® ® SERVICE MANUAL ® 534B 9103-1390 July 2002 Starting S/N 8744110 thru 0144859 Also S/N 8744079 & (534B-9) S/N 0144860 thru S/N 0144899 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES, INC. 406 Mill Avenue S.W.
® ® OPERATION & LUBRICATION MANUAL ® 534B 9103-1380 July 2002 Starting S/N 8744110 Also Covers S/N 8744079 Form #48729 Original Issue 4/87 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES, INC. 406 Mill Avenue S.W.
IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described in this manual will help to keep your Gradall Material Handler in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced operator we recommend that this manual be read, understood and followed by all who operate the unit.
INTRODUCTION General Related Manuals & Decals The manual provides important information familiarize you with safe operating procedures and operator maintenance requirements for the Gradall/ 534-B Material Handler. Separate publication are furnished with the material handler to provide information concerning safety, replacement parte, maintenance procedures, theory of operation and vendor components.
NOMENCLATURE 3
SAFETY HIGHLIGHTS Read and understand this manual, the Gradall Material Handler Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment. Operators of this equipment must have successfully completed a training program in the safe operation of this type of material handling equipment. Most safety notes included in this manual involve characteristics of the Model 534-B Material Handler.
Decals Inside Cab Located on Dashboard Part No. 9100-3040 Located on Dashboard 9103-3310 Located on Dashboard Part No.9103-3089 Located on Dashboard Part No. 9100-3039 TO PREVENT ENGINE RING GEAR DAMAGE, WAIT 10 SECONDS AFTER ENGINE ROTATION STOPS BEFORE AT ATTEMPTING TO RESTART. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE Located on Dashboard Part No. 9103-3157 Located on Firewall Part No.
Decals Inside Cab (cont.) 9100-3041 Located on Dashboard Part No. 9100-3041 BRAKING CAPACITY IS REDUCED WHEN ENGINE IS NOT RUNNING. 9103-3244 Located on Dashboard Part No. 9103-3244 9103-3135 Located on Dashboard Part No. 9103-3135 WARNING: SHUT OFF ENGINE AND SET BRAKES BEFORE LEAVING GRADALL HANDLER UNATTENDED Located on Firewall Part No. 9100-3029 WARNING: ON GRADES AND UNEVEN GROUND PLACE FORKS IN CARRY POSITION (APPROX.
Decals Inside Cab (cont.) PARK BRAKE PARK BRAKE INSTRUCTIONS PULL TO SET PUSH TO RELEASE PARKING BRAKE LIGHT IDENTIFICATION START BUTTON 91043207 Located on Firewall Part No. 9103-3279 Located on Front Face of Dashboard Part NO. 9104-3207 Located on Manual Holder Part No. 9106-3031 WARNING DO NOT OPERATE THIS MACHINE WITHOUT FIRST READING THE OPERATOR’S MANUAL. IF A MANUAL IS NOT AVAILABLE, REFER TO AN AUTHORIZED GRADALL DEALER. 9103-3103 Located on Manual Holder Part No.
GFHGHGFH Decals Inside Cab (cont.) CAPACITY CHART: MODEL 5348-8 RATED CAPACITY 2 FT. LOAD CENTER DEATH OR INJURY MAY RESULT FROM CONTACTING ELECTRICAL LINES. UNLAWFUL TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 FEET OF HIGH VOLTAGE LINES OF UP TO 50,000 VOLTS. 9 FOR MINIMUM CLEARANCES OF HIGH VOLTAGE LINES IN EXCESS OF 50,000 VOLTS, SEE YOUR LOCAL STATE ANDFEDERAL REGULATIONS DO NOT DEFACE OR REMOVED THIS SIGN FROM THIS MACHINE Located on Mudguard Part No.
Decals Outside Cab NO RIDERS FUEL - DIESEL EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING. 9104-3211 Located on Hydraulic Reservoir & Left of Cab Door Part No. 9104-3211 9100-3052 Located on Fuel Tank Part No.9100-3052 COOLANT 9100-3032 Located on Radiator Part No. 9100-3032 DO NOT INSERT HAND IN OPENING WHILE ENGINE IS RUNNING DIESEL FUEL 9103-3011 Located on Radiator Part No 9103-3011 7702-3308 Located on Fuel Tank Part No.
Decals Outside Cab (cont.) DO NOT USE THIS MACHINE FOR LIFTING PERSONNEL. PINCH POINT AREA TO PREVENT INJURY, KEEP CLEAR ANYTIME MACHINE 9104-3209 IS RUNNING 9104-3215 Located on Mudguard Part No. 9104-3215 Located Below Boom Pivot Part No. 9104-3209 DO NOT USE BOOM AS WALKAWAY DO NOT STAND UNDER LOAD OR BOOM 9104-3217 9104-3216 Located on Boom Part No. 9104-3217 Located on Boom Part No.
HAND SIGNALS Standard Signals - When handler work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No handler motions shall be made unless signals are clearly understood by both signalman and operator. EMERGENCY STOP - With both arms extended laterally hands open downward, move arms back and forth. EXTEND TELESCOPIC BOOM With both hands clenched, point thumbs outward.
OPERATOR’S CAB The standard cab is open on three sides and includes an overhead guard to provide protection from falling objects. variations in operator size. The adjustment release/lock lever is located beneath front edge of seat belt at all times. An optional windshield wiper is available for use with enclosed cabs. An ON/OFF control switch is located on the wiper motor. Never operate the handler unless the overhead guard is in place and in good condition.
Engine Oil Pressure Gage: This gage displays engine oil pressure. Normal operating pressure is 35-50 psi (241-345 kPa). A brief description of controls and Instruments is provided here as a convenience for the operator. These descriptions DO NOT provide complete operating instructions. Read and understand this manual and the FIEI Rough Terrain Forklift Safety Manual before operating the handler. Forward/Reverse Lever: This lever engages forward or reverse travel.
CHECKS AND SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift) enter these ports, it can shorten the life of o-rings, seals, packings and bearings. Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder. When adding fluids or changing filter elements, refer to the lubrication section of this manual to determine the proper type to be used. If spark arrestors are required, be sure they are in place and in good working order.
ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING ENGINE” (page 6). Starting Engine 1. Check to be sure that all controls are in neutral and that all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake. button one time only before starting engine. If you use a different starting aid, be sure to follow manufacturer’s instructions carefully. Excessive ether may damage engine. 2.
Stopping the Engine cylinder walls and dilute lubricant in crankcase. Operate engine at idle speed for a few minutes before turning it off. This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas. To stop the engine, allow engine to run at idle for a few minutes, this is to allow the turbo components to cool. Turn key counter clockwise to stop position. Be sure to remove key from ignition switch before leaving cab.
BRAKE SYSTEM Service Brakes General The service brake is applied to the front wheels of the handler. The brake system furnished on the handler includes a service brake, inching brake and parking brake. Oil for the brakes comes from the pilot circuit pump, thru an accumulator charging valve and the accumulator. When the service/inching brake pedal is depressed far enough to actuate the brake valve, the hydraulic oil flows to the wet disc brakes in both front wheel hubs.
STEERING SYSTEM Ninety degree rear wheel power steering is provided to reduce operator fatigue and to permit high maneuverability in close quarters. It is important that the operator practice maneuvering the handler in a safe, open area until he becomes thoroughly familiar with steering response and clearance required for tailswing and load when turning. Be alert for any increase in eftort needed to steer. It any difference is noted, notify maintenance personnel immediately for correction.
DRIVE TRAIN General Transmission The drive train provides two and four wheel drive and includes the engine, torque converter transmission, drive shaft and front and rear driving axles. The transmission provides three speed ranges for both forward and reverse travel. Inching travel is directly related to drive train functions and will be discussed in this section.
Rear Driving Axle travel functions only in first and second gears. There is no hydraulic flow to drive motors in third gear. The rear driving axle includes planetary hubs which are powered by hydraulic motors mounted on the inner face of the hubs. HYdraulic flow to drive motors is provided only in first and second gear speed ranges. Drive motors are free-floating in third gear. Inching travel is controlled by the service brake/inching travel pedal. This pedal has three separate functions: 1.
MOVING HANDLER (Emergency Only) If handler must be moved, when the engine is not workable, extreme care should be used because: 1. With the engine not operating there will be NO steering. 2. With the wheel hubs adjusted to permit movement, ther will be NO brakes. If the handler is to be moved, do the following: 1. Place blocks on wheels to prevent movement. 2. On both rear axles, reverse the hub disengagement caps.** 3. Loosen front hub cover bolts equally until cover moves 3/16" to 1/4".
MATERIAL HANDLING Leveling To Level Handler: 1. Position machine in best location to lift or place load and apply brake. The handler is designed to permit tilting main frame eight degrees to left or right to compensate for uneven ground conditions. 2. Observe level indicator to determine whether machine must be leveled. Note position of indicator for later realignment. 3. If necessary, position boom in carry position and move carriage tilt machine level lever to left or right to level machine.
Attachments Although the carriage/fork combination is most frequently used, a number of other attachments available for use with the handler. 180ø and 100ø swing forks are available. A material bucket can be provided for light duty work. A truss boom is available to extend maximum reach and height and can be fitted with a winch when required. Consult your Gradall Material Handler Dealer for information on attachments designed to solve special material handling problems.
O P E R AT I N G P R O C E D U R E S & T E C H N I Q U E S This section highlights some common procedures and discusses areas which may be new to even the experienced operator. With boom raised above horizontal, forks can be removed from a load by moving boom control lever back and to the left until forks move rearward horizontally.
Rated Capacity Chart extension as measured from fully retracted position to extend position. These numbers do not reflect total boom length, only the number of feet of extension from fully retracted position. General Number decals on boom section number two (4,8, 12, 16 and 20) relate directIy to boom extension. The largest number which can be read from operator’s seat indicates total boom extension.
CAPACITY CHART: MODEL 534D-8 RATED CAPACITY 2 FT. LOAD CENTER USE WITH 9045-5007 48 CARRIAGE 9045-5008 66 CARRIAGE FOR OTHER ATTACHMENTS CONSULT FACTORY FOR LOAD RATING. USE LARGEST NUMBER VISIBLE FROM CAB TO DETERMINE BOOM EXTENSION. MATCH WITH BOOM ANGLE TO DETERMINE ALLOWABLE LOAD. BOOM EXTENSION IN FEET FROM TIRE TO LOAD CENTER (24 IN FRONT OF FORK FACE). FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL. RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM. LEVEL SURFACE WITH UNDAMAGED.
