Grove HL 150c

the switch is in the OFF position and the switch S8 (SWING
BRAKE switch) in the control lever handle is in its normally closed

position, the solenoid valve SV1-1 is energized, allowing hydraulic
pressure to overcome the springs and release the swing brake.
PROPEL BRAKE.
The propel brake switch (54) is located below the swing brake
switch on the left arm rest console. The switch is used to place the
side frames in the park condition. Placing the switch in the PARK
position deenergizes solenoid valves SV1-17 and SV2-17 in order
to apply the crawler brake.
Signal Horn.
The signal horn (55) is located on the center front of the swing
control lever and is used to alert personnel of a craning function.
CIRCUIT BREAKER PANEL.
The CIRCUIT BREAKER PANEL (41) is located directly under the
right arm rest console. Access to the panel is gained by lifting up
on the armrest console. The panel contains push in, pop out circuit
breakers that are each placarded as to the circuit each breaker is
used in.
HEATER CONTROL PANEL. NOTE The following
descriptions pertain to the heater control panel. The
panel is located behind the operator's seat in the right
corner of the operator's cab. Fan Switch.
The blower FAN switch (42) is located on top of the control panel. It
controls the operation of the pressurized blower. By rotating the
switch in a clockwise direction, the operator selects low, medium or
high speed for the blower.
Heat Cable.
The HEAT cable (43) is located on top of the control panel below
the fan switch. This switch controls a water shutoff valve on the
engine which controls the flow of hot water from the engine cooling
system to the heater core.
Vent Cable.
The VENT cable (44) is located on the top of the control panel,
below the heat switch. The switch allows either fresh or recirculated
air to pass through the heater core and evaporator coils.
Air Conditioner Switch. (Optional.)

The A/C switch (45) is located on the top of the control panel below
the vent cable. This switch is a push, pull switch that turns the air
conditioner on or off and enables the operator to control the
temperature in the operator's cab.
FRONT HOIST BRAKE PEDAL.
The front hoist brake pedal (46) is located on the cab floor, on the
right side of the cab. The pedal is used to control the hoist brakes
during the hoist freefall mode of operation.
REAR HOIST BRAKE PEDAL.
The rear hoist brake pedal (47) is located on the cabfloor on the left
side of the cab. The pedal is used to control the hoist brakes during
the hoist freefall mode of operation.
HOIST ROTATION INDICATORS.
The hoist rotation indicators (48) are located on the top of each
hoist control lever. The indicators are electronically driven by a
signal from an electronic transmitter attached to each hoist frame.
A pulsating signal is sensed by the operator's thumb during
operation.
DOMELIGHT.
The domelight (49) is located in the center rear of the cab roof and
provides illumination of the cab. The light is controlled by a switch
on the light.
FIRE EXTINGUISHER.
The fire extinguisher (50) is mounted on the left side of the cab to
the rear of the operator's seat.
CRAWLER DRIVE PEDALS.
The crawler drive pedals (51 and 52) are located on the cab floor,
on the inner side of each hoist brake pedal. The pedals are used to
drive the crawler side frames.
360 DEGREE POSITIVE SWING LOCK.
The 360 degree positive swing lock (53) is located on the cab floor,
on the left side of the cab seat. The 360 degree positive swing lock
is used to lock the upperstructure in any position of the swing
rotation.
2-414
LINES AND LINE FUNCTIONS

SPRING
CYLINDER
ACTING
LINE, WORKING
w\
MISCELLANEOUS
SINGLE
ROTATING SHAFT
CYLINDER - DOUBLE
ACTING
DIFFERENTIAL
LINE, PILOT
MANUAL
LINE, DRAIN
-e
ENCLOSURE
NON-DIFFERENTIAL
<=L
i------------1
i
i________i
CONNECTOR
VALVES
LINE, FLEXIBLE
(HI
PUSH BUTTON
RESERVOIR
VENTED
CHECK
LINES JOINING
LINES PASSING
i____i
PUSH-PULL LEVER
ON-OFF
h
SHUT-OFF)
DIRECTION OF FLOW
(MANUAL
PRESSURIZED
ii
PEDAL OR TREADLE
LINE TO RESERVOIR ABOVE
FLUID LEVEL
PRESSURE RELIEF
PRESSURE GAUGE
BELOW FLUID LEVEL
CH
MECHANICAL
LINE
TO
MANIFOLD
PRESSURE REDUCING ELECTRIC MOTOR
VENTED
FLOW CONTROL,
ADJUSTABLE - NONCOMPENSATED
DETENT
FLOW CONTROL
ADJUSTABLE
(TEMPERATURE AND
PRESSURE
COMPENSATED)
PLUG OR PLUGGED
CONNECTION
RESTRICTION. FIXED PRESSURE
COMPENSATED
q=C
SOLENOID,SINGLE WINDING
REVERSING MOTOR
SINGLE,
VARIABLE
DISPLACEMENT
MOTOR, VARIABLE
DISPLACEMENT,
REVERSIBLE
?!
HEATER
it
TWO POSITION FOUR

CONNECTION
@k
COOLER
HE
THREE POSITION FOUR

CONNECTION
ACTUATORS
MOTOR,
FIXED
DISPLACEMENT
NON-REVERSIBLE
in
TWO POSITION THREE

CONNECTION
SINGLE,
FIXED
DISPLACEMENT
MOTOR, FIXED
DISPLACEMENT
REVERSIBLE
ACCUMULATOR, GAS CHARGED
TWO POSITION TWO

CONNECTION
RESTRICTION, VARIABLE
PUMPS
ACCUMULATOR, SPRING
LOADED
PILOT PRESSURE REMOTE

SUPPLY
INTERNAL SUPPLY
--C
TWO POSITION IN
TRANSITION
TEMPERATURE
CONTROLLER
SHE
VALVES CAPABLE OF INFINITE

FILTER, STRAINER
POSITIONING (HORIZONTAL
BARS INDICATE INFINITE
POSITIONING ABILITY)
ft
-o-
A.N.S.I. Graphical Symbols
6.
7.
If the pressure reading is greater than or less than 3300 psi (22,753.5
kPa/227.53 bar), install an alien wrench into the adjustment in RV2
and turn the adjustment clockwise to increase the pressure or 1.
counterclockwise to decrease.
Remove the alien wrench from the adjustment in RV2 and install the 2.
cap. Recheck the pressure reading.
3.
8.
Shut down the engine and remove the pressure guage.
9.
Install an alien wrench into the adjustment in valve RV1. Turn the
4.
adjustment counterclockwise approximately 1 1/2 turns.
CAUTION
5.
IF RV2 WAS ADJUSTED, RV1 MUST ALSO BE

ADJUSTED BY REFERRING TO, SETTING RV1 IN
THIS SECTION.
6.
Setting RV1 in M5.

1.
2.
3.
Setting RDV1 in M8.

Drain the control accumulator using the valve knob in M5. Close the
valve knob.
Install a 0 to 1000 psi (0 to 6895 kPa/0 to 68.95 bar) pressure gauge
into the test fitting in port P2 of M8.
Loosen and remove the cap on the end of the valve cartridge in port
RDV1.
Start the engine and set the throttle to FULL.
Observe the gauge for a reading of 800 psi (5516 kPa/55.16 bar).
If the pressure gauge reading is greater than or less than 800 psi
(5516 kPa/55.1 6 bar), install an alien wrench into the adjustment in
RDV1 and turn the adjustment clockwise to increase pressure or
counterclockwise to reduce pressure until the gauge reads 800 psi
(5516 kPa/
55.16
bar).
Drain the control accumulator using the valve knob in M5. Close the
7.
valve knob. Install a test fitting in M5 port TP2.
Remove the alien wrench from the adjustment in RDV1 and install the
cap. Recheck the pressure reading on the gauge to ensure a reading
Install a 0 to 5000 psi (0 to 34,475 kPa/0 to 344.75 bar) pressure
of 800 psi (5516 kPa/
gauge into the test fitting in port TP2 of M5.
55.16
bar).
Start the engine and set the throttle at FUlsL. Observe the gauge, 8.
pressure should level off at 3000 psi (20,685 kPa/206.85 bar).
Shut down the engine and remove the pressure gauge.

HORSEPOWER LIMITING CIRCUIT.
Two pressure settings in the horsepower limiting circuit must be
checked and set if necessary. There are the 250 psi (1723.75
kPa/17.23 bar) relief valve in RV1 and the flow control valve in port
FC.
Setting RV1 in M17.
1.
Install a 0 to 500 psi (0 to 3447.5 kPa/0 to 34.5 bar) pressure gauge in

port TP on valve body M17.
i
4. If pressure does not reach 3000 psi (20,685 kPa/

206.85
bar), loosen the jam nut on RV1 and install an alien wrench
in the adjustment slot. Turn the adjustment clockwise slightly until the
pressure reading on the gauge levels off to 3000 psi (20,685
kPa/206.85 bar).
5. If the pressure exceeds 3000 psi (20,685 kPa/206.85 bar), turn the
adjustment counterclockwise until pressure read on the gauge levels
off to 3000 psi (20,685 kPa/
206.85
bar).
6.
Tighten the jam nut and recheck the pressure.
7.
Shut down the engine. Remove the gauge.
2.
Start the engine and position the throttle to the MID position. Observe
the pressure gauge for a reading of 250 psi (1723.75 kPa/17.23 bar).
3.
4.
If the pressure reading on the gauge is greater than or les? than 250 4.
psi (1 723.75 kPa/17.23), loosen and remove the cap on the cartridge
valve in port RV. Install an alien wrench into the adjustment in valve
RV and turn the adjustment clockwise to increase the pressure or
counterclockwise to decrease the pressure until the pressure gauge
reads 250 psi (1 723.75 kPa/1 7.23 bar).
Shut down the engine and remove the pressure gauge from the M17
valve body. Install the cap on the cartridge valve in port RV.
Setting the Flow Control Valve.
Shut down the engine and remove the pressure gauge from the M17
valve body.
POR ADJUSTMENT.
The pressure override (POR) adjustment will now be set on the front
hoist pump (P3), the rear hoist pump (P1), and the boom hoist pump
(P2). The front and rear hoist brake pedals will be applied while
hoisting up to set the POR on pumps P1 and P3. To set the POR on
the boom hoist pump, P2, the solenoid coil on the boom hoist brake
release solenoid must be removed.
1.
Install a 0 to 500 psi (0 to 3447.5 kPa/0 to 34.5 bar) pressure gauge

into port TP on valve body M1 7.
WARNING
2.
Start the engine and position the throttle to the FULL position. Observe
the pressure gauge for a reading of 215 psi (1482.4 kPa.14.82 bar).
ENSURETHE ENGINE IS SHUTDOWN BEFORE

INSTALLING PRESSURE GAUGES IN ANY VALVE
BODIES.
Rear Hoist POR Setting.
1.
Install a 0 to 10,000 psi (0 to 68,950 kPa/0 to 689.5

bar)
pressure gauge into the M3 valve body on the rear
hoist motor. Use M3-R port TP6.
2.
Locate the POR on top the HDC on pump P1.
3.
Loosen the jam nut on the POR adjustment which is on the opposite
end of the hoses which install to the POR.
CAUTION
WHEN CHECKING OR SETTING HOIST POR
SETTING, DO NOT PUSH THE HRC FORWARD,
PULL BACK ON THE HRC FOR AN ACCURATE
READING.
3.
If the pressure reading on the gauge is greater than or less than 215
psi (1482.4 kPa/14.82 bar), move the adjustment on the flow control
valve clockwise to increase the pressure or counterclockwise to
decrease the pressure until the pressure gauge reads 215 psi (1482.4
kPa/ 14.82 bar).
4.
Start the engine and position the throttle to FULL. Place one foot on
the rear hoist brake pedal on the cab floor and pull back on the rear
hoist HRC. Observe the pressure gauge in M3-R for a reading of 5000
psi (34,475 kPa/
344.75
bar).
2-4-5
0339
POR Adjustment - Front, Rear, and Boom Hoists

NOTE
1.
The POR must be adjusted with the

engine running at full throttle, the
rear hoist brake pedal applied, and
the rear hoist HRC pulled
back.
Install a Oto 10,000 psi (Oto 68,950 kPa/0 to 689.5

bar) into M3 valve body on the front hoist motor.
Use M3-F port TP6.
2.

Loosen the jam nut on the POR adjustment which is
on the opposite end of the hoses.
5.
If the pressure reading is less than or greater than

5000 psi (34,475 kPa/344.75 bar), install an alien
wrench into the adjustment on the POR and
increase the pressure by turning the adjustment
clockwise or decrease the pressure by turning the
adjustment counterclockwise until the pressure
reading on the gauge is 5000 psi (34,475 kPa/
344.75
bar).
6.
Tighten the jam nut on the POR adjustment and observe the gauge to ensure a reading of 5000 psi
(34,475 kPa/344.75 bar).
7.
Shut down the engine and remove the pressure

gauge from the M3 valve body on the rear hoist
motor.
Front Hoist POR Setting.
CAUTION
CAUTION
6.
Shut down the engine and remove the pressure

gauge from the M3-F valve body on the front hoist
WHEN CHECKING OR SETTING

THE HOIST POR SETTING, DO NOT
PUSH THE HRC FORWARD, PULL
BACK ON THE HRC FOR AN
motor.
Boom Hoist POR Setting.
4. Start the engine and position the throttle to FULL. Observe the pressure gauge in the B line of the boom hoist
circuit for a reading of 5500 psi (37,922.5 kPa/379.22 bar).
ACCURATE READING.
3.
1.
Loosen and remove the nut that secures the

solenoid coil to the boom hoist brake release
solenoid valve. If this valve is difficult to locate,
trace the hose from the boom hoist brake which is
bolted directly to the boom hoist gearbox.
2.
Install a 0 to 1 0,000 psi (Oto 68,950 kPa/Oto 689.5

bar) pressure gauge into the B line on the pump
(P2) or the boom hoist motor.
3.

