JLG GRADALL 522 Owner'S/Operator'S Manual Download Page 88

Page: 88 / 288

PROA 3 5 2 /3 8 2

Item

Description

Center Housing

Bushing

Trunnion Oil Seal

Lubrication Fitting

Level Plug

Drain Plug

Vent Plug

Hydraulic Line Bleeder

Cover

Capscrew M8x1,25x16,0

Differential Case Assembly

Washer

Capscrew M10x1,5x80,0

Drive Disc

Driven Friction Disc

Clutch Disc Shim

Compression Disc

Thrust Washer

Side Gear

Thrust Washer

Pinion Gear

Spider

Spiral Gear & Pinion

Washer

Capscrew

Bearing Cone

Bearing Cup

Brake Housing

Capscrew

Adjuster Ring

Adjuster Ring Lock

Capscrew

Pinion Cage Shim

Pinion Cage

Bearing Cup

Bearing Cone

Drive Pinion Shim

Washer

Capscrew

Pinion Nut

Driven Sleeve

Drive Sleeve

Snap Ring

Motor Adapter Flange

Washer

Capscrew

Item

Description

Brake Piston Assembly

O-ring Piston

Piston Brake Shim

Brake Piston

O-ring Piston

Spring

Washer

Bolt–Return Spring

Spring

Brake Actuating Plate

Capscrew

Stationary Disc

Friction Disc

Brake Reaction Plate

Brake Disc Lock Pin

Sun Gear

Ring Gear

Capscrew

Planetary Pinion Spider

Planetary Pinion Shaft

Capscrew

Housing

71A

Bushing

Bearing Cone

Bearing Cup

Output Axle Shaft

Wheel Flange

Wheel Bolt

Capscrew

Axle Shaft Oil Seal

Adjusting Nut

Adjusting Nut Lock Capscrew

Thrust Washer

Kit Rollers

Spacer

Planetary Pinion

Washer

Snap Ring

Stud

Capscrew

Washer

Nut

Spacer

Brake Release Capscrew

Courtesy of Crane.Market

Summary of Contents for GRADALL 522

Page 1: ...ng S N 0588001 S ERVI CE MANUAL CORPORATE OFFI CE JLG INDUSTRIES INC 1 JLG DRIVE McConne llsburg PA 17233 9533 USA Te le phone 717 485 5161 Fa x 717 485 6417 GRADALL DI VI S I ON JLG INDUSTRIES INC 40...

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Page 3: ...OPERATOR MANUAL CORPORATE OFFI CE JLG INDUSTRIES INC 1 JLG DRIVE McConne llsburg PA 17233 9533 USA Te le phone 717 485 5161 Fa x 717 485 6417 GRADALL DI VI S I ON JLG INDUSTRIES INC 406 Mill Ave nue S...

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Page 57: ...x 8118 North Mankato MN U S A 56002 8118 Phone 507 625 6426 Facsimile 507 625 3212 MICOWest Division 701 East Francis Street Zip Code 91761 5514 P O Box 9058 Ontario CA U S A 91762 9058 Phone 909 947...

Page 58: ...ty See Specification Chart page 7 System pressure 0 2000 psi Brake line pressure See Specification Chart page 7 Master cylinder capacity 3 1 in 3 Push rod travel with power 0 2 approx Push rod force w...

Page 59: ...n the operation of the brakes Manual braking is always available whenever the hydraulic power system is not functioning This is accomplished by a mechanical follow through within the brake valve A lon...

Page 60: ...TING SPRING and when the hydraulic pressure balances against the PRESSURE REGULATING SPRING the pressure is controlled to the MASTER CYLINDER The ORIFICE controls the rate of flow to the REACTION CHAM...

Page 61: ...ed in the brake lines in manual operation is proportional to the pedal ratio and the effort which the operator is able to exert on the pedal In most cases the operator is not able to build as much pre...

Page 62: ...for disc brake systems because of the pressure they maintain in the brake lines when the pedal is released Even these relatively low pressures 12 20 PSI would develop drag in this type of brake SLIDI...