Recommended Lubricants & Capacities Lubricantion Notes l Intervals shown are for normal (8 hour day) usage and conditions. Adjust intervals for abnormal usage and conditions. l Clean air filter and cleaner housing using diesel fuel. Dry components thoroughly using a lint free cloth. l Apply a light coating of engine oil to all linkage pivot points. l Check lubricant levels when lubricant is cool. l Drain engine and gear cases only after operation when lubricant is hot.
LUBRICATION & MAINTENANCE DIAGRAM 28
Suggested Lubrication & Maintenance Frequencies Hours . *#5 Boom Bearing Pads (extend boom fully and coat all wear paths on boom sections 2 and 3 with light coat of grease-retract and extend boom fully three times and wipe excess grease from bearings).
NOTES
FORM NO. HE 28327 NOTE: See Service Manual For Complete Details FUEL TANK: Fill Daily 40 gal. #2 Diesel RADIATOR: Check Level Daily 3 gal. Water-3 gal. Anti-freeze REAR AXLE LINKAGE: Grease Daily (15) REAR AXLE PIVOT: Grease Daily CYLINDERS: Grease Daily (14) MPEP Contains Moly N LG 1 No. 2 BOOM TRUNION PIN: Grease Daily (1) FUEL FILTER: Change - Three Months HYDRAULIC RESERVOIR: TIRES: Check Pressure Weekly Check Level Daily 55 psi.
NOMENCLATURE 18. Main Valve Bank (Under Cab) 19. Operator’s Cab 20. Operator’s Controls 21. Transmission Filter 22. Transmission & Torque Converter 23. Drive Shaft 25. Pilot Relief Valve 26. Compensating Cylinder 27. Crowd Cylinder 28. Three Section Boom 29. Tilt Cylinder 30. Carriage 31. Manual”Quick-Switch” 32. Forks 33. Lift Cylinders (2) 34. Brake Master Cylinder 1. Front Axle Pivot 2. Front Planetary Axle 3. Sway Cylinder 4. Front Axle Brake 5. Front Axle Planetary 6. Batteries 7. Main Tandem Pump 8.
C O N T R O L A N D I N S T R U M E N T I D E N T I F I C AT I O N * Items preceded by an asterisk are optional and may not be furnished on your handler.
ENGINE To supply power for the front wheel drive and for various hydraulic circuits, a diesel engine is used. It runs at 900 rpm low idle. Depressing the accelerator pedal all the way, the engine will run 2800 rpm. With a nominal load the engine will average out at 2600 rpm and will produce 102 gross BHP. The engine speed governs both over-the-road travel speed and the hydraulic circuit speeds.
ELECTRICAL The electrical circuit consists of a 12 volt, 55 amp. alternator, two batteries, each rated at 565 Cold Cranking amps at 0° F, and 12 volt gages. Use the electrical schematic for trouble shooting the circuit. FUEL TANK A 40 gallon fuel tank is mounted to the frame on the right hand side of the machine. It includes a wire mesh strainer at the fill cap, a suction screen and a sending unit to the cab fuel gage.
MAIN FRAME REAR DRIVE AND STEERING AXLE The 534B has an all welded main frame with 1800 pounds of counter weight on the rear for stability. The front of the frame has a plate which is used to bolt on the front outrigger assembly. The rear axle assembly pivote up and down on the main frame. Each wheel is powered by a hydraulic motor, driving through a planetary hub. Two steering cylinders are used to turn the wheels. At maximum turn radius, the outside wheel tures about 70° to pivoting axle.
TRANSMISSION AND TORQUE CONVERTER The transmission - torque converter combination has neutral starting, shifting without stopping, 3 speeds forward and 3 speeds in reverse. Gear selection lever is on the right side of the steering column. The neutral, forward or reverse lever is on the left side. When the brake foot pedal is pressed down, either for braking or inching, the transmission de-clutches and no power goes to the front axle. This is in 1st and 2nd gear only.
BRAKE CIRCUIT NOMENCLATURE A - ACCUMULATOR B - ACCUMULATOR CHARGING VALVE C - PILOT CIRCUIT RELIEF VALVE The above components are located between the frame sides in the area of the engine radiator.
HYDRAULIC SERVICE BRAKES Brakes for the 534B are provided at both of the front wheel hubs. Each wet disc brake is fitted with a service brake port (P) and a park brake port (D). When the service brake port (P) is pressurized,,the service brakes are applied. When the park brake port (D) is open to dump, the park brakes are applied. WET DISC BRAKES This illustration shows the inside of the wet disc brakes.
HYDRAULIC SYSTEM NOMENCLATURE A - TILT CYLINDER B - RESERVOIR FILTER C - HYDRAULIC OIL RESERVOIR D - LOW TORQUE INCHING SOLENOID VALVE E - PILOT PUMP F - PILOT RELIEF VALVE (350 PSI) G - CROWD CYLINDERS H - HOIST (LIFT) CYLINDERS (2) J - COMPENSATING CYLINDER K - PARALLEL SOLENOID VALVE L - SERIES SOLENOID VALVE M - SERIES/PARALLEL VALVE N - STEEERING CYLINDERS (2) O - REAR HYDRAULIC DRIVE MOTORS (2) P - FWD/REV PILOT PRESSURE CONTROL VALVE Q - FWD/REV VALVE R - CAVITATION SOLENOID VALVE S - MAIN CONTROL V
HYDRAULIC CYLINDERS There are nine (9) hydraulic cylinders: Sway, Tilt, Compensating, Crowd (2), Lift (2), & Steering (2). (Outrigger (2) are optional). On the Tilt, Crowd and Lift Cylinders, a counterbalance valve is used to protect against broken hoses and to control lowering actions. The Sway Cylinder has a piloted check valve to provide a positive lock of oil in the cylinder.
MAIN PUMP CIRCUITS The two section main tandem pump supplies oil for two separate circuits. Oil from the base section supplies oil through a Priority valve (to assure a supply of oil for steering) and on to the Fwd/Rev Control valve in the rear wheel drive circuits. This circuit is covered by 3000 psi relief valves located in the Fwd/Rev valve. Oil from the end section of the pump is routed to the main control valve and on to the outrigger control valve.
HYDRAULIC CIRCUITS We will now cover the various hydraulic circuits as used in 534B Gradall Material Handler. We will cover them in the order that they are positioned in the main control valve bank and the outrigger valve bank. Following the oil down-stream, they are as follows: Sway, Auxiliary, Tilt, Crowd, Lift & Outrigger. (Optional) (Optional) SWAY CIRCUIT The sway circuit permits the operator to level the main frame of the machine in relation to the position of the front axle.
AUXILIARY HYDRAULIC SYSTEM When the 534B is equipped with attachments requiring additional hydraulics, such as swing forks or winch, an additional control valve section is used. It is located between the Sway Control Valve section and the Tilt Valve section. TILT & COMPENSATING CIRCUITS Both cylinders are of identical size so that as the boom angle changes, a like volume of oil is transferred to or from the tilt cylinder, keeping the fork level or in the same position.
CROWD (Boom In-Out) CIRCUIT The crowd circuit allows the operator to extend and retract the boom sections a total of 18 feet. Nine foot extension is obtained from the movement of a. hydraulic cylinder joined to the first section and the second section. Movement of the 2nd section and a combination of cables and sheaves moves the 3rd section. The control lever is the same as used to raise and lower the boom, but for the crowd the operator moves it to the right and left.
BOOM SECTIONS BOOM SLIDER PADS ABCDEFGHJKLM- Manual “Quick-Switch” Boom Head 3rd Boom Section Boom Slider Pads Boom Cables & Sheaves Push Beam 2nd Boom Section Rear Cable Anchor 1st Boom Section Boom Trunion Pin Boom Hoist Cylinder Pin Crowd Cylinder Support The boom sections move in and out on slide wear pads. These pads are positioned on the top, bottom and sides of the boom to protect the boom frame against excessive wear.
LIFT CIRCUIT The lift circuit allows the operator to raise the boom assembly up 70ø and lower it to a -4ø angle. Movement of the boom control lever back, raises the boom and a forward motion, lowers the boom. An angle indicator is located on the left side of the main boom section. At the base of both lift cylinders is a counterbalance valve. The valves serve as a lock-out valve to hold oil in the cylinder should a hose break or to prevent the engine is shut off.
OUTRIGGER CIRCUITS (OPTIONAL) To raise and lower the outriggers two control valves are located to the right of the operator’s seat. One valve controls the right and one controls the left. Pushing forward on the levers will lower the outriggers and pulling back on the levers will raise them. Oil for the outrigger valves comes from the powerbeyond port of the main control valve bank. When making a lift, the outriggers should be depressed enough to lift the front tires clear of the working surface.
FRONT & REAR WHEEL DRIVE The oil supply to the rear drive motors will vary depending on the position of the gear selection lever. The purpose of this is to coordinate the speed of the rear wheels with the speed of the front wheels. The 534B has a conventional front wheel drive, with power from the engine. It has a torque converter and transmission with a drive shaft and differential, and a pair of planetary wheel ends.
FORWARD/REVERSE LEVER (Neutral) When Forward/Reverse Lever is in neutral position, electrical contacts are not made at the Fwd/Rev Switches (J) and the oil flow in the circuit is as follows: Oil from reservoir (A) is drawn into the main pump section (B). It then flows to the priority valve (D) where a portion is available for the steering circuit. The oil leaves the priority valve and goes into the Forward/Reverse Valve (E) where it is exposed to a relief valve set at 3000 psi.
INCHING control pressure to bleed off to tank. thereby metering the Forward/Reverse valve to neutral. The inching feature allows the operator, when carrying a load, to move the handler very slowly for maneuvering in tight places. As the operator continues to depress the brakeinching pedal (A) and the inching valve (C) rotates. the pressure controlling the Fwd/Rev Valve varies. To operate the inching feature, the operator depresses the brake-inching foot pedal (A) approximately 1/4" - 1/2".
QUICK SWITCH ATTACHMENTS The 534B Material Handler is offered with a variety of standard attachments: Standard Tilt Carriage with Pallet Forks or Cubing Forks. 180° Swing Carriage 100° Swing Carriage Truss Boom Light Material Bucket Plus: Optional Instant Hook. See current product literatura for detailed specifications, capacity, and performance information.
