the switch is in the OFF position and the switch S8 (SWING BRAKE switch) in the control lever handle is in its normally closed position, the solenoid valve SV1-1 is energized, allowing hydraulic pressure to overcome the springs and release the swing brake.PROPEL BRAKE.The propel brake switch (54) is located below the swing brake switch on the left arm rest console. The switch is used to place the side frames in the park condition. Placing the switch in the PARK position deenergizes solenoid valves SV1-17 and SV2-17 in order to apply the crawler brake.Signal Horn.The signal horn (55) is located on the center front of the swing control lever and is used to alert personnel of a craning function.CIRCUIT BREAKER PANEL.The CIRCUIT BREAKER PANEL (41) is located directly under the right arm rest console. Access to the panel is gained by lifting up on the armrest console. The panel contains push in, pop out circuit breakers that are each placarded as to the circuit each breaker is used in.HEATER CONTROL PANEL. NOTE The following descriptions pertain to the heater control panel. The panel is located behind the operator's seat in the right corner of the operator's cab. Fan Switch.The blower FAN switch (42) is located on top of the control panel. It controls the operation of the pressurized blower. By rotating the switch in a clockwise direction, the operator selects low, medium or high speed for the blower.Heat Cable.The HEAT cable (43) is located on top of the control panel below the fan switch. This switch controls a water shutoff valve on the engine which controls the flow of hot water from the engine cooling system to the heater core.Vent Cable.The VENT cable (44) is located on the top of the control panel, below the heat switch. The switch allows either fresh or recirculated air to pass through the heater core and evaporator coils.Air Conditioner Switch. (Optional.)The A/C switch (45) is located on the top of the control panel below the vent cable. This switch is a push, pull switch that turns the air conditioner on or off and enables the operator to control the temperature in the operator's cab.FRONT HOIST BRAKE PEDAL.The front hoist brake pedal (46) is located on the cab floor, on the right side of the cab. The pedal is used to control the hoist brakes during the hoist freefall mode of operation.REAR HOIST BRAKE PEDAL.The rear hoist brake pedal (47) is located on the cabfloor on the left side of the cab. The pedal is used to control the hoist brakes during the hoist freefall mode of operation.HOIST ROTATION INDICATORS.The hoist rotation indicators (48) are located on the top of each hoist control lever. The indicators are electronically driven by a signal from an electronic transmitter attached to each hoist frame. A pulsating signal is sensed by the operator's thumb during operation.DOMELIGHT.The domelight (49) is located in the center rear of the cab roof and provides illumination of the cab. The light is controlled by a switch on the light.FIRE EXTINGUISHER.The fire extinguisher (50) is mounted on the left side of the cab to the rear of the operator's seat.CRAWLER DRIVE PEDALS.The crawler drive pedals (51 and 52) are located on the cab floor, on the inner side of each hoist brake pedal. The pedals are used to drive the crawler side frames.360 DEGREE POSITIVE SWING LOCK.The 360 degree positive swing lock (53) is located on the cab floor, on the left side of the cab seat. The 360 degree positive swing lock is used to lock the upperstructure in any position of the swing rotation.LINES AND LINE FUNCTIONS2-4-14CYLINDER - SINGLE ACTINGLINE, WORKINGCYLINDER - DOUBLE ACTINGDIFFERENTIALNON-DIFFERENTIALLINE, PILOTLINE, DRAINCONNECTORVALVESLINE, FLEXIBLECHECKLINES JOININGON-OFF (MANUAL SHUT-OFF)LINES PASSINGDIRECTION OF FLOWPRESSURE RELIEFLINE TO RESERVOIR ABOVE FLUID LEVELBELOW FLUID LEVELPRESSURE REDUCINGLINE TO VENTED MANIFOLDFLOW CONTROL, ADJUSTABLE - NON-COMPENSATEDFLOW CONTROL ADJUSTABLE (TEMPERATURE AND PRESSURE COMPENSATED)PLUG OR PLUGGED CONNECTIONRESTRICTION. FIXEDinTWO POSITION TWO CONNECTIONRESTRICTION, VARIABLEitPUMPSTWO POSITION THREE CONNECTIONSINGLE, FIXED DISPLACEMENTTWO POSITION FOUR CONNECTIONHESINGLE, VARIABLE DISPLACEMENTTHREE POSITION FOUR CONNECTIONACTUATORSMOTOR, FIXEDDISPLACEMENTREVERSIBLESHETWO POSITION IN TRANSITIONMOTOR, FIXED DISPLACEMENT NON-REVERSIBLEVALVES CAPABLE OF INFINITE POSITIONING (HORIZONTAL BARS INDICATE INFINITE POSITIONING ABILITY)ftMOTOR, VARIABLEDISPLACEMENT,REVERSIBLEMETHODS OF OPERATIONMISCELLANEOUS

SPRINGw\ROTATING SHAFT-e

MANUALWhen the rear hoist lever (HRC) is pushed forward to hoist down, control pressure is routed out port D1 of the HRC and enters port D1 of valve body M7 under the cab. Control pressure within M7 actuates a 75 psi (51 7.1 kPa/5.2 bar) pressure switch PS 9-7 which releases the rear hoist caliper brakes and pawl. Control pressure exits M7 port D11 and enters port 4 of the rear hoist pump P1. Control pressure within the rear hoist pump shifts a spool on the hydraulic displacement control valve (HDC) and allows charge pressure to enter one of the pumps' servo cylinders to stroke the pump.When hoisting down, the A line is still the high pressure line but directional flow is now from the motor to the pump. This is because the weight of the load exerts a force on the motor which now acts as a pump. The pump meters the flow of oil from the A line to the B line which flows to the motor as low pressure. This high pressure oil exiting the motor must pass through one poppet valve V3 when in the high speed mode and two poppets V3 and V4 in the low speed mode. Prior to entering the motor, low pressure from the pump must pass through one poppet valve V2. Refer to the Hoist Valve Condition Table for the condition of these poppet valves and their associated solenoid valves.High pressure oil within M3-R shifts a shuttle valve PSH1 and allows some low pressure in the B line to be routed to a 225 psi (1551.3 kPa/15.5 bar) pressure reducing valve RV1. Oil exiting RV1 is routed to the motor casing for cooling purposes.

MAINTENANCEREMOVAL.1.Disconnectthehoistcablefromthehookblock.Remove the cable from the hoist.NOTE. J' /The maintenance procedure for the front and rear hoists is identical.2. Discharge the hoist accumulators by turning the manual rotary valve knob on the accumulator manifold counterclockwise until pressure is relieved. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator manifold counterclockwise until pressure is relieved.3. Disconnect the pawl by removing the cotter key and the pin from the spring loaded cylinder. Disconnect the rotation indicator transmitter by removing the two bolts and lockwashers.4. Remove the caliper assembly from the arm on the hoist frame by referring to Front and Rear Hoist Brake - REMOVAL, steps 3 thru 8, in this Section.5. Tag and disconnect all hydraulic hoses and tubes on the hoist valve assembly. Discard the O-rings in the two large'tubes. Remove the hose on the hydraulic accumulator.6. Plug all open ports and cap all hoses and tubes.CAUTIONTHE SOLENOID COILS MUST BE CORRECTLY TAGGED TO ENSURE THEY ARE INSTALLED IN THEIR ORIGINAL POSITION DURING INSTALLATION.7. Tag and remove all the solenoid coils from the valve bodies by removing the nuts on the end of the solenoid and pulling the solenoid coils straight out.8. Attach a suitable lifting device to the hoist.9. Loosen and remove the two bolts and flat washers from each of the hub bearing blocks.NOTEThe hoist weighs approxiamtely 4000 pounds (1818 kg).10. Lift the hoist straight up using the lifting device. DISASSEMBLY.1. Position the hoist on a flat working surface so the hydraulic motor is pointing upward. Block, as necessary, to ensure the hoist is properly supported and balanced.2. Attach a suitable lifting device to the hydraulic motor.3. Loosen and remove the 24 bolts and flat washers that attach the hydraulic motor to the hoist drum weldment.4. Lift off the hydraulic motor and place it on a flat work bench with the valve assembly end pointing upward.5. Loosen and remove the six bolts and flat washers that attach the hoist valve assembly to the hydraulic motor.6. Attach a suitable lifting device to the valve assembly and lift the valve assembly straight up to remove it. Discard all O-rings.7. Plug all open ports on the valve assembly to prevent contamination.8. Attach a suitable lifting device to the motor hub weldment block.9. Remove the motor hub weldment block by lifting straight up while tapping with a soft-faced hammer.10. Remove the two keys from the hydraulic motor.11. Rotate the hoist drum 1 80 degrees using a suitablelifting deviceso the brake disc is facing upward.12. Loosenand remove the four bolts that secure theshaft end cap to the disc. Remove the cap.NOTEThe brake disc weighs approximately 255 pounds (116 kg).13. Attacha suitable lifting device to the brakedisc.14. Lift thebrake disc off the hoist drum shaft.1 5.Remove the outer seal from the bearing block.16. Press the bearing block from the hoist drum.1 7.Remove the remaining seal from the bearing block.1 8.Press the bearing from the bearing block.