Page 63: ...50 psi 3 12 gpm 06 460 666 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 950 psi 50 psi 3 24 gpm 06 460 668 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1000 psi 50 psi 3 12 gpm 06 460 670 SAE No 10 SAE No 1...

Page 64: ...ew cup item 9 on sleeve item 10 and new cup item 5 on spool item 6 CAUTION Assembly Lips on cups items 5 9 should be away from ends of spool item 6 and sleeve item 10 Place spring item 7 in sleeve ite...

Page 65: ...460 580 06 460 588 06 460 610 06 460 620 06 460 650 06 460 680 06 460 686 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 45...

Page 66: ...n new piston poppet assembly item 17 Install spring item 20 and piston poppet assembly item 17 in end cap item 22 NOTE If you have model 06 460 Install lock washers item 23 and bolts item 24 Torque 16...

Page 67: ...06 460 678 06 460 682 06 459 010 06 459 020 06 459 020 06 459 020 06 459 020 06 459 020 06 459 020 06 459 010 06 459 020 06 459 010 06 459 020 06 459 010 06 459 020 06 459 010 11 FIGURE 11 NOTE Resid...

Page 68: ...7 18 19 20 21 22 BOOT PRESSURE REGULATING SPRING ASSEMBLY HOUSING O RING CAP SCREW GASKET RETAINING RING PUSH ROD CUP SPOOL SPRING CUP PISTON RING SLEEVE PISTON ASSEMBLY PISTON POPPET ASSEMBLY O RING...

Page 69: ...Model Number Repair Kit 06 460 642 06 460 684 06 459 020 06 459 020 13 FIGURE 12 Items included in Repair Kit 06 459 020 Courtesy of Crane Market...

Page 70: ...reservoir Check and tighten pump belt if necessary 1 1 2 2 3 3 4 4 5 5 1 1 2 2 3 3 1 1 2 2 1 1 1 1 2 2 1 1 2 2 3 3 4 4 1 2 3 BLEEDING TheMICOOpenCenterPowerBrake Valve and remaining brake system are...

Page 71: ...th the line and brake closest to the brake valve Allow a sufficient amount of fluid to pass at brake bleeder screw to insure all air is removed from each bleeder point Continue this method until all b...

Page 72: ...es and other printed material MICO can accept no responsibility for errors from unitentional oversights that may exist Due to a continuous program of product improvement both materials and specificati...

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Page 78: ...on without notice or liability 1 You must understand all procedures and instructions before you begin maintenance and service procedures 2 You must follow your company s maintenance and service guidel...

Page 79: ...I PRA 352 Trumpet Variation No 1 47 Courtesy of Crane Market...

Page 80: ...Sleeve 38 Drive Sleeve 39 Snap Ring 40 Motor Adapter Flange 41 Washer 42 Capscrew Item Description 43 Outer Piston 44 Piston O ring 45 Piston O ring 46 Piston Brake Shim 47 Inner Piston 48 O ring Pis...

Page 81: ...65 73 73 72 64 63 62 60 59 58 61 59 57 56 55 48 49 46 50 52 51 47 53 54 44 45 43 42 40 38 39 41 38 21 20 19 26 16 17 18 24 23 22 25 27 28 40 42 45 44 47 50 49 46 54 53 52 51 48 55 56 57 59 59 60 62 6...

Page 82: ...Adjuster Ring 36 Adjuster Ring Lock 37 Adjuster Ring Lock Capscrew 38 Stationary Disc Item Description 39 Friction Disc 40 Brake Reaction Plate 41 Brake Disc Lock Pin 42 Ring Gear 43 Sun Gear Short 4...

Page 83: ...49 43 42 41 40 37 38 36 36 85 84 86 87 88 89 20 13 14 19 18 26 15 16 17 27 28 23 22 21 25 30 29 4 3 6 5 8 7 2 9 10 11 11 12 12 31 33 32 34 35 59 36 37 36 38 37 39 37 57 40 49 44 45 47 48 56 51 52 53...

