TEREX~CRANES

HIGH SPEED
HIGH MOBILITY
CRANE (HSHMC)

•
service
manual
NSN: 3810-01-268-1737

CONTRACT NUMBER: DLA700-87-C-8235

TM 09109A-34/2 OCTOBER 1989

P&H I•• regletered INdemertc of . . Hemlechteger Corp.

I I
 TABLE OF CONTENTS
SECTION

Introduction . ............................................................. .

Controls and Operation ..................................................... .

Lubrication .............................................................. .

Drive Train .............................................................. .

Hydraulic System and Components . ........................................... .

Boom System and Components ....... , ...................................•

Hoist System and Components , ........................................... .

Swing System and Components . .............................................. .

Air System and Components ................................................. .

Steering System and Components . ............................................ .

Outrigger System and Components ............................................ .

Electrical System and Components . ........................................... .

HOW TO USE THIS SHOP MANUAL

This Shop Manual is divided into the major sections shown above. Each major
section can be located using the margin tab marks on the right edge of this page as
shown in sketch. At the beginning of each major section is a Table of Contents
which identifies the topics covered in that section.

This manual has been planned to allow new information to be added as design changes occur. Therefore, this manual may
contain information not applicable to your machine.
 SAFE OPERATING PRACTICES FOR MOBILE CRANE USERS
INTBODUCTION
NOTE
This material replaces Catalog 240.
P&H cranes are carefully designed, test-
ed, and manufactured. When used prop-
erly by qualified operators, they will
give safe, reliable service. There are
P&H offices world-wide to answer any
questions about P&H products or thei r
safe use.
Because cranes are capable of lifting
heavy loads to great heights, they also
have a potential for accidents if safe op-
erating practices are not followed. This
booklet will help the operator prevent
accidents which could result in injury,
death, or property damage.
General safe practices for working on
machinery must be followed as well as the
safe operating practices recommended
here.
OPERATOR'S RESPONSIBILITY
Safety must always be the operator's
most important concern. He must refuse
to operate when he knows it is unsafe
and consult his supervisor when safety
is in doubt.
He must read and understand the Opera-
tor's Manual, all instructions and signs
on the crane. He must see that the ma-
chine is in proper order before
operating.
He must never lift a load without a load
rating plate in the cab. He must under-
stand how to read the rating plate and
know that his crane can safely lift each
load before attempting to lift it.
He must be alert, physically fit, and free
from the influences of alcohol, drugs, or
medications that might affect his
eyesight, hearing, or reactions.
He must see that people, equipment, and
material are kept out of the work area.
The area around the machine should be
properly barricaded (see Operating Pre-
cautions No.4 and 5).
When an operator's vision is blocked or
when operating in hazardous areas such
as near power lines or around people, a
signalman must be used. Because the op-
erator is not in the best position to judge
distances and can not see all parts of the
job site, a signalman may also be neces-
sary at other times. Operators must
understand standard crane signals and
take signals only from designated signal-
men; except that operators must always
obey a stop signal from anybody.
SIGNALMAN'S RESPONSIBILITY
The primary duty of a signalman is to
assist the operator in safe and efficient
operation. Operators depend on desig-
nated signalmen to assist them in making
movements without endangering people or
property.
Signalmen must have a clear understand-
i ng of the work to be done so that they
can safely coordinate each job with oper-
ators and other crew members.
Signalmen must place themselves where
they can be clearly seen and where they
can safely observe the enti re operation.
Standard crane signals must be used un-
less other methods of signaling such as
two way radios or flags have been agreed
upon.
RESPONSIBILITIES OF ALL CREW MEM-
BERS
Any unsafe condition or practice must be
corrected or reported to the job supervi-
sor.
Everyone who works around cranes, in-
cluding riggers and oilers, must obey all
warning signs and watch out for his own
safety and the safety of others. Crew
members setting up machines or handling
loads are expected to know proper ma-
chine erection and rigging procedures.
Watch for hazards during operations and
alert the operator and signalmen of dan-
gers such as power lines, the unex-
pected presence of people, other
equipment, unstable ground conditions
and approaching storms.
MANAGEMENT RESPONSIBILITY
See that operators are trained, compe-
tent, physically fit and, if required, li-
censed. Good vision is required, as are
good judgment, coordination and mental
ability. Any person who lacks any of
these qualities must not be allowed to op-
erate a crane.
Signalmen must have good vision and
sound judgment, know standard crane
signals and be able to give signals clear-
Iy. They must have enough experience to
be able to recognize hazards and signal
the operator to avoid them.
Riggers must be trained to determine
weights and distances and to select and
properly use lifting tackle.
Rigging is a complex subject far beyond
the scope of this booklet. It is manage-
ment's responsibility to see that riggers
are properly trained.
Management must assign a job supervisor
at the site to be responsible for overall
job safety. Crane operators, riggers and
crew members must know who has been
assigned this responsibility.
Crew members must be given specific
safety responsibilities and instructed to
report any unsafe conditions to their su-
pervisors.
Management must assign specific people
to coordinate and direct crane operations
for pick and carry lifts and multi-crane
ii
lifts (see Operating Precautions No. 28
and 29).
PLANNING THE JOB
Most accidents can be avoided by careful
job planning. The person in charge must
have a clear understanding of the work
to be done, consider all dangers at the
job site, develop a plan to do the job
safely, and then explain the plan to all
concerned. Factors such as these should
be considered:
• What crew members are needed and
what responsibilities will they be given?
• What is the weight of the load to be
lifted, the lift radius, boom angle, and
the rated capacity of the crane?
• How will the signalmen communicate
with the operator?
• What equipment is required to do the
job safely? Is a crane the best equipment
for the job?
• How can the equipment be safely
transported to the job site?
• Are there gas lines, power lines or
structu res wh ich mu st be moved or
avoided?
• Is the su rface strong enough to sup-
port the machine and load?
• How wi II loads be rigged?
• What special safety precautions will be
taken if a crane must travel with a sus-
pended load or if more than one crane is
needed to lift a load? (See Operating
Precautions No. 27, 28 and 29).
• Are unusual weather conditions such as
winds or extreme cold expected?
• What steps will be taken to keep un-
necessary people and equipment safely
away from the work area?
• How can cranes be positioned to use
the shortest boom and radius possible?
OPERATOR'S SAFETY CHECK
The operator must make a safety check
before starting to work each day to see
that the machine is in proper order.
Some things to check are:
• Check the machine log book to see that
periodic maintenance and inspections
have been performed and all necessary
repairs have been made.
• Check the operation of the boom hoist
upper angle limit switch, boom angle in-
dicator, backup alarms, anti two-block
warning devices, load moment or load in-
dicator devices, and other operator aids.
• Ca-refully inspect load bearing parts
such as wire rope (load lines, boom hoist
cable, suspension lines), boom, outrig-
gers, and hooks.
• Be su re no unauthorized field modifica-
tions have been made; such as added
counterweights and booms that have been
improperly repai red.
• Check for air and hydraulic oil leaks.
• After starting the engine, check all
gauges and indicators for proper read-
ings.
• Test all controls for proper operation.
• Check brakes and clutches. Test load
brakes by lifting a load a few inches off
the ground and holding it.
OPERATING PRECAUTIONS
1. Mistakes in calculating lifting capacity
can cause accidents.
Several factors must be considered, in-
cluding:
A. Load radius (the distance between the
center of the crane rotation to the
center of the load). Note that the ra-
dius will increase when the load is
lifted.
B. Weight of the load, hook, and
rigging.
C. Boom length, jib, parts of line, and
operating area (side, rear).
Use the next lower rated capacity when
working at boom lengths or radii between
the figures on the rating chart. It is
dangerous to guess the capacity for boom
lengths or radii between those listed on
the rating plate.
Safe Operating Practices for Mobile Crane Users
Trying to lift a load without knowing
whether it is within the rated capacity
while expecting the crane to start to tip
to warn of an overload is very
dangerous. Cranes may suddenly tip
over or collapse if the load is too heavy.
Crane mounted boom hoist upper angle
limit switches, boom angle indicators,
backup alarms, anti two-block warning
devices, load moment or load indicator
devices and other operator aids are no
substitute for following the rating chart,
operating instructions and safe operating
practices.
A Iways stay with i n rated capacity. The
operator must reduce the load under ad-
verse field conditions until, in his judg-
ment, the machine can safely handle the
lift.
(See Operating Precautions No.3, 11,
13, 17, 20, 28 and 29).
2. Cranes may tip over or collapse if the
operating surface cannot support their
weight. Timber mats, steel plates or con-
crete rafts may be needed under outrig-
gers pads or crawlers to distribute the
load under the crane so that the bearing
strength of the ground is not exceeded.
Determine the load bearing capacity of
the ground or other surface on which
machines will be operating. Be sure
cranes are adequately supported . Avoid
soft or unstable ground, sand, areas
with high water tables, and partially fro-
zen ground. When machines are working
near trenches, the trenches should be
shored or sloped to prevent cave-ins or
slides.
3. The rated capacity of a crane is de-
termined with the crane leveled within 1
percent of grade (1 foot drop or rise in
100 foot distance). Out of level of more
than 1 percent will drastically reduce the
Iifti ng capacity.
Be sure cranes are level. Check fre-
quently and relevel when necessary. Po-
sition outriggers according to the rating
chart. All tires must be off the ground
for "On Outrigger" ratings.
4. People can be crushed by the
scissors-Ii ke action of the upper rotating
on the lower.
iii
Stay away from rotating cranes. Erect
barricades to keep people away. Take
the time to determine that these areas
are clear before swinging.
5. People can be crushed by the rear
(counterweight) of the machine if there
is not enough room for it to swing.
Position machine and use barricades so
that people cannot be trapped between
the counterweight and any obstructions.
6. Many_ people have been injured when
riding crane hooks or loads or while be-
ing lifted in manbaskets. They have no
control over how they are handled and
no protection from impacts or falls. Small
mistakes can be fatal.
It is strongly recommended that cranes
not be used to lift people. Use ladders,
scaffolds, elevated work platforms or
other equipment designed to lift people.
Cranes should never be used to lift peo-
ple unless there is no less hazardous way
to perform the needed work and every-
one involved has read, understood and
complied with P&H Catalog 275, "Impor-
tant Safety Requirements When using
Personnel platforms with Mobile Con-
struction Cranes fl. Copies of Catalog 275
are available from your P&H distributor.
7. Power lines have killed or seriously
injured people working around cranes.
These accidents can be avoided by fol-
lowing a few simple rules.
Always determine whether there are pow-
er lines in the area before starting any
job. OSHA regulations require at least
ten (10) feet of clearance from lines car-
rying 50,000 volts or less. Greater clear-
ances are required for lines with higher
voltages. Some states require greater
clearances than OSHA. Safety requires
that you stay as far as possible from
power lines and never violate minimum
clearances.
Always take these precautions if power
lines are present.
A. Notify the Power Company before be-
ginning work.
B. You and the Power Company must
take specific precautions. These may
include locating cranes and materials
away from power lines, de-energizing
and grounding lines, rerouting lines,
iv
removing or barricading lines, and
insulating lines with rubber sleeves.
C. Use a signalman to maintain a safe
distance between any part of the ma-
chine or load and power lines. The
operator is not in the best position to
judge distances.
D. Warn people to stay away from the
machine and load at all times. If the
load must be guided into place, ask
the Power Company about special pre-
cautions such as insulated poles or
hot sticks.
E. Slow Down. Give yourself time to re-
act to problems and to double check
the distance between power lines and
any part of the machine or load.
Careful planning and supervision offer
better protection than any known device.
I nsulated boom cages, proximity warning
devices, and insulating links have limita-
tions and can fail without warning. In-
sulated boom cages and links only
protect part of the crane and can break
down electrically when contaminated with
dust and water. Operation of proximity
warning devices can be affected by dif-
ferent arrangements of power lines, the
movement of trucks, materials, and the
crane itself, and other influences. Rely-
ing on any of these devices could be
dangerous because operators may think
they are providing protection when in
fact they are not.
8. The load line can break if the hook
block contacts the end of the boom. This
is called "two-blocking". Two-blocking
can be caused by hoisting the hook into
the end of the boom, lowering the boom
or extending telescopic booms without
paying out load line. Two-blocking can
pull jibs and lattice crane booms over
backwards.
Always keep space between the hook
block and boom point. Lower the hook
when extending telescopic booms to avoid
two-blocking.
9. People can be inju red if the hook,
boom, load or outriggers are moved be-
fore everyone is clear.
Make sure everyone is in a safe place be-
fore moving the hook, boom, load or out-
riggers. Do not move loads over people
or veh icle cabs. Do not allow the load to
bump or catch on anything_
10. Injury and damage can occur if the
engine is started before servicing is fin-
ished.
Prior to servicing the crane, place
"Warning" or "Out of Order" signs on
the crane controls.
Never start or operate the crane if warn-
ing signs are on the crane controls. Look
under and around the crane to be sure
everyone is clear.
11. Rapid swings or sudden starts and
stops can cause the hook and attached
load to swing out of control.
Always start and stop movements smooth-
ly and swing at speeds that will keep the
load under control.
12. Dirty windows, darkness, bright
sunlight, fog, rain, and other conditions
can make it difficult for the operator to
see.
Keep windows clean. Do not operate if
you cannot see clearly enough to operate
safely.
13. Even light winds can blow loads out
of control, collapse booms, or tip ma-
chines. Winds aloft can be much stronger
than at ground level.
Do not lift loads if winds create a
hazard. Lower the boom if necessary.
See the rating plate for possible re-
strictions.
14. Carelessness in getting on and off
equipment can result in serious injuries.
Always wait until the machine has
stopped. Do not jump on or off. Always
use both hands and make sure you have
good footing.
15. Slippery floors and steps, tools,
trash, or other loose items can cause
falls.
Keep the machine clean and dry.
16. Damaged crane booms may collapse.
Lattice type booms will be weakened by
damaged chords, bent or missing
lacings, or cracked welds. Telescopic
booms will be weakened by distorted bot-
tom or side plates. I n either case, the
loss of strength is difficult to estimate.
Safe Operating Practices for Mobile Crane Users
Inspect the crane boom daily for damage.
Do not use damaged booms. (NOTE: Due
to the high strength steels used in
booms, special repair procedures are re-
quired. Repair procedures for lattice
booms are described in P&H Catalog 238,
"Repair Procedure for Mobile Con-
struction Crane Boom Sections". Consult
your P&H distributor for further informa-
tion. )
17. Crane booms can buckle if side load-
ed (pulled sideways). Typical causes of
side loading are rapid starts and stops
while swinging, dragging or pushing a
load sideways, winds, or lifting when the
crane is not level.
Take care to avoid side loading.
18. If the load strikes the boom or the
boom hits a building or other object, the
boom may collapse.
Never let the load or any other object
strike the boom.
19. Boom suspension lines will stretch
when the load is lifted and contract when
the load is released. At high boom angles
this may be enough to pull the boom
backward over the crane.
When releasing loads, be sure the boom
never tightens against the backstops.
Release loads slowly.
20. The load will swing out of control if
it is not directly beneath the boom point
when lifted. This can side load the boom
and may cause the crane to tip or col-
lapse.
Always place the boom point directly
above the load when lifting.
21. Trying to lift a load which is stuck,
frozen or attached to something else may
result in tipping, boom collapse or other
damage.
Be sure that loads are free before
lifting.
22. If there is not enough wire rope on
the drum, the rope can be pulled off.
Keep at least two full wraps of wire rope
on drums when operating.
23. Foot pedal brake locks are furnished
on some cranes to allow the operator to
v
rest his legs when suspending the load
for short periods of time.
The feet must be kept on the pedals whi-
le foot pedal brake locks are in use.
Brakes may cool allowing the load to fall.
24. Trying to repai r or adjust equipment
with a suspended hook or load or with
the boom raised could release machinery
and let it move unexpectedly.
Always lower the load to the ground and
the bool'{l onto proper cribbing before do-
ing maintenance or repair work.
25. Pressure in hydraulic systems can be
retained for long periods of time. If not
properly released before maintenance
people attempt to work on the hydraulic
system, this pressure can let machinery
move or cause hot oil and hose ends to
shoot out at high speed.
Release system pressure before attempt-
ing to make adjustments or repairs.
26. Pin-connected booms and jibs may
fall if not properly supported when re-
moving pins.
Make sure both ends of each boom and
jib section are supported and the boom
suspension lines completely slacked off
before removing pins. Never stand on,
inside, or under booms or jibs during
assembly or disassembly.
27. As with all heavy equipment, care
must be taken when cranes are driven
(traveled) whether on or off the job site.
Watch for people, power lines, low or
narrow clearances, bridge or road load
limits, and steep hills or uneven terrain.
Use a signalman in close quarters. Know
the height, width, and weight of the ma-
chine. Retract and lock the outriggers,
place the boom in the cradle, and set the
swing brake or lock before traveling.
Store or tie empty hook to prevent
swinging.
28. Load ratings for cranes are based on
the machine being stationary and level.
Traveling a crane with a suspended load
(pick and carry operation) or with the
boom erected involves special hazards,
including the possibility of side loading
or tipping over.
vi
Because of the many variables involved,
the user must evaluate conditions and
take precautions such as these:
• Watch for people, power lines, low or
narrow clearances, bridge or road
load limits, steep hills or uneven ter-
rain. Use a signalman in close quar-
ters. Know the height, width and
weight of the machine. Set the swing
brake or lock before traveling. Store
or tie empty hook to prevent
swinging.
• The job supervisor must specify a
person to determine and direct safe
operation before and during the pick
and carry lift.
• Check the rating plate for limitations
and instructions.
• Position the boom in line with the di-
rection of travel.
• Reduce the maximum load while travel-
ing to reflect operating conditions.
The safe load will vary depending on
speed, crane, terrain, and other con-
ditions.
• Inflate tires to specified pressure.
• Travel slowly and avoid sudden stops
and starts.
• Avoid backing away from the load.
This could increase the radius and
cause the machine to tip over.
• Use tag lines to keep loads under con-
trol.
• Keep the load close to the ground.
• Use the shortest boom possible.
29. Using two or more cranes to lift a
load involves many hazards not normally
encountered in single crane lifts.
Multi-crane lifts must be carefully engi-
neered, keeping the follOWing points in
mind.
• Since the load is not freely
suspended, careful engineering stu-
dies must be made to ensure that the
load carried by each machine is less
than its rated capacity.
• Make sure slings are arranged to di-
vide the load as planned.
• Review the lifting plan with
operators, signalmen and other crew
members before beginning the lift.
• The job supervisor must designate a
single person to determine and direct
all crane operations before and during
every stage of the lift.
• Avoid boom side loading (see No. 17).
30. Leaving a machine unattended can be
very dangerous.
Before leaving his seat, the operator
must take the following steps to prevent
his machine from moving:
• Lower the load to the ground. Lower
the boom when necessary.
• Set the swing brake or lock.
• Set all drum pawls.
• Set parking brakes.
• Set propel brakes or locks on crawler
machines.
• Disengage the engine clutch or shut
off the engine.
31. All wire rope must be inspected daily
to determine whether it should be re-
placed. See the inspection form in the
Operator's Manual and contact wire rope
manufactu rers and thei r distributors for
more information.
Wire rope should be replaced when any
of the following conditions exist:
• I n running ropes, six broken wi res in
one lay or three broken wires in one
strand in one lay.
• Wear of one-third the original diam-
eter of the outside individual wi res.
• Evidence of heat damage from any
cause.
• Reductions from nominal diameter of
more than:
1/32 inch for diameters 3/8 to 112
inch.
Safe Operating Practices for Mobile Crane Users
3/64 inch for diameters 9/16 to 3/4
inch.
1/16 inch for diameters 7/8 to
1-1/8 inches.
3/32 inch \Dr diameters 1-1/4 to
1-112 inches.
• I n standing ropes, more than two
broken wi res in one lay in sections
between end connections or more than
one broken wi re at an end con nection.
• Evidence of kinking, bird caging
crushing, cuts, abrasions, sharp
bends or any other damage that re-
sults in distortion of the rope struc-
ture.
• Rust or corrosion.
• For rotation resistant ropes, any evi-
dence of lengthening of rope lay with
a reduction in rope nominal diameter.
32. Improper wire rope connections may
fail under load.
Wire rope end connections must be in-
stalled properly and inspected daily.
• Wedge sockets should be installed so
that the loaded side of the rope is in
a straight line with the edge of the
socket and not bent by the wedge.
Prevent the rope end from slipping
out of the wedge socket by attach i ng
a short piece of rope to the rope end
with two U-bolt clamps.
• U-bolt clamps (clips) should be in-
stalled so that the .U-bolt is on the
unloaded side and the saddle is on the
loaded side.
• Review Operator's manual for installa-
tion example of U-bolt clamps.
33. Wire rope running over drums and
th rough sheaves create pinch points.
Do not use your hands to guide wire
rope onto drums. Keep clothing and all
parts of the body away from running
rope.
vii
 TABLE OF CONTENTS

List of Illustrations xi

Section I 1-1

Introduction 1-1
Scope ...... 1-1
Warnjngs, Cautions, Notes 1-1
General Information 1-1
Safety ...... 1-1
Serial Number Location 1-1
Description .... 1-2
General Dimensions 1-2

Safe Operating Practices for Mobile Crane Users

Introduction ..... ... .
Operator's Responsibility ... .
Signalman's Responsibility ... .
Responsibilities of all Crew Members
Management Responsibility
Planning the job
Operator's Safety Check
Operating Precautions iii

Contents ix
 LIST OF ILLUSTRATIONS

Figure 1-1. Machine Nomenclature 1-3

Figure 1 -2. General Dimensions 1-4

List of Illustrations xi
 TABLE OF CONTENTS
SECTION

Introduction . ......................................... , ................... .

Controls and Operation ..................................................... .

Lubrication .............................................................. .

Drive Train

Hydraulic System and Components . ........................................... .

Boom System and Components " .........................................•

Hoist System and Components ............................................ .

Swing System and Components . .............................................. .

Air System and Components ................................................. .

Steering System and Components . ............................................ .

Outrigger System and Components . ........................................... .

Electrical System and Components . ........................................... .

HOW TO USE THIS SHOP MANUAL

This Shop Manual is divided into the major sections shown above. Each major
section can be located using the margin tab marks on the right edge of this page as
shown in sketch. At the beginning of each major section is a Table of Contents
which identifies the topics covered in that section.

This manual has been planned to allow new information to be added as design changes occur. Therefore, this manual may
contain information not applicable to your machine.
 SECTION I
INTRODUCTION
SCOPE
This manual provides operating in-
structions, information concerning rou-
tine lubrication and service of this
machine. In order to become familiar
with the various parts of the machine, it
is urged maintenance personnel study
the instructions and illustrations in this
manual and use it as a reference when
performing repair or maintenance oper-
ations.
WARNINGS, CAUTIONS, NOTES
WARNINGS, CAUTIONS, and NOTES are
used th roughout this manual to empha-
size important and critical instructions.
WARNINGS and CAUTIONS will always
precede the paragraph or item to which
they apply, and NOTES will always follow
the paragraph or item to which they ap-
ply. For the pu rpose of this manual,
WARNINGS, CAUTIONS, and NOTES are
defi ned as follows:
WARNING
An operating procedure, practice,
etc., wh ich, if not strictly fol-
lowed, could result in personal in-
jury, or loss of life.
CAUTION
An operating procedure, practice,
etc. , wh ich, if not strictly ob-
served, could result in damage to,
or destruction of, equipment.
NOTE
An operating practice, condition,
etc., which is essential to high-
light.
GENERAL INFORMATION
The information, specifications, and il-
lustrations in this publication are based
on the information in effect at the time
which this manual was printed.
Part numbers are occasionally shown in
this manual to identify various parts and
assemblies. Do not use the part numbers
shown in this manual when ordering re-
pair parts. Always refer to the Parts
List for this machine.
SAFETY
It is most important that operators and
maintenance personnel r.ead and be famil-
iar with the Safe Operating Practices
printed at the front of this manual. This
will help to ensure safe working condi-
tions for machine operators, servicemen,
and other people in the area.
SERIAL NUMBER LOCATION
The machine serial number is located on
the lower front of the upper cab. I n any
correspondence regarding repair parts,
always state the machine serial number.
This will help to ensure that the correct
parts are obtained for the machine.
Section I 1- 1
OEseR I PTION
This machine is a self-propelled, rubber
tired hydraulic all terrain crane (see
Figure 1 - 1 on page 1 -3). The machine is
powered by a single engine located in the
lower of the machine. The upper opera-
tor's cab, located on the left side of the
upper, contains the controls necessary
to operate the crane and to drive the ma-
chine around the job site. The lower
operator's cab, located on the left side of
the carrier, contains the controls neces-
sary to operate the carrier and to drive
the machine from job site to job site.
The carrier mounted engine supplies
power for both the upper and the lower.
A drive shaft attached to the engine fly-
wheel is used to drive a power shift
transmission to provide the power needed
to propel the machine. Pumps mounted
on the transmission supply pressurized
fluid through the hydraulic swivel to the
di rectional control valves located on. the
mach i ne upper. When the operator
moves the appropriate control, the con-
trol valves supply pressurized fluid to
either the boom cylinders, outrigger cyl-
inders, winch motors, or the swing
motor.
An engine driven air compressor supplies
air pressure for actuating the carrier
1-2
brakes and controlling the engine throt-
tle
The telescoping boom has two powered
sections which are activated by hydraulic
cylinders.
The swing function of the upper is pow-
ered by a hydraulic motor and a swing
transmission. A spring actuated, hy-
draulically released swing park brake is
used to hold the upper in a selected po-
sition. A pedal operated hydraulic brake
can be used to hold the upper
stationa ry .
The outriggers are of the out and down
type. Each outrigger is positioned
through the use of one vertical and one
horizontal hydraulic cylinder. Each ver-
tical cylinder is equipped with a lock
valve to maintain the selected height.
Complete nomenclature of major machine
components is shown in Figure 1-1 on
page 1 -3.
GENERAL DIMENSIONS
Figure 1-2 on page 1-4 provide the di-
mensions commonly required for machine
shipping and erection.
 COUNTERWEIGHT WINCH BOOM HOIST BOOM
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SPECIFICA TIONS
AXLE SPACING: AXLE LOADS: TIRES:
MACHINE LENGTH: 41'-7 3/4" 1 TO 4: 22'-6"
1:
17,850 LB. SIZES: 22/65R25
CARRIER LENGTH: 38'-1 1/8" 2 TO 4: 17'-1"
3 TO 4: 5'-5" 2:
17,850 LB. 8 SINGLES
MACHINE WIDTH: 8'-6" 17,050 LB._
3:
1 TO 2: 5'-5" WIDTH: 21.3 IN.
17,050 LB.
4:
MACHINE HEIGHT: 11'-6 7/8" FRONT OVERHANG:
2+3+4:
51,915 LB.
LOAD/INCH OF
SPEEP: 45 M.P .H: FROM BUMPER: 4'-0" FRONT TANDEM: 35,700 LB,
WIDTH (MAX):
(MAINT AINED; LEVEL GRADEl FROM FRONT REAR TANDEM: 34,100 LB.
OF TOTAL G.V.W.: 69,800 LB. ·405 16/IN.
FRONT TIRES: 11'-3"
 TABLE OF CONTENTS

Section II 2-1

Controls and Operation 2-1

Controls-Carrier Cab 2-1
Carrier Operation 2-8
General ..... . 2-8
Preoperation Inspection 2-9
Starting the Engine 2-9
Driving the Carrier 2-11
Controls- Upper Cab 2-13
Outrigger Operation 2-23
Crane Operation 2-26
Lift Crane . . . 2-26
Pick and Carry Operation 2-26
Stopping The Engine 2-27
Hand Signals ......... . 2-27
Operation Under Unusual Conditions 2-27
Deep Water Fording 2-33
Installing Rope On Drums 2-34
Reeving .... . 2-35
Towing .... . 2-36
Hook Block Storage 2-38

Contents
 LIST OF ILLUSTRATIONS

Figure 2-1. Carrier Controls and Instruments 2-2

Figu re 2-2. Voltmeter Operation . 2-3
Figure 2-3. Pump Disconnect Lever 2-8
Figure 2-4. AIC & Heater Controls 2-9
Figu re 2-5. Seat Adjustments 2-10
Figure 2-6. I nter-Vehicle Connector ... 2-11
Figure 2-7. Upper Controls and Instruments 2-14
Figure 2-8. Anti-Two Block Console 2-17
Figu re 2-9. Outrigger Control Panel 2-24
Figu re 2-10. Outrigger Float .... 2-25
Figure 2-11. Lift Crane Operation .. 2-28
Figure 2-12. Hand Signals For Crane Operation .. 2-29
Figu re 2-13. Antifreeze Concentration and Temperatu re 2-31
Figu re 2-14. Securing Rope to Drum 2-34
Figure 2-15. Installing A Rope Socket 2-35
Figure 2-16. Reeving Diagram 2-37
Fig u re 2 -17. Caging Bolt 2-38

List of Illustrations iii

 LIST OF TABLES

Table 2-1. Hydraulic System Operating Temperatures 2-31

List of Tables v
 SECTION"
CONTROLS AND OPERATION
CONTROLS-CARRIER CAB
The instruments and controls in the car-
rier cab are shown in Figure 2-1 on page
2-2 The numbers on the illustration cor-
respond with the numbers in the follow-
ing list which identifies the controls and
describes their operation.
Before attempting to operate this
machine, the operator should carefully
study all of the information in this sec-
tion and the Safe Operating Practices at
the front of this manual. The operator
should become familiar with the location
and purpose of each control on the ma-
chine.
1. HOURMETER. This meter records the
running time of the engine in hours.
2. ENGINE HIGH TEMPERATURE INDI-
CATOR. This red indicator will glow
and a warning horn will sound when the
engine coolant is above the normal oper-
ati ng temperatu re.
3. ENGINE COOLANT TEMPERATURE.
This gauge indicates the engine coolant
temperature in degrees Fahrenheit. The
normal operating temperature of the en-
gine is 190 0 F.
4. VOLTMETER. The voltmeter measures
the voltage produced by the alternator
and indicates the condition of the
battery. See Figure 2-2 on page 2-3 for
an explanation of the voltmeter readings.
5. LOW OIL PRESSURE INDICATOR.
This red indicator will glow and a warn-
ing horn will sound when the engine oil
pressu re is below the normal operating
range.
CAUTION
Low or zero gauge reading indi-
cates a danger to the engine.
Stop the engine immediately and
locate the cause of the drop in oil
pressure.
6. ENGINE OIL PRESSURE. This gauge
indicates the engine oil pressure in
pounds per square inch. The normal en-
gine oil pressure is 30-65 psi at operat-
ing speeds.
7. FUEL GAUGE. This gauge indicates
the amount of fuel remaining in the fuel
tank.
8. LEFT TURN INDICATOR. This light
will flash when the left turn signal is en-
ergized and when the hazard warning
light switch is activated.
9. SPEEDOMETER. This speedometer in-
dicates the carrier speed in miles per
hour (mph). This gauge aLso contains
an odometer which indicates the total
number of miles the carrier has traveled.
10. HIGH BEAM INDICATOR. This blue
light will glow when the high headlight
beams are ON.
11. TACHOMETER. This instrument indi-
cates the speed of the engine in revo-
lutions per minute (rpm).
12. RIGHT TURN INDICATOR. This
light will flash when the right tu rn sig-
nal is energized and when the hazard
warning light switch is activated.
13. CONVERTER OIL TEMPERATURE
GAUGE. This gauge indicates the tran-
smission converter oil temperature.
Section II 2-1
 ITEM 45 LOCATED ON LEFT
SIDE OF CARRIER. SEE FIG- I
URE 2-3. I

Figure 2-1. Carrier Controls and Instruments

2-2
 Engine not running or Engine running fast enough to
running at slow idle. make generator" produce.

o o
Dead or disconnected battery. Disconnected or badly Disconnected meter. Engine could not run with dead
connected meter. or disconnected battery unless circuit was com-
pleted around battery.

Very low battery charge. Engine might not start.

Low battery charge. Constant reading in this area
would indicate need for check on generator and vol-
tage regulator.
When meter pointer stays below 13.3 or 26.6 with
the engine running fast enough to operate gener-
ator, it shows that generator is not operating or
voltage regulator is out of adjustment, or that current
being drawn from battery by lights, heater fan, or
other load, exceeds generator output.

Well-charged battery. This indicates a good battery

and also that generator and voltage regulator are op-
erating properly.

When engine is started, pointer may stay in this area

temporarily but should gradually rise above 13.3 or
26.6 as generator reaches normal output.
The pointer might remain in this poSition temporarily
when the engine has been stopped after consider-
able use, due to a "surface charge" in the battery. To
get a correct reading, turn on headlights for a few
minutes.

Under normal conditions, a 12V battery is fully char- This is the area in which the pointer should be when
ged at 12.8V; a 24V battery at 25.6. A Slightly higher generator, voltage regulator and battery are a" in
reading may occur under the conditions outlined in good condition and working properly.
No.5 but, generally speaking, any reading above 12.8
or 25.6 when the engine is stopped is not a true read-
ing.

"NOTE: The word "generator" refers to both gener-

ator and alternator since both require the
~
10 . ~\>.~T Gyl6
same instrumentation. When the pointer goes above 15.2 or 30.4, the volt-
WOLTS
age regulator is set too high or is jammed and con-
While a 12V gauge is shown, the principle of IT'!]
tinued operation of the engine wi" burn out the
the voltmeter is the same for a 24V electri- battery.
cal system. The only differences are the
values on the gauge face. P-100

Figure 2-2. Voltmeter Operation

Controls and Operation 2-3

Normal transmission operating temper-
ature is 180 to 250 0 F.
14. AIR INDICATOR, ACCESSORY. This
red light will glow when the air in the
accessory air system is below the normal
operating range. The warning horn will
also sound continuously when ai r pres-
sure in the accessory air system is below
the normal operating range.
15. AIR PRESSURE GAUGE,
ACCESSORY. This gauge monitors the
pressure within the accessory air system
of the machine. The gauge should read
between 100-120 psi. If the gauge pres-
sure falls below 100 psi for more than a
short period of time, the accessory air
ci rcuit should be inspected. The cause
of the low air pressure should be cor-
rected before continuing to operate the
machine.
16. AIR INDICATOR, FRONT BRAKES.
This red light will glow when the pres-
sure in the air circuit that controls the
front brakes drops below 60 psi. Also,
the warning horn will produce a contin-
uous sound if air pressure in the front
brake ci rcuit drops below 60 psi.
17. AI R PRESSURE GAUGE, FRONT
BRAKES. This gauge monitors the pres-
sure within the air circuit that actuates
the front brakes. The gauge should read
between 100-120 psi. If the gauge pres-
sure falls below 100 psi for more than a
short period of time, the front brake air
circuit should be inspected. The cause
of the low air pressure should be cor-
rected before continuing to operate the
machine.
18. AIR INDICATOR, REAR BRAKES.
This red light functions in the same
manner as the Front Brake Air Indicator.
This light will glow when the rear brake
ai r pressu re drops below 60 psi.
19. AIR PRESSURE GAUGE, REAR
BRAKES. This gauge monitors the air
pressure within the rear brake air sys-
tem of the machine, and functions in the
same manner as the front brake air sys-
tem gauge.
20. DIAGNOSTIC RECEPTACLE. This
receptacle is used to connect the STE
ICE tester to the machine to perform di-
agnostic tests on the engine.
21. PARKING BRAKE ENGAGED INDICA-
TOR. This light will glow when the car-
rier parking brakes are applied.
2-4
22. PARKING BRAKE CONTROL. Push
this knob down to apply the rear wheel
brakes when parking the carrier. Pull
this knob up to release the rear wheel
brakes.
NOTE
This control will automatically move
to the applied position when air in
the front or rear brakes air system
drops below 40 ps i .
23. DIFFERENTIAL LOCKS, FRONT AX-
LES.
CAUTION
Do not place the differentials in
the LOCK position when the carri-
er is turning. Serious damage to
the axles may result if this precau-
tion is not followed.
This switch locks and unlocks the inter-
axle differential and the axle differen-
tials. Press and hold the bottom of the
switch to LOCK the differentials when
approaching or anticipating icy or slip-
pery conditions to provide maximum axle
traction. The differentials can be shift-
ed to the LOCK position at slow carrier
speeds, except if the wheels have al-
ready lost traction and are spinning.
CAUTION
Do not place the differentials in
the LOCK position if wheels are in
a spin out condition. The carrier
drive train must be brought to a
complete stop or serious damage to
the axles may result if this precau-
tion is not followed.
Release the switch to return to the UN-
LOCK position after passing adverse
conditions. This permits the differen-
tials to compensate for differences in ti re
size and provides maximum speed and
performance.
NOTE
Let up on the accelerator to pro-
vide an interruption in torque to
the drive train when locking or un-
locking the differentials.
24. DIFFERENTIAL LOCKS, REAR AX-
LES.
CAUTION
Do not place the differentials in
the LOCK position when the carri-
er is turning. Serious damage to
the axles may result if th is precau-
tion is not followed.
This switch locks and unlocks the inter-
axle differential and the axle differen-
tials. Press the top of the switch for
UNLOCK, normal driving conditions.
Press the bottom of the switch to LOCK
the differentials when approaching or an-
ticipating icy or slippery conditions to
provide maximum axle traction. The dif-
ferentials can be shifted to the LOCK
position at slow carrier speeds, except if
the wheels have al ready lost traction and
are spinning.
CAUTION
Do not place the differentials in
the LOCK position if wheels are in
a spin out condition. The carrier
drive train must be brought to a
complete stop or serious damage to
the axles may result if this precau-
tion is not followed.
Place the switch in the UNLOCK position
after passing adverse conditions. This
permits the differentials to compensate
for differences in tire size and provides
maximum speed and performance.
NOTE
Let up on the accelerator to pro-
vide an interruption in torque to
the drive train when locking or un-
locking the differentials.
25. REAR AXLE DI FFERENTIAL LOCK
INDICATOR. This light will glow when
the rear axle differentials are locked.
26. FRONT AXLE DISCONNECT SWITCH.
This switch controls the front axle dis-
connect. Press the top of the switch to
disconnect the front axle drive. Press
the bottom of the switch to engage the
front axle drive.
27. MASTER SWITCH. The master
switch energizes the electrical ci rcuits on
this machine. This is an ON-OFF switch
which must be in the ON position before
the engine can be started.
28. MASTER SWITCH INDICATOR. The
amber indicator will glow whenever the
master switch is in the ON position.
29. ENGINE START BUTTON. With the
master switch in the ON position, de-
press and hold this black button to start
the engine. As soon as the engine
sta rts, release the sta rt button.
CAUTION
If the engine does not start within
30 seconds, release the start but-
ton and allow the starter motor to
cool before continuing the attempt
to start the engine.
30. STARTING AID BUTTON. This white
button is used to control the starting
aid. Refer to "Starting the Engine" on
page 2-7 for information on how this but-
ton is used.
31. LOWER/UPPER SELECTOR SWITCH.
This switch transfers control from the
lower to the upper. Place the switch in
the LOWER position when driving the
carrier. Place the switch in the UPPER
position when operating the crane.
32. Not applicable. Hole is covered by a
switch plug.
33. TORQUE CONVERTER LOCK-UP
SWITCH. Press the top of the switch to
allow automatic lock-up the torque con-
verter. Press the bottom of the. switch
to disengage automatic lockup of the tor-
que converter.
34. WINDSHIELD WASHER SWITCH.
Press the top of this switch to activate
the windshield washer.
35. WI NDSH I ELD WI PER SWITCH. Press
the top of this switch to operate the
windshield wiper at high speed. Place
the switch in the center position to oper-
ate the wiper at low speed. Press the
bottom of the switch to turn the wiper
OFF.
Controls and Operation 2-5
36. CENTER DEFROSTER SWITCH. De-
press the top of this switch to operate
the center defroster fan. Depress the
bottom of this switch to turn the defrost-
er OFF.
37. S IDE DEFROSTER SWITCH. Depress
the top of this switch to operate the side
defroster fans. Depress the bottom of
this switch to turn the defroster OFF.
38. CARRIER LIGHT SWITCH. The ve-
hicular light switch is located at the ex-
treme left hand side of the dash panel
and is used to control the carrier lights.
The switch assembly has three
lever-type switches. These switches op-
erate as follows:
A. LOCK LEVER. The lower right lever
locks the top lever from moving ex-
cept to the blackout position. This
lever thus prevents accidental actu-
ation of lights while operating under
blackout conditions. To use the
normal li~hting, hold the lock lever in
the "UP' position while moving the
top lever to the desired lighting.
B. OUTSIDE LAMP SELECTOR SWITCH.
This lever switch has five control po-
sitions, blackout drive, blackout
marker, off, stoplights and service
drive. The switch can only be placed
in the stoplights and service drive
position if the lock lever has been
lifted upward.
NOTE
The Outside Lamp Selector Switch
must be placed in the stoplight po-
sition when operating the crane, in
other than blackout condition, in-
order for the crane stoplight to
function.
C. PANEL LIGHT SELECTOR SWITCH.
This lever switch is used to select the
type of panel lighting. Four lighting
positions are available, Park, Off,
Dim and Bright.
39 . ACCELERATOR. This pedal is used
to control engine speed. Depress the pe-
dal to increase engine speed; release the
pedal to decrease engine speed to idle.
40. BRAKE PEDAL. Depress this pedal to
apply the carrier brakes. Release the
pedal to release the carrier brakes.
2-6
41. TURN SIGNAL LEVER. This lever
controls the operation of turn signals,
emergency flashers and headlight beams.
Each function is controlled as follows:
A. Move the lever forward to activate the
right tu rn signal. Move the lever
backward to activate the left turn
signal.
B. Pull the small lever, located below the
tu rn signal lever, down to activate
the emergency flashers. Push the le-
ver up to deactivate the emergency
flashers.
C. Pull the tu rn signal lever toward the
steering wheel and release the lever
to actuate the high headlight beams.
Pull and release the lever again to ac-
tuate the low head light beams. The
blue high beam indicator light will
light when the high beams are on.
42. STEERING WHEEL. The steering
wheel controls the position of the front
wheels on the machine. Turning the
steering wheel to the left will cause the
machine to turn left. Turning the steer-
ing wheel to the right will cause the
machine to turn right.
43. HORN BUTTON. Depress this but-
ton in the center of the steering wheel to
sound the horn.
44. TRANSMISSION SHIFT LEVER. This
lever controls the operation of the carri-
er transmission. Operation of the trans-
mission is described under the topic
"Driving the Carrier" on page 2-9.
45. PUMP DISCONNECT LEVER. The
pump disconnect lever, which is located
on the left side of the carrier just behind
the front fender, is used to disconnect
the boom hoist/telescope pump when
roading the machine (see Figure 2-3 on
page 2-7) .
NOTE
The engine must be stopped before
engaging or disengaging the hy-
draulic pump.
Move the lever to the down,
DISENGAGE, position before roading the
machine. Move the lever to the up,
ENGAGE, position before operating the
crane.
46. RANGE SELECTOR LEVER. The
range selector lever is used to select the
high and lower transmission ranges, and
provides a neutral position to disconnect
the transmission from the drive train
LOW /\,.c~",
when operating the crane. Move the le-
ver to the LO position when maximum
power and minimum speed is needed.
8 "':H~8 ~
Move the lever to the H I position when EAGLE ENGINEERING' MANUFACTURING. INC.
maximum speed and minimum power is
needed.
47. FIRE EXTINGUISHER.
48. WINDSHIELD WASHER RESERVOIR.
Figure 2-4. AIC and Heater Controls
49. AIR CONDITIONER AND HEATER
CONTROLS. The following controls are 50. SEAT CONTROLS. The operator's
used to control the operation of the cab seat contains a number of controls which
air conditioner and heater (see the operator can use to adjust the seat to
Fig u re 2 -4 ) : the most comfortable operating position
(see Figure 2-5 on page 2-8).
A. COOL. This switch is used to control
the temperature within the operators
cab. Turn the switch to the right to CARRIER OPERATION
increase the cooling of the cab.
B. FAN. This three position switch is General
used to control the speed of the fan.
The following operating instructions are
C. HEAT. This switch is used to control offered as a reminder rather than as an
the temperatu re within the operators attempt to instruct, since a machine of
cab. Turn the switch to the right to this size must not be entrusted to anyone
increase the heating of the cab. except a fully qualified operator.
D. MAIN. The main switch is used to se-
lect either the heater or air condition- Preoperation Inspection
er. When neither heater nor ai r
conditioner is desired, use the main Before operating machine each day, per-
switch to tu rn off both systems. form the 'A' Maintenance Checks as out-
lined in Section IV.
Clean the windows, headlights, .and mir-
rors to ensure full vision. Also make
sure the mirrors are properly adjusted to
suit the needs of the operator.
Adjust the operator's seat to provide a
comfortable and safe operating_ position
using the controls shown in Figure 2-5
on page 2-8.

Starting the Engine

To start the engine, proceed as follows:
1. Place the transmission lever, in both
cabs, in the NEUTRAL position.

Figure 2-3. Pump Disconnect Lever

Controls and Operation 2-7

2. Place the pump drive disconnect lever
in the disengaged position.
3. Apply the parking brake.
NOTE
The engine is designed to be
sta rted at temperatu res above 10 0
F without the use of a starting
aid. If temperatures are below
this reading, a starting aid may be
used, the crankcase oil may be
heated, engine coolant may be
heated and batteries may be
warmed. To start the engine when
the temperature is below 10 0 F,
proceed to steps 6 or 7 as applica-
ble to this machine.
~~
I~\
HEADREST
SUSPENSION
ADJUSTMENT
SLIDE FRONT FRONT HEIGHT
AND REAR AND TILT
Figure 2-5. Seat Adjustments
2-8
CAUTION
An audible engine warning will
sound until engine oil reaches the
normal operating pressure at start
up. If oil pressure does not reach
normal operating pressure within
15 seconds after start up, stop the
engine immediately and correct the
cause for low oil pressure.
4. To start the engine under normal con-
ditions, temperatures above 10 0 F, pro-
ceed as follows:
CAUTION
Do not hold starter motor on for
more than 30 seconds at one time.
If engine fails to start in this peri-
od of time, release start button,
and wait two minutes to allow the
starter motor to cool before again
attempting to start the engine. If
this procedure is not followed, se-
rious damage to the starter motor
may result.
5. Depress accelerator slightly and turn
ignition to ignition position. Depress
and hold engine start button. As soon
as engine starts, release start button.
6. To start the engine under cold condi-
tions, temperatures below 10 to -25 0 F,
using the optional starting aid, proceed
as follows:
NOTE
If a booster battery is required to
start the engine, and another mili-
tary vehicle is available, the bat-
teries of the two vehicle can be
connected through the
inter-vehicle connector locat(!d at
the rear of the right front fender
(see Figure 2-6 on page 2-9).

Figure 2-6. Inter-Vehicle Connector
A. Perform steps 1 th rough 3 above and
move the foot th rottle slightly above
slow idle.
B. Tu rn the ignition switch to the ig-
nition position.
WARNING
Do not actuate the starting aid
more than once before starting the
engine. Overloading the engine
air box with this volatile fluid can
result in an explosion.
C. Depress and hold the starting aid
button for th ree seconds.
NOTE
If the engine coolant temperature
is approximately 60 0 F, the elec-
trically controlled thermostat wi II
prevent the valve from energizing.
D. Depress the engine start button to
start the engine as previously de-
scribed in Step 5.
E. If the anticipated outside temperatu re
will be between -25 and -40 0 F, the
winterization equipment of the crane
should be connected to a 110 Volt AC
power sou rce when the crane is
parked, using the power cord sup-
plied with the crane. The crane can
then be started as described in Steps
4 through 6.
Driving the Carrier
Driving the carrier is similar to driving
any comparable heavy duty carrier;
therefore, a step-by-step operating pro-
cedure is not necessary. The following
precautions and special instructions are
provided for the proper operation of the
carrier.
WARNING
If the warning horn should sound,
or if the air indicator lights should
glow, the carrier should be
stopped immediately. These two
signals could indicate that one of
the brake systems has failed. If
one of the systems has failed, the
carrier can be stopped using the
remaining brake system. The
cause of the brake warnings
should be immediately investigated
and corrected before continuing to
operate the carrier. Failure to
correct a problem in the brake
system could lead to loss of carrier
control and injury to personnel.
1. Check that the boom is in the boom
rest and the house lock is engaged.
2. Check that the Suspension Switch, on
the upper side console, is in the cen-
tered, unlocked position.
3. With the engine warm and the brake
air pressure built up to at least 60 psi,
depress the brake pedal to set all the
wheel brakes. Then pull the parking
brake control knob out to release the
parking brake springs.
To move the machine around the job site
or from one job site to another, proceed
as follows:
1. Start the engine and allow the air sys-
tem pressure to build to normal. Retract
the outriggers, if they a re lowered, as
described under the topic "Outrigger
Ope ration" on page 2 -18.
Controls and Operation 2-9
 CAUTION
The carrier must be stopped be-
fore switching from LOW to HIGH
range and vise versa. Serious
transmission damage may occur if
this practice is not observed.
2. The transmission HI/LO range selector
must be in the LO range position if the
carrier is to be operated in all wheel
drive.
To shift from one range to the other,
proceed as follows:
A. Bring the carrier to a complete stop
and keep the brakes engaged.
B. Shift the transmission into NEUTRAL,
then shift into the desired HI or LO
range mode.
NOTE
The carrier may have to be moved
slightly to engage the transmission
in the selected range.
3. Place the gear selector lever in the
desired direction and gear range
position.
NOTE
Downshifts to the next lower gear
range can be made at full throttle,
under load, providing the carrier
is not exceeding the maximum
speed which can be attained in the
lower speed range.
4. Release the brake pedal and accelerate
the machine by depressing the foot
throttle. When the engine speed reaches
the maximum governed rpm, move the
gear selector lever to the next higher
speed range. When the road grade or
load slows the engine, move the gear se-
lector lever to the next lower range.
CAUTION
Do not shut off the carrier when
the transmission is overheating.
Running the engine at an even
speed allows the transmission to
cool.
2-10
5. If the warning system comes on dur-
ing operation, stop the machine and de-
termine and correct the faulty system. If
the transmission temperatu re rises above
250 0 F, stop the carrier immediately and
shift to neutral. Run the engine at
1000-1200 rpm. The temperature should
drop rapidly. If the temperature does
not drop, trouble is indicated. The cause
of the trouble should be determined be-
fore the carrier is operated again.
NOTE
Overheating generally occurs from
working in too high a gear ratio.
Shifting to a lower range will help
el imi nate overheati ng.
CONTROLS-UPPER CAB
The instruments and controls in the up-
per cab are shown in Figure 2-7 on page
2- 11 The numbers on the illustration
correspond with the numbers in the fol-
lowing list, which identifies the controls
and describes their operation.
Before attempting to operate this
machine, the operator should carefully
study all of the information in this sec-
tion and the Safe Operating Practices at
the front of this manual. The operator
should become familiar with the location
and purpose of each control on the ma-
chine.
1. PANEL LAMPS. These lamps are illu-
minated when the headlight switch is
placed in the ON position to illuminate
the dash panel.
2. ENGINE COOLANT TEMPERATURE.
This gauge indicates the engine coolant-
temperature in degrees Fahrenheit. The
normal operating temperatu re of the en-
gine is 190 0 F.
3. ENGINE HIGH TEMPERATURE INDI-
CATOR. This red indicator will glow
and a warning horn will sound when the
engine coolant is above the normal oper-
ating temperature.
4. ENGINE OIL PRESSURE. This gauge
indicates the engine oil pressure in
pounds per square inch. The normal en-
gine oil pressure is 30-60 psi.
01 02 03 04 06 06 07 08 09 10 11 12 13 14

-0O-\~ 0 1~~---1-\~-/- 0

S e 8 ee 0 ©S ©S 0
© ~
'-----I- ~ -/---/--\ I-I--I--I--I-~---'\
o 0 0 0

27 26 26 24 23 22 21 20 19 18 17 16 16

Figure 2-7. Upper Controls and Instruments

Controls and Operation 2-11

5. LOW OIL PRESSURE INDICATOR.
This red indicator will glow and a warn-
ing horn will sound when the engine oil
pressure is below the normal operating
range.
6. FUEL GAUGE. This gauge indicates
the amount of fuel remaining in the fuel
tank.
7 . VOLTMETER. The voltmeter measures
the voltage produced by the alternator
and indicates the condition of the
battery. See Figure 2-2 on page 2-3 for
an explanation of the voltmeter readings.
8. TACHOMETER. This instrument indi-
cates the speed of the engine in revo-
lutions per minute (rpm).
9. AIR PRESSURE GAUGE, ACCESSORY.
This gauge monitors the pressure within
the accessory air system of the machine.
The gauge should read between 100-120
psi. If the gauge pressure falls below
100 psi for more than a short period of
time, the accessory air circuit should be
inspected. The cause of the low ai r
pressure should be corrected before con-
tinuing to operate the machine.
10. CONVERTER OIL TEMPERATURE
GAUGE. This gauge indicates the tran-
smission converter oil temperature.
Normal transmission operating temper-
ature is 180 to 250 0 F.
11. HYDRAULIC OIL TEMPERATURE
GAUGE. This gauge indicates the hy-
draulic oil temperature in degrees Centi-
grade and Fah renheit. The normal
hydraulic oil temperature is 120-190 0 F.
12. PLUG. Hole not used.
13. BRAKE WARNING INDICATOR. This
red indicator light will come on when the
carrier brake air pressure is below 60
psi. This light will remain on until the
brake warning switch, located on the in-
tensifier, is manually reset.
14. PARKING BRAKE ENGAGED INDICA-
TOR. This light will glow when the car-
rier parking brakes are applied.
15. PARKING BRAKE CONTROL. Pull
this knob up to apply the rear wheel
brakes when parking the carrier. Push
this knob down to release the rear wheel
brakes.
2-12
NOTE
This control will automatically move
to the applied position when air in
the front or rear brakes air system
drops below 40 ps i .
16. MAIN WINCH SPEED SELECTOR.
CAUTION
Do not shift the main winch to high
speed or down to low speed unless
the main winch control lever is in
the neutral position. Failure to
observe this precaution may cause
winch motor damage.
This switch is used to shift the main
winch circuit between high and low
speed. To select high speed, place the
main winch control lever in the neutral
position and move the switch up to the
high speed position. To shift the winch
back to low speed, place the winch con-
trol lever in the neutral position and
move the switch down to the low speed
position.
NOTE
If winch motor preset limits are
exceeded when lifting a heavy
load, the winch motor will remain
in the LOW speed mode, even
though the winch speed selector
switch is in the HIGH speed posi-
tion. When the load is removed,
the winch motor will automatically
shift to the HIGH speed mode.
17. WINCH HI SPEED INDICATOR. The
amber indicator will glow when the winch
is operating in high speed.
18. MASTER SWITCH. The master
switch energizes the electrical circuits on
this machine. This is an ON-OFF switch
which must be in the ON position before
the engine can be started.
19. MASTER SWITCH INDICATOR. The
amber indicator will glow whenever the
master switch is in the ON position.
20. ENGINE START BUTTON. With the
master switch in the ON position, de-
press and hold this black button to start
the engine. As soon as the engine 28. TWO-BLOCK WARNING DEVICE. The
sta rts, release the sta rt button. two-block warning device is a device de-
signed to wa rn the operator that the
hook block is about to come into contact
CAUTION with the boom point. This contact of
the hook block with the boom point is
If the engine does not start within common Iy referred to a "Two- Blocking" .
30 seconds, release the start but-
ton and allow the starter motor to The warning device also contains a boom
cool before continuing the attempt angle indicator.
to start the engine.
This warning device contains the follow-
ing controls and indicators (see
21. STARTING AID BUTTON. This white Figu re 2-8):
button is used to control the starting
aid. Refer to "Starting the Engine" on
page 2-7 for information on how this but-
ton is used.
c
22. WARN ING HORN. A warning horn
will sound if engine coolant temperature
becomes excessive or if oil pressure
drops below normal.
23. WI NDSH I ELD WI PER SWITCH. Press
the top of th is switch to operate the
windshield wiper at high speed. Place
the switch in the center position to oper-
ate the wiper at low speed. Press the
bottom of the switch to tu rn the wiper J o E F A
OFF.
24. CENTER DEFROSTER SWITCH. De-
press the top of this switch to operate Figure 2-8. AntiTwo-Block Console
the center defroster fan. Depress the
bottom of this switch to turn the defrost- A. ON-OFF SWITCH. The on-off switch
er OFF. is a th ree pos ition rota ry switch
which energizes and de-energizes the
25. S IDE DEFROSTER SWITCH. Depress angle indicator and audible alarm.
the top of this switch to operate the side
defroster fan. Depress the bottom of If the switch is turned to the far left
this switch to turn the defroster OFF. "ON" position, the angle indicator is
energized, however, the audible alarm
NOTE is disconnected. In this position, the
audible alarm will not sound when a
The following light switches will two-block condition occurs or the
only function as described when preset upper and lower boom angles
the Vehicle Light Switch, in the are exceeded.
ca rrier, is not in the blackout po-
sition.
WARNING
26. DRIVING LIGHT SWITCH. Depress The audible alarm must not be si-
the top of this switch to illuminate the lenced during crane operation, as
headlights and taillights. Place the the operator may not be alerted by
switch in the center position to illuminate the red warning light, especially
the parking lights. Depress the bottom in bright sunlight.
of the switch to turn off all the lights.
27. DOME LIGHT SWITCH. Depress the If the switch is placed in the center
top of this switch to illuminate the dome "OFF" position, the angle indicator
light. Depress the bottom of the switch
to turn off the dome light.

Controls and Operation 2-13

 and audible alarm are de-energized
and will not function.
If the switch is turned to the far
right "ON" position, the angle indica-
tor and audible alarm are energized.
I n this position, the audible alarm will
sound when a two-block condition oc-
curs or the preset upper and lower
boom angles are exceeded. For nor-
mal operation the switch should be in
this position.
B. AUDIBLE ALARM. The audible alarm
will sound when an approaching
two-blocking condition occu rs and/or
the boom angle exceeds the preset
upper or lower angle limits. The au-
dible alarm will only sound when the
ON-OFF switch is to the right, or au-
dible alarm on position.
C. VISUAL ALARM INDICATOR. This
red warning light will light when an
approaching two-blocking condition
occurs and/or the boom angle exceeds
the preset upper or lower boom angle
limit.
D. MODE SELECTOR SWITCH. The mode
selector switch determines the infor-
mation which will be displayed on the
operator's console. Each mode is
identified by a number (1 to 3) dis-
played under the window of the
control knob. The function of each
position is as follows (position 5 is not
used) :
NOTE
Control lever lockouts should func-
tion in a two-block condition with
the mode selector switch in any
position. Also, control lever lock-
out are not activated by boom an-
gie preset limits.
Pos ition 1. With the mode selector
switch in this position, the digital
display will indicate the main boom
angle in degrees with reference to
the horizontal.
Position 2. With the mode selector
switch in this position, the digital
display will indicate the preset up-
per boom angle limit which has
been set using the Upper Limit
Control.
2-14
Position 3. With the mode selector
switch in this position, the digital
display will indicate the preset
lower boom angle limit which has
been set using the Lower Limit
Control.
E. UPPER LIMIT CONTROL. This con-
trol is used to preset an upper boom
limit, so that the angle indicator will
warn the operator when this angle is
reached or exceeded.
Turn the knob clockwise to increase
the boom angle setting;
counter-clockwise to reduce the set-
ting. The settings are displayed on
the digital display of the console when
the Mode Selector Switch is in Position
2.
F. LOWER LIMIT CONTROL. This con-
trol is used to preset a lower boom
limit, so that the angle indicator will
warn the operator when this angle is
reached or exceeded.
Turn the knob clockwise to increase
the boom angle setting;
counter-clockwise to reduce the set-
ting. The settings are displayed on
the digital display of the console when
the Mode Selector Switch is in Position
3.
G. DIGITAL DISPLAY. The digital dis-
play provides the operator with in-
formation regarding the angle of the
main boom. The information which is
displayed is dependent upon the posi-
tion of the Mode Selector Switch.
When the Mode Selector Switch is in
position 1, the digital display will in-
dicate the angle of the main boom.
When the Mode Selector Switch is in
position 2, the digital display will in-
dicate the preset upper boom IJmit.
When the Mode Selector Switch is in
position 3, the digital display will in-
dicate the preset lower boom limit.
H. CRANE SYMBOL. The crane symbol
symbolize a telescopic crane and
serves as a remainder of the relation-
ship between the Mode Selector switch
and the resulting digital displays.
The numbers in the symbol refer to
the Mode Selector switch numbers and
the arrows refer to the digital display
indications.
 The crane symbol also indicates that
the horizontal position of the main
boom is at zero degrees and the verti-
cal position of the main boom is at 90
degrees.
CAUTION
The test pushbutton must not be
held depressed for extended peri-
ods of time. Doing so will damage
the digital LCD display.
I. TEST PUSHBUTTON. The blue
"TEST" pushbutton allows the opera-
tor to test the functions of the angle
indicator.
WARNING
The by-pass switch by-passes the
lever lockout system, and must be
used with a great deal of dis-
cretion. Unwarranted use of the
by-pass switch to override the
control lever lockout system can
result in harm to the crane and
danger to property and persons.
J. BY-PASS SWITCH. The by-pass
switch is used to by-pass the Control
Lever Lockout System when in a
two-blocking condition.
29. REAR FLOOD LIGHT SWITCH. Move
this switch up to turn the rear flood
lights on. Move this switch down to turn
the rear flood lights off.
30. REAR FLOOD LIGHT FUSE.
31. FRONT FLOOD LIGHT SWITCH. Move
th is switch up to tu rn the front flood
light on. Move this switch down to turn
the fro n t flood I i g h t off.
32. FRONT FLOOD LIGHT FUSE.
33. BOOM FLOOD LIGHT SWITCH. Move
this switch up to turn the boom flood
light on. Move this switch down to turn
the boom flood light off.
34. BOOM FLOOD LIGHT FUSE.
35. SUSPENSION SWITCH. This switch
controls the lockout/suspension cylinders
on the axles. The top of the switch must
be depressed to lock the axles before op-
erating the outriggers. The switch
must be centered whenever the ca rrier is
moved. The bottom switch position is
for charging the suspension system (Re-
fer TM 09109A-34/2 for suspension
charging procedure).
WARNING
Do not move the suspension switch
from the locked (top) position
when the crane is on outriggers.
Doing so will cause the axles to
drop suddenly, causing possible
damage or injury.
The axle lockout system remains locked
whenever the boom is not in the boom
rest.
36. DIFFERENTIAL LOCKS, FRONT AX-
LES.
CAUTION
Do not place the differentials in
the LOCK position when the carri-
er is turning. Serious damage to
the axles may result if th is precau-
tion is not followed.
This switch locks and unlocks the inter-
axle differential and the axle differen-
tials. Press and hold the bottom of the
switch to LOCK the differentials when
approaching or anticipating icy or slip-
pery conditions to provide maximum axle
traction. The differentials can be shift-
ed to the LOCK position at slow carrier
speeds, except if the wheels have al-
ready lost traction and are spinning.
CAUTION
Do not place the differentials in
the LOCK position if wheels are in
a spin out condition. The carrier
drive train must be brought to a
complete stop or serious damage to
the axles may result if this precau-
tion is not followed.
Release the switch to retu rn to the UN-
LOCK position after passing adverse
conditions. This permits the differen-
tials to compensate for differences in ti re
Controls and Operation 2-15
size and provides maximum speed and
performance.
NOTE
Let up on the accelerator to pro-
vide an interruption in torque to
the drive train when locking or un-
locking the differentials.
37. 01 FFERENTIAL LOCKS, REAR AX-
LES.
CAUTION
Do not place the differentials in
the LOCK position when the carri-
er is turning. Serious damage to
the axles may result if this precau-
tion is not followed.
This switch locks and unlocks the inter-
axle differential and the axle differen-
tials. Press the top of the switch for
UNLOCK, normal driving conditions.
Press the bottom of the switch to LOCK
the differentials when approaching or an-
ticipating icy or slippery conditions to
provide maximum axle traction. The dif-
ferentials can be shifted to the LOCK
position at slow carrier speeds, except if
the wheels have al ready lost traction and
are s pin n i n g .
CAUTION
Do not place the differentials in
the LOCK position if wheels are in
a spin out condition. The carrier
drive train must be brought to a
complete stop or serious damage to
the axles may result if this precau-
tion is not followed.
Place the switch in the UNLOCK position
after passing adverse conditions. This
permits the differentials to compensate
for differences in tire size and provides
maximum speed and performance.
NOTE
Let up on the accelerator to pro-
vide an interruption in torque to
the drive train when locking or un-
locking the differentials.
2-16
38. REAR AXLE 01 FFERENTIAL LOCK
INDICATOR. This light will glow when
the rear axle differentials are locked.
39. FRONT AXLE DISCONNECT SWITCH.
This switch controls the front axle dis-
connect. Press the top of the switch to
disconnect the front axle drive. Press
the bottom of the switch to engage the
front axle drive.
40. Not applicable on this machine.
41. OUTRIGGER CONTROL SWITCHES.
These switches control the operation of
the outriggers. Refer to the topic, "Out-
rigger Operation" on page 2-18, for more
instructions on operating the outriggers.
42. OUTRIGGER MASTER SWITCH. This
switch supplies power to the outrigger
control switches allowing the outriggers
to be operated. Refer to the topic,
"Outrigger Operation" on page 2-18, for
more instructions on operating the out-
riggers.
43. SWI NG LEVER. With the swing brake
and the house lock disengaged, moving
this lever forward will swing the upper
to the right (toward the boom). Moving
this lever to the rear will swing the up-
per to the left (away from the boom).
Swing speed depends on engine speed
and how far the control lever is moved in
either direction.
44. TELESCOPE LEVER.
WARNING
Payout line from the winch when
extending the boom sections so the
hook is not jammed (two-blocked)
against the boom point. A
two-blocked condition may overload
the rope, causing failure of the
rope and/or failure of other_ ma-
chine components. A two-blocked
condition could cause the load to
drop and thereby injure or kill
personnel.
This lever is used to extend and retract
the boom sections. Push this lever for-
ward to extend all power assisted boom
sections. Pull this lever to the rear to
retract all power assisted boom sections.
The speed at which the sections move is
dependent on how far the lever is moved
in either direction and the engine speed.
45. HORN BUTTON. Depress this but-
ton in the center of the steering wheel to
sound the horn.
46. MAIN WINCH LEVER.
WARNING
Do not hoist a load so high that
the hook block is jammed
(two-blocked) against the boom
point. A two-blocked condition
may overload the rope and cause
rope and/or other machine compo-
nents to fail. This condition could
cause the load to drop, injuring or
killing personnel.
This lever is used to control the raising
and lowering of loads on the main winch
line. Pull this lever back to lift a load on
the main winch line. Push this lever for-
ward to lower a load on the main winch
line. Winch speed depends on engine
speed and how far the control lever is
moved in either direction.
47. MAIN WINCH DRUM ROTATION IN-
DICATOR. The button at the top of this
lever will tap the operator's finger when
the main winch drum is rotating. The
faster the drum is turning, the faster
the button will tap.
48. BOOM HOIST LEVER.
WARNING
Payout line from the winch when
loweri ng the boom so the hook is
not jammed (two-blocked) against
the boom point. A two-blocked
condition may overload the rope
and cause failure of the rope as
well as failure of other machine
components. A two-blocked condi-
tion could cause the load to drop
and thereby injure or kill person-
nel.
Push this lever forward to lower the
boom. Pull this lever to the rear to raise
the boom. The speed at which the boom
moves depends on the engine speed and
how far the lever is moved in either di-
rection.
49. LEVEL. Use this device to ensure
that the machine is level after the out-
riggers are pos itioned.
50. TRANSMISSION SHIFT LEVER. This
lever controls the operation of the carri-
er transmission. Operation of the trans-
mission is described under the topic
"Driving the Carrier" on page 2-9.
51. SWING LOCK LEVER. This lever con-
trols the operation of the spring applied,
hydraulically released, swing bra ke.
Move the lever toward the front of the
machine to release the brake (OFF).
Move the lever toward the rear of the
machine to set the brake (ON).
NOTE
Use this brake only when the up-
per is to be parked for a pro-
longed period. Do not use this
brake to stop swing motion.
52. AIR CONDITIONER AND HEATER
CONTROLS. The following controls are
used to control the operation of the cab
air conditioner and heater (see
Figure 2-4 on page 2-7):
A. COOL. This switch is used to control
the temperatu re within the operators
cab. Tu rn the switch to the right to
increase the cooling of the cab.
B. FAN. This th ree position· switch is
used to control the speed of the fan.
C. HEAT. This switch is used to control
the temperature within the operators
cab. Tu rn the switch to the right to
increase the heating of the cab.
D. MAIN. The main switch is used to se-
lect either the heater or air condition-
er, and when neither heat nor ai r
conditioning is desired, to _turn off
both systems.
53. HOUSE LOCK LEVER.
CAUTION
Never engage the house lock while
the upper is rotating. Serious
structural damage will occur if this
precaution is not observed.
The upper can be mechanically locked to
the carrier, using this control, with the
Controls and Operation 2-17
boom over the front or rear of the ma-
chine.
Move the handle up and forward to dis-
engage the houselock pin. Move the
handle back and down to engage the
houselock pin.
54. HAND THROTTLE. Use this handle
to set and maintain the engine speed re-
qui red for crane operation. For maxi-
mum efficiency and safety of operation,
engine speed must be set high enough,
by means of this control, to handle the
typical load. The foot throttle should be
used for momentary increases in engine
speed above the hand throttle setting.
Press the button and pull up on this con-
trol to increase engine speed. Press the
button and allow the handle to lower to
reduce engine speed. Fine throttle ad-
justments can be made by rotating the
knob counterclockwise to increase, or
clockwise to decrease engine speed.
NOTE
The Lower/Upper Selector Switch
must be in the UPPER position for
the engine speed to be controlled
from the upper cab.
55. FOOT THROTTLE. Depress this ped-
al to increase the engine speed. Let up
on the pedal to decrease engine speed.
Engine speed will return to idle when the
pedal is released, unless the engine
speed has been preset to a higher speed
by means of the hand throttle.
56. SERVICE BRAKE PEDAL. Depress
this pedal to apply the carrier brakes.
Release the pedal to release the brakes.
57. BOOM HOIST PEDAL.
WARNING
Payout line from the winch when
lowering the boom so the hook is
not jammed (two-blocked) against
the boom point. A two-blocked
condition may overload the rope,
causing failure of the rope and/or
failure of other machine compo-
nents. A two-blocked condition
could cause the load to drop and
thereby injure or kill personnel.
2-18
This pedal is used to raise and lower the
boom. Depress the toe of the pedal to
lower the boom. Depress the heel of the
pedal to raise the boom.
58. SWING BRAKE PEDAL. This pedal is
used to activate the hydraulically applied
swing brake. This brake is provided to
stop and hold the upper while working
the crane. Movement of the upper should
be slowed by plugging the swing lever
before the swing brake is depressed.
Depress the pedal to apply the swing
brake. Release the pedal to release the
swing brake.
OUTRIGGER OPERATION
GENERAL. The outriggers are operated
using the outrigger control switches lo-
cated on the side control console of the
upper cab. A level is provided to aid
the operator when leveling the machine.
EXTENDI NG THE OUTRIGGERS. To ex-
tend the outriggers, proceed as follows:
WARNING
Swing the boom over the front of
the machine and engage the house-
lock. A tipping condition may oc-
cur if the outriggers are
extended, or retracted, with the
boom over the side of the machine,
resulting in injury to personnel.
1. Start the engine as described under
"Starting the Engine" on page 2-7.
2. Depress the top of the park brake
switch to set the parking brake.
3. Depress the top of the suspension
switch to lock the suspension.
4. Depress the right side of the outrig-
ger master switch to activate the outrig-
ger control switches. The red indicator
light beside the master switch will be lit,
indicating that power is supplied to the
control switches.
5. Extend one horizontal outrigger beam
by depressing the end of the horizontal
outrigger switch with the arrow pointing
away from the symbol (see Figure 2-9 on
page 2-19). Hold the switch in this posi-
tion until the outrigger beam is fully
 I I I

BBB
000
~O ~SWITCH
MASTER

Figure 2-10. Outrigger Float

VERTICAL
SWITCHES WARNING
Do not set the outriggers near
holes, or on rocky, or extremely
soft ground. This may cause the
machine to tip, resulting in injury
to personnel.

7. Extend a vertical lift cylinder by de-

pressing the bottom of the vertical out-
rigger switch. Hold the switch in this
position until the float just touches the
ground.
8. Repeat this procedu re for each of the
remaining lift cylinders.
9. Continue to extend each lift cylinder,
a little at a time, until the wheels are off
the ground.
10. Make the necessary leveling adjust-
ments by extending or retracting each
lift cylinder with the UP and DOWN
Figure 2-9. Outrigger Control Panel switches. Check the level of the. machine
by using the level on the right side of
extended. Repeat this procedu re for the steeri ng wheel.
each outrigger beam.
11. Depress the left side of the outrigger
6. Attach a float to each outrigger beam master switch to de-activate the outrig-
taking care to install all lock pins (see ger control switches.
Fig u re 2 - 10) .
RETRACTING THE OUTRIGGERS. To
retract the outriggers, proceed as fol-
lows:

Controls and Operation 2-19

 WARNING
Swi ng the boom over the front of
the machine and engage the house-
lock. A tipping condition may oc-
cur if the outriggers are
extended, or retracted, with the
boom over the side of the machine,
resulting in injury to personnel.
1. Start the engine as described under
"Starting the Engine" on page 2-7.
2. Depress the top of the park brake
switch to set the pa rki ng bra ke.
3. Depress the right side of the outrig-
ger master switch to activate the outrig-
ger control switches. The red indicator
light beside the master switch will be lit,
indicating that power is supplied to the
control switches.
4. Retract each vertical lift cylinder, a
little at a time until all the wheels are on
the ground, by depressing the top of the
switch. (see Figure 2-9 on page 2-19).
Continue this procedure until each cylin-
der is fully retracted.
5. Remove the outrigger float from each
vertical lift cylinder, and place the floats
in thei r storage compartments.
6. Retract each outrigger beam by de-
pressing the appropriate end of the hori-
zontal outrigger switch. Hold the switch
depressed until all the outrigger beams
are fu lIy retracted.
7. Depress the left side of the outrigger
master switch to de-activate the outrig-
ger control switches.
8. Center the suspension switch to un-
lock the axle suspension system.
CRANE OPERATION
Lift Crane
The crane operating cycle consists of
five steps: setting boom angle (boom
hoist), setting boom length (boom tele-
scope). lifting the load (hoisting), lower-
ing the load and swinging the load.
These operations are described and illus-
trated in Figure 2-11 on page 2-22.
2-20
Observe the following precautions when
operating the lift crane:
1. Always consult the rating plate in the
cab for the maximum load which may be
lifted with the various combinations of
boom length, boom angle, and other var-
iables which may be involved with lifting
a load.
2. Perform all lift crane operations with
the engine throttle set to accommodate
the handling of the typical load.
3. When the load is being swung, it
should be kept as near the machine and
as close to the ground as possible.
4. Always payout line from the main and
auxiliary winches when the boom is being
extended and/or lowered to prevent
two-blocking.
5. Always set the outriggers before lift-
ing a load. If the machine is being oper-
ated on the tires, the rating plate must
be consulted so that the load ratings can
be decreased accordingly.
6. The axles of this crane are mounted
so they are free to oscillate up and down
with the contour of the ground. A hy-
draulic system of locking the axles to the
carrier frame has been incorporated.
When the boom is lifted out of the boom
rest at the front of the carrier, the oil in
the axle lockout cylinders will be trapped
automatically and the axles will lock in
thei r last position. Upon retu rning the
boom to the boom rest, the axles will be
free to oscillate again.
NOTE
The lockout featu re, however, will
not prevent the- machine from tip-
ping if rated loads are exceeded.
Pick and Carry Operation
The crane has been designed to perform
pick and carry operations. A pick and
carry operation is were the crane will lift
a load, wh i Ie the ca rrier is on the ti res,
and then the carrier is driven to the new
location.
While the crane is designed to perform
pick and carry operations, the crew must
be extremely cautious when perform this
operation and must be guided by the re-
qu i rements of the rating plate installed
on the crane.
In addition to the rating plate require-
ments, the following must be kept in
mind when performing pick and carry
operations:
1. Because the boom is out of the boom
rest, axle suspension system will be
locked in its last position and will not os-
cillate to follow the terrain contour.
2. If one of the tires is lifted off the
ground, propel power could be lost due
to the action of the differentials. If this
should happen, differentials can be
LOCKED to return all tires to the
ground. As soon as all tires are on the
ground, the differentials must be re-
turned to the UNLOCK position.
STOPPING THE ENGINE
To stop the engine, proceed as follows:
1. Swing the boom over the front of the
carrier and lower it to horizontal.
2. Engage the houselock and place the
gea r selector lever in the neutral (N)
position. Make certain all other controls
are in the neutral position and set the
parking brake.
3. If possible, allow the engine to idle
for 3 to 5 minutes before it is stopped.
The engine will then cool evenly and ov-
erheating, due to residual heat, will be
prevented.
4. After the engine has cooled, place the
ignition switch in the OFF position.
HAND SIGNALS
It is frequently necessary during crane
operation for the operator to depend on a
Signalman for instructions. When moving
the machine into a position where there
is very limited clearance, or when handl-
Ing loads that are out of sight of the
crane operator, the use of a signalman is
essential. The hand signals illustrated
in Figure 2-12 on page 2-23 are those
generally accepted throughout the indus-
try. To ensure that the crane is
operated in a safe manner, both the op-
erator and the signalman should be
thoroughly familiar with the standard
crane signals.
OPERATION UNDER UNUSUAL CONDI-
TIONS
GENERAL. Sometimes crane operation is
necessary in unusual environmental con-
ditions. The following paragraphs de-
scribe special precautions that should be
taken when extreme cold, heat, dust,
humidity, or salt air or high altitudes
are encountered.
OPERATION I N EXTREME COLD. Opera-
tion in extreme cold presents special
problems due to the increased brittleness
of metal and rubber parts, the danger of
freezing and the increased difficulty of
keeping parts adequately lubricated.
WARNING
Personnel should use care to keep
from spilling fuel, coolant, or oth-
er liquids upon themselves during
cold weather. The body should
not come into contact with metal
during cold weather, because seri-
ous and painful injury may result.
1. Refer to Section III, for Iubricant re-
commendations for cold weather
operation. Change the lubricant if neces-
sary.
2. Drain and flush the cooling system, to
insure proper circulation of coolant
th roughout the radiator core. Clean the
radiator cooling fins, especially the air
passages through the core.
Check the condition of the radiator
hoses, clamps, thermostat and radiator
core.
When freeze protection is required, an
ethylene glycol base permanent anti-
freeze should be used. An inhibitor sys-
tem is included in this type of antifreeze
and no additional inhibitors are required
on initial fill, if a minimum antifreeze
concentration of 30°6 by volume is used.
Solutions of less than 3096 concentration
do not provide sufficient corrosion pro-
tection and additional inhibitors may
have to be added. Concentrations over
67°6 adversely affect freeze protection as
shown in Figure 2-13 on page 2-24.
Controls and Operation 2-21
SETTING BOOM ANGLE. Position the boom at the proper angle LIFTING THE LOAD. Push the main winch control lever forward
for the load and working conditions. Refer to the rating plate fOI to lower the hook block. Attach the load to the hook block. Then
the proper angle. Pull the boom hoist level back, or depress thE pull the main winch lever back to raise the load. Control the speed
heel of the boom hoist pedal, to raise the boom. Push the boorr' at which the load is raised by depressing and releasing the winch
hoist lever forward, or depress the toe of the boom hoist pedal, te, speed button. When thewinch speed indicator illuminates amber,
lower the boom. Be sure to payout line from the main winch the winch will operate at high speed. When the light goes out. the
when lowering the boom, to prevent the hook block from comin~ winch will operate at low speed.
in contact with the boom or jib point.

Do not hoist the load so high that it comes into contact with the
boom. The overload condition could cause the rope or other boom
components to break, allowing the load to drop and kill or injure
personnel.

SETTING BOOI\f; LENGTH. Push or SWINGING. If necessary, DISEN-

pull the telescope lever to position the GAGE the house lock. Move the swing
boom at the requi,ed length. Be sure brake lever to the RELEASED position
to payout line from the main winch, (front detent). Push the swing lever
when extending the boom, to prevent forward to swing the upper to the
the hook from coming into contact LOWERING THE LOAD. Push the main right. Pull the swing lever to the rear
with the boom. winch lever forward to power down the load. to swing the upper to the left. Swing
motion should begin with a smooth
Control the speed at which the load lowers acceleration and continue to an opti-
by depressing and releasing the winch mum point at which the upper is
i speed button. When the winch speed indi- allowed to coast to the work area. As
! cator illuminates amber, the winch will the load reaches the work area, swing
operate at high speed. When the indicator

I
motion should be slowed to a stop by
light goes out. the winch will operate at low plugging the swing lever in the oppo-
speed. site direction. Depress the swing
,~ brake pedal after the upper stops. To

p free the operator's foot, move the

swing brake leverto the rear detentto
apply the spring applied swing brake.

Figure 2-11. Lift Crane Operation

2-22
 ALWAYS STAND IN CLEAR VIEW OF CRANE OPERATOR. BE SURE TO STAY ASAFE DISTANCE FROM HOOK BLOCK OR BOOM .
EMERGENCY STOP. Arm extended.
palm down. move hand rapidly right
and left.
RAISE BOOM. Arm extended. fing-
ers closed. thumb pointing upward.
SWING. Arm extended point with
finger In direction of swing of boom.
HOIST. With forearm vertical. fore-
finger pointing uP. move hand in
small hOrizontal circle.
RETRACT BOOM. (Telescoping
Boom) One Hand Signal. One fist in
front of chest. thumb pOinting
outward and heel of fist tapping
chest.
Figure 2-12. Hand Signals For Crane Operation
STOP. Arm extended. palm down,
hold position ngidly.
LOWER BOOM. Arm extended. fing-
ers closed, thumb pointing down-
ward.
TRAVEl. Arm extended forward,
hand open and slightly raised, make
pushing motion in direction of
travel.
LOWER. With arm extended down-
ward, forefinger painting down,
move hand in small horizontal
circles.
EXTEND BOOM. (Telescoping Boom)
One Hand Signal. One fist in front of
chest with thumb tapping chest.
DOG EVERYTHING. Clasp hands in
front of body.
-1 ..
';h
USE MAIN HOIST. Tap fist on head;
then use regular signals.
TRAVEl. lOne Track) Lock the tratk
on side indicated by raised fist.
Travel opposite trcick in direction in-
dicated by circular motion of other
fist, rotated vertically in front of
body. (For crawler cranes only)
RAISE THE BOOM AND LOWER THE
LOAD. With arm extended, thumb
pointing up, flex fingers in and out
as long as load movement is desired.
=i:,;'
... 1.'
EXTEND BOOM. (Telescoping
Booms) Both fists in front of body
with thumbs pointing outward.
Controls and Operation
. ~
MOVE SLOWLY. Use one hand to
gIVe any motion signal and place
other hand motionless in front of
hand giving the motion signal. (Hoist
Slowly shown as example.)
USE WHIP LINE. (Auxiliary Hoist)
Tap elbow with one hand; then use
regular signals.
~ . 'i,.I,,
-- -
;;0,:
TRAVEl. IBoth Tracks) Use both
\
fists, in front of body, making a cir-
'
cular motion, about each other, in-
dicating direction of travel; forward
or backward, IFor crawler cranes
only)
LOWER THE BOOM AND RAISE THE
LOAD. With arm extended, thumb
pointing down, flex fingers in and
out as long as load movement is de-
sired,
RETRACT BOOM. (Telescoping
Booms) Both fists In front of body
with thumbs pointing toward each
other.
2-23
 Keep the battery terminal connections
clean and free from snow or ice which
120 49 could short circuit the terminals. Clean
the cable con nectors and battery posts
100 39 thoroughly, using a baking soda and wa-
80 27
ter solution to remove corrosion.

T 60 16 T I n extremely cold weather, it is advisable

E E to remove the battery and store it ina

,
M 40 4 M heated area if the machine is to be idle
RECOMMENDED
P ~ CONCENTRATION
p overnight or for any extended period of
E 20 ........ RANGE 30·67%
·7 E time .
R 0 • · 18 R
~
A A 4. Keep the fuel tank as full as possible
T .20 ~ ·29 T at all times to minimize condensation of
U
R ·40
E
"-~ if'
~
'" -
U
40 R
E
water. If water is detected in the fuel
supply, drain the tank and refill it with
-60 ·51 clean fuel.
(OF)
-80 ~. " ·62
(DC)
5. Start the engine following the engine
·90

.100
o 10 20 30 40 50
'-
60 70
ANTIFREEZE CONCENTRATION (% BY VOLUME;
Figure 2-13. Antifreeze
Concentration and Temperature
I nhibitor depletion will occur in ethylene
glycol base antifreeze th rough normal
service. The inhibitors should be replen-
ished after approx imately 500 hou rs or
20,000 mi les with a non -ch romate type
inhibitor.
NOTE
The combination of a ch romate base
inhibitor with an ethylene glycol
antifreeze can produce chromium
hydroxide, a substance harmful to
the cooling system.
3. Keep the battery fully charged at all
times. The electrolyte in a fully charged
battery will resist freezing at lower tem-
peratures than a battery that is not fully
charged.
NOTE
If it is necessary to add water to
the battery, do so on Iy immediately
before or du ring operation, or
with an external charger connected
to the battery. Charging the bat-
tery, by any means, mixes the wa-
ter and electrolyte, and thereby
prevents the water from freezing.
80 90
·68
·73
100
manufactu rer' s recommended cold weath-
er starting procedure. Allow the engine
to idle until it has reached operating
temperatu re.
NOTE
To aid warmup, and to maintain
proper engine temperature while
the machine is operating, the radi-
ator may be partially covered.
CAUTION
Cold hydraulic fluid makes relief
valves sluggish in operation. It
can add 500 to 1000 psi to the max-
imum pressure setting of the relief
valves. Therefore, extreme care
must be used when operating a
cold hydraulic system to prevent a
hose or tube from rupturing, or
causing other damage.
6. Operate all hydraulic functions
slowly, to warm the hydraulic oit in the
system and the hydraulic components.
Bring the oil in the reservoir to the min-
imum operating temperature indicated in
Table 2-1 on page 2-25 before using any
function at full engine rpm.
NOTE
If the outdoor temperature is below
the specified temperature range
for the grade of oil in the hydrau-
lic systems, the oil must be
drained and replaced with an oil

2-24
 specified for the existing temper-
ature range. See Section 3 of this
manual for the proper hydraulic oil
specifications for various temper-
atu re ranges.
7. Before shutting down the machine,
raise the outriggers to the stored posi-
tion, and drive the machine onto wooden
plan ks or mats to prevent the mach i ne
from being frozen to the ground.
OPERATION I N EXTREME HEAT. Opera-
tion in extreme heat presents special
problems due to the difficulty of keeping
the engine and hydraulic oil from over-
heating.
P&H SPEC NUMBER 484L
AMBIENT RANGE -50 to +60 0 F -20 to +90 0 F
CRITICAL AMBIENT -50 to -10° F -20 to +30 0 F
TEMPERATURE
MINIMUM OPERAT- 40°F
ING TEMPERATURE
Table 2-1. Hydraulic System 'Operating Temperatures
4. Inspect the cooling system for leaks.
Replace worn or damaged hoses. Tight-
en the hose clamps.
5. Keep the water pump fan belt adjusted
properly.
6. If the engine becomes overheated from
lack of coolant, let the engine run at a
fast idle and add coolant slowly.
7. If the engine overheats after refilling
the cooling system, shut down the engine
and allow it to cool. Drain the cooling
system by opening the drain cocks on
the radiator and the engine block, and
flush out the system. Refill the cooling
system with clean coolant. Do not use
salt or mineral water solutions.
8. Keep as much air as possible circulat-
ing around the battery. Check the elec-
trolyte level frequently. Add distilled
water as necessary to keep the electro-
lyte level 3/8 inch above the plates.
9. Keep the air intake and exhaust
open i ngs clea r. Keep the engine clean,
and allow air to circulate freely around
the engine.
1. Refer to Section 3, for lubricant rec-
ommendations for hot weather operation.
Change the lubricant if necessary.
2. Make certain that the engine crank-
case is filled to the proper level with oil.
A low level of crankcase oil will prevent
proper dissipation of heat from the en-
gine.
3. Drain and flush the cooling system, to
ensure proper circulation of coolant
throughout the radiator core. Clean the
radiator cooling fins, particularly the air
passages through the core. Remove any
insects, leaves, dirt, or other foreign
material that could restrict ai r flow.
484S 484T 484H
+30 to +120oF +70 to +150 0 F
+30 to +50 0 F +70 to +80 0 F
70 0 F 85°F 110 0 F
10. Avoid racing the engine. Avoid oper-
ation at full throttle when partial throttle
will handle the load.
11. Avoid lugging the engine. Keep the
engine speed high enough to maintain fan
speed.
12. Avoid idling the engine
unnecessarily. Shut the engine down
during a lull in the operation.
OPERATION IN DUSTY AND SANDY
AREAS. Operation in dusty or sandy
areas presents special problems due to
the abrasive action of dust which short-
ens the life of parts. Make every effort
to keep dust and sand out of the moving
parts of the crane machinery and engine.
1. All lubricants and lubricating equip-
ment must be kept clean. Service
breathers and ai r cleaners frequently to
remove accumulated sand and dust. Lu-
bricate more frequently to keep a supply
of clean lubricant in the moving parts.
Clean all lubrication fittings thoroughly
before attaching the grease gun.
Controls and Operation 2-25
2. Keep the fuel tank filler cap tight to CAUTION
prevent sand or dust from entering the
fuel tan k. Service fuel filters frequently Never attempt deep water fording
to keep them free of sand and dust. unless water depth is known to be
60 inches or less and the water
3. Keep the hydraulic oil reservoir filler bottom is known to be hard.
caps tight to prevent sand and dust from
entering the hydraulic systems. Service
the hydraulic oil filters frequently to PREPARATION FOR FORDING. Perform
keep the system free from sand and the following procedures before this ma-
dust. chine enters the water:
4. Use wood blocking or mats under the 1. Secure all loose objects on the
outrigger floats when operating in sand. machine.
See that the carrier does not shift dur-
ing operation. 2. Make sure the battery caps are pres-
ent and are tight.
OPERATION IN HIGH HUMIDITY OR
SALT WATER AREAS. Moisture and salt 3. Make sure the hydraulic tank cap is
will cause deterioration of paint, cables, secu rely tightened.
wiring, and all exposed metallic parts.
Keep parts dry and well lubricated in 4. Make sure all vent lines are in place
high humidity or salt water conditions. (fuel tank, brake and throttle pedals,
and axles).
1. Completely remove rust and corrosion
as soon as it appea rs on any pa rt of the 5. Transfer operation of the machine to
machine. Wash off salt water and dry all the upper cab controls.
pa rts thorough Iy. Paint the exposed su r-
faces immediately. Place a film of lubri- FORDING OPERATION
cant or grease on all polished or
machined metal surfaces and other sur- 1. Operate the machine from the upper
faces which cannot be painted. cab.
2. Keep parts thoroughly lubricated to 2. Start the machine and make sure the
repel water from polished metal surfaces engine is operating properly.
and to prevent the entry of water into
bearings. Keep lifting cables lubricated. 3. Engage all wheel drive and place the
transmission shift level in "1 F" (first
OPERATION AT HIGH ALTITUDES. Op- forward) gear position.
eration at high altitudes presents special
problems due to lower atmospheric pres-
su re and wide temperatu re ranges. At al-
titudes above 5000 feet it may be
necessary to change the engine fuel in-
jectors. Make certain that the air cleaner
is clean and free from obstructions.
Check the engine frequently for over-
heating.

DEEP WATER FORDING

GENERAL. This machine is designed to
cross through water up to 60 inches
deep.

DEAD END

Figure 2-14. Securing Rope to Drum

2-26
 WARNING

Do not attempt to cross water

deeper than 60 inches. Limit the
carrier speed, while fording, to 3
to 4 miles per hour.
VIEW A
4. Enter the water slowly.
5. Maintain a even carrier speed while
fording and exit the water in an area
with a gentle slope.
AFTER FORDING OPERATION
1. If fordi ng operation was th rough salt
water, wash off or wipe off all salt de-
posits as soon as possible.
VIEWB
'\
LIVE END
NOTE

Vehicles completing a deep water

fording operation must be serviced
by Organizational Maintenance.
ROPE CLAMPS

2. Disconnect battery heater connectors
located in the battery box and, using
compressed air, blowout water in the
connectors.
INSTALLING ROPE ON DRUMS
The manner in which a new or replace-
ment wire rope is installed on the drums
will, to a large measure, determine the
service life of that rope. Improperly
wound ropes will cause undue crushing
of the rope, kin ks, excessive abrasion
and cutting of the individual wires. Bad
spooling also causes uneven application
of force and motion. This results in fast
fatiguing of the rope from the hook
block, or spreader, to the drum.
The following five precautionary steps
should be taken, particularly with a re-
placement wire rope, before starting the
actual installation of the rope.
• A check should be made of the drum to
determine the condition, size, and shape
of the drum grooves.
• Drum flanges should be checked to de-
termine the existence or severity of un-
dercutting at the base of the flange.
• Di rt, grit, or any other type of debris
should be cleaned off the drum.
VIEWC
Figure 2-15. Installing A Rope
Sock.et
• Drum bearings should be checked.
• Cracks or breaks in the drum should
be noted.
Whenever any of these conditions are ob-
served, the winch should be removed
from service and properly cleaned, re-
paired or replaced. This recommendation
is made not only to improve or maintain
good rope life, but to eliminate a poten-
tial hazard.
After establishing the satisfactory condi-
tion of the winch drum, mount the reel of
wire rope on suitable jacks at the front
of the boom. Pass the end of the rope
over the idler sheave at the boom point
and attach the rope to the winch drum as
shown in Figure 2-14 on page 2-26.
NOTE
A tension should be induced into
the rope by providing some means
of braking the shipping reel while
installing the rope on the winch
drum. A tight winding is imper-
ative.

Controls and Operation 2-27

 WARNING
Keep hands and clothing clear of
the rotating drum or serious injury
will result.
Establish a means to communicate with
and instruct the operator to slowly wind
the rope onto the drum by moving the
appropriate drum lever to the raise posi-
tion. A lead or brass hammer may be
useful in tapping the rope over as it is
being wound on the drum. Do not use a
steel hammer or pinch bar. These items
can readily cause· damage to the rope.
REEVING
Reeving diagrams for the main hoist line
are shown in Figure 2-16 on page 2-29.
The number of parts of line used in reev-
ing the main hoist line will depend on the
ioad to be lifted. Refer to the rati ng
chart in the upper cab to determine reev-
ing requirements for various loads.
Hoisting and lowering speeds decrease as
the number of parts of line increases.
When practical, use more than the min i-
mum number parts of line required to lift
the load.
The dead end of the rope is either at-
tached to the boom point or to the hook
block (or hook ball) with a wedge type
socket. The rope must be attached to the
socket as follows (see Figure 2-15 on
page 2-27):
1. Th read the rope th rough the socket
and bring it around in an easy to handle
loop. AI low the rope to assume its na-
tural lay; do not twist the rope.
WARNING
The live end of the rope must hang
in a straight line through the
socket or rope damage may result
leading to the failure of the rope.
Serious personal injury may result
if th is precaution is not observed.
2. The dead end of the rope must not ex-
tend more than 7 inches past the end of
the socket. I nsert the wedge in the rope
2-28
loop and pull the wedge and rope loop
tight enough to hold the wedge in posi-
tion during handling. Final wedge
positioning will take place under full op-
erating loads.
WARNING
Make sure the live end of the rope
is not kinked at the point where it
leaves the socket or failure of the
rope may result. Serious personal
injury may result if this precaution
is not observed.
3. After the socket is pinned to the boom
point or hook block, apply gradually in-
creasing loads until the wedge is seated
in the socket. Avoid any sudden shock
loads before the wedge is in its final po-
sition. When seated properly, the wedge
will just protrude beyond the end of the
socket.
4. Secu re two rope clamps and a short
piece of rope to the dead end of the rope
as shown in Figu re 2-15 on page 2-27.
TOWING
If it becomes necessary to tow the ma-
chine, proceed as follows:
NOTE
Each towing situation presents
special problems which cannot be
anticipated in advance.
Therefore, the following proce-
dures are general in nature. Ad-
ditional steps may also be
necessary to safely tow the ma-
chine under a given set of circum-
stances.
1. Place the Range Selector Leve-r in the
neutral position.
2. Attach a tow bar from the towing car-
rier to the tow lugs on the front of the
ca rrier frame.
3. Run the carrier engine until sufficient
air pressure is built up to release the
parking brakes.
 IDLER
J----SHEAVE
REEVING WITH EVEN
PARTS OF LINE

BOOM POINT
SHEAVE

TWO
ROPE CLAMPS
7 INCH
MAX.
DEAD
END

}
LIVE
END

REEVING WITH
ODD PARTS
OF LINE

2 PART 3 PART 4 PART 5 PART

3 BOOM POINT SHEAVES

Figure 2-16. Reeving Diagram

Controls and Operation 2-29

 WARNING
The crane carrier wheels must be
blocked with wheel chocks, or be
under total control of the towing
vehicle before, and during the
time, the brakes are manually re-
leased with brake chamber caging
bolt. When the crane carrier
brakes are released with the cag-
ing bolt, the crane carrier will
have no brakes. A runaway carri-
er will cause serious personal inju-
ry, property damage or death.
If the carrier engine is inoperative, re-
lease each rear wheel brake by turning
the caging bolt, located on the end of
the brake chamber, counterclockwise un-
til the brake is completely released (see
Fig u re 2 - 17) .
Figure 2-17. Caging Bolt
2-30
CAUTION
When a machine of this size is be-
ing towed, extra precautions must
be taken to ensure the safety of
personnel and prevent damage to
equipment.
4. When the air pressure has reached the
normal level, release the parking brakes
and begin towing the machine.
HOOK BLOCK STORAGE
GENERAL. When the machine is roaded,
the hook block must be secu red. There
is no separate storage area for the hook
block.
STORAGE. To secure the hook block for
travel, proceed as follows:
1. Fully retract the boom and swing it
over the front of the machine.
2. Raise the boom to position the hook
block such that it is hanging immediately
in front of the carrier frame.
3. Obtain a cable or chain 50-55 inches
long with hooks at both ends.
4. Attach the chain to the 2-1/4" diam-
eter holes located in the towing eyes at
the front of the carrier frame.
5. Attach the hook block to the chain,
lower the boom onto the boom rest and
raise the hook just enough to take up the
slack.
 SECTION III

LUBRICATION

This section covers the lubrication of the

machine and includes a copy of the offi-
cial Marine Corp Lubrication Instruction

Section III 3-1

 LUBRICATION LI 09109A-12
INSTRUCTION 31 January 1989
HIGH SPEED, HIGH MOBILITY CRANE (HSHMC) 25
References: (a) Operator's Manual, HSHMC 25 - 1-0M
(b) Service Manual, HSHMC 25 - 1-SM
(c) Parts Manual, HSHMC 25 - 1-PM (SHEET 1 OF 3)

Copy of this Instruction to be earned with the equipment at all times. Dotted lines
(---) indicate lubrication POints on both sides of the equipment. See Operator's
Manual or Service Manual for lubrlcatton In severe operatlnQ conditions.

LUBRICANT. INTERVAL INTERVAL. LUBRICANT

Steering Gear Box GO
Check level

Steering Joint GAA

2 fittings.

Steering Link GAA

3 fittings.
Steering Drag Link GAA
2 fittings, 2 places.
Suspension Cylinder GAA
2 fittings, each side. Steering Cvlinder
2 fittings.
Planetary Hubs GO
Check level weekly. DraIn and r",Rod
refill semi-annually. 2 fittings

Steering Joint GAA Propeller Shaft

4 fittings. each Side. 3 fittings.

Differential GO W Suspension Cylinder

Check level weekly. Drain and 2 fittings, each Side.
refill semi-annually
Tie Rod
Steering Cytinder GAA 2 fittings.
2 fittings.
Propeller Shaft
Planetary Hubs GO 3 fittings.
Check level weekly. Drain and
Battery
refill semi-annually.
Check level. 12 cells. Fill
Steering Joint GAA with distilled water
4 fittIngs, each side.
Hydraulic Reservoir
Differential GO W/S Check level (dipstick) daily.
Check level weekly. Drain and Drain (drain plug) and refill
refill semi-annually. (filter cap) quanerly.

Fuel Tank FOO Hydraulic Filters (two)

Refill at filler cap. Check visual Indicators daily.
Replace elements quanerly.
Air Reservoirs
Drain through drain cocks. GAA Propeller Shaft
3 fittings.
Planetary Hubs GO
Check level weekly. Drain and GAA Suspension Cylinder
refill semi-annually. 2 finings. each side.

GAA Propeller Shaft

Dittarenval GO 3 fittings.
Check level weekly. Drain and
GAA Suspension Cylinder
refill semi-annually.
2 fittmgs, each side.
Planetary Hubs GO GAA Pintow Hook
Check level weekly. Drain and
refill semi-annually.
3 finings.

Differential GO
Check level weekly. Drain and
refill semi-annually. CARRIER
KEY
EXPECTED TEMPeRATURES INTERVALS
!
'EG i~I~~:~EZE' I i
+40 TO OOF +'00 TO -66"F
MIL_A..46173 1 0
SYMBOVINTERVAL

-tntlvlorl0hrsJ I
I CoohngSVS1em 1 56 gals (153.0htet"sl I I W-'NeeItIVWSOhrs·JI
~:~'O;;:0:-1f-;:';';UE;;:L:::;o2ILC::0:::''''~I:''''-1i~~~~=~I-----:-:W;-:'':-:'aoo=--------j M - Monthly (or 200 '
I Fuel Tank 70 gals. (265.0 IItersl i-:G:-"-de-0:C''"'.2~'G:-,,-'-,,'-70'=.'~i-G-,
I -o-,.-,-1i a _ :~"erIY (Of 500
... i
I GAA i~~~je~utomollve I MIL-G-l0924C hrs.l
Grease F!ttlngs : S - Sem!-annu.aHy
Sliding Surfaces lor 1000 hrs l
•
GO ! LUBRICATING OIL
I Gear
MIL-L·2105C MIL-L-10324 i
i Steering Gear So)( 16 oz. (0.5 liters) SAE 90 SA! SO
I Planetary Hubs 1 gal (3.8 InerSI
I ~=I':;:~;:~~ 2 5 gals. (9 5 hters)
I Reservo!r 0.5 QlS (C.S hlets)

=~~ Reducer : :'~it~7 (:'et~~:~)

HO ! OIL. Hyclraullc i '
HydrauliC Reser\lOlr I 200 gals (757 liters) i PIoH484
LOG , LUBRICANT. Open W·L·751
: Gear al"lCl Wire Rope TypeU
I Open Gears and
R....

0' I LUBRICA.TING OIL

Iiniernal Combustion
MIL·L.-2104C MIL-L-46167

I Engine ! i
I Engine : 20 QIS (18.9 htersl !
, Transm!SS!()rI i 24 Qts (22 7 htersl

Figure 3-1. Carrier Lubrication

3-2
LI 091 09A-12 (SHEET 2 OF 3)

LUBRICANT. INTERVAL INTERVAL. LUBRICANT

Cooling Syartem Drain Cock DIS AEG Cooling System Radiator CaP
Check level dally. FllISh and
Dram, Flush cooling system
refill semj·annually
and refill at radiator cap.

V·BeIIS
Check tenSion.
Engine Oil Filters Itwo) M
Replace both filters.

Fuel Filter
Replace.

Engine Oil Drain Plug OE MI--_~;.!

Drain engine oiL Refill at
filler caps. Fuel/Weter Separator
Dram through valve on
separator.

Transmission Filter
Replace filter.

_ _ _ _ _-D Transmission Oil Level Plug

OE
~~

Check level: If oil is hot. check

top hole. If oil is cold. check
Transmiuion Oil Of'lli" Plug OE lower hole.
Drain oiL Refill at filler tube.

ENGINE - LEFT SIDE VIEW

Air Compressor Strainer

Replace.

Air Cluner Element.

Replace.

Air Cleaner Visual Indicator

Check condition of alf
cleaner.

Engine Oil Fil'" Caps Itwo)

Check engine oil at dipstick.
Add or replace oil.
OE Engine Oil Dipstick
Check level. Add oil at
filler caps.
Propel... Shaft
1 fining. 2 places.

Propel ... Shaft

, fitting.

Transmission Breather OE Transmission on Filler Tube

Replace. Drain old oil at drain plug.
Refill with new oil.

ENGINE - TOP VIEW

Figure 3-2. Engine Lubrication

Lubrication 3-3
 LI 091 09A-12 (SHEET 3 OF 3)

LUBRICANT. INTERVAL INTERVAL. LUBRICANT

~
GAA Idler Sheave
1 fitting

GAA Boom Panel Sheaves

Bottom Block GAA D , fining. each sheave.
1 flnlO9 each sheave.
, hook Pivot fittln9

Slider Pads GAA W

Apply to contact surfaces.

Boom Hoist Cylinder Rod

1 fitting.
GAA D--------------~~~~II

GO Swing Brake Reservoir

Check level.

Swing Gear LOG

2 places. Apply directly to
gear.

Hydraulic Swivel GAA

Rotate while greasing.

Swing Reducer Pinion GAA

1 fitting. I CAUTION I
"NO LUBRICATION"
Swing Reducer GO W/S
Check level daily, Orain.and INSTALL DRY. USE NO LUBRICATION
refill semi~annu81Iv. ON PIN OR JOURNAL BEARING.
GREASE AND OTHER LUBRICANTS
WILL RUIN BEARINGS.
S~win9 Rim Bearing GAA Q
2 finlngs.

W/S GO Winch
Check level weekly. Drain
and refill annusltv.

BOOM AND UPPER - SIDE VIEW

NOTES
1. PIVOT POINTS. Lubricate all pivot points not equipped with grease finings periodically with light motor
oil.
2. SEVERE OPERATION. Lubricate more often during severe operation.
3. HYDRAULIC OIL The hydraulic oil change interval depends upon the care exercised in keeping the oil
clean (changing filters) and the operating conditions. It IS recommended that a sample of oil be drawn
annually. This sample should be about 2 quansand should be taken when the oil has warmed through
normal operation. The sample should be analyzed by a qualified lubrication specialist to determine
whether It IS suitable for use.

BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS

OFFICIAL: ( )

f.i.~_!
P.B. SOUTHMAYO
DISTRIBUTION: 6025151/L77/L82/2193/5155/5156oo1.002.oo3/5165002.
Colonel, USMC
003.00515455001.002.0031722300117508023177100011
Director, Program Suppan 7718001 ml9001.oo2I7BOloo1 13111025001/2030/66001
Marine Corps Research. Development and 6901/69671740117000161121/8145004111
Acquisition Command

Figure 3-3. Upper Lubrication

3-4
 TABLE OF CONTENTS

Section III 3-1

Lubrication 3-1

Contents
 LIST OF ILLUSTRATIONS

Figure 3-1. Carrier Lubrication 3-2

Figure 3-2. Engine Lubrication 3-3
Figu re 3-3. Upper Lubrication 3-4

List of Illustrations iii

 TABLE OF CONTENTS

Subsection 4A 4A-1

Introduction 4A-1
General 4A-1
Description 4A-1
Troubleshooting 4A-1
Engine Removal ... 4A-1
Repairs and Adjustments 4A-2
Installation 4A-2

Subsection 4B 4B-1

Engine 4B-1
General .. 4B-1
Engine Description 4B-1
. Systems Operation 4B-1
Fuel System ...... . 4B-1
Air Inlet and Exhaust System 4B-8
Cylinder Head and Valves 4B-9
Lubrication System 4B-10
Cooling System .... 4B-12
Basic Block . . . . 4B-13
Electrical System .... 4B-14
Systems Test and Adjustment 4B-14
Fuel System 4B-14
Fuel I njection Lines 4B-18
Fuel I njection Pumps 4B-18
Finding Top Center . 4B-19
Fuel System Adjustments 4B-20
Fuel Setting ... ..... 4B-22
Fuel Ratio Control Adjustment 4B-24
Crossover Levers ..... 4B-25
Checking Fuel Pump Calibration . 4B-28
Adjustment of Fuel Pump Calibr:ation 4B-32
Governor Adjustments 4B-33
Air inlet and Exhaust System 4B-35
Lubrication System 4B-38
Cooling System ..... . 4B-40
Disassembly - Reassembly 4B-43
Air Inlet Manifold Removal 4B-43
Air Inlet Manifold Installation 4B-44
Valve Cover Removal .... 4B-44
Valve Cover Installation . . 4B-45
Crankcase Ventilator Valve Removal 4B-46
Cran kcase Ventilator Valve Installation 4B-46
Crankcase Ventilator Valve Disassembly 4B-46
Crankcase Ventilator Valve Assembly 4B-47
Water Separator Removal 4B-48
Water Sepa rator Installation 4B-49
Oi I Pan Removal ..... 4B-50
Oil Pan Installation 4B-50
Fuel Filter And Base Removal 4B-50
Fuel Filter And Base Installation. 4B-50
Water Temperature Regulator Removal 4B-51
Water Temperature Regulator Installation 4B-51
Fan Drive Removal 4B-52
Fan Drive Installation 4B-52
Fan Drive Disassembly 4B-53

Contents
 Fan Drive Assembly 4B-55
Exhaust Manifold Removal 4B-56
Ex haust Manifold Installation 4B-57
Ai r Compressor Removal 4B-58
Ai r Compressor Installation 4B-58
Fuel Injection Line Removal 4B-59
Fuel Injection Line Installation . . . . 4B-60
Fuel I njection Nozzles Removal and Installation 4B-61
Rocker Shaft Removal and Installation 4B-62
Valve Clearance Setting ..... . 4B-62
Rocker Shaft Disassembly .... . 4B-64
Rocker Shaft Assembly ...... . 4B-64
Valve Lifter Removal And Installation 4B-65
Tu rbocharger Removal 4B-66
Tu rbocharger Installation 4B-66
Turbocharger Disassembly 4B-67
Turbocharger Assembly 4B-70
Crankshaft Pulley Removal 4B-73
Cran kshaft Pulley Installation . 4B-74
Cran kshaft Front Seal Replacement 4B-75
Gear Cover and Oil Pump Installation 4B-79
Oil Pump And Relief Valve Removal 4B-81
Oil Pump And Relief Valve Installation 4B-82
Cylinder Head Removal 4B-84
Cylinder Head Installation 4B-85
Cylinder Head Disassembly 4B-86
Cylinder Head Assembly 4B-87
Water Pump ........... . 4B-88
Water Pump Removal And Installation: 4B-88
Water Pump Disassembly 4B-89
Water Pump Assembly 4B-90
Starter ..... 4B-92
Starter Removal 4B-92
Starter Installation 4B-92
Alternator .... ..... . 4B-93
Alternator Removal And Installation 4B-93
Engine Oil Cooler and Oil Filter Base 4B-93
Oil Cooler and Oil Filter Base Removal 4B-93
Oil Cooler and Oil Filter Base Installation 4B-94
Oil Cooler and Oil Filter Base Disassembly 4B-94
Oil Cooler And Oil Filter Base Assembly 4B-95
Fuel I njection Pump Removal 4B-95
Fuel I njection Pump Installation 4B-97
Fuel Transfer Pump Removal 4B-99
Fuel Transfer Pump Installation 4B-101
Governor Disassembly 4B-103
Governor Assembly ........ . 4B-107
Fuel I njection Pump Housing Disassembly 4B-112
Fuel I njection Pump Housing Assembly ....... . 4B-114
Shutoff Housing, Check Valve and Bypass Valve Removal 4B-115
Shutoff Housing, Check Valve and Bypass Valve Installation 4B-117
Fuel I njection Pumps Removal .... . 4B-119
Fuel I njection Pumps Installation ... . 4B-120
Fuel I njection Pumps Disassembly and Assembly 4B-121
Cran kshaft Main Bearings I nstallation and Removal 4B-121
Connecting Rod Bearing Removal and Installation 4B-124
Piston and Connecting Rod Removal 4B-125
Piston and Connecting Rod Installation 4B-126
Piston and Connecting Rod Disassembly 4B-126
Piston and Connecting Rod Assembly 4B-128
Flywheel Removal . . . . . . . . . 4B-128
Flywheel Installation ........ . 4B-129
Flywheel Housing I nstallation and Removal . 4B-129
Crankshaft Real Seal and Wear Sleeve Removal 4B-130
Cran kshaft Rear Seal and Wear Sleeve Installation 4B-130

ii
 Crankshaft and Gear Removal 4B-131
C ran kshaft and Gea r Installation 4B-132
Camshaft Bearing Removal 4B-133
Camshaft Bearing Installation 4B-134
Camshaft and Gear Removal 4B-134
Camshaft and Gea r Installation 4B-135
Subsection 4C 4C-l
Carrier Transmission and Torque Converter 4C-l
General 4C-l
Specifications 4C-l
Operation 4C-l
Troubleshooting . 4C-2
Mechanical Checks 4C-2
Hydraulic Checks 4C-3
Low Clutch Pressure . 4C-3
Low Converter Charging Pump Output 4C-3
Overheating ... .. 4C-3
Noisy Converter 4C-3
Lack of Power .... 4C-3
Torque Converter Disassembly 4C-3
Transmission Disassembly . 4C-8
4th Speed CI utch Disassembly 4C-23
Low Clutch Disassembly 4C-24
Forward Clutch Disassembly 4C-27
2nd Clutch Disassembly 4C-29
Cleaning 4C-29
Bearings 4C-29
Housings 4C-32
Inspection 4C-32
Bearings ...... . 4C-32
Oil Seals, Gaskets, Etc. 4C-32
Gears and Shafts 4C-32
Housing, Covers, etc. 4C-32
Oil Sealing Ring Sleeves 4C-32
Transmission Reassembly ...... . 4C-32
Reassembly of Forward and 2nd Clutch 4C-32
Reassembly of Low Clutch 4C-36
Reassembly of 4th Speed Clutch 4C-39
Reassembly of Transmission .. 4C-40
Torque Converter Reassembly 4C-48
Oil Sealing Ring Sleeve Removal . 4C-52
Servicing Transmission After Overhaul 4C-53
Subsection 4E 4E-l
Axles 4E-l
Description 4E-l
Removal 4E-l
Overhaul ........... . 4E-l
Planetary Hub Reducer Disassembly - 4E-l
Steering Joint Disassembly 4E-8
Differential Carrier Disassembly 4E-8
Cleaning and Inspection 4E-9
Inspection ........ . 4E-10
Assembly ......... . 4E-10
Differential Carrier Assembly 4E-1O
Steering Joint Assembly . 4E-17
Planetary Hub Reducer Assembly 4E-18
Installation . . . . . . . . . . . 4E-19

Contents iii
 LIST OF ILLUSTRATIONS

Figure 4B-1. Engine Serial Number Plate 4B-1

Figu re 4B-2. Engine I nformation Plate 4B-1
Figure 4B-3. Schematic of Fuel System 4B-2
Figu re 4B-4. Constant Bleed Valve 4B-3
Figu re 4B-5. Fuel I njection Sequence 4B-3
Figure 4B-6. Fuel Injection Nozzle 4B-4
Figure 4B-7. Water Separator . 4B-4
Figure 4B-8. Cross Section of Fuel Pump 4B-5
Figu re 4B-9. Fuel System Components 4B-6
Figure 4B-10. Torque Control Group 4B-6
Figure 4B-11. Timing Advance Unit 4B-7
Figure 4B-12. Timing Advance Unit . 4B-7
Figure 4B-13. Air Inlet and Exhaust System 4B-8
Figure 4B-14. Cylinder Head and Valves .. 4B-9
Figu re 4B-15. Schematic of Lubrication System 4B-11
Figure 4B-16. Crankshaft Oil Schematic . 4B-12
Figure 4B-17. Water Temperature Regulators 4B-12
Figure 4B-18. Vent Valve .... 4B-13
Figu re 4B-19. Vibration Damper 4B-13
Figure 4B-20. Nozzle Testing Tools 4B-15
Figure 4B-21. Removing Carbon Dam 4B-15
Figure 4B-22. Bleed Screw and Seal 4B-16
Figure 4B-23. Nozzle Ready for Test 4B-16
Figure 4B-24. Good Nozzle (Use Again) ........ . 4B-17
Figure 4B-25. Discharge with Restricted Orifice (Replacement
Necessa ry) ................. . 4B-17
Figu re 4B-26. Discharge with Horizontal Distortion (Replacement
Necessa ry) ................. . 4B-18
Figure 4B-27. Discharge with Vertical Distortion (Replacement
Necessa ry) ..... 4B-18
Figure 4B-28. Installing Carbon Dam 4B-18
Figure 4B-29. Air Inlet Pipe 4B-19
Figure 4B-30. Stopping the Engine 4B-19
Figure 4B-31. Fitting and Bolt 4B-19
Figu re 4B-32. Bolt (2) and Hole (3) 4B-20
Figure 4B-33. Timing Hole Bolt (1) 4B-20
Figure 4B-34. Timing Pin (2) 4B-20
Figure 4B-35. Bolt and Holes . 4B-20
Figure 4B-36. Cover (6) and Nuts (7) ... 4B-21
Figu re 4B-37. Washer (8) and Drive Shaft (9) 4B-21
Figure 4B-38. Puller and Bolts ..... 4B-21
Figure 4B-39. Tachometer Drive Shaft. . ... 4B-21
Figure 4B-40. Shutoff Solenoid (1) and Top Cover (2) 4B-22
Figure 4B-41. Installation of Cover 4B-22
Figu re 4B-42. Screw (6) ....... . 4B-22
Figu re 4B-43. Adapter (3) and Clamp (7) 4B-23
Figure 4B-44. I nstallation of Dial Indicator 4B-23
Figure 4B-45. I ndicator Set on Zero 4B-23
Figure 4B-46. Wrench (11) ...... . 4B-23
Figure 4B-47. Circuit Tester ..... . 4B-23
Figure 4B-48. Adjustment of Fuel Setting 4B-24
Figure 4B-49. Fuel Setting Adjustments 4B-24
Figure 4B-50. Removal of Covers 4B-24
Figure 4B-51. Fuel Ratio Control Setting 4B-25
Figure 4B-52. Flange (4) ............ . 4B-25
Figure 4B-53. Shutoff Solenoid (1) and Top Cover (2) 4B-25
Figure 4B-54. Calibration Pin (3) 4B-26
Figure 4B-55. Adapters, Screws and Bolts 4B-26

List of Illustrations v
Figure 4B-56. Screw (8) and Lever (9) 4B-26
Figure 4B-57. Crossover Levers 4B-26
Figure 4B-58. Gauge (13) and Shafts (14 and 15) 4B-26
Figure 4B-59. Gauge (13) and Feeler Gauge (16) 4B-27
Figure 4B-60. Dowel Pin (12) and Levers 4B-27
Figure 4B-61. Lever, Pin and Gauge 4B-27
Figure 4B-62. Adjustment of Crossover Levers 4B-28
Figu re 4B-63. Tightening Bolt 4B-28
Figure 4B-64. Fuel Pump Tools 4B-28
Figure 4B-65. Solenoid (9) and Cover (10) 4B-29
Figure 4B-66. Calibration Pin (7) 4B-29
Figure 4B-67. Installing Adapter and Screw 4B-29
Figure 4B-68. Screw (15) and Lever (16) 4B-29
Figure 4B-69. Calibration Pump (1) 4B-30
Figu re 4B-70. Calibration Pump Installed 4B-30
Figure 4B-71. Putting Indicator on Zero 4B-30
Figu re 4B-72. Shaft (24) and Clamp (25) 4B-31
Figu re 4B-73. Dial Indicator (4) and Clamp (25) 4B-31
Figu re 4B-74. Clamps (25) 4B-31
Figure 4B-75. Dial Indicator Reading 4B-32
Figure 4B-76. Lever (18), Bolt (26) and Wrench (A) 4B-32
Figu re 4B-77. Plunger 4B-32
Figure 4B-78. Calibration Tolerance 4B-33
Figure 4B-79. Bolt (1) and Locknut (2) 4B-33
Figure 4B-80. Bolt (1), Locknut (2) and Cover (3) 4B-34
Figure 4B-81. Engine Set Point Indicator 4B-34
Figure 4B-82. Brass Terminal Screw (4) 4B-34
Figure 4B-83. Screw (5) and Locknut (6) 4B-35
Figure 4B-84. Pressure Test Kit 4B-36
Figure 4B-85. Fitting (A) 4B-36
Figure 4B-86. Cylinder, Valve and Pump Location 4B-37
Figu re 4B-87. Valve Lash Adjustment 4B-37
Figure 4B-88. Camshaft Lobe 4B-38
Figure 4B-89. Engine Pressure Test Kit 4B-39
Figure 4B-90. Test Location (A) 4B-39
Figure 4B-91. Test Location (B) 4B-39
Figure 4B-92. Boiling Point of Water 4B-41
Figure 4B-93. Sealing Surface (A) 4B-41
Figure 4B-94. Pressurizing Pump 4B-42
Figure 4B-95. Thermistor Thermometer 4B-42
Figu re 4B-96. Bushing (1) and Gauge. (2) 4B-43
Figu re 4B-97. Disconnect Hoses and Tubes 4B-43
Figure 4B-98. Bracket (6) and Fuel Lines (5, 7 and 8) 4B-43
Figure 4B-99. Clamps, Bolts and Manifold 4B-44
Figure 4B-100. Manifold, Bolts and Hose Clamps 4B-44
Figu re 4B-101. Bracket and Fuel Lines 4B-44
Figure 4B-102. Hoses and Tubes 4B-44
Figure 4B-103. Clamp and Hose 4B-45
Figure 4B-104. Bolts and Valve Cover 4B-45
Figure 4B-105. Gasket (1) 4B-45
Figu re 4B-106. Valve Cover (2) 4B-45
Figu re 4B-107. Bolt Tightening Sequence 4B-45
Figure 4B-108. Connect Hose (3) 4B-46
Figure 4B-109. Bolts (2) and Ventilator Valve (1) 4B-46
Figure 4B-110. Gasket and Ventilator Valve 4B-46
Figure 4B-111. Screws, Cover and Housing 4B-46
Figure 4B-112. Spring (4) 4B-47
Figure 4B-113. Remove as a Unit 4B-47
Figure 4B-114. Components of Inner Sleeve 4B-47
Figure 4B-115. Housing, Gasket and Inner Sleeve 4B-47
Figure 4B-116. Piston (6) and Diaphragm (4) 4B-48
Figure 4B-117. Insert Screw 4B-48
Figure 4B-118. Clamp (1) and Element (2) 4B-48
Fig u re 4 B - 119 . Bas e (3) and Li n e (4) 4B-48
Figure 4B-120. Bolts (6) and Bracket (5) 4B-49

vi
Figure 4B-121. Bolts (6), Bracket (5) and Spacers 4B-49
Figure 4B-122. Bracket (1) and Spacers 4B-49
Figure 4B-123. Base (2) 4B-49
Figu re 4B-124. Water Separator 4B-49
Figure 4B-125. Bolts (1) and Oil Pan (2) 4B-50
Figure 4B-126. Lines (1, 2 and 3) 4B-50
Figure 4B-127. Strap Wrench 4B-50
Figure 4B-128. Fuel Filter Base and Bolts 4B-51
Figure 4B-129. Lines (4, 5 and 6) 4B-51
Figure 4B-130. Bolts (1) and Elbow (2) 4B-51
Figure 4B-131. Regulators (3) 4B-51
Figu re 4B-132. Regulators (1) 4B-52
Figure 4B-133. Elbow (3) and Bolts (2) 4B-52
Figure 4B-134. Nuts (1) and Fan Belts (2) 4B-52
Figure 4B-135. Bolts (3) and Fan Drive (4) 4B-52
Figure 4B-136. Fan Drive (2) and Bolts (1) 4B-53
Figure 4B-137. Fan Belts (4) and Nuts (3) 4B-53
Figu re 4B-138. Bolts (1) and Adapter (2) 4B-53
Figure 4B-139. Nut, Washer and Bearing 4B-53
Figure 4B-140. Bearing Spacer (6) 4B-54
Figure 4B-141. Pulley (7) and Bracket (8) 4B-54
Figure 4B-142. Sleeve (9) 4B-54
Fig u re 4 B - 143 . Sea I (10) 4B-54
Figure 4B-144. Bearing (11) 4B-54
Figure 4B-145. Bearing Races (12) 4B-55
Figure 4B-146. Bearing Races (1) 4B-55
Figure 4B-147. Bearing (2) 4B-55
Figure 4B-148. Seal (3) 4B-55
Figure 4B-149. Sleeve (4) 4B-55
Figu re 4B-150. Pulley (5) 4B-56
Figure 4B-151. Bearing Spacer (7) 4B-56
Figure 4B-152. Bearing, Washer and Nut 4B-56
Figure 4B-153. Adapter (12) and Bolts (11) 4B-56
Figure 4B-154. Two Bolts (1) 4B-57
Figu re 4B-155. Bend Tabs on Locks (2) 4B-57
Figure 4B-156. Exhaust Manifold (3) 4B-57
Figu re 4B-157. Exhaust Manifold (1) 4B-57
Figure 4B-158. Locks (2) and Bolts (3) 4B-57
Figu re 4B-159. Bolts in Flange . 4B-58
Figure 4B-160. Lines (1 and 2) 4B-58
Figure 4B-161. Hoses (3 and 4) and Belt (5) 4B-58
Figure 4B-162. Bolts (7) and Compressor (6) 4B-58
Figure 4B-163. Compressor (1) and Bolts (2) 4B-59
Figure 4B-164. Belt (5) and Hoses (3 and 4) 4B-59
Figure 4B-165. Lines (6 and 7) 4B-59
Figure 4B-166. Bolt (4) 4B-59
Figure 4B-167. Hoses (1 and 3) and Bolt (2) 4B-60
Figure 4B-168. Fuel Injection Lines (4) 4B-60
Figure 4B-169. Fuel Injection Lines (1) 4B-60
Figure 4B-170. Socket (A) 4B-60
Figure 4B-171. Hoses (2 and 4) and Bolt (3) 4B-61
Figure 4B-172. Fuel Injection Components 4B-61
Figure 4B-173. Seal Dam (6) and Seal (5) 4B-61
Figure 4B-174. Adapter (7) and Nozzle (3) 4B-62
Figu re 4B-175. Rocker Shaft, Push Rods and Bolts 4B-62
Figure 4B-176. Cylinder, Valve and Pump Location 4B-63
Figu re 4B-177. Checking Valve Clearance 4B-63
Figu re 4B-178. Tightening Locknut 4B-63
Figu re 4B-179. Rocker Shaft Assembly 4B-64
Figure 4B-180. Shaft (3) and Bracket (4) 4B-64
Figu re 4B-181. Rocker Shaft Disassembly 4B-64
Figure 4B-182. Rocker Shaft Assembly 4B-65
Figure 4B-183. Shaft (1) and Bracket (5) 4B-65
Figure 4B-184. Bolts (6) and Locks (7) 4B-65
Figure 4B-185. Magnet (1) and Valve Lifters (2) 4B-65

List of Illustrations vii

Figure 4B-186. Valve Lifters (2) 4B-66
Figu re 4B-187. Hose Clamps (1) 4B-66
Figure 4B-188. Hose Clamps (2) and Tubes (3) 4B-66
Figure 4B-189. Turbocharger (4) and Bolts (5) 4B-66
Figure 4B-190. O-Ring Seals (6) 4B-67
Figure 4B-191. Make Alignment Marks 4B-67
Figu re 4B-192. Bolts, Plates and Cartridge Assembly 4B-67
Figu re 4B-193. 0- Ring Seal (7) 4B-67
Figure 4B-194. Fixture (A) and Sliding T-Wrench (C) 4B-68
Figure 4B-195. Nut (8) and Compressor Wheel (9) 4B-68
Figure 4B-196. Wheel Assembly (10) 4B-68
Figure 4B-197. Shroud (11) 4B-68
Figure 4B-198. Backplate (13) and Bolts (12) 4B-68
Figure 4B-199. Spacer (14) 4B-69
Figure 4B-200. Two Seal Rings (15) 4B-69
Figure 4B-201. Snap Ring (16) 4B-69
Figure 4B-202. Bearing (17) 4B-69
Figure 4B-203. Snap Ring (18) 4B-69
Figure 4B-204. Screws, Plate and Collar 4B-70
Figure 4B-205. Bearing (22) 4B-70
Figure 4B-206. Snap Ring (23) 4B-70
Figu re 4B-207. Turbocharger Assembly 4B-70
Figure 4B-208. Install Rings and Bearing 4B-71
Figure 4B-209. Seal Rings and Spacer 4B-71
Figure 4B-210. Spacer (12) 4B-71
Figu re 4B-211. Backplate (13) 4B-71
Figure 4B-212. Shroud (14) 4B-71
Figure 4B-213. Wheel Assembly (15). 4B-72
Figure 4B-214. Compressor Wheel and Nut 4B-72
Figu re 4B-215. Dial Indicator 4B-72
Figure 4B-216. O-Ring Seal (18) 4B-72
Figure 4B-217. Housing, Plates and Bolts 4B-73
Figure 4B-218. Housing (22) and Clamp (23) 4B-73
Figure 4B-219. V-Belts (1) 4B-73
Figu re 4B-220. Bolts (2) and Adapter (3) 4B-73
Figure 4B-221. Bolts (4) and Adapter (5) 4B-74
Figure 4B-222. Bolt (6) and Washer (7) 4B-74
Figure 4B-223. Tool (A) and Pulley (8) 4B-74
Figure 4B-224. Pulley (1) and Tool (A) 4B-74
Figure 4B-225. Bolts and Washer 4B-75
Figure 4B-226. Adapter (6) and Bolts. (5) 4B-75
Figu re 4B-227. Adapter (7) and Bolts (8) 4B-75
Figure 4B-228. V-Belts (9) 4B-75
Figure 4B-229. Seal Puller (A) 4B-75
Figure 4B-230. Seal Installer (A) 4B-76
Figure 4B-231. Crankshaft Pulley 4B-76
Figure 4B-232. Tube (1L Adjuster (2) and Adapter (3) 4B-76
Figure 4B-233. Tube (5) and Adjuster- (4) 4B-76
Figu re 4B-234. Engine on Blocks 4B-77
Figure 4B-235. Clamp (10) and Hose (11) 4B-77
Figure 4B-236. Clips (13) and Lines(12) 4B-77
Figure 4B-237. Clamp (14) 4B-77
Figure 4B-238. Water Sleeve Removal Tool 4B-78
Figure 4B-239. Bolts, Connector and Gasket 4B-78
Figure 4B-240. Bolts, Elbow and Gasket 4B-78
Figu re 4B-241. Bolt (20) and Clamp (21) 4B-78
Figure 4B-242. Link Bracket (B) and Cover (22) 4B-79
Figure 4B-243. Link Bracket (A) and Cover (1) 4B-79
Figu re 4B-244. Clamp (3) and Bolts (2) 4B-79
Figure 4B-245. Elbow (4) and Bolts (5) 4B-79
Figure 4B-246. Connector (7) and Bolts (6) . 4B-80
Figure 4B-247. Water Sleeve Removal Tool (B) 4B-80
Figure 4B-248. Install Clamps (9) 4B-80
Figure 4B-249. Lines (10) and Clips (11) 4B-80
Figure 4B-250. Hose (13) and Clamp (12) 4B-80

viii
Figure 4B-251. Support and Adapter 4B-81
Figure 4B-252. Adjusters (18) and Tube (19) 4B-81
Figure 4B-253. Tube (20), Adjuster (21) and Adapter (22) 4B-81
Figure 4B-254. Bolts (1) and Cover (2) 4B-81
Figure 4B-255. Guide, Spring and Plunger 4B-82
Figure 4B-256. O-Ring Seal (6) 4B-82
Figure 4B-257. Inner and Outer Rotors 4B-82
Figure 4B-258. Bearing (9) and Shaft (10) 4B-82
Figure 4B-259. Bearing Driver (A) 4B-83
Figure 4B-260. Joint in Bearing 4B-83
Figure 4B-261. Check Dimension "X" 4B-83
Figure 4B-262. Inner and Outer Rotors 4B-83
Figure 4B-263. Clearance Between Rotors 4B-83
Figure 4B-264. Plunger (3), Spring (4) and Guide (5) 4B-84
Figure 4B-265. O-Ring Seal (6) 4B-84
Figure 4B-266. Check End Clearance 4B-84
Figure 4B-267. Water Sleeves (1) 4B-85
Figure 4B-268. Water Sleeve Removal Tool (A) 4B-85
Figure 4B-269. Link Brackets (B) 4B-85
Figure 4B-270. Cylinder Head (1) and Gasket (2) 4B-85
Figure 4B-271. Bolt Tightening Sequence 4B-86
Figu re 4B-272. Water Sleeve Tool (B) 4B-86
Figure 4B-273. Clamp (5) 4B-86
Figure 4B-274. Spring Compressor (C) 4B-87
Figure 4B-275. Valve Spring Tester (B) 4B-87
Figure 4B-276. Insert Puller (D) 4B-87
Figure 4B-277. Insert Puller (A) 4B-87
Figure 4B-278. Valve Components 4B-88
Figure 4B-279. Spring Compressor (C) 4B-88
Figure 4B-280. Spring Compressor (C) and Locks (4) 4B-88
Figure 4B-281. Bolts (1), Pointer (3) and Water Pump (2) 4B-89
Figure 4B-282. Pulley (1) 4B-89
Figure 4B-283. Driver Handle and Drive Plate (A) 4B-89
Figure 4B-284. Bearing and Housing 4B-90
Figure 4B-285. Spacer and Housing 4B-90
Figure 4B-286. Ring (5), Bearing (6) and Housing (2) 4B-90
Figu re 4B-287. Shaft and Seal Removal 4B-90
Figure 4B-288. Shaft and Seal 4B-90
Figure 4B-289. Bearing Installation 4B-91
Figure 4B-290. Spacer Installation 4B-91
Figure 4B-291. Install Bearing (5) 4B-91
Figure 4B-292. Pulley Installation 4B-91
Figure 4B-293. Seal Assembly (7) 4B-92
Figure 4B-294. Seal Installation 4B-92
Figure 4B-295. Spacers (C and D) 4B-92
Figure 4B-296. Bolts (1) and Starter (2) 4B-92
Figu re 4B-297. Alternator 4B-93
Figure 4B-298. Filters (2) and Clamps (1) 4B-93
Figure 4B-299. Oil Cooler and Bolts 4B-93
Figure 4B-300. Cover and Bolts 4B-94
Figu re 4B-301. Filter Base and Nuts 4B-94
Figure 4B-302. Divider & Oil Cooler 4B-94
Figure 4B-303. Plug, Spring and Valve 4B-94
Figure 4B-304. Plug, Spring and Valve 4B-95
Figure 4B-305. Cooler and Filter Base 4B-95
Figure 4B-306. Valve and Plug 4B-95
Figu re 4B-307. Divider (7) 4B-95
Figure 4B-308. Adapter (1) 4B-96
Figu re 4B-309. Drive Shaft (2) 4B-96
Figure 4B-31O. Gear Puller (A) 4B-96
Figure 4B-311. Wires and Tubes 4B-96
Figure 4B-312. Bolts (7) and Governor (6) 4B-97
Figure 4B-313. O-Ring Seals (1 and 2) 4B-97
Figure 4B-314. Bolt (B) and Pin (A) 4B-97
Figure 4B-315. Governor (3) 4B-97

List of Illustrations ix
Fig u re 48 -316 . Hand Crank (C) 4B-98
Figure 48-317. Location (5) and Hole (7) 4B-98
Figu re 48-318. Adapter (8) and 80lt (9) 4B-98
Fig u re 48 - 319 . Timing Pin (A) 4B-98
Figure 48-320. Wires and Tubes 4B-99
Figure 48-321. 8racket, Bolts and Housing 4B-99
Figure 48-322. Governor Shaft (3) 4B-99
Figure 48-323. Sleeve, Pin and 80lt 4B-100
Figure 48-324. Bolts and Pump Body 4B-100
Figure 48-325. Drain Line (7) 4B-100
Figure 48-326. Gear (8) and Seal (9) 4B-100
Figure 48-327. Seals (10) 4B-100
Figure 48-328. Drive Gear (11) 4B-101
Figu re 48-329. Key (1) and Gear (2) 4B-101
Figu re 48-330. Driver (B) and 80dy (3) 4B-101
Figu re 48-331. O-Ring (4) and Gear (5) 4B-101
Figu re 48-332. Guide (C) and Line (6) 4B-l02
Figu re 48 -333. Sleeve (7) and Washer (D) 4B-102
Fig u re 48 - 334 . Camshaft End Play 4B-l02
Figure 48-335. Governor Housing (8) 4B-102
Figure 48-336. 80lt (9) and 8racket (A) 4B-103
Figu re 48-337. 8racket, Bolts and Housing 4B-103
Figu re 48-338. Governor Springs (3) 4B-103
Figu re 48-339. Governor Components 4B-103
Figure 48-340. Seal (8) and Bush i ng (9) 4B-104
Figure 48-341. Seat (10) and Spring (11) 4B-104
Figu re 48-342. Retaining Ring Removal 4B-104
Figu re 48-343. Cover (14) 4B-104
Figu re 48-344. Shaft (15) and Lever (16) 4B-104
Figure 48-345. Cover (17) 4B-105
Figu re 48-346. Nut, 80lt and Control Group 4B-105
Figu re 48-347. Shim, Insulators and Contact 4B-l05
Figure 48-348. Lever (25) and Pin (24) 4B-105
Figu re 48-349. Lock Ring (26) and Lever (25) 4B-105
Figu re 48-350. 8ar (C) and Shield (27) 48-106
Figu re 48-351. Riser (28) 4B-l06
Figure 48-352. Riser (28) Disassembly 48-106
Figu re 48-353. Pin (0), Bolts (33) and Flyweight (34) 4B-l06
Figure 48-354. Shaft, Dowels and Flyweights 48-107
Figure 48-355. Dowel, Flyweight and Shaft 48-107
Figure 48-356. Dowel (4) ... 48-107
Figu re 48-357. Timing Pin (D) and Flyweight (5) 4B-l07
Figure 48-358. Race, Ring, Riser and Bearing 48-108
Figure 48-359. Riser (8) 4B-l08
Figure 48-360. Driver (B) 4B-108
Figure 48-361. Lever (10) 4B-l08
Figu re 48-362. Pin (11) 4B-l08
Figu re 48-363. Assemble Components on Bar (15) 48-109
Figu re 48-364. Torque Control Group (15) 48-109
Figure 48-365. Cover (16) 4B-109
Figure 48-366. Lever (17) and Shaft (18) 4B-109
Figu re 48-367. Cover (19) 4B-110
Figure 48-368. Spool (20) and Components 4B-l1O
Figu re 48-369. Spring (25) and Seat (21) 48-110
Figure 48-370. Driver (E) 48-110
Figu re 48-371. Seal with Lip Inward 4B-110
Figure 48-372. 0- Ring Seal (26) 48-111
Figure 48-373. Lever, Shaft and Washer 4B-l11
Figu re 48-374. Seat (30) and Springs (31) 4B-l11
Figure 48-375. Gasket and Governor Housing (32) 4B-111
Figu re 48-376. Bolt (33) and O-Ring (34) 4B-112
Figure 48-377. Screws and Shafts 4B-112
Figure 48-378. Levers and Shaft 4B-112
Figure 48-379. Identification Ma rks 4B-113
Figure 48-380. Roller (8) 4B-113

x
Figure 4B-381. Camshaft (9) 4B-113
Figure 4B-382. Rear Bearing (10) 4B-113
Figure 4B-383. Driver (A) 4B-114
Figure 4B-384. Reamer (B) 4B-114
Figure 4B-385. Washer and Camshaft 4B-114
Figure 4B-386. Lifter Assemblies (5) 4B-115
Figure 4B-387. Shaft and Levers 4B-115
Figure 4B-388. Shaft Assembly and Levers 4B-115
Figu re 4B-389. Remove These Components 4B-116
Figure 4B-390. Valve and Flange Assembly 4B-116
Figure 4B-391. Shutoff Housing Cover 4B-116
Figu re 4B-392. Solenoid and bolts. 4B-116
Figu re 4B-393. Shaft and Levers 4B-117
Figure 4B-394. Remove Seal (16) 4B-117
Figure 4B-395. Spring (17) and Valve (18) 4B-117
Figure 4B-396. Valve (2) and Spring (1) 4B-117
Figure 4B-397. Seal Driver (A) and Gasket 4B-118
Figure 4B-398. Levers and Shafts 4B-118
Figure 4B-399. Cover (5) and Housing (8) 4B-118
Figu re 4B-400. Shutoff Solenoid (9) 4B-118
Figu re 4B-401. Housing Cover (8) 4B-118
Figure 4B-402. Valve (10) and Flange (11) 4B-119
Figu re 4B-403. Reference Photo 4B-119
Figu re 4B-404. Wrench (A) and Extractor (B) 4B-119
Figure 4B-405. Bushing and O-Ring Seal 4B-119
Figure 4B-406. Screws (3), Pump (2) and Extractor (B) 4B-120
Figure 4B-407. O-Ring and Bushing 4B-120
Figure 4B-408. Torque Wrench (6) 4B-120
Figure 4B-409. Injection Pump Components 4B-121
Figure 4B-41O. Bearing Cap Removal 4B-122
Figure 4B-411. Bearing Tool (A) 4B-122
Figure 4B-412. Plastigage (B) 4B-123
Figure 4B-413. Final Tightening Radius 4B-124
Figure 4B-414. Dial I ndicator (D) 4B-124
Figure 4B-415. Connecting Rod Cap (1) 4B-124
Figure 4B-416. Final Tightening Radius 4B-125
Figure 4B-417. Ridge Reamer (A) 4B-125
Figure 4B-418. Connecting Rod Caps (1) 4B-125
Figu re 4B-419. Piston Assemblies (2) 4B-125
Figure 4B-420. Ring Compressor (A) 4B-126
Figure 4B-421. Connecting Rod Cap (1) 4B-126
Figu re 4B-422. Ring Expander (A) 4B-127
Figure 4B-423. Snap Rings, Pin and Connecting Rod 4B-127
Figure 4B-424. Connecting Rod Components 4B-127
Figure 4B-425. Connecting Rod Components 4B-128
Figure 4B-426. Piston Ring Groove Cleaner 4B-128
Figure 4B-427. Lifting Bracket (A) 4B-128
Figu re 4B-428. Ring Gear (2) 4B-129
Figure 4B-429. Heat Ring Gear (1) 4B-129
Figure 4B-430. Lifting Bracket (A) 4B-129
Figure 4B-431. Bolts and Flywheel Housing 4B-130
Figu re 4B-432. Lip-Type Seal Puller 48-130
Figure 4B-433. Distorter Ring (C) and Distorter (B) 4B-130
Figu re 4B-434. Seal and Sleeve Installation 4B-131
Figure 4B-435. Crankshaft Removal 4B-131
Figure 4B-436. Use Sling When Removing Crankshaft 4B-132
Figure 4B-437. Hydraulic Puller (B) 4B-132
Figure 4B-438. Bolt Tightening Sequence 4B-133
Figu re 4B-439. Washer and Bolt 4B-133
Figure 4B-440. Installation and Removal Tool 4B-134
Figure 4B-441. Rear Camshaft Bearing 4B-134
Figure 4B-442. Front Camshaft Bearing 4B-134
Figure 4B-443. Timing Pin (A) 4B-135
Figure 4B-444. Drive Gear Removal Tooling 4B-135
Figure 4B-445. Thrust Pin (2) 4B-135

List of Illustrations xi
Figure 4B-446. Camshaft (3) and Gears 4B-135
Figure 4B-447. Cams haft (1) 4B-136
Figu re 4B-448. Timing Marks 4B-136
Figu re 4B-449. Gear (3) and Shaft (2) 4B-136
Figure 4B-450. Bolt (4) and Cover Bolt (5) 4B-136
Figure 4C-1. MHR Series Transmission 4C-4
Figu re 4C-2. Plumbing Diagram 4C-4
Figure 4C-3. Low Range 4C-5
Figu re 4C-4. High Range 4C-6
Figu re 4C-5. Clutch and Gear Arrangement 4C-7
Figu re 4C-6. I nput Flange 4C-7
Figu re 4C-7. Bolts and Washers 4C-7
Figure 4C-8. Front Cover 4C-8
Figu re 4C-9. Shaft Support Bearing 4C-8
Figure 4C-1O. Remove Bolts 4C-8
Figu re 4C-11. Impeller Cover 4C-8
Figure 4C-12. Side View of Transmission 4C-9
Figu re 4C-13. Housing and Element 4C-9
Figu re 4C-14. Remove Pump and Adapter 4C-9
Figure 4C-15. Pressu re Regulating Valve 4C-9
Figure 4C-16. Pump Drive Sleeves 4C-1O
Figure 4C-17. Detent Springs 4C-1O
Figure 4C-18. Remove Cover Bolts 4C-1O
Figu re 4C-19. I nstall Bolts 4C-1O
Figure 4C-20. Remove Cover 4C-11
Figu re 4C-21. Retainer Ring 4C-11
Figu re 4C-22. Turbine Retainer Ring 4C-11
Figu re 4C-23. Turbine and Hub 4C-11
Figure 4C-24. Locating Ring 4C-11
Figure 4C-25. Retainer Ring 4C-12
Figure 4C-26. Member and Spacer 4C-12
Figure 4C-27. Retainer Ring 4C-12
Figure 4C-28. Baffle and Impeller 4C-12
Figure 4C-29. Hold Snap Ring Open 4C-13
Figure 4C-30. Housing and Clutch 4C-13
Figu re 4C-31. Remove Bolts 4C-13
Figure 4C-32. Stator Support 4C-13
Figure 4C-33. Support Bolts 4C-14
Figure 4C-34. Pump Drive Gear on Right 4C-14
Figure 4C-35. Pump Drive Gear on Left 4C-14
Figu re 4C-36. Center Pump Drive Gear 4C-14
Figu re 4C-37. Forward Clutch 4C-15
Figure 4C-38. Tap Turbine Shaft 4C-15
Figure 4C-39. Fourth Speed Clutch 4C-15
Figure 4C-40. Retainer Ring 4C-15
Figure 4C-41. Disc Hub 4C-16
Figu re 4C-42. Bearing Cap and Spacer 4C-16
Figu re 4C-43. Locating Ring 4C-16
Figure 4C-44. Rea r Bea ri ng Cap 4C-16
Figure 4C-45. Wire and Sealing Ring 4C-17
Figure 4C-46. Bolts and Plate 4C-17
Figu re 4C-47. Locating Ring 48-17
Figure 4C-48. Pry Cover from Housing 4C-17
Figure 4C-49. Remove Lock-Balls 4C-18
Figure 4C-50. Bearing Puller 4C-18
Figure 4C-51. Cup, Cone and Spacer 4C-18
Figure 4C-52. I nner Bearing Cone 4C-18
Figure 4C-53. Special Bearing Puller 4C-19
Figure 4C-54. Idler Shaft and Gear 4C-19
Figure 4C-55. Ring and Gear . 4C-19
Figu re 4C-56. Reverse and 3rd Clutch 4C-19
Figu re 4C-57. Remove Snap Ring 4C-20
Figure 4C-58. Remove Retainer Ring 4C-20
Figure 4C-59. Remove Retainer Ring 4C-20
Figure 4C-60. 2nd Gear and End Plate 4C-20

xii
Figure 4C-61. Low Clutch ..... . 4C-20
Figu re 4C-62. Remove Fork Lockscrew 4C-21
Figure 4C-63. Remove Range Shift Fork 4C-21
Figure 4C-64. Bolts and Bearing Cap 4C-21
Figu re 4C-65. Push Output Shaft 4C-21
Figure 4C-66. Remove Retainer Ring 4C-22
Figu re 4C-67. Impeller Hub Gear 4C-22
Figure 4C-68. Baffle and Seal 4C-22
Figu re 4C-69. Remove Bolts 4C-22
Figure 4C-70. Remove O-Ring 4C-23
Figu re 4C-71. Remove Retainer 4C-23
Figu re 4C-72. Remove End Plate 4C-23
Figu re 4C-73. Remove Clutch Discs 4C-23
Figu re 4C-74. Remove Components 4C-23
Figure 4C-75. Remove Piston 4C-24
Figure 4C-76. Remove Rings 4C-24
Figure 4C-77. Remove Retainer Ring 4C-24
Figure 4C-78. Remove Bearing 4C-24
Figu re 4C-79. Remove Bearing Race 4C-25
Figu re 4C-80. Remove Ring Retainer. 4C-25
Figure 4C-81. Remove Retainer Ring .. 4C-25
Figure 4C-82. Remove Bearing and Spacer 4C-25
Figure 4C-83. Ring, Plate and Discs 4C-26
Figure 4C-84. Remove Bearing ..... 4C-26
Figure 4C-85. Remove Ring and Retainer 4C-26
Figure 4C-86. Remove Retainer Rings . 4C-26
Figu re 4C-87. Washers, Spacer and Piston 4C-26
Figure 4C-88. Remove Piston Rings 4C-27
Figure 4C-89. Remove Retaining Ring 4C-27
Figure 4C-90. Remove Front Bearing 4C-27
Figure 4C-9l. Remove Locating Ring . 4C-27
Figure 4C-92. Remove Gear and Bearing 4C-28
Figure 4C-93. Remove Inner Bearing 4C-28
Figure 4C-94. Remove Retainer Ring 4C-28
Figu re 4C-95. Remove End Plate ... 4C-28
Figure 4C-96. Remove Ring from Groove 4C-29
Figure 4C-97. Ring, Retainer and Spring 4C-29
Figu re 4C-98. Remove Clutch Discs . . . . . . 4C-29
Figure 4C-99. Transmission Reassembly Specifications 4C-30
Figu re 4C-100. Transmission Reassembly Specifications 4C-31
Figu re 4C-lOl. I nstall Sealing Rings 4C-33
Figu re 4C-102. I nstall Clutch Piston 4C-33
Figure 4C-103. Insert Disc . . . . 4C-33
Figure 4C-104. Alternate Discs 4C-33
Figure 4C-105. Install End Plate . 4C-33
Figure 4C-106. Install Retainer Ring 4C-34
Figure 4C-107. Install Inner Bearing 4C-34
Figure 4C-108. Tap Gear Into Position 4C-34
Figure 4C-109. Install Outer Bearing ... 4C-34
Figure 4C-llO. Shielded Bearing Installation 4C-35
Figu re 4C-ll 1. I nstall Locating Ring 4C-34
Figure 4C-1l2. Install Front Bearing 4C-34
Figure 4C-1l3. Install Retaining Ring 4C-36
Figu re 4C-1l4. I nstall Sealing Rings 4C-36
Figure 4C-llS. Insert Piston .. 4C-36
Figure 4C-llS. Low Clutch Return Springs 4C-36
Figure 4C-1l7. Install Snap Ring 4C-37
Figure 4C-118. Install Retainer 4C-37
Figure 4C-1l9. Bearing and Discs 4C-37
Figure 4C-120. End Plate and Ring 4C-37
Figure 4C-121. Install Bearing Spacer 4C-37
Figure 4C-122. Install Low Gear 4C-38
Figure 4C-123. Install Bearing 4C-38
Figure 4C-124. Retainer Ring 4C-38
Figure 4C-125. Install Retainer Ring 4C-38

List of Illustrations xiii

Figure 4C-126. Retainer Ring Retainer 4C-38
Figure 4C-127. Install Inner Race 4C-39
Figure 4C-128. Clutch Shaft Bearing 4C-39
Figure 4C-129. Install Retainer Ring 4C-39
Figure 4C-130. Oil Sealing Rings 4C-39
Figure 4C-131. Sealing Rings 4C-39
Figu re 4C- 132. I nstall Components 4C-40
Figure 4C-133. Install End Plate . 4C-40
Figure 4C-134. Install Retainer Ring 4C-40
Figu re 4C- 135. Output Shaft . . . . . 4C-40
Figure 4C-136. Shaft, Bearing, Thrust Washer 4C-40
Figu re 4C- 137. Th rust Washer and Bearing 4C-41
Figure 4C-138. Rear Taper Bearing 4C-41
Figure 4C-139. Bearing Cap and Cup 4C-41
Figure 4C-140. Bearing Cap and Shims 4C-41
Figure 4C-141. Check Bearing Preload 4C-42
Figure 4C-142. Rail Support and Rail 4C-42
Figu re 4C-143. Torque Support Bolts 4C-42
Figu re 4C-144. Lockscrew and Lockwire 4C-42
Figu re 4C-145. I nstall Components 4C-42
Figure 4C-146. Install Bearing 4C-43
Figu re 4C-147. Low Clutch Assembly 4C-43
Figure 4C-148. End Plate and Gear 4C-43
Figure 4C-149. Install Retainer Ring 4C-43
Figure 4C-150. Install Ring Retainer 4C-43
Figu re 4C- 151. I nstall Snap Ring 4C-44
Figure 4C-152. Snap Ring Position . 4C-44
Figu re 4C- 153. I nstall Clutch Assembly 4C-44
Figure 4C-154. Gear and Retainer Ring 4C-44
Figure 4C-155. Install Gear Assembly 4C-44
Figure 4C-156. Install Taper Bearing 4C-44
Figure 4C-157. Install Bearing Spacer 4C-45
Figu re 4C- 158. Bearing Cup .... 4C-45
Figure 4C-159. Install Bearing . 4C-45
Figure 4C-160. Chamfer Toward Bearing 4C-45
Figure 4C-161. Torque and Lockwire Bolts 4C-46
Figu re 4C- 162. I nstall Sealing Ring 4C-46
Figure 4C-163. Spacer and Nut 4C-46
Figure 4C-164. Notches in Cover 4C-46
Figure 4C-165. Torque Cover Bolts 4C-46
Figure 4C-166. Install Snap Ring 4C-47
Figure 4C-167. O-Ring and Gasket .. 4C-47
Figure 4C-168. Torque Bearing Cap Bolts 4C-47
Figure 4C-169. Install Locating Ring 4C-47
Figure 4C-170. Torque Bolts 4C-47
Fig u re 4C- 171. CI utch Disc Hub . 4C-48
Figu re 4C- 172. I nstall Retainer Ring 4C-48
Figure 4C-173. Install Fourth Clutch 4C-48
Figure 4C-174. Forward and 2nd Clutch 4C-48
Figure 4C-175. Install Piston Ring Race 4C-48
Figure 4C-176. Bearing Spacer 4C-49
Figure 4C-177. Retainer Ring 4C-49
Figure 4C-178. Free Wheel Assembly 4C-49
Figu re 4C-179. Install Th rust Washer 4C-49
Figure 4C-180. Retainer Ring 4C-49
Figure 4C-181. Locating Ring 4C-50
Figure 4C-182. Front Piston Ring .. 4C-50
Figure 4C-183. Position Turbine on Shaft 4C-50
Figure 4C-184. Turbine Retainer Ring 4C-50
Figure 4C-185. Install Lock-up Cover 4C-50
Figure 4C-186. Torque Impeller Bolts 4C-51
Figure 4C-187. Install Front Bearing . 4C-51
Figure 4C-188. Adaptor Ring and Cover 4C-51
Figure 4C-189. Torque Nuts 4C-51
Figu re 4C-190. I nstall Control Valve 4C-51

xiv
Figure 4C-191. Pump Drive Sleeves 4C-52
Figu re 4C-192. Pressu re Regulator Valve 4C-52
Figure 4C-193. Install Pump ..... . 4C-52
Figure 4C-194. Retaining Ring .... . 4C-52
Figure 4C-195. Remove Screw and Washer 4C-52
Figu re 4C-196. Remove Sleeve Lock 4C-53
Figure 4C-197. Remove Sleeve ..... 4C-53
Figu re 4C-198. Sleeve Being Removed 4C-53
Figure 4C-199. Companion Flange ..... 4C-53
Figure 4E-1. Exploded View, Planetary Hub Reducer 4E-2
Figure 4E-2. Removing Wheel Nuts 4E-3
Figure 4E-3. Removing Planet Carrier 4E-3
Figure 4E-4. Removing Oil Seal 4E-3
Figure 4E-5. Removing Seal Race .. 4E-4
Figure 4E-6. Exploded View, Steering Joint ....... . 4E-5
Figure 4E-7. Exploded View, Split Torque Differential Carrier 4E-6
Figure 4E-8. Exploded View, Standard Differential Carrier 4E-7
Figure 4E-9. Lifting Differential ...... . 4E-8
Figure 4E-10. Removing Split Torque Differential 4E-8
Figure 4E-11. Removing Bearing Cone ... . 4E-8
Figure 4E-12. Removing Planet Gear .... . 4E-9
Figu re 4E-13. Removing Differential ...... . 4E-9
Figu re 4E-14. Split Torque Differential Specifications 4E-11
Figure 4E-15. Split Torque Differential Specifications 4E-12
Figure 4E-16. Standard Differential Specifications 4E-13
Figure 4E-17. Measuring Backlash .... . 4E-14
Figure 4E-18. Checking Preload .... . 4E-15
Figure 4E-19. Checking Backlash .... . 4E-15
Figure 4E-20. Measuring Planet Gear Backlash 4E-15
Figu re 4E-21. Lock Differential ..... . 4E-16
Figure 4E-22. Measuring Distance "Y" 4E-16
Figure 4E-23. Measuring Long Gauge Standard 4E-16
Figure 4E-24. Measuring Differential .... 4E-16
Figure 4E-25. Measuring Short Gauge Standard 4E-17
Figure 4E-26. Measuring Front Housing 4E-17
Figure 4E-27. I nsta"ing Lifting Flange 4E-17
Figure 4E-28. Insta"ing Seal Race 4E-18
Figu re 4E-29. Measu ring End Positioner 4E-18
Figure 4E-30. Measuring Cover Plate ...... . .. 4E-19
Figure 4E-31. Left Hand Spiral Ring Gear Tooth Contact Patterns 4E-20
Figure 4E-32. Right Hand Spiral .Ring Gear Tooth Contact Patterns 4E-21

List of Illustrations xv
 LIST OF TABLES

Table 4A-l. Diesel Engine Troubleshooting . . . . . . . . . . . . . 4A-3

List of Tables xvii

 SUBSECTION 4A
INTRODUCTION
GENERAL
This section of the manual is divided into
subsections. Each subsection describes
major components of the drive train of
this machine and includes removal and
installation procedu res. General trou-
b
eshooting' inspection and repair pro-
cedures are covered in the individual
subsections.
DESCRIPTION
The drive train of this machine consists
of the engine, the transmission, the
drive shafts, and the front and rear ax-
les.
The drive train provides and distributes
the mechanical power used to propel and
operate this machine.
The engine provides the power which is
multipled by the transmission and di-
rected to the axles by the driveshafts
connected between the transmission and
axles. This eight speed transmission
provides the machine with four travel
speeds and with four work speeds. The
transmission also provides the power to
drive machine's hydraulic pumps through
gearing in the transmission.
TROUBLESHOOTING
To aid the mechanic in determining the
probable cause and possible remedy for
problems that might be experienced with
the engine and associated systems of this
machine; a general troubleshooting guide
is provided at the end of this
subsection.
ENGINE REMOVAL
To remove the engine, proceed as
follows:
1. Extend all four outriggers until the
outrigger floats fi rmly contact the
ground. Position the upper with the
boom over the side of the machine.
2. Remove the sheet metal and sheet met-
al supports that cover the engine.
3. Disconnect the battery cables from the
battery. Tag and remove the electrical
wiring from the starting motor.
4. Drain the engine oil. Drain and re-
move the oi I cooler.
5. Drain the coolant from the engine and
radiator.
6. Remove the tubing that leads from the
air cleaner to the engine. Remove the
air cleaner.
7. Disconnect the freon lines from the air
conditioner evaporator.
8. Disconnect the drive shaft from the
transmission.
9. Remove the exhaust pipe, at the mani-
fold. Remove the muffler.
10. Tag and disconnect the fuel lines.
11. Remove the tubing leading to the
starting aid.
12. Remove the wire harness leading to
the engine.
13. Tag and disconnect any remaining
wire harnesses, hoses or lines which may
Subsection 4A 4A-1
interfere with the engine and trans-
mission removal.
14. Support the engine by connecting a
suitable lifting device to the engine lift-
ing brackets. Then remove the engine
mounting bolts located at the front and
rear of the engine.
15. Lift the engine out of the carrier
frame and move it to a suitable work
area.
REPAIRS AND ADJUSTMENTS
Engine repairs and adjustments are cov-
ered in subsection 4B.
INSTALLATION
To install the engine, proceed as follows:
1. Ma ke a check to see that all wi ri ng,
hoses and connections are clear of the
mountings and frame.
2. Using a suitable lifting device, lower
the engine into the carrier frame.
3. Place the mounting insulators, located
at the front and rear of the engine, be-
tween the carrier frame and the engine
mountings.
4. Install the engine mounting bolts and
tighten securely.
5. Install the radiator insulators on the
frame and secu re the radiator to the
frame.
4A-2
6. Install the exhaust pipe and muffler.
7. I nstall and secure the oil coolers.
8. Connect all wiring that had been dis-
connected during engine removal.
9. Connect all air and hydraulic lines
that were disconnected during engine
removal.
10. Replace the upper and lower radiator
hoses.
11. Connect the propeller drive shaft to
the transmission.
12. Install the air cleaner bracket, air
cleaner and hose.
13. Connect the fuel lines.
14. Connect the starting aid tubing.
15. Connect the freon lines to the air
conditioner evaporator.
16. Fill the engine with oil and coolant.
See Section 3 of this manual for fluid and
lubricant specifications.
17. Replace the sheet metal support and
sheet metal that covers the engine.
18. Connect the wiring to the starter mo-
tor and connect the battery cables to the
battery terminals.
19. Start the engine and check for air,
oil and/or coolant leaks.
 Troubleshooting Guide

HARD OR NO STARTING
ABNORMAL COOLANT TEMPERATURE
LOW OIL PRESSURE
EXCESSIVE ENGINE SMOKE - WHITE OR BLUE
EXCESSIVE ENGINE SMOKE - BLACK
ROUGH lOUt ENGINE VIBRATING
POOR PERFORMANCE, OR ERRATIC ACTION
LOW POWER
CAUSE SYMPTOM RECOMMENDED REMEDY
Excessive oil in or X X X X X X Service or Replace Filter as
Restriction of Air Cleaner. Required.
Faulty Injection Pump(s). X X X X !X X Have Pump Removed and
Repaired.
...I
« Contaminated or Poor Quality Fuel. X xix X I X Drain, Clean Tanks and Filter and
a: Refill per Engine Mfg. Specs.
w
Z Cranking R.P.M. Too Low I X Check Battery and Starter.
w

Mx t±
(!) (Cold or Hot). Replace if Necessary.
Low Compression.
Exhaust Blockage. Xi Px¥x I
X
X Overhaul Engine.
Remove Obstruction, Check for
Bent or Crushed Pipes.
Incorrect Calibration. X X X X X Have Engine Re-calibrated.
Injection Pump-to-Engine !X X Ix X X Re-Time to Engine Manufacturer's
Timing Incorrect. Specifications

(!) Injection Pump Drive (Train) Worn - X X X I X Remove, Inspect and Replace
~ Coupling Keyway. Worn Parts.
::E Injection Pump X xix X Ix I X Remove Injection Pump.
i= Internal Timing Incorrect. Re-Time (Internally).
Timing Advance Device X X X X X I X Remove Injection Pump.
Not Operating Properly. Replace or Repair Advance Unit .
.
Throttle Linkage Mis-Adjusted. X X X Adjust to Engine Manufacturer's
Specifications.
Throttle Linkage Sticking, X X Check for Binding, Worn or Loose
Binding or Worn. Parts, Foreign Particles.
a: Repair or Replace Parts and
0 Adjust to Specifications.
Z
a: Improper Governor Operation. X Ix Adjust or Repair to Permit
w IX
>
0
Proper Governor Operation.
(!)
Control Rack(s) or Governor Linkage IX Xix Remove Injection Pump. Repair
Sticking or Binding.
r
Worn or Loose Governor Linkage or X X X Repair or Replace.
Components or Weak or Broken
Governor Torsion Spring.

Table 4A-l. Diesel Engine Troubleshooting (Part 1 of 3)

Introduction 4A-3
 Troubleshooting Guide (cont'd)

HARD OR NO STARTING
.,
ABNORMAL COOLANT TEMPERATURE

LOW OIL PRESSURE

ExceSSIVE ENGINE SMOKE - WHITE OR BLUE

EXCESSIVE ENGINE SMOKE - BLACK

ROUGH IDLE. ENGINE VIBRATING

POOR PERFORMANCE. OR ERRATIC ACTION

lOW POWER
CAUSE SYMPTOM RECOMMENDED REMEDY
Fuel Filters Clogged or Restricted, X X Ix X Remove and Clean or Replace,
External or Internal Fuel Leaks. X X X Inspect and Repair.
Air Leaks In Fuel Suction System. X Ix X Inspect and Correct.
Replace Parts where Required.
Restriction in Fuel Suction Lines. X Clean and Repair or
Replace Parts as Required.

w
a:
Little or No Fuel In Tank X IX X Fill Tank With Proper Grade Fuel
:;:) Supply Pump Worn or Damaged. X X X Remove Supply Pump.
IJ)
IJ) ,
Replace or Repair.
w
a: Supply Pump Relief Valve Worn or X rX X Remove Supply Pump.
0..
Stuck Open. or Spring Broken. Replace or Repair.
>
....J
~ ..•

0.. Overflow Valve Leaking or X :X X Clean and Repair or Replace.

0.. .
:;:) Stuck Open. or Spring Broken.
IJ)
....J Supply Pump Check Valves X Remove Supply Pump. Repair.
w
:;:) Not Operating Properly or Damaged.
u. I
Air in Fuel System. X X X Prime System with Hand Priming
Pump to Force Out Trapped Air.
Fuel Return Line to Tank Restricted. X X Clean and Flush.
Replace if Necessary.
Improper Grade Fuel for Temperature. X X iX X I X Drain Fuel. Fill With
Correct Grade.
Fuel Pump Inoperative. X Inspect and Correct.
Replace Parts Where Required.
Improper Oil Viscosity X X X X Drain and Replace Oil With
Proper Viscosity for Conditions.
--.:
> Oil Cooler or Filter Clogged. ,
X Remove. Clean or Replace.
....J
0..
0.. Clogged Pump Intake. X Remove and Clean. or Replace.

~
:;:)
IJ) Faulty Cooler or Pump Relief Valve. X Remove. Clean. Repair or -
-0
....J
Replace
Oil Pump Damaged. X Remove and Replace.
Low Crankcase Oil Level. X ==X Check and Add Oil.

Table 4A-l. Diesel Engine Troubleshooting (Part 2 of 3)

4A-4
 Troubleshooting Guide (cont'd)

HARD OR NO STARTING

ABNORMAL COOLANT TEMPERATURE

LOW OIL PRESSURE

EXCESSIVE ENGINE SMOKE· WHITE OR BLUE

EXCESSIVE ENGINE SMOKE - BLACK

ROUGH IOlE, ENGINE VIBRATING
POOR PERFORMANCE, OR ERRATIC ACTION

lOW POWER
CAUSE SYMPTOM RECOMMENDED REMEDY
Nozzle Defective - Leaking - Worn. X X X X X Remove, Repair or Replace,
Reassemble, Test, Set
Opening Pressure.
Incorrect Nozzle Opening Pressure X XL_ X Re-Set to Specifications.
Nozzle Cap Nut Incorrectly Torqued. X X X X X Remove, Retighten Cap Nut
Using Proper Nozzle Centering
Sleeve, Replace Copper Gasket,
Clean Engine Recess and
Re-Install in Engine.
VJ Nozzle Incorrectly Installed or X X X X X Remove, Replace Copper Gasket.
LU
..,j Torqued in Engine. Clean Recess, Reassemble to
N
N Engine (Tighten Evenly to
0
Z Require Torque Value).
Nozzle Valve Sticking.

Nozzle Spray Holes Plugged or

Partially Plugged.
Incorrect Nozzle in Engine
8:::
X X X
X

X
X

X
Remove, Clean, Repair or
Replace as Required.
Remove Nozzle. Clean Holes or
Replace Nozzle as Required.
Always Use The Correct Nozzle
Recommended For The Engine.
Do Not Mix Nozzles in The
Same Engine Unless Permitted
By Manufacturer.
Oil Lines or Connections Leaking. X Repair or Replace.

LU
(!)
<t
Lube Oil Diluted.
L~
xrx- Check for Internal Oil or Water
Leak. Drain and Replace Oil.
::.::: Fuel Supply Pump Leaking X X Replace.
<t
LU
..,j Faulty Gasket or Oil Seal. X Replace.
-0
..,j

Defective Oil Pressure Sending Unit. X Check Unit and Gauge.

Replace if Necessary.

Insufficient Coolant. X X Add Necessary Coolant. -

~ Loose or Broken Fan Belt. Check and Adjust or Replace.
LU
I-
VJ Faulty Thermostat. Replace.
>
VJ Defective Water Pump. X . Repair or Replace.
(!)
Z Coolant Passages Clogged. X . Drain and Flush Cooling
.
:::i System. Check Hoses.
0 _.
0 X Check Unit and Gauge.
U Defective Water Temperature
Sending Unit. Replace if Necessary.

Table 4A-l. Diesel Engine Troubleshooting (Part 3 of 3)

Introduction 4A-5
 SUBSECTION 48
ENGINE
GENERAL
Sub-section 4B describes the removal,
repair and installation of the engine.
General troubleshooting and inspection of
the engine are also included in this
sub-section.
An engine Serial Number Plate is located
on the left front side of the cylinder
block.
Figure 48-1. Engine Serial Number
Plate
An Engine I nformation Plate is located on
the left valve cover.
ENGINE DESCRIPTION
The engine is a 636 cubic inch displace-
ment, 4.5 inch bore, 5.0 inch stroke,
fou r stroke cycle, 8 cylinder 90 0 Vee de-
sign engine. The firing order is
1-2-7 -3-4-5-6-8 and the di rection of ro-
tation is counterclockwise, a.s viewed
from the flywheel. The engine is tu rbo-
charged with direct fuel injection.
Figure 48-2. Engine Information
Plate
SYSTEMS OPERATION
Fuel System
DESCRI PTION. The sleeve metering fuel
system is a pressure type fuel system.
The name for the fuel system is derived
from the method used to control the
amount of fuel sent to the cylinders.
This fuel system has an injection pump
for each cylinder of the engine. It also
has a fuel transfer pump on the front of
the injection pump housing. A governor
is on the rear of the injection pump hous-
ing.
The drive gear for the fuel transfer
pump is on the front of the camshaft for
the injection pumps. The carrier for the
governor weights is bolted to the rear of
the camshaft for the injection pumps.
The injection pump housing has a bear-
ing at each end to support the camshaft.
The camshaft for the sleeve metering fuel
system is driven by the timing gears at
the front of the engine.
Subsection 4B 4B- 1
 3 5
\
7
A37482-1P1 9
/ 10
Figure 48-3. Schematic of Fuel System
The injection pumps, lifters and rollers,
and the camshaft are all inside of the
pump housing. The pump housing and
the governor housing are full of fuel at
transfer pump pressure (fuel system
pressu re) .
NOTE
Diesel fuel is the only lubrication
for the moving parts in the trans-
fer pump, injection pump housing
and the governor. The injection
pump housing must be full of fuel
before tu rning the camshaft.
The fuel system has governor weights, a
thrust collar and two governor springs.
Rotation of the shaft for governor con-
trol, compression of the governor
springs, movement of connecting linkage
in the governor and injection pump hous-
ing controls the amount of fuel sent to
the engine cylinders.
4B-2
6
14
Fuel from fuel tank (7, Figure 4B-3) is
pulled by fuel transfer pump (11)
through water separator (F) (if so
equipped) and fuel filter (9). From fuel
filter (9) the fuel goes to housing for fu-
el injection pumps (14). The fuel goes
in housing (14) at the top and goes
through an inside passage to fuel trans-
fer pump (11).
From fuel transfer pump (11), the fuel
under pressure fills the housing for-the
fuel injection pumps (14). Pressure of
the fuel in housing (14) is controlled by
bypass valve (12). Pressure of the fuel
at FULL LOAD is 30:!:5 psi. If the pres-
sure of fuel in housing (14) gets too
high, bypass valve (12) will move (open)
to let some of the fuel return to the inlet
of fuel transfer pump (11).
FLOW OF FUEL USING THE PRIMING
PUMP. When the handle of primi ng pump
(2) is pulled out, negative air pressure
in prIming pump (2) opens check valve
(A) and pulls fuel from fuel tank (7).
Pushing the handle in closes check valve
(A) and opens check valve (B). This
pushes air and/or fuel into housing (14)
th rough the fuel passages and check
valve (C). More operation of priming
pump (2) will pull fuel from fuel tank (7)
until the fuel lines, fuel filter (9) and
housing (14) are full of fuel. Do this
until the flow of fuel from manual bleed
valve (5) is free of air bubbles.
CONSTANT BLEED VALVE. Constant
bleed valve (4, Figure 4B-4) lets ap-
proximately 9 gallons of fuel per hou r go
back to fuel tank (7). This fuel goes
back to fuel tank (7) through return line
for constant bleed valve (3). This flow
of fuel removes air from housing (14)
and also helps to cool the fuel injection
pump. Check valve (D) makes a re-
striction in this flow of fuel until the
pressure in housing (14) is at 8::3 psi.
A12945Pl
Figure 4B-4. Constant Bleed Valve
OPERATION OF FUEL INJECTION
PUMPS. The main components of a fuel
injection pump in the sleeve metering fu-
el system are barrel (A, Figure 4B-5),
plunger (B), and sleeve (D). Plunger
(B) moves up and down inside the barrel
(A) and sleeve (D). Barrel (A) is sta-
tionary while sleeve (D) is moved up and
down on plunger (B) to make a change in
the amount of fuel for injection.
When the engine is running, fuel under
pressure from the fuel transfer pump
A
I+---B
~--c
o
E
f
2
74266-2Pl 4
Figure 48-5. Fuel Injection Sequence
goes in the center of plunger (B)
through fuel inlet (C) during the down
stroke of plunger (B). Fuel cannot go
through fuel outlet (E) at this time be-
cause it is stopped by sleeve (D), (see
position 1).
Fuel injection starts (see position 2)
when plunger (B) is lifted up in barrel
(A) enough to close fuel inlet (C).
There is an increase in fuel pressu re
above plunger (B), when the plunger is
lifted by camshaft (4). The fuel above
plunger (B) is injected into the engine
cylinder.
I njection will stop (see position 3) when
fuel outlet (E) is lifted above- the top
edge of sleeve (D) by camshaft (4).
This movement lets the fuel that is
above, and in, plunger (B) go through
fuel outlet (E) and return to the fuel in-
jection pump housing.
When the sleeve (D) is raised on plunger
(B), fuel outlet (E) is covered for a lon-
ger time, causing more fuel to be in-
jected in the engine cylinders. If sleeve
(D) is low on plunger (B), fuel outlet
(E) is covered for a shorter time, caus-
ing less fuel to be injected.
Engine 4B-3

Figure 48-6. Fuel Injection Nozzle
OPERATION OF I NJECTION NOZZLE.
The fuel injection nozzle goes th rough
the cylinder head into the combustion
chamber. The fuel injection pump sends
fuel with high pressure to the fuel in-
jection nozzle where the fuel is made into
a fine spray for good combustion.
Seal (2, Figure 46-6) goes against the
cylinder head and prevent:> leakage of
compression from the cylinder. Carbon
dam (1) keeps carbon out of the bore in
the cylinder head for the nozzle.
Fuel with high pressure from the fuel in-
jection pump goes into inlet passage (5).
Fuel then goes into passage (4) to the
area below diameter (8) of valve (7).
When the pressu re of the fuel that push-
es against diameter (8) becomes greater
than the force of spring (3), valve (7)
lifts up. When valve (7) lifts, the tip of
the valve comes off of the nozzle seat
and the fuel will go through the four
0.011 inch orifices (6) into the com-
bustion chamber.
The injection of fuel continues until the
pressure of fuel against diameter (8) be-
comes less than the force of spring (3).
With less pressu re against diameter (8),
spring (3) pushes valve (7) against the
nozzle seat and stops the flow of fuel to
the combustion chamber.
WATER SEPARATOR. The water separa-
tor is installed between the fuel tank and
the rest of the fuel system. For effi-
46-4
ciency in the action of the water separa-
tor the fuel flow must come di rectly from
the fuel tan k and th rough the water sep-
arator. This is because the action of go-
ing through a pump or valves before the
water separator lowers the efficiency of
the water separator.
The water separator can remove 95% of
the water in a fuel flow of up to 33 gph
if the concentration of the water in the
fuel is 10% or less. It is important to
check the water level in the water sepa-
rator frequently. The maximum amount
of water which the water separator can
hold is 0.8 pint. At this point the water
fills the glass to 3/4 full. Do not let the
water separator have this much water be-
fore draining the water. After the water
level is at 3/4 full, the water separator
loses its efficiency and the water in the
fuel can go through the separator and
cause damage to the fuel injection pump.
Figure 48-7. Water Separator
Drain the water from the water separator
every day or when the water level gets
to 1/2 full. This gives the system pro-
tection from water in the fuel. If the fu-
el has a high concentration of water, or
if the flow rate of fuel th rough the water
separator is high, the water separator
fills with water faster and must be
drained more often.
FUEL PUMP. Lever (1, Figu re 46-8 on
page 46-5) for the governor is connected
by linkage and governor springs (12) to
the sleeve control shafts (5). Any
movement of lever (9) will cause a
change in the position of sleeve control
shafts (5).
 Figure 48-8. Cross Section of Fuel Pump
When lever (1) is moved to give more fu-
el to the engine, lever (9) will put gov-
ernor springs (12) in compression and
move thrust collar (15) forward. As
thrust collar (15) moves forward, the
connecting linkage will cause sleeve con-
trol shafts (5) to tu rn. With this
movement of the sleeve control shafts,
levers (18) will lift sleeves (21) to make
and increase in the amount of fuel sent
to the engine cylinders.
When starting the engine, the force of
over fueling spring (14) is enough to
push thrust collar (15) to the full fuel
position. This lets the engine have the
maximum amount of fuel for injection
when starting. At approximately 400
rpm, governor weights (17) make enough
force to push spring (14) together.
Thrust collar (15) and spring seat (13)
come into contact. From this time on,
the governor works to control the speed
of the engine.
When governor springs (12) are put in
compression, the spring seat at the front
of the governor springs will make contact
with load stop lever (16). Rotation of
the load stop lever moves load stop pin
(3) up until the load stop pin comes in
contact with the stop bar or stop screw.
This stops the movement of thrust collar
(15), the connecting levers, and sleeve
control shafts (5). At this position, the
maximum amount of fuel per stroke is be-
ing injected by each injection pU!llp.
The carrier for governor weights (17) is
held on the rear of camshaft (19) by
bolts. When engine rpm goes up, in-
jection pump camshaft (19) tu rns faster.
Any change of camshaft rpm will change
the rpm and position of governor weights
(17). Any change of governor weight
position will cause thrust collar (15) to
move. As governor weights (17) tu rn
faster, thrust collar (15) is pushed to-
ward governor springs (12). When the
force of governor springs (12) is bal-
Engine 4B-5
anced by the centrifugal force of the
governor weights, sleeves (21) of the in-
jection pumps are held at a specific
position to send a specific amount of fuel
to the engine cylinders.
The parts of the dashpot work together
to make the rpm of the engine steady.
The dashpot works as piston (10) moves
in the cylinder which is filled with fuel.
The movement of piston (10) in the cyl-
inder either pulls fuel into the cylinder
or pushes it out. I neither di rection the
flow of fuel is th rough orifice (E). The
restriction to the flow of by orifice (E)
gives the dashpot its function.
When the load on the engine decreases,
the engine starts to run faster and gov-
ernor weights (17) put force against
springs (12). This added force puts
more compression on spring (12) and
starts to put spring (11) in compression.
Spring (11) is in compression because
the fuel in the cylinder behind piston
(10) can only go out through orifice.
The rate of flow through orifice (E) con-
trols how fast piston (10) moves. As the
fuel is pushed out of the cylinder by pis-
ton (10), the compression of spring (11)
becomes gradually less.
Figure 48-9. Fuel System Components
When springs (12) and spring (11) are
both in compression, their forces work
together against the force of weights
(17). This gives the effect of having a
governor spring with a high spring rate.
A governor spring with a high spring
rate keeps the engine speed from having
oscillations during load changes ..
46-6
When the load on the engine increases,
the engine starts to run slower. Gover-
nor weights (17) puts less force against
spring (12). Spring (12) starts to push
seat (13) to give more fuel to the engine.
Seat (13) is connected to piston (10) by
spring (11). When seat (13) starts to
move, the action puts spring (11) in ten-
sion. As piston (10) starts to move, a
vacuum is made inside the cylinder. The
vacuum will pull fuel into the cylinder
th rough orifice (E). The rate of fuel
flow through orifice (E) again controls
how fast piston (10) moves. Du ring this
condition, spring (11) is pulling against
springs (12). This makes the movement
of seat (13) and springs (12) more grad-
ual. This again gives the effect of a
governor spring with a high spring rate.
When the governor control lever is
turned toward the FUEL-OFF position
with the engine running, there is a re-
duction of force on governor springs
(12). The movement of the linkage in
the governor will cause fuel control
shafts (5) to move sleeves (21,
Figu re 46-9) down, and less fuel will be
injected in the engine cylinders.
To stop the engine, turn the ignition
switch to the OFF position. This will
cause the shutoff solenoid to move lin k-
age in the fuel pump housing. Movement
of the linkage will cause sleeve levers
(18) to move sleeves (21) down, and no
fuel is sent to the engine cylinders.
4
3 A92222P2
Figure 48-10. Torque Control Group

Figure 48-11. Timing Advance Unit
With no fuel going to the engine cylin-
ders, the engine will stop.
TORQUE CONTROL GROUP. When the
temperatu re of the fuel increases, the
performance of the engine decreases.
The fuel temperature compensating tor-
que control group increases the fuel set-
ting when the fuel temperature increases
to help keep engine performance normal.
The space under the cover for the tor-
que control group is completely filled
with fuel when the engine is in
operation. Bellows (1, Figure 4B-l0 on
page 4B-6) senses (feels) the temper-
atu re of the fuel. As the temperatu re of
the fuel increases, the bellows expands
(gets longer) and pushes down on the
end of rocker arm (3). This will cause
the opposite end of the rocker arm to
move up against the force of spring (2).
This will also move fuel setting screw (4)
up and increase the fuel setting. The
increase in fuel setting will keep engine
performance the same when the fuel tem-
perature increases.
When the temperatu re of the fuel de-
creases to the normal fuel temperatu re,
the bellows contracts (gets shorter) and
spring (2) pushes down on rocker arm
(3) and fuel setting screw (4). The fuel
setting will return to the normal fuel set-
ting.
TIMI NG ADVANCE UN IT. An automatic
timing advance unit (2) is installed on
the front of the camshaft (3) for the en-
gine. The automatic timing advance unit
(2) drives the gear (1) on the camshaft
for the fuel injection pump. This gear is
the drive for the camshaft for the fuel
injection pump.
Figure 48-12. Timing Advance Unit
The weights (4) in the timing advance
are driven by two slides (6) that fit into
notches made on an angle in the weights.
The slides (6) are driven by two dowels
which are in the drive gear for the en-
gine camshaft. As centrifugal force
(rotation) moves weights (4) outward
against the force of springs (5), the
movement of the notches in weights (4)
will cause the slides to make a change in
the angle between the timing _advance
gear and the two drive dowels in the
drive gear for the engine camshaft.
Since the timing advance unit drives the
gear (1) on the camshaft for the fuel in-
jection pump, the fuel injection timing is
also changed.
The automatic timing advance unit will
change the timing 5 degrees. This
change starts at approximately low idle
rpm and is operating up th rough the rat-
ed speed of the engine. No adjustment
can be made to the automatic timing ad-
vance unit.
Engine 4B-7
Lubrication oil for the timing advance
unit comes from drilled holes that con-
nect with the front bearing for the en-
gine camshaft.
Air I nlet and Exhaust System
The engine has a turbocharger (3,
Figure 48-13) located at the rear of the
engine. The exhaust gases from all of
the cylinders are used to turn the turbo-
charger. Air is pulled through the air
cleaner and adapter (2) by the tu rbo-
charger compressor wheel. The air goes
from the turbocharger through air inlet
pipe (4) to the inlet manifold (5) in each
cylinder head. The air enters the cylin-
ders when the intake valves open.
Figure 48-13. Air Inlet and Exhaust System
48-8
The exhaust gases go out of the cylin-
ders and into the exhaust ports when the
exhaust valves open. The exhaust then
goes through the exhaust manifolds (6)
to the turbocharger. The exhaust gases
enter the turbocharger turbine housing
and cause the tu rbine wheel to tu rn.
The exhaust gases leave the turbocharg-
er through the exhaust outlet.
There is a positive cran kcase ventilation
valve (1) on each valve cover. The ven-
tilation valves are connected to the air
cleaner adapter on the air inlet side of
the tu rbocharger.
When the engine load increases, more fu-
el is injected into the engine cylinders.
The volume of exhaust gas increases
which causes the turbocharger turbine
wheel and compressor impeller to tu rn
faster. The increased rpm of the impel-
ler increases the quantity of inlet air.
As the tu rbocha rger provides additional
inlet air, more fuel can be burned. This
results in more horsepower from the en-
gine.
Maximum rpm of the turbocharger is con-
trolled by the fuel setting, the high idle
speed setting and the height above sea
level at which the engine is operated.
The bea ri ngs for the tu rbocha rger use
engine oil for lubrication. The oil comes
in through the lubrication inlet passage
(5) and goes th rough passages in the
Figure 48-14. Cylinder Head and Valves
center section for lubrication of the bear-
ings. Oil from the turbocharger goes
out through the lubrication outlet pas-
sage (6) in the bottom of the center
section and goes back to the engine oil
pan.
Cylinder Head and Valves
The valves and valve system components
control the flow of inlet air and exhaust
gases into and out of the cylinder during
engine operation.
Intake valves (8, Figure 48-14) and ex-
haust valves (6) are opened and closed
by movement of these components:
crankshaft, camshaft, cam followers (2),
Engine 48-9
push rods (1), rocker arms (5), and
valve springs (9 and 10). Rotation of
the cran kshaft causes rotation of the
camshaft. The camshaft gear is driven
by, and timed to, a gear on the front of
the crankshaft. When the camshaft
turns, the cams (3) on the camshaft also
tu rn and cause the cam followers (2) to
go up and down. This movement makes
the push rods (1) move the rocker arms
(5). The movement of the rocker arms
on the rocker arm shaft (4) will make the
intake and exhaust valves in the cylinder
head open and close according to the fi r-
ing order (injection sequence) of the
engine. Two valve springs (9 and 10)
for each valve help to hold the valves in
the closed position.
There is one intake (8) and one exhaust
(6) valve for each cylinder. The valve
seat insert (7) for the intake and ex-
haust valves can be replaced. The valve
guide bore is machined in and is a part
of the cyl inder head.
Lubrication System
The lubrication system uses a six lobe,
rotor type oil pump (10, Figure 4B-15 on
page 4B-11). Bolts hold the cover for
the oil pump (11) on the front cover for
the engine (3). The gear on the crank-
shaft drives the outer rotor. The outer
rotor has rotation in a bearing in the
front cover for the engine.
The inner rotor goes on a short shaft in
front cover for the engine. The inner
rotor is driven by the outer rotor.
Oil pump bypass valve (7), in the cover
for the oil pump (11) controls the pres-
sure of the oil coming from oil pump
(10). The pump can put more oil into
the system than needed. When the pres-
sure of the oil going into the engine is
more than 55 to 80 psi the bypass valve
(7) will open. This permits the oil that
is not needed to bypass the system.
Oil from the oil pan is pulled through the
suction bell for the oil pump (12) by oil
pump (10). The oil is sent by the pump
to an oil passage in the front cover for
the engine (3). Oil from this passage
goes to the cylinder block and on to the
base for the oil cooler (8). The base for
the oil cooler is on the left side of the
engine, near the front of the engine.
Bypass valve (13) in the base for the oil
4B-1O
cooler, will let the oil go around the oil
cooler (9) when the oil is cold or if the
restriction in the oil cooler is more than
the other parts of the system. A differ-
ence in pressure of 12 to psi between the
oil inlet and the oil outlet will open the
bypass valve.
Oil from the oil cooler goes to the oil fil-
ters. Bypass valve (14) in the base for
the oil cooler will let oil go around oil fil-
ters (15) if there is a restriction in the
oil filters.
There are two pressure outlets in the
base for the oil cooler. The pressure
outlets a re on the outlet s ide of the oi I
cooler and oil filters. The pressure out-
lets are for the sending unit and switch
for the oil pressure.
Oil from the oil filters (15) goes through
a passage in the cylinder block to oil ma-
nifold (5). The oil manifold is in the
center of the cylinder block, above the
camshaft, and goes the full length of the
cylinder block. Oil goes from the oil ma-
nifold to the bearings for the camshaft.
There are grooves in the bores in the
cylinder block around the bearings for
the camshaft. The bearing surfaces
(journals) on the camshaft get lubri-
cation from these grooves through a hole
in the bearings for the camshaft.
Some of the oil goes around the grooves
and down through passages to the main
bearing bores. The main bearing bores
in the cylinder block have grooves to let
oil go to piston cooling jets (6) that
spray oil to cool the pistons and lubri-
cate the piston pin. The remaining oil
goes th rough a hole in the upper main
bearing and into a groove in the
bearing. This oil gives lubrication to
the bearing surfaces (journals) of the
crankshaft for the main bearings.
Oil gets into the crankshaft through
holes in the bearing surfaces (journals)
for the main bearings. Passages connect
each bearing surface (journal) for the
main bearing with the bearing surface
(journal) for the connecting rod next to
it.
NOTE
No.1 main bearing su rface
(journal) does not have an oil pas-
sage to a connecting rod bearing
surface (journal).
 ---\
3
10
--- ----
7
11
A90269·5P1 12
/ 13
Figure 48-15. Schematic of Lubrication System
Oil passage (4) from the rear of oil mani-
fold (5) goes up to the center housing of
the turbocharger for lubrication of the
bearings. Oil from the turbocharger
drains back to the cylinder block and
down to the oil pan.
Oil for the rocker arms comes from the
oil manifold (5) through passages in the
cylinder block. The passages in the cyl-
inder block are in alignment with a pas-
sage in each cylinder head. The passage
to the cylinder head on the left side is
near the front of the cylinder block.
The passage to the cylinder head on the
\
right side is near the rear of the cylin-
der block.
The passage in each cylinder head sends
the oil into an oil hole in the bottom of
the mounting surface of the bracket that
holds the shaft for the rocker arms.
The oil hole is in the front bracket on
the left side and in the rear bracket and
into the center of the shaft for the rock-
er arms. Oil goes along the center of
the shaft to the bearings for the rocker
arms. From the rocker arms, the oil is
pushed through small holes to give lubri-
cation to the valves, push rods, cam
followers, and camshaft lobes.
Engine 48-11
 ant is warm, the water temperatu re regu-
lators are open. When the water
temperatu re regulators are open, they
Ol~~
8S79SP1 make a restriction in the inside bypass
and the coolant goes through the radi-
~ t li JJ ~ ator top hose and into the radiator top

In
.

LJ
I

, I
1~
r::l
III

~,
/1 ' CJ
),'
'I
~
1,1
III
~ I~~
.... 11.1"
Sf .c.AIIIIGS
tan k. Coolant then goes th rough the
core of the radiator to the radiator bot-
tom tank, where it is again sent through
the cooling system. A small amount of
coolant goes through an inside bypass
{'
l

t
" '
I
I.
r,
when temperatu re regulators are open.

[TJ ~
000
I b' I b e:EoUII~C;S

1 2 5 6 7 I

Figure 48-16. Crankshaft Oil

Schematic
After the lubrication oil has done its
work, it retu rns to the oil pan for the
engine.

Cooling System
The water pump on the front cover of
the engine is driven by V-belts from the
crankshaft pulley. The inlet opening of Figure 48-17. Water Temperature
the water pump is connected to the bot- Regulators
tom radiator hose. The outlet flow of
coolant from the water pump goes NOTE
th rough inside passages in the front
cover of the engine. The water temperature regulators
are an important part of the cool-
As the coolant goes from the water ing system. They divide coolant
pump, it divides and goes th rough the flow between the radiator and the
inside passages in the front cover for inside bypass as necessary to
the engine to the cylinder block. Most maintain the correct temperature.
of the coolant goes through the cylinder If the water temperatu re regula-
block and up to the cylinder heads. tors are not installed in the
From the cylinder heads the coolant goes system, there is no mechanical
forward through orifices to the front control, and most of the coolant
cover for the engine. will take the path of least resist-
ance th rough bypass. This will
Part of the coolant going to the left side cause the engine to overheat in hot
(as seen from the flywheel) of the cylin- weather. I n cold weather, even
der block goes th rough an orifice to an the small amount of coolant that
inlet line and onto an oil cooler, to cool goes th rough the radiator is too
the lubricating oil for the engine, and much, and the engine will not get
back to the front cover of the engine to normal operating temperatu res.
through an outlet line.
From the front cover of the engine, the The radiator cap is used to keep the cor-
coolant either goes to the inlet for water rect pressure in the cooling system.
pump or to the radiator. This pressure keeps a constant supply of
coolant to the water pump. If this pres-
If the coolant is cold (cool), the water sure goes too high, a valve in the radi-
temperature regulators will be closed. ator cap opens to reduce the pressure.
The coolant will go through an inside When the correct pressure is in the cool-
bypass to the water pump. If the cool-

48-12
ing system, the valve in the radiator cap
closes.
The piston pin end of the connecting rod
is tapered to give more bearing surface
at the area of highest load. The rod is
installed on the piston with the boss on
the connecting rod on the same side as
the crater in the piston. The connecting
rod bearings are held in location with a
tab that goes into a groove in the con-
necting rod.
The force of combustion in the cylinders
is changed to usable rotating power by
the crankshaft. A gear on the front of
the cran kshaft tu rns the engine camshaft
gear and the engine oil pump. The end
play of the cran kshaft is controlled by a
thrust bearing on the No. 4 main
bearing.

Figure 48-18. Vent Valve

A vent valve is located in the front hous-
i ng next to the temperatu re regu lators.
This vent valve is used to let air out of
the cooling system when the cooling sys-
tem is filled. When the engine is in op-
eration, the vent valve will close and not
let coolant go through. This will help
increase the temperature of the coolant
at low engine loads.

Basic Block
The cylinders are a part of the cylinder
block. There are no replaceable cylinder
liners. The cylinders can be bored up
to 0.040 in. oversize for reconditioning.
The cylinders in the block are at a 90 0
angle to each other. Five main bearings
in the block ;support the crankshaft.
Figure 48-19. Vibration Damper
There is one cylinder head for each bank
of the engine. Each cylinder has one in- The twisting of the crankshaft, due to
take and one exhaust valve. Valve the regular power impacts along its
guides are a part of the cylinder head length, is called twisting (torsional) vi-
and cannot be replaced. Valve seat in- bration. The vibration damper is in-
serts for the intake and exhaust valves stalled on the front end of the
can be replaced. crankshaft. It is used for reauction of
torsional vibrations and stops the vi-
The pistons have two rings above the pi- bration from building up to amounts that
ston pin bore, one compression ring and cause damage.
one oil control ring. The oil ring is
made in one piece and has an expansion The damper is made of a flywheel ring
spring behind it. The compression ring (1, Figure 4B-19) connected to an inner
is also one piece and goes into an iron hub (3) by a rubber ring (2). The rub-
band that is cast into the piston. ber makes a flexible coupling between
the flywheel ring and the inner hub.
The piston pin is held in the piston by
two snap rings which go into the piston
pin bore.

Engine 4B-13
Electrical System
The electrical system has three separate
circuits; the charging circuit, the start-
ing circuit and the low amperage circuit.
Some of the electrical system components
are used in more than on circuit. The
batteries, circuit breaker, ammeter, ca-
bles and wires from the battery are all
common in each of the ci rcu its.
CAUTION
Never operate the alternator with-
out the battery in circuit. Making
or breaking an alternator con-
nection with heavy load on the cir-
cuit can cause damage to the
regulator.
The charging circuit is in operation when
the engine is running. An alternator
makes electricity for the charging
circuit. A voltage regulator in the cir-
cuit controls the electrical output to keep
the battery at full charge.
The starting circuit is in operation only
when the start switch is activated.
The low amperage circuit and the charg-
ing circuit are both connected to the
same side of the ammeter. The starting
circuit connects to the oppo.site side of
the ammeter.
SYSTEMS TEST AND ADJUSTMENT
Fuel System
GENERAL. Either too much fuel or not
enough fuel for combustion can cause a
problem in the fuel system.
Many times work is done on the fuel sys-
tem when the problem is really with some
other part of the engine. The source of
the problem is difficult to find, especial-
ly when smoke comes from the exhaust.
Smoke that comes from the exhaust can
be caused by a bad fuel injection valve,
but it can also be caused by one or more
of the following reasons:
1. Not enough air for good combustion.
2. An overload at high altitude.
3. Oil leakage into combustion chamber.
4B-14
4. Not enough compression.
FUEL SYSTEM I NSPECTION A problem
with the components that send fuel to the
engine can cause low fuel pressure.
This can decrease engine performance.
1. Check the fuel level in the fuel tan k.
Look at the cap for the fuel tank to make
sure the vent is not filled with dirt.
2. Check the fuel lines for fuel leakage.
Be sure the fuel supply lines do not have
a restriction or a bad bend.
3. Install a new fuel filter. Clean the fu-
el screen located in the inlet valve of
the fuel transfer pump.
4. Remove any air that may be in the
fuel system. Open the drain valve on the
fuel injection pump housing. Operate the
fuel priming pump until fuel without air
comes from the drain lines. Close the
drain valve.
To remove air from the fuel injection
lines, loosen the fuel line nuts 1/2 turn.
Move the governor lever to the low idle
position. Crank engine with the starter
motor until fuel without air comes from
the fuel line connections. Tighten the
fuel line nuts.
CHECK CYLI NDERS SEPARATELY An
easy check can be made to find the en-
gine cylinder that runs rough (misfires)
and causes black smoke to come out of
the exhaust pipe.
Run the engine at the speed that is the
roughest. Loosen the fuel line nut at a
fuel injection pump. This will stop the
flow of fuel to the cylinder. Do this for
each cylinder until a loosened fuel line is
found that makes no difference in engine
performance. Be sure to tighten each fu-
el line nut after the test before the next
fuel line nut is loosened. Check each cyl-
inder by this method. When a cylinder is
found where the loosened fuel line nut
does not make a difference in engine per-
formance, test the injection pump and
fuel injection nozzle for that cylinder.
Temperatu re of an exhaust manifold
port, when the engine runs at low idle
speed, can also indicate the condition of
a fuel injection nozzle. Low temperatu re
at an exhaust manifold port indicates no
fuel to the cylinder. This can possibly
indicate a nozzle with a defect. Extra
high temperature at an exhaust manifold
port can indicate too much fuel to the
cylinder, also caused by a nozzle with a
defect.
The most common defects found with the
fuel injection valves are:
1. Carbon on tip of the nozzle or in the
nozzle orifice.
2. Orifice wear.
3. Di rty nozzle screen.
TESTI NG FUEL I NJECTION NOZZLES
NOTE
Be sure to use clean SAE Cali-
bration Fluid when tests are made.
Dirty test fluid will damage compo-
nents of fuel injection nozzles.
The temperature of the test fluid
must be 65 to 75 D F for good test
results.
Figure 48-20. Nozzle Testing Tools
The Fuel I njection Nozzle cannot be dis-
assembled for cleaning or adjustment. Do
the tests that follow to determine if noz-
zle performance is acceptable.
Valve Opening Pressure Test.
Nozzle Flush Test.
Tip Leakage Test.
Orifice Restriction Test.
Bleedscrew Leakage Test.
NOZZLE PREPARATION FOR TEST. Be-
fore fuel injection nozzle (1) can be test-
ed, all loose carbon around the tip of the
nozzle must be removed with a brass wi re
brush (M).
NOTE
Do not use a steel brush or a wi re
wheel to clean the nozzle body or
the nozzle tip. Use of these tools
can cause a reduction of orifice
size, and this will cause a large
reduction in engine horsepower.
Too much use of the brass wire
brush (M) will also remove the
coating that is on the nozzle for
protection.
Figure 48-21. Removing Carbon Dam
Remove carbon dam (2) from fuel in-
jection nozzle (1) with needle nose pliers
and remove seal (3) from the nozzle.
Clean the groove for carbon seal dam (2)
and the body of the nozzle below the
groove with brass wire brush (M). Re-
move the carbon, but be sure not to use
the brush enough to cause damage to the
body of the nozzle.
NOTE
A change in color in the area below
the groove is normal and does not
affect the body of the nozzle.
Remove bleed screw and seal (4) from
the nozzle.
Engine 4B-15
 B74924P1
Figure 4B-22. Bleed Screw and Seal
NOTE
The bleed screw and seal must be
removed for all tests except Bleed
Screw Leakage Test.
VALVE OPENING PRESSURE TEST
1. Refer to Figu re 4B-20 on page 4B-15
I nstall tube assembly (C) on the tester.
2. Install the fuel injection nozzle with
adapter (A) on tube assembly (C). Be
su re the nozzle tip is down and extends
into extension (F) and fuel collector (J).
WARNING
When fuel injection nozzles are
tested, be sure to wear eye pro-
tection. Fuel comes from the ori-
fices in the nozzle tip with high
pressure. The fuel can pierce (go
through) the skin and cause seri-
ous injury to the operator. Keep
the tip of the nozzle poi nted away
from the operator and into the fuel
collector (J) and extension (F).
NOTE
Put a shop towel around the upper
part of the nozzle to absorb any
fuel lea kage.
3. Refer to Figu re 4B-23. Close on-off
valve (H). Open pump isolator valve
(K) .
4B-16
Figure 4B-23. Nozzle Ready for Test
4. Open gauge protector valve (E). Op-
erate the pump to make a slow increase
in pressure until the valve in the fuel in-
jection nozzle just starts to open. Read
the maximum gauge pressure at the in-
stant fluid flows from the tip.
NOTE
It is possible for the pressure
reading of the gauge to go down
fast if the valve makes a noise
(chatters) when it opens. It is al-
so possible for the pressure read-
ing of the gauge to be almost
constant when the valve in the fuel
injection nozzle opens. The valve
in the fuel injection nozzle can be
good and still not make a noise
(chatter), or not have a very fine
vapor (spray) from the orifices in
the tip of the fuel injection nozzle
during Step 4.
If the valve opening pressu re is not
within 1200 to 2350 psi, do not use the
fuel injection nozzle again.
FLUSH THE NOZZLE TEST
1. Close gauge protector valve (E).
Close on-off valve (H). Open pump iso-
lator valve (K).
NOTE
Make sure nozzle extends inside
and below the top of extension
(F) .
2. Operate the pump rapidly for th ree
full strokes.
TIP LEAKAGE TEST
1. Remove all fuel from the nozzle tip
and body with a clean cloth.
2. Put a clean cloth around the body of
the nozzle to absorb any leakage from
the bleed screw hole and to prevent any
leakage to drain down to the tip of the
nozzle.
3. Open gauge protector valve (E,
Figure 4B-23 on page 4B-16). Close
on-off valve (H). Open pump isolator
valve (K).
A25680P1
4. Make and hold for 15 seconds a pres-
su re of 200 psi less than the opening Figure 4B-24. Good Nozzle (Use
pressure measured in valve opening Again)
pressure Test and make a note of the
number of drops that fall. No more than 2. Refer to Figure 4B-20 on page 4B-15.
5 drops can fall in 15 seconds. Put the tip of the fuel injection nozzle
down inside the fuel collector (J) and ex-
5. If nozzle is not within specifications, tension (F).
DO NOT USE NOZZLE.
3. Close on-off valve (H). Open gauge
ORIFICE RESTRICTION TEST. protector valve (E) and pump isolator
valve (K).
1. Refer to Figure 4B-23 on page 4B-16.
Close gauge protector valve (E) and 4. Pump the tester until fuel injection
on-off valve (H). Open pump isolator nozzle is full of fluid and the pressure
valve (K). on the gauge is 2000 psi. There must be
no leakage between the bleed screw and
2. Point the tip of the fuel injection noz- the body of the fuel injection nozzle for
zle into the fuel collector (J) and exten- 10 seconds.
sion (F).
5. If there is leakage, replace the seal
3. Make a rapid increase in pressure and (3) . Inspect the washer face of the bolt
look at the orifice discharge when fluid for damage, replace if needed. Test the
begins to flow through the fuel injection nozzle again. If there is still leakage,
nozzle. The discharge must be the same the fuel injection nozzle must be
through all four orifices. Any change replaced.
either vertically or horizontally is an in-
dication of a bad nozzle.
BLEED SCREW LEAKAGE TEST
1. Refer to Figure 4B-22 on page 4B-16.
Install bleed screw and seal (4) in fuel
injection nozzle. Tighten the bleed
screw to a torque of 19:t7 in-Ibs.
NOTE
Do not tighten the bleed screw
more than the torque shown. The
bleed screw or seal can be dam- A25681P1
aged.

Figure 48-25. Discharge with

Restricted Orifice (Replacement
Necessary)

Engine 4B-17
 A25682P1
Figure 48-26. Discharge with
Horizontal Distortion (Replacement
Necessary)
6. If no fuel leakage is found, the fuel
injection nozzle is acceptable. Put a new
seal (3) on the nozzle. I nstall a new
carbon dam (2) in nozzle groove with
carbon seal tool eN).
Fuel I njection Lines
Fuel from the fuel injection pumps goes
to the fuel injection nozzles th rough the
fuel injection lines.
When fuel injection lines are disconnected
or removed, always put caps or plugs on
the ends to keep dirt out of the lines.
When fuel injection lines are installed, be
sure all clamps and dampers are installed
in thei r original location.
A25683P1
Figure 48-27. Discharge with
Vertical Distortion (Replacement
Necessary)
4B-18
Figure 48-28. Installing Carbon Dam
Each fuel injection line of an engine has
a special design and must be installed in
a certain location. When fuel injection
lines are removed from an engine, put
identification marks or tags on the fuel
lines as they are removed, so they can
be put in the correct location when they
are installed.
The nuts that hold a fuel injection line to
an injection nozzle and injection pump
must be tightened to the correct torque.
If the nut is loose, fuel will leak from the
connection. If the nut is tightened too
tight, the inside diameter of the line will
become smaller and cause a restriction to
the flow of fuel to the line. Use a torque
wrench and a fuel line socket to tighten
the fuel injection nuts to 30 :t5 ft-Ibs.
Fuel I njection Pumps
When injection pumps, sleeves and lifters
are removed from the injection pump
housing, keep the parts of each pump
together so they can be installed back in
thei r original location.
Be careful when disassembling injection
pumps. Do not damage the s u rfate of
the plunger. The plunger, sleeve and
barrel for each pump are made as a
set. Do not put the plunger of one pump
in the barrel or sleeve of another pump.
If one part is worn, install a complete
new pump assembly. Be careful when
putting the plunger in the bore of the
barrel or sleeve.
When an injection pump is installed cor-
rectly, the plunger is th rough the sleeve
and the adjustment lever is engaged with
the groove in the sleeve. The bushing
 Figure 4B-29. Air Inlet Pipe Figure 4B-30. Stopping the Engine
that holds the injection pump in the steel plate over the air inlet as shown to
pump housing must be kept tight. stop the engine.
Tighten the bushing to 60:!:5 lb. ft.).
Damage to the housing will result if the
bushing is too tight. If the bushing is Finding Top Center
not tight enough, the pump will leak.
No. 1 piston at top center (TOe) on the
NOTE compression stroke is the starting point
for all timing procedures.
If the sleeves on one or more of
the fuel injection pumps have been 1. Remove fitting (1) from the timing
installed wrong, damage to the en- hole (3) in the front cover. Put bolt (2)
gine is possible if cautions are not in timing hole (3).
taken at first starting. When in-
jection pumps have been removed
and installed with the fuel injection
pump housing on engine, take the
cautions that follow to stop the en-
gine, if it starts to overspeed (run
out of control).

To stop the engine in the event of over-

speed:
,. Remove the air cleaner leaving the air
inlet pipe open as shown.
2. Set the governor control at low idle.

WARNING Figure 4B-31. Fitting and Bolt

Be careful when plate is put
against air inlet opening. Due to
excessive suction, the plate can be
pulled quickly against the air inlet
pipe. To avoid crushed fingers,
do not put fingers between plate
and air inlet pipe.
3. Start the engine, and if engine starts
to overs peed (run out of control), put a
2. Turn the crankshaft counterclockwise
(as seen from the rear of engine) until
bolt (2) will go into the hole in the drive
gear for the camshaft.
3. Remove the valve cover on the right
side of the engine (as seen from rear of
engine). The two valves at the right
front of the engine are the intake and
exhaust valves for No.1 cylinder.

Engine 4B-19
 2. Turn the crankshaft counterclockwise
(as seen from rear of engine) until tim-
ing pin (2) goes into the notch in the
camshaft for the fuel injection pumps.

Figure 4B-32. Bolt (2) and Hole (3)

4. The intake and exhaust valves for No.
1 cylinder must now be closed and the
timing pointer will be in alignment with
the TDC- 1 on the damper assembly. The Figure 4B-34. Timing Pin (2)
No. 1 piston is now at top center on the
compression stroke. 3. Remove fitting from timing hole (4) in
the front cover. Put bolt (3) th rough
the front cover and into the hole with
Fuel System Adjustments threads in the timing gear. The bolt
from hole (5) can be used.
CHECKING INJECTION PUMP TIMING
ON ENG I NE. The timing of the fuel in-
jection pump can be checked and
changed if necessary, to make compen-
sation for movement in the taper sleeve
drive or worn timing gears. The timing
can be checked and if necessary changed
using the following method.

CHECKING TIMING BY TIMING PIN

METHOD

1. Remove bolt (1) from the timing pin

hole.

Figure 4B-35. Bolt and Holes

4. If the timing pin is in the notch in the
camshaft for the fuel injection pumps,
and bolt (3) goes into the hole in the tim-
ing gear th rough timing hole (4), the
timing of the fuel injection pump is cor-
rect.

NOTE

If bolt (3) does not go in the hole

in the timing gear with timing pin
(2) in the notch in the camshaft,
Figure 4B-33. Timing Hole Bolt (1) use the procedu re that follows.

4B-20

Figure 4B-36. Cover (6) and Nuts (7)
E. Turn the crankshaft counterclockwise
A. Remove nuts (7) and cover (6) for
the tachometer drive assembly.
Figure 4B-38. Puller and Bolts
(as seen from rear of engine) until
bolt (3) goes into the hole in the tim-
ing gear. With timing pin (2) in the
notch in the camshaft for the fuel in-
jection pumps, and bolt (3) in the
hole in the timing gear, the timing for
the engine is correct.

F. I nstall washer (8) and tachometer

drive shaft (9). Tighten tachometer
drive shaft to 110:t10 ft-Ibs. Remove
timi ng pi n (2).

Figure 4B-37. Washer (8) and Drive

Shaft (9)
B. Remove the tachometer drive shaft
(9) and washer (8) from the camshaft
for the fuel injection pumps.

NOTE A23857P1

Tachometer drive shaft (9) and

washer (8) are removed as an as- Figure 4B-39. Tachometer Drive Shaft
sembly.
G. Tu rn the cran kshaft two complete re-
volutions counterclockwise (as seen
C. Put puller (10) on the camshaft for from rear of engine) and put timing
the fuel injection pumps. Tighten pin (2) and bolt (3) in again. If tim-
bolts (11) until the drive gear on the ing pin (2) and bolt (3) cannot be in-
camshaft for the fuel injection pumps stalled do steps A th rough F again.
comes loose.
H. Remove bolt (3) from the timing gear
D. Remove puller (10). and install in hole (5). Install the
plug in timing hole (4). Remove tim-
ing pin (2) and install bolt (1). In-

Engine 48-21
 stall cover for the tachometer drive
assembly (6).

Fuel Setting

The procedu re that follows for fuel set-

ting can be done with the housing for
the fuel injection pumps either on or off
the engine.
The fuel ratio control must be removed
before the fuel setting is checked or ad-
justed.
The temperature of the fuel must be less
than 125 OF when checking or adjusting
the fuel setting, as the engine is Figure 48-41. Installation of Cover
equipped with a fuel temperature com-
pensated torque control. 3. Put adapter (3) and spring (4) over
zero set pin (5). Use the correct bolts
to fasten adapter (3) to the housing for
the fuel injection pumps.
4. Put screw (6) in the hole over pin (5)
and spring (4).

Figure 48-40. Shutoff Solenoid (1)

and Top Cover (2)
NOTE
Before any service work is done on
this fuel system, the outside of the
housing for the fuel injection
pumps and all parts connected to it
must be clean.
1. Remove shutoff solenoid (1) and cover
(2).
2. Put the zero set pin (5), with 17.8507
on it, in the pump housing.
Figure 48-42. Screw (6)
5. Turn screw (6) clockwise until pin
(5) is held against the housing for the
fuel injection pump. DO NOT tighten
screw (6) too tight.
6. Put clamp (7) in adapter (3).
7. Move the governor control lever to
FULL LOAD position.

4B-22

Figure 48-43. Adapter (3) and Clamp
(7)
8. Put point (9) on dial indicator (8).
Put the indicator assembly in clamp (7).
Figure 48-44. Installation of Dial
Indicator
Figure 48-45. Indicator Set on Zero
9. Adjust dial indicator (8) so both poin-
ters (10) are on "0" (zero).
10. Use wrench (11) to turn screw (6)
counterclockwise. Turn screw (6) six or
more turns.
Figure 48-46. Wrench (11)
11. Put the clip end of the ci rcuit tester
to a good ground. Put the other end of
the circuit tester on the load stop con-
tact.
Figure 48-47. Circuit Tester
12. Move the governor control lever to
the LOW I DLE position.
13. Move the governor control lever slow-
ly toward the HIGH IDLE position until
the continuity light just comes on. Make
a note of the reading on dial indicator
(8). Do this step several times to make
sure the reading is correct.
14. Make a comparison of this reading
and the specified 0.170" full load static
fuel setting.
Engine 4B-23
15. If the reading on the dial indicator
(8) is not correct, do the following:
17
16. Use wrench (18) and loosen locknut
(19) .

Figure 48-48. Adjustment of Fuel Figure 48-49. Fuel Setting

Setting Adjustments
17. Use screwdriver (16) to turn adjust- tor as shown in "Fuel Setting" on page
ment screw (17) until the reading on dial 48-22, Steps 2 through 10.
indicator (8) is 0.170".
18. When the adjustment is correct,
tighten locknut (19). Check the adjust-
ment again by doing Steps 11 through 15
a9 ain .
NOTE

The same tools that are used in

this procedure are also used for
the fuel ratio control adjustment.

Fuel Ratio Control Adjustment

NOTE
The fuel setting must be correct
before an adjustment is made to
the fuel ratio control. Refer to
"Fuel Setting" on page 48-22.
1. Remove shutoff solenoid (1) and cover
(2). Install tools and "zero" dial indica-
Figure 48-50. Removal of Covers
2. To check the fuel ratio control
setti ng, move the governor lever s~owly
to the high idle position. Make a record
of the reading on the dial indicator.
Compare the reading with the specified
0.122" fuel ratio control setting.

48-24
 Figure 48-51. Fuel Ratio Control
Setting
3. If an adjustment is needed, remove
th ree bolts (3) from the fuel ratio
control. Hold the governor lever in the
high idle position and turn flange (4)
until the fuel ratio control setting is cor-
rect.
4. Move governor lever to low idle and
again move the lever slowly to high idle
to check the fuel ratio control setti ng.
5. Install bolts (3). Flange (4) can be
turned a small amount to give alignment
for bolts.
6. Remove tools and install cover (2) and
shutoff solenoid (1).
Figure 48-52. Flange (4)
NOTE
Before any service work is done on
the fuel system, the outside of the
injection pump housing and all
parts connected with it must be
clean.
1. Remove the fuel sh utoff solenoid (1),
top cover (2) of the fuel pump housing
and the cover over the torque control
group.

Crossover Levers
CHECKI NG CROSSOVER LEVERS
NOTE
The crossover levers normally do
not need checking unless one or
more of the following conditions ex-
ist.
Figure 48-53. Shutoff Solenoid (1)
1. The engine produces too much black and Top Cover (2)
smoke.
2. Remove the fuel that is in the in-
2. The engine runs rough because fuel jection pump housing and the governor
delivery is not even. housing.
3. Some cylinders continue to fire at fuel 3. Put calibration pin (3) in calibration
shutoff position. hole as shown.
4. The complete injection group is being 4. I nstall the adapter (7) as shown.
reconditioned. Fasten it in position with bolts (5 and
6).

Engine 4B-25
 6. Adjust low idle screw (8) to position
lever (9) to 36±0.04 in. from governor
housing boss.

Figure 48-54. Calibration Pin (3)

Figure 48-57. Crossover Lev~rs

7. Loosen the bolts that hold sleeve le-

vers (A) and slide levers (A) out of the
way.

Figure 48-55. Adapters, Screws and

Bolts
5. Put setscrew (4) in the hole over a
calibration pin (3). Tighten the set-
screw (4) to 20 to 25 in-Ibs with a
socket.

Figure 48-58. Gauge (13) and Shafts

(14 and 15)
8. Put gauge (13) on shafts (14 and 15).
Slide gauge (13) toward crossover levers
(10 and 11) until dowel pin (12) goes in-
to hole in gauge (13).
9. If dowel pin (12) must be lifted to go
into the hole in gauge (13), the levers
must be adjusted. See "Adjustment of
Crossover Levers" on page 4B-27.
10. If gau~e (13) must be lifted more
than 0.008' to let dowel pin (12) go into
Figure 48-56. Screw (8) and Lever the hole in gauge (13). See "Adjustment
(9) of Crossover Levers" on page 4B-27.

4B-26
 5. Put setscrew (4) in the hole over the
calibration pin (3). Tighten the set-
screw (4) to 20 to 25 in-Ibs with a
socket.
6. Adjust low idle screw (8) to position
lever (9) to 35±0.04 in. from governor
housing boss.

Figure 48-59. Gauge (13) and Feeler

Gauge (16)
11. To check the maximum clearance of
0.008" that is acceptable under one side
of gauge (13), hold the center and one
side of gauge (13) against sleeve lever
shaft (15). Use a feeler gauge (16) to
check clearance.
Figure 48-60. Dowel Pin (12) and
NOTE Levers
After the checking of the crosso- 7. Loosen the bolts that hold sleeve le-
ver levers is complete, the two fu- vers (A) and slide levers out of the way.
el injection pumps must be
calibrated where sleeve levers
have been moved to install a
gauge. See "Checking Fuel Pump
Calibration" on page 48-28.

ADJUSTMENT OF CROSSOVER LEVERS

1. Remove the fuel shutoff solenoid (1)
top cover (2) of the fuel pump housing
and the cover over the torque control
group.
2. Remove the fuel that is in the in-
jection pump housing and the governor
housing.
3. Put calibration pin (3) in calibration Fi~ure 48-61. Lever, Pin in~Gauge
hole.
8. Loosen the bolts that hold crossover
4. Install adapter (7). Fasten it in posi- lever (10 and 11) and move lever (10) off
tion with bolts (5 and 6). dowel pin (12).

Engine 48-27
 13. Check the adjustment again with
gauge (13).
NOTE

After the adjustment of the cross-

over levers is completed, all of the
fuel injection pumps must be cali-
brated. See "Checking Fuel Pump
Calibration. "

Checking Fuel Pump Calibration

The following procedu re for fuel pump
Figure 4B-62. Adjustment of calibration can be done with the housing
Crossover Levers for the fuel injection pumps on or off the
engine.
9. Put gauge (13) on shafts (14 and 15).
Put crossover lever (11) in position so NOTE
dowel pin (12) will fit in gauge hole.
Hold gauge (13) down and torque the Before any service work is done on
bolt that holds crossover lever (11) to this fuel system, the outside of the
24&P2 in-Ibs. injection pump housing and all
parts connected to it must be
10. Check adjustment again with gauge clean.
(13). Put gauge (13) on shafts (14 and
15), slide gauge toward crossover lever
(11) to engage dowel pin (12) into hole
in gauge (13).
11. If dowel pin (12) must be lifted to go
into gauge, the lever must be adjusted
again. If gauge (13) is lifted, a maxi-
mum of 0.008" in.) clearance is accepta-
ble under one side of gauge (13). Use a
feeler gauge to check clearance.
12. Slide crossover lever (10) onto dowel
pin (l~). Torque the bolt that holds
crossover lever (10) to 24±2 in-Ibs.

Figure 4B-64. Fuel Pump Tools

1. Remove the fuel shutoff solenoid -(9),
top cover (1) of the fuel pump housing
and the cover over the torque control
group.
2. Remove the fuel that is in the in-
jection pump housing and the governor
housing.

Figure 4B-63. Tightening Bolt

4B-28
 5. Put screw (11) in the hole over cali-
bration pin (7). Tighten screw (11) to
20 to 25 in-Ibs.

Figure 48-65. Solenoid (9) and Cover

(10)
3. Install calibration pin (7) in the cali-
bration hole. Pin has 15.9410 on it.
Figure 48-68. Screw (15) and Lever
(16)
6. Adjust low idle screw (15) to position
lever (16) to 35±0.04 in. from governor
housing boss.
7. Use a fuel injector wrench and remove
the fuel injection pumps to be checked.
NOTE
If pump is removed ca refully, the
sleeve will remain in the plunger.
If sleeve falls off the pump plung-
er du ring removal, find it imme-
Figure 48-66. Calibration Pin (7) diately and replace it on the pump
plunger before you remove another
4. I nstall an adapter (13) as shown. pump. The original sleeve must
Fasten it in position on the injection remain with the same pump
pump housing with bolts (12 and 14). plunger.

NOTE
When sleeve is installed on pump
plunger, the narrower of the two
lands on the sleeve must be toward
top of pump (nea rest the pump
spring) .

8. Clean the barrel and plunger of cali-

bration pump (1). Put clean diesel fuel
on the calibration pump for lubrication.

Figure 48-67. Installing Adapter and

Screw

Engine 4B-29
 Figure 48-69. Calibration Pump (1)
9. Put calibration pump (1) in the place
of the pump to be checked with the flat
place (20) on the plunger toward tang
(17) on lever (18). When the calibration
pump (1) is all the way in the bore, turn
it 180 0 in either clockwise or counter-
clockwise di rection. Tang (17) on lever
(18) is now in groove (19) of calibration
pump (1). Then install bushing (2).
Use a fuel injector wrench and a torque
wrench to tighten the bushing to GO±5
ft-Ibs.
NOTE
Use bushing (2) and calibration
pump (1) together. The contact
surfaces of the standard bushing,
fuel injection pump and the hous-
ing for the fuel injection pumps
are sealing surfaces. Keep them
clean and free of scratches to pre-
vent leaks.
18
20
Figure 48-70. Calibration Pump
Installed
4B-30
Figure 48-71. Putting Indicator on
Zero
10. Put dial indicator (4) on microgauge
(3) and hold them together tightly. Loo-
sen lockscrew (21) and tu rn the face of
dial indicator (4) to put the pointer at
"0". Tighten lockscrew (21).
11. Remove dial indicator (4) from micro-
gauge (3). Look at the face of dial indi-
cator (4) and put dial indicator (4) on
microgauge (3) again. The pointer must
move th rough one to one and one half
revolutions before stopping at exactly
"0". If the number of revolutions is not
correct, loosen the lockn ut on collet
(23), and adjust the position of the dial
indicator until the adjustment is correct.
NOTE
If locknut (22) on the collet (23) is
too tight, it can cause interference
in the operation of the dial indica-
tor.
12. Put clamp (25) in the position shown,
next to the transfer pump end. Clamp
(25) pushes shaft (24) down against the
bottom of its bea ri ng. The other end of
shaft (24) is held down against its bear-
ing by calibration pin (7) which is held
by screw (11). The combination of forc-
es from clamp (25) and calibration pin
(7) is necessary to hold shaft (24) in its
normal operating position against the lift-
ing force from the spring in calibration
pump (1).
 Figure 48-72. Shaft (24) and Clamp Figure 48-74. Clamps (25)
(25)
14. If the dial indicator (4) reading is
more than :to.050 mm from "0.00" (out-
side the TOTAL TOLERANCE), do Steps
17 through 20, described under "Check-
ing Fuel Pump Calibration" on page
48-28.

