SUBSECTION 4F
SUSPENSION COMPONENTS
GENERAL
This subsection describes the compo­
nents of the hydraulic suspension system
and the method of recharging the sus­
pension hydraulic system after a compo­
nent has been replaced.
SUSPENSION HYDRAULIC SYSTEM
GENERAL. The suspension circuit is a
passive hydraulic system. lf any compo­
nent of the system is removed, the sys­
tem must be recharged with oil and ali
air bled out.
WARNING
Charging and bleeding the suspen­
sion hydraulic system is a two per­
son operation. Be sure all
personnel are clear of the machine
before operating outrigger and
suspension switches.
CHARGING AND BLEEDING. To charge
and bleed the suspension system proceed
as follows:
1. Place boom in boom rest to activate
suspension unlock switch.
2. Open needle valve at right rear of ma­
chine.
3. Hold Suspension Lock / Unlock switch
in the momentary unlock position and
completely extend the outriggers.
4. With the engine running at high idle
and the pumps engaged, crack open the
fitting on the rod side (bottom port) of
each suspension cylinder. Let oil run
until there is no sign of air, then tighten
fitting. Rod side of each cylinder must
be bled as described.
5. With the machine fully raised on all
outriggers, operating any outrigger ex­
tend switch and crack open the bleed
screw on the top of each cylinder. Let
oil run until there is no sign of air, then
tighten screw. Piston side of each cyl­
inder must be bled as described.
NOTE
Frequent operation of the outrig­
ger extend switch can cause over­
charging of the suspension
hydraulic system.
6. Using quick disconnects at the cylin­
ders and a suitable gauge, check system
pressure at each corner of the machine.
At rear/front and rear/rear axle, pres­
sure should be 350±50 psi, and equal at
all corners.
lf pressure is low, operate outrigger ex­
tend function over relief until correct
pressure is reached.
lf pressure is high: open bleed screw
until correct pressure is reached.
7. Close needle valve at right rear cor­
ner of machine.
8. Hold Suspension Lock / Unlock switch
in the momentary unlock position and
lower machine off the outriggers. AII
outriggers should be lowered at the same
time so that the machine is level when it
contacts the ground.
Subsection 4F 4F-1
SUSPENSION CYLINDER (38R219)
General
Servicing of suspension cylinders is
normally confined to the routine replace-
ment of seals and bearings obtained in
service kits.
Removal
To remove a suspension cylinder, pro-
ceed as follows:
1. Extend and lower the outriggers to
support the machine while a suspension
cylinder is removed from the machine.
2. Open the bleed screw at the top of the
cylinder to relieve the hydraulic pres-
sure in the cylinder.
3. Tag and disconnect the hydraulic
lines attached to the cylinder. Cap the
disconnected lines to prevent the entry
of dirt.
4. Remove the attaching hardware and
lift the cylinder from the machine.
Disassembly'
To disassemble the suspension cylinder,
proceed as follows (see Figure 4F-1 on
page 4F-3) :
CAUTION
Ordinary precautions to prevent
damage to metal parts and to seals
are required. Protect the piston
rod and cylinder bore because seal
life depends upon the smooth fin-
ish of these surfaces.
,. Clamp the cylinder in a chain-type
pipe vise.
2. Remove head (13) from cylinder barrel
(12) using a pin type spanner wrench in
the holes provided in the head.
3. Withdraw piston (6) from the cylinder
barrel. The head and piston rod will be
removed with the piston.
4. Carefully clamp the rod eye of piston
rod (11) in a vise with protective jaws.
4F-2
Remove nut (4) from the end of the pis-
ton rod. The piston and head subas-
semblies, along with the seals and wipers
attached to them, can now be removed
from the piston rod.
5. Remove and discard all seals,
a-rings, b'ack-up rings and wipers.
Cleaning and Inspection
After the cylinder has been
disassembled, clean and dry all parts in
a suitable cleaning agent. Pay particular
attention to the oil passages in the com-
ponents to be sure they are free of ob-
structions.
After the parts are dry, carefully in-
spect the parts as follows:
1. Check the body, piston, and rod for
excessive wear, distortion or other dam-
age, Replace parts as required.
2. Inspect the rod and body ports to
make sure that they are clean and free of
nicks.
3. Inspect the outside diameter of the pi-
ston and the inside diameter of the rod
end bearing. These su rfaces must be
free of nicks, scratches or scoring. If
the head is worn or damaged, replace it.
4. Replace all seals, O-rings, back-up
rings and wear rings with new parts.
These parts are provided in a seal kit
for this cylinder, (see the machine Parts
Manual) .
NOTE
It is important to keep cylinder
components as clean as possible
prior to assembly of the cylinders
to prevent di rt or other contam-
inants from getting into the hy-
draulic system. Coat all inner-
surfaces with hydraulic oil to pre-
vent rust or corrosion.
Assembly
To assemble the suspension cylinder,
proceed as follows (see Figure 4F-1 on
page 4F-3):
 (Includes bushing 112)

1 Grease Fitting
2 Bushing
3 Bleeder Plug
4 Nut
5 'T' Seal
6 Piston
7 Bearing
8 '0' Ring
9 Back Up
10 'S' Ring
'1 Rod/Bushing Assembly
'2 BarreVBushing Assembly
'3 Head
'4 '0' Ring
15 Back Up
16 Bearing
'7 '0' Ring
'8 Seal
'9 Wiper

Figure 4F-l. Suspension Cylinder (3SR219)

1. Install O-ring (14)' back-up ring (15)
and O-ring (17) in the grooves on the
outside diameter of head (13).
2. Install bearing (16), seal (1S) and
wiper (19) in the bore grooves of the
head.
3. Cpat piston rod (11) with clean oil and
carefully slide the head assembly onto
the piston rod.
4. Install S-ring (10), back-up ring (9)
and 0- ring (S) on the end of the piston
rod.
5. Install bearings (7) and T-seal (5) in
the grooves on the outside diameter of
piston (6).
6. Carefully slide the piston assembly
onto the piston rod and install nut (4).
Torque the nut to 165 ft-Ibs.
7. Lubricate the inside of barrel (12)
with clean hydraulic oil. Carefully slide
the piston assembly into the barrel.
S. With the piston assembly insert about
halfway, slide the head into the barrel
and tighten with a pin-type spanner
wrench.