Page 84: ...n Disc 38 Brake Disc Lock Pin 39 Brake Assembly 40 Pin 41 Circlip 42 Brake Control Rod 43 Brake Cylinder Support 44 Spring 45 Brake Piston Item Description 46 O ring 47 O ring 48 Brake Cylinder 49 Cap...

Page 85: ...100 70 71 48 73 1 99 97 95 96 6 5 10 4 12 11 8 9 7 29 30 33 40 39 38 37 34 35 36 28 58 85 77 84 86 65 66 60 61 62 63 83 82 57 56 55 54 53 32 76 80 81 74 79 78 21 23 22 15 14 13 43 19 18 20 46 24 26 2...

Page 86: ...lange Capscrew Washer 40 Flange Capscrew 41 Brake Housing 42 Brake Housing Capscrew 43 Adjusting Ring 44 Adjusting Ring Lock 45 Lock Capscrew 46 Stationary Disc 47 Friction Disc 48 Brake Disc Lock Pin...

Page 87: ...IX PROA 352 382 Courtesy of Crane Market...

Page 88: ...Pinion Nut 43 Driven Sleeve 44 Drive Sleeve 45 Snap Ring 46 Motor Adapter Flange 47 Washer 48 Capscrew Item Description 49 Brake Piston Assembly 50 O ring Piston 51 O ring Piston 52 Piston Brake Shim...

Page 89: ...tial Assembly Inspect Axle Shafts Inspect Main Housing 16 Inspect Yoke Inspect Planetary System Parts Inspect Brakes Repair or Replace Parts Repair Welding Liquid Adhesive 17 Disassemble Locked Sets C...

Page 90: ...all and Ramp Brake Cylinder Assembly and Install on Main Housing Section 5 Adjustments Check Ring Gear Runout Specification 0 008 in 0 20 mm 47 Adjust Pinion and Ring Gear Backlash Specification 0 005...

Page 91: ...ly Wet Disc 3 Three Function Brake Identification A tag on the main housing correctly identifies basic axle specifications When ordering parts be sure to specify information stamped on the name plate...

Page 92: ...vehicle with safety stands 4 Remove axle from vehicle 5 Plug fluid lines that were connected to axle 6 Place axle in appropriate repair stand Center main housing on stand Figure 2 1 7 Remove drain pl...

Page 93: ...p loading 1 Support trumpet to be serviced with lifting device Figure 2 3 2 Loosen and remove trumpet nuts and bolts 3 NOTE For three function brake design If bleeder and pressure ports of brake pisto...

Page 94: ...Shaft NOTE Before removing planetary gears place housing in horizontal position or place cloth between pinion gear flange and housing flange to keep rollers from falling down into housing To avoid mi...

Page 95: ...0 5 Follow steps 1 through 4 to disassemble the second brake piston Disassemble Three Function Wet Disc Brake NOTE Do not disassemble brake piston unless necessary 1 Remove return spring capscrews wit...

Page 96: ...or place assembly in press and apply 1000 lbs 450 kg pressure 5 Remove action plate capscrews Figures 2 13 and 2 14 CAUTION Before removing action plate and other parts mark the original assembly posi...

Page 97: ...Remove brake housing from main housing Hit brake housing with brass hammer or use two slots to remove it from main housing Be careful not to hit ring gear Figure 2 18 5 Depending on ring gear position...

Page 98: ...rass or rubber hammer to separate halves 4 Remove spider cross differential pinions side gears and washers If differential case is Limited Slip remove friction disc pack Figure 2 22 5 If differential...

Page 99: ...ng press operation to avoid serious personal injury and possible damage to components during removal and disassembly procedures 7 If differential case has two halves remove ring gear with a press afte...

Page 100: ...he hammer or mallet can damage the parts or cause alignment problems Do not damage the oil seal surface area 2 Remove yoke flange or splined sleeve from drive pinion with appropriate puller tool Figur...

Page 101: ...arded measure and record total thickness of the pack The dimension will be needed to calculate depth of drive pinion in main housing when gear set is installed 8 Place drive pinion and bearing cage in...

