Komatsu Mobil Cranes 150a-150fa

SMC-150FA
Shop
Manual
150A
150FA
CRANE
SERIAL NUMBERS
150A -09695 - 10827
150FA -09695 - 10827
This material is proprietary to Komatsu America International Company and is not to be reproduced,
used, or disclosed except in accordance with written authorization from Komatsu America International
Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the
right to make changes or improvements at any time without incurring any obligation to install such
changes on products sold previously.
Due to this continuous program of research and development, revisions may be made to this
publication. It is recommended that customers contact their distributor for information on the latest
revision.
Copyright 2002 Komatsu
DataKom Publishing Division
October 2002
GRADER d
PLANER 0
ROLLER d
CRANE d
C6
R O S S P O W E R STEERING GEAR
APPLICABLE GRADER MODELS : ~. SERIAL NUMBERS-..
118A 07245 thru 07600
118B 07601 thru 10750
118C 10751 thru 12013
104A 07245 thru 07600
104B 07601 thru 10750
104C 10751 thru 12013
104HA 07245 thru 07619
104HB 07620 thru 10693
160E 02155 thru 02714
160C 02715 thru 03029
160L 02121 thru 03083
T500A 02601 thru 07994
T500L 02944 thru 07994
T600B 01501 thru 02535
APPLICABLE ROLLER MODEL§ SERIAL NU-MBERS
PTR 9-Wheel R o l l e r 00101 thru 05678
APPLICABLE CRANE MODELS . SERIAL NUMBER§
80 01001 thru 03131
90 thru 125 01150 thru 08774
90A thru 125A 02006 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 02832 a n 3 Up
150FA 07305 and Up
200FA 09401 and Up
CONTENTS Page
Torque S h e e t e e . e . , . , , . . . Back o f Cover
e
Disassembly . . . . O . . . . l . . . , l . . . ~ . . . 1
. ..
S e r v i c e t o Cam and A c t u a t o r Assembly , . , . , e 9
.
S e r v i c e t o Lever S h a f t and S t u d Assembly . . . . 10 e
. . . . .. .
a
S e r v i c e t o Valve Assembly . . . . 11
Reassembly . . . . . . . . * *. . . . . . ( . . . . . 14
. .
I n s t a l l a t i o n and Adjustment o f Valve Assembly . , 22 e
Lubricant Specifications .. e. . . . ...

.e .
a e 25
.. .. . . .
a
Troubleshooting . . a e . . ,a . 25
e
CAUTl ON
ALL COMPONENTS MUST B E PROPERLY SUPPORTED DURING
DISASSEMBLY AND ASSEMBLY.
ALL JACKING, HOISTING, AND GENERAL WORKSHOP EQUIP-

MENT REQUIRED FOR THIS OPERATION MUST B E IN
GOOD WORKING ORDER.
EXTREME CAUTION TQ BE OBSERVED AT A L L TIMES TO PREVENT

INJURY.
SAFE WORKSHOP PRACTICES ARE A MUST.
The following General Torques are to be used in ail cases where SPECIFIC TORQUES are not given.
NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
I Heat treated material Grade 5 & Grade 8
Grade 8
(6 radial dashes on bolt or cap screw head)
Foot Pounds
(Nm)
__ SHOP MANUAL SECllON '20
DISASSEMBLY:
1
Remove a d j u s t i n g screw l o c k n u t .
2
Remove small cap screws f r o m c o v e r .
3
Remove n u t s and washers f r o m ends o f l a r g e r c o v e r
b o l t s (beneath s t e e r i n q g e a r mountina pad), i f so
equipped.
1
FILE A
SHOP MANUAL SECTION
Remove l a r o e c o v e r r e t a i n i n o b o l t s : if so
equipped.
On p r e v i o u s models ( w i t h s h i m - a d j u s t e d l e v e r
s h a f t ) , c o v e r may now be 1 i f t e d o f f . Proceed t o
Step 9 on page 4.
On l a t e r models ( w i t h s c r e w - a d j u s t e d l e v e r s h a f t ) ,
use s c r e w d r i v e r t o t u r n a d j u s t i n g screw c l o c k w i s e .
T h i s wil liftc o v e r f r o m housinq. Screw must be
t u r n e d a l l t h e way t h r o u g h t h e housing. Proceed
t o Step 6 on page 3.
Some p r e v i o u s model motor graders and a l l r o l l e r s

and cranes w i t h t h e Ross u n i t a r e equipped w i t h a
one- piece s t e e r i n g s h a f t . The pitman arm i s
s p l i n e d t o t h e l o w e r end o f the- lever s h a f t i n
t h e s e models.
To remove t h e pitman arm from t h e l e v e r s h a f t ,

remove n u t and washer from s p l i n e d end. Raise
l e v e r s h a f t and i n s e r t wood b l o c k under s p l i n e d
end t o r a i s e s t u d r o l l e r b e a r i n g away from cam.
T h i s p r e v e n t s damage t o s t u d r o l l e r b e a r i n g and
cam. Then d r i f t pitman arm from s h a f t .
2
FILE A
SHOP MANUAL SECTION
Pry staked portion of a d j u s t i n q screw lock n u t

from s l o t i n l e v e r s h a f t .
7
Remove a d j u s t i n g screw lock n u t .
8
L i f t a d j u s t i n g screw from pocket i n l e v e r s h a f t .
3
FILE A
SHOP MANUAL SECTION 1.20
9
On nre\iious trodels (with shim-adjusted l e v e r
s h a f t ) , remove l e v e r s h a f t and shim pack from
gear housing. Keep shim pack i n t a c t .
This s t e p i s normally done only i f t o replace
s h a f t , bushings or s e a l . I f none of t h e s e
replacements a r e r e q u i r e d , s l i d e l e v e r s h a f t u p ,
r o t a t e 180", and r e s t l e v e r on back of case.
10
On l a t e r models (with screw-adjusted l e v e r

s h a f t ) , no shim pack i s used t o a d j u s t l e v e r s h a f t
stud r o l l e r t o cam. Adjustinq screw holds l e v e r
s h a f t in p o s i t i o n .
Remove l e v e r s h a f t only i f t o replace s h a f t ,
bushings or s e a l . I f n o t required, then s l i d e
l e v e r s h a f t u p , r o t a t e 180°, and r e s t l e v e r on
back of case.
11
Remove four ( 4 ) socket head cap screws holding
valve, valve s p a c e r , and cover t o control ( o r
a c t u a t o r ) housing. Actuating l e v e r , p i n , seal
and washer w i l l be removed with t h e valve.
Previous valve configuration i s pictured. Service
t o t h i s assembly i s i l l u s t r a t e d on page 1 1 .
4
FILE A
SHOP MANUAL SECTION 1-20
12
On orevious models (with one-piece control or

a c t u a t o r housing) remove f o u r ( 4 ) cap screws,
cover, shims, and qaskets. lblheel tube can now
be removed. Inspect bearings a n d s p l i n e s f o r
serviceability.
On models wi t h two-piece ( s e p a r a t e upper cover
a n d a c t u a t o r ) a c t u a t o r housins, proceed t o Sten 18
on page 7 .
Wheel tube bearings can be replaced by removing

r e t a i n i n g snap r i n q s . I t appears t h a t each
bearing i s missing one b a l l - - t h i s i s c o r r e c t .
Balls must be replaced by s e t s only.
14
Remove cap screws, control housina, a n d qasket.

Insoect control housing f o r i n t e r n a l bearing
race wear.
5
FILE, A
15
Remove cap screws, shims, q a s k e t s , sleeve
r e t a i n e r , a n d end cover. Cam assembly can now
be removed.
16
Remove cam assembly.
17
Inspect case a t mountinq f o r wear or breakage.
Inspect l e v e r s h a f t bushing f o r wear or damaqe
and replace as required.
Proceed t o Step 24 cn paae 9 .
6
FILE A
$HOP MANUAL SECTION 1-20
18
O n models w i t h two-piece ( s e p a r a t e upper cover
and a c t u a t o r ) a c t u a t o r housinq, remove cover ( 1 )
and gasket ( 2 ) .
19
Remove a c t u a t o r r e t a i n e r screw and washer, then
remove a c t u a t o r housinq and gasket.
20
Remove cam and a c t u a t o r assembly.
7
FILE A
21
I f cam assembly b e a r i n m r e q u i r e reolacement,
remove end cover and gasket.
22
Reassemble needle bearings i n t o housing. Press
t o l o c a t i n g ring with extreme c a r e .
23
Inspect case a t mountinq f o r wear or breakape.
InsDect l e v e r s h a f t bushina f o r wear or damaae an d
rep1 ace as required.
FILE A
S E R V I C E T O CAM & A C T U A T O R ASSEMBLY
24
Later models with two-piece a c t u a t o r housing employ
an a c t u a t o r u n i t assembled on t h e cam.
Remove a d j u s t i n g n u t a f t e r s t r a i g h t e n i n g bent prong
on lock washer.
25
Remove lock washer ( l ) , tongued washer ( 2 ) , t h r u s t
washers ( 3 ) , needle bearing (4), and upper cen-
t e r i n g washer ( 5 ) from above a c t u a t o r . Do not l o s e
springs ( 7 ) i n a c t u a t o r .
Remove lower centering washer ( 5 ) , t h r u s t
washer ( 3 ) , and needle bearing ( 4 ) a f t e r removing
actuator ( 6 ) .
26
Inspect cam f o r damaqe and excessive wear. Check
cam qroove f o r chipping, s c o r i n g , or bri nnell inq.
Check cam bearinq s u r f a c e s and s p l i n e s . Wearina
away o f copper p l a t i n a i s natural a n d will come i n
time t o a1 1 cams.
Pictured i s the cam assembly used i n previous u n i t s
with one- piece control housing. Spring assemblies
a r e not a d j u s t a b l e . They a r e f a c t o r y s e t . The
smaller race o f t h e t h r u s t bearing should be lo-
cated next t o the cam.
O n l a t e r models with two-piece a c t u a t o r housinq,
reassemble a c t u a t o r assembly on cam wheel tube
assembly and a d j u s t . P r i o r t o assembly, make s u r e
t h a t threads a r e s t r a i g h t a n d t h a t n u t can be run
down by f i n g e r torque a l l t h e way. Assemble i n
order shown in Step 25.
Tighten n u t t o 10 f t . - l b s . torque. Then back o f f
n u t 10" or 5/32" ( t h e width of a lug o n t h e lockinq
washer). This adjustment must r e s u l t i n a l i g h t pre-
load on bearinas b u t allow NO end play o f a c t u a t o r
on s h a f t .
9
FILE A
SHOP MANUAL SECTION, 1-20
SERVICE TO L E V E R SHAFT & STUD ASSEMBLY
27
Check s h a f t s p l i n e s and threads on l e v e r s h a f t .

Reolace i f needed.
28
Check stud f o r f l a t s p o t s , n i c k s , o r spa11 inq
29
Adjustment of stud r o l l e r bearinq must be s e t t o

t h r e e inch-pounds preload f o r c o r r e c t o o e r a t i o n .
10
FILE A
S E R V I C E TO V A L V E ASSEMBLY
30
Remove water seal r e t a i n e r , water s e a l , valve spool
cover, and valve cover "0" r i nq by removinq t w o ( 2 )
can screws.
31
On some previous model valve assemblies, d r i f t o u t
pin with small punch a n d remove a c t u a t i n g l e v e r
from swivel bearing rod and valve body.
32
Remove c l e v i s o r swivel bearing rod from end o f
so001 by removinq c o t t e r p i n , loosening n u t , and
unscrewing rod from spool.
11
FllE A
33
Push spool o u t c l e v i s or swivel bearing rod end
a b o u t 1 / 2 " u n t i l "0" rinq i s exposed. Remove
"0" r i n g .
34
Push spool o u t o t h e r end t o expose "0" r i n g .

Remove "0" r i n q .
35
Remove s p o o l a n d i n s p e c t for wear a n d scorinq.
12
FILE A
~ ~ ~- SHOP MAMUAL SECTION '*Zo
36
I n s t a l l "0" r i n a on spool. Lubricate "0" r i n a with
Dexron or Type A o i l and then c a r e f u l l y i n s e r t
spool in valve.
37
Push spool through t h e valve body unti 1 "0" r i n a

qroove on c l e v i s or swivel bearing rod end i s
exposed. I n s t a l l "0" r i n q in groove a n d l u b r i c a t e
with Dexron or Type A o i l . Push i n t o valve with
c a r e u n t i l "0" r i n g just e n t e r s body of valve.
38
Screw n u t onto c l e v i s o r swivel bearing rod

assembly, then place lock washer next t o n u t and
screw c l e v i s rod i n t o threaded end of spool. Do
n o t tighten.
13
REASSEMBLY
39
Clean housing thorouahly.

Check housing o i l seal f o r damage or leakaqe.
Reolace i f necessary.
When r e p l a c i n g , i n s t a l l seal over s h a f t as shown
I f gear i s equipped with two-piece a c t u a t o r
housing, proceed t o Step 47 on page 1 6 .
40
On previous models with one-piece control housing,
i n s t a l l new gasket a n d control housing. Torque
cap screws t o 25 foot-pounds.
41
I n s t a l l wheel tube assembly and replace cover.

Care must be exercised durinq i n s t a l l a t i o n so as
not t o damage seal i n cover.
14
FILE A
SHOP MANUAL SECTION
42
A shim pack i s used between two qaskets t o e s t a b -

l i s h a mild preload on t h e wheel tube bearings.
Adjust by addinu o r removing shims u n t i l t h e
bearings do n o t r a t t l e as t h e wheel tube i s slowly
turned. Wheel tube must, however, turn f r e e l y
without excessive draq. (Shims .002",and .010".
Gasket .010" t h i c k a v a i l a b l e . )
43
C o a t cam s h a f t s p l i n e with grease and i n s e r t

assembly i n t o gear case.
44
Place cover i n o o s i t i o n and measure qap with f e e l e r
gauge or shims. (This measurement will i n d i c a t e
the amount of shims necessary t o eliminate end play
of cam assembly.)
15
SHOP MANUAL SECTION ' ~ ~ 0
45
I n s t a l l shims and gaskets (use a qasket on each
end of shim assembly). Gaskets a r e .010" t h i c k
b u t each become only .006" when compressed. Shims
a r e a v a i l a b l e in .002",. 0 0 3 " , a n d .010" thickness
Torque cao screws t o 25 foot-pounds.
46
Cam should turn f r e e l y i n housing by f i n q e r
pressure. I f i t does not turn f r e e l y , a d d shims
t o end cover. Cam should have no end movement by
f i n q e r Dressure. I f i t does have end movement,
remove shims from end cover.
Proceed t o Step 50 on paqe 1 7 .
47
I f s t e e r i n g gear i s equipped with two-piece
a c t u a t o r housinq, assemble cam i n housinq. Be
c e r t a i n t h a t cam r o t a t e s and o s c i l l a t e s f r e e l y in
housing.
16
FILE A
SHOP MANUAL SECTION 1*20
48
Position gasket and a c t u a t o r housing. Be c e r t a i n
t h a t s l o t i n a c t u a t o r i s horizontal t o take
r e t a i n e r screw.
49
I n s t a l l g a s k e t , r e t a i n e r washer, r e t a i n e r screw
and c o v e r . Use care n o t t o damage seal i n cover
during i n s t a l l a t i o n . Torque cap screws t o 25 f o o t -
pounds.
50
O n previous models with shim adjusted l e v e r s h a f t ,
i f s h a f t has been removed from c a s e , i n s t a l l shim
pack on l e v e r s h a f t and lower s h a f t i n t o place i n
cas e.
17
FILE A
SHOP MANUAL SECTION
51
Position lever shaft i n position with stud r o l l e r

i n c e n t e r o f cam.
I f l e v e r s h a f t i s shim a d j u s t e d , proceed t o Step

57 on page 20.
52
I f l e v e r s h a f t i s screw- adjusted,, p l a c e a d j u s t i n g
screw i n pocket o f l e v e r s h a f t .
53
I n s t a l l a d j u s t i n g screw l o c k n u t .
18
FILE A
SHOP MANUAL SECTION 1.2o
54
T i g h t e n l o c k n u t and s t a k e p o r t i o n o f n u t f l a n g e
i n s l o t on l e v e r s h a f t .
A d j u s t i n g screw must be f r e e t o t u r n a f t e r l o c k
n u t i s tiqhtened.
55
With new g a s k e t on c o v e r , p l a c e c o v e r i n p o s i t i o n
o v e r housing and a d j u s t i n g screw.
56
Screw a d j u s t i n g screw c o u n t e r c l o c k w i s e u n t i l
c o v e r f i t s t i g h t i n p l a c e on housing.
19
57
On p r e v i o u s models w i t h s h i m - a d j u s t e d l e v e r s h a f t ,
r e p l a c e c o v e r and gasket. I n s t a l l t h r e e l a r g e
c o v e r r e t a i n i n g b o l t s , i f used, and t i g h t e n
securely.
58
I n s t a l 1 l a r g e c o v e r bo1 t l o c k washers and n u t s , i f

used, beneath s t e e r i n a a e a r mountinq pad.
59
I n s t a l l s m a l l c o v e r r e t a i n i n g cap screws.
Torque t o 25 foot- pounds.
20
FILE -~ A
SHOP MANUAL SECTION
60
On p r e v i o u s models w i t h shim- adjusted l e v e r s h a f t ,

assemble a d j u s t i n g screw and jam n u t and t i g h t e n
screw u n t i l a very s l i g h t d r a g i s f e l t when t u r n i n g
gear t h r o u g h m i d p o s i t i o n .
When adjustment i s o b t a i n e d a t t h e p o s i t i v e h i g h
s p o t i n c e n t e r o f cam and w h i l e h o l d i n g screw
w i t h screw d r i v e r , t i g h t e n jam n u t . Turn g e a r
t h r o u g h complete t r a v e l t o check adjustment.
61
I f h i g h s p o t cannot be f e l t i n above adjustment,

t h e n remove one o r more shims from t h e shim pack.
(These shims wil be found i n .003", .010" and
.020" between two washers) u n t i l d r a g can be f e l t .
Repeat Step 60 above u n t i l c o r r e c t adjustment i s

obtained.
62
I f l a t e r model w i t h screw- adjusted l e v e r s h a f t ,

i n s t a l l l e v e r s h a f t a d j u s t i n g screw l o c k n u t .
To a d j u s t l e v e r s h a f t t o cam, screw a d j u s t i n g screw

c l o c k w i s e u n t i l t i g h t , t h e n c o u n t e r c l o c k w i s e one
ha1 f t u r n .
Hold i n p o s i t i o n and t i g h t e n l o c k n u t .
21
SHOP MAMUAL SECTION 1-20
63
Assemble rubber seal on a c t u a t i n q l e v e r . Pictured

i s l a t e r configuration. Previous configurations
have a c t u a t i n g 1 ever pinned t o valve. Reinstal 1
a c t u a t i n g l e v e r o n swivel bearing rod a n d valve
body a t t h i s time.
64
Assemble valve t o mounting bracket and make c e r t a i n
t h a t s l o t of a c t u a t o r l e v e r engages pin i n c l e v i s .
65
Center spool in valve.

Hold s t r a i g h t edge across valve housinq a n d with
screw d r i v e r , turn spool i n or out u n t i l spool a n d
housina a r e f l u s h .
22
FILE A
66
Holding spool securely in aligned p o s i t i o n with
screw d r i v e r , s t r a i g h t e n t h e c l e v i s or swivel
bearinq rod t o a horizontal p o s i t i o n and lock i n
place with jam n u t . Replace c o t t e r pin.
67
Reassemble water cover a n d s e a l . ( C u p of water

seal toward valve. )
68
Place s t e e r i n g qear on machine sending l e v e r s h a f t

through lower bearing. Use a d j u s t i n g screws t o
a l i g n gear. Alignment must be checked by removing
cover and picking l e v e r s h a f t u p . I f l e v e r s h a f t
i s f r e e and f l o a t s back i n place, no misaliqnment
exists.
Reconnect s t e e r i n q universal t o case s h a f t .
23
69
Center s t e e r i n g gear by moving t h r o u g h f u l l t r a v e l

and counting t u r n s of t h e s t e e r i n g wheel. Turn
t h e wheel back half t h i s number t o mid p o s i t i o n .
Reconnect s t e e r i n g (pitman) arm t o l e v e r s h a f t
with wheels s t r a i g h t ahead a t t h i s p o s i t i o n .
70
On motor g r a d e r s , t i g h t e n upper and lower v e r t i c a l

s h a f t nuts t o 450 foot-pounds.
24
FILE A
S T E E R I N G GEAR L U B R I C A N T S P E C I F I C A T I O N S
TROUBLE
TROUBLE -
CAUSE Y
Hard Steerinq 1 . Pump belt slipping Tiqhten belt, Replace belt I f worn,
( i f pump i s belt driven)
2 . Insufficient pump pressure. Refer t o t4ydP.au-Ii c Trouble Shootlng
3. Sticky relief valve Replace re4 i e f valve - Refer t o
(Prevents pressure build up. ) Hydraulic Trouble Shooting
4. Low fluid level. (Loss of Repair t o e4 iminate leaks and
hydraulic oil due t o leaks or refll1 system and reservoir.
damaged 1 i nes) .
5. Valve o u t of adjustment. Check ~ d ~ ~ o fs Thrust
~ ~ Bearing,
e n ~
then check ~ d ~ ~ s t m oe fn Valve
t Spool *
6. Spool in valve sticking. Dlsassenble valve and inspect for sticking,
C1 ean. Reassemble v a i ve or f-eplace and
reinstal 1 on g e a r s check Adju$tment of
Thrust Bearinas, Make Adjustment of Valve
Spool * Check for equal amount o f an end
movement o f spool each way from center.
7. Wear of actuator lever in Replace actuator lever and possibly
bushing of valve mounting bracket w i t h bushing o r actuator with
bracket or of actuator. bush ?' nq
8. Wheel tube bent or sprung. Replace bent parts and cof-recf
column alignment.
Cont ' d
25
FIU A
TROUBLE C
* Y
9. B i n d i n s t e e r i n g wheel t u b e Eliminate cause o f bind such as a

bearing o r s h a f t bearings. bracket clamped t i g h t over jacket
tube where bearfng i s located,
10. Improper f r o n t end a1 ignment. A I i g n to speci f j c a t j ons s
11. Taper s t u d a d j u s t e d t o o t i g h t Adjust a
i n cam groove.
12. Broken p i s t o n o r p i s t o n r i n q s Refer t o Hydraul.i’c Trp3uble Shooting.

i n hydraulic cylinder.
13. Lack o f s t e e r i n g q e a r l u b r i c a n t , Add 4 ube t o BroBrer level I
14. V a l v e l o o s e on mounting. Tiohten, then check a ~ j ~ s t m e n t ~
15. Low t i r e p r e s s u r e . Inflate t o proper pressure,

16. J a c k e t t u b e ends i n t e r f e r i n g w i t h e t tube i n upper cover t o
a x i a l movement o f wheel tube. provide necessar~clearance between
jacket tube and adjusting n u t a t Sower
end and between i t and steerlng wheel
a t upper end.
-
NO Recovery 1. I n s u f f i c i e n t c a s t e r . Increase caster,
From T u r n
S r
t
agih -
ta h e
ad 2. T i q h t b a l l s o c k e t c o n n e c t i o n s and Loosen connections b u t keep them
o t h e r l i n k a g e connections. snug *
3. T i g h t f r o n t a x l e s p i n d l e s . Make free 0
4. B i n d i n wheel t u b e El iminate b3 nd
(Prevents centering o f valve) .
5 . B i n d i n wheel t u b e b e a r i n g E7 i n i n a t e cause o f bind such as a

(Prevents centering o f valve). bracket c’iamped t i g h t over jacket
tube whel-e bearing i s located,
6. Spool i n v a l v e s t i c k i n g Disassemble valve and jnspect for

(Prevents centering o f valve). sticking, Clean, Reassemble valve or
replace and reinstall on gearp check
Adjeastm9nt o f T h ~ u s tBearings. Make
~ ~ ~ u o f~ Valve~ ~Spool. e n Check
t for
equal amount o f end movement o f spool
each way from center,
7. Stud a d j u s t e d t o o t i g h t i n Adjust.
cam g r o o v e
Shimmy 1. Loose b a l l s o c k e t connections or Tighten,

o t h e r l i n k a a e connections.
2. Wheels o u t o f balance. Balance.

3. B a d l y worn and unevenly worn t i r e s . Rep1 ace.
4. Excessive c a s t e r . Correct and have frout alignment
checked t o speci f i c a t j o n s I
5. Looseness i n s t e e r i n g qear. A d j u s t gear, and perhaps repair gear,

6. Air i n system. 13’1 eed system *
Cant"*
26
SHOP MANUAL
TROUBLE CAUSE
Lost Motion a t 1 . Loose ball socket connections o r Tighten

Steering Wheel other linkage connections.
2 . Loose thrust bearing adjustment Adjust 0
3. Excessive back lash of taper stud Adjust e
in cam groove.
4 . Steering wheel loose. Tighten wheel n u t ,
5. Pitman arm ~ O O S Son lever s h a f t . T i g h t e n IeveP. s h a f t n u t .
Noise 1. Pump belt o u t o f adjustment. Adjust,
2. Low level o f hydraulic o i l .
3. Air in system. Check a44 connections f o r tightness.

Operate several ut^^ t o bleed
from system.
4. Dirt and sludge i n pump. Drain system and clean,

5. Pump worn. Refer t o Hydraui i c Trouble Shooting,
GRADER GI
PLANER 0
ROLLER 0
CRANE El
Shop Man.ual B-2.10

’R3’/C4
‘T-ORQUE CONVERTER
:[MODELS C 2 7 2 & C2731
,~A-~-pL
i-%A E
i l .
B.
MOD-ELS : SERIAL NUMBERS

T 400 A 01001 thru 02110
T 500 A & L 02601 thru 07994
T 600 S 01501 thru 02535
90 A thru 1 2 5 A 02006 thru 08774
125 FA 07990 thru 08774
150 A 02006 & Up
150 FA 07305 & Up
Prime Mover 04331 & Up
L CAUTION
A L L COMPONENTS MUST B E PROPERLY SUPPORTED DURING
A L L JACKING, HOISTING, AND GENERAL WORKSHOP EQUIP-

MENT REQUIRED FOR THIS OPERATION MUST BE IN
GOOD WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED A T A L L TIMES TO PREVENT

INJURY I
CONTENTS Page
Torque S h e e t . . . . . . . . . . . . ............ Back o f Cover
S p e c i a l Tool s . . . . . . . . . . . . ............ . . I
Disassembly . . . . . . . . . . . . . ............ . . 1
Reassembly . . . . . . . . . . . . . ............ . . 15
Instal lation . . . . . . . . . . . . ............ . . 30
Dresser Industnes. Inc Galion Divlslon South Street * P . 0 Box 647 Gallon, OH 44833 U.S.A.
(419) 468-4321 Telex: 987430 Cable: Galiron
c4
os:,&
NOTE: Torque Values lis!ed throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size
Foot Pounds
Grade 5
(3 radial dashes on bolt or cao screw head)
Newton Meters
r foot Pounds
Grade 8
(6 radial dashes on
Newton Meters
(Ft. Lbs.! - (Nmj
- (Ft Lbs.) (Nmj -
6 d 9 12
7 9 i1 15
13 18 18 24
15 20 21 28
24 33 34 46
27 37 38 52
38 52 54 73
42 57 60 81
58 79 82 111
65 88 30 122
84 114 12C 163
33 126 132 179
115 156 165 224
130 176 185 251
295 27s 290 333
230 312 320 434
365 414 455 617
335 354 515 698
455 617 695 942
310 69 I 735 1664
610 827 990 1342
615 929 1ili) 1505
860 1166 1460 1898
955 1295 1550 2102
I130 1532 1830 248 1
1290 I749 2 085 2827
1500 2034 2 436 3295
1696 2291 2 730 3701
2370 3213 3810 5166
3550 4813 5 760 7810
*./ _I_-
FILE: -
R
SECTION: -
2.10
DISASSEMBLY
1
R e m o v e f r o m o uI t - p u t s h a f t , c o t t e r p i n ,
Washer, " 0 " r in g a n d o u t - P u t c o u p l i n g .
2
Remove c h a r g i n g pump a n d g a s k e t .
3
Remove c h a r g i n g pump d r i v e a d a p t e r .
1
FILE: B
5
Remove r e m a i n i n g h o u s i n g c o v e r p l a t e s a n d
gaskets.
Remove p r e s s u r e r e g u l a t i n g v a l v e a s s e m b l y ,
g a s k e t ( l ) , p l u n g e r a n d s p r i n g ( 2 ) . Remove
."o" ring ( 3 ) a n d discard.
JOTE: b.TSOOB torque converter, lremove i n l e t

cover instead of regulating valve ireq-
u l a t i n g valve is located on transmission).
2 c2
FILE: L
SECTION: 2.10
7
Remove i m p e l l e r c a p s c r e w s . Separate cover
from i m p e l l e r h o u s i n g by u s i n g t w o f l a t end
capscrews ( g r i n d f l a t i f rough) i n p u l l e r
holes provided.
Remove p u l l e r c a p s c r e w s from i m p e l l e r c o v e r
Remove i m p e l l e r c o v e r s l e e v e i f r e p l a c e m e n t
i s reaui red,
9
Remove c o v e r s e a l i n g r i n g ("0" ring) and
discard.
3
FILE: _B
SECTION: uo
10
Remove i m p e l l e r c o v e r b e a r i n g r e t a i n i n g r i n g
a n d r o l l e r bearing i f replacement i s required.
11
Remove t u r b i n e r e t a i n i n g r i n g .
12
L i f t t u r b i n e from d r i v e s h a f t .
a
FILE: B
SECTION: so
13
Remove t u r b i n e h u b l o c a t i n g r i n g .
14
Remove r e a c t i o n member r e t a i n i n g r i n g .
15
Remove r e a c t i o n member a s s e m b l y from s t a t o r

support and sleeve.
5
FILE: B
SECTION: 2.''
16
Remove spacer from reaction member, i f i t i s of two
( 2 ) piece design.
Later reaction members have t h e spacer c a s t as an
i n t r e g a l p a r t of t h e reaction member.
If t h e spacer i s c a s t with t h e reaction member, a
f l a t washer w i t h a tang on i t should be removed a f t e r
removing t h e reaction member. Note t h e position of
t h e f l a t washer with tang upon removal.
17
Remove t h r e e o i l b a f f l e r e t a i n i n g capscrews located
in external portion of housing as i l l u s t r a t e d .
( 2 not shown)
18
Remove impeller and b a f f l e assembly from housing.
Grasp impeller and snap a g a i n s t b a f f l e .
6
FILE: R
SECTION: 2.10
19
Remove o i l b a f f l e "0" ring and discard
20
Remove i m p e l l e r g e a r r e t a i n i n g r i n g .
21
Remove i m p e l l e r g e a r .
7
FILE: L
S ECTIOTV: ljg
22
Rem0 ve o i l seal from b a f f l e .
23
Remove o u t p u t s h a f t b e a r i n g r e t a i n i n g r i n g .
24
Remove o u t p u t s h a f t b e a r i n g f r o m i m p e l l e r
hub.
a
26
Remove c h a r g i n g p u m p d r i v e g e a r .
27
Remove h y d r a u l i c p u m p d r i v e g e a r r e t a i n i n g
ring a n d drive gear.
9
FILE: B
SECTIOiV'.. -2 . 1 0
28
Remove c a p s c r e w s from s t a t o r s u p p o r t . Remove

stator support, sleeve and o u t p u t shaft
assembly.
29
Remove t u r b i n e s h a f t g e a r from o u t p u t s h a f t .
S IJ
Remove o u t p u t s h a f t b e a r i n g r e t a i n i n g r i n g .
10
FILE: B
SECTION: 2.1O
31
Remove o u t p u t s h a f t a n d b e a r i n g from s t a t o r
support.
32
P r e s s b e a r i n g from o u t p u t s h a f t .
55
Remove h o o k r i n g s e a l s f r o m o u t p u t s h a f t
a n d s t a t o r s u p p o r t . Discard h o o k ring s e a l s
11
FILE: B
35
Remove h y d r a u l i c p u m p d r i v e s h a f t b e a r i n g
retaining ring.
36
Remove bearing r e t a i n i n g w a s h e r s .
12
FILE: B
SECTION: 2 . 1 0
37
Remove p u m p d r i v e s h a f t a s s e m b l i e s . Drive
s h a f t assemblies a r e i d e n t i c a l .
38
P r e s s b e a r i n g s a n d s p a c e r from each s h a f t
i f r e p l a c e m e n t i s n e c e s s a r y . Remov e b e a r i n
l o c a t i n g r i n g s from s h a f t s .
39
Remove g o v e r n o r i d l e r s h a f t from h o u s i n g
Remove " 0 " r i n g from s h a f t a n d d i s c a r d .
13
FILE: 2-
SECTION: 2 . 1 0
40
Remove governor d r i v e g e a r as semb l y . Remov e
o u t p u t s h a f t o i l seal a n d dis card ( a r r o w ) .
41
Remove governor d r i v e g e a r i d l e r s h a f t
retaining ring.
42
P r e s s governor d r i v e gear a n d woodruff k e y

from i d l e r d r i v e s h a f t g e a r .
14
FILE: L
43
Remove n e e d l e b e a r i n g s f r o m g o v e r n o r d r i v e
g e a r only i f r e p l a c e m e n t i s n e c e s s a r y .
44
Clean s p r a y l u b r i c a t i o n o r i f i c e i n c o n v e r t o r
h o u s i n g . O r i f i c e m u s t be o p e n a n d f r e e o f
any f o r e i g n m a t e r i a l . S i z e of o r i f i c e i s
1 / 6 4 " - D O NOT D R I L L O R R E A M OVERSIZE.
C - 2 7 3 C O N V E R T O R ASSEMBLY
45
I n s t a l l needle bearings in governor drive
g e a r h u b i f p r e v i o u s l y r e m o v e d . NOTE:
E x t r e m e c a r e must be u s e d d u r i n g p r e s s i n g
operation.
15
FILE: R
SECTION: 2.10
47
I n s t a l l governor drive gear retaining ring.
48
Apply a l i g h t c o a t o f p e r m a t e x t o o u t e r
diameter o f seal before i n s t a l l i n g . Seal
m u s t be i n s t a l l e d w i t h r a i s e d l i p o u t w a r d
and r e c e s s e d 5 / 1 6 " below f a c e of b o r e i n
housing.
P o s i t i o n governor d r i v e g e a r assembly in
h o u s i n g . The s m a l l e r g e a r i n s t a l l s t o w a r d
t h e f r o n t of t h e h o u s i n g .
16
FILE: L
SECTION: 2.10 -
-
49
I n s t a l l " 0 " r i n g o n i d l e r s h a f t and l u b r i c a t e .
I n s e r t s h a f t i n g e a r - p r e s s i n t o c a s e . Do
n o t damage " 0 " r i n g .
50
I n s t a l l bearing l o c a t i n g ring on charging
p u m p d r i v e s h a f t i f p r e v i o u s l y removed.
Press bearings a n d spacer on charging pump
d r i v e s h a f t . B e a r i n g must s e a t a g a i n s t
l o c a t i n g r i n g . Repeat t h e s e s t e p s t o
a s s e m b l e h y d r a u l i c p u m p d r i v e s h a f t assembl Y
51
I n s t a l l both p u m p d r i v e s h a f t s i n h o u s i n g .
17
FILE: B
SECTION: - ? d o
52
I n s t a l l both bearing r e t a i n i n g washers
53
I n s t a l l h y d r a u l i c pump d r i v e s h a f t b e a r i n g
retaining ring.
54
I n s t a l l charging pump drive s h a f t bearing
retaining ring.
18
FILE: L
SECTION: 2.1O
55
I n s t a l l new h o o k r i n g s e a l o n s t a t o r s u p p o r t
a n d l u b r i c a t e w i t h Type "A" o i l . Install
new h o o k r i n g s e a l on o u t p u t s h a f t a n d
l u b r i c a t e w i t h Type " A" o i 1.
56
I n s t a l l b e a r i n g on o u t p u t s h a f t .
57
Check l u b r i c a t i o n s p r a y o r i f i c e i n s t a t o r
support. O r i f i c e m u s t be o p e n a n d f r e e o f
a l l foreign material. O r i f i c e size i s 1/64"
- DO NOT D R I L L O R R E A M O V E R S I Z E .
19
FILE: _R
SECTION: LJO
58
I n s t a l l o u t p u t s h a f t a n d bearing i n s t a t o r
support and sleeve.
59
I n s t a l l o u t p u t s h a f t bearing r e t a i n i n g ring
60
I n s t a l l turbine s h a f t gear on o h t p u t s h a f t .
(Splined s i d e o f gear h u b t o w a r d threaded
end o f s h a f t . ) Gear must s e a t a g a i n s t o u t -
p u t shaft bearing.
20
FILE: B
SECTION:
61
I n s t a l l s t a t o r support and output s h a f t
assembly t o housing. I n s t a l l capscrews and
i n t e r n a l t o o t h w a s h e r s . T o r q u e t o 50 f o o t
pounds.
62
I n s t a l l h y d r a u l i c pump d r i v e g e a r a n d
retaining ring.
63
I n s t a l l c h a r g i n g pump d r i v e g e a r .
21
FILE: L
SECTION: 2.70
~
64
I n s t a l l charging pump drive gear r e t a i n i n g
ring a
65
I n s t a l l o u t p u t s h a f t bearing in impeller h u b .
56
I n s t a l l o u t p u t s h a f t bearing r e t a i n i n g r i n g .
22
FILE: B
SECTION: 2.10
67
A p p l y l i g h t c o a t of p e r m a t e x t o o u t e r d i a m e t e r
of s e a l . Install oil seal in baffle. Lip
o f seal up (arrow). I n s t a l l o i l b a f f l e on
i m p e l l e r hub.
68
I n s t a l l g e a r o n i m p e l l e r hub.
69
Install retaining ring.
23
FILE: L
SECTION:
70
Lubricate "0" r i n g and i n s t a l l o n b a f f l e .
71
I n s t a l l i m p e l l e r and b a f f l e a s s e m b l y i n
c o n v e r t o r h o u s i n g . NOTE: Mounting h o l e s i n
o i l b a f f l e p l a t e a r e n o t e v e n l y s p a c e d and
w i l l alicin w i t h h o l e s i n h o u s i n q i n one
position only.
C A U T I O N : Do n o t damage h o o k r i n g s e a l o r
"0" ring.
S u g g e s t two p i l o t b o l t s ( d o w e l s ) be i n s t a l l e d
p r i o r t o assembly t o i n s u r e c o r r e c t a l i g n m e n t .
D o w e l s , s h o u l d be a p p r o x i m a t e l y 3 " l o n g - - - -
3/8 u.S.S. thread:
72
I n s t a l l t h r e e c a p s c r e w s and l o c k w a s h e r s a n d
t o r q u e 2 5 t o 30 f o o t pounds.
24
FILE: B
SECTION:
73
I n s t a l l spacer on reaction member. It'may be
necessary t o spread r o l l pin t o obtain i n t e r f e r e n c e
f i t i n t o reaction member.
I f reaction member has spacer c a s t as one p i e c e , t h e
above assembly need n o t be done.
I n s t a l l t h e ' f l a t spacer washer on s t a t o r support
with t h e tang on t h e washer f a c i n g u p .
I4
S t a t o r i n s t a l l s w i t h spacer down.
75
I n s t a l l reaction member r e t a i n i n g r i n g
25
FILE: -s,
SECTION: 2.1 0
76
Install turbine h u b retaining ring
77
Install turbine.
78
Install turbine retaining ring.
26
FILE: B
80
Lubricate and instal 1 "0" ring (arrow) on
i m ~ e l l e rc o v e r .
^.
81
P o s i t i o n i m p e l l e r cover a n d i n s t a l l capscrews.
Use c a r e n o t t o damage " 0 " r i n g . Torque
capscrews 25 t o 30 f o o t pounds.
27
FILE: L
SE CTIO
82
Position " 0 " ring ( 3 ) i n regulating valve
body. I n s t a l l r e g u l a t i n g v a l v e g a s k e t ( l ) ,
v a l v e s p r i n g and p l u n g e r ( 2 ) i n h o u s i n g .
I n s t a l l r e g u l a t i n g v a l v e assembly t o housing.
T o r q u e c a p s c r e w s 25 t o 3 0 f o o t p o u n d s .
83
I n s t a l l housing c o v e r p l a t e s and g a s k e t s .
T o r q u e c a p s c r e w s 25 t o 30 f o o t p o u n d s .
L u b r i c a t e and i n s t a l l " 0 " r i n g ( a r r o w ) on
o f f s e t drive cover. Install o f f s e t drive
c o v e r . I n s t a l l t h r e e c a p s c r e w s and two n u t s .
Torque t o 50 f o o t p o u n d s .
84
I n s t a l l charging pump adaptor.
28
FILE: -
B
SECTION: 2.10
a5
I n s t a l l c: h a r g i n g p u m p a n d g a s k e t
86
I n s t a l l o u t p u t f l a n g e c o u p l i n g , "0" r i n g ,
w a s h e r a n d n u t . Torque n u t t o 2 2 5 f o o t
p o u n d s . . I n s t a l l c o t t e r p i n . Use c a r e n o t
t o damage o u t p u t s h a f t s e a l .
a7
Remol( e r o l l p i n ( l ! , . Spring tension w i l l
push s t o p ( 3 ) a n d 0 " r i n q ( 2 ) from body.
Remove i-nner s p r i n g ( 4 ) a n d o u t e r s p r i n g ( 5 ) .
Remove v a l v e pis.ton ( 6 ) . Remove r o l 1 Pi n
( l o ) , S t o p (8), " 0 " r i n g ( 9 ) . Assemb l e i n
reverse order.
29
FILE:
SECTION: 2.10
88
The F i b e r Ring Gear Kit i n w h i c h t h e gear c o n t a i n s
e i g h t (8) mounting holes i s being replaced w i t h a
F i b e r R i n g Gear K i t i n w h i c h t h e gear has s i x t e e n
( 1 6 ) m o u n t i n g h o l e s ; however, t h e s e two r i n g gears
a r e c o m p l e t e l y i n t e r c h a n g e a b l e . The s i x t e e n ( 1 6 )
h o l e r i n g gears can be mounted t o an e i g h t ( 8 ) h o l e
f l y w h e e l and t h e e i g h t ( 8 ) h o l e r i n g gears can be
mounted t o a s i x t e e n ( 1 6 ) h o l e f l y w h e e l .
INSTALLATION
1. Thoroughly c l e a n f l y w h e e l t o remove any b u r r s o r TORQUING THE "NYLOC" CAP SCREW$ SUPPLIED WITH THE
d i r t which may n o t a l l o w p r o p e r s e a t i n g o f t h e R I N G GEAR WITH SIXTEEN ( 1 6 ) MOUNTING HOLES.
r i n g gear t o t h e f l y w h e e l .
1) These " n y l o c " cap screws can be i d e n t i f i e d
2. P o s i t i o n r i n g gear on f l y w h e e l , by a n y l o n i n s e r t embedded i n t h e t h r e a d s .
Do n o t t a k e a t u r n i n g t o r q u e r e a d i n g on
3. I n s t a l l t h e s p e c i a l cap screws and washers t h e s e cap screws; t o r q u e them t o 30-33 f o o t
p r o v i d e d w i t h t h e r i n g g e a r . Under no pounds o f t o r q u e .
c i r c u m s t a n c e s can s t a n d a r d screws o r washers
be used. 5. B o t h s t y l e s o f cap screws s h o u l d be l o c k w i r e d
i n p a i r s . T w i s t t h e l o c k w i r e between t h e cap
4. Torque cap screws i n a c r o s s sequence screws t o e n s u r e a s e c u r e l o c k i n g a c t i o n .
s p e c i f i e d below depending on t h e cap screws
provided w i t h t h e r i n g gear. 6. L i g h t l y c o a t w i t h grease t h e p i l o t b o r e on t h e
t o r q u e c o n v e r t e r and t h e r i n g g e a r t e e t h t o ease
TORQUING OF THE INTERFERENCE F I T CAP SCREWS instal lation.
SUPPLIED WITH THE R I N G GEAR WITH EIGHT ( 8 )
MOUNTING HOLES: 7. When m o u n t i n q t h e t o r q u e c o n v e r t e r t o t h e e n g i n e ,
do n o t use f o r c e , t h e t e e t h s h o u l d mesh t o g e t h e r
1) A f t e r i n s t a l l i n g t h e cap screws by hand, easily.
use a t o r q u e wrench t o t a k e a " t u r n i n g
t o r q u e " r e a d i n g o f each cap screw t o Note: It is good procedure t o check crankshaft end
determine t h e torque r e q u i r e d t o over- pZay, b e f o r e and e, converter to engine
i n s t a Z l a t i o n . The same end pZay v u s t be
come t h e i n t e r f e r e n c e f i t between cap
screw and h o l e . Mark t h i s t o r q u e v a l v e present to ensure proper crankshaft end
b e s i d e each cap screw. clearance. Improper cZearance w i l l resuZt
i n crankshaft t h r u s t bearing f a i Z u r e .
2) Add 20-25 f o o t pounds t o t h e t u r n i n g t o r q u e
v a l v e and t o r q u e t h e cap screws t o t h i s
f i g u r e . The c o m b i n a t i o n o f t h e s e two
torques provides the proper torque valve
t o h o l d t h e r i n g gear i n p l a c e .
Note: Overtightening or andertightening
wiiZ resuLt i n premaswe faiLziire
o.? t h e r i n g gear.
30
FILE: 8 . .
SECTION: 2.10
CHECKING
POWERSHIFT TRANSMISSION & CONVERTER HYDRAULIC PRESSURES
T-600 SERIES 6 GRADER
WITH
CUMMINS & D E T R O I T DIESEL ENGINES
1. CHECK OIL LEVEL IN TRANSMISSION (DIPSTICK): 2. CHECK CLUTCH PRESSURE A T POlNTA.

(a) Oil o t operating temperature. ( a ) If c l u t c h pressure does not read 200?x) p s i an
(b) Moldboard i n ground, parking brake set. instrument panel ~ install o reliable 300-350 psi
(c) Engine idling. gage a t p o i n t A.
(d) Forward & Reverse Lever i n neutral. (b) Record pressures at engine high i d l e and l o w idle.
(e) Remove seat cushion - Slide aside 6" cover. (c) Moldboard i n ground, parking brake set.
( f ) Reach through 6" h a l e a n d pull out d i p s t i c k . ( d ) Check a l l 6 c l u t c h e s :
W i p e d i p s t i c k clean, re-insert d i p s t i c k and Forward c l u t c h engaged ~ 1, 2, 3, 4 c l u t c h i n 4th.
check a i l . *Maintain o i ! l e v e l Reverse c l u t c h engaged - 1, 2, 3, 4 clutch i n 4 h
between full ond a d d mark on dipstick.
DO NOT OVERFILL.
Forward & Reverse c l u t c h i n neutral - check
1, 2, 3, 4 clutch.
*Use T y p e " A " Suffix A, Automatic Record - pressure 200t20 psi.
0 1 1 pressures
Transmission F l u i d or Dexron.
3. CHECK CONVERTER OUT PRESSURE - P O I N T I :
( 0 ) I n s t a l l 100 P S I gage a t p o l n t B.
(b) Engine a t High idle, Transmission In Neutral.

(c) Converter Temperature 180' - Pressure 35 i 10.
B.
ou
31
FILE: L
SECTION: 2.10
CHECKING
POWERSHIFT TRANSMISSION & CONVERTER HYDRAULIC PRESSURES
GRADERS: T400A, T500A, T500L and T600B /IHC DT-407 engine

CRANES: Series A Hydcaulic Cranes
GRADER AND CRANE ENGINE SPEEDS
1. TRANSMISSION OIL LEVEL CHECK: 3. CHECK CLUTCH PRESSURES A T POINT A.**

(a) Oil a t operating temperature. (a) I f clutch pressure does not reod 260 ?: 20 psi
(b) Moldboard in ground, parking brake set. -
on instrument panel install a reliable 300 . 350
( c ) Engine idling. psi gage at p o l n t A.
id) All shiftlng levers in neutral. :b) Record pressures a t engine H X Idle and idle.
(e) Remove top plug (Polnt Ci. i f the transmission ( c ) Moldboard in ground and parking brake set.
i s over filled, a l l o w a l l the 011to drain out of
(d) Check a i l 4 clutches:
the top plug. I f there i s no 011at the top plug,
remove the bottom plug ( E l n t C). I f there I S 1 . Forward c l u t c h engaged - H i - Low i n neutral.
-
no o i l at bottom plug *ADD OIL (at converter, 2. Reverse clutch engaged - Hi ~ Low in neutral.
with engine off). Recheck w t h engine running. 3. Forward 8 Reverse clutch i n neutral
Maintain -top and bottom plug (Polnt C). H i c l u t c h engaged.
*Use Type “A” Sufflx A, Automatic
4 . Forward & Reverse clutch in neutral
Transmission F l u i d or Dexron. L o w clutch engaged.
Record a l l pressures Pressure. 260 f. 20 PSI.
2. CHECK CONVERTER OUT PRESSURE A T POINT B.

(01 I n s t a l l 100 psi gage a t Point B. “Clutch pressures may be token from Individual clutch
(b) Engine at Hi’gh Idle. Transmisslon in Neutral. N.P.T. f i t t i n g is located on
caps p o i n t D. A 1,‘8”
(C) Converter Temperature 1800 - Pressure 35+ 10. each cop for gage Installation.
32
__
FILE: B
SECTION: -
2.10
c4
33
c
4
I
.
to
c
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W
W
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+2
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0-p:
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:
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zzN
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- L
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I
NOTES
MATERIAL LIFT 0
GRADER I3
PLANER 0
ROLLER 0
CRANE ET'
SHOP MANUAL C-07.00

r31c4
TRANSMISSION
(MODEL 2420)
APPLICABLE MODELS SERIAL NUMBERS
GRADERS
T-400A 01001 thru 02110
T-500A & L 02602 thru 07994
T-600B (IH engine only) 03855 thru 03866
CRANES
90A thru 125A 02006 thru 08769
125FA 07990 thru 08769
150A 02832 thru 08623
150FA 07305 thru 08623
I ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING

DISASSEMBLY A N D REASSEMBLY.
ALL JACKING, HOISTING A N D GENERAL WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST B E IN GOOD WORKING
ORDER.
EXTREME CAUTION TO B E OBSERVED AT ALLTIMES TO PREVENT INJURY.
CONTENTS
-Sheet . . . . . . . . . . . . , . . . . . . . . Back
Special Tools . . . . . . . . . . . . . . . . . . . .
9
1
Cover
o
Transmission Disassembly . . , . . . . . . . . . . . . 1
.
Clutch Disassembly . . . . . . . . . . . . . . . . . 13
.
Clutch Reassembly . . . . . . . . . . . . . . . . . 18
Control Valve & Oil Circuit Plate Disassembly & Assembly 24
.
Transmission Reassembly . . . . . . . . . . . . . . 26
Pressure Checks . . . . . . . . . . . . . . . . . . . 40
KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. L I B E R T Y V I L L E , I L 60048

12-85
GENERAL TORQUE VALUES
The following General Torques are to be used in all cases where SPECIFIC TORQUES are not given.
F NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size
II Grade 5
Heat treated material (;rade 5 & Grade 8
! or cao screw head)

Grade 8
(6 radial dashes on bolt or cao screw head)
I (Ft Lbs.)
Newton Meters
(Nm)
Foot Pounds
(Ft Lbs.)
Newton Meters
(Nm) 1
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 I 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 - 16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 . 14 38 52 54 73
7/16 . 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 . 18 130 176 185 251
3/4 ' 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 . 14 335 454 515 698
1 - 8 455 617 695 94 2
1 . 14 510 691 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 * 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2 102
1 3/8 * 6 1130 1532 1830 248 1
1 318 . 12 1290 1749 2 085 2827
1 1/2 * 6 1500 2034 2 430 3295
1 1/2 . 12 1690 2291 2 730 370 1
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3 550 4813 5 760 7810
SPECIAL TOOL
7/16”-20 NF (M12)
\
WELD DRILL 13/64”
(5.16)
‘COUNTERSUNK
1 INSERT IN 13/64” (5.16)
DRILLED HOLE IN 7/16” 7 2-1/2” (63.50)
I
3/ 16”
(4.76) THREAD
10-24
\
1/2” (12.70) (M5)
PLAIN WASHER
( ) DIMENSIONS IN MILLIMETERS
SHOP MADE CLUTCH ASSEMBLY TOOL
-1 -
SERVICE RECORD
~
FILE: 2
SECTION: 7 -
DISASSEMBLY O F TRANSMISSION:
1
Thoroughly c l e a n t r a n s m i s s i o n assembly and
place i n suitable fixture o r position f o r
servicing .
Remove c o n t r o l v a l v e a n d g a s k e t .
NOTE: L i f t carefully t o avoid loss o f detent
m s s p r i n g s and p i n s .
3
Remove d e t e n t b a l l s , s p r i n g s a n d d e t e n t
s t o p p i n s . (Pins a r e i n s i d e s p r i n g s . )
-1
4
- 2-
I
Rev??.? c s v e r i - e t j ' n i n g s c r e w s , m c i n s t a ! !
t h r e ? p u l ? e r screlws.
Screw jt- o n s c r e w s w h i l e a i t e r n a t e i y t a p p i r g
o n e n d s of s h a f t s t o f r e e b e a r i n g s f r o 3
cover.
Remove i n p u t s h a f t q ~ ! tand washer

FILE:
SECTION: 7- SHOP 8
0 MANUAL
10
RernoL/ e i n p u t s h a f t b e a r i n g s p a c e r
11
W i t h s u i t a b l e p u l l e r - - r2move i n D u t s h a f t
bearing.
-4-
-5-
FILE: C
SECTION: 7 SHOP 13 MANUAL
16
Remove i n p u t s h a f t f l a n g e n u t , w a s h e r and
"0" r i n g .
17
Remove f 1 a n g e .
18
Remove i n p u t s h a f t , g e a r a n d b e a r i n g
-6-
FILE: C
SECTION: 7 SHOP CI MANUAL
19
Remove h i g h a n d l o w s h i f t , detent plug,

s p r i n g and b a l l .
20
C u t t i e w i r e and remove l o c k s c r e w f r o m h i g h
low s h i f t f o r k .
21
Remove s h i f t r a i l a n d f o r k .
FILE: C
SECTION: 7
22
Pry o u t p u t s h a f t b e a r i n g cap f r e e of c a s e .
Jack s p r e a d e r s a r e i l l u s t r a t e d .
Spreading gears t o press bearing off s h a f r
r e d u c e s t h e p o s s i b i l i t y o f d a m a g i n g i:he
transmission case.
24
Remove h i g h g e a r t h r u s t w a s h e r
FILE: 2-
SECTION: 7 SHOP CJ MANUAL
25
Remove h i g h g e a r and b e a r i n g a s s e m b l y .
26
Remove h i g h l o w s h i f t c o l l a r
27
B l o c k l o w s p e e d g e a r a t t o p and b o t t o m .
-9-
FILE: C
SECTION: -
7 SHOP 13 MANUAL
28
Remove f l a n g e n u t w a s h e r and " 0 'I ring.
29
Remove o u t p u t s h a f t f l a n g e .
30
Remove f l a n g e s p a c e r .
10
FILE: C
SECTION: 7 SHOP MANUAL
31
Remove o u t p u t s h a f t by t a p p i n g on l o w e r e n d
o f s h a f t w i t h s o f t hammer w h i l e l i f t i n g on
s h a f t u n t i l s h a f t i s f r e e of r e a r b e a r i n g .
32
Turn c a s e , remove b e a r i n g c a p and s h i m s ,

b e a r i n g and t h r u s t w a s h e r .
33
Remove b i o c k s , l i f t o u t g e a r and Uheari!ig
assembly.
FILE: 2
34
Remove o i l b a f f l e f r o m s u m p .
35
Remove d r a i n p l u g a n d g a s k e t .
36
Remove sump s c r e e n .
Remove a l l e x t e r n a l p l u g s .
Wash c a s e t h o r o u g h l y i n s o l v e n t a n d d r y
:xith a i r .
- 12
FILE: c
C I S A S S E M B L Y OF C L U T C H E S :
37
Rem01/ e b e a r i n g r e t a i n i n g r i n g .
38
With s u i t a b l e p u l l e r - - p u l l b e a r i n g and c l u t c h
hub.
39
When b e a r i n g i s f r e e o f s h a f t - - h u b and one

hub b e a r i n g a r e a l s o f r e e .
-1 3-
FILE: C
SECTION: -7 SHOP 13 MANUAL
40
3emove b e a r i n g s p a c e r .
41
Remove i n n e r c l u t c h h u b b e a r i n g .
42
Attach s p r i n g Compressing t o o l - - c o n p r e s s
c l u t c h S i s t o n r e t u r c s p r i n g and f r e e s n a p
p i n g frcirn g r o o v e .
- 1 4-
FILE: 2
SECTION: 7 SHOP 13 MANUAL a
43
Remove t o o l a n d l i f t o f f s n a p r i n g , w a s h e r
and s p r i n g .
44
Remove c l u t c h p l a t e r e t a i n i n g r i n g .
45
Remove c l u t c h d i s c b a c k i n g p i a t e .
-15-
FILE: C
46
Remove c l u t c h d i s c s , s t a r t i n g w i t h b r o n z e
p l a t e and t h e n a s t e e l p l a t e .
Continue u n t i l s i x bronze and f i v e s t e e l
p l a t e s h a v e been r e m o v e d .
47
Remove c l u t c h p i s t o n .
Remove a n d d i s c a r d p i s t o n s e a l i n g r i n g .
48
Remove a n d d i s c a r d i n n e r p i s t o n s e a l i n g r i n g .
-16-
FILE: _C
SECTION: 7 SHOP 1;3 MANUAL
49
I f c l u t c h s h a f t s e a l i n g r i n g s were n o t p r e -
v i o u s l y r e m o v e d , remove and d i s c a r d .
50
Remove c l u t c h s h a f t b e a r i n g s n a p r i n g .
51
Remove c i u t c h s h a f t b e a r i n g .
-1 7 -
FILE: C
52
D i s a s s e m b l y p r o c e d u r e i s t h e same f o r a l l
c l l l t c h e s except f o r t h e h i g h speed c l u t c h
s h a f t w h i c h i s removed f r o m t h e drum by
p r e s s i n g s h a f t o u t o f drum.
Forward, r e v e r s e and low speed c!utches d r e

i d e n t i c a l and s h a f t s can n o t be removed.
53
Upon c o m p l e t i o n o f d i s a s s e m b l y - - t h o r o u g h l y
c l e a n a l l drums and s h a f t s .
P a r t i c u l a r l y note and clean the c l u t c h b!ezd

o f f b a l l and s e a t .
T h i s b a l l can n o t be removed and m u s t be

washed and blown c l e a n w i t h a i r .
RE-ASSEMBLY O F CLUTCH P A C K A G E S :
54
I f s h a f t has Seen r e m o v e d f r o m h i g h s p e e d
c l u t c h - - p r e s s s h a f t i n t o drum t o be s u r e
t h a t s h a f t s h o u l d e r and f a c e o f drum meet
flush a t point indicated.
- 18 -
FILE: C
SECTION: 7 SHOP a MANUAL
56
l n s t a l i new s e a l i n g r i n g s o n s h a f t .
57
FILE: 3
58
I n s t a l l new o u t e r p i s t o n s e a l i n g r i n g a n d
i n s t a l l p i s t o n i n drum.
59
The f i v e s t e e l c l u t c h d i s c s i n e a c h c l u t c h
h a v e a . 0 1 5 " t o .020" d i s h a n d d i s h e d s i d e
s h o u l d a l w a y s p o i n t t o w a r d p i s t o n and a l l
s t e e l d i s c s s h o u l d be i n s t a l l e d i n same
di r e c t i o n .
if discs a r e h e l d t i g h t l y i n one hand a t o n e
s i d e and a gap a p p e a r s a t e i t h e r t h e i n n e r
or o u t e r diameter then a l l a r e n o t dished
t h e same direction.
60
I f when h e l d t i g h t l y a l l s u r f a c e s o f d i s c s
t o u c h - - t h e n d i r e c t i o n o f d i s h i s t h e same
in a l l discs.
NOTE: Each s t e e l d i s c a l s o h a s a t e a c h
s i d e (I80'a p a r t ) an o p e n i n g b e t w e e n t e e t h
t o f o r m o i l g r o o v e when d i s c s a r e i n s t a l l e d
and a l l d i s c s s h o u l d be i n s t a l l e d s o
openings are in alignment.
-20-
FILE: c
61
S t a r t i n g f i r s t w i t h a bronze d i s c against
p i s t o n - - a l t e r n a t e bronze and s t e e l o n t i l
s i x bronze ana f i v e s t e e l d i s c s have been
i n s t a l l e d !n d r u m .
62
I n s t a l l clutch disc backing plate.
63
Install clutch disc retaining ring
-27
FILE: C
64
P l a c e s p r i n g , w a s h e r a n d s n a p r i n g on s h a f t .
65
I n s t a l l spring compressing t o o l , compress

s p r i n g and i n s t a l l s n a p r i n g i n g r o o v e .
66
I n s t a l l one c l u t c h h u b b e a r i n g w i t h l o c a t i n g
r i n g down.
-22-
FILE:
67
A s c l u t c h hub i s i n s t a l l e d o v e r b e a r i n g and
i n t o drum, i n t e r n a l t e e t h o f b r o n z e d i s c s
m u s t be a i i g n e d w i t h s p l i n e s o f h u b a n d
b e a r i n g c e n t e r e d i n bore of h u b .
The b e a r i n g and b o r e a r e a s l i p f i t a n d
must n o t be f o r c e d .
When h u b , b e a r i n g and s p l i n e s a r e i n a l i g n -
m e n t , y e n t i e t a p p i n g on h u b s h o u l d b e
sufficient to seat hub.
P r o n o u n c e d o r c o n t i n u e d p o u n d i n g on h u b t o
f o r c e i n t o p o s i t i o n can m i s a l i g n t e e t h on
d i s c s and c a u s e s e r i o u s damage. Use c a u t i o n .
68
When h u b 4s ir, p o s i t i o n , m e a s u r e d i s t a n c e
between b o t t o m edge o f g e a r t e e t h ana f a c e
o f clutch Sacking p l a t e .
T h i s m e a s u r e m e n t s h o u l d be a ; p r o x i r n a t e ? y
7 / 1 6 " o n f o r w a r d , r e v e r s e and low s p e e d
c l u t c h e s ar!d 5 / 3 2 " o n h i g h s p e e d c l u t c h .
Larger measurements w o u l d i n d i c a t e t h a t cot
a l l bronze d i s c s a r e a l i g n e d o r enoased on
hub splines.
69
i n s t a l i b e a r i n g s p a c e r w i t h o i l Groove
f a c i n g down.
-23-
FILE: C
70
Install outer clutch h u b bearing.
NOTE: Bearing l o c a t i n g r i n g does n o t b o t z o m
o n hub g e a r b u t b o t t o m s o n s p a c e r on s h a f t .
71
I n s t a l l s h a f t b e a r i n g and r e t a i n i n g r i n g
and any r e m a i n i n g s h a f t b e a r i n g s and r e -
taining rings.
DISASSEMBLY A N D ASSEMBLY O F C O N T R O L V A L V E
OIL CIRCUIT P L A T E :
72
Remove b r a k e s l a v e c y l i n d e r and p i s t o n
a s s e m b l y ( 1 1 s l a v e s p o o l ( 2 and s p r i n g ( 3 ) .
-24-
FILE: C
SECTION: 7 SHOP I@ MANUAL
73
S e p a r a t e components o f s l a v e c y l i n d e r
assembly, discard o i l s e a l ( 1 ) "0" rings
( 2 & 4 ) and p i s t o n cup ( 3 ) .
Wash m e t a l p a r t s w i t h a l c o h o l .
Replace d i s c a r d e d components.
L u b r i c a t e w i t h brake f l u i d and r e a s s e v b l e
s l a v e c y l i n d e r and p i s t o n a s s e m b l y .
74
Remove c o n t r o l v a l v e s , wash h o u s i n g a n d
valves in alcohol.
R e p l a c e v a l v e o i l s e a l s w i t h new s e a l s .
Lubricate s e a l s w i t h type " A" o i l .
75
Reassembly c o n t r o l v a l v e a s s e m b l y .
-25-
FILE: c
76
Remove o i l c i r c u i t p l a t e f r o m c o v e r a n d
clean thoroughly.
Replace p l a t e and t i g h t e n s e c u r e i y .
REASSEMBLY O F TRANSMISSION:
77
R e p l a c e , s u m p c i l scree!; be s u r e S c r e e n i s
s e a t e d ; n p r o p e r position.
7a
i n s t a l i g a s k e t and d r a i n plug
-26-
FILE: 2
CI MANUAL
79
Install oi! b a f f l e p l a t e i n case.
Check t o make c e r t a i n t h a t p l a t e i s h o o k e d
i n proper posltion.
2 7-
FILE: c
SECTION: 7 SHOP CI MANUAL
82
Turn c a s e and i n s t a l l s p a c e r on s h a f t a n d
bearing t i g h t against spacer until spacer
w i l l n o t turn b e t w e e n b e a r i n g and g e a r .
I n s t a l l b e a r i n g cup i n c a r r i e r , add s h i m s
a n d new " 0 " ring t o c a r r i e r , t h e p l a c e
c a r r i e r o v e r s h a f t and i n housing.
C A U T I O N : Do n o t c u t " 0 " r i n g s w i t h s h i m
edges.
83
8e s u r e t h a t s i d e o f c a r r i e r marked " U P " i s

f a c i n g u p and i n s t a l l new f l a n g e o i l s e a l
i n carrier.
a4
Place spacer on shaft.
-28-
85
I n s t a l l c: o m p a n i o n f l a n g e ~
FILE: C
88
Turn o p p o s i t e s i d e o f c a s e u p a n d i n s t a l :
shift hub.
89
3e s u r e b e a r i n g s a r e r e c e s s e d b e l o # .“ace o f
g e a r a n d piace high gear on s h a f t .
30
?:ace t h r u s t washer o n s h a f t .
-30-
FILE: 2
SECTION: z SHOP 1 1 3 MANUAL
91
I n s t a l l b e a r i n g and d r i v e t i g h t a g a i n s t was h e r
92
I n s t a l l bearing c a r r i e r s containing bearing
c u p a n d new " 0 " r i n g , a t t h i s t i m e a d j u s t
b e a r i n g p r e l o a d and l o c k f l a n g e n u t w i t h
c o t t e r key.
!t w i 1 be n e c e s s a r y t o remove c o m p a n i o n
flange t o a d j u s t preload without o i l seal
drag.
R e f e r t o F i g . 87.
93
I n s t a l l new s h i f t r a i l o i l s e a l and s t a r t
r a i l into case.
-31 -
FILE: C
SECTION: 1 SM
94
Place s h i f t f o r k on s h i f t hub and i n s e r t

r a i l through fork.
96
I r . s t a l 1 s h i f t rail d e t e n t b a : l s p r j n g and
p i us.
FILE: 2.
97
Install rlew i n p u t s h a f t o i l s e a l .
98
Place i n p u t shaft, gear and bearing i n
case.
99
P l a c e f l a n g e on s h a f t a t r e a r o f c a s e .
-3
FILE: C
SECTION: 7 SHOP fl MANUAL
1 00
I n s t a l l " 0 " r i n g , w a s h e r and n u t .
The transmission may be equipped with e i t h e r a
c a s t l e n u t with c o t t e r pin or a e l a s t i c stop n u t .
Torque c a s t l e n u t t o 150-200 f t . l b s . and i n s t a l l
c o t t e r pin.
Torque e l a s t i c stop n u t t o 200-350 f t . l b s .
101
Lower high s p e e d c l u t c h assembly i n t o

postion.
102
R a i s e high s p e e d c l u t c h 5 / 8 " and i n s t a l l law
s p e e d c l u t c h t h e n lower high s p e e d c l u t c h
back i n t o c a s e .
-34-
103
Raise l o w speed c l u t c h 5 / 8 " a n d i n s t a l l forward
ci utch.
iowsr l o w s p e e d c l u t c h b a c k ir! t o c a s e .
-35-
FILE: C
106
I n s t a l l spacer on s h a f t
107
i n s t a l l w a s h e r and n u t .
T i g h t e n n u t and l o c k w i t h c o t t e r k e y .
108
P l a c e Re!# g a s k e t o n c a s e .
Align b e a r i n g bores 07 c o v e r w i t h b e a r i n g s
on s h a f t s and t a p c o v e r i n t o p o s i t i o n .
- 36
FILE: C
109
I n s t a l l c o v e r r e t a i n i n g capscrews and t i g h t e n
evenly a l l around.
Make s u r e i n p u t s h a f t b e a r i n g i s n o t b i n d i n g
in cover.
110
Screw 7/16" x 20 b o l t i n t o each c l u t c h s h a f t
and p u l l o u t w a r d u n t i l b e a r i n g l o c a t i n g r i n g
grooves are c l e a r 3f case.
lli
I n s t a l l locating rings on a i l bearinzs i n -
c ! udi n g i n p u t s h a f t .
-37-
FILE: C
112
I n s t a l l new o i l s e a l i n g r i n g s cI n e a c h s h a f t .
(Two r i n g s e a c h s h a f t )
113
L u b r i c a t e s e a l i n g r i n g s and bearings w e l l
with type " A" o i l .
Use new b e a r i n g c a p g a s k e t s a n d " 0 " r i n g s

and i n s t a l l b e a r i n g caps.
NOTE: B e a r i n g cap c o n t a i n i n g b r e a t h e r m u s t
be p l a c e d on f o r w a r d c l u t c h s h a f t .
114
Place d e t e n t s t o p p i n s i n s i d e s p r i n g s and
d e t e n t b a l l s on t o p o f s p r i n g s .
Lower c o n t r o l v a l v e w i t h gasket c a r e f u l l y
o v e r b a l l s , s p r i n g s and p i n s .
-36-
FILE: 2
SECTION: 7 SHOP
175
Attach contra: v a l v e a n d r e - c: h e c k alj

fasteners ~
P l ~ ga l l o p e n j a g s u n t i l u n i t i s i i l s t a l l e d i n
rcachine.
-39-
FILE: ,C
SECTION: 7
CHECKING
POWERSHIFT TRANSMISSION &CONVERTER HYDRAULIC PRESSURES
GRADERS: T-400AY T-500AY T-500L and T-6OOB/IH DT-407 Engine

CRANES: Series A Hydraulic Cranes ~~
1. TRANSMISSION OIL LEVEL CHECK: 3. CHECK CLUTCH PRESSURES AT POINT A.**

Oil a t operating temperature. ( a ) I f clutch pressure does n o t read
Moldboard in ground , parking brake 260i- 20 PSI (1.79+ 0 . 1 4 MPa) on
set. instrument panel - i n s t a l 1 a r e l i -
Engine i d l i n g . able 300 - 350 PSI ( 2 . 0 7 - 2.41 MPa)
-
All s h i f t i n g levers in neutral. gage a t point A.
Remove t o p pl ug ( P o i n t C ) . I f the ( b ) Record pressures a t engine High
transmission is over f i l l e d , allow i d l e and -Low i d l e .
a1 1 the oil t o drain o u t of the t o p ( c ) Moldboard i n ground and parking
plug. I f there i s no o i l a t the t o p brake s e t .
p l u g , remove the bottom plug ( P o i n t ( d ) Check a1 1 4 clutches:
C ) . If there i s no o i l a t bottom 1 . Forward clutch engaged - H i - Low
plug *ADD OIL ( a t c o n v e r t e r , w i t h i n neutral.
engi n e v R e c h e c k w i t h engine 2 . Reverse clutch engaged - Hi- Low
running. Maintain between t o p and in neutral.
bottom plug ( P o i n t r 3. Forward & reverse clutch in
*Use Type " A" Suffix A , Automatic neutral Hi clutch engaged.
Transmission Fluid or Dexron. 4. Forward & Reverse clutch in
neutral Low clutch engaged.
Approximate Capacity: 7 U.S. Gallons Record a l l pressures - Pressure
( 2 7 1i t e r s ) 2 6 0 t 20 PSI ( 1 . 7 9 2 0.1-
2. CHECK CONVERTER OUT PRESSURE AT POINT B . **Clutch pressures may be taken from
( a ) I n s t a l 1 100 PSI ( 0 . 6 9 MPa) gage individual clutch caps p o i n t D .
a t P o i n t B. A 1/8" N.P.T. f i t t i n g i s located
( b ) Engine a t High Idle. Transmission on each cap f o r gage i n s t a l l a t i o n .
in Neutral.
( c ) Converter Temperature 180°F. (82°C.) -
Pressure 35 t 10 ( 0 . 2 4 t 0.07 MPa).
-40-
-41 -
MATERIAL L I F T [ I
DRESSER GRADER [ I
PLANER [ I
ROLLER [ I
CRANE [X]
SHOP MANUAL c-10.00

c3
ALLISON MODEL TT-2421-1 TRANSMISSION
150 S e r i e s A 06201 & Up
150FA 07305 & Up
I CAUTION I
ALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING
DISASSEMBLY AND REASSEMBLY.
ALL JACKING HOISTING AND GENERAL WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST BE N I GOOD
WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

INJURY.
I
I
I
CONTENTS PAGE
General Torque Values ............................ Back o f Cover

Scope o f Manual ........................................
S p e c i f i c a t i o n s , wear L i m i t s , and S p r i n g D a t a ...........
D e s c r i p t i o n ............................................
O p e r a t i o n ..............................................
T r o u b l e s h o o t i n g ........................................
Special Tools .........................................
Removal From Crane .....................................
Disassembly o f T r a n s m i s s i o n ............................
I n s p e c t i o n and C l e a n i n g ................................
R e b u i l d o f Sub- assemblies ..............................
Reassembly o f Sub- Assemblies ...........................
I n s t a l l a t i o n i n Crane ..................................
S e r v i c i n g T r a n s m i s s i o n .................................
DRESSER INDUSTRIES, INC. EAST SUNNYSIDE AVE. LIBERTYVILLE, I L 60048
1086 c3
The following General Torques are to be used in all cases where SPECIFIC :TORQUESare not given.
NOTE Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads. ..
1 Heat treated material Grade 5 & Grade 8 - "
.
-
Thread Size
Foot Pounds
Grade 5
(3radial dashes on bolt or cap screw head)
Newton Meters
1 Foot Pounds
Grade 8
(6 radial dashes on
Newton Meters
(Ft Lbs.) (Nm) (Ft Lbs.) (Nm)
1/4 - 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 - 18 13 18 18 24
5/16 - 24 15 20 21 28
3/8 - 16 24 33 34 46
3/8 - 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
5/8 - 11 115 156 165 224
5/8 - 18 130 176 185 251
3/4 - 10 205 278 290 393
3/4 . 16 230 312 320 434
718 - 9 305 414 . 455 617
718 - 14 335 454 515 698
1 - 8 455 617 695 942
1 - 14 510 691 785 1064
1 1/8 - 7 610 827 990 1342
1 118 - 12 685 929 1110 1505
1 1/4 - 7 860 1166 1400 1898
1 114 ~ 12 955 1295 1550 2102
1 3/8 - 6 1130 1532 1830 2481
1 318 - 12 1290 1749 2 085 2827
1 1/2 - 6 1500 2034 2 430 3295
1 1/2 - 12 1690 229 1 2 730 3701
1 3/4 . 5 2370 3213 3 810 5166
2 - 4 1/2 3550 4813 5 760 7810
FILE c
SHOP MANUAL SECTION 10
-
SECTION 1
This Shop Manual section describes the OPERATION , RE-

MOVAL, DISASSEMBLY, INSPECTION, and REPAIR of the All i son
model TT-2421-1 powershf i t transmission.
A TROUBLESHOOTING GUIDE has been included in th is Shop
Manual preceding "Special Tools" on page 14 to assist in
correct diagnosis of any problem, before removing the entire
unit from the machine.
In many instances, unnecessary work and downtime can be
prevented by correct diagnosis. The Troubleshooting Guide
lists all possible conditions of malfunction, causes and re-
medies. As indicated in the chart, the engine, converter
and transmission must be considered as a single package, when
systematically searching for the trouble.
All photographs, illustrations and diagrams are repre-
sentive o f the above model transmission as incorporated in
the "Series A" Crane.
NOTE: The FRONT & REAR of t h i s transmission referred t o

i n t h i s Shop Manual does NOT correspond with the
FRONT & REAR of the crane. The REAR of the trans-
mission faces toward the FRONT of the Crane due t o
the nature of the i n s t a l l a t i o n .
-1 -
FILE c
- SHOP MANUAL SECTION 10
-
SECTION 2
SPECIFICATIONS, WEAR LIMITS, AND SPRING DATA
SPEC1 FlCATlONS
Itern Description
Transmission type Torque-converter and planetary gear.
Rotation (viewed from front) C1 ockwi se
Output - FWD operation C1 ockwi se
Mounting - drive side Modified SAE-3 flange on converter housing,
bolts to engine flywheel housing. Flex-
disc plate attaches to engine flywheel.
Gear Ranges, selector positioned Reverse, neutral , low-range (F1 ) , high-
range (F2)
Weight (dry) approx. 775 Lbs.
Torque Converter 2 stage, 4 element twin-turbine: Model
TT 425 5.1:l ratio
Gearing Constant mesh, straight spur, planetary

type.
Clutch Data - type Mu1 ti-disk, hydraul ic-actuated, spring
released, oil cooled, automatically
compensates for wear.
Clutch Data - material External - tanged polished steel -reaction
plates. Internal-splined friction plates,
resin graphite FWD and REV.
High-range sintered bronze.
Oil type, above -1 O°F Hydraulic transmission fluid, Type C-2
bel ow -1 O°F Hydraulic transmission fluid, Type C-2
NOTE: Auxiliary pre-heat is required
to raise the temperature in swnp
and external circuits to min.-1O0F.
-2-
FILE c
-
SPECIFICATIONS
I tem Description
Oil Capacity - i n i t i a l f i l l 8 1/2 U.S. Gals.

( 1 e s s external c i r c u i t s )
With all circuits incl. f i l t e r DD 4-53 36 U.S. Q t s .
Deutz F6L-912 40 U.S. Qts.
Converter out temperature 250° Max.
Main Pressure ( f u l l t h r o t t l e ) 165-195 PSI
Lubrication Pressure ( f u l l t h r o t t l e ) 15-30 PSI
Converter o u t Pressure ( s t a l l ) 40 PSI m i n .
Converter out Pressure ( f u l l t h r o t t l e ) 65 PSI max.
(no-1oad )
CRANE ENGINE SPEEDS

MODEL ENGINE LOW IDLE HIGH IDLE t 5 0 STALL f75
150 A DD 4-53 7 50 2900 2000
150 A Deutz F6L-912 750 281 5 1875
-3-
WEAR LIMITS
DESCRIPTION WEAR LIMITS (inches
Turbine Drive Gears

(First Turbine Driven Gear Thrust Washers)
Thrust washer against driven gear - thickness 0.028
Thrust washer against second turbine drive gear - thickness 0.120
Turbine Driven Gear & Freewheel Clutch

*Freewheel clutch r o l l e r - diameter 0.4980
*Freewheel cam surface - wear 0.005
* F i r s t turbine driven gear - outside diameter 3.0327
REV-Range Clutch & Planetary

REV-range steel clutch p l a t e - thickness 0.097
cone - maximum 0.030
REV-range f r i c t i o n clutch p l a t e - thickness 0.130
**Minimum clutch pack thickness 1.185
REV-planetary pinion end play i n c a r r i e r 0.055
Clutch anchor face wear
REV-rangeyy face maximum 0.020
LOW-range face maxi mum 0.020
LOW-Range Clutch Pack Thickness

LOW-planetary pinion end play i n c a r r i e r 0.055
LOW-range steel clutch p l a t e - thickness 0.097
LOW-range f r i c t i o n clutch p l a t e - thickness 0.130
HIGH-Range Clutch & Piston Housing

Transfer gear clutch face wear 0.020
HIGH-range s t e e l clutch p l a t e - thickness 0.097
HIGH-range f r i c t i o n clutch p l a t e - thickness 0.130
-4-
FILE c
DESCRIPTION WEAR LIMITS (inches)

HIGH-Range Clutch & Piston Housing ( c o n t . )
Diametral clearance between HIGH-range clutch
h u b b u s h i n g i n piston housing 0.005
Seal-ring thickness 0.088
Piston face wear 0.020
O u t p u t Shafts & Disconnect Assembly

Diametral clearance between, f r o n t o u t p u t
s h a f t and bushing in o u t p u t s h a f t 0.010
NOTE:
* Total wear of freewheel parts (2 x r o l l e r wear + sum of cam surface
a t t u 0 opposing points + gear hub wear) must not exceed 0.020".
(Determine cam surface wear by measuring depth of groove caused by
rolZer contact i n the cam pocket).
** Total individual pZate thickness. Replace p l a t e s having the most
wear, with new plates t o increase pack thickness.
SPRING DATA
1 SPR I FIG
Lub. Pressure Regulating Valve

Conv. Pressure Regulating Valve
Freewheel Clutch
1 1
I NO.COILS I DIAM.
1
!5.
I
e. 047
0.080
WIkE
0. (333
O.D.
0.403
FREE LENGTH
'2, .44
LENGTH
1.00
POUNDS
5.58 - 6.82
REV & Low-Range Clutch Piston - 37.5 0.105 0.625 6.127 4.80 45.1 - 49.9
Return Spring
I
5.14 1 0.275 I - I - 1
-5-
FILE c
SHOP MAMUAL SECTION 10
-
SECTION 3
DESCRIPTION
The TT 2421 -1 two speed forward, one speed reverse trans-

mission, i s direct mounted t o the engine flywheel housing,
through a mounting face on the torque converter housing.
Power i s transmitted from the engine flywheel t o torque
converter impeller t h r o u g h a "flex-plate" mounted on the impel -
1 er and bo1 ted t o the flywheel .
The torque converter i s o f the TWIN-TURBINE design and each
.
turbine i s connected t o i t s own gear s e t The two ( 2 ) gear sets
are referred t o as the COMBINING gears.
The FIRST turbine (outer) provides "HIGH-TORQUE" a t low
speed and the second turbine (inner) provides "HIGHER SPEED"
with less torque.
The torque converter contains four ( 4 ) elements:
.
1 Impel 1 er (or pump) - i n p u t
2. First turbine
3. Second turbine
4. S t a t o r
The f i r s t turbine drive gear, driven gear, and freewheel
clutch, connect the f i r s t turbine t o the range planetary gears
and clutches. The second turbine drive gear and driven gear,
connect the second turbine t o the the range planetary gears and
clutches.
The f i r s t turbine gear s e t provides a REDUCTION in speed
w i t h an increase i n torque delivered t o the range gearing. Al-
ternatively the second turbine gear set provides an increase
in speed with a corresponding REDUCTION in torque del ivered t o
t o the range gearing.
When the torque demand i s HIGH the freewheel clutch i s en-
gaged and t h e FIRST turbine, assisted by the SECOND turbine,
drives the range gearing.
When machine speed increases, torque demand decreases, then
the SECOND turbine assumes a1 1 the load and the freewheel clutch
disengages. A t this point there i s NO TORQUE INPUT from the FIRST
TURBINE.
The transmission has two ( 2 ) planetary range gear sets and
three ( 3 ) clutches.
-6-
FILE c
SHOP MANUAL SECTION 10 -
The FIRST range gear set behind the "Combining gears" i s

REVERSE. This consists of a ring gear, carrier assembly and sun
gear (integral with low range sun gear). The REVERSE - range i s
controlled by the reverse range clutch, attached t o the planetary
carrier .
Next i s the LOW-range planetary gear set and i t consists of
a ring gear, carrier, and sun gear. The LOW - range i s controlled
by the LOW - range clutch, attached t o the RING gear.
The HIGH range consists of a gear and clutch assembly. Tor-

que i n p u t t o the HIGH range gear i s t h r o u g h LOW range sun gear
t o HIGH range clutch.
Transmission o u t p u t consists of a transfer gear, driven by
HIGH range gear t o b o t h FRONT and REAR o u t p u t flanges. The " o u t -
p u t " shaft i s two ( 2 ) piece incorporating a dis-connect coupling
on the REAR o u t p u t shaft for either two ( 2 ) or four ( 4 ) wheel
drive.
NOTE: Rear a x l e of Crane disconnected f o r two wheel drive.
An "accessory" drive gear, driven by the impeller, powers

the torque converter and transmission, positive displacement gear
type oil pump.
Oil i s drawn from the transmission sump, through a wire mesh
strainer i n t o the oil pump ( t h i s tube i s located within the trans-
mission) * The pump delivers i t s entire o u t p u t t o a f u l l - flow
f i l t e r (26.7 micron) externally mounted and then t o the control
valve assembly mounted on the side of the transmission housing.
The control valve consists o f :
1 . Body
2. Range selection spool valve (Reverse-FWD 1 and FWD 2 )
3. Pressure regulating valve-main
The control valve delivers oil under pressure t o the range
clutch selected, lubrication pressure t o other components and
keeps the torque converter charged with oil d u r i n g operation.
Transmission oil temperature i s controlled t h r o u g h an o i l
cooler located within the engine r a d i a t o r lower tank (or when
Deutz powered, t h r o u g h an o i l t o a i r cooler mounted on the en-
g i ne) 1-
- 7-
FILE c
-
SECTION 4
OPERATION
TWIN - TURBINE TORQUE CONVERTER
The t w i n - turbine converter i s able t o extend the torque

multiplication of the converter, in each gear range, providing
a broad torque coverage equal t o two ( 2 ) normal planetary gear
ratios.
This extended coverage i s accomplished automatically and
smoothly. A t HIGH torque demand and LOW speed the "freewheel"
clutch i s engaged causing b o t h turbines t o drive, p r o v i d i n g
maximum i n p u t t o range gearing and when torque demand DROPS and
speed increases, the second turbine speed exceeds t h a t of the
f i r s t turbine and the "freewheel" clutch disengages. Likewise
when Crane speed decreases torque demand increases and the "free-
wheel" clutch re-engages a1 lowing b o t h turbines t o provide maximum
torque i n p u t t o the range gearing.
SECOND-TURBINE
FIRST-
'TURDIN\€ 1 PTO
LOW-RANGE
CbUTCH
INPU r
JT
FILE c
-
RANGE GEARING
The range gearing consists of two ( 2 ) planetary gear sets
REV and LOW (as previously described). Each set includes an
inner sun gear four ( 4 ) planet pinion gears united in a carrier,
and an outer ring gear.
Each planetary gear set i s controlled by a clutch, which
when applied, causes an interaction within the gear s e t , pro-
ducing the selected speed r a t i o and direction of travel.
LOW RANGE ( F l )
--
The low range clutch when applied holds the RING gear
stationary and the sun gear i s the driving member. Thus the
PLANET PINIONS drive the CARRIER a t a reduced speed.
HIGH RANGE ( F 2 )
--
The h i g h range clutch connects the transfer gears t o the
high range clutch h u b , which i s connected t o the i n p u t shaft.
When the clutch i s applied a simple drive i s produced from the
i n p u t t o the o u t p u t .
REVERSE RANGE
The reverse range clutch, when applied, holds the PLANE-

TARY CARRIER and the SUN gear i s the d r i v i n g member. Thus the
PLANET PINIONS drive the ring gear i n a REVERSE direction.
This reverse torque drives the r e s t of the rotating members in
a REVERSE direction.
HYDRAULIC SYSTEM
The hydraulic system generates, directs, and controls the
pressure and flow of the hydraulic fluid, w i t h i n t h e transmission.
The hydraulic fluid i s the power transmitting medium i n the tor-
que converter. I t s flow lubricates and cools the transmission
components. I t s pressure diverted by the control valve applies
the clutches and i t s velocity drives the torque converter turbines.
-9-
FILE c
-
GEARSHIFT PATTERN
A single gear s h i f t lever, connected t o the control valve
spool, controls the functions of the transmission. Movement
of the s h i f t lever produces the selected ratio and direction.
NOTE: The Crane must be brought

t o a "stop" BEFORE s h i f t -
ing from FORWARD t o RESERVE
oy. v i c e versa.
S h i f t i n g from FWD 1 t o FWD 2

o r from FWD 2 t o FWD 1 on
the move i s permitted. Care
should be taken however when
s h i f t i n g from FWD 2 t o FWD 1
a t high speed. I t i s rec-
commended t h a t t h r o t t l e be
decelerated s l i g h t l y during
downshift t o avoid a "hard
shift".
Figure 2
PUSHING -
OR TOWING
IN THE EVENT THE CRANE IS DISABLED AND MUST BE
"PUSHED" OR "TOWED" FARTHER THAN 1 / 4 MILE, IT IS MAND-
ATORY THAT BOTH DRIVE LINE SHAFTS BE DISCONNECTED.
FAILURE TO COMPLY WITH THE 1 / 4 MILE LIMIT, MAY RE-
SULT IN SERIOUS DAINGE, REQUIRJNG COMPLETE OVERHAUL
OF THE TRANSMISSION.
IF DISTANCE IS LESS THAN 1 / 4 MILE THE DRIVE LINE
SHAFTS MAY REMAIN CONNECTED, AND THE CRANE MUST ONLY
BE MOVED AT LOW SPEED (NOT MORE THAN 5 M. P. H . ) .
-1 0-
FILE c
SHOP MANUAL SECTION 10-
SECTION 5
TROUBLESHOOTING
A. LOW MAIN PRESSURE

--
Cause Remedy
1 . Low oil leve?. Add t o correct 1 eve1 .
2. Clogged oil strainer Drain transmission oil clean
strainer and r e f i l l .
3. Clogged oil f i l t e r Rep1 ace f i 1t e r el ement.
4 . Weak or broken main pres- Replace spring.
sure regulating spring
5. Oil pump worn Rebuild oil pump.
6. Air leak a t intake side Check pump mounting bolts and
o f pump internal oil pick up tube.
7 . External oil leakage Tighten bolts and/or replace
necessary gaskets.
8. Internal oil leakage Disassemble transmission and
rebuild sub-assemblies.
B. OVERHEATING
Cause Remedy
1 . Oil level t o o high Restore t o proper level.
2 . Clutch failed Rebuild transmission.
3. Low clutch apply pressure Refer t o -
A.
4. Engine coolant overheated Correct overheating problem.
( D . D . only NOT DEUTZ)
5. Engine overheated Check fan belt and oil cooler
(DEUTZ ONLY) on engine.
6. Cooler oil lines kinked or Clean or replace line.
bl oc ked
-11-
FILE c
C. LOW CLUTCH APPLY PRESSURE

-
Cause Remedy
1 . Low oil level Add oil t o correct 1 evel .

2. Clogged oil strainer Clean strainer.
3. Clogged oil f i l t e r Rep1 ace f i 1t e r el ement.
4. Air leak a t intake side Check pump mounting bolts and
of pump hose.
5. External oil leakage Tighten bolts and/or replace
gaskets.
6. Low main pressure Refer t o A.
7 . Clutch piston seal rings Overhaul transmission.
f a i 1 ed
D . AERATED (FOAMING)
Cause Remedy
1 . Incorrect type oil used Change o i l : use proper type.
2. High oil level Restore proper 1 evel .
3. Low oil level Restore proper 1 evel .
4. Air entering suction side Check pump i n l e t hose mounting.
of pump.
E. CRANE WILL NOT TRAVEL

---
Cause Remedy
1 . Low main pressure Refer t o A.
2. Low clutch apply pressure Refer t o C.
3. Range selector 1 inkage Repair or correct linkage.
broken or disconnected.
4 . Internal mechanical Overhaul transmission.
failure
-1 2-
FILE c
-
F. IN NEUTRAL WHEN ENGINE

VEHICLE TRAVELS - IS ACCELERATED
Cause Remedy
1. Selector 1 inkage out Adjust 1 inkage.
of adjustment - _i
2. Clutch failed (won't Overhaul transmission.

re1 ease)
G. VEHICLE ---
LACKS POWER AND ACCELERATION ---
AT LOW SPEED
Cause Remedy
1. Low main pressure A.
Refer to -
2. Low clutch apply pressure Refer to -
C.
3. Turbine freewheel Overhaul transmission.
clutch failed
4. Engine malfunction Check engine.
5. Aerated oi 1 Refer to E.
H. ----
STALL SPEED TOO HIGH
Cause Remedy
1. Clutch slipping Overhaul transmission.

2. Low main pressure Refer to A.
I. ----
STALL SPEED TOO LOW
Cause Remedy
1. Engine not producing Tune or repair engine.
full power
2. Torque converter failed Rebuild torque converter.
-1 3-
FILE c
SECTION 6
SPECIAL TOOLS AND EQUIPMENT
Certain "special" tools are required for overhaul of this

transmission as shown hereunder. These can be fabricated in
your shop and details are given in the following illustrations.
Improvised puller for torque

converter pump (impeller) and
bearing removal.
Figure 3
9/16NOM. I)
Freewheel cam bolt holding

fixture.
(35.81 1.25) I
(25.41-
Figure 4
In addition to normal hand tools, the following items should

be available:
1. Chain hoist (min 1 ton cap.) 6. Oil - soluble grease
2. Press (for removal and assembly 7. Dry-ice (for cooling
of press-fi t parts) interference-fit parts)
3. Supply of wood blocks 8. Heating equipment to pro-
4. Clean lint free cloths vide oil at 3OO0F for
5. Torque wrenches interference-fi t parts
-1 4-
FILE c
-
SECTION 7
REMOVAL F R O M CRANE
NOTE: The steps l i s t e d i n removal of the transmission will d i f f e r
betueen the DD 4- 53 engine (water cooled) and the Deutz F6L-
91 2 engine ( a i r cooled) .
A l l i l l u s t r a t i o n s cover the DD 4-53 engine.
(Fig. 5)
1. Disconnect air cleaner hose to engine and remove.
2. Disconnect Emergency Shut-down cable.
3. Disconnect the supply and return fuel 1 ines.
4. Remove hood top with air-cl eaner.
5. Drain engine/radiator coolant. Disconnect top and lower radiator
hoses at engine. Disconnect sur plug for STOP-TAIL- TURN lights.
Disconnect wire to Back-up alarm. Remove radiator and cowl.
6. Disconnect,plug and cap torque converter "in" and "out" 1 ines at
transmission.
7. Remove battery ground cable (top capscrew torque-converter to
engine), then remove rear dash. Ground cable runs through
grommet in right side of dash.
(Fig. 6 )
8. Remove hydraulic pump drive shaft.
9. Attach suitable sling to support engine/transmission. Remove front
engine mounting bo1 ts.
10. Raise engine to release pressure on "shim-pack" and remove shims.
(Fig. 7)
11. Remove both front and rear drive lines at transmission output and
and differential.
12. Remove rear-axle disconnect control rod and bracket on transmission.
(Fig. 8 )
13. Remove engine shut-down cable.
14. Remove throttle cable.
15. Remove ground for REAR steer light and cable to starter motor.
16. Remove both rear engine/transmission mount bolts.
Remove transmission "pressure" capill iary tube at control valve
and disconnect Range control cable at control valve.
-1 5-
FILE c
Figure 8
J
Figure 6 Figure 9
Carefully remove engine from Crane and

position on suitable stand to support
engine and allow transmission assembly
to be removed from engine.
Disassembly is covered under "Disas-
sembly o f Transmission" Page 17.
Figure 7
-1 6-
FILE c
-
SECTION 8
DISASSEMBLY OF TRANSMISSION
NOTE: The foZZowing instructions show in Zogical sequence, the

removaZ of e x t e r i o r components, through the torque conver-
t e r , t o the f r o n t sp Z i t l i n e of the transmission housing.
The transmission is then repositioned and remaining com-
ponents are removed from the rear.
It is not recommended that any MAJOR repairs be effected with the

transmission in the Crane, however in general all external sub-
assemblies and all components which can be removed from the rear
of the transmission may be serviced with the unit in the machine.
It is recommended however that the transmission assembly be re-
moved for any MAJOR repairs.
Detroit Diesel Engine

After engine is securely positioned
on stand, insert two 3/4"-10 "eye-
bolts" in top o f transmission.
Attach sui table sl ing and support
transmission.
Remove the two eng ine/transmission
mounting brackets (1) either side.
Remove 1 1 / 2 " Dluq
. - in f1 ywheel
housing (2). Through this access
hole remove each of the 8 - 3/8"
capscrews securing flex-plate to
flywheel. Turn crankshaft to
a1 ign each capscrew with hole.
Then with transmission well sup-
ported , remove the twelve 3/8"
capscrews (3) which fasten trans- Figure 1 0
mission to engine flywheel housing.
-1 7-
FILE c
-
Swing transmission assembly away from engine

and move t o tear down.area.
I t i s recommended t h a t assembly be cleaned t o
remove a l l oil and d i r t before disassembly.
Figure 11
Remove d r a i n plug ( 1 ) and drain any excess o i l

from transmission. Remove capscrews & lock-
washers ( 2 ) and remove o i l suction screen ( 3 1
w i t h gasket.
Loosen self-locking nuts ( 4 ) . Remove n u t ,
f l a t washer, ' 0 ' ring, and companion flange
( 5 ) (front & rear). A spacer i s located be-
tween "rear" companion flange and bearing.
Spacer can be removed by sliding o f f shaft.
Figure 1 2
Remove the 1 6 capscrews and lockwashers ( 6 ) t h a t attach the control valve body ( 7 ) t o
the transmission housing. Carefully remove the control valve and gasket from the trans-
mission.
Remove the 9 capscrews and lockwashers ( 8 ) t h a t a t t a c h the oil pump ( 9 ) t o the trans-
mission housing. Carefully remove the o i l pump and gasket as an assembly.
NOTE: Do not separate the o i l pump components unless inspection or parts
replacement i s necessary.
Refer t o "Rebuild of Sub-assemblies" f o r rebuild of the control

valve and oil pump. Page - 41.
-1 8-
FILE b
-
Remove the six self-locking bolts ( 1 ) t h a t

retain the flex-plate t o the impeller cover(4)
Insert two eyebolts ( 2 ) ' 1 / 2 " - 1 3 in impel'ler
cover and support with suitable hoist.
Remove the 24 self-locking nuts ( 3 ) t h a t re-
tain the impel 1 er cover ( 4 ) .
F i g u r e 13
NOTE: The turbine support bearing ( 3 ) may

remain i n the cover (1) during re-
moval. I f so remove the bearing.
To remove b o t h 1 s t and 2nd turbine assemblies
( 2 ) use two screwdrivers in holes ( 4 ) and l i f t
assembly off splined shafts.
NOTE: Do not disassemble t h i s u n i t unless
"inspection" o r "repair" i n necessary.
Remove square seal ring ( 5 ) from impeller
housing.
Figure 14
To remove stator ( 2 ) release snap ring ( 1 ) .

Pull .stator ( 2 ) u p off spline shaft.
Next remove s t a t o r spacer ( 3 ) from converter
ground sl eeve.
-1 9- Figure 15
FILE c
To remove impeller straighten the "tabs" of

lock-plates at four places equidistant around
the impeller hub and remove four of the twelv
capscrews (2).
Install the improvised puller listed under
"Special Tools" making sure the puller
sleeve (3) rests on the converter ground
sleeve (4) and extends above the end of the
1st turbine drive gear shaft.
F i g u r e 16
NOTE: When the impeZZer has been drawn from i t s seat on the ground sleeve,
remove p u l l e r . If further disassembly is not required, t i g h t e n the
four 1/4"-28 x 1 1/4" capscrews to 10-12 Fir. LBS. torque and bend
the Zock-plate "tabs" against capscrew heads.
To remove converter housing remove the 24 cap-

screws, lockwashers, and flat washers which
attach". converter housing t o main housing.
Instal 1 eyebolts (shown) and apply slight
tension on lifting sling. Using a soft
hammer, bump the converter housing away from
transmission housing.
Figure 17
WHEN CONVETER HOUSING HAS CLEARED TRANSMISSION HOUSING BY APPROX.

1 1/2, CHECK TO INSURE THAT THE 2ND TURBINE FREEWHEEL GEAR AND
FREEWHEEL CLUTCH REMAIN WITH THE TRANSMISSION AND NOT IN THE CON-
VERTER HOUSING.
-20-
FILE c
I f necessary, use two l o n g screwdrivers t o pry the freewheel clutch

f r o n t bearing from the converter housing.
NOTE: I f t h e freewheel u n i t i s raised with the converter housing,
the o i l suction tube may be damaged. I f the second turbine
drive gear i s raised with the housing, it may f a l l unexpect-
edly causing damage o r i n j u r y .
Remove the converter housing and attached parts. Remove the gasket.
Remove second turbine drive gear and shaft

( 1 ) . Remove freewheel clutch u n i t ( 2 ) .
NOTE: Sea2 ring ( 3 ) and bearing ( 4 ) may
be replaced a t t h i s time or during
.
re-assembly Repair of the free-
wheeZ clutch u n i t (2) wiZZ be
covered i n section "Rebuild of Sub-
assembliesn.
-21 -
FILE c
Remove the 19 capscrews and lockwashers t h a t

attach the rear cover (1 ) t o the transmissiol
housing ( 2 ) . Remove gasket ( 4 ) and seal
Remove h i g h range clutch piston housing ( 5 )
by straightening the lock tabs and removing
the six capscrews ( 3 ) t h a t attach the h i g h -
range clutch piston housing t o the transfer
drive gear.
Figure 20
Using two bars "pry" the h i g h range clutch

piston housing ( 1 ) and attached parts from
the transfer drive gear.
Bearing ( 2 ) should be checked for service-

a b i l i t y and replaced i f necessary.
Figure 21
Remove the high-range clutch h u b assembly

from transfer drive gear ( 3 ) .
Clutch h u b assembly consists of a drive h u b
with one polished steel plate ( 1 ) i n between
two sintered bronze plates ( 2 ) . Refer t o
Section 2 for wear limits, before rebuild.
Figure 22
-22-
FILE c
-
Rem0ve transfer drive gear (3) by releasing

snap ring (1) and sliding transfer drive
gear off low-range planet carrier (2).
Figure 23
NOTE: Before removing low-range p i s t o n

housing ( 2 ) replace two of the
t e n self- locking capscrews ( 1 )
t h a t r e t a i n the Zow-range p i s t o n
housing with two 3/8”-16 x 2 1/21i
capscrews (removed from the control
valve assembly). Install these cap-
screws ( 1 ) to r e s t r a i n the spring
pressure.
Remove remaining eight capscrews and loosen

restraining capscrews evenly. Remove low-
range piston (2) as an assembly.
Figure 24
Remove the twelve pi ston return springs (1

and guide pins. Remove the low-range plan
etary carrier ( 2 ) with low range ring gear
( 3 ) , four clutch plates (4) and the attached
reverse-range ring gear as a unit.
Remove the remaining four low-range clutch
plates.
Figure 2 5
-23-
FILE c
Before removing REV & low-range clutch

anchor ( 4 ) remove guide p i n ( 1 ) (located
under control valve body gasket) from o u t -
side.
Remove clutch anchor ( 4 ) by c a r e f u l l y pullit
upwards.
Remove REV-range planetary c a r r i e r assembly
( 3 ) w i t h one internal- splined clutch p l a t e
( 2 ) as a u n i t .
Figure 26
The REV-range planetary ring gear has a

"step" i n the splines which locate the resin-
graphite internal- spline f r i c t i o n plates.
One p l a t e ( 1 ) located above the step (shown)
and four below the step.
Remove REV-range clutch piston ( 3 ) . Do n o t
remove seal rings unless replacement i s
necessary. Repair o f REV & low-range plan-
e t a r y c a r r i e r assemblies a r e covered under
"Rebuild of Sub-assemblies" Section l a .
Figure 27
RePosition transmission housing i n a v e r t i c a l position and support w i t h hoist.
Rotate s h i f t e r f o r k s h a f t ( 1 ) counterclock-
wise t o remove from transmission housing.
Removal of s h a f t ( 1 ) will allow s h i f t e r fork
( 2 ) t o f a l l into sump area. Remove o i l seal
( 3 ) only i f replacement necessary.
Only remove o i l seal ( 4 ) and f r o n t o u t p u t
s h a f t bearing r e t a i n e r snap ring ( 5 ) i f re-
placement necessary.
NOTE: Removal of both front and rear out-
put shafts is effected through the
rear of the transmission housing .
Figure 28
-24-
FILE c
SHbP MANUAL SECTION 10-
Remove rear o u t p u t shaft o i l seal. Remove

rear bearing retainer ring ( 9 j .
Using a soft hammer, drive the "front" o u t
p u t shaft rearwards until the rear o u t p u t
shaft bearing ( 2 ) i s free from transmission
housing ( 4 ) .
Figure 29
NOTE: When s h a f t (1) is removed, gear ( 3 )

should be supported.
Remove rear o u t p u t shaft ( 1 ) with bearing

and spacer ( 2 ) located behind transfer driven
gear ( 3 ) . DO NOT remove bushing ( 4 ) in end of
shaft ( 1 ) unless replacement necessary.
Transfer driven gear ( 3 ) may now be removed.
8373
Figure 30
-25-
FILE c
-
Remove center support bearing ( 1 ) from i t s

bore in housing web.
Remove front o u t p u t shaft ( 2 ) w i t h disconnect
coup1 i n g ( 3 ) as an assembly.
A SPRING AND TWO "DETENT BALLS"
WILL BE RELEASED WHEN THE D I S -
CONNECT COUPLING I S REMOVED FROM
THE FRONT OUTPUT SHAFT.
Drape a shop rag over the assembly t o prevent

ball s from being re1 eased under spring ten-
sion.
. -
Figure 31
NOTE: Remove any remaining parts from transmission housing, only

i f replacement i s required.
-26-
FILE c
-
SECTION 9
INSPECTION AND CLEANING
NOTE: A l l parts must be clean t o permit an e f f e c t i v e inspection.

During assembly, it i s very important t h a t no d i r t or
foreign material enters the transmission. Even minute
p a r t i c l e s can cause malfunction of close f i t t i n g parts.
C1 eani ng Parts
All metallic parts of the transmission (except bearinqs) should be
cleaned thoroughly with v o l a t i l e mineral s p i r i t s or steam cleaning.
DO NOT use a Caustic soda solution for steam cleaning. Gum and
varnish deposits can be removed by soaking parts in a varnish re-
mover.
Dry parts with compressed a i r and oil a f t e r drying.
Clean a l l oil passages by working piece of s o f t wire back and forth
t h r o u g h passages and flushing with s p i r i t s . Dry with compressed a i r .
Cleaning Bearings
Bearings t h a t have been in service should be thoroughly washed in
volatile mineral s p i r i t s . If bearings are particularly d i r t y or
f i l l e d with hardened grease, soak them in s p i r i t s before cleaning.
Before inspection oil bearings with C-2 o i l .
NOTE: Never d r y bearings with compressed a i r and do not r o t a t e

bearings while they are not well lubricated.
INSPECTING PARTS
Bearings
Inspect bearings for roughness of rotation, for scoring, p i t t i n g ,
cracked or chipped races. If any of these defects are found, replace
bearings.
Also inspect the defective bearing housing and shaft for grooved,
galled or burred conditions t h a t indicate bearing has been turning
in i t s housing or on i t s shaft.
NOTE: When i n s t a l l i n g a bearing on a "shaft" heat the bearing

t o 20O0F on an e l e c t r i c hot p l a t e or an o i l bath. Bear-
ings must be heated long enough f o r s u f f i c i e n t expansion
and heating tube i s determined by the s i z e of the bearing.
Forty- five (45) minutes i s s u f f i c i e n t f o r the largest
bearing in t h i s transmission.
-27-
FILE c
-
Cast Parts & Machined Surfaces

Inspect bores and surfaces for scratches, wear, grooves and d i r t .
Remove any scratches and burrs w i t h crocus cloth. Remove foreign
matter. Replace any parts t h a t ark deeply grooved or scratched,
which would affect their operation.
Repair i f possible or replace any housings or other cast parts t h a t
are cracked.
Bushings and Thrust Washers

Inspect BUSHINGS for scores, roundness, burrs, sharp edges and any
evidence o f overheating. Remove scores w i t h crocus cloth and burrs
and sharp edges w i t h a scraper or knife blade. I f the bushing i s o u t -
of- round, deeply scored, or excessively worn, replace i t .
NOTE: Sometimes it i s necessary t o cut out a d e f e c t i v e bushing
Be carefuZ not t o damage the bore i n t o which the bushing
fits.
Inspect THRUST washers for distortion, scores, burrs and wear. Re-
place thrust washer i f defective or worn.
Oil Seals, Gaskets and Hook-Type Seal Rings

Inspect lip-type seal rings for cuts and hardness. Replace seal
rings i f defects are f o u n d .
NOTE: When replacing Z i p type sea2 rings, makes sure spring

Zoaded side i s towards oiZ t o be sealed. Use a non-
hardening sealing compound on outside diameter of the
seaZ. Coat i n s i d e diameter with high temperature
grease.
Replace composition gaskets.