Loosen the jam nut on the POR adjustment which
is on the opposite end of the hoses.
WHEN CHECKING OR SETTING
THE BOOM HOIST POR SETTING,
DO
NOT
PUSH
THE
HRC
FORWARD, PULL BACK FOR AN
ACCURATE READING.
Start the engine and position the throttle to FULL.

Apply the front hoist brake pedal and pull back on
the front hoist HRC. Observe the pressure gauge in
M3-F for a reading of 5000 psi (34,475 kPa/344.75
bar).
NOTE
front hoist brake pedal applied, and
the front hoist HRC pulled back to
hoist up.
4.

5000psi (34,475 kPa/344.75 bar), install an alien
increase the pressure by turning the adjustment
reading on the gauge is 5000 psi (34,475 kPa/
344.75
bar).
5.
NOTE
solenoid coil on the boom hoist
brake release valve removed, and
the boom hoist HRC pulled back to
boom up.
(34,475 kPa/344.75 bar).
5.

5500 psi (37,922.5 kPa/379.22 bar), install an alien
2-4-7
increase the pressure by turning the adjustment 6.

reading on the gauge is 5500 psi (37,922.5
7.
kPa/379.22 bar).
(37,922.5 kPa/379.22 bar.
Shut down the engine and remove the gauge from
the B line of the boom hoist circuit.
8.
Install the solenoid coil to the boom hoist brake release valve using the nut.
Valve Body M4.

INSTALLATION.
NOTE
1.
All components must be installed

to their correct ports as marked
during disassembly.
Cap all fittings to prevent contamination.
1.
2.
3.
CAUTION
ENSURE THE MATING SURFACES
OF THE VALVE BODIES ARE
CLEAN.
Install all plugs to the M4 valve body as marked

during removal.
2.
Remove the pipe plug (13) from port F. Install the
plug (14) into the inner bore of port F. Install the pipe
plug (13) into port F.
3.
Remove the pipe plug (13) from port G. Install the
plug (14) into the inner bore of port F. Install the pipe 4.
plug (13) into port G.
4.
5.
Remove the plug (11) from port R2. Install the orifice 5.
plug (12) into the inner bore of port R2. Install the
plug (11) into port R2.
Install the orifice plug (10), connector (9), 90 degree
6.
fitting (8), and the pressure switch (7) into port TP11.
6.
7.
8.
Install the valve cartridge plug (6) into port PV2.
7.
Install the valve cartridge plugs (5) into ports SV4,

PV1,
and PV3.
Install the valve cartridges (4) into ports SV1 and
SV3.
9.
Lubricate and install new O-rings to all the mating

ports of the M3 and M4 valve bodies.
Install the M3 valve body to the M4 valve body using

the ten bolts and washers.
Lubricate and install new O-rings in the five ports on
the M3 valve body that will mate with the hoist motor.
Attach a suitable lifting device to the M3/M4 valve
body.
Remove the plugs from the ports in the hoist motor.
Ensure the hoist motor mating surface is clean.
Lift and install the valve body to the hoist motor
using the six bolts and washers. Torque the bolts to
1 70 pounds- foot (23.5 kgm).
Install the three solenoid coils to the valve cartridges
as marked during removal. Install the solenoid coil to
the valve cartridge in the hoist port valve. Install the
nut that secures each solenoid coil.
8.
Install all electrical lines as marked during removal.
9.
Install all hydraulic lines to the M3/M4 valve body as

marked during removal.
Install the valve cartridge (3) into port SV2.

NOTE
All O-rings must be replaced with new 90 durometer O-rings. Lightly lubricate new O- rings
with clean petroleum jelly.
CLEANING AND INSPECTION.

1.
Clean all the parts in a suitable solvent.

1 0. Lubricate and install a new O-ring (35) into the
outer groove of the locator plate (33). Lubricate and
install a new 0-ring (34) into the inner bore of the
locator plate (33).
2.
Submerge the valve bodies in a suitable solvent and

11. Install the locator plate (33) onto
the M3 valve body (1).
agitate gently to flush contaminates from the internal Secure the locator plate (33) to the valve body by
installing ports. Blow dry with filtered air.
the bolt (32).
3.
It is recommended that all O-rings be replaced with

body (1) that mates
new 90 durometer O-rings. Lightly lubricate all new Othe five cartridge valves
rings with clean petroleum jelly.
4.
5.
6.
Inspect the ports on the valve bodies

poppet (31) into the port
threads, burrs, scratches, and contaminates.
away from the valve
12. Locate the face of the M3 valve

with the M4 valve body (20). Install
into the five large ports as follows.
for damaged
a.
Install the valve cartridge
with the spring end pointing outward,
body (1).
Inspect all fittings and internal components for damaged threads, burrs, and scratches. b.
Lubricate
and install a new O-ring (30) and a new
backup ring (29) into the outer
groove of the valve spacer
Replace all damaged components.
(27).
ASSEMBLY.
(27) into the port with the
c.
Install the valve spacer
deeper counterbore end installed

a new O-ring (28) into the inner
first. Lubricate and install Valve Body M3.

bore of the valve spacer
(27).
NOTE
d. Repeat this procedure for the four remaining
ports,
All components must be installed to their

correct ports as marked during disassembly.
Cap all fittings to prevent contamination.
port PP3.
13. Install the straight fitting (26) into
1. Install all plugs into the M3 valve body as marked during removal.
14. Install the orifice plug (25) into the inner bore of port . Install
CV1 the valve cartridge (24) into port CV1.
2.
Install the fitting (21) into port D4.
15.
Install the hot oil shuttle valve (23) into port PSH1.
3.
Install the straight fitting (49) into port PP2.
16.
Install the shuttle valve (22) into port SHV1.
4.
Install the relief valve cartridge (48) into port RV1.
17.
Install the 90 degree fitting (21) into port D.
5.
Install the fitting (47) into port D3.
18.
Install the test fitting (20) into port TP6.
2-4-8
6.
Install the tube (46) into the fitting in port D3.
19.
Install the check valve cartridge (19) into port CV3.
7.
Install the test fitting (20) from port TP4.
20.
Install the 90 degree fitting (1 8) into port F.
8.
Install the test fitting (44) into port PS and the fitting
21.
Install the straight fitting (1 6) into the open port closest
(45) into port D on the hoist port valve (37). Install the
to port F. Install the 90degree fitting
(17) into the open port

connector (43), fitting (42), and the pressure switch (41)
closest to port PS1. Install the tube
(15) that connects to

into the hoist port valve (37). Install the valve cartridge (40)
fittings (1 6) and (17).
into port SV on the hoist port valve (37).

9.
Mount the hoist port valve (37) to

the M3 valve body (1) using the four
bolts (36) installed through the
flange halves (38), through the hoist
port valve (37) and into the M3
valve body.
Brake Valve Body M10

DESCRIPTION
The front (M10-F) and rear (M10-R) brake valve

bodies are located on the hoist frames just below
the M3/M4 valve bodies. The brake valve bodies
each contain five solenoid valves, two velocity
fuses, and the manual drain valve for the hoist
accumulator. These five solenoids energize to

release the caliper brakes and the pawl. These
solenoids are not independantly energized, they are
all energized or all deenergized.
MAINTENANCE
REMOVAL
1.
2.
4.
Discharge the control accumulator by turning the

manual rotary valve knob on the control
accumulator manifold counterclockwise until
pressure is relieved. Discharge both hoist
accummulators by turning the manual rotary valve
knob on M10-F and M10-R counterclockwise until
pressure is relieved.
DISASSEMBLY.
NOTE
Tag and remove all hydraulic lines that connect to

the brake valve body. Cap all hoses and tubes and
plug all open ports.
CAUTION
TAG THE SOLENOID COILS WITH
THE CORRECT PORT PRIOR TO
REMOVAL
3.
Loosen and remove the three nuts and

lockwashers that secure the brake valve to the hoist
frame. Remove the brake valve body.
1.
2.
Tag and remove the solenoid coils in ports SV1 thru

3.
SV5 by removing the nut that secures each
solenoid coil and pulling the solenoid coils straight 4.
off.
As each component is removed

from the valve body, it must be
tagged with the number/letter of the
port that the component was
removed from. This will be the only
means of identifying components
during assembly.
Loosen and remove the test fitting (22) from
portTP2.
Remove the plug (5) from the port nearest port TP9.
Remove the recessed plug (11) from the open port.
Remove the recessed plug (11) from within port P6.
Remove the fitting (21) from port A1.
5.
Remove the drain cartridge valve (1 3) from port

DV1. Remove the recessed O-ring (18) and the
orifice plug (20) within port DV1.
6.
Remove the fitting (6) from port P2 and the fitting (6)
from port P1.
7.
Remove the fitting (6) from port P4.
8.
Loosen and remove the 45 degree fitting (15) from

port PP2.
9.
Remove the valve cartridge (4) from port DV2.
1 0. Loosen and remove the test fitting (22) from

portTP3.
Remove the recessed plug (11) within port TP3.
11. Remove the velocity fuses (10) from ports VF1 and
VF2.
1 2. Remove the valve cartridges (4) from ports
CV3 and CV5. Remove the recessed plug (11)
within port CV5.
13. Remove the valve cartridges (7) from ports SV'1
and SV3. Remove the O-ring (18) and the orifice
plug (19) within these ports.
2-4-10
2-4-9
Hoist Valve Condition Table
Energized
Low Speed
High Speed
Freefall
None
SV1
SV2, SV3
Solenoids
Deenergized
Pressurized
Poppet Valves
Vented
SV1, SV2, SV3

SV2, SV3
*SV1 can be energized or deenergized

cylinders while exhausting the other will
move the pump swashplate from its'
neutral position and create a high and low
pressure line in the pump. When hoisting
up, the A line exiting the pump becomes
the high pressure line while the B line
entering the pump becomes the low
pressure line.
High pressure in line A exiting the pump
enters valve body M3-R port A. This high
pressure oil entering M3-R must pass
through one poppet valve V3 for high
speed hoisting and two poppet valves V3
and V4 for low speed hoisting. These
poppet valves must be vented in order to
allow the high pressure oil to enter the
motor. There are five poppet valves within
M3-R that are either vented or
pressurized according to the mode of
hoisting
selected.
Energizing
or
deenergizing three solenoids SV1, SV2,
and SV3 are the means by which these
poppets are vented or pressurized. Refer
to the Hoist Valve Condition Table for the
condition of these poppets and solenoids
according to the selected mode of
operation.
Low pressure exiting the motor must pass
through the V2 poppet in order to return to
the B port on the pump. High pressure
entering M3-R shifts a shuttle valve PSH1
and allows some low pressure to be
routed internally to a 225 psi (1551.3
kPa/15.5 bar) pressure reducing valve,
RV1. Oil exiting RV1 is routed to the
motor casing for cooling purposes.
V2, V3, V4
V2.V3.V5
*V1.V4.V5
V1,V5
V1.V4
V2, V3
HOISTING DOWN (REAR HOIST).

>
When the rear hoist lever (HRC) is
pushed forward to hoist down, control
pressure is routed out port D1 of the HRC
and enters port D1 of valve body M7
under the cab. Control pressure within M7
actuates a 75 psi (51 7.1 kPa/5.2 bar)
pressure switch PS 9-7 which releases
the rear hoist caliper brakes and pawl.
Control pressure exits M7 port D11 and
enters port 4 of the rear hoist pump P1.
Control pressure within the rear hoist
pump shifts a spool on the hydraulic
displacement control valve (HDC) and
allows charge pressure to enter one of the
pumps' servo cylinders to stroke the
pump.
When hoisting down, the A line is still the
high pressure line but directional flow is
now from the motor to the pump. This is
because the weight of the load exerts a
force on the motor which now acts as a
pump. The pump meters the flow of oil
from the A line to the B line which flows to
the motor as low pressure. This high
pressure oil exiting the motor must pass
through one poppet valve V3 when in the
high speed mode and two poppets V3
and V4 in the low speed mode. Prior to
entering the motor, low pressure from the
pump must pass through one poppet
valve V2. Refer to the Hoist Valve
Condition Table for the condition of these
poppet valves and their associated
solenoid valves.
High pressure oil within M3-R shifts a
shuttle valve PSH1 and allows some low
pressure in the B line to be routed to a
225 psi (1551.3 kPa/15.5 bar) pressure
reducing valve RV1. Oil exiting RV1 is
routed to the motor casing for cooling
purposes.
MAINTENANCE
REMOVAL.
the
1.
hoist
Disconnect
cable
from
block.
the
hook
Re
move the cable
from the hoist.
NOTE
.J
'/
T
h
e
m
a
i
n
t
e
n
a
n
c
e
p
r
o
c
e
d
u
r
e
f
o
r
t
h
e
f
r
o
n
t
a
n
d
r
e
a
r
h
o
i
s
t
s
i
s
i
d
e
n
t
i
c
a
l
.
2.
3.
4.
5.
6.
Discharge the hoist accumulators by turning the manual rotary 1.

valve knob on the accumulator manifold counterclockwise until
pressure is relieved. Discharge the control accumulator by turning
the manual rotary valve knob on the control accumulator manifold 2.
counterclockwise until pressure is relieved.
3.
Position the hoist on a flat working surface so the hydraulic motor is

pointing upward. Block, as necessary, to ensure the hoist is
properly supported and balanced.
Attach a suitable lifting device to the hydraulic motor.
Disconnect the pawl by removing the cotter key and the pin from
the spring loaded cylinder. Disconnect the rotation indicator
4.
transmitter by removing the two bolts and lockwashers.
hydraulic motor to the hoist drum weldment.
Remove the caliper assembly from the arm on the hoist frame by
5.
referring to Front and Rear Hoist Brake - REMOVAL, steps 3 thru
8, in this Section.
Loosen and remove the 24 bolts and flat washers that attach the
Lift off the hydraulic motor and place it on a flat work bench with
the valve assembly end pointing upward.
Loosen and remove the six bolts and flat washers that attach the
hoist valve assembly to the hydraulic motor.
Tag and disconnect all hydraulic hoses and tubes on the hoist 6.
valve assembly. Discard the O-rings in the two large'tubes.
Remove the hose on the hydraulic accumulator.
7.
Attach a suitable lifting device to the valve assembly and lift the
valve assembly straight up to remove it. Discard all O-rings.
Plug all open ports and cap all hoses and tubes.
contamination.
Plug all open ports on the valve assembly to prevent
CAUTION
8.
Attach a suitable lifting device to the motor hub weldment block.
THE SOLENOID COILS MUST BE CORRECTLY

TAGGED TO ENSURE THEY ARE INSTALLED IN
THEIR
ORIGINAL
POSITION
DURING
INSTALLATION.
9.
Remove the motor hub weldment block by lifting straight up while

tapping with a soft-faced hammer.
10. Remove the two keys from the hydraulic motor.
7.
Tag and remove all the solenoid coils from the valve bodies by 11. Rotate the hoist drum 1 80 degrees using a suitable
lifting device
so the brake disc is facing upward.
removing the nuts on the end of the solenoid and pulling the
solenoid coils straight out.
12. Loosen
and remove the four bolts that secure the
8.
Attach a suitable lifting device to the hoist.
9.
Loosen and remove the two bolts and flat washers from each of the
shaft end cap to the disc. Remove the cap.