Page 102: ...e from drive pinion with press or bearing puller Puller must fit under inner face of cone to remove cone correctly without damage Figure 2 40 NOTE If bearing cup is changed the bearing cone must also...

Page 103: ...Replacement of damaged or worn parts will prevent breakdown of assembly later Clean Ground and Polished Parts WARNING To prevent serious eye injury always wear safe eye protection when you perform veh...

Page 104: ...ers are worn to a sharp edge Figure 3 1 A visible roller groove in the cup or cone inner race surfaces The groove can be seen at the small or large diameter end of both parts Figure 3 2 14 Deep cracks...

Page 105: ...ts and spline in the pinion shaft 15 Inspect Main Differential Assembly Parts that are damaged must be replaced Inspect the following parts for wear or stress Figure 3 6 Inside surfaces of both case h...

Page 106: ...and repair threads of fasteners and holes Use a die or tap of the correct size or a fine file for this purpose CAUTION Threads must be without damage and clean so that accurate adjustment and correct...

Page 107: ...hout ventilation Do not use trichloroethylene near flames welding operations or hot surfaces exceeding 900 F 482 C Clean capscrew nut or bolt tapped hole and fastener thread carefully Use a cleaning s...

Page 108: ...Remove all oil grease dirt and moisture 3 Thoroughly dry both surfaces 4 Apply according to the following procedures Three Bond 1134 or Loctite 515 Apply approximately a 0 125 inch 3 18 mm diameter c...

Page 109: ...ring bore 5 Clean components with trichloroethylene and a clean cotton cloth or a paper towel Figures 3 9 and 3 10 CAUTION Make sure that Toric ring 2 is seated in oil seal ring 1 Be careful when you...

Page 110: ...cular to ring bore Use a rapid and uniform pressure to push Toric ring under ring retention lip Figure 3 14 5 Verify mounting distance A in at least four places spaced 90 degrees apart The difference...

Page 111: ...t remove oil seal from bore and repeat steps 3 6 A Toric ring must never slide on any ramp of oil seal ring or bore To prevent sliding wait at least two minutes for trichloroethylene to evaporate befo...

Page 112: ...nter Figure 3 21 shows an incorrect installation of an oil seal in its mounting position The upper bore is stopped and the lower lodge is rotating Figure 3 22 shows the same lower bore after rotation...

Page 113: ...1 C to 82 C for 10 to 15 minutes DO NOT USE AN OPEN FLAME SUCH AS A TORCH FOR THIS PROCEDURE 3 Install ring gear on case half or in the integral differential case WARNING To avoid serious personal inj...

Page 114: ...ect position by turning side gears until pinion holes are aligned with differential pinion axle holes Figure 4 4 c Install differential pinion washers d Install differential pinion axle and lock capsc...

Page 115: ...sc followed by driven friction discs Make sure lubrication grooves are aligned Figure 4 7 Maintain the following sequence 1 Drive disc 2 Driven friction disc 3 Drive disc 4 Driven friction disc 5 Driv...

Page 116: ...ck k Repeat steps A through I for the plain differential case half l Follow steps 9 through 11 to assemble differential case Check Rotating Resistance of Differential Gears Not Limited Slip NOTE Make...

Page 117: ...1 Place bearing cage in press Figure 4 14 2 Support bearing cage with metal or wood blocks 3 Press the bearing cup into bore of bearing cage until cup is flat against bottom of bore Use correct size s...

Page 118: ...Kg cm to N m multiply by 0 098 1 Lubricate bearing cups and cones with specified oil 2 Install yoke or flange without pinion oil seal 3 Install pinion bearing cage assembly on main housing without bea...

Page 119: ...of seal The diameter of the sleeve must be larger than diameter of flange Figure 4 20 d Install yoke or flange and pinion nut into pinion e Tighten pinion nut to specified torque after installing pini...

Page 120: ...rd the number for later use 6 If the new pinion cone number is a plus add the number to the standard shim pack thickness that was calculated in step 3 or 4 Figure 4 23 7 If the new pinion cone number...

Page 121: ...r If necessary use rubber plastic or leather mallet to tap assembly into position Figure 4 25 3 Install two capscrews and washers that fasten bearing cage Tighten to minimum torque of 67 lb ft 90 N m...