Suspension Components 4F-3

Installation
To install a suspension cylinder, proceed
as follows:
1. Position a new or repair suspension
cylinder between the frame lugs and the
lugs on the axle.
2. Attached the cylinder using the at-
taching hardware.
3. Connect the hydraulic lines to the cyl-
inder.
4. Bleed and recharge the suspension
system as described under "Charging
And Bleeding" on page 4F-l.
PRESSURE REDUCING VALVE
(36Q482D1)
DESCRI PTION. The purpose of the
valve is to cut down the pump supply
pressure, and allow only fluid with re-
duced pressure to reach the suspension
ci rcuit.
ADJUSTMENT. To adjust this valve,
proceed as follows (see Figure 4F-2):
1. Loosen the locknut.
2. Turn the pressure adjusting nut
clockwise to increase the pressure set-
ting, counterclockwise to reduce the
pressure setting.
3. Tighten the locknut.
REPAIR. To repair this valve, proceed
as follows (see Figure 4F-2):
1. Fi rst check and clean a cartridge if it
is not functioning properly.
2. Loosen the cartridge removal nut and
remove the valve cartridge from the
valve block.
3. Inspect the cartridge for visible con-
taminants and carefully remove obvious
particles.
4. Through the nose of the cartridge,
manually operate the inner working parts
several times. Use a wooden or plastic
dowel to avoid damag i ng soft seats,
sharp edges or finished su rfaces. All
parts should move freely. If possible,
do this with the cartridge submerged in
clean mineral spi rits.
5. After "flushing", blow dry with clean
filtered ai r.
6. I nstall the cartridge and torque it to
40-45 ft-Ibs. Test the valve for proper
operation.

PRESSURE
ADJUSTING .~-_-J
NUT

VALVE
LOCKNUT---------~~~Lq CARTRIDGE
/"
CARTRIDGE
REMOVAL
NUT

BACK-Up·
RINGS

VALVE -----r
BLOCK

NOSE 'SEAL KIT ITEMS

END

Figure 4F-2. Pressure Reducing Valve (36Q482)

4F-4

0---'0
Figure 4F-3. Suspension Lock Valve (36Rl13)
7. If the valve cartridge does not per-
form properly after cleaning replace the
cartridge with a new one.
SUSPENSION LOCK VALVE (36R113D1)
DESCRI PTION. Four lock valves are
used in the suspension system, each con-
trolling suspension action at one corner
of the machine. The lock valve solenoids
control the flow of oil between the cylin-
ders and accumulator. The relief valve
cartridge prevents extreme pressure
from building on the rod side of the cyl-
inder, in the event of a piston seal
failure.
REMOVAL. To remove the suspension
lock valve, proceed as follows.
,. Shut down the engine and remove the
battery ground cable to prevent opera-
tion of the machine while it is being ser-
viced. Operate the controls to relieve
pressure in the hydraulic system. Clean
the area around the valve to prevent the
entry of contaminants.
--04
08
09
2. Disconnect the hydraulic lines from
the valve block. Cap the lines to pre-
vent the entry of contaminants.
3. Tag and disconnect the electrical
leads from solenoid coils.
4. Remove mounting hardware and valve
block.
REPAIR. Repair of the suspension lock
valve is limited to the replacement of the
O-rings, solenoid coils and cartridges
and the relief valve cartridge (see
Figu re 4F-3). The valve block -does not
have to be removed from the machine if
only the cartridges are being replaced.
To replace the solenoid or relief valve
cartridges, proceed as follows:
1. Clean the valve thoroughly with a sui-
table solvent.
2. Remove relief valve cartridge (01).
Suspension Components 4F-5
3. Remove nut (10) and solenoid coil (08)
from cartridge. Remove solenoid car-
tridge.
4. Clean threads in valve port and install
new cartridge.
5. Install solenoid coil and nut.
6. Operate suspension system and check
for leaks.
HOUSING
INSTALLATION. To install a new sus-
pension lock valve, proceed as follows.
1. Line valve block up with mounting BLADDER
holes. I nstall and fully tighten
hardware.
2. Remove protective caps and connect
hydraulic lines.
3. Connect electrical wires to coil leads.
4. Connect the battery ground cable.
Start the engine and bleed air from the
suspension system, as described under
"Charging And Bleeding" on page 4F-1.
Observe valve for proper operation and
leaks.
Figure 4F-4. Accumulator (46Q481)
ACCUMULATOR (46Q481)
2. Disconnect the hydraulic fitting at the
DESCRI PTION. This is a one-half bottom of the accumulator. cap the fit-
gallon, nitrogen charged, bladder type ting to prevent the entry of
accumulator, which acts as a hydraulic contaminants.
spring in the axle suspension system
(see Figure 4F-4). The accumulator 3. Remove hardware and mounting clamp
works to dampen pressure shocks when from accumulator.
the suspension is unlocked.
4. The accumulator can now be removed.
MAINTENANCE. This accumulator is
considered non-repairable. If the accu- INSTALLATION. To install the accu..;
mulator is faulty, it may be due to loss mlilator, proceed as follows.
of precharge pressure or it may be due
to a defective bladder or housing. If the ,. Line up the clamp and accumulator
housing or bladder is faulty, the com- with mounting holes. I nstall and fully
plete accumulator must be removed and tighten clamp hardware.
replaced with a new accumu lator.
2. Remove protective cap and connect
REMOVAL. To remove the accumulator, hydraulic fitting to accumulator.
proceed as follows.
3. Connect the battery ground. Start
,. Shut down the engine and remove the the engine and observe the accumulator
battery ground cable to prevent opera- for leaks.
tion of the machine while it is being ser-
viced. Operate the controls to relieve PRECHARGING PROCEDURE. There are
pressure in the hydraulic system. Clean two conditions under which the accumula-
the area around the accumulator to pre- tor precharge pressure should be
vent the entry of contaminants. checked. The fi rst is when a new accu-
mulator is installed and the second is
when it is found that the reason for a

4F-6
faulty accumulator is the loss of pre- tu rning the bar handle counterclock-
charge pressure. The accumulator is wise until it stops. Mount the swivel
precharged with dry nitrogen, prefera- of the air chuck on the accumulator's
bly, to 440:t40 psi at room temperature, gas valve stem, compressing the gas-
70 D F. A precharging kit (45Z232) is ket in the swivel to prevent gas
available from Harnischfeger for perform- leakage. Tu rn the bar handle clock-
ing this operation. wise until the shaft depresses the
valve core in the gas valve of the ac-
cumulator.
CAUTION
3. Mount the gland nut of the hose
When precharging the accumulator, assembly on nitrogen bottle.
use dry nitrogen only.
4. Remove the cap f rom the fi Iler
PRESSURE GAUGE valve and attach the swivel connector
of the hose assembly. Hand tighten

/ sufficiently to compress the gasket in

the swivel connector in order to pre-
vent gas leakage.
5. Proceed to inflate the accumulator
BAR HANDLE to 440:t25 psi by opening the valve on
the nitrogen bottle slowly, closing it
occasionally to allow the needle of the
pressure gauge to settle in position,
thus giving an accurate reading of
AIR CHUCK the precharge pressure. When the
correct precharge has been reached,
, .. __ ACCUMULATOR close the valve in the nitrogen cylin-
/

<..... der secu rely.

