Manual Operador CAT529 PDF

TABS
519-569 SM/EHC Service Manual Part # 30013158
ALPHA CHARACTER SUBJECT
TABLE OF CONTENTS
1 Operator’s Manual
2 Hydraulic Specifications & Test Procedures
3 Hydraulic Systems
4 Hydraulic Componenets
5 Swing Motor
6 Mechanical Service
7 Electrical Systems
8 Air Conditioning
Part No. 30013158
February 2010
Rev. 1
519sm-569sm Knuckleboom Loader

-
Contents
Service Manual
CAT Model 519SM-569SM Loader
SECTION SUBJECT
1.....................................................................................................................Operator's Manual
2......................................................................Hydraulic Specifications & Test Procedures
3....................................................................................................................... Hydraulic System
4............................................................................................... Major Hydraulic Components
5............................................................................................................ Hydraulic Swing Motor
6................................................................................................................... Mechanical Service
7........................................................................................................................ Electrical System
8.........................................................................................................................Air Conditioning
Information on vended components reprinted by permission. This manual has been compiled from materials
available at the time of approval for reproduction. Manufacturer reserves the right to improve its products
without giving prior notice or incurring obligation.
-ii
Contents
Part No. 30013537
October 2008
Rev. 1
519/569 ESM/EHC Knuckleboom Loader

to the operator


             

 


 




               

                 
 
                   

                


                 

                   
 
 
                 
 

  
 
                 
              
                 
                   
 

                 
                  
 
  
                  



   
             
                



              


519/569 ESM/EHC 1008

To the Operator
519/569 ESM/EHC ii 1008

to the operator
to the operator
Introduction
DO NOT USE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THIS MANUAL,
AND HAVE THE NECESSARY TRAINING AND AUTHORIZATION TO OPERATE AND MAIN-
TAIN THIS MACHINE PROPERLY.
REMEMBER THAT YOU ARE THE KEY TO SAFETY. GOOD SAFETY PRACTICES PROTECT
YOU AND THE PEOPLE AROUND YOU. MAKE THIS MANUAL A WORKING PART OF YOUR
SAFETY PROGRAM.
To safely operate this machine, follow the instructions in this operator’s manual. Directions in this manual are
referenced from the operator’s seat facing forward (see diagram below).
forward
left right
back
You can help improve this manual. If you find any mistakes, or if you know of a way to improve procedures,
please let us know. Mail your suggestions or comments to the attention of Technical Publications, Cat Forest
Products, Inc., 3249 South County Road 45, PO Box 568, Owatonna, MN 55060-0568.
This operator’s manual includes information available and current at the time of approval for printing.
Cat Forest Products, Inc. reserves the right to improve its product without giving prior notice or incurring
obligation.
This operator’s manual should be regarded as part of the machine. Suppliers of both new and second hand
machines are advised to retain documentary evidence that this manual was provided with the machine.
519/569 ESM/EHC iii 1008

To the Operator
safety symbols
safety alert symbol
The Safety Alert Symbol means

ATTENTION!
BE ALERT!
YOUR SAFETY IS INVOLVED!
This safety symbol is used for important safety messages. When you
see this symbol, follow the safety message to avoid personal injury
and/or property damage.
Understand signal words: DANGER, WARNING, and

CAUTION are used with the SAFETY ALERT SYMBOL.
DANGER identifies the hazard or unsafe
DANgER practice that will result in severe person-

al injury or death.
WARNING identifies the hazard or unsafe practice

WARNINg that could result in severe personal injury or death.
CAUTION identifies the hazard or unsafe practice

CAUTION that could result in personal injury or property
damage.
NOTICE identifies important installation, operation, or

NOTICE maintenance information.
519/569 ESM/EHC iv 1008

to the operator
contents
product protection plan
Machine ................................................................................. i
to the operator...................................................................iii
Safety Symbols..................................................................iv
general safety.................................................. section 1
safety decals..................................................... section 2
component terminology........................... section 3
controls & instruments............................ section 4
IQAN.............................................................................SECTION 5
PRESTART INSPECTION..........................................SECTION 6
Operation.............................................................. section 7
break in period.................................................. section 8
transportation................................................ section 9
lubrications......................................................section 10
Maintenance safety....................................section 11
Scheduled/periodic maintenance services........

...........................................................SECTION 12
storage.................................................................section 13
troubleshooting..........................................section 14
specifications...................................................section 15
serial numbers................................................section 16
Material safety data sheets..................SECTION 17
519/569 ESM/EHC 1008

To the Operator
519/569 ESM/EHC vi 1008

General safety
General safety
WARNINg Do not operate this machine without reading and understanding this operator’s
manual.
Safety alert symbol

Read all safety messages.
To avoid personal injury and/or property damage,
follow safety messages.
Operator preparation
Operator must be fully trained, qualified, and
authorized to operate this machine. Before operating
this machine, operator must know the location and
purpose of
• controls
• indicator lights
• instruments
• safety and instruction decals

(See Safety Decals.)
Control shut off lever
Accidental movement
of turntable or booms can cause serious personal
injury or death.
Before leaving cab, always push pilot control shut off
lever up and forward to disengage controls and to free
door entry/exit path.
519/569 ESM/EHC 1- 1008

General safety
Electric lines
DANgER SERIOUS INJURY OR

DEATH WILL RESULT FROM CONTACT WITH ELEC-
TRIC LINES.
Never move any part of machine or load closer
than 10 feet plus twice the line insulator length to
electric lines. A line insulator is what connects an
electric line to an electric pole.
For example, if a line insulator is 6 inches long,
operator must stay at least 10 feet plus twice the
line insulator length (2x6 =12 inches or 1 foot) from
electric line, which means machine must stay at
least 11 feet from the electric line.
If machine touches an electric line, stay inside the
cab. Carefully move machine or load away from
electric line, without pulling the line down.
DO NOT allow anyone else to touch machine while
it is touching an electric line. If machine cannot be
moved away from the electric line without pulling
line down, have someone contact the utility com-
pany to disconnect power from line. If this is not
possible, or if machine begins to burn, jump away
from machine to the ground with both feet togeth-
er, in one smooth jump. Do not run or walk away
from machine. Jump with feet together (“bunny
hop”) away from machine. DO NOT touch machine
and ground at the same time or else electricity in
the line will go through your body. Get away from
machine after jumping.
Notify the utility company immediately. DO NOT
let anyone near the machine while it is touching an
electric line.
Electrical storm
WARNINg Electrical storms (light-

ning) can cause severe personal injury or death.
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
Mount the machine
Dismount the machine
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
519/569 ESM/EHC 1- 1008

General safety
Falling or swinging logs
WARNINg Falling or swinging logs,

booms, or attachments can cause severe personal
injury or death.
Never operate the boom, attachment or load over or
near personnel.
G.083.03
Fire prevention/First aid
CAUTION Fires can cause personal

injury and/or machine damage.
Keep machine clean. Forest debris, rags, and trash will
cause fires. Remove all debris, rags, and trash from
machine, especially around motor and hydraulic com-
ponents.
Repair all hydraulic and fuel leaks immediately. Do not
operate machine with hydraulic or fuel leaks.
Fire prevention beats fire fighting. Remove debris from
all compartments after every 8 hours of operation, or
more often, if warranted by working conditions.
Install a first-aid kit in the cab.
Properly maintain first-aid kit and fire extinguisher. Fol-
G.111.04
low instructions provided with them.
519/569 ESM/EHC 1- 1008

General safety
Fluids under pressure
WARNINg Fluids escaping under

pressure can penetrate skin and cause severe
personal injury or death. Wear eye and personal
protection equipment (PPE)!
Always use a board or cardboard when checking oil
hoses, lines, and fittings for leaks, cracks, or defects.
Be sure all clamps are in their proper position and
torqued as required and specified. Be sure hoses are
not twisted or touching parts.
DO NOT use hands to search for leaks. Escaping fluids
can penetrate skin and enter the bloodstream. Before
disconnecting lines, relieve all pressure.
DO NOT apply pressure to a damaged line, hose, or
fitting.
If ANY fluid is injected into the skin, seek medical at-
tention immediately. A serious infection or reaction
can result without proper medical treatment.
Hand holds and steps
WARNINg Slips and falls can cause

severe personal injury or death.
Use provided hand holds and steps while maintain-
ing at least 3 points of support (1 foot and 2 hands
or 2 feet and 1 hand) when getting on and off ma-
chine. Face machine when getting on and off of it.
Never use controls as hand holds. Never use steer-
ing wheel as a hand hold. Moving the steering
wheel from its center position will COMPLETELY
turn machine right or left.
DO NOT mount machine if hand rails or steps are
broken or missing. Get them repaired first.
DO NOT jump on or off machine unless it has
touched a live electrical wire and it must be exited.
Ensure firm foot position when getting on and off
machine. Be careful of slippery conditions on plat-
form, steps, and hand holds when getting on and
off machine.
Remove oil, grease, mud, ice, etc. Before mounting
or dismounting machine.
To prevent slips and falls, replace skid-resistant ma-
terial if it is worn, damaged or missing.
519/569 ESM/EHC 1- 1008

General safety
Hand signals
WARNINg Accidents can cause

Know and use the hand signals required for particular
jobs.
Know who has the responsibility for signaling.
High voltage
WARNINg Failure to disconnect

power before servicing can cause serious personal
injury or death.
This machine is powered by high voltage electricity.
Disconnect main power supply before servicing. Install
and ground per local and national governing body
regulations. Electrical repairs should only be per-
formed by trained, qualified personnel.
Hoses and fittings
WARNINg Mismatched brands or

types of hoses and fittings can blow apart and
cause severe personal injury or death.
DO NOT interchange brands or types of hoses
and fittings.
DO NOT install a fitting from one manufacturer on a
hose from a different manufacturer.
DO NOT install crimp fittings on hoses meant for reus-
able fittings.
Wear eye and personal protection equipment (PPE)!
hoses, lines, and fittings periodically for leaks, cracks or
defects. Be sure all clamps are in their proper position
and torqued as required and specified. Be sure hoses
are not twisted or touching parts.
519/569 ESM/EHC 1- 1008

General safety
mobile phones
WARNINg Mobile phones can

interfere with remote control equipment, causing
unintentional machine movement, causing severe
personal injury or death.
Mobile phones operating in the vicinity of this ma-
chine can interfere with the remote controls. Do not
use a mobile phone near this machine while it is being
operated by remote control.
No riders on machine
WARNINg Machine riders can fall

from machine or be injured by movement of ma-
chinery, causing severe personal injury or death.
Do not allow riders on any machine that is operating
or moving.
Operator safety
WARNINg Flying debris, tree limbs,

and/or other material can cause severe personal
injury or death.
When operating machine:
1. Cab door must stay closed.
2. Window material and/or cab guarding MUST be in
place.
3. All cab openings (front, side, and rear) MUST be
covered with window material (no glass) and/or
protective screen.
4. Window guarding MUST be locked
in place.
519/569 ESM/EHC 1- 1008

General safety
Practice safe maintenance

Understand service procedures before performing
maintenance. When performing maintenance, keep
area around machine clean and dry.
DO NOT service machine while it is moving. Keep away
from power-driven parts. Lower attachment to the
ground. Disengage power. Shut motor down. Move
controls in all directions to relieve hydraulic pressure.
Remove key from ignition. Allow machine to cool
down.
Support all raised equipment.
G.104.05
Keep all machine parts in good condition, and be sure
parts are properly installed. Repair damage immedi-
ately. Repair all hydraulic and fuel leaks immediately.
Replace worn or broken parts. Remove any buildup of
grease, oil, or debris.
Disconnect battery ground cable (-) before adjusting
the electrical system.
Pressure settings
WARNINg Excessive hydraulic

pressure can cause component or structural fail-
ure, which may result in severe personal injury or
death.
Wear eye and personal protection equipment (PPE)!
DO NOT exceed factory-adjusted pressure settings.
519/569 ESM/EHC 1- 1008

General safety
Protective clothing
Wear OSHA or local governing body-approved
protective clothing when working on or near this
machine, such as
• ear protection • hard hat
• gloves • orange vest
• goggles • steel-toed shoes
Wear snug, protective clothing that is belted where

required.
Remove jewelry before working on or near this ma-
chine.
Protective devices/equipment
WARNINg Misuse, interference and

ignorance of protective equipment or devices can
cause severe personal injury or death.
Alarms, fire prevention equipment, ROPS/FOPS/OPS,
and other safety equipment is installed on machine for
your protection.
Never ignore, disconnect, disable or modify protection
equipment in any manner.
519/569 ESM/EHC 1- 1008

General safety
Electronic regulator
WARNINg Unsuitable installation

combined with powerful electromagnetic interfer-
ence fields may cause unintentional speed increase
on activated function causing severe personal
injury or death.
Installed radio/mobile telephone equipment and out-
side radio transmitters can disturb the control equip-
ment .
To avoid equipment interference, the equipment must
be installed by a professional, according to manufac-
turer’s instructions.
Unauthorized welding
WARNINg Unauthorized welding

can cause structural failure and/or severe personal
injury or death.
DO NOT weld on any structural member.
Any unauthorized welding or repair will void
the warranty.
Once authorized, be sure to turn battery disconnect
master switch OFF and place welding ground (stinger)
as close to weld site as possible. Do not allow weld cur-
G.020.05
rent to pass through bearings or pivot points.
NOTICE Unauthorized welding can

cause damage to the electrical system.
519/569 ESM/EHC 1- 1008

General safety
519/569 ESM/EHC 1-10 1008

safety decals
SAFETY DECALS
The following safety decals are located in positions on the machine as continual reminders of hazards. Serious
injury or property damage can occur if safety instructions are not followed.
Keep all safety decals clean and readable. Use soft cloth, water, and soap to clean decals if they are too dirty to
read. do not clean safety decals with solvent. Solvent can damage them.
Replace safety decals immediately if they are damaged, missing, or hard to read. Contact an authorized dealer
for replacement safety decals. Authorized dealers will provide free replacement safety decals if you give them a
valid serial number for your machine.
NOTICE
If you replace a part that has a safety decal on it, apply a new safety decal to the replace-
ment part. Before putting a new decal on the machine or part, be sure the surface where the decal will be mounted is
clean and dry.
519/569 ESM/EHC 2- 1008

safety decals
LOADER DECALS
daNgER
HaZaRdOuS VOLtagE tuRN Off POwER
wILL CauSE bEfORE OPENINg PaNEL.
SEVERE INjuRY OR
dEatH.
11/89 10000055
daNgER
CONtaCtINg ELECtRICaL LINES

wItH bOOM, LINE OR LOad
wILL CauSE SEVERE INjuRY
OR dEatH.
uNLawfuL tO OPERatE tHIS

MaCHINE OR PLaCE bOOM
LINE OR LOad wItHIN 10 fEEt
PLuS twO tIMES LINE INSuLatOR
LENgtH Of aNY ELECtRIC
LINE.
1291 1000031
WARNINg
UNSAFE OPERATION OR
MAINTENANCE CAN CAUSE
SEvERE INJURY OR DEATH.
DO NOT OPERATE OR WORk ON

THISMACHINE WITHOUT READINg
& UNDERSTANDINg THE
OPERATOR'S MANUAL.
WARNINg
FALLINg OR SWINgINg LOgS OR
BOOMS CAN CAUSE SEvERE
INJURY OR DEATH.
NEvER OPERATE THE BOOM

OR LOAD OvER OR NEAR
waRNINg
PERSONNEL.
WARNINg dO NOt fILL fuEL fILtERS

UNSTABLE PLATFORM CAN
CAUSE SEvERE PERSONAL bEfORE INStaLLINg NEw
INJURY OR MACHINE DAMAgE. fuEL fILtERS.
LOWER ALL STABILIzERS BEFORE
OPERATINg.
ELECTRIC PUMP WILL
AUTOMATICALLY FILL
WARNINg FUEL SYSTEM.
FAILURE TO PERFORM A DAILY
INSPECTION OF THE LOADER
COULD RESULT IN MACHINE
DAMAgE AND SEvERE PERSONAL
INJURY.
PERFORM A DAILY INSPECTION
waRNINg
OF THE FOLLOWINg COMPONENTS:
STRUCTURES, BOOMS, CYLINDERS,
TURNTABLE, SWINg BEARINg,
LOAD BEARINg ITEMS, AND
ALL MOUNTINgS.
CONtaCt wItH faN OR
WARNINg ExPOSEd bELtS COuLd
CauSE SEVERE
CONTACT WITH STABILIzERS
COULD CAUSE PERSONAL PERSONaL INjuRY
INJURY OR PROPERTY DAMAgE. OR dEatH.
CLEAR ALL PERSONNEL FROM
WORk AREA BEFORE LOWERINg
STABILIzERS. kEEP HANDS AWAY
AT ALL TIMES.
WARNINg 10085899 Rev a 0608
ACCIDENTAL MOvEMENT OF
TURNTABLE OR BOOMS CAN
CAUSE SEvERE
PERSONAL INJURY.
BEFORE LEAvINg CAB, ALWAYS
PUSH PILOT PRESSURE SHUT-OFF
LEvER UP AND FORWARD TO
DISENgAgE HYDRAULIC PILOT
daNgER KEEP CLEaR

CIRCUIT AND FREE
DOOR ENTRY/EXIT PATH.
WARNINg
UNEXPECTED MOvEMENT OF
SAW BLADE CAN CAUSE SEvER
PERSONAL INJURY.
HYDRAULIC PRESSURE CAN BE
APPLIED DIRECTLY TO SAW BLADE
MOTOR WHEN LOADER IS STARTED.
BE SURE SAW CONTROL LEvER IS
IN THE NEUTRAL POSITION
BEFORE ATTEMPTINg TO START
LOADER. 10049872 2/03
10084365--C-Ops
519/569 ESM/EHC 2- 1008

Component Terminology
COMPONENT TERMINOLOGY
Loader
519/569 ESM/EHC 3- 1008

Component Terminology
519/569 ESM/EHC 3- 1008

controls and instruments
left hand joystick control
left hand joystick

The left hand joystick (A) operates the main boom and
grapple as follows:
A
Push joystick lever forward (B) to lower main boom.
Pull joystick lever back (C) to raise main boom.
Push joystick lever left (D) to open grapple jaws.
Push joystick lever right (E) to close grapple jaws.
d e
519/569 ESM/EHC 4- 1008

right hand joystick control
right hand joystick

The right hand joystick (A) operates the stick boom
and grapple rotation as follows:
Push joystick lever forward (B) to lower stick boom.
A
Pull joystick lever back (C) to raise stick boom.
Push joystick lever left (D) to rotate grapple counter-
clockwise.
Push joystick lever right (E) to rotate grapple clockwise.
d e
519/569 ESM/EHC 4- 1008

swing pedal - ESM model
Control the upper frame swing as follows:

Press LEFT side of pedal (A) to swing upper frame to
the left.
Press RIGHT side of pedal (B) to swing upper frame to
the right.
pilot pressure shut-off lever - ESM model

The cab is equipped with a switch to shut off pilot
pressure to the joystick and foot pedal controls when
the operator exits the cab.
WARNINg Accidental movement

A of turntable or booms can cause serious personal
injury.
pilot pressure disengaged (A)

When the pilot pressure shut off lever is in the UP
position (A), the pilot controls (joystick and foot pedal
functions) are disabled. Before exiting cab, always lift
pilot pressure shut off lever up to disable the pilot
controls.
pilot pressure engaged (B)

When the pilot pressure shut off lever is in the DOWN
position (B) the pilot controls are operational. The pilot
pressure shut off lever must be DOWN and the pilot
reset button (C) activated to operate the loader.
519/569 ESM/EHC 4- 1008

hourmeter
The hourmeter (A) registers in full and tenths of hours.
ignition switch- ESM model

Turn key to ON position for power to the electrical
components.
Push button to start motor. When motor starts, release
button.
Turn key to OFF position to shut motor down.
NOTICE Before leaving loader, be

sure key is turned to the OFF position.
Remove the key from ignition so loader cannot be ac-
A cidentally started or started by unauthorized persons.
519/569 ESM/EHC 4- 1008

Circuit breakers - esm model

Fuses/breakers protect an electrical circuit from
current overload.
If an overload occurs, a fuse/breaker will “blow” thus
breaking the flow of current and preventing damage
to the circuit.
When replacing a fuse make sure replacement has
same amperage rating. Gently remove blown fuse and
replace by sliding replacement fuse into place.
When resetting a breaker, push breaker in and release
to reset.
dome light
dome light
Press switch on dome light (A) to turn dome light on or
off.
519/569 ESM/EHC 4- 1008

switch panel - esm model

air conditioning
CAUTION The air conditioner con-

tains R-134A refrigerant. Avoid breathing
A/C refrigerant and lubricant vapor or mist. Exposure
may irritate eyes, nose, and throat.
NOTICE Start and run motor for

2 minutes before turning on air conditioner.
Press A/C-heater switch (A) to the desired setting:
Top position - Air Conditioner
Middle Position - Off
Bottom Position - Heater
Press the fan switch (B) to the desired setting:
Top Position - High speed
Middle Position - Medium speed
Bottom position - Low speed
horn
Press switch to sound horn.
operating lights
Depress switch to turn operating lights on cab and
boom on or off.
Optional Auxiliary (turntable) Lights are available,
Depress bottom switch to turn auxiliary lights on or
off.
519/569 ESM/EHC 4- 1008

WINDSHIELD WIPER AND WASHER- ESM model
NOTICE Operating windshield wipers

on a dry window will scratch the window.
Press wiper switch (A) to activate wiper .
Top position - WASH
A b Middle position - OFF

The wiper blade will return to its stored location when
switch is in the OFF position.
Press the washer switch (B) for washer fluid. Periodi-
cally check washer fluid level in reservoir (C). Add com-
mercial windshield washer fluid as needed.
adjusting windshield washer nozzle spray

1. Insert a piece of 20-gauge wire into the nozzle ball
(D) located on the windshield wiper arm.
2. Move the ball until washer fluid sprays to desired
location.
D
519/569 ESM/EHC 4- 1008

operator seat- ESM model

Adjust operator’s seat using the following guidelines.
LH arm rest
The LH arm rest (armrest and joystick) (A) can be
swung up and back to allow easier access to the
operator’s seat.
seat front and rear position

Lift lever (B) UP and hold.
Slide seat to desired position.
Release lever.
NOTICE Make sure that seat is locked

into position before operating machine.
b
g.025.03
519/569 ESM/EHC 4- 1008

operator seat, continued
seat height
Firmly lift up and hold adjustment lever (A) until lever
releases.
While holding lever in the UP position, adjust seat
to desired height by adding or removing your body
weight to the front or rear of seat cushion.
Firmly push DOWN on lever until seat locks (a click will
be heard).
seat suspension
While seated, rotate handwheel (B) until seat cushion
is level.
backrest
C Rotate control knob to select desired backrest posi-

tion.
armrest
B
Rotate control knob (C) to select desired armrest angle.
Pivot armrest up and parallel with backrest when not
in use.
519/569 ESM/EHC 4- 1008

hydraulic reservoir sight gauge
The hydraulic reservoir sight gauge is located between

the cab and motor area near the entry door. Reservoir
capacity is 78 gallons (295 L).
oil shut off valves

Push valve handles up to shut off flow of hydraulic oil.
Pull valve handles up to turn on flow of hydraulic oil.
519/569 ESM/EHC 4-10 1008

power outlet
One power outlet (A) is provided for electrically pow-
ered accessories. It is 12 volt, 15 ampere outlet. To pro-
tect the battery against discharge, this outlet provides
power only when the key switch is ON.
519/569 ESM/EHC 4-11 1008

519/569 ESM/EHC 4-12 1008

iqaniqansystem
system ®
Introduction
The IQAN® system is a computer-based control system that delivers precision control through the valving system.
IQAN®’s menus control machine function and aid in troubleshooting.
iqan® terminal display

The IQAN®-DG terminal displays information for machine instrumentation, and consists of an LCD screen and
nine keys. With this display, the operator monitors machine functions such as joystick control, date, time, ma-
chine information and settings for individual operators.
MAIN SCREEN - This screen appears at machine start up.
To operate the IQAN® system, ignition switch must be turned to RUN or START.
F-1 - F-4 System Display Menu Buttons - Allow operator to view system settings.
Select Menu Buttons - Allow the operator to select functions displayed on the
screen.
Adjustment Screen - Used to switch between operational and menu modes,
returns user to main screen.
Arrow Button - Used to return to previous screen.

519/569 ESM/EHC 5- 1008

iqan® system
Adjustment Screen
Depress the button to access the main adjustment

screen.
Depress the button to return to the main screen.
Depress the F1 button to access:

Loader Adjustments
Depress the OK button to access the list of loader
functions to adjust.
Use up and down arrow keys to scroll to loader func-
tion to adjust.
Depress OK button to enter adjustment screen.
Depress F3 to increase (speed up) the value of the

function.
Depress F4 to decrease (slow down) the value of the
function.
Min - Milliampere supplied to the proportional valve at
minimum joystick activation.
Max - Milliampere supplied to the proportional valve
at maximum joystick activation.
Start - Milliseconds before movement occurs after
joystick activation.
Stop - Milliseconds after movement occurs after joy-
stick deactivation.
Depress F2 button to verify the reseting of the loader func-
tion.
Depress F1 or arrow button to return to Main Adjustment
Screen.
519/569 ESM/EHC 5- 1008
iqan® system
Depress the F1 button to access:

Joystick Enable
Depress the OK button to access the list of joysticks to
select.
Use up and down arrow keys to scroll to joysticks to
select.
Depress F2 button to verify the reseting of the loader func-
tion.
Depress F1 or arrow button to return to Main Adjustment
Screen.
519/569 ESM/EHC 5- 1008

iqan® system
Measurement Screen
Measurements
Depress the F2 button to access measurement screens:
Joystick Output
Digital Inputs
Depress F1 or arrow button to return to main adjust-
ment screen.
Use up and down arrow keys to scroll to select func-

tion to measure.
Depress OK button to enter measurement screen.
Joystick Output:
Percentage of movement of joystick for function listed.
Use up and down arrow keys to scroll to select joystick
function to measure.
Milliampere supplied to the proportional valve at mini-
mum joystick activation.
Depress F2 to display the raw or scaled value of the
function selected.
Depress F1 or arrow button to return to main measure-
ment screen.
519/569 ESM/EHC 5- 1008

iqan® system
Digital Inputs:
Use up and down arrow keys to scroll to select digital
input.
True or False values for functions. True the function is
activated. False the function is off.
Depress F2 to display the raw or scaled value of the
function selected.
Depress F1 or arrow button to return to main measure-
ment screen.
519/569 ESM/EHC 5- 1008

iqan® system
Preference Screen
Preferences
Depress the F3 button to access preference screens:
Display Setting
Date/Time Settings
Language

Depress F1 or use arrow button to return to main
adjustment screen.
Depress F1 button to alter display settings.

Depress F2 button to set time and/or date.
Depress F3 button to select language.
adjustment screen.
519/569 ESM/EHC 5- 1008

iqan® system
Display Settings:
Depress F1 button to alter display settings.
Depress F2 button to select backlight (brightness of

screen). Use up and down arrow buttons to increase
or decrease amount of backlight on display screen.
Depress OK button to store screen saver setting.
Depress F3 button to select screen saver. Use up and

down arrow buttons to select on or off screen saver.
Depress up arrow button to select dimmed or black for
the screen saver. Use arrow keys to access options.
Depress OK button to store screen saver settings.
519/569 ESM/EHC 5- 1008

iqan® system
Date and Time:
Depress F2 button to select date and time setting. De-
press F1 button to select date setting, year will be au-
tomatically highlighted, use up and down arrow keys
to scroll to desired setting. Depress OK button to store
setting and move to next highlighted area (month).
Repeat steps until complete date (year, month, day) is
set.
Depress F2 button to set time. Hour will be automati-
cally highlighted, use up and down arrow keys to
scroll to desired setting. Depress OK button to store
setting and move to next highlighted area (minutes).
Repeat steps until complete time (hour/minute) is set.
Language:
Depress F3 button to select language setting. set date.
Use up and down arrow keys to scroll to desired set-
ting. Depress OK button to store setting .
519/569 ESM/EHC 5- 1008

iqan® system
information Screen
Information
Depress the F4 button to access information screens:
Machine ID will be displayed on screen.

adjustment screen.
Modules:
Depress the F1 button to view modules:
Depress F1 or use arrow button to return to informa-

tion adjustment screen.
519/569 ESM/EHC 5- 1008

Pre-start Inspection
PRE-START INSPECTION
WARNINg Do not use this machine until you read, study, and understand this manual to
learn how to properly operate this machine. Operating this machine without reading, studying, and un-
derstanding this manual could result in severe personal injury or death.
Failure to perform a daily inspection of the loader could result in machine damage
WARNINg and severe personal injury.
pre-start checks: on the ground
Check for protective clothing (wear it) and safety equipment (know where it is).
Check entire machine by performing a thorough walk-around inspection.
Check for loose or missing parts. Tighten loose parts. Replace any missing parts.
Check for leaks in hydraulic hoses and/or lines (replace defective hoses and/or lines).
Check hydraulic hoses and lines for wear and/or damage. Replace any defective
hoses and/or lines.
Check that machine has been properly lubricated as spelled out in the Scheduled/
Periodic Maintenance Services section of this manual.
Check shields and guards. They must be in place and undamaged.
Check that safety decals are on machine and that they are readable.
Check that shut-off valves are open (if so equipped).
Check for dirt and grime on all hydraulic components. Clean away dirt and grime to
help prevent overheating.
Check for ice, snow, mud, oil, and grease on ladders and walkways. Clear away ice, snow, mud
oil, and grease to prevent slips and falls.
Check for any loose skid-resistant mats. Replace mats if they are loose.
Add hydraulic oil to reservoir if necessary.
Check for combustible or flammable materials. Remove them from machine if you find them.
Check mounting hardware for tightness.
Check that machine will not be near electrical wires. See Operation section in
this manual.
Check swing bearing for loose or missing fasteners. Tighten loose fasteners. Replace
missing fasteners per maintenance instructions.
Check booms for damage, cracks, debris, mounting pin retention, and other problems.
Immediately report any structural problems (cracks) to an authorized dealer for diagnosis and
repair or replacement.
Check that upper frame and motor area are free of leaves, twigs, branches and other debris.
Check electrical system for worn insulation or frayed wires and loose connections.
NOTICE You can copy the pages in this section. Check off each inspection item before operating the
machine, and file the copy as a record of inspection as required per OSHA or local governing body.
519/569 ESM/EHC 6- 1008
pre-start checks: on platform

hand holds and steps

off machine.
Remove oil, grease, mud, ice, etc. before mounting
terial if it is worn, damaged or missing.
Check hydraulic hoses in platform/boom end area for wear and/or damage. Replace any
defective hoses and/or lines.
Check safety decals. They must be present and readable.
Check control levers/pedals for free movement.
Check booms for damage, cracks, debris, mounting pin retention, and other problems.
Immediately report any structural problems (cracks) to an authorized dealer for diagnosis
and repair or replacement.

Check hydraulic reservoir fluid level. Add hydraulic oil to reservoir if necessary.
Check that all cab windows are clean and clear. Replace any damaged polycarbonate
window material.
Check for mud and debris on cab floor (clean away mud and debris)
NOTICE You can copy the pages in this section. Check off each inspection item before operating
the machine, and file the copy as a record of inspection as required per OSHA or local governing body.
519/569 ESM/EHC 6- 1008

pre-start checks: in the cab


off machine.
To prevent slips and falls, replace skid-resistant
material if it is worn, damaged or missing.
Check that there is no mud or debris on cab floor (clean away mud and debris).
Check for free movement of controls.
Check and review safety decals, that all are present and can be clearly read.
Check that all cab window material is clean and clear. Replace any damaged polycarbonate
window material.
Check that fire extinguisher is adequately charged.
Check instrument panel for broken gauges and/or broken indicator lights. Have
gauges and/or indicator lights repaired if necessary.
Check window emergency exits.
Check cab operator protection structure for damage. Have structure repaired if necessary.
Check that all items in cab that are not part of the machine, such as lunch boxes or
tools, are secured.
NOTICE You can copy the pages in this section. Check off each inspection item before operating the
machine, and file the copy as a record of inspection as required per OSHA or local governing body.
519/569 ESM/EHC 6- 1008
fire prevention
CAUTION Fires can cause personal

injury or machine damage.
Keep machine clean. Remove debris, especially from
heat sources. Fire prevention beats fire fighting. Hourly
or daily inspections can reduce the possibility of fires.
CAUTION Forest debris can collect on the machine and cause a fire. When forest debris mixes
with flammable fluids in a hot, confined space, the risk of a fire starting greatly increases. KEEP THE MACHINE
CLEAN.
Check machine daily for fire hazards. Remove debris from areas of the machine that create heat and that are
potential fire start points. Depending on machine model, check for flammable debris in the following locations:
• Electrical connections • Control valves
Fire needs fuel. Remove combustible material (fuel for fire) from heat sources. Keep the machine clean. Remove
the following materials, and other combustible materials from areas of the machine that create heat:
• Pine needles • Twigs • Debris
• Shop rags • Oil spills • Coolant mixture
• Leaves • Sticks • Sawdust
• Grease • Bark • Diesel fuel
CAUTION Keep the machine clean. Risk of fire increases if combustible materials and flam-
mable materials build up on machine. This machine is not designed to house or store combustible materials.
Regularly remove flammable materials (such as diesel fuel, hydraulic oil, and grease) from all areas of the ma-
chine. Clean up after working. Keep the hydraulic systems in good repair.
Check hydraulic hoses, fuel lines, and fittings for leaks. Tighten loose fittings. If hoses or lines are bent, kinked, or
show signs of wear, install new parts. Check electrical connections to be sure they are clean and secure.
Frayed, damaged or worn insulation on battery cables or other wires may lead to electrical fires. Check cables
and wires and replace if insulation is frayed, worn, or damaged.
NOTICE At the end of each shift ALWAYS stay with the machine for 30 minutes after shutting down
the motor to ensure there is no forest debris/trash fire start up. Keep a fire extinguisher ready during this 30 minute cool
down.
519/569 ESM/EHC 6- 1008

operation
operation
general guidelines
WARNINg Only a trained, qualified, and authorized operator shall be allowed to operate
this machine. Only use this machine after carefully reading this manual and learning how to safely oper-
ate and maintain this machine. Unsafe operation can cause severe personal injury or death.
operator preparation
Operator must be fully trained, qualified, and
authorized to operate this machine.
Before running this machine, operator must know the
location and purpose of
• controls
• indicator lights
• instruments
• local operating safety rules and procedures
• safety and instruction decals (see Safety Decal

Section)
Operators must be at least 18 years old to operate this machine (Code of Federal Regulations: Labor).
Never operate this machine while under the influence of drugs or alcohol. Use of prescription or over-the-
counter drugs or medications requires advice from a medical practitioner on whether or not machine can be
safely operated.
Operators may not run this machine if subject to dizziness, seizures, or motion disturbance.
Do not operate this machine unless it is properly mounted to a truck or trailer for stability.
Never operate this machine with stabilizers in raised position.
No riders are allowed on this machine. Machine riders can fall from machine or be injured by movement of
machinery, causing severe personal injury or death. Do not allow riders on a machine that is operating or
moving.
Follow all safety operating instructions and practices. (See General Safety Section.)
Keep machine away from power lines.
If this manual is lost, contact an authorized dealer for a new manual. Keep manual in the in the cab.
Report any noticeable machine problems to people who can repair the problems before machine is used.
Be sure cab windows are clean before operating machine. Cab windows must be clear of ice and frost. Replace
windows that are cracked, yellow, and/or hazy.
Remember, operators are key to the safe operation of this machine.
519/569 ESM/EHC 7- 1008

operation
electrocution danger
DANgER contacting electric
lines with boom, line, or load will cause
severe injury or death. WATCH FOR OVER-
HEAD POWER LINES. Treat any line as live
and dangerous. If at all possible, have the
power line disconnected before starting
work.
Never move any part of the machine or load closer to
electric lines than 10 feet plus twice the line insulator
length. A line insulator is what connects an electric
line to an electric pole.
g.026.03 For example, if a line insulator is 6 inches long, stay
at least 10 feet plus twice the line insulator length (2
x 6 = 12 inches or 1 foot) from the electric line, which
means stay at least 11 feet from this electric line.
If the machine touches an electric line, stay in the
machine. Carefully move machine or load away from
the electric line, without pulling the line down.
DO NOT let anyone else touch the machine while it is
touching the electric line. If machine cannot be moved
away from the electric line without pulling the line
down, have someone contact the utility company to
disconnect power from the line. If this is not possible,
or if the machine begins to burn, jump away from
the machine to the ground with both feet together,
in one smooth jump. DO NOT touch the machine and
the ground at the same time or else the electricity in
the line will go through your body. Get away from the
machine after jumping.
Notify the utility company immediately. DO NOT let
anyone near the machine while it is touching the
electric line.
overhead loads
WARNINg Falling or swinging logs or

booms can cause severe injury or death.
The loader operator is responsible for ensuring that
booms or loads are never suspended over or near
personnel.
• Always know where other people are working at
the job site in relation to the loader.
• Maintain good communication with everyone on
the job.
• Stop operations if someone on the ground
approaches the machine.
g.027.03
519/569 ESM/EHC 7- 1008

operation
getting on machine (stationary mount Machines)


serious personal injury.
Never use controls as hand holds. DO NOT mount
machine if hand rails or steps are broken or miss-
ing. Get them repaired first.
form, steps and hand holds when getting on and
off machine.
terial if it is damaged or missing.
519/569 ESM/EHC 7- 1008

operation
machine start up
1. Perform a pre-start inspection (see Pre-Start In-

spection section in this manual).
2. Check all controls for proper function and re-
sponse before starting work.
3. Maintain adequate distance between machine
and other equipment and personnel.
4. Insert key into key switch.
5. Turn key switch ON.
6. Depress Start button.
NOTICE Depending on your model,

the machine may use a start button and a stop but-
ton to operate also.
519/569 ESM/EHC 7- 1008

operation
feathering the controls
g.031.03
g.030.03
Rough operation can be dangerous, hard on the machine, and hard on the operator.
DO NOT jerk control levers to full speed, or from one direction to another.
Feather controls this way:
1. Move joystick control gently from neutral to feather zone motion.
2. After a slow, smooth start, move joystick control to desired speed position.
3. Just before stopping movement, move joystick control gently back to neutral.
This method of carefully manipulating the controls is called feathering. Work can be done more efficiently by
feathering controls than by jerking controls.
There is a rhythm to operating this machine. Feathering the controls will help the operator find, and take advan-
tage of, this rhythm.
519/569 ESM/EHC 7- 1008

operation
landing layout
• The loader operator is in one of the best positions

on the work site to notice a problem and warn
others by sounding the horn. The loader opera-
tor is responsible for the safety of people on the
ground.
• All landings (decks) should provide an area clear
of suspended loads for landing personnel (deck
hands) to work. Remember, logs can roll or be
thrown a considerable distance.
• If clearance of suspended loads cannot be pro-
vided, STOP loading operations and lower grapple
while deck hands are working on the landing.
• All obstructing trees should be removed to ensure
clearance for loading.
• Never locate landing near overhead electrical
g.034.03
lines. See Electrocution Dangers in this section for
instructions.
heeling – picking up logs

Follow these guidelines if using a heel attachment
with this loader.
• Always lift and heel long logs from butt end of log
(larger end). Place grapple on log as illustrated so
the log will not hit the stick boom cylinder.
• Never pinch a log. Always make sure the grapple
wraps around the log.
g.035.03
WARNINg Always place logs in heel
on opposite side of boom, away from cab. This can
reduce the risk of a log flying toward the cab if a
log slips in the grapple.
• Never heel logs from the center — this puts the
ends of the logs too close to the boom cylinders
and the cab when drag loading.
• Never swing load or grapple over truck cab being
loaded.
g.036.03
• Make sure truck driver and other personnel are

away from truck and loader when operating
loader.
• On booms without heels, pick up logs toward the
butt end. When lifting logs at their balance point,
take care when rotating logs to make sure they
clear the loader and other obstructions.
g.037.03
519/569 ESM/EHC 7- 1008

operation
grapple control
Study and learn the grapple control functions (see
Controls and Instruments Section). Improper rotation
of grapple or accidental opening of grapple will cause
loss of control of the load.
• Do not change function arrangement.
• Use proper grapple to match application.
• For log handling always use a log bypass, or com-
bination bypass/pulp grapple.
• For short wood handling, use a log bypass, combi-
g.038.03 nation bypass or butt-style pulpwood grapple.
• Never swing and load a single log or branch by
pinching the sides of the log or stem with the
grapple jaw tips. Always clamp the log or branch
within the grapple jaws.
stopping the machine
1. Bring machine to a complete stop.