Inspect hook-type seal rings for wear broken hooks and distoration.
Install a new hook-type seal r i n g should i t be worn so much t h a t
there i s no g a p between hooks of seal ring when instal led.
NOTE: The sides of the seal ring should be smooth. (0.005" rnax.
sidewear) The sides of the s h a f t groove (or the bore) i n
which the sea2 ring f i t s shouZd be smooth (50 MICRO-INCHES)
and square with the a x i s olf r o t a t i o n within 0.002". If
the sides of ring grooves have t o be reworked (0.020" rnax.
sidewear) instaZZ new sea2 r i n g .
-28-
FILE c
Inspecting --
Gears and Splined Parts
Inspect GEARS for scuffed, nicked, burred or broken teeth. I f defect
cannot be removed with a honing stone, replace gear. Also inspect
teeth for wear the.y may have destroyed orginal shape of t o o t h . Also
inspect gear thrust faces.
Inspect SPLINED parts for stripped, twisted or chipped splines. Re-
move any burrs found w i t h soft stone.
NOTE: Spline wear i s not considered detrimental except where it
a f f e c t s tightness o f splined parts.
Inspecting Clutch Plates

Inspect FRICTION-FACED plates for burrs , imbedded metal particles ,
severely pitted faces, excessive wear, cone, cracks, distortion and-.
damaged spline teeth. Remove any burrs w i t h soft h o n i n g stone.
Replace plates which have other defects.
Inspect STEEL PLATES for burrs, scoring, excessive wear, cone dis-
tortion, imbedded metal , galling, cracks, breaks and a damaged tangs.
Remove burrs and minor surface irregularities, using a soft h o n i n g
stone. Replace plates which have other defects.
NOTE: The amount of cone i s detemined by measuring the distance
between the i n s i d e diameter of the p l a t e and a lever sur-
face.
When assembling a clutch pack, soak clutch plates in type C-2 oil
for a t least two minutes and make sure t h a t each plate i s installed
so t h a t the cone i s i n the same direction as the adjacent plates.
Refer t o Section 2 of t h i s Manual - "Specifications, Wear Limits,
and S p r i n g Data", for maximum allowable cone.
I E V E L SURFACE
1
CLUTCH PLATE
8379
Figure 32
-29-
FILE c
SECTION 10
REBUILD OF SUB-ASSEMBLIES
CONTROL VALVE
DISASSEMBLY
8380
Figure 33
Remove plug ( 1 ) and gasket ( 2 ) t h a t r e t a i n main pressure regulator

valve ( 3 ) . Remove valve ( 3 ) .
Remove plug (13) and gasket ( 1 2 ) t h a t r e t a i n trimmer plug (11).
Remove trimmer plug and main pressure regulator spring ( 9 ) , spring
r e t a i n e r (8) and trimmer spring ( 1 0 ) .
Remove main pressure check p l u g ( 3 0 ) . A1 so remove selector valve
plug (29) and gasket (28).
Remove plug (23) and gasket ( 2 4 ) and one spring ( 2 6 ) and ball ( 2 5 ) .
A t the inner (mounting side) o f control valve body ( 4 ) remove valve
stop ( 7 ) from i t s position on range selector valve ( 2 2 ) .
Insert bo1 t through the 1 inkage p i n hole i n s e l e c t o r valve ( 2 2 ) and
pull the selector valve and seal (21 ) from the bore.
-30-
FILE c
BEFORE REMOVING RANGE SELECTOR ROD (22) FROM BORE OF

VALVE BODY (4) BE SURE TO DRAPE SHOP TOWEL OVER PLUG
HOLE (23) TO PREVENT DETENT BALL ( 2 5 ) FROM SPRINGING
OUT. REMOVE SPOOL, BALLAND SPRING.
NOTE: ControZ vaZve iZZustrated opposite, incorporates items
( 2 4 ) thru ( 2 0 ) a Ittransmission cZutch cut- off control".
However t h i s controZ is not connected on our Crane trans-
mission instaZlation and there is 120 need t o repair the
assembZy. These items are referenced only as they con-
s t i t u t e a "standard" controz vaZve.
DO not remove retainer plug ( 6 ) and ball ( 5 ) from control body (4)
unless parts replacement i s necessary.
Re-Assembly
If retainer plug (6) and ball ( 5 ) were removed from body (4) install
new ball and retainer. Place the retainer plug, open end upward,
over the ball and press retainer plug until it is flush with, to
0.010" below surface of the three supporting bosses.
Instal 1 one spring ( 2 6 ) and detent ball ( 2 5 ) into body. Depress ball
against spring and install range selector valve ( 2 2 ) (linkage end
last) through seal bore of control valve body. Install remaining
detent ball ( 2 5 ) and spring ( 2 6 ) plug (23) with gasket (24). Tighten
plug securely.
Position selector spool in neutral, middle detent position and install
selector valve stop in position shown Fig. 34.
Coat the outer circumference of oil

seal (21 ) with non-hardening sealer
and install with spring loaded l i p
first. Press seal into bore until,
flush with, to 0.030" below body
surface.
NOTE: A t assembZy, a22 spoo Z valves
must move freeZy within t h e i r
own bores.
Figure 34
-31 -
FILE c
Instal 1 main-pressure regulator valve ( 3 ) gasket ( 2 ) and plug ( 1 ).

Tighten plug securely. Install plug (30) and tighten.
Install spring retainer ( 8 ) concave side f i r s t , o n t o the stem end
of main-pressure regulator valve ( 3 ) . Install main-pressure reg-
ulator spring ( 9 ) , trimmer spring (10) and trimmer p l u g ( 1 1 ) i n t o
valve bore. Instal 1 gasket (1 2 ) and plug ( 1 3 ) . Tighten p l u g se-
curely.
NOTE: InstaZZ items (14) then (20) i n the order shown. The
clutch cut- off i s not connected on the transmission
controZ vaZue, but MUST be assemb Zed, correctZy t o
provide correct fZow of hydrauZic oil. within the con-
t r o l value.
FIRST A N D SECOND TURBINE ASSEMBLY
Disassembly
Locate index marks ( 1 ) i n outer rims
of 1 s t turbine support ( 2 ) and the
1 s t turbine ( 3 ) .
Drive the six roll pins ( 5 ) inward,
toward the hub, until they clear the
holes i n 1 s t turbine support ( 2 ) .
Only remove roll pins i f replacement
necessary.
8382
Remove f i r s t turbine from i t s support. Remove second turbine ( 4 )

and i t s bearing from the f i r s t turbine support ( 2 ) .
I f second turbine ( 4 ) bearing requires replacement, remove bearing
by pressing lengths of d r i l l rod through the 3 holes ( 6 ) .
Likewise i f f i r s t turbine bearing requires replacement press bear-
i n g using lengths of d r i l l rod through holes provided i n support
housing ( 2 ) .
Assembly
I f bearings removed from b o t h f i r s t and second turbine assemblies,
install replacement bearings (manufactures identification outward)
Press bearing firmly against i t s seat.
-32-
FILE c
SHOP MANUAL SECTION 10 -
Instal 1 second trubine ( 3 ) and bear-

ing i n t o f i r s t turbine support ( 4 ) .
Install f i r s t turbine ( 2 ) into the
f i r s t turbine support ( 4 ) and index
the V-groove marks ( 1 ) .
Drive the six roll pins outward until
they are flush w i t h , t o 0.030" below
the outer surface of the f i r s t tur-
bine support (4):
Figure 36
TORQUE CONVERTER PUMP
Disassembly
Straighten ears of the six lock-
plates and remove the twelve cap-
screws ( 2 ) t h a t attach the pump
retainer plate ( 3 ) and input acces-
sory drive gear ( 5 ) t o the converter
pump ( 4 ) . Remove the lock-pl ates,p
c,apscrews, pump, retainer plate,
accessory drive gear , bearing and
gasket.
Inspect the twenty-four "special"
bolts ( 6 ) and remove any defective
bolts by pressing them from the
pump f 1ange.
Figure 37
Assembly
I f any of the special bolts ( 6 ) were removed from the pump ( 4 ) install
t h e i r replacements.
Install the "double-row" ball bearing, l o a d i n g notch ( 1 ) upward, i n t o
the i n p u t accessory drive gear. Position gasket o n t o the accessory
drive gear and a1 ign holes .
Install converter pump o n t o the drive gear, bearing and gasket aligning
the bolt holes in the pump w i t h those in the gasket.
Install pump retainer ( 3 ) six lock-plates and twelve 1/4"-28 X I 1 / 4 "
capscrews. Cross tighten and torque capscrews t o 10 - 1 2 FT. LBS.
Bend lock-plate ears against capscrew heads.
-33-
FILE c
TORQUE CONVERTER DRIVE COVER
Disassembly
The torque converter housing i s of
the "13RY" type and incorporates a
DIAPHRAGM (pressed steel disc) and
oil seal. These must be removed
before the accessory gearing can be
removed.
NOTE: Removal of the diaphragm
destroys the diaphragm and
seal. The seal cannot be
purchased separately.
Figure 38
To remove the diaphragm, cut a s l i t through the diaphragm and
insert a hooked tool into the s l i t and pry the metal above the s l i t
inward, deforming the diaphragm for easy removal. Remove step-
joint seal from converter housing sleeve only i f replacement neces-
sary. To replace sleeve remove i t from front of converter housing.
A t the rear of converter housing

remove snap ring ( 4 ) from accessory
driven gear bearing. Tap shaft and
gear forward and remove attached
parts from the housing.
A1 so remove snap r i n g (1 ) from acces
sory drive gear bearing. Tap gear
forward and remove attached parts
from housing. Remove snap ring and
bearing .
I f replacement o f ground sleeve ( 8 ) i
necessary, remove the four attaching
capscrews ( 9 ) and press sleeve from
converter housing. Figure 39
NOTE: Use care during t h i s operation
t o prevent any damage t o the protruding converter
pressure reguzating valve (6).
S h o u l d either the converter pressure regulator valve ( 6 ) or lubri-
cation regulator valve ( 7 ) require replacement, remove by twisting
pins from the converter housing.
-34-
FILE c
SHOP MANUAL
,
SECTION 10-
Assembly
(Fig. 39)
If lubrication regulator valve ( 7 ) was removed, install spring and valve
o n t o guide pin.Install , pressing assembled parts into housing until
pin i s flush with .010" below housing s p l i t l i n e ( 1 0 ) .
If converter regulator valve ( 6 ) was removed, install parts as above

and press pin into housing until i t projects 1.18 t o 1.20 inches above
the valve seat.
NOTE: I f the press f i t of pins i s unsatisfactory, apply LOCTITE
Grade B or equivalent.
If ground sleeve ( 8 ) removed, "c h i l l " replacement p a r t in dry ice for
1 hour. A1 ign capscrew holes in ground sleeve with those in housing
and press t o a firm seat against rear of housing. Install four 5/16-
18 x 3/4" self locking capscrews. Cross tighten and torque t o 17- 20
FT. LBS.
Reinstall accessory drive and driven gears, bearing and snap rings.
(Fig. 38)
I f converter housing sleeve was removed, i n s t a l l replacement sleeve.
Heat sleeve and install with seal ring groove l a s t . Press i t onto
the hub of the housing and seat the sleeve firmly against shoulder of
hub. Now install step- joint seal ring into groove in converter housing
and retain seal ring w i t h some oil soluble grease.
Diaphragm Installation
(Fig. 38)
Coat the outer diameter of diaphragm with NON- HARDENING SEALER and
s t a r t i t , convex side f i r s t and "ARROW" down, pointing towards bottom
of converter housing (as i l l u s t r a t e d ) .
Using two s o f t hammers (one driving a a i n s t the other or a block of
4
wood contoured t o the circumference o the diaphragm) drive the dia-
phragm onto i t s seat in the housing bore.
Move the driver around the circumference evenly, driving only slightly
a t each position.
USE EXTREME CARE DURING INSTALLATION OF THE DIAPHRAGM,
MAKING SURE THAT THERE IS SUFFICIENT SEALANT ON THE
CIRCUMFERENCE TO ENSURE A POSITIVE SEAL.
-35-
FILE c
TURBINE -DRIVEN GEARS AND FREEWHEEL CLUTCH
Disassembly
Press the second-turbine driven
gear ( 1 ) o u t of the assembled u n i t
as shown. (The assembly must be
supported on first- turbine driven
gear ( 2 ) ) e
After pressing shaft and gear o u t
of assembly, this will free two
spacers and fifteen rollers w i t h i n
the assembly.
Remove bearing ( 3 ) a spacer and
bearing ( 4 ) from gear ( 2 ) .
Figure 40
Remove the twelve nuts from freewheel cam cage and using a screw-
driver, pry cam assembly away from mating second-turbine gear.
Remove spring plate and roll e r cage. Remove three spring pins and
springs from roller cage.
Remove the twelve square head bolts with retainer plate from cam
assembly.
Assembly
I f roll pin- ( 2 ) removed press pin t o

bottom of bore.
Insert r o l l e r cage ( 1 ) i n t o the free
wheel cam ( 4 ) and a1 ign index marks
( 3 ) (shown).
$388
Figure 41
-36-
FILE c
-
Install the three springs (2) with

spring pins ( 1 ) into the bored ears
of the roll er cage ( 3 ) .
Figure 42
If the two bearings were removed from second-turbine gear, install

by pressing them against shoulders of gear (4).
and torque nuts to 41 -49 FT. LBS.
Figure 43
-37-
FILE c
-
Install the fifteen rollers (1) into

cam pockets (2).
Use oil soluble grease to retain the
rollers in the cage.
i Figure 44. -
Instal 1 first-turbine gear (1 ) by

placing the lead chamfer (2) on the
gear hub against the rollers ( 3 ) .
While pressing downward, rotate the
first turbine gear in a counterclock
wise direction.
Figure 45
Support second-turbine driven gear (6)

Instal 1 bearing spacer (1 ) onto shaft
of second-turbine driven gear.
Instal 1 bearing (2) then spacer (3)
and bearing ( 4 ) .
NOTE: AccurateZy center spacer ( 3 ) t o
prevent it from g e t t i n g caught
on the shouZder of the s h a f t .
Press bearings and spacer firmly into

place in first turbine driven gear (5)’
while supporting gear (6).
Figure 46
-38-
FILE c
- SHOP MANUAL SECTION 10-
HIGH RANGE CLUTCH PISTON HOUSING
Di sassembl v
8394
Figure 47
Remove bearing (10) with suitable puller, from high-range clutch
piston housing ( 8 ) .
Position piston housing assembly in press, piston ( 4 ) side u p . Use
care t o prevent damage t o sleeve ( 1 0 ) . Depress piston return spring
( 2 ) and remove snap ring ( 1 ) .
Remove piston ( 4 ) , seal ring ( 5 ) and expander ( 6 ) from high-range
clutch piston housing ( 8 ) .
Remove hook-type seal r i n g ( 3 ) from inner h u b of piston housing ( 8 ) .
NOTR: Remove bushing (7) and sleeve ( 9 ) only i f replacement
necessary.
Reassembly
I f bushing ( 7 ) or sleeve ( 9 ) removed, install new parts.
NOTE; Press new bushing (7) 0.040" t o 0.080'' below face of hub.
Press sleeve ( 9 ) against shaft shoulder.
-39-
FILE _.C
-
Reassemble remainder o f high-range clutch components.

NOTE: When i n s t a l l i n g expander (6) and seal (5) onto p i s t o n ( 4 )
excerise extreme care.
Install the seal ring expander in the piston groove making sure the
free ends of the expander turn away from the seal ring. The "ends"
o f some expanders may require additional bending t o prevent galling
of seal.
Oil the installed expander and s t a r t the seal ring into the piston
groove a t a point directly opposite the gap in the expander. Now
carefully work the seal ring i n t o the groove, compressing the ex-
pander whilemoving in b o t h directions from starting point t o expander
gap location.
CLUTCH PISTON ASSEMBLY
> .
NOTE: Warming t h e T e l f o n seal r i n g s in oil a t 150°F w i l l make

them e a s i e r t o remove and i n s t a l 2 .
Do n o t use sharp-edged or pointed tools t o remove Teflon seal rings.

Use a thin f l a t blade and s l i p between seal ring and side of groove.
Work seal o u t until i t can be held with the fingers.
Check the three holes in reverse and low-range clutch pistons. One
hole should be clear and the other two holes have ball check valves.
The balls should be clean and seat properly.
NOTE: When i n s t a l l i n g Z i p type seal r i n g s i n t o t h e p i s t o n grooves,
make sure t h a t t h e l f l i p f fof each s e a l ring i s toward t h e o i l -
pressure s i d e of t h e p i s t o n .
After installation, center the seal rings in the pistons, radially.
-40-
FILE c
-
OIL - PUMP
Disassembly
Remove the pump cover (1 ) and gasket

(5).
Remove drive gear (8) and driven gear
(2).
Inspect needle bearings ( 4 ) . If re-
placement necessary, remove the bear-
ing from gear ( 3 ) .
Inspect dowel pin ( 7 ) . Remove only
i f replacement necessary.
Inspect oil seal ( 9 ) . If replacement
required drive o u t toward rear o f
pump. (Refer Note B below before re-
building original gears). Figure 48
Assembly
If oil seal ( 9 ) was removed, coat outer circumference of new seal
with NON- HARDENING SEALER. Install seal , spring loaded l i p f i r s t
into pump body. Press seal into body until i t seats l i g h t l y on
the shoulder in body bore.
NOTE: A ) If needle bearings (4) removed, i n s t a l l new bearings
and press f l u s h with, t o 0.020" b e l m end surface of
driven gear ( 3 ) .
I n s t a l l both drive gear ( 8 ) and driven gear ( 3 ) i n t o

pump body ( 6 ) .
NOTE: B) When properly i n s t a l l e d , end faces of both gears w i l l

project 0.002" t o 0.003" above the f r o n t surface of
the pwnp body (measured before gasket i n s t a l l e d ) .
If end faces of gears are below the flush l i n e of pump body, the
pump will n o t perform s a t i s f a c t o r i l y and should be replaced. Check
smoothness of pump cover ( 1 ) . Install new gasket ( 5 ) and apply a
liberal amount o f oil o n t o the pump gears.
-41 -
FILE c
-
LOW - RANGE PLANETARY CARRIER
Disassembly
NOTE: Do not disassemble Zow-range planetary carrier assembly
unless there i s evidence of undue wear or f a i l u r e . The
f a i l u r e of one pinion requires replacment of a l l pinions
i n the carrier assembly.
Steps :
1. Drill into the ends of four pinion spindles, t o weaken
the swage. Use a 3/4" d r i l l a t the spindle ends near
the smaller, splined h u b ( r e a r ) of the c a r r i e r .
DO NOT DRILL INTO THE CARRIER AS THE DIAMETER OF
SPINDLES I S SLIGHTLY MORE THAN 3/4".
2. Place c a r r i e r assembly, small hub upward in a press and

press o u t the four spindles.
3. Remove the thrust washers pinions and r o l l e r s from a l l
four locations.
Assembly
Steps :
1. If f a c i l i t i e s are available, c h i l l the four new spindles
in dry ice for one hour or heat c a r r i e r in oil b a t h t o
300OF - 350OF.
2. Install one thrust washer on spindle aligning tool.
NOTE: An aligning tool can be made by grinding a used
spindle 0.005" undersize.
3. Coat the bore of the new pinion with oil soluble grease
and install pinion on aligning tool.
4. Install twenty-two pinion r o l l e r s into the space between
aligning tool and pinion bore. Install second thrust
washer o n t o pinion.
5. Carefully remove algining tool and insert assembled
pinion parts into low-range planetary c a r r i e r . Re-
insert aligning tool t o center the assembled pinion
parts.
6. Place c a r r i e r assembly, hub end upward, into a press
remove aligning tool and s t a r t new spindle into bore.
7. Press spindle into bore t o 0.180" below the shoulder
surface, near h u b end.
-42-
FILE c
8. Support the spindle and swage it

securely at both ends, with an
octagon punch. (Refer Fig. 49)
The pinion must rotate freely
after assembly.
9. Install remaining three pinion
assemblies in the same manner.
Figure 49
Fig. 50 illustrates swaging tool and

spindle end after swaging.
EACH END OF SPINDLES
N O T E : I t is important t h a t t h e correct
too2 be used t o swage spindZes, H I CARB, H I CHROME, NITRIDE, ROCK "C" 62-63
t o ensure they are p o s i t i v e 2 y
Locked i n t h e c a r r i e r assembly. LENGTH OPTIONAL 53/64D I A (21.03 mm)
7/32 (5.53 mm)

OCTAGON
Figure 50
IF CHILLED SPINDLES WERE USED T O REBUILD CARRIER A N D
CARRIER WILL NOT BE INSTALLED INTO T H E TRANSMISSION
IN T H E NEAR FUTURE APPLY COATING OF OIL OVER CARRIER
ASSEMBLY TO PREVENT RUST.
-43-
FILE c
REVERSE -RANGE PLANETARY ASSEMBLY
Disassembly
NOTE: Do not disassemble reuerse-range planetary carrier assembZy
unless there is evidence o f undue wear or failure. The f a i l -
ure of one pinion requires- the replacemen; of a22 pinions in
the carrier assemb Zy.
Steps :
1. Drill into the ends of four pinion spindles to weaken
swage. Use a 3/4" drill at the ends which are swaged
to the hub of carrier.
DO NOT DRILL INTO THE CARRIER AS THE DIAMETER OF
SPINDLES IS SLIGHTLY MORE THAN 3/4". CENTERING
THE DRILL ACCURATELY WILL PREVENT DRILLING INTO
THE CARRIER.
2. Place carrier assembly, hub upward, in a press and press
out the four spindles.
3. Remove the thrust washers, pinions and rollers from all
four locations.
Assembl v
Steps :
1. If facilities are available, chill four new spindles in
dry ice for one hour, or heat!-carrier in an oil bath or
oven 3OO0F to 35OoF.
2. Install thrust washer onto spindle aligning tool.
NOTE: An aligning too2 can be made by grinding a used spindle
to 0.005" undersize.
3. Coat the bore o f a pinion with oil soluble grease and

install pinion onto aligning tool.
4. Install twenty-two pinion rollers into the space between
aligning tool and pinion bore. Install the second thrust
washer onto the pinion.
5. Position carrier, hub upward on level surface. Remove
aligning tool and install the assemblied pinion parts
into the carrier. Insert the aligning tool to align the
assembled pinion parts with the spindle pin bore in car-
rier.
-44-
FILE c
-
6. S t a r t spindle into the chamfered spindle bore of carrier.

Press t h e spindle into the bore until i t projects 0.130"
t o 0.150" below the location shown i n F i g . 51.
0.140 (3.55 mml

BEFORE
STAK ING
Figure 51
7. S u p p o r t one of the spindles and swage i t securely w i t h an
octagon punch. The pinion must rotate freely a f t e r assembly
(Refer F i g . 50 for swaging tool information).
8. Swage remaining three spindles in the same manner.
IF CHILLED SPINDLES WERE USED T O REBUILD CARRIER

AND CARRIER WILL NOT BE INSTALLED INTO THE TRANS-
MISSION IN T H E NEAR FUTURE, APPLY COATING OF OIL
OVER CARRIER ASSEMBLY TO PREVENT RUST.
-45-
FILE c
SECTION 11
REASSEMBLY OF TRANSMISSION
General Information
1. The specific torque value for each threaded fastener installed
in this section is stated in the applicable paragraph and figure
number.
2. Soak each friction plate (faced) in Type C-2 transmission fluid
prior to assembly.
3. Use oil-soluble grease with a low melting point (petroleum jelly)
when it is required to facilitate assembly.
4. Pack the inside diameter groove of metal-encased, lip-type, oil
seals with high-temp. grease.
5. During final assembly, lubricate -
all moving parts with transmission
fluid.
CONTINUALLY CHECK EACH OF THE COMPONENTS DURING ASSEMBLY
TO ENSURE THAT THEY ARE FREE OF LINT, DIRT AND FOREIGN
PARTICLES.
If the "front" output shaft bearing was removed (Fig. 52 shows "rear"
bearing location). Install new bearing, shield side last into the
housing bore. Install snap ring in housing bore to retain bearing.
Apply non-hardening sealant onto outside diameter of new seal. In-
stall the seal, spring-loaded lip first and press it squarely into
bore until lightly seated against counterbore shoulder.
Output Shaft Disconnect Coupling

Assemble coupling ( 3 ) onto shaft (2) Fig. 52 by installing one ball,
spring and the other ball into hole in shaft (2). While holding balls
under spring pressure, slide disconnect coupling.(3) grooved end first
onto shaft, until the rear end of coupling is flush with the shaft
rear splines (shown Fig. 52).
-46-
FILE c
Install front o u t p u t shaft ( 2 ) and

assembled coupling ( 3 ) into trans-
mission housing t h r o u g h rear bearing
bore. Feed splined end t h r o u g h front
bearing, previously installed and t a p
u n t i l shaft shoulder i s u p against
bearing .
Install bearing ( 1 ) i n intermediate
web of transmission, shield side
f i r s t and seat against shoulder i n
the housing web bore.
Figure 52
I f bushing ( 4 ) was removed, install

new bushing.
NOTE: Press new bushing i n t o bore
of s h a f t unti2 it is recessed
0.160 t o 0.200" below s h a f t
end surface.
I f bearing and spacer were removed

from shaft, install new parts (shield
side l a s t on bearing).
Install transfer driven gear ( 3 ) and
spacer ( 2 ) behind gear ( 3 ) . ( t o the
front of the transmission. )
Install assembled rear o u t p u t shaft,
bearing forward.
S e a t rear o u t p u t shaft bearing in
housing bore, install snap ring and
seal.
-47-
FILE c
Install new seal ( 3 ) . Position

s h i f t e r fork ( 2 ) onto a sliding
collar and insert s h i f t e r fork
shaft through seal and screw into
fork h u b in a clockwise rotation.
NOTE: I t i s important t h a t fork
be positioned i n transmis-
sion with long hub facing
rear.
Figure 54
Screw shaft a l l the way into the fork h u b . Final adjustment must
be made when transmission assembly i s installed into Crane.
( 4 & 5) show bearing retaining snap ring and seal installed.
Position the transmission housing on i t s front s p l i t l i n e . Install

the reverse-range piston ( 3 ) into the housing.
Beginning with an external tanged

plate, a1 ternately instal 1 four
external tanged plates and four
internal splined clutch plates ( 2 )
onto the reverse-range piston ( 3 ) .
Instal 1 the reverse-range planetary
c a r r i e r , long splines f i r s t , into
the plates stacked on the piston.
Then i n s t a l l one external tanged
and one internal splined clutch
plate o n t o the carrier assembly.
Figure 55
-48-
SHOP MANUAL
Align the "slots" of the five reverse-

range steel plates t o receive the six
pins of the clutch anchor ( 4 ) .
Install clutch anchor pin ( 1 ) i n t o
transmisiion housing from control valv e
mounting pad side. Align the anchor
pin s l o t in the anchor plate ( 1 ) w i t h
the pin and install the anchor ( 4 )
longer ends of the six pins downward.
Engage the slots of the five external
tanged clutch plates and make sure t h e
anchor i s seated i n position.
Figure 56
NOTE: I t i s recommended t h a t a 3/8"-26 x 1" capscrew with f l a t

washer be temporarily i n s t a l l e d i n the control valve
mounting pad t o prevent the anchor p i n ( 1 ) from sliding
out of position.
-49-
c2
FILE c
Starting w i t h an external tanged p l a t e ,

a1 t e r n a t e l y i n s t a l 1 three external -
tanged plates ( 4 ) and two internal
splined clutch plates o n t o low-range
ring gear ( 3 ) f i t t e d t o low-range plan-
etary c a r r i e r ( 2 ) .
I n s t a l l the twelve piston return spring
w i t h t h e i r spring guide pins ( 1 ) into
the holes i n clutch anchor assembly.
Figure 58
I n s t a l l low-range clutch piston housing

( 2 ) w i t h piston.
NOTE: Make s m e that p l u g i s replaced
in housing if removed.
I n s t a l l ten 3/8-16 x 1 1 / 2 " s e l f -
locking capscrews (1 ) . Use two of
the longer control valve body cap-
screws 3/8-16 x 2 1/2" t o draw the
piston housing down s u f f i c i e n t l y , t o
engage the sel f -1 ocking capscrews.
Remove the two draw bo1 t s and i n s t a l l
two remaining self-locking capscrews:
Torque capscrews 36-43 FT. LBS.
Figure 59
Instal 1 the t r a n s f e r drive gear ( 3 )

bearing f i r s t , o n t o low-range plane-
tary c a r r i e r ( 2 ) .
NOTE: Make sure snap ring i s located
correctZy on bearing outer race.
Using s u i t a b l e hook-type tool r a i s e
1ow-range planetary c a r r i e r enough t o
expose snap ring groove and i n s t a l l
snap ring ( 1 ) .
Figure 60
-50-
FILE c
Install the high-range clutch hub as

assembled with two f r i c t i o n plates ( 2 )
and steel disc ( 1 ) into the hub o f
transfer drive gear ( 3 ) . Correctly
locate s l o t s in steel plate with pins
in transfer drive gear.
Figure 61
Install high-range clutch piston ( 5 )

(as assembled) onto transfer drive
gear. During installation, align and
engage the recesses in piston with t h e
drive pins in the transfer drive gear.
Seat piston housing i n counterbore o f
drive gear and install the six lock
tabs and six 1/2"-20 x 2 3/4" capscrew
(3).
NOTE: Cross t i g h t e n and torque to
83-200 FT. LBS. Bend lock tabs
against boZt heads.
Figure 62
If the pipe plug was removed from the rear cover ( 1 ) t o clean clutch
oil supply hole, replace i t using non-hardeni ng seal er.
Lubricate the seal rinq and insta 11 i t into the groove in the rear
cover, then install t h e new gasket ( 4 ) . Apply oil soluble grease onto
the gasket.
Install rear cover ( 1 ) onto transmission housing ( 2 ) a1 igning the oil
supply hole in cover with hole in transmission. Install the nineteen
capscrew 3/8"-16 x 1 1/8" with lockwashers and torque t o 26-32 FT. LBS.
-51 -
FILE c
-
Reposition transmission housing on blocks, splitline facing

upwards. . ib..
Install the Reverse and Low-range sun

gear (5).
Install first turbine drive gear (1 )
and bearing (4) into transmission
housing.
Install the step joint seal ring (3)
into groove in the drive gear (1) hub
Next, install rear thrust race (3)
(first the thrust bearing race, then
need1 e roll er bearing).
Figure 63
TO INSTALL OIL SUCTION TUBE THE FOLLOWING STEPS MUST BE PRE-

FORMED EXACTLY AS RELATED IN THE FOLLOWING STEPS-
'I
1. PRELUBE THE "NEW" SEAL RING GENEROUSLY WITH TRANSMISSION
OIL PRIOR TO ASSEMBLY.
2. INSTALL NUT (6) AND SEAL ONTO THE SUCTION TUBE.
NOTE: Do Not position seal i n housing and then have t o
force tube through seal - the seal can be c u t ,
rolled or cocked, resulting i n poor sealing and/
or f a l s e torque readings.
3. PLACE TUBE, NUT AND SEAL IN POSITION INTO THE TRANSMISSION
HOUSING. INSTALL RETAINING CAPSCREW ( 7 ) AT THE TUBE SUP-
PORT BRACKET. BUT DO NOT TIGHTEN AT THIS TIME.
4. SLIDE SEAL DOWN TUBE UNTIL IT ENTERS AND SEATS IN BORE
EVENLY THEN TIGHTEN "BLUE" MALE NUT (6) TO 120-1 50 FT.
9
LBS. TORQUE.
5. TIGHTEN SUPPORT BRACKET CAPSCREW ( 7 ) to 36-43 FT. LBS.
NOTE: Earlier Production transmissions incorporated a
"gold" colored nut which had a torque of 40-60 FT.
LBS. A l l current production u n i t s have a nut whose
eo l o r appearance range from "blue" t o a " l i g h t blue"
s t e e l i n color.
-52-
FILE c
SHOP MAMUAL SECTION 10-
I t should be noted a t t h i s time, t h a t after a transmission has been

operated and i s disassembled for some reason, the "break-away" torque
of the subject n u t will be less t h a n the original assembly torque re-
quirement. However, t h i s factor does n o t imply t h a t the tube was
loose or had been installed improperly a t i n i t i a l assembly.
This occurs as a result of normal shrink and seating due t o compression
and temperature, which i s considered in i n i t i a l design.
Install freewheel clutch assembly ( 2 )

I f bearina ( 4 ) was removed from se-
cond-turbine drive gear (1 ) insta 11
a new bearing.
Install new step-joint seal ring ( 3 )
i n i t s groove.
Insta 11 the front thrust race, flange
f i r s t o n t o bottom (rear) of drive
gear ( 1 ) .
Install the second-turbine drive gear
( 1 ) and assembled parts onto f i r s t -
turbine drive gear.
Figure 64
Install new gasket onto converter

housing s p l i t l i n e , using o i l soluble
grease.
Attach sling t o housing and while
lowering housing onto transmission
housing guide the accessory driven
gear past the second-turbine drive
gear.
Seat converter housing (make sure
b o t h dowels i n place). Install the
twenty-four capscrews , f l a t washers
and lockwashers.
NOTE: Cross t i g h t e n and torque t o
42- 50 FT. LBS. Figure 65
-53-
FILE C
-
Instal 1 converter impel 1e r (pump)

onto ground sleeve.
I n s t a l l splined ( f l a t ) s t a t o r spacer
( 3 ) s t a t o r ( 2 ) , ( h u b projection f i r s t )
and r e t a i n w i t h snap ring ( 1 ) on the
converter ground sleeve.
Figure 66
I n s t a l l the first-and-second-turbine
assembly ( 2 ) . (Positioning assembly
can be f a c i l i t a t e d by holding assembly
in holes ( 4 ) ) .
I n s t a l l new seal ring ( 5 ) and mount
drive cover assembly (1 ) making
sure t h a t turbine support bearing ( 3 )
i s correctly seated i n pocket.
Figure 67
I n s t a l l the twenty-four self- locking

nuts ( 3 ) t h a t attach drive cover ( 4 ) .
NOTE: T o r q u e nuts 14- 18 FT. LBS.
Remove the two eyebolts ( 2 ) and i n -

s t a l 1 f l e x d i s c and washer assembly,
washer side f i r s t o n t o the h u b ( 1 ) .
Assemble the three f l e x d i s c s so t h a t
the "cone" of each washer assembly.
I n s t a l l three discs a s a u n i t , align
disc holes and i n s t a l l 1/2"-13 X
7/8" sel f -1 oc ki ng capscrews .
NOTE: T o r q u e capscrews t o 82-97 FT.LBS. Figure 68
- 54-
FILE c
SHOP MANUAL SECTION
Oil Pump
Instal 1 new gasket onto pump (9)
mounting face. Install pump onto
transmission carefully aligning
spline in pump drive gear with slot
in accessory-driven gear shaft.
Install nine capscrews (8) and lock-
washers ( 7 , 3/8"-16 x 2" and 2, 3/8"
16 x 3").
NOTE: Torque capscrew t o 26-32 FT.
LBS .
Figure 69
Control Valve
Remove temporary retainer capscrew and flat washer at control valve
body, mount pad.
Install new gasket and attach control valve ( 7 ) with sixteen capscrews
and lockwashers (1 5, 3/8"-16 x 2 1/2" and 1 , 3/8"-16 x 1" capscrews).
NOTE: Progressing from the center of the valve body outward, tighten
capscrews evenly and torque t o 26-32 FT. LBS.
Install spacer on "rear" output shaft, flange ( 5 ) , flat washer, ' 0 ' ring,
and self-locking nut (4) (shown in illustration).
NOTE: Coat thwads of nut with molybdenum d i s u l f i d e grease and torque
nut t o 600-700 FT. LBS.
tr I
Install "front" output shaft flange (not shown) in same manner, except
for the spacer.
Oil Strainer
Install oil strainer (3) with new gasket.
NOTE: Tighten s i x capscrews and lockwashers to 26-32 FT. LBS.
-55-
FILE c
-
SECTION 12
INSTALLATION IN CRANE
NOTE: Before assembling the transmission t o engine it i s
important t h a t the engine f l y d z e e l bg thoroughly
checked f o r CONCENTRICITY and RUN-OUT'.
The table below l i s t s the required checks and MAXIMUM allowable dial
indicator gauge readings:
1. Concentricity of p i l o t bearing bore
with respect t o flywheel housing ......................... 0.01 3"
4. Transmisssion mounting face on flywheel

housing with respect t o flex-disc mounting
face on flywheel -------------------'------
0.0005"
per inch of bolt c i r c l e diameter (flex-disc)
Detroit Diesel Engine

Insert guide dowel into one of the
tapped holes in the flex-disc ( 1 )
for aligning flywheel holes with
flex-disc holes. (use 3/8"-16 x 3"
stud)
Rotate flywheel'so t h a t one hole
i s exposed through plug ho1.e ( 2 )
Fig. 71. Align guide dowel with
hole in flywheel and assemble
transmission o n t o engine a f t e r
careful alignment.
Figure 7 0
-56-
FILE c
Install the twelve 3/8" capscrews

and lockwashers (3) that attach
the transmission to the engine.
Remove guide dowel (previously in-

stal led Fig. 70) through access ho11 e
(2) and install one of the eight
3/8"-16 Grade 8 capscrews. Rotate
engine and install the remaining
seven capscrews which attach the
Flex-disc drive to the engine fly-
wheel.
NOTE: Torque capscrews t o 40-45
FT. LBS.
Figure 7 1
d
Install both left and right hand engine/transmission mounting
brackets (1 ) .
Deutz Engine
The mounting of Deutz engine to transmission differs from the Detroit
Diesel engine and the following steps should be performed to ensure
the Flex-disc is correctly attached to engine flywheel.
1. If previously removed, install the spacer ring onto the eight
STUDS in the flywheel and tap spacer ring until it i s snugly
seated in the flywheel recess. Dial indicate flywheel and
housing per instructions previous page.
2. Align transmission to engine and assemble components with the
eight studs entered through "holes" (NOT TAPPED) in Flex-disc.
3. Through the "access" hole on left hand side of engine flywheel
housing (viewed from engine fan end) install the eight nuts.
(MI0 1 , 5p).
4. NOTE: Do not t i g h t e n nuts t i g h t a t t h i s time .
Run nuts down until they bottom onto flex-plate.
NOTE: Tighten each nut 30° ( t h i r t y degrees) i n sequence then
repeat by tightening a f u r t h e r 300. I f available use a
degree indicator.
-57-
FILE c
Using a suitable lifting device, re-sl ing engine/transmission

assembly securely, slowly raise the assembly and lower into
Crane frame.
NOTE: Exercise extreme care not t o damage any externa2,ly
mounted engine/transmission components.
I.nstal1 engine/transmission assembly in Crane in the reverse

of the "Removal procedures 1 through 16 on page -1
I'
-5 and i l lus-
trations 5 through 9 on page 16.
NOTE: With the i n s t a l l a t i o n of e i t h e r the Detroit Diesel
or Deutz engines, the shim adjustment of the f r o n t
engine mounting is important, t o ensure t h a t cor-
r e c t alignment of the main hydraulic pump drive
shaft is obtained.
Figure 72 Figure 73
-58-
FILE c
(Fig. 72)
This illustrates the method of shimming the front engine mounting
bracket .
I t i s important t h a t every attempt be made t o shim
the mounting evenZy on both s i d e s t o provide p e r f e c t
a2ignment between t h e engine crankshaft pu2Zey and
pump m i v e r s a 2 j o i n t s in both pZanes.
MAXIMUM ALLOWABLE OFFSET MISALIGNMENT IN BOTH PLANES
(Fig. 73)
This illustrates the Detroit Diesel engine to pump drive line
installed.
Transmission Dipstick
Before installing dipstick
tube (2) make sure that top
of fitting (3) is exactly
1 .38" bel ow center 1 ine of
top plug (1) on transmission.
This will ensure correct dip-
stick location and oil level
in transmission, when dipstick
tube (2) is installed.
Figure 74
-59-
FILE c
SECTION 13
The transmission, torque converter, and i t s allied hydraulic

system are important links in the drive 1 ine between the engine
and the wheels. The proper operation of either unit depends
greatly on the condition and operation of the other; therefore,
whenever repair or overhaul of one unit i s performed, the bal-
ance of the system must be considered before the j o b can be
considered completed.
After the overhauled or repaired transmission has .been installed
in the machine, the oil cooler, and connecting hydraulic system
must be thoroughly cleaned. This can be accomplished in several
manners and a degree of judgment must be exercised as t o the
method employed.
The following are considered the minimum steps t o be taken:
1. Drain entire system thoroughly.
2. Disconnect and clean a l l hydraulic lines. Where feasible,

hydraulic lines should be removed from machine for cleaning.
3. Replace oil f i l t e r elements, cleaning o u t f i l t e r case thor-
oughly.
4. The oil cooler must be thoroughly cleaned. The cooler should
be "back flushed" with oil and compressed a i r until a l l foreign
material has been removed. Flushing in direction of normal
oil flow will n o t adequately clean the cooler. If necessary,
cooler assembly should be removed from machine for cleaning,
using o i l , compressed a i r and steam cleaner for t h a t purpose.
DO NOT use flushing compounds for cleaning pruposes.
5. Refill transmission with specified quantity of o i l . S t a r t
engine and l e t engine i d l e (600-750 RPM) with transmission
in "neutral I' for approximately ( 2 ) two minutes t o f u l l y
charge a l l c i r c u i t s . Add oil as required t o establish o i l
level on dipstick.
Operate Crane until transmission lubricant has reached oper-

ating temperature - RECHECK OIL L E V E L . Oil level must be
between the High and Low marks on the dipstick with trans-
mission in neutral and engine idling.
6. Recheck a l l drain plugs, l i n e s , connections, e t c . , for leaks
and tighten where necessary.
- 60-
GRADER 0
PLANER 0
ROLLER 0
CRANE El
Shop Man,ual E- 2.03

RVC3
PRIMARY MANIFOLD & CONTROLS

80 01254 thru 04000
90, 100, 110 & 125 01001 thru 07531
90A, 100A, llOA & 125A 01001 thru 07531
150A 0'1001 thru 07531
CAUTION
ALL COMPONENTS MUST ,BE PROPERLY SUPPORTED DURING

GOOD WORKING ORDER.
EXTREME CAUTION TO 5 E OBSERVED AT A L L TIMES TO PREVENT

INJURY.
CONTENTS Page
Torque Sheet ........................ Back o f Cover
Disassembly .......................... . 1
Reassembly .......................... . 8
c3
Dresser Industries, Inc. Construction Eauipment Division P.O. Box 647 Galion, OH 44833 U.S.A.
(419)468-4321
m 1
F
NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; ValUeS should be increased 1/3 for Non-Lubricated (Dry) Threads.
I
r- Grade 5
Heat treated material 1Grade 5 CE Grade 8
K)I’t or cap screw head)

I Grade 8
(6 radial dashes on t : or cap screw head)
Thread Size
Newton Meters Foot Pounds Newton Meters
IFt. Lbs.) (Nm) (Ft Lbs.]
1/4 - 20 6 8 9 12
1/4 - 28 7 9 11 15
5/16 - 18 13 18 18 24
5/16 - 24 15 20 21 28
318 . 16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 - 20 65 18 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 - 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 14 335 454 515 698
1 - 8 455 617 695 942
1 - 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 12~ 685 929 1110 1505
1 11’4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 2481
1 3/8 . 12 1290 11749 2 085 2327
1 i/2 - 6 1500 2034 2 430 3295
1 1/2 - 12 1690 2291 2 730 3501
1 3/4 . 5 2330 3213 3810 5166
2 . 4 1/2 3550 4313 5 760 7810
FILE E
SHOP MANUAL SE CT I ON 2.03
1
I f manifold i s removed from under the
u n i t , i t must be supported in some
manner p r i o r t o removing cap screws.
There are four ( 4 ) cap screws which
h o l d manifold t o a d a p t o r p l a t e , two ( 2 )
9/16" cap screws (smal l e r head) and
two ( 2 ) 5/8" cap screws (1 arger head).
Obtain two ( 2 ) continuous thread rods
e i t h e r 9/16"-12 or 5/8"-11 and remove
two ( 2 ) of the corresponding cap screws.
I n s t a l l threaded rod. I n s t a l l a n u t
and large f l a t washer and run them
against manifold. Remove remaining
cap screws. Lower the manifold by
backing off nuts.
CAUTlON
USE EXTREME CARE WHEN LOWERING THE
MANIFOLD WHEN UNDER THE UNIT.
2
After removin manifold from crane,
4
remove s i x ( 6 sealing O-rings from
mani fo I d .
3
P1 ug a1 1 ports and supply 1 ines with
p l a s t i c caps or tape t o keep foreign
matter from entering manifold or hy-
draul i c system.
NOTE: CLEANLINESS ---IS A MUST. If
foreign matter is aZZowed t o
enter the system, hydrauZic
system l i f e wiZZ be shortened.
-1 - R1
FILE E
SHOP MANUAL SECTION 2.0?
Remove three ( 3 ) 1/2" cap screws and

lock washers from valve block.
5
Remove valve block from manifold.
Remove four ( 4 ) cap screws and lock

washers from each o f the three ( 3 )
end caps.
-2 -
FILE E
7
Remove the three ( 3 ) end caps.
NOTE: Because of sealing O-ring on t h e
end caps, some d i f f i c u l t y may be
encountered i n removing them.
Using sui table t o o l s , the cap may be

pried away from manifold. Use care
n o t t o damage components.
Remove sealing O- ring from the end caps.
Remove four ( 4 ) cap screws and lock

washers from each of the three ( 3 )
cable m o u n t i n g caps.
R1
-3-
FILE E
SHOP MANUAL SECTION 2 -03
10
Using c a r e , pull cable and mounting
cap away from manifold.
NOTE: Because of sealing O-ring on the
mounting caps, some difficulty
may be encountered in removing
them.
11
The end of the cable i s screwed i n t o
the end of the valve spool. To remove
cable, place a 1 / 2 " open end wrench
on cable jam n u t . Place a screwdriver
in the s l o t t e d notch in the opposite
end of the valve spool. With use of
the screwdriver, turn valve spool
counter-cl ockwi s e thereby 1ooseni ng
cab1 e.
12
Remove three ( 3 ) cable assemblies.
-4-
FILE ' E
13
Remove the three ( 3 ) valve spools from
mani fol d.
CAUTION
Mark each valve spool and t h e manifold

i n some manner t o assure t h e spools are
replaced in t h e same p o r t s from which
t h e y are removed.
14
Remove p l a s t i c plugs and tape and wash
e n t i r e manifold with CLEAN solvent and
dry w i t h compressed air. Rep1 ace plugs.
If the manifold has been leaking through the operating cables, the following procedure should be followed to remove
and replace seal mounting cap.
15
Remove mounting seal and mounting cap
jam n u t and f l a t washer and s l i d e on
t o cable housing.
-5 -
FILE E
SHOP MANUAL SECTION 2 .O 3
Unscrew mounting s e a l and mounting cap

assembly f r o m c a b l e housing.
17
18
S1 ide mounting s e a l and mounting cap

o f f end o f cable.
91
-6-
FILE E
SHOP MAIYUAL SECTION 2.03
19
Remove O- ring from mounting cap.
20
Remove mounting seal from mounting cap.
21
Remove O- ring from m o u n t i n g s e a l .
-7-
FILE E
22
Coat a new O- ring w i t h hydraulic o i l

and i n s t a l l on new mounting s e a l .
23
Using c a r e , i n s t a l l mounting seal in

mounting cap. Mounting seal should be
i n s t a l l e d thread end f i r s t i n t o the
machined side o f mounting cap. I n s t a l l
so t h a t the seal end of the mounting
seal i s flush with the chamfered sur-
face o f the m o u n t i n g cap.
24
Using e l e c t r i c a l tape, tape threaded

end o f cable and i n s t a l l through
threaded end of mounting s e a l .
NOTE: T"heads of cable must be taped
t o avoid damage t o seal.
Remove tape.
-8-
25
Using an adjustable wrench o r p a i r of

p l i e r s , i n s t a l l jam n u t on threaded
end of cable. The jam n u t should be
i n s t a l l e d w i t h chamfered corners on
first.
NOTE: When using p l i e r s protect cable.
DO IVOT SCORE CABLE.
--___-
26
Coat new O-ring with hydraulic o i l and

i n s t a l l on mounting cap.
27
__ ..
Examine valve spools. I f valve spool
DO NOT attempt t o use any
i s scored --
material such as sand paper, emery
cloth or crocus cloth . t o f i n i s h the
surface. A new manifold block and
spools must be ordered.
NOTE: Valve spoozs and manifold bZocks
are -
not serviced separateZy.
R1
-9 -
FILE E
28
I n s t a l l valve spools i n same ports from
which they were removed.
NOTE: Coat spools w i t h l i g h t coat of
hydrau 1 i c o i l .
SpooZs must be abZe t o move i n
and out and r o t a t e 360' easiZu.
29
I n s t a l l cable assembly i n t o valve spool.

Hold cable w i t h wrench or p a i r of p l i e r s
and turn spool clockwise w i t h screw-
d r i v e r in s l o t t e d end.
NOTE: DO NOT SCORE CABLE WITH PLIERS
Cable should be screwed i n t o

spool u n t i l jam n u t i s against
spool. Secure jam n u t .
30
I n s t a l l mounting cap and mounting seal
assembly on cable housing.
R1
-10-
FILE E
31
I n s t a l l mounting cap jam n u t and f l a t

washer on mounting cap.
32
33
Coat a new O-ring w i t h h y d r a u l i c o i l

and i n s t a l 1 on end cap.
R1
-11-
FILE E
34
Install end caps on manifold block w i t h

four ( 4 ) 3/8" cap screws and lock
washers. Torque cap screws t o 30 f t - l b
(dry).
35
Remove re1 ief valve from valve block.

Wash valve block w i t h CLEAN solvent
and dry w i t h compressed a i r .
36
Re1 i e f valve i s preset for correct
pressure and sealed. Relief valve
should n o t be tampered w i t h in any
manner.
Pressure i s stamped on lead seal.
MODELS PRESSURE
90, 90A, 100, IOOA,

110, 110A, 125, 125A ----- 1500 PSI
150~ _____-___________ 1800 PSI
-12- R1
FILE E
37
Coat new O-rings two ( 2 ) w i t h hydrau-
l i c o i l and i n s t a l l on r e l i e f valve.
-4
38
I n s t a l l r e l i e f valve in valve block.
39
Coat three ( 3 ) new seal ing O-rings
w i t h a l i g h t coat o f grease and i n s t a l l
in valve block assembly.
-1 3-
FILE E
40
I n s t a l l valve block on manifold with
three ( 3 ) 1 / 2 " cap screws and lock
washers. Torque cap screws t o 75 f t -*1b
(dry).
NOTE: Make c e r t a i n both t h e surface
of t h e vaZve bZock and t h e
m m i f o Z d are clean.
41
Coat s i x ( 6 ) new O-rings w i t h a l i g h t
coat of grease and i n s t a l l i n manifold
assembly: Remove a1 1 p l a s t i c p 1ugs
and tape from manifold and supp 1Y 1i nes.
42
Clean b o t h the surface of the adaptor
block and manifold. I n s t a l l the two ( 2 )
continuous threaded rods i n adaptor
block. Jack manifold o n t o threaded rods
and i n s t a l l f l a t washers and nuts. Raise
manifold by running i n the two ( 2 ) nuts.
Instal 1 two ( 2 ) cap screws and lock
washers. Remove threaded rod and in-
s t a l 1 remaining two ( 2 ) cap screws.
TORQUE C A P SCREWS AS FOLLOWS:
5/8" cap screws (2)(larger head)---- 70 ft-lb (lube)
9/16'! cap screws (2) (smaller head)-- 61 ft-lb (lube)
NOTE: Cap screws must be torqued
correctZy.
CAUTION
Use extreme care when instaZZinq.,
manifoZd.
-14- R1
MATERIAL LIFT 0
GRADER
PLANER 0
ROLLER 0
CRANE d il
SHOP MANUAL E-02.04

c2
PRIMARY MANIFOLD
APPLICABLE MODEUS SERIAL NUMBER/S

90 thru 125 07532 thru 08774
90A thru 125A 07532 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 07532 & Up
150FA 07532 & Up
200FA 09401 & Up
220A 07107 & Up

ALL JACKING, HOISTING AND GENERAL WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST B E IN GOOD WORKING
ORDER.
EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY.
CONTENTS PAGE
-
General Torque Values . . . . . . . . . . . . . . . Back o f Cover
System A p p l i c a t i o n . . . . . . . . . . . . . . . . . . . . . i
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dissassembly . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning and I n s p e c t i o n . . . . . . . . . . . . . . . . . . . 8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . 12
KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048

c2
The following General Torque Values must be used in all cases where SPECIFIC
TORQUE VALUES are not given.
I I
I NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET) I
I THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED (DRY) I
I THREADS. I
I I
I I I
I I Heated material Grade 5 8 Grade 8 I
I I I
I I I I
I I Grade 5 I Grade 8 I
I Thread Size I ( 3 radial dashes on head) I ( 6 radial dashes on head) I
I I .- .-----
.x I I
I I I I I I
I I Foot Pounds I Newton Meter I Foot Pounds INewton Meter1
I I ( F t . Lbs.) I (Nm) I ( F t . Lbs.) I (Nm) I
I I I, I I I
I I I I I I
I 1/4" - 20 I 6 I 8 I 9 I 12 I
I 1/411 - 28 I 7 I 9 I 11 I 15 I
I 5/16" - 18 I 13 I 18 I 18 I 24 I
I 5/16!! - 24 I 15 I 20 I 21 I 28 I
I 3/8" -- 2416 I
I
24 I 33 I 34 I
I
46 I
I 3/8" 27 I 37 I 38 52 I
I 7/16!! - 14 I 38 I 52 1 54 I 73 I
I 7/16!! - 20 I 42 I 57 I 60 I 81 1
I 1/2" - 13 I 58 I 79 I 82 I 111 I
I 1/2" - 20 I 65 I 88 I 90 I 122 1
I 9/16!! - 12 I 84 I
114 I 120 163 I
-- 18
I
I 9/16!! I 93 I 126 I 132 I 179 I

I 5/8" I 115 I 156 I 165 I 224 I
I 5/8" -- 1118 I
I
130 I
I
176 I
I
185
290
I
I
25 1
393
I
I
I 3/41! 10 205 278
I 3/4" - 16 I 23 0 I 3 12 I 320 I 434 I
I 7/8" - 9 I 3 05 I 4 14 I 455 I 617 I
I 7/8" - 14 I 335 I 454 I 5 15 I 698 I
I 1" - 8 I 455 I 617 I 695 I 942 I
I 1" - 14 I 510 I
691 I 785 I 1064 I
I 1 1/8" - 7 I 610 I 827 I 990 I 1342 I
I 1 1/8" - 12 I 685 I 929 I 1110 I 1505 I
I 1 1/4" - 7 I 860 I 1166 I 1400 I 1898 I
I 1 1/4" - 12 I 955 I 1295 I 1550 I 2102 I
I 1 3/8" - 6 I
1130 I 1532 I 1830 2481 I
1 3/8" - 12
I I
I I 1290 I 1749 I 2085 I 2827 I '

I 1 1/2" - 6 I
1500 I 203 4 I 243 0 3295 !
1 1/21! - 12
I
I I 1690 I 2291 I 2730 I 3701 I

I 1 3/41! - 5 I 2370 I 3213 I 3810 I 5 166 I
I 2" - 4 1/2 I 3550 I 4813 I 5760 I 7810 I
I I I I I I
Any discrepancies/corrections t h a t are found herein should be directly routed
to:
TECHNICAL SERVICES DEPARMENT
GALION MANUFACTURING DIVISION
Dresser Industries, Inc.
P. 0. Box 647
Gal ion, OH 44833-0647
PH: (419) 468-4321 Ext. 2285
Shop Manual Section E-2.
SYSTEM
. .
1.. .
APPLICATION
CONTROLS
P HOIST
ROTARY
I
JOINT
\
PUMP
MANIFOLD
10244
The primary manifold i s a three-valve u n i t designed t o control the

cranes 50 GPM s e r i e s flow t h r o u g h the FAST HOIST, CROWD, and BOOM
LIFT operator controls. If one of these operator control valves
a r e opened, o i l i s diverted t o a motor or a cylinder causing the
desired operation t o take place. Oil flowing from the o u t l e t s i d e
of the motor or cy1 inder returns t o the primary manifold and i s
available f o r use by one of the other two c o n t r o l s . If n o t used by
another c o n t r o l , the o i l will return t o t a n k .
The primary manifold i s located beneath the pedestal and i s attached
d i r e c t l y t o the rotary j o i n t block.
Shop Manual Section E-2.04
NOTES
REMOVAL
BEFORE ATTEMPTING TO PERFORM ANY OF THE FOLLOWING PROCEDURES,

PARK CRANE ON L E V E L SURFACE, FULLY RETRACT AND LOWER BOOM,
APPLY PARKING BRAKE, TURN OFF E N G I N E , AND BLOCK ALL WHEELS.
CAUTION
The following procedure i s only one method of removing the primary

manifold f r om a crane.
Thoroughly c lean e x t e r i o r of primary manifold as well as surrounding
areas before s t a r t i n g removal procedures. I t i s extremely important
t h a t no d i r t or foreign material e n t e r the hydraulic system while
removing , o r i n s t a l l i n g , primary manifold.
From underside of frame, remove four

capscrews w i t h lockwashers ( 1 ) and two
s p l i t flanges ( 2 ) which fastens i n l e t
tube ( 3 ) t o primary manifold ( 4 ) . Have
containers and c l o t h s ready t o catch
hydraulic o i l from i n l e t tube when i t i s
disconnected. Remove i n l e t tube and
O - r i n g . Cap and/or plug manifold and
tube openings.
Figure 1
-1 -
Shop Manual Section E 2 0 4
Remove four capscrews with lockwashers ( 1 )

and two s p l i t flanges ( 2 ) which fastens
o u t l e t tube ( 3 ) t o primary manifold ( 4 ) .
Have containers and cloths ready t o catch
hydraulic o i l from o u t l e t tube when i t
i s disconnected. Remove o u t l e t tube and
O-ring. Cap a n d / o r plug manifold and
tube openings.
Figure 2
Tag and remove three control cables ( 1 ) .

Detailed procedures a r e presented in
following two f i g u r e s .
NOTE: Primary manifoZd has been removed
t o c l a r i f y cab Ze rernova Z procedures
i n fo2 Zowing photographs.
Figure 3
Remove locknut (1 ) and unscrew cable

anchor sleeve ( 2 ) u n t i l internal cable
( 3 ) connection can be reached. If
d i f f i c u l t y i s encountered in loosening
sleeve, use pipe wrench with taped jaws.
Figure 4
- 2-
Figure 5
USE TRANSMISSION JACK OR

OTHER SUITABLE LIFTING
DEVICE CAPABLE OF LIFTING
AND SUPPORTING A MINIMUM
CAUTION OF 500 POUNDS TO SUPPORT
AND LOWER THE MANIFOLD.
P o s i t i o n t r a n s m i s s i o n j a c k under primary
manifold ( 1 ) and remove f o u r capscrews
w i t h lockwashers ( 2 ) from manifold.
C a r e f u l l y lower manifold and remove s i x
O-rings from t o p of manifold. Plug
manifold and r o t a r y j o i n t openings.
T r a n s f e r manifold t o c l e a n work a r e a
f o r disassembly.
Figure 6
-3-
DISASSEMBLY
The following procedure is only one method of disassembling the

primary manifold. Clean e x t e r i o r thoroughly before s t a r t i n g
disassembly procedures.
Figure 7
-4-
Remove small O-ring ( 1 ) glyd ring ( 2 )

stem seal r e t a i n e r ( 3 ) spring ( 4 ) , and
large O-ring ( 5 ) . Retainer may adhere
t o control end cap ( 6 ) when cap i s
removed.
Tag or match mark cy1 inder openings (-1)

before removing valves. Use valve stem
( 2 ) t o c a r e f u l l y remove valve spool ( 3 )
and spring s e a t ( 4 ) . Tag valve spool t o
match manifold opening a f t e r removal of
spool. Set a l l components aside f o r
inspection.
-5-
On other side o f c a s t i n g , remove four

capscrews with lockwashers ( 1 ) from
blank end cap ( 2 ) . Maintain pressure
on end cap while removing l a s t capscrew;
end cap i s under spring tension.
Figure 10
Remove spring ( 1 ) , O-ring ( 2 ) , and spring

s e a t ( 3 ) from manifold bore.
Figure 11
Remove remaining end caps, valve spools, and other internal components
in same manner as described above. To prevent mismatching components
during reassembly, t a g or match mark valve spools and casting bores
as valve spools are removed. Maintain disassembled components as
L -
matched assemblies.
- 6-
Remove e n t i r e r e l i e f v a l v e ( 1 , F i g u r e
1 2 ) b u t do n o t d i s t u r b l e a d s e a l ( 2 ) .
Remove two O - r i n g s ( 3 ) from v a l v e .
NOTE: Pressure r a t i n g of r e l i e f va%ve
is stamped into lead sea%.
AppZications are as f o l l o w s :
PRESSURE MODELS
1 5 0 0 PSI 90, 90A, 1 0 0 , lOOA

1 1 0 , llOA, 1 2 5 , 125A
1 2 5 F and 125FA.
1 8 0 0 PSI 1 4 0 F , 150A a n d 150FA
2300 PSI 200FA Figure 12

2500 PSI 220A
Figure 1 3
c2
CLEANING AND INSPECTION
Cleaning of internal control surfaces and/or other c r i t i c a l areas

i s required p r i o r t o inspection of such a r e a s . To accomplish t h i s ,
use low pressure compressed a i r t o blow p a r t s clean.
Check s e a l s and O-rings for visual damage, such as depressed or
twisted areas. Also check for torn, ragged, or frayed edges. Replace
any seal or O-ring t h a t shows signs of a g i n g and/or damage.
Inspect spool lands and grooves f o r scratches, nicks, or gouges
which would prevent precision control of hydraulic f l u i d . Also
check valve body bore f o r scratches, nicks, or gouges.
Tolerances between spool and valve bodies are maintained within
the 0.0002 t o 0.0010 inch range. Under no circumstances should
spools be polished w i t h crocus cloth or should any attempt be made
t o hone valve body bores. This will cause internal leakage and
r e s u l t a n t d r i f t . Spools and valve bodies a r e matched a t f a c t o r y ;
therefore, replacement of e i t h e r of these p a r t s i s considered as
a complete unit replacement.
-8-
REASSEMBLY
The following procedure i s only one method of reassembling the

primary manifold. Unless s t a t e d otherwise tighten a l l capscrews
t o standard torque values. Refer t o General Torque Values Chart
provided a t beginning of t h i s Manual f o r applicable torques.
Assemble new O-rings o n t o s i x block plugs

and i n s t a l l plugs i n manifold. Tighten
plugs.
Figure 1 4
Place two new O-rings ( 3 ) on r e l i e f valve

( 1 ) and i n s t a l l valve i n t o manifold. Do
n o t d i s t u r b lead seal ( 2 ) . Tighten and
torque valve. Q
I
Figure 1 5
-Y -
Figure 1 6
Maintain pressure on end cap t o compress

spring while i n s t a l l i n g capscrews with
lockwashers . Tighten and torque
capscrews.
Figure 1 7
Check match marks ( 1 ) and c a r e f u l l y

i ns t a 11 sr)ring s e a t ( 4 ) valve spool ( 3 )
and valve' stem ( 2 ) . Use valve stem t o
guide valve spool i n t o position.
.-.--_I" .......... x
-
"
Figure 18
-10-
I n s t a l l large O- ring ( 5 ) , spring ( 4 ) ,

stem seal r e t a i n e r ( 3 ) , and g l y d ring ( 2 )
o n t o valve stem as shown. I n s t a l l small
O - r i n g ( 1 ) i n t o recess on back of control
end cap ( 6 ) .
Figure 19
Position end cap ( 2 ) over valve stem and

use four capscrews with lockwashers ( 1 )
t o i n s t a l l end cap. Maintain pressure
on end cap t o compress spring while
i n s t a l l i n g capscrews with lockwashers .
Tighten and torque capscrews.
Figure 20
If hydraulic t e s t bench i s available, check primary manifold f o r

pressure leaks before i n s t a l l i n g manifold i n t o crane. Attach spare
control c a b l e ( s ) t o operate individual valves and check basic
operation of the overall u n i t . Any d i r t o r foreign material in
the hydraulic system may cause a valve t o s t i c k , temporarily or
permanently. If s t i c k y valve action continues, disassemble u n i t
and check f o r missing or damaged s e a l s and/or O-rings. Pressure
ratings of r e l i e f valve i s stamped i n t o lead seal on the valve.
( A l i s t i n g of applicable r e l i e f valve pressures was l i s t e d
previously under f i g u r e 1 2 . )
-11-
INSTALLATION
The following procedure i s only one method of i n s t a l l i n g the

primary manifold.
Remove p l u g s from openings in t o p of

manifold and bottom o f rotary j o i n t . On
t o p of manifold ( l ) , place s i x new
O-rings in recessed openings around
ports. Use transmission jack t o l i f t
and position primary manifold on under-
s i d e of crane. I n s e r t four capscrews with
1 ockwashers and f 1 atwashers ( 2 ) through
manifold and i n t o the rotary d i s t r i b u t o r .
Tighten and torque capscrews.
Figure 21
Apply c lamp-style p l i e r s ( 1 ) w i t h taped

jaws t o hold internal cable ( 2 ) h i l e
connect i n g valve stem ( 3 ) t o control
cab1 e . Use open end wrench t o connect
valve s tem t o cable. ( I n s t a l 1 center
control cable f i r s t t o allow maximum
clearance while i n s t a l l i n g other two
controls. )
F i g u r e 22
- 12-
After internal cable connector i s

tightened (see previous p h o t o g r a p h )
secure cable anchor sleeve ( 2 ) against
end cap; use pipe wrench with taped jaws
t o ensure t i g h t f i t . I n s m l o c k n u t ) .
Tighten and torque (standard) capscrews.
I n s t a l l remaining control cables in same
manner.
Figure 25
Remove cap from, and place new O-ring

i n t o end o f , o u t l e t tube ( 3 ) . Position
end of tube against o u t l e t port of primary
manifold ( 4 ) and locate two s p l i t flanges
( 2 ) around end tube; i n s e r t four capscrews
with lockwashers ( 1 ) through s p l i t flanges
i n t o manifold body and tighten capscrews.
Be careful n o t t o pinch O-ring. Torque
capscrews per General Torque Values Chart
provided in f r o n t of t h i s Manual.
Figure 24
-13-
Remove cap from, and place new O- ring

o n t o , end of i n l e t tube ( 3 ) . Position
end of tube against i n l e t port of primary
manifold ( 4 ) and locate two s p l i t flanges
( 2 ) around end of tube; i n s e r t four
capscrews with lockwashers ( 1 ) t h r o u g h
s p l i t flanges i n t o manifold body and
tighten capscrews. Be careful n o t t o
pinch O-ring. Torque capscrews per
General Torque Values Chart provided
i n f r o n t o f t h i s Manual.
Figure 25
After i n s t a l l a t i o n of manifold i s complete, check hour meter t o

determine i f new hydraulic o i l i s t o be used or i f old o i l can be
used again. If o l d o i l i s reused, i t must be f i l t e r e d t h r o u g h 140
micron f i l t e r before r e f i l l i n g tank. Refer t o Operator's Manual
f o r service chart data and t o Shop Manual section J-1 f o r hydraulic
oi 1 type, quantity, and s p e c i f i c a t i o n s . R e f i l l hydraulic t a n k .
Before placing crane i n t o s e r v i c e , check operation of FAST HOIST,
CROWD, and BOOM LIFT controls from cab. Secure boom and engine and
check primary manifold and associated tubes/hoses f o r v i s i b l e leaks.
a l s o recheck level of hydraulic o i l .
-1 4-
GRADER 0
PLANER 0
ROLLER 0
CRANE Q!
Shop Manual E- 2.40

SECOND M A N I F O L D c2

80 01710 & Up
90 thru 125 01254 thru 08774
90A thru 125A 02006 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 02832 ti Up
150FA 07305 & Up
200FA 09401 & Up
CAUTION

GOOD WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED AT A L L TIMES TO PREVENT

INJURY
SAFE WORKSHOP PRACTICES ARE A MUST
CONTENTS Page
Torque Sheet . . . . . . . . . . . . , . . . . . . . .. Back of Cover
Removal o f Manifold . . . . , . . . , , .. .. . . . . . . . 1
Removal of Individual Valves . . . . ... .. . . . . . . . 4
Disassembly of Valve Components . . . , . . . . . . . . . . . 6
Cleaning and Inspection . . . . . . . . . . .. . . . .... 9
Reassembly of Valve Components . , . ... .. . . . . . . . 10
Installation o f Individual Valves . . ... . . . . . .... 12
Installation of Manifold . . . . . . , . . .. . . ..... 14
Testing and Troubleshooting . . . . . . . . . . . . ..... 16

0284 c2
c NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Heat treated material Grade 5 & Grade 8
Thread Size
Foot Pounds
Grade 5
(3 radial dashes on t : or cao screw head)
Newton Meters
T Foot Pounds
Grade 8
(6 radial dashes on t or cap screw head)
Newton Meters
(Ft. Lbs.) (Nm) (Ft. Lbs.) (Nm)
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 - 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 . 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 - 18 130 176 185 25 1
3/4 - 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 . 14 335 454 515 698
1 . 8 455 617 695 942
1 . 14 510 69 1 785 1064
1 118 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 - 12 955 1295 1550 2102
1 318 - 6 1130 1532 1830 248 1
1 318 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 3701
1 3/4 - 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
Shop Manual Section E -2 . 4 0
REMOVAL OF MANIFOLD
,..
Clean a r e a around hydraulic o i l tank d r a i n

plug ( 1 ) . Place c l e a n c o n t a i n e r below
and remove plug t o d r a i n system. Catch
o i l , cover c o n t a i n e r , and s e t a s i d e .
(Hydraul i c tank c a p a c i t y i s approximately "\
75 U . S . g a l l o n s ; system c a p a c i t y i s \'.-
\
x
approximately 125 U . S . gal 1ons . )
Figure 1
Remove f r o n t panel ( 1 ) by removing f o u r

capscrews ( 2 ) ; remove panel w i t h l a s t
capscrew.
Figure 2
Remove two capscrews and lockwashers ( 1 )

from each f l a n g e ( 2 ) on i n l e t tube ( 3 )
and on o u t l e t tube ( o t h e r end of manifold) ;
disconnect i n l e t and o u t l e t tubes and
c a t c h O- rings. Also disconnect manifold
d r a i n tube ( 4 ) . Use c o n t a i n e r and c l o t h s
t o c a t c h r e s i d u e o i l . Cap and/or p l u g
a l l openings t o prevent e n t r y o f d i r t or
foreign material.
NOTE: On t h e 80 Crane, one additional
hose must be removed (from Boom
Rotation Control Value). Also
note t h a t t h e control l e v e r
extension i s - n o t used on t h e 80
Crane; t h e r e f o r e , t h e extension
does n o t have t o be removed o r Figure 3
reassemb l e d .
c1
-1 -
Tag a n d disconnect two tube nuts ( 1 ) a n d cc

remove two connectors ( 2 ) from each valve
assembly in manifold ( 3 ) . Cap a n d / o r p l u g -*
'<, ,\
<\,i , ,mbl , ,, --_
',we-""IBp
,
D
a l l openings t o prevent entry of d i r t or
1
foreign material . Remove O-rings from "i
connectors as they a r e removed.
NOTE: Secondary manifold can c o n s i s t o f
seven t o twelve individual valve
assemblies; a l l over seven valves
are optional.
Figure 4
Remove three locknuts (1 ) from rod ends

( 2 ) and t i e FAST HOIST , CROWD, a n d BOOM
LIFT c o n n e c t i n g r o d s 3 ) t o i d e of-
cowl ing. Til t control levers ( 4 ) u p and
t i e so a s t o allow removal o f secondary
manifold.
Figure 5
Block a n d / o r support weight of secondary

manifold while t h i r d person removes three
capscrews and lockwashers ( 1 ) which mounts
manifold t o dash weldment ( 2 ) . With
a s s i s t a n c e , c a r e f u l l y lower and remove
manifold from lower r i g h t side of dash.
Two 2" x 4"s inserted through f r o n t panel
opening can be used t o help lower mani-
fold a f t e r capscrews have been removed.
Figure 6
- L-
If new valve levers must be formed, remove

new 1 ever as o u t 1 ined above a n d clamp in
vise so t h a t bend point ( 1 ) i s a t edge o f
vise ( 2 ) . Heat bend point with torch
until red a n d form i n t o shape t h a t allows
s u f f i c i e n t operating clearances and easy
operator access. Use ol d lever f o r model
i f available.
DO NOT HEAT LEVERS AT WELD

JOINTS .
CAUTION
Figure 8
- , ,,.
Removal of e n t i r e manifold i s n o t always

required b u t i s recommended so t h a t a l l
s e a l s a n d O-rings can be inspected a n d / o r
replaced a t same time as r e p a i r s a r e made.
However, i f o n l y one valve assembly ( b o d y
and spool ) requires replacement, capped
holes ( 1 ) a r e provided on b o t h sides of
cowl ing ( 2 ) . These holes a1 low the
threaded r0d.s in t h e manifold t o be
shifted l e f t or r i g h t ( a f t e r removal of
end n u t s ) , other rods inserted as t i e
rods a r e s h i f t e d , and removal of in-
dividual valve assembles. See following
sectian f o r procedures covering complete
removal o f an individual valve.
Figure 9
-3-
Shop Manual Section E - 2 . 4 0
R E M O V A L O F I N D I V I D U A L VALVES
0
If e i t h e r a spool ( p i s t o n ) ( 1 ) or valve
body ( 2 ) requires replacement, the e n t i r e
valve assembly must be replaced. (The
spool a n d valve body a r e factory matched
p a r t s . ) Procedures f o r removal of individ-
ual valve assemblies from secondary mani-
fold a r e presented below. Procedures f o r
disassembly o f valve components a r e pre-
sented in the section immediately following
Figure 10
Position secondary manifold on i t s s i d e

Remove three nuts and three lockwashers
( 1 ) from t i e rods ( 2 ) . I f rod revolves
when removing n u t , use wrench on n u t a t
other end o f rod t o hold rod in place.
Figure 11
Figure 12
-4-
Remove three seal rings ( 1 ) a n d three

plain (spacing) washers ( 2 ) . Set a1 1
components aside f o r inspection.
Figure 13
Remove valve assembly (1 ) from t i e rods

(2)*
Figure 14
Using same procedures outlined above, remove remaining valve assemblies until sus-
pected or f a u l t y valve i s removed.
-5-
DISASSEMBLY O F VALVE COMPONENTS
I f a s e a l , O-ring, or other internal valve component requires replacement, the follow-

ing procedures can be used with or without removing individual valves or the manifold.
However, i t i s recommended t h a t the e n t i r e manifold be removed so t h a t a l l s e a l s a n d /
or O-rings can be inspected a n d / o r replaced a t t h e same time as any r e p a i r s a r e made.
The spool a n d valve body are factory matched p a r t s ; t h e r e f o r e , i f e i t h e r p a r t i s
f a u l t y , b o t h p a r t s must be replaced as a matched s e t or as an e n t i r e assembly. See
previous sections f o r removal procedures of individual valves. The manifold in the
following i l l u s t r a t i o n s has been removed t o provide maximum d e t a i l of each procedure.
Figure 15
,.
Use p l i e r s ( 1 ) t o remove t o p a n d bottom (, *5
boot clamps ( 2 and 3 ) . Remove b o o t (4).

NOTE: If hose clamp pZiers are available
remove boot clamps with same.
Figure 16
- 6-
for further 'hi sassembly .

NOTE: Spools are matched w i t h valve bodies
a t factory f o r 0.0002 t o 0.0004
i n c h cZearances and are not i n t e r -
changeable.
Figure 18
U S E CARE NOT T O S C R A T C H OR DAMAGE S P O O L LANDS AND GROOVES OR VALVE

BORE DURING D I S A S S E M B L Y ,
CAUTION
-7-
Figure 19
-8-
CLEANING A N D INSPECTION
Cleaning of internal control surfaces a n d / o r other c r i t i c a l areas

i s required, prior t o inspection of such a r e a s . To accomplish t h i s ,
use low pressure compressed a i r t o blow parts clean.
Check s e a l s and O-rings f o r visual damage, such as depressed or
twisted a r e a s . Also check for torn, ragged, or frayed edges. Replace
any seal or O-ring t h a t shows signs o f aging a n d / o r damage.
Inspect spool lands a n d grooves f o r s c r a t c h e s , nicks , or gouges which
would prevent precision control o f hydraulic f l u i d . A1 so check valve
body bore f o r scratches, nicks or gouges.
Tolerances between spool a n d valve bodies a r e maintained within

0.0002 t o 0.0004 inch. Under no circumstances should spools be p o l -
ished with crocus cloth or should any attempt be made t o hone valve
body bores. This will cause internal leakage a n d r e s u l t a n t d r i f t .
Spools and valve bodies a r e matched a t f a c t o r y ; therefore, replace-
ment of e i t h e r of these two parts i s considered as a complete unit
rep1 acement.
- 9-
REASSEMBLY O F VALVE COMPONENTS
I n s t a l l ring seal in groove of b o t t o m

cover ( 2 ) . P1 ace cover in position on
valve body a n d i n s e r t two capscrews ( 1 ) .
Tighten and torque capscrews t o 25 FT. LBS.,
1 ubricated.
Figure 2 2
WEAR SAFETY GLASSES WHILE

PERFORMING THE FOLLOWING
PROCEDURE.
CAUTION
Place spring washer ( 4 ) , centering spring
( 2 ) , other spring washer (4), and snap
ring ( 3 ) on spool s h a f t . Use valve l i f t e r
t o o l ( 1 ) t o compress centering spring
while i n s t a l l i n g snap ring. Release and
remove 1 i f t e r t o o l .
Figure 23
Figure 24
-1 0-
Install boot (4). Use pliers (1) to

replace top and bottom boot clamps (2
and 3 ) .
Figure 26
Insert connectinq 1 ink ( 2 ) t h r o u g h spool Q
Figure 27
-11-
INSTALLATION O F I N D I V I D U A L VALVES
I n s t a l l three seal rings ( 1 ) and three

spacing washers ( 2 ) .
Figure 29
I n s t a l l exhaust end cover ( 1 ) . (Or in-

take end cover, whichever was removed. )
Figure 30
-1 2-
~~
I n s t a l l three s e t s of hex nuts a n d lock-

washers ( 1 ) o n t o t i e rods ( 2 ) . Use
wrench on other end o f r o d / n u t while
tightening n u t so t h a t approximately
equal amounts o f rod extend from b o t h
ends of manifold. Torque nuts t o 25
FT. LBS . , 1 ubricated.
Figure 31
NOTE: If t e s t bench equipment is a v a i l a b l e , o v e r a l l performance of secondary mani-

f o l d can be checked a t same time a s s e a l s a r e checked f o r leakage. A l l t e s t s
should be performed prior t o i n s t a Z l i n g i n t o crane.
-1 3-
INSTALLATION O F M A N I F O L D
With a s s i s t a n c e , c a r e f u l l y position
secondary manifold against bottom side of
dash weldment ( 2 ) ; block a n d support
manifold. I n s e r t and s t a r t three cap-
screws, with lockwashers ( l ) , t h r o u g h
dash and i n t o manifold. Tighten cap-
screws.
NOTE: Two 2f' x 4"s can be i n s e r t e d
through f r o n t opening t o help
l i f t and p o s i t i o n manifold w h i l e
capscrews are being s t a r t e d .
Figure 32
Untie and assemble three primary control

levers ( 4 ) t o control rods ( 3 ) . Attach
three locknuts ( 1 ) a t rod ends ( 2 ) and
tighten. Check t h a t levers operate with-
o u t binding; a d j u s t as required.
Figure 33
Check t a g s , remove plugs and/or caps,

i n s t a l 1 O-rings, a n d attach connectors
( 1 ) t o matching valve assemblies in
secondary mani fol d ( 2 ) .
Figure 34
-1 4-
Remove caps a n d / o r plugs, assemble O-rings,

a n d connect secondary manifold intake tube
( 3 ) , o u t 1 e t tljbe ( o t h e r end of manifold) ,
a n d drain tube ( 4 ) . Instal 1 four spl i t -
flange connectors ( 2 ) and e i g h t capscrews
and lockwashers ( 1 ) t o secure intake and
o u t l e t tubes t o manifold.
On t h e 80 Crane, an additionaZ
hose ( t o t h e Boom Rotation ControZ
VaZvei must be reassembZed t o
compZete instaZZation of manifold.
Figure 35
I n s t a l l front panel ( 1 ) using four cap-

screws ( 2 ) .
Figure 36
Rep1 ace f i l t e r ( 1 ) and clean screen ( 2 )

in hydraulic o i l t a n k ( 3 ) . I n s t a l l drain
p l u g ( 4 ) . Check elapsed operating hours
and maintenance schedule t o determine i f
ol d hydraul i c oi 1 i s t o be reused or i f
new o i l i s t o be added. If original o i l
i s t o be reused, f i l t e r o i l with n o t l e s s
t h a n 25 micron f i l t e r before replacing.
( F i l t e r changing procedures a n d t a n k
capacity information a r e contained in
applicable o p e r a t o r ' s manual . ) After
s t a r t i n g crane a n d performing operational
t e s t s , shut off crane and recheck hydrau-
l i c oil level.
Figure 37
c1
-1 5-
TESTING A N D TROUBLESHOOTING
If control valves a r e s t i c k y , check tension on t i e rods; a l l should

be torqued a t 25 FT. L B S . , l u b r i c a t e d . I f t i e rods a r e source o f
t r o u b l e , the problem can usually be eliminated by backing off nuts
on the t i e rods a f r a c t i o n of a turn. The center t i e rod should be
backed off f i r s t .
Any d i r t or foreign material in the hydraulic system may a l s o cause
valves t o s t i c k , temporarily or permanently. If s t i c k l y valve action
continues, disassemble u n i t and check f o r missing or damaged shims
between valve bodies.
I f o i l leakage should occur between valve bodies, check for missing,
c u t , or crimped s e a l s . If o i l i s leaking i n t o b o o t , check drain
l i n e s f o r pinched tubing or other form of r e s t r i c t i o n between the
return port a n d the t a n k .
-1 6 -
MATER~ALLIFT
GRADER U
DRESSER PLANER 0
ROLLER 0
CRANE Gf
SHOP M A N U A L E- 3.1 0
HYDRAULIC CRANE CYLINDERS
APPLICABLE M O D E L i S SERIAL NUMBER/%
80, 90, 100, 110, 125, 90A, lOOA, Seri a1 Number ranges
125A, 125F, 125FA, 125P, 140F, a r e given by cy1 i n d e r .
150A, 150FA, 150P and 150T
I ALLC A COMPONENTS
U T M UIS T BEOPROPERLY
N SUPPORTED DURING

REQUIRED FOR THIS OPERATION MUST BE IN GOOD
WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED A T ALL TIMES TO PREVENT

INJURY.
~ SAFE WORKSHOP PRACTICES ARE A MUST.
CONTENTS Page
Torque Sheet . . . . . . . . . . . . . . . . . . . . . . Back of Cover
Precautions & Service Notes . . . . . . . . . . . . . . . . . 1
S e r i a l Number Ranges by Cylinder . . . . . . . . . . . . . . 1
S t e e r i n g Cylinders . . . . . . . . . . . . . ........ 2‘
Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . 8
Boom Crowd Cy1 inders (See Note # 2 , page 1 ) . . . . . . . . . 12
Swing & Hoist Brake Cylinders . . . . . . . . . . . . . . . . 18
Swing & Hoist Brake Checks and Adjustments . . . . . . . . . 22
c2
Dresser Industries. Inc. Construction Equlprnent Divlsion P 0 Box 647 Galion, O H 44833 U S A
(419) 468-4321
0484
NOTE: Torque Values listed throughout thls manual are Lubrlcated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
I
r
Grade 5 Grade 8
Thread Sue (3 radial dashes on bolt or cap screw head) (6 radlal dashes on t or cap screw head)
Foot Pounds Newton Meters Foot Pounds Newton Meters
(Ft. Lbs.) (Nm) (Ft. Lbs.) (NmJ
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 I 24 21 37 38 52
7/16 . 14 38 52 54 73
7/16 . 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
518 . 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 . 14 335 454 515 698
1 . 8 455 617 695 942
1 . 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 2481
1 318 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 3701
1 3/4 . 5 2 370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
FILE E
SHOP MANUAL SECTI ON 3.10
PRECAUTIONS
The maintenance and r e p a i r of h y d r a u l i c cy1 inders c o n s i s t s

c h i e f l y o f r e p l a c i n g packing and s e a l i n g rings.
CAUTION: Use extreme care t h a t no f o r e i g n material e n t e r s
t h e system. When removing o r replacing hydraulic com-
ponents, clean a l l f i t t i n g s before removal. Carefully
s e a l a l l hoses and openings.
I n reassembly o f c y l i n d e r s , use c a r e t h a t no f o r e i g n

m a t e r i a l enters cy1 i n d e r s .
SERVICE NOTES
S e r v i c e t o t h e boom l i f t cy1 inders can be found in F i l e

E , S e c t i o n 3.12.
I n s t a l l a t i o n of polyurethane one piece rod s e a l packing

on boom crowd c y l i n d e r s can be found i n F i l e E , Section
3.11.
SERIAL NUMBER RANGES BY CYLINDER
90 thru 150 ( S t e e r i n g ) SIN 01766 thru 04320 except 0431 3
90 thru 150 (Steering) S/N 04313, 04321 and LIP
80 ( S t e e r i n g ) S/N 04001 and Up
90 t h r u 150 ( O u t r i g g e r ) S/N 01011 thru ?
8 0 (Outrigger) S/N 04001 and Up
80 (Crowd) S/N 01001 thru 04000
80 (Crowd) S/N 04001 and Up
80 (Crowd Cy1 . 3- Section Power Boom) S/N 04001 and Up
80 thru 150 (Swing & Winch Brake) S/N 01001 and Up
125F SIN 07247 thru 08774
125FA S/N 07990 thru 08774
125P S/N 01001 and Up
140F S/N 07571 thru 08774
150FA S/N 07305 and Up
150P/T S/N 01011 and Up
c2
-1-
FILE t
SHOP MANUAL S E C TI O N 3.10
- L-
FILE E
STEERING CYLINDERS
Serial No, 1766- 4321 Except 4313
1. Remove c y l i n d e r from crane. Using spanner wrench

AH-78678 (found i n tool k i t ) remove clamp r i n g ( 3 ) ,
remove piston rod assembly.
2. Remove n u t ( l l ) , p i s t o n ( 9 ) , rings ( l o ) , r i n g s ( 7 )
and ( 8 ) , head ( 6 ) , packincl ( 5 ) and gland ( 4 ) .
3. Remove wiper ( 2 ) from gland ( 4 ) .
4. I f f r o n t s t e e r i n g c y l i n d e r , remove plug ( 1 6 ) , 0-
ring (15) and ( 1 2 ) , a l s o check valve ( 1 4 ) .
C a r e f u l l y examine a l l p a r t s t o determine i f they a r e
serviceable.
Assembly:
1. I n s e r t new wiper ( 2 ) i n gland ( 4 ) , i n s t a l l on rod
( 1 ) . I n s e r t packing ( 5 ) i n s i d e head ( 6 ) . Lubri-
c a t e packing w i t h hydraulic o i l . I n s t a l l head and
packinp on p i s t o n rod. Place r i n g s (10) on piston
( 9 ) and l u b r i c a t e w i t h hydraulic o i l , place on rod.
I n s t a l l s e l f - l o c k i n g n u t ( l l ) , torque t o 200 f t - l b s .
1 ubri c a t e d .
2. S a t u r a t e rod assembly w i t h o i l and i n s t a l l i n
c y l i n d e r ( 1 7 ) . I n s t a l l clamp ring ( 3 ) and t i g h t e n
adequately.
3. I f f r o n t s t e e r i n g c y l i n d e r , r e p l a c e check valve
( 1 4 ) , O-ring (15) and ( 1 2 ) , and plug ( 1 6 ) . I n s t a l l
c y l i n d e r on machine, o p e r a t e and check f o r l e a k s .
R1
-3-
FILE E
-
I--
R1
-4-
FILE E
-~
SHOP MANUAL SECTI ON 3.1 0
STEERING CYLINDERS
Serial No. 4313, 4321 & Up
1. Remove the c y l i n d e r from t h e c r a n e . Using t h e

spanner w e n c h AH-78678 (found i n tool k i t ) remove
clamo ring ( 4 ) and remove t h e Piston rod assembly
from the cy1 i n d e r ( 1 7 ) .
2. Removeself-lockinq n u t ( 1 2 ) , p i s t o n ( l l ) , rings ( l o ) ,
r e t a i n i n g ring ( 9 ) , new O-ring ( 7 ) , r i n g (6), packing
( 8 ) and t h e cy1 inder head ( 5 ) .
3. Remove t h e wiper ( 3 ) from t h e cy1 i n d e r head ( 5 ) .

4. I f a f r o n t s t e e r i n g cy1 inder, remove plug ( 1 3 ) , O-ring
( 1 4 ) , s p r i n g ( 1 5 ) and check b a l l ( 1 6 ) .
C a r e f u l l y examine a l l p a r t s t o determine i f they a r e

s e r v i c e a b l e . For replacement p a r t s s e e a p p r o p r i a t e Galion
parts catalog.
Assembly:
1. I n s e r t a new wiper ( 3 ) i n t o cy1 i n d e r head ( 5 ) and

i n s t a l l on p i s t o n rod ( 2 ) . Lubricate t h e lnacking
with hydraulic o i l and place packing ( 5 ) i n s i d e the
cy1 i nder head ( 5 ) . I n s t a l 1 rinq ( 6 ) , O-ring ( 7 ) and
r e t a i n i n a r i n q ( 9 ) . Place t h e r i n g s (10) on t h e p i s t o n
( 1 1 ), 1 u b r i c a t e w i t h hydraul i c o i 1 and place on rod.
I n s t a l l t h e s e l f - l o c k i n g n u t ( 1 2 ) and torque i t t o 200
f t - l b lubricated.
2. S a t u r a t e t h e rod assembly w i t h hydraulic o i l and i n -

s t a l 1 t h e rod assembly i n t o t h e cy1 inder ( 1 7 ) . In-
s t a l l clamp r i n g ( 4 ) and t i g h t e n adequately.
3. I f f r o n t s t e e r i n g c y l i n d e r , r e p l a c e check b a l l ( 1 6 ) ,
s p r i n g ( 1 5 ) , new O- ring ( 1 4 ) and plug ( 1 3 ) .
4. Before r e - i n s t a l l i n g the c y l i n d e r on t h e c r a n e , check
t h e bushings ( 1 ) f o r e x c e s s i v e wear and r e p l a c e i f
necessary.
5. I n s t a l 1 cy1 inder on machine and o p e r a t e s t e e r i n g and

check f o r leakage.
R1
-5-
FILE E
Q ‘ w
R1
-6-
FILE E
SHOP MANUAL SE CT I ON 3.1 0
MODEL 80 STEERING CYLINDERS

Serial No. 4001 & Up
1. Remove the c y l i n d e r from the c r a n e . Using t h e

spanner wrench, f o u n d i n t h e tool k i t , remove
the cy1 i n d e r head clamp ring ( 4 ) . Remove t b n
p i s t o n rod assembly from the c,yl inder ( 1 6 ) .
2. Remove the s e l f - l o c k i n a n u t ( 1 5 ) , p i s t o n washer
( 1 2 ) , p i s t o r packing ( 1 4 ; 3 p i s t o n ( 1 3 ) , p i s t o n
packing (141, O-ring ( l l ) , p i s t o n washer (12:
O-ring ( l o ) , backup ring ( 9 ) : rod seal r e t a i n .
i n ? r i n g ( 8 ) , rod s e a l spacer ( 7 ) , r o d packing
( 6 ) and cy1 i n d e r head ( 5 ) .
3. Remove wiper ( 3 ) from the cy1 i n d e r head ( 5 ) .

Carefully examine a l l p a r t s t o determine i f they a r e
s e r v i c e a b l e , For replacement p a r t s , see an appropri-
a t e Galion p a r t s c a t a l o g .
Assembly:
1. I n s e r t a new wiper ( 3 ) i n t o cy1 inder head ( 5 )
and i n s t a l l on p i s t o n rod ( 2 ) . Lubricate t h e new
rod packing ( 6 ) with h y d r a u l i c o i 1 and place i n -
s i d e c y l i n d e r head ( 5 ) . I n s t a l l the rod seal
spacer ( 7 ) , the rod seal r e t a i n i n g r i n g ( 8 ) , t h e
backup ring ( 9 ) and O-ring (10) on cy1 inder head
( 5 ) . S1 i d e Diston washer ( 1 2 ) on cy1 i n d e r rod
followed by a new O- ring (11 ) . Lubricate new
p i s t o n packing ( 1 4 ) w i t h h y d r a u l i c o i l and place
on b o t h ends of p i s t o n ( 1 3 ) . S l i d e p i s t o n on
p i s t o n r o d . S l i d e t h e remaining p i s t o n washer
( 1 2 ) on cy1 i n d e r rod followed by s e l f - 1 ocking n u t
( 1 5 ) . Torque t h e s e l f l o c k i n g n u t t o 200 f t - l b s
lubricated.
2. S a t u r a t e t h e rod assembly w i t h hydraulic o i l and
i n s t a l l t h e rod assembly i n c y l i n d e r ( 1 6 ) . I n s t a l l
clamp r i n g ( 4 ) and t i g h t e n adequately.
3. Before r e - i n s t a l l i n g t h e c y l i n d e r on t h e c r a n e ,
check the bushings ( 2 ) f o r e x c e s s i v e wear and
r e p l a c e i f necessary.
4. I n s t a l l c y l i n d e r on machine and o p e r a t e s t e e r i n g
and check f o r leakage.
R1
-7-
FILE E
OUTRIGGER CYLINDERS
1. An inspection f o r worn packing or internal scoring

can be done without removing cylinder from crane.
2. Rernove s e t screws ( 3 ) and plugs ( 4 ) . Usina spanner
wrench AH-78678 (found i n t o o l k i t ) , loosen clamp
ring ( 2 ) and remove. P u l l piston rod assembly
from cylinder ( 1 7 ) .
3. Remove n u t ( 1 5 ) , piston ( 1 4 ) , packing ( 1 2 ) , O-ring

(13) and p l a t e (11). Remove O-rings ( 9 ) and ( 1 0 ) ,
head ( 8 ) , g l a n d ( 6 ) . Remove wiper ( 5 ) from gland.
Assembly
Carefully inspect a l l components for s e r v i c e a b i l i t y .
Lubricate packings w i t h hydraulic o i l .
1. I n s t a l l new wiper ( 5 ) in g l a n d ( 6 ) . I n s t a l l on
piston rod ( 1 ) . On rod i n s t a l l packing ( 7 ) , head
( 8 ) , rings ( 9 ) a n d ( l o ) , p l a t e ( 1 1 ) and ring ( 1 3 ) .
I n s t a l l new packing ( 1 2 ) on piston ( 1 4 ) , i n s t a l l
on rod. Instal 1 n u t (15) and torque t o 700 f t - l b .
1 ubricated. I n s e r t rod assembly in cy1 i nder ( 1 7 )
( 1 ubri c a t e thoroughly). Instal 1 clamping r i n ( 2 )
a n d t i g h t e n , i n s e r t plugs ( 4 ) and s e t screws 73)
and t i gh ten.
2. Operate and check f o r leaks.
-9-
FILE E
SHOP MANUAL SE CT ION 3.10
cn
'
0
N
\ ;. ...........
fg?J
R1
- 1 0-
FILE E
?AODEL 80 CRANE OUTRIGGER CYLINDERS
1. Remove the o u t r i g g e r c y l i n d e r from t h e crane. Using

t h e spanner wrench, found i n t h e tool k i t , remove
c l ampring ( 5 ) and remove p i s t o n rod assembly from
cylinder (16).
2. Remove s e l f - l o c k i n g n u t ( 1 4 ) , p i s t o n ( 1 3 ) , piston
V-packing ( 1 2 ) , O-ring (11 ), isiston p l a t e ( l o ) ,
O-ring ( 9 ) , backup washer ( 8 ) , pi ston rod s e a l ( 7 )
and cy1 i nder head ( 6 ) .
3. Remove wiper ( 4 ) from cy1 inder head ( 6 ) .
Carefully examine a l l p a r t s f o r s e r v i c e a b i l i t y . See
a p p r o p r i a t e Galion p a r t s c a t a l o g f o r replacement p a r t s .
Assembly:
1. I n s e r t a new wiper ( 4 ) i n cy1 i n d e r head ( 6 ) and
s l i d e on p i s t o n rod ( 3 ) .
2. Lubricate p i s t o n rod seal ( 7 ) w i t h h y d r a u l i c o i l
and i n s t a l l i n c y l i n d e r head ( 6 ) followed by back-
u p washer ( 8 ) , new O-ring ( 9 ) and p i s t o n p l a t e ( 1 0 ) .
3. Lubricate new O-ring ( 1 1 ) w i t h hydraulic o i l and

i n s t a l l over p i s t o n r o d .
4. Lubricate piston V-packin (12) w i t h hydraulic o i l
3
and i n s t a l l on piston (13 , S l i d e p i s t o n on t h e
pi ston rod and add s e l f -1 ocki n a n u t ( 1 4 ) . Torque
n u t (14) t o 200 f t - l b s l u b r i c a t e d .
5. S a t u r a t e p i s t o n rod assembly w i t h hydraulic o i l and
install in cylinder (16).
6. I n s t a l 1 a new nylon pel 1 e t (15) and r e p l a c e clamp
ring ( 5 ) t i g h t e n i n g adequately.
7. Before r e - i n s t a l l i n g outrigger c y l i n d e r i n the c r a n e ,
check b u s h i n g ( 2 ) f o r e x c e s s i v e wear and r e p l a c e i f
necessary.
R1
-11-
FILE E
SHOP MANUAL SECTION- 3.10
FILE E
CROWD CYLINDER
Remove cy1 inder from c r a n e .

1. Refer t o F i l e E , Section 3.11. Follow Steps 1
through 5.
2. Remove piston rod assembly.
3. Loosen and remove n u t (1 ) . Remove washer ( 2 ) ,
packing (4), p i s t o n ( 5 ) and packing ( 4 ) . Remove
washer ( 2 ) and r i n g ( 3 ) .
4. Separate p i s t o n rod (15) from assembly of gland (10)
and head ( 8 ) . Remove wiper ( 1 1 ) from gland ( 1 0 ) .
Remove "0" rings ( 6 ) and ( 7 ) from head ( 8 ) . Remove
packing ( 9 ) from rod ( 1 5 ) .
Assembly:
C a r e f u l l y examine a l l components f o r s e r v i c e a b i l i t y .
Lubricate a1 1 packings with hydraulic o i l .
1. I n s t a l l washer ( 2 ) , O-ring ( 3 ) , packing (4),

p i s t o n ( 5 ) , packing ( 4 ) and n u t (1 ) . Torque n u t
t o 700 f t - 1 bs l u b r i c a t e d . Generously l u b r i c a t e
r o d assembly w i t h h y d r a u l i c o i l and i n s t a l l i n
cy1 i nder ( 1 6 ) .
2. Refer t o F i l e E , Section 3.11. Follow Steps 6
through 13.
3. I n s t a l l c y l i n d e r on crane and o p e r a t e . Check f o r
1eaks .
-1 3-
FILE E
R1
-14-
FILE E
MODEL 80 CRANE CROWD CYLINDERS
Serial No. 4001 81 Up
1. Remove c y l i n d e r from c r a n e . Using spanner wrench,

found i n t h e tool k i t , remove clamp ring ( 4 ) . Re-
move piston rod assembly from c y l i n d e r ( 1 5 ) .
2. Remove s e l f - l o c k i n g n u t ( 1 4 ) , piston seal ( 1 2 ) , p i s t o n
( 1 3 ) , p i s t o n seal ( 1 2 ) , O-ring ( l l ) , r e t a i n e r ( l o ) ,
O-ring ( 9 ) , backup ring ( 8 ) , cy1 i n d e r head ( 7 ) , rod
s e a l ( 6 ) , cy1 i n d e r head gland ( 5 ) .
3. Remove wiper ( 3 ) from gland ( 5 ) .
C a r e f u l l y examine a l l components f o r s e r v i c e a b i l i t y . For
replacement p a r t s s e e a p p r o p r i a t e Galion p a r t s c a t a l o g .
Assembl v:
1. I n s t a l l a new wiper ( 3 ) i n gland ( 5 ) . I n s t a l l gland
on p i s t o n rod ( 2 ) .
2. Lubricate rod s e a l ( 6 ) w i t h hydraulic o i l and i n s t a l l
i n cy1 i nder head ( 7 ) . S1 ide cy1 i n d e r head on p i s t o n
rod ( 2 ) .
3. I n s t a l l backup rin
and new O-ring (1 1 3 .( 8 ) , new O-ring (9), r e t a i n e r (10)
4. Lubricate p i s t o n s e a l s ( 1 2 ) w i t h hydraulic o i l and

i n s t a l l on piston. I n s t a l l p i s t o n on piston rod.
5. I n s t a l l s e l f - l o c k i n g n u t (12) and torque t o 700 f t - l b s
1ubricated.
6. S a t u r a t e p i s t o n rod assembly w i t h hydraulic o i l and
i n s t a l l in c y l i n d e r ( 1 5 ) . Replace clamp ring ( 4 )
and tighten adequately.
7. I n s t a l l e x i s t i n g hoses while c y l i n d e r i s s t i l l o u t
o f t h e machine and t e s t f o r leakage.
8. I n s t a l 1 cy1 i n d e r on c r a n e .
-1 5- R1
FILE E
R1
FILE E
MODEL 80 CRANE CROWD CYLINDER
3 SECTION POWER BOOM
Serial No. 4001 81 Up
1. Remove the cy1 inder from c r a n e . Remove the s e t screw ( 2 )

and nylon ball from packing n l r t (11 ) . With the use of the
spanner wrench found in t h e tool k i t , remove packing n u t
( 1 1 ) . Remove the e n t i r e t e l e s c o p i c piston rod assembly
from cy1 inder ( 2 0 ) .
2. Remove the s e t screw ( 2 ) and nylon ball from trunnion pack-
ing n u t ( 1 ) and remove n u t ( 1 ) frorr: f i r s t sleeve assembly
(17) and lay a s i d e .
3. Taking the f i r s t sleeve assembly ( 1 2 - 1 9 ) , remove piston
bearing ( 1 8 ) , piston r i n g s ( 1 9 ) and piston bearing (18)
from f i r s t sleeve assembly ( 1 7 ) .
4. Remove wiper r i n g ( 1 2 ) , bearing r i n g ( 1 3 ) , packing assembly
( 1 4 ) , wave spring (15) and s t o p r i n g ( 1 6 ) from f i r s t sleeve
assembly (17 ) .
5. Carefully examine components f o r s e r v i c e a b i l i t y . I f r e -
placement i s needed, see a p p r o p r i a t e Galion p a r t s c a t a l o g .
6. I n s t a l l stop r i n g ( 1 6 ) , wave spring ( 1 5 ) , piston packing
( 1 4 ) , bearing r i n g (13) a n d wiper r i n g ( 1 2 ) on f i r s t sleeve
assembly ( 1 7 ) .
7. I n s t a l l piston bearing ( 1 8 ) , piston rings ( 1 9 ) and piston
bearing (18) on f i r s t sleeve assembly ( 1 7 ) .
8. Taking plunger assembly ( 3 - l o ) , remove piston bearing ( 9 ) ,
piston rings (10) and piston bearing ( 9 ) from plunger assem-
bly ( 8 ) .
9. Remove wiper ring ( 3 ) , bearing r i n g ( 4 ) , packing assembly ( 5 ) ,
wave spring ( 6 ) and stop r i n g ( 7 ) from plunger assembly ( 8 ) .
10. Carefully examine components f o r s e r v i c e a b i l i t y . If replace-
ment i s needed, see appropriate Galion p a r t s c a t a l o g .
11. I n s t a l l stop r i n g ( 7 ) , wave spring (6), packing assembly ( 5 ) ,
bearing r i n g ( 4 ) and wiper r i n g ( 3 ) on plunger assembly ( 8 ) .
12. I n s t a l l piston beariKg ( 9 ) , 2iston r i n g s (10) and piston
bearing ( 9 ) on plunger assembly ( 8 ) .
13. To i n s t a l l plunger assernbly (3- 10) in f i r s t sleeve assembly
(12-19), s a t u r a t e the e n t i r e plunger assembly with hydraulic
o i l . S l i d e packing n u t ( 1 1 ) over plunger assembly. I n s t a l l
plunger assembly in f i r s t sleeve assembly. I n s t a l l the
trunnion packing n u t ( 1 ) on f i r s t sleeve assembly (17) and
t i hten with spanner wrench. I n s e r t nylon sal1 and s e t screw
(251. Tighten s e t screw.
14. S a t u r a t e e n t i r e t e l e s c o p i c piston rod assembly with hydraulic
o i l and i n s t a l l in c y l i n d e r ( 2 0 ) . Tighten packing n u t (?I)
t o cylinder ( 2 0 ) with spanner wrench. I n s e r t nylon ball and
s e t screw ( 2 ) . Tighten s e t screw.
15. P r i o r t o r e - i n s t a l l i n g in crane, place c y l i n d e r alonc s i d e
crane a n d adapt t e s t hoses from e x i s t i n g crowd c i r c u i t hoses
on crane t o c y l i n d e r . Test c y l i n d e r p r i o r t o i n s t a l l a t i o n
and check f o r l e a k s .
16, Ins.sa'ii cy7 ?der i v crane boor
~
-1 7- R1
FILE E
r 1
L --I
- 1 8-
HOIST & WINCH BRAKE CYLINDER
-
Serial No. 2832 7620
Remove cylinder from crane.