. """'- ............\
BLEEDER VALVE c}LVE
NOTE

A"ow the accumulator to rest for

..
t'~,
about 30 minutes and then check
--
~-=::::§:0C::Jlct=t.J.-:-.,
:
, . ~ .
the precharge pressure again.
Due to the nitrogen expansion I

GLAND NUT
,- -
)--- - -
__ .1
~
additional precharging may be nec-

NITROGEN BOTTLE
" ,
~,- ...--._J
essary to bring the precharge to
the desired pressure.

F111 6. The bleeder valve can be used to

let out any gas pressure in excess of
desired precharge.
Figure 4F-S. Gauge Head Installation
7. Retract the shaft of the ai r ch uck
Precharge the accumulator with the pre- by turning the bar handle counter-
charging kit as follows (see clockwise to the full stop position be-
Figu re 4F -5) : fore disconnecting the swivel,
thereby preventing excess leakage of
1. Remove the valve guard and valve cap gas from the accumulator. Remove
from the accumulator. the chuck from the accumulator gas
valve stem.
NOTE
8. The charging and gauging assem-
To read or adjust the precharge bly may either be cooled around the
pressure, hydraulic fluid must be nitrogen cylinder or the assembly may
completely drained from the fluid be removed from the cylinder and
side of the accumulator. stored.
2. To mount the gauging head, re- 9. Check the accumulator gas valve
tract the shaft in the air chuck by assembly for leaks with a soapy water

Suspension Components 4F-7

solution or oil. If the valve core is 11. Replace the accumulator valve
leaking, depress quickly once or guard.
twice to reseat the core. It may be
necessary to replace the valve core if 12. Check for precharge loss within
leakage continues. one week after installation.
10. Replace the accumulator gas valve
cap and tighten one-half turn beyond
hand tightness.

4F-8
 TABLE OF CONTENTS

Subsection 5A 5A-1

Introduction 5A-1
General ..... . 5A-1
Troubleshooting Guide .. 5A-1
Hydraulic System Description 5A-7

Subsection 5B 5B-1

Hydraulic System Maintenance 5B-1

General ......... . 5B-1
General Maintenance ... . 5B-1
Flushing the Hydraulic System ..... 5B-2
Proper Tightening of Hydraulic Connections 5B-3
General ....... . 5B-3
SAE Flareless Connection 5B-3
Pipe Th read Connection 5B-3
SAE Flare Connections .. . ..... . 5B-5
SAE Straight Thread Connection (O-ring Seal) 5B-5
Split Flange Connections 5B-7
Pressure Filter (46Q75) 5B-9
Description 5B-9
Filter Maintenance 5B-9
Retu rn Fi Iter (46U54) 5B-11
Description 5B-11
Filter Maintenance 5B-12

Subsection 5C 5C-1

Pumps 5C-1
General . . . . . 5C-1
Pumps (37R29 and 37R41) 5C-1
Description 5C-1
Troubleshooting 5C-1
Removal 5C-3
Overhaul 5C-4
Installation 5C-8

Subsection 50 50-1

Hydraulic Swivel 50-1

General ..... 5D-1
Hydraulic Swivel (945J103) 5D-1
Description 5D-1
Removal 5D~1
Overhaul 5D-2
Installation 5D-4

Subsection 5E 5E-1

Hydraulic System Valves 5E-1

General ......... . 5E-1
Thermal Bypass Valve (36U227) 5E-1
Check Valves 5E-1

Subsection 5F 5F-1

Upper Heater-Air Conditioner 5F-1

Contents
General ...................... . 5F-1
Troubleshooting .................. . 5F-1
Heater / Air Conditioner Flow Control Valve (36Q502D1) 5F-l
Heater / Ai r Conditioner Blower (51 U131 D1) 5F-2
Condenser Assembly (51 U132D1) 5F-3
Heater / Air Conditioner Drive Assembly (51 U133D1) 5F-7
Air Conditioner Compressor 5F-7
Hydraulic Drive Motor 5F-8
I nspection And Repai r 5F-8
Hydraulic Heat Pump . 5F-8
Heat Developer With Reservoi r (27U388D1) 5F-9

ii
 LIST OF ILLUSTRATIONS

Figu re 5A-l. Excessive Noise 5A-2

Figu re 5A-2. Excessive Heat 5A-3
Figure 5A-3. Incorrect Flow . 5A-4
Figure 5A-4. Incorrect Pressure 5A-5
Figure 5A-5. Faulty Operation ....... . 5A-6
Figure 5A-6. Hydraulic System Lower (3105J149) 5A-9
Figure 5A-7. Hydraulic System Upper (3105J149) 5A-1O
Figure 58-1. Tightening SAE Flare Connections 58-6
Figu re 58-2. Improper Installation ..... . 58-6
Figu re 58-3. Proper Installation ...... . 58-6
Figure 58-4. Tightening Sequence ..... . 58-7
Figure 58-5. Hydraulic Filter Assembly (46Q75) 58-11
Figure 58-6. Filter Assembly .......... . 58-10
Figure 58-7. Hydraulic Return Filter Assembly (46U54) 58-12
Figu re 5C-1. Pump Installation ..... . 5C-1
Figu re 5C-2. Double Section Pump ... . 5C-6
Figu re 5D-1. Swivel (945J103) ..... . 5D-3
Figure 5F-1. Air Conditioner System-Upper 5F-2
Figure 5F-2. Air Conditioner Schematic 5F-3
Figure 5F-3. Heat Pump Removal 5F-9
Figure 5F-4. Air Conditioner Test Ports 5F-10
Figure 5F-5. Heat Developer 5F-11

