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JLG GRADALL 522D Owner's/Operator's Manual

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®
CORP ORATE OFFI CE
JLG INDUS TRIES , INC.
1 JLG DRIVE
McCo n n e lls b u rg , PA
1 7 2 3 3 - 9 5 3 3
US A
Te le p h o n e : ( 7 1 7 ) 4 8 5 - 5 1 6 1
Fa x: ( 7 1 7 ) 4 8 5 - 6 4 1 7
S ERVI CE MAN UAL
5 2 2 D 5 3 4 D - 6
5 2 4 D 5 3 4 D - 6 T
9 1 3 3 - 4 0 0 2
Ju ly 2 0 0 2
5 2 2 D 5 2 4 D S t a rt in g
S / N 0 2 7 7 0 0 1
5 3 4 D- 6 5 3 4 D- 6 T
S t a rt in g S / N
0 5 8 8 0 0 1
®
GRAD ALL D I VI S I ON
JLG INDUS TRIES , INC.
4 0 6 Mill Ave n u e S . W.
Ne w Ph ila d e lp h ia , OH
4 4 6 6 3
US A
Te le p h o n e : ( 3 3 0 ) 3 3 9 - 2 2 1 1
Fa x: ( 3 3 0 ) 3 3 9 - 8 4 5 8
Courtesy of Crane.Market
®

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  • Page 1 0 5 8 8 0 0 1 GRAD ALL D I VI S I ON CORP ORATE OFFI CE JLG INDUS TRIES , INC. JLG INDUS TRIES , INC. 1 JLG DRIVE 4 0 6 Mill Ave n u e S . W.
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  • Page 3 Re vis e d Is s u e 1 2 / 0 0 GRAD ALL D I VI S I ON CORP ORATE OFFI CE JLG INDUS TRIES , INC. JLG INDUS TRIES , INC. 1 JLG DRIVE 4 0 6 Mill Ave n u e S . W.
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  • Page 57 Open Center HYDRAULIC POWER BRAKE VALVE MICO Incorporated MICO West Division 701 East Francis Street (Zip Code 91761-5514) 1911 Lee Boulevard (Zip Code 56003-2507) P.O. Box 8118/North Mankato, MN U.S.A. 56002-8118 P.O. Box 9058/Ontario, CA U.S.A. 91762-9058 Phone: (507) 625-6426 Facsimile: (507) 625-3212 Phone: (909) 947-4077 Facsimile: (909) 947-6054 Printed in U.S.A.
  • Page 58 TABLE OF CONTENTS System Schematic...........................Page 2 Representative Performance Data......................Page 2 Description and Operation of Power Brake Valve..............Pages 3, 4 & 5 External Dimensional Views.......................Page 5 Installation of Power Brake Valve......................Page 5 Cross Sectional Views of Three Power Brake Valve Designs..............Page 6 Specification Chart...........................Page 7 Primary Cup Design........................Pages 8 &...
  • Page 59 DESCRIPTION AND OPERATION OF THE MICO OPEN CENTER HYDRAULIC POWER BRAKE VALVE Full system pressure is always The MICO Open Center Brake brake valve. A longer pedal stroke, available for operating the rest of the Valve will provide hydraulic power usually with increased pedal effort, braking when installed in an open system.
  • Page 60 Hydraulic System Pressure Equal to Brake Line Pressure FIGURE 4 RETURN LINE PRESSURE Inlet Port From Pump Land “B” BRAKE LINE Land “C” PRESSURE Land “A” CONTROLLED PRESSURE To Brake Pedal Return Line Pressure Orifice Reaction Chamber Flow Thru Port Schematic of Brake Valve in Manual Operation FIGURE 5 RETURN LINE...
  • Page 61 is equal to one-half of the brake line one-half the brake line pressure, the a longer stroke in the pedal. This pressure. To accomplish this, the PRESSURE REGULATING SPOOL amount of pressure that can be area of the MASTER CYLINDER shifts a minute amount and the generated in the brake lines in PISTON is twice the area of the...
  • Page 62 THREE OPEN CENTER HYDRAULIC POWER BRAKE VALVE DESIGNS PRIMARY CUP DESIGN The Primary Cup Design uses a residual valve. This valve will maintain a pressure of 12 - 20 PSI in the brake lines when the pedal is released. When used in drum brake systems this low pressure aids Residual Valve in preventing air from entering the brakes...