VALVE BODY LOCATION TABLE (continued)Valve BodyM10RM13M16M17M19M20Circuit Used InRear Hoist Brakes and Brake PawlDistributionSwivelHorsepowerLimiterFront and Rear Hoist (inlet line)AdapterPhysical LocationLocated on the rear hoist frame below valve bodies M3R and M4R on the right side of the upperstructure.Located inside the upperstructure frame on the left hand side plate towards the bottom of the upperstructure.Located at the center of rotation and bolted to the crawler undercarriage.Located behind the pumps access door which is on the right side of the upperstructure. The horsepower limiter valve body is mounted to a bracket that is mounted on top of the pump drive. The valve body is located directly to the right of the valve body M1.Secured to valve bodies M3F and M3R and also mounted to the inlet hydraulic line going to the hoist.Located on the left side of the upperstructure and is secured to the underside of the frame channel.

M21Reservoir ReturnLocated on the left side of the upperstructure behind the access doors. It is inline in the return to reservoir line and is mounted directly to the reservoir.MAINTENANCEM1 VALVE BODY.Removal.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and disconnect all hydraulic lines that attach to the M1 valve body. Plug all open ports and cap all hoses.3. Loosen andremove the jam nut thatsecuresthesolenoid coil to the valve cartridge in portSV. Pullthesolenoid coil off the cartridge.4. Loosen and remove the three nuts and washers that attach M1 to the bracket on the rear of the upperstructure.5. Remove M1 from the upperstructure and place on a clean workbench for disassembly.Disassembly.1. Loosen and remove the straight fittings (9) from ports C, E, H, A, and D.2. Remove theconnector (7) from port G.3. Remove thetest fitting (8) from port TPand theplug(12) from port PS.4. Remove the 90 degree fitting (11) from port T and the check valve cartridge (1 0) from port CV.5. Loosen and remove the connector (4) from port B and the valve cartridge (5) from port SV.6. Remove the plug (2) from port R. Remove the recessed orifice plug (3) from within port R.Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. Inspect all ports on the valve body for thread damage, burrs, scratches, or contaminants.: *4. Inspect all fittings, plugs, valves, and switches for thread damage.5. Replace all defective components.Assembly.1. Install the orifice plug (3) within the recessed area of port R. Install the plug (2) into port R.2. Install the connector (4) into port B and the valve cartridge (5) into port SV.3. Install the check valve cartridge (10) into port CV and the 90 degree fitting (11) into port T.4. Install the plug (1 2) into port PS and the test fitting (8) into port TP.5. Install the connector (7) into port G.6. Install the straight fittings (9) into portsC, E, H, A, andD.Installation.1. Install the M1 valve body to the bracketon the rear ofthe upperstructure using the three washersand nuts.2. Install the solenoid coil to the valve cartridge in port SV. Install the jam nut that secures the coil.3. Install all hydraulic lines to M1 as marked during removal.Valve Body PlugOrifice PlugConnectorValve CartridgeFittingConnectorTest FittingStraight FittingCheck Valve Cartridge90 Degree FittingPlugM1 Valve Body7./M4 VALVE BODIES.Remove all remaining plugs from the valve body (2).

maintenance instructions refer to M3/M4 Valve Bo- s in Section 7 - HOISTS.i VALVE BODY.moval.Discharge the control accumulator by turning the nual rotary valve knob on the control accumulator valve fy counterclockwise until pressure is relieved.CAUTION DURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.Tag and remove all hoses that attach to the M5 valve dy. Cap all hoses and plug all open ports.Loosen and remove the four nuts and washers that :ach the control accumulator assembly to the upperstruc- re frame. Remove the M5 valve body from the upper- ucture and place it on a clean workbench for disassem- l.sassembly.Loosen and remove the check valve (7) from port CV1 id the 90 degree fitting (3) from port FM.Remove the straight fitting (4) from port T and the 90 igree fitting (3) from port CTR.Remove the cartridge valve (9) from port RV1, the test ting (10) from port TP1, and the accumulator drain valve ) from port D.Loosen and remove the cartridge valve (5) from port \J2 and the 90 degree fitting (3) from port P1.Remove the unloader valve (6) from port PV1.Loosen and remove the control accumulator (1 ) from ie valve body (2). Remove the connector (11) from the ccumulator (1) and discard the O-ring (12).Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. Inspectall portsonthevalvebodyforthreaddamage, burrs, scratches, or contaminants.4. Inspect all fittings, plugs, valves, and switches for thread damage.5. Replace all defective components.Assembly.1. Installall plugs to the valve body (2).2. Installthe connector (11) to the control accumulator(I) . Lubricate and install a new O-ring (1 2) to the connector(II) .3. Install the control accumulator assembly into the valve body (2).4. Installthe unloader valve (6) into port PV1.5. Installthe 90 degree fitting (3) into port P1and thecartridge valve (5) into port RV2.6. Install the accumulator drain valve (8) into port D, the test fitting (10) into port TP1, and the cartridge valve (9) into port RV1.7. Install the 90 degree fitting (3) into port CTR and the straight fitting (4) into port T.8. Install the 90 degree fitting (3) into port CTR and the check valve (7) into port CV1.Installation.1. Install the control accumulator assembly (M5) to the four bolts on the rear inside of the upperstructure frame using four nuts and washers.Control Accumulator Valve Body 90 Degree Fitting Straight Fitting Relief Valve RV2 Unloader Valve PV1 Check Valve CV1 Accumulator Drain Valve Cartridge Valve RV1 Test Fitting Connector O-Ring.. 033018-17-ZM5 Valve Body

2-4-862. Install all hoses to the M5 valve body as marked during removal.3. Close the accumulator drain valve.M6 VALVE BODY.Removal.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. ' Tag and remove all hoses and tubes that connect to the M6 valve body. Discard all O-rings. Plug all open ports and cap all hoses.3. Loosen and remove the nut that secures the solenoid coil to the cartridge valve in port SV1. Remove the coil.4. Tag and remove all electrical wires that connect to the switches in port TS1, TS2, and TS3.5. Loosen and remove the two bolts and washers that secure the M6 valve body to the oil cooler frame. Remove M6 and place it on a clean workbench for disassembly.Disassembly.1. Loosen and remove the temperature switch (7) from port TS3 and the cartridge valve (8) from port FV1.2. Remove the temperature switch (2) from portTSI, the cartridge valve (3)from port SV1, and the cartridge valves (4 and 5) from ports PV1 and RV1.3. Loosen and remove the temperature switch (11)from port TS2 and the 90 degree fitting (10) from port P2.4. Loosen and remove the 90degreefitting (6) from port A and the 90 degree fitting (9) from port P1.5. Remove the screw (12) from within port C. Remove the slider valve (13) and the spring (14) from the screw (12).Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. Inspect all ports on the manifold block for thread damage, burrs, scratches, or contaminants.4. Inspect all fittings, plugs, valves, and switches for thread damage.5. Replace all defective components.Assembly.1. Install the slider valve (13) and the spring (14) onto the screw (12).2. Apply Loctite 242 to the threads of the screw (12). Install the screw into port C of the valve body (1). Tighten the screw until it bottoms out.3. Install the 90degreefitting (9) into port P1 andthe90 degree fitting (6) into port A.4. Install the temperature switch (11) into port TS2 and the 90 degree fitting (10) into port P2.5. Install cartridge valves (4 and 5) into ports PV1 and RV1, cartridge valve (3) into port SV1, and the temperature switch (2) into port TS1.6. Install the cartridge valve (8) into port FV1 and the temperature switch (7) into port TS3.Installation.1. Install the M6 valve body to the oil cooler frame using the two bolts and washers.2. Install all electrical wires to the switches in ports TS1, TS2, and TS3 as marked during removal.3. Install the solenoid coil to the cartridge valve in port SV1 and secure it using the jam nut.c\cValve Body Temperature Switch Cartridge Valve Cartridge Valve Cartridge Valve 90 Degree Fitting Temperature Switch Cartridge Valve 90 Degree Fitting 90 Degree Fitting Temperature Switch Screw2-4-87Slider Valve SpringMgM0342