List of Illustrations iii

 LIST OF TABLES

Table 58-1. Pipe Thread Leaks 58-4

Table 58-2. Flare Connection Leaks 58-4
Table 58-3. Split Flange Leakage 58-8
Table 58-4. Split Flange Torque Values 58-8
Table 5C-l. Pump Troubleshooting .. SC-1
Table SF-1. Heat and A/C Troubleshooting SF-4

List of Tables v
 SUBSECTION 5A
INTRODUCTION
GENERAL
This section provides maintenance and
service information for the pumps and
valves in the hydraulic system. A cir-
cuit description and hydraulic schematic
are included to aid in troubleshooting the
system.
Later sections in this manual describe
the removal, repair, and installation of
the individual hydraulic components.
These components include the motors,
valves, cylinders and winches.
TROUBLESHOOTING GUIDE
GENERAL. The troubleshooting charts
and maintenance hints that follow are of
a general natu re, but should provide an
i ntu itive feel i ng for a specific system.
KNOWING THE SYSTEM. Probably the
greatest aid to troubleshooting is know-
ing the system. Every component has a
pu rpose in the system. The construction
and operating characteristics of each one
should be understood. Some additional
practices which will increase trouble-
shooting efficiency, and also the useful
life of the system are listed below:
1. Know the capabil ities of the system.
Each component in the system has a max-
imum rated speed, torque or pressure.
Loading the system beyond the specifica-
tions increases the possibility of failure.
2. Know the correct operating
pressu res. Always set and check pres-
su res with a gauge that is known to be
accurate. The question may arise as to
what the correct operating pressure is.
If it is not specified, the followi ng ru Ie
should be applied.
The correct operating pressure is the
lowest pressure which will allow adequate
performance of the system function and
still remain below the maximum rating of
the components. Once the correct pres-
sures have been determined, note them
for futu re reference.
DEVELOPING SYSTEMATIC PROCE-
DU RES. Analyze the system and develop
a logical sequence for setting relief
valves and mechanical stops. Develop a
cause and effect troubleshooting guide
similar to the one shown in Figu re 5A- 1
through Figure 5A-5. The initial time
spent on such a project could save hours
of downtime.
RECOGNIZING TROUBLE INDICATIONS.
The ability to recognize trouble indi-
cations in a specific system is usually
acqui red with experience. However, a
few general trouble indications can be
discussed.
1. Excessive heat means trouble. A mis-
aligned pump or motor places an exces-
sive load on bearings and can be readily
identified by the heat generated. A
warmer than normal return line indicates
that the system is operating at relief
valve setting. Hydraulic oils which have
lost viscosity will increase the internal
leakage of components resulting if! a heat
rise. Cavitation and slippage in a pump
will also generate heat.
2. Excessive noise means wear, misalign-
ment, cavitation or air in the oil. Con-
taminated oil can cause a relief valve to
stick and chatter. These noises may be
the result of dirty filters, or fluid, high
fluid viscosity, excessive drive speed,
low reservoir level, or loose intake lines.
Subsection 5A 5A- 1
 EXCESSIVE NOISE
I
IA B lC

PUMP NOISY MOTOR NOISY RELIEF VALVE NOISY

I I
, . Setting too close to
, . Cavitation
operating pressure
Remedy: a

I
2. Air in Fluid
- 2. Motor Worn or
Damaged
Remedy: e .
or to another valve
setting
Remedy: d

Remedy: b
J
I 2. Worn poppet and seat
Remedy: e
3. Coupling Misaligned
Remedy: c

I
4. Pump Worn or
Damaged
Remedy: e

REMEDIES:
a. Any or all of the following: Replace dirty filters - Clean clogged inlet line - Clean reservoir breather vent-
Change system fluid
b. Any or all of the following: Tighten leaky inlet connections - Fill reservoir to proper level- Replace pump shaft
seal
c. Align unit and check condition of seals and bearings
d. Install pressure gauge and adjust to correct pressure
e. Overhaul or replace
F283

Figure SA-I. Excessive Noise

5A-2
 IEXCESSIVE HEAT I
1
IA Is lc ID
FLUID HEATED
PUMP HEATED MOTOR HEATED RELIEF VALVE

I
1. Fluid heated
I
1. Fluid heated
1
1. Fluid heated
I
1. System pressue
Remedy: See Remedy: See Remedy: See too high
column D column D column D Remedy: d

I I I I
2. Cavitation 2. Relief or un- 2. Valve setting 2. Unloading valve set
Remedy: a loading valve incorrect too high
set too high Remedy: d Remedy: d
I Remedy: d
I T
3. Air in fluid
Remedy: b
I
3. Excessive
3. Worn or 3. Fluid dirty or low
damaged valve supply
I load
Remedy: c
Remedy: e Remedy: f
4. Relief or unloading
valve set too high
I
I
Remedy: d 4. Incorrect fluid
4. Worn or viscosity
I damaged motor
Remedy: e
Remedy: f
5. Excessive load
Remedy: c
I
5. Faulty fluid

I cooling system
Remedy: e
6. Worn or
damaged pump
Remedy: e
I
6. Worn pump, valve,
motor, cylinder or
other component
Remedy: e

REMEDIES:
a. Any or all of the following: Replace dirty filters - Clean clogged inlet line - Clean reservoir breather vent -
Change system fluid
b. Any or all of the following: Tighten leaky inlet connections - Fill reservoir to proper level - Replace pump
shaft seal

c. Align unit and check condition of seals and bearings - Locate and correct mechanical binding - Check for
work load in excess of circuit design
d. Install pressure gauge and adjust to correct pressure
e. Overhaul or replace

f. Change filters and also system fluid if of improper viscosity - Fill reservoir to proper level F284

Figure 5A-2. Excessive Heat

Introduction SA-3
 I INCORRECT FLOW I

IA B Ic
NO FLOW LOW FLOW EXCESSIVE FLOW

I
,. Pump not receiving
I
,. Flow control set too
,. Flow control set too
fluid low high
Remedy: a Remedy: d Remedy: d

I
2. Pump drive 2. Relief or unloading
not operating valve set too low
Remedy: e Remedy: d

I
3. Pump to drive 3. External leak in
coupling sheared system
Remedy: c Remedy: b

