14. Inspect the air connections lor leaks . Air leaks will
control armo Most adjusters are equipped
lorm bubbles in the soap solution where leaks are
with an installation indicator. The installation
present. Repair leaks as required.
indicator must fall within the slot for proper
instaliation. Incorrect control arm position Reler to Figure 3.
can cause tight or dragging brakes. 15. With the air system pressure within its normal oper
ating range , release both the service and park
8. Rolate the control arm (3) counterclockwise , away brake. Verily that the installation indicator (4) is
Irom the adjusting hex (5) , loward Ihe brake cham within the slol. Remove the clevis pin (8) . The
ber (10), unlil Ihe control arm (3) comes lo a deli holes in the clevis (7) and the hole in Ihe slack ad
nile internal slop . II necessary, use a plaslic mallel juster (6) should remain in alignment. II Ihe pUSll
lo lap Ihe conlrol arm (3) inlo posilion . rod (9) pulls inlo lile brake chamber (10), re peal
9. Verily Ihe inslallalion indicalor (4) is properly Steps 5 througll 14.
aligned with ilS slOI; Ihen engage Ihe conlrol arm 16. Install the clevis pin (8) and properly secure il w ilh a
(3) wilh the anchor brackel (2) and lully inslall Ihe cotter pin (not shown) .
nul (1) using Loctite 242. 17. Verily thal the applied stroke 01 Ihe push rod (9) is
within the legallimils lor tlle brake chamber being
Reler lo Figure 2.
used. Refer to "Adjusting The Brakes " lound in SM
10. Inslall the nul (2) which secures Ihe control arm (4)
Keysheet Area 01-003.
lo Ihe anchor brackel (3) . Be sure the conlrol arm
18. Complete the installation by lesting all related lunc
(4) remains in lile same posilion as the nul (2) is
lighlened. tions 01 the brakes lor proper operation. Normal
operation 01 hydraulic , air, and electrical systems
11. Adjust the brakes by turning the adjusting hex (6)
clockwise , while manually rotating the wheel until should be conlirmed. A general inspection 01 com
ponents and systems in the areas adjacenl lO lile
the brake shoes can be heard dragging on the
repair should also be performed lO ensure related
brake drum. Then, rotate the adjusting hex (6)
damage or wear is nol present o
counterclockwise, 1/2 turno A minimum 01 13 ft lb
(18Nm) is necessary to overcome the clutch, and a
racheting sound will occur.
3014
4 of 4
Dual Air Brake Chamber,
R & I (W/Automatic Slack Adjuster)
dual air brake chambers used on axles equipped with
automatic slack adjusters . For recondition procedure ,
see SM Keysheet Area 01-027 .
A DANGER
Removal of the band clamps holding dual air
brake chambers together, before caging the
power spring, will result in the chamber and its
2
internal parts being rapidly and forcefully
ejected. This may result in severe personal
injury or death. Always cage the power spring
before attempting any brake or air chamber 1. Retaining Device
adjustment or repair. If any doubt exists as to 2. Dual Air Brake Chamber (Typícal Híghway Type)
whether a potential safety hazard exists, Figure 1
contact your nearest distributor before Retain Damaged Chambers Before Caging
repairs are attempted.
A dual air brake chamber is a brake system component 5. Cage the power spring within the dual air brake
that uses two internal air chambers to control the lunc chamber being serviced. See Caging Dual Air
tions 01 the service brakes and park brakes. The cham Brake Chambers in SM Keysheet Area 01-027 lor
ber closest to the axle controls the service brake. It the correct procedure.
contains some serviceable parts. The outer chamber
controls application 01 the park brake. It is not service
able and no attempt should be made to disassemble it. A WARNING
The park brake chamber contains a large high lorce
(power) spring that will cause the unit to literally "ex hazardous. Serious personal injury may
plode " il the brake chamber housing is damaged or il result from misuse of these products. Rea d
disassembly is attempted . "Caging " the unit com and follow all the manufacturer's
presses and restrains the power spring, making it sale recommendations concerning solvents and
to service the dual air brake chamber. It is essential that cleaning solutions.
extreme caution be exercised in servicing all aspects
01 these units to prevent inadvertent, uncontrolled re 6 . Thoroughly clean area to be disassembled with an
lease 01 the power spring . Cage the power spring be approved cleaning solvent to prevent contamina
lore servicing any dual air brake chamber. tion Irom entering the air circuits. Allow the area to
air dry.
Removal
1. Park the crane on a lirm , level surface. Engage the
park brake and shift the transmission to neutral.
2 . Level the crane on lully extended outriggers , re A WARNING
lease the park brake , and shutdown the engine .
Note: If leveling the crane on outriggers is not lines and fittings before relieving air pressu re
practical, thewheels may be blocked so thatthe may result in serious injury. Shutdown the
park brake can be released . engine and drain the air system reservoir
3. Inspect the housing 01 the dual air brake chamber
lor excessive corros ion and cracks, or dents
7. Open the drain valve on the air system reservoirs to
caused by mechanical impact.
bleed the air system pressure.
4. Dual air brake chambers that appear to be dam
8. When pressure is lully relieved, close the drain
aged must be enclosed in some type 01 approved
valves on the air system reservoirs.
retaining device belore proceeding lurther. Reler
to Figure 1.
1 014
2, AII Loctite '.[ , Permatex'';' , or other sealant residue
2 3 4 5 6 should be removed from threads of hardware and
parts that are going to be reused .
tigue, stress fractures, and corrosion . Repair or re
place as required. Refer to disposal procedure
outlined in Caging Dual Air Brake Chambers
should a brake chamber need to be disposed. See
SM Keysheet Area 01-027.
4. AII "soft parts", such as seals, gaskets, back up
13-~'"" rings, and 0- rings , should be replaced.
5. Inspect the integrity of the air lines that are con
12
nected to the brake chamber being serviced . Re
pair or replace if required.
6. In the event of severe defects, contact factory per
Caging Solt any major component.
7
Installed Installation
1. Slack AdJusler 8 Jam Nul
The following installation procedure is applicable only
2. Cam shaf1 9. Clevis
3. Anchor Brackel 10. Pln to cranes with brake assemblies originally equipped
4. Air Lines 11. Nul with automatic slack adjusters. These instructions do
5 Brake Chamber 12, Chamber Bracket not apply to aftermarket automatic slack adjusters.
6. Caging BolI 13, Adius1ing Hex
7.
Figure 2
Nul
Du al Ai r Brake Chamber
A DANGER
Removal of the band clamps holding dual air
brake chambers together, before caging the
Refer to Figure 2, power spring, will resultin the chamber and its
9, Label for assembly purposes and disconnect the internal parts being rapidly and forcefully
air lines (4) from the brake chamber (5), Cap the ejected. This may result in severe personal
open ports and air lines (4) to prevent contamina injury or death. Always cage the power spring
tion of the system, before attempting any brake or air chamber
10, Remove the pin (10) which secures the clevis (9) to adjustment or repair. If any doubt exists as to
the slack adjuster (1), whether a potential safety hazard exists,
11. Remove the nuts (11,7) which secure the brake contact your nearest distributor before
chamber (5) to the chamber bracket (12); remove repairs are attempted.
Ihe brake chamber (5) from Ihe crane,
1. Check that the cranes wheels are blocked , to pre
Clean ing And Inspection vent the crane from rolling, or set the crane on out
riggers .
A WARNING
Refer to Figure 2.
2. Verify Ihat the caging bolt (6) is properly inslalled
and the power spring within the brake chamber (5)
hazardous. Serious personal injury may is contained. See Caging Dual Air Brake Chambers
resu lt from misuse of these products. Read in SM Keysheet Area 01 -027 for the correct proce
and follow all the manufacturer's dure,
reco mmendations concerning solvents and 3. Verify that the carrier brakes are fully released by
cl eaning solutions . rotaling the wheels and listening for any dragging
of the brake shoes. If necessary, rotate Ihe adjust
1, AII components should be thoroughly cleaned with ing hex (13), counterclockwise, lO release brakes.
an approved cleaning solvent, air dried , and care 4. Align the brake chamber (5) so the ports for the air
fully inspecled. line (4) connections are toward the inside of the
crane.
e01 't
5 6 Installation Indicator
Aligned With Slot
3 _ _ _ _-
2 -_ _ __
10 9 8 7
1 Brake Chamber 6. Adjusting Hex

2. Nut 7. Clevis
3 Anchor Bracket 8. Jam Nut
4. Control Arm 9. Push Rod
5. Slack Adjuster 10. Pin 10
1. Nut 6. Slack Adjuster
Figure 3 2. Anchor Bracket 7. Clevrs
Slack Ad O
uster Installation 3. Con trol Arm 8 Prn
4. Installation Indrcator 9 Push Rod
5. Adjusting Hex 10. Brake Chamber
5. Insert the mounting studs, 01 the brake chamber
(5), through the chamber bracket (12) and install Figure 4
just the lower nut (7), using Loctite : 242. Control Arm Adjustment
6. Properly orient the anchor bracket (3) over the sec
ond mounting stud, 01 the brake chamber (5), be Reler to Figure 4.
lore loosely installing the upper nut (11). The
slotted hole, 01 the anchor bracket (3), must be
positioned toward the camshaf1 (2).
CAUTION
Reler to Figure 3. Excessive positioning force may damage the
7. Disengage the control arm (4) Irom the anchor control arm o Most adjusters are equipped
bracket (3) and rotate the adjusting hex (6) , as re with an installation indicator. The installation
quired, to align the hole in the slack adjuster (5) indicator must fall within the slot for proper
with the clevis (7). installation . Incorrect control arm positi on
8. The push rod (9) should be perpendicular to Ihe can cause tight or dragging brakes.
centerline 01 the slack adjuster (5) (disregard any
offset in the lever arm), once the clevis (7) is pinned 10. Rotate the control arm (3) counterclockwise , away
lo the slack adjuster (5). II required , loosen the jam Irom th e adjusting hex (5), toward the brake cham
nut (8) and adjust the clevis (7) to achieve as close ber (10) , until the control arm (3) comes to a deli
to a 90 degree angle as possible , between the nite internal stop . II necessary, use a plastic mallet
push rod (9) and the centerline 01 the slack adjust to tap the control arm (3) into position.
er (5). 11. Verily the installation indicator (4) is properly
9. Install the pin (10) through the clevis (7). However, aligned with its slot and then engage the control
do not yet install the cotter pin (nol shown) through arm (3) with the anchor bracket (2) and lully install
the pin (10). Further steps may require the removal the nut (1), using Loctite ' 242.
01 the cotter pin.
3014
Refer to Figure 3 . 16. Inspect the air connections for leaks. Air leaks will
12 . I nstall the nut (2) which secures the control arm (4) form bubbles in the soap solution where leaks are
to the anchor bracket (3). Be sure the control arm present. Repair leaks as required.
(4) remains in the same position as the nut (2) is 17. Remove the caging bolt (6) from the brake cham
tightened . ber (5). See Caging Dual Air Brake Chambers in
13 . Adjust the brakes by turning the adjusting hex (6), SM Keysheet Area 01 -027 for the correct proce
clockwise , while manually rotating the wheel until dure.
the brake shoes can be heard dragging on the Refer to Figure 4.
brake drum . Then , rotate the adjusting hex (6), 18. With the air system pressure within its normal oper
counterclockwise , 1/2 turn o A minimum of 13 ft lb ating range , release both the service and park
(18Nm) is necessary to overcome the clutch; a ra brake. Verify that the installation indicator (4) is
cheting sound will occur. within the slot. Remove the clevis pin (8) . The
Refer to Figure 2. hales in the clevis (7) and the hale in the slack ad
14. Connect the air lines (4) to the brake chamber (5). juster (6) should remain in alignment. If the push
rod (9) pulls into the brake chamber (10) , repeat
steps 7 thru 17.
A WARNING
19. Install the clevis pin (8) and properly secure it with a
cotter pin (not shown).
20. Verify that the applied stroke of the push rod (9) is
com pounds, etc. can be hazardous. Serious
within the legallimits for the brake chamber being
pe rsonal injury may result from misuse of
used. Refer to Adjusting The Brakes found in SM
th ese products. Read and follow all Keysheet Area 01-003.
manufacturer's recommendations concerning 21 . Complete the installation by testing all related fun c
these products. tions of the brakes for proper operation. Normal
operation of hydraulic, air, and electrical systems
15. Applya soap solution to air line connections. Start
should be confirmed. A general inspection of com
the engine and apply and release both the park
ponents and systems in the areas adjacent to the
brake and the service brakes several times.
repair should also be performed to ensure related
4 of 4
1. Park Brake Chamber 4. Loc knut*

2. Power Spnng 5. Capscrew*
3 Caging Bolt 6. Servlce Brake Chamber
1. Retaining Device
*Do no! remove unless power spring is caged
2. Dual Air Brake Chamber (Typical Highway Type)
Figure 1 Figure 2
Retain Damaged Chambers Before Caging Air Brake Chamber - Power Spring Free
Caging Dual Air Brake A dual air brake chamber is a brake system component
that uses two Internal air chambers to control the func
Chambers tions of the service brakes and park brakes. The cham
ber closest to the axle controls the service brake. It
This SM Code is general in nature and applies to contains some serviceable parts. The outer chambe r
several types of dual air brake chambers . It includes controls application of the park brake. It is not service
the following procedures : able and no attempt should be made to disassemble it.
• Caging Dual Air Brake Chamber The park brake chamber contains a large high force
• Releasing A Caged Dual Air Brake Chamber
(power) sp rtng that will cause the unit to literally " ex
• Spring Brake Chamber Disposal plode " if th e brake chamber housing is damaged or if
disassembly is attempted. "Caging " the un it com
A DANGER
presses and restrains the power spring , making it safe
to service the dual air brake chamber. It is essential that
extreme caution be exercised in servic ing all aspects
Removal of the band clamps or other
hardware holding dual air brake chambers of these units to prevent inadvertent , uncontrolled re
together, before caging the power spring, will lease of the power spring. Use the following procedure
to safely cage the power spring.
result in the chamber and its internal parts
being rapidly and forcefully ejected. This may
result in severe personal injury or death.
Caging Dual Air Brake Chamber
Always cage the power spring before 1. Park the crane on a firm, level surtace . Engage the
attempting any brake or air chamber par k brake and shift the transmission to neutral .
Note: If leveling the crane on outriggers ís not
whether a potential safety hazard exists,
contact your nearest distributor before
park brake can be released.
2. Level the crane on fully extended outr iggers , re
lease the park brake, and shutdown the engine .
1 oi 4
Rotate Out
Rotate In
,- 3.0 inehes

2 2
3
n. /- r--
o, Nut is tight
against top
of park brake
, (7.6em) ehamber
3 4
,----.!.=.I--~r'
1. Nut 4. Power Spring 1. Nut 4. Power Spring

2. Caging Bol! 5. Service Brake Chamber 2. Caging Bolt 5. Service Brake Chamber
3. Park Brake Chamber 3. Park Brake Chamber
Figure 3 Figure 4
Ai r Brake Chamber - Power Spring Caged Air Brake Chamber - Power Spring Free
3. Inspect the housing 01 the dual air brake chamber Releasing A Caged Dual Air Brake
lar excessive corrosion and cracks, or dents
caused by mechanical impact. Chamber
aged must be enclosed in some type 01 approved
retaining device befo re proceeding lurther. Reler
to Figure 1.
A DANGER
Removal of the band elamps or other
Reler to Figure 3. hardware holding dual air brake ehambers
5. Rotate the nut (1), on the end of the caging bolt (2), together, before eaging the power spring, will
until 3 inches (7.6cm) 01 thread is exposed be result in the ehamber and its internal parts
twee n the bottom of the nut (1) and the bushing on being rapidly and foreefully ejeeted. This may
top 01 the pa rk brake chambe r (3). result in severe personal injury or death.
Always eage the power spring before
Note: Rotating the nut will be diffieult with the attempting any brake or air ehamber
pa rk brake applied or the air brake ehamber re adjustment or repair. If any doubt exists as to
moved from the era ne. whether a potential safety hazard exists,
eontaet your nearest distributor befo re
6. The power spring (4) has now been properly
caged . Repeat the above procedure lor each
brake cham ber assembly that is being serviced.
1. Level the crane on lully extended outriggers , re
Normal operation 01 the park brake has been dis
lease the park brake, and shutdown the engine .
ru pted.
2014
o Do not cut, torch, or penetrate

housing in joint area
Clamp Ring Enclosed
Capscrew Enclosed
Figure 5
Disarming Spring Chamber
Note: If leveling the crane on outriggers is not Spring Brake Chamber Disposal
park brake can be released. It is mandatory in an increasing number of locations
that al! spring brake chambers (single or comblnation
2. Inspect the housing of the dual air brake chamber
type) be "disarmed" prior to the unit being discarded or
for excessive corrosion and cracks, or dents
scrapped. "Disarming" means the power spring,
caused by mechanical impact.
within the park brake portion of the unit, is relieved of all
tension and rendered harmless.
aged must be enclosed in some type of approved
retaining device before proceeding further. Refer
to Figure 1.
Refer to Figure 4.
A DANGER
Do not attempt to remove the air brake
4. Rotate the nut (1), on the end of the caging bolt (2),
until no thread is exposed and the nut (1) is tight chamber before caging the power spring. If
proper directions are not followed, the
against the bushing on top of the park brake cham
ber (3). chamber and its internal parts could rapi dly
and forcefully explode. This may result in
Note: Rotating the nut will be difficult with the severe personal injury or death. Always cage
park brake applied or the air brake chamber re the power spring before attempting any brake
moved from the crane. or air chamber adjustment or repair. If any
doubt exists as to whether a potential safety
5. The power spring (4) has now been released and hazard exists, contact your nearest distributor
normal operation of the park brake is restored. Re before repairs are attempted.
peat the above procedure for each brake chamber
assembly that has been serviced. 1. Properly "Cage" the power spring of the dual air
brake chamber using the procedure found earlier
in this document.
3 of 4
2. Remove the entire dual air brake chamber from the Note: When the first coil, of the power spring, is cut
crane . See SM Keysheet Area 1-27 for the correct completely though, the unit may jump slightly and/
procedure . or make a low pitch "pop" sound. Cutting though
3. Place the unit in an approved steel container.* The the second coil does not usually produce any
container must have openings to allow access to sound or movement.
the sides of the spring chamber housing.
4. Release the power spring of the dual air brake 7. Cut completely through at least two separate coils
chamber using the procedure lound earlier in this of the power spring.
document.
Refer to Figure 5.
5. Use an acetylene torch to cut a small hole, 1.5-2.0 A WARNING
Do not place your hand or fingers inside the
inches (4.0-5.0cm) in diameter, through the side
01 the spring chamber, just large enough to expose spring chamber housing. Until confirmed, the
two or three coils of the power spring within. DO spring may still be under tension. Unexpected
NOT cut the power spring at this time . movement of the spring could cause serious
injury. Use a screwdriver or similar tool to
check that all tension is relieved from the
A DANGER power spring.
Do not cut, torch, or penetrate the spring 8. To make sure you have completely cut the power
ch amber housing in the joint area. The spring coils , use a screwdriver or similar tool to
integ rity of the housing must remain intact check that the coils are loose inside the spring
until the power spring is disarmed. Cut the chamber housing.
power spring through the side of the housing 9. After cutting through at least two of the power
only. spring coils, the unit is safe to dispose of with no
further disassembly.
6. Create a second hole on the opposite si de of the
spring chamber housing . Cutting the second hole
provides the torch with sufficient oxygen for cutting
of the power spri ng .
*Information concerning suitable steel containers is available through your local distributor.
4 of 4
13
9
Tube 4, Diaphragm 7. Elbow Connectors 10, Bu shing 13, Clamp
2. Capscrew 5. Pislon 8. Plug 11 ,O-ring 14, Park Chamber
3, Nul 6 Retaining Rings 9. Service Chamber 12, Bu sh ing
Figure 1
Dual Air Brake Chamber Assembly
Dual Air Brake Chamber,

Recondition A DANGER
Removal of the capscrews, locknuts, or other
hardware holding dual air brake chambe rs
This procedure covers the recondition of the dual air
together, before caging the power spring , will
brake chamber, For removal and installation
result in the chamber and its internal parts
procedures, see SM Keysheet Area 1-27,
being rapidly and forcefully ejected. This may
If parts are hard to disassemble and assemble, do not result in severe personal injury or death.
use a hammer unless it has a soft face, do not force Always cage the power spring before
parts together, they must be free to operate, attempting any brake or air chamber
Disassembly whether a potential safety hazard exists,
contact your nearest distributor before
It is a good practice when disassembling complex
are disassembled, Keeping the parts in this order
the assembly process,
1 of 4
1. Properly cage the power spring of the dual air 2. Carefully inspect all components for damage,
brake chamber. See SM Keysheet area 1-27 for wear, corrosion, deep scratches, and scuffed met
the correct procedure. al. Remove any burrs or sharp edges with a fine
file, hone, emery cloth, or crocus cloth. Replace
any damaged component as required. Replace all
A WARNING
3.
bushings, o-ring, diaphragm, and retaining rings.
AII Loctite®, Permatex®, or other sealant residue
resu lt from misuse of these products. Read
with Loctite<t 7070 Cleaner to ensure best perfor
mance of products.
2. Cap/plug any openings in the air brake chamber.
Thoroughly clean the exterior surface of the unit to
prevent contamination from entering it.
Refer to Figure 1. Assembly
3. Place index marks on the service chamber (9),
clamp (13), and the park chamber (14) so parts will Lubricate all sealing and sliding surfaces with WABCO®
be properly oriented during assembly. RHF1, or equivalent, prior to assembly.
4. Remove tube (1) and elbow connectors (7) from
the service chamber (9) and the park chamber Refer to Figure 1.
(14). 1. Install the bushing (12), o-ring (11), and retaining
5. Remove capscrew (2) and nut (3) from the clamp rings (6) onto the piston (5).
(13). 2. Place the bushing (10) onto piston (5) and slide the
6. Remove the clamp (13) and separate park cham assembly into the service chamber (9).
ber (14) from service chamber (9). 3. Install the diaphragm (4) into the park chamber
7. Remove the diaphragm (4) and piston (5) assem (14).
bly from service chamber (9).
Note: Use the index marks placed on the unit
8. Remove bushing (10), retaining rings (6), o-ring
during disassembly to ensure proper alignment
(11), and bushing (12) from the piston (5).
of parts.
9. Remove the plug (8) from the service chamber (9).
10. Further disassembly of the dual air brake chamber 4. Align the service chamber (9) with the park cham
is not recommended. Servicing the park chamber ber (14).
can be dangerous and may require special tools. 5. Align clamp (13) over the flanges on par k chamber
Replace the entire park chamber as an assembly, if (14) and service chamber (9).
required. 6. Install capscrew (2) and nut (3) securing clamp
(13) over park chamber (14) and service chamber
Cleaning And Inspection (9).
7. Install the elbow connectors (7) and tube (1) into
A WARNING
8.
9.
park chamber (14) and service chamber (9).
Install the plug (8) in the service chamber (9).
If the air brake chamber is not to be immediately
hazardous. Serious personal injury may installed on crane, plug all open ports to prevent
res ult from misuse of these products. Read contamination and properly store.

cleaning solvent. Place parts on a clean, lint free
tion possible to keep all parts free of dust, dirt, or
2 of 4
o Do not cut, torch, or penetrate

housing in joint area
Clamp Ring Enclosed Type
Capscrew Enclosed Type

Figure 2
Disarming Spring Chamber
Spring Brake Chamber Disposal 3. Place the unit in an approved steel container. Inlor
mation concerning sui table steel containers is
It is mandatory in an increasing number 01 locations
available through your local Link-Belt® Distributor.
that all spring brake chambers (single or combination
type) be "disarmed" prior to the unit being discarded or Reler to Figure 2.
scrapped. "Disarming " means the power spr ing , 4. Use an acetylene torch to cut a small hole throu gh
within the park brake portion 01 the unit, is relieved 01 all the si de 01 the spring chamber, just large enough
tens ion and rendered harmless. to expose two coils 01 the power spring within.
A DANGER
Do not attempt to disarm the air brake
A DANGER
Do not cut, torch, or penetrate the spring
chamber before caging the power spring. If chamber housing in the joint area. Th e
proper directions are not followed, the integrity of the housing must remain intact
chamber and its internal parts could rapidly until the power spring is disarmed. Cut the
and forcefully explode. This may result in power spring through the side of the hous ing
severe personal injury or death. Always cage only.
the power spring before attempting any brake
or air chamber adjustment or repair. If any
Note: When the first coil, of the power spring, is
doubt exists as to whether a potential safety
cut completely though, the unit may jump slight
hazard exists, contact your nearest distributor
Iy and/or make a low pitch "pop" sound. Cutting
before repairs are attempted.
though the second coil does not usually pro
duce any sound or movement.
1. Properly "Cage" the power spring 01 the dual air
brake chamber. See SM Keysheet Area 1 -27 lor 5. Cut completely through at least two separate coils
the correct procedure. 01 the power spring.
2. Remove the entire dual air brake chamber Irom the 6. Alter cutting through at least two 01 the power
crane. See SM Keysheet Area 1-27 lor the correct spring coils, the unit is sale to dispose 01 with no
procedure. further disassembly.
3014
4 of 4
Service Manual 0610 SM01 -027 -146. 00
Carrier Air System
Components,R & I
A DANGER
Do not attempt to remove and/or disassemble
This procedure is general in nature and covers the the air brake chamber before caging th e
removal and installation 01 the air system components. power spring. If proper directions are not
Specilic procedures lor maJor component removal and followed, the chamber and its internal pa rts
installation may be available. Reler to the SM Keysheet could rapidly and forcefully explode. This
lor tilles and code numbers 01 additional procedures. may result in severe personal injury an d/or
death. Always cage the power spring before
Removal attempting any brake or air cha m ber
1. Lower, detach, and secure the load, as required. adjustment or repair. If any doubt exists as to
2. Stabilize the crane lor service as lollows: whether a potential safety hazard exists,
a. Park the crane, out 01 the way, on a lirm and contact your nearest distributor before
level surlace. repairs are attempted.
the tires.
lock, as required.
d. Level the crane on lully extended outriggers.
A WARNING
e. Fully retract and position the boom, as hazardous. Serious personal injury may
required. result from misuse of these products. Read
3. Shutdown the engine and disengage the main and follow all the manufacturer's
hydraulic pump. recommendations concerning solvents and
cleaning solutions.
A WARNING 6. Thoroughly clean the area to be disassembled with
Hydraulic oil is under pressure and may be an approved cleaning solvent to prevent conta
hoto A sudden release of hot oil could cause mination. Allow the area to air dry.
burns or other serious injury. Shutdown the 7. Cage dual air brake chambers, as required. See
engine and exhaust all trapped hydraulic SM Keysheet Area 01 -027 lor proper procedure.
pressure from the system before removing 8. Remove any grilles, guards, and other types 01
any line or component. protective shields that may be covering the air
4. Relieve the hydraulic system pressure as lollows: system component that is to be removed.
a. Release any residual pressure in the hydraulic 9. II required, label lor assembly purposes and
reservoir by slowly loosening the liller/breather disconnect any hydraulic lines as necessary.
cap, located on the top 01 the hydraulic 10. II required, label lor assembly purposes and
reservoir, until pressure is lully relieved. disconnect any electrical connectors pertaining to
b. Turn the ignition switch to "ON", but DO NOT and directly connected to the air system
START THE ENGINE. Move the lunction component being removed.
lockout switch to the "OPERATE" position.
switch es back and lorth several times.
A WARNING
5. Check that all control levers are in the neutral lines and fittings before relieving air pressure
position and move the lunction lockout switch to may result in serious injury. Shutdown tlle
the "DISABLE" position. engine and drain the air system reservoir
A WARNING 11. Open the drain valves on the air system reservoirs
Air lines may contain high pressure. Opening to bleed the air system pressure.
lines and fittings befo re relieving air pressure
befare apening any line or fitting.
1 014
iI
.J'r -;,-_ 1o
(\ E
,. - '.-¡I r. ,,/.----- - ... )
- - '.
-'O lA
. -7'(lS¡\
5 6
1. Left Side Modulator Valve 5. Brake Relay Valve 8. Air Reservoir
2. Front Left Side Rid e Height Valve S/A 6. Air Reservoir 9. Right Side Modulator Valve
3. Air Reservoir 7. Dual Air Brake Chamber 10. Solenoid Valve
4. Air Dryer
Figure 1
Air System Components
2 of 4
F
~~ I
Ih
1I
1
,)
1
I
;/ >
"r
...--13
I
, "~ !j
>
,
i
16
I
15
~, _ . (~_----'<'--." I
.
1--;=--::r
)
_ ~; Lrr - 1:<71' '1
11 . Lefl Side Ride Height Valve S/A 13. Air Reservoir 15. Spring Brake Valve
12. Air Reservoir 14. Rear Air Service Valve 16. Right Slde Ride Height Valve S/A
3 of 4
SM 0 1 - 027 -146.00 0610 Service Manual
12. Label for assembly purposes and disconnect any Installation
air lines, hoses, tubes, and fittings pertaining to
and directly connected to the air system
component being removed. Cap any open air
ports, lines, hoses, tubes, and fittings to prevent
contamination of the system.
A WARNING
13 . Use an auxiliary lifting to lift component being compounds, etc. can be hazardous. Serious
removed if required . personal injury may result from misuse of
14. Remove any mounting hardware securing the air these products. Read and follow all
system component to the crane. manufacturer's recommendations concerning
15 . Remove the air system component from the crane . these products.
Cleani ng And Inspection 1. If required, use an auxiliary lifting device to support
air system component.
A WARNING
2. Position the air system component to the mounting
surface.
3 . Apply Loctite 242 to mounting hardware , as
required.
4 . Install mounting hardware and torque per
specifications in SM Keysheet Area 18-0.
recom mendations concerning solvents and Note: When installing air or hydraulic lines,
cleani ng solutions. hoses, tubes, and fittings, use two wrenches to
ensure that they are not twisted. One wrench
1. AII components should be thoroughly cleaned with must be on the malefitting and the other wrench
an approved cleaning sOlvent , air dried , and on the female fitting.
carefully inspected .
2. Al! Loctite t' , Permatex0' , or other sealant residue 5. Attach all air lines , hoses, tubes, and fittings that
should be removed from threads of hardware and were removed .
the mounting surfaces of parts that are going to be 6. Attach all hydraulic lines, hoses , tubes, and fittings
reused . Prior to applying new thread locking that were removed . Torque per specifications in
compounds or sealants , clean threads and SM Keysheet Area 7 - 18.
surfaces with Loctite 7070 Cleaner to ensure best 7. Connect any electrical connectors that were
performance of products. removed .
3. AII "soft parts ", such as seals , gaskets , back up 8. Release dual air brake chambers, as required . See
rings , and o-rings, should be replaced . SM Keysheet Area 01 - 027 for proper procedure.
4. Thoroughly inspect all parts for damage, wear, and 9. Check hydraulic reservoir oil level. Add oil as
corrosion . required. See Operator's Manual for correct type
5. Inspect the integrity of any air lines/hoses that are and procedure.
connected to the air system component being 10. Apply a soap solution to the air connections .
serviced . Repair or replace if required . Engage the main hydraulic pump. Start the engine
6. Inspect the integrity of any hydraulic lines/ hoses and let idle for five minutes .
that are connected to the air system component 11 . Inspect the air connections for leaks . Air leaks will
being serviced . Repair or replace if required . form bubbles in the soap solution where leaks are
7. I nspect the integrity of any electrical connectors present o Repair leaks as required .
supplying the air system component being 12. Inspect the hydraulic connections for leaks .
serviced. Repair or replace as required . Repair leaks as required .
8. In the event of severe defects , contact factory 13 . Replace any grilles, guards, and other types of
personnel for directions whether to repair or protective shields that were removed.
replace any major component. 14. Complete the installation by testing all related
functions of the air system component for proper
operation . Normal operation of hydraulic, air, and
electrical systems should be confirmed. A general
present o
4 of 4
2 3 4 5 6 7 8
Typical Dual Air Brake Chamber

Shown In Caged Position 1.
\\ 10
Stud Nuts
9
6. Studs
2. Washers 7. Wheel Hub
3. Tapered Dowels 8. Brake Dru m
4. Axle Shaft Flange 9. Washers*
5. Gasket 10. Capscrews*
1 Dual Air Brake Chamber 3. Adjustor Screw
2. Caging Stud. Nut, & Washer 4. Slack Adjustor * Some assemblies use a combination ofstuds and capscrews.
Figure 1 Figure 2
Dual Air Brake Chamber And Slack Adjustor Axle Shaft Assembly

Rear Wheel Hub And Brake a , Park the crane , out of the way, on a firm and
level surface.
Drum, R & I b . Engage the park brake andj or properly block
This procedure covers the removal and installation of the tires.
the rear wheel hub and brake drum . This procedure is c . Engage the swing park brake or travel swing
general in nature and minor variations in the actual lock , as required.
assembly may exist. d. Level the crane on fully extended outriggers.
e. Fully retract andjor position the boom, as re
quired.
A WARNING 3.
f. Release the park brake,
Shutdown the engine and disengage the main hy
draulic pump .
Brake Lining Fiber Warning
Older brake linings may contain asbestos
fibers, a cancer and lung disease hazard.
Brake linings manufactured today contain
A WARNING
non-asbestos fibers, whose long-term
effects to health are unknown. Use caution
when handling either asbestos or
non-asbestos materials used in brake
linings. Refer to OS HA regulations for proper
cleaning solutions.
handling of these materials. Material Safety
Data Sheets (MSDS) regarding brake lining
4, Thoroughly clean area to be disassembled with an
materials can be obtained from your local
distributor.
tion from entering the axle assembly. Allow the
area to air dry.
Removal
1. Lower, detach , and secure load , as required .
1 of 10
26 25 24 23 22 21 20 19
Disk Type Rim
4 5 6 7 8 9 10 11 12 13 14 16 17 18
1
, ~
('
.}
26 25 24 23 22 21 20 19
Spoke Type Rim

1 Axle Shatt 8. Rim C lamps 15. Studs 2 1. Spi ndle
2. Nuts 9 Outer Bearing Cup 16. Inner Bearing Cup 22 . Outer Beari ng Con e
3. Washers 10. Rim Spacer 17. Inner Rim 23. Inner Spindle Nut
4. Tapered Oowels 11 . Nu ts 18. Brake Orum 24. Lock Ring
5. Wheel Hub 12. Wash ers 19 . In ner S eal 2 5. Outer Spindle Nut
6. Nuts 13. Tapered Pilot Oowels 20. Inn er Bearin g Cone 26. Gasket
7. Outer Rim 14. Capscrews
Fig u re 3
Rea r Wheel Hub And Brake Drum Assembly
2 of 10
Service Manual 1000 SM1-28- 2 .0
A DANGER
Do not attempt to remove and/or disassemble
the air brake chamber before caging the
power spring. If proper directions are not fol
lowed, the chamber and its internal parts
could rapidly and forcefully explode. This
may result in severe personal injury and/or
death. Always cage the power spring befo re
attempting any brake or air chamber adjust
ment or repair. If any doubt exists as to
whether a potential safety hazard exists, con
tact your nearest distributor before repairs
are attempted.
1. Hammer - 5 lb (2.3kg)
2. Bra ss Drift - 1 1/2 inch (3.8cm) Diameter
5. Cage the power spring of the dual air brake cham 3. Driving Lugs
ber. See SM Keysheet Area 1 -27 for the correct 4. Axle Shaft
procedure. 5. Wheel Hub
6. If desired, remove the tires and rims from the wheel Figure 4
hubo Refer to SM Keysheet Area 1-69 for ap Axle Shaft Removal - Manual Impact Method
propriate procedure.
Note: The tires, rim, wheel hub, and brake drum

may be removed as a unit, provided an ade
quate means of handling the assembly is avail
able. This assembly may weigh as much as
A WARNING
Do not directly strike the round driving lugs on
750 lb (341 kg). the axle shaft flange, if equipped. Pieces c an
break off and cause serious personal injury.
7. Drain the oil from the axle differential into a suitable
To prevent serious eye injury, always w ear
container. Refer to the Operator's Manual for spe
safe eye protection when you perform cra ne
cific instructions . Properly store or dispose of the
maintenance or service.
used oil.
Do not use a chisel or wedge to loosen the
Refer to Figure 1. axle shaft and tape red dowels. Using a chisel
8. Back off the adjustor screw (3) on the slack adjus or wedge can result in damage to the axl e
tor (4) to provide maximum clearance between the shaft and/or the wheel hubo
brake lining and drum. See SM Keysheet Area
1 -3 for additional information on brake adjust b. Hold a 1-1/2 inch (3 .8cm) diameter brass drift
ment, as required. (2) against the center of the axle shaft (4). If
Refer to Figure 2. equipped, locate the brass drift (2) inside the
9. Remove the capscrews (10) and washers (9) and/ round driving lugs (3) on the end of the axle
or stud nuts (1) and washers (2) securing the axle shaft (4).
shaft flange (4) to the wheel hub (7).
Note: A 1-1 /2 inch (3.8cm) diameter brass
10. Place a suitable container under the wheel hub (7)
hammer can be used in place of the b ra ss
to catch the oil which will be drained from the wheel
drift, if desired.
hub (7), once the seal between it and the axle shaft
flange (4) is broken. c. Strike the end of the brass drift (2) with a large
11 . Loosen the tapered dowels (3) , in the axle flange hammer (1) , approximately 5 lb (2 .3kg), and
(4) , using one of the following methods : the axle shaft (4) to loosen tape red dowels
(3,Figure 2).
Manuallmpact Method
d. Remove the tapered dowels (3 ,Figure 2) and
Refer to Figure 4. separate the axle shaft (4) from the wheel hub
a. Index mark the location ofthe axle shaft (4) rel (5).
ative to the wheel hub (5), using a punch or in
delible marker.
3 of 10
b. Using an air hamm9r (1) and round bit, plac9
the bit against the axle shaft (2) between the
studs (3) . Operate the air hammer (1) at alter
nate locations between the studs (3) to loasen
the tapered dowels (3,Figure 2) and axle shaft
(2) from the wheel hub (4).
c. Remove the tapered dowels (3,Figure 2) and
separate the axle shaft (2) from the wheel hub
(4).
Refer to Figure 2.
12 . Allow the oil from the wheel hub (7) to drain into a
suitable container. Properly store or dis pose ofthe
used oil.
13 . Adequately s upport the wheel hub (7) and brake
drum (8) assembly with an appropriate lifting de
vice . The wheel hub (7) and brake drum (8) as
sembly weig hs approximately 250 lb (11 4kg) . If
1. Ai r Ham m er 3. Stud
2. Axle Sh aft 4. Wheel Hub
the tires , rim , wheel hub (7) and brake drum (8) are
being removed as a unit , the assembly weighs
Figure 5 approximately 750 lb (341 kg) .
Axle S haft Removal - Air Hammer Method
Refer to Figure 6 .
14. Remove outer nut (1) , lockwashers (5 and/or 6) ,
Air Hammer Method and inner nut (2) from spindle (3) .
Refe r to Figure 5 . Refer to Figure 7.

a. Index mark the location ofthe axle shaft (4) rel 15. Pull the wheel hub and drum assembly (3) outward
ative to the wheel hub (5) , using a punch or in and remove the outer cone (1) from spindle (7).
delible marker. 16. Carefully remove the wheel hub and drum assem
bly (3) from spindle (7). Use care not to damage
the machined surfaces of the wheel hub (8) and
A WARNING spindle (7) .
17. Remove inner seal (6) from the wheel hub (8) and
Powertools can project loose or broken parts. s pindle, as equipped
Píe c e s can break off and cause serious 18. Remove inner bearing cone (5) from the wheel hub
pers onal ínjury. To prevent serious eye injury, (8).
always wear safe eye protection when 19. If required, remove the outer cup (2) and inner cup
performing crane maintenance or service. (4) from the wheel hub (8) . They are pressed in
Do not use a chisel or wedge to loosen the place and may require the use of a hydraulic press
axle shaft and tape red dowels. Using a chisel to remove .
or wedge can result in damage to the axle 20. If required , the brake drum (10) can be separated
s ha ft and/or the wheel hubo from the wheel hub (8) by removing the nuts and
was hers (9) .
4 of 10
Three piece Four piece

Three piece
tang-type wheel nut tang/dowel-type wheel nut
dowel-type wheel nut
1. Outer Nut 3. Spindle 5. Lockwasher - Dowel Type 6. Lockwasher - Tang Type
2. Inner Nut 4. Dowel
Figure 6
Wheel Nut Arrangements
2 3 4 5 6 7
8 9 10
1 Outer Cone 4. Inner Cup 7. Spindle 9. Nuts & Washers
2. Outer Cup 5. Inner Cone 8. Wheel Hub 10. Brake Drum
3. Wheel & Drum Assembly 6. Seal
Figure 7
Wheel Bearing And Seal Assembly
Cleaning And Inspection 1. AII components should be thoroughly cleaned with

fully inspected.
A WARNING
2. Clean the shoulder of the axle spindle with a wire
brush. AII Loctite , Permatex't' , or other sealant
residue should be removed from threads of
hazardous. Serious personal injury may hardware and parts that are going to be reused. AII
result from misuse of these products. Read gasket material should be removed from the axle
and follow all the manufacturer's shaft flange and wheel hubo
recommendations concerning solvents and 3. Thoroughly inspect all parts for damage , wear, fa
cleaning solutions. tigue or stress fractures, and corrosion. Repair or
re place as required.
5 of 10
SM1- 28-2.0 1000 Service Manual
2 3 4
Two Piece Seal Installation
Note: Do not install the seal into the bore of the
wheel hub o
Refer to Figure 8.
a . Apply a thin coat of Permatex ' sealant to the
spindle shoulder (6) used to mount the deflec
tor ring (5) portion of the seal (4). Be sure to
coat the entire circumference to ensure an oil
tight seal.
b. Separate the seal (4) from the deflector ring (5)
and apply a light coat of clean lubricant to the
Oeflector Ring 6 5 lip of the seal (4) and inner diameter of the de
Flus h With Shoulder Face flector ring (5) . Refer to the Operator's Manual
1. Wheel Hub 4. Seal for the correct type of lubricant to use .
2. Bearing Cup - Inner 5. Deflector Ring c . Reassemble seal (4) and deflector ring (5) and
3. Bearing Cane - Inner 6. Spindle Shaulder manually rotate the parts to ensure the seal (4)
Figure 8 is properly seated in the deflector ring (5) .
Two Plece Seal (Stemco "'V Guardian w) d. Place the seal (4) and deflector ring (5) assem
bly on spindle shoulder (6) so the words "OIL
4. AI I "soft parts ", such as seals and gaskets, should BEARING SIOE" can be read . A slight step on
be replaced. inside diameter of deflector ring (5) will allow it
to be placed by hand, approximately 0 .12 in
5. Bearing cups and canes should be replaced as a
(3mm) , onto spindle shoulder (6) .
set.
6. Do not "tu rn " or rebore brake drums beyond speci Note: To ensure proper installation of the
ficatio n limit stamped or cast into the brake drum. seal and deflector ring a seal driver must be
7. In the event of severe defects, contact factory per used . The installation tool should only con
so nnel for directions whether to repair or replace tact the deflector ring and not apply any
a ny majar component. force to surfaces ofthe sea!. When properly
installed, the deflector ring should be flush
Installation and square with the face of the spindle
shoulder.
Multiple types of seals have been used in the wheel
hubs , depe nding on crane model and lubrication type. e. Using proper seal installation tool , carefully
Fig ure 8 through Figure 10 illustrate three different drive deflector ring (5) evenly onto the spindle
types used . Referto the appropriate Figure and related shoulder (6). Wipe away any excess sealant.
installation instructions for specific seal installation f. Oip bearing cone (3) in clean oil and place it on
proced u re . the spindle until it is seated against the spindle
Refer to Fig ure 7 . shoulder (6). Use care not to get oil on brake
1. Install o uter cup (2) and inner cup (4), as required. linings. Refer to the Operator's Manual for cor
2 . Assem b le the brake drum (10) to the wheel hub (8) rect type of oil.
using the nuts and washers (9) . Properly torque
the n uts per general torque s pecifications. See SM
Keysheet Area 18-0. CAUTION
3. Install the seal (6) using one of the following Do not push the wheel hub onto the seal by
procedures: hand. Uneven installation of the wheel hub
may cause misalignment of the seal causing
A WARNING
leakage and/or damage to the sea!. The wheel
hub will be seated onto the seal as the
adjusting nut is tightened.
Lubricants, sea lants, joint and thread locking
g. Do not seat the wheel hub (1) against the seal
personal injury may result from mis use of
by hand. The wheel hub will be seated using
the adjusting nut in the installation steps to fol
low.
these products.
6 of 10
Seal Fully Seated

2 3 4 In Wheel Hub
4
Seal Fully Seated

In Wheel Hub
1/32 inch Axle Ring Flush
---.;-~-- (O.8mm)
With Shoulder Face
1. Wheel Hub 4. Seal
1. Wheel Hub 3. Bearing Cone - Inner 2. Bearing Cup - Inner 5. Spindle Shoulder
2. Bearing Cup - Inner 4. Seal 3. Bearing Cone - Inner 6. Axle Ring
Figure 9 Figure 10
One Piece Seal One Piece Seal With Axle Ring
One Piece Seal Installation g. Place axle ring (6) on the spindle shoulder (5).
Refer to Figure 9 or Figure 10. Align proper installation tool on the axle ring (6)
a. Prelubricate the bearing cone (3) by packing it and strike the tool sharply to start the axle ring
with grease or dipping it in the proper oil type (6) into the spindle shoulder (5). Continue to
lubricant. Refer to the Operator's Manual to tap the installation tool until tool contacts the
determine the correct type of lubricant to use. spindle shoulder (5). Rotate the tool and tap
b. Lay wheel hub (1) on a flat surface with the several times to assure complete bottoming
bearing cup (2) facing up. out of tool and proper position ofaxle ring (6).
c. Place the bearing cone (3) into bearing cup (2). h. The axle ring (6) should be flush with the face of
d. Applya thin coat of Permatex"> sealant to the the spindle shoulder (5).
outer diameter of the seal (4). Be sure to coat
the entire circumference to ensure an oil tight
seal. CAUTION
e . Position the seal (4) in the bore of the wheel Do not seat the seal by hand. Uneve n
hub (1). Align the proper installation tool on the installation of the wheel hub may cause
seal (4) with handle in vertical position and misalignment of the seal causing leakag e
strike the tool sharply to start the seal (4) into and/or damage to the seal. The seal wi ll be
the bore. Orive the seal (4) into bore until it seated as the adjusting nut is tightened.
completely bottoms out in the bore . Check
clearance between bearing cone (3) and seal
Refer to Figure 7.
(4) . At least 1/32 inch (O.8mm) is required.
(Refer to Figure 9.) 4. Using an appropriate lifting device, carefully place
wheel hub and drum assembly (3) on the spindle
Refer to Figure 10. (7) and slide it back until the seal (6), wheel hub (8 )
f. If equipped with an axle ring (6), apply a thin and shoulder of the spindle (7) just make contact.
coat of Permatex sealant to the spindle shoul 5. Prelubricate the outer cone (1) by packing it with
der (5) . Be sure to coat the entire circumfer grease or dipping it in the proper oil type lubricant.
ence to ensure an oil tight seal. Also, fill the lubricant cavity, within the wheel hub
(8) with the same lubricant. Refer to the Operator's
Manual to determine the correct type of lubricant to
use.
6. Place the outer cone (1) in the bearing cup (2)
within the wheel hub (8) .
7 of 10
Refer to Figure 6. 14. If a tang type lockwasher (6) is used, secure the
7. Install the inner nut (2) onto spindle (3). If a dowel outer nut (1) by bending two of the lockwasher's
type wheel nut system is used, be sure the dowel (6) tangs over the outer nut (1). Choose the two
0
(4) on inner nut (2) is facing out. tangs (6) so they are 180 aparto
8. Torque the inner nut (2) to 200 ft lb (271 Nm) while Refer to Figure 11.
rotating wheel hub (8, Figure 7) to properly seat
15. Verify that wheel hub end play is 0.001-0.005 in
the bearings. (O.0025-0.0127mm) using a dial indicator. If
9. Loosen the inner nut (2) one full turno
reading does not fa 11 into acceptable range, repeat
10. Spin the wheel hub (8, Figure 7) again and torque previous steps. See "End Play Verification
the inner nut (2) to 50 ft lb (68Nm). Procedure" found later in this procedure.
11. Loosen the inner nut (2) exactly 1/4 turno
Refer to Figure 2.
16. Install gasket (5) and axle shaft flange (4) over the
studs (6) of the wheel hub (7).
CAUTION 17. Install and evenly tighten capscrews (10) and
Do not tighten adjusting nut to align dowel pin washers (9) and/or the tapered dowels (3),
ho le to the lockwasher. This can preload the washers (2), and stud nuts (1).
bearing and cause premature bearing failure. 18. Apply the final torque to the capscrews (10) and/or
Ifthe dowel pin and the hole in the lockwasher stud nuts (1) in a criss -cross pattern to ensure
are misaligned, remove the lockwasher, turn proper sealing of the axle shaft flange (4), gasket
in over, and reinstall it. If parts are still (5), and wheel hub (7).
misaligned, LOOSEN the adjusting nut just 19. Fill the axle housing with oil. Refer to the
eno ugh for alignment. Operator's Manual for the correct type of lubricant
and procedure.
12. Install lockwashers (5 and/or 6) on spindle (3). 20. If an oil type lubricant is used to lubricate the wheel
Ensure that dowel pin (4) on the inner nut (2) is bearings, fill wheel hub (7) with oil. See "Wheel
properly seated in lockwasher (5), if equipped. End Lubrication" found later in this procedure.
13. Install the outer nut (1). Torq ue outer nut (1) per the 21. Release the power spring in the dual air brake
table below: chambers. See SM Keysheet Area 1-27 for the
complete procedure.
Outer Nut 22. Properly adjust the brakes. Refer to SM Keysheet
Wheel Nut Type* Torque Value Area 1-3 for the correct procedure.
ftlb Nm 23. Install tire and rim assembly. Refer to SM Keysheet
Area 1-69 for correct procedure.
3 piece Dowel Type 350 475 24. Complete the installation by testing all related
functions of the wheel ends and brakes for proper
3 piece Tang Type 250 339
operation. A general inspection of components
4 piece Tang/Dowel Type 250 339 and systems in the areas adjacent to the repair
should also be performed to ensure related
* See Figure 6 for illustrated description. damage or wear is not present.
8 of 10
Wilh Indicalor Mounled Al

Bollom, Push/ Pull Sides 01 Drum
End Play Adjustment With End Play Adjustment With

Tire & Wheel Assembly Wheel Hub
Figure 11
Wheel End Play Verification
End Play Verification Procedure End Play Readjustment Procedure
Wheel end play is the free movement of the tire and Excessive End Play - If end play is greater than
wheel assembly along the spindle axis. Verify that .005 inch (O. 127mm), remove the outer nut and pull the
end - play meets specification using a dial indicator. lockwasher away from the inner nut , but not off the
An indicator with 0.001 in (0.03mm) resolution is spindle. Tighten the inner nut to the next allgnment
required. hole of the dowel-type washer (if used). Reassemble
the washer and retorque the outer nut. Verify end play
Correct end play is 0.001-0.005 in (0.025-0. 125mm). with a dial indicator.
1. Attach a dial indicator with its magnetic base to the
Insufficient End Play - If end play is not present ,
hub or brake drum as shown in Figure 11.
remove the outer nut and pull the lockwasher away
2. Adjust the dial indicator so that its plunger or point
from the inner nut, but not off the spindle . Loosen the
er is against the end of the spindle with its line of
inner nut to the next adjustment hole of the
action approximately parallel to the axis of the
dowel-type washer (if used) . Reassemble the washer
spindle.
and retorque the outer nut. Verify end play with a dial
3. Grasp the wheel assembly at the 3 o'clock and 9
indicator.
o'clock positions. Push the wheel assembly in and
out while osclllating it to seat the bearings. Read Fine Tuning the End Play - If, after performing the
bearing end playas the total indicator movement. readjustment procedures, end play is still not within the
0 .001-0.005 inch (0.025-0. 127mm) range ,
CAUTION disassemble and inspect the components. If parts are
found to be defective, replace the defective parts ,
Wheel end play must meet specification.
reassemble , and repeat wheel bearing adjustment
Premature failure of parts wiJl occur if proper
procedure. Verify end play with a dial indicator.
assembly procedure is not foJlowed. If end
play is not within specification, readjustment
is required.
9 of 10
Wheel End With Oil Fill Hole Wheel End Without Oil Fill Hole
Proper Proper
Lubricant Lubrican t
Level Level
Figure 12
Oil L ubricated Wheel Ends
OilWill OilWil1
Run Into Run Into
With Axle On Level Surlace. Fill Wheel End Wheel End
Housing With Oil To Botlom 01 Plug.
Temperatu re Sensor Tilt Housing Side To Side. 1 Minute Per Side.

Mounting Hale Then . Rec heck Oil Levelln Axle
Figure 13
Filling Wheel Ends With Oil Lubricant
Wheel End Lubrication (Oil Type Only) 4. Install oil fill plug and properly tighten .
Wheel Ends without oil fill hole proceed as follows:

CAUTION 1. With axle level and wheel ends assembled , add lu
B efore operating the axle, the wheel hub bricant through filler hole in axle housing cover until
c avities and bearings must be lubricated to fluid is level with the bottom of filler hole .
prevent failure. 2. Raise the right side of the axle 6 inches (15cm) or
more . Hold axle in this position for one minute .
Refer to the Operator's Manual for the correct type of 3. Lower the right side.
wheel end lubricant to use. 4. Raise the left side of the axle 6 inches (75cm) or
Axles may be equipped with either of two wheel end 5. Lower the left side .
designs : 6. With axle on a level surface, add lubricant through
• Wh ee l ends with an oil fill hole . housing coveroil filler hole until fluid is level with the
• Wheel ends without an oil fill hole . bottom of the hole.
Wheel Ends with an oil fill hole proceed as follows: Note: Axles without wheel end fill holes will require
approximately 2.5 pints (1.2Liters) additionallubri
1. Rotate the wheel end hub until the oil fill hole is up .
cant to bring the lube level even with the bottom of
2. Remove the oil fill plug.
fill hole.
3. Pour 0 .50 pint (0.25 Liter) ofaxle oil lubricant into
each hub through the wheel end fill hole.
10 of 10
5. Check that all control levers are in Ihe neutral
Rear Axles & position and move the function lockout switch to
Air Suspension, R & I the "DISABLE" position ,
The following procedures are included in this SM Code

to accommodate the specific situation .
• General Removal ...... ", ... ....... page 1
A DANGER
Do notattempt to remove and /or disassemb le
• To Remove One Axle Individually .. ", Page 4 the air brake chamber before caging the
• To Remove Both Axles As A Unit . . . , . . Page 4 power spring. If proper directions are not
• Cleaning And Inspection , . . " . ... . . , page 5 followed, the chamber and its internal parts
• To Install One Axle Individually ..... .. Page 5 could rapidly and forcefully explode. This
• To Install Both Axles As A Unit . . , , . , . , Page 6 may result in severe personal injury or death.
• Finallnstallation Procedures . .. . , . . ,. page 7 Always cage the power spring befo re
For recondition procedure, see SM Keysheet Area attempting any brake or air chamber
01-024. adjustment or repair. If any doubt exists as to
whether a potential safety hazard eXists,
General Removal contact your nearest distributor before
repairs are attempted .
1, Lower, detach , and secure load , as required.
2, Stabilize the crane for service as follows :
6, Cage Ih e power springs on the dual air brake
chambers, Refer to SM Keysheet Area 01 -02 7 for
level surface, the correct procedure .
b. Engage the par k brake and/or properly block
the tires,
c. Engage the swing par k brake or travel swing
lock, as required . A WARNING
d, Level the crane on fully extended outriggers, Air lines may contain high pressure. Openi ng
Note: Use sturdy blocking under the may result in serious injury. Shutdown the
pontoons to increase clearance below the engine and drain the air system reservoir
carrier for easier removal of the axle(s). before opening any line or fitting.
e, Fully retract and posilion the boom , as
7, Open the drain valve on the air system reservoirs lO
required.
bleed the system air pressure.
f. Release the park brake , 8. When the system air pressure is fully relieved ,
3. Shutdown the engine and disengage the main close the drain valves on the air system res ervoirs ,
hydraulic pump. 9. Remove the tires and rims from the axle (s) to being
removed , Refer to SM Keysheel Area 01 -069 for
A WARNING
the correct procedure.
10. Label for assembly purposes and disconnect all air
lines connected to the components bein g re
hazardous. Serious personal injury may moved. Cap the air lines to prevenl contamination .
result from misuse of these products. Read Refer to Figure 1.
and follow all the manufacturer's 11. Remove the drive tube(s) (10,4) , as required , from
recommendations concerning solvents and the axle(s) (11,1 2) being removed,
cleaning solutions.
4 , Thoroughly clean the areas around the air lines to

be disconnected with an approved cleaning
solvent lo prevenl conlamination from entering Ihe
air circuits. Allow the areas lO air dry,
1 of 8
2 3 4
'11~ " .,:--,,'.','

,
I " ¡
\'~\23
-=-, \)(
25 24 30
Capscrews 10. Drive Tube 18. Clevis Rods 26. Locknuts

2. Caps 11 . Front- Rear Axle 19. Bolts, Washers, & Locknuts 27 . Box Shims
3. Lower Arms 12. Rear - Rear Axle 20. Capscrews, Washers, & 28. Nuts
4. Drive Tube 13 Fit1lngs, Lockwashers, & Locknuts 29. Torque Rods
5. Washers & Nuts Jam Nuts 2 1. Shock Absorbers 30. Torque Rods
6 Equalizer Beams 14 . Air Springs 22. Bar Pin Bushings 31 . Capscrews
7. Center Pin Caps 15. Lockwashers & Nuts 23. Capscrews 32 . Washers
8 Capscrews 16. Mounting Lugs 24 . Washers 33. Washers
9 Center Pin 17. Height Control Valves 25. Washers 34 . Locknuts
Fig ure 1
Rear Axles & Suspension
2 of 8
11
~_-1D
12
3 of 8
To Re move One Axle Individually 6. Check Ihe clearance between Ihe axle (11 or 12)
and equalizer beam (6) lo ensure Ihere is enough
Two separale jacks will be required lo remove one axle
space lo move Ihe axle (11 or 12) forward or
individually. One lo supporl, lift , and move Ihe axle backward, as required lo remove axle (11 or 12). 1I
which is being removed , and a second jack lo raise Ihe may be necessary lo further raise Ihe axle (11 or
axle which will remain on Ihe crane. 1I is imporlanl Ihal 12) being removed in order lo clear Ihe equalizer
the jack used on the axle being removed is easily beam (6). Remove Ihe box shims (27).
adJustable and mounted on rollers Both jacks must be 7. Carefully lower the axle (11 or 12) and remove il
01 adequate capacity to handle Ihe loads as follows: Irom under Ihe carrier.
Description Approximale Weighl
To Remove 80th Axles As A Unit
Fronl - Rear Axle 1,840 Ib* (835kg)
Two separale jacks will be required lO remove bolh
Rear-Rear Axle 1,510 Ib* (685kg) axles as one unit. One lO supporl, lift, and move each
*AII axle assembly weighls are approximale and axle. 1I is imporlanl Ihal Ihe jacks being used are easily
rellecl axle being lull 01 lubricanl and lires removed . adjuslable and mounted on rollers. Bolh jacks musl be
01 adequale capacily lO handle Ihe loads as lollows:
A DANGER
Descriplion
Fronl-Rear Axle
Approximale Weighl
1,840Ib* (835kg)
Use straps or chains to tightly secure the axle
Rear - Rear Axle 1,510 Ib* (685kg)
to the lifting device. This will prevent any
unwanted movement 01 the axle during Suspension Parls 1,000 lb (450kg)
rem oval 01 the mounting hardware used to Tolal 4,350Ib* (1 973kg)
secure the torque rods and /or equalizer
beams to the axle . 11 proper precautions are *AII axle assembly weighls are approximale and
reflecl axle being lull 01 lubricanl and lires removed .
not 101l0wed, the axle could rotate and/ or 1all,
resulting in severe personal injury or death.
1. Using an adequale lifting device , supporl Ihe axle

A DANGER
Use straps or chains to tightly secure the
being removed. Be sure lO lightly secure the axle
to the lifting device wilh straps or chains so it will axles to the lifting devices. This will prevent
not roll or lall. any unwanted movement 01 the axles during
removal 01 the mounting hardware used to
Reler lo Figure 1.
secure the torque rods and/ or equalizer
2. Remove Ihe nuts (28) which secure Ihe lorque rod
beams to the axles. 11 proper precautions are
(29) lo Ihe mounling lug (16) . Secure Ihe torque
not 101l0wed, the axles could rotate and/or
rod (29) out 01 the way.
3. Separate the torque rod (30) Irom the mounting lug 1all, resulting in severe personal injury or
(16) by removing the capscrews (31) , locknuls death.
(34) , and washers (32,33) . Secure Ihe lorque rod 1. Using adequale lifting devices, supporl each axle
(30) out 01 the way. individually. Be sure to secure the axles lo Ihe
4. Disconnect the axle (11 or 12) being removed Irom lifting devices wilh slraps or chains so they will not
the equalizer beams (6) by removing the locknuts roll or lall.
(26) , capscrews (23), and washers (24,25) Irom
the bar pin bushings (22). Reler lO Figure 1.
5. Place Ihe second lifting device under Ihe axle (11 or 2. Remove Ihe nuls (28) which secure Ihe lorque rods
12) which will remain on the crane. Carelully raise (29) to the mounling lugs (16). Secure Ihe lorque
Ihe axle (11 or 12) until it contacts the stops on the rods (29) oul 01 Ihe way.
boltom 01 the carrier Irame. As Ihe axle (11 or 12) is 3. Separale Ihe lorque rods (30) Irom Ihe mounling
lifted , Ihe opposile end 01 Ihe equalizer beam (6) lugs (16) by removing Ihe capscrews (31),
will rolale down and should separale Irom Ihe axle locknuts (34) , and washers (32,33) . Secure the
(11 or 12) being removed . torque rods (30) oul 01 the way.
4. Remove Ihe capscrews, washers , and locknuts
(20) securing Ihe shock absorbers (21) lo the lower
arms (3). Secure Ihe shock absorbers (21) out 01
the way.
4018
5. Remove the fittings, lockwashers, and jam nuts 3. Inspect the integrity of the air lines that we re
(13), and disconnect the air lines from the height disconnected. Repair or re place if required.
control valves (17) . Cap the fittings (13) to prevent 4. Inspect the air springs. Replace if any noticeabl e
contamination . damage is observed.
6. Remove the lockwashers and nuts (15) securing 5. Inspect the bushings in the equalizer beams and
the air springs (14) to the carrier frame. torque rods. If the bushings are worn or damaged ,
7. Remove the bolts , washers, and locknuts (19) press the bushings out and install new ones .
which attach the clevis rods (18) to the mounting 6. Inspect the center pins , lower arms, and equ alizer
trames of the air springs (14). Secure the clevis beams for wear. Excessive wear may indicate a
rods (18) out of the way. lack of adequate lubrication. Replace damag ed or
8. Match mar k the caps (2) for assembly purposes . worn parts , as required .
Remove the capscrews (1) and caps (2) . 7. In the event of severe defects, contact factory
9. Carefully lower the axles (11,12) and suspension personnel for directions whether to repai r or
assembly, and remove it from under the crane. replace any major component.
10. For assembly purposes, match mark the center pin
caps (7). Installation
11. Remove the capscrews (8) and center pin caps (7) Choose one of the following procedures based on
which secure the center pin (9) and lower arms (3) whether one or both axles are being installed.
to the equalizer beams (6).
12. Removethe center pins (9) and thrust washers (not To Install One Axle Individually
shown) from the equalizer beams (6). For assem
Two separate jacks will be required to install one axle
bly purposes, label the quantity, thickness, and
individually. One to support, lift, and move the axle
location of each thrust washer.
13. If the air springs (14) require removal, remove the being installed, and a second jack to raise th e axle
washers and nuts (5) securing the air springs (14) which remained on the crane . It is important that the
to the lower arms (3). Remove the air springs (14) jack used on the axle being installed , is easily
from the lower arms (3) . adjustable and mounted on rollers. Both jacks must be
14. Disconnect the axles (11 ,12) from the equalizer of adequate capacity to han die the loads as follows
beams (6) by removing the locknuts (26) , Description Approximate Weight
capscrews (23) , and washers (24,25) from the bar
pin bushings (22). Separate the axles (11,12) from Front - Rear Axle 1,840 Ib * (835kg)
the equalizer beams (6), and removethe box shims Rear-Rear Axle 1,510Ib* (685kg)
(27) .
*AII axle assembly weights are approximate and
Cleaning And Inspection reflect axle being full of lubricant and tires removed.
A WARNING A DANGER
Solvents and cleaning solutions can be Use straps or chains to tightly secure the axle
hazardous. Serious personal injury may to the li1ting device. This will prevent any
result 1rom misuse 01 these products. Read unwanted movement 01 the axle during
and 101l0w all the manu1acturer's installation. 11 proper precautions are not
recommendations concerning solvents and 101l0wed, the axle could rotate and/or fall,
cleaning solutions. resulting in severe personal injury or death.
1. AII components should be thoroughly cleaned with 1. Using an adequate lifting device, support the axle
an approved cleaning sOlvent, air dried and care being installed. Be sure to secure the axle to th e
fully inspected. device with straps or chains so it will not ro ll or fall
2. AII Loctite®, Permatex®, or other sealant residue off the lifting device.
should be removed from threads of hardware and 2. Place the second lifting device under the axle
the mounting surfaces of parts that are going to be which remained on the crane. Carefully raise the
reused. Prior to applying new thread locking com axle until it contacts the stops on the bottom of the
pounds or sealants, cl ean threads and surfaces carrier frame. As the axle is lifted, the opposite end
with Loctite® 7070 Cleaner to ensure best perfor of the equalizer beam will rotate down and should
mance of products . allow adequate clearance to install the axle.
3. Carefully raise the axle and position it under the
carrier.
5 of 8
Reler to Figure 1.
4. Check the clearance between the axle (11 or 12)
and equalizer beam (6) to ensure there is enough
space to move the axle (11 or 12) lorward ar
A DANGER
Use straps or chains to tightly secure the
backward , as required. It may be necessary to axles to the lifting devices. This will prevent
further raise the axle (11 ar 12) being installed in any unwanted movement of the axles during
arder to clear the equalizer beam (6). installation. If proper precautions are not
5. Install the box shims (27), folded edge down and followed, the axles could rotate and/or fall,
away Irom equalizer beam (6) . resulting in severe personal injury or death.
6. Engage the bar pin bushings (22) with the axle (11
or 12) by lowering one or both 01 the lifting devices, 1. Using adequate lifting devices , support each axle
as required . It may be necessary to rotate the bar individually. Be sure to secure the axles to the
pin bushings (22) in arder far it to engage with the lifting devices with straps or chains so they will not
axle (11 or 12) . Use the flats on either end 01 the bar roll or lall off the lifting devices .
pin bushings (22) to rotate them.
Refer to Figure 1.
7. Install the washers (24) on the capscrews (23), and
2. Install the box shims (27) on the bar pin bushings
insert the capscrews (23) through the bar pin
(22) , folded edge down and away from equalizer
bush ings (22) .
beam (6).
8. Ap plya light coating of Loctite® 242 to the threads
of the capscrews (23), and install the washers (25) Note: The grease fittings on the equalizer
and locknuts (26) . Tarque the capscrews (23) to beams should be oriented to the outside and
450-600ft lb (611-813Nm) . rear of the assembly.
9. Al ign the torque rod (30) to the mounting lug (16). 3. Align the equalizer beams (6) to the axles (11 ,12).
Insta" the capscrews (31), washers (32 ,33) , and It may be necessary to rotate the bar pin bushings
locknuts (34). Tarque the capscrews (31) to (22) in order to engage the axles (11,12). Use the
245-260 ft lb (333-364Nm). flats on either end of the bar pin bushings (22) to
10. Align the tarque rod (29) ~ o the mounting lug (16) rotate them.
andinstall the nut (28). 4. Install the washers (24) on the capscrews (23), and
11 . Ensure that the tape red stud connection is tight and insert the capscrews (23) through the bar pin bush
not excessively worn ar damaged. Tarque the nut ings (22) .
(28) to 175-225 ft lb (238-305Nm) . 5. Applya light coating of Loctite® 242 to the threads
of the capscrews (23), and install the washers (25)
To Install 8 0th Axles As A Unit and locknuts (26) on the capscrews (23) . Torque
Two separate jacks will be required to insta" both the the capscrews (23) to 450-600 ft lb
axles as one unit. One to suppart , move, and lift each (611-813Nm).
axle l)eing installed. It is important that the jacks being 6. Install the center pins (9) through the equalizer
used are easily adjustable and mounted on rollers. beams (6) . Place a thrust washer (not shown) on
Both jacks must be of adequate capacity to handle the each end of the center pin (9).
loads as follows: 7. Applya light coating of Loctite® 242 to the threads
of the capscrews (8).
Description Approximate Weight 8. Align and install the center pin caps (7) and
Front - Rear Axle 1,840Ib* (835kg) capscrews (8). Torque the capscrews (8) to
250-285 ft lb (339-386Nm) .
Rear-Rear Axle 1,510Ib* (685kg) 9. If removed, install the air springs (14) to the lower
Suspension Parts 1,000 lb (450kg) arms (3) and secure with washers and nuts (5) .
Hand tarque the nuts (5) to 20-30 ft lb
Tota l 4,350 Ib* (1 973kg)
(28-42Nm).
*AII axle assembly weights are approximate and 10. Raise the axles and position the lower arms (3) and
reflect axle being full of lubricant and tires removed. air springs (14) to the carrier frame .
6 of 8
11. Applya light coating 01 Loctite® 242 to the threads Final Installation Procedures
01 the capscrews (1). 1. Connect all remaining air lines which were
12. Install the cap s (2) and capscrews (1). Torque the disconnected .
capscrews (1) to 250-285 ft lb (339-386Nm) .
Reler to Figure 1.
13 . Install the tittings, lockwashers, and jam nuts (13)
2. Installthedrivetube(s) (4,10),asrequired. Relerto
and lockwashers and nuts (15) which secure the
SM Keysheet Area 01-022 "U-Joint Installation "
air springs (14).
tor the correct procedure.
14. Connect the air lines to the height control valves
(17). Ensure the littings (13) are properly aligned, 3. Install the tires and rims on the axle(s). Reler to SM
then hand torque the jam nuts (13) to 40-50 ft lb Keysheet Area 01-069 lor the correct procedure.
(56-70Nm) and the nuts (15) to 25-30 ft lb
(34-40Nm).
15 . Align the shock absorbers (21) to the lower arms
(3), and install the capscrews, washers , and lock
.A. DANGER
Follow the proper procedure when caging or
nuts (20). releasing the power spring of the dual air
16. Carelully raise the axles (11,12), and position the brake chamber. If proper directions are not
center pin (9) with the lower arms (3). followed, the chamber and its internal parts
17. Align the torque rods (30) to the mounting lugs could rapidly and forcefully explode. This
(16), and install the capscrews (31) , washers
may result in severe personal injury or death.
(32 ,33), and locknuts (34) . Torque the capscrews
Refer to SM Keysheet Area 01-027 for the
(31) to 245-260 ft lb (333-364Nm).
correct procedure. If any doubt exists as to
18. Align the torque rods (29) to the mounting lugs (16) ,
whether a potential safety hazard exists,
and Install the nuts (28).
contact your nearest distributor before these
19. Ensure that each olthe tapered stud connections are
procedures are attempted.
tight and not excessively worn or damaged. Torque
the nuts (28) to 175-225 II lb (238-305Nm).
4. II required, release the power springs on the dual
20. Install the bolts, washers, and locknuts (19) which
air brake chambers. Reler to SrvI Keysheet Area
attach the clevis rods (18) to the mounting Irames
01-027 lor the correct procedure.
01 the air springs (14).
5. Check the oillevel in each axle differential and each
wheel end. Add oil as required. See tl1e Operator's
Manual lor correct lubricants and procedures.
6. Start the engine and let idle lor live minutes .
Inspect the connections on the air lines lor leaks .
Repair il needed .
7. Test drive the crane to ensure the drive train is
operating normally belore returning the crane to
service.
7018
8 of 8
Hydraulic System Cleaning
Procedure
A WARNING
The hydraulic system 01 a crane can become hazardous. Serious personal injury ma y
contaminated very rapidly when a component in the result from misuse of these products. Read
system lails and breaks up. The contaminants Irom the and follow all the manufacturer's
lailed component must be removed Irom the hydraulic recommendations concerning solvents and
system belore they cause lailure 01 other components cleaning solutions.
in the system. To remove as much 01 the co ntaminants
in the system as possible, the lollowing procedure is 2. Thoroughly clean area to be disassembled with an
recommended. approved cleaning solvent to prevent contamina
tion Irom entering the oil circuits. Allow the area to
air dry.
A WARNING
3. Remove, disassemble, clean, and reassemble all
hydraulic components. (Control valves, cylinders ,
motors , etc.) Reler to th e appropriate section 01
hot. A sudden release of hot oil could cause Service Manual lor specilic removal and recondi
burns or other serious injury. Shutdown the tion procedures .
engine and exhaust all trapped hydraulic 4. Disconnect all hydraulic lines and drain as much oil
pressure from the system before removing as possible.
any line or component. 5. Install all the hydraulic components on the crane
and connect all the lines . Reler to the appropriate
1. Relieve any pressure in the hydraulic system and section 01 Service Manual lor specilic installation
drain the hydraulic system oil Irom the reservoir. procedures.
Follow the procedure as outlined in Operator's 6. Follow the procedures in Operator 's Manual to
Manual. change all hydraulic oil lilters and relill the hydraulic
reservoir.
7. Start the crane and inspect all connections lor
leaks.
8. Alter 50 hours 01 operation, all hydraulic oil lilters
must be changed again. Reler to Operator's
Manual lor the correct procedure.
1 012
2 of 2
12 11 A
4 5 7
13 11 10 9 8
1. Capscrews & Lockwashers 6. By - Pass Valve Assembly 10. Plate & Stud Assembl y
2. Cap 7. Can 11. Gask et
3. O - ring 8. DiHuser 12. Locknuts
4. Housing 9. Fllte r Elem ent 13 Spring
5. O-ring
Figure 1
Hydraulic Reservoir Filter Assembly
Refer to Figure 1.
Hydraulic Reservoir Filter 1. Thoroughly clean the exterior surface of the hy
Assembly, Recondition draulic reservoir filter assembly to prevent contam
ination from entering il.
This procedure covers the recondition of the
hyd raulic reservoir filter assembly. For re moval and
installation procedures, see SM Area 01 -039 . A WARNING
The internal components of the hydrau lic
Disassembly reservoir filter assembly are under load from
spring (13). A sud den release of capscrews
A WARNING
(1) and/ or locknuts (12) could cause the unit
to pop up rapidly and cause serious inj ury.
Remove capscrews (1) and locknuts (12)
slowly until tension is relieved from spring
(13) .
2. Remove capscrews and lockwashers (1) slowly to
rel ieve tension on spring (13 ).
3. Remove cap (2), o-ring (3) and spring (13). Ois
card 0- ring (3).
4. Remove lock nuts (12).
1 012
5, Remove housing (4), o-ring (5), gasket (11) and Assembly
plate and stud assembly (10), Discard o-ring (5)
and gasket (11), Unless stated otherwise , lubricate o-rings and
6, Remove bypass valve assembly (6) and lilter ele housing bares with hydrautic oil prior to assembly, See
ment (9) Irom can (7), Discard lilter element (9), Operator's Manuat lor correct type ,
7, II required, remove diffuser (8) Irom can (7),

A WARNING
A WARNING
hazardous. Serious personal injury may manufacturer's recommendations concerning
result from misuse of these products. Read these products.
recommendations concerning solvents and Reler to Figure 1,
cl eaning solutions. 1, II required, apply a light coat 01 Loctite R 242 to
threads 01 diffuser (8) and install on can (7).
1, Thoroughly clean all metal parts with an approved 2, Install lilter element (9) and by-pass valve assem
cleaning solvent. Place parts on a clean lint Iree bly (6) in can (7),
surface and allow to air dry, Exercise every precau 3, Install o-ring (5) in housing (4).
tion possible to keep all parts Iree 01 dust, dirt or 4, Instatl gasket (11) on plate and stud assembly (10) .
any other lareign material during assembly. 5, Install plate and stud assembly (10) , housing (4)
2, Carefully inspect all components lor damage, and locknuts (12),
wear, carrosion , deep scratches and scuffed met 6, Instatl o-ring (3) on cap (2) ,
al, Remove any burrs or sharp edges with a line 7, Appty a tight coat 01 Loctite,il 242 to threads 01
file , hone, emery cloth or crocus cloth , Inspect capscrews, tnstall spring (13), cap (2) and
springs carelully lar latigue and cracks , Replace capscrews and lockwashers (1),
any damaged component as required , Replace all 8. II hydraulic reservoir lilter assembly is not to be im
o-rings and gaskets, mediatety instalted on crane , plug all open ports to
3 , AII Loctite '" residue stlould be removed Irom prevent contamination and properly store ,
threads 01 tlardware and parts that are going to be
reused ,
4 , In the event 01 severe delects, contact lactory per
sonnet far directions whether to repair or reptace
an y majar component.
2 of 2
3
Split Flange 4. Gasket 6. Hydrau li c Line

2. Fllter 5. Capscrews 7. Capscrews
3 Reservoir
Figure 1
Hydraulic Reservoir Assembly
e. Fully retraet and position the boom, as re

Hydraulic Reservoir Filter, quired.
R& I 3. Shutdown the engine and disengage the main hy
draulie pump.
Thi s procedure covers the removal and installation of
the hydraulic reservoir filter. For recondition
procedure , see SM Keysheet Area 01-039. A WARNING
Removal Solvents and cleaning solutions can be
1. Lower, detach, and secure load , as required. result from misuse of these products. Read
2. Stabilize the crane for service as follows: and follow all the manufacturer's
a. Park the crane , out of the way, on a firm and recommendations concerning solvents a nd
level surface. cleaning solutions.
the tires. 4. Thoroughly clean the area to be disassembled with
c. Engage the swing park brake or travel swing an approved eleaning solvent to prevent eonta
lock , as required. mination. Allow the area to air dry.
1 of 4
A WARNING an approved cleaning sOlvent, air dried , and care
fully inspected.
Hydraulic oil is under pressure and may be 2. AII Loctite®, Permatex®, or other sealant residue
hot. A sud den release of hot oil could cause should be removed from threads of hardware and
burns or other serious injury. Shutdown the the mounting surfaces of parts that are going to be
engine and exhaust all trapped hydraulic reused. Prior to applying new thread locking com
pressure from the system befo re removing pounds or sealants, clean threads and surfaces
any line or component. wíth Loctite (~ 7070 Cleaner to ensure best perfor
mance of products.
5. Relieve the hydraulic system pressure as follows: 3. Remove all remianing gasket material from the fil
a. Relieve any residual pressure in the hydraulic ter head and reservoir.
reservoir by loosening the filler cap 1/4 turn. 4. Thoroughly inspect all parts for damage , wear, fa
b . Turn the ignition switch to "ON", but DO NOT tigue or stress fractures, and corrosion . Repair or
START THE ENGINE. Move the function lock replace as required.
out switch to the " OPERATE" position . 5. AII "s oft parts", such as seals, gaskets, back up
c . Work the crane control levers and outrigger rings , and o-rings, should be replaced.
switches back and forth several times. 6. Inspect the integrity of the hydraulic line that was
d. Turn ignition switch to the "OFF" position. removed . Repair or replace if required.
6. Check that all control levers are in the neutral posi 7. Inspect the filter element for contamination. Any
tion and move the function lockout switch to the dirt or foreign particles on the element may indicate
"DISABLE" position. excessive system contamination and imminent
Refer to Figure 1. component failure. Replace filter element as re
7. Remove the capscrews (7) and split f1ange (1) se quired .
curíng the hydraulic line (6) to the filter (2) . 8 . In the event of severe defects, contact factory per
8. Remove the o-ring (not shown) from the face of sonnel for directions whether to repair or re place
the hydraulic line (6). any major componen!.
9. Remove the capscrews (5) securing the filter (2) to
the top of the reservoir (3). Installation
10. Break the gasket (4) seal between the filter (2) and
th e reservoir (3).
Note: Use care not to bend any of the mating

A WARNING
surfaces when separating the filter and reser Lubricants, sealants, joint and thread locking
voi r. compounds, etc. can be hazardous. Serious
1 1. Carefully remove the filter (2) from the reservo ir (3). these products. Read and follow all
Note: Do not allow any gasket material to fall
these products.
into the reservoir.
12. Adequately cover the openíng to the reservoir (3) Refer to Figure 1.
to prevent contam ination. 1. Align the holes in the gasket (4) with the mounting
holes in the top of the reservoir (3) .
Cleaning And Inspection 2 . Install the filter (2) into the opening in the top of the
reservoir (3) .
A WARNING
Note: Be sure to orient the filter so that the port
for the hydraulic line is properly positioned.
hazardous . Serious personal injury may 3. Applya light coat of Loctite® 242 to the threads of
result from misuse of these products . Read the capscrews (5).
and follow all the manufacturer's 4. Secure the filter (2) to the reservoir (3) by evenly
recommendations concerning solvents and installing the capscrews (5) . Tighten the cap
cleaning solutions. screws (5) in a criss-cross pattern .
2 of 4
5. Install a new o-ring (not shown) in the end of the 9. Start the engine and let idle for five minutes. In
hydraulic li ne (6). spect the hydraulic connections for leaks. Repair
6. Applya light coat of Loctite® 242 to the threads of leaks as required.
the capscrews (7). 10. Complete the installation by testing ali related func
7. Align the end of the hydraulic line (6) with the filter tions of the hydraulic reservoir for proper opera
(2) and install the split flange (1) and capscrews tion. Normal operation of the hydraulic system
(7). should be confirmed. A general inspection of the
8. Check the hydraulic reservoir oil leve\. Add oil as components and systems in the areas adjacent to
required. See the Operator's Manual for correct the repair should al so be performed to ensure re
type and procedure. lated damage or wear is not present.
3 of 4
4 of 4
Solenoid Valves, General
Recondition
This procedure covers the recondition of solenoid 2
valves in general.
Disassembly 3
A WARNING 4
concerning solvents and cleaning solutions.
Serious personal injury may result from
misuse of these products.
1. Thoroughly clean the exterior surface of the valve

assembly with approved cleaning solven!.
5
CAUTION
Do not clamp valve housing in any form of 6
vice unless jaws are protected by a soft
material. Brass or wood are preferred.
10 7
2. Place the valve housing (10) in a vise.
3. Note position of prongs (5) on coil (4), to ensure
proper alignment during assembly. 8
4. Remove nut (1), washer (2), coil housing (3), coil
(4), and plate (6) from valve cartridge stem (8).
5. Remove val ve cartridge stem (8) from valve hous
9
ing (10).
6. Remove and discard o-rings (7,9). 'L-=-==--=1
l-===-J
f--===-1
I I
I I
A WARNING
I
I
I
I
I
I
Follow al! manufacturer's recommendations I I
concerning solvents and cleaning solutions. I I
L _ _ _ ...J
1 . Thoroughly clean all metal parts with an approved

cleaning solven!. Place parts on a clean lint free
tion possible to keep all parts free of dust, dirt, or any 1. Nut 6. Plate
other foreign material during assemb ly. 2. Washer 7. O-ring
2. Carefully inspect all components for damage, wear, 3. Coil Housing 8. Valve Cal1ridge Stern
corrosion, deep scratches, and scuffed metal. Re 4. Coil 9. O-ring
5. Prongs 10. Valve Housing
place any damaged component as required . AI
ways use new o-rings. Figure 1
Solenoid Valve Assembly
1 of 2
Assembly 3. Install o-rings (7,9) onto valve cartridge stem (8).
4. Install valve cartridge stem (8) assembly into valve
Lubricate o-rings and threads with clean hydraulic oil housing (10) .
prior to assembly. Refer to the Operator's Manual for
the correct type.
CAUTION
Torque is critical to operation of valve.
CAUTION
Do not clamp solenoid valve housing in any 5. Torque valve cartridge stem (8) assembly to torque
fo rm of vice unless jaws are protected by a value specified in chart below.
so ft material. Brass or wood are preferred. 6. Align prongs (5) on coil (4), as they were prior to dis
assembly and torque nut (1) to torque value speci
1. Place valve housing (10) in a vise. fied in chart below.
2. Install plate (6), coil (4), coil housing (3) , washer (2), 7. If solenoid valve assembly is not to be installed on
and nut (1) onto valve cartridge stem (8). crane immediately, plug all ports to prevent contam
ination from entering and store properly.
Note : Do not torque nut at this time. Nut will be
torqued after installation.
Torque Specification Chart
Solenoid Thread Size Solenoid Installation Torque Coil Installation Torque
.438 - 20 UNF I 10-14 ft lb (14-19Nm) 7-11 ft lb (10-15Nm)

-- - - -1--- - _ .
.750 - 16 UNF 15-19 ft lb (20-26Nm) 7-11 ft lb (10-15Nm)
- - - - -- - -- - ------ _ .._- -- .. - - -
.875 - 14 Ut\lF 20-24 ft lb (27-33Nm) 7-11 ft lb (10-15Nm)
- -- - - - ~ ._-- - - .- - - '
1.000 - 14 U N F 25-29 ft lb (34-39Nm) 7-11 ft lb (10-15Nm)

-'
1.250 - 14 UNF 30-34 ft lb (41-46Nm) 12-16 ft lb (16-22Nm)
.- - , .. t- -- --_ .
1.313-12UNF 35-38 ft lb (47 -52Nm) 12-16 ft lb (16-22Nm)

... .. .. -
- ..
1.625 - 12 Uf\IF 44-47 ft lb (60-64Nm) 12-16 ft lb (16-22Nm)
2012
Outrigger Solenoid Valve
Stack, Recondition
outrigger solenoid valve stack. For removal and
installation procedures, see SM Area 1-38 or 1-43.

Disassembly
during disassembly, cleaning , and inspection will aid in
A WARNING
cleaning solutions.
1. Thoroughly clean the exterior surface of the outrig

ger solenoid valve stack to prevent contamination
from entering it.
Note: Separating valve sections may not be re 27

quired. If replacing solenoid or spool seals
only, proceed to step 6. 1. End Brac kets 15. Spring Guide
2. Nuts 16. Solenoid
2. Remove nuts (2) from the threaded rods (24) at ei 3 Vatve Body 17. Capscrew
4. Spool 18. End Plate
ther end of the valve stack assembly.
5. Spring Base Washer 19. Ground Lead Wire
3. Remove end bracket (1) from the threaded rods 6. Spring 20. O-ring
(24). 7. O-rings 21. O-ring
8. Cone 22 . Seal Plate
Note: Note seal plate (22) and o-ring (23) posi 9. Plunge r 23. O-ring
tions to ensure proper installation. 10. Inner Flux Sleeve 24. Threaded Rod s
11. Guide Tube 25. Spring
12. Spring 26 . Plug
4. Remove valve body (3) and seal plates (22) from
13. Outer Flux Sleeve 27. O-ring
threaded rods (24). 14. Push Pin
5. Remove o-ring (23).
Figure 1
Outrigger Solenoid Valve Stack
1 of 2
6. Remove the capscrews (17) holding the solenoid Assembly
(16) to the valve body (3). Remove the end plate
(18) and ground lead wire (19). as required. Lubricate all o-rings, spools , threads, and housing
bores with hydraulic oil prior to assembly. See
Note: While removing the inner flux sleeve (10)
and outer flux sleeve (13), note their order of as
sembly. The two flux sleeves must be reassem
bled In the same order or the valve will not oper
ate correctly. A WARNING
7. Remove the solenoid (16); remove the spring
guide (15) and push pin (14) from the solenoid (16)
and remove o-rings (20,21) .
8. Remove the outer flux sleeve (13) and spring (12) .
9. Remove guide tube (11) from the valve body (3) .
these products.
10 . Remove the cone (8) and plunger (9) from the
guide tube (11). Remove o-rings (7) from cone
1. Install the spring (25), o-ring (27), and plug (26) .
(8).
2. Install the spool (4) , spring base washer (5). and
11 . Remove the inner flux sleeve (10) .
spring (6).
12 . Rem ove the spring (6). spring base washer (5),
and spool (4) from the valve body (3). Note: Refer to notes taken when removing inner
13 . Remove plug (26), spring (25), and o-ring (27). flux sleeve (10) and outer flux sleeve (13). The
14. Repeat steps 4 through 13 for remaining solenoid two flux sleeves must be reassembled in the
valve stacks, as required. same order for valve to operate correctly.
Cleaning And Inspection 3. Install the inner flux sleeve (10).
4. Install o-rings (7) on cone (8).
5. Install the plunger (9) and cone (8) in the guide
A WARNING 6.
7.
tube (11).
Install guide tube (11) in the valve body (3).
Install the spring (12) and outer flux sleeve (13).
hazardous. Serious personal injury may 8. Install o-rings (20,21) on spring guide (15) and
resull from misuse of these products. Read push pin (14).
and follow all the manufacturer's 9. Install spring guide (15) and push pin (14) in the so
recomme ndations concerning solvents and lenoid (16).
cleaning solutions. 10 . Position the solenoid (16) on the valve body (3) and
install end plate (18).
1. Thoroughly clean all metal parts with an approved 11 . Install ground lead wire (19), as required.
cleaning solvent. Place parts on a clean lint free 12 . Install capscrews (17).
tion possible to keep all parts free of dust, dirt, or Note: Refer to notes taken when removing seal
any other foreign matenal during assembly. plate (22) and o-ring (23) to ensure proper
2 . Carefully inspect all components for damage , installation.
wear, corrosion, deep scratches, and scuffed met
13. Install o-ring (23) .
al. Replace any damaged component as required. 14. Repeat steps 1 through 13 for rema ining solenoid
Replace all o-rings .
valve stacks.
3 . AII Loctite '·' or other sealant residue should be re
15. Install seal plates (22) and valve bodies (3) on
moved from threads of hardware and parts that are
threaded rods (24).
going to be reused. 16. Install end bracket (1) on the threaded rods (24).
17. Install nuts (2) on the threaded rods (24) .
18. If outrigger solenoid valve stack is not to be imme
diately installed on crane , plug all open ports to
prevent contamination and properly store.
2 of 2
1
~~
~.
5
.
L
-- ----- ___
~r . ~. ~ 24
lp- ----~ 9 ~
fI .~ 10 11
17 18 19 \
20 21 22 23
" Some assemblies utilize a diHerenl style spri ng ba se.
1. Capscrews 7. Spring 13 O -ring 19. O-ring
2. End Plate 8. Inner Flux Sl eeve 14. Gui de 20. O-ring
3. Groun d Wire 9. Guide Tube Assembly 15. Plunger 2 1. Plug
4. Solenoid Case 10 Spring 16. Pin 22. Mounting Brack ets
5. Solenoid 11. Spríng Base" 17. Guide Tube 23. Thread ed Rods & Locknu ts
6. Outer Flux Sleeve 12. Spool 18 Female Co ne 24. Control Valve Body
Figure 1
Solenoid Control Valve Assembly
Four Way Solenoid Valve,

Recondition A WARNING
This procedure covers the recondition 01 the lour way hazardous. Serious personal injury may
solenoid valve . For specilic removal and installation result from misuse of these products. Rea d
procedures, see SM Area 01 - 043. General removal and follow all the manufacturer's
and installation procedures lor hydraulic components recommendations concerning solvents and
can be lound in SM Keysheet Areas 01-079. cleaning solutions.
II parts are hard to disassemble and assemble, do not
use a hammer unless it has a soft lace, do not lorce 1. Note orientation 01 mounting brackets (22) and re
parts together, they must be Iree to turn and not bind . move threaded rods and locknuts (23) and mou nt
ing brackets (22) .
Disassembly 2 . Remove plug (21), as required.
It is a good practice when disassembling hydraulic 3 . Remove capscrews (1) securing end plate (2) an d
components to lay the parts out in the order that they solenoid (5) to the control valve body (24) .
were disassembled. Keep ing the parts in this order 4. Remove ground wire (3), il equipped .
during disassembly, cleaning , and inspection will aicl in 5 . Separate solenoid (5) from solenoid case (4) , as re
the assembly process . quired.
1 012
Note: When removing flux sleeves, note their Assembly
ord er of disassembly. The flux sleeves must be
assembled in the same order that they were Lubricate 0- rings, spool, and bores with hydraulic oil
disassembled or the valve will not operate prior to assembly. See Operator's Manual for correct
correctly. type.
6. Remove outer flux sleeve (6), spring (7), inner flux
7.
sleeve (8) , and guide tu be assembly (9).
Remove spring (10) and spring base (11). A WARNING
Note: Use care when removing spool from Lubricants, sealants, joint and thread locking
valve body. Do not force spool. Machined sur compounds, etc. can be hazardous. Serious
fa c es between spool and body are very close. personal injury may result from misuse of
8. Carefully remove spool (12). manufacturer's recommendations concerning
9. If necessary, disassemble guide tu be assembly these products.
(9) :
a. Remove 0- ring (20) from female cone (18). 1. If necessary, install solenoid case (4) onto solenoid
b. Remove guide (14) from guide tube (17). (5) .
c. Remove plunger (15) and pin (16) from guide 2. If necessary, assemble guide tube assembly (9) :
tube (17). a. Install o-rings (19 ,20) on female cone (18).
d . Remove female cone (18) from guide tube b. Install female cone (18) in guide tube (17) .
(17) . c . Install pin (16) and plunger (15) in guide tube
e. Remove o-rings (19,13) from female cone (17) .
(18) and guide (14) . d . Install o-ring (13) on guide (14) .
e. Install guide (14) in guide tube (17).
Note: Do not force spool into valve body. Ma
chined surfaces between spool and body are
A WARNING
very close. Spool should slide easily into place
once it is properly aligned.
Solvents and cleaning solutions can be 3 . Carefully install spool (12) into control valve body
hazardous. Serious personal injury may (24) .
res ult from misuse of these products. Read 4. Slide spring base (11) and spring (10) onto spool
and follow all the manufacturer's (12) .
reco mmendations concerning solvents and 5. Install inner flux sleeve (8) , spring (7) , outer flux
cleaning solutions. sleeve (6), and 9 uide tu be assembly (9) in solenoid
(5) .
1. Thoroughly clean all metal parts with an approved 6. Align solenoid (5) assembly to control valve body
cleaning solvent. Place parts on a clean , lint free (24). Carefully press guide tube assembly (9) so
surface and allow to air dry. Exercise every precau that o-ring (20) seats in control valve body (24) .
tion possible to keep all parts free of dust, dirt, or 7. Install end plate (2), ground wire (3), and cap
any other foreign material during assembly. screws (1).
8. Install plugs (21), as required .
wear, corrosion , deep scratches , and scuffed met 9 . Align mounting brackets (22) to control valve body
al. Remove any burrs or sharp edges with a fine (24) and install threaded rods and locknuts (23) .
file , hone , emery cloth, or crocus cloth. Replace Torque locknuts (23) to 300 in lb (34Nm) .
any damaged component as required . Replace all 10. If four way solenoid valve is not to be immediately
0- rings.
3. AII Loctite'" or other sealant residue should be re
contamination and properly store .
moved from threads of hardware and parts that are
going to be reused .
4 . In the event of severe defects , contact factory per
2 of 2
c. Turn the ignition switch to "ON ", but DO NOT
Outrigger Directional START THE ENGINE. Move the function lock
Control Valve, R & I out switch to the "OPERATE" position .
d. Work the crane control levers and outri gg er
This procedure covers the removal and installation of switch es back and forth several times .
the outrigger directional control valve. For recondition e. Turn ignition switch to the "OFF " position .
procedure, see SM Keysheet Area 01-043 . f. When pressure is fully relieved , close the drain
valves on the air system reservoir.
Removal 6. Check that all controllevers are in the neutral posi
1. Lower, detach, and secure load , as required. tion and move the function lockout switch to the
2. Stab ilize the crane for service as follows : "DISABLE" position.
a. Park the crane out of the way on a firm and level Refer to Figure 1.
surface. 7. Label for assembly purposes and disconnect the
b. Engage the park brake and/or properly block electrical connect ions (not shown) from the control
the tires . valve (5).
c. Engage the swing park brake or travel swing 8. Label for assembly purposes and disconnect the
lock. as required . hydraulic lines (2). Cap/plug the open hydraulic
d . Level the crane on fUIlY extended outriggers. ports and lines (2) to prevent excessive oil loss and
e. FUIlY retract and lower the boom . as required . contamination of the system .
3. Shutdown the engine and disengage the main hy 9. Remove locknuts and washers (3) from studs (4) .
draulic pump.
Note: For installation purposes, note the ori enta
tion of the control valve .
.A WARNING 10. Remove control valve (5) from carrier frame (1) .
hazardous. Serious personal injury may Cleaning And Inspection
cleaning solutions.
.A WARNING
approved cleaning solvent to prevent contamina result from misuse of these products. Re ad
tion . Allow the are a to air dry. and follow all the manufacturer's
.A WARNING 1. AII components should be thoroughly cleaned with

Hydraulic oil is under pressure and may be an approved cleaning solvent. air dried , and care
hoto A sudden release of hot oil could cause fUIlY inspected .
burns or other serious injury. Shutdown the 2 . AII Loctite ®, Permatex ···. or other sealant residue
engine and exhaust all trapped hydraulic should be removed from threads of hardware and
pressure from the system before removing the mounting surfaces of parts that are going to be
any line or component. reused . Prior to applying new thread locking com
pounds or sealants , clean threads and su rfaces
5. Relieve hydraulic system pressure as fOllows: with Loctite'''' 7070 Cleaner to ensure best perfor
a. Open the drain valve on the air system reser mance of products .
voirs to bleed the air system pressure. 3. Inspect the integrity of the hydraulic lines and elec
b. Relieve the hydraulic system precharge pres trical connections. Repair or replace if requ ired.
sure by loosening the filler cap, located on the 4. In the event of severe defects, contact factory per
hydraulic reservoir, 1/4 turno sonnel for directions whether to repair or replace
1 of 2
4 3
1. Carri er Frame 3. Washers & Locknuts 5. Control Valve

2. Hyd raulic Lines 4. Studs
Figu re 1
Outrigger Directional Control Valve Assy
Installation 3. Connect the hydraulic lines (2) to the control valve

(5).
4. Connect the electrical connections (not shown) to
A WARNING
5.
the control valve (5) .
Check hyd raulic reservoir oil level. Add oil as re
quired. See Operato r' s Manual for correct type
co mpounds , etc. can be hazardous. Serious and procedure.
personal injury may result from misuse of 6. Start the engine and let idle for five minutes. In
th ese products. Read and follow all spect the connect ions on the hydraulic lines for
manufacturer's recommendations concerning leaks . Repair if needed.
these products. 7. Complete the installation by testing all related func
tions of the outriggers for proper operation . Nor
Refer to Figure 1. mal operation of hydraulic and electrical systems
1. Prope rly align the control valve (5) to the carrie r should be confirmed. A general inspection of com
frame (1). ponents and systems in the areas adjacent to the
2 . Pos ition the cont rol valve (5) on the studs (4) and repair should also be performed to ensure related
install the washers and locknuts (3) . damage or wear is not present.
2 of 2
2 3 4
5
1. Carrier Frame
2. Control Valve
3. Washer & Locknuts
4. Hydraulic Lines
5. Electrical Connectors
Note : Type and orientation of fitting may vary from illustration.
Figure 1
5th Outrigger Directional Control Valve Assembly
5th Outrigger Directional

Control Valve, R & I A WARNING
This procedure covers the removal and instattation 01 hazardous. Serious personal injury may
the 5th outrigger directional control valve. For result from misuse of these products. Read
recondition procedure, see SM Keysheet Area and fotlow atl the manufacturer's
01-043. recommendations concerning solvents and
cleaning solutions.
Removal
1. Lower, detach, and secure the load , as required . 4 . Thoroughly clean the area to be disassembled with
2. Stabilize the crane lor service as fottows: an approved cleaning solvent to prevent conta
a. Park the crane, out 01 the way, on a firm and mination . Attow the area to air dry.
level surface .
the tires.
A WARNING
lock , as required . hot. A sudden release of hot oil could ca use
d. Level the crane on futty extended outriggers. burns or other serious injury. Shutdown the
e. Position/ lower the boom , as required. engine and exhaust atl trapped hydra ulic
3. Shutdown the engine and disengage the main hy pressure from the system before removi ng
draulic pump , as equipped . any line or component.
5. Relieve the hydraulic system pressure as lollows

a. Relieve any residual pressure in the hydraulic
reservoir by pushing the button on the
pressure relief valve located on the hydraulic
reservoir (if equipped), or slowly loosenin g the
hydraulic reservoir, until pres sure is fully
relieved.
1 012
b. Turn the ignition switch to "ON", but DO NOT 4. AII "soft parts", such as seals , gaskets, back up
STARTTHE ENGINE. Move the function lock rings , and o-rings , should be replaced.
out switch to the "OPERATE" position or the 5. Inspect the integrity of the hydraulic lines that are
gate lock lever to the "OPERATION" position, connected to the control valve. Repair or replace if
as equipped. required.
c . Work the crane controllevers and/or outrigger 6. Inspect the integrity of the electrical wires and con
switches back and forth several times. nectors that supply the control valve. Repair or re
d. Turn the ignition switch to the "OFF" position. place if required.
6. Check that all controllevers are in the neutral posi 7. In the event of severe defects , contact factory per
tion and move the function lockout switch to the sonnel for directions whether to repair or replace
"01 SABLE" position or the gate lock lever to the any major componen!.
" STOP" position, as equipped .
Refer to Figure 1. I nstallation
7. Remove any sheet metal required to gain access to
the control valve (2).
hydraulic lines (4) from the control valve (2). Cap/
A WARNING
plug the open hydraulic ports and lines (4) to pre compounds, etc. can be hazardous. Serious
vent excessive oil loss and contamination of the personal injury may result from misuse of
system. these products. Read and follow all
9. Label and disconnect the electrical connectors (5), manufacturer's recommendations concerning
of the control valve (2), from the carrier wire har these products.
ness.
10. Support the control valve (2) and remove the lock
nuts and washers (3) securing the control valve (2) Refer to Figure 1.
to the carrier frame (1). 1. Align the control valve (2) to the carrier frame (1).
11. Remove the control valve (2) from the carrier frame Note: Ensure the fittings for the hydraulic lines
(1) .
are correctly oriented and tightened.
Cleaning And Inspection 2. Secure the control valve (2) to the carrier frame (1)
by installing the locknuts and washers (3).
A WARNING
So lvents and cleaning solutions can be
3.
4.
Connect the hydraulic lines (4) to the control valve
(2).
Connect the electrical connectors (5) to the carrier
wire harness.
5. Check the hydraulic reservoir oillevel. Add oil as
required. See the Operator's Manual for the
cl eaning solutions.
Inspect the hydraulic connections for leaks .
1. Al! components should be thoroughly cleaned with
an approved cleaning solvent, air dried , and care
functions of the 5th outrigger for proper operation.
fully inspected.
Normal operation of the hydraulic, air, and
2 . AII Loctite®, Permatex®, or other sealant residue
electrical systems should be confirmed. A general
present.
mance of products.
3 . Thoroughly inspect all parts for damage, wear, fa
tigue or stress fractures, and corros ion . Repair or
2 of 2
gate lock lever to the "OPERATION" position,
Outrigger Function Control as equipped.
Valve, R & I d. Work the crane controllevers and /or outrigger
switch es back and forth several times .
This procedure covers the removal and installation of e. Turn ignition switch to the "OFF" position.
the outrigger function control valves. Although there f. When pressure is fully relieved, close the drain
are two outrigger function control valves , removal and valves on the air system reservoir.
installation for each is the same. For recondition 6. Check that all controllevers are in the neutral posi
procedure, see SM Keysheet Area 01 -043. tion and move the function lockout switch to the
"DISABLE" position or the gate lock lever to the
Removal "STOP" position, as equipped .
1. Lower, detach , and secure load , as required. Refer to Figure 1.
2. Stabilize the crane for service as follows: 7. Label far assembly purposes and disconnect the
a. Park the crane out of the way on a firm and level electrical connections (not shown) from the control
surface. Engage the park brake . valve (4) .
b. Engage the swing park brake or travel swing B. Label far assembly purposes and disconnect the
lock, as required. hydraulic lines (5). Cap/plug the open hydraulic
c. Level the crane on fully extended outriggers. ports and lines (5) to prevent excessive oilloss and
d. Position/support the boom , as required . contamination of the system.
3. Shutdown the engine and disengage the main hy 9. Remove the locknuts and spacers (2) from the
draulic pump. studs (3).
Note: For installation purposes, note the orienta

A WARNING tíon of the control valve.
Solvents and cleaning solutions can be 10. Remove the control valve (4) from the carrier frame
hazardous. Serious personal injury may (1) .
and follow all the manufacturer's Cleaning And Inspection
cleaning solutions.

A WARNING
hazardous. Seríous personal injury may
tion. Allow the area to air dry.
resutt from misuse of these products. Read
A WARNING
cteaning solutions.
hot. A sudden release of hot oil could cause 1. AII components should be thoroughly cleaned with
burns or other serious injury. Shutdown the an approved cleaning solvent, air dried , and care
engine and exhaust all trapped hydraulic fully inspected.
pressure from the system before removing 2. AII Loctite®, Permatex®, or other sealant residue
any line or component. should be removed from threads of hardware and
5. Relieve hydraulic system pressure as follows: reused. Prior to applying new thread locking com
a. Open the drain valve on the air system reser pounds or sealants, clean threads and surfaces
voirs to bleed the air system pressure. with Loctite® 7070 Cleaner to ensure best perfor
b. Relieve any residual pressure in the hydraulic mance of products.
reservoir by slowly loosening the filler/breather 3. Inspect the integrity of the hydraulic lines and elec
cap, located on the top of the hydraulic trical connections. Repair ar replace if required.
reservoir, until pressure is fully relieved . 4. In the event of severe defects, contact factary per
c. Turn the ignition switch to "ON" , but DO NOT sonnel for directions whether to repair or replace
STARTTHE ENGINE. Move the function lock any major componen!.
out switch to the "OPERATE" position or the
1 01 4
) I
.. .
~o ·
~ Ii
Bottom View
2 3 4 5 2 3 4 5
Front Rear
1 Carrier Frame 3. Studs 5. Hydraulic Unes

2 Locknuts & Spacers 4. Control Valve
Figure 1
Outrigger Function Control Valve Assy
2 of 4
Installation 3. Connect the hydraulic lines (5) to the control valve
(4) .
4. Connect the electrical connections (not shown) to
A WARNING
the control valve (4).
5 . Check hydraulic reservoir oil level. Add oil as re
Lubricants, sealants, joint and thread locking quired. See Operator's Manual far correct ty pe
compounds, etc. can be hazardous. Serious and procedure .
personal injury may result from misuse of 6. Start the engine and let idle for five minutes. In
these products. Read and follow all spect the connections on the hydraulic lines far
manufacturer's recommendations concerning leaks. Repair if needed.
tions of the outriggers for proper operation. Nor
Refer to Figure 1. mal operation of hydraulic and electrical systems
1. Properly align the control valve (4) to the carrier should be confirmed . A general inspection of com
frame (1). ponents and systems in the areas adjacent to the
2. Position the control valve (4) on the studs (3) , and repair should also be performed to ensure re lated
install the spacers and locknuts (2). damage or wear is not present.
3 of 4
4 of 4
3 4 5 6
7 8 9 10
17
Check valve with relief feature
MUST be located in this position.
1 Cylinder Case 6. Relief Valve Cariridge 10. Check Valve - W/Relief 14. Back Up Rlngs
2. Tube Assemblies 7. Check Valve 11. O-ring 15. Back Up Ring
3. Back Up Ring 8. O-ring 12 O -ring 16. O-ring
4. O-ring 9. Piston 13 Back Up Ring 17. O-ring
5. O-ring
Figure 1
Outrigger Lock Valve Cartridge
3. Extend the subject outrigger jack until the pontoon

Fifth Outrigger Lock Valve just contacts the ground . Do not allow the jack cyl
Cartridge, R & I inder to exert an y pressure on the ground.
This procedure covers the removal and installation 01 hydraulic pump, as equipped .
the lock valve cartridge, used on the fifth outrigger. Re
condition procedure is inclusive.
Removal A WARNING
1. Lower, detach , and secure load , as required.
2. Stabilize the crane lar service as follows : hazardous. Serious personal injury may
a. Park the crane out of the way on a lirm and level result from misuse of these products. Read
surface. Engage the park brake. and follow all the manufacturer's
b. Position/support the boom, as required. recommendations concerning solvents and
c. Engage the swing park brake or travel swing cleaning solutions .
lock, as required.
1 014
5. Thoroughly clean area to be disassembled with an 12. Remove the 0- rings (16 ,17) and back up ring (15)
approved cleaning solvent to prevent from the check valve (7).
contamination from entering the hydraulic oil
circuits. Allow the area to air dry. Note: Record position of check valve with relief.
It must be installed in same location .
A WARNING
13. Remove the second check valve (10) from the cyl
inder case (1) . Note the difference between this
check valve (10) and the first.
Hyd raulic oil is under pressure and may be
hot. A sudden release of hot oil could cause 14. Remove the 0- rings (11,13) and back up ring (12)
bu rns or other serious injury. Shutdown the from the check valve (10).
eng ine and exhaust all trapped hydraulic
pressure from the system befo re removing
any line or component. CAUTION
Use extreme care when removing the pisto n
6. To relieve hydraulic system pressure: from the cylinder case. Hydraulic
a. Open the drain valve on the air system reser components are machined to close
voirs to bleed the air system pressure. tolerances and are damaged easily.
b. Relieve the hydraulic system precharge pres
sure by pushing the button on the pressure re 15. Use a clean, non - metallic tool to remove the pis
lief valve , located on the hydraulic reservoir or ton (9) from the cylinder case (1).
loosen the filler cap 1/4 turn, as equipped . 16. Remove the back up rings (14) and 0- ring (8) from
c. Turn the ignition switch to "ON", but DO NOT the piston (9).
START THE ENGI NE. Move the function lock 17. If the lock valve cartridges are not going to be im
out swit ch to the "OPERATE" position or the mediately installed back in the cylinder case , plug
gate lock lever to the " OPERATION" position , the open hydraulic ports to prevent contamination
as equipped . of the system .
d. Work the crane control levers and outrigger
switches back and forth several times . Cleaning And Inspection
e. Turn ignition switch to the "OFF" position .
f. When pressure is fully relieved , close the drain
valves on the air system rese rvoir.
7 . Check that all control levers are in the neutral
A WARNING
position and move the function lockout switch to Solvents and cleaning solutions can be
the "DI SABLE" position or the gate lock lever to hazardous. Serious personal injury may
the "STOP" position , as equipped . result from misuse of these products. Read
8. Label for assembly purposes and disconnect the and follow all the manufacturer's
hydraulic tube assemblies (2) from the cylinder recommendations concerning solvents and
case (1 ). Cap/plug the open hydraulic ports an d cleaning solutions.
lines to prevent excessive oilloss and contamina
tion of the system . 1. AII components should be thoroughly cleaned with
fully inspected.
2. AII Loctite ' , Permatex ,or other sealant residue
CAUTION should be removed from threads of hardware and
la b el the positions of the two check valves the mounting surfaces of parts that are going to be
before removing. Mislocating the check reused . Prior to applying new thread locking com
valves in the cylinder case will cause the valve pounds or sealants, clean threads and surfaces
to malfunction. with Loctite'f, 7070 Cleaner to ensure best perfor
mance of products.
9 . Remove the relief valve cartridge (6). 3. AII "soft parts ", such as , back up rings , and 0
10. Remove the 0- rings (4,5) and back up ring (3) rings , should be replaced .
from relief valve cartridge (6) . 4. Clean and inspect cylinder case and internal ma
11 . Remove the check valve (7) from the cylinder case chined surfaces .
(1) .
2 of 4
5. Inspect the integrity 01 the hydraulic lines/hoses 3. Install the o-rings (11 ,12) and back up ring (13) on
that are connected to the jack cylinder being the check valve (10) .
serviced. Repair or replace il required.
6. In the event 01 severe delects , contact lactory
personnel lor d irections whether to repair ar CAUTION
replace any majar component.
Positions of the two check valves are critica l.
Mislocating the check valves in the cylinde r
Installation case will cause the valve to malfunction. See
Figure 1 for proper orientation 01 the check
A WARNING
4.
valves.
Install the check valve (10) in the cylinder case (1 ).

compounds, etc. can be hazardous. Serious Tarque the check valve (10) to 25 ft lb (34Nm ).
personal injury may result from misuse of 5. Install the o-rings (16,17) and back up ring (15) on
these products. Read and follow all the check valve (7) .
manufacturer's recornmendations concerning 6. Install the check valve (7) in the cylinder case (1).
these products . Torque the check valve (7) to 25 ft lb (34Nm) .
7. Connect the hydraulic tube assemblies (2) to the
cylinder case (1).
Lubricate all back up rings , o-rings, pistons, and
8. Install the o-rings (4,5) and back up rin g (3) on re
housing bores with Cosmolube #2, or equivalent ,
liel valve cartridge (6).
prior to assembly.
9. Install reliel valve ca rtridge (6) in cylinder case (1) .
1. Install the back up rings (14) and o-ring (8) on the Torque the reliel valve cartridge (6) to 25 ft lb
piston (9). (34Nm) .
required . See Operator 's Manual lar correct type
CAUTION and procedure .
Use extreme care when installing the piston in 11 . Start the engine and let idle lor live minutes .
the cylinder case. Hydraulic components are Inspect the connections on the hydraulic lines lor
machined to close tolerances and are leaks. Repair il needed.
damaged easily. Threaded surfaces are 12. Complete the installation by testing all relatecl
sharp. O-rings can be damaged as they are lunctions 01 the jack cylinder lor proper operation.
installed over threaded areas, causing the Normal operation 01 hydraulic and electrical
assembly to leak. systems should be conlirmed . A gene ral
inspection 01 components and systems in the
2. Use a clean, non-metallic tool to position the pis areas adjacent to the repair should also be
ton (9) in the cylinder case (1). perfarmed to ensure related damage ar wear is not
present.
3014
o".· ".
• .. o· · · ·
4 of 4

MUST be located In this position.
4 5 6 7
o o
o o
1. Cylinder Case 5 O -ri ng 9. O-ring 12. Ba ck Up Rlng

2. Tube Assembly 6 Piston 10. Back Up Ring 13. O- ring
3 Hose Assemblies 7. Check Valve - W/Rel ief 11 . Ba ck Up Ring s 14. O-ring
4. Check valve 8. O-ring
Figure 1
Outrigger Lock Valve Cartridge
3. Extend the subject outrigger jack until the pontoon

Outrigger Lock Valve just contacts the ground. Do not allow the jack cyl
Cartridge, R & I And inder to exert any pressure on the ground .
4. Shutdown the engine and disengage the ma in
Recondition hydraulic pump , as equipped .
This procedure covers the removal, installation, and re

condition of the lock valve cartridge.
Removal
A WARNING
1. Lower, detach, and secure load , as required. hazardous. Serious personal injury may
2. Stabilize the crane for service as follows: result from misuse of these products. Read
a. Park the crane out of the way on a firm and level and follow all the manufacturer's
surface . recommendations concerning solvents and
b . Engage the park brake and/or properly block cleaning solutions.
the tires .
c. Engage the swing park brake and/or trav el 5. Thoroughly clean area to be disassemb led with an
swing lock, as required . approved clean ing solvent to prevent
d . Position/support the boom, as required . contamination from entering the hydraulic oil
circuits. Allow the area to air dry.
1 014
12. Remove the 0- rings (8,10) and back up ring (9)
A. WARNING
from the check valve (7) .
hot. A sud den release of hot oil could cause

burns o r other serious injury. Shutdown the
CAUTION
engine and exhaust all trapped hydraulic Use extreme care when removing the pisto n
pressure from the system befo re removing from the cylinder case. Hydraulic
any line or component. components are machined to close
tolerances and are damaged easily.
6 . To relieve hydraulic system pressure:
a. Release any residual pressure in the carrier 13. Use a clean, non-metallic tool to remove the pis
hydraulic reservoir by slowly loosening the ton (6) from the cylinder case (1).
filler/ breather cap, located on the top of the 14. Remove the back up rings (11) and 0- ring (5) from
hydraulic reservoir, until pressure is fully the piston (6).
relieved. 15. If the lock valve cartridges are not going to be im
b. Turn the ignition switch to "ON", but DO NOT mediately installed back in the cylinder case, plug
STARTTHE ENGINE. Move the function lock the open hydraulic ports to prevent contamination
out switch to the "OPERATE" position or the of the system .
gate lock lever to the "OPERATION" position , Cleaning And Inspection
as equipped.
c . Work the Crane controllevers and/or outrigger
7.
sw itches back and forth several times.
d. Turn ígnition switch to the "OFF" posítion.
Check that all control levers are in the neutral
A. WARNING
position and move the function lockout switch to hazardous. Serious personal injury may
the "DI SABLE" position or the gate lock lever to result from misuse of these products. Read
the "STOP" position, as equipped. and follow all the manufacturer's
Refer to Figure 1. recommendations concerning solvents and
8. Label for assembly purposes and disconnect the cleaning solutions.
hydraulic tube assembly (2) and hose assemblies
(3) from the cylinder case (1). Cap/plug the open 1. AII components should be thoroughly cleaned with
hydraulic ports and lines to prevent excessive oil an approved cleaning sOlvent , air dried, and care
loss and contamination of the system . fully inspected.
2. Thoroughly clean the cylinder case as well, using
only clean hydraulic oil . Flushing the ports and pis
ton bore with a solvent may contaminate the cylin
CAUTION der and ultimately the hydraulic system.
Label the positions of the two check valves 3. AII Loctite !' residue should be removed from
before removing. Mislocating the check threads of hardware and parts that are going to be
valves in the cylinder case will cause the valve reused.
to malfu nction. 4 . In the event of severe defects, contact factory
personnel for directions whether to repair or
9. Remove the check valve (4) from the cylinder case replace any major component.
(1) . 5. AII "soft parts", such as, back up rings, and 0
10. Remove the o-rings (13 ,14) and back up ring (12) rings, should be replaced.
from the check valve (4) . 6. Inspect the integrity of the hydraulic lines/hoses
11 . Remove the second check valve (7) from the cylin that are connected to the jack cylinder being
cler case (1) . Note the difference between this serviced. Repair or replace if required.
ch eck valve (7) and the first.
2 of 4
Installation
CAUTION
A WARNING
Positions of the two check valves are critica!.
Mislocating the check valves in the cylinder
case will cause the valve to malfunction. See
compounds, etc. can be hazardous. Serious Figure 1 for proper orientation of the chec k
personal injury may result from misuse of valves
manufacturer's recommendations concerning 4. Install the check valve (7) in the cylinder case (1).
these products. Torque the check valve (7) to 25 ft lb (34Nm)
5. Install the 0- rings (13,14) and back up ring (12) on
the check valve (4) .
Lubricate all back up rings, 0- rings , pistons, and
6. Install the check valve (4) in the cylinder case (1).
housing bores with hydraulic oil prior to assembly. See
Torque the check valve (4) to 25 ft lb (34Nm)
Operator's Manual lor correct type.
Note: If the orifice disc was removed with th e hy
Reler to Figure 1.
draulic line, install it with the beveled edge facing in
1. Install the back up rings (11) and o-ring (5) on the
ward .
piston (6).
7. Connect the hydraulic tube assembly (2) and hose
assemblies (3) to the cylinder case (1) .
CAUTION 8. Check hydraulic reservoir oil leve!. Add oil as
Use extreme care when installing the piston in required. See Operator 's Manual lor correct type
the cylinder case. Hydraulic components are and procedure.
machined to close tolerances and are 9. Start the engine and let idle lor live minutes .
damaged easily. Threaded surfaces are Inspect the connections on the hydraulic lines lor
sharp. 0- rings can be damaged as they are leaks. Repair il needed .
installed over threaded areas, causing the 10. Complete the installation by testing all related
assembly to leak. lunctions 01 the jack cylinder lor proper operation.
Normal operation 01 hydraulic and electrical
2. Use a clean, non-metallic tool to position the pis systems should be conlirmed . A general
ton (6) in the cylinder case (1). inspection 01 components and systems in the
3. Install the 0- rings (8,9) and back up ring (10) on areas adjacen t to the repair should also be
the check valve (7). perlormed to ensure related damage or wear is not
present.
3014
4014
~------------------~~~--~~--J ~ ~, , lo.
- ,~
.'
Case Length
2 3 7 8 9 10 11 *
6 5 4 15 14 13
Note If required, drill setscrew hole as follows: drill O 7/32- B X 0.50-0.63 at thread interface.
Tap 0.25-28UNF-2B X 0.25-0.38 (0.211 -0.220 minar O ).
1. Wear Ring 5 O-ring 9. O-ring 13. Wiper
2. Piston Seal 6. Locknut 10. Back Up Rlng 14. Rod Seal
3. O-ring 7. Case 11. Setscrew 15. Wear Rlngs
4. Piston 8. Rod 12 . Head
Figure 1
Bottom Outrigger Beam Cylinder Assembly
Bottom Outrigger Beam Disassembly

Cylinder, Recondition It is a good practice when disassembling hydraulic
components to lay the parts out in the arder that they
This procedure covers the recondition 01 the bottom were disassembled. Keeping the parts in this order
outrigger beam cylinder. For removal ancl installation during disassembly, cleaning, and inspection will aid in
procedures, see SM Keysheet Area 01 -045. the assembly process.
1 016
S M0 1 -045-048.00 0108 Service Manual
64. 20 163.07 12153 308 69 85 39 77 35 078 2.95 1.22 4.62 4,500 3 1 028
74 83 190.07 12746 3 23.75 90 41 82 37 0 .72 2.73 1.12 4.24 4,500 3 1 028
Table A
Cylínd er Specifications

use a hammer unless it has a soft face, do not force CAUTION
parts together, they must be free to rotate/operate and Use care not to damage the chrome finish on
not bind . the rod. Any nicks or scratches could result in
cylinder leakage. Weld splatter may also do
A WARNING
damage. When using a vise, clamp to
portions on the rod which are not chrome
plated, or protect the chrome surface with a
hazardous. Serious personal injury may soft material befo re clamping .
result f rom misuse of these products. Read 7. Remove the rod (8), with head (12) and piston (4)
and f ollow all the manufacturer's attached , from case (7).
recom mendations concerning solvents and 8. Remove the locknut (6) securing th e piston (4) to
cleaning solutions. lile rod (8)
9. Remove the piston (4) from the rod (8) .
1. Drain any excess hydraulic oil, remaining within 10 . Remove the 0- ring (5) from th e rod (8).
the cylinder, into an appropriate con tainer. Proper 11 . Remove the piston seal (2) , 0- ring (3), and wear
Iy store or dispose of the used oil. ring (1) from the piston (4).
2 . Cap/ plug any openings in the cylinder. Thoroughly 12. Slide the head (12) off the rod (8).
Cl f:'d n the exterior surface of the beam cy linder to 13. Remove the o-ring (9) , back up ring (10), wear
prevent contamination from entering it. rings (15) , wiper (13), and rod seal (14) from the
Refer to Figure 1. head (12).
3. Prepare to extend the rod (8) which may produce a
fl ow 01 oil from the supply and/or return ports of the Cleaning And Inspection
case (7) . Remove the plugs which were installed in
the cylinder during the cleaning process . Place a
container, of adequate size, below the open ports .
4 . Fully retract , then extend th e rod (8) until th e piston
A WARNING
(4) contacts the head (12). Drain any hydraulic oil Solvents and cleaning solutions can be
into an appropr iate conta in er. Plug ports and prop hazardous. Serious personal injury may
erly store or dispose 01 used oil. result from misuse of these products. Read
Note: Position the piston approximately 4 in and follow all the manufacturer's
(10cm ) from fuI! extend during disassembly to recommendations concerning solvents and
reduce binding which may damage seals. cleaning solutions.
5. Remove the setscrew (11) which secures the head
(12) . 1. Thoroughly clean all metal parts with an approved
6 Using a spanner wrench, rotate th e head (12), cleaning solvent. Place parts on a clean , lint free
counterclockwise , until its threads disengage the surlace and allow to air dry, Exercise every precau
case (7) . tion poss ible to keep all parts free of dust , dirt , or
any other foreign mater ial during assemb ly.
Note: If the head is hard to remove or moves er
ratically, it may be necessary to tap the case ad
jacent to the head with a brass or plastic mallet
while tu rn ing the head.
2 of 6
2. AII Loctite®, Permatex®, or other sealant residue d. Case: Visually inspect the inside bore lor
should be removed Irom threads 01 hardware and scratches or pits. There should be no
the mounting surlaces 01 parts that are going to be scratches or pits deep enough to catch the lin
reused . Prior to applying new thread locking com gernai!. Scratches that catch the lingernail but
pounds or sealants, clean threads and surlaces are less than 0.50 in (1.27cm) long, and pri
with Loctite® 7070 Cleaner to ensure best perfor marily in the circumlerential direction are ac
mance 01 products. ceptable provided they cannot cut the piston
3. Carelully inspect all components lor damage , sea!. The roughness 01 the bore should be be
wear, latigue or stress Iractures, corros ion , deep tween 10-20 J.1inch (0.25-0.50micron) RMS.
scratches, cracks, and scuffed meta!. Remove any Variations greater Ihan 8 J.1inch (0 .2micron) are
burrs or sharp edges with a line lile, hone, emery unacceptable. In the event that an unaccept
cloth , or crocus cloth. Replace any damaged com able condition occurs, the case should be re
ponent, as required, using the lollowing guide paired or replaced.
lines: e. Seals and wear rings: Replace all seals and
a. Rod : Visually inspect the rod lor scratches or wear rings whenever disassembling the beam
pits. There should be no scratches or pits cylinder.
deep enough to catch the lingernai!. Pits that 4. In the event 01 severe delects , contact lactory per
go to the base metal are unacceptable. sonnel lor directions whether to repair or replace
Scratches that catch the lingernail but are not any majar component.
to the base metal, less than 0.50 in (1.27cm)
long, and primarily in the circumlerential direc Assembly
tion are acceptable provided they cannot cut
Lubricate all back up rings , o-rings , seals, wear rings ,
the rod sea!. Chrome should be present over
the entire surlace 01 the rod and the lack there and case bore with clean hydraulic oil prior lo
01 is unacceptable. In the event that an unac assembly. See Operator's Manual lar correct type .
ceptable condition occurs , the rod should be Soak new pislon seal , wiper, wear rings , and rod seal in
repaired or replaced. clean hydraulic oil which has been heated to a temper
b. Head: Visually inspect the inside bore lor ature 01100-120 ° F (39-49° C). Allow adequate time
scratches or polishing . Deep scratches are lar Ihe parts to reach the lemperature 01 the hydraulic
unacceptable. Polishing indicates uneven oil which will greatly ease their assembly.
loading and when this occurs, the bore should Do not over slrelch the seals or 0- rings during installa
be checked lor out - 01 - roundness . II out lion . Make sure that o-rings, back up rings , and seals
ol-roundness exceeds 0.007 in (O. 178mm) , are not Iwisled after assembly. Allow one hour lar soft
this is unacceptable. Damage to the seal parts lO return lo Iheir original shape belore installing
grooves, particularly on the sealing surlaces , the pistan and head into the case.
is unacceptable. In the event that an unac
ceptable condition occurs, the head should be
repaired or replaced.
c. Piston : Visually inspect the outside surface lor
A WARNING
scratches or polishing. Deep scratches are compounds, etc. can be hazardous. Seriou s
unacceptable. Polishing indicates uneven personal injury may result from misuse 01
loading and when this occurs , the diameter these products. Read and follow all
should be checked lor out-ol-roundness. II manufacturer's recommendations concerning
out-ol-roundness exceeds 0.007 in these products.
(O. 178mm) , this is unacceptable . Damage to
the seal grooves, particularly on the sealing
surfaces , is unacceptable. In the event that an
unacceptable condition occurs, the pisto n
should be repaired or replaced.
3016
8. Install the rod (8), with the head (12) and piston (4)
attached, into the case (7). Use care to avoid dam
aging the wear ring (1) and piston seal (2) on the
internal threads of the case (7). Watch the seals as
they pass over the ports in the case (7) to be sure
they are not nicked or cut.
9. Applya light coat ofThread-Eze '" Ultra, or equiv
alent, to the threads of the head (12).
10. Insert the head (12) into the case (7) and engage
the threads. Use care to avoid damaging the the
0- ring (9) and back up ring (10) on the internal
threads of the case (7).
11. Turn the head (12), counterclockwise, until the lirst
thread just passes the engagement point with the
Note: Form seal, as shown, to prevent seal case [the head (12) will move noticeably].
from twisting during installation
12. Rotate the head (12) by hand , clockwise , until the
Figure 2 threads of the head (12) have properly started to
" C" Shape Seallnstallation engage with the case (7) .
13. Continue rotating the head (12), clockwise, until it
Refer to Figure 1. contacts the case (7). Using a spanner wrench ,
1. Install the 0- ring (9), back up ring (10) , wear rings tighten the head (12) 1/8 to 1/4 turn past fully
(15), rod seal (14), and wiper (13) in the head (12). seated.
Note: It may be necessary to form the rod seal 14. Install the setscrew (11) to secure the head (12) in
a nd/or wiper into a "C-shape", as shown in the case (7).
Figure 2, and held in that position to start instal 15. Test the cylinder per the procedure given later in
lation. Once installed, allow the assembly to sit this document.
for at least one hour to allow the seals elasticity 16. If cylinder is not to be installed immediately on
to resto re. crane, plug all open ports to prevent contamination
and properly store.
2. Slide the head (12) on the rod (8) .
3. Install the wear ring (1),0- ring (3), and piston seal Cylinder Test Procedures
(2) on the piston (4). Do not open the wear ring (1)
any wider than necessary to fit them on the piston Low Pressure Leakage & Static Friction Test
(4) . 1. Fill the lully retracted cylinder with hydraulic oil. Re
ler to the Operator's Manual for the grade 01 oil to
use.
CAUTION 2. Using only the pressure level which is required to
Use care not to damage the chrome finish on move the cylinder rod at a steady rate, cycle the
the rod. Any nicks or scratches could result in cylinder full stroke each direction a minimum ollive
cyl inder leakage. Weld splatter may also do times to remove entrapped air. If the cylinder
damage. When using a vise, clamp to squeaks or sticks, disassemble the cylinder and
portions on the rod which are not chrome replace the defective part and repeat the entire test
pl ated, or protect the chrome surface with a procedure.
soft material before clamping. 3. Stop the rod at mid stroke and examine the cylin
derfor any externalleakage . No leakage is accept
4. Install the o-ring (5) on the rod (8). able. 1I rod seal or any other external leakage ex
5. Install the piston (4) onto the rod (8). ists, disassemble the cylinder and replace the de
6. Secure the piston (4) to the rod (8) by installing the lective parts. Repeat the entire test procedure as
locknut (6). Torque the locknut (6) to 250-300 ft required.
lb (350-420Nm). 4. Fully retract the cylinder.
7. Olp the entire piston (4) and rod (8) assembly into
clean hydraulic fluid.
4 of 6
5. Slowly increase the pressure on the extend side 01 2. Relieve pressure and examine the cylinder lor
the cylinder to a maximum 0175 psi (517kPa). The structural failure evidenced by external leakage.
cylinder rod should begin to extend prior to reach No leakage is acceptable, except lor the leakage
ing the maximum pressure stated. Note the pres accumulated in the low pressure test. 1I rod seal or
sure required to initiate movement of the cylinder any other externalleakage exists , disassemble the
rOd , termed "breakaway pressure". If breakaway cylinder and replace the defective parts . Repeat
pressure exceeds 75 psi (517kPa) , disassemble the entire test procedure as required .
the cylinder and replace the defective part and re 3. Fully retract the rod and pressurize to the "Test
peat the entire test procedure. Pressure" specilied in Table A. Hold this pressure
6. Once the breakaway pressure is obtained, the lor a minimum of one minute . Leakage across the
pressure needed to maintain movement of the cyl piston should not exceed 0 .33 cc/min .
inder rOd , is termed " running pressure" . Running 4. Once again, examine the cylinder lor externalleak
pressure should not exceed 80% of the breakaway age. No leakage is acceptable, except for the leak
pressure and should diminish to 20% of the break age accumulated in the low pressure test. 1I rod
away pressure as the cylinder is extended . If run seal or any other external leakage exists, disas
ning pressure exceeds these guidelines, disas semble the cylinder and replace the defective
semble the cylinder and replace the defective parts parts. Repeat the entire test procedure as requi
and repeat the entire test procedure. red.
5. If cylinder is not to be installed on crane immediate
High Pressure Leakage Test Iy, plug all open ports to prevent contamination and
1. Extend the rod to full stroke and pressurize to the properly store.
"Test Pressure " specilied in Table A. Hold this
pressure for a minimum 01 one minute. Leakage
across the piston should not exceed 0.33 cc/ min .
5016
6 of 6
'lJ 1 ""~f
l
._I~
1
' J
'~1
J
Case Length -~
2 3 4 5 6 10 11 12 13 14
9 8 7 18 17 16 15
1 Wear Ring 6. Spacer 11 O-ring 15 Wipe r

2. Pistan Seal 7. O-rings 12. Back Up Ring 16. Rad Seal
3. O-ring 8. O-ring 13, Head 17. Wear Rings
4, Setscrews 9. Adaptar 14, O-ring 18. Case
5 Pistan 10. Rad
Figure 1
Top Outrigger Beam Cylinder Assembly
Top Outrigger Beam Disassembly

