Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. SPECIFICATIONS
  • 1.1 Capacities
  • 1.2 Component Data
    • Engine - Diesel
    • Drive System
    • Steer System
    • Swing System
    • Hydraulic Pump
    • Auxiliary Power Pump
    • Hydraulic Filter - Tank
    • Hydraulic Filter - Inline
  • 1.3 Performance Data
    • Travel Speed
    • Gradeability
    • Turning Radius
    • Boom Speed
    • Swing Speed
    • Boom Elevation
    • Machine Weight
    • Machine Stowed Height
    • Machine Stowed Length
    • Machine Width
    • Wheelbase
    • Maximum Tire Loads
  • 1.4 Torque Requirements
  • 1.5 Lubrication
    • Deutz F4L912 Engine
    • Lubrication Specifications
  • 1.6 Pressure Settings
  • 1.7 Cylinder Specifications
  • 1.8 Boom Tape
  • 1.9 Major Component Weights
  • 1.10 Serial Number Locations
  • 1.11 Critical Stability Weights
  • 1.12 Boom Limit Switches
• Section 2. PROCEDURES
  • 2.1 General
  • 2.2 Servicing and Maintenance 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 Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinders - Theory of Operation
  • 2.5 VALVES - THEORY OF OPERATION
    • Solenoid Control Valves (Bang-Bang)
    • Manual Hydraulic Control Valves
    • Proportional Control Valves - Vickers
    • Relief Valves
    • Crossover Relief Valves
  • 2.6 Boom Chains
    • Adjusting Procedures
    • Inspection Procedure
    • Auxiliary Boom Chains
  • 2.7 Wear Pads
  • 2.8 Drift Test
    • Telescope Cylinder
    • Lift Cylinder
  • 2.9 Cylinder Checking Procedures
    • Cylinder w/o Counterbalance Valves
    • Cylinders w/Single Counterbalance Valves
    • Cylinders w/Dual Counterbalance Valve
  • 2.10 Cylinder Removal and Installation
    • Telescope Cylinder Removal
    • Telescope Cylinder Installation
    • Lift Cylinder Removal
    • Lift Cylinder Installation
    • Master Level Cylinder Removal
    • Master Level Cylinder Installation
  • 2.11 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.12 Boom Maintenance
    • Removal
    • Disassembly
    • Inspection
    • Assembly
    • Installation
  • 2.13 Tilt Alarm Switch Leveling
    • Manual Adjustment
    • Voltmeter Adjustment
  • 2.14 Limit Switch Adjustments
    • Boom Limit Switch
    • Horizontal Cut-Out Switch
  • 2.15 Throttle Checks and Adjustments - Deutz F4l-912 Engine
  • 2.16 Throttle Checks and Precision Governor Adjustments - Ford Engine
    • Checks
    • Choke Adjustments
    • Carburetor and Governor Adjustments
  • 2.17 Pressure Setting Procedures
    • Sequence Pressure (Prior to 1990)
    • Sequence Pressure (1990 to Present)
    • Pilot Pressure
    • Proportional Valve
    • Solenoid Valve
    • Extend-A-Reach Valve (If Equipped)
  • 2.18 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Bearing Wear Tolerance
    • Bearing Replacement
    • Swing Bearing Torque Values
  • 2.19 Drive Torque Hub
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.20 Swing Torque hub
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.21 Swing Brake - Ausco - Machines Built To 1992
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.22 Swing Brake - Mico - Machines Built To 1992
    • Cleaning and Inspection
    • Assembly
  • 2.23 Swing Brake - Machines Built 1992 To Present
    • Cleaning and Inspection
    • Assembly
  • 2.24 Drive Brake - Ausco - Machines Built Prior To March 1992
    • Disassembly
    • Inspection
    • Assembly
  • 2.25 Drive Brake - Mico - Machines Built March 1992 TO S/N 33476
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.26 Drive Brake - Mico - Machines Built S/N 33476 To Present
    • Disassembly
    • Inspection
    • Assembly
  • 2.27 Free Wheeling Option
    • To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
    • To Engage Drive Motors and Brakes (Normal Operation)
  • 2.28 OEM Controllers
    • THRESHOLD Adjustment
    • HI RANGE Adjustment
    • IRS - RAMP RATE Adjustment
    • LO RANGE Adjustment (CREEP)
  • 2.29 Boom Marking Tape Installation
  • 2.30 Boom Length/angle Sensor Adjustment Procedures
    • 1st, and 2nd Generation Radius Cards
    • 3rd Generation Radius Cards
  • 2.31 Load Management System
    • Platform Position Indication System
    • Overmoment Control System
    • Overmoment Control Monitoring System
    • Load Management System Daily Check
  • 2.32 Load Management System Adjustment
    • Turntable 4620038
    • Turntables 4620044 and 4620078
  • 2.33 Turntable Springs
    • Turntable 4620038
    • Turntables 4620044 and 4620078
  • 2.34 Pump Coupling Conversion Procedures
    • Lovejoy Coupling
    • Hayes Coupling
  • 2.35 Platform Rotator Brake
  • 2.36 Preventive Maintenance and Inspection Schedule
• Section 3. TROUBLESHOOTING
  • 3.1 General
  • 3.2 Troubleshooting
  • 3.3 Hydraulic Circuit Checks