1. Remove b o o t clamp ( 4 ) and remove push rod assembly
( 1 , 2 and 3 ) . Remove b o o t clamp ( 6 ) and b o o t ( 5 ) .
Remove retaining ring ( 7 ) and piston ( 8 ) .
2. Remove retaining ring ( 1 4 ) and remove cap ( 1 3 ) .
From cap, remove back-up washer ( 1 2 ) and O-ring
( 1 1 ) . From piston ( 8 ) remove "U" cup ( 9 ) .
Careful l y inspect a1 1 parts f o r serviceabi 1 i t y . Cy1 inder
barrel and piston should n o t be scored. Lubricate a1 1
s e a l s , cups and O-rings before assembly.
Assembly:
1. Instal 1 new back-up washer ( 1 2 ) and O-ring (11 ) on
cap ( 1 3 ) , i n s t a l l in barre 1 and i n s t a l l retaininq
ring ( 1 4 ) .
2. I n s t a l l new "U" cup ( 9 ) on piston ( 8 ) , i n s t a l l in
cy1 inder barrel and i n s t a l 1 retaining ring ( 7 ) .
3. Before i n s t a l l i n q push rod assembly ( 1 , 2 and 3 ) ,
check length of r o d from back of jam n u t (where
n u t touches rod end), t o t a l 1 ength should be
exactly 2 11/16 inches l o n g . This will be t h e
proper 1 ength and no f u r t h e r adjustment should be
required.
4. I n s t a l l push rod assembly ( 1 , 2 and 3) thru b o o t
( 5 ) a n d i n t o piston ( 8 ) . I n s t a l l b o o t clamp ( 6 ) .
Notice there i s a very small hole t h a t could be
covered by t h e b o o t a n d clamp. This i s a drain
hole; check t o determine t h i s hole i s uncovered.
I n s t a l l b o o t clamp ( 4 ) .
Re-assemble on crane a n d tension spring t o apply brake
firmly. Operate crane, check performance.
c1
- 1 9-
FILE E
c1
-20-
FILE t
SWING & HOIST BRAKE CYLINDER
Remove cy1 inder from crane

Disassembly:
Remove boot clamp ( 4 ) and s l i d e push rod assembly ( 1 , 2 and 3 ) o u t of
c y l i n d e r . Remove b o o t clamp ( 6 ) and boot ( 5 ) . Remove r e t a i n i n g r i n g
( 7 ) and s l ide p i s t o n ( 1 0 ) w i t h packing ( 9 ) o u t of cy1 inder body ( 8 ) .
Remove packing from p i s t o n .
Inspection:
C a r e f u l l y i n s p e c t a l l p a r t s f o r s e r v i c e a b i l i t y . Cylinder b a r r e l and
p i s t o n should be f r e e of n i c k s , burrs o r s c r a t c h e s . Inspect boot f o r
t e a r s or cracking due t o age. Replace p i s t o n packing and l u b r i c a t e
both packing and p i s t o n p r i o r t o assembly. Inspect stud (1 1 ) and jam
n u t (1 2 ) and r e p l a c e i f damaged.
Assembly:
I n s t a l 1 new packing ( 7 ) on p i s t o n ( 1 0 ) and s l i d e p i s t o n assembly i n t o
brake cy1 inder ( 8 ) . I n s t a l l r e t a i n i n g ring ( 7 ) . I n s t a l l b o o t ( 5 ) and
boot clamp ( 6 ) .
Notice t h e r e i s a very small hole i n shoulder of c y l i n d e r weldment. This
i s a b l e e d e r hole t o allow any o i l t h a t escapes p a s t t h e packing t o d r a i n
o u t . Be s u r e boot clamp does n o t cover and c l o s e t h i s hole.
S l i d e boot clamp ( 4 ) over push rod assembly. S1 i d e push rod assembly
( 1 , 2 and 3) thru boot and i n t o p i s t o n .
Mount c y l i n d e r assembly on winch. Refer t o proper adjustment procedure
on f o l 1owing page.
A f t e r proper adjustment i s accomplished, apply boot clamp ( 4 ) over boot
end.
c1
-21 -
Shop Manual Section E-3-10
HOIST AND SWING BRAKE CHECKS AND ADJUSTMENTS
A L L MAJOR REPAIRS SHOULD ONLY BE ATTENDED TO BY EXPERIENCED

SERVICE PERSONNEL. SHUTDOWN UNIT WHILE MAKING ADJUSTMENTS
OR REPAIRS.
HOIST BRAKE CHECKS A N D ADJUSTMENTS:

If the h o i s t drum d r i f t s with l o a d during operation, check the following and
c o r r e c t i f necessary.
NOTE: Before inspecting h o i s t , f u l l y r e t r a c t and lower boom. Point boom i n
forward d i r e c t i o n of u n i t and lower outriggers. Rest load on ground
whiZe making adjustments.
1. SPRING EYEBOLT
There must be 0.500" ( 1 3 mm) of
threads past the n u t t o the end
of the eyebolt f o r proper applied
braking force.
TYPICAL HOIST
Figure 1
2. HOIST BRAKE CYLINDER PUSH ROD

When brake i s engaged (spring applied as when machine i s shutdown), hoist
brake cylinder push rod must be f r e e t o r o t a t e . If push rod i s n o t f r e e
t o r o t a t e , loosen jam n u t and a d j u s t push rod u n t i l there i s approximately
2.687" ( 6 9 mm) from the n u t t o the rounded end, and i t i s f r e e t o r o t a t e .
NOTE:
. .. Access t o jam nut i s accomplished by removing clamp and boot from
c y l i n d e r . R e i n s t a l l when through.
3. FLOW REGULATOR
The 1 GPM ( 4 lpm) f l o w regulator valve may be plugged. This valve i s
connected t o the junction block located under the hoist motor. Remove,
clean and r e i nstal 1 .
c2
-22-
4. OVERCENTER CHECK VALVE

Crowd cylinder overcenter check valve may be stuck open.
5. BRAKE CYLINDER
The brake cy1 inder may be scored and binding.
6. HOIST BRAKE SHOES
The brake shoes can be slipping due t o the following:
A. Oil spotting.
B. Oil soaked.
C. Glazing - which can be removed by burnishing.
Items 1 through 5, 6A and 6B should ONLY be attended t o by experienced service
personnel.
Item 6C may be attended t o by the operator. Brake shoes spotted by o i l or oi 1
soaked should be replaced then burnished. To properly burnish the h o i s t brake
shoes :
BURNISHING
1. Disconnect the o i l supply tube from hose leading t o the hoist brake cylinder.
2. P1 ug the open tube so no o i l will be l o s t .
3. Activate the Intermediate Line Speed control lever in t h e DOWN position with
the engine a t maximum RPM f o r no more t h a n 3 seconds. R e p e a t u n t i l brake
drum does n o t r o t a t e , allowing brake drum t o cool f o r 45 seconds a f t e r each
3 seconds of brake application. Allow brake shoes and drum t o cool f o r l e a s t
1 5 minutes.
4. Unplug and reconnect o i l supply tube t o h o i s t brake cylinder. Normal
operation can now be resumed.
SWING BRAKE CHECKS AND ADJUSTMENTS:
If when swinging a load, the boom continues t o d r i f t a f t e r the control valve i s

returned t o n e u t r a l , the swing brake should be inspected. The same checks and
adjustments t h a t apply t o the hoist brake a l s o apply t o the swing brake. Both
use the same principles of operation.
Prior t o performing checks and adjustments:
1. Fully r e t r a c t and lower boom.
2. Unhook load, i f any.
3 . Lower outriggers.
4 . Keep distance between hook block and head block t o a minimum ( a f t e r unhooking
l o a d ) , t o prevent pendulation of hook block.
5. Be sure there i s adequate room f o r boom r o t a t i o n .
Perform a l l checks and adjustments shown under Hoist Brake Checks and Adjustments.
- 23- c2
GRADER
PLANER
ROLLER 0
CRANE d
Shop Manual E- 3.11
B O O M C R O W D CYLINDER ROD SEAL
80, 90, 90A, 100, 100A, 110, llOA, - ALL -

125, 125A, 125F, 125FA, 125P, 140F,
150A, 150FA, 150P, 150T & 200FA
L CAUTION

GOOD WORKING ORDER.
EXTREME CAUTION T O B E OBSERVED A T A L L TIMES TO PREVENT

INJURY
2
The i n s t r u c t i o n s in t h i s section apply primarily t o the replacement
and/or changeover t o the new s t y l e one piece polyurethane rod seal
packing.
The f o u r , f i v e or s i x piece chevron type packing s e t has been re-
placed by t h i s new one piece ring, which i s completely interchangeable
with t h e o l d s t y l e . On a1 1 orders fo.r rod seal packings , only the
new one piece type wi 11 be furnished.
This packing i s a1 so used on crowd cy1 inders with two packing s e t s per
piston. When replacing packing s e t s on pistons, i n s t a l l the one piece
packings with O-rings facing away from each other towards pressure
side.
NOTE: This polyurethane packing seal cannot be cut f o r installation,
it must be installed as one complete ring.
Many crowd cylinder i n s t a l l a t i o n s permit replacing or changing the
seal without removal of the cylinder from the crane. Determination
o f the need f o r removal of the cylinder can be readily made by visual
inspection.
The procedure following depicts the i n s t a l l a t i o n with the cylinder
removed from the crane t o b e t t e r i l l u s t r a t e the components.
Dresser Industries. Inc. Construction Equipment Divislon P 0. Box 647 Galion. OH 44833 U.S.A.
(419) 468.4321
1283
I NOTE: Toraue Values llsted throughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Nowlubricated (Dry) Threads.
11
Grade 5 Gr ! 8
Thread Size (3 radlal dashes on t or cap screw head) (6 radial dashes on t or cap screw head)
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 21 37 38 52
7/16 . 14 38 52 54 73
1/16 . 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 . 18 130 176 185 251
3/4 - 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 . 14 335 454 515 698
1 - a 455 617 695 942
1 . 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 - 6 1130 1532 1830 2481
1 3/8 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 3701
1 3/4 - 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
PACKING SEAL USAGE:
MODEL
G A L I O N P A R T NO. INNER DIAMETER APPLICATION LOCATION
D-89481 3 1/2 i n . 80 (Ser. #1710-3131) Two-Sec. Power Boom

90, 90A, 100, 100A, Three-Sec. Power Boom
110, llOA, 125, 125A, Four-Sec. Power Boom - -
125F, 125FA, 125P, Second Sec. only
140F, 150A, 150P, 150T,
150FA, 200FA
D-91359 3 in. 80 (Ser. #1710-3131) Four-Sec. Power Boom --

90, 90A, 100, 100A, Third & Fourth Sec. only
110, llOA, 125, 125A,
125F, 125FA, 125P, 140F,
150A, 150P, 150T, 150FA,
200FA
D-91359 3 in. 80 (Ser. #4001 & U p ) Crowd Cy1 i nder-Staged Boom
-1-
N o t e o r i e n t a t i o n o f t h e s e a l p a c k i n g . One s i d e i s
p l a i n . The o t h e r s i d e has l i p s w i t h an O - r i n g b e -
tween.
4805
The c y l i n d e r h e a d m u s t have t h e l a r g e c h a m f e r shown

f o r easy assembly.
4806
I f t h e c y l i n d e r head does n o t have t h e l a r g e c h a m f e r

shown i n F i g . 2, m a c h i n e t h e c h a m f e r t o t h e s e s p e c i -
fications.
4807
-2-
FILE E
SHOP MANUAL SECTION
4
The s e a l p a c k i n g and c y l i n d e r head w i t h t h e l a r g e
chamfer are necessary t o complete t h e i n s t a l l a t i o n .
4808
Remove p l u g s a n d s e t s c r e w s f r o m clamp r i n g . Remove

c y l i n d e r head c l a m p r i n g f r o m t h e c y l i n d e r w i t h t h e
spanner wrench p r o v i d e d i n t h e t o o l k i t . I f a dual
c r o w d c y 1 i n d e r ( 4 s e c t i o n power boom) remove 1/8"
p i p e p l u g f r o m p i s t o n r o d . Remove t h e r o d p a c k i n q
g l a n d . I f t h e c y l i n d e r head m u s t have t h e l a r g e
c h a m f e r added, remove t h e c y l i n d e r head.
I n s p e c t O - r i n g on cy1 i n d e r head and r e p l a c e i f

r e q u i r e d . R e i n s t a l l c y l i n d e r head.
-3-
Apply grease t o t h e seal packing. S l i d e the seal
p a c k i n g o n t o t h e c y l i n d e r r o d making c e r t a i n t h a t
the l i p s are toward the c y l i n d e r .
a
S l i d e t h e p a c k i n g g l a n d on b a c k w a r d s , t o use i t as
an a s s e m b l y t o o l f o r i n s e r t i o n o f t h e s e a l p a c k i n g .
I n s t a l l t h e clamp r i n q .
FILE E
10
T i g h t e n t h e clamp r i n g u n t i l g l a n d b o t t o m s a g a i n s t
c y l i n d e r , t h e n u n s c r e w t h e clamp r i n a .
11
I n s p e c t w i p e r - s c r a p e r and r e p l a c e i f r e q u i r e d . Re-
move t h e p a c k i n g g l a n d a n d r e i n s t a l l c o r r e c t l y ,
u s i n g a m a l l e t as shown. I f a d u a l c r o w d c y l i n d e r
( 4 s e c t i o n power boom) r e p l a c e p i p e p l u g i n p i s t o n
rod.
12
I n s t a l 1 t h e c l a m p r i n g and t i g h t e n .
-5-
13
I n s e r t s e t s c r e w s and pluqs, a n d t i g h t e n .
-6-
GRADER 0
PLANER 0
ROLLER 0
CRANE El
Shop Manual E-3.1 2

RVC4
HYDRAULIC CRANE- -
-BO.O-ML-IFT CYLINDER
7-- ___ -. __ - ..
'SEU
80 01710 thru 03131
90, 100, 110 & 125 01001 thru 08774
90A, 100A, llOA & 125A 02006 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 02832 & Up
1 50FA 07305 & Up
125P, 150P & 150T 01001 & u p
Installation of the piston rod nut requires application o f 2000 to
2500 Ft.Lbs. (2712 to 3390 Nm) torque. Any combination of standard
torque wrench and mu1 tip1 iers that result in a final torque of 2000
to 2500 Ft.Lbs . (2712 to 3390 Nm) is acceptable.
The new cylinder head changeover kit and evolution o f cylinder head
and piston design information is presented on page A, 6 & C o f this
Shop Manual. This inforamtion, in conjunction with the existing Shop
Manual covers service of the new, intermediate and old design cylinder
heads and pistons.
CAUTION
ALL COMPONENTS MUST BE P R O P E R L Y SUPPOR TED DURING
DISASSEMBLY A N D ASSEMBLY.
ALL JACKING, HOISTING, AND G E N E R A L WORKSHOP EQUIP- '
MENT REQUIRED FOR THIS O P E R A T I O N MUST BE I N

GOOD WORKING ORDER.
EXTREME C A U T I O N T O BE OBSERVED A T A L L TIMES T O PREVENT

INJURY
SAFE WORKSHOP P R A C T I C E S A R E A MUST
CONTENTS Page
Torque Sheet ...................... Back of Cover
Disassembly . ........................ 1
Reassembly . ........................ 5
c4
GALION MANUFACTURING DIVISION
Dresser lndustrles. Inc , PO Box 647, Galton,Ohlo 44833, U S.A.
0282
I
r
t Grade 5
(3 radial dashes on t t or cap screw head)
Grade 8
(6 radial dashes on I t or cap screw head)
Thread Size
1/4 . 20 6 8 9 12
1/4 28 7 9 11 15
5/16 . 18 13 18 18 24
5/!6 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 23 37 38 52
7/16 . 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 . 12 a4 114 120 163
9/16 - 18 93 126 132 179
5/8 - 11 115 156 165 224
5/a - 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 - 16 230 312 320 434
718 - 9 305 414 455 617
718 - 14 335 454 515 698
1 - 8 455 617 695 942
1 - 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 2481
1 3/8 . 12 1290 1749 2085 2827
1 1/2 - 6 1500 2034 2430 3295
1 1/2 - 12 1690 2291 2730 3701
1 3/4 . 5 2370 3213 3810 5166
2 - 4 1/2 3550 4813 5760 7810
. -.
Any order f o r cylinder ire2.a ~ z r $C;-12i'7iO
t (intermedjate d e s i g n ) or Part
#G-89387 ( o l d des.ign) wii?be f i 1 led w - i t h cy1 in&r head k i t Part #AD-125814
(new design) P I ease see d!ag~rzrr on fo'! l o w i ~ gpage
~
The new cy1 inder head k i t , ; ) a r t #F\.D -I 4; c o n s i s t s o f the cy1 inder head ( 3 )
2581
Part #G-124522; piston rod packing seal ( 2 ) Part #D-89481; and the new bronze
bushing ( 1 ) 9 P a r t #H-128898, (See diagram below.) The new k i t i s availabe for
cranes u p t o Serial No. 07279. Units produced a f t e r No. 07279 will nave the new
wear ring ( 1 ) i n s t a l l e d during manufacture. Cylinders currently being assembled
with bronze bushings a r e stamped with the 1 e t t e r " E " on machined pad area o f
cylinder head.
- -.T-
4
3.Ei75 3.593
DiA 3.504
Dl A
i
c2
-A-
The new bushing ( 1 ) and the piston rod packing seal ( 2 ) are t o be installed
from the inner s i de of the head ( 3 ) whereas the rod wiper ( 4 ) , Part #D-63804,
i s t o be installed from the other side of the head prior t o installing the
pi ston rod ( 5 ) , Part #AG-89185. I t i s recommended t h a t the new bronze bushing
( 1 ) be shrunk in dry ice, freezer, or i c e , then immediately dropped into the
head ( 3 ) bore. Use the driving tool i 11 ustrated on previous page as a gage
t o check for out- of- round condition a f t e r the bushina has exPanded in the head
bore groove. DO NOT DRIVE BUSHING INTO POSITION BY HAMMERING! I f material i s
shaved from O . D . of bronze bushing, the I.D. will also be damaged or distorted
and the driving tool will be d i f f i c u l t t o remove. I f additional force i s re-
qui red, use driving tool and either a hydraul i c or mechanical press. The 1 i ps
of the one piece piston rod packing seal ( 2 ) must always be installed toward
the o i l .
KIT)
KIT)
c2
-B-
Galion boom l i f t c y l i n d e r pistons have been redesigned t o r e c e i v e a wear
ring (1 ) , P a r t # 154483, and t h e one piece pi ston packing ( 2 ) , P a r t #120922.
Any o r d e r s for Cylinder Piston P a r t #63803-A o r #120923 ( o l d d e s i g n ) w i l l

be f i l l e d w i t h Cylinder P i s t o n Kit P a r t #154675 (new d e s i g n ) . Please s e e
diagram below.
The new Cylinder P i s t o n Kit, P a r t #154675 c o n s i s t s o f : Wear R i n g ( l ) ,
P a r t #154483; Packing ( 2 ) , P a r t #120922; P i s t o n ( 3 ) , P a r t #154482;
Pi ston P l a t e ( 4 ) , P a r t #154481; and 0-Ring ( 5 ) , P a r t #58653. This new
Piston Kit i s a v a i l a b l e for a l l Mobile Cranes, Model 90 thru 150FA, u p
thru s e r i a l number 8837, and Pedesta.1 Cranes u p thru s e r i a l number 1223.
After these s e r i a l numbers, units w i l l have the new p a r t s i n s t a l l e d and
may be ordered s e p a r a t e l y .
OLD DESIGN NEW DESIGN
(1 ) 120922 PACKING (1 ) 154483 WEAR RING

(2) 120923 PISTON (Ord. 154675 KIT) (2) 120922 PACKING
(3) 100449 PISTON PLATE (3) 154482 PISTON
(4) 58653 O-RING (4) 1 54481 PISTON PLATE
(5) 58653 O-RING
t //
c4
-C-
NOTES
-D-
FILE E
SHOP MANUAL SEC7lON 3.12
DISASSEMBLY
1
A piston rod n u t tool w i l l be needed. I t i s sugges-
ted t h a t a tool be made u p from these standard GALION
parts:
One ( 1 ) H-82340 n u t
One ( 1 ) 0-60539 n u t
Two ( 2 ) D-53375 pin ( 1 / 2 " d i a . x 2" l g .
hardened)
Two ( 2 ) D-82861 washer ( 1 / 2 " f l a t )
!deld together as shown. Pins should protrude 1 1/8"

from n u t s u r f a c e .
3
Place cylinder assembly i n s u i t a b l e c r a d l e o r f i x t u r e
Remove twenty-two ( 2 2 ) cap screws and lock washers
t h a t r e t a i n head t o b a r r e l .
-1 -
FILE E
4ttach s l i n g t o piston rod and remove p i s t o n , piston

rod, and head assembly from b a r r e l . Use caution not
t o s c r a t c h piston rod.
5
Place p i s t o n , piston rod, and head assembly i n s u i t -
a b l e c r a d l e o r f i x t u r e . Remove % ( 2 ) setscrews
from piston rod n u t .
6
I n s t a l l piston rod n u t tool ( a s shown i n F i g . 2 ,
page 1 ) on piston rod n u t . Use adequate wrench t o
remove n u t as n u t i s i n s t a l l e d w i t h 2000 f t - l b
torque. Remove n u t .
-2-
7
-
Remove l o c k w i r e on s i x ( 6 ) p i s t o n to - piston
p l a t e cap screws. Remove cap screws.
Remove p i s t o n w i t h p a c k i n g .
Remove O - r i n g f r o m p i s t o n rod. Remove p i s t o n p l a t e .
-3-
FILE E
10
Remove head assembly.
11
Remove O - r i n g and back- up r i n g f r o m head.
12
Remove f o u r ( 4 ) socket- head cap screws r e t a i n i n g

a l a n d t o head.
REASSEMBLY
14
Note o r i e n t a t i o n o f t h e p o l y u r e t h a n e o n e - p i e c e s e a l
p a c k i n g . One s i d e i s p l a i n . The o t h e r s i d e has
l i p s w i t h an O - r i n g between.
15
A p p l y grease t o o u t e r l i p o f s e a l p a c k i n g . I n s t a l l
t h e o n e - p i e c e s e a l p a c k i n g i n t h e head m a k i n g c e r -
t a i n t h a t the l i p s o f the seal packing are i n s e r t e d
first.
-5-
FILE E
- SHOP MANUAL SECTION 3.12
16
Inspect rod wiper i n gland. Replace i f required.
17
Using gland as an i n s t a l l a t i o n t o o l , press seal
packing i n t o proper p o s i t i o n i n t h e head. Note
t h a t seal packing has f r e e space t o f l o a t . This
i s c o r r e c t and no shimming or a l t e r a t i o n s should
be performed.
18
I n s t a l l f o u r ( 4 ) socket-head cap screws t o r e t a i n
gland t o head. Torque t o 67 - 80 f t - 1 b .
-6-
19
concave s u r f a c e on back-up r i n g f i t s towards O-ring.
20
Apply grease t o rod wiper t o f a c i l i t a t e reassembly

on c y l i n d e r rod.
21
Apply grease t o seal packing i n n e r 1 i p t o f a c i l i t a t e
reassembly on c y l i n d e r rod.
-7-
FILE E
22
Carefully clean c y l i n d e r rod w i t h solvent. Apply a

l i g h t f i l m of o i l t o rod t o f a c i l i t a t e reassembly.
23
Position head assembly on rod using extreme c a r e

not t o damage rod wiper. Using soft- head m a l l e t ,
t a p head assembly onto rod.
24
Reinstall piston p l a t e on rod. Chamfered edge must
go towards shouldered portion of piston rod.
-8-
FILE E
25
I n s t a l l O-ring on piston rod.
26
I n s t a l l new packing on piston. Note t h a t crown o f

packing chevron points up.
27
I n s t a l l piston w i t h packing on rod.
-9-
~- SHOP MANUAL SECT10N 3* 12
28
I n s t a l l s i x ( 6 ) d r i l l e d head cap screws t o r e t a i n
piston p l a t e t o p i s t o n .
29
Torque s i x cap screws t o 117-140 f t - l b .
30
Lubricate threads o f rod n u t and i n s t a l l .
-10-
FILE E
31
Reinstal 1 rod n u t tool on rod n u t .
32
Using torque wrench and m u l t i p l i e r , torque rod n u t

t o 2000 f t - l b .
33
I n s t a l l lockwire on s i x ( 6 ) piston - to - piston
p l a t e cap screws.
-11-
FILE E
34
I n s t a l l setscrews. Torque t o 35 - 40 f t - l b .
35
Clean c y l i n d e r barrel bore with s o l v e n t .
36
Apply a t h i n coat of grease t o c y l i n d e r barrel bore
i;c a i d piston i n s t a l l a t i o n .
-1 2-
37
Apply grease t o p i s t o n packing t o a i d i n s t a l l a t i o n .
38
Align piston w i t h c y l i n d e r b a r r e l . I n s t a l l p i s t o n ,
p i s t o n rod, and head assembly i n c y l i n d e r b a r r e l
u n t i l packing rings a r e completely i n s e r t e d i n t o
b a r r e l . When a t t a c h i n g s l i n g t o piston rod, use
care n o t t o s c r a t c h rod.
39
Line u p head - t o - barrel holes in proper sequence.
Use two ( 2 ) 5/8-11 x 4 1/2" cap screws and various
spacers t o evenly draw piston and head i n t o b a r r e l .
-1 3-
FILE E
40
Reinstall twenty-two ( 2 2 ) cap screws and lock

washers t o r e t a i n head t o b a r r e l .
41
Torque cap screws t o 117 - 140 f t - l b
-14-
GRADER 0
PLANER
ROLLER 0
CRANE [II
Shop Manual E- 3.1 3

R2K2
D U A L C R O W D CYLINDER
FOU..R SECTION P O W E R B O O M
LA-PPLIC-ABLE MODELS SERIAL NUMBERS
80 04001 and Up
90 thru 125 01254 thru 08774
90A thru 125A 02006 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 02832 and Up
1 50 FA 07305 and Up
125F 07247 thru 08774
200FA 09401 and Up
125P, 150P/T 01001 and Up
The following procedure i s based on a complete removal and overhaul of a l l components
r e l a t e d t o the dual crowd c y l i n d e r .
I t i s mandatory t h a t another crane o r l i f t i n g device of adequate c a p a c i t y be a v a i l a b l e
f o r t h i s procedure.
Consistent w i t h a l l Galion Service P u b l i c a t i o n s , the boom s e c t i o n s a r e numbered s t a r t -
i n g w i t h the base ( n o n - s l i d i n g ) s e c t i o n . Thus the s e c t i o n w i t h the head block perma-
n e n t l y a t t a c h e d i s the f o u r t h s e c t i o n . The dual crowd c y l i n d e r i s anchored t o the
second s e c t i o n and o p e r a t e s the t h i r d and f o u r t h s e c t i o n simultaneously.
CAUTION

GOOD WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED AT A L L TIMES T O PREVENT

INJURY
CONTENTS Page
Removal o f Dual Crowd Cylinder from Crane . . . . . . . . . . 1
Disassembly of Dual Crowd Cy1 inder . . . . . . . . . . . . . 10
Reassembly o f Dual Crowd Cylinder . . . . . . . . . . . . . . 15
I n s t a l l a t i o n of Dual Crowd Cylinder i n Crane . . . . . . . . 25
Dresser Industries, Inc. Construction Equipment Division P.O. BOX 647 Galion, OH 44833 U S A .
(419) 468-4321 Telex: 987430 Cable: Galiron c2
Grade 5 Grade 8
Thread Size (3 radial dashes on : or cap screw head) (6 radial dashes on bolt or cap screw head)
Foot Pounds
(Ft. Lbs.)
Newton Meters
(Nm)
Foot Pounds
(Ft. Lbs.) I Newton Meters
(Nm)
1/4 . 20 6 a 9 12
114 . 2a 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
318 . 16 24 33 34 46
318 . 24 27 37 38 52
7/16 . 14 38 52 54 73
7/16 . 20 42 57 60 a1
1/2 - 13 58 79 82 111
1/2 . 20 65 aa 90 122
9/16 . 12 84 114 120 163
9/16 - 18 93 126 132 179
5/a . 11 115 156 165 224
518 . la 130 176 185 25 1
3/4 . 10 205 278 290 393
3/4 - 16 230 312 320 434
7/8 . 9 305 414 455 617
718 . 14 335 454 515 698
1 - 8 455 617 695 942
1 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/a . 12 685 929 1110 1505
1 114 - 7 a60 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3 8 - 6 1130 1532 1830 2481
1 318 - 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 3701
1 3/4 - 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
FILE E
R e t r a c t all power boom e x t e n s i o n s . ( I f t h e 3 r d and

4 t h e x t e n s i o n s wil n o t r e t r a c t due t o b r o k e n feed
hoses r e f e r t o F i l e E , S e c t i o n 15, S e c t i o n v, Page
6 o f t h i s manual f o r p r o c e d u r e i n r e t r a c t i n g . )
Lower hook b l o c k t o ground. To i n s u r e t h a t t h e

w i r e r o p e does n o t " b i r d cage" on w i n c h drum, f i r s t
r a i s e boom s l i g h t l y , l o w e r hook b l o c k w i t h w i n c h
n e a r g r o u n d t h e n l a y hook b l o c k on g r o u n d by l o w e r -
i n g boom.
Remove w i r e r o p e anchor wedge f r o m s o c k e t and

unreeve w i r e r o p e f r o m hook and head b l o c k .
- 1-
FILE f
Unspool approximately 7 5 ' o f wire rope and lay on

ground s t r a i g h t i n f r o n t of machine. I f any wire
rope i s spooled o f f o f winch drum be c e r t a i n t o
tension wire rope as i t i s unspooled t o prevent i t
from b i r d caging on winch drum.
Remove two cap screws on r o l l e r cam of second exten-

,;ion. Turn r o l l e r t o lowest p o s s i b l e p o i n t .
Remove wear p l a t e s and spacers on both s i d e s of

second extension,
-2-
7
Grasp r e t r a c t hoses under s h i e l d a t r i g h t hand s i d e
o f boom. Pull downward on hoses, i n s t a l l s u i t a b l e
tool on t r o l l e y t r a c k t o block the r e t u r n o f re-
t r a c t trolley a t t h i s point.
Disconnect crowd c y l i n d e r o i l supply hoses a t t h e

flow d i v i d e r . Mark hoses t o insure c o r r e c t re-
installation.
Remove four ( 4 ) f e r r y head cap screws and lock

washers from crowd c y l i n d e r piston rod anchor brack-
e t . On l a t e r model cranes, t h e hose guard assembly
may be e a s i l y removed a t t h i s time.
-3-
10
S l i d e t h i r d and f o u r t h e x t e n s i o n s o u t u n t i l a p p r o x i -
mately fourteen (14) f e e t o f the t h i r d extension i s
o u t o f t h e second e x t e n s i o n .
11
The b a l a n c e p o i n t c e n t e r l i n e i s a b o u t 1 2 ' 6 " f r o m

the f r o n t s i d e o f t h e h e a d b l o c k . Lower removed
e x t e n s i o n s t o ground and s e t on a p p r o p r i a t e b l o c k s .
12
:<move two ( 2 ) cap screws and l o c k washers f r o m

r o l l e r cam on t h i r d e x t e n s i o n . T u r n r o l l e r down
to t h e l o w e s t p o s s i b l e p o i n t .
-4-
SHOP MANUAL SECTION 3-13 .-
13
A t f r o n t of t h i r d extension, c u t t i e w i r e s , remove
four ( 4 ) cap screws and flatwashers.
15
I f hose guard assembly has not previously been re-
moved, loosen n u t on c y l i n d e r anchor weldment pin,
and remove hose guard assembly.
-5-
16
Remove f o u r ( 4 ) cap screws and lock washers t h a t
r e t a i n dual crowd c y l i n d e r t o t h i r d boom extension.
'X
17
iemove f i v e ( 5 ) f e r r y head cap screws from flow
Ai vider valve. DC not Lose t 5 r e e 1 3 ) &rings
:jetween vaive and eiteek v a l v e .
18
?:move c y l i n d e r anchor weldment by removing two
Di 11s
-6-
21
Remove nuts from two ( 2 ) f r o n t p i s t o n rod anchor

pins.
-7-
22
Using brass d r i f t , remove anchor pins I
23
Remove lower wear p l a t e s .
S l i d e dual crowd c y l i n d e r o u t of fourth extension.

Lower i n t o block and l o c a t e balance p o i n t .
-a-
SHOP MANUAL SECTION 30 1.3
25
Lower c y l i n d e r i n t o ground with valve end near r i g h t
f r o n t o u t r i g g e r of crane.
Reinstall flow d i v i d e r
connectors a n d tubes.
I n s t a l l hoses and t e s t
-9-
DISASSEMBLY OF D U A L CROWD CYLINDER
27
Disconnect hoses, remove flow d i v i d e r valve, t h r e e

( 3 ) O- rings, and overcenter check valve with t h r e e
( 3 ) 0-ri ngs .
28
Remove spacer block and t h r e e ( 3 ) O-rings.
29
Remove four ( 4 ) socket-head cap screws and lock

washers beneath spacer block t h a t r e t a i n s cylinder
a a r r e l t o adapter p l a t e .
-10-
Flu
SHOP MdNUAL SECTION 3-13
30
At other end of cylinder assembly, remove roller
assembly.
31
Separate cylinders with suitable tools using extreme
care not to damage base of cylinders.
32
The dual cylinders and tube assembly are shown
separated, ready for further disassembly. The
remainder o f the disassembly sequence is shown for
one of the two cylinders only, since procedure i s
identical for both.
-11-
33
Remove s e t screw from clamping r i n g . I n older

assemblies, remove brass plug o r nylon i n s e r t .
Never do u n i t s use brass plug o r i n s e r t and no
removal i s required.
34
iising spanner wrench supplied in crane tool k i t ,
remove clamping r i n g .
35
Secure blind end o f c y l i n d e r t o s u i t a b l e anchor o r
o b j e c t . Attach s l i n g t o piston rod using care not
t o damage chrome s u r f a c e of rod. Remove piston rod
and piston without placing bind o r s i d e load on
u n i t s , P r o t e c t gland and piston from damage during
removal.
Cl
- 1 2-
36
Remove p i s t o n rod l o c k n u t .
37
Remove p i s t o n washer.
38
Remove p i s t o n and p a c k i n g .
-1 3-
39
Remove p i s t o n washer.
40
Remove c y l i n d e r head.
41
Rtmove g l a n d and w i p e r - s c r a p e r .
-14-
REASSEMBLY O F D U A L CROWD C Y L I N D E R
P r i o r t o reassembly of c y l i n d e r , i t i s mandatory t h a t a l l
component p a r t s be thoroughly cleaned and c a r e f u l l y in-
spected f o r damage.
I t i s suggested t h a t a l l s e a l s , packings, wipers, O-rings
and back-up rings be renewed.
42
Note o r i e n t a t i o n of t h e polyurethane one-piece seal

packing. One s i d e i s p l a i n . The o t h e r s i d e has
l i p s with a n O-ring between.
43
I f t h e c y l i n d e r head does not have the l a r g e chamfer

shown, machine t h e chamfer to these s p e c i f i c a t i o n s .
- 1 5-
44
Inspect wiper- scraper and replace i f required. Lub-

r i c a t e wiper- scraper i n n e r l i p s and i n s t a l l gland
on piston rod. Use care not t o damage wiper- scraper
during i n s t a l l a t i o n .
45
I n s t a l 1 new O-ring on cy1 i n d e r head. Lubricate 0-
:.i ng .
46
i n s t a l l polyurethane one-piece seal packing in

c y l i n d e r head with l i p s toward shoulder i n s i d e head.
-16-
47
Apply l u b r i c a n t t o seal packing. I n s t a l l c y l i n d e r

head on p i s t o n r o d , u s i n g s o f t - h e a d m a l l e t .
48
Replace O - r i n g w i t h i n p i s t o n .
49
I n s t a l l new p i s t o n p a c k i n g w i t h l i p s o f p a c k i n g
away f r o m c e n t e r o f p i s t o n f r o m each s i d e . Use
p i s t o n washers t o r e t a i n p a c k i n g on p i s t o n .
- 17 -
FILE E
50
Lubricate O- ring w i t h i n piston. I n s t a l l piston w i t h

p a c k i n g and washers u s i n g c a r e n o t t o damage O - r i n g .
51
I n s t a l l piston rod lock nut. Torque t o 700 f t - l b s

(lubricated).
52
i..ubricate p i s t o n p a c k i n g and i n s i d e o f c y l i n d e r
::#irrel t h o r o u g h l y . C a r e f u l l y a l i g n p i s t o n and p i s t o n
rod w i t h c y l i n d e r b a r r e l .
- 1 8-
53
Use heavy soft- head m a l l e t t o s t a r t piston i n t o
c y l i n d e r b a r r e l . When a l l packings have been in-
s e r t e d i n t o barrel and alignment of rod and barrel
i s good, rod may then be pushed i n t o barrel by
various means. Insure t h a t blind end of c y l i n d e r
i s protected from damage during t h i s operation.
54
Lubricate O-ring on head. Tap head and gland i n t o

c y l i n d e r barrel with soft- head m a l l e t .
55
R e i n s t a l l clamping r i n g .
-1 9 -
FIE E
56
T i g h t e n c l a m p i n g r i n g w i t h s p a n n e r wrench s u p p l i e d
i n crane t o o l k i t .
57
On o l d e r u n i t s , i n s t a l l b r a s s p l u g o r n y l o n i n s e r t .
I n newer u n i t s , r e p l a c e s e t screw o n l y . R e c o n d i t i o n
o t h e r c y l i n d e r a t t h i s t i m e f o l l o w i n g procedure
f r o m s t e p 33 t h r o u g h s t e p 5 7 .
58
S e t t h i r d boom e x t e n s i o n on s i d e f o r use as f i x t u r e
t o reassemble cy1 in d e r components.
c1
-20-
59
P o s i t i o n c y l i n d e r s in proper r e l a t i v e position
leaving space between so t h a t tube assembly m i g h t
be i n s t a l l e d .
60
I n s t a l l new O-rings and back-up rings on c y l i n d e r

p i l o t s . Lubricate rings and make c e r t a i n n o burrs
e x i s t on c y l i n d e r ends.
61
I n s t a l l new O-rings and back-up rings on tube assem-
bly ends. I n s e r t tube assembly in space between
cylinders and i n s e r t one end o f tube assembly (two
tube ends) i n t o adjacent cylinder adapter p l a t e .
-21"
62
Align c y l i n d e r p i l o t with c y l i n d e r adapter p l a t e a t
r o l l e r end of dual c y l i n d e r assembly. Use two of
f o u r cap screws ( t h a t a r e used t o r e t a i n r o l l e r
support weldment t o adapter p l a t e ) t o a i d i n a l i g n -
ment.
63
I n s t a l l four ( 4 ) socket-head cap screws a t valve
end of dual c y l i n d e r assembly. Align a l l p i l o t s
and tube ends and begin t o draw t h e components
t o g e t h e r . Carefully complete t h e t i g h t e n i n g insur-
ing proper alignment of a l l components. Remove two
cap screws a t r o l l e r end of dual cylinder assembly.
64
I f s e r v i c e t o r o l l e r assembly i s required, remove
r o l l p i n s , support pin and r o l l e r from support weld-
'ncnt. Replace bearings i f r e q u i r e d . Reassemble in
reverse order a f t e r i n s e r t i n g two cap screws a n d
l o c k washers i n support weldment. Cap screws can-
n o t be i n s t a l l e d in two of four holes i f r o l l e r i s
in position.
-22-
F I L E L ~
SHOP MANUAL SECTION 3-A3
65
Lubricate bearings a t t h i s time regardless of

whether r o l l e r was serviced or not.
66
I n s t a l l r o l l e r assembly i n dual cylinder assembly.
67
I n s t a l l three ( 3 ) new O-rings in adapter p l a t e .

These O-rings d i f f e r s l i g h t l y in s i z e from other
s i x O-rings used i n mounting flow divider and
overcenter check valves.
-23-
FILE E
68
I n s t a l l spacer block with s i x ( 6 ) f e r r y head cap

screws and lock washers.
69
I n s t a l l t h r e e ( 3 ) O-rings i n overcenter check valve.

Attach valve with s i x ( 6 ) f e r r y head cap screws,
70
[ t i s t a l l t h r e e ( 3 ) O-rings i n flow d i v i d e r valve.

At.tach valve with f i v e ( 5 ) f e r r y head cap screws,
I n s t a l l adapter f i t t i n g s and t u b e s ,
-24-
FILE E
I N S T A L L A T I O N OF D U A L CROWD C Y L I N D E R I N C R A N E
71
Position cy1 inder assembly so t h a t valve end i s

a d j a c e n t t o r i g h t f r o n t o u t r i g g e r of crane. Connect
hoses and cycle valve t o purge a i r out of cy1 inder
assembly. When c y l i n d e r s extend and r e t r a c t smooth-
l y , completely extend and r e t r a c t cylinders t o
e f f e c t the r e l i e f valve s e t t i n g . I f any i r r e g u l a r i -
t i e s a r e observed, do not proceed u n t i l problem i s
diagnosed a n d r e c t i f i e d .
72
Leave piston rods extended no more t h a n s i x ( 6 )

inches a t each end. Detach hoses and remove flow
d i v i d e r valve.
73
Inspect r o l l e r s on fourth boom extension. Replace

i f required. Inspect wear p l a t e s and replace i f
required.
-25-
FILE E
I n s e r t dual crowd c y l i n d e r i n f o u r t h extension with

r o l l e r assembly towards head block.
75
9eolace lower wear p l a t e s in fourth extension before
cylinder i s completely i n s e r t e d . I n s t a l l lockwires.
76
Align c y l i n d e r rod and i n s t a l l anchor pins using

brass d r i f t . Secure pins with flatwashers and
lock nuts.
Any p a r t s o r o t h e r d e b r i s t h a t might f a l l i n s i d e
boom extension must be r e t r i e v e d .
-26-
77
A p p l y ample l u b r i c a n t t o wear p l a t e s on f o u r t h
extension.
78
The b a l a n c e p o i n t c e n t e r l i n e i s a b o u t 1 2 ' 6 " f r o m

t h e f r o n t s i d e o f t h e head b l o c k .
79
I n s e r t f o u r t h extension i n t h i r d extension.
-27-
FILE E
SHOP,MANUAL SECTION 3-13
80
I n s t a l l f o u r ( 4 ) cap screws and lock washers t h a t
secure c y l i n d e r assembly t o r e a r end of t h i r d exten-
sion.
81
i n s t a l l cy1 inder anchor weldment with two ( 2 ) anchor
: l i n s , flatwashers a n d locknuts. Tighten adequately.
82
i n s t a l l s i d e hlea rmlates a t f r o n t end of t h i r d ex-

t.ension. Proper clearance i s 1/8 inch centered.
The shims t h a t were previously a t t a c h e d o u t s i d e the
boorn extension a r e provided f o r necessary a d j u s t -
ment of wear p l a t e s . Those shims not used should
be reattached t o t h e o u t s i d e of t h e boom extension.
- 2t -
84
Hoist a t fourth extension u n t i l upper clearance be-

tween t h i r d and fourth extensions i s between 1/16"
t o 1/4". Rotate r o l l e r u n t i l contact i s made with
fourth extension.
85
Index cam p l a t e s t o n e a r e s t hole a n d i n s t a l l cap

screws and lock washers. Tighten r o l l e r s h a f t nuts
and indexing cap screws.
-29-
86
Lubricate t h i r d extension wearplates and i n s e r t

t h i r d and fourth extensions i n t o second extension.
a7
i n s t a l l shim p l a t e s between anchor weldment and
second extension. Use t h r e e ( 3 ) f e r r y head cap
screws and lock washers i n a l l b u t l e f t r e a r hole.
:J;e f e r r y head cap screw, lock washer a n d flatwasher
I n l e f t r e a r hole. Tighten a l l except l e f t r e a r
cap screw.
NOTE: Qllinder anchor 14 sectioz

boom) righter. capscrews frox
325 t o 350 ft. Zbs. torque (dry)
88
Ix!.all flow d i v i d e r valve w i t h t h r e e ( 3 ) O-rings

and f i v e ( 5 ) f e r r y head cap screws. I f valve i n s t a l -
l a t i o n i s n o t a c c e s s i b l e due t o piston rod extended
t o o f a r , r e f e r t o s t e p 89 before i n s t a l l i n g valve,
R2
-30-
89
Dual crowd c y l i n d e r may be collapsed by removing
pipe plug a t s i d e o f piston rod, and e l e v a t e boom.
When c y l i n d e r has collapsed t o point of a c c e s s ,
replace pipe plug i n piston rod. Proceed with
s t e o 88.
90
For ease of reassembly and f u t u r e s e r v i c e t o t h e
crane, i t i s highly recommended t h a t previous hose
guards be reworked according t o these s p e c i f i c a t i o n s .
I n no case should t h i s hose guard be omitted a t
reassembly.
91
I n s t a l l reworked hose guard between flatwasher and
anchor weldment on l e f t r e a r hole. Use socket
wrench and extension t o t i g h t e n cap screw.
-31 -
FILE E
92
I n s t a l l hoses on t r o l l e y sheaves and r e e v e on r e a r

a u i d e sheaves. A t t a c h hoses and c o n n e c t o r t u b e s t o
f l o w d i v i d e r v a l v e . Release t r o l l e y t o r e t e n s i o n
hoses. I f hoses a r e p r o p e r l y connected, p u s h i n g
c o n t r o l v a l v e l e v e r will e x t e n d s l i d i n g s e c t i o n s .
93
I n s t a l l s i d e w e a r p l a t e s a t f r o n t end o f second
extension. Proper clearance i s 1/8 inch centered.
The shims t h a t were p r e v i o u s l y a t t a c h e d o u t s i d e
t h e boom e x t e n s i o n a r e p r o v i d e d f o r n e c e s s a r y
a d j u s t m e n t o f w e a r p l a t e s . Those shims n o t used
s h o u l d be r e a t t a c h e d t o t h e o u t s i d e o f t h e boom
e x t e n s i o n . I n s t a l l cap screws, f l a t w a s h e r s
and 1 ockwi r e s .
94
H o i s t on f o u r t h e x t e n s i o n t o o b t a i n 1/16 t o 1 / 4
i n c h c l e a r a n c e between second and t h i r d e x t e n s i o n s
on t o p . R o t a t e r o l l e r u n t i l c o n t a c t i s made w i t h
t h i r d e x t e n s i o n . I n d e x cam p l a t e s t o n e a r e s t h o l e
and i n s t a l l cap screws and l o c k washers. T i g h t e n
r o l l e r s h a f t n u t s and i n d e x i n g c a p screws.
-32-
96
Reeve hook block f o r desired p a r t s of l i n e . Install

cable anchor wedge in socket.
97
Inspect wire rope.
Lubricate extension r o l l e r s and external wear s u r -
faces of boom extensions.
Cycle control valve t o void dual crowd c y l i n d e r of
any entrained a i r .
Check hydraulic tank d i p s t i c k , add approved o i l as
necessary.
-33-
GRADER 0
PLANER 0
ROLLER 0
CRANE /id
Shop Manual E - I 0.10
TCOMMERCIAL SHEAR-INGI
.....
APPLICA~B.LE~M~~~D..E.is-
...
I
S-E. R.-IACNM
L :I! E:RS2
90, 100, 110 & 125 05304 thru 08774 except

05330, 05335 & 05340
90A, 100A, llOA & 125A 05325 thru 08774 except 05328
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 04765 & Up
150 FA 07305 & Up
150P, 150T 01045 & Up
200FA 09401 & Up
CAUTION

GOOD WORKING ORDER.
EXTREME CAUTION TQ BE OBSERVED AT A L L TIMES TO PREVENT

INJURY.
CONTENTS Page
Torque Sheet . . . . . . . . . . . . . . . . . . . . . . . . Back o f Cover
Description & I d e n t i f i c a t i o n . . . . . . . . . . . . . . . . . . 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I n s p e c t i o n & Replacement . . . . . . . . . . . . . . . . . . . . -6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dresser Industries, Inc. Construction Equipment Division P.O. Box 647 Galion, OH 44833 U.S.A. c2
(419) 468-4321 Telex: 987430 Cable: Galiron
creased 1/3 for Non-Lubricated (Dry) Threads.
Grade 5 81 Grade 8
Grade 8
Thread Size (6 radial dashes on bolt or cap screw head)
7/16 . 20
9/16 . 18
785 1064
1 l/8 . 7 990
I110
1400
1550
i 830
1 1342
;%
2102
248 1
2 085 2827
2 430 3295
2 330 3901
3810 5166
5 760 a810
FILE E
-
DESCRIPTION & IDENTIFICATION
On 90, 100, 110 and 125 cranes from s e r i a l number
1254 t o 5304 and 150 cranes from s e r i a l number 2832
t o 4765 a Hydreco Winch Motor, on the l e f t , was
used.
On 90, 100, 110 and 125 cranes from s e r i a l number
5304 and u p and 150 cranes from s e r i a l number 4765
and u p a Commercial Shearing Winch Motor, on the
right i s used.
A conversion k i t may be obtained t o convert a l l cranes
l i s t e d above, from s e r i a l number 1254 and up t o the
new s t y l e Commercial Shearing Motor.
Figure 1
-1 -
FILE E
-
TROUBLE SHOOTING
Before disassembly procedures are followed, in this manual ,

trouble shoot the problems %encountered to be certain that
the winch motor is at fault.
Examples are 1 isted below:
A. WINCH DRIFTS WITH LOAD:
1. Winch brake cylinder push rod is under load or adjusted
too long.
2. One gallon per minute (gpm) flow regulator is plugged.
3. Crowd cylinder overcenter check valve is stuck open.
4. Winch brake needs burnishing or brake shoes have oil
on them.
B. WINCH CANNOT BE FEATHERED WHEN LOWERING LOAD:
1. Bottom spool in the anticavitation valve is stuck
open.
2. Top spool in the anticavitation valve is stuck open.
C. WINCH WILL NOT LOWER OR HESITATES BEFORE LOWERING:
1. Top spool in the anticavitation valve is stuck
closed due to foreign material.
D. WINCH LOWERS IN AN UNEVEN OR JERKY MANNER:
1. Top spool in anticavitation valve is "bouncing" back
and forth.
2. Winch brake drum is out of round.
E. WINCH WILL NOT LIFT LOAD:
1. Hook block is not reeved with sufficient parts of
1 ine.
2. Insufficient hydraulic pressure.
3. Winch motor cross line relief valve is stuck open.
4. Faulty winch motor.
If these steps have been adhered to as called out in Shop Manual
E-15 and winch motor has been found to be the probable cause
following are steps for disassembly and reassembly.
-2-
FILE E
DISASSEMBLY
Remove and plug anticavitation valve

sensor tube ( 1 ) , cross line re1 ief
valve drain tube ( Z ) , cross line
relief valve ( 3 ) .
Remove four ferry head cap screws
( a t t o p of anticavitation valve) and
anticavitation valve ( 4 ) .
NOTE: Do not Zose O-ring i n bottom of
anticavitation vaZve.
Figure 2
Remove and plug winch motor d r a i n tube

( 1 ) , flow regulator ( 2 ) and winch
brake tube ( 3 ) .
Figure 3
Remove four cap screws, lock washers

( 1 ) , junction block ( 2 ) and winch
motor return/supply hose ( 3 ) .
NOTE: Do not Zose O-rings a t t o p of
junction block and hose flange
halves.
Figure 4
-3-
NOTE: The pinion or driven gear side of
the motor housing i s .toward the
r i g h t of the mounting fZange and/or
drum housing..
This i s important t o remember a t
the time of reassembly.
Remove four cap screws and lock washers
( 1 ) , motor gasket and winch motor ( 2 ) .
Figure 5
Place motor in vise w i t h drive shaft

pointing down. Do n o t grip on any
machined surface. Index marks sections
of winch motor as shown.
Remove eight cap screws and washers (1 ) .
Remove p o r t end cover ( 2 ) .
Thrust plate ( 3 ) holding bearings ( 4 )
in place, will be removed with the cover.
Inspect bearings and ring seal ( 5 ) . Re-
move and replace if necessary.
Figure 6
Remove input (drive) gear and shaft

( 1 ) and pinion (driven) gear ( 2 ) .
Pry o f f gear housing ( 3 ) w i t h care ,
as t o n o t damage machined sur faces, i n -
spect gasket seals ( 4 ) .
Figure 7 -4-
SHOP MANUAL
Remove thrust plate ( 1 ) and pocket

seals ( 2 ) .
Inspect plate for wear pattern. If
wear i s in excess of suggested
tolerances on page 7 , replace.
Figure 8
Inspect r o l l e r bearings ( 1 ) , ring

seal ( 2 ) and check valves ( 3 ) . Replace
i f indicated.
Check valve (3A) gives motor clockwise

rotation. Check valve ( 3 8 ) gives
counterclockwise rotation. Check
valves in b o t h positions give b i -
directional rotation.
These check valves may be removed
with special tool on paqe 9.
Figure 9
With shaft end cover ( 1 ) repositioned

i n vise, remove snap ring ( 2 ) and
outboard bearing ( 3 ) .
NOTE: Do not g r i p cover on any
machined surface.
Figure 10
-5-
FILE E
-
Remove seal retainer (1 ) , O-ring (2)

and seal ( 3 ) with special tools 1 isted
on page 9.
Figure 11
INSPECTION & REPLACEMENT
GEAR HOUSINGS: Wear in excess of .005" cut-out necessitates replace-

ment of gear housing.
Place a straight-edge across bore. If a .005" feeler
gauge can slide under the straight-edge in the cut-
out area, replace housing.
Pressure pushes the gears against the housing on the
low pressure side. As the hubs and bearings wear, the
cut-out becomes more pronounced. Excessive cut-out
in a short period of time indicates excessive pressure
or oil contamination. If the relief valve settings
are within prescribed limits, check for shock pressures
or tampering. Withdraw oil sample, check it and tank
for dirt.
Where cut-out is moderate, .005" or less, housing
is in good condition and both parts are of the same
size, housing may be flopped over and reused.
-
GEARS : Any wear on gear hubs detectable by touch, or in
excess of .002" necessitates replacement. Scoring,
grooving, or burring outside diameter of teeth re-
quires replacement. Nicking, grooving, or fretting
of teeth surfaces also necessitates replacement.
-6-
DRIVE SHAFTS: Replace i f there i s any wear detectable by touch in
the seal areas or a t the drive coupling. (.002" wear
i s the maximum allowable).
Wear in the shaft seal areas indicates oil contamination.
Wear or damage t o splines necessitates replacement.
THRUST PLATES: The thrust plates seal the gear section a t the sides
of the gears. Wear here will a1 low internal sl i ppage,
t h a t i s , oil will bypass within the motor, (.002"
maximum wear i s allowable.)
Replace thrust plates i f they are scored, pitted or
eroded.
Check center of thrust plate where the gears mesh.
Erosion here indicates oil contamination.
Pitted thrust plates indicate cavitation or o i l
aeration.
Discolored thrust plates indicate overheating, probably
insufficient o i l .
BEAR1NGS : I f gears are replaced, bearings must be replaced.
Bearings should f i t into bore with a slight press
f i t . I f bearings can f a l l o u t , bore may be oversize.
SEALS & GASKETS: Replace a l l rubber or polymer seals whenever dis-
assembling pump. Include a l l O-rings, pocket seals
behind thrust plates, shaft seal and gasket seals.
CHECK VALVES: Examine small check valves in shaft end cover t o
make sure they are intact and functioning.
-7-
FILE E
-
Stone o f f a1 1 machined surfaces with a medium g r i t carbor-

undum stone. I f bearings have been removed, deburr bearincl
a
bores. Rinse parts i n solvent. Dry with-moisture-free -
compressed a i r and wipe with a cl ean, l i n t l e s s cloth before
starting reassembly.
All parts, with the exception of the outboard bearing, are
lubricated by the hydraulic oil i n the circuit. Particular
attention must be paid t o keep the oil in the circuit system
clean. Whenever there i s a motor failure and there i s reason
t o feel t h a t metal particles may be in the system, the o i l
must be drained, the entire system flushed clean, and any
f i l t e r screens thoroughly cleaned or replaced. New o i l
should be supplied for the entire system.
-8-
SHOP MANUAL
SPECIAL TOOLS
.375
ri
I
3.50-1
I
/-
.1875 DRILL
ROD
4.00
/
.375 DRILL ROD
/ Check valve tool-made from a

4.00" length of .375" drill rod.
.1875 The drawing gives detail for
making this handy tool .
1
-T
r
.126 +.OO5
Seal removal tool -can be easily made from an old

screwdriver. Heat the tip and bend as shown.
Grind off the tip to fit the notch behind the
shaft seal.
c
Seal retainer tool -it is bent from
a piece of .250" drill rod about
14.00" long. The ends are ground
to fit the holes in the seal retainer.
Dimensions are a guide and are not
critical .
-9-
FILE E
-
REASSEMBLY
I f removed, install ring seal, ( 2 ) . Insert

into bottom of drive gear bearing bore.
The notch in the ring seal must be visible.
Install roller bearings ( 1 ) .
Install check valves ( 3 ) i f replaced.
Screw in the new plug until one thread
of the hole i s visible. Peen around
the edge of the hole with a prick
punch t o secure.
Figure 1 2
C u t two new pocket seals ( 2 ) .344" long.

Grease these pocket seals and insert
into the middle slots in the thrust
plate ( 1 ) .
With the pocket seals down, place the
thrust plate over the bearings and t a p
with a soft hammer t o a b o u t .03 1 'I from
the machined surface.
C u t four new pocket seals a b o u t .438"
long. Push seal into each s l o t unti 1
they touch the r o l l e r bearings. Tap
the thrust plate down against the
machined surface. Use a sharp razor
blade t o trim exposed end square and
flush with the thrust plate.
Figure 13
-1 0-
FILE E
SHOP MANUAL SECTION
-
Instal 1 drive gear and shaft (1 ) and

driven gear (2).
Install gear housing (3) and gasket seals
(4) top and bottom.
NOTE: Make sure t h a t index marks
a l i g n on housing and s h a f t
end cover.
Squirt oil over the gears to provide
initial lubrication when pump is
started.
Figure 1 4
Install ring seal ( 5 ) into bearing bore

o f port end cover (2), if removed,
install roller bearings (4).
Following steps outlined in Figure 13
cut pocket seals and install thrust
plate (3).
Position port end cover aligning in-
dex marks and install eight cap screws
and washers (1). Torque diagonally
to 200 ft. pounds.
Figure 1 5
Coat the outside of the drive shaft seal with purple

Loctite Seal Retainer and press into seal retainer
with metal side down.
Grease and install O-ring on the seal retainer. Re-
position winch motor in vise with drive shaft point-
ing up. Install seal retainer, outboard bearing and
bearing retaining ring.
NOTE: Prior t o instaZZing seal and retainer i n t o s h a f t
end cover the d&ve shaft spZines are t o be
covered with shim stock or paper t o enswe t h a t
damage is not done t o seal.
-11-
SHOP MANUAL
Install new winch motor gasket. In-

s t a l l winch motor ( 2 ) with four cap
screws and lock washers ( 1 ) and torque
NOTE: When instaZZing, be c e r t a i n
t h a t t h e pinion o r d r i v e n gear
s i d e of t h e winch motor is to-
ward t h e r i g h t o f t h e mounting
fZange and/or t h e d r i v e n hous-
ing.
Figure 1 6
Instal 1 flange ha1 ves( wi t h O-ring)

around supply/return hose from rotary
joint ( 3).
Insert four cap screws and lock washers
( 1 ) thrlough junction block ( 2 ) w i t h
O-ring .
Torque cap screws.
Figure 1 7
Remove plugs and install winch

brake tube (3), flow regulator ( 2 )
and winch motor d r a i n tube ( 1 ) .
Fi<pure 18
-1 2-
With O-ring in place a t bottom of
anticavi tation valve (4) instal 1
valve w i t h four ferry head cap screws
and torque t o 40 t o 50 f t . 1 bs. (dry)
or 35 f t . 1bs. (lubricated).
Remove plugs and instal 1 cross 1 ine
re1 ief valve ( 3 ) , cross 1 ine re1 ief
valve tube ( 2 ) and anticavitation
valve sensor tube (1 ).
Figure 1 9
-1 3-
GRADER 0
PLANER 0
ROLLER 0
CRANE d
Shop Manual E 4 1.30

c2
S W I N G DRIVE HYDRAULIC M O T 0
(COMMERCIAL SHEARING)
APPLICABLE
1.,.. MODELS .SERIAL NUMBER9
~.
90 thru 125 04908 thru 08774

90A thru 125A 04908 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
125P, 150P & 150T 01 078 , 01 080, 01 083 ,
01153 & Up
140F 07571 thru 08774
150A 04908 & Up
150F 07305 & Up
180s 08502 & Up
200FA 09401 & Up
220A 07107 & Up
220s 07724 & Up


GOOD WORKING ORDER.
EXTREME CAUTION TO BE QBSERVED A T A L L TIMES TO PREVENT

INJURY.
CONTENTS Page
Torque S h e e t . . . . . . . . . . . . . . . . . . . . . Back-TCover
Swing Drive H y d r a u l i c Motor Removal . , . , . . . e 1
Swing Drive H y d r a u l i c Motor Disassembly . . . . . . . 2
Cleaning. . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . 6
Swing Drive H y d r a u l i c Motor Reassembly . e . . . 7
.
Swing Drive H y d r a u l i c Motor I n s t a l l a t i o n , . . 11
S t a r t - u p Procedure . . . . . . . . . . . . . . . . . .
e e
12
S p e c i a l Tools . . . . . . . . . . . . . . . . . . . . 13
1082 LL
NOTE: Toraue Values listed throltghout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size T Foot Pounds

(Ft Lbs.)
Grade 5
(3 radial dashes on bolt or caD screw head)

Newton Meters Foot Pounds
(Ft Lbs.)
Grade 8
16 radial dashes on bolt or cao screw head)
Newton Meters
(Nm) (Nm)
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 - 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 - 16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 . 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
518 - 11 115 156 165 224
5/8 . 18 130 176 185 251
314 - 10 205 278 290 393
3/4 . 16 230 312 320 434
718 9 305 414 455 617
7/8 - 14 335 454 515 698
1. 8 455 617 695 942
1 - 14 510 691 785 1064
1 1/8 - 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 114 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 2481
1 318 - 12 1290 1749 2 085 2827
1 1/2 - 6 1500 2034 2 430 3295
1 1/2 . 12 1690 2291 2 730 3701
1 3/4 . 5 2 370 3213 3810 5166
2 4 1/2 3550 4813 5 760 7810
FILE E
SWING DRIVE HYDRAULIC MOTOR REMOVAL
The following procedure i s only one method of obtaining a complete removal of the
swing drive hydraulic motor from a l l cranes l i s t e d on cover page.
Disconnect and remove hoses ( 1 and 2 ) and

adaptors ( 3 and 4 ) from motor ( 5 ) . Tag
hoses and p l u g .
Disconnect and remove 1 i n e , el bow and con-
nector from motor ( 5 ) a t location ( 6 ) . P l u g '
line.
Remove four capscrews and lockwashers ( 7 )
and motor ( 5 ) from swing drive ( 8 ) .
-1 -
FILE E
SWING DRIVE HYDRAULIC MOTOR DISASSEMBLY
The following procedure i s only one method of o b t a i n i n g a complete disassembly of the

swing drive hydraulic motor.
Clean a l l d i r t and o i l from motor ( 1 )

being careful t o keep any contamination
o u t of motor's i n t e r i o r . Position motor
i n a soft jaw vise and match mark as
shown.
Remove four capscrews and washers ( 2 ) and
p o r t end cover (3) from motor ( 1 ) .
Figure 2
Remove two r o l l e r bearings ( 1 ) and ring

seal ( 2 ) from p o r t end cover ( 3 ) i f
replacement i s necessary.
Figure 3
-2-
FILE E
Remove s i x pocket s e a l s ( 1 ) from thrust

p l a t e ( 2 ) and seal (3) from gear housing
(4)-
Remove gear housing ( 4 ) from s h a f t end
cover ( 5 ) .
Figure 4
Remove s i x pocket s e a l s ( 1 ) from thrust

p l a t e ( 2 ) and seal ( 3 ) from gear housing
(4) *
Use s o f t face hammer and t a p gear s h a f t s
( 5 and 6 ) on the other end t o remove
thrust p l a t e ( 2 ) and gears from gear
housing ( 4 ) . Remove remaining t h r u s t
p l a t e from gear housing.
Figure 5
Remove two bearings ( 1 ) and ring seal

( 2 ) from s h a f t end cover ( 3 ) i f rep1 ace-
ment i s necessary.
Use special t o o l ( s e e special tools sec-
t i o n of t h i s manual f o r manufacturing
of tool ) and remove two check valve
assemblies ( 4 ) from s h a f t end cover ( 3 ) .
Figure 6
-3- C’
FILE E
Remove snap ring bearing ( Z ) , seal

retainer (3) and (4) from s h a f t
end cover (5).
Figure 7
-4-
FILE E
CLEANING
A. Clean a l l metal p a r t s thoroughly using a s u i t a b l e type cleaning

fluid.
NOTE: Be careful n o t t o use a solvent on the t h r u s t p l a t e s
t h a t has an adverse e f f e c t on bronze.
I t i s recommended t h a t p a r t s being immersed in cleaning f l u i d

be moved u p and down slowly until a l l hydraulic o i l and foreign
material i s dislodged and parts a r e thoroughly cleaned.
B.
A
CAUTION
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE
HAZARDS AND INHALATION OF VAPORS WHEN USING SOLVENT
TYPE CLEANERS.
Clean bearings i n a s u i t a b l e type cleaning f l u i d . Follow

cleaning i n s t r u c t i o n s mentioned in paragraph " A " .
- 5-
FILE E
INSPECTION
A. Gear Housing: Wear in excess o f . 005" cut- out n e c e s s i t a t e s replacement of the

gear housing.
Place a straight- edge across the inside bores a t various locations. If-you can
s l i p a .005" f e e l e r gauge under the straight- edge in t h e cut-out a r e a ( s ) , replace
t h e gear housing.
Presssures push the gears against the housing on the systems working i n l e t sides.
As the hubs and bearings wear, the cut-out becomes more pronounced. Excessive
cut-out in a s h o r t period of time indicates excessive pressure or o i l contamina-
t i o n . I f the r e l i e f valve s e t t i n g s a r e within presecribed l i m i t s , check f o r
shock pressures or tampering. Withdraw o i l sample and check i t and t a n k f o r d i r t .
B. Gears: Any wear on gear hubs detectable by touch, or in excess of .002" neces-
s i t a t e s replacement. Scoring, grooving, or burring of outside diameter or teeth
requires replacement. Nicking, grooving or f r e t t i n g of t e e t h surfaces also
necessitates replacement.
C. Drive Shafts: Replace i f there i s any wear detectable by touch on t h e seal areas
or a t drive coupling. .002" wear i s t h e maximum allowable.
Wear in the shaft seal area indicates o i l contamination. Wear or damage t o
s p l i n e s , necessitates replacement.
D. Thrust Plates: The t h r u s t plates seal t h e gear section a t the s i d e s of the gears.
Wear here will allow internal slippage, t h a t i s , o i l will bypass within the pump.
.002" maximum wear i s a1 1 owabl e . Replace t h r u s t p l a t e s i f they a r e scored , eroded
or p i t t e d .
Check center of thrust p l a t e where t h e gears mesh. Erosion here indicates o i l
contamination.
P i t t e d t h r u s t p l a t e s indicate c a v i t a t i o n or o i l a e r a t i o n .
Discolored thrust plates indicate overheating, probably i n s u f f i c i e n t o i l .
E. Bearings: If gears a r e replaced, bearings must be replaced. Bearings should f i t

i n t o bore with a l i g h t press f i t . A neat hand f i t i s allowable. I f bearings can
f a l l o u t , bore may be oversized.
F. Seals: Replace a l l rubber and polymer s e a l s whenever disassembling pump. Include
a l l pocket s e a l s behind t h r u s t p l a t e s , s h a f t seal and housing s e a l s .
- 6-
L
FILE t
SWING DRIVE HYDRAULIC MOTOR REASSEMBLY
The following procedure i s only one method of obtaining a complete reassembly of the
swing drive hydraulic motor.
I n s t a l l seal ( 4 ) , seal r e t a i n e r ( 3 ) ,
bearing ( 2 ) and snap ring ( 1 ) in s h a f t
end cover ( 5 ) .
Figure 8
Use special tool and i n s t a l l two check

valve assemblies ( 4 ) in s h a f t end cover
( 3 ) i f removed a t disassembly.
I n s t a l l ring seal ( 2 ) and two bearings

( 1 ) in s h a f t end cover ( 3 ) i f removed a t
disassembly.
NOTE: Notch i n r i n g seal shouZd be
v i s i b l e . T h i s i s a check t o be
c e r t a i n t h a t the notch is n e x t
t o bearing. Arbor press may be
needed to i n s t a l l bearings.
Figure 9
-7-
FILE E
SHOP MANUAL SECTION 11.30.
C u t two pocket s e a l s (1 ) f o r center

notches of t h r u s t p l a t e ( 2 ) .
NOTE: A l i g h t coating o f grease wiZZ
hold s e a l s i n place. Order
a pocket seal s t r i p #D-101399
for each t h r u s t p l a t e .
Figure 1 0
Using sof t face hammer position t h r u s t

p l a t e (1 ) on s h a f t end cover ( 2 ) over
bearings and s e a t firmly.
Push poc ket seal s t r i p ( 3 ) i n t o notches
o f thrus t p l a t e ( 1 ) and against bearings .
C u t w i t h a sharp knife or razor blade.
Figure 11
Position s e a l s ( 1 ) in each side of gear

housing ( 2 ) .
NOTE: Use grease t o hold s e a l s i n place.
Figure 1 2
-8-
SHOP MANUAL
Position special tool over splined s h a f t

of gear ( 1 ) t o protect seal in s h a f t end
cover (3) when i n s t a l l i n g gears ( 1 & 2 )
in place on t h r u s t p l a t e .
N0TE:See speciaZ t o o l s i n t h i s manual
f o r manufacturing of tool.
Align match marks and s l i d e gear housing

( 4 ) over gears ( 1 & 2 ) and t h r u s t p l a t e .
Figure 13
Position ring seal ( 2 ) and two r o l l e r

bearings (1 ) in p o r t end cover ( 3 ) i f
removal was necessary.
NOTE: Notch i n r i n g seal should be
v i s i b l e . This i s a check to
be c e r t a i n t h a t t h e notch i s
n e x t t o t h e bearing. Arbor
press may be needed t o i n s t a l l
bearings i n cover.
Figure 1 4
I n s t a l l pocket s e a l s in center notches

o f thrust p l a t e ( 1 ) . (See Figure 1 0 ) .
Using s o f t face hammer position thrust
p l a t e ( 1 ) on port end cover ( 2 ) over
bearings and s e a t firmly.
Push pocket seal s t r i p ( 3 ) into notches
of t h r u s t p l a t e ( 1 ) and against bearing S.
C u t with a sharp knife or razor blade
flush with t h r u s t p l a t e .
Figure 1 5
-9-
SHOP MANUAL
Align match marks and position port end
cover (3) on motor ( 1 ) and install four
washers and capscrews (2).
NOTE: Snug up capscrews and turn drive
shaft t o check f o r binding. If
no binding i s detected tighten
capscrews t o 200 FT. LBS. If
binding e x i s t s , check alignment
of parts.
After assembly is completed, fill pump

with proper hydraulic oil (see Shop
Manual J-1 for proper hydraulic oil
specifications) to lubricate pump be-
fore installation.
Figure 16
-1 0-
FILE E
SWING DRIVE HYDRAULIC MOTOR INSTALLATION
The following procedure is only one method of obtaining a complete i n s t a l l a t i o n o f

the swing drive hydraul i c motor on a l l cranes 1 i s t e d on the cover page.
A l i g n splined s h a f t o f motor ( 5 ) with

swing drive ( 8 ) and position together.
I n s t a l l four lockwashers and capscrews
( 7 ) in swing drive ( 8 ) .
Unpl ug , i n s t a l 1 and reconnect connector,
el bow and 1 ine t o motor ( 5 ) a t location
(6).
I n s t a l l ada.ptors ( 3 and 4 ) in motor ( 5 ) .
Unplug hoses ( 1 and 2 ) and reconnect t o
adaptors.
Figure 1 7
-11-
r
FILE t
START-UP PROCEDURE
After the i n s t a l l a t i o n i s completed, operate the motor a t l e a s t

two minutes under a no l o a d condition (no load on boom) a t the
lowest possible engine rpm. During t h i s break-in period, the unit
should run f r e e and not develop an excessive amount of heat. Run
u n i t i n both directions being sure t h a t the boom r o t a t e s in the
direction t h a t the control lever i s held in. I f the unit operates
properly, speed and pressure can then be increased t o normal
operating conditions.
-1 2-
FILE E
SPECIAL TOOLS
The special steel sleeve i s used t o insert the drive shaft t h r o u g h the oil seal with-
o u t damage and can be made from bar stock.
,375 RAD. B L E N D I N T O
1.065 D I A .
‘I-
4.500
3.375
P’ POSITION S L E A V E O V E R
SPLINED SHAFT TO
P R O T E C T SEAL
MATL. - C O L D ROLLED STEEL
-1 3-
c
FILE t
The check v a l v e t o o l i s made f r o m d r i l l r o d s and i s used t o remove and i n s t a l l t h e

check v a l v e assemblies i n t h e s h a f t end c o v e r .
-b 3.500 c
t- c .375
r .375 D R I L L ROD 4.000
18' i .312
-.126 t.005
-.ooo
C- .310
t.000
-.005
-1 4-
GRADER 0
PLANER 0
ROLLER 0
CRANE M
SHOP MANUAL E-12.01

RVC3
TANDEM PUMP
COMMERCIAL SHEARING %STAMPING
I TANDEM HYDRAULIC PUMP MODEL 25X
ApPLlCABLE MODEUS SERIAL NUMBERS

Part fD-72989
80 01710 thru 03131
90, 100, 110 & 125 01254 thru 08774
90A, 100A, llOA & 125A 01254 thru 08774
125F 07247 thru 08774
1 25FA 07990 thru 08774
140F 07571 thru 08774
150A 02832 & Up
150FA 07305 & Up
220A 07107 & Up
Part #D-90654
125P & 150P 01001 & u p
1 50T 01001 & up
A1 1 parts contained in the two tandem pumps (D-72989 and D-90654) are
identical. The only differences is the direction of rotation and the
location o f the inlet and outlet ports.
7CAUTION
REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING
ORDER.
CONTENTS
End Cover Removal . . . . . . . ................. 1
Gear Housing Removal . . . . . . . . . ............. 4
Drive & Driven Gear Removal . .. . . . ............. 5
Disassembly o f Shaft End Cover. . . . ............. 6
Disassembly of Shaft Assembly .. . . . ............. 8
Disassembly o f Bearing Carrier. . . . ............. 10
.
Reassembly . . . . . . . . . . . . . ............. 11
Test Procedure for Rebuilt Pump. . . . ............. 21
Torque Sheet . . . . . . . ... . . . ............. 22
386 c.3
WEAR CONSIDERATIONS IN CS & S PUMPS
GEAR HOUSINGS :
Wear i n excess of .005" cutout necessitates replacement.
GEARS :
Any wear on hubs detectable by touch, or i n excess of .001 "
requires replacement. Scoring, grooving or burring of out-
side diameter of teeth requires replacement. Any nicking,
grooving, scoring or fretting of teeth surfaces requires
repl acement.
BEARINGS:
I f gears are repl aced, bearings must be replaced. Bearings
must f i t i n bore w i t h l i g h t press f i t . I f bearings can f a l l
out -- bore i s over size.
THRUST PLATES:
Replace i f scored, eroded , pitted or i f wear exceeds ,002".
DRIVE SHAFTS:
Replace i f wear pattern i s detectable by feel i n seal area or
a t drive coup1 i ng. .001 I' maximum wear a1 lowable.
Replace a1 1 rubber and polymer seals when pump i s disassembled.
Including a l l O-rings, pocket seals, low pressure seals and
gaskets, i f used.
Examine small check valves i n shaft end over t o make sure they
are intact and functioning.
3658
-0-
43
No. Description 40 Thrust Plate -___---- 58 Pocket Seal --

1 Retainer Ring - - 41 "0"Ring Gasket 59 Thrust Plate
2 Seal Retainer 4 2 Gear Housing 60 Connecting Stud -
.-
3 Double Lip Seal

~~
43 "0"Ring Gasket 61 Lock Nut
4 "0" Ring 44 Drive Gear ~ 62 "0"Ring Gasket -____
5 Bearing Cup ___ 45 Driven Gear - 63 Gear Housing - -
6 Tapered Bearing 46 Thrust Plate 64 "0"Ring Gasket - ~ -
43 Pocket Seal 65 Drive Gear
9 Shaft End Cover
14 Drive Shaft -- - 48 Roller Bearings ___--- 66 Driven Gear
15 Spacer 49 Spacer - - 67 Thrust Plate
32 Drive Shaft - 50 Roll pin ~ ~- 68 Pocket Seal
33 Snap Ring Retainer
~
51 Shaft Bushing 69 Roller Bearings -
34 Snap Ring 52 Bearing Carrier 70 Port End Cover
35 Check Valve - - 53 Connecting Shaft 71 Washer
36 Bronze Shaft Bushing ___ 54 Spacer ~
72 Stud -___
37 Conical Spring ~ _ _ - 55 Roll Pin 73 Hex Nut -
38 Roller Bearings 56 Shaft Bushing 74 Nume Plate
39 Pocket Seal 57 Roller Bearinjs 75 Drive Screws - - ~
-00-
FILE: E
SECTION: 1 2 . 0 1
W i t h small punch, unstake threaded r e t a i n e r

ring (1).
J i t h s p a n n e r w r e n c h , r e l e a s e p r e l o a d on
b e a r i n g by t u r n i n g t h r e e f u l l t u r n s .
WARN I N G : T h i s m u s t b e d o n e b e f o r e any s e r v i c e
w o r k i s p e r f o r m e d o n t h e pump.
I n d e x m a r k e a c h s e c t i o n o f t h e pump.
3
Remove f o u r n u t s a n d w a s h e r s f r o m t h e s t u d s
-1 -
4
5
Remove " 0 " r i n g g a s k e t .
6
Remove t h r u s t p l a t e and p o c k e t s e a l s ( 1 ) from
g e a r housing o r end c o v e r .
-2 -
FILE: -E
SECTION: 12.01
7
L i f t d r i v e and d r i v e n gears o u t o f gear
housing.
Remove f o u r s t u d s by d o u b l e n u t t i n g .
P r o t e c t i n p u t s h a f t and h o l d w i t h wrench
( n o t shown).
Remove l o c k n u t f r o m c o n n e c t i n g s t u d .
-3-
FILE: - E
SECTION: -12.01
---
_II--
I
10
Remove c o n n e c t i n g s t u d ( 1 1 , s p a c e r ( 2 ) a n d
connecting shaft (3).
11
Remove g e a r h o u s i n g .
12
I f t h r u s t p l a t e was n o t r e m o v e d w i t h g e a r
h o u s i n g , do s o u s i n g p o c k e t k n i f e o r t h i n
putty knife.
-4-
FILE: 2
SECTION:'%
13
Remove b e a r i n g c a r r i e r .
k A,'
14
Remove " 0 " r i n g g a s k e t .
15
Remove d r i v e a n d d r i v e n g e a r .
Keep t h e s e g e a r s t o g e t h e r - - t h e y a r e a matched
set.
-5 -
FILE: -E
SECTION: -
12.01
--
16
Remove g e a r h o u s i . n g .
OISASSEMBLY O F SHAFT END C O V E R :
17
I f t h r u s t p l a t e was n o t r e m o v e d w i t h g e a r
housing, remove.
18
Remove r e t a i n e r r i n g .
-6-
FILE: - E
SECTION:
19
L i f t s h a f t assembly o u t .
20
Bearings must be r e p l a c e d i f t h e y a r e r e -
moved.
Use p u l l e r t o remove b e a r i n g s f r o m s h a f t
end cover.
-7-
FILE: E
-
SECTION: G
O 1 - --
22
Remove b r o n z e s h a f t b u s h i n g .
23
I f check v a l v e s a r e t o be removed, use

t h i n s c r e w d r i v e r and unscrew each v a l v e
from s h a f t end cover.
DISASSEMBLY O F SHAFT ASSEMBLY:
24
P l a c e s h a f t i n v i s e , h a v i n g s o f t jaws, and
remove Tru- Arc snap r i n g .
FILE: - E
SECTION: U 1
25
Remove s p a c e r .
26
P u s h s e a l r e t a i n e r a n d " 0 " r i n g down.
I n s t a l l p u l l e r a n d pull taper r o l l e r bearing.
-9 -
FILE: -E
SECTION: 1 2 . 0 1 _I__(
za
D I S A S S E M B L Y OF B E A R I N G C A R R I E R :
~.
29
I f t h r u s t p l a t e i s on c a r r i e r - - r e m o v e .
30
P u l l c o n n e c t i n g s h a f t b e a r i n g on each s i d e
of carrier.
-10-
FILE: - E
SECTION: 12.01
31
Remove s h a f t b u s h i n g from each s i d e .
32
Remove r o l l p i n ( 1 ) u s e d t o l o c a t e s h a f t
bushing.
ASSEMBLY:
When i n s t a l l i n g t h r u s t p l a t e s and g e a r
h o u s i n g u s e I n d i a s t o n e t o remove n i c k s
and b u r r s t h a t may be p r e s e n t due t o
handling.
Oil thrust p l a t e s , b e a r i n g , e t c . p r i o r t o
assembly t o provide i n i t i a l l u b r i c a t i o n a n d
p r e s e r v a t i v e i f u n i t i s placed in storage.
Pour o i l o v e r g e a r p a i r s when t h e y a r e i n
place.
Use c a r e d u r i n g a s s e m b l y n o t t o p i n c h " 0 "
rings, score bushings, e t c .
Use a p l a s t i c f a c e d hammer t o t a p h o u s i n g s
and b e a r i n g c a r r i e r s i n p l a c e .
S e e back o f f r o n t c o v e r , t h i s s e c t i o n , f o r
assembly c o n s i d e r a t i o n .
-11-
FILE: -E
SECTION: -
-
33
P r e s s new s e a l i n r e t a i n e r r i n g with l o n g
l i p toward inside.
-12-
FILE: -E
SECTION: - 12.01
-
36
With r e t a i n e r a n d " 0 " r i n g ( 1 on d r i v e
s h a f t , i n s t a l l b e a r i n g cup ( 2 a n d cone
( 3 ) on s h a f t .
P r e s s b e a r i n g cGn? o n s h a f t w i t h c a r e .
Searinq must he pressed p a s t re t a i n e r r i n s
3rcdve.
37
I n s t a l ? spacer ( 1 ) ( 1 5 / 8 " long) on srlaft

a n d retaining r i n g ( 2 ) on s h a f t and in
groove.
38
- 13 -
FILE: -E
SECTION: L O 1 I
39
I n s t a l l check v a l v e s i n end s h a f t c o v e r .
40
I n s t a l l bronze s h a f t - b u s h i n g s h o u l d e r up,
i n end s h a f t c o v e r i n d r i v e s h a f t b e a r i n g
pocket.
41
I n s t a l l conical s p r i n g ( 1 ) in bearing
pocket, l a r g e diameter u p .
Position bearing in pocket.
-1 4-
FILE: - E
SECTION:
42
P r e s s b e a r i n g i n s h a f t end c o v e r .
- 15 -
FILE: -E
SECTION: L O 7 -
45
I n s e r t pocket s e a l s i n t o remaining four s l o t s
and against bearing.
T a p t h r u s t p l a t e i n t o p o s i t i o n and c u t o f f
excess material f l u s h with t h r u s t p l a t e .
46
I n s t a l l "0" r i n g i n grooves on b o t h s i d e s
of g e a r h o u s i n g .
Check a l i g n m e n t marks and p o s i t i o n g e a r
h o u s i n g o v e r t h r u s t p l a t e and a g a i n s t s h a f t
end c o v e r .
P l a c e s p a c e r ( 1 ) ( 1 5.18'' l o n g ) on end of
drive shaft.
47
I n s t a l l d r i v e g e a r ( 1 ) and d r i v e n g e a r ( 2 ) .
-16-
FILE: - E
SECTION: 12.01
48
I n s t a l l b e a r i n g i n d r i v e n gear s i d e O F
bearing c a r r i e r .
49
Replace r o l l pin ( 1 ) i f p r e v i o u s l y removed

from b e a r i n g c a r r i e r .
I n s t a l l s h a f t bushing ( 2 ) with l a r g e d i a -
meter o u t a n d with s l o t i n bushing over
r o l l pin.
P r e s s r o l l e r b e a r i n g in b e a r i n g c a r r i e r
Repeat above assembly procedure f o r o t h e r
s i d e of bearing c a r r i e r .
50
P l a c e pocket s e a l s i n t h r u s t p l a t e ( a s
outlined in paragraphs 44 & 4 5 ) .
With t h r u s t p l a t e in p o s i t i o n o n b e a r i n g
c a r r i e r , check index marks a n d i n s t a l l
a g a i n s t gear housing.
- 17 -
FILE: -E
SECTION: L O 1 -
51
I n s t a l l t h r u s t plate w i t h pocket seals i n

bearing carrier.
52
Assemble c o n n e c t i n g s t u d ( 1 ) , soacer ( 2 )
( 7 / 8 " l o n g ) and c o n n e c t i n g s h a f t ( 3 ) .
Use L o c k t i t e S e a l a n t on e n d o f b o l t b e f o r e
threading.
I n s t a l l i n pump t h r o u g h s h a f t b u s h i n g s
( S e e p a r a g r a p h 4 9 ) a n d pump g e a r , e t c .
T u r n c o n n e c t i n g s t u d i n t o pump d r . i v e s h a f t
several revolutions.
I n s t a l l l o c k n u t - - D O NOT T I G H T E N .
53
Hold drive shaft, tighten shaft connecting

bolt nut.
I f g e a r s a r e n o t i n p a l c e when t h i s i s done
be s u r e s p a c e r i s c e n t e r e d s o g e a r can
s l i p over it.
- 1 8-
FILE: - E
SECTION: - L O 1
54
I n s t a l l gears and studs.

P l a c e " 0 " r i n g i n groove i n g e a r housing.
55
Assemble b e a r i n g s , t h r u s t p l a t e a n d p o c k e t
s e a l s t o end c o v e r .
I n s t a l l end c o v e r .
56
I n s t a l l w a s h e r s a n d n u t s o n end c o v e r .
S h a f t s h o u l d be e a s i l y r o t a t e d by h a n d or
with a 6 " wrench.
Tighten nuts t o 200 f t . l b s . t o r q u e .
-19-
FILE: -E
SECTION: 12.01
57
Tighten the retainer r i n g (1) with a p i n type
wrench u n t i l i t i s t i g h t o r i s snug.
S c r i b e a l i n e f r o m t h e s h a f t a c r o s s ret3.i!lc:f\
r i n g and across t h e p i l o t face.
Measure 1 / 2 " a l o n g o u t e r edge o f retainer

and s c r i b e a l i n e .
Loosen r e t a i n e r u n t i l second s c r i b e mark

a l i g n e d w i t h mark on p i l o t .
T h i s will p r o v i d e . 0 0 5 " running c-earance

f o r bearing.
58
Stake o u t e r edge o f r e t a i n e r i n t o groove i n

pilot.
T h e plrmp i s now r e a d y f o r t e s t s t a n d r u n i n
-20-
FILE: -E
SECTION: 12.0’
TEST PROCEDURE FOR REBUILT PUMP

Make c e r t a i n t h e r e i s an adequate supply o f o i l f o r t h e pump, a t l e a s t
one g a l l o n o f o i 1 f o r each gpm o f pump c a p a c i t y .
I f o n l y one s e c t i o n o f t h e tandem pump i s b e i n g t e s t e d , make c e r t a i n
t h a t a l l o t h e r s e c t i o n s n o t being t e s t e d a r e adequately s u p p l i e d w i t h
o i l . I f any o f the s e c t i o n s r u n d r y , o r i f p l u g s a r e l e f t i n p o r t s ,
s e r i o u s and permanent damage w i
l result.
The o i l must be a good q u a l i t y h y d r a u l i c o i l r a t e d a t 150 SSU a t lOOOF.,

w i t h t h e o i 1 temperature he1 d a t 120OF. p l u s o r minus 5OF.
The supply l i n e must be o f adequate s i z e w i t h no more than 2 1/2 inches

o f mercury vacuum a d j a c e n t t o t h e pump i n l e t . As a r u l e , t h e f e e d 1 i n e
must p r o v i d e a feed f l o w v e l o c i t y n o t t o exceed 8 f e e t per second.
DO NOT SUPPLY A COLD PUMP WITH HOT OIL OR THE PUMP MAY
SEIZE. I F I N DOUBT, JOGGING THE PUMP MAY PREVENT SEIZURE.
Operate pump from two t o f o u r minutes a t zero pressure a t a speed from

700 t o 800 rpm.
I f pump becomes h o t t o t h e touch, i t i s b i n d i n g and may seize. Seizure

o f pump is unl ik e l y, however i f i t does happen t h e pump must be d i s -
assembled and r e b u i l t , w i t h e x t r a c a r e taken t o b u r r s and t o assure
freedom from b i n d i n g .
G r a d u a l l y increase pressure on pump, i n t e r m i t t e n t l y , u n t i l d e s i r e d

t e s t pressure o r approximately 2,000 p s i has been reached. The
gradualy i n c r e a s e o f pressure should t a k e about f i f t e e n ( 1 5) minutes
t o compl e t e .
The f o l l o w i n g t e s t i n g values a r e f o r a1 1 main1 i n e cranes 90 t h r u 150

and a1 1 pedestal cranes.
A. While o p e r a t i n g a t 1200 rpm w i t h a pressure o f 2,000 p s i t h e f r o n t

pump s e c t i o n wil d e l i v e r approximately 24 gpm and t h e r e a r s e c t i o n
wil d e l i v e r 15 gprn.
B. While o p e r a t i n g a t 2,400 rpm w i t h a pressure o f 2,000 p s i t h e f r o n t

pump will d e l i v e r approximately 51 gprn and t h e r e a r s e c t i o n w il
del i v e r 31 gpm.
T e s t i n g values a r e f o r a new pump o r a r e b u i l t pump, when you have

replaced gears , gearhousing, t h r u s t p l a t e s and bearing. Any item
mentioned n o t being rep1 aced w i 11 reduce g a l 1onage o u t p u t .
-21 -
FILE: -E
SECTION: 12.01
HEAT TREATED MATERIAL SAE GRADE 5 & GRADE 8
NOTE: INCREASE VALUES 1/3 FOR DRY THREADS
GRADE 5 GRADE 8
(3 radial dashes on bolt or (6 radial dashes on bolt or
cap screw head) cap screw head)
Foot-Pounds Metric K g m Foot-Pounds Metric Kgm
1/4 - 20 6 0,8 9 192

1/4 - 28 7 0,9 11 1,5
5/16 - 18 13 198 18 23
5/16 - 24 I5 2,l 21 2,9
318 - 16 24 3,3 34 487
318 - 24 27 3,: 38 5,3
7/16 - 14 38 5 3 54 7,5
7/16 - 20 42 5,8 60 8,3
1/2 - 13 58 8,O 82 11,3
1/2 - 20 65 8,9 90 12,4
9/16 - 12 84 11,6 120 16,6
9/16 - 18 93 12,9 132 18,2
5/8 - 11 115 159 165 22,8
518 - 18 130 17,9 185 25,6
314 10- 205 28,3 290 40,1
314 16- 230 31,8 320 44,2
7/8 9 - 305 42,2 455 62,9
7/8 14- 335 46,3 515 71,2
1-8 455 62,9 695 96,1
-
1 14 510 70,s 785 108,5
1 1/8 7 - 61 0 84,3 990 136,9
1 1 / 8 - 12 685 94,7 1110 153,5
1 1/4- 7 860 118,9 1400 193,6
1 1 / 4 - 12 955 132,c 1550 214,3
1 3/8 6 - 1130 156,2 1830 253,0
1 3/8 12 - 1290 178,3 2085 288,3
11/2-6 1500 207,4 2430 335,9
1 1/2 12 - 1690 233,7 2730 377,4
1 3/4 5 - 2370 327,7 3810 526,8
-
2 4 1/2 3550 4 s ,8 5760 796,3
-22-
GRADER 0
PLANER 0
ROLLER 0
CRANE d
Shop Man.ual E - I4
R 4 ic-Z
S W I N G COUNTERBALANCE VALVE
(GALION PART NO. 893621

80 01710 thru 03131
90 thru 125 01001 thru 08774
125F 07247 thru 08774
140F 07571 thru 08774
90A thru 125A 02006 thru 08774
125FA 07990 thru 08774
150A 02832 & Up
1 50FA 07305 & Up
125P, 150P & 150T 31001 & up
180s 08502 & Up
200FA 09401 & up
220s 07724 & Up
CAUTION

GOOD WORKING ORDER.

INJURY.
CONTENTS Page
Torque Sheet . . . . . . ............... Backofcover
Introduction . . . . . . ............... 1
Removal . . . . . . . . ............... 4
Disassembly . . . . . . ............... 5
Cleaning and Inspection . . . . . . . . . . . . . . . 8
Reassembly . . . . . . ............... 9
Installation . . . . . . ............... 12
Dresser Industries, Inc. Construction Equipment Division P.O. B OX 647 Galion, OH 44833 U.S.A.
(419)468-4321
c2
NOTE: Torque Values listed th ghout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size i Grade 5

(3 radial dashes on I
Foot Pounds
( F t Lbs.)
I Grade 8
It or cap screw head)
Newton Meters
1/4 . 20 6 12
1/4 . 28 7 15
5/16 - 18 13 24
5/16 . 24 15 28
3/8 - 16 24 46
3/8 . 24 27 52
7/16 . 14 38 73
7/16 . 20 42 81
1/2 . 13 58 111
1/2 . 20 65 122
9/16 - 12 84 163
9/16 18~ 93 179
518 . 11 115 224
5/8 . 18 130 251
3/4 - 10 205 393
3/4 - 16 230 434
718 . 9 305 617
7/8 - 14 335 698
1 - 8 455 942
1 14~ 510 1064
1 1/8 - 7 610 1342
1 1/8 - 12 685 1505
11/4- 7 860 1898
1 1/4 - 12 955 2102
1 3/8 - 6 1130 248 1
1 318 - 12 1290 2827
11/2- 6 1500 3295
1 1/2 - 12 1690 3701
1 3/4 - 5 2370 5166
2 . 4 1/2 3550 7810
Shop Manual Section E-14,
INTRODUCTION
The counterbalance valve assembly i s p a r t

o f the swing c i r c u i t . The major components
i n the swing c i r c u i t besides the control
valve include a Counterbalance Valve Assem-
b l y , a brake cylinder and an external gear
type swing motor.
Figure 1
A closer look a t the c i r c u i t shows t h a t Brake Cylinder

w i t h i n the Counterbalance Valve Assembly I 1 GPM Flow
there a r e two counterbalance valves two Regulator
cross- line r e l i e f valves and two check
valves. There a r e a l s o two external check
valves and a 1 GPM flow regulator i n the
brake release 1 ine.
Checks Valve Assembly

Swing Circuit
Figure 2
-1 -
Shop Manual Section E-14
The purpose of the counterbalance valves

i s t o provide smooth swing control when
s t a r t i n g , stopping and during operation. _-_-- +=x-
The valves do t h i s by r e s t r i c t i n g return
flow from the swing motor when the control
valve i s actuated. They a l s o block flow
from the motor when the control i s in Counterbalance
neutral . valves restrict
return flow during
operation and block
flow in neutral
I Swing Circuit
Figure 3
During swing motor operation, the internal

check valve will by-pass flow around t h e
: Checks
Brake Cylinder Extends
J
counterbalance valve in the pressurized
work l i n e and block flow t o the return work
l i n e . This forces the return flow from the
motor t o go t h r o u g h t h e opposing counter-
balance valve which i s opened by a p i l o t
l i n e from the pressurized work l i n e . The
swing can n o t "coast" . I t must be powered
in each d i r e c t i o n .
Opens valve ,
Checks Block Flow
Swing Circuit
.-.- -
Figure 4
The two external check valves and the Brake Releases

1 GPM flow regulator work together t o con- Checks at 150 psi
t r o l actuation o f t h e swing brake cylinder.
When the swing motor i s actuated flow
from the pressurized work l i n e i s allowed
t o pass f r e e l y t h r o u g h the check valve,
The opposite check valve prevents t h i s Opens after ,'
-,:
flow from entering the return work 1 ine brake releases -

so i t must g o instead, t o extend the swing at 200psi ; eb- ;
L-. 4
brake cylinder. The swing brake will re- 1
-2
lease a t a b o u t 150 PSI, which i s l e s s t h a n

the pressure required t o open the counter- Checks Block Flow
balance valve and allow the crane t o swing. Swing Circuit
This means t h a t t h e brake releases before
the motor i s allowed t o turn and applies I
a f t e r i t stops. The brake, then, i s used Figure 5
t o hold the 1 oad r a t h e r t h a n t o stop i t
-2-
The 1 GPM flow regulator becomes func-

tional when the swing control i s b r o u g h t Spring
t o neutral. I t meters flow from the brake Applies
Brake,
Oil is Pushed Out
release cylinder, which i s now being re-
tracted by an external spring, i n t o a drain 1 G P M Flow
1 Regulator
l i n e t o the reservoir. This slows swing TST-7 1 Meters FIOW
brake application, thus preventing abrupt Drain
stops.
Swing Circuit
When the swing control i s b r o u g h t t o neu- Brake is Applied

t r a l , b o t h counterbalance valves and a l l
check valves will close. Under certain
conditions the load will t r y t o continue
turning the motor (due t o i n e r t i a ) a f t e r
the control i s b r o u g h t t o neutral and
before the swing brake applies. The motor
actually becomes a pump t h a t takes o i l
from one work l i n e and pushes i t i n t o the
other. When this occurs, the cross- line
re1 i e f valve will dump o i l from one work
l i n e t o the other u n t i l the l o a d stops. Swing Circuit
This prevents shock loadinq and motor
cavitation while permitting smoother stops,
Figure 7
-3-
COUNTERBALANCE VALVE REMOVAL
Remove two hoses ( 2 ) from s t r a i g h t

f i t t i n g s ( 4 ) . Remove two tube nuts
( 1 ) from elbow f i t t i n g ( 7 ) . Remove
two hoses from f i t t i n g s ( 3 ) . Remove
two capscrews w i t h lock washers ( 5 )
and counterbalance valve ( 8 ) from
mounting bracket ( 6 ) .
NOTE: Remove counterbalance valve
from all cranes in same manner
as outlined above.
Figure 8
LOCATION ON:
80
90 thru 125
9OA thru 125A
125F
125FA
140F
150A
1SOFA
PEDESTAL SWING DRIVE GEAR CASE
VALVE
CAB
COUNTERBALANCE VALVE ACCE S S COVER

12013
12011
Figure 9 Figure 10
LOCATION ON: LOCATION ON:
220s 125P
150P
150T
-4-
COUNTERBALANCE VALVE DISASSEMBLY
The f o l l o w i n g i s only one method recommended for the complete disassembly of the
counterbalance valve.
Loosen locknuts ( 1 and 4 ) and remove

four el bows ( 2 and 5 ) . Remove two
s t r a i g h t f i t t i n g s ( 3 ) from valve ( 6 ) .
C u t and remove two safety wires ( 7 ) .
Figure 1 2
-5-
Remove flow cap (1 ) from valve body

( 2 ) . S1 ide plunger ( 3 ) o u t of valve
housing, or off spring ( 4 ) . Remove /
spring, spring guide ( 5 ) from ca ( 1 ) .
P
Remove cap ( 7 ) and push valve (8 o u t
of valve assembly ( 2 ) . Remove O-rings
( 6 and 9 ) from caps ( 7 and 1 ) .
Figure 13
Figure 14
Remove check valve cap (1 ) spring ( 2 )

and plunger (3) from valve assembly ( 4 ) *
Remove O-ring ( 5 ) from cap, i f rep1 ace-
ment i s necessary. Using a s u i t a b l e
puller a the plunger s e a t can be removed
i f necessary.
NOTE: Remove remaining check valve
(6) i n t h e some manner,
Figure 15
- 6-
Remove flow cap ( 1 ) from valve assembly

( 2 ) . Remove plunger ( 3 ) from valve
assembly or spring whichever the plunger
has remained with. Remove spring ( 4 )
and spring guide ( 5 ) from flow cap ( 1 ) .
Remove O-ring ( 9 ) from cap. Remove
cap ( 6 ) from valve assembly, and remove
O-ring ( 7 ) from cap. Slide valve ( 8 ) o u t
of valve housing.
Figure 16
-7-
Shop Manual Section . E-14
A. Clean a l l parts with an approved cleaning solvent and dry thoroughly a f t e r

cleaning w i t h a clean l i n t f r e e cloth o r compressed a i r . I t i s recommended
t h a t parts being immersed i n cleaning f l u i d be moved u p and down slowly until
a1 1 foreign material is dissolved and parts a r e thoroughly cleaned.
A
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS AND
INHALATION OF VAPORS WHEN USING CLEANER FLUIDS AND SOLVENTS.
CAUTION
B. Make c e r t a i n valve body i s completely clean. Use compressed a i r t o thoroughly

clean bores. Inspect valve f o r any visual damage such as galding, nicks or
cracks .
WEAR GOOGLES WHEN USING COMPRESSED AIR. DIRECT AIR STREAM AWAY
FROM BODY,
CAUTION
C. Inspect remaining parts such as plungers, plunger s e a t s and s h u t t l e valves

f o r excessive wear or visual damage and r e p a i r or replace as necessary.
D. Replace O-rings as necessary.
-8-
Shop Manual Section EiM.
COUNTERBALANCE VALVE REASSEMBLY
The following i s only one method recommended f o r complete reassembly of the counter-
balance valve assembly.
Position O-ring ( 1 ) on cap ( 6 ) . I n s t a l l

r e l i e f valve s e a t (8) i n valve assembly
( 2 ) . Position washer spacers ( 5 ) , spring
( 4 ) and re1 ief valve p i n ( 3 ) in cap.
S1 ide plunger ( 7 ) in r e l i e f valve s e a t .
I n s t a l l r e l i e f valve cap assembly ( 2 ) in
Val ve assembly .
Figure 18
-9-
Figure 20
Figure 21
I n s t a l l O-rings ( 6 and 9 ) on caps (1 and

7 ) . Slide valve (8) in valve assembly ( 2 )
i n s t a l l cap ( 7 ) and t i g h t e n . Position q @
(,’3
7’
i
spring guide ( 5 ) and spring ( 4 ) i n flow
cap ( 1 ) . Slide plunger ( 3 ) over spring
and i n s t a l l flow cap assembly i n valve
assembly ( Z ) , tighten flow cap-
Figure 22
-1 0-
I n s t a l l two setscrews ( 2 ) which a r e

used t o lock the r e l i e f valve s e a t
i n valve assembly ( 3 ) . I n s t a l l two
machine screws ( 1 ) t h a t lock setscrews
in place.
Figure 23
I n s t a l l four elbow f i t t i n g s ( 2 and 4 )

and two s t r a i g h t f i t t i n g s ( 3 ) in the
valve assembly ( 6 ) and tighten four
locknuts (1 and 4 ) . I n s t a l l two s a f e t y
wires ( 7 ) .
Figure 24
-11-
COUNTERBALANCE VALVE INSTALLATION
Position counterbalance valve ( 8 ) on

mounting bracket ( 6 ) and instal 1 two
lockwashers and capscrews ( 5 ) . I n s t a l l
two hoses on f i t t i n g s ( 3 ) . Position two
tubes on elbow f i t t i n g s ( 7 ) and tighten
tube nuts ( 1 ) . Instal 1 two hoses ( 2 ) on
straight fittings ( 4 ) .
N~OTE: I n s t a l l counterbalance valves
on a l l cranes i n t h e sane manner
as outlined above.
Figure 25
LOCATION ON:
80
90 t h r u 125
90A thru 125A
125F
1 2 5FA
140F
150A
150FA
SWING DRIVE GEAR CASE

PEDESTAL
m COUNTERBALANCE VALVE
CAB DOOR,
COUNTERBALANCE VALVE ACCESS COVER

12013
12014
Figure 26 Figure 27
LOCATION ON: LOCATION ON:
220s 125P
150P
l5OT
-1 2 -
GRADER 0
PLANER 0
ROLLER 0
CRANE d
Shop Mama1
HYDRAULIC CRANE TROUBLESHOOTING

90-1 00-1 10-1 25 01001 & u p
90A-100A-11 OA-l25A 02006 & Up
150A 02832 & Up
125P 01001 84 up
15OP - 150T 01011 I(I up
CAUTION

GOOD WORKING ORDER.

INJURY.
CONTENTS
Section I - Hydraulic Pressure & Engine Speed Charts
Section I1 - Hydraulic System Introduction
- Trouble-Shooting 50 Gal 1 on Per Minute System
- Trouble-Shooting 30 Gallon Per Minute System
- Rapid Warmup o f Hydraul i c System
Section I11 - Trouble-Shooting the Swing Drive C i r c u i t
Section IV - Trouble-Shooting t h e Boom L i f t Cylinder C i r c u i t
Section V - Trouble-Shooting t h e Crowd Cylinder(s) C i r c u i t
Section VI - Trouble-Shooting the Winch C i r c u i t
Section VI1 - Trouble-Shooting t h e Rear Steering Cylinders
Section VI11 - Trouble-Shooting t h e Outrigger C i r c u i t
P l
NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased 113 for Non-Lubricated (Dry) Threads.
Thread Size
Grade 5
(3 radial dashes on bolt or cap screw head) I Grade 8
(6 radial dashes on bollt or cap screw head)
Foot Pounds I Newton Meters Foot Pounds Newton Meters
(Ft. Lbs.) (Nm) (Ft Lbs.) (Nm)
1/4 - 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 . 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 . 13 58 79 a2 111
1/2 . 20 65 88 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
518 . 11 115 156 165 224
518 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 - 14 335 454 515 698
1 - 8 455 617 695 94 2
1 - 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 118 - 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 248 1
1 S/8 . 12 i 290 1749 2 085 2827
1 1/2 - 6 1500 2034 2 430 3295
1 1/2 - 12' 1690 2291. 2 730 370 1
1 3/4 . 5 2 370 3213 3810 5166
2 . 4 1/2 3550 4813 5 760 7810
FILE, E
SHOP MANUAL SEC7lON 15
INDEX
/
SECTION I
H Y D R A U L I C PRESSURE AND E N G I N E SPEED CHARTS

i
SECTION I 1
H Y D R A U L I C SYSTEM I N T R O D U C T I O N
TROUBLE- SHOOTING 50 GALLON PER M I N U T E SYSTEM

TROUBLE- SHOOTING 30 G A L L O N PER M I N U T E SYSTEM
R A P I D WARMUP O F H Y D R A U L I C SYSTEM
S E C T I O N I11
TROUBLE- SHOOTING T H E SWING D R I V E C I R C U I T
SECTION I V
TROUBLE- SHOOTING T H E BOOM L I F T C Y L I N D E R C I R C U I T
SECTION V
TROUBLE- SHOOTING T H E CROWD C Y L I N D E R ( S ) C I R C U I T
SECTION V I
TROUBLE- SHOOTING T H E WINCH C I R C U I T
SECTION V I 1
TROUBLE- SHOOTING T H E REAR S T E E R I N G C Y L I N D E R S
SECTION V I 1 1
TROUBLE- SHOOTING T H E OUTRIGGER C I R C U I T
R3
FILE - E
SHOP IMANUAL SECTION 15
SECTION I
I
SECTION II
I
SECTION Ill
I
SECTION I V
I
SECTION V
I
SECTION VI
S E C T I O N VI1
I
SECTION V l l l
F l lE - t
SECTION I
GALION HYDRAULIC CRANE ENGINE SPEEDS
ENGINE MODEL H I G H IDLE LOW IDLE STALL SPEED*
IHC UB-264 t 50
2900 - 650 -
t 50 1900 -
t 50
IHC UD-282 2600 -

t 50 650 -
t 50 1900 -
t 50
DETROIT DIESEL t 50
2900 - 750 -
t 50 2400 5 50
4-53
IHC UV-345 + 50
2900 - 750 -
t 50 2400 -
t 50
CUMMINS V-352 - C t 50
2900 - 750 -
t 50 2400 -
t 50
DD 3-53 2900 50 750 -f 50 1900 2 50
* S t a l l speeds n o t a p p l i c a b l e on t h e Gal ion H y d r a u l i c P e d e s t a l Crane.
R3
- 1-
FILE-
~~ ~ t
GALION HYDRAULIC CRANE SYSTEM PRESSURES
MODEL 30 GALLON 50 GALLON STEERING
SYSTEM SYSTEM SYSTEM
c-90 + 100
1750 - +- 100
1825 - + 100
1675 -
___ ~~~ ~~
c-11 0 1750 -
t 100 1825 -
t 100 1675 -
t 100
C-125 1750 -
t 100 1825 2 100 t 100
1675 -
C-90A + 100
1800 - + 100
1925 - + 100
1675 -
C-1 1 OA 1800 -
t 100 1925 -
t 100 + 100
1675 -
C-l25A + 100
1925 - + 100
1675 -
C-l50A + 100
2025 - 2225 -
t 100 1675 -
t 100
All p r e s s u r e s must be taken w i t h :

1 . Oil a t o p e r a t i n g temperature
2. Engine a t maximum RPM
3 . Control valve i n r e s p e c t i v e c i r c u i t
moved t o maximum t r a v e l and c y l i n d e r
f u l l y bottomed.
GALION HYDRAULIC PEDESTAL CRANE

All t r o u b l e s h o o t i n g procedures apply where a p p l i c a b l e t o the Galion
Hydraulic Pedestal Crane b u t due t o the various m o d i f i c a t i o n s which
a f f e c t t h e h y d r a u l i c p r e s s u r e s on pedestal c r a n e s , the S e r v i c e Dept.
of the Galion Iron Works & Mfg. Co. should be c o n t a c t e d f o r c o r r e c t
pressure s e t t i n g s .
-2-
FILE, t
SECTION I 1
50 GPM CONTROLS SLOW OR L A C K I N G I N POWER WHEN 30 GPM AND

FROM S T E E R I N G C I R C U I T S ARE NORMAL. .............................. 5
30 GPM CONTROLS SLOW OR L A C K I N G I N POWER WHEN 50 GPM AND

FRONT S T E E R I N G C I R C U I T S ARE NORMAL. ............................. 7 - 8
FILE, E
FLOW D I V I D E R DIVERTER VALVE ASSEMBLY
1. D i v e r t e r Valve
2. 30 GPP4 System Maximum Pressure R e g u l a t i n g Valve
3. Flow D i v i d e r Honed Assembly
4. S t e e r i n g System Maximum Pressure R e g u l a t i n g Valve
5. Check Valve
-1 -
FILE, E
30 GPM CONTROLS
-- 50 GPM CONTROLS
--
1. L e f t Rear O u t r i g g e r 8. I n t e r m e d i a t e H o i s t Winch
2. L e f t Front Outrigger 7&8. F a s t H o i s t Winch
3. Right Front Outrigger 9. Crowd
4. R i g h t Rear O u t r i g g e r 10. Boom
5. Rear S t e e r i n g
6. Swing
7. Slow H o i s t Winch
-2-
FILE, E
I n s t a l l a t i o n p o i n t s f o r gauge a n d 2 " b a r
when c h e c k i n g s t e e r i n g p r e s s u r e s .
Gauqe i n s t a l l a t i o n s f o r h y d r a u l i c s y s t e m
p r e s s u r e checks.
-3-
FILE - t
INTRODUCTION TO THE HYDRAULIC SYSTEM
The hydraul i c r e s e r v o i r has an operating capacity of approximately

70-75 gallons of o i l . I t contains two separate f u l l flow f i l t r a t i o n
systems, each in a separate compartment.
The o i l e n t e r s the t a n k and passes through two 25 micron pleated paper
elements and then enters the second compartment t o again be f i l t e r e d
through a f i n e wire 100 mesh screen basket type s t r a i n e r .
Mounted on a s h a f t in the center of t h e s t r a i n e r , i s a s e r i e s of four
round magnets t o t r a p f r e e flowing ferrous material.
The f i l t e r e d o i l then passes i n t o a t h i r d compartment and i s available
t o the hydraulic pump.
The tandem hydraulic pump i s d i r e c t l y coupled t o t h e en i n e , i s of spur
3
gear design and c o n s i s t s of a 30 gallon per minute (gpm and a 50 g a l l o n
per minute (gpm) section f o r t h e operation of two separate hydraulic c i r c u i t s .
50 GPM CIRCUIT
The 50 GPM c i r c u i t includes a primary manifold located underneath t h e

center of t h e crane, which has three spool valves and a maximum pressure
regulating Val ve.
Oil flows from t h e 50 GPM section of t h e pump d i r e c t l y t o the primary
manifold, t h r o u g h t h e manifold in s e r i e s flow and back t o t a n k .
The three primary manifold spool valves a r e used t o operate the fol lowing:
Boom
Crowd
Winch-Intermediate Hoist Speed
These three controls a r e cable operated from the o p e r a t o r ' s platform.
They have small holes d r i l l ed in the lands of t h e spools and can be feathered.
The maximum pressure regulating valve, located in the primary manifold, i s
preset t o r e l i e v e t h e hydraulic system when maximum pressure i s obtained.
-4-
NU - E
SHOP MANUAL SECTJON 15
50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT

STEERING CIRCUITS A R E NORMAL.
A. 50 GPM maximum pressure regulating valve held off i t s s e a t

by foreign material.
Instal 1 a re1 i a b l e 3000 PSI gauge in 1/8" NPT
port provided in t h e pressure l i n e a t pump ( t h e
pump section nearest the engine i s the 50 GPM c i r c u i t ) .
S t a r t engine and bottom a control valve (crowd or
boom), r a i s e engine speed t o high i d l e and observe
pressure reading. Refer t o t h e hydraulic system
pressure c h a r t a n d engine speed c h a r t f o r c o r r e c t pressure
and speed. (See index). Hydraul i c oi 1 must be a t
operating temperature before checking pressures.
If pressure i s found t o be below normal,
without breaking t h e seal remove t h e 50 GPM
maximum pressure regulating valve c a r t r i d g e in
primary manifold located underneath center of
crane.
Inspect the spool end of t h e c a r t r i d g e f o r
foreign material holding spool off i t s s e a t .
C1 ean c a r t r i d g e by i n s e r t i n g proper s i z e rod
or tool in end of valve, depressing spool so
t h a t foreign material can be flushed with solvent
or compressed a i r .
Reinstall cleaned c a r t r i d g e i n t o primary manifold.
Test f o r correct pressure.
I f pressure continues t o be below normal, remove
t h i s c a r t r i d g e and exchange i t with the 30 GPM
maximum pressure regulating valve which i s located
i n the bottom of t h e flow regulator- diverter valve,
mounted on t h e lower inside edge of t h e hydraulic
t a n k . (NOTE - Both 30 GPM and 50 GPM r e l i e f valves
a r e identical in shape and pressure s e t t i n g s . )
S t a r t engine and recheck pressure. I f pressure i s
now normal in 50 GPM c i r c u i t , t h e original r e l i e f
valve i s defective. I n s t a l l new r e l i e f valve
c a r t r i d g e assembly.
If pressure continues t o be below normal in 50 GPM
c i r c u i t , t h e hydraulic pump i s defective. Replace
Pump *
- 5-
FILE, t
30 GPM CIRCUIT
The 30 GPM c i r c u i t provides oi 1 t o operate s t e e r i n g and a1 1 controls

in the secondary manifold which i s located in t h e o p e r a t o r ' s compart-
ment.
The o i l flows from t h e 30 GPM section of t h e pump t o the flow regulator
d i v e r t e r valve assembly. Up t o 11 GPM i s regulated t o t h e f r o n t steering
booster valve and t h e remainder i s by-passed t o t h e secondary manifold.
This assures t h a t s u f f i c i e n t flow i s available f o r s t e e r i n g a t a l l times.
This regulated flow of up t o 11 GPM passes thru t h e s t e e r i n g valve a t a l l
times. I t then goes t o a d i v e r t e r valve (located within the flow regulator-
d i v e r t e r valve assembly) t h a t rejoins t h i s o i l with t h e by-passed o i l (as
mentioned above) and i s available f o r use i n t h e secondary manifold. This
now becomes a s i n g l e flow of up t o 30 GPM depending on engine RPM.
This 30 GPM flow goes t o t h e l e f t end of the secondary manifold. Through
a series- flow open center valve system i t i s now a v a i l a b l e f o r use by a l l
control valves in the secondary manifold.
The regulated flow t o t h e f r o n t s t e e r i n g booster has i t s own maximum pressure
regulating valve. This valve i s located in the f r o n t end of the flow
regul ator- di v e r t e r Val ve assembly.
The 30 GPM c i r c u i t maximum pressure regulating valve i s located in t h e bottom
of t h e flow regulator- diverter valve assembly.
The secondary manifold contains 7 or more controls f o r operating the
following:
Outriggers - ( 4 )
Rear Steering
Swing (Boom R o t a t i o n )
Winch -- Low Speed
Additional controls may be added f o r accessories.
-6-
30 GPM CONTROLS SLOW O R LACKING IN POWER WHEN 50 GPM AND FRONT STEERING
CIRCUITS ARE NORMAL.
A. 30 GPM maximum pressure regulating valve held o f f i t s seat due

t o foreign material.
Install a re1 iable 3000 PSI gauge i n 1/8" NPT p o r t
provided i n the pressure l i n e a t pump (the rear section
o f the pump i s the 30 GPM c i r c u i t . ) S t a r t engine and
bottom a control valve (outrigger or rear steering. )
Raise engine speed t o h i g h idle and observe pressure
reading. Refer t o the hydraulic system pressure chart
and engine speed chart for correct pressure and speed.
(See index). Hydraulic o i l must be a t operating tempera-
ture before checking pressures.
I f pressure i s found t o be below normal , w i t h -
o u t breaking the seal remove the 30 GPM maximum
pressure regulating valve cartridge located i n
the bottom side o f the flow regulator-diverter
valve assembly mounted on the lower inside edge
of the hydraulic t a n k .
Inspect t h e spool end o f the cartridge for foreign
material h o l d i n g spool o f f i t s s e a t .
Clean cartridge by inserting proper s i z e rod or
t o o l into end o f valve, depressing spool so t h a t
foreign material can be flushed w i t h solvent or
compressed a i r .
Reinstal 1 cleaned cartridge i n t o flow regulator-
diverter valve assembly and t e s t for correct
pressure.
I f pressure continues t o be below normal , remove
t h i s cartridge and exchange i t with the 50 GPM
maximum pressure regulating valve which i s located
i n the primary manifold underneath center o f crane.
(NOTE - Both 30 GPM and 50 GPM re1 i e f Val ves are
identical i n shape and pressure s e t t i n g s . )
S t a r t engine and recheck pressure. I f pressure i s
now normal i n 30 GPM c i r c u i t , the o r i g i n a l 30 GPM
r e l i e f valve i s defective. Install new r e l i e f valve
cartridge assembly.
I f pressure continues t o be below normal i n 30 GPM
c i r c u i t , the hydraulic pump i s defective. Replace
Pump
- 7 -
FILE - t
B. I f pressure on 30 GPM c i r c u i t i s normal , b u t controls are slow,
the d i v e r t e r valve i s n o t functioning properly. (NOTE - Refer t o
30 GPM c i r c u i t under "Introduction To The Hydraulic System" for
explanation o f d i v e r t e r valve function. See index.)
(1 ) The d i v e r t e r valve mounted i n the r e a r o f the flow
regulator- diverter valve assembly may n o t be a d d i n g the
regulated steering o i l back i n t o the 30 GPM c i r c u i t ,
resulting in lack of 11 qpm flow t o secondary manifold.
( a ) To check the d i v e r t e r valve for correct operation,
position a 2 " s t e e l bar between the front axle stop
and the axle on the l e f t hand s i d e of the crane.
W i t h engine a t approximately one-fourth RPM, turn
the steering t o the extreme l e f t and hold against the
2" s t e e l bar. A t the same time, lower the 1 e f t
hand front outrigger and observe i t s speed. While
outrigger i s s t i l l i n motion, release the steering
and a g a i n observe the outrigger speed. I f the o u t -
rigger increased i n speed a f t e r the steering i s
released, the d i v e r t e r valve & functioning properly.
I f the speed does not increase, the d i v e r t e r valve
is - n o t functioning properly.
( b ) I f the d i v e r t e r valve is n o t functioning properly
as described in ( a ) above, t h e d i v e r t e r valve sliding
spool i s sticking.
( c ) Remove the large hex head cap on the rear surface of
the flow regulator- diverter valve assembly and remove
the d i v e r t e r spool . Inspect for d i r t or scoring. I f
spool i s scored use only crocus cloth t o pol ish o u t
scratches. Spool must s l i d e freely i n housing bore
before f i n a l r e i n s t a l l a t i o n . Perform t e s t as o u t -
lined i n ( a ) above.
( d ) I f the d i v e r t e r Val ve spool cannot be repaired, replace
the e n t i r e d i v e r t e r valve cartridge.
FRONT STEERING - SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE
FUNCTIONING PROPERLY.
A. Steering maximum pressure regulating valve held o f f of s e a t due t o

foreign materi a1 .
(1 ) I n s t a l l a r e l i a b l e 3000 PSI gauge i n the 1 / 4 " NPT port i n
the rear welded boss on t o p of the l e f t hand front steering
cylinder. ( I f a 1/4" NPT port is n o t on the l e f t hand front
steering cylinder, the gauge will have t o be adapted i n t o
the hydraul i c 1 ine g o i n g t o the r e a r port o f the l e f t hand
steering cy1 inder. )
R1
-8-
FILE, t
(2) Position a 2 " steel bar between the front axle stop
and the axle on the l e f t hand side o f the crane. Start
engine, turn steering t o extreme l e f t and h o l d against
the 2 " steel bar. Increase engine speed t o maximum and
observe pressure reading. Refer t o the hydraulic system
pressure chart and engine speed chart for correct pressure
and speed. (See index. )
NOTE: Pressures can also be checked from the r i g h t hand side by
reversing a l l procedures t o the right hand side.
(3) I f the pressure reading i s low, remove the steering maximum
pressure regulating valve. (This valve i s located i n the
f r o n t side of the flow regulator- diverter valve assembly
which i s mounted t o the lower inside edge o f the hydraulic t a n k . )
1
(4) Observe the cartridge for foreign material h o l d i n g spool
o f f i t s seat.
(5) Clean cartridge by inserting proper s i z e rod or t o o l in end
o f valve, depressing spool so that foreign material can be
flushed w i t h solvent or compressed a i r .
(6) Reinstall cleaned cartridge i n t o flow regulator-diverter
valve assembly. Test for correct pressure.
(7) I f pressure i s s t i l l below the required reading, replace
the r e l i e f valve assembly.
B. Flow regulator honed assembly spool plugged or sticking.
(1 ) Remove the tube t h a t comes from the hydraulic pump (30 GPM)
a t the p o i n t where i t connects t o the flow regulator-
diverter valve assembly.
( a ) Check the opening of the tube or the valve body
for a large piece o f loose foreign material t h a t
could possibly plug the 11 GPM o r i f i c e hole i n the
honed assembly spool. The foreign material could
be lodged i n the o r i f i c e hole i t s e l f . Remove foreign
material and replace tube.
(2) I f no foreign material i s present as described in 1-a above,
the honed assembly spool i s sticking.
( a ) Remove the flow re u l a t o r diverter valve assembly.
3
Remove the four (4 cap screws holding the spring
housing plate. Remove p l a t e , cap, O- ring and spring.
Remove the honed assembly spool and determine t h a t i t
i s f r e e in the sleeve. Also check the brass r i v e t
i n the head end o f spool and make c e r t a i n t h a t i t has
n o t loosened or i s missing completely. Effect repairs
. as necessary.
- 9-
FILE, E
- __ SHOP MANUAL SECTION 15
RAPID WARMUP OF HYDRAULIC SYSTEM
The 30 GPM or 50 GPM c i r c u i t s can be warmed u p rapidly by s t a r t i n g

the engine, increasing enging speed t o maximum and bottoming a
cylinder in e i t h e r c i r c u i t . The cylinder should be bottomed f o r no
longer than 30 seconds each time. Release control lever t o the
center position for 30 seconds and repeat t h i s procedure u n t i l system
i s s u f f i c i e n t l y warmed t o gain t h e proper t e s t readings. Oil should
be 120" F t o 140" F f o r c o r r e c t t e s t readings.
-1 0-
F l lE E
& SHOP MANUAL SECTION 15
SECTION II 1
SWING RUNS AWAY WHILE SWINGING DOWN H I L L WITH LOAD --------- 3
SWING ERRATIC AND JERKY I N OPERATION ....................... 3 - 4

FILE, E
4. Swing Motor 8. Counterbalance Valve

5. Swing Brake 9. Flow R e g u l a t o r
6. Brake Cy1 inder 10. Check Valve
7. Push Rod
-1 -
FILE, E
SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL.
A. Check t h e swing brake cylinder push rod. I f the rod

i s n o t f r e e t o r o t a t e , t h e r e can be 3 causes:
(1 ) 1 GPM flow regulator plugged.
( a ) Remove and clean.
NOTE: I n s t a l l 1 GPM flow regulator so t h a t
t h e end marked "IN" faces the hydraulic
counter bal ance Val ve.
(2) Brake c l i n d e r push rod adjusted t o o long.
(a7 Adjust. Proper adjusted length i s approximately
2-11/16". This measurement includes the lock
n u t t o the rounded end of t h e push rod.
( 3 ) Brake cylinder piston scored and binding.
( a ) Replace complete swing brake cy1 inder i f scoring
i s found.
B. I f t h e swing brake cylinder push rod i s f r e e , t h e brake linings
have o i l on them.
(1) Inspect brake shoes. I f o i l i s present, the swing
drive pinion s h a f t o i l seal i s leaking.
( a ) Replace pinion s h a f t bottom seal and replace
brake shoes. NOTE: Check i n p u t flange f o r
exceeding .008 maximum a1 lowable run o u t .
C. An extreme load on the swing will sometimes cause a s l i g h t d r i f t
even i f the brake i s functioning properly.
(1 ) Swing drive brake cy1 i nder spring not tensioned properly.
( a ) Tighten swing drive brake cylinder spring t o
.proper tension.
(2) Swing drive brake shoes n o t burnished.
( a ) Burnish brake shoes. To burnish brake:
Disconnect 3/8" oi 1 supply tube t o swing
brake cylinder and cap tube. Back off on the
brake spring tension adjustment j u s t enough
t o allow the swing t o turn a t f u l l engine RPM.
Operate swing a t f u l l engine RPM f o r n o t more
t h a n 3 seconds. A1 low shoes t o cool f o r 45 seconds.
Repeat t h i s operation 5 or 6 times. Allow shoes
and drum t o cool f o r a t l e a s t 15 minutes.
Retension spring and connect, o i l supply tube t o
brake cy1 inder.
R1
-2-
FILE t
SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD.
A. Counterbalance valve n o t functioning properly.