Cylinder, Recondition It is a good practice when disassembling hydraulic
components to lay the parts out in tlle order that they
This procedure covers the recondition of the top were disassembled, Keeping the parts in this arder
outrigger beam cylinder. Far removal and installation during disassembly, cleaning, and inspection will aid in
procedures, see SM Keysheet Area 01 -045. the assembly process.
1 of 6
S M0 1-045-049.00 0108 Service Manual
57.02 144.83 98.42 249.99 60 27 53 24 0 .62 2 35 0 .9 1 3. 44 4,500 37028
69.81 777.32 125.19 3 77.98 75 34 66 30 0 .75 284 1 .17 4.43 4,500 3 1 028
Table A
Cylinder Specifications
II parts are hard to disassemble and assemble , do not

use a hammer unless it has a soft lace, do not lorce CAUTION
parts together, they must be Iree to rotate/operate and Use care not to damage the chrome finish on
not bind the rod. Any nicks or scratches could result in
A WARNING
portions on the rod which are not chrome
hazardo us . Serious personal injury may soft material before clamping.
result fro m misuse of these products. Read 6. Remove the rod (10), with head (13) and piston (5)
and fo llow all the manufacturer's attached, Irom case (18) .
recomm endations concerning solvents and 7. Remove the setscrews (4) which secure the piston
cleaning solutions. (5) to the rod (10) .
8. Remove the piston (5), adaptor (9), and spacer (6)
1. Drain any excess hydraulic oil , remainin g within Irom the rod (10) .
the cylinde r, into an appropriate container. Proper 9. Remove the piston seal (2) , o-ri ng (3) , and wear
Iy store or dispose 01 the used oil. ring (1) from the piston (5) .
2. Cap/ pl ug any open ings in the cylinder. Thoroughly 10. Remove the o-rings (7,8) from the adaptor (9).
clean the exterior surlace 01 the beam cylinder to 11 . Slide the head (13) off the rod (10) .
prevent contamination lrom entering il. 12 . Remove the o-rin gs (11,14) , back up rin g (12) ,
Refer to Fig u re 1 . wear rings (17) , wiper (15) , and rod seal (16) Irom
3. Pr epare to extend the rod (10) which may produce the head (13).
a Ilow of oil Irom the supply and/or return ports 01
the case (18) . Remove the plugs which were Cleaning And Inspection
installed in the cylind er during lile cleaning pro
cess. Place a container, 01 adequate size , below
the open ports .
4. Fully retra ct, then exte nd the rod (10) until the A WARNING
pacer (6) contacts the head (13) . Drain any hy Solvents and cleaning solutions can be
draulic oil into an appropriate container. Plug ports hazardous. Serious personal injury may
and properly store or dispose 01 used oil. result from misuse of these products. Read
Note: Position the piston approximately 4 in and fo"ow all the manufacturer's
(10cm) f rom full extend during disassembly to recommendations concerning solvents and
reduce binding which may damage seals. cleaning solutions.
5. Using a spanner wren ch, rotate the head (13) ,
counterclockwise, until its threads disengage the 1. Tlloroughly clean all metal parts with an approved
case (18). cleaning solven!. Pla ce parts on a clean , lint Iree
surfa ce and allow to air dry. Exercise every precau
Note: If t he head is hard to remove or moves er tion possible to keep all parts Iree of dust, dirt , or
ratica"y, it may be necessary to tap the case ad any other foreign material during assembly.
jacent t o t he head with a brass or plastic mallet
while turn ing the head.
2 016
2. AII Loctite®, Permatex®, or other sealant residue d. Case: Visually inspect the inside bore for
should be removed from threads of hardware and scratches or pits. There should be no
the mounting surfaces of parts that are going to be scratches or pits deep enough to catch the fin
reused . Prior to applying new thread locking com gernail. Scratches that catch the fingernail but
pounds or sealants , clean threads and surfaces are less than 0.50 in (1.27cm) long, and pri
with Loctite® 7070 Cleaner to ensure best perfor marily in the circumferential direction are ac
mance of products. ceptable provided they cannot cut the piston
3. Carefully inspect all components for damage , seal. The roughness of the bore should be be
wear, fatigue or stress fractures , corrosion, deep tween 10-20 flinch (0.25-0.50micron ) RMS .
scratches, cracks , and scuffed metal. Remove any Variations greater than 8 flinch (0 .2m icron) are
burrs or sharp edges with a fine file , hone, emery unacceptable . In the event that an unaccept
cloth , or crocus cloth . Replace any damaged com able condition occurs, the case shoulcl be re
ponent , as required , using the following guide paired or replaced.
lines: e. Seals and wear rings: Replace all seals an d
a. Rod : Visually inspect the rod for scratches or wear rings whenever disassembling the beam
pits. There should be no scratches or pits cylinder.
deep enough to catch the fingernail. Pits that 4. In the event of severe defects , contact factory per
go to the base metal are unacceptable . sonnel for directions whether to repair or replace
Scratches th at catch the fingernail but are not any major component.
to the base metal , less than 0 .50 in (1 .27cm)
long, and primarily in the circumferential direc Assembly
tion are acceptable provided they cannot cut
the rod seal. Chrome should be present over Lubricate all back up rings , 0- rings , seals , wear rings ,
the entire surface of the rod and the lack there and case bore with clean hydraulic oil prior to
of is unacceptable. In the event that an unac assembly. See Operator's Manual for correct type .
ceptable condition occurs, the rod should be Soak new piston seal, wiper, wear rings , and rod seal in
repaired or replaced. clean hydraulic oil which has been heated to a te mper
b. Heacl: Visually inspect the inside bore for ature of 100-120 °F (39-49 ° C). Allowadequatetime
scratches or polishing. Deep scratches are for the parts to reach the temperature of the hydraulic
unacceptable. Polishing indicates uneven oil which will greatly ease their assembly.
loacling and when this occurs, the bore should Do not over stretch the seals or 0- rings during installa
be checked for out-of-roundness. If out tion. Make sure that 0- rings, back up rings , ancl seals
of-roundness exceeds 0.007 in (O. 178mm), are not twisted after assembly. Allow one hour for soft
this is unacceptable . Damage to the seal parts to return to their original shape before installing
grooves , particularly on the sealing surfaces , the pisto n and head into the case.
is unacceptable. In the event that an unac
ceptable con clition occurs , the head should be
repaired or replaced .
c. Piston : Visually inspect the outside surface for
A WARNING
scratches or polishing . Deep scratches are compounds, etc. can be hazardous . Serio us
unacceptable . Polishing indicates uneven personal injury may result from misuse 01
loading and when this occurs, the diameter these products. Read and follow all
should be checked for out-of-roundness. If manufacturer's recommendations concerni ng
out-of-roundness exceeds 0.007 in these products.
(O. 178mm), this is unacceptable. Damage to
the seal grooves , particularly on the sealing
surfaces , is unacceptable. In the event that an
unacceptable condition occurs, the piston
should be repaired or replacecl.
3 of 6
8. Dip the entire piston (5) and rod (10) assembly into
clean hydraulic fluid.
9. Install the rod (10), with the head (13) and piston
(5) attached, into the case (18) . Use care to avoid
damaging the wear ring (1) and piston seal (2) on
the internal threads of the case (18). Watch the
seals as they pass over the parts in the case (18) to
be sure they are not nicked or cut.
10. Applya light coat ofThread-Eze " Ultra, or equiv
alent, to the threads of the head (13).
11. Insert the head (13) into the case (18) and engage
the threads . Use care to avoid damaging the the
o-ring (11) and back up ring (12) on the internal
threads of the case (18) .
Note: Form seal, as shown, to prevent seal
12. Turn the head (13) , counterclockwise, until the first
fro m twisting during installation
thread just passes the engagement point with the
Figure 2 case [the head (13) will move noticeably].
" C " Shape Seal Installation 13. Rotate the head (13) by hand, clockwise, until the
threads of the head (13) have properly started to
Refer to Figure 1. engage with the case (18).
1. Install the o-rings (11 ,14), back up ring (12), wear 14. Continue rotating the head (13). clockwise, until
rings (17), rod seal (16), and wiper (15) in the head the o-ring (14) contacts the case (18). Using a
(13). spanner wrench, tighten the head (13) 1/ 8 to 1/4
Note: It may be necessary to form the rod seal turn past fully seated .
and/or wiper into a "C-shape", as shown in 15. Test the cylinder per the procedure given later in
Fig ure 2, and held in that position to start instal this document.
lation. Once installed, allow the assembly to sit 16. If cylinder is not to be installed immediately on
for at least one hour to allow the seals elasticity crane, plug all open ports to prevent contamination
to resto re. and properly store .
2. Slide the head (13) on the rod (10). Cylinder Test Procedures
3. Install the o-rings (8,7) in the adaptor (9).
4. Slide the spacer (6) on the rod (10) and the adaptor Low Pressure Leakage & Static Friction Test
(9) into the end of the rod (10). 1. Fill the fully retracted cylinder with hydraulic oil. Re
5. Install the wear ring (1),0- ring (3), and piston seal fer to the Operator 's Manual for the grade of oil to
(2) on the plston (5) . Do not open the wear ring (1) use.
any wider than necessary to fit them on the piston 2. Using only the pressure level which is required to
(5) . move the cylinder rod at a steady rate , cycle the
cylinder fu 11 stroke each direction a minimum of five
times to remove entrapped air. If the cylinder
CAUTION squeaks or sticks, disassemble the cylinder and
Use care not to damage the chrome finish on replace the defective part and repeat the entire test
the rod. Any nicks or scratches could result in procedure.
cyli nder leakage. Weld splatter may also do 3. Stop the rod at mid stroke and examine the cylin
da mage. When using a vise, clamp to der for any externalleakage. No leakage is accept
portions on the rod which are not chrome able. If rod seal or any other externalleakage ex
plated, or protect the chrome surface with a ists , disassemble the cylinder and replace the de
50ft material before clamping. fective parts . Repeat the entire test procedure as
required.
6. Install the piston (5) over the adaptor (9) and onto 4. Fully retract the cylinder.
the rod (10).
7. Secure the piston (5) to the rod (10) by installing
the setscrews (4) . Torque the piston (5) to
200 - 250 ft lb (280-350Nm).
5. Slowly in crease the pressure on the extend side of 2. Relieve pressure and examine the cylinder for
the cylinder to a maximum of 75 psi (517kPa). The structural failure evidenced by external leakage.
cylinder rod should begin to extend prior to reach No leakage is acceptable, except for the leakage
ing the maximum pressure stated. Note the pres accumulated in the low pressure test. If rod seal or
sure required to initiate movement of the cylinder any other externalleakage exists, disassemble the
rod, termed "breakaway pressure". If breakaway cylinder and replace the defective parts. Repeat
pressure exceeds 75 psi (517kPa) , disassemble the entire test procedure as required.
the cylinder and replace the defective part and re 3. Fully retract the rod and pressurize to the "Test
peat the entire test procedure. Pressure" specified in Table A. Hold this pressure
6. Once the breakaway pressure is obtained, the for a minimum of one minute. Leakage across the
pressure needed to maintain movement of the cyl piston should not exceed 0.33 cc/min.
inder rod, is termed "running pressure". Running 4. Once again, examine the cylinder for externalleak
pressure should not exceed 80% of the breakaway age. No leakage is acceptable, except for the leak
pressure and should diminish to 20% of the break age accumulated in the low pressure test. If rod
away pressure as the cylinder is extended. If run seal or any other external leakage exists, disas
ning pressure exceeds these guidelines, disas semble the cylinder and replace the defective
semble the cylinder and replace the defective parts parts. Repeat the entire test procedure as requi
and repeat the entire test procedure. red.
5. If cylinder is not to be installed on crane immediate
High Pressure Leakage Test Iy, plug all open ports to prevent contamination and
1. Extend the rod to full stroke and pressurize to the properly store.
''Test Pressure" specified in Table A. Hold this
pressure for a minimum of one minute. Leakage
across the piston should not exceed 0.33 cc/min.
5 of 6
6 of 6
Outrigger Beam Assembly, a. Release any residual pressure in the carrier
R& I hydraulic reservoir by slowly loosening the
This procedure covers the removal and instaliation of hydraulic reservoir, until pressure is fully
the structural outrigger beam assemblies. Although it relieved .
specifically shows information for the right rear b. Turn the ignition switch to " ON " , but DO NOT
outrigger beam , this procedure can be used for the START THE ENGINE_ Move the function lock
removal and installation of each of the four outrigger out switch to the "OPERATE" position or the
beams . For removal , installation , or recondition of the gate lock lever to the " OPERATION" position ,
hydraulic beam cylinders , see SM Keysheet Area as equipped .
01-045 . c. Work the crane controllevers and /or outrigger
Removal d . Turn ignition switch to the " OFF" position.
1. Lower, detach , and secure the load, as required . 8. Check that all controllevers are in the neutral posi
2. Stabilize lile crane for service as follows: tion and move the function lockout switch to the
a. Park the crane, out of the way, on a firm and "DI SABLE" position or the gate lock lever to the
level surface . "STOP" position, as equipped .
b. Engage the park brake and/or properly block 9. Remove the capscrews and washers (6) securing
the tires . the cover plate (7) to the outrigger box (5).
c. Engage the swing park brake or travel swing 10. Remove the cover plate (7) from the outrigger box
lock , as required. (5).
d. Position/support the boom , as required . 11. Label for assembly purposes and disconnect the
Refer to Figure 1 . hydraulic lines (16). Cap/plug the open hydraulic
3. Extend the outrigger beam (1) being removed to ports and lines (16) to prevent excessive oil 1055
approximately 1/3 stroke. and contamination of the system.
4 . Install the position pin (2) , as shown in Figure 1, to
Note: The outrigger beam assembly weighs
lock the outrigger beam (1) sections together. approximately 1,900 lb (862kg).
draulic pump , as equipped . 12 . Place adequate support blocking (4) under the
outrigger beam (1) at the end of the outrigger box
A. WARNING
(5) to prevent the outrigger beam (1) from droppi ng
as it is removed.
13. Remove the Jam nuts (10) and setscrews (11) .
14. Remove the capscrew (15) , washer (17) , and lock
nut (14) securing the beam cylinder (13) to the out
rigger box (5).
15 . Using an auxiliary lifting device, slide the outrigger
beam (1 ) from the outrigger box (5). Reposition the
cleaning solutions.
lifting device as required to maintain a balance d
load throughout removal.
6. Thoroughly clean the area to be disa5sembled with
mination. Aliow the area to air dry.
A. WARNING
engine and exhaust all trapped hydraulic
1 of 4
S M01 -045 -059.00 0307 Service Manual
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10,11
1. Oulrigger Beam - Right Rear 4. Support Blocking 7. Cover Plate

2. Position Pin 5. Outrigger Box - Rear 8. Capscrews & Washers
3. Jack Cylinder 6. Capscrews & Washers 9. Shims
Figure 1
Rear Outriggers
2 of 4
A
The clearance between the top 01 the outrigger beam and
the inside 01 the outrigger box should be approximately
0.06 in (1.5mm) when the outrigger beam is lully
extended.
1 6 -..........~~
15
10. Jam Nuts 13 Beam Cylinder 16. Hydraulic Lines

11 . Setscrews 14. Locknut 17. Washer
12. Wear Pad 15. Capscrew
3014
Cleaning And I nspection 2. Carefully align the beam cylinder (13) tothe mount
ing surface in the outrigger box (5).
3. Secure the beam cylinder (13) to the outrigger box
A. WARNING (5) by installing the capscrew (15), washer (17),
and locknut (14). Torque the capscrew (15) to
Solvents and cleaning solutions can be 50-55 ft lb (70-77Nm).
hazard ous. Serious personal injury may 4. Connect the hydraulic lines (16).
resul t from misuse of these products. Read 5. Check the hydraulic reservoir oil leve!. Add oil as
and follow all the manufacturer's required. See the Operator's Manual for correct
recomm endations concerning solvents and type and procedure.
cleaning solutions. 6. Start the engine and let idle for five minutes . In
spect the hydraulic connections for leaks . Repair
1. AII components should be thoroughly cleaned with leaks as required .
an approved cleaning solvent, air dried , and care 7. Slowly extend and retract the outrigger beam (1)
full y inspected. while observing the movement of the systems hy
2. AII Loctite®, Permatex®, or other sealant residue draulic lines. Ensure that the hydraulic lines do not
should be removed from threads of hardware and cross, twist, or rub during outrigger operation.
t he mounting surfaces of parts that are going to be Make adjustments as required.
reused. Prior to applying new thread locking com 8. Fully extend the outrigger beam (1).
pounds or sealants, clean threads and surfaces 9. Measure the distance between the top of the out
with Loctite® 7070 Cleaner to ensure best perfor rigger beam (1) and the the inside of the outrigger
mance of products. box (5). If this dimension is approximately 0.06 in
3. Th oroughly inspect all parts for damage, wear, fa (1.5mm), proceed to Step 10. Otherwise proceed
tigue or stress fractures , and corros ion. Repair or as follows:
replace as required . a. Extend the jack cylinder (3) to relieve any load
4 . Ins pect the thickness of the wear pads. There from the wear pad (12).
b. Remove the capscrews and washers (8).
should be plenty of wear pad present to prevent
c. Add or subtract shims (9), as required, to
the mounting hardware from protruding through
achieve the 0.06 in (1.5mm) clearance.
the wear pad . Replace wear pads if required.
5. Inspect the integrity of the hydraulic lines that sup Note: Use the difference between the di
ply the outrigger beam cylinders and jack cylinder mension taken in Step 9 and the target
ofthe outrigger beam being serviced. Repair or re clearance of 0.06 in (1.5mm) to determine
p lace if required. the amount of shims to add or subtract.
6 . In the event of severe defects, contact factory per d. Apply a thin coat of Loctite® 242 to the threads
sonnel for directions whether to repair or replace of the capscrews (8), and install the capscrews
any major component. and washers (8).
e. Retract the jack cylinder (3).
Installation f. Repeat Step 9.
10. Applya thin coat of Loctite® 242 to the threads of
the capscrews (6).
A. WARNING 11. Install the cover plate (7) on the outrigger box (5),
and install the capscrews and washers (6) .
Lubricants, sealants, joint and thread locking 12. Cover the setscrews (11) threads with Bostik®
compounds, etc. can be hazardous. Serious Never-Seez, or equivalent.
personal injury may result from misuse of 13. I nstall the setscrews (11) tight against the outrig
these products. Read and follow all ger beam (1), back th em off 1/2 tu rn, and install the
manufacturer's recommendations concerning jam nuts (10) tight against the outrigger box (5).
these products. 14. Bleed any trapped air from the beam cylinder (13)
by extending and retracting it several times .
Refer to Figure 1. 15. Complete the installation by testing all related func
Note: The outrigger beam assembly weighs tions of the outriggers for proper operation. Nor
mal operation of the hydraulic system should be
approximately 1,900 lb (862kg).
confirmed. A general inspection of the compo
1. Using an auxiliary lifting device, begin sliding the nents and systems in the areas adjacent to the re
outrigger beam (1) into the outrigger box (5). Re pair should also be performed to ensure related
position the lifting device as required to maintain a damage or wear is not present.
balanced load throughout installation.
4 of 4
10. Firmly support Ihe outrigger beam cylinders (2 ,5)
Outrigger Beam Cylinder, in a padded vise to allow furlher disassembly.
R& I 11. Remove Ihe hydraulic lines (9,7). Plug/cap alllines
(9,7) and fittings lo prevenl conlamination and ex
This procedure covers the removal and installation of cessive oil loss .
the outrigger beam cylinder. For recondition 12. Using an auxiliary lifting device, supporl the weight
procedure, see SM Keysheet Area 01 -045. of the top outrigger beam cylinder (2).
13. Remove the capscrews and plates (8), and sepa
Removal rate the top outrigger beam cylinder (2) and bot
1. Remove the outrigger beam assembly from the tom outrigger beam cylinder (5).
crane . See SM Keysheet Area 01 -045 for the cor
rect procedure. Cleaning And Inspection
2. Slide the outer outrigger beam (3) juSI far enough
3.
oul of the inner oulrigger beam (4) lo expose Ihe
access hole.
Through Ihe access hole, remove Ihe capscrew
A WARNING
(11) and pin (10). hazardous. Serious personal injury may
Note: The combined weight of the outrigger result from misuse of these products. Read
beam cylinders is approximately 145 lb (66kg). and follow all the manufacturer's
Individually the top outrigger beam cylinder recommendations concerning solvents and
weighs approximately 60 lb (27kg) and the bot cleaning solutions.
tom outrigger beam cylinder weighs approxi
mately 85 lb (39kg). 1. AII components should be thoroughly cleaned with
4. Using an auxiliary lifting device, supporl Ihe oulrig fully inspected .
ger beam cylinders (2 ,5). 2. AII Loctite®, Permatex®, or other sealant residue
5. Remove Ihe capscrew (1) and pin (6) Ihal secure should be removed from threads of hardware and
Ihe bottom oulrigger beam cylinder (5) lo Ihe ouler the mounting surfaces of parts that are going to be
oulrigger beam (3). reused. Prior lo applying new thread locking com
Note: Do not completely remove the top and with Loclite® 7070 Cleaner to ensure best perfor
bottom outrigger beam cylinders from the out mance of products.
rigger beams at this time. 3. Thoroughly inspect all parts for damage, wear, fa
tigue or stress fractures, and corros ion . Repair or
6. Pull Ihe oulrigger beam cylinders (2,5) out from the replace as required .
oulrigger beams (4 ,3) far enough to expose the hy 4. AII "soft parts " , such as seals, gaskets, back up
draulic lines (12) and fitlings (13). rings, and o-rings , should be replaced.
7. Disconnecl Ihe hydraulic lines (12) from lile fittings 5. Inspect lile integrity of the hydraulic lines Illat con
(13). Plug/cap all Ihe hydraulic lines (12) to prevenl nect to tlle oulrigger beam cylinders. Repair or re
conlaminalion and excessive oilloss. place if required.
8. Reposilion Ihe lifting device loward lile cenler of 6. In the event of severe defects, contact factory per
the outrigger beam cylinders (2,5) for better sup sonnel for directions whether to repair or replace
port. any major componen!.
9. Carefully remove Ihe oulrigger beam cylinders
(2,5) from Ihe oulrigger beams (4,3).
CAUTION
Do not clamp the cylinders in any form of vise
unless the jaws are protected by a soft
material. Use extreme care not to crush and
cause damage to the cylinders.
1 of 4
3 4 A
,
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11
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1. Capscrew 6 Pin 10. Pin

2. Top Outrigger Beam Cylinder 7. Hydrau lic Line 11 . Capscrew
3 Outer Outrigger Beam 8. Capscrews & Plates 12. Hydraulic Lines
4. Inner Outrigger Beam 9. Hydraulic Line 13. Fittings
5. Bottom Outrigger Beam Cylinder
Figure 1
Outrigger Beam Assembly
2 of 4
Installation 5. Using an auxiliary litting device, slide the outrigger
beam cylinders (2,5) into the outrigger beams (4,3)
until the hydraulie lines (12) can be connected to
A WARNING the fittings (13).
Note: Position the hydraulic lines so they do not

compounds, etc. can be hazardous. Serious rub the outrigger beam cylinders or outrigger
personal injury may result from misuse of beams.
manufacturer's recommendations concerning 6. Connect the hydraulic lines (12) to the littings (13) .
these prod ucts. Use a wrench on both the lines (12) and the fittings
(13) to prevent twisting.
Note: The bottom outrigger beam cylinder rod

end must be supported with a device that will al
CAUTION low the rod end to be raised into position while
Do not clamp the cylinders in any form of vice the pin is installed.
unless jaws are protected by a soft material.
Use extreme care not to crush and cause 7. Reposition the auxiliary lifting device toward the
damage to the cylinders. end of the outrigger tleam cylinders (2 ,5). Slide the
outrigger beam cylinders (2 ,5) into outrigger
beams.
Note: The combined weight of the outrigger 8. Align the rod eye of bottom outrigger beam cylin
beam cylinders is approximately 145 lb (66kg). der (5) with mounting hole on the outer outrigger
Individually the top outrigger beam cylinder beam (3), and instalt the pin (10).
weighs approximately 60 lb (27kg) and the bot 9. Apply Loctite® 242 to the threads 01 the capscr ew
tom outrigger beam cylinder weighs approxi (11) .
mately 85 lb (39kg). 10. Install the capscrew (11) to seeure the pin (1 0) to
the bottom outrigger beam cylinder (5). Torque the
1. Using an auxiliary lifting device, secure the bottom
capscrew (11) to 40·-45 ft lb (54-61Nm) .
outrigger beam cylinder (5) in a padded vise with
11 . Align the case mounting eye 01 bottom outrigger
the littings lor hydraulic lines (7,9) lacing up.
beam cylinder (5) with the mounting hole on the in
2. Using an auxiliary lifting device, position the top ou
ner outrigger beam (4) , and install the pin (6).
trigger beam cylinder (2) over the bottom outrigger
12. Apply Loctite® 242 to the threads of the capscrew
beam cylinder (5) with the hydraulic lines (7,9) lae
(1) .
ing down .
13. Install the eapserew (1) to seeure the pin (6) to the
3. Install the eapscrews and plates (8). Torque the
top outrigger beam eylinder (2). Torque the
eapserews (8) to 120-135 ft lb (168-189Nm).
eapscrew (1) to 40-45 ft lb (54-61Nm).
4. Install the hydraulie lines (7,9) .
14. Install the outrigger beam assembly into the outrig
ger box. See SM Keysheet Area 01 -045 lor th e
correet proeedure.
3014
4 of 4
l~ 3
Case
Length
4 5 6 7 8 9 10
1. Plslon Rod Assembly 4. Wear Ring 7. O-ring 10. Rod Seal

2 Gland 5. T -seal 8. Back Up Ring 11. Rod Wiper
3 Cylinder Case 6. Wear Ring 9. Slep Seal
Figure 1
Jack Cylinder Assembly
Jack Cylinder, Recondition

This procedure covers the recondition and testing 01
A WARNING
jack cylinders with a threaded gland and welded on hazardous. Serious personal injury may
piston. See SM Keysheet Area 01-046 for other result from misuse of these products. Read
designs . For removal and installation procedure, see and follow all the manufacturer's
SM Keysheet Area 01-046. recommendations concerning solvents and
II parts are hard to disassemble and assemble, do not cleaning solutions.
parts together, they must operate freely and not bind. Note: For cylinder weight and potential oil capacity,
Disassembly refer to Table A.
It is a good practice when disassembling hydraulic 1. Thoroughly clean the exterior surlace 01 the jack
components to lay the parts out in the order that they cylinder to prevent contamination Irom entering il.
1 014
Case Weight Weight Dil Dil Maximum
Weight Working Test Holding
Length Wet Wet Capacity Capacity Breakaway
Dry Pressure Pressure Pressure
(See Figure 1) Extended Retracted Extended Retracted Pressure
in (cm) lb (kg) lb (kg) lb (kg) gal (L) gal (L) psi (kPa) psi (kPa) psi (kPa) psi (kPa)
36.25* 2 11 223 216 1.66 0 .66 3 ,000 5,000 3,840 75

(92) (96) (101 ) (98) (6.28) (2. 50) (20684 ) (34475) (26 476) (517)
3625t 230 243 235 1.84 0.70 3 ,000 5,000 4,200 75

(92 ) (1 04) ( 110) ( 107) (6.97) (2. 65) (20684 ) (344 75) (28 959) (5 17)
3625:1: 250 265 255 2.04 0.73 3,000 5,000 4,600 75

(92) ( 11 4) (1 20 ) ( 116) ( 772) (2.76) (20685 ) (344 75) (31 717) (517)
45. 00 204 217 2 10 1.87 0 .83 1,600 5,000 4,000 50

(114) (93) (98) (95) (7.08) (3.1 4) (11 032 ) (344 75) (27 5 79) (345)
46 .00 208 222 214 1. 87 083 1,600 5,000 4,000 50

(117) (94) (101) (97) (7.08) (3. 14) (11 032) (34475) (2 7 579) (345)
4800 280 297 287 2.40 0.9 1 3,000 5,000 4,200 75

(122 ) (1 27) ( 135) ( 7.10) (9.08) (.1.44) (20685) (.144 75) (28 959) (51 7)
• 5.50 in ( 14.0cm ) outside d iameter case.

t 5 .75 in (14.6cm) outside diameler case .
:1: 600 in (15.2cm) oulside diameler case.
Table A

CAUTION
Do not clamp cylinder rod in any form of vise
unless jaws are protected by a soft material. A WARNING
Nicks, scratches, dents, or weld splatter could Solvents and cleaning solutions can be
permanently damage the cylinder rod, hazardous. Serious personal injury may
allowing leakage. result from misuse of these products. Read
and follow all the manufacturer' s
2. Secure cylinder case (3) in a padded vise . recommendations concerning solvents and
3. Using a spanner wrench , fully loosen gland (2) cleaning solutions.
from cylinder case (3) .
4. Remove gland (2) and piston rod assembly (1) 1. Thoroughly clean all metal parts with an approved
togethe r Irom cylinder case (3). cleaning solven!. Place parts on a clean , lint free
5. Carelully remove gland (2) Irom cylinder rod surface and allow to air dry. Exercise every
assembly (1). precaution possible to keep all parts free 01 dust ,
6. Remove rod wiper (11) , rod seal (10) , step seal (9), dirt , or any other foreign material during assembly.
back up ring (8), and o-ring (7) from gland (2) . 2. AII Loctite[ , Permatex'f.' , or other sealant residue
should be removed Irom threads 01 hardware and
Note : The cylinder rod and piston are a welded the mounting surfaces 01 parts that are going to be
assembly. Do notattemptto disassemblethese reused . Prior to applying new thread locking
components. compounds or sealants , clean threads and
surfaces with Loctite II 7070 Cleaner to ensure best
7. Remove wear rings (4,6) and t-seal (5) Irom piston performance 01 products .
rod assembly (1) . 3. Ca refully inspect all components for damage ,
wear, corrOSion, deep scratches , and scuffed
metal. Remove any burrs or sharp edges with a
line lile, hone , emery cloth , or crocus cloth .
2 01 4
4. Replace any damaged component as required.
5. Replace all seals, wipers , 0- rings , and wear rings.
6. Inspect the integrity 01 the welds which secure the
piston to the rod. Repair or replace as required .
7. In the event 01 severe delects, contact lactory
personnel lor directions whether to repair or
replace any major componen!.
Assembly
A WARNING
compounds, etc. can be hazardous. Serious Form the rod seal into a "C-shape" as shown .
these products. Read and follow all Figure 2
manufacturer's recommendations concerning Rod Seal Installation
these products.
6. Install gland (2) in cylinder case (3) and torque to
Note: For cylinder weights, refer to Table A.
400 ft lb (542Nm).
Lubricate seals, 0- rings, wear rings, rod wiper, t-seal, 7. Test jack cylinder. See testing instructions lound
piston rod assembly, and cylinder case 1.0. with later in this document.
Cosmolube' #2 or equivalent prior to assembly. 8. II jack cylinder is not to be immediately installed on
crane, plug all open ports to prevent contamination
1. Install t-seal (5) and wear rings (4,6) on piston rod
and properly store.
assembly (1).
Note: It may be necessary to form the rod seal Cylinder Test Procedures
into a "C-shape", as shown in Figure 2, to
start installation. Low Pressure Leakage & Static Friction Test
1. Fill the lully retracted cylinder w ith hydraulic oi\.
2. Install o-ring (7), back up ring (8), step seal (9) , Reler to Table A and the Operator 's Manual lor the
rod seal (10), and rod wiper (11) on gland (2). correct amount and g rade 01 oil to use .
3. Carelully install gland (2) on piston rod assembly 2. Cycle the cylinder, full stroke each direction, a
(1) . minimum 01 live tim es to remove entrapped air,
using only the pressure level w hich is required to
CAUTION move the cylinder rod at a steady rate o II the
cylinder squeaks or sticks , disassemble the
Threaded surfaces are sharp. Seals and
cylinder and replace the delective part and repeat
0- rings can be damaged as they are installed
the entire test procedure.
over or through threaded areas, causing the
3. Stop the ro d at mid stroke and examine the
assembly to leak. Mask the threads or
cylinder lor any external leakage . No leakage is
otherwise protect seals during installation.
acceptable. Oisassemble the cylinder and replace
the delective parts, as required, and repeat the
4. Stide piston rod assembly (1) and gland (2) into
entire test p rocedure .
cylinder case (3), being carelul not to damage
4. Fully retract the cylinder.
seals on internal threads 01 cylinder case (3).
5. Gradually pressurize the extend port, at a pressure
increase 01 one to ten percent 01 the cylinder
CAUTION working pressure per minute, until rod movement
is initiated . Pressure to initiate rod movement or
Do not clamp cylinder rod in any form of vise
"breakaway" pressure, shall not exceed cylinder
breakaway pressure as listed in Table A.
Nicks, scratches, dents, or weld splatter could
permanently damage the cylinder rod,
allowing leakage.
5. Secure cylinder case (3) in a padded vise.
3014
6. Once the breakaway pressure is determined, the 3. Fully retract the cylinder.
pressure needed to maintain movement of the 4. Pressurize retract port to the "Test Pressure"
cylinder rod, is termed "running pressure". specified in Table A. Hold this pressure lar a
Running pressure should not exceed 80% of the minimum of one minute. II leakage across the
breakaway pressure and should diminish to no pistan exceeds 0.33 cc/min , disassemble the
less than 20% 01 the breélkaway pressure as the cylinder, replace the delective parts, and repeat
cylinder is extended . II running pressure exceeds the entire test procedure.
these guidelines , disassemble the cylinder and 5. Once again relieve pressure and examine the
replace the delective parts and repeat the entire cylinder lor any external leakage . No leakage is
test procedure . acceptable . II leakage is lound, disassemble the
cylinder, replace the delective parts, and repeat
High Pressure Leakage Test the en tire test procedure.
1. Extend cylinder lull stroke and pressurize extend 6. 1I the cylinder is not to be installed on crane
port to the "Test Pressure" specilied in Table A. immediately, plug all ports to prevent
Hold this pressure lar a minimum 01 one minute. II contamination and properly store .
leakage across the piston exceeds 0.33 cc/min ,
disassemble the cylinder, replace the delective
parts , and repeat the entire test procedure.
2. Relieve pressure and examine the cylinder for
structural lailure . No leakage is acceptable. If
leakage is found , disassemble the cylinder,
replace the defective parts, and repeat the entire
test procedure .
4014
o
A
MUST be located in this position.
2
3 6
7
8
1. Elbow* 4. Washers 7. Connector*

2. Outrigger Beam 5. Capscrews 8 Tube Assembly*
3. Jack Cylinder 6. Check Valve Cartridge 9. Hose Assemblies
* Some cranes use permanently welded tube assemblies which do not require fittings and are not removable.
Figure 1
Note: Use enough blocking to provide suffi

Jack Cylinder, R & I cient height for the removal of the jack cylinder
This procedure covers the removal and installation of from the bottom of the outrigger beam.
the jack cylinder. For recondition procedure, see SM
3 Place firm, sturdy blocking of sufficient size an d
Keysheet Area 01 -046.
strength under the pontoons and level the crane on
Removal outriggers.
4. Place another set of firm , sturdy blocking of suffi
1. Lower, detach , and secure the load , as required . cient size and strength under the outrigger beam
2. Stabilize the crane for service as follows : approximately 18 in (46cm) inward from the jack
a. Park the crane, out of the way, on a firm and cylinder being removed.
level surface.
5. Fully retract the jack cylinder that is being re
b . Engage the park brake and/ or properly block moved. This will allow the outrigger beam to rest
the tires. on the blocking.
c. Engage the swing park brake or travel swing 6. Shutdown the engine and disengage the main hy
lock, as required. draulic pump .
d. Position/support the boom, as required .
1 of 4
13. Remove the check valve cartridge (6) from the jack
A WARNING cytinder (3). Plug the open hydraulic port to pre

vent contamination.
Note: The jack cylinder weighs approximately
ha zardous. Serious personal injury may
325 lb (147kg).
result from misuse 01 these products. Read
and follow all the manufacturer's 14 . Support the jack cylinder (3) with an appropriate
recommendations concerning solvents and lifting device.
cleaning solutions. 15. Remove the capscrews (5) and washers (4) secur
ing the jack cylinder (3) to the outrigger beam (2) .
7. Thorougtlly clean the area to be disassembted with 16. Rotate and maneuver the jack cylinder (3), as re
an approved cteaning solvent to prevent conta quired, to avoid damaging the tu be assembly (8)
mination . Allow the area to air dry. and elbow (1). Remove the jack cylinder (3) from
the outrigger beam (2) .
A WABNING
Hydrautic oil is under pressure and may be
Note: The jack cylinder may be stuck in the out
rigger beam due to excessive dirt, rust, etc. If
necessary, tap the top of the jack cylinder with a
hot. A sudden release of hot oit could cause rubber mallet to free it from the outrigger beam.
engine and exhaust all trapped hydraulic 17 . Remove the tube assembly (8). connector (7), and
p ressure from the system before removing elbow (1) from the jack cylinder (3), as required .
Note: Some cranes use permanently welded
tube assemblies which do not require fittings
8. Relieve the hydrautic system pressure as follows:
and are not removable.
a . Release any residual pressure in the carrier
hydrautic reservoir by slowly loosening the 18. Plug the open hydraulic ports in the jack cytinder
filler/ breather cap, tocated on the top of the (3) and tube assembly (8) to prevent contamina
hydraulic reservoir, until pressure is fully tion.
relieved .
b. Turn the ignition switch to "ON", but DO NOT Cleaning And Inspection
STARTTHE ENGINE. Move the function lock
gate lock lever to the "OPERATION" position ,
as equipped.
A WARNING
c. Work the crane controt tevers and/or outrigger
switches back and forth several times . hazardous. Serious personal injury may
d . Turn ignition switch to the "OFF" position. result from misuse of these products. Read
9 . Check that all controllevers are in the neutral posi and follow all the manufacturer's
tion and move the function lockout switch to the recommendations concerning solvents and
"DI SABLE" position or the gate lock tever to the cleaning solutions.
"STOP" position , as equipped.
10. Remove the pontoon from the jack cylinder. 1. AII components should be thoroughly cleaned wilh
Note: The cylinder rod may drift down or extend fully inspected.
when the hydraulic lines are removed. Support 2 . AII Loctite®, Permatex® , or other seatant residue
the cylinder rod as required. should be removed from threads of hardware and
Refer to Figure 1.
11 . For assembly purposes, labet the hose assembties
(9) and tube assembly (8).
12. Disconnect the hose assemblies (9) from the jack
with Loctite® 7070 Cleaner to ensure besl perfor
cylinder (3) . Cap/plug the open hydraulic ports mance of products.
and hose assemblies (9) to prevent excessive oil
loss and contamination.
2 of 4
3. Tharoughly inspect al! parts for damage, wear, fa aging the tu be assembly (8) and elbow (1). Lift the
tigue or stress fractures , and carrosion. Repair ar jack cylinder (3) up through the outrigger beam (2).
replace as required. 4. Align the mounting holes in the jack cylinder (3)
4. AII "soft parts", such as seals, gaskets, back up with the threaded holes in the outrigger beam (2) .
rings, and o-rings, should be replaced . 5 . Apply Loctite® 242 to the threads of the capscrews
5. Inspect the integrity of the hydraulic lines that are (5) .
connected to the jack cylinder. Repair or replace if 6. Secure the jack cylinder (3) to the outrigger beam
required. (2) by installing the washers (4) and capscrews (5) .
6 . In the event of severe defects , contact lactary per Torque the capscrews (5) to 300 ft lb (407Nm) .
sonnel lor directions whether to repair ar replace 7. Install the check valve cartridge (6) in the jack cyl in
any majar component. der (3). Torque the check valve ca rtridge (6) to
25 ft lb (34Nm).
Installation 8. Connect the hose assemblies (9) to the jack cylin
der (3).
9. Install the pontoon on the jack cylinder.
A WARNING 10. Place adequate blocking under the pon too n so
that the blocking under the outrigger beam can be
Lubricants, sealants, joint and thread locking removed.
compounds, etc. can be hazardous. Serious 11. Check the hyd raulic reservoir oillevel. Add oil as
personal injury may result from misuse of required. See the Operatar's Manual for the
these products. Read and follow al! correct type and procedure.
manufacturer's recommendations concerning 12. Start the engine and let idle for five minutes.
these products. Inspect the connections on the hydraulic lines lar
leaks. Repair il needed.
Reler to Figure 1. 13. Extend the outrigger .i ack and remove the blocking
1. Install the elbow (1) , connector (7), and tube as from under the outrigger beam .
sembly (8) in the jack cylinder (3), as required . 14. Complete the installation by testing all related
2. Inspect the tube assembly (8) and elbow (1) to en functions 01 the outrigger jack lor proper operation.
sure they are properly installed and torqued. Reler Normal operation 01 the hydraulic system should
to SM Keysheet Area 07 -018 lor the correct torque be conlirmed . A general inspection 01 the
values. components and systems in the areas adjacent to
the repair should also be performed to ensure
Note: The jack cylinder weighs approximately
325 lb (147kg). related damage or wear is not present.
3. Using an auxiliary lifting device, rotate and maneu

ver the jack cylinder (3), as required , to avoid dam
3014
S M01-046,-047.00 0307 Service Manual
4 of 4
Note: To eliminate the possibility of damage to
Jack Cylinder, Recondition the gland during disassembling, use a fine file,
This procedure covers the recondition of jack cylinders emery, or crocus cloth to clean up any nicks or
with a threaded gland and piston. Review Figure 1 and burrs on the mounting flange.
Table A to confirm the cylinder being serviced matches
the design of the cylinder in this procedure. See SM 8. Remove the gland (4) from the rod (3).
Keysheet Area 01-046 for other designs. For removal 9. Remove the wiper seal (15), rod seal (14), step seal
and installation procedure, also see SM Keysheet Area (13), wear ring (12), 0- ring (10), and back up ring
01-046. (11) from the gland (4).
10. Remove the wear rings (5 ,7) and piston seal (6)
from the piston (1).
use a hammer unless it has a soft face, do not for ce
parts together, they must be free to operate and not
bind.
CAUTION
Disassembly Use care not to damage the chrome finish on
the rod. Any nicks or scratches could result in
portions of the rod which are not chrome
the assembly process .
soft material before Glamping.
Refer to Figure 1
1. Plug the open ports in the case (2) to prevent con
Note: Loctite® 277 and 900 ft lb (1 260Nm) of
tam ination .
torque was used to install the piston to the rod .
11 . There are limited areas on the rod (3) where clamp
A WARNING ing is permissible. Secure the rod (3) in the area
noted in Figure 1. Using a spanner wrench, re
Solvents and cleaning solutions can be move the piston (1) from the rod (3).
hazardous. Serious personal injury may result 12 . Remove the o-ring (8) and back up ring (9) from
from misuse of these products. Read and the piston (1).
follow all the manufacturer's recommendations
concerning solvents and cleaning solutions. Cleaning And Inspection
2. Thoroughly clean the exterior surface of the jack
cylinder with an approved cleaning solvent and al
low to air dry.
A WARNING
3. Place a adequate container below the ports in the
case (2). Refer to Table A for capacity.
Serious personal injury may result fro m
4. Remove the plugs which were installed during the
misuse of these products. Read and follow all
cleaning process.
the manufacturer's reeommendations concern
5. Manually extend, then retract the rod (3) to com
ing solvents and cleatrling solutions.
pletely drain the oil from both sides of the case (2).
Properly store or dispose of used oil.
Note: 400 ft lb (542Nm) of torque was used to cleaning solven!. Place parts on a clean, lint free
install the gland into the case. surface and allow to air dry. Exercise every precau
tion possible to keep all parts free of dust , dirt , or
6. Using a spanner wrench, rotate the gland (4) until it any other foreign material during assembly.
disengages from the case (2). 2. AII Loctite®, Permatex®, or other sealant residue
7. Remove the gland (4), rod (3), and piston (1) , as an should be removed from threads of hardware and
assembly, from the case (2). Place the assembly in the mounting surfaces of parts that are going to be
an area where it can be disassembled without reused. Prior to applying new thread locking com
damaging the chrome on the rod (3) or individual pounds or sealants, clean threads and surfaces
parts. with Loctite® 7070 Cleaner to ensure best perfor
mance of products.
1 of 4
. ~.
. .. ....,
. \
.. _-
....
!
5 A
-)
~/.
6
7 .
l
... :}>
. <: •..
-.~.; -::} -
--- 1
I(i
. ......, ". r .
Vise marks are permissible .
9~-
in this area to remove and
install piston on rod.
10 11
/ I
(/
15
1. Piston 4. Gland 7. Wear Ring 10. O-ring 13 Step Seal

2. Case 5. Wear Ring 8. O-ring 11 . Back Up Ring 14. Rod Seal
3. Rod 6. Piston Seal 9. Back Up Ring 12. Wear Ring 15. Wiper Seal
Figure 1
2 of 4
3. The cylinder case bore should be carefully in
spected for scoring or deep scratches. Replace as
required .
4. The rod should be carefully inspected for damage
such as dents , deep scratches, and damaged
chrome plating. Replace as required.
5. pay particular attention to the sealing grooves in
the gland, piston , and port openings in the case .
AII sharp edges should be carefully removed with a
fine file , hone , or emery or crocus cloth to prevent
damage to seals during assembly.
6. AII "soft parts" , such as seals , back up rings , wear Form the rod seal into a "C-shape" as shown.
rings , wipers , and o-rings, should be replaced.
Figure 2
7. In the event of severe defects, contact factory per Rod Sea I I nstallation
any major componen!.
Assembly
CAUTION
Use care not to damage the chrome finish on
A WARNING
the rod. Any nicks or scratches could result in
concerning lubricants, sealants, joint and
portions of the rod which are not chrome
thread locking compounds, etc. Serious
soft material before clamping.
these products. Read and follow all the
3. There are limited areas on the rod (3) where clamp
these products.
ing is permissible . Secure the rod (3) in the area
noted in Figure 1. Using a spanner wrench , torque
Lubricate the seals, 0- rings, back up rings, wear
the piston (1) to 900 ft lb (7 260Nm).
rings, cylinder case threads, and cylinder case bore
4. Install the wear rings (5 ,7) and piston seal (6) on
with Cosmolube® 2-EP Multi Purpose Grease, or
the piston (1).
equivalent, prior to assembly. Use care to avoid getting
5. After the piston seal (6) has been installed on the
the lubricant on the threaded portions of the cylinder
piston (1), a sizing tool such as a piston ring com
rod and piston, to ensure proper bonding of thread
pressor should be clamped over the outer diame
locking product (Loctite®).
ter of the piston (1) and left for a minimum of 5 min
Refer to Figure 1 utes. This will give the Teflon® piston seal (6) time
to return to its original size.
Soak the new piston seal (6), rod seal (14), wiper seal
(15), and step seal (13) in clean hydraulic oil which Note: It may be necessary to form the rod seal
has been heated to a temperature of 100-120 °F into a "C-shape", as shown in Figure 2, and
(38 _ 49 ° e) . Allow adequate time for the parts to held in that position to start installation.
reach the temperature of the hydraulic oil which will
6. Install the step seal (13), rod seal (14), wiper seal
greatly ease their assembly.
(15), wear ring (12), back up ring (11), and 0 - ring
1. Install the back up ring (9) and 0- ring (8) in the pis (10) in the gland (4).
ton (1). 7. Install the gland (4) on the rod (3).
2. Apply Loctite® 277 to the threads of the piston (1) ,
and install the piston (1) on the rod (3). Use care not
to get any Loctite® 277 on the 0- ring (8) and back
up ring (9) .
3 of 4
Case Wet Retracted Wet Extended Oil Capacity Oil Capacity Test
Length Weight Weight Retracted Extended Pressure
in cm lb kg lb kg gal L gal L psi kPa
35.31 89.69 292 132 283 128 0.94 3.56 2.22 8.40 5,000 34475
Table A
Cylinder Speci1ications
6. Once the breakaway pressure is obtained , the

pressure needed to maintain movement 01 the cyl
CAUTION inder rOd, is termed "running pressure " . Running
Threaded sur1aces are sharp. Use care to pressure should not exceed 80% 01 the breakaway
prevent damage to seals or o-rings during pressure and should diminish to 20% 01 the break
installation 01 components onto rod or during away pressure as the cylinder is extended. II run
installation 01 rod and piston assembly into ning pressure exceeds these guidelines, disas
case. semble the cylinder, replace the delective part(s),
and repeat the entire test procedure.
8. Install the piston (1) , rod (3) , and gland (4) , as an
assembly, into the case (2) . High Pressure Leakage Test
9 . Place the case (2) in a vise or anchor it in such a 1. Extend the rod to lull stroke and pressurize the ex
way to prevent it Irom rotating . Protect the case (2) tend side to the "Test Pressure " specilied in Table
Irom being damaged. A . Hold this pressure lor a minimum 01 one minute .
10. Using a spannerwrench, torque the gland (4) to Leakage across the piston should not exceed 0.33
400 ft lb (542Nm). cc/ min. II leakage exc eeds this amount, disas
semble the cylinder, replace the delective part(s) ,
Cylinder Test Procedures and repeat the entire test procedure .
2. Relieve pressure and examine the cylinder lor
Low Pressure Leakage & Static Friction Test structural lailure evidenced by external leakage.
1. Fill the lully retracted cylinder with hydraulic oil. Re No leakage is acceptable . 1I leakage exists, disas
ler to Table A and the Operator's Manual lor the semble the cylinder, replace the delective part(s),
correct amount and grade 01 oil to use. and repeat the entire test procedure.
2. Cycle the cylinder lull stroke each direction a mini 3. Fully retract the rod and pressurize to the "Test
mum 01 live times to remove entrapped air, using Pressure" specilied in Table A. Hold this pressure
only the pressure level which is required to move lor a minimum 01 one minute . Leakage across the
the cylinder rod at a steady rateo II the cylinder piston should not exceed 0 .33 cc/min . Illeakage
squeaks or sticks, disassemble the cylinder and exceeds this amount , disassemble the cylinder, re
replace the delective part and repeat the entire test place the delective part(s) , and repeat the en tire
procedure. test procedure .
3. Stop the rod at mid stroke and relieve the pressure . 4. Relieve pressure and examine the cylinder lor any
Examine the cylinder lor any externalleakage. No external leakage . No leakage is acceptable. If
leakage is acceptable. II leakage exists, disas leakage exists, disassemble the cylinder, replace
semble the cylinder, replace the delective part(s), the delective part(s), and repeat the entire test pro
and repeat the entire test procedure. cedure.
4. Fully retract the cylinder. 5. II cylinder is not to be installed on crane immediate
5. Gradually increase the pressure on the extend side Iy, plug all ports to prevent contamination and
01 the cylinder to a maximum 0175 psi (517kPa) . properly store.
The cylinder rod should begin to extend prior to
reaching the maximum pressure stated . Note the
pressure required to initiate movement 01 the cylin
der rod , termed "breakaway pressure" . II break
away pressure exceeds 75 psi (517kPa) , disas
sem ble the cylinder, replace the delective part(s),
and repeat the entire test procedure.
4014
7 8 A
1 Carrier Frame 4. Capscrews & Locknuts 6. Hydraulic Llne 8. Jack Cylinder

2. Capscrews & Washers 5. Pontoon 7. Cartridges 9. Hydraulic Lines
3. Bracket
Figure 1
5th Outrigger Jack Cylinder

5th Outrigger Jack Cylinder, the tires.
R& I c. Engage the swing park brake ar travel swing
lock , as required .
This procedure covers the removal and installation of d . Level the crane on fully extended outriggers .
the 5th outrigger jack cylinder. For recondition Add additional blocking , as required, to en
procedure, see SM Keysheet Area 01 -046. sure sufficient clearance for the removal of the
jack cylinder.
Removal
Note: When leveling the crane, do not ex
1. Lower, detach, and secure the load , as required.
tend the 5th outrigger jack cylinder.
2. Stabilize the crane far service as follows :
a. Park the crane , out of the way, on a firm and e. Position/support the boom, as required.
level surface.
1 of 4
f. Ensure that the 5th outrigger jack cylinder is 9. Label for assembly purposes and disconnect the
fully retracted . hydraulic lines (6,9) from the jack cylinder (8) .
3. Shutdown the engine and disengage the main hy Cap/ plug the open hydraulic ports and lines (6,9)
draulic pump. to prevent excessive oilloss and contamination of
the system.
10. Remove the cartridges (7) from the jack cylinder
A WARNING (8), as required.
11. Using an auxiliary lifting device, support the weight
of the jack cylinder (8) .
result from misuse of these products. Read Note: The jack cylinder weighs approximately
and follow all the manufacturer's 215 lb (98kg).
recom mendations concerning solvents and
cleani ng solutions. 12. Note the position of the bracket (3) and open hy
draulic ports on the jack cylinder (8) to ensure
4. Thoroughly clean the area to be disassembled with proper orientation during installation.
an approved cleaning solvent to prevent conta 13. Remove the capscrews and washers (2) securing
mination. Allow the area to air dry. the jack cylinder (8) to the carrier frame (1) . Re
move the bracket (3) .
14. Lower the jack cylinder (8) through the carrier
A WARNING frame (1) and remove it from beneath the crane.
Hydraulic oil is under pressure and may be Cleaning And Inspection

A WARNING
5. Relieve the hydraulic system pressure as follows: result from misuse of these products. Read
a . Release any residual pressure in the carrier and follow all the manufacturer's
hydraulic reservoir by slowly loosening the recommendations concerning solvents and
filler/breather cap , located on the top of the c1eaning solutions.
hydraulic reservoir, until pressure is fully
relieved. 1. AII components should be thoroughly cleaned with
b. Turn the ignition switch to "ON", but DO NOT an approved cleaning sOlvent, air dried, and care
START THE ENGINE. Move the function lock lully inspected.
out switch to the "OPERATE" position or the 2. AII Loctite®, Permatex®, or other sealant residue
gate lock lever to the "OPERATION" position, should be removed from threads 01 hardware and
as equipped . the mounting surfaces 01 parts that are going to be
c . Work the crane controllevers and/or outrigger reused . Prior to applying new thread locking com
switches back and forth several times . pounds or sealants, clean threads and surfaces
d. Turn ignition switch to the "OFF" position. with Loctite® 7070 Cleaner to ensure best perfor
6. Check that all controllevers are in the neutral posi mance of products .
tion and move the function lockout switch to the 3. Thoroughly inspect all parts for damage, wear, fa
"DI SABLE" position or the gate lock lever to the tigue or stress fractures, and corrosion. Repair or
"STOP" position, as equipped. replace as required.
4. AII "soft parts", such as seals , gaskets, back up
Reler to Figure 1. rings, and o-rings, should be replaced.
7. Support the pontoon (5) and remove the cap 5. Inspect the integrity of the hydraulic lines that are
screws and locknuts (4) .
connected to the jack cylinder. Repair or replace if
8. Remove the pontoon (5) from the jack cylinder (8) .
required .
Note: The cylinder rod may drift down or extend 6. In the event 01 severe defects, contact lactory per
once the hydraulic lines are removed. Support sonnel for directions whether to repair or replace
th e cylinder rod as required. any major component.
2 of 4
Installation 4. Secure the jack cylinder (8) to the carrier frame (1)
by installing the capscrews and washers (2) .
5. Torque the capscrews (2) to 435-480 ft lb
A WARNING
(609-672Nm) .
6. If removed, install the cartridges (7) in the jack cyl
Lubricants, sealants, joint and thread locking inder (8). Tarque the cartridges (7) to 25 ft lb
compounds, etc. can be hazardous. Serious (35Nm).
personal injury may result from misuse of 7. Connect the hydraulic lines (6 ,9) to the jack cylin
these products. Read and follow all der (8).
manufacturer's recommendations concerning 8. Install the pontoon (5) on the jack cylinder (8) and
these products. secure with capscrews and locknuts (4).
Refer to Figure 1. required. See the Operator's Manual for carrect
1. Using an auxiliary lifting device, raise the jack cylin type and procedure.
der (8) up through the carrier frame (1) and into 10. Start the engine and let idle lor live minutes . In
position. spect the hydraulic connections lor leaks. Repair
leaks as required.
Note: The jack cylinder weighs approximately 11. Complete tlle installation by testing all related func
215 lb (98kg). tions 01 the 5th outrigger jack cylinder lar proper
operation . Normal operation 01 the hydraulic sys
2. Applya thin coat of Loctite® 242 to the tllreads of tem should be conlirmed. A general inspection 01
the capscrews (2). the components and systems in the areas ad ja
3. Properly position the bracket (3) and open hydrau cent to the repair should also be performed to en
lic parts on the jack cylinder (8) to ensure proper sure related damage ar wear is not present.
alignment of hydraulic lines (6,9).
3014
4 of 4
A B
Y
5
4
6
7
e
9
oo o
~
8
1. Adiuster Screw 4. Cartridge 7. Back Up Ring

2. Jam Nut 5. O-ring 8. O- ring
3. O-ring 6. Back Up Ring 9 Valve Bo dy
Figure 1
Relief Valve Assembly
Relief Valve, Recondition

This procedure covers the recondition of the relief
A WARNING
valve . For removal and installation procedures, see hazardous. Serious personal injury may
the general instructions given by Lower Hydraulic result from misuse of these products. Rea d
Components, R & I found in SM Area 1 -79. and follow all the manufacturer's
The relief valve may be reconditioned without
recommendations concerning solvents an d
removing the entire valve from the crane. However,
cleaning solutions.
proper setup and hydraulic pressure relief
procedures must first be performed as follows:
1. Stabilize the crane for service : contamination from entering the hydraulic oil
a. Park the crane out of the way on a firm and level circuits. Allow the area to air dry.
surface.
the tires.
A WARNING
lock , as required.
d. Level the crane on fully extended outriggers. hot. A sudden release of hot oil could cause
e. Fully retract and position the boom, as re burns or other serious injury. Shutdown the
quired. engine and exhaust all trapped hydraulic
2. Shutdown the engine and disengage the main pressure from the system befo re removing
hydraulic pump. any line or component.
1 of 4
4. Relieve hydraLJlic system pressLJre as follows :
a. If equipped, relieve any residual pressure in CAUTION
the hydraulic reservoir by pushing the button
Hydraulic components are machined to close
on the pressure relief valve, located on the
tolerances. Use extreme care in handling not
hydraL!lic reservoir.
to crush or cause damage if clamped in a vise.
Do not clamp valve body in any form of vise
START THE ENGINE. Move the function lock
out switch to the "OPERATE" position.
c. Work the crane control levers and outrigger 2. Place valve body (9) in a vise.
switches back and forth several times. 3. Remove cartridge (4) from valve body (9).
d. Rotate the steering wheel back and forth 4. Remove and discard o-rings (5,8) and back up
repeatedly until steering beco mes hard. (On rings (6,7).
cranes equipped with emergency steering 5. Count and record the number of threads that are
system, it will take several rotations of steering exposed, and loosen jam nut (2).
wheel before steering becomes hard.) 6. Remove adjuster screw (1) , jam nut (2) and o-ring
e. Turn ignition switch to the "OFF" position. (3). Discard o-ring (3) .
position and move the function lockout switch to Cleaning And Inspection
Disassembly
A WARNING
were disassembled . Keeping the parts in this order hazardous. Serious personal injury may
d uring disassembly, cleaning and inspection will aid in result from misuse of these products. Read
the assembly process. and follow all the manufacturer's
cleaning solutions.
A WARNING 1. Thoroughly clean all metal parts with an approved

Solvents and cleaning solutions can be cleaning solvent . Place parts on a clean lint free
hazardous. Serious personal injury may surface and allow to air dry. Exercise every precau
resu lt from misuse of these products. Read tion possible to keep all parts free of dust, dirt or
and follow all the manufacturer's any other foreign material during assembly.
recom mendations concerning solvents and 2. Carefully inspect all components for damage,
cleaning solutions. wear, corrosion, deep scratches and scuffed met
al. Remove any burrs or sharp edges with a fine
1. Thoroughly clean the exterior sur1ace of the relief file, hone, emery cloth or crocus cloth. Replace
valve with an approved cleaner to prevent contami any damaged component as required. Replace all
nation from entering it. o-rings and back up rings.
rings, and o-rings, should be replaced.
4. Inspect the integrity of the hydraulic lines/hoses
that are connected to the relief valve. Repair or
replace if required .
5. In the event of severe defects, contact factory
replace any major component.
2 of 4
Assembly 7. If relief valve is already installed on the crane:
a. Check hydraulic reservoir oillevel. Add oil as
Unless stated otherwise, lubricate all back up rings, required. See Operator's Manual for correct
o-rings and valve body bores with hydraulic oil prior to type and procedure.
assembly. See Operator's Manual for correct type. b. Engage the main hydraulic pump.
1. Install jam nut (2) onto adjuster screw (1). c. Start the engine and let idle for five minutes.
2 Install o-ring (3) and adjuster screw (1) into valve Inspect the connections on the hydraulic lines
body (9). for leaks . Repair if needed.
3. Install adjuster screw (1) to setting recorded at dis d. Complete the installation by testing all related
assembly. Secure jam nut (2). functions 01 the relief valve for proper opera
4. Install o-rings (5,8) and back up rings (6,7) onto tion. Normal operation of hydraulic and electri
cartridge (4). cal systems should be confirmed. A general
inspeetion 01 components and systems in the
Note: Refer to SM Area 1-43, Solenoid Valves areas adjaeent lo the repair should also be per
General Recondition, for installation and torque formed to ensure related damage or wear is
procedures of cartridge (4). not present.
8. After reliel valve has been installed on crane, see
5. Install cartridge (4) into valve body (9).
Operator 's Manual lor correet relief pressure ad
6. If relief valve is not to be immediately installed on
justment proeedure.
and properly store.
3 of 4
4 of 4
Service Manual 0408 SM01 -()47 -038.00
(Tank) (Pump Pressure)
GF
FO
BH
CS
(Fan Supply) (Cooler Supply)
Solenold
(Cooler Bypass) Valve
1 \~,~' (, . - J
LS
)1 ,,/ .1/
)
(Load Sense)
Figure 1
Pick & Carry Manifold Block
Refer to "Lower Hydraulic Components , R & 1" in SM

Pick & Carry Manifold Keysheet Area 01-079 for general removal and
Block, IIlustrated installation guidelines , as well as crane shutdown and
hydraulic pressure relief procedures.
This SM code is intended to provide an illustration of
the manifold block so that valve locations and seal
orientations can be properly identified.
1 of 2
oo o
Pressure Compensated
Flow Control Valve Relief Valve
[ TI lf
I U U J
I I
lUí f,)
iII 111
Proportional Relief Valve Solenoid Valve

Figure 2
Seal Arrangements
2012
6. Using an auxiliary lifting device, carefully remove
Rotating Joint, Recondition the housing (5) from the rotor (4).
(5-Way) 7. Remove the piston seals (7), square ring seals (8),
This procedure covers the recondition of the rotating u-cup seals (9), bearings (10), and rotor seal (11)
join!. For removal and installation procedures for the from the rotor (4).
rotating joint, see SM Keysheet Area 01 -048. 8. If required, remove the brackets, capscrews, and
washers (1) from the housing (5).
Disassembly 9. If required, remove the bracket and capscrews (3)
from the rotor (4).
components to lay the parts out in the order that they Cleaning And Inspection
.A WARNING
.A WARNING
hazardous. Serious personal injury may recommendations concerning solvents and
result from misuse of these products. Read cleaning solutions.
recommendations concerning solvents and 1. Thoroughly clean all metal parts with an approved
cleaning solutions. cleaning solven!. Place parts on a clean, lint free
1. Plug all open ports in the rotating joint to prevent tion possible to keep all parts free of dust, dirt, or
contamination Irom entering the unit during clean any other foreign material during assembly.
ing, disassembly, and assembly. 2. AII Loctite®, Permatex®, or other sealant residue
2. Thoroughly clean the exterior surface of the rotat should be removed from the threads 01 hardware
ing joint with an approved cleaning solvent and al and the mounting surfaces of parts that are going
low to air dry. to be reused. Prior to applying new thread locking
Refer to Figure 1. compounds or sealants, clean the threads and sur
faces with Loctite® 7070 Cleaner to ensure the best
Note: The rotating joint and water swivel as performance of the products.
sembly weighs approximately 380 lb (172kg). 3. Carefully inspect all the components for damage,
Individually the rotor weighs approximately wear, corrosion, deep scratches, and scuffed met
170 lb (77kg), the water swivel weighs approx al. Pay particular attention to the grooves in the ro
imately 60 lb (27kg), and the housing weighs tor and the port openings in the housing. Remove
approximately 150 lb (68kg). any burrs or sharp edges with a fine file, hone,
3. Using an auxiliary lifting device, position the rotat emery cloth, or crocus cloth. Replace any dam
ing joint and water swivel assembly with the rotor aged component as required.
(4) end down. 4. AII "soft parts", such as piston seals, square ring
4. If equipped, remove the water swivel(2) from the seals, u-cup seals, and rotor seals, should be re
top of the rotating joint assembly. See SIV1 Key placed. Wear rings and bearings should also be
sheet Area 06-025 for the correct procedure. replaced.
5. Remove the wear ring (6) from the rotor (4). 5. The water swivel should be reconditioned at the
same time as the rotating joint. See SM Keysheet
Note: It may be necessary to tap the rotor with a Area 06-025 for the correct procedure.
soft face mallet in order to break the housing 6. In the event of severe defects, contact factory per
free. sonnel for directions whether to repair or replace
1 014
S M01 -048·-044.00 0307 Service Manual
2
B
6
8 ---..,,<~
9--+-_
10--+--_
7
10---1-_
9 --+-- 7
8 ---r--_
11--;--
4 - - __
1. Brackets , Capscrews, & Washers 5. Housing 9. U-cup Seals

2. Water Swivel* 6. Wear Ring 10. Bearings
3. Bracket & Capscrews 7. Pistan Seals 11 . Rotor Seal
4. Rotor 8. Square Ring Seals
*Optional
Figure 1
Rotating Joint Assembly
2 of 4
Assembly 5. Install the rotor seal (11), with lip-seal lacing up,
into the last groove at the port end 01 the rotor (4) ,
as shown in Detail e, Figure 1.
A WARNING
Note: Ensure that the piston seals and square ring
seals are properly identified. The Teflon® materia l
used to make the piston seals is a hard material and
compounds, etc. can be hazardous. Serious the square ring seals are made of a softer, rubb er
personal injury may result from misuse of like compound.
manufacturer's recommendations concerning 6. Install a square ring seal (8) and a piston seal (7) in
these products. the next groove, as shown in Detail e, Figure 1.
7. Install a u-cup seal (9), with lip-seal lacing up , in
the next groove , as shown in Detail e, Figure 1.
Note: The rotating joint and water swivel as 8. Install a bearing (10) in the next groove, as shown
sembly weighs approximately 380 lb (172kg). in Detail e, Figure 1.
Individually the rotor weighs approximately 9. Install square ring seals (8) and pisto n seals (7) in
170 lb (77kg), the water swivel weighs approx the next lour grooves, as shown in Detail B,
imately 60 lb (27kg), and the housing weighs Figure 1.
approximately 150 lb (68kg). 10. Install a bearing (10) in the next groove, as shown
in Detail B, Figure 1.
Reler to Figure 1. 11 . Install a u - cup seal (9), with lip - seal facing down,
1. II the brackets, capscrews, and washers (1) were in the next to last groove, as shown in Detail B ,
removed, apply a light coat 01 Loctite® 271 to the Figure 1.
threads ofthe capscrews (1) . Secure the brackets 12. Install a square ring seal (8) and a piston seal (7) in
(1) to the housing (5) by installing the capscrews the last groove, as shown in Detail B , Figure 1.
and washers (1). Torque the capscrews (1) to 13. Install as many piston ring compressors as neces
120-135 ft lb (168-189Nm). sary to compress all sets of piston seals (7) , u -cup
2. If the bracket and capscrews (3) were removed , seals (9) , bearings (10) , and rotor seals (11). Leave
applya light coat 01 Loctite® 242 to the threads of the piston ring compressors installed for several
the capscrews (3). Securethe bracket (3) to the ro minutes to allow a maximum amount of time to
tor (4) by installing the capscrews (3) . Torque the install the rotor (4) tn the housing (5). Once the
capscrews (3) lO 230-250 ft lb (322-350Nm). compressors are removed , the seals will remain
3. Soak the new wear ring (6), square ring seals (8), compressed for only a short time .
pislon seals (7), u - cup seals (9) , and rOlor seal
(11) in clean hydraulic oil. Allow adequale lime for
the parls to absorb Ihe hydraulic oil. Refer lO the CAUTION
Operator's Manual for Ihe correct grade of hydrau
lic oil lo use. Make sure piston seals, u-cup seals,
4. Using an auxiliary lifting device, position the rotor bearings, and rotor seals remain compressed
(4) port side down . as they pass across the side port openings in
the housing. If they expand in the port
openings, they will beco me damaged and
CAUTION cause leaks.
Use extreme care not to nick or cut soft parts. 14. Using an au xiliary lifting device, slowly lower the
Any nicks or cuts will cause the rotating joint housing (5) onto the rotor (4).
to leak. If this occurs, damaged components
will require replacement.
Do not stretch the components any further

than necessary or they will not compress well
enough to allow the housing to slide over the
rotor. Do not allow any seal to be twisted in the
groove after installation.
3 of 4
15. Install the wear ring (6), with the groove down , on
the rotor (4).
16. If equipped, install the water swivel (2) on the rotat
ing joint assembly. See SM Keysheet Area 06-025
for the correct procedure.
Test Procedure
Pressure test the rotating joint assembly, using clean
hydraulic oil, to ensure that no damage has occurred to
the seals during assembly. The port numbers for each
port are stamped on the end of the rotor (4). For
additional port identification , refer to Figure 2 .
AII tests require that pressure be maintained for 1.5 to 2

minutes . Check for any leakage across seals and
repair as required.
Note: Ports #1 A and 1 B are ported to the same

pass in the rotating joint. When testing these ports,
Figure 2 plug one and apply test pressure to the other.
Port Identification
1. Test Port #1 at 1,000 psi (6 895kPa).
2. Test Ports #2 thru #7 at 4,500 psi (31 026kPa).
Note: The pisto n seals, u-cup seals, bearings, and 3. Ports #1 and #5 should also be tested at a minimal
rotor seals may have to be compressed as each one pressure of 50 psi (345kPa) .
is started into the housing. It may be necessary to 4. Torque test the rotating joint. The acceptable
t ap the housing with a soft face mallet to get it range of torque required to turn the rotor is
started. Once the rotor is started into the housing, 200-800 ft lb (271-1 084Nm). If torque is outside
use a hydraulic press to slowly push the parts to this range , disassemble and corree!.
gether. The piston seals, u·-cup seals, bearings,
If the rotating joint is not to be immediately installed on
and rotor seals may have to be compressed again
the eran e, plug all open ports to prevent contamination
as they pass by the large port openings in the side
and properly store.
of the housing.
4 of 4
((.?
IIL
13
.1
J /
/
9 8 7 6
1. Capscrews & Washers 5. Rotating Joint 8. Bracket 11. Capscrew
2. Hydraulic Lines 6. Jam Nuts 9. Locknut 12. Hydraulic Lmes
3 Sp lit Flanges & 0- rings 7. Adjusting Rod 10. Spacer 13. Collector Ring
4. Capscrews
Figure 1
Center Section Assembly
Rotating Joint, R & I b. Engage the park brake and/or properly block
the tires.
This procedure covers the removal and installation of c. Engage the swing park brake or travel swing
the rotat ing joint. For recondition procedure, see SM lock, as required.
Keysheet Area 01 -048. d . Level the crane on fully extended outriggers .
Removal quired.
a. Park the crane , out of the way, on a firm and
level surface.
1 of 4
9. Label lor assembly purposes and disconnect all
A WARNING Ilange type hydraulic lines (2) Irom the rotating joint
(5) by removing the capscrews (4) and split flanges
Solvents and cleaning solutions can be and o-rings (3). Cap/plug the open hydraulic
hazardous. Serious personal injury may ports and lines (2) to prevent excessive oilloss and
result from misuse of these products. Read contamination 01 the system.
and follow all the manufacturer's 10. Label lor assembly purposes and disconnect all re
recommendations concerning solvents and maining hydraulic lines (12) Irom the rotating joint.
cl eaning solutions. Cap/plug the open hydraulic ports and lines (12) to
prevent excessive oilloss and contamination 01 the
4. Thoroughly clean the area to be disassembled with system.
mination . Allow the area to air dry. Note: The rotating joint weighs approximately
340 lb (154kg).
A WARNING 11. Using an appropriate lifting device, support the ro

tating joint (5). Do not apply excessive upward
Hydraulic oil is under pressure and may be pressure.
hot. A sud den release of hot oil could cause 12. Remove the locknut (9) , capscrew (11) , and
burns or other serious injury. Shutdown the spacer (10), securing the adjusting rod (7) to the
engine and exhaust all trapped hydraulic bracket (8) . Swing the adjusting rod (7) out 01 the
pressure from the system before removing way and secure.
any line or component. 13. Remove the capscrews and washers (1) securing
the rotating joint (5) to the upper Irame.
5 . Relieve the hydraulic system pressure as follows: 14. Carelully lift the rotating joint (5) Irom the crane .
reservoir by slowly loosening the liller/ breather Cleaning And Inspection
cap , located on the top 01 the hydraulic
reservoir, until pressure is lully relieved.
START THE ENGI NE. Move the lunetion lock
A WARNING
out switch to the "OPERATE " position.
switches back and lorth several times.
d. Turn ignition switch to the "OFF" position .
cleaning solutions.
tion and move the lunction lockout switch to the
"DI SABLE" position .
Reler to Figure 1. an approved eleaning sOlvent, air dried , and care
7. Remove the eollector ring (13). See SM Keysheet lully inspected.
Area 01-076 for the correet proeedure. 2. AII Loctite® , Permatex®, or other sealant residue
8. Install a low pressure suction pump to the hydrau should be removed Irom threads 01 hardware and
lic reservoir to minimize oilloss or drain the hydrau the mounting surlaces 01 parts that are going to be
lic reservoir. See the Operator's Manual lor the cor reused. Prior to applying new thread locking eom
rect procedure for draining the reservoir. pounds or sealants, clean threads and surlaces
Note: If the relationship between the rotor and
mance 01 products.
housing is not maintained, manual rotation of the 3. Thoroughly inspect all parts for damage, wear, fa
rotating joint during assembly will be difficult. tigue or stress Iractures , and corrosion . Repair or
Index mark the rotor and housing for installation
replace as required .
purposes .
2014
4. AII "soft parts", such as seals, gaskets, back up 4. Align the end 01 the adjusting rod (7) to the bracket
rings, and o-rings, should be replaced. (8) on the rotating joint (5) . Loosen the jam n uts (6)
5. Inspect the integrity 01 the hydraulic lines that are il necessary for alignment.
connected to the rotating joint. Repair or replace il 5. Install the capscrew (11), spacer (10), and locknut
required. (9).
6. In the event 01 severe delects, contact factory per 6. Tighten the jam nuts (6).
sonnel for directions whether to repair or replace 7. Applya light coat of Loctite® 242 to the threads 01
any major component. the capscrews (4) .
8. Align all Ilange type hydraulic lines (2) to the rotat
Installation ing joint (5) , install the o-rings and split flanges
(3), and secure with Ihe capscrews (4).
9. Connect all remaining hydraulic Iines (12) to the ro
A WARNING
10.
tating joint.
Install the collector ring (13). See SM Keysheet
Area 01 -076 lor the correct procedure.
compounds, etc. can be hazardous. Serious 11. Check the hydraulic reservoir oil leve!. Add oil as
personal injury may result from misuse of required See the Operator's Manual lor correct
these products. Read and follow all type and procedure .
manufacturer's recommendations concerning 12. Check for correct fluid levels in any relate cl
these products. components such as pump drives , gear reduction
units, engine crankcase, radiator, etc . Refer to the
crane or engine Operator 's Manual for correct
Note: Before rigging the rotating joint for installa
type/quantily 01 Iluids and proper procedure.
tion, align the index marks put on the housing and
13. Engage the main hydraulic pump, as equipped .
rotor during the removal process. If a new rotating
14. Start the engine and let idle lor live minutes . In
joint is being installed, transfer the index marks
from the old rotating joint to the new. spect the hydraulic connections lor leaks . Repair
leaks as required .
15. Test all related lunctions 01 the rotating Joint (5) lor
Note: The rotating joint weighs approximately proper operation .
340 lb (154kg). 16. Cycle each cylinder, as required, to bleed any
trapped air Irom th e individual circuils wilhin th e
Reler to Figure 1. system.
1. Using an appropriate Iifting device, carelully posi 17. Normal operation 01 Ihe hydraulic system should
tion the rotating joint (5) to Ihe carrier frame and up be conlirmed . A general inspection 01 the com po
per Irame . nents and syslems in the areas adjacent to the re
2. A pplya light coat 01 Loctite® 242 to the threads of pair should also be performed lo ensure related
the capscrews (1). damage or wear is not present.
3. Secure the rotating joint (5) to the upper frame by
installing the capscrews and washers (1). Torque
the capscrews (1) to 90-100 ft lb (122-136Nm).
3014
4 of 4
b. Turn the ignition switch to " ON", but DO NOT
Hydraulic Oil Cooler STARTTHE ENGINE. Move the function lock
Assembly, R & I C.
Work the crane control levers and outrigg er
This procedure covers the removal and installation of switches back and forth several times.
the hydraulic oil cooler assembly. For oil cooler d. Turn ignition switch to the "OFF" position.
hydraulic motor removal, installation, and recondition 6. Check that all controllevers are in the neutral posi
procedures, see SM Keysheet Area 01-050. tion and move the tunction lockout switch lO the
"OISABLE" position .
Removal Refer to Figure 1.
1. Lower, detach, and secure the load , as required. 7. If equipped , remove the oil cooler accumulator
2. Stabilize the crane for service as follows: mounted on the ladder assembly (2) . See SM Key
a. Park the crane, out of the way, on a firm and sheet Area 01 - 050 for complete inslructions .
level surface. 8. Label for assembly purposes and disconnect any
b. Engage the park brake and/or properly block electrical wires , as required .
the tires . 9 . Label for assembly purposes and disconnect the
c. Engage the swing par k brake or travel swing hydraulic lines (17,20) trom the hydraulic oil cooler
lock, as required . (19) and oil cooler hydraulic motor (18) . Cap/plug
d. Level the crane on fully extended outriggers . the open hydraulic ports and lines (17 ,20) to pre
Extend the outrigger jacks as far as possibleto vent excessive oil loss and contamination of the
provide maximum clearance underneath the system.
crane .
e. Fully retract and position the boom, as re Note: The hydraulic oil cooler and ladder
quired. assembly weighs approximately 205 lb (93kg).
10. Using an auxiliary lifting device, support the weig ht
draulic pump.
of the hydraulic oil cooler (19) and ladder (2) as
sembly.
A WARNING
11. Remove the capscrews, washers , and nylon wash
ers (11) and capscrews, washers , nylon wash ers,
and locknuts (10) that secure the handles (9) to the
hazardous. Serious personal injury may ladder assembly (2) . Remove the handles (9) .
result from misuse of these products. Read 12. Remove the locknuts (7), washers (6) , nylon wash
and follow all the manufacturer's ers (8). screws (5) , washers (4) , and nylon washers
recommendations concerning solvents and (3) that secure the hydraulic oil cooler (1 9) and lad
cleaning solutions. der (2) assembly to the fenders (1) .
13. Remove the locknuts, washers , and nylon washers
4. Thoroughly clean the area to be disassembled with (14,15) that secure Ihe hydraulic oil cooler (19) and
an approved cleaning solvent lo prevent conta ladder (2) assembly to the carrier frame .
mination . Allow the area to air dry. 14. Carefully lower the hydraulic oil cooler (19) and lad
der (2) assembly below the lip of the fenders (1)
and slide it away from the crane.
A WARNING 15. Position the hydraulic oil cooler (19) and ladder (2)
assembly on a firm, level surface .
hoto A sudden release of hot oil could cause Note: The hydraulic oil cooler assembly weighs
burns or other serious injury. Shutdown the approximately 124 lb (56kg).
pressure from the system before removing 16. Using an auxiliary lifting device, support the weight
any line or component. of the hydraulic oil cooler assembly (19) .
17. Remove the locknuts, nylon washers, washers ,
5. Relieve the hydraulic system pressure as follows: and capscrews (16) securing the hydraulic oil cool
a. Release any residual pressure in the hydraulic er assembly (19) to the ladder supports (12) .
reservoir by slowly loosening the filler/breather
reservoir, until pressure is fully relieved.
1 of 4
. 1>
I..._:¡·· .~
'1" ..r;
" { ,
B
2 3 4 5 2
1. Fenders 6. Washers
2. Ladder Assembly 7. Locknuts
3. Nylon Washers 8. Nylon Washers
4. Washers 9. Handles
5. Screws 10. Capscrews, Washers, Nylon Washers, & Locknuts
Figure 1
Hydraulic Oil Cooler & Ladder Assembly
2 of 4
19
11 . Capscrews, Washers, & Nylon Washers 16. Capscrews, Washers, Nylon Washers , & Locknuls
12. Ladder Suppons 17. Hydraulic Lines
13. Capscrews, Washers, Nylon Washers, & Locknuls 18. Oil Cooler Hydraulic Molor
14. Nylon Washers, Washers, & Locknuls 19 Hydraulic 011Cooler Assemb ly
15. Nylon Washers, Washers, & Locknuls 20. Hydraulic Lines
3 af 4
18. Remove the locknuts, nylon washers , washers , Reler to Figure 1.
and capscrews (13) securing the hydraulic oil cool
er assembly (19) to the ladder assembly (2) . Note: The hydraulic oil cooler assembly weighs
19. Carelully remove the hydraulic oil cooler assembly approximately 124 lb (56kg).
(19) Irom the ladder assembly (2) .
1. Using an auxiliary lifting device , position hydraulic
Cleaning And Inspection oil cooler assembly (19) to the ladder assembly (2).
2. Install the capscrews , washers, nylon washers ,
and locknuts (13) to secure the hydraulic oil cooler
A WARNING
assembly (19) to the ladder assembly (2).
3 . Install the capscrews, washers, nylon washers ,
and locknuts (16) to secure the hydraulic oil cooler
hazardous. Serious personal injury may assembly (19) to the ladder supports (12).
and follow all the manufacturer's Note: The hydraulic oil cooler and ladder
recommendations concerning solvents and assembly weighs approximately 205 lb (93kg).
cleaning solutions. 4. Using an auxiliary lifting device, carelully guide the
hydraulic oil cooler (19) and ladder (2) assembly
1. AII components should be thoroughly cleaned with under the lip 01 the lenders (1) and into position
an approved cleaning solvent , air dried , and care with the carrier Irame .
lully inspected . 5. Secure the hydraulic oil cooler (19) and ladder (2)
2. AII Loctite®, Permatex®, or other sealant residue assembly to the carrier Irame by installing the ny
should be removed Irom threads 01 hardware and lon washers, washers, and locknuts (14,15).
the mounting surlaces 01 parts that are going to be
6. Secure the hydraulic oil cooler (19) and ladder (2)
reused . Prior to applying new thread locking com assembly to the lenders (1) by installing the nylon
pounds or sealants , clean threads and surfaces washers (3), washers (4) , screws (5), nylon wash
with Loctite® 7070 Cleaner to ensure best perlor ers (8), washers (6), and locknuts (7).
manee 01 products . 7. Position the handles (9) to the ladder assembly (2) ,
3. Thoroughly inspect all parts lor damage, wear, la and install the capscrews , washers , nylon wash
ti gue Or stress Iractures , and corrosion . Repair or ers , and locknuts (10) and capscrews , washers ,
replace as required. and nylon washers (11) .
4. AII "soft parts ", such as seals, gaskets , back up 8. Connect the hydraulic lines (17 ,20) to the hydraulic
rings , and o-rings , should be replaced. oil cooler (19) and oil cooler hydraulic motor (1 8).
5. Inspect the integrity 01 the hydraulic lines that sup 9. II equipped, install and charge the oil cooler accu
ply the hydraulic oil cooler and oil cooler hydraulic mulator which mounts to the ladder assembly (2).
motor. Repair or replace il required . See SM Keysheet Area 01 -050 lor complete in
6 . In the event 01 severe delects, contact lactory per structions .
sonnel lor directions whether to repair or replace 10. Connect any electrical wires , as required.
any major component. 11 . Check the hydraulic reservoir oillevel. Add oil as
required . See the Operator's Manual lor correct
Installation type and procedure.
12. Start the engine and let id le lor live minutes . In
A WABNING
spect the hydraulic connections lor leaks . Repair
leaks as required.
13. Complete the installation by testing all related lunc
compounds, etc. can be hazardous. Serious tions 01 the hydraulic oil cooler lor proper opera
personal injury may result from misuse of tion . Normal operation 01 the hydraulic, air, and
these products. Read and follow all electrical systems should be conlirmed . A general
manufacturer's recommendations concerning inspection 01 the components and systems in the
these products. areas adjacent to the repair should also be per
lormed to ensure related damage or wear is not
present.
4014
Oil Cooler Hydraulic Fan tion and move the function lockout switch to the
Motor, R & I "DISABLE " position.
Refer to Figure 1.
This procedure covers the removal and installation of 7. Remove the hydraulic oil cooler and ladder assem
the oil cooler hydraulic fan motor. For re co ndition bly (1) from the crane. See SM Keysheet Area
procedure , see SM Keysheet Area 01 -050. 01-050 "Hydraulic Oil Cooler Assembly, R & 1" for
the correct procedure .
Removal 8. For assembly purposes , place alignment marks on
1. Lower, detach, and secure the load, as required . the fan motor (3), fan guard (2), and fan sh roud (7).
2. Stabilize the crane for service as follows: 9 . Remove the capscrews, washers, and lockwash
a. Park the crane , out of the way, on a firm and ers (6), and separate the fan guard (2) from the fan
level surface. shroud (7).
b. Engage the park brake and/or properly block 10. Remove the capscrews and lockwashers (8) wh ich
the tires. secure the fan (5) to the hub bushing (9) .
c . Engage the swing park brake or travel swing 11. Install the capscrews (8) in the removal holes (13)
lock, as required. in the hub bushing (9). The removal holes (13) are
d . Level the crane on fuliy extended outriggers. the threaded holes in the face of the hub bushin g
e. Fully retract and position the boom , as re (9) .
quired. 12 . Equally tighten th e ca pscrews (8) , one half turn at a
3. Shutdown the engine and disengage the main hy time , until the fan (5) is loose on the hu b bus hing
draulic pump . (9) .
13. Remove the fan (5) from the hub bushing (9) .
A WARNING
14. Loosen the setscrew (12), and remove the hub
bushing (9) and key (11) from the shaft (10) of the
fan motor (3) .
15 . Remove the capscrews , washers, lockwashers,
and nuts (4) that secure the fan motor (3) to the fan
guarcl (2) , and remove the fan motor (3).
recommendations concerning solvents and Cleaning And Inspection
cleaning solutions.

A WARNING
A WARNING
cleaning solutions.
hot. A sudden release of hot oil could cause
fully inspected.
the mounting surfaces of parts that are goin g to be
reservoir by loose ning the filler cap 1/ 4 turno
pounds or sealants , clean threads and surfaces
mance of products .
out switch to the "O PERATE" position .
tigue or stress fractures , and corrosion. Repair Or
d. Turn ignition switch to the "OFF " position.
1 of 4
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0.125" (3mm)
3
1. Hydraulic Oil Cooler & Ladder Assembly 8. Capscrews & Lockwashers

2. Fan Guard 9. Hub Bushing
3 Fan Motor 10. Shaft (Fan Motor)
4. Capscrews. Washers, Lockwashers, & Nuts 11. Key
5. Fan 12. Setscrew
6. Capscrews, Washers. & Lockwashers 13. Removal Holes (rhreaded)
7. Fan Shroud
Figure 1
Hydraulic Oil Cooler & Ladder Assembly
2 of 4
4. Al! "soft parts", such as seals, gaskets, back up 3. Tighten the setscrew (12) to secure the position 01
rings , and o-rings, should be replaced . the hub bushing (9) on the shaft (10) 01 the lan mo
5. Inspect the integrity 01 the hydraulic lines that are tor (3).
connected to the oil cooler hydraulic lan motor. Re 4. Properly align the lan (5) on hub bushing (9), and
pair or replace il required . insert the capscrews and lockwashers (8) through
6. In the event 01 severe delects, contact lactory per the lan (5) and into the threaded holes in the hub
sonnel lor directions whether to repair or replace bushing (9).
any major component. 5 . Tighten the capscrews and lockwashers (8), linger
tight.
Installation 6. Evenly tighten the capscrews (8) , one hallturn ata
time , to 108 in lb (12.2Nm) .
A WARNING
Note: When capscrews are fully tightened,
there should be a gap of 0.125 in (3mm) be
Lubricants, sealants, joint and thread locking tween the end of the fan motor shaft and the end
compounds, etc. can be hazardous. Serious of the hub bushing.
these products. Read and follow all 7. Position the lan motor (3), lan guard (2), and lan
manufacturer's recommendations concerning (5) , as an assembly, to the lan shroud (7) .
these products. 8. Install the capscrews, washers , and lockwashers
(6) to secure the lan guard (2) to the lan shroud (7).
9. Install the hydraulic oil cooler and ladder assembly
Reler to Figure 1.
(1) on the crane . See SM Keysheet Area 01-050
1. Position the lan motor (3) to the lan guard (2) and
"Hydraulic Oil Cooler Assembly, R & 1" lor the cor
install the capscrews, washers , lockwashers, and rect procedure .
nuts (4) . Use the index marks placed on the lan 10. Check the hydraulic reservoir oil leve!. Add oil as
motor (3) and lan guard (2) during removal to en
sure proper orientation 01 parts.
type and procedure .
11 . Start the engine ancl let idle lor live minutes . In
spect the hydraulic connections lor leaks. Repair
CAUTION leaks as required .
Do not use anti-seize lubricant on the 12. Complete the installation by testing all related lunc
tapered cone surfaces of the hub bushing. tions 01 the oil cooler hydraulic lan motor lor proper
Damage to fan hub and/or hub bushing may operation. Normal operation 01 the hydraulic sys
occur. Mating surfaces need only be smooth tem should be conlirmed . A general inspectlon 01
and clean. the components and systems in the areas adja
cent to the repair should also be performed to en
2. Properly position the hub bushing (9) and key (11)
sure related damage or wear is not present.
on the shaft (10). Align the outer surlace 01 the hub
bushing (9) with the end 01 the key (11). This wil!
allow some space, approximately 0.125 in (3mm) ,
between the bottom 01 the hub bushing (9) and
lace 01 the lan motor (3) . See Detail "B " in Fig u re 1.
3014
4 of 4
Hydraulic Oil Cooler START THE ENGINE. Move the function
Accumulator, R & I lockout switch to the "OPERATE" position.
the hydraulic oil cooler accumulator. It also includes d. Turn the ignition switch to the "OFF" position .
instructions for charging the accumulator. 6. Check that all control levers are in the neutral
Removal the "DI SABLE" position .
1. Lower, detach , and secure the load , as required . Refer to Figure 1.
2. Stabilize the crane for service as follows : 7 . Label for assembly purposes and disconnect the
a. Park the crane , out of the way, on a firm and hydraulic line (4) from the hydraulic oil cooler
level surface . accumulator (2). Cap/plug the open hydraulic port
b. Engage the park brake and/or properly block and line (4) to prevent excessive oil loss and
the tires. contamination of the system .
8. Remove the locknuts (3) and clamp (1) and
lock, as required.
d. Level the crane on fully extencled outriggers. remove the hydraulic oil cooler accumulator (2)
e. Fully retract and position the boom, as from the crane .
required.
3 . Shutdown the engine and disengage the main Cleaning And Inspection
hydraulic pump .
A WARNING
A WARNING
result from misuse of these products. Read and follow all the manufacturer's
cleaning solutions.
4. Thoroughly clean the area to be disassembled with an approved cleaning solvent , air dried , and
an approved cleaning solvent to prevent carefully inspected.
contamination. Allow the area to air dry. 2. AII Loctite®, Permatex®, or other sealant residue
A WARNING reused. Prior to applying new thread locking
compounds or sealants, clean threads and
Hydraulic oil is under pressure and may be surfaces with Loctite@7070 Cleaner to ensure best
hot. A sudden release of hot oil could cause performance of products .
burns or other serious injury. Shutdown the 3. Thoroughly inspect all parts for damage, wear,
engine and exhaust all trapped hydraulic fatigue or stress fractures , and corrosion . Repair
pressure from the system before removing or replace as required .
any line or component. 4. Inspect the integrity of the hydraulic line that is
connected to the hydraulic oil cooler accumulator.
5. Relieve the hydraulic system pressure as follows: Repair or replace if required.
a. Release any residual pressure in the hydraulic 5. In the event of severe defects, contact factory
reservoir by slowly loosening the filler/breather personnel for directions whether to repair or
cap, located on the top of the hydraulic replace any major componen!.
reservoir, until pressure is fully relieved .
1 of 6
A
2 3 4
1-=
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~ 1
1'1
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1. Clamp 3. Lockn uts

2. Hyd raulic Oil Cooler Accumulator 4. Hyd rau lic Line
Figure 1
Hydraulic Oil Cooler Accumulator
2 af 6
Installation 4. Check the hydraulic reservoir oil level. Add oil as
required. See the Operator's Manual lor the
A WARNING
5. Check lor correct Iluid levels in any related
components such as pump drives , gear reduction
Lubricants, sealants, joint and thread locking units, engine crankcase , radiator, etc . Reler to the
compounds, etc. can be hazardous. Serious crane or engine Operator 's Manual lar correct
personal injury may result from misuse of type/ quantity 01 Iluids and proper procedure .
these products. Read and follow all 6. Engage the main hydraulic pump .
manufacturer's recommendations concerning 7. Start the engine and let idle lor live minutes.
these products . Inspect the hydraulic connections lor leaks.
Reler to Figure 1. 8. Complete the installation by testing all related
1. Properly align the hydraulic oil cooler accumulator lunctions olthe hydraulic oil cooler accumulatar lar
(2) and install the clamp (1) and locknuts (3). proper operation. Normal operation 01 the
2. Connect hydraulic line (4) tothe hydraulic oil cooler hydraulic, air, and electrical systems should be
accumulator (2) . conlirmed. A general inspection 01 the
3. Charge the accumulator il necessary. Reler to components and systems in the areas adjacent to
"Charging The Accumulator" lound later in this the repair should also be perlormed to ensure
document. related damage or wear is not present.
3016
S M01 - 050·- 015.00 0208 Service Manual
~ _ _- - 4
3
_ _-5
2
$--6
7
1+-.~_-10
11
1. Accumulator 4. Supply Gauge 7. Chuck 10. Diaphragm

2. Regulator Valve 5. Regulator Assy 8. Adaptar' 11 . Fluid Porl
3. Regulator Gauge 6. Cap 9. Gas Valve
• An ada pIar may be required lo connecl Ihe chuck lo Ihe valve.
Figure 2
Ty pical Accumulator Charging Arrangement
Charging The Accumulator The aeeumulator is pressurized with dry nitrogen and
may be eharged with the unit installed on, or removed
from the erane.
A WARNING
1. Lower, detaeh, and seeure load, as required.
2. Stabilize the erane for serviee as follows:
a. Park the erane out of the way on a firm and level
Never use oxygen or air to charge the
accumulator. Use only dry nitrogen or other surfaee.
approved gases. Serious personal injury may b. Engage the park brake.
result from misuse of these products. Read e. Engage the swing park brake or travel swing
and follow all manufacturer's loek, as required .
recommendations concerning these products. d. Level the erane on fully extended outriggers.
e. Fully retraet and lower the boom, as required.
4 of 6
3. Shutdown the engine and disengage the main 9. Connect the regulator assembly (5) to the dry
hyclraulic pump. nitrogen tank.
10. Open the valve on the dry nitrogen tank . The
regulator gauge (3) should read O psi (OkPa).
A WARNING 11 . Note the reading on the supply gauge (4). The dry
nitrogen tank must contain suflicient volume and
Solvents and cleaning solutions can be pressure to charge the accumulator (1) to 500 psi
hazardous. Serious personal injury may (3447kPa).
result from misuse of these products. Read 12. Connect the chuck (7) to the gas valve (9) .
and follow all the manufacturer' s 13. An adaptor (8) may be required to connect the
recommendations concerning solvents and chuck (7) to the gas valve (9).
cleaning solutions . 14. Turn the t-handle on the chuck (7) clockwise to
open the gas valve (9).
an approved cleaning solvenl to prevenl Note: When charging a new accumulator, open the
contaminalion. Allow the area to air dry. regulator valve slowly until the regulator gauge
reads 5 psi (34kPa).
A WARNING 15. Slowly open the regulator valve (2) until the
regulator gauge (3) reads 500 psi (3 447kPa).
Hydraulic oil is under pressure and may be 16. Close the valve on the dry nitrogen tank and turn
hot. A sudden release of hot oil could cause the t-handle 01 the chuck (7) counterclockwise lo
burns or other serious injury. Shutdown the close the gas valve (9).
engine and exhaust all trapped hydraulic 17. Remove the chuck (7) Irom the gas valve (9).
pressure from the system befo re removing (Remove adaptor (8) il necessary.) Inspect the gas
any line or component. valve (9) lor leaks . There will be a slight discharge
01 nitrogen when the chuck (7) is removed. Repair
5. Relieve Ihe hydraulic system pressure as lollows: leaks as required .
a. Release any residual pressure in the hydraulic 18. Install the cap (6) on the accumulator (1).
reservoir by slowly loosening the liller/b realher 19. Check the hydraulic reservoir oillevel. Add oil as
cap , located on the top 01 the hydraulic required . See Operator's Manual lor correct type
reservoir, unlil pressure is lully relieved. and procedure.
b. Turn the ignilion swilch lo "ON", bul DO NOT 20. Engage the main hydraulic pump .
START THE ENGINE. Move Ihe lunction 21. Start the engine and jet idle lor live minutes.
lockoul swilch to the "OPERATE " position. Inspect the connections on the hydraulic lines lor
c . Work Ihe crane control levers and outrigger leaks. Repair il needed.
switch es back and lorth several times. 22. Complete the instailation by testing all related
d. Turn the ignilion switch to Ihe "OFF" position. lunctions 01 the carrier brakes lor proper operation.
6. Check thal all control levers are in the neutral Normal operation 01 hydraulic system should be
position and move the lunclion lockout switch lo conlirmed. A general inspeclion 01 components
Ihe "D ISABLE" position. and systems in the areas adjacenl to the repair
should also be perlormed lo ensure related
Reler lo Figure 2.
damage Or wear is not present.
7. Remove Ihe cap (6).
8. Ensure the regulator valve (2) and the valve on the
dry nilrogen tank are closed.
5016
o' • • " . : ","
6 of 6
19
18
11
21 20
22
23
1 Retaining Rlng* 7. Shaft End Cover 13. Section Seal 19. Port End Cover
2. Ball Bearing* 8. Back Up Seal 14. Gear Housing 20. Washer
3. Bearing Spacer* 9 Channel Seal 15. Section Seal 21. Capscrew
4. Reiaining Ring* 10. Bushing Block 16. Bushing Block 22. Gear Set
5. Seal Retainer* 11. Key 17. Channel Seal 23. Dowel Pin
6 Shaft Seal 12. Input Shaft 18. Back Up Seal
* Optlonal
Figure 1
Fan Motor Assembly (Parker 500 Series)
Dil Cooler Hydraulic Fan

Motor, Recondition
.A V\/ARNING
This procedure covers the recondition of the fan
motor used on the hydraulic oil cooler. However, due
economic feasibility and matched component wear,
the seals are the only recommended service parts.
cleaning solutions.
For removal and installation procedures, see SM
Keysheet Area 01 -050.
1. Thoroughly clean the exterior surface of the molor
If parts are hard to disassemble and assemble, do not to prevent contamination from entering it.
use a hammer unless it has a soft face, do not force 2. Scribe a line along the top of the motor to ensure
parts together, they must be free to turn and not bind. proper orientation of the motor sections during as
sembly process.
Disassembly
II is a good practice when disassembling hydraulic
Ihe assembly process.
1 of 4
9. Remove the bushing block (10), channel seal (9),
and back up seal (8) . Be sure to note the orienta
tion of these parts for assembly purposes.
10. Remove the retaining ring (1) which secures the
Flat ball bearing (2) in the shaft end cover (7) .
Side 11 . Tap the input shaft (12) out of the shaft end cover
Down (7), using a soft faced hammer.
Low Pressure Side

~HP 12. Remove the retaining ring (4) which secures the
bearing spacer (3) and ball bearing (2) on the input
shaft (12); remove the bearing spacer (3) and ball
Groove In Bushing Block bearing (2).
1. Bushíng Block
13. Remove the seal retainer (5) and shaft seal (6) from
3. Channel Seal
2. Back Up Seal the shaft end cover (7).
Figure 2
Seal Installation
A WARNING
CAUTION Solvents and cleaning solutions can be
Do not grip on any of the motor's machined result from misuse of these products. Read
surfaces. Excessive force while clamping and follow all the manufacturer's
could result in misalignrnent and/or serious recommendations concerning solvents and
damage to parts. Take extreme ca re not to cleaning solutions.
mar or damage any machined surface. Do not
clamp in any form of vise unless jaws are 1. Thoroughly clean all metal parts with an approved
protected by a soft material. cleaning solvent. Place parts on a clean, lint free
Refer to Figure 1. tion possible to keep all parts free of dust , dirt , or
3. Clamp the mounting flange of the motor in a vise any other foreign material during assembly.
with the drive shaft pointing down. Use the shaft 2. Carefully inspect all components for damage,
end cover (7) as the clamping surface . wear, corros ion , deep scratches , and scuffed met
4. Remove the capscrews (21) and washers(20). al. Remove any burrs or sharp edges with a line
5. Remove the port end cover (19), back up seal (18), file, hone, emery cloth, or crocus cloth. Replace
channel seal (17), and section seal (15). any damaged component as required. Replace all
6. Remove the bushing block (16). seals, o-rings, and back up rings.
3. AII Loctite'5' , Permatex ' , or other sealant residue
Note: Be sure to note the orientation of the should be removed from threads of hardware and
bushing block for assembly purposes. the mounting surfaces of parts that are going to be
7. Separate the gear housing (14) from the shaft end
cover (7). Remove the other section seal (13).
with Loctite" 7070 Cleaner to ensure best perfor
Note: Do not remove the dowel pins unless they mance of products.
are bent or damaged. 4. In the event of severe defects, contact factory per
8. Remove the gear set (22). any major component.
2014
Assembly
7~ J
Lubricate all back up seals, channel seals, section
seals, and housing bores with hydraulic oil prior to
assembly. See Operator's Manual for correct type . 2
A WARNING
I
I
~
-n :-:-.-
, 3

these products.
5
1. Retainin g Ring* 5. Retaining Ring*
2. Bal! Bearing* 6. Bearing Spa cer*
CAUTION 3. Seal Retainer* 7. Shaf1 End Cover
4. Shaf1 Seal 8 Input Shaf1
Do not grip on any of the motor's machined * Oplional
surfaces. Excessive force while clamping
could result in misalignment and /or serious Figure 3
damage to parts. Take extreme care not to Shaft End Cover Assembly
mar or damage any machined surface. Do not
clamp in any form of vise unless jaws are
protected by a soft material. Motor Final Capscrew Torque
Model Prefix in lbs
Refer to Figure 1. Nm
1. Place the shaft end cover (7) in a vise with the shaft
side pointing up . Install the shaft seal (6) in the P5 or PGP505 300 34
shaft end cover (7) . P11 or PGP511 575 65
Note: Ball bearing and associated items may be op
tional to some assemblies. P17 or PGP517 1,000 113
2. Install the seal retainer (5) to secure the shaft seal Table A
(6) in the shaft end cover (7). Torque Values
3. Place the ball bearing (2) on the input shaft (12)
and install the bearing spacer (3) and retaining ring 11. Place the rear bushing block (16) over the journals
(4), as shown in Figure 3. of the gear set (22) and slide it into the gear hous
4. Install the input shaft (12) through the shaft seal (6) ing (14). The seals should be facing up. Be sure to
and into the shaft end cover (7) until the ball bear orient the bushing block (16) correctly, as shown in
ing (2) is fully seated. Install the retaining ring (1) . Figure 2.
Use care not to damage the shaft seal (6). 12. Place the section seal (15) on the gear housing (14)
5. Remove the shaft end cover (7) from the vise and
and mount the port end cover (19) . Be sure to align
flip it over so the shaft side is now pointing down .
6. Check that the dowel pins (23) are tightly in place the index marks which were placed on the motor
and fully seated . Replace them only as necessary. sections during disassembly.
7. Place section seal (13) on gear housing (14) and 13. Locate the identification plate , riveted to the port
mount the gear housing (14) to the shaft end cover end cover (19), to determine the motor model pre
(7). Be sure to align the index marks which were fix designation .
placed on the motor sections during disassembly. 14. Install the washers (20) and capscrews (21) ; tight
8. Install channel seals (9 ,17) and back up seals en them evenly in a criss-cross pattern. Refer to
(8,18) in bushing blocks (10,16) as shown in Table A for the final torque value.
Figure 2. 15. Manually turn the input shaft of the motor with a
9. Slide the bushing block (10), seal side down, into
short wrench to ensure parts are aligned and
the gear housing (14) . Be sure to orient the bush
seated correctly for smooth operation .
ing block (10) correctly, as shown in Figure 2.
10. Place the gear set (22) in the gear housing (14) . Be 16. If the motor is not to be immediately installed on
sure it's tight against the bushing block (10) in the crane, plug all open ports to prevent contamination
shaft end cover (7) . and properly store .
3 of 4
4 of 4
Battery, R & I
A WARNING
Use care not to cause sparks at the battery
the batteries.
terminals while disconnecting the battery.
Battery gasses are volatile and could be
CAUTION ignited by a spark or f1ame, causing the
battery to explode. Keep the area around the
Disconnecting the battery with the engine in battery well ventilated and disconnect the
operation may result in damage to the negative si de of the battery first, with the
alternator due to the momentary high voltage ignition switch "OFF", to minimize hazard.
and current generated by the rapid collapse of
the magnetic field surrounding the alternator Battery posts, term ina Is, a nd related
field windings. Always shutdown the engine accessories contain lead and lead
befo re disconnecting the battery. compounds. Eating or smoking with lead
residue on hands may cause lead poisoning.
Removal Wash hands after handling lead products.
1. Lower, detach, and secure load, as required. 5. Label for assembly purposes and disconnect the
2. Stabilize the crane for service as lollows: negative battery cable (3) and negative battery dis
a. Park the crane, out 01 the way, on a lirm and connect cable (5) Irom the negative battery termi
level surlace. Engage the park brake. nals (4).
b. Engage the swing park brake or travel swing 6. Label lor assembly purposes and disconnect the
lock, as required. positive battery cable (8) and positive battery dis
c. Level the crane on lully extended outriggers. connect cable (6) Irom the positive battery termi
d. Position/support the boom, as required. nals (7).
3. Shutdown the engine and disengage the main 7. Remove the j-bolt and wing nut (1) and battery
hyclraulic pump, as equippecl. hold down bracket (2).
8. Using an auxiliary liftíng device, remove the batter
A WARNING
ies (9) Irom the crane.
Note: Each battery weighs approximately 70 lb

Solvents and cleaning solutions can be (32kg).
and follow all the manufacturer's Cleaning And Inspection
cleaning solutions.

A "'fARNING
an approved cleaning solvent. Allow the area to air
clry.
CAUTION recommendations concerning solvents and
cleaning solutions.
The ignition switch should be shut off at least
30 seconds prior to disconnecting the 1. AII components should be thoroughly cleanecl wlth
batteries. This time allows the computer to an approved cleaning solvent, air dried, and care
save needed data and protects the alternator lully inspected.
from a voltage surge. Always allow at least30 2. Inspect the integrity 01 the battery cables. Repair
seconds for the engine and computer to or replace il required.
properly shutdown. 3. Check the electrolyte level in the battery, il
applicable. II cells are low, lill to the recommended
level with distilled water.
4. Clean the battery terminals and inside surlaces 01
the cables with a terminal cleaning tool.
1 014
SM '01 -066--024.00 0307 Service Manual
le]
L ;j
A
2 3 4 5
9 8 7 6
1. J-bolt & Wing Nut 4. Negative Battery Terminals 7. Positive Battery Terminals
2. Battery Hold Down Bracket 5. Battery Disconnect Cable - Negative 8. Battery Cable - Posilive
3. Battery Cable - Negative 6. Battery Disconnect Cable - Positive 9. Batteries
Figure 1
Batteries
2 of 4
5. Inspecl Ihe lerminals lO ensure Ihey are nol 2. Position the battery hold down bracket (2) and
deformed or broken. installthej-boltandwing nut (1). Tighten thewing
6. In Ihe evenl of severe defecls , conlacl faclory nut (1) until snug.
personnel for direclions whether to repair or
replace any major component. Note: Do not over tighten the wing nut. The bat
tery cases could become distorted or broken.
Installation 3. After making sure the cables and contact surfaces
are clean and in good condition, align and connect
A WARNING
the positive battery cable (8) and the posilive bat
tery disconnect cable (6). Tighten the positive bat
tery terminals (7) to 10-15 ft lb (14 -20Nm). A light
terminals while connecting the battery. coat of grease is recommended for exposed sur
Battery gasses are volatile and could be faces of cables and battery terminals to prevent ox
ignited by a spark or flame, causing the idation
battery to explode. Keep the area around the 4. After making sure the cables and contact surfaces
battery well ventilated and connect the are clean and in good condition, align and connect
negative side of the battery last, with the the negative battery cable (3) and the negative bat
ignition switch "OFF", to minimize hazard. tery disconnect cable (5). Tighten the negalive
battery lerminals (4) to 10-15 ft lb (14-20Nm). A
Battery posts, terminals, and related Iighl coal of grease is recommended for exposed
accessories contain lead and lead surfaces of cables and battery terminals to prevent
compounds. Eating or smoking with lead oxidalion.
residue on hands may cause lead poisoning. 5. Complele the inslallation by testing all related
Wash hands after handling lead products. funclions of the batteries for proper operation .
Normal operation electrical syslem should be
1. Using an auxiliary lifting device, properly position confirmed. A general inspection of componenls
and align the batteries (9) as shown. Be sure the and syslems in Ihe areas adjacent to the repair
battery carrier is clean and that the batteries resl Sllould also be performed to ensure related
level wllen installed. damage or wear is nol present.
Note: Each battery weighs approximately 70 lb

(32kg).
3 of 4
4014
Figure 1
Tire Inflation Warning
Tires And Rims, R & I

A DANGER
A DANGER
Servicing tire and rim assemblies can be
Use a rim cage when inflating tire. Lock ri ng or
side flange may explode if damaged or
improperly assembled. Always use a rim
cage and stand clear of the tire while inflating
extremely dangerous. For your protection,
it.
read and understand all safety instructions
before removing or installing a rim and tire
assembly. A rim cage should be used when deflating or inflating
tires to protect against a lock ring flying off and inj uring
someone. Refer to Figure 1.
Check the tire inflation press ures daily when the tires
are cold. The tire inflation pressures for normal
highway travel are listed on the gross axle weight rating Tire & Rim Safety
plate . The tire inflation pressures for pick and carry
operations are listed on the capacity plates or in the
I nstructions
crane rating manual. 1. Always remove the valve cores , and exhau st all alr
pressure from the tire , prior to removing any rim or
Note : The crane should not be road driven with the wheel components , (both tires on a dual tire and
tires inflated to pick and carry pressures. Travelon rim assembly). Rim components are under
tires inflated to pick and carry pressures is limited. extreme pressure and could fly off. The lug nu ts
See Crane Rating Manual for complete pick and and rim clamps may be the only thing holding the
carry restrictions. rim assembly together.
2. Use a rim cage and stand clearwhen deflating and
Dual wheels and tires must be installed so the valve inflating tires. A damaged or improperl y
stem of the inner tire is 180 0 opposite the valve ste m of assembled rim assembly may burst. The o peratol'
the outer tire . AII tires of the same weight and s ize are should stand well away from the potentially
interchangeable . Ins pect the wheel rims , clamps , explosive force , Refer to Figure 1.
nuts , studs , etc ., on a weekly basis . If any damage is
appa rent , repair or replace before operating the crane .
1 of 8
SM1 -69-9.0 1000 Ser~ice Manual
7. Always double check to be sure rim components
are properly installed before inflating the tire.
~ 4JI' Improperly assembled parts cauld fly off during
Wrong inflation.
~~ 8. Clean and inspect all parts prior to assembly. Do
not use bent, worn , damaged, or rusted parts .
9. When inflating a tire, use an air hose with a clip-an
chuck and in - line pressure gauge . Be sure the air
hose is long enough, to permit the person inflating
the tire, to stand clear of the rim cage.
10. Inflate the tire to 10 psi (68kPa) , and check the rim
components for proper fit , before completely
inflating. If the assembly is not correct , completely
deflate the tire and correct the problem. Do not
hammer on an inflated rim and tire assembly.
Properly matched and assembled rim
components will seat without tapping .
11. Once it is determined that the tire and rim are
properly assembled, inflate the tire to fully seat the
tire bead. Then, on tube type tires, completely
deflate the tire to prevent localized over stretching
of the tube. Reinflate the tire to the recommended
operating pressure.
12 . Never use excessive force or hammering to install
1'1 a tire and rim assembly on a spoke wheel.
I
Determine the reason far the improper fit. Look far
é1J damaged and distorted parts ar companents
which are improperly assembled . Repair the
Figure 2 problem.
Rlm Cla m ps n1ay fly off, use ca_ution. 13. Do not run the crane on one tire of a dual assembly.
The excessive overload can cause damage to the
3 . Afte r deflating the tire, check the valve stem, by tire and rim assembly.
runni ng a piece ofwire through the stem, to ensure 14 . Always check rims and wheels for damage during
it is not clogged and the tire is completely deflated. normal tire inspection . Early detection of potential
Ice may form as the air leaves the tire, or foreign component failure may prevent serious injury.
material may clog the stem. 15. Do not attempt to rework, weld, heat , ar braze any
4 . Do not inflate a tire that has been run flat or damaged rim camponents. Heating may weaken
extremely under inflated. Demount the tire and the part and result in complete failure of the
ins pect it, the tube, tube flap, rim companents, and component and possible injury.
wheel assembly for damage. These components
m ay have been damaged or dislocated during the Tire & Rim Removal And
time the tire was under inflated.
5 . Exercis e caution when removing the lug nuts and Installation
rim clamps. The rim clamps could fly off suddenly
Carefully read and understand the safety instructions
and c ause injury. Loosen the lug nuts and unseat
given earlier. Then, choose one of the following
the rim clamps before completely removing the lug
procedures for tire and rim removal.
nuts. Refer to Figure 2.
6. When assembling the tire and rim assembly, use
only parts of the same type , manufacturer, and
Dual Rear Tire & Rim Removal
co rrect size . Mismatched parts may appear to fit, 1. Properly park the crane and engage the park
but when the tire is inflated they may fly apart with brake . Level the crane on outriggers and
ex plosive force . shutdown the engine.
2. Position a rim cage in front of the rim and tire
assembly, before deflating the tire.
2 of8
Service Manual 1000 SM1-69 - 9.0
10 8
~~ ----=-:.-
5 5
Spoke Wheel Disc Wheel
1. Rim Spacer 4. Brake Drum 7. Lug Nut 10. Outer Rim

2. Flange 5. Wheel 8. Stud * Valve Stem Position May Vary
3. Inner Rim 6. Rim Clamp 9. Valve Stem*
Figure 3
Dual Rim & Tire Assembly
7. Using a rubber mallet, stand to the side and strike
A DANGER the rim clamp (6) sharply to unseat them.
Exhaust all air pressure from both tires befo re

removing any wheel or rim component. Use a
rim cage and stand clear when deflating the
A WARNING
Exercise caution when removing wheel lug
tires. Rim components are under extreme
pressure and may fly off. Failure to exhaust nuts. The rim clamps may fly off suddenly and
air pressure, or use a rim cage, could result in cause personal injury.
a fatal accident.
8. Check each rim clamp (6) to be sure it is unseated .
Repeat step 7 if necessary. Remove the lug nuts
Refer to Figure 3. (7) and rim clamps (6) from the studs (8).
3 . Remove the core from the valve stem (9) on the 9. Using an appropriate lifting device, remove the
inner rim (3) and outer rim (10). Allow all air outerrim (10), rim spacer (1), and inner rim (3) from
pressure to exhaust from both tires. the wheel (5).
4. Check each valve stem (9), by running a piece of
wire through the stems, to make sure they are not Dual Rear Tire & Rim
plugged and the tires are completely deflated.
Remove the rim cage. Installation
5. Adequately support the outer rim (10) and tire The correct installation and tightening of the lug nuts
assembly with an appropriate lifting device . on a tire and rim assembly, on the spoke wheel , is one
6 . Loosen the lug nuts (7) until the outer surface of of the most important operations in wheel
each lug nut is flush with the end of the studs (8). maintenance. When tire, rim, orwheel problems occur,
Do not completely remove the lug nuts. incorrect installation and tightening procedures are
usually found to be the cause of the problem . The
following procedures must be carefully followed to
insure safe and dependable service.
3 0fa
5 Spoke Wheel Disc Wheel 6 Spoke Wheel

Figure 4
Lug Nut Torquing Sequence
A DANGER
Al! air pressure must be exhausted from the
tires befo re installing them. An inflated tire
may cause improperly assembled rim
compo nents to fly off. Failure to deflate the
tires c ould result in a fatal accident.
3
1. Check the tires to ensure that they are deflated .
Inspect all parts for damage and proper assembly.
Refer to Figure 3. j 1111I 1

1
~~ 11 I1
gí2
2 . Us ing a wire brush, thoroughly clean the mounting 1. Tire
surfaces of the inner and outer rims (3, 10), wheel 2. Stationary Object
(5), rim spacer (1), and rim clamps (6). Surfaces 3. Axle
should be free of rust, dirt, and excess paint. Figure 5
3. Using an appropriate lifting device, slide the inner Rim & Tire Alignment
rim (3) over the wheel (5) and push it into position
against the mounting surface . Be sure that the
7. Push the assembly into position, so the inner rim
valve stem (9) points outward and is centered
(3) fits snugly against the mounting surfaces ofthe
between two spokes .
wheel (5) at each spoke , and the rim spacer (1) fits
4. Carefully inspect the rim spacer (1) for
snugly and uniformly against the inner rim (3) and
concentricity. If it is distorted, bent, or damaged,
outer rim (10).
re place it.
8. Install the rim clamps (6) and lug nuts (7) on each
5. Slide the rim spacer (1) on the wheel (5) and posi
stud (8). Tighten the lug nuts (7) until the face of
tion it against the inner rim (3) . No misalignment is
each is flush with the studs (8) .
pe rmissible.
9. Rotate the wheel (5) one halfturn to allow the parts
6 . S lide the outer rim (10) on the wheel (5). Be sure
to seat naturally.
the valve stem (9) points inward and is centered
between the two spokes opposite the valve stem
(9) of the inner rim (3).
4 0f8
Spoke Wheel Disc Wheel

1. Tire & Rim Assembly 5. Wheel
2. Lu g Nut 6 . Brake Dr um
3. Stud 7 . Val ve Stem*
4. Rim Clam p * Valve Stem Pos ition May Vary
Figure 6
Front Tire & Rim Assembl
Note: Check to see that rim clamps on the

spoke wheels do not boUom out until at least CAUTION
140-180 tt lb (190-244Nm) torque is applied. Improper torque can cause damage to
The edges of the rim spacer should consistently components , rim slippage, or alignment
meet the edges of the rims. problems. Tighten the lug nuts to the
specified torque only.
10. Tighten the lug nuts (7) , oneturn at a time , following
the criss-cross sequence shown in Figure 4 .
12 . To correct misalignment , loosen the lug nut where
Always rotate the lug nut (7) to be tightened to the
the greatest distance occurs and tighten the lug
top spoke position to insure even tightening of the
nut opposite.
rim clamps (6) and proper alignment of inner and
13. Repeat steps 11 and 12 until the proper alignment
outer rims (3,10). Tighten the lug nuts (7) in this
is obtained . Check the lug nuts to be sure eac h is
manner until all are torqued to 175-225 ft lb
torqued to the specified amount.
(237.3 - 305.1Nm) for spoke wheels and 450-500
ft lb (610.2-678Nm) for disc wheels . Refer to Figure 1.
Refer to Figure 5.
11 . Check the alig n ment of the inner and outer rims by
placing an object on the floor beside the tire (1) and
rotating the wheel. Note any variation in the
A DANGER
Use a rim cage and stand clear when inflating
distance between the tire and the object. If the the tires. Rim components are under extreme
variation in distance exceeds 0 .25 in (6.3mm) , the pressure and may fly off. Failure to use a rlm
rims a re misaligned. cage could result in a fatal accidento
14. Properly position a rim cage in front of th e rim and

tire assembly.
50t 8
RQfQr to Figum 3. 4. Adequately support the tirG and rim assGmbly (1)
with an appropriate lifting device .
Note: The air system of the crane is equipped
with quick disconnect fittings, which may be
used to supply air pressure to inflate tires. The
fittlng s are located on either side of the carrier A WARNING
just behind the front axles. Exercise caution when removing wheel lug
nuts. The rim clamps may fly off suddenly and
15 . Instal/ the cores in the valve stems (9). Using an air cause personal injury.
hose equipped with a clip-on chuck and in-line
pressure gauge, inflate the tires to 10 psi (6BkPa). 5. Loasen the lug nuts (2) until the outer surface of
Inspect all parts to see that they are properly each lug nut (2) is flush with the end of the studs
seated. (3). Do not completely remove the lug nuts (2).
16. If parts are not properly seated, completely deflate 6. Using a rubber mal/et, stand to the side and strike
the tires and correct the problem . the rim clamps (4) sharply to unseat them .
17. If parts are properly seated , inflate the tire until the 7. Check each rim clamp (4) to be sure it is unseated .
tire bead is fully seated. Repeat step 6 if necessary. Remove the lug nuts
18. Co mpletely deflate the tire to prevent any localized (2) and rim clamps (4) from the studs (3).
over stretching of the tube. 8. Carefully remove the tire and rim assembly (1) from
19. In11ate the tires to the pressure listed on the gross the wheel (5).
axle weight rating plate. This plate is located on the
carrier. Front Tire And Rim Installation
Note: Lug nuttorque values should be checked The correct instal/ation and tightening of the tire and
every 10 hours, for the first 50 hours of rim assembly, on a spoke wheel , is one of the most
operation, after any rim and tire assembly is important operations in wheel maintenance . When
installed. Tighten any lug nuts, as required, to tire, rim, orwheel problems occur, incorrect instal/ation
the recommended torque value. Check the lug and tightening procedures are usual/y found to be the
nut to rque every 50 hours of operation cause of the problem . The fol/owing procedures must
thereafter. be careful/y fol/owed to insure safe and dependable
service.
20 . Start the engine, fuI/y retract the outrigger jacks
and beams , and drive the crane approximately 1 Refer to Figure 6.
m ile (1.6 km). Tighten the lug nuts again using the 1. Using a wire brush, thoroughly clean the mounting
proper torquing sequence (Figure 4) and surfaces ofthe wheel (5), tire and rim assembly (1) ,
reco mmended torque value in step 10. and rim clamps (4). Surfaces should be free of
rust, dirt, and excess paint.
Front Tire & Rim Removal 2. Slide the tire and rim assembly (1) over the wheel
1. Properly park the crane, shift the transmission to (5), and push it into position against the tapered
neutral, and engage the park brake. mounting surfaces of the wheel (5). Be sure the
valve stem (7) is centered between two spokes.
Rete r to Figure 6. 3. Instal/ the rim clamps (4) and lug nuts (2) on each
2. Loasen each of the lug nuts (2) one half turno stud (3) . Tighten the lug nuts (2) until the face of
3. Level the crane on outriggers and shutdown the each is flush with the studs (3).
eng ine. 4. Rotate the wheel (5) one halfturn to allow the parts
to seat natural/y.
6 of 8
Note: Check to see that rim clamps on the
spoke wheels do not bottom out until at least
140-180 ft lb (190-244Nm) torque is applied.
The edges of the rim spacer should consistently
meet the edges of the rims.
5. Tighten the lug nuts (2), one turn at a time,

foliowing the criss-cross sequence shown in ---1
Figure 4 . Always rotate the lug nut (2) to be
tightened to the top spoke position. This wili
3
ensure even tightening of the rim clamps (4) and I
proper alignment of the tire and rim assembly (1).
Tighten the lug nuts (2) in this manner until ali are /2
~
torqued to 175-225 ft lb (237.3-305.1Nm) for
spoke wheels and 450-500 ft lb (610.2-678Nm)
for disc wheels .
Refer to Figure 7 . 1. Tire & Rim Assembly

2. Stationary Objec t
6. Check the alignment of the tire and rim assembly 3. Axle
(1) by placing an object on the floor beside the tire
and rim assembly (1), and rotating the wheel. Note Figure 7
any variation in the distance between the tire and Tire And Rim Alignment
rim assembly (1) and the object. If the variation in
distance exceeds 0.19 in (4.8mm) , the tire and rim 9. Check the tire and rim assembly (1) to be sure the
assembly (1) is misaligned. tire is properly inflated. Correct tire pressures are
listed on the gross axle weight rating plate, located
Refer to Figure 6. on carrier.
7. To correct misalignment, loosen the lug nut (2),
where the greatest distance occurs, and tighten Note: Lug nut torque values should be checked
the lug nut (2) opposite. every 10 hours, for the first 50 hours of opera
8. Repeat steps 6 and 7 until the proper alignment is tion, after any rim and tire assembly is installed.
obtained. Check the lug nuts (2) to be sure each is Tighten any lug nuts, as required , to the recom
torqued to the specified amount. mended torque value. Check the lug nut torque
every 50 hours of operation thereafter.
CAUTION 10 . Start the engine , fully retract the outrigger Jacks

and beams, and drive the crane approximately 1
Improper torque can cause damage to
mile (1.6km) . Tighten the lug nuts (2) again using
components, rim slippage, or alignment
the proper torquing sequence (Figure 4) and
problems. Tighten the lug nuts to the
recommended torque value (step 5).
specified torque only.
Note: The air system of the crane is equipped

with a quick disconnect fittings, which may be
used to supply air pressure to inflate tires. The
fittings are located on either side of the carrier
just behind the front axles.
7 of 8
~- _ . -
- _._
- - -- ---
- - ---- --- - -
-----
8 of 8
1. Cab 2. Hole In Door
Figure1
Damage To Door - Example
3. Cut and j or rough sand the edges of the repair area

Repair of Components to "feather" the edgE~s back approximately two in
Made Of Fibrous ches all around the repair area. The feathered
edge should be done from the inside if possible to
Composite Materials allow for a better fin ~shed surface on the outside.
Some Link-Belt products have parts (such as cabs The surface of the feathered edge should be left as
and engine hoods) made of fibrous composite materi rough as possible (with scratches and gouges) to
als. The material in these parts is toug h, but like any allow for better adhesion.
other material, it can be damaged by accidents or van 4. Clean and dry the entire repair area. Remove all
dalism. If proper procedures arefollowed, this damage wax, dirt , oils or othE!r contaminants. (Use a good
can usually be easily repaired to equal the perfor cleaning solvent such as lacquer thinner if pos
mance of the orig inal construction. The following steps sible) .
outline a typical procedure required to make repairs.
1. Locate a work area out of direct sunlight with a tem
perature range of 70-80° F (21-26 OC) if possible.
The mínimum temperature for proper cure of the
A WARNING
Follow all the manufacturer's recommenda
repair materíals is 60 ° F (15 OC). Use artificial heat, tions concerning resins, solvents and cleaning
such as heat lamps, if necessary. Keep the heat solutions. Serious personal injury may result
source far enough away from the repair materials from misuse of these products.
to prevent blisters ín the resin, usually 14 in (36cm)
away for heat lamps. 5. Select a rigid substance to use as a backing mate
rial (sheet metal, aluminum, cardboard, etc.). Cut
Refer to material and tool lists described later in this
andj or shape the backing material to conform to
document.
the shapejcontour of the repair area.
2. Cut out the entire damaged area to achieve a firm
solid edge all around the cutout area. A saber saw
or keyhole saw can be used for cutting.
1 of 4
SM1 -71 -4.G 1100 Service Manual
2
3
5
4
1. Cut Une To Get Firm Surface For Repa ir 4. Cello ph ane

2. Cloth 5. Bac king Material
3. Resin
Figure2
Repalr Steps
6. Cover the backing material with cellophane (or 8. Mix an appropriate amount of resin and catalyst.
equivalent) and place it ov(~r the back of the repair Follow all the supplier's instructions and recom
area to hold the patch materials . Tape or otherwise mendations for mixing these products .
hold the backing material in place. 9. Using a brus h , coat the entire surface ofthe repair
7. C ut one layer of reinforcin g fabric to the size and area (including the bottom ofthe cutout covered by
shape of the bottom of thl~ cutout area being re the cellophane covered backing material) with the
paired. Cut a second layer of reinforcing fabric resin mix.
0. 5 in (12mm) larger (all the way around the fabric) 10. Place the first (smallest) laye r of reinforcing fabric
tha n the first layer. Cut three additionallayers of re on a flat surface (table with cardboard cover).
inforcing fabric , each 0 .5 in (12mm) larger than Brush a coat of resin mix in the fabric until it is thor
each previous layer. The fifth layer should be equal oughly saturated and coated with the resin mix.
to o r larger than the size of the top of the feathered 11. Place the first layer of reinforcing fabric in the resin
edg e cutout. (If the repair is in an area where a fin mix at the bottom of the repair area .
ished surface is not required , the last layer can be 12 . Using a roller, roll the layer of fabric into the resin
slig htly larger than the Cu lIOUt. This will allow for mix, forcing out all air bubbles and smoothing out
additional adhesion of the patch and create a the surface.
stron ger area of material.)
2 of 4
13. Brush another coating of resin mix on the entire additionallayer of resin mix after it is put in place. If
surface of the repair area. surface must be finished smooth, make sure that
14. Coat the second layer of reinforcing fabric with res- thickness of patch area is slightly more than orig i
in mix as instructed in Step 10. nal thickness . This allows for shrinkage as materi
15. Place the second layer of reinforcing fabric in the als cure/ harden.
resin mix over the top of the first layer. 20. Allow the patch to cure/ harden. (The resin mix will
16. RolI the layer of fabric into the resin mix, forcing out "heat up" during the curing process .) Once the
all air bubbles and forming a smooth level surface patch has cooled, remove the backing material.
(without raised areas). 21. Properly smooth/sand the surface where the back
17. Allow the patch to cure/harden for 6 -8 hours . ing material was removed so that the patch blends
18. Rough sand the entire surface area of the patch. in with the original materials.
19. Add third through fifth layers of reinforcing fabric, 22. Apply primer and/orfinish coats of paint to the area
following procedure in Steps 8. through 16. above. required to match the color.
(Brush on a coat of resin mix on the repair area, 23. Ifthe inside ofthe patch must be finished , allow it to
coat/saturate a layer of reinforcing fabric, place it in cure/harden for at least 8 hours. Prepare the area
the patch and ro 11 out any air bubbles.) The fifth lay (sand/scuff or whatever is desired) and paint as re
er of reinforcing fabric should be covered with an quired.
Materials List Tools

Resin I:¡oller
Fiber Fabric Brush
Hardener Saw and/or File

Note: A standard fiberglass repair kit is acceptable. Sandpaper
3 of 4
- - - - - - - -- - ---
- - - - -- - -
- - - -- -- ---- - - -
4 of 4
9. Remove the capscrews, washers, and locknuts
Engine Housing, R & I (11) securing the mounting bracket (12) to the
This procedure covers the removal and installation of engine housing (1) and carrier deck (5).
the engine housing. 10. Remove the muffler/diesel particulate filter (4) and
mounting bracket (12) lrom the crane.
Removal 11 . Secure the engine housing (1) to prevent it from
moving as the mounting hardware is removed.
1. Lower, detach, and secure load, as required .
12. Remove the locknuts (7), spacers (8) , capscrews
(6), washers (10), and nylon washers (9).
13. Remove the locknuts (18) and spacers (19) Irom
surface.
the studs (17).
the tires . Note: The engine housing weighs approximately
c. Engage the swing park brake Or travel swing 220 lb (100kg).
lock , as required.
d. Level the crane on fully extended outriggers. 14. Using an adequate lifting device, remove the
e. Fully retract and lower the boom over the rear engine housing (1) from the crane.
of the carrier.
3 . Shutdown the engine and disengage the main
hydraulic pump, as equipped .
A WARNING
A WARNING
result from misuse of these products . Read and follow all the manufacturer's
cleaning solutions.
4. Thoroughly clean area to be disassembled with an an approved cleaning solvent, air dried , and
approved cleaning solven!. Allow the area to air carefully inspected.
dry. 2. AII Loctite®, Permatex®, or other sealant residue
Refer to Figure 1. should be removed from threads of hardware and
5. If required, remove the locator caps (3) from the
reused. Prior to applying new thread locking
boom rest (2) . See SM Keysheet Area 01 -001 ,
Boom Rest, R & /, for the correct procedure . compounds or sealants, clean threads and
surfaces with Loctite® 7070 Cleaner to ensure best
6. Loosen the clamp (16) , and disconnect the
exhaust tube (1 5). performance of products.
7. Loosen the clamp (13), and disconnect the CGI 3. Thoroughly inspect all related parts for damage ,
tube (14), if equipped . wear, fatigue or stress fractures , and corrosio n.
Repair or replace as required.
Note: The muffler/diesel particulate filter and 4. Inspect weatherstripping . Replace as required.
mounting bracket weigh approximately 240 lb 5. In the event of severe defects , contact lactory
(109kg) as an assembly. personnel lor directions whether to repair or
replace any major componen!.
8. Using an adequate lifting device, rig the
muffler/diesel particulate filter (4) and mounting
bracket (12) lor removal as an assembly.
1 of 4
234
14
17
18
19
16 11 15
1. Engine Housing 8. Spacers 14. Clean Gas Induction Tube (CGI)*
2. Boom Rest 9. Nylon Washers 15. Exhaust Tube
3. Locator Caps 10. Washers 16. Clamp
4. Muffler/ Diesel Particulate Filter (DPF)* 11 . Capscrews, Washers, & Locknuts 17. Studs
5. Carrier Deck 12. Mounting Bracket 18. Locknuts
6. Capscrews 13. Clamp 19. Spacers
7. Locknuts
• Some models do not utilize CGI. Location and orientation 01 muffler/ DPF may vary.
Figure 1
Engine Housing
2 af 4
Installation Note: The muffler/diesel particulate filter and
mounting bracket weigh approximately 240 lb
(109kg) as an assembly.
A WARNING 4. Using an adequate lifting device, position the

muffler/ diesel particulate filter (4) and mounting
compounds, etc. can be hazardous. Serious bracket (12) to the engine housing (1) and carrier
personal injury may result from misuse of deck (5).
these products. Read and follow all 5. Secure the mounting bracket (12) to the engine
manufacturer's recommendations concerning housing (1) and carrier deck (5) by installing the
these products. capscrews , washers, and locknuts (11) .
6. If equipped , connect the CGI tu be (14) using the
clamp (13).
Note: The engine housing weighs approximately 7. Connect the exhaust tube (15) using the clamp
220 lb (100kg). (16) .
8. If removed, install the locator caps (3) on the boom
Refer to Figure 1. rest (2). See SM Keysheet Area 01-001 , Boom
1. Using an adequate lifting device, position the Rest, R & /, for the correct procedure.
engine housing (1) on the crane. 9. Complete the installation by testing engine
2. Install the spacers (19) and locknuts (18) on the housing door for smooth operation. Doors should
studs (17). hinge freely and latches must operate correctly.
3. Install the nylon washers (9), washers (10), Adjust latches as required .
capscrews (6) , spacers (8), and locknuts (7).
3 of 4
1of1
= = = '=0
~, ~ , /~ ,
(,' (9 ,',,)1,' ,'i'i ,
\. "\l,,.. ,, \ ~
' "" ,~ ' ~
1, '
I -10- 1 IJ(t _ o=¡
11
¡;:-- :
"
",, ':"~C~~ . ,_ I~[' ~ I~l I

; .,.. C'" 'H
_ __
,- :' -
1
;:0-;',"
!
-,
__ --1 _ _
1
I ~II 111 I ~
_1
t~!.l -:-Jlr;.- _.
- ----==--==--::....~ :=..---
- _-:: ..~ - --=---
~ - --=--- - ~-
-
" ,
~ . ,
~: l r¡~: .~
' _ .1
1"
{I
. , , f ,•
' 11
. ".; r ,
"1
"'.-.:
~. ~. ~ I- ,.
~. ..... . . ií _
,,".;J .
"
lJ
Figure 1
Typical Electronic Gauge System Instrument Layouts
provided was taken directiy from Dixon NGI '"

Electronic Gauges, Technícal Manual #072-40336-A. If more detailed
Troubleshooting information ís requíred, contact your nearest Link-Belt
distributor.
Thís document covers the basic troubleshooting 01
Díxon NGI '" electronic gauges . The ínformation
jj
Table Of Contents
Introduction ....... .. .. .. ...... ....... ... . ...... . ............ ... . ............ ...... . ... .. . .
Purpose And Scope .. .... . . .. ..... . . .. .. . ... ..... ..... ... .. .. .. .. .. ....... . . ... ..... ... .
How To Use This Information
Definitions And Abbreviations 2
Operation .. . ............. . . . . . ... ...... .. ...... . . ... ............ ....... ..... . ... ....... . . . 2
System Components ....................... .... . .... .. ................................. . 2
Activating The Instrumentation (Initialization) . . .. ............... .... . . .... . . ...... . ... . . ... . 3
Mode And Set Switch es ......... . .......... .. .... .. ........ ..... .. ..... ...... ..... .. .. . . 3
Alphanumeric Display 3
Normal Operating Mode ........... ... ......... . ........... . ....... . . . ..... .. . 3
System Diagnostic Test Mode .. . .. . . .. ... .... ....... . ...... . ...... . ... . .. . .. . . 5
Auto Test Sequence 5
Manual Test Function 6

Fault Codes And Warning Messages .. . . . .... . ......... . .. . .. . . . .. ...... ...... . ... ... . ... . 7
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 7
Warning Messages 7
Unacknowledged Warning Messages . . . . ...... .. ..... ...... . . .... . .. . .... . .... . . . 7
Acknowledged Warning Messages ............ , .. . ,. , ... ... ... ... ... , .. .. . . , ..... 7
Light Bar Telltales ......... . . ....... , . ... ,., .. ..... . . .... .. ...... . . .. " , . . , . . .. . 9
Functional Description ...... .. .. , , , . , .......... . ....... . . ... ... , , . , , .. .. .... , , .... , . . . . . . . . . 10
Vehicle Data Bus ................. . .... ........ ..... . ..... .. .. , . . . . . . . . . . . . . . . . . . . . . . . . . . 10
NGI Bus ....... , .... .. . .. .. . .... .. ... ..... . ....... .. ... , . . . .. ,.. ....... . . .... .. . .. .. ... 11
NGI Cable Assemblies ..... . . ... , ... . .. . . .. .... ..... . .... ....... , . , .. , , . . . . . . . . . . . . . . . . . . 11
NGI Modules .. , .......... ... . .... , . ....... . , ... , . , , . . . .. .. . . .. .. . .. , , . . . . . . . . . . . 11
System Control Unit ......... .. ....... .. ....... , ...... , ....... . ..... . , . , , ........... . 11
Alphanumeric Display .... . .. ....... . . ...... ....... .. ....... , .... , ... . , . . . . . . . . . . 11
Mode And Set Switches .... . .. ..... ... .. .............. .. . ..... . .. ..... . .. ... . . . 11
Audible Warning Device . . , . ..... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gauges, General Information .... .. .... , . ...... , . . . .... , .. .. . .. .. . .. . .. , ... , . . . . . . . . . . 11
Gauge Warning LEOs .. . , , ............... , , .. , ... , ..... . . .. , .. , ... .. . , . , . , . 12
LEO Steadily On ... ,.......... . .... ... . ........... .. .. . . .......... .. . . ..... 12
iii
Rapid Flashing LED ........................................................ 12
Slow Flashing LED ....................... . ..... . . ..... .. ......... ... ....... 12
Data Bus Gauges .......................................... . ................... 13
Speedometer Gauge ....................................................... 13

Odometer And Hourmeter Displays .. . .................... . ......... .. ....... 13
Tachometer Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coolant Temperature Gauge ........................................ . ....... 13

Analog Input Gauges ....... . ................................................... 14
Fuel Level Gauge ...................................... . .......... . ........ 14
Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Pressure And Hydraulic Oil Temperature Gauges ............ .. ......... . . .. 15
Light Bar Module ................................................................... 16
Service Procedures ....................................................................... . 17
Replacing Gauge ........... . .... . ..... . ........... . ................ . .................. . 17
Replacing Other NGI Modules .................. . ..... . ....................... . ....... . .. . 18
Typical Panel Wiring ... . .......... . .......... . ...... . ..... . ....... . . ................. . .. . 19
SCU Connections ............... . .......... . ..... . ...... . ......... . ....... .. ........... . 20

Light Bar Connections ................ . ..... . ...... . ..... . ......................... . .... . 21
iv
2 3 4 5 6
Typical Lower
Cab Panel
o
o
11 10 9 8 7
12 13 14
Typical Upper
Cab Panel
o o
17 16 15
1. Water Temperature 6. Secondary Air Pressure 10. Voltmeter 14. Voltmeter
2. Oil Pressure 7. Lighl Bar 11 Fuel Level 15. Hydrauli c Oil Temperature
3. Tachometer 8. Alphanumeric Display 12 Tachometer 16. Fuel Level
4. Spe edometer 9. Mode And Set Switch 13. Water Temperature 17. Oil Pressure
5. Primary Air Pressure
Figure 2
Typical Panel Layouts
Introduction Operation - This section describes how to use the

instrumentation and the information it presents .
Anyone who operates the crane should read and
Purpose And Scope understand this iniormation.
The purpose of this document is to provide the Functional Description - Describes the compo
knowledge required to understand the operation and nents that make up the instrumentation and how
iunctionality of the Next Generation Instrumentation they communicate with each other and with other
(NGI -" ) System. systems in the crane. Understanding the informa
tion in this section will help diagnose problems and
How lo Use This Information isolate instrumentation related problems.
Service - Describes how to remove and install NGI
This document is divided into iour main sections: modules. It contains complete electrical connec
Introduction - Contains a briei introduction to the tion diagrams.
product and to the document itseli.
1 of 22
1\I:;f, :u:..: ~;
:\ ~ ~ :~:I ~ ...~
<~~ ". ;';::;-;:" : :
1,' : ~~:~ !,~
;f'...,,; . !.!~. ~;,~~; ~~.: ~: .'.:
$~~~
:.
'~;
~~ :
~1:'(:'
':.:~ ~ \
;~::;:.~.
}}~~
~:iVf~ ~~:~~
'.:St~':'~
During the Initialization:

, I
o Gauge pointers move to just below minimum scale
-#. for 1/2 second, then clockwise to minimum scale.
~........ ......,..... _... ..... o Gauge warning LEOs turn on for 1/2 second.
I r"" '"\. 1/2 second o Al! Alphanumeric Display graphics turn on for
Al! graphics on for about 2 seconds.
about 2 seconds Minimum o SCU lights all Light Bar telltales for three seconds.
Scale
After the Initialization:

Not e: For example, if the park brake is o Pointers indicate actual readings .
app lied when the initialization begins, o Alphanumeric Display shows the odometer.
th e Park Brake telltale will remain on. o Light Bar telltales turn off (see note).
o Gauge warning LEOs turn off.
Figure 3
System Initialization Sequence
Definitions And Abbreviations Operation

ECU - Electronic Control Unit
Ground - Any point that measures less than two System Components
ohms resistan ce between it and the battery ground The instrumentation system consists of several
terminal when using a properly zeroed ohmmeter gauges, indicators, and telltales mounted in a panel
on its X1 range. similar to that shown in Figure 2. The purpose of the
o LC - Liquid Crystal, as in LC display. instrumentation is to display the operational status of
LCD - Liquid Crystal Display the crane. In addition to the gauges and Light Bar, the
LED - Light Emitting Diode instrumentation contains an Alphanumeric Display that
NGI - Next Generation Instrumentation alerts the driver to a condition or event that requires
SCU - System Control Unit attention.
Note: Ttl roughout this document, the terms public
data bus, vehicle data bus, and public bus refer
specifically to the J170B data bus.
2 of 22
Alphanumeric Display
Odometer Warning
(Default display) (Example)
i : ¡@.~:~~¡~~1
Trip Odo 1 Hourmeter
IM+~~~j'jlJ
Trip Odo 2 Diagnostic
Mode
Figure 4
Normal Operation Displays
Activating The Instrumentation The Alphanume ric Display can be activated in th e

following ways (refer to Figure 5):
(Initialization) Ignition Switch - Turn in g the ignition on turns on
Turning on the ignition activates the instrumentation the display and also starts the initialization se
and starts an initialization sequence. This sequence quence. The display will re main on as long as the
gives the operator a chance to verify correct operation ignition switch is on .
of the gauges and indicators. The sequence is Mode or Set Switch -- Pressing either switch when
described in Figure 3. the igni tion is off activates the display for 10 sec
onds, allowing it to be used without an ign ition key.
Service the crane if any of the following conditions
The display w ill remai n active until the 10 seconds
occur during or after the initialization:
have elapsed after the last press of the mode or set
A telltale does not light, or is always on
switch . This method does not start an initialization
A 2-inch gauge's pointer stays at minimum scale
sequence .
and its warning LEO flashes slowly, ind icating the
Backligh ting - Tu rning the backl ighting on acti
gauge is not receiving data from the vehicle data
vates the display as long as the backlighting re
bus
mains on . Th is method does not start an initializa
A 2-inch gauge's pointer goes to full or minimum
tion sequence .
scale and its warning LEO flashes rapidly, indicat
ing the gauge has received invalid or out-of Normal Operating Mode
range data
Any other symptom not described as part of the in After the initial ization sequence (or after the mode or
itialization or normal operation set switch is pressed, or the backlighting is turned on) ,
the Alphanumeric Display goes into its normal
Mode And Set Switches ope ration mode (refer to Figu re 5) . If any
unacknowledged messages exist , they will be
The mode and set switches are buttons in the displayed (most recen t first). The non-resettable
speedometer that allow you to select, set, and reset odometer is displayed next. The display goes from Oto
displays in the Alphanumeric Display. They also allow 999999.9, then from 1000000 to 9999999 (no decimal
you to scroll through active system warning messages. point), and then ro lls over to O. Leading zeros are not
displayed .
The Alphanume ric Display provides mileage , engine
hours , and messages to the driver. Examples of
displays are shown in Fig ure 4.
3 of 22
NO
D.?sh i:;¡hts
On ') VES messages VES
exist?
NO
~,,'ode or S_;,t
PreSS \~fJ)
VES
r NO
VES LeS!
One?
N:~:~i~
¡lressi::u?
NO
Display next
unacknowledged
warn ing m e9Sage .
VES -------.
To ggl es oda meter and trip

