Oshkosh Corporation JLG 1250AJP Service And Maintenance Manual
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Oshkosh Corporation JLG 1250AJP Service And Maintenance Manual

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Service and Maintenance Manual
Model
1250AJP
PN - 3121171
May 31, 2019 - Rev S
AS/NZS

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Summary of Contents for Oshkosh Corporation JLG 1250AJP

  • Page 1 Service and Maintenance Manual Model 1250AJP PN - 3121171 May 31, 2019 - Rev S 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: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - April 15, 2004 Revised B - June 15, 2004 Revised C - August 14, 2004 Revised D - December 7, 2004 Revised E - January 12, 2006 Revised F - November 29, 2006 Revised G - January 17, 2007 Revised...

  • 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. Welding on JLG Equipment ............... . . 2-6 Do the Following When Welding on JLG Equipment .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.17 Swing Drive..................3-68 Roll and Leak Testing.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.32 CAT DGC Diagnostic Support And Trouble Code Definitions ......... 3-193 List of Abbreviations in this Section .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.17 Platform ................... 4-10 Support Removal .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.35 Skyguard................... 4-123 Operation .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Routine Maintenance ............... . . 5-130 Removal and Installation of Shaft Seal .
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Step 7 - Position 7 ................6-85 Step 8 - Position 8 .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Lubrication & Operator Maintenance Diagram - Deutz 2011/CAT Engines ......1-6 1-2.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-46. Swing Drive - Carrier Sub-Assembly (SN 0300201017 through 0300254456) ......3-76 3-47.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-8. Main Boom Assembly - Sheet 1 of 4 ..............4-19 4-9.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-2. BSPT Thread..................5-3 5-3.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-59. Hydraulic Tank ..................5-92 5-60.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-1. Voltage Measurement (DC) ............... . . 7-1 7-2.
  • Page 19 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications & Performance Data ............1-1 Capacities .
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 ........... 5-31 5-19 Metric Flat Face Port (MFF) - L Series - Table 2 of 3 .
  • 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 OPERATING SPECIFICATIONS & PERFORMANCE CHASSIS SPECIFICATIONS DATA Table 1-3. Chassis Specifications Table 1-1. Operating Specifications & Performance Data Maximum Travel Grade With boom in stowed position (Gradeability) Maximum Work Load (Capacity) Maximum Travel Grade With boom in stowed position 5°...

  • Page 23: Dimensional Data

    SECTION 1 - SPECIFICATIONS DIMENSIONAL DATA Deutz BF4M2011 Table 1-7. Deutz BF4M2011 Specifications Table 1-5. Dimensional Data (Prior to SN 0300127698) Overall Width Type Liquid Cooled Axles Retracted 8 ft-2 in (2.49 m) Number of Cylinders Axles Extended 12 ft-6 in (3.8 m) Bore 3.7 in (94 mm) Stowed Height...

  • Page 24: Deutz Tcd2.9L4

    SECTION 1 - SPECIFICATIONS Deutz TCD2.9L4 MAJOR COMPONENT WEIGHTS Table 1-9. Deutz TCD2.9L4 Specifications Table 1-11. Component Weights (SN 0300201017 to Present) Component Type Liquid Cooled 445/50D710, FF Number of Cylinders Tire & Wheel 445/65-24, Solid 435.4 Bore 3.6 in (92 mm) BONFIGLIOLI Stroke 4.3 in (110 mm)

  • Page 25: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS 1.10 HYDRAULIC OIL Table 1-15. UCon Hydrolube HP-5046 Table 1-13.Hydraulic Oil Specifications Type Synthetic Biodegradable Specific Gravity 1.082 Hydraulic System Operating S.A.E. Viscosity Pour Point, Max -58°F (-50°C) Temperature Range Grade +0° to + 180° F (-18° to +83° C) Viscosity +0°...
  • Page 26 SECTION 1 - SPECIFICATIONS Table 1-18. Quintolubric 888-46 Table 1-20. Exxon Univis HVI 26 Specs Density 0.92 @ 59°F (15°C) Specific Gravity 32.1 Pour Point <-22°F (<-30°C) Pour Point -76°F (-60°C) Flash Point 572°F (300°C) Flash Point 217°F (103°C) Fire Point 680°F (360°C) Viscosity Autoignition Temperature...
  • Page 27 SECTION 1 - SPECIFICATIONS 13,15 10 17,22 MAE37800 Figure 1-1. Lubrication & Operator Maintenance Diagram - Deutz 2011/CAT Engines Figure 1-2. Lubrication & Operator Maintenance Diagram - Deutz 2.9 Engine 3121171...