2. Lower attachment to ground with the main and
stick booms fully extended. The grapple should
be open with the jaw tips on the ground. For
extra stability on unfrozen ground, jaw tips can be
closed slightly so that they dig into the ground.
g.039.03
3. Turn key switch to OFF.
4. Remove key from key switch.
NOTICE At the end of each shift AL-

WAYS stay with the machine for 30 minutes after shutting
down the to ensure there is no forest debris/trash fire start
up. Keep a fire extinguisher ready during this 30 minute
cool down.
519/569 ESM/EHC 7- 1008

operation
519/569 ESM/EHC 7- 1008

Break-In Period
break-in period
ESM/Ehc loaders
AFTER FIRST 10 HOURS OF OPERATION

KEY COMPONENT SERVICE SPECIFICATION
1. Hydraulic Reservoir Check fluid level Full Mark, Use
Premium A.S. Hydraulic Oil
2. Loader Visually check for any loose hardware or
fluid leaks
AFTER FIRST 100 HOURS OF OPERATION

KEY COMPONENT SERVICE SPECIFICATION

3A. Inner Swing Bearing - 519SM Tighten to 171-189 ft. lb. (232-256 N•m) torque* Torque Wrench
3B. Inner Swing Bearing - 569SM Tighten to 600 ft. lb. ( 813 N•m) torque* Torque Wrench
4A. Outer Swing Bearing - 519SM Tighten to 162-178 ft. lb. (220-241 N•m) torque* Torque Wrench
4B. Outer Swing Bearing - 569SM Tighten to 600 ft. lb. ( 813 N•m) torque* Torque Wrench
5A. Loader Mounting Bolts - Concrete, 519SM Tighten to 1100 ft. lb. (1496 N•m) torque* Torque Wrench
5B. Loader Mounting Bolts - Steele, 519SM Tighten to 1360 ft. lb. (1844 N•m) torque* Torque Wrench
5C. Loader Mounting Bolts - Concrete, 569SM Tighten to 1100 ft. lb. (1496 N•m) torque* Torque Wrench
5D. Loader Mounting Bolts - Steele, 569SM Tighten to 1292-1428 ft. lb. (1752-1936 N•m) torque* Torque Wrench
6. Hydraulic Return Line Filter Use only Genuine parts Filter
* use with Loc-Tite® or equivalent
NOTICE
The above fluid capacities are approximate values. Be sure to check levels after filling. DO NOT
OVERFILL!
DURING THE FIRST 100 HOURS OF OPERATION
1. Check all accessible hardware for tightness.

2. Check hydraulic fluid regularly.
519/569 ESM/EHC 8- 1008

Break-In Period
519/569 ESM/EHC 8- 1008

transporting
transporting
WARNINg Stationary mount machines are not designed for frequent

transporting. Consult your authorized dealer for transporting procedures.
NOTICE DO NOT wrap chains around machined surfaces. Travel vibration can cause
chain hammering.
519/569 ESM/EHC 9- 1008

transporting
NOTES
519/569 ESM/EHC 9- 1008

lubricants
FUELS AND LUBRICANTS
hydraulic oil
Hydraulic systems have been filled from the factory with Premium All-Season Hydraulic Oil 46.
Use the following hydraulic oils in your machine.

ambient temp ambient temp ambient temp
-25°F to 80°F -10°F to 95°F 0°F to 105°F
(-32°C to 27°C) (-23°C to 35°C) (-18°C to 41°C)
Premium All-Season Premium All-Season Premium All-Season
Hydraulic Oil 32 Hydraulic Oil 46 Hydraulic Oil 68
Hydraulic oil capacity for the

519SM is 71 gallons (269 L)
569SM is 65 gallons (246 L)
Premium NOTICE Check with an authorized

All Season
Premium
All Season l 46 Hydraulic Oil 46 dealer for hydraulic fluid recommendations and compat-
Hydraulic
Oi
ibilities.
BE SURE hydraulic fluid selection is compatible with
the hydraulic system.
RTS
GEN
FORESTRY & INDUSTRIAL

PA
BL
EQUIPMENT DIVISION
OUNTO RI
UI
D
N
Preium
ZE
E
FA
Prem mium
C TOR H
Y AUT
All as
All Se ason
Seon
l 4646
OiOil
BE SURE hydraulic fluid selection assistance is from a
Hydra
Hydra uliculic
reputable supplier.
BE SURE hydraulic specifications meet or exceed the

Premium All Season Hydraulic Oil specifications. See
an authorized dealer.
BE SURE to use a mineral-base hydraulic oil.
GREASE
Most lubricated fittings require Premium Moly-Lith EP

#2 Grease. However, there are special requirements for
your loader's swing bearing and swing drive motor
(see Grease for Swing Bearing and Swing Drive Motor
in this section).
Premium
Moly-Lith
EP No. 2 Grease
Premium
Moly-Lith
EP No. 2 Grease Premium
Moly-Lith
EP No. 2 Grease
519/569 ESM/EHC 10- 1008

grease for swing drive Bearing & swing drive motor

Follow these specifications when selecting a grease for the swing bearing and swing drive motor.
Ambient Temp. Recommended Lubricant
Above 32°F (0°C) Premium Moly-Lith EP #2 Grease

Below 32°F (0°C) EP1 Grease
lubricant for pinion and swing gear teeth

When lubricating the pinion gear and swing gear teeth, use Moly-Lith Open Gear Lubricant.
When the gear path becomes contaminated, clean with solvent to remove contamination. Relubricate gear with
Moly-Lith Open Gear Lubricant, available from your authorized dealer.
lubricant for swing drive gear box

When lubricating the swing drive gear box, use Premium Gearlube GL-5 80W-90 gear lubricant.
cylinder rod CORROSION PREVENTIVE

NOTICE If machine will be stored for an extended period, or stored in a corrosive environment (such
as salt air or industrial pollution), apply Chrome Kote Corrosion Preventive on all portions exposed to air. See Storage
section for more information.
519/569 ESM/EHC 10- 1008

STORING LUBRICANTS
Store lubricants in a clean area that will keep them protected from water, dirt, or other contamination.
Always use clean containers when handling lubricants.
Storing lubricant drums or other containers out of doors is a poor practice. To minimize the harmful effect of
unavoidable outdoor storage, a few simple precautions and procedures can be very helpful:
WATER
1. As a general rule, lubricants in small containers
smaller than drums (55, 30 and 16 gallon oil drums
and 400 and 120 lb grease drums) should never be
stored out of doors. When drums must be stored
outside, a temporary shelter or lean-to, or a water-
proof taraulin, will protect them from rain or snow.
2. Drums should be laid on their sides with the bungs

approximately horizontal. In this position, the
bungs are below the level of the contents so that
breathing of water or moisture is greatly reduced,
and water cannot collect inside the chine (ridge of
drum). For maximum protection, the drums should
be stood on end with the bung ends down on a well
drained and contained surface. Where all of these
approaches are impractical, drum covers can be
used. These are available in metal and plastic.
NO WATER AROUND BUNG TO BE 3. When drums must be stored outdoors with the
DRAWN INTO DRUM bung end up, they should be blocked up with the
bungs parallel to the block to keep water away from
the bung openings.
4. Drums that have a bung on the side should be

stored either on end, or on the side with the bung
RIGHT down. Regardless of the position drums are stored
in, they should always be placed on blocks or racks
several inches above the ground to avoid moisture
damage.
WATER AROUND BUNG MAY BE
DRAWN INTO DRUM DISPOSE OF USED FLUIDS PROPERLY.
WRONG
NOTICE If machine will be stored for an extended period, or stored in a corrosive environment (such
as salt air or industrial pollution), apply Chrome Kote Corrosion Preventive with a sponge to portions exposed to air.
See Storage section for more information.
519/569 ESM/EHC 10- 1008

notes
519/569 ESM/EHC 10- 1008

MAINTENANCE SAFETY
MAINTENANCE SAFETY
BEFORe maintenance
WARNINg Maintaining this machine improperly could result in severe personal injury or
death. Read this manual before doing maintenance. Follow all safety instructions.
preparation
1. Read all safety instructions and maintenance

instructions in this operator's manual.
2. Position equipment on firm, level ground.
3. Lower attachment to the ground.
4. Shut motor down.
5. Move controls in all directions to relieve hydraulic

pressure.
6. Disengage controls by moving control shutoff lever

UP.
7. Remove the key from ignition.
8. Turn master battery disconnect switch off (unless

needed for the procedure to be performed).
protective clothing
Wear OHSA or local governing body-approved

protective clothing when working on or near this
machine, such as
• ear protection • gloves

• goggles • hard hat
• orange vest • steel-toed boots
Wear snug, protective clothing that is belted where

required.
Remove jewelry before working on or near this
machine.
519/569 ESM/EHC 11- 1008

MAINTENANCE SAFETY
unauthorized welding
WARNINg Unauthorized welding

can cause structural failure and/or severe personal
injury or death.
DO NOT weld on any structural member. Any unau-
thorized welding or repair will void the warranty.
Once authorized, be sure to turn battery disconnect
master switch OFF and place welding ground (stinger)
as close to weld site as possible. Do not allow weld cur-
rent to pass through bearings or pivot points.
G.020.05
NOTICE Unauthorized welding can
cause damage to the electrical system.
servicing control valves, cylinders,

pumps, and motors
WARNINg Increasing relief valve

settings can cause machine or component failure,
resulting in severe personal injury or death. Do not
change pressure settings. Do not switch lines from
one valve to another.
Special tools and training are required to service con-

trol valves, cylinders, pumps, and motors. If these parts
need service, see an authorized dealer.
hydraulic safety
protection equipment (PPE).
DO NOT disconnect hoses or fittings, or attempt
to service the hydraulic accumulator or pilot circuit
without first discharging the accumulator.
If ANY fluid is injected into the skin, seek
medical attention immediately. A serious
infection or reaction can result without proper medical
treatment.
CAUTION Hot hydraulic oil can cause

severe burns. DO NOT work on hydraulic system if oil
temperature exceeds 140°F (60°C).
Wear eye and personal protection equipment
(PPE)!
hoses, lines, and fittings periodically for leaks, cracks or
defects. Be sure all clamps are in their proper position
and torqued as required and specified. Be sure hoses
are not twisted or touching parts.
519/569 ESM/EHC 11- 1008
MAINTENANCE SAFETY
practicing safe maintenance
Understand service procedures before doing

maintenance. Keep the area around the machine clean
and dry when doing maintenance.
DO NOT service the machine while it is moving. Keep

away from power-driven parts. Lower attachment to
the ground. Shut down motor. Move controls in all
directions to relieve hydraulic pressure. Disengage
controls by moving control shutoff lever UP. Remove
the key from the ignition. Let the machine cool down.
Support all raised equipment.
Keep all machine parts in good condition and be sure

parts are properly installed. Repair machine damage
immediately. Replace worn or broken parts. Remove
any buildup of grease, oil, or debris.
during maintenance
fluids under pressure

pressure can penetrate skin and cause severe per-
sonal injury or death.
DO NOT use hands to search for leaks. Always use a

board or cardboard when checking oil hoses, lines, and
fittings for leaks, cracks, or defects. Be sure all clamps
are in their proper position and torqued as required
and specified. Be sure hoses are not twisted or touch-
ing parts.
Escaping fluids can penetrate skin and enter the

bloodstream. Before disconnecting lines, relieve all
pressure.

(PPE)!
DO NOT apply pressure to a damaged line, hose, or
fitting.
If any fluid is injected into the skin, seek medical
attention immediately. A serious infection or reaction
519/569 ESM/EHC 11- 1008

MAINTENANCE SAFETY
pinch points
WARNINg Placing your hands or any

portion of your body where the machine moves can
cause severe personal injury or death. Never place
hands or any portion of your body where injury
could occur if the machine moves. Never check pin
hole alignments with your finger.
cooling fan
WARNINg Rotating fan can cause

severe personal injury or death. Cooling fan can
start at any time, even with the Motor off. Keep
away from fan at all times.
519/569 ESM/EHC 11- 1008

MAINTENANCE SAFETY
after maintenance
disposing of waste
Follow applicable local, state, federal, and international

regulations when disposing of waste. Waste may in-
clude oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not

use food or beverage containers. Do not pour waste
on the ground, down a drain, or into any water source.
storing flammable materials
• Do not smoke where flammable materials are

stored.
• Store fuels and lubricants in properly marked
containers.
• Store oily rags and other flammable materials in
protective containers.
• Clean up all fuel, oil, grease, etc. spills
immediately.
519/569 ESM/EHC 11- 1008

MAINTENANCE SAFETY
NOTES
519/569 ESM/EHC 11- 1008

SCHEDULED/PERIODIC MAINTENANCE SERVICES

LUBRICATION AND MAINTENANCE INTERVALS
Maintenance requirements for lubrication,

adjustments and checks are shown on the
maintenance charts in this section.
Intervals of maintenance are based on normal

operating conditions. If operating under more
demanding conditions, observe a shorter time interval
between maintenance.
Demanding Conditions would include:

1. Frequent handling of near maximum capacity loads
2. Operating loader with delimber/slasher or other
timber processing attachment
3. Dry work area with heavy blowing dust
4. Extreme cold, -20°F [-6°C] and below
Use your hourmeter to help determine proper

maintenance intervals.
LUBRICATION notice
Listed maintenance intervals are for normal use applications. When greasing lubrication fittings, if grease is not forced
out the bushing ends with the recommended shots, increase number of shots used until grease is forced out. If grease
cannot be forced out, check for blocked grease passage ways.
If the lubricating areas are dry at the end of a normal operating day, increase the frequency of lubricating time periods
instead of increasing the amount of grease used at one lubrication period.
position machine for maintenance
WARNINg To avoid serious per-

sonal injury or property damage, follow the steps
0
below before performing any maintenance on this

machine.
1. Lower boom and grapple to ground.

2. Shut motor down.
3. Move joysticks in all directions to relieve hydraulic
pressure on boom.
4. Disengage controls.
5. Turn master battery disconnect switch off (unless
needed for the procedure to be performed).
519/569 ESM/EHC 12- 1008

as required
5, 6
SM-Tank-Maint-Ops
SM-Loader-Ops-Maint
MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.
AS REQUIRED
KEY COMPONENT SERVICE SERVICE SPECIFICATION MATERIAL USED
1. Electrical System* Check Circuit Reset circuit breakers if they have been
Breakers tripped.
2. Accumulator*
3. Hydraulic Oil Drain & Replace Change oil seasonally. Premium All
Season Oil
4. A/C Condenser (ESM Models) Clean Condenser Maximum air pressure of 30 psi (210 kPa) Compressed Air
5. Cab Filter (ESM Models) Clean or Replace Compressed Air or
Genuine Parts
6. Windsheild Washer Reservoir Check Fluid Level Fill to top of reservoir Windsheild Washer
(ESM Models) Fluid
7. Windshield & Windows Clean Detergent/Water
(ESM Models)
* Not Shown
519/569 ESM/EHC 12- 1008

daily or every 10 hours

16
5, 6
SM-Tank-Maint-Ops
7
12
17 18
14
13 11
9
15 8
10
SM-Loader-Ops-Maint
DAILY OR EVERY 10 HOURS
KEY COMPONENT SERVICE SPECIFICATION MATERIAL USED
* DAILY VISUAL INSPECTION** Inspect Inspect loader for damage, see detail
8. Swing Bearing Lubricate Lubricate while rotating 2 complete Prem. Grease
revolutions
9. Main Boom Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
10. Main Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease
11. Main Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease
12. Main/Stick Boom Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
13. Stick Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease
14. Stick Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease
15. Adapter Knuckle/Grapple Pin Lubricate Lubricate until grease is forced out Prem. Grease
16. Hydraulic Oil Reservoir Check Level Hyd. Oil
17. Fire Extinguisher Check Charge Recharge or replace
18. Cooling Fan Inspect Replace if damaged Use Genuine Parts
NOTICE Lubricate with Premium Moly-Lith EP #2 Grease.

* Not Shown
** DO NOT WELD ON STRUCTURES. IMMEDIATELY REPORT STRUCTURAL PROBLEMS (CRACKS) TO YOUR authorized DEALER
FOR DIAGNOSIS AND REPAIR OR REPLACEMENT.
519/569 ESM/EHC 12- 1008
weekly or every 50 hours
SM-Tank-Maint-Ops
19, 20
21
SM-Loader-Ops-Maint

WEEKLY OR EVERY 50 HOURS

* WEEKLY INSPECTION Inspect Inspect loader for damage, see detail
19A. Inner Swing Bearing - 519 Check Tighten to 171-189 ft. lb. (232-256 N•m) torque* Torque Wrench
19B. Inner Swing Bearing - 569 Check Tighten to 600 ft. lb. ( 813 N•m) torque* Torque Wrench
20A. Outer Swing Bearing - 519 Check Tighten to 162-178 ft. lb. (220-241 N•m) torque* Torque Wrench
20B. Outer Swing Bearing - 569 Check Tighten to 600 ft. lb. ( 813 N•m) torque* Torque Wrench
21A. Loader Mounting Bolts - Concrete, 519 Check Tighten to 1100 ft. lb. (1496 N•m) torque* Torque Wrench
21B. Loader Mounting Bolts - Steele, 519 Check Tighten to 1360 ft. lb. (1844 N•m) torque* Torque Wrench
21C. Loader Mounting Bolts - Concrete, 569 Check Tighten to 1100 ft. lb. (1496 N•m) torque* Torque Wrench
21D. Loader Mounting Bolts - Steele, 569 Check Tighten to 1292-1428 ft. lb. (1752-1936 N•m) torque* Torque Wrench

** DO NOT WELD ON STRUCTURES. IMMEDIATELY REPORT STRUCTURAL PROBLEMS (CRACKS) TO YOUR authorized DEALER FOR
DIAGNOSIS AND REPAIR OR REPLACEMENT.
519/569 ESM/EHC 12- 1008
22
SM-Tank-Maint-Ops
23
SM-Loader-Maint-Ops

WEEKLY OR EVERY 50 HOURS

* WEEKLY INSPECTION Inspect Inspect loader for damage, see detail
22. Oil Cooler Clean Compressed Air
23. Pinion Teeth Lubricate Lubricate teeth Open Gear Lube
Spray
24. Boom Mounting &
Attaching Hardware* Check Inspect & tighten Wrench
25. Hydraulic Connections* Check Inspect & tighten Wrench


** DO NOT WELD ON STRUCTURES. IMMEDIATELY REPORT STRUCTURAL PROBLEMS (CRACKS) TO YOUR authorized DEALER FOR
DIAGNOSIS AND REPAIR OR REPLACEMENT.
519/569 ESM/EHC 12- 1008
MONTHLY or every 250 hours
26
SM-Loader-Maint-Ops

MONTHLY OR EVERY 250 HOURS

26A. Pinion Gear Mounting Bolts - 519 Check Tighten to 290 ft. lb. (393 N•m) torque* Torque Wrench
26B. Pinion Gear Mounting Bolts - 569 Check Tighten to 420 ft. lb. (569 N•m) torque* Torque Wrench
519/569 ESM/EHC 12- 1008

every 500 hours
27, 28
29
SM-Loader-Ops-Maint
SM-Tank-Maint-Ops

EVERY 500 HOURS

27. Hydraulic Return Line Filter Install New* Use only Genuine parts Filter
28. Hydrualic Reservoir Drain & Fill See detail in section Premium All Season
Oil
29. Seat (ESM Models) Inspect Lubricate
* Change interval can vary depending on operating conditions
519/569 ESM/EHC 12- 1008

as required
1. check ELECTRICAL SYSTEM
Circuit breakers protect an electrical circuit from cur-
rent overload.
If an overload should occur, circuit breaker will “trip”
and breaker will pop out of its original position. This
breaks the flow of current and prevents circuit dam-
age.
To reset a tripped circuit breaker, press the circuit
breaker back to its original position.
If breakers will not reset, replace circuit breaker and/or
have an authorized dealer diagnose and repair the
problem.
2. accumulator
protection equipment (PPE)!
Do not attempt to service the accumulator without
first discharging the accumulator.
Do not disconnect hoses or fittings without first

discharging the accumulator.
The accumulator is designed to absorb loading shocks

incurred during operation.
If the machine feels jerky during operation, the accu-

mulator may need to be serviced.
519/569 ESM/EHC 12- 1008

as required
3. change hydraulic
reservoir oil
a 1. Position the machine on level ground. Boom
should be horizontal and grapple should be
closed.
2. Shut motor down and remove key.
pressure.
4. Disengage controls by moving control shut off
lever (A) UP.
5. Purge air from hydraulic reservoir by slowly turn-
ing breather element counterclockwise.
6. Gain access to the hydraulic drain plug (B).
7. Clean around drain plug on bottom of hydraulic
reservoir.
8. Remove the drain plug and drain hydraulic oil into
properly-sized catch pan. Dispose of oil properly.
9. Reinstall drain plug.
fill hydraulic reservoir

1. Gain access to hydraulic reservoir.
2. Clean area around filter (B).
3. Use an appropriate oil supply container to fill
c hydraulic reservoir.
4. Purge air from hydraulic reservoir. Slowly turn
breather element (C) counterclockwise until pres-
sure is released. DO NOT remove breather ele-
ment.
5. Fill reservoir until oil reaches the FULL mark on the
b hydraulic oil reservoir sight gauge (D).

519 is 71 gallons (269 L)
6. Clean and replace filter.

7. Tighten breather element.
519/569 ESM/EHC 12- 1008

as required
4. CLEAN A/C CONDENSER
If the air conditioner is not cooling properly, the con-

denser cooling fins may require cleaning to remove
A debris and dirt.
1. Gain access to condenser by removing cap screws

from the access door (A).

(PPE)!
WARNINg Flying particles from

using air pressure for cleaning can cause severe
personal injury.
Wear a face shield and protective clothing. Use a maxi-

mum air pressure of 30 psi (210 kPa).
2. Clean the condenser cooling fins with compressed

air. If the fins cannot be cleaned with compressed
air, wash fins with water.
3. Secure access cover with cap screws removed in

step 1.
519/569 ESM/EHC 12-10 1008

as required
5. CLEAN/REPLACE FRESH AIR FILTER
1. Loosen retaining hardware and remove filter cover.
2. Remove filter and clean filter using one of the fol-

lowing methods:

(PPE)!

personal injury.
Wear a face shield and protective clothing. Use a

maximum air pressure of 30 psi (210 kPa) for cleaning
purposes.
A. Lightly tap filter on flat surface, dirty side down.
B. Direct 30 psi (210 kPa) maximum compressed air

through filter from the opposite direction of air
flow.
C. Wash filter with mild soap and water. Rinse until

clean with water from hose having a maximum
pressure of 30 psi (210 kPa). Lightly shake excess
water from filter and allow to dry before install-
ing.
3. Reinstall filter. If filter is damaged, replace with new.
4. Reinstall filter cover and secure with retaining knobs.
5. CLEAN/REPLACE RECIRCULATION AIR

FILTER
1. Remove filter cover from retaining brackets.
2. Clean filter using one of the following methods:

A (PPE)!
personal injury.
Wear a face shield and protective clothing. Use a maxi-

mum air pressure of 30 psi (210 kPa) for cleaning pur-
poses.
A. Lightly tap filter on flat surface, dirty side down.
B. Direct 30 psi (210 kPa) maximum compressed air
through filter from the opposite direction of air
flow.
C. Wash filter with mild soap and water. Rinse until
clean with water from hose having a maximum
pressure of 30 psi (210 kPa). Lightly shake excess
water from filter and allow to dry before installing.
3. Reinstall filter. If filter is damaged, replace with new.
519/569 ESM/EHC 12-11 1008

as required
6. Check/Replace polycarbonate
front window and skylight
WARNINg To prevent serious
personal injury or death from objects breaking
through polycarbonate windows, replace polycar-
bonate windows when they
A
A • are yellow or hazed
• are scratched on either side with scratches that
can be felt with a fingernail (.003” or greater)
• have small cracks coming from edges or
A mounting holes
A • have come into contact with fluids that result-
ed in cloudiness
• are four (4) or more years old, regardless of
their appearance
When any of the above conditions exist, your
polycarbonate window has lost enough of its strength
that it will not protect you, the operator, as designed.
7. clean windshield and windows

PREPARING TO CLEAN CAB DOOR WINDOWS
1. Loosen the four (4) knobs (A) completely until
window guard is released from frame. Guard will
fall to ground.
2. Clean windows (see Washing Windshield and Win-
dows below).
3. After cleaning windows, replace guard and tighten
knobs until window guard is locked to frame.
WASHING WINDSHIELD AND WINDOWS

DO NOT use abrasive or highly alkaline cleaner.
DO NOT scrape window with a metal scraper or sharp objects.
DO NOT use brake cleaner, engine starting fluid, (ether) carburetor/parts cleaner, ammonia or am-
monia based cleaners, caustic pressure washer chemicals, benzene, gasoline, acetone, or carbon tetra-
chloride to clean polycarbonate windows.
DO NOT clean polycarbonate windows in hot, direct sun, or in extremely hot conditions. Before washing
windshield and windows, flush away as much loose dirt and dust as possible.
Wash polycarbonate windows with a mild soap or detergent (e.g. commercial windshield washer fluid,
household cleaner) and lukewarm water, using a clean sponge or soft cloth. Rinse well with clean water. Dry with
a soft cloth or chamois to prevent water spots.
Fresh paint, grease, and tree sap can be removed before drying by rubbing lightly with naptha, isopropyl
alcohol, or butyl cellosolve (2-Butoxy Ethanol). Then wash with a mild soap or detergent solution. Rinse thor-
oughly with clean water.
REMOVING HAIRLINE SCRATCHES

Scratches and minor abrasions can be removed or minimized using a mild automobile polish. Test a small
area of the polycarbonate window with product used to be sure it does not scratch or discolor window.
519/569 ESM/EHC 12-12 1008

DAILY OR EVERY 10 HOURS
PERFORM A DAILY VISUAL INSPECTION
WARNINg Failure to perform a

daily inspection of the loader could result in ma-
0
chine damage and severe personal injury or death.
Perform a daily inspection of the following compo-

nents:
structures swing bearing
booms load bearing items
cylinders all mountings
turntable
Do not weld on structures. Immediately report struc-

tural problems (cracks) to your authorized dealer for
diagnosis and repair or replacement.
8. LUBRICATE SWING BEARING
Lubricate swing bearing with Premium Moly-Lith EP #2

Grease while rotating loader 2 complete revolutions.
There are 2 grease fittings located just outside of cab

door that you can reach with a grease gun from the
operator's seat. The lubrication fittings are located 180
degrees from each other on the bearing.
CAUTION Rotate turntable slowly.

Boom could strike people or property, which could
cause personal injury of property damage. Be sure
loader is clear of obstructions and remove personnel.
Make sure personnel not performing maintenance
are clear of loader.
9. LUBRICATE MAIN BOOM PIVOT PIN
Lubricate pivot pins with Premium Moly-Lith EP #2

Grease until grease is forced out.
519/569 ESM/EHC 12-13 1008

Daily or every 10 hours
10. LUBRICATE MAIN BOOM CYLINDER

BASE END
Lubricate base ends with Premium Moly-Lith EP #2

11. LUBRICATE MAIN BOOM CYLINDER

ROD END
Lubricate rod ends with Premium Moly-Lith EP #2

12. LUBRICATE MAIN/STICK boom PIVOT

PIN
Lubricate boom pivot pins with Premium Moly-Lith EP

#2 Grease until grease is forced out.
519/569 ESM/EHC 12-14 1008

13. LUBRICATE STICK BOOM CYLINDER

BASE END
Lubricate base ends with Premium Moly-Lith EP #2

14. LUBRICATE STICK BOOM CYLINDER

ROD END
Lubricate rod end with Premium Moly-Lith EP #2

15. LUBRICATE ADAPTER

KNUCKLE/grapple pin
Lubricate knuckle/pin with Premium Moly-Lith EP #2

519/569 ESM/EHC 12-15 1008

16. CHECK HYDRAULIC OIL RESERVOIR

LEVEL
1. Position loader properly for an accurate reading.
The booms should be horizontal and the grapple

closed.
2. Shut down motor and move joysticks in all direc-

tions to relieve hydraulic pressure.
3. Visually check the oil level sight gauge on the

hydraulic reservoir when the oil is warm.
4. Add clean, filtered oil if necessary (refer to Fill

Hydraulic Reservoir below).
519/569 ESM/EHC 12-16 1008

17. INSPECT FIRE EXTINGUISHER
Inspect the fire extinguisher for proper charge.
If gauge on fire extinguisher indicates that a recharge

is required, have an authorized service center recharge
the unit.
Recharge or replace immediately after any use.
18. INSPECT COOLING FAN
With motor shut off and key removed, check fan (A) for
A cracks, bent or loose blades. Check fan to make sure it
is properly mounted. Replace damaged fan and/or fan
guard.
519/569 ESM/EHC 12-17 1008

SCHEDULED/PERIODIC
SCHEDULED/PERIODIC
MAINTENANCE MAINTENANCE
SERVICES - weekly
SERVICES
or every 50 hours
PERFORM A WEEKLY INSPECTION

INSPECTION GUIDELINES
1. Clean the structures thoroughly. Remove all dirt,
mud, grease, oil, debris and snow/ice.
0
2. Look for rust lines in the paint, missing or cracked

paint. These are indications of crack sites.
3. Inspect all welds and adjacent areas on booms, cyl-

inders turntable, swing gear mounting and grapple
for signs of cracks.
4. Inspect the grapple around cylinder and jaw mount-

ings, the jaws, the rotator mounting and frame.
5. Check all boom cylinders, and pin keeper retainers

for broken fasteners. If broken or damaged, replace
with new fasteners.
6. Check swing mounting fasteners for correct tight-

ness. If any fastener will not torque to the specifi-
cation, remove it and the two on either side of it.
Replace all three fasteners (and washers if used)
with new ones.
7. Check the sub-frame and stabilizers. Check the areas

around the swing bearing mounting, the stabilizer
and their mounting ears, and the stabilizer cylinders
and their mounting.
WARNINg unauthorized
welding can cause structural failure and/or severe
personal injury or death.
do not weld on any structural member. Any

unauthorized welding or repair will void the warranty.
Immediately report structural

problems (cracks) to your
caterpillar dealer for diagnosis
and repair or replacement.
8. Inspect safety decals and replace as needed when
damaged or unreadable.
9. Inspect slip resistant mats. Replace any slip resistant

mat that has been damaged or has come loose.
10. Inspect ladders/steps/grab handles/railings for

damage. Repair or replace as needed.
519/569 ESM/EHC 12-18 1008

19. CHECK INNER SWING BEARING
FASTENER TORQUE
Check that the inner swing bearing fasteners (A) are

torqued at:
519 171-189 ft. lb. (232-256 N•m) torque

B 569 600 ft. lb. ( 813 N•m) torque
If fasteners are damaged, replace with new.

If a fastener will not tighten to the specified torque,
replace with a new fastener and washer. Lubricate
threads and washer with never seize. Also remove and
replace the two fasteners and washers on either side
of the damaged (replaced) fastener. Lubricate threads
and washer with never seize.
A 20. CHECK OUTER SWING BEARING

FASTENER TORQUE
Check that the outer swing bearing fasteners (B) are

torqued at:
519 162-178 ft. lb. (220-241 N•m) torque

569 600 ft. lb. ( 813 N•m) torque

21. CHECK loader mounting FASTENER

TORQUE
Check that the loader mounting fasteners (C) are

torqued at:
Concrete, 519 1100 ft. lb. (1496 N•m) torque

Steele, 519 1360 ft. lb. (1844 N•m) torque
Concrete, 569 1100 ft. lb. (1496 N•m) torque
Steele, 569 1292-1428 ft. lb. (1752-1936
N•m) torque
C
519/569 ESM/EHC 12-19 1008
22. clean oil cooler

1. Shut motor down. Remove key.
2. Gain access to the oil cooler by removing the
guard cap screws.
WARNINg Cleaning with compressed
air releases debris and flying particles that
can cause serious personal injury. Wear a face
shield and protective clothing.
3. Using a maximum air pressure of 30 psi
(210 kPa), clean debris from cooling units with
compressed air. Direct air from inside to outside
the cooling units.
4. Reinstall and secure guard with cap screws re-
moved in Step 2.
23. LUBRICATE PINION GEAR
Coat gear teeth with Heavy Duty Open Gear Lube to

prevent bare metal contact. Spray lubricant through
access hole.
24. CHECK BOOM & CYLINDER

retention hardware
Inspect and tighten all boom and cylinder retention

hardware.
AR
CLE
EP
KE
519/569 ESM/EHC 12-20 1008

25. CHECK HYDRAULIC CONNECTIONS
Inspect and tighten all hydraulic connections.
519/569 ESM/EHC 12-21 1008

monthly or every 250 hours

26. check pinion gear fastener
torque
Check that the pinion gear fastener (A) is
torqued between
519 290 ft. lb. (393 N•m) torque

569 420 ft. lb. (569 N•m) torque
A If fastener is damaged, replace with new.
519/569 ESM/EHC 12-22 1008

every 500 hours

27. replace hydraulic return line
filter
1. Lower boom and grapple to ground. Shut motor
down and remove key.
pressure.
a lever UP.
4. Gain access to filter assembly (A) on top of the
hydraulic reservoir.
5. Clean and dry area around filter head assembly.
6. Remove mounting cap screws and washers.
7. Remove filter head assembly (B).
8. Inspect sealing ring for nicks or cuts. Replace if
damaged.
9 Carefully remove hydraulic filter (C). DO NOT
b damage the filter during removal. DO NOT knock
the filter against the side of the canister during
removal.
10. Install new filter. Be careful not to contaminate
hydraulic reservoir while installing new filter.
11. Install filter head and tighten mounting cap
screws and washers to 25 ft-lbs (34 N•m) torque.
12. Cut old filter body and examine pleats. A preven-
tative maintenance check will be required if metal
particles such as brass or aluminum are found.
Contact an authorized dealer for preventative
maintenance procedures.
519/569 ESM/EHC 12-23 1008

every 500 hours
28. change hydraulic
reservoir oil
a 1. Position the machine on level ground. Boom
should be horizontal and grapple should be open.
2. Shut motor down and remove key.
pressure.
lever (A) UP.
5. Purge air from hydraulic reservoir by slowly turn-
ing breather element counterclockwise.
6. Gain access to the hydraulic drain plug (B).
7. Clean around drain plug on bottom of hydraulic
reservoir.
8. Remove the drain plug and drain hydraulic oil into
properly-sized catch pan. Dispose of oil properly.
9. Reinstall drain plug.
fill hydraulic reservoir
1. Gain access to hydraulic reservoir.
2. Clean area around filter (B).
3. Use an appropriate oil supply container to fill
hydraulic reservoir.
4. Purge air from hydraulic reservoir. Slowly turn
breather element (C) counterclockwise until pres-
sure is released. DO NOT remove breather ele-
ment.
5. Fill reservoir until oil reaches the FULL mark on the
hydraulic oil reservoir sight gauge (D).
c
6. Clean and replace filter.

b 7. Tighten breather element.
519/569 ESM/EHC 12-24 1008

every 500 hours
29. seat maintenance

1. Inspect the rollers and bushings in the seat sus-
pension for excessive wear. If damaged, replace
with new.
2. Grease the inside section of suspension frame
rails.
NOTICE Do not grease the actual rail

surface that rollers roll on. If these rails are greased,
rollers will begin to slide rather than roll, causing
img.3397 premature wear on both surfaces.
519/569 ESM/EHC 12-25 1008

519/569 ESM/EHC 12-26 1008

STORAGE
STORAGE
PREPARING MACHINE FOR STORAGE
1. Operate machine long enough to warm its fluids. Check for leaks after machine warms up.
2. Turn off machine.
3. Drain hydraulic oil and flush hydrualic reservoir.
4. Change hydrualic filters and refill hydraulic reservoir.
5. Start motor and operate the machine long enough to warm the oil. Check for leaks after machine warms up.
6. Wash machine and attachments.
7. Grease machine thoroughly. Lubricate all grease points. Grease threads on bolts used for adjustments. Coat
exposed cylinder rods with Chrome Kote Corrosion Preventive to retard rusting.
8. Retract all hydraulic cylinders if possible. If a hydraulic cylinder cannot be fully retracted, coat exposed cylinder
rods with Chrome Kote Corrosion Preventive.
NOTICE If machine will be stored for an extended period, or stored in a corrosive environment (such as salt
air or industrial pollution), apply Chrome Kote Corrosion Preventive on all portions exposed to air. Also apply Chrome
Kote Corrosion Preventive on oil cooler fins and all wiring connections. Reapply Chrome Kote every three months while
the machine remains in storage.
9. Remove all mud, excess grease, twigs, etc. Wipe up lube spills. Dispose of rags and trash.
10. If possible, store machine under cover and out of the weather in a ventilated area.
519/569 ESM/EHC 13- 1008

STORAGE
removING MACHINE from STORAGE
1. Clean machine and attachment(s) thoroughly.
2. Check hydraulic oil level. If low, check for leaks and add oil as required.
4. Cycle all hydraulic functions several times.
5. Check condition of all hoses and connections.
6. Chrome Kote Corrosion Preventive is compatible with hydraulic oil and seal materials, and it does not have to
be removed before operation. If you are using another corrosion preventive, it may have to be removed from
machine before operation.
12. Review this operator's manual.
519/569 ESM/EHC 13- 1008

TROUBLESHOOTING
troubleshooting
loader
PROBLEM POSSIBLE CAUSE SOLUTION

Hydraulic system does not work. Low hydraulic oil level. Add hydraulic fluid.
Control shutoff lever disengaged. Engage control shutoff lever.
Plugged suction line. See an authorized dealer.

Defective pump drive. See an authorized dealer
Noisy, vibrating hydraulic system. Air in system. Check fluid level and see an authorized
dealer if problem persists.
Cylinder "settle." Leaking piston seals. See an authorized dealer

Controls slow and/or lack power. Lack of hydraulic oil. Check/add hydraulic oil (see Fuels
& Lubricants section for recommended
hydraulic oils).
Aeration in suction lines. Tighten hose fittings.
Improper adjustment of relief valves. See an authorized dealer
Cylinder function poorly and/or lack Cold oil Warm up system.

power.
Wrong hydraulic oil. Replace hydraulic oil (see Lubricants section)
Damage to cylinder seals. Replace seals.
Aeration in cylinders. Bleed air from line.
Malfunctioning control valve. Repair or replace control valve.
Swing is slow or impossible to move. Obstruction under swing pedal. Remove obstruction.
Control valve problem. Repair or replace control valve.
Swing motor problem. Repair or replace swing motor.

Damage to swing gears. Repair or replace swing gears.
Damage to swing bearing. Repair or replace swing bearing.
Foaming hydraulic fluid. Suction line air leak. Repair or replace suction line.
Low hydraulic oil leak. Add hydraulic oil.
Water in hydraulic fluid. Replace hydraulic fluid & filters.
519/569 ESM/EHC 14- 1008

TROUBLESHOOTING
electric motor

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Bad connection Check electrical connections.