,-j~:-:·=L:..t;;f.tlJQ>:~': I'--------ilm__- - - . odometer di ti plays betwe.e n
k llo me.ters and m ~ e s
to System
Diagnostic
Test Mode
No effect
:}fJ.l8.G.7iSTf to Warning
lli2j·j..i.. j··..jJ..1
.. Jt~~a---~ Messages
Loop
VES
NO
Figu re 5
Normal Operation Mode
The following displays are also available by pressing In addition to these displays, the Alphanumeric Display
the mode switch: can be used to view fault codes and up to the last six
Trip Odometer - Two independently resettable trip warning messages stored by the SCU. These are
odometers, each' with a maximum display of explained in "Fault Codes And Warning Messages"
9999.9 miles or kilometers. found later in this document.
• Hourmeter - A non-resettable hourmeter that
displays up to 999999 hours.
4 of 22
System r~~~~~~~~~-~-~-~~~~~~~~~7~~-
II .. AIIG~Ug~s: . . .. Light~ar . II
Diagnostic , ... . .
.----_ _+',~
, I
Test Mode j .', I
I
1" ~~~~~-~~~~~~~~~~ i
I
1 I
I
I
I
j>
~
.;~ .,
.L--.-::.-'--_ ___
" . ~I
~:~~~
.:- . _ _ -l
1
I
'.1
1
I
1
1
.1
I
~~~~~-~~~~-~~-~-~ I
I
I
., I
to Manual I
Test Function 1
I
Note: l ight bar telU ales will s1a y on if
the condition tha! lights Ihem is true .
_ _ _•• back to Normal

Operation Mode
Figure 6
System Diagnostic Test Loop
System Diagnostic Test Mode Auto Test Sequence

To access the System Diagnostic Test mode, turn the Pressing the set switch while "AUTO " is displayed
ign iti on on and press the mode switch until "DIAGTST" starts the Auto Test sequence, During the Auto Test,
appears in the display, Then press the set switch to the seu generates its own pointer positioning data ,
enter the System Diagnostics Test mode . "AUTO" will warning LEO data, and telltale control data, Auto Test
be d isplayed , phases are shown in Figure 6 , The sequence begins
with al! po inters at zero scale and a blank
Note: The System Diagnostics Test mode is only Alphanumeric Display. The seu moves Ihe pointers in
enabled when the ignition is on. unison to mid-scale, full scale , back to mid-scale ,
back to zero, and then exils the Normal Ope ration
The System Diagnostic Test mode is shown in Figure 6, mode,
Three functions are available:
Pressing the mode or set switch during the sequence
Auto - A fully automatic test of all modules, dis halts the sequence and relurns the display lo "AUTO " ,
plays, and te lita les
Manual - Manual selection of individual modules If Ihe instrumentalion passes the Aulo Test, it is a good
and telltales to test indication thal the entire instrumentation syslem is
Fault Display - Recalls up to 128 device fault functioning properly,
codes
5 of 22
Manual
Test Function
Note: AH gauges tar which the system is con'igured will

be tested (ex.cluding mechanical pressure gauges) .
Ug hts each e ' ttal ~ one al a time
t~------~~~------~
back to System
Diagnostic Test
Mode
Figure 7
Usíng The Manual Test Function
Manual Test Function Press the set switch to start the test, or press the
Pressing the mode switch while "AUTO" is displayed mode switch to select a different module.
activates the Manual Test function and causes To end the test and display the module name,
"MAN UAL:' to be displayed. The Manual Test function is press the mode switch at any time during the se
the same as the Auto Test except that the user can quence.
select which modules to test. The Manual Test flow is The Manual Test sequence is identical to the Auto Test
shown in Figure 7. sequence except that the user must press the set
Use the set switch whlle "MANUAL:' is displayed to switch to move from one phase to the next.
select the module to be tested. The module's
name will appear in the display, starting with
"seu".
6 of 22
Fault Codes And Warning Messages appropriate gauge. That warning message overrid es
all other displays until it is acknowledged. Se e
Fault Codes "Acknowledged Warning Messages" found later in this
document. Warning messages are listed in Table A.
When a device (or EeU) attached to the vehicle data
bus detects a fault, it can place an active fault code on When the condition resulting in the active fault code is
the data bus. The active fault code describes a specific corrected, the device that detects the condition places
type of failure (for example, low oil pressure). Each an inactive fault code for that condition on the vehicle
fault code includes a device fault code that identifies data bus. When the seu receives an inactive fault
the device which detected the fault. Pressing the set code , it turns off the buzzer and the gauge warnin g
switch when "FAULTS" is displayed tells the seu to LEO.
send a request over the vehicle data bus for all devices Acknowledged Warning Messages
to send their active fault codeso During this time the
seu displays "POLLING". After all the active fault Unless otherwise stated in Table A, the user can
codes have been received, the seu displays the acknowledge an unacknowledged message by
device fault codes one-at-a-time in 3-second pressing the set switch when the message is visi ble .
intervals. Up to 128 device fault codes can be The seu will turn the buzzer off and display either the
displayed. Pressing the mode or set switch during this odometer or the next unacknowledged message if one
time exits the Fault mode. exists.
The seu stores the six most recent acknowledged
Note: A device fault code does not contain actual
messages for later viewing . If more than six messages
failure data, only the identification of the device that
have been acknowledged, the oldest one will be
detected the fault.
detected .
Messages can be viewed and acknowledged using the
Warning Messages mode and set switches as shown in Figure 8. The last
message to be acknowledged will be the first message
Unacknowledged Warning Messages
to be displayed. If the mode switch is not presse d for
When the seu receives an active fault code, it displays 15 seconds, the seu will display the odometer (or the
a warning message in the Alphanumeric Display, turns next unacknowledged message, if one exists) .
on the buzzer, and turns on the warning LED in the
7 of 22
Any
messages to
displa y? NO --------------------~~r¡:l5ZZf~U5tf~
back to Normal
Operation Mode
Last
NO message?
In crement
message r' - ..- - ::::: ''''''' ~ _~' ' '''''''~ - - '::- ~ .."" . ~.'.,-: .-..,.. -...., 7" ' ~ '.~ .,.....,., ..- ..,.....,... ~-
CQunter J
1
I 1
I 1
,-'-_-1..._--, J
I
'. VES 1
I
L..~~."..~---,-ll
:1
1
I
I
No éffe~1 1
I
I
I
I
I J
L ·..:. ....:-....: ~~:'"'-.1~:L:L:l '"'-~ ....::",,;...;; _--';...;; -";...;;-"-" ;...;;;...;; .;.;.;.;.. ;; __ ;;;..:.:. ____ -'-_ J
Figure 8
Displaying And Acknowledging Warning Messages
seu
Message
I Meamng
- I Source
I Other
Indications
I Acknowledged
Can Be I Message
Reset
MIO 128, PIO 194, PIO Buzzer, gauge warning

H20TEMP Coolant temperature high Ves None
110, FMI 00 LEO
LO AIR1 No None
• ••• ::.:': ," o"
L b AIR-2 : : ~%~g~arf:~rr. p ~'~~d§,f~5: P5i .; ..

, ' N-one
Buzzer, gauge warning

HYDTEMP Hydraulic oil temperature over 200· F Analog input No None
LEO
.... . . . . . .
·······yes : .
• o •• • •••••••••• , •• o •• o ••• • ••• , . o •••
¡~} : .\:$~,~~~:·~:#.0i6:ª:~~b"· FUe:LOK ::

Battery voltage under 10 volts or over 15
VOLTS Analog input Gauge warning LEO Ves None
volts
NOSPOQ.,: Nqpl,lbii ~ :bjjs :$p ee'déláta< jOr t5se~oh~s: ','.

.. '. -: :-: :- . . . ....... :.: :': . ", ..
No >:
NO DATA No public bus data at all lor 15 seconds None No None
o •• • ••••••••••••
NQ ODa :::- Odomet~r' i:!i¡ltá not:preseni . '-. : <';::'

0-' . ' .. . . " . ", ' , ' ••••• .;.
:Noria::··,
,'- ' -, ..... , ...... N9 N'Ot)é :
No public bus engine hour data lor 15
NO HR SCU None No None
seconds
Tabla A
Warni ng Messages
8 of 22
Cruise Engine
Control Torque Limit
On Reached
p~~~~ SlDr
Bg~~~E }NG;~[
Park Brake Check ABS

Engaged System
Figure 9
Light Bar Telltales
Light Bar Telltales but from individual switch es connected dírectly to the
The Light Bar contains 13 telltales as shown in Light Bar.
Figure 9 . Telltale control does not come from the seu,
9 of 22
Analog Inputs to SCU - - - " " Lower Cab Panel

10r Gauges:
Fuel Level
Primary Air Pressure
Secondary Air Pressure
Hydraulic Oil Temperature
Voltage
Vehicle
Data Bus
Data Bus Inputs to
SCU for Gauges:
Crane Speed and Total Miles
Engine RPM and Hours
Engine Oil Pressure
Coolant Temperature
Backlight (+)
Backlight Ground - - - - - - 1
Battery (+)
~""§:
Battery Ground
Ignition (+) ~::::
~ ~
Ignition (+) ~ ~
Battery Ground ~ ~
~~ ~
...
,
~
13 Switched Inputs: - - - - ' ~~
Left Turn Inter-Cab Cable ---j.~
~
Trans Oil Temp
Upper Cab Panel ~
Cruise
Engine Torque Limit ~
High Beam ~
Wait To Start ~""~
Service Engine
Left Turn
Rear Axle Unlocked
Park Brake
Check Engine
Stop Engine
ABS
Notes: Gauge complement may differ

from that shown. Order of connections
on NGI bus is for illustration only and
may not reflect actual order in crane.
Figure 10
System Block Diagram
Functional Description Vehicle Data Bus

The vehicle data bus is a two-wire bus that transfers
This section provides a more detailed understanding of
information to and from the crane's electronic control
how the system works . Reading and understanding
units (ECU) . Examples of ECUs are the engine ECU,
this section can help troubleshoot and service the
ABS ECU, and the instrumentation system control unlt
system. Figure 10 shows how the instrumentation
(SCU) that is built into the speedometer.. The SCU
connects to the rest of the crane.
receives road speed, engine RPM, englne hours,
engine oil pressure, and water temperature data from
the vehicle data bus.
10 of 22
NGI Bus Periodically compares calcu lated odometer data
with total crane miles
The NGI bus is an internal six-wire bus that originates Stores gauge configuration and parameters
at the SCU and is connected to all NGI components. It (range, pointer sweep, zero point)
contains a pair of wires for module power and ground, Compares input data to stored gauge confirmation
a pair for backl ight power and ground, and a pair that data to determine out-of-range conditions
carries pointer destination and gauge warning LEO Supplies power and backlight power to the gauges
data to gauges. Supplies test data to modules during the Auto Test
The NGI bus connects to the Alphanumeric Display and Manual Test functions
and is then brought outside the speedometer housing Controls the buzzer
on two six-pin connectors that are wired in parallel.
Each NGI module has a pair of these six-pin NGI
connectors . The Alphanumeric Display is a seven-digit,
multi-segment, backlit, LC d isplay. It contains a
NGI Cable Assemblies microprocessor that receives data from the SCU over
the NGI bus. During the power-on initialization
NGI cable assemblies distribute the NGI bus, module
sequence (see Figure 3), this microprocessor
power and ground , and module backlighting power
momentarily turns on all display segments and icons
and ground to every display module in the system .
for visual verification.
Because all NGI modules are connected to each other
by the NGI cable assemblies, a fault in any one of these Mode And Set Switch es
modules can affect the operation of some, or all, of the
The Alphanumeric Display also receives inputs from
others . For example, if the wire that carries backlight
the mode and set switches. The mode and set
power to the gauges is broken, the gauges between
switch es are normally open and apply ground to the
the break and the speedometer will have backlighting
Alphanumeric Display when pressed . The driver uses
while the remaining modules will not. Or, a short circuit
them to select displays, reset the trip odometers, scroll
from one data line to the other in one of the modules will
through diagnostic messages, and to perform the
disable all modules (including the Alphanumeric
diagnostic test described in " Manual Test Function"
Display) connected to the NGI bus.
found earlier in this document.
NGI Modules Audible Warning Device
System Control Unit Sometimes called the buzzer, the warning device is
mounted inside the speedometer housing anc is
The SCU is mounted inside the speedomete r housing controlled by the SCU .
and is connected to the vehicle data bus and the NGI
bus . A block diagram showing how the SCU is Gauges, General Information
connected is provided in Figure 11 .
Each gauge contains a microprocessor, a stepper
The SCU performs the following functions : motor, a red warning LEO (except the tachometer and
Receives, conditions , and processes vehicle data speedometer), and a pair of NGI bus connectors that
bus information into pointer destination data for the are wired in parallel.
data bus gauges
Applying power to a gauge causes its microprocessor
Receives, conditions, and processes analog input
to re-zero the pointer and momentarily turn on its
signals from external sensors into pointer destina
tion data for the analog gauges warning LEO. This action is not initiated by the SCU but
Controls gauge warning LEOs by the gauge's microprocessor. Because power is
applied to all gauges (through their NGI bus
Requests crane mileage and engine hour data
connections) when the ignition is switched on, all
upon power-up
pointers and LEOs will act in unisono Gauge operation
Calculates odometer and trip odometer values
can also be checked th rough the SCU by using the
Controls the Alphanumeric Display and monitors
mode and set switch es as described elsewhere in this
the mode and set switch es
document.
11 of 22
Speedometer
r 7" """ : -:- ~. """. - - - - ~ .-.,... - -,
>-=B:.;:a",lt:.::.e:..L · ~I
r _+'---__f--..:.I .. J
1: Power .1
,
)--B_a_tt_ery--'---_ _ _f---'-'..
I
: " 1 Supply
'---~----'
'----.,__--' I
I
I
F;.
Switched Inputs Input
Analog Inputs ~+-"'I""'~:,;j Conditioners
Vehicle
Data Bus
+12V from
Buffer
Ignition
Mode Button
~
---
Set Button
--~~-----~
---
pP
~ -----+----------~
Figure 11
Block Diagram For seu
The seu tells the gauge microprocessor where to low oil pressure, low fuel, and voltage too high or too
rotate the pointer, and updates the information often low).
enough to provide smooth pointer operation. The Rapid Flashing LEO
gauge microprocessor converts the point destination If the seu detects that the data it receives for a
into stepper motor drive signals, and warning LEO data particular gauge is beyond that gauge's display range,
into LEO-on , LEO-off signals . it will flash that gauge's warning LEO rapidly and
Gauge Wa rning LEDs position its pointer to zero (if the input is too low) or full
scale (if the input is too high).
LEO Steadily On
Slow Flashing LEO
Th is is the LEO's primary function. When it is on
steadily, it indicates that a condition exists in the crane If a gauge does not receive any data from the seu, it
that requires the driver's aUention (high temperature , will flash its warning LEO slowly (about once per
second) and position its pointer to zero.
>$p~~r;lorneterwitIlSC (j
System
Control
Unit
J170B Bus
to/from other devices
+----- from Speed Sensor
= NGI System +----- from RPM Sensor

~t==¡="====~-
The engine ECU generates speed, odome

ter, ROM, pressure, temperature, and gauge
Coolant
Oil PSI LED data that the SCU uses to position the
Temperature
Sensor gauge pointers and control the gauge LEDs.
Sensor
Figure 12
Block Diagram For Vehicle Data Bus Gauges
Data Bus Gauges Engine Oil Pressure Gauge

The speedometer, tachometer, engine oil pressure, The engine oil pressure gauge receives its pointer and
warning LED data (MID 128, PID 100) from the engine
and coolant temperature gauges all obtain their pointer
EeU. If the seu receives an active fault code of MID
data from the vehicle data bus through the seu and
128, PID 194, PID 100, FMI 01, it will turn on the LED in
the NGI bus. They are sometimes referred to as "data
bus gauges". Figure 12 shows the information flow for the oil pressure gauge, display "OIL PSI " in the
Alphanumeric Display, and sound the buzzer. If the
data bus gauges.
seu does not receive any more of these active fa ult
Speedometer Gauge codes during the next 30 seconds, or if the s e u
The speedometer houses the seu , Alphanumeric receives an inactive fault code for oil pressure, the s eu
Display, and the speedometer pointer drive will turn the LED and the buzzer off and will display
electronics . The seu receives current crane speed whatever it was displaying when the active fault code
data (MID 128, PID 84) from the engine EeU and sends was detected. The oil pressure fault cannot be
it to the speedometer over the (internal) NGI bus. The acknowledged.
seu updates the speedometer pointer data every 0.3
seconds . Coolant Temperature Gauge
The coolant temperature gauge receives its pointer
Odometer And Hourmeter Oisplays and warning LED data (MID 128, PID 110) from the
Each time power is applied to the instrumentation, and engine EeU. If the seu receives an active fault code of
periodically thereafter, the seu requests and receives MID 128, PID 194, PID 110, FMI 01, it will turn on l i,e
total travel distance (MID 128, PID 245) and total LED in the coolant temperatu re gauge, display
engine hours data (MID 128, PID 247) from the engine "H20TEMP" in the Alphanumeric Display, and sound
EeU. Upon receipt, the seu sends the data to the the buzzer. If the seu does not receive any more of
Alphanumeric Display over the NGI bus . The odometer these active fault codes during the next 30 seconds , or
data is updated every three seconds, the hourmeter if the seu receives an inactive fault code for coolant
data every 10 seconds. temperature, or if the seu's message is
Tachometer Gauge acknowledged, the seu will turn the LED and the
The tachometer receives engine RPM data from the buzzer off and will display whatever it was displaying
engine EeU (MID 128, PID 190) . The seu updates the when the active fault code was detected.
tachometer pointer destination often enough to ensure
smooth operation.
13 of 22
Speedometer wíth seu

SE3
1 System
Control
2 Unit
SE6 ·10 óther .

NGi .Mbdt.Jles
Fuel Level
Analog Input:
33 oh ms (Full)
240 o hms (Empty)
The fuel level sensor on the fu el tan k provides a

resistance signal to the SCU to drive the Fuel
D = NGI System
Level pointer and LED.
The SCU drives the voltmeter pointer position
and LED state from the voltage at SE3 pin 1.
Figure 13
Block Diagram For Fuel Level And Voltmeter Gauges
Analog Input Gauges The seu compensates for the effects of fuel slosh
Fue! Leve! Gauge inside the tank so the LEO does not flash erratically
The fuel level sensor output varies according to the fuel when the fuel level is near 1/8 tank.
level in the tank. This analog signal is connected to an Vo!tmeter Gauge
analog input at the seu. The seu converts the analog The seu uses its own battery (+) connection as an
signal into digital format and places the resulting analog signal input for the voltmeter gauge . It converts
pointer destination data on the NGI bus . The data flow this analog voltage into digital format and places the
for l he fuel level gauge is shown in Figure 13. resulting pointer drive data on the NGI bus . The data
When the seu detects the fuel level is less than 1/8 flow for the voltmeter gauge is shown in Figure 13.
tank, it wi'll turn on the warning LEO in the fuel level When the voltage at the seu 's battery (+) connection
gauge and display "LO FUEL' in the Alphanumeric is less than 10 volts or more than 15 volts , the seu will
Display. It does not turn the buzzer on. When the fuel turn on the warning LEO in the voltmeter gauge and
level rises aboye 1/8 tank, the seu turns the LEO in the display "VOLTS " in the Alphanumeric Display. It will not
fuel level gauge off and sends "FUEL OK" to the turn the buzzer on. When the voltage at that point is
Alphanumeric Display. within 10 to 15 volts, the seu will turn off the voltmeters
gauge's warning LEO and will display whatever it was
displaying when the active fault code was detected.
14 of 22
SE3
Speedometér wilh seu D = NGI System
1 System
Control :-""""""""""'~
2 Unit
The SCU turns on the air pressure LEDs

when the analog input represents less
than 65 psi (448kPa). The SCU turns on
the hydraulic oil temperature warning LED
when the analog input represents greater
than 200· F (93· C).
Hydraulic Oil Primary Air Secondary Air

Temperalure Sensor PSI Sensor PSI Sensor
315 ohms = 120· F (49" C) 10 ohm s = O psi (OkPa)
147 ohms = 200· F (93" C) 52 ohms = 29 psi (200kPa)
88 ohm s = 58 psi (400kPa)
124 ohms = 87 psi (600kPa)
Figure 14
Air Pressure And Hydraulic Dil Temperature Gauges
Air Pressure And Hydraulic Oil Temperature Gauges display "LO AIR1" or "LO AIR2" in the Alphanum eric
Sensors for hydraulic oil temperature and air pressure Display, and sound the buzzer. When the air pressur e
are connected to a data collector. The analog outputs rises to 65 psi (448kPa) or more, the seu turns th e
from the data collector (which is not part of the buzzer and the gauge LED off. This warning message
instrument system) are connected to the seu. The cannot be acknowledged.
seu processes the analog signals into gauge pointer When the seu detects the hydraulic oil temperature is
0 0
data and places the data on the NGI bus to drive the 200 F (93 C) or more, it will turn on the warning LED in
hydraulic oil temperature and the primary and the hydraulic oil temperature gauge , display
secondary air pressure gauge pointers. The data flow "HYDTEMP " in the Alphanumeric Display, and sound
0
for the air pressure and hydraulic oil temperature the buzzer. When the temperature drops below 200 F
gauges is shown in Figure 14. (93 o C), the seu will turn the buzzer and the gaug e
When the seu detects the air pressure is lower than 65 LED off. This warning message cannot be
psi (448kPa) in either of the air systems, it will turn on acknowledged.
the warning LED in the appropriate air pressure gauge,
15 of 22
Speedometer wiihSCU.
,- .::- .
System
Control
Unit
.:
Ignition
SW"Oh :i'ON ____________________

Low from
D = NGI System
Switch closure activates telltale.
+ + + +
Engine ECU
+
I I I I I
LBE3
I I
+ + Low from Low from
Engine ECU ABS ECU
Figure 15
Light Bar Module
Light Bar Module switched inputs to the light bar control the telltales.
Light bar power is routed through the ignition switch
The light bar contains 13 individually controlled
rather than to the battery. The light bar interacts with
telltales. each illuminated by an LEO. Individual
the NGI System and crane as shown in Figure 15.
Cutouts (2)
Remove
4
Alignment Tab
1 Clamp Ring
2 Wave Spring Lock Tabs (2)
3 Panel
4. Gauge
Figure 16
Gauge Replacement
3. Push Ihe clamp ring up againsl Ihe wave spring .

Service Procedures TWlsl il counlerclockwise aboul1 / 16 in (1 .58mm) ,
AII NGI modules are easily replaceable in Ihe lield. This Ihen pull il off Ihe rear 01 Ihe gauge .
secllon describes Ihe correcl method of removing and 4. Remove the gauge lrom the lronl 01 Ihe panel.
replacing Ihem. For a funclional description 01 Ihe To install:
inslrumentalion, see "Funclional Description " section 1. Insert Ihe gauge through Ihe lronl 01 Ihe panel,
found earlier in Ihis documenl. making sure the alignment lab on the bollo m near
Ihe bezel lils inlo the nolch in Ihe gauge mounllng
Note: NGI modules are not repairable in the field.
hole.
Replace them if defective. Opening any of the com
2. Inslalllhe wave spring lollowed by the clamp ring o
ponents voids the warranty.
Align Ihe tab wilh the culouts in the gauge houslng.
3. Press Ihe clamp ring againsllhe wave spring and
Replacing Gauge twisl clockwise aboul1 / 16 in (1.58mm) until it locks
inlo place.
Refe r lo Figure 16. 4. Plug the connectors inlo Ihe rear 01 Ihe gauge . The
To remove: connectors have locking labs Ihal musl lock .
1. Gain access lo Ihe rear of the panel.
2. Unplug Ihe connectors lrom Ihe rear of the gauge .
The conneclors have locking tabs thal must be de
pressed to release the plug.
170122
\ 4
Notch
Alignment Tab
1. #10 Torx Screw Nolch

2 U - Clamp
3. Panel
4. Module
Figure 17
Additional NGI Module Replacement
Replacing Other NGI Modules To install:

1. Insert the module through the front of the panel ,
Refer to Figure 17. making sure the alignment tab on the bottom near
To remove: the bezel fits into the notch in the mounting hole.
1. Gain access to the rear of the panel.
2. Unplug the connectors from the rear of the module.
Note: Align the module by inserting its align
AII connectors have lock ing tabs that must be de ment tab (behind the bezel) into the small cutout
pressed to release the plug .
in the mounting panel.
3 . Use a #10 Torx driver to remove the two U-clamp 2. Use a #10 Torx driver to install the two U-clamp
screws. screws.
4. Remove the module from the front of the panel. 3. Plug the connectors into the rear of the module. Al!
connectors have locking tabs that must be locked
to secure the plug.
18 of 22
o o
o
Pin 1
Pin 1 Marker
Cii
e O
ro
a..
.o
ro
U
....
Q)
a.
O a.
::>
Figure 18
Typical Panel Wiring
19 of 22
Pin# 1 Signal 1I Pin# 1 Signal
Battery (+)
1 6 J1 708 Bu s (- )
(9-32VDC)
2. Bat1ery (...;} .7' N6C6rÚiedr9n

3 Ignition (+ ) (swit ched) 8 No Connec tion
. . . . ..
4 BaCk~g hl { +i 9: NOConflécÍiOri
5 J1708 Bus (+) 10 Backlight Ground
Mating Connector Manufacturer's Part Numbers

Connector: JAE IL-AG5-10S-S3C1
Pins : JAE IL-AG5-C1-5000
Table C
Speedometer Connector SE3
Pin # 1 Signal
Fuel Level (a nalog)
2 Primary Air P:SI

Figu re 19
SCU Connections 3 Secondary Air PSI
SCU Connections 5 Analog Ground
Pln # I Signal
NGI Power (+7 .6VD C) Connector: JAE IL-AG5-16S-D3C1-A
Pins: JAE IL-AG5-C1-5000
2 NGI Gro und
3 NGI Bus Posltive (+ ) Table D

4 NG J BLJS Nega\ive (-- )
Speedometer Connector SE6
5 Backl igh t Grou nd
6 Backligh\ Pow€) r .
E1 / E2 and E4/E5 are internally connected in paralieL
Table B
NGI Bus Connections (E1, E2 , E4, And E5)
20 of 22
Light Bar
Telltale Positions 22 11
r-=. I
1'11" I
t
oo
oo
oo
o o
~ oo
00
00
00
00 _
-
Ir'
'-
, ,-- ......
12
Figure 20
Light Bar Connections
Light Bar Connections

Telltale Location I Functlon I Pin # I Activatlon
TT1 Left Turn Indicator 18 Switch to + 12V
" . . .. ..
TT;? • Transrni$$iononiempera!.ure 19 Switch to + 12V

TT3 Cruise 21 Ground from Engine ECU
tt4 •. EnglM Torq-úe Uro it 10 SwitQh to +12V
TTS High Beam Indicator 7 Switch to + 12V
. .
lT6. WaítTOStart · 6 Grolind fromErígineECU
Tn Service Engine 8 Ground from Engine ECU
'tIa ' R:ightTlúTllnd t cator 17 Switchto + 12V
TT9 Not Used
TT10 . RearAxre UnIOCK€d 15 Swite>hto +"' 2V
TT11 Park Brake 12 Switch to + 12V
rT12 •NoCUseD
TT13 Not Used
.. .. . .
TT14 .' .Check>E:ng r® 4 Grout1dfrom Erigine .ECU .

TT1S Stop Engine 5 Ground from Engine ECU
........ . ..
TIl9< . ABS .16 Groum from ABS ECU
Battery Ground Battery negative
·1<gnitl0I1 +12V 9S"Y 1tchedbClttBfY •
Connector: JAE IL-AGS-22S-D3C1
Pins: JAE IL-AGs-C1-s000
Table E
Light Bar Connector LBE3
21 of 22
22 of 22
Collector Ring, R & I

This procedure covers Ihe removal and inslallalion of
A WARNING
Ihe colleclor ringo For recondilion proceclure, see SM
Keysheel Area 01-076.
Removal and follow all the manufacturer's
1. Lower, delach, and secure Ihe load, as required. cleaning solutions.
2. Slabilize Ihe crane for service as follows:
a. Park Ihe crane, oul of Ihe way, on a firm ancl 6. Tllorougllly clean lile area lo be disassembled willl
level surface. an approved cleaning solvenl lo prevenl conla
b. Engage Ihe park brake and/or properly block mination. Allow lile area lO air dry.
Ihe lires.
c. Engage lile swing park brake or Iravel swing Refer lo Figure 1.
lock, as required. 7. Label for assembly purposes and disconnecl lile
d. Level lile crane on fully exlended oulriggers. brusll Ilarness (8) and cenler Ilarness (5).
e. Fully relracl and posilion lile boom, as re 8. Loosen lile jam nul (7), and remove lile capscrew
quired, as equipped. (7) from lile colleclor ring (1). Allow lile capscrew
3. Slluldown lile engine. and jam nul (7) lo remain willl lile brackel (6).
4. Clleck Illal all conlrollevers are in lile neulral posi 9. Remove lile capscrews (2) Illal secure lile drive
lion and move lile funclion lockoul swilcll lo lile plale (3) lo lile rolaling joinl (4).
"DI SABLE" posilion. 10. To aid in lile assembly process, lie a "pull slring" lo
lile cenler Ilarness (5).
11. Wllile lifting lile colleclor ring (1), carefully guide
A WARNING lile cenler Ilarness (5) Illrougll lile cenler of lile ro
laling joinl (4).
Use care not to cause sparks at the battery 12. Allow lile "pull slring" lO remain Illrougll lile cenler
terminals while disconnecting the cables. of lile rOlaling joinl (4). If replacing lile cenler Ilar
Battery gasses are volatile and could be ness (5), Iransfer lile "pull slring" lo lile new Ilar
ignited by a spark or flame, causing the ness.
battery to explode. Keep the area around the 13. Remove lile colleclor ring (1) from lile crane.
battery well ventilated. With the ignition
switch in the "OFF" position, disconnect the Cleaning And Inspection
negative side of the battery first to minimize
hazard.
Battery posts, terminals, and related

A WARNING
accessories contain lead and lead Solvents and cleaning solutions can be
compounds. Eating or smoking with lead hazardous. Serious personal injury may
residue on hands may cause lead poisoning. result from misuse of these products. Read
Wash hands after handling lead products. and follow all the manufacturer's
5. Ensure Ihal Ihe ignilion swilcll is in Ihe "OFF" posi cleaning solutions.
lion, and label lile battery conneclions al lile bal
leries. Disconnecl lile battery cables from lile bal 1. AII componenls sllould be Illorougllly cleaned willl
leries, negalive side firsl, or lurn lile battery discon an approved cleaning sOlvenl, air dried, and care
necl swilclles lo lile "OFF" posilion. fully inspecled.
1 of 4
--2
7 3
6----
1. Collector Ring 3, Orive Plate 5. Center Harness 7, Capscrew & Jam Nut
2. Capscrews 4, Rotating Joint 6. Bracket 8. Brush Harness
Figu re 1
Center Section Assembly
2 af 4
2. AII Loctite®, Permatex®, or other sealant residue 4. Position the rotating joint (4) so that the ca pscrew
should be removed from threads of hardware and (7) can be installed.
the mounting surfaces of parts that are going to be 5. Install the capscrew (7), and tighten the jam nut (7)
reused. Prior to applying new thread locking com against the collector ring (1).
pounds or sealants, clean threads and surfaces 6. Connect the brush harness (8) and center harness
with Loctite® 7070 Cleaner to ensure best perfor (5).
mance of products.
tigue or stress fractures, and corrosion. Repair or
A WARNING
4. Inspect the integrity of the wire harnesses. Repair
terminals while connecting the cables.
or replace if required.
ignited by a spark or flame , causing the
battery to explode. Keep the area around the
battery well ventilated. With the ignition
I nstallation switch in the "OFF" position, connect the
positive side of the battery first to minimize
hazard.
A WARNING Battery posts, terminals, a nd related

accessories contain lead and lead
compounds, etc. can be hazardous. Serious compounds . Eating or smoking with lead
personal injury may result from misuse of residue on hands may cause lead poisoning.
these products. Read and follow all Wash hands after handling lead products.
these products. 7. Ensure that the ignition switch is in the "OFF" posi
tion and connect the battery cables to the batter
ies, positive side first, or turn the battery discon
Refer to Figure 1.
nect switches to the "ON" position.
1. Using the "pull string", guide the center harness (5)
down through the center of the rotating joint (4)
tions of the collector ring lor proper operation. Nor
while positioning the collector ring (1) on the rotat
mal operation 01 the electrical system should be
ing joint (4).
conlirmed. A general inspection of the compo
2. Applya light coat of Loctite® 242 to the threads of
nents and systems in the areas adjacent to the re
the capscrews (2).
pair should also be performed to ensure re late d
3. Secure the drive plate (3) to the rotating joint (4) us
damage or wear is not presen!.
ing the capscrews (2).
3 01 4
4 of 4
Service Manual 0607 SM01-076-0'63.00
Collector Ring, Recondition
This procedure covers the recondition of the collector
ringo For removal and installation procedures , see
SM Keysheet Area 01-076 .

parts together, they must be free to turn and not bind .
Note: The photographs shown throughout this
document were taken for general purpose use and
may not depict the exact model of collector ring
being serviced.
Disassembly
1. Clamp 2. Screw
It is a good practice when disassembling complex Figure 2
components to lay the parts out in the order that they Col lector Ring Disassembly
are disassembled . Keeping the parts in this order
during disassembly, cleaning, and inspection will aid in Refer to Figure 2.
the assembly process. 3. Remove the screw (2) and clamp (1) .
1. Place the torque tube (8,Figure 10) in a padded
vise. Do not over tighten the vise.
1. Tube 5. Screws
2. Cable Ties 6. Clamps
3. Knife Connector 7 . Swi ng Potentiometer
1. Nuts 3. Cover
4. Wire Harness
2. Sealing Washers
Figure 1 Figure 3
Collector Ring Disassembly Collector Ring Disassembly
Refer to Figure 1. Refer to Figure 3.

2. Remove the nuts (1) , sealing washers (2), and 4. Remove the cable ties (2).
cover (3) . 5. Slide the tube (1) down the wire harness (4) .
6. Disconnect the knife connector (3) .
7. Loosen the screws (5), and turn the clamps (6) to
free the swing potentiometer (7).
8. Remove the swing potentiometer (7).
1 Df 10
s 0 1 -076-063.00 0607 Service Manual
1 SWlng Potentiometer 3. Orive Shaft

2 Setscrews 4 RoJl Pln 1. Bushlng 2. Mountlng Plate
Figure 4 Figure 6
Collector Ring Disassembly Collector Ring Disassembly

9. If required , remove the setscrews (2) and drive 14. If required , remove the bushing (1) from the mount
shaft (3) from the swing potentiometer (1). ing plate (2).
10. If required, remove the roll pin (4) from the drive
: ', .
shaft (3). . : ~ . : :: . . :: . . . . . . : ;: . : :::
: : .. ; . ~. : : : .. . : ,': :;:
: : .' ~ .: :: . . . , .
. :,, : :: : ' . : : :.
:: : :
1 Mounllng Plate 3. Nuts & Washers Figure 7

2 Nuts & Washers Collector Ring Disassembly
Figure 5
Collector Ring Disassembly Refer to Figure 7.
15. Remove the screws (1) and torque plate (2) .
Refer to Figure 5.
11 . Remove the nuts and washers (2).
12. Remove the mounting plate (1) .
13. Remove the nuts and washers (3).
2 0f 10
1. Rub Disc 3. Studs

2. Washers
Figure 8
Collector Ring Disassembly
Refer to Figure 8.
16. Remove the rub disc (1), washers (2), and studs
(3).
Refer to Figure 9.
17. Carefully remove the wirenuts (1) from the wires at
1. Wirenuts 8. Setscrews
the top of the outboard bearing (12), as required.
2. Spacers 9. Connector
3 Brush & Arm Assemblies 10. Cable Ties
Note: Do not remove the wirenuts by cutting the
4. Springs 11. Slip Ring Core
wires. Use pliers to squeeze them open. 5. Nut 12. Outboard Bearing
6. Base Plate 13 Set Collars & Washers
18. Remove the set collars and washers (13) holding 7. Brush Harness 14. Studs
the outboard bearing (12) in place. Slide the out
board bearing (12) over the wires and off the studs Figure 9
(14). Collector Rin Disassemb
19. Remove cable ties (10) as required.
20. Remove the spacers (2) and brush and arm 22. If the slip ring core (11) requires replacement:
assemblies (3) from the studs (14). 23. Loosen the setscrews (8).
24. Remove the springs (4), and spread the brush and
Note: Do not "over stretch" the springs when arm assemblies (3) far enough apart for the slip
removing the brush and arm assemblies. ring core (11) to clear them.
25. Remove the slip ring core (11).
brush and arm assemblies (3) being replaced from
the brush harness (7).
3 of 10
SM0 1-076-063.00 0607 Service Maln ual
18 A
19
17-----1
16---+_~
15
14
13 _ _ ~~~~~ Assembled Height

12--~
(Care Stack)
11
10----"
8 - -_ __
1. Cover 6. Connector 11. Nuts 16. Wirenuts

2. Outboard Bearing 7. Center Harness 12. Brush & Arm Assemblies 17. Rub Disc
3. Slip Ring Core 8 . Torque Tube 13. Spacers 18. Locknuts
4. Nylon Bushing 9. Base Plate 14 . Set Collars 19. Sealing Washers
5. Brush Harness 10. Washers 15. Studs
Figure 10
Collecto r Ring
Refer to Figure 10. 28. If required, remove the nylon bushing (4) from the
26. If the center harness (7) requires replacement, base plate (9).
carefully slide the center harness (7) out the 29 . If required, loasen the nut (5,Figure 9) securing the
bottom of the torque tube (8). connector (6) to the base plate (9). Remove the
27 . If required, remove the studs (15), washers (10), brush harness (5) out through the base plate (9)
and nuts (11) from the base plate (9). and nut (5,Figure 9).
4 0f 10
Base Ring
Nylon Outboard Bearing
Assembled Height (Core Sta~
Table A
Wirin Code
Swing Potentiometer Wirin Code
5 of 10
Cleaning And Inspection 4. AII Loctite®, Permatex®, or other sealant residue
A WARNING
hazardous. Serious personal injury may mance of products.
result from misuse of these products. Read 5. Inspect the integrity of the wire harnesses that are
connected to the collector ring being serviced . Re
pair or replace if required .
cleaning solutions. 6. In the event of severe defects, contact factory per
1. If required , use compressed air to remove aoy dirt any major component.
an d/or debris. Exercise every precaution possible
to keep all parts free of dust, dirt , or any other for Assembly
eign material during assembly. Refer to Figure 10.
2 . Carefully inspect all components for damage, 1. If required, install the washers (10) and nuts (11) on
wear, corrosion, deep scratches, and scuffed met the studs (15), and install the studs (15) in the base
al. Remove any burrs or sharp edges with a fine plate (9).
file, hone, emery cloth, or crocus cloth . Replace Note: Do not allow the studs to protrude
any damaged component as required. through the bottom of the base plate.
3. If corros ion exists, it may be necessary to clean the
rings using a standard non - residue solvent. After 2. If required, install the nylon bushing (4) in the base
the rings have air dried, lightly sand the brushes plate (9) .
and rings with a fine grade of sandpaper and dust 3 . If the center harness (7) was removed, install the
off with compressed airo center harness (7) through the bottom of the
torque tube (8) .
4. If required, install the brush harness (5) through
the base plate (9) and nut (5,Figure 9) . Tighten the
nut (5,Figure 9) securing the connector (6) to the
base plate (9) .
6 of 10
7. Connect the brush and arm assemblies (3) to
brush harness (7).
8. Be sure that all brush and arm assernblies (3) are
snapped in tight and making full contact with their
corresponding brass ring on the slip ring core (11) .
Also check that each spring (4) is hooked correctly
to the correct brush and arm assembly (3) .
9 . Install the outboard bearing (12) over the wires and
on the studs (14) .
Note: The outboard bearing must seat evenly

on the ring coreo
10. Install the washers and set collars (13) securing ttle
outboard bearing (12) to the studs (14).
Note: Ensure that no gaps exist between the

brush and arm assemblies.
11. Install cable ties (10) as required . Remove tails

from the cable ties (10).
A WARNING
Failure to follow wiring code specified in
''Table J!t\' and "Table B" may result in da mage
to crane and/or serious personal injury.
1. Wirenuts 8. Setscrews
2. Spacers 9. Connector 12. Carefully connect the wires as recorded during
3. Brush & Arm Assembli es 10. Cable Ties disassembly, and install new wirenuts (1) to t he
4. Springs 11. Slip Ring Core wires at the top of the outboard bearing (12) as
5. Nut 12. Outboard Bearing required. Refer to "Table A" and "Table B" for
6. Base Plate 13. Set Collars & Washers
correct wiring code information .
7. Brush Harness 14. Studs
Figure 11
Collector Ring Assembly
Refer to Figure 11 .
5 . If the slip ring core (11) was removed :
a. Ensure that the springs (4) are removed, and
spread the brush and arm assemblies (3) far
enough apart for the slip ring core (11) to clear
them.
b. Carefully feed the center harness (7,Figure 10)
through the center of the slip ring core (11),
and install the slip ring core (11).
c. Tighten the setscrews (8) .
d. Install the springs (4) on the brush and arm as
semblies (3) as required.
1. Rub Disc 3. Stud s
Note: Carefully install the brushes without 2. Washers
"over stretching" the springs.
Figure 12
6. Install the spacers (2) and brush and arm assem Collector Ring Assembly
blies (3) on the studs (14) in the same order they
were removed . Refer to "Table A" and "Table B" for Refer to Figure 12.
correct wiring code information . 13. Install the studs (3), washers (2), and rub disc (1).
7 of 10
SM 0 1 -076-063.00 0607 Service Manual
' ... . : ;. ..
':', ":.::,:
..
; :
. . . : . ... : :.
:: . . . :~ ~.' ::
: . .. :: :
::.'.:': . '
1. Mounting Plate 4. Nuts & Washers

2. Rub Disc 5. Nuts & Washers
3. Torque Plate
Figure 13
Collector Ring Assembly Figure 15
Refer to Figure 13.
14. Install the torque plate (2) and screws (1). Refer to Figure 15.
16. Install the nuts and washers (5) .
17. Install the mounting plate (1).
. :: . 18. Install the nuts and washers (4) by hand .
... :. 19. Check the assembled height (core stack), ensur
ing all parts are properly seated. Reler to
.. . .' Figure 10, Detail "A" .
20. Tighten the nuts and washers (4 ,5) after the
assembled height is established .
21 . Using feeler gauges, confirm equal clearance
between the mounting plate (1) and torque plate
(3) around the total circumference of the assembly.
22. If required, repeat Steps 18 thru 21.
Figure 14
Collector Ring Assembl
Refer to Figure 14.

15. If required, install the bushing (1) in the mounting
plate (2).
80110
1. Swing Potentlometer 3. Orive Shaft

2. Setscrews 4. RolI Pin
Figure 16 1. Clamp 2. Screw

Figure 18
Refer to Figure 16.
23. If required, install the roll pin (4) in the drive shaft
Refer to Figure 18.
(3).
30. Install the clamp (1) and screw (2).
24. If required, install the drive shaft (3) and setscrews
(2) in the swing potentiometer (1).
1 Tube 5. Screws
2. Cable Ties 6. Clamps 1. Nuts 3. Cover
3. Knife Connector 7. Torque Plate 2. Seallng Washers
4. Wire Harness 8. Swing Potentlometer
Figure 19
Figure 17 Col lector Ring Assembly
Refer to Figure 19.

Refer to Figure 17.
31. Install the cover (3), sealing washers (2), and n uts
25. Align and install the swing potentiometer (8) in the (1) .
torque plate (7). 32. If collector ring is not to be ímmediately installed on
26. Turn the clamps (6) to secure the swing crane, place in a box to prevent damage and con
potentiometer (8), and tighten the screws (5). tamination , and properly store.
27. Connect the knife connector (3).
28. Slide the tube (1) on the wire harness (4) and over
the knife connector (3).
29. Install cable ties (2). Remove tails from the cable
ties (2).
9 of 10
10 of 10
4. Turn the battery disconnect switch es to the "OFF"
position, or disconnect the battery cables from the
battery, negative cables first. See the Operator 's
Manual for battery disconnect sw itch operation.
Refer to Figure 2.
battery cables (3,8), ground cable (9), carrier har
ness wires (4,5), and alternator harness wires (6,7)
from the starter (1).
6. Support the weight of the starter (1) .
7. Remove the bolts (2) that secu re the starter (1) to
the engine flywheel.
8. Remove the starter (1).
A WARNING
Figure 1 Solvents and cleaning solutions can be
Do not use and open flame near the battery. hazardous. Serious personal injury may
Starter, R & I and follow all the manufacturer's
This procedure covers the removal and installation of cleaning solutions.
the starter.
1. Clean all connections with an approved cleaning
Removal solven!.
1. Lower, detach, and secure the load, as required . 2. Clean the mounting surfaces of the starter and en
2. Stabllize the crane for service as follows: gine flywheel housing with an approved cleaning
a. Park the crane, out of the way, on a firm and solvent.
level surface . 3 . Thoroughly inspect all parts for damage, wear, fa
b . Engage the park brake and/ or p roperly block tigue or stress fractures, and corrosion. Repair or
the tires. replace as required .
c. Engage the swing park brake or travel swing 4 . Inspect the integrity of the cables, wires , and con
lock, as required . nectors that supply the starter. Repair or replace if
3. Shutdown the engine and allow sufficient time for required.
the engine to cool. 5. In the event of severe defects, contact factory per
A WARNING Installation
terminals while disconnecting the battery. Refer to Figure 2.
Battery gas ses are volatile and could be 1. Position the starter (1) to the engine flywheel , and
ignited by a spark or flame causing the battery install the bolts (2).
to explode. Keep the area around the battery 2 . Connect the battery cables (3,8), ground cable (9) ,
well ventilated and disconnect the negative carr ier harness w ires (4,5), and alternator harness
side of the battery first, with the ignition switch w i res (6,7) to the starter (1). Cable tie any cables or
"OFF", to minimize hazard. wires , as required , to prevent damage .

compounds . Eating or smoking with lead
Wash hands after handling lead products.
1 of 2
A
4
1. Starter 4. Carrier Harness Wire - 204A Red 7. Alternator Harness Wire - 122B Black
2. Bolts 5. Carrier Harness Wire - 204B Blue 8 Battery Cable - Negatlve
3 Battery Cable - Positive 6. Alternator Harness Wire - 108A Red 9. Groun d Cable - To Carrier Frame
Figure 2
Starter Installation
3. Turn the battery disconnect switches to the "ON"
A WARNING position, or connect the battery cables to the bat

tery, positive cables firsl. See the Operator's
Use care not to cause sparks at the battery Manual for battery d isconnect switch operation.
terminals while connecting the battery. 4. Complete the installation by starting the engine
Battery gas ses are volatile and could be and testing al! electrical functions for proper opera
ignited by a spark or flame causing the battery tion .
to explode. Keep the area around the battery
well ventilated and connect the negative side
of the battery last, with the ignition switch
" OFF", to minimize hazard.
2 of 2
Service Manual 0409 SM01 -077 -02 1.00
c. Work the Crane controllevers and/or outrigger
Radiator, Charged Air & switches back and forth several times.
Transmission Oil Cooler, 6.
d. Turn ignition switch to the "OFF" position .
Check that all controllevers are in the neutral posi
R& I tion and move the function lockout switch to the
"DI SABLE" position.
This procedure covers the removal, installation, and 7. Remove the engine housing. See SM Keysheet
separation of the charged air cooler, radiator, and Area 01-071 for the correct procedure.
transmission oil cooler assembly.
Refer to Figure 1.
Removal 8. Remove any sheet metal, grilles, fenders, etc. re
quired to access the charged air cooler (23) and ra
1. Lower, detach, and secure the load, as required. diator (24) assembly.
level surface . Engage the par k brake.
b. Engage the swing park brake or travel swing A WARNING
lock , as required . Coolants may be hot. Failure to allow
c. Level the crane on fully extended outriggers . sufficient cooling could result in bu rns or
d. Position/support the boom , as required . other personal injury. Allow the engine,
3. Shutdown the engine and disengage the main hy transmission, and radiator to cool before
draulic pump, as equipped. removing caps and lines or draining coolant.
A WARNING
9. Drain the coolant from the radiator (24) into a suit
able container. Properly store or dispose of the
coolan!.
hazardous. Serious personal injury may 10. Once the coolant has finished draining , close the
result from misuse of these products. Read drain valve.
and follow all the manufacturer's 11. Label for assembly purposes and disconnect the
recommendations concerning solvents and air intake lines (2), hydraulic lines (9), vent line (4) ,
cleaning solutions. coolant lines (7), and transmission oil cooler lines
(22). Cap or plug the openings to prevent conami
4. Thoroughly clean area to be disassembled with an nation.
12. Drain any residual hydraulic oil, transmission fluid ,
tion. Allow the area to air dry.
or coolant into a suitable container. Properly store
or dispose of fluids.
A WARNING 13. Remove the capscrews and nylon washers (8) ,
and separate the fan shroud (6) from the radiator
Hydraulic oil is under pressure and may be assembly (3).
CAUTION
any line or component. Cooling fins are very delicate. Even a minor
bump can cause a deformation of the fins and
5. Relieve the hydraulic system pressure as follows: reduce efficiency. Be very careful not to
a. Releas e any residual pressure in the carrier deform the cooling fins during disassem bly.
hydraulic reservoir by slowly loosening the
Note: The radiator assembly weighs approxi
hydraulic reservoir, until pressure is fully
mately 310 lb (141kg).
relieved.
b. Turn the ignition switch to "ON", but DO NOT 14. Using an auxiliary lifting device, support the radia
STARTTHE ENGINE. Move the function lock tor assembly (3).
1 of 6
s 01 -077 -021.00 0409 Service Manual
}., --I
10 9 8 7 6
B
16
IJ
15~
\, .
14 ~ , r,/ ..~
;: .~/
( ,.
13 --....../ '
..1--._ 12
----
1. Finger Guard 8. Capscrews & Nylon Washers
2. Air Intake Lines 9. Hydraulic Lines
3. Radiator Assembly 10. Radiator Fan Motor
4. Vent Line 11. Surge Tank
5. Foam Baffles 12. Rubber Spacers
6. Fan Shroud 13. Support Braces
7. Coolanl Lines
Figure 1
Radiator, Charged Air Cooler And Transrnission Oil Cooler
2 of 6
20 21 22
23
24
. ,j
j
14. Jam Nuts 20 . Transmission Oil Cooler
15 Washers 21. Capscrews. Washers. Lockwashers. & Locknuts
16. Locknuts 22. Transmission Oil Cooler Lines
17. Washers 23. Charged Air Cooler
18. Locknuts 24 . Radiator
19 Rubber Pads
3016
SM 01 -017 - 021.00 0409 Service Manual
15 , Loosen the jam nuts (14), and remove the lock 6, Replace the foam baffles if required, The mounting
-"J i:; (16), washers (15), and rubber spacers (12) surfaces must be clean and dry to allow the foam
securing the support braces (13) to the radiator baffles to properly adhere to the radiator assembly,
assembly (3), 7, In the event of severe defects, contact factory per
16. Remove the locknuts (18), washers (17), and rub sonnel for directions whether to repair or replace
ber pads (19) securing the radiator assembly (3) to any major component.
the carrier frame,
17 , Uft the radiator assembly (3) from the crane, Installation
18, Remove the rema ining rubber spacers (12) and
washers (15) from the support braces (13),
19 . If removal of the finger guard (1) or radiator fan mo
tor (10) is required , see SM Keysheet Area 01-081
A WARNING
tor the correct procedure,
20. To separate the charged air cooler (23) and compounds, etc. can be hazardous. Serious
radiator (24), or to remove the transmission oil personal injury may result from misuse of
cooler (20), remove the capscrews, washers, these products. Read and follow al!
lockwashers, and locknuts (21) . manufacturer's recommendations concerning
these products.
Note: Silicone caulk is used to seal between the
radiator sections. This sealant may hold the Refer to Figure 1,
sections together even after the hardware is re 1. To install the transmission oil cooler (20) and join
moved. Remove caulk as required. the charged air cooler (23) , and radiator (24),
install the capscrews, washers, lockwashers, and
locknuts (21),
Clean ing And Inspection 2, If installation of the finger guard (1) or radiator fan
motor (10) is required, see SM Keysheet 01-081
A WARNING
for the correct procedure,
3, Applya bead of silicone sealant around the front,
back, and sides where the charged air cooler (23)
hazardous. Serious personal injury may and radiator (24) join, Refer to Figure 2 for an il
result from misuse of these products. Read lustration of the areas to be sealed,
clean ing solutions. CAUTION
Cooling fins are very delicate. Even a minor
1. AII components should be thoroughly cleaned with bump can cause a deformation of the fins and
an approved cleaning sOlvent, air dried, and care reduce efficiency. Be very careful not to
fully inspected, deform the cooling fins during assembly.
the mounting surfaces of parts that are going to be Note: The radiator assembly weighs approxi
reused , Prior to applying new thread locking com mately 310 lb (141kg).
pounds or sealants , clean threads and surfaces 4, Using an auxiliary lifting device, position the radia
with Loctite® 7070 Cleaner to ensure best perfor tor assembly (3) to the carrier frame for installation.
mance of products,
3 . Thoroughly inspect all parts for damage, wear, fa Note: Do not fully tighten any of the mounting
tigue or stress fractures , and corrosion, Repair or hardware until the radiator assembly has been
replace as required , properly adjusted.
4 , AII "soft parts" , such as seals, gaskets, back up
5, Loosely install the rubber pads (19), washers (17),
rings , and o-rings, should be replaced,
and locknuts (18),
5. Inspect the integrity of the air intake lines, vent line,
6. Install the washers (15) and rubber spacers (12) on
coolant lines, hydraulic lines, and transmission oil
the su pport braces (13),
cooler lines, Repair or replace if required,
4 of 6
7. Guide the radiator assembly (3) onto the support
braees (13), and install the remaining rubber Apply silicone sealant
spaeers (12), washers (15) , and loeknuts (16). 2 around tront, back,
and sides on both
8 . Seeure the position of the radiator assembly (3) by !R ends 01 radiator
\~~1 ,~____
tightening the jam nuts (14) and loeknuts (18) .
9. Align the fan shroud (6) to the radiator assembly --: ""mOl,
(3), and install the eapserews and nylon washers
(8) . Be sure the fan shroud (6) is eoneentrie to the
fan. -r1i, \
-. ./ )
(1)
Note: The vent and fill lines must run continu
ously downward from the surge tank to the ra
diator in order to allow the system to fill and
(i ;.,1 ~
deaerate properly.
10. Conneet the air intake lines (2) , hydraulie lines (9) ,
\1,1 1
r:'
vent line (4), eoolant lines (7) , and transmission oil
eooler lines (22). .". . . '---..---.... r'J)
11 . Properly fill the eooling system with engine eool
ant. See the Engine Operator's Manual for the eor o~r
reet type and proeedure.
1. Charged Ai r Cooler
12. Check the transmission fluid level. Add transmis 2. Rad iator
sion fluid as required . See the Operator's Manual
for the eorreet type and proeedure. Figure 2
Typical Radiator Assembly
13 . Check the hydraulie reservoir oillevel. Add oil as
required. See the Operator's Manual for the cor
reet type and procedure.
14. Engage the main hydraulic pump , as equipped.
15. Start the engine and let idle for five minutes . In
speet the connections on the air intake lines, hy
draulic lines , vent line, coolant lines, and transmis
sion oil eooler lines for leaks. Repair as required .
16. Install any sheet metal, grilles, fenders, etc. that
were removed.
17. Install the engine housing . See SM Keysheet Area
01 -071 for the correet procedure.
tions of the charged air cooler, radiator, and trans
mission oil eooler for proper operation . Normalop
eration of the hydraulie, air, and electrieal systems
should be eonfirmed. A general inspection of the
components and systems in the areas adjacent to
the repair should also be performed to ensure re
lated damage or wear is not present.
5 of 6
6 of 6
Service Manual 0608 SM01 - 077 - 03 3 .00
Figure 1 1. Alternator
Do not use an open flame near the battery. 2. Battery Wire - 10SA Red
3. Alternator Harness
4. Ground Wire - 1228 Black
Alternator, R & I
Figure 2
This procedure covers the removal and installation of Alternator Wiring
the alternator. Precautions must be taken when
working on or around alternators. The diodes and
Do not attempt to polarize the alternator. The alternator
transistors in an alternator circuit are very sensitive and
diodes are sensitive to heat, and care must be
can be easily destroyed. Avoid grounding or shorting
exercised to prevent damage from exposure to
the output wires or the field wires between the
extreme heat.
alternator and regulator. Do not run an alternator on an
open circuito If faulty operation 01 the alternator occurs , ensure that
all electrical connections are tight and clean before
Grounding of alternator output wires or terminals, replacing the alternator.
which are always "hot" regardless of whether or not the
engine is running, or accidental reversing the battery Removal
connections will destroy the diodes. Grounding the 1. Lower, detach , and secure load, as required .
field circuit will also result in the destruction of the 2. Stabilize the crane far service as follows :
diodes. Some voltage regulators provide protection a. Park the crane, out of the way, on a firm and
against some of these circumstances. However, it is level surface .
recommended that extreme caution be used. b. Engage the park brake and/or properly block
the tires.
Do not disconnect the battery while the alternator is in
operation. Disconnecting the battery may result in
lock, as required .
damage to the diodes due to the momentary high
voltage and current generated by the rapid collapse of
the magnetic field surrounding the field windings.
quired .
If a booster battery is to be used, the batteries must be 3. Shutdown the engine.
connected correctly (negative to negative and positive
to positive). Do not use a fast charger with the battery
connected or as a booster for battery output.
1 of 4
A B
3
1. Orive Belt 3. Capscrews & Washers 5. Alternator Pulley

2. Belt Tensioner 4. Alternator 6. Locknut
Figure 3
Alternator Assembly
2 of 4
Service Manual 0608 SM01 - 077 - 033. 00
A WARNING
A WARNING
and follow all the manufacturer's hazardous . Serious personal injury may
recommendations concerning solvents and result from misuse of these products. Read
cleaning solutions. and follow all the manufacturer's
4. Thoroughly clean area to be disassembled with an cleaning solutions.
approved cleaning solvent and allow the area to air
dry. 1. AII components should be thoroughly cleaned with
an approved cleaning solvent , air dried , and care
A WARNING 2.
fully inspected.
reused. Prior to app lying new thread locking com
pounds Or sealants, clean threads and surfaces
ignited by a spark or flame causing the battery
mance of products .
well ventilated and disconnect the negative
side of the battery first, with the ignition switch 3. Thoroughly inspect all parts for damage , wear, and
corrosion . Repair or replace as required .
"OFF", to minimize hazard.
4. Inspect the integrity of the electrical wires and con
nectors that supply the alternator. Repair or re
place if required .
5. Inspect the drlve belt for excessive wear. Replace
compounds. Eating or smoking with lead
as needed.
5. Turn the battery disconnect switches to the "OFF " any major componen!.
position, or disconnect the battery cables from the
battery (negative cable first). See the Operator's I nstallation
Manual for battery disconnect switch operation.
Refer to Figure 2.
battery wire (2) and ground wire (4) from the
A WARNING
alternator (1).
Refer to Figure 3.
7. Insert a socket driver into the belt tensioner (2) , and these products. Read and follow all
rotate the belt tensioner (2) to relieve tension on the manufacturer's recommendations concerning
drive belt (1). Remove the drive belt (1) from the
these products.
alternator (4) .
8. Support the alternator (4) , and remove the
capscrews and washers (3) securing the alternator Refer to Figure 3.
(4) to the engine. 1. If removed, install the alternator pulley (5) on the al
9. Remove the alternator (4) from the crane. ternator (4). Secure the alternator pulley (5) to the
10. If necessa ry, remove the locknut (6) , and separate alternator (4) by installing the locknut (6). Torque
the alternator pulley (5) from the alternator (4) . the locknut (6) to 70-80 ft lb (95-708Nm).
3 of 4
2, Align the alternator (4) to the engine, and install the
capscrews and washers (3), Torque the cap
screws (3) to 43-54 ft lb (5B-73Nm) ,
A WARNING
Note: Refer to Figure 3 for the correct drive belt terminals while connecting the battery.
routing. Battery gasses are volatile and could be
ignited by a spark or flame causing the battery
3, Route the drive belt (1) over the engine pulleys.
4, Insert a socket driver in the belt tensioner (2), and
well ventilated and connect the positive side
rotate the belt tensioner (2) to relieve tension on the
of the battery first, with the ignition switch
drive belt (1).
5, Install the drive belt (1) around the alternator pulley
(5) , and releas e the belt tensioner (2).
8, Turn the battery disconnect switches to the "ON"
6, The belt tensioner (2) is self adjusting, II excessive
position, or connect the battery cables to the bat
dellection is evident , replace the worn drive belt (1) tery (positive cable first).
or check the belt tensioner (2) lor damage and 9. Start the engine and test all electrical functions
proper installation ,
prior to placing crane back into service. Inspect
Refer to Figure 2, the drive belt to ensure it has remained properly
7 , Connect the battery wire (2) and ground wire (4) to
installed and is running smoothly,
the alternator (1). Torque the hardware mounting
the battery wire (2) to 50-60 in lb (5,9-7.1Nm),
Torque the hardware mounting the ground wire (4)
to 55- 70 in lb (6.5-B.3Nm).
4014
b. Turn the ignition switch to " ON" , but DO NOT
Lower Hydraulic START THE ENGINE. Move the function lock
Components, R & I out switch to the "OPERATE" position,
c, Work the crane control levers and outrigger
(Suction, Pressure, & Return Unes) switches back and forth several times ,
d, Turn the ignition switch to the "OFF" position ,
This procedure is general in nature and covers the 6, Check that all control levers are in the neutral
removal and installation of the lower hydraulic position and move the function lockout switch to
the "DI SABLE" position ,
components, Specific procedures for major
component removal and installation may be available ,
Refer to SM Keysheet for titles and code numbers of
additional procedures, A WARNING
Air lines may contain high pressure. Op ening
Removal lines and fittings befo re relieving air pressure
1, Lower, detach, and secure the load , as required, may result in serious injury. Shutdown the
2, Stabilize the crane for service as follows : engine and drain the air system reservo ir
a , Park the crane , out of the way, on a firm and before opening any line or fitting.
level surface,
b, Engage the park brake and/ or properly block 7, Open the drain valves on the air system reservoirs
the tires, to bleed the air system pressure.
c, Engage the swing park brake or travel swing 8, When pressure is fully relieved, close the drain
lock , as required, valves on the air system reservoir,
d , Level the crane on fully extended outriggers, 9, Remove any grilles , guards , and other types of
e, Fully retract and position the boom, as re protective shields that may be covering the
quired, hydraulic component that is to be removed ,
3 , Shutdown the engine and disengage the main 10, Disconnect any control cables pertaining to and
hydraulic pump , as equipped , directly connected to the hydraulic component
that is to be removed,
11, If required, label for assembly purposes and
A WARNING disconnect any electrical connectors pertaining to
and directly connected to the hydraulic
component being removed,
12 , If required , label for assembly purposes and
disconnect any air lines , hoses, tubes , and fittings
pertaining to and directly connected to th e
hydraulic component being removed, Cap/plug
cleaning solutions.
any open lines, hoses , tubes, and fittings to
prevent contamination of the system,
4. Thoroughly cl ean the area to be disassembled with
an approved cleaning solvent to prevent 13, Label for assembly purposes and disconnect any
contamination, Allow the area to air dry, hydraulic lines, hoses, tubes , and fittings
pertaining to and directly connected to the
A WARNING
hydraulic component being removed , Cap/plug
any open lines, hoses , tubes , and fittings to
prevent excessive oilloss and contamination ofthe
hoto A sudden release of hot oil could cause system ,
burns or other serious injury. Shutdown the 14, Adequately support the component with an
engine and exhaust al! trapped hydraulic appropriate lifting device, as required,
pressure from the system before removing 15 , Remove any mounting hardware that is securing
any line or component. the hydraulic component to the crane,
16, Using an au xiliary lifting device , if required , remove
5, Relieve the hydraulic system pressure as follows: the hydraulic component from the crane .
a, Release any residual pressure in the hydraulic
reservoir, until pressure is fully relieved,
1 of 6
t!
~
B
BOTTOM VIEW
RIGHT SIDE VIEW
Figure 1
Lower Hyd raulic Components
2 ot 6
SECTION A-A

e
SECTION B-B
~fJ ·
~, I
g
~ ~I
J'
I VIEW D-D
d~
SECTION C-C
Lower Hydraulic Components - Continued
3 of 6
? -l
~ 1-
.~ I'I ¡
I
l -_ _ ~_---l L
BOTTOM VIEW
G
; llR ---"- L --/ ' =l~-~-===~
o_
RIGHT SIDE VIEW
Lower Hydraulic Components - Continued
4 of 6
A WARNING A WARNING
Solvents and cleaning solutions can be Lubricants, sealants, joint and thread locking
1. AII components should be thoroughly cleaned with 1. Using an appropriate lifting device, il required ,
an approved cleaning sOlvent, air dried, and align the hydraulic component to the crane.
carelully inspected. 2. Apply Loctite® 242 to mounting hardware, as
2. AII Loctite®, Permatex®, or other sealant residue required.
should be removed Irom threads 01 hardware and 3. Install the mounting hardware and torque per
the mounting surfaces 01 parts that are going to be specilication in SM Keysheet Area 18-000.
compounds or sealants , clean threads and Note: When installing air or hydraulic lines,
surlaces with Loctite® 7070 Cleaner to ensure best hoses, tubes, and fittings, use two wrenches to
performance 01 products. ensure that they are not twisted. One wrench
3. Thoroughly inspect all parts lor damage, wear, must be on the male fitting, and the other
latigue or stress Iractures, and corrosion. Repair wrench on the female fitting.
or replace as required.
4. Attach hydraulic lines, hoses, tubes, and littings.
Torque per specilications in SM Keysheet Area
07 -018.
5. Inspect the integrity 01 the air lines/ hoses that are
5. Attach any air lines , hoses , tubes , and littings that
connected to the hydraulic componen!. Repair or
were disconnected .
replace il required .
6. Connect any electrical connectors that were
6. Inspect the integrity 01 the hydraulic lines/hoses
disconnected.
that are connected to the hydraulic componen!.
7. Connect any control cables that were removed
Repair or replace il required.
7. Inspect the integrity 01 the electrical wires and
required. See the Operator's Manual lor correct
connectors that supply the hydraulic componen!.
type and procedure.
Repair or replace il required.
9. Engage the main hydraulic pump, il equipped.
8. In the event 01 severe delects, contact lactory
10. Start the engine and let idle lor live minutes.
personnel lor directions whether to repair or
11. II required, apply a soap solution to the air line
replace any maJor componen!.
connections. Inspect the air connections lor leaks .
Air leaks will lorm bubbles in the soap solution
where leaks are presen!. Repair leaks as required .
12. Inspect the hydraulic connections lor leaks .
13. Install any grilles, guards, and other types 01
protective shields that were removed.
lunctions 01 the hydraulic component lor proper
operation. Normal operation 01 the hydraulic , air,
and electrical systems should be conlirmed . A
general inspection 01 the components and
systems in the areas adjacent to the repair should
also be performed to ensure related damage or
wear is not present o
5016
6 of 6
4. Remove the nuts (35) and washers (33) from the
Hydraulic Gear Pump, studs (34).
Recondition
Models 315/330 And 350/365 CAUTION
Integrity of machined surfaces is crit ical.
The following procedure contains instructions for the Excessive force while prying could res ult in
recondition of multiple section type gear pumps. The misalignmentor damageto parts. If prying off
illustration shown in Figure 1 is a 2 section pump. pump sections becomes necessary, t ake
Repeat the intermediate steps of this procedure as extreme care notto mar or damage machined
many times as necessary to accommodate the specific surfaces.
number of pump sections used in your application . For
removal and installation procedure see SM Area
01-081. Note: As pump sections are disassembled, leave
the dowel pins installed. There is no need to re
A tool list is also detailed on Page 8 of this document move the dowel pins unless they are to be rep laced.
to facilitate the repair of these units.
5. Remove the port end cover (32) . If necessary, pry it
Disassembly loose. The dowel pins (25) will remain with either
It is a good practice when disassembling hydraulic the port end cover (32) or the gear housing (26) .
components to lay the parts out in the order that they Do not remove the dowel pins (25) unless they are
were disassembled . Keeping the parts in this order damaged.
during disassembly, cleaning and inspection will aid in 6. Remove the thrust plate (28) from the gear housing
the assembly process . (26). Remove the channel seal (29) from the thrust
plate (28).
7. Remove the gear set (11) from the gear housing
.A WARNING (26).
8. Remove the gear housíng (26) from the bearing
Solvents and cleaning solutions can be carrier (16) .
hazardous. Serious personal injury may 9 . Remove the gasket seals (24 ,27) and thrust plate
result from misuse of these products. Read (12) from the gear housing (26) . Remove the chan
and follow all the manufacturer's nel seal (13) from the thrust plate (12).
recommendations concerning solvents and 10. Remove the connecting shaft (15) from the drive
cleaning solutions. gear (9).
11. Remove the bearing carrier (16) from the gear
1. Thoroughly clean the exterior surface of the hy housing (21).
draulic pump to prevent contamination from enter
ing it. Note: Repeat Steps 6 through 11 as req uired to
disassemble a hydraulic pump of 3 sections or
more.
CAUTION
Do not grip on any of the pump's machined 12. Remove the thrust plate (19) from the gear housing
surfaces. Excessive force while clamping (21). Remove the channel seal (18) from the thrust
could result in misalignment and serious plate (19) .
damage to parts. Take extreme care not to 13. Remove the drive gear (9) and driven gear (10)
mar or damage any machined surface. from the gear housing (21) .
14. Remove the gear housing (21) from the shaft end
Refer to Figure 1. cover (4).
2. Place the pump in a vise with the shaft end pointing 15. Remove the gasket seals (20,23) and thrust plate
down . Close the vise on the outer edges of the (8) from the gear housing (21). Remove the chan
mounting flange of the shaft end cover (4). nel seal (7) from the thrust plate (8) .
3. Index mark all pump sections with a punch , for
alignment purposes during assembly.
1 of 8
24
l. Snap Ring 8. Thrust Plate 15. Connecting Shaft 22. Oowel Pin 29. Channel Seal
2. Outboard Bearing 9. Orive Gear 16. Bearing Carrier 23. Gasket Seal 3O. Bushings
3. Lip Seal lO. Oriven Gear 17. Bushings 24. Gasket Seal 31 . Plugs*
4. Shaft End Cover 11 . Gear Set 18. Channel Seal 25. Oowel Pin 32. Port End Cover
5. Check Valves* 12. Thrust Plate 19. Thrust Plate 26. Gear Housing 33. Washer
6. Bushings 13. Channel Seal 2O . Gasket Seal 27. Gasket Seal 34. Stud
7. Channel Seal 14. Bushings 21 Gear Housing 28 . Thrust Plate 35. Nut
* Quantity and locations may vary.
Figure 1
Hydraulic Gear Pump Assembly (Models 315/330 and 350/365)
2 of 8
Service Manual 1008 SM01 -081 -01 4.00
16. Remove the snap ring (1) and use a bearing puller Pressure pus hes the gears against the hous
to remove the outboard bearing (2) from th e shaft ing on the low pressure side. As the hubs and
end cover (4). bearings wear, the cut out becomes more pro
17. Place the shaft end cover (4) in a vise with the shaft nounced . Excessive cut out in a short period of
end down . Tap the lip seal (3) out of the shaft end time indicates excessive pressure or oil con
cover (4) . tamination . If the relief valve settings are within
18. Remove the bushings (6 ,14 ,17,30) from the shaft prescribed limits , check for shock pressures or
end cover (4) , bearing carrier (16) and port end tampering . Withdraw oil sample and check it
cover (32) with a bearing pulier. and the tank for contamination .
19. Remove the check valves (5) and/or plugs (31) Where cut out is moderate, under 0.007 inch
from the shaft end cover (4) and/or port end cover (O. 177mm) , the housing may be turned over
(32) only if they are damaged or need cleaning . and reused . However, the inlet and outlet ports
must be the same size.
Cleaning and Inspection b. Gears: Any wear on the gear hubs or
detectable by touch or in excess of 0.002 inch
A WARNING
(0.050mm) necessitates replacement.
Scoring , grooving or burring of outsi de
diameter of teeth requires replacement.
hazardous. Serious personal injury may Nicking, grooving or fretting of teeth surfaces
result from misuse of these products. Read also necessitates replacement.
and follow all the manufacturer's c. Orive Gear Shafts: Replace if there is any wear
recommendations concerning solvents and detectable by touch in the seal areas . Maxi
cleaning solutions. mum allowable wear is 0.002 inch (0.050mm).
Wear in the shaft seal areas indicates oil con
1. Thoroughly clean all metal parts with an approved tamination . Wear or damage to splines neces
cleaning solvent. Place parts on a clean lint free sitates replacement.
surface and aliow to air dry. Exercise every precau d. Thrust Plates : The thrust plates seal the gear
tion possible to keep all parts free of dust, dirt or section at the sides of the gears . Wear here will
any other foreign material during assembly. allow internal slippage, that is, oil will bypass
2. Stone off the mating surfaces between pump sec within the pump . Maximum allowable wear is
tions with a medium grit carborundum stone. 0.002 inch (0.050mm) . Replace thrust plates if
Oeburr bearing bores with a fine file. they are scored, eroded or pitted . Check the
3. AII Loctite":, Permatex ,or other sealant residue center of the thrust plates where the gears
should be removed from threads of hardware and mesh . Erosion here indicates oil contamina
the mounting surfaces of parts that are going to be tion . Pitted thrust plates indicate cavitation or
reused. Clean off old gasket material from be oil aeration . Oiscolored thrust plates indicate
tween pump sections . Prior to applying new overheating, probably insufficient oil.
thread locking compounds or sealants, clean e. Oowel Pins : If either the dowel pin or dowel
threads and surfaces with Loctite' ' 7070 Cleaner lo hole is damaged , the pin or machined casting
ensure besl performance of products. or both, must be replaced . If more than rea
4 . In the event of severe defects , contact factory per sonable force is required to seat dowels , the
sonnel for directions whelher to repair or re place cause may be poorly deburred or dirty parts,
any major componen\. misalignment of the dowel in the hole, or im
5 . Inspect all parts for damage, wear and corrosion ; proper pin to hole fit.
replace as required . Use the following guidelines f. Bushings : If gears are replaced , bushings
to inspect individual components: must also be replaced . Bushings should fit
into bore with a heavy press fiI . If bush ings can
a. Gear Housing : Wear in excess of 0 .007 inch fall out, bore is oversize .
(O. 17mm) in the cut out necessitates replace g . Seals And Gaskets : Replace all rubber and
ment of the gear housing. Place a straight polymer seals whenever disassembling the
edge across bore. If a 0.007 in (0.177mm) pump . Include all channel seals, shaft seals
feeler gauge will slip under the slraightedge in and gasket seals .
Ihe cul oul area, replace the gear housing. h. CheckValves: Examinethesmalicheckvalves
in the shaft end cover to make sure they are in
tact and functioning properly.
3 of 8
5. Deburr the face of the shaft end cover (4), bearing
carrier (16) and port end cover (32), as required.
Flat Side ,... 6. Fully seat each of the dowel pins (22,25) by tapp ing
ofSeal - -
... ¡......""""" Thrust Plate it with a soft face hammer. If replacing the dowel
pins (22,25), be certain the holes and dowel pins
.... (22 ,25) are clean and free of burrs.
7. Coat the outer diameter of the lip seal (3) and its re
ces s in the shaft end cover (4) with a thin coat of
Permatex® Aviation Form-A-Gasket® or equiva
Figure 2
lent.
Channel Seal Installation
8. Place the lip seal (3) with the metal side out into its
Assembly recess in the shaft end cover (4). Press it into place
with an arbor press until it is flush with the face of
Un less stated otherwise, lubricate all seals, gaskets the recess .
an d housing bores with clean hydraulic oil prior to 9. Wipe any excess sealant out of the shaft end cover
assembly. See Operator's Manual for correct type. (4) .
10. If equipped, install the outboard bearing (2) into
A WARNING
the shaft end cover (4). This is a light press fit and
may require the use of an arbor press . Install the
snap ring (1) .
com pounds, etc. can be hazardous. Serious 11. Grease the new gasket seals (20,23) and insert
personal injury may result from misuse of them into the groove in each side of the gear hous
these products. Read and follow all ing (21) .
manufacturer's recommendations concerning 12. Install the gear housing (21) on the shaft end cover
these products. (4) . Be sure the index marks placed on the pump
during disassembly are aligned. (The large
Refer to Figure 1. rounded core within the gear housing (21) should
1. Place the shaft end cover (4) in a vise with the shaft be on the inlet side of the pump .) Align the dowel
end down . pins (22) with their matching holes and tap the gear
housing (21) evenly with a soft hammer until it rests
tightly against the shaft end cover (4) . Be careful
CAUTION not to damage the gasket seals (20,23).
Do not grip on any of the pump's machined 13 . Install the channel seal (7) into the grooves on the
surfa ces. Excessive force while clamping thrust plate (8) , with the flat side of the channel seal
could result in misalignment and serious (7) facing out. Refer to Figure 2 .
damage to parts. Take extreme care not to 14 Gently slip the thrust plate (8) through the gear
mar or damage any machined surface. housing (21) and into place on the shaft end cover
2. If the check valves (5) and/or plugs (31) are being (4) . The channel seal (7) should be seated on the
replaced , install them tightly into the shaft end shaft end cover (4), with the relief groove in the
cover (4) or port end cover (32) . Peen the edge of thrust plate (8) facing the outlet side of the pump ,
each mounting hole 0 .03 - 0.06 in ch (O.8-1.5mm) as shown in Figure 3.
with a 1.50 in (38mm) diameter steel ball . 15. Mask the splines of the drive gear (9) to prevent
3 . Examine the check valves (5) and/or plugs (31) to damage to the lip seal (3) during installation.
be sure they are tightly in place and functioning
properly.
CAUTION
Use care when installing the splines of the
CAUTION drive gear through the lip seal. Oamage to the
00 not hammer the bushings into the bores. lip seal will result in seal leakage. Mask the
Uneven installation will damage the bushings. splines or otherwise protect the lip seal from
Use an arbor press or other suitable tool. damage before installing the drive gear.
4. Install the bushings (6,14 ,17,30) in the shaft end
cover (4) , bearing carrier (16) and port end cover
(32) with an arbor press .
4 of 8
Service Manual 1008 SM01-081 -01 4.00
16. Lightly grease the shaft 01 the drive gear (9). Insert
the drive gear (9) into the shaft end cover (4) and
through the lip seal (3) with a twisting motion. Be
carelul not to damage the lip seal (3). Push down
carelully until the drive gear (9) rests against the
thrust plate (8). Insert the driven gear (10).
17. Coat the drive gear (9) and driven gear (10) with
clean hydraulic oil to provide initial lubrication
when the pump is started . Reler to the Operator's
Manual lor the correct type.
18. Install tlle channel seal (18) into the grooves on the
thrust plate (19) , with the Ilat side 01 the channel
seal (18) lacing out.
19. Gently slip the thrust plate (19) on the journals 01
the drive gear (9) and driven gear (10) with the
channel seal (18) lacing up . The reliel groove in the 1. Relief Groove 2. Thrust Plate
thrust plate (19) must lace the outlet side 01 the
Note : Install the thrust plate with the reliel groove
pump. (Reler to Figure 3.) Be sure the thrust plate
on the high pressure (outlet) side of the pump .
(19) is seated against the drive gear (9) and driven
gear (10) . Figure 3
20. Position the bearing carrier (16) over the gear Thrust Plate Relief Groove
housing (21) so that the bushings (17) receive the
journals 01 the drive gear (9) and driven gear (10).
Be sure to line up the dowel holes over the dowel Note: Repeat Steps 20 through 25 as req uíred to
pins (22) . When the parts are parallel, squeeze assemble a hydraulic pump of 3 sections or more.
them together or alternately tap over each dowel
until the parts are together. Use care not to dam 26 . Carefully install the gear set (11) in the gear hous
age the gasket seal (20) . ing (26). Be sure the splines 01 the gear set (11) are
21. Install the connecting shaft (15) in the spline 01 the lully engaged with the connecting shaft (15) and
drive gear (9). the gear set (11) is fully seated against the thrust
22. Grease the new gasket seals (24,27) and insert plate (12).
them into the groove in each side of the gear hous 27 . Install the channel seal (29) into the grooves on the
ing (26) . thrust plate (28), with the Ilat side 01 the channel
23. Install the gear housing (26) on the bearing carrier seal (29) lacing out.
(16) . Be sure the index marks placed on the pump 28. Gently slip the thrust plate (28) on the journals 01
during disassembly are aligned. (The large the gear set (11) with the channel seal (29) lacing
rounded core within the gear housing (26) should up . The reliel groove in the thrust plate (28) must
be on the inlet side 01 the pump.) Align the dowel face the outlet side 01 the pump. (Reler to
pins (25) with their matching holes and tap the gear Figure 3.) Be sure the thrust plate (28) is seat
housing (26) evenly with a soft hammer until it rests against the gear set (11).
tightly against the bearing carrier (16) . Be careful 29. Apply Loctite 242 to the threads 01 the studs (34)
not to damage the gasket seals (24,27) . and install them through the pump sections and
24. Install the channel seal (13) into the grooves on the into the shaft end cover (4) . The end 01 tlle stud
thrust plate (12), with the flat side 01 the channel (34) should be lully engaged with the shaft end
seal (13) lacing out. cover (4) but should not extend through it.
25. Gently slip the thrust plate (12) through the gear 30. Install the port end cover (32) over the journals 01
housing (26) and into place on the bearing carrier the gear set (11). Align the dowel pins (25) with
(16). The channel seal (13) should be seated on their matching holes and tap the port end cover
the bearing carrier (16), with the relief groove in the (32) evenly with a soft hammer, until it rests tightly
thrust plate (12) lacing the outlet side 01 the pump against the gear housing (26) . Be carelul not to
as shown in Figure 3. damage the gasket seal (27) .
31 . Install the washers (33) and nuts (35) on tlle studs
(34) . Tighten the nuts (35) alternately until snug .
5 018
s 0 1-081-014.00 1008 Service Manual
Pump Delivery Rate* Drop Off Volume Based On Operating Pressure
1,000 psi (48kPa) 2,000 psi (96kpa) 3,000 psi (144kPa)
gal/min L/min
gal/min L/min gal/min L/min gal/min L/min
10- 30 38-114 1.5-3 .0 5.7 -11.4 2.0-3.5 7.6-13.2 2.5-4.0 9.5-15.1
30 -50 114-189 2.0-3 .0 7.6-11.4 2.5-4.0 9.5-15.1 3.0-4 .5 11.4-17.0
50 -70 189-265 2.5-3.5 9.5-13.2 3.0-5 .0 11.4-18.9 3.5-5 .5 13.2-20.8
" Pump Delivery Al 1,800 rpm and 100 psi (4.8kPa) .
Table A
32. Rotate the shaft of the drive gear (9) with a 6 in Run the pump at least two minutes at no load and
(15cm) wrench to be certain there is no binding in moderate speed (not over 1500 rpm). If the pump
the pump. becomes excessively hot, shutdown immediately and
33. If no internal binding exists, torque the nuts (35) us locate the problem Source.
ing a cross torquing procedure, as follows :
Gradually increase pressure on pump, in 500 psi
315 Model 140 ft lb (190Nm)
(25kpa) increments until the desired test pressure has
been reached. This should take about five minutes .
365 Model 450 ft lb (610Nm) Delivery should run close figures listed on the hydraulic
34. Once again, check for internal binding by repeat schematic, which are averaged from testing several
ing Step 32. pumps . A 5% lower reading may be used as a rated
35 . If hydraulic pump is not to be immediately installed minimum if new or relatively new parts have been used.
on crane, plug all open ports to prevent contamina When rebuilding the pump with parts from the original
tion and properly store. pump, which, while worn, appear satisfactory for
reuse, a 10% or 15% lower reading may be permitted ,
Test Proced ure depending on the performance expected from the
equipment. One's own experience will prove the best
Make certain that there is an adequate supply of oil for guide here.
the pump ; at least 1.0 gal (4L) of oil for each gpm
(4Lpm) of pump capacity. Many repairmen measure the output at normal
operating speed and at zero pressure, then again at
If one section of a tandem pump is being tested, make 1000 psi (50kPa) (or the operating pressure of the
sure that all other sections not being tested are equipment) and allow a volume decrease
adequately supplied with oil. If any of the other approximating the listing shown in Table A. It is a
sections run dry, or if plugs are left in ports , serious and suggested reference only which makes allowance for
permanent damage will result. reused parts.
The oil should be a good quality hydraulic oil rated at At test speeds other than 1800 rpm, flow will vary
150 SSU at 100 °F (38 °C)., with the oil temperature held almost proportionately, but the same (drop-off)
at 120°F (49 °C), plus or minus 50 °F (10°C). (Test figures should be used .
procedures are described in detail in SAE handbooks ;
see Hydraulic Power Pump Test Procedure , SAE Be sure to run the pump in the direction for which it was
J745c.) designed and built. Driving the pump in the wrong
direction will build up pressure behind the shaft seal,
The feed line must be of adequate size with no more damaging it and necessitating replacement.
than 5" mercury (17kPa) vacuum adjacent to the pump
inlet. As a rule , the feed line must provide a feed flow After completing testing procedures, the pump is
velocity not in excess of 8 ft/sec (2.5m/sec). ready for installation and immediate duty operation on
equipment. Again, it must be remembered that to
Feeding hot oil into a cold pump may cause the pump prevent seizure, hot oil must not be fed into a cold
to seize. Jog the pump by momentarily starting and pump.
stopping repeatedly the driving engine or motor to
gradually equalize pump and oil temperatures.
6 of 8
Recommended Start-Up Procedure This is particularly important if the unit is located a bove
the hydraulic reservoir, Refer to the Operator's Manual
For New or Rebuilt Pump for the correct type of hydraulic oil to use,
Before installin g a new or rebuilt pump, back off the After connecting the lines and mounting the
circuit relief valve until the spring tension on the replacement unit, operate the pump for at least two
adjusting screw is relieved , This will avoid the minutes at no load and at low speed (400 rpm
possibility of immediate damage to the replacement minimum) , During this break-in period , the unit
unit in the event that the relief valve setting had been should run free and not develop an excessive amount
increased beyond the recommended operating of heat. If the unit operates properly, speed and
pressure , prior to removing the old unit. Refer to the pressure can then be increased to normal operating
Operator 's Manu al lor specilic instructions on relief settings,
valve settings ,
Reset the circuit relief valve to its proper setting while
Before connecting any lines to the pump, fill al! ports the pump is running, Refer to the Operator 's Manual
with clean hydraulic oil to provide initial lubrication , for specific instructions on relief valve settings,
7 of 8
t,~
C1~ 0.015 in
(O.38mm)
MAX R
(8
tLu
Make From
Pump A B C
OTC Collel No.
0.250 in ¡... in mm in mm in mm
(6. 35mm)
1~ P315
.900
.890
ggjI
22.7
.800
.790
20.3
20.1
J..QQ.
090
2.5
2.3
33863
JillQ ?1JJ. .875 22.2 J..QQ. 2.5

P330 33863
.970 24.7 Re!. Re'. .090 2.3
Figure 4
.L.QQQ. 25.4
Seal Removal Tool P350 ~ íllM Jm. 1.Jl. 33864
1.122 284 0 .990 25.2 .052 1.4
Tool List P365 ~ J.21 1.260 32.0 J..QQ. 2.5

33865
1.372 34.9 1.250 31.2 .120 3. 1
1. Arbor press
Figure 5
2. Aw l
Bushing Removal Tool
3. 1 1/2" Dia . steel ball
4. Bearing puller (Owatonna Tool Co. MD-956 or
equivalent)
Bushing Removal Tool
5. Bushing removal tool (See Figure 5) Refer to Figure 5.
6 . Clean Iint free cloth The bushings in pumps may be removed from their
7 . Deburring tool (an old file with cutting teeth ground bores using blind hole collet - type bushing pullers
off) similar to those manufactured by Owatonna Tool Co.
8. Machinist hammer Figure 5 illustrates the modifications necessary to
9. Soft hammer adapt the OTC collets to this task. Equivalent pullers
10. Permatex Aviation Form-A-Gasket No. 3 non from other suppliers may be modified in similarfashion.
hardening sealant or equivalent
11. Medium grit carborundum stone A.I.S .1. 8620 Bearing Quality Steel
12 Seal removal tool (See Figure 4) Heat Treated
~A
13. Oil and grease
14. Snap ring pliers 0.06 in ~B- t-
(1. 52~~ r 32
1r1.52mm) 0.06 i
15. Prick punch
16. Bushing installation tool (See Figure 6)
t ~~H
17. Scale (1 /32 " graduations)
18. Small screwdriver
19. Tmque wrench
20. Vise with 6 inch minimum opening [1 "'\
\ J
21. Bar for lip seal installation ~Oo Grind Relief Allowable
Note: For 315 use 1 5/8" dia x 2" bar J
For 330 use 1 3/4" dia x 2" bar Pump A B C o (Stock)
For 350 use 2 1/2" dia x 2" bar mm mm mm
in mm in in in
For 365 use 2 1/2" dia x 2" bar 2.38 2M Ul 30.7 ~ 23.79 1.250
P315 31.75
2.25 57.2 1.09 2 7.7 0935 23.75
Seal Removal Tool 3 .06 77.7 ~ J.Il.Jl. 1.054 26.77
P330 1.250 31.75
2 .94 74.7 1.41 35.9 1.052 26.73
Refer to Figure 4.
Easily made from an old screwdriver. Heat tip and P350 ~ 77.7 ~ 38.8 1.282 32.56
1.625 41.28
2 .94 74.7 1.41 35.9 1.280 32. 52
bend as shown. Grind tip to fit notch behind the shaft
sea!. P365
3.06 77.7 1.79 454 .L§g, 37.89 1.750 4445
2 .94 74.7 1:67 42.5 1.490 37. 85
Figure 6
Bushing Installation Tool
8 of 8
b . Turn the ignition switch to "ON", but DO NOT
Hydraulic Pump, R & I START THE ENGINE. Move the function lock
(Tandem Pump) out switch to the "OPERATE" position.
C. Work the crane control levers and outrigger
the hydraulic pump used to supply hydraulic oil to the
d . Turn ignition switch to the "OFF" position.
boom hoist, telescope, winch, and swing functions of
the crane. For recondition procedure, see SM
tion and move the function lockout switch to the
"DI SABLE " position.
Removal 7 . Install a suction pump to , or drain , the hydraulic
reservoir.
1. Lower, detach , and secure the load , as required .
2. Stabilize the crane for service as follows : Reler to Figure 1.
a. Park the crane , out of the way, on a firm and 8. Label for assembly purposes and disconnect the
level surface . hydraulic lines (4,5) from the hydraulic pump (2).
b. Engage the park brake and/ or properly block Cap/plug the open hydraulic ports and lines (4 ,5)
the tires . to prevent excessive oilloss and contamination of
c . Engage the swing park brake or travel swing the system .
lock , as required . 9. Disconnect the drive tube (6) from the yoke (19).
d. Level the crane on fully extended outriggers. Secure the drive tube (6) out of the way.
e. Fully retract and position the boom, as re 10. Remove the capscrew and washer (20), and slide
quired . the yoke (19) off of tl1e hydraulic pump (2) shaft.
3. Shutdown the engine and disengage the main hy 11. Using an auxiliary lifting device, support the weight
draulic pump. of the hydraulic pump (2).
Note: The hydraulic pump weighsapproximate
A. WARNING
Iy 200 lb (91kg).
12. Remove the locknuts (10,26) , capscrews (15 ,21),

hazardous. Serious personal injury may washers (14,22), rubber mounts (13 ,23), washers
result from misuse of these products. Read (11,25), and rubber mounts (12 ,24) that secure the
and follow all the manufacturer's mounting brackets (16 ,17) to the carrier Irame
recommendations concerning solvents and brackets (8 ,27) .
cleaning solutions. 13. Remove the hydraulic pump (2) Irom the crane .
14. II required, remove the capscrews , washers, and
4. Thoroughly clean the area to be disassembled with locknuts (18) that secure the mounting bracket
an approved cleaning solvent to prevent conta (17) to the hydraulic pump (2) .
mination . Allow the area to air dry. 15. If required , remove the washers and locknuts (9)
that secure the mounting bracket (16) to the hy
draulic pump (2) .
A. WARNING 16. II required , remove the washers and locknuts (7)

that secure the carrier frame bracket (8) to the car
Hydraulic oil is under pressure and may be rier frame (1).
hoto A sud den release of hot oil could cause 17. II separation 01 the two main sections 01 the hy
burns or other serious injury. Shutdown the draulic pump (2) is required:
engine and exhaust all trapped hydraulic a. Index mar k the two sections to ensure cor rect
pressure from the system before removing alignment during assembly.
any line or component. b. Remove the washers and nuts (3) .
C. Separate the pump sections, and remove the
5. Relieve the hydraulic system pressure as lollows: connecting shaft.
a. Relieve any residual pressure in the hydraulic d. If lurther disassembly 01 the pump sections is
reservoir by loosening the liller cap 1/4 turno required, see SM Keysheet Area 01-081 lor
reconditioning procedures.
1 of 4
2 3 4 A
7
26
25 17
8
24
9
23 2
22
10
21
2 11
16 12
20
13
19
14
15
18
,. Carrier Frame 10. Locknuts 19. Yoke
2. Hydraulic Pump 11. Washers 20. Capscrew & Washer
3. Washers & Nuts 12. Rubber Mounts 21. Capscrews
4. Hydraulic Lines* 13. Rubber Mounts 22. Washers
5. Hydraulic Lines 14. Washers 23. Rubber Mounts
6. Drive Tube 15. Capscrews 24. Rubber Mounts
7. Wash ers & Locknuts 16. Mounting Bracket 25 . Washers
8. Carrier Frame Bracket 17. Mounting Bracket 26. Locknuts
9. Washers & Locknuts 18. Ca pscrews, Washers, & Locknuts 27. Carrier Frame Bracket
* Exact number 01 lines may vary.
Figure 1
Hydrau lic Pump Assembly
2 of 4
Cleaning And Inspection 2. If required, align the carrier frame bracket (8) to the
carrier frame (1), and install the washers and lock
nuts (7).
A WARNING
3. If required, align the mounting bracket (16) to the
hydraulic pump (2), and install the washers and
Solvents and cleaning solutions can be lockn uts (9).
hazardous. Serious personal injury may 4. If required, align the mounting bracket (17) to the
result from misuse of these products. Read hydraulic pump (2), and install the capscrews ,
and follow all the manufacturer's washers, and locknuts (18).
recommendations concerning solvents and 5. Using an auxiliary lifting device, align the hydraulic
cleaning solutions. pump (2) to the carrier frame bracket (8).
1. AII components should be thoroughly cleaned with Note: The hydraulic pump weighsapproximate
an approved cleaning sOlvent, air dried, and care Iy 200 lb (91kg).
fully inspected.
6. Align the mounting brackets (17 ,16) to the carrier
2. AII Loctite®, Permatex® , or other sealant residue
frame brackets (27,8) .
7. Secure the mounting brackets (17,16) to the carri
er frame brackets (27,8) by installing the rub ber
mounts (13 ,23), washers (14,22) , capscr ews
(15,21) , rubber mounts (12 ,24) , washers (11,25) ,
and locknuts (10,26) .
mance of products.
8. Applya light coat of Loctite® 242 to the threads of
the capscrew (20).
tigue or stress fractures , and corrosion . Repair or
9. Slide the yoke (19) on the hydraulic pump (2), and
install the capscrew and washer (20) .
4. AII "soft parts", such as seals , gaskets , back up
10. Connectthedrivetube(6)totheyoke(19) . SeeSM
rings, and o-ring s, should be replaced.
Keysheet Area 01-022 for additional u-joinl
5. Inspect the integrity of the hydraulic lines that are
installation procedures .
connected to the pump. Repair or replace if re
11. Align the hydraulic lines (5 ,4) to the hydraulic
quired.
pump (2) , and install o-rings , split flanges, and
capscrews (not shown).
any major componen!. Note: Lightly coat the threads of the capscrews
with Loctite® 242 prior to installation.
Installation
12. Remove the suction pump, il required .
A WARNING required. See the Operator 's Manual for correct
type and procedure.
Lubricants, sealants, joint and thread locking 14. Start the engine and let idle for five minutes . In
compounds, etc. can be hazardous. Serious spect the hydraulic connections for leaks . Repair
personal injury may result from misuse of leaks as required.
these products. Read and follow al! 15 . Complete the installation by testing all related func
manufacturer's recommendations concerning tions of the hydraulic pump for proper operation.
these products. Normal operation of the hydraulic system should
be confirmed. A general inspection of the compo
Refer to Figure 1. nents and systems in the areas adjacent to the re
1. If required , install the connecting shaft, align the pair should also be performed to ensure related
two main sections of the hydraulic pump (2), and damage or wear is not present.
install the washers and nuts (3). If additional as
sembly of the pump sections is required , see SM
Keysheet Area 01-081 for reconditioning proce
dures .
3 of 4
4 of 4
d . Turn ignition switch to the " OFF" position.
Radiator Fan Motor, R & I 6. Check that all controllevers are in the neutral posi
This procedure covers the removal and installation of tion and move the function lockout switch to the
the radiator fan hydraulic motor. For recondition "DI SABLE" position or the gate lock lever to the
procedure, see SM Keysheet Area 01-081 . "STOP" position , as equipped.
Removal of the fan guard from the radiator assembly is 7 . Remove the engine housing. See SM Keysheet
required to separate the motor from the fan. area 01 - 071 for the complete procedure.
8. Remove the alternator. See SM Keysheet Area
Removal 01-063 or 01-077 for complete procedure.
1. Lower, detach, and secure load, as required .
Refer to Figure 1.
9 . Label for assembly purposes and disconnect the
Ilydraulic lines (9) from the fan motor (17). Cap/
surface; engage the carrier park brake .
Pllug the open hydraulic ports and lines (9) to pre
b. Level the crane on fully extended outriggers .
vent excessive oil loss and contamination of the
system .
lock, as required.
10. For assembly purposes, place alignment marks on
d. Position/support the boom, as required .
tan motor (17), tan guard (5). and shroud (3).
draulic pump.
CAUTION
.A WARNING Cooling fins on the radiator assembly are very
delicate. Even a minor bump can cause a
Solvents and cleaning solutions can be deformation of the fins which reduces the
hazardous. Serious personal injury may efficiency of the radiator assembly. Be very
result from misuse of these products. Read careful not to deform the radiator assembly
and follow all the manufacturer's cooling fins during removal of the fan.
cleaning solutions. 11 . Remove capscrews and washers (2) and sep arate
the fan guard (5) from the shroud (3) , with the fan
4. Thoroughly clean area to be disassembled with an motor (17) attached .
contamination from entering the hydraulic oil
circuits . Allow the area to air dry. .A WARNING
.A WARNING
Engine coolant may be hoto Failure to allow
engine to sufficiently cool before draining
coolant could result in burns or other
hoto A sudden release of hot oil could cause personal injury. Allow the engine and rad iator
burns or other serious injury. Shutdown the to cool before removing pressure cap and
engine and exhaust all trapped hydraulic lines or draining coolant from theradiator.
pressure from the carrier hydraulic system 12. Loosen or remove any coolant lines (8) or air tubes
before removing any line or component. (1), as required, to allow removal ot the tan guard
5. Relieve the hydraulic system pressure as follows: (5). If coolant lines (8) must be loosened, drain the
a. Release any residual pressure in the hydraulic coolant from the radiator (4) , using the drain hose
reservoir by pushing the button on the (6) and drain valve (7) . Properly store or dispose ot
pressure relief valve, located on the hydraulic used coolant.
reservoir (if equipped) or slowly loosen the filler 13. Remove the capscrews and lockwashers (10)
cap until pressure is fully relieved. which secure the tan (14) to the hub bushing (11) .
Note: The fan is pressed onto the hub bushing
and will not separate from the motor. The hub
bushing is keyed to the motor shaft and secured
gate lock lever to the "OPERATION" position,
with a setscrew.
as equipped.
c. Work the crane controllevers and/ or outrigger
1 of 4
10 11 12 13 14 10 11 18
/~! ,'
13
/
I
' 1/8"-1/4"
(3-6mm) 17
1, Air Tubes 7, Drain valve 13, Key

2, Capscrews & Washers 8, Coolant Lines 14, Fan
3, Shroud 9, Hydraulic Lines 15, Capscrews, Locknuts, & Washers
4, Radiator Assembly 10, Capscrews & Lockwashers 16, Setscrew
5, Fan Guard 11 , Hub Bushing 17, Fan Motor
6, Drain Hose 12, Shaft 18, Removal Hales (Threaded)
Figure 1
Radiator Fan
2 of 4
Service Manual 0209 SMO'1 -081-045.00
14. Install capscrews (10) into removal holes (18) in the Refer to Figure 1.
hub bushing (11). (The removal holes (18) are the 1. Position fan motor (17) on fan guard (5) and install
threaded holes in the face ofthe hub bushing (11) .) capscrews, locknuts, and washers (15). Use the
15. Equally tighten capscrews (10), one half turn at a index marks placed on the fan motor (17) and fan
time, until the fan (14) is loose on hub bushing (11); guard (5) during removal to ensure proper orienta
remove the fan (14) from the hub bushing (11). tion of parts.
16. Loosen setscrew (16) and remove hub bushing
(11) and key (13) from shaft (12) of the fan motor
(17). CAUTION
17. Remove the capscrews, locknuts and washers Do not use anti-seize lubricant on the
(15) and remove fan motor (17) from fan guard (5). tapered cone surfaces of the hub bush ing.
Damage to fan hub and/or hub bushing may
Cleaning And Inspection occur. Mating surfaces need only be smooth
and clean.
A WARNING 2. Properly position hub bushing (11) and key (13) on

shaft (12). They should be flush with the end of the
Solvents and cleaning solutions can be shaft (12) . This will allow some space between the
hazardous. Serious personal injury may bottom of the hub bushing (11) and face of the fan
result from misuse of these products. Read motor (17).
and follow all the manufacturer's 3. Tighten the setscrew (16) to secure the position of
recommendations concerning solvents and the hub bushing (11) on the shaft (12) of the fan
cleaning solutions. motor (17).
4. Properly align the fan (14) on hub bushing (11) and
1. AII components should be thoroughly cleaned with insert the capscrews and lockwashers (10)
an approved cleaning solvent, air dried, and care through the fan (14) and into the threaded holes in
fully inspected. the hub bushing (11) . (Not into the removal holes
2. Check that the fan hub and both the interior and ex (18) on the fan (14) hub .)
terior surfaces of the hub bushing are clean and 5. Tighten the capscrews and lockwashers (10), fin
smooth . Remove any burrs or sharp edges with a ger tight.
fine file, hone , em ery cloth , or crocus cloth. 6. Evenly tighten the capscrews (10), one half turn at
3. AII Loctite' , Permatex" , or other sealant residue a time, to 108 in lb (12 .2Nm).
the mounting surfaces of parts that are going to be Note: When capscrews are fully tightened,
reused . Prior to applying new thread locking com there should be a gap of 1/8"-1/4" (3 - 6mm)
pounds or sealants, clean threads and surfaces between the back of the fan hub and the face 01
with Loctite ' 7070 Cleaner to ensure best perfor the hub bushing . See Detail "t\', Figure 1.
mance of products.
any major component. CAUTION
Cooling fins on the radiator assembly arevery
Installation delicate. Even a minor bump can cau se a
deformation of the fins which reduces the
A WARNING
efficiency of the radiator assembly. Be very
careful not to deform the radiator assembly
cooling fins during installation of the fa n.
7. Properly position fan guard (5) to radiator assem
bly (4) and install capscrews and washers (2).
8. Connect the hydraulic lines (9) to the fan motor
these products. (17) . Be sure to install the 0- rings (not shown)
within the four bolt flange connections.
30f 4
9. Secure any coolant lines (8) or air tubes (1) whiCh 15. Apply a soap solution to the connections around
were loosened or removed to allow removal 01 the the air tubes (1).
lan guard (5). Be sure the drain valve (7) is closed 16. Let the engine continue to idle. Inspect the air con
10. Install the alternator. See SM Keysheet Area nections lor leaks . Air leaks will lorm bubbles in the
01-063 or 01-077 lor complete procedure . soap solution where leaks are present. Repair
11 . Install the engine housing. See SM Keysheet area leaks as required .
01 -071 lor the complete procedure. 17. Complete the installation by testing all related lunc
12. Check the engine coolant leve!. Add coolant as re tions 01 the lan motor lor proper operation . Normal
quired. See the Operator's Manual lor correct pro operation 01 the engine and hydraulic systems
cedure. should be conlirmed . A general inspection 01 the
13. Check the hydraulic reservoir oillevel. Add oil as components and systems in the areas adjacent to
required . See the Operator's Manual lor correct the repair should also be perlormed to ensure re
type and procedure. lated damage or wear is not present.
14 . Start the engine and let idle lor five minutes . In
spect the hydraulic line and engine coolant con
nections lor leaks. Repair leaks as required .
4014
1. Shaft End Cover 5 Thrust Plate 9 . Back Up Seal 13 Nul 16. Gasket Seal
2. Journal Bushíngs 6. Orive Gear 10. Body 14. Journal Bushíngs 17. Shatt Seal
3. Back Up Seal 7. Thrust Plate 11 . Stud 15. Oríven Gear 18. Relaínlng Ríng
4. Channel Seal 8. Channel Seal 12. Washer
Nole: Actual parts may vary slíghtly from íllustration .
Figure 1
Typical 600 Series Pump/Motor Assembly (CCW Rotation Pump Shown)
Hydraulic Gear
Pump/Motor, Recondition
A WARNING
(Parker PGP/PGM600 Series) hazardous. Serious personal injury may
The lollowing procedure contains instructions lor the and follow all the manufacturer's
recondition 01 Model PGP/PGM600 hydraulic gear recommendations concerning solvents and
pump/motor. For removal and installation procedure cleaning solutions.
see SM Keysheet Area 01-010 and/or 01-081.
1. Cap/plug any openings in the hydraulic pump/mo
Disassembly toro Thoroughly clean the exterior surlace 01 the hy
It is a good practice when disassembling hydraulic draulic pump/motor to prevent contamination from
components to lay the parts out in the order that they entering il.
during disassembly, cleaning and inspection will aid in
1 014
Cleaning and Inspection
CAUTION
Do not grip on any of the pump/ motor's
machined surfaces. Excessive force while
clamping could result in misalignment and
.A WARNING
seríous damage to parts. Take extreme care
not to mar or damage any machined surface. hazardous. Serious personal injury may
Refer to Figure 1. and follow all the manufacturer's
2. Place the pump/motor in a vise with the shaft end recommendations concerning solvents and
cover (1) down. Close the vise on the outer edges cleaning solutions.
of the mounting flange of the shaft end cover (1).
3. Index mark all pump/ motor sections with a punch 1. Thoroughly clean all metal parts with an approved
for alignment purposes during assembly. cleaning solvent . Place parts on a clean lint free
4. Remove the nuts (13) and washers (12) from the surface and allow to air dry. Exercise every precau
studs (11). tion possible to keep all parts free of dust, dirt or
2, Stone off the mating surfaces between pump/mo
CAUTION tor sections with a medium grit carborundum
Integrity of machined surfaces is critica!. stone. Deburr bearing bores with a fine file.
3. AII Loctite'"' , Permatex(~; , or other sealant residue
Excessive force while prying could result in
misalignment or damage to parts. If prying off should be removed from threads of hardware and
pump/motor sections beco mes necessary, the mounting sUrfaces of parts that are going to be
take extreme care not to mar or damage reused. Clean off old gasket material from be
machi ned surfaces. tween pump/ motor sections. Prior to applying new
thread locking compounds or sealants , clean
5. Carefully separate the body (10) from the shaft end threads and surfaces with Loctite'" 7070 Cleaner to
cover (1). ensure best performance of products .
6. Rotate the shaft end cover (1) 90 o in the vise so the 4. Replace all "soft" parts whenever disassembling
shaft of the drive gear (6) is horizontal and the re the pump/motor. Include all channel seals, shaft
taining ring (18) is accessible. seal, and gasket sea/.
7. Remove the retaining ring (18) from the shaft end 5. Inspect al/ parts for damage, wear, and corrosion ;
cover (1) . replace as required. Use the following guidelines
8. Remove the drive gear (6) and driven gear (15) to inspect individual components and replace if:
from the shaft end cover (1) . a. The PTFE coated journal bushings in body and
9. Remove the thrust plate (5) from the shaft end cov shaft end cover are worn through revealing the
er (1) . Remove the channel seal (4) and back up bronze backing .
seal (3) from the thrust plate (5). b. Gear side faces are scored. Often operation
10. Remove the gasket seal (16) and thrust plate (7) with contaminated fluid results in a distinct
from the body (10) . Remove the channel seal (8) wear step coincident with the gear tooth root
and back up seal (9) from the thrust plate (7). diameter with corresponding wear on thrust
11 Place the shaft end cover (1) in a vise with the shaft plates.
seal (17) down. Tap the shaft seal (17) out of the C. There is a noticeable wear groove on the drive
shaft end cover (1) . gear shaft where the shaft seal lips run o
12. If required, remove the journal bushings (2,14) d. The bronze thrust plates are scored .
fr om the shaft end cover (1) and body (10) with a 6. It is not recommended that damaged gears/bod
bearing puller. ies, flanges, or thrust plates be replaced individual
Iy as this wil/ not affect a good repair.
7 . In the event of severe defects, contact factory per
2 of 4
2 Orient bushing so split is ±3° of
~~ the vertical
shown.
centerline
Bushing should be
as
3~ 1I Flat flush to 0.019 inch (O.5mm) be

~ Side low the face of the bore.
e.Y Down
Hole
:~IL
~
HP
Low Pressure Side
Groove In Thrust Plate

1. Thrusl Plale 3. Channel Seal
2. Back -UpSeal
Figure 2
Seal Installation
A WARNING
Lubricants, sealants, joint and thread locking Apply a continuous bead 01 Lo ctite
compounds, etc. can be hazardous. SeriOIlS 518, or equivalent, to the mating faces
personal injury may result from misuse of of the shaft end cover and body to the
these products. Read and follow all area outside the gasket seal .
Figure 3
these products.
Bushing Installation
Assembly Refer to Figure 2.

Unless stated otherwise, lubricate all seals, gaskets 5. Install the channel seals (3) and back-up seals (2)
and housing bores with clean hydraulic oil prior to in the thrust plates (1), as shown in Figure 2. Light
assembly. See Operator's Manual for correct type. Iy coat the seals with grease to help hold them in
Refer to Figure 1. place during assembly.
1. Coat the outer diameter of the shaft seal (17) and
its recess in the shaft end cover (1) with a thin coat
of Permate x (~ Aviation Form-A-Gasket · , or
CAUTION
Do not grip on any 01 the pump/motor's
equivalent.
machined sur1aces. Excessive force w hile
2. Place the shaft seal (17) , with the metal side out ,
clamping could result in misalignment and
into its recess in the shaft end cover (1) . Press it
serious damage to parts. Take extreme care
into place with an arbor press until it is flush with
not to mar or damage any machined surfa ce.
the face of the seal mounting bore.
3. Wipe any excess sealant out of the shaft end cover Refer to Figure 1.
(1). Install the retaining ring (18). 6. Place the body (10) in a vise with the journal bush
ings (14) facing up.
7. Install the thrust plate (7) in the body (10) with the
CAUTION channel seal (8) and back up seal (9) toward the
Do not hammer the journal bushings into the journal bushings (14) . Ensure that the seals re
bores. Uneven installation will damage the main in their groove and that the two small holes in
journal bushings. Use an arbor press or other the thrust plate (7) are to the low pressure side (in
suitable tool. let side) of the pump/motor, as shown in Figure 2.
4. If required, install the journal bushings (2,14) in the 8. Place the shaft end cover (1) in a vise with the shaft
shaft end cover (1) and body (10) with an arbor seal (17) down.
press. Note the orientation of the split in the journal 9. Apply Loctite '~¡ 242 to the threads of the studs (11)
bushings (2,14) , as shown in Figure 3. The journal and fully install them into the shaft end cover (1) .
bushings (2,14) should be flush to 0.019 inch
(O.5mm) below the face of the bore .
3 of 4
PGP!PGM Thread 17. Install the washers (12) and nuts (13) on the studs
Ft Lbs Nm (11). Tighten the nuts (13) alternately in a criss
Series Size
cross pattern until tight.
610 M10 41-45 55-61 18. Rotate the shaft of the drive gear (6) with a 6 in
620 M12 65-75 89-101 (15cm) wrench to be certain there is no binding in
the pump/motor.
640 M14 98-108 134-146 19. If no internal binding exists , torque the nuts (13) to
their final torque values as listed in Table A, using a
Table A - Final Torque Values
cross torquing procedure .
10. Install the thrust plate (5) in the shaft end cover (1) 20 . Once again, check for internal binding by repeat
with the channel seal (4) and back up seal (3) to ing Step 18.
ward the journal bushings (2) . Ensure that the 21. If hydraulic pump/ motor is not to be immediately
seals remain in their groove and that the two small installed on crane , plug all open ports to prevent
holes in the thrust plate (5) are to the low pressure contamination and properly store.
side (inlet side) of the pump/ motor, as shown in
Figure 2. Recommended Start-Up Procedure
11 . Grease the new gasket seal (16) and insert it into
the groove in the shaft end cover (1) .
For New or Rebuilt Pump/Motor
12. Mask the splines of the drive gear (6) to prevent Before installing a new or rebuilt pump/ motor, back off
damage to the shaft seal (17) during installation. the circuit relief valve until th e spring tension on the
adjusting screw is relieved. This will avoid the
possibility of immediate damage to the replacement
CAUTION unit in the event that the relief valve setting had been
Use care when installing the splines of the increased beyond the recommended operating
drive gear through the shaft seal. Damage to pressure, prior to removing the old unit. Refer to the
the s haft seal will result in sealleakage. Mask Operator's Manual for specific instruetions on relief
the splines or otherwise protect the shaft seal valve settings .
fro m d amage before installing the drive gear.
Before eonnecting any Iines to the pump/motor, fill all
ports with clean hydraulic oil to províde initial
13. Lightlygreasethe shaftofthedrivegear(6) . lnsert
lubrication. This is particularly important if the unit is
the drive gear (6) into the shaft end cover (1) and
loeated aboye the hydraulic reservoir. Refer to the
through the shaft seal (17) with a twisting motion .
Be careful not to damage the shaft seal (17) . Push Operator's Manual for the correct type of hydraulic oíl
down carefully until the drive gear (6) rests against to use .
the thrust plate (5). After connectíng the lines and mounting the
14. Install the driven gear (15) . Push down carefully replacement unit, operate the pump/motor for at least
until the driven gear (15) rests against the thrust two minutes at no load and at low speed (400 rpm
plate (5) . minimum) . During thís break-in period, the unit
15. Coat the drive gear (6) and driven gear (15) with should run free and not develop an excessive amount
clean hydraulic oil to provide initial lubrication of heat. If the unit operates properly, speed and
when the pump/ motor is started. Refer to the Op pressure can then be increased to normal operating
erator's Manual for the correet type . settings .
16. Install the body (10) over the drive gear (6) and
driven gear (15) and onto the shaft end cover (1). Reset the círcuit relief valve to its proper setting. Refer
Be sure the index marks placed on the pump/mo to the Operator's Manual for specific instructions on
tor during disassembly are aligned. Be careful not relief valve settings.
to damage the gasket seal (16).
4 of 4
b. Turn the ignition switch to " ON", but DO NOT
Hydraulic Pump, R & I START THE ENGINE. Move the function lock
(O.R./Pick & Carry Pump) out switch to the "OPERATE" position.
switch es back and forth several times .
the two or three section hydraulic pump used to supply
hydraulic oil to the engine cooling fan and the
6 . Check that all controllevers are in the neutral posi
outriggers. During pie k and carry operations, it will
tion and move the function lockout switch to th e
also supply oil to the boom hoist, telescope , and winch
"DISABLE" position .
functions of the crane. For recondition procedure, see
7 . Install a low pressure vacuum pump to , or drain,
SM Keysheet Area 01 -081 .
the hydraulic reservoir.
Removal Refer to Figure 1.
1. Lower, detach, and secure the load, as required. 8. Label for assembly purposes and disconnect the
2. Stabilize the crane for service as follows: hydraulic lines (12 ,16) from the hydraulic pump (2)
a. Park the crane, out of the way, on a firm and by removing the capscrews, split flanges , and 0
level surface . rings (3) . Cap/ plug the open hydraulic ports and
b. Engage the park brake and/or properly block lines (12 ,16) to prevent excessive oilloss and con
the tires. tamination of the system.
c. Engage the swing par k brake or travel swing 9. Disconnect the drive tube (1) from the yoke (6). Se
lock, as required. cure the drive tube (1) out of the way.
d. Level the eran e on fully extended outriggers. 10. Remove the setscrew (5) and capscrews and lock
e. Fully retract and position the boom, as re nuts (7), and slide the yoke (6) off the input shaft of
quired . the hydraulic pump (2).
3 . Shutdown the engine and disengage the main hy 11. Index mark the hydraulic pump (2) and mounting
draulic pump . bracket (8) to ensure correct alignment during
installation.
A WARNING
Solvents and cleaníng solutíons can be
12. Support the weight of the hydraulic pum p (2) , an cJ
remove the capscrews , washers , and lockn uts (").
13. Carefully slide the hydraulic pump (2) from the
hazardous. Serious personal injury may mounting bracket (8) and off of the crane.
result from mísuse of these products. Read 14. If required , remove the capscrews (15), washers
and follow all the manufacturer's (14) , rubber mounts (9 ,13) , and washers (10) that
recommendatíons concerníng solvents and secure the mounting bracket (8) to the arrier
cleaning solutions. frame (11).

A WARNING
A WARNING
Hydraulíc oíl ís under pressure and may be
hot. A sudden release of hot oil could cause and follow all the manufacturer's
burns or other seríous injury. Shutdown the recommendations concerning solvents and
engíne and exhaust aH trapped hydraulic cleaning solutions.
pressure from the system before removing 1. AII components should be thoroughly cleaned with
any líne or component. an approved cleaning solvent, air dried , and care
5. Relieve the hydraulic system pressure as follows: fully inspected.
reservOir, until pressure is fully relieved.
1 of 4
A
- ' - 1" ' ....
5 7 8 9 B
4
,
\
lO 15 14 13 12
1. Orive Tube 7. Capscrews & Locknuls 12. Hydraulic Lines*

2 Hydraulic Pump- 2 or 3 Seclions 8 Mounling Brackel 13. Rubber Mounls
3. Capscrews, Splil Flanges , & 0- rings 9. Rub ber Mounls 14. Washers
4. Capscrews, Washers, & Locknuls 10. Washers 15. Capscrews
5. Selscrew 11. Carrier Frame 16. Hydraulic Lines'
6. Yoke
* Exacl number 01 lines may vary
2 of 4
2. AII Loctite®, Permatex®, or other sealant residue 2. Align the hydraulic pump (2) to the mounting
should be removed from threads of hardware and bracket (8) and install capscrews, washers , and
the mounting surfaces of parts that are going to be locknuts (4) .
reused. Prior to applying new thread locking com 3. Applya light coat of Loctite® 242 to the threads of
pounds or sealants, clean threads and surfaces the setscrew (5) .
with Loctite® 7070 Cleaner to ensure best perfor 4 . Slide the yoke (6) on the input shaft of the hydraulic
mance of products . pump (2). Install the setscrew (5) and capscrews
3. Thoroughly inspect all parts for damage , wear, fa and locknuts (7) .
tigue or stress fractures , and corrosion. Repair or 5. Connect the drive tube (1) to the yoke (6). See SM
replace as required . Keysheet Area 01-022 for additional u - joint
4. AII "soft parts", such as seals, gaskets, back up installation procedures .
rings, and o-rings , should be replaced. 6. Applya light coat of Loctite® 242 to the threads of
5. Inspect the integrity of the hydraulic lines that are the capscrews (3).
connected to the hydraulic pump . Repair or re 7. Align the hydraulic lines (12 ,16) to the hydraulic
place if required. pump (2) , and install the 0 - rings , split flanges , an d
6. In the event of severe defects, contact factory per capscrews (3).
sonnel for directions whether to repair or replace 8. Remove the low pressure vacuum pump , or fill the
any major componen!. hydraulic reservoir, as required . See the Opera
tor's Manual for correct type of hydraulic oil and
Installation proper procedure for filling the reservoir.
9. Check the hydraulic reservoir 011 leve!. Add oil as
required . See the Operator's Manual for correct
A WARNING type and procedure .
10. Start the engine and let idle for five minutes. In
Lubricants, sealants, joint and thread locking spect the hydraulic connections for leaks . Repair
compounds, etc. can be hazardous. Serious leaks as required .
personal injury may result from misuse of 11 . Complete the installation by testing all related func
these products. Read and follow all tions of the hydraulic pump for proper operation .
manufacturer's recommendations concerning Normal operation of the hydraulic system should
these products. be confirmed. A general inspection of the compo
nents an d systems in the areas adjacent to the re
Refer to Figure 1. pair should also be performed to ensure related
1. If required, secure the mounting bracket (8) to the damage or wear is not present.
carrier frame (11) by installing the rubber mounts
(9 ,13) , washers (10), washers (14) , and capscrews
(15).
3 of 4
4 of 4
Service Manual 1006 SM03-001 -075. 00
Upper Revolving Frame & Weight
Component
Turntable Bearing, R & I lb kg
Upper Assembly 13,800 6260
The upper rotates over the carrier by means of a
turntable bearing. The outer rae e of the turntable Cab Assembly 750 340
bearing is bolted to the carrier frame, while the inner
Turntable Bearing 1,036 470
race is bolted to the upper frame . The outer rae e
contains external gear teeth which mesh with the Winches (Each) 2,543 1 154
speed reducer pinion to swing the upper. The crane
must be undecked in order to fully inspect and/or Wire Rope - 730 ft (223m) 950 43 1
replace the turntable bearing.
Full Counterweight 14,400 6 532
This procedure covers the following:
Table 1
Procedure Page Approximate Component Weights
Upper Revolving Frame Removal 1
Turntable Bearing Removal 5
Turntable Bearing Installation 6
Upper Revolving Frame Installation 7 A WARNING
Upper Revolving Frame Removal hazardous. Serious personal injury may
1. Lower, detach, and secure load, as required . result from misuse of these products. Read
2. If equipped, remove the fly attachment Irom the and follow all the manufacture r' s
crane. Reler to the Operator's Manual lor recommendations concerning solvents and
co mplete instructions . cleaning solutions.
3. II equipped, remove all counterweight from the
crane. Reler to the Operator 's Manual lor the 8. Tho ro ughly clean the area to be disassembled with
co rrect procedure. an approved cleaning solvent to prevent
4. Remove the boom assembly. Reler to SM contamination from entering the hydraulic oil
Keysheet Area 17-001 for the correct proced ure. circuits. Allow the area to air dry.
5. Remove the boom hoist cylinder assembly. Reler
to SM Keysheet Area 17 - 003 for the correct
6.
procedure .
Stabilize the crane lor service as lollows :
A WARNING
a. Park the crane out 01 the way on a lirm and level
hot. A sudden release of hot oil could ca use
surlace.
engine and exhaust all trapped hydra ulic
the tires.
pressure from the system before remov ing
c. Rotate the upper Irame directly over the front of
the carrier frame.
d. Engage the swing park brake and travel swing
lock, as required.
e. Level the crane on fully extended outriggers.
reservoir by loosening the liller cap 1/4 turn.
hydraulic pump , as equipped.
START THE ENGINE. Move the lunction lock
switches back and lorth several times.
1 of 8
SM 03-001 -075.00 1006 Service Manual
A
5 2
JCI I (1 1)
-~
'\
1. Turntable Bearíng 3. Upper Frame 5. Capscrews & Washers

2. Capscrews & Washers 4. Swíng Reductíon Unít 6. Carríer Frame
Figure 1
Upper Revolving Frame And Turntable Bearing
2 of 8
- i -1
Ji;
9 -0:::::::::::--__
10
3
2
6-
9 10 e
Gear Teeth
Fully Engaged
0.018-0.036 In
(0.45-0.91mm)
0
For Full 360 Rotation
4 3
7. Pinion 9. Grease Lines

8. Swing Park Brake Inlel Port 10. Grease Fitting
3 of 8
5' 6" (1.7m)
Distance From Center
. 01 Rotation I
Center Of 'c- , Center Of
Rotation ~ ( Gravity
Fig ure 2
Upper Center Of Gravity
6
position and move the function lockout switch lO
the "DISABLE " position .
A WARNING
The auxiliary lifting device and rigging used
must be of sufficient capacity to support the
entire weight of the upper. Failure to observe
this warning may result in equipment damage
and /or severe personal injury. Use only a
lifting device of proven capacity when
handling the upper. 1. Rotating Joint 4. Center Harness
2. Capscrew, Sp acer, & Locknut 5. Hydraulic Li nes
3 Supp ort Bar 6. Mounting Bra cket
11 . Using an au xiliary litting device of sufficient
capacity, rig the upper for removal. Make sure the Figure 3
rigging is positioned to keep a balanced load Typical Rotating Joint
throughout removal. Remove any slack in the
rigging. Refer to Table 1 far approximate 13. Using an auxiliary hydraulic supply, apply hydrau
component weights and Figure 2 to locate the lic pressure to the swing reduction unit (4) swing
approximate center 01 gravity of the upper. park brake inlet part (8) to manually release the
Reler Figure 1. swing park brake.
12 . Punch mark the heads of Ihe capscrews (2) that 14. Rotate the upper frame (3) until the next capscrews
are fully visible and not obstructed by the upper (2) that were not marked in the previous step are
frame (3) . These will be the last capscrews (2) to accessible . Engage the swing park brake.
be removed. 15. Using a tarque multiplier and/ ar breaker bar, re
move the unmarked capscrews and washers (2).
A DANGER
Pinch points exist between the upper frame
16. Re peat Steps 13 thru 15 until all unmarked cap
screws and washers (2) are removed.
and carrier frame. Death or dismemberment

may result from personnel caught in these
points. Learn where these pinch points are
located and stay clear of the rotating upper
frame.
4 of 8
-"
~.- il
\.
I
I
L .. ~
, I ~' I
7 ft o in
(2. 13m)
4ft
(1 .22m)
1. Upper
2. Supports 2 3 2
3. Rotatlng Joint
Figure 4
Support Dimensions
Refer to Figure 1.
A WARNING
21. Remove the remaining capscrews and washers
(2) . Retain two of these capscrews (2) to be Llsed
later d uring ínslallation .
Refer to Figure 4.
ignited by a spark or flame causing the battery 22. Slowly and carefully lift the upper (1). Set the upper
to explode. Keep the area around the battery (1) on firm, sturdy supporls (2) . Do not allow the
well ventilated and disconnect the negative rotating joint (3) to contact the ground or supports
side of the battery first, with the ignition switch (2) .
Turntable Bearing Removal
A WARNING
17. Check that the ignition switch is in the "OFF" The upper frame must be safely supported
position. Turn the battery disconnect switch "OFF" befo re working near or under it. Failure to
or disconnect the negative cable(s) first , then properly support the upper frame may result
positive, from batteries . in it falling, causing severe personal injury
Refer to Figure 3. and /or equipment damage.
18. Label for assembly purposes and disconnect all
hydraulic lines (5) from the bottom of the rotating Refer to Figure 4.
joint (1). Cap/plug the open hydraulic ports and 1 . Carefully inspect the upper (1) lo ensure Ihat il is
lines (5) to prevent excessive oil loss and properly supporled.
contamínation of the system . Refer lo Figure 1.
19. Label for assembly purposes and disconnect all 2. Supporl Ihe lurnlable bearing (1) by some means
conneclions on the lower end ofthe center harness capable of handling il safely once Ihe capscrews
(4) .
and washers (5) are removed .
20. Remove the capscrew, spacer, and locknut (2)
attaching the support bar (3) to the mounting
bracket (6) . Secure the support bar (3) out of the
way.
5 of 8
SM03-001 -075.00 1006 Service Manual
2 3 4
5.0 in
(12.7cm)
1. Mounting Surface 2. Tapped Holes 3. Guide Pins 4. Carrier Frame
Figure 5
Guide Pin Installation
Note: It may be necessary to remove some of 1. Loeate the "S" or "G" stamped on the top surfaee of
the capscrews holding the turntable bearing to the outer bearing raee . This letter is used to identify
the upperframe in orderto properly positionthe the "hardness gap". Mark the turntable bearing in
supporting device. sueh a manner that the gear tooth adjaeent to the
3. Oisconnect the grease lines (9) from the grease stamped letter can be readily identified from any
fittings (10) on the inside diameter of the turntable angle. (Spray paint works well.)
bearing (1) . Refer to Figure 1.
4. Once the turntable bearing (1) is properly 2. If a new turntable bearing (1) is being installed ,
supported , remove the capscrews and washers remove the greasefittings (10) from the old bearing
(5) securing it to the upper frame (3). and install them in the new one. Be sure the grease
fittings (10) are aligned eorrectly.
Note: Use care not to damage the turntable
bearing or pinion teeth .
5. Carefully lower the turntable bearing (1) and

remove it from under the upper frame (3).
A WARNING
Turntable Bearing Installation result from misuse of these products. Read
A WARNING
3.
cleaning solutions.
Thoroughly elean the tapped holes in the upper

The upper frame must be safely supported
frame (3) to prepare them for the eapserews and
before working near or under it. Failure to
washers (5) whieh are to be installed using a
properly support the upper frame may result
sealant. Also clean the mounting surfaee . Allow to
in it falling, causing severe personal injury
air dry.
and/or equipment damage.
6 of 8
Service Manual 1006 SM03-001 -075 .00
Note: Use care not to damage the turntable 2. Remove the heads from the two capscrews wh ich
bearing or pinion teeth. were saved during removal. These two headless
capscrews will be used as guide pins (3) to align
4. Carefully position the turntable bearing (1) to the the upper frame (3,Figure 1) to the carrier frame
upper frame (3) and align the mounting holes . (4) .
Properly align tlle pinion (7) with the gear teeth of 3.
0
Install the guide pins (3), 180 apart, in the
the turntable bearing (1) . mounting surface (1) of the carrier frame (4). Install
them so the tops of the guide pins (3) remain
Note: Due to the enormous torque put on these
approximately 5.0 in (72. 7cm) above the mounti ng
critical capscrews (5), their structural integrity
surface (1) of the carrier frame (4).
is lost after they are removed. Use only new
capscrews (5), do not use the old ones. Tighten
the capscrews (5) until snug.
5. Apply Loctite® 571 pipe sealant to tlle capscrews

A WARNING
The auxiliary 1i1ting device and rigging must
(5) , and install the capscrews and washers (5) . be 01 su11icient capacity to support the entire
6. Before torquing the caps crews (5), clleck the weight 01 the upper. Failure to observe this
engagement of the pinion (7) with the turntable warning may result in equipment damage
bearing (1). The backlash between the two gears and/or severe personal injury. Use only a
should be 0.018-0.036 in (0.45-0.97mm) as lifting device 01 proven capacity when
shown in View D, Figure 1. If required , adjust the handling the upper 1rame.
turntable bearing (1) to obtain the proper backlash
0
for the full 360 rotation of the gears. 4. Using an auxiliary lifting device of sufficient
7. Once the proper backlash is obtained , torque capacity, rig the upper for installation . Make sure
the capscrews (5) to 2,120 - 2,335 ft lb (2968 the rigging is positioned to keep a balanced load
3 269Nm). throughout assembly. Remove any slack in the
8. Rotate the outer race of the turntable bearing (1) to rigging . Refer to Table 1 for approximate
position the gear tooth marked in Step 1 directly to component weights and Figure 2 to locate the
the front of the carrier frame (6) . approximate center of gravity of the upper.
9 . Connect the grease lines (9) to the grease fit1ings
5. Slowly and carefully position the upper so that the
(10) on the inside diameter ofthe turntable bearing upper cab is facing directly over the front of the
(1) . Check the orientation of the grease fittings (10) carrier frame .
for easy access.
Note: Use care not to damage the turntable
bearing or pinion teeth.
Upper Revolving Frame Installation
6. Align the travel swing lock pin with the carrier boss
and the guide pins (3) to the nearest holes in ttle
A WARNING
turntable bearing. Carefully lower the upper onto
the carrier frame (4).

result 1rom misuse 01 these products. Read
and 101l0w all the manu1acturer's
A WARNING
Do not put your 1ingers into the tapped holes.
cleaning solutions. Rotation 01 the upper 1rame could sever the m.
Use one 01 the mounting capscrews rather
than your 1inger to align the holes.
Refer to Figure 5.
1. Thoroughly clean the tapped holes (2) in the Refer to Figure 1.
mounting surface (1) of the carrier frame (4) to 7. Align the mounting holes in the upper frame (3)
prepare them for the capscrews (2 ,Figure 1) whic h with the tapped holes in the mounting surface of
are to be installed using a sealant. Also clean the the carrier frame (6). Engage the travel swing lock.
mounting surface (1). Allow to air dry.
7 of 8
SM 0 3-00~ -075.00 1006 Service Manual
Note: Due to the torque put on these critical 13 . Turn the battery disconnect switch to the "ON "
capscrews (2), their structural integrity is lost position or connect the negative cable(s), then
once they are removed. Use only new positive, to the batteries .
capscrews (2), do not use the old ones. Tighten Refer to Figure 1.
the ca pscrews (2) until snug. 14. Manually rota te the upper frame (3), as required,
and install the remaining capscrews and washers
8. Apply Loctite® 571 pipe sealant to the capscrews (2) as described in Steps 8 thru 10.
(2) .
9. Install the capscrews and washers (2) in all the Note: As soon as all the capscrews and washers (2)
holes that are accessible. are installed and the swing function is operational,
Note: Remove the guide pins and replace them thoroughly lubricate the turntable bearing. Rotate
with new capscrews as soon as they are the upper in 10· increments and pump grease into
accessible. the turntable bearing until grease can be seen
venting at the seals. Lubricate through two
10. Without rotating the upper frame (3), install as complete revolutions of the upper. Also coat all of
many of the capscrews and washers (2) as the exterior gear teeth of the turntable bearing with
possible. Torque all the capscrews (2) to grease. Refer to the Operator's Manual for correct
2 ,120-2 ,335 ft lb (2968-3 269Nm) . type of grease.
A DANGER
Pinch points exist between the upper frame
15. Install the boom hoist cylinder. Refer to SM
Keysheet Area 17-003 for the correct procedure .
16. Install the boom assembly. Refer to SM Keysheet
and ca rrier frame. Death or dismemberment
17. Check the hydraulic reservoir oil leve!. Add oil as
may result from personnel caught in these
required. See the Operator's Manual for correct
points . Learn where these pinch points are
type and procedure.
located and stay clear of the rotating upper 18. Start the engine and let id le for five minutes.
1rame.
Inspect the hydraulic connections far leaks .
Repair leaks as required .
Refer to Figure 3 . 19. Bleed any trapped air from both the par k brake and
11 . Manually rotate the upper, as required , to align the service brake systems using the respective
support bar (3) with the mounting bracket (6) on bleeders.
the bottom of the rotating joint (1). Install the 20 . Complete the installation by testing all related
capscrew, spacer, and locknut (2). functions of the turntable bearing and upper
12 . Connect the hydraulic lines (5) and all center revolving frame for proper operation . Normal
harness (4) connections . operation of the hydraulic and electrical systems
should be confirmed. A general inspection of the
A WARNING
the repair should also be perfarmed to ensure
21. Install the counterweight(s) and fly attachment, as
termi nals while connecting the battery.
required. Refer to the Operator 's Manual for the
ignited by a spark or flame causing the battery correct procedures .
well ventilated and connect the positive side
of the battery first, with the ignition switch
" OFF" , to minimize hazard.
resi due on hands may cause lead poisoning.
8 of 8
Service Manual 0807 SM03-01 0-025.00
Piston
Locknut ~ (( n n Gland
U
~E=»
~
"-
~ j--
~
,-
Serial Number
~
Location
~ x><><x><xx
-
Retracted Length
Cylinder Piston
Gland Breakaway Cylinder Retracted
Serial Locknut Test Pressure
Torque Pressure Stroke Length
Number Torque
SIN Prelix ft lb Nm ft lb Nm psi kPa psi kPa in cm in cm
06J0265 500 678 400 542 2,250 15514 120 827 19,0 48,3 30,12 76,5
07J0357 500 678 400 542 2,250 15514 120 827 20,0 50,8 30,12 76,5
J7J0358 500 678 400 542 4,500 31028 120 827 22,3 56,5 31,50 80,0
J8J0033 1,800 24400 400 542 4,500 31028 30 206 11,5 29,2 26,75 67,9
N4JOO05 500 678 400 542 4,500 31028 30 206 16,3 41,4 24 ,15 61,3
R3J0096 600 813 400 542 4,500 31028 30 206 22,3 56,5 31 .50 80,0
Table A
Cylinder Identifications
Counterweight Removal Cylinder Oil Volume Wet Weight

Serial Number
Cylinder, Recondition Prefix quarts liters lb kg
06J0265 3,36 3,18 59 ,1 26,8

This procedure covers the recondition 01 the
counterweight removal cylinder, Far removal and 07J0357 3,36 3.18 59.1 26,8
installation procedures , see SM Keysheet Area
J7J0358 3,72 3.52 60,6 27,5
03 - 010, Use an appropriate lifting device to handle
the cylinder during this procedure , as required. Reler J8J0033 4,00 3.79 107,0 48,6
to Table B lor approximate weights 01 cylinders and
N4JOO05 2.72 2,57 49.4 22.4
oil volumes,
R3J0096 4.84 4,58 75.8 34.4
II parts are hard to disassemble and assemble, do not
use a Ilammer unless it has a soft lace, do not lorce Table B
parts together, they must be free to operate and not Cylinder Weights & Oil Volumes
Disassembly
components to lay the parts out in the arder that they
are disassembled, Keeping the parts in this arder
the assembly process,
1 014
6 7 8 9
o
13 12 11 10
1. Cylinder Case 5. Pistan 9. Gland 13. Step Seal

2. Wear Ring 6. O-ring & Back Up Ring 10. Rad 14.0-ring
3. Pistan Seal 7. Wear Ring 11 . Rad Wip er 15. Square Ring
4. Wear Ring 8. Spanner Hale 12. Rad Seal 16. Lacknut*
• Lacknut may be reces sed in pistan
Figure 1
Counterweight Removal Cylinder
1. Drain any excess hydraulic oil , remaining within

the cylinder, into an appropriate container. Proper
Iy store or dispose of the used oil.
CAUTION
The rod surface must be protected during
disassembly procedures to avoid scratches.
A WARNING
A nylon or canvas webbed belt wrapped
around the rod will protectthe chrome surface
from damage when clamped in a vise.
hazardous. Serious personal injury may Damage/scratches to the rod surface will
resu lt from misuse of these products. Read require rod replacement.
recom mendations concerning solvents and 5. Remove locknut (16) from rod (10) .
cleaning solutions. 6. Remove piston (5) from rod (10).
7. Remove and discard o-ring (14) from rod (10).
2. Cap/plug any openings in the cylinder. Thoroughly 8. Remove and discard wear rings (2,4), square ring
clean the exterior su rface to prevent contamination (15). and piston seal (3) from piston (5).
from entering it. 9 . Remove g land (9) from rod (11) .
Refer to Figure 1. 10. Remove and discard rod wiper (11), rod seal (12),
3. En gage a spanner wrenCh , in the spanner hole (8), step seal (13), wear ring (7) and 0- ring and back
rotate the gland (9) counterclockwise until the up ring (6) from gland (9).
gland (9) and the rod (10) assembly can be re
moved from the cylinder case (1).
4. Remove rod (10) assembly from cylinder case (1) .
2 of 4
Cleaning And Inspection date installation . Temperatures must be above 70 °
F and adequate oil applied to the piston suriaces to
ease assembly.
A WARNING
3. Once the piston seal has been installed onto the
piston, a ring compressor should be clamped over
the outer diameter of the piston and left on the pis
ton until just prior to sliding the piston into the case.
Assembly
cleaning solutions.

A WARNING
clean ing solvent. Place parts on a clean , lint free compounds, etc. can be hazardous. Serious
surface and allow to air dry. Exercise every precau personal injury may result from misuse of
tion possible to keep all parts free of dust, dirt, or these products. Read and follow all
any other foreign material during assembly. manufacturer's recommendations concerning
2. AII Loctite' , Permatex ' , or other sealant residue these products.
reused. Prior to applying new thread locking com Lubricate all seals, o - rings , back up rings , wear ~n g s ,
threads and cylinder case bore with Cosmolube No.
pounds or ~ ealants, clean threads and suriaces
with Loctite 'RI 7070 Cleaner to ensure best perfor 2, or equivalent, prior to assembly.
mance of products .
wear, corrosion , deep scratches, and scuffed met CAUTION
Threaded surfaces are sharp. Seals and
file , hone, emery cloth , or crocus cloth . Use the fol
0- rings can be damaged as they are insta lled
lowing guidelines to inspect individual compo
over or through threaded areas, causing the
nents :
assembly to leak. Mask the threads or
a. Case bore for scratches, scored surfaces and
otherwise protect seals during installation.
damaged threads.
b. Rod surface far dents, deep scratches and 1. Install wear ring (7), step seal (13) , rod seal (12)
damaged threads. and rod wiper (11) into gland (9) .
C. Piston diameter for broken lands.
2. Install new 0- ring and back up ring (6) onto gland
d . Gland for damaged threads and broken lands (9) .
on inner and outer diameters . 3 . Install gland (9) onto rod (10) . Use care not to dam
4. Replace any damaged component as required . age seals and o-ring o
5. Replace all seals , wear rings , o-rings , and back
4 . Install square ring (15) , piston seal (3) , o-ring (14) ,
up rings .
and wear rings (2,4) onto piston (5).
6 . In the event of severe defects , contact factory per
5. Install pisto n (5) assembly onto rod (10).
sonnel for directions whether to repair ar replace
Preparation For Assembly CAUTION

1. Soak the new wear rings, piston seal, step seal, rod Use care not to damage the chrome fini sh on
seal and wiper in clean hydraulic oil which has the piston rod. Any nicks or scratches could
been heated to a temperature of 100-120° F result in cylinder leakage. Weld splatter may
(39-49 ° C). Allow adequate time for the parts to also do damage. When using a vise, cla mp to
absorb the heat and hydraulic oil which will greatly portions on the rod which are not chrome
ease their assembly. Refer to the Operator's plated, or protect the chrome surface w ith a
Manual for the correct grade of hydraulic oil to use . soft material before clamping .
2. Teflon® piston seals must be stretched slightly
prior to assembly, but only enough to accommo
3 of 4
SM03-010-025.00 0807 Service IM anual
6. Installlocknut (16) onto rod (10) securing piston in 4. Fully retract the cylinder.
place on rod (10). 5. Gradually in crease the pressure, approximately
7. Torque locknut (16). Refer to Table A for correct 100 psi/min (6S9kPa/min) , on the extend side ofthe
torque value. cylinder until movement of the rod is initiated. The
8. Carefully slide rod (10), pisto n (5) , and gland (9), as pressure required to initiate movement of the
an assembly, into cylinder case (1) until gland (9) is cylinder rod, termed "breakaway pressure" ,
properly seated. should not exceed that listed in Table A. If so,
9. Using a spanner wrench, engage wrench in span disassemble the cylinder and replace the defective
ner hole (8), rotate the gland (9) clockwise until part. Repeat the entire test procedure, as required .
tig ht. 6. Once the breakaway pressure is determined, the
10. :orque gland (9). Refer to Table A for correct pressure needed to maintain movement of the
tarque value. cylinder rod, termed "running pressure", should
11. Properly test the cylinder per the infarmation found not exceed 80% of the breakaway pressure ar
later in this procedure. diminish to less than 20% of the breakaway
12. If the cylinder is notto be immediately installed on pressure, as the cylinder is extended. If the
crane, plug all open parts to prevent contamination running pressure exceeds these guidelines,
and properly store. disassemble the cylinder and replace the defective
parts. Repeat the entire test procedure , as
Cylinder Test Procedures required.
Reconditioned cylinders must be tested far proper High Pressure Leakage Test
operation to ensure their integrity in the field. Use only 1. Extend the cylinder to full stroke and pressurize to
clean, uncontaminated hydraulic oil with a viscosity of the "test pressure" specified in Table A. Hold this
200 ± 100 SUS . Refer to the Operatar's Manual for the pressure far a minimum of one minute. Leakage
co rr ect grade of oil to use. across the pistan should not exceed 0.33 cc/min .
2. Relieve the pressure and examine the cylinder far
Low Pressure Externa I Leakage & Static Friction external leakage. No leakage is acceptable. If
Test leakage exists, disassemble the cylinder and
1. Fill the fully retracted cylinder with hydraulic oil. replace the defective parts. Repeat the entire test
2. Using only the pressure rever which is required to procedure, as required.
move the cylinder rod at a steady rate, cycle the 3. Fully retract the rod and pressurize to the "test
cylinder full stroke, each direction, a minimum of pressure" specified in Table A. Hold this pressure
five times to remove entrapped airo If the cylinder for a minimum of one minute. Leakage across the
squeaks or sticks, disassemble the cylinder and pistan should not exceed 0.33 cc/min .
re place the defective part and repeat the entire test 4. Again, relieve the pressure and examine the
procedure. cylinder far external leakage. No leakage is
3 . With the cylinder at mid stroke, relieve the pressure acceptable. If leakage exists, disassemble the
and examine the cylinder for any externalleakage. cylinder and replace the defective parts . Repeat
No leakage is acceptable. If leakage exists, the entire test procedure, as required.
disassemble the cylinder and replace the defective 5. If cylinder is not to be installed on crane
parts. Repeat the entire test procedure, as immediately, plug all ports to prevent
required. contamination and properly store.
4 of 4
Counterweight Removal START THE ENGINE. Move the function lock
Control Valve, R & I out switch to the "OPERATE " position.
the counterweight removal control valve. For d . Turn ignition switch to the "OFF" position.
recondition procedure, see SM Keysheet Area 7. Check that all controllevers are in the neutral pos i
07-008. tion and move the function lockout switch to the
"DISABLE" position.
Removal 8. Label for assembly purposes and disconnect the
1. Lower, detach, and secure the load, as required. hydraulic lines (7) and hoses (11) from the control
2. Check that any counterwe ight slabs (1), which are valve (8) . Cap/plug the open hydraulic ports , lines
installed on the upper frame (4), are properly se (7), and hoses (11) to prevent excessive oil loss
cured with connecting pins. See the Operator's and contamination of the system.
Manual for complete installation instructions . 9. Remove the capscrew and locknut (9) that secure
3. Stabilize the crane for service as follows: the control rod (10) to the control valve (8).
a. Park the crane, out of the way, on a firm and 10. Support the mounting plate (2) , control valve (8),
level surface. and grab handle (5).
b. Engage the park brak e and/or properly block 11. Remove the capscrews and washers (3) that se
the tires. cure the mounting plate (2) and grab handle (5) to
c . Engage the swing park brake or travel swing the upper frame (4).
lock , as required. 12. Carefully remove the mounting plate (2) , with the
d Level the crane on fully extended outriggers . control valve (8) atlached , and the grab hand le (5)
e . Fully retract and position the boom, as re from the crane.
quired. 13. Separate the control valve (8) from the mounting
4. Shutdown the engine and d isengage the main hy plate (2) by removing the capscrews , washers ,
draul ic pump. and lock nuts (6) .

A WARNING
A WARNING
and foHow aH the manufacturer's hazardous. Serious personal injury may
cleaning solutions. and follow aH the manufacturer's
cleaning solutions.
A WARNING
2.
fully inspected .
hot. A sudden release of hot oil could cause the mounting surfaces of parts that are going to be
burns or other serious injury. Shutdown the reused . Prior to applying new thread locking com
engine and exhaust all trapped hydraulic pounds or sealants, clean threads and surfaces
pressure from the system befo re removing with Loctite® 7070 Cleaner to ensure best perfor
any line or component. mance of products .
3. Thoroughly inspect all parts for damage , wear, fa
6 . Relieve the hydraulic system pressure as follows :
tigue or stress fractures, and cor rosion. Repair or
replace as required .
reservoir by loosening the filler cap 1/4 turn.
1 of 4
A
2 3 4 5
11 ~---6
10
8 7
Counterweight Slabs* 5. Grab Handle 9. Capscrew & Locknul

2. Mounling Plale 6. Capscrews, Washers, & Locknuts 10. Control Rod
3 Capscrews & Washers 7. Hydraulic Lines 11 . Hydraulic Hoses
4. Upper Frame 8. Control Valve
* Number 01 counlerweighl slabs vary based on crane model.
Figure 1
Counterweight Removal System
2014
4. AII "soft parts", such as seals, gas kets, back up 3. Align the mounting plate (2) , with the control valve
rings , and o-rings, should be replaced . (8) attached , and grab handle (5) to the upper
5. Inspect the integrity 01 the hydraulic lines that are Irame (4) .
connected to the counterweight removal control 4. Secure the mounting plate (2) and grab handle (5)
valve . Repair or replace il required . to the upper Irame (4) by install the capscrews and
6. In the event 01 severe delects, contact lactory per washers (3).
sonnel lor directions whether to repair or replace 5. Align the control rod (10) to the control valve (8) ,
any major componen!. and install the capscrew and locknut (9) .
6. Connect the hydraulic lines (7) and hoses (11) to
I nstallation the control valve (8).
A WARNING
type and procedure.
8. Start the engine and let idle lor live minutes. In
spect the hydraulic connections lor leaks. Repair
compounds, etc. can be hazardous . Serious leaks as required.
personal injury may result from mis use of 9. Actu ate the control valve several times to bleed any
these products. Read and follow all air trapped Irom the circuit.
manufacturer's recommendations concerning 10. Complete the installation by testing all related lunc
these products . tions 01 the counterweight removal control valve lor
proper operation . Normal operation 01 the hydrau
Reler to Figure 1 . lic system should be conlirmed . A general inspec
1. Secure the control valve (8) to the mounting plate tion 01 the components and systems in the areas
(2) by installing the capscrews , washers , and lock adjacent to the repair should also be perlormed to
nuts (6) . ensure related damage or wear is not presen!.
2. Applya light coating 01 Loctite® 242 to the threads
01 the capscrews (3).
3014
4 of 4
Service Manual 1006 SM03-0'10-047.00
\
\
-
.. I
._ .. ~._ =.' l~lr ' ~. / \

lf~ c~.J I
~· '~ r~ _::;._r
4 3 ~J
1. Counterweight Removal Cylinder 3. Capscrews & Washers
2. Upper Frame 4. Hydraulic Unes
Figure 1
Counterweight Removal Cylinder
Counterweight Removal Removal

Cylinder, R & I 2. Stabilize the crane lar service as lollows:
a. Park the crane , out 01 the way, on a lirm and
level surlace.
the counterweight removal cylinder. Although there
are two separate counterweight removal cylinders,
the tires.
removal and installation is similar lor each . For
c. Engage the swing park brake ar travel swing
recondition procedure, see SM Keysheet Area
lock, as required.
03-010.
1 014
d. Level the crane on fully extended outriggers. 8. Check that all controllevers are in the neutral posi
e. Fully retract and position the boom, as re tion and move the function lockout switch to the
quired. "DISABLE" position.
Refer to Figure 1.
A DANGER
When operating the crane with reduced
hydraulic lines (4) from the counterweight removal
cylinder (1). Cap/plug the open hydraulic ports
counlerweight, working ranges and lifting and lines (4) to prevent excessive oilloss and con
capacities are altered. Always refer to the tamination of the system.
Crane Rating Manual to ensure working range
Note: The counterweight removal cylinder
and Iifting capacities are not exceeded.
weighs approximately 55 lb (25kg).
3. Remove all counterweight. See the Operator's 10. Using an appropriate lifting device, support the
Man ual for the correct procedure. counterweight removal cylinder (1).
Refer to Figure 1. 11. Remove the capscrews and washers (3) securing
4. Fully retract the counterweight removal cylinders the counterweight removal cylinder (1) to the up
(1) . per frame (2).
5. Shutdown the engine and disengage the main hy 12. Remove the counterweight removal cylinder (1)
draulic pump, as equipped. from the crane.

A WARNING
haza rdous. Serious personal injury may A WARNING
result from misuse of these products. Read Solvents and cleaning solutions can be
and follow all the manufacturer's hazardous. Serious personal injury may
recom mendations concerning solvents and result from misuse of these products. Read
cleaning solutions. and follow all the manufacturer's
6. Thoroughly clean the area to be disassembled with cleaning solutions.
mination. Allow the area to air dry. 1. AII components should be thoroughly cleaned with
an approved cleaning sOlvent, air dried, and care
fully inspected.
A WARNING 2. AII Loctite®, Permatex®, or other sealant residue
should be removed from threads of hardware ancl
Hydraulic oil is under pressure and may be the mounting surfaces of parts that are going to be
hot. A sudden release of hot oil could cause reused. Prior to applying new thread locking com
burns or other serious injury. Shutdown the pounds or sealants, clean threads and surfaces
engine and exhaust all trapped hydraulic with Loctite® 7070 Cleaner to ensure best perfor
pressure from the system before removing mance of products.
any line or component. 3. Thoroughly inspect all parts for damage, wear, fa
7. Relieve the hydraulic system pressure as follows: replace as required.
a. Release any residual pressure in the hydraulic 4. AII "soft parts", such as seals, gaskets, back up
reservoir by slowly loosening the filler/breather rings, and o-rings, should be replaced.
cap, located on the top of the hydraulic 5. Inspect the integrity of the hydraulic lines that are
reservoir, until pressure is fully relieved. connected to the counterweight removal cylinder.
b. Turn the ignition switch to "ON", but DO NOT Repair or replace if required.
STARTTHE ENGINE. Movethe function lock 6. In the event of severe defects, contact factory per
out switch to the "OPERATE" position. sonnel for directions whether to repair or replace
c. Work the crane control levers and outrigger any major component.
d. Turn the ignition switch to the "OFF" position.
2 of 4
Installation 5. Check the hydraulic reservoir oillevel. Add oil as
required. See the Operator's Manual lor the
A WARNING
6. Check for correct fluid levels in any related
components such as pump drives, gear reduction
units , engine crankcase , radiator, etc . Refer to the
compounds, etc. can be hazardous. Serious crane or engine Operator's Manual for corre ct
personal injury may result from misuse of type/quantity of fluids and proper procedure .
these products. Read and follow all 7. Engage the main hydraulic pump , as equipped .
manufacturer's recommendations concerning 8. Start the engine and let idle for five minutes.
these products. Inspect the hydraulic connections for leaks.
9. Fully extend and retract the counterweight removal
Note: The counterweight removal cylinder cylinder (1) several t!mes to bleed any trapped air
weighs approximately 55 lb (25kg). from the circuit.
10. Install the counterweight, as required. See the
Refer to Figure 1. Operator's Manual for the correct procedure .
1. Using an appropriate lifting device , position the 11. Complete the installation by testing all functions of
counterweight removal cylinder (1) to the upper the counterweight removal system for proper
frame (2). operation . Normal operation of the hydraulic
2. Applya light coating of Loctite® 242 to the threads system should be confirmed . A general inspection
of the capscrews (3). of the components and systems in the areas
3. Secure the counterweight removal cylinder (1) to adjacent to the repair should also be perform ed to
the upper frame (2) by installing the capscrews ensure related damage or wear is not present.
and washers (3).
4. Connect the hydraulic lines (4) to the counter
weight removal cylinder (1).
3014
4 of 4
.a:n .a:n
Identification Code Stamped On Cover
EXPLANATION OF MODEL NUMSER

SO 66 A - SPL - 42 DAS - 05197
SO - Designates Swi ng Orive
66 - Designates Maximum Output Torque
I (66 = 66,000 lb-in.)
A - Designates Model Series Relating to
Design Changes
SPL - Designates Unit is Equipped With 1
I I or More Special Features
J
42 - Designates Overall Gear Reduction
DAS - Designates Unit is Equipped with a
Dual Acting Brake
1111 111 05197 - BRADEN Part Number of the Unit
Figure 1
Swing Reduction Unit With Park And Service Srake
which locks the gear train to the housing. preventing

Swing Reduction Unit any rotation . When sufficient pressure is applied to the
w/Brake, Recondition release piston , the springs are compressed. releasing
the brake and allowing the motor to rota te the gear
This procedure covers the recondition of the swing train. While the unit is in the "brake released "
reduction unit. For removal and installation condition. pressure can also be applied to the brake
procedures, see SM Keysheet Area 04-010. override piston to apply braking force to the rotating
gear train. The amount of this brake application is
General Information proportional to the pressure applied to the override
piston.
AII units are made up of the following sub-assemblies
and parts: The motor is directly coupled to the primary sun gear.
The friction discs are splined to the motor coupling and
Dual Acting Brake assembly. the steel spacer plates are pinned to the brake
Two planetary gear sets sharing a common housing. During "operation". the brake must be
stationary ring gear. released for the hydraulic motor to operate the drive in
either direction. The motor drives through two
Output pinion and bearing assembly planetary gear sets. The planet carrier of the second
The static brake assembly is a multiple disc pack with a stage gear set drives the output pinion. The ring gear
hydraulically actuated piston on either side. When in for the planetary gear sets is stationary. resulting in the
"parked" condition, there is no hydraulic pressure output pinion turning in the same direction as the motor
shaft.
applied to either pistan. The brake is spring applied.
1 of 10
21
20
19
18
17
16 40
15
41
14 42
13 43
12 44
11 45
10 46
47
9
8 48
7 49
6 50
51
5 52
53
4
3
2----~
----56
57
1. Housi ng (Rin g Gear) 13. O-rin g 25. Wave Spring 36. Friclion Discs 47. ShaN
2. Bearing Cu p 14. Motor Coup ling 26. Thrusl Washer (0.12 ") 37. Spacer 48. Planet Gears
3. Bearing Co ne 15. Lockwashers 27. Spring Space r 38 Back Up Ring 49 Bearing Spacers
4. Bearin g Cup 16. Capscrews 28 . Overri de Pis tan 39 . Pressu re Plate 50 Roller Bearings
5. Bearing Cone 17. Brake Cylin der 29. Need le Bea rin g 40 Pl ug 51. Thru st Washers
6 Output Carrier 18 Cylinder Seal 30. Thrust Washer (0.06 ") 41. Spring s 52. RolI Pins
7. Sun Gear - Output 19. O -rin g 31. Capscrews 42. ShaN s 53. Thrus t Button
8. Thrust Was her 20. Back Up Ring 32 . Loc kwashers 43. Plan et Gears 54 . Plug
9 Thrust Was her 21. Mo tor Support 33. Vent Pl ug 44 . Ro ll er Bearings 55 . Split Ring
10. Sun Gear - Pn mary 22. O-rin g 34. Pl ug 45. Thrust Was hers 56. ShaN Seal
11 . Primary Carri er 23 . O-ring 35. Steel Discs 46 RolI Pins 57. Pinion Shaft
12. Thrust Was her 24. O-ri ng
Figure 2
Swing Reduction Unit With Brake
2 of 10
Unit Disassembly 11 . Remove the sun gear (7) from the output carrier
(6).
It is a good practice when disassembling complex 12. Remove the output carrier (6) from the housing (1).
components to lay the parts out in the order that they 13. The split ring (55) is held in place by the output car
were disassembled. Keeping the parts in this order rier (6) and is used to maintain the preload on the
during disassembly, cleaning, and inspection will aid in tapered roller bearings (3,5) of the pinion shaft
the assembly process. (57). Use a tape red chisel or soft drift to remove the
halves 01 the split ring (55).
II parts are hard to disassemble and assemble, do not 14. Support the housing (1) on its mounting surface
use a hammer unless it has a soft lace, do not lorce and press the pinion shaft (57) out of the housing .
parts together, they must be Iree to rotate and not bind. 15. Remove the shaft seal (56) from the housing (1) .
16. Refer to the following sections for proper cleaning
1. Orain any excess 011 , remaining within the swing re
and inspection of parts or to further disassemble
duction unit, into an appropriate container. Proper
the subassemblies of the unit:
Iy store or dispose 01 the used oil.
• Brake Service
• Planet Carrier Service
A WARNING • Pinion Shaft Service
Solvents and cleaning solutions can be Cleaning And Inspection

cleaning solutions.
A WARNING
2. Cap/plug any openings in the swing reduction unit. result from misuse of these products. Read
and thoroughly clean the exterior surlace to pre and follow all the manufactu rer's
vent contamination Irom entering it. recommendations concerning solvents and
3. Place the swing reduction unit on a clean, sturdy cleaning solutions.
work surface using an adequate lifting device .
Note: The swing reduction unit weighs approxi
surlace and allow to air dry. Exercise every precau
tion possible to keep all parts Iree of dust, dirt, or
Reler to Figure 2.
4. Place index marks on each section 01 the unit to en
sure proper orientation 01 parts during assembly.
Mark the position 01 the motor to the motor support
(21). Mark the motor support (21) in relation to the
brake cylinder (17), and the brake cylinder (17) in
relation to the housing (1) .
5. Remove the vent plug (33) Irom the top 01 the mo
mance of products.
tor support (21).
3. AII "soft parts ", such as seals, gaskets , back up
6. Remove the motor pilot o-ring (24).
rings, and o-rings, should be replaced .
7. Remove the capscrews (16) and washers (15)
4. It is very important to keep the vent plug clean and
holding the brake cylinder (17) to the housing (1) .
unobstructed. Clean the vent in solvent, be sure it
8. Separate the brake cylinder (17) from the housing
is not plugged. Do not paint over the vent or re
(1) . Remove the o-ring (13) from the brake cylin
place it with a solid plug .
der (17).
5. Thoroughly clean and inspect the ring gear for
9. Remove the sun gear (10) and thrust washer (12)
damage. Check the ring gear teeth for nicks, spal
from the primary carrier (11) .
ling, or excessive wear. Replace the ring gear if
10. Lift out the primary carrier (11) and remove the
gear tooth wear is greater than 0.015 in (O.4mm)
thrust washer (8) between the primary carrier (11)
when compared to unworn area of teeth .
and output carrier (6).
30110
16
17
18
5 19
20
4
2 22
25
26
1. Molar Coupling 7. Springs 12 O-ring 17 . Capscrews 22. Thrusl Washer

2. Brake Cylinder 8 Pressure Plale 13. Back Up Ring 18. Lockwashers 23. Thrusl Washer
3. Friclion Discs 9 Back Up Ring 14 . Plug 19. O-ring 24. Needle Bearing
4. Spacer 10 . Plug 15. Molar Support 20. O-ring 25. Override PisIon
5 Spring Spacer 11 . Cylinder Seal 16. Venl Plug 21 . Wave Spring 26 Sleel Disc
6 Plug
Figure 3
Brake Assembly
4 of 10
Service Man 'l lal 0604 SM04-010-033.00
6. Thoroughly clean and inspect the bearings for any 9. Thoroughly clean all metal parts, except the friction
signs of damage or excessive wear. If the rollers discs, with an approved cleaning solvent . Place
show any signs of spalling, corrosion, discolor parts on a clean , lint free surface and allow to air
ation, material displacement or abnormal wear, the dry. Exercise every precaution possible to keep all
bearing should be replaced . Bearing cups and parts free of dust, dirt, or any othet' foreign material
cones must be replaced as a set. during assembly.
7. In the event of severe defects, contact factory per 10. Use a brush with brass bristles and compressed air
sonnel for directions whether to repair or replace to clean and inspect the friction discs.
any major component. 11. Thoroughly inspect all parts for any signs of dam
age or excessive wear. Pay particular attention to
Brake Service machined areas and sealing surfaces .
12. Place each friction disc on a flat surface and clleck
A WARNING for distortion with a straight edge . Friction material

should appear even across entire surface with
groove pattern visible. Replace friction disc if
The motor support is under brake spring
tension load. To avoid unexpected release of splines are worn to a point, disc is distorted, friction
spring pressure, loosen the four capscrews, material is worn unevenly, groove pattern is worn
one turn at a time, in a criss-cross pattern. away, or friction material is burned.
13. Place each steel disc on a flat surface and check
for distortion with a straight edge. Check surface
Disassembly for signs of material transfer or heat. Replace steel
Refer to Figure 3. disc if disc is distorted or heat discolored.
1. Carefully loosen the capscrews (17) holding the
motor support (15) to the brake cylinder (2). The
capscrews (17) must be loosened in a criss-cross
pattern, one turn at a time, to evenly release ten
A DANGER
Brake springs must be replaced as entire sel.
sion on the springs (7). Failure to replace brake springs as a set may
2. After all tension is relieved from the springs (7), re result in erratic brake operation and/or
move the capscrews (17) and lockwashers (18). repeated brake spring failure, resulting in an
3. Remove the motor support (15) from the brake cyl accidento
inder (2).
4. Remove the override piston (25) from the motor 14. Measure the free length of al16 springs . Minim um
support (15). free length is 1.1875 in (30.2mm). Check springs
5. Remove the o-ring (12,), backup ring (13), and for any sign of cracking or failure. If a brake spring
cylinder seal (11) from the motor support (15). must be replaced for any reason, then ALL brake
6. Remove the back up ring (9), spacer (4), pressure springs MUST be replaced.
plate (8), springs (7), and spring spacer (5) from
the brake cylinder (2). Assembly
7. Separate the motor coupling (1), steel discs (26), Lubricate the back up ring, o-rings, cylinder seal, and
friction discs (3), wave spring (21) , thrust washers housing bores with clean hydraulic oil prior to
(22 ,23), and needle bearing (24) from the override assembly. See Operator 's Manual for correct type .
piston (25). 1. Place the brake cylinder (2) onto a clean work sur
8. Remove the o-rings (19,20) from the override pis face. Install the springs (7) and spring spacer (5) .
ton (25). 2 . Place the motor support (15) , onto a clean work
surface, with the motor mounting surface down.
A DANGER
Do not use any type of solvent to clean the
3. Install backup ring (13) into the groove on the mo
tor support (15). The backup ring (13) should be
installed, toward the motor, with the curved surface
friction discs within the brake assembly. facing up.
Solvents will alter the braking capabilities of 4. Install the o-ring (12). The o-ring (12) fits into the
the lining material used on the friction discs, curved surface of the backup ring (13) . Be sure the
which could result in an accidento Use only a o-ring (12) is not twisted .
dry method to clean the friction discs, as 5. Install the cylinder seal (11) and the backup ring (9)
required. onto the motor support (15) . Be sure the cylinder
seal (11) is installed as shown in Figure 3.
5 of 10
16. Invert the brake cylinder (2), being careful to keep
the springs (7) and spring spacer (5) in position,
and place it onto the assembled motor support
(15) .
'\ 17. Turn the entire assembly overo

18. Align the motor support (15) to the brake cylinder
(2), using the marks made during disassembly.
\ 2
~
19. Install the capscrews (17) and lockwashers (18)
finger tight.
20. Tighten the capscrews (17) in a criss-cross pat
tern one turn at a time to evenly comp ress the
springs (7). Continue tightening until the motor
support (15) is fully seated against the brake cylin
der (2).
21. Evenly torque the capscrews (17) to 110ft lb .
" '
8 Planet Carrier Service

5 Figure 4 and the following instructions are for the out
put planet carrier assembly. The primary planet carrier
assembly follows the same procedure, except there is
1. Planet Carrier 4. Thrust Washer 7. Roller Bearing only one bearing and no spacer, under each planet
2 Gear Shaft 5. Roller Bearing 8. Planet Gear
3. RolI Pin 6. Spacer 9. Thrust Washer
gear.
Figure 4 Disassembly
Output Planet Carrier Assembly
Refer to Figure 4 .
1. Each planet gear (8) is removed by first driving the
6. Install o-rings (19,20) onto the override piston. In roll pin (3) into the gear shaft (2).
sert the override piston (25) into the motor support 2. Push the gear shaft (2) through the planet carrier
(15), being careful not to cut or damage the 0 (1) .
rings (19, 20) . 3. Drive the roll pin (3) out of the gear shaft (2) and dis
7. Install one steel disc (26) into the motor support cardo
(15) . Alternately install one friction disc (3) and one 4. Remove the planet gear (8) and thrust washers
steel disc (26) until all of the friction discs (3) are in (4,9) from the planet carrier (1) .
place. 5. Remove the roller bearings (5,7) and spacer (6)
8. Install the remaining steel discs (26) on top of the from the planet gear (8), as equipped .
last friction disc (3) . 6. Repeat this procedure for each of the other two
9. Use the motor coupling (1) to align the splines of planet gears (8) .
the friction discs (3). This will make it easier to 7. Thoroughly clean all parts with an approved sol
install the motor coupling (1) later. vent and inspect for damage and wear.
10. Install the thin thrust washer (22), needle bearing 8. The bearing rollers should not exhibit any irregular
(24) , and thick thrust washer (23) onto the motor ities . If the rollers show any sign of spalling, corro
end of the motor coupling (1) . Be sure to install the sion, discoloration, material displacement, or ab
thin thrust washer (22) first. normal wear, the bearing should be replaced.
11 . Install the wave spring (21) onto the motor cou 9. Likewise , the bearing cage should be inspected for
pling (1) . unusual wear or deformation, particularly the cage
12. While holding the wave spring (21) and needle bars . If there is any damage that will impair the
bearing (24) assembly in place, invert the motor cage 's ability to separate, retain, and guide the roll
coupling (1) and install it into the motor support ers properly, the bearing should be replaced .
(15). 10. The thrust washer contact areas should be free
13. Engage the splines of the friction discs (3) with the from any surface irregularities that may cause
motor coupling (1). abrasions or friction.
14. Install the spacer (4) and pressure plate (8) over 11. The gears and shafts should be inspected for ab
the motor coupling (1), onto the steel discs (26). normal wear or pitting and replaced if necessary.
15. Lightly lubricate the inside diameter of the brake
cylinder (2) with clean hydraulic oil.
60f 10
I '
---.:. . . -.
1. Gear Shaft 3. Planet Gear

2. Planet Carrier 1. Roll Pin 2. Planet Carrier
Figure 5 Figure 6
Planet Carrier Assembly RolI Pin Installation
Assembly Stake Rol! Pins 2
--~
The primary planet carrier assembly has a thrust wash
er (Figure 2, Item 9) that must be installed into the plan
et carrier BEFORE the planet gears are installed.
Refer to Figure 4.
, . Insert a roller bearing (5), spacer (6) , and roller
bearing (7) into a planet gear (8).
2. Place a thrust washer (4,9) on each side of the
planet gear (8) and position this assembly in the
planet carrier (1).
Refer to Figure 5.
3. Slide the gear shaft (1) through the planet carrier
(2) and planet gear (3) assembly.
4. Align the pin hole in the gear shaft (1) with the hole
in the planet carrier (2).
Refer to Figure 6.
5. Orive a NEW roll pin (1) into place. Always use
NEW roll pins (1).
6. When properly installed, 50% of the roll pin (1)
length should be engaged in the gear shaft wlth the
remaining 50% in the planet carrier (2). The roll pin
(1) should be slightly below the surface of the plan
et carrier (2). 1. Roll Pin Hale 2. Planet Carrier
Refer to Figure 7. Figure 7

7. Use a center punch to stake the planet carrier (2) Stake AII RolI Pins
next to the roll pin hole (1). This will distort the roll
pin hole (1) in the planet carrier (2) so the roll pin will
not back out when in service.
8. Repeat Steps 1 through 7 for each of the other two
planet gears.
70f 10
4 5 6
3
8
----10
1. Shah Seal 5. Thrust Butlan 8. Bearing Cup

2. Bearing Cup 6 Split Ring 9. Bearing Can e
3. Hausing 7. Drain Plug 10. Pini an Shatt
4. Bearing Can e
Figure 8
Pinion Shaft Assembly
Pinion Shaft Service Assembly

1. If the bearing sets are being replaced, press the
Disassembly bearing cups (2 ,8) into the housing (3) until fully
seated.
Refer to Figure 8 .
2. Install the bearing cone (9) in the bearing cup (8) .
1. Separate and remove the two halves of the split
3. Apply pipe thread sealant, to the threads of the
ring (6) .
drain plug (7) and install it into the housing (3).
2. Remove the pinion shaft (10) from the housing (3).
4. Apply Permatex® Farm-A-Gasket®, or oth er
3 . Remove the shaft seal (1) from the housing (3) .
non-hardening sealant, to the outslde dlameter of
4. Thoroughly clean all parts and inspect for damage
the shaft seal (1) .
and wear.
5. Press the shaft seal (1) into the housing (3) with the
5. The bea ri ng rollers should not exhibit any irregular
spring side facing inward . Use a flat plate to avoid
ities. If the rollers show any sign of spalling , co rro
distorting the the shaft seal (1) . The outside su r
sion, discolaration , material displacement, or ab
face of the the shaft seal (1) should be flush with the
normal wear, the bearing should be replaced.
housing (3) .
6. Li kewise, the cage should be inspected lar unusu
6. Lightly lubricate the sealing surface 01 the pinlon
al wear or delarmation , particularly the cage bars .
shaft (9) with clean oil and install it into the houslng
II there is any damage that will impair the cage 's
(3) . Refer to the Operatar's Manual for the correct
ability to separate, retain, and guide the rollers
type of oil used in the swing reduction uni!.
properly, the bearing should be replaced.
7. Carefully turn the assembly overo
7. Replace tape red roller bearings in sets of cups and
8. Lubricate the bearing con e (4) and install it onto the
eon es only.
pin ion shaft (9). Refer to Operator's Manual lor the
8. Inspect the thrust button (5) in the end 01 the pinion
correct type of oil used in the swing reductlon un l!.
shaft (10). If the Ilange thic kness is worn to less
9. The housing (3) should rotate smoothly and fr eely
tha n 0.0 62 in (1.6mm) , the thrust butlon should be
on the pinion shaft (9) .
re placed .
10 . Using a hydraulic press, apply approximately
22,000 lb, (97 900N) to the bearing cone (4) . Re
lease the press and install both halves 01 the spllt
ring (6) .
80110
_ Top edge al ring

gear teeth
~:L-""':":""-'--,-~ .- . -.------------ •.• ------------
0.25 inch
(6mm)
Primary planet gear
Figure 9
Primary Planet Carrier Placement
Unit Assembly 4. Apply a liberal coating al oil soluble grease or pe

troleum ¡elly to the thrust washer (8) and install it
Lubricate all back up rings , o-rings, shaft seals, and onto the pilot of the primary carrier (11).
housing bares with clean oil prior to assembly. See 5 . Install the primary carrier (11) into the housing (1) .
Operator's Manual lar correct type . It may be necessary to rotate the primary carrier
(11) to engage the output sun gear (7) with the
planet gears (43). Be sure the th rus t washer (8) re
A WARNING mains in its proper position.

6. When all components are properly installed, the
Lubricants, sealants, joint and thread locking primary planet gears (43) will be approximately
compounds, etc. can be hazardous. Serious 0.25 in (6mm) below the top 01 the ring gear teeth
personal injury may result from misuse of within the housing (1), reler to Figure 9.
these products. Read and follow all 7. Install the primary sun gear (10) into the center al
manufacturer's recommendations concerning the planet gears (43).
these products. 8. Lightly lub ricate and install the o-ring (13) onto the
brake assembly pilot in the housing (1).
Reler to Figure 2. 9. Set the brake assembly over the sun gear (10). Ro
1. Place the pinion/housing assembly on a clean tate the brake assembly, as required. to engage
work surlace with the pinion shaft (57) down. It is the motor coupling (14) with the primary sun gear
advisable to support the housing (1) on its mount (10) .
ing surlace lar increased stability. 10. Orlent the brake cylinder (17) with the housing (1).
2. Install the output carrier (6) into the housing (1). It using the marks made during disassembly.
may be necessary to rotate the output carrier (6) to 11. Ins tall the capscrews (16) and lockwashers (15)
engage the splines on the pinion shaft (57) with the securing the brake cylinder (17) to the housing (1).
planet gears (48). 12. 11 swing reduction unit is not to be immediately
3. Install the output sun gear (7) into the center 01 out installed on crane. plug all open ports to prevent
put planet gears (48). contamination and properly store.
9 al 10
10 of 10
5. Relieve hydraulic system pressure as follows :
Swing Reduction Unit And a. Open the drain valve on the air system
Brake, R & I reservoirs to bleed the air system pressure.
b. Relieve the hydraulic system precharge
This procedure covers the removal and installation of pressure by pushing the button on the
the swing reduction unit and brake. For recondition pressure relief valve, located on the hydraulic
proced ure, see SM Keysheet Area 04-010. reservoir.
c. Turn the ignition switch to " ON" , but DO NOT
Removal START THE ENGINE. Move the function
1. Lower, detach, and secure load, as required . lockout switch to the "OPERATE" position.
2. Stabilize the crane for service as follows d . Work the crane control levers and outrigger
a. Park the crane out of the way on a firm and level switches back and forth several times .
surface. e. Turn ignition switch to the "OFF" position .
b. Engage the park brake and/or properly block f. When pressure is fully relieved , close the drain
the tires. valves on the air system reservoir.
c. Engage the swing park brake or travel swing 6. Check that all control levers are in the neutral
lock , as required. position and move the function lockout switch to
d. Level the crane on fully extended outriggers. the "DISABLE" position.
e. Fully retract and lower the boom , as required.
hydraulic pump, as equipped. A WARNING
A WARNING
Iines and fittings befo re relieving air pressure
hazardous. Serious personal injury may befo re opening any line or fitting.
and follow all the manufacturer's Refer to Figure 1.
recommendations concerning solvents and 7. Remove the swing motor (1). Refer to SM
cleaning solutions. Keysheet Area 07 -006.
8. Remove the capscrews and washers (4) and
4. Thoroughly clean area to be disassembled with an remove pinion cover (6).
approved cleaning solvent to prevent 9. Index mar k the swing reduction unit and brake (2) ,
contamination. Allow the area to air dry. to the upper frame (3) , to ensure proper orientation
of the check /fill plug during installation.
A WARNING Note: The swing reduction unit weighs approxi

hot. A sudden release of hot oil could cause 10. Remove the capscrews (5).
burns or other serious injury. Shutdown the 11 . Using an auxiliary lifting device remove the swing
engine and exhaust all trapped hydraulic reduction unit and brake (2) trom the upper trame
pressure from the system befo re removing (3) and out of the crane.
1 of 4
. - ,
(~ ~
\' .~~+1
~!I ,.
' •. - - I ~¡
\~ - ' r~p
-'!"==--- -
/'
/ -~ r~r
(~ - ~:: _- -.
. ~/· /2
-- I
.::..., . ....L-.- . ":
'1
/ \
/ - _1
f
1. Swing Motor 4. Capscrews & Washers

2. Swing Reduction Unit & Brake 5. Capscrews
3. Upper Frame 6. Pinion Cover
Figure 1
Swing Reduction Unit And Brake Assembly
2 of 4
A WARNING
Solvents and cleaning solutions can be 2
3
cleaning solutions.

an approved cleaning sOlvent, air dried, and
carefully inspecteel.
4
2. AII Loctite® , Permatex®, or other sealant resielue FRONT OF CRANE
......
reused . Prior to applying new thread locking 1. Check/Fill Plug
compounds or sealants , clean threads and 2. Swing Speed Reduclion Unil
surfaces with Loctite® 7070 Cleaner to ens ure best 3. Drain Plug
4. Swing Molar
performance of products .
3. Thoroughly inspect all parts for damage , wear, Figure 2
fatigue Or stress fractures, and corrosion. Repair Check/Fill Plug Orientation
or replace as required .
4. Inspect gear teeth on pinion and turntable bearing 2. Apply Loctite® 242 to threads and install the
far damage. Refer to SM Keysheet Area 18-000 capscrews (5). Evenly tighten the capscrews (5) to
for gear inspection criteria . 435-480 ft lb (590-650Nm).
5. AII "soft parts" , such as seals, gaskets, back up 3. Align the pinion cover (6) and install the capscrews
rings, and o-rings, should be replaced. and washers (4).
6. Inspect the integrity of the hydraulic lines/hoses 4. Install the swing motor (1). Refer to SM Area
that are connected to the swing motor. Repair or 07 -006.
replace if required . 5. Check the oillevel in the reduction uni!. Add oil as
7. In the event of severe defects , contact factory required. See the Operator's Manual for the
personnel far directions whether to repair or correct type and procedure.
replace any majar componen!. 6. Grease the turntable bearing. See Operator's
Manual for correct type anel procedure.
Installation 7. Check the backlash between the teeth of the
pinion anel turntable bearing. See "Upper
Revolving Frame and Turntable Bearing, R & 1" far
A WARNING proper procedure anel adjustment.
8. Eng age the main hydraulic pump , as equipped .
Lubricants, sealants, joint and thread locking 9. Start the engine and let ielle for five minutes.
compounds, etc. can be hazardous. Serious Inspect the hydra ulic connections far leaks .
personal injury may result from misuse of Repair leaks as required.
these products. Read and follow all 10. Complete the installation by testing all related
manufacturer's recommendations concerning functions of the swing system far proper operation .
these products. Normal operation 01 the hydraulic , air, and
electrical systems should be confirmed . A general
Note: The swing reduction unit weighs approxi inspection 01 the components and systems in the
mately 300 lb (140kg). areas adjacent to the repair should also be
perlormed to ensure related damage ar wear is not
1. Using an auxiliary lifting device , properly position
presen!.
swing reduction unit (2) in the upper fr ame (3) . (Be
sure the check/fill plug is properly oriented as
shown in Figure 2.)
3 of 4
4014
eH 210 A 36110-01-1
Ti i T
Construction Max Design Gear Motor Drum Option
Hoist Rating Model Ratio Size Size
CH Construction Hoist
210 21,000 lb (93 450N) First Layer Line Pull
A Model Series Relating To Design Change
36 Total Gear Reduction
110 Hydraulic Motor Displacement In cubic inches
(Example: 110 = 11.0 cu in per revolution)
01 Drum Size
Permits Testing And Inspection Per API2C
(Offshore Cranes)
Serial Number and Model Number
are stamped into the motor end
bracket as shown aboye.
Figure 1
Identification Plate
Before doing any work on these units, all instructions

Winch, Recondition should be read completely and understood. So me
illustrations in this procedure may show details or
This procedure covers the recondition of Braden
attachments that are different from your winch. Also ,
hydraulic planetary winch model CH210. For
some components have been removed for illustrative
troubleshooting or removal and installation
purposes. IlIustrations in this procedure are of a
procedures , see SM Keysheet Area 5-6.
"typical " uni\. Some winches may differ slightly in
appearance .
Approximate Approximate
Winch Crane Serial Weight Dil Capacity
Model N°· Prefix
pounds kilograms pints liters
CH210 D7 or F2 825 375 36 17
CH210 E9 1,300 590 36 17
CH210 F7 or J6 1,300 590 36 17
CH210 J7 1,150 522 36 17
Table A
Weights And Oil Capacities
1 of 16
Unit Disassembly
components to lay the parts out in the arder they were
disassembled. Keeping the parts in this arder during
disassembly, cleaning, and inspection will aid in the
assembly process.

parts together, they must be free to rotate/operate and
not bind.
4. Install a short piece of pipe, threaded with 1 inch

pipe thread, into the larger threads of the drain
hale, to direct the oil flow through the support end
plate and out of the drum . If the drain holes were
not aligned before the winch was removed from its
mounting , the oil can be drained through the fill/
vent plug in the drum support by turning the winch
up on the drum support end.
1. Remove the wire rape from the winch drum and

align the drain plug in the drum with the hale in the
support end plate befare removing the hoses and
mounting bolts. See SM Keysheet Area 5-6 for
complete removal procedure.
A WARNING
hazardous. Serious personal injury may 5. Remove the drain plug through the pipe. Drain the
result from misuse of these products . Read oil from the winch drum. Refer to the Operator's
and follow all the manufacturer's Manual for the correct procedure. Properly sto re or
recommendations concerning solvents and dispose of the used oil.
cleaning solutions.
2. Thoroughly clean the exterior surface of the winch

to prevent contamination from entering il.
3. Refer to Figure 1 for location and explanation of the
winch model and serial number. Table A gives the
approximate weight and oil capacity, of the unit,
based on the drum size.
2 of 16
9. Remove the over-running clutch assembly (26)
from the center of the brake cylinder assembly
(27) . Refer to "Over-running Clutch Assembly
Service" later in this procedure for additional infor
mation.
10. Index mark the relative pos ition of the brake cylin
der assembly (27) to the motor end plate (28) to en
sure correct orientation of the hydraulic port during
assembly.
6. Begin the disassembly by standing the winch on

the end opposite the winch motor. Tag and remove
the hydraulic hoses that connect the brake valve
and the motor to the brake release port. (A man
ifold is used in the case of a two-speed motor.) "
e;.,. :(}~. ~ ",;" Q
¡ffi?fo})-/
\~, f / I@A~
IA... ,
I ~ L_ .- /
's .. -
'V"... "
~
;1 -P
. ~ .'
1;- . ~/ 11. Remove the capscrews (24) and lockwashers (25)

);¡¡~Qr
-~.~ and remove the brake cylinder assembly (27) fr om
(y, ~ ~~. 'Í-~~
t/--:;~(~-,- --~--
the motor end plate (28). Remove and discard the
'lc1~~
~.\ ~~
___- _-=;;;:l- l
(3 ~-pr.//ll
v-ring (30) seal that was under the brake cylinder
assembly (27). Do not remove the capscrews and
lockwashers (31) holding the motor adaptor to the
'
\ 's-:::::
:1"0-:--;: -=---- ==-~/
..-'". --:/ I
-.......:--::::~-=--:: -/ brake cylinder assembly (27) at this time. Refer to
, -=----- "Brake Cylinder Service " later in this procedure .
Refer to Figure 2.
7. Remove the capscrews and lockwashers (32) se
curing the winch motor (22) ; lift the motor (22) off
-~-
the winch. Remove the o-ring (23) installed on the
outside of the motor pilot.
...
, ¡· Ji
,,:--~~Ó/~~;¡/
."
\~___________ _J //1/
\.: )
IL /
~ /~
~
\j '
" )\ - -\ ¡-- / " ~1 I
U-'sc- ~ el (") ef~/
1 12. Remove the motor end plate (28) from the drum
1;
11
/. (7) .
8. Remove the capscrews (12) and lockwashers (13)

from the two tie plates (14), and remove the tie
plates (14).
30f 16
6
5
.•~
.~
11
f~
\ 12
13
28
29
30
31
32
1. Seal 9. Seal 17. Thrus t Washer 25 . Lockwashers

2 O - ring 10 . Plug 18. Ring Gear 26. Over- Running Clu tch
3 Drum Closure 11. Drum Suppor1 19. Ri ng Gear Ad ap tor 27 . Brake Cylinder Assembly
4. Reta ining Rings 12 . Capscrews 20 . Sun Gear - Primary 28. Motor End Plate
5. Prtmary Carrier Assem bly 13 . Lockwashers 21 . Ball Bearing 29 . Plug
6. Thrust Washer 14. Tie Plates 22 . Motor 30 . V- rin g
7. Drum 15. Secon dary Carrier Assem bly 23 . O-ring 31 . Capscrews & Lockwashers
8 Ball Bearing 16 Sun Gear - Secondary 24 . Capscrews 32. Capscrews & Lockwashers
Figure 2
Winch Assembly
401 16
Refer to Figure 2. 6. The thrust washer contact areas should be free
13. There are two 1/2 inch NC tapped holes in the from any surface irregularity that may cause exces
drum closure (3). Install two capscrews or sive abrasion or friction. Inspect thrust washers for
threaded eye-bolts to aid in removing the drum signs of excessive wear, heat damage, or metal
closure (3) from the drum (7). Remove the o-ring transfer; replace as necessary.
(2) from the outer diameter of the drum closure (3). 7. At regular service intervals, the roller bearings in
14. There are also two 1/2 inch NC tapped holes in the the planet carrier assemblies should be inspected
ring gear adaptor (19). Install two capscrews or to insu re beyond any doubt that they will function
threaded eye-bolts into these holes and lift the properly when installed. The rolle rs should not ex
ring gear adaptor (19) and ring gear (18) out of the hibit any surface irregularities. If the rollers show
drum (7). The primary sun gear (20), primary carri any sign of spalling, corrosion, discoloration, ma
er assembly (5), and secondary carrier assembly terial displacement, or abnormal wear, the bear
(15) can now be lifted out of the drum (7). ings should be replaced. Likewise, the cage
15. Lift the drum (7) off of the drum support (11). should be inspected for un usual wear or deforma
tion , particularly the cage bars. If there is any dam
Cleaning And Inspection age that will impair the cage's ability to separate,
reta in , and guide the rollers properly, the bearing
should be replaced.
A WARNING
8. Inspect the ring gear, planet, and sun gear teeth for
nicks, spalling, or excessive wear. Replace if wear
in contact areas is greater than 0 .015 inch .
hazardous. Serious personal injury may (O.4mm) when compared to unworn area of teeth .
result from misuse of these products. Read 9. If the winch was disassembled only to replace
and follow all the manufacturer's damaged seals after a short period of service, it is
recommendations concerning solvents and not necessary to replace the bearings. Experience
cleaning solutions. and common sense, along with a good inspection ,
wllI determine if parts can be used again.
10. Always coat o-rings, bearings , and the rubber
cleaning solven!. Place parts on a clean, lint free
parts of seals with oil or grease during assembly.
11 . Use a sealing compound on the outside diameter
tion poss ible to keep all parts free of dust, dirt, or
of seals, such as Permatex Form-A-Gasket No.
2, or equivalen!.
2. Carefully inspect all components for damage,
12 . Always apply a light coat of thread sealing com
we ar, corrosion , deep scratches, and scuffed met
pound on pipe fittings and plugs , such as Loctite
571 , or equivalen!. Do not use sealing tape . Be
file, hone , emery cloth , or crocus cloth. Replace
careful not to get sealing compound inside parts
any damaged component as required .
and passages which conduct oil.
3. AII Loctite(H,. , Permatex ~ , or other sealant residue
13. The shafts and carrier should be checked where
there is roller or thrust washer contact. The same
surface and material conditions that are detrimen
tal to the life of the bearing and thrust washer also
apply to the contact areas on the shaft and carrier.
with Loctite<!l 7070 Cleaner to ensure best perfor
mance of products.
4. Always replace all "soft parts" such as o-rings,
any major component .
seals , and v-rings.
5. Inspect sealing surfaces on the drum support and
brake cylinder and repair any damaged areas if
possible, or replace components as required .
5 of 16
3. Turn the drum (7) over, and set it down on the drum
support (11). Be careful not to damage the seal (1)
when lowering the drum (7) onto the drum support
(11 ).
4. Lower the secondary carrier assembly (15) into the
drum (7) and engage the three lugs on the carrier
into the three holes in the drum (7). Be sure the car
rier is firmly seated against the web in the drum (7) .
5. Install the thrust washer (6) into the recess in the
secondary carrier assembly (15), then install the
sun gear (16) into the center of the secondary plan
et gears.
Refer t o Figure 2.
6. Install the primary carrier assembly (5) on top of the
1. Place the drum support (11) assembly on a clean
secondary carrier assembly (15), engaging the
work surface with the drum support (11) facing up.
splines in the primary carrier assembly (5) with the
Lubricate the ball bearing (8) and sealing surfaces
secondary sun gear (16). Install the thrust washer
on the drum support (11) with the same oil used to
(17) onto the primary carrier assembly (5).
lubricate the winch planetary. See the Operator's
7. If the ring gear (18) and ring gear adaptor (19) had
Manual for the correct type of oil. Install a new v
been disassembled, reassemble them at this time,
ring (30) onto the drum support (11). using two retaining rings (4).
8. Install two 1/2 inch NG capscrews or threaded eye
bolts into the two tapped holes in the ring gear
adaptor (19). Using the capscrews or eye bolts,
install the ring gear (18) into the drum (7). Rotate
the ring gear (18) back and forth to engage the in
ternal splines with the primary carrier assembly (5)
and secondary carrier assembly (15). When cor
rectly installed, the bottom of the ring gear adaptor
(19) will be resting on the thrust washer (17), which
is on the primary planet carrier assembly (5).
9. Install a new ball bearing (21) in the drum closure
(3), if replacement is necessary, making certain to
press it against the shoulder in the bottom of the
2. Install a new ball bearing (8) in the drum (7) , if re bearing bore.
placement is necessary, making certain to press it 10. Goat the outside diameter of a new seal (1) with
against the shoulder in the bottom of the bearing Permatex® Form-A-Gasket® No . 2, or equiva
bore. Goat the outside diameter of a new seal (9) lent. Turn the spring side of the seal (1) toward the
with Permatex® Form-A-Gasket® No. 2, or equiv ball bearing (21), and press the seal (1) into the
alent. Turn the spring side of the seal (9) toward the seal bore, leaving it flush with the surface of the
ball bearing (8), and press the seal (9) into the seal drum closure (3) .
bore , leaving it flush with the surface of the drum 11 . Lubricate a new o-ring (2) and install it into the
bore. groove on the outside diameter of the drum closure
(3) .
60f 16
19. Continue to tighten the capscrews (24) in a criss
Drum r -0.034 inch Drum
Closure cross pattern one turn at a time until the motor end
(O.9mm)
~?
plate (28) is drawn tightly up against the brake cyl
\ -,i
I
inder assembly (27). Torque capscrews (24) to
their correct value. See SM Keysheet Area 18-0
i for "Capscrew Torques ".
20. Install the two tie plates (14) between the two end
plates of the winch, using all the capscrews (12)
and lockwashers (13). Be sure the curved sides of
~- the tie plates (14) are toward the top of the winch.
-1 Torque all capscrews (12) to their correct value .
See SM Keysheet Area 18-0 for "Capscrew
I Torques" .
21 . Install the over-running clutch (26) into the center
12. Lubricate the outside diameter of the drum closure of the brake pack. Refer to Figure 5 for correct ori
(3) and install it into the drum (7) . When correctly entation of the over-running clutch (26). "Input
installed, the drum closure (3) will be approximate Spline Side", shown in Figure 5, is the end of the
Iy 0.034 inch (O.9mm) above the drum flange. If the over-running clutch (26) facing outward, toward
drum closure (3) cannot be installed as shown, one the motor (22). It may be necessary to rotate the
or more components may be out of position or not drum (7) slightly in either direction to align the
properly seated. The most common causes of this clutch splines with the primary sun gear (20). The
problem are the thrust washers (6,17) being out of internal retaining ring in the over-running clutch
position, or the secondary carrier assembly (15) is (26) should be seated against the primary sun gear
not fully seated into the drum (7). DO NOT proceed (20) when correctly installed .
with assembly untd the source of the problem has 22 . Lubricate and install a new o-ring (23) onto the pi
been identified and corrected. lot for the motor (22). Engage the motor shaft with
13. Place the motor end plate (28) on the drum (7), the inner race of the over-running clutch (26) and
aligning it approximately with the drum support lower the motor (22) into place.
(11) and centering it on the drum (7). 23. Install motor capscrews and lockwashers (32) and
14. Lubricate and install a new v-ring (30) onto the torque to correct value. See SM Keysheet Area
motor end plate (28) . 18-0 for "Capscrew Torques".
15. Lubricate the sealing surface of the brake cylínder 24. Connect all hydraulic lines removed dUrlng disas
assembly (27) and carefully install the brake cylin sembly, then tighten all connections .
der assembly (27) through the motor end plate (28) 25. After the winch assembly is complete , check all
into the drum (7). Rotate the brake cylinder assem capscrews and fittings to make certain they have
bly (27) back and forth to align the splines with been properly installed and tightened correctly. Fill
those on the ring gear adaptor (19). the winch with the recommended oil listed in Oper
16. Position the brake release port in the same location ator's Manual.
as removed, using the index marks scribed on the 26. Before returning the winch to full service, a light
parts during disassembly. load should be lifted and held a few feet off the
17. Install the primary sun gear (20) through the center ground to be sure the static brake is functioning
of the brake cylínder assembly (27), engaging the properly. The winch should also be able to slowly
teeth on the three primary planet gears. lower the load in a smooth and controlled manner.
18 . Install the capscrews (24) and lockwashers (25) If the winch do es not perform either of these func
through the brake cylinder assembly (27) into the tions correctly, refer to SM Keysheet Area 5-6 fo r
motor end plate (28). Hand tighten all capscrews "Winch, Troubleshooting" for additional informa
(24) untd they are snug against the motor adaptor. tion.
7 of 16
2. Use a punch to drive the spiral pins (2) from the
planet gear shafts (4). DO NOT reuse the spiral
pins (2).
3. Now you can remove the planet shafts (4), roller
bearings (6), thrust washers (3,7) and planet gears
(5) .
4. Thoroughly clean all parts and inspect for damage
and wear. The bearing rollers should not exhibit
any irregularities. If the rollers show any sign of
spalling, corrosion, discoloration, material dis
placement, or abnormal wear, the bearing should
3 be replaced. Likewise , the cage should be in
spected for un usual wear or deformation, particu
1. Carrier 5. Planet Gears larly the cage bars. If there is any damage that will
2. Spiral Pins 6. Roller Bearings
impair the cage's ability to separate, retain, and
3 Thrust Washers 7. Thrust Washers
4. Shafts guide the rollers properly, the bearing should be re
placed. The thrust washer contact are as should be
free from any surface irregularities that may cause
Carrier Assembl abrasions or friction. The gears and shafts should
be inspected for abnormal wear or pitting; re place
if necessary
Primary Planet Carrier Service
Assembly
Disassembly
I
I- ~ '
Refer to Figure 3.
1. Install a roller bearing (6) into a planet gear (5) and
Refer lo Figure 3. place a thrust washer on each side of the planet
1. Remove Ihe planet gears (5) by first driving the spi gear (5). Position this assembly into an opening in
ral pins (2) into the center of the planet gear shafts the carrier (1). Slide a planet gear shaft (4) through
(4) . the carrier (1), thrust washer (3), roller bearing (6)
and remaining thrust washer (7).
., _\.. ··1¡· h1/1' "In· I

I ', ' ~ 1111[41.
'._ - - " , " -- ~
<'
- .--"I ], JL .
"'" '
8 of 16
3
2
I!
~; -. -"
. ·'iáJ'
2. Carefully align the pin hole in the carrier (1) with the 10
9
hole in the shaft (4) and drive a new spiral pin (2)
8
into place. ALWAYS use NEW spiral pins (2). 7
When properly positioned, 50% of the spiral pin (2) 6
will engage the planet gear shaft (4) and 50% will
5
remain in the carrier (1).
1. Shafts 6. Loose Rollers
2. Carrier 7. Planet Gears
¡111n ~~ ,
1 3. Thrust PI ate 8. Bearing Spacers
11' 1) I I 4. Spiral Pins 9. Loose Rollers
5. Thrust Washers 10. Thrusl Washers
I! .. J
Figure 4
Secondary Planet Carrier Assembly
( Secondary Planet Carrier Service

Disassembly
i )
3. Note that the spiral pin (2) is slightly recessed into

the carrier (1) when properly installed. With a cen
ter punch, stake the carrier (1) next to the spiral pin
hole as shown. This will distort the hole and pre
vent the spiral pin (2) from backing out during op
eration. Repeat these steps for each of the three
planet gears (5).
Refer to Figure 4.
1. Remove the planet gears (7) by first driving the spi
ral pins (4) into the center of the planet gear shafts
(1).
90f 16
3 , Apply a liberal coat of oil soluble grease to the bore
of the planet gear (7) , Stack a row of loose rollers
(9) into the planet gear (7), using the grease to hold
them in position. There are 22 loose rollers (6,9) in
each of the two rows within planet gear (7). Install a
bearing spacer (8) , Stack a second row of loose
rollers (6) on top of the bearing spacer (8) , Place a
second thrust washer (5) on the planet gear (7),
4. Carefully slide the planet gear (7), loose rollers
(6,9) and thrust washers (5,10) into the carrier (2),
Install a planet gear shaft (1) into the carrier (2) and
through the planet gear (7) and loose rollers (6 ,9),
2, Use a punch to drive the spiral pins (4) from the

planet gear shafts (1), DO NOT reuse the spiral
pins (4) ,
3, Now you can remove the planet gear shafts (1),
bearings spacers (8), thrust washers (5,10), planet
gears (7) and thrust plate (3) ,
I r::
1 L
4 , Remove the loose rollers (6,9) from the planet
gears (7) ,
~liy.ífi~ " l'
5, Thoroughly c1ean all parts and inspect for damage

and wear, The bearing rollers should not exhibit
any irregularities. If the rollers show any sign of 5, Carefully align the spiral pin hole in the carrier (2)
spalling , corrosion, discoloration, material dis with the hole in the planet gear shaft (1) and drive a
placement or abnormal wear, they should be re new spiral pin (4) into place, ALWAYS use NEW
placed, The thrust washer contact areas should be spiral pins (4), When properly positioned, 50% of
free from any surface irregularities that may cause the spiral pin (4) will engage the planet gear shaft
abrasions or friction . The gears and shafts should (1) and 50% will remain in the carrier (2) ,
be inspected far abnarmal wear or pitting; replace
if necessary,
Assembly
\~I0\
\\ ~
l'r
I
6. Note that the spiral pin (4) is slightly recessed into

Refer to Figure 4, the carrier (2) when properly installed, With a cen
1, Place the carrier (2) on a c1ean work surface with ter punch, stake the carrier (2) next to the spiral pin
the spiral pin holes down , Install the thrust plate (3) hole as shown, This will distort the hole and pre
into the center of the carrier (2), vent the pin from backing out in operation ,
2, Apply a liberal coat of oil soluble grease to a thrust 7. Repeat this procedure lar each of the planet gears
washer (10) and center it on one side 01 a planet (7) ,
gear (7), Place the planet gear (7) on a c1ean work
surface wlth the thrust washer (10) down,
10 01 16
Input Spline Side ._. ¡
iiii/ /, ,-'
Input spline to rotate - Correct location -" - Input spline to rotate

freely in CCW direction of internal freely in CCW direction
when viewed from retaining ringo when viewed from
input spline side. input spline side.
14 Tooth Internal Spline 13 Tooth Internal Spline
Figure 5
Over-Running Clutches
Over-Running Clutch Service

2
Shown above is the correct assembly of the two types
of over-running clutch assemblies used in the winch.
3
4
Certain parts within the over-running clutch are NOT
SOLO individually as replacement parts. If any of these 5
parts require replacement, the entire over-running 6
clutch assembly must be replaced. Refer to the 7
Crane's Parts Manual ta confirm the availability of
replacement parts befare disassembly. ",(
(¡¡~
J'''').
,-
, 1 /:r~~
-- .i
...
8
Carefully note the relative orientation between the inner - -./?.......1. ,; ) .!~~
and outer races, and the direction of free rotation of the
Inner race. The clutch MUST be assembled correctly
(l. ./ f 1I
.1
for proper winch operation. ~=-- ,;
1, Retaining Ring 5. Inner Race
2. Ball Bearing 6. Retaining Ring
3. Over-Running Clutch 7. Ball Bearíng
4. Outer Race 8, Retaining Ring
Figure 6
Over-Running Clutch Assembly
11 of 16
Assembly
A DANGER
Th e polished surfaces of the inner and outer
race and the over-running cams must be
perfectly smooth to insure positive
A DANGER
Failure to assemble the over-running clutch
engagement of the clutch. The slightest assembly with all parts oriented correctly may
defect may reduce clutch effectiveness. This result in reduced brake effectiveness , This
may lead to 1055 of load control and result in may lead to 1055 of load control and result in
property damage, injury, or death. It is property damage, injury or death.
ge nerally recommended to re place the entire
clutch assembly if any component is
defective. For these reasons, the Refer to Figure 6,
over-running clutch assembly should be 1, Check that the retaining ring (6) is properly
disassembled for inspection only if the winch installed inside the inner race (5),
has exhibited any unusual operation that 2 , Install ball bearing (2) on the inner race (5),
would point toward a clutch malfunction, or 3. Install the over-running clutch (3) anta the inner
the over-running clutch assembly shows race (5), Rotate the inner race (5) slightly to get the
external signs of mechanical damage or wear. over-running clutch (3) started anta the inner race
(5) ,
4, Install the other ball bearing (7) anta the inner race
Disassembly (5) ,
Refer to Figure 6 , 5, Install retaining ring (1) into the outer race (4) ,
1, Remove one of the retaining rings (1 ,8) from the 6, Carefully slide the inner race (5), with ball bearings
outer race (4) , (2,7) and over-running clutch (3) , into the outer
2, Push the inner race (5) , ball bearings (2,7), and race (4),
over-running clutch (3) through the outer race (4), 7, Install the other retaining ring (8) into the outer race
3 , Use a small punch and hammer to tap one of the (4),
ball bearings (2 or 7) off of the inner race (5), The
over-running clutch (3) can now be removed from
the inner race (5),
4, If required, remove the retaining ring (6) from in
side the inner race (5),
5 , Closely inspect the over-running clutch (3) and
the polished surfaces of the inner race (5) and out
er race (4) for wear, cracks, pitting, corrosion, or
mechanical damage, Closely inspect the ball
bearings (2,7) for any signs of damage, wear, cor
rosion , pitting, or heat discoloration, Replace
damaged parts, as required,
12 of 16
16
15
14
13
12
11
10
5
~;. , ; 4
3
2
1. Capscrew 5. O-ring 8. Spacer 11 . Pressure Plate 14 . Spring Spacer

2. Lockwasher 6. Brake Discs 9. Piston Seal 12 . Springs 15 . Plug
3. Motor Ad aptor 7. Friction Discs 10. Back Up Ring 13 . O-ring 16. Brake Cylinder
4. Back Up Ring
Figure 7
Brake Cylinder Assembly
Brake Cylinder Service discard the piston seal (9) from the brake cylinder
(16). Remove the steel back up nng (10) .
Disassembly 4. Remove the pressure plate (11), springs (12) . and