  • Page 63 SPECIFICATIONS CHART Brake Pressure Part Flow Thru Brake Return Flow Port Port Port Number Port Line Pressure Capacity (with power) * 06-460-520 SAE No. 10 1/2-14 NPTF 1850 psi ± 50 psi 3-24 gpm 1/2-20 UNF SAE No. 10 Complete unit replaced by 06-460-658 06-460-522 9/16-18 UNF SAE No.
  • Page 64 OPEN CENTER HYDRAULIC BRAKE VALVE PRIMARY CUP DESIGN (Refer to Figure 10) on end of spring (item 19). Disassembly (item 10) or bore of Assemble end cap (item 21) with housing (item 11) Remove boot (item 1) and its components to housing (item are in any way dam- pressure regulating spring 11) making sure lip on primary...
  • Page 65 Items included in Repair Kit 06-459-002 FIGURE 10 Repair Model Number 06-460-520 06-459-002 06-460-522 06-459-002 06-460-550 06-459-002 06-460-560 06-459-002 06-460-570 06-459-002 06-460-580 06-459-002 06-460-588 06-459-002 06-460-610 06-459-002 06-460-620 06-459-002 06-460-650 06-459-002 06-460-680 06-459-002 06-460-686 06-459-002 Courtesy of Crane.Market...
  • Page 66 OPEN CENTER HYDRAULIC BRAKE VALVE RING SEAL DESIGN (Refer to Figure 11) Disassembly CAUTION: If spool (item 6), sleeve residual valve for proper Remove boot (item 1) and (item 10) or bore of seating in end cap. housing (item 11) are in pressure regulating spring CAUTION: Extreme care must be...
  • Page 67 Items included in Repair Kit 06-459-010 Items included in Repair Kit 06-459-020 FIGURE 11 NOTE: Residual Valve (item 21) is only found in Model 06-460-566. Repair Model Number 06-460-654 06-459-010 06-460-656 06-459-020 06-460-658 06-459-020 06-460-660 06-459-020 06-460-662 06-459-020 06-460-664 06-459-020 06-460-666 06-459-020 06-460-668...
  • Page 68 OPEN CENTER HYDRAULIC BRAKE VALVE SLIDING PISTON DESIGN (Refer to Figure 12) Disassembly or broken, the entire CAUTION: Extreme care must be assembly must be Remove boot (item 1) and taken so as not to pressure regulating spring replaced. These parts scratch ring seal (item are select-fitted and are assembly (item 2).
  • Page 69 Items included in Repair Kit 06-459-020 FIGURE 12 Repair Model Number 06-460-642 06-459-020 06-460-684 06-459-020 (13) Courtesy of Crane.Market...
  • Page 70 GENERAL SERVICE DIAGNOSIS With Engine Off -- PEDAL GOES TO FLOOR Inoperative brakes Brakes not adjusted Brake not adjusted Check for wear Check adjustment Check adjustment Displacement problem Air in system Air in system Wheel cylinders too large for Bleed system Bleed brakes valve to handle properly.
  • Page 71 PRESSURE BLEEDING PROCEDURE Refer to Figure 13. Install a small DO NOT STEP ON THE BRAKE fittings tight, release the 50-200 BLEEDER BY-PASS LINE as PEDAL DURING THIS PSI pressure and SHUT OFF shown. A 1/4” size line or hose is BLEEDING PROCESS.
  • Page 72 MICO has made every attempt to present accurate information in catalogs, brochures and other printed material. MICO can accept no responsibility for errors from unitentional oversights that may exist. Due to a continuous program of product improvement, both materials and specifications are subject to change without notice or obligation.
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  • Page 78 Service N ot es This publication provides maintenance and service procedures for Meritor PRA 352 series planetary axles. The information contained in this publication was current at the time of printing and is subject to revision without notice or liability. 1.
  • Page 79 PRA 3 5 2 – Trum pe t Va ria t ion N o. 1 Courtesy of Crane.Market...
  • Page 80 PRA 3 5 2 – Trum pe t Va ria t ion N o. 1 Item Description Item Description Central Housing Outer Piston Piston O-ring Level Plug Piston O-ring Drain Plug Vent Plug Piston Brake Shim Inner Piston Hydraulic Line Bleeder Cover O-ring Piston Spring...
  • Page 81 PRA 3 5 2 – Trum pe t Va ria t ion N o. 2 44 47 Courtesy of Crane.Market...
  • Page 82 PRA 3 5 2 – Trum pe t Va ria t ion N o. 2 Item Description Item Description Center Housing Friction Disc Brake Reaction Plate Differential Case Assembly Brake Disc Lock Pin Side Gear Side Gear Thrust Washer Ring Gear Sun Gear, Short Pinion Gear Pinion Gear Thrust Washer...