(1) Disassemble valve and clean thoroughly.
( a ) If components a r e scored s l i g h t l y .
remove scoring with crocus cloth only.
DO NOT USE EMORY CLOTH!
( b ) I f components a r e badly scored, replace
counterbalance Val ve.
SWING REFUSES TO ROTATE, WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY.
A. Swing brake cylinder push rod adjusted t o o s h o r t .

(1) Adjust swing brake push rod t o approximately 2- 11/16"
from t h e rounded end of the p u s h rod t o and including
t h e ock n u t .
CAUTION: LOCKNUT THICKNESS MUST BE INCLUDED IN
OVERALL 2-1 1 /16" MEASUREMENT.
B. Improper i n s t a l a t i o n of one or b o t h of the one way check valves
located in t h e 3/8" drain l i n e s , leadinq from t h e counterbalance
valve, could cause t h e swing t o -r e f u s e i o r o t a t e in one o r b o t h
directions.
(1 ) Insure t h a t the arrows on the one way check valves
indicate flow away from counterbalance valve.
C. Defective swing hydraulic motor.
(1 ) Replace motor i f 30 GPM system pressure i s normal.
SWING ERRATIC AND JERKY IN OPERATION.
i i n g brake spring.
A2. Swing brake cy1 inder push rod length t o o short n o t allowing
the swing brake t o re1 ease ful l y .
(1 ) Check t h e swing brake cylinder push rod adjustment
f o r being approximately 2-1 1/16" from t h e lock n u t
t o the rounded end. (The lock n u t thickness must be
included i n t h i s measurement).
B. Brake shoes improperly i n s t a l l e d causing shoes t o misalign and
d r a g on brake drum.
(1 ) Remove brake drum and remove brake shoes. Observe
stamped r e t a i n i n g e a r on curved metal portion of brake
shoe. For proper i n s t a l l a t i o n o f shoes this stamped re-
t a i n i n g ear must be behind the expander pivot arm located
on t h e backing p l a t e . The two shoe return springs must
be hooked i n t h e holes i n brake shoes t h a t a r e nearest the
brake backing p l a t e . p' I
-3- .._ , - R
i
FILE, E
C. Brake drum o u t o f round. (Maximum run o u t .005).

(1 ) Replace brake drum.
D. Counterbalance valve n o t functioning properly.
(1 ) Disassemble valve and clean thoroughly.
(2) I f components are badly scored, replace counter-
bal ance Val ve.
' /
NOTE: The secondary manifold control valve spool f o r the swing must
have V-notches stamped i n i t for feathering. I f the valve spool
i s n o t V-notched, the swing cannot be feathered properly.
-4-
FILE, E
SECTIONV
I
BOOM L I F T CYLINDER
Page
BOOM L I F T CYLINDER REFUSES TO LOWER. ....................... 4

c
FILE, t
11. Overcenter Check Valve

12. Surge Re1 i e f Valve Body
13. Surge R e l i e f Valve C a r t r i d g e
(PRESET & SEALED -
DO NOT ADJUST)
- 1-
FILE, E
BOOM L I F T CYLINDER ~-
-- SURGE VALVE
8. C a r t r i d g e (PRESET & SEALED - DO NOT ADJUST)
9. Body
-2-
FILE, E
BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE N
I THE NEUTRAL
POSITION.
A. Surge r e l i e f v a l v e by- passing o i l . T h i s v a l v e i s l o c a t e d

a t t h e base end o f t h e boom l i f t c y l i n d e r .
(1) Foreign m a t e r i a l h o l d i n g surge r e l i e f v a l v e o f f

i t s s e a t . During d r i f t i n g c o n d i t i o n l o o s e n b u t
do n o t remove t h e 3/8" d r a i n 1 i n e a t t h e surge
r e l i e f valve. I f o i l f l o w s o u t o f t h i s loosened
c o n n e c t i o n under pressure, t h e s u r g e r e l i e f v a l v e
c a r t r i d g e wil have t o be removed f r o m t h e v a l v e
body f o r c l e a n i n g .
DANGER: BEFORE REMOVING THE SURGE RELIEF VALVE CARTRIDGE,

MAKE CERTAIN THAT THE BOOM CYLINDER I S DOWN AND
BOTTOMED OR BOOM I S BLOCKED SO I T CAN'T DROP.
( a ) Clean v a l v e by i n s e r t i n g p r o p e r s i z e r o d o r
t o o l i n end o f c a r t r i d g e , depress p l u n g e r and
f l u s h f o r e i g n m a t e r i a l w i t h compressed a i r o r
solvent.
( b ) I f v a l v e cannot be cleaned o r i f i t i s s t i c k i n g
due t o s c o r i n g , r e p l a c e complete v a l v e assembly.
I
DO NOT ATTEMPT TO DIS-ASSEMBLE THIS VALVE, I T
I S SEALED AND PRESET.
( c ) I f no f o r e i g n m a t e r i a l i s h o l d i n g t h e surge r e l i e f
v a l v e open AN OVERLOAD CONDITION EXISTS.
B. Boom l i f t c y l i n d e r l e a k i n g i n t e r n a l l y .
(1) Boom 1 i f t cy1 i n d e r p i s t o n p a c k i n g worn.
( a ) Remove cy1 inder and make r e p a i r s .
(2) Boom 1 if t cy1 i n d e r i n t e r n a l bore scored.
( a ) Remove cy1 i n d e r and make r e p a i r s .
BOOM DROPS MOMENTARILY WHEN CONTROL I S MOVED FROM NEUTRAL TO RAISE.
A. Boom o v e r c e n t e r check v a l v e i s s t u c k open.

T h i s v a l v e i s base mounted t o t h e boom l i f t c y l i n d e r .
(1) S t a r t engine, e l e v a t e boom h a l f w a y and s h u t o f f engine.

A c t i v a t e t h e boom l i f t c y l i n d e r m a n i f o l d c o n t r o l l e v e r
f o r w a r d . I f boom d r i f t s down, t h e o v e r c e n t e r check
v a l v e i s unseated.
( a ) LOWER BOOM AND BOTTOM BOOM LIFT CYLINDER.

Remove o v e r c e n t e r check v a l v e and r e p a i r o r
rep1ace.
-3-
FILE, E
BOOM LIFT CYLINDER REFUSES TO LOWER.
A. Overcenter check valve stuck closed.

(1) Lower load with winch i f hook block i s loaded.
(2) Retract boom f u l l y .
( 3 ) Drain s u f f i c i e n t o i l from hydraulic t a n k t o
accommodate o i l being returned from boom cylinder.
( 4 ) To lower boom cylinder t o bottomed position, break
the seal on the surge r e l i e f valve cartridge. Back
off adjusting screw slowly t o r e l i e v e spring tension
on valve and allow o i l t o flow o u t of cylinder, lowering
the boom.
NOTE: THE SURGE VALVE MUST BE REPLACED I F THIS SEAL I S BROKEN.
THE VALVE IS PRESET AND SEALED AND CANNOT BE RESET
IN THE FIELD.
B. Foreign material i n o r i f i c e of p i l o t l i n e f i t t i n g i n
the side of the overcenter check valve.
(1) Disconnect p i l o t l i n e from f i t t i n g ,
(2) Remove f i t t i n g and check o r i f i c e f o r
foreign material. Clean and replace,
.- . . .. R1
-4-
r
FILE - t
SECTION V
CROWD C Y L I N D E R ( S )
Page
CROWD C Y L I N D E R D R I F T S I N W I T H OR WITHOUT LOAD ------------------- '4
I N S I D E CROWD C Y L I N D E R CANNOT BE RETRACTED DUE TO BROKEN

O I L SUPPLY L I N E ON A THREE S E C T I O N POWER BOOM ------------------- 5 - 6
I N S I D E CROWD C Y L I N D E R CANNOT BE RETRACTED DUE TO BROKEN

O I L SUPPLY L I N E ON A FOUR S E C T I O N POWER BOOM .................... ,'
~.6 7 -'
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-1 -
FILE, E
-2-
FILE, t
-
3 SECTION ---
POWER BOOM FLOW D I V I D E R VALVE
11. R e l i e f Valve C a r t r i d g e s
(Preset- - Do Not A d j u s t )
12. Hex Plugs
13. Hoses To I n s i d e Crowd C y l i n d e r
14. Tubes To Outside Crowd Cy1 i n d e r
-3-
FILE, E
CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD.
A. Overcenter check valve stuck open.

(1 ) Elevate boom t o maximum.
(2) Extend a1 1 crowd cy1 inders t o maximum 1 ength.
(3) S h u t off engine.
( 4 ) Observe the speed of the d r i f t i n g boom section.
Pull the manifold crowd control 1 e v e r ( s ) back
and again observe the speed of t h e d r i f t i n g boom
s e c t i o n . I f t h e r a t e of d r i f t increases as t h e
lever i s pulled back, the crowd cylinder overcenter
check valve i s stuck open.
( a ) Disassemble, clean and r e p a i r overcenter
check valve. Replace i f necessary.
B. Cy1 inder 1 eaki ng internal l y .
(1 ) Elevate boom t o maximum.
(2) Extend a1 1 crowd cy1 inders t o maximum length.
(3) Pick up load and observe which crowd section
d r i f t s in. NOTE: Crowd control l e v e r must be
i n neutral position.
(4) Remove defective cylinder, r e p a i r o r replace.
CROWD SECTION(S) CHATTERS O R REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS.
A. Lack of 1 ubrication on boom wear p l a t e s .

(1) Lubricate a l l boom wear p l a t e s , i n s i d e and o u t .
B. Over l o a d condition e x i s t s .
CROWD CYLINDERS OUT OF PHASE. 3 AND 4 SECTION POWER BOOMS ONLY.

A. I t i s a normal function of t h e crowd cylinders, while
extending or r e t r a c t i n g , t o get o u t of phase. ( I n some
conditions approximately two f e e t ) .
(1 ) Hold crowd control lever back w i t h engine r u n n i n g a t
high i d l e u n t i l one cylinder bottoms. Continue holding
control valve open and cylinders should automatically
rephase themselves. I t i s normal f o r the cy1 inders t o
move slowly when rephasing.
-4-
F l lE E
B. If t h e crowd cylinders continually g e t o u t of phase more
t h a n normal, i t could be caused by b i n d i n g of boom sections.
(1 ) Lubricate a l l boom extension surfaces t h a t contact
wear plates .
C. If t h e crowd cylinders continually g e t o u t of phase more t h a n
normal or i f one cy1 inder always extends completely before t h e
other cylinder s t a r t s t o move, t h e flow d i v i d e r phasing valve
spool or r e l i e f valves a r e n o t functioning properly.
THREE SECTION POWER BOOM phasing valve assembly i s located under
t h e counterweight support plate.
FOUR SECTION POWER BOOM phasing valve assembly i s mounted on the
rear of t h e inside dual crowd cylinder. When a l l boom sections a r e
r e t r a c t e d , i t will then allow access t o t h e flow divider phasing
valve just ahead of t h e winch.
(1 ) Remove the large hex head plugs located on b o t h ends of
t h e valve assembly.
( a ) Remove t h e two spools and spring from the valve
body. Check f o r scoring of spools and/or scoring
of bore in valve body. Remove scoring w i t h
crocus cloth only. I f scoring cannot be removed,
replace e n t i r e valve assembly.
( b ) Check t o see i f t h e spring between the two spools
has jumped over the spring s e a t on one spool.
Decrease spring inner diameter t o proper s i z e so
t h a t spring f i t s s e a t c o r r e c t l y .
(2) Remove b o t h re1 i e f valve c a r t r i d g e s located on b o t h ends
of t h e valve assembly.
( a ) Inspect v a l v e ( s ) f o r foreign material holding
spool ( s ) open or damaged valve s e a t s .
( b ) Remove foreign material i f possible. I f v a l v e ( s )
a r e damaged, replace e n t i r e v a l v e ( s ) .
CAUTION: DO NOT CHANGE THE PRESSURE SETTINGS ON THESE RELIEF
VALVES. THEY A R E PRESET AND MAY NOT BE RESET IN THE
FIELD.
INSIDE CROWD CYLINDER CANNOT BE RETRACTED CAUSED BY BROKEN OIL SUPPLY LINE
ON A THREE SECTION POWER BOOM.
A. Retract hose broken between flow divider phasing valve and base
end of crowd cylinder.
-5- -/...
,
R1
r
FILE, t
(1 ) To r e t r a c t the extended crowd cy1 inder w i t h o u t
losing an excessive amount of o i l from the broken
hose, i t will be necessary t o eliminate the o i l
flow t o the inside crowd cy1 inder.
( a ) Remove b o t h hoses leading t o the inside
crowd cylinder where they connect t o the
flow divider phasing valve. This valve
i s located under the 1 e f t hand s i d e o f the
counterweight support plate. I n place of
the two removed hoses, i n s t a l l a single
hose (forming a l o o p ) joining b o t h open
ports together.
( b ) Start engin'e and operate crowd control
lever t o r e t r a c t the bottom crowd cylinder.
This will b r i n g the base end of the inside
crowd cylinder back t o a p o i n t where the
hose connections can be reached just forward
of the winch.
( c ) Remove the looped hose and i n s t a l 1 new hoses.
B. Hose or tube broken between base end and rod end o f inner
crowd cy1 i nder .
(1 ) To replace the broken hose or tube, i t will be
necessary t o r e t r a c t the inside crowd cylinder.
To do t h i s w i t h o u t excessive loss o f o i l , the
procedure i n A (1 ) ( a ) above must be done.
The cylinder will have t o be removed t o e f f e c t
repairs - r e f e r t o index and fol low procedure as
outlined under "Removal Of The Inside Crowd Cylinder
On A Three Section Power Boom".
INSIDE CROWD CYLINDER CANNOT B E RETRACTED. CAUSED BY BROKEN OIL SUPPLY

LINE ON A FOUR SECTION POWER BOOM.
A. Retract hose broken t h a t leads t o the dual inside crowd cylinder.
(1) S t a r t engine and lower outriggers. Activate the
control lever t o r e t r a c t the s i n g l e crowd cylinder
located under the base boom section. This w i l l pro-
vide access t o the lower piston rod end of the inside
dual crowd cylinder j u s t forward of the winch.
(2) Lower boom completely and remove the 1/8" pipe p l u g
t h a t i s located on the outer diameter o f the p i s t o n
rod end. The p i ston rod i s hollow and o i l may flow
as p l u g i s removed.
-6-
L
FIE t
SHOP MANUAL SECTIQN 15
( 3 ) W i t h the hook block reeved for 2 , 3, 4 or 5 part

l i n e , s t a r t engine and move winch control t o the r a i s e
position u n t i l hook block contacts head block. Continue
h o l d i n g the winch control i n the r a i s e position. This
will force the crowd cylinder t o be retracted. During
t h i s operation o i l w i l l spray o u t o f t h e 1/8" p l u g hole
i n the piston rod. I f i t i s undesirable t o have the
o i l spray a b o u t the winch area, connect a hose t o the
1/8" pipe p l u g hole in the piston rod and d r a i n i t
d i r e c t l y i n t o the hydraul i c tank.
( a ) When the boom section i s f u l l y r e t r a c t e d ,
new hoses can be i n s t a l led.
(b) Replace the 1/8" pipe p l u g i n the pi ston rod.
REMOVAL OF THE INSIDE CROWD CYLINDER ON A T H R E E SECTION POWER BOOM.

A. The inside crowd cylinder w i l l have t o be removed t o e f f e c t
repairs i f a leak i s caused by leaking packing, defective
f i t t i n g , a broken r e t r a c t tube or i f the cylinder i s leaking
i n t e r n a l l y . The f o l l o w i n g procedure i s suggested for inside
crowd cy1 inder removal :
Retract a l l power boom sections. (Manual sections
need n o t be removed or r e t r a c t e d ) .
Lower hook block t o ground and spool o f f 5 0 ' of cable.
Make certain t h a t the cab1 e coming o f f of the winch
drum i s kept t i g h t so t h a t "bird caging" o f cable does
not. r e s u l t .
Turn the cam down on the f i r s t extension support r o l l e r .
Remove the wear plates on b o t h sides of the f i r s t power
extension j u s t above the support r o l l e r .
Remove tension from the inside crowd cylinder o i l supply
hoses a t the right hand s i d e of boom by grasping b o t h
hoses and p u l l i n g down. This will move the t r o l l e y
rearward on the base boom section and a t the same time
apply tension t o the r e t r a c t spring. Using s u i t a b l e
t o o l , anchor the t r o l l e y t o the track i n t h i s position.
Remove b o t h hoses from the base end o f inside crowd
cy1 inder.
Remove the inside crowd cy1 inder (base end) anchor
p i n located just forward of the winch.
-7-
FIE t
. SHOP MANUAL sEcrloN 15
With s u i t a b l e h o i s t or crane, remove t h e second
crowd cylinder power extension, head block and
cy1 inder as one unit and place on ground. ( I f
manual extensions a r e present, they wi 11 be removed
with the second power extension a1 so. )
Remove cylinder piston rod anchor p i n .
Remove cy1 i nder from extens i on.
I f i t i s necessary t o locate t h e leak, connect t h e
crowd cylinder hoses t o t h e cylinder and operate
cy1 i nder .
Repai r cy1 i nder.
AFTER REPAIRS A R E MADE, TEST C Y L I N D E R ON GROUND
BEFORE INSTALLING.
Replace a l l components i n reverse order of above
procedure.
Hold tension on cable while rewinding t o allow
cable t o spool properly on drum.
R1
-8-
FILE, E
SECTION V
I
H O I S T WINCH CANNOT B E FEATHERED WHEN LOWERING A LOAD ------- 8 -9
HOIST WINCH WON'T LOWER OR HESITATES BEFORE LOWERING ------- 9
H O I S T WINCH LOWERS I N A JERKY MANNER ....................... lo

FILE, E
5. H O I S T WINCH MOTOR 8 . 1 GPM FLOW REGULATOR

6. A N T I C A V I T A T I O N VALVE 9. ADAPTOR PLATE
7. ONE WAY CHECK VALVES 10. CROSS L I N E R E L I E F VALVE
CARTRIDGE (PRESET AND SEALED
- - DO NOT ADJUST)
-1 -
FILE t
~
2. H O I S T BRAKE DRUM 5. LOWER CHECK VALVE & SEAT

3. H O I S T BRAKE CYLINDER 6. UPPER SPOOL
4. H O I S T BRAKE SPRING 7. O R I F I C E HOLE
-2-
FILE, E
I
H O I S T WINCH CROSS L I N E R E L I E F VALVE
----
8. C a r t r i d g e (PRESET & SEALED-DO NOT ADJUST)
9. Body
-3-
NLE, t
G A L I O N H O I S T WINCH OPERATION
WHEN TROUBLE- SHOOTING T H E G A L I O N WINCH, THE FOLLOWING SHOULD B E READ

' F O R A BETTER UNDERSTANDING O F THE OPERATION O F T H E G A L I O N WINCH C I R C U I T .
The winch brake cy1 inder hydraulically releases the

brake and the spring mechanically applies the brake
when the cy1 inder i s re1 ieved o f hydraul i c pressure.
The only time the winch brake i s released i s :
(1 ) when the winch i s 1 owered
or
( 2 ) when the crowd i s extended.
Because of a one way clutch (sprague g r o u p ) on the
winch motor input s h a f t , the brake needs only t o be
released when lowering the winch, b u t does not need
t o be released in winch raising operations. The
sprague g r o u p (one way clutch) i s necessary on the
hoist winch because i t keeps the payload from d r i f t i n g
down i f the payload i s stopped d u r i n g any p a r t of i t s
u p or down motion. The purpose of the one way clutch
(sprague g r o u p ) i s t h a t during the stopping and re-
s t a r t i n g of a l o a d in mid-air, the l o a d will n o t d r i f t
down before raising.
The winch brake i s released when crowding o u t due t o
Galion's exclusive crane protection feature.
The p i l o t l i n e t o the winch brake cylinder i s connected
only t o the base end of the crowd c y l i n d e r ( s ) . There-
f o r e , the winch brake i s released when the crowd c y l i n d e r ( s )
i s extended, because of the increase in hydraulic pressure
in the crowd cylinder. This increase in pressure i s present
in the p i l o t or sensor l i n e .
H O I S T WINCH D R I F T S W I T H LOAD
WHEN T R O U B L E S H O O T I N G A WINCH T H A T D R I F T S , I T I S VERY IMPORTANT T H A T

THE OPERATOR DEMONSTRATE THE D R I F T C O N D I T I O N . A CROWD C Y L I N D E R OVER-
CENTER CHECK VALVE M I G H T B E STUCK OPEN AND T H I S CAN ONLY BE DETERMINED
I F THE BOOM I S ELEVATED AND CROWDED OUT. I F THE D R I F T C O N D I T I O N CANNOT
BE DEMONSTRATED BY THE OPERATOR, I T I S A MUST THAT THE OUTRIGGERS B E
LOWERED, THE BOOM ELEVATED AND THE CROWD EXTENDED BEFORE THE FOLLOWING
TROUBLE SHOOTING I S ATTEMPTED.
A. Check the winch brake cylinder push rod and determine

i f i t i s f r e e of l o a d . ( I f the brake rod i s f r e e o f
load, i t can be rotated w i t h finger touch). I f i t i s
not f r e e , proceed with Steps 1 , 2 & 3 following. I f
the brake cylinder push rod i s f r e e , eliminate Steps
1 , 2 & 3 and proceed w i t h St- 5 which follow.
READ EACH TROUBLE SHOOTING S T E P THOROUGHLY BEFORE
PROCEEDING.
-4-
FILE t
(1 ) With the manifold control valves i n neutral ,

outriggers down, boom f u l l y elevated and boom
crowded o u t , loosen the o i l supply 1 ine tube
n u t a t the hose leading from the winch brake
cy1 inder. I f the winch brake cylinder relieves
i t s e l f and no more o i l flows from the l i n e ,
the problem i s t h a t the 1 gallon per minute
flow regulator i s plugged. This 1 GPM flow
regulator i s located a t the other end of the
winch brake cylinder o i l supply l i n e a t the
winch motor a d a p t o r plate.
( a ) Remove the 1 GPM flow regulator
and clean. I f the regulator cannot
be cleaned, replace i t . Note:
I n s t a l l 1 GPM flow regulator so t h a t
the end marked " I n " faces the hyd-
r a u l i c winch motor.
I f the winch brake cy1 inder re1 ieves i t s e l f when
the o i l supply 1 ine tube n u t i s loosened, b u t o i l
continues t o flow from the loosened tube, the
problem i s a crowd cylinder overcenter check valve
i s stuck open. To determine which crowd cylinder
overcenter check valve i s leaking ( i f the crane i s
equipped w i t h more t h a n one crowd cy1 inder) observe
the boom extensions and determine which one i s d r i f t -
i n g i n . This can be double checked by the f o l l o w i n g
procedure:
With the outriggers down, boom f u l l y elevated, crowd
cy1 inders extended and engine shut o f f , move the
manifold crowd control lever t o the r e t r a c t position
and observe the boom extensions. The extension t h a t
d r i f t s i n this condition i s the one t h a t has the over-
center check valve stuck open.
( a ) Lower the boom, r e t r a c t a l l crowd cy1 inders
and remove the defective overcenter check
valve. Clean valve i f possible and r e i n s t a l 1 ,
b u t i f the valve s e a t i s damaged, the e n t i r e
valve must be replaced.
(3) I f the o i l supply l i n e tube n u t i s loosened and no o i l
under pressure drains from the loosened l i n e and the
brake cylinder push rod i s s t i l l h o l d i n g the brake o f f
(rod cannot be freely rotated) the problem may be the
winch brake cylinder push rod i s adjusted too l o n g .
- 5-
FILE, t
( a ) Remove the winch brake cylinder and check
t h e push rod length. The length of the brake
cylinder push rod must be approximately 2 11/16"
from t h e rounded end t o , and including, the
locking n u t on the threaded end. Adjust the
push rod t o approximately 2 11/16" i f necessary.
Before r e - i n s t a l l i n g the brake cylinder, check
the brake cylinder piston and make c e r t a i n
t h a t i t s l i d e s f r e e l y in the cylinder b a r r e l .
If i t does n o t s l i d e f r e e l y , t h e cylinder will
have t o be repaired or rep1 aced.
( 4 ) I f the winch i s d r i f t i n g and the winch brake cy1 i nder
push rod can be rotated f r e e l y , when outriggers a r e
down, boom i s a t maximum elevation and crowd i s extended ,
two items can be causing the d r i f t i n g condition:
A ) The winch brake needs burnishing
B ) The winch brake shoes have o i l on them.

Proceed w i t h the e a s i e s t s t e p f i r s t ,
providing no o i l i s v i s i b l e a t brake drum.
TO PROPERLY BURNISH THE WINCH BRAKE:
( a ) Disconnect t h e o i l supply tube from t h e hose

leading t o t h e winch brake cylinder.
( b ) Block t h e open tube so no o i l will be l o s t .
( c ) Activate the intermediate h o i s t manifold control

lever i n the down position with t h e engine a t
maximum RPM f o r no more t h a n 3 seconds.
Repeat t h i s operation 5 or 6 times, allowing
the drum t o cool f o r 45 seconds a f t e r each 3
second brake application. Allow brake shoes
and drum t o cool f o r a t 1 e a s t 15 minutes.
( 5 ) After d o i n g Step No. 4 , i f t h e winch brake s t i l l d r i f t s ,
t h e brake shoes have o i l on them caused by:
A ) Winch gear case o v e r f i l l ed with o i l .
B ) Defective oi 1 s e a l .
C ) Bore for the o i l seal in t h e brake a d a p t o r

p l a t e more t h a n .008 o f f center.
D ) The seal sleeve has more than .008 run o u t .
New brake shoes , a new o i l seal and/or a
new brake adaptor p l a t e and/or seal sleeve
will have t o be i n s t a l l e d and t h e new brakes
must be burnished a f t e r i n s t a l l a t i o n .
-6-
FILE, t
* To perform t h i s j o b i t i s suggested t h a t the counter-

weight be removed from the crane. The counterweights
vary i n weight depending on the crane model.
CRANE MODEL WEIGHT
To i n s t a l l the new parts:

( a ) Lower boom t o horizontal position and
check the o i l level i n the winch gear case.
This oil level must be correct.
-- - x- ( b ) Remove counterweight.
*
.. */. x- ( c ) Remove brake housing cover casting.
-
.-
{
x- ( d ) Pull brake drum, adaptor flange, sprague g r o u p

and i n p u t shaft from winch housing as one u n i t .
* The counterweight does This will expose the brake shoes.
-
n o t have t o be r e m s
from crane s t a r t i n g ( e ) Remove brake shoes , brake backing plate and
w i t h Serial Number adaptor plate.
3990 ti Up.
( f ) Dial indicate the bore for the seal and the
Cranes a f t e r Serial p i l o t diameter o f the adaptor plate. Run o u t
Number 3990 have a between these two diameters must n o t exceed .008.
modification t o the
brake and shaft Dial indicate the seal sleeve on the i n p u t
assembly t h a t does shaft t h a t enters the seal. To do t h i s , f i r s t
n o t require removal mount the i n p u t shaft group i n a vise and d i a l
o f the counterweight indicate from the i n p u t shaft to the seal sleeve.
t o service the brake Run o u t must n o t exceed .008 when drum and clutch
and related components. i s rotated i n one direction. If e i t h e r or b o t h
The brake housing cover indicate more t h a n .008 o u t o f round, they must
was eliminated also a t be replaced.
the above serial
number. ( 9 ) Install adaptor plate and s e a l . Instal 1 brake
backing plate.
-7- ,--
r
FILE', t
SHOP MANUAL SECllON 15
I n s t a l l brake shoes. NOTE:
Observe stamped retaining e a r on curved
metal portion of brake shoe. For proper
i n s t a l l a t i o n o f shoes, this stamped
retaining ear must be behind the expander
p i v o t arm located on the brake backing plate.
The two shoe return springs must be hooked
i n the holes i n brake shoes t h a t a r e nearest
the brake backing plate.
I n s t a l l the i n p u t s h a f t and drum assembly.
I n s t a l l brake cover housing casting. NOTE:
The s e t screw i n the cover housing i s properly
adjusted by turning the s e t screw i n snug against
the i n p u t s h a f t and backing i t o u t one quarter
turn. Lock s e t screw in t h i s position.
Connect winch brake cylinder linkage t o brake arm.
Burnish new brake shoes by disconnecting the o i l
supply tube from the hose leading from the winch
brake cy1 inder. B1 ock the open tube so no oi 1
will be l o s t . Remove the brake spring, s t a r t
engine and a c t i v a t e the f a s t hoist i n the down
p o s i t i o n for 3 seconds. (Apply the winch brake
manually d u r i n g this operation). A1 low the
brake drum t o cool for 45 seconds. Repeat t h i s
operation 5 or 6 times , a1 lowing the drum t o cool
for 45 seconds a f t e r each brake application.
Allow brake shoes and drum t o cool for a t l e a s t
1 5 minutes. I n s t a l l the brake cylinder spring.
After the 15 minute cooling period, s t a r t engine
and a c t i v a t e the f a s t hoist manifold control
lever i n the down position w i t h the engine a t
maximum RPM. I f the winch refuses t o lower a t
t h i s p o i n t , the brake has been s a t i s f a c t o r i l y
burnished. Doing this s t e p proves t h a t any 1 oad
the winch will 1 i f t will be properly he1 d by the
winch brake.
Connect the winch brake o i l supply tube t o the
hose leading from the brake cylinder.
Instal 1 counterweight.
' HOIST WINCH CANNOT B E FEATHERED WHEN LOWERING A LOAD.
AN ANTI-CAVITATION VALVE I S MOUNTED O N TOP OF THE WINCH HYDRAULIC MOTOR
AND PREVENTS THE MOTOR FROM CAVITATING (STARVING FOR OIL) AND IN TURN
ALLOWS CONTROLLED FEATHERING WHEN LOWERING A LOAD.
A. Bottom Spool i n the a n t i -cavi t a t i o n valve i s stuck open and

w i l l not return t o the closed p o s i t i o n .
H1
- 8-
FILE, E
-~ SHOP MANUAL SECTION 15
( 1 ) Disconnect the large o i l supply tube

connected t o the anticavitation valve.
Remove the s t a t i o n a r y sleeve, bottom
spool valve and spring located inside the
Val ve body.
( a ) Pol ish the valve bore and spool sleeve
until i t slides freely i n the valve
body. Crocus cloth should be used i n
t h i s operation.
B. The top spool i n the anticavitation valve body i s
stuck open due t o foreign material or scoring.
( 1 ) Remove the anti-cavi tation valve and remove the
upper spool from valve body.
( a ) Clean o u t foreign material and/or
pol ish spool and bore i n valve body
w i t h crocus cloth t o remove scoring.
HOIST WINCH WON’T LOWER OR HESITATES BEFORE LOWERING.
A. The top spool i n the anticavitation valve i s stuck

closed due t o foreign material , scoring, spring over-
s i z e , no s l o t i n the small end o f the upper spool or
the o r i f i c e hole i n the end cap is plugged.
( 1 ) Remove the anticavitation valve.
Remove the upper spool from the valve body.
( a ) I f spool i s scored, remove scoring w i t h
crocus cloth and polish bore i n valve body
until spool rotates 360°, freely and slides
freely i n bore.
( b ) I f spring i s dragging i n bore o f valve body,
g r i n d spring u n t i l the outer diameter i s
the same s i z e as the retaining washers on e i t h e r
end. Clean spool thoroughly and replace.
( c ) I f there i s no slot i n the small end o f the
upper spool , g r i n d a s l o t 1 /8” wide and 1 / 8 ”
deep across the end and thru the center of
the spool. Clean spool and replace.
( d ) Check o r i f i c e hole i n end cap; i t may be
plugged with foreign material or peened shut.
Clean o u t foreign material. I f i t i s peened
shut, d r i l l o u t hole. Hole s i z e i s 1/64”
diameter. DO NOT DRILL OVERSIZE.
-9-
FILE E
l
HOIST WINCH LOWERS IN AN U N E V E N OR JERKY MANNER.

A. The t o p spool i n the anticavitation valve i s
"bouncing" back and forth due t o a s l i g h t
sticking or scoring o f spool.
( 1 ) Remove anticavitation valve and remove upper
spool .
( a ) Use crocus cloth t o polish upper spool and bore
i n valve body. Continue polishing operation
u n t i l spool s l i d e s i n bore freely and can be
rotated 360" also. Wash valve thoroughly, re-
assemble and replace.
B. Winch brake drum o u t of round.
( 1 ) Remove counterweight.
( 2 ) Remove brake housing casting.
( 3 ) P u l l brake drum, adaptor flange, sprague group
and i n p u t s h a f t from winch housing as one u n i t .
( 4 ) I n s t a l l dial indicator on i n p u t shaft and d i a l indicate
t o the inside diameter o f the brake drum where the
brake lining contacts the drum. To do t h i s f i r s t
mount the i n p u t shaft group i n a vise and d i a l indicate
from the i n p u t s h a f t t o the inside diameter o f the
brake drum.
( a ) I f the runout exceeds .005 a new drum must
be installed.
( b ) I n s t a l l new drum t o i n p u t s h a f t assembly and
dial indicate the new drum t o be certain t h a t
i t i s w i t h i n the proper .005 runout tolerance.
( c ) Dial indicate from the i n p u t shaft t o the seal
sleeve outer diameter. This runout tolerance
must n o t exceed .008.
( d ) When b o t h to1 erances a r e determined t o be
w i t h i n 1 imi t s , re-assembl e a1 1 components.
HOIST WINCH WILL NOT LIFT LOAD.
A. Hook block n o t reeved w i t h s u f f i c i e n t parts of l i n e .
(1 ) C o u n t the number o f parts of 1 ine t h a t are between
the head block and hook block and make c e r t a i n t h a t
the parts o f 1 ine a r e correct for the 1 i f t t h a t i s
being attempted.
- 10-
I
FILE, E
SHOP MANUAL S€CT/ON 15
( a ) All models of Gal ion Cranes EXCEPT the
150A Crane a r e rated a t 5400 pounds
single p a r t l i n e pull. Two part l i n e
r a t i n g i s 10,800 pounds , three p a r t 1 ine
rating is 16,200 pounds, four part l i n e
rating i s 21,600. pounds f i v e part 1 ine
rating i s 27,000 pounds.
( b ) 150A CRANE PART LINE RATING:
1 part rating 6200#

2 part rating 12,400#
3 part rating 18,600#
4 part r a t i n g 24,800#
5 part r a t i n g 31 ,OOO#
B. Insufficient hydraulic pressure on 30 gprn system or
50 gpm system, depending on which c i r c u i t i s being
used f o r l i f t i n g .
NOTE: The 50 gpm system (intermediate h o i s t ) has s l i g h t l y more
l i f t i n g capacity t h a n the 30 gpm system. The 50 gpm
system should always be used when l i f t i n g a maximum
load.
( 1 ) Refer t o index f o r section covering slow controls
or lack of power in e i t h e r 30 gprn or 50 gpm c i r c u i t s .
C. Winch motor cross 1ine re1 i e f valve stuck open due t o
foreign material.
NOTE: Cross l i n e r e l i e f valve assembly i s located on the
rear of the anticavi tation valve mounted on t o p of
the winch hydraulic motor.
(1 ) Remove re1 i e f valve cartridge from body without
breakina., the s e a l .
Inspect cartridge f o r foreign material
holding spool off s e a t .
Clean valve by inserting proper s i z e rod or
tool in end of c a r t r i d g e , depress plunger
and flush foreign material with compressed
a i r or solvent.
If valve cannot be cleaned or i f i t i s sticking
open due t o scoring, replace complete valve
assembly. DO NOT ATTEMPT TO DISASSEMBLE THIS
VALVE, I T I S SEALED AND PRESET.
D. Faulty winch hydraul i c motor.
( 1 ) If correct part l i n e i s being used, hydraulic
pressures a r e correct and cross 1 ine re1 i e f valve
i s functioning properly, the winch motor is faulty.
Repair or replace as necessary. .. .
R1
-11-
FILE E
SECTION V I I
REAR S T E E R I N G
FILE, E
REAR STEERING CYLINDERS DRIFT.
A. One or b o t h rear steering cylinders leaking internally.

(1 ) W i t h the rear wheels steered s t r a i g h t and
engine shut o f f , a c t i v a t e the r e a r steering
manifold control 1 ever i n both directions t o
relieve the hydraulic pressure.
(2) Remove access cover t o hydraul i c manifold on
the front of the operator's platform.
( 3 ) Disconnect the rear steering o i l supply tubes
a t the hydraulic manifold and cap b o t h tubes.
( 4 ) Start engine, ( d o n o t a c t i v a t e rear steering
manifold control ) , and road t e s t crane.
(5) I f the rear wheels d r i f t , one o r b o t h o f the
rear steering cylinders a r e leaking internally.
( a ) Repair or replace cylinders as necessary.
(6) I f the rear wheels do n o t d r i f t i n Step 5 , the
m a n i f o l d control v a m leaking internally.
( a ) Replace complete rear steering manifold
control valve.
FILE E
SECTION VI I I
OUTRIGGERS
Page
2
FILE E
8. CHECK VALVE
9. MAXIMUM PRESSURE VALVE
( PRESET-NON-ADJUSTABLE)
10. P I L O T VALVE
-I-
FILE, E
OUTRIGGER CYLINDER DRIFT.
ALWAYS CHECK AND BE CERTAIN THAT THE CRANE HAS PILOT OPERATED CHECK
VALVES INSTALLED BEFORE PROCEEDING WITH ( A ) BELOW. I F NO PILOT CHECK
VALVES ARE ATTACHED TO THE OUTRIGGER CYLINDERS, PROCEED IMMEDIATELY WITH
(C) '
A. P i l o t operated check valve n o t holding properly.
(1 ) Lower t h e outrigger u n t i l t i r e c l e a r s
t h e ground.
( 2 ) S h u t engine off and operate outrigger
hydraul i c manifold control 1 ever in the
r a i s e position (back). I f the outrigger
cy1 inder collapses rapidly, the p i l o t
check valve i s being held off i t s s e a t by
foreign material or t h e valve s e a t is.
defective.
( a ) Relieve pressure from outrigger
cylinder by a c t i v a t i n g t h e manifold
control l e v e r w i t h the engine shut o f f .
( b ) Remove p i l o t operated valve block
assembly from cy1 inder.
( c ) Clean, r e p a i r or replace valve.
B. Cylinder leaking i n t e r n a l l y .
(1 ) If t h e cy1 inder does n o t collapse b u t
continues t o d r i f t a t t h e same given r a t e
(when t h e control valve was activated i n
( A ) above) t h e cylinder i s leaking i n t e r n a l l y .
( a ) Remove t h e cylinder piston rod and
inspect f o r worn packing or
internal scoring. (This can be done
w i t h o u t removing t h e cylinder from
the crane). Repair i f possible, i f
n o t , replace e n t i r e cylinder.
C. If t h e crane has no p i l o t check valves i n s t a l l e d on
the outriggers, a d r i f t i n g cylinder can only be caused
by a cylinder leaking i n t e r n a l l y or excessive leakage
by t h e manifold control valve.
( 1 ) Repair cylinder i f possible or i n s t a l l a new
cy1 i nder .
( 2 ) If d r i f t continues a f t e r repairs a r e made or
a f t e r i n s t a l l i n g a new cylinder, t h e hydraulic
manifold control valve i s leaking.
( a ) I n s t a l l new manifold valve assembly.
FILE, E
OUTRIGGERS CHATTER WHEN R A I S I N G .
The p i l o t operated check v a l v e s on t h e o u t r i g g e r

cy1 i n d e r s will cause t h e o u t r i g g e r s t o c h a t t e r when
r a i s i n g them under l o a d . T h i s i s a normal c o n d i t i o n
due t o t h e design o f t h e p i l o t check valves. T h i s
c h a t t e r i s more pronounced i f t h e engine i s a t a l o w
RPM when t h e o u t r i g g e r s a r e r a i s e d . To overcome t h i s
c o n d i t i o n , i n c r e a s e t h e engine RPM t o 3/4 t h r o t t l e
o r above and f e a t h e r t h e o u t r i g g e r c o n t r o l v a l v e t o
r a i s e t h e c y l i n d e r . Unload one o u t r i g g e r a t a t i m e
u n t i l t h e y c l e a r t h e ground, t h e n b o t h can be r a i s e d
together.
The m a n i f o l d c o n t r o l v a l v e s may t e n d t o o p e r a t e " hard" ,
b u t t h i s i s normal.
I T IS A MUST THAT THE ABOVE BE EXPLAINED TO AN OPERATOR

WHEN DELIVERING A NEW CRANE.
-3-
GRADER 0
PLANER 0
ROLLER 0
CRANE Id
Shop Manual F-6.20

c3
90, 100, 110 & 125 03991 thru 08774

90A, 100A, llOA & 125A 02006 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 03990 & Up
150FA 07305 & Up
200FA 09401 & Up
CAUTION

GOOD WORKING ORDER.
I EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT

INJURY.
I SAFE WORKSHOP PRACTICES ARE A MUST.
CONTENTS Page
Configuration Changes . . . . . . . . .. . . . . . . . . Back of Cover
Removal of Winch Assembly from Crane .. ... . . ..... 1
Disassembly . . . . . . . . . . . . . .. ... . . . . . . . 2
I n s p e c t i o n & Cleaning . . . . . . . . .. . . . . . ..... 9
Reassembly . . . . . . . . . . . . . .. . . . . . ..... 10
I n s t a l l i n g Winch Assembly on Crane . .. . . . . . . . . . . 16
Testing. . . . . . . . . . . . . . . .. . , . . . . . .. . 17
General Torque Values . . . . . . . . .. ... ....... 18
1- GALION MANUFACTURING DIVISION

Dresser Industries. Inc , PO.Box 647, Galion, Ohio 44833, U S A . c3
0584
T h i s Shop Manual c o v e r s boom winch assemblies used on c u r r e n t s t y l e cranes ( e x c e p t Model 8 0 )
f r o m S e r i a l Number 3990 & Up, e x c l u d i n g 4004 & 4005.
Below a r e changes i n t h i s w i n c h assembly t h a t occured d u r i n g t h i s s e r i a l number range.
A
90/100/110/125 150A 90/100/110/125 125F/125FA/140F/150FA
200FA
Hydreco Winch 3991 t h r u 5303 3990 t h r u 4764 2006 t h r u 5324 ----
Motor and 5328
Commercial 5304 t h r u 5330, 4765 & Up 5325 & Up e x c e p t *

Shearing 5335 & 5340 5328
Winch Motor
1 / 2 " Wire 3991 t h r u 5744 ---- 2006 t h r u 5744 ----

Rope Drum
9/16" Wir e 5745 84 up 3990 84 Up 05745 & Up *

Rope Drum
From 5873 & Up t h i s h o u s i n g i s s t a n d a r d equipment.
* S e r i a l numbers on f r o n t c o v e r a p p l y t o t h e s e u n i t s f o r t h e above l i s t e d components.
c3
Dresser Industries. Inc. Construction Equipment Division P 0 . Box 647 Galion, OH 44833 U S A .
(419)468-4321
FILE F
-
Prior t o removal of winch assembly from crane, a l l wire

rope cable should be removed from t h e cable drum. Unspool
cable onto reel i n the same d i r e c t i o n as was on the drum
t o prevent kinking and evident destruction of cable. Store
reel of cable i n a dry place t o retard r u s t .
I t i s n o t necessary t o remove e n t i r e winch assembly from
crane i f problems a r e noticed i n the brake area. I t
will be necessary t o remove winch (or counterweight) i f winch
drum i s noticed t o be o u t of round and/or excessive noise
i s noticed because of gear t o o t h wear. Confined working
space and safety a l s o require winch removal.
For ease of i l l u s t r a t i n g purpose: the winch assembly in t h i s
section has been removed from t h e crane.
REMOVAL OF WINCH ASSEMBLY FROM CRANE
Disconnect and p lug hoses t o and from r o t a r y j o i n t .

Disconnect and plug tube from crowd cylinder.
W i t h s u i t a b l e h o i s t attached t o winch, remove three cap-
screws, lock washers and hex nuts holding winch assembly
t o base end of boom.
CAREFULLY LIFT WINCH ASSEMBLY FROM CRANE.
W i t h winch assembly removed and located i n a proper working

area, remove drain plug in bottom of gear case cover and
d r a i n approximately 2.50 U . S. gallons of o i l .
-1 -
FILE F
- SHOP MANUAL SECTION 6.2 0
-
DISASSEMBLY
Disconnect and plug brake tube (1)
cross 1 ine re1 ief valve tube ( 2 ) cross
,--?line relief valve (3) motor drain
tube (4) and flow regulator ( 5 ) .
Disconnect and plug anticavitation valve

sensor tube (1 ) .
Remove four cap screws, lock washers ( 2 )
oil supply/return hose ( 3 ) (to primary
manifold) and junction block (4).
NOTE: Do not lose O-ring i n top of
junction bZock or at hose fZange
half.
Figure 2
Remove four ferry head cap screws

(1) and anticavitation valve ( 2 ) .
NOTE: Do not Zose O-ring i n bottom
of anticavitation valve.
Figure 3
-2-
FILE F
-
NOTE: Notice t h e p o s i t i o n of the winch

motor, the pinion o r driven gear
side of housing i s touard the
r i g h t of the winch drum. This
i s important t o remember a t time
of reassemb Zy .
( 1 ) , motor ( 2 ) and gasket.
Figure 4
Remove input s h a f t ( 1 ) and drive coup1 ing

(2).
Figure 5
Remove four cap screws ( 1 ) , spacers

(under g u a r d ) and brake guard weldment
( 2 ) . (See note on cover page.)
Remove brake spring ( 3 ) and plunger

rod ( 4 ) from actuating lever ( 5 ) .
Remove two cap screws ( 6 ) , spacers
( 7 ) and brake cylinder ( 8 ) .
Figure 6
.
l
-3-
Remove four cap screws, lock washers ( 1 ) ,
i n p u t p i n i o n bearing r e t a i n e r cap ( 2 )
and brake drum ( 3 ) .
NOTE: Do not l o s e O-ring i.n bearing
r e t a i n e r cap.
Figure 7
Remove return springs ( 1 ) , brake shoes

( 2 ) and r o l l e r s ( 3 ) .
Figure 8
Remove i n p u t pinion bearing r e t a i n i n g

ring ( I ) , i n p u t pinion retaining ring
(2).
Remove one-way clutch housing assembly
(3) 0
Remove brake shoe actuating lever ( 4 ) .
Figure 9
-4-
FILE F
-
One-way clutch housing assembly includes:

(1) needle bearing
( 2 ) one way clutch
( 3 ) t h r u s t washer
( 4 ) bearing
Figure 10
Remove ten cap screws, lock washers ( 1 ) ,

four f e r r y head cap screws ( 2 ) , gear
case cover and gasket ( 3 ) .
Figure 11

( 1 ) and brake shoe backing p l a t e ( 2 ) .
Figure 12
-5-
FILE F
SHOP MANUAL SECTION 6.2 0
NOTE: Index mark brake adaptor p l a t e (1)

as shown, for r e -assembZy purposes.
Remove six cap screws , lock washers ( 2 )

and brake adaptor p l a t e
Remove two cap screws, lock washers
( 3 ) and pinion gear cap (4).
Remove wave washer under cap.
F i g u r e 13
Remove lock wire (1 ) , two cap screws

( 2 ) and p i n i o n gear s h a f t r e t a i n e r ( 3 ) .
Figure 14
Reposition winch, as shown, remove s i x

cap screws, lock washers ( 1 ) and winch
drum housing ( 2 ) with a s u i t a b l e h o i s t .
Figure 15
- 6-
FILE F
-
With a s u i t a b l e hoist attached t o

winch drum, l i f t against snap ring
and remove three cap screws, lock
washers and r e t a i n e r ( 1 ) .
Tension relieved on drum, remove
snap ring around drum drive s h a f t .
Lift drum from winch assembly.
Figure 1 6
Remove six cap screws, lock washers

( 1 ) and pinion gear cap ( 2 ) and
gasket.
Figure 1 7
Remove pinion gear s h a f t snap ring

( 1 ) and press s h a f t ( 2 ) t h r o u g h gear
s e t from t h i s s i d e .
Figure 18
-7-
FILE F
With pinion s h a f t removed, gear and

pinion s e t may be rolled o u t of case
in t h i s position.
Notice ball bear ing has been driven
o u t along with p inion s h a f t .
Inspection of ro l l e r bearing ( 1 ) may
require removal, f o r replacement and/or
cleaning .
Figure 19
Drive i n p u t p i n i o n ( 1 ) and bearings

from opposite side of case.
Figure 20
Remove six cap screws and lock washers.

Remove drum drive s h a f t bearing r e -
t a i n e r ( 1 ) and shims ( Z ) ,
Figure 2 1
-8-
FILE F
-
Drive drum drive s h a f t ( 1 ) from

opposite side of case and remove
s h a f t and bearings.
With drum drive s h a f t removed drum
drive gear may be r o l l e d from case.
Inner bearing cone may be removed a t
t h i s time f o r inspection.
Figure 2 2
INSPECTION 8t CLEANING
When winch i s completely disassembled, check a l l bearings,

housings, gears, s e a l s and gaskets f o r wear.
If bearings a r e scored or p i t t e d , replace. All bearings
should be immersed i n a cleaning solvent and slushed u p and
down t o make c e r t a i n a l l dirt or any type of foreign material
i s loosened or dissolved. Remove bearing from f l u i d and
s t r i k e l a r g e r s i d e of cone on a block of wood t o dislodge
s o l i d i f i e d p a r t i c l e s . Using moisture-free compressed air
dry bearings. Direct a i r across bearings, do n o t spin.
Examine housings, covers and bearing caps. Nith f i l e or crocus
c l o t h , be c e r t a i n t h a t nicks or burrs a r e removed.
Inspect gears w i t h MAGNA- FLUX process f o r cracks. Teeth
may be dressed with a f i l e or h o n i n g stone. I f t h i s process
i s n o t a v a i l a b l e , make a visual inspection f o r wear e t c .
Replace a l l worn s e a l s and old gaskets with new. P a r t numbers
a r e found i n appropriate p a r t s book.
Apply a l i g h t o i l film t o bearings and s e a l s p r i o r t o reassembly.
Bearings may be heated t o 25flOF. for ease of assembly.
-9-
FILE F
-
REASSEMBLY
Reposition winch case. Replace inner

bearing cup and cone.
S l i d e drum drive gear i n t o place in
housing and press drive s h a f t ( 1 ) into
spl i nes of gear. Rep1 ace outer bearing
cup and cone.
Position bearing r e t a i n e r cap ( 2 )
around d r i v e s h a f t w i t h o u t shims, do n o t
damage seal in cap on drive s h a f t
spl ines.
I n s t a l l s i x cap screws and lock washers
( 3 ) . Take down on cap evenly u n t i l
bearings a r e seated. Make sure s h a f t
turns e a s i l y with no preload or end play. Figure 23
Remove cap screws, lock washers, hand hold cap and measure g a p between cap and
housing. I n s t a l l enough shims t o give t h e s h a f t .003" t o .005" end play.
I n s t a l l and torque cap screws and lock washers.
Reposition winch case. I n s t a l l inner

bearing cup ( i f removed). Idith bearing
cones pressed o n t o input pinion s h a f t ,
i n s t a l l pinion. Align index marks and
i n s t a l l brake adaptor p l a t e ( 1 ) with
new seal ( 2 ) and without shims.
I n s t a l l cap screws ( 3 ) and take u p on p l a t e
evenly u n t i l bearings a r e seated. Vake
sure s h a f t turns e a s i l y with no preload
or end play.
Remove cap screws, lock washers hand hold
p l a t e and measure g a p between p l a t e and
housing. I n s t a l l enough shims t o give the
s h a f t .003" t o .085" end play. Instal 1
Figure 24 cap screws, lock washers and torque.
c1
-1 0-
FILE F
SHOP MANUAL SE C T I ON 6.2 0
-
Reposition winch assembly. With

gear and p i n i o n s e t (1 ) and bear-
i n g ( 2 ) i n place drive pinion
s h a f t ( 3 ) t h r o u g h gear s e t u n t i l i t
i s o u t the other side of case.
Figure 25
Reposition winch assembly. I n s t a l l

snap ring ( 1 ) on pinion gear s h a f t ( 2 ) .
Figure 26
I n s t a l l pinion gear s h a f t gasket

and cap ( 1 ) .
I n s t a l l s i x lock washers and torque
cap screws ( 2 ) .
Figure 27
-11-
Reposition winch assembly and with a
s u i t a b l e h o i s t place drum onto drum
drive s h a f t .
I n s t a l l snap ring. With hoist l i f t
drum against snap ring and i n s t a l l re-
t a i n e r r i n g ( 1 ) with three cap screws,
lock washers, and torque.
Figure 28
With h o i s t l i f t winch drum housing

( 1 ) i n t o place.
I n s t a l l s i x cap screws and lock
washers ( 2 ) and torque.
Figure 29
Reposition winch. I n s t a l l pinion gear

s h a f t r e t a i n e r w i t h two cap screws lock
washers, torque and lock wire.
I n s t a l l wave washer, gasket, pinion
gear s h a f t cap ( 1 ) w i t h two cap screws,
lock washers ( 2 ) and torque.
Figure 30
-1 2-
FILE F
-
I n s t a l l brake backing p l a t e ( 1 ) w i t h
four cap screws, lock washers ( 2 )
and torque.
,
Figure 31
I n s t a l l gear case gasket and cover

( 1 ) w i t h ten cap screws and lock
washers ( 2 ) and four f e r r y head
cap screws ( 3 ) . Torque a l l cap
screws.
Figure 32
I n s t a l l brake shoe actuating lever ( 1 ) .
I n s t a l l needle bearing and one-way clutch int
housing ( 2 ) .
NOTE: When i n s t a l l i n g one-way c l u t c h i n t o
housing bore make c e r t a i n t h a t t h e shoulder i
pointing outward. I f insta22ed i n reverse
t h e operation o f the winch wiZ2 be reversed.
(See page 5, Figure 7 0 f o r r e f e r e n c e ) .
Position one-way clutch housing on s h a f t .

Slowly r o t a t e counterclockwise. Sprags in
clutch will collapse and s l i d e i n t o place.
I n s t a l l t h r u s t washer, ball bearing, bearing
r e t a i n e r ring ( 3 ) and input pinion r e t a i n e r
ring ( 4 ) .
13-
FILE F
Instal 1 brake shoe r o l l e r s ( 1 ) o n t o cam

1 evers.
Instal 1 brake shoes ( 2 ) .
NOTE: 'vote t h e stamped r e t a i n i n g ear on
curved metal p o r t i o n of brake shoes. For
proper i n s t a l l a t i o n o f shoes,this stamped
r e t a i n i n g ear must be behind t h e cam l e v e r
located on t h e brake backing p l a t e .
I n s t a l l brake shoe return springs ( 3 ) .

NOTE: The too shoe r e t u r n springs must
be hooked i n t h e brake shoe holes
located nearest t h e brake backing
plate.
F i g u r e 34
I n s t a l l brake drum ( l ) , input pinion

bearing r e t a i n e r cap ( 2 ) , w i t h O-ring,
four cap screws and lock washers ( 3 )
and torque.
F i g u r e 35
I n s t a l l brake cylinder ( 1 ) w i t h two

cap screws, lock washers ( 2 ) spacers
( 3 ) and torque.
I n s t a l l brake cylinder push rod ( 4 )
~ t o actuating brake lever ( 5 ) .
I n s t a l l brake spring ( 6 ) t o actuating
lever and base end of brake cylinder.
Instal 1 brake guard ( 7 ) with four cap
screws ( 8 ) and spacers. Torque cap
screws.
F i g u r e 36 Cl
-1 4-
I n s t a l l input p i n i o n s h a f t (1 ) and
drive coupling ( 2 ) .
F i g u r e 37
Instal 1 winch motor gasket, motor (1 )

with four cap screws and lock washers
( 2 ) and torque.
NOTE: Notice t h e p o s i t i o nof t h e winch

motor. The p i n i o n o r d r i v e n
gear s i d e o f t h e housing i s
touard t h e r i g h t of t h e winch
drum.
Figure 38
I n s t a l l a n t i c a v i t a t i o n valve ( 1 ) w i t h
four f e r r y head cap screws ( 2 ) and
torque t o 40-50 f t . 1 bs. (dry) or
35 f t . l b s . ( l u b . ) .
F i g u r e 39
-1 5-
FILE F
-
I n s t a l l junction block ( 1 ) , o i l return

supply hose ( 2 ) w i t h four cap screws
lock washers ( 3 ) and torque.
Ensure t h a t O- ring i s in t o p o f
junction block and flange h a l f .
Remove plugs and i n s t a l l a n t i -
c a v i t a t i o n valve sensor tube ( 4 ) .
Figure 40
I n s t a l l flow regulator ( 1 ) . Remove

plugs and i n s t a l l motor drain tube ( 2 ) ,
cross l i n e r e l i e f valve ( 3 ) , cross l i n e
r e l i e f tube ( 4 ) and brake tube ( 5 ) .
Figure 41
INSTALLING WINCH ASSEMBLY ON CRANE
Before i n s t a l l i n g winch on crane, f i l l gear case a t t o p plug

with 2.50 U.S. gallons of l u b r i c a n t specified i n Shop Manual
F i l e J , Section 1 .
WITH HOIST,CAREFULLY LIFT WINCH INTO POSITION AT BASE E N D O F
BOOM. INSTALL THREE CAP SCREWS, LOCK WASHERS AND H E X NUTS.
TORQUE CAP SCREWS TO 300 FT. LBS.
Remove p l u g and connect crowd cylinder tube.
Remove plugs a n d connect hoses t o r o t a r y j o i n t .
-1 6 -
FILE F
-
-_
.TESTING-
- . ..
After the winch assembly has been i n s t a l l e d , i t must be operated t o

ensure t h a t proper spooling o f wire i s being achieved.
Units t h a t have a fixed counterweight must be tested in the following
manner:
1. Position boom a t intermediate angle of approximate 50°, f u l l y

extend a l l boon: sections and completely lower hook block.
2. Hoist u p hook block and observe i t s spooling action. If rope

builds u p a t eigher end of drum, the winch will have t o be
shimmed.
3. A shim k i t , AG-148583, i s available with directions on how t o

correct the misspooling.
Units t h a t have a movable counterweight do not have t o be tested.
c2
-1 7 -
GENERAL TORQUE~VALUES
NOTE: Torque Values listed thr oughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
1 Heat treated material Grade 5 & Grade 8
Grade 5 Grade 8
Thread Size (3 radial dashes on bolt or cap screw head) (6 radial dashes on bolt or cap screw head)
Foot Pounds
IFt. Lbs.) (Nm)
1/4 . 20 9 12
1/4 - 28 11 15
5/16 . 18 la 24
5/16 - 24 21 28
3/8 - 16 34 46
3/8 - 24 38 52
7/16 - 14 54 13
7/16 - 20 60 81
1/2 - 13 a2 111
1/2 - 20 90 122
9/16 - !2 120 163
9/16 - 18 132 179
5/8 . 11 165 224
5/8 - 18 185 251
3/4 - 10 290 393
3/4 - 16 320 434
7/8 - 9 455 617
7/8 . 14 515 698
1 - 8 695 942
1 - 14 785 1064
1 1/8 . 7 990 1342
1 1/8 . 12 1110 1505
1 1/4 - 7 1400 1898
1 1/4 . 12 1550 2102
1 3/8 . 6 1830 2481
1 3/8 . 12 2085 2827
1 1/2 . 6 2430 3295
1 1/2 . 12 2730 3701
1 3/4 - 5 3810 5166
2 . 4 112 5760 7810
C2
- 1 8-
GRADER 0
PLANER El
ROLLER 0
CRANE [a
Shop Manual F-I 0

RWC3
SPRING MOTORS
90 thru 125 01254 & Up
90A thru 125A 02006 & Up
125F 07247 & Up
125FA 07990 & Up
125P 01031 & up
140F 07571 & Up
150A 02832 & Up
150FA 07305 & Up
150P & 150T 01001 & up
200FA 09401 & Up
CAUTION

GOOD WORKING ORDER.
CONTENTS Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . 1
Unloading R e t r a c t Mechanism . . . . . . . . . . . . . . . . . 2
SERVICE TO O L D TYPE SPRING MOTOR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE TO NEW TYPE SPRING MOTOR
Spring Cartridges . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 23
S h a f t Bearings and Cable Drum . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reloading R e t r a c t Mechanism . . . . . . . . . . . . . . . . . 37
Adjustment . . . . . . . . . . . .............. 38
Lubrication of Gleason Reel . . ............... 40
c3
NOTE: Torque Values listed thr oughout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Grade 5 Grade 8
(Ft. Lbs.) (Nm) (Ft. Lbs.1 (Nm)
1/4 20- 6 8 9 12
1/4 - 28 7 9 11 15
5/16 - 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 . 24 33 34 46
3/8 - 24 21 37 38 52
7/16 . 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 ~12 84 114 120 163
9/16 ~18 93 126 132 179
5/8 - 11 115 156 165 224
5/8 - 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 - 9 305 414 455 617
7/8 - 14 335 454 515 698
1 - 8 455 617 695 942
1 - 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 - 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 2481
1 3/8 . 12 1290 1749 2085 2827
1 1/2 - 6 1500 2034 2430 3295
1 1/2 - 12 1690 2291 2730 3701
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
c2
FILE F
The Galion Hydraulic Crane, equipped with the four-section power

boom, utilizes a rotary spring motor and trolley system to main-
tain tension on the hydraulic hoses supplying o i l to the dual
crowd cy1 i nder .
I
8 .
Two different styles of spring motors have been installed, Proper

identification is important since the arrangement of components
is somewhat different.
Figure 1
The new type spring motor is being installed on new cranes. This
new spring motor has spring tension indicators which will indicate
a broken spring when the following test i s conducted:
Put all outriggers to the ground. Fully extend the boom horizontally
over the front of the machine. If a motor spring is broken, the
indicator will extend from the top of the case. If a spring is
functioning correctly the indicator will fall.
Changeover from the previous spring motor to the new type spring
motor requires these items:
(1 ) Threaded studs to secure spring motor to boom, originally
3/8-16 UNC x 1 " long, must be 3/8-16 UNC x 1 3/4" long.
(2) D-82864 flat washer and D-53985 lock nut that retain cable
drum to spring motor shaft must be replaced with D-85044 flat
washer and D-57988 lock nut. c1
- -
-1 -
FILE F
SHOP MANUAL
~
SECTION 10
UNLOADING RETRACT M E C H A N I S M
If crane i s equi pped with new type spring

motor, remove splanner wrench from motor.
If old type spri ng motor i s used , proceed
t o Figure 6.
Fimre 2
Remove access cover from motor.
Two holes are provided in spr i n g h u b for

insertion of spanner wrench.
..-
Figure 4 R1
FILE F
Counterclockwise rotation of spanner

wrench re1 ieves tension on hose
t r o l l ey.
Firmre 5
I f crane i s equipped w i t h o l d type spring

motor, a large (15 or 1 6 inch) adjust-
able wrench may be used on shaft f l a t s .
Counterclockwise r o t a t i o n of adjustable
wrench relieves tension on hose trolley.
.. .
Figure 6
Lock hose t r o l l ey t o track w i t h sui t a b 1 e

tool.
Figure 7 R1
-3-
a#* -
ROLLtRs~GRLotRs*CRIMS
SHOP MANUAL
FILE
SECTION
F
10
Disconnect spring motor cable from hose

trolley while assistant holds counter-
clockwise tension with wrench on spring
motor.
CAUTION: USE CARE ALLOWING SPRING MOTOR
TO UNWIND. APPROXIMATELY TWO
TURNS OF WRENCH MUST BE RE-
LIEVED SLOWLY.
SERVICE TO OLD T Y P E SPRING MOTOR

DISASSEMBLY
Remove spring motor from crane to work-

bench. With adjustable wrench on shaft
flats, loosen lock nut that retains cable
drum.
FILE F
-
Using soft-head mal l e t , t a p drum t o re-

move from shaft.
Fimre 11
Remove woodruff key from shaft .
Figure 1 2
Remove four cap screws, nuts and washers

t h a t retain spring cover t o outer
housing.
-5- Figure 13 R1
FILE F
Remove spring cover.
Figure 14
Remove two pawls and two pawl springs.

Note position o f pawls and pawl springs
upon removal.
Remove four cap screws, nuts and washers

t h a t retain outer housing t o inner
housing.
. -
Figure 16 R1
i
FILE F 1
SHOP MANUAL S E C T IO N 10
Lift outer housing from shaft.
Figure 17
Remove snap ring from shaft.
F i g u r e 18
Remove two pawls and two pawl springs.
-7 - Figure 19 R1
FILE F
Remove four cap screws, nuts and lock

washers t h a t retain inner housing t o
back plate.
F i g u r e 20
Remove inner housing from shaft.
Figure 21
Remove snap ring.
F i g u r e 22 R1
-8-
- ._
.
FILE F
Remove six flat-head mach ine screws t h a t

retain back plate t o bear ing housing.
Figure 23
Press shaft from bearing and housing.
Figure 24
I f bearing requires replacement, press

bearing from housing.
,,".
i
7
1
Figure 25 R1
FILE F
If bearing in spring cover requires re-

placement, press bearing from spring
cover.
Figure 26
Inspect spring pack assemblies closely

for broken spring (s). If spring is
broken, remove center h u b by removing
h u b hinge pin.
Fimre 27
Remove h u b from spring.
/ Figure 28 R1
-10-
FILE F
Remove n u t from s p r i n g anchor cap screw
Secure rope o f a t l e a s t 20' l e n g t h t o

i n n e r end o f s p r i n g .
Figure 30
Secure s p r i n g housing i n v i s i o r o t h e r
s u i t a b l e f i x t u r e . Standing a t a s a f e
distance, yank s p r i n g from housing by
p u l l i n g on rope.
-11-
FILE F
Spring removed from housing.
Remove cap screw and broken end of spring

hinge from housing i f required.
Clean a l l parts thoroughly before re-
assembly.
ASSEMBLY
Firmre 33
CAUTION: EXTREME CAUTION MUST BE EXER-
CISED IN REPLACING SPRING(S)
TO PREVENT PERSONAL INJURY.
Spring can be installed wrong in housing.

Make sure t h a t spring proceeds t o the
right from outer hinge inward, per
drawing.
Figure 34 R1
12
.
1
I
FILE F
Fabricate two "U"-shaped loops of No. 9

o r l a r g e r wire. Make c e r t a i n t h a t legs
o f loops a r e spaced a p a r t a distance
comparable t o thickness o f spring pack.
F i g u r e 35
I n s t a l l loops on spring pack, i n s e r t i n g

outer 1 eg o f loops between the tie- wires
and spring.
F i g u r e 36
Twist wires a s t i g h t l y as possible i n

order t o contain spring pack in original
condition.
-13- F i g u r e 37
Remove b a n d i n g material and discard.
Figure 38.
Place spring pack i n housing with outer

hinge near i t s anchor bo1 t hole.
Figure 39
Place 2 x 4 or 2 x 6 board across face

of spring and c u t original tie- wires.
CAUTION: BE CERTAIN THAT FINGERS AND
HANDS ARE CLEAR OF SPRING WHEN
CUTTING TIE-WIRES. SOME RECOIL
OF SPRING MAY TAKE PLACE A T
THIS TIME.
-1 4- Figure 40
R1
Install anchor bolt through hinge of
spring and through housing. Instal 1 lock
n u t and tighten securely.
Figure 4 1
Remove a1 1 wires. The 2 x 4 or 2 x 6

safety board must be maintained across
face of spring while these wires are
removed.
Figure 42
Insert hub i n center of spring and insert

free end of spring into hub.
Figure 43 R1
-15- ~-
FILE F
SHOP MANUAL SFCTIOH 10
Lubricate hole in h u b and spring, then

liberally apply oil to entire spring
with SAE 10 motor oil.
Figure. $4
Insert pin securing hub to spring.
Finure 45
I f inner bearing was previously removed,

press new bearing in bearing housing.
-1 6- Figure 46 R1
FILE F
SHOP MANUAL SfCTlON 10
Install shaft into housing and bearing

assembly.
Figure 47
I f outer bearing was previously removed,

install new bearing i n spring cover.
Figure 48
Using flat-head machine screws, instal 1

shaft assembly i n backplate.
17 Figure 49 R1
Install lower snap ring. Lubricate shaft
for ease of assembly of snap ring and
spring hubs.
Figure 50
Spring hous i n g assembly must be instal led

w i t h spring anchor bo1 t (arrow) toward
f 1ange t h a t has cut o u t (arrow) i n i t .
Figure 51
Install four cap screws, nuts and washers

t o retain inner housing t o backplate.
-1 8- Figure 52 R1
FILE F
SHOP MANUAL SECTIC~N 10
The pawl springs are assembled in the

deepest p o r t i o n of the shaft grooves,
with open ends of springs away from
pawls (towards shaft f l a t s ) .
Lubricate the pawls and pawl springs
generously.
Rotate shaft t o ensure proper operation

of paw 1s. The shaft should lock t o
spr i ng counterclockwise and turn freely
cl oc kw i se.
Fimre 54
Instal 1 upper snap ring.
Figure 55 R1
-1 9-
FILE F
A1 ign spring anchor bo1 t nut with nut on

inner housing to assure proper instal-
lation.
F i g u r e 56
Install four cap screws, lock nuts and

washers to retain outer spring housing
to inner spring housing.
Figure 57
Install pawls and pawl springs in shaft

and lubricate.
Again rotate shaft to ensure proper
operation of pawl s.
F i g u r e 58 R1
-20-
FILE F
Instal 1 spring cover.
Install four cap screws, nuts and washers

t o retain spring cover t o outer housing.
Figure 60
Install woodruff key i n shaft. This

key i s designated a #15 woodruff key.
Figure 61 R1
-21 -
FILE F
Use driver t o t a p drum on s h a f t .
Fimre 62
Instal 1 washer and replace lock n u t .
Figure 63
Torque lock n u t t o 73-112 ft. l b s . dry.

Reinstall spring motor on crane.
- 22- Figure 64 R1
FILE F
SERVICE TO N E W T Y P E SPRING MOTOR CARTRIDGES
Spring indicators are provided to assist

in determination of the correct function
of the spring motor. The photos show
indicators "up" in Figure 65 and "down"
in Figure 66. A fully retracted boom
wi 11 have indicators "up". Boom exten-
sions must be extended approximately
75% or more over the front of crane
before indicators will be "down". If a
malfunction occurs within the spring
motor, either one or both indicators wil 1
not go "down" upon full extension of
all boom sections.
DISASSEMBLY Figure 66
Remove pawls and pawl springs from

outer spring cartridge. Note relation-
ship of pawls and springs when removing.
Figure 67 . R1
-23-
FttE F
SHOP MANUAL SECTl6N 10
Remove four lock nuts retaining outer

cartridge to inner cartridge.
Figure 68
Remove outer spring cartridge.
Remove drive pins.
-24- Fi-gure 70 R1
Remove snap ring. Inner spring cartri dge
may now be removed by removing pawls
and pawl springs and removal of four
mounting studs and spacers.
Figure 71
Hub is retained in spring cartridge by

pin. Spring cannot be removed from the
housing. The entire assembly excluding
indicator is replaced as a unit. Remove
hubs from both cartridges if required.
Refer to page '28 for service to bearings
and cable drum.
Figure 72
Before installation of new cartridge,

inspect foam seal. Clean components
as required. Install indicator. When
cartridge is installed, indicator must
be in the upper left position.
Figure 73 R1
-25-
I n s t a l 1 hub on f r e e end o f s p r i n g i n
c a r t r i d g e w it h p i n . L u b r i c a t e generously
T h i s should be done t o b o t h c a r t r i d g e s
if requ ir e d
Figure 74
I n s t a l l f o u r spacers on mounting studs.

I n s t a l l i n n e r c a r t r i d g e over s h a f t and
o n t o mounting studs. Secure w i t h f o u r
studs.
Pawls and pawl s p r i n g s must be i n s t a l l e d

w i t h open end o f s p r i n g s away from pawls
Springs must be i n s e r t e d i n deepest
p o r t i o n o f s h a f t s l o t s , and open end o f
s p r i n g s thus f a c e f l a t p o r t i o n of s h a f t
slots.
L u b r i c a t e generously.
Fimre 75
Be c e r t a i n t h a t snap r i n g i s i n s t a l l e d
on s h a f t between s p r i n g hous i n g s . Check
proper f u n c t i o n o f pawls. S h a f t must
r o t a t e f r e e l y c l o c k w i s e and l o c k t o
s p r i n g counterclockwise.
Figure 76 R1
-26-
FILE F
Install intermediate drive pins.
Fimre 77
Install outer cartridge on shaft, align

cartridge on mounting studs. Install
pawl s and pawl springs.
Lubricate generously.
Figure 78
Install four lock nuts to retain outer

housing to inner housing.
For proper lubrication method and oil
specifications see Figures 112 thru 114,
page 40 .
-27- Figure 79 R1
FILE F
SHOP MANUAL SECTJUN 10
SERVICE TO N E W T Y P E SPRllNG MOTOR SHAFT BEARINGS AND CABLE D R U M

. ..
Remove four cap screws and lock washers

that retain inner bear ing P 1 ate to
spacer plates.
Figure 80
Using soft-head mallet, tap inner bear i ng

plate assembly from shaft.
F i n r e 81
Remove flange bearing from plate.
Figure 8 2 - R1
-28-
FILE F
Bearing may be disassembled by removal of

collar. Turn bearing i n a vertical
position i n i t s flange and remove t h r o u g h
slots provided.
A socket wrench i s required t o remove the

cable drum lock n u t t h a t may n o t be easily
obtainable from local tool sources. I t
must be a 1 13/16" six-point or twelve-
p o i n t w i t h 3 1/4 inch depth or greater.
The wrench shown was fabricated using
a standard 1 13/16" socket wrench, by
sawing the wrench and inserting a five-
inch length o f pipe, then welding se-
curely.
Figure 84
Loosen lock n u t using socket wrench and

softwood wedges a t outer flange of
ca b l e drum.
-29-
FILE
Remove l o c k nut and washer.
F i g u r e 86
With soft- head m a l l e t , t a p drum from

shaft .
F i g u r e 87
Remove woodruff key from s h a f t .
-30- F i g u r e 88 R1
FILE F
Use allen wrench t o loosen set screws i n

shaft collar.
Figure 89
Remove collar from shaft.
Figure 90
Remove shaft from bearing.
Figure 9 1 R1
-31 -
FILE F
Remove four cap screws, lock washers and

f l a t washers t h a t retain bearing t o back
plate.
F i g u r e 92
Remove bearing .
F i g u r e 93
Turn bearing in a vertical position in

i t s flange and remove t h r o u g h slots
provided.
-32- F i g u r e 94 R1
FILE F
I
ASSEMBLY
' . - - -
Make certain t h a t extended portion of

bearing hub (with set screw holes) i s
positioned away from flange, as shown.
Figure 95 . ~
Replace bearing on back plate and re-

install four cap screws, lock washers and
f l a t washers. Tighten securely.
Figure 96
Make certain t h a t snap ring i s installed

on shaft. Replace shaft in bearing.
-33-
FILE F
SHOP MANUA,L SECTION 10
I n s t a l l s h a f t c o l l a r and tighten s e t
screws securely, making certain t h a t
set screws a r e threaded t h r o u g h holes
provided i n bearing hub.
Figure 98
I n s t a l l #15 woodruff key i n s h a f t .
Figure 99
P1 ace cab1 e drum on s h a f t and with key-

way a1 i gned w i t h key, i n s t a l l cable drum
w i t h driver and mal 1e t .
Figure 100 Rl
-34-
FILE F1
,
SHOP MANUhL SECTION 10
I n s t a l l washer and replace lock n u t .
Figure 101
Utilizing s o f t wood wedges a t outer

diameter of cable drum, tighten lock
n u t . When lock n u t and washer a r e seated
torque lock n u t . t o 153-235 f t . 1 bs. dry.
I
Figure 102
Reinstall c o l l a r on bearing, making

c e r t a i n t h a t c o l l a r will be positioned
toward cable drum upon assembly. Tighten
s e t screws securely. Fasten bearing t o
p l a t e w i t h four cap screws and lock
washers.
* I
Figure 103 R1
I i
-35- - ~
Lubricate t h e smaller bearing a t this
time, since the f i t t i n g will be inacces-
sible upon assembly.
Figure 104
Lubricate the larger bearing.
Assemble the inner bearing plate t o

shaft. Install four cap screws and
tighten securely. Rotate shaft t o check
for ease of movement and lack o f inter-
ference of drum t o housing.
-36- Figure 106 R1

FILE F
RELOADING R E T R A C T M E C H A N I S M
The proper tension on the boom hoses i s vital t o hose l i f e . The

tension for the hoses i s applied by the Gleason Reel assembly.
Before properly setting the spring tension on the reel assembly
i t i s recommended t h a t the spanner wrench, mounted on t o p of the
reel, be modified.
Remove spanner wrench from

m o u n t i n g on t o p of the reel .
Figure 107
The modification below will aid i n the tensioning of the springs

in the reel.
The formed end of the wrench with the hole, should be bent 1 " or
1 1/4" from the straight piece with the studs and i t should be
parallel w i t h this piece. (See illustration below)
Weld a piece of bar stock 1 " or 1 1/2" x 1/4" x 24" i n length t o
the spanner wrench as illustrated below.
1 ii or 1112 " X 1/4 " X 24" l o n g WELD
c
T'
1'' or '11/4"
t
Figure 108
U U
S p I ./I j. G ,SPRING.TENSION
,
.d
W i t h the boom fully retracted, remove hose guards. Remove the cover
plate from the reel spring pack and attach the spanner wrench. Place
the wrench studs i n the holes provided in the reel shaft. Through
the center hole in the wrench, insert and hand tighten a 1/4- 20 x
1 1/4" or 1 1 / 2 " cap screw. This will prevent the wrench from slip-
ping o u t of the reel.
NOTE: If there is no hole in t h e center of t h e s h a f t , drill and tap
t h e reel. s h a f t t o take a 1/4- 20 cap screw.
-37 - R1
FILE F
ADJUSTMENT
Install a pair of vise-grip pliers (1 )
on trolley track approximately six
inches behind the hose sheave. This
will prevent the hoses from sliding
down the trolley when the cable has
been disconnected.
CAUTION: USE EXTREME CARE WHEN PUT-
TING TENSION ON THE SPRINGS.
HOLD THE SPANNER WRENCH WITH
A FIRM GRIP.
To disconnect the cable, turn the
spanner wrench ( 2 ) counter-cl ockwi se.
When there i s slack in the cable and
while holding the spanner wrench
firmly, have another person disconnect
the cable from the hose sheave. Figure 109
SLOWLY a1 low the spanner wrench t o turn clockwise until

there i s no tension on the reel springs. While holding
the spanner wrench ( 1 ) , rotate the cable drum clockwise
t o completely rewind a l l cable ( 2 ) onto drum.
CAUTION: DO NOT LET GO OF THE CABLE. DO NOT LET GO OF
THE SPANNER WRENCH UNTIL THERE IS NO TENSION
ON THE SPRINGS.
Figure 110
- 38- R1
FILE F
CAUTION: USE EXTREME CARE WHEN PUTTING TENSION ON THE

SPRINGS. HOLD THE SPANNER WRENCH WITH A FIRM
GRIP.
With the cable fully rewound, begin t u r n i n g the spanner
wrench ( 1 ) counter-clockwise t o slack the cable.
CAUTION: ONE PERSON SHOULD KEEP TENSION ON THE CABLE WHILE
ANOTHER TURNS THE SPANNER WRENCH.
Figure 111
Connect the reel cable ( 2 ) t o the hose sheave making certain

t h a t b o t h the jam nuts are fully threaded on the cable and I
tightened.
SLOWLY a1 1 ow spanner wrench t o turn clockwise until the slack
i s taken up i n the cable. There should n o t be any droop in
the hoses.
Remove the spanner wrench and mount on t o p of the reel assembly.
Rep1 ace the cover plate and remove the vise-grip pl iers ( 3 )
from the trolley track.
P u t a l l of the outriggers t o the ground and fully extend the
boom over the front of the machine. Retract the boom, check
hoses, they should s t i l l remain t a u t .
Install hose guards. Inspect the hose pulley t o be certain
t h a t hoses do n o t r u b a l o n g t o p of hose guard,
R1
-39-
FILE F
SHOP MANUAL SECTION 10.
LUBRICATION OF THE GLEASON REEL
Lower outriggers and f u l l y extend the

boom (Boom horizontal over front of the
crane).
I f lubricating old type Gleason Reel,
remove the two 1/4" x 1 /4" slotted
round head screws on the housing t o p .
On booms w i t h new type Gleason Reel ,
remove the two spring tension indicators
on the housing t o p .
Through the screw or spring tension

indicator holes, add approximately
one p i n t of SAE 10 o i l * t o each housing.
Each spring of the G1 eason Reel requires
approximately one p i n t of SAE 10 o i l *
applied every t h i r t y t o s i x t y days.
*When operating i n temperatures below
-2OOF. , use Dexron or automatic f l u i d
Type A, S u f f i x A.
Figure 113
Cycle Boom, r e t r a c t and extend, t o

thoroughly cover spring w i t h o i l . Note
excess o i l may drain t h r o u g h the housing
and cover plate.
NOTE: This lubrication process must be
repeated every t h i r t y to s i x t y
days.
-40- Figure 114 R1

MATERIAL LIFT 0
GRADER 0
KOmatsuDresser PLANER 0
ROLLER 0
CRANE E3'
SHOP MANUAL G-06.00

c2
PLANETARY DRIVE AXLE

(CLARK SERIES DS-12152)
90 t h r u 1 2 5 04824 thru 08774
90A t h r u 125A 04777 thru 08774
125F 07247 thru 08774
125FA 07990 thru 08774
140F 07571 thru 08774
150A 04759 thru 08090
1 50FA 07305 thru 08090
ALL COMPONENTS M U S T BE PROPERLY SUPPORTED DURING


REQUIRED FOR THIS OPERATION M U S T BE IN GOOD WORKING
ORDER.
SAFE WORKSHOP PRACTICES ARE A M U S T .
CONTENTS PAGE
General Torque Values . . . . .. . . . I) . , Back o f Cover
S p e c i a l Tool s . . . , , I . . . .. . . . , . e . . . . . I 1
Description . . . . . . . . . . . . . . . . . . . . . . . 2
Removal o f A x l e from Crane . . . . . .
e . . . . . , . 3
Dissassembly . . . , . . . .
I . . . . . . . . . , . . . 8
C l e a n i n g and I n s p e c t i o n . . . . ., . . . . . a . . . . 22
Reassembly I . . . , . . . . . . . .I . . , . . . . 24
I n s t a l l a t i o n o f A x l e t o Crane . . . . . . . . . . . . . . 38
T o o t h C o n t a c t SheetI . . . . .- . . . . . . . . . . * . 44
KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. LIBERTYVILLE, I L 60048
c2
0785
The f o l l owing General Torque Values must be used i n a l l cases where SPECIFIC
T m E VALUES are n o t given.
I I
f NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET) I
I THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED (DRY) I

I
I THREADS. i
I 1
I I !
I I Heated m a t e r i a l Grade 5 8 Grade 8 I
I I I
I I I 1
f I Grade 5 I Grade 8 i
I Thread Size I I ( 6 r a d i a l dashes on head) I
( 3 r a d i a l dashes on head)
I I - .--,._.,_
=. _* I I
1 1 1 I I I
I I Foot Pounds I Newton Meter I Foot Pounds (Newton Meter I
I I (Ft. Lbs.) I (Nm) I (Ft. Lbs.) I (Nrn) I
I I It
l__l I I I
I I I I
1/4ls - 20 I
6 I 8 I 9 I 12
1/4" - 28 I 7 I 9 I 11 I 15
5/16!! - 18 I 13 I 18 I 18 I 24
5/16!! - 24 I 15 I 20 I 21 I 28
3/8" - 16 I 24 I 33 I 34 I 46
3/8" - 24 I 27 I 37 I 38 I 52
7/16!! - 14 I 38 i 52 I 54 I 73
7/16!! - 20 I 42 I 57 I 60 I 81
1/2" - 13 I 58 I 79 I 82 I 111
1/21! - 20 I 65 I
88 I 90 I 122
9/16!!
9/16!!
- 12
- 18
I
I
84
93
I
I
114
126
I
I
120
132
I
I
163
179
5/8" - 11 I 115 I 156 I
165 I 224.
5/8" - 18 I 130 I 176 1 185 I 25 1
3/41! - 10 I
205 I 278 I
290 I 3 93
3/4" - 16 I 230 I 3 12 I 320 I
434
7/8" - 9 I 305 I
414 I 455 I 617
7/8" - 14 I 335 I
454 I
515 1 698
1" - 8 I 455 I 617 I 695 I 942
l!! - 14 I 510 I 691 I 785 I 1064
1 1/8" - 7 I 610 I
827 I 990 I 1342
1 1/8" - 12 I 685 I 929 I 1110 I 1505
1 1/4" - 7 I 860 I 1166 I 1400 I 1898
1 1/4" - 12 I 955 I 1295 I 1550 I 2102
1 3/8" - 6 I 1130 I 1532 I 1830 I 2481
1 3/8" - 12 I 1290 I 1749 I 2085 I 2827
1 1/2" - 6 I
1500 2034 I
2430 I 3295
1 1/21! - 12
I
I 1690 I 2291 I 2730 I 3701
1 3/41! - 5 I 2370 3213 I 3810 5166
-
I I
2" 4 1/2 I 3550 I 4813 I 5760 f 7810

I
I I I I 1 I
FILE G
SHOP MANUAL SE C T I ON 6
STANDARD, SPECIAL TOOLS AND MATERIALS

NEEDED FOR REMOVAL AND REBUILD OF CRANE AXLES
1. Wooden blocks f o r cribbing under outrigger frames. Eight blocks

10" x 10" x 15" l g . Use only hardwood.
2. Skid having weight capacity of two ton (4,000 l b s ) minimum, used t o
s l ide ax1 es o u t and under crane.
3. Air impact wrench and a i r hose long enough t o reach a i r o u t l e t i f
a i r i s avai 1 ab1 e . (5/8" or 3/4" square d r i v e )
4. One s e t of mechanics hand t o o l s .
5. Socket f o r wheel 1 ug nuts ( 1 1 / ? I 1 x 3" lg . )
6. Spreader bar f o r chain fa1 1 , (70" l g . )
7. Two chains 3/8" l i n k s x 1 6 ' 6 " l g .
NOTE: Spreader bar shouZd be notched t o r e c e i v e 3/8" chain Zink.
Both ends of spreader must be moused (Zocked) t o chain,
s i x f e e t from Zifting e y e ( s ) . Chains must have Z i f t i n g
capacity of n o t Zess than two t o n s (4,000 Zbs. ) .
8. S u i t a b l e containers t o s t o r e loose hardware.
9. One s i x hundred (600) 1 b. torque wrench.
10. Four #4 tube caps and two 1/8" brake 1 ine plugs.
11. One c o t t e r pin 3/16" d i a . x 3 3/4" l g . f o r d r a g l i n k .
12. Brake bleeder, pressure type, (approximately 35 p s i ) .
13. Rolling torque special t o o l . (Figure I )
14. Wheel bearing adjusting n u t wrench (special t o o l ) . (Figure 11)
15. P u l l e r sui t a b l e f o r planetary c a r r i e r assembly removal .
16. Oi 1 b a t h heater or oven with capable temperatures up t o 40OoF.
r .1/2" sq. dr. SOC.
t 1
11-
2 - -i
2
Lu DIA. DRILL
32 2 HOLES
THRU
Figure I Figure I1
-1 -
FILE G
SHOP MANUAL SECTION
DESCRIPTION
This section covers one method of complete removal, disassembly,

cleaning and inspection, reassembly and i n s t a l l a t i o n of the Clark
axles used on Galion mainline cranes. For complete major overhaul
or rebui I d , i t i s necessary t o remove axle assembly from the crane.
When repairing axle assembly by replacement of components such as
ax1 es , p l a n e t a r i e s , and brakes , removal of ax1 e assembly i s n o t neces-
sary.
- 2-
FILE G
REMOVAL OF A X L E F R O M CRANE
FRONT A X L E REMOVAL
Position outriggers ( 1 ) i n the down position

and l i f t crane as far as possible. Place
wooden blocking ( 2 ) under outrigger frame as
shown on i l l u s t r a t i o n . Locate skid (3)
d i r e c t l y under front axle ( 4 ) .
NOTE: Raise o u t r i g g e r s u n t i l crane outrigger
frame j u s t touches t h e wooden blocking
Figure 1
Remove ten wheel lug nuts (1 ) and wheel assem

bly ( 2 ) from wheel h u b ( 3 ) .
BE EXTREMELY CAREFUL WHEN REMOVING

WHEEL ASSEMBLY. WHEEL ASSEMBLY
WILL HAVE A MINIMUM WEIGHT OF 480
NOTE: Crane boom w i t h s u i t a b l e wheel s l i n g

can be used t o he l p remove wheel
assemb 22.
Figure 2
Remove 1ocknut (1 ) and 1 i f t s t e e r i n g cy1 i nder

rod end ( 2 ) o f f s t e e r i n g arm p i n ( 3 ) . Remove
c o t t e r p i n (4) and adjusting plug ( 5 ) with
spring and bearing h a l f from drag 1 ink ( 6 ) .
Remove drag l i n k from ball stud ( 7 ) . Remove
brake hose (8) and 1 ine ( 9 ) from t e e f i t t i n g
( 1 0 ) . I n s t a l 1 caps or plugs on open 1 ines and
fittings.
NOTE: Remove t e e f i t t i n g (10) only when
mounting on axle assembly.
Secure drag l i n k and c y l i n d e r away

from axle t o e l i m i n a t e i n t e r f e r e n c e
during removal and i n s t a l l a t i o n .
Figure 3
-3-
FILE G
Remove washer and locknut ( 1 ) and l i f t ( r i g h t

s i d e piston rod ( 2 ) o f f s t e e r i n g arm pin ( 3 ) .
Loosen and remove brake 1 ine ( 4 ) and hose
( 5 ) from t e e f i t t i n g ( 6 ) . I n s t a l l caps or
plugs on open l i n e s and f i t t i n g .
Figure 4
Remove c o t t e r p i n and p i n ( 2 ) and yoke ( 3 )

from parking brake ( 4 ) . Remove two nuts and
lockwashers ( 5 ) and U-clamp ( 6 ) t h a t secures
parking brake cab1 e ( 7 ) t o parking brake ( 4 ) .
Remove master cylinder supply hose (8) from
t e e f i t t i n g ( 9 ) . Remove eight nuts and lock-
washers (10) and d r i v e s h a f t (11) from park-
ing brake flange ( 1 ) .
NOTE: InstaZZ Zockwashers and n u t s (20) back
on s t u d s t o r e t a i n brake drum on park-
ing brake assembZy.
Figure 5
Remove four nuts and lockwashers ( 1 ) two

U-bo1 t s ( 2 ) and d r i v e 1 ine ( 3 ) from t r a n s -
mission universal j o i n t ( 4 ) .
Figure 6
-4-
FILE G
With l i f t i n g chain and spreader properly a t -

tached t o boom hook and axle assembly ( 2 )
tighten chain t o hold axle in place a g a i n s t
the frame. Remove e i g h t nuts and lockwashers
( 3 ) . Slowly lower axle assembly on skid, ( 1 )
located under crane. Disconnect chain from
axle assembly.
NOTE: AxZe assembZy must be turned a t an
angle, so s t e e r i n g arms wiZZ cZear
t h e s i d e frame Z i p .
Swing crane boom 90° o f f center ( t o the s i d e )

of crane. Lower boom t o Oo elevation and re-
t r a c t boom as f a r as possible. Attach chain
(1 ) t o skid and ax1 e ( 2 ) . Crowd boom o u t t o
pull axle assembly o u t from under crane.
Figure 8
REARAXLEREMOVAL
Position r e a r outriggers (1 ) in the down posi-

t i o n and l i f t crane as f a r as possible. Place
wooden blocking ( 2 ) under outrigger frame as
shown on i l l u s t r a t i o n . Locate skid ( 3 ) d i -
r e c t l y under r e a r ax1 e ( 4 ) .
NOTE: Raise o u t r i g g e r s untiZ crane o u t r i g -

ger frame j u s t touches t h e wooden
b Zocking .
<!
NOT E: With EZocking properZy p Zaced on both '\
??$
ends o f crane and aZZ o u t r i g g e r s i n ,,*,
2_/
down p o s i t i o n . Both axZes may be r e -

moved a t t h e same time. Figure 9
-5-
FILE G
SHOP MANUAL SE CT I ON 6
Remove ten wheel 1 ug nuts (1 ) and wheel assem-

bly ( 2 ) from wheel hub ( 3 ) .
BE EXTREMELY CAREFUL WHEN RE-

MOVING WHEEL ASSEMBLY. WHEEL
ASSEMBLY WILL HAVE A MINIMUM
CAUvTlON WEIGHT OF 480 POUNDS.
NOTE: Crane boom used w i t h a s u i t a b l e s l i n g

may be used t o help remove wheel assem-
bly.
Figure 1 0
Remove locknut ( 1 ) and l i f t s t e e r i n g cylin-

der rod ( 2 ) o f f s t e e r i n g arm pin ( 3 ) . Re-
move brake 1 i n e hose ( 4 ) from t e e f i t t i n g
( 5 ) . Remove two nuts , lockwashers and cap-
screws ( 6 ) clamps ( 7 ) and bracket ( 8 )
from s t e e r i n g arm ( 9 ) .
NOTE: Remove remaining r e a r s t e e r c y l i n d e r
in t h e same manner.
Remove four nuts and lockwashers, two U-bo'1 t
and d r i v e s h a f t from transmission and a x l e .
Figure 11
Rotate boom u n t i l chain and spreader ( 1 ) a r e

d i r e c t l y over the r e a r axle ( 2 ) . Attach
chain t o axle and r a i s e hook t o hold axle
t i g h t a g a i n s t crane frame. Remove e i g h t
capscrews w i t h lockwashers ( 3 ) t h a t secures
axle t o frame. Lower axle assembly on skid
( 4 ) located under crane.
Figure 1 2
-6-
FILE G
Remove chain from a x l e , Rotate boom t o s i d e

o f crane. Lower boom t o Oo elevation and
r e t r a c t crowd cy1 inder as f a r as possible.
Attach chain (1 ) t o skid and axle ( 2 ) . Crowd
boom o u t t o pull a x l e assembly o u t from under
crane.
NOTE: Remove s t e e r i n g a m p i n from s t e e r i n g
a m s by removing n u t from under a m J
Using two Zarge hammers, one as a
backup a d s t r i k i n g t h e s i d e of s t e e r -
ing arm w i t h t h e other wiZ1 Zoosen
t h e tapered f i t .
Figure 13
-7-
FILE 6
SHOP MANUAL SECTION -6 -
DISASSEMBLY
The fol lowing i s one method of di sassembly, recommended when complete overhaul of
axle i s necessary.
Using a s u i t a b l e l i f t i n g device, with a mini-

mum l i f t i n g capacity of four thousand (4,000)
1 bs. position a x l e assembly in a clean work
area , wi t h s u f f i c i e n t work area 360° around
the a x l e . C1 ean ax1 e thoroughly p r i o r t o
di sassembly .
USE EXTREME CARE DURING CLEAN-

ING OPERATION TO PREVENT DIRT
OR OTHER CONTAMINATION FROM
CAUTION ENTERING THE AXLE ASSEMBLY.
Rotate ax1 e planetary assemblies u n t i l level

plug ( 1 ) i s a t the bottom. Remove p l u g ( 1 )
from each planetary housing ( 2 ) . Remove mag- Figure 1 4
n e t i c drain plug ( 3 ) from d i f f , e r e n t i a l housing
( 4 ) and allow o i l t o drain i n t o sui t a b l e con-
t a i ners .
Match mark Dlanet cover and Dlanet c a r r i e r

assembly. Remove s i x capscrews and 1 oc k-
washers (1 ) and planet cover ( 2 ) from p 1 anet
c a r r i e r assembly ( 3 ) . Remove re1 i e f va 1 ve
( 4 ) from cover ( 2 ) only i f replacement i s
necessary.
-8-
FILE 6
Match mark planet c a r r i e r and h u b assembl i e s .

Remove f i v e capscrews and 1ockwashers (1 ) Y
f i v e nuts ( 2 ) f i v e dowels ( 3 ) and s l i d e
planet c a r r i e r assembly ( 4 ) from h u b ( 5 ) .
Remove d r a i n and level plug ( 6 ) from h u b .
Figure 16
Using a s u i t a b l e d r i f t , d r i v e p i n i o n s h a f t
( 6 ) w i t h lock ball ( 7 ) o u t thru the front
of planet spider ( 1 ) . Remove p i n i o n ( 4 )
.
and two t h r u s t washers ( 2 ) from spider (1 ) .

Remove f i f t y e i g h t needle bearings ( 3 ) and
spacer ( 5 ) from pinion ( 4 ) .
8695
Figure 1 7
Remove r e t.aining ring (1 ) and sun geal

from axle s h a f t ( 3 ) .
Figure 18
-9-
FILE G
__ SHOP MANUAL SECTION 6
Remove thrust washer ( 1 ) . Straighten tabs

on lockwasher ( 2 ) . Remove locknut ( 5 ) , lock-
washer ( 2 ) and inner hub bearing adjusting
n u t (3) from the axle s h a f t ( 4 ) .
Figure 19
S1 ide i n t e r n a l gear hub ( 1 ) o f f spindl e

assembly ( 2 ) and o u t of hub assembly ( 3 ) .
NOTE: I f hub is tight, use a s o f t hmmner

and bump gear hub t o Loosen.
Using a s u i t a b l e p u l l e r , remove tapered

r o l l e r bearing (1 ) from i n t e r n a l gear hub
( 2 ) only i f replacement i s necessary.
Figure 2 1
-1 0-
FILE G'
Attach a s u i t a b l e support or l i f t i n g device

(1 ) t o wheel hub ( 2 ) and remove h u b assem-
bly from axle and brake assembly.
NOTE: If drum i s t i g h t , Zoossn brake shoes,

which will allow removal of wheel
hub without binding.
Figure 22
..., ,,. ", ... . - .~ - .-
Using a sui t a b l e pul l e r or press, remove o i l

seal ( l ) , i nner and o u t e r bearing races ( 2 )
and bearing outer raice ( 3 ) from the h u b ( 4 ) ,
only i f rep11acement o f these parts a r e neces-
sary .
Figure 23
Use a s u i t a b l e l i f t i n g device t o support

brake assembly and backing p l a t e ( 3 ) . Re-
move e i g h t capscrews (1 ) ten capscrews with
lockwashers ( 2 ) , brake assembly w i t h backing
p l a t e ( 3 ) , oi 1 catcher ( 4 ) and spindle ( 5 )
from spindle support ( 6 ) . Remove wear sleev
(8) from spindle assembly ( 5 ) only i f re-
placement i s necessary.
NOTE: Wear s l e e v e has been heated f o r i n -
s t a l l a t i o n . One method of removal
i s t o c u t wear r i n g w i t h a sharp
coal c h i s e 2. Use extreme care not
t o cut s p i n d l e .
Figure 24
-13-
FILE G
Figure 25
S1 ide axle ( 1 ) o u t of ax1 e assembly ( 2 ) .

