JLG Lull 1044C-54 II Series Service Manual Download | Manualshive

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31200079

List of Figures

Fig. 10-1: Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Fig. 10-2: Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Fig. 10-3: Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Fig. 10-4: Outrigger Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Fig. 10-5: Outrigger Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Fig. 10-6: Boom Extension Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Fig. 10-7: Boom Extension Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Fig. 10-8: Boom Extension Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Fig. 10-9: Boom Extension Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Fig. 10-10: Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Fig. 10-11: Outrigger Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

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Summary of Contents for Lull 1044C-54 II Series

Page 1: ...Service Manual Model 1044C 54 Series II 31200079 Revised July 1 2005 ...

Page 2: ......

Page 3: ...EFFECTIVITY PAGE 31200079 i March 18 2005 A Original Issue Of Manual July 1 2005 Revised Manual ...

Page 4: ...EFFECTIVITY PAGE 31200079 ii ...

Page 5: ...t Protective Structure FOPS 1 6 Decals and Placards 1 6 General 1 6 Cleaning Decals 1 6 Attaching Decals 1 7 Decal Locations 1 7 Section 2 Identification and Specifications Serial Number Locations 2 1 Machine Serial Number 2 1 Engine Serial Number John Deere 2 2 Axle Serial Number 2 3 Attachment Serial Number Plate 2 3 Identification 2 4 Specifications 2 5 Engine Specifications 2 8 John Deere 4045...

Page 6: ...orques for Standard Bolts Capscrews and Nuts 3 10 Hydraulic Fitting Torques 3 14 Jump Starting Procedures 3 16 Conversion Charts 3 18 Section 4 Reference Diagrams Mid Inlet Hydraulic Schematic Diagram 4 1 Control Valve Diagram 4 2 4 5 Electrical Schematic Diagram 4 3 Section 5 Supply Pressure and Return Hydraulics General 5 1 Major System Components 5 1 General Description 5 1 Hydraulic Systems 5 ...

Page 7: ... Pressure Filter 5 27 Description 5 27 Replacing Pressure Filter Element 5 28 Removal 5 29 Installation 5 30 Hydraulic Pump 5 30 Description 5 30 Troubleshooting Pump Problems 5 31 Removal 5 33 Hydraulic Pump 5 33 Installation 5 37 Checking Pump Flow Rate 5 38 Mid Inlet Control Valve 5 40 Description 5 40 Removal 5 43 Installation 5 44 Rear Axle Stabilizer Control Valve 5 44 Description 5 44 Remov...

Page 8: ... Tilt Cylinder 6 18 Description 6 18 Removal 6 19 Installation 6 20 Overhaul 6 21 Rear Carriage Tilt Cylinder 6 24 Description 6 24 Removal 6 25 Installation 6 26 Overhaul 6 27 Selector Valve 6 29 Description 6 29 Removal 6 30 Installation 6 31 Overhaul 6 31 Troubleshooting 6 33 Boom Slide Pads General 6 34 Description 6 34 Slide Pad Inspection 6 34 Lubrication 6 36 Slide Area Surface Finish 6 36 ...

Page 9: ...linder 6 111 Boom Extension Proximity Switch 6 117 Description 6 117 Removal 6 118 Installation 6 119 Adjustments 6 119 Transfer Carriage 6 120 Description 6 120 Installation 6 127 Rollers Bushings and Shims 6 129 Section 7 Frame Tilt and Oscillation Frame Tilt System 7 1 General Description 7 1 Circuit Description 7 1 Frame Tilt Control Valve 7 3 Description 7 3 Removal 7 4 Installation 7 5 Overh...

Page 10: ... 39 Section 8 Transmission Transmission Assembly Component Terminology 8 1 Transmission Description 8 1 Transmission Operation 8 2 Transmission Specifications 8 3 Transmission General Specification 8 3 Transmission Performance Specification 8 3 Transmission Lubrication 8 3 Transmission Maintenance 8 4 Transmission Removal 8 6 Transmission Inspection and Internal Repair 8 10 Transmission Installati...

Page 11: ... Charging Accumulator 9 14 Checking Pre charge 9 16 Towing a Disabled Machine 9 17 Manually Releasing the Park Brake 9 18 Manually Resetting the Park Brake 9 18 Section 10 Outriggers Outriggers 10 1 General 10 1 Removal 10 2 Installation 10 3 Outrigger Cylinders 10 4 General 10 4 Removal 10 5 Installation 10 6 Overhaul 10 7 Differential Pressure Switch 10 9 Description 10 9 Boom Extension Proximit...

Page 12: ...ig 5 4 Hydraulic Reservoir 5 7 Fig 5 5 Recommended Reservoir Filling Method 5 8 Fig 5 6 Alternate Reservoir Filling Method 5 9 Fig 5 7 Hydraulic Reservoir Drain and Refill 5 11 Fig 5 8 Hydraulic Reservoir Fuel Tank Installation 5 13 Fig 5 9 Hydraulic Reservoir Sight Gauge 5 16 Fig 5 10 Reservoir Sight Gauge Installation 5 17 Fig 5 11 Suction Strainer Installation 5 19 Fig 5 12 Hydraulic Return Fil...

Page 13: ...ck Installation 6 3 Fig 6 4 Joystick Components 6 5 Fig 6 5 Pilot Pressure Diagnostic Port 6 8 Fig 6 6 Pilot Pressure Plug 6 9 Fig 6 7 Boom Hoist Cylinders 6 12 Fig 6 8 Boom Hoist Cylinder Installation 6 13 Fig 6 9 Boom Hoist Cylinder Assembly 6 15 Fig 6 10 Front Carriage Tilt Cylinder 6 18 Fig 6 11 Front Carriage Tilt Cylinder Installation 6 19 Fig 6 12 Front Carriage Tilt Cylinder Assembly 6 21 ...

Page 14: ...Front of 4 Section Boom 6 49 Fig 6 48 Upper Shim Installation Front of 4 Section Boom 6 49 Fig 6 49 Boom Section Gaps Rear of 4 Section Boom 6 50 Fig 6 50 Lower Shim Installation Rear of 4 Section Boom 6 50 Fig 6 51 Upper Shim Installation Rear of 4 Section Boom 6 51 Fig 6 52 Clearances Between Boom Sections Rear of 4 Section Boom 6 51 Fig 6 53 Gaps Between Pads and Boom Rear of 4 Section Boom 6 5...

Page 15: ...81 Hose and Tube Removal Inner Boom Section 6 76 Fig 6 82 Upper Chain Assembly 6 77 Fig 6 83 Upper Chain Roller Assembly Middle Rear Boom Section 6 77 Fig 6 84 Removing Lower Chains 6 78 Fig 6 85 Slide Pads Middle Rear Boom Section 6 79 Fig 6 86 Chain and Hose Guide Assembly 6 80 Fig 6 87 Tubes and Hoses Middle Rear and Outer Boom Sections 6 81 Fig 6 88 Side Slide Pads Outer Boom Section 6 82 Fig ...

Page 16: ...xtension Cylinder Assembly 6 114 Fig 6 119 Boom Extension Proximity Switch 6 117 Fig 6 120 Boom Extension Proximity Switch Operation 6 118 Fig 6 121 Boom Extension Proximity Switch Assembly 6 118 Fig 6 122 Boom Extension Proximity Switch Adjustment 6 119 Fig 6 123 Transfer Carriage 6 120 Fig 6 124 Disconnecting Transfer Cylinder from Transfer Carriage 6 121 Fig 6 125 Boom Elevation Proximity Switc...

Page 17: ...lation 7 32 Fig 7 21 Oscillation Control Block Exploded View 7 35 Fig 7 22 Boom Elevation Proximity Switch 7 37 Fig 7 23 Boom Elevation Proximity Switch Operation 7 38 Fig 7 24 Boom Elevation Proximity Switch Assembly 7 38 Fig 7 25 Boom Elevation Proximity Switch Adjustment 7 39 Fig 8 1 ZF Transmission 8 1 Fig 8 2 Transmission Serial Number Plate Location 8 3 Fig 8 3 The Lubrication and Maintenanc...

Page 18: ...lation 10 5 Fig 10 5 Outrigger Cylinder Assembly 10 7 Fig 10 6 Boom Extension Proximity Switch 10 10 Fig 10 7 Boom Extension Proximity Switch Operation 10 11 Fig 10 8 Boom Extension Proximity Switch Assembly 10 11 Fig 10 9 Boom Extension Proximity Switch Adjustment 10 12 Fig 10 10 Outrigger Controls 10 13 Fig 10 11 Outrigger Control Valve Installation 10 14 ...

Page 19: ...e Swivel Nuts 3 4 Table 3 5 Torque for Non adjustable O ring Fittings 3 5 Table 3 6 Torque for Adjustable O ring Fittings 3 6 Table 3 7 Torque for O ring Plugs 3 7 Table 3 8 Pipe Thread Fittings Steel 3 8 Table 3 9 Inch Fraction Decimal and Metric Conversion Chart 3 9 Table 3 10 Miscellaneous Conversions 3 10 Table 5 1 Rear Axle Stabilizer Control Valve Markings 5 1 Table 7 1 Rear Oscillation Lock...

Page 20: ...16 31200079 List of Tables ...

Page 21: ...Tire and Wheels Hazards 5 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS 6 Decals and Placards 6 General 6 Cleaning Decals 6 Attaching Decals 7 Decal Locations 7 List of Figures Fig 1 1 Decals and Placards 1 8 Fig 1 2 Instrument Panel Decals 1 8 Fig 1 3 Control Decals 1 9 Fig 1 4 Disconnect Battery Decal and Slow Moving Vehicle Sign 1 9 Fig 1 5 Steer Selector Plate...

Page 22: ......

Page 23: ...o the equipment Maintenance should always be done by trained personnel using proper tools Caution Warning and Danger Hazards are identified by the Safety Alert Symbol and followed by a signal word Caution Warning or Danger CAUTION Means that a situation COULD be hazardous and MAY result in personal injury if not avoided CAUTION is also used to alert against unsafe practices that could result in eq...

Page 24: ... the cab floor free of debris mud and other foreign matter Replace damaged loose or excessively worn no slip surfacing on cab floor Face the machine when mounting and dismounting Do not attempt to get off the machine while it is moving Never jump off the machine Do not mount or dismount the machine when carrying tools equipment etc Before Servicing the Machine Before servicing the machine position...

Page 25: ...and ignition during refueling Make sure you have adequate ventilation during refueling Do not permit anyone to be on the machine during refueling Always ground the fuel nozzle against the filler neck to avoid sparks Never use an open flame when checking the fuel level in the tank Keep sparks and open flames away from fuel Do not smoke while refueling or when handling fuel containers Never cut or w...

Page 26: ... attention immediately When venting or filling the hydraulic system loosen the filler cap slowly and remove it gradually NEVER reset any relief valve in the hydraulic system to a pressure higher than that specified in this manual Electrical System Hazards Be aware of the following safety issues when working with batteries Explosive gases are always present around batteries This is especially true ...

Page 27: ...ding on the machine CAUTION When removing the battery always remove the negative cable first When installing connect the positive cable first Tire and Wheels Hazards The stability of the forklift can be dramatically affected by incorrect inflation or the lack of ballast fill It is good practice to check your tires and wheels on a daily basis Check tires for The correct pressure Cuts or bulges Nail...

Page 28: ...he ROPS FOPS capability to provide the required protection Any modification or repair without the specific written approval of JLG will void the ROPS FOPS certification Contact your authorized JLG dealer before making any modifications or repairs Failure to do so may void the ROPS FOPS certification Decals and Placards General The decals on the machine provide instructions for safe and correct ope...

Page 29: ...1 1 Carriage Safety Decal Fig 1 7 Carry Load Low Caution Decal Fig 1 2 Caution Plate Fig 1 1 Diesel Fuel Only Decal Fig 1 6 Disconnect Battery Decal Fig 1 4 Don t Be Careless Decal Fig 1 2 Forklift Signals Decal Fig 1 1 Frame Tilt Control Decal Fig 1 3 Frame Transfer Extension Decal Fig 1 1 Hydraulic Breather Decal Fig 1 6 Hydraulic Oil Only Decal Fig 1 6 Load Chart Capacities Flip Card Fig 1 1 Lo...

Page 30: ...A N D O T H E R V A R I A T I O N S O F L O A D S I Z E E T C R A T E D L I F T C A P A C I T I E S S H O W N A R E W I T H M A C H I N E O N A F I R M L E V E L S U R F A C E W I T H U N D A M A G E D P R O P E R L Y I N F L A T E D B A L L A S T F I L L E D T I R E S INDI CATES REAR OSCILLATIO N LOCK ENGAGED 0 5 10 15 20 25 30 35 40 45 0 1 2 3 4 5 6 7 8 10 9 11 12 13 1 0 5 10 15 20 25 30 35 FEET...