I
4. Directional control 4. Worn pump. valve.
set in wrong position motor. cylinder. or
Remedy: f other component
Remedy: e
I
5. Entire flow passing
over relief valve
Remedy: d

I
6. Damaged pump
Remedy: c

REMEDIES:
a. Any or all of the following: Replace dirty filters - Clean clogged inlet line- Clean reservoir breather vent - Fill
reservoir to proper level
b. Tighten leaky connections.
c. Check for damaged pump or pump drive - Replace and align coupling
d. Adjust
e. Overhaul or replace
f. Check position of manually operated controls F285

Figure 5A-3. Incorrect Flow

5A-4
 I INCORRECT PRESSURE 1
1
/A
NO PRESSURE
Is
LOW PRESSURE ERRATIC
Ic 10
EXCESSIVE PRESSURE
PRESSURE

I
,. No flow
I
,. Pressure reo
I
,. Air in fluid
I
,. Pressure reducing,
Remedy: See lief path Remedy: b relief or unloading
Chart III, exists valve misadjusted
column A Remedy: See
Figure 5A·3, I Remedy: c

column A and
S
2. Worn relief
valve I
2. Pressure reducing
I
2. Excessive
Remedy: d

1
relief or unloading
valve worn or
damaged
external 3. Contamination Remedy: d
leakage in fluid
Remedy: b Remedy: a

I
4. Worn pump,
motor or
cylinder
Remedy: d

REMEDIES:
a. Replace dirty filters and system fluid
b. Tighten leaky connections - Fill reservoir to proper level
c. Adjust
d. Overhaul or replace
F286

Figure SA-4. Incorrect Pressure

Introduction SA-S
 LFAULTY OPERATION t

/A Is Ic 10
NO MOVEMENT SLOW MOVEMENT ERRATIC EXCESSIVE SPEED
MOVEMENT OR MOVEMENT
I
1. No flow or pressure
I
1. Low flow I I
Remedy: See Remedy: See ,. Erratic pres- 1. Excessive flow
Figure 5A·3 Figure 5A-3 sure Remedy: See
Remedy: See Figure 5A·3
I f Figure 5A-4
2. Limit or sequence
device (mechani-
2. Fluid viscosity
too high
I
cal, electrical, 2. Air in fluid
Remedy: a
or hydraulic) Remedy: See
inoperative or
misadjusted
I Figure 5A· 1

Remedy: c
3. Insufficient
control pressure 1
for valves 3. No lubrica-
f Remedy: See tion of link-
3. Mechanical bind Figure 5A-4 age

,
Remedy: b
I
No lubrication
Remedy: d

I
4. Worn or damaged 4. Worn or dam-
of linkage
cylinder or motor aged cylinder
Remedy: c Remedy: d or motor
Remedy: c
I
5. Worn or
damaged cyl-
inder or motor
Remedy: c

REMEDIES:
a. Fluid may be too cold or should be changed to clean fluid of correct viscosity
b. Locate bind and repair
c. Overhaul or replace
d. Lubricate F287

