Oshkosh JLG 400S Service And Maintenance Manual
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Oshkosh JLG 400S Service And Maintenance Manual

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Service and Maintenance Manual
Models
400S
460SJ
PVC 2001
31215016
January 16, 2020 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Models 400S 460SJ PVC 2001 31215016 January 16, 2020 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Bhydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the mobile elevat- ing work platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION nance personnel pay strict attention to these warnings and COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A precautions to avoid possible injury to themselves or others,...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - January 16, 2020 31215016...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires and Wheels ................. . . 3-1 Tire Damage .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.13 Swing Motor ..................3-66 Disassembly and inspection .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Boom Systems ..................4-1 Platform Control Enable System.
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Lubricating O-Rings in the Hydraulic System ............5-1 Cup and Brush .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ............6-1 Introduction.
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Wiring Harness Connector Labels and Wiring Harnesses ..........7-21 Connector Labels .
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine....... . . 1-5 1-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-51. Bearing Cone Press Tool ................3-59 3-52.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-7. Location of Components ................4-9 4-8.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-89. Main Lift Cylinder ................. . 5-68 5-90.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-9. Platform Control Module Pin Connections............6-18 6-10.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-48. Deutz T4F Harness - Sheet 1 of 6 ..............7-76 7-49.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Deutz D2011L03 Specification ..............1-2 Deutz D2.9L4 Specification .
  • Page 19 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 ........5-44 5-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 .
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. 31215016...
  • Page 21 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 22: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Machine Specifications - 460SJ Maximum Work Load (Capacity): Machine Specifications - 400S Unrestricted (CE and Aus) 600 lb (270 kg) Unrestricted (ANSI) 600 lb (272 kg) Maximum Work Load (Capacity): Unrestricted (CE &...

  • Page 23: Capacities

    SECTION 1 - SPECIFICATIONS 1.2 CAPACITIES Table 1-2. Deutz D2.9L4 Specification Type Liquid Cooled Fuel Tank 22 gal. (83.3 L) Number of Cylinders Hydraulic Tank 32.5 Gal (123 L) Bore 3.6 in (92 mm) Hydraulic System (Including Tank) 40 gal. (151.4 L) Stroke 4.3 in (110 mm) Drive Hub...

  • Page 24: Tires

    SECTION 1 - SPECIFICATIONS 1.4 TIRES Table 1-4. Mobilfluid 424 Specs Size Type Pressure Weight SAE Grade 10W30 14 x 17.5 Foam-Filled 328 lb (149 kg) Gravity, API 29.0 33/16LL x 16.1 Foam-Filled 440 lb (200 kg) Density, Lb/Gal. 60°F 7.35 315/55 D20 Foam-Filled...

  • Page 25: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS Table 1-9. Exxon Univis HVI 26 Specs Table 1-7. Mobil EAL 224H Specs Specific Gravity 32.1 Type Synthetic Biodegradable Pour Point -76°F (-60°C) ISO Viscosity Grade 32/46 Flash Point 217°F (103°C) Specific Gravity 0.922 Viscosity Pour Point, Max -25°F (-32°C) at 40°...
  • Page 26 SECTION 1 - SPECIFICATIONS Only MAF00560 Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine 31215016...
  • Page 27 SECTION 1 - SPECIFICATIONS Only MAF00570 Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz 2011L Engine 31215016...
  • Page 28 SECTION 1 - SPECIFICATIONS Only MAF00590 Figure 1-3. Operator Maintenance and Lubrication Diagram - Kubota Engine 31215016...