Page 31: ...079 1 9 Fig 1 3 Control Decals Fig 1 4 Disconnect Battery Decal and Slow Moving Vehicle Sign V1087 Outrigger Frame Tilt Control Transfer and Fork Control Boom Movement Control Tilt Control MV0490 Battery Disconnect ...

Page 32: ...aulic Reservoir Fuel Tank Decals Fig 1 7 Fork Carriage Decals FRONT WHEEL STEER ROUND STEER OBLIQUE STEER R1049 Steer Selector Plate Operator s Seat R1050 Hydraulic Oil Only Diesel Fuel Only Hydraulic Breather R1051 Carriage Safety Decal Attachment Capacity Plate ...

Page 33: ...Axle Serial Number 2 3 Attachment Serial Number Plate 2 3 Identification 2 4 Specifications 2 5 Engine Specifications 2 8 John Deere 4045T 2 8 List of Figures Fig 2 1 Machine Serial Number Plate 2 1 Fig 2 2 Engine Serial Number John Deere 2 2 Fig 2 3 Axle Serial Number 2 3 Fig 2 4 Attachment Serial Number Plate 2 3 Fig 2 5 Top View 2 4 Fig 2 6 Left Side View 2 4 ...

Page 34: ...ii 31200079 ...

Page 35: ... Serial Number Locations Machine Serial Number Fig 2 1 Machine Serial Number Plate Ref Fig 2 1 The machine serial number plate is located on the frame behind the right front tire TIRE BALLAST REQUIRED REFER TO LUBRICATION SCHEDULE MV0290 Serial Number Plate ...

Page 36: ...al number plate is located on the left side of the engine near the starter and fuel pump John Deere engines include an options code decal located on top of the engine manifold cover Do not damage remove or paint over this decal It is recommended that this information be written down for future reference V1006 Fuel Pump Starter Serial Number Plate ...

Page 37: ...l number plate is located on the left front side of the axle housing The rear axle serial number plate is located on the right rear side of the axle housing Attachment Serial Number Plate Fig 2 4 Attachment Serial Number Plate Ref Fig 2 4 The location of this plate varies with each attachment MV0360 SERIAL NUMBER PLATE MV0480 ...

Page 38: ...Identification and Specifications 2 4 31200079 Identification Fig 2 5 Top View Fig 2 6 Left Side View R1026 R1052 ...

Page 39: ...ght Approximately 32 000lbs Dimensions Note Dimensions listed are for forklift with all components fully retracted in travel mode Overall Height 97 Inches Overall Width 101 Inches Overall Length 24 Feet 10 Inches w 42 Fork Wheelbase 124 Inches Outside Turning Radius 14 Feet 2Inches Ground Clearance 20 5 Inches Capacities Hydraulic System Including Reservoir 65 Gallons Hydraulic Reservoir 47 Gallon...

Page 40: ...urn Filter 0 15 psi Accumulator Dry Nitrogen Pre Charge 400 psi Accumulator Charge Valve 1000 Low Limit 1125 High Limit Transmission Manufacturer Zahnradfabrik ZF Model 4WG 98TC Type 4 Speed Electric Powershift with Torque Converter Speeds 4 Forward 3 Reverse Filter Spin On Travel Speeds 1st Gear 3 5 mph 5 6 km hr 2nd Gear 6 mph 9 7 km hr 3rd Gear 15 2 mph 24 5 km hr 4th Gear Forward Only 22 mph 3...

Page 41: ...uated Internal Wet Disc Parking Brake Manufacturer Zahnradfabrik ZF Type SAHR Spring Applied Hydraulically Released Engine Models See Engine Specifications on page 2 8 John Deere 4045T F 275 115 HP 2500 rpm Hydraulic Pump Type Tandem Gear Electrical System System Voltage 12 Volt Negative Ground Battery 12 Volt 925CCA Alternator Bosch 95 Amp Working Temperatures Hydraulic Oil 140 180 F Transmission...

Page 42: ...charged Cooling Liquid Horsepower 115 HP 2500 rpm Maximum Torque 291 ft lbs 1400 rpm Piston Displacement 275 Cubic Inches Number of Cylinders 4 Vertical In Line Cycle 4 Stroke Combustion System Direct Injection Compression Ratio 17 6 1 Oil Filter Spin On Air Cleaner Dry Cartridge High rpm 2650 2750 Idle rpm 890 910 ...

Page 43: ...ications 3 5 Fuel Requirements 3 6 Grease 3 6 Care and Cleaning 3 7 Cleaning Exterior Surfaces 3 7 Cleaning the Cab 3 7 Cleaning Decals 3 8 Attaching Decals 3 8 Storage 3 8 Preparing the Machine for Long Term Storage 3 8 Preparing the Machine After Long Term Storage 3 9 Torque Specifications 3 10 General Torques for Standard Bolts Capscrews and Nuts 3 10 Hydraulic Fitting Torques 3 14 Jump Startin...

Page 44: ...Specifications 3 3 Table 3 4 Torque for JIC and SAE Female Swivel Nuts 3 4 Table 3 5 Torque for Non adjustable O ring Fittings 3 5 Table 3 6 Torque for Adjustable O ring Fittings 3 6 Table 3 7 Torque for O ring Plugs 3 7 Table 3 8 Pipe Thread Fittings Steel 3 8 Table 3 9 Inch Fraction Decimal and Metric Conversion Chart 3 9 Table 3 10 Miscellaneous Conversions 3 10 ...

Page 45: ...structions and examine all the instructions and messages on the machine When performing inspection maintenance lubrication or adjustments to the machine be alert to evidence of excessive wear including odors and noises that may indicate damage malfunction or other maintenance problems Service Preparation Procedures Choose a clean level work area Check clearances and make sure you have sufficient r...

Page 46: ...uipment while filling the fuel tank Use extra caution when fueling while the engine is hot Always ground the fuel nozzle against the filler neck to avoid sparks WARNING Never smoke while handling fuel or working on the fuel system The fumes in an empty fuel container are explosive Never cut or weld on fuel lines tanks or containers Avoid spilling fuel If a spill occurs wipe it up immediately Never...

Page 47: ...oid the warranty JLG assumes no liability for equipment damages caused by the use of unauthorized replacement parts Lubrication General For best machine performance follow the instructions found on the machine s service lubrication schedule Clean around all oil fill holes before checking or adding oil Keep all lubricants and lubricating equipment clean and free of foreign matter both while in use ...

Page 48: ...il for the initial period of operation Consult engine Operator s Manual for additional information SYSTEM OR COMPONENT FLUID OR LUBRICATION SPECIFICATION Fuel System1 See Fuel Requirements Hydraulic System Engine Cooling System1 Engine Oil1 Transmission See Transmission Oil Specifications Differential Front Rear Planetary Hub Grease Points Grease Lithium based See engine manufacturer s operator s ...

Page 49: ... Arctic oil e g MIL L 46167B 4 to 86 F 5 to 122 F 32 to 86 F 50 to 104 F 20 to 30 C 15 to 50 C 0 to 30 C 10 to 40 C Below 22 F Below 30 F MIL 46167B MV0510 MV0520 Oil Grade Minimum Oil Temperature for Engaging Transmission Recommended SAE 20W 20 14 F 10 C SAE 15W 40 SAE 10W 10W 30 10W 40 Automatic Transmission Fluid ATF ATF 4 F 20 C 5 F 15 C 41 F 5 C 23 F 5 C 32 F 0 C 22 F 30 C 14 F 10 C Automatic...

Page 50: ... engine manufacturer specifies the diesel fuel requirements Additional information can be found in the engine manufacturer s Operator s Manual Consult your local fuel distributor for the properties of the diesel fuels available in your area Grease Use a lithium base grease with E P additives and rust inhibitors A 2 grade should be used at temperatures above 32 F 0 C and 1 grade at or below 32 F 0 ...

Page 51: ...ers and detergents may be used to help clean thick deposits Do not use chemicals that can damage paint or decals Avoid spraying water on electrical components such as the alternator starter gauges and electrical items under the dash Be careful around the fuel fill and hydraulic reservoir breather Water may get into tanks and damage fuel and or hydraulic components To help prevent freezing allow wa...

Page 52: ...e will not be operated for a long period of time Preparing the Machine for Long Term Storage Prior to placing the machine into storage perform the following 1 Wash off the entire machine 2 Lubricate all grease fittings as instructed in Grease on page 3 6 of this section 3 Change engine oil according to specifications described in Table 3 2 on page 5 4 Apply grease to all exposed hydraulic cylinder...

Page 53: ... levels Add fluids if necessary 8 If battery was stored separately from the machine install it 9 Connect battery cables 10 Start engine using start safety procedures as described in the Owner Operator Manual 11 After the engine has warmed up test all hydraulic functions and controls 12 Check transmission operation 13 Shut the machine down and check for any hydraulic leaks and repair as necessary W...

Page 54: ...e intended as a guide for typical applications Values for specific applications take precedence over those in the following tables Note Values are for plated or lubricated bolts and nuts Fig 3 1 SAE Grade Identification SAE GRADE 2 SAE GRADE 5 SAE GRADE 5 1 SAE GRADE 5 2 SAE GRADE 8 2 SAE GRADE 8 SAE BOLT HEAD MARKINGS SAE NUT MARKINGS SAE GRADE 2 NO MARK SAE GRADE 5 SAE GRADE 8 Y1001 Y1000 ...

Page 55: ...General Maintenance 31200079 3 11 Fig 3 2 General Torques for Standard Bolts Capscrews and Nuts ...

Page 56: ...ce 3 12 31200079 Fig 3 3 General Torques for Metric Bolts Capscrews and Nuts SAE GRADE 5 SAE GRADE 8 Note These torque values do not apply to cadium plated fasteners VALUES FOR ZINC PLATED BOLTS ONLY UNPLATED CAP SCREWS ...

Page 57: ...e 31200079 3 13 Fig 3 4 Metric Class Identification Y1 2 4 8 4 8 4 8 9 8 8 8 9 8 8 8 12 9 10 9 12 9 12 9 12 10 10 12 10 10 5 5 AND HEAD MARKINGS PROPERTY CLASS AND NUT MARKINGS PROPERTY CLASS 5 8 8 10 10 9 10 12 9 12 9 8 ...

Page 58: ...ng with clean hydraulic fluid and torque per Table 3 5 Table 3 5 Torque for Non adjustable O ring Fittings Size SAE Port Thread Size Approx Min Torque Max Torque Flats1 1 Number of flats on nut to be turned past finger tight This method will produce the approximate torque 4 7 16 20 130 in lbs 150 in lbs 2 5 1 2 20 165 195 2 6 9 16 18 235 265 1 1 4 8 3 4 16 44 ft lbs 48 ft lbs 1 10 7 8 14 50 58 1 1...

Page 59: ...dition of O ring and replace as necessary Do not install a plug with a damaged O ring 2 Lubricate O ring with clean hydraulic fluid and torque per Table 3 7 Table 3 7 Torque for O ring Plugs Size SAE Port Thread Size Min Torque Max Torque 2 5 16 24 60 in lbs 70 in lbs 4 7 16 20 160 180 6 9 16 18 25 ft lbs 29 ft lbs 8 3 4 16 40 44 10 7 8 14 58 63 12 1 1 16 12 75 85 16 1 5 16 12 109 121 20 1 5 8 12 ...

Page 60: ...other or the machine Battery acid can cause personal injury if it contacts skin or eyes Always wear eye protection when jump starting a machine Always connect battery positive to battery positive and battery negative to ground on the machine Make the final ground connec tion away from the battery Allowing the two machines to touch during jump starting can cause damage to bearings and electrical ci...

Page 61: ...an the battery terminal 4 Connect the other end of the positive jumper cable to the positive terminal of the boost battery or auxiliary power source 5 Connect one end of the negative jumper cable to the negative terminal of the boost battery or auxiliary power source 6 Make the final connection of the negative jumper cable to the frame of the stalled machine away from the battery fuel and hydrauli...

Page 62: ...75 4 76 11 16 0 6875 17 46 13 64 0 2031 5 16 45 64 0 7031 17 86 7 32 0 2188 5 56 23 32 0 7188 18 26 15 64 0 2344 5 95 47 64 0 7344 18 65 1 4 0 2500 6 35 3 4 0 7500 19 05 17 64 0 2656 6 75 49 64 0 7656 19 45 9 32 0 2813 7 14 25 32 0 7813 19 84 19 64 0 2969 7 54 51 64 0 7969 20 24 5 16 0 3125 7 94 13 16 0 8125 20 64 21 64 0 3281 8 33 53 64 0 8281 21 03 11 32 0 3438 8 73 27 32 0 8438 21 43 23 64 0 35...