  • Page 83 PRA 3 5 3 /3 8 3 89 54 75 73 89 54 Courtesy of Crane.Market...
  • Page 84 PRA 3 5 3 /3 8 3 Item Description Item Description Center Housing O-ring O-ring Differential Case Brake Cylinder Side Gear Thrust Washer Capscrew Adjusting Nut Pinion Gear Thrust Washer Brake Cylinder Cover Differential Pinion Shaft Capscrew Pinion Shaft Lock Pin Washer Washer Capscrew...
  • Page 85 PROA 3 5 2 /3 8 2 (Wit h M e c ha nic a l Drive Opt ion) 14 13 Courtesy of Crane.Market...
  • Page 86 PROA 3 5 2 /3 8 2 (Wit h M e c ha nic a l Drive Opt ion) Item Description Item Description Spring Main Housing Return Spring Capscrew Bushing Return Spring Trunnion Oil Seal Inner Piston Differential Case Assembly Differential Case Capscrew Shim Pack Small Oil Seal...
  • Page 87 PROA 3 5 2 /3 8 2 Courtesy of Crane.Market...
  • Page 88 PROA 3 5 2 /3 8 2 Item Description Item Description Center Housing Brake Piston Assembly O-ring Piston Bushing O-ring Piston Trunnion Oil Seal Lubrication Fitting Piston Brake Shim Brake Piston Level Plug Drain Plug O-ring Piston Spring Vent Plug Washer Hydraulic Line Bleeder Cover...
  • Page 89 Table of Contents Section 1: Introduction Description ..............................1 Identification Section 2: Removal and Disassembly Remove Axle ..............................2 Disassemble Ball and Ramp Brake Disassemble Trumpet Assembly ........................3 Disassemble Planetary System and Axle Shaft ....................4 Disassemble Hydraulic Apply Wet Disc Brake....................5 Disassemble Three Function Wet Disc Brake Disassemble Main Housing ..........................7 Disassemble Differential Case ........................8 Disassemble Pinion Bearing Cage........................10...
  • Page 90 Table of Contents Assemble Hydraulic Apply Brake Housing Assembly ..................38 Hydraulic Apply Brake Housing Functional Test Assemble Three Function Brake Housing Assembly ..................39 Assemble Ball and Ramp Brakes, Brake Discs, Reaction Plate and Pins ............42 Assemble Three Function Brake, Brake Discs, Reaction Plate and Pins ............43 Install Housing Assembly into Main Housing Assemble Three Function Brake Release Bolts and Sleeves ..............44 Assemble Ball and Ramp Brake Cylinder Assembly and Install on Main Housing...
  • Page 91 Section 1 Introduction Identification Description A tag on the main housing correctly identifies basic The Meritor PRA 352 Series Planetary Axle is a axle specifications. double reduction single speed unit that has: • When ordering parts, be sure to specify information A hypoid or spiral pinion and ring gear set stamped on the name plate.
  • Page 92 Se c t ion 2 Re m ova l a nd Disa sse m bly Remove Axle Disassemble Ball and Ramp Brake WARNING To prevent serious eye injury, always wear safe NOTE eye protection when you perform vehicle • Identify all parts before disassembly to ensure maintenance or service.
  • Page 93 Se c t ion 2 Re m ova l a nd Disa sse m bly NOTE CAUTION For three function brake design: If bleeder and Loosen and remove brake cylinder capscrews pressure ports of brake piston are open, the alternately to avoid spring load damage to parts. trumpet assemblies and ring gear will come off the center section easily without using puller 5.
  • Page 94 Se c t ion 2 Re m ova l a nd Disa sse m bly Disassemble Planetary System 4. Remove pinion gear flange. Lift it through planetary gear pins. and Axle Shaft 5. Remove axle shaft assembly and cone bearing. If necessary, use press.
  • Page 95 Se c t ion 2 Re m ova l a nd Disa sse m bly Disassemble Hydraulic Apply Disassemble Three Function Wet Disc Brake Wet Disc Brake 1. Remove piston return spring capscrews. NOTE 2. Remove return springs. Do not disassemble brake piston unless necessary.
  • Page 96 Se c t ion 2 Re m ova l a nd Disa sse m bly CAUTION WARNING • Before removing action plate and other parts, Use a special tool or press to compress the mark the original assembly positions of all brake brake assembly to avoid serious personal piston assembly parts.
  • Page 97 Se c t ion 2 Re m ova l a nd Disa sse m bly 8. Use sand paper on piston surfaces if they have 5. Depending on ring gear position, remove pinion nicks or hits. Figure 2.17. bearing cage capscrews. 6.