NOTE
hub bearing blocks.
The brake disc weighs approximately 255 pounds

(116 kg).
NOTE
The hoist weighs approxiamtely 4000 pounds
(1818 kg).
10.
Lift the hoist straight up using the lifting device.

DISASSEMBLY.
13. Attach
a suitable lifting device to the brake
14. Lift the
brake disc off the hoist drum shaft.
1 5. Remove the outer seal from the bearing block.

16. Press the bearing block from the hoist drum.
1 7. Remove the remaining seal from the bearing block.
1 8. Press the bearing from the bearing block.
disc.
VALVE BODY LOCATION TABLE (continued)

Physical Location
Located on the rear hoist frame below valve bodies M3R
and M4R on the right side of the upperstructure.
Located inside the upperstructure frame on the left hand
Valve Body
Circuit Used In
M10R
Rear Hoist Brakes

and Brake Pawl
M13
Distribution
M16
Swivel
M17
Horsepower
Limiter
side plate towards the bottom of the upperstructure.

Located at the center of rotation and bolted to the crawler
undercarriage.
Located behind the pumps access door which is on the
right side of the upperstructure. The horsepower limiter
valve body is mounted to a bracket that is mounted on top
of the pump drive. The valve body is located directly to the
right of the valve body M1.
Secured to valve bodies M3F and M3R and also mounted
to the inlet hydraulic line going to the hoist.
Located on the left side of the upperstructure and is
secured to the underside of the frame channel.
M19
M20
M21
Front and Rear

Hoist (inlet line)
Adapter
Reservoir Return
Located on the left side of the upperstructure behind

the access doors. It is inline in the return to reservoir
line and is mounted directly to the reservoir.
MAINTENANCE
M1
VALVE
BODY.
Removal
.
1.
Dischar
ge
the
control
accumul
ator by
turning
the
manual
rotary
valve
knob on
the
control
accumul
ator
valve
body
counterc
lockwise
until
pressure
is
relieved.
CAUTIO
N
D
U
R
I
N
G
R
E
M
O
V
A
L
O
F
A
N
Y
C
O
M
P
O
N
E
N
T
S
O
R
A
F
T
E
R
B
R
E
A
K
I
N
G
A
N
Y
C
O
N
N
E
C
T
I
O
N
S
,
A
L
L
lines that
attach to
the
P
O
R
T
S
valve
body.
Plug
ports
and cap
all
hoses.
3.
S
H
O
U
L
D
B
E
P
L
U
4.
G
G
E
D
O
R
C
A
P
P
E
D
.
2.
Tag and
disconne 5.
ct
all
hydraulic
all
open
A
N
D
H
O
S
E
S
M1
Loosen
and
remove
the jam
nut that
secures
the
solenoid
coil
to
the valve
cartridge
in port
SV. Pull
the
solenoid
coil
off
the
cartridge.
Loosen
and
remove
the three
nuts and
washers
that
attach
M1
to
the
bracket
on
the
rear
of
the
upperstr
ucture.
Remove
M1 from
the
upperstr 5.
ucture
and
place on
a clean
workben
ch
for
disasse
mbly.
Disasse
mbly.
1.
Loosen
6.
and
remove
the
straight
fittings
(9) from
ports C,
E, H, A,
and D.
2.
Remove
the
connecto
r (7) from
port G.
3.
Remove
the
test
Clean all
the parts
in
a
suitable
solvent.
2.
Submerg
e
the
valve
body in
a
suitable
solvent
and
agitate
gently to
flush
any
contami
nants
from
within
the
block.
Remove
from port
and the
plug
(12) from
port PS.
4.
Remove
the
90
degree
fitting
(11) from
port
T
and the
check
valve
cartridge
(1
0)
from port
CV.
Remove
the plug
(2) from
port R.
Remove
the recessed
orifice
plug (3)
from
within
port R.
Cleanin
g
and
Inspecti
on.
1.
fitting (8)
TP
Loosen
and
remove
the
connect
or
(4)
from port
B
and
the valve
cartridge
(5) from
port SV.
the
2.
block
and
blow dry
with air.
3.
or
(5)
3.
scratche
or
contami
nants.
into
port SV.
thread
burrs,
and
cartridge
body for
damage,
(4)
into port
valve
the
valve
4.
connect
the
all ports
s,
the
Inspect
on
Install
:*
Inspect
all
fittings,
plugs,
valves,
and
Install
the
check
valve
cartridge
(10) into
port CV
and the
90
degree
fitting
(11) into
port T.
switches
for
4.
Install
thread
the plug
damage.
(1
2)
into port
5.
Replace
all
defective
compon
ents.
Assemb
ly.
1.
PS and
the test
fitting (8)
into port
TP.
5.
Install
the
orifice
plug (3)
6.
within
the
recesse
d area
of port
R. Install
the plug
(2) into
port R.
Install the
connect
or
(7)
into port
G.
Install the
straight
fittings
(9)
into
ports
E, H, A,
and
D.
Installat
ion.
1.
2.
Install the
M1 valve
body to
the
bracket
on
the
rear of
the
upperstr
ucture
using
the three
3.
washers
and
nuts.
Install
the
solenoid
coil
to
the
valve
cartridge
in port
SV.
Install
the jam
nut that
secures
the coil.
Install all
hydrauli
c
marked
during
removal.
Valve Body Plug

Orifice Plug
Connector
Valve Cartridge
Fitting
Connector
Test Fitting
Straight Fitting
Check Valve Cartridge
90 Degree Fitting
Plug
M1 Valve Body
lines
to M1 as
/M4 VALVE BODIES.
7.
Remove all remaining plugs from the valve body (2).

Remove the cartridge
valve (9) from port RV1, the
test ting (10) from port TP1,
and the accumulator drain
valve ) from port D.
maintenance instructions
refer to M3/M4 Valve Bo- s
in Section 7 - HOISTS.
i VALVE BODY.
Loosen and remove the
moval.
cartridge valve (5) from port

Discharge the control
accumulator by turning the
nual rotary valve knob on
the control accumulator
valve fy counterclockwise
until pressure is relieved.
AUTION
DURING
REMOVAL OF
ANY COMPONENTS OR
AFTER
BREAKING ANY
CONNECTIONS,
ALL PORTS
AND HOSES
SHOULD BE
PLUGGED OR
CAPPED.

control accumulator (1 ) from
ie valve body (2). Remove
the connector (11) from the
ccumulator (1) and discard
the O-ring (12).
Cleaning and Inspection.
2.
Submerge the valve body in

a suitable solvent and
agitate gently to flush any
contaminants from within the
block. Remove the block and
blow dry with air.

check valve (7) from port
CV1 id the 90 degree fitting
(3) from port FM.
1.
straight
fitting (4) from port T and

the 90 igree fitting (3) from
port CTR.
Remove the unloader

valve (6) from port PV1.
Clean all the parts in a

suitable solvent.
Loosen and remove the3.

four nuts and washers
that
:ach
the
control
accumulator assembly to
the upperstruc- re frame.
Remove the M5 valve body4.
from the upper- ucture and
place it on a clean
workbench for disassem- l.
5.
sassembly.
the
(3) from port P1.
1.
Tag and remove all

hoses that attach to the M5
valve dy. Cap all hoses and
plug all open ports.
Remove
\J2 and the 90 degree fitting
Inspectall
portsonthevalvebodyforthrea
ddamage, burrs, scratches,
or contaminants.
Inspect all fittings, plugs,
valves,
and
switches
for
thread damage.
Replace
all
defective
components.
Assembly.
Install all plugs to the valve
body (2).
fitting (10) into port TP1, and

2.
Install the connector (11) to
(I)
the control accumulator

. Lubricate and install a new7.
O-ring (1 2) to the connector
(II)
3.
Install
the
control
8.
accumulator assembly into
the valve body (2).
4.
Install the unloader valve (6)

into port PV1.
5.
Install the 90 degree fitting (3)

1.
into port P1
and the
cartridge valve (5) into port
RV2.
6.
Install the accumulator drain

valve (8) into port D, the test
the cartridge valve (9) into

port RV1.
Install the 90 degree fitting
(3) into port CTR and the
straight fitting (4) into port T.
Install the 90 degree fitting
(3) into port CTR and the
check valve (7) into port
CV1.
Installation.
Install
the
control
accumulator assembly (M5)
to the four bolts on the rear
inside of the upperstructure
frame using four nuts and
washers.
Control Accumulator Valve

Body 90 Degree Fitting
Straight Fitting Relief Valve
RV2 Unloader Valve PV1
Check Valve CV1
Accumulator Drain Valve
Cartridge Valve RV1 Test
Fitting Connector O-Ring
18
-
..
2.
3.
M5 Valve Body
Install all hoses to the M5 valve body as
marked during removal.
Close the accumulator drain valve.
0330
M6 VALVE BODY.
Removal.
1.
Discharge the control accumulator by turning

the manual rotary valve knob on the control
accumulator valve body counterclockwise 3.

CAUTION
DURING REMOVAL OF ANY
COMPONENTS OR AFTER
BREAKING
ANY
CONNECTIONS, ALL PORTS AND
HOSES
SHOULD
BE
PLUGGED OR CAPPED.
2.
2-4-86
' Tag and remove all hoses and tubes that

connect to the M6 valve body. Discard all Orings. Plug all open ports and cap all hoses.
Loosen and remove the nut that secures the

solenoid coil to the cartridge valve in port
SV1. Remove the coil.
4.
Tag and remove all electrical wires that

connect to the switches in port TS1, TS2,
and TS3.
5.
Loosen and remove the two bolts and

washers that secure the M6 valve body to the
oil cooler frame. Remove M6 and place it on
a clean workbench for disassembly.
Disassembly.
1.
2.
3.
4.
Loosen and remove the temperature switch 5.

(7) from port TS3 and the cartridge valve (8)
from port FV1.
Remove the temperature switch (2) from
portTSI, the cartridge valve (3)from port SV1, 1.
and the cartridge valves (4 and 5) from ports
2.
PV1 and RV1.
Loosen and remove the temperature switch
(11)from port TS2 and the 90 degree fitting
(10) from port P2.
Loosen and remove the 90degreefitting (6)
from port A and the 90 degree fitting (9) from
port P1.
3.
Remove the screw (12) from within port C.

Remove the slider valve (13) and the spring
(14) from the screw (12).
Cleaning and Inspection.
Submerge the valve body in a suitable
solvent and agitate gently to flush any
contaminants from within the block. Remove
the block and blow dry with air.
Inspect all ports on the manifold block for
thread damage, burrs, scratches, or
contaminants.
4.
Inspect all fittings, plugs, valves, and 3.

switches for thread damage.
5.
Replace all defective components.
4.
Install the 90degreefitting (9) into port P1

andthe90 degree fitting (6) into port A.
Install the temperature switch (11) into port
TS2 and the 90 degree fitting (10) into port
Assembly.
P2.
1.
Install the slider valve (13) and the spring 5.

(14) onto the screw (12).
2.
Apply Loctite 242 to the threads of the screw

(12). Install the screw into port C of the valve
body (1). Tighten the screw until it bottoms 6.
out.
Install cartridge valves (4 and 5) into ports

PV1 and RV1, cartridge valve (3) into port
SV1, and the temperature switch (2) into port
TS1.
Install the cartridge valve (8) into port FV1
and the temperature switch (7) into port TS3.
Installation.
2-4-88
1.
2.
Install the M6 valve body to the oil cooler 3.