CAUTION

Maximum permissible tolerance for

pump readings in any FUEL IN-
JECTION PUMP GROUP is 0.100 mm
(-0.050 to +0.050 mm on dial indi-
cator ).

Maximum permissible differences

between any two pumps in the
Figure 48-73. Dial Indicator (4) and same FUEL INJECTION PUMP
Clamp (25) GROUP is 0.050 mm.

NOTE TOTAL TOLERANCE shows the

maximum permissible range of poin-
When checking pumps on the ter positions which are acceptable.
"slave" side - side opposite gover- If any reading is outside the range
nor control lever (16) - put clamp of TOTAL TOLERANCE, see "Ad-
(25) on both ends of sleeve shaft justment of Fuel Pump Calibration"
as shown. on page 4B -32.

BAND is an example only. It

13. Put dial indicator (4) on the cali-
bration pump (1) as shown. Hold it
tightly in place. Move shaft (24) toward
the governor end to remove end play.
To remove any clearance in the linkage,
lift the crossover lever dowel and rapidly
let it go. Do this several times. Then
look at the reading on the dial indicator
(4) .
shows a 0.050 mm range. - This
range shows the maximum permis-
sible difference between any two
readings for all the pumps. If any
two readings are farther apart
than the 0.050 mm range, see "Ad-
justment of Fuel Pump Calibration"
on page 48 -32.

If the dial indicator (4) reading is near

either end of the TOTAL TOLERANCE,
check another pump. If the next read-
ing is outside the TOTAL TOLERANCE or

Engine 48-31
if the two readings have a difference of 4. Loosen bolt (26). Turn the lever (18)
0.050 mm or more, do the Steps 15 on shaft (24) enough to move the top of
through 19, "Adjustment of Fuel Pump plunger (28) of calibration pump (1) be-
Calibration" on page 48-32. low top surface (27) of calibration pump
(1). Tighten bolt (26) just enough for
NOTE lever (18) to hold plunger (28) station-
ary.
The mechanic doing the checking
must make the decisions of which NOTE
and how many pumps to check ac-
cording to the symptoms of the fu- When bolt (26) has the correct
el injection pump being tested. torque, pushing with a small
amount of force on lever (18)
through the wrench moves plunger
15. If the dial indicator (4) readings for (28) in calibration pump (1).
all the pumps are within the limits in
Step 13, the calibration is acceptable.
Remove the tooling, and install the parts
which were removed.
NOTE
For troubleshooting purposes, if
the dial indicator (4) reading is
"0" or near "0", the calibration of
the other pumps is probably in the
tolerance.

Adjustment of Fuel Pump Calibration

1. Remove all pumps.
2. Clean the barrel and pump of cali-
bration pump (1). Put clean diesel fuel
on the calibration pump (1) for lubri-
cation.
3. Install calibration pump (1) in the
place of one of the pumps according to
the procedu re in Step 9.
Figure 48-76. Lever (18), Bolt (26)
and Wrench (A)
5. Move shaft (24) toward the governor
to remove end play. Then push down on
lever (18) through the wrench until top
of plunger (28) is almost even with top
surface (27) of calibration pump (1) as
shown.

Figure 48-77. Plunger

Figure 48-75. Dial I~dicator Reading

48-32
6. Check dial indicator (4) according to
Step 10 of "Checking Fuel Pump Cali-
bration" on page 4B-28. Then put dial
indicator (4) in place over the center of
calibration pump (1) and hold it there
tightly. Now move plunger (28) of cali-
bration pump (1) by pushing on lever
(18) through the wrench. Stop moving
the plunger when the dial indicator is at
approximately 0.009 mm past "0.000".
Tighten bolt (26) to 24±2 in-Ibs.
NOTE
When moving plunger (28), make
sure that the last direction of
plunger (28) movement is in the up
direction. If plunger (28) goes up
too far, move plunger (28.) down to
a position below that desi red.
Then move plunger (28) up to the
desired position.
NOTE
The action of tightening bolt (26)
usually changes the reading on di-
al indicator (4) by approximately
(0. 010 mm) in the minus di rection.
CALIBRATION
TOLERANCE
74075P2
Figure 4B-78. Calibration Tolerance
Move shaft (24) toward shutoff several
times to remove clearance in the linkage.
Dial indicator (4) reading must be
(0.00±0.010 mm) as shown.
When the pump calibration is correct
make a record and then do the same pro-
cedu re for all the other pumps.
NOTE
When calibrating pumps on the
"slave" side - side opposite control
lever (16) - put clamp (25) on
both ends of the sleeve shaft as
shown in Figure 4B-74 on page
4B-31.
Governor Adjustments
NOTE
A mechanic with training in gover-
nor adjustments is the only one to
make the adjustment to the set
point rpm.
Engine rpm must be checked with an ac-
cu rate tachometer.
LOW IDLE ADJUSTMENT
WARNING
To help prevent an accident
caused by parts in rotation, work
carefully around an engine that
has been started.
Start the engine and run until the tem-
peratu re of normal operation is reached.
Check low idle rpm with no load on the
engine. If an adjustment is necessary,
use the procedu re that follows:
2
Figure 4B-79. Bolt (1) and Locknut
(2)
Engine 4B-33
 Figure 4B-80. Bolt 0), Locknut (2)
--
-.

Figure 4B-81. Engine Set Point

and Cover (3) Indicator
To adjust the LOW IDLE rpm, start the fuel system operation of the engine is
engine and run with the governor in the correct. The set point for the engine is:
low idle position. Loosen locknut (2) for
low idle screw (1). Turn the low idle • At 20 rpm greater than full load speed.
screw to get the correct low idle rpm.
I ncrease engine speed and retu rn to low • The rpm where the fuel setting adjust-
idle and check low idle speed again. ment screw and stop or fi rst . torque
Tighten the locknut. spring just make contact.
CHECKING SET POINT. The engine set Check the set point as follows.
point is an adjusted specification and is
important to the correct operation of the 1. Connect an accu rate tachometer to the
engine. High idle rpm is NOT an ad- tachometer drive.
justed specification. Set point is full
load rpm plus an additional 20 rpm. Set 2. Connect the clip end of a circuit test-
point is the rpm at which the fuel setting er to the brass terminal screw (4) on the
adjustment screw and stop or first tor- governor housing. Connect the other
que spring just start to make contact. end of the tester to a place on the fuel
At this rpm the fuel setting adjustment system which is a good ground con-
screw and stop or fi rst torque spring nection.
still have movement between them. When
additional load is put on the engine, the
fuel setting adjustment screw and stop or
fi rst torque spring will become stable
against each other. Set point is con-
trolled by the fuel setting and the high
idle adjustment screw.
There is a new and more accurate method
for checking the "set point," formerly
called the balance point, of the engine.
If the tools for the new method are not
available, there is an alternate method
for checking the "set point. "
An engine set point indicator with Multi-
tach can be used to check the set point.
Refer to instructions supplied with indi-
cator. Figure 4B-82. Brass Terminal Screw
(4 )
If the set point is correct and the high
idle speed is within specifications, the

48-34
 WARNING
Work carefully around an engine
that is running. Engine parts that
are hot, or parts that are moving,
can cause personal injury.
3. Start the engine.
4. With the engine at normal conditions
for operation, run the engine at high
idle.
5. Make a record of the speed of the en-
gine at high idle.
6. Add load on the engine slowly until
the circuit tester light just comes on
(minimum light output). This is the set
point.
7. Make a record of the speed (rpm) at
the set point.
8. Repeat Step 6 several times to make
su re the reading is correct.
9. Stop the engine. Make a comparison
of the records from Steps 5 and 7 with
the information from the ENGINE INFOR-
MATION PLATE. The set point should
be 2620 rpm. The tolerance for the set
point is ±10 rpm. The tolerance for the
high idle rpm is ±50 rpm. If the read-
ings from Steps 5 and 7 are within the
tolerance, no adjustment is needed.
NOTE
It is possible in some applications
that the high idle rpm will be less
than the lower limit. This can be
caused by high parasitic loads
such as hydraulic pumps, com-
pressors, etc.
ADJUSTING SET POINT
1. If the set point and the high idle rpm
are within tolerance, no adjustment is to
be made.
2. If the set point rpm is not correct,
remove cover (3) and loosen locknut (6).
Turn adjustment screw (5) to adjust the
set point to the mid point of the toler-
ance.
3. When the set point is correct, check
the high idle rpm. The high idle rpm
Figure 48-83. Screw (5) and Locknut
(6)
must not be more than the high limit of
the tolerance.
If the high idle rpm is more than the
high limit of the tolerance, check the
governor spring and flyweights. If the
high idle rpm is less than the low limit of
the tolerance, check for excess parasitic
loads and then the governor spring and
flyweights.
Air inlet and Exhaust System
GENERAL. There will be a reduction of
horsepower and efficiency of the engine
if there is a restriction in the ai r inlet or
exhaust system.
Air flow through the air cleaner must not
have a restriction (negative pressure
difference measu rement between atmo-
spheric ai rand ai r that has gone
through air cleaner) of more than 25 inch
of water.
Back pressure from the exhaust (pres-
sure difference measurement between ex-
haust at outlet elbow and atmospheric
ai r) must not be more than 27 inch of wa-
ter.
MEASURING PRESSURE IN MANIFOLD.
The efficiency of an engine can be
checked by comparing the pressure in
the inlet manifold with the specifications.
This test is used when there is a de-
crease of horsepower from the engine,
yet there is no real sign of a problem
with the engine.
The correct pressure for the inlet mani-
fold is 75, plus 26 or minus 13, inches of
Engine 4B-35
mercury. Development of this informa-
tion is done with these conditions:
• 29.4 inch of mercury barometric pres-
sure.
• 85°F outside air temperature.
• 35 API rated fuel.
Any change from these conditions can
change the pressure in the inlet
manifold. Outside ai r that has higher
temperature and lower barometric pres-
sure than given above will cause a lower
horsepower and a lower inlet manifold
pressure measurement than 75, plus 26
or minus, 13 inches of mercury. Outside Figure 48-84. Pressure Test Kit
ai r that has a lower temperatu re and a
higher barometric pressure will cause that fuel injection is wrong, so more
higher horsepower and a higher inlet checking of the cylinder will be needed.
man ifold pressu re measu rement.
An analysis of the engine cylinder condi-
tion can be done by using controlled
CAUTION pressu re ai r th rough the cylinder head.
Be sure air inlet and exhaust pas- 1. Remove a fuel injection nozzle.
sages are not restricted when you
check pressure in the inlet mani- 2. Connect an ai r hose to an adapter.
fold. Install the adapter in the fuel injection
nozzle opening in the cylinder head.
A difference in fuel rating will also 3. Start crankshaft rotation until the pi-
change horsepower and the pressure in ston in the cylinder being inspected is at
the inlet manifold. If the fuel is rated TC on the compression stroke. I n this
above 35 API, pressure in the inlet mani- position, the valves of this cylinder will
fold can be less than given in the Fuel be against their seats.
Setting and Related I nformation Fiche.
If the fuel is rated below 35 API, the 4. Force air into the cylinder and then
pressure in the inlet manifold can be check for air leakage. An air leak from
more than 101 inches of mercury. the exhaust opening is an indication of
exhaust valve leakage and an air leak
Use an engine pressu re test kit to check from the ai r cleaner inlet is an indication
the pressure in the inlet manifold. This of intake valve leakage. If the air leak-
kit has a gauge for reading pressure in
the inlet manifold. The kit includes en-
gine pressu re test instructions.
CYLINDER COMPRESSION TEST. An
engine that runs rough can have a leak
at the valves, or valves that need ad-
justment. Run the engine at the speed
that gives rough running. To find a cyl-
inder that has low compression or does
not have good fuel ignition, loosen a fuel
line nut at a fuel injection pump. This
will stop the flow of fuel to that
cylinder. Do this for each cylinder until
a loosened fuel line is found that makes
no difference in engine rough running.
Be sure to tighten each fuel line nut af-
ter the test before you loosen the next
fuel line nut. This test can also indicate Figure 48-85. Fitting (A)

4B-36
 age is into the cran kcase du ring this
test, the piston or piston rings can be
the cause.
VALVE CLEARANCE SETTI NG. Valve
clearance is measured by inserting a
thickness gauge between the top of the
valve stem and the rocker arm.
Check and adjust valve clearance with
engine stopped. Exhaust valve lash
should range from 0.022 to 0.028 inch;
intake valve lash from 0.012 to 0.018
inch If the measurement is within this
range, valve lash adjustment is NOT NE-
CESSARY.
If the measurement is outside this range, Figure 48-87. Valve Lash Adjustment
set exhaust valve lash to 0.025 inch and
intake valve lash to 0.015 inch. 4. After the adjustment is complete, hold
adjustment screw (1) and tighten locknut
To check and adjust valve lash: (2) to 24±5 Ib-ft. After the locknut is
tightened, check the adjustment again.
1. Remove the valve covers.
5. Turn the crankshaft 180 0 counter-
clockwise (as seen from rear of engine).
The VS mark on the damper assembly will
align with the timing pointer. Adjust the
valves for No.3 and No.7 cylinders.
8--6--4--2 .. 6. Turn the crankshaft 180 0 counter-
~~~~ clockwise (as seen from rear of engine).
The TDC-1 mark on the damper assembly

•
INTAKE
.015 in. (0.38 mm) FUEL
INJECTION
<D@@@
will be in alignment with the timing poin-
ter. Adjust the valves for No.4 and No.
5 cyli nders .
o
EXHAUST
PUMPS

7. Turn the crankshaft 180 0 counter-

.025 in.(O.64 mm)
clockwise (as seen from rear of engine) .
The VS mark on the damper assembly will
align with the timing pointer. Adjust the
valves for No.6 and No.8 cylinders.
A50695P1

When the adjustment of the valve lash

Figure 48-86. Cylinder, Valve and
Pump Location
2. Turn the crankshaft counterclockwise
(as seen from rear of engine) until No. 1
piston is at top center on the com-
pression stroke. The TDC-1 mark on
the damper assembly will align with the
timi ng poi nter.
3. Adjust the valves for No.1 and No.2
cylinders. To adjust, loosen locknut
(2). Turn the adjustment screw (1) un-
til the feeler gauge (3) will go between
the end of the valve stem and the rocker
arm.
needs to be done several times in a short
period of time, it can indicate wear in a
different part of the engine. Find the
problem and make any necessary repairs
to prevent more damage to the e_ngine.
Not enough valve lash, if not corrected,
can be the cause of rapid wear of the
camshaft and cam followers. Not enough
valve lash can also be an indication of
the seats for the valves being bad.
Some reasons for the seats for the valves
becoming bad are fuel injection nozzles
with defects, restriction s to the inlet air
or dirty air filters, wrong fuel setting,
or using the engine on loads that are too
large for the engine.

Engine 48-37
Too much valve lash, if not corrected,
can cause broken valve stems, push
rods, or spring retainers. A fast in-
crease in valve lash can indicate any of
the following:
1. Camshaft and cam follower with wear.
2. Rocker arms with wear.
3. Push rods that are bent.
4. Loose adjustment screw for the valve
lash.
5. Broken socket on the upper end of
the push rod.
If the camshaft and cam followers show
signs of rapid wear, look for fuel in the
lubrication oil or dirty lubrication oil as
a possible cause when making the neces-
sary repairs.
MEASURI NG CAMSHAFT LOBES. To find
lobe lift (A) of camshaft, use the proce-
dure that follows:
A
B rectly.
~--C-----t
A91319P2
Figure 48-88. Camshaft Lobe
1. Measurement lobe height (B) of one
exhaust and one intake lobe.
2. Measure base circle (C) of one ex-
haust and one intake lobe.
3. Subtract base circle (C) dimension
(step 2) from lobe height (B) dimension
(step 1). The difference is actual lobe
lift (A).
4. The specified (new) lobe lift (A) is :
4B-38
• Exhaust lobe ............ 0.0.370 inch
• Intake lobe ............. 0.0.367 inch
5. The maximum permissible difference
between actual lobe life (STEP 3) and
specified lobe lift (Step 4) is 0.010 inch
Lubrication System
OIL LEAKAGE ON OUTSIDE OF ENGINE.
Check for leakage at the seals at each
end of the crankshaft. Look for leakage
at the oil pan gasket and all lubrication
system connections. Check to see if oil
comes out of the cran kcase breather.
This an be caused by combustion gas
leakage around the piston. A dirty
crankcase breather will cause high pres-
sure in the crankcase, and this will
cause gasket and seal leakage.
OIL LEAKAGE INTO CYLINDERS. Oil
leakage into the combustion area of the
cylinders can be the cause of blue
smoke. There are four possible ways for
oil leakage into the combustion area of
the cylinders:
1. Oil leakage between worn valve guides
and valve stems.
2. Worn or damaged piston rings, or di r-
ty oi I retu rn holes.
3. Compression ring not installed cor-
4. Oil leakage past the seal rings in the
impeller end of the turbocharger shaft.
Too much oil consumpti,: can result if oil
with the wrong viSCOSity is used. Oil
with a thin viscosity can be caused by
fuel leakage into the cran kcase, or by
increased engine temperature.
MEASURING ENGINE OIL PRESSURE.
An oil pressure gauge that has a defect
can give an indication of low oil
pressure.
An engine pressure test kit can be used
to check engine oil pressure.
This kit has a gauge for reading oil
pressure in the engine. The kit includes
instructions for testing engine oil pres-
sure.

Figure 48-89. Engine Pressure Test
Kit
1. Be sure that the engine is filled to the
correct level with SAE lOW-30 oil. If any
other viscosity of oil is used, the infor-
mation in this procedu re does not apply.
2. Connect the test kit to the main oil
manifold at location (A) or location (B).
Figure 48-90. Test Location (A)
3. Run the engine to get the oil temper-
atu re at 200:! 10 0 F .
4. Keep the oil temperature constant with
the engine at the rated rpm, and read
the pressu re gauge. Test location (A)
should read 55 to 80 psi and test location
(B) should read 50 to 75 psi with engine
oil pressure at 2800 rpm using 10W30 oil
If the results do not fall within these
pressure ranges, find the cause and cor-
rect it. Engine failure or a reduction in
engine life can be the result if engine
'''-"
:" !\91:ltl3P1
~2; \.
Figure 48-91. Test Location (8)
operation is continued with oil pressure
outside these ranges.
CRANKCASE 01 L LEVEL. Check the
level of the oil in the crankcase. Add oil
if needed. It is possible for the oil level
to be too far below the oil pump supply
tube. This will result in the oil pump
not having the ability to supply enough
lubrication to the engine components.
01 L PUMP NOT WORK CORRECTLY. The
inlet screen of the supply tube for the
oil pump can have a restriction. This
will result in cavitation and a loss of oil
pressure. Air leakage in the supply side
of the oil pump will also cause cavitation
and loss of oil pressure. If the pressure
regulating valve for the system is held in
the open (unseated) position, the lubri-
cation system cannot get to maximum
pressure. Oil pump gears that have too
much wear will cause a reduction in oil
pressure.
OIL FILTER AND OIL COOLER. A dirty
oil filter will cause a reduction in oil
pressure. When the oil filter is filled
with dirt, a restriction of oil flow
through the filter and a reduction of fil-
tered oil pressure is the result.-
The bypass valve will cause the flow of
oil to go around the filter elements when
there is a reduction to the flow through
the elements. When the bypass valve is
open, oil that is not filtered is permitted
to flow through the engine. To correct
this problem, install a new filter.
Look for a restriction in the oil passages
of the oil cooler. If the oil cooler has a
restriction, the oil cooler bypass valve in
the oil filter base will open. This will
Engine 4B-39
cause the flow of oil to go around the oil
cooler. The oil temperature will be high-
er than normal when the engine is
running. The oil pressure of the engine
will become low if the cooler has a re-
striction.
TOO MUCH BEARING CLEARANCE.
Components that a re worn and have too
much bearing clearance can cause oil
pressure to be low. Low oil pressure
can also be caused by an oil line or oil
passage that is open, broken or discon-
nected.
01 L PRESSURE IS HIGH. Oil pressure
will be high if the bypass valve for the
oil pump cannot move from the closed po-
sition.
TOO MUCH BEARING WEAR. When some
components of the engine show bearing
wear in a short time, the cause can be a
restriction in the oil passage. A broken
oil passage can also be the cause.
If the gauge for oil pressure shows the
correct oil pressu re, but a component is
worn because it is not getting enough
lubrication, look at the passage for oil
supply to that component. A restriction
in a supply passage will not let enough
lubrication get to a component and this
will cause early wear.
INCREASED OIL TEMPERATURE. Look
for a restriction in the oil and coolant
passages of the oil cooler. If the oil
cooler has a restriction, the oil temper-
ature will be higher than normal when
the engine is operated. The oil pressure
of the engine will not get low just be-
cause the oil cooler has a restriction.
Also check the oil cooler bypass valve to
see if it is held in the open position (un-
seated). This condition will let the oil
th rough the valve instead of the oil cool-
er, and oil temperature will increase.
Cooling System
DESCRIPTION. This engine has a pres-
sure-type cooling system. A
pressure-type cooling system has two
advantages. The fi rst advantage is that
the cooling system can have safe opera-
tion at a temperatu re that is higher .than
the normal boiling (steam) point of
water. The second advantage is that
this system prevents cavitation (low
pressure bubbles suddenly made in liq-
4B-40
uids by mechanical forces) in the water
pump. With this type system, it is more
difficult for an air or steam pocket to be
made in the cooling system.
Increased engine temperature usually oc-
cu rs when regular inspections of the
cooling system are not made. Visually
inspect the cooling system before testing
with test equipment.
VISUAL INSPECTION OF THE COOLING
SYSTEM
1. Check coolant level in the cooling sys-
tem.
2. Look for leaks in the system.
NOTE
Water pump seals. A small amount
of coolant leakage across the sur-
face of the "face-type" seals is
normal, and required, to provide
lubrication for this type of seal.
A hole is provided in the water
pump housing to allow this
coolant/seal lubricant to drain from
the pump housing. Intermittent
leakage of small amounts of coolant
from this hole is not an indication
of water pump seal failure. Re-
place the water pump seals only if
a large amount of leakage, or a
constant flow of coolant is ob-
served draining from the water
pump housing.
3. Look for bent radiator fins. Be su re
that ai r flow th rough the radiator does
not have a restriction.
4. Inspect the drive belts for the fan.
5. Check for damage to the fan blades.
6. Look for air or combustion gas in the
cooling system.
7. I nspect the filler cap and the surface
that seals the cap. This surface must be
clean.
TESTING THE COOLING SYSTEM. Re-
member that temperatu re and pressu re
work together. When a diagnosis is made
of a cooling system problem, temperature
and pressure will have an effect on cool-
ing system temperatures. For an exam-
ple, look at the chart to see the effect of
pressu re and height above sea level on
the boiling (steam) point of water.
A01533Pl
A

A28417-2Pl COOLING SYSTEM PRESSURE

ALTITUDE
METERS
4300
~EET

14,000
0
0
.
2
Z5
, ,
'0 55
•
'0 IS 95
10 12 14
k ,.
PSI

J700 12..000
\ \ \ \ \ \ \
\ \ \ 1\ \ \
JDOC 10.DOC

2'00 8.DOC
\ 1\ \ \ \ \\
1100 6.DOC \. \ \ \ 1\ \ \
'200 '.000
t\ \ \ \ \ \ \
600 2.000 \. \. \ 1\ \ \ :\
Figure 4B-93. Sealing Surface (A)
SEA L..£VEL.. 0 '\ \ \ \ \ 1\\
12 II 9J " ,~ 110 115 '2"C
110 '90 200 2'0 %20 ZlO 2'0 250'F To check the pressu re cap for the pres-
BOILING POINT OF WATER sure that makes the pressure cap open,
use the procedure that follows:
Figure 4B-92. Boiling Point of Water
1. Remove the pressu re cap from the ra-
CHECK I NG PRESSURE CAP. One cause diator.
for a pressure loss in the cooling system
can be a bad seal on the radiator pres- 2. Put the pressure cap on the cooling
su re cap. system pressu rizing pump.
3. Look at the gauge for the exact pres-
WARNING sure that makes the pressure cap open.
DO NOT loosen the filler or pres- 4. Make a comparison of the reading on
sure cap on a hot engine. Steam the gauge with the correct pressu re at
or hot coolant can cause severe which the pressure cap must open.
burns.
NOTE
After the engine is cool, loosen the pres- The correct pressure that makes
su re cap and let the pressu re out of the the pressu re cap open is on the
cooling system. Then remove the pres- pressure cap and is also in the
sure cap. Specifications Section.
Inspect the pressure cap carefully.
Look for damage to the seal or to the 5. If the pressure cap is bad, install a
seali ng su rface. Any foreign material or new pressure cap.
deposits on the cap, seal or sealing sur-
face must be removed. TESTING SYSTEM FOR LEAKS. To test
the radiator and cooling system for
A cooling system pressurizing pump is leaks, use the procedure that forlows:
used to test pressure caps and to pres-
sure check the cooling system for leaks.
WARNING
WARNING DO NOT loosen the filler or pres-
sure cap on a hot engine. Steam
DO NOT loosen the filler or pres- or hot coolant can cause severe
sure cap on a hot engine. Steam burns.
or hot coolant can cause severe
burns.
1. Remove the pressu re cap from the ra-
diator.

Engine 48-41
2. Make sure the coolant is over the top
of the radiator core.
3. Put the cooling system pressurizing
pump adapter (B) on the radiator.
4. Operate the pump and get a pressure
reading on the gauge that is 3 psi more
than the pressure marked on the pres-
sure cap.
5. Check the radiator for outside
leakage.
6. Check all connections and hoses for
the cooling system for outside leakage.
7. If you do not see any outside leakage
and the pressu re reading on the gauge is
still the same after 5 minutes, the radi-
ator and cooling system does not have
leakage. If the reading on the gauge
goes down and you do not see any out-
side leakage, there is leakage on the
inside of the cooling system. Make re-
pairs as necessary.
. .•tIfII'"
Figure 48-94. Pressurizing Pump
WARNING
If a pressure indication is shown
on the gauge, to avoid personal in-
jury push release valve (A) to re-
lease all pressure in the system
before removal of hose (C) from
radiator.
GAUGE FOR WATER TEMPERATURE. If
the engine gets too hot and loss of cool-
ant is a problem, a pressure loss in the
cooling system could be the cause. If
the gauge for water temperatu re shows
4B-42
Figure 48-95. Thermistor Thermometer
that the engine is getting too hot, look
for coolant leakage. If a place can not
be found where there is coolant leakage
check the accu racy of the gauge for wa-
ter temperatu reo A temperatu re gauge
of known accuracy can be installed at the
plug locations to make this check.
WARNING
Work carefully around an engine
that is running. Engine parts that
are hot, or parts that are moving,
can cause personal injury.
Start the engine and run it until the
temperatu re is at the desi red range ac-
cording to the test gauge or
thermometer. If necessary, put a cover
over part of the radiator or cause a re-
striction of the coolant flow. The
reading on the gauge for water temper-
ature must be the same as the test gauge
or thermometer within the tolerance
range in the attachment specification
charts for water temperature gauges.
WATER TEMPERATURE REGULATORS
1. Remove the regulator from the engine.
2. Heat water in a pan until the temper-
ature is 92 DC (197 OF). Move the water
around in the pan to make it all the same
temperature.
3. Hang the regulator in the pan of wa-
ter. The regu lator must be below the
surface of the water and it must be away
from the sides and bottom of the pan.
4. Keep the water at the correct temper- 1. Remove the air inlet tubing.
ature for 10 minutes.
5. After ten minutes, remove the regula-
tor and immediately measure the distance
the regulator has opened. See the spec-
ifications for the correct opening dis-
tance.
WATER PUMP PRESSURE CHECK. The
pressu re at the outlet for the water
pump tells if the shunt system and water
pump are operating correctly. To check
the pump pressure, install pressure
gauge (2) in the front cover. The pres-
sure must be minimum of 15 psi at 2800
rpm.
If the pump pressu re is less than the mi- Figure 4B-97. Disconnect Hoses and
nimum pressure: First, check the vent Tubes
tube between the radiator top tan k and
the surge tank; it must have an inside 2. Put identification marks on all hoses,
diameter of approximately 0.19 inch. tubes and lines before any discon-
nections are made.
Second, check to see that the shunt line
has a minimum inside diameter of 0.75 3. Disconnect hoses (3) and (4) from the
inch. crankcase ventilators.
4. Disconnect tubes (1) and (2).

Figure 4B-96. Bushing (1) and Gauge

(2)
DISASSEMBLY - REASSEMBLY
Air I nlet Manifold Removal
Remove the air inlet manifold as follows:
Figure 4B-98. Bracket (6) and Fuel
Lines (5, 7 and 8)
5. Remove fuel line bracket (0). Dis-
connect fuel lines (5), (7) and (8). Put
caps and plugs in the fuel lines and fuel
injection nozzles to keep dirt out of the
fuel system.

Engine 4B-43
 Figure 4B-99. Clamps, Bolts and
Manifold
6. Disconnect hose clamps (9 and 11).
Remove bolts (12) that hold the manifold
to the cylinder head assemblies. Remove
air inlet manifold (10).
Air I nlet Manifold Installation
Install the air inlet manifold as follows:
Fig~re 4B-100. Manifold, Bolts and
Hose Clamps
1. Put air inlet manifold (2) in position
on the cylinder head assemblies. Install
bolts (4). Connect hose clamps (1) and
(3) .
48-44
Figure 4B-101. Bracket and Fuel
Lines
2. Remove the protective caps and plugs
from the fuel lines and plugs from the
fuel lines and fuel injection nozzles.
Connect fuel lines (6,7, and 8). Install
fuel line bracket (5).
Figure 48-102. Hoses and Tubes
3. connect hoses (10 and 12) to the
cran kcase ventilators. Connect tubes
(9) and (11).
4. Install the air inlet tubing.
Valve Cover Removal
Remove the valve covers as follows:
 Figure 48-103. Clamp and Hose Figure 48-105. Gasket (1)
1. Loosen clamp (1). S Iide hose (2) 1. Put gasket (1) in position in the valve
away from the crankcase ventilator cover.
valve.

Figure 48-106. Valve Cover (2)

Figure 48-104. 80lts and Valve Cover
2. Put valve cover (2) in position. In-
2. Remove bolts (4) and valve cover (3). stall the bolts that hold it.
3. Remove the gasket from the valve
cover.
4. Do Steps 1 through 3 for the other
valve cover. 5 4

Valve Cover Installation

I nstall the valve covers as follows:
7 3 2 6

AS0698P1

Figure 48-107. Bolt Tightening

Sequence

Engine 48-45
3. Tighten the bolts to a torque of
120±24 in-Ibs in the number sequences
shown.

Figure 4B-110. Gasket and Ventilator

Valve
Figure 4B-108. Connect Hose (3) 1. Put gasket (2) and ventilator valve
(1) in position.
4. Connect hose (~) to the crankcase
ventilator valve. Put the hose clamp in 2. I nstall the bolts, and tighten them to
position. Tighten the hose clamp to a a torque of 30±4 in-Ibs.
torque of 20±2 in-Ibs.
3. I nstall the valve covers.
Crankcase Ventilator Valve Removal
Crankcase Ventilator Valve Disassembly
Remove the crankcase ventilator valves
as follows: Disassemble crankcase ventilator valve as
follows:
1. Remove the valve covers.

76447P2

B17414Pl

Figure 4B-111. Screws, Cover and

Figure 4B-109. Bolts (2) and Housing
Ventilator Valve (1)
1. Remove screws (2) that hold cover (3)
2. Remove fou r bolts (2), ventilator valve on housing (1).
(1) and gasket.

Crankcase Ventilator Valve Installation

Install the crankcase ventilator valves as
follows:

48-46
 76448P3 76450P2

Figure 48-112. Spring (4) Figure 48-114. Components of Inner

2. Remove cover (3) and spring (4) from
the housing.
Sleeve
5. Remove nut (12), washer (13), spacer
(11), piston (10), diaphragm (7) and the
retainer from sleeve (8).

Crankcase Ventilator Valve Assembly

Assemble the cran kcase ventilator valve
as follows:

76449P2

Figure 48-113. Remove as a Unit

3. Remove the piston, sleeve (8), retain-
er (9) and diaph ragm (7) from the hous-
ing as a unit.
76453P2
4. Remove inner sleeve (6) and gasket
(5) from the housing.
Figure 48-115. Housing, Gasket and
Inner Sleeve
1. Put cement on both sides of gasket
(2). Install the gasket on housfng (1).
2. Install inner sleeve (3) in the
housing.

Engine 48-47
 Water Separator Removal
Remove the water separator as follows:
NOTE
Element (2) is free to fall when
clamp (1) is released.

Figure 4B-116. Piston (6) and

Diaphragm (4)
3. Put piston (6) in position next to the
side of diaphragm (4) that has the iden-
tification "PISTON SIDE".
4. Put retainer (5) in the diaph ragm.

Figure 4B-118. Clamp (1) and Element

(2)
1. Remove clamp (1) and element (2).

7645OPS;

. Figure 4B-117. Insert Screw

5. Put the screw th rough sleeve (7), re-
tainer, diaph ragm and the piston.
6. Install spacer (8) and washer and nut
(9) on the screw. Figure 4B-119. Base (3) and Line (4)
7. Put cement on the contact su rfaces of 2. Disconnect line (4) from the wate-r se-
the diaph ragm. I nstall the sleeve, re- parator base.
tainer, diaphragm and piston in the in-
ner sleeve and housing. 3. Remove the two nuts and water sepa-
rator base (3).
8. Put the spring and cover in position
on the housing, and install the screws
that hold the cover in place.

4B-48
 Figure 4B-120. Bolts (6) and Bracket
(5)
4. Remove three bolts (6), bracket (5)
and the spacers.
Figure 4B-121. Bolts (6), Bracket
(5) and Spacers
Water Separator Installation
I nstall the water separator as follows:
Figure 48-122. Bracket (1) and
Spacers
1. Put bracket (1) and three spacers in
position. Install three bolts. Tighten
bolts to a torque of 10±2 ft-Ibs.
Figure 4B-123. Base (2)
2. Put base (2) in position, and install
the nuts.
Figure 48-124. Water Separator
3. Connect line (3) to the base.
Engine 4B-49
4. Put element (4) in position, and In- Fuel Filter And Base Removal
stall clamp (5).
Remove the fuel filter and base as
NOTE follows:
Make sure clamp (5) is tight be-
cause element (4) is free to fall.

Oil Pan Removal

Remove the oil pan as follows:

Figure 4B-126. Lines (1, 2 and 3)

1. Disconnect lines (1, 2, and 3) from
the base.

Figure 4B-125. Bolts (1) and Oil Pan

(2)
1. Drain the oil from the engine.
2. Remove bolts (1), a nd remove oi I pa n
(2) .

Oil Pan Installation

I nstall the oil pan as follows:
Figure 4B-127. Strap Wrench
1. Install the gasket for the oil pan. In-
stall a new gasket if needed. 2. Use a suitable strap wrench to remove
fuel canister (6) and the element.
2. Put the oil pan in position on the en-
gine, and install the bolts that hold it in 3. Remove bolts (4) to remove fuel filter
place. Tighten the bolts to a torque of base (5).
17::3 ft-Ibs.

3. Tighten the oil pan drain plug to a Fuel Filter And Base Installation.
torque of 50::10 ft-Ibs.
I nstall the fuel filter and base as follows:
4. Fill the engine with oil to the correct
level.

4B-50
 Figure 4B-128. Fuel Filter Base and
Bolts Figure 4B-130. Bolts (1) and Elbow
(2)
1. Install fuel filter base (2) and bolts
(1) . 1. Remove bolts (1). Remove elbow (2)
and the gasket from the timing gear cov-
2. Install fuel filter canister (3) and the er.
element per the instructions on the cani-
ster.

Figure 4B-129. Lines (4, 5 and 6) 2. Remove water temperature regulators

(3) from the timing gear cover.
3. Connect lines (4, 5, and 6) to the fuel
filter base.
Water Temperature Regulator Installation
Water Temperature Regulator Removal Install the water temperature regulators
as follows:
Remove the water temperature regulators
as follows:

Engine 48-51
 ,. Remove the fan from the fan drive.

Figure 4B-132. Regulators (1) B99375?1

CAUTION Figure 4B-134. Nuts (1) and Fan

Be sure the water temperature re-
gulators are installed correctly. If
the regulators are not installed
correctly, engine overheating will
result.
Belts (2)
2. Release the tension on the fan belts
by loosening nuts (1) on the alternator
adjustment rod. Remove fan belts (2).

1. I nstall water temperatu re regulators

(1) in timing gear cover.

Figure 4B-135. Bolts (3) and Fan

Drive (4)
3. Remove bolts (3) to remove fan drive
Figure 4B-133. Elbow (3) and Bolts (4).
(2)
2. Install the gasket and elbow (3) on Fan Drive Installation
the timi ng gea r cover.
I nstall the fan drive as follows:
3. I nstall bolts (2) that hold elbow (3) in
place.

Fan Drive Removal

Remove the fan drive as follows:

4B-52
 Fan Drive Disassembly
Disassemble the fan drive as follows:
1. Remove the fan drive.

Figure 4B-136. Fan Drive (2) and

Bo 1ts (1)
1. Put fan drive (2) in position on timing 899376F'1
gear cover, and install bolts (1) that
hold it.
Figure 4B-138. Bolts (1) and Adapter
(2)
2. Remove bolts (1) to remove adapter
(2).

899372P1

Figure 4B-137. Fan Belts (4) and

Nuts (3)
2. Install fan belts (4). Tighten nuts
(3) on the alternator adjustment rod for
the correct fan belt tension. See Spec- Figure 4B-139. Nut, Washer and
ifications for the correct belt tension. Bearing
3. Install the fan on the fan drive. 3. Remove nut (3), washer (4) and bear-
ing (5).

Engine 48-53
 6. Remove sleeve (9) from the mounting
bracket shaft.

Figure 4B-140. Bearing Spacer (6)

4. Remove bearing spacer (6) from the
shaft.

Figure 4B-143. Seal (10)

7. Remove seal (10) from the pulley.

899379P1

Figure 4B-141. Pulley (7) and

Bracket (8)
5. Separate pulley (7) and mounting
bracket (8). Figure 4B-144. Bearing (11)
8. Remove bearing (11) from the bore of
the pulley.

89938OP1

Figure 4B-142. Sleeve (9}

4B-54
 Figure 4B-145. Bearing Races (12) Figure 4B-147. Bearing (2)
9. Remove bearing races (12) from the 2. Install bearing (2) in the bore of the
bore of the pulley. pulley.

Fan Drive Assembly

Assemble the fan drive as follows:

Figure 4B-148. Seal (3)

3. I nstall seal (3) in the pulley with
bearing tool group (A). Install the seal
with the lip toward the bearings.
Figure 4B-146. Bearing Races (1)
1. Lower the temperatu re of bea ri ng rac-
es (1), and install them in the bore of
the pulley. Use bearing tool (A) to make
sure the bearing races are completely in
thei r seats in bore of the pulley.

699387P1

Figure 4B-149. Sleeve (4)

Engine 4B-55
4. Install sleeve (4) on the mounting
bracket shaft.

Figure 4B-152. Bearing, Washer and

Nut
7. Install bearing (10). Install washer
(8) and nut (9) on the shaft.
Figure 4B-150. Pulley (5)
5. I nstall pulley (5) on mounting bracket
(6) .

Figure 4B-153. Adapter (12) and

Bol ts (11)
8. Install adapter (12) on the pulley with
Figure 4B-151. Bearing Spacer (7) bolts (11).
6. I nstall bearing spacer (7) on the 9. Install the fan drive.
shaft.
Exhaust Manifold Removal
Remove the exhaust manifolds as follows:

48-56
 3. Remove the bolts, exhaust manifold
(3) and the gasket.

Exhaust Manifold Installation

I nstall the exhaust manifolds as follows:

Figure 4B-154. Two Bolts (1)

,. Remove two bolts (1) from the
flanges.

Figure 4B-157. Exhaust Manifold (1)

,. Put the gasket and exhaust manifold
(1) in position.

Figure 4B-155. Bend Tabs on Locks

(2)
2. Bend the tabs back on locks (2).

Figure 4B-158. Locks (2) and Bolts

(3)
2. Put anti-seize compound on the bolt
th reads and tighten the bolts to a torque
of 32:t5 ft-Ibs.
NOTE
The locks must be bent on a flat
side of the bolt head. Bolts must
be turned no more than 30° (in the
direction of increased torque only)
for the alignment of the locks with
Figure 4B-156. Exhaust Manifold (3) a flat side of the bolt head.

Engine 4B-57
 Figure 4B-159. Bolts in Flange
3. Put bolts (4) and the flange in posi-
tion. Install the nuts.
Air Compressor Removal
Figure 4B-161. Hoses (3 and 4) and
Be lt (5)
2. Tag and disconnect hoses (3 and 4)
from the ai r compressor. Remove belt
(5) from the compressor pulley.

WARNING
Before any air lines or hoses are
disconnected, be sure the system's
pressure is zero.

Figure 4B-162. Bolts (7) and

Compressor (6)
3. Remove bolts (7) and ai r compressor
(6) .

Air Compressor Installation

Figure 4B-160. Lines (1 and 2) I nstall the ai r compressor as follows:
1. Tag and disconnect lines (1 and 2)
from the ai r compressor.

4B-58
 Figure 4B-163. Compressor (1) and
Bolts (2) Figure 4B-165. Lines (6 and 7)
1. Put air compressor (1) in position, 4. Connect lines (6) and (7) to the air
and install bolts (2) that hold it. compressor.

Figure 4B-164. Belt (5) and Hoses (3 Figure 4B-166. Bolt (4)
and 4)
2. I nstall belt (5) on the compressor pul- Fuel Injection Line Removal
ley.
Remove the fuel injection lines as
3. Connect hoses (3) and (4) to the air follows:
compressor.

Engine 4B-59
 Figure 4B-167. Hoses (1 and 3) and
Bolt (2)
1. Remove hose (1) from the air inlet
manifold and the crankcase ventilator
valve for clearance pu rposes.
2. Remove hose (3) from the air inlet
manifold for clearance purposes.
3. Remove bolt (2) from fuel
bracket.
Figure 4B-168. Fuel Injection Lines
(4)
4. Remove fuel injection lines group (4).
Install protective caps and plugs on all
the fuel openings to keep di rt out of the
fuel system.
Fuel Injection Line Installation
Install the fuel injection lines as follows:
4B-60
Figure 4B-169. Fuel Injection Lines
( 1)
NOTE
The fuel lines must not be in con-
tact with other fuel lines or engine
components except at connection
and clamp points.
Ii ne
1. Remove all protective plugs and caps
from the fuel openings as you install fuel
injection lines Cl) on the engine.
Figure 4B-170. Socket (A)
2. Use a socket wrench (A) to tighten
the fuel line nuts to a torque of 30±5
ft-Ibs.
3. Install bolt (3) on the fuel line brack-
et.
4. Install hoses (2) and (4) on air inlet
manifold and crankcase ventilator valve.

Figure 48-171. Hoses (2 and 4) and
80 It (3)
Fuel I njection Nozzles Removal and I n-
stallation
Remove and install the fuel injection noz-
zles as follows:
1. Remove the valve covers.
Figure 48-172. Fuel Injection
Components
2. Throughly clean the area around each
of the fuel line connections. Disconnect
fuel line connector (1). Disconnect fuel
injection fitting (2) from the adapter.
3. Remove bolt (4), the clamp and spacer
that hold the fuel injection nozzle in
place.
4. Slide the adapter from the cylinder
head assembly, and remove fuel injection
nozzles (3). If the fuel injection nozzle
cannot be removed by hand, install a
nozzle puller, and remove the nozzle.
NOTE
Before the fuel injection nozzles
are installed, check for fuel leak-
age, the pressure at which the in-
jection nozzle opens, and the
amount of fuel (spray pattern)
that comes out of the nozzle with
nozzle testing tools (A). See
"Testing Fuel Injection Nozzles" on
page 4B-15.
B98280P1
Figure 48-173. Seal Dam (6) and Seal
(5)
5. Remove carbon seal dam (6) and com-
pression seal (5). If necessary, use a
nozzle cleaning tool (E) to clean nozzle.
6. Install a new compression seal (5).
Install a new carbon seal dam (6) with a
seal tool.
7. Clean the bore in the cylinder head
assembly with a reamer. Use an open
end wrench or a tap drive to turn the
reamer.
8. Install new O-ring seals on adapter
(7) and fuel injection nozzle (3).
9. Install the fuel injection nozzle in the
cylinder head assembly. Never put lu-
bricant on the nozzle or bore in the cyl-
inder head assembly.
10. Install the adapter in the cylinder
head assembly. Connect the nozzle and
fuel injection line to the adapter. Tight-
en the nuts to a torque of 30:!:5 ft-Ibs.
11. I nstall the spacer and clamp that
holds the nozzles in the cylinder head
assembly.
Engine 4B-61

Figure 4B-174. Adapter (7) and
Nozzle (3)
12. Install the valve covers.
Rocker Shaft Removal and Installation
Remove and install the rocker shaft and
push rod assemblies as follows:
1. Remove the fuel injection nozzles.
2. Remove four bolts (3) and rocker
shaft assembly (1) from the cylinder
head assembly.
3. Put identification marks on the push
rods as to their location in the engine.
Remove push rods (2).
4. Inspect all components, and make any
replacements if necessary.
Figure 4B-175. Rocker Shaft, Push
Rods and Bolts
4B-62
CAUTION
Install the push rods in their ori-
ginal location in the engine. New
push rods can be mixed.
5. Install push rods (2). Put rocker
shaft assembly (1) in position on the en-
gine. Tighten the bolts to a torque of
18:t5 ft-Ibs.
6. Make an adjustment until the intake
valve clearance is 0.015" and the exhaust
valve clearance is 0.025 ". Tighten the
lockn uts to a torque of 24:t5 ft-Ibs. For
the valve adjustment procedures, see
"Valve Clearance Setting. II
7. Install the fuel injection nozzles.
Valve Clearance Setting
Check and adjust the valve clearance
with the engine stopped.
Valve clearance is measured with a
thickness gauge between the top of the
valve stem and the rocker arm.
Valve Clearance Check: Engine Stopped
Exhaust 0.022 to 0.028
Intake 0.012 to 0.018
NOTE
When the valve lash (clearance) is
checked, adj ustment is not neces-
sary if the measurement is in the
range given in the chart for Valve
Clearance Check: Engine Stopped.
If the measu re is outside this
range, adjustment is necessary.
See the chart for Valve Clearance
Setting: Engine Stopped.
Valve Clearance Setting: Engine Stopped
Exhaust 0.025
Intake 0.015
To check and make adjustment to the
valve lash, proceed as follows:
1. Remove the valve covers.
 timing pointer. Make adjustment to the
valves for Numbers 4 and 5 cylinders.
8--6--4--2

~~~~
•
INTAKE
.015 in. 10.38 mm) FUEL
INJECTION
o
EXHAUST
PUMPS

.025 in.IO.64 mm)

A50695P1

Figure 4B-176. Cylinder, Valve and

Pump Location
2. Turn the crankshaft counterclockwise
(as seen from the rear of the engine) un-
til Number 1 piston is at top center on
the compression stroke. The TDC-l
mark on the damper assembly will be in
alignment with the timing pointer.
3. Make adjustment to the valves to
Numbers 1 and 2 cylinders. To make the
adjustment, loosen locknut (2). Turn
adjustment screw (1) until feeler gauge
(3) will go between the end of the valve
stem and the rocker arm.
Figure 48-177. Checking Valve
Clearance
4. After the adjustment is complete, hold
adjustment screw (1) and tighten locknut
(2) to 24±5 Ib-ft. After the locknut is
tightened, check the adjustment again.
5. Turn the crankshaft 180 0 counter-
clockwise (as seen from the rear of the
engine). The VS mark on the damper
assembly will be in alignment with the
rA1~~P1f'--=:!--_.
Figure 48-178. Tightening Locknut
6. Turn the crankshaft 180 0 counter-
clockwise (as seen from the rear of the
engine). The VS mark on the damper
assembly will be in alignment with the
timing pointer. Make adjustment to the
valves for Numbers 6 and 6 cylinders.
When the adjustment of the valve lash
needs to be done several times in a short
period of time, it can be and indication
of wear in a different part of the engine.
Find the problem and make any neces-
sary repairs to prevent more damage to
the engine.
Not enough valve lash, if not corrected,
can be the cause of rapid wear of the
camshaft and cam followers. Not enough
valve lash can also be an indication of
the seats for the va Ives becomi ng bad.
Some reasons for the seats for the valves
becoming bad are fuel injection nozzles
with defects, restrictions to the inlet air
or dirty air filters, wrong fuel setting,
or using the engine on loads that are too
large for the engine.
Too much valve lash, if not corrected,
can be the cause for broken valve stems,
push rods, or spring retainers. A fast
increase in valve lash can be an indi-
cation of any of the following:
1. Camshaft and cam follower with wear.
2. Rocker arm with wear.
3. Push rods that are bent.
4. Loose adjustment screw for the valve
lash.

Engine 48-63
5. Broken socket on the upper end of
the push rod.
If the camshaft and cam followers show
signs of rapid wear, look for fuel in the
lubricating oil or dirty lubrication oil as
a possible cause when making the neces-
sary repairs.
Rocker Shaft Disassembly
Disassemble the rocker shafts as follows:
,. Remove the rocker shaft assemblies
and push rods.
A50080P1
Figure 4B-179. Rocker Shaft Assembly
2. Remove bolts (1), locks (2) and the
washers from each end of the rocker
shaft.
Figure 4B-180. Shaft (3) and Bracket
(4)
4B-64
Figure 4B-181. Rocker Shaft
Disassembly
3. Remove shaft (3) from bracket (4).
4. Remove rocker arm assemblies (7) and
the washers from shaft (3).
5. Remove screw (5) and nut (6) from
rocker arm assemblies (7).
Rocker Shaft Assembly
Assemble the rocker shafts as follows:
1. Make sure the oil holes in the rocker
arm assemblies, rocker shaft and bracket
are clean and free of all dirt and foreign
material.
2. Measure the bore of the bushing in
each of the rocker arms. The bore must
be 0.8603!0.008 ". The maximum permis-
sible bore is 0.8630 ".
NOTE
Replace the arm and bushing as a
unit if the bore is not correct.
The arms and bushings cannot be
ordered separately.
3. Measu re the diameter of the shaft at
each of the rocker a rm locations. The
diameter must be 0.8580 to 0.8588 "
The minimum permissible diameter is
0.8570 "
 A50085P1

Figure 4B-182. Rocker Shaft Assembly
4. I nstall the screws and nuts (2) into
rocker arm assemblies (4). Turn the
screws until they are 0.44 " below the
bottom of the rocker arm assemblies.
5. Install the rocker arm assemblies and
washers (3) on shaft (1) as shown.
Figure 4B-184. Bolts (6) and Locks
(7)
washers and bolts (6) . Tighten the
bolts to a torque of 18:t5 ft-Ibs.
8. Install the rocker shaft assembles and
push rods.
Valve Lifter Removal And Installation
Remove and install the valve lifters as
follows:
1. Remove the cylinder head assemblies.

Figure 4B-183. Shaft (1) and Bracket

(5)

6. Put shaft (1) and the rocker arm as-

semblies in position on bracket (5) with
the adjustment screws on the same side
as the oil hole on the bottom of the Figure 4B-185. Magnet (1) and Valve
bracket. Lifters (2)
7. Make sure the flat surfaces on shaft
(1) are turned up. Install locks (7),

Engine 4B-65
 Figure 4B-186. Valve Lifters (2) Figure 4B-188. Hose Clamps (2) and
Tubes (3)
2. Remove valve lifters (2) with magnet
(1). 2. Loosen clamps (2), and slide them
back on tubes (3).
3. Put an identification mark on each
lifter as to its location in the cylinder
block for in sta lIation pu rposes .
4. Put clean engine oil on the valve lift-
ers and camshaft lobes.
5. I nstall valve lifters (2) in their ori-
ginal position in the cylinder block.
6. I nstall the cylinder head assemblies.

Turbocharger Removal
Remove the tu rbocha rger as follows:

Figure 4B-189. Turbocharger (4) and

Bolts (5)

3. Remove two bolts (5) ; th en remove

turbocharger (4) from the cylinder block
and inlet manifold.
4. Remove two O-ring seals (6) from the
cylinder block.

Turbocharger Installation
Install the turbocharger as follows:
Figure 4B-187. Hose Clamps (1) 1. Inspect all O-ring seals for wear or
damage. Put a small amount of clean en-
1. Loosen hose clamps (1) on the inlet gine oil on the 0- ring seals.
manifold.
2. Put O-ring seals (6) in position in the
engine block.

48-66

Figure 48-190. O-Ring Seals (6)
3. Put turbocharger (4) in position on
the cylinder block, and install two bolts
(5) that hold it.
4. Tighten hose clamps (1) on the inlet
manifold.
5. Put clamps (2) in position, and tight-
en them.
Turbocharger Disassembly
Disassemble the tu rbocharger as follows:
1. Remove the tu rbocharger.
Figure 48-191. Make Alignment Marks
2. Make an alignment mark on compressor
housing (1), cartridge assembly (3) and
the turbine housing (4) for correct in-
stallation.
3. Loosen clamp assembly (2). Remove
compressor housing (1) and cartridge
assembly (3) from the turbine housing.
853097P1
Figure 48-192. 8olts, Plates and
Cartridge Assembly
4. Remove bolts (6) and plates (5) that
hold the cartridge assembly in the com-
pressor housing. Remove cartridge as-
sembly (3).
Figure 48-193. O-Ring Seal- (7)
5. Remove O-ring seal (7) from the car-
tridge assembly.
Engine 48-67
 BS3093P1 ;

Figure 48-194. Fixture (A) and Figure 48-196. Wheel Assembly (10)
Sliding T-Wrench (C)
8. Remove shaft and wheel assembly (10)
G. Put cartridge assembly (3) in position from the cartridge assembly.
using fixture (A) and loosen the nut on
the compressor wheel using a sliding
T -Wrench (C).
NOTE
To prevent a bent shaft, do not
put a side force on the tu rbine
shaft when the compressor wheel
nut is loosened.

. .
B53092P1 ;

Figure 48-197. Shroud (11)

9. Remove shroud (11) from the car-
tridge assembly.

B53094Pl
•
\ .

....,..,;..;.
~·a,(
•

Figure 48-195. Nut (8) and

Compressor Wheel (9)
7. Remove nut (8) and compressor wheel
(9).

853091P1

Figure 48-198. 8ackplate (13) and

80 lts (12)

4B-G8
10. Remove four bolts (12); then remove
backplate (13) from the cartridge assem-
bly.

Figure 4B-201. Snap Ring (16)

13. Remove snap ring (16) from the car-
853090Pl tridge housing using a retaining ring
pliers.
Figure 4B-199. Spacer (14)
11. Remove spacer (14) from the back-
plate.

Figure 4B-202. Bearing (17)

B53089P1 .
14. Remove bearing (17) and the rings
from the cartridge housing.
Figure 4B-200. Two Seal Rings (15)
12. Remove two seal rings (15) from the
spacer.

B53086P1

Figure 48-203. Snap Ring (18)

Engine 4B-69
15. Remove snap ring (18) from the car-
tridge housing using a retaining ring
pliers.

Figure 4B-206. Snap Ring (23)

8S3085P1

Figure 4B-204. Screws, Plate and

Collar
16. Turn the cartridge housing over;
then remove screws (20), plate (1) and
collar (19).

Figure 4B-207. Turbocharger Assembly

CAUTION

Make sure all the oil passages in

the turbocharger cartridge hous-
ing are clean and free of dirt and
B53Q8.4P1 foreign material. Put clean engine
oil on all parts of the cartridge as-
sembly.
Figure 4B-205. Bearing (22)
1. Install snap ring (1) in the cartridge
17. Remove bearing (22) from the car- housing using a retaining ring pliers.
tridge housing.
18. Remove snap ring (23) from the car- CAUTION
tridge housing using a retaining ring
pliers. Make sure the oil hole in plate (5)
is open and clean to prevent a
bearing failure.
Turbocharger Assembly
Assemble the tu rbocha rger as follows: 2. Install bearing (2), collars (3), plate
(5) and screws (4). Tighten the screws
to a torque of 22 in-Ibs.

4B-70
 B53106P1

Figure 4B-210. Spacer (12)

Figure 4B-208. Install Rings and
Bearing 5. Install spacer (12) in the backplate.
3. Turn the cartridge housing over.
Use a retaining ring pliers to install snap
ring (6), with the round edge of the
outside diameter of the ring toward the
bearings, in the cartridge housing. In-
stall snap ring (10) using a retaining
ring pliers.

Figure 4B-211. Backplate (13)

-® 6. Put backplate (13) in position on the
cartridge housing, and install the bolts
B53089P2
that hold it. Tighten the bolts to a tor-
que of 84:!:9 in-Ibs.

Figure 4B-209. Seal Rings and Spacer

NOTE
Put high vacuum grease in the
grooves for seal rings (11) at as-
sembly to one half or more of the
depth of the groove all the way
around the grooves.

4. Install seal rings (11) on spacer (12).

Figure 4B-212. Shroud (14)

Engine 4B-71
7. Put shroud (14) in position on the
cartridge housing.

Figure 48-214. Compressor Wheel and

Nut
B53103P1

Figure 48-213. Wheel Assembly (15).

NOTE

Put high vacuum grease in the

groove for the oil seal ring on
shaft and wheel assembly (15).

8. Install shaft and wheel assembly (15)

in the cartridge housing.
9. Put the cartridge assembly in position
in a fixture.
Figure 48-215. Dial Indicator
10. Put a small amount of clean engine oil
on the wheel face that will be under the 13. Put the cartridge assembly in a vise.
nut. Use a dial indicator to check end play.
The end play must be 0.020 to 0.032 in.
11. Put compressor wheel (17) in position
on the shaft.

CAUTION

Do not put a side force on the

shaft when the nut is tightened.

12. Install nut (16), and tighten it to a

torque of 35 in-Ibs. Tighten the nut
120 0 more.

Figure 48-216. O-Ring Seal (18)

4B-72
14. Put a small amount of clean engine oil 17. Install the turbocharger.
on O-ring seal (18); then install it on
the cartridge housing.
Crankshaft Pulley Removal
Remove the cran kshaft pulley as follows:

B53100P1.... .,

Figure 4B-217. Housing, Plates and

Bolts
15. Put the cartridge housing on com-
pressor housing (20), and install plates
(21) and bolts (19).
Figure 4B-219. V-Belts (1)
,. Loosen the tension on the V-belts,
and remove V-belts (1) from the crank-
shaft pulley.

Figure 48-218. Housing (22) and

Clamp (23)
Figure 48-220. Bolts (2) and Adapter
16. Put turbine housing (22) in position (3)
on the cartridge housing, and install
clamp (23) that holds it. Tighten the 2. Remove bolts (2) to remove pulley
clamp to a torque of 124:!:9 in-Ibs. adapter (3).

Engine 48-73
 Figure 4B-221. Bolts (4) and Adapter
(5)
3. Remove bolts (4) to remove pulley
adapter (5).
Figure 4B-222. Bolt (6) and Washer
(7)
4. Remove bolt (6) and washer (7) from
the crankshaft.
5. Use a push-puller tool to pull crank-
shaft pulley (8) from the crankshaft.
Crankshaft Pulley Installation
I nstall the cran kshaft pulley as follows:
1. Put clean engine oil on the lip of the
front crankshaft seal and seal surface of
the cran kshaft pulley.
2. Put crankshaft pulley (1) in position
on the end of the crankshaft.
4B-74
Figure 4B-223. Tool (A) and Pulley
(8)
Figure 4B-224. Pulley (1) and Tool
(A)
3. Install the screw of a push-puller tool
in the end of the crankshaft. Put the
crossbar of the push-puller tool on the
screw and against the pulley. Use the
push-puller tool to push the pulley onto
the crankshaft until it makes contact
with the crankshaft gear inside the tim-
ing gear housing. Remove push-puller
tool.
CAUTION
Bolt (2) and washer (3) must not
be used to install pulley (1) on the
crankshaft.
 6. Install pulley adapter (7) with bolts
(8).
7. I nstall V-belts (9) and adjust belt
tension. See V- Belt Tension Chart in
Specifications.

Figure 4B-225. Bolts and Washer

4. Install washer (3) and bolt (2) in the
end of the cran kshaft. Tighten bolt (2)
to 700±37 ft-Ibs. Tighten the bolts for
holes (4) to a torque of 41±5 ft-Ibs.

Figure 4B-228. V-Belts (9)

Crankshaft Front Seal Replacement

Remove and install the crankshaft front
seal as follows:
1. Remove the crankshaft pulley.

Figure 4B-226.Adapter (6) and Bolts

(5)
5. Install pulley adapter (6) with bolts
(5) .

Figure 4B-229. Seal Puller (A)

2. Remove the front seal using a seal
puller (A).
/ .~,;

- '~ij
C01204P1
::"'?Ztr

Figure 4B-227. Adapter (7) and Bolts

(8)

Engine 4B-75
 5. I nstall the cran kshaft pulley.

Remove the timing gear cover and oil

pump as follows:
1. Remove the oil pan.
2. Remove the crankshaft pulley.
3. Remove the fan drive.
4. Remove the air compressor.

Figure 48-230. Seal Installer (A)

3. Put cement on the outer metal su rface
of the front seal. Put the seal in posi-
tion on the short end of the seal installer
(A) . The lip of the seal must be toward
the inside of the engine.
NOTE

If a new wear surface for the front

seal is needed, put the spacer
from the seal installer (A) between
the seal and flange of the installer
assembly. Figure 48-232. Tube (1), Adjuster
(2) and Adapter (3)
4. Put the seal and installer in position 5. Remove tube (1). Remove belt adjus-
on the. crankshaft. Install washer (2) ter (2) and fan drive adapter (3).
that is used to hold the crankshaft pul-
ley and a 1"-14 UNF x 2-3/4" long bolt.
Tighten the bolt until the installer as-
sembly makes contact with the cran kshaft
gear. Remove seal installer (A) and
washer (2).

Figure 48-233. Tube (5) and Adjuster

(4)
6. Remove air compressor tube (5). Re-
move belt adjuster (4) from the timing
gear cover.
Figure 48-231. Crankshaft Pulley

48-76
 9. Loosen clamp (10), and disconnect
hose (11) from the timing gear cover.

Figure 4B-234. Engine on Blocks

7. Fasten a hoist to the front of the en-
gine. Remove the bolts that hold sup-
port (9) to the support assembly. Lift Figure 4B-236. Clips (13) and
the engine enough to remove bolts (8) Li nes(12)
and support (9) from the engine. Put
jacks or blocks under the cylinder block, 10. Remove clips (13); then disconnect
and lower the front of the engine on three lines (12).
these.
8. Remove nuts (7) and tachometer drive
adapter (6).

Figure 48-237. Clamp (14)

11. Remove clamp (14) from the water
sleeve.
Figure 4B-235. Clamp (10) and Hose
( 11)

Engine 4B-77
 Figure 4B-238. Water Sleeve Removal
Tool
12. Install water sleeve removal tool (A)
on the water sleeve; then push water
sleeve (15) into the front cover.
Figure 4B-239. Bolts, Connector and
Gasket
13. Remove two bolts (16), connector
(17) and the gasket behind it.
4B-78
Figure 4B-240. Bolts, Elbow and
Gasket
14. Remove bolts (18), elbow (19) and
the gasket behind it.
Figure 4B-241. Bolt (20) and Clamp
(21)
15. Remove bolt (20); then disconnect
clamp (21) that holds the oil pump sump
tube.

Figure 4B-242. Link Bracket (B) and
Cover (22)
16. Install link bracket (B) in the front
cover; then fasten a hoist. Remove all
the bolts that hold the timing gear cover
to the cylinder block. Remove cover
(22) and the oi I pump. The weight of
the timing gear cover and oil pump is 136
Ibs.
Gear Cover and Oil Pump Installation
Install the timing gear cover and oil
pump as follows:
Figure 4B-243. Link Bracket (A) and
Cover (1)
1. Clean the contact surfaces of the cyl-
inder block and timing gear cover.
2. Make sure the water sleeves are in-
stalled in the timing gear cover. Install
the timing gear cover gasket on the cyl-
i nder block.
3. Install link bracket (A) on timing gear
cover (1).
4. Put the cover in position, and align
the dowels and thei r respective holes.
I nstall the bolts that hold cover (1) to
the cylinder block.
Figure 4B-244. Clamp (3) and Bolts
(2)
5. Connect clamp (3) that holds the oil
pump sump tube. I nstall Bolts (2).
Figure 4B-245. Elbow (4) and Bolts
(5)
6. I nstall the gasket and elbow (4) on
the timing gear cover. Install bolts (5)
that hold it.
Engine 4B-79
 Figure 4B-246. Connector (7) and Figure 4B-248. Install Clamps (9)
Bo 1ts (6)
9. Install clamps (9) on the water sleeve.
7. Install gasket and connector (7) in
the cover, and install bolts (6) that hold
it.

Figure 4B-249. Lines (10) and Clips

( 11)
10. Connect three lines (10), and install
Figure 4B-247. Water Sleeve Removal clips (11) that hold them.
Tool (B)
8. Install a water sleeve removal tool (8)
on water sleeve (8); then push the water
sleeve into the cylinder block.

Figure 4B-250. Hose (13) and Clamp

(12)

48-80
 Figure 4B-251. Support and Adapter
11. Install hose (13) on the timing gear
cover, and install clamp (12).
12. Put engine support (16) in position,
and install the bolts (17) that hold it.
13. Fasten a hoist to the front of the en-
gine, and lift it enough to remove the
jacks or blocks from under the cylinder
block. Lower the engine so support (16)
is on the support assembly. Remove the
hoist, and install the bolts to hold the
support to the support assembly.
14. Put tachometer drive adapter (15) in
position, and install nuts (14).
Figure 4B-252. Adjusters (18) and
Tube (19)
15. Install belt adjuster (18) on the tim-
ing gear cover. Install air compressor
tube (19).
Figure 4B-253. Tube (20), Adjuster
(21) and Adapter (22)
16. I nstall fan drive adapter (22) and
belt adjuster (21).
17. I nstall tube (20).
18. Install the air compressor.
19. Install the fan drive.
20. I nstall the crankshaft pulley.
21. I nstall the oil pan.
Oil Pump And Relief Valve Removal
Remove the oil pump and relief valve as
follows:
1. Remove the timing gear cover and oil
pump.
837&491'>1:
Figure 4B-254. Bolts (1) and Cover
(2)
Engine 4B-81
2. Bend the locks away from bolts (1),
and remove the bolts. Remove cover (2)
from the timing gear cover.
Figure 4B-255. Guide, Spring and
Plunger
3. Remove guide (5), spring (4)
plunger (3) from the cover.
- 839952Pl.
Figure 48-256. O-Ring Seal (6)
4. Remove O-ring seal (6) from the back
of the cover.
4B-B2
Figure 4B-257. Inner and Outer
Rotors
5. Remove inner rotor (7) and outer rot-
or (B) from the timing gear cover.
and
Figure 48-25B. Bearing (9) and Shaft
(10)
6. Measure the inside diameter of bearing
(9). The inside diameter must be
2.B04±0.002 inch. Remove bearing (9)
only if a replacement is necessary. Re-
move shaft (10) if a replacement is nec-
essary.
Oil Pump And Relief Valve Installation
Install the oil pump and relief valve as
follows:
1. Thoroughly clean all of the parts.
Put clean engine oil on all of the pump
parts.
 3. If the shaft was removed from the tim-
ing gear cover, install the new shaft so
dimension "X" from the top of the shaft
to the counterbore in the cover is
1.423±0.010 inch.

Figure 4B-259. Bearing Driver (A)

2. If the bearing was removed from the
timing gear cover, install a new bearing
using a bearing driver (A). Make sure
the bearing is installed with the joint in
the position shown in the illustration.
Figure 4B-262. Inner and Outer
Rotors
4. Install inner rotor (1) and outer rotor
(2) in the timing gear cover.

A51104P2

Figure 4B-260. Joint in Bearing

Figure 48-263. Clearance Between

Rotors
5. Measure the clearance between the ro-
tors with a feeler gauge. The clearance
must be 0.002 to 0.008 inch. The maxi-
mum permissible clearance is 0.011 inch.
NOTE
Replace both rotors if the clear-
ance is not correct. The rotors
cannot be ordered separately.
Figure 4B-261. Check Dimension "X"

Engine 48-83
 Figure 48-264. Plunger (3), Spring
(4) and Guide (5)
6. Put plunger (3), spring (4) and guide
(5) in the cover. Use a 1-1/8 inch crow
'foot wrench and torque wrench to tight-
en guide (5) to a torque of 30:!:5 ft-Ibs.
Use a slide rule torque computer to find
the torque wrench dial reading for this
extension.
Figure 48-265. O-Ring Seal (6)
7. Install O-ring seal (6) on the cover,
and put the cover in position on the tim-
ing gear cover. Install the locks and
bolts that hold the cover in place.
8. Check the oil pump end clearance with
a feeler gauge. The end clearance must
be 0.027 to 0.053 inch.
4B-84
Figure 48-266. Check End Clearance
NOTE
If the clea rance is not correct, re-
place both rotors or the cover.
9. Install the timing gear cover and oil
pump.
Cylinder Head Removal
To remove the cylinder head proceed as
follows:
1. Remove the exhaust manifold.
2. Remove the air inlet manifold.
3. Remove the injection lines.
4. Remove the fuel injection nozzles.
NOTE
Make sure the fuel injection noz-
zles are removed before the cylin-
der head assemblies are removed.
The fuel injection nozzles go
through the cylinder head assem-
blies and the nozzle tips can be
broken off if the nozzles are not
removed from the heads.
 Figure 4B-267. Water Sleeves (1) Figure 4B-269. Link Brackets (B)
1. Before installing the cylinder head,
check the cylinder head and block for
top deck flatness. The flatness of the
cylinder head and block should be within
0.006" total, and a maximum of 0.003" for
any 60.0" span.
2. Clean the contact surfaces of the cyl-
inder head assembly and cylinder block.
Make sure the surfaces are clean and
dry. Install a new cylinder head gasket
(2).
3. Clean the bore in the cylinder head
assembly for the water sleeves. Put oil
on the seals on the water sleeves.
Figure 4B-268. Water Sleeve Removal 4. Install link brackets (A) in the cylin-
Too 1 (A) der head assembly. Fasten a hoist, and
put cylinder head assembly (1) in posi-
5. Drain the coolant from the cooling tion on the cylinder block.
system.
6. Remove clamp (2) from water sleeves
(1) in each cylinder head assembly.
Push the water sleeves into the timing
gear cover using a water sleeve removal
tool (A) and a screwdriver.
7. Remove bolt (3) from the bracket on
the dipstick tube.
8. Install link brackets (B) and fasten a
hoist. Remove bolts (7), cylinder head
assembly (6) and the gasket. The
weight of the cylinder head assembly is
120 Ibs.

Cylinder Head Installation Figure 4B-270. Cylinder Head (1) and

Gasket (2)
Install the cylinder head as follows:

Engine 4B-85
 HEAD BOLT CHART
lATER BOLTS
6. Install water sleeve (3) into the cylin-
Tightening Procedure (with seven dash der head assembly using water sleeve
marks) tool (8) and a screwdriver.
Step 1. Tighten bolts 1 150 ± 14 Nom
thru 18 in number 7. Install bolt (4) which holds the dip-
sequence to: stick tube to the cylinder head assembly.
Step 2. loosen bolts 1
thru 18 so washers are
free to rotate on bolts.
Step 3. Tighten bolts 1 80 ± 14 Nom
thru 18 in number (60 ± 10 Ib.ft.)
sequence to:
Step 4. Tighten bolts 1 150±7Nom
thru 18 in number (110 ± 5 Ib.ft.)
sequence to:
Step 5. Again tighten 165±7Nom
bolts 1 thru 10 in (120 ± 5 Ib.ft.)
number sequence to:
Step 6. Tighten bolts 19 43 ± 7 Nom
thru 22 in number (32 ± 5 Ib.ft.)
sequence to:
HEAD BOLT lOCATION CHART
Bolt
Dia. Part No. location (Bolt No.) length "l"
mm in. Figure 4B-273. Clamp (5)
6F5282 5,2,4,10 133.4 5.25
282006 7,9,3,1,6,8 120.6 4.75 8. Install clamp (5) on the water sleeves.
1/2"
L1329 16,14,12,17 76.2 3.00
28947 18,11,13,15 57.2 2.25
9. Fill the cooling system with coolant to
the correct level.
589603 19,20,21 127.0 5.00
3/8"
S1571 22 44.5 1.75 10. Instal! the fuel injection nozzles.
11. I nstall the fuel injection lines.
Figure 4B-271. Bolt Tightening
Sequence 12. Install the air inlet manifold.
5. Put engine oil on the bolt threads, 13. I nstall the exhaust manifold.
and install the bolts that hold the cylin-
der head assembly in place. Tighten the
bolts in the cylinder head assembly ac- Cylinder Head Disassembly
cording to the following procedure:

Disassemble the cylinder head as follows:

Figure 4B-272. Water Sleeve Tool (B)
1. Remove the cylinder heads.
2. Fasten a hoist, and put the cylinder
head assembly in position on a cylinder
head repai r bench. Use an adapter -plate
to hold the head in place.
3. Compress the valve springs using a
pneumatic valve spring compressor (C).
4. Remove the locks from the valves.
5. Remove the pneumatic valve spring
compressor, the retainer, spring, wash-
er and valve from the cylinder head .
Put identification marks on the valve as
to its location in the cylinder head.

48-86
 Figure 48-274. Spring Compressor (C)
Figure 48-275. Valve Spring Tester
(8)
6. Check the valve spring force with a
valve spring tester (B).
7. Do Steps 3 through 6 for the remain-
der of the valves.
8. Remove the valve seat inserts using a
valve seat insert puller (D).
9. Measure the bore in each valve guide
.75 in. from the outside edge on both
ends of each valve ~uide. The bore
must be 0.3745±0.005. The maximum
permissible bore is 0.3760". Valve
guides worn more than the maximum spe-
cification can be made to the original size
by knurling.
Cylinder Head Assembly
Assemble the cylinder heads as follows:
Figure 48-276. Insert Puller (D)
Figure 48-277. Insert Puller (A)
,. Clean and remove burrs and all for-
eign material from the valve seat bores.
CAUTION
Do not make the diameter of the
extractor--part of the valve seat
insert puller (A)--in valve seat in-
sert larger when the insert is in-
stalled in the cylinder head.
2. Lower the temperature of the valve
seat inserts, and install them using a
valve seat insert puller (A).
3. Grind the valve inserts according to
the dimensions given in Specifications.
Engine 4B-87
 Figure 4B-278. Valve Components
4. Put clean engine oil on the valve
stem. I nstall the valve, washer (3),
springs (2) and retainer (1) in the cyl-
inder head.
Fi~ure 4B-279. Spring Compressor (C)
5. Put the valve springs under com-
pression using a pneumatic valve spring
compressor, (e).
6. Install the locks on the valve stem us-
ing a valve keeper inserter.
4B-88
Figure 4B-280. Spring Compressor (C)
and Locks (4)
WARNING
Make sure locks (4) are in their
correct position on the valve. The
locks can be th rown from the valve
when the pneumatic valve spring
compressor (e) is released if the
locks are not in their correct posi-
tion on the valve.
7. Remove the pneumatic valve spring
compressor (e), and hit the valve with a
rubber hammer to be sure the locks are
in thei r correct position.
8. Do Steps 4 through 7 for the remain-
der of the valves.
9. Install the cylinder heads.
WATER PUMP
Water Pump Removal And Installation:
Remove and install the water pump as fol-
lows:
 1. Remove the water pump.

Figure 48-281. Bolts (1), Pointer

(3) and Water Pump (2)
Figure 48-282. Pulley (1)
1. Drain the coolant from the cooling
system. 2. Hold the pump shaft in a vise and re-
move the bolt and pulley (1).
2. Remove the V-belts from the front of
the engine.
3. Remove bolts (1) and pointer (3).
Remove water pump (2) from the timing
gear cover.
4. Put the gasket and water pump (2) in
position in the timing gear cover.
5. Install the pointer and bolts to hold
the water pump.
6. Put the V-belts in position on the en-
gine.
7. Use a belt tension gauge and adjust
the V-belts. Tighten new belts until the
gauge indication is 120±5. Operate the Figure 48-283. Driver Handle and
engine at high idle for a minimum of 30 Dri ve Pl ate (A)
minutes after Step 5. Make another ad-
justment of the belt tension. The
correct gauge indication for used belts is WARNING
90±10. Tighten the bolts that hold alter-
nator. The press must have a guard.
The guard has been removed for
8. Fill the cooling system with coolant to photo illustration.
the correct level.
3. Use a driver handle and drive plate
Water Pump Disassembly (A), and a press to remove the shaft,
seal and impeller from housing (2).
Disassemble the water pump as follows:

Engine 49-89
 6. Use a retaining ring pliers to remove
ring (5) from housing (2). Remove bear-
i n g (6) from h 0 us i n g (2).

A66407P1

Figure 4B-284. Bearing and Housing

4. Remove bearing (3) from housing (2).

Figure 4B-287. Shaft and Seal

Removal
7. Use a press and a pin (e) to remove
the shaft and seal assembly from impeller
(7).

A664OSP1

Figure 4B-285. Spacer and Housing

5. Remove spacer (4) from housing (2).

Figure 48-288. Shaft and Seal

8. Install the seal assembly and shaft in
housing (2). Use a press and a pin to
remove the shaft from the seal assembly.

Water Pump Assembly

, \ Assemble the water pump as follows:

Figure 4B-286. Ring (5), Bearing (6)

and Housing (2)

4S-90
 3. Make sure the outside diameter of
bearing (5) and the bore in housing (3)
are clean and dry. Apply an adhesive
sealant on outer bearing outside diameter
and housing bore before installing bear-
ing (5) in housing (3).

Figure 4B-289. Bearing Installation

1. I nstall bearing (1) in housing (3).
Use a retaining ring pliers (A) to install
ring (2) that holds bearing (1) in posi-
tion.

Figure 4B-292. Pulley Installation

4. Tu rn the pump housing over, and
make sure that the bores in the bearings
and spacer are in alignment. Install the
shaft through the bearings from the im-
peller side of the housing.
NOTE
The shaft to bearing clearance can
be 0.007" loose 0.003" tight. If it
is necessary to use a press to in-
stall the shaft, make su re the in-
ner races of the bea ri ngs have
Figure 4B-290. Spacer Installation support.
2. I nstall spacer (4) in housing (3).
5. Install pulley (6) on the shaft, and
tighten the bolt to a torque of 55±5
ft-Ibs.

Figure 4B-291. Install Bearing (5)

Engine 48-91

Figure 4B-293. Seal Assembly (7)
6. Put a new seal assembly (7) on the
shaft.
Figure 4B-294. Seal Installation
7. Use a driver (B) and a press to in-
stall the seal assembly in housing (3).
Do not use a hammer to install the seal.
Figure 4B-295. Spacers (C and D)
4B-92
8. Put a spacer (D) between impeller (8)
and the pump housing.
9. Use a press and a spacer (e) to in-
stall impeller (8) on the shaft until spa-
cer (D) can be moved between the
housing and impeller.
10. If the impeller is installed too far,
and spacer CD) cannot be removed, turn
the pump over, and remove the pu lIey.
Using a handle and a driver plate CE)
and a press, push the shaft out of the
bearings enough to remove spacer CD).
Install the pulley, and tighten the bolt to
a torque of 55±5 ft-Ibs.
11. I nstall the water pump.
STARTER
Starter Removal
Remove the sta rter as follows:
Figure 4B-296. Bolts (1) and Starter
(2)
1. Disconnect the battery cables.
2. Disconnect and put identification
marks on the wiring for the starter.
3. Remove bolts (10) and starter (2).
Starter Installation
Install the starter as follows:
1. Put the starter in position on the en-
gine.
2. Install the bolts that hold the starter ENGINE OIL COOLER AND OIL FILTER
to the flywheel housing. BASE
3. Connect the wiring and battery
cables. Oil Cooler and Oil Filter Base Removal
Remove the oil cooler and filter base as
ALTERNATOR follows:
1. Drain the coolant from the cooling
Alternator Removal And Installation system.
Remove and install the alternator as fol-
lows:

Figure 4B-298. Filters (2) and

Clamps (1)
Figure 48-297. Alternator 2. Use a strap wrench (A) to remove oil
filters (2).
1. Put identification marks on the alter-
nator wiring, and disconnect the wiring 3. Loosen clamps (1), and disconnect the
from the alternator. hoses.
2. Loosen adj u stment rod nut (3), and
remove the V-belts from the alternator
pulley.
3. Remove bolts (2) and (4). Remove al-
ternator (1).
4. Put alternator (1) in position on its
mounting bracket.
5. Install bolts (2) and (4).
6. Install the V-belts on the alternator
pulley.
7. Tighten nut (3) on the adjustment rod
to adjust the V-belts. Measure the out-
side belt toward the radiator with a belt Figure 48-299. Oil Cooler and Bolts
tension gauge. The correct gauge indi-
cation is 120:t5. For more information, 4. Remove bolt (4) and the three bolts
see V-Belt Tension chart in Specifica- from behind the oil cooler.
tions.
5. Remove oil filter base and engine oil
cooler (3) as a unit.

Engine 4B-93
Oil Cooler and Oil Filter Base I nstalla-
tion
Install the oil cooler and filter base as
follows:
1. I nspect the 0- ring seals in the oil fil-
ter base. Install new seals if needed.
Put clean engine oil on the seal.
2. Put oil filter base and oil cooler (3) in
position on the engine.
3. Install the four bolts that hold the oil
cooler in place.
4. Connect the two hoses, and install
clamps (1). Figure 4B-301. Filter Base and Nuts
5. Install new oil filters (2). See the in- 3. Remove nuts (30), and separate the
structions on the oil filter. oil cooler from oil filter base (4).

Oil Cooler and Oil Filter Base Disassem-

bly
Disassemble the oil cooler and filter base
as follows:
1. Remove the engine oil cooler and oil
filter base.

Figure 4B-302. Divider & Oil Cooler

4. Remove divider (6) from oil cooler
(5) .

Figure 4B-300. Cover and Bolts

2. Remove bolts (1), and separate cover
(2) from the oil filter base.

617434Pl

Figure 4B-303. Plug, Spring and

Valve

4B-94
5. Remove plug (9), spring (8) and by-
pass valve (7).

Figure 48-306. Valve and Plug

3. Put the valve and spring (5) in posi-
tion, and install plug (6).
Figure 48-304. Plug, Spring and
Valve
6. Remove plug (12), spring (11) and
bypass valve (10) from the oil filter
base.

Oil Cooler And Oil Filter Base Assembly

Assemble the oil cooler and filter base as
follows:

Figure 48-307. Divider (7)

Figure 48-305. Cooler and Filter
8ase
1. Put valve (1) and spring (2) in posi-
tion in oil filter base (4).
2. Install plug (3).
4. Put divider (7) in position between
the fifth and sixth plates from the flange
and sixth plates from the flange and on
the same end as the short stud.
5. Position oil filter base (4) on oil cooler
(8), and install the nuts. Tighten the
nuts to a torque of 16:t2 ft-Ibs.
6. Install the gasket, cover (2) and the
bolts.
7. Install the engine oil cooler and oil fil-
ter base.
Fuel Injection Pump Removal
Remove the fuel injection pump housing
and governor as follows:
1. Remove the fuel injection lines.

Engine 4B-95
2. Remove the air inlet manifold.
3. Remove the fan drive.
Figure 48-308. Adapter (1)
4. Remove the bolts, and remove adapter
(1) from over the tachometer drive
shaft.
Figure 48-309. Drive Shaft (2)
5. Remove tachometer drive shaft (2)
and the washer that holds the drive gear
on the fuel injection pump camshaft.
4B-96
Figure 48-310. Gear Puller (A)
6. I nstall gear puller (A) and use it to
loosen the drive gear on the fuel in-
jection pump camshaft. Remove tool gear
puller (A).
Figure 48-311. Wires and Tubes
7. Disconnect wires (3) from the fuel
shut off solenoid and the wire from the
switch.
8. Disconnect fuel supply tube (5) from
the fuel injection pump housing.
9. Remove fuel return tube (4) from the
fuel injection pump housing and the en-
gine.

Figure 4B-312. Bolts (7) and
Governor (6)
10. Remove two bolts (7), and remove
fuel injection pump housing and governor
(6) from the engine.
Fuel I njection Pump Installation
I nstall the fuel injection pump housing
and governor as follows:
Figure 4B-313. O-Ring Seals (1 and
2)
1. Clean and inspect O-ring seals (1)
and (2). Replace the seals if worn or
damaged.
~i....
Figure 4B-314. Bolt (B) and Pin (A)
2. Install a 1/2"-20 NF by 1-1/2" bolt
(B) in the fuel injection pump
camshaft. Remove the plug from the cover
on the fuel injection pump housing, and
install a timing pin (A). Use the bolt to
tu rn the camshaft until timing pin (A)
can be pushed into the groove (slot) in
the fuel injection pump camshaft.
Figure 4B-315. Governor (3)
3. Put fuel injection pump housing and
governor (3) in position on the engine.
Install the two bolts that hold the unit in
position.
Engine 4B-97
 8 .. To check the timing, remove timing
pin (A) and bolt (6). Turn the crank-
shaft with hand cran k (C) clockwise (as
seen from front of engine) two revo-
lutions, and install the timing pin (A);
then bolt (6) back in place. If bolt (6)
cannot be installed, the timing is not
correct. The procedure must be done
again. Do not tu rn the cran kshaft coun-
terclockwise (as seen from the front of
the engine) to install bolt (6). The
drive gear on the fuel injection camshaft
must be loosened to change the timing.
898277P1

Figure 48-316. Hand Crank (C)

4. Remove the starter, and install hand
crank (C) in the flywheel housing to
turn the engine.

Figure 4B-318. Adapter (8) and 80lt

(9)
9. I nstall adapter (8) over the tachom-
eter drive shaft.
10. Remove bolt (9) from the camshaft
gear, and install it back in its original
position in the front housing.
Figure 48-317. Location (5) and Hol~
(7) 11. I nstall the fitting and cap in the
front housing.
5. Install the washer and tachometer
drive shaft (4), but do not tighten shaft
(4) .

6. Remove the cap and fitting from the

front housing at location (5).
7. Install a 5/16"-18 UNF x 2-1/2" long
bolt (6). The cover bolt from hole (7)
can be used. Use hand cran k (C) to
turn the crankshaft clockwise (as seen
from front of engine) until bolt (6) can
be installed in the camshaft gear and is ......
in the center of the timing hole. With ,.
timing pin (A) in the groove (slot) in the :;"

fuel injection pump camshaft and bolt (6) W§j

in the hole in the engine camshaft gear,
the timing for the engine is correct.
Tighten tachometer drive shaft (4) to a Figure 48-319. Timing Pin (A)
torque of 110±1O ft-Ibs.

4B-98
12. Remove timing pin (A), and install
the plug in the cover on the fuel in-
jection pump housing.
Figure 4B-320. Wires and Tubes
13. Connect wires (11) to the fuel shut
off solenoid.
14. Install fuel supply tube (12) to the
fuel injection pump housing.
15. Connect fuel return tube (10) to the
fuel injection pump housing.
16. Connect the wires to the switch on
the fuel injection pump housing.
17. Install the fan drive.
18. Install the air inlet manifold.
19. Install the fuel injection lines.
Fuel Transfer Pump Removal
Remove the fuel transfer pump
follows:
1. Remove the fuel injection pump hous-
ing and governor.
2. I nstall the fuel injection pump housing
on a bracket assembly (A).
Figure 4B-321. Bracket, Bolts and
Housing
3. Remove seven bolts (1) and governor
housing (2).
NOTE
The fuel injection pump housing
has a thrust washer for the fuel
injection pump camshaft. The
thrust washer is behind the flange
for the flyweights on the camshaft.
To hold the th rust washer in
place, governor shaft (3) and the
camshaft must be held in toward
the fuel transfer pump any time
sleeve (4) is removed.
4. Remove the plug from the cover, and
install pin (8) in the hole as shown.
Tu rn the injection pump camshaft until
pin (8) can be pushed into the groove
(slot) in the camshaft.
as
Figure 4B-322. Governor Shaft (3)
Engine 48-99
 Figure 4B-323. Sleeve, Pin and Bolt Figure 4B-325. Drain Line (7)
NOTE 7. Disconnect drain line (7) from the fit-
ting on the back of fuel transfer pump
Any time the drive sleeve is re- body.
moved from the camshaft, a new
one must be installed. The cam-
shaft has serrations (splines) that
cut grooves into the drive sleeve
when it is installed to give a posi-
tive drive connection. If a former-
ly used drive sleeve is installed
again, it can slip on the camshaft.

5. Install bolt (C) in the threads of

sleeve (4). Tighten the bolt until the
sleeve can be removed.

B38212P1

Figure 4B-326. Gear (8) and Seal (9)

8. Remove gear (8) and O-ring seal (9)
from the pump body.

Figure 4B-324. Bolts and Pump Body

6. Remove four bolts (5) and fuel trans-
fer pump body (6) from the housing.

638213P1

Figure 4B-327. Seals (10)

4B-100
9. Remove seals C10) from the pump
body.

Figure 4B-329. Key (1) and Gear (2)

su re the drain hole between the seals is
open.
Figure 4B-328. Drive Gear (11)
10. Remove drive gear Cl1) and the key
from the camshaft.

Fuel Transfer Pump Installation

I nstall the fuel transfer pump as follows:

CAUTION
The fuel injection pump camshaft
must be held in toward the fuel
transfer pump during installation
of the fuel transfer pump parts to Figure 4B-330. Driver (B) and Body
hold the camshaft thrust washer in (3)
its counterbore. The thrust wash-
er will be damaged when the sleeve
is installed on the camshaft if it is
not in the correct position.

1. I nstall key (1) and drive gear (2) on

the shaft.
2. Put No. 3 Aviation Permatex on the
outside diameter of the seals for body
(3) .

3. Use driver (B) to install the first seal

in the body with the lip down and the 838211P1
second seal with the lip up. Install the
first seal to a depth of 0.453±0.101 inch
and the second seal to a depth of
0.030±0.010 inch. Figure 4B-331. O-Ring (4) and Gear
(5)
4. Remove the extra Permatex from the
body and seals after installation. Be

Engine 4B-101
5. Install O-ring seal (4) and gear (5)
on the body.
Figure 48-332. Guide (C) and Line
(6)
6. Install seal guide eC) in the end of
the fuel injection pump camshaft. Con-
nect drain line (6) to the fitting on the
back of the body, and put the body in
position on the fuel injection pump hous-
ing. Install the bolts that hold the body
in place.
Figure 48-333. Sleeve (7) and Washer
(D)
7. I nstall a pin (E) in the camshaft so it
will not tu rn.
CAUTION
Do not hit the sleeve to install.
Damage to the governor will be the
result.
4B-l02
8. Put a new sleeve (7) on the camshaft.
9. Tighten the sleeve into position on the
shaft with washer (D) approximately 0.25
inch. Tighten the sleeve the remainder
of the way with another washer until the
sleeve bottoms.
Fi gure 4B··334. Camshaft End Pl ay
10. Use a feeler gauge to check the end
play of the camshaft after the sleeve is
installed. The end play of the camshaft
must be 0.023±0.018 inch.
11. Remove pin eE) from the camshaft.
Figure 48-335. Governor Housing (8)
12. Be su re the governor springs and
gasket are in position on governor hous-
ing (8). Install the governor housing on
the fuel injection pump housing.
 2. I nstall the fuel injection pump housing
on housing bracket (A) as shown.
3. Remove bolts (1) and governor hous-
ing (2) from the fuel injection pump
housing.

Figure 4B-336. Bolt (9) and Bracket

(A)
13. Be sure bolt (9) has the washer and
0- ri ng seal on it when installed.
14. Remove the fuel injection pump hous-
ing from bracket (A). Figure 4B-338. Governor Springs (3)
15. Install the fuel injection pump hous- 4. Remov~ governor springs (3) and the
ing and governor. seat from the governor housing.

Governor Disassembly
Disassemble the governor as follows:
1. Remove the fuel injection pump hous-
ing and governor.

B38233P~

Figure 4B-339. Governor Components

5. Remove two bolts (4) from the lever.
Remove shaft assembly (5), lever (6)
and the two washers from the governor
housing. -
6. Remove O-ring seal (7) from the gov-
Figure 4B-337. Bracket, Bolts and ernor housing.
Housing

Engine 4B-103
 9. Use a retaining ring pliers (B) to re-
move snap ring from the spool on the
seat assembly. Remove retainer and pis-
ton (12) from spool. Remove the spool
and spring (13) from the seat.

B38234P1

Figure 48-340. Seal (8) and 8ushing

(9)
7. Remove seal (8) and bushing (9) from
the governor housing.

Figure 48-343. Cover (14)

10. Remove cover (14).

Figure 48-341. Seat (10) and Spring

( 11)
8. Remove seat assembly (10) and spring
(11) from the governor shaft.
Figure 48-344. Shaft (15) and Lever
(16)
11. Remove shaft (15) and lever (16)
from the housing. Remove the O-ring
seal from shaft (15).

Figure 48-342. Retaining Ring

Removal

4B-l04
 14. Remove shim (21), insulators (22)
and contact (23) from the torque control
bar.

.... -@
""I_ _ _ _

Figure 48-345. Cover (17)

12. Remove cover (17).

Figure 48-348. Lever (25) and Pin

(24)
15. Push lever (25) in, and remove pin
(24) .

Figure 48-346. Nut, 80lt and Control

Group
13. Remove nut (18), bolt (19) and tor-
que control group (20).

Figure 48-349. Lock Ring (26) and

Lever (25)

16. Remove lock ring (26) and lever (25)

from the dowel.
17. Use bar (e) to remove shield (27)
from the camshaft.

B38241P1

Figure 48-347. Shim, Insulators and

Contact

Engine 48-105
 838315P1

Figure 4B-350. Bar (C) and Shield

(27) Figure 4B-352. Riser (28)
Disassembly
CAUTION
19. Remove ri ng (32), one race (31),
Pull on the shield only a small bearing (30) and the other race (29)
amount in each location, so it will from riser (28).
not distort or be damaged. The
metal of the shield is staked
around the camshaft, and the
shield can be damaged when it is
removed. If the sh ield has
damage, use a new part for re-
placement.

Figure 4B-353. Pin (D), Bolts (33)

and Flyweight (34)
20. Install timing pin (D) to hold the
camshaft.
21. Remove bolts (33), and remove fly-
weight assembly (34) from the camshaft.
Figure 4B-351. Riser (28)
18. Remove riser assembly (28) from the
governor shaft.

4B-106

B38247P1
Figure 48-354. Shaft, Dowels and
Flyweights
22. Remove shaft (35) from the flyweight
carrier. Remove the dowel from the end
of shaft (35).
23. Remove dowels (36) and flyweights
(37) from the ca rrier.
Governor Assembly
Assemble the governor as follows:
638246P1
~U"'vV-'v~"
Figure 48-355. Dowel, Flyweight and
Shaft
1. Put clean fuel on governor parts dur-
ing assembly.
2. Put flyweights (2) in position the car-
rier, and install dowels (1) to hold them
in place.
3. Install the dowel in shaft (3). Install
the shaft in the carrier.
B38249Pi
Figure 48-356. Dowel (4)
4. Be sure dowel (4) in the shaft is en-
gaged in the groove on the back of the
carrier and that the dowel is in place
when the carrier is installed on the cam-
shaft.
Figure 48-357. Timing Pin (D) and
Flyweight (5)
5. Install timing pin (D) to hold the cam-
shaft.
6. Put flyweight assembly (5) in position
on the camshaft, and install the bolts
that hold it in place. Tighten the bolts
to a torque of 90±9 in-Ibs.
Engine 4B-107

8 7
9. Put the shield in position over the
flyweights. Use a driver (B) to install
the shield the remainder of the way on to
the camshaft. Stake the metal at two
places on the shield. 1SO:!:5° apart to hold
the shield on the camshaft.

838251P1

Figure 48-358. Race, Ring, Riser and

8earing
7. I nstall one race (6), bearing (9), the
outer race (6) and ring (7) on riser (S).

Figure 48-361. Lever (10)

10. Put lever (10) in position on the
dowel, and install the lock ring to hold it
in place.

Figure 48-359. Riser (8)

S. Install riser (S) between the fly-
weights with the. bearing in.

Figure 48-362. Pin (11)

11. Install pin (11) as shown.

Figure 48-360. Driver (8)

4B- lOS
 ~
13
B38256P1
Figure 4B-363. Assemble Components
on Bar (15)
12. Installcontact (13), insulators (14)
and shim (12) on torque control bar (15)
as shown.
Figure 4B-364. Torque Control Group
(15)
13. Put torque control group (15) in po-
sition on the stud in the fuel injection
pump housing, and install the nut and
bolt that hold it in place.
Figure 4B-365. Cover (16)
14. Insta" the gasket and cover (16).
Figure 4B-366. Lever (17) and Shaft
(18)
15. Insta" lever (17) with the ball stud
on the lever engaged in the fuel shaft
lever and the arm on lever (17) engaged
in the groove in the riser. Insta" the
O-ring seal on shaft (18), and put clean
fuel on the 0- ring seal. I nsta" shaft
(18) to hold lever (17) in place. The
O-ring seal on shaft (18) must be at the
top as shown.
Engine 48-109
 18. I nstall the small spring (25) and seat
assembly (21) on the governor shaft.

Figure 48-367. Cover (19)

16. Install cover (19).

Figure 48-370. Driver (E)

19. Use a driver (E) to install bushing in
governor housing so bushing is even
with the counterbore in the housing .

.:1:(::..-_ _,23

B38261P1

Figure 48-368. Spool (20) and

Components
17. Install spool (20) and the spring on
seat (21). I nstall piston (22) and re-
tainer (23) on the spool. Use a retaining
ring pliers to install snap ring (24) on
the spool. Figure 48-371. Seal with Lip Inward
20. Put thread lock on the outside diam-
eter of the seal for the governor
housing, and use a driver to install the
seal with the lip in as shown. Remove all
extra th read lock from the seal and hous-
ing. Be sure the drain hole between the
bushing and seal is open.

Figure 48-369. Spring (25) and Seat

(21)

4B-110
S38263P1

Figure 48-372. O-Ring Seal (26)

21. Use clean grease to hold 0- ring seal
(26) in position on the bottom of the
governor housing.
Figure 48-374. Seat (30) and Springs
(31)
23. I nstall seat (30) and governor
springs (31) on the spring guide in the
governor housing as shown.

Figure 48-373. Lever, Shaft and

Washer
22. Put lever (29) in position in the gov-
ernor housing with a washer (27) on
each side of the lever. I nstall shaft as-
sembly (28) in the governor housing.
I nstall the bolts that hold lever (29) to
shaft (28).
Figure 48-375. Gasket and Governor
Housing (32)
24. Put the gasket and governor housing
(32) in position on the fuel injection
pump housing.

Engine 4B-111
 Figure 4B-376. Bolt (33) and O-Ring
(34)
Figure 48-377. Screws and Shafts
25. Be sure bolt (33) at the bottom of
the governor housing has a washer and 4. Loosen screws (1) in the levers, and
O-Ring seal (34) on it. Install bolt (33) remove screw (3) in the crossover lever.
in the location shown, and install the re- Slide shaft assembly (2) out of the hous-
mainder of the bolts that hold the gover- ing.
nor housing in place.
26. Remove the fuel injection pump hous-
ing fr:)m the bracket assembly (A).
27. After installation of the fuel injection
pump hOl!sing and governor, adjust the
fuel setting high and low idle speeds.
28. Install the fuel injection pump hous-
ing and governor.

Fuel Injection Pump Housing Disassem-

bly
Disassemble the fuel pump housing as fol-
lows:
Figure 4B-378. Levers and Shaft
1. Remove the fuel injection pumps.
5. Loosen the screws in levers (4), and
2. Disassemble the governor. remove the screw in crossover lever (5).
Slide shaft (6) out of the housing.
3. Remove the fuel transfer pump.

4B-112
 Figure 4B-379. Identification Marks
NOTE
Put identification marks on lifters
(7) and rollers (8) for installation
in their respective bores in the
housing.
6. Use a magnet to remove eight lifter
assemblies (7).
838283P2
Figure 4B-380. Roller (8)
7. Remove roller (8) from each lifter as-
sembly.
Figure 4B-381. Camshaft (9)
8. Turn the camshaft so the groove
(slot) for the timing pin is in the posi-
tion shown, and carefully remove cam-
shaft (9). Remove the th rust washer
from the housing.
Figure 4B-382. Rear Bearing (10)
9. Remove camshaft rear bearing (10)
from the fuel pump housing. Be careful
not to damage the bearing bore in the
housing.
Engine 4B- 113

Figure 48-383. Driver (A)
10. Use driver (A) to remove the cam-
shaft front bearing from the fuel pump
housing.
Fuel I njection Pump Housing Assembly
Assemble the fuel injection pump housing
as follows:
1. Put clean fuel on all parts du ring as-
sembly.
2. Use driver (A) to install the camshaft
front bearing in the housing. Install the
bearing with the chamfer toward the in-
side of the pump housing.
3. Install the bearing so it is even with
the front face of the pump housing.
Figure 48-384. Reamer (8)
4. Use reamer (8) to machine the bore in
the camshaft front bearing to the correct
size. See special instructions supplied
48-114
with new front bearing. The bore in the
bearing must be 1O.00S±0.00S inch.
S. Use driver (A) to install the camshaft
rear bearing in the housing. Install the
bearing so the groove in the bearing fac-
es outwa rd with the outer face of the
bearing 0.017±0.00S inch below the coun-
terbore for the th rust washer.
, , '
:~'.
Figure 48-385. Washer and Camshaft
6. Install thrust washer (2) in the hous-
ing with the ear on the thrust washer in
the hole in the pump housing so the
thrust washer will not turn.
7. With the pump housing in vertical po-
sition as shown, ca refully install cam-
shaft (3). To make sure that the thrust
washer will be kept in its correct instal-
lation location, keep the pump housing in
a vertical position, and install the fuel
transfer pump and camshaft sleeve (refer
to Fuel Transfer Pump Installation).
NOTE
If the pump housing is assembled
while it is in a horizontal position,
the thrust washer can slide out of
the counterbore and into the area
between the camshaft th rust face
and the housing. Then the fuel
pump camshaft end play will not be
correct, and it will be necessary to
disassemble the fuel pump housing
so the thrust washer can be in-
stalled correctly.
8. Install each roller (8) in their respec-
tive lifters (see Figure 48-380 on page
48-113) .
 Figure 4B-386. Lifter Assemblies (5)
9. Use a magnet to install lifter assem-
blies (5) in their respective bores in the
pump housing with the groove in each
lifter in alignment with the dowel in the
lifter bore.
Figure 4B-387. Shaft and Levers
10. Install shaft (6) in the pump
housing; then through one lever (7);
then th rough crossover lever (8); then
through three levers (7) as shown. In-
stall the screw in crossover lever (8).
Tighten the screw in crossover lever
(8) . Tighten the screw to a torque of
24:!:2 in-Ibs. Do not tighten any of the
screws in the levers.
Figure 4B-388. Shaft Assembly and
Levers
11. Install shaft assembly (9) in the
pump housing; then one lever ell); then
through crossover lever (10); then
through three levers (11) as shown. In-
stall the screw in crossover lever (10).
Torque this screw to 24:!:2 in-'Ibs. Do not
tighten any of the screws in the levers.
12. After installation of the governor,
fuel injection pumps and fuel transfer
pump adjust fuel pump calibration, the
I
crossover levers, the fuel setting and
the high and low idle speeds. See Test-
ing and Adjusting.
13. Assemble the governor.
14. Install the fuel injection pump.
15. Install the fuel transfer pump.
Shutoff Housing, Check Valve and By-
pass Valve Removal
Remove the shutoff housing, check valve
and bypass valve as follows:
1. Clean the injection pump housing.
Engine 4B-115
 6. If necessary, remove check valve (8)
from flange assembly (6).

Figure 48-389. Remove These

Components
2. Disconnect wires (2) from shutoff so-
lenoid. Figure 48-391. Shutoff Housing Cover
3. Disconnect fuel supply tube (3) and 7. Remove the bolts, and remove shutoff
fuel return tube (1) from the fuel in- housing cover (9) from the fuel injection
jection pump housing. pump housing.
4. Disconnect air bleed tubes (4) and (5)
from the fuel injection pump housing.
5. Remove the two bolts to remove flange
(7), flange assembly (6) and the gaskets
from the fuel injection pump housing.

876292P1

Figure 48-392. Solenoid and bolts.

8. Remove shutoff solenoid (10) from the
876290P1 ' shutoff housing cover.
9. Remove bolts (11) to remove th e shu-
toff housing cover from shutoff housing.
Figure 48-390. Valve and Flange
Assembly

4B-116
 617102P2
Figure 48-393. Shaft and Levers
10. Remove two screws to remove lever
(13) from the shutoff housing.
11. Remove lever (14) and shaft (15) as
a unit and shaft (12) from the shutoff
housing. Remove the screws to remove
lever (14) from shaft (15).
817103P2
Figure 48-394. Remove Seal (16)
12. Remove seal (16) from the shutoff
housing.
Figure 48-395. Spring (17) and Valve
(18)
13. Remove spring (17) and bypass valve
(18) from the fuel injection pump
housing.
Shutoff Housing, Check Valve and By-
pass Valve Installation
Install the shutoff housing, check valve
and bypass valve as follows:
Figure 48-396. Valve (2) and Spring
(1) -
1. Install bypass valve (2) and spring
(1) in the fuel injection pump housing.
Engine 4B-117
 B17106P2

Figure 48-397. Seal Driver (A) and Figure 48-399. Cover (5) and Housing
Gasket (8)
2. Put liquid gasket material on the out- 5. Install shutoff housing cover (5) on
side diameter of the seal, and install the shutoff housing (8).
seal with driver (A) in the shutoff hous-
ing with the lip toward the outside. The
outer face of the seal must be 0.039 inch
below the surface of the housing. Re-
move extra sealing compound from
housing and seal after installation.

Figure 48-400. Shutoff Solenoid (9)

0--.. . . .fI!I!!il". S17105P2

6. Install solenoid
housing cover.
(9) on the shutoff

Figure 48-398. Levers and Shafts

3. Install lever (4) on shaft (6) with the
screws to hold these together. Put shaft
(3) and shaft (6) in position in shutoff
housing (5). Make sure lever (4) is cor-
rectly engaged with the groove (slot) on
shaft (3).
4. I nstall lever (7) and the screws to
hold it on shaft (6).

Figure 48-401. Housing Cover (8)

4B-118

7. Install shutoff housing cover (8) on
the fuel injection pump housing.
Figure 4B-402. Valve (10) and Flange
( 11)
8. If necessary, install a new check
valve (10) in flange assembly (11).
Figure 4B-403. Reference Photo
9. Install a gasket, flange assembly
(11), a gasket, flange (16) and the two
bolts on the fuel injection pump housing.
10. Connect air bleed tubes (17) and
(15) to the fuel injection pump housing.
11. Connect fuel return tube (12) and
fuel supply tube (14) to the fuel in-
jection pump housing.
12. Connect wires (13) to the shutoff so-
lenoid.
Fuel Injection Pumps Removal
Remove the fuel injection pumps as fol-
lows:
1. Remove the fuel injection lines.
2. Remove the shutoff housing, check
valve and bypass valve.
Figure 4B-404. Wrench (A) and
Extractor (B)
3. Install wrench (A) and Extractor (B)
on the fuel injection pump. Use wrench
(A) to loosen the bushing. Remove
wrench (A) and extractor (B).
Figure 4B-405. Bushing and O-Ring
Seal
4. Remove the bushing and O-ring seal
(1) from the fuel injection pump and
pump housing.
Engine 4B-119
 1. I nstall extractor (A) on fuel injection
pump (1). Put pump (1) in position in
the bore of the fuel injection pump hous-
ing. Make sure the groove in sleeve (2)
is engaged with lever (3).

NOTE

If lever (3) has moved on the

shaft, fuel pump must be cali-
brated. See Testing and Adjust-
ing.

Figure 4B-406. Screws (3), Pump (2)

and Extractor (B)
NOTE

Do not loosen screws (3) when the

fuel injection pump is removed or
installed. If the levers are moved,
the fuel pump calibration will be
changed.

5. Install extractor (8) on fuel injection

pump (2). Remove fuel injection pump
(2) from the fuel injection pump housing.
The sleeve on the plunger will slide off
on the lever as the fuel injection pump is
removed.
Figure 48-407. O-Ring and Bushing
2. Install O-ring seal (5) and bushing
(4) over the fuel injection pump and in
the fuel injection pump housing.

CAUTION

Keep the sleeve and plunger with

their respective barrel for installa-
- tion. Do not mix sleeve, plunger
and barrel with other sleeves,
plungers and barrels.

6. Repeat steps 3 th rough 5 to remove

the remaining fuel injection pumps.

Fuel I njection Pumps Installation

Install the fuel injection pumps as

follows:
Figure 4B-408. Torque Wrench (6)
CAUTION 3. Use wrench (8) to tighten bushing
(4) to a torque of 60±5 ft-Ibs.
Make sure the sleeve is installed
with the thin edge up. 4. Repeat steps 1 through 3 for the oth-
er fuel injection pumps.