General Guidelines for installing Hydraulic Brake Components MICO Hydraulic Brake Components are precision built devices and must be treated as such. The following guidelines must be followed at the time of installation to ensure optimum performance. Where to Mount To properly locate the brake component or brake line, you must. . . 1. Make it convenient for operator. 2. Use the shortest and most protected route. Protect components from road salts and general debris. 3.
Burnishing Procedures for MICO Caliper Disc Brakes TECHNICAL NOTICE Maximum torque will be achieved only after the brake has been properly burnished. Actual customer testing will be required to determine final acceptance and approval of brake system components. MICO recommends the following SAE burnishing procedures be performed immediately following the installation and adjustment of the brake. These “SAE recommended practices” (J360; paragraph 7.3 for parking brakes and J786a; paragraph 5.
Recommended Brake Service Procedures to Reduce Exposure to Non-Asbestos Fiber TECHNICAL NOTICE FOR ALL MICO NON-ASBESTOS BRAKE LININGS Recently manufactured brake linings no longer contain asbestos fibers. In place of asbestos, these linings contain a variety of ingredients, including glass fibers, mineral wool, aramid fibers, ceramic fibers, and carbon fibers. At present, OSHA does not specifically regulate these non-asbestos fibers, except as nuisance dust.
Service Instructions HYDRAULIC BRAKE VALVE Master Cylinder Section REPAIR KIT 02-400-184 MASTER CYLINDER SECTION - Automotive Brake Fluid POWER ASSIST SECTION - Mineral Base Hydraulic Oil FIGURE 1 This instruction sheet services the Master Cylinder Section for these model numbers: 02-460-272 02-460-392 02-460-402 TYPICAL SYSTEM SCHEMATIC MICO Broke Valve (This circuit may not apply to your installation) Brokes FIGURE 2 Power Steering Cylinder Reservoir
REMOVING BRAKE VALVE FROM VEHICLE AND SEPARATING SECTIONS (Refer to Figures 1 & 3) 1. Remove Brake Valve from vehicle by disconnecting necessary fluid lines, disconnecting push rod and removing mounting bolts. Drain fluid from assembly. 2. Separate Master Cylinder Section from Power Assist Section by removing three cap screws and three lock washers.
l Items included in Repair Kit 02-400-184 * Not used on all models FIGURE 4
BLEEDING PROCEDURES NOTE Use only proper fluid specified by vehicle manufacturer. Never reuse fluid that has been drained from the system. Be sure that you maintain a high level of fluid in the reservoir during and after the entire bleeding process. PRESSURE BLEEDING INSTRUCTIONS BENCH BLEEDING INSTRUCTIONS 1. Master Cylinder must be mounted to power assist section. 2. Fill reservoir with proper fluid. 3. Be certain all fittings are tight to avoid leaking. 4. DO NOT DEPRESS PEDAL. 5.
INTRODUCTION Before testing the hydraulic system it is important that you read and understand System Operations of 534B, and the Safety Manual. Then make the following checks: PUMPS Speed of hydraulic functions is determined by the volume of oil provided for the functions. Power (force) is determined by the pressure built up to perform work. Slow action in a circuit indicates that either the pump is not putting out the required volume or that leakage is taking place.
TOOLS NEEDED TO TEST SYSTEM Hydraulic Flow Meter. This meter measures pump Flow under varying pressure conditions. You can measure actual pump output, both with no resistance and with resistance imposed against it. Contact your Gradall Materials Handler Distributor. Hydraulic Pressure Gages. We recommend a 0-1000 psi gage and a 0-5000 psi gage for ease of testing. Kit 7713-4197 includes both gages and a selection of adapters and hoses. Other Tools Nedded: 3/16" Allen wrench for steering valve.
544 HYDRAULIC PRESSURE TEST PORTS There are seven (7) mini-check test ports on the 534B used to hold the gage while the circuit pressure is being tested. In order to gain access to the test ports, it will be necessary to remove the screen cover over the battery area, the engine cover, the cover over the valves behind the cab, and the cover pan below the operator’s cab. A - Used to test the main relief valve for the steering relief valve which is located in the priority valve.
TESTING HYDRAULIC RELIEF VALVE PRESSURES ADJUSTING RELIEF VALVES All of the relief valves can be adjusted using an allen wrench or a screwdriver. Loosen the lock nut, and turn the adjusting screw clockwise to increase the prssures. Turning it counter-clockwise will decrease the pressures. The valve adjustment is sensitive, so adjust in smalll moves, like 1/8 to 1/4 turn at a time. Tighten lock nut after adjustment.
HOW TO TEST AND ADJUST PILOT PUMP RELIEF VALVE 1. Install mini-check gage in port located by the FWD/REV Pilot Pressure Valve located behind the operator’s cab, (B). 2. Start engine and run at idle RPM, to assure accumulator charge. 3. The pilot pressure gage should read 350 psi ± 25. 4. If adjustment is needed, adjust the pilos relief valve. 5. If adjustment cannot be made, replace the relief valve or examine other components in the pilot circuit. 6. Remove gage.
HOW TO TEST TILT CIRCUIT RELIEF VALVES 1. Install gages in test ports in the Tilt Circuit Tubes (D) & (E). 2. Retract the tilt cylinder fully, raise the boom. 3. The gage should read 3250 psi while the boom is raising. 4. Adjust, reseal relief valve. 5. Remove gaye and recap test port. 6. Place gaye in other test port. 7. Extend the tilt cylinder fully, lower the boom. 8. The gaye should read 3250 psi while the boom is lowering. 9. Adjust, reseal relief valve. 10. Remove gage and recap test port.
HOW TO TEST AND ADJUST DRIVE CIRCUIT RELIEF VALVES 1. Install pressure gage in test port (1st, inboard section) of the tandem pump tube. (A) 7. Adjust, reseal or replace relief valve as necessary. The forward circuit relief valve is located closest to the inside of the machine within the Forward/Reverse Control Valve. 2. Start engine. 3. Pull parking brake valve knob up to set brake. 8. REPEAT THE ABOVE STEPS WITH TRANSMISSION IN REVERSE.
HOW TO TEST CROWD CIRCUIT RELIEF VALVE 1. Install gage in test port (C) near the main pump. 2. Start engine. 3. Extend the booms fully. Hold joystick fully to right. 4. The gage reading should be 2700 psi. 5. Adjust relief valve as needed. 6. Remove pressure gage.
TESTING THE BRAKE CIRCUITS TEST ACCUMULATOR CHARGE To test the brake circuit pressures, use the following procedures: 1. Install pressure gage in test port F. PARK BRAKE TEST 2. Run engine to fully charge accumulator (2175 psi ± 100). Make sure the test area is free of traffic and workmen. Apply the park brake. Test it by attempting to move the unit while the brake is on and the gear shift set in 2nd gear at full throttle. 3. Turn off engine, then turn key to run position. Do not restart engine. 4.
HOW TO TEST AND ADJUST THE INCHING MECHANISM 6. You are now ready to test the inching components: A. Start engine and depress the service brake oot pedal completely down. In a safe area, drive the GRADALL Material Handler and test the inching brake. If it is properly adjusted you should be able to move the Handler very slowly, and under full throttle. Attempt to inch while turning a sharp turn. If the unit does not respond smoothly, test and adjust as follows: B.
HOW TO CHECK AND ADJUST THE BOOM CABLE Two boom cables move the boom secitons. One cable is fastened to the rear of the main boom and one to the bottom side of the main boom. Start engine and run the 3rd section boom all of the way out, then retract it slightly. Stop Engine. Remove the cover from the rear of the main boom and visually check for any sag in the top cable. If there appears to be excessive sag in the top boom cable, tighten the rear cable anchor nut.
BOOM SLIDER PAD ADJUSTMENT PROCEDURE FOR INSTALLING BOOM BEARING RETAINING BOLTS Slider pads are used between boom sections. If excessive clearance appears between the boom sections, pads should be adjusted by shimming. l l HOW TO TEST PADS FOR EXCESSIVE CLEARANCE (OVER 1/16") BETWEEN BOOMS l To test the boom clearance, extend the boom fully and place the head or the attachment on the ground. Raise and lower the boom slowly and observe the clearance between the pads and the boom sections.
HYDRAULIC CIRCUITS TORQUE CHART NOTE: Use #242 Loctile.
ELECTRICAL SCHEMATIC 15
HYDRAULIC SCHEMATIC 16
NOTES
GRADALL® MATERIAL HANDLER TROUBLE SHOOTING FOR 544 & 534B DRIVE SYSTEM The Gradall Material Handlers, Models 544 and 534B have unique 4 wheel drive systems. The drive is a design between independent mechanical front drive and hydraulic rear drive systems, accomplished through an electric interface. This guide covers the hydraulic drive system and the electric interface between it and the mechanical drive. (Trouble shooting the mechanical drive proper is not covered.
REAR WHEEL SKID (LOCK UP) OR ROTATE VERY SLOWLY PROBLEM PROBABLE CAUSE REMEDY LOSS OF ELECTRIC SIGNAL TO CONTROLLER WHEN IN FIRST Wire loose or broken on first gear pressure switch ...........................................Repair Wire loose or broken at diode................................ Repair First gear pressure switch faulty............................Replace Diode faulty .......................................................... Replace Low transmission first gear clutch pressure ...............
REAR WHEELS WON’T DRIVE PROBLEM PROBABLE CAUSE REMEDY LOSS OF ELECTRIC SIGNAL TO PARALLEL SOLENOID FAULTY SOLENOID IN FIRST GEAR One hub locked out ............................................... Lock hub in. Loose or broken wire at first gear pressure switch ............................................. Repair Loose or broken wire at parallel solenoid................................................................. Repair Faulty first gear pressure switch............................
POOR INCHING PROBLEM PROBABLE CAUSE SIGNAL OR PRESSURE TO KICK OUT TRANSMISSION REMEDY Loose or broken wire at cutoff switch operated by brake lever .................... Repair Loose or broken wire at cutoff solenoid ............................................... Repair Defective cutoff switch Low pilot pressure ............................. Check wiring, or replace pressure switch .................................. Reset - 350 psi Defective cutoff solenoid ...........................
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. Problem Possible Cause Correction 1. Slow steering, hard steering, or loss of power assist. Worn or malfunctioning pump.