  • Page 28: Lubrication & Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.11 LUBRICATION & OPERATOR MAINTENANCE 2. Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Lubrication & Operator Maintenance Diagram - Deutz 2011/CAT Engines. Table 1-21. Lubrication Specifications 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 29 SECTION 1 - SPECIFICATIONS NOTE: After S/N 0300134389 machines may be built with either C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to Bonfiglioli or Reggiana Riduttori wheel drive hubs. Present) 4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128) Lube Point(s) - Level/Fill Plug Capacity - 0.5 qt (0.5 L) ±...
  • Page 30 SECTION 1 - SPECIFICATIONS A - Red = Filter Restricted; Filter Bypassed B - Green = Filter Good; Not Restricted Figure 1-3. Hydraulic Return Filter Condition Indicator - Prior to SN 139396 Red = Filter Restricted; Filter Bypassed Green = Filter Good; Not Restricted Figure 1-4.
  • Page 31 SECTION 1 - SPECIFICATIONS 6. Hydraulic Charge Filter 7. Main Valve Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter. 8. Hydraulic Oil FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator...
  • Page 32 SECTION 1 - SPECIFICATIONS 9. Suction Strainers (In Tank) 11. Oil Change w/Filter - Deutz TCD2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 Gallon (8.9 L) Lube - EO Interval - Check level daily; change every 500 hours or six months, whichever comes first.
  • Page 33 SECTION 1 - SPECIFICATIONS 15. Fuel Strainer - Deutz 2011 13. Fuel Filter - Deutz D2011 Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation. Interval - Every year or 600 hours of operation. Fuel Filter - Deutz TCD2.9 16.
  • Page 34 SECTION 1 - SPECIFICATIONS 19. Air Filter - Deutz 2011/CAT 17. Fuel Filter/Water Separator - CAT DEUTZ D2011 Lube Point(s) - Replaceable Element Interval - Drain water daily; Replace element every year or 600 hours of operation. 18. Radiator Coolant - Deutz TCD2.9 Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as shown by the condition indicator.
  • Page 35 SECTION 1 - SPECIFICATIONS 20. Air Filter - Deutz TCD2.9 21. Platform Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and then every year or 600 hours of operation thereafter. 22. Optional Fuel Filter/Water Separator Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator...
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121171 1-15...
  • Page 37 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners - Sheet 2 of 5) 1-16 3121171...
  • Page 38 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121171 1-17...
  • Page 39 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (SAE Fasteners - Sheet 4 of 5) 1-18 3121171...
  • Page 40 SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 3121171 1-19...
  • Page 41 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 42: General

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

  • Page 43: 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 At each Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic...

  • Page 44: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete 1. Use bolts of proper length. A bolt which is too long will steps in sequence. Do not partially disassemble or assemble bottom before the head is tight against its related part.

  • Page 45: Lubrication

    SECTION 2 - GENERAL Lubrication Hydraulic Oil Service applicable components with the amount, type, and 1. Refer to Section 1 for recommendations for viscosity grade of lubricant recommended in this manual, at the speci- ranges. fied intervals. When recommended lubricants are not avail- able, consult your local supplier for an equivalent that meets 2.

  • Page 46: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test. THE TOWER BOOM LIFT CYLINDER HAS A SPECIFIC PROCEDURE FOR TESTING CYLINDER DRIFT. REFER TO SECTION 4 - BOOM & PLATFORM. Measure drift at cylinder rod with a calibrated dial indicator.

  • Page 47: 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, 1.
  • Page 48 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
  • Page 49 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator 1,3,5,15,21,22 1,3,5,15,21,22...
  • Page 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection 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 Grease and Lubricate to Specifications Function Test of All Systems...
  • Page 51 SECTION 2 - GENERAL 1001159163-B Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 3121171...
  • Page 52 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUTSIDE OF T HE T EMPERAT URE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERATION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYSTEM.
  • Page 53 SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE 60 F(16 C) SPECIFICATIONS 50 F(10 C) 40 F(4 C) 30 F(-1 C) 20 F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS...
  • Page 54 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 55: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS Tire Replacement JLG recommends a replacement tire be the same size, ply and Tire Inflation brand as originally installed on the machine. Refer to the JLG Parts Manual for part number of approved tires for a particular Air pressure for pneumatic tires must be equal to air pressure machine model.