  • Page 29: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.7 MAINTENANCE AND LUBRICATION Wheel Drive Hub NOTE: The following numbers correspond to those in Figure 1-1., Figure 1-2., Figure 1-3. and Figure 1-3. OIL LEVEL CHECK Table 1-10. Lubrication Specifications AND FILL SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 30 SECTION 1 - SPECIFICATIONS Hydraulic Return Filter Hydraulic Tank MAF01180 Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or whenever Charge Lube Point(s) - Fill Cap Capacity - 15 Gal. (57 L) to Full Level Filter is replaced.
  • Page 31 SECTION 1 - SPECIFICATIONS Oil Change w/Filter - Deutz D2011 Fuel Pre-Filter - Deutz D2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Every year or 600 hours of operation. Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10 Quarts (9.5 L) w/Filter Fuel Filter - Deutz D2.9 Lube - EO Interval - Check level daily;...
  • Page 32 SECTION 1 - SPECIFICATIONS Fuel Filter (Propane) Fuel Filter - Deutz D2011 Interval - 3 Months or 150 hours of operation Comments - Replace filter. Radiator Coolant Deutz 2.9 Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation. Fuel Filter (Gasoline) Lube Point(s) - Fill Cap Capacity - 2.9 Gallon (11.3 L)
  • Page 33 SECTION 1 - SPECIFICATIONS Air Filter Wheel Bearings Lube Point(s) - Replaceable Element MAF01210 Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator Lube Point(s) - Repack Comments - Check Dust Valve daily Capacity - A/R Lube - MPG Swing Drive Hub...
  • Page 34 SECTION 1 - SPECIFICATIONS Fuel Filter (Propane) - Kubota MAF01250 Interval - Every year or 1000 hours of operation Comments - Replace filter. Refer to Section 7.6, Propane Fuel Filter Replacement (Kubota Engine). MAF01230 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.5 gal.

  • Page 35: Threadlocking Compound

    SECTION 1 - SPECIFICATIONS 1.8 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 High Strength (Red) 271™ Vibra-TITE™ 140 262™ Vibra-TITE™ 131 Medium - High Strength (Red) 0100071 NOTE: Loctite®...

  • Page 36: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.9 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
  • Page 37 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 38 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
  • Page 39 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
  • Page 40 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
  • Page 41 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 42: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
  • Page 43 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 44 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...
  • Page 45 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...

  • Page 46: General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventive Maintenance Schedule for MAINTENANCE items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for General servicing and maintenance procedures.

  • Page 47: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual (See Note) At each Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User...

  • Page 48: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Unless specific torque requirements are given within the text, standard torque values should be used on heat- treated bolts, studs, and steel nuts, in accordance with When disassembling or reassembling a component, complete recommended shop practices.

  • Page 49: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Hydraulic Oil Hydraulic System Refer to Section 1 for recommendations for viscosity ranges. The primary enemy of a hydraulic system is contamina- JLG recommends standard UTTO fluid hydraulic oil, tion. Contaminants enter the system by various means, which has an SAE viscosity of 10W-30 and a viscosity e.g., using inadequate hydraulic oil, allowing moisture, index of 152.

  • Page 50: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...

  • Page 51: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on Filament wound bearings. an external structure, or component. Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment...
  • Page 52 SECTION 2 - GENERAL NOTE: Refer the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1, 2 1, 2 Hose/Cable Carrier Installations 1, 2...
  • Page 53 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Functions/Controls Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Ground Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Function Control Locks, Guards, or Detents...
  • Page 54 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection General All Decals/Placards Installed, Secure, Legible Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers 1, 2...
  • Page 55 SECTION 2 - GENERAL 1001159163-B MAF00010 Figure 2-1. Engine Operating Temperature Specifications - Deutz 2.9 2-10 31215016...
  • Page 56 SECTION 2 - GENERAL NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINE IN THE “ENGINE OIL OPERATION CHART” MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE. 1001151190-B MAF00040 Figure 2-2.
  • Page 57 SECTION 2 - GENERAL 1. MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERAT URE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
  • Page 58 SECTION 2 - GENERAL Fluid Properties Base Classifications l i b i u l f Mobil DTE 10 Excel 32 v i n H s i Mobil EAL 224 H Mobil Envirosyn H 46 Quintolubric 888-46 NOTICE: * Readily biodegradable classification indicates one of the following: MACHINE OPERATION USING NON-JLG APPROVED CO2 Conversion >...
  • Page 59 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 60: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Wheel Replacement Tire Damage The rims installed on each product model have been designed for stability requirements which consist of track width, tire For polyurethane foam filled tires, JLG Industries, Inc. recom- pressure, and load capacity.

  • Page 61: Chassis Tilt Indicator System

    SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Wheel Torque Chart 3.4 LOCKOUT CYLINDER BLEEDING TORQUE SEQUENCE Start the engine. 1st Stage 2nd Stage 3rd Stage Position the turntable to the normal stowed position. 40 ft. lbs. (55 Nm) 96 ft. lbs. (130 Nm) 170 ft.

