Professional Documents
Culture Documents
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
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
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.
safety symbols
safety alert symbol
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.
contents
product protection plan
Machine ................................................................................. i
to the operator...................................................................iii
Safety Symbols..................................................................iv
IQAN.............................................................................SECTION 5
PRESTART INSPECTION..........................................SECTION 6
Operation.............................................................. section 7
transportation................................................ section 9
lubrications......................................................section 10
Maintenance safety....................................section 11
storage.................................................................section 13
troubleshooting..........................................section 14
specifications...................................................section 15
serial numbers................................................section 16
WARNINg Do not operate this machine without reading and understanding this operator’s
manual.
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
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.
Electric lines
Electrical storm
G.083.03
Hand signals
High voltage
mobile phones
No riders on machine
Operator safety
Pressure settings
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
Protective devices/equipment
Electronic regulator
Unauthorized welding
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.
LOADER DECALS
daNgER
HaZaRdOuS VOLtagE tuRN Off POwER
wILL CauSE bEfORE OPENINg PaNEL.
SEVERE INjuRY OR
dEatH.
11/89 10000055
daNgER
WARNINg
UNSAFE OPERATION OR
MAINTENANCE CAN CAUSE
SEvERE INJURY OR DEATH.
WARNINg
FALLINg OR SWINgINg LOgS OR
BOOMS CAN CAUSE SEvERE
INJURY OR DEATH.
waRNINg
PERSONNEL.
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
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
COMPONENT TERMINOLOGY
Loader
d e
d e
hourmeter
dome light
dome light
Press switch on dome light (A) to turn dome light on or
off.
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.
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.
b
g.025.03
seat suspension
While seated, rotate handwheel (B) until seat cushion
is level.
backrest
armrest
B
Rotate control knob (C) to select desired armrest angle.
Pivot armrest up and parallel with backrest when not
in use.
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.
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.
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.
Adjustment Screen
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.
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.
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.
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.
Display Settings:
Depress F1 button to alter display settings.
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 .
information Screen
Information
Depress the F4 button to access information screens:
Modules:
Depress the F1 button to view modules:
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.
Check for protective clothing (wear it) and safety equipment (know where it is).
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 that safety decals are on machine and that they are readable.
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.
Check for combustible or flammable materials. Remove them from machine if you find them.
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 Inspection
Check hydraulic hoses in platform/boom end area for wear and/or damage. Replace any
defective hoses and/or lines.
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.
Check that there is no mud or debris on cab floor (clean away mud and debris).
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 instrument panel for broken gauges and/or broken indicator lights. Have
gauges and/or indicator lights repaired if necessary.
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
Pre-start Inspection
fire prevention
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.
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
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.
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
machine start up
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.
landing layout
g.037.03
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.
break-in period
ESM/Ehc loaders
NOTICE
The above fluid capacities are approximate values. Be sure to check levels after filling. DO NOT
OVERFILL!
NOTICE DO NOT wrap chains around machined surfaces. Travel vibration can cause
chain hammering.
hydraulic oil
Hydraulic systems have been filled from the factory with Premium All-Season Hydraulic Oil 46.
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.
GREASE
Premium
Moly-Lith
EP No. 2 Grease
Premium
Moly-Lith
EP No. 2 Grease Premium
Moly-Lith
EP No. 2 Grease
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.
STORING LUBRICANTS
Store lubricants in a clean area that will keep them protected from water, dirt, or other contamination.
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.
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.
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.
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
protective clothing
unauthorized welding
hydraulic safety
WARNINg Fluids escaping under
pressure can penetrate skin and cause severe
personal injury or death. Wear eye and personal
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.
during maintenance
pinch points
cooling fan
after maintenance
disposing of waste
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.
as required
5, 6
SM-Tank-Maint-Ops
SM-Loader-Ops-Maint
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
5, 6
SM-Tank-Maint-Ops
7
12
17 18
14
13 11
9
15 8
10
SM-Loader-Ops-Maint
MAINTENANCE CHART USAGE
Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.