Page 122: ...m 2 Install shims Combine two shims to obtain desired thickness Figure 4 28 NOTE Usually a 0 102 0 104 inch 2 60 2 65 mm shim pack thickness is enough to obtain specified backlash and differential bea...

Page 123: ...d gasket material to main housing surface 11 Install three bolts into the brake housing to adjust differential Tighten them to 19 26 lb ft 26 36 N m 12 Apply medium torque liquid adhesive Loctite 241...

Page 124: ...de during disassembly 14 Install 3 bolts into the brake housing to adjust differential Tighten them to 19 26 lb ft 26 36 N m Figure 4 31 15 Apply medium torque liquid adhesive Loctite 241 or Three Bon...

Page 125: ...nstallation procedures 1 Use press to install new planetary pin into spider Make sure proper dimensions are used and holes are aligned Figures 4 38 and 4 39 Figure 4 37 DUO CONE OIL SEAL WARNING To av...

Page 126: ...ting nut with special tool shown on page 60 At the same time manually rotate the trumpet to assure a correct fit between bearing cups and cones and get desired preload Figure 4 43 Figure 4 42 Figure 4...

Page 127: ...lock capscrew Tighten to 17 23 lb ft 23 0 30 5 N m 10 Install inner washer planetary gears and rollers into flange Figure 4 44 11 Install outer washers 12 With correct pliers install snap rings Figure...

Page 128: ...ng assembly find and correct the problem 3 Wait five minutes then apply 600 psi 41 4 bar to the cylinder again Figure 4 49 Assemble Hydraulic Apply Brake Housing Assembly NOTE To assemble three functi...

Page 129: ...icks 1 Select piston shim pack with the following procedure a Position parts of piston assembly in a press Measure the dimension A under 441 lb 200 Kg pressure Figure 4 50 b Measure the dimension B Fi...

Page 130: ...and oil seal bores with SAE 90 oil Figure 4 53 NOTE Each piston assembly has three different sizes of oil seals three large one medium one small 3 Install medium oil seal into inner piston bore and in...

Page 131: ...arger oil seals into outer piston Make sure the oil seals fit in the bores Figure 4 58 Figure 4 57 Figure 4 58 LARGER OIL SEALS 3 2 4 1 T 10 Install shim pack into brake housing Use bolts to align hol...

Page 132: ...N DISC REACTION PLATE FRICTION DISC SPACER EXPANSIVE PLATE PIN 14 With piston still compressed apply 350 psi 24 bar into parking brake to make sure oil seals fit in bores Figure 4 61 15 Keep the parki...

Page 133: ...DISCS Install Housing Assembly into Main Housing NOTE If axle is equipped with three function brake keep parking brake pressurized 1 Install housing assembly Make sure that the mark made during disas...

Page 134: ...AL NOT ALLOWED Assemble Three Function Brake Release Bolts and Sleeves 1 Apply Loctite 516 on bolt threads Figure 4 67 2 Apply liquid gasket material Silastic 780 RTV Dow Corning on non threaded bolt...

Page 135: ...apply liquid adhesive Loctite 221 or Three Bond 1341 on threads of brake shaft Install adjusting nut until it rests against piston DO NOT TIGHTEN ADJUSTING NUT Loosen the adjusting nut one full turn F...

Page 136: ...PORT CYLINDER WITHOUT PRESSURE O RING LOCK NUT COVER 6 After 1 47 inch 37 0 mm dimension is obtained apply specified pressure to brake and check the brake torque on pinion as shown in chart Torque Dis...

Page 137: ...flange and transfer damage to ring gear In this case differential carrier must be discarded 6 After parts are repaired or replaced install main differential case and ring gear assembly into carrier Re...

Page 138: ...h Contact Patterns In the following procedures movement of the contact pattern along length of tooth is indicated as toward the heel or toe of the ring gear Figure 5 4 Verification Procedure 1 Apply a...