Problem Possible Cause Correction Steering control unit meter has a lack of oil. This can happen on problem. start-up, after repair, or long periods of non use. No flow to steering unit can be caused by: 1. Low fluid level. 2. Ruptured hose. 3. Internal steering control unit damage due to thermal shock*. Usually starting engine will cure problem. 9. Free Wheeling-Steering wheel turns with slight resistance but results in little or no steered wheel action. Piston seal blown out. Determine cause.
FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units.
NOTES
HOW THE UNITS OPERATE The transmission and hydraulic torque portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate. The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation.
With the engine running, the converter charging pump draws oil from the transmission sump through the removable oil suction screen and directs it through the pressure regulating valve and oil filter. The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and speed clutches. This requires a small portion of the total volume of oil used in the system.
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool. The same procedure is used in the speed selector. The direction or speed clutch assembly consists of a drum with internal splines and a bore to recieve a hydraulically actuated piston . The piston is “oil tight” by the use of sealing rings. A steel disc with external splines is inserted into the drum and rests against the piston.
Figure B
HR18000 CONVERTER GROUP ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 DESCRIPTION QTY Pump to Housing Gasket ............................ “O” Ring ...................................................... Charging Pump Assembly ........................... P um p M ount in g Sc re w L o c k w a s h e r ............. Pump Mounting Screw ................................. Pump Mounting Screw .................................
Figure C
HR 18000 CONVERTER AND TRANSMISSION CASE GROUP ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 DESCRIPTION QTY. Valve to Converter Housing Screw ..................... Valve to Converter Housing Screw Lockwasher ..................................................... Control Valve Assembly .................................... Control Valve Gasket ........................................ Detent Ball ......................................................
Figure D
18000 TWO AND THREE SPEED GEAR AND CLUTCH GROUP ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 DESCRIPTION QTY Output Shaft Rear Bearing ................................... Rear Bearing Cap Oil Seal .................................. Rear Bearing Cap Gasket .................................... Rear Bearing Cap ................................................. Bearing Cap Stud Lockwasher ............................
18000 SERIES 3 SPEED CLUTCH ASSEMBLY Figure E
LOW CLUTCH GROUP DESCRIPTION QTY. ITEM 1 Backing Plate Snap Ring ................................. 1 2 Clutch Disc Backing Plate ............................... 1 3 Clutch Inner Disc ............................................ 8 4 Clutch Outer Disc ........................................... 8 5 Clutch Piston ................................................... 1 DESCRIPTION ITEM QTY. 6 Outer Clutch Piston Seal ................................. 1 7 Inner Clutch Piston Seal .................................
Figure F
CONTROL VALVE ASSEMBLY ITEM DESCRIPTION QTY. Hydraulic Actuator Assembly ............................................ Piston Housing “O” Ring ................................................... Piston Balance Spring ...................................................... Spring Retainer Pin ........................................................... Piston Seal ..................................................................... Piston .....................................................................
PARKING BRAKE GROUP ITEM DESCRIPTION QTY. ITEM 1 Backing Plate Assembly .................................. 1 2 Actuating Lever ................................................ 1 3 Brake Shoe and Lining ..................................... 1 4 Brake Flange .................................................... 1 5 Brake Drum ..................................................... 1 6 Brake Drum to Flange Screw Lockwasher ..................................................... 6 7 Brake Drum to Flange Screw ..
CHECK POINTS “F” & “G” ARE FOR INITIAL CIRCUIT CHECKING ONLY. THESE FITTINGS SHOULD BE PROVIDED ON THE PROTOTYPE MACHINE. .75 I.D. MIN. HOSE TO COOLER CHECK POINT “F” C OUTLET PRESSURE. CHECK POINT “G” COOLER OUTLET TEMPERATURE. CHECK POINT “D” CONVERTER OUT TEMPERATURE (SEE SPECIFICATION PAGE) CHECK POINT “C” CONVERTER OUT PRESSURE (SEE SPECIFICATION PAGE) 18000 PLUMBING DIAGRAM 2 AND 3 SPEED INLINE .75 LINE SIZE CHECK POINT “B” CONVERTER INLET PRESSURE OPTIONAL REMOTE MOUNTED FILTER.
Baffle to be firmly supported on this surface when assembling the oil seal. Assemble lip of seal as shown. Apply a light coat of Dow Coming RTV-03-7069 Sealant to O.D. of baffle at assembly. Oil baffle puller screws to be located 15° to 30° either side of vertical center line. Note: Cover to be heated 200 to 250 F (93° - 121° C) and bearing assembled while cover is hot. Torque capscrews 30 to 35 Lbs.-Ft. [40,7 - 47, 5 N•m].
1. All lead in chamfers for oil seals, piston rings, & “0” rings must be smooth and free from burrs. Inspect at assembly, 2. Lubricate all piston ring grooves & “0” rings with oil before assembly. 3. Apply very light coat of Permatex No. 2 to 0 D. of all oil seals before assembly. 4. After assembly of parts using loctite or Permatex Forward & Reverse Clutch Return Springs there must not be any free or excess material Concave side of first belleville spring to be that could enter the oil circuit.
TYPICAL 1800 CROSS SECTION FIG.
MAINTENANCE AND SERVICE CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism.
Figure 5 Remove valve and pump assembly. Figure 8 Remove impeller cover bore plug retainer ring. Figure 6 Remove flexplate mounting screws and washers. Figure 9 Using two small screw drivers as shown, remove bore plug. Figure 10 Through bore plug hole, remove turbine retaining ring. See Figure 10-A. Figure 7 Remove flexplate and backing ring.
Figure 13 Impeller cover and turbine being removed as an assembly. Figure 10-A Figure 14 Remove turbine locating ring. Figure 11 Remove impeller cover to impeller bolts. Figure 15 Remove reaction member retainer ring. Remove reaction member and freewheel unit as an assembly. NOTE: Some units will have a fixed reaction member and some units will have a freewheeling reaction member, the unit shown has the freewheeling type. Figure 12 Remove impeller cover.
FREEWHEEL DISASSEMBY Figure 19 Remove impeller and hub assembly. Figure 16 If either the reaction member or the reewheel assembly is to be replaced remove the front outer race to reaction member retainer ring. Figure 20 Using oil baffle puller holes provided, remove oil baffle. NOTE: Puller tool like shown can be fabricated from diagram shown in Figure 20-A. Figure 17 Remove freewheel assembly from the reaction member. NOTE: The freewheel assembly cannot be serviced.
Figure 21 Oil baffle removed. Figure 24 Remove pump drive bearing support screw and lockwasher. Figure 22 Remove idler gear retaining ring. Figure 25 Using a soft hammer, tap pump drive gear and bearing support from housing. Figure 23 Remove idler gear and bearing assembly. Figure 26 Remove pump drive gear assembly from housing.
Figure 27 Remove idler stub shaft locating ring. Figure 30 Remove control valve assembly. Use caution as not to lose detent springs and balls. Figure 28 Remove sump screen assembly. Figure 31 Remove bolts securing transmission case to converter housing. Figure 29 Remove control cover bolts and washers.
Figure 36 Using an impact wrench (if available), if not a flange retainer bar must be used to hole the companion flange from turning, loosen output flange nut. Figure 33 Separate converter housing from transmission case assembly. NOTE: Reverse and 2nd clutch will remain in converter housing. Figure 34 Using spreading type snap ring pliers, spread ears on the reverse front bearing retaining ring. Figure 37 Remove flange nut, washer, “O” ring and flange.
Figure 42 Remove output shaft and low clutch rear bearing locating rings. Figure 39 Remove output shaft bearing cap. Figure 40 Remove low clutch bearing cap stud nuts and washers. Figure 43 Remove rear cover screws and washers. Figure 44 Using pry slots provided, pry cover from transmission housing, tapping on low clutch and output shaft to allow cover to be removed without shaft binding. Figure 41 Remove low clutch bearing cap.
Figure 45 Rear cover removed showing low clutch (bottom) and output shaft (top). Figure 48 Remove low clutch rear bearing. Figure 49 Remove output shaft and 3rd speed clutch assembly from housing. NOTE: The 2 speed transmission would not have a clutch on the output shaft. Figure 46 Remove low clutch rear bearing retainer ring. Figure 47 Low clutch rear bearing spacer and retainer ring. Figure 50 Remove the output shaft pilot bearing.
Figure 51 Remove 3rd gear and hub retainer ring. Remove Figure 52 Remove gear and 3rd speed clutch hub. NOTE: 2 speed would be gear only. 2nd Figure 54 clutch disc hub retainer ring. Figure 55 Remove 2nd disc hub. Figure 56 Tap low clutch and gear assembly from housing. Figure 53 Remove reverse and 2nd shaft rear pilot bearing.
Figure 57 Low clutch assembly removed. Figure 60 Remove oil baffle and baffle seals. Figure 58 Tap f or wa rd c l u tc h fro m h o u s i n g . Figure 61 Remove forward clutch sealing ring sleeve retainer. Figure 59 Forward clutch assembly removed. Figure 62 Tap sealing ring sleeve from housing as shown.
CLUTCH DISASSEMBLY Low Clutch Figure 66 R emove end pl ate retai ner ri ng. Figure 63 Remove low gear and hub, bearing spacer and low clutch front bearing. Figure 67 Remove end plate Figure 64 Remove low speed gear bearing. Figure 68 Turn clutch over. Remove inner and outer clutch discs. Figure 65 Remove low gear bearing locating ring.
Figure 69 Remove clutch piston return spring. A sleeve with a portion removed is recommended for removing the clutch piston return spring, washer, and retainer ring. Sleeve shown is a common pipe, with a 1-1/2 x 1 [39,0x26,0mm] opening. The pipe is 6 x 3-1/4 x 2-3/4 [155,0x85,0x78,0mm]. Compress spring retainer washer. Through opening remove spring retainer snap ring. Release tension on spring retainer. Figure 72 Install clutch piston inner seal ring and size as described in Figure 71.
Figure 78 Install one friction disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction. Figure 75 Compress spring and retainer. Install retainer snap ring. Figure 76 Install clutch inner bearing locating ring. Figure 79 Install clutch disc end plate. Figure 77 Install one steel disc. Figure 80 Install end plate retainer ring.
Figure 81 Install low speed gear inner bearing. Figure 84 Install low speed gear outer bearing. Figure 82 Install low speed gear bearing spacer. Figure 85 Position low gear front bearing spacer and bearing on clutch shaft. Figure 83 Install low clutch driven gear and hub into clutch drum. Align splines on clutch hub with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position Figure 86 Tap bearing into position.