Figure SA-S. Faulty Operation

5A-6
HYDRAULIC SYSTEM DESCRIPTION
GENERAL. This machine's hydraulic
system, as defined for this manual, is a
system made up of pumps, motors, actua-
tors, hoses, piping, a rotary joint
(swivel), control valves, return filter,
reservoi r, and other components that are
used to transfer power with relative ease
and flexibility. The hydraulic system has
several functional circuits, as shown in
the hydraulic schematics in Figure SA-6
on page SA-9, and Figure SA-7 on page
SA-lO.
To help cover the hydraulic system of
this machine, this topic lists the hydrau-
lic system ci rcuits and describes the
circuits and components by their func-
tions.
PUMPING CIRCUIT. The pumping cir-
cuit consists of the reservoir, pumps,
swivel, supply and return filters, and
the oil cooler.
The swing and steer pumps, and the
boom hoist and winch pumps are gear
type double section type pumps. These
pumps are physically mounted on and
driven by the the auxiliary drive portion
of the transmission.
The swing and steer pump is driven con-
tinuously. The boom hoist and winch
pump is driven when required by engag-
ing a mechanically operated disconnect.
As the pumps are driven, hydraulic oil is
drawn from the reservoir and forced out
into the various hydraulic circuits where
the oil is used by the various circuits as
described in the following topics and
shown in Figu re SA-6 on page SA-9, and
Figure SA-7 on page SA-lO.
Oil from the rear section of the swing
and steer pump flows directly through
the swivel to the inlet of the ai r condi-
tioner priority valve, through the air
conditioner drive motor and through the
swing control valve as shown in
Figu re SA-6 on page SA-9 and
Figu re SA-7 on page SA-lO. The swing
valve when in the neutral position allows
the major portion of the swing circuit oil
flow to return through the swivel, an oil
cooler, and then through the return fil-
ter to the reservoir. The neutral swing
control valve also allows a small back
pressu re, that is caused by a back pres-
sure check valve in the return line, to
be felt on both sides of the swing motor
and in the swing brake circuit.
Oil from the front section of the swing
and steer pump flows through a high
pressure filter and then flows to the
steering/winch boost circuits and re-
turns to the reservoir through the re-
turn filter, see Figure SA-6 on page
SA-9. The outrigger circuit relief valve
protects outrigger and steering circuits
from excessive pressure build-up.
Oil leaving the boom hoist and winch
pump sections flows di rectly to the swiv-
el and is directed to the winch control
valves and the boom hoist and telescope
control valves. If the winch control
valves are in neutral, oil flows through
the valves and retu rns back to the res-
ervoir through the swivel and the return
filter. If the boom hoist/telescope con-
trol valves are in neutral, oil flows
through the valves and returns to the
reservoir through the swivel.
POWER STEERING CIRCUIT (UPPER).
The power steering circuit is of the hy-
drostatic type. This means that all
steering is done with a hydraulic oil cir-
cuit and no direct mechanical connection
between the steering wheel and the
wheels.
Upper steering / outrigger pressuriza-
tion valve is a normally closed solenoid
valve. With the solenoid de-energized,
oil flow to the upper steering circuit is
blocked, making oil available for the out-
riggers. When the solenoid is energized,
a check valve is reversed which allows a
regulated flow of oil to reach the upper
steering priority valve.
When the steering circuit is in neutral,
oil enters the steer priority valve (flow
control valve) and is directed to the
steering control valve. The steering
control valve routes a small portion of oil
to the reservoir and the rest of the oil is
directed to the winch boost circuit where
the oil can be used by the winch circuits
to operate the winch or retu rned to the
reservoir through the winch return cir-
cuit.
When the operator turns the steering
wheel, a pilot pump on the end of the
steering column builds up a pressure
that is used to position the steer control
valve spool against spring pressure.
The steer valve spool allows oil flow from
the steering pump to pass th rough the
Introduction SA-7
steer valve and directs the oil through
piping to the swivel. The oil flow con-
tinues through the swivel and is directed
to the steering cylinders to cause the
desired movement of the wheels. Return
oil from the steering cylinders flows back
through the swivel and the steer control
valve and then returns to the reservoir
through the winch return lines.
When the steering wheel stops turning
and the pilot pressure is vented, spring
pressure returns the steer control valve
to the neutral position and the oil flow
from the steering pump is then directed
to the winch ci rcuits again. To straight-
en or turn the wheels in the opposite
direction, the steering wheel must be
turned in the opposite direction so that
the oil flow to and from the steering cyl-
inders is redirected to the opposite side
of the cylinders, through the operation
of the steering wheel and through the pi-
lot operated steer control valve as
previously described.
POWER STEERING CIRCUIT (LOWER).
The steering system is powered by a
pump mounted on the rear of the trans-
mission. Two steering / outrigger sole-
noid valves work in conjunction with
each other to pressu rize either the upper
or lower steering circuit or the outrigger
circuit. . If the applicable outrigger switch is
Lower steering I outrigger pressuriza-
tion valve is a normally open solenoid
valve. When the solenoid is energized a
check valve is reversed which stops the
flow of oil to the lower steering circuit,
and redi rects the oil onto the upper
steering circuit or the outrigger circuit.
With the solenoid de-energized, oil flow
is delivered to the combination flow con-
trol and relief valve (also called a flow
regulator) through a regulating orifice.
On demand from the control valve portion
of the steering gear, oil is directed to
the steering cylinders. When there is no
demand for oil from the steering gear,
the flow control and relief valve directs
oil back to the reservoir. This occurs
th rough the relief valve and the pres-
su re compensated orifice.
A solenoid operated steering selector
valve allows the lower steering circuit to
"float" while the steering is controlled
from the upper.
Place New Schematic Here
5A-8
OUTRIGGER CIRCUIT. The outrigger
circuit consists of the outrigger relief
valve, the outrigger mode valve, two
banks of outrigger control valves, four
horizontal outrigger cylinders, and four
vertical outrigger cylinders with associ-
ated holding valves. The outrigger cir-
cuit is controlled by the solenoid
operated mode and outrigger control
valves.
To supply oil to the outrigger circuit,
the two pressurization valves must work
in conjunction with each other. The low-
er pressurization valve must be ener-
gized to block the flow of oil to the lower
steering circuit, while the upper pres-
surization valve must be de-energized to
stop flow to the upper steering circuit.
When the pressurization valve spools are
positioned as described, all oil flow is
available to the outrigger circuit.
If the applicable outrigger switch is
placed in the EXTEND position the out-
rigger mode valve will shift to the extend
mode. At the same time, the applicable
outrigger control valve will shift to allow
oil flow to the head end of the applicable
cylinder. Oil leaving the cylinder will
flow back to the reservoir through the
outrigger mode control valve.
placed in the RETRACT position the out-
rigger mode valve will shift to the re-
tract mode. At the same time, the
applicable outrigger control valve will
shift. Supply oil will now be delivered
directly to the rod end of the applicable
cylinder. Oil leaving the cylinder will
flow back to the reservoi r via the shifted
outrigger control valve and the mode
control valve.
A lock (holding) valve is provided at the
top of each vertical cylinder to prevent
cylinder movement in either direction
when there is no oil flow to the cylinder.
The lock valves each have an internal_re-
lief valve which provides overload
protection to the rod end of the associ-
ated cylinder in the event of thermal
expansion. The relief valves also limit
rod end pressure caused by leakage past
the piston seals.
WINCH CIRCUIT. The winch circuit of
the machine consist of a winch motor, a
counter balance valve for the motor, a
control valve, and associated pi pi ng.
 SUSPENSION SUSPENSION SUSPENSION SUSPENSION
VERTK:AL CYLINDER CYLINDER
OUTRIGGER CYLINDER CYLINDER
HOLDNG HORIZONTAL VERTICAL

,
VALVE OUTRIGGER OUTRIGGER
CYLINDER
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U.J G U1
~ FRONT STEER
CYLINDER

u z :;; U1 U1 I
CYLINDER
z ~ U
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Cl.
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SWIVEL
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VERTICAL "' 0- <D
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OUTRIGGER HORIZONTAL
CYLINDER OUTRIGGER VERTICAL
CYLINDER OUTRIGGER
HOLDING
VALVE

r-+___-f{1 ACCUMLA@l=_

OUTRIGGER OUTRIGGER
CONTROL VAL VE CONTROL VAL VE

OIL
COOLER
THERMAL
BYPASS

I EJ
PRESSURE
REDUCING
VALVE O/R MODE
VALVE

HORIZONTAL HORIZONTAL
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
SUSPENSION SUSPENSION SUSPENSION
CYLINDER CYLINDER CYLINDER

RESERVOIR
LITER CAPACITY
VERTICAL
VERTICAL
OUTRIGGER
OUTRIGGER
HOLDING CYLINDER
VALVE Figure 5A-6. Hydraulic System Lower (3105J149)

Introduction SA-9
 BOOM
HOIST
CYLINDER
r--------------~
I MAIN
WINCH I WINCH
BRAKE I MOTOR TELESCOPE
t-~ CYLINDER

ri~' BOOM
HOLDING
VALVE
TELESCOPE
I CYLINDER
I
I
I
I
I L -I+-If+"..-

WINCH
CCUNTERBALANCE
'/ALVE

TELESCOPE
HOLDING
VALVE
TELESCOPE
HOLDING
VALVE

,------------,
\ I
CLAMSHELL \ I
CYLINDERS \ I
\ I

"AIN WINCH
vALVE
HYDRAULIC
HEATER/
A/C ~~ i
TELESCOPE
FLOW DIVIDER FOR

-,
FULL POWER BOOM

1- -I
A/C/HEATER
PRIORITY
VALVE
"
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rc---
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SWING
MOTOR
r------,
STEERING