Page 139: ...ly the full length of tooth The top of pattern will be near top of gear tooth Figure 5 8 Figure 5 7 Figure 5 8 The location of a good hand rolled pattern for a used gears set must match wear pattern i...

Page 140: ...on along length of gear teeth When toe contact pattern indicates that backlash is very low and gear is too close to drive pinion Figure 5 13 Withdraw ring gear by decreasing shim pack thickness or loo...

Page 141: ...oil until oil level is even with bottom of fill level hole See Section 6 Specifications 4 Install and tighten fill level plugs 5 Road test vehicle in an unloaded condition for one two miles 1 6 3 2 km...

Page 142: ...ighway Operation Intervals Initial Check Petroleum Synthetic Oil Oil Oil Oil Meritor Military Oil Change Level Change Change Specification Specification Description 100 250 1 500 0 84 Petroleum Base o...

Page 143: ...UNC 13 78 in 350 0 mm 0 079 in 20 0 mm 0 197 in 5 0 mm x 45 1 77 in 45 0 mm 0 57 in 14 5mm 0 078 in R 2 0 0 984 in R 5 0 3 15 in 80 0 mm 0 79 in 20 0 mm 1 97 in 50 0 mm 0 39 in 10 0 mm x 45 4 53 in 1...

Page 144: ...54 Section 6 Specifications 4 2 7 17 18 13 9 12 6 8 5 1 3 19 14 11 15 16 10 PROA 352 382 With Mechanical Drive Option Courtesy of Crane Market...

Page 145: ...3 lb ft 23 30 N m 8 Capscrew Brake Housing M8 x 1 25 6G 19 26 lb ft 26 36 N m 9 Capscrew Brake Releaser M12 x 1 75 6G 25 34 lb ft 34 46 N m 10 Capscrew Flange Adapter 3750 x 16UNC2A 39 0 53 0 lb ft 53...

Page 146: ...56 Section 6 Specifications 5 4 13 6 1 3 10 2 8 12 11 8 7 9 2 PRA 352 Trumpet Variation No 2 Courtesy of Crane Market...

Page 147: ...crew Spiral Gear M10 x 1 0 6G 66 75 lb ft 90 100 N m 6 Capscrew Pinion Cage M12 x 1 75 6G 67 91 lb ft 90 125 N m 7 Capscrew Lock Adjuster Ring M6 6G 80 115 lb in 9 13 N m 8 Capscrew Adjusting Nut Lock...

Page 148: ...58 Section 6 Specifications 5 20 19 16 21 18 6 1 15 13 11 10 4 8 3 2 17 13 12 14 11 10 9 7 22 2 17 14 PROA 352 G2H G2M Courtesy of Crane Market...

Page 149: ...ing M8 x 1 25 6G 19 26 lb ft 26 36 N m 10 Capscrew Brake Cylinder Support M8 x 1 25 6G 19 26 lb ft 26 36 N m 11 Capscrew Brake Cylinder M10 x 1 5 6G 48 64 lb ft 64 87 N m 12 Cover Brake Cylinder M80 x...

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Page 253: ...A Company IMPLEMENT CIRCUIT PERFORMANCE CHECKS Covers all C D Series Material Handlers Form No 29813 Issue Date 4 99 Rev B m a t e r i a l h a n d l e r Courtesy of Crane Market...

Page 254: ...u may determine that this Manual is complete and current with respect to Gradall Engineering Specifications Page Date Revision N A Jan 01 Updated original manual to include all C and D Series Implemen...

Page 255: ...ls for Testing Adjusting SAFETY NOTE ON USING THE MANUAL HYDRAULIC OIL RESERVOIR 1 0 HYDRAULIC FILTER CONDITION 2 0 ENGINE SPEED 3 0 CHARGE PRESSURE 4 0 STEERING CIRCUIT 5 0 MAIN CONTROL VALVE PUMP RE...

Page 256: ...tand the procedure Make sure each of you knows what to expect and when to expect it Make sure each of you knows where the other is at all times Make sure you wear all the protective clothing and perso...

Page 257: ...clean the reservoir cap and the surrounding area thoroughly before removing the cap Any fluid you add to the system must conform with the specification outlined in the Recommended Lubricants and Capa...