spring spacer (14) from the brake cylinder (16).
A WARNING
The motor adaptor is under spring tension
from the brake springs. Loosen each of the
capscrews one turn at a time until spring
tension is released.
Refer to Figure 7.
1. Stand the brake assembly on the splined end, with
the motor adaptor (3) up. Using a criss-cross pat
tern , loosen each capscrew (1) one turn at a time
5. Thoroughly clean and inspect all parts at this time
until spring (12) tension is released. Remove the
Check sealing surfaces on both the motor adaptor
capscrews (1) and lockwashe rs (2).
(3) and brake cylinder (16). Be sure the brake re
2. Remove the motor adaptor (3). Lift out all the brake
lease port is open and free of contamination .
discs (6), friction discs (7), and the spacer (8).
3. Remove and discard the o-ring (5) and back up
ring (4) from the motor adaptor (3). Remove and
13 of 16
Assembly
____ O-ring
..... - Back Up Ring
6. Place friction discs (7) on flat surface and check for

distortion with a straight edge. Friction material
Refer to Figure 7 .
should appear even across entire surface with
1. Place the motor adaptor (3) on a clean work sur
groove pattern visible. Replace friction discs (7) if
face with the motor mounting surface down. Apply
splines are worn to a point, disc is distorted, friction
a light coat of oil to a new back up ring (4) and 0
material is burned or worn unevenly, or groove
ring (5) and install them into the groove on the mo
depth is less than 0.003 inch (O.08mm).
tor adaptor (3). Back up rings are always placed
on the low pressure side of the o-ringo In this
case , the back up ring (4) is toward the motor
mounting surface. Lightly oil the brake cylinder
piston seal (9) and install it onto the motor adaptor
(3) with the seallip down.
2. Install a steel brake disc (6) into the motor adaptor
(3) , followed by a friction disc (7) . Continue to alter
nately install brake discs (6) and friction discs (7)
until there are eight brake discs (6) and seven fric
tion discs (7). A steel brake disc (6) wlll be on topo
3. Instal/ the spacer (8) on top of the last steel brake
disc (6).
7. Check brake spring (12) free length . Minimum free
length is 1-7/ 16 inches (36.5mm). Check springs
(12) for any signs of cracking or failure . If a brake
spring (12) must be replaced for any reason, then
ALL brake springs (12) must be replaced.
A DANGER
Failure to replace brake springs as a set may
result in uneven brake application pressure,
brake spring failure, and reduced brake
effectiveness. This may lead to loss of load 4. To check brake stack height, place pressure plate
control and result in property damage, injury, (11) on top of brake spacer (8) . Hold pressure
or death. plate (11) down firmly by hand and measure gap
(in three places) between motor adaptor (3) and
pressure plate (11) . Average gap must measure
between 0.080-0.160 inch (2-4mm).
14 of 16
S-e~rv.icéM a nua'l 0602 SM:S -6-25.0
5. li the gap exceeds the maximum limit, the re may 9. Apply petroleum jelly or an oil soluble grease to the
be too many d iscs in the stack-up or the d iscs are sealing surface of the brake cylinder (16) and the
distorted . li the gap is les s than the minimum, piston seal (9) . Turn the brake cylinder (16) over
there may be too iew discs or the discs are worn and lower it onto the motor adaptor (3), being ca re
beyond their serviceable limit and should be re fui not to damage the pisto n seal (9) or o-ring (5)
placed. When the gap is within the m in imum and on the motor adaptor (3). Be careful the o-ring (5)
maximum values , remove the pressure plate (11) does not fall out of place, and the oil passages are
and all brake d iscs (6) and friction discs (7) . Lubri aligned. The alternate assembly method , me n
cate all friction discs (7) with the same oil to be tioned in preceeding note, could also be used .
used in the winch planetary. Refer to the Opera 10. Turn the entire assembly over and install the cap
tor's Manual for the correct type of lubri cant to use. sc rews (1) and lockwashers (2). Afte r the cap
Install all brake d iscs (6) , i rict ion d iscs (7) , and screws (1) make contact with the motor adaptor
brake plate space r (8) as described in Steps 2 and (3) , evenly tighten them one turn at a time until the
3. motor adaptor (3) is drawn tight against the brake
6. Place the brake cyllnder (16) on a clean work sur cylinder (16) , then torque to the recommended val
face with the splined end down. Install the spring ue. See SM Keysheet Area 18-0 for "Capscrew
spacer (14) , then the springs (12). Torques ".
Brake Cylinder Pressure Test
A DANGER 1. Install a -6 ORB fitting into the brake release port
on the motor adaptor (3). Connect a hand pump
Always use the molded spring spacer to with an accurate 0-2,000 ps i (O-13 ,BOOkPa)
properly position the springs in the brake
gauge and shut-off valve to th is fitting . Apply
cylinder. Failure to install the spring spacer
1,000 psi (6,900kPa) to the brake cylinder (16) and
may allow the springs to contact each other
and become damaged. This could result in close the shut-off valve. Let the unit stand for five
lo ss of load control, property damage, injury, minutes. If there is any loss of pressure, the brake
or death. cylinder (16) should be di sassembled for inspec
tion of the sealing surfaces, piston seal (9) , and 0
7. Install the pressure plate (11) into the brake cylin ring (5). When the source of the pressure leak has
der (16). Be careful that none of the springs (12) fall been determin ed and corrected, reassemble the
over. Install the steel back up ring (10). brake cylinder (16) and repeat the test.
8. Apply petroleum jelly or an oil soluble grease to a 2. WHILE PRESSURE IS APPLlEO ANO THE BRAKE
new o-ring (13) and install it in the brake cylinder IS RELEASEO, install the over-runn ing clutch (26,
(16). Figure 2) assembly into the brake pack . Turn the
over-running clutch (26 , Figure 2) back and forth
Note: The close fitting back up ring may be de to align the splines on all the friction discs (7) . Re
pressed slightly to one side to lodge ít in the lease the pressure on the brake cylinder (16) and
brake cylinder bore and temporarily hold the remove the over-running clutch (26 , Figure 2) .
pressure plate and springs in place while the The brake cylinder assembly is now complete and
brake cylinder is inverted and lowered over the ready to be installed in the winch.
motor adaptor.
As an alternate method, the motor adaptor and
brake plates can be turned over and installed
into the brake cylinder, holding the brake plates
and spacer in place through the center opening.
Be careful to not pinch your fingers between the
spacer plate and the pressure plate.
15 of 16
G090
2. Thoroughly clean area lo be serviced wilh an
Winch Troubleshooting approved cieaning solvent to prevent
This procedure covers troubleshooting guidelines for contamination from entering the hydraulic oil
Braden winch CH210 model. For removal and circuits. Allow the area to air dry.
installation or recondition procedure, see SM Keysheet
Area 5-6.
It is suggested that before doing any work on these

A WARNING
units , all instructions should be read completely and hot. A sudden release of hot oil could cause
understood. Some illustrations in this procedure may burns or other serious injury. Shutdown the
show details or attachments that are different from your engine and exhaust al! trapped hydraulic
winch. Also, some components have been removed pressure from the system befo re removing
for illustrative purposes. IIlustrations in this procedure any line or component.
are of a "typical" unit.
3. Hydraulic pressure within lines and components
General Safety Rules must be exhausted before opening the system. To
relieve hydraulic system pressure:
Safety for operators and ground personnel is of prime
concern . Always take the necessary precautions to en reservoir by pushing the button(s) on the
sure the safety of others as well as yourself. To ensure pressure relief valve, located on the hydraulic
safety, the crane and winch must be operated by a reservoir or by loosening the cap, located on
qualified, well trained operator. Care and concern, by the hydraulic reservoir, 1/4 turn until pressure
the operator, for the equipment and a thorough knowl is fu lIy relieved.
edge of the crane's performance capabilities, are es b. Turn the ignition switch to "ON " , but DO NOT
sential for safe, efficient, and trouble free performance. START THE ENGINE. Move the function lock
The following recommendations are offered as a gen out switch to the "OPERATE" position.
eral safety guide. Instructions given in the Operator's
Manual and local rules and regulations also apply.
d. Rotate the steering wheel back and forth
1. Be certain crane is properly prepared for servicing: repeatedly until steering beco mes hard . (On
a. Park the crane out of the way on a firm and level cranes equipped with emergency steering
surface. system, it will take several rotations of steering
b. Engage the park brake and/or properly block wheel before steering becomes hard.)
the tires or track. e. Turn ignition switch to the "OFF" position .
c. Engage the swing park brake or two position 4. Check that all control levers are in the neutral
swing lock, as equipped. position and move the function lockout switch to
d. Adequately support or fully lower the boom, as the "DISABLE" position.
required. 5. Be sure personnel are clear of work area and
e. Shutdown the engine and disengage the main aware of pending activities BEFORE operating the
hydraulic pump. crane or winch.
f. Check that all control levers are in the neutral 6. Read all warning and caution tag information
position and move the function lockout switch provided for safe operation and service of winch .
to the "DISABLE" position. 7. Inspect rigging and winch at the beginning of each
work shift. Defects should be corrected immedi
ately.
A WARNING 8. Keep equipment in good operating condition.
Perform scheduled maintenance and inspections
Solvents and cleaning solutions can be as listed in the the Operator's Manual.
hazardous. Serious personal injury may 9. An equipment warm-up procedure is recom
result from misuse of these products. Read mended for all start-ups and essential at ambient
and follow al! the manufacturer's temperatures below 40°F (4 oC). Refer to "Warm
recommendations concerning solvents and up Procedure" listed in the Operator 's Manual.
cleaning solutions. 10. Operate winch line speeds to match job condi
tions.
1 of 10
eH 210 A 36110-01-1
Ti i T
Construction Max Design Gear Motor Drum Option
Hoist Rating Model Ratio Size Size
eH Construction Hoist
210 21,000 lb (93 450N) First Layer Line Pull
A Model Series Relating To Design Change
36 Total Gear Reduction
110 Hyd raulic Motor Displacement In cubic inches
(Example : 110 = 11 .0 cu in per revolution)
01 Drum Size
Permits Test ing And Inspection Per API2C
(Offshore Cranes)
Serial Number and Model Number

are stamped into the motor end
bracket as shown abov e.
Figure 1
Identification Plate
11 . Use leathe r gloves when handling w ire rape . 20. Do not attempt to clean, oil, or perform any mainte
12. Do not attempt to handle wire rape when the hook nance on a crane with the engine running, unless
end is attached . Keep all parts of body and cloth instructed to do so per the Operator 's or Service
ing clear of head sheaves, wire rape, cable rollers, Manual.
and winch drum. 21. Do not operate winch controls unless you are
13. When winding wire rape on the winch drum , do not properly positioned at the operator 's station and
attempt to maintain tension by allowing w ire rape you are sure personnel are clear of the work area.
to slip through hands . Use "Hand-Over-Hand " 22 . Ensure that personnel who are responsible for
technique. hand signals are clearly visible and that the signals
14 . Do not use wire rape with broken strands . Replace to be used are thoroughly understood by every
damaged or worn wire rape. one. Refer to the "Standard Hand Signal Chart" in
15. Do not weld on any part of the winch. the Operator 's Manual.
16. Use hydraulic oil and gear lubricant based on tem 23. Ground personnel should stay in view of the oper
perature conditions . Refer to the Operator's Manu atar and clear of winch drum. Do not allow ground
al for the correct grades of lubricant to use . personnel near a winch line under tension. A safe
17. Keep hydraulic system clean and free from conta distance of at least 1-1 /2 times the length of the
mination at all times . unspooled cable should be maintained .
18. Do not use knots to secure or altach wire rape . AI 24. Do not exceed the maximum pressure, psi (kPa) ,
ways use the proper altachment methods as ex or flow, gpm (Lpm) , stated in the winch specifica
plained in the Operator's Manual. tions for hydraulically driven winches
19. Use only the correct size anchor for the same size 25. Do not allow anyone to stand under a suspended
of wire rape and pocket in drum. Original equip load.
ment wire rape anchors are capable of supporting 26. Avo id sudden "shock " loads or attempting to "jerk"
the rated load when installed properly. For addi load free . This type of operation may cause heavy
tional safety, ALWAYS maintain a minimum of five loads , in excess of rated capacity, which may result
(5) wraps of wire rope on the drum . in failure of cable or winch.
20f 10
~
STATIC FRICTION BRAKE APPLlED
-l-l -l-l-l--1j~
-.J
~J
~LJJ
I I I I I ::..U -.J
I I I I I I I I
MITS FREE SHAFT ROTATI
LOAD ATTEMPTS TO ROTATE
WHILE HOISTING
~ SHAFT IN OPPOSITE DIRECTION,
BRAKE CLUTCH LOCKS SUN GEAR
SHAFT TO FRICTION BRAKE
Figure 2 Figure 3
Hoisting Stopped Holding Load
When the control valve is placed in the lowering

Description Of Winch position , the spool valve remains closed until suH lclent
The winch is made up of the following assemblies: pilot pressure is applied to the end of the spool to shlft it
against spring pressure and open a passage, After the
Hydraulic Motor And Brake Valve
spool valve cracks open, the pilot pressure becomes
Drum, Drum Closure, Ball Bearings And Oil Seals
flow dependent and modulates the spool valve
Support End Plate And Bearing Support
opening which controls the lowering speed,
Motor End Plate And Motor Adapter
Tie Plates The static brake system has three operating
Brake Clutch Assembly components:
Brake Cylinder And Multiple-disc Brake Parts
• Spring Applied, Hyd rau lically Released Multiple
Primary Planetary Reduce r
Friction Disc Brake Pack
Secondary Planetary Reducer
• Brake Clutch Assembly
Ring Gear And Adapter
• Hydraulic Piston And Cylinder
Theory Of Operation The static brake is released by the brake valve pllot
pressure at a pressure lower than that required to open
Dual Brake System - Description the pilot operated spool valve, This sequence assures
that dynamic braking takes place in the brake valve
The dual brake system consists of a dynamic brake
and little, if any, heat is absorbed by the friction brake,
system and a static brake system, The dynamic brake
system has two operating components: The friction brake is a load holding brake only and has
• Brake Valve Assembly nothing to do with dynamic braking or rate of descent
• Hydraulic Motor of a load,
The brake valve is basically a counterbalance val ve, It
contains a check valve to allow free flow of oil to the
motor in the hoisting direction and a pilot operated,
spring loaded spool valve that blocks the flow of oil out
of the motor when the control valve is placed in neutral.
3 of 10
2 3 4 5
6
---
Check Valve
Unseated -(;~=:===qm',W:'1!
Pressure
mi High
1,\1 Medium
D Low 8
The brake valve is basically a counterbalance valve. It contains a check valve to allow free flow of oil
to the motor in the hoisting position and a pilot operated, spring loaded spool valve that blocks the flow
of oil out of the motor when the control valve is placed in neutral.
1. Hyd raulic Reservoir 3 Drum 5. Brake Valve 7. Control Valve

2. Winch Brake 4. Case Drain 6. Motor 8. Pump
Figure 4
Hoisting Sequence
The brake clutch is splined to the primary sun gear Dual Brake System - Operation
shaft between the motor and the primary sun gear. It
When hoisting a load, the brake clutch which connects
will allow this shaft to turn freely in the direction to raise
the motor shaft to the primary sun gear, allows free
a load and lock up to force the brake discs to turn with
rotation. The sprag cams lay over and permit the inner
the shaft in the direction to lower a load. See Figure 2
race to turn free of the outer race. See Figure 2. The
and Figure 3.
friction brake remains fully engaged . The winch, in
The hydraulic cylinder, when pressurized, will release raising a load, is not affected by any braking action.
the spring pressure on the brake discs, allowing the See Figure 4.
brake discs to turn freely. When the lifting operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction.
Spring pressure prevents the brake discs from turning
This reversed input causes the sprag cams to instantly
until the hydraulic cylinder and pistan are pressurized ,
roll upward and firmly lock the shaft to the fully
releasing the brake.
engaged friction brake. See Figure 3.
40f 10
2 3
---
4 5
--- 6
Check Valve
Seated -/;~*==r;tt.';"~
Sprag
Clutch
7
Spool
Pressure
_ High
[1
D Low 8
When the control valve is placed in the lowering position, the spool within the brake valve remains
closed until sufficient pilot pressure builds and is applied to the end of the spool. Adequate pressure
to overcome the spring will shift the spool and open the passage.
1. Hydraulic Reservoir 3 Drum 5. Brake Valve 7. Control Valve

2. Winch Brake 4. Case Drain 6. Motor 8 Pump
Figure 5
Initial Lowering Sequence
When the winch is powered in reverse, to lower the When lowering a load very slowly for precise
load, the motor cannot rotate until sufficient pilot positioning, no oil flow actually occurs through the
pressure is present to open the brake valve. See winch motor. The pressure will build up to a point where
Figure 5 and Figure 6. The friction brake within the the brake will release sufficiently to allow the load lo
winch wllI completely release at a pressure lower than rotate the motor through its own internalleakage. This
that required to open the brake valve. The extent to feature results in a very slow speed and extremely
which the brake valve opens will determine the amount accurate positioning.
of oil that can flow through it and the speed at which the The friction brake receives very little wear in the
load will be lowered. Increasing the flow of oil to the lowering operation. AII of the heat generated by the
winch motor will cause the pressure to rise and the
lowering and stopping of a load is absorbed by Ihe
opening in the brake valve to enlarge, speeding up the hydraulic oil where it can be readily dissipated.
descent of the load. Decreasing this flow causes the
pressure to lower and the opening in the brake valve to
decrease thus slowing the descent of the load.
5 of 10
2 3 4 5
6
Check Valve
Seated -(;~:;===q.y¡Il=: • 1l
Sprag
Clutch
7
Spool
Pressure
11 High
LSJ
D Low 8
Adequate pilot pressure to the brake valve will shift the spool and open the passage, once enough back
pressure is available to lower the load smoothly. After the brake valve spool opens, the pilot pressure
beco mes flow dependent and modulates the spool valve opening which controls the lowering speed.
1. Hydraulic Reservoir 3. Drum 5. Brake Valve 7. Control Valve

2. Winch Brake 4. Case Drain 6. Motor 8. Pump
Figure 6
Continued Lowering Sequence
Wi nch Operation in the free rotaling direction of Ihe sprag clutch , driving
the gear train and winch drum . The friclion brake
The input section of the drive assembly is bolted to the
remains fully engaged .
motor end support and cannot rotate. The drive
ho using is the output member of the gear set and is In the lowering direction, oil flow Ihrough the motor is
bolted to the winch drum . The motor shaft is directly initially blocked by a spool in the brake valve . Oil
coupled to the primary sun gear through the inner race pressure supplied to the motor through the control
of the brake clutch. The motor turns the primary sun valve is piloted to the friction brak e and the brake valve
gear which drives three successive planetary gear spool. The friction brake is released at a lower
sets, turning the drive housing and the winch drum. pressure than that required to shift the brake valve
spool. When pressure is sufficient to shift the brake
In the hoisting direction , hydraulic oil flows through a
valve spool , oil is allowed to flow through the motor,
large check valve in the brake valve and turns the motor
rotating the winch gear train and drum.
60f 10
TROUBLESHOOTING
II a winch ever exhibits any sign 01 erratic operation, or load control difficulties
A DANGER (i.e. load creeping or chattering), appropriate troubleshooting tests and repalrs
should be performed immediately. Continued operation in this manner may re
sult in property damage, serious personal injury, or death.
TROUBLE PROBABLE CAUSE REMEDY

A Pi lot Oritice ~
The winch will nol lower Ihe load or not lower 1. The problem could be a plugged or
the load smoothly. loose pilot orilice. The pilot onlice is a
small pipe plug with a hole drilled
through il. It is located behind Ihe pilol
port litting on Ihe brake valve. (Applies
to motor and brake valve assemblies
as shown only.) II il becomes plugged,
it will prevenl Ihe pilol pressure, Irom
the manilold , Irom opening Ihe brake
valve. II it becomes loose, il will allow
an unregulaled amounl 01 oil in lo
operate Ihe brake valve which causes
erralic brake valve operalion.
Remove the pilol hose and fitting Irom the

brake val ve, Ihen use a 5/32 inch Alie n °
wrench lo remove Ihe pilot orifice . The diam e
ler 01 Ihe orifice is approximatel y 0.020 inch
(0.5mm) . Clean and inslall the pilot onfic o
tightly In the brake valve .
2. The Iriction brake may not be releasing Check brake cylinder seal as follows:
as a result 01 a delective brake
A. Dlsconnecl Ihe swivef lee Irom Ihe brake
cylinder sea!.
release port. Connect a hand pump wilh
Note: If the brake cylinder seal is accurale 0-2,000 pSI (0-73 790kPa)
defective you will usually find oil gauge and shut-off valve to Ihe 4 J I.C .
leaking from the winch vent plug. fitting in Ihe brake release port.
B. Apply 1,000 psi (6895kPa) to Ihe brake.
Close shut-off val ve and lel stand tor
live (5) minutes.
C. 11 there is any los s 01 pressure in live (5)
minules, Ihe brake cylinder should be
disassembled lor inspeclion 01 the
seallng surfaces and replacemenl 01 Ihe
seals. If available, reler lo "Winch
Counlerbalance Valve, Reconditlon "
lound in SM Keysheel Area 7-8.
3. Friclion brake will nol release as a Disassemble brake lo inspect brake discs
result of damaged brake discs. Check slack-up heighl as described in
"Wlnch, Recondition" lound in SM Keysheet
Area 5-6.
701 10
B
Oil leaks from vent plug. 1. Same as A2. Same as A2.
2. Motor seal may be defective as a result System back pressure must not exceed
01 high system back pressure or 150 psi (1 034kPa). Inspect hydraulic system
contaminaled oil. lor a restriclion in the return line Irom Ihe
conlrol valve to the reservoir. Be sure control
valve and plumbing are properly sized lO
winch motor.
Oil analysis may indicate conlaminalion has
worn motor shaft and seal. Thoroughly Ilush
entire hydraulic system and install new filters
and oil. Install new molor seal.
e
Thc bra ke will not hold a load with the conlrol Excesslve syslem back pressure Same as remedy 2 01 Trouble B2.
lever in neutral aCling on Ihe brake release port .
2 Friction brake will nol hold due lo worn Same as Remedy 3 01 Trouble A3.
or damaged brake discs.
3. Brake clulch is slipping. Improper planelary gear oil may cause Ihe
brake clutch lo slip. Drain old gear oi l and
Ilush winch with solven!. Thoroughly drain
solvenl and relill winch wilh recommended
planelary gear oil listed in Ihe Operator's
Manual.
Brake clulch may be damaged or worn . Dis

assemble and Inspecl brake clutch Refer to
"Winch, Recon d ition" in SM Keysheet Area
5-6 .
o
The winch will nol hoisl the rated load. The winch may be mounted on an Reinlorce mounting surface.
uneven or flexible surface which
II necessary, use shim stock lo level winch .
causes distortion of Ihe winch base
Reler to "Winch, R & 1" in SM Keysheet Area
and binding 01 Ihe gear Irain. Binding
5 - 6.
in Ihe gear train will absorb horse
power needed to hoisl the rated load Firsl loosen , then evenly lighten all winch
and cause heal. mounting bolts to recommended torque.
2. System relief valve may be set loo low. Check winch relief pressure as specilied in
Relief val ve needs adjustment or Ihe Operalor's Manual.
repair.
Note : 1I pressure does not increase in pro
portion to adjustment, reliel valve may be
contaminated or worn out. In either case,
the reliel valve may require disassembty or
TROUBLE "D" CONTINUED NEXT PAGE reptacement.
8 of 10
TROUBLE " D" CONTINUED FROM 3. Be cena in hyd raulic sys lem temper Same as remedies lor Trouble 01 & 02.
0
PREVIOUS PAGE ature is no t more th an 180 F (82 oC)

Same as remedies lor Troub le E2
Excess ive hyd rau li c oil tempe ratures
in crease mo tor in ternal leakage and
reduce motor performance.
4. Winch line p ull rating is based on 1st Reler to winch performance charts, located in
layer 01 wire rope. the Crane Rahng Manual, lor additional inlor
matio n.
5. Riggin g and sheaves not opera ti ng Perform riggi ng service as shown in the
efficien lly. Opera tor's Manual.
E
Th e winch runs ho!. 1. Same as 0 1 Same as remedies fo r Trouble 0 1.
2. Be cenain that the hyd raulic sys tem

0
temperature is not more than 180 F
(82 oC) Excessive hydraulic oi l tem
pera tures may be caused by:
A. Pl ugged heat exchanger. Thoroughly clean ex terior and flu sh interi or.
B. Too 101'1 or too high oil level in Fill/draln to proper leve !.

hydraulic reservoir.
C Same as 0 2. Same as remedies lor Trouble 02
O. Hydraullc pump not operating Prime mover low on ho rsepower or RPM 'S.
efficienlly. Tune/adjust prime mover.
Check suction line lor damage.
If pum p is belt dri ven, belts are slipping Re
p lace/ti gl1 ten belts.
Pum p worn. Rep lace pump.
3. Excessivel y worn or damag ed internal Oi sassemble winch to inspec tJrep lace worn
winch pans . pa ns. See "Winch, Recondition " SM Key·
sheet Area 5-6 lor the correct procedure .
9 of 10

F
Winch "chatters" while raising rated load . 1 Same as 02. Same as remedies lar Trouble 02.
2. Hydraulic oil Ilow to motor may be too Same as remedies lor Trouble E2.
low.
3 Controls being operated too quickly. Conducl operalor Iraining as required .
G
The wire rope does not spool smoolhly on Ihe 1. The winc h may be moun ted lOO close Check mounling dis tance and Ileel angle.
drum . lO the main sheave, causing Ihe Ileet Reposilion winch as required.
angle lo be more Ihan 1- 1/2 degrees.
2. The winch may nOI be mounled Reler lO "Winch , R & 1" . See SM Keysheel
perpendicular lO an imaginary line Area 5- 6.
belween Ihe cenler 0 1 Ihe cable drum
and the lirsl sheave.
3. Could possibly be using Ihe wrong lay Consull a Link- Bell ® Oislribulor lor recom
rope. There is a distincl advanlage in mendalion 0 1 wire rope Ihal besl suilS your
applying rope 01 Ihe proper direclion applicalion.
01 lay. When Ihe load is slacked off, Ihe
several coi ls on Ihe drum will sl ay
closer logelher and mainlain an even
layer. II rope 0 1 improper lay is used ,
Ihe coils will spread apart each time Ihe
load is removed. Then , when winding
is resumed, Ihe rope has a lendency 10
criss - c ross and overlap on Ihe drum.
The result is often a Ilattened and
crushed rope .
4. The winch may have been overloaded, Replace wire rope and conducl operalor or
causing permanenl sel in Ihe wire rigger Iraining as required .
rope .
10 of 10
Winch Assembly, R & I
A WARNING
the winch assembly. Although the crane may be
equipped with two winch assemblies, removal and
installation is basically the same . For recondition
engine and exhaust all trapped hydra ulic
procedure, see SM Keysheet Area 05-006.
pressure from the system before removi ng
A WARNING
Removing either winch drastically alters the
5. Relieve the hydraulic system pressure as lollows :
crane's capacities. The values listed in the reservoir by slowly loosening the liller/breather
Crane Rating Manual are no longer valid once cap, located on the top 01 the hydraulic
either winch is removed . Do not attempt to reservoir, until pressure is lully relieved .
make any lifts once either winch is removed. b. Turn the ignition switch to "ON", but DO NOT
STARTTHE ENGINE. Move the lunction lock
Removal c . Wark the crane control levers and outrigger
1. Lower, detach, and secure the load, as required. switch es back and forth several times.
2. Stabilize the crane lar service as lollows: d . Turn the ignition switch to the "OFF" position.
a. Park the crane, out 01 the way, on a lirm and 6. Check that all control levers are in the neutral
level surlace . position and move the lunction lockout switch to
b. Engage the park brake and/ar properly block the "DISABLE" position.
the tires . 7. Remove the wire rope Irom the winch . See the
c. Engage the swing park brake ar travel swing Operator's Manual lor the correct procedure .
lock, as required . 8. Label, lor assembly purposes, and disconnect the
d . Level the crane on lully extended outriggers. electrical connections Irom the drum rotation
e. Fully retract and position the boom , as re indicatar, as applicable.
quired. Reler to Figure 1.
3. Shutdown the engine and disengage the main 9. Label lar assembly purposes and disconnect the
hydraulic pump , as equipped . hydraulic lines (not shown) from the hydraulic
motor (4). Cap/plug the open hydraulic ports and
A WARNING
lines (not shown) to prevent excessive oilloss and
contamination 01 the system.
Note: The winch assembly weighs appr oxi

mately 1,270 lb (576kg) .
and follow all the manufacturer's 10. Adequately support the winch assembly (1) with
recommendations concerning solvents and an appropriate lifting device .
cleaning solutions. 11. Remove the capscrews and washers (3) that
secure the winch assembly (1) to the upper Irame
4. Thoroughly clean the area to be disassembled with (2) .
an approved cleaning solvent to prevent 12. Remove the winch assembly (1) Irom the upper
contamination . Allow the area to air dry. Irame (2).
1 014
S 05-006-038.00 1006 Service Manual
SINGLE WINCH SETUP DUAL WINCH SETUP
1. Winch Assembly 2. Upper Frame 3. Capscrews & Washers 4. Winch Motor
Figure 1
Winch Assembly
2 of 4
A WARNING
A WARNING
hazardous. Serious personal injury may compounds, etc, can be hazardous. Serious

an approved cleaning sOlvent, air dried, and care Note: The winch assembly weighs app roxi .
fully inspected . mately 1,270 lb (576kg),
2. AII Loctite@, Permatex@, or other sealant residue
should be removed from threads of hardware and Refer to Figure 1.
the mounting surfaces of parts that are going to be 1. Using an auxiliary lifting device, position the winch
reused. Prior to applying new thread locking com assembly (1) to the upper frame (2), aligning the
pounds or sealants , clean threads and surfaces holes for the mounting hardware.
with Loctite@7070 Cleaner to ensure best perfor 2. Apply Loctite® 242 to the threads of the capscrews
mance of products . (3) .
3. Thoroughly inspect all parts for damage, wear, fa 3. Secure the winch assembly (1) to the upper frame
tigue or stress fractures , and corros ion . Repair or (2) by installing th e capscrews and washers (3) .
replace as required . Torque the capscrews (3) to 795-875 ft lb
4. AII "soft parts" , such as seals, gaskets , back up (1 078-1 187Nm).
rings , and o-rings , should be replaced. 4. Connect the hydraulic lines (not shown) to winch
5. Inspect the integrity of th e hydraulic lines that are motor (4).
connected to the winch motor. Repair or replace if 5. Check and/ or fill the winch drum with lubricant.
required. See the Operator's Manual for the correct type and
6. Inspect the integrity of the electrical connections procedure .
that supply the drum rotation indicator, as app lica 6. Connect th e electrical connections to the drum
ble. Repair or replace if required . rotation indicator, as app licab le .
7. In the event of severe defects, contact factory per 7. Check the hydraulic reservoir oil level. Add oil as
sonnel for directions whether to repair or replace required . See the Operator 's Manual for the
any major component. correct type and procedure.
units , engine crankcase , radiator, etc. Reler to the
crane or engine Operator 's Manual lor correct
type/ quantity 01 Iluids and proper procedure .
9. II equipped with pump disconnect, engage the
main hydraulic pump , as equipped.
10. Start the engine and let idle lor live minutes .
Inspect the hydraulic connections lor leaks .
11 . Install the wire rope on the winch assembly. See
the Operator's Manual lor the correct procedure.
12. Complete the installation by testing all related lunc
tions 01 the winch lor proper operation . Normalop
eration 01 hydraulic and electrical systems shou ld
be conlirmed . A general inspection 01 compo
nents and systems in the areas adjacent to the re
pair should also be performed to ensure related
3014
4 of 4
a. Ensure capscrew (21) is tightened securely in
Winch Roller, Recondition torque shaft (19) .
This procedure covers the removal , installation , and b . Using a breaker bar or long handle wrench and
capscrew (21), hold tension on torsion spring
reconditionlng of the winch ro lIe r. Tension on torsion
(18) while loosening the setscrews (12) on
spring must be fully relieved before servicing .
both ends of torque shaft (19).
c. Allow torque shaft (19) to rota te counterclock
A WARNING
wise, as far as possible while maintaining con
trol of the torq ue shaft (19). then secu rely tig ht
en setscrews (12).
Do not attempt to service winch roller befo re
properly relieving torsion spring tension. If d. Reposition breaker bar or wrench on
proper directions are not followed, the torsion capscrew (21).
spring could rapidly and forcefully uncoil. e. Repeat steps b thru d until tension is fully
This may result in serious personal injury and relieved from torsion spring (18) .
component damage. Always release tension Refer to Figure 2 .
on torsion spring before attempting any winch 7. If equipped, remove 3rd wrap indicator assembly
roller repair. (2) from winch roller assembly (1) by removing
capscrews, washers , and locknuts (3) .
Removal Note: The winch roller assembly weighs

approximately 75 lb (34kg).
1. Lower, detach , and secure load , as required .
2. Stabilize the crane for service as follows: 8. Using an auxiliary lifting device and slings , support
a . Park the crane, out of the way, on a firm and winch roller assembly for removal.
level surface.
b . Engage the park brake andjor properly block Refer to Figure 1.
the tires. 9. Remove capscrews and washers (11) securing
c . Engage the swing park brake or travel swing winch roller assembly to winch frame (1) .
lock , as required. 10. Remove winch roller assembly from crane.
e . Fully retract and pos ition the boom , as Disassembly
required .
3. Shutdown the engine and disengage the main It is a good practice when disassembling compl ex
hydraulic pump . components to lay the parts out in the order that th ey
4. Check that all control levers are in the neutral were disassembled. Keeping the parts in this order
position and move the function lockout switch to during disassembly, cleaning, and inspection will aid in
the " OISABLE " position. the assembly process.
A WARNING
A WARNING
and fOllow all the manufacturer's
cleaning solutions.
cleaning solutions.
1. Thoroughly clean the exterior surface of the winch
approved cleaning solvent. Allow the area to air
roller assembly to prevent contamination from
dry.
entering it.
Refer to Figure 1.
Refer to Figure 1.
6. Properly release tension on torsion spring (18).
2. Index mark roller arms (15) and torque tube (17) to
Th e following procedure is greatly simplified by
ensure proper orientation of parts during
using two service technicians. One to hold the assembly.
breaker barj wrench , the other to loosen and
3 . Remove setscrews (12) and supports (3) from
tighten setscrews (12).
torque shaft (19) .
1 of 4
10
17
11
1. Wi nc h Frame 8. Ball Bearings 15. Roller Arms

2. Drum 9. Shaft 16. Bushings
3. Supports 10. Roller 17. Torque Tube
4. Collars 11. Capscrews & Washers 18. Torsion Spring
5. Capscrews 12. Setscrews 19. Torque Shaft
6. Retaining Rings 13. Setsc rews 20. Capscrew & Spacer
7 Washers 14. Thrust Washers & Needle Bearing s 21 . Capscrew
Figure 1
Winch Roller Assembly
2 of 4
4. Remove setscrews (13) , collars (4) , and thrust
washers and needle bearings (14) from torque
shaft (19) .
5. Remove capscrew and spacer (20) and slide
torque shaft (19) from torque tube (17) . Remove
capscrew (21) from torque shaft (19), if required.
6. Remove capscrews (5) from torque tube (17) and
separate torque tube (17) from roller arms (15) .
7. If required , use a shop press to remove bushings
(16) from torque tube (17), if required .
8. Remove retaining rings (6), roller arms (15), and
washers (7) from shaft (9). Remove shaft (9) from
roller (10) .
9. Remove ball bearings (8) from roller (10) .
Cleaning And Inspection 2 3

1. Wi n ch Roller Assemb ly
A WARNING
2.
3.
3rd Wrap Indica to r Assembly
Capscrews, Washers, & Loc knuts
Figure 2
hazardous . Serious personal injury may Optional 3rd Wrap Indicator Assembly
recommendations concerning solvents and Assembly
cleaning solutions.

cleaning solvent. Place parts on a clean , lint free
A WARNING
surface and allow to air dry. Exercise every compounds , etc . can be hazardous. Serious
precaution possible to keep all parts free of dust , personal injury may result from misuse of
dirt , or any other foreign material during assembly. these products. Read and follow al!
2. AII Loctite ' , Permatex" , or other sealant residue manufacturer's recommendations concerning
should be removed from threads of hardware and these products.
parts that are going to be reused .
3. Carefully inspect all components for damage ,
wear, fatigue or stress fractures, corrosion , deep
scratches, cracks, and scuffed metal. Remove any
CAUTION
burrs or sharp edges with a fine file , hone , emery Be sure to use the proper bearing driver to
cloth , or crocus cloth. Replace a ny damaged install the ball bearings into the roller. The ba ll
component , as required. bearings are factory lubed and seale d .
4. Bearings should not exhibit any irregularities . Integral seal and/or bearing damage can
Replace if any signs of spalling , corrosion , result from improper installation.
discoloration , material displacement, or integral
seal leakage exist. If bearing replacement is Refer to Fig u re 1.
required , replace with only genuine replacement 1. Using the proper bearing driver, install ball
parts. bearings (8) in roller (10).
5. Inspect the integrity of the torsion spring . If 2. Install shaft (9) in roller (10). Install washers (7) and
damage is apparent, replace the entire torque tube roller arms (15) on sh aft (9) and secure with
assembly. retaining rings (6) .
6. In the event of severe defects, contact factory 3 . Using a shop press , install bushings (16) in torque
personnel for directions whether to repair or tube (17) , as required ,
3 of 4
4. Pos ition torquQ tubQ (17) bQtwQQn rollm arms (15) . Installation
Applya light coat of Loctite ,n, 242 to threads of and
install capscrews (5) .
5 . Coat bushings (16) , thrust washers (14) , and
torque shaft (19) with an anti-seize compound.
6 . If removed, install capscrew (21) in end of torq ue
A WARNING
shaft (19). Insert torque shaft (19) into torque tube compounds, etc. can be hazardous. Serious
(17) and rotate torque shaft (19) to align the to rsion personal injury may result from misuse of
spring and hole for installation of capscrew (20) . these products. Read and follow all
Note: The head of the capscrew must not hit the these products.
inside of the torque tube once properly
installed . The torque shaft must rota te freely
from the torque tube. Refer to Figure 1.
7. Apply a light coat of Loctite'e' 242 to threads of Note: The winch roller assembly weighs
capscrew (20). Install capscrew and spacer (20) approximately 75 lb (34kg) .
until the head of the capscrew is below the inner
1. Using an auxiliary lifting device and slings, lift
surface of the torq ue tube (17) .
winch roller assembly onto crane.
8. Install needle bearings and thrust washers (14)
2 . Loosen setscrews (12) and align supports (3) to
and collars (4) on torque shaft (19) . Install
winch frame (1) . Install capscrews and washers
setsc rews (13) in collars (4).
(11). Before tightening capscrews and washers
9. Position s upports (3) over the ends of the torque
(11), be s ure roller (10) is parallel to the surface of
shaft (19) and loosely install setscrews (12) to
the drum (2).
secure supports (3) to the assembly.
3 . Properly center, adjust, and tension winch roller
assembly. See Operator's Manual for correct
procedure.
Refer to Figure 2.
4. If equipped, align 3rd wrap indicator assembly (2)
to winch roller assembly (1) and install capscrews ,
washers , and locknuts (3).
5. Properly adjust 3rd wrap indicator assembly (2) .
See Operator's Manual for correct procedure .
6 . Start the engine and let idle for five minutes .
functions of the winch roller for proper operation .
Normal operation of hydraulic , air, and electrical
systems should be confirmed. A general
performed to ensure related damage orwear is not
present.
4 01 4
Throttle Treadle Assembly,
R& I
the throttle treadle assembly. For recondition
procedure, il available, see SM Area 06-008. ¡
Removal
1. Lower, detach, and secure load, as required. I _.
2. Stabilize the crane lor service: Park the crane out

01 the way on a lirm and level surface, engage the I
park brake or properly block the tires, engage the

travel swing lock, level the crane on lully extended
'~\ 1 ~ \
outriggers, and/or lully lower the boom, as re 5 4
quired.
"DISABLE" position. 1. Base Plate 3. Connector 5. Clamp & Screw
4. Shutdown the engine and disengage the main hy 2. Treadle 4. Capscrews
draulic pump. Figure 1 S000279
5. Remove clamp and screw (5) Irom base plate (1). Throttle Treadle Assembly
6. Unplug connector (3) Irom socket.
7. Remove capscrews (4).
8. Remove treadle (2) and base plate (1) as an as
Installation
sembly.

A WARNING
A WARNING
hazardous. Serious personal injury may these products. Read and follow all
result from misuse of these products. Read manufacturer's recommendations concerning
and follow all the manufacturer's these products.
cleaning solutions. 1. Align treadle (2) and base plate (1), as an assem
bly, to mounting holes in cab Iloor.
1. AII components should be thoroughly cleaned with 2. Applya light coat 01 Loctite' 242 to the threads 01
an approved cleaning sOlvent, air dried, and care the capscrews (4).
lully inspected. 3. Install capscrews (4).
2. AII Loctite residue should be removed Irom 4. Install clamp and screw (5) in base plate (1).
threads 01 hardware and parts that are going to be 5. Plug connector (3) into socket.
reused. 6. Complete the installation by testing all related lunc
3. In the event 01 severe delects, contact lactory per tions 01 the throttle treadle assembly lor proper op
sonnel lor directions whether to repair or replace eration. Normal operation 01 and electrical sys
any major component. tems should be conlirmed. A general inspection 01
4. Inspect integrity 01 wire harness and connectors. components and systems in the areas adjacent to
Repair as required. the repair should also be performed to ensure re
lated damage or wear is not present.
1 012
• o·· ."
2 of 2
4 5 6 7 8 9 10 11
y y
e 1
~ i
r Y i
__
11 1
I 11 [
1 J
r-
1'=· ' '''- ,'
r~ .~-,. <
I).'_~ . j
l ' I ) eG . _~ IIU.·
~/ - i f' 1 "'--"¡- - - 14
27 / l'
26 1 ,I
25 - - - ~
1 .,
24 ~ - ....--~
o y J==--=-==':
. 1 - 01
~
_.~
. r>'~ r~ o .
t¡.~J . .
~'I ' - .•:f
~>. .
23 22 21 20 19 18 17 16 15
1. Nuts 8. Nuts 15 Capscrews 22 . Foam

2. Screws 9. Foam 16. Screws 23 . Foam
3. Washers 10. Foam 17. Housing 24 . Evaporator Coil
4. Housing 11. Foam 18 Brackets 25. Screws
5 Foam 12. Thermostat Switch 19 O-rings 26 . Washers
6. Blower 13 Wire Harness 20 Valve Block 27 . Screws
7. Capscrews 14. Tubing - 12" 21 Eva porator Coil
Figure 1
Heater Core And Air Conditioning Evaporator Coil , Illustrated
1 012
See SM Keysheet Area 18-018 for general
Heater Core And precautions regarding air conditioning service,
Ai r Conditioning Evaporator
Coil, IIlustrated CAUTION
Heat exchange fins on the heater core are very
The intent of this doeument is to illustrate the serviee
delicate. Even a minor bump can cause a
parts of the air eonditioning eoil and heater eore deformation of the fins which reduces the
assembly and provide some basie preeautionary
efficiency of the heater and adds potential for
information, For removal and installation proeedures,
leaks. Be very careful notto deform the heater
see SM Keysheet Area 06-025,
core fin s during heater removal, installation,
Note: Maintenance and repair procedures for any and storage.
ai r conditioning or refrigeration system should only
be performed by a certified technician, Safetyand It is a good praetiee when disassembling hydraulie
environmental concerns must be considered due to eomponents to lay the parts out in the order that they
the working fluid used in these types of systems. were disassembled. Keeping the parts in this order
Refrigerant used in the air conditioning system during disassembly, eleaning , and inspection will aid in
must not be allowed to escape into the atmosphere. the assembly process ,
Rather it must be recovered into a closed container
or "re~laimed" to ensure the safety of individuals
and the environment.
A WARNING
Precautionary Information hazardous. Serious personal injury may
A WAnNING
Refrigerants are under pl"essure and can be
recommendations concerníng solvents and
cleaning solutíons.
hazardous. A sud den release of refrigerant
could cause chemical burns, frostbite, or
Prior to disassembly, allow any excess coolant to drain
other serious injury. Shutdown the engine and from the unit into an appropriate container. Properly
properly "reclaim" the refrigerant from the
store or dispose of the used fluid,
system befo re removing any line or
component. Read and follow all of the
ma nufactu rer' s reco mmendatio ns
concerning use and storage of refrigerants.
2 of 2
Servilce Manual 0610 SM06-025-023.00
3. Shutdown the engine .
Upper Cab A/C Coil & 4. Evacuate the refrigerant from the air conditioning
Heater Core, R & I system by reclaiming the refrigerant into an ap
proved closed container.
Maintenance and repair procedures for any air
Refer to Figure 1.
conditioning (A/C) or refrigeration system should only
5. Remove the screws(5) which secure the fan (4) to
be performed by a certified technician. Safety and
the top of the console (3).
environmental concerns must be considered due to
the working fluid used in these types of systems.
electrical connection (not shown) from the fan (4)
Refrigerant used in the air conditioning system must
and remove the fan (4) from the console (3).
not be allowed to escape into the atmosphere. Rather,
7. Remove the screws (2) and cover panel (1) from
it must be recovered into a closed container or
the console (3).
"reclaimed" to ensure the safety of individuals and the
environment.
electrical connection (not shown) from the
evaporator coil and heater core assembly (6).
A WARNING
hazardous. A sudden release of refrigerant
A WARNING
could cause chemical burns, frostbite or other Engine coolant is hot. Failure to allow engine,
serious InJury. Shutdown the engine and radiator, and heater to sufficiently cool before
properly "reclaim" the refrigerant from system draining coolant could result in burns or other
before removing any line or component. Read personal injury. Allowthe engine and rad iator
and follow all of the manufacturer's to cool before removing pressure cap and
recommendations concerning use and storage hoses or draining coolant from the radiator.
of refrigerants.
9. Allow sufficient time for the engine and radiator to
This procedure covers the removal and installation of cool before removing pressure cap and hoses or
the upper cab evaporator coil and heater core draining coolant from the radiator.
assembly. For an exploded view illustration of the 10. Label for assembly purposes and disconnect the
assembly, see SM Keysheet Area 06-025 . For general A/C hoses (8) from the evaporator coil and heater
precautions regarding air conditioning service, see SM hoses (7) from the heater coreo Cap/ plug the open
Keysheet Area 18-018. ports and hoses (8,7) to prevent excessive coolant
loss or contamination of the system .
Removal 11. Allow any excess coolant to drain into an
appropriate container. Properly store or dispose of
the used fluid .
a. Park the crane, out of the way, on a firm and 12. Remove the capscrews and washers (11) securing
the evaporator coil and heater core assembly (6) to
level surface. Engage the park brake and/or
the mounting bracket (10).
properly block the tires.
13. Remove the locknuts and washers (9) seeurin g the
b. Level the crane on fully extended outriggers .
c. Position the upper frame , as required, to opti evaporator coil and heater eore assembly (6) to the
inside of the eonsole (3).
mize access to hose connections on the bot
tom of the upper cabo Engage the swing par k 14. Remove the evaporator coil and heater core
assembly (6) from the upper cabo
brake or travel swing lock, as required.
d. Fully retract and position the boom, as re
quired.
1 of 4
~I
3
11
6-~
, .~
" I :7
7 - -_ __
1. Cover Panel 5. Screws 9. Washers & Locknuts

2. Screws 6. Evaporator Coil & Heater Core Assy 10. Mounting Bracket
3. Console 7. Heater Hoses 11 . Capscrews & Washers
4. Fan 8. A/C Hoses
Figure 1
Upper Cab Evaporator Coil & Heater Core Assembly
2 of 4
A WARNING
A WARNING
Maintenance and repair procedures for any
hazardous. Serious personal injury may air conditioning (A/C) or refrigeration system
result from misuse of these products. Read should only be performed by a certified
and follow all the manufacturer's technician. Safety and environmental
recommendations concerning solvents and concerns must be considered due to the
cleaning solutions . working fluid used in these types of systems.
Refrigerant used in the air conditioning
1. AII components should be thoroughly cleaned wilh system must not be allowed to escape into the
an approved cleaning sOlvenl, air dried , and care atmosphere. Read and follow all of the
fully inspected. manufacturer's recommendations concerning
2. AII Loctite®, Permatex®, or other sealant residue use and storage of refrigerants. For general
should be removed from threads of hardware and precautions regarding air conditioning
the mounting surfaces of parts that are going to be service, see SM Keysheet Area 18-018.
pounds or sealants, c lean threads and surfaces Refer to Figure 1.
with Loctite® 7070 Cleaner to ensure best perfor 1 . Position the evaporator coil and heater core
mance of products . assemb ly (6) within the console (3) and mountin g
3. Thoroughly inspect all parts for damage, wear, fa bracket (10) .
tigue or stress fractures , and corrosion. Repa ir or 2. Install the washers and locknuts (9) to secure the
rep lace as required. evaporator coil and heater core assembly (6) to the
4. AII "soft parts", such as seals, gaskets, back up inside of the console (3).
rings, and o-rings, should be replaced. 3. Install Ihe capscrews and washers (11) securin g
5. InspecI the integrily of the hoses that are con the the evaporator coil and heater core assembly
nected to the evaporator coil and heater core as (6) to the mounting bracket (10).
sembly. Repair or replace if required.
6. InspecI Ihe inlegrily of Ihe eleclrical wires and con Note: If required, place two washers between
nectors that attach lO Ihe evapora lor coil and heat the mounting bracket and evaporator coil and
er core assembly. Repair or replace if required . heater core assembly at each location . The re
7. Inspect the integrity 01Ihe weatherstripping on the maining washers will be located on the outside
cover panel and console . Repair or replace il re of the mounting bracket against the heads ofthe
quired. capscrews.
8. In the event 01 severe delects , contact lactory per
sonnel lor directions whether to repair or rep lace 4. Connect Ihe hoses (7 ,8) lo the appropriate
an y major componen!. locations on the evaporalor coil and heater core
assembly (6).
5. Connect the electrical conneclion (not shown) lO
the evaporator coi l and heater COre assembly (6) .
6. I nsta ll the cover pane l (1) on the console (3) and
secure with screws (2) .
3 of 4
7. Make the electrical connection (not shown) to the 11 . Start the engine and let idle far five minutes.
fan (4) and position the fan (4) on the console (3). 12. Test all related lunctions of the upper cab air condi
8. Install the screws(5) which secure the fan (4) to the tioning and heater to ensure proper operation and
top of the console (3). installation. See the Operator's Manual lar the cor
9. Charge the air conditioning system with refriger rect operating procedures.
ant. 13. Inspect all connections for leaks. Repair leaks as
10. Check the engine coolant leve!. Add coolant as re required.
quired. See the Crane Operator's and Engine
Manufacturer's Manual for the correct type and
procedure.
4 of 4
10
___ 2
1. Control Unit 5. Exhaust Oullet Pipe 8. Circulation Pump

2. Heat Exchanger 6. Fuel Inlet Tube 9. Combustion Air Inlet Connection Pipe
3. Burner Housing 7. Coolant Inlet Connection Pipe 10. Combustion Air Fan
4. Coolant Oullet Connection Pipe
Figure 1
Webasto Diesel Coolant Heater
Diesel Coolant Heater, Troubleshooting

General Information
Troubleshooting & Troubleshooting is normally limited to the isolation of
Recondition defective components and provides information on
defective wiring and connections. The following
This procedure covers the troubleshooting and possible causes for problems have not been taken into
consideration and must always be included as a
reconditioning of Webasto diesel coolant heaters.
possible cause for malfunctions:
For removal and installation procedures, see SM
Keysheet Area 06-025. • Power supply to heater is less than 10.5 volts at
main power connections. See Figure 2 for refer
ence to power connections .
A WARNING • Blown or missing fuses. See the Crane Operat

or's Manual and electrical schematic for location
The diesel coolant heater may be hot. Failure and identification of fuses .
to allow sufficient time for cooling could result • Proper duct work connections and placement of
in burns or other personal injury. Allow the insulation in tlle cabo
heater to cool before servicing. • Tlle heater is in "Lockout " mode. See Heater
Lockout Resetting on page 3,
• Fuel supply (no fuel, shutoH valve closed , incor
Note: For best performance of the heater, kerosene rectly installed or obstructed fuel filter) . Refer to
is the recommended fu el in ambient temperatures Figure 3.
below 20°F (-l °C) . • Contaminated or improper fuel (Use #1, #2, or
arctic grade diesel fuel or kerosene), Kerosene
is the recommended fuel for use in ambient tem
peratures below 20°F (_7°C).
1 of 18
BLK
Coolant
Circulation Temperature
Pump Sensor
Combustion
Air Fan
Ceramic
Ignitor/Flame
Sensor
620 Sf'1ED
12 Volt
Power Supply
602R BLK
Top Of Heater
With Connectors
Removed
~
Diagnostic
Connector
1-Way t
602N BRN
* This wire may be located in Terminal 3 on some earlier model cranes. Improved heater performance
may be achieved by relocating this wire to Terminal 1 . See Wire Harness Rework on Page 12 for the
complete procedure for relocating this wire.
t Some cranes may not have a diagnostic connector included in the external diesel heater wire harness .
This connector and wire number 602U VIO is necessary to implement a Personal Computer in the
troubleshooting process. If this wire assembly is not available, a diagnostic wire and connector can
be added to the existing wire harness using Link-Belt part number N4R0150. See Wire Harness Rework
found on Page 12 for the complete rework procedure.
Fig ure 2
Webasto Diesel Coolant Heater Electrical Schematic
2 of 18
Theory of Operation
Heater Operation
When the heater is turned on and operating normally,
after the coolant temperature reaches 144°F (62°C)
the heater switches to the energy saving part load
operation. A rise in coolant temperature up to 162°F
(72 OC) causes the heater to enter a control idle periodo
The circulation pump and the operation indicator light
remain on during control id le. After cool-down ofthe
coolantto 140°F (60°C), the heater resumes part load
operation. Another rise in coolant temperature to
162° F (72 OC) causes the heater to enterthe control idle
period again. A drop in the coolant temperature during
part load operation due to an increased demand in
heat will cause the heater to switch to full load 1. Healer Fuel Tank 3. Shuloff Valve
operation at 133°F (56°C). 2. Fuel Filler 4. Fuel Pump
Heater Shutdown Figure 3

ical Fuel Line Com nents
When the switch is turned off, combustion terminates
and shutdown (after-run) phase starts. The
The following procedure will clear the lockout mode
circulation pump and the combustion air fan continue
and reset the heater for normal operation.
operating during the shutdown phase to cool the
heater down and wlll be automatically switched off after 1. Shutdown the engine but leave the ignition key in
cool down. The duration time and the combustion air the on position.
fan speed during the shutdown phase depend on the 2. Ensure that the heater control switch, in the cab, is
heater operating condition at the time the heater is in the off position; wait 5 seconds. See the Crane
turned off. Operator's Manual for complete heater operating
instructions.
Shutdown time normally lasts 180 seconds (3 minutes)
3. Turn heater control switch, in the cab, tothe on po
when deactivated in full load operation and 100
sition; wait at least 5 seconds.
seconds (1.6 minutes) when deactivated in part load
4. Disconnect power from the heater unit by one of
operation. Some units' shutdown periods are
the following methocls:
programmable and may vary.
a. Unplug the "X2" connector from the heater
Heater Lockout Resetting unit. Refer to Figure 2 for the heater electrical
schematic.
The diesel coolant heater is designed with a lockout b. Turn the battery disconnect switches to the
safety feature built into the control unit. After three "OFF" position.
consecutive, unsuccessful startup attempts, the C. Remove the appropriate fuse for the diesel
heater willlock itself out from any further start attempts. heater from the fuse panel in the cabo
The heater may also enter the lockout mode after 5. Wait at least 5 seconds.
experiencing an overheat condition. 6. Reconnect the power to the heater unit.
7. Cycle the heater control switch, in the cab, off for 5
seconds and then back to the on position.
8. Again, disconnect power from the heater unit; wait
at least 5 seconds.
9. Again, reconnect the power to the heater unit. The
heater should attempt to start within 10 seconds
after the power is connected.
10. The lockout mode should now be cancelled and
the diesel coolant heater should operate normally
or be ready to analyze with the troubleshooting
procedures outlined.
3 of 18
J'{(!
. P,
~~:@ "/
1 - Way Diagnostic Connector
PC Diagnostics Wire 602U VIO
Interface Cable OR
(Pa rt of Kit 3N 1330)
•,. Retrofitted N4R0150
- N
~
11'"
Interface Cable
"'/ ~
Adaptor (~~~~:.
¡.:.:-¡
(3N1331) 6-Way
Heater's External
~~::{~::. {::{~-
Connector
Installed
Wire Harness :;:{{.d:W On Top Of
Heater
Figure 4
Typical Diagnostic Cable Connection
Personal Computer Diagnostics The pe Diagnostic Interface Kit (Link-Belt part number
It is possible to read and remove (reset) stored fault 3N 1330) comes complete with pe interface cable,
codes from the diesel coolant heater's electronic software, and instructions. Also required is an
memory. This is achieved through the use of a interface cable adaptor which must be ordered
diagnostic interface kit connected to the diesel coolant separately; (Link-Belt part number 3N 1331).
heater and a compatible personal computer (PC) Note: The diesel heater's external wire harness
having the necessary software installed. must be equipped with wire number 602U VIO and
its 1-way diagnostic connector. This wire as
In addition to working with stored fault codes, the pe sembly is where the interface cable and adaptor are
Diagnostic Interface Kit provides several other installed. So me wire harnesses do not have this
fu nctions such as reading values while the heater is in wire assembly and must be reworked with Link-Belt
op eration or testing individual components. Printing part number N4R0150 in order to accommodate the
out fault codes is also possible when the computer is PC Diagnostic Setup. See Wire Harness Rework on
con nected to a compatible printer. Page 12 for complete rework instructions.
For further capabilities and instructions, see the

instruction manual supplied with the pe Diagnostic
Interface Kit.
4 of 18
NO
Did heater attempt to start?

(Combustion lan running) -- Check for l2Volts at heater
connector Xl , pin 1 or pin 3,
as equipped, with switch on.
-- Repair or replace harness,
connectors, fuse, or switch,
as required
,,
Check lor l2Volts at heater
connector X2, pin 1 with
switch on.
-- Repair or replace harness,
connectors, or fuse, as
required.
,,
Check for ground at heater Repalr or replace harness,
connector X2, pin 2.
- connectors, as requlred.
,f
VES
,,
Is combustion air intake free
from damage and
obstruction? -
.... Repair or replace air intake
tube or remove obstruction,
as required.
,r
Is combustion exhaust pipe
free from damage and
obstruction?
-- Repair or replace exhaust
pipe or remove obstruction,
as required.
,r
Continues
In
Figure 6
Figure 5
Troubleshooting - Continues in FiQure 6
5 of 18
NO
Continued
from
Figure 5
-... ...
-
Is luel available to fuel Check fuel lank , shuloH Repair or replace fu el tank ,
pump? va lve, in-line filters, lines, shutoH va lve, or in-line
and supply lines ror filters, as required .
conlaminalion or blockage.
Does fuel pump op erate

(clicking sound) du(ing
start-up cycle approximately
...
- Connect vollmeter
to fuel pump
leads. Does the
- Fuel pump
connections
sound and
...
- Repair or
replace wire
harness, as
30 seconds after swilch ing signal blink slowly harness free required
heater on? after 30 seconds or damage?
from switching
heater on?
VES
Replace heater.
~
...
-
Is combuslion air intake free Repair or
from damage and replace air
obs lruction? intake, as
requlred
Reconnect fu el pump and

turn healer on. After 30
seconds from switching
heater on, lightly tap fuel
- Replace fu el pump.
pump . Does fuel pump

begin lO operate (click)?
Continues
System should resume
normaloperalion . Pump
may have been stuck due lo
dirt in fuel or long periods of
- Check fuel tank, in-line filters ,
and supply lines ror
con tamina tion or blockage.
In lime wilh no operation.

Figure -,
Figure 6
Troubleshootinq - Continues In Figure 7
6 of 18
NO
Continued
from
Figure 6
....
Disconnect fu el line from
heater fu el inlet port. Turn
heater on and observe fuel
expelled from fuelline:
_
-
Are fuel lines and filters free of
obstructions? Are fuel lines
free of air? Are fuel lines free of
damaged, pinched sections,
- Replace fuel filter. Replace or
repair damaged or ob structed
fu el lines. Tig hlen loose fuel
line clamps. Purge alr from
12 in (30cm) with fu el pump and leaks? Are fuel line clamps lines. Fill fuel tanks with fue!.
1.5 in (4cm) gravity feed or tight? Is there suHicient fuel in
pump w/dampener the fuel tank?
Replace fuel pump .
VES ';(\~~;':~?~:'
V~··'
,r
Does coolant pump operate
when heater is on (can feel
or hear pump running .)?
-- Remove center
plastic cover
from heater. -.... Remove
coolant pump
and cover
---- Replace
coolant pump
~
Disconnect screws. Clean
coolanl pump pump thor
connector X3. ough ly.
Apply 12 Volts Assemb le and
directly lo the reconnect
pump (+ to pump . Does
,r black and - to
brown). Does
pump operale?
pump opera le?

Continues
In
Figure 8
,, lf
R"",mbl, J
pump and test
Replace healer.
run heater
~
Figure 7
Troubleshootin - Continues In Fi ure 8
7 of 18
NO
Continued
from
Figure 7
,,
Does heater start and opera te _ Check coolant hoses for any
normally but pertarms poorly? ~. .-~·I
. obstructions, kinked hoses, low
coo lant level and proper hose
,,
ro uting.
Possible intermi tten t problem. _ Check coolant hoses and fuel

Should probl em reoccur, re ~. ._~·ll
. ines far any obstructions,
peat the troubleshoo ting kinked hoses, and proper hose
procedure. routing . Ensure all electrical
connectors are tight and clean.
VES
Figure 8
Troubleshooting
8011 8
Recondition
General Information
2
It is a good practice when disassembling components
to lay the parts out in the order that they were
disassembled. Keeping the parts in this order during
disassembly, cleaning, and inspection will aid in the
assembly process.
If parts are hard to disassemble and assemble, do not 7

parts together, they must be free to rotate/operate and 6 --4
not bind .
5
A WARNING
1.
2.
Collar
Combu stion Air Fan
5.
6.
Circulatlon Pump
Screw
3 Cover 7. Clamp
hazardous. Serious personal injury may 4. Clamp
result from misuse of these products. Read Figure 9
and follow all the manufacturer's Replacement Of Circulation Pump
cleaning solutions.
Combustion Air Fan Removal
Circulation Pump Removal 1. Remove the circulation pump (5 ,Figure 9). See
"Circulation Pump Removal " tound earlier in this
Refer to Figure 9. document.
1. Remove the cover (3) , and disconnect the electri
Refer to Figure 10.
cal connector trom the circulation pump (5) .
2. Disconnect the electrical conneclor from the com
2. Loosen the clamp (4) .
3. Remove the screw (6) and clamp (7).
buslion air tan (1) .
3 . Remove the screws (8) that secure the combustion
4 . Remove the circulation pump (5) from the combus
tion air tan (2) . air tan (1) to the burner housing (13).
4. Caretully remove the combustion air tan (1) , using
5. If required, remove the collar (1) and clamp (4).
caution not to damage the tu el inlel tube (4).
Circulation Pump Installation 5. Remove the gaskel (2) and seal grommet (9) .
Reter lo Figure 9. Combustion Air Fan Installation

1. Properly clean and inspect the circulation pump (5)
per the instructions given in "Cleaning And Inspec Refer lO Figure 10.
tion" found later in this document. 1. Properly clean and inspect the combustion air fan
2. It removed, slide the clamp (4) and collar (1) on the
(1) per the instructions given in "Cleaning And In
circulation pump (5). spection" found later in this document.
3. Correctly orient the circulation pump (5) to the 2. Install the seal grommet (9) in the combustion air
combustion air fan (2), and secure with the clamp fan (1).
3 . Position the combustion air fan (1) to the burner
(7) with screw (6). Torque the screw (6) to
2.6±0.2 tt lb (3.5±O.3Nm) . housing (13), and install the gasket (2).
4. Tighten the clamp (4). 4. Slide the combustion air fan (1) onto the fuel inlet
5. Connect the circulation pump (5) electrical con tube (4) and against the burner housing (13).
nection, and install the cover (3) . 5. Secure the combustion air fan (1) to the burner
housing (13) by installing the screws (8) . Torque
Ihe screws (8) to 2.6 ±0.2 ft lb (3.5±O.3Nm) .
6 . Install the circulation pump (5,Figure 9) . See "Cir
culation Pump Installation " found earlier in this
document.
9 of 18
5 /'
,/
,/
,/
,/
,/
,/
,/
,/ ,/
/ ,/
./' ,/
,/
./ ./
,/
,/ ./
,/
,/
,/ ,/
,/ ,/
,/
8 ,/
,/
,/
,/
,/
./ ./
,/
,/
,/
,/
,/
,/
./
,/ 10
,/ ./
.. / .. /
(/ // 11
I
!
13
14
1. Combustion Air Fan 5. Glow Plug/flame Sensor 9. Seal Grommet 12. Heat Exchanger
2. Gasket 6. Cable Grommet 10. Cover 13. Burner Housing
3. Burner Insert 7. Screws 11 . Control Unit 14. Gasket
4. Fuel Inlet Tube 8. Screws
Figure 10
Diesel Coolant Heater Assembly
10 of 18
Burner Insert (With Glow Plug/Flame Cleaning And Inspection
Sensor) Removal
1. Remove the circulation pump (5,Figure 9). See
"Circulation Pump Removal" lound earlier in this
documento A WARNING
Reler to Figure 10.
2. Remove the combustion air lan (1). See "Combus hazardous. Serious personal injury may
tion Air Fan Removal" lound earlier in this docu result from misuse 01 these products. Read
ment. and follow all the manufacturer's
3. Push the cable grommet (6) 01 the glow plug/llame recommendations concerning solvents and
sensor (5) out 01 the burner housing (13). cleaning solutions.
4. Remove the screws (7) securing the burner insert
(3) to the burner housing (13). 1. Thoroughly clean all metal parts with an approved
5. Remove the gasket (14). cleaning solvent. Place parts on a clean, lint free
surlace and allow to air dry. Exercise every precau
Burner Insert (With Glow Plug/Flame tion possible to keep all parts free 01 dust, dirt, or
Sensor) Installation any other loreign material during assembly.
2. AII Loctite®, Permatexifl , or other sealant residue
Reler to Figure 10. should be removed Irom threads 01 hardware and
1. Properly clean and inspect the burner insert (3) per the mounting surlaces 01 parts that are going to be
the instructions given in "Cleaning And Inspection" reused. Prior to applying new thread locking com
lound later in this document. pounds or sealants, clean threads and surlaces
2. Align the gasket (14) on the burner housing (13). with Loctite@ 7070 Cleaner to ensure best perfor
3. Position the burner insert (3) to burner housing mance 01 products.
(13), and install the screws (7). Torque the screws 3. Carelully inspect all components lor damage,
(7) to 2.6::t0.2 ft lb (3.5::tO.3Nm). wear, latigue or stress Iractures, corrosion, deep
4. Press the cable grommet (6) olthe glow plug/llame scratches, cracks, and scuffed metal.
sensor (5) into the burner housing (13). 4. Inspect the wiring harness and connectors lor cor
5. Install the combustion air lan (1). See "Combus rosion, loose contacts, and wrong crimping. Re
tion Air Fan Installation" lound earlier in this docu pair or replace as required.
ment. 5. Check the air intake port lor obstructions. Carelully
6. Install the circulation pump (5,Figure 9). See "Cir check the air intake tu be lor restrictions an d da m
culation Pump Installation" lound earlier in this age. Repair or repla:::e il damaged.
documento 6. Check the exhaust outlet pipe lor corrosion.
7. Inspect connection pipes lor damage, restrictions,
and loose connections. Repair or replace il dam
aged.
8. Inspect the coolant circulation pump lor leakage.
Repair or replace il damaged.
9. AII "soft parts", such as the gaskets and seal grom
mets should be replaced.
10. In the event 01 severe delects, contact lactory per
sonnel lar directions whether to repair ar re place
any majar component.
11 01 18
Wíre Harness Rework
The performance of the diesel heater can be improved
on earlier model cranes by relocating wire number
602M VIO from Terminal 3, in the 6-Way connector
(X1, Figure 2) , to Terminal 1. See the following
procedure Wire 602M VIO Relocation for the complete
instructions.
Further improvement to this same wire harness can be

made by adding a diagllostic wire assembly to
Terminal 2 in tlle same 6-Way connector. Some wire
harnesses do not have this wire assembly and must be
retrofitted with Link-Belt part number N4R0150 in order 1. Wire Seals 3. Plugs
to accommodate the PC Diagnostic Setup. See 2. Wires 4. Connector
Retrofitting The Diagnostic Link Connector on page 15 Figure 12

for the complete procedure . 6- Wire Connector
Wire 602M VIO Relocation
3. The connector (4) has six Terminals available to ac
The wire connectors used on diesel Ileater's externa I commodate wires (2) , and wire seals (1). Unused
wire harnesses are AMP ' v type connectors. They Terminals will employ plugs (3); the color of the
utilize a locking feature to prevent wires from pulling plugs (3) can vary but hold no significance. Each
loose inadvertently. Use tlle following procedure to Terminal is identified by tl1e adjacent number en
remove and install wires in the diesel heater's 6-Way graved into connector (4)
conn ector.
1. Terminal 1 2. Plug
Figure 13
1. Locate the external wire harness (2) and 6-Way Plug Removed From Wire Connector
connector (3) on tl1e top of the heater (1).
2. Unplug the 6-Way connector (3) from the top of 4. Remove the plug (2) from from Terminal 1 (1).
the heater (1).
12 of 18
1. Top 01 Connector 4. Release Slot

2. Unlocked Position Hole 5. Lock
3. Locked Position Hole
Figure 16
1. Latch 2. Lock
Locking Mechanism in "UNLOCKED" Positi on
Figure 14
Connector Locking Mechanism 7, Slide the lock (5) so that the latch is positioned in
the unlocked position hole (2). It is crucial that the
5. Before any wires can be removed or added to the
latch is not moved beyond the unlocked position
connector, the lock (2) must be moved to the re
hole (2). Doing so leaves the wires locked and un
leased position, The latch (1) maintains the selec
removable.
ted position. It also serves as the indicator that is
read from the top of the connector, The lock (2) il
lustrated in Figure 14 has been greatly over exten
ded for the purpose of clearly showing the latch (1) .
1. Latch 3. Wire 602M VIO

2 Barb
2. Unlocked Position Hole 5. Lock Figure 17
Depress Barb To Release Wire
Figure 15
Locking Mechanism in "LOCKED" Position 8. Ensure that the latch (1) is in the unlocked position
(See Figure 16). Using a small pointed instrument,
6, Using a small screwdriver, press down on the lock
press on the barb (2) while pulling on wire 602M
(5) through the release slot (4). VIO (3).
13 of 18
SM 06 - 025 - 026.00 0309 Service IM anual
1. Connector 3. Wire 602M VIO

1. Terminal 1 3. Terminal 3 2. Wire Seal
2. Plug 4. Wire 602M VIO
Figure 20
Figure 18 Insert Wire In New Location
Plug and Wire Removed
11. Insert wire 602M VIO (3) into Terminal 1 of the con
9. Remove wire 602M VIO (4) from the connector. nector (1). Be sure that the barb on wire 602M VIO
(3) is oriented toward the outside of the connector
(1) and that the wire seal (2) is fuliy seated .
1. Connector 2. Plug
Figure 19 2. Unlocked Position Hole 5. Lock
Insert Plug In New Location 3. Locked Position Hole
Figure 21
10 . Insert the plug (2) into Terminal 3 of the connector Locking Mechanism in "LOCKED" Position
(1) . Be sure to fuliy seat the plug (2) .
12. Using a small serewdriver, press down on the loe k
(5) through the release slot (4) and move the lateh
to the loeked position hole (3) .
14 of 18
Order Link-Belt part

number N4R0150
Figure 24
Diagnostic Wire Retrofit
Retrofitling The Diagnostic Link Connector

For PC diagnostics, the diesel heater 's external wire
harness must be equipped with wire number 602U VIO
and its 1-way diagnostic connector. This wi re
1. Wire Seal 3. Plug
2. Wire 602M VIO assembly is where the interface cable and adaptor are
installed . Some wire harnesses do not have this wi re
Figure 22 assembly and must be retrofitted with Link-Belt part
Ensure Wire & Plug Are Seated And Locked number N4R0150 in order to accommodate the PC
Diagnostic Setup .
13. Ensure the plug (3) and wire seal (1) of wire 602M
VIO (2) are fully seated in each terminal port and
locked in place. The wire connectors used on diesel heater's external
14. Plug the reworked connector back into the top of wire harnesses are AMP '" type connectors. Th ey
the diesel heater. Perform a functional test on the utilize a locking feature to prevent wires from pUlli ng
heater to ensure it is working properly before re loose inadvertently. Use the following procedure to
turning the crane to service . remove and install wires in the diesel heater's 6-Way
connector.
1. W ire Seals 3. Plugs

2. Wires 4. Connector
Figure 23
6-Wa Wire Connector
1. Hea ter 3. 6-Way Conn ector
2. Wire Harness
Figure 25
cal Heater Wire Harness
1. Locate the wire harness (2) and 6 - Way connector

(3) on the top of the heater (1).
2. Unplug the 6- Way connector (3) from the top of
the heater (1).
15 of 18
3. The connectar (4) has six terminals available to ac
commodate wires (2) , and wire seals (1). Unused
terminals will employ plugs (3); the colar of the
plugs (3) can vary but hold no significan ce. Each
terminal is identified by the adjacent number en
graved into connectar (4)

2. Unlocked Posi lion Hole 5. Lock
Figure 28
Locking Mechanism in "LOCKED" Position
1. Plug 2. Terminal 2
Figure 26 6 . Using a small screwdriver, press down on the lock

Insert Wire Connector (5) through the release slot (4).
4. Remove the plug (1) from Terminal 2 (2).
1. Top 01 Connector 4. Release Slol

2. Unlocked Posi tion Hole 5. Lock
1. Latch 2. Lock 3. Locked Posilion Hole
Figure 27 Figure 29
Connector Locking Mechanism Locking Mechanism in "UNLOCKED" Position
5. Befare any wires can be removed or added to the

7. Slide the lock (5) so that the latch is positioned in
connector, the lock (2) must be moved to the re
the unlocked position hole (2). It is crucial that the
leased position. The latch (1) maintains the selec
latch is not moved beyond the unlocked position
ted position. It also serves as the indicator that is
hole (2). Doing so leaves the wires locked and un
read from the top of the connector. The lock (2) il
removable.
lustrated in Figure 27 has been greatly over exten
ded far the purpose of clearly showing the latch (1).
16 of 18
1. Connector 3. Wire N4R0150

2. Wlre Seal
Figure 32
Ensure Wire Is Fully Seated
1 Plug 4. Wire Seal
2. TermInal 2 5 Connector 10. Ensure wire seal (2) 01 wire N4R0150 (3) is lully
3 Wire N4R0150 seated in the terminal port 01 the connector (1) and
Figure 30 locked in place.
Insert Wire (N4R0150) In Connector 11. Plug the reworked connector back into the top 01
the diesel heater. Perform a functional test on the
8. Insert wire N4R0150 (3) into Terminal 2 (2) 01 the heater to ensure it is working properly belore re
connector (5). Be sure that the barb on wire is ori turning the crane to service.
ented toward the outside 01 the connector (5) and
that the wire seal (4) is lully seated.
1. Top 01 Connector 4. Rel ease Slot

2. Unlocked Position Hole 5. Lock
Figure 31
Locking Mechanism in "LOCKED" Position
9. Using a small screwdriver, press down on the lock

(5) through the release slot (4) and move the latch
to the locked position hole (3).
17 of 18
18 of 18
Diesel Coolant Heater, R & I 5. Check that all control levers are in the neutral
position and move the lunction lockout switch to
This procedure covers the removal and installation 01 the "DI SABLE" position.
the diesel coolant heater. Far recondition procedure,
see SM Keysheet Area 06-025.
A WARNING
A WARNING terminals while disconnecting the battery.
The diesel coolant heater may be hoto Failure ignited by a spark or flame causing the battery
to allow sufficienttimefor cooling could result to explode. Keep the area around the battery
in burns or other personal injury. Allow the well ventilated and disconnect the negative
heater to cool befo re servicing. side of the battery first, with the ignition switch
Engine coolant may be hot and could cause
burns. Avoid prolonged and repeated ski n Battery posts, terminals, and related
contact with antifreeze. Such prolonged, accessories contain lead and lead
repeated contact can cause ski n disorders or compounds. Eating or smoking with lead
other bodily injury. Keep out of reach of residue on hands may cause lead poisoning.
children. Wash hands after handling lead products.
Coolant is toxico Keep away from children and 6. Turn the battery disconnect switches to the "OFF"
pets. If not reused, dispose of in accordance position, ar disconnect the battery cables Irom the
with local environmental regulations. batteries, negative cables lirst, then positive. See
the Operatar's Manual lar battery disconnect
Removal switch operation.

2. Stabilize the crane lar service as lollows:
a. Park the crane, out 01 the way, on a lirm and A WARNING
level surface. The diesel coolant heater system is
b. Engage the park brake and/ar properly block pressurized. Do not remove the fill cap when
the tires. the system is hoto Heated coolant spray or
c. Engage the swing park brake ar travel swing steam can cause personal injury. Wait until
lock, as required. the system has cooled and slowly remove the
d. Level the crane on lully extended outriggers. filt cap.
quired. 7. Remove any grilles, guards, and covers as
3. Stlutdown the engine and disengage the main necessary to gain access to the diesel coolant
Ilydraulic pump, as equipped. heater assembly.
Reler to Figure 1.
A WARNING
8. Relieve the diesel coolant heater system pressure
by removing the lil! cap (3) Irom the coolant
reservoir (4). Install the litl cap (3) once the
hazardous. Serious personal injury may pressure has been relieved.
result from misuse of these products. Read 9. Disconnect the electrical connections Irom the
and follow all the manufacturer's diesel coolant heater (5).
recommendations concerning solvents and 10. Far assembly purposes, label the heater hoses
cleaning solutions. (12) and luelline (11).
11. Loosen the hose clamps (9), and disconnect the
4. Thoroughly clean the area to be disassembled with heater hoses (12) Irom the diesel coolant heater
an approved cleaning solvent to prevent (5). Cap/ptug the open parts and hoses (12) to
contamination. Allow the area to air dry. prevent excessive coolant loss and contamination
01 the system.
1 014
:;;-- ,
(:))[
['
A
2 3 4
'.
(~
~ --f- .¡--r
':f.;¡
'.' ~ ~I J
.~dp~~~~~-= ~~---==-~~
~
12 11 10 9 8 6 7
1. Upper Frame 4. Coolant Reservoir 7. Fuel Pump 10, Hose Clamps

2. Heater Fuel Tank 5. Diesel Coolant Heater 8 Mounting Bracket 11 . Fuel Une
3. Fill Cap 6. Locknuts & Washers 9. Hose Clamp 12, Heater Hoses
Figure 1
Diesel Coolant Heater
2 of 4
12. Loasen the hose clamp (10) , and disconnect the Installation
fuel line (11) from the diesel coolant heater (5) .
Cap/plug the open port and fuelline (11) to prevent
excessive fuel loss and contamination of the
system. A WARNING
13 . Remove locknuts and washers (6) and remove the Lubricants, sealants, joint and thread locking
diesel coolant heater (5) from the mounting compounds, etc. can be hazardous. Seriou s
bracket (8). personal injury may result from misuse 01
Cleaning And Inspection manufacturer's recommendations concerning
these products.
A WARNING Refer to Figure 1.

1. Properly position the diesel coolant heater (5) on
hazardous. Serious personal injury may mounting bracket (8) and install washers and
result from misuse of these products. Read locknuts and (6).
and follow all the manufacturer's 2. Connect the heater hoses (12) to the diesel coolant
recommendations concerning solvents and heater (5). Tighten the hose clamps (9) to 45 in lb
cleaning solutions. (5Nm) .
3. Connect the fuel line (11) to the diesel coolant
1. AII components should be thoroughly cleaned with heater (5). Tighten the hose clamp (10) to 45 in lb
an approved cleaning solvent , air dried , and (5Nm) .
carefully inspected. 4. Connect the electrical connections to the diesel
2. AII Loctite®, Permatex®, or other sealant residue coolant heater (5).
A WARNING
surfaces with Loctite® 7070 Cleaner to ensure best terminals while connecting the battery.
performance of products. Battery gasses are volatile and could be
3. Thoroughly inspect all parts for damage , wear, ignited by a spark or flame ca using the battery
fatigue or stress fractures, and corrosion. Repair to explode. Keep the area around the battery
or replace as required. well ventilated and connect the negative si de
4. Al! "soft parts" , such as seals, gaskets, back up of the battery last, with the ignition switch
rings, and o-rings, should be replaced. "OFF", to minimize hazard.
5 . Inspect the integrity of the fuel lines that are
connected to the diesel coolant heater. Repair or 5. Turn the battery disconnect switches to the "ON "
replace if required. position , or connect the battery cables to the
6. Inspect the integrity of the heater hoses that are batteries, positive cables first, then negative . See
connected to the diesel coolant heater. Repair or the Operator's Manual for battery disconnect
replace if required. switch operation .
7. Inspect the integrity of the electrical wires and 6. Check the coolant level in the coolant reservoir (4) .
connectors that supply the diesel coolant heater. Add coolant as required. See the Operator 's
Repair or replace if required . Manual for the correct type and procedure.
8 . Inspect the fuel pump and filter, replace as 7. Check the fuellevel in the heater fuel tank (2). See
required. the Operator's Manual for the correct type and
9. In the event of severe defects , contact factory procedure.
3 of 4
Note: The temperature of the coolant must be 10. Ensure the coolant level is at the proper operating
below 86° F (30° C) for start-up. level. Add coolantas required. SeetheOperator's
Manual for the correct procedure.
8. Set the heater/air conditioner selector switch to the 11. With the diesel coolant heater "ON", check for:
heater position (as equipped), turn the a. Circulating pump operation
temperature control knob to the highest heat b. Initiation of start-up sequence
position, and turn the heater "ON". See the c. Successful start-up and operation
Operator's Manual for the correct procedure. 12. Turn the heater "OFF", and inspect the installation
once more for leaks.
Note: It may take a second start-up atlemptto
fire the diesel coolant heater. If a second
functions of the diesel coolant heater for proper
atlempt is required, cycle the "ON/OFF" switch
operation. A general inspection of the
to reset the control unit.
9. With the diesel coolant heater "ON", air will purge the repair should also be performed to ensure
from the system. Refill the coolant reservoir (4), as related damage or wear is not presento
needed, during the purging cycle. Inspect the 14. Replace any grilles, guards, and covers that were
heater hose and fuel line connections for leaks. removed to gain access to the diesel coolant
Repair leaks as required. heater assembly.
4 of 4
7
Wlre Location In Clrcuit
category~
1
243-A BLU - - )
L Lco,ü<
Circuit Designation ~ B
20-D BLK7320- C
6 5 4~
Y~L . 320-B YEL
Example : Wire number 243-A BLU indicates: 1. Circuit Breaker 4. Indicator Light
Category 2, circuit 43 , conductor 2. Therm al Switch 5. Buzzer
A, blue wire. 3. Wire Connector 6. Ground Bolt
Figure 1 Figure 2
Wire Number Explanation Wire Number Suffix Sequence
2. Category 2: Engine and Transmission Control

Electrical System Wire (Blue) 200 Series numbers are used to identify
wires in circuits used in the operation and control of
Identification Code the engine and transmission.
3. Category 3: Monitoring Group (Yellow) 300 series
In order to simplify electrical troubleshooting numbers are used to identify wires in circuits used
techniques, the electrical system of this crane uses a in monitoring crane operation . Circuits that
"Wire Identification Code". The following information contain gauges Or instrumentation are included in
outlines the "Code" used to identify the wires in a this category. (See Category 8 also.)
crane's electrical system . 4. Category 4: Lighting and Horns (Green) 400
Series numbers are used to identify wires in the
Wire Harness interior and exterior lighting circuits of the crane, as
well as the horn and back up alarm circuits.
Each wire, in any given wire harness within the 5. Category 5: Equipment Control (Brown) 500
electrical system, has a colo red insulating coating. Series numbers are used to identify wires in circuits
This coating is labeled with a wire number. The color concerned with the operation and control of
and wire number, when fully understood, will allow the functions that are unique to the crane. (See
positive identification of a wire and its specific use in the Category 7 also.)
circuit. Each wire has four basic identifying elements. 6. Category 6: Accessories (Violet) 600 series
Refer to Figure 1. numbers are used to identify wires in circuits
con cerned with the operation and control of
Category operator accessory equipment such as heaters,
defrosters, windshield wipers , etc.
The first character of each wire number corresponds to
7. Category 7: Equipment Control (Brown) 700
a general category. Seven basic categories exist and
series numbers are simply an extension of
are described as follows :
Category 5. (See Category 5 also .)
1. Category 1: Primary Power (Red or Orange) 100 8. Category 8: Monitoring Group (Yellow) 800 series
series numbers are used to identify wires wh ich are numbers are simply an extension of Category 3.
used to provide the originating source of power to (See Category 3 also.)
all circuits within the electrical system.
1 of 14
Wire Location In Circuit 3. Wires that are at constant ground potential are col
ored BLACK.
Th e fourth character of the wire n um ber is a letter suffix
which is used to relate a particular wire's location rela Circuit Designation
tive to the rest of the circuit. The letter suffix, which is
assigned sequentially, generally starts from the circuits The second and third characters of each wire number
power source, changes at each of the circuits working specifically identify the circuit within any given catego
components, and ends once a wire reaches ground ry. See the category listings found later in this docu
potential. Refer to Figure 2. ment for specific wire number designations.
Note: The letter suffix does not ehange when two Note: Al! wire numbers listed in eategory listings
wíres are joined by a wire eonneetor. are typieal and may not neeessarily apply to one
Color given era ne.
The color of the wire, like the wire number, has a very
Jumper Wires
specific meaning. It can be used to identify, as well as,
describe the function of the wire in a given circuit. AII A jumper wire is defined as any wire not included in a
wires are colo red according to the category that de wire harness. These wires are not labeled with a wire
fines their corresponding circuit, with the following ex number. They are labeled however, with the actual wire
ceptions: part number which can be used toorder a replacement
1. Wires which are directly connected to the system wire.
power source, and are at constant battery poten
AII jumper wires will be colored white with the same ex
tial, are colored RED. These wires remain "HOr at
ceptions, red, orange and black as described for the
all times .
wire harness.
2. Wires that are at battery potential only when the
ignition switch is in the "ON" position are colored
ORANGE.
Category 1
Primary Power Circuits
Wire Nurnber Deseription
000 Spare Collector Ring Connection
101 Battery Charge
102- 110 Battery Distribution
111-119 Distribution Controlled By Main Switch
120-121 Main Switch Solenoid
122 -123 Chassis Ground
124 Wheel Anti-Lock Power Supply
125 Remote Control Power Supply
126 -127 Distribution Controlled By Main Switch
128- 129 Ground
130 Battery Distribution
131 Distribution Controlled By Upper Switch
132 I Controller Power
133-137 Ground
138 24 Volt Power
139 -140 Ground
141 -143 Distribution Controlled By Transmission
144 Trailer ABS FJower Supply
2 of 14
Category 2
Engine And Transmission Control Circuits
201-203 Starter Solenoid
204-205 Starter Motor
206-207 Engine Stop
208-209 Emergency Engine Stop
210 Throttle Lock
211 Throttle Control
212 Engine Torque Limit
213 Fuel Cooler
214 EMP Air Pump
215 Idie Validation
216 - 229 Other Engine Controls
230 Check/ Stop Engine Power
231 - 240 Transmission Shift Select
241-2 42 Master Clutch Control
243 Ether Control
244 Outrigger Throttle Control
245 High Idle Solenoid
246-254 Torque Convertor Control
255-256 Speed Limiting
257 Fuel Heater
258-267 Other Transmission Controls
268 Throttle Actuator
269 Other Control
270 Throttle Supply
271 Intake Air Heater
272 Other Control
273-276 Transmission Supply
277 Transmission Cooler Fan
278 J1939 CAN High
279 J 1939 CAN Low
280 J1939 CAN Shield
281 J1939 CAN Shield
3 of 14
Category 3
Monitoring Circuits (Also See Category 8)
30 1 -302 Instrument Supply
303-304 Fuel Level
305-306 Engine Oil Pressure
307 -308 Engine Coolant Temperature
309 Fuel Pressure
3 10 Voltmeter
31 1 -312 Tachometer(Engine Speed Indicator
31 3 Hourmeter
314 Transmission Oil Temperature
31 5 -316 Engine Oil Temperature
317 -318 Torque Convertor Oil Pressure
319 Speedometer
320 - 321 Hydraulic Oil Temperature
322 -326 Hydraulic Filter Indicator
327 Low Hydraulic Charge Pressure
3 28-329 Master Clutch Indicator Light
330 Gear Case Lube Indicator
33 1 -334 Drum Rotation Indicator
335 Swing Lock Indicator
336 -338 Low Air Pressure Indicator
339 Auxiliary Steer Indicator
3 40 Emergency Brake Indicator
341 Skid- TroJ Power & Fault Indicator
342 Boom Length Indicator
343 Hoist Brake Alarm
344 Cab Control Shutdown Indicator
345 Dual Function Instrument Supply
346 Load Moment Indicator - Power Supply
347 Load Moment Indicator - Logic Control
3 48 Load Moment Indicator - Swing Rotation Indicator
349 Load Moment Indicator - Function Interlock & Alarm
350 Wheel Anti-Lock System FauJt Indicator
351 Remote Control Brake Pressure Monitoring
352 Bumper Outrigger Overload Alarm
353-356 Drum Rotation Indicator
35 7 Power "ON" Indicator
358 Anti- Two Block
4 of 14
Category 3 - Continued
359-360 Drum Limit Light
361 Engine Overheat Alarm
362-363 Air Pressure
364 Free-Fall System Indicator
365 Oil Level Alarm
366 Ladder Rung Alignment Indicator
367 Open Door Indicator
368 Controller Power Indicator - Base
369 Controller Power Indicator - Platform
370 Outrigger Interlock Indicator - Left Side
371 Outrigger Interlock Indicator - Right Side
372 Over Front Indicator And Warning Buzzer
373 Oil Pressure Alarm
374 Load Moment Indicator - Swing Rotation Indicator
375- 376 Low Air Pressure Indicator
377-378 Free-Fall System
379 Engine Monitor - Upper
380 Light Test
381 Position Indicator
382-383 Engine Monitor - Carrier
384-388 Swing Potentiometer Indicator
389 Emergency Brake Boost Flow Indicator
390 Counterweight Removed/Attached Indicator
391 Auxiliary Steer Indicator
392 Suspension Lockout Indicator
393-395 Rear Axle Steer Lock Pin Indicator
396 Park Brake Indicator
397-398 Axle Differential Lock Indicator
399 Steer Indicator Gauge
Monitoring Circuits Continued As Category 8
5 of 14
Category 4
Lighting And Horns Circuits
401 Distribution Controlled By Light Switch
402-403 Headlights
404-405 Clearance Lights
406 Tail And Clearance Lights - Carrier Left Side
407 Tail And Clearance Lights - Carrier Right Side
408 BackUp Lights And Alarm
409 Backup Solenoid
410 Brake Light Switch(es)
411-412 Interior Cab Lights
413 Emergency And Turn Flasher
414 Front Turn Light - Carrier Right Side
415 Rear Turn And Stop - Carrier Right Side
416 Front Turn Light - Carrier Left Side
417 Rear Turn And Stop - Carrier Left Side
418-422 Exterior Lights
423 Tower Obstruction Light
424 Interior House Lights
425 - 426 Horn
427 Instrument Lights
428 Light Solenoid
429-430 Travel Alarm
431 Boom Telescope Override
432 Lift And Till Alarm
433 Instrument Lights
434 Rotating Beacon
435 Swing Alarm
436 Backup Light
437 Backup Alarm
438 Brake Light Switch
439 Emergency And Turn Signal Flasher
440 Tail And Clearance Lights - Upper
441 Front Turn Ught - Upper Right Side
442 Rear Turn And Stop - Upper Right Side
443 Front Turn Light - Upper Left Side
444 Rear Turn And Stop - Upper Left Side
445 Daytime Running Lights
60114
Category 5
Equipment Control Circuits (Also See Category 7)
501-502 Outrigger Power Supply
503-505 Outrigger Solenoid Control
506 Outrigger Control Circuit Left Front Jack
507 Outrigger Control Circuit Left Front Beam
508 Outrigger Control Circuit Right Front Beam
509 Outrigger Control Circuit Right Front Jack
510 Outrigger Control Circuit Right Rear Jack
511 Outrigger Control Circuit Right Rear Beam
512 Outrigger Control Circuit Left Rear Beam
513 Outrigger Control Circuit Left Rear Jack
514 Outrigger Control Circuit Retract
515 Outrigger Control Circuit - Extend
516-518 Outrigger Directional/Flow Divider Valve Supply
519 Hydraulic Reservoir Pressure/Fine Metering
520 Two-Speed Hoist
521 Free-Fall Valve
522 Axle Oscillator Control
523 Combination Steering Control
524-525 Four-Wheel Drive Control
526 Reserve Air Control
527 Pump Disconnect
528 Oscillation Override
529 Remote Steering Control
530 Remote Steering Control (Rear Winch Up*)
531 Remote Steering Control (Rear Winch Down*)
532 Remote Steer Directional & Diverter Valve Supply (Front Winch Up*)
533 Remote Steer Directional & Diverter Valve Supply (Front Winch Down*)
534 Remote Steer Directional & Diverter Valve Supply (Swing Left*)
535 Telescope Override (Swing Right*)
536 Blocking Valve Control
537 Hydraulic Pin Puller Control (Boom Hoist Up*)
538 Hydraulic Pin Puller Control (Boom Hoist Down*)
539-540 Hydraulic Pin Puller Control
541-542 Hydraulic Pin Puller Power Supply
543 Two-Speed Swing
544 Two-Speed Travel
* Alternate description for some cranes with serial number prefixes J8 or R3 only.
7 of 14
Equi pment Control Circuits (Also See Category 7)
545 - 548 Two-Speed Planetary
549 House Lock Disengage
550 -551 Cab Motion
552 Boom Hoist Cutout
553 Drum Hoist Cutout
554 Boom Lowering Cutout
555 TravelfThird Drum Selector
556 House Lock Engage
557 Cab Motion
558 Drum Cutout Override
559 Boom Cutout Override
560 -563 Axle Control ,
564 Tower Balance Arm Cutout Bypass
565 -566 Fairleader Control
567 Cab Pressure Control
568 Hoist Convertor Control
569 Boom Hoist Brake Dump
570 Boom Hoist Cutout
571 TravelfThird Drum Selector
572 -573 Drum Bypass
574 Automatic Brake
575 Park Brake
576 Drum Lowering Cutout
577 Two-Speed Hoist
578 Control Override
579 Remote Control
580 Accumulator Charge Pressure
581 Boom Hoist
582 Boom Telescope
583 Swing Lock
584 -585 Boom Hoist Auxiliary
586 Swing Auxiliary
587-592 Outrigger Control
593-595 Blocking Valve
596 -599 Free-Fall
Equipment Control Circuits Continued As Category 7
8 of 14
Category 6
Accessories Circuits
601-602 Heater
603-604 Defroster
605-607 Windshield Wiper
608-610 Windshield Washer
611 Cab Vent Fan
612-613 Air Conditioner
614-615 Propane Engine Preheater
616 Air Dryer
617 Cigarette Lighter
618-621 Air Conditioner
622 12 Volt Accessory Outlet
623 Remote Control Mirror
624 Heater
625 Seat Control
626 AM/FM Radio
9 of 14
Category 7
701 Free- Fa 11
702 Tow Winch - Out
703 Tow Winch - In
704 Load Sensing
705 Oil Cooler Control
706 Pump Disconnect
707 Rear Axle Steer Lock Upper Control
708 Rear Axle Steer Unlock - Upper Control
709 Axle Oscillation Control
710-712 Axle Differential Lock
713 Rear Axle Steer Lock Carrier Control
714 Rear Axle Steer Unlock - Carrier Control
715 Winch Interference Control
716 Steer Reversing
717 Park Brake
718 Tow Winch - Auxiliary
719 Rear Axle Steer Locking
720 Boom Telescope Control Box (Offset Fly Control*)
721 Boom Telescope Control Box (Offset Fly*)
722-723 Boom Telescope Control Box
724 Front Winch Disengage
725 Rear Winch Disengage
726 Steer Lock
727 Boom Hoist Pump Control
728 Winch Pump Control
729 Boom Hoist Winch Disengage
730 Lower Jacking/Upper Pilot Control
731 Counterweight Removal
732 Axle Oscillation Control
733 Anti- Lock Brake System (ABS) Controller
734 J1939 CAN 1 - High
735 J1939 CAN 1 - Low
736 J1939 CAN 1 - Shield
737 Boom Latching Power Supply
738-744 Boom Latching Control
745-746 Axle Oscillation Control
* Alternate description for some cranes with serial number prefixes J8 or R3 only.
10 of 14
747 Side Frame Control
748 J1939 CAN 2 - High
749 J1939 CAN 2 - Low
750 J1939 CAN 2 - Shield (Rear Winch Function Controller*)
751 J1939 CAN 3 - High (Swing Function Controller*)
752 J1939 CAN 3 - Low (Front Winch Function Controller*)
753 J1939 CAN 3 - Shield (Boom Hoist Function Controller*)
754 Auger
755 Boom Hoist Up
756 Boom Hoist Down
757 Swing Left
758 Swing Right
759 Front Winch Up
760 Front Winch Down
761 Rear Winch Up
762 Rear Winch Down
763 Horsepower Dissipation
764 Fly Extend
765 Fly Retract
766 Fan Pump Control
767 Front Winch Controller
768 Rear Winch Controller
769 Swing Controller
* Alternate description for some cranes with serial number prefixes J8 Or R3 only.
11 of 14
SM06-047 --000.00 0110 Service Manual
Category 8
801 Ammeter
802 Pyrometer Temperature
803-804 Instrument Power Supply
805 Throttle Indicator
806 Load Moment Indicator (LMI) External Light Bar - Red
807 Load Moment Indicator (LMI) External Light Bar - Amber
808 Load Moment Indicator (LMI) External Light Bar - Green
809-810 Load Moment Indicator (LMI) External Light Bar Power Supply
811 Load Moment Indicator (LMI) Display Data Signal - AA ~
812 Load Moment Indicator (LMI) Display Data Signal - AB ~
813 Load Moment Indicator (LMI) Display Reset Signal
814 Load Moment Indicator (LMI) Display Power Supply
815 Load Moment Indicator (LMI) Display Ground
816 Load Moment Indicator (LMI) Shield
817 Load Moment Indicator (LMI) Reeling Drum & Anti- Two Block (ATB)
818 Four Wheel Drive Engaged Indicator
819 Load Moment Indicator (LMI) Bypass
820 Load Moment Indicator (LMI) Counterweight Sensing
821 Suspension Height Indicator
822 Anemometer
823 Outrigger Length Reel Left Front Beam
824 Outrigger Length Reel Right Front Beam
825 Outrigger Length Reel Left Rear Beam
826 Outrigger Length Reel Right Rear Beam
827 Swing Sensor
828 Seat Belt Indicator
829 Primary SteE!r Indication - Front
830 Secondary Steer Pump Indication Rear
831 Tilt Sensor
832-833 Display/Monitor Supply
834 USB Port
12 of 14
Electrical Systenl Schematic Symbols
Switches Senders
. -
•
Maintained Contact
Normally Open 1 r
1
r
Pressure Sensitive
• -.- Maintained Contact

Normally Closed
1.
• ...
I T Liquid Level
Momentary Contact
-
• .• Mechanically Actuated
I T Thermal Sensitive
Pressure Sensitive
• --.
1• Opens As Pressure Rises ......
Speedometer
• • L _'
Pressure Sensitive
Closes As Pressure Rises
;
1 Momentary Contact
Relays Heating Element
•• Normally Open
.-., I Momentary Contact

Normally Closed
• • Coil
Contacts NO
• •
• I Make Before Break
Diode
• ¡
• • • Coil
• -
•
I
L-
Mechanically Linked
b' ~ Conlaels NO
, - - Contacts NC
Valve Solenoid
i<IIII
T Variable Resistance Contacts

- With Off Position Common • •
• • Closes With Increase In Flow Circuit Protectors Ground
-
-
• • •Fuse• I
Opens With Increase In Flow Chassis I
1 I
Circuit Breaker Gauge

Audible Signals Lights
-. .-
Manual Reset ..• '
l )
Flasher
Buzzer
l
Gauge
-- -
1
-e
Circuit Breaker
Thermal Reset
• .. e-
•
-
l
'.
Battery Motor
1,
-
Horn,
I I~ , -
Backup Alarm Head, Tail, Dome, .~ I
f-e
--- --
Brake, Etc.
Figure 3
Electrical Symbols Legend
13 of 14
14 of 14
2 A
3 6
c:======~ L - - - - 4
WITH CAP REMOVED
5
1. Cap 3. Clamp & Locknuls 5 Hydraulic Lines·
2. Accumulator 4. Bracket 6. Charging Valve
• Orientation and type 01 hydraulic lines may va ry.
Figure 1
Typical Accumulator Assembly

Pilot Control Accumulator, an approved cleaning solvent to prevent conta
R&I mination. Allow the area to air dry.

the pilot control accumulator. It also gives proper
instructions for charging the accumulator. Recondition
A WARNING
procedures are not applicable to the accumulator.
Removal burns or other serious injury. Shutdown the
engine and exhaust al! trapped hydraulic
1. Lower, detach, and secure the load , as required. pressure from the system befo re removing
2. Stabilize the crane for service as follows: any line or component.
level surface. 5. Relieve the hydraulic system pressure as follows:
b . Engage the park brake and/or properly block a. Release any residual pressure in the hydraulic
the tires. reservoir by slowly loosening the filler/breather
c. Engage the swing park brake or travel swing cap, located on the top of the hydraulic
lock, as required. reservoir, until pressure is fully relieved.
d. Level the crane on fully extended outriggers . b. Turn the ignition switch to "ON", but DO NOT
e. Fully retract and position the boom , as re START THE ENGINE. Move the fun ction lock
quired. out switcll to the "OPERATE" position.
3. Shutdown the engine and disengage the main hy c. Work the crane control levers and outrigger
draulic pump. switches back and forth several times .
d . Turn ignition switch to the "OFF" position.
A WARNING
"DISABLE " position .
hazardous. Serious personal injury may Refer to Figure 1.
result from misuse of these products. Read 7. Label for assembly purposes and slowly loosen ,
and follow all the manufacturer's then disconnect, the hydraulic lines (5) . Cap/plug
recommendations concerning solvents and the open hydraulic ports and lines (5) to prevent ex
cleaning solutions. cessive oilloss and contamination of the system .
1 of 4
Installation
A WARNING
When relieving the precharge on the
accumulator, the nitrogen gas will instantly
evaporate. The surface area of the
A WARNING
accumulator, and any surrounding areas, will compounds, etc. can be hazardous. Serious
bec ome extremely cold as the gas exits. personal injury may result from misuse of
Serious personal injury may result from these products. Read and follow all
misuse of this products. Read and follow all manufacturer's recommendations concerning
01 the manufacturer's recommendations these products.
concerning dry nitrogen.
Refer to Figure 2.
8. Remove the cap (1) and relieve the accumulator (2)
1. Turn the accumulator (1) upside down and remove
precharge by depressing the charging valve (6)
any plug from the fluid port (11).
until the pressure has been fully relieved . Replace
2. Coat the inside of the accumulator (1) with clean
cap (1) .
hydraulic oil prior to installation to provide initiallu
9. Support the accumulator (2) and remove the
brication for the bladder (10). Refer to the Opera
clamp and locknuts (3) which hold the accumula
tor's Manual for correct type .
tor (2) to the bracket (4).
10. Remove the accumulator (2) from the crane. Refer to Figure 1.
3. Properly position the accumulator (2) against the
Cleaning And Inspection bracket (4) and install the clamp and locknuts (3) .
4. Install the hydraulic lines (5).
5. If required , charge the accumulator (2) . Refer to
A WARNING
the instructions found later in this document.
required . See the Operator's Manual for correct
hazardous. Serious personal injury may type and procedure .
result from misuse of these products. Read 7 . Start the engine and let id le for five minutes. In
spect the hydraulic connections for leaks. Repair
recommendations concerning solvents and leaks as required.
cleaning solutions. 8. Complete the installation by testing all related
functions of the accumulator (2) for proper
1. AII components should be thoroughly cleaned with operation. See the crane 's Hydraulic System
an approved cleaning sOlvent, air dried, and care
Schematic Diagram for hydraulic circuits effected.
fully inspected. A general inspection of components and systems
2. AII Loctite®, Permatex@, or other sealant residue
in the areas adjacent to the repair should also be
present.
mance of products.
rep lace as required.
4. AII "soft parts ", such as seals, gaskets, back up
rings, and o-rings , should be replaced.
that are connected to the accumulator. Repair or
6 . In the event of severe defects, contact factory per
sonnel for directions whether to repair or re place
2 of 4
3
__----4
2 5
9
A
$----6
7
9
CHARGING
VALVE
I..t-~-- 10
11
1. Accumulator 5. Regulator Assembly 9. Charging Valve

2. Regulator Valve 6. Cap 10. Bladder
3. Regulator Gauge 7. Chuck 11. Fluid Pon
4. Supply Gauge 8. Adaptor *
* An Adaptor May Be Required To Connect Chuck To Valve.
Figure 2
Typical Accumulator Charging Regulator Arrangement
Charging The Accumulator

The accumulator is pressurized with dry nitrogen and
A WARNING
may be charged with the unit installed or removed lrom
the crane. hazardous. Serious personal injury may
1. Lower, detach, and secure load, as required. result from misuse of these products. Read
2. Stabilize the crane lor service as lollows: and follow all the manufacturer's
a. Park the crane out 01 the way on a lirm and level recommendations concerning solvents and
surface. cleaning solutions.
b . Engage the park brake or properly block the
tires. 4. Thoroughly clean area to be disassembled with an
c. Engage the swing park brake and/or travel approved cleaning solvent to prevent
swing lock, as required. contamination Irom entering the hydraulic oil
d. Level the crane on fully extended outriggers. circuits. Allow the area to air dry.
hydraulic pump,
3 of 4
11 . Note the reading on the supply gauge (4) . The dry
A WARNING
nitrogen tank must contain sufficient volume and
pressure to charge the accumulator (1) to 100 psi
(690kPa).
hot. A sud den release of hot oil could cause 12. Connect the chuck (7) to the charging valve (9) and
burns or other serious injury. Shutdown the turn the t-handle clockwise to open the charging
engine and exhaust all trapped hydraulic valve (9).
pressure from the system before removing 13. When charging a new accumulator (1), open the
any line or component. regulator valve (2) slowly until the regulator gauge
(3) reads 5 psi (34kPa).
5. Relieve the hydraulic system pressure as follows: 14. Slowly open the regulator valve (2) until the
a. Release any residual pressure in the hydraulic regulator gauge (2) reads 100 psi (690kPa) .
reservoir by slowly loosening the filler/breather 15. Turn the t - handle of the chuck (7)
cap , located on the top of the hydraulic counterclockwise to close the charging valve (9)
reservoir, until pressure is fully relieved. and then close the valve on the dry nitrogen tank.
b. Turn the ignition switch to "ON", but DO NOT 16. Remove the chuck (7) from the charging valve (9)
START THE ENGINE . Move the function lock and inspect the charging valve (9) for leaks. There
out switch to the "OPERATE" position. will be a slight discharge of nitrogen when the
c. Work the crane control levers and outrigger chuck (7) is removed.
switches back and forth several times. 17. If leaks are present, repair as required and repeat
d . Turn ignition switch to the " OFF" position. the charging procedure .
6 . Check that all controllevers are in the neutral posi 18. II no leaks are present, install the cap (6) on the
tion and move the function lockout switch to the accumulator (1).
"DISABLE" position. 19. Check hydraulic reservoir oil leveL Add oil as
Refer to Figure 2. required . See Operator's Manual for correct type
7. Remove the cap (6). and procedure.
8. Close the regulator valve (2) and the valve on the 20. Start the engine and let idle for live minutes.
dry nitrogen tank . Inspect the connections on the hydraulic lines lor
9. Connect the regulator assembly (5) to the dry leaks . Repair il needed.
nitrogen tan k. 21 . Complete the installation by testing all related
10. Open the valve on the dry nitrogen tank. If the functions 01 the accumulator lor proper operation.
regulator valve (2) is properly closed, the regulator Normal operation of hydraulic and electrical
gauge (3) should read O psi (OkPa) . systems should be conlirmed . A general
present.
4 of 4
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1. Solenoid Cartridge 3 Valve Body 5 Back Up Ring 7. O-ri ng 9. Back Up Ring
2. Relief Cartridge 4. O-ring 6. Back Up Rings 8 O -nng 10 O-ring
Figure 1
Solenoid/Relief Valve
b. Engage the park brake and/or properlY block

Solenoid/Relief Valve, the tires.
Recondition c. Engage the swing park brake or travel swing
lock , as required.
This procedure covers the recondition of the d. Level the crane on fully exte nded outriggers.
solenoid/relief valve. For removal and installation e. Fully retract ancl position the boom, as re
procedures, see the general instructions "Upper quired.
Hydraulic Components, R & 1" found in SM Keysheet 3. Shutdown the engine and disengage the main hy
Area 07 -004 or 07 -008. draulic pump.
The relief valve may be reconditioned without removing
the en tire valve from the crane. However, proper crane
setup and hydraulic pressure reliel procedures must
first be performed as follows:
A WARNING
Removal burns or other serious injury. Shutdown the
1. Lower, detach, and secure the load , as required. engine and exhaust all trapped hydraulic
2. Stabilize the crane for service as follows: pressure from the system before removing
a. Park the crane , out 01 the way, on a lirm and any line or component.
level surface.
1 of 4
4. Relieve the hydraulic system pressure as follows: Cleaning And Inspection
reservoir, until press'Jre is fully relieved.
A WARNING
START THE ENGINE. Move the function lock hazardous. Serious personal injury may
out switch to the "OPERATE" position. result from misuse of these products. Read
c. Work the crane control levers and outrigger and follow all the manufacturer's
switches back and forth several times. recommendations concerning solvents and
d. Turn the ignition switch to the "OFF" position. cleaning solutions.
tion and move the function lockout switch to the 1. Thoroughly clean all metal parts with an approved
"DISABLE" position. cleaning solvent. Place parts on a clean, lint free
A WARNING
Sol vents and cleaning solutions can be
2.
res ult from misuse of these products. Read
recommendations concerning solvents and with Loctite® 7070 Cleaner to ensure best perfor
mance of products.
wear, fatigue or stress fractures, corrosion, deep
burrs or sharp edges with a fine file, hone, emery
Disa ssembly cloth, or crocus cloth. Replace any damaged com
ponent, as required.
It is a good practice when disassembling hydraulic 4. Through the nose of the cartridge, manually oper
components to lay the parts out in the order that they ate the inner working parts several times. Use a
were disassembled. Keeping the parts in this order piece of plastic tubing to avoid damaging soft
cluring disassembly, cleaning, and inspection will aid in seats, sharp edges, finished surfaces, or the
the assembly process. screen protecting the pilot orifice. AII parts should
move freely. If possible, this inspection should be
Refer to Figure 1.
done with the cartridge submerged in clean miner
1. Remove the solenoid cartridge (1) from the valve
al spirits. After flushing, blow the cartridge dry with
body (3).
clean, filtered airo
2. Remove o-ring (7) and back up rings (6) from
solenoid cartridge (1).
3. Remove back up ring (5) and o-ring (4) from
solenoid cartridge (1).
4. Remove the relief cartridge (2) from the valve body
(3).
5. Remove o-ring (10) from relief cartridge (2).
6. Remove back up ring (9) a d o-ring (8) from relief
cartridge (2).
2 of 4
Installation 4. Dip cartridges (1 ,2) in clean hydraulic oil. See the
Operator 's Manual for the correct type.
5. Install the cartridges (1 ,2) in the valve body (3).
A WARNING
Torque the cartridges (1,2) to 45-50 ft lb
(60-65Nm) .
compounds, etc. can be hazardous. Serious required . See the Operator's Manual for the
personal injury may result from misuse of correct type and procedure .
these products. Read and follow all 7. Start the engine and let idle for five minutes.
manufacturer's recommendations concerning Inspect the hydraulic connections for leaks .
these products. Repair leaks as required.
8. Ensure the relief valve pressure is correctly se!.
Refer to Figure 1. See the Operator's Manual for the correct
1. Lubricate the 0 - rings (4 ,7,8,10) and the back up adjustment procedure.
rings (5 ,6,9) with clean hydraulic oil. See the Oper 9 . Complete the instaliation by testing all related
ator's Manual for the correct type. lunctions of the valves lor proper operation .
2. Install the o-rings (4,7) and back up rings (5,6) on Normal operation 01 the hydraulic system should
solenoid cartridge (1). be conlirmed . A general inspection 01 the
3. Install the 0- ring (8) ,back up ring (9) , and 0- ring components and systems in the areas adjacent to
(10) on relief cartridge (2) . the repair should also be performed to ensure
3014
4 of 4
Service Manual 0905 SM07 -003-0 06.00 1
Solenoid Valves, General

Recondi1ion
This procedure covers the recondition of solenoid 2
valves in general.
Disassembly 3
.A WARNING 4
1. Thoroughly clean the exterior surface of the valve

assembly with approved cleaning solven!.
5
CAUTION
Do not clamp valve housing in any form of 6
vice unless jaws are protected by a soft
material. Brass or wood are preferred.
10 7
2. Place the valve housing (10) in a vise .
3. Note position of prongs (5) on coil (4) , to ensure
proper alignment during assembly. 8
4. Remove nut (1), washer (2) , coil housing (3) , coil
(4), and plate (6) from valve cartridge stem (8).
9
5. Remove valve cartridge stem (8) from valve hous
ing (10).
6. Remove and discard o-rings (7,9) . ~_=~.:f

l-===-l
f-===-l
I I
I I
.A WARNING
I
I
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Follow al! manufacturer's recommendations I I
concerning solvents and cleaning solutions. I I
L ___ -.J

tion possible to keep all parts free of dust, dirt, or any 1. Nut 6. Plate
other foreign material during assembly. 2. Washer 7. O-ring
2. Carefully inspect all components for damage, wear, 3. Coil Housing 8. Valve Canridge Stem
corrosion, deep scratches, and scuffed metal. Re 4. Coil 9. O-ring
5. Prongs 10. Valve Housing
place any damaged component as required. AI
ways use new o-rings. Figure 1
Solenoid Valve Assembly
1 of 2
Assembly 3. Insta!! o-rings (7,9) onto valve cartridge stem (8).
4. Install valve cartridge stem (8) assembly into valve
Lubricate o-rings and threads with clean hydraulic oil housing (10).
prior to assembly. Refer to the Operator 's Manual for
the correct type.
CAUTION
Torque is critical to operation of valve.
CAUTION
Do not clamp solenoid valve housing in any 5. Torque valve cartridge stem (8) assembly to torque
form of vice unless jaws are protected by a value specified in chart below.
soft material. Brass or wood are preferred. 6. Align prongs (5) on coil (4) , as they were prior to dis
assembly and torque nut (1) to torque value speci
1. Place valve housing (10) in a vise. fied in chart below.
2. Install plate (6), coil (4), coil housing (3), washer (2), 7. If solenoid valve assembly is not to be installed on
and nut (1) onto valve cartridge stem (8). crane im mediately, plug all ports to prevent contam
ination from entering and store properly.
Note: Do not torque nut at this time. Nut will be
torq ued after installation.
Torque SpecHication Chart
Solenoid Thread Size Solenoid Installation Torque Coil Installation Torque

f- -
-
1 .000 - 14 U N F 25-29 ft lb (34-39Nm) 7-11 ft lb (10-15Nm)

- -
1 .250 - 14 U N F 30-34 ft lb (41-46Nm) 12-16 ft lb (16-22Nm)
-
1.313-12UNF 35-38 ft lb (47-52Nm) 12-16 ft lb (16-22Nm)

-
2 of 2
Directional Relief Valve, Cleaning And Inspection

Recondition
This procedure covers
direClional reliel valve .
Ihe recondilion 01 Ihe A WARNING
Disassembly result from misuse of these products. Read
II is a good praClice when disassembling hydraulic
componenls lo lay Ihe parls oul in Ihe order Ihal Ihey
cleaning solutions.
were disassembled. Keeping Ihe parls in Ihis order
during disassembly, cleaning, and inspeclion will aid in
1. Thoroughly clean all melal parls wilh an approved
cleaning solven!. Place parls on a clean , linl Iree
II parls are hard lo disassemble and assemlJle , do nol surlace and allow lO air dry. Exercise every
use a hammer unless il has a soft lace , do nol lorce precaution possible lo keep all parts free 01 dust ,
parls logelher, Ihey musl be Iree lO rOlale/operale and dirl, or any olher loreign malerial during assembly.
nol bind. 2. AII Loclile®, Permatex®, or olher sealanl resi due
should be removed from Ihreads 01 hardware and
Ihe mounling surfaces 01 parls Ihal are going lo be
A WARNING reused. Prior lo applying new Ihread locking
compounds or sealants , clean Ihreads and
Solvents and cleaning solutions can be surfaces wilh Loclile® 7070 Cleaner lo ensure besl
hazardous. Serious personal injury may performance 01 producls .
result from misuse of these products. Read 3 . Carelully inspecl all componenls for damage ,
and follow all the manufacturer's wear, faligue or slress fraclures , corrosion , deep
recommendations concerning solvents and scralches, cracks, and scuHed melal. Remove any
cleaning solutions. burrs or sharp edges with a fine file, hone, emery
clolh, or crocus clolh. Replace any damaged
1. Drain any hydraulic oil remaining wilhin Ihe componenl.
direclional reliel valve inlo an appropriale 4. AII "soft parls", such as seals , gaskels, back up
conlainer. Properly slore or dispose 01 Ihe used oil. rings, and o-rings, should be replaced.
2. Cap/plug any openings in Ihe direclional reliel 5. In the evenl of severe defecls , conlacl faclory
valve. Thoroughly clean Ihe exlerior surface ollhe personnel for direclions whelher lO repair or
direclional reliel valve lo prevenl conlaminalion. replace any major component.
Reler lo Figure 1.
3. Nole Ihe order and posilion 01 valves (1,6) .
4. Remove solenoid valve (1) and reliel valve (6) Irom
valve body (5).
5. Remove o-ring (2) from solenoid valve (1).
6. Remove o-rings (8) and back up rings (7) from
solenoid valve (1).
7. Remove o-ring (11) from Ihe reliel valve (6) .
8. Remove back up rings (9) and o-ring (10) Irom
relief valve (6).
9. Remove plugs (3) Irom valve body (5) .
10. Remove o-rings (4) from plugs (3) .
1 of 4
SM07-003-011 ~OO 1106 Service Manual
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4
5
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3
4
1. Solenoid Valve 4, O-ring 7, Back Up Rings 10, O-ring

2. O-ring 5, Valve Body 8, O-ring 11 ,O- ring
3 Plug 6. Relief Valve 9, Back Up Rings
Figure 1
Directional Relief Valve Assembly
Assembly 3. Install o-ring (11) on relief valve (6).
4. Instal 0- ring (10) and backup rings (9) on relief
valve (6).
A WARNING
5.
6.
Install o-ring (2) on solenoid valve (1) .
Install 0- rings (8) and back up rings (7) on
solenoid valve (1).
7. Install solenoid valve (1) and relief valve (6) in valve
body (5). Torque valves to 25 ft lb (33. 9Nm).
8. If the directional relief valve is not to be immediately
installed on the crane, plug all open ports to
these products.
Lubricate all back up rings , o-rings, spools , and

housing bares with clean hydraulic oil prior to
assembly. See Operatar's Manual far correct type .
Refer to Figure 1.
1. Install o-rings (4) on plugs (3).
2. Install plugs (3) in valve body (5).
3 of 4
..... ..... .... : ..
4 of 4
5, Relieve the hydraulic system pressure as lollows:
Upper Hydraulic a, Release any residual pressure in the hydraulic
Components, R & I reservoir by slowly loosening the liller/b reather
cap, located on the top 01 the hydraulic
Upper Cab Floor reservoir, until pressure is lully relieved,
b, Turn the ignition switch to "ON", but DO NOT
removal and installation 01 hydraulic components
out switch to the "OPERATE" position,
mounted to the upper cab Iloor. Specilic procedures
c, Work the crane control levers and outrigger
lor major component removal and installation may be
switches back and lorth several times,
available , Reler to SM Keysheet lor tilles and code
d, Turn ignition switch to the " OFF" position ,
numbers 01 additional procedures,
Reler to Figure 1,
Removal 6, Disconnect any control cables, etc, pertaining to
1, Lower, detach, and secure the load, as required, and directly connected to the hydraulic compo
2, Stabilize the crane lor service as lollows : nent that is to be removed,
a, Park the crane, out 01 the way, on a lirm and 7, II required, label lor assembly purposes and dis
level surface, connect any electrical connectors pertaining to
b, Engage the park brake and/or properly block and directly connected to the hydraulic compo
the tires, nent being removed,
c, Engage the swing park brake or travel swing 8, Label lor assembly purposes and disconnect any
lock , as required, hydraulic lines , hoses , tubes , and littings pertain
el. Level the crane on lully extended outriggers, ing to and direclly connected to the hydraulic com
e, Fully retract and position the boom, as re ponent being removed , Cap/plug any open lines ,
quired, hoses , tubes, and littings to prevent excessive oil
3, Shutdown the engine and disengage the main hy loss and contamination 01 the system,
draulic pump, as equipped, 9, Adequately support the component with an ap
propriate lifting device, as required,
10, Remove any mounting hardware that may be se
A WARNING curing the hydraulic component to the crane,
11, Using an appropriate lifting device , il required, re
Solvents and cleaning solutions can be move the hydraulic component Irom the crane,
result from misuse of these products. Read Cleaning And Inspection
cleaning solutions.
A WARNING
4, Thoroughly clean the area to be disassembled with
an approved cleaning solvent to prevent hazardous. Seriolls personal injury may
contamination, Allow the area to air dry, result from misuse of these products. Read
A WARNING cleaning solutions.
Hydraulic oil is under pressure and may be 1, AII components should be thoroughly cleaned with
hot. A sud den release of hot oil could cause an approved cleaning solvent, air dried, and care
burns or other serious injury. Shutdown the lully inspected ,
engine and exhaust all trapped hydraulic 2, AII Loctite®, Permatex®, or other sealant residu e
pressure from the system befo re removing should be removed Irom threads 01 hardware and
any line or component. the mounting surfaces 01 parts that are going to be
reused, Prior to applying new thread locking com
pounds or sealants , clean threads and surfac es
with Loctite® 7070 Cleaner to ensure best perlor
mance 01 products,
1 014
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~ 7'
1 Swing Brake Pedal Valve

2. Functian Disable Valve
Figure 1
Upper Hydraulic Components - Upper Cab Floor
2014
3. Tharoughly inspect all parts far damage, wear, fa Note: When installing air or hydraulic lines,
tigue or stress fractures, and carrosion. Repair or hoses, tubes, and fitting s, use two wrenches to
replace as required. ensure that they are not twisted. One wrench
4. AII "soft parts" , such as seals, gaskets, back up must be on the maJe fitting, and the other
rings , and o-rings, should be replaced. wrench on the femaJe fitting.
that are connected to the hydraulic component. 4. Attach hydraulic lines , hoses , tu bes, and fittings.
Repair or replace if required. Torque per specifications in SM Keysheet Area
6. Inspect the integrity 01 the electrical wires and con 07-018.
nectars that supply the hydraulic component. Re 5. Connect any electrical connectars that were dis
pair or replace if required . connected.
7. In the event of severe defects , contact factory per 6. Connect control cables, etc. that were removed.
sonnel far directions whether to repair or replace 7. Check the hydraulic reservoir oil level. Add oil as
any majar component. required. See Ihe Operator 's Manual for correct
type and procedure.
Installation 8. Check far carrect fluid levels in any related
components such as pump drives, gear reduclion
units, engine crankcase, radiator, etc. Refer lo the
A WARNING
crane or engine Operalar's Manual far carrect
type/quantity of fluids and proper procedure .
Engage Ihe main hydraulic pump, as equipped.
compounds, etc. can be hazardous. Serious 10. Start Ihe engine and lel idle far five minutes.
personal injury may result from misuse of 11. Inspect the hydraulic connections far leaks. Re
these products. Read and follow aH pair leaks as required.
manufacturer's recommendations concerning 12. Complete the installation by testing all related func
these products. tions of the hydraulic component lar proper opera
tion. Normal operation of the hydraulic and electri
Reler to Figure 1. cal syslems should be conlirmed. A general in
1. Using an appropriate lifting device, il required, speclion of the components and systems in the
align the hydraulic component to the crane. areas adjacent lO the repair should also be per
2. Apply Loctite® 242 to mounting hardware, as re lormed lo ensure related damage or wear is not
quired. present.
3. Install the mounting hardware and larque per
specilication in SM Keysheet Area 18-000.
3 of 4
",' .
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Upper Hydraulic a. Release any residual pressure in the hydraulic
Components, R & I cap, located on the top of the hydraulic
Two Winch Plumbing reservoir, until pressure is fully relieved.
removal and installation of the upper hydraulic
components associated with the winch plumbing.
C. Work the crane control levers and outrigger
Specific procedures for major component removal and
installation may be available. Refer to SM Keysheet for
titles and code numbers of additional procedures.
Refer to Figure 1.
Removal 6. Disconnect any control cables, etc. pertaining to
1. Lower, detach, and secure the load, as required. and directly connected to the hydraulic compo
2. Stabilize the crane for service as follows: nent that is to be removed.
a. Park the crane, out of the way, on a firm and 7. If required, label for assembly purposes and dis
level surface. connect any electrical connectors pertaining to
b. Engage the park brake and/or properly block and directly connected to the hydraulic compo
the tires. nent being removed.
c. Engage the swing park brake or travel swing 8. Label for assembly purposes and disconnect any
lock, as required. hydraulic lines, hoses, tubes, and fittings pertain
d. Level the crane on fully extended outriggers. ing to and directly connected to the hydraulic com
e. Fully retract and position the boom, as re ponent being removed. Cap/plug any open lines,
quired. hoses, tubes, and fittings to prevent excessive oil
3. Shutdown the engine and disengage the main hy loss and contamination of the system.
draulic pump, as equipped. 9. Adequately support the component with an ap
propriate lifting device, as required.
10. Remove any mounting hardware that may be se
A WARNING curing the hydraulic component to the crane.

11. Using an appropriate lifting device, if required, re
Solvents and cleaning solutions can be move the hydraulic component from the crane.
result from misuse of these products. Read Cleaning And Inspection
cleaning solutions.
A WARNING
4. Thoroughly clean the area to be disassembled with Solvents and cleaning solutions can be
an approved cleaning solvent to prevent hazardous. Serious personal injury may
contamination. Allow the area to air dry. result from misuse of these products. Read
A WARNING cleaning solutions.
Hydraulic oil is under pressure and may be 1. AII components should be thoroughly cleaned with
hoto A sudden release of hot oil could cause an approved cleaning sOlvent, air dried, and care
burns or other serious injury. Shutdown the fully inspected.
engine and exhaust all trapped hydraulic 2. AII Loctite®, Permatex®, or other sealant residue
pressure from the system before removing should be removed from threads of hardware and
any line or component. the mounting surfaces of parts that are going to be
mance of products.
1 of 4
,I
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,-- il
! _ ,.z
1 Winch Valve
2. Pressure Reducing Valve
Figure 1
Upper Hydraulic Components - Two Winch Plumbing
2014
3. Thoroughly inspect all parts lor damage, wear, la Note: When installing air or hydraulic lines,
tigue or stress Iractures, and corrosion. Repair or hoses, tubes, and fittings, use two wrenches to
replace as required. ensure that they are not twisted. One wrench
4. AII "soft parts" , such as seals , gaskets, back up must be on the male fitting, and the other
rings, and 0- rings, should be replaced . wrench on the femélle fitting.
5. Inspect the integrity 01 the hydraulic lines/hoses
that are connected to the hydraulic componen!. 4. Attach hydraulic lines , hoses, tubes, and fittin gs.
Repair or replace il required . Torque per specilications in SM Keysheet Area
6. Inspect the integrity 01 the electrical wires and con 07 -018.
nectors that supply the hydraulic componen!. Re 5. Connect any electrical connectors that were dis
pair or replace il required. connected.
7. In the event 01 severe delects , contact factory per 6. Connect control cables, etc . that were removed .
sonnel lor directions whether to repair or replace 7. Check the hydraulic reservoir oil level. Add oil as
any major componen!. required. See the Operator's Manual lor correct
type and procedure.
Installation 8. Check lor correct fluid levels in any related
units, engine crankcase, radiator, etc . Refer to the
A WARNING
crane or engine Operator's Manual for correct
type/ quantity 01 fluids and proper procedure.
9. Engage the main hydraulic pump , as equipped .
compounds, etc. can be hazardous. Serious 10. Start the engine and let id le lor five minutes .
personal injury may result from misuse of 11 . Inspect the hydraulic connections for leaks . Re
these products. Read and follow al! pair leaks as required.
manufacturer's recommendations concerning 12. Complete the installation bytesting all related fun c
these products. tions of the hydraulic component lor proper opera
tion. Normal operation 01 the hydraulic and electri
Refer to Figure 1 . cal systems should be conlirmed . A general in
1 . Using an appropriate lifting device , il required , spection 01 the components and systems in the
align the hydraulic component to the crane . areas adjacent to the repair should also be pe r
2. Apply Loctite® 242 to mounting hardware, as re formed to ensure related damage or wear is not
quired. presen!.
3. Install the mounting hardware and torque per
specilication in SM Keysheet Area 18-000.
3 of 4
1il1
Upper Hydraulic
Components, R & I
A WARNING
(Upper Frame) hot. A sudden release of hot oil could cause
This procedure is general in nature and covers the engine and exhaust all trapped hydraulic
removal and installation of upper hydraulic pressure from the system before removing
components mounted to the upper frame. Specific any line or component.
procedures for major component removal and
installation may be available. Refer to SM Keysheet for 5. Relieve the hydraulic system pressure as follows:
titles and code numbers of additional procedures. a. Release any residual pressure in the hydraulic
Removal
1. Lower, detach , and secure the load, as required. reservoir, until pressure is fully relieved.
2. Stabilize the crane for service as follows: b . Turn the ignition switch to "ON", but DO NOT
a. Park the crane, out of the way, on a firm and STARTTHE ENGINE. Move the function lock
level surface. out switch to the "OPERATE " position.
b . Engage the park brake and/or properly block c. Work the crane control levers and outrigger
the tires. switches back and forth several times .
c. Engage the swing park brake or travel swing d. Turn ignition switch to the "OFF" position .
lock, as required.
d. Level the crane on fully extended outriggers. Refer to Figure 1.
e. Fully retract and position the boom , as re 6. Disconnect any control cables, etc. pertaining to
quired . and directly connected to the hydraulic
component that is to be removed.
7. If required, label for assembly purposes and
hydraulic pump, as equipped.
disconnect any electrical connectors pertaining to
and directly connected to the hydraulic
A WARNING
component being removed .
8. Label for assembly purposes and disconnect any
hydraulic lines , hoses, tubes , and fittings
hazardous. Serious personal injury may pertaining to and directly connected to the
result from misuse of these products. Read hydraulic component being removed. Cap/plug
and follow all the manufacturer's any open lines, hoses, tubes , and fittings to
recommendations concerning solvents and prevent excessive oilloss and contamination of the
cleaning solutions. system.
9. Adequately support the component with an
4. Thoroughly clean the area to be disassembled with appropriate lifting device, as required.
an approved cleaning solvent to prevent 10. Remove any mounting hardware that may be
contamination. Allow the area to air dry. securing the hydraulic component to the crane.
11. Using an appropriate lifting device, if required ,
remove the hydraulic component from the crane.
1 of 4
/-11
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1:
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1. Boom Hoisl Telescope Valve 2. Swing Molor 3. Counterweigh t Lock Valve
Figure 1
Upper Hydraulic Components - Upper Frame
2 of 4
3
.'
/ ~/
, ' )
c, .
3 of 4
Cleaning And Inspection I nstallation
A WARNING A WARNING
Solvents and cleaning solutions can be Lubricants, sealants, joint and thread locking
1. AII components should be thoroughly cleaned with Refer to Figure 1.

an approved cleaning solvent , air dried, and 1. Using an appropriate lifting device, il required,
carefully inspected. align the hydraulic component to the crane.
2. AII Loctite®, Permatex®, or other sealant resiclue 2 . Apply Loctite® 242 to mounting hardware , as
should be removed from threads of hardware and required.
the mounting surfaces of parts that are going to be 3. Install the mounting hardware and torque per
reused. Prior to applying new thread locking specification in SM Keysheet Area 18-000.
surfaces with Loctite® 7070 Cleaner to ensure best Note: When installing air or hydraulic lines,
performance of products . hoses, tu bes, and fittings, use two wrenches to
3. Thoroughly inspect all parts for damage , wear, ensure that they are not twisted. One wrench
fatigue or stress fractures , and corrosion. Repair must be on the male fitting, and the other
or replace as requirecl. wrench on the female fitting .
4. AII "soft parts " , such as seals, gaskets , back up
rings , and 0- rings , should be replaced . 4. Attach hydraulic lines, hoses , tubes, and fittings.
5. Inspect the integrity of the hydraulic lines/ hoses Torque per specifications in SM Keysheet Area
that are connected to the hydraulic componen!. 07 -018.
Repair or replace if required. 5 . Connect any electrical connectors that were
6. Inspect the integrity of the electrical wires and disconnected.
connectors that supply the hydraulic componen!. 6. Connect control cables , etc. that were removed.
Repair or replace if required. 7. Check the hydraulic reservoir oil leve!. Add oil as
7. In the event of severe delects, contact factory required. See the Operator 's Manual for correct
personnel for directions whether to repair or type and procedure .
replace any major componen!. 8. Check lor correct Iluid levels in any related
units, engine crankcase, radiator, etc. Refer to the
type/quantity of fluids and proper procedure.
9. Engage the main hydraulic pump, as equipped.
11 . Inspect the hydraulic connections for leaks.
12 . Complete the installation by testing all related
functions 01 the hydraulic component lor proper
operation. Normal operation of the hydraulic and
electrical systems should be conlirmed. A general
performed to ensure related damage orwear is not
presen!.
4 of 4
Swing Motor, Recondition
CAUTION
This procedure covers the recondition of the swing Do not use any tool or object to force between
motor. For removal and installation procedures, see or pry apart either front or rear end ca p or
SM Keysheet Area 7-6. Also included in this displacement housing. The sealing surfaces
procedure is a "Troubleshooting Chart" found on of these components is critical and must not
Page 6. be damaged .
Disassembly
Note: By putting the heel of your hand o ver the
shaft, and your fingl~rs on the opposite e ar that
yourtapping on, you can keep the front end cap
parts together, they must be free to turn and not bind . It
from falling back down after each successive
is a good practice when disassembling hydraulic
tap with the soft faced mallet.
were disassembled. Keeping the parts in this order 5. Remove the front end cap (39) by using a soft
during disassembly, cleaning, and inspection will aid in faced mallet, and tap upwards on the mounting
the assembly process. flange ears . After the front end cap (39) clears the
dowel pins (33), the mallet is no longer required.
Remove the oil seal (32).
A WARNING Note: The dowel pins are a press fit and wlll re
main in the displacement housing. Do nol re
hazardous. Serious personal injury may move the dowel pins unless replacement of the
result from misuse of these products. Read displacement housing is required.
6. Using a soft faced mallet , tap upwards on the dis
placement housing (31) until the dowel pins (33)
cleaning solutions.
clear the rear end cap (13) . Remove the oil seal
(14) .
1. Thoroughly clean the exterior surface of the swing
7. Carefully remove the rear end cap (13) assembly
motor to prevent contamination from entering it.
from the vise and place it on a clean steel bench .
8. Carefully remove seal plates (18) from rotor (17).
CAUTION Note: The tip seal rollers are 1/32 in (O.79mm)

Hydraulic components are machined to close larger than the body seal rollers. Do not mix
tolerances. Use extreme care in handling not these rollers during disassembly, sto rage, or
to crush or cause damage i1 clamped in a vise. assembly.
Do not clamp the swing motor assembly in 9. Remove the tip seal rollers (16) from the rotor (17).
any form of vise unless jaws are protected by 10 . Remove the body seal rollers (15) from the rotor
a soft material. (17) .
11. Remove the capscrews (29), gear cover (30) , and
Refer to Figure 2. oil seal (12) from the rear end cap (13) .
2. Place the swing motor assembly in a vise with the
shaft (11) facing upward and the jaws of the vice
clamping on the rear end cap (13).
3. Using a punch, match mark the rear end cap (13),
A WARNING
Solvents and cleaning solutions c an be
displacement housing (31), and the front end cap
(39) to ensure proper alignment during the assem
bly process.
4. Remove the capscrews (34) securing the rear and
front end caps (13,39) and displacement housing
cleaning solutions.
(31) together.
1 of 6
SM 7-6-34.0 1200 Service ,M anual
19. For assembly purposes , using a felt marking pen,
mark the rotor (17) as to which side is facing up .
20 . Remove the rotor (17) and drive pin (10) from the
shaft (11) .
21 . Turn the rear end cap (13) on its side and remove
retaining ring (4) from the rear end cap (13).
22. Remove shaft (11) from the rear end cap (13) out
through retaining ring (4) end .
23 . Remove bearing race (5), thrust bearing (6), bear
~ Location ing race (7), and retaining ring (8) from shaft (11).
~ I Marks 24. Remove step bearings (22) , o-rings (23), and
~
back up rings (24) from rear end cap (13).
25. Remove step bearings (42) , o-rings (41) , and
back up rings (40) from front end cap (39).
R \ 26 . Remove quad ring (35), retaining ring (36), and
8 ~ seal (37) from front end cap (39) .

27 . Inspect needle bearings (21,25,38,43) in rear end
cap (13) and front end cap (39). Remove if re
quired .
28 . If dowel pins (33) must be removed from the dis
placement housing (31), measure and record the
Timing Marks
length of the pins sticking out of the displacement
housing (31) to ensure proper installation during
the assembly process . Using a shop press, re
Figure 1
Gear Ti ming move the dowel pins (33) from the displacement
housing (31).
12 . Thoroughly clean the exposed gears with a ap Cleaning And Inspection
proved solvent to allow them to be marked with a
felt marking peno
13. Using a permanent felt marking peno Mark the
gears, as shown in Figure 1, for timing and loca
tio n.
A WARNING
14. Re move retaining rings (28), timing gears (27), and hazardous. Serious personal injury may
ret aining rings (26). result from misuse of these products. Read
15. Remove retaining ring (1), timing gear (2), and and follow all the manufacturer's
spacer (3). recommendations concerning solvents and
16. Remove Woodruff keys (9,19) from shaft (11) and cleaning solutions.
abutment valves (20).
17. Lay the rear end cap (13) assembly flat on the 1. Thoroughly clean all metal parts , with an approved
bench with the rotor (17) facing upward. cleaning solvent . Place parts in order of disassem
bly, on a clean , lint free surface and allow to air dry.
Note: When properly timed, the rotor tip will
Exercise every precaution possible to keep all
pass directly through the center ofthe abutment
parts free of dust, dirt, or any other foreign material
cavity. Using a permanent felt marking pen,
during assembly.
mark for assembly purposes which abutment
2. AII Loctite'!>' , Permatex"" , or other sealant residue
valve went into which hole in the rear end cap.
18 . Rotate and position the shaft (11) so that one ofthe parts that are going to be reused .
abutment valves (20) can be lifted out of the rear 3. Inspect all parts for damage , wear, and corrosion,
en d cap (13). Continuing to rota te the shaft (11) so deep scratches , and scuffed metal. Remove any
that the other one of the abutment valves (20) can burrs or sharp edges with a fine file , hone , emery
be lifted out of the rear end cap (13) . cloth, orcrocus cloth . Replace any damaged com
ponent as required . Use the following guidelines
to inspect individual components:
2 of 6
3 ,~,
)
/
/ 11
10
44
[k
28
29
30
43
1. Retaining Ring 13. Rear End Cap 24 . Back Up Ring 35 . Quad Ring
2. Orive Gear 14. OilSeal 25. Needle Bearing 36. Retaining Ring
3. Spacer 15. Body Seal Roller 26 . Retaining Ring 37. Seal
4. Retaining Ring 16. Tip Seal Roller 27 . Timing Gear 38. Needle Bearing
5. Bearing Race 17. Rotor 28 . Retaining Ring 39. Front End Cap
6. Thrust Bearing 18. Seal Plate 29. Capscrews 40. Back Up Ring
7. Bearing Race 19. Woodruff "'Key 30 . Gear Cover 41 O-ring
8. Retaining Ring 20. Abutment Valve 31. Oisplacement Housing 42 . Step Bearing
9. Woodruff'" Key 21 . Needle Bearing 32. OilSea l 43 . Needle Bearing
10. Orive Pin 22. Step Bearing 33. Oowel Pins 44 . Manufacturer's Identifica
11 Shatt 23 . O-ring 34 . Capscrews tion Plate
12 . Oil Seal
Figure 2
Swing Motor Assembly
3 of 6
~. Housing and End Caps: RGplacG housing if NotQ: RQmovQ all traCQS of LoctitQ® from
deep scratc hes and/or sc uffs are found on around needle bearings and bores after instal
moun ting/sealing surfaces, bearing bores a re lation.
damaged and not to s ize, a nd cracks and/ or
porosity exist. 1. If required , apply a light coat of Loctite (" 609 on the
b. Dowel Pins: If either the dowel pin or dowel outside diameter of needle bearings (21 ,25) . Us
hole is damaged , the pin or machined casting ing a shop press , install them into there prospec
or both , mus t be replaced . If more than rea tive bores in the rear end cap (13).
sonable force is required to seat dowels, the 2. If required , apply a light coat of Loctite@609 on the
cause may be poorly deburred or dirty parts, outside diameter of needle bearings (38,43). Us
misalignment of the dowel in the hole, or im ing a shop press, install them into there prospec
proper pin to hole fit. tive bo res in the front end cap (39) .
c . Shaft and Abutment Valves: If there are any 3. Place rear end cap (13) on its side .
burrs on the shaft or abutment valves at the 4. Install retain ing ring (8) , bearing race (7) , thrust
Woodruff " keys slot locations, remove with a bearing (6), and bearing race (5) on shaft (11) and
fine hone or emery cloth. insert shaft (11) throug h rear end cap (13).
d. Bearings : Bearings should fit into bore with a 5. Making sure that all components are seated in the
light press fit. A neat han d fit is allow able. If bottom of the bore , install retaining ring (4) .
bearings can fall out , the bore may be oversize.
Note: Install drive gear with timing marks facing
e . Seals: Replace all rubber and polymer seals
outward.
wheneve r d isassembling the swing motor. In
clude all seals , o-rings, quad rings , and back 6. Ins tall spacer (3) , drive gear (2) , and retaining ring
up rings . (1) on shaft (11) .
4. In the event of severe defects , contact factory per 7. Place rear end cap (13) on the table with s plined
sonnel for directions whether to repair or replace end of shaft (11) facing upward .
a ny major component. 8. Install back up ring s (24), o-rings (23), and step
bearings (22) through needle bearings (21) and
Assembly into there pros pective bores in the rear end cap
(13) .
A WARNING
Note: Install rotor with timing marks facing out
ward .
compounds, etc. can be hazardous. Serious 9. Install drive pin (10) and rotor (17) on shaft (11).
p e rsonal injury may result from misuse of
Note: When properly timed, the rotor tip will
pass directly through the center ofthe abutment
cavity.
the se products.
10. Rotate and position the shaft (11) so that one ofthe
Lubric ate all back up rings, o - rings , quad rings , abutment valves (20) can be lowered into its pro
nee d le bearing s, and housing bores with hydraulic oil s pective bore in the rearend cap (13) . Continuing
prior to assembly. See Operator 's Manual for correct to rota te the shaft (11) so that the other one of the
type . abutment valves (20) can be lowered into its pro
spective bore in the rear end cap (13).
Refer to Figure 2. 11 . Continue rotating s haft (11) several revolutions to
ensure that no binding occurs. If binding occurs ,
remove abutment valves (20) and reinstall per s tep
CAUTION 10 and preceding Note .
Do not apply excess Loctite " to parts. Over 12. Place rear end cap (13) assembly on its side .
use of thread locking compound can cause 13. Install retaining rings (26) and Woodruff® keys
working parts to stick and malfunction. Use (9 ,19) in shaft (11) and abutment valves (20).
minimal amounts of Loctite ~ on working parts
and wipe clean any excess.
4 of 6
Torque Chart
Motor Model Prefix Capscrew Torque
RSB 41 ft lb (55.6Nm)
RSC 150 ft lb (203Nm)
Note: Make sure that timing gears are installed

according to location and timing marks that
were placed on them during disassembly.
14. Align and install timing gears (27) and retaining

rings (28) on abutment valves (20).
15. Apply a light coat of Loctite ' 242 to threads of
capscrews (29) before installation. Install oil seal
(12), gear cover (30), and capscrews (29) on rear
end cap (13). Torque capscrews (29) in a criss Timing Gear ,-'
cross pattern to 125 in lb (14Nm). \
16. Place rear end cap (13) assembly on the gear cov
er (30) with shaft (13) facing up.
17. If required, using a shop press, install dowels (33) Timing Marks
in displacement housing (31) per dimensions
noted during disassembly. Figure 3
18. Install oil seal (14) in rear end cap (13). Gear Timing
19. Align dowels (33) and displacement housing (31)
to there prospective dowel holes and bores in the 22. Install back up rings (40), o-rings (41), and step
rear end cap (13). Use a soft faced mallet to seat bearings (42) through needle bearings (43) and
dowels (33) and displacement housing (31) down into there prospective bores in the front end cap
flat onto rear end cap (13). (39).
23. Install oil seal (32) in front end cap (39).
Note: The tip seal rollers are 1/32 in (0.79mm)
24. Align dowels (33) to there prospective dowel holes
larger than the body seal rollers. Due not mix
and bores in the front end cap (39). Use a soft
these rollers during the assembly process.
faced mallet to seat the front end cap (39) down flat
20. Applya liberal amount of multipurpose grease to on the displacement housing (31).
outside diameter of rotor and install the body seal 25. Apply a light coat of Loctite' 242 to threads of
rollers (15), tip seal rollers (16), and seal plates (18) capscrews before installation. Install capscrews
on the rotor (17). (34) through front end cap (39), displacement
housing (31), and into the rear end cap (13).
Note: Before assembly, apply a light coat of 26. Identify the "Motor Model Prefix" located on the
PermatexQt¡ Aviation Grade 2 to the outside di Manufacturer's Identification Plate (44). Torque
ameter of the sea!. capscrews (34) per "Torque Chart" in a criss
cross pattern.
21. Install seal (37), retaining ring (36), and quad ring 27. Ifthe swing motor is not to be immediately installed
(35) in front end cap (39). on crane, plug all open ports to prevent contamina
tion and properly store.
5 of 6
Trou bleshooting Chart
The following chart lists the possible problems that may occur, the probable cause , and the corrective action
recom mended.
Problem Probable Cause Corrective Action

No pressure 1. Loose coupling 1. Repair or replace coupling
2. System relief open 2. Clean , adjust, or replace if
necessary
Noisy system 1. Cavitation at pump 1 . Check for inlet air leaks
Check pump inlet for restriction
2. Reservoir low 2. Fill to recommended level
Motor will not develop torque 1. System relief unloading 1 . Disassemble, clean, and adjust
2. Worn out 2 . Repair or replace
3 . High Temperature operation 3. Change to fluid with higher
viscosity index
Blown rear cover 1. Orain restriction 1. Drain directly to tank
2. High case drain 2. Repair motor
Leakage around shaft 1 . Shaft seal worn out 1. Replace
Mo tor turns in wrong direction 1. Hose connection wrong 1. Reverse connections
6 of 6
Winch Motor, Recondition A WARNING
Do not use force by prying or hammering. Use
This procedure covers the recondition of the winch
motor. For removal and installation procedures, see care separating port housing from case.
SM Keysheet Area 07 -006. Mounting faces or internal components cou ld
be damaged. Upon separation of the case
If parts are hard to disassemble and assemble , do not and port housing, several components will be
use a hammer unless it has a soft face, do not force loose and could fall. Serious personal injury
parts together, they must be free to turn and not bind. or component darnage may result If
precautions are not followed.
components to lay the parts out in the order that tlley 8. Using care , separate ¡:lort housing (36) from case
are disassembled . Keeping the parts in tllis order (3) .
the assembly process . Note: Secure shaft, cradle, and cylinder block
assembly on bench with blocking to prevent
Disassembly rolling.
Note: The use of an auxiliary lifting device is recom 9. Remove shaft (16), cradle (18) , and cylinder block
mended when handling the winch motor as an as (10) assembly from case (3) .
sembly. The winch motor assembly weighs approx
imately 93 lb (42kg) . Note: For assembly purposes, record location
and attach to bearing cupo
10. Remove o-rings (4) , retaining ring (1) , seal (2),

A WARNING
and bearing cup (6) from case (3) .
11. Remove sliding bearings (17) and spring dowels
(15) from case (3).
result from misuse of these products. Read Note: For assembly purposes, record location
and follow all the manufacturer's and attach to bearing cupo Record location and
recommendations concerning solvents and thickness and attacll to shims.
cleaning solutions.
12. Remove port plate (32) , dowel pins (35), bearing
1. Drain any excess hydraulic oil, remaining within cup (33) , and shims (34) from port housing (36).
the winch motor, into an appropriate container.
Note: For assembly purposes, record location
Properly store or dispose of the used oil.
and attach to pipes and servo pistons. Record
2. Cap/plug any openings in the winch motor. Thor
location and thickness and attach to shi ms and
oughly clean the exterior surface of the winch mo
shim washers.
tor to prevent contamination from entering it.
3. Thoroughly clean the exterior of the winch motor 13. Remove pipes (59), shims (62), shim washers (63),
with an approved cleaning solvent to prevent and servo pistons (58) from port housing (36).
contamination from entering . Allow the area to air 14. Remove o-rings (61) and back-ups (60) from
dry. pipes (59) .
4. Place the winch motor on a clean steel bench prior 15. Remove seal rings (57) from servo pistons (58) .
to removing any component. 16. Remove capscrews (49) , magnet (48) , and sleeve
5. Remove plugs (8,56) from case (3) and port hous (84) assembly from port housing (36) .
ing (36). 17. Remove o-ring (47), solenoid (51) and seal (50)
6. Remove o-rings (9,55) from plugs (8,56) . from magnet (48).
7. Remove capscrews (24) securing port housing 18. Remove bushing (46), spool (45) , support washer
(36) to case (3) . (86), spring washer (83) , spring (82) , and spring
washer (81) from sleeve (84) .
I of 8
s 07 -006-095.00 0509 Service Manua'l
19. Remove o-rings (80,85) from sleeve (84). Note: Secure shaft before removing retaining
20 . Remove capscrews (44) and sensor housing (43) ringo Shaft may slide out of cylinder block.
assembly from por! housing (36).
21. Remove capscrew (39) and impulse wheel (38) 34. Using a shop press, collapse spring (28) and re
from shaft (16). move retaining ring (26). Release spring (28) and
remove shim (30), washer (27) , spring (28) , and
Note: Multiple variations 01 the impulse wheel washer (29) from shaft (16).
assemblyexist. Refer to Figure 2 for alternate 35. Remove shaft (16) from cylinder block (10).
versions.
Note: Piston orientation to cylinder block bores
22 . Remove spríng dowels (54) and o-rings (37,40) is critical to pump performance. Ensure that
from impulse wheel (38) and sensor housing (43). pistons will be replaced in the same bores at as
23 . Remove sensor (41) from sensor housing (43) and sembly by recording, tagging, and/or match
0- ring (42) from sensor (41) . marking.
24 . Remove housíng (78) assembly, plug (69), spring
(71), housing (68) assembly, and spring (65) from 36. Remove cylinder block (10) from pistons (19).
port housing (36).
Note: For assembly purposes, record position
25. Remove plug (74), spríng (76), ball (77), and 0
and location and attach to shims, lock plates,
ríngs (75 ,79) from housíng (78) .
and back plate.
26 . Remove spools (67,73) and o-ríngs (66 ,72) from
housing (68) . 37. Remove capscrews (11 ,23), lock plates (12 ,22),
27. Remove o-ríng (70) from plug (69) . shims (13,21) , back plate (20) , and pistons (19)
from cradle (18).
Note: For assembly purposes, count and re
38. If required , remove spring dowels (14) from cradle
cord the number of exposed threads on both
(18).
studs.
28. Loosen seal nuts (52) an d remove studs (53) from

por! housing (36). Remove seal nuts (52) from
studs (53) .
Note: For assembly purposes, record locations A WARNING

an d attach to each orifice.
29. Remove plugs (87,89) ancl orífices (88,90,91) from result from misuse of these products. Read
por! housing (36). and follow all the manufacturer's
30 . Do not attempt to remove expansion plugs (64) recommendations concerning solvents and
from por! housing (36). If they are leaking , a new cleaning solutions.
port housing (36) will be required. They are
installed and swedged into port housing (36) at the 1. Thoroughly clean all metal parts with an approved
factory. cleaning solvent. Place parts on a clean, lint free
31. If required, remove plugs (!56, ) and dowel pins (35) surface and allow to air dry. Exercise every precau
from por! housing (36). tion possible lo keep all parts free of dust, dirt, or
any olher foreign material during assembly.
2 . Carefully inspecI all components for damage,
and location and attach to bearing cone.
wear, corrosíon, deep scratches, and scuffed met
32 . Using the correct bearing puller, remove bearing al. Remove any burrs or sharp edges with a fine
cone (7) and wear ring (5) from shaft (16). file, hone, emery cloth, or crocus cloth. Replace
any damaged component as required.
and location and attach to bearing cone and
spa cer.
33. Using the correct bearing puller, remove bearing

cone (25) and spacer (31) from shaft (16) .
2 of 8
Service Manual 0509 S M07 - 006 - 095 .00
3. AII Loctite't:.; , Permatex ,or other sealant residue Assembly
with Loctite'''' 7070 Cleaner to ensure best perfor
A WARNING
mance of products.
4. Inspect all parts for damage, wear, and corrosion ;
personal injury may result from misuse 01
replace as required. Use the following guidelines
these products. Read and follow aU
to inspect individual components:
a. Case and Housings: Replace case and hous
these products.
ing or cylinder block if deep scratches and/ or
scuffs are found on mounting/sealing sur
faces , bearing, or piston bores are damaged Lubricate all back up rings, o-rings, quad rings,
and not to size, and cracks and/or porosity ex spools, case , and housing bores with hydraulic oil pri or
ist. Port Housing is a non-serviceable parto If to assembly. See Operator's Manual for correct type.
this component is damaged, contact factory Apply sealants and thread locking compoun ds
personnel for directions. sparingly. Do not us Teflon tape on hydraulic
b. Spools and Pistons: Replace spools or pistons components. Excess compound or tape remn ants
if deep scratches and/or scuffs are found on may enter circuits and cause blockages an d/or
sealing surfaces. Light burrs on land edges sticking.
may be removed. Replace pistons as a seto
C. Springs: Inspect for fatigue and/or stress When installing bearings , seals , wear rings , and
cracks. Ensure that springs are to specified retaining rings that secure compressed springs.
lengths, free and installed height. Replace if Ensure that the drivers fits the component correctly
any specification is found not to be correct. and will not cause any damage, burrs , an d/or
d. Shaft and Cyllnder Block Splines: Replace if interference with the assembly process .
splines show signs of wear, fretting , or fatigue .
Note: The use of an auxiliary lifting device 1s recom
e. Sliding Bearings and Cradle: Replace bear
mended when handling the winch motor as an as
ings or cradle if deep damage , wear,
scratches , or scuffed metal are found on mat
ing surfaces. Spring dowel holes cannot show imately 93 lb (42kg) .
any signs of wear or enlargement.
f. Spring Oowels or Oowel Pins: If either the Note: If lead in chamfer on spring dowels only
spring dowel , dowel pin or dowel hole is dam exist on one end, install in cradle chamfer first.
aged, spring dowel , dowel pin , machined cast
ing, or both , must be replaced . If more than 1. If required , install spring dowels (14) in cradle (18).
reasonable force is required to seat dowels,
Note: Ensure that used pistons, shims, lock
the cause may be poorly deburred or dirty
plates, and back plate are installed in the same
parts, misalignment ofthe dowel in the hole , or
positions as removed. Pistons must be
improper spring dowel to hole fit.
installed as a set, new or used.
g. Bearings : Bearings should fit into bore with a
light press fit. A neat hand fit is allowable. If 2. Assemble cradle (18) , pistons (19) , and cylinder
bearings can fall out, the bore may be oversize block (10) as follows:
and casting must be replaced. Tapered bear a. Install pistons (19) through back plale (20) .
ings must be replaced as a set. Cup and cone. b. Align back plate (20) to spring dowels (14) and
h. Seal and gaskets: Replace all rubber and poly cradle (18).
mer seals whenever rebuilding the hydraulic C. Align shims (13,21) and lock plates (12 ,22) lo
pump. Include all pocket seals, ring seals, spring dowels (14) and cradle (18) .
shaft seals, o-rings, and gasket seals.
5. In the event of severe defects, contact factory per Note: Apply a light coat of Loctite® 648 to
sonnel for directions whether to repair or replace threads of capscrews.
3 of B
10
1. Retaining Ring 10. Cylinder Block 19, Pistons 28. Spring

2, Seal 11 , Capscrews 20, Back Plate 29 Washer
3 Case 12, Lock Plate 21. Shim 30, Shim
4. O-rings 13, Shim 22, Lock Pl ate 31 , Spacer
5. We ar Ring 14 , Spring Dowels 23, Capscrews 32, Port Plate
6, Bearing Cup 15, Spring Dowels 24 , Capscrews 33, Bearing Cup
7. Bearing Cone 16. Shaft 25, Bearing Cone 34, Shim
8, Plug 17, Sliding Bearing 26, Retaining Ring 35 Dowel Pins
9 O-ring 18, Cradle 27, Washer 36 Port Housing
Figure 1
Winch Motor
4 of 8
41
* See Figure 2 for alternate

variations of the impulse
wheel assembly.
40 44
37 51
52
53 ~
.
I
r\ 8\~1
87 I
54
/
91
. . ~
" ~~83
8586
58
" CO
~~
84
79 82
/ 78 81
dr 77 80
64 36
59 60 61 62 63 65 6667 68
37. O-ring 48. Magnel 59. Pipes 70. O-ring 81. Spring Washer
38. Imp ulse Wheel * 49. Capscrews 60. Back Up Rings 71. Sprin g 82. Spring
39 Capscrew 50. Seal 61. O -rings 72. O-ring 83. Sp ring Washer
40. O- ring 51 . Solenoid 62. Shims 73 . Spool 84. Sleeve
41. Sensor 52. Seal Nuls 63. Shim Washers 74. Plug 85. O-ring
42. O- ring 53. Sluds 64. Expander Plugs 75. O-rings 86. Support Washer
43. Sensor Housing 54. Spring Dowel 65 O-ring 76. Spring 87. Plug
44 . Capscrews 55 , O-ring 66. O-ring 77. Bal! 88 , Ori fice
45, Spool 56. Plug 67. Spool 78, Housing 89 Plug
46. Bushing 57. Seal Rings 68. Housing 79. O-ring 90, Orifice
47 , O-ring 58. Servo Pislons 69 Plug 80. O-ring 91 . Orifice
5 of 8
t;/2
1
9 1
~/2
V
9
9
1. Sensor 4. Spring Pin 7. Capscrew

2. 0- Ring 5. Sensor Housing 8. Impulse Wheel
3. Capscrew 6. O -Ring 9. Shaft Extension
Figure 2
Alternate Impulse Wheel Designs
6 of 8
Service Manual 0509 SM07 - 006- 095. 00
d. Install capscrews (11,23) through lock plates Note: Applya light coat of Permatex® Aviation
(12 ,22) and shims (13,21). Torque capscrews Form-A-Gasket® to the 0.0. of seal. Ensu re
(11 ,23) to 23-25 ft lb (102-111Km). that seallip is install in the same position as re
e. Place cylinder block (10) on its lace with piston moved.
(19) bores lacing upward.
f. Align pistons (19) to there respective bores in 10. Install seal (2) and retaining ring (1) in case (3) .
the cylinder block (10) and install.
Note: If lead in chamfer on spring dowels only
Note: Ensure that bearing cone is align and exist on one end, install in case chamfer first.
installed on shaft as removed . Apply a light
11. Install spring dowels (15) and sliding bearings (17)
coat of Loctite ® 648 to the 0.0. of wear ringo Re
in case (3) .
move any access Loctite® after installation.
12. Install o-ring (9) on plug (8).
3. Using the correct size driver and a shop press , 13. Install plug (8) and o-rings (4) in case (3).
install bearing con e (7) and wear ring (5) on shaft
Note: If lead in chamfer on dowel pins only exist
(16).
on one end, install in port housing chamfe r first.
4. Align and install shaft (16) through cradle (18) and
cylinder block (10). 14. Install o-ring (55) on plug (56) and install plug (56)
and dowel pins (35) in port housing (36) .
Note: Secure shaft while moving and placing in
15 . Using the correct size driver, install shims (34) ,
shop press . Shaft may slide out of cylinder
bearing cup (33) , and port plate (32) in port hous
block and cradle.
ing (36).
5. Install washer (29) , spring (28) , washer (27), shim 16. Install seal rings (57) on servo pistons (58) . lightly
(30) , ancl retaining ring (26). coat seal rings (57) with Vaseline ' ~ and using a de
6. Using the correct size driver, collapse spring (28) burred round shank 01 a screwdriver or similar tool ,
and install retaining ring (26) in its correct groove make several passes around seal rings (57) to si ze
on shaft (16) . and seat them within the groove 01 servo pistons
(58).
Note: Ensure that bearing cone is align on shaft 17. Install servo pistons (58) in port housing (36).
as removed. 18. Install o-rings (61) and back-ups (60) on pipes
(59).
7. Using the correct size driver, install spacer (31) and 19. Install shims (62), shim washers (63) , and pipes
bearing cone (25) on shaft (16). (59) in port housing (36).
8. Remove shaft, cradle, and cylinder block assem
bly Irom shop press and place on bench with
blocking to prevent rolling.
CAUTION
Note: Ensure that bearing cup is aligned and Threaded surfaces are sharp. Seals and can
installed in case as removed. be damaged as shafts are feed through them,
causing the assembly to leak. Mask the
9. Using the correct size driver, install bearing cup (6) splined area of the shaft or otherwise protect
in case (3) . seals during installation.
20. Apply a thin layer 01 masking tape on splines 01

shaft (16) that will be passing through seal (2) .
A WARNING
Secure assembly firmly by the shaft, do not
attempt to hold assembly by the cylinde r
block, the cylinder block is not secured and
shaft assembly will fall. Serious personal
injury or component damage may result if
precautions are not followed.
7018
21 . Position case (3) standing on end with seal (2) 28. Install o-rings (75,79) on plug (74) and housing
down over a hole in the bench large enough for (78) .
shaft (16) to pass through . Install shaft (16) , cradle 29. Install ball (77), spring (71) , and plug (74) in hous
(18) , and cylinder block (10) assembly in case (3) ing (78).
making sure that cradle (18) and bearing cone (7) 30 . Install housing (78) in port housing (36).
rest in sliding bearings (17) and bearing cup (6) 31 . Install o-rings (66,70,72) on spools (67,73) and
and over spring pins (15). plug (69).
32. Install spools (67,73) in housing (68).
33 . Install spring (65), housing (68) , spring (71), and
CAUTION plug (69) in port housing (36) .
Do not use force by hammering or pulling Note: Apply a light coat of Loctite® 648 to
case and port housing together using threads of capscrew.
cap screws. Use care assembling port
housing to case. Mounting faces or internal 34 . Install o-ring (37) , impulse wheel (38) , and caps
components could be damaged. Upon the crew (39) in port housing (36) and shaft (16).
assembly of the case and port housing,
seve ral components will be loose and could Note: Multiple variations of the impulse wheel
beco me misaligned. Component damage assembly exist. Refer to Figure 2 for alternate
ma y result if precautions are not followed. versions.
35 . Install o-rings (40,42) , sensor (41) , and spring

22 . Using care , lower port housing (36) assembly
dowels (54) on sensor housing (43).
down and over shaft (16). Ensure that port plate
36 . Install sensor housing (43) and capscrews (44) to
(32) an d bearing cup (33) are seated on cylinder
port housing (36).
block (10) and bearing cone (25) .
37. Install o-ring (47) , seal (50) , and solenoid (51) on
23. Install capscrews (24) securing port housing (36)
magnet (48).
to case (3) . Torque capscrews (24) to 43-47 ft lb
38 . Install o-rings (80,85) on sleeve (84) and spring
(19 1 - 209Km).
washer (80), spring (82), and spring washer (83) in
24. Lay hydraulic pump assembly down on case (3)
sleeve (84).
bottom and remove masking tape from shaft (16) ,
39. Install sleeve (84) in port housing (36).
using care not to damage seal (2) .
40. Install support washer ( ) , spool ( ), and bushing ()
25 . Placing a rag over splines on shaft (16) to protect
in port housing (36) .
them , using a wrench , rotate the motor 360°. The
41 . Install magnet (48) on port housing (36) using
motor should rotate with moderate resistance . If
capscrews (49) .
for any reason the motor does not rotate or rotates
partway and then locks up, disassembly the motor Note: The use of an auxiliary lifting device is recom
and repair. mended when handling the winch motor as an as
Note: Apply a light coat of Loctite® 571 to
imately 93 lb (42kg).
threads of plugs.
42 . If winch motor is not to be immediately installed on
26. Install orifices (91 ,90,88) and plugs (87,89) in port
crane , plug all open ports to prevent contamination
housing (36) .
and properly store.
27. Install studs (53) in port housing (36) to specified
depth and secure using seal nuts (52).
8 of 8
5. Relieve the hydraulic system pressure as follows :
Winch Motor, R & I a. Release any residual pressure in the hydraulic
This procedure covers the removal and installation of reservoir by slowly loosening the filler/ breather
the winch motor. Although Figure 1 depicts removing cap , located on the top of the hydraulic
the winch motor from the rear winch, removal and reservoir, until pressure is fully relieved.
installation of the winch motor for both winches is b. Turn the ignition switch to "ON" , but DO NOT
similar. For recondition procedure , see SM Keysheet START THE ENGINE. Move the function lock
Area 07 -006 . out switch to the "OPERATE" position .
Removal switch es back and forth several times.
d. Turn the ignition switch to the "OFF" position .
1. Lower, detach, and secure the load , as required.
level surface.
b. Engage the park brake and/or properly block Refer to Figure 1.
the tires. 7 . Drain the oil from the winch (1) into a suitable con
c. Engage the swing park brake or travel swing tainer. Properly store or dispose of the oil See the
lock , as required. Operator 's Manual for the correct procedure .
d. Level the crane on fully extended outriggers. 8. Disconnect any electrical connectors that are at
e. Fully retract and position the boom , as re tached to the winch motor (2).
quired. 9. Remove the winch counterbalance valve (5) from
3. Shutdown the engine and disengage the main hy the winch motor (2). See SM Keysheet Area
draulic pump, as equipped . 07 -008 for the correct procedure.
hydraulic lines (4) from the winch motor (2) . Cap/
A WARNING plug the open hydraulic ports and lines (4) to pre
vent excessive oil loss and contamination of the
Solvents and cleaning solutions can be system.
result from misuse of these products. Read Note: The winch motor weighs approxim atel y
and follow all the manufacturer's 95 lb (43kg) .
cleaning solutions. 11. Using an appropriate lifting device , support the
winch motor (2).
4. Thoroughly clean the area to be disassembled with 12. Remove the capscrews and washers (3) that se
an approved cleaning solvent to prevent conta cure the winch motor (2) to the winch (1).
mination . Allow the area to air dry. 13. Remove the winch motor (2) from the crane.
14. Remove the o-ring (not shown) from between th e
winch motor (2) and the winch (1).
A WARNING 15. If required, protect the open end of the winch (1)
with some type of temporary enclosure to prevent
Hydraulic oil is under pressure and may be moisture or other contamination .
engine and exhaust al! trapped hydraulic
1 of 4
SM07 - 006 -1 09.00 1006 Service Manual
\ R ,. ". ,
,
" .
1 Winch 3 Capscrews & Washers S, Winch Counterbalance Valve

2, Winch Motor 4 Hydraulic Lines
Figure 1
Winc h Assembly
2 of 4
Cleaning And Inspection Lubricate all "soft parts", such as o-rings, with clean
hydraulic oil prior to installation, See the Operator's
Manual lor the correct type ,
A WARNING Reler to Figure 1,

1, Install the o-ring (not shown) between the winch
Solvents and cleaning solutions can be motor (2) and winch (1),
result from misuse of these products. Read Note: The winch motor weighs approximately
and follow all the manufacturer's 95 lb (43kg).
cleaning solutions. 2, Using an appropriate lifting device, align the winch
motor (2) to the winch (1) ,
1, AII components should be thoroughly cleaned with 3, Apply Loctite® 242 to the threads 01 the capscrews
an approved cleaning solvent, air dried, and care (3) , Install the capscrews and washers (3) to se
fully inspected, cure the winch motor (2) to the winch (1) ,
2, AII Loctite®, Permatex®, or other sealant residue 4, Connect the hydraulic lines (4) to the winch motor
should be removed Irom threads 01 hardware and (2) ,
the mounting surlaces 01 parts that are going to be 5, Install the winch counterbalance valve (5) on the
reused , Prior to applying new thread locking com winch motor (2), See SM Keysheet Area 07 - 008
pounds or sealants, clean threads and surlaces lor the correct procedure ,
with Loctite® 7070 Cleaner to ensure best perlor 6, Connect any electrical connections to the winch
manee 01 products, motor (2),
3, Thoroughly inspect all parts lor damage, wear, la 7, Fill the winch (1) with oil. See the Operator 's Manu
tigue or stress Iractures , and corrosion, Repair or al lor the correct type and procedure,
replace as required , 8, Check the hydraulic reservoir oil level, Add oil as
4, AII "soft parts", such as seals, gaskets, back up required, See the Operator's Manual lor the
rings , and o-rings, should be replaced , correct type and procedure,
5, Inspect the integrity 01 the hydraulic lines that are 9, Check lor correct Iluid levels in any related
connected to the winch motor, Repair or replace il components such as pump drives , gear reduction
required, units, engine crankcase, radiator, etc , Refer to the
6, Inspect the integrity 01 the electrical wires and con crane or engine Operator's Manual lor correct
nectors that are connected to the winch motor. Re type/quantity 01 Iluids and proper procedure,
pair or replace il required, 10, Engage the main hydraulic pump , as equipped ,
7, In the event 01 severe delects , contact lactory per 11, Start the engine and let idle lor live minutes,
sonnel lor directions whether to repair or replace Inspect the hydraulic connections for leaks,
any major component. Repair leaks as required ,
12, Complete the installation by testing all related
I nstallation functions 01 the winch (es) lor proper operation,
Normal operation 01 the hydraulic and electrical
systems should be confirmed, A general
A WARNING
inspection 01 the components and systems in the
compounds, etc. can be hazardous. Serious present.
these products.
3014
4 af 4
1. Swing Motor 3. Swing Bra ke

2. Hydraulic Lin es 4. Cap screws
Figure 1
Swing Motor

Swing Motor, R & I draulic pump, as equipped.
the swing motor. For recondition procedure, see SM
Keysheet Area 07 -006. A WARNING
Removal Solvents and cleaning solutions can be
1. Lower, detach, and secure the load , as required. result from misuse of these products. Read
2. Stabilize the crane for service as follows: and follow al! the manufacturer's
a. Park the crane, out of the way, on a firm and recommendations concerning solvents and
level surface . cleaning solutions.
the tires . 4. Thoroughly clean the area to be disassembled with
c. Engage the swing park brake or travel swing an approved cleaning solvent to prevent conta
lock, as required . mination. Allow the area to air dry.
quired.
1 of 4
A WARNING
hot. A su d den release of hot oil could cause
A WARNING
engine and exhaust all trapped hydraulic hazardous. Serious personal injury may
pressure from the system before removing result from misuse of these products. Read
any line or component. and follow all the manufacturer's
5. Relieve the hydraulic system pressure as follows: cleaning solutions.
a, Release any residual pressure in the hydraulic
reservoir by slowly loosening thefiller/breather 1. AII components should bethoroughly cleaned with
cap, located on the top of the hydraulic an approved cleaning solvent, air dried, and care
reservoir, until pressure is fully relieved. fully inspected,
b. Turn the ignition switch to "ON", but DO NOT 2, AII Loctite®, Permatex®, or other sealant residue
START THE ENGINE. Move the function lock should be removed from threads of hardware and
out switch to the "OPERATE" position, the mounting surfaces of parts that are going to be
c. Work the crane control levers and outrigger reused. Prior to applying new thread locking com
switch es back and forth several times. pounds or sealants, clean threads and surfaces
d. Tu rn the ignition switch to the "OFF" position. with Loctite® 7070 Cleaner to ensure best perfor
6. Check tn at all controllevers are in the neutral posi mance of products.
tia n and move the function lockout switch to the 3. Thoroughly inspect all parts for damage, wear, fa
"DISABLE" position, tigue or stress fractures, and corrosion, Repair or
Refe r to Figure 1, replace as required,
7 . Lab el for assembly purposes and disconnect the 4. AII "soft parts", such as seals, gaskets, back up
hyd raulic lines (2) from the swing motor (1), Cap/ rings, and o-rings, should be replaced.
plug the open hydraulic ports and lines (2) to pre 5. Inspect the integrity of the hydraulic lines that are
vent excessive oil loss and contamination of the connected to the swing motor, Repair or replace if
system, required,
8, Place ill dex marks on the swing motor (1) and 6, In the event of severe defects, contact factory per
sw ing brake (3) to ensure proper orientation during sonnel for directions whether to repair or replace
installation, any major component.
9, Remove the capscrews (4) which secure the swing
motor (1) to the swing brake (3), Installation
10, Separate the swing motor (1) from the swing brake
(3), and remove the swing motor (1) from the
crane,
11, Remove tll e 0- ring (not shown) which is located
A WARNING
betw een the swing motor (1) and swing brake (3),
12. If the swing motor (1) is going to be removed for an
ext ended period of time, provide some means to
p rotect the inside of the swing brake (3) from
moisture, dust, dirt, or any other contaminants,
these products.
Refer to Figure 1,
1, Lubricate the o-ring (not shown) to be installed
between the swing motor (1) and swing brake (3)
with clean hydraulic oil. Seethe Operator's Manual
for the correct hydraulic oil.
2 of 4
Note: 11 a new swing motor is to be installed, 5. Check the hydraulic reservoir oillevel. Add oil as
trans1er the index marks to the new swing motor required. See the Operator's Manual for the
prior to installation. correct type and procedure.
6 . Engage the main hydraulic pump, as equipped .
2. Position the 0- ring (not shown) and swing motor 7. Start the engine and let idle for five min utes .
(1) on top of the swing brake (3). Be sure to orient Inspect the hydraulic connections for leaks .
the swing motor (1) correctly by aligning the index Repair leaks as required .
marks placed on the swing motor (1) and swing 8. Complete the installation by testing all related
brake (3) during removal. functions of the swing motor for proper operation .
3. Apply Loctite® 242 to the threads of the capscrews Normal operation of the hydraulic system should
(4) . Install the capscrews (4) to secure the swing be confirmed. A general inspection of the
motor (1) to the swing brake (3) . components and systems in the areas adjacent to
4 . Connect the hydraulic lines (2) to the swing motor the repair should also be performed to ensure
(1) . related damage or wear is not present.
3 of 4
.
••
. ".
o • •
.
".
.
4 of 4
13 12 11
1. Stud Nut 5. Check Assembly 9 Assembly Slud 12 . Relief Valve

2. Inlet Cover 6. Mid Inlel Seclion 10. SIud Nul 13. Manual Control Lever
3. Seclion Seals 7. Spool Aclion Assembly 11. Cable Control Connec\ion 14. Relief Valve
4 Work Sedon (4 Places) 8. Oullet Cover
Figure 1
Typical Control Valve Assembly - V20 Model

Control Valve, Recondition components to lay the parts out in the order that they
(V20 Model) were disassembled. Keeping the parts in this order
This procedure covers the recondition of multiple during disassembly, cleaning and inspection will aid in
section control valves. The procedures are intended the assembly process.
to be general in nature so that instructions given will Replacing Valve Sections Or
accommodate all control valves of this series. Some
information given here may not apply, depending Section Seals
upon options, function, or other variables . For
removal and installation procedures, see SM
Keysheet Area 03-010 or 07 -008.
The following procedures are outlined in the SM :
A WARNING
Replacing Valve Sections Or Section Seals hazardous. Serious personal injury may
Replacing Spool Seals result from misuse of these products. Read
Reconditioning Spool Positioner and follow all the manufacturer's
Reconditioning Anti-Cavitation Check Assembly recommendations concerning solvents and
Reconditioning Lockout Check Assembly cleaning solutions.
Reconditioning Load Check Plug
Reconditioning WHA Relief Valve 1. Thoroughly clean the exterior surface of the control
Reconditioning RP51 Relief Valve valve to prevent contamination from entering il.
2. Using a center punch, marker or other method,
mark each valve section for position and orienta
parts together, they must be free to move and not bind . tion to ensure proper assembly.
1 of 8
2 3 4 5
CAUTION 6
Do not grip on any of the machined surfaces

01 the control valve. Excessive force while
clamping could result in misalignment and/or
serious damage to parts. Take extreme care
not to mar or damage any machined surface.
Do not clamp in any form of vise unless jaws
are protected by a 50ft material.
Refer to Figure 1.
1. Remove the stud nuts (1) from assembly studs (9) .
2. Remove the inlet cover (2) , each work section (4),
mid in let section (6), and outlet cover (8), as appli 1. Spool 5. Return Sp ring
cable, by carefully separating the sections and 2. BOd y 6. Bon net
sliding them off the assembly studs (9). 3. Lockwasher 7. Sp ool Collar
4. Screw 8. Spring Retainer
3. Rem ove the section seals (3) from the ports of the
inlet cover (2), work sections (4) , mid inlet section Figure 2
(6) , and outlet cover (8) . Spool Positioner Assembly
4. Thoroughly clean machined surfaces of each valve
section paying particular attention to the counter Refer to Figure 2 .
bores and sealing surfaces of the section seals (3) . 2. Remove the screws (4) and lockwashers (3) which
5. Lubri cate the section seals (3) and counterbores in secure the bonnet (6) to the body (2) ; remove the
the valve sections with clean hydraulic oil. See Op bonnet (6).
erator's Manual for correct type. 3 . Remove the spool collar (7), spring retainers (8)
6 . Place the section seals (3) in the counterbores of and return spring (5) from the end of the spool (1).
the valve sections . Note there are two different size Refer to Figure 3 .
section seals (3) . Be sure to place the correct size 4. Remove the seal retainer (11) , back up washer
section seal (3) in the appropriate counterbore . (10) , and spool seal (9) from the body (2).
7. Slide the valve sections on the assembly studs (9) 5. Remove the screws (4) and plate (5) .
one at a time , using care to ensure section seals (3) 6 . Remove the seal retainer (6) , back up washer (7) ,
are properly seated between valve sections . and spool seal (8) from the body (2).
8. Install the stud nuts (1) and tighten evenly. Final 7. Thoroughly clean counterbores in each end of the
torque on the stud nuts (1) is 32 ft lb (43.5Nm). work section. Lightly oil counterbores and new
Replacing Spool Seals spool seals (8,9) with clean hydraulic oil. Refer to
Operator's Manual for correct type of oil to use.
Spool seals can be replaced without disassembling 8. Install the spool seal (8) , back up washer (7), and
the valve or removing the spool. Prevent the spool from seal retainer (6) over the spool (3) and into the
turn ing or moving by running a rod through the hole in counterbore.
the spool end and using it as a han die. Do not hold the 9 . Install plate (5) and screws (4) to secure new spool
spool with a wrench. This may destroy the finish and seal (8), back up washer (7) , and seal retainer (6).
could cause spool to bind . 10. Install the spool seal (9) , back up washer (10), and
seal retainer (11) over the spool (3) and into the
cou nterbore.
A WARNING Refer to Figure 2.
11 . Place one of the spring retainers (8) over the spool
hazardous. Serious personal injury may (1). Install the return spring (5) and then the other
result from misuse of these products. Read spring retainer (8).
and fo llow all the manufacturer's 12. Install the spool collar (7) and torque to 10ft lb
recomme ndations concerning solvents and (1 3Nm).
cleani ng solutions. 13. Install bonnet (6) with lockwasher (3) and screws
(4) .
1. horoughly clean the exterior surface of the control 14 . Tighten the screws (4) evenly. Final torque on the
valve to prevent contamination from entering it. screws (4) is 10 ft lb (13Nm).
2 of 8
12 11 10 9 8 7 6 5 4
1. Check Assembly 5. Plate 8. Spool Seal 11 . Seal Retainer

2. Body 6. Seal Retainer 9. Spool Seal 12. Spool Positioner Assy
3. Spool 7. Ba ck Up Washer 10. Back Up Washe r 13. Screw
4. Screw
Figure 3
Typical Work Section Assembly
Reconditioning Spool Positioner 3. Remove the spool collar (7) , spring retainers (8)
and return spring (5) from the end of the spool (1).
Dispose 01 the return spring (5).
A WARNING
cleaning solvent. Place parts on a clean lint free
hazardous. Serious personal injury may tion possible to keep all parts free 01 dust , dirt or
result from misuse of these products. Read any other loreign mat erial during assembly.
and follow all the manufacturer's 5. Place one of the spring retainers (8) over the spool
recommendations concerning solvents and (1). Install the new return spring (5) and then the
cleaning solutions. other spring retainer (8).
6. Install the spool collar (7) and torque to 10ft lb
1. Thoroughly clean the exterior surface of the control (13Nm).
valve to prevent contamination from entering it. 7. Install the bonnet (6) using the lockwasher (3) and
Refer to Figure 2. screws (4).
2. Remove the screws (4) and lockwashers (3) which 8. Tighten the screws (4) evenly. Final torque on the
secure the bonnet (6) to the body (2); remove the screws (4) is 10ft lb (13Nm).
bonnet (6) .
3 of 8
2 3 4 5 6 7 8 9 2 3 4 5 6 7 8
1. Body 6. Retainer
2. O-ring 7. Spring 1. Cap 5. Spnng
3. Back Up Ring 8. Back Up Rings 2. O-ring 6. Sall
4. O-ring 9. Check 3. O-ring 7. O-ring
5 Ball 10. O-ring 4. Sody 8. Back Up Ring
Figure 4 Figure 5
Anti- Cavitation Check Assembly Lockout Check Assembl
Reconditioning Anti-Cavitation 7. Install the check (9) and spring (7) in the valve.
Check Assembly 8. Install the new back up rings (8) and 0- ring (10) on
the retainer (6).
9. Place the retainer (6) and ball (5) in the valve .
A WARNING
10. Install the new back up ring (3) and 0- rings (2,4)
on the body (1).
Solve nts and cleaning solutions can be 11 . Install the body (1) in the valve and tighten to 20 ft lb
haza rdous. Serious personal injury may (27Nm).
and follow all the manufacturer's Reconditioning Lockout Check
recommendations concerning solvents and Assembly
cleaning solutions.
1. Thoroug hly clean the exterior surface of the control

valve to prevent contamination from entering it.
A WARNING
Refer to Figure 4. hazardous. Serious personal injury may
2. Remove the body (1) from the work section of the result from misuse of these products. Read
valve and remove the o-rings (2,4) and back up and follow all the manufacturer's
ring (3) from the body (1). Discard the 0- rings recommendations concerning solvents and
(2,4) and back up ring (3). cleaning solutions.
3. Remove the ball (5) and retainer (6) from thevalve.
Remove and discard the o-ring (10) and back up 1. Thoroughly clean the exterior surface of the control
rings (8) from the retainer (6) . valve to prevent contamination from entering it.
4. Remove the spring (7) and check (9) from the
valve. Refer to Figure 5.
5. Thoroughly clean all metal parts with an approved 2. Remove the cap (1) while the lockout check as
cleaning solvent. Place parts on a clean lint free sembly is still installed in the valve. Remove and
surface and allow to air dry. Exercise every precau discard the o-ring (2) from the cap (1) .
tion possible to keep all parts free of dust, dirt or 3. Remove the body (4) from the work section of the
any other foreign material during assembly. valve and remove the spring (5) and ball (6) from
6. Lightly oil the new o-rings (2,4,10) and back up the body (4).
rings (3 ,8) with clean hydraulic oil. Refer to Opera
tor's Manual for correct type of oil to use.
4 of 8
4. Remove the o-rings (3,7) and back up ring (8)
from the body (4). Discard the o-rings (3,7) and 234 5 6 7
back up ring (8).
tion possible to keep all parts free of dust , dirt or
6. Lightly oil the new 0- rings (2,3,7) and back up ring
(8) with clean hydraulic oil. Refer to Operator's
Manual for correct type of oil to use .
7. Install the new back up ring (8) and o-rings (3,7)
on the body (4).
8. Install the body (4) in thevalve and tighten to 20 ft lb
8
(27Nm). 1. Load Check Plug 5. Spring
9. Place the ball (6) and spring (5) in the body (4). 2. O-ring 6. Back Up Rlng s
10. Install a new o-ring (2) on the cap (1). 3. Back Up Ri ng 7. Pop pet
4. O-ring 8. O- ring
11. Install the cap (1) in the body (4) and tighten to 20 ft
lb (27Nm). Figure 6
Load Check Plu
Reconditioning Load Check Plug
Reconditioning WHA Relief Val ve
A WARNING
A WARNING
and follow all the manufacturer's hazardous. Serious personal injury may
cleaning solutions. and follow all the manufacturer s
1. Thoroughly clean the exterior surface of the control cleaning solutions.
valve to prevent contamination from entering i!.
Refer to Figure 6 . 1. Thoroughly clean the exterior surface of the cont rol
2. Remove the load check plug (1) from the work sec valve to prevent contamination from enterin g it.
tion of the valve and remove the 0- rings (2.4.8) 2. Remove the relief valve from the valve .
and back up rings (3 ,6) from the load check plug Refer to Figure 7.
(1). Discard the o-rings (2.4,8) and back up rings 3 . Remove the acorn nut (14) from the relief valve .
(3,6). Count and record the number of expose d threads
3. Remove the spring (5) and poppet (7) from the on the adjusting stem (13) , for assembly purposes .
valve . 4 . Remove the jam nut (12) and adjustln g stem (13)
4 . Thoroughly clean all metal parts with an approved from the cap (11) .
cleaning solven!. Place parts on a clean lint free 5. Remove the cap (11) and spring (6) from the body
surface and allow to air dry. Exercise every precau (5) ; remove the piston (10) from the cap (11).
tion possible to keep all parts free of dust , dirt or 6 . Remove and discard the o-rings (8 ,9) from the
any other foreign material during assembly. cap (11) and pisto n (10).
5 . Apply clean hydraulic oil on the new o-rings 7 . Remove the poppet (4) from the body (5) .
(2.4 ,8) and back up rings (3,6) . Refer to the Opera 8 . Remove and discard the o-rings (1 ,7) and back
tor's Manual for the correct grade of hydraulic oil to up ring (2) from the body (5).
use . 9. The seal (3) on the poppet (4) is not replaceable .
6. Install the new o-rings (2.4 ,8) and back up rings 10. Thoroughly clean all metal parts Witll an approved
(3 ,6) on the load check plu g (1) . cleaning solven!. Place parts on a clean lint free
7. Place the poppet (7) and spring (5) in the valve. surface and allow to air dry. Exercise every precau
8 . Install the load check plug (1) in the valve and tight tion possible to keep all parts free of dust, dirt or
en to 20 tt lb (27Nm). any other forei gn material during assembly.
5 of 8
SM07 -008-032.00 051 0 Service Manual
2 3 4 5 6 7 8 9 10 11 12 13 14
1. O-ring 4. Poppet 7. 0- ring 10 Piston 13. AdjuSling Slem

2 Back Up Ring 5. Body 8 O-ring 11. Cap 14 . Acorn Nut
3. Seal 6. Spring 9. O-ring 12. Jam Nul
Figure 7
WHA Differential Poppet Rel ief Valve
1 Filter 6. Body - Reliel Valve 11 . Back Up Ring 15. Poppet - Relief 19. Body - Pilot Assy
2 Retaining Ring 7. Spring 12. Seal 16. Spring 20. Cove r Washer
3 O - ring 8. Back Up Ring 13. O-ring 17. Adjustment Screw 2 1. Jam Nut
4. Back Up Ring 9 O-ring 14. O-ring 18. O-ring 22 . Cover
5. Poppel - Main 10. O-ring
Figure 8
RP51 Pilot Operated Relief Valve
6 of 8
11. Lightly oil the new 0- rings and back up rings with 8. Remove the spring (16) and poppet (15) from bocly
clean hydraulic oil. Refer to Operator's Manual for (19).
correct type of oil to use. 9. Remove the pilot assembly body (19) from the re
12 . Install the 0- rings (1 ,7) and back up ring (2) on the lief valve body (6). Remove the seat (12), o-rings
body (5) . (10,14), and back up ring (11) from the pilot assem
13 . The seal (3) on the poppet (4) is not replaceable. bly body (19). The seal on the seat (12) is not re
Lubricate and install a new poppet (4) in the body placeable.
(5). 10. Remove the spring (7) and poppet (5) from the
14. Install the o-ring (8) on the cap (11). body (6). Remove the o-ring (9) and back up ring
15 . Install th e 0- ring (9) on the piston (10) and place (8) from the poppet (5).
the piston (10) inside the cap (11). Be sure the pis 11 . Remove the retaining ring (2) which secures the fil
ton (10) is properly oriented as shown in Figure 7. ter (1) to the poppet (5); remove the filter (1).
16. Install the spring (6) in the body (5). 12 . Thoroughly clean a ll metal parts with an approved
17. Install the cap (11) on the body (5). cleaning solvent. Place parts on a clean lint free
18. Install the adjusting stem (13) in the cap (11) and surface and allow to air dry. Exe rcise every precau
tighten the adjusting stem (13) until the correct tion possible to keep all parts free of dust , dirt or
number of threads are left showing as recorded in any other foreign material during assembly
Step 3. 13. Lightly oil the new o-rings and back up rin gs with
19. Install the jam nut (12) on the adjusting stem (13) . clean hydraulic oil. Refer to Operator 's Manual for
20. Install the acorn nut (14) on the adjusting stem correct type of oil to use.
(13). 14 . Install the filter (1) on the end of the poppet (5) and
21. Install the relief valve back in the valve section and secure it with the retaining ring (2).
tighten to 20 ft lb (27Nm). 15 . Install the o-ring (9) and back up ring (8) on the
poppet (5).
Reconditioning RP51 Relief Valve 16. Install the poppet (5) and spring (7) in the body (6).
17. Install the o-rings (10,14), and back up ring (11)
A WARNING
18.
19.
from the pilot assembly body (19).
Place the seat (12) in the body (19) seal end first.
Install the pilot assembly body (19) in the relief
valve body (6) and tighten to 15-18 f1 lb
(20-24Nm).
20. Install the o-ring (18) on the adjustment screw
(17).
21. Plac e the poppet (15) and spring (16) in the body
cleaning solutions.
(19).
22. Install the adjustment screw (17) in the body (19)
1. Thoroughly clean the exterior surface of the control
and tighten the adjusting screw (17) untll the cor
valve to prevent contamination from entering it.
rect number of threads are left showing as re
2. Remove the relief valve from the valve section.
corded in Step 6.
Refer to Figure 8. 23. Install the cover washer (20) with the large diame
3. Remove and discard the 0- rings (3 ,13) and back ter up and secure with the jam nut (21) . Try not to
up ring (4) from the body (6). rotate the adjustment SCrew (17) as the Jam nut
4. Carefully pry the cover (22) off th e end of the relief (21) is installed. Tig hten the jam nut (21) to 15 -1 8
valve. ft lb (20-24Nm).
5. Remove the jam nut (21) and cover washer (20) 24. Crimp the cover (22) over the cover washer (20) to
from the adjustment screw (17). Try not to rotate secure it on the relief valve.
the adjustment screw (17) as the jam nut (21) is re 25. Install the o-rings (3,13) and back up ring (4) on
moved. the body (6).
6. Count and record the number of exposed threads 26. Install the relief valve in the valve section and tight
on th e adj ustment screw (17), for assembly pur en to 20 f1lb (27Nm).
poses.
7. Remove the adj ustment screw (17) from the body
(19). Remove and discard 01 the 0- ring (18) on the
adjustment screw (17).
7 of 8
8018
Pressure Reducing Valve,
Recondifion
A WARNING
Hydraulic oH is under pressure and may be
This procedure covers the removal, recondition , and hot. A sudden release of hot oil cou ld cause
installation 01 the pressure reducing valve cartridge. It burns or other serious injury. Shutdown the
also contains procedures lar cleaning and engine and exhaust all trapped hydraulic
troubleshooting the valve. While considered pressure from the system before removing
serviceable items, these cartridg es are not designed to any line or component.
be disassembled in the lield . II lar any reason the
pressure reducing valve does not lunction as required, 6. Relieve the hydraulic system pressure as follows
after performing the proper cleaning and a. Relieve any residual pressure in the hydraulic
troubleshooting procedures , the entire valve cartridge reservoir by pushing the button on the
should be replaced. pressure relief valve, located on the hyclraulic
reservoir Or loosen the filler cap 1/4 turn.
The cartridge is easily removed from its mounting body b. Turn the ignition switch to "ON", but DO NOT
without the need to remove the entire valve from the STARTTHE ENGINE. Move the function lock
crane. Refer to the following procedure to remove the out switch to the "OPERATE" position .
cartridge from the crane. C. Wark the crane control levers and outri gger
switches back and forth several times .
Removal d. Turn ignition switch to the " OFF" position .
1. Lower, detach , and secure the load, as required. 7. Check that all controllevers are in the neutral posi
2. Stabilize the crane for service as follows: tion and move the function lockout switch to the
a. Park the crane, out 01 the way, on a lirm and "DISABLE" position .
level surface and engage the park brake.
Refer to Figure 1.
b. Engage the swing park brake or travel swing
8. Slowly unscrew and remove the cartridge (2) from
lock, as required.
mounting body (1) Cap/ plug the open hydraul ic
C. Level the crane on lully extended outriggers.
part to prevent excessive oil loss and conta mina
d. Fully retract and position the boom , as
tion 01 the system.
required.
9. Remove the back up rings (4 ,7,9) and o-rings
(5,6,8) Irom the cartridge (2), as required.
hydraulic pump.
4. On cranes with air charged hydraulic reservoirs:
a. Open the drain valves on the air reservoirs to
Cleaning, Inspection, And
bleed the air system pressure. Troubleshooting
b. When pressure is fully relieved, close the drain
valves on the air system reservoir. The most common cause 01 a malfunction 01 the
pressure reducing valve is dirt in the hydraulic fluid .
Fareign material can lodge in the working parts of th e
A WARNING
cartridge and interfere with proper operation . The
cartridge can generally be cleaned , without disturbing
the lactory settings, using the following procedures :
A WARNIN G
cleaning solutions.
recommendations concerning solvenl s and
cleaning solutions.
1. AII components should be thoroughly cleaned w ith

fully inspected.
1 of 4
D
2
2
2
5 6
8
7
9
1. Mounting Body 4. Back- Up Ring 7. Back- Up Ring

2. Cartridge 5 O-ring 8. O-ring
3. Hex Nut 6. O-ring 9. Back - Up Ring
Figure 1
Pressure Reducing Valve
2 of 4
2. AII Loctite®, Permatex®, or other sealant residue Installation
pounds or sealants, clean threads and surfaces .A WARNING
with Loctite® 7070 Cleaner to ensure best perfor Lubricants,.sealants, joint and thread locking
mance of products. compounds, etc. can be hazardous. Seriou s
3. Thoroughly inspect all parts for damage, wear, fa personal injury may result from misuse of
tigue or stress fractures, and corrosion. Repair or these products. Read and follow ali
replace as required . manufacturer's recommendations concerning
4. Through the nose of the cartridge, manually oper these products.
ate the inner working parts several times. Use a
piece of plastic tubing to avoid damaging soft Refer to Figure 1.
seats, sharp edges , finished surfaces or the screen 1. Lubricate the back up rings (4,7,9) and o-rings
protecting the pilot orifice. AII parts should move (5,6,8) in clean hydraulic oil before installation. Re
freely. If possible, this inspection should be done fer to the Operator's Manual far the correct type of
with the cartridge submerged in clean mineral spir oi!.
its. 2. Installthe back up rings (4,7 ,9) and o-rings (5,6,8)
5. After flushing the cartridge (2) with clean mineral on the cartridge . Be sure the back up rings (4,7 ,9)
spirits, blow dry the cartridge with clean filtered airo and o-rings (5,6,8) are properly ariented as illus
6. AII "soft parts " , such as back up rings, and trated.
o-rings, should be replaced. 3 . Dip the cartridge (2) in clean hydraullc oil before
7. If this procedure does not eliminate any operation threading the cartridge (2) back into the mounting
al problems with the pressure reducing valve, re body (1). Use only the hex nut (3) surface closest
place the entire cartridge. to the mounting body (1) to tighten the cartridge
(2) .
4. Torque the cartridge (2) to 30-35 ft lb (40-50Nm).
5. If pressure reducing valve is not already installed or
the assembly is not to be immediately used on
and properly store.
required. See the Operator 's Manual far correct
type and procedure.
leaks as required.
3 of 4
4 of 4
11
2~
3
8--
10 21
1. Cap 6. Wire 10. Pin 14. Retain er 18. Pu sh Pins
2. Rotation Indica tor 7. 8 00t 11 . Cap screws 15. Anchor Plate 19. BOd y
3. Screws 8 Cable Tie 12. Jam Nut 16. Mountln g Plate 20. Plug
4. Handl e 9. Jam Nut 13 Swivel Plate 17. Ca pscrews 21 O -ring
5. Screws
Figure 1
Controller Valve Assembly
Dual Axis Controller Valve,

Recondi1:ion
A WARNING
hazardous. Serious personal injury ma y
This procedure covers the recondition 01 Ihe
hydraulic controller valve. For removal and
inslallation procedures, see SM Keysheet Area 7 - 8.
II parts are hard to disassemble and assemble, do not cleaning solutions.
use a hammer unless it has a soft lace, do not force
parts together, they must be Iree lo operate and nol 1. Drain any excess hydraulic oil, remaining wilhin
bind. the valve , into an appropriale container. Properly
store or dispose 01 the used oil.
Disassembly 2. Cap/ plug any openings in the valve . Thoroughly
clean the exterior surface 01 the valve lo prevent
It is a good practice when disassembling hydraulic contaminalion from entering il.
components to lay the parts out in Ihe order that they
Refer to Figure 1.
are disassembled . Keeping the parts in this order
3. Carelully work the cable tie (8) up, toward the han
die (4), over the bool (7) ; remove the cable tie (8).
1 014
A y
3
4
2
13
f-'4
~r- _ _ 15
ID NO'91261a11~
B
5
~--16
6
7
8
Spring Pack
9 Identification N°·
10
11
12
1. Retainlng Ring 5 Spool 8. Retainer 11 . Washer 14. Spring Pack

2. Spring Retainer 6. O-ring 9. Washer 12. Retaining Ring 15. Return Spring
3. Spring 7. Seal 1Q. Retainer 13. Push Pin Assembly 16. BOdy
4. Push Pin
Figure 2
Push Pin And Spring Pack Assemblies
4. Separate the boot (7) from the body (19) to access 9. Loosen the jam nut (12) and unscrew the swivel
the jam nuts (9 ,12). plate (13) from the anchor plate (15); remove the
5. Loosen the jam nut (9) and unscrew the handle (4) swivel plate (13).
from the swivel plate (13); remove the handle (4). 10. Remove the capscrews (11) and separate the re
6 . Remove the jam nut (9) and boot (7) from the han tainer (14) and anchor plate (15) from the body
die (4). (19) .
7. If required , remove the cap (1) from the handle (4) 11 . Remove the capscrews (17) and/or pins (10), as
and remove the screws (3,5). Separate the rota equipped, and separate the mounting plate (16)
tion indicator (2) from the handle (4) . from the body (19).
12. If required, remove the plug (20) from the body (19)
and separate the 0- ring (21) from the plug (20).
CAUTION Refer to Figure 2.
AII parts in plunger and spool assemblies are 13. Remove the spring packs (14), return springs (15),
mated to their corresponding port in control and push pin assemblies (13) from the body (16).
valve housing. If any assembly or part in the 14. Using the spring retainer (2), compress the spring
assembly is replaced or separated from the (3) and remove the retaining rings (1) from the
proper port, the complete control valve must push pins (4) .
be replaced. 15. Remove the spring retainers (2) and springs (3)
from the push pins (4).
8. Label for assembly purposes, each push pin (18) 16. Slide the push pins (4) through the spools (5) and
and its location within the body (19). remove the retaining rings (12), if required.
17. Remove the retainers (8,10) , washers (9,11), seals
Note: As the valve is disassembled, leave the push
(7), and 0- rings (6) from the spools (5).
pins engaged in the body.
2 of 4
Service Manual 0505 SM07 - 008 -1 07. 00
Cleaning And Inspection Refer to Figure 2.
1. Install the washers (9 ,11), seals (7) , and retainers
(8 ,10) in the spools (5) .
2 . Install the o-rings (6) on the spools (5).
A WARNING 3 . If required , install the retaining rings (12) on the
push pins (4) .
4 . Slíde the push pins (4) through the spools (5) .
5. Install the springs (3) and spring retainers (2) on
the push pin (4).
6. Using the spring retainer (2) , compress the springs
(3) and install the retaining rings (1) on the push
cleaning solutions.
pins (4).
7. Install the return springs (15), spring packs (14) ,
and push pin assemblíes (13) in the body (16).
surface and allow to air dry. Exercise every precau Refer to Figure 1.
tion possible to keep all parts free of dust , dirt , or 8. If required, install the o-ring (21) on the plug (20)
any other foreign material during assembly. and install the plug (20) in the body (19).
2. Carefully inspect all components for damage , 9. Align the mounting plate (16) with the body (19)
wear, corrosion , deep scratches , and scuffed met and install the capscrews (17) and/or pins (10), as
al. Remove any burrs Or sharp edges with a fine equipped. Torque the capscrews (17) to 40 in lb
file , hone , emery cloth , or crocus cloth . Replace (5Nm).
any damaged component as required. Replace all 10. Align the anchor plate (15) and the retainer (14)
seals, o-rings, and back up rings . with the mounting hales in the body (19). Install the
3. Spring packs must be replaced as an entire as capscrews (11) and torque the capscrews (11) to
sembly. When ordering spring pack replace 40 in lb (5Nm).
ments, the identification number located on the top 11. Apply clean, all purpose grease to the top of each
of the assembly may be required to positively iden of the push pins (18) and to the universal joint of the
tify the par!. Refer to Figure 2. anchor plate (15).
4. AII Loctite ' , Permatex F , or other sealant residue 12 . Screw the swivel plate (13) on to the anchor plate
should be removed from threads of hardware and (15) until it just contacts the tops of the push pins
the mounting surfaces of parts that are going to be (18). Do not allow the swivel plate (13) to compress
reused. Prior to applying new thread locking com the push pins (18).
pounds or sealants, clean threads and surfaces 13 . Install and tíghten the jam nut (12) to 20 ft lb
f
with Loctite 7070 Cleaner to ensure best perfor (30Nm) .
mance of products. 14 . If required , install the rotation indicator (2) in the
5. In the event of severe defects , contact factory per handle (4) and secure it with the screws (3 ,5) .
sonnel for directions whether to repair or replace Install the cap (1) on the handle (4).
any majar componen!. 15. Install the boot (7) and jam nut (9) on the shaft of
the handle (4) .
Assembly 16 . Screw the handle (4) into the swivel plate (13) and
tighten the jam nut (9) to 20 ft lb (30Nm) .
17 . Carefullywork the boot (7) down the handle (4) an d
A WARNING
stretch it over the edge of the swivel plate (13).
18. Install the cable tie (8) to secure the boot (7) in
Lubricants, sealants, joint and thread locking place .
compounds, etc. can be hazardous. Serious 19. If the valve is not to be immediately installed on
personal injury may result from misuse of crane , plug all open ports to prevent contamination
these products. Read and follow all and properly store.
these products.
Lubricate all back up rings, 0- rings, seals , spools , and

3 of 4
SM 07 - 008 -1 07.00 0505 Service Manual
4 of 4
9--~
8--
----3
4
7
~~~=-t.-t---5
1. Adiuslmenl Screw 4. Back Up Ring 7. Body

