Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. specifications
  • 1.1 Capacities
    • Fuel Tank
    • Hydraulic Oil Tank
    • Hydraulic System (Including Tank)
    • Engine Crankcase
  • 1.2 Component Data
    • Engine - Diesel (Liquid-Cooled)
    • Swing System
    • Auxiliary Power Pump
  • 1.3 Performance Data
    • Turning Radius (Outside)
    • Turning Radius (Inside)
    • Boom Elevation
    • Machine Weight approximately
    • Machine Height (Stowed)
    • Machine Length (Stowed)
    • Machine Width
  • 1.4 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.5 Torque Requirements
  • 1.6 Lubrication
    • Deutz F4M1011F Engine
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.7 Pressure Settings
  • 1.8 Cylinder Specifications
  • 1.9 Major Component Weights
  • 1.10 Critical Stability Weights
  • 1.11 Serial Number Locations
• Section 2. General
  • 2.1 Machine Preparation, Inspection, and Maintenance
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Service and Guidelines
    • General
    • Safety and Workmanship
    • Cleanliness
    • Components Removal and Installation
    • Component Disassembly and Reassembly
    • Pressure-Fit Parts
    • Bearings
    • Gaskets
    • Bolt Usage and Torque Application
    • Hydraulic Lines and Electrical Wiring
    • Hydraulic System
    • Lubrication
    • Battery
    • Lubrication and Servicing
  • 2.3 Lubrication and Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinder Drift Test
    • Platform Drift
    • Cylinder Drift
  • 2.5 Pins and Composite Bearing Repair Guidelines
• Section 3. Turntable
  • 3.1 Tilt Alarm Switch
    • Manual Adjustment
  • 3.2 Throttle Checks and Adjustments - Deutz
    • General
    • Procedure
    • Controller Status
    • Failure Modes
  • 3.3 Swing Hub
    • Adjustment Procedures
  • 3.4 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Replacement
    • Swing Bearing Torque Values.
  • 3.5 Swing Brake - Mico
    • Disassembly
    • Inspection
    • Assembly
• Section 4. Boom & Platform
  • 4.1 Platform
    • Platform Sections Replacement
  • 4.2 Boom Rope Torquing Procedures
    • Torque Procedures
  • 4.3 Wear Pads
    • Main Boom
  • 4.4 Wire Rope
    • Inspection
    • Three Month Inspection
    • Five Year Inspection
    • Replacement Criteria
  • 4.5 Boom Maintenance
    • Removal
    • Disassembly of Boom Sections
    • Inspection
    • Assembly
    • Installation
  • 4.6 Articulating Jib Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
  • 4.7 Limit Switch Adjustment
  • 4.8 Rotator - Helac
    • Disassembly
    • Inspection
    • Assembly
  • 4.9 Foot Switch Adjustment
  • 4.10 SUPERFLEX Controller
    • System Overview
    • System Elements
    • General Description
    • SUPERFLEX Terminal Identification
    • SUPERFLEX Terminal Assignments
    • Setup and Tuning
    • How to Perform the Normal-Active Tuning Process
    • How to make Bench-Static Adjustments
    • Troubleshooting
    • How To Troubleshoot the SUPERFLEX Controller
    • How to Troubleshoot the Digisensor
    • Important Reminders
    • Crawler Tracking Adjustments
    • Drive & Steer Function Check
    • Superflex Inputs And Outputs
• Section 5. hydraulics
  • 5.1 Cylinders - Theory of Operation
    • Systems Incorporating Double Acting Cylinders
    • Systems Incorporating Holding Valves
  • 5.2 Valves - Theory of Operation
    • Solenoid Control Valve - Rexroth
    • Relief Valves
  • 5.3 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valves
  • 5.4 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.5 Cylinder Removal and Installation
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
  • 5.6 Pressure Setting Procedures
    • Main Relief, Steer, Swing and Lift Down
    • Platform Level
    • Articulating Jib Boom (If Equipped)
  • 5.7 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
  • 5.8 Hydraulic Component Start-Up Procedures and recommendations
• Section 6. Undercarriage
  • 6.1 Track Carrier Roller
    • Removal
    • Installation
    • Disassembly
    • Assembly
  • 6.2 Track Roller
    • Removal
    • Disassembly
    • Assembly
    • Installation
  • 6.3 Track
    • Separate
    • Connect
  • 6.4 Front Idler and Recoil Spring
    • Removal
    • Installation
    • Front Idler Disassembly
    • Front Idler Assembly
    • Recoil Spring Disassembly
    • Recoil Spring Assembly
  • 6.5 Track Adjuster
    • Removal
    • Disassembly
    • Assembly
    • Installation
  • 6.6 Final Drive Sprocket
    • Removal
    • Installation
  • 6.7 Travel Brake Valve
    • Removal
  • 6.8 Travel Motor
    • Removal
  • 6.9 Travel Brake Valve
    • Disassembly
  • 6.10 Travel Brake Valve
    • Assembly
    • Installation Procedure
  • 6.11 Travel Motor
    • Disassembly
    • Assembly
    • Installation
  • 6.12 Final Drive
    • Removal
    • Disassembly
    • Assembly
    • Installation
    • Final Drive Oil - Change
    • Final Drive Oil Level Check
  • 6.13 Swivel
    • Removal
    • Disassembly
    • Assembly
    • Installation
  • 6.14 Towing Information
    • Towing the Machine
    • Final Drive Sun Gear Removal
  • 6.15 Track Adjustment - Adjust
    • Measuring Track Tension
    • Tightening the Track
    • Loosening the Track
    • Track Adjustment - Inspect
  • 6.16 Undercarriage- Check
• Section 7. schematics
  • 7.1 General
  • 7.2 Troubleshooting
  • 7.3 Hydraulic Circuit Checks