frame using the two bolts and washers.
Install all electrical wires to the switches in
ports TS1, TS2, and TS3 as marked during
removal.
Install the solenoid coil to the cartridge valve

in port SV1 and secure it using the jam nut.
2487
Valve
Body
Tem
perat
ure
Swit
ch
Cartr
idge
Valve
Cartr
idge
Valve
Cartr
idge
Valve
90
Degr
ee
Fittin
g
Tem
perat
ure
Swit
ch
Cartr
idge
Valve
90
Degr
ee
Fittin
g 90
Degr
ee
Fittin
g
Tem
perat
ure
Swit
ch
Scre
w
Slide
r
Valve
Sprin
g
MgM
4.
5.
M6 Valve Body
Lubri
rotary
cate
valve
and
knob
install
on
new
the
Ocontr
rings
ol
to the
accu
tubes
mulat
that
or
attach
valve
to
body
M6.
count
ercloc
Instal
kwise
l
all
until
hoses
press
and
ure is
tubes
reliev
to the
ed.
M6
valve
body
as
mark
ed
durin
g
remo
val.
M7
VALV
E
BOD
Y.
Rem
oval.
1.
0342
Disch
arge
the
contr
ol
accu
mulat
or by
turnin
g the
manu
al
CAUT
ION
D
U
R
I
N
G
R
E
M
O
V
A
L
O
F
A
N
Y
C
O
M
P
O
N
R
T
S
E
N
T
S
A
N
D
O
R
A
F
T
E
R
B
R
E
A
K
I
N
G
A
N
Y
C
O
N
N
E
C
T
I
O
N
S
, 2.
A
L
L
P
O
H
O
S
E
S
S
H
O
U
L
D
B
E
P
L
U
G
G
E
D
O
R
C
A
P
P
E
D
.
Tag
and
remo
ve all
hoses
and
tubes
that
conne
ct to
the
M7
valve
body.
Plug
all
open
ports
and
cap
all
hoses
.
3.
Loos
en
and
remo
ve the
three
bolts,
nuts,
and
flatwash
ers
that
secur
e M7
to the
cab
floor.
Remo
ve
valve
body
M7
and
place
it on a
clean
workb
ench
for
disas
sembly.
Disas
semb
ly.
NOTE
A
s
e
a
c
h
c
o
m
p
o
n
e
n
t
i
s
r
e
m
o
v
e
d
f
r
o
m
t
h
e
v
a
l
v
e
b
o
d
y
,
i
t
m
u
s
t
b
e
t
a
g
g
e
d
w
i
t
h
t
h
e
n
u
m
b
e
r
/
l
e
t
t
e
r
o
f
t
h
e
p
o
r
t
t
h
a
t
t
h
e
c
o
m
p
o
n
e
n
t
w
a
s
r
e
m
o
v
e
d
f
r
o
m
.
T
h
i
s
w
i
l
l
b
e
t
h
e
o
n
l
y
m
e 1.
a
n
s
o
f
i
d
e
n
t
i
f
y
i
n
g
t
h
2.
e
c
o
m
p
o
n
e
n
t
s
d
u 3.
r
i
n
g
a
s
s
e
m
b
l
y
.
Loos
en
and
remo
vethe
90
degre
e
fitting
(2) in
portT
3 and
the
straig
ht
fitting
(3)
from
port
P3.
Rem
ove
the
fitting
s (4)
from
ports
PS3,
PS4,
PS6,
PS7,
PS9,
and
PS10.
Loos
en
and
remo
ve the
check
valve
cartri
dges
(5)
from
port
CV1
and
CV2.
4.
5.
6.
7.
Loos
en
and
remo
ve the
straig
ht
fitting
s (6)
from
port
E21,
A21,
C11,
D11,
D21,
A11,
C21, 8.
and
E11.
Rem
ove
the
cartri
dge
valve
plugs
(7)
from
ports
SV1
and
SV2.
Loos
en
and
remo
vethe
flow
valve
s (8)
from
ports
FV1
and
FV2.
Remo
vethe
straig
ht
fitting
s (9)
from
ports
T1,
T2,
A2,
E2,
D2,
A1,
C2,
D1,
C1,
E1,
P2,
and
P1.
Rem
ove
all
remai
ning
plugs
from
the
valve
body
(1).
Clea
ning
and
Inspe
blow
ction
dry
with
.
1.
air.
Clean
3.
all the
parts
in
suitab
le
solve
nt.
2.
Subm
erge
the
valve
body
in
4.
Inspe
ct all
suita
fitting
ble
s,
solve
plugs
nt
and
valve
agitat
s,
and
gentl
y
Inspe
ct all
ports
on
the
manif
old
block
for
threa
d
dama
ge,
burrs,
scrat
ches,
or
conta
mina
nts.
switc
to
hes
flush
for
any
threa
conta
mina
dama
nts
ge.
from
within
5.
Repl
the
block.
ace
Rem
ove
all
the
block
and
defect
ive
comp
onent
s.
Asse
mbly.
NOTE
A
l
l
c
o
m
p
o
n
e
n
t
s
m
u
s
t
b
e
i
n
s
t
a
l
l
e
d
t
o
t
h
e
i
r
c
o
r
r
e
c
t
p
o
r
t
s
a
s
m
a
r
k
e
d
d
u
r
i
n
g
d
i
s
a
s
s
e
m
b
l
y
.
C
a
p
a
l
l
f
i
t
t
i
n
g
s
ports
T2,
T1,
A2,
E2,
D2,
A1,
C2,
D1,
C1,
E1,
t
o
P2,
and
p
r 3.
e
v
e
n
t
c
o
n 4.
t
a
m
i
n
a
t
i
o
n
.
1.
Install
all
plugs
into
the
valve
body
(1).
P1.
Install
the
flow
valve
s (8)
into
ports
FV1
and
FV2.
Install
the
cartri
dge
valve
plugs
(7)
into
ports
SV1
and
SV2.
5.
Instal
l
the
straig
ht
fitting
s (6)
into
2.
Install
ports
the
E21,
straig
A21,
ht
C11,
fitting
D11,
s (9)
D21,
into
A11,
C21,
and
El 1.
6.
Instal
l the
check
valve
cartri
dges
(5)
into
ports
CV1
and
CV2.
7.
Valve Body 90 Degree

Fitting Straight Fitting Straight
Fitting Check
Valve Cartridge
Straight Fitting
Cartridge
Valv&Plug Flow
Valve Straight
Fitting
Install
the
straight 8.
fittings (4) into ports
PS3, PS4, PS6, PS7,
PS9, and PS10.
Install the 90 degree

fittings (2) into port T3
and the straight fitting
(3) into port P3.
0366
M8 VALVE BODY.
clean workbench for

disassembly.
Removal.
1.
Discharge the control

accumulator by turning
the
manual
valve
knob
control
NOTE
rotary
on
the
accumulator
valve
body
counterclockwise until
pressure is relieved.
CAUTION
DURING
REMOV
AL
OF
ANY
COMPO
NENTS
OR
AFTER
BREAKI
NG ANY
CONNECTIO
NS, ALL
PORTS
AND
HOSES
SHOULD
BE
PLUGGE
D
OR
CAPPED
.
2.
Disassembly.
Tag and remove all

hoses and tubes that 1.
connect to the M8
valve body and the
solenoid valve. Plug all
open ports and cap all
hoses.
3.
Tag and removethe 2.

four electrical wires
that connect to the
solenoid valve in M8.
4.
Loosen and remove

the three bolts, nuts,
3.
and flat- washers that
attach the M8 valve
body to the cab floor.
Remove the M8 valve
body and place it on a
As each
compon
ent
is
removed
from the
valve
body, it
must be
tagged
with the
number/lette
r of the
port that
the
compon
ent was
removed
from.
This will
be
the
only
means
of
identifyi
ng
compon
ents
during
assembly.
Loosen and remove
the straight fittings (2)
in ports PS4, PS6, and
PS7. Remove the
cartridge valve (3) in
port RDV.
Remove the 90
degree fittings (4) from
ports T2, P3, G, and F.
Loosen and remove
the test fitting (5) from
port P2.
Loosen
and
removethe
straight
fittings (6) from ports
F1,
G1,
and
T.
Remove the swivel tee
(7) and the straight 5.

fitting (6) from port P.
4.
Loosen and remove

the four screws (8) that
secure the cap (9) to 6.
the solenoid valve
(10). Remove the cap
(9).
Inspect all fittings,

plugs, valves, and
switches for thread
damage.
Replace all defective
components.
/
Assembly.
NOTE
5.
6.
Loosen and remove

the bolts that attach
the solenoid valve (10)
to the valve body (1).
Discard the O-rings.
Remove all remaining
plugs from the valve
body (10). Cleaning
and Inspection.
1.
Clean all the parts in a
2.
Submerge
suitable solvent.
body
solvent
in
the
a
and
gently to
valve
suitable
agitate 1.
any
flush
contaminants
within
the
from
block. 2.
Remove the block and

blow dry with air.
3.
4.
It is recommended
3.
that all O-rings be
replaced.
Lubricate
new O-rings with clean
petroleum jelly.
All
compon
ents
must be
installed
to their
correct
ports as
marked
during
disasse
mbly.
Cap all
fittings
to
prevent
contami
nation.
Install all plugs to the
valve body (1).
Lubricate and install
new O-rings to the
mounting face of the
solenoid valve (10).
Install the solenoid

valve (10) to the valve
body (1) using the four
bolts. Install the cap
(9) to the solenoid
valve
Inspect all ports on the
(10)
using
the four screws
manifold block for
(8).
thread damage, burrs,
scratches,
or
contaminants.
CAUTION
6.
DURING REMOVAL OF ANY COMPONENTS OR AFTER
BREAKING ANY CONNECTIONS, ALL PORTS AND HOSES
SHOULD BE PLUGGED OR CAPPED.
Assembly.
NOTE
2.
Tag and remove all hoses that attach to the M17 valve body. Plug all open
ports and cap all fittings.
3.
Tag and remove the six solenoids on the valve cartridges by removing the
jam nut that secures each solenoid and pulling the solenoids straight off.
Ensure the solenoids are properly tagged to facilitate installation to their 1.
correct valves.
2.
4.
Loosen and remove the two nuts and washers that attach the M17 valve
body to the rear of the upperstructure. Remove M17 and place it on a clean
3.
workbench for disassembly.
Disassembly.
4.
1.
Tag and remove the pressure valves (2, 3, 4, and 5) from ports PV1, PV2,
PV3, and PV4.
Install all plugs to the M1 7 valve body.

Lubricate and install new O-rings to the flow control valve (11). Install the
flow control valve (11) to the valve body (1) using the four bolts (10).
Install the cartridge valves (6) into ports SV1 thru SV6 as tagged during
removal.
Install the 90 degree fitting (9) into port P and the reducing valve (7) into
5.
Install the straight fittings (8) into ports T and T1.
6.
Install the pressure valves (2, 3, 4, and 5) into ports PV1, PV2, PV3, and
PV4 as tagged during removal.
Installation.
1.
Install the M17 valve body to the two protruding bolts

the
rear of the upperstructure using the two nuts and
washers.
2.
Install the six solenoid coils to the appropriate cartridge valves as marked
during removal. Secure the solenoid coils to the valves using the six jam
nuts.
2.
Loosen and remove the straight fittings (8) from ports T and T1.
3.
Remove the cartridge valves (6) from ports SV1 thru SV6.
4.
Remove the reducing valve (7) from port RV and the 90 degree fitting (9)
from port P.
5.
Loosen and remove the four bolts (10) that attach the flow control valve (11) 3.
to the valve body (1). Remove the flow control valve (11). Discard the Orings.
6.
All components must be installed to their correct ports as

marked during disassembly. Cap all fittings to prevent
contamination.
port RV.
NOTE
As each component is removed from the valve body, it
must be tagged with the number/letter of the port that the
component was removed from. This will be the only
means of identifying the components during assembly.
Install all hoses to the M17 valve body as marked during removal.
Remove all remaining plugs from the M17 valve body. Cleaning and
Inspection.
1.
2.
Submerge the valve bodies in a suitable solvent and agitate gently to flush
contaminates from the internal ports. Blow dry with filtered air.
3.
It is recommended that all O-rings be replaced. Lubricate new O-rings with

clean petroleum jelly.
4.
Inspect the ports on the valve bodies for damaged threads, burrs,
scratches, and contaminates.
5.
Inspect all fittings and internal components for damaged threads, burrs, and
scratches.
2-4-104
1.
2.
Valve Body
Pressure Valve
3.
4.
Pressure Valve
Pressure Valve
5.
6.
7.
8.
9.
Pressure Valve
Cartridge Valve
10.
11.
Reducing Valve
Straight Fitting
90 Degree Fitting
Bolt
Flow Control Valve
(p) (g) (p/ (pj)
BH
0341
38.
assemble them over the exposed ring, rotor, and vanes. Ensure the scribe
marks are in line.
NOTE
The cast-in arrows, located next to the socket head
screws, indicate the direction of rotation of the cartridge.
40.
Thread the two socket head screws (31) into the cartridge until snug (hand
tight).
NOTE
HI 4 HI
HI
The OD of all component parts of the cartridge

kit must be in-line with each other or the
cartridge will bind during assembly. Align the
cartridge as follows.
HI 1
T2
41. Build a V block from hardwood, or if a metal V block is

available, use that. Place the cartridge into the V block on its side. Loosen
the socket head screws (31) enough to allow each section of the cartridge to
come into alignment within the V block. Torque the socket head screws (31)
to 30 pounds-foot (4.15 kgm). Recheck the alignment after torquing.
Hold the cartridge assembly together to prevent movement and rotate it 180
degrees so the outlet support plate rests on a flat surface, and the wooden
board is upward. Remove the wooden board.
42.
39.
PG
Lubricate the exposed surface of the rotor and vanes with clean hydraulic
fluid. Locate the scribe mark on the inlet support plate (29) and flex side
plate (27). Hold the inlet support plate and flex side plate together and
Check the rotor (23) for bind by inserting the index finger through the shaft
opening of the inlet support plate (29). Hold the cartridge kit in a horizontal
shaft position and lift the rotor with the finger. The rotor should move freely
back and forth within the cartridge. If the rotor binds, open the kit, clean and
2-4-105
stone all possible areas of bind, then reassemble using the aforementioned 51. Install the rotor (8) onto the shaft (33). Insert the vanes (9) into the rotor
procedure. The rotor must move freely within the cartridge when assembled.
slots. Ensure the radius edges on the vanes (9) are toward the cam ring,
43.
Lubricate and install a new O-ring (17) and backup ring (1 6) onto the outlet
support plate (20).
52.
44. Lubricate and install a new 0-ring (19) and sealing ring (18) onto the outlet
53.
support plate (20).
with the sharper edge towards the direction of rotation.

Lubricate and install a new O-ring (5) in the front cover (1).
Place the spring (6) over the pressure plate (7) and install onto the front
cover (1).
45.
46.
Install the cartridge assembly onto the shaft (33) with the inlet plate facing
54.
towards the main section (3).
Install the mid section (2) to the main section (3) using the two bolts (15),
INSTALLATION.
torque to 45 pounds-foot (6.2 kgm).