Page 63: ... mPa x 145 psi x 0 00689 MPa Power W J s Kilowatt kW Kilowatt kW Kilowatt kW Watt W x 1 36 x 1 34 x 0 948 x 0 74 PS cv HP Btu s ft lb s x 0 736 x 0 746 x 1 055 x 1 36 kW kW kW W Energy J N m m Kilojoulè kJ Joule J x 0 948 x 0 239 Btu calorie x 1 055 x 4 19 kJ J Velocity and Acceleration Meter per sec2 m s2 Meter per sec m s Kilometer per hour km h x 3 28 x 3 28 x 0 62 ft s2 ft s mph x 0 305 x 0 30...

Page 64: ...General Maintenance 3 20 31200079 ...

Page 65: ...31200079 i Section 4 Reference Diagrams Table of Contents Mid Inlet Hydraulic Schematic Diagram 4 1 Control Valve Diagram 4 2 Electrical Schematic Diagram 4 3 ...

Page 66: ...31200079 ii ...

Page 67: ...BELOW 100 PSI OPEN ABOVE 100 PSI 1 3 VIEWED FROM THE TOP FRONT OF MACHINE X X T T LS P PUMP 1 PUMP 2 STABILIZER G1 STABILIZER G2 BRAKES STEERING PILOT ACCUMULATOR P A PRESSURE FILTER 3000 PSI 3150 PSI SEE SERVICE MANUAL SEE SERVICE MANUAL 330 PSI 2375 PSI 450 PSI 400 PSI PRE CHARGE 1075 PSI LOW LIMIT 1950 PSI HIGH LIMIT C B VALVE BRAKE VALVE L H OUTRIGGER CYLINDER C B VALVES 4000 PSI R H OUTRIGGER...

Page 68: ...R BOOM HOIST CYLINDER C B VALVE 2800 PSI P B2 B A AUX 2 OPTION 3000 PSI B NOTE HUSCO VALVE ASSEMBLY IS ORIENTATED SO THAT THE A PORTS ARE FRONT FORWARD OF THE B PORTS S4 B STABILIZER CONTROL VALVE A8 B8 A7 B7 REAR AXLE STABILIZER VALVE OR3 040 OR4 040 SV3 CV1 OR2 08 100 PSI CV2 RCB RCR V PC1 V PC2 CBP CB OR1 03 040 CV3 CV4 60 PSI SYS T PR 3500 PSI 150 PSI PIL OR5 PIL 040 OR3 G1 PC3 270 PSI T RCB R...

Page 69: ...Reference Diagrams 31200079 4 3 Diagram 4 1 Mid Inlet Hydraulic Schematic cont d NOTES ...

Page 70: ...Reference Diagrams 4 4 31200079 Diagram 4 1 Mid Inlet Hydraulic Schematic cont d NOTES ...

Page 71: ... Inlet Control Valve MV0410 OPTION 3150 PSI L H OUTRIGGER R H OUTRIGGER FRAME TILT TRANSFER CARRIAGE TILT AUX 1 A A A A A A B B B B B B 2800 PSI A3 A4 B4 B3 BOOM HOIST TELESCOPE A A B BOOM A2 B5 A5 A1 B1 A6 B6 2800 PSI P B2 B A AUX 2 OPTION 3000 PSI B A8 B8 A7 B7 ...

Page 72: ...Reference Diagrams 4 6 31200079 NOTES ...

Page 73: ...TIC PANEL LOW BRAKE PRESSURE SWITCH 66680A DPST N C SWITCH 850 PSI TAN 16 RED 16 WHITE 16 RED 16 BLACK 16 YELLOW 16 66941A DPST N C SWITCH 100 PSI PARKING BRAKE PRESSURE SWITCH UNDER DASH PANEL P11092 WHITE 16 VIOLET 16 TAN 16 BLUE 16 J9 YELLOW 16 WHITE 16 66906A HARNESS FOOT SWITCH CONNECTS UNDER DASH J11 J16 J12 WHITE 14 YELLOW 16 VIOLET 16 BLACK 16 J13 4923233 DASH HARNESS CONNECTS TO CIRCUIT B...

Page 74: ...BATTERY 12V MOUNTING BOLT TO LOWER STARTER CONNECT BATT GRD NEG CABLE 65724A STARTER SOLENOID MOTOR MAINFRAME ENGINE TO GROUND 38200C 4 2 0 BLACK 95 AMP BOSCH ALTERNATOR D B 4923247 WIRE W DIODE BLACK 10 67789A RELAY STARTER SV1 ON REAR STABILIZER CYLINDER REAR AXLE STABILIZER VALVE 2 WAY SOLENOID VALVE ON 38329A COIL SV3 38329A COIL SV2 VALVE ON VALVE PLATE REAR AXLE STABILIZER CONTROL 3 WAY SOLE...

Page 75: ...a 30 85 86 87 87a 30 85 86 87 87a 30 85 86 87 87a 30 85 86 87 87a 30 85 86 D F E B C A C D A B 11 12 10 9 8 7 1 3 7 2 4 6 7 5 6 5 4 3 2 1 B D C A MV0460 5 PSI 7 29 28 26 27 24 25 15 23 22 20 21 18 19 16 17 11 13 14 12 9 10 8 3 5 6 4 1 2 G3 A2 A1 A3 B1 B2 B3 C2 C1 E3 D1 C3 D2 E1 D3 E2 F3 F1 F2 G2 G1 K1 H2 H1 H3 J2 J1 J3 K2 K3 C A B F D E H G J C A B C A B 120 OHM 120 OHM B C A A B A B A B A B A B A...

Page 76: ...Reference Diagrams 4 10 31200079 Diagram 4 3 Electrical Schematic cont d NOTES ...

Page 77: ...Reference Diagrams 31200079 4 11 Diagram 4 3 Electrical Schematic cont d NOTES ...

Page 78: ...Reference Diagrams 4 12 31200079 ...

Page 79: ...1 Removal 5 13 Installation 5 15 Sight Gauge 5 16 Description 5 16 Removal 5 17 Installation 5 18 Suction Strainer 5 19 Description 5 19 Removal and Cleaning 5 20 Installation 5 20 Hydraulic Return Filter 5 21 Description 5 21 Checking Filter Condition 5 21 Replacing Return Filter Element 5 22 Removal 5 25 Installation 5 26 Reservoir Breather 5 26 Description 5 26 Removal and Installation 5 27 Hyd...

Page 80: ... Components 5 3 Fig 5 3 Hydraulic Reservoir Location 5 6 Fig 5 4 Hydraulic Reservoir 5 7 Fig 5 5 Recommended Reservoir Filling Method 5 8 Fig 5 6 Alternate Reservoir Filling Method 5 9 Fig 5 7 Hydraulic Reservoir Drain and Refill 5 11 Fig 5 8 Hydraulic Reservoir Fuel Tank Installation 5 13 Fig 5 9 Hydraulic Reservoir Sight Gauge 5 16 Fig 5 10 Reservoir Sight Gauge Installation 5 17 Fig 5 11 Suctio...

Page 81: ...ponents 5 40 Fig 5 27 Mid Inlet Control Valve Configurations 5 42 Fig 5 28 Mid Inlet Control Valve Installation 5 43 Fig 5 29 Rear Axle Stabilizer Control Valve Location 5 44 Fig 5 30 Rear Axle Stabilizer Control Valve Ports 5 45 Fig 5 31 Rear Axle Stabilizer Control Valve 5 47 Fig 5 32 Boom Extend Lockout Valve 5 49 Fig 5 33 Hydraulic Diagnostic Ports Models with Mid Inlet Hydraulics 5 49 Fig 5 3...

Page 82: ...iv 31200079 ...

Page 83: ...ollowing circuits Boom Extension See Section 6 Boom Hoist See Section 6 Carriage Tilt See Section 6 Transfer Carriage See Section 6 Frame Tilt See Section 7 Auxiliary 1st Standard 2nd Optional See Section 6 Steering Service Brakes See Section 9 Rear Axle Oscillation Lock See Section 6 Outriggers K1099 Hydraulic Pump Hydraulic Control Valve Hydraulic Reservoir Fuel Tank Hydraulic Oil Return Filter ...

Page 84: ...o relief plugs The steering circuit is controlled by a steering control unit and steering mode selector valve The service brake circuit is controlled by a hydraulic power brake valve and includes an accumulator The boom extension boom hoist carriage tilt outrigger and frame tilt cylinders are equipped with externally mounted counterbalance valves The counterbalance valves prevent movement of the c...

Page 85: ...uses a rear axle stabilizer control valve along with a mid inlet directional control valve assembly to control all hydraulic functions General Hydraulic Maintenance Practices Safe Maintenance Practices MV0030 Mid Inlet Directional Control Valve Assembly Rear Axle Stabilizer Control Valve WARNING HIGH PRESSURE FLUID HAZARD To prevent serious personal injury or death Relieve system pressure before a...

Page 86: ...alves seize pumps and clog orifices causing expensive repair jobs Steam clean or use solvents to clean the area of the machine around a hydraulic component before it is removed When steam cleaning or using water to clean a machine be sure the reservoir breather filter is protected to keep water out of the system Use caps or plugs to cover ends of disconnected lines or to plug openings when working...

Page 87: ... stains or build up of dirt or other foreign material in a suspect area Replace any tube lines that are pinched or dented Replace a hose if any of the following conditions exist Any evidence of hydraulic oil leakage at the surface of the hose or its junction with the metal end couplings Any blistering or abnormal deformation to the outer covering of the hose Hydraulic oil leakage at any threaded o...

Page 88: ...ounted on the right hand side of the machine and is located next to the fuel tank It has a capacity of 47 gallons The major components associated with the hydraulic reservoir are Hydraulic Tank Breather Hydraulic Tank Sight Gauge Pressure Gauge Hydraulic Oil Return Filter Hydraulic Oil Strainer A breakdown of hydraulic reservoir parts is shown in Fig 5 4 K1090 ...

Page 89: ...sembly Item 1 is threaded into the top of the reservoir It allows for expansion of fluid and prevents vacuum in the tank Check the hydraulic reservoir daily for the proper oil level Maintain oil level at the full mark on the sight gauge Item 2 with all cylinders retracted Important Do not operate the machine if the oil level falls below the low mark on the sight gauge Low oil level could damage th...

Page 90: ...he frame must be level 2 Retract all cylinders except frame tilt cylinder Apply the park brake and stop the engine 3 Clean area around hex cap Item 1 on the cover Item 2 Loosen and remove the hex cap 4 Provide a hydraulic hose of suitable length to run between hydraulic oil fill pump and male JIC 37 filler fitting Item 4 in return filter housing cover The reservoir end of the hose must be fitted w...

Page 91: ...ler fitting Item 4 Install hex cap Item 1 and torque to 70 ft lbs Filling Hydraulic Reservoir Alternate Method CAUTION Do not fill reservoir through breather opening The hydraulic system can become contaminated Oil must be filtered through the return filter to ensure purity Contamination even small amounts can permanently damage hydraulic system components and void the warranty Fig 5 6 Alternate R...

Page 92: ...ilter element Item 5 It takes several moments for oil to drain through the element Continue to add oil until HIGH mark is reached on hydraulic reservoir sight gauge 7 Make sure the cover Item 3 and spring Item 4 are clean 8 Place spring Item 4 in position on filter element assembly Item 5 9 Place the cover Item 3 in position and secure it to the filter housing Item 1 with four 4 flange nuts Item 2...

Page 93: ...in plug Item 4 and drain hydraulic oil into an appropriate container Dispose of drained oil properly 3 To remove the return filter assembly Item 2 see Removal on page 5 25 4 To remove the suction strainer Item 3 see Removal and Cleaning on page 5 20 5 Clean inside of reservoir of rust sludge scale metallic particles deposits and other residue with solvent Drain into suitable container and wipe cle...

Page 94: ...en two or three turns past finger tight If it is necessary to use thread sealant to stop fluid leakage apply sealant only to last few threads close to the drain plug head CAUTION To avoid contamination of hydraulic system do not apply thread sealant to end threads of drain plug 8 To install return filter assembly Item 2 see Installation on page 5 26 9 Install a new breather filter assembly Item 1 ...

Page 95: ...Adapter 4 Hose Clamp 5 Fuel Supply Hose 6 Flatwasher 7 Nut 8 Wiring Harness 9 JIC Pipe Connector 10 Return Manifold Tube 11 Hydraulic Oil Return Filter 12 Hydraulic Reservoir Fuel Tank 13 Swivel Branch Tee 14 Check Valve Description 15 90 Elbow 16 Hose Clamp 17 Fuel Return Hose 18 Fuel Tank Drain Plug 19 Hydraulic Reservoir Drain Plug 20 Flange Halve 21 Hydraulic Suction Hose 22 Tank Support Mount...

Page 96: ...d 16 on fuel lines Cap elbow Item 15 and pipe adapter Item 3 7 Remove the four 4 capscrews Item 26 and lockwashers Item 27 securing the two 2 flange halves Item 20 and the hydraulic suction hose Item 21 to the hydraulic strainer Item 28 Remove the flange halves 8 Loosen and remove the return manifold tube Item 10 connected to the JIC pipe connector Item 9 on the hydraulic oil return filter Item 11...