  • Page 56: Wheel Installation

    SECTION 3 - CHASSIS & TURNTABLE Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM AXLE.

  • Page 57: Axle Extension System

    SECTION 3 - CHASSIS & TURNTABLE AXLE EXTENSION SYSTEM automatically reduce the wheel angle to 25 degrees during axle retraction. The Axle Extension System allows each of the four axles to be NOTE: For more detailed information concerning system adjust- extended and retracted together while maintaining full steer- ment and operation, refer to Section 6 - JLG Control Sys- ing control as the machine is driven.

  • Page 58: Drive System

    SECTION 3 - CHASSIS & TURNTABLE DRIVE SYSTEM The drive system utilizes 2 traction pumps so each side is pow- ered individually. This produces maximum tractive effort to wheels by minimizing flow divider losses. The maximum drive speed is modulated with the steered angle of the wheels to eliminate the whiplash effect of driving at full speed and maxi- mum steering lock.

  • Page 59: Drive/Steering Speed Control

    SECTION 3 - CHASSIS & TURNTABLE DRIVE/STEERING SPEED CONTROL DRIVE ORIENTATION SYSTEM The Drive/Steering Speed Control system uses the steering The Drive Orientation System (DOS) is intended to indicate to sensors from the steering control system (see Section 3.5, the operator conditions that could make the direction of Steering Control System) to increase operator control and movement of the chassis different than the direction of move- comfort by reducing the effect of turning the chassis and the...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 0274670 D Figure 3-5. Chassis Component Location - Sheet 1 of 2 3121171...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear) 2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear) 3. Steer Valve (Front) 11. Chassis Module 4. Axle Lockout Valve 12.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 0274670 D Figure 3-7. Turntable Component Location - Sheet 1 of 2 3121171...
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 1. Headlight 13. Glow Plug Relay 24. Tower Lift Enable Valve 2. 2500W Generator 14. Drive Pump 25. Tower Tele Enable Valve 3. 2500W Generator Control Box 15. Swivel 26. Main Control Valve 4. Alternator 16.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE DETAIL A * AXLE STOP SHIMMING PROCEDURE: ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 11,12,B,G 11,12,A,G 11,12,C,G DETAIL A 11,12,E,G 11,12,F,G A - Assemble to Axle Box Mid Plate; Typical 8 Places. DETAIL B B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 inches (12.7 ±...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE MAE38440 * - JLG Threadlocker PN 0100011 ** - JLG Threadlocker PN 0100081 *** - JLG Threadlocker PN 0100019 Figure 3-11. Axle JLG Threadlocker Application 3-12 3121171...
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes Apply JLG Threadlocker PN 0100011 Apply JLG Threadlocker PN 0100019 Apply JLG Threadlocker PN 0100035 Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut 1. Spindle 4. Steer Cylinder Pivot Pin 2.

  • Page 68: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.10 OSCILLATING AXLE SYSTEM 3.11 OSCILLATING AXLE BLEEDING PROCEDURE AND 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 Lockout Cylinder Bleeding when traveling on rough terrain.

  • Page 69: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 6. Drive machine off of block and ramp back on level sur- face. The front axles will oscillate when the boom is in the transport 7. Have an assistant check left front wheel remains locked position.

  • Page 70: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.12 WHEEL DRIVE ASSEMBLY NOTE: The drive hub and drive motor assembly weighs approxi- mately 267 lbs. (121 kg). Removal 4. Use a supporting device capable of handling the weight of the drive hub and drive motor, and unbolt the drive NOTE: The drive motors can be removed through the axle flange hub from the frame.

  • Page 71: Drive Hub - If Equipped With Rexroth

    SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE HUB - IF EQUIPPED WITH REXROTH 15. Inspect planetary stage assemblies as complete units. Thoroughly clean and check gearing and the bearings The final drive consists of two planetary stages with an inte- for damage and apply new oil.

  • Page 72: First Stage Planetary (7) Assembly

    SECTION 3 - CHASSIS & TURNTABLE First Stage Planetary (7) Assembly 6. Before installation of motor, CHECK THERE IS 1-2 mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER (62). 1. Pre-freeze planet pins (5) and install into planet carrier (7).
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 3121171 3-19...
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 3-20 3121171...

  • Page 75: Drive Hub - If Equipped With Bonfiglioli

    SECTION 3 - CHASSIS & TURNTABLE 3.14 DRIVE HUB - IF EQUIPPED WITH BONFIGLIOLI 1. Clean the mating surfaces from oils or paint and fit the wheel drive on the machine frame. NOTE: After SN 0300134389 machines may be built with either 2.

