AA520 Frame Hydraulic System Overview
AA520 Frame Hydraulic System Overview
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37
42 %22.
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6 5
4 5 7 %22.
2 3 4 3 &217(176 LIFT PUMP
36 REF
1
53
8 2 6(&7,21
9
&217(176 LIFT PUMP
REF ITEM 6
10 26
52 35 AUX PUMP
REF AUX PUMP
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REF
11 ITEM 32 30
3$*(
ITEM 20
REF
23 13 BRAKE ASSEMBLY
32
REF
ITEM 52 SEE DETAIL E
38 VIEW A - A REF
21 12 28
35(9,286
2 SPOOL W/ FAST FUNCTION 24
22
3$*(
29
A
43 33 ITEM 23
25
34 ITEM 15
REF
STEERING MOTOR 32
REF
D
A C 1(;7 26
VIEW C - C VIEW D - D
VIEW B - B
20 3$*(
C 17 /$67 48 51
50 49 44 45 46
D VIEW A - A 3$*( F
1 SPOOL/2 SPOOL 13
B 15 40
26 $/3+$ 41
F
,1'(; VIEW F - F SECTION E - E
DETAIL E
B 180(5,&
,1'(;
6($5&+
+(/3
3
+20( 10 1 772-104 Lock Washer #8
11 1 771-109 Flat Washer #8
12 1 792-624 O-Ring Tee: includes
SECTION B - B %22.
1 530-454/007 O-Ring
&217(176
13 1 123-000-428 Mechanical Plug B, C
14 1 530-412 O-Ring Packing B, C
6(&7,21 15 1 520-212 Relief Valve Cartridge A
24 32 33 38 &217(176 1 520-212/01 Seal Kit (includes 2 O-Rings)
29 33 35 16 4 1-010-033 Terminal A, B
25 32
8 1-010-033 Terminal C
25 27
29 ),567
18 1 1-030-009 Terminal Strip C
26 28
3$*(
28 19 1 1-030-010 Marker Strip C
13 20 1 1-030-003 Terminal Strip A, B
14 35(9,286 21 1 1-030-004 Marker Strip A, B
24 15
3$*( 22 2 701-066 Machine Screw #6-32 x 1/2
42 13 23 2 772-107 Lock Washer #6
14 1(;7 24 2 520-457 Solenoid Valve - N.O. (See Figure 5-3.) C
41 16 3$*( 25 2 792-531 90 Degree O-Ring Elbow: includes
40
39 1 530-454/007 O-Ring
23 22 21 20
/$67 26 1 782-075 Nipple 1/2 FFS C
18 3$*( 27 1 782-064 Nipple 1/2 - 4 A, B
19
22 28 1 790-619 Female Elbow - 90 Degree
31
23 29 1 520-207 Relief Valve
31 14
$/3+$ 1 520-207/03 Seal Repair Kit: includes
44
12 12
,1'(; 2 O-Rings
37 11 10 9 8 7 5 7 10 11 38
5
2 Gaskets
180(5,& 31 2 782-422 Mechanical Plug
3
4
,1'(; 32 1 792-527 45 Degree Male O-Ring Elbow: includes
530-454/007 O-Ring
6($5&+ 33 2 520-139 Flow Control Valve
12 A A 520-129/01 Seal Repair Kit (includes 4 O-Rings)
4
A A 34 (N/S) 1 530-428 O-Ring Seal C
36 1 520-312 Check Valve
2
+(/3 37 1 154-010-236 Diode Module Assembly C
1 2 A= 1 Spool
B= 2 And 3 Spool
FAST FUNCTION 1, 2 & 3 SPOOL C= Fast Function
123-003-148/ (A1)
N/S= NOT SHOWN
Figure 5-2: Manifold Assembly
List 5-2: Manifold Assembly
FIGURE 5-2 PART
QTY DESCRIPTION USED ON
ITEM NO. NUMBER
38 1 701-097 Machine Screw #8-32 x 7/8 A & /,& .# 72
39 1 123-000-719 Manifold C * 2 # 72=
40 2 714-111 Cap Screw #5/16-18 x 2-1/4 C
41 2 773-019 Lock Washer 5/16 C
&'0520
42 1 792-451 90 Degree O-Ring Elbow: includes C
+20(
1 530-454/006 O-Ring
44 1 520-174 Regulator Valve
A= 1 Spool %22.