Page 97: ...the hydraulic reservoir fuel tank is properly supported and in the proper position attach the two 2 tank hold down straps Item 1 over the two pieces of chemprene belting and to the tank support mount Item 22 using four 4 each nuts Item 24 and lockwashers Item 23 For final tightening torque nuts to 35 ft lbs 3 Reconnect the suction tube elbow Item 21 to the JIC pipe connector Item 20 4 Reconnect sw...

Page 98: ... of the reservoir see Fig 5 10 Item 1 The hydraulic fluid level in the reservoir changes considerably during operation and a reading should not be taken until the boom is lowered to the ground the parking brake is applied the engine is stopped and all hydraulic pressure is released in the system The hydraulic reservoir sight gauge should then show the fluid level being near the high level If neces...

Page 99: ...manifold tube Item 8 connected to the JIC pipe connector Item 7 on the hydraulic oil return filter assembly Item 6 4 Remove four 4 each capscrews Item 5 and lockwashers Item 4 that secure the hydraulic oil return filter assembly Item 6 to the hydraulic reservoir Item 9 Remove the hydraulic oil return filter assembly 5 Reaching inside the opening for the hydraulic oil return filter assembly in the ...

Page 100: ...t gauge Item 1 on hydraulic reservoir Item 9 with hollow hex head bolts Item 2 and nuts Item 10 Tighten as necessary 6 Install hydraulic oil return filter assembly Item 6 as per instructions on page 5 26 7 Reconnect return manifold tube Item 8 to the JIC pipe connector Item 7 on the hydraulic oil return filter assembly Item 6 For final tightening torque hex head connector on return manifold tube t...

Page 101: ...ion Ref Fig 5 11 The suction strainer is located behind the hydraulic reservoir It removes contaminants as oil is pumped out of the hydraulic reservoir MV0080 3 7 1 2 4 8 5 6 Description 1 Drain Plug 2 O Ring 3 Hydraulic Oil Strainer 4 Flange Half Description 5 Lockwasher 6 Capscrew 7 O Ring 8 Hydraulic Suction Hose ...

Page 102: ...ing Item 7 from the hydraulic suction hose 5 Loosen and remove the strainer Item 3 from the reservoir Take the strainer to an appropriate area for further cleaning 6 Clean the strainer Item 3 by back flushing with solvent Dry the strainer element thoroughly with compressed air Installation Suction Strainer Ref Fig 5 11 The following procedures describes installation of the suction strainer on mode...

Page 103: ...n filter assembly is located on the hydraulic reservoir Its function are to filter return hydraulic oil entering the reservoir and provide a means to fill the reservoir Checking Filter Condition Fig 5 13 Return Filter Pressure Gauge Note Check indicator with engine at idle after thirty minutes of operation K1100 psi 0 5 10 15 20 25 30 psi K1009 1 2 3 4 ...

Page 104: ... 15 psi orange arc 3 and red arc 4 indicate that the return filter element must be serviced Replacing Return Filter Element Fig 5 14 Filter Housing Cover Disassembly Return Filter Element Ref Fig 5 14 The following procedure describes removal of the return filter element 1 Follow preparation procedures as outlined in Section 3 of this manual Be sure to follow the guidelines in this section detaile...

Page 105: ...when removing cover Do not remove flange nuts There is pressure under cover from spring Item 5 3 Remove spring Item 5 and return filter element assembly Item 6 and take to a suitable location for further inspection and cleaning 4 To protect system from contamination while working on filter element assembly place cover Item 3 back on return filter housing Item 1 and tighten flange nuts Item 2 Fig 5...

Page 106: ...nt Item 7 Connect bypass spring assembly Item 8 to end of tie rod Tighten by turning bypass spring assembly clockwise until snug and completely engaged on tie rod 8 Reassemble flatwasher Item 3 trestle Item 2 and lock nut Item 1 on other end of tie rod Reassembly Return Filter Element Ref Fig 5 14 The following procedure describes installation of the return filter element 1 Loosen four 4 flange nu...

Page 107: ...tube Item 4 connected to the connector Item 5 on the hydraulic oil return filter assembly Item 6 4 Loosen and remove four 4 capscrews Item 3 and lockwashers Item 2 that secure the hydraulic oil return filter assembly Item 6 to the hydraulic oil reservoir Item 1 Remove the hydraulic oil return filter assembly To avoid contamination place all parts on a clean surface 5 Remove the rubber gasket Item ...

Page 108: ... the return filter assembly on the hydraulic reservoir with the four 4 lockwashers Item 2 and capscrews Item 3 Torque the capscrews evenly to 276 in lbs 3 Connect the return manifold tube Item 4 to the connector Item 5 on the hydraulic oil return filter assembly Item 6 Torque the nut on the return manifold tube to 188 213 ft lbs Reservoir Breather Description Fig 5 17 Reservoir Breather Ref Fig 5 ...

Page 109: ...d sealant or Teflon tape CAUTION To avoid the possibility of the hydraulic system being contaminated do not fill the reservoir through the breather opening Hydraulic Pressure Filter Description Fig 5 18 Hydraulic Pressure Filter Control Manifold Hydraulics The hydraulic pressure filter is located on the mounting bracket for the pressure filter and accumulator which is attached to the valve plate W...

Page 110: ...neral Hydraulic Maintenance Practices on page 5 3 2 Clean hydraulic pressure filter assembly to avoid contamination of system while removing hydraulic pressure filter assembly 3 Unscrew and remove filter element bowl Item 4 from filter head Item 1 4 Remove filter element Item 3 and discard it 5 Remove bowl O ring Item 2 clean with an solvent and dry with compressed air Replace it if damaged 6 Clea...

Page 111: ...r General Hydraulic Maintenance Practices on page 5 3 2 Clean the hydraulic pressure assembly to avoid contamination of the system while removing the hydraulic pressure filter assembly 3 Tag and slowly loosen the three 3 fittings Items 4 6 and 7 from the pressure filter assembly and bleed any remaining oil Cap fittings 4 While securing the hydraulic pressure filter assembly Item 5 loosen and remov...

Page 112: ...ssembly through the hole in the filter mounting bracket making sure that the bypass indicator is closest to back of the mounting bracket 2 Secure the pressure filter assembly to the mounting bracket with the four 4 each capscrews and lockwashers For final tightening torque the capscrews to 75 in lbs 3 Connect the three 3 fittings Items 4 6 and 7 to the pressure filter assembly For final tightening...

Page 113: ...he system 1 Operate hydraulic system until purged 2 Check inlet suction lines and fittings for air leaks C Vacuum condition 1 Check inlet suction lines and fittings for restrictions 2 Check reservoir breather filter conditions D Oil too thick Be certain correct type of oil is used for refilling or adding to the system Viscosity must be correct for ambient temperatures E Cold weather Run hydraulic ...

Page 114: ...s of fluid A Ruptured hydraulic lines B Loose fittings C Leaking gaskets or seals in pump or circuit 1 Check all external connections tubing and hoses Tighten connections and replace any ruptured tubes or hoses 2 Observe mating sections of pump for leaks 3 Replace seals or gaskets if possible Problem Probable Cause Solution ...

Page 115: ...all brake pressure diagnostic port test gauge into brake diagnostic port see page 5 49 MV0330 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description 1 Hydraulic Hose to Test Port 2 Hydraulic Hose to Accumulator 3 Hydraulic Hose to Test Port 4 Reducer Adapter 5 Branch Tee 6 Elbow 7 Hydraulic Hose to Steer Motor 8 Hydraulic Hose to Steer Motor 9 Hydraulic Hose to Accumulator 10 Hydraulic Hose to Stee...

Page 116: ...m diagnostic port 4 Thoroughly clean the hydraulic pump to ensure that dirt will not get into the system transmission 5 Tag and slowly loosen the ten 10 hydraulic hoses shown in Fig 5 22 Items 1 2 3 7 thru 11 14 and 16 and the two 2 hydraulic hoses shown in Fig 5 24 Items 1 12 Bleed any remaining oil into appropriate container Disconnect hoses Cap fittings and hoses ...

Page 117: ...shers Item 10 securing the two 2 flange halves Item 9 to the hydraulic suction hose Item 12 Remove the flange halves MV0320 25 26 24 23 22 19 20 21 18 16 17 15 14 13 12 11 10 9 8 5 6 7 4 3 1 2 2 1 Description 1 Hydraulic Hose 2 Elbow 3 Capscrew 4 Lockwasher 5 Hydraulic Pump 6 O Ring 7 Transmission 8 O ring 9 Flange Half 10 Lockwasher 11 Capscrew 12 Hydraulic Suction Hose 13 Nut Description 14 Lock...

Page 118: ...fittings and O rings for the hydraulic pump after it has been removed 1 Ref Fig 5 23 Remove and discard O rings Items 6 and 8 2 Make notes of positions of hydraulic fittings shown in Fig 5 22 and Fig 5 23 Tag and remove all fittings Clean with appropriate solvent and dry with compressed air Inspect and replace if damaged 3 Clean exposed areas of hydraulic pump with appropriate solvent and dry with...

Page 119: ... and capscrews Item 19 4 Connect hydraulic suction hose Item 12 to pump by installing two 2 flange halves Item 9 and four 4 lockwashers Item 10 and capscrews Item 11 5 Connect two 2 hydraulic hoses Item 1 on connectors Item 2 on side of pump Step 6 thru Step 16 refer to Fig 5 23 6 Install hydraulic hose Item 3 from Pump 1 test port to reducer adapter Item 4 7 Install hydraulic hose Item 1 from tes...

Page 120: ...ssure port of pump Item 5 to be tested 3 Loosen and remove hex cap Item 2 from top of return filter housing Item 1 4 Assemble a hydraulic tester Item 3 in a test loop between the pump and return filter Use hydraulic hose Item 4 with a minimum burst pressure rating of 12 000 psi Hose end fittings for the pump and return filter must be 1 1 16 12 JIC 37 female 5 Determine the system s maximum rated p...

Page 121: ...fications for your model forklift in Section 2 8 Open load valve Record maximum pump flow at zero pressure 9 Slowly close the load valve until the system is at the maximum rated pressure Record the pump flow 10 Open load valve until pump pressure is again at zero 11 Shut off the engine 12 Disconnect test loop from pump and return filter housing Reconnect pump pressure hose Item 6 and install hex c...

Page 122: ...Control Valve Location Fig 5 26 Mid Inlet Control Valve Components 0 8 0 6 0 4 0 2 0 2 0 K1140 K1141 Mid Inlet Outlet Section Boom Extension Boom Hoist Relief Valve Pump 2 Test Port Relief Valve Inlet From Priority Valve on Pump Outlet Return to Tank Work Ports Inlet Section Inlet From Pump 2 Valve Sections ...

Page 123: ...ng circuits L H Outrigger R H Outrigger Carriage Fork Tilt Transfer Carriage 1st Auxiliary Hydraulics 2nd Auxiliary Hydraulics Frame Tilt To the right of the mid inlet section there are two boom controlling sections for the following circuits Boom Hoist Boom Extension Telescope The presence of these circuits and the controlling valve sections depends upon the machine model and installed options se...

Page 124: ... Auxiliary Frame Tilt Carriage Tilt 7 Spool Valve For Models with Unloader Natural Engine Carriage Tilt Transfer Carriage Auxiliary Frame Tilt L H Outrigger R H Outrigger L H Outrigger R H Outrigger Carriage Tilt Transfer Carriage 1st Auxiliary 2nd Auxiliary Frame Tilt 8 Spool Valve For Models with Outriggers Only 9 Spool Valve For Models with Outriggers and Optional 2nd Auxiliary Hydraulics 6 Spo...

Page 125: ...le watching the test gauge press the brake pedal numerous times until the pressure gauge reads 0 psi Remove the test gauge and cap the diagnostic port 4 Tag and disconnect all hydraulic lines from control valve fittings Cap all hoses tubes and fittings Tag all fittings 5 Remove three 3 capscrews and lockwashers securing the mid inlet control valve to the valve plate 6 Using appropriate lifting dev...

Page 126: ...to remove air from the system 4 Stop engine and check for hydraulic leaks Tighten connections as necessary Rear Axle Stabilizer Control Valve Description Fig 5 29 Rear Axle Stabilizer Control Valve Location Ref Fig 5 29 The rear axle stabilizer control valve is located on the valve plate near the middle of the machine This valve controls hydraulic functions using the following valves Solenoid Valv...

Page 127: ...s and markings Table 5 1 is a list of markings for each side of these valves Fig 5 30 Rear Axle Stabilizer Control Valve Ports MV0730 G3 B A OR4 OR2 FB PD1 OR3 SV1 G1 OR1 ACC FTB FCB RCB OR5 RCR PC3 PD4 PD3 PD2 PS1 G2 S1 RCR BR RB CBP PB PIL SV2 T A B C D E F A Top View E Front View F Left View C Right View B Back View T ...