Motor runs then dies down Power failure Check electrical connections.
ELECTRICAL SYSTEM

Lights will not work. Tripped circuit breaker switch. Reset breaker.
If lights still will not work,
see an authorized dealer.
519/569 ESM/EHC 14- 1008

TROUBLESHOOTING
Contamination of Hydraulic Components
Cleanliness in hydraulics is essential. Be sure to keep contaminants out of the machine's hydraulic system. Main-
tain your loader properly to reduce the risk of contaminating hydraulic components.
Clearances in hydraulic components can be very small. Many hydraulic systems have clearances of less than 25
microns, or .001 inch. Abrasive particles can enter the space between moving parts and hone surfaces to wider
clearances. Increased clearance decreases the efficiency of pumps, motors, and cylinders. This damage wastes
horsepower and generates potentially damaging system heat.
The following figure lists the sizes of different common particles in inches and microns to show how even very
small particles can contaminate hydraulic components.
NOTE: Contaminant particle size is measured in microns. One micron equals one millionth of a meter, or
.000039 inch.
inches microns
130
.005
120
110 Table salt
.004 100
90
80 200 Mesh screen
.003 Human hair
70
Pollen
60
Fog
.002
50
Visibility limit
40
White blood cells
.001 30
20 Talcum
Red blood cells
Bacteria
10
519/569 ESM/EHC 14- 1008

TROUBLESHOOTING
519/569 ESM/EHC 14- 1008

SPECIFICATIONS
SPECIFICATIONS
519SM 519SM/EHC 569SM 569SM/EHC

Power Supply Mounting: Turntable Mount S S S S
Remote Skid Mount O O
Hydraulic System
Pumps: Three (3) In-Line gear Pumps S S S S
Flows: gPM @ 1800 RPM 44-33-22 44-33-22 45-54-16 45-54-16
Pressures: System PSI 2200 2200 2500 2500
Swing PSI 2400 2400 2500 2500
Swing Motor: Radial Piston Motor S S S S
Swing Speed: Revolutions Per Minute 8 8 7 7
Rotation: Continuous S S S S
Non-Continuous Limited Rotation O O O O
Controls: Pilot Joystick S S
Electro Hydraulic (EHC) S S
Filtration: Single Element Return (3 mic) S S
Two Dual Element Return (3 mic) S S
Bypass Indicators S S S S
Oil Reservoir Heater O O O O
Serviceability: Diagnostic Nipples @ Pump S S S S
Cylinders: (Bore X Rod) Main 6x4 6x4 6x4 6x4
Stick 6x4 6x4 7x4 7x4
Live Heel 6x4 6x4
Booms
7.6 m (25’) knuckleboom O O
8.2 m (27’) knuckleboom S S
9.1 m (30’) knuckleboom O O
9.9 m (32’6”) knuckleboom S S
10.2 m (33’6”) Live Heel Boom O O
10.9 m (36') knuckleboom O O
grapple Mounting knuckle: 22.8 cm (9”) Length S S S S
30.5 cm (12”) Length O O O O
Heels: Single “v” Heel O O O O
Double “vv” Heel O O O O
Structural
Cab: 96.5 cm x 142.2 cm Right Side Mounted S
(38” x 56”) Left Side Mounted S
Reverse Slope Windshield S S
Tinted Safety glass S S
Lexan Skylight S S
Sun visor S S
Adjustable Seat with Armrests S S
Operator Protection guard S S
Pressurized Cab with Heater S S
Air Conditioner O O
Analog gauges S S
Electronic gauges S S
Horn S S
Windshield Wiper/Washer S S
Defroster Fan S S
Lighter S S
Dome Light S S
Control Panel S S
Circuit Breaker Panel S S
Swing Bearing: Diameter 109.2 cm (43”) OD 109.2 cm (43”) OD 137.2 cm (54”) OD 137.2 cm (54”) OD
gearing External External External External
Mounting: Steel S S S S
Concrete O O O O
30” Subframe Riser O O O O
Capacities
Reservoir (gallons) 42 42 125 125
Unit Weight kg 7218.9 6946.7 8593.3 8321.1

lbs 15,915 15,315 18,945 18,345
S = Standard
O = Optional
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
569SM and 569SM/EHC Loaders 9.6m (32’6”) Boom

1.5m (5’) 3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’) 9.1m (30’)
kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs.
30’/9.1m
25’/7.6m 5118 11274

4453 9808
20’/6.1m 5850 12885 4577 10082
5089 11210 3982 8771
15’/4.6m 6422 14145 5560 12247 2997 6601
5587 12306 4837 10655 2607 5743
10’/3m 7558 16647 7002 15422 6115 13470 4093 9016
6575 14483 6091 13417 5320 11719 3561 7844
5’/1.5m 10730 23634 8567 18870 7127 15698 4740 10441
9335 20562 7453 16417 6200 13657 4124 9084
0 0.0 18803 41417 12247 26975 9179 20217 7305 16090 4939 10878
16359 36033 10654 23468 7985 17589 6355 13998 4297 9464
-5’/-1.5m 9850 21695 12595 27741 9205 20275 7026 15475
8569 18875 10957 24135 8008 17639 6112 13463
-10’/-3m 3712 8177 9507 20940 11367 25037 8250 18172 5897 12990
3230 7114 8271 18218 9889 21782 7178 15810 5131 11301
569SM and 569SM/EHC Loaders 10.9m (36’) Boom

3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’) 9.1m (30’) 10.6m (35’)
35’/10.6m 5110 11255
4446 9792
30’/9.1m 4985 10979
4337 9552
25’/7.6m 5744 12653 4697 10345
4998 11008 4086 9000
20’/6.1m 6087 13407 5508 12132 3943 8685
5295 11664 4792 10555 3430 7556
15’/4.6m 6629 14601 5997 13210 5037 11094
5767 12703 5218 11493 4382 9652
10’/3m 8808 19400 7924 17454 6701 14761 5444 11992 2748 6053
7663 16878 6894 15185 5830 12842 4737 10433 2391 5266
5’/1.5m 11401 25113 8652 19057 7024 15472 5873 12936 3306 7283
9919 21848 7527 16580 6111 13461 5109 11254 2877 6336
0 0.0 12364 27233 9096 20036 7171 15795 5804 12784 3200 7048
10757 23693 7914 17431 6239 13742 5049 11122 2784 6132
-5’/-1.5m 4876 10740 12156 26775 8973 19763 6956 15321 5420 11939
4242 9344 10575 23294 7806 17194 6051 13329 4716 10387
-10’/-3m 5803 12783 10713 23598 8081 17799 6170 13591 4454 9810
5049 11121 9321 20530 7030 15485 5368 11824 3875 8535
Caterpillar Stationary Mount Loader Specifications

519SM 519SM/EHC 569SM 569SM/EHC
Motor Power Supply
Electric Motor: 56 kW (75 HP) @ 1800 RPM S S
74 kW (100 HP) @ 1800 RPM S S
Electric Power Supply: 460 volt: 60 Hz S S S S
575 volt: 60 Hz O O O O
Collector Ring: Four (4) Ring High voltage S S S S
Auxiliary Low voltage Collector N/A O N/A O
Service Panel: NEMA 12 Enclosure S S S S
Pump Drive: Direct Through Flex Coupling S S S S
Magnetic Starting System: Across-the-line S S S S
S = Standard
O = Optional
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
Caterpillar Stationary Mount Loader Lift Charts

The Stationary Mount Loader features a hydraulic system that provides smooth, efficient operation
in a variety of millyard applications.
Notes 4. Manufacturer assumes no responsibility for the proper fit

Do not attempt to lift or hold any load that is greater than the or structural integrity of the mounting pedestal and/or platform
rated values over the end or side at their specified lift point and supplied by the customer.
height. The weight of the grapple and all lifting accessories must 5. Operator shall be fully acquainted with the Operator’s Manual
be deducted from lift capacities shown. and all safety instructions furnished prior to operating
the machine.
1. All figures shown in these charts represent rated lift capacities.
6. Lift capacities are in compliance with SAE J2417, “Lift
2. Capacities shown in bold are 100% of hydraulic capability;
Capacity Calculation Method-knuckleboom Log Loaders
other capacities shown are 87% of hydraulic capability.
and Certain Forestry Equipment”.
3. The lift point is located at the boom/grapple pivot pin.
Lift Chart
1.5m (5') 3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’)
kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs.
25’/7.6m 5021 11060
4368 9622
20’/6.1m 5177 11402 4486 9882
4504 9920 3903 8597
15’/4.6m 5311 11698 4634 10207
4620 10177 4032 8880
10’/3m 3788 8343 5854 12894 4799 10571 3962 8728
3295 7258 5093 11218 4175 9197 3447 7593
5’/1.5m 7229 15923 5951 13107 3890 8568
6289 13853 5177 11403 3384 7454
0 0.0 8730 19229 6469 14249 4061 8946
6603 16729 5628 12397 3533 7783
-5’/-1.5m 4764 10494 8057 17747 5811 12800 3040 6697
4145 9130 7010 15440 5056 11136 2645 5826
-10’/-3m 3050 6718 6276 13824 6152 13552 4083 8993
2654 5845 5460 12027 5353 11790 3552 7824
-15’/4.6m 3494 7697 2564 5648
3040 6696 2231 4914

1.5m (5’) 3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’) 9.1m (30’)
30’/9.1m 4206 9264
3659 8060
25’/7.6m 4714 10384 3940 8679
4101 9034 3428 7551
20’/6.1m 4179 9206 3088 6802
3636 8009 2687 5918
15’/4.6m 4419 9734 4267 9398 3713 8178
3845 8469 3712 8176 3230 7115
10’/3m 4942 10886 4488 9885 3769 8301
4300 9471 3904 8600 3279 7222
5’/1.5m 6380 14053 5670 12490 4407 9707 1996 4397
5551 12226 4933 10866 3834 8445 1737 3825
0 0.0 8448 18608 6299 13874 4873 10733
7350 16189 5480 12070 4239 9338
-5’/-1.5m 2892 6369 7983 17583 5894 12983 4320 9515
2516 5541 6945 15297 5128 11295 3758 8278
-10/-3m 2039 4492 4532 9983 6538 14401 4775 10517 2937 6470
1774 3908 3943 8685 5688 12529 4154 9150 2556 5629
-15’/4.6m 4942 10885 3981 8768 2518 5547
4299 9470 3463 7628 2191 4826
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
Caterpillar 519 and 569 Stationary Mount Loader

®
Loader Frame
Basic Dimensions Mounting Bolt
Locknut
Washer
Shock Pad
17.8 cm (7")
Min.
624.8 cm 243.8 cm Shock Pad
(20’ 6”) (96")
Max. Tailswing
Base Plate
288.3 cm
(9' 5.5")
262.9 cm 25.4 cm (10")
(8' 7.5") 5.1 cm 6.3 cm Min.
(2.0") (2.5")
(Min.) (Min.)
100.3 cm
(3' 3.5")
Steel Platform Resilient Pad System

77.5 cm 76.2 cm OPTIONAL 76.2 cm (30”) (Supplied by customer)
(30.5") (30") Sub-frame Riser
519 SM
NOTE: Overall Height dimension to 8.2 m (27’) boom
articulation point is taken with main boom cylinder fully
extended. Add 76.2 cm (30”) to this dimension for 9.1 m
(30’) knuckle boom. 238.7 cm
660.4 cm
(21’ 8”)
(94")
Tailswing
• Operator’s
cab is not present on EHC models.
• models
EHC available with Turntableor RemotePower. 266.7 cm
(8' 9")
• Installations
on concrete include “J” Bolts in lieu
251.5 cm
Mounting
of Bolt. (8' 3")
27.9 cm (11")
76.2 cm 77.5 cm
569 SM (30") (30.5")
NOTE: Overall Height dimension to 9.1 m (30’)
boom articulation point is taken with main boom
cylinder fully extended. Add 106.9 cm (42”) to
this dimension for 10.9 m (36’) knuckle boom.
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
Hydraulic Connection Torque Specifications

SAE 37° FLARE CONNECTION
How connection works: This connection seals on two mating 37° seats.
How to tighten connection: Use a torque wrench to rotate and tighten nut. Turn nut to value shown in
table below.
Torque
Dash size (or tube size) Thread size Inch–lbs. Newton–Meters

–3 3
/8–24 95–105 11–12
–4 /16–20
7
135–145 15–16
–5 1
/2–20 170–190 19–21
–6 /16–18
9
215–245 25–27
–8 3
/4–16 430–470 49–53
–10 7
/8–14 680–750 77–84
–12 1 /16–12
1
950–1050 108–118
–14 1 3/16–12 1000–1100 113–124
–16 1 /16–12
5
1300–1360 147–153
–20 1 5/8–12 1520–1600 172–180
–24 1 7/8–12 1900–2000 215–225
–32 2 1/2–12 2940–3100 332–350
The above torque values are good for:

• machined adapters and hose fittings
• flared tubes (with sleeve and nut)
• universal radius flared tubes.
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
Hydraulic Connection Torque Specifications

O–RING FACE SEAL CONNECTION
How connection works: This connection seals with an O–Ring on the male against a flat surface.
How to tighten connection: Use a torque wrench to rotate and tighten nut. Turn nut to value shown in
table below.
Torque
Dash size (or tube size) Thread size Inch–lbs. Newton–Meters

–4 9
/16–18 120–144 14–16
–6 11
/16–16 216–240 24–27
–8 13
/16–16 384–420 43–47
–10 1–14 552–600 62–68
–12 1 3/16–12 780–840 88–95
–16 1 7/16–12 1104–1200 125–136
–20 1 11/16–12 1500–1680 170–190
–24 2–12 1800–1980 204–224
Make sure the O–Ring does not fall out of the male end before connection is made. Proper lubrication helps.
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
Torque Chart for Fasteners
This torque chart applies to lubricated threads for bolts, cap screws, and studs.
These specifications do not apply to self–locking nuts or cap screws. To obtain proper torque, do not use lockwashers.
Hardened flat washers recommended.
GRADE 8 FASTENERS
COARSE THREAD FINE THREAD

Nominal Size Torque (ft. lbs.) Torque (N•m) Nominal Size Torque (ft. lbs.) Torque (N•m)
1
/4–20 8–9 11–12 1
/4–28 9–10 12–14
5
/16–18 17–19 23–26 /16–24
5
19–21 26–28
3
/8–16 33–36 45–49 3
/8–24 34–37 46–50
7
/16–14 52–57 71–77 /16–20
7
53–58 72–79
1
/2–13 76–84 103–114 1
/2–20 86–94 117–128
9
/16–12 105–115 142–156 /16–18
9
124–136 168–184
5
/8–11 162–178 220–241 5
/8–18 171–189 232–256
3
/4–10 266–294 361–399 3
/4–16 304–336 412–456
/8–9
7
437–483 593–655 7
/8–14 475–525 644–712
1–8 646–714 876–968 1–12 703–777 953–1054
1 1/8–7 912–1008 1237–1367 1 1/8–12 979–1081 1328–1466
1 /4–7
1
1292–1428 1752–1936 1 /4–12
1
1425–1575 1932–2136
1 1/2–6 2242–2478 3040–3360 1 1/2–12 2527–2793 3427–3787
1 3/4–5 3048–3688 4133–5001 1 3/4–12 4004–4424 5429–5999
2 –4 1/2 4610–5096 6251–6910 2–12 6116–6760 8293–9167
Use these torque values unless otherwise specified. Exceptions are noted where applicable. SAE Grade 8
fasteners (A.S.T.M. A354, Grade BD) are made from quenched and tempered medium carbon steel. Grade 8 fasteners
have six (6) equally spaced radial lines embossed on the head of the fastener (see illustration below).
Examples of Grade 8 Fastener Heads
519/569 ESM/EHC 15- 1008

SPECIFICATIONS
cylinder torque specifications

C Y L IN D E R T O R Q U E S P E C IF IC A T IO N S
g r a d e 8 z i n c – p l a te d H e x H e a d C a p S c r e w s , D r y
Da s h S iz e T orque
ft. lbs . N•m

7
/16– 1 4 U N C 76– 84 103– 114
1
/2– 1 3 U N C 105– 115 142– 156
g r a d e 8 E l a s ti c L o c k N u ts , P h o s . a n d O i l F i n i s h , L u b r i c a te d T h r e a d s
ft. lbs . N•m
1– 14 U N F 540 732
1 1/4– 1 2 U N F 750 1017
1 3/8– 1 2 U N F 1000 1356
1 1/2– 1 2 U N F 1200 1627
1 3/4– 1 2 U N F 1500 2034
2 1/4– 1 2 U N F 2500 3390
519/569 ESM/EHC 15- 1008

SERIAL NUMBERS
SERIAL NUMBERS
PR
EN
TI
CE
384
Machine Serial Number
R
CLEA
KEEP
Pump Serial Number
Part Number
Swing Drive Serial Number
Part Number
519/569 ESM/EHC 16- 1008

SERIAL NUMBERS
Main Boom Part Number
Stick Boom Part Number
Main Boom Cylinder Part Number

and Date of Manufacture
519/569 ESM/EHC 16- 1008

SERIAL NUMBERS
Stick Boom Cylinder Part Number

Stabilizer Cylinder Part Number

Hydraulic Oil Reservoir Return Line Filter Identification

Number
519/569 ESM/EHC 16- 1008

SERIAL NUMBERS
NOTES
519/569 ESM/EHC 16- 1008

MATERIAL SAFETY DATA SHEETS

(MSDS)
The Federal Occupational, Safety, and Health Administration (OSHA) Standard 29 CFR 1910.1200, and in some
cases state and local right–to–know laws, may require that specific material safety data sheets (MSDS) be avail-
able to employees before operating this equipment. This may include information on substances contained in
this equipment such as antifreeze, brake fluid, battery acid, hydraulic fluid, and R–134a refrigerant (if machine is
equipped with an air conditioner).
Cat Forest Products, Inc. will provide, at no cost, MSDS which apply to its Prentice product line. Simply ask an
authorized dealer for them.
To ensure a prompt response to your MSDS request, include your return address (including zip or postal code)
and the machine's model number and serial number with your request.
519/569 ESM/EHC 17- 1008

NOTES
519/569 ESM/EHC 17- 1008

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other reproduc-
tive harm.
Battery post terminals and related

accessories contain lead and lead
components, chemicals known
to the State of California to cause
cancer and reproductive harm. Wash
hands after handling.
CAT, CATERPILLAR, their respective logos and "Caterpillar Yellow," and the POWER EDGE trade dress as well as
corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permis-
sion.
© 2008 Caterpillar
All Rights Reserved Printed in the U.S.A.
2-
Hydraulic Specifications & Test Procedures
Warning: to avoid personal injury or property damage, read

and follow all safety materials in the operator's manual.
This section provides information to help the service technician check and adjust the hydraulic components that
operate the boom and swing functions of this machine.
Hydraulic specifications & test procedures

Table of Contents
Hydraulic Settings
Cycle Times................................................................................................. 2-2
Safety and Cleanliness.................................................................... 2-3
Pressure check locations.............................................................. 2-4
Settings....................................................................................................... 2-5
Adjustment Procedures
Checking Flow........................................................................................ 2-7
Checking Pressure.............................................................................2-12
Checking Pilot Pressure................................................................2-16
Cylinder Test..........................................................................................2-18
Valve Leakage Test.............................................................................2-19
Information on vended components reprinted by permission. This manual has been compiled from materials available
at the time of approval for reproduction. Manufacturer reserves the right to improve its products without giving prior
notice or incurring obligation.
2-
Cycle Times
cat 519sm
All Pressure Checks should be taken with the Oil Temperature at

43 Degrees C to 60 Degrees Celsius (110 Degrees F to 140 Degrees F).
Item Setting
Cycle Times
Main Boom Up 11 seconds
Main Boom Down 8 seconds
Stick Boom Out 8 seconds
Stick Boom In 5 seconds
Swing 5 revs/40 second
Cycle Times
cat 569 SM

Item Setting
Cycle Times
Main Boom UP (Ground to Full Raise).......................................................10 seconds
Main Boom DOWN (Full Raise to Ground)....... 7 seconds
Stick Boom UP/OUT........................................................................................8 seconds
Stick Boom DOWN/IN.....................................................................................5 seconds
Swing....................................................................................................................8 RPM
Swing (one 360° rotation).............................................................................7.5 seconds
2-
Settings & Adjustments

Always have the motor shut down for maintenance and service operations
unless the procedure requires the motor running. The procedures used to
check machine performance require the motor to be running. Only qualified technicians shall per-
form these procedures. To avoid serious personal injury or property damage, do the following before
performing these operations:
1. Severe personal injury or death may result 3. Before disconnecting lines, turn off motor and
from unexpected movement of hydraulic relieve pressure in all circuits. Allow oil to cool
cylinders. Keep all personnel away from an below 49°C (120° F).
unsupported boom. Extend stick cylinder to
straighten boom and rest attachment on the
ground with jaws open.
2. Be sure the operator knows where you are and
what you want done. Agree on signals.
Use the following information to check and adjust performance of loaders.
To properly troubleshoot the Attachment hydraulic system the following diagnostic aids will be needed:
• an accurate, reliable flow meter sized for maximum pump flow

• an accurate 0-4136 kPa/600 psi test gauge
• a Port-o-Power with 0-41369 kPa/6000 psi test gauge (for Grapple Cyl Port Reliefs)
Most hydraulic malfunctions in the Attachment systems can be readily corrected by using these gauges and fol-
lowing the steps outlined in Hydraulic System and Settings & Adjustments. These aids assume that the reservoir has
a sufficient quantity of oil, the filters and strainers are clean and that the air breather on top of the reservoir is not
clogged.
When Working with Hydraulics, Add fluid to the hydraulic system through the filters
cleanliness is of vital importance only. New oil in jobbers’ or distributors’ drums may be
clean only to a particle size of 25 microns.
Dirt is the enemy of your hy- Illustrations

draulic system. Keep your tools and your work area clean.
Dirt in any hydraulic system causes prema- In each of these adjustment

ture wear and erratic performance. procedures, the illustrations will be displayed along with
the corresponding procedures.
Dirt that accumulates around relief valve and com-
pensator cartridges can be carried into threads while
How to Use This Section
the cartridge is being adjusted, possibly damaging the
seals. Be sure to thoroughly clean valve cartridges and Most hydraulic system malfunctions can be readily cor-
their surroundings before making adjustments. rected by referring to the troubleshooting charts, using
the tools listed above, and following the adjustment
Dirt that accumulates around test ports can fall onto di-
procedures immediately following.
agnostic nipple after cap is removed, and thus enter the
system and your gauges. Be sure to thoroughly clean These aids assume that the reservoir has sufficient oil, the
test fittings and their surroundings before connecting filters are clean and that the reservoir breather / pressure
hydraulic test equipment. release valve is free of obstructions.
Ambient dirt can enter a disconnected hose or tube
without the technician’s knowledge. Clean hose and
tube fittings before disconnecting. Keep open ports
and disconnected hydraulic lines capped unless proce-
dure requires that they be left open. Always clean lines
or hoses prior to installation by flushing and blowing
out with filtered compressed air.
2-
Pressure Check Locations
Test Test Test

Fitting Fitting Fitting
2-
Hydraulic Settings 519 SM

OIL FLOW, Pump @ 1800 GPM 2200 PSI (152 bar)

Main System
Pump No. 1 (Main) Pump #1 159L/min (42GPM)
Pump No. 2 (Stick) Pump #2 125L/min (33GPM)
Pump No. 3 (Swing) Pump #3 87L/min(23GPM)
MAIN RELIEF SETTINGS (full flow)

Main 15168 kPa/2200 PSI (152 bar)
Stick 15168 kPa/2200 PSI (152 bar)
Live Heel 16547 kPa/2400 PSI (166 bar)
Grapple Open & Close 15168 kPa/2200 PSI (152 bar)
Grapple Rotation 15168 kPa/2200 PSI (152 bar)
Swing 16547 kPa/2400 PSI (166 bar)
PORT RELIEF SETTINGS

Main Boom Up 19305 kPa/2800 PSI (193 bar)
Main Boom Down 10342 kPa/1500 PSI (110 bar)
Stick Boom Out 19305 kPa/2800 PSI (193 bar)
Stick Boom In 19305 kPa/2800 PSI (193 bar)
Live Heel Out 15168 kPa/2200 PSI (152 bar)
Live Heel In 15168 kPa/2200 PSI (152 bar)
Grapple Rotation
Non Continuous 11031 kPa/1600 PSI (110 bar)
Continuous 9308 kPa/1350 PSI (93 bar)
Swing Cross Over Relief 17926 kPa/2600 PSI (179 bar)
Pilot Pressure
3103 kPa/450 PSI (31 bar)
2-
Hydraulic Settings 569 SM

OIL FLOW, Pump @ 1800 GPM 2200 PSI (173 bar)

Main System
Pump No. 1 (Stick) Pump #1 144L/min (38GPM)
Pump No. 2 (Main) Pump #2 204L/min (45GPM)
Pump No. 3 (Swing & jib/telestick
standard controls) Pump #3 110L/min(31GPM)
Pump No. 3 (Swing & jib/telestick
EHC controls) Pump #3 53L/min(14 GPM)
MAIN RELIEF SETTINGS (full flow)

Main 17237 kPa/2500 PSI (173 bar)
Stick 17237 kPa/2500 PSI (173 bar)
Live Heel/Telestick 16203 kPa/2350 PSI (162 bar)
Grapple Rotation 17237 kPa/2500 PSI (173 bar)
Swing 17237 kPa/2500 PSI (173 bar)
PORT RELIEF SETTINGS

Main Boom Up 18961 kPa/2750 PSI (190 bar)
Main Boom Down 6895 kPa/1000 PSI (69 bar)
Stick Boom Out 20684 kPa/3000 PSI (207 bar)
Stick Boom In 20684 kPa/3000 PSI (207 bar)
Live Heel Out 20684 kPa/3000 PSI (207 bar)
Live Heel In Anti-Cav Check
Grapple Open & Close None
Grapple Rotation
Non Continuous 11031 kPa/1600 PSI (110 bar)
Continuous 9308 kPa/1350 PSI (93 bar)
Swing Cross Over Relief 18271 kPa/2650 PSI (182.8 bar)
Pilot Pressure
3103 kPa/450 PSI (31 bar)
2-
Checking hydraulic oil flow in a typical open-center system

Purpose
The flowmeter test is used to diagnose problems by 2. Is the GPM/LPM reading for a loaded circuit (at cor-
checking the efficiency of the components of a hydrau- rect system pressure) at least 80% of the GPM/LPM
lic system. This procedure will enable the technician to: reading for the same circuit in a "no-load" condition?
1. Check the efficiency of the entire system. If the answer is YES, the circuit is working as intend-
ed.
2. Check the efficiency of the hydraulic pumps.
3. Check the efficiency of the hydraulic control valves. Flowmeter characteristics
4. Check the efficiency of the hydraulic actuator (motor Flowmeters are available from several different manu-
or cylinder). facturers, general commonality factors are:
An efficiency test will determine the amount of fluid 1. A typical flowmeter is equipped with a Loading Valve,
bypass the component is allowing ( the amount of fluid to induce a load on the system being tested. Closing
that is passing through the component without doing the loading valve is the same a deadheading the line
any work). leading out of the flowmeter.
2. A typical flowmeter is not equipped with pressure
relief valves.
Fluids escaping under
pressure can penetrate skin and cause severe Per-
sonal injury or death. Hot fluids escaping under
DO NOT use your hands to search for leaks. pressure can burn and penetrate skin and cause
Before disconnecting lines, relieve ALL pressure. severe Personal injury or death.
If ANY fluid is injected into your skin, seek medical help Closing the flowmeter loading valve will cause a rupture
immediately. Serious infection can result without proper in the system. Always open flowmeter loading valve
medical treatment. before beginning a test.
Hot fluids escaping under 3. The typical flowmeter is equipped with a tempera-
pressure can burn and penetrate skin and cause ture gauge to show when oil has reached operating
severe Personal injury or death. temperature. Oil must be a to operating temperature
Verify that flowmeter to be used is large enough to before the flowmeter readings will be accurate.
handle maximum possible pump flow from the unit be- 4. Oil can flow through a flowmeter in one direction
ing tested. If flowmeter is too small, it may rupture only. Flowmeter ports are clearly labelled "IN" or "
INLET", and "OUT" or "OUTLET".
Measuring efficiency
5. All flowmeters are equipped with pressure gauges.
There are two questions to be answered when measur-
6. All flowmeter tests can be performed without mov-
ing system efficiency:
ing the flowmeter once it has been set up.
NOTE: Test all circuits in the hydraulic system.
1. Does the "no-load GPM/LPM reading drop at 80% Performing hydraulic oil flow check
of system pressure? If the answer is NO, the circuit is Loaders have capped tees on all pressure lines. These
working as intended. tees will be located either at the pump pressure outlets,
the valve bank, pressure inlets, or on the pressure lines
EXAMPLE HYDRAULIC SYSTEM TEST in between. These tees are the inlet oil source for all
flowmeter tests. The line connected to the flowmeter
Condition Reading % Result outlet carries the oil back into the system.
Under load 48 GPM 90% OK Connect the flowmeter INLET to the appropriate test
No-load 54 GPM tee and the flowmeter OUTLET through an SAE #16 hose
to the oil reservoir filler opening. Be sure the hose is
Under Load 36 GPM 67% Repair or securely clamped in place and that the open end is well
No-load 54 GPM replace below the fluid level to prevent aeration of the hydraulic
fluid.
2-
System check
Begin test with the main boom pump circuit. On most
loaders, the main boom control valve is paired in the
same valve bank with the grapple/attachment cylinder
control valve.
1. Record the correct pressure and flow readings for the
system(s) being tested.
2. Connect the flowmeter INLET to the #1 test port,
which is the pump section nearest the shaft.
3. Remove all personnel from the area. Start motor and
run until operating speed and temperature have
been reached. Have an assistant activate the grapple
control lever. Gradually close the loading valve until
the grapple/attachment cylinders are bottomed out.
4. With the grapple/attachment control still activated,
open the loading valve completely. Record the read-
ing on the flowmeter pressure gauge. The result will
be your System Back Pressure reading.
5. After completing test and recording reading, fully
open the flowmeter loading valve.
6. Have an assistant activate the grapple/attachment
control lever completely. While slowly closing the
loading valve, verify that pressure gauge is rising.
7. Record the GPM/LPM reading when the pressure
reading reaches 1000 PSI/6895 kPa.
reading reaches 80% of the system main relief set-
ting.
2-
Efficiency Actuator check

EXAMPLE TEST RESULTS
Recordings Test #1 % Test #2 %
Flow at No Load 37 GPM 90% 37 GPM
Flow Under Load 33GPM 90% 25 GPM 68%
Results of the system check

In the above examples:.
TEST #1 - At 90% efficiency this circuit is fine; move onto
the next circuit.
TEST #2 - At 68% efficiency there is definitely a problem
with this circuit.
When a low efficiency is detected with in a circuit,
continue this procedure to isolate the component that is
causing the low readings.
Repeat process for all hydraulic circuits on the machine.
1. Stop motor and wait for oil to cool to 120 Degrees F
Hot fluids escaping under (49 Degrees C)..
pressure can burn and penetrate skin and cause 2. Cap lines at the actuator or plug the work ports at
severe Personal injury or death. the control valve.
Begin with the valve closest to

the valve bank inlet and proceed downstream.
3. Repeat steps 2-8 as described in system check pro-
cedures. If low readings are not repeated, the cause
of the problem has been isolated. If the low readings
continue to appear, test next actuator in the hydrau-
lic circuit.
If low readings persist with

all actuator checks, actuators are not the cause of the
problem.
2-10
Pump check
Stop motor, wait until hydraulic oil cools to 120 Degrees

F (49 Degrees C) and configure the flowmeter for the
Pump Check by plugging the pressure line leading to
the control valve.
Hot fluids escaping under

pressure can burn and penetrate skin and cause
severe Personal injury or death.
Do not work on hydraulic system if oil temperature ex-
ceeds 120 Degrees F (49 Degrees C). Use caution when
disconnecting hoses.
Blocking a pressure line

can cause a system component to explode, causing
Open loading valve before beginning pump test.

There is no provision for pressure relief in this test. Clos-
ing the flowmeter loading valve will cause a rupture in
the system. Always open flowmeter loading valve before
beginning test.
1. Remove all personnel from the area. Start motor and 4. Divide the "under load" value by the "no load" value.
run until operating speed and temperature have If the quotient is 80% or higher the pump is not at
been reached. fault. If the quotient is lower , the pump should be
2. With flowmeter loading valve wide ope, observe the repaired or replaced.
flowmeter CPM/LPM reading. Record this reading as
"no load" value.
3. Slowly close the flowmeter loading valve to induce a
load on the pump. When pressure gauge reaches sys-
tem pressure, stop. Record the flowmeter GPM/LPM
reading. Record this reading as "under load" value.
2-11
Control valve check System pressure check
If problem persists after all of the actuators (motors

and cylinders), and the pump in each circuit have been The flowmeters used for this procedure are equipped
tested, the problem is in the auxiliary valves or the with pressure gauges. A complete system check can
control valve. be performed with one instrument. To check pressures
keep the flowmeter in "system check" configuration and
With the flowmeter in "system check" configuration,
close the loading valve completely. Activate each func-
conduct a systematic search. Eliminate each component
tion and record each reading. When all circuits supplied
in the actuator circuit by beginning at the end of the
by a particular pump have been tested, move the meter
line (cylinder or motor) and working back toward the
to the next pump circuit.
control valve, checking all auxiliary components such
as selector valves, cushion valves and crossover valves.,
one at a time, until the control valve is reached.
Reference chart
If the problem still persists, the trouble is in the con-
trol valve. Replace the main relief and any port reliefs
80% OF SYSTEM PRESSURE REFERENCE CHART
or anti-cavitation checks as needed to find where the
problem exists. The 80% value is used because main relief valves
are set at full flow, they start to open (crack) at
approximately 80% of that setting.
Full Flow % age Crack Flow
1000 PSI x 80% = 800 PSI
1800 PSI x 80% = 1500 PSI
2000 PSI x 80% = 1600 PSI
2200 PSI x 80% = 1760 PSI
2350 PSI x 80% = 1880 PSI
2400 PSI x 80% = 1920 PSI
2500 PSI x 80% = 2000 PSI
2650 PSI x 80% = 2120 PSI
Round off the 80% reading to the nearest 50.
2-12
Checking & setting Hydraulic control Valves

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
Grapple & FROM hp-50 Valve
main Pressure outlet
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #2 hP-50 SURE VALVE)
PUMP #3 VALVE
Hydraulic System Description

Turntable loader hydraulic systems are actually three 3. Remove all personnel from the area. Start motor and
separate systems. Each system is powered by a separate run until operating speed is reached. Verify clearance
hydraulic pump. All three pumps are coupled together to manipulate boom and activate Stick Boom Out
in tandem and driven by a single input shaft directly off function until cylinders bottom out, hold stick boom
the drive motor through a flexible coupling. out, forcing oil over relief at full flow.
4. Observe the 600 PSI (420 Bar) gauge after the indica-
Control Valve Actuation tor has stopped rising. Main relief reading should be
The valve bank supplied by the #1 pump (closest to the according to the spec sheet.
shaft) energizes Stick Boom and Grapple Rotor func- 5. If reading is not to specification, the #1 pump main
tions. Port reliefs are located in the A & B ports of the relief (stick boom & grapple rotor functions) must be
Stick Boom and Rotor control valve. Both Stick Boom adjusted. Rest boom/attachment on the ground or
port reliefs are above the main relief setting. Both deck, shut off motor and gain access to valve. Loosen
Grapple Rotor port reliefs are below the main relief set- lock nut and turn adjusting screw in (CW) to raise
ting. Relief pressure test port is located at the valve bank pressure setting, out (CCW) to lower setting. Repeat
pressure inlet. steps 2 -4 to verify setting. When setting is to specifi-
Checking and setting pump #1 main relief cations, shut off motor, remove test equipment and
pressure cap test fittings.
warm the oil to operating temperature, 110 Degrees
F (43 Degrees C) to 130 Degrees F (54 Degrees C).
2. To check main relief pressure, stop motor and con-
nect a 600 PSI (420 Bar) gauge to the #1 pump test
port. Test hose must be long enough to permit read-
ing the gauge from the operator's seat.
2-13

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE

Turntable loader hydraulic systems are actually three 3. Remove all personnel from the area. Start motor
separate systems. Each system is powered by a separate and run until operating speed is reached. Activate
hydraulic pump. All three pumps are coupled together Grapple Close function until cylinders bottom out,
in tandem and driven by a single input shaft directly off and hold, forcing oil over relief at full flow.
the drive motor through a flexible coupling. 4. Observe the 600 PSI (420 Bar) gauge after the indica-
tor has stopped rising. Main relief reading should be
Control Valve Actuation according to the spec sheet.
The valve bank supplied by the #2 pump (center sec- 5. If reading is not to specification, the #2 pump main
tion) energizes Main Boom and Grapple Open/Close relief (main boom & grapple open/close functions)
functions. Port reliefs are located in the A & B ports of must be adjusted. Rest boom/attachment on the
the Main Boom and Grapple function control valve. The ground or deck, shut off motor and gain access to
A port relief is below the main relief setting, the B port valve. Loosen lock nut and turn adjusting screw in
relief is above the main relief setting. Grapple Cylinder (CW) to raise pressure setting, out (CCW) to lower set-
control valve has not port reliefs. Relief pressure test ting. Repeat steps 2 -4 to verify setting. When setting
port is located at the valve bank pressure inlet. is to specifications, shut off motor, remove test equip-
Checking and setting pump #2 main relief ment and cap test fittings.
pressure
F (43 Degrees C) to 130 Degrees F (54 Degrees C) by
holding the Grapple Close function over relief.
2-14

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE

separate systems. Each system is powered by a separate run until operating speed is reached. On units with
hydraulic pump. All three pumps are coupled together Live Heel function, actuate Heel out function and
in tandem and driven by a single input shaft directly off hold, forcing oil over relief at full flow. On units with
the drive motor through a flexible coupling. Telescopic Stick function, activate Telescope Out
function and hold. On units without a boom function
Control Valve Actuation in the valve bank, secure boom so that machine will
The valve bank supplied by the #3 pump (end section) not rotate left or right, then activate Swing function
energizes Swing Boom and Live Heel/Telescopic Boom and hold.
functions. The swing valve section has no port reliefs, 4. Observe the 600 PSI (420 Bar) gauge after the indica-
but the swing motor is protected by a crossover relief tor has stopped rising. Main relief reading should be
valve located at the swing motor inlet. Both crossover according to the spec sheet.
reliefs are above main relief setting. Main relief valve is 5. If reading is not to specification, the #3 pump main
located on the HP-50 valve. Relief pressure test port is relief (Swing & Live Heel/Telescopic Boom functions)
located at the HP-50 (pilot pressure valve) pressure inlet. must be adjusted. Rest boom/attachment on the
Checking and setting pump #3 main relief ground or deck, shut off motor and gain access to
pressure valve cartridge (located on the HP-50 pilot pressure
valve). Loosen lock nut and turn adjusting screw in
1. Remove all personnel from the area. Start motor and (CW) to raise pressure setting, out (CCW) to lower set-
warm the oil to operating temperature, 110 Degrees ting. Repeat steps 2 -4 to verify setting. When setting
F (43 Degrees C) to 130 Degrees F (54 Degrees C) by is to specifications, shut off motor, remove test equip-
holding the Grapple Close function over relief. ment and cap test fittings.
2-15
Pressure Check Procedure for Open-center Systems