5. Install the fuel injection lines.

48-120
6. Install the shutoff housing, check
valve and bypass valve.
Fuel I njection Pumps Disassembly and
Assembly
Disassemble and assemble the fuel in-
jection pumps as follows:
1. Remove the fuel injection pumps.
CAUTION
Be careful when the fuel injection
pumps are disassembled. Do not
damage the surface of the
plungers, barrels and bonnets.
Any scratches will cause leakage
inside the fuel injection pump.
The plunger and barrel for each
pump are made as a set. Do not
put the plunger of one pump in the
barrel of another pump. The
check assemblies are made as a
set. Do not mix the parts of check
assemblies. If one part has wear,
install a complete new pump assem-
bly. Be careful when the plunger
is put into the bore of the barrel.
Figure 48-409. Injection Pump
Components
2. Remove ring (2), and separate bonnet
(1) and barrel (3).
3. Remove spring (7) and check assem-
bly (8) from the bonnet.
4. Remove washer (4), plunger (5) and
sleeve (6) as a unit from the barrel.
Remove washer (4) and sleeve (6) from
plunger (5). Remove spring (9) from
the barrel.
CAUTION
Install the sleeve on the plunger
with the thin edge up. Make sure
the sleeve and plunger are in-
stalled in their original barrel and
the large hole in the plunger is up
(toward the barrel).
NOTE
Put clean fuel oil on all parts be-
fore assembly.
5. I nstall spring (9) on barrel (3). I n-
stall sleeve (6) and washer (4) on plung-
er (5). I nstall sleeve (6), washer (4)
and plunger (5) as a unit in the barrel.
6. Install spring (7) and check assembly
(8) in bonnet (1).
CAUTION
Do not slide bonnet (1) across the
face of barrel (3) when ring (2) is
installed. The check assembly in
the bonnet can put scratches in
the face of the barrel (3).
7. Put bonnet (1) in position on barrel
(3), and install ring (2) to hold the bon-
net and barrel together.
8. Install the fuel injection pumps.
Crankshaft Main Bearings Installation
and Removal -
Remove and install the crankshaft main
bearings as follows:
1. Remove the oil pan.
Engine 4B-121

Figure 4B-410. Bearing Cap Removal
2. Check each main bearing cap for its
location on the engine. Each cap has a
number which gives the location of that
cap. Make a note that the number on
each cap is toward the front of the cyl-
inder block.
3. Remove the bolts and washers (1) that
hold main bearing cap (2) in place. Re-
move the bearing cap and the lower half
of the main bearing. Use wrench to re-
move the bolts that hold the No. 1 main
bearing cap in position.
Figure 48-411. Bearing Tool (A)
4. Turn the crankshaft until a bearing
installation and removal tool (A) can be
installed in the oil hole in the crankshaft
in the direction which will push the up-
per main bearing out tab-end first.
NOTE
The No.1 main bearing journal has
no oil hole. To remove this bear-
ing, put a thin piece of soft mate-
4B-122
rial, that will not damage the
cran kshaft jou rnal, against the
end of the bearing opposite the
tab. Hit the bearing with the soft
material until the tab of the bear-
ing is free from the groove in the
block.
CAUTION
If the crankshaft is turned in the
wrong direction, the tab of the
bearing will be pushed between the
crankshaft and the cylinder block.
This will cause damage to the
crankshaft and block.
CAUTION
I nstall the bearings dry when the
clearance checks are made. Put
clean engine oil on the bearings
for final assembly.
5. Install the lower bearing in the bear-
ing caps. Install upper bearings (bear-
ing with the oil hole) in the cylinder
block with the bearing removal and in-
stallation tool. (A).
NOTE
When bearing caps are installed,
make sure the number on the side
of the cap is next to and respec-
tive with the number on the engine
block.
6. Measure the bearing clearances with
Plastigage. Lead wire, shim stock or use
of a dial bore gauge can damage the
bearing surface. The following points
must be remembered.
• Make sure that the backs of the bear-
ings and the bores are clean and dry.
• Make sure that the bearing locking
tabs are properly seated in their
slots.
• The cran kshaft must be free of oil
where the Plastigage touches it.
• If the main bearing clearances are
checked with the engine upright or on
its side, the cran kshaft must be sup-
 ported. Use a jack under an adjacent
crankshaft counterweight, and hold
the crankshaft against the crown of
the bearing. If the crankshaft is not
supported, the weight of the crank-
shaft will cause incorrect readings.
• Put a piece of plastigage on the crown
of the bearing half that is in the cap.
Do not allow the plastigage to extend
over the edge of the bearing.
• Install the bearing cap using the cor-
rect torque-tu rn specifications. Do
not use an impact wrench. Be careful
not to dislodge the bearing when the
cap is installed.
Figure 48-412. Plastigage (8)
• Do not tu rn the cran kshaft with the
Plastigage installed. 7. Check the bearing clearance with
Plastigage (B) as follows: put cap (3) in
• Carefully remove the cap but do not position and install the bolts. Tighten
remove the Plastigage. Measure the bolt (5) to a torque of 30±3 ft-Ibs ..
width of the Plastigage while it is in Tighten bolt (4) to a torque of 30±3
the bearing cap or on the crankshaft ft-Ibs.. Put a mark on both bolts heads
journal. Do this by using the correct and the bearing cap. Tighten bolt (4)
scale on the package. Record the 1200±5 D more. Tighten bolt (5) 1200±5 D
measu rements.
8. Remove the bearing cap, and measure
• Remove the Plastigage before rein- the thickness of the Plastigage. The
stalling the cap. main bearing clearance must be 0.030 to
0.066 inch. The maximum permissible
• When using Plastigage, the readings clearance is 0.007 inch.
can sometimes be unclear. or
example, all parts of the Plastigage 9. Put th read lubricant on the bolt
are not the same width. Measure the threads and washer faces. Put clean en-
major widths to make su re that they gine oil on the lower half of the main
are within the specification range. bearing. Put the bearing cap and lower
Also, experience has shown that when half of the main bearing in position on
checking clearances tighter than the engine. I nstallthe bolts. Tighten
0.004 inches the readings may be low bolt (5) to a torque of 30±3 ft-Ibs ..
by 0.005 to 0.010 inches. Tighten bolt (4) to a torque of 30±3
Out-of-round journals can give faulty ft-Ibs. Put a mark on both heads and
readings. Also, journal taper may be the cap. Tighten bolt (4) 1200± 5° more.
indicated when one end of the Plasti- Tighten bolt (5) 120o±5° more.
gage is wider than the other.
10. Repeat steps 2 th rough 9 for the re-
mainder of the bearings.

Engine 4B-123
 30912P1
Figure 48-413. Final Tightening
Radius
Figure 48-414. Dial Indicator (D)
11. Check the cran kshaft end play using
a dial indicator (D). The end play is
controlled by the trust bearing on No.4
main bearing. The end play with new
bearings must be 0.003 to 0.010 inch.
The maximum permissible end play with
used bearings is 0.014 inch.
12. Install the oil pan.
Connecting Rod Bearing Removal and
Installation
Remove and install the connecting rod
bearings as follows:
1. Remove the oil pan.
48-124
Figure 48-415. Connecting Rod Cap
(1)
2. Turn the crankshaft until two pistons
are at bottom center. Remove connecting
rod caps (1) from the two connecting
rods. Remove the lower half of the bear-
ings from the caps.
CAUTION
8e careful not to damage the
crankshaft journals. Do not turn
the crankshaft while any of the
connecting rod caps are removed.
3. Push the connecting rods away from
the cran kshaft, and remove the upper
half of the bearings.
4. Clean the surfaces where the bearings
fit. Install the upper half of the bearing
in the connecting rod. Pull the connect-
ing rod slowly onto the crankshaft.
NOTE
Install the bearings dry when the
clearance checks are made. Put
clean engine oil on the bearings
for final assembly.
CAUTION
When the connecting rod caps are
installed, make sure that the num-
bers on the side of the caps are
next to and respective with the
number on the side of the connect-
ing rods.
 5. Install the lower half of the bearing in
the cap.
6. Check the bearing clearance with
Plastigage (A). Put Plastigage (A) on
the bearing.
93833P1
Figure 48-416. Final Tightening
Radius
Piston and Connecting Rod Removal
Remove the pistons and connecting rods
as follows:
1. Remove the cylinder head assemblies.
2. Remove the oil pan.
Figure 48-417. Ridge Reamer (A)
3. Remove the carbon from the top inside
surface of the cylinders by using a ridge
reamer (A).
Figure 48-418. Connecting Rod Caps
(1)
4. Turn the crankshaft until two pistons
are at bottom center.
CAUTION
Do not turn the crankshaft while
any of the connecting rods are in
the engine without the caps in-
stalled.
5. Remove connecting rod caps (1) from
the two connecting rods. Put pieces of
rubber hose or tape on the th reads of
the connecting rod bolts as protection
for the cran kshaft.
6. Push the pistons and connecting rods
away from the cran kshaft until the piston
rings are above the cylinder block.
Figure 48-419. Piston Assemblies (2)
7. Remove the two piston assemblies (2)
and the connecting rods. Keep each
Engine 48-125
connecting rod cap with its respective
connecting rod and piston. Put identifi-
cation marks on each connecting rod as
to its location for use at installation.
8. Repeat steps 3 through 7 for the re-
mainder of the pistons.
Piston and Connecting Rod Installation
Install the pistons and connecting rods
as follows:
1. Put clean engine oil on the piston
rings, connecting rod bearings, cylinder
walls and crankshaft bearing journals.
2. Turn the crankshaft until the bearing
jou rnal of the pistons to be installed is at
bottom center.
3. Make sure the piston ring gaps are at
least 120 0 apart on the piston.
Figure 48-420. Ring Compressor (A)
4. Using a ring compressor (A), install
the piston in the same cylinder bore from
which it was removed. The hole (crater)
in the top of the piston must be toward
(nearest) the center of the engine.
NOTE
For more detail about the installa-
tion of connecting rod bearings,
see Connecting Rod Bearing Re-
moval and Installation.
5. Check the bearing clearances with
Plastigage (B).
4B-126
6. Put thread lubricant on the threads of
the bolts and contact su rfaces of the
nuts for the connecting rod caps.
CAUTION
When the connecting rod caps are
installed, make sure that the num-
ber on the side of the cap is next
to and respective with the number
on the s ide of the con necti ng rod.
Figure 48-421. Connecting Rod Cap
(1)
7. Put the cap (1) in position on the
connecting rod, and install the nuts.
Tighten the nuts to a torque of 30±3
ft-Ibs. Put a mark on each nut and the
end of each bolt. Tighten the nuts 60±5°
more. (see Figure 4B-416 on page
4B-125) .
8. Check the side clearance between the
connecting rods on the same cran kshaft
journal. Clearance must be 0.003 to
0.033 inch for new rods.
9. Repeat steps 1 th rough 8 for the re-
mainder of the pistons.
10. Install the cylinder head assemblies.
11. I nstall the oil pan.
Piston and Connecting Rod Disassembly
Disassemble the pistons and connecting
rods as follows:
1. Remove the pistons and connecting
rods.
2. Remove the rings from the piston us-
ing a ring expander (A).
Figure 48-422. Ring Expander (A)
3. Remove the bearings from the connect-
ing rod and connecting rod cap.
Figure 48-423. Snap Rings, Pin and
Connecting Rod
4. Remove the snap rings (2), pin (1)
and connecting rod (3) from the piston.
5. Heat the connecting rod to a temper-
ature of 350 to 500°F. Put spacer (11)
in the base plate. Put the connecting
rod on the base plate of the connecting
rod bearing press (8).
6. Put the connecting rod piston pin
bearing end in the center of the port as-
sembly of the connecting rod bearing
press (8). Install pin (7) in the center
of the bore for the connecting rod bear-
ings.
Figure 48-424. Connecting Rod
Components
7. I nstall adapter (9). Put the hole in
the adapter in alignment with the hole in
the base plate of the connecting rod
bearing press (8).
8. Install clamp bar (10) and clamp pin
(6).
9. Install new piston pin bearing (5) on
adapter (9).
NOTE
The old bearing is pushed out by
the connecting rod bearing press
(8) as the new bearing is
installed.
10. Put adapter (8) in position' as shown
with the taper side down. The piston
pin bearing joint must be in alignment
with the hole in adapter (9) and the base
plate of the connecting rod bearing press
(8) .
11. Put pusher (4) on adapter (8).
12. Use the press (8) to push the new
piston pin bearing into the connecting
rod until adapter (8) of the press makes
full contact with the connecting rod sur-
face.
13. Remove the connecting rod and the
old piston pin bearing from the press.
14. Check the piston pin bearing bore
diameter after the bearing is installed.
The correct dimension is 1.501O:!:O.003
inch.
Engine 48-127
Piston and Connecting Rod Assembly
Assemble the piston and connecting rods
as follows:

Figure 4B-426. Piston Ring Groove

Cleaner
6. I nstall the connecting rod bearings.
Figure 4B-425. Connecting Rod 7. Install the piston and connecting rod
Components assemblies.

1. Install connecting rod (1) in the pis- Flywheel Removal

ton with the boss on the small end of
connecting rod on the same side as the Remove the flywheel as follows:
hole (crater) in top of the piston.
2. I nstall piston pin (2) and snap ring
(3) .

3. When oil pistons are to be used, clean

the piston grooves with a suitable piston
ring groove cleaner (A).
4. Install the spring for the oil ring.
Install the oil ring using a piston ring
expander (B). The gap in the ring must
be approximately 180 0 from the oil ring
spring connections.
5. I nstall the compression ring using a
piston ring expander (B). The side of
the ring that has the identification
"TOP" must be toward the top of the pis- Figure 4B-427. Lifting Bracket (A)
ton. The gaps in the ri ngs must be ap-
proximately 120 0 apart. 1. Fasten a hoist to flywheel (1) with a
lifting bracket.
NOTE
2. Remove the bolts, and remove fly-
Compression rings that do not wheel (1) from the end of the crankshaft
have identification marks must be and the flywheel housing. The weight of
installed with the edge that has the flywheel is 62 Ibs.
the bevel toward the top of the pi-
ston

4B-128

Figure 48-428. Ring Gear (2)
3. If necessary, remove ring gear (2)
from the flywheel.
Flywheel Installation
Install the flywheel as follows:
NOTE
When a new flywheel is installed,
check the th ickness of the new
flywheel at the bolt holes in re-
lation to the thickness of the old
flywheel. I nstall the correct
length bolts so they will be fully
engaged in the crankshaft flange.
Bolts that are too long will make
contact with the block on the back
side of the crankshaft flange and
pull the crankshaft back. This
will cause the crankshaft thrust
bearing to fail.
Figure 48-429. Heat Ring Gear (1)
1. If necessary, heat ring gear (1) to a
maximum temperature of 400 D F, and in-
stall it on the flywheel. Make sure the
ring gear is against the shoulder of the
flywheel and the part number is toward
the engine.
2. Install a 5/8"-NF guide bolt (2) in the
end of the cran kshaft.
Figure 48-430. Lifting 8racket (A)
3. Fasten a hoist to flywheel (3) with a
lifting bracket. Make sure the dash
mark on the flywheel and the dash mark
on the crankshaft are in alignment. Put
flywheel (3) in position on the guide bolt
and the end of the cran kshaft.
CAUTION
Make sure the correct sealant is
put on the bolt th reads. The
holes for the bolts in the crank-
shaft flange are drilled through so
the holes are open to the oil in the
engine. Leakage along the bolt
threads can be the result if the
correct sealant is not used.
4. Put sealant on the threads of the fly-
wheel bolts. I nstall the flywheel bolts,
and remove the guide bolt. Install the
last flywheel bolt, and tighten all the
bolts to a torque of 66±5 ft-Ibs.
Flywheel Housing Installation and Re-
moval
Remove and install the flywheel housing
as follows:
1. Remove the sta rter.
Engine 4B-129
2. Remove the flywheel.

Figure 4B-432. Lip-Type Seal Puller

Figure 4B-431. Bolts and Flywheel 2. Remove the cran kshaft rear seal from
Housing the flywheel housing with a lip-type seal
puller.
3. Remove bolts (2) and flywheel housing
(1) from the cylinder block. 3. Install a distorter ring (e) in the rear
seal bore.
4. Remove the flywheel housing gasket,
and clean the flywheel housing to cylin-
der block contact surfaces.
5. Install 3/8"-16 Ne guide bolts with a
minimum length of 40.00 inch.
6. Put flywheel housing (1) in position
over the guide bolts. I nstall bolts (2) to
hold the flywheel housing, and remove
the guide bolts. I nstall the last two
bolts, and tighten all the bolts to the
standa rd torques.
7. I nstall the flywheel.
8. Install the starter.
Figure 4B-433. Distorter Ring (C)
Crankshaft Real Seal and Wear Sleeve and Distorter (B)
Removal
4. Install a distorter (8) between the
Remove the crankshaft rear seal and distorter ring (e) and the wear sleeve.
wear sleeve as follows: Turn the distorter until the edge of the
tool rna kes a flat place (crease) in the
NOTE wear sleeve. Do this in two or more
places until the wear sleeve is loose.
Any time the cran kshaft seal is
removed from the wear sleeve, a 5. Remove the distorter ring and the
new sleeve and seal must be in- wear sleeve by hand.
stalled as a unit. If the seal is
put back on the sleeve, the seal
wi II be damaged. Crankshaft Rear Seal and Wear Sleeve
Installation
1. Remove the flywheel. I nstall the cran kshaft rear seal and wear
sleeve as follows:

48-130
 CAUTION
The crankshaft seal and wear
sleeve come as a set and must not
be separated from each other at
any time. Carefully read special
instructions that are included with
each seal and wear sleeve before
you handle the seal group.
1. Clean and prepare the crankshaft out-
side diameter using a quick cure primer.
Apply a retaining compound to the
cran kshaft outside diameter.
2 3
4----~
6 Figure 4B-435. Crankshaft Removal
7---+4:~~
B84143P4
Figure 48-434. Seal and Sleeve
Installation
2. I nstall locator (3) and the bolts on the
rear of the cran kshaft (4).
3. Put wear sleeve (2) and seal (7) as a
unit on locator (3) with the lip of the
seal toward the front of the engine.
4. Put installer (5) in position on the lo-
cator.
5. Put clean engine oil on the face of nut
(6) and install it on the locator. Tighten
the nut until installer (5) bottoms out.
6. Remove nut (6), installer (5), bolts
and locator (3), and check the wear
sleeve and seal for correct position.
7. I nstall the flywheel.
Crankshaft and Gear Removal
Remove the cran kshaft and gea r as fol-
lows:
1. Remove the flywheel housing.
2. Remove the valve lifters.
3. Remove the pistons and connecting
rod assemblies.
4. Remove the timing gear cover and oil
pump.
5. Fasten a hoist, and put the engine in
position on an engine stand.
6. Turn crankshaft (3) until the timing
mark on the crankshaft gear is in align-
ment with the timing mark on the cam-
shaft gear.
7. Remove bolts (1) and main bearing
caps (2). Remove the lower halves of
the main bearings from the caps (refer to
"Crankshaft and Gear Removal").
8. Install two of the bolts that hold the
flywheel in place in the end of the
cran kshaft.
CAUTION
Be careful not to damage the
crankshaft journals when the
crankshaft is removed.
9. Fasten a hoist, and remove cran kshaft
(3) from the engine. Weight of the
crankshaft is 120 Ibs.
10. Remove the upper halves of the main
bearings from the cylinder block.
Engine 4B-131
 for final assembly.

4. Install the upper main bearings (the

bearings with an oil hole) into the engine
block (refer to "Crankshaft and Gear
Removal" on page 4B-131).
5. I nstall two of the bolts that hold the
flywheel in place in the end of the
cran kshaft. Fasten a hoist, and put the
crankshaft in position in the block. Make
sure the timing mark on the crankshaft
gear is in alignment with the timing mark
on the camshaft gear.
NOTE
Figure 48-436. Use Sling When
Removing Crankshaft When the bearing caps are in-
stalled, make sure the number on
11. Install a hydraulic puller (B), and the side of the cap is next to and
remove the gear from the crankshaft. respective with the number on the
engine block.

6. If the crankshaft journals and bores

for the block and rods were measu red at
disassembly and found to be within spec-
ifications, no fu rther checks a re neces-
sary. To measure the bearing
clearances, Plastigage is recommended.
Lead wire, shim stock or use of a dial
bore gauge can damage the bearing sur-
face.
NOTE
Figure 48-437. Hydraulic Puller (8) When the bearing clearance is
checked and the engine is in a
vertical position, the crankshaft
Crankshaft and Gear Installation will have to be lifted up with a
force equal to the weight of the
I nstall the cran kshaft and gear as crankshaft and held against the
follows: upper halves of the main bearings
to get a correct measurement with
1. I nstall the key for the cran kshaft Plastigage. The Plastigage will not
gear so it is even with the end of the hold the weight of the cran kshaft
crankshaft. and give a correct indication. If
the engine is in a horizontal posi-
2. Heat the crankshaft gear to a maxi- tion, such as on an engine stand,
mum temperature of 500 D F. Install the it is not necessary to hold the
gear on the crankshaft with the timing cran kshaft up. Do not tu rn
mark on the gear toward the pulley end crankshaft when Plastigage is in
of the cran kshaft. position to check clearance.
3. Install the thrust bearing for the No.
4 main. 7. Check the bea ring clea rance with
Plastigage. Put the lower main bearings
NOTE into the caps. Put the caps in position,
and install the bolts. Tighten the bolts
Install the bearings dry when the in number sequence as follows:
clearance checks are made. Put
clean engine oil on the bearings

4B-132
 11. Install timing gear cover and oil
pump.
12. Install the pistons and connecting
rod.
13. Install the valve lifters.

14. Install the flywheel housing.

Camshaft Bearing Removal

Remove the camshaft bearings as follows:
1. Remove crankshaft and gear.
Figure 4B-438. Bolt Tightening NOTE
Sequence
The cran kshaft does not have to
A. Tighten bolts 1 through 10 to a tor- be removed for removal and instal-
que of 30:!:3 ft-Ibs. lation of the camshaft bearings,
but must be removed to correctly
clean the oil passages in the cylin-
CAUTION der block.
Do not use an impact wrench to
tighten the nuts the additional 120
:t5 °.

B. Put a mark on each bolt head and

bearing cap. Tighten bolts 1 through
10 an additional 120D:!:5 D.

8. Remove the bearing caps, and meas-

u re the thickness of the Plastigage. The
main bearing clearance must be 0.030 to
0.066 inch. The maximum permissible
clearance is 0.007 inch.
9. Put thread lubricant on the bolt
th reads and washer faces. Put clean en-
gine oil on the main bearings. Put the Figure 4B-439. Washer and Bolt
bearing caps in position, and install the
bolts. Tighten the bolts inn umber se- 2. Remove the camshaft and gears.
quence as follows:
3. Install camshaft bearing installation
A. Tighten bolts 1 through 10 to a tor- and removal tool (B) through the fly-
que of 30:!:3 ft-Ibs. wheel housing end of the cylinder block.
B. Put a rna rk on each bolt head and 4. Install washer (1) and bolt (2) in the
bearinQ cap. Tighten bolts 1 through end of the shaft of the camshaft beari ng
10 120°:!:5° more. removal and installation tool (B). (see
Figu re 4B-439 and Figu re 4B-440 on
10. Install a dial indicator and check the page 4B-134). Remove the bearings from
end play of the crankshaft. The end the cylinder block. Start with the front
play is controlled by the thrust bearing bearing.
on No. 4 main bearing. The end play
with new bearings must be 0.003 to 0.010
inch. The maximum permissible end play
with a used bearing is 0.014 inch.

Engine 4B-133

Figure 4B-440. Installation and
Removal Tool
5. Thoroughly clean the oil passages and
surfaces where the camshaft and bear-
ings fit.
Camshaft Bearing Installation
I nstall the camshaft bearings as follows:
1. Start with the rear camshaft bearing,
and install the bearings in the cylinder
block using a camshaft bearing installa-
tion and removal tool (A and B, shown in
Figure 4B-441). Make sure the oil holes
in the bearing are in alignment with the
oil holes in the cylinder block.
Figure 4B-441. Rear Camshaft Bearing
2. To install the front camshaft bearing,
put tube (1) from camshaft bearing in-
stallation and removal tool in position
shown with the tube over the boss in
front of the cylinder block, and pull the
bearing into place. Make sure the oil
holes in the bearings are in alignment
4B-134
with the oil holes in the cylinder block
(see Figu re 4B-442).
Figure 4B-442. Front Camshaft
Bearing
3. Install the camshaft and gears.
4. Install the crankshaft and gear.
Camshaft and Gear Removal
Remove the camshaft and gears as
follows:
1. Remove the timing gear cover and oil
pump.
2. Remove the valve lifters.
3. Remove the tu rbocha rger.
4. Remove the plug from the fuel in-
jection pump housing, and install timing
pin (A, Figure 4B-443 on page 4B-135).
5. While the crankshaft is turned clock-
wise (as seen from the front of the en-
gine), push on timing pin (A) until it
slides into the groove (slot) in the fuel
injection pump camshaft.
6. Remove tachometer d rive adapter
shaft (1).
7. Refer to Figu re 4B-444 on page
4B-135. I nstall Fuel Setting Tool Body,
bolt, and flat washer into the camshaft
drive gear for the fuel injection pump.
Turn both bolts evenly until the drive
gear is free of the shaft. Remove Fuel
Setting Tool Body, bolt and flat washer.
 Figure 48-443. Timing Pin (A) Figure 48-445. Thrust Pin (2)
Camshaft and Gear Installation
Install the camshaft and gears as follows:
1. Install the camshaft gear on the cam-
shaft if it was removed. Heat the gear
to a maximum temperature of 600 o F. Put
the gear in position on the camshaft.
Put th read lubricant on the camshaft
lobes (see Figure 48-447 on page
48-136). Install camshaft (1) and the
gears as a unit. Make sure the timing
marks on the crankshaft gear and cam-
shaft gear are in alignment (see
Figure 48-448 on page 48-136).

Figure 48-444. Drive Gear Removal

Tooling

8. Remove thrust pin (2) that holds the

camshaft in place from the rear of the
cylinder block (see Figure 48-445).
9. Remove camshaft (3) and gears from
the cylinder block as a unit. (see
Figure 48-446). 8e careful not to dam-
age the camshaft bearing or camshaft
lobes.
NOTE
The camshaft gear can be removed
from the camshaft if a replacement
is necessary.

Figure 48-446. Camshaft (3) and

Gears

Engine 48- 135

r
./
!

Figure 4B-447. Camshaft (1) Figure 4B-449. Gear (3) and Shaft
(2)
slides into the groove (slot) in the
fuel injection pump camshaft.
D. Remove the plug from the timing hole
in the front cover, and install a
5/16"-18 x 2-1/2" long bolt (4,
Figure 4B-450). Cover bolt (5) can
be used. Check to make sure bolt (4)
can be installed into the timing gear
and is in the center of the timing
hole. The camshaft for the fuel in-
jection pump is now in correct time
with the engine.

Figure 4B-448. Timing Marks

2. Install the thrust pin. Tighten the
pin to a torque of 35:!:5 ft-Ibs.
3. Put gear (3, Figure 4B-449) in posi-
tion, and install tachometer drive adapt-
er shaft (2). Tighten the shaft to a
torque of 110::!:10 ft-Ibs
4. After the valve lifters and timing gear
cover have been installed, check the tim-
ing as follows:
A. Remove timing pin (A).
Figure 4B-450. Bolt (4) and Cover
B. Tu rn the cran kshaft clockwise as . Bo 1t (5)
seen from the front of the engine ap-
proximately 1/2 tu rn. I nstall timing E. Remove the bolt, and install the plug.
pin (A) again. Remove timing pin (A, Figure 4B-443
on page 4B-135), and install the
C. While turning the crankshaft clock- plug.
wise, push on timing pin (A) until it

4B-136
 NOTE
If the bolt cannot be installed in
the hole of the camshaft gear, cor-
rect timing as follows:
A. With the timing pin (A) installed, re-
move the tachometer drive adapter
housing and shaft.
B. Loosen the gear from the fuel in-
jection pump camshaft. Turn the
crankshaft clockwise approximately
two full turns until bolt (4) can be
installed. I nstall the bolt.
C. Install the tachometer drive adapter
shaft, and tighten it to a torque of
110:!:10 ft-Ibs. Install the adapter
housing. Remove the bolt and timing
pin, and install the plugs.
5. Install the valve lifters.
6. Install the timing gear cover and oil
pump.
7. Install the turbocharger.
Engine 4B-137
 SUBSECTION 4C
CARRIER TRANSMISSION AND TORQUE CONVERTER
GENERAL
This subsection covers operation, trou-
bleshooting, removal, disassembly, as-
sembly and installation of the carrier
powershift transmission and integral tor-
que converter.
SPECIFICATIONS
CONVERTER OUT PRESSURE. 25 psi
minimum pressure at 2000 rpm engine
speed and a maximum of 70 psi outlet
pressure with engine operating at
no-load governed speed.
CONTROLS. Forward and Reverse - Ma-
nual
Speed Selection - Manual
CLUTCH TYPE. Multiple discs, hydrau-
lically actuated, spring released, auto-
matic wear compensation and no
adjustment. All clutches oil cooled and
lubricated.
CLUTCH INNER DISC. Friction.
CLUTCH OUTER DISC. Steel.
01 L FI LTRATION. Full flow oil filter
safety by-pass, also strainer screen in
sump at bottom of transmission case.
CLUTCH PRESSU RE. 240-280 psi - With
parking brake set (see note), oil temper-
ature 180-200oF, engine at idle (400 to
600 rpm), shift thru direction and speed
clutches. All clutch pressure must be
equal within 5 psi. If clutch pressure
varies in anyone clutch more than 5 psi
repair clutch.
NOTE
Never use service brakes while
making clutch pressure checks.
Units having brake actuated de-
clutching in forward and/or re-
verse will not give a true reading.
ALWAYS USE PARKING BRAKE
WHEN MAKING CLUTCH PRESSURE
CHECKS.
OPERATION
With the engine running, the converter
charging pump draws oil from the trans-
mission sump through the removable oil
suction screen and directs it through the
pressure regulating valve and oil filter.
The pressu re regulating valve maintains
pressure to the transmission control cov-
er for actuating the di rection and speed
clutches. This requires a small portion
of the total volume of oil used in the sys-
tem. The remaining volume of oil is
di rected th rough the torque converter
circuit to the oil cooler and returns to
the transmission to provide positive lu-
brication. This regulator valve consists
of a hardened valve spool operating in a
closely fitted bore. The valve spool is
spring-loaded to hold the va-Ive in a
closed position. When a specific pres-
sure is achieved, the valve spool works
against the spring until a port is ex-
posed along the side of the bore. This
sequence of events provides the proper
system pressure.
After oil enters the converter housing, it
is di rected th rough the stator support to
the converter blade cavity and exits
through a passage between the turbine
shaft and converter support. The oil
then flows out of the converter to an oil
Subsection 4C 4C-l
cooler. After leaving the cooler, the oil
is directed to a fitting on the trans-
mission and then th rough a series of
tubes and passages to lubricate the tran-
smission bearings and clutches. The oil
then gravity drains to a transmission
sump.
The hydraulic torque converter consists
of th ree elements and thei r related
parts. These elements are an impeller, a
turbine and a reaction member. Engine
power is transmitted from the engine
flywheel to the impeller element th rough
the impeller cover. This element is the
pump portion of the hydraulic torque
converter and is the primary component
which starts the oil flowing to the other
components. This results in torque mul-
tiplication. The impeller cover can be
compared to a centrifugal pump in that it
picks up fluid at its cen.ter and dis-
charges at its outer diameter.
The torque converter turbine is mounted
opposite the impeller and is connected to
the output shaft of the torque converter.
The turbine receives fluid at its outer
diameter and discharges at its center.
Torque is produced when the impeller di-
rects fluid into a turbine and a reaction
member multiplies torque.
The reaction member of the torque con-
verter is located between and at the cen-
ter or inner diameters of the impeller and
tu rbi ne elements. The reaction member
takes fluid which is exhausting from the
inner position of the turbine and changes
its di rection to allow correct entry for
recirculation into the impeller.
The torque converter multiplies engine
torque to its designed maximum multipli-
cation ratio when the output shaft is at
zero rpm. Therefore, as the output
shaft is decreasing in speed the torque
multiplication is increasing.
A shift control valve assembly consists of
a valve body with selector valve spools.
A detent ball and spring in the selector
spool provides one position for each
speed range. A detent ball and spring
in the direction spool provides three po-
sitions, one each for forward, neutral
and reverse.
With the engine running and the direc-
tional control lever in neutral position,
oil pressure from the regulating valve is
blocked at the control valve, and the
4C-2
transmission is in neutral. Movement of
the forward and reverse spool will direct
oil,. under pressure to either the forward
or reverse direction clutch as desired.
TROUBLESHOOTING
The following guide will help you locate
the source of difficulty in a malfunction-
ing unit. You must consider the torque
converter charging pump, transmission,
oil cooler and connecting lines as a com-
plete system when determining the
sou rce of trouble since the proper opera-
tion of any unit depends on the operation
of the others. By studying the princi-
ples of operation together with data in
this section, you should be able to cor-
rect any malfunction which may occur in
the system.
The TROUBLESHOOTING PROCEDURE
involves MECHANICAL AND HYDRAULIC
checks.
Mechanical Checks
Make the following mechanical checks be-
fore you make any hydraulic checks.
1. Observe all safety rules such as
blocking the vehicle while making
checks.
2. Check all test instruments and equip-
ment - gauges, tachometer, etc. to en-
su re thei r accu racy.
3. Be sure all control lever linkage is
connected and adjusted at all connecting
points.
4. Check shift levers and rods for bind-
ing or restrictions in travel that would
prevent full engagement. Shift levers
by hand at control valve. If full en-
gagement cannot be obtained the difficul-
ty may be in the control cover and -valve
assembly.
5. Check engine and transmission mount-
ings and mounting bolts.
6. Correct any and all mechanical prob-
lems as necessary.
7. If the machine as electrically con-
trolled shift control valve, ensure the
electrical circuits are operating
correctly.
8. Perform the checks outlined under the Low Converter Charging Pump Output
topic, Hydraulic Checks.
1. Low oil level:
Hydraulic Checks Fill to proper level.
Before checking the torque converter, 2. Suction screen plugged:
transmission, and allied hydraulic sys-
tems for pressures and rate of oil flow, Clean suction screen.
make the following preliminary checks:
3. Defective oil pump:
1. Check oil level in transmission. This
should be done with oil temperatures of Replace Pump
180 to 200°F. DO NOT ATTEMPT THESE
CHECKS WITH COLD 01 L.
Overheating
2. To bring the oil temperature to this
specification you must either work the 1. Worn oil sealing rings:
machine or 'stall" out the converter.
Where the former means is impractical, Remove, disassemble, and rebuild con-
the latter means should be employed as verter assembly.
follows:
2.Worn oil pump:
• Engage shift levers in forward and
high speed and apply brakes. Acceler- Replace pump.
ate engine half to three-quarter throttle.
3. Low oil level:
• Hold stall until desired converter outlet
temperature is reached. Fill to proper level.

CAUTION Noisy Converter

Full throttle stall speeds for an 1. Worn oil pump:
excessive length of time will over-
heat the converter. Replace pump
2. Worn or damaged bearings:
Low Clutch Pressure Complete transmission disassembly will be
necessary to determine what bearing is
1. Low oil level: faulty.
Fill to proper level.
Lack of Power
2. Clutch pressure regulating valve
spool stuck open: Low engine rpm at converter stall.
Clean valve spool and housing. Tune engine check governor.
3. Faulty charging pump: See "Overheating" and make same
checks.
Replace pump.
Make corrections as explained in "Over-
4. Broken or worn clutch shaft or piston heating" .
sealing rings:
Replace sealing rings. TORQUE CONVERTER DISASSEMBLY
5. Clutch piston bleed valve stuck open. To disassemble the transmission torque
converter:
Clean bleed valves thoroughly.

Carrier Transmission and Torque Converter 4C-3

 TIGHTEN
10 250 LBS. FT.
1271.2· 338,9 N·m.]

DRAIN BACK LINE

10 TRANSMISSION SUMP

Figure 4C-l. MHR Series Transmission

iYPE "A" FILTER

USE REPLACEMENT
ELEMENT 215502
INSTALL GAUGE IN THIS
LINE FOR CONVERTER
1-...--- DO NOT SUBSTITUTE

"OUT" PRESSURE·

OIL LEVEL
FROM COOLER TO - - ' - CHECK POINT
TRANSMISSION
LUBE DISTRIBUTOR
NOTE: ALL iYPE "A" FILTERS
USE CLARK FILTER REPLACEMENT
ELEMENT PART NO.2' 5502.
CHARGING PUMP OIL
SUCTION SCREEN DO NOT SUBSTITUTE.

Figure 4C-2. Plumbing Diagram

4C-4
 LOW RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • •• • 4TH (HI)

Figure 4C-3. Low Range

Carrier Transmission and Torque Converter 4C-5

 HIGH RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • • • • 4TH (HI)

Figure 4C-4. High Range

4C-6
 INPUT - "

4TH

OUTPUT--- - OUTPUT

Figure 4C-5. Clutch and Gear Arrangement

2. Remove input flange retaining nut,

washer, O-ring, and flange.

Figure 4C-6. Input Flange

1. Remove front cover to transmission
sump drain back line.
Figure 4C-7. Bolts and Washers

Carrier Transmission and Torque Converter 4C-7

3. Remove bolts and washers secu ring
converter housing front cover to con-
verter housing.

6. Remove impeller cover to impeller

bolts.
Figure 4C-8. Front Cover
4. Remove converter housing front
cover.

Figure 4C-11. Impeller Cover

7. Remove impeller cover.
Figure 4C-9. Shaft Support Bearing Proceed with disassembly of the trans-
mission by using the information in this
5. Remove input shaft support bearing. manual.

TRANSMISSION DISASSEMBLY
These instructions cover the disassembly
and reassembly of the transmission in a
sequence that would normally be followed
after the unit has been removed from the
crane and is to be completely
overhauled.

4C-8
 CAUTION NOTE

Cleanliness is of extreme impor- See lubrication section for filter

tance in the repair and overhaul of cartridge change interval.
this unit. Before attempting any
repairs, thoroughly clean the ex-
terior of the unit to prevent the
possibility of dirt entering the
transmission.

fi gure 4C-14. Remol!e Pump and

Figure 4C-12. Side View of
Transmission
Adapter
2. Remove charging pump to regulating
valve stud nuts. Remove pump and fil-
ter adapter.

Figure 4C-15. Pressure Regul~ting

Figure 4C-13. Housing and Element Valve
1. Remove filter housing and filter ele- 3. Remove pressure regulating valve as-
ment. sembly.

Carrier Transmission and Torque Converter 4C-9

 Figure 4C-16. Pump Drive Sleeves
4. Remove pump drive sleeves.
Figure 4C-17. Detent Springs
5. Remove control valve bolts and wash-
ers. Remove control valve. Use caution
as not to lose detent springs and balls.
4C-1O
Figure 4C-18. Remove Cover Bolts
6. Remove impeller cover bolts.
Figure 4C-19. Install Bolts
7. I nstall two bolts in th readed holes
180 0 apart to remove cover from impeller.
NOTE
Some units may have pry slots in-
stead of th readed holes.
 ~

Figure 4C-20. Remove Cover Figure 4C-22. Turbine Retainer Ring

8. Remove impeller cover. 10. Remove turbine retainer ring.

Figure 4C-21. Retainer Ring Figure 4C-23. Turbine and Hub

9. If impeller cover bearing is to be re- 11. Remove turbine and hub assembly.
placed remove retainer ring. Pry bear-
ing from pocket.

Figure 4C-24. Locating Ring

Carrier Transmission and Torque Converter 4C-ll

12. Remove turbine locating ring.

Figure 4C-27. Retainer Ring

15. Remove oil baffle retainer ring.
Figure 4C-25. Retainer Ring
13. Remove reaction member retainer
ring.

Figure 4C-28. Baffle and Impeller

16. Using pry slots in converter
housing, pry oil baffle and impeller from
housing.
Figure 4C-26. Member and Spacer
NOTE
14. Remove reaction member and spacer.
Impeller, oil baffle and impeller
hub gear are removed as an as--
sembly.

4C-12
 Figure 4C-29. Hold Snap Ring Open
Figure 4C-31. Remove Bolts
17. Remove bolts secu ri ng converter
housing to transmission housing. Sup- 19. Remove stator support to housing
port converter housing with a chain fall. bolts.
Using spreading type snap ring pliers,
spread ears on the fourth speed clutch
front bearing retaining ring. Holding
snap ring open tap converter housing
from transmission housing.

Figure 4C-32. Stator Support

20. Remove stator support.
NOTE
Figure 4C-30. Housing and Clutch
Support must be turned to clear
18. Remove converter housing and for- pump drive gear.
ward and 2nd clutch from transmission
housing as an assembly.

Carrier Transmission and Torque Converter 4C-13

 Figure 4C-33. Support Bolts
Figure 4C-35. Pump Drive Gear on
21. Remove pump drive gear bearing Left
support bolts.
23. Remove pump drive gea r on the left.

Figure 4C-34. Pump Drive Gear on

Right Figure 4C-36. Center Pump Drive Gear
22. Move center gear toward the rear of 24. Remove center pump drive gear.
converter housing. Remove pump drive
gear on the right.

4C-14
 Figure 4C-37. Forward Clutch
25. Use a spreading type snap ring pli-
ers to spread the ears on forward clutch Figure 4C-39. Fourth Speed Clutch
front bearing retainer ring. Remove
forward clutch with pry bar. 27. Remove fou rth speed clutch assembly
from transmission housing.

Figure 4C-38. Tap Turbine Shaft

26. Remove turbine shaft gear retainer
ring and gear. From rear of converter
housing tap turbine shaft and bearing
from housing.
Figure 4C-40. Retainer Ring
28. Remove fourth speed clutch disc hub
retainer ring.

Carrier Transmission and Torque Converter 4C-15

 Figure 4C-41. Disc Hub Figure 4C-43. Locating Ring
29. Remove fourth speed clutch disc 31. Remove idler shaft rear bearing lo-
hub. cating ring.

Figure 4C-42. Bearing Cap and Spacer Figure 4C-44. Rear Bearing Cap
30. Remove idler shaft bearing cap bolts, 32. Remove low clutch rear bearing cap.
bearing cap, idler shaft nut and spacer.

4C-16
 Figure 4C-45. Wire and Sealing Ring
33. Cut and remove lock wire. Remove
low clutch shaft oil sealing ring.
Figure 4C-46. Bolts and Plate
34. Remove 3 bolts and bearing retainer
plate.
Carrier Transmission and Torque Converter
Figure 4C-47. Locating Ring
35. Remove bearing locating ring.
Figure 4C-48. Pry Cover from Housing
36. Remove rear cover bolts. Using pry
slots provided, pry cover from trans-
mission housing, tapping on low clutch
and idler shaft to allow cover to be re-
moved without shaft binding.
NOTE
The use of alignment studs will fa-
cilitate cover removal.
4C-17
 38. Remove low clutch double bearing
cup, outer cone and spacer.

CAUTION
Outer cone, double bearing cup,
spacer and inner bearing cone are
replaced as a set.

Figure 4C-49. Remove Lock-Balls

37. Remove bearing lock-balls.

Figure 4C-52. Inner Bearing Cone

39. Remove low clutch inner bearing
cone.
NOTE
To remove the inner cone bearing
at this time without damage, a spe-
cial bearing puller must made (see
Figure 4C-50. Bearing Puller diagram Figu re 4C-53 on page
4C-19) . It may also be removed
following further disassembly of
transmission. Then the outer cage
and rollers may be pulled from the
bearing inner race and the inner
race can be removed after the low
clutch assembly has been removed
from the transmission. See caution
in Figu re 4C-51.

Figure 4C-51. Cup, Cone and Spacer

4C-18
 49164
1116 R. CENT. CUT WITH 1116 RUBBER
WHEEL AFTER HDN.
1/16R.

4-17/64
"O"RING DIA.

Figure 4C-53. Special Bearing Puller Figure 4C-55. Ring and Gear
40. A Bearing Cup must be use with 42. Remove low speed drive gear retainer
bearing puller. ring and drive gear.

Figure 4C-54. Idler Shaft and Gear Figure 4C-56. Reverse and 3rd Clutch
41. Remove idler shaft and gear assembly 43. Remove reverse and 3rd clutch as-
from housing. sembly.

Carrier Transmission and Torque Converter 4C-19

 45. Remove 2nd gear retainer ring.

Figure 4C-57. Remove Snap Ring

44. Remove 2nd gear ring retainer snap
ring. Figure 4C-60. 2nd Gear and End Plate
46. Remove 2nd gear, and 2nd gear bear-
ing end plate.

Figure 4C-58. Remove Retainer Ring

Figure 4C-6l. Low Clutch

47. Remove low clutch assembly.

Figure 4C-59. Remove Retainer Ring

4C-20
 Figure 4C-62. Remove Fork Lockscrew
48. With all clutches and shafts removed,
cut lockwire on range shift fork lock-
screw. Remove fork lockscrew.
Figure 4C-63. Remove Range Shift
Fork
49. Remove range shift rail support
bolts. Remove rail support, rail and
range shift fork.
Carrier Transmission and Torque Converter
Figure 4C-64. Bolts and Bearing Cap
50. Remove output shaft rear bearing
cap bolts and bearing cap.
Figure 4C-65. Push Output Shaft
51. Remove front output flange nut,
washer, O-ring, flange and bearing cap
from housing. Block output gears.
Push output shaft from rear through
gears and taper bearing.
4C-21
 Figure 4C-66. Remove Retainer Ring Figure 4C-68. Baffle and Seal
52. Remove impeller hub gear retainer 54. Lift oil baffle and oil seal assembly
ring. from impeller.

Figure 4C-67. Impeller Hub Gear Figure 4C-69. Remove Bolts

53. Remove impeller hub gear. 55. Remove impeller to hub bolts.

4C-22
 Figure 4C-70. Remove a-Ring Figure 4C-72. Remove End Plate
56. Remove impeller hub O-ring. 2. Remove end plate.

4th Speed Clutch Disassembly

Figure 4C-73. Remove Clutch Discs

3. Remove inner and outer clutch discs.
Figure 4C-71. Remove Retainer
,. Remove end plate retainer.

Figure 4C-74. Remove Components

Carrier Transmission and Torque Converter 4C-23

 6. Remove clutch shaft oil sealing rings.
4. Compress spring retainer washer.
Remove spring retainer snap ring. Re-
lease tension on spring retainer. Re-
move snap ring, spring retainer and
return spring.

Figure 4C-77. Remove Retainer Ring

7. Remove clutch shaft bearing retainer
ring.

Figure 4C-75. Remove Piston

5. Remove clutch piston.

Figure 4C-78. Remove Bearing

8. Remove clutch shaft bearing.

Figure 4C-76. Remove Rings Low Clutch Disassembly

4C-24
 Figure 4C-79. Remove Bearing Race
1. Remove low clutch shaft front bearing
race.
Figure 4C-80. Remove Ring Retainer.
2. Remove low speed gear taper bearing
retainer ring retainer.
Carrier Transmission and Torque Converter
Figure 4C-81. Remove Retainer Ring
3. Remove low speed gear taper bearing
retainer ring.
Figure 4C-82. Remove Bearing and
Spacer
4. Remove low speed gear and outer ta-
per bearing. Remove low clutch taper
bearing spacer.
4C-25
 7. Remove snap ring, ring retainer.

Figure 4C-83. Ring, Plate and Discs

5. Remove clutch end plate retainer
ring. Remove clutch end plate and inner
and outer clutch discs. Figure 4C-86. Remove Retainer Rings
8. Remove clutch piston return Belleville
washer retainer ring. A sleeve with a
portion removed is recommended for re-
moving the clutch piston return spring
Belleville washers and retainer ring.
Sleeve shown is a common pipe, with a
1-1/2" x 1" opening. The pipe is 6" x
3-1/4" x 2-3/4". Compress Belleville
washer. Through opening remove re-
tainer ring. Release tension on washers.
Remove spring retainer ring.

Figure 4C-84. Remove Bearing

6. Remove low gear inner taper bearing.

Figure 4C-87. Washers, Spacer and

Piston
9. Remove Belleville washers and spacer.
Turn clutch over and tap clutch shaft on
a block of wood to remove clutch piston.
Figure 4C-85. Remove Ring and
.Retainer

4C-26
Forward Clutch Disassembly 2. Remove front bearing retainer ring.
Disassemble the forward clutch as
follows:

Figure 4C-90. Remove Front Bearing

3. Remove front bearing.
Figure 4C-88. Remove Piston Rings
,. Remove clutch shaft piston rings.

Figure 4C-91. Remove Locating Ring

4. Remove front bearing locating ring.
Figure 4C-89. Remove Retaining Ring

Carrier Transmission and Torque Converter 4C-27

 Figure 4C-92. Remove Gear and
Bearing Figure 4C-94. Remove Retainer Ring
5. Remove clutch driven gear and outer 7. Remove end plate retainer ring.
bearing.

Figure 4C-95. Remove End Plate

Figure 4C-93. Remove Inner Bearing
8. Remove end plate.
6. Remove inner bearing.

4C-28
 Figure 4C-96. Remove Ring from
Groove
9. Compress return spring retainer.
Remove retainer ring from groove.
Figure 4C-97. Ring, Retainer and
Spring
10. Relieve spring compression. Remove
retainer ring, retainer and spring.
Carrier Transmission and Torque Converter
Figure 4C-98. Remove Clutch Discs
11. Remove inner and outer clutch discs.
Turn clutch over and tap clutch shaft on
a block of wood to remove clutch piston.
2nd Clutch Disassembly
Disassemble 2nd clutch by using the pre-
ceding procedure for forward clutch dis-
assembly.
CLEANING·
Clean all parts thoroughly using an ap-
proved cleaning fluid. Immerse parts in
the fluid and move them up and down
slowly until all old lubricant and foreign
material is dissolved and parts are thor-
oughly cleaned.
CAUTION
Care should be exercised to avoid
skin rashes, fire hazards and inha-
lation of vapors when using sol-
vent type cleaners.
Bearings
Remove bearings from cleaning fluid and
strike flat against a block of wood to dis-
lodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush
out particles. Repeat above operation
until bearings are thoroughly clean.
Dry bearings using moisture-free com-
pressed air. Be careful to direct a
stream across bearing to avoid spinning.
4C-29
 Tighten Impeller Hub
Bolts 41 to 45 Lbs. Ft.
[55,6 - 61,0 N·m)

Tighten Oil Filter

Tighten Turbine Hub 20 to 25 Lbs. Ft.
Bolts 30 to 35 Lbs. Ft. [27,2 - 33, 8 N·m)
[40,7 - 47,4 N·

Tighten Elastic Stop

Nut 200 to 250 Lbs. Ft.
[271,2 - 338,9 N·m)

View"R"

.34
Tighten Elastic Stop 8,6
Nut 200 to 250 Lbs.
[271,2 - 338,9 N·m)

Optional Disconnect
Tighten Elastic Stop
Nut 200 to 250 Lbs. Ft.
[271,2 - 338,9 N·m)

Permatex No. 2
to . of plug
before assembly.

HR 28000 8 SPEED TRANSMISSION

Figure 4C-99. Transmission Reassembly Specifications

4C-30
&. Gear to be .assembled with long hub length to this Notes
side. A. Use Permatex & Crane Sealer Only where
specified.
& Four clutches, 6-outer steel plates, 6- inner bronze B. All lead in chamfers for oil seals, piston rings &
plates. Assemble alternately, starting with outer "0" rings must be smooth & free from burrs.
steel plate. SEE NOTE BELOW C. Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
& Must be loose internal fit bearings, No. "3" etched O. Apply very light coat of Permatex No.2 to 0.0.
on bearing. of all oil seals before ass'y.
E. After assembly of parts using Permatex or
.&. Bearing shield out. Crane sealer, there must not be any free or
excess material that could enter the oil circuit.
.&. Low clutch, 9-outer steel plates, 9-inner bronze F. Apply light coat of Crane Sealer to all pipe
plates. Assemble alternately, starting with outer plugs. .
steel plate. SEE NOTE BELOW G. Apply a thin coating of grease between seal
lips on lip type seals prior to ass'y .
.& Tighten oil screen ass'y. 10 to 15 Lbs. Ft. H. Apply light coat of Permatex No.2 to all thru
[13,6 - 20,0 N·m] hole stud threads.
&. Shim output shaft bearings to produce 6 to 8 Lbs. -
In. [0,68 - 0,90 N·m] preload. NOTE: Metric dimensions shown
.&. Heat nose bushing to 200°F (93°C) before ass'y. in brackets [ ] .
of bushing to cover.

NOTE: The friction discs in

the 1_ clutch has a higher co-efficient. rating than the
friction discs in the other clutches, therefore the discs
must not be mixed. The low clutch inner disc can be
identified by an "X" stamped on one side of the inner
teeth. The 1_ clutch inner disc also has a strip of
non-soluble yellow paint sprayed on the outer edge
of the disc.

View "R" View "a"

Low Clutch Return Springs.

Concave side of first belleville washer to be
Enlarged view of Piston Ring & Expander placed against clutch piston. Remaining four
Note: Expander gap to be approx. 180° from ring washers to be stacked alternately reversed
hook joint to aid ring assembly. as shown.

Torque Specification for Lubricated

or Plated Screw Threads
Grade 5 ED Grade a@
NOM. FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD
SIZE LB·FT [N·M] LB·FT [N·M] LB·FT [N'M] LB·FT -[N·M]
.7500 223·245 [302,4 • 332.11 200·220 [271 .2 . 298.21 315·347 [427.1 ·470,4] 282·310 [382.4· 420.3]
.6250 128·141 [173,6·191.11 113·124 [153.3·168.11 180·198 [224.1 . 268.4] 159·175 [215.6·237.2]
.5625 91·100 [123.4·135.51 82· 90 [111.2· 122.01 128 ·141 [173.6 ·191.1] 115 ·127 [156,0·172.2]
.5000 64· 70 [ 86.8· 94.91 57· 63 [ n.3· 85,41 90· 99 [122.1·134.2] 80· 88 [108.5·119.3]
.4375 41· 45 [ 55.6· 61.01 37· 41 [ 50.2· 55.51 58· 64 [ 78.7· 86.7) 52· 57 [ 70.6· n.2]
.3750 26· 29 [ 35.3· 39.3) 23· 25 [ 31.2· 33.8) 37· 41 [ 50.2· 55.5) 33· 36 [ 44.8· 48.8]
.3125 16· 20 [ 21.7· 27.1) 12· 16 [ 16.'3· 21.6) 28· 32 [ 38.0· 43.3) 26· 30 [ 35.3· 40.6]
.2500 9· 11 [ 12.3· 14.9] 8· 10 [ 10.9· 13.5] 11· 13 [ 15.0· 17.6] 9· 11 [ 12.3· 14.9]

Figure 4C-IOO. Transmission Reassembly Specifications

Carrier Transmission and Torque Converter 4C-31

Do not spin bearings when drying.
Bearings may be rotated slowly by hand
to facilitate drying process.
Housings
Clean interior and exterior of housings,
bearing caps, etc., thoroughly. Cast
parts may be cleaned in hot solution
tanks with mild alkali solutions providing
these parts do not have ground or pol-
ished surfaces. Parts should remain in
solution long enough to be thoroughly
cleaned and heated. This will aid the
evaporation of the cleaning solution and
rinse water. Parts cleaned in solution
tanks must be thoroughly rinsed with
clean water to remove all traces of alkali.
Cast parts may also be cleaned with
steam cleaner.
All parts cleaned must be thoroughly
dried immediately by using moisture-free
compressed air or soft, lintless absor-
bent wiping cloths free of abrasive mate-
rials such as metal filings, contaminated
oil or lapping compound.
INSPECTION
The importance of careful and thorough
inspection of all parts cannot be over-
stressed. Replacement of all parts show-
ing indication of wear or stress will
eliminate costly and avoidable failures at
a later date.
Bearings
Carefully inspect all rollers, cages and
cups for wear, chipping or nicks to de-
termine fitness of bearings for fu rther
use. Do not replace a bearing cone or
cup individually without replacing the
mating cup or cone at the same time. Af-
ter inspection, dip bearings in Automatic
Transmission Fluid and wrap in clean
lintless cloth or paper to protect them
until installed.
Oil Seals, Gaskets, Etc.
Replacement of spring-load oil seals,
a-rings, metal sealing rings, gaskets
and snap rings is more economical when
unit is disassembled than premature ov-
erhaul to replace these parts at a futu re
time. Further loss of lubricant through
4C-32
a worn seal may result in failure of other
more expensive parts of the assembly.
Sealing members should be handled care-
fully, particularly when being installed.
Cutting, scratching, or curling under lip
of seal seriously impai rs its efficiency.
Apply a thin coat of Permatex No. 2 on
the outer diameter of the oil seal to as-
su re an oil tight fit into the retainer.
When assembling new metal type sealing
rings, lubricate them with coat of chassis
grease to stabilize rings in their grooves
for ease of assembly of mating members.
Lubricate alia-rings and seals with the
recommended automatic transmission fluid
before assembly.
Gears and Shafts
If Magna-flux process is available, use
process to check parts. Examine teeth
on all gears carefully for wear, pitting,
chipping, nicks, cracks or scores. If
gear teeth show spots where case hard-
ening is worn through or cracked, re-
place with new gear. Small nicks may be
removed with suitable hone. Inspect
shafts and quills to make certain they
are not sprung, bent, or splines
twisted, and that shafts are true.
Housing, Covers, etc.
Inspect housings, covers and bearing
caps to be certain they are thoroughly
cleaned and that mating surfaces, bear-
ing bores, etc., are free from nicks or
burrs. Check all parts carefully for ev-
idence of cracks or conditions which
would cause subsequent oil leaks or fail-
ures.
Oil Sealing Ring Sleeves
Check forward, reverse and 4th clutch
front oil sealing ring sleeves for wear.
If a groove is starting to wear in the
sleeve, replace sleeve. See Oil Sealing
Ring Sleeve Removal.
TRANSMISSION REASSEMBLY
Reassembly of Forward and 2nd Clutch
To reassemble forward and 2nd clutch:
 3. Install clutch piston return spring,
spring retainer and retainer snap ring.
Insert one steel disc.

Figure 4C-IOI. Install Sealing Rings

,. I nstall new clutch piston inner and
outer sealing rings.
NOTE
Size the rings before you install
the clutch drum by rotating piston
while holding a round object
against the new seal ring as
shown. Rotate piston until seal
ring is flush with inner and outer
diameter of piston. Figure 4C-I04. Alternate Discs
4. Install one friction disc. Alternate
steel and friction discs until the proper
amount of discs are installed. First disc
next to the piston is steel, last disc in-
stalled is friction.

Figure 4C-I02. Install Clutch Piston

2. Insert clutch piston in clutch drum.
Be careful to avoid damaging the sealing
rings.

Figure 4C-I05. Install End Plate

5. Install end plate.

Figure 4C-I03. Insert Disc

Carrier Transmission and Torque Converter 4C-33

 gear into position. Do not force this op-
eration. Gear splines must be in full po-
sition with internal teeth of all friction
discs.

Figure 4C-106. Install Retainer Ring

6. I nstall end plate retainer ring.

Figure 4C-109. Install Outer Bearing

9. Install driven gear outer bearing.

Figure 4C-107. Install Inner Bearing

7. Install clutch driven gear inner bear-
ing.

Figure 4C-111. Install Locating Ring

10. Install front bearing locating ring.

Figure 4C-108. Tap Gear Into

Position
8. Install clutch-driven gear into clutch
drum. Align splines on clutch gear with Figure 4C-112. Install Front Bearing
internal teeth of friction discs. Tap

4C-34
 BEARING SHIELD
MUST FACE OUT

..,--_ _ BEARING SHIELD

MUST FACE OUT

BEARING SHIELD~
FACE OUT

~ BEARING SHIELD
/' MUST FACE OUT

Figure 4C-110. Shielded Bearing Installation

Carrier Transmission and Torque Converter 4C-35

11. I nstall front bearing.
NOTE
Snap ring groove in front bearing
must be down.
Figure 4C-113. Install Retaining
Ring
Figure 4C-114. Install Sealing Rings
13. I nstall clutch shaft oil sealing rings.
Grease rings to facilitate reassembly into
front housings.
Reassembly of Low Clutch
To reassemble low clutch:
4C-36
Figure 4C-115. Insert Piston
1. Install new clutch piston inner and
outer sealing ring. I nsert piston into
clutch drum using caution as not to dam-
age seals. I nstall piston to Belleville
washers spacer. Install Belleville wash-
ers. First washer with large diameter of
washer toward spacer. Alternate (5)
five washers.
Figure 4C-116. Low Clutch Return
Springs
2. Concave side of first Belleville washer
to be placed against clutch piston. Re-
maining four washers to be stacked al-
ternately reversed as shown.
 NOTE

The friction discs in the low clutch

have a higher co-efficient rating
than the friction discs in the other
clutches, therefore the discs must
not be mixed. The low clutch in-
ner disc can be identified by an
"X" stamped on one side of the in-
ner teeth. The low clutch inner
disc also has a strip of non-soluble
yellow paint sprayed on the outer
edge of the disc.

8. Alternate steel and friction discs until

the proper amount of discs are installed.
Figure 4C-117. Install Snap Ring First disc next to the piston is steel, last
disc installed is friction.
3. Position piston return spring Belle-
ville washer snap ring. Compress Belle-
ville washers and install snap ring.

Figure 4C-120. End Plate and Ring

9. I nstall end plate and retainer ring.

Figure 4C-11? Install Retainer

4. Install snap rin~ retainer.

Figure 4C-121. Install Bearing

Spacer
10. Install low clutch taper bearing spa-
Figure 4C-119. Bearing and Discs cer.
5. I nstall low gear inner taper bearing. NOTE

6. Install one steel disc. When installing the 3rd gear in the
3rd speed clutch a bearing space
7. Install one friction disc. is used between the inner and out-
er 3rd gear bearing also.

Carrier Transmission and Torque Converter 4C-37

 NOTE

Retainer ring is selected at assem-

bly for proper thickness. A snap
ring kit is available. Select the
thickest of the three rings in the
kit that can be fitted into the snap
ring groove to assure a proper ta-
per bearing tightness. Check ring
as shown for tight ring-to-bearing
fit.

Figure 4C-122. Install Low Gear

11. I nstall low gear into latch drum.
Align splines on low gear with internal
teeth of friction disc. Tap gear into po-
sition. Do not force this operation.
Gear splines must be in full position with
internal teeth of all friction discs.

Figure 4C-125. Install Retainer Ring

14. Install low speed gear taper bearing
retainer ring.

Figure 4C-123. Install Bearing

12. Install low gear outer taper bearing.

Figure 4C-126. Retainer Ring

Figure 4C-124. Retainer Ring
13. Install low clutch taper bearing re-
tainer ring.
Retainer
15 .. I nstall low speed gear taper bearing
retainer ring retainer.

4C-38
 Figure 4C-127. Install Inner Race
Figure 4C-129. Install Retainer Ring
16. Install low clutch shaft front bearing
inner race with large diameter of race 2. Install bearing retainer ring.
down.

Reassembly of 4th Speed Clutch

To reassemble 4th speed clutch:

Figure 4C-130. Oil Sealing Rings

3. Install clutch shaft oil sealing rings.
Grease the rings to facilitate reassembly
into front housing.

Figure 4C-128. Clutch Shaft Bearing

1. I nstall clutch shaft bearing.
NOTE

Bearing snap ring groove must be

down.

Figure 4C-131. Sealing Rings

4. Install new clutch piston inner and
outer sealing rings. Insert clutch piston

Carrier Transmission and Torque Converter 4C-39

in clutch drum. Use caution as not to
damage sealing rings.

Figure 4C-134. Install Retainer Ring

9. I nstall end plate retainer ring.
Figure 4C-132. Install Components
5. Install clutch piston return spring, Reassembly of Transmission
spring retainer and retainer snap ring.
Reassemble the transmission as follows:
6. Insert one steeldisc. Install one fric-
tion disc.
7. Alternate steel and friction discs until
the proper amount of discs are installed.
Fi rst disc next to the piston is steel, last
disc installed is friction.

Figure 4C-135. Output Shaft

1. View of output shaft as it would be
positioned in transmission case. Note
front bearing cone and output gear
th rust washer shouldered on shaft with
large diameter of bearing in.
Figure 4C-133. Install End Plate
8. I nstall End Plate.

Figure 4C-136. Shaft, Bearing,

Thrust Washer

4C-40
2. Position high and low range gears,
shift hub, hub sleeve and needle bear-
ings in transmission case as shown in the
previous figure. Insert output shaft,
front bearing and thrust washer through
output gears. Use caution as not to
damage high and low range gear needle
bearings.

Fi g-ure 4C-139:-Bearing Cap and Cup

Figure 4C-137. Thrust Washer and
Bearing
3. Position output gear thrust washer
and rear taper bearing on output shaft.
5. Using new O-rings install rear output
bearing cap and taper bearing cup on
transmission case. Lube opening in
bearing cap must be aligned with lube
opening in case. Tighten bearing cap
bolts to specified torque (see Torque
Specifications at the beginning of this
subsection) .

Figure 4C-140. Bearing Cap and Shims

4. Block output shaft from the front and
install rear taper bearing.
6. Install front bearing cap and shims.
Tighten bolts to specified torque. Tap
output shaft front and rear to seat taper
bearings. Loosen front bearing cap
bolts.

Carrier Transmission and Torque Converter 4C-41

 Figure 4C-141. Check Bearing Preload
Figure 4C-143. Torque Support Bolts
.7. Using an inch lb. torque wrench, de-
termine the rolling torque of the output 9. Tighten support bolts to specified
shaft and record. Tighten front bearing torque (see Torque Specifications at the
cap bolts to specified torque. Check beginning of this subsection.
rolling torque with bolts tight. Torque
must be 6 to 8 in-Ibs more than when
bearing cap bolts were loose. Add or
omit shims on the front bearing cap to
achieve the proper preload.

Figure 4C-144. Lockscrew and

Lockwi re
Figure 4C-142. Rail Support and Rail 10. Locate lockscrew hole in shift rail
with hole in shift fork. Install
8. Locate high-low range shift fork in lockscrew, tighten securely and lockwire
shift hub with offset of fork toward to prevent loosening.
rear. I nsert shift rail support and rail
into bore in transmission housing and in-
to shift fork.

Figure 4C-145. Install Components

4C-42
11. I nstall output shaft front companion
flange, flange 0- ring, washer and flange
nut. Block output gear. Tighten nut
200 to 250 ft-Ibs torque.

14. Install 2nd speed bearing end plate

and 2nd speed gear on low clutch shaft.

Figure 4C-146. Install Bearing

12. Install low clutch front bearing.

Figure 4C-149. Install Retainer Ring

,. 15. Install 2nd speed gear retainer ring.
Figure 4C-147. Low Clutch Assembiy
13. Install low clutch assembly from rear
of transmission case.

Figure 4C-150. Install Ring Reta ner

16. Install 2nd speed gear retainer ring
retainer.

Carrier Transmission and Torque Converter 4C-43

 Figure 4C-154. Gear and Retainer
Figure 4C-151. Install Snap Ring Ring
17. Install 2nd gear ring retainer snap 19. Install low speed drive gear and re-
ring as shown in the next illustration. tainer ring.

Figure 4C-152. Snap Ring Position

Figure 4C-155. Install Gear Assembly
20. I nstall idler shaft gear assembly.

Figure 4C-153. Install Clutch

Assembly
18. Install reverse and 3rd clutch assem-
bly from the front of the transmission.
Figure 4C-156. Install Taper Bearing

4C-44
 23. Install bearing cup.
21. Install low clutch inner taper
bearing.
NOTE
Heat bearing in hot oil bath prior
to installation.

Figure 4C-159. Install Bearing

24. Install outer taper bearing.
NOTE
Heat bearing in hot oil bath prior
to installation.
Figure 4C-157. Install Bearing
Spacer
22. Install

Bearing
25. Install retainer plate, inner diameter
chamfer toward bearing.

Figure 4C-158. Bearing Cup

Carrier Transmission and Torque Converter 4C-45


Figure 4C-161. Torque and Lockwire
Bolts
26. Install bolts and block gears. Tor-
que bolts to specifications and lockwi re
together.
Figure 4C-162. Install Sealing Ring
27. Install low clutch shaft sealing ring.
Figure 4C-163. Spacer and Nut
4C-46
28. Install idler shaft spacer and nut.
Torque nut 250 to 300 ft-Ibs.
Figure 4C-164. Notches in Cover
29. I nstall alignment studs and new gas-
ket. Place lock balls in low shaft and
idler shaft. A light coat of grease will
hold lock balls in place. Position shafts
so lock balls align with notches in rear
cover.
30. Tap cover in place and secure with
bolts and lock washers. Torque cover
bolts to specifications.
 33. Install bearing cap with bolts and
lockwashers. Torque to specifications.

Figure 4C-166. Install Snap Ring

31. Tap low clutch and idler shaft to
rear of transmission to allow for rear
bearing snap ring clearance. Install
snap ring.
Figure 4C-169. Install Locating Ring
34. Install idler shaft rear bearing locat-
ing ring.

Figure 4C-167. O-Ring and Gasket

32. I nstall new O-ring and gasket on low
shaft bearing ca .
Figure 4C-170. Torque Bolts
35. Use new gasket and install idler
shaft bearing cap and cap bolts and
lockwashers. Torque bolts to specifica-
tions.

Carrier Transmission and Torque Converter 4C-47

 38. Position pilot bearing on fourth
speed clutch shaft. Install fourth clutch
on disc hub. Be careful to avoid damage
to the pilot bearing.

Figure 4C-171. Clutch Disc Hub

36. Position 4th speed clutch disc hub on
idler shaft.

39. Position 2nd speed clutch shaft pilot

bearing on shaft. From the front of the
transmission case install the forward and
2nd clutch assembly.

TORQUE CONVERTER REASSEMBLY

To reassemble the integral torque con-
verter:

Figure 4C-172. Install Retainer Ring

37. Install disc hub retainer ring.

Figure 4C-175. Install Piston Ring

Race
1. I nstall new oil sealing rings on the
turbine shaft piston ring race. Grease
rings lightly and position race in trans-
mission housing.
2. Position the converter housing on the
transmission housing.
Figure 4C-173. Install Fourth Clutch

4C-48
 NOTE
With reaction member in full posi-
~ion on support it must free-wheel
in a clockwise direction.

3. Install impeller hub bearing spacer.

Figure 4C-179. Install Thrust Washer

...
6. Install reaction member th rust
washer.

,_
Figure 4C-177. Retainer Ring
4. I nstall bearing spacer retainer ring.

7. Install thrust washer retainer ring.

Figure 4C-178. Free Wheel Assembly
5. Install free wheel assembly on free
wheel support.

Carrier Transmission and Torque Converter 4C-49

 10. Pos ition tu rbi ne on tu rbi ne shaft.

Figure 4C-181. Locating Ring

8. Install turbine locating ring.
Figure 4C-184. Turbine Retainer Ring
11. Install tu rbine retainer ring.

Figure 4C-182. Front Piston Ring

9. I nstall turbine shaft front piston
ring. Figure
12. With new O-Ring in position and
lightly lubricated, install lock-up cover
to impeller. Align teeth on clutch disc
tu rbine hub with internal teeth in clutch
disc.

Figure 4C-183. Position Turbine on

Shaft

4C-50
 15. Using new gaskets install adaptor
ring and front cover to converter hous-
ing.
NOTE
Drain back hole in front cover
must be in the lowest posit!on
when the transmission is reIn-
stalled in the machine; this to al-
lows leakage oil to return to the
transmission oil sump.

Figure 4C-186. Torque Impeller Bolts

13. Install lock- up cover to impeller bolts
and tighten to specified torque.

Figure 4C-189. Torque Nuts

16. Install washers, bolts and nuts.
Tighten 23 to 25 ft-Ibs torque.

Figure 4C-187. Install Front Bearing

14. Install input shaft front bearing.

Figure 4C-190. Install Control Valve

17. Loeate detent balls and springs in
control valve. Position new gasket. Se-
cure valve with boJts and washers.
Figure 4C-188. Adaptor Ring and Tighten to specified torque.
Cover

Carrier Transmission and Torque Converter 4C-51


,d,
Figure 4C-191. Pump Drive Sleeves
18. Install_pump drive sleeves.
Figure 4C-192. Pressure Regulator
Valve
19. Position new gasket and O-rings on
pressu re regulator valve. I nstall valve
on studs.
Figure 4C-193. Install Pump
20. With new valve body to pump gasket
in position insert pump drive shaft
4C-S2
th rough valve body. Do not damage the
valve body oil seal. You may have to
tu rn impeller one way or the other to
align pump shaft with drive sleeves.
21. Install new O-Ring in filter adaptor
housing. Install filter element and hous-
ing. Tighten filter housing 20 to 25
ft-Ibs torque.
Oil Sealing Ring Sleeve Removal
Figure 4C-194. Retaining Ring
1. Remove clutch front bearing retaining
ring.
Figure 4C-195. Remove Screw and
Washer
2. Remove front oil sealing ring sleeve
retainer screw and washer.

Figure 4C-196. Remove Sleeve Lock
3. Remove sleeve lock.
Figure 4C-197. Remove Sleeve
4. Using a sleeve puller like the one
shown, remove sleeve.
Figure 4C-198. Sleeve Being Removed
Carrier Transmission and Torque Converter
5. Sleeve being removed.
NOTE
When installing a new sleeve it is
recommended a press or a driver
be used to prevent damage to the
sleeve and be sure the notch in
the sleeve is aligned with sleeve
lock notch.
Figure 4C-199. Companion Flange
6. Install companion flange, flange
O-Ring, washer and nut. Tighten nut
200 to 250 ft-Ibs torque. I nstall front
cover to transmission sump drain back
line.
NOTE
Drain back hole in front cover
must be in the lowest position
when the transmission is rein-
stalled in the machine; this will al-
low leakage oil to return to the
transmission oil sump.
SERVICING TRANSMISSION AFTER OV-
ERHAUL
After the overhauled or repai red trans-
mission has been installed in the
machine, the oil cooler and connecting
hydraulic system must be thoroughly cle-
aned. This can be accomplished in se-
veral manners and a degree of judgment
must be exercised as to the method em-
ployed.
The following are considered the minimum
steps to be ta ken:
4C-53
1. Drain entire system thoroughly.
2. Disconnect and clean all hydraulic
lines. Where feasible, hydraulic lines
should be removed from machine for cle-
aning.
3. Replace oil filter elements, cleaning
out filter cases thoroughly.
4. The oil cooler must be thoroughly, cle-
aned. The cooler should be 'back
flushed" with oil and compressed air un-
til all foregoing material has been re-
moved. Flushing in direction of normal
oil flow will not adequately clean the
cooler. If necessa ry, cooler assembly
should be removed from machine for cle-
aning, using oil, compressed air and
steam cleaner for that pu rpose. DO NOT
use flushing compounds for cleaning
pu rposes.
5. Reassemble all components and use on-
ly the type of oil recommended in lubri-
4C-54
cation section. Fill transmission th rough
filler opening as follows:
A. Remove LOWER check plug, fill until
oil runs from LOWER oil hole. Re-
place filler and level plug.
B. Run engine two minutes at 500-600
RPM to prime torque converter and
hydraulic lines. Recheck level of flu-
id in transmission with engine run-
ning at idle (500-600 RPM).
C. Add quantity necessary to bring fluid
level to the LOWER oil level check
plug hole. Install oil level plug. Re-
check with hot oil (180 to 200 0 F).
D. Bring oil level to the UPPER oil level
plug.
E. Recheck all drain plugs, lines, con-
nections, etc., for leaks and tighten
where necessary.
 SUBSECTION 4D

DR IVE SHAFTS

GENERAL ence is the length of the shafts, and

This subsection describes the drive
shafts used on this machine, and in-
cludes information concerning the disas-
sembly, repai r, and reassembly of these
shafts.
DRIVE SHAFTS
OESCRI PTION. The five drive shafts
used on this machine are nearly
identical. They have double roller bear-
ing universal joints with bolt on bearings
and slip type yokes. The major differ-
made up of the components shown in
Figure 40-1.
INSPECTION ANO REPAIR. Periodic in-
spections of the drive shafts are recom-
mended to check for proper lubrication,
excessive wear, and/or any loose, miss-
ing or damaged components.
To service a drive shaft, proceed as fol-
lows, (see Figure 40-1):

GREASE
FITTING

I
'0,

STUB
YOKE CORK
WASHER
" \ __ " CAPSCREW

~ ~M \t?\ /
SPLIT
FELT
SEAL ~'-:~t::ER
GREASEV
FITTING
r

1-
- £t)~71 WING
~-... J V -

""'-' " - BEARING F260

Figure 40-1. Drive Shaft

Subsection 40 40-1
 WARNING
Prior to removing the drive shaft,
support the drive shaft to prevent
it from dropping. Block the wheels
to prevent the machine from
rolling.
1. Remove the drive shaft as follows:
NOTE
If only one of the spiders and
bearings require replacement, only
partial shaft removal is necessary
due to the slip yoke and the bolt
on bearings.
A. Remove the capscrews which secure
the wing bearings to the yoke fitting
on the transmission or axle.
B. If necessary, tap the wing bearings
slightly to free the bearing drive lugs
from their seat in the yoke fittings.
Remove the complete drive shaft from
the mach i ne.
2. Disassemble the drive shaft as
follows:
A. Clamp the drive shaft in a bench
vise, being careful not to distort the
slip yokes or drive tube. Then re-
move the remaining bearings and spi-
ders.
B. If necessa ry, unscrew the stuffing
cap and pull the stub/tube yoke as-
sembly from the internal splines of
the slip yoke assembly.
C. Remove the washers, felt seal and
stuffing cap from the stub or tube
yoke.
D. I nspect the components for excess
wear or damage. Check the yoke
splines to be sure they are clean and
free of burrs, etc.. Repair of the
drive shafts is limited to the replace-
ment of parts found in the service
kits for the shafts.
NOTE
Replace both the spider (jou rnal
cross) and bearings if replacement
of any part is necessary. Do not
4D-2
use old bearings with a new
spider, or new bearings on an old
spider or problems may result.
3. Assemble and install the spider (jour-
nal cross), and bearings on the drive
shaft yoke as follows, (see Figure 4D-l
on page 4D-l):
A. I nstall the cork washer and wing
bearings on the spider.
B. With the wi ng bea ri ngs assembled on
the spider, insert one of the wing
bearings in the keyway of the drive
shaft yoke. Make sure the key of the
bearing is resting in the slot of the
yoke. Do Not attempt to install the
capscrews until both wing bearings
are seated in the yoke.
C. The bearing washers, see
Figu re 4D-1 on page 4D-l, must be
compressed slightly before the wing
bearings can be seated in the yoke.
This washer compression can be done
by clamping the opposite bearings
with a "C"clamp then pushing the
bearings into the yoke pilot until the
bearing keys are seated into their as-
sociated slots.
D. Install the wing bearing capscrews.
Tighten the capscrews in equal steps
with a final torque of 37-49 ft-Ibs.
4. If the slip yoke was separated from
the stub or tube yoke, install the stuff-
ing cap, outer washer, felt seal, and in-
ner washer over the splines of the stub
or tube shaft.
5. Apply a coating of molybdenum disul-
fide grease or equivalent to the splines
of the yoke assemblies. Then make sure
the arrows stamped in the slip yoke and
the stub or tube yoke are aligned, en-
gage the splines of the stub or tube yoke
into the internal splines of the slip yoke
6. Screw the stuffing cap onto the
threads of the slip yoke, then check the
shaft length slippage. The shafts should
be able to slip approximately 2.25 inches
7. While supporting the shaft assembly
under the machine, assemble and connect
the bearing and spider assemblies to the
associated yokes on the transmission and
axle differential.
8. Grease the spider and slip yoke brication specifications in Section 3 of
grease fittings as required, see the lu- this manual.

Drive Shafts 40-3

 SUBSECTION 4E
AXLES
DESCRIPTION
This machine is equipped with four
axles: two drive-steer axles at the front,
and two rigid. drive axles at the rear.
Both inner axles (rear-front and
front-rear) use split torque differentials
to provide drive power to the front-front
and rear-rear axles.
REMOVAL
To remove an axle from the machine,
proceed as follows:
1. Swing the boom over the front of the
machine and lower it onto the boom rest.
2. Raise the tires off of the ground us-
ing the outriggers and place jacks or
wooden blocking under the frame. Lower
the machine onto the blocking and re-
tract the outriggers.
3. Remove the wheels.
4. Disconnect the propeller shaft be-
tween the axle and the transmission, as
described in Subsection 4D.
5. Tag and disconnect the hydraulic
lines at the steering cylinders. Move the
lines to the side where they will not in-
terfere with axle removal. Place caps
and covers on the hydraulic lines and
cylinders to prevent hydraulic system
contami nation.
6. Tag and disconnect the brake supply
lines at the brake chambers and move
them clea r of the work a rea.
NOTE
Make a thorough visual inspection
of the area around the axle to
make sure that all hydraulic, air
and electric lines are clear of the
axle.
7. Place suitable jacks under the axle to
prevent the axle from moving while the
mounting hardware is removed.
8. Remove the bolts which secure the ax-
le to the suspension cylinders.
9 .. Lower the axle from the mounting po-
sition and remove the axle from below the
carrier.
10. Move the axle to a suitable work
area.
OVERHAUL
Planetary Hub Reducer Disassembly
Disassemble the planetary hub reducers
according to the following procedu reo
(Refer Figure 4E-1 on page 4E-2)
NOTE
Drain the axle and differential
housing before starting disassem-
bly.
1. Place the axle on steel horses or a re-
pai r stand to facil itate disassembly.
Subsection 4E 4E-1
 II

1
13
01. BRAKE ASSEMBLY
02. SEAL RACE
03. WHEEL HUB ASSEMBLY
04. OIL SEAL
05. TAPER BEARING
06. TAPER BEARING
07. RING GEAR CARRIER
08. TAPER RING
09. LOCKING WASHER
10. SPINDLE NUT
11. AXLE SHAFT
12. PLANET GEAR CARRIER
13. COVER
14. SECTOR
15. THRUST RETAINING WASHER
16. O-RING
17. DRAIN PLUG
18. DRAIN PLUG SEAL
19. SCREW
20. SUN GEAR
21. SLEEVE
22. SCREW
23. AXLE END POSITIONER
24. SPINDLE RING
25. WHEEL STUD
26. WHEEL NUT
27. BRAKE DRUM

Figure 4E-l. Exploded View, Planetary Hub Reducer

4E-2
 WARNING
Install a "c" clamp on each end of
the axle housing to secure the axle
to the supporting structure to
prevent the axle assembly from
slipping off the repair stand. Inju-
ry to personnel may result if this
precaution is not observed.

Figure 4E-3. Removing Planet Carrier

sary to tap the ring gear with a mallet to
remove the taper ring.
8. Remove the ring gear, using a pinch
bar, and tap out the bearing. Remove
the wheel hub assembly.

Figure 4E-2. Removing Wheel Nuts

2. Remove the wheel nuts. Remove the
three brake drum screws.
3. Intal1 a MlO screw in each brake drum
screw hole, and tighten each screw
equally to jack the brake drum from the
planetary hub.
NOTE
The brake shoes should be fully
released to facilitate brake drum
removal.

4. Remove the cover plate screws, the
cover plate, a-ring, and sector plate.
On drive-steer axles, remove the sun
gear retainer screw and the sun gear.
On rigid drive axles, the axle shafts is
pulled out with the sun gear.
5. Remove the three planet carrier
screws.
6. Intall a M10 screw in each planet car-
rier screw hole, and tighten each screw
equally to jack the planet carrier from
the axle (see Figu re 4E-3).
7. Remove the spindle nut and lockwash-
er, and the taper ring. It may be neces-
Figure 4E-4. Removing 0;1 Seal
9. Remove the oil seal and the bearing
cups using a mallet and spike tool.
NOTE
If it is necessary to change the
wheel studs, remove them on a
press and replace with studs
stamped with an "R".
10. Remove the brake assembly. Save the
baffles if the brakes are to be changed.

Axles 4E-3
 NOTE
11. Remove the seal race (see
Tag the brake assemblies (right or Figure 4E-5).
left) to facilitate reassembly.

Figure 4E-5. Removing Seal Race

4E-4
 09

07
06

20 19 04
22
06
18
21

tol------03

18
06
19
04
11 06

13
07
12
10

09

01. CONSTANT VELOCITY JOINT 13. DUST COVER

02. SEALING KIT 14. NUT
03. PIVOT AND SPINDLE 15. DOWEL
04. LINK KIT 16. TIE ROD CLAMP
as. OIL SEAL 17. STEERING ARM
06. ADJUSTING SHIM KIT lS. BUSHING
07. GREASE FITTING 19. KING PIN
OS. FLANGE 20. BEARING
09. SCREW 21. RETAINER
10. STEERING SWIVEL ARM 22. WASHER
11. TRACK LOAD 23. WASHER
12. TIE ROD END

Figure 4E-6. Exploded View, Steering Joint

Axles 4E-5
 40
i
, I I I I
i 454.448 41 36 38393735
i ~~...I
I f~
I e.

o~~I 27
46

32
'--~--r""-I..- - - - - - - - - - - -,
33 242526 I

1312 11 10 ~9 03 06
, 070805
,
I I I !
!
02
Ol. DIFFERENTIAL CARRIER 20. DRIVEN GEAR 39. FORK FINGER
02. HOUSING 2l. ADJUSTING SHIM KIT 40. LOCKING CYLINDER
03. HOUSING AND COVER 22. TAPER BEARING 41. SCREW
04. LOCATING PIN 23. ADJUSTING NUT 42. SCREW
05. SCREW 24. STUD 43. SHIMS
06. ADJUSTING NUT 25. NUT 44. CONTACTOR
07. NUT, LOCK PLATE 26. WASHER 45. PROTECTOR
OB. SCREW 27. ADJUSTING NUT 46. OIL SEAL
09. FRONT HOUSING 2B. INPUT FLANGE 47. BALL
10. SCREW 29. DUST COVER 4B. LOCK NUT
11. COVER 30. OIL SEAL 49. OUTPUT SHAFT
12. SCREW 31. ADJU'STING SHIM KIT 50. BEARING
13. SCREW 32. TAPER BEARING 51. O-RING
14. DIFFERENTIAL AND BEVEL GEAR 33. SPLIT TORQUE 52. OUTPUT HOUSING
15. TAPER BEARING 34. DIFFERENTIAL LOCK 53. OUTPUT HOUSING
16. TAPER BEARING 35. CLUTCH GEAR 54. SCREW
17. ADJUSTING SHIM KIT 36. FORK KIT- 55. OIL SEAL
lB. TAPER BEARING 37. FORK RETAINING RING 56. OUTPUT FLANGE
19. ADJUSTING SHIM KIT 3B. FORK PIN
Figure 4E-7. Exploded View, Split Torque Differential Carrier

4E-6
 18 15
20

17

01. DIFFERENTIAL CARRIER 11. ADJUSTING SHIM KIT

02. HOUSING AND COVER 12. TAPER BEARING
03. SCREW 13. ADJUSTING SHIM KIT
04. LOCATING PIN 14. ADJUSTING SHIM KIT
05. ADJUSTING NUT 15. TAPER BEARING
06. NUT, LOCK PLATE 16. OIL SEAL
07. SCREW 17. FLANGE
OB. DIFFERENTIAL AND BEVEL GEAR lB. DUST COVER
09. TAPER BEARING 19. ADJUSTING NUT
10. TAPER BEARING 20. DIFFERENTIAL LOCK

Figure 4E-8. Exploded View, Standard Differential Carrier

Axles 4E-7
Steering Joint Disassembly NOTE

The following procedu re is only applica- On the standard differential, pro-

ble to the drive-steer axle (see ceed directly to removal of the in-
put flange (see Figure 4E-8 on
1. Remove the upper flange screws and page 4E-7) .
the upper flange. If necessary, use pul-
ler screws to loosen the flange. Mark and
save the shims. Remove the king pin.
NOTE

Use the same procedu re for the

lower flange.

2. Remove and discard the upper and

lower seals.
3. Remove the pivot and spindle. Re-
move the upper and lower bushings.
4. Pull the axle shaft from the housing.
Remove the seals, washers, retainer,
and bearings from the axle.
Figure 4E-IO. Removing Split Torque
Differential Carrier Disassembly Different i a 1
The following procedure applies specif- 3. Remove the front housing cover
ically to the split-torque differential, screws. Carefully lift off the front hous-
which also includes a standard differen- ing cover along with the split torque dif-
tial. Relevant exceptions, applicable to ferential
the standard differential, are noted (see
Figure 4E-7 on page 4E-6 and
Figure 4E-8 on page 4E-7):

Figure 4E-ll. Removing Bearing Cone

Figure 4E-9. Lifting Differential
1. Lift the differential carrier from the
axle housing and fasten it to a swivel
bracket plate to facilitate disassembly.
2. Remove the nut and input flange. I n-
tall the removal tool.
4. Remove the oil seal from the front
cover housing. Tap out the bearing cup
from the cover housing, and pull the
bearing cone from the split torque dif-
ferential.

4E-8

Figure 4E-12. Removing Planet Gear
5. Remove the planet gear, bushing, and
bearing cone as an assembly. Then sep-
arate the bearing cone and bushing.
6. Remove the differential lock actuating
cylinder, the fork pin, clutch gear, and
the fork.
NOTE
The split-torque differential carri-
er has differential locks. The
standard differential carrier has
one lock.
Figure 4E-13. Removing Differential
7. Remove the differential bearing caps
and the differential nut and lift out the
differential assembly.
8. Pull off the cone bearing from the dif-
ferential and bevel gear, and the cone
bearing from the side gear, or crown
wheel side.
NOTE
It may be necessary to break the
bearing cage to place the puller
hooks.
9. Remove the bevel pinion nut (Item 23,
Figure 4E-7 on page 4E-6) and the bevel
pinion. Separate the bearing cones,
shims, spacer, and the driven gear (only
on split-torque differentials) from the
pinion shaft.
10. Remove bearing cups from the hous-
ing.
Cleaning and Inspection
GENERAL
WARNING
Care should be exercised to avoid
skin rashes, fire hazards and inha-
lation of vapors when using sol-
vent type cleaners. Serious injury
may result to personnel if this
precaution is not observed.
Thoroughly clean all parts of the axle us-
ing a suitable cleaning agent. It is re-
commended that the parts be immersed in
cleaning fluid and moved slowly up an d
down until all old lubricant and foreign
material is dissolved and the parts are
thoroughly clean.
The importance of careful and thorough
inspection of all parts cannot be
over-stressed. Replacement of all parts
showing indication of wear or stress will
eliminate costly and avoidable failures at
a later date.
CAUTION
Dry all parts using low pressure
compressed a.ir .. Do not use paper
towels or shop towels to dry parts.
The use of paper or cloth to dry
parts will introduce lint into the
axle assembly possibly leading to
axle component failure.
Axles 4E-9
BEARING CLEANING. Remove the bear-
ings from cleaning fluid and strike the
larger side of the cone flat against a
block of wood. This will dislodge solidi-
fied particles of lubricant. Again im-
merse the bearing in cleaning fluid to
flush out the remaining particles. Re-
peat the above operation until the bear-
ing is thoroughly cleaned. Dry the
bearing using moisture free compressed
air. Be Careful to direct the air stream
across the bearing to avoid spinning the
inner race. DO NOT SPIN BEARINGS
WHILE DRYING THEM OR THE BEAR-
INGS WI LL BE DESTROYED. Bearings
may be rotated slowly, by hand, to facil-
itate drying.
WARNING
Care should be exercised to avoid
skin rashes and inhalation of va-
pors when using alkali cleaners or
serious personal injury may result.
Thoroughly clean the interior and exteri-
or of the housings, bearing caps, etc.,
in solution tanks using a mild alkali sol-
ution, providing these parts do not have
ground or polished surfaces. Parts
should remain in solution long enough to
be thoroughly cleaned and heated. This
will aid in evaporation of the cleaning
agent and rinse water. Parts cleaned in
solution tanks must be thoroughly rinsed
with clean water to remove all traces of
al kali. Cast parts may also be cleaned
with a steam cleaning system. Thorough-
ly dry all parts using moisture-free
compressed ai r.
WHEEL AND PARKI NG BRAKE CLEAN-
ING. Do not use solvents or cleaning
fluids on brake shoes. Thoroughly clean
the brake shoes with a wire brush.
Inspection
BEARI NGS. Carefully inspect all
rollers, cages and bearings cups for
wear, chipping or nicks to determine fit-
ness of the bearings for further use. Do
not replace a bearing cone or c;up indi-
vidually without replacing the mating cup
or cone at the same time. After in-
spection, dip the bearings in clean light
oil and wrap in clean lintless paper to
protect them until they are installed.
4E-10
01 L SEAL, GASKET AND SNAP RI NG.
Replacement of spring loaded oil seals,
gaskets and snap rings is more econom-
ical when the unit is disassembled than
taking the risk of having to disassemble
the unit just to replace an oil seal. Loss
of lubricant th rough a worn seal may re-
sult in failure of other, more expensive,
parts of the axle. Sealing members
should be handled carefully, particularly
when being installed. Cutting, scratch-
ing or cu rling under the lip of an oil seal
seriously impai rs its efficiency. At reas-
sembly, lubricate the lips of all seals
with Lubriplate.
GEAR AND SHAFT. If a magna-flux
testing process is available, use this
process to check the parts. Carefully
examine the teeth and ground and pol-
ished surfaces of all gears and shafts for
wear, pitting, chipping, nicks, cracks
or scratches. If the gear teeth are
cracked or show spots where the case
hardening has worn th rough, replace the
gear. Small cracks may be removed by
using a suitable hone. Inspect the shaft
to make certain they are not sprung or
bent, or that the splines are twisted,
and that they are true.
NOTE
The differential pinions and side
gea rs must be replaced as sets.
The differential ring gear and
bevel pinion must be replaced as a
set. This is because the pinion
and the gears sets are matched
sets and replacing only one gear
or one pinion will cause prematu re
failure of the remaining parts.
HOUSING AND COVER. Inspect the
housings, covers, planet spider, and the
differential case to be certain they are
thoroughly cleaned and that the mating
surfaces, bearing bores, etc. are free of
nicks, burrs and foreign materials.
Check all parts carefully for evidence of
cracks, or conditions which would cause
subsequent oil leaks of failures.
ASSEMBLY
Differential Carrier Assembly
The following procedure applies specif-
. ically to the split-torque differential,
 INSTRUCTIONS FOR THE ASSEMBLY OF DIFFERENTIAL CARRIER 500 WITH DROP GEAR

A
Engraved dimension

,I '
I
Ii
.~ I

ADJUSTMENTS
• 500 DG

BEARING SHIM IN THE HOUSING

=X-Y

X = Actual size measured from bearing carrier shoulder

to differential axis
y = Height to the bearing (h) + value of the engraved
dimension (corrected tapered distance) marked on
the bevel pinion

SPACER RING ON THE BEVEL PINION

=b+c

•
Measure dimensions «b» and «C)l

ADJUSTMENT OF THE BEVEL PINION PRELOAD

Select shims (1) to get rotational resistance torque of the bevel
pinion (without sea)) : 2.5 to 3.25 ft-)bs
BACKLASH ADJUSTMENT ACCORDING TO BEVEL
GEAR SET:
Se lect the sh im to get a back lash of : .012 to .016 inch
ADJUSTMENT OF THE DIFFER'ENTIAL BEARING PRELOAD
Tighten differential nut to get proper spacing at the bearing caps: .01 to .02 inch 4.3 to 5 ft-Ibs
Check the rotational resistance torque of the bevel gear set
(measured at the flange after assembly of the differential carrier)

As.mbly of the beering QPI

Tightening torque of the screws: 123 to 137 ft-Ibs
Loclcing of the differential nut
ITigntening torque of the screws: 11 to 18 ft-Ibs -
01 Aaambly of the flange
Tightening torque of the nut: 542 to 578 ft-Ibs
• CHECKING OF THE PLANETARY GEAR SIDE CLEARANCE Measure dimensions x and y : y - x ;;.. .01 inch

IADJUSTMENT OF THE SPLIT TORQUE DIFFERENTIAL

IPRELOAD
I Adjust the thickness of the shim: (A - B) measured + P
P = bearing preload = .004 to .006 inch
ICheck the rotational resistance torque of the assembly
i(measured at the flange) : 4.7 to 5 ft-Ibs

Figure 4E-14. Split Torque Differential Specifications

Axles 4E-ll
 INSTRUCTIONS FOR THE ASSEMBLY OF DIFFERENTIAL CARRIER 500 WITH DROP GEAR

ADJUSTMENTS 500 DG

•• Assembly of the input housing

Tightening torque of the screws:

Assembly of the input flange

Tightening torque of the screws:

Assembly of the differential carrier housing

43 ft-Ibs

759 to 795 ft-Ibs

Tightening torque of the studs: 76 ft-Ibs

• ,Tightening torque of the nuts: thread pitch = 2.0 127 to 137 ft-Ibs
thread pitch = 1 .50 : 141 to 152 ft-Ibs

•
I
Assembly of the rear output
Tightening torque of the screws: 127 ft-Ibs -
Assembly of the seal cap
0 Tightening torque of the screws: 72 to 80 ft-Ibs

•
•
I
Assembly of the output flange
Tighten ing torque of the screws:

IAssembly of the differential lock actuating cylinder

I Tightening torque of the screws:
542 to 578 ft-Ibs

25 to 33 ft-Ibs

Figure 4E-15. Split Torque Differential Specifications

4E-12
 INSTRUCTIONS FOR THE ASSEMBLY OF DIFFERENTIAL CARRIERS 300 - 500 - 1000

ADJUSTMENTS SOD
1 ~Engraved dimension
~.~:" (±5/1QOe)
I. THICKNESS OF THE BEARING SHIM IN THE HOUSING =X - V

'-~
.......
'
~.., ' J
, _._._ ..
-'1---'-·
1 X =Actual size measured from bearing carrier shoulder to differential axis
Y =Height of the bearing (h) + value of the engraved dimension (corrected tapered
distance) marked on the bevel pinion

~. -. • -'A-ctual dimension
I
i
THICKNESS OF THE BEARING SHIM ON THE BEVEL PINION =b+c
Measure dimension «b» and «c»
1 ADJUSTMENT OF THE BEVEL
PINION PRELOAD
Select sh ims (1) to get rotational
resistance torque of the bevel pinion 2.5 to 3.25 ft-Ibs
(without seall
2 A_mbly of the flange
Tightening torque of the nut: 542 to 570 ft-Ibs

3 BACKLASH ADJUSTMENT ACCOR.

DING TO BEVEL GEAR SET:
Select shim (3) to get a backlash of : .012 to .016 inch
4 ADJUSTMENT OF THE DIFFEREN.
TIAL BEARING PRELOAD
Tighten nut (4) to get proper spacing
at the bear ing caps : .01 to .02 inch
Check the rotational resistance torque
of the bevel gear se~ (measured at the 4.3 to 5 ft-Ibs
flange after assemblv of the differential
carrier)

5 A_mbly of the baring .:.pI :

Tightening torque of the screws : 123 to 137 ft-Ibs .
6 Locking of the diff_nti., nut
Tightening torque of the screws: 10.8 to 18 ft-Ibs
7 A_mb.y of m. diff_tilll lock KtU8ting
cylinder: tightening torque of the screws 25 to 33 ft ·Ibs
8 AI.mbly of m. differentill' C81"rier
on the ex•• housing
Tightening torque of the screws: 142 to 152 ft·lbs

Figure 4E-16. Standard Differential Specifications

Axles 4E-13
which generally includes a standard dif-
ferential. Relevant exceptions are noted.
Critical dimensions and tolerances for as-
sembling both types of carriers, split
torque and standard, are presented in
Figure 4E-14 on page 4E-ll and
Figu re 4E-16 respectively, and will be
referred to throughout the following pro-
cedures. Refer also to Figure 4E-7 on
page 4E-6 and Figure 4E-8 on page 4E-7.
1. Determine and record the thickness of
the bearing shim required in the carrier
housing (X - Y in Figure 4E-14 on page
4E-ll).
2. Heat the bearing Cone (Item 14,
Fig u re 4E -7 on page 4E -6) to about
180 0 F and install it on the pinion shaft.
3. Install the shim selected in Step 1,
and the bearing cup (Item 19,
Figure 4E-7 on page 4E-6) in the carrier
housing.
4. Determine the thickness of the bevel
pinion spacer ring (b + c in Figure 4E-14
on page 4E-l1). Temporarily install the
pinion in the housing using a dummy'
spacer of known thickness. Measure lib t the differential case and place the as-
as shown in Figure 4E-14 on page 4E-ll.
"c" is the difference between the cup
and cone of the second bearing.
5. Remove the bevel pinion and dummy
spacer, and install the bearing cup (Item
27, Figu re 4E-7 on page 4E-6) in the
carrier housing. Install the selected spa-
cer, the driven gear, and the shim on
the pinion shaft. Heat the second bear-
ing cone to about 180 0 F and install it on
the pinion shaft.
6. Install the pinion assembly into the
carrier housing and secure it with the
adjusting nut (Item 23, Figure 4E-7 on
page 4E-6). Tighten the nut to 11-18
ft-Ibs. Check bevel pinion preload as
shown in Figure 4E-14 on page 4E-ll.
NOTE
Installation of the bevel pinion in
the standard carrier is basically
identical to the above procedu re as
follows. Refer also to Figure 4E-8
on page 4E-7.
A. Repeat Steps 1,2, and 3, and refer to
Figu re 4E-16 on page 4E-13 for spec-
ifications.
4E-14
B. Determine the thickness of the bear-
ing shim on the bevel pinion (b + C in
Figure 4E-16 on page 4E-13). Install
the bevel pinion and secure it with
the flange. Measure "b" with a dial
indicator. "c" is the difference in
thickness between the cone and cup
of the second bearing.
C. Install the bearing cup in the carrier
housing. Install the selected shim on
the pinion and install the pinion as-
sembly in the housing. Install the
front bearing cone and the input
flange, tightening the flange nut to
542-570 ft-Ibs.
D. Remove the input flange. Grease the
internal face of the oil seal and the
seal lips and install on the pinion
shaft. Install the input flange and re-
tighten the flange nut to 542-570
ft-Ibs.
7. I nstall and adjust the differential
bearings as follows. Using two dummy
bearings, measure the difference "t" be-
tween the dummy bearing and the correct
bearing. I nstall the dummy bearings on
sembly in the housing. Rotate the
differential to assure contact between the
bevel pinion and side gear.
Figure 4E-17. Measuring Backlash
8. I nstall and zero the long pointer on
the dial gauge. Rotate the differential to
contact the shoulder of the bearing cap.
Read and record the displacement on the
dial indicator. The thickness of the shim
= S:!:t - .012 inch. (.012 inch isthees-
timated average valve for a correct
backlash) .
9. Intall the differential bearing cones.
Heat the bearing cups to about 180 0 F and
place them in position.
10. Install the selected shim and the dif-
ferential case, and secure with the dif-
ferential nut.
11. Install the bearings caps using Loc-
tite SR-242 on the screws, and tighten
the screws to 123-137 ft-Ibs.
Figure 4E-18. Checking Preload
12. Tighten the differential nut and
check preload. Preload, measured on
the upper diameter of the bearing cups,
must be .01-.02 inch at 4.3 - 5 ft-Ibs.
rotational resistance.
Figure 4E-19. Checking Backlash
13. Check backlash between the bevel
pinion and the crown wheel. Backlash
must be .012-.016 inch. Apply Loctite to
the differential nut locking screw and
tighten it to 10 - 18 ft-Ibs.
14. Check the ring gear and pinion for
the proper tooth contact. Paint the ring
gear with a mixture of red lead and lin-
seed oil. When the ring gear and pinion
are rotated, the red lead is squeezed
away by the contact of the teeth, leavi ng
bare areas the exact size, shape and lo-
cation of the contacts. As a rule,
painting 10 to 12 teeth is sufficient for
this checking procedure.
Sharper impressions may be obtain by
applying a small amount of resistance to
the ring gear with a flat steel bar and
using a wrench to rotate the pinion.
Gears should be rotated, under slight
load, until the ring gear has turned at
least one complete revolution in each di-
rection.
Check the tooth contact pattern on the
drive side (convex side) of the ring gear
teeth. Coast side will be automatically
corrected when the drive side pattern is
corrected.
Refer to Figu re 4E-3l on page 4E-20 for
right hand spiral ring gears and
Figure 4E-32 on page 4E-21 for left hand
spiral rings gears.
15. Install the fork and clutch gear, and
secu re the assembly with the fork pin.
Lock the fork pin by staking the pin at
three points.
16. Install the split torque assembly. In-
stall the bearing cup in the housing.
17. Heat the bearing cone to about 180°F
and install the cup on the shaft.
Figure 4E-20. Measuring Planet Gear
Backlash
Axles 4E-15

18. Check planet gear backlash. Measure
and record the distance "x" from the
face to the shoulder as shown.
19. Install the pinion on the split torque
differential and place the assembly on a
fitting fixture.
Figure 4E-21. Lock Differential
I nstall the flange on the pinion, lock the
assembly, and rotate the gears until
there is a slight resistance to rotation.
Figure 4E-22. Measuring Distance "Y"
20. Measure and record the distance "y"
from the split torque differential to the
pinion face. Backlash = y - x > .008
inch.
4E-16
21. Heat bushings and bearing cone to
about 180 0 F, and install them on the out-
put side of the differential. I nstall the
split torque differential in the housing.
Figure 4E-23. Measuring Long Gauge
Standard
22. Adjust the split torque differential
preload as follows. Determine shim thick-
ness. Adjust the dial indicator on the
long standard. Zero the long pointer
and record the position of the short
pointer.
Figure 4E-24. Measuring Differential
23. Place the dial indicator on the split
torque differential. The variation of the
pointer is "B".
 Figure 4E-25. Measuring Short Gauge
Standard
24. Adjust the dial indicator on the short
standard. Zero the long pointer and re-
cord the position of the short pointer.
Figure 4E-26. Measuring Front
Housing
25. Place the dial indicator in the front
housing. The variation of the pointer is
"A". Shim thickness then is (A - B) + P,
where P = preload in deformation as
shown in Figu re 4E- 14 on page 4E-1 1.
26. Install the selected shim and the
bearing cup in the cover housing, and
install the cover housing on the split
torque differential. I nstall the lifting
flange to facilitate handling (see
Figu re 4E-27).
27. Coat the face of the cover housing
with Loctite Instajoint 510, and install
the split torque differential and cover
housing assembly on the carrier housing.
Figure 4E-27. Installing Lifting
Flange
28. Apply one drop of Loctite 242 to the
cover housing screws. Tighten the
screws to 43 ft-Ibs.
29. Install the differential lock cylinder
using a "telltale" lamp. Plug in the two
cable lugs and the compressed air. When
the cylinder locks, the actuating cylin-
der sighting slit lights the lamp. When
the cylinder is not locked, the lock actu-
ating cylinder is free and the sighting
slit is not lighted.
30. If necessary, adjust the contactor
screw on the sighting slit. Recheck
when the differential is on the vehicle.
31. Remove the lifting flange and install
the input flange and tighten the flange
nut to 759-795 ft-Ibs.
Steering Joint Assembly
The following procedu re applies only to
the drive-steer axles. Refer also to
Figure 4E-6 on page 4E-5.
1. Install the shaft bearings into the axle
housing and pivot spindle. Grease the
oil seals and install them on to the shoul-
der of the shaft at the joint. Insert the
shaft into the axle housing.
2. Install the upper and lower bushings
into the pivot and position the pivot on
the axle housing knuckle.
3. Grease the oil seals before installing
on the king pins.
Axles 4E-17
4. Install the lower king pin, shims
(tagged at disassembly) and the steering
arm. Tighten the screws.
5. Install the upper king pin, shims
(tagged at disassembly) and flange,
Tighten the flange screws.
Planetary Hub Reducer Assembly
Refer to Figure 4E-1 on page 4E-2 and
proceed as follows.
1. Apply Loctite 549 to all sealing sur-
faces between the planetary hub and the
axle housing, including the seal race
land.
Figure 4E-28. Installing Seal Race
2. Heat the seal race to approximately
180 0 F and install it on the axle spindle.
I nstall the brake spacer, if it had been
previously removed.
3. Carefully align and install the brake
assembly.
4. Install the bearings cups on the hub
and the ring gear carrier. Install the
bearing cone on the hub. Apply Loctite
510 to the oil seal, and install the seal.
Heat the second bearing cone to approx-
imately 180 0 F, and install it on the ring
gear carrier (Item 7, Figure 4E-1 on
page 4E-2).
4E-18
5. I nstall the wheel hub assembly and
the ring gear carrier. Position the taper
ring and the locking washer, and start
the spindle nut (Item 10, Figure 4E-1 on
page 4E-2) .
6. Tighten the spindle nut while rotating
the hub to correctly position the bear-
ings and taper ring. Tighten the spindle
nut to 185-220 ft-Ibs., then back the nut
off 1/8 of a tu rn to establish th rust
clearance of .002 to .006 inch. Secure
the spindle by bending over the ears of
the locking washer.
7. I nstall the sun gear and axle shaft as
an assembly.
NOTE
On drive-steer axles, the axle
shaft was installed as part of the
steering joint installation proce-
dure. Install the sun gear secure
with the socket screw.
Figure 4E-29. Measuring End
Positioner
8. Install the planet gear carrier. Install
the shaft positioner and measu re the clis-
tance between the positioner and the
face.

Figure 4E-30. Measuring Cover Plate
9. Measu re the distance between the fac-
eand the middle th rust. Select the end
shaft positioner to establish the axial
clearance of of .041 to .080 inch.
10. Place the O-ring and cover plate on
the planet gear carrier, making sure to
align the drain hole with the lubrication
hole in the planet gear carrier. Tighten
the cover screws to 33 ft-Ibs.
11. Install the brake drum. Apply one
drop of Silicomet to each screw and
tighten'the screws.
12. Fill the hub with oil through the
drain hole. Check the oil level before op-
erating.
INSTALLATION
To install the axle on the machine, pro-
ceed as follows:
1. Position the axle below the carrier
with the input flange facing toward the
associated drive shaft connection. Jack
the axle into position with the mounting
holes aligned with the suspension cylin-
ders. I nstall the suspension cylinder
and torque arm hardware to secure the
axle in position.
2. Reconnect the hydraulic lines to the
appropriate steering cylinder ports, if
necessary.
3. Reconnect the brake lines to the
brake chambers.
4. Install the propeller shaft, see Sub-
section 4D.
5. Install the wheels.
6. Reconnect any hydraulic and electric
lines, other than those already
mentioned, which may have been discon-
nected to remove the axle.
7. Bleed the steering cylinders by turn-
ing the wheels all the way to the left and
then all the way to the right. Repeat this
procedure several times. This will force
all air out of the steering cylinders.
8. Lift the machine on the outriggers and
remove all blocking from under the
frame.
9. Check the planetary hubs and differ-
entials to be sure that they are filled to
the proper level with the type of lubri-
cant specified in Section 3 of this
manual.
Axles 4E-19
 SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART

MOVE PINION TOWARD ~

GEAR IN THIS DIRECTION r
•
·=::......-""'DE""'DE.nNDUM PROFilE
t
GEAR

MOVE GEAR AWAY FROM

PINION IN THIS DIRECTION
MOVE GEAR TOWARD
PINION IN THIS DIRECTION
A
LARGe eND ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT 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 PINION. 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 INDI CA TOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU·
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.