2. Back Up Ring 5. O -ring 8. O-ring
3. O-ring 6. Back Up Ring 9. Canridge
Figure 1
Pressure Reducing Valve Assembly
Pressure Reducing Valve,

Recondition A WARNING
This procedure covers the recondition of the pressure
reducing valve. General removal and installation
and follow all the manufacturer' s
procedures, for hydraulic components, can be found in
SM Keysheet Areas 07 -004 and 07 -008.
cleaning solutions.
Disassembly
1. Drain any hyd ra ulíc oil remaining within the valve
It is a good practice when disassembling hydraulic into an appropriate container. Properly store or
components to lay the parts out in the order that they dispose of the used oil.
were disassembled. Keeping the parts in this order 2. Cap/plug any openings in the valve. Thoroughly
during disassembly, cleaning, and inspection will aid in clean the exterior surface of the valve to prevent
the assembly process. contamination from entering il.

parts together, they must be free to rotate/ope rate and
not bind .
1 012
tion possible to keep all parts Iree 01 dust, dirt, or
CAUTION any other foreign material during assembly.
Do not grip on any of the machined surfaces. 2. Carefully inspect all components lor damage,
Excessive force while clamping could result in wear, fatigue or stress fractures, corrosion, deep
misalignment and/or serious damage to scratches , cracks, and scuffed metal. Remove any
parts. Take extreme care not to mar or burrs or sharp edges with a line file , hone , emery
da mage any machined surface. Do not clamp cloth , or crocus cloth .
in any form of vise unless jaws are protected 3. AII "soft parts ", such as back up rings and 0- rings ,
by a soft material. should be replaced .
Note: Prior to disassembly, note and record the sonnel for directions whether to repair or replace
number of exposed threads on the adjustment any major component.
screw. In the event it is moved, having this Assembly
information will ease resetting the valve pressure.
Lubricate all back up rings , 0 - rings , and bores in the
Refer lO Figure 1. valve body with clean hydraulic oil prior to assembly.
3. Remove Ihe cartridge (9) from the body (7). See Operator 'S Manual for correct type .
4. Remove Ihe o-rings (8,3,5) and back up rings
(2,4,6) Irom the cartridge (9).
Note: Further disassembly of the cartridge is not

recom mended.
A WARNING
Cleaning And Inspection personal injury may result from misuse of
these products.
A WARNING
Refer to Figure 1.
hazardous. Serious personal injury may 1. Installth e back up rings (2,4,6) and o-rings (8,3,5)
resu lt from misuse of these products. Read on the cartridge (9).
and follow all the manufacturer's 2. Install the cartridg e (9) in the body (7). Torque the
recommendations concerning solvents and cartridge to 19-21 ft lb (26-28Nm).
cl eaning solutions. 3 . II pr essure reducing valve is not to be immediately
1. Thoroughly clean all metal parts with an approved contamination and properly store.
cleaning solvent. Place parts on a cl ean, lint fr ee
2012
Service Manua'l 1205 SM07-008-116.00
) - .'-.
1 Controller Valve 3, Electncal Connection 5, Control Console

2 Hydraulic Lmes 4, Screws. Washers. & Locknuts
Figure 1
Dual Axis Controller Valve Assembly
Dual Axis Controller Valve,

R& I A WARNING
This procedure covers the removal and installation 01 hazardous. Serious personal injury may
the dual axis controller valve, For recondition result from misuse of these products. Read
procedure, see SM Keysheet Area 07 -008, and follow all the manufacturer's
Removal cleaning solutions.
1, Lower, detach, and secure the load, as required,
2, Stabilize the crane lor service as lollows: 4. Thoroughly clean Ihe area lo be disassembled with
a, Park the crane, out 01 the way, on a lirm and an approved cleaning solvent lo prevent conta
level surlace. mination. Allow Ihe area lO air dry.
the tires.
e. Engage the swing park brake or travel swing
lock, as required .
A WARNING
d. Level the crane on lully extended outriggers. Hydraulic oil is under pressure and may be
e. Fully retraet and position the boom , as re hot. A sudden release of hot oil could cause
quired . burns or other serious injury. Shutdown the
3. Shutdown the engine and disengage the main hy engine and exhaust all trapped hydra ulic
draulic pump . pressure from the system before removi ng
1 012
5. Relieve the hydraulic system pressure as follows: 3. Thoroughly inspect all parts for damage, wear, fa
a. Relieve any residual pressure in the hydraulic tigue Or stress fractures, and corrosion. Repair or
reservoir by pushing the button (if equipped) replace as required.
on the pressure relief valve, located on the 4. AII "soft parts", such as seals , gaskets, back up
hydraulic reservoir or loosen the filler cap 1/4 rings, and o-rings, should be replaced.
turn . 5. Inspect the integrity of the hydraulic lines that are
b. Turn the ignition switch to "ON", but DO NOT connected to the controller valve . Repair or re
START THE ENGINE. Move the function lock place if required.
out switch to the "OPERATE" position . 6. Inspect the integrity ofthe electrical connector. Re
c. Work the crane control levers and outrigger pair or replace if required.
switches back and forth several times. 7. In the event of severe defects, contact factory per
d . Turn ignition switch to the " OFF" position . sonnel for directions whether to repair or replace
6. Check that all controllevers are in the neutral posi any major component.
" DISABLE" position. Installation
7. Label for assembly purposes and disconnect hy
d raulic lines (2) from cab floor. Cap/plug open hy
draulic lines (2) and fittings to prevent excessive oil
loss and contamination of system.
A WARNING
Note: For assembly purposes, note the orientation compounds, etc. can be hazardous. Serious
of the control/er valve to the control console. personal injury may result from misuse of these
products. Read and follow all manufacturer's
8. Remove screws , washers, and locknuts (4) secu recommendations concerning these products.
ring controller valve (1) to control console (5).
9 . Lift controller valve (1) out of control console (5) far 1. Align controller valve (1) to control console (5) per
enough to access hydraulic lines (2). notes taken during removal procedure.
10. Label for assembly purposes and disconnect hy 2. Connect electrical connector (3) .
draulic lines (2) from controller valve (1). Cap/plug 3. Connect hydraulic lines (2) to controller valve (1).
open hydraulic lines (2) and fittings to prevent ex 4 . Secure controller valve (1) to control console (5) by
cessive oilloss and contamination of system. installing screws , washers , and locknuts (4).
11 . Disconnect electrical connector (3). 5. Connect hydraulic lines (2) on cab floor.
12. Remove controller valve (1) from crane . 6. Check hydraulic reservoir oil leve!. Add oil as re
quired. See Operator's Manual for correct type
Clea ning And Inspection and procedure.
A WARNING
spect the connections on the hydraulic lines for
leaks . Repair if needed .
8 . Complete the installation by testing all related func
hazardous. Serious personal injury may tions of the dual axis controller valve for proper op
res ult from misuse of these products. Read eration. Normal operation of hydraulic and electri
and fol/ow all the manufacturer's cal systems should be confirmed . A general in
reco mmendations concerning solvents and spection of components and systems in the areas
clea ning solutions. adjacent to the repair should also be performed to
fully inspected .
mance of products.
2 of 2
Swing Brake Pedal Valve,
Recondition
This procedure covers Ihe recondition and testing of
the swing brake pedal valve. For removal and
installation procedures, see SM Keysheet Area
07-008.
Disassembly
were disassembled . Keeping the parts in this order
Tank Outlet
If parts are hard lo disassemb le and assemble, do not
use a hammer unless it has a 50ft face, do not force Pressu re Inlet
not bind.
A WARNING
1. Peda l & Base Assy 3. Valve Assy
2. Capscrews & Washers
recommendations concerning solvents and Figure 1
cleaning solutions. Swing Brake Pedal Valve Assembly
1. Dra in any excess hydraulic oil, remaining within 6. Carefully remove cup (8) and seal (9) from housing
the valve, into an appropriate container. Properly (10) .
store or dispose of the used oil.
2. Cap/plug any openings in the valve. Thoroughly Note: Care must be taken to not scratch or mar
clean the exterior surface of the valve to prevent the housing bore.
contamination from entering il.
7. Remove plug (14) and spring (12) from housing
Refer to Figure 1 . (10) .
3. Separate pedal and base assembly (1) from valve 8. Remove o-ring (13) from plug (14).
assembly (3) by removing capscrews and washers 9. Carefully remove spool (11) from housing (10).
(2) .
Note: Remove the spool from the bottom end of
Refer to Figure 2.
the housing. Note the orientation of the spool to
4. If equipped, remove boot (1) from piston (2) and
facilitate assembly. Care must be taken to not
housing (10).
damage the spool or housing bore.
5. Remove piston (2), springs (3,4,5), shim(s) (6) ,
and retainer (7) from housing (10) .
Note: For assembly purposes, note the number

of shims that are removed from the housing.
1 of 4
10
11--~
12-_ _
13~
14~
1. 8001* 5. Spring* 9. Seal 12 Spring