REVERSE AND 2nd CLUTCH DISASSEMBLY (Reverse being disassembled) Figure 90 Pry reverse gear from clutch assembly far enough to use a gear puller. Figure 87 Remove clutch shaft piston ring and expander springs. See page 50 for proper piston ring installation. Figure 91 Remove gear as shown. Figure 88 Remove front bearing retainer ring. Figure 89 Remove front bearing. Figure 92 Remove bearing spacer.
Figure 96 Remove clutch disc Figure 93 Remove inner bearing. Figure 97 Refer to procedure shown in Figure 69 for removing return spring retainer ring. Remove ring, piston return spring washers and spacer. Turn clutch over and tap shaft on a block of wood to remove clutch piston. Repeat procedure for 2nd and 3rd clutch disassembly. NOTE: 2nd and 3rd clutch will not have washers for piston return. See note on page 51. REVERSE AND 2ND CLUTCH DISASSEMBLY Figure 94 Remove end plate retainer ring.
Figure 102 Install next steel disc. Alternate friction and steel discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction. Figure 99 Install piston return spring spacer, disc spring washers and retainer ring. See note on page 51. 2nd clutch uses a return spring and not disc spring washers. Figure 103 Install end plate. Figure 100 Install 1st steel disc. Figure 104 Install end plate retainer ring. Figure 101 Install one friction disc.
Figure 105 Install inner clutch driven gear bearing. Figure 108 Install outer spacer. Figure 106 Install bearing spacer. Figure 109 Install front bearing. NOTE: Snap ring groove in front bearing must be up. Figure 107 Install clutch driven gear into clutch drum. Align splines on clutch gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.
Figure 111 Install new clutch shaft piston rings and expander springs per instructions on page 50. NOTE: 2nd and 3rd clutch uses a return spring and not disc spring washer for piston return. Figure 114 Remove reverse idler capscrews. Figure 112 Forward clutch will disassemble and reassemble the same as the reverse clutch. Install new clutch shah piston rings and expander springs per instructions on page 50. Figure 115 Remove reverse idler shaft front capscrews.
Figure 117 Remove forward shaft pilot bearing. Figure 120 Recommended procedure for removing bearing. Figure 118 Using spreader type snap ring pliers spread ears on the turbine shaft bearing snap ring. Tap turbine shaft from converter housing. Figure 121 Remove reaction member support capscrews. Figure 119 Remove oil sealing ring and turbine shaft bearing retainer ring and washer. Figure 122 Tap reaction member support from housing.
Housings Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali.
wear, pitting, chipping, nicks cracks or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small all nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. Housing, Covers, etc. Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that mating surfaces, bearing bores, etc., are free from nicks or burrs.
Figure 130 Press turbine shaft bearing into position. Install bearing washer and retainer ring. Install new turbine shaft oil sealing ring. Figure 133 Position reverse idler and bearing assembly into converter housing. NOTE: Long hub of gear out. Figure 134 Install reverse idler shaft capscrews and lockwashers. Ti ghten 58 to 64 ft. l bs. torque [78,6 - 86, 8 N. m ] . Figure 131 Spread ears on turbine shaft bearing retainer ring located in reaction member support. Tap turbine shaft into position.
Figure 139 With front and rear baffle seals in position locate baffle in housing. Figure 136 Tap forward shaft rear bearing into housing Figure 140 Position forward clutch assembly into transmission housing. Use caution as not to damage forward shaft piston rings. Figure 137 With roll pin in place tap forward shaft piston ring sleeve into position. Figure 141 Tap clutch assembly into position Figure 138 Install piston ring sleeve retainer ring.
Figure 145 Locate forward shaft pilot bearing. Figure 142 Locate low clutch assembly in housing. Tap into position. Figure 146 Install 2nd speed clutch shaft rear pilot bearing on shaft. Figure 143 Install the 2nd clutch disc hub. Figure 147 Position reverse and 2nd speed clutch on disc hub aligning splines of disc hub with internal teeth of 2nd speed clutch friction discs. Disc hub must be in full position with friction discs. Do not force this operation. Figure 144 Install disc hub retainer ring.
The 2 speed trasmission will not have a clutch on the output shaft. Figure 148 Locate gear and clutch disc hub on forward clutch shaft. NOTE: The 2 speed transmission will have Only a gear and not a clutch disc hub on it. Figure 151 Oil sealing ring tool. Figure 149 Install gear retainer ring Figure 152 Install output shaft and 3rd speed clutch. Figure 150 Install new oil sealing ring on output shaft. NOTE: New ring must be sized before shaft can be assembled in transmission housing.
Figure 154 Install low clutch rear bearing washer and retainer ring. Figure 157 Install rear cover, bolts and lockwashers. Figure 155 Install new oil sealing ring on low clutch shaft. Figure 158 Tighten bolts 37 to 41 ft. lbs. torque [50,2 - 55,5 N.m]. NOTE: New ring must be sized before installing low shaft bearing cap. Figure 156 Position new gasket and “O” ring on rear of transmission housing. A thin coat of chassis grease will hold the gasket and “O” ring in place.
Figure 160 Install new bearing cap and low clutch pressure port “O” rings on low shaft bearing cap. Position bearing cap onlow shaft. Install washers and stud nuts. Figure 163 Install output flange “O” ring, washer and flange nut. Block flange to prevent turning. Tighten flange nut to 200 to 250 ft. lbs. torque [271 ,2 - 339,0 N.m]. Figure 161 Position new gasket on output shaft studs. bearing cap. Install washers and nuts.
Figure 166 Spread ears on the reverse clutch front bearing snap ring. Lock pliers open to hold snap ring open. Tap converter housing in place. Use caution as not to damage reverse clutch front piston ring. Note aligning stud. Figure 169 Install charging pump drive gear. Snug capscrews to hold gear in place Figure 167 Install a cap screw in the front and one in the rear of the converter housing and snug up but do not tighten. This will hold the converter housing to the transmission housing.
Figure 175 Apply a light coat of Dow Corning RTV-03-7069 to O.D. of oil baffle or counter bore in converter housing. Remove immediately any excess sealant that could enter the oil circuit. Figure 172 If fidler shaft bearing locating ring was removed, install new ring on stub shaft. Figure 173 Position pump idler gear and bearing on stub shaft. Figure 176 Assemble new oil baffle oil seal in baffle. Position oil baffle puller screw holes 15° to 30° either side of vertical center line.
Figure 181 Figure 178 Position reaction member to impeller hub gear spacer on reaction member support. NOTE: If a fixed reaction member is used, install reaction member on support with thick side of blades out and proceed with Figure 183. MUST FREEWHEEL IN CLOCKWISE ENGINE ROTATION FREEWHEEL REASSEMBLY Figure 182 NOTE: Some units have a bolted on turbine hub. If either the turbine or hub is replaced see page 36 for reassembly.
Figure 184 Figure 187 Position inner turbine locating ring on turbine shaft. Install turbine on shaft. Install impeller cover assembly on impeller. Use caution as not to damage “O” ring. Bearing retainer plate must be aligned with the turbine shafts. Figure 185 Figure 188 If the impeller cover bearing retaining washer or bearing was replaced, use the following procedure for reassembly. Heat cover 200° to 250° F [93°- 121° C]. Position snap ring in groove. Place bearing retainer washer in cover.
Figure 192 Position flexplate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate flex plate backing ring with holes impeller cover. NOTE: Two dimples 180° apart in backing ring must be out (toward engine flywheel). Install capscrews and washers. Figure 189-A Figure 193 Figure 190 Tighten flex plate capscrews 23 to 25 ft. lbs. torque [31,2 - 33,8 N.m]. Position new “O” rinq on impeller cover bore plug. Lubricate ring to facilitate reassembly. Install plug in cover.
Figure 195 Figure 198 Using a new gasket and “O” ring, position charging pump assembly on studs. Install washers, nuts and capscrews. If the control cover valve spools are to be inspected or the spool oil seals changed, remove the valve spool stops as shown and pull spools out of oil seals. Always replace oil seals if valve spools are removed for inspection. Sharp edges on valve spool will cut lip of oil seal.
Figure 200 Position new gasket and detent springs on converter housing. Install control cover and cover to housing capscrews and washers. Figure 201 Tighten capscrews 23 to 25 ft. lbs. torque [31,2 - 38.8 N.m]. If the turbine or turbine hub was replaced or disassembled, this procedure must be used for reassembly. TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS 1. Clean hub mounting surface and tapped holes with solvent. Dry thoroughly being certain tapped holes are dry and clean.
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes. The transmission, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels.
CONVERTER OUT PRESSURE SPECIFICATIONS AND SERVICE DATA-POWER SHIFT TRANSMISSION AND TORQUE CONVERTER Full flow oil filter safety by-pass, also OIL FILTRATION Converter outlet oil temp. 180° - 200° F. 82.3° - 93,3° C]. Transmission in NEUTRAL. Operating specifications: 25 P.S.I. [172,4 kPa] minimum pressure at 2000 R.P.M. engine speed AND a maximum of 70 P.S.I. [482,6 kPa] outlet pressure with engine operating at no-load governed speed.
TROUBLE SHOOTING GUIDE For The HR Model. 18000 Transmission The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to consider the torque converter, charging pump, transmission, oil cooler, and connecting lines as a complete system when running down the source of trouble since the proper operation of any unit therein depends greatly on the condition and operations of the others.
18000 2 SPEED TRANSMISSION POWER FLOW 18000 3 SPEED TRANSMISSION POWER FLOW -40-
PRESSURE CHECK POINTS 1. 2. 3. -41- HOSE LINE OPERATING REQUIREMENTS: PRESSURE LINES AMBIENT TO 250° F [121° C] FOR CONTIMUOUS OPERATION. MUST WITHSTAND 300 P.S.I. [2068 kPa] CONTINUOUS OPERATION WITH 600 P.S.I. [4137 kPa] SURGE PRESSURE REF. SAE 100RI HYDRAULIC HOSE. OIL SPECIFICATIONS: SEE LUBRICATION SECTION. ALL HOSE LINES USED MUST CONFORM TO SAE SPEC NO. SAE J1019 TESTS & PROCEDURES FOR HIGH-TEMPERATURE TRANSMISSION OIL HOSE, LUBRICATING OIL HOSE & HOSE ASSEMBLIES.