M6 Valve Body4. Lubricate and install new O-rings to the tubes that attach to M6.5. Install all hoses and tubes to the M6 valve body as marked during removal.M7 VALVE BODY.Removal.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and remove all hoses and tubes that connect to the M7 valve body. Plug all open ports and cap all hoses.3. Loosen and remove the three bolts, nuts, and flat- washers that secure M7 to the cab floor. Remove valve body M7 and place it on a clean workbench for disassembly.Disassembly.NOTEAs each component is removed from the valve body, it must be tagged with the number/letter of the port that the component was removed from. This will be the only means of identifying the components during assembly.1. Loosen and removethe 90 degree fitting (2) in portT3 and the straight fitting (3) from port P3.2. Remove the fittings (4) from ports PS3, PS4, PS6, PS7, PS9, and PS10.3. Loosen and remove the check valve cartridges (5) from port CV1 and CV2.4. Loosen and remove the straight fittings (6) from port E21, A21, C11, D11, D21, A11, C21, and E11.5. Remove the cartridge valve plugs (7) from ports SV1 and SV2.6. Loosen and removethe flow valves (8) from ports FV1 and FV2.7. Removethe straight fittings (9) from ports T1, T2, A2, E2, D2, A1, C2, D1, C1, E1, P2, and P1.8. Remove all remaining plugs from the valve body (1). Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. Inspect all ports on the manifold block for thread damage, burrs, scratches, or contaminants.4. Inspect all fittings, plugs, valves, and switches for thread damage.5. Replace all defective components.Assembly.NOTEAll components must be installed to their correct ports as marked during disassembly. Cap all fittings to prevent contamination.1. Install all plugs into the valve body (1).2. Install the straight fittings (9) into ports T2, T1, A2, E2, D2, A1, C2, D1, C1, E1, P2, and P1.3. Install the flow valves (8) into ports FV1 and FV2.4. Install the cartridge valve plugs (7) into ports SV1 and SV2.5. Install the straight fittings (6) into ports E21, A21, C11, D11, D21, A11, C21, and El 1.6. Install the check valve cartridges (5) into ports CV1 and CV2.

2-4-90

M7 Valve Body2-4-89o

O

0366Valve Body 90 Degree Fitting Straight Fitting Straight Fitting Check Valve Cartridge Straight Fitting Cartridge Valv&Plug Flow Valve Straight Fitting

7. Install the straight fittings (4) into ports PS3, PS4, PS6, PS7, PS9, and PS10.8. Install the 90 degree fittings (2) into port T3 and the straight fitting (3) into port P3.M8 VALVE BODY.Removal.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and remove all hoses and tubes that connect to the M8 valve body and the solenoid valve. Plug all open ports and cap all hoses.3. Tag and removethe four electrical wires that connect to the solenoid valve in M8.4. Loosen and remove the three bolts, nuts, and flat- washers that attach the M8 valve body to the cab floor. Remove the M8 valve body and place it on a clean workbench for disassembly.Disassembly.NOTEAs each component is removed from the valve body, it must be tagged with the number/letter of the port that the component was removed from. This will be the only means of identifying components during assembly.1. Loosen and remove the straight fittings (2) in ports PS4, PS6, and PS7. Remove the cartridge valve (3) in port RDV.2. Remove the 90 degree fittings (4) from ports T2, P3, G, and F. Loosen and remove the test fitting (5) from port P2.3. Loosen and removethe straight fittings (6) from ports F1, G1, and T. Remove the swivel tee (7) and the straight fitting (6) from port P.4. Loosen and remove the four screws (8) that secure the cap (9) to the solenoid valve (10). Remove the cap (9).5. Loosen and remove the bolts that attach the solenoid valve (10) to the valve body (1). Discard the O-rings.6. Remove all remaining plugs from the valve body (10). Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. It is recommended that all O-rings be replaced. Lubricate new O-rings with clean petroleum jelly.4. Inspect all ports on the manifold block for thread damage, burrs, scratches, or contaminants.5. Inspect all fittings, plugs, valves, and switches for thread damage.6. Replace all defective components./Assembly.NOTEAll components must be installed to their correct ports as marked during disassembly. Cap all fittings to prevent contamination.1. Install all plugs to the valve body (1).2. Lubricate and install new O-rings to the mounting face of the solenoid valve (10).3. Install the solenoid valve (10) to the valve body (1) using the four bolts. Install the cap (9) to the solenoid valve(10) using the four screws (8).CAUTIONoDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and remove all hoses that attach to the M17 valve body. Plug all open ports and cap all fittings.3. Tag and remove the six solenoids on the valve cartridges by removing the jam nut that secures each solenoid and pulling the solenoids straight off. Ensure the solenoids are properly tagged to facilitate installation to their correct valves.4. Loosen and remove the two nuts and washers that attach the M17 valve body to the rear of the upperstructure. Remove M17 and place it on a clean workbench for disassembly.Disassembly.NOTEoAs each component is removed from the valve body, it must be tagged with the number/letter of the port that the component was removed from. This will be the only means of identifying the components during assembly.1. Tag and remove the pressure valves (2, 3, 4, and 5) from ports PV1, PV2, PV3, and PV4.2. Loosen and remove the straight fittings (8) from ports T and T1.3. Remove the cartridge valves (6) from ports SV1 thru SV6.4. Remove the reducing valve (7) from port RV and the 90 degree fitting (9) from port P.5. Loosen and remove the four bolts (10) that attach the flow control valve (11) to the valve body (1). Remove the flow control valve (11). Discard the O-rings.6. Remove all remaining plugs from the M17 valve body. Cleaning and Inspection.o1. Clean all the parts in a suitable solvent.2. Submerge the valve bodies in a suitable solvent and agitate gently to flush contaminates from the internal ports. Blow dry with filtered air.3. It is recommended that all O-rings be replaced. Lubricate new O-rings with clean petroleum jelly.4. Inspect the ports on the valve bodies for damaged threads, burrs, scratches, and contaminates.5. Inspect all fittings and internal components for damaged threads, burrs, and scratches.6. Replace all damaged components.Assembly.NOTEAll components must be installed to their correct ports as marked during disassembly. Cap all fittings to prevent contamination.1. Install all plugs to the M1 7 valve body.2. Lubricate and install new O-rings to the flow control valve (11). Install the flow control valve (11) to the valve body (1) using the four bolts (10).3. Install the cartridge valves (6) into ports SV1 thru SV6 as tagged during removal.4. Install the 90 degree fitting (9) into port P and the reducing valve (7) into port RV.5. Install the straight fittings (8) into ports T and T1.6. Install the pressure valves (2, 3, 4, and 5) into ports PV1, PV2, PV3, and PV4 as tagged during removal.Installation.1. Install the M17 valve body to the two protruding boltstherear of the upperstructure using the two nuts andwashers.2. Install the six solenoid coils to the appropriate cartridge valves as marked during removal. Secure the solenoid coils to the valves using the six jam nuts.3. Install all hoses to the M17 valve body as marked during removal.

2-4-#

2-4-931.Valve Body

2.Pressure Valve

3.Pressure Valve

4.Pressure Valve

5.Pressure Valve

6.Cartridge Valve

7.Reducing Valve

8.Straight Fitting

9.90 Degree Fitting

10.Bolt

11.Flow Control Valve

ft/117 Valve Body

(p) (g) (p/ (pj)