Checking Grapple Cylinder Port Relief 7. Plug the disconnected tube at the boom base, and
The system will not generate enough pressure to check connect the Port-O-Power to the hose that leads to
Grapple Cylinder port reliefs. These port reliefs must be the Grapple control valve “B” port.
verified with a high-volume Port-O-Power as follows: 8. Pressurize Port-O-Power, bleed-off any air, and stroke
it to build pressure. The port relief should begin to
Port-O-Power Test Method relieve as gauge approaches 5000 PSI. If setting is
Conduct this test with motor OFF, control valve not correct, adjust as follows:
in “Neutral” and grapple work lines discon- 9. Gain access to Grapple Cylinder “B” port relief. Use
nected. a 15/16" wrench for the lock nut and a flat blade
screwdriver for the adjusting screw. Back off lock nut
and turn adjusting screw in (CW) to increase pressure
Unexpected movement of reading, or out (CCW) to decrease pressure reading.
hydraulic actuators can cause severe personal injury When setting is to specification, tighten lock nut.
or death.
10. Open Port-O-Power “Bleed off” valve to remove
1. Fully extend the boom and set the grapple on the residual pressure from the circuit
ground with jaws open. 11. Disconnect the Port-O-Power and connect the
grapple “B” port hose to the tube on the boom.
12. Clean the area to be tested and disconnect work line
at boom base that leads to grapple cylinder Base
pressure can penetrate skin and cause severe per-
End ports.
sonal injury or death.
13. Plug the disconnected tube at the boom base, and
DO NOT use your hands to search for leaks. Relieve
connect the Port-O-Power to the hose that leads to
ALL pressure before disconnecting lines or removing
the control valve “A” port.
components. If ANY fluid is injected into your skin, seek
medical help immediately. Serious infection can result 14. Pressurize Port-O-Power, bleed-off any air, and
without proper medical treatment. stroke it to build pressure. The port relief should
begin to relieve as gauge approaches 5000 PSI. If
Before opening hydraulic system, follow BEFORE SER- setting is not correct, adjust as follows:
VICE instructions in Safety Section.
15. Gain access to Grapple Cylinder “A” port relief. Use
Thoroughly clean the area to be serviced. a 15/16" wrench for the lock nut and a flat blade
2. Shut down motor and remove key. screwdriver for the adjusting screw. Back off lock
nut and turn adjusting screw in (CW) to increase
3. Move joysticks in all directions to relieve pressure.
pressure reading, or out (CCW) to decrease pressure
4. Swing pilot shut-off lever UP to disengage controls. reading. When setting is to specification, tighten
5. Purge air from the reservoir. lock nut.
16. Open Port-O-Power “Bleed off” valve to remove
residual pressure from the circuit
Hot Hydraulic Fluid can 17. Remove the Port-O-Power and connect the grapple
cause severe burns. “B” port hose to the tube on the boom. .
Do not work on hydraulic system if oil temperature ex- 18. When test is complete, start the motor and check for
ceeds 120°F [49°C]. Use caution while disconnecting leaks.
hydraulic hoses.
FIELD SERVICE TIP: If “B” port relief tests OK but “A”
6. Clean the area to be tested and disconnect work line port relief does not hold its setting, switch them to
at boom base that leads to grapple cylinder Rod End the opposite ports until a replacement is available.
ports.
2-16
Checking & adjusting HP-50 Pilot pressure valve

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #2 hP-50 SURE VALVE
PUMP #3 VALVE
2-17

Hp-50 valve purpose & location
The HP-50 valve is located on a bracket just below
the swing control valve bank. It's purpose is to charge The HP-50 valve is extremely
the pilot control system of the loader. The main relief sensitive to contamination. If the valve does not respond
cartridge for the swing and jib functions is located here, correctly to adjustments, it must be removed, disassembled
along with the other valve cartridges which enable the and thoroughly cleaned, then tested again.
HP-50 to function properly.
7. When all HP-50 valve settings are correct, shut off
Checking and setting Hp-50 pressure motor, remove test equipment and cap test fittings.
2. To check HP-50 pilot pressure relief pressure, stop
motor and connect a 600 PSI (420 Bar) gauge to the
#3 pump test port. Start motor and run until operat-
ing speed is reached. Verify that main relief setting is
to specification and adjust if necessary.
NOTE: Pressure differential valve is no longer adjust-
able.
3. Shut off motor, remove the 6000 PSI (420 Bar) gauge
and connect a 600 PSI (42 Bar) gauge to the #3 pump
test port. Start motor and run until operating speed
is reached. While observing the gauge, back out on
the pilot pressure build up valve until the pressure
no longer drops. The reading at this point is the back
pressure for this circuit. Reading should be 150 - 220
PSI (1034 - 1517 kPa).
4. Adjust the pilot pressure build up valve in (CW) until
pressure reaches 400 PSI.
Do not operate any loader

function or the gauge will be destroyed.
5. Shut off motor, remove 600 PSI (42 Bar) gauge from
the high pressure test port, cap the fitting and con-
nect the gauge to the pilot pressure test port, located
in line between the pilot port and the pilot manifold.
6. Start motor and run until operating speed is reached.
Observe the pilot pressure reading on the 600 PSI
(42 Bar) gauge. A reading of 400 - 450 PSI (2758
- 3103 kPa) will confirm that the pressure reducing
valve is working properly. If reading is below 300 PSI
(2068 kPa) or above 500 PSI (3447 kPa) the pressure
reducing valve cartridge (non adjustable) must be
replaced.
2-18
Any Hydraulic Loader

Cylinder Piston Seal Bypass Test
The motor must be operated at no more than 1100 RPM during this test.
1. Position the cylinder to be tested so that it is at maximum stroke, either fully extended or fully retracted. Shut
down the motor and remove the key.
Falling load, boom, or attachment can cause severe personal injury or death.
Never allow load, boom, or attachment to be over or near personnel.
2. Ensure that the hose on the end of the cylinder to be tested can be safely removed without unexpected move-
ment of the boom or attachment.
Hot oil can cause severe burns.
Do not work on hydraulic system if oil temperature exceeds 49°C (120° F). If you are injured by escaping fluid, see
a doctor at once. Proper medical treatment must be administered immediately. A serious infection or reaction
3. Remove the hose from the “bottomed-out” end of cylinder and plug or cap the end of the hose.
4. Attach one end of a test hose to the cylinder port and securely place the other end of the hose into a container
in order to catch any leaking oil.
5. Start the motor and run at low idle. Actuate the cylinder being tested toward the “bottomed-out” end and note
the leakage at the end of the test hose. Any leakage indicates the need to repack or replace the cylinder.
6. Repeat steps 1 through 5 above for testing the other end of the cylinder.
7. If it is suspected that the cylinder is leaking at mid-stroke, it will be necessary to block the movement of the
cylinder rod at mid-stroke prior to performing the above test, or to follow the procedure on the following page.
2-19
Any Hydraulic Loader

Valve Leakage Test
Use this test to check main cylinder control valve assembly for internal leakage:
5. Remove all personnel from the area. Start the motor

Falling load, boom, or at- and extend the stick boom to its maximum reach.
tachment can cause severe personal injury or death. Swing the boom until the grapple is just alongside of
Never allow load, boom, or attachment to be the trailer frame. Shut down the motor and remove
over or near personnel. the key. Standing on the trailer frame alongside the
boom, measure and record the length of the exposed
1. Remove all personnel from the area. Secure the area
cylinder rod.
so that no one will pass beneath the suspended
boom. 6. Let the unit stand for one minute, then measure and
record the length of the exposed rod. Compare this
2. Complete the cylinder leakage test on the preceding
measurement with the one recorded in Step 5. The
page, and repair or replace as required.
difference should be less than 3/4 inch [19 mm].
3. Lower stabilizers, extend boom and rest grapple on
If the boom has settled 3/4 of an inch [19 mm] or more,
ground with jaws open. Shut down motor.
and there is no external leakage from anywhere in the
circuit, the valve spool or the port relief may be sus-
Hot hydraulic fluid can pected.
cause severe burns. Do not work on hydraulic system 7. Make sure that the cylinder is not at fault (refer to
if oil temperature exceeds 120°F [49°C]. Use caution Step 2).
when disconnecting hoses. 8. If the cylinder checks out OK, either the valve spool
If you are injured by escaping fluid, see a doc- or the port relief may be the cause of the leakage.
tor at once. Proper medical treatment must be 9. Replace the port relief with one that is known to be
administered immediately. A serious infection OK, then run the test again. If the boom continues
or reaction can result without proper medical to drift down, remove the valve spool and inspect
treatment. it for wear. If scoring can be felt with the fingernail,
replace the valve section.
4. Relieve pressure in the suspect circuit by working the
joystick with motor OFF, electric power ON, and pilot
system engaged. Shut off electric power and remove
key.
A standard tolerance for leakage past the valve spool is
40 cc per minute from the base end of the cylinder. In a
5-inch cylinder, this translates to about 5/8 inch [16 mm]
of cylinder rod travel per minute.
2-20
3-
Hydraulic Systems

This section provides information to help the service technician troubleshoot the hydraulic components that oper-
ate the boom, swing, stabilizer and processor functions of this machine.
Hydraulic systems
Table of Contents
Circuit Descriptions
Pump . ................................................................................................................ 3-2
Work Circuit 519SM................................................................................... 3-4
Work Circuit 569SM................................................................................... 3-5
Hydraulic System Troubleshooting

Safety, tools & cleanliness................................................................ 3-8
Main System................................................................................................... 3-9
Slow Functions........................................................................................3-10
SWING ................................................................................................................3-11
INOPERATIVE FUNCTION...........................................................................3-12
GRAPPLE ROTATION.....................................................................................3-12
NOISE . ..............................................................................................................3-13
CYLINDER DRIFT............................................................................................3-13
VALVE PROBLEMS..........................................................................................3-14
Hydraulic Schematic Drawing

. ..............................................................................................................3-17
3-
Hydraulic Systems
PRESSURE & RETURN CIRCUIT, PUMP NO. 1
PILOT
GENERATOR
A 2500 PSI 2500 PSI 2500 PSI

Power
SWING MAIN STICK Beyond
BOOM
TELE GRAPPLE BOOM

ROTATE

B
RETURN
RETURN
FILTER
OIL COOLER
UPPER VALVE BANK
2500 PSI 2500 PSI 2500 PSI

A MAIN
Power
SWING STICK Beyond
BOOM
TELE GRAPPLE BOOM

ROTATE

B
RETURN
RETURN
FILTER
OIL COOLER
3-
Hydraulic Systems
UPPER VALVE BANK
2500 PSI 2500 PSI 2500 PSI

A MAIN
Power
SWING STICK Beyond
BOOM
TELE GRAPPLE BOOM

ROTATE

B
3-
Hydraulic Systems
Work Circuit - 519SM
VALVE BANK FRONT OF UNIT

As seen from right side of machine, with valve
bank mounted (looking at underside of valve IN
bank with work ports facing
away from you). B A
3000 PSI END INLET 3000 PSI
Grapple open 5000 PSI Grapple 5000 PSI Grapple close
Main boom up Main Main boom

2800 PSI 1500 PSI Down
2200 PSI Main Relief

Stick boom Stick boom
2800 PSI Stick 2800 PSI
down down
Rotor ccw 1600 PSI Rotor Rotor cw

1600 PSI
Plugged
Plugged
OUT
3-
Hydraulic Systems
Work Circuit - 569SM
VALVE BANK FRONT OF UNIT

As seen from right side of machine, with valve
bank mounted (looking at underside of valve IN
bank with work ports facing
away from you). B A
stick boom up 2500 PSI Stick 3000 PSI stick boom down
rotor ccw 3000 PSI Rotor 3000 PSI rotor cw
grapple close 1000 PSI grapple 2750 PSI grapple open
main boom up 2750 PSI main 1000 PSI main boom down
heel up HEEL heel down
rotor ccw 2650 PSI swing 2650 PSI rotor cw
OUT
3-
Hydraulic Systems
Work Circuits – Valve bank 519SM
Rotor “B” CCW
Grapple “A” Closed

Rotor “A” CW
Grapple “B” Open
5000 PSI
2800 PSI
3500 PSI
Inlet 1600 PSI
Grapple
Main
Boom Rotor
Main
Relief Outlet
2200 PSI 5000 PSI
44GPM
1600 PSI
1500 PSI
2800 PSI
2200 PSI
3-
Hydraulic Systems
Work Circuits – Valve bank 569SM
Rotor “B” CCW
Grapple “A” Closed

Rotor “A” CW
Grapple “B” Open
STICK
FRONT
STICK 3000 PSI
REAR
ROTATE 1600 PSI
ROTATE FRONT
REAR GRAPPLE
FRONTMAIN
GRAPPLE FRONT 1000 PSI
3000 PSI REAR
1600 PSI MAIN HEEL
REAR FRONT SWING
HEEL FRONT
REAR
2750 PSI SWING
REAR 2500 PSI
MAIN
3000 PSI RELIEF
3-
Hydraulic Systems
Always have the engine shut down for maintenance and service operations
unless the procedure requires the engine running. The procedures used
to check machine performance require the engine to be running. Only qualified technicians shall
perform these procedures. To avoid serious personal injury or property damage, do these things
before performing these operations:
1. Move the machine to firm, level ground, and set unsupported boom. Extend stick cylinder to
carrier parking brake. straighten boom and rest attachment on the
2. Raise stabilizers so loader rests on carrier tires. ground with jaws open.
Then lower stabilizers so they rest on the ground 4. Be sure the operator knows where you are and
without raising the loader. what you want done. Agree on signals.
3. Severe personal injury or death may result 5. Before disconnecting lines, turn off engine and
from unexpected movement of hydraulic relieve pressure in all circuits. Allow oil to cool
cylinders. Keep all personnel away from an below 120° F [49°C].
Use the following information to check and adjust performance of Knuckle Boom loaders.
To properly troubleshoot the Attachment hydraulic system the following diagnostic aids will be needed:
• an accurate, reliable flow meter sized for maximum pump flow

• an accurate 0-600 psi test gauge
• a Port-O-Power with 0-6000 psi test gauge (for Grapple Cyl Port Reliefs)
Most malfunctions in the hydraulic system can be readily corrected by using these gauges and following the
steps outlined in this section and in Hydraulic Specifications & Test Procedures. These aids assume that the
reservoir has a sufficient quantity of oil, the filters and strainers are clean and that the air breather on top of the
reservoir is not clogged.
When Working with Hydraulics, cleanliness and open hose and tube ends capped unless procedure
is of vital importance requires that they be left open. Always clean lines or
hoses prior to installation by flushing and blowing out
with filtered compressed air.
Dirt is the enemy of your hy- Add fluid to the hydraulic system through the filters
draulic system. Keep your tools and your work area clean. only. New oil in jobbers’ or distributors’ drums may be
Dirt in any hydraulic system causes prema- clean only to a particle size of 25 microns.
ture wear and erratic performance.
Dirt that accumulates around relief valve and com- How to Use This Section
pensator cartridges can be carried into threads while Most hydraulic system malfunctions can be readily cor-
the cartridge is being adjusted, possibly damaging the rected by referring to the troubleshooting charts, using
seals. Be sure to thoroughly clean valve cartridges and the tools listed above, and by following the procedures
their surroundings before making adjustments. in Hydraulic Specifications & Test Procedures.
Dirt that accumulates around test ports can fall onto di- These aids assume that the reservoir has sufficient oil,
agnostic nipple after cap is removed, and thus enter the the filters are clean and that the reservoir breather/pres-
system and your gauges. Be sure to thoroughly clean sure check valve is free of obstructions. See also VG-20
test fittings and their surroundings before connecting Valve Troubleshooting.
hydraulic test equipment.
3-
Hydraulic Systems
Problem Probable Cause Possible Solution
Hydraulic System Does Low Hydraulic Fluid Level Fill to proper level
Not Work (All Func-
tions) Faulty Or Plugged Suction Hose Clean or replace hose
Defective Hydraulic Pump Flush system completely and refill

with clean oil.
Check the hydraulic pump oil flow

to ensure that it is pumping the cor-
rect amount of oil. Repair or replace
pump if needed.
Pilot system not activated Activate pilot system

Check pilot shut-off valve
Hydraulic System Cold Oil Warm up system oil.

Works Slow (All Func-
tions) Wrong Oil Drain, flush and refill, using the
proper oil.
Check to ensure that no hoses are

Faulty Plumbing
kinked or pinched causing restricted
oil flow. Check suction hose to en-
sure that it is not partially plugged.
Check the hydraulic pump to en-

sure that it is pumping the correct
amount of oil. Repair or replace
Faulty Hydraulic Pump
pump if needed.
Check pilot pressure. If low, trou-

Pilot pressure low bleshoot cause.
Check and repair

Pilot cap leaking
3-10
Hydraulic Systems
Individual Hydraulic Movement of controls restricted Remove restriction

Function Operates (E.g. mud under foot pedal)
Slow
Pilot cap leaking Check and repair
Faulty plumbing Check hoses to ensure they are

not pinched or damaged internally
causing an oil flow restriction..
Check the cylinder to ensure that no

damage has occurred to either the
Faulty hydraulic cylinder rod or the cylinder barrel. Check the
piston packing to ensure that no oil
is passing the piston.
Check the port reliefs to ensure that

the O-rings are in good condition
and that the relief is not stuck open.
Faulty valve section
Check the pins and bushings to

ensure that they are not worn badly
enough to slow down the move-
Faulty pins and bushings ment of the function. Check to
ensure that all pins and bushings are
properly lubricated..
Swing Doesn't Operate Swing parking brake dragging Check release pressure at motor; if
or Operates Slow (All below 325 PSI, replace brake piston
seals.
other functions operate
normally)
3-11
Hydraulic Systems
Unit will not swing in House brake locked Release

either Direction. (All
other functions operate Foreign object in swing ring gear or Remove object. Repair or replace
normally) a broken ring gear tooth ring gear.
Faulty swing motor Repair or replace swing motor as

necessary
Faulty swing gear box Repair or replace gear box
Check to ensure that the pilot lines

Faulty pilot plumbing or component
from the foot pedal to the control
valve are properly installed. Check
pilot supply pressure, check pres-
sure at controller and at valve spool
cap
Faulty hydraulic plumbing

Check all hoses to ensure that they
are not pinched or damaged inter-
nally preventing oil flow.
Unit will swing in one Faulty pilot plumbing or component Check to ensure that the pilot lines
Direction only from the foot pedal to the control
cap
Foreign Object In Swing Ring Gear

Or A Broken Ring Gear Tooth Remove object. Repair or replace
ring gear
Faulty Plumbing
Check all hoses to ensure that they
are not pinched or damaged inter-
nally preventing oil flow.
Foreign object under swing

pedal
Remove foreign object
3-12
Hydraulic Systems
Any one function will Faulty pilot plumbing or component Check to ensure that the pilot lines
not operate from the controller to the control
cap
Faulty load check (if equipped)
Check to ensure that the poppet is
not jammed closed.
Faulty plumbing
Check all hoses going to and com-
ing from the hydraulic cylinder to
ensure that they are not pinched or
damaged internally causing an oil
flow restriction.
Grapple will not ro- Port Relief poppet stuck open. Clean, repair or replace cartridge.
tate (all other functions
operate normally) Faulty pilot plumbing or component Check to ensure that the pilot lines
from the controller to the control
cap
Faulty plumbing
Check all hoses from the control
valve to the rotator to ensure that
they are not pinched or damaged
internally causing an oil flow restric-
tion.
Faulty rotator
Repair or replace rotator
3-13
Hydraulic Systems
Hydraulic system noisy Loose mounting hardware Tighten
Low hydraulic oil level Fill to proper level with the proper
oil
Air in system Tighten hose connections. Replace

hoses if needed.
Restriction in suction hose to hy- Remove restriction. Check suction

draulic pump. hose to ensure that it is not dete-
riorating internally causing a flow
restriction.
Hydraulic cylinder
Check cylinders for damage to the
drifts or settles Faulty cylinder
barrel and/or rod.
Check cylinder packing to ensure
that oil is not passing them. Replace
cylinder or repair.
Check the valve pilot cap compo-

Faulty pilot caps nents to ensure that they are not
binding, keeping the valve from
returning to the neutral position.
Check the control valve to ensure

Faulty control valves that the valve spool is not worn al-
lowing oil to pass.
If valve is worn or damaged it must
be replaced.
3-14
Hydraulic Systems
Valve spools sticking Contamination such as paint, dirt, or Remove spool from valve body and
in valve body metallic particles between the valve clean. Determine the cause of con-
body and spool. tamination and repair.
Scored, bent, or damaged spool Replace the complete valve section.
Loosen the tie bolts and

Tie bolts over torqued Torque to the proper
Setting.
Hydraulic cylinders Excessive wear between the valve Replace the valve section.
leaking down or load body and spool caused by contami-
nation.
settling
Remove the relief valve and inspect
Circuit relief valve leaking due the seat area. Clean the relief valve
To wear or particles in the seat or replace if worn. Check all O-rings
to ensure that they are not dam-
aged.
Check all linkages to ensure that

Valve spool not centering when
they are not bent or out of adjust-
Control is in the neutral position ment. Repair or replace and adjust
correctly. Check the centering
spring in the valve body to ensure
that it is not broken..
Adjust the pressure to the correct

Circuit relief pressure too low
pressure setting.
3-15
Hydraulic Systems
Load check will not Seat or poppet worn Replace load check assembly.
hold
Dirt or foreign material between the Remove the load check and clean or
poppet and the seat replace the load check assembly.
Spool seals leaking oil Seals cut, pinched, or hard due to Install new seals
age or being subjected to excessive
heat..
Valve body or valve spool worn Replace valve section and torque
excessively or scored. the tie bolts to the proper setting.
Section seals leaking

oil Seals cut or pinched Replace seals and torque the tie
bolts to the proper setting.
Improper torque on the tie bolts. Tighten bolts to the proper torque
setting.
3-16
Hydraulic Systems
3-17
Hydraulic Systems
10036019--1--569SM
3-18
Hydraulic Systems
3-19
Hydraulic Systems
10036023--A--569SM
3-20
Hydraulic Systems
4-
Major Hydraulic Components

Major hydraulic components

Table of Contents
Oil Reservoir...................................................................................................... 4-2
Filter........................................................................................................................ 4-4
Hydraulic Gear Pump
Exploded View......................................................................................... 4-5
General Information......................................................................... 4-7
Repair Instructions............................................................................. 4-8
Parts Inspection..................................................................................4-20
Startup Procedure............................................................................4-20
Hydraulic Control Valves
System Description............................................................................4-21
Checking & setting control valves.......................................4-21
Checking & setting crossover relief...................................4-24
Checking & adjusting HP-50 pilot pres valve..................4-26
Checking oil flow .............................................................................4-28
System check..........................................................................................4-30
Valve sections.......................................................................................4-34
Valve bank service..............................................................................4-36
Troubleshooting...............................................................................4-43
Pilot Controllers........................................................................................4-44
Pilot Joysticks................................................................................................4-45
Swing Pedal......................................................................................................4-46
Oil Cooler..........................................................................................................4-47
4-
Oil Reservoir 519SM

Filter Micron Rating
Main Return: 3.8 micron absolute
Filter Bypass Valve

Main Return: 40 PSI crack
OIL SHUT OFF VALVES

OIL DRAIN
PORT
10087281--1
HYDRAULIC oil RESERVOIR Inspection Cover Installation

The oil supply for the Loader is contained in a hydraulic Use Loctite “Master Gasket” sealant when installing
reservoir with an oil fill capacity of 71 gallons [269 liters]. upper & lower inspection covers on the oil tank. Prime
The reservoir is equipped with a 7 micron filtered breath- surfaces with Loctite “N” primer and use Loctite “Master
er. Residual pressure is released by pressing the relief Gasket” sealant to form the gasket.
button on the 7-micron breather assembly. To ensure If the Loctite sealant is not available, use NAPA RTV
that only clean oil enters the system, replenishment oil is silicone sealant or equivalent.
pumped through the return filters by a hand pump.
4-
Oil Reservoir 569SM

Filter Micron Rating
Main Return: 3.8 micron absolute
Filter Bypass Valve

Main Return: 40 PSI crack
OIL SHUT OFF VALVES
10083842--1
HYDRAULIC oil RESERVOIR Inspection Cover Installation

The oil supply for the Loader is contained in a hydraulic Use Loctite “Master Gasket” sealant when installing
reservoir with an oil fill capacity of 65 gallons [246 liters]. upper & lower inspection covers on the oil tank. Prime
The reservoir is equipped with a 7 micron filtered breath- surfaces with Loctite “N” primer and use Loctite “Master
er. Residual pressure is released by pressing the relief
button on the 7-micron breather assembly. To ensure
that only clean oil enters the system, replenishment oil is
pumped through the return filters by a hand pump.
4-
Return Line Filter

Oil Filter
The oil filter is mounted in the oil reservoir upper The filter will handle 100 GPM maximum flow.
inspection cover. The filter is equipped with a 40-
PSI bypass valve and an indicator to show when
the filter element is in a bypass condition.
3
When removing filter element from canister, do not 1
let contaminants on outside of element drop into

canister. Remove rubber grommet from bottom of 10
4
element, clean it and place it in the new element.

5
Oil Filter Parts List 11

Item Qty Description
0 REF FILTER ASSEMBLY, Return Line
1 1 PORT
8
2 1 BOWL ASSEMBLY
3 1 O-RING, Square
4 1 ELEMENT
5 1 CHECK VALVE
6 1 CAP ASSEMBLY (includes items 7-12) 12
7 1 CAP
8 1 VALVE ASSEMBLY, By pass
9 1 SPRING 0032078--b
10 3 HHCS
11 1 O-RING
12 4 CAP BOLT
Drawing of the in-tank return line hydraulic
oil filter used on the loader.
4-
Hydraulic Pump
#3
#2
#1
TOTAL WEIGHT: 175 lbs [79.4 kg]
Torque Notes
Use cross-tightening method to
tighten connecting studs
Item 17 Stud....................200 ft-lbs
Item 29 Stud....................200 ft-lbs
Item 38 Cpsw..................140 ft-lbs
4-
Hydraulic Pump
FUNCTIONS
GPM Hi Idle/Top Gov 51/46 42/38 33/30 4.6/4.2
GEAR PUMP PARTS LIST

1 1 RING, Snap 21 1 GEAR SET
2 1 BEARING, Ball 22 1 HOUSING, Gear
3 1 SEAL, Lip 23 2 PLATE, Thrust
4 1 HOUSING, Shaft End Cover 24 4 PIN, Dowel
5 4 SEAL, Gasket 25 2 SEAL, Channel
6 16 PIN, Dowel 26 2 not used
7 4 PLATE, Thrust 27 1 SHAFT, Connecting
8 1 GEAR SET, Shaft 28 1 HOUSING, Port End Cover
9 1 HOUSING, Gear 29 4 STUD (Torque 200 ft-lbs)
10 4 SEAL, Channel 30 2 PLATE, Thrust
11 1 SHAFT, Connecting 31 4 PIN, Dowel
12 1 HOUSING, Gear 32 1 HOUSING, Gear
13 1 GEAR SET 33 1 GEAR SET
14 1 HOUSING, Gear 34 1 HOUSING, Port End Cover
15 1 SHAFT, Connecting 35 2 SEAL
16 1 HOUSING, Port End Cover 36 2 SEAL, Channel
17 4 STUD (Torque 200 ft-lbs) 37 2 not used
18 4 WASHER 38 4 CAPSCREW (Torque 140 ft-lbs)
19 8 NUT 39 4 WASHER
20 2 SEAL, O-RING
4-

Uncontrolled movement of without the technician’s knowledge. Clean hose and
the loader can cause severe personal injury or death. tube fittings before disconnecting. Keep open ports
Prior to removing or doing other work on any pump, and open hose and tube ends capped unless procedure
valve or motor, place the machine in Maintenance requires that they be left open. Always clean new lines
position (see Maintenance Section in the Operator's or hoses prior to installation by flushing and blowing out
Manual). with filtered compressed air.
GENERAL Information
pressure can penetrate skin and cause severe Per- Pumps under Warranty may
sonal injury or death. be disassembled ONLY with the permission of the Warranty
DO NOT use your hands to search for leaks. Manager. Pumps returned under Warranty must be prop-
Before disconnecting lines, relieve ALL pressure. erly plugged before shipment.
If ANY fluid is injected into your skin, seek medical help
These service instructions will familiarize you with the
immediately. Serious infection can result without proper
component parts, the relative position of each part, the
medical treatment.
proper methods for disassembly and assembly and care
Before working on hydraulic system, follow BEFORE of the gear pump so that the best performance and
MAINTENANCE OR SERVICE instructions in the Operator's longer working life will result.
Manual.
To aid the repair of these units and before any work
is completed, we suggest that you first read all of the
Flying debris from cleaning steps used in disassembly and all of the steps used in
parts with compressed air can cause severe personal reassembly of the units.
injury. Dirt is the enemy of any hydraulic system. The first
Wear a face shield and protective clothing (PPE!). requirement of good maintenance of hydraulic equip-
Compressed air used for parts cleaning must be regu- ment is cleanliness. Disassemble and assemble hydrau-
lated at 30 PSI [210 kPa]. lic equipment in a clean area.
Disassembly and Assembly NOTES:

Improper lifting of heavy 1. Use care in gripping all parts in a vise to avoid dam-
objects can cause serious personal injury. aging machined surfaces.
Pump weighs 175 lbs [78.4 kg]. Always use a lifting 2. If prying off sections becomes necessary, take extreme
device. care not to mar or damage machined surfaces. Exces-
sive force while prying can result in misalignment and
can seriously damage parts.
Some cleaning solvents are 3. If parts are difficult to assemble, do not force them and
flammable. never employ an iron or steel-headed hammer.
To avoid possible fire, do not use cleaning solvents in an 4. Gears are closely matched, so therefore they should
area where a source of ignition may be present. be kept together as sets when removed from a unit.
Handle with care to avoid damage to the journals or
teeth.
Dirt is the enemy of your
hydraulic system. 5. Never hammer roller bearings or bushings into their
bores. Use only an arbor press or other suitable
Keep your tools and your work area clean.
tool.
Dirt that accumulates around relief valve cartridges
6. This pump has no bearing lubrication plugs. As-
can be carried into threads while the cartridge is being
sembly steps 3, 4 and 20 having to do with plug
adjusted, possibly damaging the seals. Be sure to thor-
installation are not applicable to this unit.
oughly clean components and their surroundings before
making adjustments.
4-
Repair Instructions
Disassembly
1. Place the pump in a soft-jawed machinist’s vise

with the drive shaft facing down. Match mark all
sections. Be sure to align these marks when assem-
bling.
2. Remove hex nuts, studs and washers.
3. Lift off the port end cover. Dowel pins will remain
in either the port end cover or the gear housing.
DO NOT remove them.
4-
Repair Instructions
Disassembly, continued
4. Remove the thrust plate.
5. Carefully remove the drive and driven gears. Keep

these gears together as a set. Remove the thrust
plate from the bearing.
6. Lift the gear housing from the bearing carrier.

4-10
Repair Instructions
7. Carefully pry off the bearing carrier to prevent

damage to contact face and edges. Dowel pins
will remain in either the bearing carrier or the gear
housing. DO NOT remove them.
8. Remove the connecting shaft. Remove the thrust

plate. Remove the gears and drive shaft. Keep the
gears together as a set.
9. Lift or pry off the first section gear housing. Take

care not to damage the machined surfaces.
4-11
Repair Instructions
10. Inspect the bushings for scoring, discoloration and

wear. Replace if needed.
If replacement is indicated, use a bushing puller to

remove the bushings.
11. Place the shaft end cover in a soft-jawed machinist’s

vise with the mounting face up. Remove the snap
ring or spiral lock.
12. Use a bearing puller to remove the outboard bear-

ing.
4-12
Repair Instructions
13. Reposition the shaft end cover in the vise

with the mounting face down.
Tap the seal out of its bore.
DO NOT clamp the vise jaws

on the pilot diameter of the shaft end cover.
Repair Instructions
Assembly
1. Clean up all machined surfaces with a medium

Carborundum stone.
2. If bushings have been removed, deburr the bushing

bores with emery cloth. Clean parts with solvent
and blow dry.
Flying debris from cleaning

parts with compressed air can cause severe personal
injury.
Wear a face shield and protective clothing (PPE!).
Compressed air used for parts cleaning must be regu-
lated at 30 PSI.
4-13
Repair Instructions
Assembly, continued
3. Place the shaft end cover in a soft-jawed machin-

ist’s vise with the mounting flange facing down.
Check the bearing lubrication plug in

the outlet side (if present) to ensure
that it is tight.
4. If a new plug is installed, it should be screwed in

tightly. Stake plug with prick punch at both ends
of the screwdriver slot and around edges. Peen
the edges of the hole 1/32" to 1/16" with a 1-1/2"
diameter steel ball.
5. If bushings have been removed, follow the steps

below for installing:
Bushings should be installed in the DRIVE BORES

with the groove toward the TOP of the unit.
Bushings should be installed in the DRIVEN

BORES with the groove toward the BOTTOM of
the unit.
4-14
Repair Instructions
Assembly, continued
6. The Bushing should be pressed into the bore

until it is flush with the casting face.
Use an arbor press.
7. Repeat Steps 1 and 2.
8. If new castings are being used, install dowel

pins. Be sure that the holes are clean, and that
they are free from dirt or other obstructions.
4-15
Repair Instructions
Assembly, continued
9. When installing a new seal in the shaft end

cover, coat the outer edge of the seal with
Permatex non-hardening sealant. With the
metal side of the seal facing up, press it into
the mounting flange of the shaft end cover
with the arbor press. Be careful not to damage
the lip of the seal.
10. Install bearing in shaft end cover. This is a light

press fit that may require light tapping to in-
stall.
11. Install snap ring in groove to retain bearing.

4-16
Repair Instructions
Assembly, continued
12. Grease the new gasket seals and install them in

all gear housings. Position the first gear hous-
ing over the shaft end cover. Tap it with a soft
hammer until it rests tightly against the mating
surface.
13. Assemble the channel seals into the grooves

in the thrust plates with the flat side of the seal
facing away from the thrust plate, as shown in
the drawing below.
14 Gently slip the thrust plate through the gear

housing and into place on the shaft end cover.
The channel seal from Step 13 should face the
shaft end cover. The relief groove in the thrust
plate should face the outlet side of the pump.
4-17
Repair Instructions
Assembly, continued
15. Slide the driven gear through the housing

and into the bushing in the shaft end cover.
Coat the drive shaft lightly with grease. Slide
the greased drive shaft through the shaft end
cover and the seal until the gear rests against
the thrust plate. Take care to avoid damage
to the lip seal.
16. Place the thrust plate, with its channel seal,

over the gear journals and into the housing
bore. The flat side of the channel seal should
face UP, and the relief groove in the thrust
plate should face the outlet side of the pump.
17. Position the bearing carrier over the gear

housing so that the shaft and gear journals
align with the bushings. Make sure the dowel
pins align with the dowel holes. Alternately
tap over each dowel pin until the parts are
tight together.
4-18
Repair Instructions
Assembly, continued
18. Insert the connecting shaft into the spline of

the drive gear. Place the second gear housing
on the bearing carrier as shown in Step 12.
19. Install the thrust plate in the gear housing by

following Step 12. Install the drive and driven
gears in their proper locations. Place the port
end cover plate in the housing by following
the procedure in Step 13.
20. Check the bearing lubrication plug in the

bearing carrier or port end cover to be sure
it is tight. Follow the procedure in Step 4 for
installing new plugs.
NOTE: Repeat Steps 17 through 20 for assem-

bling additional sections.
4-19
REPAIR INSTRUCTIONS
Assembly (cont)
21. Position the port end cover over the gear shafts
so that the gear journals align with the bushings.
Make sure the dowel pins align with the dowel
holes. Alternately tap over each dowel pin until the
parts are tight together.
22. Install the studs, washers, and nuts into the shaft
end cover and tighten lightly by the cross corner
method. Rotate the drive shaft with a 6" wrench
to make certain there is no internal binding of the
pump.
Sections 1, 2 and 3:
Torque the stud nuts to 200 ft-lbs
using the cross-tightening method.
Section 4 (Pilot Pump):

Torque the capscrews to 141 ft-lbs using the cross-
tightening method.
4-20
Gear Pump
PARTS INSPECTION
Gear Housing or machined casting, or both, must be replaced.
Wear in excess of .007" cut-out necessitates replacement If more than reasonable force is required to seat dowels,
of the gear housing. Place a straight-edge across bore. the cause may be poorly deburred or dirty parts; cock-
If you can slip a .007" feeler gage under the straight- ing of dowel in the hole; or improper pin-to-hole fit.
edge in the cut-out area, replace the gear housing.
Bushings
Pressure pushes the gears against the housing on the
If gears are replaced, bushings must be replaced. Bush-
low pressure side. As the hubs and bushings wear, the
ings should fit into bore with a heavy press fit.
cut-out becomes more pronounced.
Excessive cut-out in a short period of time indicates Seals and Gaskets
excessive pressure or oil contamination. If the relief Replace all rubber and polymer seals, including all O-
valve settings are within prescribed limits, check for rings, thrust plate channel seals, shaft seal and gasket
shock pressures or tampering. Withdraw oil sample and seals.
check it, and tank, for dirt. Where cut-out is moderate,
.007" or less, gear housing is in good condition and may Plugs
be reused. Examine the check valves in the shaft end and port end
cover to make sure they are in the proper position and
Gears
tight. The P365 has one plug in the shaft and port end
Any scoring on gear hubs necessitates replacement. high pressure side only.
Scoring, grooving, or fretting of teeth surfaces also ne-
cessitates replacement. Recommended start-up procedure for new
or rebuilt PUMP
Drive Shafts
Before installing a new or rebuilt pump, back off the
Replace if there is any wear detectable by touch in the
main relief valve until the spring tension on the ad-
seal area or at the drive coupling.
justing screw is relieved. This will avoid the possibility of
.002" wear is the maximum allowable. immediate damage to the replacement unit in the event
Wear in the shaft seal area indicates oil contamination. that the relief valve setting had been increased beyond
Wear or damage to splines, keys, or keyways necessi- the recommended operating pressure prior to removing
tates replacement. the old unit.
Thrust Plates Before connecting any lines to the pump, fill all ports
with clean oil to provide initial lubrication. This is par-
The thrust plates seal the gear section at the sides of the
ticularly important if the unit is located above the oil
gears. Wear here will allow internal slippage, that is, oil
reservoir.
will bypass within the pump.
After connecting the lines and mounting the replace-
.002" wear is the maximum allowable.
ment unit, operate the pump at least two minutes at no
Replace thrust plates if they are scored, eroded or pitted. load and at low rpm (400 minimum) During this break-
Check center of thrust plates where the gears mesh. in period, the unit should run free and not develop an
Erosion here indicates oil contamination. excessive amount of heat. If the unit operates properly,
Pitted thrust plates indicate cavitation or oil aeration. speed and pressure can then be increased to normal
operating settings.
Discolored thrust plates indicate overheating, probably
insufficient oil. Reset the main relief valve to its proper setting while the
pump is running at maximum operating engine (motor)
Dowel Pins speed for the vehicle.
If either the dowel or dowel hole is damaged, the dowel
4-21

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE

separate systems. Each system is powered by a separate run until operating speed is reached. Verify clearance
hydraulic pump. All three pumps are coupled together to manipulate boom and activate Stick Boom Out
intandem and driven by a single input shaft directly off function until cylinders bottom out, hold stick boom
the drive motor through a flexible coupling. out, forcing oil over relief at full flow.
Control Valve Actuation tor has stopped rising. Main relief reading should be
The valve bank supplied by the #1 pump (closest to the according to the spec sheet.
shaft) energizes Stick Boom and Grapple Rotor func- 5. If reading is not to specification, the #1 pump main
tions. Port reliefs are located in the A & B ports of the relief (stick boom & grapple rotor functions) must be
Stick Boom and Rotor control valve. Both Stick Boom adjusted. Rest boom/attachment on the ground or
port reliefs are above the main relief setting. Both Grap- deck, shut off motor and gain access to valve. Loosen
ple Rotor port reliefs are below the main relief setting. lock nut and turn adjusting screw in (CW) to raise
Relief pressure test port is located at the valve bank pressure setting, out (CCW) to lower setting. Repeat
pressure inlet. steps 2 -4 to verify setting. When setting is to specifi-
Checking and setting pump #1 main relief cations, shut off motor, remove test equipment and
pressure cap test fittings.
F (43 Degrees C) to 130 Degrees F (54 Degrees C).
4-22