  • Page 62: Drive System (4Wd & 2Wd)

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE SYSTEM (4WD & 2WD) Drive speed is varied by a combination of drive pump dis- placement, engine speed, and motor displacement. Traction The four wheel drive system consists of one variable displace- control is full-time and is present in all drive modes.

  • Page 63: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.6 OSCILLATING AXLE SYSTEM 3.7 OSCILLATING AXLE LOCKOUT TEST The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground when traveling on rough terrain. There are two lockout cylin- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- ders connected between the frame and the axle.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE MAF00360 1. Bolt 5. Washer 8. Wear Pad 11. Axle 2. Bolt 6. Washer 9. Shim 12. Axle Lockout Cylinder 3. Bearing 7. Bolt 10. Shim 13. Pin 4. Keeper Pin Figure 3-1. Axle Installation 31215016...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE MAF00460 1. Thrust Bearing 5. Keeper Pin 8. Steer Cylinder 11. Kingpin 2. Bolt 6. Washer 9. Link 12. Spindle 3. Bolt 7. Washer 10. Nut 13. Pin 4. Bolt Figure 3-2. Steer Installation (Without Tow Package) 31215016...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE MAF00470 1. Thrust Bearing 6. Bearing 11. Washer 15. Steer Cylinder 19. Spindle 23. Link 2. Bolt 7. Pin 12. Washer 16. Link 20. Bracket 24. Pin 3. Bolt 8. Keeper Pin 13. Washer 17.

  • Page 67: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.8 WHEEL DRIVE ASSEMBLY NOTE: The drive hub and drive motor assembly weighs approxi- mately 149 lb (68 kg). Removal Use a supporting device capable of handling the weight of the drive hub and drive motor, and unbolt the drive NOTE: The drive motor can be removed through the axle flange as hub from the frame.

  • Page 68: Torque Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.9 TORQUE HUB Tightening and Torquing Bolts Roll and Leak Testing USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN Always roll and leak test Torque-Hubs after assembly to make sure that the unit’s gears and sealants are working properly. BOLTS BEYOND THEIR TORQUE SPECIFICATION.

  • Page 69: Main Disassembly For "B" Drives

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly for “B” Drives Hub-Spindle Disassembly Turn hub (1G) on side, Remove coupling (14) from wide NOTE: Start with large end of hub facing up and large end of spin- end of spindle (1A). dle facing down.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE MAF00540 Figure 3-6. Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 1 of 2 3-11 31215016...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Roll Pin Thrust Spacer Gasket 1A Spindle Ring Gear Sun Gear Cylinder 1B Seal O-Ring Thrust Washer Piston Bearing Cone O-Ring Bolt Ball Bearing 1D Bearing Cup Cover Assembly Dowel Pin Retaining Ring Bearing Cup Thrust Spacer Coupling...
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE MAF00550 Figure 3-8. Drive Hub (4WD Front Only) - Sheet 1 of 2 3-13 31215016...
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Carrier Assembly Cover Assembly Shaft Spindle 3A Carrier Thrust Spacer Retaining Ring Seal 3B Retaining Ring Cover Plate Spring Bearing Cone 3C Needle Bearing O-Ring Thrust Spacer Bearing Cup 3D Thrust Washer Disconnect Rod Gear, Sun Bearing Cup...
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 1. Hub-Spindle Sub-Assembly 2. Internal Gear A. Cover C. Spring A. Spindle 3. Carrier Sub-Assembly B. Cover Cap D. Spacer A. Carrier Housing B. Seal C. Bolt 8. Input Gear B. Thrust Washer C. Bearing Cup 9.

  • Page 75: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Assemble Carrier Apply grease to inside of one cluster gear (3F) and line one Remove two bolts (6C) holding disconnect cap (6D) to half of cluster gear with 16 needle rollers (3C). cover (6A).
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE Set carrier housing (3A) on table, sideways. Insert a Following cluster gear, place one more thrust washer planet shaft (3E), roll pin hole last, into one of the planet (3B) onto planet shaft (3E) through opposite planet shaft shaft holes from roll-pin-holed side of carrier housing hole in carrier housing (3A).