MOVING THE AXLE NOT TO DAMAGE
O I L SEAL I N AXLE HOUSING.
Figure 25
Position inner axle s h a f t ( 1 ) i n a s o f t jaw

vise ( 2 ) w i t h constant velocity j o i n t in
the downward position as i l l u s t r a t e d in f i g .
Using a s o f t d r i f t ( 3 ) positioned against
the inner race, s t r i k e d r i f t w i t h hammer t o
separate velocity j o i n t from inner s h a f t .
DO NOT USE HARDENED STEEL

DIRECTLY AGAINST THE INNER
RACE.
CAUTION
Figure 27
-1 2-
FILE G
Remove r e t a i n i n g ring (1 ) from inner ax1 e

shaft (2).
Figure 28
Place velocity j o i n t assembly i n a s o f t jaw

vise. I n s e r t a bar ( 1 ) in center spl ined
hole, t o be used f o r 1 everage, and t i 1 t in-
ner race ( 2 ) in outer race ( 3 ) u n t i l one
ball ( 4 ) can be l i f t e d o u t . Continue t i l t -
i n g inner race in d i f f e r e n t d i r e c t i o n s until
a1 1 s i x ball s have been removed.
Figure 29
Rotate cage (1 ) and inner race ( 2 ) t o a

r i g h t angle w i t h the outer race ( 3 ) . There
a r e two elongated opening in cage shown a t
point " A" . Rotate cage so elongated holes
a r e a t the two "B" points and l i f t o u t of
outer race ( 3 ) .
-1 3-
FILE G'
Figure 31
Using a sui tab1 e p u l l e r , remove grease re-

taining boot assembly from axle assembly
(1 ) . Loosen clamp ( 2 ) and remove b o o t ( 3 )
and clamp from boot support ( 4 ) . Use sui t-
ab1 e p u l l e r and remove o i l seal ( 5 ) only
i f replacement i s necessary.
Figure 32
FILE G.
SHOP MANUAL SECTION
Remove s i x capscrews and f l a t washers ( 1 )

and l i f t s t e e r i n g arm ( Z ) , shims ( 3 ) and
O-ring from spindl e support ( 5 ) . Using
a s u i t a b l e press, remove trunion and cone
assembly ( 6 ) from spindl e supports. Remove
grease f i t t i n g ( 4 ) only i f replacement i s
necessary.
Figure 34
., ..
Remove capscrews and lockwashers ( 1 ) , lower

trunion w i t h cone ( 2 ) and shims ( 3 ) from
spindl e support ( 4 ) . Remove cone from lower
trunion only i f replacement i s necessary.
Figure 35
T i l t the t o p of spindle support (1 ) away

from axle housing ( 2 ) and lower in order t o
remove support from lower bearing ( 3 ) .
Figure 36
-1 5-
FILE 6
SHOP MANUAL
i .
SE CT I ON 6
Using a sui t a b l e p u l l e r or press , remove

upper trunion bushing (1 ) bearing sleeve ( 2 )
and grease r e t a i n e r ( 3 ) from axle housing
(4).
-.
Figure 37
Remove bearing cone (1 ) from 1ower trunion

cap ( 2 ) only i f rep1 acement i s necessary.
Remove trunion seal ( 3 ) . With the use o f
sui tab1 e p u l l e r , remove cone ( 4 ) from axle
housing ( 5 ) .
NOTE: Disassemble remaining end o f a x l e

assembly i n t h e sane manner as out-
l i n e d i n s t e p s 14 t h r u 32 and 34
thru 38.
Remove fourteen nuts w i t h lockwashers ( 1 )

and three tapered dowels ( 2 ) t h a t secures
the cap and c a r r i e r assembly ( 3 ) t o ax1 e
housing ( 4 ) .
Figure 39
-1 6-
FILE G
Figure 40
Position cap and c a r r i e r assembly ( 5 ) on a

clean work bench. Match mark bearing cap
( 1 ) w i t h c a r r i e r ( 5 ) , a l s o mark which s i d e
of c a r r i e r bearing cap was removed from,
i n order t o insure c o r r e c t reassembly. Re-
move two capscrews w i t h lockwashers ( 3 ) and
two a d j u s t i n g n u t lockplates ( 4 ) from bear-
i n g caps ( 1 ) . Remove four-capscrews and
lockwashers ( 6 ) and two bearing caps ( 1 )
from c a r r i e r .
Figure 41
L i f t ring gear assembly ( 1 ) out of c a r r i e r

( 4 ) and remove a d j u s t i n g n u t ( 2 ) and bearing
cups ( 3 ) .
Figure 42
-1 7-
FILE 6
Using sui table puller, remove two bearing

cones ( 1 ) . Remove twelve capscrews w i t h
f l a t washers ( 2 ) .
NOTE: Match mark case haZves ( 3 and 4 )

across t h e s p i d e r ( 5 ) .
Remove case ha1 f ( 3 ) from flanged d i f f e r -

ential case ( 4 ) .
Figure 43
Remove spider assembly ( 1 ) from the case

half ( 2 ) .
Figure 44
Slide four pinion thrust washers ( 1 ) and

four pinion gears ( 2 ) o f f the spider cross
(3).
NOTE: Pinion gears are i n matched s e t s of
fowl and must be repZaced as a s e t
on@.
Figure 45
-18-
FILE G
L i f t s i d e gear ( 1 ) and s i d e gear t h r u s t

washer ( 2 ) o u t of case half ( 3 ) .
NOTE: Remove remaining s i d e gear and

thrust washer from remaining ease
haZf.
Figure 46
Remove twelve nuts and bo1 t s ( 1 ) and ring

gear ( 2 ) from case half ( 3 ) only i f replace-
ment i s necessary.
Figure 47
Remove c o t t e r p i n ( 1 ) , n u t ( 2 ) and flange

coupling ( 3 ) from pinion s h a f t ( 4 ) .
-19-
FILE
I
Remove s i x capscrews with lockwashers ( 1 ) 1
and oi 1 seal r e t a i n e r ( 2 ) from pinion bear-
i n g cage ( 3 ) . Remove oi 1 seal ( 4 ) from
1
seal r e t a i n e r only i f replacement i s nec-
essary.
Figure 49
Using a sui tab1 e pull e r , remove pinion bear-

i ng cage ( 1 ) , bearing inner race ( 2 ) and
1 i f t shims ( 3 ) from c a r r i e r assembly ( 4 ) .
NOTE: Record t h e number and t h i c k n e s s of

shims removed t o insure c o r r e c t r e -
assembly.
Figure 50
S1 ide spacer (1 ) o f f pinion s h a f t ( 2 ) . Re-

move outer bearing race ( 3 ) from pinion
bearing cage ( 4 ) only i f replacment i s
necessary.
Figure 51
-20-
FILE 8
Using a s u i t a b l e press or s o f t d r i f t , press

or d r i v e pinion s h a f t assembly (1 ) o u t of
c a r r i e r assembly ( 2 ) .
Figure 52
Bearing outer race ( 1 ) w i 11 be removed from

c a r r i e r case ( 2 ) when pinion shaft .( 5) i s
pressed o u t . Remove tapered bearing ( 4 ) and
ball bearing ( 3 ) from pinion s h a f t ( 5 ) with
the use of a sui tab1 e press or p u l l e r . Re-
move capscrew and plain washer from car-
rier (2).
Figure 53
-21 -
FILE 6'
CLEANING AND IINSPECTION
A. Clean a l l p a r t s thoroughly using solvent type cleaning f l u i d . I t i s

recommended t h a t p a r t s be immersed in cleaning f l uid and moved up and
down slowly u n t i l a l l o i l l u b r i c a n t and foreign material i s dissolved
and p a r t s a r e thoroughly clean.
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS AND

INHALATION OF VAPORS WHEN USING SOLVENT TYPE CLEANERS.
CAUTION
B. Remove bearings from cleaning f l u i d and s t r i k e f l a t against a block o f
wood t o dislodge s o l i d i f i e d p a r t i c l e s of l u b r i c a n t . Immerse again i n
cleaning f l u i d t o flush o u t p a r t i c l e s . Repeat above operation u n t i l
bearings a r e thoroughly clean. Dry bearings using moisture f r e e com-
pressed a i r . Be careful t o d i r e c t a i r stream across bearing t o avoid
spinning. Do n o t spin bearings when drying. Bearings may be rotated
slowly by hand t o f a c i 1 i t a t e drying process.
C. Clean i n t e r i o r and e x t e r i o r of housings , bearing caps , e t c . , thoroughly
Cast p a r t s may be cleaned i n h o t s o l u t i o n tanks w i t h mild a l k a l i solu-
t i o n s providing these p a r t s do n o t have ground or polished s u r f a c e s .
Parts should remain in solution l o n g enough t o be thoroughly cleaned
and heated. This will aid the evaporation of cleaning s o l u t i o n and
r i n s e water. Parts cleaned in solution tanks must be thoroughly rin-
sed with clean water t o remove a l l t r a c e s of a l k a l i . Cast p a r t s may
akso be cleaned w i t h a steam cleaner.
CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPORS AND

SKIN RASHES WHEN USING ALKALI CLEANERS!
CAUTION
D. A1 1 p a r t s cleaned must be thoroughly dried immediately by using moisture
f r e e compressed a i r or s o f t l i n t l e s s absorbent wiping rags f r e e of abra-
s i v e m a t e r i a l s such as metal f i l i n g s , contaminated o i l or lapping com-
pound.
E. Carefully inspect a1 1 bearing r o l l e r s , cages and cups for wear, chipping
o r nicks t o determine condition. Do n o t replace a bearing cone or cup
individually w i t h o u t replacing the mating cup or cone a t the same time.
After inspection, dip bearings in EP 80 or EP 90 and wrap in clean l i n t -
l e s s c l o t h or paper t o protect them u n t i l i n s t a l l e d .
F. Replacement of o i l s e a l s , O-rings, gaskets and snap rings a r e more econ-
omical t o replace when u n i t i s disassembled than premature f a i 1 ure, r e f e r
t o Parts Book for p a r t number o f 'replacement i terns. Be extremely careful
when i n s t a l l i n g s e a l , t o avoid c u t t i n g o r scratching. Lubricate a l l
O-rings and . s e a l s before assembly.
-22-
FILE
G. I f a v a i l a b l e , use magna- flux process for checking for cracks t h a t a r e n o t

v i s i b l e t o the naked eye. Examine t e e t h on a1 1 gears c a r e f u l l y for wear,
p i t t i n g , chipping , nicks, cracks or scores. Replace a1 1 gears showing
cracks or spots where case hardening has worn t h r o u g h ' . . Small.nicks may
be removed with s u i t a b l e hone. Inspect s h a f t s and q u i l l s t o make c e r t a i n
they have n o t been sprung, bent, or s p l i n e s twisted, and t h a t s h a f t s a r e
true.
H. Inspect housings and covers t o be c e r t a i n they a r e thoroughly cleaned and
t h a t mating s u r f a c e s , bearing bores, e t c . , a r e f r e e from nicks or burrs.
Check a l l p a r t s c a r e f u l l y for evidence of cracks or condition which would
cause subsequent o i l leaks or f a i l u r e s .
-23-
FILE G
REASSEMBLY
Instal 1 (7/8"-14 x 1 1 / 2 " lg,) capscrew and

plain washer ( 6 ) in c a r r i e r assembly ( 2 ) .
Press ball bearing ( 3 ) and tapered r o l l e r
bearing ( 4 ) on p i n i o n shaft ( 5 ) . Using a
c o t t e r punch and hammer, stake b a l l bearing
( 3 ) t o s h a f t ( 5 ) t o hold i t t i g h t . Position
pinion s h a f t ( 5 ) with bearings in c a r r i e r
Press outer bearing r a c e ( 1 ) i n t o proper lo-
cation i n c a r r i e r
Figure 54
( 6 ) on pinion s h a f t .
NOTE: Make c e r t a i n bearing cage ( 4 ) and
shims (5) are i n proper alignment
w i t h c a r r i e r ( 7 ) . Replace same
amount and t h i c k n e s s of shims t h a t
were removed.
Figure 55
I ns t a1 1 seal ( 4 ) in seal r e t a i n e r ( 2 ) i f
removed during disassembly. Position seal
r e t a i n e r ( 2 ) on c a r r i e r ( 3 ) and i n s t a l l s i x
(1 /2"-12 x 1 11/16" l g ) capscrews and lock-
was hers (1 ) .
-24-
SHOP MANUAL
Position f l ange coup1 i ng (3) on pinion shaft
( 4 ) and instal 1 n u t ( 2 ) .
NOTE: . T i g h t e n n u t (2) t o 400 S t . Zbs.
torque minimum.
I n s t a l l an inch 1 b. torque wrench and socket

on n u t ( 2 ) and r o t a t e pinion assembly. Pin-
ion torque must run between 13 and 23 inch
pounds. I f torque i s t o o high, add shims
t o spacer assembly ( 1 , F i g . 55), however, i f
torque i s t o low reduce the amount of shims
with spacer assembly. Instal 1 c o t t e r pin ( 1 ) ,
After f i n a l t o r q u i n g of n u t ( 2 ) t o 400 f t .
lbs. min.
Position ring gear ( 2 ) on case half ( 3 ) and

instal 1 twelve bo1 ts and nuts ( 1 ) i f removed
during disassembly.
Figure 58
P1 ace t h r u s t washer ( 2 ) and side gear ( 1 ) i n

beari nlg h a l f ( 3 ) .
NOTE: InstaZZ remaining s i d e gear and t h r u s t
washer in t h e remaining ease h a l f .
Figure 59
-25-
FILE
Figure 60
P1 ace spider assembly (1 ) i n case ha1 f ( 2 ) .

NOTE: Make c e r t a i n match marks on s p i d e r
and bearing h a l f are l i n e d up.
Figure 61
Position bearing- h a l v e s . ( 3 and 4) together

w i t h spider cross ( 5 ) i n proper location
according t o match marks. I n s t a l l twelve
capscrews and p l a i n washers ( 2 ) t h a t secures
the ha1 ves together.
Using a sui t a b l e press, i n s t a l 1 two bearing
cones ( 1 ) .
Figure 62
- 26-
FILE G
Pos i t i on bearing cups ( 3) on ring gear as-

sembly ( 1 ) . Place ring gear assembly i n
c a r r i e r ( 4 ) and i n s t a l 1 adjusting nuts ( 2 ) .
Figure 63
Place match marked bearing caps ( 1 ) in t h e i r
proper 1 ocation on c a r r i e r assembly ( 5 ) and
i n s t a l 1 two capscrews and lockwashers ( 6 ) .
Tighten adjusting nuts ( 2 ) t o o b t a i n zero
end play in bearings. A1 1 bearing r o l l e r s
must r o t a t e when ring gear r o t a t e s , however,
you should be a b l e t o move r o l l e r sideways
in cage when prying against them with a
screwdriver. Using a d i a l i n d i c a t o r , check
backlash between ring gear and p i n i o n gear.
Backlash i s adjusted by moving ring gear t o -
ward o r away from pinion s h a f t gear. Ring
gear ispoved by lossening one adjusting n u t
and tightening the opposite, move each n u t
the same d i s t a n c e so t h a t bearing end play
adjustment which has already been made will
n o t be disturbed. Move ring gear until back Figure 64
lash i s between .009" and .013" i f new ring
and pinion gears i s used. For reassembly o f old gears r e f e r t o backlash readings t h a t
were recorded d u r i n g disassembly.
Check ring and p i n i o n gear for proper t o o t h contact. Apply a mixture o f red lead and
1 inseed o i l t o approximately twelve t e e t h for checking purposes. Gears should be ro-
t a t e d , under s l i g h t l o a d for a t l e a s t one revolution in b o t h d i r e c t i o n s . A f l a t s t e e l
bar may be used t o apply l o a d against ring gear. Tooth contact pattern should be
checked on d r i v e (convex) s i d e of ring gear tooth. Refer t o page 44 for c o r r e c t t o o t h
contact p a t t e r n .
I n order t o o b t a i n c o r r e c t t o o t h contact i t may be necessary t o a d j u s t the p i n i o n gear
depth. Add shims t o reduce pinion gear depth i n t o ring gear and remove shims t o in-
crease pinion gear depth.
NOTE: I t wilZ be necessary t o r e a d j u s t r i n g gear backZash a f t e r changing p i n i o n gear
depth.
Position two adjusting n u t lockplates ( 4 ) on bearing cap ( 1 ) and i n s t a l l capscrews and

1 ockwas hers ( 3 ) .
-27-
SHOP MANUAL
Apply a s u i t a b l e s e a l e r t o f l a n g e o f a x l e
assembly ( 3 ) . U s i n g a s u i t a b l e l i f t i n g
device w i t h a capacity o f n o t less t h a t
500 l b s . p o s i t i o n cap and c a r r i e r assembly
( 2 ) i n a x l e assembly ( 3 ) .
NOTE: Cap and c a r r i e r assembly must be

Zowered s t r a i g h t i n t o t h e axZe
housing.
Figure 65
P o s i t i o n cap and c a r r i e r assembly ( 3 ) i n t h e

ax1 e assembly ( 4 ) . I n s t a l1 three tapered
dowels ( 2 ) i n p r o p e r 1o c a t i o n and i n s t a l 1
f o u r t e e n n u t s and lockwashers ( 1 ) .
NOTE: T i g h t e n t h e t h r e e n u t s f i r s t , t h a t
are Zocated on t h e s t u d s w i t h tapered
dowe 2s.
Figure 66
With a s u i t a b l e press o r driver, i n s t a l l

cone ( 4 ) i n a x l e housing (5). I n s t a l l
t r u n i o n s e a l ( 3 ) . Press b e a r i n g cone ( 1 )
on 1ower t r u n i o n cap ( 2 ) o n l y i f rep1 aced
d u r i n g disassembly .
Figure 67
-28-
FILE G
Using a s u i t a b l e d r i f t or press i n s t a l l
grease r e t a i n e r ( 3 ) bearing sleeve ( 2 ) and
upper trunion bushing (1 ) i n the axle hous-
ing (4).
Figure 68
L i f t spindle support i n t o position a t the

end o f the axle ( 2 ) l i f t i n g t o p of spindle
support (1 ) away from ax1 e and locating
bottom of spindle support (1 ) on bottom of
bearing ( 3 ) and then locating t o p o f sup-
port i n place on a x l e .
Figure 69
Instal 1 bearing cone i n lower trunion ( 2 )

only i f removed during disassembly. Posi-
t i o n shims ( 3 ) and lower trunion ( 2 ) on
spindl e support ( 4 ) and i n s t a l 1 s i x cap-
screws and lockwashers (1 ) .
Figure 70
-29;
FILE 1~
Using s u i t a b l e press, i n s t a l l trunion and

cone assembly ( 6 ) i n spindle supports.
Position O-ring, shims ( 3 ) and s t e e r i n g
arm ( 2 ) i n spindle support ( 5 ) and i n s t a l 1
s i x capscrews w i t h lockwashers ( 1 ) . In-
s t a l l grease f i t t i n g ( 4 ) i f removed d u r i n g
disassembly.
NOTE: Tighten capscrews ( 2 ) from 282

t o 320 ft. Zbs. torque.
Figure 7 1
Position boot ( 3 ) on b o o t support ( 4 ) and

i n s t a l l clamp ( 2 ) . Using a s u i t a b l e press
o r d r i v e r , i n s t a l 1 o i l seal ( 5 ) i n ax1 e
assembly ( 1 ) i f removed d u r i n g disassembly.
Position the grease r e t a i n i n g boot assembly
( 1 ) and i n s t a l 1 w i t h sui t a b l e d r i v e r or
press.
N-OTE: Apply P e m a t e x No. 2 to t h e inner

and outer f l a n g e of boot support
r i n g (4).
Figure 7 2
FILE G'
Position two elongated holes in cage ( 2 ) a t

location " A" , i n l i n e with outer race a t
location points "B". Twist inner race and
cage unti 1 i t i s proper location in the outer
race ( 3 ) .
CAGE AND INNER RACE MUST SLIDE

INTO OUTER RACE SMOOTHLY WITH
ONLY SLIGHT FINGER PRESSURE.
CAUTION DO NOT FORCE.
Figure 74
Place velocity j o i n t assembly in a s o f t jaw

v i s e . I n s e r t bar ( 1 ) in center spl ined hole,
t o be used for 1 everage, and t i 1t inner race
( 2 ) i n outer race ( 3 ) u n t i l one ball ( 4 ) can
be i n s t a l l e d . Continue t i l t i n g race i n d i f -
f e r e n t d i r e c t i o n s u n t i l a l l s i x b a l l s have
been i n s t a l l e d .
NOTE: Move i n n e r race w i t h f i n g e r s t o make

c e r t a i n t h e v e l o c i t y j o i n t has f r e e -
dom of movement. Pack v e l o c i t y j o i n t
w i t h grease.
Figure 75
Instal 1 r e t a i n i n g ring ( 1 ) on inner axle s h a f t

( 2 ) . Position inner ax1 e shaft s p l i n e s in
a1 ignment with s p l i n e s i n velocity inner race.
Using a s o f t hammer s t r i ke axle s h a f t , driving
i t i n t o the v e l o c i t y j o i n t . Check t o make
c e r t a i n the r e t a i n i n g r i ng i s seated i n j o i n t .
Figure 76
-31 -
FILE 6
S l i d e axle ( 1 ) in a x l e housing ( 2 ) . Make

c e r t a i n axle s p l i n e i s seated i n the d i f -
f e r e n t i a l assembly.
BE EXTREMELY CAREFUL WHEN 12-

STALLING AXLE SO AXLE SEAL WILL
NOT BE DAMAGED.
CAUTION
NOTE: Pack boot and support assembly about

three- quarters fu22 w i t h EP L i t h i m
Soap Base Grease No. 1 .
Figure 77
If removed during disassembly, i n s t a l 1

spindle bushing ( 3 ) o i l seal ( 2 ) and
t h r u s t washer ( 1 ) on spindle h u b ( 4 ) .
NOTE:, Stake t h r u s t washer ( 2 ) i n hub t o

hoZd it i n pZace.
Figure 78
-32-
FILE 6
I f wear sleeve (8) was removed d u r i n g di s-

assembly, the i n s t a l l a t i o n of new wear ring
w i l l require preheating. Preheat wear ring
w i t h o i l b a t h , oven, or with an acetylene
torch t o approximately 40OoF. , however, when
using torch make c e r t a i n wear ring i s heated
evenly. Cost s e a l i n g surface w i t h Loctite
HVV Catalog #71 s e a l e r . Press heated wear
sleeve (8) on s p i n d l e assembly ( 5 ) . Press
wear sleeve f l u s h with bearing shoulder.
NOTE: Remove excess seaZant from wear
sZeeve edges. None shouZd be
l e f t on t h e f i n i s h e d working
surface o r oiZ seal Zeakage may
result.
Figure 79
Position spindle assembly ( 5 ) on spindle support ( 6 ) with o i l hole i n spindle in the

down pos i t i on.
Apply small amount o f Permatex #2 t o the o i l catcher ( 4 ) t o hold catcher in position

on brake backing p l a t e ( 3 ) during i n s t a l l a t i o n . Position brake assembly w i t h backing
p l a t e ( 3 ) on spindl e assembly ( 5 ) and i n s t a l 1 ten capscrews with lockwashers ( 2 ) and
e i g h t twelve p o i n t capscrews ( 1 ) .
NOTE: Tighten twe Zve p o i n t capscrews ( 2 ) from 115 t o 127 S t . Zbs. torque.
.. . . . ....
Using a sui t a b l e press, i n s t a l 1 outer bear-

ing race ( 3 ) , bearing assembly ( 2 ) and o i l
seal (1 ) in hub ( 4 ) only i f removed during
disassembly.
NOTE: A p p l y Permatex No. 2 on outer dia-

meter of s e a l . Lubricate Zips of
sea 2. L i p s of sea2 must be toward
p Zanetary assemb Zy .
Figure 80
-33-
FILE
Using a s u i t a b l e l i f t i n s device (. 1 ). position

.
hub ( 2 ) over brakes and-on axle support..
NOTE: If difficulty is experienced in-

stalling hub, retract brakes as
necessary.
BE EXTREMELY CAREFUL DURING

INSTALLATION NOT TO DAMAGE
HUB SEAL.
CACYTIOM
Figure 81
Using a sui t a b l e p r e s s , i n s t a l l tapered

r o l l e r bearing inner race (1 ) on internal
gear h u b ( 2 ) only i f removed during d i s -
assembly.
Figure 8 2
Position i n t e r n a l gear h u b ( 1 ) on spindle

assembly ( 2 ) and s l i d e i n t o position in
h u b assembly ( 3 ) .
-34-
FILE G
I n s t a l l inner h u b bearing adjusting n u t ( 3 )

and a d j u s t as follows:
A. Tighten wheel bearing adjusting n u t t o
i t s limit while r o l l i n g the wheel. S t r i k e
the rim and surrounding p a r t s w i t h a mal-
l e t t o shock the wheel end and b e t t e r
s e a t bearing cups and cones t h a t may n o t
a1 ready be seated. Reverse adjusting
n u t ( 3 ) and again s t r i k e rim with a mal-
l e t . Loosen adjusting n u t u n t i l a s l i g h t
bearing end play i s detected.
B. Using special r o l l ing torque bar (Refer
t o special tool , page 1 ) and an inch
pound torque wrench , determi ne roll i ng
torque of wheel with bearings i n a no- Figure 84
load end play condition. Due t o u n b a l -
ance of p a r t s , e t c . there will be a
v a r i a t i o n of r o l l i n g torque as the -
wheel hub i s r o t a t e d . Record maximum value o f r o l l i n g torque throughout a complete
revol ution. This f i g u r e i s a I' No-1 oad r o l l i ng torque" value recorded.
C. Tighten adjusting n u t ( 3 ) t o achieve a bearing pre-load in f t . l b s . above the "No--
load r o l l ing torque" value recorded. New bearings 7 t o 1 2 f t . 1 bs. torque and used
bearings 3 t o 5 f t . l b s . torque g r e a t e r t h a n no- load value.
NOTE: I t i s b e s t t o use t h e lowest pre-load value as t h e pre-load may i n c r e a s e

when jam n u t is i n s t a l l e d and t i g h t e n e d . Also record wrench torque when
tightening adjusting nut.
When proper pre-load i s achieved, i n s t a l l lock washer ( 2 ) and jam n u t ( 5 ) . Tighten

jam n u t ( 5 ) t o a higher wrench torque t h a n the adjusting n u t ( 3 ) . Recheck r o l l i n g
torque.
NOTE: Pre-load must n o t be g r e a t e r than h i g h e s t vaZue plus "No-load r o l l i n g torque"

value.
Bend two tangs of lockwasher ( 2 ) on f l a t s of adjusting n u t ( 3 ) and two tangs on f l a t

of jam n u t ( 5 ) . S l i d e t h r u s t washer ( 1 ) on axle ( 4 ) .
-35-
FILE 6
Slide sun gear ( 2 ) on axle s h a f t and in-

s t a l l r e t a i n i n g ring (1 ) .
Figure 55
Use a d r i f t p i n approximately the same d i a -

meter as pinion s h a f t (6), however, p i n must
be no longer than .pinion gear ( 4 ) . I n s e r t
d r i f t p i n i n gear ( 4 ) . I n s e r t twenty-nine
needl e bearings ( 3 ) around d r i f t pin in gear
( 4 ) . From opposite end s l ide spacer ( 5 ) on
d r i f t p i n and i n gear. I n s t a l l remaining
twenty-nine needl e bearings ( 3 ) around d r i f t
i n s i d e gear. Position pinion gear ( 4 ) and
t h r u s t washers ( 2 ) i n position on planet
spider ( 1 ) . Drive pinion s h a f t ( 6 ) thru
spider ( 1 ) and p i n i o n gear ( 4 ) , d r i v i n g pin
o u t of pinion gear. Position lock b a l l ( 7 )
i n p i n i o n s h a f t p r i o r t o i n s t a l l i n g pinion
s h a f t flush with spider ( 1 ) . 8695
Figure 86
NOTE: Make c e r t a i n t a b s on t h r u s t washers (2)
Line up w i t h notches in spider c a s t i n g
Stake spider casting t o secure pinion s h a f t

i n place.
-35-
FILE G
Apply a coat of Permatex No. 2 on wheel h u b

t o planet c a r r i e r m o u n t i n g surface. Position
planet c a r r i e r ( 4 ) on h u b assembly ( 5 ) . Ro-
t a t e planet gears t o a1 ign with i n t e r n a l ring
gear and sun gear. Carrier and h u b assembly
was match marked a t disassembly. I n s t a l l
f i v e tapered dowels ( 3 ) and f i v e nuts ( 2 ) .
I n s t a l l f i v e (1/2"-13 x 1 3/4" l g ) capscrews
and lockwashers.
NOTE: T i g h t e n n u t s ( 2 ) and capscrews (1)

form 80 t o 88 f t . Zbs. torque.
Figure 87
Apply a coat of Permatex No. 2 t o mating sur-

faces between planet cover and planet car-
r i e r . Position planet cover ( 2 ) on planet
c a r r i e r assembly ( 3 ) . Align match marks t h a t
were made d u r i n g disassembly. I n s t a l l s i x
(3/8"-14 x 1 l g ) capscrews and lockwashers
(1).
NOTE: T i g h t e n capscrew ( 2 ) from 37 t o 41
S t . Zbs. torque.
I n s t a l l r e l i e f valve ( 4 ) only if removed

d u r i n g disassembly.
NOTE: Make c e r t a i n r e l i e f operates properZy . Figure 88
I n s t a l l magnetic drain p l u g ( 3 ) in d i f f e r -
e n t i a l housing ( 4 ) . I n s t a l l plug ( 1 ) in
each planetary housing ( 2 ) .
Figure 89
-37-
FILE G
INSTALLATION OF AXLE TO CRANE

REAR A X L E INSTALLATION
. - .
With ax1 e placed on s k i d , position crane boom

over s i d e of crane, lower boom t o Oo elevation
and r e t r a c t crowd cylinder as far as possible.
Attach chain ( 1 ) t o s k i d and axle ( 2 ) . Crowd
boom o u t t o pull axle under crane.
Figure 90
Rotate boom u n t i l chain and spreader ( 1 ) a r e
d i r e c t l y over the r e a r axle ( 2 ) . Attach
chain t o axle and r a i s e hook t o hold axle
t i g h t against crane.
NOTE: When r a i s i n g a x l e i n t o p o s i t i o n it
w i l l be necessary t o move a x l e from
s i d e t o s i d e t o c l e a r s t e e r i n g arms
over crane a x l e mounting pads.
I n s t a l l e i g h t capscrews and lockwashers ( 3 )

t h a t secures axle t o frame.
NOTE: Tighten capscrews ( 3 ) t o 460 S t . Zbs.
torque.
Pos i t i o n s t e e r i n g arm pins ( 5 ) in s t e e r i n g

arm and i n s t a l l nuts ( 6 ) . Figure 9 1
Pos i t i o n bracket ( 8 ) and clamp ( 7 ) on s t e e r i n g

arm (9) and i n s t a l 1 two capscrews, lockwashers
and nuts ( 6 ) . I n s t a l l brake l i n e hose ( 4 ) on
t e e f i t t i n g ( 5 ) . Position cylinder rod ( 2 )
on s t e e r i n g arm pin ( 3 ) and i n s t a l 1 locknut
(1).
Position d r i v e s h a f t on axle and transmission
universal j o i n t s and i n s t a l l two U-bo1 t s ,
f o u r lockwashers and nuts.
NOTE: I n s t a l l remaining rear s t e e r i n g cyZ-
inder i n t h e same manner.
Figure 92
-38-
FILE b
Using a s u i t a b l e s l i n g and boom, l i f t wheel

assembly ( 2 ) i n t o position on hub assembly
( 3 ) and i n s t a l l ten stud nuts ( 1 ) .
NOTE: Using suitabZe torque wrench (41
t i g h t e n n u t s ( 1 ) to 300 ft. Zbs.
torque.
BE EXTREMELY CAREFUL WHILE IN-

STALLING WHEEL ASSEMBLY. MINI-
MUM WHEEL WEIGHT i s 480 LBS.
CAUTION
Figure 93
Lower r e a r outriggers ( 1 ) t o 1 i f t r e a r of
crane o f f wooden blocking ( 2 ) . Remove
wooden blocking ( 2 ) and skid ( 3 ) o u t from
under the crane. Raise outriggers t o
stowed p o s i t i o n .
NOTE: BZeed brakes, r e f e r to Fig. 103.
Figure 94
- -
FRONT AXLE INSTALLATION
Swing crane boom 90° o f f center ( t o the s i d e )

of crane. Lower boom t o Oo elevation and
r e t r a c t boom as far as possible. Attach
chain (1 ) t o skid and axle ( 2 ) . Crowd boom
o u t t o p u l l axle assembly i n t o position
under crane.
-39-
FILE
W i t h l i f t i n g c h a i n and s p r e a d e r p r o p e r l y
a t t a c h e d t o boom hook and a x l e assembly ( 2 ) ,
l i f t a x l e by r a i s i n g boom hook and hold a x l e
t i g h t a g a i n s t c r a n e frame.
NOTE: I t wiZZ be necessary t o t w i s t axZe t o
a2 Zow s t e e r i n g arms t o cZear t h e Z i p
on s i d e of frame.
I n s t a l 1 e i g h t bo1 t s and n u t ( 3 ) which secures
ax1 e t o c r a n e .
NOTE: Tighten n u t s ( 3 ) t o 460 S t . Zbs. tor-
que.
Four i n s i d e boZts ( 3 ) have tangs weZded
on them t o eZiminate turning whiZe Figure 96
tightening nuts.
MAKE CERTAIN TANGS ON BOLTS DO NOT C O X IN CONTACT WITH WIRING HARNESS

DURING TIGHTENING.
CAUTlQM
Remove c h a i n from a x l e assembly ( 2 ) .
P o s i t i o n d r i v e l i n e ( 3 ) on t r a n s m i s s i o n
u n i v e r s a l j o i n t ( 4 ) and i n s t a l 1 two U-bo1 t s
( 2 ) and f o u r nuts and lockwashers (1 ) .
Figure 97
-40-
FILE G
Remove washers and nuts (10) t h a t were i n -

s t a l l e d t o hold p a r k i n g b r a k e c o v e r on
d u r i n g removal. P o s i t i o n d r i v e s h a f t (11)
on p a r k i n g b r a k e f l a n g e (1 ) and i n s t a l 1
e i g h t nuts and l o c k w a s h e r s ( 1 0 ) . I n s t a l l
master cy1 i nder s u p p l y hose (8) on tee
f i t t i n g ( 9 ) . Position parking brake c a b l e
( 7 ) on p a r k i n g b r a k e ( 4 ) and i n s t a l l U-clamp
( 6 ) and two nuts and lockwashers ( 5 ) . In-
s t a l l yoke ( 3 ) on b r a k e assembly and i n s t a l l
p i n and c o t t e r p i n ( 2 ) .
Figure 98
P l a c e steering arm p i n ( 3 ) i n s t e e r i n g arm

and i n s t a l l n u t ( 7 ) . P o s i t i o n p i s t o n r o d
( 2 ) on p i s t o n rod p i n ( 3 ) and i n s t a l l washer
and l o c k n u t . I n s t a l 1 b r a k e hose ( 5 ) and
brake 1 ine ( 4 ) on tee f i t t i n g ( 6 ) .
Figure 99
I f new steering arm or a x l e assembly i s

b e i n g i n s t a l l e d , b a l l s t u d and a d a p t e r
p l a t e ( 1 1 ) ( P a r t #AD-120063) must be
welded t o l e f t hand s t e e r i n g arm f o r i n -
s t a l l a t i o n o f drag l i n k . I n s t a l l brake
h o s e (8) and l i n e ( 9 ) on tee f i t t i n g ( 1 0 ) .
Position d r a g l i n k ( 6 ) on b a l l s t u d ( 7 ) and
i n s t a l l b e a r i n g h a l f , s p r i n g and a d j u s t i n g
p l u g ( 5 ) . PI a c e s t e e r i n g arm p i n ( 3 ) i n
s t e e r i n g arm and i n s t a l l n u t ( 1 2 ) . P o s i t i o n
cy1 inder r o d end ( 2 ) on p i n ( 3 ) and i n s t a l 1
n u t and washer ( 1 ) .
Figure 100
-41 -
FILE
Position wheel assembly ( 2 ) on hub ( 3 ) and

i n s t a l 1 ten nuts (1 ) .
NOTE: T i g h t e n n u t (1) t o 300 f t . Zbs. torque
NOTE: A suitabZe sZing and m a n e boom can
be used to pZace wheel assembZy on
hub. Wheel assembly has a minirnm
weight of 480 pounds.
Figure 101
Lower outrigger (1 ) and remove wooden

blocking ( 2 ) and skid ( 3 ) o u t from under
crane assembly. Raise outriggers t o
stowed pos it i on.
Figure 102
-42-
FILE G
BRAKE BLEEDING
Remove o p e r a t o r ' s s e a t from s e a t post ( 3 ) .

Remove four screws ( 4 ) and cover p l a t e ( 5 )
from f l o o r p l a t e under the s e a t . This p l a t e
removal wi 11 a1 low access t o the master
brake cylinder ( 2 ) .
Remove master brake cy1 inder cover ( 1 ) and
i n s t a l l adapter t h a t can be used with a
pressurized bleeder bomb. Attach a bleeder
bomb with a low a i r pressure of approxi-
mately t h i r t y pounds which i s s u f f i c i e n t
t o bleed the brakes.
Using a sui t a b l e wrench crack open the
bleeder valve behind each o f t h e e i g h t
wheel cy1 inders (two per wheel ) . Keep
bleeder valve open u n t i l a1 1 a i r has es-
caped, and only a s o l i d stream of brake Figure 103
f l u i d i s v i s i b l e . Tighten bleeder valve. Remove bleeder bomb, and i n s t a l l master
cy1 inder cover (1 ) . Test brakes f o r proper operation.
-43-
SHOP MANUAL
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
c
TOE' MOVE PINION TOWARI)

GEAR IN THIS DIRECTION #
MOVE PINION AJUrAY FROM
GEAR IN THIS DIRECTION
i
V MOVE GEAR AWAY FROM
PINION IN THIS DIRECTION
MOVE GEAR TOWARD
PINION IN THIS DIRECTION A
-
LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE O N RIGHT HAND SPIRAL
RING GEAR - THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING O N BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING O N BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH.-GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING O N PiNION. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING O N PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
-44-
GRADER 0
PLANER 0
ROLLER 0
CRANE lid
Shop Manual 6-7

c1
ROCKWELL AXLE A S S E M B L Y
Applicable Model Serial Number
150A 05835 & Up

1 50 FA 07305 & Up
CAUTl ON
ALL COMPONENTS MUST B E P R O P E R L Y SUPPORTED DURING
ALL JACKING HOISTING AND G E N E R A L WORKSHOP EQUIPMENT

REQUIRED FOR THIS OPERATION MUST B E IN GOOD
WORKING ORDER.
EXTREME CAUTION TO B E OBSERVED A T A L L TIMES TO PREVENT

INJURY.
CONTENTS
-_II
2aqe
___
Torquesheet. . . . . . . . . . . . . . . . . . . . . . . Back o f Cover
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 1
Removal o f Axles from Crane . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . ....... . . If?
Cleaning and Inspectio7 . . . . . . . . . . . . . . . . . . . 23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . :‘9
Brake Adjustment, Bleeding 8 Burnishing . . . . . . . . . . . 44
c1
1 DRESSER
1
-r
lNOUSTRlE5
Dresser Industries, Inc. Gallon Dlvlston South Street
(419) 468-4321 Telex: 987430 Cable: Gallron
P 0 Box 647 Gallon. OH 44833 U S.A
1179
The following General Torques are to be used in all cases where SPECIFIC TORQUES are nat given.
I Heat treated mater Grade 5 & Grade 8
Grade 5 Grade 8
1/4 . 20 6 a 9 12
114 - 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 - 24 15 20 21 28
318 . 16 24 33 34 46
318 - 24 2: 37 38 52
7/16 . 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
518 . 11 115 156 165 224
518 . 18 130 176 185 251
3/4 - 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 - 14 335 454 515 698
1 - 8 455 617 695 942
1 . 14 510 69 1 785 1064
1 118 . 7 610 827 990 1342
1 118 . 12 685 929 1110 1505
1 1/4 - 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 318 - 6 1130 1532 1830 2481
1 318 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 370 1
1 3/4 . 5 2370 3213 3810 5166
2 - 4 1/2 3550 4813 5760 7810
FILE G
SPECIAL TOOLS
1. Wooden blocks f o r cribbing under outrigger frames. Eight

blocks 10" x 10" x 15" l g . Use only hardwood.
2. Skid having weight capacity of two t o n (4,000 l b s ) minimum
used t o s l i d e axles o u t a n d under crane.
3. Air impact wrench a n d a i r hose l o n g enough t o reach a i r o u t l e t
i f a i r i s available. (5/8" or 3/4" square d r i v e ) .
4. One s e t of mechanics hand tools , should include heavy d u t y
wrenches a n d sockets up t o and including 2 1 / 2 " .
5. Socket f o r wheel l u g nuts ( 1 1 / 2 " x 3" l g . ) heavy duty impact
socket.
6. Spreader bar f o r chain fa1 1 , (70" l g . ) .
7. Two chains 3/8" links x 1 6 ' 6 l g .
NOTE: Spreader bar should be notched t o receive 3/8" chain
l i n k . Both ends of spreader must be moused (locked)
t o chain, s i x f e e t from l i f t i n g e y e ( s ) . Chains must
have l i f t i n g capacity of not l e s s than two tons
(4,000 l b s . i.
8. Suitable containers t o s t o r e loose hardware.
9. One s i x hundred (600) f t . 1 b . torque wrench.
10. Four #4 tube caps and two 1/8" brake 1 ine plugs.
11. One c o t t e r p i n 3/16" dia. x 3 3/4" l g . f o r drag link.
12. One t a p , 1 " - 14 UNS/2A.
13. Brake bleeder, pressure type, (approximately 35 psi ) .
1
FILE l
i
SHOP MANUAL
,
SECTION 7
MASTER CYLINDER BLEEDING ADAPTOR
2
FILE b
3
FILE G
REMOVAL OF AXLES FROM CRANES

GENERAL
Position crane on a f l a t smooth surface. There must be approximately thirty

(30) f e e t 360' around the crane t o a1 low boom t o swing with one section extended.
A. F R O N T A X L E REMOVAL
Figure 1
2. Remove eight stud nuts ( 1 ) . Loosen

remaining two stud n u t , b u t do n o t
remove. Leave two nuts on studs
approximately one-quarter o f an inch.
N O T E : The two nuts t h a t are s t i Z 2
on whee2 shouZd be a t Zoea-
".
t i o n "A
Figure 2
4
FILE l
i
3. Position porta-power ( 1 ) as i 11 us t r a t e d ,
t o break wheel assembly ( 2 ) away from
drum ( 3 ) . Remove porta-power, two re-
maining wheel s t u d nuts a n d wheel assembly
( 2 ) from drum ( 3 ) . Replace a l l stud nuts
on drum t o protect studs.
A
CAUTION
MOVING WHEEL ASSEMBLY. WHEEL
ASSEMBLY WILL HAVE A MINIMUM
WEIGHT OF 480 POUNDS.
NOTE : Crane boom w i t h s u i t a b l e whee 2

s l i n g can be used t o he l p re-
move whee 2 assembly.
Figure 3
4. Remove locknut and bearing half ( 1 ) a n d

l i f t steering rod end ( 2 ) off steering
arm pin ( 3 ) . Remove c o t t e r p i n ( 4 ) a n d
adjusting plug ( 5 ) with spring and bearing
ha1 f from drag 1 ink ( 6 ) . Remove d r a g 1 ink
from b a l l stud. Disconnect brake l i n e ( 8 )
from connector ( 9 ) . Remove nut, lockwash-
e r , f l a t washer ( 1 0 ) and bracket ( 1 1 ) from
steering arm ( 7 ) . Cap and plug brake
1 ines.
NOTE: Secure drag l i n k , c y l i n d e r and brake
hose assemblies away from a x l e t o
eliminate i n t e r f e r e n c e during r e -
mova 2 and i n s t a 2 l a t i o n .
Figure 4
5. Remove locknut and bearing h a l f ( 1 ) , a n d

l i f t (right s i d e ) piston rod ( 2 ) off
steering arm p i n ( 3 ) . Loosen tube n u t
( 4 ) t o remove tube ( 5 ) . Remove n u t ,
lockwasher and f l a t washer ( 6 ) and
bracket ( 7 ) w i t h brake hose ( 8 ) from
steering arm ( 9 ) . Cap and plug brake
lines.
NOTE: Secure s t e e r i n g cy l i n d e r and brake
hose away from a x l e t o eliminate
i n t e r f e r e n c e during removal and
installation.
Figure 5
5
FILE li
6. Remove four nuts and lockwashers ( 1 )

two U-Bo1 t s ( 2 ) a n d drive l i n e ( 3 ) from
transmission o u t p u t s h a f t ( 4 ) .
COMPLETELY REMOVE DRIVE LINE

TO ELIMINATE POSSIBLE INJURY
I F TRANSMISSION I S BUMPED INTO
CAUTION GEAR*
Figure 6
Remove c o t t e r p i n a n d p i n ( 2 ) a n d yoke
( 3 ) from parking brake ( 4 ) . Remove two
nuts and lockwashers ( 5 ) and U-clamp ( 6 )
t h a t secures parking brake cable ( 7 ) t o
parking brake ( 4 ) . Remove n u t & lock-
washer ( 8 ) and bracket ( 9 ) t h a t secure
brake 1 ines t o ax1 e assembly (10) rein-
s t a l l lockwasher and n u t ( 8 ) . Remove
eight nuts a n d lockwashers ( 1 1 ) and drive
s h a f t ( 1 2 ) from parking brake flange ( 1 ) .
NOTE: I n s t a l l spacers, Zockwashers and
n u t s back on brake fZange studs
t o p r o t e c t both studs and brake
shoes i n t r a n s i t .
Figure 7
6
FILE b
8.
Figure 8
NOTE: Stamp the l a s t four d i g i t s of crane
s e r i a l number i n axle mounting pads
6. REAR AXLE REMOVAL
9. Remove eight stud nuts ( 1 ) . Loosen re-

maining two stud nuts, b u t do n o t remove.
Leave two nuts on studs approximately one-
quarter o f a n inch.
NOTE: The two n u t s t h a t are sti?YZ on whee 2
should be a t location "A".
NOTE: Remove remaining rear whee?, i n the

sane manner.
Figure 9
10 . Position porta-power ( 1 ) as i l l u s t r a t e d ,
t o break wheel assembly ( 2 ) away from
drum ( 3 ) . Remove porta-power (1 ) two
remaining wheel stud nuts a n d wheel
assembly ( 2 ) from drum ( 3 ) . Replace
a l l stud nuts on drunl t o protect
wheel studs .
BE EXTREMELY CAREFUL WHEN REMOV-
ING WHEEL ASSEMBLY. WHEEL ASSEM-
BLY WILL HAVE A MINIMUM WEIGHT OF
CAUTION 480 POUNDS.
NOTE: Crane boom used w i t h a s u i t a b l e
s l i n g may be used t o help remove
whee 2 assemb Zy .
Figure 10
7
FILE
11. Remove locknut and bearing half ( 1 ) a n d

l i f t s t e e r i n g cylinder rod ( 2 ) off s t e e r -
ing arm pin ( 3 ) . Remove two nuts , lock-
washers and capscrews ( 4 ) , clamp ( 5 ) and
bracket ( 6 ) from s t e e r i n g arm ( 7 ) . Loosen
tube n u t ( 8 ) and remove tube from con-
nector ( 9 ) . Remove n u t , lockwasher a n d
bracket ( 1 0 ) from s t e e r i n g arm.
NOTE: Secure s t e e r i n g cylinder and brake
hose assemblies away from axle t o
eliminate i n t e r f e r e n c e during re-
moval and i n s t a l l a t i o n .
Figure 11
12. Remove locknut a n d bearing half ( 1 ) a n d

1 i f t s t e e r i n g cy1 i nder rod ( 2 ) off s t e e r -
i n g arm pin ( 3 ) . Loosen tube n u t and
remove brake tube ( 4 ) from adapter ( 5 ) ,
remove n u t , lockwasher, f l a t washer, and
bracket ( 6 ) from s t e e r i n g arm ( 7 ) .
NOTE: Secure s t e e r i n g cylinder and brake
hose away from axZe t o eliminate
i n t e r f e r e n c e during remova 2 and
instal lation.
Figure 12
13. Remove e i g h t nuts and lockwashers ( l ) ,

four U-bo1 t s ( 2 ) a n d d r i v e 1 ine ( 3 ) from
transmission o u t p u t s h a f t ( 4 ) and r e a r
axle ( 5 ) .
A
CAUTION
COMPLETELY REMOVE DRIVE LINE TO
ELIMINATE POSSIBLE INJURY I F
TRANSMISSION I S BUMPED INTO GEAR
Figure 13
8
FILE
1 4.. Rotate boom u n t i l chain and spreader

( 1 ) a r e d i r e c t l y over the rear axle
( 2 ) . Attach chain t o axle and r a i s e
hook t o h o l d axle t i g h t against crane
frame. Remove e i g h t capscrews w/lock-
washers (4), t h a t secure axle t o frame.
Lower axle assembly ( 2 ) t o skid ( 3 )
located under crane.
BE EXTREMELY CAREFUL WHEN
ROTATING BOOM ASSEMBLY CAB
DOORS MUST BE CLOSED AS
THERE WILL BE AN INTERFER-
CAUTION ENCE BETWEEN COUNTERWEIGHT
AND DOORS.
NOTE: Before lowering axle i t will
be necessary t o t u r n wheels Figure 14
a l l t h e way i n one d i r e c t i o n
t o c l e a r steering arms over
Crane a x l e mounting pads.
Remove chain and spreader from axle ( 2 ) . Rotate boom w/chain t o one s i d e of
crane. Lower boom t o 0' elevation and r e t r a c t crowd cylinder as f a r as possible,
Attach chain ( 1 ) t o skid and axle. Crowd boom out t o p u l l axle assembly o u t
from under crane.
NOTE: Stamp t h e l a s t four d i g i t s o f crane s e r i a l number i n axle mounting pads.
9
FILE G
DISASSEMBLY
The following i s one method of disassembly, cleanning and inspection, a n d
reassembly when complete overhaul of axle i s necessary.
Using a s u i t a b l e l i f t i n g device, w i t h a minimum l i f t i n g capacity of four thousand
(4,000) l b s . position axle assembly i n a clean work a r e a , with s u f f i c i e n t work area
3600 a r o u n d the ax1 e . C1 ean axle thoroughly p r i o r t o disassembly.
USE EXTREME CARE DURING CLEANING OPERATION TO PREVENT DIRT OR OTHER
CONTAMINATION FROM ENTERING THE AXLE ASSEMBLY.
CAUTION
15. Rotate axle planetary assemblies ( 1 )

u n t i l drain plug ( 2 ) i s located a t
t h e bottom. Remove d r a i n p l u g from
d i f f e r e n t i a l and allow o i l t o drain
i n t o a clean s u i t a b l e container.
> ,I
Figure 1 5
16. Match mark planet cover and planet

c a r r i e r assembly. Remove eight cap-
screws ( 1 ) and planet cover ( 2 ) from
planet c a r r i e r assembly ( 4 ) . Remove
o i l level p l u g ( 3 ) from planet cover.
Figure 16
lo
FILE G
17. Remove retaining ring ( 1 ) and sun gear

( 2 ) from axle s h a f t ( 3 ) .
Figure 17
18. Remove sixteen capscrews and lockwashers

( 1 ) a n d planet c a r r i e r ( 2 ) from wheel
hub (3).
Figure 18
19. Using a siiitable d r i f t , drive pinion

s h a f t ( 1 ) o u t thru the f r o n t of planet
spider ( 2 ) . Remove planet gear ( 3 ) a n d
two t h r u s t washers ( 4 ) from spider ( 2 ) .
Figure 19
17
FILE G
20. Remove t h r u s t washer ( 4 ) from h u b

bearing n u t ( 5 ) . Remove planetary
ring gear ( 1 ) from planetary ring
gear h u b ( 2 ) and h u b assembly ( 3 ) .
Figure 20
21. Remove two screws (1 ) and n u t lock

( 2 ) from planetary ring gear h u b ( 4 ) .
Remove n u t ( 3 ) and gear h u b ( 4 ) from
wheel bearing spindle ( 5 ) .
Figure 2 1
22. Using a s u i t a b l e p u l l e r , remove

bearing cone ( 1 ) from planetary ring
gear h u b ( 2 ) .
Figure 22
12
FILE
23. Using a s u i t a b l e l i f t i n g s t r a p ( 1 ) re-

move h u b a n d drum ( 2 ) from ax1 e assembly
(3).
Figure 23
24. Remove c o t t e r pin ( 1 ) , n u t ( 2 ) a n d drag-

link ( 3 ) from spindle support ( 4 ) . Re-
move four capscrews and lockwashers ( 5 )
and two dust guards ( 6 ) from axle
assembly.
25. Using extreme care, remove spring ( 1 )

from brake shoe assemblies ( 4 ) . Re-
move retaining rings ( 2 ) a n d 1 ink ( 3 )
from the two brake shoe pins ( 5 ) . Re-
move brake shoes ( 4 ) from pins ( 5 ) .
Figure 25
13
FILE
26. Remove ten nuts a n d lockwashers ( l ) ,

two capscrews and lockwashers ( 2 ) a n d
o i l seal and r e t a i n e r ( 3 ) and spindle
( 4 ) from axle assembly ( 5 ) .
Figure 26
27. Remove ax1 e ( 1 ) from ax1 e assembly ( 2 ) .
Figure 27
28. Remove four capscrews a n d 1 ockwas hers

( 1 , 6 ) and l i f t s t e e r i ng arm ( 2 ) a n d
shims ( 3 ) from s t e e r i ng knuckle ( 4 ) .
Remove grease f i t t i n g ( 5 ) from s t e e r i n g
arm ( 2 ) only i f repla cement i s necessary
Figure 28
14
FILE G
Figure 29
30. Remove four capscrews ( 1 & 7 ) . Instal 1

two (3/8" - 16NC x 1 1 / 2 " l g ) capscrews
( 2 ) in bearing cap ( 3 ) , tighten cap-
screws t o p u l l cap ( 3 ) and shims ( 4 ) from
knuckle assembly ( 5 ) . Remove grease
f i t t i n g ( 6 ) only i f replacement i s
necessary.
Remove o i l seal and bushing ( A ) behind
i t . (Obtain new seal before discarding
old seal. )
Figure 30
31. Remove t h r u s t washer ( 1 ) from lower cap

( 2 ) . Tag a n d record shim thickness f o r
reassembly procedure.
.
. ......
Figure 31 c1
15
FILE G
32. Attach a s u i t a b l e l i f t i n g device t o

knuckle assembly ( 3 ) and remove from
axle assembly. Remove two capscrews
and lockwashers ( 1 ) and wheel cy1 inder
( 2 ) from knuckle assembly.
Figure 32
cy1 i nder ( 3 ) .
Figure 33
34. Remove cam ( 1 ) a n d spring ( 2 ) o n l y i f

replacement i s necessary. Using a
sui t a b l e grinder remove end of capscrew
a t p o i n t " A " . Remove cams ( 1 ) , springs
( 2 ) and capscrews ( 3 ) from knuckle ( 4 ) .
Figure 34
16
FILE G
35. Remove n u t and lockwasher ( 1 ) and brake

shoe anchor pin ( 3 ) from steering
knuckle ( 4 ) .
Figure 35
36. Loosen n u t ( 1 ) and remove bo 1 t ( 2 ) from

knuckle ( 3 ) . Using a sui t a b l e puller,
remove studs ( 4 ) only i f rep 1 acement i s
necessary.
Figure 36
37. Using a sui table puller, remove upper

bushing ( 1 ) and lower bushing ( 2 ) from
axle assembly ( 3 ) .
NOTE: Disassemble remaining end of a x l e
assembly i n t h e same manner as
outlined i n s t e p s 15 thru 37.
Figure 37
17
FILE
38. Remove e i g h t nuts and lockwashers ( 1 )

spacers ( 2 ) and parking brake cover ( 3 )
from axle drive flange ( 4 ) .
39. Remove two brake springs ( 1 ) a n d brake

shoes ( 2 ) from brake backing p l a t e ( 4 )
and g u ide pins ( 3 ) .
BE EXTREMELY CAREFUL WHEN
REMOVING BRAKE SPRING.
CAUTION
Figure 39
40. Remove n u t and lockwasher ( 1 ) from

pinion s h a f t ( 3 ) and remove drive flange
( 2 ) from pinion s h a f t .
Figure 40
18
FILE
41. Remove brake ac tuating r o l l e r ( I ) ,

opera t i ng 1 ever cam ( 2 ) from backing
plate (4) and pin ( 3 ) .
Figure 41
. .
42. Remove s i x capscrews a n d lockwashers ( 1 )

and brake backing p l a t e ( 2 ) from axle
assembly ( 3 ) .
43. Loosen n u t ( 4 ) and back-off on s e t screw

( 5 ) . Remove fourteen nuts and lock-
washers ( 1 ) t h a t secures cap a n d c a r r i e r
assembly ( 2 ) t o axle assembly ( 3 ) .
Figure 43
19
FILE
44. Using two bo1 t s (7/16" - 1 4 NC x

3" l g . ) ( 1 ) and l i f t i n g chains ( 3 ) ,
remove cap and c a r r i e r assembly ( 2 )
from axle ( 4 ) .
NOTE: A f t e r placing cap and c a r r i e r (2)
on a s u i t a b l e work bench, remove
l i f t i n g chain and b o l t s ( 3 , l ) .
Remove two capscrews and lockwashers

( 5 ) and o i 1 r e t a i n e r ( 6 ) from cap and
carrier.
Figure 44
45. P a i n t or s c r a t c h , match mark ( 1 ) t o

indicate original position between ad-
j u s t i n g n u t ( 4 ) cap ( 2 ) and c a r r i e r ( 3 )
t o insure proper reassembly.
Figure 45
46. Remove two c o t t e r pins (adjusting n u t

locks) ( 1 ) , four capscrew and lockwash-
e r s ( 2 ) a n d two bearing caps ( 4 ) from
c a r r i e r assembly ( 3 ) .
Figure 46
20
FiLE G
47. L i f t ring gear ( 3 ) o u t of c a r r i e r assem-

bly ( 4 ) a n d remove two adjusting nuts
(1 ) a n d two bearing cups ( 2 ) from ring
gear assembly ( 3 ) . Using a n approved
method, place match mark ( 5 ) on ring
assembly t o show r e l a t i v e position be-
tween spider ( 6 ) and bearing halves ( 7 ) .
48. Using a sui t a b 1 e p u l l e r , remove two

bearing cones ( 4 ) only i f replacement
i s necessary. Remove twelve capscrews
( 1 ) d i f f e r e n t i a l case ( p l a i n h a l f ) ( 2 )
from d i f f e r e n t i a l case (flanged h a l f )
(3).
49. Remove s l i d e gear ( 1 ) , spring ( 2 ) cam

a n d cl utch ( 3 ) and spider ( 4 ) from the
remaining cam and clutch assembly ( 5 ) .
Figure 49
21
FILE G
50. Remove cam a n d clutch assembly ( 1 ) ,

spring ( 2 ) and s l i d e gear ( 3 ) from
d i f f e r e n t i a l case (flanged h a l f ) (4).
Remove r i v e t s ( 5 ) and ring gear
( 6 ) from d i f f e r e n t i a l case, only i f
repl acement i s necessary.
Figure 50
51. Remove locknut ( 1 ) and adjusting screw

( 2 ) from c a r r i e r assembly ( 3 ) . Using a
p u l l e r i f necessary, remove pinion
assembly ( 4 ) a n d gasket ( 5 ) from c a r r i e r
assembly ( 3 ) .
Figure 51
52. Remove gasket ( 1 ) from pinion assembly

( 4 ) . Using s u i t a b l e press or p u l l e r ,
remove pinion ( 3 ) with bearing race ( 6 ) 1
and bearing ( 8 ) from cage assembly ( 4 ) .
Remove bearing race ( 5 ) from cage assem-
bly. Remove retaining ring ( 7 ) and bear-
i ng ( 8 ) from pinion ( 3 ) . Remove bearing
cups from cage assembly ( 4 ) only i f
repl acement i s necessary.
Figure 52
22
FILE li

A. C1 ean a1 1 parts thoroughly using sol vent type cleaning f l u i d . I t i s recommended
t h a t parts be immersed in cleaning f l u i d and moved u p and down slowly until a l l
o i l l u b r i c a n t a n d foreign material i s dissolved and p a r t s a r e thoroughly clean.
CARE SHOULD BE EXERCISED TO A V O I D SKIN RASHES, FIRE HAZARDS AND

INHALATION OF VAPORS WHEN USING SOLVENT TYPE CLEANERS.
CAUTION
B. Remove bearings from cleaning f l u i d and s t r i k e f l a t against a block o f wood t o

dislodge s o l i d i f i e d p a r t i c l e s o f l u b r i c a n t . Immerse again in cleaning f l u i d t o
flush o u t p a r t i c l e s . Repeat above operation u n t i l bearings a r e thoroughly clean.
Dry bearings using moisture f r e e compressed a i r . Be careful t o d i r e c t a i r stream
across bearing t o avoid spinning. Do n o t spin bearings when drying. Bearings
may be rotated slowly by hand t o f a c i l i t a t e drying process.
C. Clean i n t e r i o r and e x t e r i o r of housings, bearing caps, e t c . , thoroughly. Cast
parts may be cleaned i n h o t solution tanks with mild a l k a l i solutions providing
these parts do n o t have ground or polished surfaces. Parts should remain in
solution long enough t o be thoroughly cleaned a n d heated. This w i l l aid the
evaporation of cleaning solution and r i n s e water. Parts cleaned i n solution tanks
must be thoroughly rinsed with clean water t o remove a l l traces of a l k a l i . Cast
parts may a1 so be cleaned with a steam cleaner.
D.
A
CAUTION
CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPORS A N D SKIN RASHES
WHEN USING ALKALI CLEANERS.
All parts cleaned must be thoroughly dried immediately by using moisture f r e e

compressed a i r or s o f t l i n t l e s s absorbent wiping rags f r e e of abrasive materials
such as metal f i l i n g s , contaminated o i l or lapping compound.
E. Carefully inspect a1 1 bearing r o l l e r s , cages a n d cups f o r wear, chipping or nicks
t o determi ne condition. Do n o t replace a bearing cone or cup individually with-
o u t replacing the mating cup or cone a t the same time. After inspection, dip
bearings in E P 80 or EP 90 and wrap i n clean l i n t l e s s cloth or paper t o protect
them until i n s t a l l e d .
F. Replacement of o i l s e a l s , O-rings, gaskets and snap rings a r e more economical t o
replace when u n i t i s disassembled t h a n premature f a i l u r e , r e f e r t o Parts Book f o r
part number of replacement i tems. Be extremely careful when i n s t a l 1 ing seal , t o
avoid c u t t i n g or scratching. Lubricate a1 1 O-rings and s e a l s before assembly.
23
FILE
G. If a v a i l a b l e , use magna-flux process f o r checking f o r cracks t h a t a r e n o t v i s i b l e

t o t h e naked eye. Examine teeth on a1 1 gears c a r e f u l l y f o r wear, p i t t i n g , chipp-
i n g , nicks, cracks or scores. Replace a l l gears showing cracks or spots where
case hardening has worn t h r o u g h . Small nicks may be removed with sui t a b l e hone.
Inspect s h a f t s a n d q u i l l s t o make c e r t a i n they have n o t been sprung, bent, or
splines twisted, and t h a t s h a f t s a r e t r u e .
H. Inspect housings and covers t o be c e r t a i n they a r e thoroughly cleaned and t h a t
mating surfaces, bearing bores, e t c . , a r e f r e e from nicks or burrs. Check a l l
parts c a r e f u l l y f o r evidence of cracks or condition which would cause subsequent
o i l leaks or f a i l u r e s .
24
FILE
REASSEMBLY
53. Posi t i o n bearing ( 8 ) on pinion ( 3 ) a n d
i n s t a l l retaining ring ( 7 ) . Press bear-
ing cup in cage assembly ( 4 ) i f removed
during disassembly. Position bearing
( 6 ) on pinion ( 3 ) a n d press cage ( 4 )
and bearing ( 5 ) in location on pinion ( 3 ) .
Position gasket ( 1 ) on bearing cage.
Figure 53
54. I n s t a l l locknut ( 1 ) on adjusting screw

( 2 ) and i n s t a l l adjusting screw in
c a r r i e r assembly ( 3 ) . Position pinion
c a r r i e r assembly ( 4 ) and gasket ( 5 )
in c a r r i e r assembly ( 3 ) .
Figure 54
55. Position ring gear ( 6 ) on d i f f e r e n t i a l

case ( 4 ) and i n s t a l l r i v e t s (5) i f re-
placed during di sassembly . P1 ace sl i de
gear ( 3 ) in d i f f e r e n t i a l case h a l f ( 4 )
a n d position spring ( 2 ) a n d cam and
clutch assembly ( 1 ) over end of s l i d e
gear ( 3 ) .
Figure 55
25
FILE
... ". ,
56. Position spider ( 4 ) on cam and clutch

assembly ( 5 ) . Make c e r t a i n t h e match
marks which were p u t on spider prior t o
disassembly a r e in proper alignment.
I n s t a l l cam and clutch ( 3 ) , spring ( 2 )
and sl ide gear ( 1 ) on spider ( 4 ) .
. .
Figure 56
57. Position d i f f e r e n t i a l case ( p l a i n h a l f )

( 2 ) on d i f f e r e n t i a l case (flanged h a l f )
( 3 ) and i n s t a l l e i g h t ( 1 / 2 " - 13 x 3"
1s) twelve point head capscrews ( 1 )
a n d four ( 1 / 2 " - 13 x 2 1/4" l g ) twelve
point head capscrews ( 1 ) t h a t secure
d i f f e r e n t i a l cases together.
NOTE: Check match marks t h a t were made
p r i o r t o disassembly t o i n s u r e
proper alignment.
Using a sui t a b 1 e press a n d sleeve in-

s t a l l bearing inner races ( 4 ) on d i f f -
e r e n t i a l assembly, i f removed during
disassembly procedure.
58. Position ring gear ( 3 ) i n c a r r i e r assem-

bly ( 4 ) and i n s t a l 1 two bearing races
( 2 ) and adjusting nuts ( 1 ) .
Figure 58
26
FILE G
59 . Position two bearing caps ( 4 ) on

c a r r i e r ( 3 ) a n d i n s t a l 1 four lock-
washers and (5/8" - 11 NCX 4 1 / 2 " 1 g :
Grade 8 ) capscrews ( 2 ) .
NOTE: Tighten capscrews ( 2 ) t o 220 f t .
Zbs . torque.
NOTE: Make c e r t a i n bearing caps have

been instaZZad on proper s i d e of
c a r r i e r and match marks are
i n proper aZignment.
I
\
Figure 59
60. Tighten adjusting nuts ( 4 ) t o obtain
zero end play in bearings. A1 1
bearing r o l l e r s must r o t a t e when ring
gear r o t a t e s , however you should he
able t o move r o l l e r sideways i n cage
when prying against them with a screw-
d r i v e r . Using a d i a l i n d i c a t o r , check
backlash between ring gear and pinion
gear.
Backlash i s adjusted by moving ring
gear toward or away from pinion s h a f t
gear. R i n g gear i s moved by loosening
one adjusting n u t and tightening the
opposite, move each n u t the same d i s -
tance so t h a t bearing end play a d j u s t -
ment which has already been made will Figure 60
n o t be distrubed. Move ring gear
u n t i l backlash i s between .005" t o .015" i f new ring and pinion gears i s used.
For reassembly of o l d gears r e f e r t o backlash readings t h a t were recorded d u r i n g
disassembly.
Check ring a n d pinion gear for t o o t h contact. Apply a mixture of red 1 ead and
linseed o i l t o approximately twelve teeth for checking purposed. Gears should
be r o t a t e d , under s l i g h t load f o r a t l e a s t one revolution in b o t h d i r e c t i o n s . A
f l a t s t e e l bar may be used t o apply load against ring gear. Tooth contact
pattern should be check on drive (convex) s i d e of ring gear t o o t h . Refer t o page
38 f o r c o r r e c t t o o t h contact p a t t e r n .
I n order t o o b t a i n correct t o o t h contact i t may be necessary t o a d j u s t the pinion
gear depth. Add shims t o reduce pinion gear depth i n t o ring gear and remove shims
t o increase pinion gear depth.
NOTE: I t wiZ2 be necessary t o r e a d j u s t r i n g gear backZash a f t e r changing pinion
gear depth.
I n s t a l l two locking c o t t e r pins ( 1 ) t h a t prevents adjusting nuts ( 4 ) from turning.

27
FILE
61. Position o i l r e t a i n e r ( 6 ) and i n s t a l l two

( 7 / 1 6 " - 14NC x 1 3/4" 1 g . ) capscrews and
lockwashers ( 5 ) . Use two (7/16" - 14NC x
3" l g . ) capscrews and washers (1 ) t o
i n s t a l 1 chain ( 3 ) t o cap and c a r r i e r
assembly, with a s u i t a b l e l i f t i n g device
i n s t a l l cap and c a r r i e r on axle housing
( 4 ) . Remove chain ( 3 ) and capscrews ( 1 ) .
Figure 6 1
62. I n s t a l l fourteen nuts and lockwashers

( 1 ) t h a t secures cap and c a r r i e r assem-
bly ( 2 ) t o axle housing ( 3 ) . I n s t a l l
setscrew ( 5 ) and locknut ( 4 ) . Tighten
locknut.
Figure 62
63. Position parking brake backing p l a t e

( 2 ) on ax1 e assembly ( 3 ) a n d i n s t a l 1
s i x capscrews and lockwashers ( 1 ) .
Figure 63
28
FILE G
64. P o s i t i o n o p e r a t i n g cam 1 e v e r ( 2 ) on p i n
( 3 ) and l o c a t e on b a c k i n g p l a t e ( 4 ) .
I n s t a l l brake a c t u a t i n g r o l l e r ( 1 ) .
Figure 64
65. P o s i t i o n s p l i n e d r i v e f l a n g e ( 2 ) on
p i n i o n s h a f t ( 3 ) and i n s t a l l p l a i n -
washer and n u t ( 1 ) .
NOTE: T i g h t e n nut ( 2 ) to 9 0 St. Zb9.
torque.
Figure 65
66. P o s i t i o n b r a k e shoes ( 2 ) on b a c k i n g
p l a t e ( 4 ) and o v e r g u i d e p i n s ( 3 ) .
I n s t a l l two b r a k e s h o e return s p r i n g s
( 1 ) on b r a k e shoes.
Figure 66
29
FILE G
67. Position parking brake cover ( 3 ) on

axle drive flange ( 4 ) a n d i n s t a l l eight
spacers ( 2 ) and eight 1 ockwashers a n d
nuts ( 1 ) .
Figure 67
68. Using a s u i t a b l e press or pressing

method, i n s t a l l upper bushing ( 1 )
a n d lower bushing ( 2 ) i n axle
assembly ( 3 ) , i f removed during
disassembly.
Figure 68
69. I n s t a l 1 ten ( 9 / 1 6 " - 18 x 9/16" - 1 2

x 2 3/8" 1 g . ) studs ( 4 ) in knuckle
( 3 ) , i f removed during disassembly.
Instal 1 n u t ( 1 ) on capscrew ( 2 ) and
i n s t a l l stud in knuckle ( 3 ) .
NOTE: Adjust capscrew and nut (2&2)
a f t e r a x l e reassembly has been
completed.
Figure 69
FILE G
70. Position brake shoe anchor pin ( 3 ) i n

s t e e r i n g knuckle ( 4 ) and i n s t a l l lock-
washer and locknut ( 1 ) . I n s t a l l re-
maining anchor p i n i n the same manner.
Figure 70
71. Position capscrew (3) in knuckle ( 4 ) .

Instal 1 spring ( 2 ) a n d cam ( 1 ) on
special capscrew and peen end o f screw
a t location " A " t o r e t a i n cam. I n s t a l l
remaining cam i n same manner.
Figure 71
72. Position wheel cylinder adapter ( 2 ) on

wheel cy1 inder ( 3 ) and i n s t a l 1 two
(3/8" - 16NC x 4 1 / 2 " l g . ) capscrews
a n d lockwashers ( 1 ) .
Figure 72
31
FILE G
73. Position wheel cylinder assembly ( 2 ) on

knuckle assembly ( 3 ) and i n s t a l 1 two
(7/16" - 14NC x 4 1 / 2 " l g Gr.#8) capscr
and lockwashers ( 1 ) . Attach a s u i t a b l e
1 i f t i n g device t o knuckle assembly ( 3 )
and i n s t a l l on end of axle assembly.
75. Position lower bearing cap ( 3 ) on

knuckle assembly ( 5 ) and i n s t a l 1 two
(3/4" - l O N C x 2 1/4" l g - Gr.#8) a n d
two (7/8" - 14NF x 2" l g . - Gr.#8)
capscrews ( 7 & 1 ). Ins t a l 1 grease
f i t t i n g ( 6 ) only i f removed d u r i n g
disassembly. Remove two (3/8" - 16NC
x 1 1/2" 1s.) capscrews ( 2 ) i f they
were n o t removed d u r i n g disassembly.
NOTE: Make c e r t a i n tangs on t h e t h r u s t
washer aZign w i t h grooves i n the
knuckZe assembZy.
Figure 75
32
FILE G
77. Determine the amount of shims required by

adjusting steering knuckle t o ,005" - .013"
endplay, using shims located under the upper
and lower bearing caps. The s i z e of b o t h
shimpacks should be equalized t o center the
s t e e r i n g knuckle r e l a t i v e t o the drive s h a f t
Position s t e e r i n g arm ( 2 ) with shims
( 3 ) on steering knuckle ( 4 ) and i n s t a l l
two (3/4" - l O N C x 2 1 / 4 " l g - Gr.#8)
capscrews a n d lockwashers ( 1 ) and two
(7/8" - 14NF x 2" l g . - Gr.#8) capscrews
( 6 ) . I n s t a l l grease f i t t i n g ( 5 ) i f
removed during disassembly.
Apply l i g h t coat of grease t o and i n s t a l l Figure 77
bushing; then i n s t a l l seal ( A ) .
78. Using extreme c a r e s l i d e axle assembly

( 1 ) i n t o axle housing ( 2 ) . Rotate
axle s l i g h t l y t o a l i g n axle s h a f t
splines w i t h the s p l i n e s in cap and
c a r r i e r assembly.
Figure 78
33 c1
FILE lj
79. Place spindle ( 4 ) o i l seal and r e t a i n e r

( 3 ) on ax1 e assembly ( 5 ) and i n s t a l 1
ten nuts and lockwashers ( 1 ) a n d two
capscrews and washers ( 2 ) .
Figure 79
80. I n s t a l l brake shoes ( 4 ) on anchor pins

( 5 ) . I n s t a l l l i n k (3) on anchor pins
and secure with two retaining rings ( 2 ) .
Make c e r t a i n brake shoes ( 4 ) a r e prop-
e r l y located in wheel cylinder pins
and i n s t a l l spring ( 1 ) .
NOTE: Use extreme care and proper
spring expander when i n s t a l l i n g
spring ( 2 ) .
Figure 80
81. Position d r a g l i n k ( 3 ) in spindle

support ( 4 ) and i n s t a l l n u t ( 2 )
and c o t t e r pin ( 1 ) . Place two dust
guards ( 6 ) on a x l e assembly and
i n s t a l 1 four (3/8" - 16NC x 1 / 2 " l g )
capscrews and lockwashers ( 5 ) .
Figure 81
34
FILE G
82. Using a s u i t a b l e l i f t i n g device ( l ) ,

i n s t a l 1 h u b and drum ( 2 ) on ax1 e
assembly ( 3 ) .
Figure 82
84. Place gear h u b ( 4 ) on wheel bearing

spindle ( 5 ) and i n s t a l l n u t ( 3 ) .
If wheel bearings have been replaced
with new bearings , check the r o t a t i n g
torque ( n o t s t a r t i n g torque) by means o f
a pull s c a l e and cord (wrap cord around
h u b ) . Advance adjusting n u t ( 3 ) i n
small increments u n t i l the proper pre-
l o a d of 5 t o 9 f t . l b s . pull i s re-
quired t o continue r o t a t i o n of wheel
assembly. Position lock p l a t e ( 2 )
in proper location i f possible and in-
s t a l l two screws ( 1 ) . If n u t must be
turned t o a l l o w lockplate i n s t a l l a t i o n ,
f i r s t tighten i f increase i n torque i s Figure 84
s l i g h t i n s t a l l lockplate, however, i f
torque i s g r e a t l y increased, back n u t off t o nearest f l a t t h a t lockplate can be in-
stalled. 35
FILE
85. Instal 1 planetary ring gear ( 1 ) on

planetary ring gear h u b ( 2 ) and h u b
assembly ( 3 ) . Position thrust washer
( 4 ) over hub bearing n u t ( 5 ) . Make
c e r t a i n tangs of washer f i t i n s l o t s of
n u t (5).
Figure 85
86. Posi t i o n gear ( 3 ) a n d t h r u s t washers

(2,4) i n planet c a r r i e r and i n s t a l l
pinion s h a f t ( 5 ) .
NOTE: Make c e r t a i n t h e tangs on t h r u s t
washers are properly seated in
t h e i r mating grooves i n the pZanet
housing.
Figure 86
87. Sl ide planet c a r r i e r assembly ( 2 ) in

wheel h u b ( 3 ) and r o t a t e planets u n t i l
mounting holes a r e matched u p . I n s t a l l
sixteen capscrews and lockwashers ( 1 ) .
Figure 87
36
FILE G
88. S1 ide sun gear ( 2 ) on axle s h a f t ( 3 )

and i n s t a l l retaining ring ( 1 ) .
Figure 88
89. Apply permatex #2 on cover ( 2 ) . Place

cover on planet c a r r i e r assembly ( 4 )
and insta 11 eight capscrews ( 1 ) . In-
s t a l l dra i n p l u g ( 3 ) in cover i f re-
moved during disassembly.
NOTES: Cover was match marked a t time i
of disassembly check t o make
c e r t a i n marks are i n align-
ment .
Reassemble remaining end o f
ax Ze assembly i n t h e same
manner as o u t l i n e in s t e p s
53 thru 89. . I .
Figure 89
Fill aZZ planetaries t o DroDer oi2 l e v e l a t bottom 0.f l e v e l pZua ( 3 ) . Use
EP 80 or 50 lubricant c i p a i i t y of c a r r i e r assembly is 9 q t s : a d capacity
o f each planetary is 5 p t s .
37
FILE G
~~ SHOP MANUAL SECTION 7
TOE1 MOVE PINION TOWARI)
MOVE PINION AWAY FROM

GEAR IN THIS DIRECTION
v MOVE GEAR AWAY FROM

MOVE GEAR TOWARD
PINION IN THIS DIRECTION A
LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL
RING GEAR - THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH - GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON P!NIOtJ. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
38
FILE G
INSTALLATION
A. REAR A X L E INSTALLATION
90. Position axle on skid beside crane.

Rotate boom w/chain t o the opposite
s i d e of crane. Lower boom t o Oo
elevation and r e t r a c t crowd cylinder
as f a r as possible. Attach chain t o
axle and skid. Crowd boom o u t t o p u l l
axle assembly in position under crane.
Remove chain from axle. Elevate boom
and swing boom w/chai ns over engine,
i n l i n e with r e a r axle. Lower chain
( 1 ) and attach t o axle ( 4 ) . L i f t
axle from skid ( 3 ) i n t o position
against crane frame and i n s t a l 1 e i g h t
( 1 " - 14UNS x 8 1 / 2 " l g . ) capscrews
and lockwasher ( 2 ) .
Figure 90
NOTE: T i g h t e n capscrews (2) to 460
St. Zbs. torque.
Remove chain ( 1 ) from axle assembly ( 4 ) .
BE EXTREMELY CAREFUL WHEN RO-
TATING BOOM ASSEMBLY. CAB
DOORS MUST BE CLOSED AS T H E R E
WILL BE A INTERFERENCE BETWEEN
CAUTION COUNTERWEIGHT AND DOORS.
Figure 91
39
FlLE G
92. I n s t a l l bracket, flatwasher, lockwasher

a n d n u t ( 6 ) on s t e e r i n g arm ( 7 ) .
Position brake tube ( 4 ) on adapter ( 5 )
and tighten tube n u t . Place steering
cylinder rod ( 2 ) on s t e e r i n g arm pin
( 3 ) and i n s t a l 1 bearing ha1 f a n d
locknut ( 1 ) .
Figure 92
93. I n s t a l l bracket, f l a t washer, lockwasher

and n u t (10) on s t e e r i n g arm ( 7 ) . Align
tube n u t ( 8 ) on connector ( 9 ) and t i g h t -
en. Locate bracket ( 6 ) and clamp ( 5 )
on s t e e r i n g arm ( 7 ) a n d i n s t a l l two
capscrews, lockwashers a n d n u t ( 4 ) . I n -
s t a l 1 s t e e r i n g cy1 i nder rod ( 2 ) on s t e e r -
ing arm pin (3) and i n s t a l l bearing
half and locknut ( 1 ) .
Figure 93
94 . Remove ten stud nuts t h a t were r e i n s t a l l -
ed on wheel studs f o r protection. Using
a s u i t a b l e sling and boom, l i f t wheel
assembly ( 2 ) i n t o position on hub
assembly (3) a n d i n s t a l 1 ten stud nuts
(1).
NOTES: Using a s u i t a b l e torque wrench (4)
t i g h t e n n u t s (1) to 300 S t . lbs.
torque.
I n s t a l l remaining rear whee Z. i n

t h e same manner.
A CAUTION
BE EXTREMELY CAREFUL WHILE IN-
STALLING WHEEL ASSEMBLY.
MINIMUM WHEEL WEIGHT IS 480 LBS.
40
Figure 94
FILE
B. FRONT AXLE INSTALLATION
95. Place axle on skid beside crane.

Rotate boom w/chain t o the opposite
s i d e of crane. Lower boom t o 00
elevation and r e t r a c t crowd cylinder
as f a r as possible. Attach chain t o
skid and axle. Crowd boom o u t t o
pull axle assembly in position under
crane. Remove chain from axle.
Elevate and swing boom w/chains over
operators compartment. Lower chain
( 4 ) and a t t a c h t o axle ( 2 ) . L i f t ax1 e
from skid ( 1 ) i n t o position agaiKst
crane frame a n d i n s t a l l four tanged ti
four plain ( 1 " - 14UNS x 8 1 / 2 " l g . )
capscrews lockwashers & nuts ( 3 ) .
Remove chain from axle.
NOTE: Tighten capscrews ( 3 ) t o 460 Figure 95
S t . Zbs. torque.
96. Remove e i g h t nuts a n d lockwashers ( 1 1 )

and spacers t h a t were i n s t a l l e d on
brake assembly t o protect studs d u r i n g
shipment and storage. Position drive
s h a f t ( 1 2 ) on brake flange ( 1 ) and
i n s t a l l eight lockwashers a n d nuts
( 1 1 ) . Place brake l i n e bracket ( 9 )
on axle assembly (10) and i n s t a l l n u t
and lockwasher ( 8 ) . Position parking
brake cable ( 7 ) on parking brake ( 4 )
and i n s t a l l U-clamp ( 6 ) and two nuts
and lockwashers ( 5 ) . Position yoke
( 3 ) on brake ( 4 ) and i n s t a l 1 pin and
c o t t e r pin ( 2 ) .
Figure 96
97. Position drive l i n e ( 3 ) on transmission

o u t p u t s h a f t ( 4 ) a n d i n s t a l l two
U-bolts ( 2 ) a n d four lockwashers and
nuts ( 1 ) .
Figure 97
41
FILE G
98. Position bracket ( 7 ) with brake hose

( 8 ) on steering arm ( 9 ) and i n s t a l 1
flatwasher, lockwasher a n d n u t ( 6 ) .
Remove cap and pl ug from brake 1 i nes.
I n s t a l l tube n u t ( 4 ) on tube ( 5 ) .
Position p i s t o n rod ( 2 ) on steering
arm p i n ( 3 ) and i n s t a l l bearing ha1 f
and locknut ( 1 ) .
Figure 98
99. Position bracket ( 1 1 ) on steering arm

( 7 ) a n d i n s t a l l flatwasher, lockwasher
and n u t ( 1 0 ) . Remove brake l i n e cap
and p l u g and i n s t a l 1 brake 1 ine ( 8 )
on connector ( 9 ) a n d tighten. Place
draq link ( 6 ) on ball stud and i n s t a l l
bearing haif; s p r i n g a n d adjusting p l u g
( 5 ) . I n s t a l l cot t e r p i n ( 4 ) . Position
steering rod end ( 2 ) on steering arm
pin ( 3 ) and i n s t a 11 bearing half and
locknut ( 1 ) .
Figure 99
100. Remove ten stud nuts t h a t were rei nstal 1 -
ed on wheel studs f o r protection. Using
a s u i t a b l e s l i n g and boom, l i f t wheel
assembly ( 2 ) i n t o position on hub assemb-
ly ( 3 ) and i n s t a l l ten stud nuts ( 1 ) .
NOTES: Using a suitabZe torque wrench ( 4 )
t i g h t e n nuts ( 1 ) t o 300 S t . Zb.
torque.
I n s t a 22 remaining f r o n t wheel i n
same manner.
A CAUTION
EE EXTREMELY CAREFUL WHILE IN-
STALLING WHEEL ASSEMBLY.
MINIMUM WHEEL WEIGHT IS 480 LBS.
Figure 100
42
FILE ki
REAR STEER ADJUSTMENT
101. S t a r t crane engine a n d move rear

s t e e r control lever unti 1 r e a r wheels
a r e s t r a i g h t ahead. Loosen bolts
( 1 ) and move bracket ( 2 ) until r o l l -
e r ( 3 ) i s against micro switch ( 4 )
depressing i t just enough t o make
contact. The r e a r s t e e r ( r e d ) l i g h t
( 5 ) in instrument panel ( 6 ) w i l t g o
o u t when switch i s properly depress-
ed. Tighten bo1 ts ( 1 ) and recheck
steering f o r proper operation.
Figure 101
43
FILE -
la -
BRAKE ADJUSTMENT, BLEEDING & BURNISHING
Any time brake appear spongy or when brake l i n e have been disconnected, wheel
cy1 i nders over hauled o r new brake shoe 1 inings have been i n s t a l led, i t wi 11 be
necessary t o bleed and a d j u s t the brake system.
.005 INCH CLEARANCE

THROUGHOUT ARC
-.005 INCH CLEARANCE

THROUGHOUT ARC
891 5
Figure 1 0 2
A. BRAKE ADJUSTMENT
102. With the crane s t i l l on the blocking, place transmission i s n e u t r a l , release

parking brake a n d r e a r axle disconnect i f engaged. Remove dust shields i f
they were i n s t a l 1 ed.
Loosen anchor pin locknut.
Each shoe must be adjusted t o center brake shoe a r c i n r e l a t i o n s h i p t o the
drum. Adjust e c c e n t r i c cam t o move linings i n t o contact with the drum a n d
r o t a t e anchor p i n s u f f i c i e n t l y t o r e l i e v e d r a g . Repeat procedure until addi-
tional r o t a t i o n of anchor p i n will n o t r e l i e v e d r a g . Tighten anchor pin lock-
n u t 1 eavi ng .005" clearance thru the e n t i r e arc o f brake shoe.
44
FILE
NOTE: Subsequent adjustments t o compensate f o r l i n i n g wear are made with t h e

e c c e n t r i c cam only. Turn cam t o bring l i n i n g to w i t h i n .005" o f
drum. Repeat on opposite shoe.
B. BLEEDING
After brake shoes a r e centered, anchor pins locked and a .005" clearance
maintained. Back eccentric cam off on a l l upper brake shoes as f a r as possible.
This helps t o reduce the a i r pocket in the wheel cy1 i nder due t o i t s mounting in a
vertical position.
103. Swing b a i l wire ( 3 ) t o one side and

remove cover ( 1 ) from master brake
cy1 i nder ( 2 ) .
Figure 103
45
FILE
104. Position adapter ( 1 ) on master

cy1 inder ( 2 ) and a t t a c h bleeder
ball hose ( 3 ) t o adapter.
NOTE: Refer t o speciaZ tooZs pages
2 & 3 o f t h i s manual f o r manu-
f a c t u r i n g dimensions of adapter.
With valve on bleeder b a l l , press-

urize b a l l t o 1 5 psi. maximum, a n d
open bleeder valve. S t a r t bleeding
operation i n following order:
a. Left Rear Wheel Cylinder
b. Right Rear Wheel Cylinder
c. Left Front Wheel Cylinder
d. Right Front Wheel Cylinder Figure 104
Open bleeder valve (Refer t o Fig. 102) a t wheel cylinder until a l l a i r i s
expelled from brakeline & cylinder and then close bleeder. Repeat t h i s
operation a t each wheel. After each wheel has been completed turn off bleeder
ball valve.
NOTE: Using shim stock or other f l e x i a b l e material, d i v e r t brake f l u i d away
f r o m drums and l i n i n g s whi l e bleeding.
Start crane a n d pump brakes for a p p r o x . one minute.

Open bleeder ball valve and repeat bleeding operation.
105. Adjust upper brake shoes w i t h eccen-

t r i c cam ( 1 ) t o .005" clearance again.
Close bleeder ball valve when f i n i s h e d .
S t a r t crane and pump brakes. Free
travel should be from 1/16" t o 1/4"
maximum. Solid pedal must be from
2 1 / 2 " t o 3 1 / 2 " maximum. If brake
pedal i s beyond these l i m i t s repeat
bleeding operation above.
With crane s t i l l u p on blocking s t a r t
crane. Place i n gear, engage four
wheel drive and t e s t brakes.
Figure 105
46
FILE G
106. Disconnect bleeder b a l l hose ( 3 )

and remove a d a p t o r ( 1 ) from master
cy1 i nder ( 2 ) .
Figure 106
107. Position cover ( 1 ) on master

cylinder ( 2 ) and swing bail wire
( 3 ) i n t o place.
Wipe a l l excess brake fluid from
lines. Have one peson s t a r t crane
a n d apply brakes while another
checks for leaks. If a leak i s
discovered, repair leak a n d repeat
bleeding procedures.
Figure 107
C. BURNISHING
New linings (brake shoes) may require burnishing t o achieve desired performance.
Also when brake lines are blead i t i s i m p o r t a n t t o burnish i f any brake fluid has
contacted brake linings. The following steps should be used t o ensure proper burnish-
i ng.
47
FILE G
108. W i t h c r a n e s t i l l on b l o c k i n g , p o s i t i o n t r a n s m i s s i o n i n f o u r wheel d r i v e and

l o w g e a r . A p p l y enough b r a k e l i n e p r e s s u r e t o s l i p a l l f o u r wheels a g a i n s t
t h e e n g i n e t o r q u e ( n e a r maximum).
A CAUTION
DO NOT ALLOW OUTSIDE DRUM TEMPERATURES TO EXCEED 300° TO 3500 F.
A1 1ow drums t o c o o l f r o m 1500 t o 200' F. b e f o r e r e p e a t i n g . The number o f c y c l e s

f o r b u r n i s h i n g b r a k e s a r e based on a c h i e v i n g an e x c e p t a b l e p e r f o r m a n c e l e v e l .
It i s e s t i m a t e d a t l e a s t f i v e c y c l e s w o u l d be r e q u i r e d t o show marked b r a k e
improvement.
IMPROPER BURNISHING COULD RESULTNI 'IGLAZING.~~ SINCE THE MAXIMUM

TEMPERATURE LIMITS ARE CRITICAL AND DIFFICULT TO DETERMINE EXTREME
CARE MUST BE EXERCISED.
CAUTION
48
MATERIAL L I F T [ ]
GRADER [ ]
PLANER [ ]
ROLLER [ ]
CRANE [X]
SHOP MANUAL G-07.10

CLARK AXLE ASSEMBLIES
(MODELS DS-13311 or D l280736,
AND DS-13550 or D12S0840)
150-A 9390 &Up

150-FA 9390 &Up
(SEE MATRIXHARTSIN MANUAIFOR ACCURATESERIALNUMBERGES)
CAUTION
ALL COMPONENTS MUST BE PROPERLYSUPPORTEDDURING
DISASSEMBLYANDREASSEMBLY.
ALL JACKINGHOISTING4NDGENERA~ORKSHOPEQUIPME~
REQUIREDFOR THIS OPERATIONMUST BE IN GOOD
WORKINGORDER.
EXTREME CAUTIONTO BE OBSERVEDAT ALL TIMES TO PREVENT
INJURY.
SAFE WORKSHOPPRACTICESAREAMUST.
FOR TABLE OF CONTENTS SEE PAGE 1
KOMATSUDRESSERCOMPM EASTSUNNYSIDEAVE. LIBERTYVILLQ 60048

0291
Refer to “General Torque Values” shop manual section when SPECIFIC TORQUES are not given in this shop
manual section. All values listed throughout this manual are lubricated (WET) unless stated otherwise.
METRIC CONVERSIONS
For metric conversion of U.S. Measurements refer to “Metric Measurements and Conversion” manual publication
number 1085 804 R2.
SHOP MANUAL SECTION G-07.10
CONTENTS PAGE
SPECIALTOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADAPTOR BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIFFERENTIAL CARRIER SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIFFERENTIAL CARRIER SUPPORT PLATE LEGS . . . . . . . . . . . . . . . . . . . . . . . 5
SPINDLE NUT WRENCH (FOR HUB RETAINING NUT P/N 1259 944 H1) . . . . . . 6
SPINDLE NUT WRENCH (FOR HUB RETAINING NUTS P/N 134701. 134758.
75491) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPREADERBARANDCHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PLUG TOOL (FOR P/N 134705. 1257 751 H91 AND 1260 021 H91) . . . . . . . . . . 9
MASTER CYLINDER BLEEDING ADAPTOR TOOL . . . . . . . . . . . . . . . . . . . . . . 10
AXLE HOUSING BUSHING AND OIL SEAL DRIVER . . . . . . . . . . . . . . . . . . . . . 12
AXLE TRUNNION BUSHING DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPINDLE BUSHING DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPINDLE OIL SEAL DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
NoSPlN (FRONT AXLE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERALDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PLANETARYDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
GENERAL REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIFFERENTIAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PLANETARY REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PLANETARY CARRIER ASSEMBLY (P/N 134705. 1257 751 H91 AND
1260021H91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 81803. 81804. 81771 AND
81772) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 1228 948 H91. 1228 949 H91.
1228 944 H91 AND 1228 943 H91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REAR AXLE DIFFERENTIAL & CARRIER ASSEMBLY (P/N 134762 AND
1260034H91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PINION GEAR ROLLING TORQUE (55); PINION GEAR INSTALLATION
(56); REASSEMBLY OF RING GEAR AND DIFFERENTIALASSEMBLY(58);
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT (58); CHECK
ROLLING PATTERN OF RING GEAR AND PINION (59); FINAL
INSTALLATION OF DIFFERENTIAL & CARRIER (60)
1
FRONT AXLE DIFFERENTIAL & CARRIER ASSEMBLY (WITH PARKING BRAKE

ASSEMBLY) (P/N 134728 AND 1260 025 H91) ...................... 61
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PINION GEAR ROLLING TORQUE (66); PINION GEAR INSTALLATION
(67); REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY (70);
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT (71); CHECK
ROLLING PATTERN OF RING GEAR AND PINION (72); FINAL
INSTALLATION OF DIFFERENTIAL & CARRIER (72)
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
FRONT AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REAR AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TOOTH CONTACT CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
STEERING ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES) . . . . . . . . . . . 79
BRAKE SHOE ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES) . . . . . . . . 79
PARKING BRAKE ADJUSTMENT PROCEDURE (FRONT AXLE) . . . . . . . . . . . . . . . . 80
BRAKE BLEEDING PROCEDURE (FRONT AND REAR AXLES) . . . . . . . . . . . . . . . . 81
BURNISHING PROCEDURE (FRONT AND REAR AXLES) . . . . . . . . . . . . . . . . . . . . 83
REAR STEERING INDICATOR ADJUSTMENT PROCEDURE (REAR AXLE) . . . . . . . . 84
2
SPECIAL TOOLS
ADAPTOR BAR
Shown here are manufacturing details for the adaptor bar used to get proper rolling torque on the planetary carrier
assembly.
Figure 2, shows how the adaptor bar is used to set rolling

torque by bolting it to the cup and stud assembly hub. Bolts
used for planet carrier assembly can be used to secure bar
into position.
A dial indicator torque wrench must be used to show rolling

torque. DO NOT USE a clicker (over-center-snap) type
torque wrench.
A ~ A P T O RBAR
3
DIFFERENTIAL CARRIER SUPPORT PLATE

Shown here are manufacturing details for the differential carrier support plate used to hold the differential carrier
assembly during servicing.
NOTE: Three of these must be manufactured.
15842
igure 3 MANUFACTURING DETAILS FOR DIFFERENTIAL CARRIER SUPPORT PLATE
Figure 4, shows the differential carrier support plate and legs

(1). They are used to hold carrier assembly (2) for service.
Use appropriate hardware (bolts, plain washers and hex

nuts) to attach three plates to carrier, and legs to plates.
t . . .
Figure 4APPLICATIONOF DIFFERENTIALCARRIEF
SUPPORT PLATE &. LEGS
4
DIFFERENTIAL CARRIER SUPPORT PLATE LEGS

Shown here are manufacturing details for the differential carrier support plate legs used to hold the differential carrier
assembly during servicing.
NOTE: Three of these must be manufactured.
3/4" x 2" LG. BOLT
15852
I
I
Figure 5 MANUFACTURING DETAILS FOR DIFFERENTIAL CARRIER SUPPORT PLATE
LEGS
5
SPINDLE NUT WRENCH

(FOR HUB RETAINING NUT P/N 1259 944 H I )
Shown here are manufacturing details for the spindle nut wrench. It is used to apply proper torque to hub retaining
nut. Refer to appropriate "Parts Manual" for your unit to find part number of hub retaining nut used on axle. There
are two spindle nut wrenches shown in this manual. Be sure to the pick correct one. This spindle nut wrench is
available under Dresser Part Number DR08-715-3. Refer to "Service Tools Catalog" 1128-166-R1.
E D (CARB. TO 0.031'
-W0.045 D e
HARDEN TO Rc 68 - 62
AND GRIND.
MATERIAL:
-
(0 4.00' MA. X 260' L O PECE BARSTOCK 4140 STEEL.
-
(r) 4.00' OD. X 3.00' ID. x 5.25 L G SEAWESS TLWNG 4140 ANNEALED
H836
igure 6 MANUFACTURING DETAILS FOR HUB RETAINING NUT TOOL
Figure 7, shows the spindle nut wrench being used to apply

torque to nut. Torque applied to this nut is critical to getting
proper rolling torque of cup and stud assembly hub.
6
SPINDLE NUT WRENCH

(FOR HUB RETAINING NUTS P/N 134701, 134758, 75491)
Shown here are manufacturing details for the spindle nut wrench. It is used to apply proper torque to hub retaining
nut. Refer to appropriate "Parts Manual" for your unit to find part number of hub retaining nut used on axle. There
are two spindle nut wrenches shown in this manual. Be sure to pick the correct one.
2 1/4"
IFigure 8 MANUFACTURING DETAILS FOR HUB RETAINING NUT TOOL 15835
Figure 9, shows the spindle nut wrench being used to apply
torque to nut. Torque applied to this nut is criiical to getting
proper rolling torque of cup and stud assembly hub.
7
SPREADER BAR AND CHAINS

Shown here are manufacturing details for the spreader used to hold chains apart while removing and installing axle
assembly
(4) 0.125" HOLES
1.500 (REF.)
0.500" (TYP.)
1-1/2 X 1 1/2 X 3/16" ANGLE
15853
Figure 10 MANUFACTURING DETAILS FOR SPREADER BAR
Figure 11, shows how the spreader bar should be attached

between chains.
Two chains 17 Ft. (5.18 m) long with 3/8"links are required.
NOTE: Spreader bar should be notched to receive 3/8"

chain link. Both ends of spreader must be moused
(locked) to chain, 6 Ft. (7.83 m) from lifting eye(s).
Chains must have a lifting capacity of not less than
2 Tons (7.87 Mg).
A piece of wire passed through the two drilled holes and
twisted will hold chain in position in spreader bar.
8
PLUG TOOL
(FOR P/N 134705,1257 751 H91 AND 1260 021 H91)
Shown here are manufacturing details for the plug tool used to install planetary carrier plugs. Plugs are only used
on planetary carrier assemblies with part numbers shown above.
CONVENIENT LENGTH
15841
Figure 12 MANUFACTURING DETAILS FOR PLUG TOOL
Figure 13, shows the plug tool being used to install plug in
planetary carrier.
NOTE: Use Permatex #3, Loctite #515 or # 518, or Dow

Corning Q3-7069 R.T.V. as bore plug sealant.
I
Figure 13 APPLICATION OF PLUG TOOL
9
MASTER CYLINDER BLEEDING ADAPTOR TOOL

Shown here are manufacturing details for the master cylinder bleeding adaptor tool used to bleed hydraulic brake
system. The tool is made up of three parts; the plate, gasket and clamp.
1/2’ 90 DEGREE STREET

ELBOW
9”
------- 1 316 RAD.
7 7/8 DIA. DRILLED HOLE
3/16’ THICK M S . PLATE
15839
igure 14 MANUFACTURING DETAILS FOR MASTER CYLINDER SEAL PLATE
Shown in Figure 15, is how plate (Figure 14), gasket

(Figure 16) and clamp (Figure 17) are used together to
provide a means for a bleeder ball to be attached to master
cylinder.
Figure 15
10
1 3/# RAD.
1' DIA. HOLE
1/8" THllCK GASKET MATL.
15851
igure 16 MANUFACTURING DETAILS FOR MASTER CYLINDER SEAL PLATE GASKET
3' x 3" x l/#ANGLE
(2) 3 / 8 - 16 UNC - 26
TAPPED HOLES THRU
3 / 8 FILET
WELD
15840
igure 17 MANUFACTURING DETAILS FOR MASTER CYLINDER BLEEDER CLAMP
11
AXLE HOUSING BUSHING AND OIL SEAL DRIVER

Shown here are manufacturing details for the axle housing bushing and oil seal driver. It is used to install axle
housing bushing and oil seal.
15904
Figure 18 MANUFACTURING DETAILS FOR AXLE HOUSING BUSHING AND OIL SEAL DRIVER
Figure 19, shows axle housing bushing and oil seal driver I
BUSHING PRESSEO IN,
being used to install axle bushing. The tool is also use to TO eE FLUSH WITH
install axle shaft oil seal. THIS SURFACE
I 15902 A
Figure 19 APPLICATION OF AXLE HOUSIN(
BUSHING AND OIL SEAL DRIVER
12
AXLE TRUNNION BUSHING DRIVER

Shown here are manufacturing details for the axle trunnion bushing driier used to install axle trunnion bushings.
15903
Figure 20 MANUFACTURING DETAILS FOR AXLE TRUNNION BUSHING DRIVER
Figure 21, shows axle trunnion bushing driver being used to

install axle trunnion bushings.
I 15902 B
Figure 21 APPLICATION OF AXLE TRUNNIOI
BUSHING
13
SPINDLE BUSHING DRIVER

Shown here are manufacturing details for the spindle bushing driver used to install spindle bushing.
I5899
Figure 22 MANUFACTURING DETAILS FOR SPINDLE BUSHING DRIVER
Figure 23, shows where the spindle bushing driver will be

used to install spindle bushing.
WOO1 A
Figure 23 APPLICATION OF SPINDLE BUSHIN(

DRIVER
14
SPINDLE OIL SEAL DRIVER
15900
Figure 24 MANUFACTURING DETAILS FOR SPINDLE OIL SEAL DRIVER
Figure 25, shows where the spindle oil seal driver will be
used to install spindle oil seal.
I I
Figure 25 APPLICATION OF SPINDLE OIL SEAL
DRIVER
15
INTRODUCTION
Axle assembly must be identified, prior to servicing it. A
serial number plate is located on differential housing of axle
(Figure 26).
Information on this plate gives supplier axle model, supplier

serial number and supplier part number.
Next find serial number of unit.
Refer then to appropriate “Parts Manual” for unit, and

determine KDC part number.
Once axle is identified, use the following two pages of matrix

diagrams to determine which sections of this manual to use
to properly service your axle. These matrixes contain
KDC part numbers of major sub-components in your axle.
Section headings for major sub-components list part
numbers shown in matrix charts.
16
H H
E E
Li s;
2
ln
*
W
17
E
f In
N
0
0
i![
Li
2
c c
e z
c c
N N
0 0
v) v)
*
W
*
W
I I
N
E % n
au %
w *&
p:
c w
In
gb
N
c 2
18
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION
-
-
Loss of lubricant. Incorrect type or excessive Change lubricant.

lubricant.
~~ ~
Worn, damaged or broken oil Replace seals.

seals.
loose drain and fill plugs. Tighten or replace plugs.
Cracked case. Repair or replace case.
Wrong torque on bolts. Tighten or replace bolts.
Excessive noise. Damaged or worn final drive or Replace gears as necessary.