Figure 4E-31. Left Hand Spiral Ring Gear Tooth Contact Patterns

4E-20
 SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART

".
TOE i MOVE PINION TOWARD ~
.,t'
CENTER I
I
I t GEAR IN THIS DIRECTION r
;(' ----,ACJ'"'=0+EN"""0C":"UM---.,.----P-.0...L.
"I
I

'DEDe~OUM
HEEL F1LE

GEAR

MOVE GEAR AWAY FROM

PINION IN THIS DIRECTION
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 - GEAR SET 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 PINION. 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 lOWARD 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.
Figure 4E-32. Right Hand Spiral Ring Gear Tooth Contact Patterns

Axles 4E-21
 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. If any compo-
nent of the system is removed, the sys-
tem must be recharged with oil and all
ai r 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.
If pressure is low, operate outrigger ex-
tend function over relief until correct
pressure is reached.
If pressu re 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. All
outriggers should be lowered at the same
time so that the machine is level when it
contacts the ground.
Subsection 4F 4F-l
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
I
:::i
U.J G U1
~ FRONT STEER
CYLINDER

u z :;; U1 U1 I
CYLINDER
z ~ U
'"
'"--' '"~ '" ~
I U1
z
~ l'9 !!! Cl.
Cl.
U.J
Cl.
~ ~ HYDRAULIC
SWIVEL
z z z "- U1
U1
i='
'"2 '"~ '"2w '"i='w
I Cl r Z
"- u z I r
:;(
I Z ~ <5 "-
U.J
'"
.. ~
W iii
[Il U1 a
'" '" ...,
0: U1 -'
co Q::~~
VERTICAL "' 0- <D
'"
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
"
r'
I
I
I
I
I
I
I
I
rc---
I I
SWING
MOTOR
r------,
STEERING

I I r±l ,i
I

"
VALVE I I SWING
I
r' LtJ CHECK BRAKE

I I I
r------------..J
I
VALVE

-----~~l l~ _____ ~
I
I I I

I I I
I
I
I
I

i i i
I I
I
II

I
I
I
SWING
BRAKE
RELEASE
I
:

,J
I
I CHECK VALVE
CLAMSHELL
SOLENOID
VALVE I - tiIV
i-~-..Jli( I,~ ~I
I
i:
I
I
I
I
I
BOOM HOIST/
-~ I- - i

~~~==~~--~ ~-~
TELESCOPE
r-.-+- VALVE

r-1Q+- ' SWING VALVE ! ~! ..J

:1:

~ ~.,=ld:,,=:!
I
I
:
I -- I ~-~
I I I SWING
I I I I I
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.
 SU6SECTION 56
HYDRAULIC SYSTEM MAINTENANCE
GENERAL
This subsection describes recommended
hydraulic system general maintenance
procedures and includes maintenance and
service procedu res for hydraulic system
components not covered in other sections
or subsections of this manual.
GENERAL MAINTENANCE
The following points should be kept in
mind when working on the hydraulic sys-
tem or any hydraulic component:
1. A hydraulic system, as· defined for
this manual, is a system that is made up
of pumps, motors, actuators, hoses, pip-
ing, a swivel, control valves, return and
supply filters, and reservoir.
There are two factors that govern the
operation of the hydraulic system; name-
Iy, volume and pressure.
Volume is the amount of oil that a pump
will push through the system in a given
amount of time at a predetermined pump
speed. It is usually expressed in gallons
per minute (gpm). Volume determines the
speed of operation. The greater the vo-
lume, the faster a cylinder will fill with
hydraulic oil and the faster its rod will
move.
Pressu re is the amount of force or work
capability exerted by the hydraulic oil on
all parts of the system opening di rectly
to the pump, when the pump is deliver-
ing oil. The amount of pressure that a
pump produces has no relationship to the
speed at which an actuator operates.
Pressure is expressed in pounds per
square inch (psi).
When the pump is merely circulating oil
through a system which has no re-
strictions or is not under load, pressure
is negligible. But when a restriction or
load is introduced, pressure builds up
almost immediately. The pressure will
conti n ue to increase u nti I the restriction
or load is overcome, the pump reaches
the Iimit of its capacity, or some portion
of the system ruptures and relieves the
pressure. Relief valves are normally
provided in a hydraulic system, to limit
the system pressu re to safe operating
levels.
2. Any structure has limits of strength
and durability. To prevent the failure of
structu ral parts of hydraulic
components, relief valves are provided in
hydraulic circuits to limit the pressures
to safe operating limits. The settings of
these relief valves must never be
changed, except as described under the
topic Relief Valve Adjustment.
3. Tolerances of working parts in the
hydraulic system are very close. Even
small amounts of dirt or foreign material
in the system can cause wear or damage
to components, as well as faulty opera-
tion of the system. Every precaution
must be taken to assure absolute cleanli-
ness of the hydraulic oil.
4. Samples of hydraulic oil should be
drawn from the reservoir at regular in-
tervals using ISO Standard 4021 or an
equivalent method of sampling. I n this
procedure, fluid is removed from highly
active oil mixing zones, through fully
opened and appropriately flushed ball
valves and sterile tubing. The oil is then
analyzed to determine if it is suitable for
fu rther use.
5. Whenever there is a hydraulic compo-
nent failure which gives reason to be-
Subsection 56 58-1
lieve that there are metal particles or
other foreign materials in the system,
drain and flush the entire system, and
replace the filter elements. A complete
change of hydraulic oil must be made un-
der these ci rcumstances.
6. Whenever the hydraulic system is
drained, check the hydraulic oil for met-
al particles. If metal particles are pres-
ent, flush the system and add a new
change of oil. The presence of metal
particles also may indicate the possibility
of imminent component failure.
7. All containers and funnels used in
handling hydraulic oil must be absolutely
clean. Use a funnel with a 200 mesh
screen for filling the hydraulic oil reser-
voir, and fill the reservoir only through
the filler opening. The use of a cloth to
strain the oil should be avoided to pre-
vent lint from getting into the system.
8. When removing any hydraulic compo-
nent, be sure to cap and tag all hydrau-
lic lines involved. Also plug the ports of
the removed component.
9. All hydraulic components must be dis-
assembled and assembled in spotlessly
clean surroundings. Care should be
taken during component disassembly to
identify the parts to ensure proper re-
assembly.
10. Metal component parts should be cle-
aned with clean mineral oil solvent pay-
ing particular attention to the internal
passages to ensure the passages are tho-
roughly clean. After the parts are
dried, lay them on a clean, lint-free
cloth for inspection.
11. Replace all O-rings, and seals when
overhauling any component. Lubricate
all parts with clean hydraulic oil during
assembly. Use small amounts of petroleum
jelly to hold O-rings in place during re-
assembly.
12. Be sure to replace any lost hydraulic
oil in the system when completing the in-
stallation of the repaired component, and
bleed any ai r from the system as re-
qui red. Refer to Section 3 for the hy-
draulic oil specifications.
13. All hydraulic connections must be
kept tight. A loose connection in a
pressure line will permit the oil to leak
out or air to be drawn into the system.
5B-2
Air in the hydraulic system can cause
damage to the components and noisy or
erratic system operation.
14. Do not use synthetic or fire resistant
oils in this machine. The packings in
this system are designed for a good
grade mineral oil.
CAUTION
Engine oil was, at one time, an ac-
ceptable alternate for hydraulic
oil. This is however, no longer
true. Engine oil does not contain
all of the additives required for
proper hydraulic system operation
and must not be mixed with, or
used as, a substitute for hydraulic
oil.
15. The presence of water in the hydrau-
lic system is harmful to the entire hy-
draulic system since it will corrode
hydraulic components. Water alone, in
significant quantities, will also cause fil-
ter elements to swell and plug. At
regular intervals, drain a sufficient
amount of hydraulic oil to remove any
water which has settled to the bottom of
the reservoi r.
FLUSHING THE HYDRAULIC SYSTEM
If there is evidence of a grossly contam-
inated hydraulic system, caused by a
pump or motor shelling out, water caus-
ing "milkiness" of oil or vandalism, it will
be necessary to flush the hydraulic sys-
tem. If the cause of the contamination is
due to a faulty component, the compo-
nent must be repai red or replaced before
the hydraulic system is flushed.
NOTE
Since hydraulic system flushing i-s
expensive, time consuming and the
results not totally assured, flush-
ing should be done only when ab-
solutely necessary.
1. Run the machine engine and hydraulic
pumps to warm the hydraulic oil to nor-
mal operating temperature. Then shut
the machine down and place the battery
switch in the open position, or discon-
nect the battery cables from the battery.
2. Remove the hydraulic reservoir drain
plug and drain the oil into a suitable
container. Allow sufficient time for all
the oil to drain from the walls of the res-
ervoi r.
3. Install the drain plug. Fill the reser-
voi r with clean hydraulic oil.
4. Cycle the machine th rough all crane
functions and operate the steering and
outrigger systems several times to circu-
late the flushing oil throughout the hy-
draulic system.
5. Ci rculate the oil th rough the system
until inspection shows the equipment to
be in satisfactory condition, or until it is
obvious that the system will have to be
disassembled and cleaned manually.
6. Remove the drain plug and drain the
flushing oil from the reservoir. Remove
the cover from the top of the reservoir
and clean the inside of the reservoir ma-
nually. Replace the drain plug and the
reservoir cover. Refill the reservoir with
clean hydraulic oil. 8e sure to replace
the system filter before refilling the sys-
tem.
7. Disconnect the hose attached to the
retract side of the boom hoist cylinder,
and slowly raise the boom to its maximum
elevation. This will force the flushing oil
from the cylinder.
8. Reconnect the hose to the boom hoist
cylinder, and lower the boom to the hori-
zontal position. Add clean oil to the res-
ervoir as required to maintain the proper
oil level.
9. Disconnect the hoses attached to the
retract side of the telescope cylinders at
the base of the boom. Extend the boom to
force the flushing oil from the telescope
cylinders.
10. Reconnect the telescope cylinder
hoses and retract the boom. Add clean
oil to the reservoir as required to main-
tain the proper oil level.
11. Disconnect the hoses attached to the
retract side of the outrigger cylinders,
and then extend the outriggers fully,
this will force the flushing oil from the
cylinders.
12. Reconnect the hoses to the outrigger
cylinders, and raise the outriggers. Add
oil to the reservoir as required to main-
tain the proper oil level.
13. Operate the upper and lower steering
wheels left and right several times to
force the flushing oil in the steering sys-
tem back to the reservoi r.
14. Swing the upper of the machine in
both directions, and operate the winches
in both directions several times to force
the flushing oil in these motors back to
the reservoi r.
15. Replace the filter elements. Cycle the
machine through all crane functions and
operate the steering and outrigger sys-
tems several times to filter out any re-
maining contamination.
PROPER TIGHTENING OF HYDRAULIC
CONNECTIONS
General
The following information provides the
proper tightening procedu res for hy-
draulic lines and tubing. The use of
these tightening procedu res should help
to eliminate leaks.
SAE Flareless Connection
This connection is sensitive to torque or
tightening. It will leak if undertorqued.
It will also leak if overtorqued. If over-
torqued, the tube and sleeve must be
replaced.
Pipe Th read Con nection
Pipe threads tend to leak more at high
pressure than any other style of con-
nection. National standa rd pipe th reads
(NPT) leak much more than the dry seal
pipe thread (NPTF), and either type of
threaded fitting will leak if undertorqued
or overtorqued.
The use of a good pipe dope on the N PT
th reads is recommended to to help pre-
vent leaks. When applying pipe dope,
always put dope on the male th reads,
never on the female th read and Do Not
put dope on the fi rst two th reads from
the end.
Some causes and cures for pipe thread
leaks are listed in Table 58-1.
Hydraulic System Maintenance 58-3
 CAUSES : CURES
Connector not tight Tighten
Cracked port or connector I
Replace defective parts
I,
I Oversized threads in port Use proper thread size
I
Undersized thread on connector Use proper thread size
Galled threads (torn threads) Replace defective parts
i
Damaged threads, nicks, cuts, etc. ! Replace defective parts
1
i
!
Threads not dry-seal standard for hydraulics Use "NPTF DRYSEAL" standard
'---- I
I

Struight pipe threads, instead of tapered

! I Use "NPTF DRYSEAL" standard
i Contaminated threads, dirt, chips, etc.
i I Clean I

High vibration loosening connection Retighten connector

Heat expansion of female threads Retighten while hot
Too tight, causing thread distortion Replace worn parts

Table 58-1. Pipe Thread Leaks

CAUSES CURES
Foreign particles in the joint Wash them off
i
I Cracked seats Replace them
I i
i Seat mismatching or not concentric with the I Replace the adapter
I
threads I
I
I
I Deep nicks in the seats I Replace faulty part
I

i Excessive seat impression. This indicates too soft Replace the part
i
a material for high pressures.
!
I
Phosphate treatment. This is an etching process Replace faulty parts
I which if overdone leaves a rough sandpaper-like
surface
Chatter or tool mark-High and low spots on seats Replace faulty part
iI
I
I SAE 45° nuts-When connected to an SAE 37° male Use all SAE 37° flare
flare fitting will 1eak. parts
I i
Table 58-2. Flare Connection Leaks

5B-4
SAE Flare Connections
Most leaks from this type of connection
are due to the lack of tightening and

--~
human error. It is impossible to tell if
the nut has been tightened by just look-
i ng at the con nection . Fig u re 58 -1 on
page 58-6 shows one method of tighten-
i ng th is type of con nection. '. TIGHTEN NUT FINGER TIGHT UNTIL IT
BOTTOMS THE SEAT.
If the joint leaks after it has been tight-
ened, refer to Table 58-2 on page 58-4
and make the checks listed. MARK A LINE ON
NUT AND ADAPTER
LBEFORE TORQUING
SAE Straight Thread Connection
(O-ring Seal)
This type of connection leaks most often
because the jam nut and washer are not
backed up prior to assembly of the fit-
ting.
-~
2. MARK A LINE LENGTHWISE ON THE NUT
AND EXTEND IT ONTO THE ADAPTER. USE
When the jam nut and washer have not AN INK PEN OR MARKER.
been backed up, there is not enough
room for the O-ring when the squeeze
takes place. The washer cannot seat MISALIGNMENT OF
properly on the face of the boss as MARK SHOWS
shown in View A, Figure 58-2 on page AMOUNT WHICH
NUT WAS
58-6. The compressed rubber between
the washer and the boss face will cold ~ T. IGHTENED
flow out of compression and the fitting
/, ,.1

--rSaTI
will loosen and leak as shown in View 8,
Figu reo 58-2 on page 58-6).
Leakage from straight thread connectors
will be indicated as follows:
3. USING A WRENCH. ROTATE THE NUT TO
1. Fitting loosen after short service TIGHTEN. TURN THE NUT THE AMOUNT
SHOWN IN TABLE BELOW.
2. O-ring leakage after short service.
3. O-ring leakage after long service.
4. Instant leakage upon start-up. Line Size Rotate No.
(1.0.) of Hex Flats
To eliminate leakage, proceed as follows
(see Figure 58-3 on page 58-6): -.4 (1.4) 2-1 2
-.5 (5 16) 2-1 ,,;."
1. The jam nut and washer must be -.6 (3.8) 2
-.8 (1 2) 2
-
backed up to the end of the smooth por-
tion of the fitting (see View A, -.10 (5.8) 1 -1 2 - 2
Figu re 58-3 on page 58-6). -.12 (3. 4) 1
-.16 (1) 3 4 - 1
2. Lubricate the O-ring; this is impor- -.20 (1-1 4) 3.4- 1
tant. -.24 (1·1 2) 1 2 - 3 4

3. Thread the fitting into the port until

the O-ring just touches the spot face.
Figure 58-1. Tightenins SAE Flare
4. Tighten the jam nut (see View 8, Connections
Figure 58-3 on page 58-6).

Hydraulic System Maintenance 58-5

 Split Flange Connections
JAM NUT
VIEWA Table 5B-3 gives leakage causes and
WASHER cu res for split flange connections.
To install a split flange connection, pro-
ceed as follows (see Figu re 5B-4 on page
5B-7) :
JAM NUT 1. Thoroughly clean the sealing surfaces
and the flanges.
WASHER FITTING

O-RING 2. Lubricate and install the proper

O-ring in the fitting groove.

VIEW B 3. Align the fitting with the port and as-

semble the flanges over the fitting.
4. Snug the bolts in a diagonal manner to
1/3 of the torque value in Table 5B-4 on
page 5B-8. Note that the flanges are
square with the fitting and bolt surface.
Figure 58-2. Improper Installation
5. Repeat step 4 to 2/3 of the final tor-
que. Repeat step 4 to the final torque
value.
SMOOTH PORTION
VIEW A OF FITTING
JAM NUT

JAM NUT

SPOTFAC .. _~~~~~_
WASHER

~~O-RING VIEW B
SEAL
Figure 58-4. Tightening Sequence

Figure 58-3. Proper Installation

5B-6
! SERIES SPLIT FLANGE SIZE GRADE 5 BOLT SIZE TORQUE (IN-LBS)
!
,
Standard 3-1/2 5/8-11 1400-1600 I
Pressure I
4 5/8-11 1400-1600
I
5 5/8-11 I 1400-1600 I,
! I
High 1/2 5/16-18 175-225 I
I Pressure I
!
I
I 3/4 3/8-16 300-400 I,
I I I
I
1 7116-14 500-600
I
I
, 1-1/4 1/2-13 750-900
I
i
I I 1-1/2 5/8-11 I 1400-1600
I
I 2 3/4-10 I 2400-2600 ,
i i I I

Table 5B-4. Split Flange Torque Values (Part 2 of 2)

PRESSURE FILTER (46Q75)
BYPASS
VALVE
Description
The pressure filter, shown in
Figure S8-S on page S8-9, is an in-line,
indicator type filter with a bypass valve
and a replaceable filter element. Service C·RING
of this filter assembly consists of re-
placement of the filter element, seals and
if necessary replacement of the bypass HEAD
valve.

Filter Maintenance
Regular maintenance of the filter is a key
to clean fluid and long hydraulic system
component life. Filters do not function
when the filter element is clogged to the
point of filter bypass. Therefore, it is
important to do the following:
1. Check the filter indicator frequently
to determine the condition of the filter
assembly, namely the indicator, element,
and the seals.,
2. Replace the filter element when the
filter indicates "change filter" or after
SOO hours of service. SQUARE
DRAIN PLUG
DRIVE F205
3. Make sure the filter is fitted with the
correct element. Refer to the machine Figure 58-5. Hydraulic Filter
Parts Manual, for the correct filter num- Assembly (46Q75)
ber.

58-8
 CAUSES CURES
Split flanges not tightened down Tighten bolts to proper torque
Flange tightened unevenly caus- Check O-ring for ni cks or cuts. Replace
ing O-ring extrusion O-ring. Lubricate. Ti ghten fl anges to prop-
er torque
Wrong size of O-ring. O-ring Replace with proper size
must fill groove completely
I
! No O-ring in fitting Install proper O-ring
i I
I

!i Sealing surface not smooth

I Repair or replace
I
I O-ring groove too deep. O-ring I Replace
does not extend above face of
filling
I
Wrong style bolts. Hex bolts Obtain proper bolts
should have three radial dashes
120 0 apart on head (Grade 5)
1

I
O-ring damaged I Replace with new O-ring
!
Dirty O-ring groove I
I
Clean and install new O-ring
Paint on sealing surface Ii Clean
Connection keeps loosening Inspect flanges and make sure the machine
step has an adequate flat to bear down on
the fitting. Make sure the depth is uniform.
Make sure bolts are SAE Grade 5. Retighten
after system reaches operating temperature.

Table 5B-3. Split Flange Leakage

i
! SERIES TORQUE (IN-LBS)
I SPLIT FLANGE SIZE I
I GRADE 5 BOLT SIZE
Standard I 1/2 5/16-18 175-225
Pressure I
3/4 3/8-16 250-350
I

1 3/8-16 325-425
1-1/4 7/16-14 425-550
1-1/2 1/2-13 550-700
2 1/2-13 650-800
i
2-1/2 1/2-13 950-1100
I
I 3 5/8-11 1650-1800

Table 5B-4. Split Flange Torque Values (Part 1 of 2)

Hydraulic System Maintenance 58-7

To service the filter element, proceed as
follows, (see Figure 58-6 on page
58-11):
NOTE
It is not necessary to remove the
filter assembly from the hydraulic
system for service, unless re-
placement of the bypass valve is
necessary.
1. Shut the machine down and vent the
pressure in the system.
2. If desired, drain the filter by remov-
ing the plug from the bottom of the bowl.
3. Unscrew the filter bowl and vertically
lower it to clear the element assembly
and spring which should remain in the
element.
NOTE
The filter spring may drop free of
the element when the bowl is re-
moved and the spring may be
found in the bowl.
4. Remove the element from the filter
head and pull the spring out of its re-
cess in the base plate of the element.
Save the spring for reinstallation.
5. If the filter is fitted with a magnet as-
sembly, remove it by unscrewing the
hexagon locknut securing the magnet as-
sembly to the element end plate and
th read the assembly out of the element.
6. Discard the filter element if the ele-:
ment is a paper or synthetic material fil-
ter.
7. Clean the interior of the bowl and
other accessible areas of the filter.
8. I nspect the filter head bore for
bu rrs, scratches. Carefully, smooth out
the machined surfaces as required. In-
spect the bowl 0- ri ng for cuts etc., re-
place O-rings as necessary.
NOTE
It is recommended that the bowl
O-ring be replaced whenever the
element is cleaned or replaced.
9. If necessary, remove the indicator
and replace the seals as follows, (see
Figure 58-6 on page 58-11).
A. Remove screws (22) and indicator
plate (02).
8. Remove Allen screws (03), washers
(04) and shroud (11) from filter head
(01) .
C. Locate setscrew (12) in the side of
dial (13) and loosen the set screw
enough to remove dial (13) from shaft
(21) .
D. Remove dial (13) and spring (14)
from filter head (01).
E. Loosen and remove hex screw (15),
along with shaft (21), washers (19),
bearing (20), O-rings (18 and 17)
and washer (16) from filter head
(01) .
F. Pull shaft (21) out of hex screw (15).
8e sure to keep roller bearing (20)
and washers (09). O-ring (18) and
backup washer (16) should now be vi-
sible. Using an awl or other suitable
device, gently pry and lift O-ring
(18) and washer (16) out of the hex
screw. Replace O-rings (18 and 17)
then install the new O-rings with
washer (16) in hex screw (15).
G. Lubricate dial shaft (21) and inner
O-ring (18).
H. I nstall dial shaft with bearing (20)
and washers (19) into hex screw
(15), being careful not to damage the
installed O-ring (18).
I. I nstall the dial shaft and hex screw
assembly into the filter head.
NOTE
Make su re that the lever on tire di-
al shaft will rest against the end of
the bypass valve socket head
screw when fully installed. How-
ever, be careful while tightening
hex screw (15) to a final torque of
135 to 140 ft-Ibs, that the shaft
lever does not hang up on the
socket head screw.
J. Ins ta II d ia I ( 13) and d ia I s p r i n g (14 )
making certain that the tab is in the
drilled hole in the filter head assem-
Hydraulic System Maintenance 58-9
 bly, and the hook is secu red in the
notch under the dial (13).
K. Tighten dial setscrew (12) to a torque
of 5 to 10 inch-pounds.
L. Position shroud (11) on filter head
(01) and secure with washers (04)
and Allen head screws (03). Tighten
screws (03) to a torque of 25 to 30
inch-pounds.
M. Install indicator plate (02) and posi-
tion it so that the word CLEAN is to-
wa rd the top of the fi Iter head.
Secure the indicator plate with screws
(Ol) .
10. Place the system into operation and
check the filter assembly to ensure it is
operating properly and is free of leaks.
RETURN FILTER (46U54)
Description
The return filter, shown in Figure 5B-7
on page 5B-12, is an in-line, indicator
type filter with a replaceable filter ele-
ment. Service of this filter assembly con-
sists of replacement of the filter element
and the seals. 22 _ _ _ _
02 ____ '. _

o~~~
~ @

/..7 12

~:~~/
01. HEAD 12. SETSCREW
02. INDICATOR PLATE 13. DIAL
03. SCREW 14. SPRING
04. WASHER 15. HEX SCREW
05. BYPASS VALVE 16. WASHER
06. FILTER ELEMENT 17. O-RING 13 _ _ _ _ _ e-HOOK

::__--TAB
07. SPRING 1S. O-RING
OS. O-RING 19. WASHERS
09. FILTER BOWL 20. ROLLER BEARING
10. DRAIN PLUG AND O-RING 21. SHAFT
~
1.1. INDICATOR SHROUD 22. SCREW
17____
16 -~ -------(0)
1 8 - -_ _~

-----®
19 ®

SOCKET
HEAD ::~
LEVER

o.O\d
ARM

F259

58-6. Filter Assembly

5B-10
 To service the filter element, proceed as
follows, (see Figure 5B-7 on page
5B-12):
HEAD
NOTE
HEA D --=:-:8!!=""'lr:LL..!
O·RING f----." It is not necessary to remove the
filter assembly from the hydraulic
INDICATOR system for service.
O·RING

1. Shut down the machine and render the

starting system inoperative. Open the
pressu re taps on either side of the filter
to bleed off any positive pressure.

HOUSING 2. Remove the housing by turning the

ELEMENT _-'~I
SPRING
GASKET
F211
Figure 5B-7. Hydraulic Return Filter
Assembly (46U54)
Filter Maintenance
Regular maintenance of the filter is a key
to clean fluid and long hydraulic system
component life. Filters do not function
when the filter element is clogged to the
point of filter bypass. Therefore, it im-
porta nt to do the followi ng:
1. Check the filter indicator frequently
to determine the condition of the filter
assembly, namely the indicator, element,
and the seals.
2. Replace the filter element when the
filter indicates "change filter" or after
500 hours of service.
3. Make sure the filter is fitted with the
correct element. Refer to the machine
Parts Manual, for the correct filter num-
ber.
capscrew counterclockwise until the
housing is free from the head.
3. Remove the indicator from the element
and discard the element.
NOTE
All replacement parts are sold as
separate items for this filter
4. Carefully remove the a-rings from the
indicator and the head and discard them.
Remove the gasket from the housing cap-
screw.
5. Replace all a-rings and gaskets with
new ones.
6. Rinse out the housing with clean oil to
remove any contaminants. Thoroughly
dry the housing with a clean cloth before
reassembly.
7. Check the indicator and the machined
head bore for bu rrs or scratches. Care-
fu lIy smooth out both surfaces as re-
quired.
8. Apply clean hydraulic oil, of the type
currently being used in the machine's
hydraulic system, to the indicator. Do
the same to the housing O-ring and posi-
tion it in the head.
9. Place the element into the housing
making sure that the spring (with the
large end towards the element), gasket
and capscrew are in their proper
position.
10. Place the housing into the head and
torque the capscrew to 40 ft-Ibs.

Hydraulic System Maintenance 5B-11

11. Open the pressure tap (hydraulic oil circulating. Allow some oil leakage at
tank inlet side) and operate one of the the pressure tap, then close both pres-
machine's hydraulic functions to get the su re caps and check for leaks.

58-12
 SUBSECTION 5C

PUMPS

GENERAL hydraulic fluid flow for the operation of

the winch, the boom hoist cylinder and
This subsection provides information on the boom telescope (extension)
the removal, repai r and installation of cylinders. Pump (37R41) provides hy-
the pumps used in the hydraulic system draulic fluid for the operation of the
of this machine. A troubleshooting guide swing, steering, outrigger and suspen-
is also provided in this subsection to aid sion systems.
in determining hydraulic pump problems.

PUMPS (37R29 AND 37R41)

Troubleshooting
Description Table 5C- 1 lists some of the difficulties
that may be experienced with the hy-
These fixed displacement gear type dou- draulic pumps. The table lists the pos-
ble pumps are mounted on the rear of the sible causes and possible remedies for
transmission of this machine, as shown in the problems listed.
Figu re 5C-l. Pump (37R29) provides
."...,.,.,.
PUMP
DISCONNECT
LEVER

l.
~ BOOM H . T AND
WINCH PUMP
\~, ....
Figure 5C-l. Pump Installation

Subsection 5C 5C-l
 TROUBLE PROBABLE CAUSE REMEDY
Pump does not Fluid level in reservoir Fill the reservoir with the proper
deliver fluid. too low. grade and type of fluid. Check for
possible external leaks.
Pump inlet line plugged. Remove and clean. Check filters and
reservoir for other possible ob-
structions.
Air leak in pump inlet Repair leak.
1i ne.
Pump speed too slow. Increase speed.
Fluid viscosity too high Use only those fluids recommended
in Section 3.
Broken or worn parts in- Analyze the conditions that brought I
side the pump or pump on the failure and correct them.
disconnect.
Pump disconnected. Engage pump disconnect.
No pressure. Pump not delivering Follow the remedies given above.
fluid.
Fluid recirculating back Mechanical failure of some other
to reservoir and not go- part of the system, especially a
ing to functions. relief valve. If contamination is
involved, clean and refill the sys-
tem with clean fluid as specified
I ! in Section 3.
, Low or erratic Cold fluid. i Warm up system. Operate only at re-
pressure. commended operating temperature
range (see Operator's Manual).
Fluid viscosity wrong. See Section 3. Use only those lu-
bricants listed.
Air leak or restriction Repair or clean.
at inlet line.
Pump speed too slow. Increase speed.
Internal parts of pump Replace pump.
I are worn excessively.
Excessive flu- Damaged seal or packings Check and replace. Check to be sure
id leakage. around drive shaft. that chemicals in fluid are not de-
stroying packing or seals. follow
recommendations on grade and type
!
of fluid in Section 3.

Table 5C-1. Pump Troubleshooting (Part 1 of 4)

5C-2
 TROUBLE PROBABLE CAUSE REMEDY
Internal parts Excessive pressure above Check for possible relief valve
breakage. I maximum limits for pump. malfunction or other parts
failures. Adjust if necessary.
Seizure due to lack of Check pump inlet line.
fluid.
Pump making Restricted or clogged in- Clean or repair.
noise. let line.
Air leaks in intake line Repair. To check for leaks, pour
or air drown through in- fluid around joints and listen for
let line. a change in sound of operation.
Low fluid level. Fill to proper level with the grade
and type of fluid specified in Sec-
tion 3.
Air in the system. Check for leaks. Bleed air from the
system.
Fluid viscosity too high. Fill only with fluids recommended
in Section 3.
Pump speed too fast. Check engine speed.
Worn or broken parts. Ch~ck and correct cause of parts
failure. Replace pump.
Excessive Abrasive contaminants or Check for cause of -contaminants.
wear: sludge in the fluid. Replace filter elements. Replace
pump. Replace fluid with recom-
mended grade and quantity.
Viscosity of fluid too Replace fluid with proper grade and
low or too high. type (see Section 3).
Sustained high pressure II Check for possible relief valve
above maximum pump malfunction or other parts
rating. failures. Adjust if necessary.
Air leaks or restriction Eliminate from system. Replace pump
in system causing cavita- if necessary.
tion.

Table 5C-1. Pump Troubleshooting (Part 2 of 2)

Removal
To remove the pumps from the rear of
the transmission, proceed as follows (see
Figure 5C-l on page 5C-1):
1. Swing the boom clear of the work area
to provide clearance for lifting the pump
out through the top of the machine deck.
2. To prevent hydraulic fluid from drain-
ing out of the pump supply lines, pro-
ceed as follows:
A. Either drain the hydraulic reservoir
or attach a shop vacuum line to the
reservoir breather opening.
B. After attaching the vacuum, allow it
to run and build vacuum for a short
period of time before removing the
pump supply lines.

Pumps 5C-3
C. After the supply lines have been re-
moved, they can be tightly capped
and the vacuum can be tu rned off.
3. Remove the sheet metal deck covers
that a re located above the pump.
4. Remove the pressure lines at the
pump and cap the lines. Plug all pump
ports to prevent contamination.
5. Match mark the pump being removed
with the transmission, so that the pump
can be properly reinstalled.
6. Securely support the pump with a sui-
table lifting device prior to removing the
pump attaching hardware.
7. Remove the hardware which secures
the pump to the transmission. Lift the
pump out of the machine.
Overhaul
GENERAL. Repair of these pumps is lim-
ited to the replacement of the pump
seals. The enti re pump must be replaced
if inspection reveals excessive wear or
other damage.
FRONT SECTION SEAL REPLACEMENT.
To replace the front section seals, pro-
ceed as follows (see Figure 5C-2 on page
5C-5) :
NOTE
Notches are provided in the parts
so that they can be properly reas-
sembled. Keep wear plates and
gea rs sepa rate so that they a re not
interchanged.
1. Secu re the rea r section of the pump in
a vise with protective covered jaws.
2. Remove nuts (01) and washers (02) .
3. Lift front cover (04), wear plate (10)
and center section (11) off studs (03).
4. Remove driven gear (12), drive gear
(13) and wear plate (14).
5. Note the relationship of the seal
glands to their retainers so that they can
be properly installed when the pump is
being assembled. Remove and discard
seal glands (08) and seal retainers (09).
5C-4
6. Carefully remove outer shaft seal
(05), retaining ring (06) and inner shaft
seal (07) from the bore in front cover
(04). Discard the shaft seals.
7. Clean and inspect all parts.
8. Dip all parts in clean hydraulic oil.
9. The taper-lock end of studs (03) must
be installed in port section (15). Torque
the studs to between 50 and 70 ft-Ibs.
After torquing, the distance from the
face of port section (15) to the end of
each stud must be 3.88 ±0.09 inch.
CAUTION
The external notches in each part
must be in line after assembly.
The bronze surface of the wear
plates must face the gears after
assembly.
10. Assemble a seal gland (08) to each
seal retainer (09). I nstall a seal gland
and retainer in the groove provided in
port section (15). Make su re the seal
gland is nearest the port section.
11. Assemble wear plate (14) over studs
(03) and onto the face· of the port
section.
12. Insert the short shafted end of drive
gear (13) through the hole in the port
section so that the shaft splines engage
the splines of coupling (17). Assemble
driven gear (12) to the port section and
the drive gear.
13. Assemble center section (11) over
the studs. Assemble wear plate (10) ever
the studs.
CAUTION
The spring loaded members of
shaft seals (05 and 07) must be
toward the inside of the pump af-
ter the seals are installed. Lubri-
cate the seals with hydraulic fluid
to provide initial lubrication.
27 25

Y ---
_
----- -----09 08
.
\\
-- - -- ~~
i

WEAR PLATE

><:\
~ / (BRONZE SIDE
TOWARD GEARS]

SEAL RETAINER
(FLAT SIDE
TOWARD
WEAR PLATE)

! CONTAINED
CONTAINED IN ~~~~~~~~T10N SEAL KIT
IN
ION SEAL KIT

10. WEAR PLATE 19. WEAR PLATE

01. NUT
02
03' LOC KWASHER ~~: g~~:EENR SECTION ~~: g~~:iNR GSECTION
· STUD 1 GEAR 22 EAR
04. FRO NT COVER 3. DRIVE GEAR · DRIVE GE
'05 23 AR
14. WEAR PLATE · WEAR PLATE
· OUTER
.~6. RETAIN~NH;FT SEAL t~65. OPORT SECTION
24.
25 REAR CO VER
7. INNER RING . -RING · LOCKWAS
26 S HER
S~~~: :~~~~~)
:t08. SEAL GSHAFT SEAL 17. COUPLING
t09 SE LAND 27:
· AL RETAINER 18. ADAPTER
F272

Figure SC-2. Double Sect'lon Pump

Pumps 5C-5
14. I nstall inner shaft seal (07) in the
bore of front cover (04). Make sure the
seal is not cocked in the bore and that it
is touching the shoulder of the bore. In-
stall retaining ring (06). Install outer
shaft seal (05) against the other shoul-
der in the bore.
15. Assemble a seal gland and retainer in
the groove provided in front cover (04).
While taking every precaution to prevent
damage to the shaft seals, carefully as-
semble front cover (04) over studs (03).
16. Oil the stud and nut th reads. Install
lockwashers (02) and nuts (01) so that
the nuts are finger tight. Using a
cross-bolt pattern, tighten the nuts to
between 110 and 120 ft-Ibs.
17. After assembly, the torque requi red
to turn drive gear (13) must not exceed
150 inch-Ibs.
REAR SECTION SEAL REPLACEMENT.
To replace the rear section seals, pro-
ceed as follows (see Figure 5C-2 on page
5C-5) :
NOTE
Keep the wear plates and gears
separate 'so that they are not in-
terchanged.
1. Secu re the front section of the pump
in a vise with protective covered jaws.
2. Remove screws (26 and 27) and lock-
washers (25).
3. Lift rear cover 24) and wear plate
(23) away from center section (20).
4. Remove driven gear (21) and drive
gear (22).
5. Separate center section (20) and wear
plate (19) from adapter (lB). Remove
the adapter from port section (15).
6. Remove coupling (17) from port sec-
tion (15).
7. Note the relationship of the seal
glands to their retainers so that they can
be properly installed when the pump is
being assembled. Remove and discard
seal glands (OB), seal retainers (09),
and O-ring (16).
5C-6
B. Clean and inspect all parts.
9. Dip all parts in clean hydraulic oil.
10. Fit O-ring (16) to the groove in port
section (15). Do not allow the 0- ring to
become twisted.
11. Assemble coupling (17) to the splines
of drive gear (13) in port section (15).
CAUTION
The external notches on each part
must be in line after assembly.
The bronze surface of the wear
plates must face the gears after
assembly.
12. Assemble adapter (lB) to the dowel
pins on port section (15).
13. Assmble a seal gland (OB) to each
seal retainer (09). Install a seal gland
and retainer in the groove provided in
adapter (lB). Make sure the seal gland is
nea rest the adapter.
14. Align the holes in wear plate (19)
with the holes in adapter (lB). Assemble
center section (20) over the wear plate
so that the dowel pins engage the wear
plate and adapter.
15. Insert the splined end of drive gear
(22) th rough center section (20) and
adapter (lB) and into engagement with
coupling (17). Install driven gear 21).
16. Assemble wear plate (23) to the dow-
el pins on center section (20).
17. Assemble a seal gland and retainer in
the groove provided in rear cover (24).
Place the rear cover over the wear plate
and into engagement with the dowel pins
on center section (20).
lB. Lubricate and install lockwashers
(25) and screws (26 and 27) finger
tight. Using a cross-bolt pattern, torque
the screws to between 55 and 65 ft-Ibs.
19. After assembly, the torque required
to turn drive shaft (13) must not exceed
1S0 inch-Ibs.
Installation
To install an overhauled pump, proceed
as follows (see Figu re SC-2 on page
SC-S) :
1. Lower the pump into the machine. Use
the pump mou nti ng capscrews to attach
the pump to the mounting flange on the
transmission.
2. Attach a vacuum device to the breath-
er upening on the hydraulic reservoir.
Remove t.he caps from the pump supply
and pressure lines.
3. Attach the supply and pressu re lines
to the pump.
4. Check the fluid level in the hydraulic
reservoir.
S. Start the vehicle engine and engage
the pump. Allow the pump to run without
load until all air is purged from the pump
and lines.
6. Recheck the fluid level in the reser-
voir and add fluid if necessary.
7. Check the pump and connecting lines
for leaks before putting the machine
back in service.
Pumps SC-7
draulic oil and the entry of foreign
material.
7. Working at the lower end of the
swivel, tag and disconnect the air and
hydraulic lines at the stem ports. Cap
the lines to prevent an excessive loss of
oil and the entry of foreign material.
8. Remove the hardware that secures the
stem mounting bracket to the carrier.
Rotate the stem so the mounting bracket
is clear of the frame brackets.
9. Mark the location of the swivel body
support bracket in relation to the upper
frame.
10. Attach a lifting device atound the
swivel support arms. Then remove the
capscrews and lockwashers that secu re
the swivel body to the machine upper.
11. Lift the swivel from the machine. The
swivel weighs approximately 225 pounds.
Overhaul
DISASSEMBLY. To disassemble the
swivel, proceed as follows (see
Figu re 5D-1 on page 5D-3) :
CAUTION
Extreme care must be taken not to
damage the stem or body during
removal of the stem.
1. Stand the swivel in a vertical position
on a clean work surface and, if neces-
sary block it up.
2. Remove the upper retaining ring and
th rust washer.
3. Using a hoist, lift the body from the
stem or push the stem out the bottom of
the body. The body weighs approximate-
ly 150 pounds.
4. Remove the lower mounting bracket
f rom the stem.
5. Cut the seal and O-rings from the
grooves in the stem.
5D-2
INSPECTION AND REPAIR. After the
swivel has been disassembled, proceed as
follows:
1. Thoroughly wash the stem and body
with cleaning solvent.
2. Carefully inspect the stem and body
for deep scratches, scoring or other
damage. If the body or stem are worn
excessively, they should be replaced.
3. I nspect all ports in the body and stem
for nicks or scratches. Remove defects
by using fine emery cloth and lapping.
NOTE
Excessive scoring or deep scratch-
es are usually caused by foreign
material in the hydraulic system.
If these defects are found, the en-
tire hydraulic system should be
flushed.
4. Clean the sealing grooves in the stem
and body bore. Look for traces of corro-
sion and remove as necessary.
ASSEMBLY. To assemble the swivel,
proceed as follows (see Figure 5D-l on
page 5D-3) :
CAUTION
Use only hydraulic system fluid for
lubrication of seals and O-rings.
Do not use grease or any other
type of assembly lubricant.
1. Generously lubricate the swivel stem
with hydraulic oil.
2. Break the inside edges of the new seal
rings with fine sandpaper or emery
cloth. Clean the seal rings and dip both
the seal rings and seal O-rings in clean
hydraulic oil.
3. Heat the seal rings in hydraulic oil to
a maximum temperature of 150 o F. to ease
installation of the seals.
 SUBSECTION 50
HYDRAULIC SWIVEL
GENERAL
This subsection describes the hydraulic
system swivel and provides instructions
for the removal, disassembly, repair, as-
sembly and installation of the swivel.
HYDRAULIC 'SWIVEL (945Jl03)
Description
The hydraulic swivel consists of a stem,
a body and a mounting bracket, as
shown in Figu re 5D-1 on page 5D-3.
The swivel mounts between the rotating
upper frame and the fixed carrier. The
body of the swivel is fastened to the up-
per deck plate and the stem is fastened
to the carrier. The machines electrical
collector ring assembly mounts on top of
the swivel.
The purpose of the hydraulic swivel is to
transport air and hydraulic fluid from
the stationary machine lower to the rotat-
ing upper without restricting a full 360 0
rotation of the upper. The swivel does
this by allowing the passage of air and
hydraulic fluid through a combination of
internal bores, and sealed grooves in the
stem and matching bores and tubing in
the swivel body. Ai r and hydraulic lines
connected to the swivel stem and to the
body mounting bracket can remain fixed,
while the stem with the grooved passages
can rotate in respect to the swivel body
and still allow air and oil to flow through
the grooves to and from the associated
lines. An electric cable harness from the
collector ring assembly is routed down
th rough a bore in the stem. Du ring up-
per rotation, the swivel body rotates
around the swivel stem which is held sta-
tionary.
The swivel is located at the center of the
machine and can be accessed from above
and below the upper frame.
Removal
Remove the hydraulic swivel as follows:
1. Position the machine so that it is
level, with the boom over the front cen-
ter of the machine.
2. Raise the boom to gain sufficient ac-
cess to the hydraulic swivel. Stop the
engine and disconnect the battery cables
from the battery.
3. Remove the capscrews that attach the
collector ring assembly to the top of the
swivel.
4. Disconnect the electrical plug at the
end of the electrical wiring harness that
extends out the bottom of the swivel
stem. Detach the wiring harness from
the brackets on the lower frame.
5. Remove the collector ring assembly
from the top of the swivel.
NOTE
The wIring harness plug must be
in line and carefully guided up
through the swivel stem, as the
collector ring assembly is lifted
from the top of the swivel.
6. Working at the upper end of the swiv-
el, tag and disconnect the air and hy-
draulic lines from the top of the swivel
body. Cap the lines and plug the swivel
ports to prevent an excessive loss of hy-
Subsection 5D 5D-1
 CAUTION
Do not keep the seal rings and
O-rings in an expanded state for
any prolonged period, this may
prevent the seals from returning
to their original shape.
4. Install the 11 lubricated O-rings in
the seal grooves (see Figu re 5D-1 on
page 5D-3). Carefully work the heated
seal rings into the 11 grooves with the
O-rings.
5. Lubricate and install the crown seals,
with it back-up O-ring, in the four large
seal grooves.
NOTE
A crown seal is installed in the
groove nearest the top and bottom
of the stem. The two remaining
crowd seals are installed in the two
large grooves near the bottom of
the stem.
6. Stand the swivel stem, top end up, in
a vertical position. Install the lower
mounting bracket on the stem with cap-
screws. Tighten the capscrews
securely.
7. Lower the body, tubes pointing up,
over the stem. Compress the seal rings
as they enter the body bore.
8. Place the thrust ring and upper re-
taining ring over the swivel stem. Install
and securely tighten the retaining ring
capscrews.
9. Rotate the swivel stem in the body ten
times to check for proper operation.
1. Lift the swivel into position at the
opening in the upper with the swivel
support bracket lined up as marked dur-
ing removal.
2. Align the mounting holes, then install
and securely tighten the swivel mounting
capscrews and lockwashers.
3. Rotate the swivel stem to align the
stem mounting bracket with the brackets
on the carrier frame.
4. Install the capscrew and nut through
the frame brackets and stem mounting
bracket to secure the swivel stem.
5. Connect the air and hydraulic lines to
the ports as marked on the swivel rotor.
When required, make sure port O-rings
are installed.
6. Guide the plug and harness from the
collector ring assembly down the center
of the swivel stem. Attach the wiring
harness to the brackets on the lower
frame and connect the plug as tagged.
7. Attach the collector ring assembly to
the top of the swivel with the mounting
capscrews.
8. Attach the air and hydraulic lines to
the body tubes. Make sure split flange
O-rings are installed.
9. Check the level of the hydraulic res-
ervoir. Add oil, as required, to bring
the oil to the FU LL mark on the dipstick.
10. Connect the battery cables to the
battery and start the engine. Rotate the
machine several times and operate all hy-
draulic functions in the upper to bleed
air from the system. Check the swivel
and all connections for leaks.

Installation
Install the hydraulic swivel as follows:

5D-4
O-RINGS &
SEAL
RINGS

UPPER
RETAINING LUBE
PLATE FITTING

/I
.J

I
I
I
I -BODY
I
I
I
I
I
I
I
I

:
, I

./
./
./
./
./
./
,/
./
./
)

./
./
./
,/
c/

wlvel (945J103)
F-1 gure 5D-1 _ S-

Hydraulic S Wlvel
. 5D-3
 SUBSECTION 5E
HYDRAULIC SYSTEM VALVES
GENERAL
This subsection provides instructions for
the removal, disassembly, repai r, assem-
bly and installation of the various valves
and other special components of the ove-
rall machine hydraulic systems, that are
not covered in other sections or sub-
sections of this manual.
THERMAL BYPASS VALVE (36U227)
DESCRI PTION. This valve is mounted at
the rear of the transmission next to the
hydraulic pumps. When the oil temper-
atu re in the hydraulic system reaches
100 z5·o F the cooler port in the bypass
valve will begin to open and the tank
port begins to close. This allows hot oil
to pass through the oil cooler. When a
temperature of 125 z5°F is reached, the
cooler port will be fully open and the
tank port fully closed, ensuring a steady
flow of oil th rough the oil cooler.
REMOVAL. To remove the thermal by-
pass valve, proceed as follows:
1. Shut the machine down and disconnect
the battery leads.
2. Thoroughly clean the valve and sur-
rounding area with solvent.
3. Tag and disconnect the hydraulic
lines attached to the valve. Cap the lines
and plug the ports to prevent the entry
of contaminants and loss of oil.
4. Remove the mounting hardware, if
any, which secu res the valve to the ma-
chine.
REPAIR. This valve cannot be repaired
or adjusted. If the valve malfunctions, it
must be replaced.
INSTALLATION. Install the thermal by-
pass valve using the following
procedu re:
1. Secure the valve to the machine using
the mounting hardware, if provided.
2. After cleaning the hydraulic lines and
the valve ports, connect the hydraulic
lines to the appropriate valve ports.
3. Connect the battery cables to the bat-
tery and start the machine.
4. Operate various hydraulic system
functions while checking the thermal by-
pass valve for leaks.
CHECK VALVES
DESCRI PTION. The hydraulic system of
this machine uses check valves as a me-
ans of controlling the di rection of oil
flow. A check valve will allow oil to flow
in a predetermined direction, preventing
reverse flow when hydraulic system
pressure is lost. These check valve are
not repai rable and must be replaced as a
unit if they malfunction.
REPLACEMENT. Replace a check valve
using the following procedu re:
-
1. Clean the check valve and the sur-
rounding area using a suitable cleaning
agent.
2. Note the symbol on the side of the
valve do that the new valve will be in-
stalled in the same position.
3. Tag, disconnect and plug the hydrau-
lic lines to the check valve.
Subsection 5E 5E-l
4. After cleaning the valve ports, con- the check valve. Make sure the valve is
nect the appropriate hydraulic lines to installed properly.
 SUBSECTION 5F
UPPER HEATER-AIR CONDITIONER
GENERAL
The upper cab heater and air condition-
ing systems are both driven by a
common, constant drive, hydraulic motor
(see Figure SF-l on page SF-2).
The air conditioning is a conventional
system consisting of a belt driven freon
compressor with integral electric clutch,
an electric condenser and an evaporator.
Cab heat is provided by an independent
hydraulic system consisting of a flexible
·coupling, electric clutch, hydraulic
pump, heat developer with reservoi r,
and a heater coil.
This subsection contains information de-
scribing the removal, maintenance, and
installation of the heater and air condi-
tioner components.
The evaporator wiring schematic illus-
trates the wire routing and connectors
used to make up the heater / air condi-
tioner assembly wiring harness (see
Figu re SF-2 on page SF-3).
TROUBLESHOOTING
Table SF-1 on page SF-4 is a trouble-
shooting chart which lists the causes and
corrections of possible malfunctions that
are associated with a hydraulic heat and
air conditioning systems.
HEATER / AIR CONDITIONER FLOW
CONTROL VALVE (36Q502D1)
DESCRI PTION. Flow control valve regu-
lates delivery of oil to the heater drive
motor. A relief valve protects the motor
circuit from high pressure.
REMOVAL. It is not necessary to remove
this valve to perform the repai rs that are
possible on this valve. The only reason
for removing the valve would be to re-
place the complete valve assembly. If it
is necessary to replace the complete
valve assembly, proceed as follows:
WARNING
Escaping hydraulic fluid can cause
inJury. Relieve all hydraulic pres-
sure in the system by turning off
engine and operating all hydraulic
control levers before disconnecting
hoses.
1. Stop engine and relieve pressure from
hydraulic system.
2. Tag, disconnect and plug all hydrau-
lic hoses.
3. Remove the hardware which secures
the valve to the machine, and remove the
valve.
REPAIR. Repair of this valve is limited
to the replacement of the flow control
and relief cartridges. These items can
be replaced without removing the valve
from the machine.
INSTALLATION. Install a new or re-
paired valve as follows:
1. Position the valve in the mounting po-
sition and secu re it with the original
hardware.
2. Make sure all O-rings are installed
and reconnect the hydraulic lines and
fittings.
Subsection SF SF-1
 FROMA/C
Figure SF-I. Air Conditioner System-Upper
3. Start the engine and operate the cab
heater and swing ci rcuits to check the
operation of the valve and to pu rge any
air from the circuits. Check all hydrau-
lic liones for leakage.
HEATER / AIR CONDITIONER BLOWER
(51 U131 D1)
DESCRI PTION. The blower assembly
consists of an electric motor with dual
blower wheels, a combination air condi-
tioner evaporator/heater coil and opera-
tor controls.
MA I NTENA~~CE. Clean reci rculating ai r
filter using air pressure.
REMOVAL. To remove blower assembly
proceed as follows:
,. Disconnect ground cable at battery.
5F-2
HYDRAULIC
MOTOR
2. Tag and disconnect all electric wires
from blower.
WARNING
Escaping freon can cause inJury.
Open fittings slowly, to bleed
pressure from system, before re-
moving hoses.
3. Tag, disconnect and plug all hydrau-
lic and freon hoses.
4. Remove mounting hardware and blower
from cab.
INSTALLATION. To install blower as-
sembly proceed as follows:
,. I nstall blower and mounting hardware.
Tighten secu rely.
 EVAmlATOI (BIt{; HYIIlAIUC
arut{; & IEATIt{; nmmTATICAl.l.Y IDflIIll.B) ItASTBl SVITOI

I. IEAT lUI 11M TBltIIW..

2. nmmTAT 11M TBltlNAl. 4. 8..EClRIC a.lITOlIEATIt{;
5. 8..ECTRIC QlITOl mlINl
~ 3.
~
~

aID. IN
o FAN IN
aID. (lJT o
a.lITOl (lJT

" FBIAlf IDHITOI ~ IlllET TBItINAl.

o BIlET TBltIIW.. t=> IIW..ATIItl eN'
Il.W. 1lH£CT(Il 0 lBIIINAl. 1ISIlt{;

Figure 5F-2. Air Conditioner Schematic

2. Connect all hydraulic and freon WARNING
hoses.
Escaping freon can cause inJury.
3. Connect all electric wires to blower. Open fittings slowly, to bleed
pressure from system, before dis-
4. Connect ground cable to battery. connecting hoses.

5. Purge, evacuate and charge the freon

system. 3. Tag, disconnect and plug all freon
hoses.
CONDENSER ASSEMBLY (51 U132D1) 4. Remove mounting hardware and con-
denser assembly.
DESCRI PTION. The condenser assembly
consists of two electric motors with suc- INSTALLATION. To install condenser
tion fans, a receiver/dryer, assembly proceed as follows:
hi/low-pressu re limit switch and conden-
ser coil. 1. I nstall condenser and mounting hard-
ware. Apply Loctite 242 to threads of
MAl NTENANCE. Flush out the conden- mounting hardware and tighten securely.
ser coil using clean water.
2. Connect all freon hoses.
REMOVAL. To remove condenser assem-
bly proceed as follows: 3. Connect all electric wires to condenser
assembly.
1. Disconnect ground cable at battery.
4. Connect ground cable to battery.
2. Tag and disconnect all electric wires
from condenser assembly. 5. Purge, evacuate and charge the freon
system.

Upper Heater-Air Conditioner 5F-3

 CONDITION POSSIBLE CAUSE CORRECTION
Belt slipping 1. Loose 1. Adj ust belt to 1/2" de-
pression
2. Overcharge 2. Correct Charge
3. Ai r in System 3. Evacuate and recharge
Excessive belt wear 1. Pulley not in line 1. Align pulley
2. Belt too tight 2. Adjust or replace
II 3. Bad idler bearing 3. Replace part
I

3. Belt wrong width 3. Replace part

I
Vibration in compressor 1. Stuck compressor or 1. Replace part
area clutch
2. Overcharge 2. Correct Charge
3. Air in System 3. Evacuate and recharge
I
i 3. Mount or compressor 3. Tighten
I belts loose
Noise, clutch engaged 1. Bad compressor 1. Replace part

i
Noise, clutch engaged or 1. Clutch bearing 1. Replace part
I not
2. Loose clutch 2. Tighten
3. Clutch rubbing field 3. Align
4. Bad belt 4. Replace part
Chatter or knock in com- 1. Compressor low on oil 1. Add oil
pressor area
2. Valve plate broken 2. Replace part
Evaporator unit rubbing 1. Fan blade or blower 1. Replace or repair
or scrapping
t

Hissing 1. Low charge and/or 1. Repair leak and/or cor-

I leak rect charge
I
Chatter or knock 1. Expansion valve 1. Replace part
Noise case 1. Loose brackets or 1. Tighten
screws
Motor squeal 1. Dry bearings 1. Replace parts

Table SF-I. Heat and A/C Troubleshooting (Part 1 of 4)

5F-4
 CONDITION POSSIBLE CAUSE CORRECTION
Cooling quits l. Moisture l. Replace drier
2. Thermostat 2. Replace part
3. Clutch 3. Check pull-in of clutch
or replace it necessary
Cooling intermittent l. Moisture l. Replace drier
2. Thermostat 2. Replace part
Blower motor or conden- l. Defective circuit l. Replace part, clean and
sor fan motor inopera- breaker, bad wiring con- tighten connections
tive nection
2. Tight motor bearing 2. Repair or replace motor
I 3. Switch open or short- 3. Repair or replace
I ed switch
Slow running blower l. Blower shaft binding l. Replace motor
2. Wheel misaligned 2. Replace part
3. Bad blower switch 3. Replace switch
Clutch inoperative l. Defective circuit l. Replace part
breaker
2. Loose Connection 2. Clean and tighten con-
nection

I
3. Broken ground wire 3. Repair wire
! 4. Shorted or open field 4. Replace field
High head pressure l. Overcharge of refri- l. Purge as necessary
gerant
2. Air in System 2. Evacuate and recharge
3. Condenser clogged 3. Clean
4. Defective condenser 4. Check electrical before
I fan motor replacing fan motor

Table SF-I. Heat and AIC Troubleshooting (Part 2 of 4)

Upper Heater-Air Conditioner SF-S

 CONDITION POSSIBLE CAUSE CORRECTION
Low head pressure I. Undercharge of refri- I. Complete the charge
gerant
2. Bad compressor valve 2. Replace or repair
plate or gasket
3. Restriction in drier 3. Replace drier
4. Restriction in lines 4. Clean the lines
5. Restriction in expan- 5. Replace expansion valve
sion valve and drier
I
6. Improper expansion I 6. Replace the expansion
valve in charge valve

I
7. Broken expansion 7. Replace expansion valve
valve cap tube (valve
I remains closed
,
8. Freon leak 8. Check hoses and fit- i
tings for leaks and repair I
Inadequate heat i
I
I. RPM's too low I. Increase to 2,000 RPM
2. Heat pump worn 2. Replace pump
I 3. Heat developer valve 3. Replace valve
not building pressure
4. Electric selector 4. Check electric input,
valve not closing replace if faulty
5. Hydraulic level in 5. Fill to proper 1eve 1 , I
reservoir low check for 1eaks
6. Incorrect hydraulic 6. Refill with P&H 484S
fluid
7. Thermostat set too 7. Adjust to desired tem-
low perature
8. Thermostat not oper- 8. Replace thermostat
ating
9. Low voltage or open 9. Test for proper voltage I
circuit -
10. HI-LO Limit not 10. Check for continunity,
functioning replace if necessary
II. Suction screen II. Clean screen and re-
plugged fill with clean oil

Table 5F-1. Heat and AIC Troubleshooting (Part 3 of 4)

5F-6
I CONDITION
POSSIBLE CAUSE CORRECTION
Excess heat 1. Thermostat setting to l. Adjust thermostat
high
2. Thermostat stuck in 2. Replace thermostat
I
ON position
3. Selector valve stuck 3. Replace valve
in closed position
4. Hydraulic level in 4. Fi 11 to proper 1eve 1 ,
reservoir low I check for leaks
I !
i 5. Incorrect
I
hydraulic II 5. Refill with P&H 484S
I fl ui d
I 6. Suction screen 6. Clean screen and refill
I plugged with clean oil
I
High pressure heat
.7. 7 . Replace valve
i developer valve stuck
I closed I
i 8. Clutch slipping 8. Check voltage
I I
I i
No Heat No voltage to unit I 1. Check for loose wires
I I or open circuit breaker
I
2. No voltage to heat 2. Check for loose or bro- I
I ! pump clutch ken wires from air condi-
I
I tioner to heat developer
I and onto clutch
3. Clutch failure 3. Replace clutch
4. Flex coupling broken 4. Replace coupling
5. Loss of all hydraulic I 5. Check for leaks or bro-
fl uid I ken hoses. Refill with hy-
draulic oil
I
Table SF-I. Heat and AIC Troubleshooting (Part 4 of 4)
WATER I AIR CONDITIONER DRIVE REMOVAL. To remove air conditioner
ASSEMBLY (51 U133D1) compressor proceed as follows:

DESCRIPTION. The heater I air condi- 1. Disconnect ground cable at battery.

tioner drive assembly consists of a hy-
draulic drive motor, drive pulley, drive
belt, flex coupling, clutch adapter, elec-
tric clutch assembly, hydraulic heat
pump and air conditioner compressor.
MAl NTENANCE. Adjust air conditioner
compressor drive belt tension.
AIR CONDITIONER COMPRESSOR
2. Tag and disconnect all electric wires
from air conditioner compressor.
WARNING
Escaping freon can cause inJury.
Open fittings slowly, to bleed
pressure from system, before dis-
connecting hoses.

Upper Heater-Ai r Conditioner 5F-7

3. Tag, disconnect and plug all freon
hoses.
4. Remove compressor guard.
5. Remove mounting hardware.
6. Disconnect drive belt and remove
compressor.
INSTALLATION. To install air condi-
tioner compressor proceed as follows:
1. Install compressor, drive belt
mounting hardware.
2. Adjust belt tension. Tighten mount-
ing hardware securely.
3. I nstall compressor guard.
4. Connect all freon hoses.
5. Connect all electric wires to compres-
sor.
6. Connect ground cable to battery.
7. Purge, evacuate and charge the freon
system.
HYDRAULIC DRIVE MOTOR
REMOVAL. When servIcing hydraulic
drive motor, removal or repair of the
drive pulley, drive belt, flex coupling,
cl utch adapter or electric cl utch assem-
bly can be done. To remove hydraulic
drive motor proceed as follows:
WARNING
Escaping hydraulic fluid can cause
inJury. Relieve all hydraulic pres-
sure in the system by turning off
engine and operating all hydraulic
control levers before disconnecting
hoses.
1. Stop engine and relieve pressure from
hydraulic system.
5F-8
2. Tag, disconnect and plug all hydrau-
lic hoses.
3. Remove ai r conditioner compressor.
(See "Air Conditioner Compressor" on
page 5F-7) .
4. Remove compressor support.
5. Remove mounting hardware and motor
with drive pulley and belt.
and INSPECTION AND REPAIR
Inspect flex coupling, adapter and elec-
tric clutch assembly for damage or wear.
Replace if necessary.
INSTALLATION. To install hydraulic
drive motor proceed as follows:
1. Install hydraulic drive motor with pul-
ley and belt. Secure with original hard-
ware.
2. Install compressor support.
3. Install air conditioner compressor (See
"Air Conditioner Compressor" on page
5F-7) .
4. Connect all hydraulic hoses.
5. Start the engine and operate the cab
heater and swing ci rcuits to check the
operation of the motor and to pu rge any
air from the circuits. Check all hydrau-
lic lines for leakage.
HYDRAULIC HEAT PUMP
REMOVAL. To remove hydraulic heat
pump proceed as follows:
1. Tag, disconnect and plug all hydrau-
lic hoses.
2. Remove two mounting cap screws -(A)
and hydraulic heat pump (see
Figure 5F-3 on page 5F-9).

Figure 5F-3. Heat Pump Removal
INSTALLATION. To install hydraulic
heat pump proceed as follows:
NOTE
When installing mounting
hardware, make sure to connect
ground wire (B).
1. I nstall hydraulic heat pump and
mounting hardware. Tighten securely.
2. Connect all hydraulic hoses.
3. Start the engine and operate the cab
heater to check the operation of the
pump and to purge any air from the cir-
cuits. Check all hydraulic lines for
leakage.
HEAT DEVELOPER WITH RESERVOIR
(27U388Dl )
DESCRI PTION. The heat developer as-
sembly generates heat by passing hy-
draulic oil through a relief valve. A the 200 psi (A) and 1200 psi (B) relief
normally open solenoid valve di rects oil
flow to the reservoir when no heat is re-
quired. When the solenoid coil is ener-
gized, oil flow is directed to the heat
developer relief valve. Hi/low switches
sense oil temperature and de-energize so-
lenoid coil should temperature is beyond
switch set points. Oil is heated by fric-
tion as it passes th rough the relief
valve. A second relief valve protects
the heater' coil from excess pressure and
volume during cold start-up. Excess oil
flows directly to reservoir until oil warms
up and flows more freely.
TROUBLESHOOTING. Use the system
description and Table 5F-1 on page 5F-4
to isolate a problem in the cab heater
circuit. Figure 5F-4 on page
5F-lOiliustrates the gauges and con-
nections required for testing the heat
developer assembly.
Check with the machine operator to see
how the cab heater performed, when it
started to malfunction or if tbere is any-
thing unusual about it. Operate the
heater and check for unusual noises.
Visually inspect the heater components,
looking for oil leaks. Examine the pump,
motor, reservoir, suction screen and all
lines checking for loose connections or
collapsed hoses.
REMOVAL. It is not necessary to remove
the entire assembly to perform the possi-
ble repairs or tests. The only reason
for removing the heat developer valve
would be to replace the complete valve
assembly or clean and change a clogged
reservoir suction screen. Remove the
valve as follows:
1. Disconnect ground cable at battery.
2. Tag and disconnect all electric wires
from heat developer assembly.
3. Tag, disconnect and plug all hydrau-
lic hoses.
4. Remove heat developer cover.
5. Remove the hardware which secures
the valve to the reservoir.
6. Remove the valve assembly.
MAINTENANCE AND REPAIR. Repair of
this assembly includes the replacement of
cartridges, solenoid valve cartridge (C)
and Hi/Low sensor switch (D). These
items can be replaced without removing
the valve from the machine (see
Figu re 5F -5 on page 5F -11) .
To clean or replace a clogged suction
screen (F), remove the complete valve
assembly from the reservoir (E) and
twist off suction screen.
Upper Heater-Air Conditioner 5F-9
 RETURN FLOW TEST PORT
FROM HEAT COIL COIL

-; IN FLOW
-s TEMP. GAUGE
-7 FLOW METER
-~
6-7 GPM (THERMOSTAT OFF)
150
-:;, I (THERMOSTAT OFF)
-4 5-6 GPM (THERMOSTAT ON)
I 200-250 PSI 100 200
-3
-2 200 PSI I 190-225 PSI
RELIEF VALVE : (THERMOSTAT ON)
150 ...-25"0
o
-:

{,'---I.~--0
-0

-:----;-:------------------·-00
. .'::
:
.~-
J
__ ~;.------- .. ------- --- ---'-I
L------C---~.'
:.---- ... -.. ~_ . . _.. ___ .

COlLIN TO COIL OUT

1200 PSI
RELIEF VALVE-'--- ~O-~------ ----0';
'Ii::: _:i' _______ .. ............... •

SELECTOR

SUCTION
TO HEAT
PUMP

- c
-5
FLOWMETER -4
S GPM (TERMOSTAT OFF)
7 GPM (THERMOSTAT ON) -z
- !
@2000RPM
-0

200-250 PSI (THERMOSTAT OFF) 0

1200-1500 PSI (THERMOSTAT ON) PSI
@2000RPM
TEST PUMP PRESSURE FROM
HEAT PUMP HEAT PUMP

Figure SF-4. Air Conditioner Test Ports

5F-10
 INSTALLATION. To install hydraulic
heat developer assembly proceed as fol-
lows:
1. Install reservoir suction screen, if
removed.
2. Position valve with new O-ring on
reservoir and secure with original hard-
ware.
3. Connect all hydraulic hoses.
4. Install heat developer cover.
5. Connect all electric wires.
6. Connect ground cable at battery.
7. Start the engine and operate the cab
heater to check the operation of the heat
developer assembly and to purge any air
from the circuit. Check all hydraulic
lines for leakage.

Figure SF-S. Heat Developer

Upper Heater-Ai r Conditioner 5F-ll

 TABLE OF CONTENTS

Subsection 6A 6A-1

Introduction 6A-1
General 6A-1
Description 6A-l

Subsection 6B 6B-1

Boom System 6B-1

General 6B-1
Boom Removal 6B-1
Boom Installation 6B-1
Boom (1 OOJ 5335 ) 6B-2
Description 6B-2
Boom Repair 6B-2

Subsection 6C 6C-1

Boom Hoist Cylinder 6C-1

General ......... . 6C-1
Boom Hoist Cylinder (100Pll37) 6C-l
Description . 6C-1
Maintenance And Repair 6C-1
Removal 6C-1
Overhaul 6C-2
Installation 6C-3

Subsection 60 60-1

Boom Telescope Cylinders 60-1

General ............. . .... 6D-l
Boom Telescope Cylinders (38Rl72 and 38R173) 6D-1
Description ..... 6D-l
Maintenance and Repair 6D-l
Removal 6D-l
Overhaul 6D-3
Installation 6D-8

Subsection 6E 6E-1

Boom Hoist and Telescope Control Valves 6E-1

General .................. . 6E-l
Boom Hoist and Telescope Control Valve (36U290) 6E-l
Description . . . . 6E-l
Troubleshooting ... . 6E-2
Removal ....... . 6E-4
Valve Service and Repair 6E-4
Control Valve Installation ..... 6E-7
Boom Telescope Holding Valve (36R37Dl) .. 6E-8
Flow Divider/Crossover Relief Valve (36U183D3) 6E-8
Repair ........... . 6E-9
Boom Hoist Holding Valve (36R97) 6E-9
Description 6E-l0

Subsection 6F 6F-1

Boom Adjustments and Alignments 6F-1

General ........... . 6F-l

Contents
Slider Pad Adjustment . 6F-l
Boom Alignment Procedure 6F-l

ii
 LIST OF ILLUSTRATIONS

Figure 6A-1. Boom System 6A-2

Figure 6B-1. Boom Assembly (100J5335) 6B-5
Figu re 6B-2. Hose Loop Installation 6B-6
Figure 6C-1. Boom Hoist Cylinder Assembly (100P1l37) 6C-4
Figure 6D-1. Hose Loop Installation 6D-2
Figu re 6D-2. C-Clamp Installation 6D-3
Figure 6D-3. Boom Telescope Cylinders (38Rl72 and 38R173) 6D-5
Figure 6D-4. Inner Seal Ring Installation 6D-6
Figure 6D-5. Piston Ring Installation 6D-6
Figure 6D-6. U-Cup and Wiper Installation 6D-6
Figu re 6D-7. Assembly Sleeve Installation 6D-7
Figure 6D-8. Assembly Sleeve Dimensions 6D-7
Figu re 6D-9. Piston Installation 6D-7
Figure 6D-1O. Boom Assembly (100J5335) 6D-9
Figu re 6E-1. Boom Hoist And Telescope Control Valve 6E-1
Figu re 6E-2. Boom Hoist and Telescope Control Valve (36U290) 6E-5
Figu re 6E-3. Telescope Holding Valve Installation 6E-8
Figure 6E-4. Flow Divider/Crossover Relief Valve 6E-9
Figure 6E-5. Boom Hoist Holding Valve Installation 6E-1O
Figure 6F-1. Side Loading the Boom 6F-3

List of Illustrations iii

 LIST OF TABLES

Table 6E-1. Control Valve Troubleshooting 6E-2

Table 6E-2. Relief Valve Troubleshooting 6E-3

List of Tables v
 SUBSECTION 6A
INTRODUCTION
GENERAL
Section 6 is divided in subsections which
cover the boom system components used
on this machine. Each subsection de-
scribes individual assemblies or compo-
nents and includes procedu res for the
removal, disassembly, assembly, and in-
stallation of the boom system
components. Recommended inspection,
and repair procedures are also included
in the individual subsections.
DESCRIPTION
The boom provided on this machine is
shown· in Figu re 6A-l on page 6A-2.
This boom consists of the base section
and two hydraulically powered sections.
The two powered sections are extended
and retracted using two telescope cylin-
ders which are operated simultaneously.
When the boom telescope control valve is
operated, hydraulic oil is ported to and
from the telescope cylinders and the first
and second sections of the boom are ex-
tended or retracted in relation to the
boom base section, depending on the op-
erator's control position. The action of
extending or retracting the boom sec-
tions wi II conti n ue u nti I the control valve
is retu rned to the neutral position by
operator control, or u nti I the boom tele-
scope cyl i nders are fu Ily extended or
retracted.
The boom is pin-mounted on the upper
frame of the machine and is supported by
the boom hoist cylinder. The boom hoist
cylinder is pin-connected between the
machine's upper frame and the base sec-
tion of the boom and is the means by
which the boom is raised and lowered.
Control valves in the machine's hydraulic
system and holding valves mounted on
the telescope and boom hoist cylinders,
transfer oil to and from the cylinders to
allow safe and smooth telescope and
hoisting functions of the boom. The
holding valves prevent the flow of hy-
draulic oil from the cylinders until a
minimum preset pressure is reached in
the hydraulic system.
A cable system has been set up inside
the boom to retain the hose loop formed
by the hydraulic line which connects the
upper and lower telescope cylinders.
Subsection 6A 6A-l
 SECTION 1

BOOM POINT BOOM HOIST

CYLINDER

Figure 6A-l. Boom System

6A-2
 SUBSECTION 6B
BOOM SYSTEM
GENERAL
This subsection provides the necessary
information to remove, disassemble, re-
pair, assemble and install the boom on
this machine.
BOOM REMOVAL
Remove the boom as a complete unit us-
ing the following instructions as a guide-
line:
1. Position the machine on a hard level
surface.
2. Unreeve the hoist line and remove the
hook block from the boom.
WARNING
Support the boom using a suitable
lifting device before removing any
components. If this precaution is
not followed, the boom will fall
possibly causing serious injury to
personnel or damage to the ma-
chine.
3. Lower the boom to the horizontal posi-
tion and shut the machine down.
4. Release the hydraulic system pressure
by operating the boom hoist and boom
telescope control levers in both di-
rections. Vent the hydraulic reservoir
by loosen i ng the breather cap.
5. Support the boom using a sling and a
suitable lifting device.
6. Tag, disconnect and plug any hydrau-
lic lines which are connected to the boom
holding valves. Tag, disconnect and
plug any hydraulic lines which may in-
terfere with the removal of the boom.
7. Disconnect any electrical leads which
may interfere with the removal of the
boom.
8. Remove the capscrews and lockwash-
ers which secu re the boom base pins to
the upper frame. Remove the boom base
pins.
WARNING
Before removing the boom hoist
cylinder rod pin, support the boom
hoist cylinder using a suitable lift-
ing device and blocking. This will
prevent the cylinder from drop-
ping when the rod pin is removed.
If this precaution is not followed
serious injury to personnel or
damage to the machine may result.
9. Remove the capscrews and lockwash-
ers which secure the boom hoist cylinder
rod pin to the boom base. Remove the
cylinder rod pin.
10. Lift the boom from the machine and
move to a su itable work a rea.
11. Lower the boom hoist cylinder onto
blocking and remove the lifting device.
BOOM INSTALLATION
The following directions are general in
nature and should be used and a guide-
line when the boom is being installed.
Install the boom as follows:
Subsection 6B 6B-1
1. Using a sling and suitable lifting de-
vice, position the boom over the machine
and lower it into place.
2. I nsert the boom base pins and secu re
them with the capscrews and lockwashers
provided.
3. Raise the boom hoist cylinder, using a
suitable lifting device, and pin the cyl-
inder to the boom base. Secure the cyl-
inder rod pin using the capscrews and
lockwashers provided.
4. After cleaning the hydraulic lines and
valve ports, connect the hydraulic lines
to the appropriate valve ports.
5. Connect any electrical leads which had
been disconnected in order to remove the
boom.
6. Reeve the hoist line and hook block as
described in Section 2 of this manual.
7. Operate the boom hoist and boom tele-
scope functions while checking for leaks
especially around the holding valves.
Correct any leaks which are found.
8. Add hydraulic oil to the reservoir as
required to bring the oil level to the full
mark on the dipstick.
9. Adjust and align the boom as de-
scribed in Subsection 6F under the
topic, Boom Adjustments and Alignment.
BOOM (1 OOJ5335)
Description
The boom consists of a base section and
two hydraulically powered sections. The
boom telescope system components con-
sist of two telescope cylinders mounted
one over the other, as shown in
Figu re 6B-1 on page 6B-5, and a sup-
port bracket for each cylinder.
I n addition, the telescope system compo-
nents include interconnecting tubing and
flexible hydraulic lines, and a hose ten-
sioning system. The inter-connecting
tubing and flexible hydraulic lines
inter-connect the telescope cylinder hold-
ing valves and the boom extension flow
divider valve, which is mounted on a pad
on the under side of the boom base sec-
tion.
6B-2
The hose tensioning system mounts be-
tween the bottom sides of the base and
first sections of the boom. The tension-
ing system keeps the flexible hose be-
tween the cylinder holding valves under
tension and prevents the hose from being
damaged during boom telescoping oper-
ations.
Boom Repair
DISASSEMBLY. Disassemble the boom
using the following procedure (see
Figu re 6B-1 on pa~e 68-5):
1. Remove the boom from the machine as
described earlier in this subsection un-
der the topic, 800m Removal.
2. Position the boom assembly on block-
ing.
CAUTION
The hydraulic line between con-
nections (01 and 02) is under ap-
proximately 55 Ibs of spring
tension. This tension must be re-
lieved before disconnecting the
loop hose assembly or problems
may result.
3. Fasten a rope, at least 30 feet in
length, to the hydraulic hose fitting at
connection (01) and put a slight strain
on the line. Then remove the fitting
capscrews. I nstall covers on the lines
and then, carefully allow the spring ten-
sion to relax.
4. Tag and disconnect the hydraulic
lines to the upper and lower telescope
cylinder holding valves. I nstall covers
and plugs on the lines and ports to pre-
vent the entry of contami nants.
5. Remove the capscrews, lockwashers,
keeper plates and trunnion block pins
from the lower rod end trunnion block
and base section.
6. Place a sling around boom sections one
and two of the boom and pull the com-
bined sections of boom from the base sec-
tion until approximately 9 feet of the
combined boom sections remain in the
base section.
 NOTE
As the front sections of boom are
being removed, the hose carrier,
tensioning cable, and hydraulic
hose, shown in Figure 6B-2 on
page 6B-6, will be pulled toward
the front of the base section.
Make sure the hose passes through
the base section by maintaining a
slight tension to the rope previous-
ly attached to the hose.
7. Remove the nut, lockwasher and cap-
screw from the hose tensioning cable
bracket, at the front of the boom base
section. Disconnect the other end of the
tensioning cable from the anchor pin on
the bottom of section one of the boom.
8. Remove the slider pads and fastening
hardware from the front, sides and in-
termediate sections of base section.
9. Carefully, finish pulling the boom sec-
tions out of the base section. Make sure
the rear skid on the bottom of the first
section clears the hydraulic line and the
hose carrier and tensioning assembly.
10. If necessary, remove the tensioning
assembly from the bottom of the base
section.
11. If necessary, disconnect the loop
hose and tube assembly from the base
section.
12. Remove the lower telescope cylinder
from the boom sections as follows:
A. Remove the capscrews, lockwashers
and retaining plates from the trunnion
lugs in the fi rst section.
B. Using suitable equipment, support
the lower telescope cylinder and care-
fully pull the cylinder from the boom
assembly.
13. Remove the upper telescope cylinder
from the boom sections as follows, (see
Figu re 6B-1 on page 6B-5):
A. Remove capscrews, lockwashers,
keeper plates and trunnion block pins
from the upper rod end trunnion
block and fi rst section.
B. Make sure hydraulic lines to the up-
per telescope cylinder holding valve
have been disconnected and that cov-
ers and plugs are on the lines and
ports to prevent the entry of contam-
inants.
C. Carefully, pull section two out of sec-
tion one until approximately nine feet
remain inside section one. Then re-
move the bottom and side slider pads.
D. After the sl ider pads have been re-
moved finish pulling section two out
of section one.
NOTE
Make sure the upper cylinder rod
end trunnion block clears the
brackets in the first section.
E. Remove the capscrews, lockwashers
and retaining plates from the trunnion
lugs in section two of the boom.
F. Using suitable equipment, support the
upper telescope cylinder and carefully
pull the cylinder from the boom as-
sembly.
14. If the telescope cylinders are to be
repaired, refer to the topic, Boom Tele-
scope Cylinders in Subsection 6D.
ASSEMBLY. Assemble the boom using
the following procedure (see Figure 6B-1
on page 6B-5):
NOTE
If the slider pads need replacement
and/or adjustment, replace and ad-
just them at this time prior to as-
sembling the boom. The boom
must be disassembled to replace
and adjust some of the pads.
1. I nstall the support brackets on the
ends of the cylinders. Tighten the cap-
screws to 150 ft-Ibs.
2. Apply a coating of lubricant to the in-
ner surfaces of the boom which are in
contact with the slider pads.
3. Check the applicable section of the
boom to ensure the trunnion lugs and
boom section are clea r of obstruction s.
4. Carefully, slide the upper cylinder
assembly into section two until the cylin-
der body trunnions can be pinned to the
trunnion lugs in section two of the boom.
Boom System 6B-3
5. I nstall the trunnion retainer plates
with capscrews and washers. Tighten the
capscrews to 54-59 ft-Ibs of torque.
6. I nstall the upper and side slider pads
into section two of the boom.
7. Carefully, slide boom section two into
the front of boom section one, until the
rod end trunnion of the upper cylinder
is aligned with the brackets in section
one. Make sure the slider pads on the
rear clear the top and side plates of the
first section. Clearance should be 0.06
inches. If not, shim the pads as requi red
to obtain the proper clearance, (see
Figure 6B-1 on page 6B-5).
8. Install the front lower slider pads and
collar pads in section 1.
9. Carefully, slide the lower cylinder as-
sembly into the assembled sections of the
boom, until the cylinder body trunnions
are seated in the trunnion lugs in section
one of the boom.
10. Install the trunnion pins to secure
the upper cylinder rod and the lower ex-
tend cylinder body to boom section 1.
Secure the pins with retainer plates,
capscrews and washers. Tighten the re-
tainer capscrews securely to 54-59
ft-Ibs.
11. Install the upper and side slider
pads on section 1.
12. Lift the built up boom sections, con-
sisting of sections one and two of the
boom and the upper and lower cylinders,
and place them into position at the front
end of the base section.
13. Align the lower cylinder rod end
trunnion block with the brackets in the
boom base section boom.
14. Assemble and partially install the
hose loop and tensioning assembly as fol-
lows:
A. Attach one end of the cylinder inter-
connecting hose loop to the right rear
fitting (connection 02) of the first
section, (see Figure 6B-2 on page
6B-6) .
B. Assemble the cylinder interconnecting
hose into the hose carrier, (see
Figure 6B-2 on page 6B-6).
6B-4
C. Attach a length of rope to the free
end of the interconnecting hose and
pass the rope th rough the base sec-
tion. Pull the free end of hose into
the front opening of the boom base
section.
D. Pass the tension cable through the
small sheave on the hose carrier as-
sembly. Then, attach one end of the
tension cable to the spring assembly
as shown in Figu re 6B-2 on page
6B-6. )
15. Install the combined boom section as-
sembly into the base section as follows:
A. Lift the combined boom section assem-
bly and position the rear skid of the
first section in the hose loop. While
pulling the rope and free end of the
hose assembly into the boom, from the
rear of the base section; carefully,
guide the hose carrier assembly into
the boom and slide the boom sections
into the base section approximately 9
feet.
B. Attach the free end of the hose loop
to the fitting at the rear of the boom
base section, con nection (01) as
shown in Figure 6B-2 on page 6B-6.
c. Attach the free end of the tension
spring assembly to the front of the
boom base section with bracket and
hardware. Tighten the capscrews.
D. Install the lower front and side slider
pads in the boom base section with
capscrews and washers. Tighten the
capscrews.
E. Pull the free end of tension cable un-
til it is tensioned to 55 Ibs ±3 Ibs
spring tension, then fasten the cable
to the anchor pin on the bottom plate
of the first section (see Figure 6B-2
on page 6B-6) .
NOTE
When fastening the end of the ten-
sioning cable, strip approximately
9 inches of covering from the end.
Seize the dead end as shown in
Figure 6B-2 on page 6B-6.
F. Slide the boom sections the rest of the
way into the boom base, until the low-
er cylinder trunnion block is engaged
in the base section brackets. Make
 oIt) o
,... ,...
It)

o o

BASE
SECTION
SECTION #1
0.06 MAX.
SECTION #2

0.625
BASE SECTION
0.625

SECTION #1

~
~ ~N
o LOWER TELESCOPE
HOSE CYLINDER
LOOP
FRONT

NOMINAL CLEARANCE BETWEEN BOOM Figure 6B-l. Boom Assembly (lOOJ5335)

SECTIONS OF RETRACTED BOOM

Boom System 6B-5

 SECTION N·N , ST SECTION
PIN C::;:=:;::====-""- BOTTOM PLATE

CAPSCREW & TENSION ANCHOR REAR SKID CONNECTION

BRACKET CABLE PIN T E N S I O N , ST SECTION 02

/ / I CABLE \ \

~I ~ ! ! i1 I/i! ! l ,~-~-,:>1! ! ! ! ! ! ! '! ! ! ! ! Sf'17l/ L/!_~i {'/ /\ ~I'-

. ==...... - 7
! ~'
I
- / ,_ _ ~i~\~.~. ,.....~~=-...2/111111_==
='
/---=:J ~
\ ANCHOR PIN WELDED
TENSION ON BOTTOM SIDE HOSE LOOP CONNECTION
SPRING OF' ST SECTION CARRIER HOSE 0'
ASSEMBLY
TENSION
CAPSCREW SPRING TENSION
CABLE

I
\ /
I~~;=I

BASE SECTION ~~~Z]::

TENSION
CABLE
I
HOSE CARRIER SECTION L·L
SECTION M·M ASSEMBLY

Figure 68-2. Hose Loop Installation

sure that the base section slider pads I. Install the interconnecting hose as-
on both sides of the boom have proper semblies and flow divider (see
clearance, and that the hose loop ten- Figure 6B-1 on page 6B-5).
sioning assembly is operating proper-
ly. 16. Install the boom as described earlier
in this subsection under the topic, Boom
NOTE Installation.
The slider pads, away from the 17. Check that the boom has clearance to
boom end, on the sides of the base operate, start the machine and operate
section should have 0.06 inch max- the boom telescope and boom hoist sys-
imum clearance. Add shims as nec- tems. Check the hydraulic connections
essary to obtain proper clearance. for leakage especially around the holding
valve and the rod bearing seals.
G. I nstall the lower cylinder trunnion 18. Add oil to the hydraulic reservoir as
pins, with retainer plates, capscrews required, to bring the oil level to the
and washers. Tighten the retainer full mark on the dipstick.
capscrews secu rely.
19. Adjust and align the boom as de-
H. Install the boom telescope cylinder scribed in Subsection 6F under the
holding valve. Tighten the holding topic, Boom Adjustments and Alignment.
valve capscrews to 54-59 ft-Ibs of
torque.

6B-6
 SUBSECTION 6C
BOOM HOIST CYLINDER
GENERAL
This subsection describes the boom hoist
cylinder used on this machine and in-
cludes removal, disassembly, assembly
and installation procedures. Also in-
cluded are recommended inspection and
repair procedures for the cylinder.
BOOM HOIST CYLINDER (100P1137)
Description
This cylinder assembly consists of a
double acting piston rod assembly and a
cylinder body. The rod end eye is
pinned to the boom, and the base of the
cylinder body is pinned to the machine's
upper frame. The cylinder assembly
weighs approximately 800 pounds.
Maintenance And Repair
Maintenance requirements for this cylin-
der are minimal, however it is recom-
mended that periodic inspections of the
cylinder be made, to check the cylinder
assembly for abnormal wear, loose or
damaged components, and hydraulic
leaks. Repair of the boom hoist cylinder
is limited to the replacement of worn or
damaged seals, wear rings and other
parts listed in the machine parts manual.
Removal
To remove the boom hoist cylinder, pro-
ceed as follows:
NOTE
The following instructions provide
the necessary precautions which
must be taken to remove the boom
hoist cylinder. However, because
the equipment available will vary,
the following instructions do not
describe in detail the manner in
which to remove the boom hoist
cylinder or lift the boom.
1. Position the machine on fi rm level
ground with the boom over the front of
the machine.
2. Fully retract the boom and position it
in such a manner which allows the great-
est access to the boom hoist cylinder.
The boom must be lowered onto suitable
blocking or held in position with an out-
side assist.
3. Place blocking around the collector
assembly, to prevent damage to the col-
lector when boom hoist cylinder is re-
moved.
4. Shut the machine down and vent the
hydraulic system reservoir, by carefully
opening the reservoir fill cap.
5. Tag and disconnect the Dydraulic
lines, from the boom hoist cylinder hold-
ing valve. Securely cap all hydraulic
lines and cylinder ports to prevent oil
loss and contamination of the hydraulic
system.
S. Remove the retaining bolt, nut and
washer from the boom hoist rod end pin
and the retaining bolt from the cylinder
end pin.
7. Remove any tension at the rod end of
the boom hoist cylinder. While support-
Subsection SC SC-l
ing the cylinder with suitable lifting
equipment and blocking, remove the rod
end pin from the boom hoist cylinder and
remove the cylinder end pin from the
upper frame and the boom hoist cylinder.
8. Remove the boom hoist cylinder from
the machine and lower the cylinder onto
suitable blocking. This boom hoist cylin-
der weighs approximately 800 pounds
dry.
Overhaul
DISASSEMBLY. This procedure is writ-
ten on the basis that a complete disas-
sembly is required for overhaul of the
cylinder assembly. Partial disassembly
can be accomplished for replacing seals
etc., by referring to the applicable
steps.
To disassemble this boom hoist cylinder
proceed as follows, (see Figure 6C-1 on
page 6C-4):
1. Remove the holding valve from the
cylinder.
2. Pull the rod out to mid-stroke and
support it in a horizontal position.
3. Using a' spanner, chain or strap
wrench, u nth read the head gland.
CAUTION
Once the head gland is disengaged
from the body th reads, the rod
must be supported near the body
prior to the piston being pulled
past the body threads. If this pre-
caution is not observed, the body
threads and/or piston may be dam-
aged.
4. While pulling the rod from the body,
gently "bump" the head gland with the
piston and remove the rod, head gland,
and piston.
5. Remove the piston and head gland as
follows:
A. Loosen the setscrew in the piston.
Using a spanner, strap or chain
wrench, unscrew and remove the pis-
ton.
6C-2
B. Using a soft mallet, tap the head
gland off of the rod.
INSPECTION. After the cylinder has
been disassembled, clean all parts in a
suitable cleaning solvent and allow the
parts to dry. Pay particular attention to
the oil passages in the components to be
sure they are free of obstructions.
After the parts are dry; carefully in-
spect the parts for scoring, pitting' and
excessive wear. Replace parts as in-
spection dictates. It is recommended that
all seals, O-rings, back up rings, wear
rings and thread locks be discarded and
replaced with new parts provided in the
cylinder seal kit, (see the machine Parts
Manual) .
NOTE
It is important to keep cylinder
components clean as possible prior
to assembly of the cylinders to
prevent di rt or other contaminants
from getting into the hydraulic
system. Coat all inner surfaces
with hydraulic oil to prevent rust
or corrosion.
REPAIR .. To replace the seals and cyl-
inder parts, proceed as follows (refer to
Figu re 6C-1 on page 6C-4) :
CAUTION
The rod and piston seals cannot be
removed without being damaged.
If a rod or piston seal is removed,
a new seal must be installed.
1. If necessary, remove the self-aligning
bushing and install a new one. The frac-
ture of the new bushing should be posi-
tioned at a 45° angle to the cylinder
center line.
2. Thoroughly clean all parts. Carefully
inspect each part for excessive wear or
damage; replace parts as required.
3. Liberally lubricate all seals with clean
hydraulic oil prior to installation.
4. The piston seal and O-ring must be
assembled to the piston before the piston
rings. Install the O-ring in the center
groove. Soak the piston seal in hot oil or
water, or hang it in front of a heater, to
make it more pliable. "Walk" the piston
seal over the piston and into the first
groove. Then walk the piston seal into
its own groove. Do not allow the piston
seal to become twisted in the groove.
5. Install a piston ring in each groove.
Use extreme care when removing a seal
from the respective groove to avoid
scratching or marring the groove's fin-
ished surface. Minor imperfections can
be removed by buffi ng. Deep scratches
will, however, necessitate replacement of
the part. A pointed object should be
used to pick the rod seal from its
groove. The piston seal and back-up
rings can be cut with a razor blace to aid
in their removal. Discard all O-rings.
The piston rings can be reused if not
damaged.
6. Insert one edge of the rod seal in the
innermost head gland groove. Work the
remainder of the seal into the groove
while taking care not to cut or nick ei-
ther seal lip. Make sure the seal lips
point toward the small diameter end of
the head gland.
Assemble the rod wiper to the head gland
so that the wiper lip points away from
the rod seal.
Install the O-ring and back-up ring in
the outside groove of the head gland.
The back-up ring must be nearest the
gland threads.
ASSEMBLY. To assemble the boom hoist
cylinder proceed as follows, (see
Figure 6C-1 on page 6C-4):
NOTE
The boom hoist cylinder parts
should be lubricated with clean
hydraulic oil as they are installed
to aid in the assembly. It is impor-
tant to protect the parts from dirt
or other contaminants to prevent
contamination of the hydraulic sys-
tem.
1. Throughly lubricate all parts includ-
ing the body bore and mouth with clean
hydraulic oil.
2. Carefully slide the head gland onto
the rod. Th read the piston onto the rod
and tighten it. Apply Loctite No.242 to
the piston setscrew and th read it into
the piston. Torque the setscrew to 35
ft-Ibs.
3. The mouth of the body is chamfered at
the rear of the threads to compress the
piston rings. It may be necessary to os-
cillate the rod to aid in compressing the
piston rings as they enter the bore. Use
extreme care to prevent damage to the
piston seal and/or body threads· when in-
stalling the rod in the body.
If the piston seal was overstretched at
replacement, it may be necessary to
"shrink" the seal into its groove before
the piston will enter the bore. This can
be done as follows:
A. Assemble a piston ring compresor
over the piston seal and leave the seal
compressed for several hou rs.
B. Freeze or chill the piston seal by us-
ing C02, dry ice or ether type diesel
starting fluid just prior to installing
the piston in the body bore.
4. With the rod securely supported in
the horizontal position, insert the th read
locks into the head gland. Th read the
head gland into the cylinder body and
tighten.
5. Push the rod all the way into the body
and install the holding valve on the body
manifold.
Installation
To install the boom hoist cylinder pro-
ceed as follows:
1. Position the machine on firm level
ground with the upper in the forward,
lockout position.
-
2. If the boom is partially installed, the
boom should be retracted and blocked or
held with an outside assist in a position
that will allow the greatest access to the
boom hoist cylinder mounting bracket.
3. Place blocking around the collector
assembly, to prevent damage to the col-
lector while the boom hoist cylinder is
installed.
Boom Hoist Cylinder 6C-3
 CAUTION 5. Using suitable lifting equipment, posi-
tion the boom hoist cylinder assembly
Do not use lubricants on the head head end into the mounting brackets.
end pin, or the boom hoist cylin- Align the bore in the head end with the
der journal bearings. Grease or bores in the lower frame and install the
other lubricants will ruin the bear- head end pin.
ings.
6. Fasten the pin in place with the re-
taining capscrew and washer. Tighten
4. Position the boom hoist cylinder on the ret2ining capscrew to 190-210 ft-Ibs.
the revolving frame.

HOLDIN~
VALVE ""

'--
I -- __
---- -
-----
\
I, ----
PISTON - - __ __
SEAL
---~--- _
PISTON
RING
/ /
·O·RING

O-RING'
---J'

!~~tfo
J HEAD
GLAND 'ROD
r ~-
~.~,
/
I
SEAL

r- / ,\i'~(
--- ------ --
I - - __ PISTON
/ :., . . .
-- RING 'BACK-UP \I\G.'. ' .
RING '-.:./ ' !
/e
-- --- -- - THREAD
LOCK '~OD
I !

---- -- -- -- --
WIPER

jY
-ROD
--
'SEAL KIT ITEMS ~-BUSHING
Figure 6C-1. Boom Hoist Cylinder Assembly (100P1137)

6C-4
7. I nstall O-rings in the hydraulic lines
and attach the hydraulic lines to the
ports of the boom hoist cylinder holding
valve. Tighten the fittings evenly to
prevent distortion.
8. Extend the rod of the cylinder if nec-
essary to position the rod end eye of the
boom hoist cylinder in the lugs on the
bottom of the boom base. Align the holes
and install the rod eye pin. I nstall the
rod eye pin retaining bolt, washer, and
nut and tighten to 190-210 ft-Ibs.
9. Remove all blocking from the machine.
Then operate the machine. Cycle the
boom hoist system and check for leaks
especially around the holding valve.
10. Add oil to the hydraulic reservoir as
required, to bring the oil level to the
full mark on the dipstick.
Boom Hoist Cylinder 6C-5
 SUBSECTION 60
BOOM TELESCOPE CYLINDERS
GENERAL
This subsection provides information on
the removal, disassembly, inspection,
repai r, assembly and installation of the
boom telescope cylinders used on this
machine.
BOOM TELESCOPE CYLINDERS (38R172
AND 38R173)
Description
The boom telescope cylinder assembly
consists of a double acting piston and a
cylinder body with associated seals, rod
bearing, spacers, etc. Both the piston
rod and cylinder have trunnions that
fasten to the boom sections. When hy-
draulic oil is ported to the telescope cyl-
inder, the cylinder body is actuated and
the boom sections are extended or re-
tracted. The telescope cyl i nders each
weigh approximately 1150 pounds. The
following service procedures apply to
both of the telescope cylinders.
Maintenance and Repair
Maintenance requirements for these cyl-
inders are minimal, however, it is re-
commended that periodic inspections of
the cylinder be made to check the cylin-
der assembly for abnormal wear, loose or
damaged components, and hydraulic
leaks. Repair of the boom telescope cyl-
inder is limited to the replacement of
worn or damaged seals, wear rings and
other parts listed in the machine parts
manual.
Removal
To remove the boom telescope cylinders,
proceed as follows, (see Figure 6D-1O on
page 6D-9):
WARNING
Support the boom using a suitable
lifting device before removing any
components. If this precaution is
not followed, the boom will fall,
possibly causing serious injury to
personnel or damage to the ma-
chine.
1. Remove the boom as described in Sub-
section 6B under the topic, Boom Re-
moval.
2. Position the boom assembly on block-
ing.
CAUTION
The hydraulic line, shown in
Figure 60-1 on page 60-2, be-
tween connections (01 and 02) is
under approximately 55 Ibs of
spring tension. This tension must
be relieved before disconnecting
the loop hose assembly or problems
may result.
3. Fasten a rope, at least 30 feet in
length, to the hydraulic hose fitting at
connection (01) and put a a slight strain
on the line. Then remove the fitting
capscrews. I nstall covers on the lines
and then, carefully allow the spring ten-
sion to relax (refer to Figu re 6D-1 on
page 6D-2).
Subsection 6D 6D-1
4. Tag and disconnect the hydraulic
lines to the upper and lower telescope
cylinder holding valves. Install covers
and plugs on the lines and ports to pre-
vent the entry of contaminants.
5. Remove the capscrews, lockwashers,
keeper plates and trunnion block pins
from the lower rod end trunnion block
and base section.
6. Place a sling around boom sections one
and two of the boom and pull the com-
bined sections of boom from the base sec-
tion until approximately 9 feet of the
combined boom sections remain in the
base section.
NOTE
As the front sections of boom are
bei ng removed, the hose ca rrier,
tensioning cable, and hydraulic
hose, shown in Figu re 60-1, will
be pulled toward the front of the
base section. Make sure the hose
passes th rough the base section by
maintaining a slight tension to the
rope previously attached to the
hose.
7. Remove the nut, lockwasher and cap-
screw from the hose tensioning cable
bracket, at the front of the boom base
section. Disconnect the other end of the
tensioning cable from the anchor pin on
the bottom of section one of the boom.
8. Remove the slider pads and fastening
hardware from the front, sides and in-
termediate sections of base section.
9. Carefully, finish pulling the boom sec-
tions out of the base section. Make sure
the rea r s kid on the bottom of the fi rst
section clears the hydraulic line and the
hose carrier and tensioning assembly.
10. If necessary, remove' the tensioning
assembly from the bottom of the base
section.
11. If necessary, disconnect the loop
hose and tube assembly from the base
section.
12. Remove the lower telescope cylinder
from the boom sections as follows:
A. Remove the capscrews, lockwashers
and retaining plates from the trunnion
lugs in the fi rst section.

SECTION N·N 1ST SECTIO~

t:::::;::=;====Y'" BOTTOM PLATE

REAR SKID CONNECTION

CAPSCREW & TENSION ANCHOR \ 02
BRACKET CABLE P/IN T~il~N 1 ST SE\ON _~
/
~ I U.
L....:._
If!'~-t~"'"
,; ,- - r~
I , ' '--

I' I ,
j
i
1

----
\

'
~~~--~~~~~~/~
i
ANCHOR PIN WEl.DED LOOP CONNECTION
ON BOTTOM SIDE HOSE 01
OF 1 ST SECTION