HI 4 HIHI2HI1

T2BH

PG034138. Hold the cartridge assembly together to prevent movement and rotate it 180 degrees so the outlet support plate rests on a flat surface, and the wooden board is upward. Remove the wooden board.39. Lubricate the exposed surface of the rotor and vanes with clean hydraulic fluid. Locate the scribe mark on the inlet support plate (29) and flex side plate (27). Hold the inlet support plate and flex side plate together and assemble them over the exposed ring, rotor, and vanes. Ensure the scribe marks are in line.NOTEThe cast-in arrows, located next to the socket head screws, indicate the direction of rotation of the cartridge.40. Thread the two socket head screws (31) into the cartridge until snug (hand tight).NOTEThe OD of all component parts of the cartridge kit must be in-line with each other or the cartridge will bind during assembly. Align the cartridge as follows.41. Build a V block from hardwood, or if a metal V block is available, use that. Place the cartridge into the V block on its side. Loosen the socket head screws (31) enough to allow each section of the cartridge to come into alignment within the V block. Torque the socket head screws (31) to 30 pounds-foot (4.15 kgm). Recheck the alignment after torquing.42. Check the rotor (23) for bind by inserting the index finger through the shaft opening of the inlet support plate (29). Hold the cartridge kit in a horizontal shaft position and lift the rotor with the finger. The rotor should move freely back and forth within the cartridge. If the rotor binds, open the kit, clean and stone all possible areas of bind, then reassemble using the aforementioned procedure. The rotor must move freely within the cartridge when assembled.43. Lubricate and install a new O-ring (17) and backup ring (1 6) onto the outlet support plate (20).44. Lubricate and install a new 0-ring (19) and sealing ring (18) onto the outlet support plate (20).45. Install the cartridge assembly onto the shaft (33) with the inlet plate facing towards the main section (3).46. Install the mid section (2) to the main section (3) using the two bolts (15), torque to 45 pounds-foot (6.2 kgm).47. Lubricate and install a new O-ring (32) into the groove of the mid section (2).48. Insert the two locating pins (12) into the mid section (2).49. Assemble the ring assembly by placing the O-ring(11) between ring (10 and 13), align the scribe marks.50. Install the ring assembly on the locating pins (12).51. Install the rotor (8) onto the shaft (33). Insert the vanes (9) into the rotor slots. Ensure the radius edges on the vanes (9) are toward the cam ring, with the sharper edge towards the direction of rotation.52. Lubricate and install a new O-ring (5) in the front cover (1).53. Place the spring (6) over the pressure plate (7) and install onto the front cover (1).54. Install the front cover (1) to the mid section (2) using the four bolts (14), torque to 40 pounds-foot (5.5 kgm).INSTALLATION.1. Attach a suitable lifting device to the pump, remove the pump from the vise.2. Align the spline on the pump with the spline on the pump drive and carefully slide the pump into the drive.3. Secure the pump to the drive using the two bolts and washers.4. Remove the caps from the fittings and hoses and attach the hoses to the pump.PRESSURE SETTINGSDESCRIPTIONThis subsection outlines procedures for adjusting several major pressure settings within the hydraulic system. Test fittings have been provided for easy installation of the proper pressure gauges. It is recommended that these pressures be checked every six months and adjusted as required for maximum machine efficiency.CHARGE CIRCUIT.The charge pressure will be set to 450 psi (3103 kPa/31.03 bar) using a 0 to 1000 psi (0 to 6895 kPa/0 to 68.95 bar) pressure gauge.1. Locate the M1 charge valve body.2. Install a 0 to 1000 psi (0 to 6895 kPa/0 to 6.895 bar) pressure gauge in M1, port TP1.3. Locate the charge relief valve on the charge filter assembly on the rear of the upperstrucutre.4. Loosen the jam nut on the charge relief valve.5. StarttheengineandsetthethrottletoFULL. Observe the pressure gauge installed in M1. If the pressure reading is less than 450 psi (3103 kPa/31.03 bar), use an alien wrench to turn the adjusting screw on the charge relief clockwise until the correct pressure is read on the gauge. If the pressure reading is greater than 450 psi (3103 kPa/ 31.03 bar) turn the adjusting screw counterclockwise until the correct pressure is indicated on the gauge.6. Tighten the jam nut on the charge relief valve. Recheck the pressure reading on the gauge to ensure a reading of 450 psi (3103 kPa/31.03 bar).7. Shut down the engine and remove the pressure gauge from Ml.CONTROL CIRCUIT.WARNINGBEFORE INSTALLING ANY PRESSURE GAUGES IN THE CONTROL CIRCUIT, DRAIN THE CONTROL ACCUMULATOR BY TURNING THE MANUAL ROTARY VALVE KNOB ON THE M5 VALVE BODY COUNTERCLOCKWISE UNTIL PRESSURE IS RELIEVED.Setting RV2 in M5.1. Drain the control accumulator using the valve knob in M5. Close the valve knob.2. Loosen the nut on valve RV1. Install an alien wrench into the adjustment in RV1 and turn the adjustment clockwise until it bottoms out.

3. Loosen and remove the cap on the end of valve RV2. Install an alien wrench into the adjustment in RV2 and turn the adjustment counterclockwise 1 1 /2 turns.4. Install a 0 to 5000 psi (0 to 34,475 kPa/0 to 344.75 bar) pressure gauge into the test fitting in port TP1 of M5.5. Starttheengineandsetthethrottleto FULL. Observe the pressure gauge for a reading of 3300 psi (22,753.5 kPa/227.53 bar).

2-4-72

2-4-#

*

M8 Valve Body

Vlave Body Straight Fitting Cartridge Valve 90 Degree Fitting Test Fitting Straight Fitting Swivel Tee Screw CapSolenoid Valve0365

4. Install the straight fitting (6) and the swivel tee (7) into port P. Install the straight fittings (6) into ports F1, G1, and T.5. Install the test fitting (5) into port P2 and the 90 degree fittings (4) into ports G, F, T2, and P3.6. Install the cartridge valve (3) into port RDV. Install the straight fittings (2) into ports PS4, PS6, and PS7.Installation.1. Install the M8 valve body to the underside of the cab floor using the three bolts, nuts, and flatwashers.2. Install the four electrical wires to the solenoid valve in M8 as tagged during removal.3. Install all hoses and tubes to the M8 valve body and the solenoid valve as tagged during removal.M10 VALVE BODIES.For maintenance instructions refer to Brake Valve Body M10 in Section 7-HOISTS.M13 VALVE BODY.Removal and Disassembly.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and remove all hoses and tubes that connect to the M1 3 valve body. Plug all open ports and cap all hoses.3. Loosen and remove the two nuts and washers that attach the M13 valve body to the inner left side of the upperstructure frame.4. Remove M13 and place it on a clean workbench for disassembly.5. Tag and remove all fittings and plugs in the M13 valve body.Cleaning and Inspection.1. Clean all the parts in a suitable solvent.2. Submerge the valve body in a suitable solvent and agitate gently to flush any contaminants from within the block. Remove the block and blow dry with air.3. Inspect all ports on the manifold block for thread damage, burrs, scratches, or contaminants.4. Inspect all fittings, plugs, valves, and switches for thread damage.5. Replace all defective components.Assembly and Installation.NOTEAll components must be installed to their correct ports as marked during disassembly. Cap all fittings to prevent contamination.1. Install all plugs and fittings to the M13 valve body as marked during removal.2. Install the M13 valve body to the inner left side of the upperstructure frame using the two nuts and washers.3. Install all hoses to M13 as tagged during removal. M16 VALVE BODY.For maintenance instructions refer to SWIVEL in Section 8 - SWIVEL.Ml7 VALVE BODY.Removal.1. Discharge the control accumulator by turning the manual rotary valve knob on the control accumulator valve body counterclockwise until pressure is relieved.

Valve Body M3 Valve Body M4 Valve Cartridge Valve Cartridge Valve Cartridge Plug Valve Cartridge Plug Pressure Switch 90 Degree Fitting Connector Orifice Plug PlugOrifice Plug Pipe Plug Plug T ubeStraight Fitting90 Degree Fitting90 Degree FittingCheck Valve CartridgeTest Fitting90 Degree FittingShuttle ValveHot Oil Valve CartridgeValve CartridgeOrifice PlugStraight FittingValve SpacerO-RingBackup RingValve Cartridge Pressure Switch Fitting Connector Test Fitting Fitting T ube FittingRelief Valve Cartridge Straight FittingO-RingValve Cartridge Poppet BoltLocator Plate O-RingO-Ring,.Bolt{IHoist Port Valve Flange Half O-R ingro*a

M3/M4 Valve Body

1.Remove the valve cartridge (3) from port SV2.8. Removethehotoil valve cartridge (23) from portPSH!

1.Remove the valve cartridge (3) from port SV2.8. Removethehotoil valve cartridge (23) from portPSH!

22.Remove all remaining plugs from the M3 valve body.