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE

Turntable loader hydraulic systems are actually three 3. Remove all personnel from the area. Start motor
separate systems. Each system is powered by a separate and run until operating speed is reached. Activate
hydraulic pump. All three pumps are coupled together Grapple Close function until cylinders bottom out,
intandem and driven by a single input shaft directly off and hold, forcing oil over relief at full flow.
the drive motor through a flexible coupling. 4. Observe the 600 PSI (420 Bar) gauge after the indica-
Control Valve Actuation according to the spec sheet.
The valve bank supplied by the #2 pump (center sec- 5. If reading is not to specification, the #2 pump main
tion) energizes Main Boom and Grapple Open/Close relief (main boom & grapple open/close functions)
functions. Port reliefs are located in the A & B ports of must be adjusted. Rest boom/attachment on the
the Main Boom and Grapple function control valve. The ground or deck, shut off motor and gain access to
A port relief is below the main relief setting, the B port valve. Loosen lock nut and turn adjusting screw in
relief is above the main relief setting. Grapple Cylinder (CW) to raise pressure setting, out (CCW) to lower set-
control valve has not port reliefs. Relief pressure test ting. Repeat steps 2 -4 to verify setting. When setting
port is located at the valve bank pressure inlet. is to specifications, shut off motor, remove test equip-
Checking and setting pump #2 main relief ment and cap test fittings.
pressure
4-23

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE

separate systems. Each system is powered by a separate run until operating speed is reached. On units with
hydraulic pump. All three pumps are coupled together Live Heel function, actuate Heel out function and
intandem and driven by a single input shaft directly off hold, forcing oil over relief at full flow. On units with
the drive motor through a flexible coupling. Telescopic Stick function, activate Telescope Out
function and hold. On units without a boom function
Control Valve Actuation in the valve bank, secure boom so that machine will
The valve bank supplied by the #3 pump (end section) not rotate left or right, then activate Swing function
energizes Swing Boom and Live Heel/Telescopic Boom and hold.
functions. The swing valve section has no port reliefs, 4. Observe the 600 PSI (420 Bar) gauge after the indica-
but the swing motor is protected by a crossover relief tor has stopped rising. Main relief reading should be
valve located at the swing motor inlet. Both crossover according to the spec sheet.
reliefs are above main relief setting. Main relief valve is 5. If reading is not to specification, the #3 pump main
located on the HP-50 valve. Relief pressure test port is relief (Swing & Live Heel/Telescopic Boom functions)
located at the HP-50 (pilot pressure valve) pressure inlet. must be adjusted. Rest boom/attachment on the
Checking and setting pump #3 main relief ground or deck, shut off motor and gain access to
pressure valve cartridge (located on the HP-50 pilot pressure
valve). Loosen lock nut and turn adjusting screw in
1. Remove all personnel from the area. Start motor and (CW) to raise pressure setting, out (CCW) to lower set-
warm the oil to operating temperature, 110 Degrees ting. Repeat steps 2 -4 to verify setting. When setting
F (43 Degrees C) to 130 Degrees F (54 Degrees C) by is to specifications, shut off motor, remove test equip-
holding the Grapple Close function over relief. ment and cap test fittings.
4-24
Checking & setting swing Crossover relief

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE
SWING
MOTOR
CROSSOVER
RELIEF
4-25
Checking & setting swing Crossover relief

Control Valve Actuation
The valve bank supplied by the #3 pump (end section)
energizes Swing Boom and Live Heel/Telescopic Boom
functions. The swing valve section has no port reliefs,
but the swing motor is protected by a crossover relief
valve located at the swing motor inlet. Both crossover
reliefs are above main relief setting. Relief pressure test
port is located at the HP-50 (pilot pressure valve) pres-
sure inlet.
Checking and setting swing crossover

relief
2. To check crossover relief pressure, stop motor and
connect a 600 PSI (420 Bar) gauge to the #3 pump
test port at the HP-50 valve. Test hose must be long
enough to permit reading the gauge from the opera-
tor's seat. Gain access to Swing Valve main relief and
back off one turn. Rest boom/attachment on ground
or deck and secure boom so machine will not rotate.
3. Remove all personnel from the area. Start motor
and run until operating speed is reached. Activate
Swing Left function and observe the 6000 PSI (420
Bar) gauge, the activate the Swing Right function and
observe the 6000 PSI (420 Bar) gauge. Both readings
should be according to the pressure spec sheet.
according to the spec sheet.
5. If either reading is not to specification, the crossover
relief cartridge for that direction of rotation must be
adjusted. Shut off motor and gain access to crossover
relief valve at swing motor. Loosen lock nut and turn
adjusting screw in (CW) to raise pressure setting, out
(CCW) to lower setting. Repeat steps 3 and 4 to verify.
If cartridge cannot be adjusted, or reading is erratic
and there is no air in the hydraulic system, relief car-
tridge must be cleaned or replaced.
6. When setting is correct, adjust main relief to speci-
fication. Release boom/attachment so machine will
swing, rest boom/attachment on ground deck, shut
off motor, remove test equipment and cap test fit-
tings.
4-26

Cap
Test fitting
From
PUMP #1
From Stick &

PUMP #2 rotor
SWING
PUMP #3 swing
test fitting
PUMP #3 main
relief valve
PUMP #1
FROM PUMP #3 TO
hp-50 (PILOT PRES-
PUMP #3 VALVE
4-27

Hp-50 valve purpose & location
The HP-50 valve is located on a bracket just below the
swing control valve bank. It's purpose is to charge the The HP-50 valve is extremely
pilot control system of the loader. The main relief car- sensitive to contamination. If the valve does not respond
tridge for the swing and jib functions is located here, correctly to adjustments, it must be removed, disassembled
along with the other valve cartridges which enable the and thoroughly cleaned, then tested again.
HP-50 to function properly.
7. When all HP-50 valve settings are correct, shut off
Checking and setting Hp-50 pressure motor, remove test equipment and cap test fittings.
2. To check HP-50 pilot pressure relief pressure, stop
motor and connect a 600 PSI (420 Bar) gauge to the
#3 pump test port. Start motor and run until operat-
ing speed is reached. Verify that main relief setting is
to specification and adjust if necessary.
NOTE: Pressure differential valve is no longer adjust-
able.
3. Shut off motor, remove the 6000 PSI (420 Bar) gauge
and connect a 600 PSI (42 Bar) gauge to the #3 pump
test port. Start motor and run until operating speed
is reached. While observing the gauge, back out on
the pilot pressure build up valve until the pressure
no longer drops. The reading at this point is the back
pressure for this circuit. Reading should be 150 - 220
PSI (1034 - 1517 kPa).
4. Adjust the pilot pressure build up valve in (CW) until
pressure reaches 400 PSI.
Do not operate any loader

function or the gauge will be destroyed.
5. Shut off motor, remove 600 PSI (42 Bar) gauge from
the high pressure test port, cap the fitting and con-
nect the gauge to the pilot pressure test port, located
in line between the pilot port and the pilot manifold.
6. Start motor and run until operating speed is reached.
Observe the pilot pressure reading on the 600 PSI
(42 Bar) gauge. A reading of 400 - 450 PSI (2758
- 3103 kPa) will confirm that the pressure reducing
valve is working properly. If reading is below 300 PSI
(2068 kPa) or above 500 PSI (3447 kPa) the pressure
reducing valve cartridge (non adjustable) must be
replaced.
4-28

Warnings & tools
Sudden machine move-

ment can cause sever personal injury or death.
Ensure that hoses leading to actuators being tested can
be safely removed without causing sudden movement
of machine or attachment.
NOTE: Most tests require two technicians.
Required tools
NOTE: Knowledge of proper flow meter operation is
essential.
1. Flowmeter sized for maximum pump flow.
2. Two SAE #16 hoses of correct pressure rating and
with the necessary adapters.

Verify that flowmeter to be used is large enough to han-
dle maximum possible pump flow from the unit being
tested. If flowmeter is too small, it may rupture
Tips
1. Open loading valve completely before beginning any
flow check.
2. Never run hydraulic fluid through flow meter back-
wards.
3. Make hydraulic connections before bringing hydrau-
lic oil up to operating temperature.
4. Bring hydraulic oil up to operating temperature (110-
130 Degrees F, 43-54 Degrees C)
5. Make sure return hose is thoroughly cleaned before
being inserted into oil reservoir.
6. Connect the flowmeter INLET to the test tee and
insert return OUTLET line into the oil reservoir filler
opening. Be sure hose is securely clamped in place
and that the open end is below the fluid level.
4-29

Purpose
The flowmeter test is used to diagnose problems by 2. Is the GPM/LPM reading for a loaded circuit (at cor-
checking the efficiency of the components of a hydrau- rect system pressure) at least 80% of the GPM/LPM
lic system. This procedure will enable the technician to: reading for the same circuit in a "no-load" condition?
1. Check the efficiency of the entire system. If the answer is YES, the circuit is working as intend-
ed.
2. Check the efficiency of the hydraulic pumps.
3. Check the efficiency of the hydraulic control valves. flowmeter characteristics
4. Check the efficiency of the hydraulic actuator (motor Flowmeters are available from several different manu-
or cylinder). facturers, general commonality factors are:
An efficiency test will determine the amount of fluid 1. A typical flowmeter is equipped with a Loading Valve,
bypass the component is allowing ( the amount of fluid to induce a load on the system being tested. Closing
that is passing through the component without doing the loading valve is the same a deadheading the line
any work). leading out of the flowmeter.
2. A typical flowmeter is not equipped with pressure
relief valves.
pressure can penetrate skin and cause severe Per-
sonal injury or death. Hot fluids escaping under
DO NOT use your hands to search for leaks. pressure can burn and penetrate skin and cause se-
Before disconnecting lines, relieve ALL pressure. vere Personal injury or death.
If ANY fluid is injected into your skin, seek medical help Closing the flowmeter loading valve will cause a rupture
immediately. Serious infection can result without proper in the system. Always open flowmeter loading valve
medical treatment. before beginning a test.
Hot fluids escaping under 3. The typical flowmeter is equipped with a tempera-
pressure can burn and penetrate skin and cause ture gauge to show when oil has reached operating
severe Personal injury or death. temperature. Oil must be at operating temperature
Verify that flowmeter to be used is large enough to han- before the flowmeter readings will be accurate.
dle maximum possible pump flow from the unit being 4. Oil can flow through a flowmeter in one direction
tested. If flowmeter is too small, it may rupture only. Flowmeter ports are clearly labelled "IN" or "
INLET", and "OUT" or "OUTLET".
Measuring efficiency
5. All flowmeters are equipped with pressure gauges.
There are two questions to be answered when measur-
6. All flowmeter tests can be performed without mov-
ing system efficiency:
ing the flowmeter once it has been set up.
NOTE: Test all circuits in the hydraulic system.
1. Does the "no-load GPM/LPM reading drop at 80% Performing hydraulic oil flow check
of system pressure? If the answer is NO, the circuit is Loaders have capped tees on all pressure lines. These
working as intended. tees will be located either at the pump pressure outlets,
the valve bank, pressure inlets, or on the pressure lines
EXAMPLE HYDRAULIC SYSTEM TEST in between. These tees are the inlet oil source for all
flowmeter tests. The line connected to the flowmeter
Condition Reading % Result outlet carries the oil back into the system.
Under load 48 GPM 90% OK Connect the flowmeter INLET to the appropriate test
No-load 54 GPM tee and the flowmeter OUTLET through an SAE #16 hose
to the oil reservoir filler opening. Be sure the hose is
Under Load 36 GPM 67% Repair or securely clamped in place and that the open end is well
No-load 54 GPM replace below the fluid level to prevent aeration of the hydraulic
fluid.
4-30
System check
Begin test with the main boom pump circuit. On most
loaders, the main boom control valve is paired in the
same valve bank with the grapple/attachment cylinder
control valve.
1. Record the correct pressure and flow readings for the
system(s) being tested.
2. Connect the flowmeter INLET to the #1 test port,
which is the pump section nearest the shaft.
run until operating speed and temperature have
been reached. Have an assistant activate the grapple
control lever. Gradually close the loading valve until
the grapple/attachment cylinders are bottomed out.
4. With the grapple/attachment control still activated,
open the loading valve completely. Record the read-
ing on the flowmeter pressure gauge. The result will
be your System Back Pressure reading.
5. After completing test and recording reading, fully
open the flowmeter loading valve.
6. Have an assistant activate the grapple/attachment
control lever completely. While slowly closing the
loading valve, verify that pressure gauge is rising.
reading reaches 1000 PSI/6895 kPa.
reading reaches 80% of the system main relief set-
ting.
4-31
Efficiency Actuator check

EXAMPLE TEST RESULTS
Recordings Test #1 % Test #2 %
Flow at No Load 37 GPM 90% 37 GPM
Flow Under Load 33GPM 90% 25 GPM 68%
Results of the system check

In the above examples:.
TEST #1 - At 90% efficiency this circuit is fine; move onto
the next circuit.
TEST #2 - At 68% efficiency there is definitely a problem
with this circuit.
When a low efficiency is detected with in a circuit, con-
tinue this procedure to isolate the component that is
causing the low readings.
Repeat process for all hydraulic circuits on the machine.
1. Stop motor and wait for oil to cool to 120 Degrees F
Hot fluids escaping under (49 Degrees C)..
pressure can burn and penetrate skin and cause se- 2. Cap lines at the actuator or plug the work ports at
vere Personal injury or death. the control valve.
Begin with the valve closest to

the valve bank inlet and proceed downstream.
3. Repeat steps 2-8 as described in system check pro-
cedures. If low readings are not repeated, the cause
of the problem has been isolated. If the low readings
continue to appear, test next actuator in the hydrau-
lic circuit.
If low readings persist with all

actuator checks, actuators are not the cause of the prob-
lem.
4-32
Pump check
Stop motor, wait until hydraulic oil cools to 120 Degrees

F (49 Degrees C) and configure the flowmeter for the
Pump Check by plugging the pressure line leading to
the control valve.

Do not work on hydraulic system if oil temperature ex-
ceeds 120 Degrees F (49 Degrees C). Use caution when
disconnecting hoses.
Blocking a pressure line

can cause a system component to explode, causing
Open loading valve before beginning pump test.

There is no provision for pressure relief in this test. Clos-
ing the flowmeter loading valve will cause a rupture in
the system. Always open flowmeter loading valve before
beginning test.
1. Remove all personnel from the area. Start motor and 4. Divide the "under load" value by the "no load" value.
run until operating speed and temperature have If the quotient is 80% or higher the pump is not at
been reached. fault. If the quotient is lower , the pump should be
2. With flowmeter loading valve wide ope, observe the repaired or replaced.
flowmeter CPM/LPM reading. Record this reading as
"no load" value.
3. Slowly close the flowmeter loading valve to induce a
load on the pump. When pressure gauge reaches sys-
tem pressure, stop. Record the flowmeter GPM/LPM
reading. Record this reading as "under load" value.
4-33
Control valve check System pressure check
If problem persists after all of the actuators (motors

and cylinders), and the pump in each circuit have been The flowmeters used for this procedure are equipped
tested, the problem is in the auxiliary valves or the with pressure gauges. A complete system check can
control valve. be performed with one instrument. To check pressures
keep the flowmeter in "system check" configuration and
With the flowmeter in "system check" configuration,
close the loading valve completely. Activate each func-
conduct a systematic search. Eliminate each component
tion and record each reading. When all circuits supplied
in the actuator circuit by beginning at the end of the
by a particular pump have been tested, move the meter
line (cylinder or motor) and working back toward the
to the next pump circuit.
control valve, checking all auxiliary components such
as selector valves, cushion valves and crossover valves.,
one at a time, until the control valve is reached.
Reference chart
If the problem still persists, the trouble is in the control
valve. Replace the main relief and any port reliefs or
80% OF SYSTEM PRESSURE REFERENCE CHART
anti-cavitation checks as needed to find where the prob-
lem exists. The 80% value is used because main relief valves
are set at full flow, they start to open (crack) at
approximately 80% of that setting.
Full Flow % age Crack Flow
1000 PSI x 80% = 800 PSI
1800 PSI x 80% = 1500 PSI
2000 PSI x 80% = 1600 PSI
2200 PSI x 80% = 1760 PSI
2350 PSI x 80% = 1880 PSI
2400 PSI x 80% = 1920 PSI
2500 PSI x 80% = 2000 PSI
2650 PSI x 80% = 2120 PSI
Round off the 80% reading to the nearest 50.
4-34
519 SM Sectional Valves
Grapple
Main
Boom Stick
Inlet Boom
Rotor
Main
Relief
Outlet
5000 PSI
Grapple 2800 PSI
Front
MAIN
GRAPPLE front 3500 PSI
REAR
STICK 1600 PSI
MAIN Front ROTOR
rear FRONT
STICK
Rear
ROTOR
2200 PSI Rear
44GPM
5000 PSI
1500 PSI
2800 PSI
2200 PSI 1600 PSI
4-35
569 SM Sectional Valves
STICK
ROTOR
GRAPPLE
MAIN
HEEL
SWING
Section-Information
STICK
FRONT
STICK
3000 PSI
REAR ROTATE 1600 PSI
FRONT
ROTATE
REAR GRAPPLE
FRONT
MAIN
FRONT
GRAPPLE 1000 PSI
3000 PSI REAR
1600 PSI MAIN
HEEL
REAR
FRONT
SWING
FRONT
HEEL
REAR
2750 PSI SWING
REAR
2500 PSI
MAIN
RELIEF
3000 PSI
Port-PSI-Information
4-36
Valve Bank Service

Introduction
Uncontrolled movement of This topic has been prepared to assist you in the proper
the loader can cause severe personal injury or death. maintenance of directional control valves. Read the
Prior to removing or doing other work on any pump, instructions completely before beginning disassembly
valve or motor, place the machine in Maintenance and assembly.
position (see Maintenance section in the Operator's Also remember that the first rule of good maintenance
Manual). is cleanliness, including the work environment. MAKE
SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HY-
Fluids escaping under DRAULIC EQUIPMENT IN A CLEAN AREA, away from
pressure can penetrate skin and cause severe Per- airborne dust particles. Dirt is the natural enemy of any
sonal injury or death. hydraulic system.
DO NOT use your hands to search for leaks. We recommend that you use only original replacement
Before disconnecting lines, relieve ALL pressure. parts in repairing these valves. Manufactured on the
If ANY fluid is injected into your skin, seek medical help same production lines to the same exacting tolerances
immediately. Serious infection can result without proper and quality controls as the original equipment, genuine
medical treatment. replacement parts are your best hedge against prema-
ture component failure and costly downtime. Service
Before working on hydraulic system, follow BEFORE parts and assemblies are available from Product Sup-
MAINTENANCE OR SERVICE instructions in the Operator's port.
Manual.
General Information
Flying debris from clean- Model valves are contemporary versions of well-proven
ing parts with compressed air can cause severe per- open-center valve designs. The models are cast from
sonal injury. compacted graphite, a high strength iron alloy which
allows the valve to be rated at 3500 psi. VA models
are cast from grey iron and are rated at 2500 psi. The
Compressed air used for parts cleaning must be regu- valves are of sectional or stack type construction which
lated at 30 PSI [210 kPa]. permits additional work sections to be added to the
valve bank. The internal coring of each valve section
Improper lifting of heavy determines its circuitry and the number of gasket seals
objects can cause serious personal injury. Always use it requires. All sections with optional features such as
a lifting device. port relief valves, crossover relief valves and anti-cavi-
tation checks are dimensionally larger as measured
from the top of the port to the bottom of the housing.
Some cleaning solvents are These are referred to as “hi-boy” sections. Those with-
flammable out these features are low profile or “lo-boy” sections
To avoid possible fire, do not use cleaning solvents in an (see Figure 9).
area where a source of ignition may be present.
Overhaul
Hydraulic valves are often used in hazardous environ-
Dirt is the enemy of your ments. Therefore, care should be taken to frequently
hydraulic system. inspect the product for damage due to improper use,
Keep your tools and your work area clean. corrosion or normal wear. Repairs should be made im-
Dirt that accumulates around relief valve cartridges mediately if needed.
can be carried into threads while the cartridge is being Remove the valve bank from the equipment and dis-
adjusted, possibly damaging the seals. Be sure to thor- connect all hoses, fittings, control handles and link-
oughly clean components and their surroundings before age connectors that might be attached to the valve.
making adjustments. Plug all ports and thoroughly clean the valve bank's
Ambient dirt can enter a disconnected hose or tube exterior, after which the port plugs can be removed.
and open hose and tube ends capped unless procedure
requires that they be left open. Always clean new lines
or hoses prior to installation by flushing and blowing out
with filtered compressed air.
4-37
Sectional Valves
Disassembly and Assembly Cautions: 3. Mark the port boss closest to you on each work sec-
1. Use care in gripping all parts in a vise to avoid dam- tion with an "A".
aging machined surfaces. 4. If relief valves must be removed from the valve
2. If prying of sections becomes necessary, take ex- bank they should be marked with the number of
treme care not to mar or damage machined surfac- the section and port to which they belong. Inlet
es. Excessive force while prying can result in serious and mid-inlet relief valves are marked with their
damage to parts. section number only.
3. If parts are difficult to assemble, do not force them B Remove Tie Bolts
and never use an iron or steel-headed hammer. Remove the tie bolts which hold the valve bank to-
4. Spools are hone-fitted to their individual housings. gether and separate the sections. Valve fasteners pass
Therefore, damage to either of these components through the entire bank and have a hex nut and washer
means the entire section must be replaced. Handle fastened at both ends.
with care to avoid damage to the mating surfaces.
C Remove and Discard Section Seals
Valve Bank Disassembly The inlet, mid-inlet and each parallel work section
Place the valve bank on a clean, flat surface with the have section seals on the downstream mating face.
work ports facing up and inlet on the left with main These section seals should be removed and dis-
relief facing toward you. carded.
A Mark the Valve Bank

This step is the most critical step in the disassembly
procedure. It should be followed very closely to ensure
that the valve bank is properly reassembled after repairs
have been made.
Lo-Boy Sections:
1. Use a waterproof, quick-drying marker to mark each Stabilizer & Swing
casting with a sequential number. Start by mark-
ing the inlet section as #1 and finish by marking the
outlet with the highest number.
2. Mark the port boss farthest from you on each work
section with a "B" .
Hi-Boy Sections:
Stick, Rotor,
Main, Grapple, and
Slasher
IN OUT
Drawing of typical valve to show marking of sections

prior to disassembly. Drawing of typical control valves to identify section
types and seals.
4-38
Sectional Valves
Items 6–8 Spool Seal & Retainer req'd only

on Saw Valve 30006847. Use Seal Installa-
tion Tool #30004315; follow instructions in
tool kit.
Drawing of typical valve work section to show major component parts. Inset shows the names of oil passages
within the valve.
Section Seals
Item Qty Description Item Qty Description
1 3 Square Seal 8 2 Spool Seal

2 1 Square Seal 9 2 Retainer Plate Screw
3 N/A Not Present 10 1 Transition Check Valve Cap
11 1 0 Ring Seal
Typical Work Section 12 1 Transition Check Spring
Item Qty Description 13 1 Transition Check Valve Poppet
14 1 Stripper Bolt
4 2 Back Cap Screw
15 1 Centering Spring
5 1 Back Cap
16 2 Spring Guide
6 3 Retainer Plate
7 2 Backup Ring NOTE: See Fig. 15 for Spool Pilot Caps
4-39
Sectional Valves
D Disassemble Valve Section Valve Bank Assembly
Refer to Service Instructions for Remote Control Op- F Assemble Valve Section
erators on the next page.
For valve spool insertion, refer to the topic Service In-
Item numbers in Steps D and E refer to Fig. 10. structions for Remote Control Operators on the next
1. If valve spool is to be removed, it should be tagged page.
or marked with its work section's identification
G Install Transition Check
number (from Step A).
When installing the transition check refer to Step E.
2. Spool seals (Item 8) and backup rings (Item 7)
Torque the cap (Fig. 10, Item 10) to 75 ft-lbs.
should be discarded.
H Assemble the Valve Bank
E Remove Transition Check
Place the valve bank components on a clean, flat surface
The transition check is located in the bottom center of
with the work ports facing up, the inlet on the left and
the work section housing.
the main relief facing toward you.
1. Remove the check valve cap (Item 10) and its 0-Ring
seal (Item 11) To assemble the valve bank, follow steps A through E
in reverse order.
2. Remove the check spring (Item 12) and the check
valve poppet (Item 13). 1. Return all relief valve cartridges to their proper
locations (see Step A).
NOTE: Only cylinder work sections (those with ports
blocked in neutral) have transition checks. 2. Coat the section seals with grease and place them
Swing and Saw Motor valve sections do not. in their proper grooves as shown in previous illus-
tration.
INSPECTION of Parts NOTE: Be sure valve sections are oriented correctly,
1. Inspect the spool bores, check seats and spools for with work ports facing up and downstream
deep scratches, gouges or excessive wear. It any of side (with section seal grooves) on the right.
these conditions exist, replace the section. Minor 3. Place the valve sections on the tie bolts in their
surface damage on the control spool and check proper sequence (see Step A). Torque the tie bolts
poppet may be carefully polished away with very in a cross pattern to 500 inch-pounds / 41.6 foot
fine crocus cloth. pounds [56,6 N•m].
2. Examine the machined surfaces of the valve hous-
ing for nicks and burrs that could cause leakage
between sections. Lightly stone these surfaces to
remove any rough spots.
A shallow milled relief area

(noted in Figure 9) extends across the O-Ring face of the
valve housing. It should not be stoned or ground off.
CLEANING of Parts

injury.
Compressed air used for parts cleaning must be regu-
lated at 30 PSI [210 kPa].
3. Wash all parts thoroughly in a clean solvent and
blow dry before beginning reassembly. Pay special
attention to the number and letters marked on the
parts in Step A. If any marks are removed during
cleaning, remark immediately.
4-40
Sectional Valves
Service Instructions for Remote Control with LOCQUIC™ Primer Grade NF and let dry. Apply
Operators Loctite™ 262 Red to threads.
Read these instructions carefully. Failure to follow these 3. Slide one of the spring retainers (Item 7) on to the
procedures can result in poor performance and / or end of the shoulder bolt (Item 3). Next, slide the
product failure. Make sure all work is done in a clean springs (Item 4 & 5) onto the shoulder bolt. Place
area, away from airborne dust particles. the other spring retainer on the end of the spool
Item numbers in text refer to following illustrations. and start the shoulder bolt into the hole by hand.
BE SURE THE SPRING RETAINER SLIDES FREELY.
A Valve Section Disassembly
4. Torque the shoulder bolt (Item 3) to 175 inch
1. Remove capscrews (Item 8) from both ends of the pounds and set the spool assembly aside to cure for
valve section. a minimum of 1 hour. After curing, test the shoul-
2. Remove end caps (Item 6), seal (Item 10) and end der bolt to be sure it withstands 125 inch-pounds of
cap tube (Item 11) from each end of the casting. breakaway torque.
3. Remove seal retainer (Item 2) and seals (Item 1 & 10) 5. Apply light grease to seals. Assemble O-Ring (Item
from the clevis end of the spool assembly. 10) on OD of seal retainer (Item 2) and O-Ring (Item
4. Grasp the spring end of the spool with a clean rag 1) in the end of the seal retainer.
and pull the spool with a twisting motion to remove NOTE: Seals are similar in size. Be sure to insert seals
it and the spring package assembly from the cast- (Item 1 & 10) in their proper locations. These
ing. Remove seal retainer (Item 2) and seals (Item 1 seals are not interchangeable.
& 10). Be sure to replace the spool seals with new 7. Make sure that the spool is the correct one for the
ones. housing and that the spool and housing are prop-
5. If shoulder bolt (Item 3) must be removed from the erly oriented (see Step A). Install one seal retainer
spool for replacement of parts, it may be necessary with O-Rings on spool. Apply a light coating of
to apply heat to the spool end and shoulder bolt hydraulic fluid to the spool and carefully slide it into
to loosen the adhesive that was applied to the the housing.
threads. Use heat carefully to avoid warping the 8. Lightly grease O-Ring (Item 10) and install it on the
spool. valve cap (Item 6).
B Preparation of Parts 9. Install end cap tube (Item 11) on seal retainer (Item
1. Clean the adhesive from threads of spool, shoul- 2) . Then slip end cap (Item 6) on the end cap tube
der bolt, housing and cap screw holes with Loctite (Item 11).
Chisel™ Gasket Remover. 10. Spray threads of the capscrews (Item 8) and the cap
screw holes in the housing with LOCQUIK™ Primer
Grade NF and let dry.
injury. Follow the adhesive manufac-
turer's instructions for proper cleaning and curing. Failure
to clean and prepare parts properly may result in assembly
Compressed air used for parts cleaning must be regu- failure.
lated at 30 PSI [210 kPa].
11. Apply Loctite™ 262 Red to threads of the two cap-
2. Wash all parts in solvent to remove grease and oil.
screws (8 Insert them through valve cap (Item 6)
Blow dry with filtered, dried compressed air.
and screw them into the valve housing. Tighten
C Valve Section Assembly capscrews evenly and torque to 100 inch-pounds
Product should be thoroughly tested to ensure proper (±17 inch-pounds)
operation before the valve is put into service. 12. Install seal retainer (Item 2) with seals on clevis end
NOTE: If shoulder bolt (Item 3) was not removed from of spool. Install end cap tube (Item 11) and valve
the spool, proceed to step 6. cap (Item 6) as shown in following illustration.
1. Place valve spool in a soft-jawed vise, with the inter- 13. Install two capscrews (Item 8). Tighten evenly and
nally-threaded end facing up. torque to 100 inch-pounds (± 17 inch-pounds ) to
complete the assembly.
2. Spray the threads of the new shoulder bolt (Item 3)
4-41
Sectional Valves
Drawing of typical valve work section to show components of pilot actuator (parts list below). All valves except
MAIN & STICK have spring assembly at “B” end of spool.
PARTS LIST
Typical Pilot Actuated Work Section
Quantities listed are for one complete valve section.
1 2 Seal, O-Ring – 1-1/2 x 1-5/16
2 2 RETAINER, Seal 8 4 CAPSCREW, Socket Head
3 1 SHOULDER BOLT 9 1 TUBE, End Cap
4 1 SPRING, Inner 10 4 Seal, O-Ring – 1-7/16 x 1-1/4
5 1 SPRING, Outer 11 1 TUBE, Spool Stop
6 2 CAP, Valve End
7 2 RETAINER, Spring
Valve Relief Cartridges

Main Relief
The main relief valve protects the hydraulic system
against overload pressures. It is located in the end inlet
housing and mid-inlet section of the main valve bank.
Following illustrates the arrangement of parts and the
serviceable seals. This is a cartridge type relief valve and
is removed from the control valve as an assembly for
replacement or cleaning.
Torque Note
When installing relief cartridges, torque them to a value
of 75 ft-lbs.
Main Relief PARTS LIST

Sectional view of typical main relief cartridge.
1 2 Seal, O-Ring
2 1 Seal, O-Ring
3 1 BACKUP RING
4 1 WASHER, Gasket
4-42
Sectional Valves
Valve Relief Cartridges
Port Relief Port Relief with Anti-Cavitation Check
The full-flow work port relief valve normally functions In some applications, cavitation and over-pressurization
when the valve spool is in the neutral position. Its pur- can occur simultaneously in the same work section. In
pose is to protect the function from induced load when these situations, a relief valve with an integral anti-cavi-
the main relief passage is blocked by the control valve tation check is used to protect the system.
spool. It also relieves spike pressures to reduce stresses The pilot-operated port relief works to protect the func-
on structural members caused by load shocks or fluc- tion from induced overload. The anti-cavitation check
tuations in the loading cycle. allows make-up oil to enter the low pressure side of the
The pressure setting is normally higher than that of the work circuit, e.g. to deal with a rapidly descending load,
main relief valve. Fluid is discharged from the work port or the volume differential between the base and rod end
passage to the tank return passage of the valve section. of a cylinder.
The work port relief valve shown below is shim ad- This port relief is used in the Grapple Cylinder, Saw Motor
justable and is used in both ports of the Grapple Rotor and Saw Feed “A” and “B” ports, and in the “B” ports of the
control valve and in the “A” Port of the Stick and Main Main and Stick Cylinder valves.
Boom valve sections.
Torque Note
Torque Note When installing relief cartridges, torque them to a value
When installing relief cartridges, torque them to a value of 75 ft-lbs.
of 75 ft-lbs.
Sectional view of typical port relief cartridge. Sectional view of typical port relief cartridge with
anti-cavitation check.
PORT Relief PARTS LIST PORT Relief PARTS LIST

1 2 Seal, O-Ring 1 2 Seal, O-Ring
2 1 BACKUP RING 2 1 BACKUP RING
4-43
Sectional Valves
4-44
Pilot Controllers
General Description
The control valves of the Loader are actuated by pilot
signals from hand and foot-operated controllers. Pilot
pressure and return oil are routed through two manifolds
located beneath the cab floor. Pressure and return lines
lead from these manifolds to the hand and foot con-
trollers.
The left joystick actuates the main boom and grapple
cylinders. The right joystick actuates the stick cylinder
and grapple rotor. The rocker pedal controls the swing
function.
Hand Controller (Joystick)

Functional Description View of operator's station, with cab removed, to show
The control joystick is a hydraulic proportional control the left joystick and the swing pedal.
manufactured by Kawasaki. A pivoting handle tilts a
disc which depresses one or another of the four plung-
ers protruding from the top of the valve block. Each
plunger is connected to a spring-loaded valve spool.
The valve spool pressurizes the port toward which the
control is moved.
Controller Components
All joystick hydraulic controllers have the same internal
components. Control command pressure is regulated by
the amount of resistance offered by the valve spool return
springs each control valve section.
Foot Controller (Pedal)

Functional Description
The swing controller is a foot-operated hydraulic pro-
portional control manufactured by Kawasaki.
A rocker pedal, which pivots from the center, is bolted
to the top portion of the controller, which protrudes
beneath the cab floor . As with the joystick, the pivoting
top plate presses against one of the control plungers,
releasing pilot oil flow to the swing control valve. See
parts diagram.
4-45
Pilot Joysticks - 569SM
Detail drawings show the handle bend angle for

Right and Left joysticks.
Parts List, Hand Controller

1 1 CASING 16 4 SEAL
2 1 PLATE, Port 17 1 PLATE
3 1 O-RING 18 1 JOINT
4 2 SHCS 19 1 PLATE, Circular
5 2 WASHER, Seal 20 1 NUT, Adjusting
6 1 PIN, Spring 21 1 NUT, Lock
7 1 BUSHING 22 1 LEVER
8 4 SPOOL 23 1 PIN, Spring
9 4 WASHER 24 1 BELLOWS
10 4 SPRING 25 1 KNOB
11 4 SPRING 26 1 BUSHING (not shown)
12 4 SEAT, Spring 27 8 CONNECTOR (not shown)
13 4 PLUG 28 8 SLEEVE, Insulating (not shown)
14 4 O-RING KIT, Seal (includes items 3,14,16)
15 4 ROD, Push
* 519SM/EHC Joysticks are not serviceable. Contact an authorized dealer.

4-46
Swing Pedal
S1 R
LEFT P = PRESSURE
S2 RIGHT
R = RETURN
Exploded view of pilot foot controller to show the major component parts.
Parts List, FOOT Controller

1 1 CASING 13 2 PLUG
2 1 COVER 14 2 SCRAPER (not shown)
3 2 SHCS, M8 x 30mm 15 2 O-RING
4 2 SPOOL 16 2 NUT, Lock M10
5 2 WASHER 17 2 SCREW, Set
6 2 WASHER 18 1 CAM
7 2 SPRING 19 2 BUSHING
8 2 SPRING 20 1 SHAFT, Cam
9 2 SEAT, Spring 21 1 SCREW, Set
10 4 WASHER 22 1 BELLOWS
11 2 ROD, Push - - KIT, Seal (includes items 12,14,15)
12 2 SEAL
4-47
Oil Cooler
10038422--A--OPS
Drawing of return side of hydraulic system to show path of return oil through oil cooler.
GENERAL DESCRIPTION
The purpose of the oil cooler is to remove heat from
oil returning from the working circuits of the hydraulic
system.
All oil returning from the upper and lower main valve
banks (Pumps No. 1 & 2, max pump flow 51 + 42 = 93
GPM) is passed through the oil cooler.
Oil returning from Pump No. 3 (swing) is routed directly
to tank through the return filter.
Because the cooler is rated for 100 full flow GPM at 250
PSI, no oil cooler bypass valve is required.
For cleaning instructions, see Scheduled Maintenance
section in the Operator's Manual.
Remove oil cooler guard by extracting four capscrews.