TENSION
TENSION
CAPSCREW SPRING
CABLE
\ I

BASE SECTION
~~~~:::: :.:
TENSION
CABLE
I
HOSE CARRIER SECTION L·L
SECTION M·M ASSEMBLY

Figure 60-1. Hose Loop Installation

60-2
B. Using suitable equipment, support
the lower telescope cylinder and care-
fully pull the cylinder from the boom
assembly.
13. Remove the upper telescope cylinder
from the boom sections as follows, (see
Figu re 6D-1O on page 6D-9):
A. Remove capscrews, lockwashers,
keeper plates and trunnion block pins
from the upper rod end trunnion
block and first section.
B. Make sure hydraulic lines to the up-
per telescope cylinder holding valve
have been disconnected and that cov-
ers and plugs are on the lines and
ports to prevent the entry of contam-
inants .
C. Ca refu lIy, pu II section two out of sec-
tion one until approximately nine feet
remain inside section one. Then re-
move the bottom and side slider pads.
D. After the slider pads have been re-
moved finish pulling section two out
of section one.
NOTE
Make sure the upper cylinder rod
end· trunnion block clears the
brackets in the first section.
E. Remove the capscrews, lockwashers
and retaining plates from the trunnion
lugs in section two of the boom.
F. Using suitable equipment, support the
upper telescope cylinder and carefully
pull the cylinder from the boom as-
sembly.
Overhaul
DISASSEMBLY. To disassemble a boom
telescope cylinder, proceed as follows
(refer to Figu re 6D-3 on page6D-5):
1. Support the cylinder at both ends.
Pull or power the cylinder rod out to ap-
proximately mid-stroke. Place a support
under the extended rod.
CAUTION
The head gland should unscrew
freely. Damage to the cylinder
and/or the head gland will occur if
the head gland is forcibly
removed.
2. Use a spanner wrench, chain wrench
or strap wrench to unscrew the head
gland. If after several tu rns on the head
gland a bind is noticed, place a C-clamp
over the th readed end of the ba rrel (see
Figure 6D-2). Gradually draw down on
the C-clamp until the head gland can be
unscrewed easily. If necessary, an addi-
tional C-clamp can be placed behind the
cylinder support.
3. When the head gland threads are fully
disengaged from the cylinder case
threads, pullout the cylinder rod to
gently bump the head gland, forcing it
out of the case mouth.
4. Support the rod near the cylinder
case mouth as the rod is being removed
from the cylinder to prevent damage to
the cylinder case threads and/or the pis-
ton and piston seals. If the piston binds
in the cylinder as it nears the end of the
cylinder, place a C-clamp just behind the
A1679
Figure 60-2. C-Clamp Installation
Boom Telescope Cylinders 6D-3
cylinder support and in line with the
clamp (see Figure 6D-2). Tighten the
C-clamp until the piston slides freely out
of the cylinder.
5. Place the rod assembly on supports
and loosen setscrews (04) in nut (03). It
is not necessary to completely remove the
setscrews.
6. Using a spanner, chain or strap
wrench, unscrew the piston nut from the
rod.
7. Fi rmly bump the head gland against
spacer (14) to drive the piston and spa-
cer tube off the th readed end of the rod.
8. Using a soft mallet, tap the head
gland off the rod.
CAUTION
Use extreme care in removing all
seals from their respective grooves
to avoid damaging the surface fin-
ish of the seal goove.
9. Remove O-ring (09) and back-up
rings (08) from the inside of the piston.
Remove seal rings (06 and 07) from the
outside of the piston. Carefully slide
iron piston rings (05) off the piston.
10. Remove O-ring (10) and back-up
ring (11) from the outside of the head
gland. Use a sharp pointed ice pick to
remove U-cup (12) and rod wiper (13)
from the head gland.
INSPECTION AND REPAIR. After the
cylinder has been disassembled, wash all
parts in approved solvents and inspect
the pa rts as follows:
1. I nspect the body, piston and rod for
excessive wear, distortion or other dam-
age. Replace parts as required.
2. I nspect the rod and cylinder ports to
make sure that they are clean and free of
nicks.
3. I nspect the outside diameter of the pi-
ston and the inside diameter of the head
gland. These surfaces must be free of
nicks, deep scratches or scoring. If the
head gland is worn or damaged, replace
it.
6D-4
4. Replace threaded parts if the threads
a re damaged.
5. Replace all seals, O-rings and
back-up rings.
6. Replace the piston rings if they are
damaged beyond further service.
ASSEMBLY. To assemble a boom tele-
scope cylinder, proceed as follows (refer
to Figure 6D-3 on page 6D-5).
1. Check the head gland for fit at this
time. The gland should easily thread into
the cylinder. If the gland binds, do not
force it in. Use a 12 inch C-clamp located
as shown in Figure 6D-2 on page 6D-3.
Gradually draw down on the clamp until
the head gland can be easily th readed
in. If necessary, an additional C-clamp
can be placed behind the cylinder sup-
port.
NOTE
The C-clamp must remain on the
cylinder until after the head gland
is s·ecured during final assembly.
2. Place piston (02) and the piston seal
rings on a clean work surface. Sandwich
0- ring (09) between leather back-up
rings (08) and install this seal assembly
into the groove inside the piston (see
Figu re 6D-4 on page 6D-6).
3. Install Sirvon O-ring (07) and then
Sirvon seal ring (06) in the groove on
the outside of the piston (see
Figure 6D-5 on page 6D-6). Do n·:>t allow
the Si rvon ring to twist in the seal
groove.
NOTE
The Si rvon seal can be made more
pliable by soaking it in hot water
or oil.
4. Carefully slide piston rings (05) over
the piston ends until they are seated in
the ring grooves (see Figu re 6D-5 on
page 6D-6).
CAUTION
Use extreme care to avoid nicking
or scratching the two seal lips of
U-cup (12) during installation.
 "
.... .... I
I
I
I
I
I
I
I
./
I
.... ./
./
....
/'
./
./
....-
....-
./
/'
....
.... ./
....-
./
....-
....-
./
....-
.... /
....-
.... ....
....-
.... /'
./
/
....-
....
....
....-
....-
./
./
./
.... ....-
(
I 16
I
I
I 11
I

01. HEAD GLAND "10. O-RING

02. PISTON "11. BACK-UP RING
03. PISTON NUT "12. ROD U-CUP
04. SETSCREW "13. ROD WIPER
"OS. PISTON RING 14. ROD SPACER
"06. SIRVON RING 15. BODY
"07. SIRVON O-RING 16. ROD
"08. LEATHER BACK-UP RING
"SEAL KIT ITEMS
"09. O-RING

Figure 60-3. Boom Telescope Cylinders (38R172 and 38R173)

Boom Telescope Cylinders 6D-5

 the pocket (see Figure 60-6). Make cer-
tain that the two seal lips are facing to-
ward the inside of the cylinder (toward
BACK-UP the piston).
RINGS

O-RING

INNER
GROOVE
PISTON
RING
GROOVES

SIRVON
O-RING AND
SEAL GROOVE
A1680

Figure 60-4. Inner Seal Ring

Installation

5. Insert an edge of U-cup (12) into the Figure 60-6. U-Cup and Wiper
seal pocket in the head gland and care- Installation
fully work the remainder of the seal into
6. Install rod wiper (13) with the lip fac-
ing away from the inside of the cylinder
(away from the piston).
7. Install back-up ring (11) followed by
O-ring (10) on the outside of the gland
nut (see Figu re 60-3 on page 60-5) .
8. Inspect the rod to be sure it is clean
and then install an assembly sleeve to
prevent seal damage (see Figu re 60-7 on
page 60-7). The sleeve can be fabri-
cated from a piece of steel tubing as
shown in Figure 60-8 on page 60-7.
9. With the head gland and piston end of
the rod thoroughly oiled, carefully slide
the newly resealed head gland onto the
rod followed by spacer (14), piston (02)
and piston nut (03). Securely tighten
the piston with a spanner, strap or chain
wrench (see Figure 60-9 on page 60-7).
PISTON
RING
After the piston nut is tightened, secure
it with two setscrews (04). Use a punch
A1681 to stake the setscrews after they are
tight.
Figure 60-5. Piston Ring
Installation

60-6
 Figure 60-7. Assembly Sleeve
Installation
CAUTION

Use extreme caution when slipping

the piston and piston rings past
the cylinder mouth threads to
avoid damage to the piston seals
and the cylinder threads.
10. With a clean cloth and solvent, wipe
the' rod to remove any contaminants,
then thoroughly lubricate the piston and
cylinder mouth threads. Slide the piston
into the cylinder bore. It may be neces-
sary to slowly oscillate the outer end of
the cylinder rod to cause the piston
rings to compress as they pass the cham-
fered area of the cylinder barrel.
NOTE: DO NOT BREAK CORNER
3/4" --i
POLISH SMOOTH~· ',I
I
A1684
Figure 60-9. Piston Installation
NOTE
If the Sirvon piston seal has been
overly stretched du ring installa-
tion onto the piston, it may be ne-
cessary to shrink this ring into its
groove in order to get the piston
to enter into the cylinder. Shrink-
ing can be accomplished by cooling
with a CO-2 type fi re
extinguisher, dry ice or ether
starting fluid. Compressing the
seal with a piston ring compressor
for several hou rs prior to assembly
is also effective.

I: f
1/8 x 15 0
I 11. Continue sliding the piston and rod
4,750" 4,565"
assembly into the cylinder until the rod
4,749" 4.567"
is approximately at the mid-stroke posi-
DIA. DIA.
/: tion. Make su re the rod is supported to
keep the rod and cylinder on the same

.
: I
II
plane.
12. Thoroughly lubricate the threads of
the head gland and cylinder, then slide
;--------J--- -- ------------1--- the head gland into the cylinder using
I caution not to damage the head gland
f.o.!. 0 - - - - - - - 6,0" --------<.--1
O-ring as it is slipped past the cylinder
threads.
Figure 60-8. Assembly Sleeve 13. Screw the head gland into the cylin-
Oimensions der with a spanner or chain wrench until

Boom Telescope Cylinders 6D-7

it is secu rely tightened. Remove the
C-clamp from the cylinder tube.
14. Move the rod to the fully retracted
position and install the telescope cylinder
in the boom.
NOTE
If the cylinder is tested prior to
installation on the machine, ex-
treme care must be taken to ensure
that the outer end of the rod is
fully supported, when the rod is
extended.
Installation
Install the boom telescope cylinders us-
ing the following procedure (see
Figure SO-10 on page SO-9):
NOTE
If the slider pads need replacement
and/or adjustment, replace and ad-
just them at this time prior to as-
sembling the boom. The boom
must be disassembled to replace
and adjust some of the pads.
1. I nstall the support brackets on the
ends of the cylinders. Tighten the cap-
screws to 150 ft-Ibs.
2. Apply a coating of lubricant to the in-
ner surfaces of the boom which are in
contact with the slider pads.
3. Check the applicable section of the
boom to ensure the trunnion lugs and
boom section are clea r of obstructions.
4. Carefully, slide the upper cylinder
assembly into section two until the cylin-
der body trunnions can be pinned to the
trunnion lugs in section two of the boom.
5. I nstall the trunnion retainer plates
with capscrews and washers. Tighten the
capscrews to 54-59 ft-Ibs of torque.
S. Install the upper and side slider pads
into section two of the boom.
7. Carefully, slide boom section two into
the front of boom section one, until the
rod end trunnion of the upper cylinder
is aligned with the brackets in section
one. Make sure the slider pads on the
SO-8
rear clear the top and side plates of the
first section. Clearance should be O.OS
inches. If not, shim the pads as required
to obtain the proper clearance (see
Figu re SO-lO on page SO-9).
8. I nstall the front lower slider pads and
collar pads in section 1.
9. Carefully, slide the lower cylinder as-
sembly into the assembled sections of the
boom, until the cylinder body trunnions
are seated in the trunnion lugs in section
one of the boom.
10. Install the trunnion pins to secure
the upper cylinder rod and the lower ex-
tend cylinder body to boom section 1.
Secure the pins with retainer plates,
capscrews and washers. Tighten the re-
tainer capscrews secu rely to 54-59
ft-Ibs.
11. Install the upper and side slider
pads on section 1.
12. Lift the built up boom .sections, con-
sisting of sections one and two of the
boom and the upper and lower cylinders,
and place them into position at the front
end of the base section.
13. Align the lower cylinder rod end
trunnion block with the brackets in the
boom base section boom.
14. Assemble and partially install the
hose loop and tensioning assembly as fol-
lows:
A. Attach one end of the cylinder inter-
connecting hose loop to the right rear
fitting (connection 02) of the first
section, (see Figure SO-1 on page
SO-2) .
B. Assemble the cylinder interconnecting
hose into the hose carrier, (see
Figure SO-1 on page SO-2).
C. Attach a length of rope to the -free
end of the interconnecting hose and
pass the rope through the base sec-
tion. Pull the free end of hose into
the front opening of the boom base
section.
O. Pass the tension cable th rough the
small sheave on the hose carrier as-
sembly. Then, attach one end of the
tension cable to the spring assembly
as shown in Figu re SO-1 on page
SO-2. )
 BOOM
BASE TELESCOPE
HOLDING VALVES
UPPER TELESCOPE
CYLINDER

=
=
r::-~
BASE L--.;;,J
SECTION

C=========~~t.r~
SECTION #1
0.06 MAX.
SECTION #2

0.625

t;~-/----r--o::~
BASE SECTION
0.625

' - SECTION #1

~ .~ RE:AJ
Ll"l ~
cD N
o N LOWER TELESCOPE
HOSE CYLINDER
LOOP
FRONT

NOMINAL CLEARANCE BETWEEN BOOM

SECTIONS OF RETRACTED BOOM
Figure 60-10. Boom Assembly (100J5335)

Boom Telescope Cylinders 6D-9

15. Install the combined boom section as-
sembly into the base section as follows:
A. Lift the combined boom section assem-
bly and position the rea r s kid of the
first section in the hose loop. While
pulling the rope and free end of the
hose assembly into the boom, from the
rear of the base section; carefully,
guide the hose carrier assembly into
the boom and slide the boom sections
into the base section approximately 9
feet.
B. Attach the free end of the hose loop
to the fitting at the rear of the boom
base section, con nection (01) as
shown in Figure 60-1 on page 60-2.
C. Attach the free end of the tension
spring assembly to the front of the
boom base section with bracket and
hardware. Tighten the capscrews.
o. Install the lower front and side slider
pads in the boom base section with
capscrews and washers. Tighten the
capscrews.
E. Pull the free end of tension cable un-
til it is tensioned to 55 Ibs :t3 Ibs
spring tension, then fasten the cable
to the anchor pin on the bottom plate
of the first section (see Figure 60-1
on page 60-2).
NOTE
When fastening the end of the ten-
sioning cable, strip approximately
9 inches of coveri ng from the end.
Seize the dead end as shown in
Figu re 60- 1 on page 60-2.
F. Slide the boom sections the rest of the
way into the boom base, until the low-
er cylinder trunnion block is engaged
60-10
in the base section brackets. Make
sure that the base section slider pads
on both sides of the boom have proper
clearance, and that the hose loop ten-
sioning assembly is operating
properly.
NOTE
The slider pads, away from the
boom end, on the sides of the base
section should have 0.06 inch max-
imum clearance. Add shims as nec-
essary to obtain proper clearance.
G. I nstall the lower cylinder trunnion
pi ns, with retai ner plates, capscrews
and washers. Tighten the retainer
capscrews secu rely.
H. I nstall the boom telescope cylinder
holding valve. Tighten the holding
valve capscrews to 54-59 ft-Ibs of
torque.
I. Install the interconnecting hose as-
semblies and flow divider (see
Figu re 60-10 on page 60-9).
16. Install the boom as described earlier
in this subsection under the topic, Boom
Installation.
17. Check that the boom has clearance to
operate, start the machine and operate
the boom telescope and boom hoist sys-
tems. Check the hydraulic connections
for leakage especially around the holding
valve and the rod bearing seals.
18. Add oil to the hydraulic reservoir as
required, to bring the oil level to the
full mark on the dipstick.
19. Adjust and align the boom as de-
scribed in Subsection 6F under the
topic, Boom Adjustments and Alignment.
 SUBSECTION 6E

BOOM HOIST AND TELESCOPE CONTROL VALVES

GENERAL BOOM HOIST AND TELESCOPE CON-

This subsection provides instructions for
the removal, disassembly, repai r, assem-
bly and installation of the boom system
control valves used to operate the boom
hoist and boom telescope functions of
this machine. This subsection also in-
cludes control valve troubleshooting and
special adjustments required on the indi-
vidual valves.
TROL VALVE (36U290)
Description
The boom hoist and telescope control
valve shown in Figure 6E-1 is a four sec-
tion stack valve which consists of an in-
let, an outlet and two control sections.
This valve is used to control the boom
hoist and telescope hydraulic circuits.

)
~
~, ------,
BOOM HOIST
& TELESCOPE
_~_ - :::::::=:.......::::: .____ _ ;ONTROL VALVE

-~~ krF
----I
UPPER
--,\ '\.
I II.
IIII
IIII
I III
I III
FRAME I,ll
I II,
, II,

]Fr
HyDRAULIC ............... It
SWIVEL ~
il. !" ~ I

Figure 6E-1. Boom Hoist And Telescope Control Valve

Subsection 6E 6E-1
Troubleshooting
If problems occur with the boom hoist or
telescope circuits, the boom hoist and
telescope control valve operation can be
evaluated by using Table 6E-l. This ta-
ble lists some of the difficulties which
may be experienced with control valves,
and the hydraulic system. The table in-
dicates the probable cause and the
recommended remedy for the trouble list-
ed.
When troubleshooting the control valves
or the hydraulic system, it should always
be remembered that adequate pressu re
gauges and a thorough understanding of
the operation of the complete hydraulic
system are essential for diagnosing im-
proper valve operation. Remember also
that pressure and delivery are factors
which are dependent upon each other.
Table 6E-2 on page 6E-3 lists some of the
difficulties which may be experienced
with the relief valve cartridges. The ta-
ble is intended to aid in determining
when a relief valve cartridge should be
removed and replaced with a new one.

PROBLEM CAUSE REMEDY

Sticking Spool. Excessively high oil tem- Eliminate restriction in
perature. pipe.
I
Dirt in oil. ! Change oil; clean system. I
I
Pipe fittings too tight. Check torque.
Valve warped from mount- t Loosen valve and check
I ing. I operation.
I
I Excessively high pressure Check system pressure at
I
in valve. pump with gauge.
i
I
I Linkage binding. Free up linkage.
,

Spool Bent. I Replace valve.

Return spring damaged. Replace faulty parts.
Spring cap binding. Loosen cap, recenter and
retighten.
Valve not at thermal Let system warm up.
equilibrium.
Unable to move spool in Dirt in valve. Clean and flush out.
or out.
I
I
Spool cap full of oil. Replace seals.
Bind in linkage. I Free up linkage. -
Load wi 11 not hold. I
Cylinder leaking or worn. Check cylinders.
Oil bypassing valve plun- Replace valve.
ger.
I
Relief valve not holding. I Remove and clean.

Table 6E-l. Control Valve Troubleshooting (Part 1 of 2)

6E-2
PROBLEM CAUSE REMEDY
Leaking seals. Paint on or under seal. Remove and clean.
Excessive back pressure. Open line to reservoir.
Dirt under seal. Remove and clean.
Scored spool. Replace valve.
Loose seal plates. Clean and tighten.
Cut or scored seal. Replace faulty parts.
Poor hydraulic system Defective pump. Check pressure or
performance or failure. replace.
Dirt in relief valve. Disassemble and clean.
Relief valve defective. Replace.
Worn cylinders. Repair or replace.
Load too heavy. Check line pressure.
Internal valve crack. Replace valve.
Spool not at full stroke. Check movement and link-
age.
Reservoir low on oil. Add oil.
System filters clogged. Clean or replace.
Line restricted. Check lines.

Table 6E-l. Control Valve Troubleshooting (Part 2 of 2)

.-
PROBLEM CAUSE REMEDY
Erratic Pressure. Pilot poppet seat Replace cartridge.
damaged. Piston poppet
sticking. ;

Pressure setting not Wear due to dirt. Lock- Adjust relief valve. Re- I
correct. nut and adjusting screw place cartridge if ~eces- I I

loose. sary.

Leaks. I Damaged seats. Worn Replace O-rings or entire

i O-rings. Parts sticking cartridge, as necessary.
due to dirt.
I
Table 6E-2. Relief Valve Troubleshooting

Boom Hoist and Telescope Control Valves 6E-3

Removal
To remove the boom hoist and telescope
control valve, proceed as follows (see
Figu re 6E-2 on page 6E-5) :
1. Retract all boom sections and lower
the boom to the horizontal position.
2. Stop the engine and render the start-
ing means inoperative.
3. Operate the boom hoist and telescope
control levers in both directions to re-
lieve system pressure. Disconnect the
control linkage from the plungers of the
control valve.
4. Thoroughly clean and dry tlie exterior
of the control valve and valve fittings.
5. Tag and remove the hydraulic line
split flanges from the control valve
ports. Place protective covers on the
hydraulic lines to prevent system contam-
ination.
6. Remove the hardware which secures
the valve to the upper frame and remove
the valve from the machine.
Valve Service and Repair
SEPARATING VALVE SECTIONS. The
individual sections of the control valve
are held together with studs. Refer to
Figure 6E-2 on page 6E-5, and separate
the valve sections as follows:
1. Stand the control valve on the inlet
section (01). Support the valve securely
in this position.
2. Loosen nuts (02) in small alternating
increments initially, then remove all of
the nuts and washers.
3. Carefully, slide outlet section (04),
telescope section (05) and boom section
(06) off of studs (35) one at a time.
4. If the reason for section sepa ration
was only to replace the O-rings between
the sections, then proceed to reassemble
the valve sections as described in the
topic, Reassembling Valve Sections.
Otherwise, service the valve sections as
described in the following steps.
INLET SECTION REPAIR. The inlet sec-
tion of this control valve is not a repair-
able item. If it is damaged it must be
6E-4
replaced with a new inlet section. The
main relief valve cartridge, item (09) in
Figure 6E-2 on page 6E-5, can be re-
moved and replaced with a new relief
valve cartridge if necessary.
BOOM HOIST CONTROL SECTION RE-
PAIR. To service and/or repair the
boom hoist control section, proceed as
follows (see Figure 6E-2 on page 6E-5):
1. Position the valve section on a clean
work surface and disassemble it as fol-
lows:
A. Remove screws and washers (10 and
11) and remove end cap (12) and seal
retainers (13) from housing (14).
B. Remove stripper bolt (15) from plun-
ger (16). Remove spring guides (17)
and spring (18).
C. Remove seal retainer (13) and careful-
ly, pull plunger assembly (16) from
the housing bore. Remove plunger
end (19) from the plunger.
D. Remove O-ring (20) and back-up ring
(21) from plunger end (19) and strip-
per bolt (15). Also, remove O-ring
and back-up ring (22 and 23) from
the grooves in the housing. Discard
all O-rings and back-up rings.
E. Thoroughly clean and dry all control
valve parts in an approved solvent.
Pay particular attention to the holes
in the housing and the plunger. In-
spect the valve parts for wear or
damage. Replace the discarded
0- rings and back-up rings and any
pa rts wh ich a re damaged. Refer to
the machine Parts Manual for parts
ordering information. Dip the valve
parts in clean hydraulic oil, to give
the parts a protective coating. Cover
the parts until time for assembly.
NOTE
The telescope control valve hous-
ing and the spool are machined as
sets and are not sold individually.
If either the housing or plunger
are damaged the entire control
valve housing must be replaced.
2. Assemble the boom hoist control valve
housing as follows, (see Figure 6E-2 on
page 6E-5):
 12

f1)----36
./

13

01. INLET SECTION

02. NUT ./
03. WASHER /'
./
04. OUTLET SECTION ./
./
OS. TELESCOPE SECTION /' ./
06. BOOM HOIST SECTION ./ ./
07. O-RING ./
.::.
OS. O-RING
---- ----
---- ---- 06
09. MAIN RELIEF VALVE CARTRIOGE ---- ----
10. SCREW
11. WASHER 31
12. END CAP
13.
14.
SEAL RETAINER
NOT USED
---- -----,
1S. STRIPPER BOLT ---- ---... ----,
./
16. PLUNGER (BOOM HOIST) ./
./
17. SPRING GUIDE ./
./
1S. SPRING
19. PLUNGER END
20. O-RING
21. BACK-UP RING
22. O-RING
23. BACK-UP RING
24. END CAP
2S. NOT USED
26. STRIPPER BOLT
27. PLUNGER (TELESCOPE)
2S. SPRING GUIDE
29. SPRING
30. SPRING GUIDE
31. STRIPPER BOLT
32. SPACER
33. RETAINER 05
34. SPACER
3S. STUDS
36. PLUG ASSEMBLY

A1353
Figure 6E-2. Boom Hoist and Telescope Control Valve (36U33803)

Boom Hoist and Telescope Control Valves 6E-S

A. Dip the valve parts in clean hydraulic
oil to lubricate the parts prior to as-
sembly.
B. I nstall a new 0- ring (22) and
back-up ring (23) in the groove at
each end of housing (14). A coating
of grease on the O-rings and back-up
rings will aid holding them in place.
C. Install a new O-ring (20) and
back-up ring (21) in the groove of
plunger end (19). Thread plunger
end (19) into the end of plunger (16)
and tighten secu rely.
D. Instnll plunger assembly (16) in the
bore of housing (14) with a slight
twisting motion, taking care not to
cut O-rings (20 and 22).
E. Install a new O-ring (20) and back-up
ring (21) in the groove of stripper
bolt (15).
F. I nstall seal retainer (13) with spring
guides (17), spring (18), onto hous-
i ng (14) and th read stripper bolt as-
sembly (15) into the end of installed
plunger (16). Ensure the stripper
bolt is secure in the plunger.
G. Install end cap (12) with screws (10)
and washers (11), over the installed
stripper bolt, spring and retainer as-
sembly. Tighten screws (10) secure-
Iy, using equal alternating steps.
H. Install seal retainers (13) with screws
(10) and washers (11) onto housing
(06) over the end of plunger
assembly. Tighten screws (10) se-
curely, using equal alternating steps.
3. Cover the assembled boom hoist con-
trol housing until the control valve sec-
tions are ready to be assembled.
TELESCOPE CONTROL SECTION RE-
PAIR. To repair the telescope control
section, proceed as follows (see
Figure 6E-2 on page 6E-5):
1. Position the valve housing on a clean
work surface and disassemble the hous-
ing as follows:
A. Remove screws and washers (10 and
11) and remove end cap (24) and seal
retainers (13) from housing (25). Re-
move spacer (32) from the end cap.
6E-6
B. Remove stripper bolt (26) from plun-
ger (27). Remove spring guides (28),
spring (29), retainers (33), and
spring guide (30) from the plunger.
C. Remove screws (10) and washers (11)
and seal retainers (13) from the plun-
ger end of housing (05).
D. Carefully, pull plunger assembly (27)
from the housing bore. Remove plun-
ger end (19) from the plunger.
E. Remove stripper bolt (31) from plung-
er (27). Remove O-rings (20) and
back-up rings (21) from plunger end
(19) and stripper bolt (31). Also,
remove O-rings and back-up rings
(22 and 23) from the grooves in hous-
ing (25). Discard all O-rings and
back-up rings.
F. Remove spacer (34) and seal retainer
(13) .
G. Thoroughly clean and dry all control
valve parts in a suitable solvent. Pay
particular attention to the holes in the
housing and the plunger. Inspect the
valve parts for wear or damage. Re-
place the discarded O-rings and
back - up ri ngs a nd any pa rts wh ich
are damaged. Refer to the machine
Parts Manual for parts ordering in-
formation. Dip the valve parts in
clean hydraulic oil, to give the parts
a protective coating. Cover the parts
until time for assembly.
NOTE
The control valve housing and the
spool are machined as sets and are
not sold individually. If either the
housing or plunger are damaged
the entire control valve housing
must be replaced.
2. Assemble the boom telescope control
valve housing as follows, (see
Figure 6E-2 on page 6E-5):
A. Dip the valve parts in clean hydraulic
oil ~bricate the parts prior to as-
semiJly.
B. Install a new O-ring (22) and
back-up ring (23) in the grooves at
each end of housing (25). A coating
of grease on the O-rings and back-up
rings will aid holding them in place.
C. Install a new O-ring (20) and
back-up ring (21) in the groove of
plunger end (19). Thread plunger
end (19) into the end of plunger (27)
and tighten secu rely.
D. Install plunger assembly (27) in the
bore of housing (25) with a slight
twisting motion, taking care not to
cut O-rings (22 and 20).
E. Install a new O-ring (20) and back-up
ring (21) in the groove of stripper
bolt (26).
F. Install seal retainer (13), and spacer
(34) and thread stripper bolt assem-
bly (26) into the end of installed
plunger (27). Ensure the stripper
bolt is secure in the plunger.
G. I nstall spring guide (30), retainers
(33), spring (29), and spring guide
(2B) to stripper bolt (31). Secu rely
th read stripper bolt (26) to stripper
bolt (31).
H. I nstall end cap (24) with screws (10)
and washers (11), over the installed
stripper bolt, spring and retainer as-
sembly. Tighten screws (10)
securely, using equal alternating
steps.
I. Install seal retainers (13) with screws
(10) and washers (11) onto housing
(05) over the end of the plunger as-
sembly. Tighten screws (10)
secu rely, using equal alternating
steps.
J. Cover the assembled telescope control
housing until the control valve sec-
tions are ready to be assembled.
OUTLET SECTION REPAI R. The outlet
housing is not repai rable. If the outlet
housing is damaged it must· be replaced
with a new section, see the mach i ne
Parts Manual.
REASSEMBLING CONTROL VALVE SEC-
TIONS. To reassemble the control valve
sections, proceed as follows (see
Figu re 6E-2 on page 6E-5):
1. On a clean work area, position the as-
sembled valve inlet housing (01) on its
outboard side with studs (35) in place.
2. Position new O-rings (07 and OB) in
their associated port grooves on the inlet
section.
Boom Hoist and Telescope Control Valves
3. Carefully, slide the assembled boom
hoist control housing (06) over the studs
and onto the inlet section. Make sure
O-rings (07 and 08) are not dislodged.
4. Install new O-rings (07 and 08) in the
associated port grooves on the boom
hoist control housing (06).
5. Carefully, slide the assembled tele-
scope housing (05) over the studs and
onto the boom hoist section. Make sure
O-rings (07 and 08) are not dislodged.
6. Carefully, slide the assembled outlet
housing (04) over the studs and onto the
telescope section. Make sure O-rings (07
and 08) are not dislodged.
7. I hstall washers (03) and nuts (02) on
the studs and tighten the stud nuts (02)
finger tight.
B. Lay the control valve assembly down
in its mounting position. Align the sec-
tions as perfectly as possible using a ra-
whide mallet then tighten the stud nuts
securely.
Control Valve Installation
To install a new or repai red boom hoist
and telescope control valve, proceed as
follows (see Figure 6E-2 on page 6E-5):
1. Position the control valve on the ma-
chine mounting so that the holes line up,
and the plungers point toward the con-
trol linkage.
2. Install the mounting hardware and
tighten the capscrews secu rely.
3. Make sure that the hydraulic line fit-
ting O-rings are installed, then connect
the fittings to the matching valve ports.
Tighten the fittings secu rely, making
sure the fittings are tight, but not so
tight as to cause distortion.
4. Check to ensure the plungers are in
the neutral position and connect the con-
trol linkage to them. Do not pull the
plungers from the neutral position to
meet the control lin kage. If necessa ry ,
adjust the control linkage to meet the
plungers.
5. Make sure the machine is ready to op-
erate, then start the engine and operate
the control valve slightly in both di-
6E-7
rections, while observing for leaks or
binding at the valve.
6. Add hydraulic oil to the system reser-
voir as necessary, to bring the oil to the
proper level.
BOOM TELESCOPE HOLDING VALVE
(36R37D1)
DESCRI PTION. The boom telescope hold-
ing valve, shown in Figure 6E-3, is in-
stalled on the end of each boom telescope
cylinder. These valves prevent the tele-
scope cylinders from retracting until
pressure is developed in the hydraulic
system. These valves also prevent the
boom from retracting when the control
lever is in the neutral position or if sys-
tem pressure is lost.
REPAIR. The boom telescope holding
valve is not a repai rable item. In the
event the valve does not operate proper-
Iy, it must be removed and replaced with
a new valve.
NOTE
The holding valve is factory set at
the proper settings. Do not tamper
with the adjusting screws in the
valve. Tampering with this valve
will void the warranty.
REMOVAL AND INSTALLATION. Re-
moval and installation of the boom tele-
scope holding valve is not covered in
detail in this topic due to the relative
ease of these tasks. However, it is im-
portant to note the following prior to re-
moving a holding valve:
1. The boom must be lowered to the hori-
zontal position before attempting to re-
move the holding valve.
2. The machine engine should be shut
down and the hydraulic system pressure
should be relieved and the hydraulic
reservoir vented before removing the
holding valve.
3. Tag the hydraulic lines for ease of
identification.
During the installation of a new holding
valve do the following:
6E-8
LOWER
• TELESCOPE
CYLINDER
VIEW AT RIGHT
A910, REAR OF BOOM
Figure 6E-3. Telescope Holding Valve
Installation
1. Make sure that the mating surfaces of
the valve are clean and free of nicks.
2. Install new O-rings in the various hy-
draulic line connections and ports on the
holding valve.
3. Use hardened flat washers and 7/16
inch grade 5 bolts to mount the valve.
Tighten bolts with lubricated th reads to
35 ft-Ibs torque, or tighten bolts with
dry threads to 50 ft-Ibs torque.
FLOW DIVIDER/CROSSOVER RELIEF
VALVE (36Ul83D3)
DESCRt PTION. The flow divider /
crossover relief valve is two valves, one
mounted on top of the other (see
Figure 6E-4 on page 6E-9). The crosso-
ver relief valve acts to protect the tele-
scope circuit from damage caused by
sudden stopping of the boom. The flow
divider, mounted below the crossover re-
lief valve, is a pressure compensated
fixed flow control which divides input
flow proportionately into both telescope
cylinders. When retracting the telescope
cylinders the flow divider combines the
two return flows into one main return
flow.
Repair
The flow divider/crossover relief valve is
repai rable to the extent of a seal kit for
each valve and the quad rings between
the valves. Cartridge relief valves for
 CARTRIDGE RELIEF VALVE

*SEAL KIT
ITEMS

PLUG
PLUG
BODY

Figure 6E-4. Flow Divider/Crossover Relief Valve

the crossover relief and piston subas- are clean and free of nicks. Be su re to
semblies for the flow divider are avail- reinstall the quad rings between the two
able. valves.
The cartridges for the crossover relief
valve are factory adjusted to the proper BOOM HOIST HOLDING VALVE (36R97)
setti ngs. Do not tamper withy these ca r-
tridges. Tampering with these cartridges
will void the warranty on the valve. Description
Make sure system pressure is relieved The boom hoist holding valve, shown in
before removing the valves. Figure 6E-5 on page 6E-lO, is mounted
on a block on the underside of the boom
When reassembling the valves, make sure hoist cylinder. The valve mounting
that the mating surfaces of the valves

Boom Hoist and Telescope Control Valves 6E-9

block is located in the middle of the cyl-
inder body.
The functions of the boom hoist holding
. 'r
:, '" .". t
valve are to prevent the lowering of the VIi:':T'
" , TUBE REAR OF Ii
boom until pressure is developed in the
,. . ASSEMB~V., BOOM HOIST.
machine hydraulic system, and to pre-
vent the boom from lowering in the event
of a loss of hydraulic system pressure.
"~ "".~.~ C,V,LlNDER.

The boom hoist holding valve also pre- J -s"

,;;;.) ('-./i ',.

vents the boom from lowering when the

control lever is returned to the neutral o v r-'
, '
position.
,..-",-,-,''-' .",

MAINTENANCE AND REPAIR. The boom

hoist holding valve is not a repairable
item. I n the event the valve does not
operate properly, it must be removed
and replaced with a new valve.
NOTE
The holding valve is factory set at
the proper settings. Do not tam-
per with the adjusting screws in
the valve. Tampering with this
valve will void the warranty.
REMOVAL AND INSTALLATION. Re-
moval and installation of the boom hoist
holding valve is not covered in detail in
this topic due to the relative ease of
these tas ks. However, it is important to
note the following prior to removing a
holding valve.
1. The boom must be lowered to the hori-
zontal position before attempting to re-
move the holding valve, or the boom will
lower without any control.
2. Stop the engine, render the starting
means inoperative, relieve hydraulic sys-
".-.
A909
Figure 6E-5. Boom Hoist Holding
Valve Installation
tern pressure and vent the hydraulic res-
ervoir before you remove the holding
valve.
During the installation of a new holding
valve do the following:
1. Make sure that the mating surfaces of
the valve are clean and free of nicks.
2. I nstall new 0- rings in the various hy-
draulic line connections and ports on the
holding valve.
3. Use hardened flat washers and .438
inch grade 5 bolts to mount the valve.
Tighten bolts with lubricated th reads to
35 ft-Ibs torque, or tighten bolts with
dry threads to 50 ft-Ibs torque.

6E-10
 SUBSECTION 6F
BOOM ADJUSTMENTS AND ALIGNMENTS
GENERAL
This subsection covers the adjustment of
the boom slider pads and the procedu re
for checking and aligning the boom.
SLIDER PAD ADJUSTMENT
The boom slider pads must be adjusted
any time they are replaced or whenever
the boom cannot be aligned as specified
in the topic, Boom Alignment.
The front, bottom and side slider pads
can be adjusted with the boom
assembled. The rear top and side slider
pads, however, can only be adjusted
with the boom disassembled. Adjust the
slider pads as follows:
1. Adjust the rear upper (top) slider
pads to a clearance of 0.03 to 0.06 inch
between sections (boom retracted).
Re-shim when this clearance exceeds
0.25 inch.
2. The lower front slider pads must be
adjusted to provide 2.50 inch clearance
between the boom base and section one
on the boom (0.625 inch on all other
booms), and a clearance of 0.625 inch
between section s two and th ree. Read-
just when wear reduces the clearance to
0.50 inch respectively.
3. With the boom retracted, there should
be 0.01 to 0.03 inch clearance between
the rear side slider pads and the adja-
cent boom sections.
4. All front side slider pads are to be
shimmed initially to center each boom
section of the retracted boom within the
adjacent inner section within 0.06 inch
and to give minimum clearance to the
widest parts of each section as the boom
sections are extended.
NOTE
The front side slider pads are
used to align the extended boom
(see the following topic, Boom
Alignment Procedure). This may
require side slider pad adjustment
that may result in boom sections
not being centered when retracted
after boom alignment.
5. Intermediate slider pads should be
shimmed to provide 0.01 to 0.03 inch
clearance with the boom retracted.
BOOM ALIGNMENT PROCEDURE
To align the boom, proceed as follows:
1. The boom must be reeved and the
hook block installed.
2. Extend and set the outriggers and
level the machine.
3. Establish and mark the boom base cen-
terline. The boom base centerline is a
line from the center of the top plate at
the rear of the base section to the center
of the top plate at the front of the base
section.
4. Establish and mark the center of the
boom point on the end of the last tele-
scope section.
CAUTION
All lifts for this procedure must be
made over the rear of the machine.
Subsection 6F 6F-1
5. Elevate the boom to 75° and fully ex-
tend all powered sections.
6. Attach a 10,000 pound load to the
hook block and lift the load just clear of
the ground.
7. The center of the boom point must be
in line with the centerline of the boom
base to within 3 inches.
8. Correct misalignment by adjusting the
front side slider pads of the base section
and the fi rst section, using the set-
screws.
NOTE
Additional correction of misalign-
ment may require shimming of the
rear side slider pads.
9. Recheck the boom alignment per steps
6 and 7. Record the amount and di rec-
tion (to left or right) of lateral deflection
of the boom point center from the boom
base centerline.
NOTE
Determine the total weight being
lifted (load plus hook block).
Th ree percent of the total weight
6F-2
equals the side load to be applied
in the followi ng steps (see
Figure 6F-1 on page 6F-3).
10. Apply a three percent side load to
the freely suspended load, in a direction
opposite to that of normal deflection (if
deflection is to the left, side loading is
to the right). Record the amount of de-
flection of the boom point center from the
position without side load.
11. Apply a three percent side load, in
the direction opposite to that of step 10.
The additional deflection shall be equal
to the deflection found in step 10 to with-
in 6 inches.
12. If the side loaded boom point de-
flections are not within the tolerance
specified instep 11, the boom poi nt cen-
ter is too far from the boom base center-
line. Return to step 8, and shim the
slider pads to bring the boom point cen-
ter to the closest possible alignment with
the boom base centerline.
 SECTION 2

,. FULLY EXTENDED BOOM.

ELEVATED TO 75 DEGREES
ABOVE HORIZONTAL

SECTION'

BASE
2. ATTACH '0.000 POUND
SECTION
LOAD TO THE HOOK BLOCK.

3. ATTACH A SUITABLE SPRING

SCALE TO LOAD.

4. PULL ON THE SPRING SCALE UNTIL

IT READS 3 PERCENT OF THE TOTAL
~
WEIGHT AT THE HOOK BLOCK

NOTE: 3% SIDE LOAD IS WEIGHT OF HOOK BLOCK "'0.000 POUNDS = TOTAL WEIGHT" .03 = SIDE LOAD

Figure 6F-l. Side Loading the Boom

Boom Adjustments and Alignments GF-3

 TABLE OF CONTENTS

Subsection 7A 7A-1

I ntrod uction 7A-1

General 7A-1
Description 7A-1

Subsection 7B 7B-1

Wi nch Motor ... 7B-1

Winch Motor (41 R22) 7B-1
General 7B-1
Troubleshooting 7B- 1
Removal 7B-2
Overhaul 7B-3
Installation 7B-7

Subsection 7C 7C-1

Hoist Winch 7C-1

Winch 7C-1
General 7C-1
Description 7C-1
Removal 7C-1
Overhaul 7C-1
Input Carrier 7C-7
Output Ca rrier 7C-8
Winch Brake . 7C-10
Winch Installation 7C-13

Subsection 70 70-1
Winch Control Valve 70-1
General ........ . 7D-1
Winch Control Valve (36R83) 7D-1
Description 7D-1
Troubleshooting 7D-1
Removal 7D-3
Disassembly ... . .. 7D-4
Cleaning, Inspection and Repair 7D-4
Assembly ........ . 7D-4
Installation 7D-5
Counterbalance Valve (36Q286) 7D-6
Description 7D-6
Removal 7D-6
Repair 7D:.6
Installation 7D-6

Contents
 LIST OF ILLUSTRATIONS

Figure 7A-1. Winch System 7A-1

Figure 7B-1. Special Motor Assembly Tools 7B-4
Figure 7B-2. Winch Motor (41 R22) 7B-5
Figu re 7C-1. Drum Installation 7C-5
Figure 7C-2. Brake Installation 7C-6
Figure 7C-3. Input Carrier . 7C-7
Figure 7C-4. Input Carrier Pin Installation 7C-S
Figure 7C-5. Output Carrier ..... . 7C-S
Figure 7C-6. Winch .......... . 7C-9
Figu re 7C-7. Output Carrier Pin Installation 7C-1O
Figure 7C-S. Winch Brake (915J139) 7C-10
Figu re 7C-9. One-Way Clutch Installation 7C-11
Figure 7C-10. Inner Race Installation 7C-12
Figure 7C-ll. Spring Installation 7C-12
Figure 7C-12. Brake Final Assembly .. 7C-12
Figure 7C-13. Winch Brake Assembly (915J139) 7C-13
Figu re 7D-1. Winch Control Valve Installation . 7D-1
Figure 7D-2. Winch Control Valve (36RS3) . 7D-5

List of Illustrations iii

 LIST OF TABLES

Table 78-1. Winch Motor Troubleshooting 78- 1

Table 7D-1. Control Valve Troubleshooting 7D- 1
Table 7D-2. Relief Valve Troubleshooting 7D-3

List of Tables v
 SUBSECTION 7A

INTRODUCTION

GENERAL ward of the counterweight, as shown in

This section is divided into subsections
that cover the load hoist (winch) system
components used on this machine. Each
subsection describes individual assem-
blies or components and includes proce-
dures for the removal, disassembly,
assembly, and installation of the winch
system components. Recommended in-
spection and repair procedures are also
included in the individual subsections.
This subsection describes the load hoist
(winch) system used on this machine.
DESCRIPTION
This machine has a load hoist winch
mounted on the upper frame, just for-
Fig u re 7 A - 1 .
The winch is driven by a hydraulic motor
that is mounted 011 the winch housing.
The winch is controlled by a control
valve mounted on the right side of the
upper frame. The winch motor has a
counterbalance (holding) valve attached.
The counterbalance valve provides a me-
ans of locking the motor and holding a
load until the motor drive hydraulic
pressu re is adequate to control the load.
The hoist winch contains p·lanetary re-
duction gearing and a brake as integral
parts of the winch drum.

WINCH
BOOST
VALVE

WINCH
MOTOR WINCH CONTROL VALVE

WINCH

Figure 7A-l. Winch System

Subsection 7 A 7A- 1
 SUBSECTION 7B

WINCH MOTOR

WINCH MOTOR (41 R22) Troubleshooting

General
This topic provides the information nec-
essary to troubleshoot and overhaul the
winch motor. Repai r of the motor con-
sists of disassembly, cleaning and in-
spection, replacement of worn or broken
parts, and assembly. All motor service
procedures must be performed in a clean
envi ronment.
Table 7B-1 lists some of the difficulties
which may be experienced with the winch
motor. The table lists the pi'obable
cause and possible remedies for each of
the troubles listed. This chart should
be helpful in making a general diagnosis
of wi nch motor problems.

TROUBLE PROBABLE CAUSE REMEDY I

I
I

External leakage. Seal failure. Replace the seal. i.

I I Defective casting.
Leakage at fitting. Cracked casting.
Defective threads.
Damaged a-rings.
Burr.
Loss in speed under Low inlet pressure.
load.
Scored port plate or end
cap.
Hi gh oil temperature.
Poor speed control. Insufficient fluid sup-
ply.
Replace the casting.
Replace the casting.
Repair or replace the fitting.
Replace the a-ring.
Stone or fil e fl at.
Check the relief valve.
Relap flat to clean up.
-
Use the correct oil for the am-
bient temperature, use an oil
cooler, adjust relief valve
setting.
Troubleshoot components down-
stream of the motor.

I Worn rotating group. I Replace.

Table 7B-1. Winch Motor Troubleshooting (Part 1 of 2)

Subsection 7B 7B-1
 TROUBLE PROBABLE CAUSE REMEDY
Shaft play Worn bearings Replace the bearings.
I
Hammering coupling on I Coupling bore should be slip
I shaft. fit on shaft.
i
, I
I Bursting of fluid Excessive pressure. Check system relief valves. I
I supply inlet or
outlet lines.
Motor fails to Insufficient torque. Check relief valve pressure
start turning. setting.
Excessive motor leakage. Check flow from motor outlet.
If excessive, check shuttle
valve in front port plate.
Pressure is not loading plate,
causing plate to move away from
cam ring.
Worn port plates. Replace the port plates.
Worn rotating group. Replace the rotating group.
Defective O-ring on 0.0. Replace the O-ring if damaged.
of front port plate.
I Insufficient pump deliv- Troubleshoot pump.
I ery.
Excessive noise. Worn or damaged internal Disassemble the motor. Inspect
I parts. for excessive wear. Check con-
dition of faces of port plate
and end cap. Rework (lap) or
replace if scuffed.
Air in system. Bleed air off, check fittings
for tightness.
Seal failure. Abrasive contaminants or Check for the cause of contam-
sludge in the fluid. i nants. Fl ush system and over-
haul the motor.
Wrong viscosity of Replace the fluid with the
fluid. proper grade and type (see Sec-
tion 3).
Sustained high pressure Check for possible relief valv-e
above maximum motor rat- malfunction or other parts fai-
ing. lure. Adjust if necessary.

Table 7B-1. Winch Motor Troubleshooting (Part 2 of 2)

Removal 2. Clean the fittings on the hydraulic
lines and the areas around the motor
Use the following procedu re to remove ports.
the winch motor:
3. Tag and disconnect the hydraulic
1. Remove any load from the winch and lines at the motor. Cap the lines and the
secure the wire rope.

78-2
motor ports to prevent the entry of for-
eign material.
4. Match-mark the motor and the winch
housing so that the motor can be rein-
stalled in the same position.
5. Remove the hardware used to secure
the motor to the winch housing and lift
the motor from the machine. The motor
weighs approximately 180 pounds.
Overhaul
Prior to disassembly of the motor, drain
all fluid from the motor and thoroughly
clean the motor exterior su rfaces. Pre-
pare a clean, lint-free surface on which
to lay the internal parts of the motor.
DISASSEMBLY. Disassemble the winch
motor using the following procedure (see
Figu re 7B-2 on page 7B-5):
CAUTION
To avoid damage to the machined
surfaces of the motor, do not grip
these surfaces with the jaws of a
vise.
1. Remove the holding valve and associ-
ated lines from the winch motor. Plug
the valve and motor ports to prevent
contaminants from entering the valve or
motor. Move the valve to a clean area.
2. Mount shaft end cover (04) of the mo-
tor in a vise, with the shaft end pointing
down. Match mark all adjacent motor
sections to ensure proper alignment dur-
ing assembly.
3. Remove two-speed valve assembly (23)
from the motor. Remove hex nuts (20),
lockwashers (18) and studs (19) from the
motor.
4. Remove capscrews (27), lockwashers
(28), porting block (26), pipe (31),
O-rings (25 and 29), back-up rings (30)
from bearing carrier (13).
5. Lift off port end cover (17). If it is
necessary to pry the cover loose, exer-
cise extreme caution to avoid scratching
or damaging the machined surfaces. If
thrust plate (09) remains in gear housing
(16), the th rust plate can be tapped free
with a wooden hammer handle after the
gear housing has been removed.
6. Pry from opposite sides to slide gear
housing (16) past dowel pins (22) and
away from gears (15). Remove gear set
(15). Remove drive gear connecting
shaft (14).
7. Pry bearing carrier (13) from opposite
sides to slide the carrier over dowel pins
(21) . Exercise caution to avoid damage
to machined surfaces.
8. Pry gear housing section (12) loose.
Remove integral drive shaft and gear set
(10). Pry. thrust plates (09) from the
shaft end cover. Do not distort the
thrust plates.
9. If bearing replacement is necessar'Y,
remove bearings (07) with a suitable pul-
ler. After the bearings have been re-
moved, ring seals (06) can be removed
from the bottom of the bearing bores.
10. To remove double lip seal (24), place
shaft end cover (04) in a vise with the
mounting face up. Remove snap ring
(01), ball bearing (02) and retainer
(03) . Rotate the end cover in the vise
so that the mounting face is down. In-
sert the special seal removal tool (see
Figure 7B-1 on page 7B-4) into the
notch between the seal and the shaft end
cover. Use a hammer to tap the seal
out.
CLEANING AND INSPECTION
CAUTION
Dry all parts using low pressure
compressed air. Do not use paper
towels or shop towels to dry parts.
Use of these will introduce lint into
the hydraulic system possibly
causing damage to system compo-
nents.
Thoroughly clean each of the motor parts
in a suitable cleaning agent. Use low
pressure (15 psi maximum) to dry the
parts. Do not use paper towels or shop
cloths. Cover the parts to prevent dirt
or other contaminates from settling on
them.
After the motor has been completely dis-
assembled, inspect the motor parts to de-
Winch Motor 7B-3
termine if wear is within the following 2. If the gears show wear of the type or
specifications: amount listed below, the entire motor
must be replaced:
1., Place a straightedge across the bore
of the gear housing at the cut-out area. A. Gear hub wear detectable by touch or
If a 0.005 inch feeler gauge will fit be- in excess of 0.002 inch.
neath the straightedge, the gear housing
is worn beyond the allowable limits, and B. Scoring, grooving, or burring of the
the motor must be replaced. if wear at outside diameter of the teeth.
the gear housing is less than 0.005 inch,
the gear housing may be turned end for
end .an_d reused.
Check valve tool is made
3·1/2" 3/8"
from a 4" (10.16 cm) length of
(8.89 cm) (0.95 cm)
3/8" (0.95 cm) drill rod. The
drawing gives details for making ~1
this tool.
•
/
3/16" DRILL ROO
(0.48 cm)
3/8" DRILL ROO Eu
(0.95 cm) - - -
...
~

...c:i

3/16"
(0.48 cm)

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
·000 )
notch behind the shaft seal. +.0127) ( .787 _:0127cm
( 0.320 -.000 cm

DRILL 114"
DIAMETER HOLE

5·3/8"
4·1/4"
.015" x 60 0 STEEL SLEEVE
CHAMFER This special steel sleeve is used
to insert the driveshaft through
1.250· .002 ~ the lip seal without damage.
It can be made from bar stock.
-
1.290·
-
.000
.000--
.002
"
- Use a bar that is 1·3·8" in
diameterby5·' 2"long.
Figure 78-1. Special Motor Assembly Tools F165C

7B-4
 17

06 \

/
1
/
/

01. SNAP RING 12. GEAR HOUSING

02. BALL BEARING 13. BEARING CARRIER
03. SEAL RETAINER 14. CONNECTING SHAFT 23. TWO SPEED VALVE
04. SHAFT END COVER 1 S. MATCHED GEAR SET 24. LIP SEAL
OS. CHECK VALVE 16. GEAR HOUSING 25. O-RING
06. RING SEAL 17. PORT END COVER 26. PORTING BLOCK
07. ROLLER BEARING 18. LOCKWASHER 27. CAPSCREW
08. POCKET SEAL 19. STUD 28. LOCKWASHER
09. THRUST PLATE 20. NUT 29. O-RING
10. DRIVE SHAFT AND GEAR 21. DOWEL PIN 30. BACK-UP RING
11. GASKET SEAL 22. DOWEL PIN 31" PIPE
F361

Figure 78-2. Winch "Motor (41R22)

Winch Motor 78-5

C. Nicking, grooving, or fretting
teeth surfaces.
3. If the drive shaft shows any wear de-
tectable by touch in the the seal area or
at the drive coupling, or if wear in these
areas is more that 0.002 inch, the motor
must be replaced.
4. Damage to the dowel pins or pin holes
requires replacement of the pins or ma-
chined housings or both.
5. If a thrust plate is scored, pitted,
eroded, or worn beyond 0.002 inch, the
th rust plate must be replaced.
6. Check valves (05) located in the shaft
end cover, must be examined for proper
operation.
7. Examine the bearings for scoring,
spalling, or pitting. Any bearing show-
ing anyone of these conditions must be
repaired. Bearings should be replaced
with a suitable bearing puller. New
bearings should fit into their bores with
a light press fit.
8. If two speed valve (23) is defective it
must be replaced.
9. All seals, O-rings, back-up rings and
gaskets must be replaced when the motor
is being overhauled.
ASSEMBLY. Use the following procedure
to assemble the winch motor (see
Figu re 7B-2 on page 7B-5):
1. Remove burrs on all machined sur-
faces with a medium grit carborundum
stone. If the bearings have been re-
moved, deburr the bearing bores.
2. Place shaft end cover (04) in a vise
with the mounting face down. Tightly
install check valves (05) in their respec-
tive bores, using a screwdriver or the
special tool shown if Figu re 7B-1 on page
7B-4. Peen the edge of the bore 1/32
inch to 1/16 inch with a 1-112 inch diam-
eter steel ball.
3. Place ring seals (06) in the bottoms of
the bearing bores. Position the ring
seals so the notch in the seal faces the
bearing.
4. To replace the bearings in the shaft
end cover (04), port end cover (17),
and bearing carrier (13), press the bear-
7B-6
of ings into their bores with an arbor
press.
5. To install a new lip seal (24) in shaft
end cover (04 ) , first coat both the outer
edge of the seal and the bore into which
the seal fits, with a non-hardening seal-
ant. With the metal side of the seal up,
press the seal into the mounting flange
s ide of the s haft end cover, with a n a r-
bor press and a bar. Press only until
the seal is flush with the face of the seal
bore.
6. Install thrust plate (09) and pocket
seals (08) as follows:
A. Grip the shaft end cover in a vise
with the mounting face down.
B. Check to make sure that thrust plates
(09) are clean and free of nicks on
the machined surface.
C. Cut two pocket seals (08) 7/32 inch
long from the pocket seal strip.
Grease the pocket seals well and in-
sert them into the middle slots of
th rust plate (09).
D. With the pocket seals facing down,
place the thrust plate over the bear-
ings in the shaft end cover.
E. Tap the thrust plate with a soft ham-
mer until it is about 1/32 inch from
the machined surface.
F. Cut four pocket seals (08) approxi-
mately 1/4 inch long from the pocket
seal strip. I nsert the pocket seal into
each of the slots in the thrust plate.
Push each pocket seal all the way in
so that it touches the roller bearings.
Tap the thrust plate down firmly
against the machined su rface with a
soft hammer. Use a sharp razor blade
to trim the exposed ends of the pock-
et seal square and flush with _the
th rust plate.
7. Repeat item 7 for the port end cover
and bearing carrier thrust plates, and
pocket seals.
8. Insert the spline end of drive shaft
(10) into the steel sleeve (see
Figure 7B-1 on page 7B-4). Lightly
grease the drive shaft and sleeve. I n-
sert the drive shaft with sleeve into
shaft end cover (04) with a twisting mo-
tion. Be careful not to damage double
lip seal (24). Push down carefully until
the gear rests against thrust plate (09).
Remove the steel sleeve. I nsert the dri-
ven gear.
9. Grease new gasket seals (11) and in-
sert them into the grooves in both sides
of gear housings (12 and 16). Insert
dowel pins (21) into the holes in shaft
end cover (04).
10. Position gear housing (12) over shaft
end cover (04) so that holes in the hous-
ing line up with the dowels in the cover.
When the housings are parallel, squeeze
them together or tap gently over alter-
nate dowels using a plastic hammer.
Parts should move smoothly together.
Do not force the parts together.
11. Coat gears· (10) with oil to provide
initial lubrication when the motor is
started. I nsert dowel pins (21) into
gear housing (12).
12. Position bearing carrier (13) on gear
housing (12) so the roller bearings re-
ceive the journals of the drive and driv-
en gears. Make sure that the housing
match marks are properly aligned. In-
sert dowel pins (22) into bearing carrier
(13) .
13. Insert connecting shaft (14) into the
spline of the drive gear. Insert drive
and driven gear set (15) into bearing
carrier (13). Make certain that the
gears are in contact with the thrust plate
face.
14. Position gear housing (16) over bear-
ing carrier (13) so the holes in the hous-
ing line up with the dowel pins in the
carrier. When the parts are parallel,
squeeze them together or tap over alter-
nate dowel pins with a plastic hammer.
15. Insert dowel pins (22) into gear
housing (16) so that the holes in the
cover line up with the dowel pins in the
housing. Tap the cover gently with a
plastic hammer to slide the cover over
the dowels and down onto the face of the
gear housing.
16. Insert studs (19) into the port and
cover, through the motor, and thread in-
to shaft end cover (04). Place washers
(18) and nuts (20) on the studs and
cross-tighten the nuts. Rotate drive
shaft (10) to make certain that the motor
does not bind internally.
17. Slide seal retainer (03) into the
mounting face of shaft end cover (04).
Insert ball bearing (02) and snap ring
(Ol) .
18. After the nuts are tight and the mo-
tor has been checked to ensu re that
there is no internal binding, torque the
nuts to 200 ft-Ibs using a diagonal tight-
ening pattern.
19. Attach two speed valve (23) to the
motor. Install a-rings (29), back-up
rings (30), pipe (31), a- ring (25), port-
ing block (26) securing these parts to
the motor with lockwashers (28) and cap-
screws (27).
20. Replace the a-ring on the holding
valve and install the holding valve on the
motor. Attach the lines from the holding
valve to the motor.
21. Install the winch motor assembly as
described under the topic, Winch Motor,
Installation.
Installation
I nstall a new or repai red winch motor us-
ing the following procedure:
1. Check the mounting flange on the
winch housing, the pilot diameter on the
motor, the spline in winch input shaft
coupling and the splined motor shaft for
bu rrs or imperfections that could pre-
vent the motor from seating properly on
the winch. Carefully remove any imper-
fections by lapping with a stone.
2. Replace the motor mounting a-ring.
3. lift the motor into position on the
winch housing.
4. Align the match-marks and make sure
that the motor shaft engages the spline
of the input shaft coupling.
5. Lubricate the mounting screws with
SAE 30 oil, install and torque the screws
to 76-84 ft-Ibs.
6. Fill the motor ports with clean hydrau-
lic oil to provide initial lubrication.
7. Make sure that the split flange
a-rings are installed, then reconnect the
hydraulic lines to the motor ports.
Tighten all fittings evenly. Add oil to
the reservoir as required.
Winch Motor 7B-7
8. Reeve the wire rope and start the ma- any ai r in the system and check the op-
chine. eration of the machine.
9. Operate the winch motor, in both di- 10. Check for leaks.
rections, for several minutes to eliminate

7B-8
 SUBSECTION 7C
HOIST WINCH
WINCH
General
This subsection covers the removal, dis-
assembly, assembly, and installation of
the winch.
DESCRIPTION
This winch utilizes two planetary systems
located inside the drum to provide the
necessary gear reductions for load handl-
ing. Also mounted in the drum, is a
spring-set brake and one-way clutch as-
sembly ·that is attached di rectly to the
winch input shaft.
The brake and one-way clutch assembly
allows drum rotation in one (hoist) direc-
tion when the brake is set. When the
brake is hydraulically released, the drum
is free to rotate in both directions and
rope can be spooled from the drum.
A fixed displacement hydraulic motor is
used to drive the winch. The winch mo-
tor is mounted on the winch housing, so
that the splined motor shaft will engage
the drive coupling on the input shaft of
the winch.
Two hydraulic working lines and one
drain line are connected to the motor
ports to allow two directional drive of the
motor.
Removal
The brake piston seals and the winch mo-
tor can be serviced with the winch in-
stalled on the machine. All other winch
service can best be accomplished by re-
moval and disassembly of the winch.
Remove the winch as an assembly using
the following procedure:
1. Un reeve the block and remove the
wire rope from the drum.
2. Thoroughly clean the hydraulic con-
nections before disconnecting the lines.
3. Disconnect the delivery and retu rn
lines from the winch motor and counter-
balance valve. Cap the hydraulic lines,
and plug the motor and valve hose con-
nections to prevent contaminants from
entering the hydraulic system.
4. Securely attach a hoist to the winch.
The winch weighs approximately 760
pounds.
5. Remove the hardware which secures
the winch to its base, and lift the winch
from the base.
Overhaul
NOTE
The following procedu res are writ-
ten on the basis that the winch is
disassembled into subassemblies
and then reassembled from the su-
bassemblies. Separate procedures
are included for the service of in-
dividual winch subassemblies. Re-
fer to the separate topics for the
disassembly and assembly of the
particular winch subassemblies as
necessary.
DISASSEMBLY. Disassemble the winch
using the following procedure (see
Figure 7C-6 on page 7C-9):
Subsection 7C 7C- 1
1. Remove the drain plug in the bottom
of the motor and drain the hydraulic oil
from the motor ipto a suitable container.
2. Tag, disconnect and plug the hydrau-
lic hoses between the counterbalance
valve and the motor manifold. Install
plastic or aluminum plugs in the valve
body and the manifold to prevent the en-
trance of dirt or contaminants. Tag,
disconnect and plug the hydraulic lines
to the winch motor. Plug these lines us-
ing plastic or aluminum plugs to prevent
the entrance of dirt or contaminants.
3. Remove the capscrews and lockwash-
ers whic!' secu re the winch motor, and
remove the motor.
4. Remove drain plug (17) from the
winch drum and drain the winch oil into
a suitable container. The winch holds
approximately 16 quarts of gear oil.
5. Remove capscrews (01), cover plate
(02), nut (03), piston (04), O-ring (09)
and back-up ring (08) from bearing sup-
port (07).
NOTE
It may be necessary to apply ai r or
hydraulic pressure through the
brake release port to force piston
(04) out of the bearing support.
Keep nut (03) threaded on the pis-
ton rod to control the removal of
the piston. A blind hole puller
may also be used to remove the
brake piston.
6. Remove O-ring (05) from piston (04),
and discard the 0- ring.
7. Loosen retainer plate capscrews (10).
8. Remove nuts (18), tie rods (20), and
spacers (19) from winch housing (22).
9. Support the winch on blocking with
the input end up.
10. Remove breather (49) from bearing
support (46).
11. Match-mark bearing support (46) and
winch housing (22) to ensure proper as-
sembly. Remove snap ring (45), washer
(44) and bushing (43) from the winch
input shaft.
7C-2
12. Remove capscrews (48) and bearing
support (46) from the winch assembly.
NOTE
Lifti ng eyes may be th readed into
bearing support (46) to aid in re-
moving it from the winch housing.
13. Remove shim stack (50) making sure
that the shims are kept together.
14. Install a 5/16-24 lifting eye in the
tapped end of input shaft (30).
15. Remove capscrews (47) and insert
three of the capscrews into the threaded
jacking holes in bearing carrier (36).
Carefully jack the bearing carrier free of
the drum.
WARNING
Use caution when removing the
carrier assemblies from the winch.
Ring gear (33) may come out with
the carrier assembly, and can fall
free, if the assembly gearing binds
in the ring gear. Failure to ob-
serve this precaution may lead to
serious personal injury.
16. Lift input shaft (30), bearing carrier
(36) and planetary carriers (34 and 35)
out of ring gear (33), as an assembly.
17. Position the carrier assembly with
bearing carrier (36) end on blocking.
18. Pull input shaft (30) out of the plan-
etary and bearing carrier assemblies.
19. Remove input carrier (34), pinion
(32) with snap ring (31), and output
carrier (35) from bearing carrier (36).
Disassemble and assemble the input and
output carriers, as necessary. Refer to
the applicable topic in this section.
20. Remove O-ring (37) from bearing
carrier (36).
21. Remove seal (40) from bearing carri-
er (36).
22. Using a suitable puller, remove bear-
ing (39) and seal ring (41) from bearing
support (46), only if they are to be re-
placed.
 NOTE
If bearing (39) or bearing cup
(38) are removed, both must be
replaced.
23. Remove bearing cup (38) from bear-
ing carrier (36), only if it is to be re-
placed.
24. Remove ring gear (33) from drum
(21) .
25. If bearing (42) is damaged, remove it
from bearing support (46).
26. Remove four nuts (29) and lift brake
assembly (28) from retainer plate (27)
studs, and the splines of bearing sup-
port (07). Be careful, to pull the brake
assembly straight up off retainer plate
(27) to ensure that the brake push rod
clears bearing support bushing (26),
O-ring (12) and back-up ring (13).
27. Remove snap ring (25) and retainer
plate (27) from bearing support (07).
28. Disassemble and assemble the brake
assembly as described under the topic,
Wi nch Bra ke.
29. Return the winch to a horizontal po-
sition and support the drum with a lift-
ing sling. The approximate weight of
the drum is 200 pounds.
30. Match-mark bearing support (07) and
the winch housing to ensure proper as-
sembly. Remove capscrews (06) and
bearing support (07).
31. Lift drum (21) out of winch housing
(22).
32. Remove seal (15) and bearing cup
(24) from drum (21).
NOTE
If bearing (23) or bearing cup
(24) are removed, both must be
replaced.
33. Remove bearing (23) and seal ring
(14) from bearing support (07).
34. Remove capscrews (10), retainer
plate (11), O-ring (12), and back-up
ring (13) from bearing support (07). If
bushing (26) is damaged or excessively
worn, remove it from bearing support
(07) and replace it.
35. Clean, inspect, repair and/or replace
winch components as described. under the
topic, Cleaning and Inspection.
CLEANING, REPAIR AND INSPECTION.
Clean and inspect the winch components
using the following procedure as a guide-
line (see Figu re 7C-6 on page 7C-9) :
CAUTION
Dry all parts using low pressure
compressed air (15 psi maximum).
Do not use paper towels or shop
towels to dry parts. Use of these
will introduce lint into the hydrau-
lic system possibly causing damage
to system components.
1. Thoroughly wash each part of the
winch in a suitable cleaning agent and
air dry using low pressure (15 psi maxi-
mum) filtered, compressed air.
2. Discard all O-rings, back-up rings,
and seals. Replace discarded compo-
nents with new pa rts.
3. Inspect all machined surfaces for ex-
cessive wear or damage, and replace
parts as necessary.
4. Check all bearings for excessive
wear, pitting or galling. Replace bea r-
ings as necessary.
5. Inspect the one-way clutch rollers and
springs for damage.
6. Inspect bushings (26 and 43) for
wea r, a nd replace each if necessa ry .
7. Check the brake friction and reaction
discs for excessive wear, warpage and
evidence of overheating. Check brake
springs for warpage and/or signs of ov-
erheati ng. Replace components that
show excessive wear, warpage and/or
signs of overheating.
8. I nspect the su rface on seal sleeves
(14 and 41). If the sleeves are pitted or
grooved, replace them as follows:
A. Remove bearing (23 or 39, as applica-
ble) from the bearing support.
Hoist Winch 7C-3
B. Remove the sleeve by tapping with a
flat hammer, heating or by careful
use of a rounded, blunt chisel.
C. Prior to installing the new sleeve,
remove all dirt and oil from the seat-
ing surface.
D. Coat the bearing support with a liq-
uid sealant or gasket cement.
E. Press the new sleeve into position
with an installation tool or a tube of
the proper size. The sleeve must be
installed with the inside diameter ra-
dius fi rst.
F. Remove any excess sealant from the
seal sleeve edges. Sealant on the
sealing surface could cause seal leak-
age.
G. Press bearing (23 or 39) onto the
bearing support until it bottoms out.
ASSEMBLY. Use the following procedure
to assemble the winch (see Figure 7C-6
on page 7C-9):
1. Assemble bearing carrier (36) as fol-
lows:
A. Press bearing cup (38) into bearing
carrier (36) until the cup bottoms in
the bore of the carrier. To prevent
damage to the bearing cup, press on-
lyon the outer edge of the bearing
cup. The bearing cup must bottom in
the carrier bore.
B. Press seal (40) into bearing carrier
(36) with a tool that will allow the seal
to fu lIy seat in the bea ri ng ca rrier.
Press only on the outer edge of the
seal.
C. Lubricate O-ring (37) and carefully
slide it over bearing carrier (36) until
the O-ring is seated on the carrier
flange.
2. Subassemble drum (21) as follows:
A. Press bearing cup (24) into drum
(21) until the cup bottoms in the bore
of the drum. To prevent damage to
the bearing cup, press only on the
outer edge of the bearing cup. The
bearing cup must bottom in the drum
bore.
B. Press seal (15) into drum (21) using
a tool that will allow the seal to fully
7C-4
seat in the drum. Press only on the
outer edge of the seal.
3. Assemble bearing support (07) as fol-
lows:
A. If necessary, press bushing (26) into
support (07). When properly in-
stalled the end of the bushing will be
flush with the bearing support.
B. Dip O-ring (12) and back-up ring
(13) in winch lubricant. Put the
back-up ring into bearing support
(07) with the concave side of the ring
facing out, (see Figu re 7C-6 on page
7C-9) ..
C. Install O-ring (12) against the con-
cave side of back-up ring (13).
D. Install retainer plate (11) and cap-
screws (10) to secure O-ring (12) and
back-up ring (13) in the bearing
support. Do not tighten retainer
plate capscrews (10) at this time, just
snug them down.
NOTE
Be sure retainer plate (11) is fully
seated in the counterbore. The
plate must be centered so it does
not contact the piston rod du ring
final assembly.
E. If seal sleeve (14) needs to be re-
placed, refer to the topic, Cleaning
and Inspection.
F. If necessary, press bearing (23) onto
bearing support (07). Make sure that
the large end of the bearing is down
before installing the bearing.
4. Assemble bearing support (46) as fol-
lows:
A. Install bearing (42) into bearing ~up­
port (46). The bearing should be
pressed into the support until the
outer end of the bearing is flush with
the end of the support (see
Figu re 7C-6 on page 7C-9).
B. If seal sleeve (41) needs to be re-
placed, refer to the topic, Cleaning
and Inspection.
C. If necessary, press bearing (39) onto
bearing support (46). Make sure that
 the large end of the bearing is down
before installing the bearing.
D. Install bushing (43) and breather
(49) in bearing support (46) at this
time.
5. Lift the drum into the winch housing.
Be sure the end of the drum with the
level plug is toward the holes in the
housing, (see Figure 7C-l). The drum
assembly weighs approximately 200
pounds.
6. Coat the lip of seal (15) with lubricant
and install bearing support (07) into the
winch housing and drum, taking care not
to damage the seal.
NOTE

Use the match marks made during

disassembly to initially align the
bearing support to the winch hous-
ing.

7. Align the holes in bearing support

(07) with the tapped holes in the winch
housing and install capscrews (06).
Torque the capscrews to 76-84 ft-Ibs.
8. Place the winch in a vertical position
on blocking with the large opening up.
This assembly weighs approximately 435
pounds.
9. I nstall retainer plate (27) and snap
ring (25) on bearing support (07).
10. Install the assembled brake (28) into
the drum as follows, (see Figure 7C-2 on
page 7C-6):
A. Carefully lower brake assembly (28)
into the drum while guiding the brake
pushrod through bearing support
(07), bushing (26), O-ring (12),
back-up ring (13) and retainer plate
(11) .
B. Continue lowering the brake assembly
over the splines of bearing support
(07), while aligning the retainer plate
studs with the stud holes in the brake
assembly.
C. Secure brake assembly (28) to retain-
er plate (27) with nuts (29). Torque
nuts (29) to 36-39 ft-Ibs.
11. Install input shaft (30) into the
brake assembly. The input shaft splines
HOUSING PLUG A1688
OPENINGS
Figure 7C-l. Drum Installation
must be fully engaged in the splines of
the brake one-way clutch.
12. Place ring gear (33) into the drum.
Be sure the end of the ring gear with
the short spline is toward the center of
the drum.
13. Install input carrier (34) over input
shaft (30) and inside ring gear (33).
Align the pinion teeth as necessary to
install the input carrier.
NOTE
Installation of the input carrier
may requi re two people, one to
support the carrier and the other
to align the pinions.
14. Install snap ring (31) on pinIon (32)
and place the pinion inside of input car-
rier (34), as shown in Figure 7C-6 on
page 7C-9.

Hoist Winch 7C-5

 BRAKE STUD
ASSEMBLY HOLE
RETAINER
STUD
Figure 7C-2. Brake Installation
15. Install output carrier (35) into ring
gear (33) over input shaft (30) and pin-
ion (32).
16. Install the assembled bearing carrier
(36) into the winch drum as follows, (see
Figu re 7C-6 on page 7C-9):
A. Be sure a-ring (37) is in place on
bearing carrier (36).
B. I nstall carrier (36) by engaging the
splines of the carrier with ring gear
(33) splines and seating the carrier
on drum (21).
C. Fasten the carrier to drum assembly
(21) with capscrews (47). Torque
the capscrews to 76-84 ft-Ibs.
17. Install bearing support assembly (46)
into the winch housing and drum assem-
bly as follows (see Figu re 7C-6 on page
7C-9) :
NOTE
Use the match marks made during
disassembly to initially align the
bearing support to the winch hous-
ing.
A. Coat the lip of seal (40) with lubri-
cant.
7C-6
CAUTION
Be sure that splines on bearing
support (46) and output carrier
(35) are aligned, and take care not
to damage· seal (40) or bearing
(38) during the following step.
Damage to seal (40) will result in
oil leaks.
B. Insert bearing support (46) into the
winch housing and drum assembly,
until the bearing support is seated in
the splines of output carrier (35) and
seated on the winch housing. Do not
install the mounting capscrews at this
time.
C. Using a feeler gauge, measure the
gap between bearing support (46) and
winch housing (22) at four equally
spaced intervals around the circum-
ference of the bearing support.
D. Determine the average measured air
gap by adding the four measurements
together and dividing by four.
Then, subtract 0.010 from the aver-
age measured air gap and this is the
thickness of shims (50) which must be
used.
E. Remove bearing support (46) and in-
stall the required number of shims.
F. I nstall bearing support (46), making
sure that breather (49) is in the
proper position.
G. I nstall mounting bracket in its proper
position. Install capscrews (48) into
bearing support (46) and mounting
bracket. Alternately torque cap-
screws (48) to 155-166 ft-Ibs.
18. Check to see that bushing (43) is in
place, then install washer (44) and snap
ring (45) on the input shaft. To ensu re
that snap ring (45) fully seats in- its
groove, pull input shaft (30) out.
NOTE
To aid in pulling the input shaft
out, th read a 5/16-24 lifting eye
into the end of the input shaft.
Attach a hoist or other suitable
lifting device to the lifting eye,
raise the shaft and install the snap
ring.
19. Return the winch to a horizontal po-
sition.
20. Torque capscrews (10) to 12 ft-Ibs.
These are the capscrews which secure
the brake piston rod O-ring and back-up
ring retainer plate.
21. Install the brake piston as follows,
(see Figure 7C-6 on page 7C-9):
A. Lubricate O-ring (09) and back-up
ring (08) with winch lubricant, then
install the O-ring and back-up ring in
bearing support (07).
NOTE
The back-up ring has a concave
surface that must face the O-ring,
as shown in Figu re 7C-6 on page
7C-9.
B. Lubricate and install O-ring (05) in
piston (04). Then install the piston
on the piston push rod.
C. Secure the piston with nut (03).
Torque nut (03) to 175-185 ft-Ibs.
D. I nstall cover (02) with the vent hole
located at the four o'clock position.
Secu re the cover with capscrews
(Ol), torqued to 12 ft-Ibs.
22. Install spacers (19), tie rods (20)
and nuts (18) on the winch housing.
Torque the nuts to 165-175 ft-Ibs.
23. With the hoist drum level and the
drain hole positioned at the 90 0 position,
fill the winch drum with approximately 16
quarts of lubricant (refer to Section 3
for the type of lubricant to be used).
24. Install the level plug. Rotate the in-
put shaft slowly about 30 revolutions in a
clockwise direction to coat all internal
parts with lubricant. The input shaft
should turn freely by hand (10 inch-Ibs
or less torque).
I nput Carrier
DISASSEMBLY. To disassemble the in-
put carrier, proceed as follows (see
Figu re 7C-3):
BEARING
CARRIER
F230
THRUST
WASHER
Figure 7C-3. Input Carrier
NOTE
All parts in the input carrier must
be replaced if any parts are defec-
tive. A planetary pinion kit is
available if necessary.
1. Remove the lock plate capscrews and
lock plates.
2. Press the pins out of the carrier.
Remove the gears, thrust washers and
bearings.
NOTE
The pins must be pressed out to-
ward the lock plate side of the
carrier. The shaft bores on the
side opposite the lock plates are
smaller in diameter.
ASSEMBLY. To assemble the input car-
rier assembly, proceed as follows (see
Figu re 7C-3):
1. Set the input carrier on a clean work
surface with the lock plate side up.
2. Place the carrier thrust washer in the
bottom of the ca rrier.
3. Lubricate the input planet bearings
with winch lubricant and install them into
the planet gear bores.
Hoist Winch 7C-7
 SLOT INPUT
is available if necessary.

1. Remove the lock plate capscrews and

lock plates.
2. Press the pins out of the carrier.
Remove the gears and the bearings.
Remove the bearing cups only if they are
to be replaced.

TAPPED NOTE
HOLE
The pins must be pressed out to-
ward the lock side of the carrier.
The shaft bores on the side oppo-
site the lock plates are smaller in
GEAR diameter.

ASSEMBLY. To assemble the output car-

rier assembly, proceed as follows (see
A1695 Figure 7C-.5):
Figure 7C-4. Input Carrier Pin
Installation 1. Set the output carrier on a clean work
surface with the lock plate side up.
4. Assemble a thrust washer to each side
of a gear and bearing assembly, then in- 2. Place the carrier thrust washer in the
stall the gear into the carrier. Press a bottom of the ca rrier.
planet pin th rough the planet th rust
washer and bearing keeping the slot in 3. Lubricate the output planet bearings
the pin in proper alignment with the and bearing cups with winch lubricant
tapped holes in the carrier (see PIN
Figure 7C-4).
BEARING "'./Y
NOTE
G E \ BEARING ~0/
The bores are smaller on the oppo-
site side of the carrier, therefore BEARING CU~\' ~r/!)\
the pins must be installed from the
lock plate side. CUP \t.~ /

5. Install the lock plate and secure it

BEAR~~~ K:c;~R CAPSCREW

with a capscrew. Use Loctite No. 242 or

equivalent on the capscrew and torque it
to 29-32 ft-Ibs. \:::JJf1
I
6. Repeat steps 4 and 5 for the other two
gears.

output Carrier
DISASSEMBLY. To disassemble the out-
put carrier; proceed as follows (see
Figu re 7C-5):
NOTE
F362
All parts in the output carrier
must be replaced if any parts are
"'-
CARRIER
defective. A planetary pinion kit Figure 7C-5. Output Carrier

7C-8
 I
I
I
)

/'
/'
/' 39
/'
/'
38

36

51
33
52 33

BACK·UP RING
BACK·UP RING

01. CAPSCREW 14. SEAL SLEEVE 27. RETAINER PLATE 40. SEAL /
02. COVER PLATE 15. SEAL 28. BRAKE 41. SEAL SLEEVE /
03. LOCKNUT 16. WEDGE 29. NUT 42. BEARING 22
04. PISTON 17. PLUG 30. INPUT SHAFT 43. BUSHING
05. O·RING 18. NUT 31. SNAP RING 44. WASHER
06. CAPSCREW 19. SPACER 32. PINION 45. SNAP RING
07. BEARING SUPPORT 20. TIE ROD 33. RING GEAR 46. BEARING SUPPORT
08. BACK·UP RING 21. DRUM 34. INPUT CARRIER 47. CAPSCREW
09. O·RING 22. HOUSING 35. OUTPUT CARRIER 48. CAPSCREW
10. CAPSCREW 23. BEARING 36. BEARING CARRIER 49. BREATHER A2399
11. RETAINER PLATE 24. BEARING CUP 37. O·RING 50. SHIM STACK
12. O-RING 25. SNAP RING 38. BEARING CUP 51. THRUST WASHER
13. BACK·UP RING 26. BUSHING 39. BEARING 52. THRUST WASHER
Figure 7C-6. Winch

Hoist Winch 7C-9

 SLOT CARRIER

TAPPED
HOLE

END PLATE

REACTION
DISCS
PLATE
GEAR WASHER
A1696

Figure 7C-7. Output Carrier Pin SPIDER

Installation
and install them into the planet gear
bores, then install the gear into the car-
rier. Press a planet pin through the
carrier and and bearing, keeping the A1694
slot in the pin in proper alignment with
the tapped holes in the carrier (see
Figure 7C-7). Figure 7C-8. Winch Brake (915J139)
NOTE 2. Refer to Figu re 7C-13 on page 7C-14,
and proceed as follows:
The bores are smaller on the oppo-
site side of the carrier, therefore A. Ca refu Ily , remove fou r capscrews
the pins must be installed from the (16) . Alternately, loosen capscrews
lock plate side. (16) a few threads at a time to pre-
vent bending of the brake components
and allow a slow release of the spring
4. Install the lock plate and secure it force.
with a capscrew. Use Loctite No. 242 or
equivalent on the capscrew and torque it B. Lift end plate (02), spacer plates
to 29-32 ft-Ibs. (03), reaction discs (04), friction
discs (05), spacer tubes (09), and
5. Repeat steps 4 and 5 for the other two the one-way clutch assembly fr~m
gears. spider (01).
C. Remove the piston rod assembly, and
Winch Brake springs (07) from spider (01).
DISASSEMBLY. To disassemble the D. Disassemble the piston rod assembly
winch brake, proceed as follows: by removing nut (17), washer (11),
spring guide (08) and release plate
(06) from piston rod (10). Pull bear-
1. Place the brake assembly on the ing (19) out of the piston rod, only if
(brake end) bearing support, (see it is to be replaced.
Figure 7C-8). Hold the assembly in a
soft-jawed vise with the input end up. E. Disassemble the one-way clutch as-
sembly by removing snap rings (20),

7C-10
 bearings (18), thrust washers (15)
and outer race (13) from the inner
race (12). Be careful when removing
clutch (14) from the inner race,
dropping or rough handling may dam-
age the clutch.
3. Clean, inspect and, if necessary, re-
place any damaged or excessively worn
brake parts. Refer to the topic, Winch
Repai r, Cleaning and Inspection.
ASSEMBLY. To assemble the winch
brake, proceed as follows (see
Figure 7C-13 on page 7C-14):
NOTE
OUTER
RACE
it is important that the brake as-
sembly process be kept free from
contamination. All parts should be
thoroughly cleaned, as described
under the topic, Cleaning and In- Figure 7C-9. One-Way Clutch
spection, except for new bearings Inst.;:Ill'ltion
and friction discs which should be
clean when received.
C. Support the outer race and clutch on
a socket and carefully install inner
1. I nstall release plate (06), spring race (12) with the internal spline to-
guide (08), washer (11) and stop nut ward the top of the assembly, see
(17) on piston rod (10). Center the Figure 7C-1O on page 7C-12.
spring guide on the rod and torque the
stop nut to 500 ft-Ibs. D. Remove the a-ring from the clutch
and check the rotation of the inner
2. Press bearing (19) into piston rod race.
(10). The bearing must be assembled
with the stamped identification end fac- NOTE
ing out against the pressing tool.
When properly installed, the
NOTE one-way clutch will only allow a
clockwise rotation of inner race
Bearing (19) must be pressed into (12) when the inner race is viewed
the piston rod bore until the end from the input end of the brake
of the bearing is at least flush assembly (see Section A-A,
with the top of the bore and no Figure 7C-13 on page 7C-14).
more than 0.030 inch below the top The clutch should not rotate in the
of the bore. counterclockwise di rection.

3. Assemble the one-way clutch assembly
as follows, (see Figure 7C-13 on page
7C-14):
A. Set outer race (13) on the work sur-
face with the input end up.
B. Place a tight a-ring around clutch
(14). This is to compress the sprags
against the clutch spring. Then in-
sert the clutch into the outer race, as
shown in Figure 7C-9.
E. Install thrust washers (15) and bear-
ings (18). Secure the bearings with
snap rings (20).
F. Dip the one-way clutch assembly in
winch lubricant and check the rota-
tion of the inner race as described in
step D.
4. Assemble brake spider (01), belleville
springs (07) and piston rod assembly as
follows, (see Figure 7C-13 on page
7C-14):

Hoist Winch 7C-ll

 INPUT
SPLINE

OUTER
RACE

A1692
Figure 7C-10. Inner Race
Installation
A. Set bra ke spider (01) on the (brake
end) bearing support, and install
springs (07) in the spider, as shown
in Figure 7C-ll on page 7C-l2.
NOTE
Figure 7C-11. Spring Installation
til a total of six reaction discs and
five friction discs are installed. The
last disc is a reaction disc (04).
Then install a spacer plate (03) on
top.

Du ring installation, the six belle-

ville brake spring washers must al-
ternate cone out, cone in, etc., as
shown in Figure 7C-l3 on page
7C-l4.

B. Install the piston rod assembly into

the spider, with spring guide (08)
passing th rough all of the springs.
5. Assemble spacer plates (03), reaction
discs (04), friction discs (05), and spa-
cer tubes (09) onto the spider assembly
as follows, (see Figure 7C-l3 on page
7C-l4):
RELEAS
A. I nstall spacer tubes (09) and one PLATE
spacer plate (03) on the spider as-
sembly, then install a reaction disc
(04) followed by a friction disc (05).
NOTE

Dip the friction discs in winch lu-

bricant prior to assembly.
A1694
B. Continue installing reaction discs (04)
and friction discs (05) alternating un- Figure 7C-12. Brake Final Assembly

7C-12
Figure 7C-13. Winch Brake Assembly (915J139)4. Apply and release hydraulic pressure
6. Align the friction discs by carefully
installing the one-way clutch assembly
into the spider and disc assembly. Then
install the input pinion shaft, as shown
in Figure 7C-12, to center the one-way
cI utch assembly.
7. I nstall end plate (02) and four cap-
screws (16). Tighten the capscrews in
small alternating steps, taking care that
all parts are in the correct position as
the end plate is pulled down against the
spacer tubes. Torque the capscrews to
36-39 ft-Ibs.
NOTE
Compressing the brake spring
washers prior to tightening cap-
screws (16) will aid assembly.
The springs can be compressed by
assembling the brake piston and
performing the brake release por-
tion of the brake test procedu re,
see the topic, Brake Testing.
B. Test the brake for proper operation,
see the topic, Brake Testing.
BRAKE TESTI NG. The brake should be
tested before installation to ensure prop-
er operation. To test the winch brake
proceed as follows:
1. Set the brake assembly on bearing
support (07), as shown in Figure 7C-12
on page 7C-12.
2. Assemble the brake piston in bearing
support (07) by installing back-up rin9s
(OB and 13), O-rings (05, 09 and 12),
retainer plate (11), piston (04) and nut
(.03) as shown in Figure 7C-6 on page
7C-9, and described in this subsection
(see the topic, Winch Assembly).
3. Attach a hydraulic fluid supply line to
the brake release inlet port.
to the brake release piston. The brake
release plate must move smoothly with no
binding.
5. Check the force requ i red to sta rt
movement of the release plate against the
springs. This force should be 3000 to
3400 pounds (450 to 475 psi on the brake
piston) .
6. Release the brake and check for free
rotation of the brake input (inner clutch
race) in both directions.
7. Release the pressure on the piston
and immerse the brake in winch
lubricant. Hold the brake spider
through the spline and apply torque to
the input. The brake should not slip at
less than 600 ft-Ibs of torque. .
B. Insert input shaft (30) into the inner
race and needle bearing of the brake.
Release and set the brake to ensure that
the inner race is aligned properly with
the needle bearing in the piston rod.
Winch Installation
Install a repaired or overhauled winch
using the following procedure:
1. Lift the winch into position on the ma-
chine. The winch weighs 760 Ibs.
2. Install the eight bolts and nuts which
secure the the winch and tighten them to
190-210 ft-Ibs.
3. Connect the delivery and return lines
to the winch motor and counterbalance
valve.
4. I nstall the rope on the drum and
reeve as necessary.
Hoist Winch 7C-13
 ,....--19
10 £i) /
/
/ "
I

P
/'

/'
,/

/'
/
03
/'

, /'
( /'

" 08
"
/'

,,"
"
./

09
/'
,/

,/
/'

./
./
./
./
./
/'
,/ 12
./
/'
./
./
(

01. SPIDER
02. END PLATE
03. SPACER PLATE
04. REACTION DISC
05. FRICTION DISC
06. RELEASE PLATE
07. BELLEVILLE SPRING SECTION A-A
OB. SPRING GUIDE 07
09. SPACER TUBE
10. PISTON ROD 02
11. WASHER
12. INNER RACE
13. OUTER RACE
14. SPRAG CLUTCH
15. THRUST WASHER
16. CAPSCREW
17. NUT
18. BEARING
19. BEARING
20. SNAP RING
21. LOCKNUT
22. INPUi SHAFT
15

F256
Figure 7C-13. Winch Brake Assembly (91SJ139)

7C-14
 SUBSECTION 70

WINCH CONTROL VALVE

GENERAL quate pressure gauges and a thorough

This subsection provides instructions for
the removal, disassembly, repair, assem-
bly and installation of the winch control
valve and other relevant valves of the
machine winch hydraulic system. This
subsection also includes control valve
troubleshooting and special adjustments
required by the individual valves.
understanding of the operation of the
complete hydraulic system are essential
for diagnosing improper valve operation.
Table 70-2 on page 70-3 lists some of
the difficulties which may be experienced
with the relief valve cartridges. The ta-
ble is intended to aid in determining
when a relief valve cartridge should be
removed and replaced with a new one.

"
WINCH CONTROL VALVE (36R83)

Description
The winch control valve is a three posi-
tion, spring centered, directional valve,
with one spool (plunger). The center po-
sition is the neutral (open) position. The
winch control valve is mounted on the
right hand side of upper frame side plate
(see Figure 70-1).

Troubleshooting
Table 70-1 lists some of the difficulties
which may be experienced with the con-
trol valve and the hydraulic system. It
indicates the probable cause and the re-
commended remedy for the trouble listed. Figure 70-1. Winch Control Valve
It should always be remembered that Installation
pressure and delivery are factors which
are dependent upon each other. Ade-

Subsection 70 70-1
 PROBLEM CAUSE REMEDY
I
Sticking Spool. i
I
Excessively high oil tem- I
Eliminate restriction in
I
I
perature. pipe.
I
i
! Dirt in oil. I Change oi 1 ; clean system.
I I I
!
I
Pipe fittings too tight. II Check torque.
i
I,
Valve warped
i ing.
from mount- I Loosen valve and check I
! I operation.
I
II

,
i
! Excessively
. high pressure Check system pressure at
1n va.ve. pump with gauge.
I
Linkage binding. Free up linkage.
I Spool bent. Replace valve.
Return spring damaged. Replace faulty parts.
Spring cap binding. Loosen cap, recenter and
I retighten.
Valve not at thermal Let system warm up.
equil ibrium.
I
Leaking seals. Paint on or under seal.
I Remove and clean.
I
I
!
i
I
Excessive back pressure. Open line to reservoir.
I
I
Dirt under seal. Remove and clean.
Scored spool. Replace valve.
Loose seal plates. Clean and tighten.
I

I
Cut or scored seal. Replace faulty parts.
Unable to move spool in Dirt in valve. Clean and flush out.
or out.
I Spool cap full of oil. Replace seals.
Bind in linkage. Free up linkage.
Load will not hold. Cylinder leaking or worn. Check cylinders.
i I I
Oil bypassing valve plun- Replace valve. -
ger.
I
I
I
Relief valve not holding. Remove and clean.

Table 70-1. Control Valve Troubleshooting (Part 1 of2)

7D-2
 PROBLEM CAUSE
I REMEDY
Poor hydraulic system I Defective pump. I Check pressure or
performance or failure.
J replace.
I
Dirt in relief valve. I Disassemble and clean. I
I
II
Relief valve defective. II Replace. I
I
I
I
Worn cylinders. I Repair or replace.
I I
I, Load too heavy. I Check line pressure. I
I I I
I
I Internal valve crack. I Replace valve. I
I I
Spool not at full stroke. Check movement and link- I
age.
Reservoir low on oil. I Add oil. I

System filters clogged. I Clean or replace.

I
Line restricted. Check lines.

Table 70-1. Control Valve Troubleshooting (Part 2 of 2)

i
PROBLEM i CAUSE I REMEDY I
Erratic Pressure. I Pilot poppet seat Replace cartridge.
damaged. I
I Piston poppet sticking. I
Pressure setting not Wear due to dirt. See ADJUSTMENT OF RELIEF !
correct. Locknut and adjusting VALVES. Replace car-
screw loose. tridge if necessary.

Leaks. Damaged seats. Replace O-rings or entire

Worn O-rings. cartridge, as necessary.
Parts sticking due to
dirt.

Table 70-2. Relief Valve Troubleshooting

Removal
To remove the winch control valve, pro-
ceed as follows (see Figu re 7D-1 on page
7D-1) :
1. Lower all loads to the ground and stop
the engine. Render the starting means
inoperative.
2. Operate the appropriate control lever
in both directions to relieve system pres-
sure.
3. Thoroughly clean and dry the -exterior
of the valve and fittings.
4. Tag and remove the split flanges and
the valve ports. Place protective caps on
hydraulic lines to prevent system contam-
ination.
5. Remove the hardware which secures
the valve to the upper frame and remove
the valve from the machine.

Winch Control Valve 7D-3

Disassembly
To disassemble the winch control valve,
proceed as follows (see Figure 7D-2 on
page 7D-5):
1. Establish a clean work area, free of
dirt and corrosive material.
2. Remove the plug in the top of the
valve housing.
3. Remove the plugs in each side of the
valve housing. Remove and discard the
0- rings from the plugs.
4. Remove the relief and unloading valve
ca rtridges. Remove the 0- ri ngs on the
valves and discard them.
5. Remove and disassemble the valve
plungers (spools) as follows:
A. Remove the seal plate, wiper and
0- ring from the tang end of the plun-
ger.
B. Remove the plunger cap from the
housing.
C. Insert a pin through the hole in the
tang end of the plunger to prevent
the plunger from turning and remove
the screw from the cap end of the
plunger.
D. Remove the spring and spring seats
from the plunger:
E. Remove the cap end seal plate, wiper
and O-ring from the plunger bore.
F. Ca refu lIy, slide the pi unger out of
the control valve housing.
Cleaning, Inspection and Repair
I nspection and later assembly should on-
ly be attempted in the cleanest area pos-
sible. To perform the cleaning,
inspection and repair of the valve, pro-
ceed as follows:
1. The control valve seal kit, see the
machine Parts Manual TM 09109A-24P/3,
provides new O-rings and wipers. It is
recommended that all valve 0- rings and
wipers be discarded and new ones be in-
stalled during valve assembly.
7D-4
2. Thoroughly, clean all valve parts in
an approved cleaning solvent and blow
dry.
3. Inspect all springs for distortion or
cracks. Also inspect the valve ports,
and mating parts for excessive wear or
deep scratches.
4. Inspect the plunger, and the plunger
bore, for excessive wear or deep
scratches.
NOTE
All metallic parts of the control
valve, with the exception of the
valve housing and plunger are re-
placeable, and must be replaced if
excessively worn or damaged, see
the machine Parts Manual. If the
valve housing or plungers are ex-
cessively worn or damaged the en-
tire valve assembly must be
replaced with a new valve.
5. Repair to the relief valve cartridge is
limited to replacement of the cartridge
with a new cartridge.
6. Cover the control valves with a lint
free cloth until ready for assembly.
Assembly
Assemble the winch control valve using
the following procedure (refer to
Figu re 7D-2 on page 7D-5) :
1. All valve parts must be lubricated
with a light coat of clean hydraulic oil
prior to assembly.
2. Assemble and install the control valve
plunger using the following procedure:
A. Carefully slide the plunger into the
control valve housing bore.
B. Install the plunger O-rings.
NOTE
When installing O-rings do not roll
them into place, stretch them
slightly and slide them into their
respective groove. Be very careful
not to damage the 0- rings when
they pass over th reads or s ha rp
edges.
C. I nstall the plunger wipers.
NOTE
When installing the wipers ensure
the "V" lip of the wipers face away
from the inside of the valve hous-
ing. Ensure the wipers are prop-
erly seated in their associated
bores, by pressing them firmly in-
to place with a blunt instrument.
O. I nstall the seal plate, on the control
cable end, and secure with the attach-
Ing screws.
E. Install the spring seats and spring.
Secure these to the plunger using the
spri ng retai ner screw. I nsert a pin
through the tang end of the plunger,
to prevent the plunger from turning,
and tighten the spring retaining
screw.
F. Install the plunger cap and secure it
with the attach i ng screws.
3. Assemble the O-rings to the relief and
unloading valve cartridges and install
the ca rtridges.
4. Assemble the O-rings to the valve
housing plugs and install the plugs in
the side of the valve housing.
5. Assemble the O-rings to the valve
housing plugs and install the plug in the
top of the valve housing.
6. Tighten all parts securely, in even al-
ternate steps to prevent distortion.
Installation
I nstall a new or repai red control valve as
follows:

~
PLUG O.RING- \
PLUG
SPRING SEAT
SCREW
\ "
;Q?
~ "
~'<) ~ "
I \ lS) .
\ . c:r
SPRING \
PL~~;ER
~ /~ SPRING SEAT ~fjj
O.RING· __ <. \~
O
//
--->:Gi'
,/
~
~ UNLOADING
\d.!
VALVE
O·RING
\
. /
PLUG

O·RING-
I r:3&;. . . . . . -SEAL PLATE \ ~C)
PLUG .

'LJ_(}~ /§)
----
" WIPER·

" --
__ O.RING-

'~
'\1, '

........... " \
O·RING·

·SEAL KIT ITEMS

Figure 70-2. Winch Control Valve (36R83)

Winch Control Valve 70-5

1. Position the control valve on the ma-
chine mounting so that the holes line up,
and the plunger points toward the con-
trol linkage.
2. Install the mounting hardware and
tighten the capscrews secu rely.
3. Make sure that the hydraulic line fit-
ting O-rings are installed, then connect
the fittings to the matching valve ports.
Tighten the fittings secu rely, as de-
scribed in Subsection 5B, making sure
the fittings are tight, but not so tight as
to cause distortion.
4. Position the valve plunger in the neu-
tral position and connect the control
linkage to the plunger. Do not pull the
plunger from the neutral position to meet
the control linkage. If necessary, adjust
the control linkage to meet the plunger.
5. Make sure the machine is ready to op-
erate, then start the engine and operate
the winch control valve slightly in both
directions, while observing for leaks or
binding at the valve.
6. Add hydraulic oil to the system reser-
voir as necessary, to bring the oil to the
proper level.
COUNTERBALANCE VALVE (36Q286)
Description
The counterbalance valve is mounted on
the winch motor. The purpose of this
valve is to prevent the rotation of the
winch drum urtil a predetermined pres-
sure has been developed in the winch
motor circuit. The valve also prevents
rotation of the winch drum in the event
that pressu re in the winch motor pres-
sure lines is reduced below preset limits.
Removal
Remove the winch counterbalance valve
using the following procedure:
7D-6
WARNING
Extreme caution should be used
when removing the winch counter-
balance valve from a winch motor,
as this valve is the only hydraulic
means of preventing drum rotation
and load lowering.
1. Lower the hook block to the ground to
relieve all tension on the load lines.
2. Tag, disconnect and plug all hydrau-
lic lines from the valve and the control
valve block.
3. Remove the four mounting capscrews
which secu re the counterbalance valve to
the winch motor.
Repair
This valve is not repairable and should
be replaced as a unit if it malfunctions.
Installation
Install a new winch counterbalance valve
using the following procedure:
1. Clean the O-ring .surface on the winch
motor and on the counterbalance valve.
2. Lubricate the 0- ring and attach the
valve to the motor. Make sure that the
0- ring in in place. Secu rely tighten the
mounting capscrews.
3. Attach the hydraulic lines to the valve
making sure to use new O-rings in the
appropriate places. Refer to Subsection
5B for fastening procedures.
4. Operate the winch motor in both di-
rections with a light load on the hook
block while checking for leaks and prop-
er operation of the winch motor and
valve.
5. If necessary, check and fill the hy-
draulic tank to the proper level.
 TABLE OF CONTENTS

Subsection 8A 8A-1

Introduction 8A-1

Swi ng System 8A-1

General 8A-1
Description 8A-1
Troubleshooting 8A-2

Subsection 89 89-1

Swing Motor ... 89-1

Swing Motor (41 U41) 8B-1
Swing Motor (41 U41) 8B-1
Troubleshooting 8B-1
Removal 8B-3
Overhaul 8B-3
Installation 8B-8

Subsection 8C 8C-1

Swing Valves and Components 8C-1

General ......... . 8C-1
Swing Control Valve (36U329) .. 8C-1
Swing Brake Master Cylinder (38U57) 8C-6
Swing Lock Control Valve (36Z948) 8C-8

Subsection 80 80-1

Swing Reducer 80-1

General ... 8D-1
Swing Reducer (9353J8) 8D-1
Description ... . 8D-1
Removal ..... . 8D-1
Disassembly ... . 8D-2
Cleaning and Inspection 8D-3
Assembly .... 8D-3
I nput Carrier 8D-8
Output Carrier 8D-9
Reducer Installation 8D-1O

Subsection 8E 8E-1

Slewing Ring 8E-1

General ... 8E-1
Slewing Ring (1 R13) 8E-1
Description 8E-1
Repair 8E-1
Removal 8E-1
Installation 8E-2

Contents
 LIST OF ILLUSTRATIONS

Figure 8A-1. Swing System 8A-2

Figure 8B-1. Swing Motor Installation 8B-3
Figure 8B-2. Cam Ring Assembly 8B-4
Figure 8B-3. Shaft Inspection Points 8B-4
Figure 8B-4. Port Plate Assembly 8B-5
Figure 8B-5. Swing Motor (41 U41) 8B-5
Figure 8B-6. Swing Motor Assembly Tools 8B-7
Figu re 8C-1. Swing Control Valve Installation 8C-1
Figu re 8C-2. Swing Control Valve (36U329) 8C-5
Figure 8C-3. Checking Cylinder Bore 8C-7
Figure 8C-4. Master Cylinder (38U57) 8C-7
Figu re 8C-5. Swing Lock Control Valve (36Z948) 8C-9
Figu re 80-1. Swing Reducer Installation 80-1
Figure 80-2. Swing Reducer Assembly 80-2
Figure 80-3. Holding Tool Oimensions 80-2
Figure 80-4. Torquing Tool 80-4
Figure 80-5. Adjusting Bearing 80-4
Figu re 80-6. Staking Nut 80-5
Figu re 80-7. Pinion Gear Installation 80-5
Figure 80-8. Input Carrier Installation 80-5
Figure 80-9. Bearing Support Installation 80-6
Figure 80-10. Cover Installation 80-6
Figure 80-11. Swing Reducer (9353J8) 80-7
Figure 80-12. Input Carrier 80-8
Figu re 80-13. I nput Carrier Pin Installation 80-9
Figure 80-14. Output Carrier 80-9
Figure 80-15. Output Carrier Pin Installation 80-10
Figure 8E-1. Slewing Ring Installation 8E-3

List of Illustrations iii

 LIST OF TABLES

Table 8A-1. Swing System Troubleshooting 8A-2

Table 8B-1. Swing Motor Troubleshooting . 8B-1
Table 8C-1. Swing Control Valve Troubleshooting 8C-2

List of Tables v
 SUBSECTION SA

INTRODUCTION

SWING SYSTEM

GENERAL supplies oil from a hydraulic pump. The

This section covers the troubleshooting,
removal, repair and installation of the
components in the swing system. A de-
scription of the swing system and trou-
bleshooting information is provided in
this subsection. Service information for
the individual swing system components
is located in the subsections that follow.
DESCRIPTION
hydraulic swing motor is mounted on the
top of the swi ng reducer (see
Figu re 8A-l on page 8A-2). Motor out-
put is controlled by the swing control
valve which provides variable oil flow to
the motor to increase or decrease the mo-
tor speed. The motor output shaft is
splined to the input of the reducer. A
dry disc brake is located in the upper
section of the reducer.

Power for rotation of the upper (swing)

is provided by a hydraulic system that

Subsection 8A 8A-l
 SWING
MOTOR

CONTROL
VALVE

Figure 8A-I. Swing System

I nput torque at the reducer passes
through two planetary reductions to the
output pinion which meshes with the
teeth of the outer slewing ring member.
Swing speed is controlled by the com-
bined effects of load, control lever
movement, and swing brake application.
TROUBLESHOOTING
Table 8A-l contains a list of troubles
which may be experienced with the swing
system, along with probable causes and
remedies for each. It is recommended
that the schematics in Subsection 5A be
studied before troubleshooting the swing
circuit.

8A-2
TROUBLE PROBABLE CAUSE REMEDY
Swing system House lock in the applied po- Di>engage the house lock.
completely in- sition.
operative.
Swing brake not releasing due Disassemble and resea 1 the
to excessive internal leakage. swing brake.
Swing brake stuck in applied Check swing brake valve spool
I position. for binding.
Main relief valve stuck in Replace the valve.
open positi::;n.
Swing motor has excessive in- Replace or reseal the motor
ternal leakage. (see Subsection BB).
Mechanical fault in swing re- Repair the swing reducer or
ducer or slewing ring. replace the slewing ring (see
Subsections BC and 80).
Faulty swing pump. Repair or replace the swing
pump (see Subsection 5C).
Swing motion Faulty swing pump. Repair or replace the swing
sluggish. pump.
Swina motor has excessive in- Replace or reseal the motor.
ternal leakage.
Main relief valve stuck in Replace the relief valve.
open position.
Excessive leakage around the Replace or reseal the control
swing control valve spool. valve.
Swing motion Low hydraulic oil level. Add oil as required.
erratic.
Swing brake not releasing com- Check operation of swing brake
pletely. and/or swing lock.
Slewing ring not lubricated Lubricate the slewing ring.
properly.
Malfunction of the main relief Check the main relief valve
valve. i setting (see Subsection BC).

Table BA-I. Swing System Troubleshooting

Swing System BA-3

 SUBSECTION 8B

SWING MOTOR

GENERAL tor has two working lines to provide

The information in this subsection covers
the removal, repair and installation of
the swing motor. A troubleshooting guide
is also provided to help in determining
motor problems.
pressu re to the motor ports and one
drain line (see Figure 88-1 on page
88-3) .
Troubleshooting

Table 8B-1 lists some of the difficulties

SWING MOTOR (41U41)
DESCRI PT ION. A fixed displacement ro-
tary balanced vane type motor is used to
swing the upper of this machine. The
swing motor is mounted on and splined to
the input of the swing reducer. The mo-
which may be experienced with the swing
motor. The table lists the probable cause
and possible remedies for each of the
troubles listed. This chart should be
helpful in making a general diagnosis of
swing motor problems.

TROUBLE PROBABLE CAUSE REMEDY

External leakage. Seal failure. Replace the seal.
Defective casting. Replace the casting.
Leakage at fitting. Cracked casting. Replace the casting.
Defective threads. Repair or replace the fitting.
Damaged O-rings. Replace the O-ring.
Burr. Stone or file flat.
Loss in speed under I Low inlet pressure. Check the relief valve.
load.
Scored port plate or end Relap flat to clean up.
cap.
High oil temperature. Use the correct oil for the am-
bient temperature, use an oil
cooler, adjust relief valve
sett i ng.

Table 8B-l. Swing Motor Troubleshooting (Part 1 of 2)

Subsection 88 8B-1
 TROUBLE PROBABLE CAUSE REMEDY
Poor speed control. Insufficient fluid sup- Troubleshoot components down-
ply. stream of the motor.
Worn rotating group. Replace.
Motor fails to Insufficient torque. Check relief valve pressure
start turning. setting.
Excessive motor leakage. Check flow from motor outlet.
If excessive, check shuttle
valve in front port plate.
Pressure is not loading plate,
causing plate to move 'away from
cam ring.
Worn port plates. Replace the port plates.
Worn rotating group. Replace the rotating group.
Defective O-ring on 0.0. Replace the O-ring if damaged.
of front port plate.
Insufficient pump deliv- Troubleshoot pump.
ery.
Shaft play. Worn bearings. Replace the bearings.
Hammering coupling on Coupling bore should be slip
shaft. fit on shaft.
Bursting of fluid Excessive pressure. Check system relief valves.
supply inlet or
outlet lines.
I
Excessive noise. Worn or damaged internal I Disassemble the motor. Inspect
parts. for excessive wear. Check con-
dition of faces of port plate
and end cap. Rework (lap) or
replace if scuffed.
Air in system. Bleed air off, check fittings
for tightness.
I Seal failure. Abrasive contaminants or Check for the cause of contam-
sludge in the fluid. inants. Flush system and over-
haul the motor.
Wrong viscosity of Replace the fluid with the
fluid. proper grade and type (see Sec-
tion 3).
Sustained high pressure Check for possible relief valve
I above maximum motor rat- malfunction or other parts fai-
ling. lure. Adjust if necessary. I

Table 8B-l. Swing Motor Troubleshooting (Part 2 of 2)

8B-2

Figure 8B-1. Swing Motor
Installation
Removal
To remove the swing motor, proceed as
follows (see Figure 8B-1):
1. Engage the house lock. Stop the en-
gine and disconnect the battery cable
from the negative terminal of the
battery.
2. Tag and disconnect the hydraulic
lines at the motor. Cap the lines and the
motor ports to prevent the entry of for-
eign material.
3. Match-mark the motor and the trans-
mission ~o that the motor can be rein-
stalled in the same position.
4. Remove the hardware used to secure
the motor to the swing reducer and lift
the motor from the machine. The motor
weighs approximately 35 pounds.
Overhaul
GENERAL. The overhaul of this motor
includes the disassembly, inspection and
assembly. Prior to disassembly of the mo-
tor, drain all fluid from the motor and
thoroughly clean the motor exterior su r-
faces. Prepare a clean, lint-free surface
on which to lay the internal parts of the
motor.
NOTE
A preassembled cam ring assembly
is available for rapid field repair
of this motor. A seal kit, contain-
ing all motor seals, is also avail-
able. All other parts of the motor
should be replaced as inspection
dictates or, the enti re motor
should be replaced with a new mo-
tor.
DISASSEMBLY. To disassemble the
swing motor, proceed as follows (see
Figure 8B-5 on page 8B-5):
1. Secure the motor in a vise with shaft
(15) extending down.
2. Remove capscrews (01) and lift end
ca p (02) f rom bod y (18).
3. Remove O-ring (03) from the end cap.
4. Check needle bearing (04) in the end
cap. If it is worn or damaged, remove
and disca rd it.
5. Remove dowel pin (05) from cam ring
assembly (06).
6. Thread two UNC 10-24 capscrews in
the tapped holes provided in the cam
ring assembly. lift the cam ring assem-
bly out of body (18). If resistance is
encountered when lifting the cam ring
assembly out, lightly tap the outside of
the body.
7. Disassemble the cam ring assembly as
follows (see Figure 8B-2 on page 8B-4):
WARNING
The pump vanes are held against
the cam ring by tension from the
springs in the rotor. If the rotor
is pulled from the cam ring with no
protection, tension from the
springs will throw the vanes out in
all directions.
A. Place the cam ring assembly on a cle-
an, flat surface. Push the rotor and
vanes from the cam ring far enough to
secure a piston ring compressor over
the vanes and around the rotor.
Swing Motor 8B-3

F253
Figure 88-2. Cam Ring Assembly
B. After the compressor is in place,
push the rotor and vanes the remain-
der of the way out of the cam ring.
C. Release the tension on the compressor
and remove the vanes and vane
springs from the rotor.
B. Remove dowel pin (07) from port plate
(OB).
9. Install two UNC 10-24 capscrews into
the puller holes provided in the port
plate and lift the plate out of the body.
10. Remove a-rings (09 and 10) from the
grooves in the port plate.
11. Remove snap ring (11) from the
body. Press on the external end of shaft
(15) and remove the shaft and bearing
assembly from the body.
12. Remove felt wiper (17) and shaft seal
(16) from the body.
CLEAN I NG AND INSPECTION. Clean
and inspect the motor parts as follows:
1. Wash all metal parts in cleaning sol-
vent and dry thoroughly.
2. I nspect the seals for wear, breaks,
cuts and brittleness. Check the shaft
seal closely for scratches or cracks. Dis-
card all defective seals.
BB-4
CAUTION
If bearing (13) must be replaced,
snap rings (12 and 14) must be
removed from the shaft end oppo-
site of the seal surface (see
Figure BB-3). A damaged seal
surface will cause the seal to leak.
3. Examine bearing (13) for wear by ap-
plying a little pressure to the outer race
and rotate the bearing to check for wear
and cracks in the steel balls or races.
Check for looseness. Remove snap ring
(12) and press the bearing from the
shaft if replacement is necessary. Re-
move snap ring (14) from the same end
of the' shaft as the bearing was removed.
4. Remove the screws from the sides of
the port plate (see Figu re BB-4 on page
BB-5), and remove the shuttle spool from
the port plate bore. I nspect the port
plate holes and shuttle spool for exces-
sive wear, scoring or other damage.
Replace the enti re port plate assembly if
damage is evident.
5. I nspect the cam ring assembly for ex-
cessive wear (ripples or washboard
marks on contour). Replace a badly worn
or defective cam ring assembly.
6. Inspect the wear surfaces on the port
plate and end cap for deep scratches.
Replace if defective.
7. Inspect the body and end cap for
cracks or other casting damage. Replace
all damaged castings.
B. Inspect the shaft splines, bearing and
seal surfaces and drive end for damage
or excessive wear, (see Figure BB-3).
Replace the shaft if defective.
9. Coat all motor part su rfaces with a
light film of hydraulic lubricating oil_and
BEARING
SURFACES
SNAP RING
GROOVES
F254
Figure 88-3. Shaft Inspection Points
 MOTOR

DOWEL
PIN

PRESSURE
PORTS

PORT _ _~-.,
PLATE SHUTTLE
SPOOL

PORT PLATE SECTION A·A

F249
END VIEW OF MOTOR

Figure 88-4. Port Plate Assembly

06

.. I
I

------_.

i_____ 18

01. CAPSCREW 07. DOWEL PIN 13. BEARING

02. END CAP 08. PORT PLATE ASSEMBLY 14. SNAP RING
03. O·RING 09. O·RING 15. SHAFT
04. NEEDLE BEARING 10. O·RING 16. SHAFT SEAL
05. DOWEL PIN 11. SNAP RING 17. FELT WIPER
06. CAM RING ASSEMBLY 12. SNAP RING 18. BODY
F234
Figure 88-5. Swing Motor (41U41)

Swing Motor 88-5

cover all of the motor parts to prevent
dust and dirt from settling on them.
Keep the parts covered until assembly.
ASSEMBLY. Immerse the seals and bear-
ings in clean hydraulic oil to make as-
sembly easier and provide initial
lubrication. Assemble the motor as fol-
lows (see Figu re 8B-5 on page 8B-5) :
NOTE
Two special tools are required to
assemble the motor. These tools
should be fabricated prior to motor
assembly (see Figure 8B-6 on page
8B-7) .
1. Install snap ring (14) over the inter-
nal end of shaft (15) and install the snap
ring in the groove between the bearing
surface and the seal surface. Do not al-
low the snap ring to touch the seal sur-
face on the shaft or the seal surface may
be damaged.
2. Press bearing (13) over the end of
the shaft and up against snap ring (14).
Do not apply enough pressu re to distort
the snap ring. Install snap ring (12).
Be sure that snap rings (12 and 14) are
fully seated.
3. Position body (18) on a flat surface
with the large open end facing up. In-
sert felt wiper (17) in the wiper bore of
the motor body (18).
4. Position shaft seal (16) on the end of
the shaft seal driver with the open face
of the seal against the driver. Apply
lubricating fluid to the O. D. of the seal
and install the seal in the seal bore of
the motor body (18).
·5. Position the thimble over the coupling
end of the shaft so that the tapered end
is facing away from the shaft. Press the
shaft assembly into the body. Press on
the outer race of bearing (13) until the
bearing is seated against the bottom of
the bearing bore. Remove the thimble
from the shaft.
6. I nstall snap ring (11) in the internal
groove of body (18) against bearing
(13). Make sure snap ring (11) is fully
seated.
7. Assemble port plate assembly (08) as
follows, (see Figure 8B-4 on page 8B-5):
8B-6
A. Remove all grease from port plate
(08), the sh uttle spool and screws.
Apply a very small amou nt of Loctite
No. 242 to the screws and allow the
Loctite to cu re for one hou r.
CAUTION
If an excessive amount of Loctite is
placed on the screws, some Loctite
will be forced into the shuttle
spool bore when the screws are in-
stalled.
B. Inst,,11 one screw in the shuttle spool
bore. Torque the screw to 3-5 ft-Ibs.
Install the shuttle spool in the bore
and install and torque the other
screw. Tilt the port plate back and
forth to make sure that the shuttle
spool travels the full length of the
bore.
C. Install O-rings (09 and 10) in the ap-
propriate grooves in the port plate.
Also insert dowel pin (07) in the hole
in the port plate.
8. Thread two UNC 10-24 capscrews in
the tapped holes in the face of the port
plate and insert the port plate into the
motor body (18).
9. Remove the two handling capscrews
from the port plate.
10. Assemble the cam ring assembly as
follows (see Figure 8B-2 on page 8B-4):
A. Place the cam ring, rotor, vanes and
vane springs on a clean flat surface.
Arrange the vanes side by side with
the three spring holes up. Insert the
vane springs in the vanes. Install
the vanes with the springs in the
slots in the rotor.
NOTE
Be certain that the springs are
started in the holes in each rotor
slot before performing the next
step.
B. Place a ring compressor around the
vanes and tighten the compressor
gradually until the springs and vanes
are in the position they will occupy
while in the cam ring. Place a
back-up plate, slightly smaller than
the outside diameter of the rotor in
the ring compr'essor and push the ro-
tor, springs and vanes into the cam
ring. The back-up plate will prevent
the vanes from sliding endwise in the
rotor slots and damaging the slots and
springs.
CAUTION
Be certain that the rotor and vane
assembly is inserted far enough in
the cam ring to prevent the vanes
from flying out of position when
the ring compressor is removed.
1116" x 45°
~ CHAMFER (TVP)
11. I nsert dowel pin (05) in the hole In
cam ring assembly (06).
12. Install two UNC 10-24 capscrews in
the tapped holes in the cam ring assem-
bly anc position the assembly in body
(18) over dowel pin (07).
13. Remove the two handl i ng capscrews
from the cam ring assembly.
14. Assemble and install end cap assem-
bly (02) as follows:
BLEND IN RADIUS
NO SHARP CORNERS
POLISH FINISH 1.490"

I
1 .489" D.

2.043"
2.045" D.

....--++-----'1--5/8 "
3/8"

SEAL
.....1 - - - - - - - - - - 6 TO 8" --------Jl~ DRIVER

.M
2-1/2" (6.4 em)
-
BLEND 1 /64" R
15, 16" DIA. TVP

J~oc L
7

1·' . 6 4" DIA.

INSTALLATION
THIMBLE
I
L-
0.876"
0.886" D
1\
20° \ t

Figure 88-6. Swing Motor Assembly Tools

Swing Motor 88-7

A. Press needle bearing (04) into end
cap (02) with the markings on the
bearing 1/16 inch below the face of
the end cap.
B. Lubricate and install new O-ring (03)
in the groove in the end cap.
C. Position end cap (02) over the dowel
pin in cam ring assembly (06). Hold
the end cap fi rmly agai nst the cam
ring assembly then rotate it to line up
the bolt holes.
D. Install and tighten capscrews (01)
evenly to 70-80 ft-Ibs.
Installation
To install a new or repaired swing motor,
proceed as follows (see Figure 8B-1 on
page 8B-3):
1. Check the mounting flange on the
swing reducer, the pilot diameter on the
motor, the input spline on the reducer
and the splined motor shaft for burrs or
imperfections that could prevent the mo-
tor from seating properly on the
reducer. Carefully remove any imperfec-
tions by lapping.
8B-8
2. Lift the motor into position on the
swing reducer.
3. Align the match marks and make sure
that the motor shaft engages the input
spline of the reducer.
4. Lubricate the mounting screws with
SAE 30 oil, install and torque the screws
to specifications.
5. Fill the motor ports with clean hyd rau-
lic oil to provide initial lubrication.
6. Make sure that the split flange
O-rings are installed, then reconnect the
hydraulic lines to the motor ports.
Tighten all fittings evenly. Add oil to
the reservoir as required.
7. Reconnect the battery cable to the
battery, and start the machine.
8. Disengage the house lock and operate
the swing motor, in both directions, for
several minutes to eliminate any air in
the system.
9. Check for leaks. Adjust the relief
valves as necessary.
 SUBSECTION 8C

SWING VALVES AND COMPONENTS

GENERAL 3. Disconnect the flex cable to the con-

trol valve plunger. Tag and disconnect
The information contained in this sub- the hydraulic lines attached to the swing
section describes the removal, repai r, control valve.
and installation of the swing valves.
4. Remove the hardware which secures
the valve to the upper frame and remove
SWING CONTROL VALVE (36U329) the swing control valve.
DESCRI PTION. The swing control valve DISASSEMBLY. To disassemble the
is a pressure compensated, 3-position, swing control valve, proceed as follows
4-way, di rectional control valve. The (see Figure 8C-2 on page 8C-5):
control valve plunger is spring-returned
to the blocked (neutral) position. The 1. Unscrew and remove relief housing
valve plunger houses anti-cavitation plug (01) and plug assembly (02). Re-
valves which prevent system cavitation. move compensator piston (03) and com-
pensator spring (04) from the valve
The swing control valve is mounted on housing bore. Disassemble relief housing
the deck of the upper frame forward of plug (01) as follows:
the swing reducer (see Figure 8C-1).
A. Remove pilot seat (05), poppet as-
TROUBLESHOOTING. Table 8C-l on sembly (06) and spring (07) from the
page 8C-2 lists some of the difficulties relief housing plug.
which may be experienced with the swing
control valve. The table indicates the
probable cause and possible remedies for
the problem listed. It should be remem-
bered that pressu re and delivery are
factors which are dependent upon each
other. Adequate pressure gauges and a
thorough understanding of the hydraulic
system are essential to diagnosing im-
proper swing valve operation.
REMOVAL. To remove the swing control
valve, proceed as follows:
1. Swing the boom over the front of the
machine and engage the house lock. Stop
the engine and disconnect the battery
cable from the negative terminal of the
battery.
2. Thoroughly clean the exterior of the
control valve and the fittings attached to Figure 8C-I. Swing Control Valve
it. Dry the valve. Installation

Subsection 8C 8C-l
 PROBLEM CAUSE REMEDY
Entire valve Compensator piston stuck open. Remove the piston, clean, ex-
inoperative. amine, and replace if neces-
sary.
Shuttle valve stuck. Remove the valve, clean, exam-
ine, and replace if necessary.
Relief poppet stuck open. I Remove the poppet, clean, ex-
amine, and replace if neces-
sary.
Relief valve set too low. Install a pressure gauge and
set the pressure.
Relief valve pilot spring dam-Replace the spring.
aged.
Valve response Compensator piston sticking. Remove, clean, and check for
slow. scratching, replace if neces-
sary.
Shuttle valve sticking. Remove, clean, and check for
scratching, replace if neces-
sary.
Sticking plun- Excessively high oil temper- Eliminate restrictions in line
ger ature. and filters that may cause
high temperature.
Dirt in oil. Change oil, clean system.
Valve warped from mounting. Loosen valve and check.
Excessively high pressure. Check pressure with gauge.
Linkage binding. Free up linkage.
Plunger bent. Replace entire valve.
Centering spring damaged. Replace.
Binding in end cap. Loosen cap, rece~~er and re-
tighten.
Valve temperature not equal. Let system warm up.
Leaking seals. Paint on or under seal. Remove and clean.
Excessive pressure. Check relief valve setting.
Dirt under seal. Remove and clean.
Scored plunger. Replace valve section.
Loose seal plates. Clean and tighten.
Cut or scored seal. I Replace seals.

Table 8C-l. Swing Control Valve Troubleshooting (Part 1 of 2)

8C-2
 PROBLEM CAUSE REMEDY
Unable to move Dirt in valve. Clean and flush out.
plunger in or
out. End cap full of oil. Replace seals.
Bind in linkage. Free up linkage.
Poor swing Defective pump. Repair or replace.
system per-
formance or Dirt in relief valve. Disassemble and clean.
failure.
Relief valve defective. Replace.
Worn motor. Repair or replace.
Internal valve crack. Replace valve.
Plunger not at full stroke. Check movement and linkage.
Reservoir low on oil. Add oil.
System filters clogged. Clean or replace.
Line restricted. Check lines.
Cavitation. Anti-cavitation poppet stuck Remove and clean.
closed.

Table 8C-l. Swing Control Valve Troubleshooting (Part 2 of 2)

B. Remove plug assembly (08) and set-
screw (09) from the relief housing
plug.
C. Remove and discard O-rings (10 and
11) .
2. Remove plug assembly (12) and shut-
tle valve (13).
3. Remove screws and lockwashers (14
and 15) and remove seal plate (16) from
the control end of the plunger.
4. Remove screws (14) and end cap (17)
from the other end of the plunger.
5. Remove screw (18), washers (19),
centering washers (20), guide stop (21),
centering spring (22) and spacer (23)
from the end of the plunger.
6. Remove seal plate (16) and carefully
pull the plunger out of the valve
housing. Remove and discard wipers
(24). Disassemble the plunger as follows:
A. Taking every precaution to prevent
damage to the plunger, remove plung-
er end (25) and plug screw (26) fr,om
the ends of the pi unger.
B. Remove anti-cavitation spring (27)
and poppet (28) from the bore in each
end of the plunger.
C. Remove O-rings (29) from the groove
in plug screw (26) and plunger end
(25).
CLEANING, INSPECTION AND REPAIR.
I nspection and assembly of the control
valve should only be attempted in as cle-
an an area as possible.
1. Thoroughly clean all valve parts with
an approved solvent. Pay particular at-
tention to those parts with grooves and
orifices to make sure they are free of
foreign material. Dry all parts.
2. Discard all O-rings and wipers with
the exception of the O-rings on plug as-
semblies (02, 08 and 12). If the O-rings
on the plugs are damaged, the entire
plug assembly must be replaced. All oth-
er rubber parts are available for
replacement.

Swing Valves and Components 8C-3

3. Carefully inspect poppet assembly
(06) and anti-cavitation poppets (2S) for
excessive wear and deep scratches. In-
spect the poppet seats in the mating
parts for the same damage. Minor imper-
fections can be removed by lapping the
poppet to the seat.
4. Carefully inspect the plunger and
compensator piston for scoring, deep
scratches, and excessive or uneven
wear. Also inspect the corresponding
valve bores. If any of these parts are
damaged, the enti re valve must be re-
placed.
5. All other metallic parts of the control
valve are replaceable. Replace these
parts as dictated by inspection. Replace
springs which are cracked or distorted.
ASSEMBLY. To assemble the control
valve, proceed as follows (see
Figure SC-2 on page SC-5):
1. Thoroughly lubricate all parts liberal-
ly with clean hydraulic fluid.
2. Thread plug assembly (02) into the
valve housing and tighten it securely.
Slide compensator piston (03), the end
with the small hole fi rst, into the com-
pensator bore. I nstall compensator
spring (04) in the bore in the compensa-
tor spool.
3. Assemble relief housing plug (Ol) as
follows:
A. Thread setscrew (09) into the relief
housing plug so that the setscrew is
flush with the end of the plug.
B. From the other end of the relief hous-
ing plug, install spring (07) and pop-
pet assembly (06) . The poppet
assembly should taper away from the
spring.
C. Install pilot seat (05) into the bore in
the relief housing plug so that the
shoulder rests up against the plug.
D. Install new O-rings (10 and 11) in the
grooves in the relief housing plug.
4. Carefully thread relief housing plug
(01) into the compensator piston bore in
the valve housing.
5. Carefully slide shuttle valve (13), the
end with the hole last, into the hoie near
SC-4
the top of the valve housi ng. Secu rely
install plug assembly (12).
6. Assemble the pi unger as follows:
A. Insert anti-cavitation poppets (2S) in-
to the holes in either end of the plun-
ger.
B. I nstall anti-cavitation spring (27) in
the bore in each poppet.
C. I nstall new 0- rings (29) in the
groove at the threaded end of plunger
end (25) and plug screw (26). Se-
curely fasten the plug screw and
pi unger end to the pi unger.
7. Carefully slide the plunger into the
valve housing bore.
S. Install wiper (24) in the housing
groove at each end of the plunger.
9. Install seal plate (16) at the plunger
end of the plunger. Tighten the hard-
ware secu rely.
10. Assemble spacer (23), centering
washer (20), centering spring (22),
guide stop (21) and another centering
washer (20) to the plug screw end of the
plunger. Securely fasten washer (19)
and screw (18) to plug screw (26).
11. Liberally grease the parts on the
plug screw end of the plunger. Install
and securely fasten seal plate (16) and
end cap (17) to the valve housing.
INSTALLATION. To install a new or re-
paired swing control valve, proceed as
follows (see Figure SC-1 on page SC-l):
1. Position the control valve, plunger
towards the front, on the upper frame so
that the th ree holes in the valve body
line up with the mounting holes in the
upper frame.
-
2. Install the mounting capscrews, wash-
ers and nuts. Tighten the capscrews se-
cu rely.
3. Connect the hydraulic lines to the ap-
propriate valve ports.
4. Make sure that the valve plunger is in
neutral and connect the control linkage
to the plunger end. Do not pull the
plunger from its neutral position to meet
the lin kage. If necessary, adjust the
 24 26

r@~
/'
.............................. / ,/
.................... /

28
/ 27 29

MAIN
f/i!ft)11~
CONTROL
VALVE
lIJ'
/
~

07 OS 25

~11
I tID
;S
"t~~
06
SEAL KIT FO R THIS VALVE.
'PARTS CONTAINEDII~ HOUSING PLUG
01. REL MBLY 16. SEAL PLATE
P
1 7 . END CA
02. PLUG ASS~TOR PISTON
18. SCREW
03. COM PENS ATOR SPRING
04 COMPENS
. EAT 19. WASHER G WASHER
CENTERIN
05. PILOT ~ ASSEMBLY 20. STOP
06. POPPE
21.
22. GUIDEERING SPRING
CENT
07. SPRIN':SSEMBLY
08 PLUG 23. SPACER
· SETSCREW WIPER·
o9 . GO 24. GER END
10. O-RIN ° 25 PLUN W
11 O-RING MBLY 26· PLUG SCRE TION SPRING
. G ASSE
12. PLU TTLEVALVE 27: ANTI-CAV:~:TlON
POPPET
13. SHU 28. ANTI-CAV
GO F236
SCREW 29. O-RIN
14. LOCKW ASHER
15.

Figure 8C-2. Swing Control Valve (36U329)

: 9 Valves an d Components
SWln 8C-5
 control linkage to meet the plunger end
as described in Subsection 5B.
·5. Start the engine and disengage the
house lock. Swing the upper in both di-
rections for several minutes. Observe
the valve for leaks and binding. Add oil,
as required, to bring the level of the
reservoir to the full mark on the
dipstick.
SWING BRAKE MASTER CYLINDER
(38U57)
DESCRI PTION. This master cylinder is
activated when the swing foot brake ped-
al in the operator's cab is depressed.
The master cylinder is mounted below the
cab floor in the forward left hand
corner.
When a brake application is made, the
cylinder piston moves in. As the piston
moves in, the primary cup closes off the
bypass port and fluid is displaced from
the master cylinder until sufficient pres-
sure is developed to apply the swing
brake.
Upon release, the piston is returned
against its stop by a spring. Some res-
ervoir fluid is allowed to flow through
the passages in the piston face and
around the primary cup lips to relieve
the vacuum caused by the slower return
of the displaced fluid from the system.
Finally, the piston clears the bypass
port, opening the port so that excess
fluid can return to the reservoir.
I n the normal off position, fluid move-
ment th rough the bypass port compen-
sates the closed hydraulic system for
temperature expansion or contraction and
seepage.
REMOVAL. To remove the maste~ cylin-
der, proceed as follows:
,. Disconnect the hydraulic line at the
master cylinder. Cap the line to prevent
the entry of foreign material and an ex-
cess loss of fluid. Allow the cyiinder to
drain.
2. Disassemble the boot from the cylinder
body.
3. Remove the hardware which secures
the master cylinder to the cab base and
remove the master cyl i nder.
8C-6
4. If necessary, remove the boot and
push rod from the reach rod.
OVERHAUL. To overhaul the master cyl-
inder, proceed as follows (see
Figu re 8C-4 on page 8C-7):
1. Remove the piston stop wire from the
groove in the body. Then, remove the
parts from the cylinder bore.
2. Discard the boot, piston and primary
cup.
3. After disassembly, clean and inspect
the master cylinder as follows:
A. Clean all parts in alcohol and/or hy-
draulic oil. Dry all parts with com-
pressed air or a lint-free cloth.
NOTE
Solvents such as gasoline, kero-
sene, carbon tetrachloride, ace-
tone and paint thinner cause
deterioration to rubber parts. Do
not use these substances for clean-
ing parts.
B. I nspect the cylinder bore for small
scratches and imperfections. Use a
clean-up hone to repair the bore if
necessary.
C. Check the piston to cylinder clear-
ance by sliding a new piston into the
cylinder bore with a 1.4 inch wide,
0.007 inch thick feeler shim in place.
If the piston can be inserted when the
shim is in place, the cylinder- is over-
sized and should be replaced (see
Figure 8C-3 on page 8C-7).
Figure 8C-3. Che:king Cylin:er Bore
 01. CYUNDER HOUSING 07. PUSH ROD ASSEMBLY 13. DRILLED CAPSCREW
02. SPRING 08. SNAP RING 14. GASKET
03. PISTON ASSEMBLY 09. BOOT 15. GASKET
04. VALVE STOP 10. CAP 16. BLEED SCREW
05. SPACER 11. O·RING 17. COVER
06. GASKET 12. CONNECTOR 18. BAU.

Figure 8C-4. Master Cylinde~ (38US7)

D. Excessive scratches and/or pitting
which cannot be removed from the pi-
stOil and cylinder bore requires re-
placement of the enti re assembly.
E. Check to make sure the intake and
bypass ports are open. It will be dif-
ficu It to see the bypass hole, but if a
copoer wire no larger than 0.020 inch
in diameter is used, the port can be
probed without damage.
4. Lubricate the cylinder bore and install
the spring in the bore.
5. Make sure that the secondary cup is
installed on the piston. I nstall a new
primary cup on the end of the piston.
6. Insert the piston assembly in the cyl-
inder bore.
7. I nsert the piston stop washer in the
cylinder bore and assemble the stop wire
to the groove in the bore.
INSTALLATION. To install the master
cylinder, proceed as follows:
1. If it was removed, assemble the reach
rod and yoke to the brake lever.
2. Turn the jam nut, on the cylinder end
of the reach rod, all the way onto the
reach rod.
3. Assemble the push rod to the reach
rod. I nstall the boot on the push rod
with the small boot retainer.

Swing Valves and Components 8C-7

 4. While engaging the push rod with the
master cylinder, securely attach the mas-
ter cylinder to its mounting below the
cab· base.
5. Adjust the stop nut so that the pedal
is perpendicu la r to the floor.
6. Adjust the push rod so that it just
bottoms out in the master cylinder piston
bore. The pedal and linkage is now ad-
justed for no free play. Tighten the jam
nut.
7. Assemble the boot to the body with
the large boot retainer.
8. Connect the hydraulic line to the mas-
ter cylinder.
9. Remcve the master cylinder fill plug
and fill the cylinder with the type of flu-
id specified in Section 3.
10. Bleed the brake system as described
under the topic, Installation, in Sub-
section 80. Make sure the master cylin-
der fluid level is approximately 3/8 inch
below the fi II open i ng.

8C-1O

SWING BRAKE VALVE (36Z948)
DESCRIPTION. This valve is manually shifted by the swing
park brake lever. When the swing park brake lever is in the
park position, this valve vents pressurized fluid from the
spring applied disc brake which is mounted on the swing
transmission.
When the swing park brake lever is in the released posi-
tion, this valve blocks the flow of fluid from the swing brake,
and the fluid releases the swing brake by maintaining pres-
sure against the springs that apply the swing brake.
REMOVAl. To remove the swing brake valve proceedasfol-
lows:
1. Disconnect the hydraulic lines at the valve and tag them.
2. Remove the mounting hardware from the valve and re-
move the valve from the machine.
OVERHAUL. To overhaul the swing brake valve, proceed as
follows (see Figure 70-8):
1. Slowly remove the plug from the valve. Remove the
spring, poppet, and plunger from the valve bore.
2. Pull the cam and lever from the other valve bore. Re-
move and discard the O-rings and back-up rings from the
grooves in the cam.
("C o
• •
.....,,-.~/
PLUG
........
POPPET
INLET
BACK-UP
RING
Figure 70-8. Swing Brake Valve (36Z948)
3. Thoroughly clean the valve parts with a suitable solvent
and blow dry with compressed air.
4. Inspect the valve bores for excessive wear, or deep nicks
and scratches. Examine the poppet taper and mating seat in
the valve bore. These surfaces must be free of nicks. If wear
is excessive. the entire valve must be replaced.
5. Lubricate all parts with clean hydraulic oil. Install new 0-
rings and back-up rings in the cam grooves. When properly
installed, the back-up rings must be nearest the ends of the
cam.
6. Carefully slide the cam into the valve bore, taking care
not to cut the O-rings.
7. Install the plunger, poppet, spring, and plug in the other
valve bore.
INSTALLATION. To install the swing brake valve. proceed as
follows:
1. Use the mounting hardware to attach the valve to the
underside of the cab base.
2. Attach the hydraulic lines to the valve.
3. Slightly open the fitting on the outlet port and put the
swing brake lever in the released position. Allow fluid to
drain from the valve until all air is expelled from the valve.
 SUBSECTION 8D

SWING REDUCER

GENERAL
This subsection describes the swing re-
ducer used on this machine and provides
information on the removal, disassembly,
assembly, and installation of the swing
reducer.

SWING REDUCER (9353J8)

Description
The swing reducer is mounted on the re-
volving frame, as shown in
Figu re 8D-1, with the output gear en-
gaged in the slewing ring gear. Input
from the swi ng motor is transmitted
through the two planetary gear systems
located inside the reducer housing to
provide the necessary gear reductions to
swing the machine.
The reducer is equipped with a dry disc,
spring set, hydraulically released brake Figure 80-1. Swing Reducer
with a hydraulic override. The brake is Installation
spring set when the machine is shut
down or if the machine will be idle for 1. Refer to Subsection 8B and remove
extended periods. The hydraulic over- the swing motor.
ride portion of the brake is actuated by
a foot pedal in the operator's cab and is 2. Tag and disconnect the hydraulic
used to stop swing motion while working lines attached to the swing reducer.
the machine. -
3. Install two lifting eyes (112-13 UNC)
The brake piston seals and the swing mo- in the motor mounting holes in the top of
tor can be serviced with the reducer in- the reducer.
stalled on the machine. All other swing
reducer service can best be accomplished 4. Attach a lifting device to the lifting
by removal and disassembly of the re- eyes. The swing reducer weighs approx-
ducer. imately 275 pounds.
5. Remove the hardware which secures
Removal the reducer to the upper frame and lift
the reducer from the machine.
To remove the swing reducer from the
machine, proceed as follows:

Subsection 8D 8D-1
Disassembly
To disassemble the swi ng reducer, pro- BLEEDER
ceed as follows (see Figure 80-11 on
page 80-7):
SWING
BRAKE

~; --- FITTING

cov~ ",,_1~~",,~",~
BREATHER
NOTE AND FILL

The following instructions describe

the procedu res for disassembly of
the swing reducer into subassem-
blies and assembly of the reducer
from these subassemblies. Refer
to the appropriate topic for the di-
sassembly and assembly of a par-
ticular subassembly.

1. Place the reducer in a holding tool as

shown in Figure 80-2.
NOTE

The holding tool can be fabricated

locally and is required to assemble
the reducer. Dimensions for the
tool are given in Figure 80-3.
MOUNTING DRAIN
CAPSCREW PLUG A2068

2. Remove plug (45) and drain the lubri-

cant from the reducer. The reducer Figure 80-2. Swing Reducer Assembly
holds approximately four quarts.
8. Lift input carrier (41) out of the ring
3. Turn adjusting screw (02) out (coun- gear. Disassemble the input carrier as
terclockwise) to remove the spring pres- described in the topic, Input Carrier, la-
sure from the brake. The screw shoulder ter in this subsection.
will bottom in the brake housing.
9. Use a sharp chisel to separate ring
4. Remove capscrews (59), then gently gear (39) from housing (53). Gently rap
rap the side of the brake housing with a
soft hammer to free the brake housing 8" I.D. (3/8" WALL) x 5" LG. TUBE
from cover (19).
5. Remove the piston assembly, springs /'0""""" THK PlATE
and adjusting screw from the brake hous- ..-~=""-~
ing. Disassemble the piston assembly by
removing retaining ring (10). Separate
the outer and inner pistons and discard
the 0- rings and backup rings.
6. Remove capscrews (20) from cover
(19) and pull the cover from bearing
support (32). Lift plate (23), the brake
disc assembly and dowel pins (31) from
the reducer.
7. Remove capscrews (57) and lift bear-
ing support (32) from the reducer. Pull
retaining ring (36) from pinion shaft
(33), then press the pinion shaft out of TACK WELD THREE (3) NUTS
bearing (35). Press bearing (35) and F232 INSIDE TO ENGAGE GEAR TEETH
seal (34) out of the bearing support.
Figure 80-3. Holding Tool Dimensions

80-2
on the chisel around the circumference of
the ring gear taking care not to damage
the mating surfaces of the ring gear or
housing.
10. Take output carrier (44) off output
shaft (54). Disassemble the output carri-
er as described in the topic, Output
Carrier, later in this subsection.
11. Remove stake nut (47) with the tor-
quing tool illustrated in Figure BD-4 on
page BD-4. Turn the nut in a counter-
clockwise di rection to loosen it.
12. Support housing (53) so that output
shaft (54) is free to move downward,
then rap the top of the output shaft with
a soft hammer to remove the output shaft
from bearing cone (49). Remove and dis-
card oil seal (46).
13. Inspect bearing cone (51) and if re-
placement is necessary, press the bear-
ing off shaft (54). Remove seal (52) if
the bearing cone is removed.
NOTE
Bearing cone (51) must be removed
before seal (52) can be replaced.
Take care not to damage the seal if
the bearing cone is not going to be
replaced.
Cleaning and Inspection
To clean and inspect the reducer, pro-
ceed as follows (see Figure BD-ll on
page BD-7):
1. Clean all parts in solvent and ai r dry.
2. Discard all O-rings, backup rings and
seals (34 and 46).
NOTE
Do not replace seal (52) unless the
seal has been damaged or has
shown signs of excessive leakage.
3. Inspect all machined surfaces for ex-
cessive wear or damage, replacing parts
as necessary.
4. Check all bearings for excessive
wear, pitting and galling.
5. Inspect springs (06 and 16) for signs
of warping, overheating and cracks.
6. Check brake disc (25) for warpage,
cracking and signs of overheating. Re-
place the disc if the lining on either side
of the brake disc is worn to within 0.015
inch of the metal disc.
Assembly
To assemble the swing reducer proceed
I
as follows (see Figure 8D-ll on page
8D-7) :
NOTE
Assembly of the swing reducer re-
quires the use of two special tools.
Dimensions are given in
Figure BD-3 on page 8D-2 and
Figure 8D-4 on page 8D-4 for fab-
rication of the tools. These tools
should be made up before attempt-
ing to assemble the swing reducer.
1. Assemble housing (53) subassembly as
follows:
A. Press bearing cups (4B and 50) into
housing (53). Be sure the cups are
pressed tight against the shoulders in
housing (53).
NOTE
Installation of the bearing cups is
easier if the cups are chilled be-
fore installation.
B. Press seal (52) onto shaft (54). When
properly installed the seal should be
flush to 0.030 inch beyond the shoul-
der on the shaft.
C. Press bearing cone (51) onto shaft
(54) until the bearing cone_ is tight
against the shoulder on the shaft.
Lubricate the bearing rollers after in-
stallation.
NOTE
The bearing cone may be heated
for installation. Use an oil bath or
oven to heat the bearing to a max-
imum of 300 0 F. Do not overheat
the bearing.
Swing Reducer BD-3
 2" NUT
NOTE

The force must be measured while

the housing is rotating. Use the
force required to keep the housing
moving, not the force required to
4" 0.0. x 4" LG. #95 TUBE start it moving.

TORQUING
TOOL

4-1/2" OIA. x 1/2" THK PLATE

3-1/4"1.0. /
I 'j
89::::
3/4"
!------i
:r"
___
3/S" OIA. x 3/4" LG. PIN
F233
Figure 80-4. Torquing Tool
D. Place housing assembly (53) over
output shaft (54) taking care not to
damage seal (52). Check to be sure
that bearing cup (50) rolls smoothly
on cone (51). SPRING HOLDING
SCALE TOOL A1785
E. Place the output housing assembly in
the holding tool illustrated in Figure 80-5. Adjusting Bearing
Figure 8D-2 on page 8D-2. Do not
tighten the housing holding capscrews H. Continue to tighten the stake nut whi-
at this time. The housing must be le checking the force necessary to ro-
free to rotate on bearing cone (51). tate the housing. Stop tightening the
stake nut when the force determined
F. Lubricate the rollers of bearing cone in the previous step is reached (19
(49) and press the cone onto shaft pounds in the example).
(54) until stake nut (47) can be
th readed on at least two th reads. I. Use a blunt ended tool to stake the
nut in th ree places equally spaced
G. Continue to press the cone on the around the nut (see Figure 8D-6 on
shaft by rotating the stake nut with page 8D-5). Take care not to frac-
the tool shown in Figure 8D-4. As the ture the staking ring on the stake
stake nut is tightened, rotate the nut.
housing and check the end play on
the bearing. As soon as 0.000 to J. Tighten the four capscrews in the
0.003 inch bearing end play is ob- holding tool to prevent housing (53)
served, check the force required to from moving during the remaining as-
rotate the housing using a spring sca- sembly steps.
le as shown in Figure 8D-5. Add 9
pounds (5 pounds for a used bearing) K. Carefully tap seal (46) into housing
to this number to determine the final (53) around the stake nut. Install
force required to rotate the housing plug (45) and fitting (55) if they
on the bearing. For example, if a have been removed.
force of 10 pounds is required to ro-
tate the housing when the rollers of 2. I nstall two dowel pins (40) if they
bearing cone (49) just begin to were removed du ri ng disassembly. Place
rotate, 10 pounds is added to 9 gasket (56) on housing (53) over the
pounds (5 pounds for a used bearing) dowel pins.
to give a final force of 19 pounds (15
pounds for a used bearing). 3. Set output carrier assembly (44) over
the splined output shaft. Install ring

8D-4
 ROUND
NOSE OUTPUT
PINION
GEAR

A1787
HOUSING
Figure 80-7. Pinion Gear
Installation
Figure 80-6. Staking Nut
B. Press seal (34) into bearing support
gear (39) over the output carrier gears (32) until the top of the seal is flush
and seat the ring gear against the with the top of the bearing support.
gasket.
C. Place pinion shaft (33) on a hard flat
NOTE surface with the output end facing
up. Set the bearing support onto the
I nstall the long gear teeth of the pinion shaft so seal (34) passes over
ring gear down to match the longer the shaft before bearing (35). Care-
teeth of the output carrier pinion fully tap or press on the inner race of
gears. bearing (35) until the bearing is fully
seated against the shoulder of the
pinion shaft. Press only on the inner
4. I nstall snap ring (42) on pinion gear
(43), then install the pinion into the the
output carrier gears as shown in PINION
SHAFT
Figu re 80-7.
5. Slide input carrier (41) over the out-
put pinion gear and into the ring gear.
Use pinion shaft (33) to align the pinion
gears of carrier (41) during installation
(see Figure 80-8).
6. I nstall two dowel pins (38) into the
ring gear if they were removed during
disassembly. Place gasket (58) on the
ring gear over the dowel pins.
7. Assemble bearing support assembly
(32) as follows:
A. Place bearing support (32) on a flat
surface and press or tap bearing (35)
into the support. Press only on the
outer race when installing the bearing
into the support.
Figure 80-8. Input Carrier
Installation

Swing Reducer 8D-5

 race when installing the bearing over BEARING PINION
the pinion shaft. I nstall retaining SUPPORT SHAFT
ring (36) on shaft (33) to secure the
bearing.
8. I nstall the bearing support assembly
onto dowel pins (38) making sure the fil-
ler opening is aligned with the drain
opening (see FiglJre 80-9). Secure the
bearing support to the ring gear with
capscrews (57) torqued to 50-55 ft-Ibs.
9. Assemble brake disc (25) to brake
hub (24) with capscrews (26). Torque
the capscrews to 22-24 ft-Ibs.
10. Slide the brake assembly onto pinion
shaft (33) with the capscrew heads in
the brake hub down.
11. Install two dowel pins (31) into bear-
ing support (32) and place brake plate
(23) over the pins. The brake plate must DRAIN
be installed with the flat side down PLUG A1789
against the brake lining (see
Figure 80-10). Tap two dowel pins (37)
into the bearing support. Figure 80-9. Bearing Support
Installation
NOTE
C. Lubricate O-ring (13) and backup
Check to be su re the plate slides ring (14) and install them on piston
freely on the pins to ensure prop- (15). Place spring (16) into the bore
er brake application. of piston (12) and then slide piston
(15) into piston (12) taking care not
to damage the O-ring or backup ring
12. Lubricate and install backup ring on piston (15). Press retaining plate
(18) and O-ring (17) into cover (19). (11) down on piston (15) and then in-
Place the cover over dowel pins (31 and stall retaining ring (10).
37), gently rapping the cover in place
with a soft hammer if necessa ry. Secu re D. Lubricate O-ring (09) and backup
the cover to support (32) with capscrews rings (08) and install them into the
(20) torqued to 22-24 ft-Ibs.
PINION
SHAFT COVER
13. Assemble the brake housing and pis-
ton assembly as follows:
A. Lubricate O-ring (04) with reducer
lubricant and install on adjusting
screw (02). I nstall the adjusting
screw into housing (05) making sure
the adjusting screw is bottomed in the
brake housing.
B. Set the housing so the open end is up
and install brake springs (07). The
first spring goes in with the concave
side up, followed by the second
spring with the concave side down.
Continue to install the springs, alter-
nating each one until all five are
installed as shown in Figure 80-11 on A1790
page 80-7.
Figure 80-10. Cover Installation

80-6
 01. SWING REDUCER
~02 r- ------l
I
I
02.
03.
04.
ADJUSTING SCREW
SETSCREW
O-RING
H /08 j
27
I
I

05. BRAKE HOUSING @?--04 ~ 28

1
J1/1
06. BLEEDER FiniNG
~07 '--:.3~1
07.
OS.
BELLEVILLE SPRING
BACKUP RING
/ ,D __ 32 (:>--46
/~08
09. O-RING 29 I \
10. RETAINING RING 130
11. RETAINING PLATE I
12. BRAKE PISTON 09 ~-
_ 10
11 I ~47
13.
14.
15.
O-RING
BACKUP RING
BRAKE PISTON
-13
8.- - - 114 9---- 35 ~
@ ____ 49
16. SPRING 5
17.
1S.
19.
O-RING
BACKUP RING
COVER 59
~ _ _ 16
§ __ 48

20. CAPSCREW 0_ _ 40
21.
22.
23.
24.
25.
26.
COVER PLATE
CAPSCREW
BRAKE PLATE
BRAKE HUB
BRAKE DISC
CAPSCREW
~
(0_ J__---- 38

58
~----

53

27. VENT
I ~~
22 61

b
rfi '
2S. ELBOW 03
29. PIPE NIPPLE 21 0 0

30. BUSHING ,:..../?l/ 0

31. DOWEL PIN

C1a/~-(). -.------~- 19
! I - _--39

J
32. SUPPORT t C"')"
33. PINION SHAFT a 'I<:::::>' -~ ~ ... I I
34.
35.
SEAL
BEARING
~ €-~
I\. ~/ ~/ - - .' ~
/ 1
\~
~//
,
I
36. RETAINING RING i I Cg--- 42
u

~
37. DOWEL PIN 62
3S.
39.
40.
41.
DOWEL PIN
RING GEAR
DOWEL PIN
INPUT CARRIER ,
1
1
~~]
/"'~
,----43
0_ 52

42.
43.
44.
RETAINING RING
OUTPUT PINION GEAR
OUTPUT CARRIER
•
)
(g)-56
45. PLUG 60
46. SEAL 54
47. STAKE NUT
4S.
49.
BEARING CUP
BEARING CONE
r
50. BEARING CUP I
51. BEARING CONE I 1_---44
52. SEAL
53. HOUSING
54. OUTPUT SHAFT
@A--26 :
55. LUBE FiniNG
56.
57.
5S.
GASKET
CAPSCREW
GASKET
33-----ffilhl :
59.
60.
61.
CAPSCREW
GASKET
GASKET
W--@ I
:I
I
L ________ IJ i I
62. GASKET -- ____ - - - - - - - _J

Figure 80-11. swing Reducer (9353J8)

54 52

Swing Reducers 8D-7

 brake housing as shown in 16. Pump grease (P&H 472) through fit-
Figure 80-11 on page 80-7. Careful- ting (55) until grease appears at the re-
ly slide the piston assembly into the lief hole on the opposite side of the
brake housing. housing.
E. Slide 0- ring (09) over the bottom of
the brake housing. Place the brake
housing on the cover and carefully
insert the brake piston through the Input Carrier
cover past the O-ring and backup
ring. Secure the brake housing to the DISASSEMBLY. To disassemble the in-
cover with capscrews (59) torqued to put carrier, proceed as follows (see
22-24 ft-Ibs. Figure 80-12):
14. Adjust and test the brake as follows: NOTE

A. Place a 0.015 inch feeler gauge be- All parts in the input carrier must
tween the top brake disc and brake be replaced if any parts are defec-
plate (23). Access is gained th rough tive. A planetary pinion kit is
the opening behind cover plate (21) available if necessary. See the re-
in the cover. placement parts manual.
B. Loosen setscrews (03).
C. Turn adjusting screw (02) in (clock-
wise) until drag is felt on the feeler BEARING
gauge. Remove the feeler gauge and
tighten the adjusting screw an addi-
tional three and one quarter (3-1/4)
turns. Hold the adjusting screw and
tighten setscrews (03).
o. Install cover plate (21) and secure
with capscrews (22).
CAPSCREW
E. Attach a hydraulic pump to one of the
pressure ports on the brake housing.
Apply 2500 psi pressure and check
for a pressu re drop. There should be
a maximum pressure drop of 25 psi in
five minutes. There should be no vis- CARRIER
ual evidence of leaks around the
housing on top of the reducer or pis-
ton when observed th rough the disc THRUST F230
inspection port in the cover. WASHER

F. The brake torque must test between
1200 in-Ibs minimum and 1500 in-Ibs
maximum. If the initial setting is be-
low or above this range, reposition
adjusting screw (03) -- maximum of
one (1) turn in either direction -- un-
til the brake torque is within this
range.
15. Check to be sure plug (45) is in-
stalled and tight, then fill the reducer
with the amount and type of lubricant
specified in Section 3 through the fill
opening. I nstall bushing (30), pipe nip-
ple (29), elbow (28) and vent (27).
Figure 8D-12. Input Carrier
1. Remove the lock plate capscrews and
lock plates.
2. Pres s the pi n s out of the ca rrier. Re-
move the gears, thrust washers and
bearings.
NOTE
The pins must be pressed out to-
ward the lock plate side of the
carrier. The shaft bores on the
side opposite the lock plates are
smaller in diameter.

80-8
ASSEMBLY. To assemble the input car- SLOT
rier assembly, proceed as follows (see
Figure 80-12 on page 80-8):
,. Set the input carrier on a clean work
su rface with the lock plate up.
2. Place the carrier thrust washer in the
bottom of the carrier.
3. Lubricate the input planet bearings
with reducer lubricant and install them
into the planet gear bores. TAPPED
HOLE
4. Assemble a thrust washer to each side
of a gear and bearing assembly, then in-
stall the gear into the carrier. Press a
planet pin through the planet thrust
washer and bearing keeping the slot in GEAR
the pin in proper alignment with the
tapped holes in the carrier (see A1695
Figu re 80-13).
Figure 80-13. Input Carrier Pin
NOTE Insta 11 ati on
The bores are smaller on the oppo- NOTE
site side of the ca rrier, therefore
the pins must be installed from the The pins must be pressed out to-
lock plate side. ward the lock side of the carrier.
The shMt bores on the side oppo-
site the lock plates are smaller in
5. Install the lock plate and secure it diameter.
with a capscrew. Use Loctite No. 242 or
equivalent on the capscrew and torque it
to 30 ft-Ibs. ASSEMBLY. To assemble the output car-
rier assembly, proceed as follows (see

I
6. Repeat steps 4 and 5 for the other two Figure 80-14): PIN LOCKPLATE
gears.
~

~q~i
GEAR \

Output Carrier
DI SASSEMBL Y. To disassemble the out-
put carrier, proceed as follows (see
Figu re 80-14):
CAPSCREW
NOTE
All parts in the output carrier
must be replaced if any parts are
defective. A planetary pinion kit is
available if necessary. See the re-
placement parts manual.

1. Remove the lock plate capscrews and

lock plates.
2. Press the pins out of the carrier. Re- CARRIER
move the gears, thrust washers, bear-
ings and spacers.
F231
Figure 80-14. Output Carrier

Swing Reducer 80-9

1. Set the output carrier on a clean work
surface with the lock plates up.
CARRIER
2. Place the carrier thrust washer in the
bottom of the carrier.
3. Lubricate the output planet bearings
and spacers with reducer lubricant and
install them into the planet gear bores.
4. Assemble a thrust washer to each side
of a gear and bearing assembly, then in-
stall the gear into the carrier. Press a
planet pin through the planet thrust
washer and bearing, keeping the slot in
the pin in proper alignment with the
tapped holes in the carrier (see
Figure 8D-1S).
NOTE
The bores are smaller on the oppo-
site side of the carrier, therefore
the pins must be installed from the
lock plate side.
Figure 80-15. Output Carrier Pin
5. Install the lock plate and secure it Ins ta 11 at ion
with a capscrew. Use Loctite No. 242 or
equivalent on the capscrew and torque it with SAE 30 oil, install the hardened
to 30 ft-Ibs. . washers and capscrews and torque the
capscrews to 380 ft-Ibs.
6. Repeat steps 4 and 5 for the other two
gears. 3. Refer to Subsection 88 and install the
swing motor and connect all hydraulic
lines to the motor and reducer.
Reducer Installation 4. Refer to Section 3 and fill the reducer
with the specified lubricant.
To install the swing reducer after over-
haul, proceed as follows: 5. Operate the swing system, to check
the swing reducer operation. Purge air
1. Install the lifting eyes in the swing in the spring set portion of the swing
reducer and lift the reducer into position brake by engaging and releasing the
on the upper frame. Lower the reducer brake with the brake lock lever. Bleed
onto the upper so that the output shaft air from the override brake by applying
gear engages the slewing ring gear. pressure to the swing brake pedal in the
operator's cab while gradually opening
2. Align the reducer so that the drain the bleeder screw on the brake cylinder
and fill ports are facing away from the housing. Securely tighten the bleeder
upper. Lubricate the mounting capscrews screw when all has been pu rged.

8D-1O
 SUBSECTION BE
SLEWING RING
GENERAL
This subsection describes the slewing
ring (rim) assemblies and includes the
removal and installation procedures for
the slewing ring.
CAUTION
Replacement of the slewing ring
assembly is a critical and precise
procedure and must not be at-
tempted during the warranty peri-
od without factory supervision.
Any attempt to remove the slewing
ring without factory supervision
will void the warranty.
The procedures described below are pro-
vided to aid in the removal and installa-
tion of the slewing ring after the
warranty period has expired. It is,
however, recommended that a factory re-
presentative be contacted prior to
attempting these procedures.
SLEWING RING (lR13)
Description
The slewing ring (rim) assembly is the
large ring gear and bearing assembly lo-
cated between the upper and lower sec-
tions of this machine. The engagement
of the swing shaft pinion in the slewing
ring gear provides the means of driving
the swinging motions of the machine.
As shown in Figure BE-1 on page BE-3,
an arrangement of ball bearings is in-
stalled between the inner and outer ring,
to provide a rolling support of the inner
ri ng and upper frame. Th ic:; roller sup-
port allows the upper to rotate (swing)
360 0 right or left in relation to the lower
frame. Seals are provided at the top and
bottom of the slewing ring to prevent
contamination entry into the bearings.
The outer ring of the slewing ring as-
sembly (the swing gear) is bolted to a
ring tub which is welded to the lower
frame of the machine; and the machine's
upper frame is bolted to the inner ring.
Grease fittings are provided to the inner
ring to allow periodic lubrication of the
ball bea rings, (see Lubrication Section).
Repair
The slewing ring is not a repairable
item. If there has been bearing or struc-
tural failure, the slewing ring must be
replaced as a complete unit.
Removal
To remove the slewing ring, proceed as
follows:
1. Move the machine onto firm level
ground and block the lower so that it will
not move while the upper is being re-
moved. Position the boom over the front
of the machine.
2. Shut the machine down and disconnect
the battery cable from the negative ter-
minal of the battery.
3. Disconnect the upper from the lower
at the swivel as follows:
A. Tag and disconnect all of the lower
hydraulic and air lines from the lower
to the swivel stem. I nstall caps and
Subsection BE BE-1
 covers on the hydraulic lines and
ports to prevent contamination of the
hydraulic system.
B. Tag and disconnect all of the elec-
trical connectors that extend from the
bottom of the swivel.
4. Loosen the 34 capscrews wh ich secu re
the slewing ring to the upper frame in
equal steps starting with two capscrews
180 0 apart then the next two capscrews
180 0 apart but 90 0 displaced from the
first two capscrews. Follow this pattern
until all 34 capscrews are loose to pre-
vent distortion of the slewing ring. Then
remove the 34 capscrews.
CAUTION
To ensure that the upper does not
shift or fall while removing the
slewing ring assembly, be very
careful in the placement of block-
ing and the removal and discon-
nection of the mounting hardware
and fittings between the upper and
lower sections of the machine.
5. Remove the upper from the lower.
6. Remove the 30 capscrews securing the
slewing ring to the lower and remove the
slewing ring from the lower.
Installation
To install a new slewing rIng, proceed as
follows:
1. Clean the mounting su rface of the
ring tub to remove any dirt or grease.
2. Position the slewing ring assembly on
the rin$, tub with the stamped word
"FRONT' on the ring gear (outer racer)
facing the working front of the carrier
(the end opposite the cab).
NOTE
The stamped words "FRONT" on
the inner and outer races should
be 180 0 apart when the machine is
in the transport mode.
8E-2
3. Lubricate the mounting bolts with SAE
30 oil before installing and finger tight-
ening them.
NOTE
The word "FRONT" stamped in the
outer race must be positioned on
the rear of the carrier.
4. Tighten two bolts 180 0 on the outer
race to 270 ft-Ibs.
5. Tighten two more bolts 180 0 apart and
90 0 from the fi rst bolts to 270 ft-Ibs.
Continue this pattern until all 30 bolts
are tightened.
6. Return to the first bolt tightened and
using the same tightening pattern, tight-
en the bolts to 800 ft-Ibs.
7. I nstall the dowel pin in the hole in the
inner race of the slewing ring. Position
the machine upper onto the slewing ring
(lower) so that the dowel pin engages
the dowel pin hole in the upper.
NOTE
The front of the upper frame (the
boom end) should now align with
the word "FRONT" stamped on the
slewing ring inner race.
8. Lubricate all of the mounting bolts
with SAE 30 oil. I nstall and tighten the
bolts finger tight. Torque the bolts as
follows:
9. Tighten two bolts 180 degrees apart to
270 ft-Ibs.
10. Tighten two bolts 180 degrees apart,
and 90 degrees from the first two bolts
to 270 ft-Ibs.
11. Continue this cross bolting pattern
until all of the bolts have been torqued
to 270 ft-Ibs.
12. Return to the first bolts tightened
and begin retightening the bolts in the
same pattern to to 800 ft-Ibs.
13. Connect all hydraulic and air lines to
the ports in the swivel stem. Make sure
that all applicable O-rings are installed.
Tighten all connections evenly to prevent
distortion.
 LUBE
FITTINGS

BASE PLATE
UPPER FRAME

DOWEL
PIN

SECTION "A-A"

Figure 8E-I. Slewing Ring Installation

Slewing Ring BE-3

14. Connect the electrical connectors at
the end of the harness extending from
the swivel to the mating connectors in
the lower.
15. Add hydraulic oil to the hydraulic
reservoir to bring the level to the full
mark on the dipstick and lubricate the
slewing ring with grease, refer to Sec-
tion 3 of this manual for Lubrication Spe-
cifications.
16. Remove blocking as necessary, then
connect the negative battery cable to the
battery and start the engine.
17. Operate the various machine func-
tions slowly, while checking the swivel
for leaks. Then operate the various sys-
tems of the machine for several minutes
8E-4
to allow air to be purged from the vari-
ous hydraulic lines, and check the
operation of all hydraulic, air and elec-
trical components.
18. Swing the upper for several minutes,
then check the swivel for leaks.
19. Check the hydraulic reservoir and
fill as necessary to bring the hydraulic
oil to the proper level.
NOTE
The slewing ring capscrews should
be checked for proper tightness
after 800 hou rs of operation and
then checked every 200 hours
thereafter to ensu re proper slew-
ing ring tightness.
 TABLE OF CONTENTS

Subsection 9A 9A-1
Introduction 9A-1
General ...... . 9A-1
Testing For Serviceability 9A-1
Ai r System Description 9A-2
Ai r Schematics 9A-3
Subsection 9B 9B-1
Air Compressors 9B-1
General 9B-1
Air Compressor 98-1
Description 98-1
Operation . 9B-1
Service Checks 98-2
TrQubleshooting 98-2
Removal 98-2
Installation 98-2
Subsection 9C 9C-1
Air System Components 9C-1
General ..... 9C-1
Governor (36Z1283) 9C-1
Description 9C-1
Governor Service 9C-2
Installation 9C-4
Adjustment . 9C-5
Safety Valve (36Z1153) 9C-5
Ai r Reservoi rs 9C-6
Brake Valve (36Z225) 9C-7
Description 9C-7
Maintenance 9C-7
Removal 9C-7
Overhaul 9C-7
Installation ..... 9C-7
Dual Brake Valve (36U373) 9C-7
DESCRIPTION. 9C-7
Maintenance 9C-7
REMOVAL. . 9C-8
INSTALLATION. 9C-8
Relay Valve (36U330) .. 9C-8
Spring Brake Valve (36Q192) 9C-9
Th rottle Control Valve (36U322) 9C-n
Throttle Control Valve (36U29) 9C-14
Throttle Cylinder (38U107) .. 9C-16
Parking Brake Control Valve (36Q483) 9C-18
Subsection 90 90-1
Brake Chambers 90-1
General 9D-1

Contents
 LIST OF ILLUSTRATIONS

Figu re 9A-l. Ai r Schematic ...... . 9A-4

Figure 9C-l. Governor (36Z1283) ... . 9C-l
Figure 9C-2. Governor Assembly .... . 9C-3
Figu re 9C-3. Adjustment Screw Measu rement 9C-4
Figure 9C-4. Safety Valve (36Z11S3) 9C-6
Figure 9C-S. Brake Valve (36Z22S) 9C-8
Figure 9C-6. Dual Brake Valve (36U373) .. 9C-8
Figure 9C-7. Carrier Relay Brake Valves (rear) 9C-l0
Figure 9C-8. Carrier Relay Brake Valve (front) 9C-l0
Figure 9C-9. Rear Brake Valve Plate ..... 9C-ll
Figure 9C-1O. Throttle Control Valve Operation 9C-12
Figure 9C-ll. Throttle Control Valve Assembly 9C-13
Figure 9C-12. Throttle Control Valve (36U29) 9C-1S
Figure 9C-13. Throttle Control Valve Assembly 9C-16
Figure 9C-14. Throttle Cylinder (38U107) .. 9C-17
Figure 9C-1S. Parking Brake Control Valve (36Q483) 9C-19

List of Illustrations iii

 LIST OF TABLES

Table 9A-1. Air and Brake System Troubleshooting 9A-3

Table 9B-1. Compressor Troubleshooting .... 9B-2

List of Tables v
 SUBSECTION 9A
INTRODUCTION
GENERAL
Section 9 of this manual is divided into
subsections that describe major compo-
nents of the air systems of this machine.
The subsections also include recom-
mended removal, service and installation
procedu res.
This subsection describes the machine
air system and includes an operational
description of the systems that use ai r.
This subsection also includes general in-
spection and troubleshooting procedures
for the ai r and brake systems. Compo-
nent inspection and repair procedures
are covered in the individual
subsections.
TESTING FOR SERVICEABILITY
To ensure that the brake system is func-
tioning properly and to aid in scheduling
brake system service, a systematic meth-
od of checking the serviceabilty of the
system must be employed to be sure that
all parts of the system are inspected.
The procedure outlined below is one such
method (refer to Table 9A-1 on page
9A-3) .
WARNING
Do not use the brake system to
hold the machine while performing
the following tests. Hold the ma-
chine by blocking the wheels with
wheel chocks.
l. DRAIN AIR TANKS. Charge the air
brake system. Open the drain cocks on
each air tank. Close the drain cocks af-
ter all devices have been completely
drained of all air pressure and condensa-
tion.
2. CHECK STOP LIGHT SWITCHES. With
no air pressure in the system, start the
engine and depress the carrier brake
pedal. Observe the dash gauge pressu re
when the stop lights light up. Release
the brake pedal and the stop light should
go out. Repeat this step in the operating
cab.
3. CHECK BRAKE CHAMBER PUSH ROD
TRAVEL. Apply the brakes and check
the push rod travel of each rear brake.
Adjust if the stroke is excessive.
4. CHECK LOW AI R PRESSURE LIGHT
AND ALARM. Run engine, continuing
pressure build-up. Low pressure light
must remain lit and the alarm must
sound, until the dash gauge pressu re
reaches approximately 60 pounds (4.13
bars), at which point the light should go
out and the alarm should stop sounding.
5. PRESSURE BU I LD-UP TEST. Run the
engine at fast idle. The time required to
raise the air pressure from 50 to 90
pounds (3.44-6.20 bars) will vary, but
should not exceed 5 minutes.
6. GOVERNOR SETTI NG TEST. Run the
engine, the governor should - cutout,
stopping further compression at approx-
imately 120 pounds. Reduce air pressure
by making a series of brake applications.
The governor should cut in, resuming
compression, at approximately 105
pounds.
7. LEAKAGE TEST. Run the engine until
the governor cuts out. Stop the engine.
Wait until the air pressure stabilizes.
With the brakes released, dash gauge
pressure drop should not exceed 2
pounds per minute (0.13 bars/min).
Subsection 9A 9A-1
Make a full brake application and hold it.
Allow the pressure to stabilize. Pressure
drop should not exceed 3 pounds per mi-
nute (0.20 bar/min). Check system con-
nections and applicable devices if leakage
in either test is excessive.
8. OPERATING TESTS. Connect accurate
test gauges to the treadle valves deliv-
ery lines. Fully charge the air system.
Depress the treadle valve fully. Test
gauge pressures should approximately
equal dash gauge pressu res. Hold the
pedal in several different positions; de-
livery should vary rapidly in accordance
with change in pedal position. Check for
quick application and release of all
brakes.
A.. With the engine stopped, reduce the
pressure in the air system to approx-
imately 40 psi (2.76 bars) by making
a series of brake applications. The
parking brake valve should automat-
ically shift to the park position when
the pressure drops below 40 psi (2.76
ba rs). Check the rear bra kes to be
sure they are in the applied position
when the parking brake valve is in
the park position.
B. Fully charge the air system; then
drain the air pressure from the pri-
mary air tank. Depress the treadle
valve and observe the rear brakes.
The rear brakes should apply when
the treadle valve pedal is depressed
and should release when the pedal is
released.
AIR SYSTEM DESCRIPTION
Compressed ai r for the operation of the
brake system is supplied by an engine
driven air compressor, and is stored in
two reservoirs on the machine. The air
reservoi rs are connected and protected
by check valves, in such a fashion as to
isolate the reservoirs serving the front
brakes from the reservoi rs serving the
rea r bra kes.
A governor, mounted on the air compres-
sor, senses the pressu re of the ai r in
the reservoirs, and controls the com-
pressor output. Compression starts when
the pressure drops to approximately 105
psi (7.24 bars) and is stopped by the
governor when it reaches approximately
120 psi (8.27 bars).
9A-2
This machine is equipped with dual air
brake system which serves three func-
tion. These functions are service
brakes, parking brake and emergency
bra kes. The operation of ea'ch of these
sUbsystems as well as the air throttle
and transmission shifting systems are
described below.
SERVICE BRAKES. Supply air from the
front and rear brake reservoirs is avail-
able at the lower cab brake treadle valve
at all times. When the operator depresses
this brake treadle, air from each reser-
voi r passes th rough the respective valve
segment in the treadle valve to the front
and rear relay valves, which admit air to
the front and rear service brake cham-
bers. Air pressure in the brake
chambers forces the brake shoes apart,
placing them in contact with the brake
drums, and braking force is applied to
the wheels. Inasmuch as the air pressure
delivered to the brake chambers is con-
trolled by the treadle valve, the driver,
by operating the treadle valve and con-
trolling the air press.ure delivered to the
brake chambers, also controls the brak-
ing force being developed.
NOTE
Since the lower cab service brake
system is served by two isolated
air supply systems, the loss of air
pressu re in one system will not
disable the other brake system. If
air pressure is lost in the front
brake system, the front brakes
will not apply but, the rear brakes
will. If air pressure is lost in the
rear brake system, the front
brakes will apply in the normal
manner and the rear spring brakes
(also called parking brakes) will
apply in a modulating manner
through the spring brake valve.
Supply air from the rear brake reservoir
is available at the upper cab brake trea-
dle valve at all times. When the operator
depresses this brake treadle, air from
the rear reservoir passes through the
treadle valve to the front and rear relay
valves, which admit ai r to the front and
rear service brake chambers. Air pres-
sure in the brake chambers forces the
brake shoes apart, placing them in con-
tact with the brake drums, and braking
force is applied to the wheels. Inasmuch
as the air pressure delivered to the
brake chambers is controlled by the
treadle valve, the driver, by operating
the treadl€ valve and controll i ng the ai r
pressure delivered to the brake cham-
bers, also controls the braking force be-
i ng developed.
The relay valves are provided in the
brake system to speed up the application
and release of the brakes. The relay
valves operate as pilot controlled brake
valves, delivering air directly from the
reservoi rs to the brake chambers. The
relay valve serving the front brakes,
supplies air directly from the front brake
reservoir, while the relay valves serving
the rear brakes supply air from the rear
brake reservoir.
The pressure delivered to the brake
chambers, by the relay valves, is direct-
ly proportional to the pressure delivered
to the relay valves by the treadle
valves. The relay valves vent the ai r
pressure from the brake chambers
locally, making it unnecessary for the air
to travel back, through the air lines, to
the brake treadle valve. This speeds up
the release of all the brakes.
PARKING BRAKES. By pulling a parking
brake control knob outward, the opera-
tor can use the rear spring brakes as
parking brakes. Pulling out a parking
brake control knob cuts off pressure to
the parking brake valve, which in turn
vents the pressure from the spring
bra ke chambers of the rea r bra kes.
Venting the spring brake chambers al-
lows the power springs to expand and
apply the rear wheel spring brakes.
The rear wheel spring brakes will remain
set until air pressure is reapplied to the
spring brake chambers, compressing the
power springs and releasing the brakes.
Depressing a parking brake knob applies
air pressure to the spring brake valve,
which delivers air to the parking brake
relay valve. Air pressure in the spring
bra ke chambers compresses the power
springs, releasing the rear wheel
brakes.
EMERGENCY BRAKES. The purpose of
the spring brakes is to provide parking
brake and a means of stopping the vehi-
cle in the event that air pressure is lost
or drops below the minimum level when
the vehicle is in motion.
The parking brake control valve func-
tions automatically as well as manually. If
the air pressure in the entire air system
drops to 40 psi (2.76 bars), or less, the
spring within the valve will overcome the
force appl ied to the pi unger of the
valve, and the spring will shift the valve
to the applied position. This will vent
the pressure from the parking brake
valve, which vents the parking brake re-
lay valve. Venting the pressure from the
parking brake relay valve will allow the
air pressure in the spring brake cham-
bers to escape, allowing the power
springs to apply the rear wheel spring
brakes.
If the brakes are applied in the above
manner, they will remain in the applied
position until the cause of the pressure
loss is repaired, and normal pressure is
restored.
If pressure to the rear reservoir drops
while the carrier is transporting, the
spring brake valve will act as a modlat-
ing valve and supply a limited amount of
front reservoir air to the spring brakes
enabling them to be used as service
bra kes.
TH ROTTLE SYSTEM. The engine th rottle
is ai r operated. The engi ne th rottle ai r
cylinder can be regulated from foot ped-
als located in the carrier and the upper
cabs. To operate the engine th rottle from
the upper cab, the th rottle control valve
(located in the lower cab) must be placed
in the UPPER position.
A no air warm-up cylinder IS also at-
tached to the air throttle. This cylinder
uses a power spring to advance the
th rottle when no ai r pressu re is
available. As the engine runs enough to
produce a supply of compressed air, air
pressure counteracts the spring located
inside the no air warm-up cylinder and
thereby decreases engine speed.
AXLE LOCKOUT SYSTEM. Electric sole-
noid valves shift to deliver air to engage
and disengage the axle differential lock-
outs.
AIR SCHEMATICS
The air schematic shown in Figure 9A-l
on page 9A-4 illustrates the air systems
for both the upper cab and the machine
carrier.
Introduction 9A-3
 INTER·AXLE
DIFF LOCK DIFF LOCK GAUGE
WITH AXLE 121 WITH AXLE LOWER CAB
AIR THROTTLE

MAIN
WINCH
2·SPEED

PR4 PRESSURE
SOLENOID VALVE INTER·AXLE PROTECTION VALVE r- ___ ,
DIFF.LOCK DIFF.LOCK as PSI C, 1
WITH AXLE (2) WITH AXLE
~~~----~ I
~-!J ~-- I PARKING BRAKES
I
I
CONTROL VALVE
PP5
I
r-----------J
1 AUXILIARY
I SWIVEL SWIVEL
1 L ____________________ ~