Page 128: ...ridge Valve B Back View S1 Shuttle Cartridge Valve RB Rear Brakes SV2 Solenoid Valve PS2 Sequence Valve BR Brake CBP Stabilizer Lock Valve PB Power Brake PIL Stabilizer Lock Valve T Tank C Right View A Port A B Port B G3 Gauge 3 Test Port Rear Osc Lock FB Front Brakes OR2 Orifice 2 OR4 Orifice 3 E Front View RCR Stabilizer Lock Valve G1 Gauge 1 FTB Piloted Sequence Valve FCB Frame Tilt Cylinder RC...

Page 129: ...ACC Port 6 Hose for Elbow at RCR Port 7 Hose for Connector at FB Port 8 Hose for Run Tee at A Port 9 Hose for Run Tee at A Port 10 Hose for Connector at B Port 11 Hose for Connector on Boom Extend Lockout Valve 12 Hose for Connector on Boom Extend Lockout Valve Description 13 Hose for Elbow at BR Port 14 Hose for Elbow at PIL Port 15 Hose for Run Tee at T Port 16 Hose for Elbow at RB Port 17 Hose ...

Page 130: ...on page 5 3 2 Install brake pressure diagnostic port test gauge into brake diagnostic port see page 5 49 3 While watching test gauge press brake pedal numerous times until pressure gauge reads 0 psi Remove test gauge from diagnostic port 4 Thoroughly clean the rear axle stabilizer control valve 5 Disconnect intermediate wiring harness from the low brake pressure switch and solenoid valve 6 Tag and...

Page 131: ... rear axle stabilizer control valve Hydraulic Diagnostic Ports General The eight 8 hydraulic diagnostic ports are located beneath the operator s compartment and can be accessed through the opening in the operator s step Fig 5 33 Hydraulic Diagnostic Ports Models with Mid Inlet Hydraulics Ref Fig 5 33 The hydraulic ports on models with mid inlet hydraulics are SV1 PD1 OR3 C D K1154 Front View PUMP ...

Page 132: ... lock circuit Brakes Used for reading pressure of the brake circuit and is used to indicate when pressure is eliminated from the system prior to discon necting hydraulic hoses Pressure limit is 425 psi Steering Used for reading pressure of the steering circuit Pressure limit is 2355 psi Pilot Used for reading pressure of the joystick circuit Pressure limit is 500 psi Accum Used for reading of pres...

Page 133: ...51 Roll Back Hose Tray General Fig 5 34 Roll Back Hose Frame Location Control Manifold Hydraulics Ref Fig 5 34 The roll back hose tray is located near the middle of the machine above the valve plate Removal Roll Back Hose Tray 0 80 60 40 2 0 20 K1069 ...

Page 134: ...8 to the front hose tray support bracket Item 3 2 Remove the two 2 each button head socket capscrews Item 9 lockwashers Item 10 and flatwashers Item 11 securing the roll back hose tray to the rear hose tray support bracket Item 12 3 Remove the roll back hose tray from the machine Description 1 Nut 2 Lockwasher 3 Front Hose Tray Support Bracket 4 Hose Mount 5 Button Head Socket Capscrew 6 Button He...

Page 135: ...e roll back hose tray on the two support brackets making sure it is in the same position as when removed 3 Secure the roll back hose tray Item 8 to the rear hose tray support bracket with two 2 each flatwashers Item 11 lockwashers Item 10 and button head socket capscrews Item 9 Tighten as necessary 4 Secure the roll back hose tray to the front hose tray support bracket Item 3 with two 2 lockwasher...

Page 136: ...Supply Pressure and Return Hydraulics 5 54 31200079 ...

Page 137: ... 6 12 Removal 6 13 Installation 6 14 Overhaul 6 15 Front Carriage Tilt Cylinder 6 18 Description 6 18 Removal 6 19 Installation 6 20 Overhaul 6 21 Rear Carriage Tilt Cylinder 6 24 Description 6 24 Removal 6 25 Installation 6 26 Overhaul 6 27 Selector Valve 6 29 Description 6 29 Removal 6 30 Installation 6 31 Overhaul 6 31 Troubleshooting 6 33 Boom Slide Pads General 6 34 Description 6 34 Slide Pad...

Page 138: ...ain Tension Check 6 108 Boom Hose Replacement 6 109 Extension Cylinder 6 111 Boom Extension Proximity Switch 6 117 Description 6 117 Removal 6 118 Installation 6 119 Adjustments 6 119 Transfer Carriage 6 120 Description 6 120 Installation 6 127 Rollers Bushings and Shims 6 129 List of Figures Fig 6 1 Major Boom and Transfer Hydraulic Components 6 1 Fig 6 2 Joystick 6 2 Fig 6 3 Joystick Installatio...

Page 139: ...ide Surface Repair 6 37 Fig 6 26 Slide Pad Installation 2 Section Shown 6 38 Fig 6 27 Positioning Retaining Block 6 38 Fig 6 28 Determining Capscrew Length 6 39 Fig 6 29 Correctly Installed Capscrew 6 39 Fig 6 30 Quick Attach Rear View 6 40 Fig 6 31 Release Handle 6 40 Fig 6 32 Lock Plate 6 41 Fig 6 33 Rotating Quick Attach Downwards 6 41 Fig 6 34 Lowering Boom 6 41 Fig 6 35 Retracting Boom 6 42 F...

Page 140: ...4 Section Boom Pivot Pins 6 61 Fig 6 67 Slide Pad Removal Outer Boom Section 6 64 Fig 6 68 Lower Front Slide Pad Removal Middle Rear Boom Section 6 65 Fig 6 69 Disconnecting Hoses Between Sections 6 66 Fig 6 70 Extension Cylinder Removal 4 Section Boom 6 67 Fig 6 71 Upper Front Slide Pad Removal Middle Rear Boom Section 6 68 Fig 6 72 Upper Front Slide Pad Removal Middle Forward Boom Section 6 69 F...

Page 141: ...l Assembly Middle Forward Boom 6 99 Fig 6 106 Rear Slide Pad Installation 6 99 Fig 6 107 Front Slide Pad Installation Outer and Middle Rear Boom Sections 6 100 Fig 6 108 Lower Chain Installation Inner Boom Section 6 101 Fig 6 109 Lower Chain Installation Middle Forward Boom Section 6 101 Fig 6 110 Upper Chains Middle Rear to Outer Boom Sections 6 102 Fig 6 111 Upper Chain Middle Forward to Middle ...

Page 142: ...stallation 6 125 Fig 6 130 Transfer Carriage Installation 6 126 Fig 6 131 Transfer Carriage Front Rollers Bushings and Shims 6 129 Fig 6 132 Shims for Front Transfer Rollers 6 130 Fig 6 133 Scraper Plate 6 131 Fig 6 134 Transfer Carriage Rear Rollers Bushings and Shims 6 132 Fig 6 135 Spacer Washers for Rear Transfer Rollers 6 133 Fig 6 136 Rear Slide Block Installation 6 134 ...

Page 143: ...ponents Boom 2 3 or 4 Sections Boom Extension Cylinder not visible in illustration Front Carriage Tilt Cylinder Boom Hoist Cylinder Rear Carriage Tilt Cylinder Joystick Controls Transfer Carriage Further information on the hydraulic system can be found in Section 4 Carriage 0 80 60 40 20 20 Boom Rear Carriage Hoist Front Carriage Tilt Cylinder Tilt Cylinder Transfer Cylinder Joystick Controls J111...

Page 144: ... Action is quicker at higher engine speeds Joysticks can be moved in any direction and are not limited to front back left right movement Moving a joystick in a diagonal direction will cause a combination of actions A switch is located on the top of the front joystick under a protective rubber cap Pressing this switch down with your thumb activates the auxiliary function Note Releasing the switch w...

Page 145: ...s Item 14 and lockwashers Item 15 securing side panel Item 13 to control panel Item 8 Remove side panel J1120 Description 1 Button Head Socket Capscrew 2 Lockwasher with Internal Teeth 3 Phillips Truss Head Screw 4 Flatwasher 5 Wiring Harness 6 Lead Connector 7 Joystick 8 Control Panel Description 9 Connector 10 Connector 11 Swivel Tee 12 Hydraulic Hose 13 Side Panel 14 Capscrew 15 Lockwasher 3 5 ...

Page 146: ...ll two 2 connectors Item 9 one in center port in bottom of joystick Item 7 and the other in the bottom of the manifold Torque connectors to 25 29 ft lbs 2 Install remaining four 4 connectors Item 10 in ported guides in bottom of joystick body Torque connectors to 25 29 ft lbs 3 Install assembled joystick on control panel Item 8 with four 4 each capscrews Item 1 and lockwashers Item 2 Torque capscr...

Page 147: ...6 Switch 7 Guide 8 Hex Nut 9 Hex Nut 10 Seal 11 Setscrew 12 Lever Joint 13 Retaining Nut 14 Stem 15 Clip 16 Socket Head Capscrew 17 Boot 18 Cam Description 19 Retainer 20 Flange 21 Socket Head Capscrew 22 Manifold 23 O ring 24 Body 25 Wiper 26 Guide 27 O ring 28 Seal 29 Spreader 30 Plunger 31 240 32 Spool 33 Spring 34 O ring 35 O ring 36 Ported Guide J1121 3 1 4 5 6 7 8 10 11 13 17 18 19 16 20 21 ...

Page 148: ...Items 34 and 35 from ported guide Discard O rings 3 Remove spool Item 32 and spring Item 33 from body 4 Remove guide assembly Items 25 thru 31 from body 5 Remove O ring Item 27 from guide Item 26 Discard O ring 6 Clean remaining parts with solvent Dry with compressed air Inspect and replace if damaged Note Items 25 thru 31 cannot be purchased individually The O ring Item 27 can only be purchased a...

Page 149: ...o 2 half handles Item 3 and remove the push button Item 5 e Remove switch Item 6 from guide Item 7 if damaged f If the switch is damaged remove connecting wires and discard switch Solder wires to outside tabs on new switch Install switch in guide g Inspect remaining parts and replace if damaged Note Unless they are damaged it will not be necessary to remove lever joint Item 12 and retaining nut It...

Page 150: ...e the cam is backed off enough to ensure that all four 4 plungers Item 30 are in the spring offset position b Apply thread locking compound to flange thread c Screw cam and stem on flange until cam just touches the plungers d Screw cam a maximum of 1 4 turn and then torque back cam against stem to 160 in lbs 11 Return boot to correct position covering retainer Fig 6 5 Pilot Pressure Diagnostic Por...

Page 151: ...nal valve adjustments as required Hydraulic Cylinders Description All hydraulic cylinders used on JLG forklifts are a double acting non cushioned type with chromed rods The boom hoist carriage tilt boom extension and frame tilt cylinders are equipped with externally mounted counterbalance valves These counterbalance valves prevent movement of the cylinders in the event of downstream hydraulic line...

Page 152: ... worn bushings that will need to be replaced Note When the machine or cylinders are stored retract the cylinder rods to protect them Cylinder maintenance requires periodic inspection for wear and checks for leakage External Leakage If a cylinder end cap is leaking or if the cylinder leaks around the rod the seals must be replaced WARNING DO NOT use your hand to check for leaks Use a piece of cardb...

Page 153: ...ine and activate the control that will supply hydraulic oil to the rod end of the cylinder 6 If there is leakage from the disconnected end of the cylinder remove the cylinder and make repairs If there is no leakage reconnect the hose and tighten see installation procedures for each cylinder for torque specifications ...

Page 154: ... hoist cylinders are used to raise and lower the boom They are attached on one end to the outer boom and the other end is attached to the transfer carriage boom cradle near the rear of the operator s compartment Daily lubrication of the two grease fittings on each cylinder is required 0 80 60 40 2 0 20 J1126 REV 001 ...

Page 155: ...the engine 3 Loosen and remove hydraulic hoses Item 1 from fittings on hoist cylinder Item 2 Bleed any remaining oil into a suitable container Cap fittings and hoses 4 Loosen and remove capscrew Item 6 and lockwasher Item 7 from rod end lock pin Item 5 0 80 60 40 2 0 20 Description 1 Hydraulic Hose 2 Hoist Cylinder 3 Outer Boom 4 Pivot Pin Rod End 5 Lock Pin 6 Hex Capscrew Description 7 Lockwasher...

Page 156: ... required to install boom hoist cylinders 1 Using sling s crane or other suitable means position base end of cylinder Item 2 in its proper location on the transfer carriage boom cradle Item 8 WARNING To avoid personal and or equipment damage make sure the cylinder is properly supported until it is completely installed Note Be sure to apply thread locking compound to the threads of the capscrews be...