B= 2 And 3 Spool +20(
C= Fast Function
N/S= NOT SHOWN
%22.
List 5-2: Manifold Assembly (Continued) &217(176
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Solenoid Valve Assemblies FIGURE 5-3
QTY
PART
DESCRIPTION USED ON
ITEM NO. NUMBER
& /,& .# 72 1 1 520-455/01 Cartridge Valve Kit: includes
* 2 # 72= 2 O-Rings
1 Back-Up Ring
2 1 520-457/01 Coil
&'0520
3 1 560-202/07 Hex Nut
+20(
4 1 520-468/01 Cartridge Valve Assembly: includes
5 1 520-807/13 Seal Repair Kit : includes
%22. 5 O-Rings
+20( 6 1 520-807/01 Coil
7 1 750-406 Hex Nut 1/4-20
8 1 772-116 Lock Washer 1/4
%22.
9 1 560-202/06 Cartridge Valve Kit: includes
&217(176
2 O-Rings
1 Back-Up Ring
6(&7,21
&217(176 List 5-3: Solenoid Valve Assemblies
520-457 ),567
3$*(
520-464
35(9,286
3$*(
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3$*(
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3$*(
$/3+$
,1'(;
180(5,&
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6($5&+
520-468
+(/3
180(5,&
,1'(; 45 2 821-003-508 Retaining Pin A, H
3 821-003-508 Retaining Pin B, D, E, F, G
6($5&+ A= 1 Spool Without Clamp
B= 2 Spool Without Clamp
C= 3 Spool Without Clamp
USED ON C D= 2 Spool With Fast Function Valve And Clamp
E= 2 Spool With Fast Function Valve And Clamp (Cold Storage)
USED ON D, E, F & G
+(/3 F= 2 Spool With Fast Function Valve, Without Clamp
G= 2 Spool With Fast Function Valve, Without Clamp (Cold Storage)
H= 2 Spool With Clamp
123-003-149/ (B)
N/S= NOT SHOWN
Figure 5-4: Control Valve Assembly
List 5-4: Control Valve Assembly
FIGURE 5-4 FIGURE 5-4
QTY PART NUMBER DESCRIPTION USED ON QTY PART NUMBER DESCRIPTION USED ON
ITEM NO. ITEM NO.
4 821-003-508 Retaining Pin C & /,& .# 72 1 530-454/005 O-Ring
46 4 681-831 Link A, H * 2 # 72= 104 (N/S) 2 792-347 O-Ring Elbow: includes
6 681-831 Link B, D, E, F, G 1 530-454/004 O-Ring
8 681-831 Link C 121 1 (REF) 520-076 Control Valve - 2 Spool
&'0520
47 8 771-104 Flat Washer #10 A 122 1 123-001-505/002 Valve Actuator Shaft D, E, F, G
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48 2 810-909 Cotter Pin A, H 123 (N/S) 2 520-043/05 Cap
3 810-909 Cotter Pin B, D, E, F, G 124 (N/S) 3 821-003-508 Retaining Pin
4 810-909 Cotter Pin C %22. 125 (N/S) 6 681-831 Link
49 6 771-025 Washer +20( 126 (N/S) 8 771-104 Flat Washer #10
61 1 520-076 Control Valve - 2 Spool (See Figure 5-7.) B, D, E, F, G, H 127 (N/S) 3 810-909 Cotter Pin
62 1 123-001-505/001 Valve Actuator Shaft B 128 (N/S) 2 464-016 Thrust Washer
%22.