2. Remove the valve cartridges (4) from ports SV1 and SV3.3. Remove the valve cartridge plugs (5) from ports SV4, PV1, and PV3.4. Remove the valve cartridge plug (6) from port PV2.5. Remove the pressure switch (7), 90 degree fitting (8), connector (9), and the orifice plug (10) from port TP11.6. Remove the plug (11) from port R2. Remove the orifice plug (12) from the inner bore of port R2.7. Remove the pipe plug (13) from port G. Remove the plug (14) from the inner bore of port G.8. Removethepipeplug(13)fromportFs. Removetheplug (14) from the inner bore of port F.9. Tag and remove all remaining plugs in the M4 valve body.Valve Body M3.NOTEAs each component is removed from the valve body, it must be tagged with the number/letter of the port that the component was removed from. This will be the only means of identifying the components during assembly.1. Remove the tube (1 5) that runs over the fitting in port F.2. Remove the straight fitting (16) and the 90 degree fitting (17) that the tube (15) was connected to.3. Removethe 90 degree fitting (18) from portF.4. Removethe check valve cartridge (19) fromport CV3.5. Remove the test fitting (20) from port TP6.6. Removethe 90 degree fitting (21) from portD.7. Loosenand remove the shuttle valve (22)fromportSHV1.9. Remove the valve cartridge (24) from port CV1. Loosen and remove the orifice plug (25) from the inner bore of port CV1.10. Remove the straight fitting (26) from port PP3.11. Locate the face of the valve body (1) that mates with the M4 valve body (2). Remove the five cartridge valves from the five large ports as follows.a. Carefully pryoutthevalvespacer(27). Discardthe O-ring (28) in the inner bore and the backup ring (29) and O-ring (30) in the circumferential channel of the valve spacer (27).b. Remove the valve cartridge poppet (31) from theport.c. Repeat this procedure for the four remainingports.12. Loosen and remove the bolt (32) that attaches the locator plate (33) to the valve body (1).13. Remove and discard the O-ring (34) from the inner bore and the O-ring (35) from the outer groove of the locator plate (33).14. Loosen and remove the four bolts (36) that attach the hoist port valve (36) and the two flange halves (38) to the valve body (1). Discard the O-ring (39).1 5. Remove the valve cartridge (40) from port SV on the hoist port valve (37). Remove the pressure switch (41), fitting (42), and the connector (43) from the hoist port valve (37). Remove the test fitting (44) from port PS and the fitting (45) from port D on the hoist port valve (37).1 6.Removethe test fitting (20) from port TP4.17. Removethe tube (46) from the fitting in portD3.1 8.Removethe fitting (47) from port D3.1 9.Removethe relief valve cartridge (48) from portRV1.20. Remove the straight fitting (49) from port PP2.V'21. Removethe fitting (21) from port D4.Valve Bodies M3 And M4DESCRIPTIONThe valve bodies are aluminum blocks that have several interconnecting passages between valves. They control fluid flow direction, pressure, and flow rate with the use of modular valves that are secured in the valve bodies using multiple threaded ports and internally threaded ports.

The valve bodies M3 and M4 are bolted together and then bolted directly to the hoist motor. Three main internal ports A, B, and C control hydraulic flow to the working ports in the distributor of the radial piston motor and the motor case is bolted directly to the drum flange. Poppet valves V1, V2, V3, V4, and V5 are used internally in the working ports of the valve body for direction and check functions. Each poppet valve contains two internal ports for fluid passage. One is a pilot port that controls the valve function via the use of solenoid valves that are contained in the valve body M4. The other port is the main passage for working fluid to the distributor.

2-9-1

MAINTENANCE

REMOVAL.f. Discharge the control accumulator by turning the manual rotary valve knobon the control accumulator manifold counterclockwise until pressure is relieved.CAUTIONDURING REMOVAL OF ANY COMPONENTS OR AFTER BREAKING ANYCONNEC- TIONS, ALL PORTS AND HOSES SHOULD BE PLUGGED OR CAPPED.2. Tag and remove all hydraulic lines that attach to the M3 and M4 valve body. Plug all open ports and cap allhoses.CAUTIONTAG THE SOLENOID COILS WITH THE CORRECT PORT PRIOR TO REMOVAL.3. Tag and remove the three solenoid coils on the M4 valve body by removing the nut that secures each solenoid coil to the valve body. Pull the coils straight off the valve cartridges. Tag and remove the solenoid coil from the hoist port valve.4. Tag and remove the remaining electrical lines that run to the valve body.5. Attach a suitable lifting or supporting device to the valve body.6. Loosen and remove the six bolts and washers that attach the valve body to the hoist motor.7. Remove the valve body from the hoist motor. Discard the O-rings. Plug all open hoist motor ports.8. Position the valve body on a clean, flat working surface.9. Loosen and remove the ten bolts and washers that attach the M3 valve body to the M4 valve body. Separate the valve bodies and discard the O-rings.DISASSEMBLY.Valve Body M4.NOTEAs each component is removed from the valve body, it must be tagged with the number/letter of the port that the component was removed from. This will be the only means of identifing the components during assembly.SECTION 9 ELECTRICAL SYSTEMTABLE OF CONTENTSPageELECTRICAL SYSTEMDescription 2-9-3Maintenance2-9-3HOIST SPEED SELECT, FREEFALL, AND STATUS PANEL ELECTRICAL CIRCUITS2-9-13Description 2-9-13LIST OF FIGURESTitlePageEngine Instrument Removal and Installation 2-9-6Toggle Switch Removal2-9-7Bumper Switch Removal 2-9-7Windshield Wiper Removal and Installation 2-9-8Hoist Circuit 2-9-15Hoist Freefall Circuit 2-9-16Status Panel Circuit 2-9-17LIST OF TABLESTitlePageAlternator Belt Tension and Attaching Hardware Torque Table2-9-5Upperstructure Electrical Component, Location, and Primary Function2-9-9WARNING SAFETY SUMMARYPageWARNING2-9-3IF IT SHOULD BECOME NECESSARY TO PERFORM ELECTRICAL MAINTENANCE ON LIVE OR HOT CIRCUITS, REMOVE ALL RINGS, WATCHES, AND OTHER JEWELRY BEFORE PERFORMING MAINTENANCE AS SERIOUS BURNS RESULT FROM ACCIDENTAL GROUNDING OR SHORTING OF LIVE CIRCUITS.

ELECTRICAL SYSTEMDESCRIPTIONThe crane electrical system is 24-volt consisting of an alternator and lead-acid batteries series parallel connected. Four batteries are used and are installed on the rear left side of the upperstructure. Two batteries are connected in parallel to make two parallel sets of batteries for a higher amperage rate. Both parallel sets are connected in series to provide 24 volts. The system is the single wire ground return type, utilizing the crane's structure as ground. Some accessories of the crane require 12 volts for operation. These are supplied from a 12-volt power supply regulator located in the electrical junction box under the cab.All electrical circuits are protected by circuit breakers. A circuit breaker panel is located in the operator's cab and is the right rear panel under the right arm rest. The breaker panel contains 19 circuit breakers. There are three remote mounted circuit breakers. One is located inside the electrical box that is mounted in the engine compartment. The two other circuit breakers are located on the fill pump assembly box, which 3 located on top the hydraulic reservoir. If a circuit breaker has tripped, a white band will be visible. Depress the circuit breaker to reset it.In addition to the above mentioned circuit breakers, some circuits are controlled and protected by a combination toggle switch/circuit breaker.An electrical junction box located under the cab contains most of the of relays and associated electrical components that control the electrical functions. The box also provides the junction point between the cab controls and the remainder of the crane.There is one fuse in the electrical system. The fuse (F2) is located in a conduit box located on the gantry hydraulic relief valve on rear left side of the upperstructure. The cover on the box must be removed to gain access to the fuse.For a location and primary functions of circuit breakers, fuses, and relays see chart titled Electrical Component, Location, and Primary Function.ALTERNATOR.The alternator is mounted on the engine and is belt driven. It is a 50 ampere alternator with 24-volt output terminals which supply the voltage to recharge the batteries and maintain them at a full state of charge.BATTERIES.The 12-volt batteries are located on the left side of the upperstructure in the rear corner. The batteries are secured with two J hooks and a strap.The batteries are the maintenance free type and are completely sealed except for a small vent hole in the side of the battery. The vent hole allows what small amount of gasses that are produced in the battery to escape. A test indicator located on the top of the battery is used to determine if the battery can be tested in case of a starting problem. For information concerning the use of this indicator, refer to Delco-Remy Service Bulletin 1B-116 in the back of this Service Manual.