planetary pinion gear.
~~~
Worn planetary bearing rollers. Replace rollers and/or gears as

necessary.
Axle bearings scarred or rough. Replace bearings.
Excessive noise - Continuous. Worn bearings. Replace bearings.
Damaged or worn parts. Replace parts as necessary.
Loss of lubricant. Replenish lubricant. Determine

cause of leak and repair as
necessary.
Excessive noise - Under load. Bevel pinion shaft adjustment too See “Pinion Rolling Torque” and
loose. “Backlash Adjustment” sections in
this manual.
Worn bearings. Replace bearings.
Excessive heat - Under load. Bevel pinion shaft adjustment too See “Pinion Rolling Torque” and
tight. “Backlash Adjustment” sections in
this manual.
Loss of lubricant. Replenish lubricant. Determine

cause of leak and repair.
_ _ _ _ _ ~ ~
Wrong type or not enough Add or change lubricant as

lubricant. necessary.
19
NoSPlN
(FRONT AXLE ONLY)
Two methods can be used to determine if NoSpin unit is operating properly.
METHOD ONE
One is the static method which is accomplished by raising all four drive wheels off ground by blocking frame. Next,
engage front axle disconnect lever in four-wheel drive. Then apply parking brake so drive shafts will not turn.
With an assistant on a drive wheel of opposite end of axle, start test by rotating driie wheels as far as possible in
forward direction. Then with one person firmlv holding right wheel forward against stop, rotate left wheel rearward.
Listen for regular indexing or clicking sounds. See “Notes on Testing.”
NOTE: Be sure right wheel is held firmlv against stop or left wheel will nor disengage.
Next, rotate both wheels rearward until they stop. With one person holding right wheel firmlv against stop in rearward
direction, rotate left wheel forward. Again listen for indexing or clicking sounds. Finally, repeat these tests, except
this time hold left wheel against stops and rotate right wheel forward and rearward.
Notes on Testinq
If operating properly, rotating wheel should cam out easily by hand and rotate freely in both directions until direction
of rotation is reversed or unless pressure on opposite wheel is relaxed.
With standard type NoSpin, clicking or indexing noise is normal and quite prominent as driven clutch alternately
disengages from spider and then re-indexes with spider while it is rotating.
With silent-type NoSpin used in crane, however, only faint indexing noises will be heard, and possible none, until
direction of rotation is reversed. When reversed clutch will re-index and a slight noise should be heard. If you do hear
repeated loud indexing or clicking sounds when checking a silent-type NoSpin, one of the holdout ring and clutch
assemblies may not be operating properly.
METHOD TWO
Second method of testing NoSpin is by driving machine. In checking to see that NoSpin is driving both wheels, the
driving test should be made under stress so some torque load is on driving clutch teeth of NoSpin. One way to get
this load is to drive up against a solid obstruction in low gear in loose dirt or gravel. See if you can spin both wheels
in both directions.
Another driving test is to check for proper camming action for both wheels in both directions. On a flat surface with
good traction conditions, drive crane in a tight circle. Do this in forward and rearward to left and to right to be sure
that outside wheels are free and outside tires do not scuff excessively. If machine fails this test, find and correct
problem.
20
SERVICING
The following is only one method of obtaining a removal, disassembly, cleaning and inspection, reassembly, and
installation of axle assembly on crane. For complete major overhaul or rebuild, it is necessary to remove axle
assembly from crane. When repairing axle assembly for replacement of parts, such as axles, planetaries, and brakes,
removal of axle assembly is not necessary.
Thoroughly clean part to be serviced and surrounding area. This will help prevent contamination from entering part
or system being serviced.
REMOVAL
1. Park unit on a smooth, level surface with adequate room for a fork lift or other similar device to remove axle from
under unit.
NOTE: If a fork /
iffor other piece of similar equipment is nor available, the crane itself can be used as a lifting
device for hoisting axle and removing axle from under unit. This procedure does require however that
the crane is operable (except the axle to be repaired), and that adequate room is available to rotate
boom 360" in a horizontal position and be extended 70 Ft. Also room to fully raise boom must be
available. (Most likely these conditions only exist ourside.)
2. Fully extend front and/or rear outriggers (1, Figure 27 or Figure 28) in the down position as far as possible.
Place wooden blocking (2) under outrigger frame as shown in Figure 27 or Figure 28. Raise outriggers until
frame is resting solidly on blocking. Outrigger pads must remain in contact with ground.
A WARNING! All four tires must clear ground once crane is resting on front and rear blocking.
3.
A WARNING1 Leave enough room in front of and behind crane to stop in case it is knocked off
blocking.
Locate a skid (3, Figure 27 or Figure 28) capable of supporting 2 Tons (1.81 Mg) under axle assembly.
IFigure 27 15731
1
Figure 28
15739
21
4. On axle to be serviced, remove all but two wheel nuts

(1, Figure 29). Two remaining nuts should be located at
about the 12 o’clock and 6 o’clock positions. Loosen
these two nuts leaving them engaged on studs by about
0.250 In. (6.350 mm). These nuts will prevent tire and
wheel assembly from falling off axle when freed.
Figure 29
5. Position a port-a-power (1, Figure 30) between frame (2)

and wheel (3) as shown. Using port-a-power break
wheel away from axle.
A WARNING! Do not place port-a-power

against tire.
6. Using a suitable lifting device and tire tongs, sling tire

and wheel assembly. Remove two remaining wheel nuts
and wheel from axle.
A WARNING! Be extremely careful when

removing wheel assembly. Wheel
assembly will have a minimum weight of
480 Lbs. (217.7 kg).
NOTE: Crane boom can be used as suitable lifting

device.
7. Once tire and wheel assembly is removed, install wheel nuts on studs, flush with end. This will protect threads
from damage.
8. Repeat this procedure for remaining tire and wheel assembly.
22
FRONT AXLE REMOVAL

1. Remove self-locking nut and retaining washer
(1, Figure 31), and steering cylinder rod end (2) from pin
(3). Secure steering cylinder to side of frame to prevent
interference with axle removal. Repeat this procedure for
steering cylinder on other side of unit.
2. Remove cotter pin (4), adjusting plug (5), spring and

bearing half from drag link (6). Remove drag link from
ball stud.
NOTE: On later model cranes equipped with orbitrol

steering the drag link was eliminated.
3. Disconnect brake line tube (7) from connector (8) and

brake assembly wheel cylinder. Remove hex nut, lock
washer and flat washer (9), securing bracket (10) to
steering arm. Plug and cap wheel cylinder, brake tube
Figure 31
and brake hose to prevent contamination from entering
brake system. Secure brake hose and bracket to frame
to prevent interference with axle removal. Repeat this
procedure for brake line assembly on other side of unit.
4. Remove two hex nuts, lock washers and U-bolt holding
parking brake cable sheath to bracket. Remove cotter
pin and pin (1, Figure 32) from parking brake cable
clevis (2) and parking brake lever (3).
5. Remove mounting hardware securing brake line hose

and tubing bracket (4) to differential housing. Install
mounting hardware once bracket is free.
6. Remove nuts and lock washers securing drive shaft (5)

to front axle input flange (6).
NOTE: Once drive shaft is removed, install hex nuts on

input flange to protect threads and prevent
parking brake drum from coming off during
removal process.
'igure 32
7. Remove four nuts and lock washers (1, Figure 33), two
U-bolts (2) and drive shaft (3) from front output flange of
transmission.
WARNING! Completely remove drive

shaft to eliminate possible injury if
transmission is bumped into gear.
Figure 33
23
8. With lifting chains and spreader properly set up, attach

chains to 2 Ton (1.81 Mg) lifting device and axle
assembly (1, Figure 34). With lifting device, tighten
chains to hold axle assembly against frame.
NOTE: Before removing axle mounting hardware,

inspect axle assembly to be sure that all, brake
lines and tubes, parking brake cable, steering
cylinders and any other obstruction are free
and clear of axle assembly.
9. Remove eight self-locking nuts and bolts (2) that secure

axle assembly to frame (3).
NOTE: There are electrical wiring harnesses that are

located in frame. Use care when removing bolts
not to pinch these wires with axle mounting bolt
tab. An access hole is located on inside of Figure 34
frame to reach bolts and wiring.
10. Very slowly and carefully, lower axle assembly onto skid. Axle may have to be turned slightly when lowering to
allow steering arms to clear mounting pad on frame.
11. Once axle assembly is resting solidly on skid, remove chains.
12. Remove axle assembly out from under crane, using a

fork lift or other similar device.
NOTE: If a 2 Ton (7.87 Mg) lifting device and/or fork

lift is not available, use crane (Figure 35) to
remove axle. Crane boom can rise to a point
where hook block is directly over center line of
axle. Attach chains with spreader to hook block.
After axle is lowered to ground, disconnect
chains and lower to boom to 0" elevation and
fully retract it. Swing boom about 90 * in either
direction and attach chains to skid and axle.
Slowly extend boom and drag axle assembly
out from under unit.
:igure 35
24
REAR AXLE REMOVAL

1. Remove self-locking nut and retaining washer
(1, Figure 36),and steering cylinder rod end (2) from pin
(3). Secure steering cylinder to side of frame to prevent
interference with axle removal. Repeat this procedure for
steering cylinder on other side of unit.
2. Remove two nuts, lock washers and bolts (4), clamp (5)
and bracket with roller (6) from steering arm (7).
3. Disconnect brake line tube (8)from connector and brake

assembly wheel cylinder. Remove hex nut, lock washer
and flat washer, securing bracket to steering arm. Plug
and cap wheel cylinder, brake tube and brake hose to
prevent contamination from entering brake system.
Secure brake hose and bracket to frame to prevent
interferencewith axle removal. Repeat this procedure for
brake line assembly on other side of unit. (Refer to
Figure 31,for reference). F'igure 36
4. Remove eight nuts and lock washers (1 , Figure 37),four

U-bolts (2) and drive shaft (3) from between rear
transmission output flange and rear axle input flange.
A WARNING! Completely remove drive

shaft to eliminate possible injury if
transmission is bumped into gear.
Figure 37

chains to 2 Ton (1.81 Mg) lifting device and axle
assembly (1, Figure 38). With lifting device, tighten
chains to hold axle assembly against frame.
NOTE: Before removing axle mounting hardware]

inspect axle assembly to be sure that all, brake
lines and tubes, steering cylinders and any
other obstruction are free and clear of axle
assembly.
6. Remove eight bolts and lock washers (2) that secure

axle assembly to rear axle mount (3).
7. Very slowly and carefully, lower axle assembly onto skid.

Axle may have to be turned slightly when lowering to
allow steering arms to clear rear axle mount.
:igure 38
8. Once axle assembly is resting solidly on skid, remove
chains.
25
9. Remove axle assembly out from under crane, using a

fork lift or other similar device.

lift is nor available, use crane to remove axle
(Figure 39). Crane boom can rise to a point
where hook block is directly over center line of
axle. Attach chains with spreader to hook block.
M e r axle is lowered to ground disconnect
chains and lower to boom to 0" elevation and
fully retract it. Swing boom about 90" in either
direction and attach chains to skid and axle.
Slowly extend boom and drag axle assembly
out from under unit.
26
GENERAL DISASSEMBLY
PLANETARY DISASSEMBLY
1. Remove cotter pin from tie rod socket assembly and
castle nut (1, Figure 40). Loosen castle nut three turns.
Using a sledge hammer, strike spindle tie rod arm (2) as
shown, to free taper portion of socket assembly from
arm. Repeat this procedure for other socket assembly.
Leave castle nuts on socket assemblies to prevent
planetary ends from moving during next step.
I 15858
Figure 40
2. Using a 2 Ton (1.81 Mg) lifting device, sling and position

axle (1, Figure 41) on a support stand and/or a table
with 8 In. (203.200 mm) high blocks (2) under mounting
pads.
NOTE: Mounting pads are located on “TOP” side of I

axle housing. Thus when axle is resting on
blocks, bottom side is “UP. ’I
3. Remove two castle nuts and tie rod assembly (3).

NOTE: Match mark tie rod assembly sockets to tie rod
arms of spindle.
‘igure 41
4. Remove bolts and washers (1, Figure 42), and planetary

carrier assembly (2) from axle.
NOTE: See appropriate “Planetaty Carrier Assembly”

section for axle being serviced for disassembly
and reassembly instructions.
II I 15860
Figure 42
27
5. Remove retaining ring (1, Figure 43), sun gear (2) and
thrust washer (3) from axle shaft (4).
6. Bend tabs on lock washer (5) back with a punch.
Figure 43
Using spindle nut tool (1, Figure 44) loosen hub

retaining nut.
NOTE: Do not remove hub retaining nut.
NOTE: There are two types of hub retaining nut

configurations available.
One arrangement uses two light thin hex nuts

with a lock washer located between them. The
lock washer is keyed to the spindle and
prevents the two nuts from turning.
The second arrangement uses one slotted nut

and a lock washer that engages splines of
internal ring gear.
lgure 44
A different spindle nut wrench is required for
each of these arrangements. Refer to proper
Parts Manual to identify part number for hub
retaining nut(s). The “Special Tool” section
shows both types of tools, with part number of
hub retaining nut@) that it is used for.
28
8. Using a suitable lifting device, sling hub and stud

assembly (1 , Figure 45) as shown.
9. Remove hub retaining nut (2), lock washer (3), internal

ring gear (4) and hub and stud assembly from spindle.
NOTE: Brake shoes may have to be backed off to

allow removal of hub and stud assembly.
I I 15863
Figure 45
10. Remove bearing cone (1, Figure 46) from internal ring
gear (2), if replacement is necessary.
NOTE: Remove mating bearing cup from hub and stud

assembly also if replacement is necessary. It is
advised to replace both cup and cone.
I
Figure 46
11. Remove oil seal (1, Figure 47) and bearing cone (2)
from hub and stud assembly (3).
12. Remove two remaining cups from hub and stud

assembly, if replacement is necessary.
Figure 47
29
13. Using a suitable lifting device, sling brake assembly

(1, Figure 48) as shown.
14. Mark position of 12 Pt. bolts (2) holding brake assembly

and spindle to spindle support.
NOTE: 72 Pt. bolts do not have plain washers.
15. Remove 6 Pt. bolts and plain washers (3), and 12 Pt.
bolts that secure brake assembly and spindle to spindle
support.
16. Separate brake assembly, spindle and support.
NOTE: There is a hub oil deflector (4) located between

brake assembly and spindle. A small tab on
O.D. of deflector engages oil drain hole (5)
located on spindle. This drain hole is located at
the
. - bottom
_ _ . when axle is mounted on crane.
Remember, since axle mounting pads are resting on blocking, bottom of axle is up in these illustrations.
NOTE: Brake assembly should also be marked for proper orientation for reassembly. Brake return springs with
long hook ends are different colors from one end of axle to the other. Axle has black springs for R H .
brake assembly, and yellow for L.H. brake assembly.
17. Remove oil seal (1, Figure 49) and bushing (2) from
spindle (3).
Figure 49
30
18. Remove axle shaft assembly (1, Figure 50) from axle
housing.
Figure 50
19. Remove five bolts and plain washers (1, Figure 51) that I n
secure lower arm trunnion (2) and shims in place.
NOTE: Remember, since axle mounting pads are

resting on blocking, bottom of axle is up in
these illustrations.
20. Pry lower arm trunnion out of spindle support (3). Keep
shims with trunnion.
15893
Figure 51
21. Using a suitable lifting eye, sling spindle support I II

(1, Figure 52).
NOTE: Positioning lifting eye in hole shown will

balance spindle support during removal.
22. Remove five bolts and plain washers (2) that secure
upper steering arm trunnion (3) and shims in place.

23. Pry upper steering arm trunnion out of spindle support.

Keep shims with trunnion.
24. With both trunnions removed carefully remove spindle

Figure 52
support from axle trunnion pivots.
31
25. Remove upper and lower nylon trunnion seals

(1, Figure 53) from trunnion bosses.
26. Remove thrust washer (2) from lower trunnion boss.

resting on blocking, boftom of axle is up in
27. If necessary, remove upper and lower bearing sleeves

and grease retaining plates (3).
28. Remove axle shaft oil seal (4) and bushing (5) from axle
housing, if replacement is necessary.
Figure 53
DIFFERENTIAL DISASSEMBLY
1. For servicing differential assembly refer to matrix to find proper part number for your axle. Then turn to the
section that covers that differential.
32
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign
material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as
thrust bearing, matched parts, etc.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved and
parts are thoroughly clean.
A WARNING1 Care should be exercised to avoid inhalation of vapors, exposure to skin and
creating fire hazards when using solvent type cleaners.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then remove
bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean.
To dry bearings, use moisture-free compressed air. Be careful to direct air stream across bearing to avoid
spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING; bearings may be rotated
slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing mating cup or cone at same time. After inspection,
dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective bearing
housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of any
seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing,
on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals. If this
happens, that portion of seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye. Examine
teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks
or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.
33
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that are deeply
grooved or scratched which would affect their operation.
7. NO-SPIN:
A. Inspect splines on side gears and clutches. Remove any burrs or small chipped edges with an abrasive
stone or electric burr grinder. If any sections of spline are broken away, replace NoSpin. Check side gear
hubs for fractures.
B. Carefully, examine differential subcase. If trunnion holes are worn or scored, or if thrust surfaces on inside
ends of differential subcase are worn or scored, case should be replaced. Examine threads of all bolts, nuts
and/or bolts, and replace those which show indications of being stripped or damaged. It is a good practice
also to carefully examine bearings and ring gear for wear or damage.
C. Check thrust and bearing surfaces of subcase for signs of pick up of metal or wear. Replace if necessary.
D. Check each clutch and holdout ring assembly for correct indexing of holdout ring to cam ring. Be sure
holdout ring rotates on clutch with only a little resistance.
E. Check holdout rings in NoSpin for fractures and chipping or excessive wear of teeth. If wear is evident,
replace assembly.
F. Check center cam for free movement. It must be free to rotate within limits of key in spider. It is not
necessary to remove center cam from spider, since these parts are serviced only as an assembly. If either
part is excessively worn or damaged, complete spider-center cam assembly should be replaced.
G. Inspect clutch teeth on spider and driven clutches. Very slight chips can be touched up with an abrasive
stone. If excessively chipped or rounded, NoSpin must be replaced. Check tooth protruding radially inward
from spider for signs of improper alignment with gap in either holdout ring.
H. Assemblies must not be excessively chipped. A smooth wear pattern up to 50% of cam face width is
acceptable.
I. Check side gear spline fit on its mating axle shaft. Be sure splines do not bind. Also check internal side gear
splines for wear or chipping.
J. Check spring load with valve spring tester at 0.72 In. (18.288 mm) operating height. If reading is less than
90 Lbs. 2 10% (40.8 kg ? lo%), replace spring.
34
GENERAL REASSEMBLY
- IMPORTANT -
Efficient and successful reassembly of the axle is dependent on the accomplishment of a series of
specific tasks in the exact order presented in this manual. The block diagram in Figure 54 shows
the order in which these tasks must be completed.
Throughout the following procedures all measurements must be to the nearest .W1'(0,0254 mm),
35
DIFFERENTIAL REASSEMBLY
1. For servicing differential assembly refer to matrix to find proper part number for your axle then turn to the section
that covers that differential. Once differential is reassembled and installed in axle housing proceed to “Planetary
Reassembly” section that follows.
PLANETARY REASSEMBLY
NOTE: Mounting pads are located on “TOP” side of axle housing. Thus when axle is resting on blocks, the
bottom side is “UP.”
1. Using axle housing bushing and oil seal driver, install bushing (5, Figure 55) in axle housing. Make sure that
bushing is seated as shown in Figure 56.
NOTE: Refer to “Special Tools“ section of this manual for manufacturing details of axle housing bushing and
oil seal driver.
2. Using same driver, apply a coat of Loctite Sealer H W Catalog No. 71 to oil seal bore. Install axle shaft oil seal
(4, Figure 55) in housing with lips of seal “IN.” Coat lip of seal with grease to aid further assembly of axle.
3. Using trunnion bushing drive, install upper and lower grease retaining plates and bearing sleeves (3).
NOTE: Refer to “Special Tools” section of this manual for manufacturing details of axle trunnion bushing
driver.
4. Coat thrust washer (2) with grease and position it on lower trunnion boss.
NOTE: Remember] since axle mounting pads are resting on blocking, bottom of axle is up in these illustrations.
5. Coat I.D. of upper and lower nylon trunnion seals (1) with grease and position them on trunnions. Make sure
that lips on nylon trunnion seals are away from axle.
WSHINQ PRESSED IN, BUSHINO PRESSED IN,

TO BOTTOM OUT ON TO BE FLUSH WITH
R€TA*(W PLATE THIS SURFACE
15902
igure 55 ‘igure 56
36
6. Using a suitable lifting eye, sling spindle support

(1, Figure 57).
NOTE: Positioning lifting eye in hole shown will

balance spindle support during installation.
7. Carefully position spindle support over axle trunnion

pivots. Use extreme care not to damage nylon trunnion
seals.
8. Install upper steering arm trunnion (3) in spindle support

on axle pivot. DO NOT install shims now.
NOTE: Coat bore of trunnion bushing with grease.

9. Install five plain washers and bolts (2). Tighten bolts to 300 - 330 Ibf ft (406.7 - 447.4 Nmm).
NOTE: DO NOT apply Loctite 271 to bolts until proper end play is set up.
10. Install lower arm trunnion (2, Figure 58) in spindle

support (3) on axle pivot. DO NOT install shims now.
NOTE: Coat bore of trunnion bushing with grease.

11. Install five plain washers and bolts (1). Tighten bolts to
175 - 190 Ibf ft (237.3 - 257.6 Nmm).
NOTE: DO NOT apply Loctite 271 to bolts until proper

end play is set up.
In 15893
‘igure 58
12. Using a dial indicator as shown, pry on spindle support

(1, Figure 59). End play (“UP” and “DOWN”) movement
must be 0.010 In. (0.254 mm).
NOTE: Remove trunnions and shim equally “TOP” and

“BOTTOM” until end play is within 0.010 In.
(0.254 mm). Shims packs (top and bottom)
must be equal to each other within 0.010 In.
(0.254 mm).
13. Recheck end play movement as many times as

necessary.
14. Once proper end play is set up remove trunnion bolts

and apply Loctite 271 to them. Install and torque them
to proper values.
Figure 59
37
15. Carefully install axle shaft assembly (1, Figure 60) in axle
housing.
NOTE: Differential input shaff may have to be turned to
align splines. Make sure that shaft is fully
seated.
L
Figure 60
16. Using spindle bushing drive, install spindle bushing (2, Figure 61) in spindle. Make sure that bushing is seated
to depth shown in Figure 62.
NOTE: Refer to “Special Tools” section of this manual for manufacturing details of spindle bushing driver.
17. Apply a coat of Loctite Sealer H W Catalog No. 71 to oil seal bore of spindle (3, Figure 61). Using spindle oil
seal driver, install oil seal (1) in spindle with lip of oil seal “IN.” Coat lip of seal with grease to aid further
assembly of axle.
NOTE: Refer to “Special Tools” section of this manual for manufacturing details of spindle oil seal driver.
I 15901
:igure 61 :igure 62
NOTE: It is also important to note that when a RH. & L.H. brake assembly is installed that top brake wheel
cylinder is located 6" fotward of vertical centerline of axle towards fotward travel direction of unit, as
shown in Figure 63.
On a rear axle the top wheel brake cylinder will be 6" towards input flange of axle.
On a front axle the top wheel cylinder will be 6" towards to oil level check plug.
TOP OF VERTICAL TOP OF VERTICAL

MOUNTING POSITION MOUNTING POSITION
FRONT AXLE
TOP OF VERTICAL TOP OF VERTICAL

MOUNTING POSITION MOUNTING POSITION
REAR AXLE
15910
igure 63
39
18. Using a suitable lifting device, sling brake assembly

(1, Figure 64) as shown.
19. Position spindle, hub oil deflector (4, Figure 64) and
brake assembly against spindle support.
NOTE: The hub oil deflector (4) is located between the

brake assembly and spindle. A small tab on
O.D. of deflector engages oil drain hole (5)
located on spindle. This drain hole is located at
the bottom when axle is mounted on crane.
Remember, since axle mounting pads are
resting on blocking, the boffom of the axle is up
in these illustrations.
20. Apply Loctite 271 to 12 Pt. bolts (2). In positions marked

during disassembly, install 12 Pt. bolts to hold brake
‘igure 64
assembly and spindle to spindle support.
NOTE: 72 R. bolts do not have plain washers.
21. Apply Loctite 271 to 6 Pt. bolts (3). Install plain washers and 6 Pt. bolts (3),to hold brake assembly and spindle
to spindle support.
22. Tighten 12 Pt. and 6 Pt. bolts from 125 - 140 Ibf ft (169.5 - 189.8 Nmm).
NOTE: Brake assembly should also have been marked for proper orientation at reassembly. Brake return
springs with long hook ends are different colors from one end of axle to the other. Axle has black
springs for R.H. brake assembly, and yellow for L.H. brake assembly.
NOTE: Tubes are installed so bends point to rear of
machine when axles are viewed from top n n
(Figure 65).
AXLES SHOWN BRAKE

AS VIEWED TUBE
FROM TOP
REAR AXLE
15843
‘igure 65
40
23. Install two new bearing cups in hub and stud assembly
(3, Figure M), if removed during disassembly.
NOTE: Large diameter of bearing cup raper must face

out from bearing cup bore.
24. Position bearing cone (2) in hub and stud assembly.
25. Coat I.D. of oil seal bore with Loctite Sealer HW Catalog
No. 71. Install oil seal (1) with lip of seal pointing
“TOWARDS” bearing cone (2). Coat lip of seal with
grease to aid further assembly of axle.
Figure 66
26. Using a suitable bearing drive, install bearing cove

(1, Figure 67) on internal ring gear, if removed during
disassembly.
1
Figure 67
27. Using a suitable lifting device, sling hub and stud

assembly (1, Figure 68) as shown.
28. Install hub and stud assembly, internal ring gear (4), lock
washer (3) and hub retaining nut (2) on spindle.
NOTE: Make sure lock washer is engaging splines.
NOTE: Brake shoes may have to be backed off to

allow installation of hub and stud assembly.
I II 15863
Figure 68
41
NOTE: There are two types of hub retaining nut configurations available.
One arrangement uses two light thin hex nuts with a lock washer located between them. The lock
washer is keyed to the spindle and prevents the two nuts from turning.
The second arrangement uses one slotted nut and a lock washer that engages splines of internal ring
gear.
A different spindle nut wrench (7, Figure 69) is required for each of these arrangements. Refer to
proper Parts Manual to identify part number for hub retaining nut(s). The “Special Tool” section shows
both types of tools, with part number of hub retaining nut(s) that it is used for.
29. Tighten hub retaining nut to about 500 Ibf ft (677.9 Nmm) while rotating hub and stud assembly (2, Figure 69).
Strike hub and surrounding parts with a mallet to shock wheel end and better seat bearing cups and cones.
Slowly loosen hub retaining nut and again strike rim with a mallet. Loosen hub nut until a slight bearing end play
is detected.
30. Using adaptor bar (1, Figure 70), rotate hub and stud assembly (2) through entire rotations and determine no-
load rolling torque value. Slowly tighten hub retaining nut until rolling torque just starts to increase. Record and
use this reading as no-load rolling torque value. Repeat this step several times.
No-load Rolling Torque
NOTE: Refer to “Special Tools” section of this manual for manufacturing details of adaptor bar.
31. Tighten hub retaining nut until bearing preload rolling torque value is at recommended rolling torque value above
no-load rolling torque.
New Bearings; Used Bearings;

7 - 12 Ibf ft (9.5 - 16.3 N-m) 3 - 5 Ibf ft (4.1 - 6.8 N-m)
+ No-Load Rolling Torque + No-Load Rolling Torque
-
- Recommended Rolling - Recommended Rolling Torque
Torque
NOTE: When final recommended rolling torque is obtained with slotted hub retaining nut, it may be necessary
to loosen nut and index it on splines and repeat this procedure to get proper alignment between lock
washer tabs and slots in nut.
r 1
Figure 69
42
32. Bend tabs on lock washer (5, Figure 71) to prevent loosening of hub retaining nut.
NOTE: If double hub retaining nut arrangement is used with a lock washer located between is used bend tabs
over both nuts as shown in Figure 72.
33. Install thrust washer (3, Figure 71), sun gear (2) and retaining ring (1) on axle shaft (4).
JAM NUT 16906
‘igure 71
34. Coat mating surface of hub and stud assembly and

planetary carrier (2, Figure 73) with Loctite #515.
NOTE: See appropriate “Planetary Carrier Assembly”

section for axle being serviced for disassembly
and reassembly instructions.
35. Align holes and position planetary carrier on axle.
NOTE: Once planetary gears are engaged on sun gear

and internal ring gear the input flange on axle
can be rotated to help align holes.
36. Apply Loctite 271 to bolts (1). Install washers and bolts
to secure carrier to axle. Tighten bolts from
-
90 100 Ibf ft (122.0 - 135.6 N-m). II I 15860 I
Figure 73
43
37. Align match marks and install tie rod assembly

(3, Figure 74) in steering arms. Install castle nuts and
tighten them to 300 Ibf ft (406.7Nmm). Secure castle
nuts in position with cotter pins.
38. Using a 2 Ton (1.81 Mg) lifting device, sling and remove
axle (1) from support stand and/or a table and blocks
/P
(2).
39. Axle is now ready for installation on unit.
44
PLANETARY CARRIER ASSEMBLY

(P/N 134705,1257 751 H91 AND 1260 021 H91)
1
I 2
1622.00
igure 75
DISASSEMBLY
1. Using a sharp pointed punch at a 45" angle as shown
in Figure 76, remove plug (8, Figure 75)from carrier (9).
Discard plug.
2. Remove retaining ring (7) from carrier (9).
3. Using a suitable adaptor and arbor press, remove planet

shaft (6) and planet shaft ball (5) from carrier assembly.
Use care not to lose ball.
NOTE: Press on end of shaft opposite flange.
4. Slide planet gear (3) and two planet thrust washers (2)
out of carrier (9).
Figure 76
45
5. Remove forty-eight planet needle rollers (2)and spacer (4) from planet gear (3).
NOTE: Twenty-four needle rollers are located on each side of spacer.
6. Repeat this procedure for remaining planetary gears.
REASSEMBLY
1. Coat inside of planet gear (3, Figure 75) with clean grease. Position spacer (4) with twenty-four planet needle
rollers (2) on each side, in gear.
NOTE: A total of forfy-eight pinion needle rollers will be installed. Grease is sued to help hold rollers in
position.
2. Position a planet thrust washer (1) on each end of planet gear (3).
NOTE: Tang on thrust washers must face awav from ends of gear.
3. Carefully slide gear (3) and two thrust washers (1) into carrier (9). Tangs on thrust washers must engage grooves
on carrier.
NOTE: Use care not to dislodge planet needle rollers.
4. Using a suitable adaptor and arbor press, install planet shaft (6) and planet shaft ball (5) into carrier (9) and
planet gear assembly. End of shaft must be even with or below retaining ring groove in shaft bore of carrier.
NOTE: Press shaft into position from flange side of carrier.
NOTE: When installing shaft make sure that ball aligns with notch in carrier.
NOTE: Use care not to dislodge or damage thrust washers, needle rollers or spacer, when installing shaft.
5. Install retaining ring (7) in carrier (9).

NOTE: Make sure retaining ring is fully seated in groove.
6. Apply a band of sealant in planet housing bore plug

(8, Figure 75) hole.
NOTE: Use Permatex #3, Loctite #515 or # 518, or

Dow Corning Q3-7069 R. T.V. as bore plug
sealant.
7. Using plug tool and arbor press (Figure 77), install new
plug (8, Figure 75) in shaft bore of carrier (9).
NOTE: Be sure plug is installed straight in bore and

bottoms out on shoulder in carrier housing.
NOTE: See “Special Tools” section of this manual for

manufacturing details of plug tool.
8. Repeat this procedure for remaining planetary gears. Figure 77
46
PLANETARY CARRIER BRAKE ASSEMBLY

(PIN 81 803, 81804, 81771 AND 81772)
DISASSEMBLY
0373.02
igure 78
1. Remove four brake shoe return springs (20 and 21, Figure 78).
2. Remove guide pin lock ring, shoe guide nut, shoe guide washer (Items 4, Figure 78) and brake shoe (6) from
shoe guide pin (4).
NOTE: If guide pin lock ring is damaged during removal a new guide pin kif must be ordered which includes
all ltems Numbered 4.
NOTE: Use care when removing brake shoes (6,Figure 78) from wheel cylinder push rods (15).
NOTE: Mark location and position of each brake shoe (6,Figure 78) for reassembly.
3. Remove connector tube (1, Figure 78) from wheel cylinders (9). Remove bolts (3), wheel cylinder assemblies
(9) and wheel cylinder covers (8).
NOTE: Mark location of hydraulic brake tube for reassembly.
4. Remove screw (17, Figure 78) and adjusting wheel spring (16) from backing plate (5) at each star wheel (18).
Turn star wheel (18) to unscrew adjusting screw (19) from backing plate (5).
47
5 . Remove push rod (15, Figure 78), wheel cylinder boot (13), wheel cylinder piston (14) and brake cylinder cup
(12) from each end of wheel cylinder housing (9). Remove piston cup spring (1 1) from housing. Remove bleeder
screw (10) from bottom wheel cylinder.
REASSEMBLY
1. Install bleeder screw (10, Figure 78) in bottom wheel cylinder housing (9).
2. Coat internal parts of wheel cylinder assembly with clean brake fluid before reassembly. Position piston cup
spring (11, Figure 78) in wheel cylinder housing (9). Install brake cylinder cup (12), wheel cylinder piston (14),
wheel cylinder boot (13) and push rod (15) in each end of wheel cylinder housing.
NOTE: Make sure that spring is properly seated in brake cylinder cup.
3. Position star wheel (18, Figure 78) in slot of backing plate (5) and screw adjusting screw (19) into backing plate
(5) engaging I.D. of star wheel.
NOTE: Lightly coat adjusting screw with lubricant.
4. Mount wheel cylinder covers (8, Figure 78) and wheel cylinder assemblies (9) on backing plate (5) with bolts
(3).
5. Install hydraulic brake tube (10, Figure 78) between
wheel cylinders (9).
NOTE: lnstall brake tube in location noted at

disassembly. Tubes are installed so bends
point to rear of machine when axles are viewed
from top (Figure 79).
6. Position shoe guide pin (4, Figure 78) in backing plate

1 FRONT AXLE
AXLES SHOWN
AS VIEWED
FROM TOP
(5). Position brake shoe (6) in wheel cylinder push rods
(15) and over shoe guide pin (4). Install shoe guide
washer and shoe guide nut on shoe guide pin (Items 4).
Tighten shoe guide nut until guide pin lock ring hole is
visible in nut slot. Using hog ring pliers, install guide pin
lock ring (4) in shoe guide pin.
REAR AXLE
16843
I
7. Install four brake shoe return springs (6,Figure 78).
Figure 79
48
PLANETARY CARRIER BRAKE ASSEMBLY

(P/N 1228 948 H91, 1228 949 H91,1228 944 H91 AND 1228 943 H91)
DISASSEMBLY
NOTE: Long shank springs (6, Figure 80) have two colors. Black for R H . planetary end brake assemblies and
yellow for L.H. planetary end brake assemblies.
49
2. Remove cotter pin (20,Figure 80),castle nut (l), two washers (2),brake shoe (3)and spacer (4) from brake
shoe retaining bolt (5).
NOTE: One washer (2, Figure 80) is located on each side of brake shoe web.
NOTE: Dust covers (not shown) ,must be removed to allow brake shoe retaining bolt (5,Figure 80) to come
out of spider (9).
NOTE: Use care when removing brake shoes (3, Figure 80) from wheel cylinder (8) push rods.
NOTE: Mark location and position of each brake shoe for reassembly.
3. Hydraulic brake tube (10,Figure 80)and dust covers (not shown) must be removed to gain access to wheel
cylinder mounting bolts (15)and lock washers (19).
NOTE: Mark location of hydraulic brake tube for reassembly.
4. Remove bolt (14,Figure 80), lock washer (21)and adjuster retainer clip (13)from spider (9)at each star wheel
(1 1). Turn star wheel (1 1) to unscrew brake shoe adjuster (12)from spider (9).
5 . Remove push rod (7, Figure 81), wheel

cylinder boot (6),wheel cylinder piston (2),
brake cylinder cup (3) and spring retainer
(5) from each end of wheel cylinder
housing (1). Remove piston cup spring (4)
from housing. Remove brake tube seat (8)
from housing. Remove bleeder screw
(16,Figure 80)from bottom wheel cylinder.
NOTE: Brake tube seat (8, Figure 81) is
located in wheel cylinder housing
port closest to outside edge of
spider (9, Figure 80).
I 5612
Figure 81
REASSEMBLY
1. Install bleeder screw (16,Figure 80) in bottom wheel cylinder housing (1, Figure 81).Install brake tube seat (8)
in wheel cylinder housing (1).
NOTE: Brake tube seat (8, Figure 81) is located in wheel cylinder housing port closest to outside edge of
spider (9, Figure 80).
2. Coat internal parts of wheel cylinder assembly with clean brake fluid before reassembly. Position piston cup
spring (4, Figure 81) in wheel cylinder housing (1). Install spring retainer (5), brake cylinder cup (3), wheel
cylinder piston (2),wheel cylinder boot (6)and push rod (7) in each end of wheel cylinder housing.
NOTE: Make sure that spring is properly seated in spring retainer.
50
3. Position star wheel (11, Figure 8 0 ) in slot of spider (9) and screw brake shoe adjuster (12) into spider engaging
I.D. of star wheel.
NOTE: Lightly coat brake shoe adjuster with lubricant.
4. Mount wheel cylinder assemblies (8, Figure 80)on spider (9) with lock washers (19) and bolts (15).
NOTE: Remember, brake tube seat (8, Figure 87) is located in wheel cylinder housing port closest to outside
edge of spider (9, Figure 80).
5. Position brake shoe retaining bolt (5, Figure 80) in spider (9) before installing dust covers (not shown).
6. Install dust covers (not shown) then hydraulic brake tube

(10, Figure 80).
- -
NOTE: lnstall brake tube in location noted at
1 FRONT AXLE r
-
disassembly. Tubes are installed so bends
point to rear of machine when axles are viewed f-
from top (Figure 82). AXLES SHOWN
AS VIEWED
FROM TOP
7. Position spacer (4, Figure 8 0 ) and washer (2) on brake
shoe retaining bolt (5). Position brake shoe (3) in wheel
1 :+I
cylinder push rods and over bolt (5). Install second
washer (2) and castle nut (1) on retaining bolt. Tighten
castle nut until cotter pin hole is visible in castle nut slot. REAR AXLE
Install cotter pin (20).
8. Install four brake shoe return springs (6 and

17, Figure 80).
Figure 82
NOTE: Long shank springs (6, Figure 80) have Iwo
colors. Black for R.H. planetary end brake assemblies and yellow for L.H. planetary end brake
assemblies.
51
REAR AXLE DIFFERENTIAL & CARRIER ASSEMBLY

(P/N 134762 AND 1260 034 H91)
DISASSEMBLY
1. With planetaries removed, position axle housing
(1, Figure 8 3 ) on blocking as shown, with input flange
pointing “UP.”
2. Match mark pinion gear seal retainer (2) to differential

carrier (3).
3. Match mark differential carrier to axle housing.
4. Using a suitable lifting device, sling input flange (4) as

shown.
5. Remove hex nuts and plain washers (5) that secure

differential carrier to axle housing.
6. Using a punch remove three tapered attaching dowels

I
from carrier mounting studs. Discard locators.
Figure 83
7. Carefully remove differential assembly from axle housing.
8. Remove pinion shaft nut (1, Figure 8 4 ) and input flange
(2) from pinion gear shaft.
NOTE: Loctite on splines of flange may inhibit its

removal.
9. Remove dust shield (3) from input flange, if necessary.
10. Loosen jam nut (4) and back thrust screw (5) out.
NOTE: If this thrust screw is not backed out the

differential assembly can not be removed from
carrier housing.
I
Figure 84
52
11. Attach three differential carrier support plates and legs

(1, Figure 85) to carrier housing (2).
NOTE: Refer to “Special Tools” section of this manual

for manufacturing details of plates and legs.
12. Match mark carrier caps (3) to carrier housing.
13. Remove adjusting nut retaining bolt and lock washer (4)
from each cap.
14. Remove two bolts and plain washers (5) that hold each
cap in place. Remove both caps.
15. Loosen adjusting nuts (6) and remove differential

assembly (7) and adjusting nuts from carrier housing. Be
careful not to drop bearing cups on each end of
differential assembly.
16. Using a suitable puller remove bearing cones (1 and

2, Figure 8 6 ) from differential assembly halves.
17. Match mark flanged case half (3), differential spider (4),
and plain case half (5) as shown with a diagonal match
mark. This style of match mark will ensure that
differential is properly reassembled.
18. Remove bolts and plain washers (6) holding case halves
together. Remove plain case half.
Figure 86
19. Remove bronze colored side gear thrust washer

(1, Figure 87) and side gear (2) from bevel side pinion
gears (3). Remove thrust washer (1) from side gear if
necessary.
20. Remove differential spider (4) and bevel side pinion

gears (3) with pinion thrust washers (5) from flanged
case half. Remove thrust washers and bevel gears from
spider if replacement is necessary.
21. Remove remaining differential side gear and thrust

washer from flanged case half.
22. Remove hex nuts, ring gear bolts (6) and ring gear (7)
from flanged case half.
I 1
NOTE: If ring gear is replaced, pinion gear must also
Figure 87
be replaced, since they are a matched set.
53
-
- IMPORTANT -
Match mark seal retainer to differential housing. There are oil passages in
the differential housing which must align with passages in the shims and
seal retainer.
23. Remove bolts and lock washers (1 I Figure 88) holding seal retainer (2) in place. Remove seal retainer and shims
from differential housing (3). Note position of shim oil passages to notches in seal retainer, shown in Figure 89.
NOTE: On Serial Numbers, 9390 thru 9450, 9455, 9456, 9460,9463 thru 9482, 9487 thru 9522, 9532 thru 9694
there was a gasket used instead of shims.
NOTE: On Serial Numbers, 9695 thru 9700, 9703 & UP shims replaced the gasket.
24. Using a suitable driver remove pinion gear assembly (4) from carrier housing.
25. Remove seal (5)from seal retainer (2), if necessary.
ALIGN NOTCH WITH

OIL PASSAGE HOLE
IN SHIM.
NOTE: THIS HOLE IN SHIM

WILL BE BLOCKED. ,5897
Figure 88 lgure 89
26. Using a suitable puller remove bearing assembly

( I I Figure 90) and roller bearing (2) from each end of
pinion gear (3). P
b 15898
Figure 90
54
REASSEMBLY
PINION GEAR ROLLING TORQUE
1. Using an arbor press and suitable adaptor, press roller

bearing (2, Figure 91) and bearing assembly (1) onto
pinion gear (3).
NOTE: Stake roller bearing in four equally spaced

around diameter of end of pinion gear. Use a
square staking tool (See next step.).
NOTE: lnstall bearing assembly on pinion gear with

letter "P" stamped on bearing cup towards
pinion gear teeth. Use original shim and spacer
between bearing cones as a starting point to
establish rolling torque.
Figure 91
2. When inner pinion bearing or pinion gear and ring gear are being replaced, staking of pinion end to roller
bearing is required.
A. If a staking groove is in pinion gear shaft, use procedure in Figure 92, and a square end staking tool.
B. If pinion gear has no staking groove, use procedure in Figure 93, and a standard prick punch to upset metal
over bearing inner race.
OPTIONAL CONSTUCTION
(NO STAKING GROOVE
(e, PLACES
15907
I
Figure 92 igure 93
55
3. Install input flange (1, Figure 94) and pinion nut on

pinion gear (2).
4. Using a piece of angle iron (3) with a hole and a couple

of appropriate bolts, tighten pinion nut to 365 Ibf ft
(494.9 Nm).
NOTE: Coat bearing assembly with oil and slowly

rotate it while torque is being applied to pinion
nut.
5. Once torque is applied, remove pinion gear assembly

from angle and check rolling torque. Gently hold bearing
assembly cone in a vise. Rolling toque must be from
-
13 23 Ibf in (1.47 - 2.60 N-m). Disassemble parts and
add shims to decrease rolling torque, or, remove shims 1
to increase rolling toque. I 15908
Figure 94
6. Repeat pinion gear rolling torque procedure as many
times as required to obtain proper rolling toque.
7. Remove pinion gear nut and input flange when through. Then proceed to “Pinion Gear Installation.”
PINION GEAR INSTALLATION
1. Using a soft face hammer, drive pinion gear assembly

(4, Figure 95) into differential housing (3). Make sure
bearing assembly is fully seated.
2. Coat I.D. of oil seal bore with Loctite Sealer H W Catalog

No. 71. Install seal (5) in seal retainer (2),if removed at
disassembly.
3. When seal retainer (2) was removed, were there shims

or a gasket?
A. If a gasket was used, proceed to Step 7.
B. If shims were used, proceed with next step.

NOTE: On Serial Numbers, 9390 thru 9450,9455,9456,
9460, 9463 thru 9482, 9487 thru 9522, 9532 thru Figure 95
9694 there was a gasket used instead of shims.
NOTE: On Serial Numbers, 9695 thru 9700, 9703 & UP shims replaced the gasket.
4. Using soft face hammer, seat seal retainer (2) on pinion gear assembly (4). Measure gap between seal retainer
and differential housing (3). Subtract 0.005 In. (0.127 mm) from measurement to obtain proper shim pack
thickness.
Measured Gap
- 0.005” Adjustment To Measurement

- Recommended Shim Pack Thickness
56
5. Remove seal retainer (2), for installation of proper shim pack.
I
- IMPORTANT -
Seal retainer was matched marked to differential housing. This was to
ensure oil passages in the differential housing align with passages in the
shims and seal retainer. I
6. Apply Loctite #277 to mating surfaces of seal retainer (2),all shims, and differential housing (3).
7. Align match marks and oil passages and install shims or

gasket and seal retainer (2, Figure 95) on differential ALIGN NOTCH WITH
housing (3). Make sure that oil passage in shims or OIL PASSAGE HOLE
gasket align with notch in seal retainer shown in IN SHIM.
Figure 96.
NOTE: On Serial Numbers, 9390 thru 9450,9455, 9456,

9460, 9463 thru 9482, 9487 thru 9522,9532 thru
NOTE: On Serial Numbers, 9695 thru 9700, 9703 & UP

shims replaced the gasket.
8. Apply Loctite #277 to threads of bolts (1, Figure 95).

Install lock washers and bolts to hold seal retainer and
@ 0

0
shims in position. Tighten bolts from 90 - 100 Ibf ft WILL BE BLOCKED. ,5897
(122.0 - 135.6 Nmm).
Figure 96
9. Install dust shield (3, Figure 97) on input flange (2) if

10. Apply Loctite #277 on internal splines of input flange.

Install input flange on pinion gear shaft.
NOTE: Coat oil seal surface of input flange with oil to

help aid installation through oil seal in seal
retainer.
11. Apply Loctite #277 on input shaft nut (1). Install input
shaft nut and tighten it to 365 Ibf ft (494.9 N-m).
12. At this time DO NOT turn thrust screw (5) and jam nut
(4). Leave then loose until ring gear assembly is installed
and properly adjusted.
57
REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY
1. Install ring gear (7, Figure 98), ring gear bolts (6) and
hex nuts on flanged case half. Tighten nuts from
-
60 65 Ibf ft (81.3 - 88.1 N-m).
2. Install a thrust washer (1) and side gear (2) in flanged
case half.
3. Install bevel side gears (3) and pinion thrust washers (5)
on differential spider (4). Align match mark and set
spider assembly on side gear in flanged case half.
4. Set side gear (2) and thrust washer (1) on bevel side
gears.
~~~ ~
Figure 98
5. Align plain case half (5, Figure 99) match mark with
differential spider (4) and flanged case half (3), and set
case half into position.
6. Apply Loctite #277 to threads and install plain washers

and bolts (6) to secure case halves together. Tighten
bolts from 90 - 100 Ibf ft (122.0 - 135.6 N-m).
7. Install bearing cones (1 and 2) on differential assembly.
Figure 99
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT
1. Set adjusting nuts (6, Figure 100) in carrier housing (2). Make sure that threads are not crossed.
2. Position differential assembly (2), with bearing cups on each end, in carrier housing between adjusting nuts.
3. Align match marks and position carrier caps (3) in position on carrier housing. Install two plain washers and bolts
(5) to hold caps in position. DO NOT tighten bolts now.
4. Tighten adjusting nuts until ring gear is difficult to move with thumb and forefinger pressure. When this point is
reached, preload on bearings is set.
5. Move adjusting nuts equally to achieve 0.008- 0.012 In. (0.203 - 0.305 mm) backlash, while maintaining proper
preload. Use a dial indicator to check backlash as shown in Figure 101.
58
I I
igure 100
CHECK ROLLING PAlTERN OF RING GEAR AND PINION
1. Apply white lead to both sides of 10 - 12 ring gear teeth. When ring gear is rotated, white lead is squeezed out
by pressure between ring gear and pinion gear teeth. This leaves bare areas thg same size, shape and location
of the contact area. Sharper impressions may be made by applying pressure to ring gear to create resistance
while it is rotated. Check tooth contact pattern on drive side (convex side) of ring gear against “Tooth Contact
Charts” in this manual. Coast side will automatically correct itself when drive side pattern is corrected.
2. Make any necessary corrections now.

3. Once correct rolling pattern and backlash is achieved, tighten bolts (5, Figure 100) from 125 - 140 Ibf ft
(169.5 - 189.8 N-m).
NOTE: Loctite #277 must be applied to threads of bolts (5) before final torque being applied.
4. Install lock washer and adjusting nut retaining bolt (4) in each cap. Adjusting nuts (6) may have to be turned
slightly to install retaining bolt.
5. Remove carrier support legs and plates from differential assembly.
59
FINAL INSTALLATION OF DIFFERENTIAL & CARRIER
1. Turn thrust screw (1, Figure 102) “IN” until it touches

ring gear. Back thrust screw out 1/4 turn and tighten
jam nut.
NOTE: Apply Loctite #277 to threads of thrust screw.
2. Apply Loctite #515 to mating surfaces of differential

assembly (2) and axle housing (3).
3. Using a suitable lifting device, sling input flange (4).
4. Align match marks and position differential assembly in

axle housing.
5. Install three tapered attaching dowels in tapered holes

of differential flange.
6. Install plain washers and hex nuts (5) to secure :igure 102
differential assembly in axle housing. Tighten three hex
-
nuts located over tapered dowels first then remaining nuts. Tighten all nuts from 60 65 Ibf ft (81.3 - 88.1 Nmm).
60
FRONT AXLE DIFFERENTIAL & CARRIER ASSEMBLY

WITH PARKING BRAKE ASSEMBLY)
(PIN 134728 AND 1260 025 H91)
DISASSEMBLY
1. With planetaries removed, position axle housing
(1, Figure 103) on blocking as shown, with input flange
pointing “UP.”
2. Match mark differential carrier (2) to axle housing.
3. Using a suitable lifting device, sling input flange (3) as

shown.
4. Remove hex nuts and plain washers (4) that secure

differential carrier to axle housing.
5. Loosen jam nut (5) and back thrust screw (6) out.
NOTE: If this thrust screw is not backed out, dif-

ferential assembly can not be removed from
carrier housing.
‘igure 103
6. Using a punch remove three tapered attaching dowels
from carrier mounting studs. Discard locators.
7. Carefully remove differential assembly from axle housing.

8. Remove hex nuts (1, Figure 104) and parking brake
drum (2) from input flange (3).
9. Remove pinion shaft nut (4) and input flange from pinion
gear shaft (5).
NOTE: Loctite on splines of flange may inhibit its

removal.
61
10. Pull on parking brake lever (1 Figure 105) to spread

brake shoes (2 and 3). Using a pry bar, remove strut (4)
from under brake shoe retaining tab located on back
side of brake shoe. Remove strut from brake assembly
once freed.
'igure 105
11. Operate parking brake lever ( I I Figure 106) in both direction and disengage brake shoe (2) from guide pins (3
and 4). Then pry up on brake shoe (1, Figure 107) over actuator cam (2).
-
/
Figure 106 igure 107
12. Attach three differential carrier support plates and legs

(1 Figure 108) to carrier housing (2).
NOTE: Refer to "Special Tools" section of this manual

for manufacturing details of plates and legs.
13. Match mark carrier caps (3) to carrier housing.
14. Remove adjusting nut retaining bolt and lock washer (4)
from each cap.
15. Remove two bolts and plain washers (5) that hold each
cap in place. Remove both caps.
16. Loosen adjusting nuts (6) and remove differential

assembly (7) and adjusting nuts from carrier housing. Be
careful not to drop bearing cups on each end of dif- Figure ,08
ferential assembly.
62
17. Insert a 3/8" Dia. threaded rod 18" Long (1, Figure 109)
through differential assembly. Install a 3" O.D. washer on
each end of threaded rod with appropriate hex nuts (2).
Tighten hex nuts and washers against differential case
halves (3 and 4). This rod will retain spring pressure
exerted by No-Spin springs.
18. Match mark flanged case half (4), differential spider (5),
and plain case half (3)as shown with a diagonal match
mark. This style of match mark will ensure that
differential is properly reassembled.
19. Remove bolts and plain washers (6) holding case halves
together.
20. Once bolts are removed, slowly unscrew hex nuts on

threaded rod to allow case halves to separate and allow Figure ,09
No-Spin springs to expand.
21. Remove threaded rod and No-Spin parts (1 thru 8, Figure 110) in order shown from between case halves
IFigure 110 15911
LEGEND FOR NO-SPINASSEMBLY
1. SIDE GEAR 5. HOLDOUT RING

2. SPRING 6. SPIDER ASSEMBLY
3. SPRING RETAINER 7. RETAINER RING
4. CLUTCH ASSEMBLY 8. CENTER CAM
22. Using a suitable puller remove bearing cones (7 and 8, Figure 109) from differential assembly halves.
23. Remove hex nuts, ring gear bolts (9) and ring gear (10) from flanged case half.
NOTE: If ring gear is replaced, pinion gear must also be replaced since they are a matched set.
63
I - IMPORTANT - I
I I
Match mark seal retainer to differential
housing. There are oil passages in the
differential housing which must align with
passages in the shims and seal retainer.
24. Remove bolts (1, Figure 111) holding brake backing

plate (2) and seal retainer (3) in place. Remove backing
plate, seal retainer and shims from differential housing
(4). Note position of shim oil passages to notches in
Figure 112.
NOTE: On Serial Numbers, 9390 rhru 9450,9455,9456,

9460, 9463 rhru 9482, 9487 rhru 9522, 9532 rhru 9694 there was a gasket used instead of shims.
NOTE: On Serial Numbers, 9695 rhru 9700, 9703 & UP shims replaced the gasket
25. Using a suitable driver remove pinion gear assembly

(5, Figure 111) from carrier housing. ALIGN ‘NOTCH WITH
OIL PASSAGE HOLE
IN SHIM.

WILL BE BLOCKED.
15923
Figure 112
26. Remove seal (1, Figure 113) from seal retainer (2),if
necessary.
64
27. Remove lock nut (1, Figure 114), flat washer (2) and
lever (3) from cam shaft (4).
28. Remove cam shaft from backing plate (5).
15925
gure 114
29. Using a suitable puller remove bearing assembly

(1, Figure 115) and roller bearing (2) from each end of
pinion gear (3). P
Figure 115
65
REASSEMBLY
PINION GEAR ROLLING TORQUE
1. Using an arbor press and suitable adaptor, press roller

bearing (2, Figure 116) and bearing assembly (1) onto
pinion gear (3).
NOTE: Stake roller bearing in four equally spaced

around diameter of end of pinion gear. Use a
square staking tool (See next,step.).
NOTE: Install bearing assembly on pinion gear. Letter

“P” stamped on bearing cup, must be towards
pinion gear teeth. Use original shim and spacer
between bearing cones as a starting point to
establish rolling torque.
Figure 116
2. When inner pinion bearing or pinion gear and ring gear are being replaced, staking of pinion end to roller
bearing is required.
A. If a staking groove is in pinion gear shaft, use procedure in Figure 117, and a square end staking tool.
B. If pinion gear has no staking groove, use procedure in Figure 118, and a standard prick punch to upset
metal over bearing inner race.
c -
OPTIONAL CONSTUCTION
(NO STAKING GROOVE
(6) PLACES ,5907
I -
Figure 117 Figure 118
66
3. Install input flange (1, Figure 119) and pinion nut on

pinion gear (2).
4. Using a piece of angle iron (3) with a hole and a couple

of appropriate bolts, tighten pinion nut to 365 Ibf ft
(494.9 N-m).
NOTE: Coat bearing assembly with oil and slowly

rotate it while torque is being applied to pinion
nut.
5. Once torque is applied, remove pinion gear assembly

from angle and check rolling torque. Gently hold bearing
assembly cone in a vise. Rolling toque must be from [.-----
-
13 23 Ibf in (1.47 - 2.60 Nmm). Disassemble parts and
add shims to decrease rolling torque, or, remove shims
to increase rolling toque. I 15908
Figure 119
6. Repeat pinion gear rolling torque procedure as many
times as required to get proper rolling toque.
7. Remove pinion gear nut and input flange when through. Then proceed to “Pinion Gear Installation.”
PINION GEAR INSTALLATION
1. Coat I.D. of oil seal bore with Loctite Sealer H W Catalog

No, 71, and install seal (1, Figure 120) in seal retainer
(2), if removed at disassembly.
Figure 120
67
2. Install cam shaft (4, Figure 121) in backing plate (5).
3. Install lever (3), flat washer (2) and lock nut ( 1 ) on cam
shaft.
I 15925
Figure 121
4. Using a soft face hammer, drive pinion gear assembly

(5,Figure 122) into differential housing (4). Make sure
bearing assembly is fully seated.
5. When seal retainer (3) was removed, were there shims

or a gasket?
A. If a gasket was used proceed to Step 9.
B. If shims were used proceed with next step.

9460, 9463 thru 9482, 9487 thru 9522, 9532 thru

6. Using soft face hammer, seat seal retainer (3) on pinion
gear assembly (5). Measure gap between seal retainer and differential housing (4). Subtract 0.005 In. (0.127 mm)
from measurement to get proper shim pack thickness.
Measured Gap
- 0.005" Adjustment To Measurement

- Recommended Shim Pack Thickness
7. Remove seal retainer (3), for installation of proper shim pack.
- IMPORTANT -
Seal retainer was matched marked to differential housing. This was to
ensure oil passages in the differential housing align with passages in the
shims and seal retainer.
~~ _ _ _ _ ~
8. Apply Loctite #277 to mating surfaces of seal retainer (3), all shims, and differential housing (4).
68
9. Align match marks and oil passages and install shims or

gasket, and seal retainer (3,Figure 122) on differential ALIGN NOTCH WITH
housing (4).Make sure that oil passage in shims or OIL PASSAGE HOLE
gasket align with notch in seal retainer shown in IN SHIM.
Figure 123.Make sure oil passage in shims aligns with
@
notch in relationship to parking brake lever relief.

9460, 9463 thru 9482,9487 thru 9522, 9532 thru
0 0
10. Align match marks and position brake support backing NOTE: THIS HOLE IN SHIM
plate (2,Figure 122) on seal retainer (3). WILL BE BLOCKED. 15923
1 I. Apply Loctite #277 to threads of bolts (1, Figure 122). Figure 123
Install bolts to hold brake backing plate, seal retainer
and shims in position. Tighten bolts from 90 - 100 Ibf ft
(122.0- 135.6 N-m).
12. Hook a pair of springs (1, Figure 124) between brake
shoes (2and 3)at one end. Position the brake shoes on
backing plate under guide pins (4and 5).
NOTE: Brake shoes will spread apart from each other

on end that is not hooked. Have another person
hold the shoes against the guide pins until
remaing pair of springs is installed.
13. Using an awl, hook the two remaing springs (6)into

brake shoes.
Figure 124
14. Pull on parking brake lever (1 , Figure 125) to spread

brake shoes (2 and 3). Position strut (4)under brake
shoe retaing tab on each brake shoe.
Figure 125
69
15. Apply Loctite #277 on internal splines of input flange

(3, Figure 126). Install input flange on pinion gear shaft
(5).
NOTE: Coat oil seal surface of input flange with oil to
help aid installation through oil seal in seal
retainer.
16. Apply Loctite #277 on input shaft nut (4). Install input
shaft nut and tighten it to 365 Ibf ft (494.9 N-m).
17. Install parking brake drum (2) on input flange. Install hex
nuts (1) to hold drum in place until axle is installed on
unit.
REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY
I
2 3 1
I
~
15911
Figure.127
LEGEND FOR NO-SPINASSEMBLY
1. SIDE GEAR 5. HOLDOUT RING

2. SPRING 6. SPIDER ASSEMBLY
3. SPRING RETAINER 7. RETAINER RING
4. CLUTCH ASSEMBLY 8. CENTER CAM
70
1. Pass threaded rod (1 ,, Figure 128)through flanged case

half (4). Then install No-Spin parts (1 thru 8, Figure 127)
in order shown, on rod in order shown in preceding
sections according to No-Spin part number. When No-
Spin parts are in position on threaded rod, position plain
case half (3) on rod. Use a 3" O.D. washer and
appropriate hex nut (2) on each end of rod to draw
differential assembly parts together.
2. Align plain case half (3) match mark with differential

spider (5) and flanged case half (4).
3. Apply Loctite #277 to threads and install plain washers

and bolts (6)to secure case halves together. Tighten
bolts from 90 - 100 Ibf ft (122.0- 135.6N-m).
4. Once bolts (6) are installed remove threaded rod from

differential. Figure 128
5. Install bearing cones (7 and 8) on differential assembly.
6. Install ring gear (lo), ring gear bolts (9)and hex nuts on flanged case half. Tighten nuts from 60 - 65 Ibf fi
(81.3- 88.1 N-m).
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT
1. Set adjusting nuts (6, Figure 129) in carrier housing (2). Make sure that threads are not crossed.
2. Position differential assembly (2),with bearing cups on each end, in carrier housing between adjusting nuts.
3. Align match marks and position carrier caps (3)in position on carrier housing. Install two plain washers and bolts
(5) to hold caps in position. DO NOT tighten bolts now.
4. Tighten adjusting nuts until ring gear is difficult to move with thumb and forefinger pressure. When this point is
reached, preload on bearings is set.
5. Move adjusting nuts equally to achieve 0.008- 0.012 In. (0.203- 0.305 mm) backlash, while maintaining proper
preload. Use a dial indicator to check backlash as shown in Figure 130.
. . .
igure 129 Figure 130
71
CHECK ROLLING PAlTERN OF RING GEAR AND PINION
1. Apply white lead to both sides of 10 - 12 ring gear teeth. When ring gear is rotated, white lead is squeezed out
by pressure between ring gear and pinion gear teeth. This leaves bare areas the same size, shape and location
of contact area. Sharper impressions may be made by applying pressure to ring gear to create resistance while
it is rotated. Check tooth contact pattern on drive side (convex side) of ring gear against “Tooth Contact Charts”
in this manual. Coast side will automatically correct itself when drive side pattern is corrected.
2. Make any necessary corrections now.
3. Once correct rdling pattern and backlash is achieved, tighten bolts (5, Figure 100) from 125 140 Ibf ft -
-
(169.5 189.8 N-m).
NOTE: Loctite #277 must be applied to threads of bolts (5) before final torque being applied.
4. Install lock washer and adjusting nut retaining bolt (4) in each cap. Adjusting nuts (6) may have to be turned
slightly to install retaining bolt.
5. Remove carrier support legs and plates from differential assembly.
FINAL INSTALLATION OF DIFFERENTIAL & CARRIER
1. Turn thrust screw (1, Figure 131) in until it touches ring

gear. Back thrust screw out 1/4 turn and tighten jam
nut.
NOTE: Apply Loctite #277 to threads of thrust screw.
2. Apply Loctite #515 to mating surfaces of differential

assembly (2) and axle housing (3).
3. Using a suitable lifting device, sling input flange (4).
4. Align match marks and position differential assembly in

axle housing.
5. Install three tapered attaching dowels in tapered holes

of differential flange.
Figure 131
6. Install plain washers and hex nuts (5) to secure differen-
tial assembly in axle housing. Tighten three hex nuts
-
located over tapered dowels first then remaining nuts. Tighten all nuts from 60 65 Ibf fi (81.3 - 88.1 Nsm).
72
INSTALLATION
FRONT AXLE INSTALLATION
1. Using a fork l i f t or other similar device, position axle
assembly (1, Figure 132) under crane.

lift is not available, use crane to position axle
under frame. Lower boom to 0" elevation and
fully retract it. Swing boom about 90" to side
opposite that axle is laying] and attach chains
to skid and axle. Slowly extend boom and drag
axle assembly under unit. Crane boom can rise
to a point where hook block is directly over
center line of axle. With hook block over
centerline of axle and crane, hoist axle into
position against frame.

chains to 2 Ton (1.81 Mg) lifting device and axle Figure 132
assembly. Slowly raise axle into position against frame.
3. Install eight bolts and self-locking nuts (2) that secure axle assembly to frame (3). Tighten bolts to 510 Ibf ft
(691.5 N-m).
NOTE: There are electrical wiring harnesses that are located in frame. Use care when installing bolts not to
pinch these wires with axle mounting bolt tab. An access hole is located inside frame to reach bolts
and wiring.
4. Position front drive shaft (3, Figure 133) against front

output flange of transmission. Secure in place with two
U-bolts (2) and four lock washers and nuts (1).
Figure 133
73
5. Remove hex nuts on front axle input flange

(6, Figure 134) that were installed to protect threads and
prevent parking brake drum from coming off during
installation process. Position drive shaft (5) against front
axle input flange. Secure driie shaft in place with lock
washers and nuts.
6. Secure brake line hose and tubing bracket (4) to

differential housing using differential case mounting
hardware. Tighten nut from 60 65 Ibf ft -
-
(81.3 88.1 N-m).
7. Attach parking brake cable clevis (2) to parking brake

lever (3) with clevis pin and cotter pin (1). Secure
parking brake cable sheath to mounting bracket with
U-bolt and two lock washers and nuts. .-.--
‘igure 134
NOTE: Refer to “Parking Brake Adjustment Procedure”
section of this manual for proper adjustment of
parking brake once axle is installed.
8. Attach bracket (10, Figure 135) to steering arm with flat

washer, lock washer and nut (9). Connect brake line
tube (7)between connector (8) and brake wheel cylinder
assembly. Repeat this procedure for brake line assembly
on other side of unit.
9. If equipped, position drag link (6) on ball stud. Install

bearing half, spring, adjusting plug (5) and cotter pin (4).
NOTE: On later model cranes equipped with orbitrol

steering, the drag link was eliminated.
10. Install steering cylinder rod end (2) on pin (3). Install
retaining washer and self-locking nut (1).
and wheel assembly (1, Figure 136). Position tire and
wheel assembly on axle. Install all wheel nuts (2). Make
sure that wheel is properly centered on axle. Refer to
Operator’s Manual for “Rim Centering.”

installing wheel assembly. Wheel
480 Lbs. (217.7 kg).

device.
12. Using a cross tightening pattern, tighten wheels nuts to

230 Ibf ft (311.8 N9m).
13. Now perform all adjustment procedures that pertain to

the front axle assembly.
74
REAR AXLE INSTALLATION

1. Using a fork lift or other similar device, position axle
assembly (1, Figure 137) under crane.
NOTE: If a 2 Ton (1.81 Mg) lifting device and/or fork lift

is not available, use crane to position axle under
frame. Lower boom to 0" elevation and fully
retract it. Swing boom about 90" to side
opposite that axle is laying, and attach chains to
skid and axle. Slowly extend boom and drag
axle assembly under unit. Crane boom can rise
to a point where hook block is directly over
center line of axle. With hook block over
centerline of axle and crane, hoist axle into
position against frame.

chains to 2 Ton (1.81 Mg) lifting device and axle I
:igure 137
assembly. Slowly raise axle into position against frame.
3. Install eight bolts and lock washers (2) that secure axle assembly to rear axle mount (3). Tighten bolts to
510 Ibf ft (691.5 N-m).
NOTE: There are electrical wiring harnesses that are located in frame. Use care when installing bo/ts not to
pinch these wires with axle mounting bolt tab. An access hole is located inside frame to reach bolts
and wiring.
4. Secure rear drive shaft (3, Figure 138) to rear

transmission output flange and rear axle input flange,
with four U-bolts (2) and eight lock washers and hex
nuts (1).
15845
Figure 138
75
- - SHOP MANUAL SECTION G-07.10
5. Attach brake tube mounting bracket to steering arm with

flat washer, lock washer and nut. Connect brake line
tube (8) between connector and brake wheel cylinder
assembly. Repeat this procedurefor brake line assembly
on other side of unit. Refer to Figure 135, for reference.
6. Secure bracket with roller (6, Figure 139) and clamp (5)
to steering arm (7) with two bolts, lock washers and hex
nuts (4).
NOTE: Refer to “Rear Steering lndicator Adjustment
Procedure” section of this manual for proper
adjustment of rear steering indicator,
7. Install steering cylinder rod end (2) on pin (3). Install

retaining washer and self-locking nut (1).

and wheel assembly (1, Figure 140). Position tire and
wheel assembly on axle. Install all wheel nuts (2). Make
sure that wheel is properly centered on axle. Refer to
Operator’s Manual for “Rim Centering.”

installing wheel assembly. Wheel
480 Lbs. (217.7 kg).

device.
9. Using a cross tightening pattern, tighten wheels nuts to

230 Ibf ft (31 1.8 N-m).
10. Now perform all adjustment procedures that pertain to

the rear axle assembly.
76
TOOTH CONTACT CHARTS

T
OE
1 MOVE PINION TOWARD
GEAR IN THlt DIRECTION I
QEMm TMS DYIECTION
V MOVE EAR AWAY FROM

MOVE WAR TOWARD
PWON IN Ti46 DlRECllON A
ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL
RING GEAR. THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
WHILE UNDER A LIGHT LOAD.
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH. GEAR SET NOISY.
TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITH-
IN LIMITS BY MOVING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH. GEAR SET NOISY
AND COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEAR-
ING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY
MOVING GEAR TOWARD PINION.
FIG. 4
I -. .. BEARING ON GEAR AND HlGH BEARING ON PINION. CORRECT
LOW
BY PULLING PINION AWAY FROM GEAR. (INCREASE MOUNTING
DISTANCE.)
FIG. 5
BY MOVING PINION IN TOWARD GEAR. (DECREASE MOUNTING
DISTANCE.)
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RlGlDW MOUNTED WITH THE
STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
15855
igure 141
77

TOE I
PINION TOWARD
Y THS D(RECT1ON

MAR U THIS DIIIECTION
COWEX sm
V MOVE QEAR AWAY FROM

PINION IN THIS DReCTlOW
MOVE Q E M TOWARD
PINION IN THO DRECllON A
- ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL
RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
WHILE UNDER A LIGHT LOAD.
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH. GEAR SET NOISY.
TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITH-
IN LIMITS BY MOVING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH. GEAR SET NOISY
AND COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEAR-
ING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY
MOVING GEAR TOWARD PINION.
FIG. 4
LOW BEARING ON GEAR A W HIGH BEARING ON PWION. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTtNG
DISTANCE.)
FIG. 5
BY MOVING PINION IN TOWARD GEAR. (DECREASE MOUNTING
DISTANCE.)
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL NDICATOR RIGIDLY MOUNTED WITH THE
STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
15856
igure 142
78
STEERING ADJUSTMENT PROCEDURE

(FRONT AND REAR AXLES)
Wheel mounting flanges on an axle must be parallel within a maximum total of 0.030 In. (0.762 mm) with each other.
Wheel mounting flange must be parallel with centerline of crane within 0.030 In. (0.762 mm). Adjust tie rod
assemblies on axles to set parallelism.
Steering adjustment (front and rear axles) is made with crane set up on outriggers. Steer crane to left. Adjust left
hand axle steering stop so there is 0.060In. (1 524 mm) gap between head of bolt and axle housing and tighten lock
nut. Steer crane to right. Adjust right hand axle steering bolt stop so there is 0.060In. (1.524 mm) between head
of bolt and axle housing and tighten lock nut. Repeat procedure to check gaps.
BRAKE SHOE ADJUSTMENT PROCEDURE

1. Fully extend front outriggers (1, Figure 143) in down
position as far as possible. Place wooden blocking (2)
under front outrigger frame as shown in Figure 143.
Raise outriggers until frame is resting solidly on
blocking. Outrigger pads must remain in contact with
ground. Repeat this procedure for rear outrigger.
A WARNING! All four tires must clear

ground once crane is resting on front
and rear blocking.
2.
A WARNING! Leave enough room in front
of and behind crane to stop in case it is
knocked off blocking.
Place transmission in “NEUTRAL.” Release parking

brake.
15857
Figure 143
3. Disengage four wheel drive lever.
4. Remove two rubber dust covers from brake shoe backing plate across slots (top and bottom).
5. Using star wheel adjusting tool, rotate bottom star wheel by engaging tool into teeth of star wheel and moving
tool handle toward axle. Repeat until brake lining drags heavily against drum. Then, back off star wheel adjuster
5 notches (clicks) to relieve drag.
NOTE: It may be possible to achieve a “nodrag” condition on brake drum by backing off star wheel less than
5 notches (clicks). This can be best detected, if an operator applies brake pedal, after a notch is taken
Off.
6. Using star wheel adjusting tool, rotate top star wheel by engaging tool into teeth of star wheel and moving tool
handle toward axle. Repeat until brake lining drags heavily against drum. Then, back off star wheel adjuster 5
notches (clicks) to relieve drag.
NOTE: It may be possible to achieve a “nodrag” condition on brake drum by backing off star wheel less than
5 notches (clicks). This can be best detected, if an operator applies brake pedal, after a notch is taken
Off.
79
7. Firmly depress brake pedal to center shoes, and again rotate star wheels to decrease lining to drum clearance
until drag is felt on drum.
8. Relieve drag by backing off star wheels 5 notches (clicks).
9. Rotate wheel and drum. There should not be any “drag” of lining against drum.
10. Install two rubber dust covers removed in Step 1.
11. Repeat steps for all wheels.
PARKING BRAKE ADJUSTMENT PROCEDURE

(FRONT AXLE)
For parking brake to be used as an emergency brake, it must be adjusted when the following conditions exist:
1. When parking brake is applied and slide “ A ’ has bottomed out on its upward stroke “B.”
14304
I
Figure 144
2. When parking brake is applied and there is no contact between brake drum and brake shoes.
3. When brake is applied and with engine throttle between 1/3 to 1/2, machine is placed in forward travel and
brake fails to hold unit.
Brake adjustment is accomplished by turning knob on brake lever clockwise in disengaged position with no tension
on cable. This adjustment is good until slide on lever bottoms out on its upward stroke and no more adjustment can
be made at lever knob. Adjustment can then be made at jam nuts through seat box deck.
80
BRAKE BLEEDING PROCEDURE

Anytime that brakes are spongy or that brake lines or cylinders have maintenance performed involving them, such
as replacement of/or repairing lines, shoes, cylinders, axles, etc. the system may be exposed to the atmosphere.
The following procedure must be done to be sure proper brake shoe adjustment and bleeding.
Fully extend front outriggers (1 Figure 145) in down

A WARNING1 All four tires must clear

and rear blocking.
A WARNING! Leave enough room in front

of and behind crane to stop in case it is
Place transmission in “NEUTRAL.”

I
16857
Shutdown engine. Figure 145
Swing bail wire (1, Figure 146) to one side and remove
cover (2) from master brake cylinder (3).
Figure 146
81
5. Position bleeder adaptor (1, Figure 147) on master

cylinder (2)and attach bleeder ball hose (3) to adaptor.
6. With valve on bleeder ball closed bring pressure in ball

up to 30 PSI (207kPa). Open valve on bleeder ball.
7. Start bleeding brake lines in the following order;

a. Left Rear
i. Bottom Wheel Cylinder
ii. Top Wheel Cylinder
b. Right Rear
c. Left Front
-147
d. Right front
Open bleeder valve at wheel cylinder until all air is expelled from line and then close. Do this at each wheel
cylinder.
NOTE: There is a “top” and “bottom” wheel cylinder at ever location. Bleed bottom cylinder first, and top
cylinder second.
NOTE: Use a rubber hose on bleeder valve at each wheel, to divert brake fluid away from brake linings. Also
immersing other end of hose in a container of clean brake fluid, will show when air is expelled when
air bubbles do not appear.
8. After bleeding is completed, turn off bleeder ball.
9. Start crane and pump brakes for about one minute. Shutdown engine.
10. Open bleeder ball valve and bleed brake lines again as in Step 7.
11. Close bleeder ball valve again.
12. Start crane and pump brakes. Free travel should be from 0.0625 In. (1.588 mm) to 0.250 In. (6.350mm)
maximum. Sdid pedal must be from 2.500 In. (63.500mm) to 3.500 In. (88.900 mm). If brake pedal is beyond
these limits, repeat Steps 7 thru 9.
82
BURNISHING PROCEDURE
New linings (brake shoes) may require “burnishing” to achieve desired performance. Also when brake lines are bled
it is important to get rid of brake fluid that may have gotten into linings and brake drum. The following steps should
be used to ensure proper burnishing.
1. Fully extend front outriggers (1I Figure 148) in down

A A
WARNING! All four tires must clear
and rear blocking.
WARNING! Leave enough room in front

A of and behind crane to stop in case it is
2. Using FIRST GEAR (or low range) apply enough brake 15857
line pressure to slip all four wheels against engine Figure 148
torque (near maximum).
A WARNING! Do not allow brake drum outside temperatures to exceed 300°F (149°C)to 350°F
(177”C).
3. Allow drums to cool down to 150°F (66°C)to 200”F (93°C)before repeating. The number of cycles should
be based on achieving an acceptable performance level. It is estimated that at least five cycles will be required
to show marked brake improvement.
A WARNING! Improper burnishing could result in “glazing.” Since maximum temperature limits
are somewhat critical, and difficult to determine, extreme care must be exercised.
83
REAR STEERING INDICATOR ADJUSTMENT PROCEDURE

(REAR AXLE)
Start crane and move rear steer control lever until rear
wheels are in straight ahead position. Loosen bolts
(1, Figure 149) and move bracket (2) until roller (3) is against
micro switch (4), depressing it just enough to make contact.
Rear steer (red) indicator light (5) on instrument panel will go
out when switch is properly depressed. Tighten bolts (1) and
recheck rear steering for proper operation.
:igure 149
84
85
MATERIAL LIFT C
d
GRADER a
TECHNICAL SERVI CES( PLANER ld
ROLLER Id
CRANE El
SHOP MANUAL J-02.00

R3
LUBRICATION SPECIFICATIONS
APPLICABLE MATERIAL L I F T MODELS SERIAL NUMBER
ML-40 40001 & Up
APPLICABLE GRADER MODELS SERIAL NUMBER
503 L 06112 & Up
A SERIES A-5 00 09251 & Up

A-55 0 09269 & Up
A-600 02950 & Up
AWD SERIES A-556 09275 & Up

A-5 66- E 11164 & Up
A-606 09275 a UP
E SERIES A-400-E 11501 & Up
A-450-E 10477 & Up
S-450-E 10477 & Up
A-500-E 10477 & Up
S-500-E 10477 & Up
A-560-E 10893 & Up
S-560-E 10893 & Up
T SERIES T-400-A 01001 thru 02110

T-500-C 07995 thru 10739
T-500-M 07995 thru 10487
T-600-C 02536 thru 03099
APPLICABLE PLANER MODELS SERIAL NUMBER
RP-12 00137 t h r u 00190

RP-30/42 01001 t h r u 01123
RP-60 04001 t h r u 04043
SP-600 60001 & Up
APPLICABLE ROLLER MODELS SERIAL NUMBERS
S 3-5 A 8 S 4-6 A 55703 t h r u 60664 & 60678

S 3-5 B 8, S 4-6 8 59375 b, u p
S 5-8 A t h r u S 10-14 A 57392, 58035 8, Up
P-3000 BZ 6301 & Up

P-3500 05604, 05605 8, 05679 S l;p
GALION MANUFACTURING DIVISION, DRESSER INDUSTRIES, INC. rn P.O. B O X 647, GALION, OHIO 44833 a PHONE: 4 1 ~ 4 6 8 - 4 3 2 1
0585
APPLICABLE ROLLER UODELS (Cont'd.1 SERIAL NUWERS
66" SERIES 490001 a up

84'' SERIES 450001 a up
2-42 SERIES 510002 a up
2-66 SERIES 470003 8 Up
APPLICABLE CRANE MODELS SERIAL NUWERS
80 04001 8 Up
90 t h r u 125 02965 thru 08774
90 A t h r u 125 A 02006 thru 08774
125 F 07247 thru 08774
125 FA 07990 thru 08774
125 P 01001 a up
140 F 07571 thru 08774
150 A 02832 a up
150 FA 07305 a up
150 P a T 010?1 8 up
180 S 08502 a up
200 FA 07107 a up
220 s 07724 a up
TABLE L E l l E R LUBE CHART CODE SPECIFICATION TYPE PAGE NUWER
A ATF TRANSMISSION FLUID 7

B E050 SAE 50 HD ENGINE OIL 8
C EP80 EXTREME PRESSURE SAE 80 GEAR OIL 8
D EP90 EXTREME PRESSURE SAE 90 GEAR OIL 9
E WGL WORM GEAR LUBRICANT 9
F OGL OPEN GEAR LUBRICANT (SPECIAL PURPOSE) 10
G SAE80 STRAIGHT MINERAL SAE 80 GEAR OIL 11
H SAE90 STRAIGHT MINERAL SAE 90 GEAR OIL 11
I SHC HIGH TEMPERATURE GEAR LUBRICANT
(SYNTHESIZED HYDROCNON BASE FLUID) 12
J C-2 TRANSMISSION FLUID 12
K c-3 TRANSMISSION FLUID 13
L HO HYDRAULIC OIL 13
M HO HYDRAULIC OIL 14
N MPG MULTI-PURPOSE LITHIUM BASE GREASE 15
0 BF HYDRAULIC BRAKE FLUID 15
P 10W30 SAE 10W30 ENGINE OIL 16
Q HO HYDRAULIC OIL - LOW TEMPERATURE 16
R 80W140 SAE 8OW-140 17
S SAE40 SAE 40 ENGINE OIL 17
T 68 HYDRAULIC OIL - PETROLEUM BASE -
ANTI-WEAR ADDITIVES 18
U SAElOW SAE 1OW ENGINE OIL 18
TECHNICAL SERVICES S H O P M A N U A L SECTION J-02.00
MATERIAL LIFT
GRADER
BRAKE MASTER CYLINDER ALL 0
CIRCLE 8, SHOES 503 L 0
A SERIES F
AWD SERIES F
E SERIES F
A SERIES C
AWD SERIES C
E SERIES C
T SERIES C
FRONT WHEEL GEAR CASE ASSEMBLY AWD SERIES A
GREASE ZERKS ALL A
HYDRAULIC SYSTEM AL L A
a l l u n i t s w i t h FUNK K
a l l u n i t s w i t h CLARK A
-1-
W% SHOP M A N U A L SECTION 5-02.00
_s9EL
PLANER
RP-30/42 L
RP-60 L
SP-600 R
RP-60 D
ROLLER
TECHNICAL SERVICES S H O P M A N U A L SECTION 5-02.00
ROLLER (Cont'd. 1
66" SERIES I
CRANE
AXLE DIFFERENTIAL 80 D
90 t h r u 125 C or D
90A thru 125A C or D
125 F C or D
125 FA C or D
140 F C or D
150 A D
150 FA C or D
180 S D
200 FA D
220 A D
TECHNlCAk SERVICES SHOP M A N U A L S E C T I O N 5-02.00
CRANE (Cont'd.1
HYDRAULIC SYSTEM (Cont'd.1 90 thru 125 M or Q

90A thru 125A AI MI Q
125 F AI MI Q
125 FA AI M I Q
125 P M or Q
140 F M or Q
150 A AI MI Q
150 FA AI MI Q
150 P 8 T M or Q
180 S M or Q
200 FA M or Q
220 A M or Q
90 thru 125 C or D
90A thru 125A C or D
125 F C or D
125 FA C or D
140 F C or D
150 A C or D
150 FA C or D
180 S D
200 FA D
220 A D
i
TECHNICAL SERVICES SHOP M A N U A L SECTION 5-02.00
CRANE (Cont'd. 1
STEERING GEAR (Cont'd.1 90A thru 125A C or D
125 F C or D
125 FA C or D
140 F C or D
150 A C or D
90 thru 125 B
90A thru 125A 6, CI D
125 F C or D
125 FA C or D
125 P 6
140 F C or D
150 A C or D
150 FA C or D
150 P & T C
180 S C or D
200 FA C or D
220 A C or D
90 thru 125 B
90A thru 125A B or D

-5 -
TRANSMISSION (Cont'd.1 125 F
125 FA
140 F
150 A 8, 15
180 S
200 FA
220 A
220 s
-6-
i
SHOP M A N U A L S E C T I O N 5-02.00
AUTOMATIC TRANSMISSION FLUID

DEXRON I1
LUBRICATION CHART CODE: ATF or D

TYPICAL PROPERTIES: TEST
. . . . . . . . . . .. ,. ., ,, .. .. 31.0
G r a v i t y , API , ,
V i s c o s i t y , C e n t i s t o k e s 8 104OF (4OoC) 37.0 . , .
. D287
D44 5
7.5 . . .
.. .. .. . ... .,. ,.. ,., ... ,.. 19052.0
V i s c o s i t y , C e n t i s t o k e s 8 212OF (lOO°C)
V i s c o s i t y , SUS 8 100°F (38OC)
V i s c o s i t y , SUS 8 210°F (99OC) ,
. .. .
.
D44 5
D m 1 , D445
Viscosity Index .. . . . . . . .. ,, ,. , . . 168 . . .

, , ,
D m 1 t D445
D2270
V i s c o s i t y , C e n t i p o i s e 8 -4OOF (-40%)
. . .. . . .. .. .. .. .. ., .. .. ..40,000
Pour P o i n t O F ( O C ) , , .. 390 ....
-45 ( - 4 3 ) . D97
*
Color . .. . . . . . . . , . . . . (199) .
F l a s h P o i n t OF ( O C )
, , , ,
, , ,
, , RED
D92
* Procedure i s same as D2983
L i s t e d below a r e some companies and t h e i r Dexron I1 p r o d u c t s which meet t h e

Allison C-3 Specifications.
C a s t r o l L i m i t e d , A s s o c i a t e CompaniesAgencies . C a s t r o l TQ Dexron I 1
. .. .. . . .. .. .. .. .. ,, ... ... .. .,. ...

. . . 8,
Conoco, I n c o r p o r a t e d
Pennzoil Products
. . . . ,
,
. Conoco Dexron I 1
H y d r a f l o Dexron I 1
Shell International , S h e l l ATF Dexron I 1
Union O
Val v o l ine . . . . .. .. . ... .. ... ... ... ... ,. ... .,, ... ... ...
li Company
Valvoline International
,
,
, ,
ATF - -
Dexron I1
V a l v o l ine ATF Dexron I 1
V a l v o l i n e ATF Dexron I1
o r equivalent
- 7-
SAE 50 HEAVY DUTY ENGINE OIL
LUBRICATION CHART CODE: E050
M i l i t a r y S p e c i f i c a t i o n : MIL-L-2104 B
A P I Engine Service CC
1%Ash (Maximum)
Gravity, A P I . . . . . ., ,. ,. ,, .. .. .. ., .. ., .. .. .. .. 50027.5(260)
Flash P o i n t OF (OC)
. . .. D287
D92
Viscosity, SUS 8 lOOOF
Viscosity, SUS d 21OOF
(38%) . . . , . . , . . ,1134 , , . ,
(99OC) . . . . . . , . . . 97 . . . .
D2161
D2161
V i s c o s i t y Index
Pour P o i n t OF (OC)
. .. .. .. ,. ,. .. .. .. , .. . ,. ,, ., .. ., 101 .,..
-0 (-18) .
D2270
D97
S u l f a t e d Ash % Weight , . , . . . . . . . . , . . 1.0 . . . D874
Sources:
Sun O
Mobil O
li Company . . . .. .. . . . .. .. .. .. .. .. .. .. .. Delvac
li Corporation
, S u n f l e e t Super C SAE 50
Texaco ., , ..
, , , , , , . . . . , . . . . , , Ursa E x1150 t r a Duty 50
EXTREME PRESSURE SAE 80 GEAR OIL
LUBRICATION CHART CODE: 80 or EP80
Mliit a r y S p e c i f i c a t i o n : MIL-L-2105 B, API-GL-4, API-GL-5 EP
TYPICAL PROPERTIES:
Gravity, A P I . . . . . . . . . . . . . . .
F1ash P o i n t O F ( O C )
Viscosity, SUS @ 210°F (99OC)
, . . . .. .,. . ,.. ... ,. ., .. .. .. .. 3952555 --(202)
29
85
minimum
V i s c o s i t y Index e
Channel P o i n t OF ( O C )
,
. , . .. .. ., .. ,. .. ,, .. ,, .. .. -30
, ,
101 minimum
Moisture . , , . . . . . . , . . . . . . , . 0.2%(-34)maximum
, , ,
maximum
Sources :
Sun O li Company
.
li Corporation ,
..
. ,, .. . .. ,. ,. .. ,. .. . ,. Mobilube
, , , S u n f l e e t GL-5 8OW-90
Mobil O
Texaco
Standard O
., , . . . . . , . . , , . , . , Texaco Multi-
.
,
.
li (Ohio)
,
. .
,
.
, . . . , , . , . . Gearep 80
HD 8OW-90
gear EP80
Shell .. . .
, , . , . . . . . , . . . . Spirax HD 8OW-90
, , , ,
-8-
TECHNICAL SHOP M A N U A L SECTION 5-02.00
EXTREME PRESSURE SAE 90 GEAR OIL
LUBRICATION CHART CODE: 90 or EP90
M i l i t a r y S p e c i f i c a t i o n : MIL-L-2105 B, API-GL-4, API-GL-5 EP
TYPICAL PROPERTIES:
G r a v i t y , A P I . . . . . . . . , . . . . . . . . . .
F1ash Poi n t O F (OC) . . . . . .. .. .. .. .. .. .. .. .. .. 350752 4 --(177212071 m i nimum
Viscosity, SUS 8 210°F (99OC)
. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 90-0 minimum
Channel P o i n t OF ( O C ) (-18) maximum
Moisture ..................... 0.2% maximum
Sou rces :
Sun O
Mobil O
li Company . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. Mobilube
li Corporation
S u n f l e e t GL-5 8OW-90
HD 8OW-90
Texaco
Standard O
. . . . . . . . .. .. .. ....... .. .. .. .. .. .... . . Gearep
li (Ohio)
Texaco Multi- gear EP90
Shell . . . . . . . . . . . . . . . . . . . . . . Spirax 90HD 85W-90
W GEAR LUBRICANT
W
LUBRICATION CHART CODE: WGL
TYPICAL PROPERTIES:

Viscosity, SUS @ 210°F (99OC)
.. .. .. .. .. .. .. .. .. .. 3,000
125
- 4,000
- 175
. . .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Pour P o i n t O F ( O C )
S a p o n i f i c a t i o n Number
30
11
- -35 (-1 -2)
- 14
Rust Test .................... None
Sources :
Sun O li Company
Mobil O
,
li Corporation
. . .. . ,. .. ,. ,. ,. .. ,. ,. ,. ,. ,. .. 600W
, Sunoco Gear Oli 8C
Super C y l i n d e r
O li
Texaco
Shell .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. VTexaco 650-T Cyl.
a l v a t t a 5-77
Oli
-9-
OPEN GEAR LUBRICANT (SPECIAL PURPOSE)
LUBRICATION CHART CODE: OGL or ML 2
NLGI Grade . . . . . . . . . . . . . . .. .. .. .. .. .. . 28002 . . . .

P e n e t r a t i o n . Worked 8 77OF (25OC) D217
. . . .. .. .. .. .. .. .. .. .. .. ... ... ... ... ... ... ..L i t h8.5i u.m .. ... ...
V i s c o s i t y . Mac M i c h a e l 8 70OF (21OC) ... SUN M-15
Soap? Type d128
Soap. !Z L i t h i u m d128
. . . . . . . . . . . . . . 375 ( 1 9 11
D r o p p i n g P o i n t OF ( O C ) D2265
BASE OIL DATA
V i s c o s i t y ? SUS 8 l O O O F (38OC)
V i s c o s i t y . SUS 8 21OOF (99OC)
.. .. .. .. .. .. .. .. .. .. 79059.2 .. .. .. D2161
(201) .
D2161
F1 ash? COC. OF ( O C ) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 395
A n i l i n e P o i n t ? OF ( O C ) 166 ( 7 4 ) .
D97
D611
Water? !Z . . .. ......... ... ... ... ............. ... ... ... ......... .. .. 19.1
G r a v i t y . API ...
NIL . . .
D287
d1283
Rust Test Rating 2.0 . . .
Pass . . .
d1743
Copper C o r r o s i o n. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ----
Oxidation S t a b i l i t y ... d1261
D942
PSI Drop 8 100 H r s
P S I Drop 8 500 H r s
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. --- 8.5
Water Washout? !Z 8 100°F (38OC)

Wheel B e a r i n g Leakage? gms . . . .. .. .. .. .. .. .. .. .. .. 3.1 ...
3.0 . . .
d1264
d1263
TimkenLb.Pass . . . . . . . . . . . . . . . . . 45 . . . D25 09
Four B a l l s T e s t
Load
Wear
Weld
Wear I n d e x
S c a r ? mrn
P o i n t ? kg
. .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..28037.6
50 ... ... ... .
FED 6503
D2266
.
FED 6503
Ball J o i n t T e s t ? rng Wear . . . . . . . . . . . . . 18 ... SUN 5-123
Sources :
Sun O
Mobil O
li Company . . . .. .. .. .. .. .. .. .. .. .. .. .. .. ..
li C o r p o r a t i o n
S u n f l e e t HP Grease
Mobilgrease Special
Texaco ..................... Mol y t e x #2
-10-
SHOP M A N U A L SECTION 5-02.00
STRAIGHT MINERAL SAE 80 GEAR O I L
LUBRICATION CHART CODE: SAE 80

Flash P o i n t O F (OC)
Channel P o i n t OF (OC)
. .. .. .. .. ... ... ... ... ... ... ... ... ... ... 325
Viscosity, SUS d 210°F (99OC) 55 - 65
(163)
. .- . . .. . .. .. . . .. . .. ,. ,. ,. ,. ,. Pass
-30 (-34)
Rust P r o t e c t i o n , , ,
Foam I n h i b i t e d
, , , , . D665
Yes . . . . STM 75
Temperature Range below O°F (-18OC)
Sources:
Sun O li Company
Mobil O
. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. Mobil
li Corporation
Sunvis 951
Delvac 1130/1230
Texaco
Standard O
. . . . . . . .. .. .. .. ....... .. .. .. .. .... . . Thurban
li (Ohio)
80
I n d u s t r o n 66
STRAIGHT MINERAL SAE 90 GEAR O I L
LUBRICATION CHART CODE: SAE 90
. .. .. .. .. ... ... ... ... ... ... ... ... ... ... 350850 -(177)
Viscosity, SUS d 210°F (99OC)
F1ash P o i n t O F ( O C )
95
Pass . . . . D665
Channel P o i n t OF ( O C ) (18)
. . . . . . . . . . . . . . .
. .- . . . . . . . . . . . . . . . . Yes . . . . STM 75
Rust P r o t e c t i o n . .
Temperature Range below O°F (-18OC)
Sources:
Sun O li Company
Mobil O
. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. Mobilube
li Corporation
Sunvis 999
C-90
Texaco . . . . . . . . .. .. .. .. ....... .. .. .. .. .... . . Thurban
Standard O li (Ohio)
90
I n d u s t r o n 80
Shell O li Company . . . . . . . . . . . . . . . . Dentax 90
-11-
3iwLx
SHC - HIGH TEMPERATURE GEAR LUBRICANT
(-SIZED- BASE FLUID)
LUBRICATION CHART CODE: SHC

.. .. .. .. .. .. .. .. .. 2060 189
Flash Point, OF ( O C ) .. .. .. .. .. .. .. .. .. .. .. .. .. .. 500 ---- (260)
. .. .. .. .. ... ... ... ... ... .. ... ... ... .. .. ... .. ----
Channel Point, O F ( O C )
Rust P r o t e c t i o n Pass
V i s c o s i t y Index, Max. , 148
Pour Point, OF ( O C ) . . . . . . . . . . . .. . . ,. -40
S p e c i f i c Gravity, 60/60 OF (15.6/15.6
(-40)
0.848
. .. .. .. ... ... ... ... ... ... . . .. .. .. . .. , 35.4

OC)
Gravity, API ,
Color, ASTM L1.0
IS0 V i s c o s i t y Grade ----
Copper Corrosion
24 h 8 212OF (1OOOC)
. . .. .. . .. .. .. .. . .. .. .. . . .. ----l b . . . Dl30
Phosphorus, W
Temperature Range
.t %
-
. . . . . . . . . . . . 0.01
above OOF (-18OC)
Sources:
Mobil Oli Corporation .............. SHC 634
TRANSMISSION FLUID TYPE C-2

LUBRICATION CHART CODE: C2
Type: C-2 8, M i l i t a r y S p e c i f i c a t i o n : MIL-L-2104 Grade 10 Above -1OOF

Type: C-2 Rep1ace Type C-1 8, Type A O li
Gravity, API . . . . ., ,. ,. .. .. . ., .. ., ,, .. .. ,. .. 39527.9(202)

Flash P o i n t O F ( O C )
, ..
.. D287
D92
. . . . (-18OC)
Pour P o i n t OF ( O C ) . . . ,. ., ,, .. .. . ,. . -50 (-46)
,
.. .. .. . D97
(38OC) , . . . , , , , .
Viscosity, Centipoise, O°F 2000 D2602
, 200 D2161
Viscosity, SUS @ 100°F
Viscosity, SUS @ 210°F
V i s c o s i t y Index. (99OC) . . . . , , , , . , 47.0 .. . ..
, . . . . . . , , . . . . . 105
, ,
D2161
D2270
Sources :
Sun O li Company
Mobil O
. . .. .. . ,, .. .. .. .. .. .. .. .. .. .. Mobil
,
li Corporation
S u n f l e e t C2/C3
Delvac or
Fluid
1210
Powerfl C-2/C-3
uid
Texaco , . . , , , . . . , , , . . , . , . C-2 Torque
, Fluid
S h e l l . , . . . , , . , . . . . . . . . , . . . . Donax T-55-77
-12-
TRANSMISSION FLUID TYPE C-3
LUBRICATION CHART CODE: C3

TYPE: M i l i t a r y S p e c i f i c a t i o n : MIL-L-10295 t o l a t e s t S p e c i f i c a t i o n
M i l i t a r y S p e c i f i c a t i o n : MIL-L-2104C Grade 10
G r a v i t y , API .. , , , , . . .. .. ., ., ., . 30.6
V i s c o s i t y , C e n t i s t o k e s Q 100°F
, ,
(38OC) 43.21
.. . .. D287
D445
V i s c o s i t y , SUS 8 100°F (38OC) .(99OC)
. . . .. .. ,. . ,. ,. 2 0 1 .. ., ., D2161
V i s c o s i t y r C e n t i s t o k e s @ 210°F , 6.52 D445
V i s c o s i t y , SUS 8 210°F (99OC) . . , . . . . , 47.5 . . , 02161
. .. .. . .. .., ... .., ... .,, ,. .,. ... .,. .. -425 . . . D57
,
Viscosity Index , , , , 113
Pour P o i n t , O F ( O C ) , 20 ( - 2 9 ) . . D97
Color. . . . .. .. . .. . . . . , .. .. .. ,. .. .. .. .. . .. 60.11( 2 1 8 .), .,. ... Dl500

F l a s h P o i n t , OF ( O C )
Z i n c , Wt., % , , , ,
, D92
STM-208
Ash, S u l f a t e d , Wt., % . . . . . . . , . . . 05000.98 . . . D874
Sources :
Sun O li Company
Mobil O
. . . . .. .. .. .. . ., .. ., .. ,, .. .. ..
e S u n f l e e t C2/C3 F l u i d
M o b i l D e l v a c 1310 o r
P o w e r f l u 1d C-2/C-3
Texaco . , . . , , . . . , , , . . . , . , . Torque F1 u i d C-3
Chevron Oli Company . , . . . . . , . . , , , . Chevron D e l 0 400 M o t o r
O li SAE 1OW
la3LLL
HYDRAULIC O I L
LUBRICATION CHART CODE: HO

. . . . . .(38OC)
G r a v i t y , API , , , . . ., .. .. .. .. .. 29.9
V i s c o s i t y r SUS 8 100°F (38OC) . . . ,. .. ., .. .. ., 300
.(99OC)
65
, 8.2
Viscosity Index
. . . . . . . .
. . . .. . . .. ., ., ., . .. ., .. .. ., . 53950 (-18)
,
Pour P o i n t , OF ( O C ) ,
. .. .. ,. ., ,, ., .. ., ., ,, ,. . 400
F1 ash P o i n t , OF ( O C ) , (204)
C o l o r , ASTM maximum
Specific Gravity . . . .,
. . . . . . , . . . . 0.877 . . . D665 A/B
, , ,
, . 3.5
Rust . . . . . . . . . . . . . . . . . . Pass
Cincinnati M liacron, I n c o r p o r a t e d C M Co. H e a t T e s t
1 week 8 275OF (135OC) , . . . , . . . . , , , . Pass
Sources :
Sun O
Mobil O
li Company . . . . . . . .. .. .. .. , .. ., ,. . ..
li C o r p o r a t i o n , , , ,
S u n v i s 831
DTE 26
Texaco . . . . . . . . . . , .. ,. . . .. ,. ..
,
S h e l l . . , . . . . . . .
, ,
e
,
Rando O
T e l l us 33
li HD 315
-13-
IeELE-M
HYDRAULIC OIL

Grade . . . . . . . .. . .. .. .. .. .. .. .. . .. .. .. .. .. 3442
IS0 V i s c o s i t y Grade ,
. .. .. . . .. . .. .. .. ,. .. .. .. ,. .. .. 30.9
G r a v i t y , API
Pounds p e r G a l l o n
, , , ,
a 7.25
. . . . D287
Viscosity
.. .. . .. .. .. .. ,. .. 30.1
K i n e m a t i c , C e n t i s t o k e s 8 40OC
Centistokes Q lOOOC
. . . , D445
5.0 . . . . D445
Viscosity
. . .. .. ,. ., ,, ., .. .. ,. ,15343 .. ,. ,. ,. D2161
S a y b o l t , SUS @ lOOOF
SUS @ 21OOF (99OC)
, , D2161
Pour P o i n t , OF (OC) . .. ... . .. .. ... .,. .,, ,.. .., ... .,, ... -2049529 ( 4 0.0 ). ... ... D2270
V i s c o s i t y Index, M i n.
F l a s h P o i n t , OF (OC)
,
, , (-20) D97
D92
C o l o r , ASTM . . . . . . .. .. .. .. .. .. .. . .. .. . . L1.0( 1 0 0 ). .. .. Dl500
A n i l i n e Number, OF ( O C )
,
, 212 D611
. . . . . . . . Yes
Seal Guard C o n d i t i o n i n g A d d i t i v e
---
AGMANo.
ASTMGrade. . . . . . .. .. .. .. .. .. .. .. .. .. .. 1501OW
SAE No, (Crankcase O
. . . . . . . . * . . . . . .
, e
i
l
)
e
. . . e
. . . . . . . . . ---
SAE No. (Gear L u b r i c a n t ) ,
Sources:
Sun Oli Company . . . . . . . . . . . . . . . Sun Premium150

Hydraulic
Oli
Mobil C o r p o r a t i o n . . . . . . . . . , . . . . DTE 13
( O h i o ) . , , . , . . . . , , . . , , I n d u s t r o n 44
Oli
Standard O li
Shell . . . . . . . . . . . . . . . . . . . . . Tellus25
-14-
. . . .
uELEJ!l
MULTI-PURPOSE LITHIUM BASE GREASE
LUBRICATION CHART CODE: Mffi
TYPE: SAE 5310
Penetration
Unworked . .. ....... ... ... ... ... .......... ... ... ... ... ...... .. .. 275
Worked 60 s t r o k e s
. . . . . . D217
27 0
Worked 10,000
Dropping P o i n t
. . . . . . . . . . . . . .
. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 38OoF . . . Less than 5% r a i s e
minimum
Water Resistance
Texture
Excel 1e n t
. .. .. ........... ... ... ... ... ........... ... ... ... ... ...... . . Negative
ASTM O x i d a t i o n . D942
B u t t e r y & Smooth
Soap Base Lithium
BaseOil,Pour.................. -10
Oxidation I n h i b i t e d
. . .. .. .. .. .. ... ... ... ... ... ... ... ... ... ... 7895Yes
Coordi n a t i ng Research Council Test
Wheel B e a r i ng
Wheel Bearing Overpacked
. . . . . . .. .. .. .. .. .. .. .. .. .. .. Passes Passes
Sources:
Sun O
Mobil O
li Company
li Corporation
. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. Sunfleet HP Grease
Mobilgrease 77
Texaco
She11 . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. M u l t i f a k EP 2
Alvania EP-2
HYDRAULIC BRAKE FLUID
LUBRICATION CHART CODE: BF
TYPE: SAE 7 OR -3
TYPICAL PROPERTIES:
F1ash P o i n t
Color . . . . . . . . .. .. .. .. ....... .. .. .. .. .. . .
Cleveland Open Cup 27OoF (132OC)
L i g h t Straw
Sources:
Wagner
Mobil O
-
Lockheed
li Corporation
. . ,. ,. .. ,. .. .. . ,. ,. .. . . .
,
21 B
Mobil Super Heavy Duty
Brake F1u i d
Uses:
TO BE USED I N ALL BRAKE SYSTEMS
-15-
i
TECHNlCAL SERVICES SHOP M A N U A L SECTION 5-02.00
IAEuU?
SAE 1OW-30 ENGINE OIL
LUBRICATION CHART CODE: 10W30
M i l i t a r y S p e c i f i c a t i o n : MIL-L-46152 API Engine S e r v i c e CC 1.5% Ash (Maximum)
. . . .. . .. .. .. . . .. . . .. . .
G r a v i t y , API
F1 ash P o i n t , OF ( O C )
,
, ,
,
,
,
,
, . .. .. D92
28.5 D287
445 ( 2 2 9 )
V i s c o s i t y , SUS 8 O°F (-18OC)

V i s c o s i t y , SUS @ 100°F (38OC)
.. .. . ... . .. ... .. .. . .. ... .. ... D445,D2161
V i s c o s i t y , C e n t i p o i s e 8 O O F (-18OC) ,
,
,
, 22.3
11,150
, , 349
D2602
D341
Viscosity Index . . .. . . . . .. .. . .. . ... ... ... . .. . . .. ... D445,D2161

V i s c o s i t y , SUS 8 21OoF (99OC) ,
Pour P o i n t , OF ( O C )
, , , ,
,
,
, ,
,
,
,
67.5
158 D2270
-25 ( - 3 2 )
D97
Color . . . . .. .. . . .. . . . . . .. . . .. .. . . .. . . .. .. ., Dl500
Z i n c , Wt., % , ,
, , ,
,
, , 3.5
0.097 STM-208
Ash, S u l f a t e d , Wt., %... ... , , , ..
, , . . . D874
0.94
Sources:
Sun O
Mobil O
li Company . . . . .. .. . .. ,. .. ,. .. .. .. .. .
,
li C o r p o r a t i o n ,
, S u n f l e e t HP 10W30
Mobil Delvac Special
Texaco
Standard O
. . . .. .. . .. . . . . .. .. .. .. ., ., ., .. ..
li ,
,
, , , , ,
U r s a t e x 1-W-30
M u l t r o n 1OW-30
Shell O li Company .... ........... Rotella T Multigrade
1OW-30
Swepco ................... . D e l u x e 8301 1OW-40
HYDRAULIC O I L S LOW TEMPERATURE
Type: M i l i t a r y S p e c i f i c a t i o n : MIL-H-5606 A 8 MIL-H-5605 D
TYPICAL PROPERTIES:
. . ..
V i s c o s i t y , C e n t i s t o k e s @ 4OoF (4OC) , , , 14
.. .. .. .. . . .. ... ... ...

V i s c o s i t y , C e n t i s t o k e s 8 -4OOF (-4OOC)
V i s c o s i t y , SUS @ 100°F (38OC)
V i s c o s i t y , SUS @ 210°F (99OC) ,
, ,
458
76.6
Viscosity Index , . .. .. . . . .. .. . .. .. . . .. .. ..
Pour P o i nt, OF ( O C ) , ,
,
, ,
220
-85 ( - 6 5 )
F1 ash P o i n t , OF ( O C )
Color, , , . .. , . . . . . .. . .. .. .. . ..
, , ,
, , , ,
, ,
,
, 215 (102)
Red
Sources:
Chevron O .....,., .,.,

li C o r p o r a t i o n Chevron A v i a t i o n
H y d r a u l i c F1 u i d A/D
Standard (Ohio) . . . .
Oli , . . , . , . . . . E l d o r a n 5606
Company . . , . . , , . . . . , , . , . A e r o s h e l l F1 u i d 4
Swepco , . . . , . . . . . . . . . . . . ...
Shell Oli
, Hydraul i c O li #704 SAE
10
-16-
TECHRIBCAL SERVICE SHOP M A N U A L S E C T I O N 5-02.00
li3EU-B
SAE 8OW-140
LUBRICATION CHART CODE: 80W140
M i l i t a r y S p e c i f i c a t i o n : MIL-L-2105C
API D e s i g n a t i o n GL-4, GL-5, GL-6
G r a v i t y r API . . . . . . . . . . .. ., ., ,. .. 30.1
,
V i s c o s i t y , C e n t i s t o k e s 8 21OOF (98OC) ,
,
24.5
.. . . D287
. D445
. . . . . ., . .. ,. .. 285.0
V i s c o s i t y , SUS 8 21OOF (98OC)
V i s c o s i t y , C e n t i s t o k e s 8 l O O O F (38%)
142.8 . . . . D2161
,
.. .. .. .. D445
Viscosity Index .. . .
V i s c o s i t y , SUS 8 21OOF (99OC)
,
. . .
, , ,
. , . 1,321,
. . . . , . . . 152 . . . . . D2270
,
D2161
F1 ash P o i n t , OF (OC) . . . . .
,
.,.
V i s c o s i t y 8 -15OF (-26OC) B r o o k f i e l d Cp . . , . , D2983
141,000
, , . . -20 ( - 2 9 ) . . D92
, , ,
Pour P o i n t , OF ( O C ) ,. . , . . , -45 ( - 4 3 ) . . FTM3456
, , , , , , ,
Timken OK Load (Lbs.) . . . . . ., ., ,. ,. .. 551B . .. ,. .. .. DD2782

Copper C o r r o s i o n 3 h r . 8 25OoF ( 1 2 l 0 C ) .
, , ,
l30
Sources:
Sun O li Company , . . . .. .. .. .. . .. ,. ., ., .. ., ..
e
S u n f l e e t XL 80W140
Mobil O
Texaco . . . . . . . .. .. ., . .. .. ., .. ., , ., ..
, , , , ,
M o b i l u b e HD 80W140
M u l t i g e a r Lub EP 85W140
. . . . .. .. . .. .. .. .. ., . ,, .. ., ,. ., ..
Standard O li ( O h i o ) Gearep 80W140
Shell O li Company , S p i r a x HD 85W140
Valvoline , ESP SAE 80W140
SAE 40 ENGINE OIL
LUBRICATION CHART CODE: SAE40

M i l i t a r y S p e c i f i c a t i o n : MIL-L-2104 B
A P I E n g i n e S e r v i c e CC
1%Ash (Maximum)
0.07% Z i n c (Minimum)
Sources:
Sun O
Mobil O
li Company . . . .. .. . ., . .. .. ., ,. ., .. . .. ..
S u n f l e e t HP 40
D e l v a c 1140 o r 1240
Texaco
Standard O
. . . . .. . . .. ., . .. .. .. ,, .. , ., ., ..
li ( O h i o ) ,
, U r s a Super P l u s SAE 40
V a n e l l u s Super DF 40 o r
V a n e l l u s MCS-3 40
She1 1 O
li Company . . . , . . . . . . , . , . . . R o t e l 1 a 40 o r R o t e l 1 a T
40
Valvol i n e . . . . . . . . . ... .. ... HD-40 o r HDT-40
-17-
SHOP M A N U A L SECTION 5-02.00
___i_
HYDRAULIC OIL
-
PETROLEUH BASE ANTI-WEAR ADDITIVES
LUBRICATION CHART CODE: 68
Grade, I S 0 VG , . . . . . . . . . . . . , . 68 . , . . D2422
, , ,
V i s c o s i t y Index . . .. .. . .. .. . . . .. .. .. ... .,, ,., 61.2

V i s c o s i t y , C e n t i s t o k e s 8 104OF (40OC)
,
,
, ,
, ,
,
, , - 74.8 D445
95 , . . , . D2270
0 (-18) . . D97
Rust T e s t , , ,
Oxidation Test
.. .. .. .. . . . .. . . . .. . . .. ,. 2,000
, ,
, , , , , , P a s s . . . . . D665
. . . . . D943
SAE 1OW ENGINE OIL
LUBRICATION CHART CODE: SAElOW
M i l i t a r y S p e c i f i c a t i o n : MIL-L-2104B9 MIL-L-2104Cf MIL- 46152
API E n g i n e S e r v i c e CD, SE
1%Ash (Maximum)
G r a v i t y , API , . , ,
F l a s h P o i n t , OF ( O C )
.. .. . .. .. . . .. .. .. .. .. .. 42530.5( 3 9 3 ). .. .. D92
,
, ,
,
,
D287

. .. .. .. .. ., ,. ., .. 20147.5 .. .. .. .. D2161
,
.
,
D2161
Viscosity Index , . .. .. . .. . . . . . .. . .. .. ,. . -20

, , , 113 . . . . . D2270
S u l f a t e d Ash, % W e i g h t . . . . . . . . . . . 0.98( - 2 9 ). .. .. D97
,
D874
Sources :
Sun O
Mobil O
li Company , . . . . . .. .. .. .. .. ., ., .. . ,
,
,
,
S u n f l e e t HP 10
D e l v a c 1110
Texaco
Standard O
,. . . . . .. .. . .. . .. ., ,, ,. ., ,. ..
,
li ( O h i o ) ,
, , ,
, , ,
U r s a E x t r a Duty 10
N i t r o n Motor O
. . . . .. . .. . . . . .. .. .. ., . .. ..
li 10
Shell O li Company , e R o t e l l a 1OW
Swepco , , , , , , , , D e l u x e Long D i s t a n c e Oli
#301 SAE 1OW-40
V a l v o l ine Oli Company (Ash1 and) . . , . . . . . . HD Super HPO SAE 1OW
-18-
OIL CHANGE RECOMMENDATIONS

It i s i m p e r a t i v e t h a t t h e new s p e c i f i c a t i o n l u b r i c a n t s n o t be mixed w i t h t h e
o l d s p e c i f i c a t i o n s i n any manner.
When c h a n g i n g t o a new s p e c i f i c a t i o n , p a r t i c u l a r l y i n t h e M a t e r i a l L i f t and t h e

H y d r a u l i c Crane H y d r a u l i c tanks, t h e f o l l o w i n g p r o c e d u r e s h o u l d be p r a c t i c e d :
1. A f t e r t h e u n i t has been o p e r a t e d s u f f i c i e n t l y , t o b r i n g t h e l u b r i c a n t
t o normal o p e r a t i n g t e m p e r a t u r e s , remove t h e d r a i n p l u g and c o m p l e t e l y
d r a i n t h e 1u b r i c a n t .
2. A f t e r draining, flushing i s desirable, Clean and r e p l a c e t h e d r a i n

p l u g and c l e a n t h e fill p l u g area. Fill u n i t t o t h e c o r r e c t 1 eve1 w i t h
a l i g h t flushing o i l . O p e r a t e t h e u n i t f o r a s h o r t p e r i o d o f t i m e (5
t o 10 m i n u t e s ) under e x t r e m e l y l i g h t o r no l o a d c o n d i t i o n s . D r a i n ALL
o f t h e f l u s h i n g o i l f r o m t h e u n i t w h i l e it i s warm. Clean and r e p l a c e
t h e d r a i n plug.
3. To r e f i l l , c l e a n around t h e fill p l u g a r e a and fill t h e u n i t t o t h e

c o r r e c t l e v e l w i t h t h e new s p e c i f i c a t i o n l u b r i c a n t . DO NOT OVERFILL as
an e x c e s s i v e amount w i
l s e r v e no u s e f u l purpose.
4. Use same l e v e l checks and d r a i n i n t e r v a l s as o u t 1 i n e d on 1 u b r i c a t i o n

c h a r t and/or i n O p e r a t o r ' s Manual f o r t h e new l u b r i c a n t .
NOTE: M I X I N G OF THE LUBRICANTS COULD CAUSE DAMAGE AND €ANNOT BF, TQLUU\TFD. IF
THERE I S ANY DOUBT WHETHER THE UNIT HAS BEEN FILLED WITH THE OLD OR NEW
LUBRICANT, THE U N I T SHOULD BE D R A I N E D AND FLUSHED ( A S PRESCRIBED
ABOVE).
-19-
-20-
GRADER d
PLANER 0
DRESSER ROLLER 0
CRANE d
SHOP MANUAL K-2

RVC5
WAGNER POWER MASTER CYLINDER
USED WITH
FOUR WHEEL SERVICE BRAKES
Two designs o f power m-as~ter-cyrnders--have been used- on GALION equipment;
these will be referred t o a s the "old sty1 e" and the "new s t y l e " . The
disassembly of the power cylinder for b o t h s t y l e s i s the same, the d i f -
ference between the two s t y l e s i s i n the master cylinder section. Identify
the s t y l e of your power master cylinder by referring t o the following l i s t
or t o Figure 1 , page 1 .
GRADER MODELS OLD STYLE NEW STYLE
104C 10750 thru 11214
104HB 10182 thru 10693
118B 07601 10182 thru 10750
118C 10750 thru 12013
1606 021 55 02577 thru 02705
160C ---- 02706 thru 03029
160L 021 01 thru 02580 02581 thru 03083
T-400A 01 001 thru 01006 01007 thru 01 745
T-500A 02601 thru 03459 03460 thru 07994
T-500L 02601 thru 03459 03460 thru 07994
T-600 01 292 thru 01500 01501 thru 02496
T-600B 01 501 thru 01778 01779 thru 02535
T-700 01 061 thru 01081 ----
CRANE MOdELS
80 04001 thru 07323
90 thru 125 01254 thru 07323
90A thru 125A 02006 thru 07323
125F 07247 thru 07323
150A 02832 thru 07323
150FA 07305 thru 07323
220A 07107 thru 07112
25A Prime Mover 04331 thru 07323
CONTENTS Page
Power Function . . . . . . . . . . . . . . .. . . . . . . . . . 3
Manual Function . . . , . . . . . . . . . .. . . . . . . . . . 3
Disassembly of Power Unit . . . . . . . . .. . . . . . . . . . 4
Reassembly of Power Unit . . . . . . . . . .. . . . . . . . . . 8
Disassembly of Old S t y l e Master Cylinder . .. . . . . . . . . . 11
Reassembly of Old S t y l e Master Cylinder . .. . . . . . * . . .13
Disassembly of New S t y l e Master Cy1 inder . .. . . . . . . . . . 16
Reassembly of New S t y l e Master Cy1 inder .... . . ... . . .17
Special Tools . . . . . . . . . . . . . .... . .
~
... . . *
~-
19
DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE. LIBERTYVILLE, fL 60048
0183
CS
CAUTl ON
DISASSEMBLY AND ASSEMBLY,

GOOD WORKING ORDER.