63 1 123-000-779/005 Spacer B, H 130 (N/S) 1 123-003-154 Auxiliary Handle Weldment D, E, F, G
&217(176
64 (N/S) 2 520-043/05 Cap 131 (N/S) 3 810-739 Elbow
65 (N/S) 3 821-003-508 Retaining Pin 132 1 123-000-779/005 Spacer D, E, F, G
66 (N/S) 6 681-831 Link
6(&7,21 133 1 123-003-156 Handle Assembly (See Figure 5-9.) D, E
67 (N/S) 8 771-104 Flat Washer #10
&217(176 134 (N/S) 2 792-359 O-Ring Elbow: includes
68 (N/S) 3 810-909 Cotter Pin 1 530-454/005 O-Ring
69 (N/S) 4 464-016 Bearing 135 (N/S) 1 792-496 Swivel Tee
),567
71 1 123-003-154 Auxiliary Handle Weldment B, C, H 136 2 716-118 Shoulder Screw D, E, F, G
3$*(
72 1 810-739 Elbow B, H 137 2 123-000-485 Link D, E, F, G
2 810-739 Elbow C 138 2 460-008 Sleeve Bearing D, E, F, G
3 810-739 Elbow D, E, F, G
35(9,286 139 1 760-006 Lock Nut 1/4-20 D, E, F, G
73 2 792-359 O-Ring Elbow: includes B, C, D, E, F, G, H
3$*( 140 1 520-071 Valve Assembly (See Figure 5-10.) D, E, F, G
1 530-454/005 O-Ring 141 3 710-133 Cap Screw 3/8-24 x 1 D, E, F, G
77 1 123-003-160 Handle Assembly (See Figure 5-9.) B, H 1(;7 142 3 772-123 Lock Washer 3/8 D, E, F, G
91 1 520-077 Control Valve - 3 Spool (See Figure 5-8.) C 3$*( 143 1 792-360 O-Ring Adapter: includes D, E, F, G
92 1 123-001-505/001 Valve Actuator Shaft C 1 530-454/006 O-Ring
93 (N/S) 3 520-043/05 Cap /$67 144 1 792-612 O-Ring Tee: includes D, E, F, G
94 (N/S) 4 821-003-508 Retaining Pin 3$*( 1 530-454/008 O-Ring
95 (N/S) 8 681-831 Link 145 1 123-001-549 Line Assembly D, E, F, G
96 (N/S) 8 771-104 Flat Washer #10 146 1 123-001-550 Line Assembly D, E, F, G
97 (N/S) 4 810-909 Cotter Pin $/3+$ 147 2 792-364 Adapter D, E, F, G
98 (N/S) 5 464-016 Bearing ,1'(; 148 1 792-363 O-Ring Adapter: includes D, E, G
100 (N/S) 1 123-001-511 Auxiliary Handle Weldment 1 530-454/006 O-Ring
101 (N/S) 2 810-739 Spirol Pin 180(5,& 150 1 790-808 Male Run Tee D, E, F, G
102 1 123-003-155 Auxiliary Handle Weldment C ,1'(; 151 1 802-025/005 Hose Fitting D, E, F, G
103 (N/S) 2 792-359 O-Ring Elbow: includes 152 (N/S) 1 782-424 Mechanical Pipe Plug D, E, F, G,
A= 1 Spool Without Clamp 6($5&+ A= 1 Spool Without Clamp
B= 2 Spool Without Clamp B= 2 Spool Without Clamp
C= 3 Spool Without Clamp C= 3 Spool Without Clamp
D= 2 Spool With Fast Function Valve And Clamp D= 2 Spool With Fast Function Valve And Clamp
E= 2 Spool With Fast Function Valve And Clamp (Cold Storage) E= 2 Spool With Fast Function Valve And Clamp (Cold Storage)
F= 2 Spool With Fast Function Valve, Without Clamp +(/3 F= 2 Spool With Fast Function Valve, Without Clamp
G= 2 Spool With Fast Function Valve, Without Clamp (Cold Storage) G= 2 Spool With Fast Function Valve, Without Clamp (Cold Storage)
H= 2 Spool With Clamp H= 2 Spool With Clamp
N/S= NOT SHOWN N/S= NOT SHOWN
List 5-4: Control Valve Assembly (Continued) List 5-4: Control Valve Assembly (Continued)
FIGURE 5-4
QTY PART NUMBER DESCRIPTION USED ON
ITEM NO.
153 1 123-003-158 Handle Weldment F, G & /,& .# 72
154 2 791-407 Tube Nut 1/2 D, E, F, G * 2 # 72=
159 1 1-150-046 Pushbutton Switch (Standard) D, F
164 1 1-150-078 Pushbutton Switch (Cold Storage) E, G
&'0520
A= 1 Spool Without Clamp +20(
B= 2 Spool Without Clamp
C= 3 Spool Without Clamp
D= 2 Spool With Fast Function Valve And Clamp
%22.