MAINTENANCEGENERAL.WARNINGElectrical system maintenance includes replacement ofdamaged components. Standard wiring practices shouldIF IT SHOULD BECOME NECESSARY TObe observed when replacement is necessary.PERFORM ELECTRICAL MAINTENANCEON LIVE OR HOT CIRCUITS, REMOVE ALL RINGS, WATCHES, AND OTHER JEWELRY BEFORE PERFORMING MAINTENANCE AS SERIOUS BURNS RESULT FROM ACCIDENTAL GROUNDING OR SHORTING OF LIVE CIRCUITS.WARNINGENSURE THE BATTERIES ARE DISCONNECTED BEFORE PERFORMING ANY MAINTENANCE ON AN ELECTRICAL CIRCUIT WHICH IS NOT FUSED.CAUTIONNEVER REPLACE ORIGINAL WIRING WITH WIRING OF A SMALLER DIAMETER.TROUBLESHOOTING.To isolate electrical troubles, a multimeter should be used. The multimeter, when used properly, can provide readings necessary for service personnel to determine the following.1. Opens in the electrical system.2. Resistance in the electrical system.Tfiere may be a loose or corroded connection in the pin type connectors. Check the connectors to ensure that the wire pins are properly seated and engaged in the receptacle. If the male and female pins show any signs of corrosion, use a good quality electrical contact cleaner or a fine sandpaper to clean them. When the pins show signs of arcing or burning, it will probably be necessary to replace them.The following is a list of Deutsch and AMP tools necessary for connector maintenance.Extraction.6 ga. wire - #4 size contact, 114009 8 ga. wire - #8 size contact, 114008 14 ga. wire - #12 size contact, 114010 16 ga. wire - #16 size contact, 0411 -204-1605Crimping.6 ga. wire - #4 size contact, HDT-0408 8 ga. wire - #8 size contact, HDT-0408 14 ga. wire - #12 size contact, HDT-48-00 16 ga. wire - #16 size contact, HDT-48-00 1 6 ga. wire - #1 2 size contact - (AMP), 90353-2 14 ga. wire - #1 6 size contact - (AMP), 90353-2Because the pins are crimped to the wires, it is not possible to remove the pin. Using the proper extraction tool, remove the pin(s)from the plug or receptacle. Cut the wire as close to the pin as possible. After cutting the pin off, the wire will most likely be too short. Using a wire that is too short will allow pressure to be applied to the pin and wire where they are crimped when the pin is inserted in the plug or receptacle. Add a short length of the same size wire to the short wire by crimp splice or solder. Use heat shrinkable tubing or other suitable material to insulate the splice.ALTERNATOR.Removal.1. Swing the upperstructure over the front or rear to gain access to the underside of the engine compartment.2. Tag and disconnect the electrical leads from the terminals on the alternator.3. Loosen the alternator attaching hardware and remove the belts from the alternator pulley.4. Remove the attaching hardware from the belt tension adjusting bracket.5. Remove the nuts, washers, and bolt attaching the alternator to the mounting bracket and remove the alternator.Installation.1. Position the alternator on the mounting bracket and secure with the bolt, washers, and nut. Do not tighten at this time.2. Install the hardware attaching the alternator to the belt tension adjusting bracket.3. Position the belt around the alternator pulley.4. Refer to the Alternator Belt Tension and Attaching Hardware Torque Table for proper belt tension.5. Connect the electrical leads to the terminals as tagged during removal.BATTERIES.Removal.1. Remove the locknut and washer from each end of the threaded J hooks.2. Remove the strap, securing the batteries to the battery box weldment.3. Disconnect the ground strap that is secured to the upperstructure frame,4. Tag and disconnect all leads from the battery terminals, starting with the negative terminals.5. Remove each battery and the plywood spacer it sits on.Installation.1. If necessary, replace the plywood before installing the batteries.2. Install each battery.3. Connect all leads to the battery terminals, starting with the positive terminals.4. Connect the ground strap to the upperstructure frame.5. Install the J hooks into the battery weldment.6. Place the strap on the top of the batteries and place each hole of the strap over one of the J hook's threaded ends. Using the two locknuts and washers, secure the strap in place by tightening each locknut evenly until the strap bottoms out on the top of all four batteries.Removal.1. In the operator's cab, tag and disconnect the connector plugs that run along the trough on the right side of the cab floor.2. Tag and disconnect plugs on the floor in front of the cab heater.3. On the left arm console, remove the six finishing screws, securing the panel in place.4. At this time, also tag and disconnect the safety interlock switch.5. Tag and disconnect the plug P16 in the left arm console.6. Tag and disconnect the plugs from the electrical box.7. Remove the heat shrink tubing, tag and disconnect the following spade connectors: PS3-7, PS4-7, PS6-7, PS9-7, PS10-7, PS4-8, PS6-8, PS7-8, SV3A and B, PS1 -F, and PS1-G.8. Remove the heat shrink tubing from the work light and horn connections, tag and disconnect their connections.

CAB ELECTRICAL BOX.9. Remove the locknuts and washers from inside the cab electrical box.

2-9-6

2-9-5

Alternator Belt Tension and Attaching Hardware Torque TableAttaching Hardware TorqueBelt Tension

EngineNo. of BeltsLB-FTKGM

GMC260-708.29 - 9.78Press with thumb in center of belt. Maximum deflection is 0.5 to 0.75- inch (13 - 19 mm).Belt tension gauge pressure is 40 - 50 lbs. (18 - 23 kg).

Cummins260-708.29 - 9.78Belt tension gauge pressure is 80 lbs. (36 kg).

Cat260-708.29 - 9.78Apply a 25 pound (11 kg) force perpendicular to the belts, midway between the driver and driven pulley.Maximum deflection is 0.50 to 0.75 inch(13-19 mm) for the first check. Maintain later adjustments at 0.875 inch (22 mm) deflection.

10. While removing the box, also feed the harness through the floor of the operator's cab.Installation.1. Feed the harness through the floor of the operator's cab.2. Install the cab electrical box on the threaded studs and install the washers and locknuts that secure the box in place.3. As tagged during removal, connect all chord connectionsthat were disconnected during removal.4. Tag or use heat shrink tubes around allchordconnections.5. . As tagged during removal, connect the plugs to the electrical box.6. Install the plug in the left arm console.7. Secure the safety interlock switch.8. Install the left arm console using the six screws that secure the panel in place.9. As tagged during removal, connect the plugs in front of the cab heater.10. As tagged during removal, connect the plugs along the trough on the right side of the cab foor.INSTRUMENTS. Removal.1. Remove the screws securing the instrument panel to the right front corner of the cab.2. Remove the hardware securing the gauge to the instrument panel, then remove the gauge.

3651

Engine Instrument Removal and Installation3. Tag and disconnect the electrical leads to the gauge; then tape the lead ends.Inspection.1. Examine gauges for cracked and broken lenses.Check gauge terminals and mounting studs for damage.... ,kJ2. Check wiring for damaged insulation or damaged terminals.Installation.1. Connect the electrical leads as marked prior to removal.2. Place the gauge into position on the panel and secure it with the attaching hardware.3. Position the cab instrument panel and secure the panel with the screws.Functional Check.Start the engine and observe for proper functioning of the repaired indicator. (Refer to Operator's Handbook). Troubleshoot further as necessary, any system malfunction not corrected by repair or replacement of the indicator or associated wiring.

Toggle Switch Removal

Removal.1. Gain access to all panels in the operators cab by removing the screws from each panel and lifting each panel out.

7665

7666

1. Visually check the switch for evidence of cracks, damaged connections, or other damage.2. Check wiring for damaged insulation or damaged terminals.3. Perform the following check to determine switch serviceability.a. Using an ohmmeter, check for continuity between the switch terminals with switch in ON or activated position.b. Position switch to OFF. Ohmmeter should register zero (no continuity).Installation.1. Conenct the electrical leads as marked prior to removal.2. Position any switches that were removed from the panel and secure them with the attaching hardware.3. Install the panels in place using the screws that were removed.Functional Check.Operate the switch as described in the Operator's Handbook. Observe it for proper functioning in the applicable circuit. Continue troubleshooting as necessary any system or circuit malfunction not corrected by repair or replacement of the switch or associated wiring.WINDSHIELD WIPER ASSEMBLY. Removal.1. Gain access to the cab windshield wiper motor by removing the four screws from a panel located under the center front console.2. Taganddisconnectthethreeelectrical leadsfromthe motor.3. Remove the nuts and washers securing the wiper arms; then remove the wiper arms.

ELECTRICAL SWITCHES.Inspection.

ELECTRICAL SWITCHES.Inspection.4. Remove the serrated collar.

Bumper Switch Removal5. Remove the capscrews securing the mounting plate to the motor mounting bracket.

u6. Remove the motor and mounting bracket, mounting plate, and gasket.Inspection.Visually check the motor housing for evidence of cracks or other damage. Check for excessive shaft end play indicating worn or damaged bearings. Inspect the wiper blade for serviceability.Installation.1. Install the motor and mounting bracket, mounting plate, and gasket in position.