Page 157: ...oil in the cylinder which may be under pressure Wear proper eye and hand protection when removing counterbalance valve cartridges Hydraulic fluid under pressure can be injected under skin or into eyes resulting in serious personal injury or death MV0620 16 15 14 13 11 12 10 9 8 6 5 4 3 2 1 7 Description 1 45 Degree Elbow 2 Grease Fitting Cover 3 Grease Fitting 4 Self Aligning Bushing Base End 5 Cy...

Page 158: ...pect bushings for damage The following steps are necessary if bushing s need to be replaced a Remove bushing Item 4 from cylinder barrel Item 5 and or remove bushing Item 14 from cylinder rod Item 13 using a bushing driver and hammer or press b Install new bushing so that it is centered in axle boss c To ensure proper lubrication make sure an adequate amount of grease is applied to the grease fitt...

Page 159: ...ton 22 Lubricate new O ring backup ring seals and wear rings with hydraulic oil and install on head Using a seal driver install new wiper seal in head Lubricate wiper seal with hydraulic oil 23 Slide head Item 12 and piston Item 10 onto rod Item 13 Lubricate threads on rod with hydraulic oil and install rod nut Item 9 Torque rod nut to 2600 2800 ft lbs 24 Lubricate new seal and wear rings with hyd...

Page 160: ...is located inside the inner boom section at the front of the machine connecting to the inner boom and to the quick attach assembly It controls attachment tilt when the appropriate joystick handle is activated Maximum operating pressure is at approximately 3175 psi Daily lubrication of the two grease fittings is required 0 80 60 40 2 0 20 J1126 ...

Page 161: ...onnect two 2 hydraulic hoses Item 6 from connectors Item 8 Cap fittings and hoses 3 Support cylinder Item 7 with sling s and crane or other suitable means Make sure equipment has sufficient capacity to support weight of cylinder the cylinder weighs approximately 200 pounds J1070 6 5 1 2 3 4 7 8 Description 1 Inner Boom Section Pin Boss 2 Lock Pin 3 Lockwasher 4 Capscrew Description 5 Upper Pivot P...

Page 162: ...omponents for condition and wear Replace as necessary Installation Front Carriage Tilt Cylinder Ref Fig 6 11 The following steps are required to install the front carriage tilt cylinder 1 Using sling s crane or other suitable means position cylinder in boom nose Align cylinder with pin bosses in boom and install pivot pin Secure pin with lock pin lockwasher and capscrew Torque capscrew to 55 ft lb...

Page 163: ...lly with rod end down Hydraulic oil in cylinder will drain out during disassembly Place a suitable pan or tray under the cylinder 2 Release oil pressure in the cylinder as follows MV0630 2 4 2 9 3 13 12 11 10 8 7 8 6 1 5 Description 1 O ring Connector 2 Bushing 3 Set Screw 4 Grease Fitting 5 Counterbalance Valve Cartridge 6 Rod Nut 7 Cylinder Barrel 8 Bushing 9 Cylinder Rod Description 10 Grease F...

Page 164: ...ad back and forth during removal 7 Remove rod nut Item 6 piston Item 11 tube Item 12 and rod bearing head from cylinder rod 8 Remove the two 2 connectors Item 1 from the cylinder manifold block Item 2 9 Inspect bushings for damage The following steps are necessary if bushing s need to be replaced a Remove bushing Item 8 from cylinder barrel and or remove bushing Item 2 from cylinder rod using a bu...

Page 165: ...er install new wiper seal in head Lubricate wiper seal with hydraulic oil 19 Slide head Item 13 tube Item 12 and piston Item 11 onto rod Item 9 Lubricate threads on rod with hydraulic oil and install rod nut Item 6 Torque rod nut to 2600 2800 ft lbs 20 Lubricate new seal and wear rings with hydraulic oil and install on piston 21 Apply removable blue thread locking adhesive to threads on 1 set scre...

Page 166: ...nders are located at the rear of the outer boom section one on each side These cylinders maintain the attachment tilt position as the boom is raised and lowered As boom elevation changes a specific amount of oil in the cylinders moves to the front carriage tilt cylinder automatically adjusting the attachment tilt 0 80 60 40 2 0 20 J1128 ...

Page 167: ... Section 3 2 Lower the boom to the ground apply the park brake retract the cylinder and stop the engine 1 J1129 Description 1 Outer Boom 2 Lock Pin 3 Lockwasher 4 Hex Head Capscrew 5 Cylinder Pivot Pin Rod End 6 Rear Carriage Tilt Cylinder 7 Hydraulic Hose Description 8 Grease Fitting Cover 9 Grease Fitting 10 Lock Pin 11 Lockwasher 12 Hex Head Capscrew 13 Cylinder Pivot Pin Base End 14 Transfer C...

Page 168: ... from transfer carriage boom cradle Item 14 12 Slowly remove the cylinder from the machine and take it to a location suitable for inspection and disassembly Installation Rear Carriage Tilt Cylinder Ref Fig 6 14 The following steps are required to install rear carriage tilt cylinders 1 Using sling s crane or other suitable means position base end of cylinder Item 6 in its proper location on the tra...

Page 169: ... Ref Fig 6 15 The following steps are required to overhaul the rear carriage tilt cylinder 1 Lay cylinder horizontally in a vice or hold it down with a strap wrench Hydraulic oil in cylinder will drain out during disassembly Place a suitable pan or tray under the cylinder 2 Remove the two 2 elbows Item 1 from the manifold block on the cylinder barrel Item 2 3 Remove the setscrew Item 3 4 Install a...

Page 170: ...ponents and discard 10 Thoroughly clean components with solvent and dry with compressed air 11 Inspect inner surface of barrel outer surface of piston and length of rod for scratches and scoring If barrel piston or rod is damaged it must be replaced 12 Check condition of threads on rod and rod nut Do not attempt to repair damaged threads 13 Lubricate new O ring with hydraulic oil and install insid...

Page 171: ... fittings with EP lithium based grease Selector Valve Description Fig 6 16 Selector Valve The 6 port circuit selector valve directional control valve is located on the valve plate near the center of the machine It directs fluid to the control valve when the joystick is activated The 6 port selector valve directs the flow of hydraulic oil from the joystick controller to the appropriate control valv...

Page 172: ...n of the system clean selector valve 6 Disconnect joystick wiring harness Item 8 from selector valve 7 Tag and loosen six 6 hydraulic hoses Items 3 4 and 6 and bleed any remaining oil into a suitable container Disconnect hoses Cap fittings and hoses 8 Remove two 2 each nuts Item 1 lockwashers Item 2 and capscrews Item 7 securing selector valve Item 5 to the valve plate 9 Take selector valve and mo...

Page 173: ...ports A1 and B1 on selector valve and torque hose swivel nuts to 130 150 in lbs 4 Reconnect joystick wiring harness Item 8 to selector valve Overhaul Selector Valve Fig 6 18 Selector Valve Assembly Ref Fig 6 18 The following steps describe disassembly and overhaul of the selector valve assembly in models with a mid inlet hydraulic system 1 Loosen and remove four 4 connectors Item 9 from valve body...

Page 174: ... O ring and backup ring before installing it Install O rings on each solenoid valve in descending order making sure the largest is installed first and the smallest last Make sure that O rings Items 6 and 8 are installed between their backup rings 10 Check valves for any visible contamination Dip each valve in clean oil up to the largest O ring Item 4 before installing it in the valve body 11 Insta...

Page 175: ...r cylinder seals C Repair or replace damaged components D Check pump pressure 3 Excessive boom pivot pin or cylinder pivot pin wear A Failure to grease at regular intervals B Worn bushings A Replace worn pins and lubricate at recommended intervals B Replace bushings and lubricate at recommended intervals 4 Excessive Slide Pad Wear A Improper shimming of slide pads B Contaminated or rusted slide pa...

Page 176: ...ds are located at the front and on the top of a boom section that contains another section Pads that are located at the rear and on the bottom of a boom that fits inside of another or any pads that are located on a side of any boom section are also non load bearing slide pads Slide Pad Inspection Fig 6 19 Load Bearing Pad Ref Fig 6 19 Except for the lower slide pads located at the rear of the midd...

Page 177: ...ad is OK and does not need to be replaced Fig 6 21 Pad Must Be Replaced Ref Fig 6 21 When the chamfer is gone the pad must be replaced Important Never use a boom slide pad that has worn past the chamfer The boom will be damaged Fig 6 22 Bolted Boom Slide Pad Ref Fig 6 22 Chamfered slide pads that have nut inserts are secured to the boom with capscrews lockwashers spring and or star and flatwashers...

Page 178: ...f EP Lithium based grease on exposed pad slide areas Retract the boom fully and use the grease fittings provided at the rear of the boom section s for lubricating those areas Slide Area Surface Finish The areas on each boom section where the main load bearing pads slide must be smooth and free of nicks and scratches Rough surfaces will greatly reduce the service life of slide pads The general rule...

Page 179: ...ther option is to install replace boom wear strips Contact the JLG Service Department or your dealer for information about available wear strips Fig 6 24 Damaged Slide Surface Fig 6 25 Slide Surface Repair J1040 0 030 Max J1041 0 030 Max ...

Page 180: ...provided on following pages Usually the main load bearing pads caged pads are the only pads that will need shimming The other pads are not normally subjected to heavy wear Fig 6 27 Positioning Retaining Block Ref Fig 6 27 After shimming caged pads the retaining block must be correctly positioned to prevent possible damage to the boom Shims Bolted Pad Caged Pad Pad Capscrew Lockwas her Pad Cage Ret...

Page 181: ...urchased from JLG come in three 3 lengths 3 4 1 and 1 1 4 Clearance is measured from under the capscrew head to the lockwasher A lockwasher must always be used under the capscrew head Apply nonpermanent thread locking compound to the first few threads of the capscrew before final installation Fig 6 29 Correctly Installed Capscrew Ref Fig 6 29 The end of the installed capscrew should be flush with ...

Page 182: ...ng the release handle attachments can be easily interchanged Disconnecting an Attachment 1 Come to a complete stop on flat level ground 2 Set the park brake 3 Raise the boom so attachment clears the ground 4 Extend the boom a short distance 5 Lower the boom to rest the attachment on level ground 6 Shut off engine 7 Disconnect attachment hydraulic lines if equipped Fig 6 31 Release Handle J1004 J10...

Page 183: ...e attachment clearing the lock plate 3 from the attachment stop 4 Fig 6 33 Rotating Quick Attach Downwards 10 Start the engine Fully rotate quick attach 5 downwards by using the attachment tilt control Fig 6 34 Lowering Boom 11 Lower boom enough to clear quick attach pivot pin 6 from attachment 7 J1013 J1007 J1008 ...

Page 184: ...chment 7 Connecting an Attachment Fig 6 36 Extending Boom 1 With quick attach 5 rotated fully downwards extend the boom until quick attach pivot pin 6 is properly aligned underneath the attachment 7 Fig 6 37 Raising Boom 2 Raise the boom to engage the quick attach pivot pin 6 with the attachment 7 J1009 J1015 J1016 ...

Page 185: ...ment 7 4 Shut off engine Fig 6 39 Lock Plate Engaged 5 Check to see that the lock plate 3 is engaged ahead of the attachment stop 4 6 Connect attachment hydraulic hoses if equipped J1017 J1014 MAKE SURE ATTACHMENT IS SECURELY CONNECTED TO QUICK ATTACH ATTACHMENT MAY FALL AND CAUSE SERIOUS PERSONAL INJURY OR DEATH WARNING W1048 ...

Page 186: ...position shut off engine and remove ignition key from switch Block all wheels Fig 6 40 Lower Pivot of Carriage Tilt Cylinder 4 Ref Fig 6 40 Remove capscrew Item 3 lockwasher Item 4 and lock pin Item 5 from lower pivot pin Item 2 of front carriage tilt cylinder Item 6 Remove pivot pin from quick attach Item 1 J1067 6 5 4 3 2 1 Description 1 Quick Attach 2 Pivot Pin 3 capscrew Description 4 Lockwash...

Page 187: ...Item 6 to boom Check gaps between quick attach and boom Select shims to center quick attach on boom 2 Ref Fig 6 41 Install quick attach pivot pin Item 1 and shims Item 5 Secure pivot pin with capscrew Item 2 lockwasher Item 3 and nut Item 4 3 Ref Fig 6 40 Align rod end of front carriage tilt cylinder with quick attach Install pivot pin and secure with lock pin lockwasher and capscrew 4 Lubricate g...

Page 188: ...pacities Replacement Fig 6 43 Boom Angle Inclinometer Installation 1 Remove two 2 each round head screws Item 4 starwashers Item 3 and flatwashers Item 2 along with the boom angle indicator Item 1 from the boom 2 Discard old boom angle inclinometer 3 Clean and inspect hardware for damage and replace as necessary 4 Install new boom angle inclinometer with two 2 each flatwashers starwashers and roun...