  • Page 76: General Information

    SECTION 3 - CHASSIS & TURNTABLE CONNECTING THE BRAKE After running-in the gearbox, follow steps below. The gearbox is fitted with a negative multi disk safety brake 6. Check there are no oil leaks. If leaks are present, fix with hydraulic control release (parking brake). For information them before proceeding.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5......Filling, draining and oil level plugs 2= 7/16” - 20 UNF - 2B..Brake port Figure 3-17. Hub Assembly 3121171 3-23...

  • Page 78: Gearbox Disengagement

    SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade Ambient temperature -20°C / +30°C +10°C / +45°C Oil viscosity SAE 80W/90 SAE 85W/140 Manufacturer Oil Brand SHELL SPIRAX HD SPIRAX HD AGIP ROTRA MP ROTRA MP...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE 3. Remove cap nut (5). MAXIMUM WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. 4. Turn cap nut (5) upside down. Pin (3) will be pushed inside to permit disengagement of the gearbox. Figure 3-18.

  • Page 80: Maintenance Information

    SECTION 3 - CHASSIS & TURNTABLE 6. Tighten two socket head screws M8x16 (4) with a male Maintenance Information hex head torque wrench to 18.4 ft-lb (25 Nm) torque. PERIODIC MAINTENANCE The gearbox only requires the scheduled maintenance proce- dures set out by the manufacturer (see Table 3-4). Good maintenance will ensure an ongoing functioning in time as well as maximum reliability.

  • Page 81: Disassembly Information

    SECTION 3 - CHASSIS & TURNTABLE TROUBLESHOOTING The following table is provided to help locate problems in the gearbox. Table 3-5. Troubleshooting Symptom Causes Remedies External oil leakage: From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal From the end cover a) O-ring seal damaged a) Replace O-ring seals...
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE 1. Install special tool (6689960310) on the flanged hub 4. Mark position of springs (45) for reassembly. (31). Turn screw until it compresses springs (45). 5. Remove springs (45) from brake piston seats (44). 2.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring 2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring 3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 7. Using a puller, remove at the same time, the brake pis- 10. Remove external O-Ring seal (38) and backup ring (37) ton (44), spacer (39) and brake shaft (35). from their seat in the spacer (39). 11.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 13. Remove disengagement shaft kit (15). 16. Use pliers to remove elastic ring (11) from splined shaft (14). 14. Place the disengagement shaft kit (15) inside the special 17. Remove special tool, spring (13), and washers (12). tool (6689960240).
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 19. Remove cap nut (5). 22. Remove draining-filling-level oil plugs (6) using a male hex head wrench. 20. Remove pin (3). 23. Remove 10 screws M10X25 (1) from end cover (7). 21. Remove O-ring seal (2) from its seat in the end cover (7). 24.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 25. Remove O-ring seal (9) from its seat in the end cover (7). 28. Remove 2nd stage sun gear (17). 29. Remove 2nd reduction assembly (18). 26. Remove 1st stage sun gear (10). 30. Using pliers, remove circlips (19) from their seats in the 27.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 31. Using a puller, remove planet assemblies of the 3rd 34. Using a tackle, place torque multiplier (ATZ.09.016.0) on reduction (20). ring nut (22). 32. Remove spacer (21) from their seats in the pins of the 35.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 37. Using a puller and a metal stopper, remove the flanged 40. Using a screwdriver, remove 1st half-seal (29) from the hub (31) from the gearbox housing (23). flanged hub (31). 38. Using a tackle, remove gearbox housing (23) from 41.