18000 SERIES - 3 SPEED INLINE CLUTCH & GEAR ARRANGEMENT -42-
18000 SERIES TRANSMISSION CONVERTER DRIVE PLATE KITS Proper Identification by Bolt Circle Diameter Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below. Note four (4) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits with three intermediate drive plates. “A” Dimension (Bolt Circle Diameter) “A” Dimension (Bolt Circle Diameter) 11.38" [288,900 mm] Diameter Kit No. 802229 13.12" [333,375 mm] Diameter Kit No. 802230 13.
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1. Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. 2. Check engine flywheel and housing for conformance to standard S.A.E. #3 - S.A.E. J-927 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play. 3. Install two 2.50 [63, 50 mm] long transmission to flywheel housing guide studs in the engine flywheel housing as shown.
1 - Idler Gear Shaft 2 - Shaft “O” Ring 3 - Shaft Lock Ball 4 - Bearing Spacer 5 - Idler Gear Bearing Assembly 6 - Bearing Spacer 7 - Idler Shaft Lock Nut 8 - Idler Gear DISASSEMBLY AND REASSEMBLY OF LOCK NUT TYPE IDLER SHAFT DISASSEMBLY Figure 202 Unclinch lock nut by straightening upset metal in notch in idler shaft. Remove idler shaft nut. Figure 203 Remove nut spacer.
Figure 207 Remove bearing spacer. Figure 204 Remove idler gear and outer taper bearing from idler shaft. Figure 208 Remove idler shaft, use caution as not to lose shaft lock ball. Refer to page 21 for further disassembly. Figure 205 Remove bearing spacer. REASSEMBLY OF LOCKNUT TYPE IDLER SHAFT Figure 209 With new “O” ring on shaft, position idler shaft and lock ball in converter housing. Tap shaft into position. Note lock ball. Figure 206 Remove inner taper bearing.
Figure 210 Install reverse idler shaft spacer. Figure 213 Position idler gear on bearing with hub of gear up. Figure 211 Install inner taper bearing on shaft with large diameter of taper down. Figure 214 Install idler gear outer taper bearing with large diameter of taper up. Figure 215 Position outer spacer on shaft. Figure 212 Position bearing spacer on shaft.
Figure 218 Stake nut securely in shaft notch. Figure 216 Install retainer nut. Figure 217 Tighten nut 200-250 ft. lbs. torque [271,2-338,8 N.m].
Assemble speed sensor bushing in housing to specified dimension with Loctite 262 or 270 and stake 3 places.
PROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS 1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the teflon ring and expander spring in the ring groove for installation. 2. Position the expander spring in the inner groove of the new piston ring, with the expander spring gap 180° from the hook joint gap of the piston ring. 3.
NOTE: Clutch return disc spring packs are certified according to compression weight specifications and are pre-packed in quantities to repair one (1) specific clutch. The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack. Each disc spring assembly is made up of selected springs to precisely match each part within this assembly.
NOTES
SOM #5 AXLE PLANETARY WITH WET DISC BRAKE GRADALL MODEL 532 STARTING S/N 0166050G (1)
GENERAL INFORMATION FOR THE WET DISC BRAKE SYSTEM (1A)
SPECIAL TOOLS FOR THE WET DISC BRAKE SYSTEM (1B)
PLANETARY WITH WET DISC BRAKE DISASSEMBLY 0F THE WHEELEND. Clean the outside of the planetary reducer to prevent contamination of the oil systems. Remove the sector plates (1). Drain the axle and wheelend. Remove the bolts (1) and discard the o-ring. Remove the cover (2) and discard the o-ring. Using two bolts (1) planetary gear carrier (2). (2) remove the Remove the bearing (1) and the sun gear shim. Remove the bolts (2). Remove the sun gear (1).
PLANETARY WITH WET DISC BRAKE Remove the rotor brake disc with inner (1). Remove the brake pressure plate (1). Remove the stator brake disc with the outer slot (1). Using a special tool, compress the spring (3). Remove the snapring (1). Remove the special tool. Remove the spring retainer (2). Remove the spring (3). WARNING - CAUTION Removing the snapring (1) without compressing the spring (3) may cause injury to personnel and damage to axle components. (3) Remove the brake disc hub (1).
PLANETARY WITH WET DISC BRAKE Remove two holes opposite each other (1). Remove the brake reaction piston (1) and discard the seal (2). Remove the parking brake piston (3) and remove the belleville springs. Install the special tool (1) and tighten both bolts (2). Tighten the center bolt (3) to compress the belleville springs. Remove and discard the seal (1). Remove the shaft (2). Remove the bearing (3) on steer axles. Remove the snap ring (1).
PLANETARY WITH WET DISC BRAKE Remove the ring gear carrier (1). Keep the preload shim (2) for the reuse if there in no change of hub, bearings or ring gear carrier Install a lifting devise (1). Using a mallet, strike the hub (2) on the side of the wheel stud heads, and remove the hub (2). WARNING: Retain the bearing inner race (3) during this operation. Remove the hub seal (1), using a screwdriver. Remove the bearing inner race (2). Check the condition of the outer race, no scoring or pitting is allowed.
PLANETARY WITH WET DISC BRAKE Install the bearing (1) in the hub using tool (3). Follow the same procedure for the other bearing in the hub. Install the hub (2) fitted with bearings on fixture (1). Put the bearings (3) under a load of 220 lbs. (0.100) T metric). Turn the hub (2) seat the bearings. Measure distance “A”. Install the ring gear carrier (1). Install six bolts (2), tighten them in two steps, follow Specification STB 1-204.
PLANETARY WITH WET DISC BRAKE Position part A of the special tool and pass the snap ring (2) over the special tool. Install the lockinq ring in its and tighten the bolts (2) Tighten bolt (3) to compress the belleville springs. Intall the locking ring in its location, using snap ring pilers (1). Remove the compression tool (2). Install a new seal (1) (outer sealing of service brake piston) in spindle (2). Install a new seal (1) in service brake piston (2).
PLANETARY WITH WET DISC BRAKE Install the shaft (1) and engage the splines. Install the inner race of bearing (1). Install the hub seal (2) with lip and spring positioned toward the inside of the hub, using a special tool (3). See Specification STB 1-204. Position the Hub (1) on the spindle with a lifting device. Be careful of the lip seal when installing the hub on the spindle. Engage and install the bearing inner race (2) in the hub. (Use a brass drift to ease with the installation of the bearing).
PLANETARY WITH WET DISC BRAKE Install the pressure plate (1) and engage the holes on the bolt heads. Install the brake disc hub (2) and engage the splines in the shaft. Install the stator and rotor disc (1) and engage slot (2) on the ring gear centering pin. Install the rotor disc (1) then alternate the stator and rotor discs. See Specification STB 1 204. Install the reaction plate (1) on the sun gear (2). Insert the sun gear in the brake disc hub (3).
PLANETARY WITH WET DISC BRAKE Install the sector plates (1). Install with the sharp edges toward the outside.T Clean and remove grease from the bolts (2) and the threaded holes. Install and tighten bolts (2). See specification STB 1-204 Install the special tool (1) and tighten bolts (2). Tighten bolt (3) to remove slack from the brake system. Measure distance “B” between the bearing surface of the sun gear and the upper surface of the sector. plates. Remove the special tool.
PLANETARY WITH WET DISC BRAKE Install the cover (1) on the hub with the blind holes aligned with the bolts on the sector plates. Install a new seal to bolt (2). Apply a dab of silicone under the bolt heads. Install and tighten bolts (2) to their proper torque. Install the bearinq inner race (1) on the sun gear. NOTE: The race is mounted very free on the sun gear with .078 (2mm) play.
CORRECTION SHEET Enter page numbers at the bottom of each page starting with page number one (MAINTENANCE RECOMMENDATIONS) to page number forty-four (CONVERSION FACTORS). Page 1 MAINTENANCE RECOMMENDATIONS: Part II, Para 2, Line 4, omit the words “the cone”. Page 15 PLANETARY HUB REDUCERS: Second picture omit the second sentence, “Remove the planet gear carrier”. Page 16 PLANETARY HUB REDUCERS: Third picture change the word “tapper” to “taper”.
CORRECTION SHEET Page 31 SPECIFICATIONS Item 4, change “UPPER ADJUSTMENT” to “UPPER SHIM PACKAGE”. Line one under Item 4, change the word “adjustment” and replace with the word “shim package”. Item 5, FINAL ASSEMBLY: Line four under Item 5, change the number “120” to “125”. Line five under Item 5, change the number “120” to “125”. Page 33 SPECIFICATIONS: Line two, change the number “84” to “184”. Line four, change the number “.0045” to “.0059”.
SOMA TECHNICAL SERVICE BULLETIN TSB 017-84 SUBJECT: Hub seal installation. MODELS AFFECTED: All “S” range axles. At replacement the hub seal should be recessed as shown below. P.O.
SOMA TECHNICAL SERVICE BULLETIN T SB 023-86 SUBJECT: Grease to be used in the trunnion bearings of all PDI 25, PDI 65, PDD 35, and PDD 50 pivots. MODELS AFFECTED: All “S” range steer axles. The recommended grease to use must be a NLGI No.2 consistency multi-purpose type grease (like Lithium 12 Hydroxy Stearate Soap) with a 800 SUS to 1200 SUS at 100 F petroleum type oil base containing an EP (extreme pressure) additive and added rust and oxidation inhibitors. P.O.
SOMA OF AMERICA ENGINEERING STANDARD OFFICE REGISTER: STC SPECIFICATION: STC 5-102 SECTION: 5 PAGE: 1 OF 2 SERIES: 100 RECOMMENDED LUBRICATION PRACTICES FOR AXLES AND GEAR BOXES DELIVERY The machined unpainted parts are delivered greased and must be used as delivered. The gear boxes and axles are delivered without lubricant. The wheel hubs are greased for life.
SOMA OF AMERICA SPECIFICATION: STC 5-102 PAGE: 2 OF 2 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 5 SERIES: 100 TRANSFER CASES RA: 90° angle transmission (R): Differential split torque Gear boxes for off highway vehicles OIL CHANGE Drain oil at operating temperature. Clean the drain plug. The oil change interval varies due to the type of vehicle and operating duties: it is very important to observe the oil level and to change oil according to the oil contamination.
MAINTENANCE RECOMMENDATIONS I MAINTENANCE OF THE AXLES For the lubrication of the SOMA axles refer to specification STC 5-101 The filling and draining are explained in the specification STC 5-102. II TAPERED ROLLER BEARINGS If the parts are clean and properly lubricated, it is rare to find damaged bearings during removal. Therefore, one must avoid removing them because they may be damaged by the puller. 1) Reasons for bearing removal. Abnormal wear of the bearing surface.