Lubricate and install a new O-ring (32) into the groove of the mid section 1.
(2).
2.
48. Insert the two locating pins (12) into the mid section (2).
47.
49. Assemble the ring assembly by placing the O-ring

(11) between ring (10 and 13), align the scribe marks.
50.
Install the front cover (1) to the mid section (2) using the four bolts (14),
torque to 40 pounds-foot (5.5 kgm).
Install the ring assembly on the locating pins (12).
Attach a suitable lifting device to the pump, remove the pump from the vise.
Align the spline on the pump with the spline on the pump drive and carefully
slide the pump into the drive.
3.
Secure the pump to the drive using the two bolts and washers.
4.
Remove the caps from the fittings and hoses and attach the hoses to the
pump.
2-4-106
PRESSURE SETTINGS
DESCRIPTION
This subsection outlines procedures for adjusting several major
pressure settings within the hydraulic system. Test fittings have
been provided for easy installation of the proper pressure gauges.
It is recommended that these pressures be checked every six
months and adjusted as required for maximum machine efficiency.
BEFORE INSTALLING ANY PRESSURE GAUGES

IN THE CONTROL CIRCUIT, DRAIN THE
CONTROL ACCUMULATOR BY TURNING THE
MANUAL ROTARY VALVE KNOB ON THE M5
VALVE BODY COUNTERCLOCKWISE UNTIL
PRESSURE IS RELIEVED.
CHARGE CIRCUIT.
The charge pressure will be set to 450 psi (3103 kPa/31.03 bar)
using a 0 to 1000 psi (0 to 6895 kPa/0 to 68.95 bar) pressure
gauge.
1.
Locate the M1 charge valve body.
2.
Install a 0 to 1000 psi (0 to 6895 kPa/0 to 6.895 bar) pressure

gauge in M1, port TP1.
3.
Locate the charge relief valve on the charge filter assembly on the
rear of the upperstrucutre.
4.
Loosen the jam nut on the charge relief valve.
5.
StarttheengineandsetthethrottletoFULL. Observe the pressure

gauge installed in M1. If the pressure reading is less than 450 psi 1.
(3103 kPa/31.03 bar), use an alien wrench to turn the adjusting
screw on the charge relief clockwise until the correct pressure is
read on the gauge. If the pressure reading is greater than 450 psi 2.
(3103 kPa/ 31.03 bar) turn the adjusting screw counterclockwise
until the correct pressure is indicated on the gauge.
Setting RV2 in M5.
6.
Tighten the jam nut on the charge relief valve. Recheck the
3.
pressure reading on the gauge to ensure a reading of 450 psi
(3103 kPa/31.03 bar).
7.
Shut down the engine and remove the pressure gauge from Ml.
CONTROL CIRCUIT.
WARNING
2-4-107
Drain the control accumulator using the valve knob in M5. Close
the valve knob.
Loosen the nut on valve RV1. Install an alien wrench into the
adjustment in RV1 and turn the adjustment clockwise until it
bottoms out.
Loosen and remove the cap on the end of valve RV2. Install an
alien wrench into the adjustment in RV2 and turn the adjustment
counterclockwise 1 1 /2 turns.
4.
Install a 0 to 5000 psi (0 to 34,475 kPa/0 to 344.75 bar) pressure

gauge into the test fitting in port TP1 of M5.
5.
Starttheengineandsetthethrottleto FULL. Observe the pressure

gauge for a reading of 3300 psi (22,753.5 kPa/227.53 bar).
Vlave Body Straight

Fitting Cartridge
Valve 90 Degree
Fitting Test Fitting
Straight Fitting
Swivel Tee Screw
Cap
Solenoid Valve
0365
4.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
(
6
)
a
n
d
t
h
e
s
w
i
v
e
l
t
e
M8 Valve Body
e
(
7
)
i
n
t
o
p
o
rt 5.
P
.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
s
(
6
)
i
n
t
o
p
o
rt
s
F
1
,
G
1
,
a
n
d
T
.
I
n
s
t
a
ll
t
h
e
t
e
s
t
fi
tt
i
n
g
(
5
)
i
n
t
o
p
o
rt
P
2
a
n
d
t
h
e
9
0
d
e
g
r
e
e
fi
tt
i
n
g
s
(
4
)
i
n
t
o
p
o
rt
s
G
,
F
,
T
2
,
a
n
d
P
3
.
6.
I
n
s
t
a
ll
t
h
e
c
a
rt
ri
d
g
e
v
a
l
v
e
(
3
)
i
n
t
o
p
o
rt
R
D
V
.
I
n
s
t
a
ll
t
h
e
s
tr
a
i
g
h
t
fi
tt
i
n
g
s
(
M8 Valve Body
2
)
i
n
t
o
p
o
rt
s
P
S
4
,
P
S
6
,
a
n
d
P
S
7
.
I
n
s
t
a
ll
a
ti
o
n
.
1.
I
n
s
t
a
ll
t
h
e
M
8
v
a
l
v
e
b
o
d
y
t
o
t
h
e
u
n
d
e
r
s
i
d
e
o
f
t
h
e
c
a
b
fl
o
o
r
u
s
i
n
g
t
h
e
t
h
r
e
e
b
o
lt
s
,
n
u
t
s
,
a
n
d
fl
a
t
w
a
s
h
e
r
s
.
2.
I
n
s
t
a
ll
t
h
e
f
o
u
r
e
l
e
c
tr
i
c
a
l
w 3.
ir
e
s
t
o
t
h
e
s
o
l
e
n
o
i
d
v
a
l
v
e
i
n
M
8
a
s
t
a
g
g
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
I
n
s
t
M8 Valve Body
a
ll
a
ll
h
o
s
e
s
a
n
d
t
u
b
e
s
t
o
t
h
e
M
8
v
a
l
v
e
b
o
d
y
a
n
d
t
h
e
s
o
l
e
n
o
i
d
v
a
l
v
e
a
s
t
a
g
g
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
M
1
0
V
A
L
V
E
B
O
D
I
E
S
.
F
o
r
m
a
i
n
t
e
n
a
n
c
e
i
n
s
tr
u
c
ti
o
n
s
r
e
f
e
r
t
o
B
r
a
k
e
V
a
l
v
e
B
o
d
y 1.
M
1
0
i
n
S
e
c
ti
o
n
7
-
H
O
I
S
T
S
.
M
1
3
V
A
L
V
E
B
O
D
Y
.
R
e
m
o
v
a
l
a
n
d
D
i
s
a
s
s
e
m
b
l
y.
D
i
s
c
h
a
r
g
e
t
h
e
c
M8 Valve Body
tr
tr
w
i
s
e
u
n
ti
l
p
r
e
s
s
u
r
e
i
s
r
e
li
e 2.
v
e
d
.
C
A
U
TI
O
N
DURI
NG
REM
OVA
L OF
ANY
COM
PON
ENT
S OR
AFT
ER
BRE
AKIN
G
ANY
CO
NNEC
TION
S,
ALL
POR
TS
AND
HOS
ES
SHO
ULD
BE
PLU
GGE
D OR
CAP
PED.
T
a
g
a
n
d
r
e
m
o
v
e
a
ll
h
o
s
e
s
a
n
d
t
u
b
M8 Valve Body
e
s
t
h
a
t
c
o
n
n
e
c 3.
t
t
o
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
.
P
l
u
g
a
ll
o
p
e
n
p
o
rt
s
a
n
d
c
a
p
a
ll
h
o
s
e
s
.
L
o
o
s
e
n
a
n
d
r
e
m
o
v
e
t
h
e
t
w
o
n
u
t
s
a
n
d
w
a
s
h
e
r
s
t
h
a
t
a
tt
a
c
h
t
h
e
M
1
3
v
a
l 4.
v
e
b
o
d
y
t
o
t
h
e
i
n
n
e
r
l
e
ft
s
i
d
e
o
f
t
h
e
u
p
p
e
r
s
tr
u
c
t
u
r
e
fr
a
m
e
.
R
e
m
o
v
e
M
1
3
a
n
d
p
l
a
c
e
it
o
n
a
c
l
e
a
n
w
o
r
M8 Valve Body
k
b
e
n
c
h
f
o
r
d
i
s
a
s
s
e
m
b
l
y
.
5.
T
a
g
a
n
d
r
e
m
o
v
e
a
ll
fi
1.
tt
i
n
g
s
a
n
d
p
l
u
g
s
i
n
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
.
C
l
e
a
n
i
n
g
a
n
d
I
n
s
p
e
c
ti
o
n
.
C
le
a
n
al
l
t
h
e
p
a
rt
s
in
a
s
ui
t
a
bl
e
s
ol
v
e
n
t.
2.
S
u
b
m
e
r
g
e
t
h
e
v
a
l
v
e
b
o
d
y
i
n
a
s
u
it
a
b
l
e
s
o
l
v
e
n
t
a
n
d
a
g
it
a
t
e
g
e
n
tl
y
t
o
fl
u
s
h
a
n
y
c
o
n
t
a
m
i
n
a
n
t
s
fr
o
m
w
it
h
i
n
t
h
e
b
l
o
M8 Valve Body
c
k
.
R
e
m
o
v
e
t
h
e
b
l
o
c
k
a
n
d
b
l
o
w
d
r
y
w
it
h
a
ir
.
3.
I
n
s
p
e
c
t
a
ll
p
o
rt
s
o
n
t
h
e
m
a
n
if
o
l
d
b
l
o
c
k
f
o
r
t
h
r
e
a
d
d
a
m
a
g
e
,
b
u
r
r
s
,
s
c
r
a
t
c
h
e
s
,
o
r
c
o
n
t
a
m
i
n
a
n
t
s
.
ll
4.
d
s
w
it
c
h
e
s
f
o
r
t
h
r
e
fi
tt 5.
i
n
g
s
,
p
l
u
g
s
,
v
a
l
v
e
R
e
pl
a
c
e
al
l
d
e
f
e
ct
iv
e
c
o
m
p
o
n
e
n
ts
.
s
,
a
A
s
s
M8 Valve Body
e 1.
m
b
l
y
a
n
d
I
n
s
t
a
ll
a
ti
o
n
.
N
O
T
E
I
n
s
t
a
ll
a
ll
p
l
u
g
s
a
n
d
fi
All
com
pone
nts
must
be
insta
lled
to
their
correct
ports
as
mark
ed
durin
g
disa
sse
mbly
. Cap
all
fittin
gs to
prev
ent
cont
amin
ation
.
tt
i
n
g
s
t
o
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
a
s
m
a
r
k
e
d
d
u
ri
n
g
r
e
m
o
v
a
l.
2.
I
n
s
t
a
ll
t
h
e
M
1
3
v
a
l
v
e
b
o
d
y
t
o
t
h
e
i
n
n
e
r
l
e
ft
s
i
d
e
o
f
t
h
e
u
p
p
e
r
s
tr
u
c
t
u
r
e
fr
a
m
e
u
s
i
n
g
t
h
e
t
w
o
n
u
t
s
a
n
d
w
a
s
M8 Valve Body
h
e 6
r
s VA
.
LV
3.
E
Install
BO
all
DY
ho
.
se
s
to
M1
3
as
tag
ge
d
dur
ing
re
mo
val
.
M1
F
o
r
m
a
i
n
t
e
n
a
n
c
e
i
n
s
tr
u
c
ti
o
n
s
r
e
f
e
r
t
o
S
W
I
V
E
L
i
n
S
e
c
ti
o
n
8
S
W
I
V
E
L
.
M
l
7
V
A
L
V
E
B
O
D
Y
.
R
e
m
o
v
a
l.
1.
D
i
s
c
h
a
r
g
e
t
h
e
c
o
n
tr
o
l
a
c
c
u
m
u
l
a
t
o
r
b
y
t
u
r
n
i
n
g
t
h
e
m
a
n
u
a
l
r
o
t
a
r
y
v
a
l
v
e
M8 Valve Body
k
n
o
b
o
n
t
h
e
c
o
n
tr
o
l
a
c
c
u
m
u
l
a
t
o
r
v
a
l
v
e
b
o
d
y
c
o
u
n
t
e
r
c
l
o
c
k
w
i
s
e
u
n
ti
l
p
r
e
s
s
u
r
e
i
s
r
e
li
e
v
e
d
.
M3/M4 Valve Body
2.
R
e
m
o
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
s
(4
)
fr
o
m
p
or
ts
S
V
1
M8 Valve Body
22.
Remove
all
remainin
g plugs
from the
M3 valve
body.
a 3.
n
d
S
V
3.
R
e
m
o
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
pl
u
g
s
(5
)
fr
o
m
p
or
ts
S
V
4,
P
V
1,
a
n
d
P
V
3.
4.
R
e
m
ov
e
th
e
va
lv
e
ca
rtr
id
g
e
pl
u
g
(6
)
fr
o
m
p
or
t
P
V
2.
5.
R
e
m
o
v
e
th
e
pr
e
s
s
ur
e
s
wi
tc
h
(7
),
9 6.
0
d
e
gr
e
e
fit
ti
n
g
(8
),
c
o
n
n
e
ct
or
(9
),
a
n
d
th
e
or
ifi
c
e
pl
u
g
(1
0)
fr
o
m
p
or
t
T
P
1
1.
R
e
m
o
v
e
th
e
pl
u
g
M8 Valve Body
(1
1)
fr
o
m
p
or
t
R
2.
R
e
m
o
v
e
th
e
or
ifi
c
e
pl
u
g
(1
2)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
R
2.
7.
R
e
m
o
v
e
th
e
pi
p
e
pl
u
g
(1
3)
fr
o
m
p
or
t
G
.
R
e
m
o
v
e
th
e
pl
u
g
(1
4)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
G
.
8.
R
e
m
o
v
et
h 9.
e
pi
p
e
pl
u
g(
1
3)
fr
o
m
p
or
tF
s.
R
e
m
o
v
et
h
e
pl
u
g
(1
4)
fr
o
m
th
e
in
n
er
b
or
e
of
p
or
t
F.
T
a
g
a
n
d
re
m
o
v
e
al
l
re
m
ai
ni
n
g
pl
u
g
s
in
th
e
M
4
v
al
v
e
b
o
d
y.
V
al
v
e
B
o
M8 Valve Body
d
y
M
3.
m.
Thi
s
will
be
the
only
mea
ns
of
iden
tifyi
ng
the
com
pon
ents
duri
ng
ass
emb
ly.
N
O
T
E
As
eac
h
com
pon
ent
is
rem
ove
d
fro
m
the
valv
e
bod
1.
y, it
mus
t be
tag
ged
with
the
nu
mber/
lette
r of
the
port
that
the
com
pon
ent
was
2.
rem
ove
d
fro
R
e
m
ov
e
th
e
tu
b
e
(1
5)
th
at
ru
ns
ov
er
th
e
fitt
in
g
in
p
or
t
F.
R
e
m
o
v
e
th
e
st
ra
ig
ht 3.
fit
ti
n
g
(1
6)
a
n
d
th
e
9
0
d
e
gr
e
e
fit
ti
n
g
(1
7)
th
at
th
e
tu
b
e
(1
5)
w
a
s
c
o
n
n
e
ct
e
d
to
.
R
e
m
ov
e
th
e
9
0
d
e
gr
e
e
fitt
in
g
(1
8)
fr
o
M8 Valve Body
4.
9)
fr
or
F.
or
ov
3.
th 5.
ch
ec
ov
va
th
lv
te
ca
st
rtr
fitt
id
in
(2
(1
0)
6.
fr
in
(2
1)
or
fr
6.
or
D.
7.
m
ov
e
th
e
9
0
d
e
gr
e
e
Lo
os
e
n
a
n
d
re
m
ov
e
th
e
sh
ut
tle
va
lv
e
(2
2)
fr
o
m
p
fitt
M8 Valve Body
or
t
S
H
V
1.
9.
m
o
v
e
th
e
or
ifi
pl
th
(2
5)
fr
al
th
ar
in
tri
er
or
(2
4)
of
fr
or
or
1.
C
V 10.
1.
L
o
o
s
e
n
a
n
d
re
R
e
m
ov
e
th
e
st
ra
ig
ht
fitt
in
g
(2
6)
fr
o
m
p
or
t
P
P
3.
11.
L
o
c
at
e
th
e
fa
c
e
of
th
e
v
al
v
e
b
o
d
y
(1
)
th
at
m
at
e
s
wi
th
th
e
M
4
v
al
v
e
b
o
d
y
(2
).
R
e
m
o
v
e
th
e
fi
v
e
c
ar
tri
d
g
e
v
al
v
e
s
fr
o
m
th
e
fi
v
e
la
rg
e
p
or
ts
a
s
fo
ll
o
w
s.
M8 Valve Body
a.
C
ar
ef
ul
ly
pr
y
o
ut
th
e
v
al
v
e
s
p
a
c
er
(2
7)
.
Di
s
c
ar
dt
h
e
O
ri
n
g
(2
8)
in
th
e
in
n
er
b
or
e
a
n
d
th
e
b
a
c
k
u
p
ri
n
g
(2
9)
a
n
d
O
ri
n
g
(3
0)
in
th
e
ci
rc
u
m
fe
re
nt
ia
l
c
h
a
n
n
el
of
th
e
v
al
b.
c.
m
v
ai
e
ni
n
s
g
p
p
or
a
ts.
c
er
12.
(2
L
7)
o
.
o
s
R
e
e
n
m
ov
a
e
n
th
e
d
va
re
lv
e
m
ca
o
rtr
id
v
g
e
e
p
th
o
e
p
p
b
et
ol
(3
1)
t
fr
(3
o
m
2)
th
th
e
at
p
or
at
t.
ta
c
R
h
e
e
p
e
s
at
th
thi
s
e
pr
lo
oc
e
c
d
at
ur
e
or
fo
pl
r
th
at
e
e
fo
ur
(3
re
M8 Valve Body
3)
to
th
e
v
al
v
e
b
o
d
y
(1
).
er
b
or
e
a
n
d
th
e
O
ri
n
g
(3
13.
R
e
m
o
v
e
a
n
d
di
s
c
ar
d
th
e
O
ri
n
g
(3
4)
fr
o
m
th
5)
fr
o
m
th
e
o
ut
er
gr
o
o
v
e
of
th
e
lo
c
at
or
pl
at
e
(3
3)
.
e 14.
in
L
n
o
o
s
e
n
a
n
d
re
m
o
v
e
th
e
fo
ur
b
ol
ts
(3
6)
th
at
at
ta
c
h
th
e
h
oi
st
p
or
t
v
al
v
e
(3
6)
a
n
d
th
e
t
w
o
fl
a
n
g
e
h
al
v
e
s
(3
8)
to
th
e
v
al
v
e
b
o
d
y
(1
).
Di
s
c
ar
d
th
e
O
ri
n
g
(3
9)
.
1
5.
R
e
m
o
M8 Valve Body
v
e
th
e
v
al
v
e
c
ar
tri
d
g
e
(4
0)
fr
o
m
p
or
t
S
V
o
n
th
e
h
oi
st
p
or
t
v
al
v
e
(3
7)
.
R
e
m
o
v
e
th
e
pr
e
s
s
ur
e
s
wi
tc
h
(4
1)
,
fit
ti
n
g
(4
2)
,
a
n
d
th
e
c
o
n
n
e
ct
or
(4
3)
fr
o
m
th
e
h
oi
st
p
or
t
v
al
v
n
e
th
(3
e
7)
h
.
oi
R
st
e
p
m
or
o
t
v
v
e
al
th
v
e
e
te
(3
st
7)
fit
.
ti
1
n
6.
g
R
e
(4
m
4)
ov
e
fr
th
o
e
te
m
st
p
fitt
in
or
g
t
(2
0)
P
fr
S
o
a
m
p
n
or
d
t
T
th
P
e
4.
fit
ti 17. R
n
e
g
(4
m
5)
fr
ov
o
m
e
p
or
th
t
D
e
o
M8 Valve Body
tu
ov
th
(4
6)
fitt
fr
in
(4
th
7)
fr
fitt
in
in
or
or
3.
3.
9.
8.
ov
th
re
lie
1.
R
e
f
m
ov
e
va
th
e
st
lv
ra
ig
ht
e
fitt
in
g
ca
(4
9)
fr
rtr
o
m
id
p
or
t
g
P
P
2.
e
V'
21. R
e
(4
m
ov
e
8)
th
e
fitt
fr
in
g
(2
o
1)
fr
m
o
m
p
p
or
t
D
or
4.
20.
M8 Valve Body
Valve Bodies M3 And M4