  • Page 90: Inspection Of Parts

    SECTION 3 - CHASSIS & TURNTABLE Inspection of Parts a. Carefully clean seats (A and B) using, if necessary, metallic brushes or solvent (surfaces in contact with Pieces that are subject to general wear and tear are: or (C) must be perfectly clean and dry). - Gears.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 3. Assemble 1st half seal (29) on gearbox housing (23). 6. Insert seal ring (30) in its seat in the flanged hub (31). 4. Using the same tool (6689960300), assemble 2nd half 7. Apply grease TECNOLUBE SEAL GS730 on seal ring (30). seal (29) on the flanged hub (31).
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 9. Using a press and a metallic stopper, push gearbox 11. Using multiplier (ATZ.09.016.0), tighten ring nut (22), housing (23) against shoulder on flanged hub (31) until using a torque wrench with an input multiplier torque of assembling of unit is complete.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE 13. Install spacers (21) on flanged hub (31)pins. 16. Using pliers, assemble circlips (19) in flanged hub pin seats (31). 14. Place five planet assemblies of the 3rd reduction (20) on 17. Assemble 2nd reduction assembly (18). flanged hub's pins (31).
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble 1st reduction assembly (16). 22. Place end cover (7) on gearbox housing (23). 20. Install 1st stage sun gear (10). 23. Tighten 10 socket head screws M10x25 (1),grade 12,9, by a torque wrench to 62.7 ft-lb torque (85 Nm). 21.
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 25. Install O-ring (2) into its seat in the end cover (7). 28. Torque two screws M8x16 (4) to 18.4 ft-lb (25 Nm). 29. Install 1st washer (12) on splined shaft (14). 26. Protect seat and pin (3) with grease type MOLYKOTE G6000.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 31. Insert splined shaft (14) in special tool (6689960240). 34. Using pliers, assemble elastic ring (11) into its seat in the splined shaft (14). 32. Insert 2nd washer (12) correctly in the splined shaft (14). 35.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 36. Using pliers, install circlip (36) into its seat in the brake 39. Insert an internally toothed steel disc (32). Repeat opera- shaft (35). tion until all five sintered bronze discs and four steel discs are installed.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 42. Insert spacer (39) inside flanged hub (31). Do not dam- 44. Lube seal seats into flanged hub (31) and assemble the age seals already installed. O-ring seal (42) and the backup ring (43). 43.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 45. Insert brake piston (44) inside flanged hub (31). Do not 47. Insert springs (45) in previously marked brake piston damage seals already fitted. (44) holes. 48. Install spring retainer disc (46). 46. Using a rubber hammer and a metal stopper, push brake piston (44) against flanged hub (31).

  • Page 100: Final Test And Reinstallation

    SECTION 3 - CHASSIS & TURNTABLE 49. Install special tool (6689960310) on flanged hub (31). Final Test and Reinstallation Turn screw until it compresses springs (45). Check product by remounting it to the machine. Check function of drive hub following all checks shown in Startup and Running In.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Figure 3-21. Drive Hub Special Tools - Sheet 1 of 4 3121171 3-47...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Drive Hub Special Tools - Sheet 2 of 4 3-48 3121171...
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE Figure 3-23. Drive Hub Special Tools - Sheet 3 of 4 3121171 3-49...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE Figure 3-24. Drive Hub Special Tools - Sheet 4 of 4 3-50 3121171...

  • Page 105: Drive Hub - If Equipped With Reggiana Riduttori

    SECTION 3 - CHASSIS & TURNTABLE 3.15 DRIVE HUB - IF EQUIPPED WITH REGGIANA 8. Wrench for M6, M8, M10 socket head screws and 1/4”G plug. RIDUTTORI 9. Socket wrench for M6 hexagonal screw. NOTE: After SN 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Ø210 Ø130 Ø30 M- 1321 LOCTITE 2701 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-27. Bearing Spacer Mounting CO16117 Figure 3-28. Assembly Diagram 1 3-52 3121171...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE M- 1316 M- 1020 M- 1317 M- 1317 N° 4 M- 1317 216.5 Ø11 Ø230 10x45° M- 1316 Ø17 M- 1317 M- 1317 Figure 3-31. Anti-rotation Block M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-29.
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-33. Assembly Diagram 2 3-54 3121171...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE M- 1546 M- 1548 Ø105 Ø93.5 Ø48 +0.1 Ø20 Ø46 +0.2 Ø8.5 Ø13.5 Ø40.5 Ø46 M- 1547 Ø39.5 Ø20 -0.1 VTCEI M8X16 n°1 Figure 3-34. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 3121171 3-55...

  • Page 110: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly 3. Release the screws from the release cover and pull the pin out. 1. Remove plugs and pour lubricant in a container. 4. Remove the BR250 ring and pull cover out. Do not dam- age O-Ring.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 3121171 3-57...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 3-58 3121171...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE 6. Loosen the M10x25 flathead socket screws. Remove 9. Loosen the M6x6 socket headless screws and remove planetary ring. Do not damage O-Ring. the 3/16” balls. 7. Remove release joint together with the spring. 10.