2. Pistan 6. Shim(s) 10 . Housing 13 . 0-ring
3. Spring 7. Retainer 11 Spool 14. Plug
4. Spnng 8. Cup
* Nol aH models use these parts
Figure 2
Valve Recondition
2 of 4
Cleaning And Inspection Assembly
Lubricate spool, housing bore, and all sealing
A WARNING
components with clean hydraulic oil prior to assembly
See Operator's Manual for correct type.
hazardous.
and follow
Serious personal injury may
all the manufacturer's
A WARNING
cleaning solutions.
these products . Read and follow all
1. Thoroughly clean all parts with an approved clean
manufacturer's recommendations concern ing
ing solvent. Place parts on a clean, lint free surface
these products.
and allow to air dry. Exercise every precaution pos
sible to keep all parts free of dust, dirt, or any other
foreign material during assembly. Refer to Figure 2.
2. AII Loctite®, Permatex®, or other sealant residue 1. Carefully slide spool (11) through plug (14) open
should be removed from threads of hardware and ing in housing (10) .
Note : Pay attention to the direction in which the
spool is installed . The spool must slide f reely
into the bore. If either part is damaged, re place
the entire unit.
mance of products.
3. Carefully inspect all components for damage , 2. Install o-ring (13) on plug (14).
wear, fatigue or stress fractures corrosion, deep 3. Install spring (12) and plug (14) into housing (10).
scratches , cracks , and scuffed metal. Remove any Torque plug (14) to 35-40 ft lb (47.5-54.2Nm).
burrs or sharp edges with a fine file, hone , emery 4. Carefully install cup (8) and seal (9) into housing
cloth, or crocus cloth. Replace any damaged com (10).
ponent , as required .
4. AII "soft parts ", such as seals, gaskets, back up Note: Pay attention to the direction and order
nngs, and o-rings, should be replaced. that the cup and seal are installed.
5. Replace capscrews used secure valve assembly
to pedal and base assembly. 5. Install retainer (7), shim(s) (6), and springs (5,4,3)
6. In the event of severe defects, contact factory per in piston (2).
sonnel for directions whether to repair or replace 6. Carefully install piston (2) into housing (10).
any major componen!. 7. If originally equipped, install boot (1) on housing
(10) and piston (2) .
Refer to Figure 1.
8. Align valve assembly (3) to pedal and base assem
bly (1), and install capscrews and wa shers (2).
Torque capscrews (2) to 18-22 ft lb
(24.4-29.8Nm).
9. Test the brake pressure in the valve. See "Pedal
Valve Test Procedure" found later in this document.
10. If swing brake pedal valve is not to be immediately
contamination and properly store.
3 of 4
Pedal Valve Test Procedure Refer to Figure 1 for port identification.
12. Disconnect any connection to the brake outlet port
To test the pedal valve after assembly, it may be on the pedal valve .
installed on the crane or adapted to a hydraulic test 13. Adapt a 0-3,000 psi (0-4 068kPa) pressure
stand capable of producing 2,500 psi (3 390kPa). gauge to the brake outlet port.
Maximum operating pressure on the pedal valve is 14. Connect the hydraulic pressure supply line to the
3,000 psi (4068kPa). pressure inlet port and a return line to the tank out
let port.
Note: 11 the pedal valve is installed on the crane, ad
15. Generate pressure to the test circuit and manually
just the relief valve in the supply circuit to 700 psi
actuate the pedal valve . Observe the pressure
(950k Pa) . Refer to the Operator 's Manual for the re
gauge.
lief valve location and proper adjustment proce
16. The brake outlet pressure of the pedal valve should
dure.
be 500-600 psi (678-813kPa) .
17. If required, disassemble the pedal valve and add or
subtract shims (6,Figure 2) to achieve the proper
A WARNING pressure at the brake outlet port . Reassemble the
pedal valve and repeat this test.
hoto A sudden release of hot oil could cause Note: If the relief valve in the pedal valve circuit was
burns or other serious injury. Shutdown the adjusted to accommodate this test procedure, be
en gine and exhaust all trapped hydraulic sure to reset the relief valve. Refer to the Operator 's
pressure from the system before removing Manual for the relief valve location and proper ad
any line or component. justment procedure.
11. Re lieve and pressure trapped in the pedal valve hy

draulic circuit or test stand circuit. Refer to SM Key
sheet Area 00-000 for safety instructions.
4 of 4
o
o ~: 9
- _. 1
1 Counterbalance Valve Body 4 O-ring 7. Back Up Ring
2. Counterbalance Valve Canridge 5. O-ring 8. O-ring
3. Back Up Ring 6. Back Up Ring 9. Back Up Ring
Figure 1
Winch Counterbalance Valve
Winch Counterbalance
Valve, Recondition
A WARNING
This procedure covers the recondition 01 the winch
counterbalance valve. Far removal and installation
and follow all the manufacture r's
procedures, see SM Keysheet Area 07 -008 .
Disassembly cleaning solutions.
It is a good practice when disassembling hydraulic Refer to Figure 1.

components to lay the parts out in the order that they 1. Drain any excess hydraulic oil remaining within the
were disassembled. Keeping the parts in this arder winch counterbalance valve into an appropriate
during disassembly, cleaning , and inspection will aid in container. Properly store or dispose of the used oil.
the assembly process . 2 . Cap/ plug any openings in the w inch
coun terbalance valve body (1). Thoroug hly clean
1I parts are hard to disassemble and assemble, do not
the exterior surface 01 the winch counterbalance
use a hammer unless it has a soft lace , do not lorce
valve to prevent contamination.
3. Remove the counterbalance valve cartridge (2)
not bind.
from the counterbalance valve body (1). Cap/plug
Note: The internal components of the cartridge the opening in the winch counterbalance valve
assembly are not field serviceable. Remove the body (1) to prevent contamination.
cartridges for cleaning, inspection, externa I seal 4 . Note the position of each of the back up rings
replacement. or complete replacement of the (3 ,6,7,9) and o-rings (4 ,5,8) and remove all
cartridge . o-rings and back up rings from the body 01 the
counterbalance va lve ca rtridge (2).
1 of 2
Cleaning And Inspection c. Seals: Replace all seals whenever disassem
bling the winch counterbalance valve.
4. Place parts on a clean /int free surface and allow to
A WARNING
air dry. Exercise every precaution possible to keep
all parts free of dust, dirt, or any other foreign
material during assembly.
5. AII "soft parts" such as back up rings and 0- rings
haza rdous. Serious personal injury may
should be replaced.
6. In the event of severe defects, contact factary
replace any majar component.
cleaning solutions.
Assembly
surface and allow to air dry. Exercise every
precaution possible to keep all parts free of dust,
dirt, or any other foreign material during assembly.
A WARNING
these products.
surfaces with Loctite® 7070 Cleaner to ensure best
performance of products.
3. Carefully inspect all components for damage, Lubricate all back up rings, o-rings, cartridge, and
wear, fatigue or stress fractures, corrosion, deep housing bore with clean hydraulic oil prior to assembly.
scratches, cracks , and scuffed metal. Remove any See Operator's Manual lor correct type.
burrs or sharp edges with a fine file, hone, emery Refer to Figure 1.
cloth, or crocus cloth. Replace any damaged 1. Install back up rings (3,6,7,9) and o-rings (4,5,8)
component, as required, using the following on counterbalance valve cartridge (2). Refer to
guidelines: Figure 1 for the correct orientation of parts.
a. Housing : Replace housing if cracks or poros 2. Install counterbalance valve cartridge (2) in
ityexist. Replace if deep scratches , cracks, or counterbalance valve body (1). Torque
scuffs are found on mounting or sealing sur counterbalance valve cartridge to 150-160 ft lb
faces. (203-217Nm).
b. Cartridge : Submerge the cartridge in clean 3. If the winch counterbalance valve is not to be
solvent. Through the nose of the cartridge, immediately installed on the crane , plug all open
manually operate the inner working parts sev ports to prevent contamination and properly store.
eral times. Use a wooden or plastic dowel to
avoid damaging soft seals, sharp edges , or fin
ished surfaces .
2012
Control Valve, Recondition Control Valve Disassembly
(Husco 7000 Series)
recondition 01 Husco 7000 Series control valves . For
A WARNING
removal and installation procedures , see SM hazardous. Serious personal injury may
Keysheet Areas 07 -004 and/ar 07 -008. result from misuse of these products . Read
Valve disassembly should only be attempted on a and follow all the manufacturer's
workbench , in a clean environment. The warkbench , recommendations concerning solvents and
mechanic's hands, and all tools must be clean. cleaning solutions.
Disassembled valve parts must be protected from
moisture, airborne dust, and all other types 01 1. Drain any excess hydraulic oil remaining within th e
contaminants. Handle valve parts with extreme care control valve into an appropriate container. Prop
to prevent damaging mating surfaces. Minar burrs ar erly store or dispose 01 the used oil.
nicks can cause leakage . 2. Cap/plug any openings in the control valve. Thor
oughly clean the exterior surface 01 the control
It is a good practice when disassembling hydraulic valve to prevent contamination.
are disassembled. Keeping the parts in this arder Note: Separating the valve sections is only neces
during disassembly, cleaning, and inspection will aid in sary if there is leakage between the sections. Wh en
the assembly process. disassembling the valve sections, be careful not to
lose any shuttle disks or 0- rings that are mounted
between them.
CAUTION
Hydraulic components are machined to close To separate the valve sections, complete Steps 3 thru 7.
tolerances. Use extreme care in handling not
Reler to Figure 1.
to crush or cause damage if clamped in a vise.
3. Far assembly purposes , index mark each 01 the
Do not clamp the control valve or its
valve sections (1,5,8) .
components in any form of vise unless the
4. Position the control valve so it sits on the inlet sec
jaws are protected by a 50ft material. tion (5) with the tie rods (4) positioned vertically.
5. Remove the nuts (3) and compression washers (2)
Valve spools are custom lit to respective bores with Irom the tie rods (4).
extremely close tolerances . Spools lor one section 6. Separate and remove the outlet section (1), spool
should not be interchanged with another. sections (8), and inlet section (5) Irom the tie rods
(4), as required. Removethe o - rings (9 ,11,12,13)
and shuttle disks (10) Irom the valve sections
(1,5,8) as they are separated .
7. Remove the compression washers (7) and nuts (6)
Irom the tie rods (4), as required .
1 018
1 Oullet Seetíon 5. Inlet Seetíon 8. Spool Seetíons 11. O-ring*

2. Compressíon Washers 6. Nuts 9. O-ríng* 12. O-ring*
3. Nuts 7. Compressíon Washers 10. Shuttle Dísk 13. O-ríng*
4. Tíe Rods
* Seetlon seals are loeated between ea eh of the valve seetions.
Figure 1
Typical Husco 7000 Series Control Valve
2018
2 3 4 5 6 7
11 12 13 14 15 16
8
19 18 17
1
1. Pressure Regulating Valve 6. O-ring 11 . Filter 16. Cap

2. O-ring 7. Back Up ring 12. Spring 17. Plug
3. Back Up Ring 8. Anti-void Plug 13. Fitting 18. Seal
4. O-ring 9. O-ring 14. O-ring 19. Shut-oH Plug
5. Back Up Ring 10. Inlet Housing 15. O-ring
Figure 2
Typical Inlet Section Components
Inlet Section Disassembly 2. Remove the o-rings (2,4,6) and back up rings
(3,5 ,7) from the pressure regulating valve (1) or the
The inlet section illustrated in Figure 2 is general in
o-ring (9) from the anli-void plug (8), as
nature and depicts only some of the options available
equipped.
with Husco 7000 Series control valves. For a more
accurate representation of the control valve being 3. Remove lhe shut-off plug (19) from the inlet hous
serviced, refer lO the crane Parts Manual. ing (10). Remove the seal (18) from the shul-off
plug (19).
Refer lo Figure 2. 4. Remove the cap (16), fitting (13), spring (12), and
1. Remove the pressure regulating valve (1) or anti filter (11) from the inlet housing (10).
void plug (8) from the inlet housing (10), as 5. Remove the o-rings (14,15) from the fitting (13).
equipped. 6. Remove the plug (17) from the inlet housing (10).
Note: If service other than external seal
replacement is required, replace the entire
pressure regulating valve or anti-void plug.
3 of 8
2 3 4 6 7 8 9 10
25 26 27
j~
- le II ====~8
1. Co mpensator Spool
37
9. O -ríng
36 35 34
17.
33 32
O-ríng
-A\\
31 3029 28
25. Setscrew 32. Wash er
2. Spríng 10. Spring 18. Back Up Ríng 26. Plu g 33. O-ring
3. O-ring 11. Back Up Ríng 19. O-ríng 27. Capscrews 34. Retaíner
4. Plug 12. O-ríng 20 . Shut- oH Plug 28. Shut- oH Plug 35. O -rín g
5 Plu g 13. Spríng 21. Spríng 29. O-ríng 36. Spool
6. O -ríng 14. O - ríng 22. Tub e 30. O-ríng 37 Spool Sectíon
7. Setscrew 15. Spríng 23. O-ring 31. Back Up Ríng Housín g
8. Back Up Rín g 16. Relí ef Valve 24. Cap
Figure 3
Typical Spool Section Components
Spool Sectiol1 Disassembly 4. Remove the o-rings (9, 12,14), back up rings
(8 ,11), and springs (10,13,15) from the relief valve
The spool section illustrated in Figure 3 is general in
(16) ar the 0- rings (17,19) and back up ring (18,)
from the shut-oH plug (20).
with Husco 7000 Series control valves . For a more
5. Remove the capscrews (27) securing the solenoid
accu rate representation of the control valve being
assembly to the spool section housing (37).
serviced , refer to the crane Parts Manual. Repeat these
6. Separate the cap (24) from the tube (22).
procedures far each of the spool sections needing
7. Remove the o-ring (23) and plug (26) ar setscrew
service .
(25), as equipped , from the cap (24) .
Refer to Figure 3. 8. Remove the tube (22), spring (21) , washer (32),
1. Remove the plug (4), spring (2) , and compensator and retainer (34) from the spool (36).
spool (1) from the spool section housing (37) . Re 9. Remove the 0- rings (33,35) from the retainer (34).
move the o-ring (3) from the plug (4) . 10. Remove the shut - oH plug (28) from the spool sec
2. Remove the plug (5) and setscrew (7) from the tion housing (37) . Remove the 0- rings (29 ,30)
spool section housing (37) . Remove the 0- ring (6) and ba ck up ring (31) from the shut-oH plug (28).
from the plug (5). 11. Repeat Steps 3 thru 10, as equipped , to service the
3 . Remove the relief valve (16) or shut -oH plug (20) other side of the spool section housing (37).
from the spool section housing (37) , as equipped . 12. Remove the spool (36) from the spool section
housing (37). Be careful not to damage the spool
(36) as it is removed.
4 of 8
15
14 _ _ _
13 I
~-:I
:i
, ,1
7 8 5 6
l~ \ ..
~
I
)-1 JII
I
1, Plug 5, O-ring 9, Outlet Housing 13, Plu g

2 O-ring 6 Plug 10, Se tscrews 14, O-ring
3, Spring 7, Plug 11 , Seal 15. Check Valve
4, Spool 8, O-ring 12, Relief Valve
Figure 4
Typical Outlet Section Components
Cutlet Section Disassembly 5, Remove the relief valve (12) and setscrews (10)
The outlet section illustrated in Figure 4 is general in from the outlet housing (9),
6. Remove the seal (11) from the relief valve (12) ,
with Husco 7000 Series control valves , For a more Note: Al! internal components ofthe relief valve
accurate representation of the control valve being are not serviceable. If service other than the ex
serviced, refer to the crane Parts Manual. ternal seal replacement is required, replace the
Refer to Figure 4 . entire assembly.
1, Remove the plugs (6,7) from the outlet housing (9) ,
2. Remove the o-rings (5,8) from the plugs (6,7), 7, Remove the plug (13) and check valve (15) from
3, Remove the plug (1), spring (3), and spool (4) from the outlet housing (9) ,
the outlet housing (9). 8. Rem ove the o-ring (14) from the plug (13) ,
4, Remove the o-ring (2) from the plug (1),
5 of 8
Cleaning And Inspection 6. Install the o-ring (2) on the plug (1) .
7. Install the spool (4), spring (3), and plug (1) in
the outlet housing (9) . Torque plug (1) to
94-116ft lb (132-162Nm).
A WARNING 8.
9.
Install the o-rings (5 ,8) on the plugs (6,7) .
Install the plugs (6 ,7) in the outlet housing (9). Tor
Solvents and cleaning solutions can be que plugs (6,7) to 66-82 ft lb (92-114Nm).
haza rdous. Serious personal injury may
resu lt from misuse of these products. Read Spool Section Assembly
Lubricate all o-rings, back up rings, spools, and
cleaning solutions.
1. Thoroughly clean all metal parts with an approved Refer to Figure 3 .
cleaning solvent. Place parts on a clean, lint free 1. Carefully install the spool (36) in the spool section
surface and allow to air dry. Exercise every precau housing (37).
tion possible to keep all parts free of dust, dirt, or 2. Installtheo-rings (29 ,30) and back up ring (31) on
any other foreign material during assembly. the shut - off plug (28).
2. AII Loctite®, Permatex®, or other sealant residue 3. Install the shut-off plug (28) in the spool section
should be removed from threads of hardware and housing (37). Torque shut-off plug (28) to
the mounting surfaces of parts that are going to be 16-20 ft lb (22-2BNm).
reused . Prior to applying new thread locking com 4. Install the o-rings (33,35) on the retainer (34).
pounds or sealants, clean threads and surfaces 5. Position the retainer (34) on the spool (36).
with Loctite® 7070 Cleaner to ensure best perfor 6. Install the 0- ring (23) and plug (26) or setscrew
mance of products. (25), as equipped, in the cap (24). Torque plug (26)
3. Carefully inspect all components for damage, to 16-20 ft lb (22 - 2BNm) Or setscrew (25) to
wear, fatigue or stress fractures , corrosion, deep 3.5-4.5 ft lb (4.9-6.3Nm), as equipped .
scratches, cracks, and scuffed metal. Remove any 7. Install the washer (32) , spring (21), tube (22), and
burrs Or sharp edges with a fine file , hone, emery cap (24) to complete the solenoid assembly.
cloth , or crOcus cloth . Replace any damaged com 8. Secure the solenoid assembly to the spool section
ponent, as required. housing (37) by installing the capscrews (27) .
4. AII "soft parts ", such as seals , gaskets, back up Torque capscrews (27) to 12.5-15.5 ft lb
rings , and o-rings, should be replaced. (17.5-21.7Nm).
5. Ensure the mating surfaces of each section are ab 9. Installthe o-rings (9 ,12 ,14), back up rings (8,11),
solutely free of contamination (dirt, paint, paint and springs (10,13,15) to the relief valve (16) or the
chips, etc.). 0- rings (17 ,19) and back up ring (18) to the shut
6. In the event of severe defects, contact factory per off plug (20).
sonnel for directions whether to repair or replace 10. Install the relief valve (16) or shut-off plug (20) in
any major component. the spool section housing (37). Torque reliefvalve
(16) or shut-off plug (20) to 42-52 ft lb
Outlet Section Assembly (59-73Nm), as equipped.
Lubricate all o-rings, back up rings, seals, and 11. Install the o-ring (6) on the plug (5) .
housing bores with hydraulic oil prior to assembly. See 12. Install the setscrew (7) and plug (5) in the spool sec
Operator's Manual for correct type. tion housing (37). Torque setscrew (7) to 22-26 in lb
(2.2-2.6Nm) and plug (5) to 6-8 ft lb (B-11Nm).
Refer to Figure 4. 13. Install the o-ring (3) on the plug (4).
1. Install the o-ring (14) on the plug (13).
2 . Install the check valve (15) and plug (13) in the out Note: Install the spring with the large end point
let housing (9) . Torque plug (13) to 6-8 ft lb ing up as illustrated in Figure 3.
(B-11Nm) .
14. Install the compensator spool (1), spring (2) , and
3. Install the setscrews (10) in the outlet housing (9) .
plug (4) in the spool section housing (37) . Torque
Torque setscrews (10) to 22-26 in lb (2.2 -2.6Nm).
plug (4) to 81-99 ft lb (113-13BNm).
4. Install the seal (11) on the relief valve (12).
5. Install the relief valve (12) in the outlet housing (9).
Torque relief valve (12) to 29.5-35.5 ft lb
(41.3-51 .1Nm) .
6 of 8
Inlet Section Assembly Note: Care should be taken not to pinch the section
seals when restacking the valve.
Lubricate all 0- rings , back up rings , seals, and
Refer to Figure 1.
1. The tie rods (4) are threaded to different lengths on
Refer to Figure 2 . each end. If removed, install the nuts (3) fully onto
1. Install the plug (17) in the inlet housing (10) and the short thread end of each tie rod (4).
torque to 66 - 82 ft lb (92 -114Nm). 2 . If removed, install the compression washers (2)
2. Install the 0- rings (14,15) on the fitting (13) . onto the tie rods (4) with the "con e" open to the in
3. Install the filter (11), spring (12) , and fitting (13) in let section (5) surface.
the inlet housing (10). Torque fitting (13) to 3. Install the tie rods (4) through the outside face of
16-20 ft lb (22-28Nm) . the inlet section (5).
4. Install the cap (16) on the fitting (13) and torque to 4. Place the inlet section (5) on a clean workbenCh ,
6-8 ft lb (8-11Nm). outside face down and tie rods (4) up .
5. Install the seal (18) on the shut - off plug (19) and 5. Install the o-rings (9 ,11,12,13) and shuttle disks
the shut -off plug (19) in the inlet housing (10). (10), as applicable, in the grooves in the inlet sec
Torque shut-off plug (19) to 43-53 ft lb tion (5) face.
(60-74Nm). 6. Slide the first spool section (8) onto the tie rods (4)
6 . Install the 0- rings (2,4,6) and back up rings (3,5,7) and against the inlet section (5) .
on the pressure regulating valve (1) or the 0- ring 7. Install the 0- rings (9,11,12 ,13) and shuttle disks
(9) on the anti-void plug (8) , as equipped. (10), as applicable, in the grooves in the spool sec
7. Install the pressure regulating valve (1) or anti tion (8) face .
void plug (8) in the inlet housing (10), as equipped . 8. Continue repeating Steps 6 and 7 until all the spool
Torque pressure regulating valve (1) to 22.5-27.5 sections (8) are installed .
ft lb (31.5-38.5Nm) or the anti-void plug (8) to 9. Slide the outlet section (1) onto the tie rods (4) and
43 - 53 ft lb (60-74Nm) , as equipped . against the spool section (8) .
10. Install the compression washers (7) on the tie rods
Control Valve Assembly (4) with the "cone" open to the outlet section (1)
face .
11. Install the nuts (6) on the tie rods (4) until snug
A WARNING against outlet section (1). Torque nuts (6) to 10ft lb
(14Nm).
compounds, etc. can be hazardous. Serious Note: Incorrect torque and torquing on an un
personal injury may result from misuse of even surface can cause the valve spools to
these products. Read and follow all bind. Ensure the control valve assembly is seat
manufacturer's recommendations concerning ing securely on its feet, on a flat surface, before
these products. completing final torque adjustments.
12. Place the control valve assembly, on its mount

Lubricate all o-rings and housing bores with hydraulic
ing feet , on a flat surface. Torque nuts (6) to
oil prior to assembly. See Operator's Manual for
66-82 ft lb (92-114Nm).
correct type.
13. Ifthe control valve is not to be immediately in stalled
on the crane , plug all open ports to prevent con
If the valve sections were separated, com plete Steps
tamination and properly store.
1 thru 13 for reassembly. Otherwise , skip directly to
Step 13.
7 of 8
8 of 8
Winch Counterbalance STARTTHE ENGINE. Move the lunction lock
Valve, R & I out switch to the " OPERATE " position .
the winch counterbalance valve. Although Figure 1 de d. Turn the ignition switch to the "OFF" position .
picts a crane with two winches, removal and installa 6. Check that all controllevers are in the neutral posi
tion of the winch counterbalance valve used with a tion and move the function lockout switch to the
single winch configuration is similar. For recondition "DISABLE" position .
procedure, see SM Keysheet Area 07 -008.
Refer to Figure 1.
Removal 7. For assembly purposes, label the hydraulic línes
(2) connected to the winch counterbalance valve
1. Lower, detach, and secure the load, as required .
(5).
8. Remove the capscrews (6) securing the splít
flanges (3) to the winch counterbalance valve (5).
level surface.
9. Remove the split flanges and 0- rings (3), ancl dís
b. Engage the park brake and!or properly block
connect the hydraulic lines (2) from the wínch
the tires.
counterbalance valve (5). Cap!plug the open hy
draulic ports and lines (2) to prevent excessive oil
lock, as required.
los s and contamination of the system .
10. Support the winch counterbalance valve (5), and
remove the capscrews and washers (4).
quired.
11 . Remove the winch counterbalance valve (5) from
3 . Shutdown the engine and disengage the main hy
the crane.
A WARNING
A WARNING
and follow all the manufacture r' s
cleaning solutions.
cleaning solutions.
mination . Allow the area to air dry.
an approved cleaning sOlvent, air dried, and ca re
fully inspected.
A WARNING
hot. A sud den release of hot oil could cause reused. Prior to applying new thread locking com
burns or other serious injury. Shutdown the pounds or sealants, clean threads and surfaces
engine and exhaust all trapped hydraulic with Loctite® 7070 Cleaner to ensure best perfor
pressure from the system before removing mance of products.
any line or component. 3. Thoroughly inspect all parts lor damage, wear, fa
5. Relieve the hydraulic system pressure as follows: replace as required.
a. Release any residual pressure in the hydraulic 4 . AII "soft parts" , such as seals , gaskets , back up
reservoir by slowly loosening the filler!b reather ríngs , and o-rings, should be replaced.
cap , located on the top of the hydraulic
reservoir, until pressure is fully relieved.
1 of 4
~:- .>
;~ .) It Jl
(
, . :'. _P
( ~
I
l ·
6 ¡~
'"
e
. --- '1
,ir
. I I
3
1. Winch Motor 3. Split Flanges & 0- rings 5. Winch Counterbalance Valve
2 Hydraulic Lines 4. Capscrews & Washers 6. Capscrews
Figu re 1
Winch Assembly
2014
5. Inspect the integrity 01 the hydraulic lines that are 2. Apply Loctite® 242 to the threads of the capscrews
connected to the winch counterbalance valve . Re (4). Install the capscrews and washers (4) to se
pair or replace il required. cure the winch counterbalance valve (5) to the
6. In the event 01 severe delects, contact lactory per winch motor (1).
sonnel lor directions whether to repair or replace 3. Align the hydraulic lines (2) to the winch counter
any major component. balance valve (5), and install the 0- rings and split
flanges (3). Secure the split flanges (3) to the
Installation winch counterbalance valve (5) by in sta llin g the
capscrews (6).
4. Check the hydraulic reservoir oillevel . Add oil as
A WARNING
required . See the Operator's Manual for the
compounds, etc. can be hazardous. Serious components such as the winch, pump drives , gear
personal injury may result from misuse of reduction units , engine crankcase , rad iator, etc.
these products. Read and follow all Reler to the crane or engine Operator's Manual for
manufacturer's recommendations concerning correct type/ quantity of fluids and proper
these products. procedure.
6. Engage the main hydraulic pump, as equipped
Lubricate all "soft parts" , such as o-rings, with c lean 7. Start the engine and let idle lor five minutes .
hydraulic oil prior to installation. See the Operator's Inspect the hydraulic connections lor leaks.
Manual lor the correct type. Repair leaks as required.
Refer to Figure 1. lunctions of the winch(es) for proper operation .
1. Position the winch counterbalance valve (5) to the Normal operation of the hydraulic an d electrical
winch motor (1). systems should be confirmed. A general
Note: There are two washers used with each of
areas adjacent to the rep air should a lso be
the capscrews that mount the counterbalance
performed to enSure related damage or wear is not
valve to the winch motor.
present.
3 of 4
; .....
4014
-)L
2
View From Underneath The Operator's Cab
1. Swing Brake Pedal Valve 3. Hyd raulic Unes

2. Fl oor Plale 4. Capscrews
Figure 1
Operator's Cab Floor
Swing Brake Pedal Valve,

R& I
A WARNING
This procedure cove rs the removal and installation 01 hazardous. Serious personal injury may
the swing brake pedal valve. For recondition result from misuse of these products. Rea d
procedure, see SM Keysheet Area 07 -008. and follow all the manufacturer' s
Removal cleaning solutions.
2. Stabilize the crane lor service as lollows : 4. Thoroughly clean the area to be disassembled with
a. Park the crane, out 01 the way, on a lirm and an approved cleaning solvent to prevent conta
level surface. mination. Allow the area to air dry.
the tires.
c. Level the crane on lully extended outriggers.
d . Fully retract and position the boom, as re
A WARNING
quired. hot. A sud den release of hot oil could cause
e. Swing the upper over the side to ease access burns or other serious injury. Shutdown the
to the swing brake pedal valve. engine and exhaust all trapped hydra ulic
f. Engage the swing park brake or travel swing pressure from the system before removing
lock, as required. any line or component.
1 of 2
5. Relieve the hydraulic system pressure as follows: 4. AII "soft parts", such as seals, gaskets, back up
a. Release any residual pressure in the hydraulic rings, and o-rings, should be replaced .
reservoir by slowly loosening the filler/breather 5. Inspect the integrity of the hydraulic lines that are
cap , located on the top of the hydraulic connected to the swing brake pedal valve . Repair
reservoir, until pressure is fully relieved. or replace if required.
b. Turn the ignition switch to "ON", but DO NOT 6. In the event of severe defects , contact factory per
STARTTHE ENGINE. Move the function lock sonnel for directions whether to repair or replace
out switch to the "OPERATE" position. any major component.
c . Work the crane control levers and outrigger
switches back and forth several times. I nstallation
d . Turn the ignition switch to the "OFF" position.
"OISABLE " position.
A WARNING
Refer to Figure 1 . compounds, etc. can be hazardous. Serious
7 . Label for assembly purposes and disconnect the personal injury may result from misuse of
hydraulic lines (3) from the swing brake pedal valve these products. Read and follow all
(1). Cap/plug the open hydraulic ports and lines manufacturer's recommendations concerning
(3) to prevent excessive oilloss and contamination these products.
of the system.
8 . Remove the capscrews (4) securing the swing
brake pedal valve (1) to the floor plate (2). Refer to Figure 1 .
9 . Remove the swing brake pedal valve (1) from the 1. Align the swing brake pedal valve (1) to the floor
crane . plate (2).
2 . Secure the swing brake pedal valve (1) to the floor
Cleaning And Inspection plate (2) by installing the capscrews (4).
3. Connect the hydraulic lines (3) to the swing brake
pedal valve (1).
A WARNING
4 . Check the hydraulic reservoir oil leve!. Add oil as
haza rdous. Serious personal injury may 5. Check for correct fluid levels in any related
resul t from misuse of these products. Read components such as pump drives, gear reduction
and follow all the manufacturer' s units, engine crankcase, radiator, etc. Refer to the
reco mmendations concerning solvents and crane or engine Operator's Manual for correct
cle aning solutions. type/ quantity of fluids and proper procedure.
6 . Engage the main hydraulic pump, as equipped.
1. AII components should be thoroughly cleaned with 7. Start the engine and let idle for five minutes .
an approved cleaning sOlvent, air dried, and care Inspect the hydraulic connections for leaks .
fully inspected. Repair leaks as required.
2. AII Loctite®, Permatex®, or other sealant residue 8. Complete the installation by testing all related
should be removed from threads of hardware and functions of the swing brake pedal valve for proper
the mounting surfaces of parts that are going to be operation. Normal operation of the hydraulic
reused . Prior to applying new thread locking com system should be confirmed. A general inspection
pounds or sealants, clean threads and surfaces of the components and systems in the areas
with Loctite® 7070 Cleaner to ensure best perfor adjacent to the repair should also be performed to
mance of products . ensure related damage or wear is not present.
tigue or stress fractures , and corrosion. Repair or
2 of 2
1 Upper Frame 3 Capscrews. Washers. & Locknuts

2. Hydraulic Lines 4. Winch Control Vatve
Figure 1
Winch Assemblies
Winch Control Valve, R & I

A WARNING
the winch control valve. Although Figure 1 depicts a
crane with two winches, removal and installation of the
winch control valve used with a single winch
configuration is similar. For recondition procedure, see
SM Keysheet Area 07 -008.
cleaning solutions.
Removal
level surface.
the tires.
A WARNING
lock, as required. hot. A sudden release of hot oil could cause
d. Level the crane on fully extended outriggers. burns or other serious injury. Shutdown the
e. Fully retract and position the boom, as re engine and exhaust all trapped hydra ulic
quired. pressure from the system before removing
3. Shutdown the engine and disengage the main hy any line or component.
1 of 2
5. Relieve the hydraulic system pressure as follows : 4. AII "soft parts", such as seals, gaskets , back up
a. Release any residual pressure in the hydraulic rings, and o-rings , should be replaced.
reservoir by slowly loosening the filler/breather 5. Inspect the integrity of the hydraulic lines that are
cap, located on the top of the hydraulic connected to the winch control valve. Repair or re
reservoir, until pressure is fully relieved. place if required.
b. Turn the ignition switch to "ON", but DO NOT 6. In the event of severe defects, contact factory per
STARTTHE ENGINE. Move the function lock sonnel for directions whether to repair or replace
out switch to the "OPERATE" position. any major component.
switches back and forth several times. Insta Ilation
d. Turn the ignition switch to the "OFF" position.
" DI SABLE" position.
A WARNING
Refer to Fig ure 1 . compounds, etc. can be hazardous. Serious
7. Label for assembly purposes and disconnect the personal injury may result from misuse of
hydraulic lines (2) from the winch control valve (4). these products. Read and follow all
Cap/plug the open hydraulic ports and lines {2) to manufacturer's recommendations concerning
prevent excessive oilloss and contamination of the these products.
system .
Note: The winch control valve weighs approxi Note: The winch control valve weighs approxi
mately 130 lb (59kg). mately 130 lb (59kg) .
8. Using an appropriate lifting devlce, support the
weight of the winch control valve (4). Refer to Figure 1.
9. Remove the capscrews , washers, and locknuts (3) 1. Using an appropriate lifting device , position the
securing the winch control valve (4) to the upper winch control valve (4) to the upper frame (1).
frame (1) . 2. Secure the winch control valve (4) to the upper
10. Remove the winch control valve (4) from the crane. frame (1) by installing the capscrews, washers,
and locknuts (3).
Clea ning And Inspection 3. Connect the hydraulic lines (2) to the winch control
valve (4) .
A WARNING
correct type and procedure .
hazardous. Serious personal injury may components such as pump drives, gear reduction
resul t from misuse of these products. Read units, engine crankcase, radiator, etc. Refer to the
and follow all the manufacturer's crane or engine Operator's Manual for correct
recommendations concerning solvents and type/quantity of fluids and proper procedure.
cl eaning solutions. 6. Engage the main hydraulic pump, as equipped .
1. AII components should be thoroughly cleaned with Inspect the hydraulic connections for leaks.
an approved cleaning solvent, air dried , and ca re Repair leaks as required.
fully inspected. 8 . Complete the installation by testing all related
2. AII Loctite®, Permatex®, or other sealant residue functions of the winch(es) for proper operation.
should be removed from threads of hardware and Normal operation of the hydraulic system should
the mounting surfaces of parts that are going to be be confirmed. A general inspection of the
reus ed. Prior to applying new thread locking com components and systems in the areas adjacent to
pounds or sealants, clean threads and surfaces the repair should also be performed to ensure
with Loctite® 7070 Cleaner to ensure best perfor related damage or wear is not present.
mance of products.
2 of 2
r··
,--
-Ji (-((
-y ->' ~
1. Upper Frame 3. Capscrews, Washers. & Locknu ts

2. Hydraulic Lines 4. Swing Control Valve
Figure 1
Swing Control Valve
Swing Control Valve, R & I

A WARNING
the swing control valve . For recondition procedure , Solvents and cleaning solutions can be
see SM Keysheet Area 07 -008. hazardous. Serious personal injury may
Removal and follow all the manufacture r's
cleaning solutions.
2. Stabilize the crane for service as lollows:
a. Park the crane , out 01 the way, on a firm and
level surface.
the tires .
lock, as required .
A WARNING
quired . hot. A sud den release of hot oil could cause
3. Shutdown the engine and disengage the main hy burns or other serious injury. Shutdown th e
draulic pump, as equipped. engine and exhaust all trapped hydrau lic
pressure from the system before removin g
1 of 2
5. Relieve the hydraulic system pressure as follows: 3 , Thoroughly inspect all parts for damage, wear, fa
a, Release any residual pressure in the hydraulic tigue or stress fractures, and corrosion . Repair or
reservoir by slowly loosening the filler/ breather replace as required,
cap , located on the top of the hydraulic 4, AII "soft parts ", such as seals , gaskets, back up
reservoir, until pressure is fully relieved , rings, and o-rings, should be replaced.
b, Turn the ignition switch to " ON", but DO NOT 5. Inspect the integrity of the hydraulic lines that are
START THE ENGINE. Move the function lock connected to the swing control valve, Repair or re
out switch to the "OPERATE" position . place if required.
c , Work the crane control levers and outrigger 6, In the event of severe defects, contact factory per
sw itches back and forth several times , sonnel for directions whether to repair or replace
d , Turn the ignition switch to the "OFF" position . any major component.
tion and move the function lockout switch to the Installation
"DISABLE " position.
Refer to Figure 1.
hyd raulic lines (2) from the swing control valve (4) .
A WARNING
Cap/plug the open hydraulic ports and lines (2) to compounds, etc. can be hazardous. Serious
prevent excessive oilloss and contamination of the personal injury may result from misuse of
system , these products. Read and follow all
8. Support the swing control valve (4) , and remove manufacturer's recommendations concerning
the capscrews, washers, and locknuts (3), these products.
9, Remove the swing control valve (4) from the upper
trame (1).
Refer to Figure 1.
Clea ning And Inspection 1. Position the swing control valve (4) to the upper
frame (1) , and install the capscrews, washers , and
locknuts (3).
A WARNING 2 . Connect the hydraulic lines (2) to the swing control

valve (4).
Sol vents and cleaning solutions can be 3. Check the hydraulic reservoir oillevel. Add oil as
hazardous. Serious personal injury may required . See the Operator's Manual for the
resu lt from misuse of these products. Read correct type and procedure.
and follow all the manufacturer's 4 . Check for correct fluid levels in any related
recommendations concerning solvents and components such as pump drives, gear reduction
cl eaning solutions. units, engine crankcase, radiator, etc . Refer to the
1, AII components should be thoroughly cleaned with type/ quantity of fluids and proper procedure .
an approved cleaning sOlvent, air dried, and care 5. Engage the main hydraulic pump, as equipped.
fully inspected , 6. Start the engine and let idle for five minutes.
2. AII Loctite®, Permatex®, or other sealant residue Inspect the hydraulic connections for leaks.
should be removed from threads of hardware and Repair leaks as required.
the mounting surfaces of parts that are going to be 7. Complete the installation by testing all related
reused, Prior to applying new thread locking com functions of the swing control valve for proper
pounds or sealants, clean threads and surfaces operation . Normal operation of the hydraulic
with Loctite® 70 70 Cleaner to ensure best perfor system should be confirmed . A general inspection
mance of products, of the components and systems in the areas
2 of 2
2 _ _-r
1 Upper Frame 3. Con trol Valve

2 Capscrews & Washers 4. Hydraullc Unes
Figure 1
Boom HoistrTelescope Control Valve
Boom Hoist/Telescope
Control Valve, R & I A WARNING
This procedure covers the removal and installation 01 hazardous. Serious personal injury may
the boom Iloist/telescope control valve. For result from misuse of these products. Read
recondition procedure, see SM Keysheet Area and follow all the manufacturer's
07-008. recommendations concerning solvents and
cleaning solutions.
Removal
1. Lower, detach, and secure the load , as required. 4. Thoroughly clean the area lo be disassembled wilh
2. Stabilize the crane lor service as lollows : an approved eleaning solvenl lo prevent eonta
a. Park the crane, out 01 the way, on a lirm and mination. Allow Ihe area lo air dry.
level surface.
the tires.
e. Engage the swing park brake or travel swing
A WARNING
lock, as required. hot. A sud den release of hot oil could ca use
d. Level the crane on lully extended outriggers. burns or other serious injury. Shutdown the
e. Fully retraet and position the boom , as re engine and exhaust all trapped hydrau lic
quired. pressure from the system before removing
3. Shutdown the engine and disengage the main hy any line or component.
draulie pump, as equipped.
1 012
SM07 - 008 -156.00 1106 Service -M anual
5. Relieve the hydraulic system pressure as follows: 3. Thoroughly inspect all parts far damage, wear, fa
a. Release any residual pressure in the hydraulic tigue ar stress fractures, and carrosion. Repair or
reservoir by slowly loosening the filler/breather replace as required.
cap , located on the top of the hydraulic 4. AII "soft parts", such as seals, gaskets, back up
reservoir, until pressure is fully relieved. rings, and 0- rings , should be replaced.
b. Turn t he ignition switch to "ON", but DO NOT 5. Inspect the integrity of the hydraulic lines and elec
START THE ENGINE. Movethe function lock trical connectors that are connected to the control
out switch to the "OPERATE" position. valve. Repair or replace if required.
c. Work the crane control levers and outrigger 6. In the event of severe defects, contact factory per
switch es back and forth several times. sonnel far directions whether to repair ar replace
d . Turn the ignition switch to the "OFF" position. any major component.
6 . Check that all controllevers are in the neutral posi
tio n and move the function lockout switch to the I nstallation
"DISABLE" position.
Refer to Figure 1.
7. Label far assembly purposes and disconnect the
hydraulic lines (4) from the control valve (3) . Cap/
A WARNING
plug Ule open hydraulic parts and lines (4) to pre compounds, etc. can be hazardous. Serious
vent excessive oil loss and contamination of the personal injury may result from misuse of
system. these products. Read and follow all
8. Label for assembly purposes and disconnect the manufacturer's recommendations concerning
electrical connections from the control valve (3). these products.
Note: The control valve weighs approximately
130 lb (59kg ) . Note: The control valve weighs approximately
130 lb (59kg).
9. Using an appropriate lifting device, suppart the
weig ht of the control valve (3).
10. Remove the capscrews and washers (2) securing Refer to Figure 1.
the control valve (3) to the upper frame (1). 1. Using an appropriate lifting device, position the
11. Rem ove the control valve (3) from the crane. control valve (3) to the upper frame (1).
2. Secure the control valve (3) to the upper frame (1)
Cleaning And Inspection by installing the capscrews and washers (2).
3. Connect the electrical connections to the control
valve (3).
A WARNING
Solvents a nd cleaning solutions can be
4. Connect the hydraulic lines (4) to the control valve
(3) .
hazardous. Serious personal injury may required. See the Operatar's Manual for the
result from misuse of these products. Read correct type and procedure.
and foll ow all the manufacturer's 6. Check far carrect fluid levels in any related
recomm endations concerning solvents and components such as pump drives , gear reduction
cleaning so lutions. units, engine crankcase, radiatar, etc. Refer to the
crane ar engine Operatar's Manual far correct
1. AH com ponents should be thoroughly cleaned with type/quantity of fluids and proper procedure.
an app roved cleaning solvent, air dried, and care 7. Engage the main hydraulic pump, as equipped.
fully inspected. 8. Start the engine and let idle for five minutes.
2. AII Loctite®, Permatex®, ar other sealant residue Inspect the hydraulic connections far leaks .
should be removed from threads of hardware and Repair leaks as required .
th e mounting surfaces of parts that are going to be 9. Complete the installation by testing all related
reused. Prior to applying new thread jocking com boom hoist/telescope functions far proper
pounds or sealants, clean threads and surfaces operation. Normal operation of the hydraulic
with Loctite® 7070 Cleaner to ensure best perfor system should be confirmed. A general inspection
mance of products. of the components and systems in the areas
ºof 2
Refer to Figure 1.
Boom Telescope Electronic 7. Label for assembly purposes and unplug the elec
Foot Control, R & I trical connector (5) which services the electronic
foot control (3).
This procedure covers the removal and installation of 8. Remove the capscrews (1) sec uring the electronic
the boom telescope foot control. Electronic foot control (3) to the floor plate (2).
components within the unit are not repairable. 9. Remove the electronic foot control (3) from the
crane.
Removal
level surface.
A WARNING
the tires . hazardous. Serious personal injury may
c. Level the crane on fully extended outriggers. result from misuse of these products. Rea d
d. Swing the upper over the left side of the carrier and follow all the manufacturer's
to ease access to the underside of the upper recommendations concerning solvents and
cabo Apply the swing park brake. cleaning solutions.
quired. 1. AII components should be thoroughly cleaned with
3. Shutdown the engine. an approved cleaning solvent , air dried, and care
4. If equipped with pump disconnect , disengage the fully inspected.
main hydraulic pump. 2. AII Loctite®, Permatex®, or other sealant residue
A WARNING
hazardous. Serious personal injury may with Loctite® 7070 Cleaner to ensure best perfor
result from misuse of these products. Read mance of products .
and follow all the manufacturer's 3. Thoroughly inspect a ll parts for damage, wear, fa
recommendations concerning solvents and tigue or stress fractures , and corrosion. Repair or
cleaning solutions. replace as required.
4. AII "soft parts " , such as seals, gaskets, back up
5. Thoroughly clean the area to be disassembled with rings, and o-rings, should be replaced.
an approved cleaning solvent to prevent conta 5. Inspect the integrity of the electrical conne ctors
mination. Allow the area to air dry. and wires that service to the electronic foot control.
6. Check that all controllevers are in the neutral posi Repair or replace if required .
tion and move the function lockout switch to the 6. In the event of severe defects , contact factory per
"DISABLE " position. sonnel for directions whether to repair or replace
1 of 4
SM 07 - 01 0-006.00 0306 Service Manual
View From Underneath The Cab
1. Capscrews 4. Swing Brake Ped al Va lve

2. Floor Plate 5. Electrical Connector
3 Electronlc Foot Con trol
Figure 1
Boom Telescope Electronic Foot Control
2 of 4
I nstallation 2. Apply Loctite® 242 to the threads of the capscrews
(1) .
3. Secure the electrontic foot control (3) to the floor
A WARNING
plate (2) by installing the capscrews (1).
4 . Connect the electrical connector (5) to the electro
ntic foot control (3).
compounds, etc. can be hazardous. Serious 5. Secure any loose wire with cable ties , as required.
personal injury may result from misuse of 6 . Complete the installation by testing all related func
these products. Read and follow all tions of the electrontic foot control for proper op
manufacturer's recommendations concerning eration . Normal operation of the telescope system
these products. should be confirmed. A general inspection of the
Refer to Figure 1. the repair should also be performed to ensure re
1. Align the electronic foot control (3) to the mounting lated damage or wear is not present.
holes in the floor plate (2).
3 of 4
S M 07 - 01 0-006.00 0306 Service Manual
4 014
Hydraulic Machine And

Oulside 01
Speed - 0- Matic System Toe
01
Sleeve
Hydraulic Tube Fittings
The best hydraulic machine system is only as good as "T" 01
the operator's maintenance 01 the tube littings. Sleeve
The basic causes 01 Iluid system leakage are human Maximum Minimum
error and lack 01 education resulting in improper Fiare Fiare
assembly or mismatched parts. Use 01 properly
matched parts, correct tube preparation, correct Figure 1
Proper Tube Fiare
installation procedure, and time table inspection will go
lar toward maintaining leak Iree hydraulic system
machinery operation.
A WARNING
AII trapped hydraulic pressure must be
exhausted from the system before removing
any line or component. A sudden release of 2
hot oil could cause burns or other serious
injury.
3
Tube Preparation
As a general rule, a properly prepared tube should be

cut off square and internal and external burrs should be
removed from both Ilareless and Ilared tube litting 1. 37 ' Fining
2. 37' Tube Fiare
app lications . 3. Proper Fit
Although incorrectly lormed fiares may seem to make Figure 2

up satislactorily and pass initial pressure tests , they Typical 37° Fiare
cannot be depended upon lor continuous service.
Inspect leaking flared tube littings for following
JI the tube is properly prepared and a flaring tool
properly used , the fiare will normally be correc!. 1. Fiare too shor!. Full clamping area 01 fitting not uti
lized resulting in thinning . This causes leakage or
Angle , length , and diameter 01 liare must conform to breakage due to pullout strains.
the fitting being used. Identily litting , and fiare the tube 2. Fiare too long . Fiare will stick and jam on nut
accord ingly. threads when assembled.
3. Incorrect fiare angle lor fitting where used
Correct length and diameter of fiares for 37 degree
3 - piece littings should extend beyond the countersink Note: Do not intermix 37 degree and 45 deg ree
of the inside diameter 01 the toe of the sleeve, but not fittings. Parts are not interchangeable a nd will
beyond the outside diameter 01 the sleeve. Diameter 01 leak. Refer to Figure 2 .
maximum liare is equal to the outside diameter 01 the 4. Fiare not square and concentric and/or tube not
sleeve; diameter 01 the minimum fiare is equal to the properly prepared before Ilaring.
countersink of the inside diameter 01 the sleeve. Reler 5. Damaged or distorted fiares.
to Figure 1.
1 of 10
Note: Do not attempt to repair damaged fiares. This fitting can be visually identified as to type, without
Cut off and reflare if tube is of sufficient length, disassembly, by the sleeve extending out on the tube
othe rwise replace tube. from the back of the nut.
Flaring tools are available from the Link-Belt Parts Reassemble as follows :
Department. Tool "PX 0110" should be used to fiare 1. Assemble nut and sleeve on tube.
3/ 16" through 5/8" tube and tool "PX 0355" should be 2. Re-fiare tube .
used to fiare 3/ 4" tu be. 3. Check fiare angle, diameter, and length in relation
to tube before tightening nut.
Tube Fittings 4 . Tighten nut.
Note: The same information for the 37 degree
Inspect leaking fitting for the following :
fiare fittings also applies to 45 degree fittings.
1. Proper assembly and nut tightness. Remember, do not intermix the 37 and 45 de
2. Foreign material in tu be or fitting. gree fittings.
3. Tube damage or improper preparation of tube for
flaring. Lenz O-ring:
4 . Correct flaring for that particular fitting.
5. Damaged or mismatched parts. Three piece fitting consisting of a body assembly
(body, o-ring, and teflon back-up washer), tapered
Note: Replace fitting s or fitted parts by
split ring, and nut. The o-ring and teflon washer are
man ufacturer, size and type. A variety of fittings
replaceable in the body. Refer to Figure 4.
may be found in the same hydraulic system.
Du e to similarity, careful identification is re
quired.
Representative types of reusable tube fittings to be

found in Link-Belt machinery are as follows:
37 Degree Fiare:
Three piece fitting consisting of a body, nut, and
sleeve, requiring 37 degree tube flaring. Refer to 2 3 4 5 6
Figure 3 .
1. Tub e 4. Washer
2. Tapered Splil Ring 5 O-ring
3. Nut 6. Body
Figure 4
Lenz 0- ring Fitting
Tube locking is accomplished by tightening the nut

over the tapered split ring and compressing the
2 3 4 tapered split ring against the tube. It is independent of
the sea!. Sealing is accomplished by the o-ringo
1. Tube 3. Nul
2. Sleeve 4. Body
This fitting can be visually identified as to type , without
Fig ure 3 disassembly, by the split flange which is flush with and
37 ° Fiare Fitting visible from the back of the nut.
Reassemble as follows :
Locking and sealing is accomplished by tightening the 1. Check tube for burrs and de-burr if required .
nut and compressing the tube against the body. Note
that the nut turns on the sleeve rather than the tu be
providing a "triple-Iock" action.
2 of 10
2. Slide nut and tapered split ring on tube with large 5. Thread the fitting into the port until the washer bot
end of split ring facing the fitting. toms out on the spot face.
3. Replace and lubricate o-ringo 6. Position the elbow by turning the fitting counter
4. Insert the tube into the body past the 0- ringo clockwise up to 359 degrees.
5. Position the split ring against the fitting. 7. Tighten jam nut , maintaining the elbow position.
6. Hand tighten the nut. Tighten per Ctlart B.
7. With a wrench, tighten the nut without turning the Note: The importanee of lubrieating the 0- ring,
fitting body. and baeking up the washer and 0- ring, ea nnot
be overstressed.
Straight Thread O-ring Seal:
Three piece fitting consisting of a bOdy, washer, and
jam nut assembly and an o-ringo The o-ring is
replaceable. Refer to Figure 5. 2
6 5 4 3
1 Por! Spot Face 4. Washer

2. Fitting Body 5. O-ring
3. Jam Nul 6. 0- ring Gland
2 3 4
Figure 6
Correet Assembly of 0- ring
1 O-ring 3. Jam Nut
2. Washer 4. Fitting Body
When the 0- ring is dry, rotary motion 01 assembly can
Figure 5 cause friction, pinching the o-ring between the
Straight Thread 0- ring Fitting washer and the spot face. Refer to Figure 7.
Sealing is accomplished by threading the fitting into

the port, compressing the o-ring into the "gland" 2 3
formed in assembly, between the port and the flat
surface of the fitting. Locking is accomplished by
tightening the jam nut against the washer to ttle spot 4
6 --t--_l,t---<.
face . Refer to Figure 6.
Note: Lubrieation of the 0- ring and eorreet as

sembly proeedure are extremely important on
this type fitting.
5--
Reassemble as follows:
1. Replace and lubricate 0- ringo 1. O-ring 4. Fitting Body
2. Make sure that port and fitting threads are clean 2. Washer 5. 0- ring Gland
3. Jam Nul 6. Por! Spot Face
and free from damage .
3. Position washer and o-ring as far back on the flat Figure 7
surface of ttle fitting as possible. Ineorreet Assembly 01 Fitting Due to
4. Position jam nut against washer. Non-Iubrieation of O-ring
301 10
SM 07 - 018 - 001 .00 0905 Service Manual
If the washer and o-ring are not backed up before
2 3 4 5
assembly, there is not sufficient room for 0- ring
compression into the reduced gland area. This causes
the o-ring to pinch off between the washer and the
spot face or catch between the fitting and port threads.
Reler to Figu re 8.
234
6 --r--_-'U
1. Sl eeve 4. Washer
2. Shoulder 5 Flange
3. Bolt 6. O-ring
Figure 9
4-Bolt Split Flange Fitting
1. 0 - ri ng 4. Fittin g Body The flange halves are designed to overhang the

2. Was her 5. O- ring Gland shoulder containing the 0- ring seal to insure that the
3 Jam Nut 6. Port Spot Face shoulder will make contact with the mating surface
Figure 8 before the flange halves. Refer to Figure 10.
Incorreet Assembly 01 Fitting Due to Improper
Back- up 01 O-ring and Washer Prior to
Assembly 1 2 3 4 5
This fitt ing depends on compression of jam nut,

washer, face 01 the boss, and the body threads for
locking. The washer can not bottom properly if the
o - ring is pinched, resulting in a loose and usually
leaking connection . If the jam nut is not locked
because of 0- ring obstru ction, the jam nut willloosen
6--
and the whole fitting will become loose and leak .
4-801t Split Flange Connection:

This connection is face sealing and is extremely 1. Sleeve 4. Washer
2. Shoulder 5. Flange
sensitive to bolt torquing . The shoulder, which
3. Bolt 6 O-ring
contains the o-ring, must lit firmly against the matting
surface . The flange is held against the sleeve shoulder Figure 10
with even torque tension on all lour bolts. Reler to 4 - Bolt Split Flange Conneetion
Figure 9 .
4 of 10
Because of the overhang, the flanges tend to tip up 4. Make sure that the sleeve is lined up with the part
when the bolt at one end is excessively tightened and that the shoulder containing the 0- ring fits
before the bolt at the other end. Tightening the bolt at flush against the mating surface befare installing
the other end can cause the flange to bow, tip up in a the flange halves.
see-saw fashion, or bend around and away from the 5. Lubricate bolts and install lockwashers. Lock
sleeve shoulder resulting in bent bolts or bent flanges. washers should be installed with the cupped side
This results in loss of flange to shoulder contact and toward the flange.
leakage. Refer to Figure 11. 6. Position flanges over sleeve shoulders and install
bolts. DO NOT TIGHTEN.
7. Finger tighten all four bolts evenly and alternately.
Make sure that flanges do not hang up on bol!
threads during tightening. Do not tighten one bolt
befare going on to another until all bolts are finger
tight.
8. Refer to Chart A and tighten bolts to recom
mended torque level using a hand torque wrench.
Bowed Flanges Do not fully tighten any one bolt before going on to
another until recommended torque is attained on
all bolts.
Note: Air wrenches tend to tip flanges.
9. Check installed flanges for distortion.
Tipped Flanges Note: Capscrews must be tightened to the val

ues given in Chart A to insure proper fl ange
connections. Lubricate all threads with oil be
fore tightening.
Proper alignment of sleeve to part priar to assembly is

of extreme importance to assure correct assembly and
a leak free connection.
Aliqn bent or replacement sleeve to part as follows:
Figure 11 1. Clamp one end oftube in place and align other end
Incorrect Flange Installations far best fit possible.
2. Using a torch with a large heating tip, heat the tube
cherry red in the area previously bent when arigi
If leakage is suspected, check bolt torque level and/or
nally formed.
flanges for distortion.
Note: Adhere to AII Safety Precautions.
Note: Torque wrench reading could be atthe re
3. Heat a large area befare attempting to bend tube
quired level but shoulder tension could be dis
far the largest possible radius bend. Always heat
sipated due to bent bolts and distorted flanges.
the tube in such a way that bending the tube will
Reassemble as follows: stretch the heated metal rather than compressing
it. This will keep the tu be from upsetting or wrin
1. Check flange halves far bending or bowing and
kling. Do not overheat.
make sure that bolts are not bent or threads dam
4. Clamp or hold sleeve in position and allow thetube
aged.
to cool slowly in the airo
2. Replace and lubricate 0- ring to insure compres
5. Recheck the alignment. If necessary, reheat and
sion in flange seal groove.
rebend tube.
3. Make sure that all mating surfaces are clean and
undamaged.
5 of 10
6. Install flanges and check for unobstructed fit 3. To simplify installation of the self restrained gasket,
over the shoulders. install the lower half of the gasket first , leaving the
split area of the steel retention ring free at the top of
Marman Flexmaster Self-Restrained the tube. (Shown by dotted line in Figure 13.)
Joint: Stretch the gasket and split area of the pipe or tube
into position .
Consists of two couplings, two gaskets with notched 4. Center sleeve over the pipe ends and position gas
retention rings , two gasket retainers, and one sleeve . kets and retainers flush against the sleeve.
Refer to Figure 12 . 5. Make sure that sleeve overlaps pipe ends by 1/4 in
(6.35mm) minimum on 2 in (50.8mm) and smaller
diameter pipe and by 1/2 in (12. 7mm) minimum on
2 in (50.8mm) ar larger diameter pipe. (Refer to
Figure 13, dimension A.)
6. Assemble both couplings and tighten nuts until O
in to 1/4 in (O - 6.35mm) gap is obtained between
coupling ends. (Refer to Figure 13, dimension B.)
7. Make sure that coupling encompasses all compo
nents befare tightening. Do not tighten either cou
pling until the entire joint is assembled.
5 4 3 2
1 Retainer 4. Sleeve
2 Coup ling 5. Tube
3. Gasket w/ Retaining
Ring
Figure 12
Flexmaster Self-Restrained Fitting
This joint cannot be visually identified without

disassembly from the Marman 6500 series joint. The 2 354
difference between the two joints is a notched retention Assembly Seq uence
ring used in the special Buna rubber gasket for the

Flexmaster Self - Restrained joint.
Lock and sealing action is by compression of the

gaskets during tightening of the couplings whi ch
exerts pressure on the gasket and the notched, split
retention rings whi ch in turn grip the pipe ar tube.
Note: This is a sealing joint and is not intended

to support pipe or tube end load.
tO
Reassemble as follows: Assembly Layout
1. Clean and align both pipe ends.

2. Install retainer, gasket, and sleeve on opposing
Figure 13
pipe end. Flexmaster Assembly
Note: Assembly can be made easier by dipping
the gaskets in water prior to use. Do not use pe
troleum or non-drying lubricant.
~ of 10
Marman Flexmaster Model 6500: Check all hydraulic system tube fittings upon receiving
a new machine. Pay particular attention to hard to
Consists of two couplings , two gaskets, two gasket
reach fittings which might be missed or ignored during
retainers , and one sleeve. Refer to NO TAG .
subsequent "on the job" routine inspections.
Adhe re strictly to recommended time table inspection

schedules. Do not assume that a fitting will remain tight
with no evidence of loosening or leakage. Check all
fittings and tighten, if necessary, during each
scheduled inspection.
Maintain an "open eye" policy for evidence of leakage

at all times . Consider any evidence of leakage as a red
flag. Check and tighten, or replace, leaking fittings or
fitting parts immediately to avoid resultant hydraulic
5 4 3 2 system component damage.
1. Retainer 4. Sleeve
2. Coupling 5. Tube Consider every fitting as a working component of the
3. Gasket w/ Retaining
Ring
hydraulic system. Become acquainted with the
characteristics of every fitting used in the particular
Figure 14 hydraulic system.
Flexmaster Model 6500
When replacinq fittings or fitting parts:
This joint can not be visually identified without 1. Make sure that the tube is properly prepared .
disassembly, from the Marman Flexmaster 2. Make sure that the fiar e is properly formed for that
Self - Restrained joint. The Self - Restrained and particular fitting .
Model6500 joints are identical except that the notched 3. Replace fitting or fitting parts by manufacturer, si ze
retaining ring in the gasket is not used in the Model and type.
6500 joint. 4. Follow correct assembly procedures for each par
Lock and sealing action is by compression of the ticular fitting .
gaskets during tightening of the couplings which exert 5. Use Loctite® on pipe threaded fittings only.
pressure on the gasket which in turn grips the pipe or 6. Use a torque wrench where torque specifications
tube . apply.
Installation procedure is identical to procedure as Loctite® 242

outlined for the Flexmaster Self - Restrained joint.
As a product improveme nt, Loctite® has on the market
Note: This is a sealing joint and is not intended
a pipe thread sealant , Loctite® 242 , that does not
to support pipe or tube end load.
require the use of a primer. Fittings can now be used in
the "as received " co ndition . (See instructions belowfor
Preventative Maintenance using the sealant.)
Using Loctite® 242 will aid in preventin g hydraulic pip e

There is no shortcut to hydraulic machinery tube fitting
fittings from leaking ancl it should prove to be easier
preventive maintenance. It is impossible to detect a
and quicker to apply. Therefore , it is recommen d that
potentialleaking joint or fitting until the trouble actually
Loctite® 242 be used in place of the existing Loctite®
begins . There is no way of telling if a fitting is loose
pipe sealant (Link-Belt specification 806004) where the
without tightening it. Leaks can develop in a new
thread is the sealing mechanism.
machine or any time during continuous service from
fittings which appear secure and leak free.
The seemingly time consuming preventive

maintenance inspections can result in avoiding costly
hydraulic system component damage and/or loss of
costly operational efficiency.
7 of 10
The following quantities of Loctite® 242 can be Recommended Torque Values For
obtained from the Link-Belt Parts Department.
Hydraulic Fittings
Item Number Quantity (Bottle)
In conjunction with using Loctite® 242 to prevent
806033001 250cc hydraulic fittings from leaking , our engineering
806033002 50cc department has issued recommended torque values
for various sizes of split flange connections , 37 o flared
806033003 10cc tube connections, o-ring boss fittings and pipe swivel
adaptors. These torque specifications are being
The following instructions are for using Loctite® 242 adhered to during the assembly of the machine . (See
Pipe Thread Sealant. It is to be used on all connections Charts A , B, C, and D for torque specifications .)
where threads are the sealing mechanism .
1, New fittings may be used in the "as received " con Yellow Crackling Paint
dition.
2, Be certain used fittings are free of dirt , oil, grease, As a quality control measure, a small strip of "crackling
paint, and other contaminants by cleaning male paint", yellow or orange in color, is applied across
and female threads with solvent (806006) and al critical connections after the connections have been
lowing to dry. tightened to proper torque value. This crackling paint
3. Shake sealant thoroughly and apply to male wlII later serve as an indicator to show if the connection
threads of the joint. Use application nozzle on the has loosened after the machine has been operated for
bottle to apply enough sealant to fill the first three a period of time.
threads. Avoid excessive application.
4, After tightening threads, allow to cure for one hour. If upon examination of the connection, the strip of paint
Note: has cracked or broken, this would then be a good
indication that the connection has seen some stress
a, Locquic® primers must be used on non-me and has loosened . Therefor, retighten the connection
tallic parts. to the proper torque value to alleviate or prevent a
b , Locquic® primers may be used on metallic sur potentialleak .
faces where a rapid cure is desirable.
8 of 10
Bolt Diameter Tarque Majar Tarque
Tube
Thread
SAE Metric in lb ft lb Nm 0.0. Diameter in lb ft lb Nm
Standard Thread
Thread 1/8 5/16-24 36 3 4
5/16 M8 156 13 17 3/ 16 3/8-24 96 8 11
3/8 M10 276 23 31 1/4 7/16-20 96 8 11
7/16 -- 420 35 47 5/16 1/2-20 132 11 15
1/2 M12 660 55 74 3/8 9/16-18 225 19 25
5/ 8 M16 1,320 110 149 1/2 3/4-16 360 30 40
3/4 M20 2,400 200 271 5/8 7/8-14 456 38 51
3/4 1 1/16-12 648 54 73
SAE Cagscrew Head
7/8 13/16-12 735 61 82
0
Grade 5
®,
.... ....
Grade 8
1
1 1/4
15/ 16-12
1 5/8-12
900
1,350
75
113
101
153
1 1/2 1 7/8-12 1,896 158 214
2 21 /2-12 2,700 225 305
Metric Cagscrew Head
@ @
(lt)]OO
Grade5
i
Grade8
19 ¡--t- -..r - - ..
("'¡ 11 1
t;c~
--
,.(0-@\
( Xf:;
Note: Do not overtighten reducing fittings . See
SAE 4 Bolt Flange installation instructions .
Tightening Sequence
1-2-3-4 Chart 8
0- ring 80ss Fittings
\(J/{[)"
-
Note: Bolts mus be Grade 5 or better.
Chart A
SAE Split Flange Clamp 80lts
9 of 10
Major Torque Major Torque
Tube Tube
Thread Thread
0.0. in lb ft lb Nm 0.0. in lb ft lb Nm
Oiameter Oiameter
1/8 5/16-24 36 3 4 1/ 8 13/32 225 19 25
3/ 16 3/ 8-24 96 8 11 1/4 17/32 270 23 31
1/4 7/16-20 132 11 15 3/8 11 / 16 360 30 40
5/ 16 1/2-20 180 15 20 1/2 27/32 516 43 58
3/ 8 9/16-18 276 23 31 3/4 1 1/ 16 735 61 82
1/2 3/4-16 456 38 51 1 1 5/16 900 75 101
5/8 7/8-14 648 54 73 1 1/4 1 21/32 1,163 97 131
3/4 1 1/16-12 900 75 101 1 1/2 1 29/32 1,650 113 153
7/8 1 3/ 16-12 1,056 88 119 2 2 3/ 8 2,700 225 305
1 1 5/ 16-12 1,200 100 135
1 1/4 1 5/8-12 1,896 158 214 [Q~O'
I I I
). ~r::. '='
'-~
1 1/2 1 7/8-12 2,700 225 305

2 21/2-12 3,996 333 451
. [~---1 See
rü
Note B
See Note A ~I-
"
--,r.
lL_.lII
Note A: Use aboye torques on this type 01 swivel

nut only. Do not use Loctite@
[~J ~:. =.:IJ

Note B: No torque values lor t!lis type 01 pipe
Chart O
thread. Use Loctite® 242.
Pipe Swivel Adaptor

Note: Do not overtighten reducing fittings. See
installation instructions.
C ha rt C
JIC 37 Degree Fiare Swivel Nut
10 of 10
/
...
1. Head Machinery
2. Tip Section
3. Tip Section Extend Cable & Pulley
? /
7
4. Outer Secti on
5. Center Section
6 Inner Section
7. Base Section
Figure 1
Typical Five Section Boom Nomenclature
Hydraulic Boom Inspection

4;~
.. .
'-
~;
Introduction ~. : I~
'J
The following information is provided far the identifica
tia n and inspection of two pie ce formed hydraulic l••. .
I
boom sections manufactured by Link-Belt Construc
tion Equipment (LBCE) . LBCE cannot assume respon . ---f-!-+~
~
sibility for repairs of any kind made to hydraulic boom

sections because it will neithe r cont rol nor inspect the Identification Tag
repairs. This document is far refe rence purposes only.
Packet Number
For information concerning tubular fly and jib attach
Part Number
ments for hydraulic cranes, refer to SM Keysheet Area
9-1.
J7M1534 445
It is very important to maintain the hydraulic boom sec
BTJ7012
tia n in good working condition. Damaged hydraulic
boom sections may result in boom failure. The steels
o 0702038
o
used in the manufacture of hydraulic boom sections
necessitate the use of special procedures.
OB 01 TW
Inspection procedures should be performed by quali
fied individuals with knowledge and experience in steel Boom Section
fabrication. It is of the utmost impartance to study Serial Number
these instructions and follow them closely. Identifica
tion of terms used throughout this SM are given in Figure 2
Figure 1.
Typical Identification Tag5
Identification Documentation & Analysis

The part number and serial number, of each boom sec 1. The specific inspection criteria on the "Hydraulic
tion, is located on an identification tag . On the tip sec Boom Field Inspection Farm " must be followed in
tion, it is located on the side plate of the head machin arder to evaluate the boom section properly. A
ery. On all other sections it is located on the front 01 the sample of the form is shown on pages 7 -12 .
botlom shoe suppart. Figure 2 shows an example of 2. The information gathered should be given to a
an identification tag. LBCE Representative or Product Specialist at the
factory for proper evaluation .
1 of 12
;
~
" ' .'." , .
c:..:.
~ 2
1 \1, \1
h
'¡ -- - :::::;:;:;::1
/ 1.1 ¡
1\ / / 1,
I
11
1, Use Typical Saw Horses Wh en Placing Secti on On Flat

A WARNING
2. Use Form Fit Saw Horse When Placing Section On Round Solvents and cleaning solutions can be
Figure 3 hazardous. Serious personal injury may
Set Boom Section On Stable Blocking result from misuse of these products. Read
General Inspection recommendations concerning solvents and
cleaning solutions.
AII inspection procedures suggested in this document
must be performed on a non-working boom which
1, Thoroughly clean the entire boom section with an
has been disassembled and separated into individual
approved cleaning solvent. Remove all mud , dirt ,
sections. For boom disassembly procedure, see SM
grease , oil, etc" so adequate inspection may be
Keysheet Area 17 -1, These sections are then to be
performed, Allow the boom section to air dry,
positioned and secured in such a manner that the work
2, Throughout the inspection, you will be asked to
can be performed in a safe , proper fashion ,
collect data from different locations on the boom
The inspection equipment needed are such standard section, Positions of "TOP", "BOTTOM ", "LEFT",
items as: portable light and "RIGHT" are to be interpreted as if the boom
wire brush were installed on the crane, viewing the boom from
probe the operator's sea!.
digital inclinometer 3, Set boom section on blocking or sawhorses of
24 inch (60cm) straight edge equal height approximately 4 ft (1,2m) from each
10X magnifying glass end of the subject boom section. Make sure the
marker (chal k, crayon, etc,) width of the blocking or sawhorses is greater than
string line the width of the boom section, See Figure 3,
two magnetic blocks of equal size 4 . Observe closely those areas where the paint has
magnetic particle compound be en chipped, w ri nkled , or missing , or contains
dye penetrant faint rust lines or marks.
other nondestructive testing equipment 5 , Other types of damage , such as dents in the top,
bottom , or side plates , brackets with dents or
cracked welds , interference between boom sec
A DANGER
Secure boom sections to adequate, stable
tions, etc, requires review by a LBCE representa
tive to determine if boom section can be repaired,
6, Inspect boom foot pin hole, in the base section , to
su pports during inspection. Boom sections be sure the bushing is tight , uniform, and concen
are extremely heavy. Unexpected movement tric within the machined hole, Replace bushing if
of boom sections could cause damage, injury, necessary,
or death. Properly stabilize boom sections 7, The nature and dimensionallocation of any defor
before beginning work. mity should be recorded on the "Hydraulic Boom
Field Inspection Form",
2 of 12
Measure Twist
On Bottom Flat
Inclinometer
Sectional View
Boom Section Secured,
Bottom Side Up o "'o
Figure 5
Boom Section Twist
Boom Section Twist Inspection

Boom section twist is the axial relationship from the 2. Adjust the position of the boom section , at Location
rear of the section to the front oi the section. This in A-A, to achieve level reading from side to side . (Ii
spection also helps to determine ii the boom section is equipped, use Zero ieature on inclinometer.)
straight. To inspect ior twist, the boom section should 3. Maintain the boom section in this position during
be placed bottom side up on blocking or sawhorses. the remainder of twist inspection.
Inspect in four places per "Hydraulic Boom Field In 4. Move inclinometer to next location (Location B-B).
spection Form" and record values. An digital inclinom 5. Record the location and inlinometer reading per
eter will be required with an accuracy oi ± 5 o. the diagram above , using the "Hydraulic Boom
Field Inspection Form ".
Reier to Figure 5. 6. Repeat Steps 4 through 5 every 10ft (3.1 m) down
1. Level the boom section, from end to end, on two the length oi the boom section (Location C-C ,
equal size saw horses. The boom section should Location O-O).
be botlom side up.
Note: Location O-O on the base section sh ou ld
be located directly above the boom foot pin o
3 oi 12
MeI~_G_a_p________
Sidewall
,,------- --:
24inch
,..- Straight Edge
(60cm)
Lalecal Weld ~J
Figu re 6
Sidewall Flatness
Sidewall Flatness
Srdewall flatness is a measurement of the waviness of 2. Starting at the base of the section , divide and verti
the vertical left and right hand walls of the boom. To in cally mark the boom section in 24 inch (60cm) seg
spect flatness, the boom section should be right side ments , along both sidewalls of the boom section.
up on blocking or saw horses. Inspect the entire length 3. Measurements will be taken along the entire length
of each side of the boom , beginning at the weld seam of the boom section, above the lateral weld. Be
at the rear. Continue up and down the length of the sure to mark the boom section along its entire
boom in 24 inch (60cm) increments, recording the spe length and on both sides.
cific location on the sidewall where it is least flat. 4. Using a straight edge , locate and measure the
Refer to Figure 6. largest gap in each marked segment along the
1 . Position boom section on its bottom surface so the boom section.
head machinery or collar clears the ground. Se 5. Record the size and location of each gap on the
cure the boom section to sturdy saw horses or "Hydraulic Boom Field Inspection Form ".
blocking .
4 of 12
Measure Distance From Sidewalt

To Each String Line Every 3 ft (1 m)
- - -- ~
Spacer
Block
Top View Boom
Right Bow Lel1 Bow
Figure 7
Minor Axis Bow
Minor Axis Bow 3. Measurements will be taken at the top and the bot
tom of the flat portio n of the sidewall, down the en
Minor axis bow is when the boom section is bowed to tire length of both sides 01 the boom section.
the left or right. To inspect the boom section for this 4. Position spacer blocks, 01 equal size, at each end
condition, the boom section must be in the upríght of the boom section. Be sure the spacer block is
position. Take measurements every 3 ft (1m) and re resting on the flat portion of the sidewall.
cord measurements on the "Hydraulic Boom Field In 5. Pull a string over each spacer block and tie it to the
spection Form " . very end of the boom section. See Figure 7 .
6. The string must be taut and span clearly between
Reler to Figure 7. the spacer block at each end of the boom section .
1. Position boom section on its boltom surface so the 7. Measure and record the distance between the
head machinery or collar clears the ground . Se sidewall and the string at each of the vertically
cure the boom section to sturdy saw horses or marked locations.
blocking 8. Relocate the spacer blocks and string to the oppo
2. Starting at the base 01 the section, divide and verti site side of the boom section.
cally mark the boom section in 3 ft (1m) segments. 9. Repeat Steps 4 through 8 for the other side of the
boom section.
5 of 12
Measure Distance From Flat Plate

To Each String Une Every 3 ft (1m)
'r
String
Line I
Spacer
Block
~
Side View Of Boom

Negative Camber
c==----'--fF~ ------t)
1-
\
, \
\
. -'
[ Positive Camber
~~--L---f~
Fig ure 8
Major Axis Camber
Majar Axis Camber 4. Measurements will be taken on both the top and
the bottom 01 the boom section down its entire
Majar axis camber is when the boom section is bowed length .
up or down. To inspect the boom section lor this condi 5. Position spacer blocks, 01 equal size, at each end
tion the boom section must be positioned on its side. 01 the boom section .
Take measurements every 3 ft (1m) and record mea 6. Pull a string over each spacer block and tie it to the
surements on the "Hydraulic Boom Field Inspection very end 01 the boom section.
Farm ". 7. The string must be taut and span clearly between
the spacer block at each end 01 the boom section.
Reler to Figure 8. 8. Measure and record the distance between the Ilat
1. Position boom section on its side so the head ma surlace 01 the boom section and the string at each
chinery or collar clears the ground. Secure the 01 the marked locations.
boom section to sturdy saw harses or blocking. 9. Relocate the spacer blocks and string to the oppo
2. Starting at the base 01 the section, divide and verti site surface.
cally mark the boom section in 3 ft (1 m) segments. 10. Repeat Steps 6 through 9 lor the opposite surface.
3. Be sure to mark the boom section along the entire
length.
6 of 12
Hydraulic Boom Field Inspectioh>Form

" . ".
This form is used lo colleel and document inspection data for link-B~ ~ tWo pieca,tormed, telescopic
boom seetions usad on hydraulic cranes. Detailed inspection procedt:ire~are outlinedin Service Manual
document SM17 -1 -53.0 and should be performed byqualified indiviqu(ils with knowledgé and experience
in steel fabrication. The information collected should be given to a LBCEBepresentativiúmd forwardéd to a
Product Specialist at the factory for proper evaluation. .
Crane Model Number: RíC~80/00 JT -"'Z:::..··_>-~•.·.<e:;-

Crane Serial Number: ...;JIo<...LZ .. "'-. .: :O:. . . <;,.I,.¡..,.¿.{_ __
.....J",-·
Date: B / ~ /0 Z Hourmeter Reading: ~/<........::Z=-9:........:2=-_-:----,-____
Section: _O=..=u'---n'--""'é:!.;Je==---_ _ _ _ _ _ _ Section Part Number: J 7rll (Z7
Sectlon Serial Number: 08 O Z 1.3 3 InspectecfSY; .. ' ~.. 'C Z:c.
Position Nomenclature
Top left (Tl)
Ic)P>fllght (TR)
• • •• o ••••• • •
Bottom left (Bl)
Bottom Right (BR)
>Córrect docu~htatiOn is crltical to arrive at an accurate analysis of the condition 01 a

boom secti6rfTllr6@hout this inspection form, you will be asked to collect data 1rom
differentloca.tions on1he boom section. Positions 01 "TOP". "BOTTOM", "LEFT", and
·¡~JGHr".are to be interpreted as it the boom were installed on the crane, viewing the boom
fróffithe operator's~~ªt. The illustration above clearly defines the location of each 01 the
boom section9J9u( friáin locations. The abbreviation for each 01 these tour locations is
also given it1parénfhesis.
F00075
7 0112
Hydraulic Boom Field Inspection :Form
Measut~twlsl
:; ::Oll:ªc)ttOm Flal
Inclinometer
10ft
~ :>,0.?
~:'..:\•\....
~c~-"
Sectional View
Boom Seetíon Seeured,
Boltom Side Up
4[ < , \
\
.. ',,'
' ,"'-_I~C/ I
Location A-A, " , L~r6;'8 :'; ~ Location e- e Location D - D

Inclinometer ínc1tnometer o Inclinometer t> Inclinometer
Reading : 0.0
0
. Reading:~ Reading : o .Z Reading : O,So
1. Level th~' bb6mséCii6h. from end to end, on two equal size saw horses.
2. AdjListtheposition6f\he boom section, at Location A-A, to achieve level reading Irom slde to side.
, a. M~ifiiE'ifi1 the boom s1!!ction in this position during the remainder 01 twist inspection.
4; Mo~einclinometeri()next location (Location 8-8).
'S:', Record inclinometéi':ieading per the diagram aboye.
6. RepeatSt~p~4#lrOúgh 5 every 10 ft (3. 1m) down length 01 boom section, (Locations C-C & D-D) .
. .. ,.
Note:location ÍJ - D on lhe base sectlan should be located directly aboye lhe boom fool pino
FOOO76
8 of 12
Hydraulic Boom Field Inspection Form
, 13 :
Measure Gap
I 12 I
~~
,~
I 'e
,
I
'
-¡ 1
e
~ '; 7
sidewallJ
T
6
1
~ ,
~
I 5
24inch S- 4
3 ' '-
Straight Edge
(60cm)
2
" '\
Lateral Weld
~'
\ :~
~ G:::)
..
1. Place and secure the boom section on two equal sizes8v.{iíorses.

2. Divide and vertically mark the boom sectiof:l.! in 24 inch«&)cm) $ffiments , along both sidewalls.
3. Measurements will be recorded alorig < th~éhtife. length 01 thebóom ·section, above the lateral weld.
4. Using a straight edge, locate and mea~. lJrethela(gEl~t gap in each marked segment along boom.
5. Reco rd the size and location 01 each gapbeloW.
Sidewall Flatnes$ll1specHol'lData
Left Sidewall Loc~(i()ri .. Right Sldewall Location
.. ..
.. :-: .1=. ......
1-
1 O. 08 16"> .. . á;/¿j (). 03 16
O· Ot.P
..
2 O. 03 17 O~ > O7 2 O.OS' 17 O . 07
3 O. 03 18 O. OC¿; 3 O, Ot.P 18 O, O
4 Q, O(P 19 4 O, O$" 19

..
5 O. 07 26 :
<:: 5 0 ,-03 20
6
O· 05" ..
2.1 6 O. 03 21
7 O. O 3 ¿¿ ..;
7 0.07 22
..
8 O. 03 23 .. 8 0,/0 23
9 c:; •.6) <:5. 24 9 O, 09 24
::-;.: .: -
10 O ·~< OS'" 25 10 O.Ot.P 25
11 . ti, o~ ..
29 11 0,07 26
12 1:. iJ· 05'.· :
27 .. 12 O .03 27
13 O oS--
.. .
..'-:: ''; :
;" . . ... .: : ~....
.
.. 28 13 O tJ3 28
-
14 O.! o3 29 _..
14 O ,03 29
15 O , 03 . 30: • 15 0 1 07 30
FOOO75
9 of 12
Minor Axis Bow Inspection
Top ViewóH¡¡oom
,,'.:
Sectlon
..
on Sawhorses
Spacer Block
Right Bow Left80w

,St) TA
~---<; BR • .!JC)
Top View 01 Boom Sectiori ·.
(Exaggeraled Bow)
·St) TR
.-H---< BR ~ SO
.,S"'I!) TR
.-H_--< BR ' f,7J
Spacer Block Thickness:
•.¡.s TR
1. Position boom section on its bottom surfá6~so the heác( :: .-H---< BR~
machinery or collar cle¡)rs the ground. Secur:lfthe boom
section to sturdy sal,V;f1orseSo:rblocking ..• . TR
2. Starting at the base ót1h:Ei~ection:;dl\ljd~aild\l~iiq¡¡¡:ltymark BR~
the boom section in 3 ft> {}ln)s~gments " ..... .
3. Measurements will be takenanhe:t9p.~nd the boltomolthe TR
tlat portion 01 the sidewall, down' the $r:rtfre length 01 both SR.J....i'7
sides 01 the boom seclion . .
4. Posilion spacer blockS, 01 equal size, atea6flend 01 the ,L/9 TR
boom sectió:n~ B~$l.iréthespacer block is resting on the tlat .¡..¡..--< SR~
portion 01 tb~$¡déwa.H. .. .... ••... ">:
5. Pull a string biiereach spacerplóckahdlleit to the very end
01 the boom se6tiOi), ."
6. The string mus(:bé taut.and span clearly between the
spacer block at eaéh>€lr\~()i the boom seetion. (:;ITA
7. Measure and record the.distance between the sidewall and SR .$V
tt:iE:!~Úing at each 01 Ihe :vel1lcally marked localions.
8, Reioc~Üe the spacer bloc~a.~dstring lo the opposite side ..5"0 TR
.01 the boom seGtiOó;., . ..' ~---< SR .,5"0
9. Repeat Steps4il1rough 8 lodhe other side 01 the boom
seetíon. ·· .... . . .. .!['t) TA
-"-t------/ BR~O
TL = Top Left BL = B?f\~m'lelt TR = Top Right SR = Bottom Right
FOOO75
10 of 12
Major Axis Camber Inspection
Top Vlew:ofeoom Secti~r on Sawhorses
Spacer Block ."
t Neg~
c===-----,--- String
,so BR
..¡"f~-< Bl .SO
1 ~5V
,5lJ BR
[ Positive Camber . . . ,SI BR

-.LL.... / BL~@
~-----=-I~.
, E BR
_ L l . _../ Sl' SO
,so SR
.-< Bl L5"¿)
Right Síde View Of Boorn .Sections
,~OBR
(Exaggerated Cariihér) : .1 1.- / BL~~O
m;SO ,S-O BR
J.SO Tl _11._ / Bl'5O
Spacer Block Thickness: 0,:5"0 /"yc# TR -=- Q ,J'l!.. BR

'.2 Tl 7 Bl ,S¿)
1. Positíon boom sec1ionOnits>side so Ihe head m~chinery or
collar elears Ihe groufid. $eG\JlelfJ$:Qoomsectionto~turdy TR'sO . S-¿) BR
saw horses or blockíh¡f . .... ..... .. . ..
,.s-O~ ~ sv
2. Slarting at the base 01 Ihesectibn;divíde and vertícany mark
Ihe boom section in 3 ft (1m) segments . .49 BR
TR...!....1J
3. Be sure to mark the boom seelíori aloflQ 1he.entire length . ......._ ../ Bl' S-¿)
· -~Q- Tl
4. Measuremenls will be taken on both Ihe tOPéln.d.the bonom
01 Ihe boorti $~ctiondownits entire length. ··· ··· ,sO BR
Position spacerbiocks~ ofe)c¡uál si:z.e, al each end 01 the
5.
boom secHón: , . . . .'.' , .. .. " . . '. ' ~S-I
6. Pull a string ov.e.r :ea,ch Spac.El(pIOCk andiíe it lo Ihe very end
01 the boom sed¡oó.~< ............ .
,S'CJ BR
--Wi--......./ Bl' S-O
7. The string must bet@tand!¡pan clearly bet'vveen the spacer
block at each end oft@tioom sectíon.
,5'0 BR
8. M.El<l$UFe .a nd record theCfislance bet'vveen the Ilal surface 01
Bl ,.5"0
<!hebo9m seetíon andthestring al eaeh 01 Ihe marked
::localioris. '.' . : -:. . '.' ,~OBR
9. Reloeale thespac!'l:l' blocksand slring to Ihe opposile Bl' ~o
surfaee . . ' .:. '.':>: . . .. . .
io. Repeéll Siépá 6 Ihroughi3'for Ihe opposite surface.
-,:'.
Tl = Top left Bl =B()~i:im lalt TR = Top Rig ht BR = Bottom Right
FOOO75
11 of 12
t-.otes ,4 SMAU ARéA

I
ABOuT Z MellEs . > /.
~~ .
J:>/;tfñ?ezz:;.e'} DF FL../~R.éD 7t4M1T WA$ é)'BS,fRvEb
M_'J7(~ _~JS.L ~CI20A/. --;;¡ ~R : , ¿tf I-r>
ff~ /o/07/c6"l::> Ir t4T -r#L EA/i:¿ ~i~/-s_~Jfr¿ ·
d K,A/Pw:s rr L<), s /./OT -rJl'.&E .;Xt :>;.rAi<·
. .
~¿)b u s
-:-'.:."
QA~. ---;;;¡ .QEE.teA7l2R eéLd-4R.KED -rilAr : A:¿LL;)Er:s
/'d~L_~ D&)" ,dIZE_ wéU LULrtt/A/ªii;~_
/:5'
. ~I);>f_ oF
=>-0_ .....3E¿¿¿¿.¡D_
- --- - - - - - - -
.- - -- - .-..-i-'
.~-- ~..~
. -----------
- - - - -- -- ------,-,... . -'-"-'-'~~ ----~".,..,.:----------
.. '. , ', .;•... .: ...
'. " "-: . .;
120f 12
c. Wark the crane control levers and outrigger
4-Section Boom, R & I switches back and larth several times.
This procedure covers the removal and installation 01 d. Turn the ignition switch to the "OFF" position.
the 4-section boom. Far recondition procedure, see 6. Check that all control levers are in the neutral
SM Keysheet Area 17 -001 . position and move the lunction lockou t switch to
the "DI SABLE" position.
Removal Reler to Figure 1.
1. Lower, detach, and secure the load , as required . 7. Label lar assembly purposes and disconnect the
2. Stabilize the crane lar service as lollows : hydraulic lines and wire harnesses (7). Cap/plug
a. Park the crane, out 01 the way, on a lirm and the open hydraulic ports and lines (7) to prevent
level surface. excessive oilloss and contamination 01 the system.
b. Engage the park brake and/or properly block 8. On cranes equipped with an electronic boom
the tires. length/ang le indicator, anti-two block, and or
c. Engage the swing park brake or travel swing boom Iloodlight, label and disconnect the wire
lock , as required. harnesses to these devices .
3.
quired.
Shutdown the engine and disengage the main
A DANGER
The auxiliary lifting device and rigging must
hydraulic pump , as equipped.
ha ve the rated capacity to safely handle the
weight of the boom assembly at all angles and
A WARNING
radii required for removal. Failure to adhere to
this danger may result in crane damage,
severe personal injury, or death.
and follow all the manufacturer's Note : The boom assembly weighs
recommendations concerning solvents and approximately 18,000 lb (8 165kg).
cleaning solutions. Note: The balance point of the boom assemb ly
is approximately 19 ft 8 in (5.9m) from the
4. Tharoughly clean the area to be disassembled with centerline of the boom foot pin with the b oom
an approved cleaning solvent to prevent fully retracted and at a 0° boom angle .
contamination Allow the area to air dry.
9. Position an auxiliary lifting device clirectly above the
A WARNING
balance point 01 the boom assembly (1). Rig the
boom assembly (1) lar a double sling lift .
Hydraulic oil is under pressure and may be Note: The boom hoist cylinder we ighs
hot. A sud den release of hot oil could cause approximately 2,868 lb (1 301kg) when fully
burns or other serious injury. Shutdown the retracted .
pressure from the system befo re removing 10. Place adequate blocking (3) on the carrier deck (5)
any line or component. under the boom hoist cylinder (4) close to the
mounting pin (2).
5. Relieve the hydraulic system pressure as lollows : 11. Using a second auxiliary lifting device, suppart lile
a. Release any residual pressure in the hydraulic weight 01 the boom hoist cy linder (4).
reservoir by slowly loosening the liller/breather 12. Remove the capscrews (17) and washers (18)
cap, located on the top 01 the hydraulic securing the keeper plate (19).
reservoir, until pressure is lully relieved. 13. Remove the keeper plate (19) and thrust washers
b. Turn the ignition switch to "ON", but DO NOT (16).
1 016
SM 17 - 001 - 068.00 1106 Service Manual
Approximate
Balance Point
8
.........
5
4 2
3
1. Boom Assembly 6. Upper Frame

2. Mounting Pin 7. Hydraulic lines & Wire Harness
3. Blocking 8. Boom Foot Pin
4. Boom Hoist Cylind er 9. Bearings
5. Carrier Deck 10. Thrust Washers
Fig ure 1
Upper Assem bly
2 of 6
8 9 6 10 11 12 13 14 15
[1
rIT
[ :L
- -· - i
I I ~
-- - - ~ ..
0.25 in
(6. 35mm) "1'"
e
16
/
I
'.
o )
f
-¡ ;' j
/ I . 18
19
/
20
11 . Washer 16. Thrust Washers

12. Capscrew 17. Capscrews
13. Locknut 18. Washers
14 . Thrust Washers 19. Keeper Plate
15. Grease Flttlng s 20. Grease Fitting
3 of 6
A DANGER
Do not stand under the boom or boom hoist
cyli nder. Once the pin is removed, the boom compounds or sealants, clean threads and
hoist cylinder may drop slightly. surfaces with Loctite® 7070 Cleaner to ensure best
performance of products.
Note: The mounting pin weighs approximately 3. Tharoughly inspect all parts for damage, wear,
87 lb (39.5kg). fatigue or stress fractures, and corrosion. Repair
or replace as required .
Note: Use care not to damage grease fittings
4. Inspect the boom foot pin bearings (9) for
(20 ).
excessive wear. Replace as required .
14. USlng a brass drift, carefully drive the mounting pin 5 . Inspect the integrity of the hydraulic lines. Repair
(2) from the boom hoist cylinder (4). Use an or re place if required.
auxiliary lifting device, as required , to maneuver 6. Inspect the integrity of the electrical wires and
the mounting pin (2). connectors. Repair or replace if required.
15. Lower the boom hoist cylinder (4) onto the 7. In the event of severe defects, contact factory
blocking (3). personnel for directions whether to repair ar
16. Remove the locknut (13), capscrew (12), and replace any major component.
washer (11) securing the boom foot pin (8) in the
boom assembly (1). Installation
17 . Using an auxiliary lifting device, carefully raise the
boom assembly (1) just enough to relieve the
weight of the boom assembly (1) from the boom
foot pin (8).
A DANGER
The auxiliary lifting device and rigging must
Note: For assembly purposes, record the
have the rated capacity to safely handle the
quantity of thrust washers (10,14) as the boom
weight ofthe boom assembly at all angles and
fo ot pin is removed .
radii required for installation. Failure to
Note: The boom foot pin weighs approximately adhere to this danger may result in crane
150 lb (68kg) . damage, severe personal injury, or death.
Note: Use care not to damage grease fitting s

(15) . Note: The boom assembly weighs
approximately 18,000 lb (8 165kg).
18. Using a brass drift, drive the boom foot pin (8) from
the upper frame (6) and boom assembly (1) . Note: The balance point of the boom assembly
Remove the thrust washers (10,14) as the boom foot is approximately 19 ft 8 in (5.9m) from the
pin (8) is removed . Use an au xiliary lifting device, as centerline of the boom foot pin with the boom
required, to maneuver the boom foot pin (8). fully retracted and at a O· boom angle.
19. Carefully remove the boom assembly (1) from the
crane. Refer to Figure 1.
1. Position an auxiliary lifting device directly above the
Cleaning And Inspection balance point of the boom assembly (1). Rig the
boom assembly (1) far a double sling lift.
A WARNING 2 . Using an auxiliary lifting device, carefully position

the boom assembly (1) to the upper frame (6),
So lvents and cleaning solutions can be making sure to properly align the boom foot pin (8)
hazardous. Serious personal injury may mounting holes .
an d follow all the manufacturer's
re commendations concerning solvents and
cl eaning solutions.

an approved cleaning solvent, air dried, and
carefully inspected.
4 of 6
Note: The mounting pin weighs approximate ly
A WARNING 87 lb (39.5kg).
11. Coat the mounting pin (2) with Bostik®

compounds, etc. can be hazardous. Serious l\Jever-Seez or an equivalent anti-seize
personal injury may result from misuse of compound. Use an auxiliary lifting device to
these products. Read and follow all maneuver the mounting pin (2).
manufacturer's recommendations concerning 12. Using a brass drift, install the mounting pin (2) into
these products. the boom hoist cylinder (4) and boom assembly
(1). Use care not to damage the thrust washers
Note: The boom foot pin weighs approximately (16).
150 lb (68kg). 13. Rotate the mounting pin (2), as required to align
the keeper plate (19) holes.
3. Coat the boom foot pin (8) with Bostik,j 14. Applya light coating of Loctite® 242 to the threads
Never-Seez or an equivalent anti-seize of the capscrews (17).
compound. Use an auxiliary lifting device to 15. Position the keeper plate (19) to the mounting pin
maneuver the boom foot pin (8). (2), and install the capscrews (17) and washers
4. Position the capscrew (12) mounting hole in the (18). Torque the capscrews (17) to 350- 385 ft lb
boom foot pin (8) directly upward, begin installing (1557-1713Nm).
the boom foot pin (8), tapered end first, into the 16. Lubricate the boom hoist cylinder mounting pin (2)
upper frame (6). through the grease fitting (20). See the Operator's
Manual for the correct type of lubrican!.
Note: The thrust washers must be installed as
17. On cranes equipped with an electronic boom
the boom foot pin is installed. Approximately
length/angle indicator, anti-two block, and or
four thrust washers will be required per side to
boom floodlight, connect the wire harnesses to
achieve the required 0.25 in (6.35mm). Refer to
these devices.
Figure 1. The maximum allowable gap is 0.06 in
18. Connect the hydraulic lines and wire harness (7).
(1.52mm) per side.
5. Install the thrust washers (14) as the boom foot pin required. See the Operator's Manual for correct
(8) passes through the upper frame (6), before it type and procedure.
starts into the boom assembly (1). 20. Start the engine and let idle for five minutes.
6. Using a brass drift, continue driving the boom foot Inspect the hydraulic connections for leaks.
pin (8) into place, installing the four thrust washers Repair leaks as required.
(10) before the boom foot pin (8) enters the other 21. Raise the boom assembly (1) and remove the
side of the upper frame (6). blocking (3) from below the boom hoist cylinder
7. Once the boom foot pin (8) is properly installed, (4).
install the capscrew (12), washer (11), and locknut 22. Raise, lower, extend, and retract the boom several
(13) . times to evenly distribute the lubricants and to
8. Using the grease fittings (15), lubricate the boom bleed any air from the hydraulic lines and
foot pin (8) until grease can be seen venting past cylinders.
the bearings (9). See the Operator's Manual for the 23. Install any attachments and rigging as required.
correct type of lubrican!. See the Operator's Manual for the correct
procedures.
Note: The boom hoist cylinder weighs 24. Complete the installation by testing all related
approximately 2,868 lb (1 301kg) when fully functions of the boom for proper operation.
retracted. Normal operation of lile hydraulic and electrical
systems should be confirmed. A general
9. Install the thrust washers (16) in the side of the inspection of the components and systems in the
boom hoist cylinder (4). areas adjacent to the repair should also be
10. Using an auxiliary lifting device, carefully align the performed to ensure related damage or wear is not
boom hoist cylinder (4) to the boom assembly (1). present.
Use care not to lose the thrust washers (16).
5 of 6
6 of 6
Service Manual 0607 SM17 -001 -069 .00
4 - Section Boom, Approximate Weight
Boom Component
Recondition lb kg
Base Section 4,800 2 177
This procedure covers the recondition of the four
section boom. For removal and installation T1 Section 3,500 15BB
procedures, see SM Keysheet Area 17 -001. T2 Section 2,700 1 225
Page
General Precautions 1 T3 Section 2,600 1 179
Approximate Boom Component Weights 1
Telescope Cylinder
Boom Disassembly 2 3,400 1542
Assembly
Cleaning And Inspection 9
Boom Assembly 10 Remaining
1,000 454
Boom Components
General Precautions
Total Boom Assembly 18,000 8165
A WARNING
Table A
Approximate Boom Component Weights
Read and understand all general precautions
3. Prepare two sets of wark stand s to be used as sup
before servicing the boom . The potential for
porting structures. These stands must be capable
serious injury is present if all instructions are
of supparting the entire weight of the boom assem
not strictly followed. bly. Refer to Table A for approximate weights. Use
nylon straps and ratchet binders to prevent the
boom section(s) from rolling. Do not use any steel
A WARNING
binders, chains , or comealongs to secure the sec
tions to the stands. They could scratch, dent,
gouge, ar damage the contact surfaces.
Disassembly and assembly procedures
require reaching inside the boom sections. 4. No section should extend beyond a point where
Inadvertent movement of the boom sections less than 5-6 ft (1. 5 -1.8m) remains in the section
could cause serious personal injury. Secure from which it is installed unless supported by an
the boom sections before inserting any auxiliary lifting device. Failure to follow these
instructions during servicing may result in damage
extremities, tools, etc. into them.
to the equipment ar injury to personnel.
5. Always relieve any hydraulic pressure, that may be
1. When handling the boom sections, always keep
trapped in the system, befare removing any hy
the load well balanced and level. Move slowly and
draulic line ar componen!. A sud den release 01 hot
keep the load under control. Do not attempt to
oil could cause burns ar other serious inJury.
handle the boom sections or telescope cylinder
6. To avoid personal injury, do not climb, stand, ar
without assistance.
2. When lifting the boom sections ar telescope cylin walk on the boom sections. Use a ladder or similar
device to reach the necessary areas.
der, use only a lifting device which has the proper
capacity to handle the load. AII rigging must also 7. When disassembling complex components, it is a
be in good, sound condition and be the proper size good idea to lay the parts out in the arder that they
are disassembled. Keeping parts in this arder dur
far the job to be perfarmed. Refer to Table A far
approximate weights. ing disassembly, cleaning, and inspection will aid
in the assembly process.
8. If parts are hard to disassemble or assemble, do
not use a hammer unless it has a soft face . Do not
force parts together, they must be free to operate
smoothly and not bind.
1 of 16
SM 17 -001 -069.00 0607 Service Manual
2. Disassemble and recondition the boom head ma
chinery, if required. See SM Keysheet Area
17 -009 for the correct procedure.
3. Remove the boom angle indicator from the side of
the Base section (4).
4. Remove the boom length reeling drum. See SM
Keysheet Area 18-007 for the correct procedure .
5. Remove the telescope cylinder length reel (91).
See SM Keysheet Area 17 -002 for the correct pro
cedure.
Refer to Figure 1.
telescope cylinder hydraulic lines (4) and wire har
ness. Cap/plug open hydraulic lines (4) to prevent
contamination of the system .
7. Using a double sling lift , support the weight of the
1. Boom telescope cylinder (5), and remove the capscrews ,
2. Capscrews, Washers, & Locknuts washers , and locknuts (2) that secure the retaining
3. Retaining Plates plates (3) to the boom (1).
4. Hydra ulic Unes
8. Remove the retaining plates (3) from the boom (1).
5. Telescope Cylinder
Figure 1
Te lescope Cylinder Removal/lnstallation CAUTION
Damage to the roller brackets, pin pullers, and
Boom Disassembly other boom and telescope cylinder
components can occur during telescope
cylinder removal. The telescope cylinder
A WARNING
Read and understand all general precautions
must be carefully guided from the boom,
avoiding hard contact with any of the internal
components ofthe boom. Keep the telescope
befo re servicing the boom. The potential for
cylinder at a slight angle as it is removed from
serio us injury is present if all instructions are
the boom. As the support roller on the end of
not strictly followed.
the telescope cylinder assembly nears the
roller brackets inside the boom, raise the
cylinder slightly to allow the support roller to
A WARNING
pass over the top of the roller brackets.
Ensure the pin puller bellcrank on the
telescope cylinder assembly does not cause
Disassembly procedures require reaching
inside the boom sections. Inadvertent damage to the pin pullers.
movement of the boom sections could cause
serious personal injury. Secure the boom 9. Using a double sling lift , remove the telescope cyl
sections before inserting any extremities, inder (5) from the boom (1), and place it on an ade
tools, etc. into them. quate supporting surface that will prevent it from
rolling or sagging.
1. Secure the Base section (4) to an adequate sup 10. Remove the capscrews and washers (6) that se
porting structure. The rear of the Base section (4) cure the bar (5) to the Base section (4). Remove
must be attached to a fixed point to prevent the the bar (5).
Base section (4) from sliding as the other sections 11 . Remove the capscrews and washers (8) and cover
(1 ,2, 3) are pulled from it. The Base section (4) (7) from the Base section (4).
must lay level, front to back and side to side. 12. Remove the capscrew and locknut (11), shaft (9),
and roller (10) from the Base section (4).
2 of 16
13. Remove the capscrews , washers, and locknuts 34 . Secure the T1 section (3) to an adequate support
(12 ,14 ,16) securing the wire rope wear pads ing structure. The rear of the T1 section (3) m ust be
(13 ,15,17) to the boom sections (2,3,4). Remove attached to a fi xed point to prevent the T1 section
the wear pads (13 ,15,17). (3) from sliding as the other boom sectio ns (1,2)
14 . Remove the capscrews and washers (27), and are pulled from it. The T1 section (3) must lay level,
separate the pin (26) from the pin puller (31). Re front to back and side to side .
move the pin (26). 35 . Remove the capscrews and washers (22), an d
15. Support the pin puller (31), and remove the separate the pin (23) from the pin puller (30). Re
capscrew, washers , and pin (83) and spring (82) move the pin (23),
from the pin puller (31) . 36. Support the pin puller (30), and remove the
16. Remove the pin puller (31) from the T1 section (3) . capscrew, washers, and pin (74) and spring (73)
17. Remove the Jam nuts (87) and adjustment screws from the pin puller (30).
(90). 37 . Remove the pin puller (30) from the T2 section (2) .
18. Remove the capscrews and washers (33) that se 38, Remove the jam nuts (78) and adjustm ent screws
cure the brackets (32) to the T1 section (3) . Re (81 ).
move the brackets (32) . 39, Remove the capscrews and washers (39) that se
19. Remove the wear pads (89) and plates (88) from cure the brackets (40) to the T2 section (2). Re
the brackets (32). move the brackets (40),
20. Pull the T1 section (3) out until the pin pocket is 40, Remove the wear pads (79) and plates (80) from
centered in the last pin hole opening in the top of the brackets (40).
the Base section (4). 41. Pull the T2 section (2) out until the pin poc ket is
21. Lower the T1 section (3) until the boom head centered in the last pin hole opening in the top of
touches the floor and the rear of the Base section the T1 section (3).
(4) raises. 42. Lower the T2 section (2) until the boom head
22. Remove the jam nuts (59,61) and adjustment touches the floor and the rear of the T1 section (3)
screws (58 ,62). raises .
23. Remove the capscrews and washers (60). 43 . Remove the jam nuts (59,61) and adjustment
24 . Remove the retaining bars (56) , backing plates screws (58,62).
(63) , and top front wear pads (57). 44. Remove the capscrews ancl washers (60).
25 . Remove the capscrews and washers (34) securing 45. Remove the retaining bars (56) , backing plates
the roller bracket assembly (37) to the T1 section (63) , and top front wear pads (57).
(3). 46. Remove the capscrews and washers (36) securing
26. Remove the roller bracket assembly (37) and the roller bracket assembly (42) to the T2 section
shims (35) from the T1 section (3). (2) .
27. Lift the T1 section (3) until it is against the top inside 47 , Remove the roller bracket assembly (42) and
of the Base section (4) , and remove the bottom shims (43) from the T2 section (2).
front wear pads and spacers (54) from the Base 48. Lift the T2 section (2) until it is against the top inside
section (4). If required, remove the Teflon inserts of the T1 section (3), and remove the bottom front
(54) from the wear pads (54). wear pads and spacers (55) from the T1 section
28. Remove the top rear wear pad jam nuts (84) and (3) . If required , remove the Teflon inserts (55) from
adjustment screws (85) . the wear pads (55).
29. Position the T1 section (3) , as required, to gain ac 49. Remove the top rear wear pad jam nuts (75) and
cess to the top rear wear pads (86). adjustment Screws (76).
30 . Remove the capscrews and washers (28) and top 50. Position the T2 section (2), as required, to gain ac
rear wear pad retainer plates (29). ces s to the top rear wear pads (77).
31, Remove the spacers and wear pads (86), If re 51. Remove the capscrews and washers (25) and top
quired , remove the Teflon inserts (86) from the rear wear pad retainer plates (24).
wear pads (86). 52. Remove the spacers and wear pads (77). If re
32. Using a double sling lift, remove the boom sections quired, remove the Teflon inserts (77) fr o m the
(1,2,3) from the Base section (4) . wear pads (77) ,
33. Position the T1 section (3) as required , and remove 53. Using a double sling lift, remove the boom sections
the locknuts and cam rollers (38) from the sides of (1 ,2) from the T1 section (3).
the T1 section (3) . 54 . Position the T2 section (2) as required , and remove
the locknuts and cam rollers (41) from the sides of
the T2 section (2),
3 of 16
(110];
¡
11 10
Detail I -8 - D H H
F :--G ~,
K I, ~ _. ~
"""',
G
-e
- 8
12 13
í--
,,
Detail K
1. T3 Section 7. Cover 13. Wear Pad