  • Page 98 Se c t ion 2 Re m ova l a nd Disa sse m bly 5. If differential case is “integral,” remove Disassemble Differential Case differential pinion axle lock capscrew and differential pinion axle. Then turn side gears and 1. Before disassembling differential case, mark remove differential pinions, side gears and position of both halves and spider cross for washers.
  • Page 99 Se c t ion 2 Re m ova l a nd Disa sse m bly 6. If necessary, separate ring gear from differential 7. If differential case has two halves, remove ring gear with a press after capscrews have been case.
  • Page 100 Se c t ion 2 Re m ova l a nd Disa sse m bly Disassemble Pinion Bearing CAUTION Cage To avoid oil leaks, be careful not to damage the mounting surface of the bearing cage. 1. If pinion bearing cage was not removed, hold 3.
  • Page 101 Se c t ion 2 Re m ova l a nd Disa sse m bly Figure 2.37 CAUTION Do not use pry bar to remove bearing cage from carrier. A pry bar can damage bearing cage, shims and main housing. 5.
  • Page 102 Se c t ion 2 Re m ova l a nd Disa sse m bly 10. If pinion bearings need to be replaced, remove inner bearing cone from drive pinion with press or bearing puller. Puller must fit under inner face of cone to remove cone correctly without damage.
  • Page 103 Se c t ion 3 Pre pa re Pa rt s for Asse m bly Clean Ground and Polished Clean Axle Assemblies Parts • A complete axle assembly can be steam cleaned on the outside to remove dirt. • Before the axle is steam cleaned, close or put a WARNING cover over all openings in the axle assembly.
  • Page 104 Se c t ion 3 Pre pa re Pa rt s for Asse m bly • Inspect Tapered Roller Deep cracks or breaks in the cup, cone inner race or roller surfaces. Bearings • Bright wear marks on the outer surface of the roller cage.
  • Page 105 Se c t ion 3 Pre pa re Pa rt s for Asse m bly Inspect Main Differential • Damage on the cup and cone inner race surfaces that touch the rollers.Figure 3.5. Assembly Figure 3.5 Parts that are damaged must be replaced. Inspect SPALLING &...
  • Page 106 Se c t ion 3 Pre pa re Pa rt s for Asse m bly Inspect Main Housing CAUTION • For fractures and burrs in machined areas. Threads must be without damage and clean so that accurate adjustment and correct torque Inspect Yoke values can be applied to fasteners and parts.
  • Page 107 Se c t ion 3 Pre pa re Pa rt s for Asse m bly Liquid Adhesive Reassembly • Meritor uses the following liquid adhesives to retain Check the type of liquid adhesive to be used and threaded fasteners: where the adhesive is to be applied. •...
  • Page 108 Se c t ion 3 Pre pa re Pa rt s for Asse m bly Apply Silicone Gasket Material 5. Assemble components quickly to permit gasket material to compress evenly between parts. Liquid gasket material used by Meritor: • Loctite FAG 3 Figure 3.8 0.125"...
  • Page 109 Se c t ion 3 Pre pa re Pa rt s for Asse m bly WARNING CAUTION To avoid serious personal injury, trichloroethylene Make sure that Toric ring (2) is seated in oil seal must not come in contact with your skin. Do not ring (1).
  • Page 110 Se c t ion 3 Pre pa re Pa rt s for Asse m bly 5. Verify mounting distance (A) in at least four NOTE places spaced 90 degrees apart. The difference Do not use any liquid that leaves a film of oil or in the mounting distance (A) around ring cannot does not evaporate quickly.
  • Page 111 Se c t ion 3 Pre pa re Pa rt s for Asse m bly 10. Make sure both bores are correctly aligned and CAUTION concentric. Move slowly and carefully. Figure 3.19. • Misalignment or a twisted Toric ring may cause leakage in the DUO-CONE oil seal.
  • Page 112 Se c t ion 3 Pre pa re Pa rt s for Asse m bly • Warped ring can cause irregular pressure on ring surface resulting in oscillating movements of oil seal. • Different pressures on oil seal surfaces can cause seepage, wear and leaks.
  • Page 113 Se c t ion 4 Asse m bly a nd I nst a lla t ion Assemble Differential Case 4. Apply Loctite 271 or Three Bond 1305 adhesive to ring gear fasteners. See Section 3, “Liquid Adhesive.” Install ring gear fasteners and fasten with the specified torque, 66-75 lb-ft WARNING (90-100 N•m).