  • Page 114: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 12. Disassemble the Ø160 inner snap ring and pull the Assembly spring holder spacer out. Remove springs. Using a com- pressed air jet in the brake control hole, pull piston out 1. Make sure all wheel gear components are devoid of of the spindle.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE 4. Fit brake sealing rings O-Ring and PARBAK (lubricated 6. Prepare hub support, mounting on it the two roller bear- with grease) in the respective spindle seats. Place the ing outer tracks. Place first roller bearing inner track. brake discs making sure to center them on the spindle and on the input shaft.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE 9. Check unit roll torque and proceed in the following 11. Using special tool and hammer, make four dents on the order: spindle thread by the M6 holes of the ring nut. 10. Keeping spindle locked, apply a setting preload by tight- ening ring nut at 40daNm, turn completely the hub sup- port twice using the special wrench to recover any bearing cage misalignments.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 13. Fit bearings on 3rd stage planetary gears and using a 15. Place hub on support making the two holes coincide for spacer mounting mount everything on the spindle pins. tightening the M10x25 flathead socket screws at the Lock with an outer snap ring.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE 17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit O-Ring 2-163 suitably greased, on motor coupling ably greased and lock it with the shimming ring. Lubri- flange S-D LC/KC. Mount flange on spindle with 6 M8x25 cate the bearings.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-37. Swing System (SN 0300201017 through 0300254456) 3121171 3-65...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE MAE37970 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-38. Swing System (SN 0300254457 to Present) 3-66 3121171...

  • Page 121: Swing Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING DRIVE HUB 5. Place swing drive hub in the clean area. 6. Refer to Figure 3-39., Swing Drive Installation, for swing Removal drive maintenance. 1. Gently loosen the setscrew (1). Do not remove. Assembly/Disassembly 2.

  • Page 122: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll and Leak Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 123: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36). Remove fittings from Brake (26) and Motor Control Valve 1. Place unit on bench with motor end up. (32). 2.

  • Page 124: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 3. Remove Gasket (31) between Brake (26) and Motor (10). 4. Remove Brake (26) from Main Torque-Hub Assembly 1. With unit resting on bench with Motor (10) end up, and dump oil out of Brake (26). loosen Hex Bolts (29) and remove Lift Lugs (28) from Motor (10).

  • Page 125: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15) between Input Cover (6) and Carrier (3A) Subassembly. 1. With unit resting on Output Shaft (Pinion) (1A), remove 7. Remove Ring Gear (4) from Housing (1G). eight Bolts (17), four Shoulder Bolts (18), and four Lock Washers (19) from Input Cover (6).

  • Page 126: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 4. Remove Bearing Cone (1F) from Housing (1G). 5. Invert Housing (1G) and remove Lip Seal (1B) if not 1. Using retaining ring pliers, remove Retaining Ring (1I) already removed when Output Shaft (1A) was pressed from groove in Output Shaft (1A) and discard.

  • Page 127: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 3. Slide Planet Gear (3F), two Ball-Indented Thrust Washers (3H), and two Thrust Washers (3B) out of Carrier (3A). 1. Using a 3/16” (5 mm) punch drive Roll Pin (3G) which 4. Remove both rows of Needle Bearings (3C) and Spacer holds Planet Shaft (3E) in Carrier (3A) down into the (3D) from bore of Planet Gear (3F).

  • Page 128: Hub-Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly 9. Install Bearing Spacer (1H) on Output Shaft (1A) and against Bearing Cone (1F). 1. Press Bearing Cone (1D) onto Shaft (1A). 10. Install Retaining Ring (1I) in groove of Output Shaft (1A). 2.

  • Page 129: Carrier Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Sub-Assembly 8. Slide second Thrust Washer (3E) between Cluster Gear (3F) and Carrier (3A) with tang of washer located in the 1. Apply a liberal coat of grease to the bore of Cluster Gear cast slot of Carrier (3A).
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE 3A. Carrier 3E. Planet Shaft 3B. Tanged Thrust Washer 3F. Cluster Gear 3C. Needle Bearing 3G. Roll Pin 3D. Thrust Washer 3H. Ball Indented Washer Figure 3-46. Swing Drive - Carrier Sub-Assembly (SN 0300201017 through 0300254456) 3-76 3121171...

  • Page 131: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh 1. With Hub Shaft Sub-Assembly resting on Shaft (1A) with the Internal Gear (2) and Input Gear (13). On the install Internal Gear (2).
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE 2. Internal Gear 15. Thrust Bearing 4. Ring Gear 16. Thrust Washer 5. O-Ring 17. Hex Bolt 6. Input Cover 18. Shoulder Bolt 8. Hex Bolt 19. Lockwasher 13. Sun Gear 20. Pipe Plug Figure 3-47.