Page 258: ...ER This symbol indicates a hazard which may result in injury or damage to equipment or property if proper precautions are not taken CAUTION DANGER WARNING and CAUTION notes in this Manual will help yo...

Page 259: ...certain basic precautions and steps you should take before conducting the test These precautions are outlined in the Introduction under the heading Preparing the Material Handler for Service You must...

Page 260: ...racted and forks on the ground ADJUST 1 Refer to the Lubrication Chart in the appropriate Owner Operator Manual for oil specifications NOTE The system contains approximately 45 gallons of hydraulic oi...

Page 261: ...use Gradall Filters may void warranty WARNING 2 0 FILTER RESTRICTION INDICATOR SET UP 1 With the park brake engaged and the transmission in Neutral start the material handler 2 Warm the hydraulic oil...

Page 262: ...d RPM 2 At low idle engine speed should be 800 900 RPM 3 At full throttle engine speed should be 2500 150 0 RPM ADJUST 1 Adjust low idle engine speed using the screw on the injection pump 2 When testi...

Page 263: ...g screw clockwise to increase charge pressure 4 Turn the adjusting screw counter clockwise to reduce charge pressure 5 Be sure to note the amount that the relief turns in either direction 6 When finis...

Page 264: ...turned 2 The gauge should read 2500 100 PSI for all Models except the 544C 10 and 544D 10 which should read 3000 100PSI ADJUST 1 If adjustment is necessary turn the steering slightly in the opposite d...

Page 265: ...24 532C 6 534C 6 522D 524D 534D 6 3000 100PSI 534C 9 534C 10 534D 9 534D 10 3200 100PSI 544C 10 544D 10 3600 100PSI ADJUST 1 Before attempting any adjustment you must switch the engine off Also make s...

Page 266: ...Raise the forks or other attachment until the cylinder bottoms 4 Observe the gauge while holding the Attachment Tilt Lever fully backward Again the gauge should read 2800 100 PSI for all Models except...

Page 267: ...th the engine running at low idle 800 900 RPM extend the boom fully and hold over relief 2 The gauge should read 2700 100 PSI ADJUST 1 Before attempting any adjustment you must switch the engine off A...

Page 268: ...auge The gauge should read 2000 100 PSI 4 Release the lever 5 Observe the gauge while holding the Auxiliary Control Lever fully backward to pressurize Work Port B The gauge should read 2000 100 PSI 6...

Page 269: ...functioning 4 Service Brake Pump is faulty 5 Air is trapped in the hydraulic lines 6 Leaking hydraulic fittings tubes and hoses 7 Leaking or bypassing Axle Pistons or Calipers ADJUSTMENT OF THE BRAKE...

Page 270: ...522 524 532C 6 534C 6 534C 9 53 Boom Up fully retracted 10 00 14 00 12 00 Boom Down fully retracted 7 00 10 25 10 00 Boom Extend level 7 00 10 75 12 50 Boom Retract level 10 00 14 00 13 50 Attachment...

Page 271: ...Courtesy of Crane Market...

Page 272: ...is Manual is protected by copyright Unauthorized reproduction of this Manual in whole or in part in any form whatsoever is strictly prohibited Specifications are correct at time of publication However...

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Page 285: ...mechanical linkage Bending of linkage or cylinder rod Loose cylinder piston Severe wear in steering control unit Worn or damaged steering linkage Leakage of cylinder piston seals Worn steering contro...

Page 286: ...Severe wear and or broken pin Thermal shock Parts assembled wrong Steering unit improperly timed Lines connected to wrong ports Lines connected to wrong cylin der ports Sticking check valve on steerin...

Page 287: ...will use the full life of the filter at maximum efficiency B Improper Servicing Your engine is vulnerable to abrasive dust contaminants during servicing The most common cause of engine damage is care...

Page 288: ...by looking at it Measure how restricted its airflow is Never leave an air cleaner open longer than necessary Don t ignore a worn or damaged gasket in the housing replace it Don t use a damaged or bun...

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