DIFFERENTIAL CARRIER
DIFFERENTIAL CARRIERS 300 - 500 - 1000 l Lift the differential carrier and fasten it to a work stand. l Swivel the assembly through l Remove the locking bolt. l Loosen the bearing specifications STC 2-204 l Loosen the differential nut l Unstake and unscrew the pinion nut with a socket holding the input flange with a spanner. l Remove the bolts and the bearing the differential nut l Remove the differential assembly l Remove the nut and the input flange.
DIFFERENTIAL CARRIERS 300 - 500 - 1000 l Remove the upper and lower pinion bearing cups.
DIFFERENTIAL CARRIERS 300 - 500 - 1000 ADJUSTMENT OF THE PINION Determine the thickness of the bearing shim in the housing. l Adjust the dial gauge equipment on the control rest. l Set the long pointer of the dial gauge on the 0 position l Note the position of the short pointer l Measure the total thickness of the ring behind the head of the l Note the value of the distance” marked on the bevel pinion l Calculate Y = thickness of the bearing + tapered distance.
DIFFERENTIAL CARRIERS 300 - 500 - 1000 l l Remove the pinion Install the bearing cup into the housing l With a torque meter check the with specification STB l l Install the pinion Insert the selected shim l Install the bearing cone with a pusher l Remove the input flange Install oil seal with a pusher according to specification STC 2-111 l Install the input flange l Torque the nut according to specification STB 1-110 and stake the nut.
DIFFERENTIAL CARRIERS 300 - 500 - 1000 l Insert the selected shim. l Measure the preload on the upper diameter l With a dial gauge, check the backlash betInstall, the differential case of the bearing cups. The preload must be ac- ween pinion and ring gear: This backlash l Install the nut. cording to specification STB 1-110 after must be according to specification STB 1l Install the bearing caps and the bolts tightening of the differential nut. 110.
DIFFERENTIAL CARRIERS 300 - 500 - 1000 1. NOT ENOUGH BACKLASH: MOVE THE RING GEAR AWAY 3. PINION ENGAGED TOO MUCH: ADD ADJUSTMENT SHIMS If tooth contact occurs as illustrated above, the ring gear must be moved away from the pinion by increasing the longitudinal bearing. This movement will change the contact on the profile and an adjustment of the pinio will be necessary. A. Profile contact adjustment B. Increase longitudinal bearing 2.
DIFFERENTIAL CARRIERS with differential lock 300 - 500 - 1000 l Remove the differential lock actuating cylinder. Reassemble by holding a vice. l l l Swivel the assembly through 180 Extract the fork pin with a pin punch. Install fork with the pin. Test the differential lock. l Stake the casting in two locations at each end of the pin hole. l l l l Disassemble the clutch gear, the fork and the lock ring.
PLANETARY HUB
PLANETARY HUB REDUCERS REMOVAL OF THE PLANETARY l Remove the three screws. HUB REDUCER l Remove the planet gear carrier. l If installed, remove the wheel nuts. l Remove the drain lubricant l l Remove the cover plate bolts Remove the cover plate discard the o’ring. l l Remove the planet gear carrier. Remove the three screws. l Remove the brake drum with three jacking bolts. Pull out the on rigid axles remove the shaft and coupler). l Remove the thrust button.
PLANETARY HUB REDUCERS l Unstake the spindle nut tap washer l Remove the nut with wrench Remove the l Remove the bearing with the help of a the ring gear pin punch. l Remove the ring gear with the help of a pry bar. l l Remove pry bar. the oil seal with the help of a l Remove the bearing cups. lRemove the wheel If necessary: Change the wheel studs. l Remove them on a press. l Replace them with wheel studs stamped with an “R” l Press fit them.
PLANETARY HUB REDUCERS l Remove bolts. •If necessary remove the spacer •Remove the seal race with puller •In case of brake change, save the dust cover. ASSEMBLY OF THE PLANETARY HUB REDUCER • Look according to specification • Fit the tow bearing cups • Install the brake spacer • Torque the spacer bolts according to specification STB 1-406. • Install the brake: Position carefully the cam with regard to the axle housing.
PLANETARY HUB REDUCERS l Install l l l wheel hub assembly. Install ring gear carrier. Install the tapper ring. Position the locking washer correctly l Install the spindle nut. l l l Replace the ring. FOR RIGID AXLES ONLY l Install the planet gear carrier l Install the axle shaft couple l Tighten the screws according to sun gear FOR STEER AXLES ONLY specification STB 1-203.
STEERING PARTS
STEERING PARTS REMOVAL bolts. lRemove the upper flange. l If necessary, use puller bolts to remove the flange. l Remove l l Save and mark the shims Remove the trunnion l Remove the upper and lower seals with a screwdriver or pry bar Replace when reassembling. * flange = cap or lever l Remove the horizontally l Remove: l the nut lthe cover l the oil seal lthe spherical shell (bowl) These elements must be replaced when reassembling.
STEERING PARTS ASSEMBLY Install the guide bushing grease according to specification STB 1-306. l l Install the constant velocity joint and shaft assembly. l l Apply a bead of silicone to the threaded area of the nut l Start turning the nut by hand “CCW” to align the leading thread. Install the cover. l Tighten the nut with wrench according to specification STB 1-305. l Install the spherical shell (bowl).
STEERING PARTS l Install the bearing cone with pusher l Remove tool. l Insert the selected shim(s). l Install the flange. l l Install the bearing cups with pusher Place the constant joint in horizontal axis. l Sling or support the pivot. Check the fitting of the spherical shell (bowl) l in the pivot. l Install the bolts. l Torque them according to specification STB 1-305.
SPECIFICATIONS
SOMA OF AMERICA SPECIFICATION: STB 1-110 PAGE 1 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 1 SERIES: 100 INSTRUCTIONS FOR THE ASSEMBLY OF DIFFERENTIAL CARRIERS 300 - 500 - 1000
SOMA OF AMERICA SPECIFICATION: STB 1-203 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 1 SERIES: 200 INSTRUCTIONS FOR THE ASSEMBLY OF PLANETARY HUB REDUCERS 2.68 - 3.55 - 4.63 - 5.6 Planetary Hub Reducer type 3.55 Planetary Hub Reducer type 5.6 1 Fit the seal land according to specification STC 2-202 2 Fit the oil seal according to specification STC 2-203.
SOMA OF AMERICA SPECIFICATION: STB 1-201 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION:1 SERIES: 200 AXIAL CLEARANCE ADJUSTMENT BETWEEN THE END SHAFT POSITIONER AND THE THRUST SPACER J = axial clearance between the end shaft positioner (1) and the thrust spacer (2) after adjustment: this axial clearance must be: 1 to 2mm. (.039 - .078 inches). l l Choose the end shaft positioner with the help of the appropriate gauge to determine the difference between «A» and «B» equal to J.
SOMA OF AMERICA SPECIFICATION: STB 1-305 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 1 SERIES: 300 INSTRUCTIONS FOR THE ASSEMBLY OF STEERING PARTS TYPE PDI 25 AND 26 PDD 35 AND 50 Before assembly of the pivot on the axle housing, determine the dimensions: X = middle of the pivot to the lower cap shoulder, get by adding or subtracting from the theoretical size, the value engraved on the pivot (see drawing for the engraved position). theoretical size: PDI 25: 152mm (5.
SOMA OF AMERICA SPECIFICATION: STB 1-306 PAGE: 1 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 1 SERIES: 300 LUBRICATION OF THE STEERING PARTS TYPE PDI 25/65 - PDD 35/50 1 - Grease the inner and outer surfaces of the elastomer seals (with lips, with or without frame, and U or quadring types). 2 - Grease the bearings and the guide ring of spherical shell Fill: the free intervals between the parts and the cavities of the guide ring.
SOMA OF AMERICA SPECIFICATION: STB 1-305 PAGE 2 OF 2 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 1 SERIES: 300 1 LUBRICATION OF THE STEERING PARTS To be done according to specification STB 1-306 2 ASSEMBLY OF THE CARDAN JOINT SPHERICAL SHELL l l l Apply at the bottom of the bore a single continuous bead of silicone (corrosion protection of the bore). Apply on the nut thread, silicone sealant on a complete thread (locking if the nut).
SOMA OF AMERICA SPECIFICATION: STB 3-201 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 3 SERIES: 200 ADJUSTMENT OF SPINDLE NUT FOR ON HIGHWAY VEHICLES Planetary Hub Reducers - Ratios (2.68 - 3.55) 4.6 - 5.6 l Tighten the spindle nut (1) while rotating the hub to correctly position all components (bearing and tapper ring) tightening torque: 250 to 300 N.m (84-221 foot pounds). l Unscrew nut (1) through 45° (1/8 of a turn). The end thrust clearance must be between 0.05 and 0.15mm (.0019 -.
SOMA OF AMERICA SPECIFICATION: STB 3-202 PAGE: 1 ENGINEERING STANDARD OFFICE REGISTER: STB SECTION: 3 SERIES: 200 ADJUSTMENT OF SPINDLE NUT FOR ROUGH TERRAIN VEHICLES Planetary Hub Reducers - Ratios (2.68 - 3.55) 4.6 - 5.6 Tighten the spindle nut (1) while rotating the hub to correctly position all components (bearings and tapper ring) tightening torque: 350 to 400 N.m (258 - 295 foot pounds). l Adjust the nut by slackening until rotation of the hub is obtained by applying the following tangential.
SOMA OF AMERICA SPECIFICATION: STC 2-103 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 2 SERIES: 100 SEALING THE PLANETARY HUB REDUCERS PRECAUTIONS Check: l The cleanliness of the parts (bore, seal race, and oil seal). l The surface of the seal race must not be scored or damaged. l The oil seal lips must not be cut or torn. The spring must be correctly positioned and the P.T.F.E. coating on the dust lip for certain oil seals, free of burrs.
SOMA OF AMERICA SPECIFICATION: STC 1-109 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 1 SERIES: 100 LUBRICATION OF THE OIL SEALS BEFORE FITTING All oil seals must be lubricated to avoid dry working at the start of each operation. In every case, the internal face of the oil seals must be greased before fitting. l Oil seals with single lip: grease the internal face and lip. Oil seals with two lips: grease the internal face and pack grease between the two lips. l Two oil seals: fitted together.