2. Secure the mounting plate to the motor bracket with attaching capscrews.

2-9-8

2-9-#

Windshield Wiper Removal and Installation3. Install the serrated collar.4. Install the wiper arms and secure them with attaching washers and nuts.5. Connect the electrical leads to the motor as marked prior to removal.6. Install the access cover panel under the front console using the four screws.'QComponentLocationFunction

CB1 (60 AMP)Engine compartment 6x6 electrical boxProtects all other circuit breakers and relays within the system, with the exception of the gantry controller and fill pump.

CB2 (20 AMP)Breaker panelProtects the domelight and cigar lighter.

CB3 (5 AMP)Breaker panelProtects the engine solenoid (SV2-0).

CB4 (5 AMP)Breaker panelProtects the engine start switch K1, K2, and the quick start circuit.

CB5 (5 AMP)Breaker panelProtects the throttle switch in the IDLE and MID position.

CB6 (7.5 AMP)Breaker panelProtects the throttle switch in the FULL position and protects the optional horsepower limiting circuit.

CB7 (15 AMP)Breaker panelProtects the gauges, gauge lights, panel lights, and status panel.

CB8 (10 AMP)Breaker panelProtects relays K11, K12, K13, K14, TK1 and TK5.

CB9 (20 AMP)Breaker panelProtects the heater and air conditioner.

CB10 (5 AMP)Breaker panelProtects switches within the boom hoist circuit.

CB11 (10 AMP)Breaker panelProtects components within the optional third hoist circuit.

CB12 (10 AMP)Breaker panelProtects relays K6, K28 K30, K5, TK6 and components within the front hoist circuit.

CB13 (10 AMP)Breaker panelProtects relays K9, K8, K17.K29, K10, K31, and TK7.

CB14 (5 AMP)Breaker panelProtects pressure switches (PS7-8, PS1-19F, and PS1-19R) for charge/control indicator light and relay.

CB15 (5 AMP)Breaker panelProtects the cab extend/retract circuit.

CB16 (5 AMP)Breaker panelProtects the hoist rotation indicators.

CB17 (5 AMP)Breaker panelProtects the A2B/LM1 system.

CB18 (5 AMP)Breaker panelProtects the accessory.

Electrical Component, Location, and Primary Function

Electrical Component, Location, and Primary Function (continued)

Electrical Component, Location, and Primary Function (continued)

ComponentLocationFunction

CB19Right front switch panelProtects the optional upper front work lights.

CB20Right front switch panelProtects the optional lower front work lights.

CB21Right front switch panelProtects the optional rear work lights.

CB22Breaker panelProtects the signal horn and the temperature switch at the oil cooler.

CB23Breaker panelProtects the PARK/PROPEL switch and solenoid valves SV1-17 and SV2-17.

CB29 (50 AMP)Hydraulic tank electrical box 4x4Protects the fill pump motor.

CB30 (5 AMP)Hydraulic tank electrical box 4x4A circuit breaker switch which protects relay K23.

F2 (4 AMP)Gantry relief valveProtects the gantry controller.

K1StarterIs energized when the IGNITION switch is in the ON portion and engine switch is depressed to START to engage the starter through K1.

K2Engine compartmentIs energized as described in K1 function, K2 completes the circuit to energize K1.

K4Cab electrical boxIs grounded through the safety interlock switch to provide power to the crane functions.

Z)Cab electrical boxIs energized by the front hoist freefall switch and brake pedal to place the front hoist in freefall mode and provide power to the front hoist freefall indicator light.

2Cab electrical boxIs energized by the front hoist high speed switch to place the front hoist in the high speed mode and provide power to the front hoist indicator light.

K8Cab electrical boxIs energized by the rear hoist high speed switch to place the rear hoist in the high speed mode and provide power to the rear hoist high speed indicator light.

ComponentLocationFunction

K9Cab electrical boxIs energized by the optional clamshell select switch and creates the condition necessary for clamshell operation of the front and rear hoist.

K10Cab electrical boxIs energized by the rear hoist freefall switch and brake pedal to place the rear hoist in freefall mode and provide power to the rear hoist freefall indicator light.

K11Cab electrical boxIs energized by the switch turned to the ON position through K19 and TK1 and provides power to front hoist high speed and front hoist freefall indicator lights.

K12Cab electrical boxIs energized in the same manner as K11 and provides power to the rear hoist high speed and rear hoist freefall indicators.

K13Cab electrical boxIs energized in the same manner as K11 and provides power to the low hydrauic oil temperature, charge pressure, control pressure, and engine indicator lights.

K14Cab electrical boxIs energized in the same manner as K11 and provides power to the high hydraulic oil temperature and change hydraulic filter indicator light.

K17Cab electrical boxIs energized by relay K9 and switch S22 and provides a holding circuit for K9 through PS6B-7 and PS7B-7.

K19Cab electrical boxIs energized by the ignition switch in the ON position. Provides power to cab controls and instruments, swing horn, oil cooler temperature switch, status panel, relays TK1 and TK5, and throttle switch.

K23Hydraulic tank electrical box 4x4Is energized by a circuit breaker switch (CB30) and provides power to the hydraulic field fill pump motor.

Cab electrical boxIs energized by a pressure switch (PS6A-7 or PS7A-7) to prevent switching speed on the front hoist when the hoist is rotating.

ComponentLocationFunction

K29Cab electrical boxIs energized by a pressure switch (PS10-7 or PS9-7) to prevent switching speed on the rear hoist when the hoist is rotating.

v!)Cab electrical boxIs energized by depressing the front hoist brake pedal and positioning the front hoist freefall svyitch to NORM in order to exit freefall which deenergizes relay K5.

K31Cab electrical boxIs energized by depressing the rear hoist brake pedal and positioning the rear hoist freefall switch to NORM in order to exit freefall by deenergizing relay K10.

TK1Cab electrical boxIs energized by K19 providing status panel power and times out after 5 seconds. TK1 deenergizes relays K11, K12, K13, and K14.

TK5Cab electrical boxIs energized by any of the red indicators circuits after starting the engine. After 30 seconds, the relay breaks its contacts and stops the alarm.

^TK6^)Cab electrical boxIs energized by relay K5 which energizes SV1-19F, after 1 second breaks it's contacts to deenergize SV1-19F.

TK7Cab electrical boxIs energized by relay K10 which energizes SV1-19R, after 1 second breaks it's contacts to deenergize SV1-19R.

Electrical Component, Location, and Primary Function (continued)