Page 189: ...oom Description Fig 6 44 4 Section Boom The 4 section boom is used on 1044C 54 models It is a fully synchronized slide boom with a 54 foot maximum lift height The boom on the 1044C 54 has a maximum forward reach of 45 feet J1152 0 80 60 40 20 20 ...

Page 190: ... are serviceable See Slide Pad Inspection on page 6 34 Have replacement pads ready as required Fig 6 46 Boom Section Gaps Front of 4 Section Boom 0 80 60 40 20 20 0 80 60 40 20 20 J1160 1 1 3 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 NOTE Items 1 and 3 are load bearing pads 2 Description 1 Boom Pad 1 Thick x 3 Wide 2 Boom Pad 9 16 Thick x 2 Wide 3 Boom Pad 3 4 Thick x 3 Wide Description 4 Boom Pad 3 4 Thick x...

Page 191: ...fied range proceed to Step 5 Fig 6 47 Lower Shim Installation Front of 4 Section Boom 4 Ref Fig 6 47 Install remove shim s under indicated pads to obtain clearances specified in Step 3 Fig 6 48 Upper Shim Installation Front of 4 Section Boom J1162 Install shim s under these pads J1155 0 03 0 09 0 05 0 11 0 06 0 12 gap between boom and pad gap between boom and pad gap between boom and pad 1 32 3 32...

Page 192: ...g between the middle rear and outer boom section cannot be adjusted If the dimensions are not within the specified range proceed to Step 7 If the dimensions are within the specified range proceed to Step 8 Fig 6 50 Lower Shim Installation Rear of 4 Section Boom 7 Ref Fig 6 50 Install remove shim s under indicated pads to obtain clearance specified in Step 6 J1156 1 04 1 10 1 22 1 47 This dimension...

Page 193: ...arances Between Boom Sections Rear of 4 Section Boom 9 Ref Fig 6 52 Adjust boom positions to obtain clearances between boom sections as shown Measure these clearances at the slide pad locations J1158 0 07 1 16 0 06 1 16 J1187 Rear of Boom Looking Forward 0 47 0 53 0 595 0 655 19 32 21 32 0 72 0 78 15 32 23 32 25 32 17 32 0 595 0 655 19 32 21 32 0 72 0 78 23 32 25 32 0 47 0 53 15 32 17 32 ...

Page 194: ...h sides of each boom section are the same Fig 6 54 Clearances Between Boom Sections Front of 4 Section Boom J1188 0 02 0 08 1 64 5 64 0 03 0 09 1 32 3 32 0 03 0 09 1 32 3 32 0 02 0 08 1 64 5 64 0 03 0 09 1 32 3 32 0 03 0 09 1 32 3 32 Rear of Boom Looking Forward J1189 Front of Boom Looking Rearward 0 47 0 53 0 595 0 655 19 32 21 32 0 72 0 78 15 32 23 32 25 32 17 32 0 72 0 78 23 32 25 32 0 47 0 53 ...

Page 195: ... boom section are the same 13 Extend boom and lubricate as described under Lubrication on page 6 36 14 Check boom extension and retraction for binding against slide pads Inspection Procedures 4 Section Boom These procedures are intended to determine if localized deformation has occurred on the inner middle forward and middle rear boom sections 1 Extend the boom and lower the forks to the ground J1...

Page 196: ...um deflection will be found just in front of the middle forward boom section 3 Ref Fig 6 56 The side walls may also deflect outward at the window areas Take this measurement across the inner boom tube through the windows Maximum allowable deflection is 3 16 0 19 per side The maximum allowable inner boom tube width is 10 5 8 10 625 measured through the windows Fig 6 57 Middle Forward Boom Cross Sec...

Page 197: ...ttom surface of the middle rear boom section Measure the distance from the straight edge to the bottom surface of the boom tube This distance should not exceed 1 4 0 25 The maximum deflection will be found just in front of the outer boom section 7 Ref Fig 6 58 The side walls may also deflect outward at the window areas Take this measurement across the middle rear boom tube through the windows Maxi...

Page 198: ...6 Remove boom elevation proximity switch See Boom Elevation Proximity Switch in Section 7 7 Remove boom extension proximity switch See Step 8 on page 6 123 Fig 6 60 Hose Connections 4 Section Boom J1169B Description 1 Nut 2 Lockwasher Description 3 Flatwasher 4 Boom Cover 2 4 1 3 J1220 1 2 3 4 Description 1 Auxiliary Hydraulic Hoses 2 Carriage Tilt Hoses Description 3 Boom Extension Hoses 4 Boom E...

Page 199: ... boom CAUTION Make sure crane slings and chains have sufficient capacity to support the weight of the boom A 4 section boom assembly including boom extension cylinder weighs approximately 6 650 pounds Fig 6 61 Cylinder Pivot Pins 11 Ref Fig 6 61 Remove four 4 capscrews Item 3 and lockwashers Item 2 from lock pins Item 1 securing rear carriage tilt cylinders Item 6 and boom hoist cylinders Item 7 t...

Page 200: ...ch of the two 2 hoist cylinders Item 7 by using a slide hammer puller threaded into pivot pin Item 5 to remove it After the pivot pin has been removed allow the cylinder to swing down and away from the boom Fig 6 62 Upper Rear Slide Pad Removal Middle Rear Boom Section 15 Ref Fig 6 62 Remove upper rear slide pads from middle rear boom section as follows a Remove two 2 each capscrews Item 6 lockwas...

Page 201: ... four 4 capscrews Item 8 and lockwashers Item 7 securing slide pads Item 2 to top rear of middle forward boom section Remove slide pads and shims Item 1 Fig 6 64 Upper Rear Slide Pad Removal Inner Boom Section J1245 1 2 4 3 5 6 7 8 Description 1 Shim 2 Rear Upper Slide Pad 3 Pad Retainer 4 Lockwasher Description 5 Flatwasher 6 Capscrew 7 Lockwasher 8 Button Head Socket Capscrew J1269 8 1 2 3 4 5 6...

Page 202: ...g upper slide pads Item 2 to rear of inner boom section Remove the two 2 slide pads Fig 6 65 Locations for Chain Attachment Inner Boom Section 18 Ref Fig 6 65 Because the chain and hose guide assembly interferes with removal of the boom pivot pins it will be necessary to extend the boom approximately eight 8 inches To do so attach a chain to one of the openings either on the front or top of the in...

Page 203: ...uller remove the two 2 boom pivot pins and shims Item 5 21 Ref Fig 6 66 Carefully lift the boom assembly Item 7 clear of the transfer carriage boom cradle Item 6 22 Swing the boom away from the machine and position it above a firm level surface Rotate the boom upside down and lower it onto support blocks 23 Remove the front carriage tilt cylinder See page 6 19 J1222 3 1 2 3 4 2 1 5 6 5 7 4 Descrip...

Page 204: ... with the matching boss on the boom Insert pivot pin and secure with lock pin lockwasher and capscrew Repeat this procedure for the other hoist cylinder and rear carriage tilt cylinders 8 The slings chains and crane may be removed at this point 9 Ref Fig 6 61 Connect the two 2 auxiliary hydraulic hoses and two 2 carriage tilt hoses to the rear of the boom 10 Connect the two 2 hoses to the boom ext...

Page 205: ...wer boom to ground and shut off engine c Complete proximity switch adjustment before proceeding to Step 18 18 Inspect hydraulic connections for leaks and tighten as necessary 19 Ref Fig 6 59 Install boom cover Item 4 with six 6 each flatwashers Item 3 lockwashers Item 2 and nuts Item 1 Tighten nuts to 180 in lbs Boom Disassembly 4 Section Boom 1 Remove boom assembly from machine 2 Place boom assem...

Page 206: ...rews Items 10 and 14 and lockwashers Items 9 and 11 securing retainer blocks to outer boom section Remove two 2 each lower slide pads Item 1 shims Item 2 and retainer blocks J1271 Description 1 Lower Slide Pad 2 Shim 3 Right Hand Retainer Block 4 Pad Retainer 5 Flatwasher 6 Lockwasher 7 Capscrew 8 Left Hand Retainer Block Description 9 Lockwasher 10 Capscrew 11 Lockwasher 12 Upper Slide Pad 13 Shi...

Page 207: ... Item 3 lockwashers Item 4 and pad retainers Item 5 from rear of middle rear boom section b Remove four 4 capscrews Item 7 and lockwashers Item 6 securing upper slide pads to rear of middle rear boom section Remove two 2 slide pads Item 1 and shims Item 2 J1270 7 2 1 5 6 4 3 Description 1 Lower Front Slide Pad 2 Shim 3 Capscrew 4 Lockwasher Description 5 Pad Retainer 6 Lockwasher 7 Button Head Soc...

Page 208: ...xiliary Hydraulic Tube 2 Carriage Tilt Hydraulic Tube 3 Middle Front Boom Section 4 Hose Guard 5 Lockwasher 6 Capscrew 7 Auxiliary Tilt Hydraulic Hose 8 Carriage Tilt Hydraulic Hose 9 Middle Rear Boom Section Description 10 Auxiliary Hydraulic Tube 11 Carriage Tilt Hydraulic Tube 12 Half Clamp 13 Round Head Screw 14 Auxiliary Hydraulic Hose 15 Carriage Tilt Hydraulic Hose 16 Lockwasher 17 Nut 18 O...

Page 209: ... carriage tilt Items 14 and 15 from hydraulic tubes Items 10 and 11 at rear of outer boom section Item 18 Bleed any remaining oil into a suitable container Tag and cap hoses and tubes d For early production models remove four 4 each nuts Item 17 lockwashers Item 16 round head screws Item 13 and half clamps Item 12 Fig 6 70 Extension Cylinder Removal 4 Section Boom 0 80 60 40 20 20 MV0390 1 2 3 4 5...

Page 210: ...e rod nut and rod boss Item 3 securing boom extension cylinder to front of middle rear boom section Item 4 f Loosen and remove hardware securing extension cylinder to outer boom section as follows Remove two 2 each nuts Item 14 capscrews Item 6 and flatwashers Item 7 securing extension cylinder base mount Item 11 to outer boom section Remove the shim s Items 12 and 13 g Remove the extension cylind...

Page 211: ...e upper front slide pads from middle front boom section as follows a Remove two 2 capscrews Item 1 and lockwashers Item 2 securing each of the two 2 upper slide pads to the front of the middle forward boom section b Remove two 2 slide pads Item 4 and shims Item 3 Fig 6 73 Upper Chain Middle Forward to Middle Rear Boom Sections J1245 1 2 4 3 Description 1 Button Head Socket Capscrew 2 Lockwasher De...

Page 212: ...ller Assembly Middle Forward Boom Section 13 Ref Fig 6 74 Remove capscrew Item 10 lockwasher Item 9 and lock pin Item 8 from chain roller pin Item 7 14 Ref Fig 6 74 Remove chain roller pin two 2 guide washers Item 1 bushing Item 2 chain roller Item 3 and chain roller bushing Item 4 0 80 60 4 0 2 0 20 J1224 1 2 3 4 1 7 8 9 10 5 6 Description 1 Chain Guide Washer 2 Bushing 3 Chain Roller 4 Chain Rol...

Page 213: ...onnecting Chains at Rear of Middle Forward Boom 16 Ref Fig 6 76 Disconnect chains from rear of middle forward boom as follows J1229 8 Description 1 Inner Boom 2 Upper Chain 3 Lock Nut 4 Lockwasher Description 5 Capscrew 6 Lower Chain 7 Shoulder Bolt 8 Rear Chain Anchor 2 3 4 5 6 7 1 J1228 13 14 15 16 1 2 6 2 7 9 11 10 8 3 12 5 4 Description 1 Upper Chain 2 Lock Nut 3 Upper Chain Anchor 4 Capscrew ...

Page 214: ...lock nut Item 9 shoulder bolt Item 11 and lower chain anchor from lower chain Item 10 17 Ref Fig 6 75 Pull upper chain Item 2 out through front of boom 18 Slide inner and middle forward boom sections out of middle rear boom section Place middle forward section with inner on work stands upside down Fig 6 77 Slide Pad Removal Inner Boom Section 19 Ref Fig 6 77 Remove eight 8 capscrews Items 1 and 3 ...

Page 215: ...e rear side slide pads b Ref Fig 6 78 Remove two 2 each capscrews Item 6 lockwashers Item 5 flatwashers Item 4 and pad retainers Item 3 from front of middle forward boom section 1 2 3 4 5 6 7 9 10 8 12 13 16 17 7 9 11 MV0090 15 14 1112 Description 1 Front Bottom Slide Pad 2 Shim 3 Pad Retainer 4 Flatwasher 5 Lockwasher 6 Capscrew 7 Side Slide Pad 8 Shim 9 Button Head Socket Capscrew 10 Lockwasher ...