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VALVE I I SWING
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VALVE

-----~~l l~ _____ ~
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SWING
BRAKE
RELEASE
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CLAMSHELL
SOLENOID
VALVE I - tiIV
i-~-..Jli( I,~ ~I
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r-1Q+- ' SWING VALVE ! ~! ..J

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L_ - - - - - - - - - - - - - . - - - - - -STEER'NG-' i- ---- --- -- --- ---- ---- ---- --- ---------- -- ---- _.f Y1Y Y Y Y Y Y Y '-t-- --- -- -- ---- -------- ---- ----------_ ...... ___________________________________ ..J
MASTER
CYLINDER

PRIORITY : I
VALVE L _____ ..J

HYDRAULIC
SWIVEL

Figure 5A-7. Hydraulic System Upper (3105J149)

SA-10
The winch circuit functions as follows,
(see Figure 5A-6 on page 5A-9 and
Figure 5A-7 on page 5A-1O):
When the boom hoist and winch pump
drive is engaged, oil flows from the
winch pump output, through the swivel,
through the winch control valve and
back th rough the swivel to the
reservoir.
When the operator moves the control le-
ver the control valve plunger is moved in
or out and oil flow is di rected to the ap-
pi icable port of the wi nch motor.
When the winch is operated in the hoist-
ing direction, oil from the control valve
flows to the counter balance valve, whe-
re the oil develops a low pressure and
shifts the counter balance valve plunger.
Oil then flows th rough the counter bal-
ance valve to the motor and drives the
winch in a hoisting direction. If the
hoisting operation is stopped the counter
balance valve plunger shifts and causes
a hydraulic lock on the motor. This hy-
draulic lock and a disc brake in the
winch prevent the load from lowering un-
til the control valve is placed in the
lower position and sufficient pressu re is
present to lower the load safely.
NOTE
The disc brake in the winch re-
mains fully engaged during hoist
operation and an overriding clutch
between the motor drive shaft and
the brake discs allows complete
freedom of motor rotation in the
hoisting direction.
When the winch control valve is shifted
to the lower position, hydraulic oil from
the winch pump will build up pressu re
sufficient to release the winch counter-
balance valve. Pressure will continue to
build causing the winch brake to release
and allow oil to flow through the motor
and return to the reservoir. The winch
motor can not be driven until sufficient
pressure is developed to shift the count-
er balance valve plunger enough to allow
oil to flow th rough the motor. The speed
at which the motor is driven and the load
can be lowered is determined by the
amount of plunger movement of the winch
control valve and the amount of oil pres-
su re that is felt by the counter balance
valve. The more pressu re felt by the
counter balance valve the larger the
opening that allows oil flow to the motor.
When the control valve is returned to
neutral the counter balance valve will
close and the lowering of the load will
stop. The disc brake will engage and
hold the load when the counter balance
valve closes and back pressure drops to
the point that the brake spring engages
the brake.
To lower a load very slowly for precise
positioning, the winch control valve is
opened very slightly to allow oil .pressure
in the winch ci rcuit to build up enough
that the disc brakes will release; howev-
er, not enough to cause the counter
balance valve to open. I nternal leakage
in the motor will allow the weight of the
load to rotate the motor and lower the
load. To stop the slow lowering of the
load, return the control valve to neutral.
This will cause the brakes to engage,
and will stop the internal flow of oil
which will stop the slow rotation of the
motor.
When the output of the steer pump is not
required by the outrigger circuit or the
steer ci rcu it, its output is used to boost
the speed of the winch motor, by adding
the additional oil flow to the winch ci r-
cuit.
The two-speed winch motor provides
high and low speed operation. When the
two-speed solenoid is shifted to the HIGH
position, all oil flow to the motor is di-
rected to the rear motor section. This
provides high speed, low torque opera-
tion. If the two-speed solenoid is
shifted to the LOW speed position, oil
flow is directed to both motor sections
for low speed, high torque operation.
BOOM HOIST CIRCUIT. The boom hoist
circuit consists of the boom hoist control
valve assembly, a holding valve
assembly, and the boom hoist cylinder,
(see Figure 5A-7 on page 5A-1O).
As shown in Figure 5A-7, the- control
valve is part of a double control valve
assembly that also includes the boom
telescope control valve.
The boom hoist circuit functions to raise
and lower the boom when the operator
moves the manually operated boom hoist
control valve.
When the boom hoist control valve is in
the neutral position, oil from the boom
hoist/telescope pump flows up through
the swivel and passes th rough the boom
Introduction 5A-ll
hoist and telescope control valves and
returns back to the reservoir through
the return piping and swivel.
When the control valve is opened to the
hoist position, a pressure builds up in
the hoist circuit which causes the boom
hoist holding valve to open and direct oil
to the head end of the cylinder and the
hoist cylinder extends, hoisting the
boom. As the cylinder extends, oil from
the rod end of the cylinder is routed
back to the reservoir through the hold-
ing valve, the control valve and the
swivel.
When the control valve is positioned in
neutral and the cylinder is extended,
weight on the cylinder causes pressure
in the circuit holding valve, placing a
hydraulic lock on the hoist cylinder that
will hold the boom in position until the
control valve is positioned to the lower
position and hydraulic pressu re in the
supply line has increased to a safe oper-
ating level. Then the holding valve will
open, which allows supply oil to flow to
the rod end of the cylinder and oil from
the head end to retu rn to the reservoi r.
This retracts the boom hoist cylinder.
Relief valves in the boom hoist/telescope
control valve protect the hoist and tele-
scope circuits from the possibility of
damage due to excessive system
pressu reo
BOOM TELESCOPE CIRCUIT. As shown
in Figure 5A-7 on page 5A-1O, the boom
telescope circuit consists of two telescope
cylinders, two holding valves a flow di-
vider valve and a telescope control
valve. The telescope control valve is
part of a double control valve assembly
that includes the boom hoist control
valve.
The boom telescope circuit shares the
output of the boom hoist/telescope pump.
When the boom hoist control valve is in
neutral, the telescope ci rcuit gets full
pump output which flows through the
swivel, th rough the boom hoist control
valve and th rough the center of the tele-
scope valve and retu rns to the
reservoir. If the boom hoist control
valve is in any position other than neu-
tral or full open, the telescope circuit
wi lion Iy have a portion of the pump out-
put. If the boom hoist control valve is
fu II open the telescope ci rcu it has no
flow.
5A-12
When the telescope control valve spool is