2-9-12

2-9-14

2-9-15HOIST SPEED SELECT, FREEFALL, AND STATUS PANEL ELECTRICAL CIRCUITSDESCRIPTION

HOIST SPEED SELECT CIRCUIT.The front hoist circuit will be described in this description, the rear hoist circuit is identical with the exception of the relay and solenoid numbers. The sjx major components of the hoist speed select circuit are the controller pressure switches (PS6A-7 & PS7A-7). relay K26, relay K28, relay K6, hoist speed switch, and PST-3F. The controller pressure switches supply power to energize the coil of relay K28. The contacts of relay K26 control power from pressure switch PS6A-7 in the up direction. In the event of two block, the contacts of relay K26 will open and eliminate power from the hoist speed select circuit. Relay K28 has two functions; when selecting high speed it provides power to the coil of relay K6 when K28 is deenergized and when energized provides a holding circuit to prevent changing hoist speed while the hoist is rotating. Relay K6 is the high speed relay and when energized provides power to solenoid valve SV1-4F and the high speed indicator frgfli The hoist speed switch determines the hoist speed. Pressure switch PS1-3F provides the high speed circuit with a holding circuit and will change the hoist speed from high to low if the hydraulic system pressure reaches 4500 psi (31,028 kPa/310 bar).The hoist high speed holding circuit is maintained electrically until system pressure reaches 4500 psi (31,028 kPa/310 bar) or until the hoist speed switch is manually switched to low while the controller is in the neutral position. The control lever must be in the neutral position to allow K28 to be deenergized. Positioning the hoist speed switch to high allows power to pass through the closed contacts of deenergized K28 to the coil of K6. When the coil of K6 is energized, a holding circuit is established from the speed select switch terminal 5, across contacts 10 to 6 of relay K6, back to the switch terminals 2 to 1, through pressure switch PS1-3Fto the coil of K6. This will maintain the hoist in high speed after releasing the speed select switch.A second holding circuit is established when the control lever is actuated. This holding circuit will bypass the hoist speed switch and provide an additional source of power to the coil of K6 to prevent changing speed while the hoist drum is rotating. Energizing K28 allows power to be supplied from contact 6 of K6 through the now closed contacts 10 to 6 of K28 to contact 1 of the speed select switch through pressure switch PS1-3F to the coil of K6. This prevents changing from high to low speed while rotating the hoist.HOIST FREEFALL CIRCUIT.The front hoist freefall circuit will be described in this description, the rear hoist is identical with the exception of the relay and solenoid numbers. The five major components within the freefall circuit are the select switch, relay K5, relay TK6, PS6-8, and relay K30. The select switch is spring return to the center position and supplies power to the freefall circuit. Relay K5 is the freefall relay which when deenergized provides the circuit for automatic hoist brake operation. When relay K5 is energized, it's contacts energize the freefall indicator light, TK6, various solenoid valves, a holding circuit to maintain K5 energized, and provides a second source of power to K4, bypassing the charge and control pressure switches. Relay TK6 allows solenoid valve SV1-1 9F to be energized. After one second, the contacts of energized TK6 will open to deenergize SV1 - 19F. When the brake foot pedal is depressed, pressure switch PS6-8 is activated and supplies power to either K30 or K5 coil depending on the position of the select switch. Relay K30 has two functions; when deenergized it's contacts are part of the holding circuit for K5, when energized it's contacts open to break the circuit to K5.To enter freefall, position the hoist brake switch to AUTO and simultaneously depress the freefall select switch to FREE and depress the brake foot pedal. Power is supplied from the switch terminal, across the contacts of pressure switch PS6-8 to the coil of K5. Since K30 is deenergized a holding circuit is established from the switch through K30 contacts across contacts 9 to 5 of K5 to the coil of K5. The hoist will remain in the freefall, mode.To exit freefall, simultaneously depress the freefall select switch to NORM and depress the brake foot pedal. This will supply power across the contacts of pressure switch PS6-8 to the coil of K30. The coil of K30 will energize to open it's contacts and break the holding circuit for K5. The hoist is now out of the freefall mode.STATUS PANEL AUTOMATIC TEST CIRCUIT.The status test panel has two functions. The first function is to test itself for proper operation to ensure the alarm and indicator lights are functioning. The second function is to alert the operator of any problems or conditions after the engine has started. There are three colored indicator lights used, amber (advisory), orange (caution), and red (warning). In addition, the alarm will sound whenever a red (warning) light illuminates.The status panel receives power through circuit breaker CB8 when the ignition switch is turned to the ON position. Relays K11, K12, K13, and K14 will energize through closed contacts of relay TK1. When these relays energize, all indicator lights on the status panel will illuminate. Atthe same time, the alarm will sound. After 5 seconds TK1 will open it's contacts and remove power from relays K11, K1 2, K13, and K14. At this time all of the lights will go out except the charge pressure, control pressure, and engine indicator lights. These lights will remain illuminated because the engine has not been started. The alarm will sound for an additional 25 seconds until TK5 opens it's contacts or the engine is started. After starting the engine, if a problem or condition becomes apparent through any of the relays, temperature switches, or pressure switches, power will be routed across the contacts of the relays to the appropriate indicator light.

s'CJLa

Hoist Freefall Circuit

2-9-#,2-9-18

2-9-17,2-9-18

0438-3Status Panel Circuit?f

2-4-#

2-4-79

VALVE BODIESDESCRIPTION

There are several valve bodies located throughout the up- perstructure hydraulic system. The valve bodies are aluminum blocks that are ported internally to route hydraulic flow to different components of the upperstructure. The valve bodies reduce the need for external piping, heavy mounting brackets and externally mounted valves, thereby dramatically cutting the weight of the upperstructure. The valve bodies also allow for quick removal of modular valves that are found to be defective, by removing them from a threaded port. Also, because piping is reduced, so are leaks which are associated with loose fittings and connections.

VALVE BODY LOCATION TABLE

Valve Body M1M3FM4FM3RCircuit Used InChargeFront Hoist Front Hoist Rear Hoist Rear Hoist ControlOil Cooler (Control)Physical LocationSituado detrs de la puerta de acceso de la bomba que est en el lado derecho de la estructura superior. El cuerpo de la vlvula de carga est asegurada a la abrazadera que est montada en la parte superior de la unidad de bomba.Located on the right side of the upperstructure and secured directly to the front hoist frame and the Hagglands motor distributor.Located on the right side of the upperstructure and secured directly to valve body M3F.Located on the right side of the upperstructure and secured directly to the rear hoist frame (middle frame) and the Hagglands motor distributor.M4RM5M6Located on the right side of the upperstructure and secured directly to the valve body M4R.Located on the control accumulator and the accumulator is located below the pump drive on the tail section of the upperstructure.Located on the left side of the upperstructure behind the door for gaining access to the oil cooler radiator. The valve body is located behind the radiator and is mounted on the bottom of the radiator frame mount.M7ControlM8ControlM9Cab Control LeverFront Hoist Brakes and Brake PawlM10FLocated under the operator's cab. The valve body is placed over a cutout in the cab floor for routing hoses to the cab control lever, valve body.Located under the operator's cab, the valve body routes control pressure to the valve body M7 and the hoist brake pedals in the operator's cab.Located in the operator's cab between the operator's control levers. There are two if the optional third drum hoist is used.Located on the front hoist frame below valve bodies M3F and M4F on the right side of the upperstructure.

Valve Bodies Location2-4-807548

VALVE BODY M4VALVE BODY M4VALVE BODY M3BRAKE PAWL VALVE BODY M10BRAKE ACCUMULATORREAR HOISTBRAKE ACCUMULATORFRONT HOIST^^CALIPER BRAKE

brake pawl valve BODY M10VALVE BODY M3

47438Front and Rear HoistsCLEANING AND INSPECTION.1. Clean all the parts in a suitable solvent. Blow dry with filtered air. Do not dry the bearing by spinning with compressd air.2. Inspect the bearing for excessive wear and replace as needed.3. It is recommended that all seals and O-rings be replaced.4. Inspect the splines on the shaft for damage or excessive wear.5. Inspect the machined surfaces of the shaft for scratches and burrs. Minor scratches may be polished out using a crocus cloth.6. Replace all damaged components.ASSEMBLY.NOTEWhen replacing O-rings, be sure to use 90 durometer O-rings. Lubricate new O-rings with clean petroleum jelly.1. Press the bearing into the bearing block.2. Lubricate and install a new seal into the smaller diameter bore of the bearing block.3. Press the bearing block onto the splined shaft on the hoist drum.4. Install the remaining seal into the exposed bore of the bearing block.5. Lubricate the splines of the shaft with Never-Seeze.'it,.6. Install the brake disc onto the splined shaft.7. Install the shaft end cap to the end of the shaft using the four bolts. Wrench tighten the bolts.8. Install the two keys to the input end of the hydraulic motor.9. Slide the motor hub weldment block over the keys and onto the hydraulic motor using a suitable lifting device.assembly and the hydraulic motor. Lubricate and install new O-rings in the valve assembly.11. Apply Loctite to the six Grade 8 bolts used to mount the valve assembly.1 2. Using a suitable lifting device, install the valve assembly to the hydraulic motor using the six bolts and hardened flat washers. Torque the bolts to 1 70 pounds-foot (24 kgm).1 3. Attach a suitable lifting device to the hydraulic motor and install it to the hoist.NOTEEnsure the hoist is positioned so the hydraulic motor end is pointing upward. Block, as necessary, to thoroughly support and balance the hoist.14. Apply Loctite 242 to the 24 Grade 8 bolts used to mount the hydraulic motor.15. Install the 24 bolts and flat washers that attach the hydraulic motor to the hoist drum. Torque the bolts to 170 pounds-foot (24 kgm).INSTALLATION.1. Attach a suitable lifting device to the hoist.2. Lift and position the hoist into its mounting bracket on the upperstructure.3. Apply loctite to the four bolts that attach the hub bearing blocks to the hoist frame.4. Install the two hub bearing blocks to the hoist frame using the four bolts and flat washers. Torque the bolts to1 360 pounds-foot (188 kgm).5. Install the rotation indicator transmitter using the two bolts and lockwashers.6. Connect the pawl by installing the pin through the clevis on the spring loaded cylinder and through the pawl. Install the cotter pin to the pin.7. Lubricate and install new O-rings to the tubes that use split-flanges.8. Connect the hydraulic tubes, using the split flanges, to their corresponding ports as marked previously.

10. Thoroughly clean the mounting faces of the valve