DESCRIPTION
The valve bodies are aluminum blocks that have several
interconnecting passages between valves. They control fluid flow
direction, pressure, and flow rate with the use of modular valves that
are secured in the valve bodies using multiple threaded ports and
internally threaded ports.
control hydraulic flow to the working ports in the distributor of the

radial piston motor and the motor case is bolted directly to the drum
flange. Poppet valves V1, V2, V3, V4, and V5 are used internally in
the working ports of the valve body for direction and check functions.
Each poppet valve contains two internal ports for fluid passage. One
is a pilot port that controls the valve function via the use of solenoid
valves that are contained in the valve body M4. The other port is the
main passage for working fluid to the distributor.
The valve bodies M3 and M4 are bolted together and then bolted
directly to the hoist motor. Three main internal ports A, B, and C
MAINTENANCE
REMOVAL.
4.
f. Discharge the control accumulator by turning the manual rotary

5.
valve knobon the control accumulator manifold counterclockwise
6.
CAUTION
7.
DURING REMOVAL OF ANY COMPONENTS OR
AFTER BREAKING ANYCONNEC- TIONS, ALL
PORTS AND HOSES SHOULD BE PLUGGED OR
CAPPED.
2.
Tag and remove all hydraulic lines that attach to the M3 and M4
valve body. Plug all open ports and cap all
hoses.
Tag and remove the remaining electrical lines that run to the valve
body.
Attach a suitable lifting or supporting device to the valve body.
Loosen and remove the six bolts and washers that attach the valve
body to the hoist motor.
Remove the valve body from the hoist motor. Discard the O-rings.
Plug all open hoist motor ports.
8.
9.
Position the valve body on a clean, flat working surface.

Loosen and remove the ten bolts and washers that attach the M3
valve body to the M4 valve body. Separate the valve bodies and
discard the O-rings.
DISASSEMBLY.
CAUTION
TAG THE SOLENOID COILS WITH THE CORRECT
Valve Body M4.

NOTE
PORT PRIOR TO REMOVAL.

3.
Tag and remove the three solenoid coils on the M4 valve body by
removing the nut that secures each solenoid coil to the valve body.
Pull the coils straight off the valve cartridges. Tag and remove the
solenoid coil from the hoist port valve.
As each component is removed from the valve

body, it must be tagged with the number/letter of
the port that the component was removed from.
This will be the only means of identifing the
components during assembly.
SECTION 9
ELECTRICAL
SYSTEM
TABLE OF CONTENTS
Page
ELECTRICAL SYSTEM
Description ......................................................................................................................................................................................2-9-3
Maintenance.....................................................................................................................................................................................2-9-3
HOIST SPEED SELECT, FREEFALL, AND STATUS PANEL ELECTRICAL CIRCUITS........................................................................2-9-13
Description ....................................................................................................................................................................................2-9-13
LIST OF FIGURES
Title
Page
Engine Instrument Removal and Installation ...............................................................................................................................................2-9-6

Toggle Switch Removal...................................................................................................................................................................................2-9-7
Bumper Switch Removal ................................................................................................................................................................................2-9-7
Windshield Wiper Removal and Installation ................................................................................................................................................2-9-8
Hoist Circuit ...................................................................................................................................................................................................2-9-15
Hoist Freefall Circuit................................................................................................................................................... .............................2-9-16
Status Panel Circuit ......................................................................................................................................................................................2-9-17
LIST OF TABLES
Title
Page
Alternator Belt Tension and Attaching Hardware Torque Table..................................................................................................................2-9-5

Upperstructure Electrical Component, Location, and Primary Function...................................................................................................2-9-9
WARNING SAFETY SUMMARY

Page
WARNING
2-9-3
IF IT SHOULD BECOME NECESSARY TO

PERFORM ELECTRICAL MAINTENANCE ON LIVE
OR HOT CIRCUITS, REMOVE ALL RINGS,
WATCHES, AND OTHER JEWELRY BEFORE
PERFORMING MAINTENANCE AS SERIOUS
BURNS
RESULT
FROM
ACCIDENTAL
GROUNDING OR SHORTING OF LIVE CIRCUITS.
ELECTRICAL SYSTEM
DESCRIPTION
The crane electrical system is 24-volt consisting of an alternator and leadacid batteries series parallel connected. Four batteries are used and are
installed on the rear left side of the upperstructure. Two batteries are
connected in parallel to make two parallel sets of batteries for a higher
amperage rate. Both parallel sets are connected in series to provide 24

volts. The system is the single wire ground return type, utilizing the crane's
structure as ground. Some accessories of the crane require 12 volts for
operation. These are supplied from a 12-volt power supply regulator
located in the electrical junction box under the cab.
the upperstructure. The cover on the box must be removed to gain access
to the fuse.
All electrical circuits are protected by circuit breakers. A circuit breaker

panel is located in the operator's cab and is the right rear panel under the
right arm rest. The breaker panel contains 19 circuit breakers. There are
three remote mounted circuit breakers. One is located inside the electrical
box that is mounted in the engine compartment. The two other circuit
breakers are located on the fill pump assembly box, which 3 located on
top the hydraulic reservoir. If a circuit breaker has tripped, a white band will
be visible. Depress the circuit breaker to reset it.
ALTERNATOR.
For a location and primary functions of circuit breakers, fuses, and relays
see chart titled Electrical Component, Location, and Primary Function.
The alternator is mounted on the engine and is belt driven. It is a 50

ampere alternator with 24-volt output terminals which supply the voltage to
recharge the batteries and maintain them at a full state of charge.
BATTERIES.
The 12-volt batteries are located on the left side of the upperstructure in
the rear corner. The batteries are secured with two J hooks and a strap.
In addition to the above mentioned circuit breakers, some circuits are

controlled and protected by a combination toggle switch/circuit breaker.
The batteries are the maintenance free type and are completely sealed
except for a small vent hole in the side of the battery. The vent hole allows
what small amount of gasses that are produced in the battery to escape. A
test indicator located on the top of the battery is used to determine if the
battery can be tested in case of a starting problem. For information
concerning the use of this indicator, refer to Delco-Remy Service Bulletin
1B-116 in the back of this Service Manual.
An electrical junction box located under the cab contains most of the of
relays and associated electrical components that control the electrical
functions. The box also provides the junction point between the cab
controls and the remainder of the crane.
There is one fuse in the electrical system. The fuse (F2) is located in a
conduit box located on the gantry hydraulic relief valve on rear left side of
MAINTENANCE
GENERAL.
____________
WARNING
Electrical system maintenance includes replacement of

damaged components. Standard wiring practices should
be observed when replacement is necessary.
WARNING
ENSURE THE BATTERIES ARE DISCONNECTED
BEFORE PERFORMING ANY MAINTENANCE ON AN
ELECTRICAL CIRCUIT WHICH IS NOT FUSED.
CAUTION
NEVER REPLACE ORIGINAL WIRING WITH WIRING OF A
SMALLER DIAMETER.
TROUBLESHOOTING.
To isolate electrical troubles, a multimeter should be used. The multimeter,
when used properly, can provide readings necessary for service personnel
to determine the following.
1.
Opens in the electrical system.
2.
Resistance in the electrical system.