1
1

~ r--- --------+-------------------------, III

,
AIR HORN
I
I II
BRAKE LIGHT
VALVE
r ' ----------------------------------~- ------------------------rm SWITCH
6~ : I
~
I 1 BRAKE LIGHT 1
I
I
I
1
:
I
1
I
I
,--------
I PARKING
. SWITCH I :
1
I
I
I

I I BRAKE LIGHT I
I ________ A- __ J SWITCH I
I-r~
I
I I
I
--------4
I
GAUGE GAIJGE
I --- -
-~
--------+---<Q~+- 1
I 'I ;_1 -1 I'
1
I
LOW PRESSURE LOW PRESSUREf>J I o :: I 1
INDICATOR
_~ I

:J-_J
INDICATOR I

r~
BRAKE

fl- I
I ___
1
I
I RELAY VALVE
I REAR SERVICE
---1
I
LIGHT
SWITCH

I I RELAY VALVE VALVE RELAY VALVE I R14 I

I I FRONT SERVICE REAR EMERGENCY IL...- _ _ _ _ _ _ _ _ _ I
~

R14 R14
I I
I I AIR VALVE 9336J67F1
45 AIR VALVE S . A
I I SER 9336J66F1

I I
I I FRONT BRAKE
CHAMBERS REAR BRAKE
L _________W- _
AXLE
_ 141_ _ _ _ _ _ _ _ _ _ _ CHAMBERS WI AXLE 141
-------,
I
DUAL BRAKE ,
I
TREADLE VALVE
E6
r-------,
I 1
I I
SAFETY VALVE I
150 PSI
----1
I SHUTTLE VALVE 13)
I
L_____ .:..-, _____ -.!I
,LOWER) PARKING BRAKES
CONTROPL VALVE

GOVERNOR
100-120 PSI

Figure 9A-l. Air Schematic

9A-4
INDICATION POSSIBLE PROBLEM
Air pressure will not rise to Defective air gauge (regi steri ng
normal. incorrect 1y) .
Excessive leakage.
Reservoir drain cock open.
Governor out of adjustment.
No clearance at compressor unloading valve.
Defective compressor.
Air pressure rises to normal Excessive leakage.
slowly.
Clogged compressor air strainer.
Engine speed too slow.
No clearance at compressor unloading valve.
Compressor discharge valves leaking.
Worn compressor.
Excessive carbon in compressor cylinder head
or discharge line.
Air pressure rises above nor- Defective air gauge (registering
mal. incorrectly).
Compressor governor out of adjustment.
Defective compressor governor.
Restriction in line between governor and com-
pressor unloading mechanism.
Too much clearance at compressor unloader
valves.
Unloading valve cavities or unloading passage
in compressor cylinder head blocked with car-
bon.
Compressor unloading valves stuck closed.
Air pressure drops rapidly Leaking brake treadle.
with engine stopped and brakes
released. Leaking tubing or hose line.
Compressor discharge valve leaking.
Compressor governor leaking.
Excessive leakage elsewhere in the air
system.

Table 9A-l. Air and Brake System Troubleshooting (Part 1 of 3)

Introduction 9A-5
 INDICATION POSSIBLE PROBLEM
Air pressure drops rapidly Leaking brake chamber.
with engine stopped and brakes
applied. Leaking brake treadle.
Leaking tubing or hose line.
Safety valve blows off. Safety valve out of adjustment.
Air pressure in the Air System above normal.
Excessive oil or water in the Reservoirs not being drained often enough.
air system.
Compressor passing excessive oil.
Compressor air strainer dirty.
Compressor knocks continuously Defective compressor drive.
or intermittently.
Backlash in drive gears or drive coupling.
Worn or burnt out bearings.
Excessive carbon deposits in compressor cyl-
i inder head. 1

Insufficient brakes. Brakes need relining.

Brakes apply slowly.
Brakes release slowly.
Low air pressure in the brake system (below
80 psi).
Brake valve delivery pressure below normal.
Low air pressure in the brake system (below
80 psi).
Brake treadle delivery pressure below normal.
Excessive leakage with brakes applied.
Restricted tubing or hose line.
Defective brake rigging (at wheel).
Brakes need adjusting.
I

Brake treadle not returning to fully released I

position. -I
Restricted tubing or hose line.
Exhaust port of brake treadle restricted or I
plugged.
Defective brake treadle.
I
Table 9A-l. Air and Brake System Troubleshooting (Part 2 of 3)

9A-6
INDICATION
Brakes do not apply.
Brakes do not release.
POSSIBLE PROBLEM
No air pressure i~ brake system.
Restricted or broken tubing or hose line.
Defective brake treadle.
Brake rigging binding.
Brake treadle not in full released position.
Defective brake treadle.
Restricted tubing or hose line.

Brakes grab. Grease on brake lining (reline brakes).

Brake drum out of round.
Brake rigging binding.
Uneven brakes. Brakes need adjusting or relining.
Grease on brake linings (reline brakes).
Brake shoe release spring broken.
Brake drum out of round.
Brake converter diaphragm leaking.

Table 9A-l. Air and Brake System Troubleshooting (Part 3 of 3)

Introduction 9A-7
 SUBSECTION 9B
A I R COMPRESSORS
GENERAL
This subsection describes the operation
of this machines air compressor and in-
cludes service checks, removal, and in-
stallation procedures for the air
compressor.
A I R COMPRESSOR
Description
The air compressor used on this machine
is a single stage, reciprocating piston
type compressor with two cylinders and
pistons. The compressor is water cooled
and engine oil lubricated.
The function of the air compressor is to
build up and maintain a supply of com-
pressed air in the machines air system,
at a pressu re that will operate the ai r
operated devices on the machine.
The air compressor location varies on the
individual machines due to the various
engine options, etc.
Operation
GENERAL. The air compressor is driven
continuously by the machine engine.
But, the compression of air is stopped
and started as required depending on
the minimum and maximum setting of an
air system governor which senses the air
pressure stored in the air system reser-
voirs.
COMPRESSION. When the reservoir air
pressu re is below, or if it drops to, the
governor minimum setting, the compres-
sor inlet valves are allowed to open and
shut as the compressor pistons go
through intake and compression cycles as
follows.
During the down stroke of each piston,
air is drawn into the cylinder through an
inlet valve in the cylinder head. As
each piston begins an upstroke, the inlet
valve closes and the air above the piston
is compressed. When the air pressure in
the cylinder becomes greater than the
discharge valve spring pressure and air
pressure above the discharge valve, the
discharge valve is forced off its seat.
The compressed ai r passes th rough the
discharge valve into the discharge line
and onto the ai r system reservoi rs.
As the pistons reach the top of their
strokes and start down, the discharge
valve springs retu rn the discharge
valves to their seats, and the inlet
valves open again. The seating of the
discharge valves prevent the compressed
air in the discharge lines from returning
to the cylinder as the intake and com-
pression cycles are repeated.
NON-COMPRESSION. The air compres-
sor's compression cycle stops when the
air pressure in the air system reservoir
reaches the maximum setting of the gov-
ernor, and the governor allows ai r from
the reservoi r to pass back th rough the
governor and into the cavity beneath the
compressor unloader pistons. The un-
loader piston plungers are lifted by the
unloader pressure forcing the compres-
sor inlet valves off their seats. With the
inlet valves held off their seats, air is
pumped back and forth between the two
cylinders and not compressed.
When the governor senses the ai r tan k
drop to the minimum pressure the air is
vented from under the unloader pistons
and spring pressure releases the unload-
er plungers and allows the inlet valves to
Subsection 9B 9B-1
retu rn to thei r seats. Compression is
then resumed.
Service Checks
INSPECTION. The following service
checks should be performed periodically
to ensu re proper operation of the ai r
compressor.
WARNING
Do not use the brake system to
hold the machine while testing or
working on the air system. Hold
the machine by blocking the wheels
with wheel chocks.
1. It is of utmost importance that the
compressor is taking in clean air. Check
the air filter often to ensure the filter
element is clean, if required clean or re-
place the filter element. Be sure the
compressor intake is air tight and that
the connections are tight.
2. Check the compressor mounting to be
sure it is secure.
3. Inspect the oil supply and return
lines. Be su re the compressor is getting
the proper supply of oil, and just as im-
portant, that the oil is returning to the
engine properly.
4. Check the coolant lines to and from
the compressor for any loose or damaged
connections.
AIR LEAKAGE TEST. Leakage past the
discharge valves can be detected by re-
moving the discharge line, applying shop
air back through the discharge port, and
listening for escaping air. Also the dis-
charge valves and unloader pistons can
be checked for leakage by building up
the air pressure until the governor cuts
out, then stopping the engine. While the
engine is stopped, carefully listen for
escaping air at the intake. If leakage is
noted, apply a soap solution around the
unloader pistons to pinpoint the leakage.
If there is no noticeable leakage at the
unloader pistons, the discharge valves
may be leaking.
98-2
Troubleshooting
Table 9B-1 is prov'ided to aid the me-
chanic troubleshoot possible problems
with the ai r compressor. It is recom-
mended that the mechanic become thor-
oughly familiar with the air system by
studying the schematic in Subsection 9A
before attempting to troubleshoot the air
compressor.
Removal
These removal instructions are general
and apply to compressors mounted on all
engines even though the location and
compressor drives may differ.
To remove the compressor from the en-
gine, proceed as follows:
1. Drain the air from the air system, by
opening the reservoir drain valves.
2. Drain the engine cooling system and
compressor cylinder head and block.
3. Disconnect all air, coolant and oil
lines to and from the compressor.
4. Remove the compressor mounting
bolts. Then remove the compressor from
the engine.
Installation
Installation of the air compressor is bas-
ically the reverse of removal. However,
to ensure proper performance of the
compressor, the following items should
be inspected before actually installing. it.
1. Check the oil supply line clean, and
prior to connecting this line run the en-
gine briefly to be sure oil is flowing free-
ly through the oil supply line.
2. If the compressor uses a mounttng
gasket, use a new mounting gasket when
installing the compressor. Ensure the
new gasket is properly aligned on the
compressor mounting flange.
3. If necessary, adjust the drive belt to
the proper tension.
 PROBLEM CAUSE/CORRECTION
Compressor fails to maintain Dirty intake filter.
, sufficient pressure.
Restriction in compressor cylinder head
intake, discharge cavities, or line.
Leaking or broken inlet or discharge valve.
Excessive wear.
Drive mechanism slipping.
Excessive system leakage or usag~.

Defective governor.
Worn unloader seals.
Noisy operation. Loose drive mechanism.
Restrictions in cylinder head or discharge
line.
Worn or burned out bearings.
Compressor not getting proper lubrication.
Excessive wear.
Compressor passes excessive Excessive wear.
oil
Dirty air compressor fi lter. I
High inlet vacuum. I
Small or restricted oil return is flooding the
compressor.
I
Excessive oil pressure.
I
Defective or worn oil seal in rear beari ng
cap.
Piston rings not properly in sta 11 ed.
i
Back pressure from engine crankcase. -
I
Compressor not unloading Defective unloader pins or seals.
(excessive pressure)
Defective governor.
Reservoir line to governor restricted.
Unloader mechanism binding or stuck.
I
Table 9B-1. Compressor Troubleshooting

Ai r Compressors 98-3
 SUBSECTION 9C

AIR SYSTEM COMPONENTS

GENERAL

This subsection descr-ibes various serv-

iceable ai r system components and in-
cludes recommended service procedures,
such as operational tests, adjustment and COVER

ADJusnNG~
repair procedures.

GOVERNOR (36Z1283) SCREW i\

Description
The air system governor is the control-
ling element of the machine air system
see Figure 9C-l The governor working
in conjunction with the air compressor
unloading mechanism, automatically main-
tains air pressure in the machine air sys-
tem between the desired, predetermined
maximum and minimum pressures.
The governor senses the build up or the
reduction of air pressure in the air sys-
tem reservoir through the reservoir
ports in the governor, (see
Figure 9C-l). In the governor the air
pressure change is felt by the inlet and
ex haust valve of the governor.
When the compressor is charging, the
pressure change acts against the inlet
valve and preset spring pressure, so
that when the maximum air pressure set-
ting is reached, the air pressure over-
comes the spring pressure and air is
passed through the valve and out the un-
loader ports to the air compressor
unloader mechanism. This pressure at
the unloader ports causes the compressor
to unload and stop compressing air. Al-
so, if the machine has an air dryer the
unloader pressure causes the dryer
pu rge valve to open.
ADJUSTING
SCREW
LOCKNUT
EXHAUST
PORT
·UNLOADER ...____~5F~~_J.JW/
PORTS
·RESERVOIR~~~====~~::~~
PORTS
Figure 9C-1. Governor (36Z1283)
The air compressor is driven continually
while the engine runs, but the actual
compression of ai r is controlled by the
governor. When the air pressure from
the system reservoir drops to the mini-
mum setting the air pressure at the
unloader port is allowed to exhaust to
atmosphere and the unloader mechanism
operates to allow the compressor to com-
press ai r again.
The charge cycle will continue until the
machine is shut down. The governor mi-

Subsection 9C 9C-l
nimum and maximum ai r pressu re settings
for this machine are 100 psi and 120 psi.
Governor Service
GENERAL. The following topic describe
the removal and installation procedu res
for the air system governor and includes
governor service procedu res. The fi Iter
service topic is a preventative mainte-
nance item. The operation test and leak-
age test are checks to be performed if
the governor is suspected of causing an
air system malfunction.
FILTER SERVICE. It is recommended
that the filters in the unloader ports and
the reservoi r ports be replaced every
th ree months or 900 hou rs of operation,
see Figu re 9C-2 on page 9C-3.
REMOVAL. To remove the governor,
proceed as follows:
1. If necessa ry, block the ca rrier
wheels.
2. Open the drain cocks at the bottom of
the air system reservoirs and drain the
air pressure from the system.
3. Disconnect the air lines from the inlet
and unloader ports, as necessary.
4. Remove the mounting bolts and remove
the governor from the machine.
DISASSEMBLY. It is recommended that
the governor be disassembled, cleaned,
inspected every 3000 operating hours as
follows, (see Figure 9C-2 on page 9C-3):
1. Remove the governor from the machine
as described in the topic, Removal.
2. Unscrew and remove top cover (01).
3. Remove spring assembly retaining
ring (02).
4. Remove the adjusting screw and
spring assembly consisting of components
(03 through 09) from the governor body.
5. If necessary, carefully unscrew lock-
nut (03) to relieve spring tension. Then
remove the upper spring seat (04),
spring (05), lower spring seats (06 and
08), and spring guide (07) from adjust-
ing screw (09).
9C-2
6. Remove exhaust stem (10), spring
(11), and washer (12) from the governor
piston and body.
7. Remove piston assembly (14), valve
assembly (17) and spring (18) from gov-
ernor body (19) by inverting and tap-
pi ng the governor body.
NOTE
Be careful not to drop the piston
assembly, as the piston assembly
along with the valve and spring
should slide out and drop free of
the body.
8. Remove grommets (15 and 16) from the
side grooves in piston (14) and remove
grommet (13) from the end bore of piston
(14) .
9. Remove spring (18) and valve assem-
bly (17) from the bore in piston (14).
10. If necessary, remove filters (20 and
21) from their associated ports in the
governor body.
NOTE
The filters will have to be replaced
with new filters if they are re-
moved.
11. Clean all parts of the governor in a
good cleaning solvent. Be particularly
careful that all ai r passages in the body,
exhaust stem, and piston are clean and
not obstructed.
12. Inspect all parts and replace exces-
sively worn or damaged parts. It is re-
commended that all rubber grommets
(O-rings) be replaced with new parts
ASSEMBLY. To assemble the governor
proceed as follows, (see Figure 9C-1 on
page 9C-3) :
1. Prior to assembly, lubricate the walls
of the inner half of body bore, the top
of piston and piston grooves, piston
grommets, pressure setting spring
guide, and adjusting screw with a lubri-
cant.
2. Assemble the piston assemble as fol-
lows:
 01 r-----i
I ~
I 10---
02 .~

05

06
18
01-

02---0
e l'
12
13
~
e
e
08 03 6) 15~
15
12

21
05-1
04-@

16
Q-'4
¢¢ : »
17 ~
~oe
17 18 14
G-07 18
1
01,
02.
03.
04.
05,
06.
07,
COVER
RETAINING RING
LOCKNUT
SPRING SEAT (UPPER)
SPRING
SPRING SEAT
SPRING GUIDE
12.
13.
14.
15.
16.
17.
1S.
19.
WASHER
GROMMET
PISTON
GROMMET
GROMMET
VALVE ASSEMBLY
VALVE SPRING
BODY
r09
©-08
20

I
~
~

21
OS. SPRING SEAT I
09, ADJUSTING SCREW 20. FILTER I
L _____ ...1I /
.'·
21. FILTER
10.
11.
EXHAUST STEM
STEM SPRING O."

Figure 9C-2. Governor Assembly
A. I nstall ex haust stem grommet (13) in
the groove in the stem bore of piston
( 14) .
B. Install valve assembly (17) in the
large bore of piston (14). Then install
spring (18) with its narrow end
against valve assembly (17). Press
spring (18) into the bore until the
large coil end snaps into the groove
in the piston bore.
C. Install new grommets (15 and 16) in
the outer piston grooves.
D. Position the exhaust stem spring (11)
over stem (10) and then install wash-
er (12) on stem (10).
E. Carefully, position the exhaust stem
assembly into the stem bore of piston
(14) making sure not to damage
grommet (13). Then push the stem in-
to the bore
3. Install piston assembly (14) into the
bore of body (19) starting with the
inlet-exhaust valve assembly end of the
piston in the bore.
F257
,4. Assemble the adjustment screw and
spring assembly by installing the bottom
lower seat (08), spring guide (07), lower
seat (06), pressure spring (05), upper
spring seat (04) onto adjusting screw
(09).
5. Screw spring seat (04) onto the ad-
justing screw, compressing the spring
until the dimension from the top of upper
spring seat (04) to the bottom of the ad-
justment screw (09) is approximately 1
7/8 inches, as shown in Figure 9C-3 on
page 9C-4. Then install locknut (03).
6. Ensure exhaust stem (10) and stem
spring (11) are in place in piston (14).
Then install the adjustment screw and
spring assembly into the governor body.
7. Install retaining ring (02) into the
body bore groove.
8. If necessary, install filters (20 and
21) in their associated bores, (see
Figu re 9C-2).
9. Screw top cover (01) on the adjusting
screw.

Ai r System Components 9C-3


STEM _ ___
UPPER
SPRING
SEAT
'·7/8
F258
Figure 9C-3. Adjustment Screw
Measurement
10. Mount the governor on a
suitable test
mount or on the machine and adjust the
governor for the proper pressu re cut out
and cut in pressures as described in this
subsection, see the adjustment topic.
11. Perform operation and leakage tests
as described in this subsection.
Installation
To install a new or serviced governor,
proceed as follows:
1. Clean the mounting pad on both the
compressor and governor block. Also be
sure the connecting line and the com-
pressor unloading ports are clean and
clear. If the filters were removed, en-
sure new filters have been installed in
the reservoir and unloader ports, (see
Figure 9C-2 on page 9C-3).
2. Position a new mounting gasket on the
compressor, and install the governor.
The exhaust port should point down.
3. Connect the associated air lines to the
governor inlet and unloader ports as re-
qui red.
4. Perform the governor operation and
leakage tests described in this sub-
9C-4
section, (see the topics, Operation Test
and and Leakage Test).
OPERA T ION TEST The operation test
checks out the cut out and cut in pres-
sure settings of the governor. To per-
form the operation test proceed as
follows:
1. Start the engine and build up air
pressure in the air system.
2. While monitoring the system pressure
gauge, observe at what pressure the
governor cuts out and stops the com-
pression of ai r. The cut out pressu re
should be approximately 120 psi.
3. With the engine still running, monitor
the system pressure gauge and make a
series of brake applications.
4. Observe at what pressure the gover-
nor cuts in and allows the compressor to
compress air. The cut in pressure
should be approximately 100 psi ..
5. 1+ the pressure setting of the gover-
nor is incorrect, adjust the governor as
described in this subsection, see the ad-
justment topic.
NOTE
Never condemn or adjust the gov-
ernor pressure settings unless the
questionable pressure readings are
checked with an accurate test
gauge or a dash gauge that is
known to be accu rate.
LEAKAGE TEST. The leakage test is to
determine if the governor has excessive
leakage which would cause problems with
the ai r system.
Perform the leakage test as follows:
1. With the machine engine running -and
the compressor compressing air, apply a
soap solution at the exhaust port. If a
leakage is indicated the leakage could be
the bottom piston grommets which may
prevent the compressor from cutting out.
2. With the machine engine running and
the compressor cut out (not
compressing), apply a soap solution at
the exhaust port. If leakage is indicated,
the leakage could be the upper piston
grommets.
 NOTE
If the governor does not function
as described in the operation test
or if the leakage is excessive, it is
recommended that the governor be
replaced or repaired to the limits
of the repair kit. All necessary
parts and instructions are con-
tained in the repair kit.
Adjustment
To adjust the pressure setting of the
governor, proceed as follows:
1. Start the engine and build up air
pressure in the air system.
2. While monitoring the system pressure
gauge, observe at what pressu re the
governor cuts out and stops the com-
pression of air. The cut out pressure
should be approximately 120 psi.
3. If the cut out pressure is below the
desired pressure, do the following:
A. Remove the governor cover (see
Figure 9C-2 on page 9C-3).
B. Loosen the adjusting screw locknut.
C. With a screwdriver, turn the adjust-
ing screw counterclockwise until the
governor cuts out at the des ired
pressure.
4. If the cut out pressure is above the
desired pressure, perform steps 3A and
3B, the tu rn the adjusting screw clock-
wise until the governor cuts out at the
desired pressure.
5. After setting the cut out pressure,
tighten the adjustment screw locknut.
Make sure the screw locknut is tight
against the upper spring seat so that the
governor setting will not change.
NOTE
The cut in pressure is set at the
same time as the cut out pressure
due to the design of the governor.
6. Install the adjusting screw cover.
7. After adjusting the governor, perform
the operation and leakage tests as de-
scribed in this subsection, se~ Operation
Test and Leakage Test topics.
SAFETY VALVE (36Z1153)
DESCRI PTION. The safety valve, con-
sisting of the parts shown in
Figure 9C-4 on page 9C-6, is located on
the air system reservoir. The safety
valve protects the air system against ex-
cessive ai r pressu re above 150 psi. If
the air system reservoir pressure below
the ball valve should raise to a point
above the setting of the safety valve,
the force developed will overcome the re-
gulating spring pressure against the ball
and the ball will lift. When the ball lifts,
the excessive air will vent to the atmos-
phere through the valves exhaust port.
As soon as the air pressure in the reser-
voir drops below the valve setting, the
valve ball will seat under spring pres-
sure and the venting of the air will stop.
MAINTENANCE. The safety valve should
be checked periodically, to be sure it is
operative. By pulling the exposed end of
the valve stem, the spring load is re-
moved from the ball which allows the
valve to exhaust. If the safety valve
does not "lift" when the valve stem is
pulled, the valve ball may be stuck on
the seat. The valve should be removed
and cleaned if the valve sticks shut.
The safety valve should also be checked
for leakage periodically. The leakage at
the safety valve exhaust port should not
exceed a three inch soap bubble in three
seconds.
It is recommended that the safety valve
be removed and cleaned annually, as fol-
lows, (see Figure 9C-4 on page 9C-6):
1. While the engine is shut down, drain
the ai r from the ai r system reservoi rs.
Unscrew the spring cage from the body
of the safety valve. Lift the ball valve
from the body and remove the spring,
spring seat and release pin from the
spring cage.
2. Clean all valve parts in cleaning sol-
vent. I nspect the parts for excessive
wea r, cracks or damage. If wea r or
damage is excessive the complete safety
valve must be replaced.
3. Assemble the valve by placing the ball
valve in the body. Place the spring re-
lease pin and spring seat into the spring
Ai r System Components 9C-5
cage. Then position the body over the
ball valve. Screw the spring cage onto
the body.
4. After assembling the safety valve,
perform the operation test and leakage
test on the valve to ensure proper opera-
tion.
AIR RESERVOIRS
DESCRIPTION. A reservoir is a storage
tank. The function of the reservoir is to
provide a place to store compressed ai r
so that there will always be an ample
supply available for immediate use in air
system operation. Reservoirs also pro-
vide storage for sufficient compressed
air to permit several brake applications
after the engine has been stopped.
A reservoi r has no moving parts and
could hardly be said to operate. Never-
theless, things do happen inside the res-
ervoir which should be understood. All
compressors must pass a certain amount
of oil in order to lubricate the cylinder
walls and piston rings; otherwise, rapid
wear or even seizing will result. Also,
depending on the humidity, the atmos-
phere entering the compressor contains a
certain amount of water. This oil and
water normally passes into the reservoir
in the form of vapor because of the heat
generated during compression. After
J..---- RELEASE
PIN
SPRING ?\-:::,....;::....;;.-- SPRING
CAGE
BALL
VALVE
Figure 9C-4. Safety Valve (36Z1153)
9C-G
reaching the reservoir, the vapors cool
and condensate in the form of an oil and
water emulsion and are drained off be-
fore entering the air system itself.
This drainage is often referred to as oil,
but in most cases analysis will show it to
be practically all water. An easy method
of checking the amount of oil and water
in the drainage is to put it in a sealed
clear glass container and set it aside for
several days. At the end of this period,
the oil and water will separate and a vis-
ual inspection will show the percentage
of oil and water in the mixture.
ROUTINE INPSECTION. There is proba-
bly no other device in the air system re-
quiring simpler maintenance and yet more
important maintenance than the air res-
ervoir.
Many an efficient reservoir arrangement
has been defeated in its normal function
through haphazard maintenance. Any col-
lector of unwanted oil and water conden-
sation will fail in its function if it is not
properly and regularly drained. The
simple routine of draining all the reser-
voir daily will pay dividends far beyond
what is generally recognized.
Draining does not mean opening the
drain cock and draining some air. Satis-
factory draining is only accomplished by
leaving the drain cock open after the ai r
has escaped and until all drainage stops.
MINOR REPAIRS. Minor repairs to a
reservoir consist of examining the reser-
voir mounting and the inspection of the
outside for corrosion or damage. The
outside should be kept painted because,
based on actual experience, the possibil-
ity of corrosion causing a failure except
from -the outside is very remote.
MAJOR REPAI RS. Except in unusual
cases, major repairs on reservoirs are
not economical or practical. If a reser-
voir has been damaged so as to be unfit
for use, it is most economical to replace
it with a new one.
In exceptional cases where the inside of
the reservol r has become excessively
coated with sludge which which cannot
be drained off, it is sometimes advisable
to remove it and clean it out with steam
and hot water.
BRAKE VALVE (36Z225)
Description
The brake valve, shown in Figure 9C-5
on page 9C-8, is an air pressure control
valve used to control the braking of the
carrier.
The brake valve delivers output pres-
sure from it's outlet port proportional to
the position of the foot pedal.
Maintenance
It is recommended that an operational
and leakage test be run on the brake
valve periodically to determine the ser-
viceability of the valve.
OPERATING TEST. To perform the op-
erating test proceed as follows:
,. If necessary, start the machine and
allow the air system reservoirs to fully
pressurize.
2. Attach a test gauge to the output port
of the brake valve.
3. Depress the pedal to several positions
and check the delivered pressure to see
that it varies proportionately with the
movement of the pedal. When the pedal is
fully depressed, the reading on the test
gauge should be approximately that of
full reservoir pressure. The gauge
reading should fall to zero when the ped-
al is released.
LEAKAGE TEST. Perform leakage tests
on the brake valve as follows:
,. With the valve fully released, check
the exhaust port for leakage. No leak-
age is permissible.
2. Make and hold a high pressure appli-
cation. Coat the ex haust port and the
top of the valve with soap suds. No leak-
age is permissible.
Removal
To remove a brake valve, proceed as fol-
lows:
,. Chock the wheels of the machine.
2. Shut the machine off.
3. Open the drain cock on each reservoir
to drain the pressure from the air
system.
4. Disconnect the air lines attached to
the brake valve.
5. Remove the brake valve from its
mounting position.
Overhaul
Overhauling a brake valve is limited to
replacing the valve parts found in the
repair kit. Damage to other parts of the
valve that is not in the kits requi res re-
placement of the entire valve.
Installation
To install a new or repaired brake valve,
proceed as follows:
,. Clean and inspect the air lines which
connect to the brake valve valve. Re-
place a ny lines wh ich a re damaged.
2. Mount the brake valve securely with
the mounting hardware.
3. Connect the air lines to the brake
valve ports.
4. Test the brake valve as described in
the topic Maintenance.
DUAL BRAKE VALVE (36U373)
DESCRIPTION.
The brake valve (see Figure 9C-6 on
page 9C-8) is a control unit of the air
brake system. It provides the driver
with an easily operated and graduated
means of appling and releasing the vehi-
cle brakes, and also separates the front
and rear service brakes into independent
circuits.
Maintenance
OPERATING TEST. Using an air gauge
known to be accu rate, check the delivery
pressure from the brake valve. Depress
the brake valve pedal to several posi-
tions between fully applied and released.
Ai r System Components 9C-7
 PISTON
INLET
~~S;;;;;~~~::::r- EXHAUST
VALVE
EXHAUST
DIAPHRAGM I!.lla......=i---SPRING

INSERT
DELIVERY
RETAI N I N G -..!:=,.jEeifF=
PORTS
RING EXHAUST

Figure 9C-5. Brake Valve (36Z225)

Check the gauge to see that the deliv-
ered pressure varies proportionately
with movement of the pedal. When the
pedal is fully depressed, the gauge read-
ing should be approximately that of full
reservoir pressure. The gauge reading
should fall off to zero when the pedal is
released.
LEAKAGE TEST. With the brake valve
fully released, check the exhaust port
for leakage. No leakage is permissible.
Make and hold a high pressure applica-
tion Coat the exhaust port and the top of
the valve wth a soap solution. No leakage
as evidenced by bubbles, is permissible.
p.lf the brake valve does not operate in
the proper manner or, if leakage is ex-
cessive, the brake valve must be
replaced.
REMOVAL.
Remove the brake valve as follows:
1. Block and hold the vehicle by some
means other than the carrier brakes.
2. Open the drain cocks on the reservoi r
and completely drain the air system.
3. Tag and disconnect the air lines at
the brake valve ports. Remove the
mounting hardware and remove the brake
valve from the cab.
Figure 9C-6. Dual Brake Valve
( 36U373)
INSTALLATION.
Install the brake valve as follows:
1. Position the brake valve through the
hole in the cab floor. Securely install the
attaching hardware.
2. Clean the air lines to the brake valve.
onnect the air lines to the appropriate
valve ports.
3. Clos'e the drain cocks and fully charge
the air system. Test the valve for ser-
viceability by performing the Operating
and Leakage Tests.
4. I nstall the sheet metal over the bottom
of the cab.
RELAY VALVE (36U330)
DESCRI PTION. The relay valves (see
Figure 9C-7 on page 9C-10 and
Figure 9C-8 on page 9C-1O) function as
a relay stations to speed up the applica-
tion, modulation and release of the vehi-
cle brakes. These relay valves are used
for the front and rear service brakes
and the rear parking brake. The ser-
vice relay valves are pilot controlled

9C-8
brake valves, delivering air pressure di-
rectly from the reservoir to the brake
chambers, at a rate proportional to the
pressure delivered from the dual brake
valves.
The valves are attached to valve plates
which are attached to the vehicle frame.
OPERATING AND LEAKAGE TEST. To
determine the relay valves serviceabilty,
perform the following tests:
1. Chock the wheels, fully charge the air
system, and adjust the brakes if neces-
sary.
2. Make several brake applications, ser-
vice and parking, and check for prompt
application and release of the corre-
sponding brakes.
3. Make a full service brake application
and hold. Coat the delivery exhaust port
with soap solution to check for leakage.
Leakage indicates inlet valve and O-ring
damage.
4. Release the brakes. Again check for
leakage at the delivery exhaust port.
Apply a soap solution at the point where
the cover joins the body. There should
be no lea kage.
5. With the brakes released, apply a
soap solution to the quick release ex-
haust cover. Leakage at this point indi-
cates a faulty diphragm exhaust seat.
6. If the relay valve does not operate
properly or leaks excessively, it must be
replaced.
REMOVAL. Remove the relay valve as fol-
lows:
1. Block and hold the vehicle with wheel
chocks.
2. Open the drain cocks and completely
drain the system.
3. Tag and disconnect the air lines at
the valve ports.
4. Remove the mounting hardware and
remove the valve from the valve plate.
I NST ALLATION. Install the relay valve
as follows:
1. Securely mount the relay valve to the
valve plate.
2. After cleaning all lines, reconnect the
air lines to the appropriate valve ports.
3. Close the drain cocks and fully charge
the air system.
4. Check for air line leaks. Check for
proper brake light switch operation. Per-
form the Operating and Leakage Test.
SPRING BRAKE VALVE (36Q192)
DESCRIPTION. The spring brake valve
is located on rear brake valve plate (see
Figure 9C-9 on page 9C-ll). The func-
tion of the spring brake valve is to sup-
ply limited pressure to the rear parking
brakes in the event of pressu re loss to
the rear brake supply reservoir, and to
modulate the application of the parking
brakes through the use of the treadle
valve. When a parking brake control is
placed in the set position, the supply of
ai r to the spring brake valve and the
brake chambers is exhausted, setting the
brakes.
OPERATI NG TEST. To determine the
spring brake serviceabilty, perform the
following tests:
1. Chock the wheels and fully charge the
air system.
2. Set the parking brake.
3. Install a test gauge in the parking
brake supply line.
4. Release the parking brake and note
the gauge reading.
5. Releasing the parking brake should
cause the gauge to drop to zero imme-
diately.
6. Release the parking brake and drain
the rear brake air reservoir.
7. Apply the service brake several times
and note that the pressure reading on
the test gauge decreases each time the
brakes are applied. After the brakes
have been applied several times, the
pressure will not be sufficient enough to
release the parking brakes.
Air System Components 9C-9
 REAR . . . . .

Figure 9C-7. Carrier Relay Brake Valves (rear)

LEAKAGE TEST. Perform the following
test to determine if the cause of poor
spring brake valve operation is due to
leakage:
1. Chock the wheels and fully charge the
air system.
2. Release the parking brake .
3. Coat the exhaust port and valve cor-
ners with a soap solution. Slight leakage
is permissible.
I the spring bake valve does not function
as described in the Operating Test, or
leakage is excessive, it is recommended
that the valve be replaced.

. . . . . FRONT

BRAKE
RELAY

Figure 9C-8. Carrier Relay Brake Valve (front)

9C-l0
 PARKING BRAKE
RELAY

STOP LIGHT ___~--t;~7'1

SWITCH

SERVICE BRAKE
RELAY

Figure 9C-9. Rear Brake Valve Plate

REMOVAL. Remove the spring brake used to control the positioning of the en-
valve as follows: gine throttle cylinder. The throttle con-
trol valve is mounted to the underside of
1. Set the parking brake and chock the the cab floor just below the foot th rottle
wheels. pedal.
2. Open the drain cocks and completely The th rottle control va Ive del ivers out-
drain the system. put pressu re from it" s outlet port pro-
portional to the position of the pedal or
3. Tag and disconnect the air lines at lever. The output pressure range is
the valve ports. fixed however, the minimum pressure can
be adjusted to obtain desired throttle
4. Remove the mounting hardware and cylinder preload, as described in the Ad-
remove the valve from the valve plate. justment topic. The throttle control valve
operates as described in Figure 9C-l0 on
I NST ALLATI ON. I nstall the spring brake page 9C-12.
valve as follows:
MAINTENANCE. It is recommended that
1. Securely mount the valve to the valve an operational and leakage test be run on
plate. the throttle control valve periodically to
determine the serviceability of the valve.
2. After cleaning all lines, reconnect the
air lines to the appropriate valve ports. To perform the operational and- leakage
tests proceed as follows:
3. Close the drain cocks and fully charge
the ai r system. 1. If necessary, start the machine and
allow the air system reservoirs to fully
4. Check for air line leaks. Perform the pressurize.
Operating and Leakage Test.
2. Have an assistant move the th rottle
control valve from the full ON position to
THROTTLE CONTROL VALVE (36U322) the full OFF position and back on several
times and observe the operation of the
DESCRIPTION The throttle control throttle cylinder at the engine. The
valve, shown in Figure 9C-1O on page throttle cylinder should respond smooth-
9C-12, is an air pressure control valve ly to changes in the th rottle valve

Air System Components 9C- 11

position. If the throttle cylinder re-
sponds smoothly, proceed to step 3. If
the throttle cylinder does not respond
smoothly the throttle control valve con-
trol spring is damaged, and the complete
valve portion of the throttle valve must
be replaced.
3. With the air system fully charged, po-
sition the th rottle control valve to the off
position.
NOTE
The throttle must be in the full
OFF position to check the valve for
leaks, since the throttle valve has
a normal bleed of ai r th rough it's
ex haust muffler when the output
line is pressurized.
4. Coat the muffler section of the valve
with a soap solution and check for any
PLUNGER
INLET
VALVE
AIR
FROM
THROTTLE
CONTROL
,..=..-,.- SPRING
o o
-t= "1
OECREASING PRESSURE - When the
operator moves the valve plunger up.
the inlet valve opens. allowing pressure
from the out pon to· exhaust to the at-
mospher.. throu9h the muffler. As
pressure decreases in the out pon. the
l'NIin piston moves upward due to the
force of the control sprin9 until the e.-
haust valve a9aln seats due to the bal-
ance of force across the piston.
Figure 9C-10. Throttle Control Valve Operation
9C-12
leaks. No leakage is permissible at this
point. If a control valve leaks at the
muffler with the control valve in the OFF
position, the valve seals are defective,
and the control valve shou Id be repai red
or replaced.
REMOVAL. To remove a th rottle control,
proceed as follows:
1. Shut the machine off.
2. Open the drain cock on each reservoir
to drain the pressure from the air
system.
3. Disconnect the air lines attached to
the throttle control valve.
4. Remove the th rottle control from its
mounting position.
OUTLET
INLET INLET . . .
PORT .---_ .. PORT
PORT
AIR
. . . THROTTLE
o
0 .' o .
t:--:J M
C1.0SEO CENTER POSITION (NO INCREASING I'RESSURE - When the
FLOWl - When the outlet pressure is operator moves the valve plunger
eQual to the force produced bv the con- down. thiS seats the exhaust valve and
trol spring, the inlet valve and the ex- unseats the ,nlet valve. A,; pressure
haust valve are both seated. Thus. the in from the ,n port flows through the un-
and out ports are both sealed. seated ,nlet valve and to 1he out pon.
the main piston moves downward.
compreSSing the control sprong until the
inlet valve again seats because of the
balance of forces across the piston.
 MUFFLER
F178
Figure 9C-11. Throttle Control Valve Assembly
OVERHAUL. Overhauling a throttle con-
trol is limited to replacing the valve
parts found in the repair kit. Damage to
other parts of the valve that is not in
the kits requires replacement of the en-
tire valve. If the actuator part of the
th rottle control is excessively worn or
damaged, it can also be removed and re-
placed with a new unit.
To overhaul a throttle control valve, dis-
assemble the valve as shown in
Figu re 9C- 11. Then, replace all of the
parts noted with an asterisk (*) in
Figure 9C-ll, with new parts found in
the repai r kit.
Reassemble the valve in reverse order of
disassembly. Du ring the th rottle control
valve assembling operation, use Dow
Corning No. 55 Pneumatic Grease to lu-
bricate all rubber parts. Lubricate all
metal-to-metal contact su rfaces with No.
107 Lubriplate.
INSTALLATION. To install a new or re-
paired throttle control, proceed as fol-
lows:
1. Clean and inspect the air lines which
connect to the throttle control. Replace
any lines which are damaged.
2. Mou nt the th rottle control secu rely
with the mounting hardware.
'PARTS CONTAINED IN REPAIR KIT
3. Connect the air lines to the throttle
control ports.
4. Adjust the throttle control as de-
scribed in the topic, Adjustment. Dur-
ing the adjustment of the throttle control
check the control to be sure there are no
air leaks.
ADJUSTMENT. The throttle control
valve is a pressure control valve, whose
output range of pressure is used to con-
trol the throttle cylinder.
The output ranges of the th rottle control
valve (minimum to maximum) is fixed by
the control spring, shown in
Figure 9C-ll. The minimum pressure of
the output pressure range is set by ad-
justing the throttle control spring seat,
see Figure9C-ll. By turning the
spring seat clockwise the minimum output
pressure will be increased; turrring the
spring seat counterclockwise will lower
the minimum output pressure.
To adjust a throttle control proceed as
follows:
1. With the air system fully charged, and
the throttle control valve open slightly,
adjust the spring seat, see
Figure 9C-ll, until the control valve
outlet pressure causes the throttle con-
trol cyiinder to extend slightly.
Ai r System Components 9C-13
2. Tighten the spring seat jam nut.
3. On the foot pedal, adjust the small
stop screw to set the engine low idle
speed.
4. Operate the foot pedal to speed up the
engine. Adjust the large stop screw on
the pedal to stop the pedal when the
engine reaches maximum governed rpm.
THROTTLE CONTROL VALVE (36U29)
DESCRIPTION The throttle control
valve, shown in Figure 9C-12 on page
9C-15, is an air pressure control valve
used to control the positioning of the en-
gine throttle cylinder. The throttle con-
trol valve is mounted to the underside of
the cab floor just below the foot throttle
pedal.
The throttle control valve delivers out-
put pressure from it's outlet port pro-
portional to the position of the pedal or
lever.
MAINTENANCE. It is recommended that
an operational and leakage test be run on
the th rottle control valve periodically to
determine the serviceability of the valve.
To perform the operational and leakage
tests proceed as follows:
1. If necessary, start the machine and
allow the air system reservoirs to fully
pressu rize.
2. Have an assistant move the th rottle
control valve from the full ON position to
the full OFF position and back on several
times and observe the operation of the
throttle cylinder at the engine. The
throttle cylinder should respond smooth-
ly to changes in the th rottle valve
position. If the throttle cylinder re-
sponds smoothly, proceed to step 3. If
the throttle cylinder does not respond
smoothly the throttle control valve con-
trol spring is damaged, and the complete
valve portion of the th rottle valve must
be replaced.
3. With the air system fully charged, po-
sition the th rottle control valve to the off
position.
4. Coat the muffler section of the valve
with a soap sol ution and check for any
leaks. No leakage is permissible at this
9C-14
point. If a control valve leaks at the
muffler with the control valve in the OFF
position, the valve seals are defective,
and the control valve should be repaired
or replaced.
REMOVAL. To remove a throttle control,
proceed as follows:
1. Shut the machine off.
2. Open the drain cock on each reservoir
to drain the pressu re from the ai r
system.
3. Disconnect the air lines attached to
the throttle control valve.
4. Remove the th rottle control from its
mounting position.
OVERHAUL. Overhauling a throttle con-
trol is limited to replacing the valve
parts found in the repair kit. Damage to
other parts of the valve that is not in
the kits requi re$ replacement of the en-
tire valve.
To overhaul a throttle control valve pro-
ceed as follows (refer to Figure 9C-11 on
page 9C-13) :
1. Remove the six body screws and re-
move the outlet body.
2. Remove the barrier plate assembly and
lift out the balance piston. The barrier
plate assembly may be discarded.
3. Remove the balance spring and wear
shim from the outlet body. Wash the
parts and inspect the outlet body for ex-
cessive wear in the area where the piston
contacts the body bore.
4. Remove the balance piston U-cup and
thrust ring. These items can be easily
replaced without distu rbing the seal re-
tai ner.
5. Install a new thrust ring and U-cup
on the balance piston. Make sure that
the sealing surface of the U-cup is point-
ing toward the retainer.
6. Install the wear shim and balance
spring in the outlet body cavity.
7. Using light grease, coat the body
bore and the face of the small diameter of
the assembled balance piston.
8. Install the balance piston in the outlet
body and place the new barrier plate as-
sembly in position on the outlet body.
Make su re that the plate is set into the
mating counterbore of the body, and that
the small diameter of the balance piston
engages the bore in the bottom of the
outlet body.
9. Install the O-ring in the inlet body
cou nterbore.
10. Install the outlet body on the inlet
body with a slight turning motion to seat
the O-ring. Install the six body screws.
INSTALLATION. To install a new or re-
paired throttle control, proceed as fol-
lows:
BALANCE
PISTON -------=~M::J
EXHAUST
SEAT
Figure 9C-12. Throttle Control Valve (36U29)
1. Clean and inspect the air lines which
con nect to the th rottle control. Replace
any lines which are damaged.
2. Mou nt the th rottle control secu rely
with the mounting hardware.
3. Connect the air lines to the throttle
control ports.
4. Adj u st the th rottle control as de-
scribed in the topic, Adjustment. Dur-
ing the adjustment of the throttle control
check the control to be su re there a re no
air leaks.
ADJUSTMENT. To adjust a th rottle con-
trol proceed as follows:
.wRl----------_BALANCE
SPRING
Ai r System Components 9C-1S
1. Disconnect the throttle linkage at the
throttle cylinder and use the cylinder to
determine control adjustment.
2. Adjust the stop screw under the heel
of the the pedal so that the valve will de-
liver pressure as soon as the pedal is
depressed.
3. Run the stop screw up until pressure
begins to be delivered at the throttle cyl-
inder.
4. Tu rn the adjustment screw back
slightly and tighten the locknut.
THROTTLE CYLINDER ·(38Ul07)
DESCRIPTION. The throttle cylinder,
shown in Figu re 9C-14 on page 9C-17,
moves the th rottle lever, on the engine,
in response to movement of the throttle
control valve. I naddition to th rottle op-
eration, the th rottle cylinder incorpo-
rates a fast idle control.
When system pressure is below 30 psi, at
the fast idle port, the push tube extends
to the fast idle position. This causes the
engine throttle lever to move and in-
crease engine speed. With approximately
30 psi air pressure at the fast idle port,
the push tube returns to the slow idle
position in which the adapter shoulder is
in contact with the cylinder bushing.
When the throttle control is moved, a
corresponding amount of air flows
through the throttle valve port and acts
on the effective area of the th rottle pis-
ton. When the force of the air pressure
is greater than the force of the graduat-
ing spring, the push tube is extended
toward the full throttle position to the
extent of the ai r pressu re delivered by
the throttle control. As air pressure is
reduced or completely exhauster:! through

