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