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
SM-Tank-Maint-Ops
19, 20
21
SM-Loader-Ops-Maint
22
SM-Tank-Maint-Ops
23
SM-Loader-Maint-Ops
26
SM-Loader-Maint-Ops
27, 28
29
SM-Loader-Ops-Maint
SM-Tank-Maint-Ops
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
WARNINg Fluids escaping under
pressure can penetrate skin and cause severe
personal injury or death. Wear eye and personal
protection equipment (PPE)!
Do not attempt to service the accumulator without
first discharging the accumulator.
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.
WARNINg unauthorized
welding can cause structural failure and/or severe
personal injury or death.
STORAGE
PREPARING MACHINE FOR STORAGE
1. Operate machine long enough to warm its fluids. Check for leaks after machine warms up.
5. Start motor and operate the machine long enough to warm the oil. Check for leaks after machine warms up.
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.
2. Check hydraulic oil level. If low, check for leaks and add oil as required.
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.
troubleshooting
loader
Noisy, vibrating hydraulic system. Air in system. Check fluid level and see an authorized
dealer if problem persists.
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.
electric motor
ELECTRICAL SYSTEM
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
SPECIFICATIONS
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
S = Standard
O = Optional
S = Standard
O = Optional
Lift Chart
519SM and 519SM/EHC Loaders 8.2m (27’) Boom
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
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")
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.
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
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
Make sure the O–Ring does not fall out of the male end before connection is made. Proper lubrication helps.
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
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).
Da s h S iz e T orque
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
Da s h S iz e T orque
1– 14 U N F 540 732
SERIAL NUMBERS
PR
EN
TI
CE
384
Machine Serial Number
R
CLEA
KEEP
Part Number
Part Number
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.
NOTES
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
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.
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-
Hydraulic Specifications & Test Procedures
Cycle Times
cat 519sm
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-
Hydraulic Specifications & Test Procedures
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.
Pilot Pressure
3103 kPa/450 PSI (31 bar)
2-
Hydraulic Specifications & Test Procedures
Pilot Pressure
3103 kPa/450 PSI (31 bar)
2-
Hydraulic Specifications & Test Procedures
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-
Hydraulic Specifications & Test Procedures
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.
8. Record the GPM/LPM reading when the pressure
reading reaches 80% of the system main relief set-
ting.
2-
Hydraulic Specifications & Test Procedures
Pump check
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
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
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
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
Hydraulic Specifications & Test Procedures
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.
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
can result without proper medical treatment.
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
Hydraulic Specifications & Test Procedures
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
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.
3-
Hydraulic Systems
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
RETURN
RETURN
FILTER
OIL COOLER
3-
Hydraulic Systems
Plugged
Plugged
OUT
3-
Hydraulic Systems
main boom up 2750 PSI main 1000 PSI main boom down
OUT
3-
Hydraulic Systems
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
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:
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.
Ambient dirt can enter a disconnected hose or tube
without the technician’s knowledge. Clean hose and
tube fittings before disconnecting. Keep open ports
3-
Hydraulic Systems
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
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 swing in one Faulty pilot plumbing or component Check to ensure that the pilot lines
Direction only 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
Any one function will Faulty pilot plumbing or component Check to ensure that the pilot lines
not operate from the controller to the control
valve are properly installed. Check
pilot supply pressure, check pres-
sure at controller and at valve spool
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
valve are properly installed. Check
pilot supply pressure, check pres-
sure at controller and at valve spool
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
Low hydraulic oil level Fill to proper level with the proper
oil
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.
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.
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.
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.
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
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.
4-
Major Hydraulic Components
10087281--1
10083842--1
3
When removing filter element from canister, do not 1
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-
Major Hydraulic Components
Hydraulic Pump
#3
#2
#1
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-
Major Hydraulic Components
Hydraulic Pump
FUNCTIONS
GENERAL Information
Fluids escaping under
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.
Repair Instructions
Disassembly
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-
Major Hydraulic Components
Repair Instructions
Disassembly, continued
Repair Instructions
Disassembly, continued
Repair Instructions
Disassembly, continued
Repair Instructions
Disassembly, continued
Repair Instructions
Assembly
Repair Instructions
Assembly, continued
Repair Instructions
Assembly, continued
Repair Instructions
Assembly, continued
Repair Instructions
Assembly, continued
Repair Instructions
Assembly, continued
Repair Instructions
Assembly, continued
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.