  • Page 77: Cover Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Sub-Assembly Set cover (6A) on table, exterior side up. Place cover cap (6B) on cover (6A). Align pipe plug hole in cover cap over Using disconnect rod, push O-ring (6F) into groove pipe plug hole in cover. inside cover cap (6B).

  • Page 78: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE With large end down, place disconnect cap (6D) on Apply a light coat of “Never-Seize” to pipe plug (6H) and cover cap (6B), aligning pipe plug hole in disconnect cap tighten it in pipe plug hole in cover (6A). over pipe plug hole in cover cap.
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE Apply a light coat of “Never-Seize” to two pipe plugs (1J) Press seal (1B) in small end of hub (1G). and tighten them in two pipe plug holes in side of hub (1G). Oil spindle, then lower hub (1G) small end down, onto spindle (1A).

  • Page 80: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly Place spacer (1H) on spindle (1A) in hub (1G). SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING. Grease O-ring (5) and place it into counterbore in hub (1G).
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE Place thrust washer (11) around spindle (1A) so it rests Place other spacer (7D) on smooth end of input shaft on bottom of internal gear (2). (7A). Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A).
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Place thrust spacer (9) onto input shaft (7). Place carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning “X” marked shoulder bolt hole in ring gear (4) over one of the shoul- der bolt holes in hub.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten. SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALL- ING O-RING. Set cover (6A) on table, interior side up. Grease O-ring (5) and place in counterbore around edge of cover (6A).
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE Torque shoulder bolts (13) 18 to 25 ft. lbs. (25 to 34 Nm). Roll test unit in clockwise and counterclockwise direc- Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 Nm). tions. Perform same number of turns in each direction as the ratio of the unit.

  • Page 85: Tool List

    SECTION 3 - CHASSIS & TURNTABLE Tool List T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E). The following specialized tools are used to assemble this unit. Tool diagrams in this manual are intended for the customer who may wish to have a tool made. All tools are one piece and must be made from mild steel.

  • Page 86: Re-Align Torque Hub Input Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.10 RE-ALIGN TORQUE HUB INPUT COUPLING 3.11 DRIVE MOTOR This procedure applies to torque hubs with integral brakes: Description Drive motors are low to medium power, two-position axial pis- Equipment Required ton motors incorporating an integral servo piston. They are designed for operation in open and closed circuit applications.

  • Page 87: Shaft Seal Replacement

    SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement Loop Flushing Valve REMOVAL REMOVAL Remove snap ring (1) and support washer (2). Remove plug (1) and (2) with 11/16 in. internal hex wrench. 1. Snap Ring 2. Support Washer 3. Shaft Seal Figure 3-13.

  • Page 88: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-4. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level and ensure oil supply to motor is adequate and supply to motor.

  • Page 89: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts are lubricated during start-up. Replace all O-Rings and gaskets. Lightly lubricate O-rings with clean petroleum jelly prior to assembly.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 27. O-ring 29. Angle Stop 23. End Cap 26. End Cap 28. O-ring 30. Servo Spring 24. O-ring Figure 3-17. End Cap Figure 3-18. Valve Plate & Rear Shaft Bearing Using an 8 mm internal hex wrench, remove endcap screws (22).
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 31. Cylinder Kit Assembly Figure 3-19. Cylinder Kit Turn housing on its side and remove cylinder kit assem- bly (31). Set assembly aside. Do not to scratch running 32. Snap Ring surface. 33. Support Washer NOTE: Grooves on surface of cylinder kit identify its displacement: 34.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-22. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer Turn housing over and remove swashplate (39) by lifting 46.

  • Page 93: Inspection

    SECTION 3 - CHASSIS & TURNTABLE Inspection Table 3-8. Slipper Foot Thickness & End Play Wash all parts after disassembly (including end-cap and hous- Measurement L Frame K Frame ing) thoroughly with clean solvent and allow to air dry. Blow Slipper Foot Thickness 2.71 4.07...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE VALVE PLATE Inspect journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively Valve plate condition is critical to motor efficiency. Inspect worn. Polymer wear layer must be smooth and intact. valve plate surfaces for excessive wear, grooves, or scratches.