  • Page 114 Se c t ion 4 Asse m bly a nd I nst a lla t ion d. Install differential pinion axle and lock NOTE capscrew. Fasten capscrew to specified torque For limited slip differential, go to step 12. 17-23 lb-ft (23-31 N•m). 7.
  • Page 115 Se c t ion 4 Asse m bly a nd I nst a lla t ion 10. Apply Loctite 271 or Three Bond 1305 liquid d. Place disc pack stack in vise. Use micrometer adhesive to capscrews. Install four capscrews to determine “D”, the height (thickness) of into case halves equally spaced and tighten to limited slip disc stack (includes thrust washer...
  • Page 116 Se c t ion 4 Asse m bly a nd I nst a lla t ion f. Place removed plain half side gear on top as Check Rotating Resistance shown in Figure 4.10. Use depth gauge to of Differential Gears determine “A”, distance from differential case half flange to backside of differential side gear.
  • Page 117 Se c t ion 4 Asse m bly a nd I nst a lla t ion 2. Support bearing cage with metal or wood blocks. 2. Attach torque wrench to the tool nut and rotate differential gears. As differential rotates, read 3.
  • Page 118 Se c t ion 4 Asse m bly a nd I nst a lla t ion 9. Install outer bearing cone on pinion shaft against 5. Use appropriate tool to fasten pinion through spacer. Figure 4.16. yoke, flange or splined sleeve. Figure 4.17. NOTE Figure 4.17 Do not install pinion oil seal in bearing cage...
  • Page 119 Se c t ion 4 Asse m bly a nd I nst a lla t ion 10. After getting specified preload, remove bearing d. Install yoke or flange and pinion nut cage from main housing and disassemble yoke or into pinion. input flange.
  • Page 120 Se c t ion 4 Asse m bly a nd I nst a lla t ion 2. Record the pinion cone (PC) variation number on 7. If the new pinion cone number is a minus (–), the old drive pinion that is being replaced. If the subtract the number from the standard shim pack PC variation number cannot be located, assemble thickness that was calculated in step 3 or 4.
  • Page 121 Se c t ion 4 Asse m bly a nd I nst a lla t ion Install Pinion Bearing Cage 3. Install two capscrews and washers that fasten bearing cage. Tighten to minimum torque of Assembly on Main Housing 67 lb-ft (90 N•m). Figure 4.26. NOTE Figure 4.26 Use minimum of three shims in pack.
  • Page 122 Se c t ion 4 Asse m bly a nd I nst a lla t ion 5. If ring gear is mounted on opposite brake housing 4. Install differential case assembly. Figure 4.29. side, loosen two capscrews that fasten pinion bearing cage.
  • Page 123 Se c t ion 4 Asse m bly a nd I nst a lla t ion Install Differential Housing 7. Install differential case bearing adjusting nut on brake housing. Figure 4.31. Assembly into Main Housing 8. Install pinion bearing cage assembly and (With Adjusting Ring 2 Sides) shim pack.
  • Page 124 Se c t ion 4 Asse m bly a nd I nst a lla t ion 7. Install pinion bearing cage assembly and shim 9. Check backlash, differential preload and teeth pack. Figure 4.34. See “Install Pinion Bearing contact. See Section 5, “Adjustments.” Cage Assembly on Main Housing,”...
  • Page 125 Se c t ion 4 Asse m bly a nd I nst a lla t ion 2. Install Duo-Cone oil seal into axle shaft and into Figure 4.39 44.60 axle shaft housing bore as specified on page 18. 44.80 Figure 4.37. Figure 4.37 DUO-CONE OIL SEAL...
  • Page 126 Se c t ion 4 Asse m bly a nd I nst a lla t ion 5. Install planetary spider and axle shaft bearing CAUTION adjusting nut. Rollers must come from the same manufacturer 6. Measure trumpet flange radius. With a spring and have the same tolerance range.
  • Page 127 Se c t ion 4 Asse m bly a nd I nst a lla t ion 8. Check trumpet assembly preload and subtract 13. Apply liquid gasket material on contact surfaces value obtained before tightening adjusting nut. of trumpet and ring. Figure 4.46. Value must be 15-35 lb-in (1.7-4 N•m).
  • Page 128 Se c t ion 4 Asse m bly a nd I nst a lla t ion 6. Apply high torque liquid adhesive, Loctite 271 or Assemble Hydraulic Apply Three Bond 1305, to capscrew threads. Install Brake Housing Assembly return springs and return spring capscrews. Tighten to 80-115 lb-in (9.0-13.0 N•m).