E= 2 Spool With Fast Function Valve And Clamp (Cold Storage)
F= 2 Spool With Fast Function Valve, Without Clamp
+20(
G= 2 Spool With Fast Function Valve, Without Clamp (Cold Storage)
H= 2 Spool With Clamp %22.
N/S= NOT SHOWN &217(176
List 5-4: Control Valve Assembly (Continued)
6(&7,21
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Control Valve Assembly
FIGURE 5-5
& /,& .# 72 ITEM NO.
QTY PART NUMBER DESCRIPTION USED ON
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520-048
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520-075 - 1 SPOOL
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520-076 - 2 SPOOL
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520-077 - 3 SPOOL
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FAST FUNCTION
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SEE DETAIL A
ADAPTER WITH
SAFETY CHAIN
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B STRAINER
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C
C
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DETAIL A
B %22.
VIEW C- C &217(176
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123-001-495/ (E)
35(9,286
Figure 5-12: Lift Pump And Motor Assembly
VIEW B - B 3$*(
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FIGURE 5-13
QTY
PART
DESCRIPTION USED ON
35(9,286
ITEM NO. NUMBER 3$*(
1 1 500-420/10 Seal Kit: includes A
2 Body Seal (Molded Rubber)
1(;7
2 Body Seal O-Ring
3$*(
4 Backing Washer
2 Lobe Seal
/$67
1 Oil Shaft Seal
3$*(
1 500-420/311 Seal Kit: includes B
6 Seals
1 500-420/312 Seal Kit: includes B
$/3+$
1 Oil Seal
,1'(;
1 Retaining Ring
1 500-420/361 Seal Kit C
180(5,&
1 500-348/367 Bearing and Seal Kit: includes D
,1'(;
1 500-348/370 Shaft Seal
2 500-348/373 Bearing Block
2 500-348/372 E Seal
6($5&+
2 500-348/371 Back Up Ring
2 500-348/374 O-Ring
A= Dowty
B= Barnes +(/3
C= FCD
D= Barnes /250
E= Barnes 500-348/350
List 5-13: Lift Pump Assemblies
Lift Pump Assemblies FIGURE 5-14
QTY
PART
DESCRIPTION USED ON
ITEM NO. NUMBER
& /,& .# 72 1 1 500-420/311 Seal Kit: includes
* 2 # 72= 6 Seals
2 1 500-420/312 Seal Kit: includes
1 Oil Seal Kit
&'0520
1 Retaining Ring
+20(
Barnes Gear Pump - 500-423/300
List 5-14: Lift Pump Assemblies
%22.
+20( FIGURE 5-14 PART
QTY DESCRIPTION USED ON
ITEM NO. NUMBER
%22. 1 1 pr. 500-423/111 Spline Gear Set
&217(176 2 1 500-423/112 Body & Dowel
3 2 pr. 500-423/113 Composite Bushes
6(&7,21 4 1 500-423/114 Bolt 3/8 UNF
&217(176 5 1 500-423/115 Mounting Flange
6 1 500-423/116 End Cover
7 1 500-423/117 Seal Kit
),567 Dowty Gear Pump - 500-423/100, 500-437
3$*( List 5-14: Lift Pump Assemblies
35(9,286
FIGURE 5-14 PART
3$*( ITEM NO.
QTY
NUMBER
DESCRIPTION USED ON
1 1 500-423/411 Seal Kit
1(;7 FCD Pump - 500-423/400
3$*(
List 5-14: Lift Pump Assemblies
/$67
3$*(
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180(5,&
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500-423/
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180(5,&
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570-236/100
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View At A
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570-236/500
570-236/400 - 36 VOLT
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123-001-491 (D)
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500-417/201
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570-445/100
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+(/3
123-001-492/ (H))
6($5&+ OACH USE S/S USE REEL HOSE LENGTH CABEL LENGTH COLD
CARRIAGE STORAGE
68 - 72 870-518 870-454/002 35.00 95.00 NO
80 - 84 870-518 870-454/002 47.00 95.00 NO
85 - 89 870-518 870-454/002 52.00 108.00 NO
+(/3 92 - 96 870-517 870-454/002 59.00 108.00 NO
98 - 102 870-517 870-454/002 65.00 121.00 NO
123-001-471/ (D) 80 - 84 870-518 870-473/002 47.00 95.00 YES
Figure 5-24: Auxiliary Hydraulic System 85 - 89 870-518 870-473/002 52.00 108.00 YES
92 - 96 870-517 870-473/002 59.00 108.00 YES
Auxiliary Hydraulic System FIGURE 5-25
QTY PART NUMBER DESCRIPTION USED ON
ITEM NO.