4-48
5-
Swing Motor

and follow all safety materials in the operator’s manual.
Swing motor
Table of Contents
Description.................................................................................................................. 3
Principles of operation...................................................................................... 3
Repairs............................................................................................................................. 5
Disassembly................................................................................................................. 5
Inspection of parts................................................................................................ 6
Assembly........................................................................................................................ 7
Troubleshooting.................................................................................................... 8
Parts breakdown..................................................................................................10
5-
Swing Motor
5-
Swing Motor
General Description
The hydraulic motor is used to rotate heavy loads at low
speeds, such as track drives on crawler cranes, drum
drives on road rollers, winch drives on fishing boats and
upper structures on log loaders. It has five or seven ra-
dial pistons that push on the throw of the crankshaft to
rotate it. It can be rotated in either direction from creep
to full speed.
There is very little internal friction or slip therefore, the

motor should never contribute to system overheating.
Hydraulic balancing of the distributor valve and piston
connecting rod assemblies reduce friction Wear com-
pensating rings on piston and valve spool reduce slip or
internal leakage.
Principles of operation
Oil is supplied by a pump to the distributor valve spool of
the motor. The valve directs the oil to two of the cylinders.
The pistons in these cylinders push down on the off center
throw of the crankshaft causing it to rotate.
The remaining cylinders exhaust their oil back through the

valve to the exhaust port. Oil supplied to the front port pro-
duces right hand rotation (clockwise). Oil supplied to the
rear port produces left hand rotation (counterclockwise).
The valve is keyed to the crankshaft so both rotate together

and port oil to each of the cylinders is succession. The tim-
ing is slightly out of phase so there is no dead spot at top
dead center.
5-
Swing Motor
The two wide center slots in the spool are the supple and
exhaust ports for the cylinders. The narrow end slots are
balancing grooves.
There is a hole down through each piston and connect-

ing rod to a window on the bottom of the connecting rod
shoe. The widow is only slightly smaller than the top of the
piston, which hydraulically balances the piston-connecting
rod assembly so that it rides lightly on the crankshaft. Oil
trapped in the window area provides the force that rotates
the shaft.
The restrictor (plug) in the connecting rod shoe has a tiny

hole through it to prevent excessive loss of oil into the
crankcase.
Two half rings (piston retaining rings) and a snap ring

(circlip) hold the piston and connecting rod together. Two
large rings (connecting rod retaining rings) keep the con-
necting rods aligned withe the crankshaft.
There are two split rings in the piston ring groove. The top
ring (piston backing ring) pushes down on the bottom ring
(piston ring), forcing it out against the cylinder wall. As the
piston ring wears it will continue to seal against the cylinder
wall providing the wear compensation feature. The blue
piston backing ring is nylon and the white piston ring is
glass filled Teflon so that they do not stick together.
5-
Swing Motor
Repairs
Tools Required:
Hex wrenches
3/8"-24 bottoming tap
1/2"-20 bottoming tap
2" to 5" ring compensator
8" bent nose snap ring pliers (internal)
Tools Helpful But Not Required:

Two 3/8"-24 x 2 flat point socket set screws
Two 1/2"-24 x 3 flat point socket set screws
1/2"-20 eye bolt
3/4"-16 eye bolt
Hoist
Screwdriver that exactly fits restrictor slot
Disassembly
Clean motor and repair area thoroughly before starting
repairs. Set motor on its end cap with shaft up. Remove Pull each piston connecting rod assembly back into the
shaft nut, washer and key. Remove any burrs or sharp edges crankcase and take them out. Remove the snap ring from
of keyway so they will not damage the shaft seal when the the pistons to separate them from the connecting rods.
front cover is removed. Mark the cylinders, connecting rods and pistons so they can
be returned to the same cylinders. The pistons and con-
necting rods are interchangeable, but it is best if they are
returned as they came out.
Run a bottoming tap into the jack screw holes in the front
cover and blow them out to clean them. (If these threads
are stripped the motor cannot be taken apart.) Remove the Lift the Oldham's coupling out of the end of the valve spool.
front cover capscrews. Wedge a round file in the hole in the end of the valve spool
and lift the spool until it can be grasped and lifted out. If
the spool will not come out this way, it will be necessary to
Turn socket cap screws into jack screw holes until they remove the end cap and tap the spool out.
bottom. Two front cover screws may be used if socket cap
screws are not available. The front cover screws are too
short, however, to lift the plate off. Shim stock will have to Usually, no further disassembly is necessary. The cylinder
be put under then to jack the plate the rest of the way off. heads should be removed only if they have been leaking.
Turn in the screws about one half turn at a time. Turn then The valve housing should be removed only if the bore is
alternately so the plate can come up evenly. scored or if it has been leaking. .
Lift the plate off carefully so the seal and shims are not
damaged. Lay it down so she bearing side is up. Put the
large o-ring back on the cover plate on top of the shims.
Remove the jack screws from the cover.
5-
Swing Motor
Inspection of parts Restrictors

If the splines are damaged or badly worn, the shaft Restrictors are very difficult to remove as they are installed
must be replaced. Grooves in the shaft under the seal with Loctite. A screwdriver exactly fitting the slot is neces-
lips can be salvaged with a speedi-sleeve. Cut off the sary for removal.
speedi-sleeve with tin snips so it will extend just past
the seal when installed. Tap it onto the shaft until the lip O-rings
is against the bearing. Peen the edge down against the Only the front cover o-ring needs to be replaced unless the
shaft so it can not cut the seal. others are leaking or have hardened.
Polish off any roughness on the throw shaft. Use fine

emery cloth because the surface is hard. The surface Pistons
must be smoother than a finish grind. Vertical scratches are normal and can be polished to
remove any raised material. Scored pistons should be re-
placed. Piston sockets are rarely damaged because of their
hardness.
Motor Case
If the cylinder bores are deeply scored the motor case
must be replaced. Light scratches are normal and can be Connecting Rods
polished out by hand so they do not wear the piston rings. Normally, the connecting rod ball has a mirror finish on the
Light honing is permissible if little metal is removed. The top half. If it is scuffed or scored the rod must be replaced.
diametral piston to bore clearance should be .0005" to .005". The connecting rod may be reused if the window frame is
Remove any burrs or sharp edges from ends of the cylinder no heavily worn, damaged or heavily scored. The window
bores. recess must be .010" deep minimum.
Bearings Valve Housing

Discolored or pitted bearings must be replaced. One or two Scratches in the bore are not detrimental and may be pol-
lines on the rollers are not serious. The bearings are pressed ished out. Light honing is permissible. Valve spool to bore
on and cannot be removed without damaging the cage. diameter clearance must be .0005" to .005".
Highly polished rollers or cup indicate high loading and the
bearing is about to fail. Discoloration or polish on one end
of the rollers indicates improper shimming. Valve Spool
Scored valves must be replaced. Light scratches (normally
too light to catch with a fingernail) are permissible.
Piston and Valve Rings
These need to be replaced only if there is visible wear. These
are normally shipped uncut. See following for proper meth- Connecting Rod Retaining Rings
od of cutting. Where iron rings are used, the gap should be Broken or deformed rings must be replaced.
not more than .031".
Detail of valve displaying scarf cut-
ting angles for plastic seals. Note the Shaft Seal
two rings of opposite hand are fitted It is recommended that the shaft seal be replaced when
to each groove and that the chamfer repairing the motor.
on each ring runs next to the wall of
the groove.
Detail of piston displaying scarf

cutting angles for seal ring. Note the
relative positions of the two rings.
The ring must not be fitted upside
down.
5-
Swing Motor
Assembly Before installing the front cover make certain the surfaces
of the motor case and front cover are smooth. Put the
Some motors have iron valve rings. The gaps should not
shims on the front cover and check that they are smooth
be together. These rings break easily, so expand them only
and undamaged. Push the front cover o-ring down firmly
far enough to get them over the end of the spool. A ring
against the shims. Screw the socket set screws into tow
compressor is necessary to fit the spool into the bore. After
of the tapped holes in the motor case to guide the cover
inserting the spool into the bore, replace the valve end cap
plate. Lift the cover plate onto the motor taking care not to
and turn the motor shaft end up.
damage the shaft seal. A thin sleeve covering the splines is
necessary to protect the high pressure shaft seal. Tap the
Valve spools having nylon valve rings can be inserted down cover place with a plastic or rawhide hammer to start it into
through the valve housing without a ring compressor. Both the motor case.
ends of the valve spool and the crankshaft are stamped
with the letters TDC and an arrow. Mark the motor case at
Remove the socket set screws and start all the cap screws
the spot where the arrow on the valve spool points.
by hand. Tighten them alternately a little at a time to pull
the cover plate down evenly. Turn the shaft by hand. If it
Replace the cylinder heads if they have been removed. will not turn add shims. Tighten all the bolts in the motor to
Attach the connecting rods to the pistons and insert them the correct torque specification according to the following
into the cylinder bores. These should slip in easily without chart:
using force. Drop in the bottom connecting rod retaining
ring and lift the two connecting rods nearest your mark on
the crankcase of the rings and push the pistons into the 5/16 UNF 27 lb/ft (37 Nm) +/- 5 lb/ft (7 Nm)
bores. 3/8” UNF 45 lb/ft (61 Nm) +/- 5 lb/ft (7 Nm)
1/2” UNF 110 lb/ft (149 Nm) +/- 10 lb/ft (14 Nm)
Center the Oldhams's coupling in the slot in the valve spool. 5/8” UNF 215 lb/ft (292 Nm) +/- 20 lb/ft (27 Nm)
Turn the shaft so its TDC and arrow point toward the mark 3/4” UNF 355 lb/ft (481 Nm) +/- 20 lb/ft (27 Nm)
on the motor case and lower it into the motor. Rotate the
shaft slightly back and forth until it engages the coupling.
Lift the other connecting rods over the bottom retaining
ring and drop on the top ring. Rotate shaft, it should turn
easily.
Reshimming will be necessary if the shaft, motor case or

bearings have been replaced. Some motors have a 0.31"
thick steel shim. Plastic shims are .002", .005" and .010" thick.
Motors are shimmed so that there will be .002" to .004"
shaft preload. Shims are removed to reduce end play.
One way to determine the shimming needed is to remove

all shims, bolt down the front cover and measure the gap
between the plate and motor case with a feeler gage. An-
other is to use a height gage. Install all shims, then rap the
shaft sharply to seat it in the lower bearing. Set the magnet-
ic base of the height gage on the machined surface of the
motor case and zero in the dial indicator on the end of the
shaft. Lift the motor by using the eye bold in the end of the
shaft with a hoist. The dial indicator will read the end play.
Install the new shaft seal in the cover plate. It should be

pressed in, using a ring slightly smaller than the seal. The
open end of the seal faces inward. High pressure seals have
two lips pointed in.
5-
Swing Motor
Troubleshooting
Contamination
If a motor has been damaged by material entering it
through the oil (contamination) the valve spool will be
scored in the areas shown. If the scoring is severe the top
halves of the pistons may also be scored. This material can-
not get into the crankcase.
Heaviest scoring a "A" means dirt in the oil. Heaviest scoring

at "B" means the motor overheated. Heaviest scoring at "C"
means the contamination came from inside the crankcase.
Also, check the location of scoring in the cylinders.
Overheating
Overheating is caused by an oil supply which is too hot, the
wrong kind of oil or too much friction inside the motor. If
the oil supply temperature is higher than 180 D Fahrenheit
(82 D Celsius), the oil may char and the inside of the mo-
tor is dark brown or black. Occasionally, the valve spool is
scored its entire length and the rings are distorted. Some-
times on or more pistons will be scored particularly at area
"B".
If wrong oil is used, the pistons may be scored at area "B".

The polished area at the connecting rod balls will have a
bluish cast, be scuffed or scored. The under side of the balls
will be brown from charred oil. The connecting rod shoes
may be damaged also.
If the throw of the crankshaft, is not smooth enough it will

generate heat and may damage the connecting rod shoes.
Always inspect the crankshaft for smoothness.
Cavitation
This occurs when the motor is starved of fluid and can stem
from several causes. If the oil supply is shut off while mo-
tor is running, it will cavitate. If the motor overruns the oil
supply, it will cavitate. Connecting rod retaining rings will
be distorted or broken if cavitation has occurred. The only
other reasons for these rings being damaged comes from a
piston sticking in its bore or high case pressure.
5-
Swing Motor
Troubleshooting
Motor overloaded
If the motor is operated at excessive pressure, the valve
housing or a cylinder head could crack. Seals might leak.
Both the polished area on the connecting rod ball and the
connecting rod shoes will show signs of wear and the bear-
ing rollers will be polished or pitted.
Overhung load too great

If the front bearing shows signs of wear and the rear bear-
ing does not, the side load on the shaft is too great. In
extreme cases it may break the shaft between the front
bearing and the throw.
Improper shimming
If the bearing rollers are highly polished or pitted only on
the outside ends, there has been too much shaft end play.
If the bearings have overheated and the shaft cannot be
turned by hand it is too tight and shims must be added.
Shaft seal blown

A blown shaft seal is caused by high crankcase pressure.
This can be due to severe internal damage or the drain line
sized too small or blocked.
Failure to prefill the crankcase

If everything inside the crankcase is blue and the rest of the
motor is not, the crankcase has not been prefilled. Always
prefill the crankcase after installation and before operating.
Spline wear
This can be caused by dirt in the splines, coupling misalign-
ment, or the mounting not being rigid. If the coupling
slides back and forth on the shaft the spline will wear out.
5-10
Swing Motor
5-11
Swing Motor
ITEM QTY DESCRIPTION
1 1 CASE, Motor
2 1 COVER, Front
3 1 BEARING, Front
4 1 BEARING, Rear
5 5 HEAD, Cylinder
6 5 SEAL, Piston
7 5 SEAL, Backing
8 2 RING, Retaining, Connecting Rod
9 A/R SHIM, Plastic, .002
10 A/R SHIM, Steel, .032
11 1 SEAL, Shaft
12 1 O-RING
13 5 O-RING
14 55 SHCS, M10 x 1.50 x 30 mm
15 -
16 2 PLUG, Drain
17 2 SEAL, Bonded
18 1 HOUSING, Valve
19 1 SPOOL, Valve
20 1 END CAP, Valve
21 12 RING, Seal, Valve
22 1 COUPLING, Oldham
23 1 O-RING
24 5 O-RING
25 2 O-RING
26 1 O-RING
27 4 SHCS
28 5 SHCS
29 5 PISTON
30 5 ROD, Connecting
31 5 FILTER
32 5 SCREW, Restrictor
33 10 RING, Half, Piston Retaining
34 5 CIRCLIP
35 1 CRANKSHAFT
36 1 KEY
37 1 PIN, Spliot
38 1 WASHER
39 1 NUT
42 1 VALVE ASSEMBLY (includes items 18 - 21, 23, 24, 26 & 27)
43 1 O-RING
44 1 KIT, Seal (includes items 6, 7, 9, 11 - 13, 17, 21, 23 - 26, 40 & 41)
5-12
Swing Motor
5-13
Swing Motor
ITEM QTY DESCRIPTION
1 5 HHCS
2 1 CAP, End
3 2 PLUG
4 6 O-RING
5 12 SEAL
6 1 SPOOL, Valve
7 -
8 -
9 -
10 5 HHCS
11 1 HOUSING, Valve
12 1 BEARING, Rear
13 1 O-RING
14 5 O-RING
15 1 CASE, Motor Swing
16 2 SEAL, Bonded
17 2 PLUG, Drain
18 -
19 1 COUPLING, Valve
20 2 RING, Retaining
21 1 CRANKSHAFT
22 5 SCREW, Restrictor
23 5 ROD, Connecting
24 5 PR RING, Retaining
25 5 FILTER, Piston
26 5 CLIP
27 5 PISTON
28 5 RING, Backing
29 5 SEAL, Piston
30 50 HHCS
31 5 HEAD, Cylinder
32 1 BEARING, Front
33 1 O-RING
34 1 COVER, Front
35 1 HHCS
36 A/R SHIM
37 A/R SHIM
38 A/R SHIM
39 1 SEAL, Crankshaft
40 1 PLATE, Shim
41 5 HHCS
42 1 VALVE (not called out)(includes items 1-6, 10, 11, 13 & 14)
43 1 KIT, Seal (not shown)
5-14
Swing Motor
6-39
Mechanical Service
Cross Section Drawing
T a b l e 3 : S c r e w T h r e a d S i z e s a n d T i g h te n i n g T o r q u e
I te m W i d th T i g h te n i n g
P a rt Na me S iz e
No. A c r o s s F la t T orque
H e x S oc k e t H e a d M1 4 ( I S O 7 2 4 ) 1 1 8 ft-lbs
602 1 2 mm
C a ps c re w ( S H C S ) x 1 3 0 mm [1 6 0 N -m]
901 P lug P T 1 /2 1 0 mm 4 8 ft-lbs [6 5 N -m]
925 P lug, V e nt P T 1 /4 1 4 mm 1 6 ft-lbs [2 2 N -m]
926 F itting, Z e rk P T 1 /4 1 4 mm 1 6 ft-lbs [2 2 N -m]

6-40
Mechanical Service
6-
Mechanical Service

The information in this section will help the Service Technician to maintain and repair the mechanical components
of the machine.
Mechanical service
Table of Contents
Hydraulic Swivel....................................................................................... 6-2
Hydraulic Swivel Seal Installation
Tools........................................................................................................... 6-3
Procedure............................................................................................... 6-3
Hydraulic Swivel Installation........................................................ 6-4
Torque Specifications
Torquing Procedure....................................................................... 6-6
Swing Bearing....................................................................................... 6-7
Swing Motor.......................................................................................... 6-7
Hyd Swivel Mounting...................................................................... 6-9
Stationary Heel Mounting.......................................................... 6-9
Hydraulic Fittings..........................................................................6-10
Bolts, capscrews, & studs..........................................................6-12
Hydraulic Cylinder Torques....................................................6-14
Structural Inspection Procedure
Daily...........................................................................................................6-15
Weekly.......................................................................................................6-15
Swing drive overhaul
Table of Contents............................................................................6-16
Information on vended components reprinted by permission. This manual has been compiled from materials
available at the time of approval for reproduction. Manufacturer reserves the right to improve its products
without giving prior notice or incurring obligation.
6-
Mechanical Service
6-
Mechanical Service
TORQUE SPECIFICATIONS
for Knuckle Boom Loaders
Always have the engine shut down for maintenance and service operations
unless the procedure requires the engine running. Some of the procedures used
in torquing critical fasteners require the engine to be running. Only qualified technicians shall perform these
procedures. To avoid serious personal injury or property damage, do the following before performing these
operations:
1. Move the machine to a firm, level work area large Keep all personnel away from an unsupported
enough to swing the turntable through a com- boom. Extend stick cylinder to straighten boom
plete revolution. Set parking brake. and rest attachment on the ground with jaws
Designate an operator. open.
2. Have operator raise stabilizers so loader rests on 4. Be sure the operator knows where you are and
carrier tires. Then lower stabilizers so they rest on what you want done. Agree on signals.
the ground without raising the loader. 5. Before disconnecting lines, turn off engine and
3. Severe personal injury or death may result from relieve pressure in all circuits. Allow oil to cool
unexpected movement of hydraulic cylinders. below 120° F [49°C].
TORQUING INSTRUCTIONS
Tightness values given must be developed and regularly maintained using a good-quality torque wrench. The
values given in these torquing instructions apply to clean, lightly-oiled threads.
All bolts, capscrews and studs used in the assembly of Knuckle Boom Loaders are of Grade 8 or greater quality
and all flat washers are specially hardened for the applications in which they are used, unless otherwise specified.
Exceptions would be components supplied by vendors such as engines, clutches and seats. If a fastener on one
of these vended components requires replacement, use a fastener of the same grade as the original. Always use
grade-matched fastener hardware (nuts, bolts, washers and cap screws) when maintaining or repairing the ma-
chine.
IMPROPER TORQUING CAN RESULT IN FAILURE OF THE FASTENER.

When checking torque of capscrews or bolts in a ring, such as the swing bearing or swing drive, use the cross-tight-
ening method, such as 12 o'clock to 6 o'clock, and 9 to 3, then 1 o'clock to 7 o'clock and 10 to 4, and so on, until all
fasteners have been evenly checked or tightened. It will be necessary to start the engine and operate the loader in
order to reach these fasteners.
When checking torque of capscrews with nuts on the swing bearing, place the torque wrench on the capscrew
head while holding the nut (if present) with another wrench. Because some of these fasteners do not have nuts,
this is done to ensure that all capscrews will be consistently tightened.
Swing bearing outer race capscrews have no nuts and are tightened from above, with access through openings in
the turntable deck. Access openings are provided at 180° intervals.
Swing bearing inner race capscrews are all tightened from below, with access through openings in the sub frame.
Access openings are provided at 180° intervals. Capscrews located beneath the main boom cylinders are threaded
into the cylinder mounting blocks.
LOOSE SWING BEARING bolts OR CAPSCREWS CAN CAUSE THE UPPER AND
LOWER FRAME TO SEPARATE, resulting in severe injury or death.
Always be sure that the fasteners shown in this section are regularly maintained. See the maintenance schedule in
the Operator's Manual.
Follow these steps if a loose bolt or capscrew is found on the swing bearing:
1. Torque any loose fastener according to the information in this section. Recheck the fastener every
10 hours of operation until torque stabilizes. Do not use an air wrench for this step.
2. Check fasteners adjacent to the loose fastener for proper torque. Recheck fasteners adjacent to the loose fas-
tener every 10 hours of operation until torque stabilizes. Do not use an air wrench for this step.
If any fastener does not tighten to the specified torque value, replace it with the correct new fastener. Clean thor-
oughly, then lubricate with SAE 30 non-detergent oil. Fasteners adjacent to the failed fastener must also be re-
placed. Verify torque on any new fastener after 10 hours’ operation (do not use an air wrench).
6-
Mechanical Service
SWING BEARING AND SWING MOTOR MOUNTING BOLTS
TURNTABLE
sWing
motor
OUTER
drive
gearbox
mtg. capscrew
SWING 437-483 ft-lbs
BEARING INNER [593-655 n-m]
hardened
Washer
Inner Fasteners:
Torque (lubed threads)
500 Ft-Lbs [678 N•m]
SUBFRAME
Turntable Weldment
Outer Fasteners:
Torque (lubed threads)
500 Ft-Lbs [678 N•m]
Swing bearing
Swing bearing inner race
outer race
SWING BEARING
SECTIONAL VIEW
Subframe Weldment
Bolt Circle Torquing Procedure: Torque to specification using a cross-tightening method until all fasteners are
properly tightened.
6-
Mechanical Service
6-
Mechanical Service
Stationary Heel
spacer
CHECK STATIONARY HEEL FASTENER TORQUE
Check that the stationary heel fasteners are torqued at 340-

370 ft. lb. [461–502 N·m] torque.

6-
Mechanical Service
Hydraulic Fittings
JIC
SAE 37 Degree Flare Fitting
How it works: This connection seals on the two mating 37 degree seats located on the male
half and inside the female half of the fitting.
How to tighten: Using a torque wrench, rotate the nut to tighten. Tighten the nut to the correct
torque specification listed in the chart below. Always use two (2) wrenches
when tightening.
THREAD TORQUE TORQUE

SIZE SIZE NEWTON - METERS INCH - LBS
-3 3/8 - 24 11 -12 95 - 105

-4 7/16 - 20 15 -16 135 - 145
-5 1/2 - 20 19 - 21 170 - 190
-6 9/16 - 18 25 - 27 215 - 245
-8 3/4 - 16 49 - 53 430 - 470
-10 7/8 - 14 77 - 84 680 - 750
-12 1 1/16 - 12 108 - 118 950 - 1050
-14 1 3/16 - 12 113 - 124 1000 - 1100
-16 1 5/16 - 12 147 - 153 1300 - 1360
-20 1 5/8 - 12 172 - 180 1520 - 1600
-24 1 7/8 - 12 215 - 225 1900 - 2000
-32 2 1/2 - 12 332 - 350 2940 - 3100
The torque specifications above are good for 37 degree swivel connections which include:
Machined adapters and hose fittings
Flared tube (with sleeve and nut)
Universal radius flared tubes
The following are the three (3) main reasons why 37 degree swivel connections leak:
CAUSE CURE
Lack of proper tightening Always use the recommended torque for max-
imum service life.
Damaged or worn 37° seat Be sure that the tube flare or angled surface of
fitting is not distorted or deformed.
Misalignment Be sure to correctly align hydraulic fittings before
engaging threads.
6-
Mechanical Service
Hydraulic Fittings
ORFS
O-ring Face Seal Fitting
O-Ring
Male Half Female Half
How it works: This connection seals with an O-ring on the male half against a flat surface in the
female half of the fitting.
How to tighten: Using a torque wrench, rotate the nut to tighten. Tighten the nut to the cor-
rect torque specification listed in the chart below. Always use two (2) wrench-
es when tightening.
THREAD TORQUE TORQUE

SIZE SIZE NEWTON - METERS INCH - LBS
-4 9/16 - 18 14 - 16 120 - 144

-6 1 1/16 - 16 24 - 27 216 - 240
-8 1 3/16 - 16 43 - 47 384 - 420
-10 1 - 14 62 - 68 552 - 600
-12 1 3/16 - 12 88 - 95 780 - 840
-16 1 7/16 - 12 125 - 136 1104 - 1200
-20 1 11/16 - 12 170 - 190 1500 - 1680
-24 2 - 12 204 - 224 1800 - 1980
The following are the three (3) main reasons why ORFS fittings leak:
CAUSE CURE
Lack of proper tightening Always use the recommended torque for maximum
service life.
No O-ring in the groove Be sure that the o-ring does not fall out of the
male end before connection is made. Petroleum
jelly will help hold o-ring in place.
Improper O-ring size It is critical that the correct size of o-ring be
used. caterpillar forest products Inc. of-
fers an ORFS O-ring Kit through Service Parts.
Always install a new O-ring whenever the fitting
is opened for service.
6-
Mechanical Service
Bolts, Capscrews and Studs

Lubricated Threads Only
Bolt identification:
Grade 5 - Identified by three (3) equally spaced radial lines embossed
on the head of the bolt. See figure 1.
Grade 8 - Identified by six (6) equally spaced radial lines embossed on
the head of the bolt. See figure 2.
Grade 5
Figure 1
NOTE: These specifications do not apply to self-locking nuts or capscrews.

To obtain proper torque, use no lockwashers. Hardened flat washers are
recommended.
GRADE 5
COARSE THREAD (NC) FINE THREAD (NF)
Nominal Size Torque (Ft-Lbs) Nominal Size Torque (Ft-Lbs)
1/4 - 20 6-7 1/4 - 28 7-8

5/16 - 18 12 - 14 5/16 - 24 13 - 15
3/8 -16 22 - 24 3/8 -24 24 - 26
7/16 - 14 33 - 37 7/16 - 20 38 - 42
1/2 - 13 52 - 58 1/2 - 20 62 - 68
9/19 - 12 76 - 84 9/19 - 18 85 - 95
5/8 - 11 104 - 116 5/8 - 18 123 - 137
3/4 - 10 190 - 210 3/4 - 16 209 - 231
1-8 418 - 462 1 - 12 456 - 504
1 1/8 - 7 570 - 630 1 1/8 - 12 627 - 693
1 1/4 - 7 798 - 882 1 1/4 - 12 874 - 966
1 3/8 - 6 1045 - 1155 1 3/8 - 12 1197 - 1323
1 1/2 - 6 1387 - 1533 1 1/2 - 12 1558 - 1722
1 3/4 - 5 1872 - 2068 1 3/4 - 12 2460 - 2720
6-10
Mechanical Service
Bolts, Capscrews and Studs

Lubricated Threads Only
Bolt identification:
Grade 5 - Identified by three (3) equally spaced radial lines embossed
on the head of the bolt. See figure 1.
Grade 8 - Identified by six (6) equally spaced radial lines embossed on
the head of the bolt. See figure 2.
Grade 8
Figure 2
NOTE: These specifications do not apply to self-locking nuts or capscrews.

To obtain proper torque, use no lockwashers. Hardened flat washers must be used
with these fasteners.
GRADE 8
COARSE THREAD (NC) FINE THREAD (NF)
Nominal Size Torque (Ft-Lbs) Nominal Size Torque (Ft-Lbs)
1/4 - 20 8-9 1/4 - 28 9 - 10

5/16 - 18 17 - 19 5/16 - 24 19 - 21
3/8 -16 33 - 36 3/8 -24 34 - 37
7/16 - 14 52 - 57 7/16 - 20 53 - 58
1/2 - 13 76 - 84 1/2 - 20 86 - 94
9/19 - 12 105 - 115 9/19 - 18 124 - 136
5/8 - 11 162 - 178 5/8 - 18 171 - 189
3/4 - 10 266 - 294 3/4 - 16 304 - 336
7/8 - 9 437 - 483 7/8 - 14 475 - 525
1-8 646 - 714 1 - 12 703 - 777
1 1/8 - 7 912 - 1008 1 1/8 - 12 979 - 1081
1 1/4 - 7 1292 - 1428 1 1/4 - 12 1425 - 1575
1 1/2 - 6 2242 - 2478 1 1/2 - 12 2527 - 2793
1 3/4 - 5 3048 - 3688 1 3/4 - 12 4004 - 4424
6-11
Mechanical Service
C Y L INDE R T O R Q U E S P E C IF IC A T IO NS
G r a d e 8 Z i n c – p l a te d H e x H e a d C a p S c r e w s , D r y
ft. lbs . N•m

7
/16– 1 4 U N C 76– 84 103– 114
1
/2– 1 3 U N C 105– 115 142– 156
G r a d e 8 E l a s ti c L o c k N u ts , P h o s . a n d O i l F i n i s h , L u b r i c a te d T h r e a d s
ft. lbs . N•m
1– 14 U N F 540 732
1 1/4– 1 2 U N F 750 1017
1 3/8– 1 2 U N F 1000 1356
1 1/2– 1 2 U N F 1200 1627
1 3/4– 1 2 U N F 1500 2034
2 1/4– 1 2 U N F 2500 3390

6-12
Mechanical Service
STRUCTURAL INSPECTION PROCEDURE

DAILY OR EACH SHIFT
Visually inspect the Main Boom, Stick Boom, Main Boom Cylinders, Stick Boom Cylinders, Turntable,
Swing/Gear Mounting and Grapple for signs of cracks. If indications of a crack are seen, clean the suspect
area and inspect carefully as per the weekly inspection procedure.
WEEKLY
Clean the structures thoroughly. Remove all dirt, mud, grease, oil, debris and snow. Use a solvent as
needed to remove oil or grease. Look particularly for rust lines in the paint, missing or cracked paint.
These are indications of crack sites. Normally a visual inspection is adequate, BUT if in doubt use a por-
table light, wire brush, probe, a 10x magnifying glass, magnetic particle, dye penetrant or other nonde-
structive testing equipment as needed. An inspection MUST be conducted on all welds and adjacent
areas.
To ensure all areas of the main boom and stick boom are exposed for inspection:
1. Extend the stick boom to full reach and open the grapple all the way. Lower the main boom to place
the grapple on the ground and relieve all hydraulic pressures by operating the controls with the en-
gine shut down, but with the electric circuits still turned on. Shut off electric power and remove the
key. Inspect the grapple around the cylinder and jaw mountings, the jaws, the rotator mounting and
frame.
2. With the loader in the same position as #1, check the stick boom. Make sure all welds can be seen for
complete viewing and evaluation. It may be necessary to fold the stick boom under the main boom
to inspect some of the welds.
3. Again with the loader in the same position as #1, check the main boom. Depending on the mount-
ing height and size of the loader it may be necessary to use some form of working platform to elevate
the inspector high enough to see both the main boom foot, point and cylinder attaching areas. Make
sure that all welds are completely inspected. It will be necessary to fully raise the main boom to
inspect the underside of the main boom foot. Use cylinder locks to hold the main boom in the raised
position. Do not place the inspector under any part of the loader without mechanical blocking the
main boom and stick boom. Check all cylinders and pin retainers for broken ears or bolts.
4. With the main boom raised at approximately 45' to horizontal inspect the head sides and the main
boom cylinders. Use mechanical cylinder locks on the main boom cylinders. Do not place the inspec-
tor under any part of the loader without mechanical blocking in place.
5. Check the mounting to the truck or trailer frame, where applicable. Ensure that the bolts are tight and
any spacers are in good condition and in their correct locations.
6. Check the sub-frame and stabilizers, where applicable. Check the areas around the swing bearing
mounting, the stabilizers and their mounting ears, and the stabilizer cylinders and their mountings.
If a crack is found, call Product Support for further instructions.
EVERY 250 HOURS

Check the swing drive mounting bolts for correct tightness. If any fastener will not torque to the correct
specification, remove it and the two on either side of it. Replace all three fasteners (and hardened wash-
ers) with new ones. Verify torque on any new fastener after 10 hours’ operation.
EVERY 500 HOURS

Check the swing bearing mounting bolts for correct tightness. If any fastener will not torque to the cor-
rect specification, remove it and the two on either side of it. Replace all three fasteners (and hardened
washers) with new ones. Verify torque on any new fastener after 10 hours’ operation.
Mechanical Service 6-13
Mechanical Service
Swing Drive Gearbox Service
CONTENTS
DESCRIPTION Page
1. Introduction....................................................................................8-20
2. Construction...................................................................................8-20
3. Installation
3.1 Installation Procedure.................................................................................8-20
3.2 Gear oil / Grease............................................................................................8-21
3.2.1 Supply oil volume..............................................................................8-21
3.2.2 Oil brand...............................................................................................8-21
3.3 Cautions before operation........................................................................8-21
3.4 Cautions for operation................................................................................8-21
4. Troubleshooting..............................................................................8-22
5. Service Procedures
5.0 Safety Precautions........................................................................................8-23
5.1 Exploded View...............................................................................................8-24
5.2 Part inspection procedures and replacement criteria.....................8-26
5.3 Disassembly / Reassembly........................................................................8-28
5.3.1 Thread size used and Tightening torque...................................8-28
5.3.2 Tools used.............................................................................................8-28
5.3.3 Disassembly procedures...............................................................8-29
Assembly procedures..................................................................................8-33
5.3.5 Special Tools........................................................................................8-38
Installation..............................................................................................................8-39
Part list......................................................................................................................8-40
Cross-section..........................................................................................................8-41
The following information is taken from the

Kawasaki RG10D20 Instruction Manual,
Document #02293710, dated Sept. 2000
Reprinted with permission

6-14
Mechanical Service
Swing Drive Installation
sWing
motor
drive
gearbox
mtg. capscrew
437-483 ft-lbs
[593-655 n-m]
hardened
Washer
INDEX MARK
Fig. 1: Drawing shows swing drive installed. Index mark all swing components prior to removal.
T A B L E 1: S W IN G DR IV E G E A R R A T IO S
S un gea r P l a n e ta r y g e a r R ing gea r R e d u c ti o n r a ti o
1 s t s ta g e 14 18 52 i1 = 4 . 7 1 4 3
2 n d s ta g e 16 17 52 i2 = 4 . 2 5
T o ta l r a ti o i1 x i2 = 2 0 . 0 4
1. INTRODUCTION
This gear-reduced motor is composed of the following: The tooth count of each gear is shown in Table 1.
1) Hydraulic motor ———— M5X180
3. Installation
2) Reduction gear ———— RG10D20**
3.1 Installation Procedure
This manual describes the Service procedures for the
Reduction Gear Drive. For Hydraulic Swing Motor Ser- Fig. 1 shows an installed view of the swing drive assem-
vice refer to Swing Motor section. bly.
Install the swing motor on top of the gearbox. Align the
2. CONSTRUCTION index marks (Fig. 1) making sure to orient the oil supply
The weight of the unit is 374 lbs. [170 kg] port and dipstick port the way they were prior to remov-
The reduction gearing is accomplished through two al. Take care to connect the hoses as they were marked
planetary stages producing a total gear reduction ratio prior to removal.
of 20.04 to 1. The input shaft and output shaft both
rotate in the same direction.
6-15
Mechanical Service
3.2 Gear Oil / Grease

3.2.1 Gear Oil Volume / Grease Volume
1) Gear oil B
The fill port (A) is located on the motor bell housing
beneath the dual reliefs. The dipstick port is located
90 degrees counterclockwise from it (Fig. 2). Re-
A
move the fill plug and set the pipe and dipstick (Fig.
5 item 15 & 16) into the gear casing “DP” port. Put oil
into fill port (A) until gear oil shows on the lower part
of the dipstick (B) between the scale lines. About 0.9
gal. [3.4 liters] are required. Install the fill plug (Fig. 5
item 31)
2) Grease
Install grease fitting (C) in the “GN” port and the
vent plug in the “AN” port (D). Apply grease Fig. 2: Swing drive gear oil fill port (A) and dipstick
through the grease fitting until grease shows on (B).
the vent.
3.2.2 Lubricants (Gear Oil & Grease)
1) Gear oil
Use gear oil of SAE #90 - 140 weight, that is equiv-
alent to Service Classification GL3 to GL4. C
For vertical installation the gear case cannot be drained
completely, but this is not a problem. Oil may be replen-
ished at this stage. Different brands of oil, service class
GL3 or GL4, can be mixed.
When replacing oil, check the drained oil for for-
eign matter or large bits of debris. The presence
of larger particles would indicate the need for
service.
2) Grease
Use grease equivalent to EP type. Fig. 3: Swing drive “GN” port with output shaft
bearing grease fitting (C).
3.2.3 Recommended Replacement Standard
Gear oil: Maintenance Interval................1000 hours
Grease: Maintenance Interval................1000 hours
3.3 Cautions before Operation
1) Set the pipe and dipstick on the gear casing “DP”
port. D
Confirm that the gear casing is filled with gear oil
to the specified level.
2) Fill the hydraulic motor casing (through the case
drain port) with hydraulic fluid.
3.4 Cautions for Operation
1) Continue the running-in operation fully with a low
load, without abruptly applying load, for about fif-
teen minutes.
2) Pay attention to the casing temperature during
Fig. 4: Swing drive output shaft bearing grease
operation. This should be no greater than ATMO-
chamber vent plug (D).
SPHERIC temp. plus 140 degrees Fahrenheit
[+ 60 degrees Centigrade].
6-16
Mechanical Service
Troubleshooting
4. Troubleshooting Chart
Most mechanical problems that could occur with the swing drive gearbox are shown here. In
case of hydraulic trouble, however, refer to Hydraulic Swing Motor Section.
PROBLEM PROBABLE CAUSE POSSIBLE SOLUTION
1) Reduction gear will not ro-

tate.
Hyd. motor inlet pressure is suf- Overload Reduce Load.
ficiently high. Damaged reduction gear Replace reduction gear.
Swing brake is ON Check pilot pressure.
Check brake piston seal.
Hyd. motor inlet pressure is not
sufficiently high.
Rotation sound is heard in Motor shaft has broken Replace hydraulic motor.
hydraulic motor Reduction gear is damaged Replace reduction gear.
No rotation sound is heard in Abnormality in pump or valve Troubleshoot component and cor-
hyd. motor. rect the problem.
2) Oil Leakage.
Oil leakage from mating faces. Gearbox sealant improperly Disassemble gearbox and apply
applied sealant correctly.
Loose bolts have allowed mating Disassemble gearbox and assemble
faces to slip correctly.
Oil leakge around shaft
Damaged oil seal Disassemble gearbox and replace
oil seal.
2) Temperature is too high.