Tfiere may be a loose or corroded connection in the pin type connectors.
Check the connectors to ensure that the wire pins are properly seated and
engaged in the receptacle. If the male and female pins show any signs of
IF IT SHOULD BECOME NECESSARY TO

PERFORM ELECTRICAL MAINTENANCE
ON LIVE OR HOT CIRCUITS, REMOVE ALL RINGS, WATCHES, AND
OTHER JEWELRY BEFORE PERFORMING MAINTENANCE AS
SERIOUS BURNS RESULT FROM ACCIDENTAL GROUNDING OR
SHORTING OF LIVE CIRCUITS.
corrosion, use a good quality electrical contact cleaner or a fine sandpaper
to clean them. When the pins show signs of arcing or burning, it will
probably be necessary to replace them.
The following is a list of Deutsch and AMP tools necessary for connector
maintenance.
Extraction.
6 ga. wire - #4 size contact, 114009 8 ga. wire - #8 size
contact, 114008 14 ga. wire - #12 size contact, 114010 16 ga.
wire - #16 size contact, 0411 -204-1605
Crimping.
6 ga. wire - #4 size contact, HDT-0408 8 ga. wire - #8 size
contact, HDT-0408 14 ga. wire - #12 size contact, HDT-48-00
16 ga. wire - #16 size contact, HDT-48-00 1 6 ga. wire - #1 2
size contact - (AMP), 90353-2 14 ga. wire - #1 6 size contact (AMP), 90353-2
Because the pins are crimped to the wires, it is not possible to remove the
pin. Using the proper extraction tool, remove the pin(s)from the plug or
receptacle. Cut the wire as close to the pin as possible. After cutting the pin 3.
off, the wire will most likely be too short. Using a wire that is too short will
allow pressure to be applied to the pin and wire where they are crimped 4.
when the pin is inserted in the plug or receptacle. Add a short length of the
same size wire to the short wire by crimp splice or solder. Use heat
shrinkable tubing or other suitable material to insulate the splice.
5.
Removal.
1.
If necessary, replace the plywood before installing the batteries.
2.
Install each battery.
3.
Connect all leads to the battery terminals, starting with the positive
terminals.
Tag and disconnect the electrical leads from the terminals on the
4.
alternator.
3.
Loosen the alternator attaching hardware and remove the belts from the 5.
alternator pulley.
6.
4.
Remove the attaching hardware from the belt tension adjusting bracket.
5.
Remove the nuts, washers, and bolt attaching the alternator to the
mounting bracket and remove the alternator.
1.
Installation.
1.
2.
Remove each battery and the plywood spacer it sits on.
Swing the upperstructure over the front or rear to gain access to the
underside of the engine compartment.
2.
Tag and disconnect all leads from the battery terminals, starting with the
negative terminals.
Installation.
ALTERNATOR.
1.
Disconnect the ground strap that is secured to the upperstructure frame,
Position the alternator on the mounting bracket and secure with the bolt,
2.
washers, and nut. Do not tighten at this time.
Install the hardware attaching the alternator to the belt tension adjusting 3.
bracket.
4.
3.
Position the belt around the alternator pulley.
4.
Refer to the Alternator Belt Tension and Attaching Hardware Torque Table 5.
for proper belt tension.
6.
5.
Connect the electrical leads to the terminals as tagged during removal.
7.
Connect the ground strap to the upperstructure frame.

Install the J hooks into the battery weldment.
Place the strap on the top of the batteries and place each hole of the strap
over one of the J hook's threaded ends. Using the two locknuts and
washers, secure the strap in place by tightening each locknut evenly until
the strap bottoms out on the top of all four batteries.
Removal.
In the operator's cab, tag and disconnect the connector plugs that run
along the trough on the right side of the cab floor.
Tag and disconnect plugs on the floor in front of the cab heater.
On the left arm console, remove the six finishing screws, securing the
panel in place.
At this time, also tag and disconnect the safety interlock switch.
Tag and disconnect the plug P16 in the left arm console.
Tag and disconnect the plugs from the electrical box.
Remove the heat shrink tubing, tag and disconnect the following spade
connectors: PS3-7, PS4-7, PS6-7, PS9-7, PS10-7, PS4-8, PS6-8, PS7-8,
BATTERIES.
SV3A and B, PS1 -F, and PS1-G.

Removal.
1.
2.
8.
Remove the heat shrink tubing from the work light and horn connections,
tag and disconnect their connections.
9.
Remove the locknuts and washers from inside the cab electrical box.
Remove the locknut and washer from each end of the threaded J hooks.
Remove the strap, securing the batteries to the battery box weldment.
Alternator Belt Tension and Attaching Hardware Torque Table
Attaching Hardware Torque

Belt Tension
Engine
No. of Belts
LB-FT
60-70
GMC
KGM
8.29 - 9.78
Press with thumb in center of belt. Maximum deflection is 0.5 to 0.75- inch (13 - 19
mm).
Belt tension gauge pressure is 40 - 50 lbs. (18 - 23 kg).
Cummins
60-70
8.29 - 9.78
Belt tension gauge pressure is 80 lbs. (36 kg).
Cat
60-70
8.29 - 9.78
10. While removing the box, also feed the harness through the floor of
the operator's cab.
INSTRUMENTS. Removal.
1.
2.
1.
Feed the harness through the floor of the operator's cab.
2.
Install the cab electrical box on the threaded studs and install the
washers and locknuts that secure the box in place.
3.
As tagged during removal, connect all chord connections

were disconnected during removal.
4.
Tag or use heat shrink tubes around all

nections.
3.
that
chord
1.
Examine gauges for cracked and broken lenses.

Check gauge terminals and mounting studs for damage.
2.
Check wiring for damaged insulation or damaged terminals.
..
6.
Install the plug in the left arm console.
7.
Secure the safety interlock switch.
1.
8.
Install the left arm console using the six screws that secure the
panel in place.
2.
As tagged during removal, connect the plugs in front of the cab

heater.
3.
As tagged during removal, connect the plugs along the trough on
Tag and disconnect the electrical leads to the gauge; then tape the
lead ends.
Inspection.
con
. As tagged during removal, connect the plugs to the electrical box.
the right side of the cab foor.
Remove the hardware securing the gauge to the instrument panel, then remove
the gauge.
Engine Instrument Removal and Installation
5.
10.
Remove the screws securing the instrument panel to the right front corner of the
cab.
Installation.
9.
Apply a 25 pound (11 kg) force perpendicular to the belts, midway between the
driver and driven pulley.
Maximum deflection is 0.50 to 0.75 inch(13-19 mm) for the first check. Maintain later
adjustments at 0.875 inch (22 mm) deflection.
.,
Installation.
Connect the electrical leads as marked prior to removal.
Place the gauge into position on the panel and secure it with the
attaching hardware.
Position the cab instrument panel and secure the panel with the
screws.
Functional Check.
Start the engine and observe for proper functioning of the repaired
indicator. (Refer to Operator's Handbook). Troubleshoot further as
necessary, any system malfunction not corrected by repair or
replacement of the indicator or associated wiring.
3651
kJ
ELECTRICAL SWITCHES.
Removal.
Inspection.
1.
Visually check the switch for evidence of cracks, damaged

connections, or other damage.
1.
Gain access to all panels in the operators cab by removing the

2.
screws from each panel and lifting each panel out.
Check wiring for damaged insulation or damaged terminals.
3.
Perform the following check to determine switch serviceability.
a.
Using an ohmmeter, check for continuity between the switch

terminals with switch in ON or activated position.
b.
Position switch to OFF. Ohmmeter should register zero (no

continuity).
Installation.
1.
Conenct the electrical leads as marked prior to removal.
2.
Position any switches that were removed from the panel and
secure them with the attaching hardware.
3.
Install the panels in place using the screws that were removed.
Functional Check.
Operate the switch as described in the Operator's Handbook.
Observe it for proper functioning in the applicable circuit. Continue
troubleshooting as necessary any system or circuit malfunction not
corrected by repair or replacement of the switch or associated
wiring.
7665
Toggle Switch Removal
Bumper Switch Removal
7666
WINDSHIELD WIPER ASSEMBLY.

Removal.
1.
Gain access to the cab windshield wiper motor by removing the

four screws from a panel located under the center front console.
2.
Taganddisconnectthethreeelectrical leadsfromthe motor.
3.
Remove the nuts and washers securing the wiper arms; then
remove the wiper arms.
4.
Remove the serrated collar.
5.
Remove the capscrews securing the mounting plate to the motor

mounting bracket.
6.
Remove the motor and mounting bracket, mounting plate, and

gasket.
Inspection.
Visually check the motor housing for evidence of cracks or other
damage. Check for excessive shaft end play indicating worn or
damaged bearings. Inspect the wiper blade for serviceability.
Installation.
1.
Install the motor and mounting bracket, mounting plate, and gasket
in position.
2.
Secure the mounting plate to the motor bracket with attaching

capscrews.
Windshield Wiper Removal and Installation

3.
Install the serrated collar.
4.
Install the wiper arms and secure them with

attaching washers and nuts.
5.
Connect the electrical leads to the motor as

marked prior to removal.
6.
Install the access cover panel under the front

console using the four screws.
'
Component
Location
2-9-8
Function
CB1 (60 AMP)
Engine compartment 6x6

electrical box
Protects all other circuit breakers and relays within

the system, with the exception of the gantry
controller and fill pump.
CB2 (20 AMP)
Breaker panel
Protects the domelight and cigar lighter.
CB3 (5 AMP)
Breaker panel
Protects the engine solenoid (SV2-0).
CB4 (5 AMP)
Breaker panel
CB5 (5 AMP)
Breaker panel
CB6 (7.5 AMP)
Breaker panel
Protects the engine start switch K1, K2, and the

quick start circuit.
Protects the throttle switch in the IDLE and MID
position.
Protects the throttle switch in the FULL position and

protects the optional horsepower limiting circuit.
CB7 (15 AMP)
Breaker panel
CB8 (10 AMP)
Breaker panel
Protects relays K11, K12, K13, K14, TK1 and TK5.
CB9 (20 AMP)
Breaker panel
Protects the heater and air conditioner.
CB10 (5 AMP)
Breaker panel
Protects the gauges, gauge lights, panel lights, and

status panel.
Protects switches within the boom hoist circuit.
CB11 (10 AMP)
Breaker panel
CB12 (10 AMP)
Breaker panel
CB13 (10 AMP)
Breaker panel
CB14 (5 AMP)
Breaker panel
Protects components within the optional third hoist

circuit.
Protects relays K6, K28 K30, K5, TK6 and
components within the front hoist circuit.
Protects relays K9, K8, K17.K29, K10, K31, and
TK7.
Protects pressure switches (PS7-8, PS1-19F, and

PS1-19R) for charge/control indicator light and relay.
CB15 (5 AMP)
Breaker panel
Protects the cab extend/retract circuit.
CB16 (5 AMP)
Breaker panel
Protects the hoist rotation indicators.
CB17 (5 AMP)
Breaker panel
Protects the A2B/LM1 system.
CB18 (5 AMP)
Breaker panel
Protects the accessory.
Component
Location
CB19
Right front switch panel
Protects the optional upper front work lights.
CB20
Protects the optional lower front work lights.
2-9-9
Function
CB21
CB22
Breaker panel
CB23
Breaker panel
Protects the optional rear work lights.

Protects the signal horn and the temperature switch
at the oil cooler.
Protects the PARK/PROPEL switch and solenoid
valves SV1-17 and SV2-17.
CB29 (50 AMP)
Protects the fill pump motor.

Hydraulic tank electrical box 4x4
CB30 (5 AMP)
A circuit breaker switch which protects relay K23.
F2 (4 AMP)
Gantry relief valve
Protects the gantry controller.
K1
Starter
Is energized when the IGNITION switch is in the ON
portion and engine switch is depressed to START to
engage the starter through K1.
K2
Engine compartment
Is energized as described in K1 function, K2
completes the circuit to energize K1.
K4
Cab electrical box

Is grounded through the safety interlock switch to
provide power to the crane functions.
Z)
Cab electrical box
Is energized by the front hoist freefall switch and brake

pedal to place the front hoist in freefall mode and provide
power to the front hoist freefall indicator light.
Cab electrical box

Is energized by the front hoist high speed switch to place
the front hoist in the high speed mode and provide power
to the front hoist indicator light.
2
K8
Cab electrical box

Is energized by the rear hoist high speed switch to place
the rear hoist in the high speed mode and provide power
to the rear hoist high speed indicator light.
Component
Location
K9
Cab electrical box
Function
Is energized by the optional clamshell select switch

and creates the condition necessary for clamshell
operation of the front and rear hoist.
K10
Cab electrical box
2-9-10
Is energized by the rear hoist freefall switch and

brake pedal to place the rear hoist in freefall mode
and provide power to the rear hoist freefall indicator
light.
K11
Cab electrical box

Is energized by the switch turned to the ON position through
K19 and TK1 and provides power to front hoist high speed
and front hoist freefall indicator lights.
K12
Cab electrical box

Is energized in the same manner as K11 and provides
power to the rear hoist high speed and rear hoist
freefall indicators.
K13
Cab electrical box
K14
Cab electrical box

power to the low hydrauic oil temperature, charge
pressure, control pressure, and engine indicator
lights.

power to the high hydraulic oil temperature and
change hydraulic filter indicator light.
K17
Cab electrical box

Is energized by relay K9 and switch S22 and provides
a holding circuit for K9 through PS6B-7 and PS7B-7.
K19
Cab electrical box

Is energized by the ignition switch in the ON position.
Provides power to cab controls and instruments,
swing horn, oil cooler temperature switch, status
panel, relays TK1 and TK5, and throttle switch.
K23
Is energized by a circuit breaker switch (CB30) and

provides power to the hydraulic field fill pump motor.
Cab electrical box

Is energized by a pressure switch (PS6A-7 or PS7A7) to prevent switching speed on the front hoist when
the hoist is rotating.
Component
Location
K29
Cab electrical box
Function
Is energized by a pressure switch (PS10-7 or PS9-7) to
prevent switching speed on the rear hoist when the hoist is
rotating.
v!)
Cab electrical box

Is energized by depressing the front hoist brake pedal
and positioning the front hoist freefall svyitch to NORM
in order to exit freefall which deenergizes relay K5.
K31
Cab electrical box

Is energized by depressing the rear hoist brake pedal
and positioning the rear hoist freefall switch to NORM
in order to exit freefall by deenergizing relay K10.
2-9-11
TK1
Cab electrical box

Is energized by K19 providing status panel power and
times out after 5 seconds. TK1 deenergizes relays
K11, K12, K13, and K14.
TK5
Cab electrical box

Is energized by any of the red indicators circuits after
starting the engine. After 30 seconds, the relay breaks
its contacts and stops the alarm.
^TK6^)
Cab electrical box
TK7
Cab electrical box
Is energized by relay K5 which energizes SV1-19F,

after 1 second breaks it's contacts to deenergize SV119F.
Is energized by relay K10 which energizes SV1-19R,
after 1 second breaks it's contacts to deenergize SV119R.
HOIST SPEED SELECT, FREEFALL, AND

STATUS PANEL ELECTRICAL CIRCUITS
DESCRIPTION
HOIST
SPEED
CIRCUIT.
SELECT
The front hoist circuit will be

described in this description,
the rear hoist circuit is
identical with the exception of
the relay and solenoid
numbers. The sjx major
components of the hoist
speed select circuit are the
controller pressure switches
(PS6A-7 & PS7A-7). relay
K26, relay K28, relay K6,
hoist speed switch, and PST3F. The controller pressure
switches supply power to
2-9-12
energize the coil of relay K28.