  • Page 129 Se c t ion 4 Asse m bly a nd I nst a lla t ion • If there are no leaks, proceed to Step 4. Figure 4.51 • If there are leaks, disassemble brake housing assembly, find and correct the problem. Repeat Steps 1 to 3.
  • Page 130 Se c t ion 4 Asse m bly a nd I nst a lla t ion 2. Lubricate internal brake housing surfaces, inner 5. Install springs into bores in inner piston. and outer piston surfaces and oil seal bores with Figure 4.55.
  • Page 131 Se c t ion 4 Asse m bly a nd I nst a lla t ion 10. Install shim pack into brake housing. Use bolts to align holes. Figure 4.59. WARNING To avoid serious personal injury, be careful when using Loctite. Follow the manufacturer’s Figure 4.59 instructions for safe use to prevent irritation to GUIDE BOLTS...
  • Page 132 Se c t ion 4 Asse m bly a nd I nst a lla t ion 14. With piston still compressed, apply 350 psi Assemble Ball and Ramp (24 bar) into parking brake to make sure oil Brakes, Brake Discs, Reaction seals fit in bores.
  • Page 133 Se c t ion 4 Asse m bly a nd I nst a lla t ion 4. Install stationary disc lock pins. Install Housing Assembly into 5. Install reaction plate with lubrication hole on down Main Housing side of axle. 6.
  • Page 134 Se c t ion 4 Asse m bly a nd I nst a lla t ion Assemble Three Function Assemble Ball and Ramp Brake Release Bolts and Brake Cylinder Assembly and Sleeves Install on Main Housing 1. Apply Loctite 516 on bolt threads. Figure 4.67. 1.
  • Page 135 Se c t ion 4 Asse m bly a nd I nst a lla t ion 2. While out of the axle, connect cylinder assembly 4. While the cylinder is pressurized with 400 psi to hydraulic system. Apply 400 psi (27.6 bar) (27.6 bar), apply liquid adhesive, Loctite 221 or pressure to compress spring until piston is against Three Bond 1341, on threads of brake shaft.
  • Page 136 Se c t ion 4 Asse m bly a nd I nst a lla t ion 6. After 1.47 inch (37.0 mm) dimension is obtained, 8. Install cover. Figure 4.75. apply specified pressure to brake and check the brake torque on pinion as shown in chart. Figure 4.75 Torque Disc...
  • Page 137 Se c t ion 5 Adjust m e nt s Check Ring Gear Runout Adjust Pinion and Ring Gear Specification: 0.008 inch Backlash Specification: (0.20 mm) 0.005-0.015 inch (0.13-0.38 mm) WARNING 1. Attach dial indicator on mounting flange of To prevent serious eye injury, always wear safe carrier.
  • Page 138 Se c t ion 5 Adjust m e nt s 6. Loosen one bearing adjusting ring one notch, Verification Procedure then tighten opposite ring the same amount to keep differential roller bearing preload. 1. Apply a marking compound to approximately 12 Figure 5.3.
  • Page 139 Se c t ion 5 Adjust m e nt s 3. Compare contact patterns on ring gear teeth to The location of a good hand-rolled pattern for a used good contact patterns in Figure 5.7. If contact gears set must match wear pattern in ring gear. The patterns are not satisfactory, go to Incorrect contact pattern will be smaller in area than the wear Contact Patterns on this page.
  • Page 140 Se c t ion 5 Adjust m e nt s Deep Contact Pattern Variations Along Length of Gear Teeth A deep contact pattern indicates that the drive pinion was installed too far in the carrier. Adjust backlash of ring gear within specification Figure 5.11.
  • Page 141 Se c t ion 5 Adjust m e nt s Replace Lubricant An acceptable contact pattern is centralized between toe and heel along the length of gear teeth. Figure 5.15. 1. Install and tighten drain plug in central housing and brake housing.
  • Page 142 Se c t ion 6 Spe c ific a t ions PRA 352 Series Planetary Drive Axle Oil Change Intervals and Specifications Off-Highway Operation Intervals Initial Check Petroleum Synthetic Meritor Military Change Level Change Change Specification Specification Description 1,500 — 0-84 —...
  • Page 143 Se c t ion 6 Spe c ific a t ions Nut Lock Special Tool 13.78 in. (350.0 mm) 0.079 in. 15.55 in. 1.77 in. (20.0 mm) (395.0 mm) (45.0 mm) 0.57 in. 0.078 in. (14.5mm) R 2.0 0.197 in. (5.0 mm x 45°) 0.984 in.
