Service Manual User Manual

General Information, Specifications, and Maintenance
2-15
2.9.3 Bearing Installation
1. Always install bearings carefully to help avoid
damaging their delicate surfaces.
2. Install bearings using one of the following methods:
• PRESS FIT for installation on rotating parts such
as shafts and gears;
• PUSH FIT into static locations such as reduction
gear housings.
3. Always install the bearing into the rotating part first
whenever possible.
4. Use a press or the proper installation tools when
installing a bearing or bushing.
5. In the absence of a press or proper installation tools,
carefully heat the casing and/or bearing in hot oil to
assist in the installation.
2.10 PRESSURE TESTING AND
ADJUSTMENT
Prior to pressure testing or adjustment, verify that all
hoses and tubes are in good condition and that all fittings
are tight.
Use pressure gauges with the proper ranges and ratings
to measure the specified pressures.
Use correct test procedures to help prevent personal
injury, damage to the system or test equipment.
Verify that the hydraulic oil is at proper operating temper-
ature, 80°-120°F (27°-49°C), before adjusting the pressure
reducing valve, or relief valves. If necessary, operate the
vehicle to raise the oil temperature. In the absence of a
temperature gauge, the oil temperature can be checked
by placing a hand against the side or the bottom of the
reservoir; if the tank is too hot to keep the hand in contact
with it, the oil temperature should be within the proper
range.
2.11 AFTER SERVICE STARTUP AND
CHECKS
2.11.1 After Service Startup
Note: Refer to the owners/operators manual for engine
cold-start procedures.
1. Check fluid levels.
2. Connect the negative (-) battery cable to the battery if
it is disconnected.
3. Start and idle engine. Check for leaks from hydraulic
components, engine, axles, transmission, brakes and
reservoirs or tanks. Check the levels of all fluids and
lubricants.
4. Purge the hydraulic system of air by operating all
vehicle functions through their entire range of motion
several times.
5. Check for proper operation of all components.
6. Retract all cylinders fully. Turn the engine OFF and
check the hydraulic reservoir level. Recheck the level
when the hydraulic oil is cold.
7. Replace the hydraulic filter if required.
2.11.2 After Electrical/Electronic Component
Service
1. Check the torque of all fasteners securing replaced
electrical/electronic components.
2. Check wiring connections to components.
3. Verify that wiring components are dry and free of
moisture.
4. Check connectors for broken, frayed, or loose wires.
5. Check for brittle or frayed wire shielding.
6. Connect the negative (-) battery cable terminal to the
battery; if it is disconnected.
7. Start the engine and bleed the hydraulic system of air.
8. Recalibrate sensors as required.
9. Check the operation of the replaced component(s).
2.11.3 After Hydraulic Component Service
1. Check torque of fasteners on replaced components.
2. Check that hoses and tubes are properly attached,
positioned, and tightly connected.
3. If a hydraulic component failed and contaminated the
system, flush the system, clean the hydraulic oil
reservoir (tank), and replace the hydraulic oil filter.
4. After normal hydraulic component maintenance,
check the hydraulic fluid level and add fluid as
required.
5. Start engine and bleed hydraulic system of air.
Operate all boom functions through their full range of
motion several times. Cycle the hoist and extend
cylinders to bleed air from the system. Visually check
for leaks.
6. Recalibrate sensors as required.
7. Check operation of all systems in the hydraulic circuit
by operating the controls through all functions several
times.
Model 3606 • Origin 10/99