The contacts of relay K26
control power from pressure
switch PS6A-7 in the up
direction. In the event of two
block, the contacts of relay
K26 will open and eliminate
power from the hoist speed
select circuit. Relay K28 has
two functions; when selecting
high speed it provides power
to the coil of relay K6 when
K28 is deenergized and when
energized provides a holding
circuit to prevent changing
hoist speed while the hoist is
rotating. Relay K6 is the high

speed relay and when
energized provides power to
solenoid valve SV1-4F and
the high speed indicator frgfli
The hoist speed switch
determines the hoist speed.
Pressure
switch
PS1-3F
provides the high speed
circuit with a holding circuit
and will change the hoist
speed from high to low if the
hydraulic system pressure
reaches 4500 psi (31,028
kPa/310 bar).
The hoist high speed holding
circuit is maintained electrically until system pressure
reaches 4500 psi (31,028
kPa/310 bar) or until the hoist
speed switch is manually
switched to low while the
controller is in the neutral
position. The control lever
must be in the neutral
position to allow K28 to be
deenergized. Positioning the
hoist speed switch to high
allows power to pass through
the
closed
contacts
of
deenergized K28 to the coil of
K6. When the coil of K6 is
energized, a holding circuit is
established from the speed
select switch terminal 5,
across contacts 10 to 6 of
relay K6, back to the switch
terminals 2 to 1, through
pressure switch PS1-3Fto the
coil of K6. This will maintain
the hoist in high speed after
releasing the speed select
switch.
A second holding circuit is
established when the control
lever is actuated. This holding
circuit will bypass the hoist
speed switch and provide an
additional source of power to
the coil of K6 to prevent
changing speed while the
hoist
drum
is
rotating.
Energizing K28 allows power
to be supplied from contact 6
of K6 through the now closed
contacts 10 to 6 of K28 to
contact 1 of the speed select
2-9-13
switch
through
pressure
switch PS1-3F to the coil of
K6. This prevents changing
from high to low speed while
rotating the hoist.
HOIST FREEFALL CIRCUIT.
The front hoist freefall circuit
will be described in this
description, the rear hoist is
identical with the exception of
the relay and solenoid
numbers. The five major
components within the freefall
circuit are the select switch,
relay K5, relay TK6, PS6-8,
and relay K30. The select
switch is spring return to the
center position and supplies
power to the freefall circuit.
Relay K5 is the freefall relay
which when deenergized
provides the circuit for
automatic
hoist
brake
operation. When relay K5 is
energized,
it's
contacts
energize the freefall indicator
light, TK6, various solenoid
valves, a holding circuit to
maintain K5 energized, and
provides a second source of
power to K4, bypassing the
charge and control pressure
switches. Relay TK6 allows
solenoid valve SV1-1 9F to be
energized. After one second,
the contacts of energized TK6
will open to deenergize SV1 19F. When the brake foot
pedal is depressed, pressure
switch PS6-8 is activated and
supplies power to either K30
or K5 coil depending on the
position of the select switch.
Relay K30 has two functions;
when deenergized it's contacts are part of the holding
circuit for K5, when energized
it's contacts open to break the
circuit to K5.
To enter freefall, position the
hoist brake switch to AUTO
and simultaneously depress
the freefall select switch to
FREE and depress the brake
foot pedal. Power is supplied
from the switch terminal,
across the contacts of

pressure switch PS6-8 to the
coil of K5. Since K30 is
deenergized a holding circuit
is established from the switch
through K30 contacts across
contacts 9 to 5 of K5 to the
coil of K5. The hoist will
remain in the freefall, mode.
To exit freefall, simultaneously
depress the freefall select
switch to NORM and depress
the brake foot pedal. This will
supply power across the
contacts of pressure switch
PS6-8 to the coil of K30. The
coil of K30 will energize to
open it's contacts and break
the holding circuit for K5. The
hoist is now out of the freefall
mode.
STATUS
PANEL
AUTOMATIC TEST CIRCUIT.
The status test panel has two
functions. The first function is
to test itself for proper
operation to ensure the alarm
and indicator lights are
functioning.
The
second
function is to alert the
operator of any problems or
conditions after the engine
has started. There are three
colored indicator lights used,
amber (advisory), orange
(caution), and red (warning).
In addition, the alarm will
s'
CJ
2-9-14
sound whenever a red

(warning) light illuminates.
The status panel receives
power through circuit breaker
CB8 when the ignition switch
is turned to the ON position.
Relays K11, K12, K13, and
K14 will energize through
closed contacts of relay TK1.
When these relays energize,
all indicator lights on the
status panel will illuminate.
Atthe same time, the alarm
will sound. After 5 seconds
TK1 will open it's contacts
and remove power from
relays K11, K1 2, K13, and
K14. At this time all of the
lights will go out except the
charge
pressure,
control
pressure,
and
engine
indicator lights. These lights
will
remain
illuminated
because the engine has not
been started. The alarm will
sound for an additional 25
seconds until TK5 opens it's
contacts or the engine is
started. After starting the
engine, if a problem or
condition becomes apparent
through any of the relays,
temperature switches, or
pressure switches, power will
be routed across the contacts
of
the
relays
to
the
appropriate indicator light.
LA
2-9-15
2-9-16
2-9-17
2-9-18
2-9-19
Hoist Freefall Circuit
Status Panel Circuit
0438-3
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VALVE
BODY
LOCATIO
N TABLE
Valve Body
Circuit Used In
M1
Charge
M3F
Front Hoist
M4F
Front Hoist
M3R
Rear
Hoist
Rear
Hoist
Physic
al
Locati
on
Situado
detrs de
la puerta
de
acceso
de
la
bomba
que est
en el lado
derecho
2-4-83
Control
Oil Cooler (Control)
de
la
estructur
a
superior.
El cuerpo
de
la
vlvula
de carga
est
asegurad
a a la
abrazade
ra
que
est
montada
en
la
parte
superior
de
la
unidad
de
bomba.
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
the front
hoist
frame
and the
Haggland
s motor
distributor
.
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
valve
body
M3F.
Located
on
the
right side
of
the
upperstru
cture and
secured
2-4-84
directly to
the
rear
hoist
frame
(middle
frame)
and
the
Haggland
s
motor
distributor
.
M4R
M5
M6
Located
on
the
right side
of
the
upperstru
cture and
secured
directly to
the valve
body
M4R.
Located
on
the
control
accumula
tor
and
the
accumula
tor
is
located
below the
pump
drive
on
the
tail
section of
the
upperstru
cture.
Located
on
the
left side
of
the
upperstru
cture
behind
the door
for
gaining
access to
the
oil
cooler
radiator.
The valve
body is
located
2-4-85
behind
the
radiator
and
is
mounted
on
the
bottom of
the
radiator
frame
mount.
M7
Control
Located under the operator's cab. The valve body is placed over a cutout in the cab
floor for routing hoses to the cab control lever, valve body.
M8
Control
Located under the operator's cab, the valve body routes control pressure to the
valve body M7 and the hoist brake pedals in the operator's cab.
M9
Cab Control
Lever
Located in the operator's cab between the operator's control levers. There are two if
the optional third drum hoist is used.
M10F
Front Hoist Brakes
Located on the front hoist frame below valve bodies M3F and M4F on the right side
and Brake Pawl
of the upperstructure.
2-4-86
2480
7548
Valve
Bodies
Locati
on
BRAKE ACCUMULATOR
REAR HOIST
BRAKE ACCUMULATOR
FRONT HOIST
VALVE BODY M4
BRAKE PAWL VALVE
BODY M10
VALVE BODY M3
VALVE BODY M4
VALVE BODY M3
BRAKE PAWL VALVE BODY M10
^^CALIPER BRAKE
Front and Rear Hoists

CLEANING AND INSPECTION.
1.
'it,.
6.
Clean all the parts in a suitable solvent. Blow dry with filtered air. Do not dry the bearing
by spinning with compressd air.
7.
2.
Inspect the bearing for excessive wear and replace as needed.
3.
It is recommended that all seals and O-rings be replaced.
4.
Inspect the splines on the shaft for damage or excessive wear.
5.
Install the shaft end cap to the end of the shaft using the four bolts. Wrench tighten the
bolts.
8.
Install the two keys to the input end of the hydraulic motor.
9.
Slide the motor hub weldment block over the keys and onto the hydraulic motor using a
suitable lifting device.
assembly and the hydraulic motor. Lubricate and install new O-rings in the valve
assembly.
Inspect the machined surfaces of the shaft for scratches and burrs. Minor scratches may
be polished out using a crocus cloth.
6.
Install the brake disc onto the splined shaft.
11. Apply Loctite to the six Grade 8 bolts used to mount the valve assembly.
1 2. Using a suitable lifting device, install the valve assembly to the hydraulic motor
using the six bolts and hardened flat washers. Torque the bolts to 1 70 pounds-foot (24
kgm).
ASSEMBLY.
NOTE
1 3. Attach a suitable lifting device to the hydraulic motor and install it to the hoist.
When replacing O-rings, be sure to use 90 durometer O-rings.

Lubricate new O-rings with clean petroleum jelly.
1.
Press the bearing into the bearing block.
2.
Lubricate and install a new seal into the smaller diameter bore of the bearing block.
3.
Press the bearing block onto the splined shaft on the hoist drum.
4.
Install the remaining seal into the exposed bore of the bearing block.
5.
Lubricate the splines of the shaft with Never-Seeze.
NOTE
Ensure the hoist is positioned so the hydraulic motor end is
pointing upward. Block, as necessary, to thoroughly support and
balance the hoist.
14. Apply Loctite 242 to the 24 Grade 8 bolts used to mount the hydraulic motor.
15.
Install the 24 bolts and flat washers that attach the hydraulic motor to the hoist drum.
Torque the bolts to 170 pounds-foot (24 kgm).
4
7438
1.
INSTALLATION.
5.
Attach a suitable lifting device to the hoist.
6.
2.
Lift and position the hoist into its mounting bracket on the upperstructure.
3.
Apply loctite to the four bolts that attach the hub bearing blocks to the hoist frame.
4.
Install the two hub bearing blocks to the hoist frame using the four bolts and flat
washers. Torque the bolts to
1 360 pounds-foot (188 kgm).
Install the rotation indicator transmitter using the two bolts and lockwashers.
Connect the pawl by installing the pin through the clevis on the spring loaded cylinder
and through the pawl. Install the cotter pin to the pin.
7.
8.
Lubricate and install new O-rings to the tubes that use split-flanges.
Connect the hydraulic tubes, using the split flanges, to their corresponding ports as
marked previously.
10. Thoroughly clean the mounting faces of the valve

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the switch is in the OFF position and the switch S8 (SWING

BRAKE switch) in the control lever handle is in its normally closed

Air Conditioner Switch. (Optional.)

LINES AND LINE FUNCTIONS

BELOW FLUID LEVEL

PRESSURE REDUCING ELECTRIC MOTOR

TWO POSITION FOUR

THREE POSITION FOUR

TWO POSITION THREE

ACCUMULATOR, GAS CHARGED

TWO POSITION TWO

PILOT PRESSURE REMOTE

VALVES CAPABLE OF INFINITE

A.N.S.I. Graphical Symbols

Shut down the engine and remove the pressure guage.

IF RV2 WAS ADJUSTED, RV1 MUST ALSO BE

Setting RV1 in M5.

Setting RDV1 in M8.

Shut down the engine and remove the pressure gauge.

Install a 0 to 500 psi (0 to 3447.5 kPa/0 to 34.5 bar) pressure gauge in

4. If pressure does not reach 3000 psi (20,685 kPa/

Tighten the jam nut and recheck the pressure.

Shut down the engine. Remove the gauge.

Install a 0 to 500 psi (0 to 3447.5 kPa/0 to 34.5 bar) pressure gauge

ENSURETHE ENGINE IS SHUTDOWN BEFORE

Install a 0 to 10,000 psi (0 to 68,950 kPa/0 to 689.5

Locate the POR on top the HDC on pump P1.

POR Adjustment - Front, Rear, and Boom Hoists

The POR must be adjusted with the

Install a Oto 10,000 psi (Oto 68,950 kPa/0 to 689.5

Locate the POR on top the HDC on pump P3.

If the pressure reading is less than or greater than

Shut down the engine and remove the pressure

Shut down the engine and remove the pressure

WHEN CHECKING OR SETTING

Loosen and remove the nut that secures the

Install a 0 to 1 0,000 psi (Oto 68,950 kPa/Oto 689.5

Locate the POR on top the HDC on pump P2.

Start the engine and position the throttle to FULL.

If the pressure reading is less than or greater than

If the pressure reading is less than or greater than

increase the pressure by turning the adjustment 6.

Valve Body M4.

All components must be installed

Install all plugs to the M4 valve body as marked

Install the valve cartridge plug (6) into port PV2.

Install the valve cartridge plugs (5) into ports SV4,

Lubricate and install new O-rings to all the mating

Install the M3 valve body to the M4 valve body using

Install all electrical lines as marked during removal.

Install all hydraulic lines to the M3/M4 valve body as

Install the valve cartridge (3) into port SV2.

CLEANING AND INSPECTION.

Clean all the parts in a suitable solvent.

Submerge the valve bodies in a suitable solvent and

It is recommended that all O-rings be replaced with

Inspect the ports on the valve bodies

12. Locate the face of the M3 valve

Install the valve cartridge

with the spring end pointing outward,

Install the valve spacer

deeper counterbore end installed

first. Lubricate and install Valve Body M3.