13
14
15
17

1 ~2~
7
6
5

_1 21
~ ®~
~

12

1. PUSH ROD
___ ---I 2. DUST BOOT
12. U-CUP
13. THRUST RING
3. NUT

L----- ---- --------- 4

I
I
I
4.
5.
6.
ROD GUIDE
INLET BODY
SEAL WASHERS
14. BALANCE PISTON
15. BOOSTER SPRING
16. BALANCE SPRING
17. WEAR SHIM

~~~~~
7. SCREEN
18. PLUG
8. SCREWS
19. OUTLET BODY
9. O-RING
20. AIR FILTER
10. O-RING
21. BODY SCREWS
11. BARRIER PLATE ASSEMBLY

Fi gure 9C-13. Throttle Control Valve Assembly

9C-16
 MOUNTING
HOLE BUSHING
CYLJNOER
CAP
FASTIOLE
PISTON
GRAOUATING NUT
'·7/8" SPRING
TOTAL
STROKE

PISTON ROO

PUSH TUBE
AOAPTER
FOUO~!
PISTON LUBRICATING
PACKING PIPE PI..UGS
CYUNOER
CUP
BUSHING THROTTLE
VALVE FAST IOLE PORT
F197 PORT (FROM RESERVOIR)

Figure 9C-14. Throttle Cylinder (38UI07)

the throttle control, the push tube is
moved toward the idle position by the
graduating spring.
NOTE
The throttle cylinder is secured to
the engine th rottle lever at the
right side of the engine.
OPERATI NG TEST. Test the throttle cyl-
inder for proper operation as follows:
1. Block the wheel to prevent the vehicle
from moving. Open the reservoir drain
cocks and completely drain the system.
2. The push tube should now be ex-
tended to the fast idle position (9/32 in).
3. Slowly build system pressure. At ap-
proximately 30 psi the push tube should
retract to the point where the adapter
shoulder is in contact with the cylinder
bushing.
4. After system pressu re has retu rned to
normal , move the th rottle control to var-
ious positions to see that the th rottle cyl-
inder responds quickly and
proportionately.
LEAKAGE TEST. Test the throttle cylin-
der for lea kage as follows:
1. With normal system pressu re there
should be no noticeable leakage at the
vent hole in the cyl i nder cap. Iflea kage
is present, then the grommets on the
fast idle piston must be replaced.
2. Move a throttle control Chand or foot)
to the fully applied position. There
should be no noticeable leakage past the
th rottle piston as evidenced by ai r es-
daping through the vent hole in the
body. If leakage is present, then the
grommet, felt oilers and packing cup
must be replaced.
3. There must be no leakage at the lu-
bricating pipe plugs with air pressure at
the fias idle and th rottle valve ports.
REMOVAL. Remove the throttle cylinder
as follows:

Ai r System Components 9C-17

1. Block and hold the vehicle with wheel
chocks.
2. Open the reservoir drain cocks and
completely drain the system.
3. Tag and disconnect the air lines at
the cyl i nder ports.
4. Disconnect the ball joint at the engine
th rottle lever.
5. Remove the shoulder bolt and remove
the throttle cylinder from the engine
bracket.
6. Remove the ball hoint from the push
tube adapter.
OVERHAUL. Disassemble, inspect and
assemble the throttle cylinder as follows:
1. Remove the cylinder cap and nut.
2. Remove the fast idle spring and fast
idle piston.
3. After loosening the setscrew, remove
the push tube adapter and take up
spring.
4. Remove the push tube assembly and
graduating spring through the threaded
end of the cylinder.
5. Disassemble the push tube assembly.
The piston has a screwdriver slot in one
end oand a hex nut at the packing cup
end. After removi ng the nut, remove the
piston cup follower, packing cup, piston
and push tube from the piston rod.
6. Remove the felt oilers and grommets
from the appropriate parts. Discard
therse parts, as well as the piston pack-
ing cup.
7. Thoroughly wash all metal parts and
dry. I nspect for excessive wear or dam-
age. The original finished inside diam-
eter of the mounting hole bushing was
0.376 to 0.378 inch.
Prior to assembly, lubricate all moving
parts and bores with molybdenum disul-
phide lubricant.
ASSEMBLY. To assemble the throttle cyl-
i nder, proceed as follows:
1. Assemble new grommets in the fast
idle piston grooves and the groove near-
est the th readed end of the piston rod.
9C-18
Install a new felt oiler in the piston rod
groove and the throttle piston groove.
2. Assemble the push tube assembly as
shown in the illustration. Take care not
to cut the seals. As the nut is tightened
do not distort the piston packing cup.
3. I nstall the graduating spring and
push tube assembly in the cylinder.
4. Place the take up spring and push
tube and assemble the push tube adaptor
to the tube. Tighten the nut securely
and then tighten the setscrew secu rely.
5. While taking care not to cut the grom-
mets, slide the fast idle piston into the
cylinder. Place the fast idle spring in
the piston and assemble the nut and cyl-
inder cap to the cylinder. Thread the
nut all the way on. Tightne the cylinder
cap until it bottoms out and then tighten
the nut against the cap.
INSTALLATION. Install the throttle cyl-
i nder as follows:
1. Line up the cylinder mounting hole
bushing with the hole in the engine
bracket. Securely install the shoulder
bolt.
2. After cleaning the air lines, connect
the air lines to the cylinder ports.
3. Make sure the drain cocks are closed.
Start the engine and build system pres-
sure to 30psi, or until the push tube is
fully retracted. It may be necessary to
operate the th rottle lever by hand to get
the engine started.
4. Assemble the ball hoint to the push
tube adapter. Adjust the ball hoint until
it can be connected to the engine throttle
lever. During this adjustment the thrott-
ler lever must be in the idle position.
Install the nut to secure the ball joint to
the lever. Tighten the ball joint jam -nut
against the push tube adapter.
5. Build system pressure to normal and
check for proper th rottle operation and
leakage.
PARKING BRAKE CONTROL VALVE
(36Q483)
DESCRIPTION. This control valve is
used in conjuction with the parking
brake valve to control the operation of
the rear axle parking brakes.
When the control valve knob is
depressed, the inlet and exhaust seat of
the valve moves downward to block the
exhaust port and connect the supply
port to the delivery port. The force of
the air pressure acting on the top of the
inlet and exhaust valve will hold it off its
inlet seat and on its exhaust seat, main-
taining the flow of air out the delivery
port (see Figure 9C-15).
If the pressure within the air system
drops below 40 psi (2.76 bars), the
valve will move to the applied position.
This is due to the fact that the pressure
acting on the top of the inlet and ex-
:laust seat is insufficient to overcome the
force of the spring acting on the
plunger.
When the control knob is pulled outward,
the inlet and exhaust valve moves up-
wared, blocking the inlet port and open-
ing the exhaust port. Air will now
exhaust out the open exhaust port.
OPERATI NG AND LEAKAGE TEST. To
determine the serviceabilty of this valve,
perform the following test:
NOTE
An accu rate test gauge is requi red
to perform the following test.
1. Block the carrier in position with
wheel chocks while performing this test.
2. Open the drain cock on each reservoir
to exhaust air pressure from the air sys-
tem. Close the drain cocks when all
pressure has been exhausted.
3. Connect the test gauge to the delivery
port of the valve.
NOTE
This valve has two delivery ports,
one of which is plugged. The test
gauge can be connected to the
plugged delivery port, if desired.
4. Start the engine and charge the air
system to 100 psi (6.9 bars).
5. When the air system is fully charged,
shut down the engine and observe the
test gauge. The test gauge should read
zero.
6. Depress the control knob and oserve
the test gauge. The test gauge pressure
should be the same as the primary and
seconda ry ai r pressu re gauges on the
dashboard.
7. Open the drain cock on each reservoir
to reduce the pressure in the air system,
and observe the test gauge while the
pressure is being drained. Test gauge
pressure should drop gradually until the
prssu re reaches 35-45 psi (2.4-3.1
bars), at which point the pressure
should drop immediately to zero.
8. If the valve does not function as de-
scribed above, or leakage is excessive,
it is recommended that the valve be re-
placed.
REMOVAL. To remove the parking brake
control valve, proceed as follows:
1. Drain the air pressure by opening the
drain cock on each reservoir.
2. Disconnect the air lines attached to
the valve.
KNOB
ROLL
PIN
DelIVERY
(2)
INLET &
eXHAUST VALVE
eXHAUST
Figure 9C-15. Parking Brake Control
Valve (360483)
Air System Components 9C-19
3. Remove the mounting nut; then re- 2. Position the knob on the plunger and
move the valve. install the roll pin through the knoband
plunger.
INSTALLATION. To install a new park-
ing brake contol valve, proceed as fol- 3. Connect the air lines to the valve.
lows:
4. Check the operation of the valve by
1. Position the valve on the control panel performing the Operating and Leakage
and secu re it to the panel with the Test.
mounting nut.

9C-20
 SUBSECTION 90

BRAKE CHAMBERS

GENERAL brake system is to convert compressed

The information in this subsection covers
the description, leakage test, disassem-
bly, and assembly procedures for the
front and rear brake chambers.
FRONT BRAKE CHAMBERS
DEseRI PTION. Two brake chambers are
used on each of the front wheels. The
purpose of brake chambers in an air
e SHOE
air energy into mechanical force and
movement, which applies the vehicle
brakes.
Air pressure enters the pressure side of
the brake chamber and forces against the
diaphragm, which in tu rn moves the
push rod forward (see Figure 90-1).
The push rod is connected to a wedge
assembly which forces two plungers
apart when the wedge is forced between
the plungers by the push rod.
BRAKE
ASSEMBLY

6 CLAMPING
RING

PLUNGER
HOUSING
WEDGE
SPRING INLET
ADJUSTING PORTS
PLUNGER

DIAPHRAGM

PRESSURE
ANCHOR
HOUSING
PLUNGER
(SOUD,

g g NON'-PRESSURE
HOUSING F172

e
Figure 90-1. Front Brake Mechanism

Subsection 90 9D-1
This spreads the plungers apart, push-
ing the brake shoes outward to apply the
brakes.
When air pressure is vented from the
brake chamber, the wedge spring re-
turns the wedge and diaphragm to their
released position, releasing the brakes.
LEAKAGE TEST. Perform the following
test periodically to determi ne whether or
not the brake chamber is suitable for
continued service:
,. Have an assistant make and hold a full
brake application.
2. Coat the non-pressure housing,
clamping ring and inlet pots and fittings
with a soap solution. No leakage is per-
missible at these points.
3. If leakage is detected around the
clamping ring, the clamp bolt should be
tightened, but only enough to stop the
leakage. Excessive tightening could dis-
tort the diaph ragm sealing flange.
4. If leakage occurs at the non-pressure
housing or leakage cannot be stopped by
tightening the clamp bolt, the brake
chamber shou Id be disassembled.
DISASSEMBLY. The following procedure
describes the method of removing the
diaphragm and boot which are the main
causes of leakage (see Figure 90-2).
,. Disconnect the air line or lines at the
brake chamber.
2. Remove the clamp ring nut and bolt.
Spread the clamp ring and remove it,
while holding the pressure housing in
place.
3. Hole the diaphragm against the
non-pressure housing and remove the
pressure housing.
4. Carefully remove the diaphragm while
holding the diaph ragm plate against the
wedge rod. This will prevent the wedge
assembly from coming out of engagement
with the plungers.
NOTE
If the wedge assembly backs out of
the plungers at anytime during the
procedure, it will oenecessary to
90-2
remove the brake shoes to replace
the wedge assembly.
5. Continue to hold the diaphragm plate
and inspect the boot. If the boot is torn
or not attached to the non-pressure
housing, strip the old boot from the
housing.
6. Carefully extract th~ diaphragm plate
from the wedge assembly The boot and
wedge guide will remain on the dia-
ph ragm plate push rod.
ASSEMBLY. Install a new diaphragm and
boot as follows:
,. I nstall a new boot on the diaph ragm
plate push rod and press the wedge
guide all the way to the end of the push
rod.
2. Clean the non-pressure housing with
cement thinner or similar solvent in the
area where the boot is to be cemented.
3. Apply cement to the non-pressure
housing around the tube end. Position
the diaphragm plate push rod in the
tube. Carefully engage the wedge rod so
as not to pull it out of the plungers.
4. While holding the diaphragm against
the wedge assembly, press the boot into
position for cementing.
5. I ntall a new diaphragm over the dia-
phragm plate and onto the non-pressure
housing while pushing the diaphragm
plate against the wedge assembly.
WEDGE
GUIDE PRESSURE
HOUSING
NON.PRESSURE
HOUSING
F173
Figure 90-2. Front Brake Chamber
6. Install the pressure housing over the
diaphragm. I nstall th~ clamp ring over
the non-pressure and preSSlH"e housing
flanges, and secure the clamp ring with
the clamp ring bolt and nut.
7. Reconnect the ai r line or lines to the
brake chamber. Have an assistant make
and hold a full brake application, and
check the brake chamber for leakage.
Then, road test the machine and check
brake periormance.
MAXIBRAKE CHAMBER
OESCRI PTION. A Maxibrake chamber is
a combination service brake chamber and
spring- brake, which provides two meth-
ods of applying the carrier brakes (see
Figure 90-3).
Service air pressure is supplied to the
spring chamber air inlet by the service
brake relay valve. Air pressure from the
dual brake valve causes the relay to
CLAMP POWER
RING SPRING
~ PISTON.
SPRING
RETAINER RETAINER
Figure 90-3. Maxibrake Chamber
shift, letting air from the reservoir pass
to the service brakes.
Air pressure entering the service brake
air inlet will force the diaphragm against
the push rod assembly, extending the
push rod from the chamber. Since the
push rod is connected to a slack
adjuster, outward movement of the push
rod will rotate the brake cam and apply
the brakes. Venting air pressure from
the chamber will retract the push rod,
which in turn rotates the brake cam in
the opposite direction, releasing the
brakes.
If the air pressure is vented from the
spring chamber by shifting the parking
brake relay valve to the vented position,
either automatically or manually, the
power spring will expand, forcing the
piston outward. Outward movement of
the piston places the neck of the piston
against a flange nut on the end of the
push rod. This pushes the push rod
outward, rotating the brake cam to apply
the brakes.
FELT WIPER CYLINDER
RING
NYLON
BUSHING
F144
. Brake Chambers 90-3
LEAKAGE TEST. The Maxibrake system
should be checked periodically to deter-
mine that the brakes are suitable for
continued service or to determine wheth-
er a problem is caused by a faulty Max-
ibrake chamber. Test the system as
follows:
1. Start the engine and build-up maxi-
mum air pressure. Stop the engine and
depress the parking brake control valve
knob. Then, check the air gauge for a
drop in pressure. A drop in pressure
indicates that a leak exists in the air
supply system.
2. Pull the parking brake control valve
knob outward from the dash panel and
check the air gauge for a drop in pres-
sure after the Maxibrakes are released.
A drop in pressure indicates that a leak
exists beyond the control valve.
3. Coat the pressure plate, clamp ring
and push rod of the Maxibrake chamber
with a soap solution to determine if the
leakage is within the chamber itself. Max-
imum permissible leakage at these points
is lib-min. with a total volume of 200
cu.in.l100 psi (3.227 ml/S.89 bars) test
pressure.
4. Make a full service brake application
by depressing and holding the dual
brake valve. Check the air gauge for a
drop in pressure. An air pressure drop
of over 3 pounds per minute indicates
that excessive leakage beyond the dual
brake valve exists.
5. If leaks occur at the points indicated
above, they should be repai red before
the machine is returned to service.
OISASSEMBL Y. To disassemble a Maxib-
rake chamber, proceed as follows (refer
to Figure 90-4, unless otherwise di-
rected) :
NOTE
To ensure that the Maxibrake
chamber is serviced quickly and
safely, it is recommended that the
caging tool and servicing bracket
shown in Figure 90-5 on page
90-5 be used . These tools can be
manufactured locally or purchased

01. CYUNDER ASSEMBLY

02. O-RING. SMAll
1f----08
03. PISTON ASSEMBLY
04. O-RING. LARGE

06.
05. POWER SPRING
SPRING SUPPORT
e 10

1-..
07. CAPSCREW
as. PUSH ROO
09. PUSH ROO RETURN SPRING
10. SPRING RETAINER

~
11. PUSH ROO BUSHING
12. FLANGE NUT 11
13.
14.
15.
CLAMP BAND ASSEMBLY
PRESSURE PLATE
DIAPHRAGM
@-06
<: ~

~o.
16. JAM NUT
17. WATERPROOF PLUG
18. FELT WIPER RING
19. NYLON BUSHING ~ --------

Figure 90-4. Maxibrake Chamber

90-4
 1/32 X 45° CHAMF.
25/32 DIA. DRILL
CD
"-
po "-
<
0
N j
"-
~
1/8 po

.a
STEEL TUBING
2·1/2 00 X 1/8 WALL 118 R SQ. EDGE OPTIONAL
DETAIL OF END PLATE

3/4-10 HEX NUT

f----------- 22.t 1 / 8 - - - - - - - - - - - i WELD 5.1/2 orA. ~ 1/8

2·3/40.0. X 1/4 PLATE

w/25/32 DIA.
HOLE AT ¢.
mmmmmmmmmm~~mwmmmwmmmftmmmmmmnmmm~mmmmmri_+
,...."...,~J ~-~I
0
N
1
y
il
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...... II ~
//,'
L
":' \\
1.218.± .010 DIA. 3/4·10 HEX NUT U-I.g...-...L.N ~-~/ /
/
25/32 1/32 BOTH SIDES 3/4·10 FULL THO.
DRILL 1·1/16DIA
MAXIBRAKE ASSEMBLY TOOL PIN 131108-4 1/4 3/4.10 HEX NUT
DIA.

1·112 DIA. C.R. BAR

TOL. NOT NOTED ~1/64 UP TO 2"

3.1 /i
1.500 + .0000.0. =1/32 2" & GREATER
-.003

6 X 3·1/2 X 3/8
ANGLE
rr -4·3/4-----1

2·318 2·3/8

1/4" MS PLATE
6

3·15/16'
I I

~---.-h----1W 1-25/32

t----3·9/16---I

1--------6·1/2 -----!.-,-I
9/16 DRILL
4 HOLES
F132
Figure 90-5. Maxibrake Tools

B rake Chambers 9D-5

 from the chamber manufacturer at
the address shown on Figure 90-5
on page 90-5.

1. Mount the Maxibrake chambers on the

servicing bracket and secu re it with the
stud nuts (see Figu re 90-6).
2. Note the location of the pressure plate
inlet port with respect to the cylinder.
Loosen the clamp band nuts and bolts,
and remove the clamp band halves.
3. Remove the pressu re plate and dia-
phragm.
4. Press down on the push rod face plate
to remove the jam nut and flange nut se-
curing the push rod (see Figure 90-7).
5. Remove the push rod assembly from
the cylinder. The push rod, spring re-
tainer and push rod return spring will
be removed with the assembly.
6. Free the push rod bushing from the
piston boss by inserting the caging tool
shaft through the piston tube and tap-
ping the tool lightly (see Figure 90-8).
Remove the push rod bushing.
7. I nsert the caging tool from the back
of the chamber, through the piston tube.
I nstall the machined end of the caging
tool bushing into the neck of the piston.
I nstall the nut on the caging tool and
tighten the nut down until the caging
tool is centered and resting firmly
against the spring support (see
Fig u re 90-9 on page 90-7) .
Figure 90-7. Removing Flange Nut
8. Remove the eight capscrews holding
the spring support to the cylinder.
9. Gradually back off the nut on the cag-
ing tool until all spring pressure is re-
moved. Remove the caging tool, power
spring and spring support.
10. Using the caging tool bushing on the
piston neck, drive the piston assembly
from the cylinder. Remove the piston as-
sembly from the cylinder (see
Figure 90-10 on page 90-7).
11. Remove the felt wiper ring and
O-ring from the piston.
12. Remove the O-ring and nylon bush-
ing from the cylinder center boss. Use a
sharp pointed instrument to remove the
bushing; work clockwise from the cut to
pry the bushing out of the groove (see
Figure 90-11 on page 90-7).

,.

Figure 90-8. Removing Push Rod

Figure 90-6. Service Bracket Bushing

Figure 90-9. Caging Power Spring
INSPECTION ANO REPAIR. After the
Maxibrake chamber has been disassem-
bled, wash all the metal parts in cleaning
solvent and inspect and repair the follow-
ing:
1. Check the bore diameter of the cylin-
der for rust, scoring and dents. Sand-
blasting of the cylinder removes the
plating and is not recommended. Inspect
a cylinder with a suitable bore finish for
other defects, such as damaged or worn
studs and push rod bushing wear.
2. Remove all nicks and scratches from
the piston skirt. The piston neck is
chrome plated and only pistons with
necks in good condition should be
reused. If the piston neck is corroded,
scored or notched, corrective action
should be taken to prevent a reoccur-
rence. Painting the outside diameter of
the piston neck must be avoided.
Figure 90-10. Removing Piston
Assembly
<::>
A151
Figure 90-11. Removing Nylon Bushing
3. The power spring should be wire
brushed and immediately coated with a
rust inhibiting compound. It is impor-
tant that all rust on the inside diameter
of the spring be removed.
4. The spring support should be wire
brushed and coated with rust inhibiting
compound.
5. I nspect the push rod for a loose pres-
sure plate and rod wear. If rust is pres-
ent, wire brush and coat with rust
inhibiting compound.
6. If the push rod return spring is
rusty, it should be wire brushed and
coated witA a rust inhibiting compound.
7. The remaining parts should be in-
spected in accordance with standard
brake service and shop practices.
ASSEMBLY. To assemble the Maxibrake
chamber, proceed as follows:
1. Fill the inside center boss groove and
lightly coat the cylinder bore, with
grease. Install the small O-ring_ in the
inner center boss groove. Then, install
the nylon bushing in the outer center
boss groove with the beveled edge of the
bushing toward the inside of the cylinder
(see Figure 90-12 on page 90-8).
2. Install the large O-ring in the piston
groove nearest the neck. Install the sa-
turated felt wiper ring in the remaining
groove.
3. I nsert the piston assembly all the way
into the cylinder, holding the felt wiper
Brake Chambers 90-7
 Figure 90-12. Installing Nylon
Bushing
ring in place as the piston is inserted
(see Figure 90-13).
4. Assemble the spring support and pow-
er spring onto the caging tool and insert
the tool through the piston assembly. In-
stall the caging tool bushing and nut on
the end of the tool. Tighten the nut
slightly and center the power spring
over the piston hub and spring support.
5. Tighten the caging tool nut until the
holes in the spring support are aligned
with the holes in the cylinder. Install the
eight capscrews used to secu re the
spring support to the cylinder. Alter-
nately tighten each capscrew.
6. Remove the caging tool. Then, install
the push rod bushing in the piston (see
Figure 90-14). Tap the bushing lightly
to be sure it is seated properly.
Figure 90-13. Installing Piston
Assembly
90-8
Figure 90-14. Installing Push Rod
Bushing
7. Assemble the spring retainer and
push rod return spring on the push rod,
and install the assembly through the
push rod bushing and piston tube. In-
stall the flange nut on the end of the
push rod (see Figure 90-15).
8. I nstall the diaphragm with the crown
surface in the pressure plate, and center
the assembly over the cylinder. Apply
pressure to the top of the pressure plate
to squeeze the diaphragm into place. In-
stall the clamp band on the pressu re
plate and cylinder. Be sure the service
air inlet is in the position it was before
the unit was disassembled. Tighten the
clamp band bolts to 100 to 150 in-Ibs.
9. Connect a shop air supply to the
spring chamber air inlet and compress
the power spring. Adjust the flange nut
to provide a 1/16 to 1/8 inch gap at the
piston neck. Secure the flange nut with
the jam nut (see Figure 90-16).
Figure 90-15. Installing Push Rod
10. Test the chamber -for air lea~s by 1/16 to 1/8 inch. Adjust the gap if-nec-
applying air pressure to both inlets. essary and tighten the jam nut.
Maximum permissible leakage is lib-min
with a total volume of 200 cu. in. /100 psi 4. Adjust the service brakes so that
test pressure. push rod travel is as short as possible
with no brake sho~ drag.
I NSTALLA T ION. I nstall a new or recon-
ditioned Maxibrake chamber as follows:
1. Position the chamber on the mounting
bracket and run on the stud nuts. Tor-
que the nuts to 100-150 ft-Ibs.
2. Connect a shop air supply to the
spring chamber air inlet and compress
the power spring. Adjust the slack ad-
juster so it is perpendicular to the push
rod when the push rod is at 50% of its
stroke. Connect the push rod yoke to
the slack adjuster. Remove the air sup-
ply. A156

3. Connect all service air lines to the

chamber and compress the power spring.
Check the clearance between the flange Figure 90-16. Adjusting Flange Nut
nut and piston neck. The gap should be

Brake Chambers 9D-9

 TABLE OF CONTENTS

Subsection lOA 10A-1

Power Steering System 10A-1
General ...... . . . . . 10A-1
Filling and Bleeding The System 10A-1
Wheel Alignment . 10A-1
Steering Adjustment 10A-3
Subsection lOB 10B-1
Steering Gears 10B-1
General .... 10B- 1
Steering Column (20Q337) ... 10B- 1
Right Angle Steering Gear (53U157) 10B-4
Power Steering Gear (53U156) 10B-6
Steering Control Valve (36U158) lOB-15
Subsection 10C 10C-l
Steering Valves 10C-1
General ..... . lOC-1
Flow Control Valve (36U149) . 10C-1
Steering Selector Valve (36U394) 10C-3
Flow Regulator (36Z293) . . . . . . . . . . . lOC-4
Lower Steering/outrigger Pressurization Valve (36U395) 10C-4
Upper Steering/outrigger Pressurization Valve (36U391) 10C-6
Subsection 100 100-1
Steering Cylinders 100-1
General ....... . 10D-1
Steering Cylinder (38R220) 10D-1

Contents
 LIST OF ILLUSTRATIONS

Figure 10A-1. Toe-In Adjustment lOA-2

Figure lOA-2. Parallel Wheel Adjustment 10A-3
Figure lOB-1. Steering Column Installation 10B-2
Figure 10B-2. Steering Column (20Q337) ..... 10B-3
Figure lOB-3. Right Angle Steering Gear Installation 10B-4
Figure lOB-4. Right Angle Steering Gear (S3U1S7) lOB-S
Figure 10B-S. Power Steering Gear (S3U1S6) 10B-9
Figure lOB-6. Timing Mark, Steering Gear .... 10B-10
Figure lOB-7. Pressing Bearing from Housing . . lOB-lO
Figure lOB-8. Poppet Seat and Sleeve Assembly Removal 10B-11
Figure 10B-9. Poppet Seat and Sleeve Installation 10B-12
Figure lOB-lO. Timing Marks, Valve Sleeve ..... lOB-13
Figure 10B-11. Valve Sleeve I nstalled in Valve Housing lOB-13
Figure lOB-12. Worm/Input Shaft Timing Marks .. 10B-14
Figure lOB-13. Steering Control Valve Installation lOB-16
Figure 10B-14. Steering Valve and Column lOB-19
Figure lOC-1. Flow Control Valve Installation 10C-1
Figure 10C-2. Flow Control Valve (36U149) lOC-2
Figure 10C-3. Steering Selector Valve (36U394) 10C-4
Figure lOC-4. Flow Regulator (36Z293) .............. . 10C-S
Figure lOC-S. Lower Steering/Outrigger Pressurization Valve (36U39S) 10C-S
Figure lOC-6. Lower Steering/Outrigger Pressurization Valve (36U39S) lOC-6
Figure lOD-1. Steering Cylinder Removal lOD-1
Figure lOD-2. Steering Cylinder (38R220) lOD-2

List of Illustrations iii

 LIST OF TABLES

Table 108-1. Steering Gear Troubleshooting 108-7

List of Tables v
 SUBSECTION lOA
POWER STEERING SYSTEM
GENERAL
The information in this subsecticn is
concerned with filling and bleeding the
system, wheel alignment and steering
stop adjustment.
FILLING AND BLEEDING THE SYSTEM
The system should be bled any time any
portion of the system is replaced. The
following procedure should be followed to
ensure that the steering system is prop-
erly bled of all ai r.
CAUTION
Do Not operate the machine until
all air is bled from the steering
system.
1. Check the oil level in the reservoir.
Add oil as necessary to bring the capaci-
ty to its proper level.
2. Start the engine and let it idle.
3. Turn the steering wheel rapidly in
one direction until the road wheels have
reached the stops in that direction.
Then, quickly reverse the steering wheel
rotation. Keep rotating the steering
wheel left and right, u nti I all ai r is bled
from the system. Note, that the air will
bleed out only at the oil reservoir,
therefore, the oil must be circulated re-
peatedly. When the system is free of
air, the oil reservoir will be clear (not
cloudy or creamy) .
NOTE
If after the system has been bled
of ai r, steeri ng of the veh icle
seems sluggish or erratic, ai r may
be trapped between the steering
gear and the steering cylinders.
To correct this problem, crack the
fittings at the steering cylinders
until there is a steady stream of oil
from the cylinders.
4. Check the oil level at the oil
reservoir. Add oil as necessary.
WHEEL ALIGNMENT
GENERAL. To obtain the best tire wear
life and proper steering of the carrier,
two types of alignment must be checked
and maintained for the front wheels. The
wheels on each axle must be adjusted so
that they "toe-in". This prevents the
vehicle from tending to wander when
steering in a straight line, by allowing
the forces applied to the tires during
travel to act to keep the wheels set to
steer straight.
In addition, the parallel wheel alignment
must be set so that the wheels on the
front axles are as nearly paralle.l to each
other, relative to the centerline of the
carrier, as possible. This adjustment is
necessary to assure that all wheels will
steer in the same direction.
If the ti res begin to show signs of exces-
sive or uneven wear, and they have been
maintained at the proper inflation pres-
sure, check the alignment of the wheels
as described below.
Subsection lOA lOA-l
 NOTE
Toe-in must be adjusted properly
before adjusting parallel
alignment. All tires must be in-
flated to the proper pressure, and
matched in outer diameter, for the
following adjustments to be effec-
tive. The adjustments must be
made with the wheels set to steer
in a straight line, since the front
wheels turn in slightly different
arcs.
TOE-I N ADJUSTMENT. The recom-
mended toe-in for the carrier is 1/16
inch::1/16 inch (1 .6&::6mm). To check and
adjust the amount of toe-in, proceed as
follows (see Figure 10A-l):
IMPORTANT
B MINUS A EQUALS TOE·IN
TOE·IN RECOMMENDATION IS
1/16" t 1/16"'1.6 t 1.6 mml
Figure IDA-I. Toe-In Adjustment
1. Place the carrier on a flat and level
concrete su dace, and jack up the front
of the ca rrier.
2. Whiten the center of the tread areas
of all four tires, around the circumfer-
ence, with chalk. Scribe a straight line
a rou nd the ci rcumference of each ti re,
by positioning a scribe or other pointed
object against the whitened area of the
ti re. Rotate the ti re while holding the
scribe firmly.
3. Lower the carrier to the ground, and
move the carrier backward and then for-
ward approximately 6 feet C1 .8m). This
will cause the tires and steering linkage
to assume their normal driving positions.
10A-2
NOTE
Do not measure toe-in with the
front axle jacked up. Toe-in must
be measu red with the weight of the
carrier on the axles, so that the
tires are in their normal driving
position.
4. Measure the distance between the
scribed lines at the rear of each tire on a
particular axle, and at the height of the
hubs, using a trammel bar or other suit-
able measuring device. Measure the dis-
tance between the same lines that the
front of each tire. Subtract the front
measurement from the rear measurement
to obtain the total toe in.
5. If adjustment is necessary, disconnect
front drag link ball socket at the pitman
arm ball and the rear drag link ball
socket at the ball on the front rear axle.
Loosen the ax Ie clamps and rotate the tie
rod until the required toe-in is obtained.
Tighten the ax Ie clamps.
6. Repeat steps 4 and 5 to check and ad-
just the toe-in of the other axle.
7. Proceed to check and adjust parallel
alignment as necessary.
PARALLEL WHEEL ALIGNMENT. Parallel
wheel is adjusted through adjustment of
the drag links shown inFigure 10A-2 on
page lOA-3, and can only be attempted
after toe-in adjustments have been made.
To adjust the parallel wheel alignment,
proceed as follows:
1. Set the wheels in the straight ahead
position. Raise the machine on the front
outriggers just high enough to relieve
the load on the front tires. Lock the out-
riggers in this position (see topic Out-
rigger Operation).
-
2. Locate the center position of the
steering wheel. (Position index marks on
steering gear output shaft perpendicular
to input shaft centerline.)
3. Check the setti ng of the front drag
link. It should measure 25.25 inches
(64.1 cm) front ball center to ball
center.
4. Check the position of the vertical cen-
ter line of the pitman arm in relation to
the vertical center line of the power
 STEERING 0
~______C_Y_L_IN
__ __~
D_ER

FRONT
FRONT
AXLE

REAR
DRAG LINK

ARM

POWER
_ _ STEERING
GEAR

BALL SOCKET I~
1\ 60
":-j i-"REF.

Figure lOA-2. Parallel Wheel Adjustment

steering gear. The pitman arm should be
approximately 6 degrees to the rear of
center. If the position of the pitman arm
is more or less than 6 degrees proceed
with step 5. If the position is correct,
proceed to step 6.
5. Loosen the front drag link clamp.
move the pitman arm mounting nut
washer. Rotate the pitman arm and
drag link socket enough to achieve
desi red 6 degree offset. Reinstall
pitman arm and tighted the clamp.
6. Check the setting of the rear drag
link. It should measure 66.20 inches
(168.1 cm) from ball center to ball
center. Adjust if necessary.
STEERING ADJUSTMENT
Re-
and To afford the minimum turning radius in
the either direction and prevent tire or car-
the rier damage, the steering cylinders must
the be adjusted to limit the turning angle of
the wheels. To adjust the steering cyl-
inders proceed as follows:

Power Steering System 10A-3

 NOTE
The steering gear is equipped with
poppets which unload pump pres-
sure at maximum steering angle.
These poppets are automatically
adjusted the first time the steering
gear is turned to maximum angle in
each di rection. After initial ad-
justment, these poppets can be ad-
justed to a smaller angle only by
disassembly of the power steering
gear. To prevent accidental
over-adjustment of these poppets
while adjusting minimum tire clear-
ance, disconnect the front drag
link and steer with the upper
steering.
NOTE
All alignment adjustments must be
done with the ax les positioned at
normal ride height and level with
the frame.
1. Disconnect the rear steering cylinder
from the axle king pin connection.
10A-4
2. Turn the wheels to the left until the
L.H. front tire is 0.5 in (1.27 mm) from
the edge of the frame rail bottom plate.
3. Adjust the rear cylinder so it meas-
ures 31.5 in (80 mm) from ball center to
ball center when fully extended. Connect
the rear cylinder to the axle king pin
connection. Check that L. H. front tire
clearance is still 0.5 in (1.27 mm).
4. Disconnect the front steering cylinder
from the axle king pin connection.
5. Turn the wheels to the right until the
R.H. front tire is 0.5 in (1.27 mm) from
the edge of the frame rail bottom plate.
6. Adjust the front cylinder so it meas-
u res 32 in (81 mm) from ball center to
ball center when fully extended. Connect
the front cylinder to the axle king pin
connection. Check that R.H. front tire
clearance is still 0.5 in (1.27 mm).
7. Torque all rod end clamp locknuts to
50-60 ft-Ib (68-81 N m).
8. Connect the front drag link.
 SUBSECTION lOB
STEERING GEARS
GENERAL
This subsection describes the compo-
nents of the upper and carrier systems
and includes recommended removal, re-
pair and installation procedures.
The carrier steering system consists of a
steering column, a right angle steering
gear and a power steering gear. The
upper steering system is controlled by a
steering control valve.
STEERING COLUMN (20Q337)
REMOVAL. To remove the steering col-
umn, proceed as follows (see
Figure lOB-1 on page lOB-2):
1. Remove turn signal assembly (A) from
steering column and place it aside within
the cab.
2. Disconnect horn wire, near the base
of the steering column.
3. Lift rubber boot (B) to expose yoke
shaft. Remove lock nut and capscrew
(C) from the base of the steering
column.
4. Remove brackets (D) and cushions
from the dash panel.
5. Lift the steering column to disengage
the shaft from the yoke.
6. Remove steering column (E) from the
cab.
DI SASSEMBL Y. To disassemble steering
column, proceed as follows (see
Figure 10B-2 on page 10B-3):
1. Remove rubber boot (19) from base of
steeri ng col umn .
2. Remove horn button (02) by pushing
down on emblem (Ol) while turning coun-
terclockwise.
3. Remove contact cup (03) and spring
(04) .
4. Remove screws (05 and 05A) to re-
move base plate (06).
5. Remove wheel nut (07). Loosen wheel
using a wheel puller. If puller is not
available, grasp wheel firmly with both
hands and pull up steadily while rocking
wheel back and forth slightly. Remove
wheel (OB).
6. Remove screws (10) to remove contact
ring (09) from wheel.
7. Remove spacer (11) and spring seat
(12) from upper end of shaft.
B. Remove shaft (14) from lower end of
housing (15).
9. Remove dust cup (lB), spring (17),
and spring seat (12) from lower end of
shaft.
10. Remove horn contact brush-(16), by
pulling out with pliers. Take care not to
damage bakelite shell or cut
wi re/insulation.
11. Remove bearing assemblies (13) from
housing by prying or pressing only
against the outer shell flange.
ASSEMBLY. To assemble the steering
column, proceed as follows (see
Figure lOB-2 on page 10B-3):
Subsection lOB 10B-1
 Figure lOB-I. Steering Column Installation

1. I nstall bearing assemblies (13) in 6. Install base plate (09) to wheel with
housing by pressing only against the three screws (10).
outer shell flange.
7. Install wheel (08) with nut (07).
2. Route horn wi re th rough tube and Torque wheel nut to 55-65 ft:lbs
carefully press horn contact brush into (7.6-8.9 kg-m).
housing.
8. I nstall base plate (06) with screw (05
3. Install spring seat (12), spring (17), and 05A).
and dust cup (18) to lower end of shaft.
9. Install spring (04) and contact cup
4. Insert shaft (14) into lower end of (03) .
housing (15) through bearing
assembl ies. 10. Install horn button (01 and 02) by
depressing horn button and turning it
5. Install spring seat (12) and spacer clockwise until seated.
(11) to upper end of shaft.

108-2
 / ~ 14

13,!//~ /
'7'8 ~
})
19

01. EMBLEM PLATE 10. DRIVE SCREW

02. HORN BUTTON 11. SPACER
03. CONTACT CUP 12. SPRING SEAT
04. SPRING 13. BEARING-JACKET TUBE
05. CONTACT SCREW 14. SHAFT
05A. CONTACT SCREW 15. HOUSING
06. BASE PLATE ASSEMBLY 16. HORN
06. WHEEL NUT 17. SPRING
OS. WHEEL 1S. DUST CUP
09. CONTACT RING 19. RUBBER SHIELD

Figure 108-2. Steering Column (20Q337)

Steering Gears 108-3

11. Install rubber boot (19) on base end
of column housing.
INSTALLATION. To Install a new or re-
paired steering column, proceed as fol-
lows (see Figure lOB-1 on page lOB-2):
1. Insert the splined end of steering col-
umn (E) into the yoke shaft.
2. Install and tighten capscrew (C) and
lock nut at the base of the steering col-
umn. Push rubber boot (B) down to the
floor.
3. Assemble cushions and brackets (D)
to the steering column, and secure to
dash panel with original fasteners.
4. Connect the horn wire near the base
of the steering column.
5. Install turn signal assembly (A) on
the steering column at the 9 O'Clock po-
sition.
6. Secure the turn signal wire harness to
the steeri ng col umn with wi re ties.
RIGHT ANGLE STEERING GEAR
(53U157)
REMOVAL. To remove the right angle
steering gear, proceed as follows (see
Figu re lOB-3):
1. Remove capscrews from the yokes on
the input and output shafts.
2. Remove capscrews secu ring the steer-
ing gear to the brackets.
3. Slip yokes from the steering gear
shafts and remove the steering gear from
vehicle.
D I SASSEMBL Y. To disassemble the right
angle steering gear, proceed as follows:
NOTE
It is a good practice to always re-
place the oil seals when disassembl-
ing the steering gear.
1. Unbolt cap (05). Remove assembled
pinion shaft (02) from the housing (see
Figu re lOB-4 on page lOB-5).
10B-4
2. Remove the cap from the pinion shaft.
Remove roll pin (14) using a suitable
punch.
3. Remove the pinion shaft from lower
bearing cone (19) by pressing on the
shaft end closest to the toothed side of
gear (11).
4. Unbolt blank cap (17). Remove bear-
ing cone (10), washer (18) and spacer
(12) from thru-shaft (15).
5. Remove shaft assembly from housing.
6. Remove remaining bearing cone (10)
from thru-shaft. Remove roll pin (14)
using a suitable punch, and slide gear
(11) off the shaft.
7. Use a slide hammer puller to remove
bearing cup (20) from the housing.
Bearing cups (01) must be removed us-
ing a punch, through the shaft opening
in the caps, on the back of the cups.
8. Remove oil seals (06) from the caps.
Do not attempt to reuse an oil seal once
it has been removed.
9. Discard old gaskets (07, 08 or 09).
Thoroughly clean and inspect all parts
for wear or damage. If necessary, three
1/4-inch pipe plugs (16) can be removed
from housing.
ASSEMBLY
1. Install gear (11) on the pinion shaft
Figure 108-3. Right Angle Steering
Gear Installation
 t
1-- 04 02
~01-- __
Q--10
1

i
~03
~
©
~"!
07 .., __ 05
17 08 09 '" 'I
'4 "

~
u

'D' ____'9
~ ~20
!
I
S----06
~ I 07
08
09

11
,................... 18
I - ....
I --
1
1
1
1
--
'- ....
I ....
----_
-- .... 16 13

-- ....
I
........ 1
-.............. I
.... --I

05 04

Figure 108-4. Right Angle Steering Gear (53U157)

(02). Line up holes in shaft and pinion 5. Install bearing cone (10) on the
gear. Drive in roll pin (14) (see thru-shaft. Bearing cone should be
Figure 10B-4 on page 10B-5). flush with back of gear (11).

2. I nsert key (03) in keyway from 6. Assemble the caps: Press _bearing
toothed side of gear. Press bearing cone cups (01) into the caps (05 and 17). Do
(19) onto stepped end of pinion shaft. not install new seals at this time. Seals
will be installed after backlash and drag
3. Install bearing cone (10) on pinion adjustments are completed (see
shaft (02). Bearing cone should be Figure 10B-4).
flush with the back of gear (11).
7. Assemble the housing: Press bearing
4. Install key (03) in Keyway of cup (20) into center bore of housing
thru-shaft (15). Slide gear (11) over (13). Install three 1/4-inch pipe plugs
the key. Drive roll pin (14) through (16) in housing.
holes In the gear and shaft (see
Figu re 1OB-4) 8. Install pinion shaft (02) assembly in
housing. Install two 0.015 in. (0.4 mm)

Steering Gears 10B-5

gas kets (07) and cap (05) (see
Figu re 1OB-4)
NOTE
Adjustment gaskets are available in
o.015, 0 . 005 and O. 003 in. (0 . 4,
0.1 and 0.08 mm) sizes.
9. Adjust bearing drag: Turn the pinion
shaft. If the shaft is hard to turn, add
gaskets. If the shaft turns too easily,
remove gaskets. There should be a small
amount of bearing drag. When adjust-
ment is complete, remove cap and install
seal (06). Apply RTV slicone gasket
compound to gasket su rfaces. Tape
spline of pinion shaft to prevent seal
damage when installing cap. Torque
capscrews (04) to 18 ft-Ibs (24.4 Nm).
10. Install thru-shaft (15) assembly
through core of housing. Install two
0.015 in. (0.4 mm) gaskets (07) and cap
(05) on housing end nearest the gear
(11 ) .
NOTE
Adjustment gaskets re available in
O. 015, O. 005 and 0.003 in. (0.4,
0.1 and 0.08 mm) sizes.
11. Push the thru-shaft assembly firmly
against the cap. Check the pinion shaft
(02) for backlash. If there is too much
backlash, gaskets must be removed. If
there is too little backlash, gaskets
should be added. When adjustment is
complete, remove cap and install seal
(06). Apply RTV slicone gasket com-
pound to gasket surfaces. Tap spline of
pi n ion shaft to prevent seal damage when
installing cap. Torque cap screws (04)
to 18 ft-Ibs (24.4 Nm).
12. Install spacer (12) on thru-shaft,
until it contacts core and butted against
the toothed side of the gear. Place
washer (18) against the spacer and in-
stall bearing cone (10) flush against the
washer.
NOTE
Adjustment gaskets are available in
0.015,0.005 and 0.003 in. (0.4,
0.0 and 0.08 mm) sizes.
10B-6
13. Adjust bearing drag: Install blank
cap (17) and two 0.015 in. gaskets
(07). Turn the thru-shaft. If the shaft
is hard to turn, add gaskets. If the
shaft turns too easily, remove gaskets.
There should be a small amount of bear-
ing drag. When adjustment is complete,
remove cap and apply RTV slicone gasket
compound to gasket surfaces. Torque
cap screw (04) to 18 ft-Ibs (24.4 Nm).
14. Remove a pipe plug (19). Install 16
oz of EP-90 grease or equivalent into
gear housing. Install the pipe plug se-
curely in housing.
INSTALLATION. To install a new or re-
paired right angle steering gear, pro-
ceed as follows (see Figu re 10B-3 on
page lOB-4):
1. I nstall the steering gear between the
brackets and slip yokes onto the input
and output shafts.
2. Install capscrews secu ring the steer-
ing gear to the brackets.
3. install capscrews securing the yokes
to the input and output shafts.
POWER STEERING GEAR (53U156)
DESCRI PTION. Turning the steering
wheel transmits force to the steering
gear input shaft. A torsion bar, con-
nected to the input and worm shafts,
turns the input shaft and exerts rota-
tional force on the worm shaft. This
force causes the worm shaft, th rough the
recirculating ball mechanism, to try to
move the rack piston through the gear
housing cylinder bore. this movement is
resisted by the sector gear, attached by
steering linkage to the steered wheels.
This resistance causes the torsion bar to
be twisted by the input shaft, thus actu-
ating the control valve. The control
valve directs pressurized fluid to _the
rack piston to assist its movement
through the cylinder bore. The rack pi-
ston then turns the sector shaft to steer
the vehicle.
The hydraulic pressure required for the
gear to steer the vehicle is created by
the swing , outrigger, and steering
pump. The control valve senses the
pressure requirements and sends fluid at
suitable flow rate and pressu re to the
cylinder cavity.
 NOTE
To assist in the elimination of
pump heat problems or damage
from excessive hydraulic pressure,
two unloading (poppet) valves
have been incorporated in the rack
piston. One of these valves will
open and release pressu re in the
gea r housing as the steered wheels
reach the axle stops.
A shock load to the steered wheels tran-
smits force to the sector shaft, to the
rack piston and onto the worm shaft.
This causes the control valve to send
pressurized fluid to the proper side of
the piston to resist the shock forces.
The 'blocking action' prevents kick-back
of the steering wheel.
This unit has an automatic bleed system.
No servicing is required.
TROUBLESHOOTING. Table 10B-1 lists
some of the problems, and thei r probable
causes, which may be experienced with
the power steering gear and the steering
components.
Steering Gears 10B-7
 Oversteer or Darting Excessive Heat (150°F [6S.6°C] Over Ambient)
1. Front end components binding. 1. An undersize replacement hose or line can cause excessive
heat.
2. Sector shaft adjustment too tight.
3. Control valve spool sticking. 2. A restricted hose or line due to a kink or severe bend can
cause excessive heat.
4. Steering geometry incorrect (pitman arm and/or axle arm
ball position). 3. If poppets have not been adjusted properly to relieve pres-
sure at ends of steering gear travel excessive heat may
S. Steering column binding. result.
High Steering Effort in One Direction 4. If the hydraulic system fluid becomes overheated it can
1. Vehicle overloaded. cause the seals in the steering gear to dry out and harden
Hydraulic control valve adapter seal failure. and lose their sealing ability.
2.
3. Auxiliary cylinder lines crossed. 5. If the hydraulic system fluid has been overheated it will have
a rancid odor.
4. Inadequate flow.
6. The internal parts of the steering gear may show some
5. Inadequate pressure. discoloration if the hydraulic system fluid has been highly
6. Low tire pressure on one side. overheated.
7. Thrust bearing adjustment nut loose. Road Wander
B. Lower worm shaft seal failure. 1. Components in steering linkage such as ball sockets on drag
link or axle arm loose or worn.
High Steering Effort in Both Directions
2. Tire pressure incorrect or unequal left to right.
1. Vehicle overloaded.
3. Wheel bearings improperly adjusted or worn.
2. Low flow or pressure from pump, may be due to sticky flow
control or relief valve, or high internal leakage in pump. 4. Steering gear mounting bolts loose on frame.
3. Components of steering system binding. High back pres- S. Front end alignment out of specification.
sure caused by clogged return line filter. 6. Steering gear center adjustment improperly adjusted.
4. Restriction in return line. 7. Steering geometry incorrect (pitman arm and/or axle arm
5. Excessive internal leakage in steering gear. ball pOSition).
6. Low hydraulic fluid level. B. Slip joint in upper column sticking or binding.
7. Control valve spool or sleeve sticking. 9. Thrust bearing adjustment nut improperly adjusted.
B. Low tire pressure. No Recovery
9. Restriction in supply line. 1. Front end alignment incorrect.
Lost Motion at Steering Wheel 2. Front end components binding.
1. Loose ball socket connections or other leakage connections. 3. Pump flow insufficient.
2. Loose steering gear adjustments - Side cover adjustment 4. Tire pressure low.
and/ or worm adjustment. 5. Control valve spool sticking.
3. Steering wheel loose on shaft. 6. Tight front axle spindles.
4. Pitman arm loose on output shaft. 7. Steering column binding.
5. Steering g~ar loose on frame. Shimmy
6. Loose connections between steering column and steering 1. Front end alignment incorrect.
gear.
2. Air in hydraulic system.
Abnormal Noise
I
3. Wheels out of balance.
1. A "clicking'" noise heard when initiating a steering man·
euver or when changing directions of turn may indicate that 4. Components In steering linkage such as ball sockets on drag
some component is loose and is shifting under load. link or axle arm loose or worn. -
2. A change in the normal noise from the power steering 5. Badly worn or unevenly worn tires.
pump may indicate that an excessive amount of air has 6. Wheel bearings improperly adjusted or worn.
been trapped in the fluid or that the fluid level IS low.
Extemal Oil Leakage
3. Excess noise from the power steering pump may indicate
that the hydraulic system has dirt. sludge or other impurities 1. No external leakage is acceptable at steering gear.
trapped or that the power steering pump is worn and 2. Vent plug leaking at side cover indicates failure of sector
defective. shaft oil seal inside cover.

Table 108-1. Steering Gear Troubleshooting

10B-8
ALTERNATIVE SERVICE CONSTRUCTION 48 49
"NOTE: Teflon Back-Up Washer (45) is as Lategral 47 \ / 50
Pan of 2 Piese Seal (44) in Latest Seal Kit. \ ~® / '
46 ~~ _ _ 51

~,:\ \ ti ~r4.p 17 27 28

42 ~"" ,~"cl //
57 41 "'" ~ ~ :, (J/i)11
37
~o_
\ 29 40 ~ ~424 ? Vv
~
~~ ___ ............ 22
,/ ..". ~ '" -.... 23
38-_ ~' ~25
39 f) 26 06 06
30 ~~ U ~)6 15 14 \ 11;403 02 56
32"",-~ ~ ~~
\ 66 / '2" @(V
1,112 13 /rOIf}OO /,.../"
34"::sr~
36",,~~
35
31 i
I

t=:: 18
7,,-,T\
/

19 21 2~ I
~
~~O.~~;'
09
<--

I\ '\'-01
.A.. 19 18 08 55
~5' 07
AUTOMATIC POPPET ADJUSTMENT

Figure 10B-5. Power Steering Gear (53U156)

REMOVAL. To remove the power steer-
ing gear, proceed as follows:
1. Tag and disconnect the
lines at the steering gear.
2. Remove the capscrew and locknut
which secures the steering arm to the
output shaft. Disengage the steering
arm from the output shaft.
3. Loosen the ha rdwa re wh ich secu res
the steering shaft to the input shaft.
4. Securely support the steering (ap-
proximate weight is 80 Ibs (36 kg)). and
remove the hardware which secures the
steering gear to the carrier.
5. Disengage the steering shaft and re-
move the steering gear from below the
ca rrier.
DISASSEMBLY. Disassemble the steering
gear using the following procedure (see
Figu re lOB-5):
WARNING
Solvents are flammable. Do not use
near spark or flame. Extreme per-
hydraulic sonal injury could result. Wear
eye protection when using solvent.
NOTE
Clean the gear housing before dis-
assembly using petroleum-based
solvent. Blow dry using low pres-
sure (15 psi maximum) filtered
compressed ai r.
NOTE
If the automatic poppet assembly is
not to be removed, do not rotate
the input shaft more than 1.5
turns from the straight ahead posi-
tion. Doing so will disturb the ad-
justment of the poppet.

Steering Gears 10B-9

1. Disassemble the side cover and sector
shaft as follows:
A. Rotate input shaft (14) such that the
timing mark is perpendicular to the
input shaft centerline (see
Figure lOB-6) .
Figure 10B-6. Timing Mark, Steering
Gear
B. Remove dirt and water seal (36).
C. Clean paint or corrosion from sector
shaft (40) and loosen adjusting screw
jam nut (49).
D. Remove side cover capscrews (51).
Tap lightly with a soft faced hammer
on the end of the sector shaft and
remove side cover (48), and sector
shaft assembly.
NOTE
Replace capscrews (51), if neces-
sary, only with identical special
capscrews.
E. Remove retaining ring (35), steel
back-up washer (34), Teflon back-up
washer ~33), and two-piece seal (32).
F. Remove bearing (31) from the housing
if inspection shows it to be damaged
or worn. Use special bearing mandrel
(Kent-More J26651) to press bearing
out (see Figu re lOB-7).
G. Remove adjusting screw jam nut (49).
Turn adjusting screw (41) clockwise
to disengage side cover. Remove the
sector shaft from the side cover.
lOB-10
Figure 10B-7. Pressing Bearing from
Housing
H. Remove side cover retaining ring
(43), two-piece seal (44), Teflon
back-up washer (45), steel back-up
washer (46), and vent plug (50) from
the side cover.
I. If necessary, unstake retainer (42)
and remove the retainer and the ad-
justing screw from the sector shaft.
2. Remove the valve assembly as follows:
A. Loosen adjusting screw (38) and pop-
pet stop screw (37).
B. Scribe a line across valve housing
(07) and housing (29) to aid in posi-
tioning valve housing during reas-
sembly.
C. Remove seal protector (56) from input
shaft (14).
D. Remove capscrews (01) and the valve
housing.
E. Remove valve sleeve (13), th-rust
washers (09), and th rust bearing
(10) from the valve housing.
F. Remove seal O-ring (08) and automat-
ic bleed passageway seal (55) from
the valve housing.
G. Remove di rt and water seal (02), re-
taining ring (03), steel back-up
washer (04), seal cup (05), and
O-ring (06) from the valve housing.
3. Disassemble the rack piston and input
shaft as follows:
 NOTE
If automatic poppet assembly is not
to be removed, do not rotate the
input shaft more than 1.5 tu rns
from the straight ahead position.
Doing so will disturb the poppet
adjustment.
A. Remove rack piston (17) and input
shaft (14) from housing (19).
B. Remove ball retu rn cap (25), seal
(24), and guide halves (23).
WARNING
Balls (22) are a matched set. If
one is damaged, they must all be
replaced as a complete set. Fail-
ure to observe this warning may
result in the loss of steering and
vehicle control which may cause in-
jury or death of personnel.
C. Remove 25 steel balls (22) from the
rack piston. Rotate the worm/input
shaft (14) until all of the balls have
been removed.
D. Remove the worm/input shaft from the
rack piston.
E. Remove seal ring (16) and O-ring
(15) from the worm shaft.
F. Remove Teflon seal ring (28) and
O-ring (27) from the rack piston.
G. Remove automatic bleed screw (52),
pin (53), and spring (54) from the
rack piston.
4. Remove the automatic poppet assembly
as follows:
WARNING
Wear eye protection while servicing
the spring loaded poppet
assembly. Failure to observe this
warning could result in eye injury
or blindness due to poppet parts
being propelled into the eyes.
CAUTION
Do not use the oil slot in the end
of the smaller diameter poppet seat
to turn the poppet seat and sleeve
assembly. Damage to the seat may
result.
A. Remove poppet seat and sleeve as-
sembly (18) using a special poppet
seat tool (Kent-Moore J36452) as
shown in Figure 10B-8. Remove pop-
pets (19), spring (20), and nylon
spacer rod (21).
Figure 10B-8. Poppet Seat and Sleeve
Assembly Removal
CLEANING AND INSPECTION
WARNING
Solvents are flammable. Do not
use solvents near spark or flame.
Extreme personal injury could re-
sult. Wear eye protection when
using solvents.
Clean all parts using petroleum-based
solvents. Blow each part dry using low
pressure (15 psi maximum) filte.red com-
pressed air. Avoid using cloth to wipe
parts, since lint may cause binding or
sticking of closely fitted components.
Check to make sure that all sealing sur-
faces are free of nicks and corrosion.
Replace all seals. I nspect all su rfaces
for cracks or flaking. Replace all dam-
aged parts.
ASSEMBLY. Assemble the steering gear
using the following procedure (see
Figure 10B-5 on page 10B-9):
Steering Gears 10B-11
 NOTE
Dip all parts in clean hydraulic oil
prior to assembly.

1. I nstall automatic poppet assembly as

follows:

WARNING
Wear eye protection when servicing
the spring loaded poppet
assembly. Failure to observe this
warning may lead to eye injury or
blindness caused by parts pro-
pelled by the force of the springs.
CAUTION
Do not use the oil slot in the end
of the smaller diameter poppet seat
to turn the poppet seat and sleeve
assembly. Damage to the seat may
result.
A. Reverse the poppet seat and sleeve
assembly (18) and screw it into its
hole in rack piston (17), such that
the end with the retaining ring is fac-
ing out. Press the seat into the
sleeve until the retaining ring on the
seat bottoms against the poppet sleeve
(see Figu re lOB-9). Remove the as-
sembly from the rack piston.
B. Apply Locquic grade 'I' primer to the
th reads of the poppet seat and sleeve
assembly. Allow time for the primer
to dry (approximately 10 minutes).
Apply Loctite 222 and install (in
order) poppet seat assembly (18),
poppet (19), spring (20), nylon spa-
cer rod (21), poppet (19), and
poppet seat assembly (18). Torque
poppet seats to 9-11 ft-Ibs. (12-15
Nm) using special poppet seat tool
(Kent-Moore J36452) .
2. Assemble the rack piston and input
shaft as follows:
NOTE
Do not rotate the input shaft more
than 1.5 turns from the straight
ahead position. Doing so will dis-
turb the poppet adjustment.
Figure 10B-9. Poppet Seat and Sleeve
Installation
A. Install a-ring (15), and seal ring
(16) onto worm shaft (14).
B. I nstall bearing (31), if removed, us-
ing special bearing mandrel
(Kent-Moore J26651). Press bearing
in from the cover side. Install retain-
ing ring (30).
C. I nstall worm/input shaft in rack pis-
ton (17).
WARNING
Do not seat guides with a hammer.
Damaged guides can cause lock-Up
or loss of steering, resulting in
loss of control of the veh icle wh ich
may cause injury or death of per-
sonnel.
D. Install ball return guide halves (23)
into rack piston. Install 25 balls (22)
into guide hole. Rotate the
worm/input shaft (14) to pull the
balls into the grooves.
E. Install seal (24) and cap (25) on the
rack piston. Torque the screws to
14-22 ft-Ibs (19-20 Nm).
F. Install 0- ring (27) and seal ring (28)
into rack piston grooves. Liberally
coat the seals and O-rings with
grease.
G. Grease housing (29) cylinder bore.
Install the rack piston-worm/input
shaft assembly into the housing.

10B-12
H. Install sealing nut (39), adjusting
screw (38), poppet stop screw (37),
and a-ring (57) into the housing.
Torque the poppet stop screw to
15-25 ft-Ibs (20-34 Nm).
3. Assemble the control valve as follows:

WARNING
Valve sleeves are matched to right
or left hand worm screw th reads.
An incorrect valve sleeve can
cause driver injury due to loss of
veh icle control.
Figure 108-11. Valve Sleeve
A. Grease a-rings (12) and seal rings Installed in Valve Housing
(11). Install the rings onto the valve
sleeve (13). G. Align the timing marks on the
worm/input shaft (14) and valve
B. Grease and install seal ring (08) and sleeve (13) as shown in Figure lOB-12
bleed passageway seal (55) onto the on page lOB-14. Install the valve
valve housing (07). housing assembly. torque the cap-
screws to 45-55 ft-Ibs (61-75 Nm).
c. Grease and install one thrust washer
(09) and thrust bearing (10) flat in
the valve housing.
D. Grease and install the other th rust
washer (09) on the smooth end of
valve sleeve (13).
E. Note the timing mark on the valve
sleeve. Make a corresponding mark
on the front face of the valve (see
Figu re lOB-lO).

Figure 108-12. Worm/Input Shaft

Timing Marks
4. Install the side cover and sector shaft
as follows:
A. Apply wheel bearing grease_to bear-
ing (31).
NOTE
There are two seal kits available.
Figure 108-10. Timing Marks, Valve Assembly instructions differ. If
Sleeve Teflon seal (45) is not an integral
part of two-piece seal (44), AND
F. I nstall the valve sleeve into the valve the chamfer on short side of sector
housing. Properly installed, the shaft (40) has rough edges, skip
valve sleeve face should be about 0.40 steps Band E, and follow steps C
in (10.2 mm) below the valve housing and F.
face (see Figure 10B-11).

Steering Gears 10B-13

B. I nstall steel back-up washer (46),
Teflon back-up washer (45), seal
(44), and retaining ring (43) in side
cover (48).
C. I nstall steel back-up washer (46),
and Teflon back-up washer (45) into
side cover (48).
D. Apply wheel bea ri ng grease to ex-
panded end of adjusting screw (41).
Install adjusting screw and new re-
tainer (41) to eliminate end play in
sector shaft (40). Stake retainer to
sector shaft.
E. Grease sector shaft and install side
cover. Turn adjusting screw into
side cover until tight, then back off
one full turn.
F. Put retaining ring (43) on sector
shaft (40). Install two-piece seal
(44) about 1 inch (15.4 mm) onto sec-
tor shaft. I nstall sector shaft and
seal assembly, and retaining ring into
side cover (48). Turn adjusting
screw into side cover until tight, then
back off one full turn.
G. I nstall jam nut (49), vent plug (50)
and greased gasket (47) onto side
cover.
H. There are fou r teeth on rack piston
(17). Align the space between tooth
two and tooth th ree with the center of
the sector shaft opening. Torque ad-
justi ng screw (38) to 10-15 ft-Ib
(13.6-10.3 Nm). Loosen adjusting
screw 1/4 to 1/2 turn. The torque
required to rotate worm/input shaft
(14) through a 90 0 arc to each side of
the center must not exceed 15 in-Ibs
(1.7 Nm). Adjust screw (38) as nec-
essary to accomplish the required
turning torque.
I. Center the rack piston and install the
sector shaft/side cover assembly into
housing (29). Torque the special
capscrews (51) to 150-170 ft-Ibs
(203-230 Nm).
J. I nstall two-piece seal (32), Teflon
back-up washer (33), steel back-up
washer (34) with small O. D. facing
away from the housing, and retaining
ring (35). Pack the area around seal
(32) with Mobil temp 1 or 2 grease, or
equivalent. Install dirt and water
seal (36). Install 0- ring (06), seal
10B-14
cup (05) flat side out, steel back-up
washer (04), and retaining ring (03).
Pack area around seal (06) with Mobil
temp 1 or 2 grease, or equivalent.
Install di rt and water seal (02).
K. Install spring (54), pin (53) and au-
tomatic bleed screw (52). torque
screw to 16-20 ft-Ibs (22-27 Nm).
5. Make final adjustments as follows:
NOTE
Do not rotate the input shaft more
than 1.5 tu rns from the straight
ahead position. Doing so will dis-
tu rb the poppet adj u stment.
A. Center the steering gear (timing mark
perpendicular to worm/input shaft
(14)) as shown in Figure 10B-6 on
page 10B-1O. Tighten adjusting
screw (41) to provide 25-30 in-Ibs
(2.8-3.4 Nm) of torque required to
rotate the worm/input shaft through a
180 0 arc to each side of the centered
position.
B. Loosen adjusting screw one turn.
Note max imum torque requi red to ro-
tate the worm/input shaft through a
180 0 arc to each side of the centered
position.
C. Tu rn the adjusting screw to increase
maximum torque noted in previous
step by 2-4 in-Ibs (0.23-0.45 Nm).
Torque jam nut (49) to 40-45 ft-Ibs
(54-61 Nm). Check worm/input shaft
torque and adjust if torque exceeds
20 in-Ibs (2.3 Nm).
D. Adjust worm/input shaft adjusting
screw (38) to increase maximum
worm/input shaft torque noted in
previous step by 10-15 in-Ibs
(1.1-1.7 Nm). Torque sealing nut
(39) to 40-50 ft-Ibs (54-68 Nm). Ad-
just if worm/input shaft torque
exceeds 35 in-Ibs (4.0 Nm).
INSTALLATION. To install a new or re-
pair power steering gear, proceed as fol-
lows:
NOTE
Make sure the road wheels are in
the straight-ahead position and
that the steering wheel is properly
 aligned before connecting the
steering shaft and arm to the
steering gear.
1. Position the steering gear at its mount
below the carrier. Engage the steering
shaft to the input shaft and install the
ha rdwa re used to secu re the steeri ng
gear to the carrier frame. Torque
mounting capscrews to 180-200 ft-Ibs
(26.6-27.7 kg-m). Tighten the steering
shaft hardware.
2. Install the steering arm on the output
shaft. Tap the steering arm slightly so
that it seats secu rely on the s haft and
tighten the hardware.
3. Connect the hydraulic lines to the ap-
propriate ports on the steering gear.
4. Start the engine and operate the
steering wheel in both directions to
check the operation of the steering gear
and to bleed all air from the system.
Check for leakage at the steering gear
and hose connections.
STEERING CONTROL VALVE (36U158)
DESCRI PTION. The steering control
valve consists of a manually operated di-
rectional valve and servo feedback meter
element in a single body. The steering
control valve is located at the base of the
steering column below the cab floor (see
Figure 108-13 on page 108-16) The
steering control valve is used to link the
hydraulic system fluid flow to and from
the machine steering cylinders and the
hydraulic system pump.
REMOVAL. To remove the steering con-
trol valve from the machine, proceed as
follows, (see Figu re 108-13 on page
108-16) :
1. Shut the machine down.
2. If equipped, remove the turn signal
from the steering column.

12

01. STEERING VALVE

02. STEERING COLUMN
03. BRACKET
04. BRACKET
06. SCREW
06. LOCKWASHER
07. WASHER
OS. MOUNT
09. WASHER
10. LOCKWASHER
11. SCREW
12. NUT
13. SCREW
14. LOCKWASHER
16. WASHER
16. PLATE
17. WASHER
1S. LOCKWASHER
19. SCREW A1902

Figure 108-13. Steering Control Valve Installation

3. Remove the cover at the front bottom caps and covers on the hydraulic lines
of the cab and tag and disconnect the and valve ports.
hydraulic lines at steering valve. Install

Steering Gears 108-15

4. Remove the cap from the center of the
steering wheel and remove the nut from
the end of steering column. Pull the
steering wheel off the column with a
wheel puller.
5. Remove the bracket that secures the
steering column to the dash.
6. Note the position of the steering valve
with relation to the cab floor and remove
nuts, washers, screws and lockwashers
that secure the valve and column to the
cab floor.
7. Remove the steering valve and column
from the machine.
DISASSEMBLY. To disassemble the
steering valve and column, proceed as
follows, (see Figu re 1OB- 14 on page
1OB-19) :
1. Mark the position of tube (33) in re-
lation to housing (15). Also, mark the
holes in which capscrews (32) are in-
stalled. Remove capscrews (32) and pull
the steering column away from the steer-
ing valve.
2. If the steering column does not re-
quire disassembly skip step 2 and pro-
ceed to step 3. However, if the steeri ng
column is to be disassembled, proceed as
follows, (see Figure lOB-14 on page
1OB-19) :
A. Remove retaining ring (28) and pull
shaft (31) out of tube (33).
B. Remove one snap ring (29) and pull
bearing (30). Remove the other snap
ring (29).
3. Disassemble the steering valve hous-
i ng as follows:
A. Remove retaining ring (02) and seal
gland (03) from housing (15), then
remove needle bearing races (06 and
08) and needle bearing (07).
B. Remove seal (01) and quad seal (05)
from the seal seats in seal gland (03).
Remove 0- ring (04) from the seal
gland or the housing bore, whichever
is the case.
C. Remove setscrew (09) from housing
(15). Remove check seat (11), check
ball (13), and ball retainer (14) from
the bore in housing (15). Remove
1OB-16
O-rings (10 and 12) from the grooves
in check seat (11).
D. Match mark housing (15), spacer
(21), gear ring (23) and end cap (26)
with relation to each other so that
these parts can be properly reassem-
bled.
E. Place housing (15) on a flat surface
with end cap (26) up. Remove cap-
screws (27).
F. Separate end cap (26), spacer (25),
gear ring (23) and spacer (21) from
housing (15). Remove gear star (24)
from gear ring (23).
G. Lift drive (22) out of housing (15).
With the ports facing up, rotate spool
(17) and sleeve (16) until pin (19) is
parallel with the ports. Remove
sleeve (16) and spool (17) from the
housing. Remove centering pin (19)
and separate the spool from the
sleeve.
NOTE
It may be necessary to twist the
sleeve while it is drawn from the
housing bore. Due to the close fit
of these parts, be extremely care-
ful as the sleeve is twisted, to
prevent the sleeve from binding in
the bore.
H. Push centering spring set (18) out of
the slots in spool (17).
I. Remove O-rings (20 and 34) from the
appropriate parts.
CLEANING, INSPECTION AND REPAIR.
Perform all of the following steps prior to
assembling the power steering control
valve unit.
1. Discard all of the O-rings and seals
that were removed from the unit. Obtain
new 0- rings and seals for reassembly.
2. Clean all valve parts by rinsing the
parts in clean solvent and drying with a
lint free cloth or clean dry air.
3. Inspect all moving surfaces to insure
that the surfaces are not scored, abrad-
ed or otherwise damaged.
 NOTE
Slightly scored parts can be cle-
aned with 600 grit abrasive paper,
using hand rubbing only.
4. To prepare the steering valve for re-
as,sembly and insure all edges are burr
free, place a piece of 600 grit abrasive
paper on an extremely flat, clean, hard
surface. If the abrasive is new it should
fi rst be rubbed down with a piece of
scrap steel to remove sharp grit that
would produce scratches. Clean both
sides of gear ring (23) and gear star
(24). Clean the gear end of housing
(15) and the gear side of end cap (26).
Stroke each surface across the abrasive
su rface and observe the part. Any small
bright area near an edge indicates a
bu rr which must be removed. Hold the
parts as flat as possible. Check each
part after 6 to 10 strokes. After polish-
ing each part, rinse in solvent and blow
dry. Keep these parts absolutely clean
until assembly.
NOTE
Any part with imperfections that
can not be removed by the above
polishing procedure, should be re-
placed.
5. Replace all snap and retaining rings
which have lost their spring.
6. Replace damaged bea ri ngs.
ASSEMB LY. To assemble the steering
control valve and column, refer to
Figure 10B-14 on page lOB-19, and pro-
ceed as follows:
1. Stand housing (15) on a clean surface
with the gear side up.
2. Install spool (17) within sleeve (16) as
follows:
A. Some spool and sleeve sets have iden-
tification marks, align these marks
and insert the spool in the sleeve.
B. Rotate the spool and sleeve while slid-
ing the parts together.
C. Test the assembly for smooth rotation
of the spool by using finger tip force
on the splined end of the spool.
D. Align the spring slots in spool (17)
and sleeve (16).
E. Stand the spool and sleeve assembly
on end.
3. Install centering springs (18) in the
spool and sleeve assembly slots as
follows:
A. Position two sets of three centering
springs (18) on a flat surface so that
the extended edge of the springs are
down and the arched centers are to-
gether, see Figu re lOB-14 on page
10B-19.
B. Insert one end of the positioned
spring sets in the aligned slots.
Keep the end of the springs together
by grasping the ends of the springs
with a needle nose pliers from the
other side of the slot. While pushing
the spring set into the sleeve and
spool, withd raw the pi iers.
C. Center the sp ri ng set in the pa rts so
they push down evenly and flush with
the upper su rface of the spool and
sleeve.
4. Install centering pin (19) in the
al igned holes of sleeve (16) and spool
(17). Push the pin into place until it is
flush or slightly below the sleeve diam-
eter on both sides.
5. Carefully, insert the splined end of
the spool and sleeve assembly down into
the bore (gear side) of housing (15). Do
not allow the parts to cock. Push the
parts gently into place with a slight
twisting motion until the spool and sleeve
assembly is flush with the housing.
Check that the spool and sleeve assembly
- are free to rotate within the housing by
turning the assembly with a light finger
tip force on the splined end.
6. Assemble the bearing by installing in-
ner race (08), needle bearings (07) and
outer race (06) over the splined end of
spool (17) which is extending out of
housing (15) . Install 0- ri ng (04) in
housing (15).
7 . Carefully, assemble dry quad seal
(05) into the seal seat on the large diam-
eter side of seal gland (03). I nstall seal
(01), metal backing first, in the groove
on the small diameter side of seal gland
(03). Make sure that both seals are
tight against the seal gland shoulders.
Steeri ng Gea rs 10B-17
8. Taking care not to cut seals and
O-ring, carefully install seal gland as-
sembly (03) (O-ring first) into valve
housing assembly (15), over the end of
spool (17). Make su re gland assembly
(03) is flush against bearing race (06).
9. Install retaining ring (02) into the
groove in housing (15).
10. Position housing assembly (15) in a
vise, taking care not to allow the spool
and sleeve to fallout. Use a vise with
protective covered jaws.
11. Ensure the machined surfaces of the
housing and other valve parts are clean
by wiping with a clean lint free cloth.
Check that the machined surfaces are
free of bu rrs.
12. Install O-ring (20) in the groove in
housing (15). Place spacer (21) over
the end of the housing so that the holes
in the spacer line up with the tapped
holes in housing (15).
13. Install O-ring (34) in the groove on
the end of gear ring (23) and place the
gear ring assembly (O-ring first) against
spacer (21). Align the holes in the gear
ring, spacer and housing.
14. If necessary, rotate the spool and
sleeve assembly in the housing until pin
(19) is parallel with the port face.
15. Assemble and install gear star (24)
and drive (22) into the ring gear and
valve housing assembly as follows, (see
Figure lOB-14 on page 10B-19):
A. Insert the splined end of drive (22)
into gear star (24) so that the slot in
the drive shaft lines up with two op-
posite valleys in the gear star teeth.
B. Push the splined end of the drive
through the gear star so that the
splines extend about one-half their
length beyond the gear star. Hold
the drive in this position and careful-
ly, insert the drive and star gear
assembly into the ring gear. Wiggle
the parts, keeping the drive in posi-
tion and continue pushing the drive
and star gear assembly into the ring
gear until the slot in the drive shaft
engages centering pin (19). A slight
rotation of the star and drive shaft
assembly may be necessary to engage
the slot and pin.
lOB-18
C. Position spacer (25) at the end of
gear ring (23). If the drive shaft
and star are properly installed the
spacer will be flush with the end of
the valve assembly.
16. Install O-ring (34) in the groove in
end cap (26). Place the end cap over
the gear ring so that the holes line up.
Install two capscrews (27), equally
spaced, and tighten them finger tight.
Then install the remaining capscrews.
Gradually, tighten capscrews (27) in
equal alternating steps to a final torque
of 240 in-Ibs.
17. Assemble and install check seat (11)
and ball assembly as follows:
A. Install O-rings (10 and 12) on check
seat (11).
B. Insert ball retainer (14) and check
ball (13) into the check seat bore of
housing (15). Make sure retainer
(14) is straight in bore.
C. I nsert check seat (11) assembly
(small end fi rst) into the bore of
housing (15).
D. Install setscrew (09) in housing (15).
Tighten the setscrew to 100 in-Ibs
torque.
18. Assemble and install the steering co-
lumn assembly on the valve assembly as
follows, (see Figure lOB-14 on page
lOB-19) :
A. I nstall snap ring (29) in the groove
fa rthest from the th readed end of
shaft (31).
B. I nstall bearing (30) tight against
snap ring (29).
C. Install snap ring (29) against bearing
(30). Make sure snap ring is fully
seated in the groove.
D. I nsert shaft assembly (22) th rough
tube (33) until bearing (30) seats
squarely in the end of the tube.
E. Install retaining ring (28) in the slots
in the end of tube (33).
F. Position steering shaft (31) and tube
(33) assembly on housing (15). Make
sure that the splines of shaft (31)
 /1
I
I
I
,I
/ I
~/ _I

-- - -- 32
--
22
--

.;-
.;-
..-
.;-
..- --- -..-

..- 27
05

(
..- ~
1
I
-............. I
08 ............. I
...........
11 ____ -> I
10 \ ci$..........
09 -~\ ' \ 13 14
01 ~ 12

01. SEAL 13. CHECK BALL 24. GEAR STAR

02. RETAINING RING 14. BALL RETAINER 25. SPACER
03. SEAL GLAND 15. HOUSING 2S. END CAP
04. O·RING 1S. SLEEVE 27. CAPSCREW
05. QUAD SEAL • 17. SPOOL 2B. RETAINING RING
OS. BEARING RACE 1B. CENTERING SPRINGS (S EACH) 29. SNAP RING
07. NEEDLE BEARING 19. CENTERING PIN 30. BEARING
OB. BEARING RACE 20. O·RING 31. SHAFT
09. SETSCREW 21. SPACER 32. CAPSCREW
10. O·RING 22. DRIVE 33. TUBE
11. CHECK SEAT 23. GEAR RING 34. O·RING
12. O·RING

Figure 108-14. Steering Valve and Column

Steeri ng Gea rs 108-19

 properly engage the internal splines
of spool (17).
NOTE
The tube and valve housing should
be assembled in the same position
they were in prior to disassembly,
rotate the tu be u nti I the match
marks align.
G. Install capscrews (32) in the original
tapped holes. If necessary, install the
mounting bracket in preparation for
valve installation.
INSTALLATION. To install the steering
control valve and column assembly, pro-
ceed as follows, (see Figure 10B-13 on
page 10B-16):
1. If necessary, install the mounting
plate over the steering column and posi-
tion it on the control valve. AI ign the
plate so that the holes used to secu re the
steering control valve to the cab floor
a re on the same centerl i ne as the va Ive
ports.
lOB-20
2. Install the column mounting screws in
the aligned holes and tighten the screws
securely. Then install rubber mounts in
the plate, if the mounts were removed
from the mounting plate holes.
3. Position the steering control valve be-
low the cab so that the steering column
will pass up through the hole in the
floor. Ensure the control valve ports
face the proper way.
4. Install the mounting plate capscrews
and associated hardware. Tighten the
capscrews secu rely.
5. Secu re the steering column to the
dash, as shown in Figure 10B-13 on page
lOB-16. Then install the turn signal on
the steering column.
6. Connect the hydraulic lines to the
steering control valve. Bleed the system
of air and add oil to the reservoir to
bring the oil to the proper level.
 SUBSECTION lOC

STEERING VALVES

GENERAL 3. Remove the hardware which secures

the valve to the upper frame and remove
This subsection describes various hy- the valve.
draulic valves that are used in this ma-
chines steering system and includes REPAIR. To repair the flow control
removal, repai r and installation proce- valve, proceed as follows (see
dures. Figu re 10C-2 on page 10C-2):
The carrier steering system consists of a 1. Unscrew and remove the relief valve
steering column, a right angle steering and the plug at each end of the plunger.
gear and a power steering gear. The
upper steering system is controlled by a 2. Remove the spring and plunger from
steering control valve. the valve bore.
3. Remove and discard the 0- ring on the
FLOW CONTROL VALVE (36U149) pi ug with the tapped hole. The 0- ri ng
on the other plug can only be replaced if
DESCRI PTION. The flow control valve is the entire plug is replaced.
secu red to the right hand side of the LEFT
upper side frame near the winch control SIDE
FRAME
valve (see Figure lOC-l). The purpose
of this flow control valve is to provide a
predetermined amount of the steering
system pump's total flow, to the steering
control valve when the steering circuit' is
activated by the steering wheel. When
the steering circuit is idle, the flow con-
trol valve relief valve provides overload
protection to the steering circuit and al-
lows pump How to be diverted to other
hydraulic circuits or the reservoir.
REMOVAL. To remove the flow control
valve, proceed as follows (see
Figu re lOC-l):
1. Engage the house lock. Stop the en-
gine and disconnect the negative battery
cable at the battery terminal.
2. Tag and disconnect the hydraulic
lines at the flow control valve. Cap the
hydraulic lines to prevent the entry of
contaminants.
Figure IDC-l. Flow Control Valve
Installation

Subsection lOC 10C-l


LOAD SENSING
TO STEERING
FROM STEERING
PUMP
~igure 10C-2. Flow Control Valve
(36U149)
4. The O-ring on the relief valve can be
replaced with a new one if it is damaged.
5. If the relief valve is damaged, it must
be replaced with a new one. The new re-
lief valve will be supplied with a new
port O-ring.
6. Thoroughly clean all parts with a sui-
table solvent and blow dry with com-
pressed air. Pay particular attention to
the grooves and orifice in the plunger.
Make sure that the orifice in the tapped
plug is clean. Make sure the valve body
ports are clean and free of obstructions.
Clean the screen on the end of the relief
valve.
NOTE
The entire valve must be replaced
if the body is damaged beyond fu r-
ther use. Replace plugs with dam-
aged th reads.
7. Make sure that O-rings are installed
in the O-ring grooves in the plugs and
relief valve. Install the plug assembly in
the body bore. Make sure the plug is
tight.
8. Carefully slide the plunger, the end
with the orifice first, into the body bore
with a slight twisting motion. I nstall the
spring. Securely install the plug.
10C-2
9. Securely thread the relief valve into
the associated port in the body.
INSTALLATION. To install a new or re-
paired flow control valve, proceed as fol-
lows (see Figure lOC-l on page lOC-l):
1. Position the flow control valve on the
upper frame with the load sensing and
relief ports toward the front. Install
and tighten the hardware used to secure
the valve to the upper evenly.
RELIEF
FLOW 2. If a new flow control valve is being
installed, remove all fittings from the old
valve and install them in the appropriate
ports of the new valve. Make sure all fit-
ting O-rings are installed.
F271
3. Connect the hydraulic lines to the
flow control valve ports as tagged during
removal. Tighten the fittings securely
but not so tight as to cause distortion.
4. Add oil to the reservoir, as required,
to bring the level of the oil to the full
mark on the dipstick.
5. Reconnect the negative battery cable
and start the engine. Check the valve
and connections for leakage.
6. Check the relief setting of the valve
as described in the following topic.
ADJUSTMENT. To check and adjust the
relief setting of the flow control valve,
proceed as follows:
CAUTION
The pressure setting for this relief
valve, listed on the machine's
pressure decal, must be adhered
to. Any attempt to change the
setting without the specific ap-
proval of the Harnischfeger Ser-
vice Department could cause-
serious damage to the machine and
will void the machine warranty.
1. Operate the machine until the hydrau-
lic oil temperature is a minimum of 70DF.
2. Obtain an accu rate pressu re gauge, at
least 0-5000 psi, with a hose of suitable
length.
 CAUTION
This procedure must be performed
carefully or damage to the system
components may result. In no case
should the system be held on relief
any longer than absolutely neces-
sary.
3. Attach the gauge to the fitting pro-
vided on the line at port CF (see
Figu re 10C-l on page lOC-l).
4. Start the engine and increase speed to
fu II th rottle.
S. Rotate the steering wheel until the
wheels are fully turned in one direction.
Observe the gauge to determine at which
point the relief valve opens. The valve
should relieve at the pressure shown on
the decal, plus or minus SO psi.
6. If adjustment is required, shut the
machine down and remove the hydraulic
line and the fitting it is attached to at
port T. I nsert a hexhead wrench in the
port and rotate the adjusting screw in
one-quarter turn increments; clockwise
to increase pressure and counterclock-
wise to decrease pressure.
7. Attach the fitting and line and repeat
steps 4, Sand 6 until the proper relief
pressure is achieved.
8. When properly adjusted, remove the
pressure gauge and check for leaks.
STEERING SELECTOR VALVE (36U394)
DESCRIPTION. The steering selector
valve is secured to the inside of the low-
er frame, in front of the front axle. The
solenoid operated selector valve is used
to direct oil flow to the steering cylin-
ders. When the solenoid coil is
de-energized, oil from the lower steering
valve flows th rough the selector valve
and onto the steering cylinders. With
the coil energized, oil flow path from the
lower steering valve to the cylinders is
blocked while steering oil is delivered to
the cylinders from the upper steering
valve.
A pushbutton is provided at the end of
the solenoid coi I so that the valve can be
shifted manually in the event of valve
malfunction or electrical power loss.
REMOVAL. It is not necessary to remove
this valve to perform the repai rs that are
possible. The only reason for removing
the valve would be to replace the enti re
valve with a new one. If it is necessary
to replace the enti re valve, proceed as
follows, otherwise refer to the Repair
topic:
1. Stop the engine and disconnect the
negative battery cable.
2. Tag and disconnect the electrical
leads at the solenoid.
3. Tag and disconnect the hydraulic
lines at the valve. Cap the lines to pre-
vent the entry of foreign material into
the system.
4. Remove the attaching hardware and
remove the valve from the machine.
REPAIR. Repair of this valve is limited
to the replacement of the solenoid coil,
guide tube assembly, or springs. To
replace these items, proceed as follows
(see Figure 10C-3 on page 10C-4):
1. Loosen each of the fou r screws which
secure the solenoid to the valve, a few
tu rns at a time, to relieve the spring
force on the nameplate. When the spring
force is relieved, remove the nameplate
and screws.
2. Slide the solenoid off the guide tube
assembly. If only the solenoid is to be
replaced, the new one can now be in-
stalled on the guide tube assembly. Se-
cu re it with the nameplate and screws.
Be sure to tighten the screws evenly to
prevent distorting the guide tube assem-
bly.
If the guide tube assembly is to be re-
placed, continue with the remaining
steps of this procedure.
3. Remove the inner and outer flux
sleeves, and the spring between them.
4. Remove the guide tube by pulling it
outward with a slight twisting motion.
Remove the female cone, if it did not
come out with the guide tube, with the
same pulling, twisting motion.
S. Remove plug and centering spring
from valve body.
Steering Valves 10C-3

END
PLATE
Figure 10C-3. Steering Selector Valve (36U394)
6. Discard the guide tube, plunger, fe-
male cone, push pin and the O-rings at-
tached to these parts.
7. Position the centering spring on the
end of the valve spool and install plug
8. Lubricate the valve body bore and the
guide tube assembly with clean hydraulic
oil. Then install the replacement guide
tube assembly with a pushing, twisting
motion.
9. I nstall the solenoid on the guide tube
assembly and secu re it with the name-
plate and screws. Be sure to tighten the
screws evenly to prevent distorting the
guide tube assembly.
INSTALLATION. Install a new or over-
hauled steering selector valve as follows:
1. Position the valve on the machine and
secure it with the attaching hardware.
Tighten the hardware evenly.
2. Connect the hydraulic and electric
lines to the valve as tagged. Connect
the battery ground cable.
lOC-4
PUSH PIN
GUIDE
VALVE
BODY
CENTERING
NUT
TIE
ROD /
MOUNTING PLUG
FOOT
3. Start the engine and operate the steer
selector switch in each position to check
the operation of the valve and to pu rge
any air from the steering circuit. Check
all hydraulic lines for leakage.
FLOW REGULATOR (36Z293)
DESCRI PTION. Maximum pump delivery
and maximum system pressure, to the
power steering circuit, is determined by
this flow control and relief valve. The
valve functions both as a compound relief
valve an a by-pass type pressu re com-
pensated flow control. The valve is
mounted in the center opening of the
lower frame, near the hydraulic swivel.
REPAIR. This valve is not considered a
repai rable item. If the valve does not
operate in the proper manner, it must be
removed from the machine and replaced
with a new one. Faulty valve operation
is most likely due to dirt trapped in the
valve. The valve should be removed
from its mounting position, disassembled
(see Figure lOC-4 on page 10C-5), and
cleaned prior to discarding it for a new
one.
 TANK
PILOT VALVE

SERVICE

Figure 10C-4. Flow Reg~lator

(36Z293)

Steering Valves lOC-5

 SUBSECTION 100
STEERING CYLINDERS
GENERAL
This subsection covers the removal, re-
pair and installation procedures for the
steering cylinders used on this machine.
STEERING CYLINDER (38R220)
DESCRI PTION. The double acting steer-
ing cylinders are connected to the axle
spindle and housing and are used to turn
the front wheels. The cylinders are
connected hydraulically to operate in
conjunction with each other. Fluid for
these hydraulically operated cylinders is
supplied th rough either the upper or
lower steering valves.
REMOVAL. To remove a steering cylin-
der, proceed as follows, (see
Figu re lOD-1):
Figure 100-1. Steering Cylinder
Removal
1. Stop the engine and render the start-
ing means inoperative.
2. Block the wheels, using wheel chocks,
to prevent the machine from moving dur-
ing repairs.
3. Tag, disconnect and plug the two hy-
draulic lines connected to the cylinder
ports.
4. Remove cotter pins, lock nuts and
washers from cylinder ends.
5. Remove cylinder from machine.
D ISASSEMBL Y. To disassemble a steer-
ing cylinder, proceed as follows (see
Figu re lOD-2 on page lOD-2):
NOTE
Removal of end sockets is not re-
quired when disassembling cylin-
der. End socket!= should only be
removed when they need to be re-
paced or when replacing the cylin-
der rod or body.
1. Loosen clamp lock nut and unscrew
end sockets from rod and body.
2. Remove set screw (01) . Using a
spanner wrench, unscrew cylinder head
(06) from body.
3. Carefully pull cylinder head and pis-
ton rod assembly out of cylinder.
4. Remove lock nut (04) and carefully
pull piston (05) from rod (02).
5. Remove O-ring (13), seal ring (14)
and wear ring (15) from piston. Remove
Subsection lOD lOD-1
 03~
Figure 100-2. Steering Cylinder (38R220)
O-ring (11) from inside piston. Discard
these pa rts.
6. Carefully remove cylinder head (06)
from rod.
7. Remove O-ring (11) and back-up ring
(10) from head. Remove wiper (07),
U-cup seal (08) and wear rings (09) from
inside head. Discard these parts.
INSPECTION AND REPAIR. Use the fol-
lowing list for general inspection and re-
pair of the steering cylinder.
1. Throughly clean and dry all parts of
the steering cylinder.
2. Inspect the piston, piston rod, cylin-
der head and cylinder body for damage.
3. Replace any part which is damaged
beyond further use.
4. Replace all O-rings, wear rings and
seals with new parts.
100-2
ASSEMBLY. Assemble the steering cyl-
inder as follows (see Figure 190-2):
Liberally lubricate all parts of the
steering cylinder using the same type
of hydraulic fluid which is used in the
machine's hydraulic system.
1. Install wear rings (09) in the inner-
most grooves on the inside of the cylin-
der head. Install U-cup seal (08) in the
next groove. Install wiper (07) in the
outermost groove.
2. Install back-up ring (10) and O-r-ing
(11) in the outside groove of the head.
3. Carefully slide assemblied cylinder
head (07) onto piston rod. Ta ke every
precaution not to cut the wiper, U-cup
seal or wear rings.
4. Install O-ring (12) on inside of
piston.
5. Install wear ring (15)' seal ring (14)
and O-ring (13) in outer grooves of pis-
ton.
6. Carefully slide assemblied piston (05)
over the end of the rod. Take every
precaution not to cut inside O-ring. Se-
cure piston to rod with locknut (04).
7. Carefully slide assemblied piston rod
(02) into cylinder body.
8. Using a spanner wrench, securely
tighten cylinder head to body. Install
setscrew (01).
NOTE
To insure adequate strength,
th read engagement should be equal
for both end sockets.
9. With cylinder fully extended,
th read end sockets to rod and body
until they bottom out. Equally back
sockets off until dimension from sock-
et centerl i ne-to-centerl i ne is:
Torque clamp lock nut to 50-60 ft-Ibs
(68-81 N. m).
I NST A LLA T ION. I nstall a new or re-
paired steering cylinder as follows
(see Figu re lOD-l on page lOD-l):
1. Position steering cylinder on the
machine. Secure end sockets with
flat washer and slotted nut. Torque
nut to 110-125 ft-Ibs (149-170 N.m)
dry. When specified torque is
reached, advance nut to next slot and
install cotter pin.
2. Grease end sockets with the typed
of grease specified in the lubrication
chart.
3. Reconnect hydraulic hoses to cyl-
i nder ports.
4. Start the engine and turn steering
wheel in both directions to purge air
from the cylinder. Check all con-
nections for leakage. Add oil as re-
quired to bring the hydraulic
reservoi r up to the proper level.
Steering Cylinders 10D-3
 TABLE OF CONTENTS

Subsection llA 11A-l

Introduction 11A-l
General 11 A-l
Description 11A-1
Troubleshooting 11A-1
Subsection 11 B 11B-1

Outrigger Valves 11 B-1

General ............. . 11 8-1
Extend/Retract Control Valve (36U392) 11 8-1
Outrigger Control Valves (36U393) 11 8-3
Relief Valve (36Q246Dl) 118-5
Subsection 11C 11C-l

Outrigger Cylinders 11C-1

General ............. . 11C-l
Horizontal Outrigger Cylinder (38R217) 11 C-l
Removal 11 C-l
Overhaul 11 C-l
Installation . 11C-2
Vertical Outrigger Cylinder (38R216) 11C-3
Description , 1 C-3
Removal 11C-4
Overhaul llC-4
Installation 11C-6

Contents
 LIST OF ILLUSTRATIONS

Figu re 11 B-1. Outrigger Extend/Retract Valve Installation 11 B-2

Figu re 11 B-2. Outrigger Extend/Retract Valve (36U392) 11 B-2
Figu re 11 B-3. Outrigger Control Valve (36U393) 11 B-4
Figure 11B-4. Relief Valve Installation ...... . 11 B-6
Figure 11C-1. Outrigger Cylinder Installation 11 C-2
Figu re 11 C-2. Outrigger Horizontal Cylinder (38R217) 11 C-3
Figure 11C-3. Vertical Outrigger Cylinder (38R216) 11 C-5

List of Illustrations iii

 LIST OF TABLES

Table 11 A-1. Outrigger Troubleshooting llA-1

List of Tables v
 SUBSECTION 11A

INTRODUCTION

GENERAL with fou r outriggers; two located at the

Section 11 is divided into subsections
that cover the outrigger system used on
this machine and also covers the valves,
cylinders and other components used to
operate the outriggers. Since the outrig-
gers are electrically controlled and hy-
draulically actuated, service personnel
should study the electrical schematics in
Section 12 and the hydraulic schematics
in Section SA.
This subsection describes the outrigger
system and includes a troubleshooting
guide which lists problems and remedies
that could be experienced with the out-
rigger system.
front of the machine and two located at
the rear.
Each outrigger assembly consists of one
horizontal and one vertical cylinder. The
horizontal cylinder moves the outrigger
float away from the machine, whereas the
function of the vertical cylinder is to
raise the machine up enough so the
wheels clear the ground.
I n addition to the horizontal and vertical
cylinders, the outrigger system consists
of valves which control the flow of hy-
draulic fluid to the outrigger cylinders.
The operation of these valves is de-
scribed in detail in Subsection 11 B.

DESCRIPTION TROUBLESHOOTING

The outrigger system is used to raise the Table 11A-1 lists some of the problems
machine off the wheels whenever addi- which may be experienced with the out-
tional machine stability is required for riggers. The troubleshooting chart also
load handling. This machine is equipped lists probable causes as well as remedies.

PROBLEM : PROBABLE CAUSE REMEDY

Outriggers will not ex- Damaged outrigger pump. Repair the pump, see Sub-
tend, retract, lower or section 5C.
raise due to lack of oil
flow to the outrigger Relief valve bypassing. Replace relief valve.
I ci rcuit.
The extend/retract con- Manually shift the valve
trol valve is not shift- in both directions. If
ing. the system operates prop-
erly, then the problem is
electrical (solenoid coil
I or supply power).

Table llA-l. Outrigger Troubleshooting (Part 1 of 2)

Subsection 11 A llA-1
 PROBLEM PROBABLE CAUSE REMEDY
Outriggers will not lift Damaged outrigger pump. Repair pump, see Sub-
the machine because of section 5C.
insufficient hydraulic
pressure. 1 Relief valve bypassing or Adjust or replace the re-
the pressure setting is lief valve.
incorrect.
The extend/retract con- Replace the valve.
trol valve is leaking ex-
cessively.
Individual outrigger Valve not shifting due to i Replace coils.
will not operate because bad solenoid coil(s).
of a faulty control
valve. Faulty selector switch or Check switch and Wlrlng;
wire. repair or replace.
Excessive valve leakage. Replace the valve.
Excessive cylinder leak- Repair the cylinder.
age.
Lock valve not operating. i Replace the lock valve
cartridge,
Individual outriaaer Leaking outrigger control Replace the control
will not hold the ~ma­ valve. va lYe.
chine.
1 Leaking cylinder. Repair the cylinder.

Table llA-l. Outrigger Troubleshooting (Part 2 of 2)

11 A-2
 SUBSECTION 11 B
OUTRIGGER VALVES
GENERAL
This subsection provides the necessary
information to remove, repair and install
the hydraulic valves used to control the
operation of the vertical and horizontal
hydraulic outrigger cylinders.
EXTEND/RETRACT CONTROL VALVE
(36U392)
DESCRI PTION. This solenoid operated,
4-way, 3-position di rectional control
valve is used to control oil flow for ex-
tending and retracting all the vertical
and horizontal outrigger cylinders. The
valve is mounted on a valve plate be-
tween the lower frame members towards
the rear of the machine (see
Figu re 11 B-1 on page 11 B-2) .
I n the extend mode of the extend/ retract
control valve, pressurized oil is directed
to every outrigger control valve. I n the
retract mode, pressurized oil is directed
to the rod end of each outrigger cylinder
and return oil passes through the out-
rigger control valves.
The extend/retract valve spool is spring
centered. A pushbutton is provided at
the end of each solenoid so that the
valve can be manually shifted in the
event a solenoid malfunctions.
REMOVAL. All repai rs to this valve can
be made without removing the valve from
the machine. If it is necessary to replace
the entire valve, proceed as follows (see
Figure 11B-1 on page 11B-2):
1. Disconnect the battery cable con-
nected to the negative terminal of the
battery.
2. Tag and disconnect the electrical
leads attached to the solenoids of the
valve.
3. Tag and disconnect the hydraulic
lines attached to the valve. Cap the lines
to prevent the entry of contaminants.
4. Remove the hardware which secures
the valve to the valve plate, and remove
the valve.
REPAIR. Repair of this valve is limited
to the replacement of the valve
solenoids, guide tube assemblies and
springs. These items can be replaced
without removing the valve from the ma-
chine. To replace these items, proceed
as follows (see Figure 11 B-2):
1. Loosen each of the four screws which
secure the solenoid to the valve, a few
turns at a time, to relieve the spring
force on the endplate. When the spring
force is relieved, remove the endplate
and screws.
2. The solenoid can now be removed from
the guide tube assembly. If only the so-
lenoid is to be replaced, the new one can
now be installed on the guide tube as-
sembly and secu red with the endplate
and screws. Be su re to tighten the
screws evenly to prevent distortion of
the guide tube assembly.
If the guide tube assembly is to be re-
placed, conti n ue with the rema i n i ng
steps of this procedure.
3. Remove the inner and outer flux
sleeves, and the spring between them.
4. Remove the guide tube by pulling it
outward with a slight twisting motion.
Remove the female cone, if it did not
Subsection 11 B 11 B-1
 EXTEND/RETRACT
CONTROL VALVE

REAR - . . .
RELIEF
VALVE

------f)~---

REAR OUTRIGGER
CONTROL VALVES ~

"---(-~'~ ~~~
HIGH
PRESSURE
FILTER )
=========::::=::~=-=:~---
---C)I--,-------())----
CARRIER
FRAME

Figure 118-1. Outrigger Extend/Retract Valve Installation

come out with the guide tube, with the
same pulling, twisting motion. Be sure
the centering spring is not lost when the
guide tube assembly is removed.
5. Discard the guide tube, plunger, fe-
male cone, push pin, and the O-rings at-
tached to these pa rts .
6. Position the centering spring on the
end of the valve spool.

SOLENOID PUSH PIN

COIL SPRiNG GUICE

OUTERFL1X
SLEEVE INNER FLUX CENTERING
/ SLEEVE GUICE TUBE SPRING

~~ / / F~~~~E
~Qe:::Q~H/
VALVE
END
BODY
PLATE SCREW

~ ~~~

F1&3

Figure 118-2. Outrigger Extend/Retract Valve (36U392)

11 B-2
7. Lubricate the valve body bore and the
guide tube assembly with clean hydraulic
oil. Then install the replacement guide
tube assembly with a pushing, twisting
motion.
8. Install the solenoid on the guide tube
assembly and secure it with the endplate
and screws. Be su re to tighten the
screws evenly to prevent distortion of
the guide tube assembly.
INSTALLATION. Install a new or over-
hauled solenoid valve as follows (see
Figure 11B-1 on page 11B-2):
1. Position the valve on the mounting
plate and secure it with the hardware
provided.
2. Make sure O-rings are installed and
reconnect the hydraulic lines and
fittings.
3. Attach the electrical wires to the sole-
noid coils.
4. Connect the battery cable to the nega-
tive battery terminal.
S. Start the engine and operate the out-
rigger selector switches in all position to
check the operation of the valve and to
pu rge any ai r from the outrigger ci rcuit.
Check all hydraulic lines for leakage.
OUTRIGGER CONTROL VALVES
(36U393)
DESCRIPTION. Two stacks of four,
two-way, two-position solenoid operated,
spring returned, control valves like the
stack shown in Figure 11 B-3 on page
11 B-4, are used on this machine to direct
oil to and from the horizontal and the
vertical outrigger cylinders. One stack
of these control valves, mounted on the
inner side of the front outrigger box,
directs the flow of oil to and from the
front outriggers. The other outrigger
control valve stack, mounted on the in-
ner side of the rear outrigger box,
directs oil flow to and from the rear out-
riggers.
I n the extend mode, pressu rized oil is
availible at all the control valves but is
supplied to head end of an associated
vertical or horizontal cylinder, depend-
ing upon the choice made by the
operator. During extension, return oil
from the rod end of the cylinder is free
to flow to the retu rn ci rcu it.
In the retract mode, oil is supplied from
the extend/retract valve directly to the
rod end of the vertical and horizontal
cylinders. The outrigger control valves
allow retu rn oil to flow to the reservoi r
from the head end of the selected cylin-
der and thereby allows either a
horizontal or vertical cylinder to retract.
REMOVAL. It is not necessary to remove
an outrigger control valve bank to per-
form the repairs that are possible on the
control valves. The only reason for re-
moving the complete valve bank would be
to replace seals between each control
valve, or to replace a complete control
valve or valves within the valve bank.
If removal of the valve ban k is not nec-
essary, proceed to the paragraph on re-
pair. If removal of the valve bank is
necessary, proceed as follows:
1. Shut down the machine, and discon-
nect the battery cable from the negative
terminal of the battery.
2. Tag and disconnect the electrical
wi res attached to each solenoid coil.
3. Tag and disconnect the hydraulic
lines at each control valve. Cap the hy-
draulic lines, and all ports of the valve
bank, to prevent the entry of contam-
inants.
4. Remove the mounting hardware which
secures the valve bank to the carrier
frame and remove the valve bank from
the machine.
REPAIR. Repair of this valve is limited
to replacement of the valve solenoids,
guide tube assemblies, and centering
springs. These items can be replaced
without removing the valve bank from
the machine (see Figure 11 B-3 on page
11 B-4):
1. Shut down the machine and disconnect
the battery cable from the negative ter-
minal of the battery.
2. Loosen each of the fou r screws wh ich
secu re the solenoid to the control valve,
a little at a time, to relieve the spring
tension on the endplate. When the spring
force is relieved f remove the endplate
and screws.
Outrigger Valves 11 B-3
 SOLENOID
COIL SPRING
I OU;CE~~~UX INNER FLUX
/ /
C]ITIP /
r:::o~c:l;//
END
PLATE SCREW
Figure 118-3. Outrigger Control Valve (36U393)
3. The solenoid can now be removed from
the guide tube assembly. If only the so-
lenoid is to be replaced, the new one can
be installed on the guide tube assembly
and secu red with the endplate and
screws. Tighten the screws evenly.
If the guide tube assembly is to be re-
placed, continue with the remaining
steps of this procedure.
4. Remove the inner and outer flux
sleeves, and the spring between them.
5. Remove the guide tube by pulling it
outwa rd with a slight twisting motion.
Remove the female cone, if it did not
come out with the guide tube, with the
same twisting motion.
6. Discard the guide tube, plunger, fe-
male cone, push pin, and the O-ring at-
tached to these pa rts.
11 B-4
PUSH PIN
GUIDE
CENTERING
SPRING
F~~~;E
. SLEEVE GUIDETUBE
/ VALVE
BODY
r:::ttJ@Jj__
,-'
TIE
ROD F263
7. Position the centering spring on the
end of the valve spool.
8. Lubricate the valve body bore and the
guide tube assembly with a clean, re-
commended hydraulic oil. Then install
the replacement guide tube assembly with
a pushing, twisting motion.
9. Install the solenoid on the guide tube
assembly and secu re it with the endplate
and screws. Tighten the screws evenly.
If it is determined that a complete control
valve must be replaced, the following
steps should be followed:
10. Remove the valve ban k from the ma-
chine.
11. Loosen and remove the nuts and
studs which secure the control valves to
each other.
12. Remove the faulty control valve or
seals to be replaced and position the new
valve and seals in the valve bank.
13. I nstall the studs and nuts in the
holes in the control valves, and torque
the nuts to 125 in-Ibs.
INSTALLATION. To install a new or ov-
erhauled valve bank on this machine,
proceed as follows:
1. Position the valve bank on the mount-
ing bracket and secure it with the hard-
ware provided.
2. Recon nect the electrical wi res to the
solenoid coils.
3. Make sure O-rings are installed and
then connect the hydraulic lines and fit-
tings.
4. Connect the battery cables to the bat-
tery terminals.
5. Start the engine and operate the out-
rigger system in all positions to check
the operation of the valve bank and to
purge any air from the system. Check all
hydraulic lines for leakage.
RELIEF VALVE (36Q246D1)
DESCRIPTION. This pilot operated re-
lief valve protects the components in the
outrigger circuit from excessive
pressure. This valve is located next to
the steering/outrigger high pressure fil-
ter (see Figure 11 B-4 on page 11 B-6).
REPLACEMENT. This relief valve is not
repairable. If the relief valve does not
operate properly, it must be removed
and replaced as follows:
1. Shut the machine down and disconnect
the battery cable from the negative ter-
minal of the battery.
2. Thoroughly clean the valve and the
surrounding area with solvent.
3. Tag and disconnect the hydraulic
lines attached to the valve. Cap the lines
and plug the ports to prevent the entry
of contaminants and loss of oil.
4. Remove the attaching hardware and
lift the valve from the machine.
5. Install the new valve in the reverse
order of removal.
6. Check the reservoir oil level and the
valve for leaks after installation. Adjust
the valve as described in the following
topic.
RELI EF VALVE ADJ USTMENT. The re-
lief valve pressure setting should always
be checked and adjusted when a new
valve is installed. I n addition, improper
relief valve adjustment could be the
cause of various system malfunctions.
To check and, if necessary, adjust the
setting of the relief valve, proceed as
follows (see Figu re 11 B-4 on page
11 B-6) .
CAUTION
The pressure setting for this relief
valve is 2700 psi and must be ad-
hered to. Any attempt to increase
the setting could cause severe
damage to the machine.
1. Operate the machine until the hydrau-
lic oil temperature is a minimum of 70 0 F.
2. Obtain an accurate pressure gauge, at
least 0-5000 psi with a hose of suitable
length.
CAUTION
This procedure must be performed
carefully or damage to the system
components may result. I n no case
should the system be held on relief
any longer than absolutely neces-
-sary.
3. Install the necessary fittings to ac-
commodate the gauge at the pojnt indi-
cated in Figure 11 B-4 on page 11 B-6.
4. Start the engine and increase speed to
fu II th rottle.
5. Run one of the horizontal cylinders to
the end of its retract stroke and hold.
Observe the gauge to determine the point
at wh ich the relief valve opens. The
valve should relieve at 2700 psi plus or
minus 50 psi.
Outrigger Valves 11 B-5

F~gure 118-4. Relief Valve Installation
6. If adjustment is required, remove the
acorn nut from the valve.
NOTE
Initially, back the adjusting screw
out a few tu rns so that the relief
valve opens and flushes thorough-
Iy. Then adjust the relief valve to
the proper setting.
7 ..Loosen the jam nut and turn the ad-
justing screw IN to increase the pressure
setting or OUT to decrease the pressure
setting.
118-6
HIGH
PRESSURE
FILTER
8. Increase engine speed to full throttle.
Again stall the cylinder, as described in
step 5, and observe the gauge. The
point at which the relief valve opens
should be 2700 psi plus or minus 50 psi.
9. While holding the adjusting screw, se-
curely tighten the jam nut. Assemble
the acorn nut over the adjusting screw.
10. Remove the pressure gauge and in-
stall hardware as required. Make sure
there a re no lea ks .
 SUBSECTION llC
OUTRIGGER CYLINDERS
GENERAL
The information in this subsection covers
the removal, repair and installation of
the outrigger horizontal extension and
vertical lift cylinders.
HORIZONTAL OUTRIGGER CYLINDER
(38R217)
Removal
To remove a horizontal cylinder, proceed
as follows:
1. Install blocking in the outrigger box
for support of the cylinder when the at-
taching pins are removed. Take care not
to pinch the hydraulic lines which run
below the cylinder.
2. Extend the horizontal cylinder until
the rod end pin is exposed (see
Figu re 11 C-1 on page 11 C-2). Remove
the rod end pin and retract the cylinder.
3. Tag and disconnect the hydraulic
lines at the head end of the cylinder.
Cap the lines and plug the cylinder ports
to prevent the entry of foreign material.
4. Remove the cotter pin from the lug at
the head end of the cylinder and pull the
head end pin (see Figu re 11 C-1 on page
llC-2).
5. Carefully pull the horizontal cylinder
out of the outrigger box.
Overhaul
DI SASSEMBL Y. To disassemble a hori-
zontal cylinder, proceed as follows (see
Figure 11C-2 on page llC-3):
1. Support the cylinder case at both
ends.
2. Position the piston rod so that it is
extended to one-half the distance of the
maximum rod travel. Support the rod at
the extended end.
3. Use a spanner wrench to loosen and
remove the head gland. If the head gland
threads are fully disengaged, and the
head gland cannot be removed from the
cylinder, pull on the piston rod to gently
bump the head gland with the piston
spacer.
4. After the head gland has been re-
moved from the mouth of the cylinder
case, support the cylinder rod at the
mouth of the cylinder. This will prevent
damage to the case th reads or the piston
when the piston is pulled past the case
mouth.
5. Remove the cylinder rod, including
the spacer and piston, from the cylinder
case.
6. Remove the piston nut from the cylin-
der rod.
7. Remove the piston from the cylinder
rod. If necessa ry, the head gland can be
tapped gently against the piston spacer
to slide the piston from the cylinder
rod.
8. Remove and disca rd all 0- ri ngs,
seals, and wipers.
CLEANING AND INSPECTION. To clean
and inspect the cylinder, proceed as fol-
lows:
1. Wash all parts with clean solvent.
Subsection 11 C 11C-l
2. Carefully inspect all metal parts for
excessive wear, cracks or distortion.
Replace parts as required. Minor defects
can be removed by polishing.
ASSEMBLY. To assemble the horizontal
cylinder, proceed as follows (see
Figu re 11 C-2 on page 11 C-3) :
1. Prior to assembly, coat all seals and
a-rings with clean hydraulic fluid.
2. Install the piston seal and the a-ring
on the piston.
3. Install the a-ring, back-up ring, rod
seal, and rod wiper on the head gland.
4. Thoroughly oil both ends of the cylin-
der rod. Slide the head gland onto the
cylinder rod. Slide the piston spacer and
piston onto the cylinder rod. Screw the
piston nut onto the rod and tighten.
5. Oil the piston and the mouth of the
cylinder case. Gently slide the piston
through the mouth of the cylinder case.
Use caution to avoid damage to the
threads of the cylinder case or to the pi-
ston seal.
6. Oil the head gland and the mouth of
the cylinder case. Gently start the head
gland into the mouth of the cylinder
case. Use caution to avoid damage to the
head gland and 0- ring. Screw the head
gland into the cylinder case and tighten
until snug.
Installation
To install a new or repaired horizontal
cylinder, proceed as follows (see
Fig u re 11 C - 1 ) :
1. If necessary, install the cylinder sup-
port bracket on the rod end of the cylin-
der body.
2. Make sure that the outrigger beam is
extended so that the rod end pin hole is
exposed and if necessary install blocking
in the outrigger box.
3. Insert the horizontal cylinder into the
outrigger box using the cylinder rod end
bracket and blocking for support.
4. Align the cylinder head end lug with
the holes in the outrigger box (see
Figu re 11 C-1), and install the head end
pin. Install the cotter pin.
5. Connect the hydraulic lines to the
ports at the head end of the cylinder.
Tighten the fittin'gs evenly to prevent
distortion.

HORIZONTAL
OUTRIGGER CYLINDER ROD

FRAME ~ / ~END PIN

""~
VERTICAL
OUTRIGGER
CYLINDER
.

]-/

MOUNTING HORIZONTAL
SCREWS OUTRIGGER
CYLINDER HEAD
END PIN

Figure 11C-1. Outrigger Cylinder Installation

11 C-2
 O-RING'

-..,
--
CASE

___ ----- -- ----- I

I
- BACK-UP I
-- --- --- I
NUT ---
O-RING
PISTON SEAL'
I I
-- --- --- ---
ROD
WIPER J
ROD

J ROD END
BACK-UP
RING
BEARING

Figure 11C-2. Outrigger Horizontal Cylinder (38R217)

6. Extend the cylinder until the rod end
lines up with the holes in the outrigger
beam. I nstall the rod end pin with wash-
ers, lockwashers and capscrews.
7. Operate the horizontal and vertical
outrigger cylinders several times to
bleed any ai r from the system. Check the
horizontal cylinder for leaks and replen-
ish the hydraulic reservoir with clean
recommended fluid as necessary.
VERTICAL OUTRIGGER CYLINDER
(38R216)
cylinder movement in either direction
when there is no hydraulic pressure in
the circuit (refer to Figure llC-3 on
page 11 C-5). One valve contains an in-
ternal relief valve which provides over-
load protection to the rod end of the
cylinder in the event of thermal expan-
sion or when the cylinder reaches the
end of its stroke.
REPAIR. The lock valve cartridge is re-
placeable. If the valve will not hold the
machine, or leaks excessively, replace
the cartridge as follows:

Description
Lock valves mounted in the top of each
outrigger vertical lift cylinders prevent

Outrigger Cylinders llC-3

 WARNING
Place blocking under the vertical
lift cylinder piston rod to prevent
the rod from extending/dropping
when the cartridge is removed.
1. Shut the machine down and disconnect
the battery cable from the negative ter-
minal of the battery.
2. Thoroughly clean the valve cartridge
and surrounding area with solvent.
3. Remove the cartridge and replace it
with a new one.
4. Con nect the battery cables to the bat-
tery terminals, and start the machine.
Check the valve cartridge for leakage
and extend and retract the outrigger se-
veral times to check operation.
Removal
To remove a vertical lift cylinder, pro-
ceed as follows (see Figure llC-l on
page 11 C-2):
CAUTION
Do not remove the holding car-
tridges from the vertical cylinders
until the cylinder has been re-
moved from the machine or unde-
sired extension or retraction of the
cylinder may result. These car-
tridges hold the piston rod in the
last controlled position.
1. Move the machine onto firm level
ground and raise the machine on the out-
riggers. The machine must be raised
high enough to allow adequate room to
lower the vertical lift cylinder through
the bore in the outrigger beam.
2. Secu rely block the outrigger beam
from which the vertical lift cylinder is to
be removed. Retract the vertical lift cyl-
inder being removed.
3. Tag and disconnect the hydraulic
lines at the cylinder. Cap the cylinder
ports to prevent the entry of foreign ma-
terial.
4. Remove the capscrews which secure
the cylinder to the outrigger beam. Low-
11C-4
er the cylinder through the bore in the
outrigger beam. The cylinder weighs ap-
proximately 275 pounds.
Overhaul
DISASSEMBLY. To disassemble a verti-
cal lift cylinder, proceed as follows (see
Figure 11 C-3 on page 11 C-5):
1. Remove the holding cartridges from
the head end of the cylinder assembly.
2. Remove the rod end bearing
setscrews.
3. Using a spanner wrench, unscrew the
rod end bearing from the body.
4. Carefully pull the rod out of the body
bore.
5. Using a spanner wrench, unthread
the piston ring nut.
6. Pull the rod end bearing and the pis-
ton assembl ies off the rod.
7. Remove the O-ring, back-up ring,
rod wiper and rod seal and wear ring
from the rod end bearing. Discard these
pa rts.
8. Remove the back-up rings and O-ring
from inside the piston.
9. Remove the piston rings, O-ring seal
and piston sea! from the outside of the
piston.
I NSPECTION AND REPAI R. After the
cylinder has been disassembled, clean all
parts in a suitable solvent and dry. Pay
pa rticu la r attention to the ports in the
body to be su re they are clean and free
of obstructions.
1. With the exception of the piston seal
and wear rings, all seals and O-rings
should be replaced.
2. Carefully inspect all metal parts for
excessive wear, cracks or distortion.
Replace parts as required. Minor defects
can be removed by polishing.
ASSEMBLY. To assemble a vertical out-
rigger cylinder, proceed as follows (see
Figure 11 C-3 on page 11 C-5):
 LOCK
RING :-----__..
VALVES~
NUT~ ~~~I

~STON ~ ""-~
'P
RING~'

PISTON~

~
i
BACK-UP i
RINGS ~-O-RING :
<.0 i
PISTON
<:)
SEAL ____
I
iBODY
O-RING
SEAL ----0 i
i
PISTON
RING ----0
~

WEAR
RING~§
O-RING ---..~

Q;
BACK-UP
RING ---..C,

Figure 11C-3. Vertical Outrigger Cylinder (38R216)

1. Liberally lubricate all cylinder parts
with the appropriate clean hydraulic flu-
id.
2. Install a new back-up ring and O-ring
in the outside groove of the rod end
bearing. The back-up ring must be in-
stalled nearest the bearing th reads.
3. Install a new rod seal, seal lips facing
in, in the inside groove of the rod end
bearing.
4. Install a new rod wiper, wiper lip fac-
ing out, in the other inside groove of the
rod end bearing.
5. Carefully slide the rod end bearing
onto the rod so the th readed end of the
bearing is nearest the ball socket end of
the rod.
6. Install the O-ring and back-up rings
in the inner groove of the piston.

Outrigger Cylinders " C-5

7. If removed, install new wear rings in
the grooves at the outside ends of the
piston. Heat the wear rings in oil at
150 Q F to make them easier to install. Heat
the piston seal in the same manner and
install a new O-ring and piston seal (in
that order) in the outside center groove
of the piston. Do not hold the wear rings
or piston ring stretched for long
periods, as they may not retu rn to thei r
original shape.
8. Slide the assembled piston onto the
rod making sure that the cupped end of
the piston is towards the threads of the
rod.
9. Thread the ring nut on the end of the
rod and tighten the nut with a spanner
wrench.
10. Lubricate the piston and the cylinder
body bore and carefully slide the piston
and rod into the body. Compress all
rings and seals by hand as they enter
the bore.
11. Lubricate the rod end bearing
threads, then using a spanner wrench,
tighten the bearing until it is snug.
NOTE
Do not use a locking compound on
the rod end bearing threads.
11 C-6
12. Lubricate the rod end bearing set-
screw, install and tighten it.
13. Install the lock cartirdges into head
end of the cylinder body.
Installation
To install a new or repaired vertical out-
rigger cylinder, proceed as follows (see
Figure 11C-1 on page l1C-2):
1. Lift the vertical lift cylinder up and
through the bore in the outrigger beam
in the same manner it was removed.
2. Install the eight capscrews and torque
to 55 ft-Ibs.
3. Connect the hydraulic lines to the
ports in the cylinder body. Tighten the
fittings evenly to prevent distortion.
4. Install the outrigger pad on the cylin-
der piston rod.
5. Operate the vertical lift cylinder se-
veral times in each di rection to bleed any
air from the system. Check the cylinder
for leaks. Add oil, as necessary, to
bring the level of the reservoir to the
full mark on the dipstick.
 TABLE OF CONTENTS

Subsection 12 12-1
Electrical System 12-1

Contents
 LIST OF ILLUSTRATIONS

Figure 12-1. Electrical Schematic 12-3

Figure 12-2. Electrical Schematic 12-4

List of Illustrations iii

 SUBSECTION 12

ELECTRICAL SYSTEM

This subsection contains schematics of ing the cause of an electrical system mal-
the electrical system of this crane. The function (see Figure 12-1 on page 12-3
schematics should be helpful in determin- and Figure 12-2 on page 12-4).

Subsection 12 12-1
 IVC
~
o 12V ~ 12V

~III~!~III~III~I:JIIIP< 199

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"f.t) Jr{£"
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46
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~
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29 33
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3 145 P
15
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20
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2 SPD. WINCH

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198
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25

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~)
30
143

144 o ~'24'
./L~ FlFH
3 145

44 r -n:-----l R53

~/B~
35

.
FRONT OUTRIGGER
40

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CONTROL
TURN
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01110, .rG IND

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45
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110
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~
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~ ~ ~r. 240 (10)®-1> DASH & DOME

~ 319 ® R52 (2) ®---t> B.O. BRAKE
60
g@ 317 @---l> B.O. DRIVE
o 540 (9) A
CLEAR, SM
I.D. LIGHTS

IND 318
65
~46
HEAD
"6 263 'v R47 • ~

70

®
: 28
B

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~~
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243 39 ! x: ~t:
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DRIVE LIGHTS
~ ~ASHLIGHTS

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~
249
240

29
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1 .
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5A.

15A<.o--_ _ _ _ _- .
30 6 ) ,
HORN R47 HORN
r THRonLE BUnON
to
C PRESS'N
-s
n> 234 STEER SELECTOR
80
~
N
I
239 ~35 I
~
L--~'--..---t I-+--_J \,,__---+--2-60---1:42 ) ~o--C> PRESS'N
MAIN
rn At 149 >It 148 ()--c.
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f"\ _.....
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285

284
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261

\:...:I

III
90
(/)
n SPEED
SENSE
ex 288
289
~
E
LOCKUP
CONTROL
C.P.U.

ex
::r
n>
3 286 ~
III CONTROL 287
c+ VALVE. .
95
n
m ~ ______ J
(1)
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c+
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(/)
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(I)
c+
(1)
3
92140 ~ 234 291 261 35 ~240

15 1 239 295 249

N
I
W
 192 4Q 234 291 249

151 1 239 295 261 351240

LOWER XSMN CONTROL

100 R RNFFFF
2 1 1 2 3 4
--------
234~
295 II R R N F F F F
2 1 1 2 3 4
261

= Enl
I
I
105 UPPER
XSMN
CONTROL
~
~
~
110

L n
r=-:
::J __
4
Cd__
::J 1\ 26 1111111
... f;"L~-~
VRl
XSMN
115 VALVES \.::.r-;;,---
F

2~

~~ III11
REVERSE
292 ALARM

120
R \ 299 ::,H:......i°O
1~n R51

~ 0) 1 ~
I I 31
r=-Q--t> 4 35 I •

b. "'~
554 START START 454

125 239
1 154 ®) l ~ REAR! ALL DRIVE

~
,
'w r::o:t> '"
'w @)
U @) : ."
...w 0-
0, '"
FRONT DIFFS

REAR DIFFS

130

135 IGN
ATB
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35
...
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MAIN
A
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35
• 17 )) •
140

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35 ......c...... ~MO 140 f.\\ ......LL- 35

+ 00 - ~J 00 •
START AID ~ U. ~S:yR: ~I~
145
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+ _____ VO~S
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~ 83 @)
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'\7
~
(t;\ XSMN OIL
TEMP. +
I
N
I
~
150
L-____ -+________-.________________~8~1__~17) n ENG.
~qj TEMP.
~ 1
~ ~ ENG.OIL
~_) PRESS.
80 1.
155

~
V
L-____~------------~------------8=2~--_{lB

160 15 n ~ I
L-_ _~---~---------------~1~5--__{14 ) ~q) TACH ~

SPE~
II
~
to 22 VOLTS 35
C 165
ru
-S _ 0 .......,
35
rD
0- T~ ~11/
.......
N
PARK BRAKE III
96
J\I\I"-- -{>. 0) ,1\1\1\-{>

I
N
192
170
rn
\\\
rD
n +---- 325 (41 LOAIR ....
.....
c+
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n 175 AIR
III 240
AIR

l/)
249
ENG. OIL
n 35
::Y AIR
rD
3 180
III ENG. TEMP.
c+
n 13
12 ) I!
~______________________~E~N~G~.O£~IL~___ '\\~\\
14 ~
...
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III 1 1 / 1 3)
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\\\
~
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185 'VV\ 14

......
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