  • Page 95: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Install new O-ring (1) and piston seal (2) to servo piston COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY. COMPRESS- (3). Install piston seal over O-ring. ING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE NOTE: Installing piston seal stretches it, making it difficult to EFFORT.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Press front shaft bearing (15) onto shaft (16). Press bear- ing onto shaft with lettering facing out. Lubricate bear- IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. ing rollers. Install snap-ring (17) on shaft. Install pistons (11) to slipper retainer (12).
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Verify swashplate and bearings are properly seated. Press rear shaft bearing (22) into endcap. Install bearing Install cylinder kit (19) onto shaft. Install with slippers with letters facing out. Press until bearing surface is facing swashplate.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE Install endcap (25) on housing with endcap screws (26). Cover shaft splines with an installation sleeve. Install a Check endcap properly seats on housing without interfer- new shaft seal (27) with cup side facing motor. Press seal ence.

  • Page 99: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE Initial Start-Up Procedures Install orifice poppet (30). Follow this procedure when starting up a new motor or after Install shift spool (31). reinstalling a motor. Install spring retaining washers on springs (32 and 33). Prior to installing motor, inspect for damage incurred during Carefully install centering springs (34, 35, and 36).
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 5, 6 1001228492-C MAF15370C 1. Bolt 3. Nut 5. Shim 2. Washer 4. Spacer Sleeve 6. Swing Hub and Motor Assembly Figure 3-35. Swing System 3-41 31215016...

  • Page 101: Swing Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SWING DRIVE HUB Record the release pressure. If brake does not release within limits shown in Table 3-10, Brake Chart, check to see if it has the proper number of springs using the SPRING CHECKING Users of this manual should note that each part mentioned is PROCEDURE.

  • Page 102: Spring Checking Procedure

    SECTION 3 - CHASSIS & TURNTABLE Spring Checking Procedure Brake Leak Repair Procedure Install two Flat Socket Head Capscrews 0.250-20 UNC, 1/2 in. Remove brake piston from housing using the Brake Disassem- length into holes in brake piston. Tighten bolts evenly to bly Procedure.

  • Page 103: Tightening And Torquing Bolts

    SECTION 3 - CHASSIS & TURNTABLE THE LEAK TEST Tightening and Torquing Bolts The purpose of a leak test is to make sure the unit is airtight. To If an air impact wrench is used to tighten bolts, extreme care perform a leak test use the leak test fixture from the table should be taken to ensure the bolts are not tightened beyond below.

  • Page 104: Lubrication Information

    SECTION 3 - CHASSIS & TURNTABLE Lubrication Information Motor Removal Refer to Figure 3-37. and Figure 3-38. GENERAL PROPERTIES Place unit on bench with the motor end up. The lubricant used should be petroleum based gear fluid con- taining anti-oxidation, anti-foaming and extreme pressure Remove the magnetic Pipe Plug (1P) and drain the oil additives.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE Figure 3-37. Swing Motor Valve Removal Figure 3-38. Swing Motor Removal 3-46 31215016...

  • Page 106: Input Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Brake Disassembly Lift Brake Piston Assembly (8A) out of the Brake Housing (6). If the Brake Piston assembly (8A) will not lift out, apply less than 50 psi air to the Brake port to remove Refer to Figure 3-39.

  • Page 107: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Sub-Assembly. Refer to Figure 3-40. Remove Ring Gear (4) from Housing (1G). Remove O-ring (5) from between Ring Gear (4) and SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

  • Page 108: Housing-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Shaft Disassembly While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing Refer to Figure 3-41. (1G). Set the unit on a bench so that the Housing (1G) flange NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by is down.

  • Page 109: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A). Refer to Figure 3-42. Using a hammer and punch, drive the pieces of the Roll Drive the Planet Shaft (3E) out of the carrier pin holes; Pin (3G) out of the Planet Shaft (3E) and Carrier (3A).

  • Page 110: Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Assembly Using ample grease to hold them in position, locate Thrust Washer (3B) onto each side of interior carrier wall Refer to Figure 3-43. with tangs located into slots in Carrier pads. Apply a liberal coat of grease to the bore of Cluster Gear With large end of Cluster Gear (3F) facing the roll pin (3F).