2. T2 Section 8. Capscrews & Washers 14. Capscrews, Washers, & Locknuts
3 T1 Section 9 Shaft 15. Wear Pad
4. Base Section 10. Roller 16. Capscrews, Washers, & Locknuts
5. Bar 11. Capscrew & Locknut 17. Wear Pad
6. Capscrews & Washers 12. Capscrews, Washers, & Locknuts 18. Pin
Figure 2
4-Section Boom Assembly
4 of 16
18 19 20 21 22 23 24 25 27 28 29
----30
-~
_ - - - 31
)
50
33
44 36 43 42 41 40 39 38 37 35 34
Section A-A
Section s-s
19 _ Capscrews & Washers 25 _ Capscrews & Washers 31. Pin Puller
20 _ Retainer Plates 26 _ Pln 32_ Brackets
21. Capscrews & Washers 27_ Capscrews & Washers 33_ Capscrews & Washers
22 _ Capscrews & Washers 28_ Capscrews & Washers 34 Capscrews & Washers
23 Pin 29_ Retainer Plates 35 Shims
24 _ Retainer Plates 30_ Pin Puller 36 Capscrews & Washers
5 of 16
57 58 59
60
~~~~============~
-::,:,
j.!------ \
Section o-o
(Common View For
Base, T1, & T2)
64 67 68
Section E-E
(T3 Section - Cross Section)
37. Roller Brackel Assembly 43. Shims 49. Cam Rollers & Locknuls
38. Cam Rollers & Locknuls 44. Roller Bracket Assembly 50. Pin Puller
39. Capscrews & Washers 45. Shims 51. Covers
40. Brackels 46. Capscrews & Washers 52. Washers & Locknuls
41 .Cam Rollers & Locknuts 47. Brackels 53. Wear Pads, Teflon Inserts, & Spacers
42. Roller Bracket Assembly 48. Capscrews & Washers Boltom Fronl - T2 Section
4-Section Boom Assembl - Continued
6 of 16
73 74 75 76
Section F-F
Section G-G
54. Wear Pads, Tef lon Inserts, & Spacers - 59. Jam Nu ts 66. Jam Nuls
Bo tlom Fro nl - Base 60. Capscrews & Washers 67 . Ad juslment Screws
55 Wea r Pads, Teflon Inserts, & Spacers - 61. Jam Nuts 68 Wear Pads, Teflon Inserts, & Spacers
Bo tlom Fronl - T1 Seclion 62. Adjustmenl Screws 69. Jam Nuls
56. Retaining Bars 63 Backing Plales 70. Wear Pads
57. Wear Pad s 64 Spring 71 . Plales
58. Adjuslmenl Screws 65. Pin, Cap screw, & Washers 72 . Ad juslmenl Screws
7 of 16
OrientWear Pads So Teflon Inserts

Overlap On AII Sections
Orient Spacer So Larger

Face Is Contacting Wear
Pads On AII Sections
91
Section H-H
Section J-J
73 . Spring 80 . Plates 87. Jam Nuts

74. Pin, Capscrew, & Washers 81. Adjustment Screws 88. Plates
75, Jam Nuts 82, Spring 89, Wear Pads
76 . Adj us tment Screws 83. Pin, Capscrew, & Washers 90, Adjustment Screws
77. Wear Pads, Teflon Inserts, & Spacers 84 . Jam Nuts 91. Telescope Cylinder Le ng th Reel
78. Jam Nuts 85. Adjustment Screws
79. Wear Pads 86. Wear Pad s, Teflon Inserts, & Spacers
4-Section Boom Assembl - Continued
80116
55. Secure the T2 section (2) to an adequate support 75 . Using a double sling lift, remove Ihe T3 section (1)
ing structure . The rear of the T2 section (2) must be from the T2 section (2).
attached to a fixed point to prevent the T2 section 76. Remove the locknuts and cam rollers (49) from the
(2) from sliding as the T3 section (1) is pulled from sides of the T3 section (1).
it. The T2 section (2) must lay level, front to back
and side to side. Cleaning And Inspection
56. Removethewashers and locknuts (52) and covers
(51) from the end of the T3 section (1) .
57. Remove the capscrews and washers (19) , and
separate the pin (18) from the pin puller (50). Re
move the pin (18) .
A WARNI NG
58. Support the pin puller (50), and remove the hazardous. Serious personal injury may
capscrew, washers, and pin (65) and spring (64) result from misuse of these products. Read
from the pin puller (50) . and follow all manuf acturer's
59. Remove the pin puller (50) from T3 section (1). recommendations concerning solvents and
60. Remove the jam nuts (69) and adjustment screws cleaning solutions.
(72).
61. Remove the capscrews and washers (48) that se 1. Thoroughly clean all parts by steam clean ing or
cure the brackets (47) to the T3 section (1) . Re with an approved cleaning solven\. Exercise every
move the brackets (47) . precaution possible to keep all parts free of dust,
62 . Remove the wear pads (70) and plates (71) from dirt, or any olher foreign material during assem bly.
the brackets (47) . Allow parts lo air dry.
63 . Pul! the T3 section (1) out until the pin pocket is 2. Carefully inspect all components for damage,
centered in the last pin hole opening in the top of wear, fatigue 01' stress fractures, corrosion, deep
the T2 section (2). scratches , cracks, and scuffed metal. Remove any
64. Lower the T3 section (1) until the boom head burrs or sharp edges with a fine file, hone, emery
touches the floor and the rear of the T2 section (2) cloth , or crocus cloth. Replace any damaged com
raises. ponent, as required.
65 . Remove the jam nuts (59,61) and adjustment 3. Run a chase tap through all tapped holes . Al!
screws (58,62). Loctite®, Permatex®, or other sealant res idue
66. Remove the capscrews and washers (60). should be removed from threads of hardware and
67 . Remove the retaining bars (56), backing plates mounting surfaces of parts that are going to be
(63) , and top front wear pads (57). reused. Prior to applying new thread locking
68. Remove the capscrews and washers (46) securing compounds or sealants, clean threads and
the roller bracket assembly (44) to the T3 section surfaces with Loctite® 7070 Cleaner to ensure best
(1) . performance of products .
69. Remove the roller bracket assembly (44) and 4. Check the thickness of the boom wear shoes. Re
sh ims (45) from the T3 section (1) . place or rotate the wear shoes, as required . Refer
70. Lift the T3 section (1) until it is against the top inside to tlle Operator's Manual for minimum wear sh oe
of the T2 section (2), and remove the bottom front thickness and replacement procedure .
wear pads (53) from the T2 section (2) . If required , 5. Inspect the boom sections for damage. See SM
remove the Teflon inserts (53) from the wear pads Keysheet Area 17 -001 for the correct procedur e.
(53). 6. Inspect the integrity of the hydraulic lines . Repair
71. Remove the top real' wear pad jam nuts (66) and or replace as required .
adjustment screws (67). 7. AII "soft parts", such as seals, gaskets, back up
72 . Position the T3 section (1), as required, to gain ac rings , and o-rings, should be replaced .
cess to the top real' wear pads (68). 8. For information concerning the recondition of the
73 . Remove the capscrews and washers (21) and top telescope cylinder" see SM Keysheet Area
real' wear pad retainer plates (20) . 17-002.
74. Remove the spacers and wear pads (68) . If re 9. In event of severe defects, contact factory person
quired , remove the Teflon inserts (68) from the nel for directions whether to repair or replace any
wear pads (68). major componen\.
90116
Boom Assembly 11. Lower tlle T3 section (1) onto the bottom front wear
pads (53) in the T2 section (2).
Note: Apply a light coating of Loctite® 242 to the
A WARNING
Read and u nderstand all general precautions
threads of the capscrews (60) and Keystone®
No-Weld to the threads of the adjustment screws
(58,62).
before servicing the boom. The potential for
12. Position the top front wear pads (57) and backing
serious injury is present if all instructions are
plates (63) in the T2 section (2). Install the retaining
nol strictly followed .
bars (56), capscrews and washers (60), adjust
ment screws (58,62) , and jam nuts (59,61). Do not
tighten the adjustment screws (58) and jam nuts
A WARNING
13.
(59) at this time.
Adjust the side adjustment SCrews (62) to the fol
Assembly procedures require reaching inside
lowing criteria:
the boom sections. Inadvertent movement of
a. The wear pads (57) must be square with the
lhe boom sections could cause serious sides of the T3 section (1).
personal injury. Secure the boom sections b. The space between the T3 section (1) and T2
before inserting any extremities, tools, etc. section (2) should be the same within 0.04 in
into them. (1mm) on both sides.
14. Torque the jam nuts (61) to 150-175 ft lb
Refer to Figure 2. (203-237Nm) .
1. Insta ll the covers (51) on the end of the T3 section 15. Lower the T3 section (1) enough that the top rear
(1 ), and secure with the washers and locknuts (52). wear pads (68) are just touching the inside of the
2. Install the cam rollers (38,41,49) in the sides of T2 section (2).
each boom section (1,2,3), and secure with the Note: Apply Keystone® No-Weld to the threads of
lock nuts (38,41,49). Torque the locknuts the adjustment screws (67).
(38,41,49) to 70 ft lb (95Nm).
3. Sec ure the T2 section (2) to an adequate support 16. Install the top rear wear pad adjustment screws
in g structure with the rear against a fixed stop . En (67) and ¡am nuts (66), and adjust to the following
sure the T2 section (2) is level, front to back and criteria:
side to side . a. The space between the T3 section (1) and T2
4. Usin g a double sling, lift and slide the T3 section (1) section (2) at the back must be the same within
¡nto the T2 section (2) until the pin pocket in the rear 0.04 in (1mm) on both sides. This measure
of the T3 section (1) is centered in the first pin hole ment is to be taken through the 2 in (5.0Bcm)
op ening in the top of the T2 section (2). diameter hole in the side of the T2 section (2)
5. Lift the T3 section (1) until it is against the inside top on each side . Measure the space between the
of th e T2 section (2) at the outer end . actual boom sections.
6. If removed, install the Teflon inserts (53) in the bot b. Use the adjustment screws (67) to equalize the
tom front wear pads (53). space between boom sections. The final
7. Insert the bottom front wear pads (53) in the T2 spacing must be achieved when tightening the
section (2) to support the T3 section (1). adjustment screws (67). Sections must be
8. If removed, install the Teflon inserts (68) in the top pushed into position; loosening the adjust
rear wear pads (68). ment screws (67) does not alter the position of
the boom sections .
Note: Orient the top rear wear pads so the Teflon c. There is to be no space between the top rear
inserts overlap. Orient the spacers so the larger face wear pads (68) and the curve of the bend in the
Is contacting the wear pads. Refer to Figure 2, T2 section (2).
Section H-H. d. Torque the jam nuts (66) to 150-175 ft lb
9. Insert the top rear wear pads and spacers (68) in (203 -237Nm).
the T3 section (1). 17. Lower the T3 section (1) until the boom head
touches the floor and the rear of the T2 section (2)
raises.
threads of the capscrews (21).
10. Install the top rear wear pad retainer plates (20)
with the capscrews and washers (21) .
10 of 16
18. Install the roller bracket assembly (44) to the T3 b. The end 01 each adjustment screw (72) must
section (1) with lour shims (45) between them . be lower than the Ilat surlace 01 the cam roller
a. II the roller bracket assembly (44) rocks on the (49) that is closest to the center 01 the T2 sec
rollers belore touching the shims (45) , add one tion (2). II an adjustment screw (72) is sticking
additional shim (45). out lurther than the cam roller (49) , locate the
b. II the roller bracket assembly (44) does not adjustment screw (72) and adjust accardingly.
rock on the rollers belore touching the shims c . Torque the jam nuts (69) to 150-175 ft lb
(45) , remove one shim (45) at a time until the (203 -237Nm) .
roller bracket assembly (44) rocks on the roll 26. Check to ensure the cam rollers (49) are level wit h
ers belare touching the shims (45) . Once the each other. II not , roll the T3 section (1) inside the
roller bracket assembly (44) rocks, add one T2 section (2) by adjusting the top Iront wear pads
additional shim (45). (57) until the cam rollers (49) align.
27. I nstall the pin puller (50) in the T3 section (1). Reler
Note: Apply a light coating 01 Loctite® 242 to the to Figure 2, Section A-A lar an illustration 01 the
threads 01 the capscrews (46). correct orientation.
19. Put the remaining shims (45) on top 01 the roller Note: Apply a light coating 01 Loctite® 242 to the
bracket assembly (44) , and install the washers and threads 01 the capscrew (65).
capscrews (46) .
20. Push the T3 section (1) into the T2 section (2) until it 28. Position the spring (64) in the pin puller (50) , and
bottoms out. install the pin, washers , and capscrew (65) . Make
21 . Check the squareness between the T3 section (1) sure the large washer is seated in the counterbare
and T2 section (2) . There must be no more than 01 the pin pocket.
0.19 in (0.48cm) misalignment between the 1 in
(2.54cm) thick vertical plates at any point. Note: Apply a light coating 01 Loctite® 242 t o the
22. II there is misalignment in excess 01 0.19 in threads 01 the capscrews (19) and Keysto ne®
(0 .48cm) , carrect the misalignment by adjusting No-Weld to the sides 01 the pin (18).
the top Iront wear pads (57) . The difference in the
29. I nstall the pin (18) to the pin puller (50), and secure
measurement 01 space between the T3 section (1)
with the capscrews and washers (19). Make sure
and T2 section (2) at the Iront 01 the boom can not
the pin (18) and pin puller (50) will slide Ireely up
exceed 0.25 in (0.64cm).
and down. Look lar paint drips , wel d splatter, or
Example: 11 the measurement on one side is anything that might make the pin (18) hang - up .
0.75 in (1 .91cm) and the other side is 1 in 30. Tighten the top Iront wear pad top adjustment
(2.54cm), the maximum tolerance has been screws (58) until the wear pads (57) are against the
reached. T3 section (1) , and secure with the jam nuts (59) .
Tarque the jam nuts (59) to 150-175 ft lb
23. Install the plates (71) and side rear wear pads (70) (203-237Nm).
in the brackets (47) . 31. Secure the T1 section (3) to an adequate support
ing structure with the rear against a lixed stop . En
Note: Apply a light coating 01 Loctite® 242 to the sure the T1 section (3) is level, front to back and
threads 01 the capscrews (48). side to side.
32 . Using a double sling, lift and slide the boom sec
24. Position the brackets (47) to the T3 section (1), and
tions (1 ,2) into the T1 section (3) until the pin poc k
secu re by installing the capscrews and washers
et in the rear 01 the T2 section (2) is centered in the
(48).
lirst pin hole opening in the top 01 the T1 section
Note: Apply Keystone® No- Weld to the threads 01 (3) .
the adjustment screws (72). 33. Lift the boom sections (1 ,2) until they are ag ai nst
the inside top 01 the T1 section (3) at the oute r end .
25. Install the adjustment screws (72) and jam nuts 34 . II removed, install the Tellon inserts (55) in the bot
(69), and adjust to the lollowing criteria: tom Iront wear pads (55) .
a. Adjust the adjustment screws (72) out until the
side rear wear pads (70) just touch the sides 01
the T2 section (2) . Do not try to shift boom with
the adjustment screws (72) .
11 01 16
Note: When installing the bottom front wear Note: Applya light coating of Keystone®No- Weld to
pa ds and spacers, always begin with a wear the threads of the adjustment screws (76).
pa d. Spacers must be installed between each 45. Install the top rear wear pad adjustment screws
wear pad. It may be necessary to install the last (76) and jam nuts (75), and adjust to the lollowing
two wear pads, then install the last spacer be criteria:
tween them. a. The space between the T2 section (2) and T1
section (3) at the back must be the same within
35. Install the bottom Iront wear pads and spacers (55)
0.04 in (1mm) on both sides. This measure
in the T1 section (3) to support the T2 section (2). ment is to be taken through the 2 in (5.08cm)
36. II removed, install the Tellon inserts (77) in the top diameter hole in the side 01 the T1 section (3)
rear wear pads (77). on each side. Measure the space between the
actual boom sections.
Note: Orient the top rear wear pads so the Teflon
b. Use the adjustment screws (76) to equalize the
inserts overlap. Orient the spacers so the larger fa ce
space between boom sections. The linal
is contacting the wear pads. Refer to Figure 2, spacing must be achieved when tightening the
Section H-H. adjustment screws (76) . Sections must be
pushed into position; loosening the adjust
37. Insert the top rear wear pads and spacers (77) in
ment screws(76) does not alter the position 01
the T2 section (2). the boom sections.
Note: Apply a light coating of Loctite® 242 to the c. There is to be no space between the top rear
wear pads (77) and the curve 01 the bend in the
threads of the capscrews (25).
T1 section (3).
38. Install the top rear wear pad retainer plates (24) d. Torque the jam nuts (75) to 150-175 ft lb
with the capscrews and washers (25). (203-237Nm).
39 . Lower the T2 section (2) onto the bottom front wear 46. Lower the T2 section (2) until the boom head
touches the lIoor and the rear 01 the T1 section (3)
pads (55) in the T1 section (3) .
raises.
Note: Apply a light coating 01 Loctite® 242 to the 47 . Install the roller bracket assembly (42) to the T2
threads of the capscrews (60) and Keystone® section (2) with lour shims (43) between them.
No - We ld to the threads 01 the adjustment screws a. II the roller bracket assembly (42) rocks on the
(58,62). rollers belore touching the shims (43), add one
additional shim (43).
40. Position the top lront wear pads (57) and backing b. II the roller bracket assembly (42) does not
plates (63) in the T1 section (3). Install the retaining rock on the rollers belore touching the shims
bars (56), capscrews and washers (60), adjust (43), remove one shim (43) at a time until the
ment screws (58,62), and jam nuts (59,61). Do not roller bracket assembly (42) rocks on the roll
tighten the adjustment screws (58) and jam nuts ers belore touching the shims (43). Once the
(59) at this time . roller bracket assembly (42) rocks, add one
41. Adjust the side adjustment screws (62) to the fol additional shim (43).
lowing criteria: Note: Apply a light coating of Loctite® 242 to the
a. The wear pads (57) must be square with the threads 01 the capscrews (36).
sides 01 the T2 section (2).
b. The space between the T2 section (2) and T1 48. Put the remaining shims (43) on top 01 the roller
section (3) should be the same within 0.04in bracket assembly (42), and install the washers and
(1mm) on both sides. capscrews (36).
42. Torque the jam nuts (61) to 150-175 ft lb 49. Push the boom sections (1,2) into the T1 section
(203-237Nm). (3) until they bottom out.
43. Adjust the top Iront wear pad top adjustment 50. Check the squareness between the T2 section (2)
screws (58) by tightening them down to touch the and T1 section (3). There must be no more than
backing plates (63) with the top front wear pads 0.19 in (0.48cm) misalignment between the 1 in
(57) down against the T2 section (2). (2.54cm) thick vertical plates at any poin!.
44. Lower the T2 section (2) enough that the top rear
wear pads (77) are just touching the inside 01 the
T1 section (3) .
12 01 16
51. If there is misalignment in excess of 0.19 in d. Install the capscrews and washers (36, 46),
(O.48cm), correct the misalignment by adjusting e, Repeat Step 58.
the top front wear pads (57). The difference in the
measurement of space between the T2 section (2) Note: Apply a Iight coating of Loctite® 242 lo the
and T1 section (3) at the front of the boom can not threads of the capscrews (22) and Keystone®
exceed 0.25 in (O.64cm). No-Weld to the sides of the pin (23).
Example: If the measurement on one side is 59, I nstall the pin (23) on the pin puller (30), ancl secure
0.75 in (1.91cm) and the other side is 1 in with the capscrews and washers (22), Make sure
(2.54cm), the maximum tolerance has been the pin (23) and pin puller (30) will slide freely up
reached. and down, Look for paint drips, weld splatter, or
52. Install the plates (80) and side rear wear pads (79) anything that might make the pin (23) hang-up,
in the brackets (40). 60, Tighten the top front wear pad top adjustment
screws (58) until the wear pads (57) are against the
Note: Apply a light coating of Loctite® 242 to the T2 section (2), and secure with the jam nuts (59),
threads of the capscrews (39). Torque the jam nuts (59) to 150-175 ft lb
53. Position the brackets (40) to the T2 section (2), and (203-237Nm) ,
secure by installing the capscrews and washers 61, Secure the Base section (4) to an adequate sup
(39). porting structure with the rear against a fixed stop ,
Ensure the Base section (4) is level, front to back
Note: Applya light coating of Keystone® No- Weld to
and side to side,
the threads of the adjustment screws (81).
62, Using a double sling, lift and slide the boom sec
54. Install the adjustment screws (81) and jam nuts tions (1,2,3) into the Base section (4) until the pin
(78), adjust to the following criteria: pocket in rear ofthe T1 section (3) is centered in tlle
a. Adjust the adjustment screws (81) out until the first pin hole opening in the top of the Base section
side rear wear pads (79) just touch the sides of (4),
the T1 section (3). Do not try to shift the boom 63, Lift the boom sections (1,2,3) until they are against
with the adjustment screws (81). the inside top of the Base section (4) at the outer
b. The end of each adjustment screw (81) must end.
be lower than the flat surface of the cam roller 64, If removed, install the Teflon inserts (54) in the bot
(41) that is closest to the center of the T1 sec tom front wear pads (54),
tion (3). If an adjustment screw (81) is sticking
out further than the cam roller (41), locate the Note: When installing the bottom front wear
adjustm ent screw (81) and adjust accordingly. pads and spacers, always begin with a wear
c. Torque the jam nuts (78) to 150-175 ft lb pad. Spacers must be installed between each
(203-237Nm). wear pad. It may be necessary to install the last
55. Check to ensure the cam rollers (38,41,49) are lev two wear pads, then install the last spacer be
el with each other. If not, roll the appropriate boom tween them.
section (1,2) by adjusting the top front wear pads
(57) until the cam rollers (38,41,49) align. 65, Install the bottom front wear pads and spacers (54)
56. Install the pin puller (30) in the T2 section (2). Refer in the Base section (4) to support the T1 section
to Figure 2, Section A-A for an illustration of the (3),
correct orientation. 66. If removed, install the Teflon inserts (86) in the top
rear wear pads (86),
threads of the capscrew (74). Note: Orient the top rear wear pads s o the Teflon
inserts overlap. Orient the spacers so the largerface
57. Position the spring (73) in the pin puller (30). and is contacting the wear pads. Refer to Figure 2,
install the pin, washers, and capscrew (74). Make Section J - J.
sure the large washer is seated in the counterbore
of the pin pocket. 67, Insert the top rear wear pads and spacers (86) in
58. Check to ensure the pin pullers (30,50) are level the T1 section (3),
with each other. If not:
a. Lift the appropriate boom section (1,2) through
Note: Apply a light coating of Loctite® 242 lo the
the pin hole to relieve weight from the roller threads of the capscrews (28).
bracket assembly (42,44).
68, Install the top rear wear pad retainer plates (29),
b. Remove the capscrews and washers (36,46).
and secure with the capscrews and washers (28),
C. Add or remove shim (43,45) as required.
13 of 16
69. Lower Ihe T1 seclion (3) onlo Ihe bollom fronl wear 76. Lower the T1 section (3) unlil the boom head
pads (54) in Ihe Base seclion (4). touches the Iloor and the rear of the Base section
(4) raises.
Note: Apply a light coating of Loctite® 242 to the 77. Install the roller bracket assembly (37) to the T1
threads of the capscrews (60) and Keystone® section (3) with lour shims (35) belween them.
No - Wel d to the threads of the adjustment screws a. II the roller bracket assembly (37) rocks on Ihe
(58,62) . rollers belare louching the shims (35), add one
addilional shim (35).
70 . Posilion Ihe lop Ironl wear pads (57) and backing
b. II Ihe roller brackel assembly (37) does not
plales (63) in Ihe Base seclion (4). Inslall Ihe re
rock on Ihe rollers belare louching Ihe shims
taining bars (56), capscrews and washers (60), ad
(35) , remove one shim (35) al a lime unlil the
juslmenl screws (58,62), and jam nuls (59,61). Do
roller brackel assembly (37) rocks on Ihe roll
nol tighlen Ihe adjustmenl screws (58) and jam
ers belare louching Ihe shims (35). Once the
nuls (59) al Ihis lime.
roller bracket assembly (37) rocks, add one
71. AdjuSI Ihe side adjuslmenl screws (62) lO Ihe 101
addilional shim (37).
lowing crileria:
a. The wear pads (57) musí be square wilh Ihe Note: Apply a light coating of Loctite® 242 to the
sides 01 T1 seclion (3). threads of the capscrews (34) .
b . The space belween Ihe T1 seclion (3) and Ihe
Base seclion (4) musl be Ihe same wilhin 0.04 78. Put Ihe remaining shims (35) on top of Ihe roller
in (1mm) on bolh sides. brackel assembly (37), and inslall Ihe washers and
72 . Tarque Ihe jam nuls (61) to 150-175 ft lb capscrews (34).
(203-237Nm). 79 . Push Ihe boom sections (1 ,2,3) inlo Ihe Base sec
73. Adjust the top Iront wear pad 10p adjuslment lion (4) unlil Ihey bottom out.
screws (58) by tighlening them down to touch the 80. Check Ihe squareness belween Ihe T1 seclion (3)
backing plates (63) with the top Iront wear pads and Base seclion (4) . There musí be no more than
(57) down against the T1 seclion (3). 0.19 in (O.48cm) misalignmenl belween Ihe 1 in
74 . Lower the T1 section (3) enough that Ihe top rear (2.54cm) Ihick verlical plales al any point.
wear pads (86) are just touching the inside 01 Ihe 81. If Ihere is misalignmenl in exces s 01 0 .19 in
Base section (4). (0.48cm), carrecI the misalignmenl by adjusting
Ihe 10p !ronl wear pads (57). The difference in Ihe
Note: Ap plya light coating 01 Keystone® No- Weld to measuremenl 01 space belween Ihe T1 section (3)
the threads 01 the adjustment screws (85) . and Base seclion (4) al the Iront 01 Ihe boom can
nol exceed 0.25 in (O.64cm).
75 . Install the lop rear wear pad adjustment screws
(85) and jam nuts (84) , and adjust lo the lollowing Example: 11 the measurement on one side is
criteria: 0.75 in (1.91cm) and the other side is 1 in
a. The space between the T1 seclion (3) and (2.54cm), the maximum tolerance has been
Base section (4) at the back musl be the same reached.
within 0.04 in (1mm) on both sides. This mea
surement is to be taken through the 2 in 82 . Place a straighl edge Ihrough Ihe boom 1001 pin
(5.08cm) diameter hole in the side 01 the Base bares in Ihe Base section (4) and zero an angle in
section (4) on each side. Measure the space clinometer on Ihe slraight edge. Check Ihe boom
between the actual boom sections. headshaft angle lo the boom foot pin angle. These
b. Use the adjuslment screws (85) to equalize the must be with in 1 o 01 each olher. Adjust Ihe 10p Ironl
space between boom sections. The linal wear pad side adjuslmenl screws (62) , as needed ,
spacing must be achieved when tightening the to roll Ihe T1 seclion (3) inside the Base seclion (4).
adjustment screws (85). Sections must be Adjustmenls can be made on Ihe olher seclions
pushed inlo position ; loosening the adjust loo, as long as misalignmenl is held lO 0.19 in
ment screws(85) does not alter the pos ilion 01 (O.48cm) or less .
the boom sections . 83. Inslall Ihe plates (88) and side rear wear pads (89)
c. There is to be no space between Ihe top rear in Ihe brackets (32).
wear pads (86) and the curve in the bend of the
Base section (4).
d . Tarque the jam nuts (84) to 150-175 ft lb
(203-237Nm).
14 01 16
Note: Apply a light coating 01 Loctite® 242 to the Note: Apply a light coating 01 Loctite® 242 to the
threads 01 the capscrews (33). threads 01 the capscrews (27) and Keysto ne®
No- Weld to the sides 01 the pin (26) .
84 . Position the brackets (32) to the T1 section (3), and
secure by installing the capscrews and washers 90 . Install the pin (26) on the pin puller (31), and secure
(33) . with the capscrews and washers (27) . Make sure
the pin (26) and pin puller (31) will slide Ireely up
Note: Applya lightcoating 01 Keystone® No-Weld to and down . Look lar paint drips, weld splatter, or
the threads 01 the adjustment screws (90). anything that might make the pin (26) hang -u p .
91. Tighten the top Iront wear pad top adj ustme nt
85. Install the adjustment screws (90) and jam nuts
screws (58) until the wear pads (57) are against the
(87), and adjust to the lollowing criteria:
T1 section (3) , and secure with the jam nuts (59).
a. Adjust the adjustment screws (90) out until the
Tarque the jam nuts (59) to 150-175 ft lb
side rear wear pads (89) just touch the sides 01
(203-237Nm) .
the Base section (4). Do not try to shift the
92. Install the roller (10) and shaft (9) , and secu re with
boom with the adjustment screws (90) .
the capscrew and locknut (11) .
b. The end 01 each adjustment screw (90) must
be lower than the Ilat surlace 01 the cam roller
(38) that is closest to the center 01 the Base
section (4). II an adjustment screw (90) is
CAUTION
sticking out lurther than the cam roller (38) , 10 Damage to the roller brackets, pin putlers , a nd
cate the adjustment screw (90) and adjust ac other boom and telescope cylind er
cordingly. components can occur during telesco pe
c. Torque the jam nuts (87) to 150-175 ft lb cylinder installation. The telescope cylinder
(203-237Nm) . must be care1utly guided into the boo m ,
86. Check to ensure the cam rollers (38,41,49) are lev avoiding hard contact with any 01 the internal
el with each other. II not, roll the appropriate boom components 01 the boom. Keep the telesco pe
section (1 ,2,3) by adjusting the top Iront wear pads cylinder with the rear angled up as it is
(57) until the cam rollers (38,41,49) align. inserted into the boom. As the support ro tl er
87. Install the pin puller (3 1) in the T1 section (3). Reler on the end 01 the telescope cylinder assem bly
to Figure 2, Section A-A lor an illustration 01 the passes the last rotler bracket inside the boom ,
correct orientation. level the cylinder and allow the support roller
to roll inside the boom sections. Ensure t he
Note: Apply a light coating 01 Loctite® 242 to the
pin puller bellcrank on the telescope cylinder
threads 01 the capscrew (83).
assembly does not cause damage to the pin
88. Position the spring (82) in the pin puller (31), and putlers.
install the pin , washers, and capscrew (83). Make
sure the large washer is seated in the counterbore Reler to Figure 1.
01 the pin pocket. 93 . Using a double sling lift, carelully install the tele
89 . Check to ensure the pin pullers (30,31 ,50) are level scope cylinder (5) in the boom (1).
with each other. II not:
a. Lift the appropriate boom section (1 ,2,3) Note: The locknuts (2) should be insta ll ed to
through the pin hole to relieve weight Irom the the inside 01 the boom (1).
roller bracket assembly (37 ,42,44) .
b. Remove the capscrews and washers 94. Engage the telescope cylinder (5) with the boom
(34 ,36,46) . (1) , install the retaining plate (3) , an d secure by
c. Add ar remove shim (35,43,45) as required. installing the with capscrews, washers, and lock
d . Install the capscrews and washers (34,36,46). nuts (2) .
e. Repeat Step 89 . 95. Connect the telescope cylinder hydraulic lines (4)
and wire harness .
15 01 16
Reler to Figure 2. 100. Install the boom length reeling drum. See SM Key
96. Position the cover (7) on the Base section (4), and sheet Area 18-007 lor the correct procedure.
install the capscrews and washers (8). 101. II required , recondition and assemble the boom
97. Install the bar (5), and secure with the capscrews head machinery. See SM Keysheet Area 17 -009
and washers (6). lor the correct procedure.
98. Install the telescope cylinder length reel (91). See 102. Install the wire rope wear pads (13,15,17) on the
SM Keysheet Area 17 -002 lor the correct proce top Iront 01 each boom section (2,3,4), and secure
dure . with the capscrews, washers, and locknuts
99 . Install the boom angle indicator. See the Opera (12,14 ,16) .
tor's Manual lor the correct adjustment procedure.
16 01 16
Boom Telescope
Counterbalance Valve, R & I
any 01 the boom telescope counterbalance valves.
While considered service items , counterbalance valve
cartridges are not designed to be disassembled in the
lield . 11, lor any reason, the counterbalance valve does
not perlorm as required , remove, clean, and install it
per the lollowing instructions. II the counterbalance
valve continues to perform poorly, it must be replaced.
Removal
1. Lower, detach, and secure the load , as required . 1. Counterbalance Cartridge
2. Stabilize the crane lor service as lollows: 2. Counterbalance Cartridge
3. Counterbalance Cartridge
a. Park the crane, out 01 the way, on a lirm and
4. Counterbalance Valve Manifold
level surface .
Note: Cylinder case and rod end may va ry in appearance.
the tires . Figure 1
c. Engage the swing park brake or travel swing Telescope Counterbalance Valve
lock, as required.
d. Level the crane on lully extended outriggers . 5. Relieve the hydraulic system pressure as lollows
e. Fully retract and lower the boom to the boom a. Relieve any residual pressure in the hydraulic
res!. reservoir by loosening the liller cap 1/4 turn o
3. Shutdown the engine and disengage the main hy b. Turn the ignition switch to " ON ", bu t DO NOT
draulic pump. START THE ENGINE. Move the lunction lock
out switch to the "OPERATE " position .
A WARNING
switches back and lorth several times .
d. Turn ignition switch to the " OFF" position.
"DI SABLE" position .
recommendations concerning solvents and Reler to Figure 1.
cleaning solutions. 7. Label lor assembly purposes , the location of the
counterbalance valves (1 ,2 ,3), as required, to en
4. Thoroughly clean the area to be disassembled with sure proper installation .
A WARNING
1 of <1
Refer to Figure 2.
2 3 4 5 6 7 8
10. Remove the back up rings (1 ,3,4,7) and o-rings
(2,5 ,6) from the body (8). Repeat process on each
counterbalance valve cartridge .
A WARNING
recommendations eoncerning solvents and
cleaning solutions.
1 Back Up Ring 5. O-rlng

2. O-ring 6. O-ring an approved cleaning solvent and air dried.
3 Back Up Ring 7. Back Up Ring 2. Inspect the counterbalance valve cartridge for vis
4. Back Up Ring 8. Body ible contaminants; if found , carefully remove any
obvious particles.
Figu re 2
3 . Through the nose of the cartridge, manually oper
Co unterbalanee Valve Cartridge
ate the inner working parts several times. Use a
piece of plastic tubing or a wooden dowel to avoid
damaging soft seats, sharp edges , finished sur
A DANGER
faces , or the screen protecting the pilot orifice. AII
parts should move freely. If possible, this inspec
tion should be done with the cartridge submerged
Do not remove any boom teleseope eylinder
cou nterbalanee valve without first fully in clean mineral spirits.
lowering the boom to the boom rest. If the 4. After flushing , blow dry the cartridge with clean fil
boo m is extended , removing the tered airo
co unterbalanee valve will allow the boom to 5. Check the port opening in the telescope cylinder
retraet uneontrollably. counterbalance valve manifold to be sure that it is
clean and ready to receive the counterbalance
8. Remove the counterbalance valves (1,2,3) from valve cartridge.
the counterbalance valve manifold (4). 6. AII "soft parts", such as o-rings and back up rings,
9 Cap/plug the open hydraulic ports to prevent oil should be replaced.
loss and contamination of the system. 7. In the event of severe defects , contact factory
Note: Do not disassemble the eounterbalanee replace any major componen!.
valves. Internal parts are faetory set and are not
fiel d servieeable.
2 of 4
Installation
CAUTION
A WARNING
Do not overtighten valve cartridges during
assembly. The body of the cartridge an d/or
internal components may be damaged. Li mit
compounds, etc. can be hazardous. Serious torque to the specified value given.
these products. Read and follow all 5. Torque the counterbalance valve (1) to 150-160 ft
manufacturer's recommendations concerning lb (200-215Nm).
these products. 6. Torque the counterbalance valves (2,3) to 45 - 50 ft
lb (60-68Nm).
Reler to Figure 2. required. See Operator's Manual lor correct type
1. Lubricate the 0- rings (2,5,6) and back up rings
and procedure.
(1,3,4,7) with clean hydraulic oil. Reler to the Oper
8. Engage the main hydraulic pump.
ator's Manual lor the correct grade to use. 9. Start the engine and let idle lor live minutes.
2. Install the o-rings (2,5,6) and back up rings
Inspect the counterbalance valve cartridge for
(1,3,4,7) on the counterbalance valve cartridge leaks. Repair as required.
body (8). Repeat process lor each 01 the counter
10. Extend and retract the telescope cylinder several
balance valve cartridges.
times to remove any air trapped in the system.
3. Dip the nose 01 the body (8) in clean hydraulic oil to
lubricate the internal working components, mount lunctions 01 the telescope cylinder lor proper
ing threads, back up rings (1,3,4,7), and o-rings operation. Normal operation of hydraulic system
(2,5,6). See the Operator's Manual for the correct
should be conlirmed. A general inspection 01
type to use. components and systems in the areas adJacent to
Reler to Figure 1. the repair should also be performed to ensure
4. Properly install the counterbalance valves (1,2,3) in related damage or wear is not present.
the counterbalance valve manilold (4).
3014
4 of 4
Secure Case
To Support
Approximate
Center Of
Case
Secure Case
To Support
Rod Extended To
2 Approximately
Half Stroke
Adjust Support To
Ensure Rod Stays
Centered 1n Case
1 Case 3. Straps
2. Supports 4. Rod
Figure 1
Correet Cylinder Supporting
Boom Telescope Cylinder, Disassembly

Recondition It is a good practice when disassembling hydraulic
This procedure covers the recondition of the boom were disassembled . Keeping the parts in this order
telescope cylinder. For removal and installation during disassembly, cleaning , and inspection will aid in
procedures, see Boom, R & I in SM Keysheet Area the assembly process.
17 -001 . For troubleshooting procedures, see SM
If parts are hard to disassemble and assemble , do not
Note: A special tool is required to remove and parts together, they must be free to rotate/operate and
install the gland in telescope eylinder case. This not bind .
spanner wreneh is needed to effeetively apply the Refer to Figure 1.
torque needed to ensure proper installation of the 1. Using an auxiliary lifting device, position the cylin
gland. This spanner wreneh ean be ordered der on adequate supports (2). Support the cylin
through your distributor under Part No. 3J 17915. der at the rod (4) end and three equally spaced
locations along the case (1). Refer to Table A for
the boom telescope cylinder weight.
1 of 6
2 3 4 5 6
, 7 A
__ c~ I I
c====
n J l I
J
~~ I I
v
l'-.
0 1 J'"
R .JLJ _\
\
n f \ \ \
I
I
12
\
11
\
10
\ 9
\
8
1. Back Up Ring 5. Square Ring Seal 9, Rod

2. O-ring 6 Setscrew 10, Piston
3. Back Up Ring 7. Stop Tube 11 , Wear Ring
4, Teflon® Seal 8 Case 12, Wear Ring
Note: Cylinder case and rod end may vary in appearance,
Figure 2
Boom Telescope Cylinder Assembly
2 of 6
16 17
22 21 20 19 18 9
13. Counterbalance Valve* 17. Stepseal 20. Gland

14. Counterbalance Valve 18. Rod Wíper 21. Back Up Ríng
15. Counterbalance Valve 19. Double Líp Seal 22. O-ríng
16. Wear Ríng
* Loca líon on rod end may vary.
3 of 6
Wet Wet Oil Oil
Crane
Dry Retracted Working Test
Weight Extended Capacity Capacity
SIN Weight Weight Retracted Pressure Pressure
Extended
Prefix
lb kg lb kg lb kg gal L gal L psi kPa psi kPa
.• -----------------------
2 ,715 1232 2,987 1355 3,255 1476 37.48 141.86 74.40 281.60 3,300 26890 5,000 34475
N3 2 ,040 925 2,230 1012 2,429 1 102 26.29 99.52 54.00 204.41 4,300 29647 5,000 34475
N4 2,371 1076 2,560 1 162 2,760 1253 26.29 99.52 54 .00 204.41 4,300 29647 5,000 34475
P9 2 ,563 1 164 2,750 1249 2,972 1350 25.80 97.65 56.40 213.47 3 ,900 26890 5,000 34475
R3 2,715 1232 2 ,987 1355 3 ,255 1476 37.48 141 .86 74.40 281.60 3,300 26890 5,000 34475
S2 2 ,629 1 194 2,901 1317 3,168 1438 37 .48 141.86 74.40 281 .60 3,300 26890 5,000 34475
Table A
Boom Telesco pe Cylinder Specifications
Refer to Figure 2.
CAUTION 7. Remove the counterbalance valves (13,14 ,15)
Use care not to damage the chrome finish on from the rod (9). Remove all o-rings and back up
the rod. Any nicks or scratches could result in rings from the cou nterbalan ce valves (13 ,14,15).
cylinder lea ka ge. Weld splatter may also do
damage. 11 the use of a vise is required, clamp
only on portions of the rod which are not
CAUTION
chrome plated , or protect the chrome surface The cylinder must be adequately supported
with a 50ft material before clamping. with the rod centered within the case before
attempting to disassemble the cylinder. An
2. To prevent the cylinder Irom rolling or sliding during improperly supported cylinder will sag at the
cJ isassembly, secure the case (1) to the supparts gland, causing irreparable damage to the
(2) uSlng straps (3). threads as the gland is removed.
3. Place an appropriate container under the rod (4)
en d 01 the cylinder. Reler to Table A lar the boom B. Using a spanner wrench, rotate the gland (20) until
telescope cylinder capacity. Ihe threads disengage Irom the case (B).
4. Fully extend ancl retract the rod (4) lo drain any ex 9. Using an auxiliary lifting device , carefully slide the
cess hydraulic oil remaining within Ihe cylinder inlo rod (9) , gland (20), stop lube (7), and pistan (10) as
th e container. Properly slare ar dispose 01 Ihe an assembly Irom the case (B). Place the assembly
u ed oil. in a location where it can be disassembled without
5. Exlend the rod (4) approximately hall slroke. Ad damaging the chrome on the rod (9).
just the support at the rod (4) end to ensure the rod 10 . Remove Ihe Teflon® seal (4), square ring seal (5) ,
(4) stays centered within the case (1). and wear rings (11,12) from Ihe pistan (10) .
11. Remove the setscrew (6) securing the pistan (10)
to Ihe rod (9).
A WARNING 12. Using a spanner wrench, remove the piston (10)
Irom the rod (9).
Solvents and cleaning solutions can be 13. Remove the back up rings (1,3) and o-ring (2)
hazardous. Serious personal injury may Irom Ihe piston (10).
result from mis use of these products. Read 14. Remove the stop tube (7) from the rod (9).
and follow all the manufacturer's 15. Slide the gland (20) off the rod (9) .
recommendations concerning solvents and 16. Remove the o-ring (22), back up ring (21) , wear
cleaning s o lutions. ring (16), slepseal (17), rod wiper (1 B), and double
lip seal (19) lrom the gland (20).
6 . Cap/p lug any openings in the cylinder. Thoroughly
clean the exterior surface 01 the cylinder lo prevent
contam ination.
Cleaning And Inspection 2. Soak the Tellon® seal (4) , rod wiper (18) , double lip
seal (19), and stepseal (17) in clean hydraulic oil ,
which has been heated to a temperature 01
100 - 120 °F (38-48 °C). Allow adequate time lor
A WARNING the parts to reach the temperature of the hydraulic
oil which will greatly ease their assembly.
Solvents and cleaning solutions can be 3 . Install the wear ring (16) , 0- ring (22), back up ring
hazardous. Serious personal injury may (21) , stepseal (17), double lip seal (19) , and rod
result from misuse of these products. Read wiper (18) in the gland (20).
cleaning solutions. CAUTION
Threaded surfaces are sharp. Use care to
1. Thoroughly clean all metal parts with an approved prevent damage to the seals and o-rings
cleaning solven!. Place parts on a clean, lint free during installation of the components onto the
surface and allow to air dry. Exercise every precau rod or during installation of the rod, gland ,
tion possible to keep all parts Iree of dust, dirt, or stop tube, and pistan assembly into the case .
any other loreign material during assembly.
2. AII Loctite®, Permatex®, or other sealant residue Use care not to damage the chrome finis h on
should be removed Irom threads 01 hardware and the rod. Any nicks or scratches could res ult in
the mounting surlaces 01 parts that are going to be cylinder leakage. Weld splatter may also do
reused. Prior to applying new thread locking com damage . If the use of a vise is required, cl amp
pounds or sealants, clean threads and surlaces only on portions of the rod which are not
with Loctite® 7070 Cleaner to ensure best perlor chrome plated, or protect the chrome su rface
mance 01 products. with a soft material befo re clamping.
3. Carelully inspect all components lor damage,
wear, latigue or stress fractures, corrosion, deep 4. Install a thin layer 01 masking tape over the threacls
scratches, cracks, and scuffed metal. Remove any 01 the rod (9) .
burrs or sharp edges with a line lile, hone, emery 5. Carelully slide the gland (20) on the rod (9) , using
cloth, or crocus cloth. Replace any damaged com care to not damage the seals. A slight oscillating
ponent, as required. motion should be used to enable the lips 01 the
4. AII "soft parts ", such as seals, back up rings, and seals to slip onto and past the rod (9) shoulder.
o-rings, should be replaced . 6. Slide the stop tube (7) on the rod (9) .
5. In the event 01 severe delects , contact lactory per 7. Install the o-ring (2) and back up rings (1 ,3) in the
sonnel lor directions whether to repair or replace piston (10) .
any maJor componen!. 8. Remove the masking tape Irom the threads 01 the
rod (9) .
Assembly 9. Applya light coating of Loctite® 242 to the threads
01 the piston (10) .
10 Carelully slide the piston (10) on the rod (9), using
A WARNING
care to not damage the seals. Start the threads by
rotating the piston (10) by hand. Once the piston
(10) is started , use a spanner wrench to torque the
compounds, etc. can be hazardous. Serious piston (10) to 800 ft lb (1 085Nm) .
personal injury may result from misuse of 11. Secure the piston (10) to the rod (9) by installing
these products. Read and follow all the setscrew (6).
manufacturer's recommendations concerning 12. Insta/l the wear rings (11 ,12) , square ring seal (5) ,
these products. and Tellon® seal (4) on the piston (10) .
Refer to Figure 2.
1. Lubricate the 0- rings (2 ,22) , back up rings
(1,3,21), wear rings(11,12,16) , case (8) bore , and
all threads with Cosmolube® No . 2 or equivalent
prior to assembly.
5 of 6
S M 17 - 002 - 055.00 0510 Service Manual
the cylinder rod at a steady rate. If the cylinder
CAUTION squeaks or sticks, disassemble the cylinder and
The cylinder must be adequately supported replace the defective part and repeat the entire test
procedure.
wi1 h the rod centered within the gland before
3. Stop the rod at mid stroke , relieve the pressure,
attempting to assemble the cylinder. An
and examine the cylinder for any externalleakage .
im properly supported cylinder will sag at the
No leakage is acceptable. If leakage is found, dis
gland, causing irreparable damage to the
assemble the cylinder and replace any defective
threads, as the gland is installed.
parts, as required; repeat the entire test proce
dure.
Refer to Figure 1 .
4. Fully retract the cylinder.
13. Using an auxiliary lifting device, position the case
5. Gradually pressurize the extend port, at a pressure
(1) on adequate supports (2). (Refer to Table A for
increase of one to ten percent of the cylinder work
the boom telescope cylinder weight.) Place the ing pressure per minute, until rod movement is initi
supports (2) at three equally spaced locations
ated. Pressure to initiate rod movement or "break
along the case (1).
away" pressure, shall not exceed 120 psi (827kPa).
14. To prevent the cylinder from rolling or sliding during
6. Once the breakaway pressure is determined , the
assembly, secure the case (1) to the supports (2)
pressure needed to maintain movement of the cyl
using straps (3).
inder rod, is termed "running pressure". Running
Refer to Figure 2. pressure should not exceed 80% of the breakaway
15 . Using an auxiliary lifting device, carefully slide the pressure or diminish to less than 20% of the break
rod (9), gland (20), stop tu be (7), and piston (10), away pressure as the cylinder is extended. If run
as an assembly, into the case (8). Use care to ning pressure exceeds these guidelines, disas
avoid damaging any of the seals. semble the cylinder and replace any defective
16 Slowly rotate the gland (20) by hand until the parts; repeat the entire test procedure.
threads engage in the case (8). Make sure the
threads are not being damaged as the gland (20) is High Pressure Leakage Test
installed. Using a spanner wrench (3J 17915), 1. Extend cylinder full stroke and pressurize extend
torque the gland (20) to 400 ft lb (542Nm). port to the "Test Pressure " specified in Table A .
17 . Carefully retract the rod (9) into the case (8). Hold this pressure for a minimum of one minute. If
18. Test the boom telescope cylinder for leaks and leakage across the piston exceeds 0.33 cc/min,
proper operation prior to installing the counterbal disassemble the cylinder, replace the defective
ance valves (13,14 ,15) . See "Cylinder Test Proce parts, and repeat the entire test procedure.
dures " found later in this document. 2. Relieve pressure and examine the cylinder for
19. Using new 0- rings and back up rings, install the structural failure evidenced by external leakage.
counterbalance valves (13,14,15) in the rod (9). No leakage is acceptable. If leakage is found, dis
Torque the counterbalance valves (13,14) to assemble the cylinder, replace the defective parts,
45-50 ft lb (61-68Nm) and the counterbalance and repeat the entire test procedure.
valve (15) to 150-160 ft lb (203-217Nm). 3. Fully retract the cylinder.
20 . Test the boom te les cope cylinder for leaks and 4. Pressurize retract port to the "Test Pressure" speci
proper operation with the counterbalance valves fied in Table A. Hold this pressure for a minimum of
(13 ,14,15) installed . See "Cylinder Test Proce one minute. If leakage across the piston exceeds
dures" found later in this document. 0.33 cc/min, disassemble the cylinder, replace any
defective parts, and repeat the entire test proce
Cyli nder Test Procedures dure.
5. Once again relieve pressure and examine the cyl
Low Pressure Leakage & Static Friction Test inder for any external leakage . No leakage is ac
1. FIII the fully retracted cylinder with clean hydraulic ceptable. If leakage is found, disassemble the cyl
oil. Refer to Table A and the Operator's Manual for inder, re place any defective parts , and repeat the
the correct amount and grade of oil to use. entire test procedure.
2. Cycle the cylinder, full stroke each direction, a mini 6. If the cylinder is not to be installed on crane im
mum of five times to remove entrapped air, using mediately, plug all ports to prevent contamination
only the pressure level which is required to move and properly store.
6 of 6
Figure 1
Celesco PT9000 Series Transducers
2. Remove the cable cover (7).

Telescope Cylinder Length 3. Remove the capscrews (17) holding the sensor
Reel, Recondition end plate (16) to the transducer body (24) .
Note : If the transducer is a model PT91 01 with a

This procedure covers the replacement 01 the
bridge circuit, PT9420, or PT9510 , be ca reful
measuring cable and timing belt for Celesco PT9000
not to damage the wires connected to the e lec~
series transducers. For removal and installation tronics assembly.
procedures, see SM Keysheet Area 17-002.
4. Remove the sensor end plate (16) .
General Instructions 5. Remove the capscrews (20) holding the sensor
mounting plate (13) to the transducer body (24).
6. Remove the sensor mounting plate (13) .
7. Note the exact position 01 the main shaft gear (22) ,
and remove the main shaft gear (22) .
8. If there is cable (27) on the spool (32), pull the cable
(27) out to the fully extended position.
II parts are hard to disassemble and assemble, do not 9. II the cable (27) has wrapped around the main
use a hammer unless it has a soft lace , do not lorce shaft (31) and/or cannot be extended, proceed to
parts together, they must be free to rotate/operate and Step 14. II the cable (27) can be lully extended,
not bind. continue with Step 10.
10. With the cable (27) lully extended, hold the spool
Measuring Cable Replacement (32) to keep it Irom rotating .
11. Unhook the cable (27) Irom the spool (32) and dis
Disassembly card the cable (27).
Reler to Figure 2.
1. Remove the pan head screws (8) and Ilat washers
(9) that hold the cable cover (7) to the transducer
body (24).
1 016
2 4 5 6 7
i
11 12
14
17
24
23
19
1. Capscrews 9. Flat Washers 17. Capscrews 25. Bushings
2 O-ring 10. Screws 18. Pan Head Screws 26 . Cable Guide Assembly
3. End Bracket 11. Elec1rical Connector 19. Electronics Assembly 27. Cable
4. Phenolic Disk 12 . Seal 20. Capscrews 28. Spring Arbor
5. Power Spring 13. Sensor Mounting Plate 21. Sensor Gear 29. Timing Belt
6. Spring Housing 14. Potentiometer 22 Main Shaft Gear 30. Pulley
7. Cable Cover 15. O-ring 23. Bearing 31. Main Shaft
8. Pan Head Screws 16. Sensor End Plate 24. Body 32. Spool
Figure 2
PT9000 Series Transducer Exploded View
2 of 6
Range
A WARNING inches meters
Spring Winds
The spring motor can be dangerous when
under tension. The spring can suddenly 75 1.91 25
uncoil itself and shoot out of the spring 100 2.54 25
housing. The spring has enough tension to
pop the end plate off when bolts are removed. 150 3.81 25
The spring is sharp and can cause injuries. Be 200 5.08 25
careful when servicing with the spring
exposed. Wear gloves and safety goggles. 250 6.35 25
300 7.62 29
12. Carelully release spring tension by allowing the
spool (32) to rotate slowly until all spring tension is 350 8.89 33
released. The best way to accomplish this is to let
the spool (32) rotate slowly by hand. This will allow 400 10.16 37
"controlled slippage" 01 the spool (32) to release 450 11.43 41
the spring tension.
500 12.70 45
Note: The cable guideassembly may haveto be
550 13.97 48
pried off. Take precautions to prevent damage
to the parts. 600 15.24 55
13. Remove the cable guide assembly (26). Proceed 800 20.32 69
to Step 9.
1,000 25.40 84
14. Turn the transducer body (24) on the open end so
the spring housing (6) is lacing up. 1,200 30.48 101
15. While holding the end bracket (3) securely, remove
the capscrews (1) that hold the spring housing (6) 1,500 38.10 124
to the body (24). 1,700 43.18 140
16. Tilt one edge 01 the end bracket (3) just enough to
slide gloved lingers in between the spring housing Table A
(6) and end bracket (3). Spring Windings
17. Slide one hand all the way in to contain the power
spring (5) while lifting the end bracket (3) off. Keep 22. While keeping the power spring (5) co ntained with
pressure on the power spring (5) by hand. a gloved hand, separate the spring housing (6)
18. Remove the end bracket (3). from the body (24) and slowly lift the spring hous
19. II the cable (27) is broken allowing the spool (32) to ing (6). Once the spring arbor (28) disengages, the
spin freely, the momentum 01 the spool (32) may power spring (5) will suddenly lose all tension.
have wound the power spring (5) partially in the Keep the power spring (5) contained in th e spring
wrong direction. Check the power spring (5). II the housing (6) until no movement is presento
coils are all going the same direction, proceed to 23. Remove the spring housing (6), including the pow
Step 22. II the power spring (5) is partially wound er spring (5) and spring arbor (28).
the wrong way, continue with Step 20. Note: The cableguideassembly mayhaveto be
20. Pinch the good coils 01 the power spring (5) and
pried off. Take precautions to prevent damage
the spring housing (6) together lirmly with a gloved to the parts.
hand.
21. With the other hand, pull the backward-wound 24. Remove the cable guide assembly (26).
coils up out 01 the spring housing (6) and rewind 25. Remove the timing belt (29).
that portion 01 the power spring (5). Proceed to 26. Pull the main shaft (31) and spool (32), as an as
Step 23. sembly, Irom the body (24). Remove and discard
the damaged cable (27).
3016
SM17 -002 -059.00 0705 Service Ma,n ual
Assembly 20. Hold the cable (27) firmly and release the spring
winding tool.
Refer to Figure 2.
1. Install the maín shaft (31) and spool (32) assembly. Note: It is very important to maintain cable ten
2. Install the timing belt (29) loosely over the main sion at all times.
shaft pulley (30).
3. Install the spring housing (6) on the body (24). 21. Allow the spring tension to slowly wind the cable
4. Engage the power spring (5) in the spring arbor (27) onto the spool (32).
(28) . 22. Install the cable cover (7).
5. If any oil was spilled from the spring housing (6) , 23. Secure the cable cover (7) to the transducer body
replace the oil as required. (24) with the pan head screws (8) and flat washers
6. Make sure the 0- ring (2) is seated correctly in the (9).
end bracket (3) . 24. Fully extend and retract the cable (27) to ensure
smooth cable travel.
Note: The short capscrew goes in the hole clos 25. Install the main shaft gear (22) to its original posi
est lo the ca ble guide. tion as noted in Step 7.
26. Ifthe unit has a potentiometer (14) , check the po
7. Install the phenolic disk (4) and end bracket (3), and
tentiometer (14) for damage. If the cable (27) has
secure with capscrews (1) .
been free-released or the cable (27) has broken,
8. With the spring end pointing up, rotate the spool
the potentiometer (14) may be broken. Turn the
(32) clockwise by hand to ensure the power spring
potentiometer (14) shaft all the way in both direc
(5) is engaged . Noticeable tension should build
tions. The potentiometer (14) should travel
up.
smoothly with no resistance until it suddenly stops.
9. Attach a spring winding tool to the transducer body
If rough spots, resistance, or "soft" stops are felt,
(24) and main shaft (31) .
the potentiometer (14) is damaged and must be re
10 . Using the spring winding tool, wind the power
placed .
spring (5) per Table A.
27 . Install the sensor mounting plate (13) and
11. On the cable guide assembly (26), position the
capscrews (20). Do not tighten the capscrews (20)
cable guide 0.25 in (O.64cm) from the pulley on the
completely at this time.
lead screw.
28. Check the position of the main shaft gear (22) and
12 . Place the bushing (25) on the cable guide assem
sensor gear (21) to make sure they line up proper
bly (26) shaft next to the pulley (30).
Iy. Adjust as required.
13. Using an " L.:' shaped Allen wrench or a bent paper
29 . If the transducer is a model PT9150, proceed to
clip , hook onto the timing belt (29) and pull it up
Step 35 .
ove r the bushing (25) onto the cable guide assem
30. Connect a 10 VOC power supply to the potentiom
bly (26) pulley. Make sure the timing belt (29) stays
eter (14) terminals so the + 1OVOC is connected to
on the pulley (30).
CCW and the -10VOC is connected to Cw.
Note: If white bushings are used, make sure the 31. Connect a voltage meter to the potentiometer (14)
flange is inside the cable exit. 11 black bushings terminals so the positive lead is connected to S and
are used , secure with Loctite® 401. the negative lead is connected to Cw.
32. Adjust the potentiometer (14) so the output is be
14. Snap the bushing (25) into the groove in the trans tween 0.04 and 0.1 VOC.
ducer body (24). 33. Position the sensor mounting plate (13) such that
15. Place the second bushing (25) on the other end of the gear teeth mesh but the gears are not forced
the cable guide assembly (26). Snap it into the oth into each other.
er groove in the transducer body (24) . 34. Tighten the capscrews (20) to secure the sensor
16. Insert the bare end of the replacement cable (27) mounting plate (13).
through the cable guide (26) . 35 . Fully extend and retract the cable (27) to ensure
17. Use crimp to make an approximately 0.50 in smooth travel.
(1 .27cm) diameter loop in the end ofthe cable (27) . 36. Install the sensor end plate (16), making sure the
18. Rotate the spring winding tool until the slot in the 0- ring (15) is seated correctly.
sp ool (32) is visible. 37. Install the capscrews (17) and tighten firmly.
19. Attach the cable loop to the hook on the inside of
the spool (32). Make su re the cable (27) comes u p
through the slot in the spool (32).
4 of 6
Timing Belt Replacement 13. Turn the transducer body (24) on the open end so
the spring housing (6) is facing up.
Removal 14. While holding the end bracket (3) securely, remove
the capscrews (1) that hold the spring housing (6)
Refer to Figure 2. to the body (24).
1. Remove the pan head screws (8) and flat washers 15. Remove the end bracket (3).
(9) that hold the cable cover (7) to the transducer 16. Remove the phenolic disk (4) to expose the power
body (24). spring (5).
2. Remove the cable cover (7). 17. Disengage the power spring (5) from the spring ar
3. Remove the capscrews (17) holding the sensor bor (28).
end plate (16) to the transducer body (24).
Note: Record the orientation of the spring a rbor
Note: If the transducer is a model PT91 01 with a prior to removal.
bridge circuit, PT9420, or PT9510, be careful
not to damage the wires connected to the elec 18. Remove the spring arbor (28).
tronics assembly. 19. Carefully separate the spring housing (6) from the
transducer body (24), taking care not to spill any
4. Remove the sensor end plate (16). oil.
5. Remove the capscrews (20) holding the sensor 20. Remove the timing belt (29).
mounting plate (13) to the transducer body (24).
6. Remove the sensor mounting plate (13). Installation
7. Note the exact position of the main shaft gear (22),
Refer to Figure 2.
and remove the main shaft gear (22).
1. Install a new timing belt (29) on the main shaft
8. If there is cable (27) on the spool (32), pull the cable
pulley (30).
(27) out to the fully extended position.
2. Install the spring housing (6) on the body (24).
9. With the cable (27) fully extended, hold the spool
(32) to keep it from rotating.
3. Properly orient and install the spring arbor (28).
4. Engage the power spring (5) in the spring arbor
10. Unhook the cable (27) from the spool (32) and dis
(28).
cardo
5. If any oil was spilled from the spring housing (6),
replace the oil as required.
A WARNING 6. Make sure the o-ring (2) is seated correctly in the

end bracket (3).
The spring motor can be dangerous when
under tension. The spring can suddenly Note: The short capscrew goes in the hole clos
uncoil itself and shoot out of the spring est to the cable guide.
housing. The spring has enough tension to
7. Install the phenolic disk (4) and end bracket (3), and
pop the end plate off when bolts are removed.
secure with capscrews (1).
The spring is sharp and can cause injuries. Be
8. With the spring end pointing up, rotate the spool
careful when servicing with the spring
(32) clockwise by hand to ensure the power spring
exposed. Wear gloves and safety goggles.
(5) is engaged. Noticeable tension should build
up.
11. Carefully release spring tension by allowing the
9. Attach a spring winding tool to the transducer body
spool (32) to rotate slowly until all tension is re
(24) and main shaft (31).
leased. The best way to accomplish this is to let the
10. Using the spring winding tool, wind the power
spool (32) rotate slowly by hand. This will allow
spring (5) per Table A.
"controlled slippage" of the spool (32) to release
11. On the cable guide assembly (26), position the
the spring tension.
cable guide 0.25 in (O.64cm) from the pulley on the
Note: The cable guide assembly may haveto be lead screw.
pried off. Take precautions to prevent damage 12. Place the bushing (25) on the cable guide assem
to the pa rts. bly (26) shaft next to the pulley (30).
13. Using an "L' shaped Allen wrench or a bent paper
12. Remove the cable guide assembly (26). Proceed clip, hook onto the timing belt (29) and pull it up
to Step 9. over the bushing (25) onto the cable guide assem
5 of 6
bly (26) pulley. Make sure the timing belt (29) stays 23 . Install the main shaft gear (22) to its original posi
on the pulley (30). tion as noted in Step 7.
24. Install the sensor mounting plate (13) and
Note: 11 white bushings are used, make sure the capscrews (20) . Do not tighten the capscrews (20)
flang e is inside the cable exit. If black bushings completely at this time.
are used, secure with Loctite® 401. 25 . Check the position 01 the main shaft gear (22) and
sensor gear (21) to make sure they line up proper
14. Snap the bushing (25) into the groove in the trans
Iy. Adjust as required .
ducer body (24) .
26. II the transducer is a model PT9150, proceed to
15. Place the second bushing (25) on the other end 01
Step 31.
the cable guide assembly (26) . Snap it into the oth
27. Connect a 10 VDC power supply to the potentiom
er groove in the transducer body (24).
eter (14) terminals so the + 10VDC is connected to
16. Rotate the spring winding tool until the slot in the
CCW and the -10VDC is connected to Cw.
spool (32) is visible.
28 . Connect a voltage meter to the potentiometer (14)
17. Attach the cable loop to the hook on the inside 01
terminals so the positive lead is connected to S and
the spool (32). Make sure the cable (27) comes up
the negative lead is connected to Cw.
through the slot in the spool (32).
29. Adjust the potentiometer (14) so the output is be
18. Hold the cable (27) lirmly and release the spring
tween 0.04 and 0.1 VDC.
winding tool.
30. Position the sensor mounting plate (13) such that
Note: It is very important to maintain cable ten the gear teeth mesh but the gears are not torced
sion at all times. into each other.
31. Tighten the capscrews (20) to secure the sensor
19. Allow the spring tension to slowly wind the cable mounting plate (13).
(27) on to the spool (32). 32. Fully extend and retract the cable (27) to ensure
20. Install the cable cover (7). smooth travel.
21. Secure the cable cover (7) to the body (24) with the 33. Install the sensor end plate (16), making sure the
pan head screws (8) and Ilat washers (9). 0- ring (15) is seated correctly.
22. Fully extend and retract the cable (27) to ensure 34. Install the capscrews (17) and tighten lirmly.
smooth cable travel.
6 of 6
Service Manual 0111 SM17-002-066 . 00
Boom Latching/Pinning
Cylinder, R & I
A. WARNING
This procedure covers the removal and installation of hot. A sudden release of hot oil could cause
the boom latching/pinning cylinder. For recondition burns or other serious injury. Shutdown the
procedure, see SM Keysheet Area 17 -002. engine and exhaust all trapped hydraul ic
pressure from the system before removin g
Removal any line or component
6. Relieve the hydraulic system pressure as follows
level surface. reservoir by slowly loosening the filler/breather
the tires. reservoir, until pressure is fully relieved.
c. Engage the swing park brake or travel swing b. Turn the ignition switch to "ON", but DO NOT
lock, as required. START THE ENGINE. Move the function lock
d. Level the crane on fully extended outriggers. out switch to the "OPERATE" position.
e. Fully retract and position the boom in the boom c. Work the crane control levers and outrigger
resto switches back and forth several times.
f. Extend the inner mid section of the boom d. Rotate the steering wheel back and forth
approximately 30" (76.2cm) and retract the repeatedly until steering becomes hard. (On
telescope cylinder by itself. cranes equipped with emergency steering
3. Shutdown the engine. system, it will take several rotations of steering
4. If equipped with pump disconnect, disengage the wheel before steering becomes hard.)
main hydraulic pump. See the Operator's Manual e. Turn ignition switch to the "OFF" position.
for the correct procedure. 7. Check that all control levers are in the neutral
A. WARNING
Refer to Figure 1.
8. Remove the capscrews and washers (2) and
access cover (1).
hydraulic lines (4) from the cylinder (7). Cap/plug
the open hydraulic ports and lines to prevent
excessive oilloss and contamination of the system.
cleaning solutions.
10. Support the weight of the cylinder (7), and remove
the pin, cotter pin, and washer (5) from the clevis
(6) end of the cylinder (7).
an approved cleaning solvent to prevent
11. Remove the cotter pin (3), pin and washer (8), and
contamination. Allow the area to air dry.
washers (9) from the cylinder (7).
12. Remove the journal bearing (not shown) after the
pin (8) has been removed.
13. Remove the cylinder (7) from the crane.
1 of 4
SM 17 -002 - 066.00 0111 Service Manual
,p,
~:~
. r- ~~
A
3
1. Access Cover 4. Hydraulic Línes 7. Cylinder

2. Capscrews & Wa shers 5. Pin , Cotter Pin, & Washer 8. Pin & Washer
3. Cotter Pin 6. Clevis 9. Washers
Figure 1
Boom Latchíng/Pinning Cylinder
2 of 4
A WARNING
A WARNING
hazardous. Serious personal injury may compounds, etc . can be hazardous. Serious
recommendations concerning solvents and manufacturer's recommendations concern ing
1. AII components should be thoroughly cleaned with Reler to Figure 1.

an approved cleaning solvent, air dried , and 1. Properly position the cylinder (7) in the boom , and
carelully inspected. align the clevis (6) end 01 the cylinder (7) to the
2. AII Loctite®, Permatex®, or other sealant residue boom.
should be removed Irom threads 01 hardware and 2. Install the pin, cotter pin , and washer (5).
the mounting surlaces 01 parts that are going to be 3. With the ports 01 the cylinder (7) properlyoriented ,
reused. Prior to applying new thread locking align the case end 01 the cylinder (7) , and install the
compounds or sealants, clean threads and journal bearing (not shown), pin and washer (8) ,
surlaces with Loctite® 7070 Cleaner to ensure best washers (9), and cotter pin (3).
performance 01 products. 4. Install the hydraulic lines (4) on the cylinder (7) .
3. Thoroughly inspect all parts lor damage, wear, 5. Check the hydraulic reservoir oil leve!. Add oil as
latigue or stress Iractures, and corrosion. Repair required . See the Operator's Manual lor correct
or replace as required. type and procedure .
4. Inspect the integrity 01 the hydraulic lines 6. II equipped with pump disconnect, engage the
supplying the boom latching/pinning cylinder. main hydraulic pump. See the Operator's Manual
Repair or replace il required. lor the correct procedure.
5. In the event 01 severe delects, contact lactory 7. Start the engine and let idle lor l ive minutes .
personnel lor directions whether to repair or Inspect the hydraulic connections lor leaks.
replace any major componen!. Repair leaks as requi red.
8. Install the access cover (1) using the capscrews
and washers (2) .
9. Complete the in stallation by testing all related
lunctions 01 the boom lor proper operation.
Normal operation 01 the hydraulic, air, and
electrical systems should be conlirmed. A general
perlormed to ensure related damage or wear is not
present.
3014
4 of 4
8. Carefully remove the length reel (2) from the
Telescope Cylinder Length mounting surface in the boom base section (3) . Do
Reel, R & I not allow the length cable (4) to become crimped
or damaged in any way.
This procedure covers the removal and installation of 9. While holding the length cable (4) to prevent it from
the telescope cylinder length reel and its integral retracting uncontrolled, remove the cotter pin (5)
encoder. Refer to SM Keysheet Area 17 -002 for an d detach the length cable (4) from the latch
Recondition procedure. Other related procedures are bracket (6). Allow the length cable (4) to retract
Boom Te/escape Cylinder Ca/ibration in SM Keysheet slowly into the length reel (2).
Area 17 -002 and Latching Boom Te/escape System 10. Remove the length reel (2) from the boom base
Troub/eshooting in SM Keysheet Area 17 -002. section (3) and off the crane .
11. If necessary, remove the capscrews, locknuts and
Length Reel Removal washers (1) that secure the length reel (2) to the
1. Lower, detach, and secure the load , as required. mounting plate (8) .
2. Stabilize the crane for service as follows : 12. For removal of the encoder (10) from the length reel
a. Park the crane, out of the way, on a firm and (2) , see Encoder Remova/ found on Page 4.
level surface .
the tires.
lock, as required.
d. Level the eran e on fully extended outriggers.
A WARNING
Solvents and cleaníng solutions can be
e. Position the boom above 50° boom angle and hazardous. Serious personal injury may
fully retract the boom. If required, refer to the result from misuse of these products. Read
Operator's Manual for manual boom retract and follow all the manufacturer's
ing. recommendations concerning solvents and
3. Shutdown the engine . cleaning solutions.
A WARNING
1. AII components should bethoroughly cleaned with
an approved cleaning solvent , air dried, and care
fully inspected.
Solvents and cleaníng solutions can be
hazardous. Serious personal injury may 2. AII Loctite®, Permatex®, or other sealant residue
result from misuse of these products. Read should be removed from threads of hardware and
and follow all the manufacturer's the mounting surfaces of parts that are going to be
recommendations concerning solvents and reused. Prior to applying new thread locking com
cleaning solutions. pounds or sealants, clean threads and surfaces
4. Thoroughly clean the area to be disassembled with mance of products.
an approved cleaning solvent. Allow the area to air 3. Thoroughly inspect all parts for damage , wear, fa
dry. tigue or stress fractures , and corrosion . Repair or
5. Check that all controllevers are in the neutral posi re place as required.
tion and move the function lockout switch to the 4. Inspect the integrity of the electrical wires and con
"DISABLE" position. nectors. Repair or replace if required.
5. Inspect the integrity of the length cable. Replace if
Refer to Figure 1. required .
6. Disconnect the encoder cable (7) and remove the
clamp (not shown) which secures the encoder
sonnel for d irections whether to repair or replace
cable (7) to the mounting plate (8). any major componen!.
7. Support the length reel (2) , and remove the lock
nuts and washers (9).
1 01 8
S M 17 - 002 - 068.00 0408 Service Manual
1 Capscrews, Washers, & Lockn uts 5. Co tter Pin 8. Mounting Plate

2. Length Reel 6. Latch Bracket 9. Washers & Locknuts
3. Boom Base Section 7. En code r Ca ble 10. Encoder
4. Length Cable
Figure 1
Telescope Cylinder Length Reel
2 of 8
Length Reel Installation 5. While holding the cotter pin (5) and length cable (4)
together, connect the length cable (4) to the latcll
bracket (6) by installing the cotter pin (5) th roug ll
A WARNING
the hole in the latch bracket (6) and ben ding it se
curely.
Position the length reel (2) on the mounting stu ds
compounds, etc. can be hazardous. Serious of the boom base section (3), and secure by in
personal injury may result from misuse of stalling the washers and locknuts (9).
these products. Read and follow al! Refer to Figure 2.
manufacturer's recommendations concerning 7. Connect the encoder cable (1) and secure it to th e
these products. mounting plate (3) with the clamp (5), capscrew,
locknut, and washer (4). Be sure to rou te tll e en
Refer to Figure 1. coder cable (1) so that any bends have at least a 3
1. If necessary, calibrate and install the encoder (10) in (76mm) minimum radius.
on the length reel (2). For calibration instructions, 8. Properly calibrate the boom telescope cylinder.
see Encoder Ca/ibration found on Page 5 . For in Refer to Boom Te/escope Cy/inder Ca/ibration in
stallation instructions, see Encoder /nstallation SM Keysheet Area 17 -002 .
found on Page 6. 9. Complete the installation by testing all related func
2. If necessary, install the capscrews, locknuts and tions of the telescope cylinder length reel for prop
washers (1) that secure the length reel (2) to the er operation . Normal operation of the electrical
mounting plate (8). system should be confirmed. A general inspection
3 . Install the cotter pin (5) in the length cable (4) end. of the components and systems in th e areas adja
4 . Position the length reel (2) near its mounting loca cent to the repair should also be performed to en
tion in the boom base section (3). sure related damage or wear is not present.
3 of 8
SM1 7- 002-068.00 0408 Service Manual
12 11 10
5
Radius
3 in (76mm)
~
Minimum
8
9
1. Encoder Cable 4. Capscrew, Locknu t, & Washer 7. Capscrews 10. Length Cable
2. Capscrew, Locknut, & Washer 5. Clamp 8. Encoder 11 . Cotter Pin
3. Mounting Plate 6. Length Reel 9. Cable Connector 12. Cable Anchor
Figure 2
Encoder Ca ble - Minimum Bend Radius 3 in (76mm).
Encoder Removal
The encoder is an integral part of the length reel. In
order to remove the encoder the length reel must first
be removed from the crane.
A WARNING
and follow all the manufacturer's Figure 3
recommendations concerning solvents and Install Lock Screw
cleaning solutions. 5. Install the lock screw in the side ofthe length reel as
shown; do not over tighten.
1. Th oroughly clean the area to be disassembled with ~===
an approved cleaning solvent. Allow the area toair
dry.
Refer to Figure 2.
2. Remove the length reel (6) from the crane. For
complete instructions see Length Reel Removal
found on Page 1.
3 . Remove the capscrews, locknuts, and washers (2)
that secure the mounting plate (3) to the length reel
(6); remove the mounting plate (3).
4 . Rem ove one of the capscrews (7) from the end of
th e len gth reel (6). This capscrew (7) will be used Figure 4
as a lock screw to keep the length reel (6) from Remove The Access Cover
spooling . 6. Remove capscrews and open the access cover.
4 of 8
Figure 5 Figure 7
Loosen Cou Setscrew Remove The Encoder Mounti Screws
7. Loosen the setscrew which secures the coupling 9. Remove the mounting screws which secure the
between the length reel and encoder. encoder to the end cover; remove the encoder.
Note: It may be necessary to rotate the coupling

so the setscrews are facing the access hole.
Loosen the lock screw and pull the length cable
so the coupling is oriented correctly; tighten the
lock screw to hold the coupling in place.
Figure 8
Remove The O-ring
10. Remove the o-ring from the end cover.
Encoder Calibration
Figure 6
Remove The End Cover Befare installation , the encoder must fi rst be
calibrated. Use the following procedure to cal ibrate the
encoder.
8. Remove the remaining capscrews which secure
the end cover to the body of the length reel. Re 1. Connect the encoder cable to the encoder.
move the end cover with the encoder attached . 2. Turn the crane ignition switch on and activate the
rated load indicatar (RCL) .
3. Rotate the input shaft of the encoder so the length
reading on the RCL reads zero.
4. Rotate the input shaft of the encoder clockwise so
the length reading on the RCL reads 34 inches (ap
proximately 25 turns).
5 of 8
SM11- 00'2-068.00 0408 Service Manual
5 . Using an indelible marker, place an index mark on
the in put shaft and encoder housing. See
Fi gure 10.
6 . Attach a piece of tape to the input shaft to prevent it
fmm rotating until properly installed on the length
reel.
Encoder Installation
Before installation , the encoder must first be
cal ibrated. See Encoder Calibration found on page 5.
4. Install the coupling on tlle input shaft of the en

coder. Leave a minimal gap between the coupling
and the encoder so they do not rub o Try to orient
the setscrews of the coupling so they will face the
access hole in the length reel, once the encoder is
installed. Be sure to maintain the calibration set
ting of the encoder.
Orient The Encoder & End Cover
1. Position the encoder in the end cover. Orient the

cab le connector, as shown. Be sure to maintain
tll e calibration setting of the encoder.
Figure 12
Torque Coupling Setscrew to 10 in lb (1.1Nm)
5. Torque the coupling setscrew to 10 in lb (7 .7Nm).

Be sure to maintain the calibration setting of the en
coder.
Figure 10
Install The Encoder Mounti Screws
2. Install the mounting screws which secure the en

coder to the end cover. Be sure to maintain tlle cal
ibration setting of tlle encoder.
3 . Install tlle o-ring in the end cover. Make sure the
o-ring is not twisted.
6 of 8
Figure 15
Figure 13 Torque The Coupling Setscrew
Lock Screw In Place
8. Tighten the setscrew which secures the coupling
6. Check that the Length reel cable is lully retracted
between the length reel and encoder. Use the ac
and the lock screw is in place. Tighten the lock
cess hole in the length reel body.
screw so the length reel will not rotate.
Note: It may be necessary to rotate the cou pling
slightly so the setscrew is facing the access
hole. Use a screwdriver, or similar tool, to rotate
the coupling a minimal amount so the sets crew
is accessible.
Figure 16
Install The Access Cover
7. Install the end cover, with the encoder and coup 9. Properly position the gasket and access cover on
ling, on the length reel. Engage the coupling with the length reel; install capscrews.
the length reel output shaft. Secure the end cover
to the length reel with three 01 the lour mounting
capscrews.
Figure 17
Remove The Lock Screw
10. Remove the lock screw in the side 01 the length

reel. The lock screw is the lourth capscrew which
secures the end cover to the length reel; install the
capscrew in the end cover.
7 01 8
8 of 8
2 3 4 5
o
14 13 12 11 10 9 8 7 6
1. Pistan 5. Wiper 9. O-ring 12. Seal

2. O-ring 6. Rad 10. Head 13 Wea r Rlng
3. Case 7. Retaining Wire 11.0-ring 14 . Lacknut
4. Seal 8. Back Up Ring
Figure 1
Boom Latching/ Pinning Cylinder Assembly
Boom Latching/Pinning
Cylinder, Recondition
A WARNING
This procedure covers the recondition of the boom
latehing/pinning eylinder. For removal, installation ,
and troubleshooting procedures , see SM Keysheet
Area 17-002 .
cleaning solutions.
Disassembly
1. Extend and retraet the cylinder several times to
It is a good praetiee when disassembling hydraulic drain any remaining hydraulic oil from the cylinder
eomponen ts to lay the parts out in the order that they into an appropriate container. Properly store or
were disassembled. Keeping the parts in this order dispose of the used oil.
during disassembly, eleaning, and inspection will aid in 2. Cap/plug any openings in the eylinder. Thoroughly
the assembly proeess. elean the exterior surfaee of the cylinder to prevent
contamination.
Refer to Figure 1.
3. Fully extend the rod (6) to position the piston (1)
against the head (10) .
not bind .
1 014
7. Remove the locknut (14) from the rod (6).
8. Remove the piston (1) from the rod (6).
9. Remove the wear ring (13) , seal (12) , and o-rings
I Mounting
/, ¡
¡
Hole (11 ,2) from the pisto n (1) .

10. Remove the head (10) from the rod (6).
Opening ! " / 1_ 11 . Remove the o-ring (9), back up ring (8), wiper (5),
In Case ~J i" I and seal (4) from the head (10).
I¡'
'.~ J
'/ j Cleaning And Inspection
./
2
r
3
A WARNING
1. Case
2. Retainlng Wlre recommendations concerning solvents and
3. Head cleaning solutions.
Figure 2
Retai ning Wire Removal/lnstallation 1. Thoroughly clean all metal parts with an approved
tion possible to keep all parts free of dust , dirt, or
CAUTION any other foreign material during assembly.
Hydraulic components are machined to close 2 . AII Loctite®, Permatex® , or other sealant resídue
tolera nces. Use extreme care when handling should be removed from threads of hardware and
not to crush or cause damage to the case the mounting surfaces of parts that are going to be
when clamping in a vise. Do not clamp in any reused. Prior to applying new thread locking com
form of vise unless jaws are protected by a pounds or sealants , clean threads and surfaces
soft material. with Loctite® 7070 Cleaner to ensure best perfor
mance of products.
Refer to Figure 2 .
wear, fatigue or stress fractures , corros ion , deep
4. Secure the case (1) in a vise with padded jaws.
scratches , cracks, and scuffed metal. Remove any
Note: Rotating the head will force the retaining burrs or sharp edges with a fine file , hone, emery
wire from the opening in the case. cloth, or crocus cloth. Replace any damaged com
ponent , as required .
5. Use a screwdriver to pry up on the retaining w ire (2) 4 . AII "soft parts ", such as seals , gaskets, back up
an d begin rotating the head (3) counterclockwise. rings, and o-rings, should be replaced.
Continue rotating the head (3) until the retaining 5. In the event of severe defects, contact factory per
wire (2) is completely removed. sonnel for directions whether to repair or replace
Refer to Figure 1. any major component.
6. Remove the rod (6), head (10) , and piston (1), as
an assembly, from the case (3).
2 of 4
Assembly 6. Secure the piston (1) on the rod (6) by installing the
locknut (14). Torque the locknut (14) to 30-35 ft lb
(41-47Nm).
A WARNING
Lubricants, sealants, joint and thread locking CAUTION
compounds, etc. can be hazardous. Serious Hydraulic components are machined to close
personal injury may result from misuse of tolerances. Use extreme care when handl ing
these products. Read and follow all not to crush or cause damage to the case
manufacturer's recommendations concerning when clamping in a vise. Do not clamp in any
these products. form 01 vise unless jaws are protected by a
soft material.
Lubricate all seals , back up rings , 0- rings, wipers, and
the I.D. of the case with clean hydraulic oil prior to 7. Secure the case (3) in a vise with padded jaws.
assembly. See the Operator's Manual for the correct 8. Install the rod (6) , head (10) , and piston (1), as an
type. assembly, in the case (3) .
Refer to Figure 2.
Refer to Figure 1.
9. Rotate the head (3), as required , to align the retain
1. Install the seal (4), and wiper (5) in the head (10).
ing wire (2) mounting hole in the head (3) with the
2. Install the back up ring (8) and o-ring (9) on the
opening in the case (1).
head (10).
10. Install the retaining wire (2) in the hole.
3. Install the head (10) on the rod (6) .
11. Rotate the head (3) clockwise to feed the en tire re
4. Install the o-rings (2,11), seal (12), and wear ring
taining wire (2) through the opening and secure
(13) on the piston (1).
the head (3) in the case (1 ).
5. Install the piston (1) on the rod (6).
12. If the boom latching/ pinning cylinder is not to be
immediately installed on the crane, plug all open
ports to prevent contamination and properly store.
3 of 4
4 of 4
a:
o
!ñ
ISW~ 1--PI~
LATCH
I MANUAL
EX1,RET
r-RETHACT,
EXTEND, TELESCOPE,
PEDAL
¡¡,
UJ
..,o:z
SO~:~~ID I
POT SENSORS & PIN
a: L _ SENSORS 0.5 · 1, 5V
o
<- .... .. ...r.:
Lo
'!! ~
V)
UJ a:
¡--
a: w
r- 1
t-
<.:)
_0--
~p
Z CI
...z
>=
:;¡
RCL
DISPLAY COMPUTER
ATB
SWITCH
BOOM
REEL
I fCON TROLLLn I
ENCODER ~
a:
UJ
TI l 1_
<
C\
o
~
L l· -- - - - -
_J - -
I r
, L
:
~"'-- -~
í :
I
CAN HIGH
. GROU'
(YELLOW)
CAN LOW --,
SHIELD
(GREEN)
(S TRANDED )
Figure 1
Latching Boom Telescope System Component Diagram
Latching Boom Telescope Resource Documents

Listed below are a few resource documents that may
System Troubleshooting be beneficial to have wllen troubleshootin g this
system:
This procedure covers the troublesllooting of the
latching boom telescope system , For boom telescope • Crane electrical , hydraulic , and air schematics -
cylinder calibration procedures, see SM Keysheet Area available from your distributor
17 -002. • Boom Teles cope Cylinder Calibration pro ced ures
(describes how to recalibrate the telescope cylin
Table of Contents Page der length and pin locations). Refer to SM Key
Latching Boom Telescope System sheet Area 17 -002.
Component Diagram ...... .... ... , . . ... .. . • Operator's Manual (describes both automatic
Resource Documents .... .. , ... ... . . . . ... . . , and manual telescope operations) - available
Latching Boom Telescope System from your distributor
Components - IlIustrated , .. . , , . . .. ...... ,. 2 • RCL Manual (describes normal operation as well
Latching Boom Telescope System as calibration 01 the RCL computer) - available
Components List . , .... .. .. ...... .. . ... .. .. 5 Irom the computer manufacturer
CAN Message Identification .. , . . , ... ... . .. .. 6
CAN Troubleshooting Tips .... . ..... .... .. . .. 9
General Diagnostic Chart . .. .... , . . .. " . ... 10
Troubleshooting Chart .. . ..... , .... " ...... 11
1 of 20
¡:¡:
¡-o~
2
~,
L
I
l o
I : ~~-
'".,..
I~
5 D
1 RCL Computer 10 Pin/Latch Cylinder 19. Pins

2. Boom Length Reel 11 Wedge Slider Bracket 20 Base Section
3 RCL Display 12. Latches & Latch Wedges 21. Tl Section
4 Telescope Foot Pedal 13. Not Pinned Sensor 22. T2 Section
5 Boom Hoist/Telescope Valve 14. Telescope Cylinder 23. T3 Section
6. Cylinder Length Reel & Encoder 15. Not Latched Sensor 24. Manual Mode Switch - Extend/Retract
7. Latched Sensor 16. Crossover Relief Valve 25. Manual Mode Switch - Pin/Latch
8. Pinned Sensor 17. Pin Pullers 26. Valve Controller
9. Pln Puller Bellcrank 18. Springs
Figure 2
Latchi ng Boom Telescope System Components (Continued on Pages 3 & 4)
2 of 20
10
13
15
"Not Latched" Sensor Location
Latching Boom Telescope System Components - Continued
3 of 20
SM 17- 002-070.00 0310 Service Manual
17 18 19 17 18 19 17 18 19
----- ..
ti '...
- t
JI
I
I
·--Il @l
_\ _ _ -=- __ ~_ ~0~_
) -- - . \
23 22 21 20 6
24
-=..a..=-
--=:-..., = _ ~ -=-~~~~=-~T
~- - - _ .. . :.- - - -- - - - I )
.' -- - . [11
.---. .", ",TC H'O 1\1
l
!
P.,"'NED
PFlEEENT - '\
i ) [ ~~...: J:i
I P~ _)
(..,.-,- -
j
NOT
J l
NO'
_. . - .. LAlCH CENTEFlEO ______ . - _ :::::=...
- '-, i- -- ------=-_ ~~~ -, 1

25 . --n -=-LI
Boom Telescope Remote Control Box
Latching Boo m Telescope System Components - Continued
4 of 20
Latching Boom Telescope System Components List
Component RefN° Component Ref N°

Valve Controller 26 Manual Mode Switches 24,25
Boom Length Reel 2 Pinned Sensor 8
Cylinder Length Reel & Encoder 6 Not Pinned Sensor 13
Telescope Foot Pedal 4 Latchecl Sensor 7
RCL Computer & Display 1,3 Not Latched Sensor 15
..
Component Ref N° Component Ref N°
Boom Hoist/Telescope Valve 5 Pin/Latch Cylinder 10
Telescope Cylinder 14 Crossover Relief Valve 16
Component RefN° Component Ref N°

Pins 19 Springs 18
Pin Pullers 17 Latches & Latch Wedges 12
Pin Puller Bellcrank 9 Wedge Slider Bracket 11
Note: "Ref N° " refers to illustrated location in Figure 2.
Table A
18FF
...
Message ID
01
• ••
32
•
, 01
I I
FF
I
FF
Message Data
l'
FF
•
FF
••
FF
•
FF
1;
FF
Table 8
Sender ID I Description
32 Controller
DO RCL computer
01 Boom reel
02 RCL display
07 External bar graph
08 Internal bar graph
FRABA See "CAN Open " Page 6
Table e
5 of 20
Message#
620
Description
Set message repeat rate
I Sent By
I Sent lo
I Controller Encoder
000 Encoder startup Controller ¡Encoder
1AO Cylinder length Encoder ' Everyone
Table o
...
Message ID
I I I
Message Data
l' I lo I 1:
1AO D3 11 00 00 FF FF FF FF
Table E
•
18FF
.
Message ID
..
11
- • -
32
I I
83
I
OB
•
00
Message Data
l'
00
•
FF
l.
FF
I
FF
.
FF
:
Table F
CAN Message Identification CAN Open
Most all of the Controller Area Network "CAN " The main difference in the CAN Open messages is the
messages used with the boom latching circuit are Message ID, Only the encoder uses CAN Open , There
based on SAE J1939 with a 29 bit identifier. Refer to are only three messages that are used for the encoder,
Tab le B for an example, The only exception is the all of them will be described below. They are shown in
en coder, which uses CAN Open and an 11 bit identifier. Table D, Any communication to or from the encoder
Refer to Table D and Table E for an example, must be in this format.
J1939 Messages A sample CAN Open message is 1AO D3 11 0000 FF

TI18 messages that show up on the documentation FF FF FF. Refer to Table E,
start with Ox, This denotes that the message is in
The CAN Open message ID is shorter than J1939
Hexadecimal format. The Ox is not displayed on the
messages, The message ID in this case is 1AO, this
CAN diagnostic screen , message is for the cylinder length in inches , The data
A sam ple CAN message would look like 18FF0132 01 is displayed in bytes D1-D4, The data sent from the
FF FF FF FF FF FF FF. Refer to Table B, encoder is in the format of Low Byte, High Byte also
know as Little Indian, Big Indian, This means that the
For the boom latching messages, all messages start data "D3 11 0000" is in this form at. To understand this
witll the Message ID of 18FFxxxx. The first 4 digits are message, first reverse the bits:
always the same, 18FF, Digits 5 and 6 are for the
message number. Digits 7 and 8 designate the sender The message "D3 11 0000" now becomes "00 00 11
of the message. For example, if the Message ID was D3 ",
18FF01 32, this would mean message 1 from sender # Now convert between Hex and Decimal. The easiest
32 , Each sender has a unique ID, The sender numbers way to do this is by using a scientific calculator.
are shown in Table C,
The corresponding number in Decimal is 4563 so:
The remaining digits after the Message ID are for the
message Data. There are 8 Data positions consisting 00 00 11 D3 Hex = 4563 in Decimal
of a 2 digit Hex number each, In the sample message,
the data in position D1 is 01, This sample message This number is in "bits". This number must be
would mean message #1 from the controller with 01 for converted into inches, There are 323,207 bits/ inch,
data, This would mean the controller is in boom mode
1. A breakdown of each individual message is This conversion is complicated to explain but for
contain ecl in the CAN Message documents, Contact documentation purposes, here is how the 323 .207
tlle factory for interpretation of CAN messages , conversion factor is calculated :
60f 20
The encoder is connected to a cable reel which is 1AO D3 11 00 00 FF FF FF FF (encoder position)
geared such that when the encoder is turned one full 18FF1132 83 08 00 00 FF FF FF FF (home po sitíon)
turn, the cable is pulled out 12.673 inches. The
encoder has 4096 steps or bits per turn so: First convert to decimal
4096/12.673 = 323.207 bits/inch (at full resolution). Reverse data 03 11 00 = 00 00 11 03
Convert to Decimal = 4563
The range of the reel is 350 inches so:
350 x 323.207 = 113122 bits (at 17 bit resolution). Reverse data 83 OB 00 00 = 00 00 OB 83
Convert to decimal = 2947
To convert 4563 into inches, divide by 323.207:
4563/323.207 = 14.12 inches. Now subtract the data:
Encoder position - home value = 4563-2947 = 1616
This however is not the actual position of the cylinder.
The cylinder home position must be known to find the Now convert to inches:
actual cylinder position. This will be explained in the oata/323.207 = 1616/323.207 = 5 inches.
next section. So in this example, the cylinder would be extended 5
inches.
Actual Cylinder Position
The telescope valve controller works with 16 bit
To find the actual cylinder position, the home position numbers instead of 17 bit numbers. (A 16 bit number is
of the cylinder and the position of the cylinder encoder simplya 17 bit number divided by 2.) For this reason,
must be known. The home position is maintained and all the buffers and pin positions are half what is
broadcast by the controller. The message is a J 1939 obtained by converting the hex numbers shown in the
message, 18FF1132 in the format of: CAN messages. So to convert a pin position or buffer
18FF1132 83 08 00 00 FF FF FF FF. Refer to Table F. from decimal to inches, divide by 2. Example:
323.207/2 = 161.603. If the pin position variable is a
01-04 contains the data of the Home position in Low negative number, to get inches add 65536 to it and
Byte, High Byte format. divide by 161.603. Example: -13338 + 65536 =
52198 and 52198/161.603 = 323.
The actual position = encoder position - home
position. For example using the messages:
7 of 20
Press the Status/ Error

"Display Select" Messages
button lor CAN
diagnostic screen
Message
Screen
Message number
lor each device
on the CAN Bus
Contact the Link-Belt If the device is comm unicating,

service department lor the count will be increasing
a breakdown 01 data
Figure 3
CAN Diagnostics Through The RCL Display
8 of 20
CAN Troubleshooting Tips o If the resistance is 120 ohms , one of the ter
The tips listed below are provided to aid in the minating resistors is missing.
troubleshooting of the CAN system . o If the resistance is an open circuit, then both
• CAN High (Yellow) - Terminal A of the terminating resistors are missing.
CAN Low (Green) - Terminal B o If the resistance is O ohms, then a short cir
Shield (Bare Stranded Wire) - Terminal C cu it exists.
• The resistan ce between the Green and Yellow o Any other resistance means that a compo
(Terminals A & B) can be measured at the follow nent of the CAN system has the wron g re
ing component connectars: RCL Display, RCL sistance.
Computer, and Boom Length Reel. • Errors can be isolated by unhooking various
CAN components located on the BUS.
To ensure a correct reading, the Display, Encod • Remove both the terminating resistors and re
er, Computer, and/ar Boom Length Reel must be sistance between the Yellow and Green (Termi
disconnected from the CAN BUS harness. Also, nals A & B) should be an open circuit.
far a correct reading the two terminating resis • With the resistors removed, check the continuity
tors must remain installed in the CAN BUS sys between the Shield and Yellow and between the
tem. The first terminating resistor is located in Shield and Green. Both should be open circuits .
either a 3-way connector in a "Y" connectar be If not, a wire is shorted to Shield.
hind the RCL Display or is part of the Internal • There should be continuity between the Shield
Light Bar. The second terminating resistar is part and Crane Ground.
of the Boom Cylinder Length Reel. The resist
ance should be 60 ohms.
9 of 20
General Diagnostic Chart
Boom extension is
only possible in
X X X X X No No No manual mode with
visual position con
firmation.
Display will be pow
2 X X X X No No No ered on, but will not
show any data.
Display will be pow
ered on , but only
3 X X X No No Ves
the boom length will
be displayed.
AII RCL functions
4 X X Ves No Ves will work , but boom
can't be extended.
Boom extension is
only possible in
5 X Ves No Ves manual mode with
visual position con -
firmation.
Boom extension is
only possible in
6 X Ves No Ves manual mode with
visual position con
firmation.
Display will only
show boom length,
7 X No Ves Ves
cylinder length , ancl
CAN messages .
Boom length will
not show and ATB
signal will flag an
8 X Partial No Ves overload condition .
Boom extension
only possible in
manual mode .
Boom extension still
possible, stays in
9 X Partial Ves No
last boom mode se
lected.
Note: For more further troubleshooting information, refer to the Troubleshooting Chart starting on page 11 .
Table G
10 of 20
No movement of Is the boom overloaded? • Correct overload condition.

boom sections
Is the boom two blocked? • Correct two block condition .
Trying to telescope a very large • Reduce hookload or increase boom angle.
load or telescoping at a low boom
angle?
Are all the electronic components • Check CAN bus connectors and wiring between
communicating? (Look at General device that is not communicating and CAN back
Diagnostic Messages on RCL bone.
Boom Telescope Screen.)
• Check power to device not communicating.
• Check ground to device not communicating .
Is there a telescope controller • Cur1 Err or Cur2Err (The telescope controller is
error? (Look at Telescope not getting the expected amount of current flow to
Operation Mode Display on RCL the telescope valve.)
Boom Telescope Screen .)
o Power must be cycled to clear this error.
o Check the solenoids in the teles cop e valve .
• OvrLoad (The LMI system is still sending a mes
sage on the CAN bus that there is an active over
load or two block condition.)
o Correct any overload or two block cond ition .
o Cycle power to attempt to clear the message.
o If it still will not clear, it is probably an internal
software problem with the computer.
• CylErr (The telescope cylinder is in an invalid
position tor the currently selected boom mod e
and boom length.)
o Check the telescope cylinder length reel
cable.
No movement of o Check to ensure that the telescope cylinder
boom sections length reel is calibrated correctly. With th e
continued cylinder PINNED and NOT LATCHED retrac!
the cylinder in manual mode until the cylinder
bottoms out (see the Emergency Telescope
Operation section in the Operator's Manual).
The cylinder length should be between 0.010
and -0.010. Ideally it should be 0.000. (The
cylinder length should never be less than
-0.010 or greater than 326 .)
11 af 20
No movement of o If the cylinder length does not return to near
boom sections - .000, the encoder may have spun on the
continued length reel shaft. Remove the encoder as
sembly from the mounting plate and remove
the small square cover from the reel. Check
the screws on the shaft coupler to make sure
they are tight.
o If error reoccurs after calibrating cylinder
length and this is a new encoder, remove it
from the cable reel and spin the shaft at least
30 revolutions eilher direction and Ihen rein
stall il. Recalibrate Ihe cylinder lenglh.
o Power must be cycled lo clear Ihis error.
• BoomErr (The boom length is invalid for Ihe cur
renlly selected boom mode.)
O Check, and if needed, resel the boom zero
and span. The boom may have lo be manu
ally exlended and/or relracted to accomplish
Ihis .
O Does Ihe General Diagnoslic Messages dis
play No Communicalions wilh Exlension
Reel? Check Ihe CAN bus and conneclors
belween Ihe reel and Ihe CAN backbone.
Check Ihal Ihe reel is receiving eleclrical pow
er and ground .
o Check the lenglh pOlenliomeler in Ihe boom
lenglh reel. Gear may have disengaged or
jumped leelh. Polenliomeler may nol have
been engaged in a delenl pos ilion on Ihe
plaslic gear. Polenliomeler may be bad.
o Check anli-Iwo block cable on lenglh reel.
Cable anchor on boom head may have
slipped.
12 of 20
No movement 01 • PdlErr (The controller is receiving an invalid volt
boom sections - age signal Irom the telescope pedaL)
continued
o The upper limit is 4.75 volts and the lower lim
it is 0.25 volts. The telescope pedal has me
chanical adjustments to set the voltage
range.
• Int_Err (The telescope controller detected an in

ternal error when it was powered up.)
o Cycle the power to the controller to try to
clear the error.
o 1I the error won't clear, replace the controller.
• Sw_Err (The controller is getting an invalid signal
Irom one 01 the sensars.)
o Cycle the power to the controller to try to
clear the error.
o 1I the error occurred while extending or re
tracting a section, check the adjustment 01
the two pin sensors.
o 1I the error occurred during the latching or
pinning process, check the adjustment 01 the
Pinned, Not Pinned, Latched, and Not
Latched sensors.
o Check the operation 01 the sensors by plac
ing a metal target on the sensing lace while
checking lor the LEO illumination.
o Check the pin and latch relays lor correct op
eration. With the relays removed, check con
tinuity to ground on wires 745A and 7458 lor
pinned relay and wires 738P and 738R lar
latched relay.
o Check the resistan ce between wires 744K
and 744R, 743A and 7438, and 743C and
7430. Resistance should be 26k ohms.
130120
No movement 01 • PdlCtr? (The telescope pedal was not centered
boom sections when the crane was started.)
continued
o Ensure pedal is centered and cycle power.
Is the telescope valve controller • StopExt (Boom will extend no lurther in the mode
doing something? (Look at currently selected.)
Telescope Operation Mode Display o The only option is to retract the boom.
on RCL Boom Telescope Screen.
• E_SRB,E_SRTR_SEB,orR_SET
o Is the cylinder length displayed inside the
boom graphic getting smaller? Be patient.
Continue holding the telescope pedal down.
It could stay in this operation mode as long
as 6 seconds when everything is adjusted
correctly.
o Is the cylinder length displayed inside the
boom graphic not changing or changing very
slowly? The telescope cylinder is probably
latched to a boom section and is pushing
back (retracting) against the section but the
section is bottomed out and can't move lur
ther back so the telescope cylinder is retract
ing over relief. On the RCL display with the
telescope display screen selected, select the
bottom right button next to the label "CAN
Diagnostics/Boom Calibration". Press "Re
quest Boom Pin/Latch Calibratíon". While
holding the telescope pedal in either the ex
tend or retract position, press "Yes" to conlirm
selection. That specilic pin position has now
been recalibrated.
o Check to ensure that there is nothing be
tween the sections holding one section lur
ther out than it should be. Note: the Tele 4
section (tip) bottoms out on blocks between
the boom head and the base section horse
collar.
o Check to ensure that the telescope cylinder
length reel is calibrated correctly. With the
cylinder PIf\If\IED and NOT LATCHED retract
the cylinder in manual mode until the cylinder
bottoms out. The cylinder length should be
between 0.010 and -0.010. Ideally it should
be 0.000. Reler to "Boom Telescope Cylinder
Calibration", SI\II Keysheet Area 17-002.
140120
No movement of o If the cylinder length does not return to near
boom sections - 0.000 , the encoder may have spun on the
continued length reel shaft. Remove the encoder as
sembly from the mounting plate and remove
the small square cover from the reel. Check
the screws on the shaft coupler to ensure
they are tight.
o Check the pin locations. This requires a lap
top with a CAN card , the connecting harness ,
and the Variable Editor software. Correct pin
locations that are incorrect. Refer to "Boom
Telescope Cylinder Calibration", SM Keysheet
Area 17 -002.
o Check that the valve is being driven to retracto
On the RCL display with the Telescope Dis
play screen selected, select the bottom right
button next to the label "CAN Diagnostics".
Look for the Message 18FFF132. The third
and fourth pair of numbers in the Data col
umn should be something other than zero
when the telescope pedal is actuated . If the
numbers in either the third or fourth column
don't change when the pedal is actuated ,
something is wrong with the computer.
o Check that the solenoids on the telescope
valve are receiving voltage and have a good
ground .
o Check that the telescope valve spool is not
stuck.
• NEUTRAL
o Is the telescope pedal being actuated? Make
sure that when the pedal is rocked either way,
it turns the controller shaft .
o Is the controller doing something without op
erator input? Wait for the operation to com
plete. Look to see if the controller is doing
something as follows: On the LMI display
with the Telescope Display screen selected,
select the bottom right button next to the label
"CAN Diagnostics". Look for the Message
18FFF132. The first and third pair of numbers
in the Data column will be something other
than zero if the controller is doing something .
o Is the pedal voltage going high or low enough
to get outside of the neutral range of 2.5 ±
0.25 volts?
15 of 20
SM 17 -002 -070.00 0310 Service Manual
Telescope Is the weather very cold? • Cold weather changes the viscosity of the oil
cylinder just which slows down the latching cylinder so it may
cycles back and take some time for the cylinder to complete its
fortl, a small stroke befo re the telescope cylinder can move a
amount boom section or move to another section. Be
patient and allow some time for the cylinder to
complete its stroke.
Is it trying to pin a section? • Reverse the telescope direction for a short dis-
tance and then try again . If it doesn't work the
second time, change the boom angle and try
again.
• The l\Jot Latched sensor may be out of adjust
ment. Ensure that with the latches fully disen
gaged, the Not Latched sensor is actuated.
• The Pinned sensor may be out of adjustment.
Ensure that with the latches fully disengaged, the
Pinned sensor is actuated.
• The latches may not be unloading so they trap
the wedges. Assuming the pin is fully inserted
this would be caused by incorrect pin positions or
incorrect telescope cylinder length calibration.
Check and recalibrate cylinder length first and
then recalibrate pin positions if necessary.
• The pin may not be fully inserting into the hole.
This could be caused by a broken spring, a bind
ing pin, or by the pin hitting in front of or behind
the pin hole. Missing the hole would be caused
by incorrect pin positions or incorrect telescope
cylinder length calibration . Recalibrate cylinder
length or pin positions.
• Latching valve solenoid burned out.
• No voltage to the latching valve solenoid .
o Look for wiring or connector problems from
the controller to the solenoid.
o Look for 12 volts acroSS the 740A and 740C
wires. No voltage would indicate a problem
in the controller.
Is it trying to unpin a section? • The Not Pinned sensor may be out of adjustment .
Readjust sensor so that when the pin is fully dis-
engaged, the sensor is activated.
• The Latched sensor may be out of adjustment.
Readjust sensor so that when the latches are fully
engaged , the sensor is activated.
• The pin may be binding in the hole.
o Look for foreign matter between pin and hole.
o Look for a bent bellcrank cam roller.
• The pin may not be unloaded .
16 of 20
Telescope o Look for incorrect shimming of boom head to
cylinder just boom base section. None of the pins should
cycles back and be loaded in the 0% pinning location .
forth a small
amount o Look for a section not staying pinned in the
continued 0% location. This could allow another pin to
remain loaded .
o This could be caused by incorrect pin posi
tions or incorrect telescope cylinder length
calibration. Recalibrate cylinder length or pin
positions .
• Look for bent or broken parts on pin puller bell
crank mechanism.
• The latching wedges don't insert all the way be
tween the latches.
o Look for mechanical interference problems
between the wedge slider bracket and the
telescope cylinder.
o The latches may not be fully engaging the
holes in the rear of the section . This would
be caused by incorrect pin positions or incor
rect telescope cylinder length calibration . Re
calibrate cylinder length or pin positions.
• Insufficient oil pressure in latching cylinder to pull
the pino
o Check the pilot pressure. It should be
500-550 psi (3447-3 792kPa).
o Look for a pinched hose.
o Look for a leaking hose.
o Clleck for internal leakage in the latching cyl
inder.
Cover plate pops Is boom extending? • Not Pinned switch set too high, pin does not pul!
off the top of the down far enough to clear hole .
base section
• Top rear wear pads worn too mucho Pin does not
clear the hole.
• Extending too much load at too low of a boom
angle. Reduce load or increase boom angle .
• Incorrect calibration of telescope cylinder length .
Recalibrate cylinder length.
17 of 20
Cover plate pops Is boom retracting? • Retracted boom length is not calibrated correctly.
off the top of the The main working screen and the telescope
base section screen might show 38 feet of boom length but the
continued boom length calibration screen might show that
the length is actually negative. Recalibrate boom
length and span. Ensure the potentiometer in the
boom length reel is properly engaged in the
gears.
Is boom being operated in manual • Follow the telescoping procedure in the Opera
mode? tor's Manual exactiy.
No change in Is there communication with the • Check CAN bus connectors and wiring between
pin/latch state on computer? device that is not communicating and CAN back
display bone.
• Check power to device not communicating.
• Check ground to device not communicating.
• Could be a software or hardware problem with
the computer or display. Change out computer
or display. Note: Recalibrate the boom length
and span if components are changed.
Is the controller seeing a pin/latch • Look at message 18FFF332 on the CAN Diagnos
sta te change? tics screen:
o The pair of numbers in the first column of
data is 00 if the cylinder is trying to latch into
boom section and 01 if boom section is being
pinned into place .
o The pair of numbers in the second column of
data is 00 if no pin is present and 01 if pin is
present.
O The pair of numbers in the third column of
data is 00 if there is no "not latched " signal
and 01 if the latches are pulled.
O The pair of numbers in the fourth column of
data is 00 if there is no "Iatched" signal and
01 if latched.
O The pair of numbers in the fifth column of
data is 00 if there is no "not pinned " signal
and 01 if the pin is pulled .
O The pair of numbers in the sixth column of
data is 00 if there is no "pinned" signal and 01
if pinned.
• If there is no pin/latch state change at the control
ler, check the wiring, connectors, and pin and
latch switches. (The wires are numbered 738.)
18 of 20
Rough boom Is the telescope valve unstable? • Stabilize valve .
extension
(shudders or Are the wear pads loose? • Adjust wear pads .
chatters) Are the wear pads worn • Replace worn wear pads .
excessively?
If nothing else warks • We do not recommend grease on the boom . Use
a spray-on silicone based lubricant or something
like WD40, if required .
Slow boom Is the weather very cold? • Cold weather changes the viscosity of the oil
extension which slows down the latching cylinder so it may
take some time for the cylinder to complete its
stroke befare the telescope cylinder can move a
boom section or move to another section. Be
patient and allow some time for the cylinder to
complete its stroke.
Pin locations off slightly • Recalibrate pin locations .
Trying to telescope a very large • Reduce hookload or increase boom angle.
load or telescoping at a low boom
angle?
19 of 20
20 of 20
Boom Telescope Cylinder

Calibration
This procedure covers the calibration of the telescope
cylinder length and pin switches. It also covers swing
potentiometer and crane data reset calibration. For
latching boom telescope system troubleshooting see
SM Keysheet Area 17 -002.
Refer to the Crane Operator's Manual for specific
descriptions and correct operation of the boom
telescope controls, latching system, and Rated
Capacity Limiter (RCL) display features.
Crane Set Up
Figure 1
level surface; engage the park brake.
b. Engage the swing park brake or travel swing 2. Press the DISPLAY/SELECT button to access the
lock, as required. boom telescope screen.
c. Level the crane on fully extended outriggers.
d. Fully retract and position the boom, as re
quired.
3. Properly install the boom telescope remote control
o
~
box. See "Emergency Te/escape Operation" in the 1I
Operator's Manual for complete instructions. -XX)()(h
P n .p.nd UlCf': Slalus
Leave the remote control box connected until in
structed to remove. . ~ :-.'
Swing Potentiometer Calibration

RSET
Gener-al Diag rostic Messagcs

D
In order to calibrate the latching system the swing .'..••..·7.·m.
': .: :.· : : ·
.
······:····1
D
potentiometer must first be "zeroed".
1. With the boom over the front of the carrier and posi
l D
",... ",,, .. ,, .. ",. " " , " " '''''''~
tioned in the boom rest with the travel swing lock

engaged, turn the upper ignition key tothe on posi
~ CAN UI "-t'J I'C ~1x ~3ootr l Ca~r.n [.Orl ~
~ ........................ .•••••••••• J§ D
tion.
Figure 2
3. Press the button adjacent to the boom display.
1 of 8
SM 17- 002-071.00 1109 Servli ce Manual
D ,1 D~
[QJ ::1: l1J ¡[]J I
D~ D
[±] ~ @] [2] D D
@J [2] El D D D
@] G D ~ D D
rE::"..............··..·....·..·..§:
USP
e
ln ~ Keyp
D
lo Ul ler L" e
bra Hl'\ 50: ,,,,l y COde !, ............................................... ....... . .. .. ................. .:-.;~ D
1=] lQJ ~ Figure 5
6. Press the ZERO SWING SENSOR button. (The

boom must be positioned in the boom rest with the
travel swing lock engaged.)
Figure 3
D
4. Use t he keypad to enter the security code "123E".
(Select a number by pressing the button adjacent D
to the column and row of the desired chara cter.)
Note: Once the above screen is displayed, the

D
security co de must be entered before you can
proceed forward or return to the previous
D
screen. D
D~
,,, ,,, .. ---
........... ... " . . . . . ......................... .. .....
~ ~
Figure 6
: f X11J1SiO'1 $1)1$ 0(5
:
~
~
!... ......................... .... ......................................... .......... ... ..... ~
..." ....... , ........... ............
D
~
7. Press the BACK button .

: i\no,le S8'1sar
~ D ~
, . . ................. ...................~ .......................... ................ :s~
¡:~~::~:~~:: ::::::::::::::::~ D~
~... ~ ...... . . n . . . . . . . ..... ... " .......................... ~
! 1', ..... <JI" S"" ';O"

:... ..... D ~
:;)
" ............................................ ............................... , ... .:-.:
, ................................... :&
! op a C3p a¡; ,ly
:.............. ....... .... ........................... . . ........ . . ......
..-"-'
D ~
~
~
r;;-.;·O~;I;~ ..·.............. D ·~
!....................................~
Figure 4
5. Press the SWING SENSOR button.

Figure 7
8. Press the DISPLAY/SELECT button to return tothe

normal operation screen.
2 of 8
Crane Data Reset Calibration
When a new RCL flash card is installed , the crane data I 1
I o
within the display must be reset to ensure proper boom
telescope system calibration.
[Q] mJ ~ [l] D~
1. With the boom over the front of the carrier and posi
tioned in the boom rest with the travel swing lock
0 [§J [§J [Z] D
engaged , turn the upper ignition key to the on posi
tion .
~ @] El D D
[9 G D ~ D
'Use lh e Keyp ad 'o l,.... ,er in ?
;::-~ b 7.1 1 S"'. lI·I' Y Code
D
1= 1= '·1
Figure 10
4. Use the keypad to enter the security code " 123E".

(Select a number by pressing the button adJacent
to the column and row of the desired character.)
Note: Once the above screen is displayed, the

security code must be entered before yo u can
proceed forward or return to the previous
screen.
Figure 8
2. Press the DISPLAY/SELECT button to access the

boom telescope screen. !'I~~';'e;,S'I;;';' S'';;S'O~S''''''''''''''~
L...................................~ D
" .... " , ... ,."""." ............ --:-
:: Anole
,~~~
~
38'1 "'"
... .................................. . . . . ........
,
~
~
~
D
: ..... --. --., .. -------- ........ -- ... ~
~ SWlnG $ e--sor ~
D
~
: ......................................... :~
......................... -- .......... ~
- XX,XXIt : ' ¡''::SSlre S l:?'l!.Gt S

~ ..... ,,, ......................................... . ....... ~
~
D
f·~--¿~--¿··¿;·,~ ~·~~;,~· ......·........ ~
"SEr D l.................",...."......... ~ D
General Diagoostic Messages :......... " ...... " ................ ~
D~
~
D : More C:W OIS
:...................... --" -- .... -- ..~
D
Figure 11
5. Press the MORE OPTIONS button .

Figure 9
3. Press the button adjacent to the boom display.
3 of 8
>",,,,, ••,, .... .. . ....... ,, " ••..•• ~
: RaOiusiMomenl
:\. ~ . . ....... "~..... " ............ , ... ,, ............................... ~
~
~
D
,""..... . ",,,,,. , "",,,,,,,,,,,, "'
: Detlecllon
:.......... , .. ,,, ........... ... ... ".'i§
~
D
:., , " " "" " " ' " ' ' ' .. " .......... ,~
: Huod Angle
1....... , ....... "-...... "'-.. , ....................... .............. ........ ~
~
D
,.. ,,,. '"''. " " " " " " " .",,, ... "'
: E nBUle Dlsable Fly s
:...........................................~
,
i§:
D
:" ... ""''' '''''' ''' '' ''.'''''''''~
: '3 ack ~
~ . . . . . ................................................... ...... , ...................~
D
................. . .. '" ....... ... .........
¡
~
D~
MOle Opl ions ~
\. ...... ." .......... " . .. ......... ........... .......... . ... .. ... :\
Figure 12
6. Press the MORE OPTIONS button, again .

Figure 14
8. Press the DISPLAY/SELECT button to return to the

.- ... " .............. .......... """,,§¡
D~
normal operation screen.
................................................ .......... . ..........
: Resel e allb ratlon
~ , ~
~
D
D
f ·r\;~~· M;~~'FI;~·,·····"" "''' ''~
:.... ... .... .. ...... . .. "
D
.. ... .................lS
:..._"...""-""--"-""".. ""~ D
L~_~"_,, ..""""""" ..."""~
r M~l:,; ·Óp;,~~~········ · ..·.... ····~ D
~ .. "--- ............ ,, .......... _,,}
Figure 13
7. Press the RESET CALIBRA-nON button.
4 of 8
Zero The Telescope Cylinder 14. Retract the cylinder slightly until NOT LATC HED is
displayed.
1. Using the boom telescope remote control box,
15. Switch back to LATCH and confirm with LATCHED
latch into T3 and confirm boom is fully retracted.
light. Continue retracting the cylinder slowly until
2. Switch the latching cylinder to PIN.
the cylinder bottoms out.
3. Confirm thatthe PINNED and NOT LATCHED lights
16. With the cylinder boltomed oul in T3 press SET
on the remote control box are on. The telescope
PIN/LATCH POSITIOI\J and confirm wilh YESo
cylinder may have to be extended or retracted
slightly to obtain NOT LATCHED light. 17. Switch lo PIN and bump the cylinder loward ex
tend direction. The PINNED and NOT LATCHED
4. Fully retract the telescope cylinder until it bottoms
lighls should be on.
out.
18. Retract the cylinder to 11.5"'. Extend or Retract
5. On the RCL display, go into the calibration menu.
slightly lo obtain the PIN CENTERED light.
6. Press EXTENSION SENSORS (should be first op
19. Latch into T2, LATCHED and NOT PINNED should
tion).
be displayed, and retracl the cylinder untll it bot
7. Press ZERO TELESCOPE CYLlI\JDER. Once calib
toms out.
rated il should read "0.000".
20. Wilh the cylinder bottomed out in T2, press SET
8. Extend the cylinder slightly and retract it again to
PIN/LATCH POSITION and confirm with YES
verify that the cylinder length relurns lo 0.000. It
21. Extend the T2 section to 356".
should stop at 0.000 ± .009.
9. Exit the calibration screen by pressing the green 22. Switch to PII\J, extend slightly until pin pops in and
CRANE SETUP button and get back to the tele PINNED is displayed.
scope display. 23. Retract the cylinder slightly until NOT LATCHED is
displayed.
10. Extend the telescope cylinder lo approximately
22.5". 24. Switch back to LATCH and confirm with LATCHED
11. Extend or Retract cylinder slightly to obtain PII\J light. Continue retracting the cylinder slowly until
CENTERED light on remote control box. the cylinder bottoms out.
12. Switch the latching cylinder to LATCH. The 25. With the cylinder bottomed out in T2 press SET
LATCHED and NOT PII\II\IED lights on the remote PII\I/LATCH POSITION and confirm with YESo
26. Switch to PIN and bump Ihe cylinder loward ex
control box should be illuminaled.
tend direction. The PINNED and NOT LATCH ED
Calibrate The Pin Positions lights should be on.
27. Retract the cylinder to 1.0". Extend or Retracl
1. Setup the crane on outriggers.
slightly to obtain the PIN CENTERED light.
2. Set the boom angle to 75 o.
28. Latch into T1, LATCHED and NOT PINNED should
3. Make sure the boom is in EM1 mode.
be displayed, and retract Ihe cylinder until it bot
4. Go into the calibration menu on RCL display.
toms out.
5. Press EXTENSION SENSORS.
29. With the cylinder bottomed out in T1, press SET
6. Press ZERO EXTENSION SENSOR. Confirm ex
PIN/LATCH POSITION and confirm with YESo
tension sensor reads "00".
30. Extend the T1 section to 356.5".
7. Confirm the cylinder is LATCHED and NOT
31. Switch to PIN, extend slightly until pin pops in and
PINNED into the T3 section. (Cylinder length
PINNED light is displayed.
should be 21.5" -22.5").
32. Retract Ihe cylinder slightly until NOT LATCHE D is
8. Retract the cylinder until it bottoms out (should be
displayed.
around 21.5").
9. Go into the calibration menu on RCL display.
10. Press EXTENSION SENSORS.
the cylinder bottoms out.
11. Press SET PIN/LATCH POSITION; press YES to
34. With the cylinder bottomed out in T1 press SET
confirmo
PIN/LATCH POSITION and confirm with YE So
NOTE: After pressing SET PIN/LATCH 35. On the RCL display, press SPAN EXTENSIO N
POSITION, make sure "Calibration Successful" SENSOR. Enter "86.1 E" using the rows and
appears. This ensures controller accepted the columns.
calibration. 36. At this point all 0% and 100% positions are calib
rated.
12. Extend the T3 section to 355.5". 37. Fully retract the boom.
13. Switch to PIN, extend slightly until pin pops in and 38. The boom should now be fully retracted with the
PINNED Iight is displayed. cylinder LATCHED and NOT PINNED tothe T3 sec
5 of 8
tion. If not already, unplug the manual control box 62. Latch into T2, LATCHED and NOT PIf\INED should
a nd on RCL display, press the green CRANE be displayed.
SETUP and select an outrigger configuration. 63. Extend T2 to 183.8".
Tllen change boom mode to EM3. 64 . Switch to PIN , extend slightly until pin pops in and
39. Plug up the remote control box. Confirm the cylin PINNED is displayed .
der is approximately 22.5". 65. Retract the cylinder slightly until NOT LATCHED is
40. Extend or Retract slightly to obtain the PIN displayed .
CENTE RED light. 66. Switch back to LATCH and confirm with LATCHED
41. Latch into T3 , LATCHED and NOT PINNED should light. Continue retracting the cylinder slowly until
be disp layed . the cylinder bottoms out.
42 . Extend T3 to 189". 67. Wittl the cylinder boUomed out in T2 press SET
43 . Sw itch to PIN and extend slightly until pin pops in PIN/ LATCH POSITION and confirm with YES o
an d PI NNED is displayed. 68. Switch to PIN and bump the cylinder toward ex
44. Retract the cylinder slightly until NOT LATCHED is tend direction . The PINNED and NOT LATCHED
d isplayed. lights should be on.
45 . Switch back to LATCH and confirm with LATCHED 69. Retract the cylinder to 1.0". Extend or Retract
light. Continue retracting the cylinder slowly until slightly to obtain the PIN CENTERED light.
th e cylinder bottoms out. 70. Latch into T1, LATCHED and NOT PINNED should
46. W ith the cylinder bottomed out in T3, go back ¡nto be displayed.
RCL display calibration screen, then extension 71. Extend T1 to 178.6".
sensors, then press SET PIN/LATCH POSITION 72. Switch to PIN, extend slightly until pin pops in and
a nd confirm with YES o PINNED is displayed.
47. Sw itch to PIN and bump the cylinder toward ex 73. Retract the cylinder slightly until NOT LATCHED is
tend direction. The PINNED and NOT LATCHED displayed.
lights should be on. 74. Switch back to LATCH and confirm with LATCHED
48. LATCH and UNPIN T3 and retract it and pin it at the light. Continue retracting the cylinder slowly until
0% position . the cylinder bottoms out.
49. Unplug the remote control box and on RCL display, 75. With the cylinder bottomed out in T1 press SET
press the green CRANE SETUP and select an out PIN/ LATCH POSITION and confirm with YESo
rig ger configuration. Then change boom mode to 76. At this point al! 50% positions and the one 25% pos
EM4 ition are calibrated.
50. Confirm that the cylinder has moved to 21"-22". 77. Ful!y retract the boom.
51. Extend or Retract slightly to obtain the PIN 78. Calibration is now completed .
CENTERED light. 79. Remove and properly store the boom telescope
52. Latch into T3, LATCHED and NOT PIf\If\IED should remote control box.
be displayed.
53. Extend T3 to 94.5".
54. Sw itch to Pin and extend slightly until pin pops in
an d PINNED is displayed.
55 . Retract the cylinder slightly until NOT LATCHED is
disp layed.
th e cylinder bottoms out.
57. With the cylinder bottomed out in T3, go back into
RCL display calibration screen
58 Press EXTENSION SENSORS.
59 . Press SET PIN/LATCH POSITION and confirm with
YES o
60. Switch to PIN and bump the cylinder toward ex
tend direction . The PINNED and NOT LATCHED
lights should be on .
61 . Retract the cylinder to 11.5". Extend or Retract
slightly to obtain the PIN CENTERED light.
6 of 8
Testing 6. Fully extend and retraet boom at 30° boom angle
without load.
7. Put boom in EM4 mode.
A DANGER
Testing must be done by a qualified, trained
8.
9.
Fully extend and retraet boom at 75 o boom ang le
without load .
0
Fully extend and retraet boom at 30 boom angle
operator. Follow all limitations and without load.
requirements as specified in the Crane Rating 10. Put boom in EM1 mode.
Manual. Do not perform any lifting with the 11. With 12,000 lb (5 448kg) load, lully extend and re
crane unless you are a qualified, trained traet boom at 75 o boom angle.
operator. 12. Put v in EM3 mode.
13. With 12 ,000 lb (5 448kg) load , lully extend and re
0
1. Put boom in EM1 mode. traet boom at 75 boom angle.
2. Fully extend and retraet boom at 75 o boom angle 14. Put boom in EM4 mode .
without load. 15. With 12 ,000 lb (5 448kg) load, lully extend ancl re
0
3. Fully extend and retraet boom at 30 boom angle traet boom at 75 o boom angle.
without load. 16. II problems oeeur during testin g, reea librate , re
4. Put boom in EM3 mode. pair, and/or troubleshoot as required.
5. Fully extend and retraet boom at 75 o boom angle
without load.
7018
8018
6. Remove capscrews (62) and capscrews a nd
Boom Telescope Cylinder washers (67) which secure the wear pads (6 1,66)
Mechanism, Recondition in the end of the hose tube (19). Remove the wear
pads (61,66).
7. Attach a pull cord to the ends of the hoses (4,5) an d
wire harness (14) to facilitate installation of t he
telescope cylinder mechanism used in the four
hoses (4,5) and wire harness (14) during assem
section boom. For removal and installation
bly. Be sure the connectors on the wire Ilarn ess
procedures, see 4-Section Boom, Recondition in SM
(14) are separated and neatly secured to the hoses
(4,5) with cable tieso Cable tie in a way that m ini
Disassembly mizes the overall size of the items being pulled
through the hose tube (19).
The weight and center of gravity of the telescope
8. Pull the hoses (4,5) and wire harness (14) out of 1he
cylinder mechanism will change during the assembly
hose tube (19). After the hoses (4,5) and wire ha r
process. Even after fully disassembled, the hydraulic
ness (14) are removed, disconnect the pull corel
oil within the telescope cylinder may move back and
and leave it laying in the hose tube (19).
forth within the cylinder while handling it. It is essential
that a double sling lift is used to maintain control of the
telescope cylinder mechanism during handling.
CAUTION
Note: The entire telescope cylinder mechanism Do not kink or crush the pressu re or return
weighs approximately 3,600 lb (1 633kg), depending hoses. These hoses are made of special,
on its stage of disassembly and the amount of hy flexible materials which are extra durable for
draulic oH in the cylinder. Individually, the telescope this application. However, the sam e hoses are
cylinder weighs approximately 3,000 lb (1 361kg). easily damaged if mistreated. Do not stand,
drive, or place concentrated loads on the
hoses or hoses may have to be re placed.
A WARNING
9. Fold each of the links on the hose chain (55) down
to expose the hoses (4,5) and wire harness (14).
10. Remove the capscrews and locknuts (50) and
clamps (49) used to secure the hoses (4,5) to the
channel (1).
11. Remove the capscrews, washers, and locknuts
(51) and extension and clamp (56).
cleaning solutions.
12. Cut the cable ties securing the wire harness (14) to
the hoses (4,5).
1. Drain any excess hydraulic oil, remaining within
13. Removethe hoses (4,5) and wire harness (14) from
the telescope cylinder, into an appropriate contain
the hose chain (55).
er. Properly store or dispose of the used oil.
14. Remove the screws, washers, and locknuts (52)
2. Cap/plug any openings in the telescope cylinder.
which secure the hose chain (55) to the channel
Thoroughly clean the exterior surface of the tele
(1) .
scope cylinder mechanism to prevent contamina
15. Remove the screws and washers (63) which se
tion.
cure the hose chain (55) to the channel (1). Re
Refer to Figure 1. move the hose chain (55).
3. Remove the locknuts and clamps (16) which se 16. Remove the capscrews, washers, and locknuts
cure the hoses (4,5) to the wire harness bracket (20) securing the wear pad (18) in the channel (1).
(15). Remove the wear pad (18).
4. Remove the capscrews and washers (17) which 17. Remove the hose tu be (19) from the channels (1).
secure the hose tu be (19) to the wire harness 18. Cut any cable ties used to secure the loose wires
bracket (15). and wire harness (14) at the rod end of the tele
5. Remove the locknuts (64) and clamps (65) which scope cylinder (35).
secure the hoses (4,5) to the hose tu be (19).
1 of 12
19. Disconnect the wire harness (14) from each of the 41 . Remove the capscrews and washers (42) that se
sensors (37,38,40 ,78,45). cure the wire harness bracket (15) to the bracket
20 . Remove the capscrews and locknuts (53) and on the telescope cylinder (35). Remove the wire
clamps (54) which secure the hoses (4,5) along the harness bracket (15).
top of the channels (1) . 42 . Remove the spacers , capscrews, and washers
21. Disconnect the hoses (4 ,5) from the crossover (24) which secure the pivot (25), bracket (28), and
valve (3) . latches (30) to the telescope cylinder (35) . Re
22 . Disconnect the hoses (9, 21) from the crossover move the pivot (25) , bracket (28) , and latches (30).
valve (3) and latching cylinder (10). Remove the
hoses (9,21 ).
23. For assembly purposes, label the not latched sen
sors (78). Remove the not latched sensor (78) from
A DANGER
Stay clear of the telescope cylinder as it is
the bracket (77). lifted and handled during the disassembly
24. Remove the capscrews , washers, and locknuts process. If proper precautions are not
2,6) and clamp (76) securing the crossover valve fOllowed, parts could shift suddenly and/or
(3) and brackets (7,77) to the channel (72). Re fall, resulting in severe personal injury, death,
move the crossover va lve (3) and brackets (7,77) . and/or component damage. Use only lifting
25. Remove the capscrews and washers (48) which devices and rigging of adequate size and
secure the channels (1) to the top of the telescope capacity to handle the telescope cylinder.
cylincler (35). Remove the channels (1) .
26. Re move the capscrews (75) , washers (74), an d 43 . Position the telescope cylinder (35) on a sturdy
bu mpers (73) which secur e the two sided chan work surface so the bottom of the telescope cylin
neis (72) to the top of the telescope cylinder (35) . der (35) is facing up.
Remove the channels (72) . 44 . Remove the spacers, capscrews, and washers
27. Remove the pin , washer, & cotter pin (8) which (84) which secure the latches (34) and bracket (85)
connect the latching cylinder (10) to the slider as to the telescope cylinder (35) . Remove the latches
sembly (11) . (34) and bracket (85).
28. Remove the pin , washer, and cotter pin (12) that 45 . Remove the capscrews and washers (79) that se
connects the latching cylinder (10) to the bellcrank cure the nylon slider wear pads (80) tothe slider as
(22). Re move the latching cylinder (10). sembly (11) .
29. Remove the shoulder scr ews (27,29) that secure 46 . Remove the capscrews , washers, and locknuts
the bellcrank (22) tothe linkages (23,46) . Remove (13) that secure the slider mounting bracket (81) to
the bellcrank (22) . the slider assembly (11) . Remove the slider
30. For assemb ly purposes , label the front and rear pin mounting bracket (81) .
pull er sensors (45). 47. Remove the capscrew, washer, locknut, and
31. Rem ove the sensors (45) from the bellcrank (22). spacer (82) securing the wedge (83) to the slider
32. Remove the capscrews and wear block (47) from mounting bracket (81). Remove the wedge (83).
tl1e bellcrank (22) . 48. Remove the slider assembly (11) .
33 . Remove the shoulder screws (26) that secure the 49 . Remove the capscrews and locknuts (58) and pins
drivin g linkage (23) and idler linkage (46) to the (59) securing the nose wheels (60) to the nose
bellcrank (22). Remove the linkages (23,46). guide (57). Remove th e nose wheels (60) .
34 . For assembly purposes , label the pinned and not 50. Remove the capscrews and locknuts (70) and pins
pinned sensors (37,40) . (71) which secure the nose guide (57) to the tele
35 . Remove the screws , washers , and locknuts scope cylinder (35). Remove the nose guide (57).
(36,41) that secure the sensors (37,40) to the 51 . If necessary, remove the capscrews, washers, and
brackets (33,43). locknuts (69) which secure the wear pads (68) to
36. Remove the capscrews and washers (32,44). the nose guide (57) ; remove the wear pads (68).
37. Remove the capscrews and washers (31) and the 52. Remove the counterbalance cartridges (86,87)
brackets (33,43). from the rod end of the telescope cylinder (35).
38. For assembly purposes , label the latched sensor Cover the openings in the telescope cylinder (35)
(3 8). to prevent contamination .
39. Remove the latched sensor (38) from the bracket 53. If necessary, remove the bushings from the latches
(39). (30,34), latching cylinder (10), pivot (25), and link
40. Remove the capscrews , washers, and bracket ages (23,46) .
(39) . 54. If necessary, recondition the telescope cylinder
(35) . See SM Keysheet Area SM17 -002 .
2 of 12
Cleaning And Inspection Assembly
The weight and center of gravity of the teles cope
A WARNING
cylinder mechanism will c hange during the assembly
process . Even after fully assembled, the hydraulic oil
within the telescope cylinder may move back and forth
hazardous. Serious personal injury may within the cylinder while handling i!. It is essential that a
result from misuse of these products. Read double sling lift is used to maintain control of th e
telescope cylinder mechanism during handling .
Note: The entire telescope cylinder mechanism
cleaning solutions.
weighs approximately 3,600 lb (1 633kg), dependíng
1. Thoroughly clean all metal parts with an approved on its stage of disassembly and the amount 01 hy
cleaning solven!. Place parts on a clean, lint free draulic oil in the cylinder. Individually, the telescope
surface and allow to air dry. Exercise every precau cylinder weighs approximately 3,000 lb (1 361kg).
any other foreign material cluring assembly. Refer to Figure 1 .
2. AII Loctite®, Permatex®, or other sealant resiclue 1. Apply Loctite® 242 to the capscrews (47) .
should be removed from threacls of hardware ancl 2. Align the wear block (47) on the new bellcrank (22)
the mounting surfaces of parts that are going to be and install the capscrews (47). Torque the cap
reused . Prior to applying new thread locking com screws (47) to 60-70 ft lb (82-94Nm) .
pounds or sealants, clean threads and surfaces 3. If removed , press the bushings into the latches
with Loctite® 7070 Cleaner to ensure best perfor (30,34) , linkages (23 ,46) , latching cylincler (10) ,
and pivot (25) .
mance of products.
3. Carefully inspect all components for damage , 4. Insert the spacer (82) in the mounting hole of the
wear, fatigue or stress fractures, corrosion, deep wedge (83).
5. Apply Loctite® 242 to the threads of the capscrew
burrs or sharp edges with a fine file, hone, emery (82).
cloth, or crocus cloth. Replace any damaged com 6. Position the slider mounting bracket (81) above the
ponent , as required . wedge (83), and insert the capscrew (82) through
4. Al! "soft parts" , such as seals, gaskets , back up the slider mounting bracket (81), spacer (82), and
rings , and 0- rings , should be replaced. wedge (83).
5. Replace the capscrews used to mount the top and 7. Install the washer and locknut (82) which secures
bottom latches. Also use new cotter pins to ensure the wedge (83) to the slider mounting bracket (81) .
the installation of all pinned components.
6. Nylon wear pads, latch and bellcrank bushings,
ancl slider assembly should be inspected closely A DANGER
Stay clear of the telescope cylinder as it is
and evaluated for wear and damage. Replace
ment of these parts is recommended if worn or lifted and handled during the assembly
damaged . process . If proper precautions are not
7. The wear block , used to operate the pin puller in followed, parts could shift suddenly an d/or
the boom, should be inspected to see that the top fall, resulting in severe personal injury, death ,
and bottom wear surfaces are smooth . Remove and/or component damage. Use only lifting
any burrs or sharp edges with a fine file , hone , devices and rigging of adequate size and
emery cloth, or crocus cloth. Replace the wear capacity to handle the telescope cylinder.
block if it has worn down to a height of 0.94 in
(23.8mm) or less. 8. Position the telescope cylinder (35) on a sturcly
8. In the event of severe defects, contact factory per work surface so the bottom of the telescope cylin
der (35) is facing up.
3 of 12
9. If necessary, rotate the rod end of the telescope 22. Ensure the latches (30) and bracket (28) are prop
cylinder (35) to correctly orient the counterbalance erly oriented. Torque the capscrews (24) to
cartridges (86,87). 325-360 ft lb (441-488Nm).
10. Position an oil collection container under the coun 23. Manually actuate the slider assembly (11) so the
terbalance cartridges (86,87). top and bottom latches (30,34) operate smoothly.
11. Install the counterbalance cartridges (86,87) in the If necessary, disassemble the latches (30,34) and
telescope cylinder (35). Torque the counterbal remove any contamination. Grind smooth and re
ance valve (86) to 45-50 ft lb (61-68Nm) and the move any metal burrs from the latches (30,34) or
counterbalance cartridges (87) to 150-160 ft lb telescope cylinder (35), which prevent free move
(203-217Nm). ment of the latches (30,34).
12 . Apply Loctite® 242 to the capscrews (84) which se 24. Install the bracket, capscrews, and washers (39).
cure the latches (34) to the telescope cylinder (35). 25. Install the latched sensor (38) to the bracket (39).
13. Align the holes in the latches (34) and bracket (85) 26. Adjust the latched sensor (38) as follows:
with the tapped holes in the telescope cylinder a. Move the slider assembly (11) all the way to the
(35), and install the spacers, capscrews, and rearo
washers (84). b. Position the sensor (38) face 1/8-1/4 in
14. Ensure the latches (34) and bracket (85) are prop (3 -6mm) from the wedge (83) on the slider as
erly oriented, and torque the capscrews (84) to sembly (11).
325-360 ft lb (441-488Nm). C. Torque the jam nuts on the sensor (38) to 18 ft lb
15 Position the telescope cylinder (35) on a sturdy (24Nm).
working surface so the top side of the telescope 27. Apply Loctite® 262 to the threads of the shoulder
cylinder (35) is facing up. screws (26,27,29).
16. Positlon the wear pads (80) inside the rails on the 28. Install the driving linkage (23) and idler linkage (46)
telescope cylinder (35) with the mounting holes using the shoulder screws (26). Torque the shoul
aligned. der screws (26) to 100-110 ft lb (136-149Nm).
17. Position the slider assembly (11) over the tele 29. Install the pin puller sensors (45) in the bellcrank
scope cylinder (35), and align the slider mounting (22), and secure with jam nuts. Adjust the sensors
bracket (81) with the mounting holes of the slider (45) so the faces are 1 in (2. 54cm) above the
assembly (11). mounting surface. Torque the jam nuts to 18 ft lb
18. Install the capscrews and washers (79) thatsecure (24Nm).
the wear pads (80). 30. Install the bellcrank (22) using the shoulder screws
19 Install the capscrews, washers, and locknuts (13) (27,29). Torque the shoulder screws (27,29) to
which secure the slider mounting bracket (81) to 100-110ftlb (136-149Nm).
the slider assembly (11). 31. Apply Loctite® 242 to the threads of the capscrews
20. Apply Loctite® 242 to the capscrews (24) which se (31).
cure the latches (30) to the telescope cylinder (35). 32. Install the sensor brackets (33,43) using the
21. Align the holes in the latches (30), bracket (28), capscrews and washers (31).
and pivot (25) with the tapped holes in the 33. Install the not pinned sensor (37) using the screws,
telescope cylinder (35), and install the spacers, washers, and locknuts (36).
capscrews, and washers (24). 34. Install the pinned sensor (40) using the screws,
washers, and locknuts (41).
Note: The top left latch has a sensor bracket
welded to it, make sure it is proper oriented.
4 u: 12
1. Channels - Three Sided 30. Latch es 59. Pins

2. Capscrews, Washers , & Locknuts 31. Capscrews & Washers 60. Nose Wheels
3 Crossover Valve 32. Capscrew & Washers 61. Wear Pad
4. Pressure Hose 33 Bracket - Not Pinned Sensor 62 Capscrews
5. Return Hose 34. Latches 63. Screws & Washers
6. Capscrews, Washers, & Locknuts 35. Telescope Cylinder 64 . Locknuts
7. Bracket - Crossover Valve 36. Screws, Washers, & Locknuts 65 Clamps
8. Pin, Washer, & Cotter Pin 37. Sensor - Not Pinned 66. Wear Pad
9. Hose 38. Sensor - Latched 67. Capscrews & Washers
10. Latching Cylinder 39 . Bracket, Capscrews, & Washers 68. Wear Pads
11. Slider Assembly 40. Sensor - Pinned 69. Capscrews, Washers, & Locknuts
12. Pin, Washer, & Cotter Pin 41. Screws, Washers, & Locknuts 70 Capscrews & Locknuts
13. Capscrews, Washers, & Locknuts 42 . Capscrews & Washers 71. Pins
14. Wire Harness 43. Bracket - Pinned Sensor 72. Channels - Two Sided
15. Wire Harness Bracket 44 Capscrew & Washers 73. Bumpers
16. Clamps & Locknuts 45. Sensors - Pin Puller 74 . Washers
17. Capscrews & Wa shers 46. Linkage - Idler 75. Capscrews
18. Wear Pad 47. Wear Block & Capscrews 76. Clamp
19. Hose Tube 48. Capscrews & Washers 77. Bracket - Not Latched Sensor
20. Capscrews, Washers, & Locknuts 49. Clamps 78. Sensor - Not Latched
21 . Hose 50. Capscrews & Lockn uts 79. Capscrews & Washers
22. Bellcrank 51 . Capscrews, Washers, & Locknuts 80. Wear Pads
23. Linkage - Driving 52. Screws, Washers , & Locknuts 81 . Slider Mounting Bracket
24. Spacers, Capscrews, & Washers 53 Capscrews & Locknuts 82. Spacer, Capscrew, Washer, & Locknut
25. Pivot 54. Clamps 83. Wedge
26 Shoulder Screws 55. Hose Cha in 84. Spacers, Capscrews, & Washers
27. Shoulder Screw 56. Extension & Clam p 85. Bracket
28. Bracket 57. Nose Guide 86. Counterbalance Cartridge
29. Shoulder Screw 58. Capscrews & Locknuts 87 . Counterbalance Ca rtridge
Figure 1
Boom Telescope Cylinder Mechanism - Continued On Next Page
5 of 12
18
17
16
5
15
6
5 7
¡ "'
·tv ~ :=:
41 ---L_
26
40
27
28
39 29
Boom Telescope Cylinder Mechanism - Continued
6 of 12
Service Manual 02 11 SM17-002-090.00
50
51
52
_---'<-- 57
\ _ :-c/~~ .<
JI I .t-, ~- 58
/I:¡T I
/
/
- ~/
59
60
7 of 12
75
1
r 1
I
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[ I 1
1
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74 1 I I ./
1
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,1, 1 _
~" t
./ I
_/\ 72
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8 of 12
, I
1' . r I I
76
77
Alternate Style Crossover

Valve And Mounting
80
35
34---1-.-'-
85---r-~
90112
35. Ap ply Loctite® 242 to the threads of the capscrews 52. Position the wear pad (18) inside the channel (1),
(32 ,44). and install the bottom capscrew, washers, and
36. Install the capscrews and washers (32,44). Use locknut (20) . The capscrew and locknut (20)
two washers (32,44) under each bolt (32,44) for ini should be tightened fully.
tial ad justment. After the telescope cylinder 53. Install the top capscrew, washers, and locknut
(35) assembly is slid into the boom sections , the fi (20). Tighten this capscrew (20) justfar enough to
nal adjustments will be made. engage the nylon insert within the locknut (20). No
37. Connect the latching cylinder (10) to the driving clamping force is intended. Over tightening the
Iin kage (23) using the pin, washer, and cotter pin capscrew and locknut (20) will damage the wear
(12) . pad (18) and prevent free movement of the hose
38 . Align the mounting holes in the latching cylinder tube (19).
(10) clevis with the lug on the slider assembly (11), 54. Layout the pressure hose (4) and return hose (5)
an d install the pin, washer, & cotter pin (8) on a clean flat surface to ensure allloops and twists
39 . Arrange the three sided channels (1) on top of the in the hoses (4,5) are uncoiled .
telescope cylinder (35). Make sure the channel (1), 55. Position the crosSOver valve (3) and brackets
located nearest the rod end of the telescope cylin (7 ,77) on the channel (72), and install the caps
der (35) , has alignment tabs on only one end. crews, washers, and locknuts (2,6) and clamp (76)
40. Arrange the two sided channels (72) on top of the securing the crossover valve (3) and brackets
telescope cylinder (35) . Make sure the channel (7,77) to the channel (72). See Detail H.
(72), located nearest the nose guide (57) , has cut 56. Install the not latched senSOr (78) on the bracket
outs at only one end. (77).
41. Interlock the alignment tabs on each of the chan 57. Adjust the not latched sensor (78) as follows :
neis (1 ,72) such that all channels (1,72) are butted a. Move the slider assembly (11) all the way for
tog ether. It may be necessary to bend the align ward.
men t tabs open slightly to allow the channels b. Position the sensor (78) face 3/16-5/16 in
(1,72) to properly fit together. (4-8mm) from the target on the slider assem
42. Ap ply Loctite® 242 to the threads of the capscrews bly (11).
(75,48) . c. Torque the jam nuts on the sensor (78) to 18 ft lb
43. Secure the two sided channels (72) by installing (24Nm).
the bumpers (73) , washers (74), and capscrews 58. Install the hoses (9,21) between the the crossover
(75) . valve (3) and latching cylinder (10).
44. Secure the three sided channels (1) by installing
the capscrews and washers (48) .
45. Any alignment tabs which were bent open to en
sure the fit of the channels (1 ,72) should be ham
CAUTION
mered flat. Do not kink or crush the pressure or return
46 . After fully securing the channels (1), ensure the ny hoses. These hoses are made of special,
lon wear pad (18) can move freely within the chan flexible materials which are extra durable for
neis (1) from end to end . It may be necessary to this application. However, the same hosesare
"over bend " the channels (1) slightly to ensure easily damaged if mistreated. Do not stand,
smooth movement of the wear pad (18). drive, or place concentrated loads on the
47. Install the hose tu be (19) by positioning the hose hoses or hoses may have to be replaced.
tu be (19) inside the channels (1) with the top
against the left side of the channel (1) . Raise the 59. Connect the pressure hose (4) and return hose (5)
hose tube (19) while rotating until the bottom to the crossover valve (3).
swin gs into place. 60. Clamp the pressure hose (4) and return hose (5)
48 . Slide the hose tube (19) as far forward as possible. along the channels (72) using the clamps (54) and
49. Apply Loctite® 242 to the threads of the capscrews capscrews and locknuts (53). The hoses (4,5)
(62 ,67). must be straight and untwisted before tightening
50. Install the bottom wear pad (61), aligning the holes the clamps (54).
in it with the holes in the hose tube (19) bracket. 61. Connect the wire harness (14) to each of the sen
Install the capscrews (62) . sors (37,38,40,78,45) .
51 . Install the top wear pad (66), aligning the holes in it
with the holes in the hose tube (19) bracket. Install
the capscrews and washers (67).
10 of 12
62, Route the wire harness (14) under the hoses (4,5) and neatly secured to the hoses (4,5) in oppos ite
to ensure they are protected , Wires should not be directions to minimize the overall size of the items
tight. Use cable ties to secure the loose wires and to be pulled through the hose tube (19) .
wire harness (14) , 77, While beginning to pull the cord , feed the hoses
(4 ,5) and wire harness (14) into the hose tube (19).
Note: If a new hose chain is being installed, re Keep the return hose (5) on the bottom of the hose
move one of the end mounting links and rein tube (19) , Remove the cable ties as the hoses (4,5)
stall it 180 0 from it's original position. 80th and wire harness (14) enter the hose tube (19) ,
mounting links must be located on the same
side of the hose chain . Note: Wait until the hoses are secured at the
nose guide end of the hose tube befo re instal
63 . Position the hose chain (55) within the channels ling the clamps.
(1) , When open , the links should fold downward.
64 , Install the screws, washers, and locknuts (52) to 78. Open a few links on the hose chain (55) near the
secure the end of the hose chain (55) to the chan center of the hose chain (55),
nel (72), 79. Place an index mark on each of the hoses (4 ,5)
65, Install the screws and washers (63) to secure the where the hoses (4,5) meet the end of the hose
other end of the hose chain (55) to the hose tube chain (55).
(19) , 80, From the area where the links are open in the cen
66, Open each of the links on the hose chain (55) . ter stretch of the hose chain (55), pull the hoses
67 , Feed the pressure hose (4) and the return hose (5) (4,5) into the hose chain (55) so the index marks
into the hose chain (55), Be sure to locate the pres are approximately 2 in (5. OBem) from the end of the
sure hose (4) in the bottom of the hose chain (55). hose chain (55).
68, Secure the hoses (4 ,5) to the channel (72) by 81 , Secure the position of the hoses (4 ,5) by installing
installing the the extension and clamp (56) using the clamps (65) and locknuts (64),
the capscrews , washers , and locknuts (51). 82. After the hoses (4,5) are secured by the clamps
69 , Ensure the hoses (4,5) make a smooth loop , and (65), push the hoses (4 ,5) into the hose chain (55)
install the clamps (49) and capscrews and lock and close the open links. Use cable ties to secure
nuts (50) , the wire harness (14) to the hoses (4 ,5),
70 , Secure the wire harness (14) to the loop in the 83, Apply Loctite® 242 to the threads of the capscrews
pressure hose (4) and the return hose (5) with (17) .
cable ties , 84. Align the wire harness bracket (15) to the hose
71, Feed the wire harness (14) into the hose chain (55), tube (19) , and install the capscrews and washers
and close the links after the pressure hose (4), re (17) .
turn hose (5) , and wire harness (14) are neatly and 85 . Secure the wire harness bracket (15) to the bracket
uniformly in place , on the telescope cylinder (35) using the capscrews
72, Position the remaining length of the pressure hose and washers (42).
(4), return hose (5), and wire harness (14) out in 86, Secure the hoses (4,5) using the clamps and lock
front of the telescope cylinder (35) assembly. Lay nuts (16) ,
the hoses (4,5) and wire harness (14) tlat to ensure 87. Apply air pressure, 120 psi (B25kPa) maximum , to
allloops and twists are removed, the pressure hose (4) , then to the return hose (5) to
73. Install cable ties every 24 in (60em) to maintain the test the operation of the latching mechanism . The
smooth and uniform arrangement of the pressure mechanism must slide smoothly in both directions
hose (4) , return hose (5), and wire harness (14). and the latches (30,34) must open and close com
74, Inspect the inside diameter of the hose tu be (19) to pletely.
ensure the edges are smooth and do not contain 88. While operating the latching mechanism with air