moved to the extend position, oil will
flow through the flow divider to the hold-
ing valves of both cylinders. The check
valves unseat and oil will flow to the
head end of the cylinders causing them
to extend. Oi I from the rod end of the
lower cylinder flows through the rod end
of the upper cylinder and returns to
reservoir with oil from the lower cylinder
via the control valve and the swivel.
That is unless the control valve is in the
full extend position then the oil in the
return line is added to the supply line
which will help increase the speed of the
telescope operation.
When the control valve is positioned in
the retract position, oil will flow to the
rod end of the telescope cyl i nder, but
the cylinder will not retract until suffi-
cient pressu re is developed to cause the
holding valve to open and allow oil from
the head end of the cylinder to return to
the reservoi r via the the control valve
and the swivel.
SWING CIRCUIT. The swing circuit con-
sists of a back pressure check valve, a
swing control valve, a swing motor, and
a swing brake circuit. The swing brake
system includes a check valve, an
orifice, a brake lock valve, a swing
brake and the brake master cylinder.
Oil from the swing section of the swing
and steer pump flows from the pump
through the swivel to the input port of
the swing control valve and if swing is
not desired, the oil is dumped by the
compensator spool in the control valve
and returned to the reservoir via a back
pressure check valve, the swivel, the oil
cooler and the retu rn filter. Some oil
flows through the swing motor for lubri-
cation.
When the swing control valve spool is
moved in either direction, the pressure
opposite the spring end of the compensa-
tor spool drops and the spring shifts the
compensator spool. Pump output is now
metered to the swing motor where pres-
sure is developed and used to drive the
motor and swing the upper. Load pres-
sure flows through the shuttle valve and
is directed to the spring end of the com-
pensator spool. Pump pressu re is
sensed opposite the spring end of the
compensator spool. The center lands of
the valve plunger form an orifice which
allows an increase or decrease in flow, to
the motor, in relation to the amou nt of
plunger movement. When the operator
moves the control lever he selects the
size of orifice and thus, the speed at
which the upper will swing. The pur-
pose of the compensator spool is to main-
tain a constant rate of flow (as set by
the size of the orifice) regardless of
changes in the load or changes in pump
flow. The rate of flow th rough the ori-
fice is dependent upon its size and upon
the difference in pump pressure on one
side and load pressure on the other side.
Load pressure, sensed on the spring
side of the compensator spool, is also
sensed at the main relief valve. If sys-
tem pressure reaches the setting of the
relief valve, the relief valve will open
and vent the pressu re on the spring side
of the compensator spool. Pump pres-
sure on the other end of the compensator
spool will cause the spool to shift and un-
load some or all of the pump's output.
When pressure drops to normal, pressure
will again build on the spring side of the
compensator spool causing it to shift and
normal operation will resume.
Due to the back pressure in the system,
hydraulic pressure is delivered to the
swing brake system via a check valve.
This pressure causes the swing brake to
release against spring pressure and will
keep the brake released until the pres-
su re is vented from the brake system by
operating the brake lock valve. This
brake lock valve is used to hold the up-
per stationary.
Du ring swing operation, swing of the
upper can be stopped by positioning the
swing control valve lever in the opposite
position and plugging the swing motion
by causing the swing motor to oppose the
swing. In addition, the machine is pro-
vided with a swing brake master cylinder
that is foot pedal operated. When the
pedal is pressed, hydraulic pressure is
applied to the inner piston of the swing
brake, see Figure 5A-7 on page 5A-1O.
The inner piston works against spring
pressure and applies pressure on the
swing brake discs. When the pedal is re-
leased the swing bra ke master cylinder
and inner piston of the swing brake is
released.
If for any reason the swing motor should
tu rn faster than the rate at which oil is
supplied to it, the motor will act Ii ke a
pump. This action will cause a pressure
drop at the motor inlet and return oil will
increase. This pressure drop could cause
cavitation at the inlet of the motors ex-
cept for the anti-cavitation checks in the
system.
Load pressure acting on the back side of
an anti-cavitation check will normally
keep it closed. Should load pressu re
drop off, however, return oil pressure
will increase and unseat the check. Re-
tu rn oil adds to pump oil to fill the void
at the motor inlet. When pressure re-
turns to normal, the anti-cavitation
check closes and normal swing operation
resumes. The back pressure check
valve in the swing retu rn line serves as
a low pressure relief valve to help su-
percharge the swing anti-cavitation
checks du ring periods of low flow.
AXLE SUSPENSION CIRCUIT .. This is a
passive circuit consisting of nitrogen
charged accumulators and hydraulic sus-
pension cylinders. For the purpose of
replenishment from the outrigger mode
valve, a pressure reducing valve, needle
valve and check valves are included.
Solenoid operated lock valves are incor-
porated for the purpose of suspension
"Lock-Up. "
The pressure reducing valve allows only
reduced pressure to reach the suspen-
sion circuit during charging and bleed-
ing operations, thus preventing
displacement of oil into the accumulators.
The needle valve insu res isolation of the
suspension circuit after charging.
Suspension action (float or lock) at each
corners of the machine is controlled by
solenoid operated lock valves. When so-
lenoids are energized the spools are
shifted to the 'open center' position.
This allows oil to travel through the
valve, in either direction, while the cyl-
inders 'float' with the contour of the
ground. Oil is free to flow to the accu-
mulator which acts as a progressive
hydraulic spring. An optimal -level of
damping is provided by the flow re-
striction of the circuit. An integral
relief valve directs rod side oil from the
suspension cylinder to tan k in the event
of piston seal failure.
De-energizing the solenoids causes the
check valves to seat. This action blocks
oil to the accumulators and stiffens the
suspension. Oil is still free to transfer
between the cylinders, providing for
damped load equalization between axles.
Introduction 5A-13
HEATER / AIR CONDITIONER CIRCUIT.
Oil from the swing circuit is used to
drive the heater / air conditioner hy-
draulic motor.
A flow control valve, in the swing pres-
sure line, bleeds flow off the circuit at
the regulated level needed to constantly
5A-14
drive the heater / air conditioner hy-
draulic motor. One the motor has been
driven, oil returns to the swing circuit
as make-up flow. A pilot operated relief
valve senses the motor inlet pressure
and relieves oil to tank, through the
swing return circuit, should the valve's
set point be exceeded.