INJURY.
r
. . Threads: values should be increased 1/3 for Non-Lubricated IOrv)
NOTE: Torque Values listed thr ounhout this manual are Lubricated [Wet) . Threads.
I .

Grade 5 Grade 8
(Ft Lbs.) (Nm) ( F t Lbs.) (Nml
1/4 - 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 - 24 15 20 21 28
3/8 - 16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 - 12 84 114 120 163
9/16 - 18 93 126 132 179
5/8 - 11 115 156 165 224
5/8 - 18 130 176 185 251'
3/4 - 10 205 278 290 393
3/4 - 16 230 312 320 434
718 - 9 305 414 455 617
7/8 . 14 335 454 515 698
1. 8 455 617 695 942
1 - 14 510 691 785 1064
1 1/8 - 7 610 827 990 1342
1 1/8 - 12 685 929 1110 1505
1 1/4 -7 860 1166 1400 1898
1 1/4 - 12 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 248 1
1 318 . 12 1290 1749 2 085 2827
1 1/2 - 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2 730 3701
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5 760 7810
SECTION 2
OLD STYLE
NEW STYLE
0 0
i EZzE @ @
I
I
I
I
I
Fig. 1
-1 -
NOTES
-2-
FILE K
SECTION 2
HYDRAULIC POWER MASTER CYLINDER
INLET OWUT
Fig. 2
POWER FUNCTION The 1 ine pressure , acting on the face o f

the small reaction piston ( F ) , creates a
In the relaxed o r non-appl ied position, force which i s transmitted d i r e c t l y
the return spring ( E ) holds the connec- through the valve piston t o the pedal
tor ( D ) , and the power piston ( C ) butted linkage p r o v i d i n g operator f e e l . Ad-
a g a i n s t the end cap as shown i n the draw- d i t i o n a l application force a t the pedal
ing. produces a correspondingly higher 1 i ne
pressure.
F1 u i d flows through the u n i t as indicated
by the arrows. During an application, When the back pressure developed on the
the force and movement i n i t i a t e d a t the i n l e t s i d e of the power piston exceeds
pedal i s transmitted through the push the normal system pressure by 180 p s i ,
rod ( A ) t o the valve piston ( B ) moving the re1 i e f valve ( H ) unseats and permits
i t t o the right. f l u i d t o by-pass the power piston as
indicated by upper arrow.
The return spring ( E ) holds the connec- MANUAL FUNCTION
tor ( D ) and the power piston ( C ) s t a t i o n -
ary. For manual operation o f the u n i t , the
pedal force and movement i s transmitted
The f i r s t movement of the valve piston t o the Val ve piston ( B ) . After the
( B ) reduces the area of by-pass port ( I ) valve piston moves t o the right 5/32"
creating a flow r e s t r i c t i o n and a corres- (while the return spring ( E ) holds the
p o n d i n g back pressure. A1 1 movement of connector ( D ) s t a t i o n a r y ) , i t bottoms
valve piston ( B ) i s transmitted d i r e c t l y i n the connector (D) and c a r r i e s i t
t o the reaction piston ( F ) . through the remainder of the motion.
The val ve piston and connector , moving
The back pressure e x i s t s only on the as a s i n g l e piece, serve as a push rod
i n l e t s i d e of the power p i s t o n ( C ) and t o actuate the master cylinder piston
produces a force on the face of the ( G ) and the reaction piston ( F ) which,
power piston. This force overcomes the i n turn, closes off the master cylinder
return spring ( E ) and moves the power p o r t hole and develops 1 ine pressure.
piston ( C ) , connector ( D ) , and master
cylinder piston ( G ) t o the right closing NOTE: Figure 2 is a cross- sectional
the master cylinder port hole and c r e a t - drawing of t h e oZd s t y Ze cy Zinder; how-
i n g l i n e pressure. ever, the f u n c t i o n of the new s t y & is
t h e sane.
-3-
FILE K
SECTION 2
Hydraulic power master cylinder i n -

s t a l l e d on grader.
DISASSEMBLY OF POWER UNIT FOR BOTH OLD & NEW STYLES
Remove from machi ne.
3
Remove push rod and boot.
-4-
FILE K
SECTION 2
Remove r e t a i n i n g ring.
End cover, valve, and piston are removed

as a unit.
Return spring retainer and return spring
are also removed a t t h i s time.
6
Remove end cover and piston from valve
piston and rod.
Remove 0-ri ng from end cover ( 1 ) and
O-ring from piston ( 2 ) . Discard O-ring.
-5-
FILE K
-
SECTION 2
Remove back up washer (1 1 and vee block

packing ( 2 ) .
To disassemble valve piston and rod:
Place push rod end o f valve piston and

rod on work surface.
Compress return spring w i t h connector.
Remove retaining ring .
Discard retaining ring.
Remove back u p washer and vee block

packing from connector end of piston
rod.
Discard washer and packing.
-6-
FILE K
SECTION 2
10
To disassemble by-pass valve:
Remove r e t a i n e r and gasket ( l ) , spring
( 2 ) , and by-pass valve ( 3 ) .
11
Remove r e t a i n e r ring ( I ) , back u p ring
( 2 ) , back up washer ( 3 ) , and vee block
packing (4) from power cy1 inder body.
Discard back u p washer a n d vee block
packing.
12
Remove r e t a i n e r ring, s t r a i n e r , h a i r , and

second s t r a i n e r from cavity d r a i n .
NOTE: On a l l power master c y l i n d e r s
instaZled on cranes and prime movers,
t h e r e t a i n i n g ring, s t r a i n e r s and h a i r
are i n s t a l l e d i n a breathing cap screw
which attaches t h e master cyZinder
assembly t o t h e power u n i t .
-7-
FILE K
SECTION 2
ASSEMBLY OF POWER CYLINDER UNIT FOR BOTH OLD & NEW STYLES
Clean power cylinder body. Inspect and discard a l l components t h a t a r e

worn or damaged. Use a l l components i n r e p a i r k i t d u r i n g re-assembly.
All components should be generously lubricated w i t h hydraulic o i l prior
t o assembly.
13
I n s t a l l s t r a i n e r , h a i r , second s t r a i n e r ,
and retaining ring i n cavity drain.
14
I n s t a l l vee block packing (4) w i t h vee
toward power piston, back u p washer (31,
back u p ring ( 2 ) , and retaining ring
(1).
Back u p ring must f l o a t f r e e l y between
washer and retaining ring.
-8-
FILE K
SECTION 2
15
I n s t a l l by-pass valve (3), spring ( 2 ) ,
and r e t a i n e r and washer (1 ) i n power
cy1 i nder body.
16
I n s t a l l vee block packing w i t h vee t o -
ward push rod end.
I n s t a l l back up washer on piston rod
behind vee packing.
17
Place return spring on piston rod.
Carefully i n s t a l 1 connector.
Compress return spring.
I n s t a l l r e t a i n i n g ring i n groove on
pi s t o n rod.
Crimp ring evenly i n place.
-9-
FILE K
SECTION 2
18
I m t a l l vee block packing ( 2 ) w i t h vee
toward connector.
Instal 1 back up washer (1 ) behind vee
packing.
19
Instal 1 O-rings on p i s t o n ( 2 ) and end
cover ( 1 ) .
20
Assemble piston and end cover assemblies

on valve piston and rod.
Place spring return r e t a i n e r and spring
on valve piston and rod assembly.
I n s t a l l w i t h care i n power cylinder
body.
-1 0-
FILE K
-
SECTION 2
21
I n s t a l l r e t a i n i n g r i n g i n body b e h i n d
end cover.
22
I n s t a l l b o o t a n d push r o d .
DISASSEMBLY OF MASTER CYLINDER ASSEMBLY FOR OLD STYLE

(Turn to S t e p 35 f o r disassembly of new s t y l e )
23
M a s t e r c y l i n d e r removed from power

cy1 i n d e r .
-1 1-
-
SECTION 2
24
Remove snap ring from cy1 inder body.
25
Remove piston assembly ( l ) , piston
return spring ( 2 ) , s e a t (3) and valve
seat (4).
26
Remove secondary cup (1 ) , U-cup r e t a i n e r

( 2 ) and U-cup (3).
Push reaction piston assembly ( 4 ) from
piston ( 5 ) .
-1 2-
FILE K
- SECTION 2
27
Remove vee block packing ( 1 ) and O-ring

( 2 ) from reaction piston.
28
Remove r e t a i n e r ring (1 ) r e t a i n e r ( 2 ) ,
spring ( 3 ) and check valve (4) from
reaction piston.
ASSEMBLY OF MASTER CYLINDER - Old Style
Clean, inspect, and assemble master cy1 inder i n a dust

f r e e area. Lubricate a l l components prior t o assembly
w i t h approved brake f l u i d .
Dow-Corning Silicon Grease #33 may be used as an a l t e r -
nate lubricant d u r i n g assembly.
DO NOT USE MINERAL OIL OF ANY TYPE AS A LUBRICANT IN
THE MASTER CYLINDER PORTION OF THIS UNIT.
-13-
FILE
SECTION 2
29
To assemble reaction piston:
Instal 1 check valve ( 4 ) w i t h concave

side t o p i s t o n , spring (3), r e t a i n e r
( 2 ) , and retaining ring (1 ) .
30
Instal 1 O-r i n g ( 2 ) i n groove near
1arge d i ame t e r o f piston.
Instal 1 vee block packing ( 1 ) w i t h l i p
toward smal 1 diameter o f piston.
31
I n s t a l l reaction piston assembly ( 4 )

in piston ( 5 ) .
Assemble secondary cup (1 ) , U-cup
r e t a i n e r ( 2 ) , and U-cup ( 3 ) t o piston
assembly.
-14-
FILE K
SECTION 2
32
Instal 1 valve s e a t ( 4 ) and valve (3) ,
piston return spring ( 2 ) and piston
assembly ( 1 ) i n master cylinder body.
33
Comp ress piston and return s p r i ng in
cy1 inder body and i n s t a l 1 snap ring in
groove.
34
I n s t a l l master cylinder assembly on
power cylinder.
Torque cap screws 25-32 f t - l b s .
Power cylinder assembly i s ready f o r
i n s t a l l a t i o n on grader.
-1 5-
DISASSEMBLY OF MASTER CYLINDER - New Style
35
Remove snap ring from cylinder body.
36
Remove piston assembly ( 1 ) U-cup ( 2 )
U-cup r e t a i n e r ( 3 ) , spring ( 4 ) valve
(5) and valve s e a t ( 6 ) .
37
Remove secondary cup (1 ) .
Push reaction piston assembly ( 2 ) from
piston (3).
-16-
FILE K
SECTION 2
38
Remove vee rings from each end o f

reaction piston.
ASSEMBLY OF MASTER CYLINDER - New Style

Clean, inspect, and assemble master cylinder i n a dust free
area. Lubricate a l l components prior t o assembly with approved
brake fluid.
Dow-Corning Silicon Grease #33 may be used as an alternate
lubricant during assembly.
DO NOT USE MINERAL OIL OF ANY TYPE AS A LUBRICANT
IN THE MASTER CYLINDER PORTION O F THIS UNIT.
39
I n s t a l l one vee block packing on each

end of reaction p i ston w i t h the 1 ips
facing away from each other.
40
Instal 1 secondary cup ( 1 ) on piston ( 3 ) .

I n s t a l l reaction p i s t o n ( 2 ) i n t o piston
(3).
-1 7-
FILE K
SECTION 2
41
t a l l valve s e a t ( 6 ) valve ( 5 )
i n g ( 4 ) U-cup r e t a i n e r ( 3 ) U-cup
and piston assembly ( 1 ) i n t o master
i nder body.
42
Compress p i s t o n and spring i n cylinder

body and ins t a l 1 snap ring i n groove.
43
I n s t a l l master cylinder assembly on
power cylinder.
Torque cap screws 25-32 f t - l b s .
Power cy1 inder assembly i s ready f o r
installation.
CAUTION: Master c y l i n d e r must be f i l l e d
onZy w i t h approved brake fZuid.
Bleed brake system of a1 1 a i r w i t h

engine n o t running. (Use Wagner "F1 u i d -
Bal" brake bleeder f o r t o t a l removal of
a i r from system.)
See File J , Section 1 of this manual
f o r brake f l u i d s p e c i f i c a t i o n s .
-1 8-
FILE K
SECTION 2
WAGNER POWER MASTER CYLINDER ASSEMBLY TOOLS
7- - I
A
For F i g u r e 1 6 ,
i page 9 .
15 O
I - 1 305
-
1 DIA.
2
.333
DIA. DIA.
7!
t
' POLISH C O R N E R
Use t o o l ( A ) t o s l i d e vee b l o c k p a c k i n g i n t o g r o o v e o f v a l v e
p i s t o n and rod.
r- 5
I -16
- -- POLISH C O R N E R
B
For F i g u r e 1 7 ,
1 page 9 .
DIA.
t
-
' R 45O
16
S1 i d e t o o l ( B ) o v e r s e a l w i t h f l anqe toward c o n n e c t o r t o h o l d
the s e a l l i p .
Guide the l i p i n t o c o n n e c t o r I.D.
-19-
FILE K
SECTION 2
C
For Figure 18,
page 10.
__- .___
POLISH CORNER
Use tool ( C ) t o s l i d e vee block packing i n t o groove.

This s t e p should be preceded by f i r s t s l i d i n g power piston
i n t o place on the valve piston and rod.
*324 DIA.
.325
D
I
SPHERIC For Figure 20,
RADIUS page 10.
DIA.
Use w i t h tool ( E ) .
For use, see Figure E .
-20-
FILE K.
-
SECTION 2
E
For Figure 20,
page 10.
Use with tool (D) .
P1 ace tool ( D ) on spring loaded p i l o t tool ( E ) .

Carefully place cylinder over spring loaded p i l o t tool w i t h the
p i 1 o t extending t h r o u g h the vee 61 ock packing which had been pre-
viously assembled i n t o the cylinder.
Remove tool ( D ) .
Use arbor press w i t h c o l l a r on ram t o surround push rod so t h a t
force will be applied
-
t h r o u g h the end cap.
Carefully i n s t a l l i n t e r n a l s .
Spring loaded pi l o t tool w i 11 p i 1 o t the connector safely t h r o u g h
i t s O.D. s e a l .
-21-
MATERIAL LIFT 0
GRADER 0
' i ) DRESSER PLANER 0

ROLLER 0
CRANE
SHOP MANUAL
R2
DELCO M O R A I N E
H Y D R A U L I C M A S T E R BRAKE C Y L I N D E R
APPLICABLE M O D E L I S SERlAL.NUMBER/S
150A with Rockwell Axles Only 02832 thru 08339

150F Series A with Rockwell Axles Only 07305 thru 08339
ICALL COMPONENTS MUST BE PROPERLY SUPPORTED DURING


WORKING ORDER.
EXTREME CAUTION TO BE OBSERVED A T ALL TIMES TO PREVENT

INJURY.
CONTENTS Page
Torque Sheet . . . . . . . . . . . . . . . . . . . . . . Back o f Cover
Special Tools . . . . . . . . . . . ............. 7
Removal . . . . . . . . . . . . . . ............. 3
Disass'embly . . . . . . . . . . . . ............. 5
Cleaning and Inspection . . . . . .............. 8
Reassembly . . . . . . . . . . . . ............. 9
Installation . . . . . . . . . . . ............. 12
Brake Adjustment and Bleeding . . .............. 14
Burnishing . . . . . . . . . . . . ............. 19
DRESSER MARKETING DIVISION EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048

' 0484,
I NOTE: Toroue Values listed throughout thls manual are Lubrlcated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size
Foot Pounds
Grade 5
GI ? 8
Newton Meters
1
(Ft. Lbs.) (Nml (Ft. Lbs.) (NN
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 21 37 38 52
7/16 . 14 38 52 54 73
7/16 . 20 42 57 60 81
1/2 . 13 58 79 82 111
1/2. ' 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 . 18 130 176 185 251
3/4 . 10 205 278 2 90 393
3/4 . 16 230 312 320 434
718 . 9 305 414 455 617
7/8 . 14 335 454 I 515 698
1 . 8 455 617 695 942
1 . 14 510 69 1 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 . 12 955 1295 1550 2102
1 318 . 6 1130 1532 1830 248 1
1 3/8 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 ' 12 1690 2291 2730 370 1
1 3/4 . 5 2 370 3213 3810 5166
2 . 4 1/2 3 550 4813 5760 7810
FILE K
SPECIAL TOOLS
L 3 ”
46
-1 -
FILE K
-2-
FILE K
7
REMOVAL
Figure 1
Disconnect wire ( 1 ) from flow switch assembly ( 2 ) .

Remove n u t ( 3 ) and wire ( 4 ) from terminal.
Remove capscrew and 1 ockwasher ( 5 ) and solenoid assembly- ( 6 ) from power head
assembly ( 7 ) .
NOTE: Secure solenoid out of way f m ease of removal and instaZZation of
power brake assembly.
Disconnect brake 1 ine ( 8 and 9 ) from unions ( 1 0 and 11 ) and cap 1 ines. Remove
unions from master brake cycl inder ( 1 2 ) .
Loosen clamp ( 1 3 ) and remove hos2 ( 1 4 ) from flow switch assembly ( 2 ) a n d p l u g
hose.
-3-
FILE K
7
Figure 2
Unscrew push rod ( 1 ) from brake linkage ( 2 ) .
Remove 1 i ne ( 3 ) from union ( 4 ) and plug 1 i ne. Remove union from power head
assembly ( 5 ) .
Remove four nuts and lockwashers ( 6 ) two capscrews ( 7 ) and power head assembly
( 5 ) from mounting bracket ( 8 ) .
- 4-
FILE K
D ISASSEM BLY
The following procedure i s only one method o f obtaining a complete disassembly of the
master brake cylinder and power head assembly.
Remove four capscrews and lockwashers ( 1 ) 4

move g r o u n d i n g bracket ( 2 ) o u t of the way
and p u l l master cylinder (. 3 .) . away from
power booster assembly ( 4 ) .
NOTE:.
"^.. See appropriate shop manual for
~~ ~
servicing of Deleo-Moraine power

booster assembly.
Figure 3
Swing b 3 i 1 wire ( 1 ) off of reservoir cover

( 2 ) and remove cover. Remove diaphragm ( 3 ) .
Drain brake f l u i d from reservoir.
Figure 4
- 5-
FILE K
Remove gasket ( 1 ) from master cy1 inder ( 2 ) .

Remove retainer ring ( 3 ) from master cy1 -
inder . Remove primary p i ston ( 4 ) .
NOTE: Depress p i s t o n ( 4 ) t o f a c i l i t a t e
removal o f r e t a i n i n g r i n g ( 3 ) .
YJ 8776
Figure 5
Remove primary seal ( 1 ) from primary piston

assembly ( 2 ) .
77
Figure 6
- 6-
Shop Manual Section K -6 ,
Remove b l eeders ( 1 ) and tube

f i t t i n g i n s e r t s ( 2 ) from master
cy1 inder ( 3 ) i f necessary.
Figure 8
-7-
FILE K
SHOP MANUAL SE CT ION 6
A. Clean a1 1 metal parts thoroughly using a sui table type cleaning

f l u i d . I t i s recommended t h z t parts be immersed in cleaning f l u i d
and moved u p and down slowly u n t i l a1 1 brake f l u i d and foreign ma-
a
t e r i a l i s dissolved and parts a r e thoroughly cleaned.
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE
TYPE CLEANERS.
B. Inspect housings, covers and pistons t o be certain they are

thoroughly cleaned and t h a t mating surfaces bore, e c t . , are f r e e
from nicks or burrs. Check a l l parts carefully f o r evidence of
cracks or conditions which would caiuse subsequent brake f l u i d
leaks or f a i l u r e s . If available, use magna-flux process f o r
checking f o r cracks, t h a t may n o t be v i s i b l e t o the naked eye.
C. Rep1 ace a1 1 seals , O-rings , and gaskets. I t i s economical when

unit i s disassembled t o replace parts t o prevent premature f a i l u r e .
Refer t o parts book f o r replacement items. Be extremely careful
when i n s t a l l i n g sealing members, t o avoid cutting or scratching.
C u r l i n g under o f any seal 1 i p will seriously impair i t s efficiency,
Apply a t h i n coat of brake f l u i d on the s e a l s and parts t o insure
proper i n s t a l l a , t i o n .
-8-
FILE K
REASSEMBLY
The following procedure i s only one method of obtaining a complete reassembly of t h e

master brake cylinder and power head assembly.
I n s t a l l tube f i t t i n g i n s e r t s ( 2 ) and
bleeders ( 1 ) in master cylinder ( 3 ) i f
Figure 9
I n s t a l l protector seal ( 6 ) , seal ( 3 ) ,

spring r e t a i n e r ( 2 ) , spring ( 1 ) and two
s e a l s ( 4 ) on secondary piston ( 5 ) . Posi -
tion piston assembly in master cylinder.
-9-
FlLE K
Instal 1 seal (1 ) on primary pi ston

assembly ( 2 ) .
‘77
Figure 11
Slide primary piston ( 4 ) into master cy-

1 inder ( 2 ) . Instal 1 r e t a i n e r ring ( 3 )
and gasket ( 1 ) on master cylinder.
NOTE: I t may be helpfuZ t o depress
p i s t o n t o make retainer ring
(3) easier t o i n s t a l l .
A DO NOT PINCH LIPS OF SEALS

WHEN POSITIONING IN POWER
HEAD.
w 8776
Figure 1 2
I n s t a l l diaphragm ( 3 ) i n cover ( 2 ) place
an5
Figure 13
- 1 0-
Shop Manual Section, K - 6
Position master cylinder ( 3 ) against

power head assembly ( 4 ) . Swing
g r o u n d i n g bracket ( 2 ) back i n place
and ins t a l 1 four capscrews and
lockwashers (1 ) in power head
assembly ( 4 ) .
Tighten capscrews from 99
t o 135 i n . Zb. torque.
Figure 1 4
-11-
FILE K
INSTALLATION
Figure 1 5
Position power head assembly ( 5 ) against mounting bracket ( 8 ) and i n s t a l l

two capscrews ( 7 ) and four lockwashers and nuts ( 6 ) .
Instal 1 union ( 4 ) on power head assembly ( 5 ) . Unpl ug 1 ine ( 3 ) and connect
t o union.
Connect push rod (1 ) t o break 1 inltage ( 2 ) .
-1 2-
FILE K
Figure 1 6
Unplug hose ( 1 4 ) and s l i d e on flow switch assembly ( 2 ) and tighten clamp ( 1 3 ) .

I n s t a l l unions (10 a n d 11 ) on master brake cylinder ( 1 2 ) and connect l i n e s
( 8 and 9 ) t o unions.
Position solenoid assembly ( 6 ) against power head assembly ( 7 ) and i n s t a l l

capscrew and lockwasher ( 5 ) .
Connect wire ( 4 ) t o terminal and i n s t a l l n u t ( 3 ) .
Connect wire ( 1 ) t o flow switch assembly ( 2 ) .
-1 3-
FILE
SHOP MANUAL SECTION
BRAKE ADJUSTMENT & BLEEDING
Anytime t h a t the brakes a r e spongy o r t h a t t h e brake l i n e s o r cylinders have mainte-

nance performed i n v o l v i n g them such as replacement o f / o r repairing l i n e s , shoes, c y l i n -
ders, a x l e s , e t c . the system stands a chance of being exposed, or has been exposed t o
t h e atmosphere. The following procedure must be followed t o ensure proper brake shoe
adjustment and/or bleeding.
-14-
FILE K
.005 INCH CLEARANCE

THROUGHOUT ARC
UPPER BRAKE SHOE

CCENTRIC CAM ADJUSTMENT
ANCHOR PIN LOCK N U

LEEDER V A L V E
ANCHOR PIN
LOWER BRAKE SHO

BRAKE DRUM

THROUGHOUT ARC
Figure 18
4. Loosen anchor p i n lock n u t .

5. Each shoe must be adjusted t o center brake shoe arc i n relation t o the drum.
Adjust eccentric cam t o b r i n g linings into contact with the drum and r o t a t e
anchor p i n s u f f i c i e n t l y t o relieve d r a g . Repeat u n t i l additional r o t a t i o n of
anchor pin w i l l no longer relieve dra.g. Tighten anchor p i n lock n u t leaving
.005" clearance thru e n t i r e arc of brake shoe.
NOTE: Subsequent adjustments t o compensate f o r Zining wear are made with the
eccentric cam only. Turn cam t o bring l i n i n g t o w i t h i n .005" of drum.
Repeat on opposite shoe.
- 1 5-
P’ ..
Shop Manual Section,
B. BLEEDING
6. After brake shoes a r e centered, anchor pins locked and a .005” clearance main-
tained. Back eccentric cam off on a l l upper brake shoes as f a r as possible.
This helps t o reduce the a i r pocket i n the wheel cylinder due t o i t s mounting
in a v e r t i c a l position.
7. Swing bail wire ( 3 ) t o one side and

remove cover ( 1 ) from master brake
cy1 inder ( 2 ) .
Figure 19
8. Position adaptor ( 1 ) on master

cy1 inder ( 2 ) and attach bleeder
b a l l hose ( 3 ) t o a d a p t o r . See
special t o o l s in t h i s manual f o r
manufacturing of adaptor.
Figure 20
9. W i t h valve on bleeder ball closed bring pressure i n ball up t o 1 5 P S I . Open

valve on bleeder b a l l .
-1 c-
FILE K
10. Start bleeding brake l i n e s i n the following order: Left Rear

R i g h t Rear
Left Front
R i g h t Front
Open bleeder valve (See Fig. 18) a t wheel cy1 inder until a l l a i r i s expelled
from the 1 ine and then close. Do t h i s a t each wheel . After bleeding i s com-
pleted turn off bleeder ball valve.
NQTE: Divert fZow of brake fZuid away from drwns and Zinings while bleed-hg.
11. S t a r t crane and pump brakes f o r approximately one minute.
12. Open bleeder ball valve and bleed brake 1 ines again as in step 10.
13. Adjust upper brake shoes w i t h eccen-

t r i c cam ( 1 ) t o .005" clearance again.
C1 ose bleeder ball valve when t h r o u g h .
Figure 21
14. S t a r t crane and pump brakes. Free travel should be from 1/16" t o 1/4" maximum.
Solid pedal must be from 2 1 / 2 " t o 3 1 / 2 " maximum. If brake pedal i s beyond
these l i m i t s repeat step 6 and steps 10 thru 1 3 .
15. With crane s t i l l u p on blocking s t a r t crane. Place in gear, engage four wheel
drive and t e s t brakes.
- 17-
Shop Manual Section K - 6
16. Disconnect bleeder b a l l hose

( 3 ) and remove adaptor ( . l )
from master cylinder ( 2 ) .
Figure 2 2
17. Position cover ( 1 ) on master

cy1 inder ( 2 ) and swing b a i l
wire ( 3 ) into place.
Figure 23
18. Wipe a l l excess brake f l u i d from l i n e s . Have one person s t a r t crane and
apply brakes while another looks f o r leaks. I f a leak i s spotted r e p a i r
and repeat e n t i r e bleeding procedure.
-18-
Shop Manual Section K -6
BURNISHING
New linings (brake shoes) may require "burnishing" t o achieve desired

performance. Also when brake lines a r e bled i t is important t o get rid of
brake f l u i d t h a t may have gotten i n t o linings and brake drum. The
following steps should be used t o ensure proper burnishing.
Figure 24
3.
A DO NOT ALLOW OUTSIDE DRUM TEMPERATURES TO EXCEED 300'
TO 350°F.
Allow drums t o cool from 150" t o 200°F before repeating. The number of
cycles should be based on achieving an acceptable performance level. I t
is estimated t h a t a t l e a s t f i v e cycles would be required t o show marked
brake improvement.
A IMPROPER BURNISHING COULD RESULT IN "GLAZING". SINCE

THE MAXIMUM TEMPERATURE LIMITS ARE SOMEWHAT CRITICAL, AND
DIFFICULT TO DETERMINE, EXTREME CARE MUST BE EXERCISED.
-19-
MATERIAL LIFT 0
GRADER 0
TECHNICAL SERVICES~ PLANER 0
ROLLER 0
CRANE
SHOP M A N U A L K- 6.58
R1
B E N D I X M A S T E R BRAKE CYLINDER 1 .
APPLICABLE M O D E L / S SERIAL N U M B E R / S
150A with Rockwell Axle 08340 & Up
150FA with Rockwell Axle 08340 & Up
180s 08502 & Up
220s 07724 & Up
I ALLC A COMPONENTS
U T MUST ' O N
BE PROPERLY SUPPORTED DURING
1
WORKING ORDER.

INJURY.
CONTENTS Page
SpecialTools . . . . . . . . . . . . . . . . . . . . . . . . 1
Removal
Removal from 150A and 150FA . . . . . . . . . . . . . . . . 3
Removal from 180s and 220s . . . . . . . . . . . . . . .. 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .. 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation
Installation on 150A and 150FA . . . . . . . . . . . . . . 14
Installation on 180s and 220s . . . . . . . . . . . . . . . 16
Bleeding Procedure - 180s and 220s . . . . . . . . . . . . . 17
Brake Adjustment - 180s and 220s . . . . . . . . . . . . . . 20
Burnishing - 180s and 220s . . . . . . . . . . . . . . . . . 21
Brake Adjustment and Bleeding for 150A and 150FA . . . . . . 22
Burnishing - 150A and 150FA . . . . . . . . . . . . . . . . . 25
Dresser Industries, Inc. Construction Eauiprnent Division P.O. Box 647 Galion, OH 44833 U S A .
(419).468-4321
0484
~. . ~. .., Shop. Manual Section K-6.50
SPECIAL TOOLS
The a d a p t o r plate i s used in conjunction w i t h a bleeder ball t o bleed the

brake lines on the unit.
MANUFACTURING DETAILS:
tW
K
6
CONT'D. ON NEXT PAGE

..
-1-
Shop Manual Section K-6.50
INSTALLATION:
After reservoir cover has been
removed, f i l l reservoir (1, Figure
1 ) w i t h brake f l u i d . Position
Gasket ( 2 ) and adaptor plate ( 3 ) on
reservoir. Use two pieces of
3/16 In. threaded rod ( 4 ) 18.00 In,
(457.20 mm) long bent i n a "U" shape
w i t h four hex nuts ( 5 ) t o hold
gasket and adaptor plate in
position. Attach bleeder ball hose
( 6 ) t o elbow.
Figure 1
- 2-
Shop Manual Section K.6.50
REMOVAL FROM 1 5 0 A A N D 150FA

The f o l l o w i n g p r o c e d u r e i s o n l y one method o f o b t a i n i n g a removal o f t h e
Bendix H y d r a u l i c Power Brake Assembly f r o m t h e c r a n e .
Park u n i t on a l e v e l s u r f a c e and p l a c e b l o c k i n g i n f r o n t o f and b e h i n d
each t i r e . T u r n key o f f .
Figure 2
~ NOTE:
.. . I f the u n i t is equipped with a Bendix Master CyZinder, the removaZ
procedure w i Z Z be the same as t h i s one shown f o r the DeZco Moraine
Master Cy Zinder.
D i s c o n n e c t w i r e ( 1 , F i g u r e 2 ) f r o m f l o w s w i t c h assembly ( 2 ) .
Remove n u t ( 3 ) and w i r e ( 4 ) f r o m t e r m i n a l .
Remove capscrew and l o c k washer ( 5 ) and s o l e n o i d assembly ( 6 ) f r o m power
head assembly ( 7 ) .
NOTE::
. -.. Secure soZenoid out o f way for ease of removaZ and instaZZation of
power brake assembZy.
D i s c o n n e c t b r a k e l i n e ( 8 and 9 ) f r o m u n i o n s ( 1 0 and 1 1 ) and cap l i n e s .
Remove u n i o n s f r o m m a s t e r b r a k e c y l i n d e r ( 1 2 ) .
Loosen clamp ( 1 3 ) and remove hose ( 1 4 ) f r o m f l o w s w i t c h assembly ( 2 ) and
p l u g hose.
- 3-
Figure 3
Unscrew push rod ( 1 , Figure 3) from brake linkage ( 2 ) .

Remove l i n e ( 3 ) from union ( 4 ) and plug l i n e . Remove union from power head
assembly ( 5 ) .
Remove f o u r nuts and lockwashers ( 6 ) two capscrews ( 7 ) and power head
assembly ( 5 ) from mounting bracket ( 8 ) .
- 4-
REMOVAL FROM 180s AND 220s
The following procedure i s only one method of obtaining a removal o f the

Bendix Hydraulic Power Brake Assembly from the crane.
Park unit on a level surface a n d place blocking in front of a n d behind
each t i r e . Turn key o f f .
Figure 4
P u l l wire terminal ( 1 , Figure 4 ) off flow switch ( 2 ) .

Remove hex n u t and lock washer ( 3 ) , and two wires ( 4 ) from solenoid terminal,
Remove two capscrews and lock washers ( 5 ) , and solenoid bracket ( 6 ) from
power brake assembly ( 7 ) . Reinstall two lock washers and capscrews, a f t e r
bracket has been removed.
Disconnect two brake lines ( 8 ) from power brake assembly. Cap and p l u g brake
l i n e s and power brake assembly t o prevent contamination of the system.
Loosen hose clamp ( 9 ) and p u l l hose (10) off flow switch. Disconnect
remaining hose from power brake assembly. P l u g and cap hoses and power
brake assembly.
C O N T ' D . NEXT PAGE - 5-
Loosen jam n u t ( 1 1 , Figure 4 ) and unscrew push rod ( 1 2 ) from adjuster (13).
Remove jam n u t from push rod.
NOTE: BefoIOe Zoosening jam nut, measure the amount o f exposed threads
on push rod and record.
Remove two hex nuts, lock washers and capscrews ( 1 4 ) from mounting
bracket (15) and power brake assembly. Remove two remaining hex nuts
and lock washers from studs. Remove power brake assembly from bracket.
- 6-
DISASSEMBLY
The f o l l o w i n g procedure i s only one method o f obtaining a disassembly

of the master brake cylinder.
Remove four capscrews a n d lock

washers ( 1 , Figure 5 ) and separate
Swing bail wires ( 1 and 2 , Figure

6) t o the s i d e . Remove reservoir
cover ( 3 ) from reservoir ( 4 ) . Drain
brake f l u i d from reservoir.
Remove gasket ( 5 ) from cover. 1
Remove four capscrews ( 6 ) and
reservoir from body ( 7 ) .
Figure 6
-7-
Remove two valve stems and springs

( 1 , Figure 7 ) , O-ring ( 2 ) a n d p i n
( 3 ) from body (4).
Figure 7
Remove two compress ion seals ( 1 ,

Figure 8) from reservoir ( 2 ) .
Remove bai 1 wires ( 3 and 4 ) from
reservoir i f replacement i s
necessary.
Figure 8
Using s u i t a b l e a d a p t o r , position
body ( 1 , Figure 9 ) in an arbor press
as shown. Apply pressure t o
primary piston ( 2 ) and remove
retaining ring ( 3 ) . Relieve pres-
sure a n d remove piston from body.
Figure 9
- 8-
-__
Remove secondary piston ( 1 , Figure

1 0 ) and spring ( 2 ) from body ( 3 ) .
s i i d e out.
Remove spring from piston.
Figure 10
Figure 11
-9-
A. Clean a l l metal parts thoroughly using a s u i t a b l e type cleaning f l u i d .

. .
I t i s recommended t h a t parts be immersed in cleaning f l u i d and moved
u p and down slowly until a l l brake f l u i d a n d foreign material i s
dissolved and parts are thoroughly cleaned.
A CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE

TYPE CLEANERS .
B. Inspect housing, covers and pistons t o be certain they are thoroughly
cleaned and t h a t mating surfaces bore, e t c . , a r e f r e e from nicks or
burrs. Check a l l parts carefully for evidence o f cracks or conditions
which would cause subsequent brake f l u i d leaks or f a i l u r e s . I f
available, use magna- flux process for checking for cracks t h a t may
not be v i s i b l e t o the naked eye.
C. Replace a l l s e a l s , O-rings, and gaskets. I t i s economical when unit
unit i s disassembled t o replace parts t o prevent premature f a i l u r e .
Refer t o parts book for replacement items. Be extremely careful
when i n s t a l l i n g sealing members, t o avoid cutting or scratching.
Curling under of any seal l i p will seriously impair i t s efficiency.
-10-
REASSEMBLY
The following procedure i s only one method of obtaining a reassembly of the

master brake cy1 inder.
I n s t a l l O-rings ( 1 thru 3 , Figure

1 2 ) on primary piston ( 4 ) and
secondary p i ston ( 5 ) .
NOTE: Coat O-rings with brake
f Zuid t o aid i n s t a ZZation.
Figure 1 2
Position spring ( 2 , Figure 13) i n

secondary piston ( 1 ) . Slide second-
ary piston i n t o body ( 3 ) .
NOTE: Use a wooden hammer handle
to heZp push p i s t o n i n to
body. Be sure t h a t spring
remains i n p i s t o n . Coat
p i s t o n w i t h brake f l u i d t o
aid i n s t a l Zation.
-11-
Figure 15
Figure 16
- 1 2-
P o s i t i o n r e s e r v o i r (1, F i g u r e 1 7 )
a g a i n s t body ( 2 ) and i n s t a l l f o u r
capscrews ( 3 ) .
I n s t a l l gasket i n cover (4).
P o s i t i o n c o v e r on r e s e r v o i r and
s w i n g b a i l w i r e s ( 5 and 6 ) i n t o
place.
BE SURE THAT VALVE

STEMS ARE PROPERLY
SEATED AFTER RESER-
V O I R I S POSITIONED
AGAINST BODY.
Figure 1 7
Figure 18
- 1 3-
INSTALLATION ON 150A AND 150FA.
The following procedure i s only one method of obtaining an i n s t a l l a t i o n

o f the Bendix Power Brake Assembly on the crane.
~
Figure 1 9
Position power head assembly ( 5 , Figure 1 9 ) against mounting bracket (8) and
i n s t a l l two capscrews ( 7 ) and four lockwashers and nuts ( 6 ) .
I n s t a l l union ( 4 ) on power head assembly ( 5 ) . U n p l u g 1 ine ( 3 ) and connect
t o union.
Connect push rod ( 1 ) t o break 1 inkage ( 2 ) .
-1 4-
Figure 20
Unplug hose (14, Figure 20) and slide on flow switch assembly (2) and tighten
clamp (13).
Install unions (10 and 11) on master brake cylinder (12) and connect lines
(8 and 9) to unions.
Position solenoid assembly (6) against power head assembly (7) and install
capscrew and lockwasher ( 5 ) .
Connect wire (4) to terminal and install nut (3).
Connect wire (1 ) to flow switch assembly ( 2 ) .
- 1 5-
INSTALLATION ON 180s AND 220s
The following procedure is only one method of obtaining an i n s t a l l a t i o n o f

the Bendix Power Brake Assembly on the crane.
Figure 2 1
P o s i t i o n power brake assembly ( 7 , Figure 2 1 ) against mounting bracket (15).

I n s t a l l two capscrews, lock washers and hex nuts (14). I n s t a l l two lock
washers and hex nuts on studs.
Instal 1 jam n u t (11 ) on push rod ( 1 2 ) . Screw push rod in t o adjuster ( 1 3)
and tighten jam n u t .
NOTE: After jam nut is tightened, the amount of exposed threads on push rod
must equaZ measurement taken during remouaZ. Readjust if necessary.
Unplug and uncap hoses and power brake assembly. Slide hose (10) on flow
switch ( 2 ) and tighten hose clamp ( 9 ) . Connect remaining hose t o power
brake assembly.
Remove two capscrews and lock washers ( 5 ) from power brake assembly. Position
solenoid bracket ( 6 ) against power brake assembly, and r e i n s t a l l two lock
washers and capscrews,
I n s t a l l two wires ( 4 ) , lock washers and hex nuts ( 3 ) on solenoid terminal.
Connect wire terminal ( 1 ) t o flow switch.
- 1 6-
Shop M a n u a l S e c t i o n K-6.50
BLEEDING PROCEDURE - 180s AND 220s
Any time t h a t the brake lines or cylinders have maintenance performed involving
replacement o f / o r repairing 1 ines, shoes, cylinders, axles e t c . , the sytem
stands a chance of being exposed t o the atmosphere. The following procedure
must be followed t o ensure proper bleeding.
1. Fully extend outrigger jack cyl-

inder ( 1 , Figure 2 2 ) and posi-
tion 30 I n . (762.00 mm) of
blocking ( 2 ) under outrigger box
( 3 ) as shown, Lower crane, t i l 1
outrigger box i s resting on
blocking. Leave s u f f i c i e n t
room in f r o n t of a n d behind
crane t o stop i n case i t should
accidentally be knocked o f f
blocking.
2. Place transmission in neutral
a n d s e t parking brake.
Figure 22
3. Swing bail wires ( 1 and 2 ,

Figure 23) t o the side a n d re-
move reservoir cover ( 3 ) from
the master brake cylinder ( 4 ) .
4. Position gasket and a d a p t o r
p l a t e on master brake cy1 inder
using the U-bo1 t s t o h o l d i t in
place. Connect bleeder b a l l t o
a d a p t o r plate.
NOTE: Refer t o ttSpeciaZ TooZs" sec-
t i o n of t h i s manual f o r the
manufacturing of adaptor
p l a t e , gasket and U-bolts,
and instaZlation. Be sure
bleeder b a l l is f u l l .
Figure 23
5. W i t h valve on bleeder ball
closed bring pressure in
b a l l u p t o 1 5 PSI ( 0 . 1 0 MPa).
Open valve on bleeder b a l l .
- 1 7-
6. S t a r t bleeding brake lines in the following order:

1. Left Rear Wheel
2. Right Rear Wheel
3. Left Front Wheel
4. R i g h t Front Wheel
5. Parking Brake
7. Remove cap (1 , Figure 24) from

bleeder screw ( 2 ) a t brake cyl-
inder. Open bleeder screw until
a1 1 a i r i s expelled from the
l i n e then close. Do t h i s a t
each wheel.
NOTE: Divert flow of brake f l u i d
away from drums and Zinings
while bleeding.
Figure 24
8. Loosen tube/hose f i t t i n g ( 1 ,
Figure 25) until a l l a i r i s ex-
pelled from the l i n e then t i g h t -
en. Loosen p l u g ( 2 ) on bottom
side o f parking brake ( 3 ) t o
expel a i r , then tighten.
NOTE: Divert flow of brake f h i d
away from pads and disc (4).
9. T u r n o f f bleeder b a l l valve.
10. Remove a d a p t o r plate and gasket
from master brake cylinder.
Reinstal 1 reservoir cover on
cy1 inder.
Figure 25
- 1 8-
11. S t a r t crane and pump brakes for approximately one minute. Operate the
parking brake several times. Shut- down engine.
12. Reconnect a d a p t o r plate t o master brake cylinder and repeat bleeding
procedure t o t h i s p o i n t once again. Remove a d a p t o r plate when through
and r e i n s t a l l reservoir cover.
13. With crane s t i l l up on blocking s t a r t engine. S h i f t transmission in t o
"LOW" and t e s t brakes. Shutdown engine.
-NOTE: m e n the transmission is in "LOW", four wheeZ drive is engaged.
14. Wipe a l l excess brake f l u i d from l i n e s . Have one person s t a r t crane

and apply brakes while another looks f o r leaks. I f a leak i s spotted,
repair a n d repeat e n t i r e bleeding procedure.
15. S t a r t crane and remove blocking from under outrigger box.
16. The brake shoes should be burnished a f t e r "Bleeding Procedure" i s
compl eted.
-19-
- Shop Manual Section K.6.50
1. Remove two dust cover plugs ( 1 ,

Figure 26) a n d two inspection
plugs ( 2 ) from dust cover ( 3 ) .
2. Insert a 0.010 I n . ( 0 . 2 5 mm)
f e e l e r gauge t h r o u g h the inspec-
tion hole(s) t o check clearance.
Clearance must be the same on
b o t h sides.
3. Using a brake spoon, turn each

s t a r wheel as many "CLICKS" as
necessary t o obtain 0.010 I n .
t o 0.020 I n . ( 0 . 2 5 mm t o 0.50
mm) clearance between brake 1 i n -
ings and drum. S t a r wheels turn
in opposite directions (see
Figure 2 7 ) .
,NOTE: Brake spoon may have t o be
modified t o obtain easy
access t o s t a r wheels.
DO NOT touch adjustor
b o l t (4).
4. After proper clearance i s

obtained on each side, i n s t a l l
two dust cover plugs ( 1 , Figure
26) and two inspection plugs ( 2 )
i n dust cover ( 3 ) .
5. During normal operation the
brake shoes automatically
adjust.
Figure 2 7
- 20-
BURNISHING - 180s AND 220s

performance. Also when brake l i n e s a r e bled i t i s important t o burnish t o
get r i d of brake f l u i d t h a t may have gotten on t o linings and brake drum.
The following steps should be used t o ensure proper burnishing.
1. Fully extend outrigger jack cylinders ( 1 , Figure 28) and position 30 In.
(762.90 mm) of blocking ( 2 ) under outrigger box ( 3 ) as shown. Lower
crane, t i l l outrigger box i s resting on blocking. Leave s u f f i c i e n t
room i n f r o n t of and behind crane t o stop i n case i t should accidentally
be knocked off blocking.
2. Using "FIRST GEAR" , and placing transmission i n " LOW" , apply enough
brake pressure t o s l i p a l l four wheels against the engine torque
(near maxi mum) .
'NOTE:' Parking brake must be released.
- DO NOT ALLOW OUT-

SIDE DRUM TEMPERA-
TURE TO EXCEED 300"
TO 350°F (157" TO
177°C).
3. Allow drums t o cool from 150" t o
200°F (66" t o 93°C) before
repeating. The number of cycles
should be based on achieving
an acceptable performance 1 eve1 .
I t i s estimated t h a t a t l e a s t
f i v e cycles would be required
t o show a marked brake
improvement.
Figure 28
IMPROPER BURNISHING COULD RESULT IN "GLAZING". SINCE THE MAXI-
MUM TEMPERATURE LIMITS ARE SOMEWHAT CRITICAL AND DIFFICULT TO
DETERMINE, EXTREME CARE MUST BE EXERCISED.
4. After "Burnishing Procedure" i s completed remove blocking from under
outrigger box.
-21-
BRAKE ADJUSTMENT A N D BLEEDING FOR 1 5 0 A A N D 150FA
Any time t h a t the brakes are spongy or t h a t the brake lines o r cylinders
have maintenance performed involving them such as replacement o f / o r
repairing l i n e s , shoes, cylinders, axles, e t c . , the system stands a
chance of being exposed, or has been exposed t o atmosphere. The following
procedure must be followed t o ensure proper brake shoe adjustment
and/or bleeding.
A. BRAKE ADJUSTMENT
1. Position crane on outriggers ( 1 ,
Figure 29) with a l l four wheels
off the ground. Place blocking
( 2 ) under outrigger frame ( 3 ) .
Leave s u f f i c i e n t room in front
o f and behind crane t o stop in
case i t should accidentally be
knocked o f f blocking.
2. Place transmission in neutral,
release parking brake and rear
axle disconnect i f engaged.
3. Remove upper & 1 ower d i r t
shields from each drum. Figure 29
- 22-
,005 I N C H C L E A R A N C E
T H R O U G H O U T ARC
U P P E R B R A K E SHOE C C E N T R I C CAM ADJUSTMENT
.ANCHOR P I N L O C K N U T
BLEEDER VALVE
ANCHOR P I N
LOWER B R A K E SHO BRAKE DRUM

T H R O U G H O U T ARC
Figure 30
4. Loosen anchor p i n lock n u t .
5. Each shoe must be adjusted t o center brake shoe a r c i n relation t o the
drum. Adjust eccentric cam t o b r i n g linings i n t o contact w i t h the drum
and r o t a t e anchor p i n s u f f i c i e n t l y t o relieve drag. Repeat until
additional rotation o f anchor p i n will no longer relieve drag. Tighten
anchor pin lock n u t leaving .005--In. (.1270'mm) clearance thru e n t i r e
a r c of brake shoe.
INOTE: Subsequent adjustments to compensate f o r Lining wear are made with
the eccentric e m o n l y . Turn e m to bring lining to within .005 In.
( . 1 2 7 0 mmi of drum. Repeat on opposite shoe.
-23-
Shop M a n u a l S e c t i o n K.6.50
B. BLEEDING
6. After brake shoes are centered, anchor pins locked and a .005 I n . ( . 1 2 7 0 mm)
clearance maintained. Back eccentric cam off on a l l upper brake shoes as
f a r as possible. This helps t o reduce the a i r pocket in the wheel
cylinder due t o i t s mounting in a vertical position.
7. Attach the a d a p t o r plate t o the Bendix Master Cylinder as outlined in
the Special Tool section of t h i s manual.
8. With valve on bleeder b a l l closed bring pressure in b a l l u p t o 1 5 PSI.
Open valve on bleeder b a l l .
9. S t a r t bleeding on brake lines in the following order: Left Rear
Right Rear
Left F r o n t
Right Front
Open bleeder valve (See Figure 30) a t wheel cylinder until a l l a i r i s
expelled from the l i n e and then close. Do t h i s a t each wheel. After
bleeding i s completed turn off bleeder ball valve.
NOTE: Divert f l o w o f brake fluid may from drwns and l i n i n g s while bleeding.
10. S t a r t crane and pump brakes for approximately one minute.

11. Open bleeder valve and bleed brake lines again as in s t e p 9 .
12. Adjust upper brake shoes with
eccentric cam ( 1 , Figure 31 ) t o
.005 I n . ( .1270 mm) clearance
again. Close bleeder b a l l
valve when t h r o u g h .
13. S t a r t crane and pump brakes.
Free travel should be from
1 / 1 6 I n . t o 1 / 4 I n . maximum.
Solid pedal must be from 2 1 / 2
I n . t o 3 1 / 2 I n . maximum. I f
brake pedal i s beyond these
1 imits repeat s t e p 6 and steps
9 thru 1 2 .
14. With crane s t i l l on blocking

s t a r t crane. Place in gear,
engage four wheel drive and Figure 31
t e s t brakes.
15. Disconnect bleeder ball hose and remove a d a p t o r from master cylinder.
16. Position cover on master cylinder a n d swing bail wires into place.
17. Wipe a l l excess brake f l u i d from l i n e s . Have one person s t a r t crane a n d
a p p l y brakes while another looks for leaks. I f a leak i s spotted repair
and repeat e n t i r e bleeding procedure.
- 24-
Shop Manual Section K-6-50
BURNISHING - 150A AND 150FA

performance. Also when brake lines are bled i t i s important t o burnish t o
get r i d of brake f l u i d t h a t may have gotten into 1 inings and brake drum.
The following steps should be used t o ensure proper burnishing.
Position crane up on outriggers
( 1 , Figure 32) with a l l four
wheels off the ground. Place
blocking ( 2 ) under outrigger
frame ( 3 ) . Leave s u f f i c i e n t
room in front of and behind
crane t o stop in case i t should
accidentally be knocked off
blocking.
2. Using FIRST GEAR (or low range)
apply enough brake l i n e pres-
sure t o s l i p a l l four wheels in
against the engine torque (near
maximum).
.-
Figure 32
DO NOT ALLOW OUTSIDE DRUM TEMPERATURES TO EXCEED 300" TO
350°F (157" TO 177°C.).
3. A1 low drums t o cool from 150" t o 200°F (66" t o 93°C) before repeating.
The number of cycles should be based on achieving an acceptable
performance level. I t i s estimated t h a t a t l e a s t f i v e cycles would
be required t o show marked improvement.
A IMPROPER BURNISHING COULD RESULT IN "GLAZING". SINCE THE

MAXIMUM TEMPERATURE LIMITS ARE SOMEWHAT CRITICAL, A N D
DIFFICULT TO DETERMINE, EXTREME CARE MUST BE EXERCISED.
- 25-
MATERIAL LIFT 0
GRADER I 3
DRESSER PLANER M
ROLLER 0
CRANE d
SHOP MANUAL K-07.00

RVC2
MINNESOTA BRAKE VALVE
T-400-A 01746 thru 02110

T-500-A 07740 thru 07994
T-500-L 07740 thru 07994
T-600-B 02497 thru 02535
T-500-C 07995 thru 10739
T-500-M 07995 thru 10487
T-600-C 02536 thru 03099
RP-30/42 01001 t h r u 01123
80 07324 thru 08356
90 t h r u 125 07324 thru 08339
90-A t h r u 125-A 07324 thru 08339
125-F 07324 thru 08339
125-FA 07990 thru 08339
140-F 07571 thru 08339
150-A 07324 thru 08339
150-FA 07324 thru 08339
200- FA 09401 thru 08339
. 220-A 07113 thru 08339
CAUTION

ORDER.
CONTENTS ON BACK OF COVER
DRESSER INDUSTRIES, INC. EAST SUNNYSIDE AVE. LIBERTYVILLE, IL 60048

0786 c2
CONTENTS PAGE
General Torque Values ........................ ........ i

Removal from Machine .................................. 1
Disassembly o f Reservoir .............................. 2
Reassembly of Reservoir Section ....................... 3
Disassembly o f Power Assist Section ................... 4
Reassembly o f Power Assist Section .................... 5
I n s t a l l a t i o n of Brake Valve on Machine ................ 8
Brake Bleeding Procedure .............................. 10
c2
K-07.00

The f o l l o w i n g General Torque V a l u e s must be used i n a1 1 cases where SPECIFIC
TORQUE VALUES a r e n o t g i v e n .
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET)
THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED (DRY)
THREADS.
HEATED MATERIAL GRADE 5 & GRADE 8
GRADE 5 GRADE a
THREAD S I Z E (3 RADIAL DASHES ON HEAD) ( 6 RADIAL DASHES ON HEAD)
FOOT POUNDS NEWTON METER FOOT POUNDS NEWTON METE1

(FT. LBS.) (Nm) (FT. LBS.) (NN
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/21' - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 2 78 290 393
3/4" - 16 230 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 335 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1500 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
c2
i
K-07.00
NOTES
c2
ii
FILE- __
SHOP MANUAL SECTION
REMOVAL OF BRAKE IVALVE FROM MACHINES
Remove brake valve from machine by disconnecting necessary fluid lines, disconnecting
push rod and removing mounting bolts.
Drain fluid from unit.
Capacity: approximately 1 U.S. pint (0.47 liters)
Figure 1 Figure 3
FP-30 T-600B
Figure 2 Figure 4
T-500A L T-400A
-1 -
FILE K
Figure 4A Figure 4B
T-SOOC, T-500M 6 T-600C RP-60
-1 A- c2
FILE
9241
0 1. GASKET, f i l l e r cap 22. COVER ,end

2. CAP, f i l l e r .23. O-RING
0 3. SEAL, V - CUP 24. PISTON, power
0 4. PISTON, reaction m25. O-RING
0 5. PISTON, master cylinder 26. RETAINER, return spring
0 6. u-CUP 27. SPRING
7. PLUG, r e t a i n e r 28. SPRING, return
8. O-RING (or copper r i n g ) 29. PISTON, connector
9. SPRING 830. RING, r e t a i n e r
.lo. RING, r e t a i n e r 031. RING, r e t a i n e r
R11. WASHER, back-up 32. LOCK WASHER
812. RING, back-up 33. CAP SCREW
m13. SEAL , V - C U P 034. RETAINER, U - CUP
14. VALVE, relief/bypass 035. VALVE, check
15. BODY, power cylinder 36. SPRING, piston r e t a i n e r
16. RING, r e t a i n e r 37 * SEAT, Val ve
S17. BOOT 38. BODY, cylinder reservoir
18. PUSH ROD 039. CUP, secondary
19. PISTON, valve 40. ASSEMBLY, master cylinder piston
i20. RING, back-up 41. ASSEMBLY, power piston
821. SEAL, V - C U P
0 REPAIR KIT (D-125096)
U REPAIR KIT (D-125097)
-1 B-
FILE K
DISASSEMBLY OF RESERVOIR
Separate cy1 inder reservoir section (38)

from power a s s i s t section (15) by re-
moving three 3/8 - 16 x 1 1 / 4 capscrews
(33).
Figure 5
Remove r e t a i n e r ring (31) from cyljnder

reservoi r body (38).
NQTE: Beccdse of spring tension being
appZied t o back s i d e of r e t a i n e r
ring removaZ is b e s t accompZished
by applying a moderate m o u n t of
thumb pressure t o p i s t o n (5)
whiZe removing ring.
Figure 6
Inspect components inside cylinder res-

ervoir. Replace rubber s e a t s and s e a l s .
Replace f i l l e r cap gasket ( 1 ) .
Inspect housing, check valve (35) and
U-cup r e t a i n e r (34) f o r d i r t , e t c .
Figure 7
-2-
SHOP MANUAL
FILE
SECTION
-
K
I
REASSEMBLY OF RESERVOIR SECTION
Figure 8
Clean a l l parts thoroughly before reassembly.

I n s t a l l s e a t (37) and check valve (35) in bore of housing ( 3 8 ) . Attach
r e t a i n e r (34) t o small end of spring ( 3 6 ) . I n s t a l l assembly w i t h l a r g e end
of spring over check valve. Lubricate cup (39) with brake f l u i d and i n s t a l l
over r e t a i n e r . Note d i r e c t i o n o f cup. Lubricate V-cup s e a l s ( 3 ) with brake f l u i d
and i n s t a l l on reaction piston ( 4 ) . Note direction of s e a l s . I n s t a l l reac-
tion piston in master cylinder p i s t o n . Note direction o f cup. I n s t a l l assem-
bly i n housing. I n s t a l l r e t a i n e r ring (31) while adding a moderate amount of
t h u m b pressure. Instal 1 gasket ( 1 ) and f i l l e r cap ( 2 ) .
-3-
FILE K
ANUAL SECTION 7
DISASSEMBLY OF POWER ASSIST SECTION

Drain f l u i d from u n i t before disassembly.
Remove push rod and boot.
Remove outboard r e t a i n e r ring (16) from
around end cover ( 2 2 ) . Due t o spring
pressure being applied t o back s i d e of
end cover t h a t cannot be overcome by
t h u m b pressure, place in an arbor press,
apply enough pressure t o compress spring
and r e t a i n e r ring can then be removed.
Figure 9
Remove components inside housing bore

and inspect. Replace rubber s e a l s ,
damaged r e t a i n e r ring and rubber
O-rings t h a t appear t o have been worn,
etc.
Remove plug ( 7 ) , 0-r ing ( 8 ) , valve
stem ( 1 4 ) and spring ( 9 ) .
F i g u r e 10
Remove snap ring (10) , washer (1 1 ) back-

u p ring ( 1 2 ) and V-cup seal ( 1 3 ) .
F i g u r e 11
-4-
FILE K
REASSEMBLY OF POWER ASSIST SECTION
Figure 1 2
Clean a l l parts thoroughly before reassembly.
I n s t a l l valve stem ( 1 4 ) and spring ( 9 ) i n housing. I n s t a l l O-ring ( 8 ) or copper
ring ( 7 ) .
NOTE: I f an O-ring was found on plug replace w i t h an O-ring. I f a copper ring
was found on plug replace w i t h a copper ring.
I n s t a l l V-cup seal ( 1 3 ) , back-up ring ( 1 2 ) , washer (11) and snap r i n g ( 1 0 ) .

Lubricate V- ring s e a l s ( 2 1 ) with brake f l u i d and i n s t a l l on valve piston ( 1 9 ) .
Note direction of s e a l s . Lubricate O-ring (25) with brake f l u i d and i n s t a l l on
power piston ( 2 4 ) . I n s t a l l power piston on valve piston. Note direction of
pistons.
-5-
FILE K
Lubricate back-up rings ( 2 0 ) and i n s t a l l on valve piston behind V-cup s e a l s .

Install spring ( 2 7 ) on piston assembly. I n s t a l l connector piston ( 2 9 ) . If removed
lubricate O-ring (23) and i n s t a l l on end cover ( 2 2 ) . I n s t a l l components t o make up
assembly.
After components are reassembled on piston

position in arbor, as shown. Exert enough
pressure on spool t o overcome spring ten-
sion and i n s t a l l r e t a i n e r ring ( 3 0 ) .
Figure 13
Install return spring r e t a i n e r ( 2 6 ) .

Return spring (28) in housing.
I n s t a l l piston assembly. Once again use
arbor pressure t o i n s t a l l outboard re-
t a i ner r i ng .
, -.
Figure 1 4
I n s t a l l rubber b o o t ( 1 7 ) and p i s t o n plunger

(18).
Figure 15
Attach cylinder reservoir section (38) t o

power a s s i s t section ( 1 5 ) .
and lockwashers (33). Torque t o 30 FT.

LBS. (41 Nm) .
-7 -
SHOP MANUAL
INSTALLATION OF BRAKE VALVE O N MACHINE
Refill with Wagner Lockheed Brake Fluid 21B or equivalent meeting VV-B-680 s p e c i f i -
cations. Capacity: approximately 1 U.S. pint (0.47 l i t e r s ) .
Connect unit t o mounting flange with four 7/16" - 14 x 1 1 / 2 capscrews and torque t o
50 FT. LBS. Remove plugs; connect necessary f l u i d 1 ines and reconnect push rod.
F i g u r e 17 Figure 19
W-30 T-600B
F i g u r e 18 F i g u r e 20
T-500A G L T-400A
-8-
FILE K
...
Figure 21
T-SOOC, T-500M 6 T-600C
NOTE: Purge aZZ a i r from brake l i n e system a t transmission control v a l v e .
-9- c2
FILE K
SHOP MANUAL SECTIQN 7
BRAKE BLEEDING PROCEDURE
GRADERS AND RP-30
Charge bleeder ball t o 15 PSI (0.10 MPa) (minimum) and attach w i t h

s u i t a b l e adaptor t o master cylinder.
Bleed f l u i d a t transmission control valve. Bleed each wheel cylinder
beginning a t wheel f a r t h e s t from master cylinder.
After bleeding procedure i s complete, s t a r t engine and pump brake
pedal f o r approximately one minute. Shut-down engine and repeat
bleeding procedure. Remove bleeder ball , adaptor and replace cap
on master cylinder.
-1 0- c2
MATERIAL LIFT 0
DRESSER GRADER 0
PLANER 0
ROLLER 0
CRANE FD
SHOP M A N U A L K- 10.30
D E L C O - M O R A I N E P O W E R BOOSTER
ASSEMBLY
APPLICABLE MODEL/S SERIAL N U M B E R / S

150A w i t h Rockwell Ax1 e 02832 & Up
150FA w i t h Rockwell Axle 07305 & Up
180s 08502 & Up
220s 07724 & Up
I ALL C A U T ' O
COMPONENTS MUST BE PROPERLY SUPPORTED DURING
N 1

WORKING ORDER.

INJURY.
CONTENTS PAGE
Torque Sheet . . . . . . . . . . . . . . . . . . . Back o f Cover
Introduction . . . . .................... 1
Troubleshooting . . .................... 2
Identification . . . .................... 5
Service Chart . . . .................... 7
Special Tools . . . .................... 8
Piston Rod Gauge . .................... 8
150A and 150FA . . .................... 9
180s and 220s . . .................... 11
Cont'd on back o f cover -
DRESSER INDUSTRIES, INC. EAST SUNNYSIDE AVE. LIBERTYVILLE, I L 60048