  • Page 111: Housing - Shaft Assembly

    SECTION 3 - CHASSIS & TURNTABLE Housing - Shaft Assembly Start the Bearing Cone (1E) onto the Output Shaft (1A). Press or tap the Bearing Cone (1E) onto the Output Shaft Refer to Figure 3-44. (1A) until it is just seated in the Bearing Cup (1F), while NOTE: Spray a light film of oil on all component parts during rotating the Housing (1G).

  • Page 112: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly After engaging internal gear teeth and before rotating carrier, look at the Carrier sub-assembly in the main Refer to Figure 3-45. assembly and insure the timing is correct by locating the timing marks in the slots in the carrier and at 12 o’clock Slightly tap the Internal Gear (2) with spline side down on the gear that the timing mark is visible in the carrier onto Output Shaft (1A) splines to ensure Internal Gear...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE Figure 3-45. Main Assembly 3-54 31215016...

  • Page 114: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-46. Brake Port Alignment Motor and Brake Assembly Grease O-rings (8D, 8F) and install smaller diameter O- Ring (8F) into smaller diameter O-Ring groove in Brake Starting with a Stator (8K), alternately stack and install Housing (6) and install larger diameter O-Ring (8D) into Stators (8K) into Lobes of Brake Housing (6) and Rotors larger diameter O-Ring groove in Brake Housing (6).
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to the figure below for installing O-Rings (8D), (8F) Grease and install the O-Ring (26) into the Motor (31) and Backup Rings (8E), (8H). pilot. Install Motor (31) into the Brake Housing (6). Insure the motor valve mounting face is aligned with the radial brake release port in the Housing (1G).
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Figure 3-48. Motor and Brake Assembly 3-57 31215016...

  • Page 117: Motor Control Valve Installation

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Installation Install Tube Assembly (35) to elbow fittings as shown in picture. Torque tube assembly nut to 13-15 ft. lbs. (17.5- 20 Nm). Tighten Jam Nut on Elbow Fitting (30) into 13- NOTE: Verify o-rings are located in between the motor and valve.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Bearing Cone Press Tool Figure 3-51. Bearing Cone Press Tool 3-59 31215016...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Figure 3-52. Bearing Cup Press Tool 3-60 31215016...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE Figure 3-53. Lockout Wrench Tool 3-61 31215016...
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Figure 3-54. Bearing Cup Press Tool 3-62 31215016...
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. Seal Press Tool 3-63 31215016...
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE Figure 3-56. Leak Test Adapter Plate 3-64 31215016...
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE Figure 3-57. Swing Drive Test Plate 3-65 31215016...

  • Page 125: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING MOTOR Disassembly and inspection Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE MAF01630 1. Bolt 6. Ring 10. Drive Link 14. Thrust Washer 18. Housing 2. End Cover 7. Manifold 11. Coupling Shaft 15. Thrust Bearing 19. Bearing 3. Commutator Seal 8. Rotor Set 12. Woodruff Key 16.
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE If the end cover (2) is equipped with shuttle valve com- Remove commutator ring (6). Inspect commutator ring for cracks, or burrs. ponents, remove the two previously loosened plugs (21). Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE NOTE: The rotor set (8) components may become disassembled Remove manifold (7) and inspect for cracks surface scor- ing, brinelling or spalling. Replace manifold if any of during service procedures. Marking the surface of the rotor these conditions exist.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Remove drive link (10) from coupling shaft (12) if it was Remove coupling shaft (12), by pushing on the output end of shaft. Inspect coupling shaft bearing and seal sur- not removed with rotor set and wear plate. Inspect drive faces for spalling, nicks, grooves, severe wear or corro- link for cracks and worn or damaged splines.
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE Remove seal (16) and backup washer (17) from Small Inspect housing (18) assembly for cracks, the machined Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimen- sional characteristics.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) with- out damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13).

  • Page 132: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 in. (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing man- drel that was used to press in the outer bearing/bushing (19).
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE Place housing (18) assembly into a soft jawed vise with Assemble thrust washer (14) then thrust bearing (15) the coupling shaft bore down, clamping against the that was removed from the Torqlink™. mounting flange. NOTE: Torqlinks™...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID.
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE NOTE: The rotor set rotor counterbore side must be down against Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the original rotor-drive link spline contact.
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. If shuttle valve components items #21, were removed Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one onto the manifold.
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. Assemble the 5 or 7 special bolts (1) and screw in finger tight.