Reduction gear casing tem-
perature is too high Gear oil level is low Check dipstick and supply oil to cor-
rect level.
Bearing grease is insufficient Refill bearing cavity with grease.
6-17
Mechanical Service
Safety Precautions
5. SERVICE PROCEDURES
Dirt is the enemy of
5.0 Safety Precautions your hydraulic system.
Keep your tools and your work area clean.
To avoid serious per- Dirt that accumulates around relief valve cartridges
sonal injury or property damage, follow can be carried into threads while the cartridge is being
the steps below before performing any adjusted, possibly damaging the seals. Be sure to thor-
SERVICE on this machine. oughly clean components and their surroundings before
1. Fully extend boom, fully open grapple, and lower making adjustments.
boom and grapple to ground. Ambient dirt can enter a disconnected hose or tube
2. Raise stabilizers so loader rests on carrier tires. Then without the technician’s knowledge. Clean hose and
lower stabilizers so they touch the ground without tube fittings before disconnecting. Keep disconnected
raising the loader. hoses and tubes capped unless procedure requires that
they be left open. Always clean new lines or hoses prior
3. Shut down engine, leaving electric power on.
to installation by flushing and blowing out with filtered
4. Move joysticks in all directions to relieve hydraulic compressed air.
pressure on boom.
5. Disengage pilot controls by moving pilot shut- off Components under Warranty
lever all the way up to vertical position. may be disassembled ONLY with the permission of the
6. Turn off electric power and remove key from key Warranty Manager. Components returned under Warranty
switch. must be properly plugged before shipment.
These service instructions will familiarize you with the
component parts, the relative position of each part, the
Fluids escaping un- proper methods for disassembly and assembly and care
der pressure can penetrate skin and cause of the component so that the best performance and
severe Personal injury or death. longer service life will result.
DO NOT use your hands to search for leaks. To aid the repair of these units and before any work
Before disconnecting lines, relieve ALL pressure. is completed, we suggest that you first read all of the
If ANY fluid is injected into your skin, seek medical help materials in this section before beginning repair work
immediately. Serious infection can result without proper on the component.
medical treatment. Dirt is the enemy of any hydraulic system. The first
Before working on hydraulic system, follow BEFORE requirement for good maintenance of hydraulic equip-
MAINTENANCE OR SERVICE instructions in the Operator's ment is cleanliness. Disassemble and assemble hydrau-
Manual. lic equipment in a clean area.
Disassembly and Assembly NOTES:

FLYING DEBRIS FROM 1. Use care in gripping all parts in a vise to avoid dam-
CLEANING PARTS WITH COMPRESSED AIR CAN aging machined surfaces.
CAUSE SEVERE PERSONAL INJURY. 2. If prying off sections becomes necessary, take ex-
Wear eye protection and protective clothing. treme care not to mar or damage machined surfaces.
Compressed air used for parts cleaning must be regu- Excessive force while prying can result in misalign-
lated at a maximum of 30 PSI [2.07 bar]. ment and can seriously damage parts.
3. If parts are difficult to assemble, do not force them
and never employ an iron or steel-headed hammer.
IMPROPER LIFTING OF 4. Transmission parts are closely matched, so there-
HEAVY OBJECTS CAN CAUSE SERIOUS PERSONAL fore they should be kept together as sets when
INJURY. Always use a lifting device. removed from a unit. Handle with care to avoid
damage to these components.
5. Tighten fasteners with a torque wrench that has
SOME CLEANING SOL- been set to the correct value for the item being
VENTS ARE FLAMMABLE. installed.
To avoid possible fire, do not use cleaning solvents in an
area where a source of ignition may be present.
6-18
Mechanical Service
5.1 Swing Drive Exploded View
28
30
1
17
29 18
22
23
24
15
16
10
4
13
7 27
14
20
21
3 31
25
26
12
19
6
9 12
5 11
Fig. 5: Drawing shows an exploded view of the swing drive gearbox

6-19
Mechanical Service
5.1 Swing Drive Exploded View

Swing Drive Assembly 30009747
Part numbers are provided for convenience. Always verify part numbers before ordering.
Item KHI Item* Part Number Qty Part Name

0 - - 10048378 1 SWING DRIVE ASSEMBLY
0.2 - - 30009747 1 REDUCTION GEAR BOX ASSEMBLY
1 102 30009748 1 CASING
2 201 30009749 1 SHAFT, Drive
3 202 30008417 1 GEAR, Ring
4 203 30008418 4 GEAR, Planetary
5 204 30008419 1 GEAR, Sun
6 210 30008420 3 GEAR, Planetary
7 211 30009750 1 GEAR, Sun
8 230 30008422 1 CARRIER
-- 030 - - 1 CARRIER ASSEMBLY, No. 1 (includes items 9 & 11)
9 231 NSS 1 CARRIER PLATE
10 282 30008424 4 PIN
11 283 NSS 3 PIN
12 285 30008426 6 PLATE, Side
13 286 30008427 4 PLATE, Side
14 287 30008428 1 WASHER, Thrust
15 311 30009751 1 DIPSTICK
16 312 30009752 1 PIPE
17 401 30008431 1 BEARING, Spherical
18 402 30008432 1 BEARING, Spherical
19 403 30008433 3 CAGE, Needle
20 602 30008434 14 SHCS, M14 x 130 mm
21 - - 30009753 14 WASHER, FLAT - M14 (hardened)
22 801 30008435 1 SEAL, Oil
23 901 30008436 1 PLUG
24 902 30009754 1 FITTING, Relief
25 910 30008438 4 PIN, Spring
26 911 30008439 3 RING, Snap
27 912 30008556 1 RING, Snap
28 913 30008441 1 RING, Snap
29 915 30008442 1 SEAL, Bearing
30 - - 30009755 1 FITTING, Lube
31 - - 30008404 1 PLUG, Fill
~
*KHI Item refers to item numbers used in Kawasaki's service procedure and cross-section diagram.
6-20
Mechanical Service
Parts Replacement Standards

5. SERVICE PROCEDURES (Cont’d)
5.2 Parts Inspection and Replacement Criteria
This reduction gear is a balanced design using few parts to give approximately equal service
life to all components. Since many of the parts are matched, they should be replaced at the
same time as shown in the following table, even though they can be supplied separately.
NOTE: Three-digit item numbers refer to the parts list and sectional drawing at the end
of this Section.
T a b l e 2 S u m m a r y o f S i m u l ta n e o u s l y - r e p l a c e d P a r ts
P a r t to b e r e p l a c e d s i m u l ta n e o u s l y
201 401 402 203 230 282 285 910 210 231 283 403
Planetary gear
Planetary gear
Roller bearing
roller bearing
Needle cage
Carrier No.2
Carrier No.1
Drive shaft
Spring pin
Side plate
Spherical
Pin No.2
Pin No.1
No.2
No.1
201 D rive S ha ft - O O
S pe ric a l
401 R olle r X - X
B e a ring
R olle r
402
B e a ring X X -
P la ne ta ry
203
ge a r N o. 2 - X O X O
Part to be replaced
C a rrie r
230
N o. 2 X - O X O
282 P in N o. 2 X X - X O
285 S ide pla te X X O - O
910 S pring pin X X O X -
P la ne ta ry
210
ge a r N o. 1 - X X X
C a rrie r
231
N o. 1 X - O X
283 P in N o. 1 X O - X
N e e dle
403
c a ge X X X -
Mark “O” shows the part that must be replaced simultaneously.
Mark “X” shows the part that SHOULD be replaced simultaneously.
6-21
Mechanical Service
Parts Replacement Standards

5.2 Parts Inspection and Replacement Criteria
1) Tooth faces of Sun, Planetary & Ring Gears
When pitting is found, replace the gear
(if pit size is 1 mm or larger in diameter, and the area is 5% or more).
2) Oil Seal
When the lip face is damaged or worn away, replace the oil seal.
When the reduction gear is disassembled for inspection, the oil seals MUST be
replaced.
The following parts are those of the Drive Shaft Assembly. Do not disassemble these parts un-
less one of its component parts has failed.
3) Bearing (input side of reduction gear)
Check the bearings without removing from the drive shaft, following the procedures
listed below.
1- Check the outer race and rollers and confirm that they are free of pitting and
flaking.
2- Since the inner race is inside the cone and cannot be seen, check it as follows :
a. Check for presence of large wear particles in gear oil.
b. Check for presence of large wear particles between the rollers and retainer.
c. Can the inner race be rotated smoothly by hand?
If any abnormality is found during the above check, replace the part. Any bearing re-
moved from the shaft should not be reused.
4) Bearing (the output side of the reduction gear)
When there is pitting or flaking on the outer race and rollers, replace the bearing.
5) Planetary Gear No. 2
Check the radial play of the planetary gear No. 2.
If this play is 0.5 mm or more, replace the pin.
6) Thrust Washer and Thrust plate
When sliding face of thrust washer and thrust plate is deeply scratched, (scratches can be
detected with finger nail) replace these parts.
7) Needle cage and pin No.1
When pitting or flaking is present, replace the needle cage and pin No.1.
6-22
Mechanical Service
Service Tools & Procedures

5.3 Disassembly/Reassembly Procedures
5.3.1 Thread Sizes and Tightening Torques
The thread sizes used in the reduction gear and their tightening torques are shown in Table 3.
T a b l e 3 : S c r e w T h r e a d S i z e s a n d T i g h te n i n g T o r q u e
I te m W i d th T i g h te n i n g
P a rt Na me S iz e
No. A c r o s s F la t T orque
H e x S oc k e t H e a d M1 4 ( I S O 7 2 4 ) 1 1 8 ft-lbs
602 1 2 mm
C a ps c re w ( S H C S ) x 1 3 0 mm [1 6 0 N -m]
901 P lug P T 1 /2 1 0 mm 4 8 ft-lbs [6 5 N -m]
925 P lug, V e nt P T 1 /4 1 4 mm 1 6 ft-lbs [2 2 N -m]
926 F itting, Z e rk P T 1 /4 1 4 mm 1 6 ft-lbs [2 2 N -m]
5.3.2 Tools Used

Allen wrench (Width across flat: 12 mm, 10 mm, 6 mm)
Socket wrench
Adjustable angle wrench
Open end wrench
Box-end wrench
Hammer with soft or dead-blow head
Screwdriver
Torque wrench
Special jig (see Item 5.3.5)
Liquid packing (THREEBOND No.1104B or equivalent),
Tank for shrinkage fit (176-212 degrees Fahrenheit [0-100 degrees Centigrade])
5.3.3 Disassembling and Reassembling Guidelines
1) Handle replacement parts with care.
2) Before reassembling, check parts by following the inspection procedures shown in
Topic 5.2, Parts Inspection and Replacement Criteria.
3) Clean all parts with cleaning oil and dry them with compressed air. DO NOT spin
roller bearings with compressed air to dry them.
4) If liquid packing has been applied, remove it with a gasket scraper, and finish surfaces
with an oilstone.
5) Follow Item 5.3.1 for the tightening torque.
6-23
Mechanical Service
Disassembly Procedure
sWing
motor
drive
gearbox
mtg. capscrew
437-483 ft-lbs
[593-655 n-m]
hardened
Washer
Fig. 6: Swing drive mechanical components.
5.3.3.1 Disassembly Procedure
Unexpected movement
of turntable CAN CAUSE SEVERE PERSONAL
INJURY or death.
Secure turntable so it can not rotate
(see Precautions in this manual)
1. Lift up swing drive using a suitable lifting
device. Be careful not to damage the ring
gear on the swing bearing.
Turn the drive assembly so that the drive
shaft is horizontal, with the drain plug fac-
ing downwards. Place a catch pan under
the drain port. Remove drain plug and let Fig. 7: Remove sun gear from No. 1 carrier.
gear oil drain out.
NOTE: Check the drained oil for wear par-
ticles with a magnet and your fingers.
2. Place the unit in a vertical position on a
firm, level, clean work surface. Loosen
hexagon socket head screws (602) and
remove the hydraulic motor.
3. Remove No. 1 sun gear (211), as shown in
Fig. 7.
4. Remove No. 1 carrier assembly, as shown in
Fig. 8.
Fig. 8: Remove No. 1 carrier assembly.
6-24
Mechanical Service
Disassemble No. 1 Carrier
5. Disassemble the No. 1 carrier assembly:
1) Remove snap ring (911) and upper side

plate (285), as shown in Fig. 9.
2) Remove (3@) No. 1 planetary gear (210)

and needle cage (403), as shown in Fig.
Fig. 9: Remove snap ring and upper side plate from 10.
No. 1 carrier assembly.
3) Remove lower side plate (285), as shown

in Fig. 11.
4) Remove the No. 1 thrust washer (287) as

shown in Fig. 12.
NOTE: Do not remove (3@) No. 1 pin (283)

from the No. 1 carrier plate. These
items are not serviced separately.
Fig.10: Remove needle cage.
Fig.11: Remove lower side plate from No. 1 carrier Fig.12: Remove thrust washer from No. 1 carrier as-
assembly. sembly.
6-25
Mechanical Service
6. Remove No. 2 sun gear (204), as shown in
Fig. 13.
7. Remove No. 2 carrier assembly (230), as
shown in Fig. 14.
8. Disassemble the No. 2 carrier
assembly.
1) Place the No. 2 carrier (230) in a soft-
jawed machinist's vise.
2) Drive spring pin (910) into planetary-
gear pin (282) to release it from carrier
Fig.13: Remove No. 2 sun gear.
No. 2 (230), as shown in Fig. 15.
3) Pull out (4@) planetary-gear pin (282) to
remove planetary gear No. 2 (203) and
side plate (286).
NOTE: Examine the parts of the No. 2 Car-
rier assembly (Refer to Topic 5.2, Part
Inspection Procedures).
If damage found, replacement of all
carrier components recommended.
9. Remove Ring Gear (202), as shown in Fig. 16
(below).
Fit two M12 (ISO 724) bolts (602) into lifting
screw holes on ring gear (202), and lift it
away from the casing.
Fig.14: Remove No. 2 carrier assembly.
Fig.15: Drive spring pin inward with soft hammer Fig.16: Remove ring gear.
and drift.
6-26
Mechanical Service
(Cont’d).
10. Remove snap ring (913) from drive shaft
(201), as shown in Fig. 17.
11. Place the reduction gear in a vertical posi-
tion with pinion end of drive shaft facing
downward.
Remove shaft assembly from casing using
a soft faced hammer. Drive upper bearing
from casing (if worn or damaged).
Disassemble drive shaft:
Fig.17: Remove snap ring from drive shaft. NOTE: During a normal overhaul procedure,
it is unnecessary to disassemble the
Drive Shaft assembly.
Refer to Topic 5.2, Part Inspection
Procedures.
If partial replacement is inevitable, fol-
low the procedure in step 12.
12. Remove bearing seal (915) and spherical
roller bearing (401) from drive shaft using
press and jig as shown in Fig. 18
For drawing of the jig refer to Fig. 34.
13. Remove oil seal (801) from casing (102)

using a soft faced hammer and drift, as
shown in Fig. 19 (below).
Fig.18: Use special jig to remove spherical bearing Fig.19: Remove oil seal from casing.
from drive shaft.
6-27
Mechanical Service
Assembly Procedure
5.3.3.2 assembly Procedure
Assemble Drive Shaft:
1. Assemble the drive shaft assembly:
1) Install lower bearing seal (915) to shaft
(201).
NOTE: Protect the lip of the oil seal from
damage by wrapping the splines
with plastic tape. Remove tape after
installing seal.
2) Paint inside of lower bearing (401) with
Fig.20: Pack the spherical roller bearing with grease and press the bearing onto the
grease. shaft.
Pack the lower bearing (401) with
grease, as shown in Fig. 20.
2. Place the casing (102) upside down on a
firm, clean, level work surface.
3. Lift the drive shaft assembly using lifting

screw hole on end of drive shaft, and insert
it into the casing (Fig. 21).
4. Place the assembled shaft and casing in

Fig.21: Lift the drive shaft assembly and insert into
a vertical position with the pinion facing
the casing. downward (Fig. 22).
5. Insert oil seal (801) into top of casing (102)

with lip facing upwards, using seal driver
(see Fig. 35 for dimensions).
6. Press upper bearing (402) into housing us-

ing special bearing driver (see Fig. 36).
Fig. 22 shows a cross-sectional view of the as-

sembled drive shaft, showing the shaft (201),
casing, (102), lower spherical bearing (401), oil
seal (801), and upper spherical bearing (402).
Assemble Drive Shaft (Cont’d).
Fig.22: Sectional view of the drive shaft assembly
installed in the casing.
6-28
Mechanical Service
Assembly Procedure
7. Insert snap ring (913) above the bearing, as
shown in Fig. 23.
8. Apply thread sealant to the vent plug (902)

and insert it into the casing (102).
Insert grease fitting into the port opposite
the vent plug. Pump grease into casing
until a little grease shows on the vent.
NOTE: If any components of the No. 2 carrier
assembly were damaged, replace the
entire assembly.
Fig.23: Insert the bearing-retaining snap ring. 9. Apply metal-to-metal gasket compound
to the ring gear mating surface of the cas-
ing (102).
10. Install ring gear (202) to casing (102), as

shown in Fig. 24. Make sure the bolt holes
are aligned.
11. Secure ring gear to casing, temporarily, by

inserting four socket head cap screws with
washers at 90° intervals. Use washers to
prevent damage to the machined surface.
Assemble No. 2 Carrier.

Fig.24: Place ring gear on casing.
12. Assemble No. 2 carrier components:
1) Place the No. 2 carrier (230) in a soft-
jawed machinist's vise.
2) Insert one of the four planetary gears
(203) and one of the side plates (286)
into the No. 2 carrier (230). Side plate
goes on downward side of gear.
3) Tap No. 2 planetary-gear pin (282) into
place with a soft-head hammer, mak-
ing sure spring pin holes are aligned. To
secure planetary-gear pin, drive spring
pin (910) until flush with carrier housing,
as shown in Fig. 25. Repeat Steps 1) & 2)
Fig.25: Secure gear pins in No. 2 carrier with spring
pins. with the other three pins.
6-29
Mechanical Service
Assembly Procedure
13. Install No. 2 carrier assembly into ring gear,
as shown in Fig. 26.
Fig.26: Install the No. 2 carrier assembly.
14. Install No. 2 sun gear (204) inside the No. 2

carrier assembly (Fig. 27).
Fig.27: Install the No. 2 sun gear.

Assemble No. 1 Carrier.
15. Assemble the No. 1 carrier assembly.
1) Put No. 1 carrier (231) on a clean, level

work surface.
2) Install thrust washer (287) in center of

No. 1 carrier assembly (Fig. 28).
Fig.28: Install thrust washer.

6-30
Mechanical Service
Assembly Procedure
Assemble No. 1 Carrier (Cont’d):
15. Assemble the No. 1 carrier assembly

(Cont’d).
3) Install side plate (285) and needle cage

(403) on each of the three No. 1 plan-
etary-gear pins (Fig. 29).
Fig.29: Install (3@) side plate and needle cage.
4) Install a planetary gear (210) on each of

the three pins of the No. 1 carrier (Fig.
30).
Fig.30: Install No. 1 planetary gears.
5) Install side plate (287) and snap ring

(911) on each gear pin (Fig. 31).
Fig.31: Install (3@) snap ring and side plate.

6-31
Mechanical Service
Assembly Procedure
Assemble Swing Drive
16. Install the No. 1 carrier assembly (Fig. 32).
Fig.32: Install No. 1 carrier assembly.
17. Place the sun gear into the center of the

No. 1 carrier assembly (Fig. 33).
18. Place the drive gearbox in a vertical

position with the pinion facing downward.
19. Remove the temporary bolts and washers

(installed in Step 11).
Fig.33: Install sun gear into No. 1 carrier.

20. Apply metal-to-metal gasket compound
to top surface of casing (102).
21. Install snap ring (912) to drive shaft of

swing motor, then place the motor on the
gearbox. Check index marks made prior
to disassembly to be sure mounting holes
are properly aligned.
22. Insert and tighten the socket head cap-
screws (602).
Refer to the tightening torque chart in this
manual.
6-32
Mechanical Service
Special Tools
DIMENSIONS IN MILLIMETERS
Fig.35: Special tool for installing oil seal.
Fig.34: Drawing of special tool for removing spheri-

cal roller bearing.
Fig.36: Drawing of special tool for installing spheri-

cal roller bearings.
6-33
Mechanical Service
Installation Procedure
CASE DRAIN LINE BRAKE
RELEASE
LINE
to return
case drain
filter
Pilot
Brake Pressure
Release
325 PSI
Index Mark
make-up line PRESSURE LINES
test fittings
s2
s1
r
l mounting bolt
b 7/8-9 unc
a
torque 437-483 ft-lbs
hardened
Washer
swngmotr
Fig. 37: Views of swing drive to show control valve, brake release, case drain and anti-cavitation make-up con-
nections.
1. Install swing drive gearbox on the turn- Install the dipstick.

table, making sure index marks are
aligned. Tighten the mounting cap- 5. Fill gearbox with 0.9 gal [3.4 L] of cor-
screws (dry) to 437 ft-lbs, then draw rect gear oil until it reaches correct level
them up to 483 ft-lbs, using the “cross- mark on dipstick (see Topic 3.2, Gear Oil /
tightening” method described in this Grease). Install fill plug (item 31 in Fig. 5,
manual. Exploded View).
2. Connect hydraulic hoses according to mark- 6. Prior to starting up the machine, refer to
ings made prior to removal (refer to Fig. 37). KAWASAKI SWING MOTOR, START-UP ROU-
TINE. Refer also to Topic 3.3, Cautions be-
3. Apply thread sealant to the drain plug (901) fore Operation and Topic 3.4, Cautions
and insert it into the casing (102). for Operation..
4. Apply thread sealant to the dipstick pipe
(312) and insert it into the casing (102).
6-34
Mechanical Service
Parts List
I te m N o . P a rt Na me Q ty C la s s C la s s
C o de Me a n i n g
102 C A S IN G 1 C P a rts s upplie d s ub-
B
a s s e mble d
201 S H A F T , D rive 1 C
P a rts individua lly
C
202 R IN G G E A R 1 C s upplie d
/ P a rts not s upplie d

203 G E A R , P la ne t - N o. 2 4 C
S ta nda rdiz e d pa rts
204 G E A R , S un - N o . 2 1 C D
c ommonly a va ila ble
210 G E A R , P la ne t - N o. 1 3 C
211 G E A R , S un - N o . 1 1 C
230 C A R R I E R , P la ne ta ry - N o. 2 1 C
030 C A R R I E R , P la ne ta ry - N o. 1 1 B
231 P L A T E , C a rrie r N o. 1 1 /
283 P I N , C a rrie r N o. 1 3 /
282 P I N , C a rrie r N o. 2 4 C
285 S I D E P L A T E , C a rrie r N o. 1 6 C
286 S I D E P L A T E , C a rrie r N o. 2 4 C
287 W A S H E R , T hr u s t 1 C
-- D I P S T I C K A S S E MB L Y 1 B
311 D IP S T IC K 1 /
312 P IP E 1 /
401 B E A R I N G , R olle r - S phe ric a l 1 C
402 B E A R I N G , R olle r - S phe ric a l 1 C
403 NE E DL E C AG E 3 C
602 C A P S C R E W , S oc k e t H e a d 14 C
801 S E A L , O il 1 C
901 P LUG 1 D
925 F I T T I N G , R e lie f ( V e nt) 1 C
926 F I T T I N G , Z e rk - 1 /8 N P T 1 D
910 P I N , S pring ( R oll P in) 4 D
911 S N A P R IN G 3 D
912 S N A P R IN G 1 D
915 B E A R IN G S E A L 1 C
7-
Electrical Systems
Warning: To avoid personal injury or property damage, read all safety ma-
terials in the Operator's Manual.
This section covers the electrical system and its components.
Electrical system
Table of Contents
Electric Motor
Standard Induction Motors........................................................................................7-3
Installation..............................................................................................................................7-4
Location......................................................................................................................................7-4
Mounting....................................................................................................................................7-5
Electrical Connections..................................................................................................7-5
Thermal Protection Information............................................................................7-6
Changing Rotation..............................................................................................................7-6
Low Voltage Starting.........................................................................................................7-6
Operation...................................................................................................................................7-7
Before Initial Starting......................................................................................................7-7
Collector Rings.....................................................................................................................7-7
Brushes........................................................................................................................................7-7
Allowable Voltage & Frequency Range................................................................7-7
Cleanliness...............................................................................................................................7-8
Condensation Drain Plugs............................................................................................7-8
Service...........................................................................................................................................7-8
Lubrication Procedures..................................................................................................7-8
Lubrication Intervals........................................................................................................7-9
Troubleshooting............................................................................................................... 7-10
Troubleshooting Chart............................................................................................... 7-11
Instrument Panel - SM Models Only............................................................................ 7-12
Circuit Breaker Panel - SM Models Only................................................................... 7-12
Electrical Box............................................................................................................................. 7-12
Electrical Schematics........................................................................................................... 7-14
7-
Electrical Systems
7-
Electrical Systems
Standard induction motors

Below is the typical layout cutaway view of a drip-
proof, horizontal integral horsepower motor. Parts are
described in table below view.
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
1 Frame Vent Screen ** 11 Bracket O.P.E. 21 Bracket Holding Bolt

2 Conduit Box Bottom 12 Baffle Plate O.P.E. 22 Inner Bearing Cap P.E.
3 Conduit Box Top - Holding Screw 13 Rotor Core 23 Inner Bearing Cap Bolt
4 Conduit Box Top 14 Lifting Eye Bolt 24 Grease Plug
5 Conduit Box Bottom - Holding Bolt 15 Strator Core 25 Ball Bearing * P.E.
6 Ball Bearing* O.P.E. 16 Frame 26 Shaft Extension Key
7 Pre-loading Spring 17 Strator Winding 27 Shaft
8 Inner Bearing Cap O.P.E. 18 Baffle Plate Holding Screw 28 Drain Plug (grease)
9 grease Plug 19 Baffle Plate P.E. 29 Bracket Screen **
10 Inner Bearing Cap Bolt 20 Bracket P.E.
P.E. = Pulley End
O.P.E. = Opposite Pulley End
* = Bearing numbers are shown on motor nameplate when requesting information or parts always give complete motor description, model & serial numbers.
** = Bracket & frame screens are optional.
7-
Electrical Systems
General information
These instructions must be

followed to ensure safe and proper installation, op-
eration and maintenance of the motor. They should
be brought to the attention of all persons who
install, operate or maintain this equipment. Serious
personal injury or death could occur if instructions
are not followed.
LOCATION
Installation
Selecting a location for the

After uncrating, check motor should include consideration for environment
for any damage which may have been incurred in and ventilation. A motor with the proper enclosure
handling. The motor shaft should turn freely by hand. for the expected operation condition should be
Repair or replace any loose or broken parts before selected.
attempting to use the motor.
Check to be sure that motor has not been exposed
Location selection:
to dirt, grit or excessive moisture in shipment or stor-
age before installation. 1. The ambient temperature of the air surrounding the
motor should not exceed 40 Degrees C (104 Degrees F)
Measure insulation resistance. Clean and dry the
unless the motor has been especially designed for high
windings as required.
ambient temperature applications. The free flow of air
Never start a motor which has been wet without around the motor should not be obstructed.
having it thoroughly dried.
1. The motor should never be placed in a room with a

Motors should be in- hazardous process, or where flammable gases or com-
stalled, protected and fused in accordance with bustible material may be present, unless it is specially
latest issue of National Electric Code, NEMA, Stan- designed for this type of service.
dard Publication No. MD2 and local codes. 2. Dripproof (open) motors are intended for use indoors
where atmosphere is relatively clean, dry and non
corrosive.
ALWAYS FOLLOW THE LISTED SAFETY PRECAUTIONS:
3. Dripproof (open) fire pump motors are to be installed
1. Eye bolts or lifting lugs are intended for lifting the mo- in a Type 2 dripproof environment as defined in NEMA
tor only. These lifting provisions should never be used 250.
when lifting or handling the motor with other equip-
ment (i.e. pumps, gear boxes, fans or other driven 4. Totally enclosed motors may be installed where dirt,
equipment) as a single unit. Be sure the eye bolt is fully moisture and corrosion are present, or in outdoor
threaded and tight in its mounting hole. locations.
2. Eye bolt lifting capacity ratings are based on a lifting 5. Explosion proof motors are built for use in hazardous
alignment coincident with the eyebolt centerline. Eye- locations as indicated on the motor's UL Listing Mark
bolt capacity reduces as deviation from this alignment plate. Consult UL, NEC, and local codes for guidance.
increases. See NEMA MG2.
3. Frames and accessories of motors should be grounded
in accordance with National Electrical Code (NEC)
Article 430. For general information on grounding refer
to NEC Article 250.
4. Rotating parts such as pulleys, couplings, external fans,
and shaft extensions should be permanently ground-
ed. .
7-
Electrical Systems
Mounting Electrical connections
Floor Mounting
Install and ground per
Motors should be provided with a firm, rigid foundation, local and national codes. Consult a qualified techni-
with the plane of four mounting pads flat within .010" cian with questions or if repairs are required. Serious
for 56 to 210 frame; .015" from 250 through 500 frame. personal injury or death could occur if warning
This may be accomplished by shims under the motor instructions are not followed.
feet. For special isolation mounting, contact an autho-
rized dealer. 1. Disconnect power before working on motor or
driven equipment.
2. Motors with automatic thermal protectors will au-
V-Belt Drives tomatically restart when protector temperature
1. Select proper type and number of belts and sheaves. drops sufficiently. Do not use motors with auto-
Excessive belt load will damage bearings. Sheaves matic thermal protectors in applications where
should be in accordance to NEMA Spec. MG-1 or as automatic restart will be hazardous to personnel
approved by the manufacturer. or equipment.
2. Align sheaves carefully to avoid axial thrust on motor 3. Motors with manual thermal protectors may start
bearing. The drive sheave on the motor should be po- unexpectedly after protector trips. If manual pro-
sitioned toward the motor so it is as close as possible tector trips, disconnect motor from power line.
to the bearing. After protector cools (five minutes or more) it can
3. When adjusting belt tension, make sure the motor is be reset and power may be applied to motor.
secured by all mounting bolts before tightening belts. 4. Discharge all capacitors before servicing motor.
4. Adjust belt tension to belt manufacturers recommen- 5. Always keep hands and clothing away from mov-
dations. Excessive tension will decrease bearing life. ing parts.
6. Never attempt to measure the temperature rise
Direct Connected Drive of a motor by touch. Temperature rise must be
Flexible or solid shaft couplings must be properly measured by thermometer, resistance, imbedded
aligned for satisfactory operation. On flexible couplings, detector, or thermocouple.
the clearance between the ends of the shafts should be 7. Electrical repairs should be performed by trained
in accordance with the coupling manufacturer's recom- and qualified personnel only.
mendations or NEMA standards for end play and limited 8. Failure to follow instructions and safe electri-
travel in coupling. cal procedures could result in serious injury or
Misalignment and run-out between direct connected death.
shafts will cause increased bearing loads and vibration 9. If safety guards are required, be sure the guards
even when the connection is made by means of flexible are in use.
coupling. Excessive misalignment will decrease bear-
ing life. Proper alignment, per the specification of the
coupling being used is critical. 1. All wiring, fusing, and grounding must comply with
National Electrical Codes and local codes.
2. To determine proper wiring, rotation and voltage con-
Some Large Motors are furnished with roller bearings. nections, refer to the information and diagram on the
Roller bearings should not be used for direct drive. nameplate, separate connection plate or decal. If the
plate or decal has been removed, contact an autho-
rized representative.
3. Use the proper size of line current protection and
motor controls as required by the National Electrical
Code and local codes. Recommended use is 120% of
full load amps as shown on the nameplate for motors
with 40 Degrees C (104 Degrees F) ambient and a ser-
vice factor over 1.0. Recommended use is 115% of full
load amps as shown on the nameplate for all other
motors. Do not use protection with larger capacities
than recommended. Three phase motors must have
all three phases protected.
7-
Electrical Systems
Thermal protector information Low voltage starting
The nameplate will indicate one of the following: Motors to be used on reduced voltage starting should
1. Motor is thermally protected. be carefully selected based on power supply limita-
2. Motor is not thermally protected. tions and driven load requirements. The motors starting
torque will be reduced when using reduced voltage
3. Motor is provided with overheat protective device.
starting. The elapsed time on the start step should
Refer to references below: be kept as short as possible and should not exceed 5
1. Motor is equipped with built-in thermal protec- seconds. It is recommended that this time be limited to
tion have "THERMALLY PROTECTED" stamped on 2 seconds. Contact an authorized dealer for application
the nameplate. Thermal protectors open the motor assistance.
circuit electrically when the motor overheats or is
overloaded.
The protector cannot be reset until the motor cools.
If the protector is automatic, it will reset itself. If the
protector is manual, press the red button to reset.
2. Motors without thermal protection have nothing
stamped on nameplate about thermal protection.
3. Motors that are provided with overheat protective
device that does not open the motor circuit directly
will indicate "WITH OVERHEAT PROTECTIVE DEVICE".
Changing rotation
Keep hands and clothing

away from rotating parts. Serious personal injury or
death could occur.
1. Before motor is coupled to the load, determine proper

rotation.
2. Check rotation by jogging or bumping. Apply power
to the motor leads for a short period of time, enough
to just get motor shaft to rotate a slight amount to
observe shaft rotating direction.
3. Three phase motor - inter change any two (2) of the
three (3) line leads.
Single phase motor - reconnect per the connection
diagram on the motor.
7-
Electrical Systems
Operation Collector rings

(Wound Rotor Motors Only)
Disconnect and lock out The collector rings are sometimes treated at the factory
motor before performing any service on motor or to protect them while in stock and during shipment.
driven equipment. Serious personal injury or death The brushes have been fastened in a raised position.
could occur. Before putting the motor into service, the collector
rings should be cleaned to remove this treatment. Use
a cleaning fluid that is made for degreasing electrical
Before initial starting equipment. All of the brushes must be released and
Measure the insulation resistance of the stator winding. lowered to the collector surface. Keep the rings clean
Minimum Insulation Resistance Rated Voltage and maintain their polished surfaces. Usually, the rings
In Megohms =1+ 1000 will require only occasional wiping with a piece of can-
vas or non-linting cloth. Do not let dust or dirt accumu-
late between the collector rings.
Do not attempt to run the
motor if the insulation resistance is below value.
Brushes
1. If insulation resistance is low, dry out the moisture (Wound Rotor Motors Only)
utilizing one of the following methods:
A. Bake in oven at temperature not more than 90 De-
See that the brushes move freely in the holders and at
grees C (194 Degrees F).
the same time make firm, even contact with the collec-
B. Enclose motor with canvas or similar covering, leaving tor rings. The pressure should be between two (2) and
a hole at the top for moisture to escape, and insert three (3) pounds per square inch of brush surface.
heating units or lamps.
When installing new brushes, fit them carefully to the
C. Pass a current at low voltage (rotor locked) through collector rings. Be sure that the copper pigtail conduc-
the stator winding. Increase the current gradually tors are securely fastened to, and make good contact
until the winding temperature, measured with a with, the brush holders.
thermometer, reaches 90 Degrees C (194 Degrees F).
Do not exceed this temperature.
2. See that voltage and frequency stamped on motor Allowable voltage & frequency
and control nameplates correspond with that of the
range
power line.
3. Check all connections to the motor and control with
the wiring diagram. If voltage and frequency are within the following range,
motors will operate, but with somewhat different char-
4. Be sure rotor turns freely when disconnected from
acteristics than obtained with correct nameplate values.
the load. Any foreign matter in the air gap should be
removed. 1. Voltage: within 10% above or below the value
stamped on the nameplate. On three phase systems
5. Leave the motor disconnected from the load for the
the voltage should be balanced within 1%. A small
initial start. Check for proper rotation and that it is
voltage unbalance will cause significant current
balanced within 1% at the motor terminals. After the
unbalance.
machine is coupled to the load, check that the name-
plate amps are not exceeded. Recheck the voltage 2. Frequency: Within 5% above or below the value
level and balance under load. stamped on the nameplate.
Shut down the motor if the above parameters are not 3. Voltage & Frequency together: Within 10% ( provid-
met or if any other noise or vibration disturbances are ing frequency above is less than 5%) above or below
present. Consult NEMA guidelines or the equipment values stamped on the nameplate.
manufacturer if any question exist before operating
equipment.
Motors with "belted duty only"

on nameplate should never be run without belts properly
installed.
7-
Electrical Systems
Cleanliness Service
Keep both the interior an exterior of the motor free

from dirt, water, oil and grease. Motors operating in Disconnect power before
dirty places should be periodically disassembled and working on motor or driven equipment. Motors with
thoroughly cleaned. automatic thermal protectors will automatically
restart when the protector cools. Do not use motors
with automatic thermal protectors in applications
where automatic restart will be hazardous to per-
Condensation drain plugs
sonnel or equipment.
All explosion proof and some totally enclosed motors

are equipped with automatic drain plugs, they should Overgreasing bearings can
be free of oil, grease, paint, grit and dirt. The drain sys- cause premature bearing and/or motor failure. The
tem is designed for normal floor (feet down) mounting. amount of grease added should be carefully controlled.
For other mounting positions, modification of the drain
system may be required, consult an authorized dealer.
If lubrication instructions are
. shown on the motor nameplate, they will supersede this
general instruction.
Motors are pregreased with a polyurea mineral oil NGLI
grade 2 type grease unless stated otherwise on the
motor nameplate. Some compatible brands of polyurea
mineral base type grease are: Chevron SRI #2, Rykon
Premium #2, Exxon Polyrex EM or Texaco Polystar RB.
Lubrication procedures
1. Stop motor. Disconnect and lock out of service.

2. Remove contaminants from grease inlet area.
3. Remove filter and drain plugs.
4. Check filler and drain holes for blockage and clean as
necessary.
5. Add proper type and amount of grease. See the
lubrication time intervals table for service schedule and
volume of grease required.
6. Wipe off excess grease and replace filler and drain
plugs.
7. Motor is ready for operation. .
7-
Electrical Systems
Lubrication intervals
. Service NEMA Frame Size

Condition 140-180 210-360 400-510
1800 RPM Over 1800 1800 RPM Over 1800 1800 RPM Over 1800
and less RPM and less RPM and less RPM
Standard 3 yrs. 6 months 2 yrs. 6 months 1 yrs. 3 months
Severe 1 yr. 3 months 1 yr. 3 months 6 months 1 month
For seasonal operation lu-

bricate at the beginning of the season then follow normal
lubrication intervals.
For motors name plated as

"belted duty only" divide the above listed intervals by 3.
Seasonal Service: If motor remains idle for 6 months or

more.
Standard Service: Up to 16 hours of operation per day,
indoors, 38 Degrees C (100 Degrees F)
Severe Service: greater than 16 hours of operation
per day. Continuous operation under high ambient
temperatures (38 - 66 Degrees C (100 - 150 Degrees F)
and or any of the following: dirty, moist locations, high
vibration (above NEMA standards), heavy shock loading,
or where shaft extension end is hot.
NEMA VOLUME cu. in. (fluid oz.)