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal 150A and 150FA . . . . . . . . . . . . . . . . 14
Removal 180s a n d 220s . . . . . . . . . . . . . . . . , 16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 18
General . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly o f 124287 . . . . . . . . . . . . . . . . . 18
Disassembly o f 126448 . . . . . . . . . . . . . . . . . 24
Disassembly o f 138622 . . . . . . . . . . . . . . . . . 29
Disassembly o f 148399 . . . . . . . . . . . . . . . . . 33
Cleaning a n d Inspection . . . . . . . . . . . . . . . . . 37
Reassembly . . . . . . . . . . . . . . , . . , . . . . . 38
Reassembly o f 124287 . . . . . . . . . . . . . . . . . 38
Reassembly o f 126448 . . . , . . , . . . . . . . . . . 44
Reassembly o f 138622 . . . . . . . . . . . . . . . . . 49
Reassembly o f 148399 . . . . . . . , . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . 58
I n s t a l l a t i o n 150A a n d 150FA . . , . . . . . . . . . . . 58
I n s t a l l a t i o n 180s and 220s . . . . . . . . . . . . . . 60
Brake Adjustment a n d Bleeding 150A a n d 150FA . . . . . . 61
Burnishing 150A a n d 150FA . . , . . . . . . . . . . . . . 66
Bleeding Procedure 180s a n d 220s . . . . . . . . . . . . 67
Brake Adjustment 180s a n d 220s . . . . . . . . . . . . . 69
Burnishing 180s and 220s . . . . . . . . . . . . . . . . 70
~~~~
NOTE: Toraue Values listed throughout this manual are Lubricat (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size
L Foot Pounds
G le 5
(3 radial dashes on ,It or cap screw head)
Grade 8
(6 radial dashes on bolt or cap screw head)
Newton Meters
(Ft Lbs.) (Nm) (Ft. Lbs.) (Nm)
1/4 . 20 6 8 9 12
114 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 21 37 38 52
7/16 . 14 38 52 54 73
7/16 . 20 42 57 60 81
112 . 13 58 79 82 111
1/2 . 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
518 . 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
?/8 . 14 335 454 515 698
1 . 8 455 617 695 94 2
1 . 14 510 691 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 141’ . 12 955 1295 1550 2102
1 318 . 6 1130 1532 1830 2481
1 3/8 . 12 1290 1749 I 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 370 1
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
INTRODUCTION
The power b o o s t e r assembly i s used t o p r o v i d e a h y d r a u l i c b o o s t t o t h e m a s t e r

b r a k e cy1 inder .
The b o o s t e r i s n o r m a l l y s u p p l i e d w i t h h y d r a u l i c o i l from t h e s t e e r i n g and b r a k e

c i r c u i t r y o f t h e u n i t i t i s i n s t a l l e d on.
I n t h e e v e n t a h y d r a u l i c problem a r i s e s , t h e b o o s t e r i s equipped w i t h a back- up

pump t h a t c i r c u l a t e s o i l w i t h i n t h e b o o s t e r t o g i v e a power a s s i s t t o t h e b r a k e s .
The i g n i t i o n key must be "ON" f o r t h e b.;.~'k-up pump t o o p e r a t e .
There a r e s e v e r a l v e r s i o n s o f b o o s t e r s b e i n g used. Be s u r e t o keep a c c u r a t e s e r v i c e

r e c o r d s f o r p r e s e n t and f u t u r e r e f e r e n c e .
Use t h e " I d e n t i f i c a t i o n o f B o o s t e r " s e c t i o n , t o d e t e r m i n e w h i c h model o f b o o s t e r

y o u r u n i t i s equipped w i t h .
-1 -
TROUBLESHOOTING
Hard brake pedal w i t h Low hydraulic oil level Check system for leaks and
engine running . make repairs i f necessary.
Add f l u i d t o proper 1 evel .
Air i n hydraulic o i l Add hydraulic oil a n d bleed

(often caused by low sys tem .
f l u i d 1 evel ) .
Pedal interference of Check, clean, lubricate or
linkage b i n d i n g . replace pedal 1 inkage parts.
,-_PI_.___ - -
Internal damage t o
power booster or pump Unless damaged u n i t i s o b v i o u s
conduct pressure t e s t s . See
causes and corrections fol1 ow-
ing.
Damage t o pump. Remove and repair pump.
Damage t o power booster. Remove and repair/overhaul
power booster.
Pinched hose or l i n e . Check hoses and tube l i n e s i n

brake and replace as required.
Internal damage t o Unless damaged u n i t i s obvious
power booster or pump. conduct pressure t e s t s . See
causes and corrections follow-
ing.
_I-
Damage t o power booster. Remove and repair/overhaul

power booster.
Air i n hydraulic o i l Add hydraulic a i l and bleed

(often caused by low system.
f l u i d 1 evel ) . --
Excessive back pressure Refer t o causes and correct-
on pump. ions for " S 1 uggish Power
Booster Operation".
-2-
POSSIBLE CAUSE CORRECT1ON
E x c e s s i v e pump n o i s e Trapped a i r i n pump. Depress b r a k e pedal l i g h t l y

(gurgle, chatter, etc.) w i t h t h e engine o f f f o r
t h i r t y seconds and r e l e a s e .
Recheck and s h o u l d t h e p r o -
blem p e r s i s t , r e p e a t above
procedure a f t e r a t h r e e
minute waiting period.
NOTE: This noise will dimin-

i s h upon a continued
use o f the brakes
under normal driving
conditions.
Low o r no v o l t a g e a t Check c o n d i t i o n o f b a t t e r y and

motor connection o f b a t t e r y t e r m i n a l s . C o r r e c t an
w i r i n g harness. abnormally low b a t t e r y condi-
t i o n and/or c l e a n b a t t e r y t e r -
m i n a l s i f necessary.
Check e l e c t r i c a l l e a d s a t
battery terminal o f s t a r t e r o r
i g n i t i o n bus b a r - n o t c o r r o d -
ed o r l o o s e .
----
Check v o l t a g e t o i g n i t i o n s i d e
o f relay coil .
Check v o l t a g e a t b a t t e r y con-
nection t o relay.
_m-.-
Check v o l t a g e a t E . H . pump.
m
-
N o n - f u n c t i o n i ng m o t o r . Check e l e c t r i c a l c o n n e c t i o n
between m o t o r l e a d w i r e and
w i r i n g harness. I f l o o s e ,
corroded, o r disconnected,
c l e a n and s e c u r e c o n n e c t i o n .
--
Check g r o u n d i n g o f pump housin!
t o b o o s t e r . The pump h o u s i n g
must be s e c u r e l y b o l t e d t o t h e
b o o s t e r t o p r o p e r l y ground t h e
motor.
__y__-,___a_--&=_l
Replace E.H. pump.
E.H. pump o p e r a t e s b u t M i s s i n g r e 1 ie f Val ve I n s t a l l proper p a r t s

and/or s p r i n g
O li l e a k a t b o o s t e r and Damaged o r m i s s i n g O - r i n g : Rep1 ace two O - r i n g s ,

E.H. pump m a t i n g s u r f a c e . a t p r e s s u r e and/or r e t u r n
port.
O li 1 eak f r o m pump Damaged o r m i s s i n g end Replace E.H. pump assembly.

end p l a t e p l a t e seal ,
O li l e a k f r o m E.H. pump Damaged s h a f t s e a l , Replace E.H. pump assembly.

motor.
PROBLEM ITEM TO CHECK
E l e c t r i c pump and l i g h t does n o t come on when 1. Check pedal s w i t c h .

pedal i s depressed w i t h e n g i n e o f f and i g n i t i o n 2 . Check c o n t i n u i t y t h r o u g h
key t u r n e d on. f l ow s w i t c he
3 . Check v o l t a g e t o i g n i t i o n
side o f relay c o i l .
4 . Check v o l t a g e a t b a t t e r y
connection t o r e l a y .
5 . Check f a r "open" i g n i t i o n
diode.
6. Check v o l t a g e a t E . H .
t e r m i n a l on r e 1 a y .
I f pump, b u t n o t l i g h t , comes o n when pedal 1, Check v o l t a g e a t w a r n i n g

i s depressed w i t h e n g i n e o f f and i g n i t i o n 1i g h t b u l b .
key t u r n e d on. 2 Replace b u l b .
e
If l i g h t , b u t n o t pump, comes on when pedal 1 Check p o l t a g e a t E . H . pump

i s depressed w i t h e n g i n e o f f and i g n i t i o n motor e
key t u r n e d on. 2 . Replace pump.
I f e l e c t r i c pump and w a r n i n g l i g h t s t a y on 1. Air i n b o o s t system.

a f t e r engine i s s t a r t e d . 2 . Check f o r s h o r t e d f l o w
switch (or stuck i n
position).
3. Relay stuck closed.
IDENTIFICATION OF BOOSTER
There a r e s e v e r a l v e r s i o n s o f t h e Delco Moraine Power B o o s t e r b e i n g used i n G a l i o n
equipment. T h i s s e c t i o n i s p r o v i d e d t o h e l p i d e n t i f y w h i c h v e r s i o n of b o o s t e r t h e
u n i t employs .
The y e a r t h e b o o s t e r was m a n u f a c t u r e d
can be d e t e r m i n e d b y t h e assembly code
stamped on t h e edge o f t h e cap (1,
F i g u r e 1 ) . T h i s i s a f o u r d i g i t code
r e p r e s e n t i n g t h e y e a r and c h r o n o l o g i c a l
day o f t h e y e a r .
12 18
EXAMPLE: --
C h r o n o l o g i c a l Day ( 2 1 8 t h )
L a s t D i g i t o f Year (1981)
Figure 1
GALION PART NUMBER 123914

S I N 02832 06946 -
YEAR 1974 t o Mid- 1976
T h i s b o o s t e r can be e a s i l y s p o t t e d b y
t h e use o f a p l a s t i c b o o t r e t a i n e r (1,
Figure 2).
Figure 2
-5-
F'igure 3
GALION PART NUMBERS 138622 & 148399

S I N 07663 & UP
YEAR 1978 & L a t e r
These b o o s t e r s have an aluminum i d e n t i -

f i c a t i o n t a g (1, F i g u r e 4) w h i c h c o n t a i n s
t h e m a n u f a c t u r e r ' s p a r t number.
The m a n u f a c t u r e r ' s number must be used

t o d e t e r m i n e w h i c h b o o s t e r t h e u n i t con-
t a i n s s o t h a t p r o p e r s e r v i c e k i t s can
be o r d e r e d .
The m a n u f a c t u r e r numbers a r e a s f o l l c w s :
18004202 = G a l i o n Number 138622

( S e r v i c e Chart-unsl:aded column)
18004527 = G a l i o n Number 138622

( S e r v i c e Chart- shaded column)
18006232 = G a l i o n Number 148399 Figure 4

NOTE: *en referring to Service Chart i n t h i s manuaZs be careful t o use proper
coZwnns under 138622 when seZecting kits.
The s e r v i c e code l e t t e r s "MR" a r e stamped on t h e edge o f t h e cap, n e a r t h e assembly

code.
-6-
SERVICE CHART
T h e f o l l w o i n g c h a r t i s p r o v i d e d a s a n a i d f o r s e r v i c i n g t h e D e l c o - M o r a i n e Power
B o o s t e r . The p a r t n u m b e r s a r e s u b j e c t e d t o c h a n g e w i t h o u t n o t i c e . A l w a y s r e f e r
t o t h e l a s t p a r t s m i c r o f i c h e f o r y o u r u n i t when s e r v i c i n g b o o s t e r .
DELCO BRAKE BOOSTER
KIT-POWER
HEAD ASM.
K I T - POW ER
HEAD R E P A I R
KIT-POWER
HEAD SPRING
KIT- PISTON ROD,

SELECTIVE F I T
PUMP ASM.
ELECTROHYD.
PISTON D I A .
* I f b o o s t e r i s s e r v i c e d w i t h p o w e r h e a d a s s e m b l y k i t 148665, a n y f u t u r e s e r v i c e
m u s t u s e k i t s shown i n s h a d e d p o r t i o n o f c h a r t .
I T I S IMPORTANT TO KEEP ACCURATE SERVICE RECORDS. AN IMPROPERLY

S E R V I C E D BOOSTER COULD RESULT N
I INJURY AND DAMAGE.
SPECIAL TOOLS
PISTON ROD GAUGE
The p i s t c n r o d gauge i s used t o e n s u r e t h a t a p r o p e r l e n g t h p i s t o n r o d i s i n s t a l l e d

between t h e power b o o s t e r and m a s t e r c y l i n d e r .
NOTE: I f too long a p i s t o n rod is used, the master cyZinder w i l l not return to
a proper r e s t i n g p o s i t i o n and couZd possibZy Z P ~ M t h e brakes block on.
If too short a rod is used, the booster w i l l not be able to g i v e maximum
stroke to cylinder.
T h i s t o o l can be a1 so o r d e r e d f r o m :
Kent- Moore Tool Group

29784 L i t t l e Mac Rd.
R o s e v i l l e, M.
I 48066
U.S.A. Phone (313) 774-9500
Order: NO- GO GAUGE 5-24866

K a K IO 1 1 1 4 1-79 10411
APPLICATION UNLESS OTHERWISE SPECIFIED

TOLERANCES ON: ANGLES - - , I
1
1
1
/a i
UNLESS OTHERWISE N O T E D A L L
CORNERS A N D EDGES SHOWN SHARP
___
7./7-731 -, RLL-EA5ED ~,,'IL3LS
M U g T BE BROKEN A P P R O X . - O / n L . DATE i LET. C H A N G E , B Y ! NO.
JM -7 POMP-TYPE +30
57H/NL&Ss
NO. 2 5 F/N/SH S E R V I C E T 00L D I V I S I 0N
COUNTERSINK A L L TAPPED HOLES HEAT TREAT
-
t a c . 3 5 MOUND Q O ~ D
WARREV MIcH,dsoDZ K E N T - M O O R E CORP. ~~c~EkToZLE~1~~v
80. T O M A J O R D I A M E T E R
F I N A L HEAT TREAT
N A M E PUSH ROiJ HC/G//T- G9Gc
UNLESSOTHERWISESPECIFIEUALL
M A C H I N E D BURFACES T O HAVE \T - - PERM NO
F I N I S H . CAYTINGS. FORGINGS, S T A M P I N G S
A N D F A B R I C A T I O N S . SEE K - M S T D . NO. 1 9 0 . - SCALE 1 DATE 7-12.7 3
S T A M P E D C H A R A C T E R S SEE K - M S T D . NO. 6 s .
'
A L L D I M E N S I O N S
A F T E R
A P P L Y
P L A T I N G 1 D A N . 8Y JZJ
-8-
150A AND 150FA
// \
Cont'd on next page -

- 9-
-10-
180s AND 220s
The a d a p t o r p l a t e i s used i n c o n j u n c t i o n w i t h a b l eeder b a l l t o b l eed t h e b r a k e

l i n e s on t h e u n i t .
MANUFACTURING DETAILS :
;-i
(4) 0.187" (4.75 mm) OIA.

HOLES THRU
2.250"
4.500" (57.15 mrn)
(114.30 rnm)
0 . 5 0 0 90" STREET ELBOW
DRILL AN0 TAP HOLE FOR

0.500" 90' STREET ELBOW
NOTE: MAKE GASKETTO FIT PLATE NOTE MATERIAL. MILD STEEL PLATE
WITH A 2.000 (50.80 rnrn) OEBURR ALL CORNERS
HOLE IN THE CENTER SO
BRAKE FLUID WILL FLOW NOTE: ALL DIMENSIONS 0.003" (f0.07rnrn) 12060
TO BOTH RESERVOIRS.
C o n t ' d on n e x t page -
-11-
INSTALLATION:
After reservoir cover has been removed,
f i l l reservoir (1, Figure 5 ) with brake
f l u i d . Position gasket ( 2 ) and adaptor
plate ( 3 ) on reservoir. Use two pieccs
of 3/16" threaded rod ( 4 ) 18.00"
( 4 5 7 . 2 0 mm) long bent in a " U " s!-,ape
w i t h four hex nuts ( 5 ) t o hold gasket
and adaptor plate in posit-ioq. Attach
bleeder ball hose ( 6 ) t o el bow.
Figure 5
-12-
SERVICING
The f o l l o w i n g procedures a r e o n l y one method o f o b t a i n i n g a removal, d i s a s s e m b l y ,

c l e a n i n g and i n s p e c t i o n , reassembly, and i n s t a l l a t i o n o f t h e Delco-Moraine Power
B o o s t e r Assembly.
Park u n i t on a l e v e l s u r f a c e and p l a c e blocking i n f r o n t o f and behind each t i r e .
S e t p a r k i n g brake and turn i g n i t i o n key o f f .
-13-
REMOVAL
REMOVAL 150A AND 150FA
Figure 6
D i s c o n n e c t w i r e (1, F i g u r e 6 ) f r o m f l o w s w i t c h assembly ( 2 ) .
Remove n u t ( 3 ) and w i r e ( 4 ) f r o m t e r m i n a l .
Remove capscrew and l o c k washer ( 5 ) and s o l e n o i d assembly ( 6 ) f r o m power b o o s t e r

assembly ( 7 ) .
NOTE: Secure solenoid out of way for ease of removal and instazlation of
p m e r brake assembly.
D i s c o n n e c t b r a k e 1 i n e ( 8 and 9 ) f r o m u n i o n s ( 1 0 and 11) and cap l i n e s . Remove

u n i o n s f r o m m a s t e r b r a k e cy1 i n d e r ( 1 2 ) .
Loosen clamp ( 1 3 ) and remove hose ( 1 4 ) f r o m f l o w s w i t c h assembly ( 2 ) and p l u g

hose.
-14-
Figure 7
Unscrew push rod (1, Figure 7 ) from brake 1 inkage ( 2 ) .
Remove l i n e ( 3 ) from u n i o n ( 4 ) and plug l i n e . Remove u n i o n from power booster
assembly ( 5 ) .
Remove four nuts and lock washers ( 6 ) two capscrews ( 7 ) and power booster assembly
( 5 ) from m o u n t i n g bracket ( 8 ) .
-15-
REMOVAL 180s AND 220s
Figure 8
F u l l w i r e t e r m i n a l (1, F i g u r e 8) o f f f l o w s w i t c h ( 2 ) .
Remove hex n u t and l o c k washer ( 3 ) and two w i r e s ( 4 ) f r o m s o l e n o i d t e r m i n a l .
Remove two capscrews and l o c k washers ( 5 ) and s o l e n o i d b r a c k e t ( 6 ) f r o m power

b o o s t e r assembly ( 7 ) . R e i n s t a l l two l o c k washers and capscrews, a f t e r b r a c k e t
has been removed.
D i s c o n n e c t two b r a k e l i n e s ( 8 ) f r o m power b r a k e assembly. Cap and p l u g b r a k e

l i n e s and power b o o s t e r assembly t o p r e v e n t c o n t a m i n a t i o n o f t h e system.
Loosen hose clamp ( 9 ) and p u l l hose (10) o f f f l o w s w i t c h . D i s c o n n e c t r e m a i n i n g

hose f r o m power b o o s t e r assembly. P l u g and cap hoses and power b o o s t e r assembly.
C o n t ' d Next Page
-1 5-
Loosen jam n u t (11) and unscrew push r o d ( 1 2 ) f r o m a d j u s t e r ( 1 3 ) . Remove jam n u t

f r o m push r o d .
NOTE: Before loosening jam nut, measure the amount af exposed threads on push
rod and record.
Remove two hex n u t s , l o c k washers and capscrews (14) f r o m m o u n t i n g b r a c k e t ( 1 5 )

and power b o o s t e r assembly. Remove two r e m a i n i n g hex n u t s and l o c k washers f r o m
s t u d s . Remove power b o o s t e r assembly f r o m b r a c k e t .
-17 -
DISASSEMBLY
GENERAL
Remove four capscrews and lock washers

(1, Figure 9 ) and separate master
cy1 inder ( 2 ) from power booster assem-
bly ( 3 ) . Remove gasket.
NOTE: Remove plugs and caps and drain
brake f Zuid and hgdraulic o i l
a s much as possib2.e. Do not
alZow f l u i d s to mi;..
NOTE: See appropriate shop manuaZ f o r
servicing the mcrster brake
cy Zinder .
Service the brake booster according t o Figure 9

the appropriate part number.
DISASSEMBLY OF 124287
Remove Piston rod (1, Figure 1 0 ) from

power booster assembly ( 2 ) a n d s\l!?:::
g r o u n d i n g bracket ( 3 ) o u t of the way.
Figure 10
. * POSITION POWER BOOSTER

ASSEMBLY ( 2 , Figure 11)
AS SHOWN IN AR8OR PRESS.
APPLY SLIGHT PREJZ!IRE
AGAINST CAP ( 3 ) .
Remove two f l a t head screws (1) from
power booster assembly ( 2 ) . Re1 ?ase
arbor press pressure slowly t o *elieve
spring tension.
Figure 11
-18-
Remove s u p p o r t p l a t e (1, F i g a r e 1 2 )
expander ( 2 ) s e a l ( 3 ) cap ( 4 ) and s p r i n g
( 5 ) f r o m power b o o s t e r assembly ( 6 ) .
Figure 1 2
Remove r o d s e a l (1, F i g u r e 1 3 ) f r o m cap

( 2 ) i f r e p l a c e m e n t i s necessary.
Figure 1 3
Tap power b o o s t e r assembly (1, F i g u r e

1 4 ) a g a i n s t a b l o c k o f wood t o remove
piston (2).
-1 9-
Figure 15
Remove r e a c t i o n p i s t o n ( L y F i g u r e 1 6 )
from p i s t o n ( 2 ) .
Figure 16
Remove O- rings ( 1 and 2 - i g u r e 17 j

from r e a c t i o n p i s t o n ( 3 ) .
Figure 17
-20-
Remove spring (1, Figure 18) from power

booster assembly ( 2 ) .
Figure 18
NOTE: Pu2l push rod out through power

booster and remove b m p e r seal
from push rod.
Figure 19
Remove V-block seal (1, Figure 2 0 ) a n d

O-ring ( 2 ) from power booster ( 3 ) .
Figure 20
-21-
Remove tube f i t t i n g i n s e r t ( 1 , Figure

2 1 ) check valve stem ( 2 ) and spring
from power booster ( 3 ) i f necessary.
Remove flow switch assembly ( 4 ) from
power booster ( 3 ) . Remove O-ring from
flow switch assembly i f necessary.
Figure 2 1
Remove two capscrews and lock washers

(1, Figure 2 2 ) and pump ( 2 ) from power
booster ( 3 ) .
Figure 22
Remove two O-rings (1, Figure 23) from

pump ( 2 ) .
F i g u r e 23
-22-
Remove p l u g (1, F i g u r e 2 4 ) s p r i n g and

r e 1 i e f v a l v e f r o m power b o o s t e r ( 2 ) .
Remove O - r i n g f r o m p l u g i f n e c e s s a r y .
Figure 24
Figure 25
-23-
Figure 26
POSITION POWER BOOSTER

ASSEMBLY (1, F i g u r e 2 7 )
AS SHOWN NI ARBOR PRESS.
APPLY SLIGHT PRESSURE
AGAINST CAP ( 2 ) .
Remove two f l a t head screws ( 3 ) f r o m

power b o o s t e r assembly ( 1 ) . Re1 ease
a r b o r press pressure s l o w l y t o r e l i e v e
spring tension.
Figure 27
Remove cap (1, F i g u r e 28) s u p p o r t p l a t e

( 2 ) s e a l ( 3 ) expander ( 4 ) and s p r i n g
Figure 28
Remove r o d s e a l (1, F i g u r e 2 9 ) f r o m cap

Figure 29
Tap power b o o s t e r assembly ( 1 , F i g u r e

30) a g a i n s t a b l o c k o f wood t o remove
piston (2).
,/'
Figure 30
Remove s e a l (1, F i g u r e 31) snap r i n g ( 2 )

v a l v e s e a t ( 3 ) r e a c t i o n (4) and s p r i n q
\ WHEN REMOVING SNAP RING,

THE VALVE SEAT I S UNDER
,-*
S P R I N G PRESSURE. '
Figure 31
-25-
Remove O-rings (1, Figure 32) from

reaction piston ( 2 ) .
Figure 32
Remove boot (1, Figure 33) a n d push rod

( 2 ) from power booster ( 3 ) .
NOTE: Pull push rod out through housing.

Remove bumper seal from push r o d .
Figure 33
Remove O-ring (1, Figure 34) and V-block

seal ( 2 ) from power booster ( 3 ) .
Figure 34
-25-
Remove tube f i t t i n g i n s e r t (1, Figure

35) check valve stem ( 2 ) and spring
from power booster ( 3 ) i f Recessary.
power booster ( 3 ) . Remave C-ring from
Figure 35
Remove three capscrews and lock washers

(1, Figure 36) and pump ( 2 ) from power
booster ( 3 ) .
NOTE: Pump is under sprin.g pressure.
Figure 36
Remove two O-rings ( 1, Figure 37) from

pump ( 2 ) .
Figure 37
-27-
Remove sprir-ig (1, F i g u r e $8) and r e 1 i e f

v a l v e f r o m power b o o s t e r ( 2 ) .
Remove r e t a i n e r p l u g ( 3 ) and O - r i n g
f r o m power b o o s t e r ( 2 ) i f n e c e s s a r y .
NOTE: If removaZ o f pZug i s necessary,

bend a piece o f welding wire
i n t o a "Ut'shape and feed
through t h e i n t e r n a l port t o
push pZug our from behind.
I ,
Figure 38
-28-
Remove p i s t o n r o d ( 1, F i g u r e 3 9 ) from
power b o o s t e r assembly ( 2 ) .

ASSEMBLY (1, FIGURE 40)
AS SHOWN N
I ARBOR PRESS.
APPLY SLIGHT PRESSURE
AGAINST CAP ( 2 ) .
Remove two f l a t head screws ( 3 ) from

power b o o s t e r assembly ( 1 ) . Re1 ease Q
a r b o r press s l o w l y t o r e l i e v e s p r i n g
tension.
Figure 4ii

( 2 ) s e a l ( 3 ) expander ( 4 ) and s p r i n g
Figure 4,
- 2 9-
Shop Manual S e c t i o n K-10.30
Remove r o d s e a l ( 1, F i g u r e 42) f r o m cap

Figure 42
Tap power b o o s t e r assembly (1, F i g u r e

43) a g a i n s t a b l o c k o f wood t o remove
piston (2).
NOTE: In t h i s booster, the p i s t o n i s

an alwninwn casting.
Remove r e t a i n e r r i n g (1, F i g u r e 44) and

v a l v e seat ( 2 ) from p i s t o n (3) i f r e -
placement o f s e a t i s necessary.
Remove s e a l ( 4 ) f r o m p i s t o n .
Figure 44
-30-
Shop Manual Section (-10.30
Remove spring (1, Figure 45) from push

rod ( 2 ) .
NOTE: Pull push rod of housing ( 3 ) .
Remove washer and bumper sea2
from r o d .
Figure 45
Remove seal (1, Figure 4 6 ) from power

booster housing ( 2 ) .
Figure 46
-31-
Figure 48
Remove two O-rings (1, Figure 4 9 ) from

pump ( 2 ) .
Figure 49
Remove spring (1, Figure 50) and re1 i e f @......,

valve from power booster ( 2 ) .
Remove retainer plug ( 3 ) a n d O-ring
NOTE: If removal, of plug is necessary,
bend a piece of wel,ding wire
into a "U" shape and feed
through the internal, port to
push plug out from behind.
Figure 50
-32-
Remove p i s t o n r o d (1, F i g u r e 51) from

Figure 51

ASSEMBLY (1, F i g u r e 5 2 ) AS
SHOWN I N ARBOR PRESS. APPLY
SLIGHT PRESSURE AGAINST
CAP ( 2 ) .
Remove two f l a t head screws ( 3 ) from

power b o o s t e r assembly ( 1 ) . Release
a r b o r press s l o w l y t o r e l i e v e s p r i n g
tension.
Figure 52

( 2 ) s e a l ( 3 ) expander (4) and s p r i n g ( 5 )
f r o m power b o o s t e r assembly ( 6 ) .
Figure 53
-33-
Remove rod seal (1, Figure 54) from

cap ( 2 ) i f replacement i s necessary.
33lb
Figure 54
Tap power booster assembly (1, Figure
55) against a block of wood t o remove
p i ston ( 2 ) .
NOTE: I n this booster, t h e p i s t o n i s
an aZuminm casting.
Figure 55
Remove retainer ring (1, Figure 56) and

valve s e a t ( 2 ) from piston ( 3 ) i f re-
placement o f s e a t i s necessary. Q
Remove seal ( 4 ) from piston.
Figure 56
-34-
Remove spring (1, Figure 5 7 ) from push

rod ( 2 ) .
NOTE: Pull push rod of housing ( 3 1 .
Remove washer and bumper seal
from r o d .
Figure 57
Remove seal (1, from power

booster housing
Figure 58
Remove tube f i t t i n g i n s e r t (1, Figure

5 9 ) check valve stem ( 2 ) and spring
power booster ( 3 ) . Remove O-ring from
Figure 59
-35-
Figure 60
Remove tw O-rings (1, Figure 61) from

pump ( 2 ) .
Figure 61
Remove spring (1, Figure 6 2 ) a n d re1 i e f

valve from power booster ( 2 ) .
a
Remove retainer plu ( 3 ) and O-ring
from power booster 2 ) i f necessary.
NOTE: I f removal of plug i s necessary,
bend a piece of welding wire i n t o
a rrU” shape and feed through the
i n t e r n a l p o r t to push plug out
@om behind.
Figure 62
-36-
A , Clean a l l m e t a l p a r t s t h o r o u g h l y u s i n g a s u i t a b l e t y p e c l e a n i n g f l u i d . I t
i s recommended t h a t p a r t s be immersed i n c l e a n i n g f l u i d and moved up and
down S l o w l y u n t i l a l l b r a k e f l u i d and f o r e i g n m a t e r i a l i s d i s s o l v e d and
p a r t s a r e t h o r o u g h l y c l eaned.
A CARE SHOULD BE EXERCISED TO A V O I D S K I N RASHES, FIRE HAZARDS

AND INHALATION OF VAPORS WHEN U S I N G SOLVENT TYPE CLEANERS.
B . I n s p e c t housings, c o v e r s and p i s t o n s t o be c e r t a i n t h e y a r e t h o r o u g h l y c l e a n e d
and t h a t m a t i n g s u r f a c e s , bores, e t c . , a r e f r e e from n i c k s o r b u r r s . Check a l l
p a r t s c a r e f u l l y f o r e v i d e n c e o f c r a c k s o r c o n d i t i o n s w h i c h would cause subse-
q u e n t b r a k e f l u i d l e a k s o r f a i l u r e s . I f a v a i l a b l e , use magna- flux process f o r
c h e c k i n g f o r c r a c k s t h a t may n o t be v i s i b l e t o t h e naked eye.
C . Replace a l l s e a l s , O - r i n g s , and g a s k e t s . It i s economical when u n i t i s d i s -

assembled t o r e p l a c e p a r t s t o p r e v e n t p r e m a t u r e f a i l u r e . R e f e r t o p a r t s book
f o r r e p l a c e m e n t i t e m s . Be e x t r e m e l y c a r e f u l when i n s t a l l i n g s e a l i n g members,
t o a v o i d c u t t i n g o r s c r a t c h i n g . C u r l i n g under o f any s e a l l i p wil s e r i o u s l y
i m p a i r i t s e f f i c i e n c y . A p p l y a t h i n c o a t o f b r a k e f l u i d on t h e s e a l s and p a r t s
t o insure proper i n s t a l l a t i o n .
-37-
I n s t a l l O-ring on plug (1, Figure 64)

i f removed a t disassembly.
Position re1 i e f valve and re1 i e f valve
spring in power booster ( 2 ) and i n s t a l l
plug ( 1 ) .
Figure 64
I n s t a l l two O-rings (1, Figure 6 5 ) on

pump ( 2 ) .
Figure 65
-3a-
Position pump ( 2 , Figure 6 6 ) on power

booster ( 3 ) and i n s t a l l two capscrews
and lock washer ( 1 ) .
NOTE: Torque capscrews (1) from 16 t o
30 Ft. L~bs. (22 - 40 Nm).
Figure 66
I n s t a l l check valve spring and stem ( 2 ,

Figure 6 7 ) and tube i n s e r t ( 1 ) i n power
head ( 3 ) i f removed
I n s t a l l O-ring on f low switch assembly
( 4 ) i f removed a t d isassembly.
I n s t a l l flow switch assembly ( 4 ) on
power booster.
NOTE: Torque fzow switch from 20 t o 30
3t. Lbs. (27 - 40 lVm).
Figure 67
I n s t a l l V-block seal (1, Figure 68)

and O-ring ( 2 ) i n power booster ( 3 ) .
Figure 68
-39-
I n s t a l l bumper s e a l on push r o d ( 4 ,
F i g u r e 6 9 ) . S l i d e push r o d i n t o p o s i -
t i o n t h r o u g h power b o o s t e r ( 3 ) .
I n s t a l l r e t a i n e r ( 2 ) and b o o t (1) on
power b o o s t e r ( 3 ) .
Figure 69
I n s t a l l s p r i n g (1, F i g u r e 7 0 ) i n power
b o o s t e r assembly ( 2 ) .
NOTE: P4ake sure it is seated properly

on push rod.
Figure 70
I n s t a l l O - r i n g s ( 1 and 2, F i g u r e 7 1 ) on
reaction piston (3).
Figure 71
-40-
Position reaction piston (1, Figure 7 2 )

i n piston ( 2 ) .
Figure 72
Position valve plate ( 2 , Figure 73) i n

piston ( 4 ) and i n s t a l l retainer (1) and
seal ( 3 ) .
Figure 73
S1 ide piston ( 2 , Figure 74) i n power

NOTE: Make sure r e l i e f valve spring
seats on p i s t o n properly. Use
extreme care not t o cut o r
pinch seal when i n s t a l l i n g
p i s ton.
Figure 74
-41-
I n s t a l 1 r o d s e a l ( 1, F i g u r e 7 5 ) i n
cap ( 2 ) .
Figure 75
P o s i t i o n power b o o s t e r assembly ( 6 ,
F i g u r e 7 6 ) as shown i n a r b o r p r e s s .
P o s i t i o n s p r i n g ( 5 ) s u p p o r t ( 1 ) expand-
e r ( 2 ) seal ( 3 ) and cap ( 4 ) i n power
b o o s t e r assembly.
NOTE: Make sure t h a t a l l four p a r t s

are lined up and i n proper
order as shown.
A p p l y p r e s s u r e s l o w l y t o compress
s p r i n g and p o s i t i o n cap assembly i n
power b o o s t e r
DO NOT P I N C H L1F OF SEAL

WHEN POSITIONING N I POWER
BOOSTER. Figure 76
I n s t a l l two f l a t head screws (1,

F i g u r e 7 7 ) i n power b o o s t e r assembly
( 2 ) . Re1 i e v e a r b o r p r e s s p r e s s u r e
f r o m cap ( 3 ) .
Figure 77
-42-
S1 i d e p i s t o n r o d (1, F i g u r e 78) i n
power b o o s t e r assembly ( 2 ) . Swing
g r o u n d i n g b r a c k e t ( 3 ) o u t o f t h e way,
NOTE: Use "Piston Rod Gauge" shown

in specia2 too2 section o f
t h i s mama2 t o seZect correct
piston rod.
Figure 78
Pos it i o n m a s t e r c v l i n d e r ( 3 .. F i g u r e
7 9 ) a g a i n s t power" b o o s t e r 'assembly ( 4 ) .
Swing g r o u n d i n g b r a c k e t ( 2 ) back i n
p l a c e and i n s t a l 1 f o u r capscrews and
l o c k washers (1) i n power b o o s t e r as-
sembly (4).
NOTE: Torque capscrews from 9 9 to

135 ;:n. Lbs. (11 - 15 Urn).
Figure 79
-43-
REASSEMBLY OF 126448
I n s t a l l O-ring and retainer plug ( 3 ,

Figure 80) i n power booster ( 2 ) i f
removed a t disassembly.
Position r e l i e f valve and spring (1) i n
power booster.
Figure SO
Instal 1 two O-rings ( 1, Figure 81) on

pump ( 2 ) .
Figure 81
Position pump ( 2 , Figure 82) against

power booster ( 3 ) and instal 1 three
lock washers a n d capscrews ( 1 ) .
Figure 82
-44-
I n s t a l l spring, check valve stem ( 2 ,

Figure 83) and tube f i t t i n g i n s e r t ( 1 )
i n power booster ( 3 ) i f removed a t
disassembly.
I n s t a l l new O-ring on flow switch as-
sembly ( 4 ) i f ol d one was removed a t
disassembly. I n s t a l l flow switch as-
sembly i n power booster ( 3 ) .
NOTE: Torque flow switch from 20 to 30
Ft. Lbs. (27 - 40 Nmi.
Figure 83
I n s t a l l V-block seal ( 2 , Figure 84) and

O-ring (1) in power booster ( 3 ) .
Figure 84
I n s t a l l bumper seal on push rod ( 2 ,

Figure 8 5 ) . Slide push rod into position
t h r o u g h power booster ( 3 ) .
Instal 1 b o o t ( 1 ) on power booster ( 3 ) .
Figure 85
-45-
Instal 1 O-rings (1, Figure 86) on re-

action piston ( 2 ) .
Figure 86
Position spring, reaction piston ( 4 ,

Figure 87) and valve s e a t ( 3 ) and
i n s t a l l snap ring ( 2 ) i n piston ( 5 ) .
I n s t a l l seal (1) on piston ( 5 ) ,
Figure 87
Slide piston ( 2 , Figure 88) into booster
assembly ( 1 ) .
NOTE: Use extreme care not t o cut or
pinch sea2 on piston when
insta2iing p i s t o n .
Figure 88
-46-
I n s t a l l r o d s e a l (1, F i g u r e 89) i n cap

( 2 ) i f removed a t d i s a s s e m b l y .
Figure 89
P o s i t i o n power b o o s t e r ( 6 , F i g u r e 90)
i n a r b o r p r e s s shown. P o s i t i o n s p r i n g
( 5 ) , s u p p o r t p l a t e ( 2 ) expander ( 4 )
s e a l ( 3 ) and cap (1) i n power b o o s t e r
assembly.
NOTE: Make sure t h a t aZZ f o u r p a r t s are

lined up and in proper order as
shown.
A p p l y p r e s s u r e s l o w l y t o compress s p r i n g
and p o s i t i o n cap assembly i n power b o o s t e r .
DO NOT PINCH L I P OF SEAL

WHEN POSITIONING N I POWER
BOOSTER. Figure 90
I n s t a l l two f l a t head screws ( 3 , F i g u r e

91) i n power b o o s t e r assembly ( 1 ) . Re-
1 i e v e a r b o r p r e s s p r e s s u r e f r o m cap ( 2 ) .
Figure 91
-47-
S 1 i d e p i s t o n rod (1, F i g u r e 9 2 ) i n
NOTE: Use “Piston Rod Gauge“ shown

i n special too?,section o f
this manual t o s e l e c t correct
piston rod.
Figure 92
Figure 93
-48-
REASSEMBLY OF 138622
I n s t a l l O-ring and retainer plug ( 3 ,

Figure 94) i n power booster ( 2 ) i f
removed a t disassembly.
Position r e l i e f valve and spring (1)
in power booster.
Figure 94
Figure 95
Position pump ( 2 , Figure 96) against

power booster ( 4 ) and i n s t a l l three
lock washers and capscrews ( 1 ) .
NOTE: Be sure i d e n t i f i c a t i o n tag 13)
i s secured t o power booster.
Figure 96
-49-
I n s t a l l s p r i n g , check v a l v e stem ( 2 .
F i g u r e 97) and t u b e f i t t i n g i n s e r t (1)
i n power b o o s t e r ( 3 ) i f removed a t
disassembly.
I n s t a l l new O - r i n g on f l o w s w i t c h assem-
b l y ( 4 ) i f o l d one was removed a t d i s -
assembly. I n s t a l l f l o w s w i t c h assembly
i n power b o o s t e r .
NOTE: Torque f l o w switch from 20 to 30

Ft. Lbs. ( 2 7 - 40 Nm),
Figure 97
I n s t a l l s e a l (1, F i g u r e 98) i n power
booster housing ( 2 ) .
Figure 98
I n s t a l l bumper s e a l and wasi;er

r o d ( 2 , F i g u r e 9 9 ) . S l i d e push
p o s i t i o n t h r o u g h power b o o s t e r
I n s t a l l b o o t on power b o o s t e r .
I n s t a l l s p r i n g (1) on push r o d
Figure 99
-50-
Secure valve s e a t ( 2 , Figure 100) i n

piston ( 3 ) w i t h retainer ring ( 1 ) .
I n s t a l l seal ( 4 ) on piston.
Figure 100
Slide piston ( 2 , Figure 101) into power

NOTE: Use extreme care not t o cut or
pinch s e a l on p i s t o n when i n -
stalling piston.
Figure 101
I n s t a l l rod seal (1, Figure 1 0 2 ) in cap

Figure 102
-51-
Position power booster assembly ( 6 ,

Figure 103) i n arbor press a s shown.
Position spring ( 5 ) support plate ( 2 )
expander ( 4 ) seal ( 3 ) and cap (1) i n
power booster assembly.
NOTE: Make sure t h a t a22 four parts are
lined up and in proper order as
shorn.
Apply pressure slowly t o compress spring

and position cap assembly i n power
booster.
A DO NOT PINCH LIP OF SEAL

WHEN POSITIONING IN POWER
BOOSTER.
I n s t a l l two f l a t head screws ( 3 , Figure

Figure 103
1 0 4 ) i n power booster assembly ( 1 ) .

Re1 ieve arbor press pressure from cap ( 2 ) . ,,P
Figure 104
S1 i de piston rod (1, Figure 1 0 5 ) i n

power booster assembly ( 2 ) .
NOTL Use "Piston Rod Gauge" shown i n
special too2 section of t h i s
manual. t o seZect correct p i s t o n
rod.
Figure 105
-52-
P o s i t i o n master c y l i n d e r (3, Figure 106)

a g a i n s t power b o o s t e r assembly ( 4 ) .
Swing g r o u n d i n g b r a c k e t ( 2 ) back i n p l a c e
and i n s t a l l f o u r capscrews and l o c k
washers (1) i n power b o o s t e r assembly ( 4 )
NOTE: Torque capscrews from 99 t o 135

In. Lbs. (11 - 15 TJm),
Figure 106
REASSEMBLY OF 148399 0,
I n s t a l l O - r i n g and r e t a i n e r p l u g ( 3 ,
F i g u r e 107) i n power b o o s t e r ( 2 ) i f
removed a t d i s a s s e m b l y .
P o s i t i o n r e l i e f v a l v e and s p r i n g (1) i n
power b o o s t e r .
Figure 107
I n s t a l l two O - r i n g (1, F i g u r e 108) on

pump ( 2 ) .
Figure 108
-53-
Figure 110
Install seal (1, F i g u r e 111) in power

b o o s t e r housing ( 2 ) .
Figure 111
-54-
I n s t a l l bumper s e a l and washer on push

r o d ( 2 , F i g u r e 1 1 2 ) . S l i d e push r o d i n t o
p o s i t i o n t h r o u g h power b o o s t e r ( 3 ) .
I n s t a l l b o o t on power b o o s t e r .
I n s t a l l s p r i n g (1) on push r o d .
P
Figure 112
Secure v a l v e s e a t ( 2 , F i g u r e 113) i n
p i s t o n ( 3 ) w i t h r e t a i n e r r i n g (1).
I n s t a l l s e a l ( 4 ) on p i s t o n .
Figure 113
S1 i d e p i s t o n (2, F i g u r e 114) i n t o power

b o o s t e r assembly ( 1 ) .
NOTE: Use extreme care not t o c u t o r

pinch sea2 on p i s t o n when i n -
stalling piston.
Figure 114
-55-
I n s t a l l rod seal (1, Figure 115) i n cap

Figure 115
Position power booster assembly ( 6 ,

Figure 116) i n arbor press as shown.
Position spring ( 5 ) support plate ( 2 )
expander ( 4 ) seal ( 3 ) and cap (1) in
power booster assembly.
NOTE: Make sure t h a t a l l f o u r parts are
lined up and i n proper order as
shown.
Apply pressure slowly t o compress srri:,g
and position cap assembly in power
booster.
A DO NOT PINCH L I P OF SEAL

W H E N POSITIONING IN POWER
BOOSTER.
I n s t a l l two f l a t head screws ( 3 , Figure

Figure 116
117) i n power booster assembly ( 1 ) . Re-

1 ieve arbor press pressure from cap ( 2 ) .
Figure 117
-56-
rod.
Figure 118
Position master cylinder ( 3 , Figure

against power booster assembly ( 4 ) .
S w i n g g r o u n d i n g bracket ( 2 ) back in
and i n s t a l l four capscrews and lock
washers ( 1 ) i n power booster assemb
NOTE: Torque capscrews from 99 to
In. 1 2 s . ( 1 2 - 15 P J r n ) .
Figure 1 1 9
-57-
INSTALLATION
INSTALLATION 150A AND 150FA
Position power booster assembly ( 5 , Figure 1 2 0 j against m o u n t i n g bracket ( 8 ) and

i n s t a l l two capscrews ( 7 ) and four lock washers and nuts ( 6 ) .
I n s t a l l union ( 4 ) on power booster assembly ( 5 ) . Unplug l i n e ( 3 ) a n d connect t o
union.
Connect push rod (1) t o break linkage ( 2 ) .
-58-
Figure 1 2 1
Unplug hose (14), F i g u r e 121) and s l i d e on f l o w s w i t c h assembly ( 2 ) and t i g h t e n

clamp ( 1 3 ) .
I n s t a l l u n i o n s ( 1 0 and 11) o n m a s t e r b r a k e c y l i n d e r ( 1 2 ) and c o n n e c t l i n e s ( 8 and

9) t o unions.
P o s i t i o n s o l e n o i d assembly ( 6 ) a g a i n s t power b o o s t e r assembly ( 7 ) and i n s t a l l

capscrew and 1o c k washer ( 5 ) .
Connect w i r e ( 4 ) t o t e r m i n a l and i n s t a l l n u t ( 3 ) .
Connect w i r e (1) t o f l o w s w i t c h assembly ( 2 ) .
-59-
INSTALLATION 180s AND 220s
Figure 1 2 2
I n s t a l l jam n u t (11) on push r o d ( 1 2 ) . Screw push r o d i n t o a d j u s t e r ( 1 3 ) and

t i g h t e n jam n u t .
NOTE: Aster jam nut i s tightened, the amount of exposed threads on push rod must
equal measurement taken during removal. Readjust i f necessary.
Unplug and uncap hoses and power b r a k e assembly. S l i d e hose ( 1 0 ) o n f l o w s w i t c h

( 2 ) and t i g h t e n hose clamp ( 9 ) . Connect r e m a i n i n g hose t o power b r a k e assembly.
Unplug and uncap b o t h b r a k e l i n e s ( 8 ) and power b r a k e assembly. Connect b o t h b r a k e

l i n e s t o power b r a k e assembly.
Remove two capscrews and l o c k washers ( 5 ) f r o m power b r a k e assembly. P o s i t i o n

s o l e n o i d b r a c k e t ( 6 ) a g a i n s t power b r a k e assembly, and r e i n s t a l l two l o c k washers
and capscrews.
I n s t a l l two w i r e s ( 4 ) , l o c k washers and hex n u t s ( 3 ) on s o l e n o i d t e r m i n a l I
Connect w i r e t e r m i n a l (1) t o f l o w s w i t c h .
-50-
BRAKE ADJUSTMENT AND BLEEDING 150A AND 150FA

Any t i m e t h a t t h e brakes a r e spongy o r t h a t t h e b r a k e l i n e s o r c y l i n d e r s have main-
t e n a n c e p e r f o r m e d i n v o l v i n g them such as r e p l a c e m e n t o f / o r r e p a i r i n g l i n e s , shoes,
c y l i n d e r s , a x l e s , e t c . , t h e system s t a n d s a chance o f b e i n g exposed, o r has been
exposed t o t h e atomosphere, t h e f o l l o w i n g p r o c e d u r e must be f o l l o w e d t o ensure
p r o p e r b r a k e shoe a d j u s t m e n t a n d / o r b l e e d i n g .
BRAKE ADJUSTMENT
1. P o s i t i o n c r a n e on o u t r i g g e r s ( 1,
F i g u r e 1 2 3 ) w i t h a1 1 f o u r wheels
o f f t h e ground. P l a c e b l o c k i n g ( 2 )
under o u t r i g g e r frame ( 3 ) . Leave
s u f f i c i e n t room i n f r o n t o f and
b e h i n d c r a n e t o s t o p i n case i t
s h o u l d a c c i d e n t a l l y be knocked o f f
blocking.
2 . Place t r a n s m i s s i o n i n n e u t r a l , r e -
1 ease p a r k i n g b r a k e and r e a r ax1 e
d i s c o n n e c t , if engaged.
3 . Remove upper and l o w e r d i r t s h i e l d s

f r o m each drum. Figure 123
-51-
.005 INCH C L E A R A N C E
THROUGHOUT ARC
U P P E R B R A K E SHOE E C C E N T R I C CAM A D J U S T M E N T
ANCHOR P I N L O C K N U T
LEEDER VALVE
ANCHOR P I N
LOWER B R A K E SHO B R A K E DRUM
-,.005 INCH C L E A R A N C E
T H R O U G H O U T ARC 891 5
Figure 124
4 . Loosen p i n lock n u t .
5 . Each shoe must be adjusted t o center brake shoe a r c i n relation t o the drum.
Adjust eccentric cam t o bring linings i n t o contact with the drum and r o t a t e
anchor p i n s u f f i c i e n t l y t o relieve drag. Repeat until additional rotation o f
anchor p i n will no longer relieve drag. Tighten anchor p i n lock n u t leaving
.005" ( 0 . 1 2 7 m m ) clearance t h r o u g h e n t i r e a r c o f brake shoe.
NOTE: Subsequent adjustments t o compensate f o r l i n i n g wear are made u i t h the

eccentric cam only. Turn cam t o bring l i n i n g t o w i t h i n ,005" (0.127 ,ml
of drum. Repeat on opposite shoe.
-52-
BLEEDING
6. A f t e r b r a k e shoes a r e c e n t e r e d , anchor p i n s l o c k e d and a ,005" (0.127 mm)

c l e a r a n c e m a i n t a i n e d , back e c c e n t r i c cam o f f on a l l upper b r a k e shoes as
f a r as p o s s i b l e . T h i s h e l p s t o r e d u c e t h e a i r p o c k e t i n t h e wheel c y l i n d e r
due t o i t s m o u n t i n g i n a v e r t i c a l p o s i t i o n .
7 . Swing b a i l w i r e ( 3 , F i g u r e 125) t o
one s i d e and remove c o v e r (1) from
m a s t e r b r a k e cy1 i n d e r ( 2 ) .
Figure 125
8 . P o s i t i o n a d a p t o r (1, F i g u r e 126) on
m a s t e r c y l i n d e r ( 2 ) and a t t a c h
b l e e d e r b a l l hose ( 3 ) t o a d a p t o r .
See s p e c i a l t o o l s i n t h i s manual
f o r manufacturing o f adaptor.
Figure 126
9 . W i t h v a l v e on b l e e d e r b a l l c l o s e d , b r i n g p r e s s u r e i n b a l l up t o 15 P S I
(0.10 MPa). Open v a l v e on b l e e d e r b a l l .
-63-
10. S t a r t bleeding brake l i n e s in t h e following order:
A . Left Rear
B. Right Rear
C. Left Front
D. Right Front
Open bleeder valve (See Figure 1 2 4 ) a t wheel cylinder until a l l a i r i s expelled

from the l i n e and then close. Do t h i s a t each wheel. After bleeding i s com-
pleted, turn off bl edder b a l l valve.
NOTE: Divert flow of brake f l u i d away from drums and l i n i n g s while bleeding.
11. S t a r t crane a n d pump brakes for zpproximately one minute.
1 2 . Open bleeder ball valve a n d bleed brake l i n e s again as in step 1 0 .
13. Adjust upper brake shoes with ecc2n-

t r i c cam (1, Figure 1 2 7 ) t o .005"
(0.127 m m ) clearance again. Close
bleeder ball valve when t h r o u g h .
Figure 1 2 7
14. S t a r t crane a n d pump brakes. Free travel should be from 1/16" t o 1 / 4 " (1.53 mm
t o 6.35 mm) maximum. Sol id pedal must be from 2 1 / 2 " t o 3 1 / 2 " (63.5 mm t o
88.9 m m ) maximum. If brake pedal i s beyond these l i m i t s , repeat step 6 and
steps 10 t h r o u g h 13.
15. With crane s t i l l u p on blocking, s t a r t crane. Place in gear, engage four wheel
drive a n d t e s t brakes.
-54-
1 6 . D i s c o n n e c t b l e e d e r b a l l hose ( 3 ,
F i g u r e 128) and remove a d a p t o r (1)
f r o m m a s t e r cy1 i n d e r ( 2 ) .
Figure 128
1 7 . P o s i t i o n c o v e r (i, F i g u r e 1 2 9 ) on
m a s t e r cy1 i n d e r ( 2 ) and swing b a i l
w i r e ( 3 ) i n t o place.
Figure 129
18. Wipe a l l excess b r a k e f l u i d f r o m 1 i n e s . Have one p e r s o n s t a r t c r a n e and a p p l y

b r a k e s w h i l e a n o t h e r l o o k s f o r l e a k s . I f a l e a k i s s p o t t e d , r e p a i r and r e p e a t
e n t i r e bleeding procedure.
-65-
BURNISHING 150A AND 150FA

New l i n i n g s ( b r a k e shoes) may r e q u i r e " b u r n i s h i n g " t o a c h i e v e d e s i r e d performance.
A l s o when b r a k e l i n e s a r e b l e d , i t i s i m p o r t a n t t o b u r n i s h t o g e t r i d o f b r a k e
f l u i d t h a t may have g o t t e n o n t o l i n i n g s and b r a k e drum. The f o l l o w i n g s t e p s s h o u l d
be used t o e n s u r e p r o p e r b u r n i s h i n g .
1. P o s i t i o n c r a n e up on o u t r i g g e r s (1,
F i g u r e 130) w i t h a1 1 f o u r wheels
o f f t h e ground. P l a c e b l o c k i n g ( 2 )
under o u t r i g g e r frame ( 3 ) 1 eave
s u f f i c i e n t room i n f r o n t o f and
b e h i n d c r a n e t o s t o p i n case i t
s h o u l d a c c i d e n t l y be knocked o f f
blocking.
2. U s i n g FIRST GEAR ( o r l o w r a n g e )
a p p l y enough b r a k e l i n e p r e s s u r e
t o s l i p a l l wheels a g a i n s t t h e
e n g i n e t o r q u e ( n e a r maximum).
DO NOT ALLOW OUTSIDE

DRUM TEMPERATURES TO
EXCEED 300" t o 350°F
(157" TO 177°C).
3 . A l l o w drums t o c o o l f r o m 150" t o 200°F (C6" tcj 92°C) b e f o r e r e p e a t i n g . The num-

b e r o f c y c l e s s h o u l d be based on a c h i e v i n g an a c c e p t a b l e performance l e v e l . It
i s e s t i m a t e d t h a t a t l e a s t f i v e c y c l e s would be r e q u i r e d t o show marked b r a k e
improvement.
IMPROPER BURNISHING COULD RESULT I N "GLAZING". S I N C E THE MAXIMUM

TEMPERATURE LIMITS ARE SOMEWHAT CRITICAL y AND DIFFICULT TO DETERMINE,
EXTREME CARE MUST BE EXERCISED.
-65-
BLEEDING PROCEDURE 180s AND 220s
Any t i m e t h a t t h e b r a k e l i n e s o r c y l i n d e r s have maintenance performed i n v o l v i n g

r e p l a c e m e n t o f / o r r e p a i r i n g l i n e s , shoes, c y l i n d e r s , a x l e s , e t c . , t h e system
s t a n d s a chance o f b e i n g exposed t o t h e atornosphere, t h e f o l l o w i n g p r o c e d u r e must
be f o l l o w e d t o e n s u r e p r o p e r b l e e d i n g .
1. F u l l y e x t e n d o u t r i g g e r j a c k c y l i n -
d e r s (1, F i g u r e 131) and p o s i t i o n
30 I n . ( 7 6 2 . 0 0 mm) o f b l o c k i n g ( 2 )
under o u t r i g g e r box ( 3 ) as shown.
Lower crane, u n t i l o u t r i g g e r box
i s r e s t i n g on b l o c k i n g . Leave s u f -
f i c i e n t room i n f r o n t o f and b e h i n d
c r a n e t o s t o p i n case i t s h o u l d
a c c i d e n t a l l y be knocked o f f b l o c k i n g .
2 . P l a c e t r a n s m i s s i o n i n n e u t r a l and
s e t parking brake.
Figure 131
3. Swing b a i l w i r e s (1 and 2, F i g u r e
1 3 2 ) t o t h e s i d e and remove r e s e r -
v o i r cover ( 3 ) from t h e master
b r a k e cy1 in d e r ( 4 ) .
4 . P o s i t i o n g a s k e t and a d a p t o r p l a t e
on m a s t e r b r a k e c y l i n d e r u s i n g t h e
U-bo1 t s t o h o l d i t i n p l a c e . Con-
n e c t b l eeder b a l l t o a d a p t o r p l a t e .
NOTE: Refer t o "Special Tools" s e c t i o n

of t h i s manual f o r the manufac-
turing of adaptor p l a t e , gasket
and U-bolts, and i n s t a l l a t i o n .
Be sure bleeder b a l l i s f u l l .
5 . W i t h v a l v e on b l e e d e r b a l l c l o s e d , Figure 132
b r i n g p r e s s u r e i n b a l l up t o 1 5 P S I
(0.10 MPa). Open v a l v e on b l e e d e r
ball .
6. S t a r t b l e e d i n g b r a k e l i n e s i n t h e f o l l o w i n g o r d e r :
A . L e f t Rear
B. R i g h t Rear
C. L e f t Front
D. R i g h t F r o n t
E. P a r k i n g B r a k e
-67-
7 . Remove cap (1, F i g u r e 133) f r o m

b l eeder screw ( 2 ) a t b r a k e cy1 i n d e r .
Open b l e e d e r screw u n t i l a l l a i r i s
expelled from t h e l i n e , then close.
Do t h i s a t each wheel.
NOTE: Divert flow of brake fZuid away
from drums and Zinings while
bleeding.
Figure 133
8 . Loosen t u b e / h o s e f i t t i n g (1, F i g u r e
134) u n t i l a l l a i r i s e x p e l l e d f r o m
t h e l i n e , t h e n t i g h t e n . Loosen p l u g
( 2 ) on b o t t o m s i d e o f p a r k i n g b r a k e
( 3 ) t o expel a i r , then t i g h t e n .
NOTE: Divert flow of brake f l u i d away

from pads and disc (4).
9. T u r n o f f b l e e d e r b a l l v a l v e .
10. Remove a d a p t o r p l a t e and g a s k e t f r o m

m a s t e r b r a k e cy1 i n d e r . R e i n s t a l 1
r e s e r v o i r c o v e r on c y l i n d e r .
11. S t a r t c r a n e and pump brakes f o r

a p p r o x i m a t e l y one m i n u t e . Operate
t h e parking brake several times. Figure 134
Shut down e n g i n e .
12. Reconnect a d a p t o r p l a t e t o m a s t e r b r a k e cy1 i n d e r and r e p e a t b l e e d i n g p r o c e d u r e

t o t h i s p o i n t once a g a i n . Remove a d a p t o r p l a t e when t h r o u g h and r e i n s t a l l
r e s e r v o i r cover.
13. W i t h c r a n e s t i l l up on b l o c k i n g , s t a r t e n g i n e . S h i f t t r a n s m i s s i o n i n t o "LOW"
and t e s t b r a k e s . Shut down e n g i n e .
NOTE: Vaen the transmission is i n "LOW", four wheel d r i v e is engaged.

14. Wipe a l l excess b r a k e f l u i d from l i n e s , Have one p e r s o n s t a r t c r a n e and a p p l y
brakes w h i l e a n o t h e r l o o k s f o r l e a k s . I f a l e a k i s s p o t t e d , r e p a i r and r e p e a t
e n t i r e b l e e d i ng p r o c e d u r e .
1 5 . S t a r t c r a n e and remove b l o c k i n g from under o u t r i g g e r box.
The b r a k e shoes s h o u l d be b u r n i s h e d a f t e r " B l e e d i n g Procedure" i s completed.

BRAKE ADJUSTMENT 180s AND 220s

There a r e two t y p e s o f b r a k e a d j u s t m e n t procedures w h i c h must be f o l l o w e d e x p l i c i t l y
t o a c c o m p l i s h p r o p e r b r a k e a d j u s t m e n t . They a r e " A " and " B " as f o l l o w s :
A. FIELD ADJUSTMENT - t h i s i s done f o r normal wear o f b r a k e l i n i n g s where o n l y t h e

p r o p e r c l e a r a n c e between b r a k e drum and l i n i n g must be m a i n t a i n e d . F o l l o w " BRAKE
ADJUSTMENT" s t e p s 1, 2, 3, 5 and 6.
B. REBUILD ADJUSTMENT - t h i s i s done any t i m e t h a t t h e b r a k e shoes a r e r e p l a c e d o r

t h e p l a n e t a r y i s disassembled. F o l l o w " BRAKE ADJUSTMENT" s t e p s 1, 2, 4, 5 and 6.
BRAKE ADJUSTMENT
1. Remove two d u s t c o v e r p l u g s (1,

F i g u r e 135) and two i n s p e c t i o n
plugs ( 2 ) from d u s t cover ( 3 ) .
2. ' I n s e r t a 0.010" (0.25 mm) f e e l e r

gauge t h r o u g h t h e i n s p e c t i o n h o l e ( s )
t o check c l e a r a n c e . Clearance must
be t h e same on b o t h s i d e s .
3 . U s i n g a b r a k e spoon, t u r n each s t a r
wheel as many "CLICKS" as n e c e s s a r y
t o o b t a i n 0.010" t o 0.020" ( 0 . 2 5 mm
t o 0.50 mm) c l e a r a n c e between b r a k e
l i n i n g s and drum. S t a r wheels t u r n i n
o p p o s i t e d i r e c t i o n s (See F i g u r e 1 3 6 ) .
Figure 135
NOTE: Brake spoon may have t o be modified t o obtain easy access t o s t a r wheels.
DO NOT touch adjustor bolt ( 4 ) .
4. D u r i n g reassembly o f t h e a x l e , a d j u s t o r b o l t ( 4 ) was o n l y t i g h t e n e d enough t o
a l l o w a d j u s t o r assembly t o s l i d e back and f o r t h . I n s e r t a 0.010" ( 0 . 2 5 mm)
f e e l e r gauge i n t o each i n s p e c t i o n h o l e between b r a k e l i n i n g and drum. Leave
f e e l e r gauges i n p l a c e . Use a b r a k e spoon and t u r n s t a r wheels - AN EQUAL AMOUNT - ~
OF "CLICKS". T u r n i n g s t a r s an equal amount o f c l i c k s will c e n t e r t h e a d j u s t o r
-~
assembly i n r e l a t i o n s h i p t o t h e b r a k e drum. S t a r wheels t u r n i n o p p o s i t e d i -
r e c t i o n s (See F i g u r e 1 3 6 ) . C o n t i n u e t o t u r n s t a r wheels u n t i l c l e a r a n c e i s t h e
same on b o t h s i d e s . T i g h t e n a d j u s t o r bo1 t (4) t o 125 F t . Lbs. ( 1 6 9 Nm) .
5 . A f t e r p r o p e r c l e a r a n c e i s o b t a i n e d on
each s i d e , i n s t a l l two d u s t c o v e r
p l u g s (1 , F i g u r e 136) and two i n -
spection plugs ( 2 ) i n dust cover (3) s
6. D u r i n g normal o p e r a t i o n , t h e b r a k e
shoes a u t o m a t i c a l l y a d j u s t .
-69- Figure 136

BURNISHING 180s AND 220s

New l i n i n g s ( b r a k e shoes) may r e q u i r e " b u r n i s h i n g " t o a c h i e v e d e s i r e d performance.
A l s o when b r a k e l i n e s a r e b l e d , i t i s i m p o r t a n t t o b u r n i s h t o g e t r i d o f b r a k e
f l u i d t h a t may have g o t t e n on t o l i n i n g s and b r a k e drum. The f o l l o w i n g s t e p s s h o u l d
be used t o e n s u r e p r o p e r b u r n i s h i n g .
1. F u l l y e x t e n d o u t r i g g e r j a c k cy1 i n -
d e r s (1, F i g u r e 137) and p o s i t i o n
30 I n . (762.00 mm) o f b l o c k i n g ( 2 )
under o u t r i g g e r box ( 3 ) as shown.
Lower c r a n e u n t i l o u t r i g g e r box i s
r e s t i n g on b l o c k i n g . Leave s u f f i c i e n t
room i n f r o n t o f and b e h i n d c r a n e t o
s t o p i n case i t s h o u l d a c c i d e n t a l l y
be knocked o f f b l o c k i n g .
2 . U s i n g FIRST GEAR and p l a c i n g t r a n s -

m i s s i o n i n LOW, a p p l y enough b r a k e
p r e s s u r e t o s l i p a l l f o u r wheels
against t h e engine torque (near
maximum).
NOTE: Parking brake must be r e l e a s e d .

Figure 137
A DO iiOT ALLOW OUTSIDE DRUM TEMPE2ATLIRES TO EXCEED 300" TO 350°F

(157" TO 177°C).
3. A1 l o w drums t o c o o l f r o m 150" t o 200°F: (66" t o 93" ) b e f o r e r e p e a t i n g . The num-

b e r o f c y c l e s s h o u l d be based on a c h i e v i n g an a c c e p t a b l e performance l e v e l . It
i s e s t i m a t e d t h a t a t l e a s t f i v e c y c l e s would be r e q u i r e d t o show a marked b r a k e
improvement.
A IMPROPER BURNISHING COULD RESULT I N "GLAZING". S I N C E THE MAXIMUM

TEMPERATURE LIMITS ARE SOMEWHAT CRITICAL AND DIFFICULT TO DETERMINE,
EXTREME CARE MUST BE EXERCISED.
4. A f t e r " 3 u r n i s h i n g Procedure" i s completed, remove b l o c k i n g f r o m under o u t -

r i g g e r box.
-70-
GRADER 0
PLANER 0
ROLLER 0
CRANE d
Shop Manual L- 3
R3
WIRING DIAGRAMS - CRANES
CRANE ENGINE SERIAL N U M B E R WIRING DIAGRAM PAGE
MODEL MODEL RANGE NUMBER NUM,&FR
80 DD 3- 53N 01710 thru 0 3 1 3 1 111379 9

DD 3- 53N 04001 and Up 111379 9
IH UB- 264 01710 thru 03131 96962 1
IH UB- 264 04001 thru 04638 96962 1
1i-l UB- 264 04639 thru 05644 109795 5
IH UC- 263 01710 thru 03131 109795 5
IH UC- 263 05645 and Up 109795 5
IH UD- 282 01710 thru 0 3 1 3 1 92695 2
IH UD- 282 04001 and Up 109796 6
90, 100, DD 3 - 5 3 N 0 5 4 1 0 and Up 111379 9

110 & 125 IH UB- 264 0 1 0 0 1 thru 0 4 6 7 7 e x c e p t
94655 thru 04.657 96962 1
IH UB- 264 0 4 6 5 5 thru 0 4 6 5 7 , 0 4 6 7 8
and Up 109795 5
IH UC- 263 9 5 5 6 3 and Up 109795 5
IH UD- 282 0 1 0 0 1 thru 0 4 6 7 7 92695 2
IH UD- 282 0 4 6 7 8 and Up 109796 6
125F DD 4- 53N 0 2 9 6 5 and Up 109797 7
90A, 1 OOA, CUM u v - 3 5 2 c 02006 and Up 97869 4

O
ll A & 125A DD 4-5314 02006 and Up 109797 7
IH UV- 345 02006 thru 0 4 6 7 7 96704 3
H
I UV- 345 04678 and Up 109798 8
125FA I H UV- 345 0 7 9 9 0 and Up 10 9 7 9 8 8

DD 4 - 5 3 N 0 7 9 9 0 and Up 10 9 7 9 7 7
140F DD 3-53N 0 7 5 7 1 a n 3 Up 1 11 3 7 9 9
1 5 0 & 150FA CUM u v - 3 5 2 c 02832 thru 0 4 2 4 6 97869 4

DD 4 - 5 3 N 02832 and Up 109797 7
DEUTZ F 6 L - 9 1 2 02832 and Up 122748 10
IH UV- 345 02832 thru 0 4 6 7 7 96704 3
IH UV- 345 04678 and Up 109798 8
1 &OS DD 6V- 53N 3 8 5 0 2 and Up 138253 11
(MORE INFORMATION ON BACK OF COVER)
Dresser Industries, Inc. Construction Equipment Division 0 P.O. Box 647 0 Galion, OH 44833 U S A
(419)468-4321 0 Telex: 987430 Cable: Galiron
068 2
WM-NGDIAGRAM IP A G E
flUUMW?,?,, &.U'I!@ ER
09401 and Up 109797 7
220A DD 4-53N 07107 and Up 109797
220s DD 6V-53N 07724 and Up 138253 11
125P ALL ENGINES 01001 and Up 12

ELECTRIC MOTOR 01001 and Up 13
150P & 150T ALL ENGINES 01011 and Up 14

ELECTRIC MOTOR 01011 and Up 15
NOTE: A Z Z wiring diagrams ure subject t o change without n o t i f i c a t i o n .

S ho 3 Manual Section L-3
~~ ~~~~ ~
IH UB-264
NO. 92962
-
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L
- 1 -
Shop Manual Section L-3
IH UD-282
NO. 92695
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- 2 -
IH UV-345
NO. 96704
i
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- 3 -
CUMMINS UV-352-C
NO. 97869
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IH UB-264 X
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NO. 109795
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- 5 -
Shop Manual Section ;L-3.
IH UD-282
NO. 109796
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I I I I
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- 6 -
Shop Manual Section .L-3
DD 4-53N "I
NO. 97137 E
NO. l@7$Jz
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- 7 -
Shop Manual Section IL-3,:
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I
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- 8 -
Shop Manual Section L-3,
DD 3-53N
----I
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I I l l
I I II
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I I l l
I I l l
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- 9 -
Shop Manual Section LL-3
DEUTZ F6L-912
NO. 122748
I 1
I I
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I 8
I I I
- 10 -
DD 6V-53N
NO. 138253
- 11 -
Shop Manual Section cL:3A
125P (ALL ENGINES)
- 12 -
Shop Manual Section r L - 3 ,
125P (ELECTRIC MOTOR)
d
i
1
3
n
- 13 -
Shop Manual Section [L-3
150P & 150T (ALL ENGINES)
- 14 -
Shop Manual Section &-3
1 5 0 P & 150T (ELECTRIC MOTOR).
- 15 -
Shop Manual Section u,
r--T
- 16 -
MATERIAL LIFT ci(
GRADER d
PLANER d
ROLLER d
CRANE d
Shop Manual L-I 0

c3
TROUBLESHOOTING & REMOVAL
OF C R A N K I N G MOTORS
APPLICABLE MODELS
A1 t h o u g h the s t y l e of mechanical linkage may vary from u n i t t o u n i t
(Bendix drive, exposed s h i f t l e v e r , enclosed s h i f t lever, e t c . ) , the
basic components (solenoid, brushes, commutator , armature, e t c . ) and
functions o f cranking motor remain the same. Therefore, t h i s Shop
Manual covers basic service i n f o r m a t i o n for two s p e c i f i c motors of
similar s t r u c t u r e and/or r a t i n g s .
Standard torque specifications apply unless otherwise s t a t e d .
CAUTIO

GOOD WORKING ORDER.

INJURY
CONTENTS Page
Torque Sheet . . . . . . . . . . . . . . . . . . . . . Back of Cover
Preliminary Checks . . . . . . ............ 1
Removal. . . . . . . . . . . . . ........... 5
BenchTesting . . . . . . . . . ........... 6
Ins t a l 1 ation . . . . . . . . . . ........... 9
Lubrication . . . . . . . . . . ........... 10

c3
1182:
1
I
NOTE: Torque Values listed throu;g h w t this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
F Thread Size
Foot Pounds
(Ft Lbs.)
Grade 5
13 radial dashes on bolt or cap screw head)

Newton Meters
(Nm)
I
I
Foot Pounds
(Ft Lbs.)
Grade 8
(6 radial dashes on bo1t or cap screw head)
~
Newton Meters
(Nml
1/4 . 20 6 8 9 12
1/4 - 28 7 9 11 15
5/16 - 18 13 18 18 24
5/16 . 24 15 20 21 28
3/8 -16 24 33 34 46
3/8 . 24 27 37 38 52
7/16 - 14 38 52 54 73
7/16 -20 42 57 60 81
~~
1/2 . 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 -12 84 114 120 163
9/16 - 18 93 126 132 179
518 11- 115 156 165 224
5/8 - 18 130 176 185 251
3/4 . 10 205 278 290 393
3/4 - 16 230 312 320 434
718 . 9 305 414 455 617
718 . 14 335 454 515 698
1 - 8 455 617 695 942
1 - 14 510 69 1 785 1064
1 1/8 - 7 610 827 990 1342
1 1/8 - 12 685 929 1110 1505
1 1/4 - 7 860 1166 1400 1898
1 114 12- 955 1295 1550 2102
1 3/8 . 6 1130 1532 1830 248 1
1 3/8 -12 1290 1749 2 085 2827
1 1/2 - 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2 730 3701
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5 760 7810
FlLE L
PRELIM INA R!Y CHECKS
Prior t o servicing cranking motor , record

i t s model and s e r i a l number. Unit infor-
mation can be found on s e r i a l no. p l a t e
( 1 ) o r stamped d i r e c t l y i n t o body. Use
t h i s information t o o b t a i n p a r t s and/or
l a t e s t service b u l l e t i n s from Local
Del co-Remy parts d i s t r i b u t o r . If powered
by Cummins or Deutz engine, contact engine
d i s t r i b u t o r f o r cranking motor service
information and/or p a r t s .
Figure 1
REGARDLESS OF CONSTRUCTIONy NEVER OPERATE CRANKING MOTOR FOR MORE THAN 30

SECONDS AT A TIME WITHOUT PAUSING TO ALLOW IT TO COOL FOR AT LEAST 2 MINUTES.
OVERHEATING CAUSED BY EXCESSIVE CRANKING, COULD SERIOUSLY DAMAGE CRANKING
MOTOR.
CAUTION
Check battery t o insure i t i s f u l l y

charged. Use hydrometer ( 1 ) t o check
s p e c i f i c gravity of each c e l l . (Hydro-
meter should have temperature compensation
s c a l e ( 2 ) or b u i l t - i n temperature com-
pensator.) If s p e c i f i c gravity readings
a r e below 1.230, recharge b a t t e r y . I f
readings show variation of more t h a n
0.050 between c e l l s , replace battery.
Figure 2
I F BATTERY ACID I S SPLASHED ON FACE OR Irj EYES , IMMEDIATELY WASH WITH PLENTY
OF CLEAN WATER ONLY AND SEEK MEDICAL AID. IF ACID IS SPILLED ON HANDS,
SKIN , OR OTHER EXPOSED AREAS , IMMEDIATELY WASH WITH SOAP AND CLEAN WATER.
ACID SPILLED ON CLOTHING CAN BE NEUTRALIZED WITH DILUTED AMMONIA WATER OR A
CAUTION SOLUTION OF BAKING SODA.
-I-
FILE L
SH0.P MANUAL SECTION 10
I f battery checks a r e good, check battery

terminal s ( 1 ) closely. I f corroded ,
loosen battery cable connectors and remove
w i t h battery terminal p u l l e r ( 2 ) . Clean
terminals and connectors w i t h wire brush
( 3 ) and pol ish w i t h emery cloth. Replace
connectors and tighten securely.
Figure 3
Check a l l wiring and connections to/from

t h e cranking motor, solenoid, magnetic
switch, ignition switch, and battery.
Check f o r loose or corroded connections
and cut/worn insulation. Especially
check battery ground connection. Clean
and/or r e p a i r as required.
Figure 4
- 2-
FILE L
Figure 5
DO NOT JUMPER OR SHORT OUT CRANKING MOTOR, SOLENOID, OR MAGNECTIC SWITCH

TO CHECK OPERATION OF THESE COMPONENTS. JUMPERING/SHORTING BYPASSES SAFETY
DEVICES AND EOUIPMENT.
I f equipment uses same style cranking

motor ( 1 ) as t h a t shown in Figure 6 ,
remove rear plate t o inspect brushes ( 2 )
and commutator ( 3 ) . Check brushes for
wear, pitting or other signs of damage.
If brushes are worn beyond half of t h e i r
original 1 ength (compare with new brush) ,
replacement i s recommended. Replace
brushes in s e t s for equal wear and ser-
vice periods. If commutator i s worn
excessively, d i r t y , o u t of round or i f i t
i s has high insulation, the cranking motor
should be removed and serviced by a
qualified technician. While being ser-
viced i t should also be checked for shorts,
opens, and/or grounds.
Figure 6
-3-
FILE L
If equipment uses same s t y l e cranking

motor as t h a t shown i n Figure 7 , inspec-
tion of brushes and commutator should be
performed as a bench procedure. (Brushes
a r e mounted on r e a r cover and a r e removed
when cover i s removed and requires special
e f f o r t t o replace. ) Therefore, a suspected
cranking motor should be replaced with a
new or known working u n i t . This proce-
dure minimizes equipment downtime and
allows check and/or r e p a i r of the sus-
pected u n i t when convenient.
I f b a t t e r y , magnetic switch, ignition
switch, wiring and terminals a r e in good
operating condition, remove cranking
motor for f u r t h e r t e s t i n g or replacement Figure 7
as outlined on the following pages.
-4-
FILE
REMOVAL
Mat.ch mark, tape, o r i d e n t i f y a1 1 el e c t r i -

cal 1 eads (1 1 and terminal s ( 2 ) before
removing 1 eads from cranking 'motor. Then
remove a1 1 1 eads. Tape terminal end of
battery lead t o prevent accidental
grounding.
Figure 8
Remove two of the three capscrews (1 ) which

mount cranking motor t o engine flywheel
housing ( 2 ) . Remove cranking motor with
l a s t capscrew by pulling cranking motor
s t r a i g h t back and o u t .
Figure 9
-5-
FILE 1
BENCH TESTING
Check cranking motor p i n i o n ( 1 ) for
freedom of operation by turning i t on the
screw shaft. The armature should be
checked for freedom of r o t a t i o n by prying
the pinion (1 ) w i t h a screwdriver ( 2 ) .
Tight bearings, a bent armature s h a f t , or
a loose pole shoe screw w i l l cause the
armature t o n o t turn f r e e l y . If t h e
armature does n o t turn f r e e l y , the motor
s h o u l d be disassembled immediately. How-
ever, i f the armature does r o t a t e f r e e l y ,
the motor should be given a no-load t e s t
before disassembly.
Figure 10
THE FOLLOWING TEST IS TO BE PERFORMED WITH THE CRANKING MOTOR REMOVED FROM
THE ENGINE. DO NOT APPLY VOLTAGE ABOVE WHAT I S SPECIFIED; EXCESSIVE VOLT-
AGE MAY CAUSE THE ARMATURE TO THROW WINDINGS.
CAUTION
No-Load Test :
Prior t o s e t t i n g up t e s t , check the indenti-
f i c a t i o n tag on s i d e of cranking motor t o
be t e s t e d . Use t h e model number found there
I
1
t o reference c o r r e c t t e s t data i n t a b l e pre-
sented on following page. I f cranking motor
i s a Delco-Remy product and not l i s t e d i n
t a b l e , contact local d i s t r i b u t o r for l a t e s t
t e s t data. I f power u n i t i n manufactured
by Cummins or Deutz, contact Cummins or
Deutz d i s t r u b u t o r s for t e s t data.
Connect a VOLTMETER ( w i t h 20,000 ohms/vol t
r a t i n g ) from the motor terminal t o t h e motor
frame as shown i n Figure 1 1 . Use an rprn
indicator t o measure armature speed and
connect the motor and an ammeter (capable Figure 11
of indicating a 0 t o 60 amp range) i n s e r i e s
w i t h a f u l l y charaed batterv of the sDecified
voltage, and a switch i n t h e open p o s i t i o n from the solenoid battery terminal t o the
solenoid switch terminal. Close the switch and compare the voltage, current , and rprn
readings with those presented i n the f o l l o w i n g t e s t t a b l e or l a t e s t manufacturer's speci-
f i c a t i o n s . I t i s n o t necessary t o o b t a i n the exact voltage specified since an accurate
i n t e r p r e t a t i o n can be made by recognizing t h a t i f the volatage is s l i g h t l y higher t h a n
s p e c i f i e d , the rpm r a t e will be proportionately higher, w i t h the current remaining
e s s e n t i a l l y unchanged. However, i f the exact voltage i s desired , a carbon p i l e (stand-
ard automotive model ) connected across t h e battery can be used t o reduce the voltage t o
-6-
FILE L
the specified value. I f more than one 12- volt b a t t e r y i s used i n series, connect the
carbon p i l e across only one o f the 12- volt b a t t e r i e s . I f the specified current draw
does not include the solenoid, deduct from the ammeter reading the specified current
draw of the solenoid hold-in w i n d i n g . Make disconnections only w i t h the switch open.
NO LOAD TEST
(WITH SOLENOID IN CIRCUIT)
- --
IELCO-REMY
IELCDREMY MIN. MAX. MIN. MAX. DELCO-REMY
-
VOLTS ERVICE
VlODEL NO. AMPS
--
AMPS RPMS RPMS
IULLETIN NO,
SPEC I FlCATlON NO.
1107249 9 35 75 6000 9000 1 M-151 2444

1107343 9 50 80 5500 10500 ’ 1M-151 3573
1107539 9 50 80 5500 9000 1M-151 3534
1107679 9 55 80 3500 6000 1M-151 2438
110771 0 9 55 80 3500 6000 1M-151 2438
1108438 9 35 80 3500 6000 1M-151 2438
1109272 12 60 175 6900 14900 1M-151 3586
1109427 9 60 85 6800 10300 1M-151 3592
1113089 9 50 70 3500 5500 1 M-153 241 2
1113236 9 50 70 3500 5500 1M-153 241 2
1113240 9 50 70 3500 5500 1M-153 241 2
1113245 9 50 70 3500 5500 1M-153 241 2
1113424 9 75 105 5000 7000 1M-153 241 5
1113425 9 130 160 5000 7000 1M-153 3574
1113475 9 75 105 5000 7000 1M-153 241 5
1113675 9 130 160 5000 7000 1M-153 3574
1114058 9 140 190 4000 7030 1M-153 3501
1114081 9 120 150 3000 4500 1M-153 2431
1114086 9 140 190 4000 7000 1M-153 3501
11 14714 9 140 21 5 4000 7000 1M-153 3501
1114115*
11164994**
* Contact Cummins Distributor f o r l a t e s t s p e c i f i c a t i o n s

** Contact Deutz Distributor f o r l a t e s t s p e c i f i c a t i o n s
c3
-7 -
FILE
Test Indications:
1. Rated current draw and no- load speed indicates normal condition of the cranking
motor.
2. Low f r e e speed and h i g h current draw i n d i c a t e s :
a. Too much f r i c t i o n - t i g h t , d i r t y , or worn bearings, bent armature s h a f t or
loose pole shoes allowing armature t o drag.
b . Shorted armature. This can be f u r t h e r checked on a growler a f t e r disassembly.
c . Grounded armature or f i e l d s . Check f u r t h e r a f t e r disassembly.
3. Failure t o operate w i t h h i g h current draw i n d i c a t e s :
a. A d i r e c t ground in the terminal o r f i e l d s .
b. "Frozen" bearings ( t h i s should have been determined by t u r n i n g the armature by
hand).
4. Failure t o operate w i t h no current draw i n d i c a t e s :
a. Open f i e l d c i r c u i t . This can be checked a f t e r disassembly by inspecting
internal connections and tracing c i r c u i t w i t h a t e s t lamp.
b. Open armature c o i l s . Inspect the commutator for badly burned bars a f t e r
disassembly.
c . Broken brush springs, worn brushes, h i g h insulation between t h e commutator
bars or other causes which would prevent good contact between the brushes and
commutator.
5. Low no-load speed and low current draw indicates:
a . High internal r e s i s t a n c e due t o poor connections, defective leads, d i r t y
commutator and causes l i s t e d under Number 4.
6. High f r e e speed and h i g h current draw indicate shorted f i e l d s . I f shorted f i e l d s
a r e suspected, replace the f i e l d c o i l assembly and check for improved performance.
I f f u r t h e r disassembly/test procedures a r e required, l a t e s t service b u l l e t i n s and/or

p a r t s can be obtained from your local Delco-Remy d i s t r i b u t o r . I f powered by Cummins
or Deutz engine, contact engine d i s t r i b u t o r t o obtain l a t e s t service b u l l e t i n s and/or
parts.
-8-
FILE L
INSTALLATION
Insert cranking motor s h a f t into engine

flywheel housing opening, align mounting
holes and i n s e r t three capscrews ( 1 ) ,
previously removed, into flywheel housing
( 2 ) . Tighten as required.
Figure 1 2
Carefully match, then replace a1 1 e l e c t r i -

cal leads ( 1 & 2 ) . Be sure t o remove tape
from battery terminal before attaching t o
cranking motor.
Figure 13
-9 -
FILE L
LUBRICATION
Some cranking motors do n o t require lubrication except during overhaul, whereas

others a r e provided with lubrication f i t t i n g s . If a means f o r 1 u b r i c a t i n g . i s
provided, the motor should be lubricated a t perio.dic i n t e r v a l s as d i c t a t e d by
operating conditions.
1. Hinge cap o i l e r s o r o i l tubes sealed w i t h a pipe plug should have 8 t o 1 0
drops of medium grade engine o i l .
2. Grease cups should be turned down one turn. Refill i f necessary w i t h
Delco-Remy Lubricant No. 1960954 (molydisulphide f i l l e d multi-purpose
grease, Grade No. 1 ) .
When the motor i s disassembled f o r any reason, l u b r i c a t e as follows:

1. Oil wicks, i f present, should be resaturated.
2. The armature s h a f t and bushings should be coated w i t h Delco-Remy Lubricant
No. 1960954.
3. The r o l l type overrunning clutch requires no l u b r i c a t i o n . However, the d r i v e
assembly should be wiped clean.
DO NOT CLEAN IN ANY DEGREASING TANK OR WITH GREASE DISSOLVING SOLVENTS;

THIS WILL DISSOLVE THE LUBRICANT IN THE CLUTCH MECHANISM.
CAUTION
4. Avoid excessive l u b r i c a t i o n .
-1 0-
MATERIAL LIFT d
GRADER d
PLANER d
ROLLER d
CRANE d
Shop Manual L-11

TROUBLESHOOTING & R E M O V A L
OF ALTERNATORS
L CAUTION

GOOD WORKING ORDER.

INJURY
CONTENTS Page
Torque S h e e t . . . ......... . ........ Back o f Cover
Prel irni nary Checks . . . . . . . . . . . . . . . . . . 1
Removal . . . . . ......... . ........ 5
Installation . . . ......... . ........ 7
Lubrication . . . ......... . ........ 8
Dresser Industries, Inc. Construction Eaulpment Division P.O. Box 647 Galion. OH 44833 U.S.A.
(419) 468-4321
0182
NOTE: Torque Values listed throughout this manual are Lubrlcated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
Thread Size
Foot Pounds
GI
(3 radial dashes on
5
or cap screw head)
Newton Meters
r Foot Pounds
(Ft. Lbs.)
Grade 8
(6 radial dashes on t t o r cap screw head)
Newton Meters
1
(Ft. Lbs.) (Nm)
1/4 . 20 6 8 9 12
1/4 . 28 7 9 11 15
5/16 . 18 13 18 18 24
5/16 - 24 15 20 21 28
3/8 . 16 24 33 34 46
3/8 . 24 2: 37 38 52
7/16 - 14 38 52 54 73
7/16 - 20 42 57 60 81
1/2 - 13 58 79 82 111
1/2 - 20 65 88 90 122
9/16 . 12 84 114 120 163
9/16 . 18 93 126 132 179
5/8 . 11 115 156 165 224
5/8 . 18 130 176 185 251
3/4 - 10 205 278 290 393
3/4 . 16 230 312 320 434
7/8 . 9 305 414 455 617
7/8 - 14 335 454 515 698
1 - 8 455 617 695 942
1 . 14 510 691 785 1064
1 1/8 . 7 610 827 990 1342
1 1/8 . 12 685 929 1110 1505
1 1/4 . 7 860 1166 1400 1898
1 1/4 - 12 955 1295 1550 2102
1 318 - 6 1130 1532 1830 2481
1 318 . 12 1290 1749 2085 2827
1 1/2 . 6 1500 2034 2430 3295
1 1/2 . 12 1690 2291 2730 3701
1 3/4 . 5 2370 3213 3810 5166
2 . 4 1/2 3550 4813 5760 7810
SHOP MANUAL
PRELIMINARY CHECKS
Prior t o removal of the a l t e r n a t o r , check

the BATT-GEN meter ( i f equipped with
c l u s t e r gauge) or t h e BATT-CHG meter. Do
n o t s t a r t engine b u t do turn key switch
ON an observe meter indications. Dial
pointer should be i n the green zone, be-
tween 1 2 and 12.9 v o l t s . I f pointer
indicates l e s s than 1 2 v o l t s , the battery
i s undercharged and a complete battery
check i s required.
IF BATTERY ACID IS SPLASHED
ON FACE OR IN EYES, WASH OUT
IMMEDIATELY WITH PLENTY OF Figure 1
CLEAN WATER AND SEEK MEDICAL
AID. IF ACID IS SPILLED ON
CAUTION HANDS, SKIN, OR OTHER EX-
POSED AREAS, WASH IMMEDI-
ATELY WITH SOAP AND CLEAN
WATER. ACID SPILLED ON
CLOTHING CAN BE NEUTRALIZED
WITH DILUTED AMMONIA WATER
OR WATER SOLUTION OF
BAKING SODA.
Figure 2
To check b a t t e r y , use hydrometer t o t e s t

s p e c i f i c gravity of each c e l l . (Hydro-
meter should have b u i l t - i n temperature
compensator or s c a l e . ) If s p e c i f i c
gravity readings a r e below 1.230, re-
charge battery. I f readings indicate a
variation of more t h a n 0.050 between
c e l l s , replacement of t h e battery i s
recommended.
Figure 3
-I-
FILE
SHOP MA SECTION 11
If battery checks good, check battery

terminals and cable clamps next. If
corroded, loosen clamps, and remove
with battery terminal p u l l e r . Clean
terminals and clamps with wire brush
and then polish with emery c l o t h . Re-
i n s t a l 1 battery cables on proper
terminal s .
Figure 4
Check tension on drive b e l t as possible

cause of problem. If b e l t i s loose or
t o o t i g h t , a d j u s t b e l t a s required
(following s t e p ) . If b e l t does not
require adjustment, loosen adjustment
screw and s l i p b e l t off a1 t e r n a t o r
pully. Rotate pulley by hand t o check
f o r worn or seized bearings. (Noisy
operation could i n d i c a t e lack of
lubrication or f a u l t y bearings.)
Figure 5
While a1 t e r n a t o r drive b e l t i s removed,

check b e l t and pulley f o r signs of
binding or slipping such a s glazing,
frayed edges, e t c . Replace badly worn,
greasy, o r cracked b e l t s immediately.
If equipped with two b e l t s , replace
both b e l t s a t same time t o insure even
wear. If no problem i s found, replace
b e l t . Then adjust mounting bar hard-
ware so t h a t a firm push w i t h the t h u m b
(approx. 25 FT. LB. pressure) a t a
point midway between two pulleys will
depress the b e l t approximately 1 / 2 in.
Do n o t overtighten b e l t since t h i s
could cause bearing f a i l u r e by imposing
a sideload on the armature s h a f t . Figure 6
FILE
Check a l l wiring and connectors t o and

from b a t t e r y , a l t e r n a t o r , BATT-GEN (or
BAIT-CHG) meter, and ignition switch.
Check f o r cut and worn insulation or
other visual signs of damage. Repair
and wrap damaged insulation as required.
Also clean and tighten a l l connectors
and/or terminals t o insure good e l e c t r i -
cal connections.
Figure 7
Remove and check plug-in diode located in

wiring harness near a l t e r n a t o r . (This
diode allows current t o flow in only one
d i r e c t i o n . ) Use ohmmeter powered by 1 . 5
v o l t battery t o check diode; s e t on R x 10
meter s c a l e . Good diode will indicate low
forward r e s i s t a n c e ( 5 t o 8 ohms as shown
in Figure 5) and extreme high r e s i s t a n c e
(opposite end of s c a l e ) when ohmmeter t e s t
leads a r e reversed t o measure back r e s i s t -
ance. If dial pointer does n o t d e f l e c t
( i n d i c a t e s open or no connection) or i f
pointer indicates very small difference in
e i t h e r d i r e c t i o n ( i n d i c a t e s s h o r t ) , diode
should be replaced.
I F DIODE I S NOT REMOUNTED
SECURELY INTO ITS CONNECTOR,
ARCING AND POSSIBLE DAMAGE TO
THE ALTERNATOR CAN OCCUR.
CAUTION
WHEN STARTING ENGINE, NEVER OPERATE CRANKING MOTOR FOR MORE THAN 30
SECONDS AT A TIME WITHOUT PAUSING TO ALLOW I T TO COOL FOR AT LEAST
2 MINUTES. OVERHEATING CAUSED BY EXCESSIVE CRANKING COULD SERIOUSLY
DAMAGE CRANKING MOTOR.
CAUTION
-3-
FILE
With engine warmed up and running

a t i d l e , check BATT-GEN (or BATT-
CHG) meter. Dial poi.nter should
indicate between 1 3 . 2 and 15.2
volts charging r a t e . Allow 2 or
3 minutes for dial pointer t o
stab1 ize before taking f i n a l
reading. I f pointer indicates
a voltage bel ow or above t h i s r a t e ,
the voltage regulator section should
be checked by a qualified technician.
NOTE: The voltage regulator por-
t i o n of the a l t e r n a t o r i s
compensated t o permit the
charging system t o produce
more voltage during cold
ueather. Therefore, the
BATT-GEN(or BATT-CHG) meter
will indicate s l i g h t l y
higher voltage readings
during coZd weather than
i n warm weather.
I f BATT-GEN (or BATT-CHG) meter indicates

a l t e r n a t o r i s not charging, a quick check
of the voltage regulator section of i n t e -
gral a l t e r n a t o r s can be performed as
follows: With engine running s l i g h t l y
above i d l e , i n s e r t screwdriver into t e s t
hole (1 ) in rear of a1 ternator. This
grounds the t e s t t a b t o the end frame and
bypasses voltage regulator c i r c u i t r y .
If BATT-GEN (or BATT- CHG) meter now indi-
cates charging, the problem i s in the
voltage regulator section. Engine speed
may be increased gradually b u t do n o t
rev engine when voltage regulator i s
bypassed by screwdriver t e s t .
Figure 10
-4 -
FILE
Connect voltmeter between o u t p u t terminal

(BAT) of a l t e r n a t o r and ground. S t a r t
engine - observe a l l s a f e t y r u l e s and
have operator a t c o n t r o l s . Check voltage
indicated on t e s t voltmeter while engine
i s a t i d l e , then slowly increase engine
speed u n t i l t e s t voltmeter indicates 13
t o 15 v o l t s charging r a t e . If t h i s r a t e
i s obtained and remains steady, b o t h the
generator and voltage regulator sections
of t h e a1 t e r n a t o r a r e probably working
normally.
Operation of the BATT-GEN (or BATT- CHG)
meter can be checked by comparing i t s
reading w i t h those taken w i t h the t e s t
meter. Small , c o n s i s t e n t variations a r e
acceptabl e.
Constant overcharging indicates a problem in the voltage regulator section.
If the 13 t o 15 v o l t charging r a t e cannot be obtained, t h e problem may e x i s t in the
generator section.
I n e i t h e r of the l a s t two cases, or i f a l l other components i n t h e e l e c t r i c a l system
checks good, remove t h e suspected a l t e r n a t o r and take t o authorized Delco-Remy dealer
for complete t e s t i n g and/or service on t e s t s t a n d .
-5-
FILE
REMOVAL
Identify a l t e r n a t o r l e f t and right hand

e l e c t r i c a l p l u g leads ( 1 ) . Remove
e l e c t r i c a l p l u g by i n s e r t i n g screwdriver
between a1 t e r n a t o r housing and p l u g and
forcing tab toward p l u g and p u l l i n g p l u g
s t r a i g h t up. Also remove and tape t e r -
minal end of a1 t e r n a t o r battery 1 ead ( 2 )
t o prevent accidental g r o u n d i n g .
Figure 1 2
Loosen a1 t e r n a t o r adjustment screw (1 ) and

remove drive b e l t s . Do not remove adjust-
ment screw y e t . F i r s t remove lower
p i v o t i n g screw, washer, and n u t ( 2 ) .
S u p p o r t a l t e r n a t o r w i t h one hand while
removing adjustment screw and washers.
Figure 13
NOTE: To insure minimum equipment downtime, it i s recowonended t h a t the f a u l t y or

suspected alternator be replaced w i t h a new or r e b u i l t u n i t . The removed
alternator then can be s e m i c e d a f t e r the. equipment has been returned t o
normal operation.
- 6-
FILE L
._ SHOP MANUAL SECTION 11
IN STALLATION
While supporting a l t e r n a t o r with one h a n d ,

align a l t e r n a t o r and engine mounting holes
and i n s e r t lower pivot screw and washer
assembly ( 2 ) . Attach n u t . Now i n s e r t
adjustment screw, with washers attached,
t h r o u g h adjustment arm and into a l t e r n a t o r
housing mounting hole. Attach drive b e l t
(or b e l t s ) . Tighten adjustment screw and
pivot screw for approximately 1 / 2 inch
depression of drive b e l t s a t midpoint
between pulleys. (See Figure 6 ) .
Figure 14
Check l e f t and r i g h t hand markings placed

on a1 ternator e l e c t r i c a l plug and connector
during removal . Rep1 ace e l e c t r i c a l plug
( 1 ) securely. Untape and replace battery
1 ead ( 2 ) on a1 t e r n a t o r . Double-check
a l l connections before removing markings.
Figure 1 5
-7-
FILE L
LUBRICATION
The newer Delcotron a l t e r n a t o r s , with b u i l t - i n sol id s t a t e voltage

regulators, use generator rotor bearings t h a t contain a s u f f i c i e n t
supply of l u b r i c a n t t o eliminate the need f o r frequent l u b r i c a t i o n .
Bearings should be lubricated i f replaced a n d / o r a l t e r n a t o r i s
overhauled. A1 t e r n a t o r overhaul periods a r e usually scheduled t o
coincide with engine overhaul periods.
-8-
GRADER 0
PLANER 0
ROLLER 0
CRANE
Shop Man.ual 0-1

R 1f C 1
HEAD & HOOK BLOCK

90 thru 150 A1 1
b CAUTIO

GOOD WORKING ORDER.

INJURY.
CONTENTS Page
Torque Sheet . . . . . . . .. . . . . ., . . . . . Back o f Cover
Disassembly . . . . . . . . . . . . . . . . . . . 1
Inspection . . . . . . . . . .. ......... 5
Reassembly. . . . . . . . . . . . . . . . . . . . 6
Care o f Wire Rope . . . . . . . . . . . . . . . . 8
Wire Rope Replacement . . . . . . . . . . . . . . 9
Methods o f Lubrication . . .. .......... 10
c1
0484
r
NOTE: Torque Values listed thrlwghout this manual are Lubricated (Wet) Threads; values should be increased 1/3 for Non-Lubricated (Dry) Threads.
1 Heat treated material Grade 5 & Grade 8
Thread Size t Grade 5 I Grade 8

t or cap screw head)
Newton Meters
1/4 . 20 12
1/4 . 28 15
5/16 . 18 24
5/16 - 24 28
3/8 - 16 46
3/8 . 24 52
7/16 - 14 73
7/16 - 20 81
1/2 . 13 111
1/2 - 20 122
9/16 - 12 163
9/16 - 18 179
5/8 . 11 224
5/73 . 18 251
314 . 10 393
3/4 . 16 434
7/8 . 4 617
7/8 . 14 698
1 - 8 942
1 . 14 1064
1 :I8 - 7 1342
1. 1/8 . 12 1505
1 1/4 . 7 1898
1 1/4 . 12 2 102
1 3/8 ~ 6 2481
1 3/8 . 12 2827
1 1/2 - 6 3295
1 1/2 . 12 3701
1 3/4 - 5 5166
2 . 4 1/2 7810
FILE 0
DISASSEMBLY
Before s t a r t i n g disassembly, the hook block
i s t o be rested on the ground. The fol low-
i n g procedure will reduce chances of "bird
caging" the wire rope when removing/chang- 1
i n g hook blocks or replacing/lubricating the
wire rope.
Raise boom head block approximately 3 f e e t
(914.40 mm) above the f u l l y depressed posi-
t i o n . Using the hoist c o n t r o l , lower the
hook block u n t i l i t j u s t touches the ground.
Lower the boom u n t i l the hook block i s r e s t -
i n g on the ground and wire rope i s slack.
Remove cable anchor wedge ( 1 ) . C1 imb i n t o
o p e r a t o r ' s cab and hoist cable o n t o winch
drum until a l l cable i s f r e e o f hook block. Figure 1
With s u i t a b l e h o i s t position hook block on

work bench as i l l u s t r a t e d . Remove two
lock nuts and two 1 - 1 4 x 1 2 1 /4" cap-
screws.
Remove weights e i t h e r s i d e of hook block
side plates.
.NOTE: Care must be taken t o obseme t h e
p o s i t i o n of t h e s i d e weights i n t h e
hook block assembly t o i n s u r e re-
assembZy of t h e s e weights i n e x a c t l y
t h e same p o s i t i o n s as originalZy
found.
Remove hook assembly.
Remove two 3/4 - 10 and one 1 1 / 4 - 1 2

lock nuts on e i t h e r s i d e of sheave assembly.
Remove s i d e p l a t e ( 1 ) and stqeave assembly
(2)
Figure 3
-I-
FILE 0
After removal o f sheaves, t h r u s t washers,

e t c . inspect spacer ( 1 ) , cable anchor ( 2 )
for wear remove and replace i f necessary.
Figure 4
Remove three 3/8 - 16 x 3/4" capscrews ,

lockwashers, and plain washers bearing
cap ( 1 ) and gasket ( 2 ) .
Remove roll pin ( 3 ) and s l o t t e d n u t ( 4 ) .
Remove hook ( 8 ) .
Place bearing block ( 6 ) i n arbor press.
Remove brass bushing ( 7 ) and t h r u s t r o l l e r
bearing ( 5 ) .
Inspect a l l component parts and replace i f
necessary.
Figure 5
-2-
FILE 0
SHOP MANUAL SECTION
Inspect hook block sheave assembly ( 1 ) Y

t h r u s t washers (Z), bearings ( 4 ) and
grease s e a l s ( 3 ) .
Figure 6
Remove 1 1 / 4 - 1 2 lock n u t (1 ) from bottom

sheave assembly i n head block ( 2 ) .
W i t h proper support applied t o three
sheaves remove p i n , sheaves and t h r u s t
washers.
Figure 7
Remove 1 1 / 4 - 1 2 lock n u t (1 ) from t o p

sheave and spacer assembly.
Carefully remove pin, spacers and sheave.
Figure 8
-3-
FILE 0
SHOP MANUAL SECTION
Inspect component parts of head block

sheave assemblies.
Inspect needle bearings ( 1 ) , spacers ( 2 ) ,
pins ( 3 ) t h r u s t washers ( 4 ) for adequate
wear and replace i f necessary.
Figure 9
INSPECTION
.A wire rope, l i k e a chain, is only as good a s i t s weakest p o i n t SHOWING THE MOST WEAR.
,The following information i s taken from a National Concensus Standard as references
by Federal Government Agencies supplied by CIMA. All wire rope will eventually wear
t o a point where i t i s no longer useable. Wire rope shall be taken o u t of service
when any of the folloiwng conditions e x i s t :
1. In running ropes, s i x randomly d i s t r i b u t e d broken wires i n one lay or three
broken wires i n one strand i n one l a y .
2. Wear o f one- third the wriginal diameter of outside individual wires. K i n k i n g ,
crushing, b i r d caging, or any other damage r e s u l t i n g i n d i s t o r t i o n of the rope
structure .
3. Evidence of any heat damage from any cause.
4. Reduction from nominal diameter o f more than 3/64" ( 1 . 1 9 mm) for a 9/16"
( 1 4 . 2 8 ) wire rope.
5. In standing ropes, more t h a n two broken wires i n one lay i n sections beyond
end connections o r more than one broken wire a t an end connection.
Certain sections of wire rope often get more wear t h a n o t h e r s . Rope on a drum w i t h
two or more layers will wear a t the p o i n t where the rope s t a r t s each sucessive
l a y e r , and a l s o a t the points where the upper layer crosses the lower. Wire rope will
f a t i g u e each time i t passes over a sheave. Rope often f a i l s from v i b r a t i o n f a t i g u e
a t t h e p o i n t where they a r e dead-ended.
A CAUTION
AFTER A NEW WIRE ROPE IS INSTALLED, FIRST OPERATE CRANE WITH A
LIGHT LOAD TO LET WIRE ROPE ADJUST ITSELF.
-4-
Shop Manual Section 0-1
After i n s t a l 1 ing a new wire rope, a few t r i p s through the working cycle a t slow
speeds and l i g h t loads will - s e t the strands more firmly i n place. I t will a l s o
give t h e operator an opportunity t o see t h a t the drum and sheaves a r e operating
properly and a r e f i t t e d t o the new rope. Operate slowly and c a r e f u l l y ; a new
rope can be easi 1y damaged by any operating e r r o r .
HOOK BLOCK INSPECTION
I t i s recommended t h a t a daily/lO hour inspection and a 500 hour and/or annual

inspection be made of the hook block.
DAILY/10 HOUR SERVICE:
A d a i l y l l 0 hour inspection can be made by visually and physically examining the
hook block as outlined in the following s t e p s .
1. The hook must be able t o r o t a t e f r e e l y 360" without any binding.
*----zz-..,y
LNOT& While r o t a t i n g the hook, push it upwards t o see i f there i s any
noticeable end play i n t h e t h r u s t bearing. I f there is an abnormal
m o u n t o f end play, t h e hook block must be disassembled t o make
a f u r t h e r i n s p e c t i o n of t h e t h r u s t bearing, in accordance t o t h e
appropriate Shop Manual Section.
2. Hook blocks with trunnion mounted hooks must be checked t o be sure t h a t the
hook can pivot f r e e l y . The hook i s designed t o pivot so t h a t the e n t i r e
hook does n o t r e a c t t o motions of t h e load which i s being l i f t e d . Also,
this design helps prevent l o a d s h i f t i n g of chains, s l i n g s , e t c . , in the
hook which can cause damage t o the hook.
3. The sheaves must be able t o r o t a t e f r e e l y . I f they do n o t r o t a t e properly,
the wire rope and sheave will i n t e r a c t together, wearing b o t h of them and
a l s o cause load jerking. Raise and lower the hook without any load t o
observe whether t h e sheaves a r e r o t a t i n g f r e e l y . If jerky motion i s ob-
served, the hook block must be disassembled t o make a f u r t h e r inspection
in accordance t o the appropriate Shop Manual Section.
4. Check the hook f o r cracks, gouges or other indications of wear. If any of
these conditions e x i s t , the hook must be taken o u t of service and destroyed.
5. Check f o r hook spreading or twisting. An easy way t o determine t h e
s a t i s f a c t o r y l i m i t i s t o check t o see i f the hook l a t c h does n o t contact
the hook, then, i f so, the hook must be replaced, as the hook i s n o t
s a t i s f a c t o r y and i s unsafe. Destroy the unsafe hook.
c1
- 5-
ANNUAL/500 HOUR SERVICE:

I t i s required t h a t a complete inspection be made of the hook block assembly on
a regular schedule, a t each 500 hours of operation or annually, whichever comes
first.
For t h i s inspection, the hook block assembly must be completely disassembled.
Care must be taken t o observe the position of s i d e weights in the hook block
assembly f o r reassembly of the s i d e weights in exactly the same position as
o r i g i n i a l l y found. Refer t o the appropriate Shop Manual f o r complete instruc-
t i o n s on disassembly and reassembly of the hook block.
Clean a l l p a r t s i n s u i t a b l e cleaning solvent before the inspection i s made. I n -
spect the hook f o r twisting or spreading. An easy way t o determine the s a t s i f a c t o r y
l i m i t i s t h a t i f the l a t c h does n o t contact the hook, then the hook must be re-
placed, as the hook i s n o t s a t i s f a c t o r y and i s unsafe. If the hook i s n o t replaced
f o r twisted or spreading condition, then a magnetic p a r t i c l e inspection must be
performed, including the thread area. If one or more cracks a r e found, then
replacement of the hook i s necessary. I t i s p a r t i c u l a r l y important t o inspect
t h e threads on the hook f o r any wear cracks, pulling or other damage of any kind.
If any thread damage i s found, then the hook must be replaced.
c-”-
!jNO.T,E;, Always destroy worn and damaged hooks.
The n u t which i s used t o secure the hook t o the hook block assembly i s a l s o t o
be t e s t e d and inspected in the same manner as the hook. Besides inspecting f o r
thread damage and cracks, i t must a l s o be tested f o r proper hardness. The
following i s a l i s t . o f nuts t o be used on various hook block assemblies with
t h e i r hardness values. Refer t o appropriate microfiche or Parts Book f o r n u t
used with your hook block.
PART NUMBER HARDNESS VALUE
7520 Rockwell C-32

17046 Rockwell C-24 - 38
102474 Brinell Test 150 - 200
102560 Rockwell C-19 or
Brine1 1 Test 223
c1
- 5A-
REASSEMBLY
Reposition two spacers and sheave in

head block while inserting pin t h r o u g h
them. I n s t a l l a washer and self- locking
n u t ( 1 , Figure 10) on each end of pin.
Torque nuts t o 418 Ft.Lbs. (567 Nm).
Figure 1 0
Reposition three bottom sheaves and two

t h r u s t washers in head block while
inserting pin. I n s t a l l a washer and
self- locking n u t ( 1 , Figure 1 1 ) on
each end o f pin. Torque nuts t o 418
Ft.Lbs. (567 Nm).
&QT€: -_ Position t h r u s t washers between

head bZock and sheaves. No
t h r u s t washers are Zocated
between sheaves.
Figure 11
CONT' D NEXT PAGE -

c1
-6-
Reassemble parts of hook assembly.

If brass bushing ( 7 , Figure 1 2 ) and
t h r u s t bearing ( 5 ) have been removed,
reposition bearing block ( 6 ) in arbor
press and r e i n s t a l 1 .
-.- .
.NOTE:
I..
._ The word "TOP" is marked on one
s i d e of t h e t h r u s t bearing (5).
%en bearing is instaZZed in the
bearing bZock (6), be sure t h a t
t h e s i d e marked "TOP" is facing
t h e bottom surface of t h e bearing
hoZe bore. The space betueen
t h e inner and outer races of t h e
bearing must be visibZe a f t e r
instaZZation. Figure 1 2
Position hook (8) through block. I n s t a l l

c a s t e l l a t e d n u t ( 4 ) and run u p on s h a f t
u n t i l f i n g e r t i g h t and a s l i g h t binding
i s f e l t when the hook i s rotated. Then
back o f f the n u t one s l o t and i n s t a l l
r o l l pin ( 3 ) . I n s t a l l gasket ( 2 ) and
cap ( 1 ) . I n s t a l l three capscrews, lock
washers and torque.
Lubricate the bearing block and brass
bushings thoroughly with mu1 tipurpose
grease a f t e r reassembly.
CONT'D NEXT PAGE -
c1
- 6A-
FILE 0
Reassemble sheaves ( 2 ) o n t o hook block.

Position three t h r u s t washers between
sheaves and side plates ( 1 ) .
I n s t a l l side p l a t e .
I n s t a l l 1 1 / 4 - 1 2 lock nuts on center
pin and torque t o 418 FT. L B .
I n s t a l l 3/4 - 10 lock nuts on outside pins
and torque t o 75 FT. LBS.
Figure 13
I n s t a l 1 hook assembly.
Position spl i t weight so t h a t solid portion
of weight i s toward the cable anchor.
Hol low end o f weight will face operator
when reeved w i t h wire rope.
This i n s t a l lation permits hook block t o be
level when hoisting. Insert two 1 - 14 x
1 2 1 / 4 capscrews , lock nuts. Torque t o
200 FT. LBS.
Figure 1 4
See page 9 f o r wire rope reeving.

After wire rope i s reeved, attach end in
cable anchor (1 ). Insert anchor wedge
and remove a l l slack in l i n e s .
-7-
FILE 0
CARE OF WIRE ROPE

Due t o varying conditions a d e f i n i t e time interval for inspection and
lubrication o f wire rope cannot be s t a t e d . Lubricant serves two purposes:
i t reduces wear and protects the wire rope.
I t i s comparatively easy t o observe t h a t a wire rope i s i n need of a lubri-
cant by n o t i n g t h e following c h a r a t e r i s t i c s : creaking noise while the
rope i s spooling (may a l s o indicate a bad water c o n d i t i o n ) ; breaking
of wires i n valley of rope w i t h o u t any indication o f uniform strand
nicking; spring of rope lessening w i t h o u t the l a y being pulled down
noticeably.
I f a rope i s allowed t o become d r y , corroded or rusty and sheave i n
which rope i s r u n n i n g i s i n a s i m i l a r condition, i t will cause rope t o
s l i p . This s l i p p i n g over the sheave abrades and c u t s the rope and r e -
duces i t s s t r e n g t h .
When a "rust-bound" rope receives a sudden j e r k i t cannot absorb the
shock of the load throughout i t s length; instead i t i s confined t o
one spot and r e s u l t s i n breaking one or more strands and occasionally
the e n t i r e rope.
When ropes t h a t have been i n service a r e kept i d l e , as i n shutdown of
operation, they should receive protective care. Condensed moisture,
i n many cases s e t t l e s on the rope causing heavy corrosion and r u s t .
Lubricant "weathers" o u t ; p a r t i c u l a r l y , i f rope i s exposed t o outside
conditions or kept in a h o t , dusty area.
I t i s advisable t o run rope several times a week even t h o u g h i t i s run
a t l i g h t l o a d . I f rope must be kept i n a c t i v e l y wound on the drum for
any length o f time, i t i s wise t o smear each layer of rope, as i t i s
wound on t h e drum, w i t h a covering o f . petrolatum, cup grease, or similar
j e l l y - l i k e petroleum covering. Otherwise moisture seeps i n t o rope
often causing dangerous d e t e r i o r a t i o n .
NOTE: Frayed o r kinked ropes are dangerous and should be replaced.
Just l o o k i n g a t rope i s n o t enough. When an inspector takes a look

a t a rope he may see sections showing kinks o r excessive wear. By
f l a g g i n g the rope, he can quickly determine where rope i s r u b b i n g and
then r e p a i r , rep1 ace or modify t h e condition causing wear.
Even t h o u g h wire rope i s one o f t h e most uniform mechanical products
made a c e r t a i n number of ropes do f a i l prematurely. I n most cases
these f a i l u r e s a r e the d i r e c t r e s u l t of abuse.
-8 -
FILE 0
WIRE ROPE REPLACEMENT
A wire rope can be permanently damaged even

before i t has gone i n t o operation.
Unwinding from a reel the wrong way
can p u t destructive kinks and doglegs
in the rope. If reel can be s e t on
jacks, unwind from topside of reel
as i l l u s t r a t e d . If wire rope i s supplied
in a c o i l , uncoil by r o l l i n g i t slowly
l i k e a wheel, leaving behind a t r a i l of
s t r a i g h t rope. Uncoiling by laying
coil f l a t and pulling off t o p gives
hard-to- hand1 e , kinky rope.
When replacing wire rope, extreme care must be taken

n o t t o p u t kinks or unnecessary bends into the rope.
As i l l u s t r a t e d above, when i n s t a l l i n g wedges in e i t h e r
hook block or winch drum, the rope must be b r o u g h t
back s t r a i g h t and turned, n o t twisted, around wedge and
inserted i n t o s l o t .
-9-
FILE 0
METHODS OF LUBRICATION
Metal s p l i t box - f o r bath treatment has a burlap
c o l l a r or wiper a t o u t l e t end. The sloping
i n t e r i o r requires l e s s o i l , gives greater
contact, b e t t e r penetration.
ALWAYS WEAR SUITABLE GLOVES

WHEN HANDLING WIRE ROPE.
CAUTION
The pour-on method i s e f f e c t i v e and

adhesive when heated 10 W o i l i s used.
BE SURE TO HOLD THE WIPING

SWAB BEHIND THE SHEAVE.
THIS CATCHES ANY EXCESS
OIL THAT WOULD BE CARRIED
CAUTION ON ALONG THE ROPE.
Hot bath method of applying

heavier-bodied l u b r i c a n t a t high
temperature. Gas burners or
steam heat may be used. Preheated
lubrication is always more
penetrating. Rope should run
t h r o u g h slowly t o ensure
penetration.
LUBRICATION IN STORAGE
Ropes kept in storage dry o u t quickly. Lubricate them frequently, or have a

sealing compound applied which will r e t a i n the l u b r i c a n t . Before putting i n t o
s e r v i c e , c a r e f u l l y inspect rope f o r condition of l u b r i c a n t and presence of corrosion.
-1 0-
FILE 0
HOOK & HEAD BLOCK REEVING
B C
Five part l i n e - as shown above.

Four p a r t 1 ine - remove wire rope from wedge socket "A" and i n s t a l 1 i n wedge
socket "B" .
Three p a r t l i n e - remove rope from wedge socket " A" . Remove rope from sheave
#3 and sheave #5, then i n s t a l l rope in wedge socket " A" .
Two - P a r t Line - remove rope from wedge socket " A" and from sheave #2, 3, and 5.
Thread rope from sheave #1 t o sheave #5, and i n s t a l 1 in wedge socket "C".
Single p a r t l i n e - remove rope from wedge socket "A" and from sheaves #2, 3, 4 ,
and 5. Attach rope t o s i n g l e - l i n e weighted hook block.
A ALWAYS WEAR SUITABLE GLOVES WHEN HANDLING WIRE ROPE.
CAUTION
-11-
FILE -
~
. 0
I n s e r t working portion o f wire rope i n t o s t r a i g h t side o f socket. If

n o t i n s t a l l e d c o r r e c t l y , clamp will bend and weaken wire rope.
A
ALWAYS WEAR SUITABLE GLOVES WHEN HANDLING WIRE ROPE.
CAUTION
-7 2-
MATERIAL L I F T [ ]
GRADER [ ]
PLANER [ ]
ROLLER [ ]
CRANE [X]
SHOP MANUAL 0-03.00

RlK1
DRESSER HYDRAULIC CRANE
WIRE ROPE SPECIFICATIONS
A l l Models See T e x t
T h i s m a n u a l c o n t a i n s w i r e r o p e s p e c i f i c a t i o n s f o r DRESSER H y d r a u l i c C r a n e s . T h e
i n f o r m a t i o n i s p r e s e n t e d by m o d e l n u m b e r and s e r i a1 n u m b e r range. F o l l o w i n g t h e
MODEL BREAKDOWN i s t h e MANUFACTURERS DESCRIPTION o f e a c h w i r e r o p e by DRESSER
P a r t Number.
CAUTION

REQUIRED FOR T H I S OPERATION MUST BE I N GOOD
WORKING ORDER.

INJURY.
CONTENTS PAGE
MODEL BREAKDOWN ......... .......... 1

MODEL 80 .... ...... .......... 1
MODEL 90, 100, 110 AND 1 2 5 . .......... 1
MODEL 1 2 5 F ... ...... .......... 2
MODEL 90A, 100A, l l O A AND 1 2 5 A ......... 2
MODEL125FA. .. ...... .......... 3
MODEL 140F ... ...... .......... 3
MODEL 1 5 0 A ... ...... .......... 3
MODEL150FA. . . . . . . . . . . . . . . . . . . 4
MODEL 180s ... ...... .......... 4
(CONTENTS CONT’D ON BACK OF COVER)
KOMATSU DRESSER COMPANY EAST SUNNYSIDE AVE. LIBERTYVILLE, I L 60048

0388 c1
CONTENTS PAGE
.
MODEL 2 2 0 A .
. . .. . . . . . . . . . . . . . 4
MODEL200FA . .
. . .. . . . . . . . . . . . . . 6
.
MODEL 2 2 0 s .
... . . . ........... 5
MODEL 400s . .
... . . . ........... 5
.
MODEL 1 2 5 P .
. . .. . . . . . . . . . . . . . 5
...
MODEL 1 5 0 P AND 1 5 0 T . ........... 5
FRONT END WINCH ( A L L MODELS) .......... 6
...
MANUFACTURERS DESCRIPTION ........... 7
WIRE ROPE ............ .......... 9
.
WIRE ROPE SPECIFICATIONS ........... 9
MAINTENANCE RECOMMENDATIONS ........... 9
SERVICE AND INSPECTION OF WIRE ROPE ......... 10
. . . .
RESTING HOOK BLOCK . . . . . . . . . . . 10
.
IMPORTANCE OF LUBRICATION ........... 10
RECOMMENDED LUBRICANTS FOR WIRE ROPE ...... 11
..
METHODS OF LUBRICATION ........... 12
..
LUBRICATION I N STORAGE ........... 13
........
I D L E ROPES ........... 13
COMPONENT PARTS OF WIRE ROPE .......... 14
INSPECTION OF WIRE ROPE. SHEAVES & DRUM ..... 14
WIREROPE .... . . ........... 14
.
SHEAVES AND DRUM . . ........... 16
WIRE ROPE REPLACEMENT . . . ........... 16
INSTALLATION OF WIRE ROPE . ........... 17
BREAKING I N WIRE ROPE . . . . . . . . . . . . . . 18
HOOK AND HEAD BLOCK REEVING ........... 18
c1
Shop Manual Section ,O-3.00,
MODEL BREAKDOWN
MODEL 80
SERIAL NUMBERS 01710 THRU 031 31
MAIN HOIST
PART NUMBER S I Z E AND LENGTH APPLICATION

63749 1/2" x 245' Two s e c t i o n power boom
78238 1/2" x 330' T h r e e s e c t i o n power boom
SERIAL NUMBERS 33132 THRU 03999
- NO MODEL 8 0 ' s WERE BUILT -

SERIAL NUMBERS 04000 AND UP
MAIN HOIST

105892 1/2" x 165' T h r e e s e c t i o n power
s t a g e d boom
MODELS 90,100,110 AND 125

M A I N HOIST
PART NUMB E R S I Z E AND LENGTH APPLICATION
63749 1/2" x 245' Two s e c t i o n boom
M A I N HOIST

84220 1/2" x 400' F o u r s e c t i o n power boom
113529 1/2" x 450' Optional for four section
power boom
M A I N HOIST

89 346 9/16'' x 330' T h r e e s e c t i o n power boom
89347 9/16" x 450' Four s e c t i o n power boom
89 348 9/16'' x 500' Optional f o r f o u r section
power boom
- 1-
Shop Manual Section 0-3.00
MODEL 125F
M A I N HOIST

89346 9/16'' x 330' T h r e e s e c t i o n power boom
89348 9/16" x 500' Optional f o r f o u r section
power boom
AUXILIARY HOIST
PART N UMB E R S I Z E AND LENGTH APPLICATION

89345 9/16" x 2 4 5 ' Standard
MODELS 90A, 100A, l l O A AND 125A

M A I N HOIST

MAIN HOIST

89346 9/16'' x 330' T h r e e s e c t i o n power boom
89348 9/16" x 500 I Optional f o r four section
power boom
AUXILIARY HOIST

89345 9/16" x 2 4 5 ' Standard
-2-
Shop Manual Section a-3.00
MODEL 125FA
MAIN HOIST

89 346 9/16" x 330' T h r e e s e c t i o n power boom
89348 9/16" x 500' Optional f o r f o u r section
power boom
AUXILIARY HOIST

89345 9/16" x 2 4 5 ' Standard
MODEL 140F
MAIN HOIST

89346 9/16'' x 3 3 0 ' T h r e e s e c t i o n power boom
89347 9/16" x 4 5 0 ' F o u r s e c t i o n power boom
89348 9/16" x 5 0 0 ' Optional f o r f o u r section
power boom
AUXILIARY HOIST

89 345 9/16" x 2 4 5 ' Standard
MODEL 150A
M A I N HOIST

89 34 5 9/16" x 245' Two s e c t i o n power boom
89 346 9/16" x 330' T h r e e s e c t i o n power boom
89348 9/16" x 500' Optional f o r four section
power boom
AUXILIARY HOIST

89345 9/16" x 2 4 5 ' Standard
-3-
Shop Manual Section 0 - 3 . 0 0
MODEL 150FA
SERIAL NUMBERS 0 7 3 0 5 AND UP
MAIN H O I S T
PART NUMBER -
S I Z E AND LENGTH APPLICATION
89346 9/16" x 330' Three s e c t i o n power boom
89347 9/16" x 450' Four s e c t i o n power boom
89 348 9 / 1 6 " x 500 I Optional f o r f o u r s e c t i o n
power boom
A U X I L I A R Y HOIST
PART NUMB E R S I Z E AND LENGTH -

APPLICATION
89345 9/16" x 245' Standard
MODEL 180s
MAIN HOIST

126075 9/16" x 500' Standard

142246 9/16" x 300' Auxiliary hoist without
jib
1 4 1 521 9/16" x 350' Auxiliary hoist w i t h j i b
MODEL 220A
MAIN HOIST

126075 9/16" x 500' Standard

89345 9/16'' x 245' Standard
- 4-
Shop Manual Section ;O-3.06
MODEL 220s
MAIN HOIST

126075 9/16" x 500' Standard
AUXILIARY HOIST

142246 9/16" x 300' Auxiliary h o i s t without
jib
141521 9/16" x 350' Auxiliary h o i s t w i t h j i b
MODEL 400s
SERIAL NUMBERS 071 13 THRU 071 18
MAIN HOIST

113591 3/4" x 700' Standard
MODEL 125P
SERIAL NUMBER AN D
- 7
UP
MAIN HOIST

63749 1/2" x 245' Two section power boom
78238 1/2" x 330' Three section power boom
84220 1/2" x 400' Four section power boom
power boom
MODEL 150P AND 150T

~~~ ~
MAIN HOIST

89346 9/16" x 330' Three section power boom
power boom
AUXILIARY HOIST

89345 9/16" x 245' Standard
(CONT'D. NEXT PAGE)
-5-
-
Shop Manual Section '.Og.
L"
1500 FT. HOIST

114411 9/16" x 1500' Standard brake
114411 9/16" x 1530' Disc brake
T END WINCH'(ALL MoDQLs)'~
FRONT END WINCH
The f r o n t end winch i s capable of developing 15,000 pounds of l i n e pull.

A 9/16" d i a . hole i s provided i n the drum f o r the i n s e r t i o n of wire rope.
MODEL 200FA
M A I N HOIST
PART NUMBER S I Z E AN5 LENGTH APPLICATION

89345 9/16" x 245' Standard
c1
-6-
Shop Manual Section .a
-&.
MANUFACTURERS DESCRIPTION
GALION PART NUMBER DESCRIPTION
63749 S I Z E AND LENGTH; 0 . 5 0 " D I A . x 2 4 5 ' LG.
TYPE; 8 x 25 FS IWRC ( S P I N RESISTANT)
MATERIAL; IMPROVED PLOW STEEL
BREAKING STRENGTH; APPROX. 10 TONS
75042 S I Z E AND LENGTH; 0 . 5 0 " D I A . x 500' LG.
TYPE; 8 x 2 5 FS IWRC ( S P I N RESISTANT)
78238 S I Z E AND LENGTH; 0.50" D I A . x 330' LG.
89345 S I Z E AND LENGTH; 0 . 5 6 " D I A . x 2 4 5 ' LG.
BREAKING STRENGTH; APPROX. 1 2 . 8 TONS
BREAKING STRENGTH; APPROX. 12.8 TONS
89347 S I Z E AND LENGTH; 0.56" D I A . X 450' LG.
TYPE; 8 x 2 5 FS IWRC ( S P I N RESISTAIIT)
TYPE; 8 x 25 FS INRC ( S P I N RESISTANT)
BREAKING STRENGTH; APPROX. 1 2 . 8 TONS
105892 S I Z E AND LEXGTH; 0 . 5 0 " D I A . x 1 6 5 ' LG.
1081 5 1 S I Z E AND LENGTH; 0 . 5 0 " D I A . x 2 0 0 ' LG.
11 1434 S I Z E AND LENGTH; 0.50" D I A . x 550 I LG.
TYPE; 8 x 2 5 FS INRC ( S P I N RESISTANT)
BREAKING STRENGTH ; APPROX. 10 TONS
11 3 5 2 9 S I Z E AND LENGTH; 0.50" D I A . x 4 5 0 ' LG.
(CONT I D. NEXT PAGE)

-7-
Shop Manual Section
GALION PART NUMBER DESCRIPTION

11 3591 S I Z E AFjD LENGTH; 0.75" D I A . x 700' LG.
11441 1 S I Z E AND LENGTH; 0.56" D I A . x 1,500' LG.
MATERIAL; EXTRA IMPROVED PLOW STEEL
141 521 S I Z E AND LENGTH; 0.56" D I A . x 3 5 0 ' LG.
-8-
SHOP MANUAL SECTION 0-03.00
WIRE ROPE
Even t h o u g h wire rope i s one of the most uniform mechanical products made, a
c e r t a i n number of ropes f a i l prematurely. I n most cases these f a i 1 ures are the
r e s u l t of abuse. Some of the more common types of abuses t o wire rope are:
1 WARNING! KINKING - which r e s u l t s i n localized wear, i s gen-

era1 l y caused by a1 1 owing a 1 oop t o form i n a slack 1 ine and
then p u l l i n g the loop t o a t i g h t permanent s e t .
WARNING! OVERLOADING - which r e s u l t s i n complete f r a c t u r e of
the rope or crushing and d i s t o r t i o n on the drums and
sheaves, i s caused by working the rope w i t h a l o a d t o o near
i t s breaking strength.
WARNING! IMPROPER SIZING - permits strands i n rope t o become
loose and unbalances a rope, throwing a1 1 of the 1 oad onto a
few strands.
WARNING! IMPROPER SPOOLING - r e s u l t s i n crushed and d i s -
t o r t e d ropes and comes from careless application and opera-
t i o n of the rope.
WARNING! WHIPPING A LINE - which r e s u l t s i n many wires
broken square o f f , comes from jerking the 1 ine or running i t
1 oose.
WIRE ROPE SPECIFICATIONS

DRESSER Construction Equipment Division has c a r e f u l l y selected the 8 x 25 spin
r e s i s t a n t construction f o r the cranes because t h i s type best s u i t s the appl ica-
t i o n . The spin r e s i s t a n t feature i s highly desirable in l i f t i n g unguided loads
when reeved f o r s i n g l e part l i n e . The 8-strand construction i s favored over
6-strand construction due t o g r e a t e r f l e x i b i l i t y , I n extremely i m p o r t a n t feature
t h a t insures proper spooling on the hoist drum.
Substitutions may be made on the basis of minim.rm breaking strength a t l e a s t
equal or exceeding those for the 8 x 25 construction, the spin r e s i s t a n t fea-
t u r e , and the f l e x i b i l i t y necessary t o spool properly on the hoist drum.
MAINTENANCE RECOMMENDATIONS
Due t o v a r y i n g conditions, a d e f i n i t e time interval f o r inspection and lubrica-
tion can n o t be s t a t e d . See "Service and Inspection of Wire Rope" f o r further
information.
9
SERVICE AND INSPECTION OF WIRE ROPE

RESTING HOOK BLOCK
Before performing any o f the f o l l owing services t o the wire rope, the hook block
must be r e s t i n g on the ground. The f o l l owing procedure will reduce changes of
displacing the wire rope when lubricating, changing h o o k blocks or replacing
wire rope.
1. Raise boom head block (1 , Figure
1 ) t o approximately 3 ' (914.40
mm) above a f u l l y depressed
position.
2. Using hoist lower hook block ( 2 )
until i t j u s t touches the
ground.
14292
Figure 1
3. Lower boom u n t i l hook block (1,

Figure 2 ) i s r e s t i n g on ground
and wire rope ( 2 ) i s slack.
14293
Figure 2
IMPORTANCE OF LUBRICATIdN
Lubrication i s a v i t a l part of the maintenance of the wire rope. Lubricate s e r -

ves two purposes: i t reduces wear and protects the wire rope.
When wire rope i s i n use, i t gradually loses l u b r i c a n t . The lubricant i s
squeezed o u t o f a rope as i t i s worked under load. The internal wires rub
against each other, and outside wires also wear against sheaves and drums. Lub-
r i c a t i o n reduces wear, b o t h on the inside and on the outside of the wire rope.
10
SHOP MANUAL SECTION 0- 03.00
I t i s comparatively easy t o observe t h a t a rope i s in need o f lubrication by

noting the following c h a r a c t e r i s t i c s .
1. Creaking noise while the wire rope i s
spool i ng .
2. Breaking of the wires i n the Val ley o f
the wire rope without any indications o f
uniform strand nicking. When a wire rope
passes over a sheave there. should be
smooth interaction of wires.
3. The spring o f the wire rope lessening
without the lay being pulled down
noticeably.
If a wire rope i s allowed t o become dry, corroded or r u s t y , and the sheave i n
which the rope i s running i s i n a s i m i l a r condition, i t will cause the rope t o
s l i p . This s l ipping over the sheave abrades and cuts the rope and reduces i t s
strength.
When a "rust-bound'' rope receives a sudden j e r k : t can n o t absorb the shock o f
the load t h r o u g h o u t i t s length; instead, i t i s confined t o one spot and r e s u l t s
i n the breaking o f one or more strands, and occasionally, the e n t i r e rope.
RECOMMENDED LUBRICANTS FOR WIRE ROPE
A recommended lubricant f o r wire rope i s one t h a t a v o l a t i l e solvent. This

lubricant should have a consistency t h a t permits cold application by brush, d r i p
method or b o t h . The v o l a t i l e solvent c a r r i e s the lubricant i n t o the core of the
rope, quickly evaporates, and leaves a film o f lubricant as a residue. There are
several brands o f t h i s type o f lubricant on the market. One type i s :
BRAND NAME SUPPLIER
G U L F FLUID LUBCOTE #3 GULF
Generally, t h e best and/or most economical f i e l d lubrication and protection can
be obtained through the use o f a continuous application system while the rope i s
i n operation. The f o l l owing products or t h e i r equals may be used:
BRAND NAME SUPPLIER

TEXACO CRATER A TEXACO
BROOKS KLINGFAST 85 BROOKS OIL CO.
G U L F SENECA 39 GULF
WHITMORE'S WIRE R O P E LUBRICANT WHITMORE M F G . C O .
NOTE: Crude or used o i l s and greases should not be used as wire rope 7 u b r j c a n t s
because t h e y c o n t a i n g r i t or a c i d , e i t h e r o f which can have a d e t r i m e n t a l
e f f e c t on w i r e rope.
11
Generally, a good field lubricant should have thess characteristics.

1. Contain no acids or alkalis which will deteriorate wire
rope.
2. Good adhesive properties, so it will stay on the rope.
3. Excellent penetrating qualities, so it can easily infiltrate
the strands and wires.
4. Good protection against corrosion.
5. Non-solubility under all or most service conditions.
6. Resistance to oxidation, hardening, or crystallization.
METHODS OF LUBRICATION
Prior to lubricating a wire rope it is recommended that it be cleaned to remove
accumulations of dirt, grit and other abrasive materials. Use a stiff wire brush
and solvent, with compressed air, or steam. Lubricate wire rope immediately
after cleaning using any of the following methods.
A WARNING! Pressure at air nozzle must not exceed 30 PSI (0.207

.
MPa) Always wear goggles when using compressed air.
WARNING! Care should be exercised 20 avoid inhalation of vapors,
exposure to the skin and creating fire hazards when using sol vent
type cl eaners.
Metal split box for bath treatment
has a burl ap col 1 ar or wiper at out-
let end. The sloping interior re-
quires 1 ess oi 1 , gives greater con-
tact, better penetration.
WARNING! Always wear suit-
ab1 e gloves when hand1 ing
wire rope.
14294
Figure 3
Hot bath method of applying heavier
bodied lubricant at high tempera-
tures. Steam heat may be used to heat
the lubricant. Preheated lubrication
is always more penetrating. Rope
should run through slowly to ensure
penetration. - ...5
14295
Figure 4
12
The p o u r - o n method i s a f f e c t i v e and

adhesive when heated o i l i s used.
A WARNING! Be sure t o hold
w i p i n g swab BEHIND the
sheave. This catches any
excess oi 1 t h a t would be
c a r r i e d on along the rope.
14296
Figure 5
LUBRICATION IN STORAGE
Ropes kept in storage dry out quickly. Lubricate them frequently, or have a
sealing compound applied which will r e t a i n the lubricant. Before p u t t i n g the
i n t o service, c a r e f u l l y inspect rope f o r c o n d i t i o of lubricant and presence of
corrosion.
IDLE ROPES
When ropes t h a t have been in service a r e kept i d l e , as in shutdown of operation,
they should receive protective care. Condensation in many instances, s e t t l e s on
the rope causing heaver corrosion and rust. The rope lubricant "weathers" o u t ,
p a r t i c u l a r l y i f the rope i s exposed t o outside conditions or kept i n a h o t or
dusty area.
I t i s advisable t o run the rope several times a week even i f only w i t h a l i g h t
load. I f the rope must be kept inactively wound on t h e drum f o r any length of
time, i t i s wise t o smear each layer of the rope a s i t i s wound on the drum,
w i t h a covering of petrolatum, cupgrease or simil .r j e l l y - 1 i ke protective coat-
ing. Otherwise moisture seeps i n t o the rope, ofte.1 causing dangerous deteriora-
tion.
13
COMPONENT PARTS OF WIRE ROPE
CORE
W'IRE RC
14297
Figure 6
INSPECTION OF WIRE ROPE, SHEAVYS & DRUM
Wire Rope
In some operations, the wire rope can be run t o i t s complete service l i f e with-
o u t injuring o r endangering l i f e .
Where risk i s involved, i t i s desireable t o estimate the remaining strength and
service l i f e of a worn rope.
A rope, l i k e a chain, i s only a s good a s i t s weakest point; t h a t p o i n t being the
POINT SHOWING THE MOST WEAR. The following information i s taken from a National
Consensus Standard as referenced by Federal Government Agencies supplied by CIMA
(Construction Industry Manufactures Association).
Wire rope rep1 acement may vary according t o Federal, S t a t e , or Local
Codes and i n accordance t o the type of rope u;ed. Specific information
on t h e c a r e , inspection, and replacement of ' l i r e rope can be obtained
from any wire rope manufacturer.
14
Some general guidelines for wire rope replacement using s t e e l sheaves

a r e t h e following.
1. In running rope, s i x randomly d i s t r i b u t e d broken wires in
one l a y o r t h r e e broken wires in one strand i n one l a y .
2. One outer wire broken a t t h e point of contact with t h e core of
t h e rope which has worked i t s way out of t h e rope s t r u c t u r e and
protrudes or loops o u t from t h e rope s t r u c t u r e . Additional in-
spection of t h i s section i s required.
3. Wear o f one-third of the original diameter of outside i n -
dividual wires.
4. Kinking, crushing, birdcaging, or any other damage r e s u l t i n g i n
d i s t o r t i o n of t h e rope s t r u c t u r e .
5. Evidence of any heat damage from any cause.
6. Reduction from nominal diameter of more than:
a. 1/64 In. (0.4 mm) f o r diameters u p t o and includ-
ing 5/16 In. (8.0 m m ) .
b. 1/32 I n . (0.8 mm) f o r diameters 3/8 I n . (9.5 m m ) ,
t o and including 1/2 In. (13.0 mm) .
c. 3/64 In. (1.2 mm) f o r diameters 9/16 I n . (14.5
m m ) , t o and including 3/4 In. ( 1 9 . 6 m m ) .
d. 1/16 I n . ( 1 . 6 mm) f o r diameters 7/8 In. (22.0 mm
t o and including 1-1/8 In. ( 2 9 . 0 m m ) .
e. 3/32 I n . ( 2 . 4 mm) f o r diameters 1-1/4 In. (32 .o
m m ) , t o and including 1-1/2 In. (38.0 m m ) .
7. In standing ropes, more than two broken wires i n one l a y i n
sections beyond end connections o r more than one broken wire
a t an end connection.
8. When evidence o f core f a i l u r e i n r o t a t i c r r e s i s t a n t ropes i s
recognized by a lengthening o f the 1 ay and a 1 oca1 ized r e -
duction in diameter.
9. Inspect sheave grooves f o r excessive wear.
Certain sections o f wire rope often g e t more wear than o t h e r s .

Rope on a drum w i t h two or more layers will wear a t t h e point where the rope
s t a r t s each successive l a y e r , and a l s o a t the p o i n t where they a r e dead-ended.
15
Sheaves and Drum

The sheaves and drum should be inspected frequent’iy. A scored drum and battered
1 agging wi 11 impair wire rope service. Broken or scored sheaves w i 11 damage the
outer wires o f t h e rope. Worn sheave guards may permit a rope t o j u m p the
sheaves and cause an expensive, and possibly dangerous accident.
These p o i n t s a r e watched carefully by a l l good operator’s.
WIRE ROPE REPLACEMENT
Figure 7
When replacing wire rope extreme care must be taken n o t t o p u t kinks or unneces-
sary bends i n t o the rope.
16
As illustrated, when installing wedges in either drum or socket, the rope must
be brought back straight and turned, not twisted, around wedge and inserted into
slot.
14299
Figure 8
Insert working portion of the wire rope into straight side of socket. If not
instal 1 ed correctly, clamp will bend and weaken wire rope.
A WARNING! Always wear sui tab1 e gloves when hand1 ing wire rope.
INSTALLATION OF WIRE ROPE
A wire rope can be damaged permanent-

ly even before it has gone into oper-
ation. Unwinding from a reel the
wrong way can put destructive kinks
and dog legs in the rope. I f the reel
can be set on jacks, unwind from the
topside of the reel as shown in Fig-
ure 9. If the wire rope is suppl ied
in coi 1 , uncoi 1 by roll ing the coil
slowly 1 i ke a wheel , 1 eaving behind a
trail o f straight rope. Uncoiling by
laying the coil flat and pulling off
the top will give you hard-to-handle,
kinky rope.
Figure 9
c1
17
BREAKING I N WIRE ROPE
A WARNING! After new wire rope is installed, first operated crane with a
1 iqht load to let wire rope adjust itself.
A new rope can be easily damage by any operating error. A few trips trough the
working cycle at slow speeds and light loads will set the strands more firmly in
pl ace.
It will a1 so give the operator an opportunity to see that the drums and sheaves
are operating properly and are fitted to the new rope.
HOOK AND HEAD BLOCK REEVING
For the proper method of hook and head block reeving for your unit, refer to the
Operator’s Manual. It will describe the various reeving combinations for hook
and head block arrangement.
c1
18
MATERIAL L I F T [X]
GRADER [X]
ii) DRESSER PLANER
ROLLER
[X]
[X]
CRANE [X]
SHOP MANUAL YE01 .oo

ALL MODELS ALL SERIAL NUMBERS
CAUTION

ORDER.
~ SAFE WORKSHOP PRACTICES ARE A MUST.
CONTENTS PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS . . . . . . . . . . . . . . . . 2
BOLT IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TYPE 1 , 5 AND 8 NON-PHOSPHATE COATED HARDWARE . . . . . . . . . . . . . 2
TYPE 8 PHOSPHATE COATED HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE VALUES FOR STANDARD METRIC FASTENERS . . . . . . . . . . . . . . . . . 5
TORQUE VALUES FOR HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS . . . . . . . . . . . . . . . . . . 7
TORQUE VALUES FOR HYDRAULIC TUBES AND FllTlNGS . . . . . . . . . . . . . . . 8
0989
METRIC CONVERSIONS
For metric conversion of U.S. Measurements refer to "Metric Measurements and Conversion" manual
publication number 1085 804 R2.
SHOP MANUAL SECTION Y-01.00
INTRODUCTION
This section is intended to supercede the "GENERAL TORQUE VALUES" chart, located on the back cover
of most shop manual sections.
Since the introduction of Phosphate Coated Hardware into the DRESSER product line, different torque charts
are required to specify the value of torque required for the various hardware.
This manual IS NOT INTENDED to supercede SPECIAL BOLT TORQUES given in the text portion of the
various manuals, only to give standard values to that hardware not specified.
1
~ ~~~~
TORQUES
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS
BOLT IDENTIFICATION CHART
I I
DESCRIPTION
WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD

Low or Medium Carbon Steel Not Heat Treated
~~
WILL HAVE THREE RADIAL LINES

Quenched and Tempered Medium Carbon Steel
8 8 WILL HAVE 6 RADIAL LINES

Quenched and Tempered Special Carbon or Alloy Steel
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE

Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
a. All thread surfaces are clean and lubricated with SAE-30 engine oil (See Note.)
b. Joints are rigid, that is, no gaskets or compressible materials are used.
c. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.

0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used
0.90 when hardened surfaces are used under the nut or bolt head.
When reusing bolts and nuts in service, use minimum torque values.
2
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE - CONTINUED

The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not
given
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS CHART ARE LUBRICATED (WET
THREADS; VALUES SHOULD BE INCREASED 113 FOR NON-LUBRICATED (DRY]
THREADS.
r HEAT TREATED MATERIAL GRADE 5 & GRADE 8
GRADE 5 GRADE 8
THREAD SIZE (3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
FOOT POUNDS NEWTON METER FOOT POUNDS NEWTON METER

(Ft. Lbs.) (N'm) (Ft. Lbs.) (N'm)
1/4" - 20 6 a 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3 p- 16 24 33 34 46
3/alf - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16 - 20 42 57 60 a1
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
518" - 11 115 156 165 224
518" - 18 130 176 185 25 1
314" - 10 205 278 290 393
314" - 16 240 312 320 434
7/8" - 9 305 414 455 617
718" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 69 1 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8"- 12 685 929 1110 1505
1 1 /A"- 7 860 1166 1400 1898
i i;14$,- 12 955 1295 1550 21 02
1 318" - 6 1130 1532 1830 2481
1 318"- 12 1290 1749 2085 2827
1 112"- 6 1400 2034 2430 3295
1 112"- 12 1690 2291 2730 3701
1 314" - 5 2370 3213 3810 5166
' 2 " - 4 112 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is recommended
that the loose bolt and/or nut be replaced with a new one.
3
TYPE 8 PHOSPHATE COATED HARDWARE

This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases,
original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened
flat washers (Rockwell "C" 38-45), all phosphate coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted
threads or plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required
torque.
STANDARD TORQUE f 10%

NOMINAL
THREAD
DIAMETER NEWTON METER FOOT POUNDS
(N-m) (Ft. Lbs.)
1/4 10 8
5/16 21 16
3/8 38 28
7116 60 45
1/2 92 70
9/16 130 100
518 180 140
3/4 325 240
718 520 390
1 780 580
1 - 1/8 1110 820
1 - 1/4 1565 1160
1 - 3/8 2050 1520
1 - 1/2 2720 2020
1 - 3/4 3380 2510
2 5080 3780
4
TORQUE VALUES FOR STANDARD METRIC FASTENERS

This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. Original equipment
standard hardware is defined as coarse thread metric class 10.9 bolts and class 10.0 nuts and thru hardened
flat washers (Rockwell "C" 38-45), all phosphate coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted
threads or plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicated material class ONLY and are NOT to be used to determine
required torque.
NOMINAL THREAD STANDARD TORQUE

DIAMETER 10%
MILLIMETER NEWTON METERS FOOT POUNDS

(N.m) (Ft. Lbs.)
6 10 7
7 16 12
8 23 17
10 46 34
12 80 60
14 125 90
16 200 150
18 275 200
20 385 290
22 530 390
24 670 500
27 980 730
30 1330 990
33 1790 1330
36 2325 1730
39 3010 2240
5
TORQUE VALUES FOR HOSE CLAMPS

The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator,
air cleaner, operating lever boots, hydraulic system, etc.).
TORQUE PLUS OR MINUS 5 In. Lbs. (0.6 N-m)
RADIATOR, AIR HYDRAULIC ~
CLEANER, BOOTS, ETC. SYSTEM

CLAMP
TYPE AND SIZE NEWTON INCH NEWTON INCH
METER POUNDS METER POUNDS
(N.m) (In. Lbs). (N.m) (In. Lbs.)
1 "T" Bolt (Any Diameter) 1I 6.2-7.3 1 55-65

l - l -
Worm Drive - 1/3/4 in.
Open Diameter & Under
Worm Drive - Over 1-3/4 in.
2.2-3.3 20-30 4.5-5.6 iI 40-50 i
Open Diameter 4.5-5.6 40-50
Worm Drive - All "Ultra-Tite" 10.7-11.8
~
95-105
~
4.5-5.6
I -
40-50
6
TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS

The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE: Overtorquing bolts will damage the flanges and/or bolts, which may cause leakage.
I BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE NEWTON METER FOOT POUNDS
(N-m) (Ft. Lbs.)
112 5116 20 - 24 15 - 18
314 318 30 - 37 22 - 27
1 318 37 - 47 27 - 35
1 -114 7116 47 - 61 35 - 45
1 -112 112 62 - 79 46 - 58
2 112 75 - 88 55 - 65
2 -112 112 107 - 123 79 - 91
3 518 187 - 203 138 -150
3 -112 518 159 - 180 117 -133
(*) - Inside diameter of flange on end of hydraulic tube or hose fitting.
NOTE: Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.
7
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS
"0" RING BOSS PLUGS

TUBE NUTS AND SWIVEL NUTS
FOR 37" FLARED FllTlNGS I JIC - 37" SEAT

TORQUE
SIZE TUBING THREAD
O.D. SIZE MINIMUM MAXIMUM MINIMUM IMAXIMUM
FOOT FOOT NEWTON NEWTON
POUNDS POUNDS METER METER
(Ft. Lbs.) (Ft. Lbs.) (N*m) (NW
4 7/16-20 9 12 12 16
5 1/2-20 12 15 16 20
6 9116-18 21 24 29 33
8 314-16 35 40 47 54
10 718-14 53 58 72 79
12 1-1/16-12 77 82 104 111
14
16
1-3116-12
1-5116-12
90
110
100
120 I 122
149
136
163
iiz II
20 1-5/5-1 2 140 150 190 204
24 1-718-12 162 217 237
32 2-112-12 225 305 325
Above torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations.
Swivel nuts either swaged or brazed.
These torques are not recommended for tubes with wall thickness of 0.035" or less.

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SMC-150FA

Lubricant Specifications .. e. . . . ...

ALL JACKING, HOISTING, AND GENERAL WORKSHOP EQUIP-

EXTREME CAUTION TQ BE OBSERVED AT A L L TIMES TO PREVENT

SAFE WORKSHOP PRACTICES ARE A MUST.

Some p r e v i o u s model motor graders and a l l r o l l e r s

To remove t h e pitman arm from t h e l e v e r s h a f t ,

Pry staked portion of a d j u s t i n q screw lock n u t

On l a t e r models (with screw-adjusted l e v e r

On orevious models (with one-piece control or

Wheel tube bearings can be replaced by removing

Remove cap screws, control housina, a n d qasket.

S E R V I C E T O CAM & A C T U A T O R ASSEMBLY

SERVICE TO L E V E R SHAFT & STUD ASSEMBLY

Check s h a f t s p l i n e s and threads on l e v e r s h a f t .

Adjustment of stud r o l l e r bearinq must be s e t t o

Push spool o u t o t h e r end t o expose "0" r i n g .

Push spool through t h e valve body unti 1 "0" r i n a

Screw n u t onto c l e v i s o r swivel bearing rod

Clean housing thorouahly.

I n s t a l l wheel tube assembly and replace cover.

A shim pack i s used between two qaskets t o e s t a b -

C o a t cam s h a f t s p l i n e with grease and i n s e r t

Position lever shaft i n position with stud r o l l e r

I f l e v e r s h a f t i s shim a d j u s t e d , proceed t o Step

I n s t a l 1 l a r g e c o v e r bo1 t l o c k washers and n u t s , i f

On p r e v i o u s models w i t h shim- adjusted l e v e r s h a f t ,

I f h i g h s p o t cannot be f e l t i n above adjustment,

Repeat Step 60 above u n t i l c o r r e c t adjustment i s

I f l a t e r model w i t h screw- adjusted l e v e r s h a f t ,

To a d j u s t l e v e r s h a f t t o cam, screw a d j u s t i n g screw

Assemble rubber seal on a c t u a t i n q l e v e r . Pictured

Center spool in valve.

Reassemble water cover a n d s e a l . ( C u p of water

Place s t e e r i n g qear on machine sending l e v e r s h a f t

Center s t e e r i n g gear by moving t h r o u g h f u l l t r a v e l

On motor g r a d e r s , t i g h t e n upper and lower v e r t i c a l

9. B i n d i n s t e e r i n g wheel t u b e Eliminate cause o f bind such as a

11. Taper s t u d a d j u s t e d t o o t i g h t Adjust a

12. Broken p i s t o n o r p i s t o n r i n q s Refer t o Hydraul.i’c Trp3uble Shooting.

13. Lack o f s t e e r i n g q e a r l u b r i c a n t , Add 4 ube t o BroBrer level I

14. V a l v e l o o s e on mounting. Tiohten, then check a ~ j ~ s t m e n t ~

15. Low t i r e p r e s s u r e . Inflate t o proper pressure,

5 . B i n d i n wheel t u b e b e a r i n g E7 i n i n a t e cause o f bind such as a

6. Spool i n v a l v e s t i c k i n g Disassemble valve and jnspect for

Shimmy 1. Loose b a l l s o c k e t connections or Tighten,

2. Wheels o u t o f balance. Balance.

5. Looseness i n s t e e r i n g qear. A d j u s t gear, and perhaps repair gear,

Lost Motion a t 1 . Loose ball socket connections o r Tighten

3. Excessive back lash of taper stud Adjust e

2. Low level o f hydraulic o i l .

3. Air in system. Check a44 connections f o r tightness.

4. Dirt and sludge i n pump. Drain system and clean,

Shop Man.ual B-2.10

MOD-ELS : SERIAL NUMBERS

A L L JACKING, HOISTING, AND GENERAL WORKSHOP EQUIP-

EXTREME CAUTION TO BE OBSERVED A T A L L TIMES TO PREVENT

SAFE WORKSHOP PRACTICES ARE A MUST.

JOTE: b.TSOOB torque converter, lremove i n l e t

Remove r e a c t i o n member a s s e m b l y from s t a t o r

Remove o i l b a f f l e "0" ring and discard

Remove c a p s c r e w s from s t a t o r s u p p o r t . Remove

P r e s s governor d r i v e gear a n d woodruff k e y

I n s t a l l both bearing r e t a i n i n g washers