  • Page 144 Se c t ion 6 Spe c ific a t ions PROA 352/382 (With Mechanical Drive Option) Courtesy of Crane.Market...
  • Page 145 Se c t ion 6 Spe c ific a t ions Torque Chart - PROA 352/382 ITEM DESCRIPTION/THREAD TORQUE Pinion Nut - M24 x 1.5-6H 465-570 lb-ft (630-775 N•m) Nut (Stud - Center Housing) M14 x 1.5-6H 120-150 lb-ft (160-205 N•m) Capscrew (Differential Case) M10 x 1.5-8G 48-64 lb-ft (64-87 N•m) Capscrew (Spiral Gear) M10 x 1.0-6G...
  • Page 146 Se c t ion 6 Spe c ific a t ions PRA 352 – Trumpet Variation No. 2 Courtesy of Crane.Market...
  • Page 147 Se c t ion 6 Spe c ific a t ions Torque Chart - PRA 352 ITEM DESCRIPTION/THREAD TORQUE Pinion Nut - M24 x 1.5-6H 465-570 lb-ft (630-775 N•m) Capscrew (Center Housing) - M14 x 1.5-6G 150-185 lb-ft (205-250 N•m) Nut (Stud - Center Housing) - M14 x 1.5-6H 120-150 lb-ft (160-205 N•m) Capscrew (Differential Case) - M10 x 1.5-6G...
  • Page 148 Se c t ion 6 Spe c ific a t ions PROA 352 G2H, G2M Courtesy of Crane.Market...
  • Page 149 Se c t ion 6 Spe c ific a t ions Torque Chart - PROA 352, G2H, G2M ITEM DESCRIPTION/THREAD TORQUE Pinion Nut - M24 x 1.5-6H 465.0-570 lb-ft (630-775 N•m) Capscrew (Center Housing) M14 x 1.5-6G 180.0-215.0 lb-ft (245-290 N•m) Nut (Stud - Center Housing) M14 x 1.5-6H 120-150 lb-ft (160-205 N•m) Capscrew (Differential Case) M10 x 1.5-6G...
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  • Page 253 MPLEMENT IRCUIT ERFORMANCE HECKS Covers all C & D Series Material Handlers Company ® ® Form No. 29813 Issue Date 4/99 Rev. B Courtesy of Crane.Market...
  • Page 254 EVISIONS This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications. Page Date Revision Jan/01 Updated original manual to include all C and D-Series Implement Functions. Courtesy of Crane.Market...
  • Page 255 TABLE OF CONTENTS REVISIONS ............. inside front cover TABLE OF CONTENTS INTRODUCTION..........Orientation Preparing the Material Handler for Service Additional Maintenance/Service Precautions Hydraulic System Precautions Required Tools for Testing/Adjusting SAFETY NOTE ON USING THE MANUAL HYDRAULIC OIL RESERVOIR ......HYDRAULIC FILTER CONDITION ......ENGINE SPEED ..........
  • Page 256 NTRODUCTION This Manual details Implement Circuit Performance Checks and Adjustments for all Gradall C & D Series Material Handlers. Use the Manual in conjunction with the appropriate Owner/Operator Manual and the appropriate Hydrostatic Drive WARNING Performance Checks Manual. Make sure you read the entire Manual before testing, adjusting, or troubleshooting on any Gradall Material Handler.
  • Page 257 YDRAULIC YSTEM RECAUTIONS • Make sure the hydraulic fluid level in the reservoir is maintained at the proper level. If the fluid level drops unduly, the pumps will be starved and WARNING will be destroyed almost immediately. • Hydraulic fluid must be completely free of contamination at all times. Contaminated hydraulic fluid can severely damage hydraulic components.
  • Page 258 AFETY THE FOLLOWING SYMBOLS CALL YOUR ATTENTION TO IMPORTANT SAFETY NOTICES: This symbol indicates an extreme hazard which DANGER will result in high probability of death or serious injury if proper precautions are not taken. This symbol indicates a hazard which could result in WARNING death or serious injury if proper precautions are not taken.
  • Page 259 SING ANUAL This Manual contains a series of tests designed to assess the performance of various implement circuits on the Material Handler. In every instance, there are certain basic precautions and steps you should take before conducting the test. These precautions are outlined in the “Introduction” under the heading, “Preparing the Material Handler for Service”.
  • Page 260 YDRAULIC ESERVOIR • CHECK 1. The hydraulic oil level gauge is on the outside of the reservoir. 2. Proper level is to “Full” mark in the sight gauge. 3. Do not operate the machine if below “Add” line. 4. Check level with boom fully retracted and forks on the ground. HYDRAULIC OIL LEVEL SIGHT GAUGE •...