Frame
Size
140 .25 (.14)
180 .50 (.28)
210 .75 (.42)
250 1.00 (.55)
280 1.25 (.69)
320 1.50 (.83)
360 1.75 (.97)
400 2.25 (1.2)
440 2.75 (1.5)
500 3.00 (1.7)
7-10
Electrical Systems
Troubleshooting
Disconnect power before

working on motor or driven equipment. Motors with
automatic thermal protectors will automatically
restart when the protector cools. Do not use motors
with automatic thermal protectors in applications
where automatic restart will be hazardous to per-
sonnel or equipment. Motors with manual thermal
protectors may start unexpectedly after protector
trips. If manual protector trips, disconnect motor
from power line. After protector cools ( 5 minutes
or more) it can be reset and power may be applied
to the motor. Discharge all capacitors before servic-
ing motor. Always keep hands and clothing away
from moving parts. Never attempt to measure the
temperature rise of a motor by touch. Temperature
rise must be measured by thermometer, resistance,
imbedded detector, or thermocouple. Electrical
repairs should be performed by trained and quali-
fied personnel only. Failure to follow instructions
and safe electrical procedures could result in serious
personnel injury or death. .
If safety guards are required,

be sure guards are in use.
Operational troubleshooting:
Verify that:
The bearings are in good condition and operating
properly.
There is no mechanical obstruction to prevent rotation
in the motor or in the driven load.
The air gap is uniform.
All bolts and nuts are tightened securely.
Proper connection to drive machine or load has been
made.
Electrical troubleshooting:
Verify that:
The line voltage and frequency correspond to the volt-
age and frequency stamped on the nameplate of the
motor.
The voltage is actually available at motor terminals.
The fuses and other protective devices are in proper
condition.
All connections and contacts are properly made in the
circuits between the control apparatus and motor.
7-11
Electrical Systems
7-12
Electrical Systems
Instrument Panel
All electrical instruments and controls are contained
within the instrument panel at the right upper of the
cab.
Electrical box
Accidental contact with

live electrical components can cause personal
injury or property damage.
The electrical box is located at the rear of the upper

frame.
Circuit breaker Panel

Branch circuits are protected from current overload
by individual circuit breakers. If an overload should
occur, the affected breaker will open, thus protect-
ing the components within that circuit from damage.
The circuit breakers are located at the right upper of
the cab. Remove covers to gain access to fuses and
circuit breakers.
7-14
Electrical Systems
10083739--1--WIRING SCHEMATIC - 519SM Standard

7-15
Electrical Systems
7-16
Electrical Systems
10087308--A-- 519SM/569SM EHC ELECTRICAL SCHEMATIC

7-17
Electrical Systems
7-18
Electrical Systems
10087309--A-- 519SM/569SM EHC ELECTRICAL SCHEMATIC Limited Rotation

7-19
Electrical Systems
7-20
Electrical Systems
10083738--1S1-- 569 SM ELECTRICAL SCHEMATIC

7-21
Electrical Systems
7-22
Electrical Systems
10083378--1S2--569SM ELECTRICAL SCHEMATIC

7-23
Electrical Systems
7-24
Electrical Systems
10087348--1-- 569SM EHC ELECTRICAL SCHEMATIC

7-25
Electrical Systems
8-
Air Conditioner
WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE, Read

and Follow ALL SAFETY MATERIALS in the operator’s Manual.
The information in this section will help the Service Technician to troubleshoot and repair the Air Conditioning
System.
Air Conditioner Service

Table of Contents
refrigerant & lubricant capacity................................................. 8-3

Air Conditioning Safety....................................................................... 8-4
Pressure & Temperature
Relationship Chart......................................................................... 8-5
Flow Diagram............................................................................................... 8-6
Installation Diagram............................................................................. 8-7
Inspection & Maintenance.................................................................. 8-8
Troubleshooting Procedures.......................................................8-10
Troubleshooting Charts..................................................................8-11
Preventive Maintenance Schedule.............................................8-16
Refrigerant Charging / Recovering...........................................8-20
Evacuating & charging the a/c system......................................8-23
8-
Air Conditioner
8-
Air Conditioner
Refrigerant & Lubricant capacity
Refrigerant used in units
Refrigerant-----------------------------------------------------------------------------R134A
Refrigerant Capacity
Units with Red Dot air conditioner:--------------------------------------2 lbs, 8 oz.
System Lubricant-------------------------------------------------- SP 20 Refrigerant Oil
Lubrication Capacity----------------------------------------------------------- 2.0 ounces
8-
Air Conditioner

all safety materials in the operator's manual..
Air Conditioning Safety
Serious personal injury may occur if the following safety precau-

tions are not observed while servicing any air conditioning system.
1. Servicing any air conditioning system should be performed only by a trained and qualified
service technician.
2. Always wear safety glasses, goggles or face shield to protect the eyes from refrigerant.
3. Never apply discharge pressures to refrigerant container. Discharge pressure could cause
container to explode causing severe personal injury.
4. Do not use a torch, electricity or engine heat to raise the temperature of any refrigerant con-
tainer. If it becomes necessary to heat a container in order to remove the last of its contents,
apply heat by placing it in a pan of water heated to NO MORE THAN 130°F [54°C] while the
container is connected to the air conditioning system.
DO NOT EXCEED 130°F [54°C] OR DANGER OF EXPLOSION WILL EXIST.
5. Refrigerant storage area should never exceed 130°F [54°C] or danger of explosion will exist.
6. Never allow refrigerant gas or liquid to come into contact with skin or eyes. When refrigerant
is released into the air, its temperature drops INSTANTLY to –26°F
[–32.2°C]. If it touches your skin or your eyes, you should flood the area with cool water and
GET MEDICAL ATTENTION IMMEDIATELY.
7. Do not allow refrigerant gas or liquid to come into contact with any open flame. The open
flame will break down the refrigerant, releasing phosgene gas. Phosgene gas is poisonous,
colorless and has an unpleasant odor. Phosgene gas causes severe respiratory irritation.
8. Work ONLY in a well-ventilated area.
9. The air conditioning system contains fluid under high pressure. NEVER loosen or remove
hoses UNLESS the system has been evacuated (depressurized) first. Serious personal injury
can occur from the release of high pressure refrigerant gas or liquid.
8-
Air Conditioner
Pressure and Temperature Relationship Chart
American Standard
Ambient Air Temp (°F) 70° 80° 90° 100° 150°
Average Compressor
Head Pressure – PSI 150–190 170–220 190–250 220–300 270–370
Average Compressor
Suction Pressure – PSI 14–26 14–26 14–26 14–26 14–26
Average Evaporator
Discharge Air Temp (°C) 38–45 39–47 40–50 42–55 45–60
Note: Pressure and outlet temperatures shown in this

chart are approximate. Pressures and tempera-
tures will vary according to ambient humidity
and condition of filter elements.
Metric Standard
Ambient Air Temp (°C) 21° 27° 32° 38° 65°
Average Compressor
Head Pressure – bar 10.35–13 11.73–15.18 13.11–17.25 15.18–20 18.63–25.53
Average Compressor
Suction Pressure – bar 966–1.794 .966–1.794 .966–1.794 .966–1.794 .966–1.794
Average Evaporator
Discharge Air Temp (°C) 3–7 4–8 4.4–10 5.5–12.6 7–15.6
8-
Air Conditioner
Air Conditioning Flow Diagram
D D
Fig. 1: Air Conditioner flow diagram. Circled Letters are explained in the “Key Letters” charts in Figs. 2, 3, 4 &
5 (inset).
Air Conditioner Components requiring frequent maintenance
BELTS COMPRESSOR CLUTCH CONDENSER ADD REFRIGERANT REFRIGERANT LINES VALVES
Service Note: Refer to Scheduled Maintenance Section for recommended maintenance intervals. Actual
operating conditions for the machine being serviced will determine or influence maintenance
frequency and requirements.
8-
Air Conditioner
Installation Diagram
CumminS line SChemATiC Key Letters
Key Description
d d A = Water pump to Heater
B = Evaporator to Compressor
b d C d (low pressure gas)
C = Compressor to Condenser
(high pressure gas)
b C
D = Condenser to Evaporator (liquid)
E = Heater to Water Jacket
wiring deTAil -- drier mounTing brACKeT
breAKer
30 Amp
plenum diffuSer b
heATer &
evAporATor CompreSSor
heater hose 49.0"
(to water Jacket)
e e
CondenSer A
b d
w
flo C
drier
Arrow on drier muST Align

wiTh direCTion of flow
(See line SChemATiC) heater hose 62.0"
b
(to water pump)
C
b
noTeS:
A C
. ChArge SySTem wiTh 2 lbs, 8 oz r34A refrigerAnT.
A 2. ATTACh hoSeS To The CompreSSor before mounTing.
3. Add 2 oz. SAnden Sp-20 pAg oil
b
C
b
e C
A
d
C A C
b e d
8-
Air Conditioner
#1. INSPECTION AND MAINTENANCE

There are three important reasons to perform regular • The third is the knowledge and the efficiency you will
inspections and maintenance on your machine. obtain as you familiarize yourself with your vehicle.
• The first is that it will save money. Checking your sys- Surveys of A/C system owners show that over 30% of
tem regularly will help you to detect problems in their the systems are serviced every 6 months or less, and
early stages, when they could be less costly to repair another 62% are serviced at least once a year. The
and do not require as much down time. following chart shows which A/C components require
frequent maintenance. Keep in mind that the failure
• The second is that it improves operator comfort and
of any one of these components could result in failure
safety. Studies have shown that an operator will be
of the system.
more alert in machine whose climate control system
is working properly.
THE FOLLOWING INSPECTION PROCEDURES SHOULD TAKE APPROXIMATELY 15 TO 20 MINUTES,

DEPENDING ON THE AMOUNT OF CORRECTIVE ACTION NECESSARY.
VISUAL INSPECTION - SYSTEM OFF

Observe the System
Be able to answer the following questions: ence needed, so the gauge will no longer be neces-
Has the vehicle just been in operation? sary. Replace belts that look frayed or worn. If the
Has the Heater/AC system been in use? clutch pulley/belt alignment is obviously off, loosen
Has a prior operator, or the work order, explained or the compressor and/or mounting bracket and use
described any problems with the system? an alignment bar to line up the clutch pulley with
Has the system been worked on recently? the drive pulley. Tighten the compressor mounting
bolts first, then the bolts on the mounting bracket.
Inspect the Parts Then, adjust the belt tension.
Inspect the system and look for anything that might Refrigerant Metering Valves: Valves should be free of
come loose, leak, wear out or become dirty and not any obstruction. If the valve is clogged with sludge
function up to par. Visually inspect the following com- or other obstruction, the result is a valve problem,
ponents for the conditions listed. but the cause is contamination in the system. Valves
Condenser: The condenser should be clean and free can get stuck in the open or closed position (al-
of leaves, bugs, bird feathers, mud and other debris. though, most often they stick closed), which makes
If necessary, a condenser fin comb, air hose and the valve defective. Defective valves need to be
nozzle, or soap and water may be used to remove replaced.
the debris. Make sure that the condenser mount-
Check Hoses and Fittings
ing bolts or screws are tight, and that the hoses are
securely clamped. All hose connections are potential wear points. Tighten,
re-fasten, add, or replace hoses and/or clamps as indi-
Evaporator: Remove recirculation air filter and grill.
cated by your inspection.
The evaporator should be clean and free of debris. If
not, remove the roof and evaporator housing lid and Check for Refrigerant Leaks
clean the evaporator using a mild soap and water Leaks can occur anywhere throughout the system, but
solution. some places are more common and obvious. The com-
Air filters: Both the fresh and recirculation filters pressor shaft seal, which is hidden behind the clutch
should be clean and sealing properly. If not, clean or assembly, is a common location for refrigerant leaks. A
replace as needed. soap and water solution works well for detecting leaks.
Components under the hood: The compressor mount- When checking the evaporator, feel around drain hole.
ing bracket, compressor clutch assembly, drive If there is an oily residue, a leak is possible.
belt and pulley alignment should all be fastened Service Note: Pressure is different in a system at rest,
securely, with the clutch groove in line with the drive so small leaks may be hard to detect.
pulley. You may want to use a leak detector to check for
Drive Belt and Compressor Clutch: The drive belt leaks in the system when the air conditioner is op-
should be tight and in good condition. Use a belt erating.
tension gauge to check tension (120 psi maximum.
Repeat action of this procedure will give the experi-
8-
Air Conditioner
#1. INSPECTION AND MAINTENANCE (Cont’d)

ELECTRICAL SYSTEM INSPECTION clutch cycling under load.
Inspect Electrical Connections 2. Touch the suction and discharge lines. The dis-
charge line should be getting hotter, while the suc-
Inspect visually and by feel. Look for corrosion on leads
tion line gets cooler.
or connectors, and clean them when necessary. Make
sure all leads and wires are properly supported and Check Sight Glass
securely connected. The receiver-drier sight glass should be clear when
system is stabilized.
Check Electrical Current Flow and Device Functions
Note: The sight glass will be clear under low load
Follow the steps below:
conditions. However, it will become cloudy as
1. Turn on ignition (must be on to check current flow) the load increases. This is normal for systems
2. Turn A/C system on. This powers the thermostat and using R-134a refrigerant. The cloudy condition
clutch is caused by the refrigerant oil separating from
NOTE: If the system fails to engage, use the A/C mode the refrigerant.
switch to check leads.
HEATER SYSTEM INSPECTION
3. Check fuses (In-cab and In-line)
The heater system inspection is a combination engine
4. Check clutch engagement: Drive plate should be cooling system and heater inspection. All heater/cool-
against pulley (and not slightly spaced from it) if ing system rubber parts deteriorate due to outside con-
clutch is engaged. ditions (air, heat, coolant and oils). Therefore, they need
5. Test blower speed operation for air flow and blower to be replaced at regular intervals to prevent break-
sound (speed) changes. down. Metal parts and gaskets are subject to malfunc-
Service Note: The on and off cycling of the thermostat tion or breakdown due to fatigue and corrosion.
cannot be checked until performance inspection is In addition, coolant has a limited life and needs to be
done. replaced regularly. When dirty, it should be drained,
and the system should be flushed or back flushed (using
PERFORMANCE INSPECTION - ENGINE RUNNING special equipment) before refilling with a 50-50 mix of
clean water and antifreeze.
Inspect System Component Cycling and Cab Tem-
perature Levels Coolant must be hot when using a hydrometer to check
protection (freeze-up level).
Turn on the engine and A/C system and inspect system
for compressor cycling and cab temperature levels. Check Heater Control Valve Function
This can be accomplished more rapidly if the doors and Follow the steps below:
windows of that cab are closed.
1. Cool engine - Start with the engine cool, set tem-
Check Thermometer Readings perature to cool and leave the fan off. As the engine
In the cab, use thermometer to measure air temperature gets warmer, feel the heater return hose. If it is
at the vents. In evaporator (if accessible), use probe to warm or hot, there is an internal leak in the heater
measure evaporator temperature. When the A/C unit is control valve, which can seriously reduce the perfor-
on, the evaporator temperature will be approximately mance level of the air conditioner system.
32°. It will rise 6-10°, and then move back down again. 2. Warm engine - Next, let the engine warm up to
This is called a “temperature swing”, and it indicates that normal operating temperature and set both fan
the clutch is cycling and the thermostat is working cor- and temperature on high. Feel both heater supply
rectly. and return hoses. If there is a noticeable difference
Please note that readings at the vents will be higher, in their temperature, a low flow of coolant is going
and the temperature swing slower and less obvious. through the heater core. This could be the result of
Swing temperatures vary depending on outside condi- a partially closed or blocked heater control valve,
tions. which (if not corrected) could cause poor heating
performance during cold weather.
Check Clutch Cycling Under Load
This is to be done outside the cab while waiting for the
system to stabilize. Follow the steps below:
1. Open the engine compartment and observe the
8-10
Air Conditioner
#2. TROUBLESHOOTING Procedures

TROUBLESHOOTING OVERVIEW
Troubleshooting includes collecting enough infor- or hang the manifold gauge set in a convenient
mation to locate the cause of the problem, then location.
correcting the problem and its cause by replacement, B) Connect the high/low pressure hoses from the
adjustment, and/or repairing. You begin by gathering manifold gauge set to the service ports located
information from the most to the least important on the compressor fittings.
sources. C) Follow the steps listed below during and after
installing the manifold gauge set:
Starting with the most important:
1. Your personal knowledge and experience with AC Purging Air From Gauge Set Hoses.
systems. Environmental regulations require that all ser-
2. The vehicle operator’s knowledge and experience vice hoses have a shut-off valve within 12 inches
- question him or her. of the service end. These valves are required to
3. The work order. ensure that only a minimal amount of refrigerant
is lost to the atmosphere.
4. Good testing equipment and the Heater/AC system.
The R-134a compatible gauge sets have a combi-
The routine you follow when troubleshooting should nation quick disconnect and shut-off valve on the
proceed from the most to least productive way to locat- high and low sides. The utility (center) hose also
ing the problem and fixing the cause. requires a valve.
Experienced troubleshooters talk to the operator if they
can, then personally verify the symptoms of the prob- Attach the utility (center) hose to a vacuum pump. Ac-
lem whenever possible. They attempt quick fixes on the tivate vacuum pump and draw the gauge set down into
basis of their knowledge of common system problems the vacuum. Turn pump off, connect the gauge fittings
and causes when appropriate. They know where com- to access ports. This process removes air from the hose
ponents are located, and make repairs when they have a assemblies.
good idea of what the problem is. They fix the cause or Service Note: Initial purging is best accomplished
causes as well as the immediate problem. when connected to recovery or recycle equipment.
INITIAL INSPECTION Preparing to add Refrigerant to the System

Before you begin to trouble shoot with the manifold Now that the gauges are connected, you may need to
gauge set, follow the procedures as shown in Topic #1, add some refrigerant to the AC system before an effec-
“INSPECTION AND MAINTENANCE”. This chapter out- tive performance inspection can be completed. How-
lines the required inspections below: ever, if leaks are obvious, they should be repaired prior
to adding refrigerant.
1. Visual Inspection
Service Note: Loss of some refrigerant is not unusual
2. Electrical System Inspection
over an extended period of time. Adding refrigerant
3. Performance Inspection is a typical procedure when the AC system is main-
4. Heater System Inspection. tained on a regular basis.
As stated in Topic #1, conducting this preliminary evalu- When adding refrigerant to the system, connect the
ation can help eliminate potential problems. utility (center) hose from the manifold gauge set to the
refrigerant dispensing valve on the container.
TROUBLESHOOTING USING MANIFOLD GAUGE SET
Before adding refrigerant to the system, study the sight
Manifold Gauge Set Installation glass while the engine is running and the air conditioner is
on. Even if a leak was found during the system inspection,
it is impossible to know just how much refrigerant has
Refrigerant escaping
leaked. Bubbles in the sight glass indicate a low amount of
under pressure can cause severe personal
refrigerant in the system.
injury.
Next, check the gauges for unusually high or low read-
Never hook up the gauge set when the engine and air ings, or a lack of pressure. Following this procedure, and
conditioner are running. Be sure all the valves on the using your knowledge and experience, decide if it is safe
manifold are closed all the way (turn them clockwise). and necessary to add refrigerant.
Check the hose connections on the manifold for tight-
You are now ready to add the refrigerant. For your
ness.
safety and to prevent system damage, use the following
A) Locate the low and high side system service fit-
procedure:
tings and remove their protective caps. Position
8-11
Air Conditioner
#2. TROUBLESHOOTING Procedures (Cont’d)

Adding Refrigerant to the System
Service Note: To add refrigerant using a charge/re-
Refrigerant escaping
covery unit, see Operator Manual provided by the
under pressure can cause severe personal
recovery unit manufacturer.
injury.
Add refrigerant using manifold gauge set, refrigerant
If the gauges show any abnormally high or low pres-
canister, and weight scale.
sures as you are adding refrigerant, stop and investigate
1. Turn on the engine and set the idle at 1200 to 1500 for probable cause. Never add more than one Pound of
RPM and then turn on the air conditioner. refrigerant. If the system is low enough on refrigerant
to require more than that amount, you should stop and
check again for leaks. Then recover all of the refrigerant.
over-pressurizing the Repair, evacuate and recharge the air conditioning
refrigerant container can cause an explo- system.
sion, resulting in severe personal injury or
4. When the gauges show normal, close the hand
death.
valve on the manifold, the hose end shut-off valve,
Do not open the high pressure hand valve on the and the valve on the refrigerant container. You can
manifold gauge set. The compressor could pump now proceed with the performance inspection.
refrigerant into the container and cause it to BURST.
Stabilizing the A/C System
NOTE: Be sure to keep the refrigerant container up-
For reliable gauge readings as an aid in troubleshooting,
right to prevent liquid refrigerant from entering
the A/C system must be stabilized.
the compressor.
Tools and equipment

Refrigerant escaping placed next to drive belts can sling out
under pressure can cause severe personal and cause personal injury or property
injury. damage.
2. Open the refrigerant dispensing valve on the con- Be sure your tools and test equipment are clear of all
tainer and then the low pressure hand valve on the moving parts of the engine and air conditioner.
manifold. This allows refrigerant to enter the system Start the engine and set to a fast idle of 1200 to 1500
as a gas on the low pressure or suction side of the RPM. Turn on the air conditioner. After a quick in-cab
compressor. The compressor will pull refrigerant performance test of control function, blower speeds
into the system. and air flow, set the A/C system controls to maximum
3. Add refrigerant in 1/4-lb increments, checking cooling and blower speed on high. All windows must
gauges and sight glass until the gauges read in the be closed. If cab temperature is high, open the windows
normal range and the sight glass appears clear. The for a minute or so to let the hot air out. Run the engine
sight glass may not be clear for a moment just be- and air conditioner about five minutes for the system to
fore or after the clutch cycles on and off but should stabilize.
generally be clear. Gauge readings will fluctuate as
the compressor cycles on and off.
Service Note: Pressure within the air conditioning

system will vary with ambient temperature. A
normal pressure range is defined as follows:
Low side 15-30 PSIg
High side 150-250 PSIg
8-12
Air Conditioner
TROUBLESHOOTING
Blower fans, condenser fans Blown fuse Replace fuse.
and clutch do not operate. Faulty blower fan switch Replace switch.
Faulty wiring Replace or repair wiring.
Condenser fans and magnetic Faulty blower fan switch Replace fuse.
clutch do not operate Faulty thermostat switch Replace switch.
Faulty solenoid Replace solenoid.
Blower fan does not operate Faulty blower fan switch Replace switch.
Faulty wiring between fan switch Replace or repair wiring.
and blower motor
Faulty blower motor Replace or repair motor.
Condenser fans do not operate Faulty thermostat switch Replace thermostat switch.
Faulty solenoid Replace solenoid.
Faulty condenser fan motor Replace condenser fan motor.
Magnetic clutch does not

operate Faulty binary switch Replace switch.
Faulty magnetic clutch coil Replace clutch coil.
Compressor not turning

Loose or broken drive belt Tighten or replace belt.
Slipping compressor clutch Clean or replace clutch.
Faulty compressor Repair or replace compressor. Discharge
and flush system, replace receiver-dryer,
evacuate system and recharge.
Obstructed air flow through Clean

evaporator or condenser cores Plugged evaporator core Clean
Plugged condenser core Faulty thermostat switch or expansion
Evaporator core iced up valve. Replace or repair as needed.
8-13
Air Conditioner
TROUBLESHOOTING
Unit shuts off too soon Faulty thermostat switch Replace switch.
Faulty binary switch Replace switch.
System overcharged Discharge unit and recharge to proper
level.
Suction pressure too high Expansion valve not closing prop- Replace expansion valve.
erly.
Faulty compressor Repair/replace compressor.
Evacuate system, replace receiver-dryer,
flush system and recharge.
Suction pressure too low Low refrigerant charge Install gauges and add refrigerant.
Check thermostat switch and expansion
Evaporator icing up
valve.
Moisture in system Install gauges, discharge and flush sys-
tem. Replace receiver-dryer, evacuate
system and recharge.
Discharge pressure too low Low refrigerant charge Install gauges and add refrigerant.
Compressor belt slipping Adjust/replace belt.
Compressor clutch slipping Clean/replace clutch.
Faulty compressor Repair/replace compressor.

Evacuate system, replace receiver-dryer,
flush system and recharge.
Discharge pressure too high Condenser fins dirty Clean condenser
Condenser fan inoperative Repair fan/motor
Air or excessive oil in condenser or Install gauges, discharge and flush sys-
system overcharged tem. Replace receiver-dryer, evacuate
system and recharge.
High pressure side restriction Discharge system, remove restriction
and flush system. Replace receiver-dryer,
evacuate system and recharge.
8-14
Air Conditioner
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
SUMMARY OF TROUBLESHOOTING DIAGNOSES
PROBLEM Probable CAUSE
1. Excessive Pressure - High Side 1. Air in system.

2. Overcharge of R-134a.
3. Engine overheating.
4. Fan belt slipping.
5. Clogged condenser.
6. Excessive oil in system.
7. Restricted lines.
8. Expansion valve superheat setting too low.
9. Filters or screens plugged.
10. Expansion valve stuck closed.
11. Defective thermostatic switch.
2. Excessive Pressure - Low Side 1. Defective expansion valve (stuck open).

2. Moisture in system.
3. Insufficient oil in system
4. Slipping compressor drive belt.
5. Compressor valves defective.
6. Condenser malfunction.
7. Excessive air in system.
3. Insufficient Pressure - High Side 1. Low charge.

2 Compressor malfunction.
4. Insufficient Pressure - Low Side 1. Low charge.

2. Evaporator blower malfunction.
3. Defective expansion valve (closed).
4. Restricted liquid line.
5. Restricted suction line.
6. Thermostatic switch inoperative.
7. Compressor clutch will not release.
8. Water present - frozen in expansion valve.
5. Insufficient Cooling of Air Flow 1. Defective thermostatic switch.

2. Slipping compressor belt.
3. Compressor defective.
4. Compressor clutch malfunction.
5. Expansion valve malfunction.
6. Low charge.
7. Oil overcharge.
8. Plugged condenser.
9. Overcharge of R-134a.
10. Moisture in system.
11. Air in system.
12. Clogged evaporator.
13. Restricted lines.
14. Engine overheating.
15. Plugged evaporator drain.
16. Evaporator icing
8-15
Air Conditioner
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS (Cont’d)
SUMMARY OF TROUBLESHOOTING DIAGNOSES
PROBLEM Probable CAUSE
6. System Noisy 1. Excessive oil

2. Blower blades not clearing housing.
3. Loose compressor mounts.
4. Loose compressor belt.
5. Loose air ducts.
6. Lines vibrating.
7. Blower motor defective.
8. Obstructed air flow.
9. Defective compressor.
10. Defective expansion valve.
7. Insufficient Air Flow 1. Defective blower.

2. Defective wiring.
3. Defective battery/low voltage.
4. Defective vehicle charging system (voltage).
5. Clogged ducts.
6. Evaporator icing.
7. Loose duct connections.
8. Dirty evaporator.
9. Closed or blocked air outlet louvers.
10. Plugged filters.
8. No Air Flow 1. Blower motor not operating

2. Blown fuse
3. Broken wiring or bad connection
4. Fan motor malfunction.
5. Broken resistor.
6. Fan motor switch malfunction.
9. Sight Glass Bubbles 1. Restricted condenser air flow.

2. Low charge.
3. Moisture in system (tiny bubbles)
4. Air in system.
10. Intermittent Cooling 1. Frozen moisture in expansion valve.
11. Short & Rapid Cycling of Compressor 1. Defective thermostatic switch.

2. Low air flow across the evaporator.
12. Engine Overheating 1. Condenser plugged.
13. Compressor Not Turning 1. Compressor mechanical malfunction.

2. Overcharged.
3. Belt loose.
4. Inadequate voltage at clutch.
5. Condenser inoperative.
6. Faulty clutch coil.
7. Improper gap between clutch faces.
8-16
Air Conditioner
#3. Preventive maintenance Schedule
NOTE: A larger version of this chart, suitable for copying, is provided on Pg 16-17
** When inspecting the compressor, run the system for at least five (5) minutes (40°F
minimum outside temperature), to circulate oil and lubricant components.
*** To guard against the damaging effects of moisture in your air conditioning system,
check the moisture indicator on the receiver-drier once monthly, as specified on the
Preventive Maintenance Schedule above. Dependent on the degree of contamina-
tion, a color change will be evident in the drier sight glass.
COLOR MOISTURE CONTENT ACTION REQUIRED
Blue Dry None

Pink Wet Replace Drier
**** Fresh and recirculation filters should be inspected and cleaned daily, depending
upon operating conditions.
8-17
Air Conditioner
8-18
Air Conditioner
#3. Preventive maintenance Schedule form

This form provided for making copies
8-19
Air Conditioner
8-20
Air Conditioner
#4. REFRIGERANT - CHARGING / RECOVERING

DESCRIPTION AND PROPERTIES OF REFRIGERANTS includes both a chemical analysis and distillation of
Refrigerants are contained in the closed system of an air the recycled refrigerant.
conditioner and circulate under pressure, moving heat Refer to the section below “RECLAIMING THE REFRIG-
energy from the cab to the outside air. Different refrig- ERANT” for a complete description of the reclaiming
erants require different operating pressures, causing the process.
refrigerant to undergo a “change of state”.
Recharging an A/C system requires the following
CHANGES IN SERVICE PROCEDURES procedure:
Since the beginning of 1992, the EPA has required Flush - You flush certain A/C system components and
that any refrigerant removed from an A/C system be hoses to remove contaminants within them. Flush-
recovered and recycled before reuse, Unlike the purging prepares the A/C system for the new refrigerant.
ing process which releases ozone-depleting refrig- Refer to the section below “FLUSHING THE A/C SYS-
erant into the atmosphere, the recovery processes TEM”.
allow service personnel to use the same refrigerant Evacuate - You evacuate the A/C system to remove
over and over. moisture and air. Refer to the section below “EVACU-
A major difference between purge and recover/recycle ATING AND CHARGING THE A/C SYSTEM”.
procedures is the refrigerant is contained in an external- Charge - You charge the A/C system by adding new
ly sealed container when undergoing recovery/recycle refrigerant to the system.
procedures in order to ensure environmentally safe
processing. RECOVERING AND RECYCLING THE REFRIGERANT
In order to reuse a refrigerant in an A/C system, the fol- Recovery / Recycle Station
lowing steps are required: When troubleshooting indicates that a component in a
1. Prepare the station for the recovery process. closed A/C system be replaced or removed for service,
2. Recover refrigerant from the A/C system. refrigerant must be removed from the system. A handy,
dual purpose station performs both recovery and
3. Recycle the recovered refrigerant.
recycle procedures allowing service personnel to follow
4. Perform the maintenance or repair the system. the new guidelines for handling used refrigerant. The
5. Flush the A/C system when necessary. recovered refrigerant can then be recycled to reduce
6. Evacuate the A/C system. contaminants and reused.
7. Charge the A/C system with recycled refrigerant. Equipment is also available to just remove or extract the
refrigerant. Extraction equipment does not clean the
Recycling the refrigerant involves the following refrigerant. It is used to recover the refrigerant from an
procedure: A/C system prior to servicing.
Recovery - You recover a refrigerant when you remove To accomplish this, the recovery/recycle station sepa-
it from an A/C system (in order to repair or replace a rates the oil from the refrigerant and filters the refriger-
component) and then store, transport, recycle, or re- ant multiple times to reduce moisture, acidity, particu-
claim it. This is a closed loop process. The recovered late matter found in a used refrigerant.
refrigerant may vary in quality.
Refer to the section below “RECOVERING AND RECY-
CLING THE REFRIGERANT” for a complete description Mixing refrigerant types dam-
of the recovery process. ages equipment. Dedicate a separate recovery / recycle
station to each type of refrigerant processing to avoid
Recycle - You recycle a refrigerant when you remove
equipment damage.
contaminants such as moisture, acidity, or particu-
late matter. Many refrigerants are reusable at this Recycle equipment must meet certain standards as pub-
stage. lished by the Society of Automotive Engineers and carry
Refer to the section below “RECOVERING AND RECY- a “UL approved label”. The basic principles of operation
CLING THE REFRIGERANT” for a complete description remain the same for all machines, even if the details of
of the recycling process. operation differ somewhat.
Reclaim - You reclaim a refrigerant when you send it Service Note: Keep the collection cylinder in an
to an outside facility which can restore it to a new
product specification. This reprocessing usually
8-21
Air Conditioner
#4. REFRIGERANT - CHARGING / RECOVERING (Cont’d)

upright position for the duration of the recovery/re- and stops, there is a major leak. Refer to Topic #2,
cycle process to ensure that no liquid is drawn back ”TROUBLESHOOTING” for troubleshooting leak pro-
into the system. cedures.
Draining the Oil From the Previous 9. Check the system pressure after the recovery equip-
Recovery Cycle ment stops. After five minutes, system pressure
should not rise above “0” gauge pressure. If the pres-
In preparation for recovery, do the following:
sure continues to rise, restart and begin the recovery
1. Place the power switch and the controller on the sequence again. This cycle should continue until the
recovery unit in the OFF position. system is void of refrigerant.
2. Plug in the recovery station to the correct power 10. Check the sight glass oil level to determine the
source. amount of oil that needs to be replaced.
3. Drain the recovered oil through valve marked OIL 11. Mark the cylinder with a RECOVERED (red) magnetic
DRAIN on the front of the machine. label to reduce the chance of charging a system with
4. Place the controller knob in the ON position. The contaminated refrigerant. If possible, keep a record
low pressure gauge will show a rise. of the amount of refrigerant recovered.
5. Immediately switch to the OFF position and allow NOTE: Check the sight glass oil level to determine the
the pressure to stabilize. If the pressure does not rise amount lost during recovery. You must add
to between 5 PSIg and 10 PSIg, switch the controller this amount of oil back into the system.
ON and OFF again. With practice, this procedure
Performing the Recycling Procedure
should become easier.
The recovered refrigerant contained in the cylinder
6. When the pressure reaches 5 to 10 PSIg, open
must undergo the recycle procedure before it can be
the OIL DRAIN valve, collect oil in an appropriate
reused. The recycle or clean mode is a continuous loop
container, and dispose of container as indicated by
design and cleans the refrigerant rapidly. Follow equip-
local, state, or Federal Regulation. THE OIL IS NOT
ment manufacturer’s instructions for this procedure.
REUSABLE DUE TO CONTAMINANTS ABSORBED DUR-
ING ITS PREVIOUS USE. Purging Non-Condensable Gases (Air)
Performing the Recovery Cycle During purging and refrigerant recovery, air can be
entrapped in the refrigerant container. Air must not be
You are now ready to recover. Follow these steps:
put into an A/C system. The result is higher operating
1. Be sure the equipment you are using is designated pressures and possible system damage.
for the refrigerant you intend to recover.
A simple check can be performed as follows:
2. Record the sight glass oil level. Because it has been
1. Store the recovered refrigerant at constant tempera-
drained, it should be zero.
tures above 65˚ F (18.7˚ C). The container should in-
3. Check the cylinder refrigerant level before begin- clude a pressure gauge reading to 1 psi increments.
ning recovery to make sure you have enough capac- The container should not be in direct sunlight or
ity. near a heat source.
4. Confirm that all shut-off valves are closed before 2. Use a calibrated thermometer to establish tempera-
connecting to the A/C system. ture within 4 inches of the container.
5. Attach the appropriate hoses to the system being 3. Compare the pressures for like temperatures in the
recovered. table below. If the container pressure is equal to or
6. Start the recovery process by operating the equip- less than the pressure shown in the table, excess air
ment in accordance with the equipment manufac- is not present.
turer’s instructions. 4. If container pressure is greater than shown in the
7. Continue extraction until a vacuum exists in the A/C table, connect the container to recovery or recycle
system. equipment with the pressure gauge in place.
8. If an abnormal amount of time elapses after the 5. Bleed a small amount of vapor from the container
system reaches 0 PSIg and does not drop steadily until the pressure is below that shown on the table,
into the vacuum range, close the manifold valves then close the valve.
and check the system pressure. If it rises to 0 PSIg 6. Tank temperature may change during the bleed off
process. Mild shaking will assist in temperature sta-
8-22
Air Conditioner
#4. REFRIGERANT - CHARGING / RECOVERING (Cont’d)

Purging Non-Condensable Gases (Air), Cont’d taminants from the A/C system hoses, evaporator and
bilizing, but it is a good idea to let it set for several condenser. Any other component of an A/C system
hours before again checking pressure against the should be bench checked or replaced, since flushing
table. may be ineffective or may damage a component. Flush-
ing is usually performed after the recovery process. We
7. If the pressure remains above that shown on the
recommend it before you replace the compressor, or
table, excess air or another contaminant (for exam-
when you find contamination in other components
ple, another refrigerant) is still present. This material
(receiver-drier, expansion valve, or connections). Some
must be recycled or reclaimed.
recover/recycle machines have optional “flush kits.” The
8. If the pressure is equal to or below that shown on only proper way to flush system components is to use
the table, identify the cylinder as “recycled”. refrigerant in a closed-loop system.
FLUSHING THE A/C SYSTEM
Flushing has long been recommended as a means of
removing contaminants or other debris from certain
system components.
Using compressed air is not a good method of flushing.
Air should never be used in an R-134a system. Closed
loop flushing kits are now available, although they may
not remove all foreign material.
The primary use of a flushing kit is to remove con-
#5. EVACUATING AND CHARGING THE A/C SYSTEM

Evacuate the system once the air conditioner compo- Your vacuum pump can draw most of the air out pretty
nents are repaired or replacement parts are secured, quickly. But, a deep vacuum requires more time; the
and the A/C system is reassembled. Evacuation removes deeper the vacuum, the longer it takes to get there. To
air and moisture from the system. Then, the A/C system ensure the least possible amount of air and moisture in
is ready for the charging process, which adds new refrig- the system, buy a good quality vacuum pump, take care
erant to the system. of it, and use it for at least an hour.
Evacuating the System
Follow this procedure:
1. Tighten all connections and attach a vacuum pump Lubricants removed during
to the center hose of the gauge set. the recovery process must be replaced with new lubricants.
2. Start the vacuum pump and open both the hand
valves on the manifold all the way. Run the pump Charging the A/C System
for five minutes, then close the hand valves and shut
NOTE: Use a charging station whenever possible.
off the pump.
When adding a full charge of refrigerant, you can put it
3. Check the gauge readings for five minutes. If the
in as a gas or as a liquid. Adding refrigerant as a liquid is
gauge needles move up, the system is not sealed.
faster, but can damage the compressor if not done cor-
There is a leak. Air and moisture are being sucked
rectly. The procedure you use, and where you add the
into the system by the vacuum.
refrigerant in the A/C system makes a difference. When
4. Tighten any loose connections. Restart the pump, using refrigerant as a liquid, never add more than two
and open the hand valves on the gauges again. thirds of system requirements as a liquid. Finish charg-
Repeat the vacuum test. ing the system using gas. Always keep the refrigerant
5. Run the vacuum pump for at least an hour to re- containers in an upright position so that no liquid is
move the moisture from the system. drawn into the system,
The moisture must turn to gas before the pump can pull Refer to the “CHARGING WITH REFRIGERANT GAS” sec-
it out. The moisture takes time to boil away, so that it tion below for the procedure for gas charging. Refer
can be drawn out of the system.
8-23
Air Conditioner
#5. EVACUATING AND CHARGING THE A/C SYSTEM (Cont’d)

to the “CHARGING THE SYSTEM WITH LIQUID REFRIG- valves.
ERANT” section for liquid charging.
Charging the System with Liquid Refrigerant
Charging with Refrigerant Gas (On the Low Side) This process is used as a time-saver, but requires much
Perform this procedure to charge with more care to avoid compressor damage.
refrigerant gas:
1. Use a charging meter or station to select the exact
amount of refrigerant required. Never add more Make sure that the A/C system
than the amount of refrigerant recommended by and the vehicle engine is turned OFF.
the manufacturer (in pounds and ounces). To mea-
1. Check the amount of refrigerant recovered, and add
sure, use a container and scale, or charging station.
approximately two thirds of that amount, and no
2. Connect the center service hose from the gauge set more than recommended by the manufacturer (in
to the refrigerant container dispensing valve. Purge pounds and ounces).
the hose of any air using refrigerant gas pressure
2. Connect the center service hose from the gauge set
from the container.
to the refrigerant container dispensing valve.
3. Run the engine at 1200 to 1500 RPM, with the A/C
3. Add refrigerant liquid through the compressor
unit on maximum cool.
discharge service valve (high side of the system).
4, Open the dispensing valve, then the low side hand If an accumulator is used, add the liquid refriger-
valve on the manifold, ant (and gas during final charging) via a Schrader
Service Note: If there are no manufacturer’s charging valve.
specifications, you can watch the sight glass first for 4. Open the refrigerant dispensing valves and hand
bubbles, then clearing. valves on the hose and gauge set. Liquid refrigerant
In certain conditions, using R-134a refrigerant, the flows in the system.
sight glass will be cloudy. 5. When you have added two thirds of the recorded,
5. Check the sight glass when you have added nearly actual recovered amount of refrigerant, shut off the
the specified amount of refrigerant. Keep adding refrigerant supply. If you added liquid refrigerant at
refrigerant until the sight glass clears or you have the compressor high side service fitting, there may
added the specified refrigerant charge. Use an oil be liquid in the compressor.
injector to replace oil drained from the system. Re- 6. Finish charging the system with refrigerant gas
member, a large leak may have resulted in nearly all by starting the engine and A/C system, Follow
the lubricant being lost. the procedure for charging with gas as shown in
6. Close the valve on the refrigerant container. Close figure.
the hand valve on the gauge set and check the
gauge readings. The gauges should read in the RECLAIMING REFRIGERANT
normal range. Reclaiming refrigerant reprocesses the material to virgin
7. Turn off the engine and A/C system. Check for leaks. purity. For sources of reclaimed refrigerant or to send
If the system checks out OK, back seat the service refrigerant for reclamation, contact the EPA, the inde-
valves. Remove the manifold gauge set hose fittings pendent industry organizations, or your state’s Depart-
from the compressor. ment of Ecology.
If Schrader valves are in use, be sure to remove the
manifold hose fitting quickly and carefully, using a
glove or shop towel to protect your hand. Replace
the protective caps on the compressor service
8-24
Air Conditioner
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other reproduc-
tive harm.
Battery post terminals and related

accessories contain lead and lead
components, chemicals known
to the State of California to cause
cancer and reproductive harm. Wash
hands after handling.
CAT, CATERPILLAR, their respective logos and "Caterpillar Yellow," and the POWER EDGE trade dress as well as
corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permis-
sion.
© 2010 Caterpillar
All Rights Reserved Printed in the U.S.A.

Manual Operador CAT529 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Operador CAT529 PDF

Uploaded by

Copyright:

Available Formats

TABS

519-569 SM/EHC Service Manual Part # 30013158

ALPHA CHARACTER SUBJECT

519sm-569sm Knuckleboom Loader

519/569 ESM/EHC Knuckleboom Loader

519/569 ESM/EHC  1008

519/569 ESM/EHC ii 1008

519/569 ESM/EHC iii 1008

The Safety Alert Symbol means

Understand signal words: DANGER, WARNING, and

DANGER identifies the hazard or unsafe

DANgER practice that will result in severe person-

WARNING identifies the hazard or unsafe practice

CAUTION identifies the hazard or unsafe practice

NOTICE identifies important installation, operation, or

519/569 ESM/EHC iv 1008

general safety.................................................. section 1

safety decals..................................................... section 2

component terminology........................... section 3

controls & instruments............................ section 4

break in period.................................................. section 8

Scheduled/periodic maintenance services........

Material safety data sheets..................SECTION 17

519/569 ESM/EHC  1008

519/569 ESM/EHC vi 1008

Safety alert symbol

• safety and instruction decals

Control shut off lever

519/569 ESM/EHC 1- 1008

DANgER SERIOUS INJURY OR

WARNINg Electrical storms (light-

519/569 ESM/EHC 1- 1008

Falling or swinging logs

WARNINg Falling or swinging logs,

Fire prevention/First aid

CAUTION Fires can cause personal

519/569 ESM/EHC 1- 1008

Fluids under pressure

WARNINg Fluids escaping under

Hand holds and steps

WARNINg Slips and falls can cause

519/569 ESM/EHC 1- 1008

WARNINg Accidents can cause

WARNINg Failure to disconnect

Hoses and fittings

WARNINg Mismatched brands or

519/569 ESM/EHC 1- 1008

WARNINg Mobile phones can

WARNINg Machine riders can fall

WARNINg Flying debris, tree limbs,

519/569 ESM/EHC 1- 1008

Practice safe maintenance

WARNINg Excessive hydraulic

519/569 ESM/EHC 1- 1008

Wear snug, protective clothing that is belted where

WARNINg Misuse, interference and

519/569 ESM/EHC 1- 1008

WARNINg Unsuitable installation

WARNINg Unauthorized welding

NOTICE Unauthorized welding can

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1-10 1008

519/569 ESM/EHC 2- 1008

519/569 ESM/EHC 1008

519/569 ESM/EHC 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 1- 1008

519/569 ESM/EHC 2- 1008

519/569 ESM/EHC 2- 1008

519/569 ESM/EHC 3- 1008

519/569 ESM/EHC 3- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 4- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008

519/569 ESM/EHC 5- 1008