& /,& .# 72 1 1 123-001-175 Carriage Alteration
* 2 # 72= 2 1 812-003-073/013 Hose and Cable Assembly
3 1 (REF) 870-473/002 Hose/Cable Reel
4 1 (REF) 870-454/002 Hose/Cable Reel
&'0520
5 2 792-523 O-Ring Male Connector: includes
+20(
1 530-454/005 O-Ring
2 710-240 Cap Screw 1/2-13 x 1
%22. 2 772-225 Lock Washer 1/2
+20( 6 1 792-360 O-Ring Connector: includes
1 530-454/006 O-Ring
1 790-614 Swivel Elbow
%22.
7 1 792-511 O-Ring Elbow: includes
&217(176
1 530-454/006 O-Ring
8 1 123-001-251 Mast Main Frame Alteration
6(&7,21 9 1 123-001-254 Hose Clamp
&217(176 2 701-184 Machine Screw 1/4-20 x 5/8
2 772-116 Lock Washer 1/4
10 2 030-308-___/_16 Hose Assembly
),567
1 123-001-290/ Cable Assembly
3$*(
11 1 (REF) 123-001-146/002 Manifold - Junction Block Kit
12 2 611-028 Strap
35(9,286 24" Carriage W/ Switching Solenoid
3$*(
List 5-25: Auxiliary Hydraulic System
1(;7
3$*(
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180(5,&
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123-001-517/
1(;7
3$*(
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123-001-493/
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550-027
1(;7 Figure 5-28: Hydraulic Motor
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123-001-744 (C)
FIGURE 5-28 PART
Figure 5-27: Hydraulic Motor Assembly /$67 ITEM NO.
QTY
NUMBER
DESCRIPTION USED ON
3$*( 1 4 550-026/01 Cap Screw
FIGURE 5-27 PART 2 1 550-004/03 Mounting Flange
QTY DESCRIPTION USED ON
ITEM NO. NUMBER 3 1 550-004/06 Bearing Race
1 1 550-027 Hydraulic Motor (See Figure 5-28.) $/3+$ 4 1 550-004/07 Thrust Needle Bearing
1 550-015/09 Seal Kit (Standard) ,1'(; 5 1 550-015/02 Output Shaft
1 550-015/10 Seal Kit (Cold Storage) 6 1 550-028/01 Housing
2 1 710-010 Cap Screw 1/4-20 x 3/4 180(5,& 7 1 550-027/01 Drive
3 1 724-445 Screw Set 5/16-18 x 1/2 ,1'(; 8 1 550-026/04 Spacer Plate
4 2 771-033 Spacer 9 1 550-027/02 Geroler Sub-Assembly
5 1 771-049 Flat Washer 6($5&+ 10 1 550-028/04 End Cap
6 1 772-116 Lock Washer 1/4 11 7 550-027/03 Cap Screw
7 2 792-451 90 Degree Elbow 12 1 550-026/11 Seal Kit: includes
8 1 850-114 Key 1 Exclusion Seal
9 1 401-165/001 Sprocket +(/3 1 Back-Up Washer
List 5-27: Hydraulic Motor Assembly 1 Pressure Seal
4 Seals
List 5-28: Hydraulic Motor
Hydraulic Attachment Installation
& /,& .# 72
* 2 # 72=
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6($5&+
Figure 5-29: Hydraulic Attachment Installation
FIGURE 5-29
QTY PART NUMBER DESCRIPTION USED ON
ITEM NO.
+(/3
1 870-485 Push-Pull Attachment
2 030-306-018/027 Hose Assembly
List 5-29: Hydraulic Attachment Installation