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
Major Hydraulic Components
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
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
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
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
SWING
MOTOR
CROSSOVER
RELIEF
4-25
Major Hydraulic Components
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
4-27
Major Hydraulic Components
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.
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
Major Hydraulic Components
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
Major Hydraulic Components
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.
8. Record the GPM/LPM reading when the pressure
reading reaches 80% of the system main relief set-
ting.
4-31
Major Hydraulic Components
Pump check
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
Major Hydraulic Components
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
Major Hydraulic Components
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.
Hi-Boy Sections:
Stick, Rotor,
Main, Grapple, and
Slasher
IN OUT
Sectional Valves
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
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.
CLEANING of Parts
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.
Flying debris from cleaning
parts with compressed air can cause severe personal
injury. Follow the adhesive manufac-
turer's instructions for proper cleaning and curing. Failure
Wear a face shield and protective clothing (PPE!).
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
Major Hydraulic Components
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.
Item Qty Description
Item Qty Description
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
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.
Sectional Valves
4-44
Major Hydraulic Components
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.
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.
Swing Pedal
S1 R
LEFT P = PRESSURE
S2 RIGHT
R = RETURN
Exploded view of pilot foot controller to show the major component parts.
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.
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
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.
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.
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 two wide center slots in the spool are the supple and
exhaust ports for the cylinders. The narrow end slots are
balancing grooves.
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)
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
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.
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.
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".
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.
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.
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
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
40 A/R SHIM, Plastic, .005
41 A/R SHIM, Plastic, .010
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
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
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]
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.
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
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
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.
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
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.
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
Grade 5
Figure 1
GRADE 5
COARSE THREAD (NC) FINE THREAD (NF)
Grade 8
Figure 2
GRADE 8
COARSE THREAD (NC) FINE THREAD (NF)
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
Da s h S iz e T orque
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
Da s h S iz e T orque
1– 14 U N F 540 732
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.
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
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
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
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.
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.
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.
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
Part numbers are provided for convenience. Always verify part numbers before ordering.
*KHI Item refers to item numbers used in Kawasaki's service procedure and cross-section diagram.
6-20
Mechanical Service
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
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]
Disassembly Procedure
sWing
motor
drive
gearbox
mtg. capscrew
437-483 ft-lbs
[593-655 n-m]
hardened
Washer
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
Disassembly Procedure
Disassemble No. 1 Carrier
5. Disassemble the No. 1 carrier assembly:
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
Disassembly Procedure
6. Remove No. 2 sun gear (204), as shown in
Fig. 13.
7. Remove No. 2 carrier assembly (230), as
shown in Fig. 14.
Disassemble No. 2 Carrier
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
Disassembly Procedure
Disassemble No. 2 Carrier
(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.
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.
Assembly Procedure
7. Insert snap ring (913) above the bearing, as
shown in Fig. 23.
Assembly Procedure
13. Install No. 2 carrier assembly into ring gear,
as shown in Fig. 26.
Assembly Procedure
Assembly Procedure
Special Tools
DIMENSIONS IN MILLIMETERS
DIMENSIONS IN MILLIMETERS
DIMENSIONS IN MILLIMETERS
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.
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
Warning: To avoid personal injury or property damage, read all safety ma-
terials in the Operator's Manual.
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
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.
7-
Electrical Systems
7-
Electrical Systems
General information
LOCATION
Installation
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
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
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.
Cleanliness Service
Lubrication procedures
Lubrication intervals
Troubleshooting
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
The information in this section will help the Service Technician to troubleshoot and repair the Air Conditioning
System.
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.
8-
Air Conditioner
8-
Air Conditioner
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
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
American Standard
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
Metric Standard
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
D D
Fig. 1: Air Conditioner flow diagram. Circled Letters are explained in the “Key Letters” charts in Figs. 2, 3, 4 &
5 (inset).
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
b
C
b
e C
A
d
C A C
b e d
8-
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.
Faulty wiring Replace or repair wiring.
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 wiring Replace or repair wiring.
Faulty condenser fan motor Replace condenser fan motor.
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.
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
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.
**** Fresh and recirculation filters should be inspected and cleaned daily, depending
upon operating conditions.
8-17
Air Conditioner
8-18
Air Conditioner
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.