any rough or sharp edges that could damage the pressure, check the adjustment of the latched and
pressure hose (4), return hose (5), and wire har not latched sensors (38,78) . Repeat Assembly
ness (14) . Smooth any sharp edges with a fine file. Steps 26 and 57 if necessary.
75 , If the pull cord was inadvertently removed from the 89, If removed , align the wear pads on the nose guide
hose tube (19) , use compressed air to blow a pull (57). Install the capscrews, washers , and locknuts
cord through the entire length of the hose tube (69) which secure the wear pads (68) to the nose
(19) . guide (57) .
76. Attach the nose guide end of the pull cord to the 90. Align the nose guide (57) with mounting holes on
hoses (4,5) and wire harness (14). Be sure the the telescope cylinder (35) , and install the pins (71)
connectors on the wire harness (14) are separated and capscrews and locknuts (70).
11 of 12
SM17 -002-090.00 0211 Service Man:ual
91 . Position tlle nose wheels (60) on the nose guide Note: After cycling the latch mechanism with air
(57). Insert the pins (59) through the nose guide pressure, leave the latches in the unlatched posi
(57) and nose wheels (60). tion.
92 . Secure the nose wheels (60) to the nose guide (57)
by installing the capscrews and locknuts (58) . 93. If the telescope cylinder mechan ism is not to be im
mediately installed on crane, plug all open ports to
12 of 12
1. Straps 3. Gland 5. Rod End

2. Case 4. Rod
Figure 1
Typical Cylinder Support
2. Adjust the height of the support at the rod end (5) to

Boom Hoist Cylinder, be sure rod (4) is centered in gland (3).
Recondition 3. Secure case (2) to supports w ith straps (1), to pre
vent it from rolling or sliding during disassembly.
This procedure covers the recondition of the boom
hoist cylinder. For removal and installation proce
dures, refer to SM Keysheet Area 17 -003.
Table B illustrates the design of the spanner wrench
A WARNING
needed to disassemble and properly torque the piston concerning solvents and cleaning solutio ns.
during assembly. Serious personal injury may result fro m
Disassembly misuse of these products.
Refer to Figure 1 .
4. Plug open ports of the cylinder. Thoroughly clean
1. Firmly support the cylinder at the rod end (5) and exterior surface of cylinder with an approved clean
three places equally spaced along case (2). Refer
er to prevent contamination during disassembly.
to Table A to determine the weight of the cylinder
1 of 6
8 6 7
11 16 17
11 18 19 20
1 Bushing 6. Back Up Ring 11. Gland 16. O-ring

2. Wea r Rings 7. O-ring 12. Wear Ring 17. Back Up Ring
3. Piston 8. Rod 13. O-ring * 18. Step Seal *
4. Stop Tube 9. Bearing 14. Piston Seal 19. Rod Seal
5. Nylon Plug * 10. Case 15. O-ring 20. Wiper
* Some cyllnder assembli es do not utilize these items.
Figure 2
Boo m Hoist Cylinder
2016
Service Manual 0711 SM17-003- 01 3~OO
Case Wet Retracted Wet Extended Oil Capacity Oil Capacity Test
Diameter Weight Weight Retracted Extended Pressure
in cm lb kg lb kg gal L gal L psi kPa
8.25 20.96 865 393 926 420 7.48 28.31 16.01 60.60 5,250 36 198
*9. 75 24.77 1,720 780 1,846 837 14.40 54.51 31.80 120.38 4,500 31027
+9.75 24. 77 1,040 472 1,102 500 13.40 50.72 21.90 82.89 4,350 29993
10.00 25.40 1,243 564 1,317 598 14.00 52.99 24.20 91.60 4,725 32578
ti 0.00 25.40 1,839 835 1,975 897 14.60 55.26 33.40 126.45 5,250 36198
*11.00 27.94 1,517 689 1,594 724 18.40 69.64 29.10 110.14 4,350 29993
+11.00 27.94 2,228 1012 2,385 1083 21.60 81.76 43.30 163.89 4,900 33786
t11.00 27.94 2,515 1 142 2,714 1232 17.20 65.10 44.70 169.19 5,000 34 4 75
11.25 28.58 2,590 1 176 2,810 1276 18.50 70.02 49.50 187.36 4,500 3102 7
11.50 29.21 2,692 1222 2,938 1334 16.20 61.32 50.20 190.0 1 5,000 34 475
14.50 36.83 3,880 1 760 4,180 1896 30.80 116.60 71.70 271 .41 5,000 34475
15.75 40.00 4,156 1887 4,492 2040 45.14 170.85 89.64 339.29 5,000 34 4 75
• Cranes which use one boom hoist cylinder.
+ Cranes which use two boom hoist cylinders.
t Boom hoist cylinder with integral counterbalance valves, (cartridges mounted in cy linder case vs. manifold block).
Table A
5. Prepare to extend the cylinder rod which may pro 8. Using an auxiliary lifting device, carefully slide the
duce a flow of oil from the supply andjor return rod (8), gland (11), stop tube (4), and pisto n (3) out
ports of the cylinder case. Remove the plugs of case (10) , and place in an area where it can be
which were installed in the cylinder during the disassembled without damaging the chrome on
cleaning process. Place a container, of adequate the rod (8) or individual parts.
size, below the open ports. Refer to Table A to de Refer to Figure 2.
termine how much oil may be contained in the cyl 9. Use a spanner wrench to rotate gland (11) until its
inder. threads disengage case (10).
6. Fully extend, then fully retract the rod (4) to com
pletely drain the oil. Properly store or dispose of
used oil. CAUTION
7. Extend rod (4) approximately half way. The length Use care not to damage the chrome finish on
of the exposed portio n of the rod (4) should be the piston rod. Any nicks or scratches could
equal to half the length of the cylinder case (2). Ad result in cylinder leakage. Weld splatter may
just the support under the rod (4), as required, to also do damage. When using a vise, clamp to
ensure the rod (4) is centered within the gland (3). portions of the rod which are not chrome
plated , or protect the chrome surfa ce wilh a
soft material before clamping.
CAUTION
The cylinder must be adequately supported 10. Use special tool shown in Table B to rotate piston
and the rod centered within the gland before (3) until its threads disengage from the rod (8).
attempting to disassemble the cylinder. An 11 . Remove and discard wear rings (2) , piston seal
improperly supported cylinder will sag at the (14), and o-ring (15) from piston (3) .
gland, causing irreparable damage to the 12. Remove the back up ring (6) and o-ring (7) from the
threads, as the gland is removed. rod (8).
13. Remove nylon plugs (5) from rod (8), if equipped.
3 of 6
SM1 7 - 003-013.00 0711 Service Manual
14. Remove the stop tu be (4) from the rod (8) . Assembly
15. Sli de gland (11) off the rod (8).
16. Remove and discard o-ring (16), back up ring (17),
red seal (19), o·ring (13) and wiper (20) from the
gland (11). A WARNING
17. Remove the wear ring (12), step seal (18) and ny
lon plug (5) from the gland (11), if equipped. concerning lubricants, sealants, joint and
18. Remove the bushing (1) from the case (10) and the thread locking compounds, etc. Serious
bearing (9) from the rod (8) if worn or damaged. personal injury may result from misuse of
these products.
Cleaning and Inspection
Lubricate seals, o-rings, back up rings, wear rings, cyl
A WARNING
inder case bore, bushing and bearing with Cos
molube ® No. 2 or equivalent prior to assembly. Use
care to avoid getting the lubricant on the threaded por
hazardous . Serious personal injury may tions of the cylinder case, rod, piston and gland .
and foll ow all the manufacturer's Refer to Figure 2.
recommendations concerning solvents and Soak new pisto n seal (14) , wiper (20) , rod seal (19) and
cleaning solutions. if equipped, step seal (18), in clean hydraulic oil which
has been heated to a temperature of 100-120°F
1. Thoroughly clean all metal parts with an approved (39-49 °C) . Allow adequate time for the parts to reach
cleaning solvent. Place parts on a clean, lint free the temperature of the hydraulic oil which will greatly
surface and allow to air dry. Exercise every precau ease their assembly.
tion possible to keep all parts free of dust, dirt , or
1. Press the bushing (1) into the case (10) and the
bearing (9) into the rod (8).
2. Install the o-ring (16), back up ring (17), rod seal
wear, corrosion , deep scratches, and scuffed met
(19), o-ring (13) and wiper (20) in the gland (11).
3. Install the wear ring (12), step seal (18) and nylon
file, hone, emery cloth, or crocus cloth. Replace
plug (5) in the gland (11), if equipped.
any damaged component as required . Replace all
4. Install the wear rings (2), o-ring (15) and piston seal
seals, o-rings, and back up rings.
(14) in the piston (3).
3. The cylinder case (10) bore should be thoroughly
5. Install a thin layer of masking tape over the threads
cleaned with an approved cleaner and carefully in
of the rod (8).
spected for signs of "scoring" or deep scratches.
In the event of severe defects, contact factory per
the cylinder case.
CAUTION
Threaded surfaces are sharp. Use care to
4. AII Loctité ¡', Permatext!ll , or other sealant residue
prevent damage to seals or o-rings during
installation of components on to rod or during
installation of rod and piston assembly into
case.
with Loctite ® 7070 Cleaner to ensure best perfor
6. Carefully slide the gland (11) onto rod (8) taking
mance of products.
care not to damage the seals. A slight oscillating
motion should be used to enable the lips of seals
to slip onto and past the shoulder of the rod (8).
Slide the gland (11) at least half way up rod (8).
4 of 6
Use ASTM A514-90

...
R 1.0
2 Plaees í
Material, or Equivalent.
0.625 - 11 NC
2 Plaees
r_
---
7.75
1.25 Grade 8 Capserew Head

I
.~
f
2.0
~. - ~~~ ,r- - - - - qJ
\
;I¡\g
~
J~
/
;'0 ~
.. ..
I I
'-<.~.Y
r=
I
....
0#
A - -'
Hall 01 Dimension ''t<'
- ~ 2.12
r
1+5 [
1
1- -11
1 1 11
15.5
,
1 , --,
•
Maximum 0.125 Weld
11
11 1 11
i
~ ~ I~~
I
~
11 11
I 11 -.ll
I
Notes: • AII dimensions are in inehes .
• Maehining Toleranees are as follows: 0.625 - 11 NC Grade 8
.X ±0.1 (Minimum Thread Length of 2.00)
.XX ±0.015
)<XX ± 0.003
• Additional sets of holes may be added to
aeeommodate other pistons, as spaee allows. I TTI
I
--
Induetion Harden to Re 50-60 ~
--== J_
0.5
0.484 ~
IT
~
Boom Hoist Cylinder With Crane Serial Number Prefix Dimension "Pt ±O.03 in
69 & 71 6.00
53,57,58,59,63,64,65,70,06,07, E1, E8, E9, F2, F3, F7, F8, J9, N3, 7.00
N4, P9, R2, R8
J6, L8 7.25
J7 11.25
J8, R3, S1 12.75
Table B
Piston Removal And Installation Tool
5 of 6
7. Slide stop tube (4) onto the rod (8) . the cylinder rod at a steady rate. II the cylinder
8. Install o -ring (7) and back up ring (6) onto the rod squeaks or sticks , disassemble the cylinder and
(8). replace any defective parts and repeat the entire
9 . If equipped, install the nylon plugs (5) in the holes test procedure.
in the rod (8) and trim flush with the outer diameter 3. Stop the rod at mid stroke and examine the cylin
of the t hreads . derfor any externalleakage. No leakage is accept
10. App ly Loctite@242 to the threads of the piston (3). able. If leakage is found, disassemble the cylinder
11 . Carefully slide the piston (3) on rod (8) to avoid and replace the defective parts, as required; re
damaging the o-ring (7) and back up ring (6) . Start peat the entire test procedure.
threads by rotating piston (3) by hand . After piston 4 . Fully retract the cylinder.
(3) is started , linish tightening by using special tool 5. Gradually pressurize the extend port, at a pressure
shown in Table B. increase 01 one to ten percent of the cylinder wark
12. Tarque to 1,200 ft lb (1 627Nm). ing pressure per minute, until rod movement is initi
ated . Pressure to initiate rod movement or "break
Refer to Figure 1. away" pressure, shall not exceed 120 psi (827kPa).
13. Place three equally spaced supports along case 6. Once the breakaway pressure is determined, the
(2) . pressure needed to maintain movement of the cyl
14. Secure case (2) to the supports with straps (1), to inder rod , is termed "running pressure". Running
prevent it Irom rolling or sliding during assembly. pressure should not exceed 80% of the breakaway
pressure or diminish to no less than 20% of the
breakaway pressure as the cylinder is extended . If
CAUTION running pressure exceeds these guidelines, disas
The cylind er must be adequately supported semble the cylinder and re place any defective
and the rod centered within the gland before parts ; repeat the entire test procedure .
attempting to assemble the cylinder. An
Improperly supported cylinder will sag at the High Pressure Leakage Test
gland, causing irreparable damage to the 1. Extend cylinder fuI! stroke and pressurize extend
threads, as l he gland is installed. port to the "Test Pressure" specilied in Table A.
Hold this pressure far a minimum 01 one minute. If
leakage across the piston exceeds 0 .33 cc/min,
Refer to Figure 2 . disassemble the cylinder, replace the defective
15. Using an auxiliary lifting device, carefully slide the parts, and repeat the entire test procedure .
rod (8), gland (11), stoptube (4), and piston (3) into 2 . Relieve pressure and examine the cylinder for
the case (10). Use care to avoid damaging the structural failure. No leakage is acceptable. If leak
seals and o-rings on the gland (11) and piston (3) age is found, disassemble the cylinder, replace the
as the assembly is installed in the case (10) . delective parts, and repeat the entire test proce
16 . Slowly rotate gland (11) into case (10) making sure dure.
the threads are not being damaged as the gland is 3. Fully retract the cylinder.
installed. Tarque to 400 ft lb (542Nm). 4. Pressurize retract port to the "Test Pressure" speci
17. Carefully retract the rod (8) into the case (10). fied in Table A. Hold this pressure far a minimum of
18. Test the reconditioned cylinder for leaks and prop one minute. If leakage across the piston exceeds
er operation. Use the following procedure. 0 .33 cc/min, disassemble the cylinder, replace any
delective parts; repeat the entire test procedure .
Cyllnder Test Procedures 5. Once again, relieve pressure and examine the cyl
inder for any external leakage. No leakage is ac
Low Pressure Leakage & Static Friction Test
ceptable. If leakage is found, disassemble the cyl
1. Fill the lully retracted cylinder with clean hydraulic
inder, replace any defective parts ; repeat the entire
oil. Reler to Table A and the Operatar's Manual far
test procedure.
the correct amount and grade 01 oil to use.
6. II the cylinder is not to be installed on crane im
2 . Cycie the cylinder, full stroke each direction, a mini
mediately, plug all ports to prevent contamination
mum of five times to remove entrapped air, using
and properly stare.
only the pressure level which is required to move
6 of 6
Eye Bolt Location
8
2
1. Boom Assembly 5. Hydraulic Lines 9. Washers 13. Mounting Pin
2. Boom Hois1 Cylinder 6. Capscrews 10 Keeper Plate 14. Capscrews
3. Upper Frame 7. Hydraulic Lines 11 Mounting Pin 15. Washers
4. Spli1 Flang es 8. Capscrews 12. Thru st Washers 16. Keeper Plate'
• Keeper plate location may vary from side to side.
Figure 1
Typical Upper Assembly
Boom Hoist Cylinder, R & I b. Level the crane on lully extended outriggers (il
equipped).
This procedure covers the removal and installation 01 c. Remove all attachments and rigging. See the
the boom hoist cylinder. For recondition procedure, Operator's Manual lor the correct procedures .
see SM Keysheet Area 17-003. d. Position the upper directly over the Iront and
engage the travel swing lock.
Removal e. Fully retract and position the boom so it can be
adequately supported once the boom hoist
cylinder is removed.
2. Stabilize the crane lor service as follows:
a. Park the crane, out of the way, on a firm level Note: HTC Models may use the boom rest
suriace and apply the park brake, if applicable. to support the boom.
1 of 4
3. Ad equately support the full weight of the boom
with an appropriate stand or lifting device.
Note: Th e boom assembly weighs approxi
A DANGER
mately 20,700 lb (9 390kg). Do not stand under the boom or boom hoist
cylinder. Once the hydraulic lines are
4. Shutdown the engine(s) .
disconnected or the mounting pins are
5. If equipped with pump disconnect, disengage the
removed, the boom hoist cylinder may drop
main hydraulic pump.
slightly.
WARNING Refer to Figure 1.

9. Label the hydraulic lines (7) for assembly pur
Solvents and cleaning solutions can be poses .
hazardous. Serious personal injury may 10. Remove the capscrews (6), split flanges (4), and
result from misuse of these products. Read o-rings (not shown) .
and foll ow all the manufacturer's 11 . Disconnect the hydraulic lines (7) from the boom
recommendations concerning solvents and hoist cylinder (2) . Cap/plug the open hydraulic
cleaning solutions. ports and lines (7) to prevent excessive oilloss and
contamination of the system.
6. Thoroughly clean the area to be disassembled with 12. Label for assembly purposes and disconnect the
an approved cleaning solvent to prevent conta hydraulic lines (5) from the boom hoist cylinder (2).
mination . Allow the area to air dry. Cap/ plug the open hydraulic ports and lines (5) to
prevent excessive oilloss and contamination of the
A WARNING
system.
Note: The boom hoist cylinder weighs approxi
mately 2,880 lb (1 306kg) .
hot. A sudden release of hot oil could cause 13. If necessary, install an eye bolt (NC - .75) in the
burns or other serious injury. Shutdown the boom hoist cylinder (2) to use as a lifting point. Re
engine and exhaust all trapped hydraulic fer to Figure 1 for the eye bolt location .
pressure from the system befo re removing 14. Using an auxiliary lifting device, support the weight
any IIne or component. of the boom hoist cylinder (2).
15. Remove the capscrews (14) and washers (15) se
7. Relieve the hydraulic system pressure as follows : curing the keeper plate (16) .
a. Release any residual pressure in the hydraulic 16. Remove the keeper plate (16) and thrust washers
reservoir. Refer to the Operator's Manual for (12) .
correct procedures.
Note: Each mounting pin weighs approximately
90 lb (41kg). Use an auxiliary lifting device to
STAHT THE ENGINE. Move the function lock
maneuver the mounting pins when required.
out switch to the "OPERATE " position .
c. Work the crane control levers and outrigger 17. Using a brass drift , carefully drive the mounting pin
switches (if applicable) back and forth several (13) from the boom hoist cylinder (2) and boom as
times . sembly (1).
d. Turn ignition switch to the "OFF" position. 18. Remove the capscrews (8) and washers (9) secur
8 . Check that all controllevers are in the neutral posi ing the keeper plate (10).
tion and move the function lockout switch to the 19. Remove the keeper plate (10) .
"DISABLE" position . 20 . Using a brass drift, carefully drive the mounting pin
(11) from the boom hoist cylinder (2) and upper
frame (3) .
21. Remove the boom hoist cylinder (2) from the
crane .
2 of 4
Cleaning And Inspection 3. Using a brass drift, install the mounting pin (11) into
the boom hoist cylinder (2) and upper frame (3) .
4 . Rotate the mounting pin (11), as requi red to align
A WARNING
the keeper plate (10) holes.
5 . Applya light coating of Loctite® 242 to the threads
of the capscrews (8).
hazardous. Serious personal injury may 6. Properly align the keeper plate (10), and install the
result from misuse of these products. Read capscrews (8) and washers (9). Torque the
and follow all the manufacturer's capscrews (8) to 350-385 ft lb (475-522Nm).
recommendations concerning solvents and 7 . Install the thrust washers (12) in the side of the
cleaning solutions. boom hoist cylinder (2).
8. Using an auxiliary lifting device, carefully align the
1. AII components should be thoroughly cleaned with boom hoist cylinder (2) to the boom assembly (1) .
an approved cleaning solvent, air dried, and care Use care not to lose the thru st washers (12) .
fully inspected . 9. Coat the mounting pin (13) with Bostik® Nev
2. AII Loctite®, Permatex®, or other sealant residue er-Seez or an equivalent anti-seize compound .
should be removed from threads of hardware and 10. Using a brass drift, install the mounting pin (13) into
the mounting surfaces of parts that are going to be the boom hoist cylinder (2) and boom assembly
reused . Prior to applying new thread locking com (1). Use care not to damage the thrust washers
pounds or sealants , clean threads and surfaces (12) .
with Loctite® 7070 Cleaner to ensure best perfor 11. Rotate the mounting pin (13), as required to al ign
mance of products. the keeper plate (16) holes.
3. Thoroughly inspect all parts for damage, wear, fa 12. Applya light coating of Loctite® 242 to the threads
tigue or stress fractures , and corrosion . Repair or of the capscrews (14).
replace as required. 13. Properly align the keeper plate (16) , and install the
4. AII "soft parts ", such as o-rings , should be re capscrews (14) and washers (15). Torque the
placed. capscrews (14) to 350-385 ft lb (475 - 522Nm).
5. Inspect the integrity of the hydraulic lines. Repair 14 . Lubricate the boom hoist cylinder mounting pins
or replace if required . (11,13). See the Operator 's Manual lor the correct
6. In the event of severe defects , contact factory per type and location .
sonnel for directions whether to repair or replace 15. Applya light coating of Loctite® 242 to the threads
any major component. of the capscrews (6).
16. Connect the hydraulic lines (5 ,7). Install the o-rings
Installation (not shown), split flanges (4), and capscrews (6) to
secure the hydraulic lines (7) to the boom hoist cyl
Refer to Figure 1.
inder (2) .
Note: The boom hoist cylinder weighs approxi 17. Check the hydraulic reservoir oil leve!. Add oil as
mately 2,880 lb (1 306kg). required . See the Operator's Manual lor correct
1. Using an auxiliary lifting device, carefully align the type and procedure.
boom hoist cylinder (2) to the upper frame (3). 18. If equipped with pump disconnect, engage the
main hydraulic pump .
19. Start the engine and let idle lor live minutes . In
A WARNING
leaks as required .
20. Cycle the boom hoist cylinder several times to
compounds, etc . can be hazardous. Serious bleed any air Irom the system.
personal injury may result from misuse of 21 . Install any attachments and rigging as required .
these products. Read and follow al! See the Operator's Manual lor the correct proce
manufacturer's recommendations concerning dures .
tions 01 the boom hoist cylinder lor proper opera
Note: Each mounting pin weighs approximately tion . Normal operation 01 the hydraul ic system
should be conlirmed. A general inspection of the
90 lb (41kg). Use an auxiliary lifting device to
maneuver the mounting pins when required.
the repair should also be performed to ensure re
2. Coat the mounting pin (11) with Bostik® Nev lated damage or wear is not present.
er-Seez or an equivalent anti-seize compound.
3 of 4
4 of 4
Service Man,ual 0711 SM17 -003-040.00
Boom Hoist
Counterbalance Valve, R & I
the valve cartridges in the boom hoist counterbalance
valve. In this procedure, the counterbalance valve is an
integral part of the boom hoist cylinder. For other
types, see SM Keysheet Area 17 - 003. 2
Removal
1. Lower, detach, and secure the load, as required. 3
a. Park the crane, out of the way, on a firm and 4
level surface.
the tires , as equipped.
lock, as required . 1. Semi-Restrictive Counterbalance Cartridg e
d. Level the crane on fully extended outriggers (if 2. Counterbalance Valve Cartridge
3. Boo m Hoist Co unterbalance Valve
equipped). 4. Boo m Hoist Cylinder
Note: The boom and boom hoist cylinder Figure 1

can weigh as much as 25,000 lb (11 340kg). Boom Hoist Counterbalance Valve
e. Fully retract and position the boom , as

5. Relieve the hydraulic system pressure as follows
required. If possible, position the boom in the
boom rest, if equipped . Otherwise, use an
reservoir. Refer to the Operator's Manual for
appropriate lifting device to adequately
correct procedures .
support the boom and boom hoist cylinder.
b. Turn the ignition switch to " ON" , but DO NOT
STARTTHE ENGINE. Movethe function lock
draulic pump, if equipped.
out switch to the "OPERATE " position.
c . Work the crane control levers and outrigger
A WARNING
switches (if equipped) back and forth several
times.
Solvents and cleaning solutions can be d. Turn ignition switch to the "OFF" position.
hazardous. Serious personal injury may 6. Check that all controllevers are in the neutral posi
result from misuse of these products. Read tion and move the function lockout switch to the
and follow all the manufacturer's "DISABLE" position .
cleaning solutions.
A DANGER
4. Thoroughly clean area to be disassembled with an Once the counterbalance valve cartridges are
approved cleaning solvent to prevent removed, boom hoist cylinder will no longer
contamination from entering the oil circuits. Allow support the boom. Properly support, and sta y
the area to air dry. clear of, the boom during cartridge removal.
A WARNING
Refer to Figure 1.
7. Label for assembly purposes and remove
cartridges (1,2) from counterbalance valve (3).
hot. A sudden release of hot oil could cause Plug the open ports to prevent excessive oil los8
burns or other serious injury. Shutdown the and contamination of oil circuits.
pressure from the system befare removing
any Une or component.
1 01 2
6. In the event of severe delects, contact factory
2 personnel for directions whether to repair or
lnstallation
A WARNING
Lubricants , sealants, joint and thread locking
3
these products.
1. Cartridge 3. Back Up Rings
2. O-rings
Reter to Figure 2.
Figure 2
1. Install o-rings (2) and back up rings (3) on
O-ring Placement
cartridges (1) in the order shown.
Refer to Figure 2.
8. Remove o-rings (2) and back up rings (3) from
cartridges (1).
A WARNING
Boom hoist counterbalance valve cartridges
Cleaning And Inspection must be installed in the correct ports.
Cartridges are factory set and malfunction of
the boom hoist cylinder will occur if cartridges
A WARNING
are reversed.
hazardous. Serious personal injury may Reter to Figure 1.

result from misuse of these products. Read 2. Insta" semi-restrictive counterbalance cartridge
and foll ow all the manufacturer's (1) in counterbalance valve (3) and torque to
recommendations concerning solvents and 150-160 ft lb (203-217Nm).
3. Install counterbalance valve cartridge (2) in
cleaning solutions.
counterbalance valve (3) and torque to 45 -55 ft lb
1. AII components should be thoroughly cleaned with (61-75Nm).
an approved cleaning solvent, air dried, and
carefully inspected. required. See Operator's Manual tor correct type
2. AII Loctitel.[" Permatex®. or other sealant residue and procedure.
should be removed from threads of hardware and 5. Start the engine and let idle for tive minutes.
parts that are going to be reused. Inspect the hydraulic connections for leaks.
3. Tlloroughly inspect all parts for damage, wear,
6. Cycle boom hoist cylinder several times to remove
fatigue or stress fractures, and corrosion. Repair
or replace as required. any trapped air trom the system.
7 . Complete the installation by testing all related
4. Replace all back up rings and o-rings.
5. Do not attempt to disassemble or adjust the coun tunctions of the boom hoist cylinder tor proper
terbalance valve cartridges . These components operation. Normal operation 01 hydraulic system
are factory set and contain no serviceable parts be should be confirmed. A general inspection of
yond the seals. components and systems in the are as adjacent to
the repair should also be performed to ensure
2 of 2
2 3 4 5 6
21
Proper orientation of
shafts is critical. Top
surface of both shafts
is marked with "T" or
center punch mark.
20 8
19
9
18--
17
10
16
11
~--1 2
15
14 13
1. Sh lms 7. Clip Pin 12. Clip Pln 17. Shims

2 Pins. Washers. & Hair Pins 8. Tapered Pin 13. Tapered Pin 18. Sheaves
3. Rollers 9. Capscrew & Locknut 14. Grease Fit1 ings 19. Boom Head
4. Sheaves 10. T-Handle 15. Capscrew 20. Space r
5. Spacer 11. Swivel Nut 16. Bot1om Shaft 21. Grease Fl lin gs
6. Top Shaft
Figure 1
Five Sheave Boom Head Machinery
Five Sheave Boom Head Machinery, Recondition

This procedure covers the recondition of a five sheave of boom head machineries , see SM Keysheet Area
boom head machinery with nylon or steel head 17-009. Refer to SM Keysheet Area 17-001 for
sheaves. For recondition 01 lour sheave or other types complete boom recondition .
1 of 4
A WARNING
2
cleaning solutions.

approved cleaning solvent. Allow the area to air
3 dry.
Reler to Figure 1.
7. Remove the pins, washers, and hair pins (2) which
secure the rollers (3) to the boom head (19) ; re
move the rollers (3).
8. Remove the clip pins (7 ,12) and tapered pins (8,13)
---- 4 Irom the top shaft (6) and bottom shaft (16).
9. Remove the swivel nut (11) and t-handle (10) Irom
the bottom shaft (16).
10. Remove the capscrew and locknut (9) Irom the top
shaft (6) .
1. Grease Fitting 3. Ball Bearings
11. Remove the capscrew (15) lrom the bottom shaft
2. Sheave 4. Center Web '
'Stee l sheaves utillze a retaining ring VS . the center web.
(16) .
Figure 2 Note: The holes used in the top and bottom

Sheave Assembly shafts, to mount the fly, are drilled at a slight
angle. The top surface of the shaft is marked
Disassembly with the letter "1" or a center punch mark to en
1. Lower, detach, and secure load, as required . sure proper orientation of the shaft during as
2. Properly store or remove the fly from the boom and sembly.
remove the wire rope from the head machinery.
12. Count and record the number 01 shims (1) used be
See the Operator's Manual lor the corree! proce
tween the spacer (5) and the inside surface 01 the
dures.
boom head (19) on the left side 01 the boom.
3. Stabilize the crane for service as lollows :
13. Orive the top shaft (6) out 01 the boom head (19).
a. Park the crane out 01 the way on a lirm and level
As the top shaft (6) is being removed, the shims (1) ,
surface.
sheaves (4) and spacers (5,20) will come off the
b. Engage the park brake, il applicable.
top shaft (6).
14. Count and record the number 01 shims (17) used
lock , as required. between the end sheave (18) and the inside sur
d. Level the crane on lully extended outriggers, il face 01 the boom head (19) on the left side 01 the
applicable. boom.
e. Extend and lower the boom , as required, to 15. Orive the bottom shaft (16) out of the boom head
ease access to the boom head machinery. Re
(19). As the bottom shaft (16) is being removed,
ler to the Crane Rating Manual to ensure allow the shims (17) and sheaves (18) will come off the
able working range limitations are not exceed bottom shaft (16).
ed .
draulic pump, il applicable.
"OISABLE" position.
2014
16. If required, remove the grease fittings (14,21) from Assembly
the boom head (19).
CAUTION A WARNING
Do not remove both ball bearings from one
side of the sheave. The ball bearings within
the sheaves are separated by a retaining ring
these products. Read and follow aH
or center web made into the sheave. Remove
manufacturer's recommendations co nceming
each ball bearing separately by evenly
these products.
tapping it from the center outward.
Refer to Figure 2.
Refer to Figure 2.
1. If removed, install the grease fittings (1) in the
17. If required, tap the ball bearings (3) out of the
sheaves (2), as shown. Grease fitting (1) must
sheaves (2). Each ball bearing (3) must be evenly
point outward and extend 0.19 inch (5mm) to per
tapped from the center outward to avoid damaging
form properly.
the center web (4) or retaining ring (not shown).
2. If equipped, install the retaining rings (not shown)
18. If required, remove the grease fittings (1) from the
in the sheaves (2) .
sheaves (2) .
19. If equipped, remove the retaining rings (not
shown) from the sheaves (2) .
CAUTION
Cleaning And Inspection Do not install both ball bearings from one side
of the sheave. The ball bearings within the
sheaves are separated by a retaining ring or
A WARNING center web made into the sheave. Install each
ball bearing separately by pressing it in from
one side and then the other.
3. If required, press the ball bearings (3) into the
sheaves (2), until flush with the outer fa ce of the
sheave (2). Each ball bearing (3) must be pressed
cleaning solutions.
in from each side separately, to avoid damaging
the center web (4) or retaining ring (not shown).
an approved cleaning solvent and air dried . Refer to Figure 1.
2. Carefully inspect all components for damage, 4. If required, install the grease fittings (14,21) in the
wear, corrosion, deep scratches, and scuffed met boom head (19).
al. Remove any burrs or sharp edges with a fine 5. Lubricate the bottom shaft (16) with grease. Refer
file, hone, emery cloth, or crocus cloth. Replace to the Operator's Manual for the correct type.
any damaged component as required. 6. Partially insert the bottom shaft (16) into the right
3. AII Loctite " Permatex®, or other sealant residue side of the boom head (19).
should be removed from threads of hardware and 7. Install one shim (17) onto the bottom shaft (1 6) .
Note: The grease fittings in the sheaves should
fa ce the closest outward direction; two to the
left, three to the right.
with Loctite'''' 7070 Cleaner to ensure best perfor
mance of products. 8. Ins~all one sheave (18) and then one shim (17)
4. In the event of severe defects, contact factory per whlle contlnulng to insert the bottom shaft (16) into
sonnel for directions whether to repair or replace the boom head (19).
3 of 4
12. Install the tapered pin (13) through the boom head
(19) and bottom shaf1 (16) . Install the clip pin (12)
through the tapered pin (13).
13. Install the capscrew (15) in the bottom shaf1 (16) .
14. Install the swivel nut (11) and t-handle (10) in the
bottom shaf1 (16).
0.075 inch 15. Lubricate the top shaf1 (6) with grease. Refer to the
(2mm) ---~~""E--- Operator's Manual for the correct type.
Maximum 16. Partially insert the top shaf1 (6) into the right side of
the boom head (19) .
17. Install one shim (1) onto the top shaf1 (6).
18. Install one sheave (4) onto the top shaf1 (6) while
continuing to insert the top shaf1 (6) through the
boom head (19).
19. Install the short spacer (20), sheave (4), and long
spacer (5) on the top shaf1 (6). However, do not ful
Iy install the top shaf1 (6) through the boom head
(19).
20. Use the shims (1) , as required , to minimize the gap
between the long spacer (5) , on the top shaf1 (6) ,
and the insidesurface olthe boom head (19). Max
imum gap should be 0 .075 inch (2mm). Refer to
Figure 3 .
21. Check that the orientation mark on the top shaf1 (6)
is lacing up . Rotate top shaf1 (6), as required .
Shim as required.
22. Install the tapered pin (8) through the boom head
0.075 in (2mm) Maximum Gap (19) and top shaf1 (6). Install the clip pin (7) through
Top & Bottom Shafts the tapered pin (8) .
23. Install the capscrew and locknut (9) through the
Figure 3 spacer (5) and top shaf1 (6).
Shim Installation 24. Install the rollers (3) , using the pins, washers, and
hair pins (2) to secure them to the boom head (19).
9. Alternate the installation 01 sheave (18) then shim 25. Properly grease the top shaf1 (6) , bottom shaf1 (16) ,
(17) until all live botlom sheaves (18) are on the and all the sheaves (4,18) 01 the head machinery.
bottom shaft (16) . However, do not lully install the See the Operator 's Manual lor the correct type 01
bottom shaf1 (16) through the boom head (19). grease to use.
10. Use the shims (17), as required, to minimize the 26. Reeve wire rope on the head machinery. See the
gap between the last shim (17) on the bottom shaf1 Operator's Manual lor reeving inlormation.
(16) and the inside surface 01 the boom head (19). 27. Complete the installation by testing all related func
Maxim um gap should be 0.075 inch (2mm). Reler tions 01 the boom head machinery lor proper op
to Figure 3 . eration. Sheaves should rotate smoothly with no
interference between grease fittings or sheaves.
Note: The holes used in the top and bottom
Ad just or repair, as required .
shafts, to mount the fly, are drilled at a slight
an gle. The top surface of the shaft is marked
with the letter "T" or a center punch mark to en
sure proper orientation of the shaft during as
sembly.
11. Check that the orientation mark on the bottom

shaf1 (16) is lacing up. Rotate the bottom shaf1
(16) , as required.
4 of 4
The dry torque column should be used for fasteners as
Capscrew Torques they come from the package, with no lubrication ap
plied to threads.
Proper tightening of capscrews, studs and nuts is very
important when assembling or instaJling components Note: The dry torque column should be used wh en
on the machi ne. The charts included in this service tlghtenlng a fastener wlth Loctlte® thread locklng
manual section list torque values for popular SAE sizes compound applled.
of grade 2, 5, B and alloy steel as well as metric classes
8.8, 10.9 and 12.9 capscrews, studs and nuts.
The lube torque column should be used when fasten
These torque values are applicable in all cases except ers are lubricated with oil, white lead, anti -seize,
where speciaJ tightening instructions are given in the graphite, etc.
operator's and/or service manual. Two columns of
torque values are given: "Dry and Lube".
Grade 2 (Zinc Plated) Alloy Steel Fasteners

Basic Dry Torque Lube Torque Dry Torque Lube Torque
Dia
(in .) ft-Ib Nm ft-Ib Nm ft-Ib Nm ft-Ib Nm
1/4 85-96 11.5-13 6 .8-7.5 92-102 15.8 - 17 .3 214-23 .5 11 .8-13 16-176
5/16 18-20 24-27 14-16 19-22 30-35 41-47 20-25 27-34
3/8 31 -35 42-47 25-28 34 - 38 55-60 75-81 40-45 54-61
7/16 50-55 68-75 40-44 54-60 90-100 122-136 65-70 88-95
1/2 77 - 84 104 -114 61 - 68 83-92 140-155 190-210 105-115 142-156
9/ 16 110-122 149-165 88-98 119-133 200-220 271 -298 150-165 203-224
5/8 152-168 206-228 122-134 165-182 280-310 380-420 210 - 235 285-319
3/4 270-298 366 - 404 216-238 293 -323 495 - 545 671-739 370-410 502 - 556
7/8 800-880 1085-1193 600-660 814-895
1 1200-1320 1627-1790 900-990 1220-1342

1 -1 /8 1700 -1870 2305-2536 1270 - 1400 1722-1898
1 -1 /4 2410-2655 3268-3600 1800-1980 2441-2685
1 -3/8 3140-3455 4258 - 4685 23 50-2585 3187-3505
1 -1 /2 4180-4600 5668-6238 3130-3445 4244-4671
1 -3/4 6590-7250 8936-9831 4940-5435 6699-7370
2 9920-10915 13452 - 14801 7430-8175 10075 - 11 085
2-1 /4 14490-15940 19648 -21615 10870 - 11960 1474 0 -16218
2-1 / 2 19830-21815 26889-29581 14880-16370 20177 -22198
2 - 3/4 26890- 29580 36463-40110 20160-22180 27337 - 30076
3 35350-38885 47935 -52728 26510- 29165 35948-39548
Identificabon Identificabon
Capscrew Head Nul Capscrew Head Nut
Slyle A Slyle B Style C
~
/~
~ ~ /~ ~I
.-.., . ('~
: ~ ,
;"
'
-
.-.., . '
0 .,--,, ' ,
~) ~y
,
l '''-. ''',J ~c/ /
"-
~.--
r
i
/ '» ~/
~/ 12 Pt . Hex Sockel
No Markings Round or
Raised or " 0::7 "
No Markmgs Depressed
>-<.'> :-..,
Rae!. Dol '>-<> -<>,
Markings
~,,-- ,
1 of 4
ServiceManual 0296 SM18-0-1.0
Grade 5 Grade 5 (Zinc Plated)

Basic Dry Torque Lube Torque Dry Torque Lube Torque
Dia.
(in .) ft-Ib Nm ft-Ib Nm ft-Ib Nm ft-Ib Nm
1/4 11-12.3 14 .9-167 8 .7-9.7 11 .8-13.2 138-15.4 187-20.9 10.8-12.1 14.6-16.4
5/ 16 20-24 27-33 16 - 20 22-27 25-30 34-41 20-25 27-34
3/8 40-44 54-60 32-36 43-49 50-55 68-75 40-45 54-61
7/16 64-72 87-98 52-60 71 - 81 80-90 108-122 65-75 88-102
1/2 96-108 130-146 80-88 108-119 120-135 163-183 100-110 136-149
9/16 140-156 190-212 112-124 152-168 175-195 237-364 140-155 190-210
5/8 196-216 266-293 156-172 212-233 245-270 332-366 195-215 264-292
3/4 348 -384 472-521 280-308 380-418 435-480 590-650 350-385 475-522
7/8 564 -620 765-841 452-500 613-678 705-775 956-1051 565-625 766 -848
1 848 -936 1150-1269 680-748 922-1014 1060-1170 1437-1587 850-935 1153-1268
1-1/8 1048-1156 1421-1568 840-924 1139-1253 1310-1445 1776-1959 1050-1155 1424-1566
1- 1/4 1480-1628 2007-2208 1184-1304 1606- 1768 1850-2035 2509-2759 1480 -1630 2007-2210
1 - 3/8 1944-2144 2636-2907 1560-1716 2115-2327 2430-2680 3295-3634 1950 - 2145 2644-2909
1-1 /2 2584-2844 3504-3856 2064-2272 2799 - 3081 3230-3555 4380-4821 2580-2840 3498-3851
1-5/8 3040-3344 4122-4534 2432-2680 3298-3634 3800-4180 5153-5668 3040-3350 4122-4542
1 - 3/4 3488-3840 4730-5207 2792-3072 3786-4166 4360-4800 5912-6509 3490-3840 4732-5207
1 -7/8 4744-5224 6433-7084 3792-4176 5142 - 5663 5930-6530 8041-8855 4470-5220 6061-7078
2 5248-5776 7116-7832 4200-4624 5695-6270 6560-7220 9017-9790 5250-5780 7119-7838
2- 1/4 7680 - 8448 10414 -11455 6144-6760 8331 - 9167 9600-10560 13018-14319 7680-8450 10414-11458
2- 1/2 10496-11552 14233-15665 8400-9240 11390 - 12529 13120-14440 17700-19581 10500-11550 14238 - 15662
2-3/4 14240-15664 19309- 2 1240 11392-12536 15448 - 16999 17800-19580 24137 -26550 14240 - 15670 19300-21249
3 18800- 20680 25493-28042 15040-16544 20394 -22434 23500 - 25850 31866 -35053 18800 - 20680 25493-28042
Identi fication
Capscrew Head Nul
StyleA Style B Style C
.~ ~ ./ ~ :: ....
,
~)
,r'\. ,
I I;Q; . 'V ')
, - ..... ~./
~.
"""rj'
Raised or >-.,.... .....~
Round or Rectangular Dot
Depressed Markings ~
2 of 4
Grade 8
Basic Dry Torque Lube Torque
Dia.
(In .) N-lb Nm f1-lb Nm
1/4 13-15 17.6-20.3 9-11 122-14 .9
5/16 25-30 34-41 20-25 27-34
3/8 50-55 68-75 35-40 47-54
7/16 80-90 108-122 60-70 81 - 95
1/2 120-135 163-183 90-100 122-136
9/16 180-200 244-271 130-145 176-197
5/8 245-270 332-366 185-205 251-278
3/4 435-480 590-651 325-360 441-488
7/8 700-770 949-1044 530-585 719-793
1 1060-1170 1437-1587 795-875 1078-1187
1-1/8 1500-1650 2034-2237 1130-1245 1532-1688

I
1 -1/4 2120-2335 2875-3166 1590-1750 2156-2373
1 -3/8 2780-3060 3770-4149 2080-2290 2820-3105
1 -1/2 3690-4060 5004-5505 2770-3050 3756-4136
1 -5/8 5060-5570 6861- 7553 3800-4180 5153-5668
1 -3/ 4 5820-6405 7892-8685 4360-4800 5912-6509
1 -7/8 7910-8700 10726-11797 5930-6525 8041-8848
2 8750-9625 11 865 - 13052 6560-7220 8895-9790
2-1/4 12790-14070 17343 - 19079 9590-10550 13004 -14306
2 - 1/2 17500-19250 23730-26103 13120-14435 17791 - 19574
2-3/4 22160-24375 30049-33053 16620 - 18285 25537-24794
3 29240-32165 39649-43616 21930-24125 29737 -32714

Idenlificalion
Capscrew Head Nut
Style A Style B Style C
<~ '3l
~
~
I
.~ .
. "":, >
\ '-.,./ !
,~,
I
~ /
<J~
~>
Round or Rectangular. Dol
Raised or
Depressed Marl<ings ~B
3 of 4
Metric Class 8.8 (Zinc Plated)9 Metrlc Class 10.9

Bas ic Dry Torque Lube Torque Dry Torque Lube Torque
Oia.
(in.) n-lo Nm ft-Ib Nm ft-Ib Nm ft-Ib Nm
M5 7-9 10-12 5-7 7-9 7-9 10-12 5-7 7-9
M6 12-15 17-20 10-12 14-16 12-15 17-20 9-11 13-15
M8 31-35 42-47 25-28 34-38 31-35 42-47 24-26 32-35
Ml 0 62-68 84-92 49-55 67-74 62-68 84-92 46-51 63-69
M1 2 108-119 147-161 87-95 118-129 108-119 147-161 82-90 111-122
M14 173-190 234-257 138-152 187-206 173-190 234-257 130-143 176-194
M16 268-295 364-400 215-236 291-320 268-295 364-400 202-221 274-300
M20 524 -575 710-780 419-461 586-625 524-575 710-780 394-433 534-587
M24 907-998 1230-1353 726-799 984-1083 907-998 1230-1353 682-751 925-1018

Identification Identification
Cap screw Head Nut Capscrew Head Nut
Style A Style B Style C Style A Style B Style C
/~ ~"'\
\
...
..
/~
.:=::.,.. \ \
10 \. .,,----,. \ , "-
88
\ H ~' ~
"--
Raised or Depressed Depressed Raised or Depressed Depressed
Depressed Markings Markings Depressed Markings Markings
Marklngs On On Slde 01 Markings On On Sloe
Top Of Nut Wrenching Nut Top Of Nut Wrenching OfNul
Surface Surface
Identificatlon
Metric Class 12.9
Ba slc Dry Torque Lube Torque ,~
Ola.
(in.) ft-Ib Nm ft-Ib Nm
~~, '
"
'/~""
...., \
, \
M5 8-11 12-14 6-8 8-10 \
M6 15-17 21-23 11-13 15-17 ~/; ~~,
M8 37-41 50-55 27-30 37-41 12 PI. Hex Socket
M 10 73-80 99-108 55-60 74-81
M 12 128-140 173-190 96-105 130-143 Style A Style B Style C
M1 4 202-222 274-301 152-167 206-227 q

M 16
M20
316-348
616-678
429-472
836-920
237-261
462-509
322-354
627-690
@ '0
@ 10 '
I 1O ~
.,
,-A
'-'
M24 1336-1470 1812-1993 802-862 1087-1196 Depressed
Raised or Depressed Depressed
Markings - On
M30 2119-2329 2874-3158 1590-1749 2156-2372 Markings- Top Of Markings - On
Wrenching Sur-
Nut Sida Of Nut
face
M34 3706-4077 5026-5529 2779-3058 3769-4146
4 of 4
Service Manual 1003 SM18-000- 002. 00
Bearing, Gear, Shaft, & Cleaning Rough Parts
(Cast Housings, Covers, Brackets, Etc.)
Housing Inspection
This procedure is general in nature and to be used as
a supplement to the cleaning and inspection
A WARNIN G
procedures outlined within specific reconditioning
instructions. hazardous. Serious personal injury may
Cleaning Ground & Polished Parts and follow all the manufacturer's warníngs
(Gear Teeth, Shafts, Spool Landings, Etc.) and recommendations concerni ng these
chemical solutions. Work only in a well
ventilated area and use the proper protective
A WARNING equipment, such as safety glasses, rubber
gloves , breathing protection , etc. when
Solvents and cleaning solutions can be cleaning parts.
result from misuse of these products. Read 1. Thoroughly clean all metal parts with an approved
and follow all the manufacturer's warnings cleaning solvent or in a hot tan k with a diluted alka
and recommendations concerning these line solution . In some cases ke rosene or diesel fuel
chemical solutions. Work only in a well can be used as a "cold " solvent. Use only ap
ventilated area and use the proper protective proved agents in the hot tank .
equipment, such as safety glasses, rubber 2. Do not use gasoline or any other highly volatile
gloves, breathing protection, etc. when solutions as a solven!.
cleaning parts. 3. Parts cleaned in a hot tank must be allowed ade
quate time to reach temperature and dissolve
1. Thoroughly clean all metal parts with an approved grease and dirt. Afterwards, parts must be rinsed
cleaning solvent. In some cases kerosene or thoroughly with clean water until all traces of the
diesel fuel can be used for this purpose. However, alkaline solution are removed .
do not use gasolíne or any other highly volatile 4. Use a tool with a flat blade to remove sealant mate
solution. rial from parts, if required . Be careful not to dama
ge mounting or sealing surfaces of the parts .
5. Remove any burrs or sharp edges with a fi ne file ,
CAUTION hone, emery cloth, or crocus cloth . However, do
Use only solvent cleaners to clean ground or not overwork parts past the point of exceed ing fin
polished metal parts. Hot solution tanks or ished tolerances.
water and alkaline solutions will damage 6. Place parts on a clean, lint free surface and allow to
these parts. Isopropyl alcohol, kerosene, or air dry. Exercise every precaution possible to keep
diesel fuel can be used for this purpose. all parts free of dust, dirt, or any other foreign mate
rial during assembly.
2. Do not clean ground or polished parts with water or 7. Filtered compressed air may also be used to accel
steam . Do not immerse ground or polished parts erate the drying proc ess. However, do not allow
in a hot solution tank or use strong alkaline solu the compressed air to place the parts in motion;
tions . Smooth sealing surfaces may be damaged parts can be damaged . Rolle r bearings are an ex
by these methods . ample of parts wh ich can be ru ined by spinning
3. Use a tool with a flat blade to remove sealant mate with compressed airo
rial from parts, if required. Be careful not to dam
age the polished or smooth su rfaces of the parts. Cleaning Undercarriage Components
4. Remove any burrs or sharp edges with a fine file, (Axle and Transmission Housings, Etc.)
hone, emery cloth, or crocus cloth. However, do
not overwork parts past the point of exceeding fin For certain components it is impractical to clean with
ished tolerances . solutions or within a hot tank. The exterior surfaces of
5. Place parts on a clean, lint free surface and allow to the undercarriage fall into this category.
air dry. Exercise every precaution possible to keep 1. The outside surfaces of large undercarriage co m
all parts free of dust, dirt, or any other foreign mate ponents can be pressure washed or steam
rial during assembly. cleaned to remove grease and road d irt .
1 of 4
Acceptable Not Acceptable
" ~':?ll
" .~ .:}
2
1 . Worn Radiu s (S harp Edge)
1. Wear Marks
2. Worn Surface (Enlarged Di ameter)
Figure 1 Figure 3
Bearing Rollers Bearing Cones
Inspecting Parts
It is very important to completely inspect all parts
before assembling critical components. Carefully
inspect all components far damage, wear, corrosion,
deep scratches, and scuffed metal. Replacement of
damaged or worn parts will prevent fai lure of the
assembly later.
Tapered Roller Bearings

1. Inspect the cup, cone, ro llers , and cage of al! ta
pered rol/er bearings in the assembly. If any of the
following conditions exist, the bearing must be re
placed :
• The center of the large diameter end of the rollers

3 is worn level with or below the outer surface. Re
1. Crack 3. Pitting fer to Figure 1.
2. Wear Groove • The radius at the larg e diameter end of the rollers
Figure 2 is worn to a sharp edge. Refe r to Figure 1.
Bearing Cups And Rollers • A visible ro ller groove is apparent in the cup or
cone inner race surfaces. The groove can be
seen at the small and/or large diameter end of
2. Before using a pressure washer or steam cleaner,
parts. Refer to Figure 2.
plug, cap, ar otherwise seal al! openings in the as
• Deep cracks or breaks in the cup, cone inner
sembly. Examples of openings are breathers or
race, or roller surfaces. Refer to Figure 2.
vents in air chambers.
• Bright wear marks on the outer surface of the roll
3 . Drying is not usually of concern with these parts
er cage. Refer to Figu re 3.
since they are routinely exposed to the elements .
• Damage on rollers and on surfaces of the cup
However, if the painted surfaces of these compo
and cone inner race that touch the rollers. Refe r
nents become compromised, be sure to repair any
to Figu re 4 and Figure 5 .
wear or damage to the paint befare corrosion be
gins.
2 of 4
Differential Case Halves
.
t
\~ G
./
.. . '
.. B':
.(.
....•....
,.)"
.
1. Etching & Pit1ing
Figure 4 Differential Gear Nest Assembly

Bearing Cups And Rollers
3
1. Inspect Inside Surfaces

2. Pinions & Thrust Washers
3. Si de Gears & Thru st Wash ers
1. Spalling & Flaking 4. Inspec t Spi der (C ros s)
Figure 5 Figure 6
Bearing Cones Differential Gear Set
5. Inspect hypoid pinions and gears lor wear or dam

Gears age . Gears that are worn or damaged must be re
placed .
1. Inspect teeth lar signs 01 wear. Concentric grooves
6. Always replace thrust washers , differential side
or notches indicate advanced wear 01 heat treated
gears, and pin ion gears in lull matched sets. A
surlaces or interlerence 01 parts.
higher stress on original parts and early lailu re 01
2 . Contact patterns 01 gear teeth should be checked
the enti re assembly will result il a new part is used
lar evidence 01 incarrect alignment and adjusted,
in combination with parts that are older or worn .
as required.
7. Inspect differential assemblies, shown in Figure 6,
3. Look lar pitting ar cracking along gear contact
as lollows:
lines. Scuffing, delarmation , ar discolaration are
signs 01 excessive exposure to heat, usually due to • Inslde surlaces 01 both case halves.
improper lubrication. • 80th surfaces 01 al! thrust washers.
4. Hypoid drive pinions and ring gears are machined • The lour trunnion ends 01 the spider (cross).
in matched sets. When a drive pin ion or ring gear 01 • Teeth and splines 01 both differential side gears.
a hypoid set needs to be replaced , both drive gear • Teeth and bore 01 al! differential pin ions .
and pinion must be replaced at the same time.
3 014
Figure 7 Figure B
Carefulln spections Payoff Housing Inspection
Shafts Housings
1. Inspect shafts for wear and cracks along their 1. Examine housings for cracks or leaks . They must
length and on each spline . be free of cracks, scoring, and wear.
2. Inspect all machined surfaces for smoothness. 2. Look for loose studs or cross-threaded holes .
Sealing surfaces along shafts will not perform if 3. Look for elongation of drilled holes .
damage is present o 4. Check for wear on surfaces machined for bearing
3. I.. ook for pitting or cracking along spline contact and seal fits and nicks or burrs in mating surfaces.
llnes . Scuffing, deformation , or discoloration are 5. Inspect inner surfaces and pockets within castings
signs of excessive exposure to heat, usually due to for moisture or alkaline residue. Be sure hidden
improper lubrication . areas are clean and dry before beginning assem
4. Shafts with an integral flange must be checked for bly.
squareness and any elongation of mounting holes
in the flange .
5 . Stíaightness is usually the most critical element of
a working shaft; particularly when high speeds of
rotation (rpms) are involved.
4 of 4
Crane System Schematics

Crane system schematic diagrams are available
through your distributor. Many cranes included
these schematic diagrams, as part of the crane's
manual package, during its initial delivery. Contact
your distributor, with the crane's serial number, to
arder the air, electrical, and hydraulic system
schematic diagrams package which applies to the
specific crane.
1 of 2
2 of 2
Service Manual 0705 SM18-0,0 7 - 006.00
13 , Unplug the fi xed cable (8) from the RCL computer
Reeling Drum, R & I connecter plug (12),
This procedure covers the removal and installation of 14. Remove the capscrews and clamps (10) securing
the reeling drum, For recondition procedure , see SM the fixed cable (8) to the upper frame (9) and boom
Keysheet Area 18-007, base section (7) ,
15. Remove the capscrews that secure the ree ling
Removal drum (6) to the boom base section (7), and remove
the reeling drum (6) .
1, Lower, detach, and secure the load , as required .
2, Stabilize the crane for service as follows: Cleaning And Inspection
a , Park tl1e crane, out of the way, on a firm and
level surface,
b, Engage the park brake and/ or properly block
the tires,
c , Engage the swing park brake or travel swing
A WARNIN G
lock , as required . hazardous. Serious personal Injury may
d . Level tl1e crane on fully extended outriggers , result from mis use of these produ cts. Read
e, Fully retract and position tl1e boom over the and follow all the ma nufacturer's
front of the carrier at a 0 ° boom angle, recommendations concerning solvents and
3. Shutdown the engine, cleaning solutions.
1. AII electrical connections should be thoroughly

A WARNING cleaned with an approved cleaning solvent, air
dried , and carefully inspected,
2, Al! Loctite®, Permatex®, or other sealant resid ue
reused, Prior to applying new thread locking com
cleaning solutions.
mance of products,
4, Thoroughly clean the area to be disassembled with
3, Inspect the integrity of the wires and cable ends
an approved clean ing solvent. Allow the area to air
that are connected to the reeling drum , Repair or
dry,
Refer to Figure 1, 4, In the event of severe defects , contact fa ctory
5, Cut and remove any cable ties (11) that may be at personnel for directions whether to repair or
either end of the reeling drum cable (5), replace any major component.
6, If required, remove the lock-out pin (15) from the
ATB switch (14), Installation
7, Remove the cover from the ATB switch (14),
8, Label for assembly purposes and disconnect the
reeling drum cable (5) from the terminal strip (16) ,
9, Remove the capscrews and clamps (13) securing A WARNI NG
the reeling drum cable (5) to the head machinery
(1) , compounds, etc. can be hazardous. Serious
10, Hold the reeling drum cable (5) to prevent it from personal injury may result from misuse 01
retracting , and remove the cable clamp (3) from these products. Read and follow all
the reeling drum cable (5) , manufacturer's recommendations concerning
11. Unwind the reeling drum cable (5) from the anchor these products .
bolt (2) located on the head machinery (1),
12, Allow the reeling drum cable (5) to thread through Refer to Figure 1,
the cable guides (4) and wind onto tl1e reeling 1, Apply a light coat of Loctite® 242 to the th reads of
drum (6) until the reeling drum (6) stops turning, the capscrews that secure the reeling drum (6) to
Coil the remaining reeling drum cable (5) and se the boom base section (7) ,
cure it to prevent damage, 2, Align the reeling drum (6) to the boom base section
(7), and install the capscrews ,
1 of 4
14
ATB SWITCH SIGNAL (W/lNSULATION)
,~ BLACK
15 ~) PLUG CABLE
WHITE
ATB Switch
2 3 4 5 6 7 8
J
1. Head Machinery
2. Anchor Bolt
14 13
7.
8.
Boom Base Section
Fixed Cable
12.
13.
12 11 10 9
RCL Computer Connecter PluQ
Capscrews & Clamps
3. Cable Clamp 9. Upper Frame 14. ATB Switch
4. Cable Guides 10. Capscrews & Clamps 15. Lock-Out Pin
5. Reeling Drum Cable 11 . Cable Tíes 16. Terminal Strip
6. Reeling Drum
Figure 1
Reeling Drum
3. For proper tensioning of the reeling drum (6): c,

Route the reeling drum cable (5) down the
a. Turn th e reeling drum (6) clockwise until a click boom base section (7) and through the cable
is heard, Then, turn the reeling drum (6) live guides (4) and wrap it around the anchor bolt
turns counterclockwise and hold it in place. (2) on the head machinery (1) live to seven
b, While holding the reeling drum (6), unwrap en times. Install the cable clamp (3) to secure the
ough 01 the reeling drum cable (5) Irom the reeling drum cable (5).
reeling drum (6) to route it through the cable d. Gradually release the reeling drum cable (5) ,
g uides (4) tothe anchor bolt (2) and to connect allowing the reeling drum (6) tension to pull the
it to the ATB switch (14). reeling drum cable (5) back.
4. Route the reeling drum cable (5) down the head
Note: Make sure enough cable is left after machinery (1) to the ATB switch (14).
wrap ping on the anchor bolt to reach and 5. Applya light coat 01 Loctite® 242 to the threads 01
connect to the ATB switch. the capscrews (13), and secure the reeling drum
cable (5) to the head machinery (1) using the
capscrews and clamps (13) .
2 of 4
6. Using the diagram shown in Detail "B", connect the 11. Replace any cable ties (11) that were removed
reeling drum cable (5) to the terminal strip (16) . from either end of the reeling drum cable (5) .
7. Install the cover on the ATB switch (14). 12. If required , replace the lock-out pin (15) in the ATB
8. Route the fi xed cable (8) along the boom base sec switch (14).
tion (7) and upper frame (9). 13. Complete the installation by testing all related
9. Apply a light coat of Loctite® 242 to the threads of functions of the reeling drum for proper operation .
the capscrews (10) , and secure the reeling drum A general inspection of the components and
cable (5) using tll e capscrews and clamps (10) . systems in the areas adjacent to the repair should
10. Plug the fixed cable (8) into the RCL computer con also be performed to ensure related damage or
necter plug (12). wear is not presento
3014
4 of 4
Reeling Drum, Recondition Installation
Refer to Figure 1.
This procedure covers the replacement of the circuit 1. Route the wires coming out of the main shaft as
board , slip ring , and reeling drum cable. For removal sembly (7) through the hole in the circuit board
and installation procedures for the reeling drum, see (10) .
SM Keysheet Area 18-007. 2. Hold the gears (11), which are spring loaded , away
from the splines on the main shaft assem bly (7) .
General
It is a good practice when disassembling components CAUTION
to lay the parts out in the order th at they were Correct orientation of the circuit board is
disassembled. Keeping the parts in this order during crucial to ensure proper operation.
disassembly, cleaning . and inspection will aid in the
assembly process. 3. Slide the circuit board (10) onto the main shaft as
sembly (7) and properly align per the notes ta ken
A WARNING
during disassembly.
4. Connect the signal cable (8) wires to the "BLD "
connections on the circuit board (10), as show n in
Figure 1, Detail A.
5. Position the slip ring connector (12) on the main
shaft assembly (7), and install the screws (18) .
6. Generously apply lubricant to the slip ring connec
recommendations concerning solvents and tor (12) post.
cleaning solutions. 7. Install the slip ring (1) and supportarm (17) assem
bly on the slip ring connector (12). Make sure the
slip ring (1) and slip ring connector (12) snap to
Thoroughly clean the exterior surface of the reeling
gether securely.
drum with an approved cleaning solvent to prevent
contamination. Note: Ensure there is enough space for the su pport
arm to clear al! wires when it rotates.
Replacing The Circuit Board
Removal Note: System calibration is required with in stalla~
tion of a new circuit board.
Refer to Figure 1.
1. Remove the screws (4) and cover (2) from the reel 8. Ensure the 0- ring (3) is seated properly in the reel
ing drum (6). ing drum (6).
2. Remove the slip ring (1) and support arm (17) as 9. Install the cover (2) to the reeling drum (6) using
sembly from the slip ring connector (12). screws (4) .
3. Remove the screws (18) which attach the slip ring
connector (12) to the main shaft assembly (7), and Replacing The Slip Ring
remove the slip ring connector (12). Removal
4. Label and disconnect the signal cable (8) wires
from the "BLD" connections on the circuit board Refer to Figure 1.
(10). 1. Remove the screws (4) and cover (2) from the reel
5. Hold the gears (11) . which are spring loaded, away ing drum (6) .
from the splines on the main shaft assembly (7). 2. Remove the slip ring (1) and support arm (17) as
sembly from the slip ring connector (12) .
Note: For assembly purposes, note the orientation 3. Holding the reeling drum cable (5) against the sup
of the circuit board in relation to the reeling drum port arm (17), cut the cable ties (13) .
and main shaft assembly 4. Disconnect the reeling drum cable (5) from the ter
minal block (14) on the support arm (17).
6. Remove the circuit board (10). 5. Disconnect the slip ring (1) wires from the terminal
7. Clean and inspect the assembly. See "Cleaning block (14) on the support arm (17) .
And Inspection" found later in this document. 6 . Remove the nut (15) and washer (16) securing the
slip ring (1) to the support arm (17).
7. Remove the slip ring (1) from the support arm (17).
8. Clean and inspect the assembly. See "Cleaning
And Inspection " found later in this document.
1 014
10~ 3 4
9~ , ,, /;~~~~~;lrm~
5
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.'.
1
1 :
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=-Ll . ~- - -.'
~ .
-
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t1j---
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í 6
10 A
-
\ o'· LS2 ~S3
LS1
, ~
. '...'
J
IJ;=¡
1
A3
A2 8
; A1
~ --
\1 i
'. ,0 1\)\
"c1- , I
CH fBLDu
CL [ BLD 2 l": I =
~T ) WHITE
GREEN
\-r
~,
,
, \
+B ~1 M--1 RED
Bl 8 BLD 6 BLD 5 . BLD 7
~53ElEl
11
-B IBLD 4 r:-· i ~......J BLUE
I I
ATB - FEED IBLD 7 '- r T f- BLACK i I
ATB - SIGNAL IBLD 8 ,- 1[- t 1- BROWN ~-)
ATB - FEED BLD 5 ' , I F ~LACK
ATB - SIGNAL l elD 6 c... I C...=l~WN ...:~
7
12
1 Slip Ríng 7. Main Shatt Assembly 13. Cable Ties

2. Cover 8. Signal Cable 14. Terminal Block
3. O-ring 9. Strain Relief 15 Nut
4. Screws 10. Circuit Board 16. Washer
5. Reeling Drum Cable 11. Gears 17 . Support Arm
6. Reeling Drum 12. Slip Ring Connector 18. Screws
Figure 1
Reeling Drum Assembly
2 of 4
B
5 13
\ ¡- _
~I _ _ -.1
17 15
~l
e
5 17 14 12 18
~ _=- _ ~-------L\
l\1_ h. ~ ~:_-l:"
B~CK \ j
'f
-íf-¡ I I -=1'-_1'-11 _ - , l e !
- 1 A~- 1 B 7~~~\
13 BROWN 1
3 of 4
SM1 8 -007-007.0 0705 Service Marnual
Installation 3. Remove 0.25 in (6. 35mm) of the insulation from the
reeling drum cable (5) center wires.
Reter to Figure 1.
4 . Connect the reeling drum cable (5) to the terminal
1 . Position the slip ring (1) to the support arm (17) , block (14) on the support arm (17).
an d install the washer (16) and nut (15) . 5 . Secure the reeling drum cable (5) to the support
2 . Attach the slip ring (1) wires lo the terminal block arm (17) with cable ties (13) .
(14) . 6. Tighten the strain relíef (9) .
3. Attach the reeling drum cable (5) wires to Ihe termi
nal block (14) . Note: Ensure there is enough space for the support
4. Secure the reeling drum cable (5) to the supporl arm to clear all wires when it rotates.
arm (17) using cable ties (13).
5. Generously apply lubricant to the slip ring connec 7. Ensurethe o-ring (3) is seated properly in the reel
tor (12) post . ing drum (6).
6 . Install th e slip ring (1) and support arm (17) assem 8. Install the cover (2) to the reeling drum (6) using
bly on the slip ring connector (12). Make sure the screws (4).
slip ring (1) and slip ring connector (12) snap to 9. Install the reeling drum cable (5) onto the reeling
gether securely. drum (6). Refer to "Reeling Drum, R & 1" located in
SM Keysheet Area 18-007 for proper procedure .
Note: Ensure there is enough space for the support
arm to clear all wires when it rotates. Cleaning And Inspection
7. Ensure the 0- ring (3) is seated properly in the reel
8.
in g d rum (6) .
Install the cover (2) to the reeling drum (6) using
screws (4).
A WARNING
Replaci ng The Reeling Drum Cable hazardous. Serious personal injury may
Removal
Refer to Figure 1. recommendations concerning solvents and
1. Remove the screws (4) and cover (2) from the reel cleaning solutions.
ing drum (6) .
2. Holding the reeling drum cable (5) against the sup 1. AII components should be thoroughly cleaned with
port arm (17), cut the cable ties (13). an approved cleaning sOlvent, air dried, and care
3. Disconnect the reeling drum cable (5) from the ter fully inspected .
m inal block (14) on the support arm (17) . 2. AII Loctite®, Permatex®, or other sealant residue
4 . Loosen the strain relief (9) mounted on the inside of should be removed from threads of hardware and
the reeling drum (6). the mounting surfaces of parts that are going to be
5. Pull the reeling drum cable (5) through the strain reused. Prior to applying new thread locking com
relief (9) and out of the reeling drum (6). pounds or sealants , clean threads and surfaces
6. Clean and inspect the assembly. See "Cleaning with Loctite® 7070 Cleaner to ensure best perfor
And Inspection" found later in this documento mance of products.
InsfalJation tigue or stress fractures, and corrosion. Repair or
Refer to Figure 1. replace as required.
1. Feed the reeling drum cable (5) through the wall of 4. AII "soft parts", such as seals, gaskets, back up
th e reeling drum (6) , leaving enough slack to easily rings, and 0- rings, should be replaced.
work with the reeling drum cable (5) . 5. Inspect the integrity of the electrical wires and con
2. If not already stripped , remove 1 in (25.4mm) ofthe nectors . Repair or replace if required .
outer jacket of the reeling drum cable (5) . Unravel 6 . In the event of severe defects , contact factory per
the stainless steel braid and twist it into a single sonnel for directions whether to repair or replace
wire . any major component.
Note: The insulation bonded to the center wire

is difficultto remove. Remove small increments
about 0.1 in (2.54mm) at a time.
4 of 4
Service Manual 1299 SM18-1 8-1 .0
8. Refrigerant oil, contained in a hermetic compres
Air Conditioning Service sor which has had a burnout, may be very aCldlc.
Precautions This oil should not be allowed to touch the skin . It
may cause acid burns.
Maintenance and repair procedures for any air 9. Always check for recommended operating pres
conditioning or refrigeration system should only be sures for each refrigerant and install gaug es to flnd
performed by a certified technician. Safety and the pressures in the system.
environmental concerns must be considered due to 10. Do not mix different types of refrigerants within a
the working fluid used in these types of systems. system . Check refrigerant "R" number before
Refrigerant used in the air conditioning system must charging, to avoid mixing refrigerants.
not be allowed to escape into the atmosphere. Rather, 11 . When switching refrigerants within a system, the
it must be recovered into a closed container or lubrication used in the system must also be
"reclaimed" to ensure the safety of individuals and the changed. Chemical residue from the original re
environment. frigerant will reside in the lubricant and adversely
effect the new refrigerant.
A WARNING
12. If moisture is allowed to enter a refrigerating sys
tem, it is likely to cause considerable damage to
the system. AII parts of refrigerating mechanisms
must be kept dry at all times. Containers of oil must
always be kept tightly sealed to avoid the possibil
could cause chemical burns, frostbite or other
ity of absorbing moisture from the airo
serious injury. Shutdown the engine and
13. Always charge refrigerant into the low side of the
properly "reclaim" the refrigerant from
system. Liquid refrigerant entering a co m pressor
system before removing any line or
may damage the compressor or cause it to burst.
component. Read and follow all of the
14. Make sure that a refrigerant service cylinde i ;:0 not
manufacturer's recommendations
completely filled with liquid refrigerant. It a service
concerning use and storage of refrigerants.
cylinder is completely filled with liquid refrigerant
and then allowed to become warm, the hydrostatic
Review Of Safety pressure inside the cylinder may burst it.
15 . Refrigerant cylinders should always be stored in a
1. When a leak is suspected, make certain that the
cool dry place. Carefully assemble fittings and tub
room is thoroughly ventilated befo re working on
ing to cylinders. Damaged threads are dangerous
the unit. Breathing refrigerants can be deadly.
and costly. Do not use refrigerant storage cylin
2. Refrigerants can be very irritating to the eyes and
ders for any other purpose.
lungs. Service technicians must always avoid ex
posure to refrigerants.
3 . Wear goggles and gloves at all times when servic
Environmental Consideratio ns
ing the system, especially when charging or dis The ozone layer is a thin layer of the earth's upper
charging . These will help protect the eyes , skin,
atmosphere, primarily consisting of ozone (0 3 ) gas,
and hands in case of a sudden leak.
approximately 30 miles (48 km) above the earth's
4. Liquid refrigerant on the skin will freeze the skin
surface. It is often called a screen or shiel d from the
surface and cause "frostbite". If this should hap sun's harmful rays . The ozone layer functions as a filter
pen, quickly wash away the refrigerant with water
from the sun and protects human, plant and sea life
and immediately seek medical attention.
from the damaging effects of ultraviolet rays.
5. Many refrigerants do not have a strong odor and it
Products, such as refrigerants, which contain
might be possible to work in an area without being
chlorofluorocarbons (CFCs) dismantle the ozone layer
aware that there is a considerable amount of refrig
by acting as a catalyst which abnormally breaks down
erant vapor presento
ozone 's molecular structure, converting it into other
6. Many refrigerants are heavier than air and will re
by-products which do not possess ozone's sun
place the fresh air in a room. Danger of asphyxi
blocking abilities. Reckless dumping of CFCs into the
ation is possible.
atmosphere must be prevented to avoid further
7. Refrigerants which contain fluorocarbon must not
destruction of the earth's atmosphere. Conscientous
be exposed to an open flame . Dangerous gases
handling, reclaiming, and recycling of CF~s is
are produced which could result in personal injury.
everyone's responsibi/ity to ensure a healthy
environment now and for generation5 to co m e.
1 of 2
2 of 2
Air Conditioning Compressor,

Recondition
This procedure covers the recondition of the air It is a good practice when disassembling complex
conditioning compressor. For removal and components to lay the parts out in the order that they
installation procedures, see SM Area 18-18. were disassembled. Keeping the parts in this arder
The following pages are taken directiy from the seNice the assembly process.
Ilterature produced by the compressor manufacturero
Multiple compressar models may be covered by this
information. Proper identification of the compressor is
crucial to obtain the correct information to follow from
A WARNING
the charted specifications included in this procedure.
Based on the specific application of this compressor, result from misuse of these products. Rea d
lInk-Belt literature will supersede any discrepancies and follow all the manufacturer 's
in operation, lubrication, maintenance, or service, recommendations concerning solvents an d
implied by the compressor manufacturero Any cleaning solutions .
reviewed with a Link-Belt distributor.
Thoroughly clean the exterior surface of the
If parts are hard to disassemble and assemble , do not compressor to prevent contamination from entering it
use a hammer unless it has a soft face, do not force before beginning the disassembly process.
Service Notes:
SO COMPRESSOR SERVICE MANUAL
TABLE OF CONTENTS
1. Compressor Models 11. Field Replaceable Parts

1.1 1II10del Conversions 11.1 Compressor
2. Compressor Nomenclature 11.2 Clutch
2.1 Identification 12 . Service Operations - General Inlormatlon
3. Cautionary Information 12 .1 General Service Information
3.1 Pressure Release 13. Service Operations - Oil Charging
3.2 Recovery of Refrigerant 13.1 Compressor Repaired Internally and
3.3 Handling of Refrigerant Reinstalled in the System
3.4 Ventilation 13.2 Sanden Compressor Replaced by a New
3.5 Avoid Use of Compressed Air Sanden Compressor of the Same Type
3.6 Warranty for Recycled Refrigerant 13.3 Sanden Compressor Used to Replace a
4. R134a Information Compressor of a Different Type
4.1 R134a / PAG Oil Handling Precautions 13.4 Oil Charge Determination for Long Hose
4.2 Table of Saturation Temperatures and Applications
Pressures 13.5 Oil Retained in System Components
5. Compressor Identification 14. Service Operations - Clutch
5.1 Label 14.1 Armature Assembly Removal
5.2 Manulacturing Date Codes Stamped on 14.2 Rotor Assembly Removal
Compressor - Manulactured in USA Only 14.3 Field Coi! Assembly Removal
6. Compressor Specifications 14A Field Coil Assembly Installation
6.1 Belt Tension 14.5 Rotor Assembly Installation
6.2 Speed Rating 14.6 Armature Assembly Installation
6.3 Basic Compressor Specifications 15. Service Operations - Shaft Seal
6.4 Assembly Torques 15.1 Replacement of Lip Type Shaft Seal
6.5 Acceptable Mounting Angles (SD5H14, SD7B10, SD7H13, SD7H15)
7. Cylinder Head / Porting Guide 16. Service Operations - Cylinder Head / Valve Plate
7.1 SD R134a Compressor Series 16.1 Cylinder Head Removal
8. Service Tools 16.2 Valve Plate Removal
8.1 Special Service Tools 16.3 Valve Plate and Cylinder Head Installation
8.2 Standard Tools 17 . Service Operations - Thermal Protector SWitch
9. Service Procedures 17.1 TPS Testing
9.1 Troubleshooting Chart 17.2 TPS Replacement
10. Inspection Procedures 18. Service Operations - High Pressure Relief Va lve
10.1 Leak Checking 18.1 HPRV Replacement
10 .2 Oil Level Measurement (In Vehicle) 19. Converting R-12 Systems to R134a
10.3 Shaft Turning Smoothness Inspection 19.1 Recommended Procedures for Sanden
10A Clutch Inspection R-12 Compressors Retrofitted with R134a
10.5 Unusual Noise Not Due to Compressor 19.2 Sanden's Procedure for Conversion from
10.6 Unusual Noise Due to Compressor R-12 to R134a
10.7 Valve Plate Test
** Service Oil Information
This service manual has been prepared by Sanden International (USA), Inc. It Includes information on application,
troubleshooting , and repair of auto motive air conditioning compressors manufactured by Sanden Corporation and
its subsidiaries, in accordance with the appropriate SAE standards for mobile air conditioning. Service operations
not described in this manual are not authorized for Sanden compressors. For further inlormation contact your
nearest Sanden representative.
1 0132
Compressor Models
1.1 Model Conversions
TYPE R-12 R134a

5 Cylinder SO-505 S07810 / S05H09
SO-507 S05H11
SO-508 S05H14
SO-510 S07H15HO and S05H14HO
7 Cylinder S08-706 S07810
SO-708 S07H13
SO-709 S07H15
S08-709 S07815
COMPRESSOR NOMENCLATURE
2.1 Identification
R-12 Compressors
so 7 09
S nden reciprocating Number of Cylinders Approximate displacement, in

wobble plate cubic inches
compressors
so 7 H 15 HO
Sanden Number of Por! location Approximate Heavy Out y (H O)

reciprocating Cylinders displacement, or Sealed
wobble plate (H if on head, 8 if in cubic Heavy Out y (SHO)
com pressors on body) centimeters clutch
(divided by 10)
2 of 32
CAUTIONARV INFORMATION
3.1 Pressure Release
Before disconnecting any lines, always make sure refrigerant has been removed from the A/C system by recoveri ng
it with the appropriate recovery equipment.
When working on compressors, separate from the system, always be sure to relieve internal pressure first. Internal
compressor pressure can be relieved by removing the oil plug ( if necessary) or by removing shipping caps / pads
from both ports.
3.2 Recovery of Refrigerant
Never discharge refrigerant to the atmosphere. Always use approved refrigerant recovery / recycling equipment to
capture refrigerant which is removed from the A/C system. Do not mix refrigerants in the same piece of equipment;
one should be designated for R-12 and another for R134a.
3.3 Handling of Refrigerant
Always wear eye and hand protection when working on an A/C system or compressor. Liquid refrigerant can cause
frostbite and / or blindness.
3.4 Ventilation
Keep refrigerants and oils away from open flames. Refrigerants can produce poisonous gasses in the presence 01a
flame. Work in a well-ventilated area.
3.5 Avoid Use of Compressed Air
Do not introduce compressed air into an A/C system due to the danger of contamination.
3.6 Warranty for Recycled Refrigerant
The warranty offered by San den International (U.S.A.), Inc., on air conditioning compressors when used with
recycled refrigerant will be the same as for new refrigerant provided that the following SAE standards are met
R-12 R-134a
Refrigerant Purity J1990 J2099
Recycling Machine J1989 J2210
Recycling machines must be validated to the appropriate SAE standard by Underwriters Laboratories. Recycled
refrigerant from other sources must meet the appropriate ARI standards. Failure to comply with these provisions
may void any warranty on the compressor.
R134a Information
4.1 R134a / PAG Oil Handling Precautions
As a conscientious member of the global community, Sanden Corporation wlth its subsidiaries is committed to the
elimination of CFC-based refrigerants. This manual focuses on service information for Sanden com pressors
intended for use with R134a and PAG oils.
3 of 32
4.1 (Cont.)
1. Always follow safety precautions described in Section 3.
2. Do not discharge R134a into the atmosphere. Even though its ozone depletion potential is zera, it does have
g lobal warming potential. Recovery and recycling are mandated by the Clean Air Act. Use recovery equipment
designated only for R134a. Never introduce another refrigerant into the R134a equipment.
3 . Never mi x R134a with other refrigerants or A/C systems failure is likely to occur.
4. Use only Sanden specified PAG lubricants for R134a systems using Sanden compressors . If other lubricants
are used, A/ C system failure is likely to occur.
5. Never Introduce R134a or PAG oil into a system not designed for them except when following the appropriate
retrof it pracedure described in Section 19 .
6. The Sanden specified PAG oils used in R134a systems absorb atmospheric moisture very quickly. Moisture in
the A/C system can cause major damage or failure.
Never leave PAG oil exposed to air for a prolonged time. Tightly reseal the oil container immediately after
each use.
During A/C system repair, cap all fittings as soon as opened and leave capped until just before they are
reconnected .
If a repa ir is performed on an R134a compressor or system , evacuate the system for at least 45 minutes
before recharging to ensure the removal of moisture which may have been absorbed by the PAG oil in the
compressor and system .
4.2 Table of Saturation Temperatures and Pressures
Tem p. (F) Pressure (psig) Temp. (F) Pressure (psig) Temp. (F) Pressure (psig)
-40 -7.2 in. Hg 25 22 105 135
-30 -4.8 in . Hg 30 26 110 147
-20 -1.7 in. Hg 40 35 115 159
-15 O 50 45 120 172
-10 2 60 57 130 200
-5 4 70 71 140 231
O 6 80 85 150 264
5 9 85 95 160 301
10 12 90 104 180 3
15 15 95 114 200 485
20 18 100 124 210 549
4 of 32
COMPRESSOR IDENTIFICATION
5.1 Label
,.---------------------------------- - ,~ ...".'-----------------------------"..
Manufacturing location code SS)iH1:}
00-006 Japan
70-79 USA ··..···..·..···..···..···.. ··t::: ..............................................,
80-89 Singapore )~:Ml~N\?,; ....., .. ,J.,
¡ {"\.'''' ,t ¡::: o' ! n·1 i '1· • ',;,,) :
! :.. ::.?:~~t:.,.!~ .. l.~\ ....~~... :.~.\.i
Serial Number ········································1·············.. ........ . . _-, . -_ ... ,-----------, --_ ...... _-, ...
: _. _. "" . _---:-.
'_ ... ,_ ......... _.... _........................ ,--~,
l\t1 onth of man ufactu re (1 -12T-""""""""'"''''''''''''''''''''''''''''
Year of manufactu re (Iast dig it)·"""·""·"""·"",,,·,,,,··,,,,,·,··,,···,,,·,,·
5.2 Manufacturing Date Codes Stamped on Compressor - Manufactured in USA Only
Manufacturing date codes are stamped on the mounting Sanden internal I.D. code
or boss at the front left of the compressor as seen when
facing the clutch, with oil plug or adaptor up.
Year of manufacture (first digit): ................................... :::

(i.e.3 indicates manufacture in 1993),,, ........ ,,,··.. ·..
Month of manufacture (Iast digit):'···..
Jan. - Sept.: 1-9
OcL: X
Nov.: Y
Dec.: Z
5 of 32
COMPRESSOR SPECIFICATIONS
6.1 Belt Tension
Grooves Tension, lb (kgf)

A 121 ± 5 (55 ± 2)
8 132 ± 5 (60 ± 2)
e 132 ± 5 (60 ± 2)
M 132 ± 5 (60 ± 2)
PV4 132 ± 5 (60 ± 2)
PV6 198 ± 5 (90 ± 2)
(PolyVee tension based on 33 lb (15kgf) per groove).
6.2 Speed Rating
Maximum RPM
Model Clutch Type
Constant Downshift
S05H14 Std. 6,000 7,000
S05H14 HO 4,000 6,000
S07810 AII 6,000 7,000
SD7H13 AII 6,000 8,000
S07H15 Std. 6,000 8,000
SD7H15 HD 4,000 6,000
S07H15 SHD 4,000 4,000
6.3 Basic Compressor Specifications
Typieal Weight , lb. (kg.) Standard Oil Charge

Oisplaeement
Model Refrigerant Amount Rotation
Oil System
Cu.in. (ce) Compressor Cluteh Assembly fl. 02.
Type Type
(ce)
7.2=0.5
TXV
(210=15)
Elther
S05H14 R134a 8.4 (138) 11 .2 (5.1) 6.0 (2.7) 17.2 (7.8) SP-20 Way
No
CCOT
Standard
CW
No
S07610 R134a 6.1 (100) 5.9 (2.7) 3.3 (1.5) 9.2 (4.2) SP-l0 TXV (Cl ockwlse
Slandard
only)
CW
4.6=0 .5
S07H13 R134a 7.9 (129) 9.3 (4 .2) 4.6 (2.1) 13.9 (6.3) SP - 20 TXV (Clockw,se
(135=15)
only)
4.6=0.5
TXV
(135= 15) CW
S 07H15 / HO R134a 9.5 (155) 9.9 (4.5) 5.3 (2.4) 15.2 (2.4) SP-20 (Clockwlse
8.1 =0.5 only)
CCOT
(240= 15)
4.6=0.5
TXV
(135=15) CW
S07H15/ 17.6 (8.0) SP-20 (Clockwise
R134a 9.5 (155) 9.9 (4 .5) 7.7 (3.5)
SHO 8.1 =0 .5 only)
CCOT
(240= 15)
6.4 Assembly Torques
Item ft-Ib N-m kgf-c m

Armature retaining nut, 1/2" - 20 22.4:::':::2.9 30.4:::':::3.9 31 O:!.. 40
Armature retaining nut, M8 13.0:::':::2.2 17.7:::':::2.9 180 + 30
Cylinder head bolts, M6 10:::':::2.2 13.7:::':::2.9 140 :::'::: 30
Cylinder head bolts, M8 25.3:::':::3.6 34.3:::':::4.9 350:::':::50
Oil filler plug 14.5:::'::: 13.6 19.6:::':::4.9 200 :::'::: 50
Hose fitting 1" - 14 rotolock 26.7:::':::2.9 36.3:::':::3.9 370 :t 40
7/8" Tube-O 23.9:::':::2.9 32.4:::':::3.9 330 :::'::: 40
3/4" Tube-O 17.3:::':::2.5 23.5:::':::3.4 240:::'::: 35
Pad fitting bolt, M10 28.9:::':::2.9 39.2:::':::3.9 440:': 40
Pad fitting bolt, 3/8" - 24 28.9:::':::2.9 39.2:::':::3.9 440 :::'::: 40
Pad fitting bolt, M8 26.3:::':::2.9 34.3 _ 3.9 350 :::'::: 40
Clutch lead wire clamp screw 11 :::':::3 in-lb 1.3:::':::0.3 13:!.:: 3
High pressure relief valve 7.2:::':::1.4 9.8:::':::2.0 100:::':::20
Thermal protector switch clamp bolt 7.2:::':::2.2-1.4 9.8:::':::2.9-2.0 100:::':::30-20
Clutch dust cover screws (6 - M5) 6.5:::':::1.4 9:::':::2 90:::':::20
Clutch dust cover screws (3 - 1/4" - 20) 2.7:::':::0.9 3.6 :t 1.2 37-+ 12
6.5 Acceptable Mounting Angles
AII SO - R134a Compressors
7 of 32
CYLINDER HEAD / PORTING GUIDE
7.1 SD R134a Compressor Series
For SDSH14 , SD7H13, SD7H15 and SD7H15HD / SHD Units

Hose Por! Inlo rmation SO Compressor Series
Sande n Posilion on
Se rvicc Kit Name Cylinder Suction POr! Discharge Port TPS or 7HI5
Part No. head 5HI4 7HI3 7H15
Dimension/l"ype DimensionlType Switch? HO/SHO
956D-;¡('O;) C VertIcal Tube - O 1"" - 14 rotoloc k Tube-.Q 1" - 14 rotolock No X
roa FL V leal Tube-O # 10 (7 ! R") Tube-O #8 (3/4") No X
!JCO. gf30 K Hm .l lJm~1 Tu lJe-O ii l O (7/8"1 Tube -O #8 (3W) No X

gl%.Jq LH~O' M ~ U/ll..u 13 ' I U01:- - 0 1" - 14 lowuck Tube- Q 1" - , 4 rotolo ck No X
9 1:'1,1 91>3Q' Q Hor fw ntal GM Pa tl , 3/S' - 24 13"11 GM Pad, 3/8 ' - 24 Bol1 No X
G~.r1 PilO. 3 18
4
969!J-963 0 ~ OH HOrlzontat - 2 4 Bnll GM Pad, 318" - 24 Boll Ves X
9298-9630' U VI~rt¡ c,Ji Dad - M10 x 1 Boll Pad - MI O x 1 Boll No X
95 17 -9630' UB Ve ! I(:';~, Pad - M IO x 1,25 &JII Pad - MlO x 1,25 BolI No X
9511,- ~1330' lIB HtJrllO nlal Paa - M IO x l ,~S BolI Pad - MIO x 1,25 Boll No X
7.-11 2-ljf~::W CB Vertical l ube - O 1 . - 14 rülo lock lltb e- O ' " - 14 rotolo ck No X X X
7532-9630 JI) Vert l (! ~1 Tube -O "" 0 {l iS J Tube-O #S (3 /4" ) No X X X
1860- 963 0 JE Vort lcol Tube-O #10 (7'S ) Tube-O #8 (3 /4") No X X X
7!lI;2-9630 KG HOII1-ü nla J T,.be- O ., 10 (7IS") Tube-O #S (3/4 ) No X X X
7406-9830' "-1D '-/.Orilu maJ Tuue-O 1" - 14 ro Ioc''"'i Tube - O r· - '4 rololo ck No X X X
7J33 963 0 OC HorilOfl1al GM Pad, 3 'S . '1 :1 8011 GM Ped, 3/S' - 24 Bol1 No X X X
7" 84 - 9630 OD Hm ,zont;¡1 P':l cf - MlO x , .25 SoU Ped - M10 x 1,25 Boll No X X X
72>'IQ -3631 UK VeMII.:~1 Pao - MIO x l 2 5 BOl! Pad - MIO x 1.25 Boll No X X X
A) Sanden R134a compressors do not offer the option of charging valves on the compressor,
8) * Indicates that a compressor featuring this cylinder head should not be mounted with the suction port at the
bottom ,
~j~~iJ~~
\:) :\f
·'\,::::2..i:x::;···
u
~" ~l~~
,.,,:-'\.
{ ...~ ~~.'
8 of 32
SERVICE TOOLS
8.1 Special Service Tool5
These tools can be obtained from your local tool supplier.
\'~.::
. ';.'"
:' 1 / ... :.~:"~.
: ~~~~
.......:
:,
.. _-~,~~~
···············:;r~:¡W~:·~;;~;:··········
~. ':: ~ ~:.~ r;." ~ ',<
«'t~;'l
t:~~:':Li~~,l· .~ .'0'''''--''-' ." \.~.."'.~... /
.. ".~
", .'
1. Oil Dipstick 5. Lip Seal / SD7 Seal Plate Tool 9. Rotor Installation Driver
2. Armature Plate Spanner 6. Armature Driver 10 . O-Ring Hook
3. Armature Plate Puller 7. Rotor Puller Jaws
4. Rotor Puller Set 8. Shaft Seal Protecti ve Sleeve
8.2 Standard Tool5
.. .... "
<>.w ."'::
.. ~,~;:~~. '.~
",,>[~<¡~,;~;~::;;: .
.:..:., .'
1. External Snap Ring Pliers 4. Gasket Scraper

2. Internal Snap Ring Pli ers 5. Graduated Cylinder
3. Feeler Gauges
9 of 32
SERVICE PROCEDURES
9.1 Trou bleshooting Chart
This chart refe rs spe cially lo the Sanden compressor. During diagnosis follow Ihe inspeclion procedures in Ihe
seq uence shown until a d efect is found . Then perform the re pai r in the Cause and Remedy Seclion. If th is repair
does not fully solve Ihe p roblem , proceed lo the next inspectio n step .
Symptom Problem Diagnosi s and Inspection Cause and Remedy
'.... ",:.: : .:J:~ ~~ ."

~:"r ~~~~:~~;~;:~~~" : ~~S:~~~~:" ............................................ .
:::.::;.::~:..,~:-,. ::~.;x:; :.:'';:~'~,~;:~<: : ;:
.. ::..' ~::..:.:.•::~:,. :~.:.,,".:::-:. p:-:.::.:..:.',:. : :~ ~~:-.:.~:::j~ ~·x:~·: ;~~ ~"::~X~ ~~,~:..~;'~ : .~~~:;
o::~".:~:,.;1~ ,~. ~~:~:-'~:::~~':~:~: :~:-'~~.:~:~~~ ¡~:~
~.:..;. >:-~::-:-:~:-: ~.~~::: ::<;-::~:';>: '
.~ ,·:~~~+::0~~:t~'~f·~/~~C ..... ... . ) .<':,.:
.::-:.::...; .:~::; .. :: .,-... ....
:'.:~, :.,;':-:.:-~;.; .. ;: .
:~: \~::-;~j~ ~,~:,;\:: ~.~:-'" ~ ~~~~~

.:. <.~.~,:.:,,~:-' >~:-:::~~~ :;.<.::...'~
.: <;~~~. ~. ~ ~:"~' : ,'..~ -:
.~ ~):; f~}:,,~' :::~:"':-) ~.~:~.
: : <;~':~<~~~~ <~~~::;<~:\..:::-:~~;:~
::. i :>,,\,,: ~;:-~..::::~::~ :~ ó.~:"::"t~ ';.~""«
::> ~~~< ,~~~::,}:: .:;~.:~~;....... . :. '~::'~~'<~:'::. :. ..::~"~~~~~ ; :::' .

::'..,::~:-:-. . .
.:>::.~ ~ .'>':~::~~.:':~: . . ...................:: .: ~ ..., ~ ~:"'\~':-" ~~ ~ }.«;:;$" :-'<:';,~
~'.~.~: :',~ f>·~: ~~,:-,::::~~ . ~:::~~:-,:~::.~:
::' '~:-.<:~:-~.: -(.. :~:::-:::",::; '::~':-":-:' :;~.~~>:~.. \
: :~ ...~\t~:~~~\ ................................
" .... ~~~ . " . ,', .... , ... , " , ...... ,',................ ... .
<~..:~~~ .~ :~~:~::~:.:~~?:::~~":~:.'~~:>
.. ~: ... ~'::~:;>~{:~:::-~',::-~~:::,\~~::~~~~:.<,,~:'
~\:~~:~:~ .~~':,.~::.::-.
.~
:"~~~~:~~.::~:"~:~\~~:;;~~~;.~' .
: ..'....:.~..~:-~. ::;::-. ~.:;.:~.:
. ~.=::~ :;.':~·:::~::x <.:::.~::.;-;- ~:-;::~~:: .•:. ~:::'
10 of 32
INSPECTION PROCEDURES
10.1 Leak Checking
1. Visual Inspection - Although oil seepage does not necessarily indicate leakage of refrigerant, it should be
considered a sign that a leak may exist. Look for the following items:
Oil seepage in shaft seal area (between clutch and compressor) - repairable.
Pinching or extrusion of front housing O-ring - nonrepairable.
Oil around cylinder head (gaskets, service valves, fittings) - repairable.
Oil around oil plug - repairable.
Stripped threads - nonrepairable.
Oil around crack in compressor body - nonrepairable.
2. Soap Bubble Oetection - Any leak showing up as bubbles on the compressor will require repair.
3. Shop Type Electronic Oetectors

Ensure that the detector being used is sensitive to R134a refrigerant. Many leak detectors intended for
R-12 cannot detect R134a leaks.
Use the leak detector in accordance with the manufacturer's instructions.
The leak rate at any portian of the compressor should not exceed 1.0 oz./yr. Make sure that a suspected
leak is an actual flow of refrigerant, not a small pocket of refrigerant trapped in a recess. Cleaning the
suspect area with soap and water (never a solvent) or blowing off the area with compressed air can help
confirm a suspected leak.
Leak check procedures should be in accordance with SAE J1628.
4. Leak Oetection Oyes - The use of leak detection dyes is not recommended by Sanden as their chemical ca m
positions are proprietary and their effects on Sanden oils and elastomers are unknown at this time.
10.2 Dil Level Measurement (In Vehicle)
Oillevel in the compressor should be checked when a system component has been replaced, when an 011 leak is
suspected, or when it is specified as a diagnostic procedure.
1. Run the compressor for 10 minutes with the engine at idle.
2. Recover all refrigerant from the system, slowly so as not to lose any oil.
3. Determine the mounting angle of the compressor from horizontal (i.e., oil plug or adapter on top). This is most
readily done by using a machinist's universal level, if access to the compressor permits.
11 of 32
10.2 (Cont.)
4. Remove the oil filler plug. Using a socket wrench on the armature retaining nut, turn the shaft clockwise until the
counterweight is positioned as shown.
5. Insert oil dipstick up to the stop, as shown in the figure above, with the angle pointing in the correct direction .
6. Remove dipstick and count number of notches covered by oil.
7. Add or subtract oil to meet the specifications shown in the table.
8. Reinstall oil plug. Seat and O- ri ng must be clean and not damaged. Torque to 11-15 ftalb (15-20 Nam ,
150-200 kg¡acm).
Acceptable oil level in increments

Mounting Angle (Degrees)
SD5H14 SD7H15
O 3-5 5-7
10 4-6 6-8
20 5-7 7-9
30 6-8 8-10
40 7-9 9-11
50 8-10 10-12
60 8-10 11-13
90 8-10 16-18
12 of 32
10.3 Shaft Turning Smoothness Inspection
1. If on vehicle, remove refrigerant from A/C system and disconnect hoses.
2. If on bench, uncap fittings.
3. Using a socket wrench on the armature retaining nut, turn the shaft clockwise only.
4. If severe rough spots or catches are felt while turning shaft, the compressor has be en damaged internally and
must be replaced.
10.4 Clutch Inspection
1. Measure voltage at clutch. Low voltage at the clutch may be due to poor ground or power connection, or prob
lems with the vehicle electrical system. Check for tight fit of field coil retaining snap ringo
2. Measure current draw when clutch is engaged. Normal current should be 3.6 - 4.2A at 12VDC.
Overcurrent- Short circuit within field coil or in compressor circuit.
No current - Open circuit.
If a short or open is found in the field coil, it must be replaced.
3. Air Gap
Clutch air gap should be 0.016 - 0.031 in (0.4 - 0.8 mm). Measure with a feeler gauge.
Adjust as per Section 14.6
4. Suspected Clutch Rotor Bearing Noise

Remove drive bel!.
With clutch disengaged, rotate pulley by hand. If excessive roughness or wobble is found, replace the
clutch rotor assembly.
10.5 Unusual Noise Not Due to Compressor
Unusual noises may be caused by components other than the compressor.
1. Compressor Mounting - Check for:

Loose belt - see belt tension specifications.
Broken bracket or compressor mounting ear. Replace broken componen!.
Missing, broken, or loose mounting bolts. Replace, reinstall, or tighten.
Flush fit of compressor to bracket and vehicle engine. Replace any part not properly fitted.
Loose or wobbling crankshaft pulley. Check for damage to pulley, incorrect center bolt torque or center bolt
bottoming. Repair to vehicle manufacturer's specifications.
Bad idler pulley bearing. Replace if necessary.
2. Other Engine components - Check for noise in:

Alternator bearing
Air pump (if present)
Water pump bearing
Valves
Timing belt or chain
Power steering pump (if present)
Loose engine mount bolts.
13 of 32
10.6 Unusual Noise Due lo Compressor
1. Su ctio n pressure less than about 5 psig can cause unusual noise. Charge refrigerant to proper amount and test
by applying heat to evaporator to increase suction pressure.
2 Clutch beari ng--See clutch Inspection in section 10.4.
3 . Oil level--insuffici ent oil can cause unusual nois e. See O il Level Check Procedure in Section 10.2.
4. Val ve Noise- -test for valve plate assembly failure per Valve Plate Test Procedure in Section 10.7.
10.7 Valve Plale Tesl
1. Suction or discharge valve b reakage will cause a clacking sound at idle.
2. If head gasket failure occurs , discharge pressure will be low and suction pressure will be high at ¡die.
3. Va lve and gasket condition can be checked as follows:

Connect gauge set to suction and discharge service valves.
Run compressor for 5 minutes at idle and stop.
Observe time for discha rge pressu re and suction pressure to equalize. If less than 2 minutes , in a TVX
system , a valve or gasket may be damaged . CCOT systems will equalize more quickly.
FIELD REPLACEABLE PARTS
11.1 Compressor
., I;(.: 1,':~·~Jl : ·~
,.'
" \.
: :.
1. Stlaft Ke y* 7. Valve Plate Assembly* 13. TPS Clip (Optiona l)

2 Fe lt Rmg* 8. Head Gasket* 14. TPS Screw (Optional)
3. Shaft Seal Snap Ring* 9. Cylinder Head* 15. Shaft Seal Kit - 2, 3 & 4
4. Li p Seal wlth O-rin g* 10 Cylinder Head Bol! 16. Valve Plate Kit - 6, 7 & 8
5. Oi l Pl ug 11 Pressure Relief Valve (Optional) 17. Cylinder Head Kit - 8 & 9
6. Blo ck Gasket* 12. Thermal Protector Switch 18. Gasket Ki t - 6 & 8
(Optional)
14 of 32
Service Manual 0999 SM18-1 8-4 .0
11.2 Clutch
20A Armature Oust Cover Screw (SO-S) 23 Armature Plate* 27 Rotor Assembly*
20B Armature Oust Cover Screw (SO - 7) 24 Clutch Shims* 28 Field Coil Assembly Snap Ri ng ·
21A Arma ture Oust Cover (SO- S) 25 Rotor Snap Ring* 29 Field Coil Assembly
21B Armature Oust Cover (SO- 7) 26A Rotor Bearing Oust Cover (SO-S) 30 Accessory Kit - 1, 22 , 24, 25 & 28
22 Shaft Nut* 268 Rotor Bearing Oust Cover (SO - 7) 31 Armature / Rotor Assembly Kit
23 & 27
Service Operations - Generallnformation
12.1 General Service Information
It is reeommended that a new reeeiver-drier or aeeumulator-drier be installed if a eompressor is replaeed or an

internal repair is made.
1. Keep dirt and foreign material from getting on or into the eompressor or the A/C system. The area arou nd the
A/C hose fittings should be earefully eleaned with a non-petroleum based solvent before the eonneetions are
broken. AII parts to be reused or installed should be eleaned with a non-petroleum based solvent and b lown
dry with elean eompressed air or lint-free eloths.
2. Trouble-free installation and operation of an SD eompressor require:

Correet pulley alignment.
Correet fit of eompressor mounting surfaees to the braeket and eorreet fit of the braeket to the eng in e.
Clearanee between eompressor and braeket should not exeeed 0.2mm (O.008in) per ea r for ear- maunt
eompressors or OAmm (0.016in) total for 2 ears.
Correet torque of all mountlng bolts and nuts.
Correet drive belt tension.
3. Never operate the eompressor at high speed or for a prolonged time without a suffieient refrigerant eharge in the
system. Probable results are overheating , internal damage and seizure.
4. If an internal repair is performed on an R134a eompressor, evaeuate the A/C system far at least 45 minutes be
fore reeharging to remove moisture whieh may have been absorbed by the PAG oil in the eompressor.
5. Parts whieh require lubrieatian before assembly, sueh as O- ri ngs, should be lubrieated with elean 5GS refriger
ant oil.
15 of 32
Service Operations - Oil Charging
13.1 Com pressor Repaired Internally and Reinstalled in the System
1. Before any internal repair is done , drain the oil from

the compressor.
Remove the oil plug and drain as much oil as
possible into a suitable container.
Remove the caps (if present) from suction and
discha rge ports.
Drain oil from the suction and discharge ports
into a suitable container while turning the shaft
clockwise only with a socket wrench on the
armature retaining nut.
2. Measu re and record the amount of oil drained from

the compressor.
3. Ins pect the oil for signs of contamination such as

discoloration of foreign material.
4. Pe rform repair to the compressor.

~'''''''''.,-;..
' ..
16 of 32
13.1 (Cont.)
5. Add the same amount of new oil to the compressor

as was measured in step 2. Be sure to use the cor
rect oil for the compressor as shown in Section 6.3.
6. Reinstall oil plug. Seal and O-ring must be clean
and not damaged. Torque to 11-15 ft-Ib (15-20
Nm , 150-200 kgf·cm). Be careful not to cross
thread the oil plug.
7. It is recommended that the oil quantity be con
firmed after reinstallation of the compressor to the
vehicle as per Section 10.2.
13.2 Sanden Compressor Replaced by a New San den Compressor of the Same Type
1. Drain oil from the old compressor; measure and record the amount as per the procedure in section 12.1
2. Drain oil from the new compressor as per section 13.1
3. Add new oil of the correct type to the new compressor as shown in section 6.3. Use the same quantity as was
removed from the old compressor in step 1.
4. Reinslall oil plug. Seal and O-ring must be clean and not damaged. Torque lo 11-15 ft 'lb (15-20 Nm,
150-200 kgf·cm).
5. II is recommended Ihal Ihe oil quantity be confirmed after inslallalion of Ihe new compressor to Ihe veh icle per
seclion 10.2.
13.3 Sanden Compressor Used to Replace a Compressor of a Different Type
This section applies lo replacemenl of anolher manufacturer 's compressor or lo Ihe replacemenl of a Sanden
compressor by a differenl model San den compressor. In Ihis case , Ihe procedure of Section 13.2 should be
followed , except Ihal Ihe oil quantily musl be confirmed after inslallation of Ihe new compressor lo Ihe vehicle as
shown in Seclion 10 .2.
17 of 32
13.4 Di l Charge Determination for Long Hose Applications
13.4.1 TXV Systems, Less than 56 OZ. (1600g) Refrigerant Charge
1. The desired oil charge for the systems with unusu

al/y long hoses, such as trucks , tractors, etc., can
be determined based on the total refrigerant
charge when less than 56 oz. (1600g) refrigerant is
used.
2. Calculate the desired oil charge as below:
SD5H14: Oil amount (f1.oz.) = (Refrigerant

charge in oz. x 0.125) + 1.35. Oil amount (cc) =
(Refrigerant charge in grams x 0.125) + 40.
SD7H15: Oil amount (f1.oz.) = [(Relrigerant

charge in oz. x 0.06) + 2.2] -:- 0.9. Oil amount (cc) =
[(Refrigerant charge in grams x 0.06) + 60] -:- 0.9.
3. For a new compressor to be used in this type 01

system , subtract the standard oil charge shown in
Section 6.3 from the desired total oil charge to de
termine how much oil should be added to the com
pressor.
4. Remove the oil filler plug and charge the compres

sor with the amount of additional oil determined in
step 3 . Use only new oil of the correct type as
shown in Section 6.3 .
5. Reinstall 011 plug. Seat and O-ring must be clean

and not damaged. Torque to 11-18 fHb (15-25
Nm, 150-200 kgf.cm).
13.4.2 TXV Systems, More than 56 OZ. (1600g) of Refrigerant
For systems with more than 560z. (1600g) refrigerant, on-vehicle testing is required to determine oil
charge .
1. Charge system with refrigerant.
2. Set up the vehicle as follows:

Doors open.
Maximum blower speed.
Ambient temp . at least 75 oF (24 oC).
3. Run the compressor at one of the speeds listed in

the table below for 10-15 minutes.
4. Wllile maintaining engine speed , turn off A/C sys

tem and immediately turn off engine.
5. Recover relrigerant from the system .
6. Remove compressor from vehicle.
7. Remove the oil plug and drain as much oil as pos

sible into a suitable container.
18 of 32
13.4.2 (Cont.)
8. Drain oil from the suction and discharge ports into

a suitable container while turning the shaft clock
wise only with a socket wrench on the armature re
taining nut.
9. Measure and record the volume of the oil drained

from the compressor.
10. Approximately 0 .5 fl.oz. (15cc) will remain in the

compressor as a film coating the internal surfaces.
Add 0.5 fl.oz. (15cc) to the recorded volume of the
oil. This is the calculated amount of oil in the com
pressor.
11. The amount of oil in the compressor after running

for 10-15 minutes should be as per the table at
right, if the proper amount of oil was in the system.
Determine from the table what the correct amount
of oil should be for the particular speed used in
step 3. (The table shown applies to SD5H14 com Oil in compressor
pressors. Other compressors will exhibit a lesser Comp. RPM
fl.oz . ce
oil amount dependent upon type. It is important
that a quantity of oil remains in the crankcase after 1,000 3.4 100
the test.) 2,000 2.5 75
12. Compare the desired amount of oil as determined 3,000 1.7 50
in step 11 wlth the calculated actual amount of oil in 4,000 1.3 40
the compressor, which was determined in step 10.
If the amount of oil actually in the compressor 5,000 1.2 35
[amount drained plus 0.5 fl.oz. (15cc)) is less than o Vehicle doors open
the desired amount of oil, add oil as necessary to o Maximum blower speed
the container and pour back into the compressor, If o Ambient temperature at least 75 o F
the amount of oil actually in the compressor is too
much, remove oil from the container until the cor
rect amount is reached , and pour back into com
pressor. the amount of oil poured back into the
compressor should equal the desired amount
(from the table), minus 0.5 fl.oz. (15cc). Use the
correct oil type as per Section 6.3.
13. Reinstall 011 plug. Seal and O-ring must be clean

and not damaged. Torque to 11 -15 ftolb
(15-20 Nom, 150-200 kgfocm).
19 of 32
13.5 Oil Retai ned in System Com ponents Typical oil amou nt
Component
f1.02. ce
For I'efer ence, the amount of oil typically retained in Evaporator 2.0 60
other system components after running at 100 rpm
compressor speed is shown at righl. These volumes Condenser 1.0 30
wi ll of course vary with different designs of the Rece iver - Drier 0.5 15
cO lll ponents and compressar speeds prior to shut Accumulatar 2.0 60
down .
Hoses (normal length) 0.3 10
SERVICE OPERATIONS - CLUTCH
14.1 Armature Assembly Removal
14.1a Keyed Shaft Armature Removal
(Note: Keyed shaft can be identified in that the holes for the armature plate spanner will have
threads in them. )
1. If armature dust cover is present, remove the 3 or 6

bolts holding it in place and remove cover. If auxilia
ry sheet metal pulley is present, remove the screws
holding it in place. Then remove pulley.
2. Insert pins of armature plate spanner into threaded

holes of armature assembly.
3. Hold armature assembly stationary while removing

retain ing nut with 3/4" , 19mm or 14mm socket
wrenc h, as appropriate.
4. Remove armature assembly using puller. Thread 3

puller bolts into the threaded holes in the armature
assembly. Turn center screw clockwise until arma
tu re ass embly comes loose.
5. If shims are above shaft key, remove them now. If

shims are below shaft key, the key and bea ring
d ust cover (if present) must be removed befare
sh ims can be removed .
6. Rem ove bearing dust cover (if present). Use cau

tion to prevent distorting cover when removing il.
7. Rem ove shaft key by tapping loose with a fl at blade

sc rewdriver and hammer.
8. Remove shims. Use a pointed tool and a small

screwdriver to prevent the shims from binding on
the shaft.
20 of 32
14.1 b Spline Shaft Armature Removal
(Note: Spline shaft can be identified in that the holes for the armature plate spanner will not have
threads in them.)
1. If armature dust cover is present, remove the 3 or 6

bolts holding it in place and remove cover. If auxil
iary sheet metal pul ley is present, remove the
screws holding it in place. Then remove pulley.
2. Insert pins of armature plate spanner into threaded
holes of armature assembly.
3. Hold armature assembly stationary while removing
retaining nut with 3/4", 19mm , or 14mm socket
wrench, as appropriate.
4. Lift off armature plate with fingers. If armature does
not come off easily, spray an anti seize oil into shaft
to loosen. Armature plate can also be loosened by
gently prying between rotar and armature plate
with two flat screwdrivers.
5. If shims are above shaft key, remove shims. If
shlms are below shaft key, the key and bearing
dust cover (if present) must be removed befare the
shims can be removed.
6 . Remove bearing dust cover (if present) . Use cau
tion to prevent distorting cover when removing il.
7. Remove shims. Use a pointed tool and a small
screwdriver to prevent the shims from binding on
the shaft.
21 of 32
14.2 Rotor Assembly Removal
1. If bear ing dust cover has not been removed , re

move it now. See step 6 of Section 14.1 , for Arma
ture Assembly Removal.
2. If internal snap ring for bearing is visible above the
bearing , remove it with internal snap ring plie rs.
3. Remove rotor s nap ring o
4. Remove shaft key.
5. Remove rotor pulley assembly :
Insert the lip of the jaws into the snap ring
groove.
Place rotor pulley shaft protector (Puller set)
over the exposed shaft .
Align thumb screws to puller jaws and finger
tighten . Turn puller center bolt clockwise using
a socket wrench until rotor pulley is free.
14.3 Field Coil Assembly Removal
1. Loosen lead wire clamp screw with #2 Phillips

screwdriver until wire(s) can be slipped out from
under clamp.
2 . Undo any wire connections on the compressor
wh ich would prevent removal of the field coil as
sembly.
3 . Remove snap ring o
4 . Remove the field coil assembly.
14.4 Fi eld Coil Assembly Installation
Reverse the steps 01 Section 14.3. Protrusion on underside of coil ring must match hole in front housing to prevent
m ovement and correctly locate lead wire(s).
22 of 32
14.5 Rotor Assem bly I nstallation
1. Place compressor on support stand, supported at
rear end of compressor. If the compressor must be
clamped in a vise, clamp only on the mounting
gears, never on the body of the compressor.
2. Set rotor squarely over the front housing boss.
3. Place the rotor installer ring into the bearing bore.

Ensure that the edge rests only on the inner race of
the bearing, not on the seal, pulley, or outer race of
the bearing.
4. Place the driver into the ring and drive the rotor
down onto the front housing with a hammer or ar
bor press. Drive the rotor against the front housing
step. A distinct change of sound can be heard
when using the hammer to install the rotor.
5. Reinstall rotor bearing snap ring, if it has been re
moved, with internal snap ring pliers.
6. Reinstall rotor retaining snap ring with external
snap ring pliers. If a bevel is present on the snap
ring, it should face up (away from the body of the
compressor) .
7. Reinstall rotor bearing dust cover (if present) by
gently tapping it into place.
14.6 Armature Assembly Installation
1. Install shaft key wlth pliers.
2. Install clutch shims. NOTE: Clutch air gap is deter

mined by shim thickness. When installing a clutch
on a used compressor, try the original shims first.
When installing a clutch on a compressor that has
not had a clutch installed before, first try 0.04",
0.02", and 0.004" (1.0,0.5, 0.1 mm) shims.
23 of 32
14.6 (C ont.)
3. Align keyway in armature assembly to shaft key.

Using driver and a hammer or arbor press, drive
the armature assembly down over the shaft until it
bottoms on the shims. A distinct sound change will
be noted if driving with a hammer.
4. Replace retaining nut and tarque to specification.
1/2 -20: 20-25 ftolb

(27-34 Nom, 270-350 kgocm)
M8: 11-15ft o lb
(15-21 Nom, 150-210 kgfocm)
5. Check air gap with feeler gauge . Specification is

0.016" -0 .031" (OA -O.8mm). If gap is not even
around the clutch , gently tap down at the high
spots. If the overall gap is out of spec., remove the
armature assembly and change the shims as nec
essary.
6. Replace armature dust cover (if used) and to rque 3

ar 6 bolts to specification below.
3 - 1/4-20 bolts (SO-5): 2-4 ftolb

(2-5 Nom, 25-50 kgfocm)
6 - M5 bolts (SO-7): 5-8 ftolb

(7-11 Nom , 70-110 kgfocm)
*Note: Over torque of SD508/SH14 dust cover bolts

will cause air gap to become out of spec.
24 of 32
SERVICE OPERATIONS - SHAFT SEAL
15. Replacement of Lip Type Shaft Seal (SD5H14, SD7B10, SD7H13, SD7H15)
Note: Lip seal assembly and felt ring must never be reused. Always replace these components.
1. Be sure all gas pressure inside the compressor has

been relieved .
2. Remove armature dust cover (if used) , armature

assembly, rotor bearing dust cover (if used), shaft
key, and clutch shims as per section 14.1 .
3. Insert the points of a pair of snap ring pliers into the

holes of the felt ring retainer and pry out the retainer
and felt ringo
4. Remove seal snap ring with internal snap ring pli

ers.
25 of 32
15. (Cont.)
~
\\,~~~~ii"~
5. Use lip seal removal and installation tool to remove
lip seal assembly. Twist the tool until the 2 lips on
the tool engage the slots in the lip seal housing and
pull the seal out with a twisting motion.
6. Clean out shaft seal cavity thoroughly. Debris can

':<\~.,/
be removed using a non-petroleum based sol
vent and lint free cloth. The area should then be
blown out with clean, dry compressed air. Make
sure all foreign material is completely removed .
7. Place shaft seal protective sleeve over compressor

shaft . Inspect the sleeve to ensure that it has no
scratches and is smooth so that the lip seal will not
be damaged. Make sure there is no gap between
the end of the sleeve and the seal surface on the
shaft.
8. Engage the lips of the seal removal and installation

tool with the slots in the new lip seal housing. Make
sure the lip seal assembly, especially the O-ring,
is clean. Dip the entire lip seal assembly, on the
tool , into clean 5GS refrigerant oil. Make sure the
seal assembly is completely covered with oil.
9. Install lip seal over shaft and press firmly to seat.

Twist the tool in the opposite direction to disen
gage it from the seal and withdraw the tool.
10. Reinstall shaft seal snap ring with internal snap ring
pliers . Beveled side should face up (outward/away
from compressor body). Ensure that snap ring is
completely seated in groove . It may be necessary
to tap the snap ring lightly to seat it in the groove. ,.... ..
,)
i
11 . Tap new felt ring assembly into place.
12. Reinstall clutch shims, shaft key, rotor bearing dust

cover (if used), and armature assembly as de ':.:.:.
scri bed in Section 14.6
13. Check and adjust air gap as necessary as shown in

Section 14.6.
: ....,..~ :::::-:. ~\~~:.< .... ~
14. Reinstall armature dust cover (if used) as de ..;~.'
scribed in Section 14.6 .
26 of 32
SERVICE OPERATIONS - CYLINDER HEADNALVE PLATE
16.1 Cylinder Head Removal
1. Be sure all internal compressar pressure has been

relieved.
2. Inspect cylinder head lar litting ar thread damage .

Replace il damaged
3. Remove cylinder head bolts.
4. Use a small hammer and gasket scraper to sepa

rate the cylinder head Irom the valve plate. Be
carelul not to scratch the gasket surtace 01 the cyl
inder head .
", . ':: ~_ ... ,
5. Carelully lift the cylinder head Irom the valve plate.
6. It is recommended that both the head gasket (be

tween the cylinder head and the valve plate) and
the block gasket (between the valve plate and the
cylinder block) be replaced any time the cylinder
head is removed . However, il no servlce is required
to the valve plate, it may be left in place. II the valve ~.~:
plate comes loose Irom the cylinder block, the
block gasket must be replaced.
~ '~ii) ~
'"r'
7. Carelully remove old head gasket Irom top 01 valve
plate with gasket scraper. Be carelul not to disturb
the valve plate to cylinder block joint il valve plate
has been left in place. II valve plate comes loose
Irom cylinder block, proceed to Section 16.2, Valve
Plate Removal, and replace block gasket.
270132
16.2 Valve Plate Removal
~t'
1. Using a small hammer and gasket scraper, careful
Iy separate valve plate from cylinder block. Be
careful not to damage sealing surface of cylin
der block.
...(T)::;yJ,:".,..
.<,,~: :: ,~...... ... . .
'too, ... ...
¡~~:t\ :~~:~:,!
2. Insp ect reed valves and retainer. Replace valve
plate assembly if any part is damaged.
3. Carefully remove any gasket material remaining on
valve plate, cylinder block or cylinder head . Do not :\~""""~~ ¡
.')·~":·:l·:':J~~:~>~~:~::<~'::
damage sealing surfaces on components.
J:::.
16.3 Valve Plate and Cylinder Head Installation ': ,., ,, ..:
.' ."
" ':
..:
,:I~t~:f;r:,
1. Large gasket: 00 of block gasket is 4-3/4"
(120mm) and sealing face of block does not have a
4-1 /2" (114.7mm) diameter step.
2. Small gasket: 00 of gasket is 4-1 /2" (114.7mm) ~ \,;:- ~~~:\~/ .:.,,:,,:~ ~~;:,,} ..
and sealing face of the cylinder block has a 4-1 /2" \ ',. .~' .~,~~. ,,'~~ ...;.;.
(114.7mm) diameter step .
3. Coat new block gasket with clean 5GS refrigerant
oil.
4. Insta" block gasket. Align new gasket to location
pin holes and orifice(s) . Notch (if present) should
face same direction as oil plug or adapter.
5. Place valve plate on cylinder block with discharge
valve , retainer and nut facing up (away from cylin
der block) and location pins properly located in
holes.
~l~~;J~::~:jtl
6. Use vacuum pump and small tube to remove resid
ual oil from each bolt hole . If this step is not per
formed , hydraulic pressure can be created when
the cylinder head bolts are tightened. This pres
sure can break the cylinder block.
7. Coat head gasket with clean 5GS refrigerant oil. t~t~J
8. Insta" head gasket cover location pins, checking ~
far correct arientation.

9. Insta" cylinder head.
10 . Install cylinder head bolts and tighten in a star pat
tern o Tarque first to approximately 14 ftolb (19.6
Nom, 200 kgfocm), then finish by torqu ing to 24-27
ftolb (32.4-36.3 Nom , 330-370kg ocm).
. .; :~~~S~ :.,','",'.~.,t·~.~,~
. .:~., ..,""'.
'<:.·,~:,~fJ~ e1(;;~!'\
.
~·; t;:-}:je .,.,':f ',:~ :'
. .:- ~ ',.'
o,, ' .' .. , .....
\
28 of 32
Service Manual 0999 SM18-1 8 4.0
SERVICE OPERATIONS - THERMAL PROTECTOR SWITCH
17.1 TPS Testing
Some models of SO compressors are equipped with a bi-metal type thermal protector switch (TPS) to
protect against abnormally high temperatures . Contact Sanden Application Engineering for additional
information.
1, Check continuity at room temperature, If switch is open at room temperature, remove and
replace ,
2, Check actuating temperature, Remove TPS and place in container of PAG oil. Heat oil using
an electric hot plate while monitoring oil temperature, TPS should open at 116 ± 5°C (241 ±
9°F), If it does not function properly, re place it.
17.2 TPS Replacement
1, Oisconnect all electrical connections ,

2, Remove TPS retaining clip bolt.
3, Spray around TPS with commercial non-petroleum based solvent (volatile type such as 1,1,1
trichloroethane or approved substitute), to loosen silicone,
4, Remove TPS with pliers, Use care to prevent deforming the TPS housing because this can
change the temperature setting,
5. Clean silicone out of TPS well with flat bladed screwdriver, Wipe out the TPS well with a
cloth, Make sure well area is clean and dry,
6, Apply a dot of silicone RTV (Oow Corning #8390 or 1340 recommended) approximately 1/ 4"
(6mm) in diameter and 1/8" (3mm) high at the bottom of the TPS well ,
7, Install TPS , making sure lead wires are oriented to the clearance notch,
8. Install TPS retaining clip and bolt. Hold clip tight against stop whlle torquing bolt to 6-9 ftolb
(8- 13 Nom, 80-130 kgfocm)
9, Reconnect electrical connections and check function,
SERVICE OPERATIONS - HIGH PRESSURE RELIEF VALVE
18.1 HPRV Replacement
Some models of Sanden compressors are fitted with a high pressure relief valve (HPRV) to protect against
damage from abnormally high discharge pressures ,
1, Note: When replacing a failed HPRV with a new one, be sure to identify whether the A/C
system is for R-12 or R134a, The HPRV and the small O-ring at the threaded portion are both
different for R134a, Contact your supplier for additional information,
2, Be sure all gas pressure has been released from inside the compressor,
3, Remove HPRV.
4, Coat O-ring of a new HPRV with clean 5GS refrigerant oil. Seat and O-ring must be clean
and not damaged ,
5, Install new HPRV and torque to 6-9 ftolb (8-12 Nom, 80-120 kgfocm),
29 of 32
CONVERTING R-12 SYSTEMS TO R134a
19.1 Recommended Procedures for Sanden R-12 Compressors Retrofitted with R134a
The use of R134a in mobile A/C systems designed far R-12 refrigerant use causes higher discharge
pressures (as much as 10-15%) and necessitates changing the compressor lubricant from mineral oil (5GS)
to PAG oil (Sanden's SP-1Q or SP-20) to ensure compatibility.
These changes result in greater wear to the internal components of the compressor. Therefore, to ensure
consistent and expected reliability, Sanden does not recommend using R134a in systems and compressors
designed for R-12.
However
Sanden recognizes the realities of the automotive service markets and consumer preferences. If a retrofit is
required, please follow the vehicle manufacturer's published retrofit procedures. Ensure all work done complies
with SAE recommended practices as described in J1660 &J1661:
Repair any problems or leaks before retrofitting.

Affix labels to the vehicle showing conversion status.
Observe all safety recommendations.
If an OEM retrofit procedure is not available, Sanden recommends the following procedure:
19 .2 Sanden's Procedure for Conversion from R-12 to R134a
1. If the R-12 vehicle air conditioning system is optional, run it at idle with the AlC blower on high speed
for five (5) minutes to maximize the amount of oil in the compressor.
2. Recover all R-12 refrigerant from the vehicle's A/C system.
3. Remove the compressor from the vehicle.
4. Remove the compressor oil plug and then drain as much mineral oil as possible from the compressor
body.
5. Orain mineral oil from the cylinder head suction and discharge ports while turning the shaft with a
socket wrench on the clutch armature retaining nut.
6. Remove the existing R-12 receiver-drier or accumulator-drier from the vehicle and discard. Allow as
much oil as possible to drain from the AlC hoses.
7. Change any O-rings on the receiver-drier or accumulator-drier joints to approved HNBR O-rings ;
replace any other O-rings that have been disturbed.
8. Replace the receiver-drier or accumulator-drier with a new R134a compatible one containíng XH7 or
XH9 desiccant.
9. If a CCOT system is being repaired due to compressor damage, or foreígn material is found in the oil
drained from the system, this foreígn material must be removed from the system. At thís time an in-line
fl lter should be installed in the líquid line. Allow as much oil as possible to draín from the AlC
línes when installing the filter. Change any O-rings disturbed in the installation of the filter to
approved HBNR O-rings.
10. Perform any necessary repairs to the compressor or A/C systems.
11. Using the original refrigerant oil quantity specification, add SP-20 or SP-10 oil to the compressor (SP-10
for TR, SOV-710, SOB-705, SOB-706 and SOB-709; SP-20 for all other SO compressors).
12. Replace the compressor oil plug O-ring with an HNBR O-ringo
13 . Reinstall the compressor oil plug. The plug seat and O-ring must be clean and free of damage. Torque
the plug to 11-15 ftolb (15-20 Nom, 150-200 kgfocm)
30 of 32
19.2 (Cont.)
14. Change any seals at the compressor ports to approved HI\lBR seals.
15. Reinstall the compressor to the AlC system. Evacuate the A/C system for at least forty-five (45)
minutes to a vacuum of 29 in. Hg, using R-12 equipment, to remove as much R-12 as possible from the
residual mineral oil.
16. Remove all R-12 service equipment and disable the R-12 service fittings to prevent any refrigerant
other than R134a from being used. Permanently install R134a quick connect service fittings to the A/C
system.
17. Connect R134a service hoses and other equipment. Re-evacuate the system for thirty (30) minutes
using the R134a equipment.
18. Charge the A/C system with R134a. Generally, about 5% (by weight) less than the R-12 charge
amount is required . Leak check the system per SAE J1628 procedure.
19. If the A/C system is a CCOT type, which has been repaired due to damage or the discovery of foreign
material in the oil drained from the system, run the system for sixty (60) minutes to capture this
material in the filter installed in step 9. Recover the refrigerant, remove and dispose of the filter,
reconnect the lines, evacuate for at least forty-five (45) minutes, and recharge the A/C system . This
step should not be necessary for TXV systems, since the drier is fitted with an internal filter.
20. Check the A/C system operating parameters. The system should function correctly within acceptable
limits of temperatures and pressures. This will ensure that the correct amount of R134a has been
charged .
21. In extreme circumstances when expected cooling performance cannot be achieved and high discharge
pressures are experienced, it may be necessary to add more condensing capacity to the A/C system. An
electric fan(s) and/or larger capacity condenser can be used .
22. Replace all R-12 compressor labels with retrofit labels per SAE J1660 in arder to provide information
on the R134a retrofit which has been performed.
Retrofit PAG oil amount fluid ounces (ce)

Model
Expansion valve systems Orifice tube systems
SO-505 3.4±0.5 (1 OO± 15) No Standard
SO-507 5.5±0.5 (165±15) No Standard
SO-508 7.2±0.5 (210±15) 9.5±0.5 (280±15)
SO-510 No Standard 8.1 ±0.5 (240±15)
SOB-706 No Standard No Standard
SO-708 4.6±0.5 (135±15) No Standard
SO-709 4.6±0.5 (135± 15) 8.1 ±0.5 (240±15)
31 of 32
Sanden SP-20 REFRIGERANT OIL FOR

R134a SD COMPRESSORS
Sanden provides field service containers of SP-20 PAG oil
for Sanden SO-series compressors in convenient 250cc
canso These cans are designed to withstand moisture
ingression. Always keep the cap of the can tightly closed
when not handling the oil.
Can s are packed in "six-packs " and avallable through your

Sanden representative. Material safety data is also available.
Sanden limits the warranty of SO compressors for field

service with the condition that only Sanden-approved SP-20
is utilized.
"Six-Pack" of 250 ce cans of SP-20 oil -Sanden Number

7803-1997.
32 of 32
2 3 A 6 7
5 4 5 8
1 Capscrew, Washers, & Locknut 4. Motor 7. Condenser Line
2. Drive Belt 5. Compressor 8. Capscrew, Spacer, & Washer
3. Bracket 6. Evaporator Line
Figure 1
Air Conditioning Compressor
Air Conditioning Removal

Compressor, R & I 2. Stabilize the crane for service as follows:
level surface.
the air conditioning compressor. For recondition
procedure, see SM Keysheet Area 18-018. Before
the tires.
performing any procedures, review SM18-018-001.00
''Air Conditioning Service Precautions" for safety
lock, as required.
instructions.
The evacuation, charging, and maintenance of the air e. Fully retract and position the boom, as re
conditioning system must be performed by a qualified quired.
air conditioning technician. At no time should lines, 3. Shutdown the engine and disengage the main hy
fittings, or components be loosened or removed after draulic pump.
the system has been charged without the assistance of
a qualified air conditioning technician.
1 of 4
SM18 -018-0:13.00 0305 Service Manual
9. Label for assembly purposes and disconnect
A WARNING evaporator line (6) and condenser line (7) from
compressor (5). Cap/plug open ports and lines
Solvents and cleaning solutions can be (6,7) to prevent excessive oilloss and contamina
hazardous. Serious personal injury may tion of system .
result fr om misuse of these products. Read 10. Remove capscrew, washers , and locknut (1).
and fo llow all the manufacturer's 11 . Remove drive belt (2) from compressor (5) pulley.
recommendations concerning solvents and 12 . Support compressor (5), and remove capscrew,
cleaning solutions. spacer, and washer (8).
13. Remove compressor (5) from bracket (3) and off of
4. Thoroughly clean the area to be disassembled with crane.
m ination. Allow the area to air dry. Cleaning And Inspection
6. Remove any sheet metal required to gain access to
A WARNING
the air conditioning compressor. Solvents and cleaning solutions can be
A WARNING and follow all the manufacturer's

Re1rigerants are under pressure and can be cleaning solutions.
could cause chemical burns, frostbite, or other 1. AII components should be thoroughly cleaned with
serious InJury. Shutdown the engine and an approved cleaning solvent, air dried , and care
properly "reclaim" the refrigerant from system fully inspected.
before removing any line or component. Read 2. AII Loctite®, Permatex®, or other sealant residue
and follow all of the manufacturer's should be removed from threads of hardware and
recommendations concerning use and storage the mounting surfaces of parts that are going to be
01 refrigerants. reused. Prior to applying new thread locking com
with Loctite dll 7070 Cleaner to ensure best perfor
mance of products.
A WARNING 3. Thoroughly inspect all parts for damage, wear, fa
Avoid skin and eye contact with refrigerant.
Wear appropriate personal protective safety
4. Inspect the integrity of the evaporator and con
equípment such as long sleeves, gloves, and
denser lines . Repair or replace if required.
goggles when working with refrigerant.
5. Inspect the integrity of the electrical connectors
Failure to do so may result in personal injury.
that supply the compressor. Repair or replace if re
7. Properly reclaim refrigerant from system. quired .
Reter to Figure 1. sonnel for directions whether to repair or replace
8. Disconnect electrical connection from compressor any major component.
(5) .
2 of 4
Installation 3. Install drive belt (2) around compressor (5) pulley
and corresponding pulley on motor (4).
4. Rotate compressor (5) to achieve tension on drive
A WARNING
Avoid ski n and eye contact with refrigerant. 5.
belt (2), making sure drive belt (2) is properly
seated in both pulleys.
Fully tighten capscrews (1,8).
Wear appropriate personal protective safety 6. Connect evaporator line (6) and condenser line (7)
equipment such as long sleeves, gloves, and to compressor (5).
goggles when working with refrigerant. 7. Connect electrical connection to compressar (5).
Failure to do so may result in personal injury. 8. Charge the system with the proper relrigeran!. Re
ler to the 1.0. plate located on the compressar or
the equipment manulacturer's literature lar the
The evacuation, charging, and maintenance 01 the air correct type 01 relrigerant to use.
conditioning system must be performed by a qualilied
air conditioning technician. At no time should lines, Note: The system must be evacuated with a
littings, or components be loosened ar removed after vacuum pump prior to charging the sy ste m.
the system has been charged without the assistance 01 This procedure is the responsibility of the a ir
a qualilied air conditioning technician. conditioning technician and must be done for
the maximum performance of and longevity of
the system.
A WARNING 9. Once the system has been properly charge, oper
Lubricants, sealants, joint and thread locking ate the air conditioning lor thirty minutes in an am
compounds, etc. can be hazardous. Serious bient temperature 01 at least 65°F (36°C). Check
personal injury may result from misuse of lor leaks during this time and repair as required.
these products. Read and follow all 10. Install any sheet metal that was removed.
manufacturer's recommendations concerning 11. Complete the installation by testing all related lunc
these products. tions 01 the air conditioning compressar lar proper
operation. A general inspection 01 components
Reler to Figure 1. and systems in the areas adjacent to the repair
1. Position compressor (5) to mounting surface, and should also be perlormed to ensure related dam
loosely install capscrew, spacer, and washer (8). age or wear is not presen!.
2. Align compressor (5) to bracket (3), and loosely
install capscrew, washers, and locknut (1).
3014
4 of 4
2 3 4 5 6 A
1. Compressor 4. Drive Belt 7. Mou nting Bracket

2. Capscrew, Washers , & Locknut 5. Capscrews & Washers 8 Dri ve Motor
3. Bracket 6. Hydraultc Une 9. Hydraultc Une s
Figure 1
Air Conditioning Hydraulic Drive Motor
d . Level the crane on fully extended outriggers.

Air Conditioning Hydraulic e. Fully retract and position the boom, as re
Orive Motor, R & I 3.
quired.
Shutdown the engine and disengage the main hy
This procedure covers the removal and installation of draulic pump.
the air conditioning hydraulic drive motor. For
recondition procedure, see SM Keysheet Area
18-018. Before performing any procedures, review
SM18-018-001.00 "Air Conditioning Service
A WARNING
Precautions" for safety instructions. hazardous. Serious personal injury ma y
Removal result from misuse of these products . Read
1. Lower, detach, and secure the load, as required. recommendations concerning solvents and
2. Stabilize the crane for service as follows: cleaning solutions.
level surface. 4. Thoroughly clean the area to be disassembled with
b. Engage the park brake and/or properly block an approved cleaning solvent to prevent conta
the tires. mination. Allow the area to air dry.
lock, as required.
1 of 2
A WARNING
4 . AII "soft parts", such as seals, gaskets, back up
hot. A sud den release of hot oil could cause rings, and o-rings, should be replaced.
burns o r other serious injury. Shutdown the 5. Inspect the integrity of the hydraulic lines that are
engine and exhaust all trapped hydraulic connected to the drive motor. Repair or replace if
pressure from the system before removing required.
any line or component. 6. In the event of severe defects, contact factory per
5. Relieve the hydraulic system pressure as follows: any major component.
reservoir by loosening the filler cap 1/4 turn. Installation
c. Work the crane control levers and outrigger A WARNING
switches back and forth several times . Lubricants, sealants, joint and thread locking
d. Turn ignition switch to the "OFF" position. compounds, etc. can be hazardous. Serious
6 . Cll eck that all controllevers are in the neutral posi personal injury may result from misuse of
tlon and move the function lockout switch to the these products. Read and follow all
"DI8ABLE" position. manufacturer's recommendations concerning
these products.
Refer to Figure 1.
7. Label for assembly purposes and disconnect hy
drau lic lines (6,9) from drive motor (8). Cap/plug Refer to Figure 1.
open hydraulic ports and lines (6,9) to prevent ex 1. Position drive motor (8) to mounting bracket (7).
cessive oilloss and contamination of system. 2 . 8ecure drive motor (8) to mounting bracket (7) by
8. Loosen capscrew, washers, and locknut (2) to re installing capscrews and washers (5).
lieve tension on drive belt (4) . 3. Install drive belt (4) around drive motor (8) pulley
9. Remove drive belt (4) from drive motor (8) pulley. and corresponding pulley on compressor (1) .
10. 8upport drive motor (8), and remove capscrews 4. Rotate compressor (1) to achieve tension on drive
and washers (5) . belt (4), making sure drive belt (4) is properly
11 . Remove drive motor (8) from mounting bracket (7) seated in pulleys.
and off of crane . 5 . Tighten capscrew, washers, and locknut (2) to
secure compressor (1) to bracket (3) .
Cleaning And Inspection 6. Connect hydraulic lines (6 ,9) to drive motor (8).
required . 8ee the Operator's Manual for correct
A WARNING
type and procedure.
8. 8tart the engine and let idle for five minutes. In
spect the hydraulic connections for leaks . Repair
hazardous. Serious personal injury may leaks as required.
result from misuse of these products. Read 9. Complete the installation by testing all related func
and foll ow all the manufacturer's tions of the air conditioning compressor for proper
recommendations concerning solvents and operation. A general inspection of components
cleaning solutions. and systems in the areas adjacent to the repair
should also be performed to ensure related dam
1. AII components should be thoroughly cleaned with age or wear is not present.
fully inspected.
sh ould be removed from threads of hardware and
mance of products.
2 of 2
Air Conditioning Hydraulic

CAUTION
Orive Motor, Recondition Do not grip on any of the hydraulic motors
machined surfaces. Excessive force while
This procedure covers the recondition 01 the air
clamping could result in misalignment and /or
conditioning hydraulic drive motor. For removal and
serious damage to parts. Take extreme ca re
installation procedures, see SM Keysheet Area not to mar or damage any machined surface.
18-018. Do not clamp in any form of vise unless jaws
Note: Some of the photographs depicted in are protected by a soft material.
Figure 1 and Figure 2 contain multiple section mo
torso These photographs are general in nature. The 4. Secure shaft end cover (11), shaft (3) pointing
disassembly and assembly procedures have been down , in a vise with padded jaws.
written to specifically address the single section 5. For assembly purposes, index mark all sections
(11,14,15).
motor used for this application .
6. Remove capscrews (17) and washers (16).
7. Lift or pry port end cover (15) from gear housing
Disassembly (14) .
It is a good practice when disassembling hydraulic Note: If prying is necessary, be carefu l n01 to
components to lay the parts out in the order that they damage the machined surfaces.
during disassembly, cleaning, and inspection will aid in 8. Remove square ring seal (2) and thrust plate (1).
the assembly process. 9. Carefully remove gear shaft set (3) from gear hous
ing(14).
use a hammer unless it has a soft face, do not force Note: Avoid tapping the gear teeth ag ainst
parts together, they must be free to rotate/operate and hardened surfaces.
not bind.
10. Lift or pry gear housi ng (14) from shaft end cover
(11 ) .
A WARNING
Note: If prying is necessary, be careful not to
damage the machined surfaces.
11. Remove square ring seal (5) and thrust plate (4).
12 . Reposition shaft end cover (11) in vise , mounting
tace up, to allow for removal of snap ring (9) and
recommendations concerning solvents and beari ng (8) .
cleaning solutions.
13. Using snap ring pliers, remove snap ring (9) from
shaft end cover (11).
1. Drain any excess hydraulic oil, remaining within
14. Using a bearing puller, remove bearing (8) from
the drive motor, into an appropriate container.
shaft end cover (11) .
Properly store or dispose of the used oil.
15. Remove seal reta iner (12) from shaft end cover
2. Cap/plug any openings in the drive motor. Thor
(11 ).
oughly clean the exterior surface of the drive motor
16. Using a seal removal tool, remove lip seal (7) from
to prevent contamination from entering it.
shaft end cover (11).
Refer to Figure 1 & Figure 2. 17. Remove seals (6) from from thrust plates (1,4).
3. Remove key (10) from gear shaft set (3). 18. Remove dowel pins (13), as required .
1 of 6
2 3 4 5 6 7 8 9
17 16 15 14 13 12 11
1. Thrusl Plale 6 Seals 10. Key 14 . Gear Housing

2. Square Ring Seal 7. Lip Seal 11. Shaf1 End Cover 15. Port End Cover
3. Gear ShaH Sel 8. Bearin g 12. Seal Relainer 16. Washers
4. Thrusl Plale 9. Snap Ring 13. Dowel Pins 17. Capscrews
5 Square Ring Seal
Figure 1
Air Co nditioning Hydraulic Drive Motor Cross Section
2 of 6
Steps 3-5 Step 6 Steps 7-8
Step 9 Steps 10-11 Steps 12-13
Steps 14-15 Step 16 Steps 8 & 11
Step 17 Step 18
Figure 2
Disassembly Steps
3 al 6
Cleaning And Inspection e. Thrust Plates: Check the center of the thrust
plates where the gears mesh. Erosion here in
di cates oil contamination. Pitted thrust plates
A WARNING
indicate cavitation or oil aeration . Oiscolor
ation usually indicates overheating, likely due
to insufficient oil. Replace if they are scored,
eroded, or pitted. A maximum of 0.002 in
(0.051mm) wear is allowable.
f. Seal and gaskets: Replace all rubber and poly
mer seals, including all o-rings, channel
seals, shaft seal, and gasket seals.
cleaning solutions.
surface and allow to air dry. Exercise every precau Assembly
tlon possible to keep all parts free of dust, dirt, or
_. AII Loctite , Permatex®, or other sealant residue
A WARNING
,,,¡ith Loctitei<l 7070 Cleaner to ensure best perfor
mance of products.
these products.
wear, fatigue or stress fractures corrosion , deep
scratches, cracks , and scuffed metal. Remove any
burrs or sharp edges with a fine file, hone , emery
cioth , or crocus cloth . Replace any damaged com
ponent, as required , using the following guide CAUTION
lines: Do not grip on any machined surfaces.
a. Gear Housing : Place a straight edge across Excessive force while clamping could result in
the bore . If a 0 .007 in (O. 178mm) feeler gage misalignment and/or serious damage to
can slip under the straight edge in the cutout parts. Take extreme care not to mar or
area, replace the gear housing . damage any machined surface. Do not clamp
b . Oowel Pins: If either the dowel pin or dowel in any form of vise unless jaws are protected
hole is damaged , the pin, machined casting, by a soft material.
or both , must be replaced. If more than rea
sonable force is required to seat the dowels, Refer to Figure 1 & Figure 3 .
the cause may be poorly deburred or dirty 1. Secure shaft end cover (11), mounting face up, in a
parts, misalignment of the dowel in the hole, or vise with padded jaws.
improper pin to hole fi!.
c. Gears: If any evidence of scoring is present on Note: Before installing dowel pins, ensure that the
the gear hubs, replace the gear seto Scoring, holes are clean and free from burrs.
grooving , or burring of the outside diameter of
the gear teeth requires that the gear set oe re 2. Start dowel pins (13) straight into holes by hand ,
placed. Any nicking , grooving , or fretting of then tap lightly with a soft hammer to properly sea!.
the gear teeth surfaces also requires that the 3. Coat outer edge and recess of lip seal (7) with Per
gear set be replaced . matex® Aviation Form-A-Gasket® No. 3 non
d . Orive Shaft: Replace if any wear Is detectable hardening sealant or equivalen!.
in the seal area, spl ines , or keyway. Wear in
the shaft seal area ind icates oil contamination.
40f6
Cleaning And Inspection e. Thrust Plates: Check the center of the thrust
plates where the gears mesh. Erosion here in
dicates oil contamination. Pitted th rust plates
indicate cavitation or oil aeration. Oiscolor
A WARNING ation usually indicates overheating, likely due
to insufficient oil. Replace if they are scored,
Sol vents and cleaning solutions can be
eroded, or pitted. A maximum of 0.002 in
(0.051mm) wear is allowable.
f. Seal and gaskets: Replace all rubber and poly
an d follow all the manufacturer's
mer seals, including all o-rings, channel
seals , shaft seal , and gasket seals.
cleaning solutions.
1. Thoroughly clean all metal parts with an approved sonnel for directions whether to repair or replace
cleaning solvent. Place parts on a clean, lint free any major component.
surface and allow to air dry. Exercise every precau Assembly
tlon possible to keep all parts free of dust, dirt, or
2. AII Loctite@, Permatex@, or other sealant residue
should be removed from threads of hardware and A WARNING
these products . Read and follow all
mance of products.
these products.
wear, fatigue or stress fractures co rrosion , deep
burrs or sharp edges with a fine file, hone, emery
cloth, or crocus cloth. Replace any damaged com
ponent, as required , using the following guide CAUTION
lines : Do not grip on any machined surfaces.
a. Gear Housing: Place a straight edge across Excessive force while clamping could result in
the bore. If a 0.007 in (O. 178mm) feeler gage misalignment and/or serious damage to
can slip under the straight edge in the cutout parts. Take extreme care not to mar or
area, replace the gear housing. damage any machined surface. Do not clamp
b. Oowel Pins: If either the dowel pin or dowel in any form of vise unless jaws are protected
hole is damaged, the pin, machined casting , by a soft material.
or both, must be replaced. If more than rea
sonable force is required to seat the dowels, Refer to Figure 1 & Figure 3.
the cause may be poorly deburred or dirty 1. Secure shaft end cover (11), mounting face up, in a
parts, misalignment of the dowel in the hole , or vise with padded jaws.
improper pin to hole fit.
c. Gears: If any evidence of scoring is present on Note: Before installing dowel pins, ensure that the
the gear hubs, replace the gear set. Scoring, holes are clean and free from burrs.
grooving, or burring of the outside diameter of
the gear teeth requires that the gear set be re 2. Start dowel pins (13) straight into holes by hand,
placed. Any nicking, grooving, or fretting of then tap lightly with a soft hammer to properly seat.
the gear teeth surfaces also requires that the 3. Coat outer edge and recess of lip seal (7) with Per
gear set be replaced. matex® Aviation Form-A-Gasket® No . 3 non
d. Orive Shaft: Replace if any wear is detectable hardening sealant or equivalent.
in the seal area, splines, or keyway. Wear in
the shaft seal area in d icates oil contamination.
Steps 3-5 Step 6 Steps 7-8
Step 9 Steps 10-11 Steps 12-13
Steps14-15 Step 16 Steps 8 & 11
Step 17 Step 18
Figure 2
Disassembly Steps
3 016
Steps 1-2 Steps 3-5 Step 6
Step 7 Step 9 Step 12
Step 13 Steps 14-16 Step 17
Steps 18-19 Steps 20-22
Figure 3
Assembly Steps
5 of 6
Note: Be careful not to pinch the square ring
seals.
12. Install seals (6) into grooves in thrust plates (1,4).
Flat Side Thrust Note: Ensure the flat side of seal is facing away
of Seal Plate from the thrust plate. Refer to Figure 4 for an ex
ample.
13. Gently install thrust plate (4) through gear housing

(14), into place against shaft end cover (11).
Note: The seal side of the thrust plate should

face the shaft end cover.
14. Coat gear shaft set (3) with clean hydraulic oil.
15. Slide driven gear of gear shaft set (3) through gear
Figure 4 housing (14) into shaft end cover (11).
Cha nnel Seal Installation 16. Using a slight twisting motion, guide drive gear
shaft (3) through end of shaft end cover (11) unti I
integral gear rests against thrust plate (4).
4. With metal si de facing up, press lip seal (7) into
mounting flange si de of shaft end cover (11) using Note: Avoid damaging the lip seal. To avoid
an arbor press and bar. Press until flush with re damage, it may be necessary to use a steel
cess, and wipe off any excess sealanL sleeve to guide the drive gear shaft through the
shaft end cover.
Note: Be careful not to damage the lip of the lip
sea l. 17. Slide thrust plate (1) over gear (3) journals and into
gear housing (14).
5. Install seal retainer (12) into shaft end cover (11)
against li p seal (7). Note: The seal side of the thrust plate should
6. Install bearing (8) into its recess in shaft end cover fa ce out.
(11) .
18. Position port end cover (15) over gear (3) journals.
Note: This is a light press fit. It may be neces
sary to tap the bearing into the bore. Note: Align index marks made during disas
sembly.
7. Using snap ring pliers, install snap ring (9) to retain
bearing (8) in shaft end cover (11). 19. Tap port end cover (15) lightly with a 50ft mallet until
8. Lubricate square ring seals (5,2) with clean hy it rests tightly against gear housing (14).
draulic oil. Refer to the Operator's Manual for cor
rect type. Note: Be careful not to pinch the square ring
9. Install square ring seals (5,2) in both sides of gear seals.
housing (14). 20. Install washers (16) and capscrews (17).
10. Position gear housing (14) over shaft end cover 21. Rotate gear shaft set (3) to check for binding. Re
(11) and dowels (13). pair if required.
22. Evenly tighten capscrews (17), in a criss-cross
Note: Align index marks made during disas
pattern, to a final torque of 200 ft lb (280Nm).
se mbly.
23. If the air conditioning hydraulic drive motor is not to
11. Tap gear housing (14) lightly with a 50ft mallet until be immediately installed on the crane, plug all
it rests tightly against shaft end cover (11). open ports to prevent contamination and properly
sto re.
6 of 6
Air Conditioning
Compressor, R & I
A WARNING
This procedure covers the removal and installation of hazardous. A sudden release of refrigera nt
the air conditioning compressor For recondition could cause chemical burns, frostbite, or other
procedure , see SM Keysheet Area 18-018. Before serious InJury. Shutdown the engine and
periorming any procedures, review SM18-018-001 .00 properly " reclaim" the refrigerant from system
''Air Conditioning Service Precautions" for safety before removing any line or component. Read
instructions. and follow all of the manufacturer's
recommendations concerning use and storage
The evacuation, charging, and maintenance of the air of refrigerants.
conditioning system must be performed by a qualified
air conditioning technician. At no time should lines,
fittings, or components be loosened or removed after
a qualified air conditioning technician .
A WARNING
Avoid skin and eye contact with refrigerant.
Removal Wear appropriate personal protective safety
1. Lower, detach, and secure load , as required. equipment such as long sleeves, gloves, and
2. Stabilize the crane for service as follows: goggles when working with refrigerant.
a. Park the crane, out of the way, on a firm and Failure to do so may result in personal injury.
level surface.
b. Engage the park brake and/or properly block 7. Properly reclaim refrigerant from system .
the tires . Refer to Figure 1.
c. Engage the swing park brake or travel swing 8. Label for assembly purposes and disconnect the
lock , as required . evaporator line (4) and condenser line (3) from the
d. Level the crane on fully extencled outriggers . compressor (6). Cap/plug the open ports and lines
e. Fully retract and position the boom , as to prevent contamination of the system.
required . 9. Disconnect the electrical ground wire from the
3. Shutdown the engine and disengage the main compressor (6).
hydraulic pump , as equipped. 10. Using a socket driver, rotate the belt tensioner (1)
4. Check that all controllevers are in the neutral posi to relieve tension on the drive belt (2).
tion and move the function lockout switch to the 11. Remove the drive belt (2) from the pulley on the
"D ISABLE " position. compressor (6).
12. Support the compressor (6), and remove the
A WARNING
capscrews and washers (5).
13. Remove the compressor (6) from the crane .
cleaning solutions.
A WARNING
hazardous. Serious personal injury ma y
5. Thoroughly clean the area to be disassembled with result from misuse of these products. Read
an approved cleaning solvent to prevent and follow al! the manufacturer's
contamination . Allow the area to air dry. recommendations concerning solvents and
6. If required, remove the engine housing . See SM cleaning solutions.
Keysheet Area 01-071 for correct procedure .
an approved cleaning solvent, air dried , and
carefully inspected.
1 of 4
1. Bell Tensioner 3. Condense r Lin e 5. Capscrews & Washers

2. Orive Belt 4. Evaporator Line 6. Com pressor
Figure 1
Air Conditioning Compressor
2 of 4
2. AII Loctite®, Permatex®, or other sealant residue Refer to Figure 1.
should be removed from threads of hardware and 1. Align the compressor (6) to the engine , and Install
the mounting surfaces of parts that are going to be the capscrews and washers (5) . Torque lile
reused . Prior to applying new thread locking capscrews (5) to 22-28 ft lb (30-38Nm).
compounds or sealants , clean threads and 2. Install the electrical ground wire on the
surfaces with Loctite® 7070 Cleaner to ensure best compressor (6).
performance of products . 3. Using a socket driver, rotate the belt tensioner (1)
3. Thoroughly inspect all parts for damage, wear, to facilitate the installation of the drive belt (2) .
fatigue or stress fractures , and corrosion. Repair 4. Install the drive belt (2) around the compressor (6)
or replace as required . pulley.
4. Inspect the integrity of the evaporator and 5. Carefully allow the belt tensioner (1) to rotate back
condenser lines . Repair or replace if required. into position and apply tension to drive belt (2) .
5. Inspect the integrity of the electrical wires and
connectors that supply the compressor. Repair or Note: As the belt tensioner rota tes ba ck ¡nto
replace if required. position, ensure that the drive belt properly
6. In the event of severe defects , contact factory seats around each of the pulleys. Refer to
personnel for directions whether to repair or Figure 1 for an illustration of the correet drive
replace any major componen!. belt routing.
6. Connect the evaporator line (4) and condenser line

Installation (3) to the compressor (6).
Note: The system must be evacuated with a

A WARNING
Avoid skin and eye eontaet with refrigerant.
vaeuum pump prior to eharging the system .
This procedure is the responsibility 01 the air
eonditioning teehnician and must be done tor
Wear appropriate personal protective safety
the maximum performance and longevity 01 the
equipment such as long sleeves, gloves, and
system.
goggles when working with refrigerant.
Failure to do so may result in personal injury. 7. Charge the system with the proper refrigeran!.
Refer to the 1.0. plate located on the compressor
(6) or the equipment manufacturer's literature for
The evacuation, charging , and maintenance of the air
the correct type of refrigerant to use.
conditioning system must be performed by a qualified
8. Once the system has been properly charged ,
air conditioning technician . At no time should lines,
operate the air conditioning for thirty minutes in an
fittings, or components be loosened or removed after
ambient temperature of at least 65 °F (36 °C)
Clleck lor leaks during this time and repair as
a q ualified air conditioning technician .
required .
9. If required , install the engine housing. See SM
A WARNING
10. Complete the installation by testing all relate d
Lubricants, sealants, joint and thread locking functions of the air conditioning compressor for
compounds , etc. ean be hazardous. Serious proper operation . A general inspection of
personal injury may result from misuse of components and systems in the areas adjacent to
these products. Read and follow all the repair should also be performed to ensure
manufacturer's recommendations coneerning related damage or wear is not presen!.
these products.
3 014
" ,: '. . .. '.
4 of 4

Manual de Servicio P9K1-1812

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Manual de Servicio P9K1-1812

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MODEL HTC-867511

CRANE SERIAL NUMBER

Ll r~-B e l t Cansuucnnn Eqlll pmént Comp any F00056

n TST R I BUTOR: M7\QUTNAS O TES El.,S.7\.. DE C.V. S7\.LE S ORDER: 0 211:11 2

SH CODE DESCRIPTTON SM ConF. DESCRJPTTON

SMOI - 0 01-006.00 BOOM REST, R & T SM01-022-00S.00 U-JO TN T TNST7\I.T.7\T TON

$M CODE DE s crUPTION SM CODE DESCRTPTION

SMOI-043-04S.00 OUTRIC,GER DTRECTION7\L SMOI-077 - 00ü.OO STARTF.R, R & 1

MOTOR, R & T SH04-010-0 :U.OO SWTNG REDUCTJ ON UNT'f

ORDER NO.- P9XP006 MODEL - HTC-8675XP 11 SERIAL NO. - P9Kl - 1812

SM CODE DESCRIPTION SM CODE DESCRIPTION

SM06-000-009.00 THROTTLE TREADLE, R & I SM07-008-122.00 WINCH COUNTERBALANCE

IDENTIFICATION CODE SM07-000-1 55 .00 SWING CONTROL VALVE, R&T

OIU)E R NO. - P')XP006 MODEL - HTC-8675XP 11 SERIAL NO. - P,)KI - IU12

SM COOE OESCRIPTION SH COOE OESCRIPTION

SH17-003-040.00 BOOM HOIST COUNTERBAI.ANCE

SMlü SPECIl\L l\TTACHMENTS

SH10 - 0 00-001 .00 Cl\PSCRRW TORQUES

MOTOR, RECON (UPPER)

1. Engine Housing 5. Capscrews, Washers, & Locknuts 9. Pins

Note: The pivot assembly weighs approxi­

If parts are hard to dísassemble and assemble , do not

It is a good practice when disassemblíng comple x

Section 2: Periodic Service

Section 3: Axle Overhaul

PARTS IDENTIFICATION/NOMENCLATURE General

Eaton® Steer Axle Models and Specifications

Beam F3 -3 .50" F3 -3 .50" 3.50" 350" T2 -1.50 " T2 -1.50"

Eaton EB-150' EB-150 EB-165 EB-165 EB-165 EB-165

\ - Note EB-,165 Brake is optional on ':FA-12F4 Steer Axle.

Wheel Alignment: For specifications , refer to vehicle manufacturer's instructions.

Ste er Axle Idenfification Piafe

EFA 12 F4 XXXXX on pi ate) is the

C"" CmoO "",

Nominal Load Capacity

Eaton EFA-12F3/F4, 13F3/F5 Steer Axles

CAPSCREW LUBE FITTING JI

conER PIN _'

BEA~,,,~'N tlk ~~~~ ~/ e, G~_~~~MP

PARTS IDENTIFICATION/NOMENCLATURE General

Eaton EFA-1 BF3, 20F4, 22T2/T5, 24T2 /T5 Steer Ax/es

LUBE FITTING - - - -""- \~KEY

CAPSCREW - ~",,-, \. ------STEERING ARM

STEER I NG I '; , '-"' :jr! .;. " ORAW KEY

*Tubu/ar Ax/e Beams for EFA-22T2/T5, 24T2 /T5

Inspection Recommendations and Intervals

General Inspection Wheel Bearings and Knuckle Thru st

Wheel Alignment Lubrication

Knuckle Vertical Play Inspection

SPECIAL NOTE : Inspection procedures above assume axle is assembled and

Knuckle Pin Fit Inspection

2. Move top of wheel in and out with a push/pull

Lower Bushing Inspection

Upper Bushing Torque Deflection . ' .,,::.:::::~

Lower Bushing Torque Deflection

Tie Rod Inspection

Typical Bearing Failures

Normal Wear and Pitting Pitted and Spalled

Typical Bearing Failures (cont'd)

Chipped and Spalled Surface Fatigue Failure Pitted and Spalled

Wheel Alignment Inspection

Camber is the vertical tilt of the wheel as viewed from POSITIVE

"Negative" camber is an inward tilt of the wheel at the

A CAUTION: Eaton expressly prohibits

Note: The pivot assembly weighs approxi

SPECIAL NOTE: When installing bush