  • Page 139: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.

  • Page 140: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BEARING Verify the dial indicator has not shifted. Record the value for bearing play. Swing Bearing Wear Tolerance Return the machine to Figure 3-60., Swing Bearing Wear Tolerance, Position 1. The dial indicator should to return See Figure 3-60., Swing Bearing Wear Tolerance.

  • Page 141: Turntable Bearing Mounting Bolt Condition Check

    SECTION 3 - CHASSIS & TURNTABLE Turntable Bearing Mounting Bolt Condition Check Check the turntable to bearing. Attach bolts as follows: a. Elevate the fully retracted main boom to full eleva- tion as shown in Figure 3-60. b. At the positions indicated on Figure 3-59. try and THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL insert the 0.0015 in.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Measurement Point 2” (50.8 mm) DIAL INDICATOR POINTER LOCATION 1 DIAL INDICATOR FEELER GAUGE MEASURING POINT MEASURING POINT POSITION 2 DIAL INDICATOR & FEELER GAUGE MEASURING POINT POSITION 1 Figure 3-60. Swing Bearing Wear Tolerance 3-83 31215016...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE 3-84 31215016...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE 3-85 31215016...

  • Page 145: Swing Bearing Removal

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Removal Swing Bearing Installation NOTE: The swing bearing approximately weighs 138 lb (55 kg). From ground control station, operate the boom ade- quately to provide access to frame opening to rotary Using suitable lifting equipment, carefully lower the coupling.

  • Page 146: Procedure For Setting Swing Gear Backlash

    SECTION 3 - CHASSIS & TURNTABLE Install the rotary coupling mount bracket, apply a light Apply High Strength Threadlocking Compound to the coating of Medium Strength Threadlocking Compound pivot bolt and torque to 205 ft. lbs. (280 Nm). to the attaching bolts and secure the mount bracket to the turntable with the mounting hardware.

  • Page 147: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Values Tighten the jack bolt until the pinion is completely snug against the shim and bearing. After the pinion is snug, loosen the jack bolt. Outer Race - 190 ft. lbs. (258 Nm) with High Strength Threadlocking Compound.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE INSTALL BEARING TO FRAME WITH POINT OF MINIMUM GEAR BACKLASH (MARKED WITH YELLOW PAINT) TOWARDS CENTERLINE OF THE SWING DRIVE (AS CLOSE TO THE BOLT PATTERN WILL ALLOW) ORIENT ZERK TO THIS POSITION WITH RESPECT TO FORWARD FORWARD Figure 3-63.

  • Page 149: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.15 ROTARY COUPLING Table 3-12. Coupling Port Information Table - Upper/ Use the following procedure to install the seal kit. Turntable If not already removed, remove the axle oscillation valve Operating Proof Port Port from the cylinder barrel.
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE MAF06100 1. Housing 6. Torque Lug 11. Seal 2. Center Body 7. Proximity Switch 12. Seal 3. Ring 8. Bolt 13. Seal 4. Spacer 9. Washer 5. Retaining Ring 10. O-ring Figure 3-64. Rotary Coupling Cutaway 3-91 31215016...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE 10, 11 1001188334-G MAF15360G 1. Bolt 5. Nut 9. Proximity Switch 2. Bolt 6. Rotary Coupling Assembly 10. Bolt 3. Washer 7. Mount 11. Washer 4. Nut 8. Threaded Spigot Figure 3-65. Rotary Coupling Cutaway 3-92 31215016...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE 4,6,8 1001188334-G MAF15200G Figure 3-66. Rotary Coupling Port Location 3-93 31215016...

  • Page 153: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.16 GENERATOR Overload Protection STOP ENGINE BEFORE CARRY OUT SCHEDULE MAINTENANCE. STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER. NOTE: Do often service, if operating in hostile environment. Maintenance Schedule The circuit breaker protects the generator windings from over- load.
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New Figure 3-67. Inspecting Generator Brushes, Replacing Brushes and Cleaning Slip Rings 3-95 31215016...
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly Remove brush holder assembly. Disassemble generator parts shown in Figure 3-68. Refer to Figure 3-69. and Figure 3-70. to determine if trouble is in stator, rotor, control box, or combination of these compo- Clean all parts with approved solvent and dry with com- nents.

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