  • Page 133: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble Hex Bolts (29) with Lift Lugs through the Motor (10) and 1. Place O-ring (27) onto end of Brake (26) and locate brake Brake (26) against the motor flange.

  • Page 134: Motor Control Valve Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque 13 to 15 ft-lb (18 to 21 Nm). 1. Lay assembly down with motor ports facing up. Remove 5. Install O-ring Plugs (21) into Motor Control Valve (32) two plastic plugs in motor ports, being careful not to and torque 30 to 31 ft-lb (42 to 43 Nm).
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE 1001228488-B MAE37600B Figure 3-50. Swing Motor (SN 0300254457 to Present) - Sheet 1 of 2 3121171 3-81...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring 2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover 3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw 4. Bearing 14.

  • Page 137: Swing Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING BRAKE HYDRAULIC/MECHANICAL To check brake release, connect an appropriate hydraulic pres- Pre-Installation Checks sure supply set to the required level up to a maximum of 3000 psi (200bar). Check brake shaft (1) is free to rotate. MECHANICAL Remove hydraulic supply from brake.

  • Page 138: Installation

    SECTION 3 - CHASSIS & TURNTABLE Installation 6. Remove springs (8). Note quantity and orientation of springs. Position 1-off gasket (5) over male pilot on brake housing (4). 7. Should it be necessary to replace ball bearing (10) or Locate brake shaft (1) and secure brake in position using 2-off shaft seal (12), reverse remainder of brake sub-assembly, 1/2”...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 2. Apply ring of Loctite 641 or equivalent adhesive to full 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or circumference of housing (2) bearing recess adjacent to equivalent) silicone grease and assemble together with shoulder.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 8. Cylinder 15. O-Ring 2. Housing 9. Piston 16. Backing Ring 3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring 4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring 5.

  • Page 141: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.19 SWING MOTOR Disassembly and inspection 1. Place Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and vise jaws clamping firmly on sides of housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 16. Seal 2. End Cover 8C. Vane 17. Backup Washer 3. Seal Ring-Commutator 8D. Stator Half 18. Housing 4. Seal Ring 9. Wear Plate 18A. O-Ring 5.
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into ing the internal orifice plug, are free of contamination.
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisas- semblyforservice.Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur- link for cracks and worn or damaged splines.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is ment of retained rollers.
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE 21. If housing (18) assembly has passed inspection to this NOTE: The depth or location of bearing/bushing (13) in relation to point, inspect housing bearings/bushings (19) and (13) the housing wear plate surface and the depth or location and if they are captured in the housing cavity, the two of bearing/bushing (19) in relation to the beginning of thrust washers (14) and thrust bearing (15).

  • Page 148: 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 149 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below housing wear plate contact face. Use opposite end of bearing mandrel used to press in outer bearing/bushing (19).
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15) the coupling shaft bore down, clamping against the removed from the Torqlink™. mounting flange. NOTE: Torqlinks™...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE NOTE: One or two alignment studs screwed finger tight into hous- ing (18) bolt holes, approximately 180 degrees apart, will OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC facilitate the assembly and alignment of components as FLUID.
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE 12. Apply a small amount of clean grease to a new seal ring 14. Apply clean grease to a new seal ring (4) and assemble it (4) and assemble it into the seal ring groove on the wear in the seal ring groove in the rotor set contact side of plate side of the rotor set stator (8B).
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE 17. Assemble commutator ring (6) over alignment studs 20. Assemble a new seal ring (4) into end cover (2) and onto the manifold. assemble end cover over the alignment studs and onto the commutator set. If end cover has only 5 bolt holes make sure cover holes are aligned with the 5 threaded holes in housing (18).

  • Page 154: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE 21. Assemble the five or seven special bolts (1) and screw in 22. Torque two shuttle valve plug assemblies (21) in end finger tight. Remove and replace the two alignment cover assembly to 9-12 ft-lb (12-16 N m) if cover is so studs with bolts after the other bolts are in place.
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE 3. Assemble rotor (8A), counterbore down if applicable, 5. Grasp output end of coupling shaft (12) with locking pli- into stator (8B), and onto wear plate (9) with rotor ers or other appropriate turning device and rotate cou- splines into mesh with drive link (10) splines.