  • Page 261 YDRAULIC ILTER ONDITION • SET UP 1. With the park brake engaged and the transmission in “Neutral”, start the material handler. NOTE! 2. Warm the hydraulic oil to 100°F by stalling the “Crowd-In” If the hydraulic filters have function at full engine speed. more than 1000 hours on them, change them.
  • Page 262 NGINE PEED • SET UP 1. With the park brake engaged and the transmission in “Neutral”, start the material handler. 2. Raise the boom high enough to gain access to the engine compartment. • CHECK 1. Install an adequate tachometer and check the engine speed (RPM).
  • Page 263 HARGE RESSURE (Also used as Pilot Pressure on Joystick Machines) • SET UP NOTE! 1. Install a 1,000 PSI pressure gauge, hose and adapter on the For more details, see page 73 charge pump test port. of the Material Handler 2.
  • Page 264 TEERING IRCUIT • SET UP 1. Install a 10,000 PSI gauge, hose and adapter to the test port in the outlet tube of the main implement pump. Make sure you can see the gauge from the operator’s cab. NOTE! The location of the main implement test port varies by machine vintage.
  • Page 265 ONTROL ALVE ELIEF • SET UP 1. Install a 10,000 PSI gauge, hose and adapter to the test port in the outlet tube of the main implement pump. Make sure you can see the gauge from the operator’s cab. NOTE! The location of the main implement test port varies by machine vintage.
  • Page 266 IRCUIT ELIEF ALVES • SET UP 1. Install a 10,000 PSI gauge, hose and adapter to the test port on the outlet tube of the main implement pump. Make sure you can see the gauge from the operator’s cab. NOTE! The location of the main implement test port varies by machine vintage.
  • Page 267 ROWD IRCUIT XTEND ELIEF ALVE NOTE! • SET UP The 534C-9, 534C-10, 534D-9 Install a 10,000 PSI gauge, hose and adapter to the test port and 534D-10 are the only C or on the outlet tube of the main implement pump. Make sure you D Series Material Handlers can see the gauge from the operator’s cab.
  • Page 268 UXILIARY IRCUIT ELIEF ALVES • CHECK # 1 1. Inspect the quick-disconnect fittings at the boom head for signs of leakage. 2. Replace any leaking fittings. • CHECK # 2 1. Install a 10,000 PSI gauge, hose and adapter to the test port on BOOM-HEAD QUICK-DISCONNECT the outlet tube of the main implement pump.
  • Page 269 ERVICE RAKE ALVE • SET UP NOTE! 1. Install a 10,000 PSI gauge, hose and adapter to the test port on The Service Brake Test Port the service brake system. Make sure you can see the gauge may be in one of three from the operator’s cab.
  • Page 270 PPENDIX YCLE IMES UNCTIONS 1. Position the handler safely, in a level, open area, well away from traffic lanes, buildings, other equipment or personnel. 2. Position the handler so that all cylinders may bottom out in both directions. 3. Run the engine at full throttle (2500 RPM) during testing. C-Series Cycle Times FUNCTION TIME...
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  • Page 272 The information contained in this Manual is protected by copyright. Unauthorized reproduction of this Manual, in whole or in part, in any form whatsoever, is strictly prohibited. Specifications are correct at time of publication. However, Gradall reserves the right to make any necessary changes without prior notice.
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  • Page 285 Steering Control Units, Char-Lynn Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated before removing any components. The steering control unit is generally not the cause of most steering problems. The following is a list of steering problems along with possible causes and suggested corrections.
  • Page 286 Problem Possible Cause Correction Steering control unit meter has a Usually starting engine will cure lack of oil. This can happen on problem. problem. start-up, after repair, or long per- iods of non use. No flow to steering unit can be caused by: 1.
  • Page 287 ® Cyclopac Service Procedures media. Don’t be fooled by filter appearance..Proper air cleaner servicing results in maximum the filter should look dirty. By using proper filter engine protection against the ravages of dust. measurement tools you will use the full life of the Proper servicing can also save time and money filter at maximum efficiency.
  • Page 288 Air Filter Service Tips The Important “Don’t” 7 Important Steps to Follow Don’t remove filter for inspection. (1) Remove the old element Never rap a filter to gently to prevent knocking clean it. Rapping only dust off of it. damages the filter. 2) Always clean the inside of the housing carefully...

This manual is also suitable for:

Gradall 534d-6Gradall 524dGradall 534d-6tGradall 522Gradall 524

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