SOMA OF AMERICA SPECIFICATION: STC 2-202 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 2 SERIES: 200 APPLICATION OF LOCTITE FORM-IN-PLACE GASKET #549 WHERE TO USE l l Bearing area between differential carrier and axle housing. Other use according to SOMA Engineenng recommendation. CHARACTERISTICS OF THE PRODUCT l Color: dark red. Adhesive power important: Do not use on the centering (only on the bearing areas) never on parts with thin section. l Temperature: resistance from — 55° C to + 150° C.
SOMA OF AMERICA SPECIFICATION: STC 2-111 PAGE: 1 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 2 SERIES: 100 SEALING THE INPUT FLANGES OF DIFFERENTIAL CARRIERS 300 - 500 - 1000 TRANSFER CASES - AND DROP BOXES FIG1 Flush or slightly recessed diff. carriers 300 (3mm flush) (0.118) FIG2 Recessed by 6mm (0.236 in.) Transfer case drop box FIG3 Shoulder fitment Diff. carriers 500 - 1000 500 DG (input-output) PRECAUTIONS Check: l The cleanliness of the parts (bore, seal land, and oil seal).
SOMA OF AMERICA SPECIFICATION STC 2-204 PAGE: 1 ENGINEERING STANDARD OFFICE REGISTER: STCE SECTION: 2 SERIES: 200 APPLICATION OF LOCTITE THREAD LOCK WHERE TO USE l Screws and bolts with a diameter less than 6mm (0.236 in.) or with an engaging length greater than the normal diameter x 1.5: use Locite Thread Lock 222. l Other screws and bolts: use Locite Thread Lock 242. O.E.M. INSTALLATION l Clean and degrease carefully with a solvent.
SOMA OF AMERICA SPECIFICATION: STC 2-203 PAGE: 1 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 2 SERIES: 200 APPLICATION OF LOCTITE FORM-IN-PLACE GASKET -510 WHERE TO USE l Flange caps of differential carrier and gear boxes. boxes and industrial reducers housings. l Input housing of drop gear and interaxles differential. l Covers of planetary hub and industrial reducers. l Other use according to SOMA Engineering recommendation.
SOMA OF AMERICA SPECIFICATION: STC 5-102 PAGE: 1 OF 2 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 5 SERIES: 100 RECOMMENDED LUBRICATION PRACTICES FOR AXLES AND GEAR BOXES DELIVERY The machined unpainted parts are delivered greased and must be used as delivered. The gear boxes and axles are delivered without lubricant. The wheel hubs are greased for life.
SOMA OF AMERICA SPECIFICATION: STC 5-102 PAGE: 2 OF 2 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 5 SERIES: 100 TRANSFER CASES RA : 90° angle transmission (R) : Differential split torque Gear boxes for off highway vehicles OIL CHANGE Drain oil at operating temperature. Clean the drain plug. The oil change interval varies due to the type of vehicle and operating duties: it is very important to observe the oil level and to change oil according to the oil contamination.
SOMA OF AMERICA SPECIFICATION: STC 2-205 ENGINEERING STANDARD OFFICE REGISTER: STC SECTION: 2 SERIES: 200 APPLICATION OF SILICONE WHERE TO USE Bearing area between differential carrier and axle housing. l Gear box and industrial reducer housings. l Wheel end reducer and industrial reducer covers. l Flange caps and clutch gear box covers. l Drop gear and interaxle differential locking control housings.
CONVERSION FACTORS To Convert Into Multiply by Millimeters (mm) Kilometers (km) Newton-Meter (N.m.) Meter-Kilogram (mkg) Newton-Mete, (N.m.) Meter-Kilogram (mkg) Newtons (N) Liter (l) Liter (l) Inches (in) Miles (mi) foot-pound (ft-lb) foot-pound (ft-lb) inch-pound (in-lb) inch-pound (in-lb) pounds-force )lb) quart (qt) pints (pt) 0.03937 0.6214 0.7376 7.233 8.8512 86.796 0.2248 1.057 2.
TOE-IN PROCEDURE FOR GRADALL/LOED Model 534B (Rear Steer) The correct toe-in adjustment is 5/16" for each rear tire. Incorrect toe-in will cause the rear wheels to drift or float erratically. How to check for toe-in: With wheels straight, measure A and B. They should be equal ( 1/16"). C½ + C½ = 2 Correct adjustment is: A + B + 5/8” = C HOW TO ADJUST: 1. Turn rear wheels full left and sway machine 8 for easy removal of tie rod bolt. Turn engine off. 2. Remove tie rod bolt. 3.
Introduction This Service Manual is a step-by-step guide designed for the customer or shop mechanic who is servicing or repairing a particular model of Torque-Hub Final Drive. (The model covered by this copy of the Manual is specified on the Manual cover.) Included are— 1. assembly and exploded view drawings 2. disassembly procedure 3. main assembly procedure (assuming all sub-assemblies to be intact) 4. sub-assembly procedures.
W3-P “A” Drive Disassembly Procedure 1. Loosen all 12 Cover Bolts and drain the oil from the unit. 2. Remove the 12 Cover Bolts and lift off the C o v e r S u b - A s s e m b l y. D i s c a r d t h e ‘ O ’ r i n g Seal from the Cover counterbore. 3. L i f t o u t t h e C a r r i e r S u b - A s s e m b l y a n d T h r u s t B e a r i n g S e t . A T h r u s t Wa s h e r m a y s t i c k i n s i d e t h e C o v e r. 4. Pry the Ring Gear loose and remove it. Discard the ‘O’ ring Seal from the Hub counterbore.
Main Assembly Procedure 1. Using an arbor type press if available. (if not, a hammer may be used), install the wheel studs. The hub flange should be supported from the underside during this operation. Note: Wheel studs are optional. 2. Using an arbor type press if available, press Bearing Cups with large inside diameters facing out, into Hub counterbores. Cup #JM716610 will go into small end of Hub, and Cup #JM515610 will go into large end of Hub. 3.
5. Lower Hub onto Spindle with large open end up. 6. Place Bearing cone #JM515649 over end of Spindle and into Bearing Cone. 7. Place Bearing Shim over end of Spindle and against Bearing Cone. 8. Secure Retaining Ring completely into Spindle groove and against Bearing Shim. Be sure that Retaining Ring is entirely in groove. Eye protection should be worn during Retaining Ring installation. 9. The pipe plugs are installed in the Hub. The us of lub-seal is recommended on the pipe plug.
10. The disengage spacer and spring are installed into the co’bore of the Spindle. 11. Another spacer and the correct Retaining Ring are installed into the Spindle co’bore and Retaining Ring groove provided. Eye protection should be worn during Retaining Ring installation. 12. The internal gear is installed matching the Bore Spline the Spindle Spline. 13. The thrust washer/thrust bearing set is installed on the portion of the Spindle which extends into the internal gear. 14.
15. Install retaining ring into input shaft retaining ring groove. 16. The input shaft is installed into the spindle. The action of the spring should be checked at this point. 17. The thrust spacer is installed on the input shaft. 18. Locating the four counter reamed holes in the face of the hub, mark them for later identification. These holes are reamed to accept the shoulder bolts. 19. Place Carrier Assembly on a flat surface with the large gears up and positioned as shown.
20. With shoulder side of Ring Gear facing down, place Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation. The side of the Ring Gear with an “X” stamped on it should be up. 21. The input gear is now installed into the carrier, meshing with the small diameter cluster gear. The counterbore in the bore of the input gear must be to the outside of this assembly. 22.
24. After inserting at least one shoulder bolt in the proper location, rotate the carrier. This is to check freedom of rotation and recheck timing. 25. Another thrust washer/thrust bearing set is now installed into the counterbore in the face of the carrier. 26. Place O’Ring into cover assembly counterbore. Slight stretching may be necessary. Use sufficient grease or petroleum jelly to hold in place. 27.
29. Install grade eight bolts into the remaining eight holes and torque all bolts to 47 ft. lbs. Use the 180° to 90° method in torqueing all bolts. 30. Place Coupling into the Spindle and onto the Input Shaft. Note: W3C units must have one external and one internal Snap Ring installed. All units with an “X” on the end of the model number must have two internal Snap Rings with a spacer between them installed in the Coupling. This completes the assembly.
3. Install 14 Needle rollers (3C) into lower half of Cluster Gear (3F) using sufficient grease or petroleum jelly to assist in holding Needle Rollers (3C). 4. Install Spacer (3D) onto Planet Pin (3E) locating on inboard end of Needle Rollers (3C). 5. Install another 14 Needle Rollers (3C) into the remaining half of Cluster Gear (3F) using sufficient grease or petroleum jelly to assist in holding Needle Rollers (3C) in place once Planet Pin (3E) is removed. 6.
8. Insert Planet Pin (3E) into the Planet Pin hole of Carrier (3A) from the Roll Pin hole side. Care is to be taken to align Planet Pin (3E) with the chamfered end of the Roll Pin hole up. This chamfered hole is to assist in aligning the Roll Pin holes in the Carrier (3A) and Planet Pin (3E) as Roll Pin (3G) is tapped into location. 9. Using sufficient grease or petroleum jelly to assist in holding in position. Thrust Washer (3B) is installed onto Planet Pin (3E).
Cover Sub-Assembly 1. Screw Pipe Plug into Cover. 2. Place ‘O’ Ring into Cover Cap internal groove. The Disconnect Rd may be used to push ‘O’ Ring into groove. Rod will be held in place by friction from the ‘O’ Ring. 3. Slip ‘O’ Ring over Cover Cap and against face. 4. Place Cover Cap into Cover with large hole located over Pipe Plug.
5. Install two 1/4 x 20 x 3/4 bolts 180° apart and torque to 70 - 80 in. lbs. 6. Place disconnect cap over cover cap with nipple facing out and align with two open holes. Secure disconnect cap to cover with two 1/4 x 20 x 3/4 and 70 - 80 in. lbs.
Cyclopac® Service Procedures Proper air cleaner servicing results in maximum engine protection against the ravages of dust. Proper servicing can also save time and money by maximizing filter life and dust cleaning efficiency. Two of the most common problems: A) Over Servicing.
Air Filter Service Tips 7 Important Steps to Follow The Important “Don’t” Don’t remove filter for inspection. (1) Remove the old element gently to prevent knocking dust off of it. Never rap a filter to clean it. Rapping only damages the filter.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