  • Page 156: Procedure For Setting Gear Backlash

    SECTION 3 - CHASSIS & TURNTABLE 3.20 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque capscrews (shown below) to 90 ft-lb (122 Nm) with JLG Threadlocker PN 0100019. 1. Set backlash to 0.010 to 0.015" using the following pro- cedure. 2. Place shim (JLG PN 4071041) between pinion and bear- ing on bearing high spot.

  • Page 157: Swing Drive Lubrication

    SECTION 3 - CHASSIS & TURNTABLE 8. Tighten jam nut (shown below) with JLG Threadlocker The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API PN 0100019. Service Classification GL-5 Extreme Pressure Gear Lube. Fill to cover the ring gear..
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE MAE37630 Swing Gearbox/Brake Fill Port Swing Gearbox/Brake Drain Port Figure 3-59. Swing Drive Ports (SN 0300254457 to Present) The brake on swing drive uses same oil cavity as gearbox. Remove the swing gearbox/brake fill plug and fill the unit with 105 ounces (3.1 L) of ISO VG 150 oil, until oil reaches halfway of the plug opening.

  • Page 159: Turntable Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.22 TURNTABLE BEARING d. Check a sample of bolts in this 90° quadrant (45° left and right of indicated position) of the bolt circle. Turntable Bearing Mounting Bolts Condition Check e. Swing turntable 90 degrees and check selected bolts at the new position.

  • Page 160: Turntable Bearing Wear Measurement

    SECTION 3 - CHASSIS & TURNTABLE e. Fully raise the tower boom. Lower main boom to be c. Position indicator point to measure turntable base horizontal and fully extended. Position jib and plat- plate (on doubling plate) 3.5 in (88.9 mm) from gear form to be horizontal and centered.
  • Page 161 SECTION 3 - CHASSIS & TURNTABLE 6. Position machine back to the first position as outlined in Determine turntable bearing wear measurement allowance by Step 1 and shown in Figure 3-68. The dial indicator bearing model as shown in Figure 3-7. should return to zero.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE Figure 3-68. Turntable Bearing Service Boom Placement - 1 3-108 3121171...
  • Page 163 SECTION 3 - CHASSIS & TURNTABLE Figure 3-69. Turntable Bearing Service Boom Placement - 2 3121171 3-109...
  • Page 164 SECTION 3 - CHASSIS & TURNTABLE Figure 3-70. Turntable Bearing Service Boom Placement - 3 3-110 3121171...

  • Page 165: Turntable Bearing Removal

    SECTION 3 - CHASSIS & TURNTABLE Turntable Bearing Removal Turntable Bearing Installation 1. From Ground Control Station, elevate tower boom to 1. Using suitable lifting equipment, carefully lower turnta- about 10° or enough to gain access to bearing bolts. Set ble bearing into position on frame.
  • Page 166 SECTION 3 - CHASSIS & TURNTABLE 3-112 3121171...
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE 10. Torque bolts to 190 ft-lb (260 Nm) following sequence 14. At ground control station, use boom lift control to lower shown in Figure 3-72., Turntable Bearing Torque boom to stowed position. Sequence. 15. Using all applicable safety precautions, activate hydrau- 11.

  • Page 168: Swing Speed Proportioning

    SECTION 3 - CHASSIS & TURNTABLE 3.23 SWING SPEED PROPORTIONING 3.24 CHASSIS TILT INDICATOR SYSTEM Swing Speed Proportioning uses main boom length switches The Chassis Tilt Indicator System measures turntable angle in and envelope control sensors to improve comfort, speed, and comparison to level ground.

  • Page 169: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.25 ROTARY COUPLING 6. Reassemble O-ring. 7. Heat cap seals in hydraulic oil for 5 minutes at 300° F Use the following procedure to for installing the seal kit. (149° C). 1. Remove snap ring from end. 8.
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE JLG Threadlocker PN 0100011 5B. Rotary Circuit Contactor Bolt Locknut Bolt Not Used Swivel Bracket Flatwasher Rotary Coupling & Collector Ring Assembly 5A. Rotary Coupling Figure 3-74. Rotary Coupling Installation 3-116 3121171...
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE Figure 3-75. Rotary Coupling Port Location 3121171 3-117...

  • Page 172: Generator

    SECTION 3 - CHASSIS & TURNTABLE Every 500 hours Table 3-8. Coupling Port Information Table Every 500 hours of operation, service generator brushes and slip rings. Hostile environments may require more frequent Operating Proof Port Port service. Description Pressure Pressure Size PSI (Bar) PSI (Bar)

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