Page 216: ...ove slide pad and shim s Item 16 22 Slide inner boom section out of middle forward boom section Place inner boom on work stands in upright position 23 Remove auxiliary hydraulic quick disconnects from inner boom Fig 6 79 Grease Hose Assembly 24 Ref Fig 6 79 Remove bulkhead adapter Item 4 from rear of inner boom section Item 2 25 Ref Fig 6 79 Loosen and remove grease hose Item 1 and elbow Item 3 fr...

Page 217: ...wo 2 chain guide washers Item 7 bushing Item 8 chain roller Item 9 and chain roller bushing Item 10 28 Turn over inner boom section and place on work stands in upside down position 29 Remove front carriage tilt cylinder from inner boom See page 6 19 Steps 2 6 J1233 Description 1 Grease Fitting Cover 2 Grease Fitting 3 Chain Roller Pin 4 Lock Pin 5 Lockwasher Description 6 Capscrew 7 Chain Guide Wa...

Page 218: ...y and carriage tilt hydraulic tubes Items 4 and 5 in mounting channels Item 6 b Slide cushion clamps from mounting channel and remove hydraulic tubes from inner boom section c Remove hydraulic hoses Items 1 and 2 from tubes J1246 3 4 5 6 1 2 Description 1 Auxiliary Hydraulic Hoses 2 Carriage Tilt Hydraulic Hoses 3 Cushion Clamp Description 4 Auxiliary Hydraulic Tubes 5 Carriage Tilt Hydraulic Tube...

Page 219: ...83 Upper Chain Roller Assembly Middle Rear Boom Section 0 80 60 4 0 2 0 20 J1225 1 3 4 5 2 Description 1 Chain Anchor 2 Jam Nut 3 Lockwasher Description 4 Nut 5 Outer Boom Section 0 80 60 40 2 0 20 J1226 5 1 2 7 8 9 10 3 4 3 2 1 6 Description 1 Chain Guide Washer 2 Chain Roller Bushing 3 Hardened Bushing 4 Chain Roller 5 Grease Fitting Cover Description 6 Grease Fitting 7 Lock Pin 8 Lockwasher 9 C...

Page 220: ...ove lower chains from the middle rear and outer boom sections as follows a Remove capscrew Item 2 and lockwasher Item 1 b Remove chain adjustment rod Item 3 c Pull the chain assembly Items 4 thru 7 out through rear of boom 35 Slide middle rear boom out of outer boom section and place it on work stands in upright position 0 80 60 40 2 0 20 J1230 1 2 3 6 7 4 5 1 2 3 6 7 5 4 Middle Rear Boom Section ...

Page 221: ...lockwashers Item 8 securing side slide pads to rear of middle rear boom section Remove two 2 slide pads Item 10 and shims Item 9 c Remove four 4 each capscrews Item 5 and lockwashers Item 6 securing lower slide pads to rear of middle rear boom section Remove two 2 slide pads Item 12 and shims Item 11 J1232 Description 1 Front Side Slide Pad 2 Shim 3 Lockwasher 4 Button Head Socket Capscrew 5 Butto...

Page 222: ...s Item 1 hose guide spacers Item 5 hose spacers Item 6 plastic bushings Item 7 and left hand hose guides Item 8 from chain and hose roller Item 12 d Remove two 2 chain roller washers Item 10 and the hardened bushing Item 11 from the chain and hose roller J1238 13 14 15 2 3 4 5 6 7 8 10 11 12 10 4 3 7 5 6 2 8 9 9 1 1 Description 1 Roller Bushing 2 Washer 3 Capscrew 4 Right Hand Hose Guide 5 Hose Gu...

Page 223: ... container and remove hoses from inside middle rear boom section Item 3 Tag and cap hoses and fittings 39 Flip middle rear boom section upside down and place on work stands 40 Ref Fig 6 87 Remove hydraulic tubes from bottom of middle rear boom section as follows MV0100 1 2 3 4 5 6 9 8 7 10 Description 1 Auxiliary Hydraulic Hose 2 Carriage Tilt Hydraulic Hose 3 Middle Rear Boom Section 4 Hydraulic ...

Page 224: ...tem 10 Slide cushion clamps out of channel and remove hydraulic tubes from boom section Fig 6 88 Side Slide Pads Outer Boom Section 41 Ref Fig 6 88 Remove side slide pads from outer boom section as follows a Remove four 4 capscrews Item 1 and lockwashers Item 2 securing side slide pads to outer boom b Remove the two 2 slide pads Item 4 and shims Item 3 J1237 Description 1 Button Head Socket Capscr...

Page 225: ...uter boom section over and place it upside down on work stands a Loosen and remove four 4 auxiliary and front carriage tilt hydraulic tubes Items 9 and 10 from hydraulic manifold blocks Item 11 Bleed any remaining oil from tubes into a suitable container Tag and cap hydraulic tubes and open ports on hydraulic manifold blocks 11 MV0110 1 2 3 12 4 10 9 8 7 6 5 Description 1 Outer Boom Section 2 Auxi...

Page 226: ...d installation of additional items such as the boom angle indicator is covered elsewhere in this manual Additional information of removal and installation of the boom elevation proximity switch and the boom extension proximity switch is also covered in this manual Assembly 4 Section Boom 1 Use crane chains and slings to lift and place outer boom section on work stands in upside down position CAUTI...

Page 227: ...on of each tube will be close to bottom of the boom section Item 1 Torque swivel nut on tubes to 50 58 ft lbs c Place hoses through openings in bottom of outer boom section Item 1 and install hydraulic manifold blocks on outer section with lockwashers Item 12 and capscrews Item 13 Torque capscrews to 55 ft lbs MV0120 6 5 7 8 9 10 13 12 11 1 2 3 4 16 15 14 Description 1 Outer Boom Section 2 Auxilia...

Page 228: ... of boom section with two 2 each clamps Item 7 lockwashers Item 6 and nuts Item 5 Torque nuts to 96 in lbs Fig 6 91 Extension Cylinder Installation 3 Ref Fig 6 91 Install extension cylinder on outer boom section as follows a Using sling s crane or other suitable means position rod end of cylinder Item 5 in its proper location on the middle rear boom section Item 4 1 2 3 4 5 6 7 8 9 10 14 11 12 13 ...

Page 229: ...all cushion clamp Item 10 on each hydraulic tube as described in Substep d under Step 2 on Page 68 4 Apply EP lithium based grease to the inside top surfaces of outer boom section slide pad slide areas 5 Turn outer boom section over and place it in upright position on work stands Fig 6 92 Lower Chains on Outer Boom Section 6 Ref Fig 6 92 Add lower chain to inside of outer boom section as follows a...

Page 230: ...at inside of outer boom section Attach a cord or wire to end of chain for ease in handling after all four sections are assembled 7 Place middle rear boom section upside down on work stands Fig 6 93 Lower Rear Slide Pad Installation Middle Rear Boom Section 8 Ref Fig 6 93 After applying thread locking compound to the capscrews install two 2 lower rear slide pads Item 1 and shim s Item 2 to bottom o...

Page 231: ...crews Item 4 Torque capscrews to 55 ft lbs c Install cushion clamp Item 10 on each hydraulic tube and secured in mounting channel as described in Substep d under Step 2 on page 6 85 d Securing hydraulic tubes to bottom of boom section with two 2 each clamps Item 9 lockwashers Item 8 and nuts Item 7 Torque nuts to 96 in lbs e Install auxiliary and hydraulic hoses Items 1 and 2 to hydraulic manifold...

Page 232: ...ll two hose guide spacers Item 5 between left and right hand hose guides with two 2 lock nuts Item 9 and capscrews Item 3 Torque the lock nuts to 180 in lbs e Install chain and hose roller assembly on rear of boom section with chain and hose roller shaft Item 13 f Install two 2 grease fittings Item 14 and grease fittings covers Item 15 on chain and hose roller shaft J1238 13 14 15 2 3 4 5 6 7 8 10...

Page 233: ...ment block tight against back of anchor base Item 4 at bottom of middle rear boom section as shown in View A c Thread chain adjustment rod Item 3 into block until specified measurement is obtained d Push adjustment rod fully into anchor base e Lay chain flat inside of middle rear section Attach a cord or wire to end of chain for ease in handling after all four sections are assembled J1250 2 3 5 6 ...

Page 234: ...w to 110 ft lbs e Install grease fitting Item 6 and grease fitting cover Item 5 on chain roller pin Tighten the grease fitting 2 3 turns past finger tight 14 Lift and slide middle rear boom section into outer boom section Release strap securing extension cylinder to outer boom section and install cylinder end through orifice of middle rear section 15 Apply EP lithium based grease to the inside bot...

Page 235: ...in Tighten grease fitting 2 3 turns past finger tight f Repeat the preceding steps to install chain roller assembly to the rear of the boom section g Install upper chain anchor Item 3 on upper chains Item 1 with chain anchor rod Item 6 and two 2 lock nuts Item 2 Torque lock nuts to 108 in lbs h Install upper chain anchor to rear of boom section with lockwasher Item 5 and capscrew Item 4 Make sure ...

Page 236: ... two 2 side slide pads Item 7 and shim s Item 8 to rear of boom section with two 2 each lockwashers Item 12 and capscrews Item 11 according to drawing specifications Torque capscrews to 180 in lbs 19 Ref Fig 6 99 Install bottom slide pads and shims on front of boom section as follows 13 MV0150 1 2 3 4 5 6 7 8 9 10 11 12 17 16 7 8 15 14 12 11 Description 1 Front Bottom Slide Pad 2 Shim 3 Pad Retain...

Page 237: ... top surfaces of middle forward boom section slide pad slide areas 21 Turn middle forward boom section over to upright position on work stands 22 Place inner boom section upside down on work stands Fig 6 100 Hydraulic Hose and Tube Installation Inner Boom Section 23 Ref Fig 6 100 Install auxiliary and front carriage tilt cylinder hydraulic hoses and tubes as follows a Connect hydraulic hoses Item ...

Page 238: ... Boom Section 26 Ref Fig 6 101 After applying thread locking compound to the capscrews install two 2 lower and two 2 side slide pads Items 1 and 2 on inner boom section according to drawing specifications with lockwashers Item 3 and capscrews Item 4 Torque capscrews to 180 in lbs Fig 6 102 Grease Hose Installation J1247 1 2 3 4 4 3 Description 1 Lower Slide Pad 2 Side Slide Pad Description 3 Lockw...

Page 239: ...ease fittings 2 3 turns past finger tight 28 Turn inner boom section over and place it on work stands in upright position Fig 6 103 Upper Chain Installation Inner Boom Section 29 Ref Fig 6 103 Install upper chain assembly on inner boom section as follows a Install rear chain anchor Item 9 on inner boom section with two 2 lockwashers Item 6 and capscrews Item 7 Torque capscrews to 280 ft lbs b Inst...

Page 240: ...ocking compound to the capscrews install two 2 upper slide pads Item 4 and shims Item 3 on front of middle forward boom section with lockwashers Item 2 and capscrews Item 1 according to drawing specifications Torque capscrews to 180 in lbs 32 Lift middle forward and inner boom sections and slide them into middle rear boom section J1245 1 2 3 4 Description 1 Button Head Socket Capscrew 2 Lockwasher...

Page 241: ...shims Item 10 on rear of boom sections with lockwashers Item 7 and capscrews Item 8 Torque slide pad capscrews to 180 in lbs Note See Shimming Procedures on page 6 48 for details in determining the number of shims that will be required when performing Steps 34 and 37 Description 1 Upper Chains 2 Lock Nut 3 Upper Chain Anchor 4 Capscrew 5 Lockwasher Description 6 Chain Anchor Rod 7 Hose Reel 8 Caps...

Page 242: ...cking compound to the capscrews install remaining slide pads Item 6 and shims Item 5 on front of outer and middle rear boom sections with lockwashers Item 9 and capscrews Item 8 Torque capscrews to 180 in lbs 38 Ref Fig 6 106 Install remaining slide pad retainers Item 4 with flatwashers Item 3 lockwashers Item 2 and capscrews Item 1 Torque capscrews to 200 ft lbs J1258 5 6 6 5 1 2 3 4 5 6 8 9 8 9 ...

Page 243: ...assembly from inside outer boom section to middle front boom section as follows a Install lower chain anchor Item 6 on lower chain Item 4 with shoulder bolt Item 5 and lock nut Item 1 Torque lock nut to 108 in lbs b Install lower chain anchor on rear of boom section with two 2 lockwashers Item 3 and capscrews Item 2 Torque capscrews to 280 ft lbs J1255 4 1 3 2 Description 1 Lock Nut 2 Lower Chain ...

Page 244: ... 6 on the middle rear boom section Item 5 b Install jam nut Item 2 on chain anchor Item 1 and insert threaded portion of chain anchor through opening in bracket at top of outer boom section c Secure chain anchor with lockwasher Item 3 and nut Item 4 Torque anchor nut to 120 ft lbs 0 80 60 40 2 0 20 J1225 1 3 4 5 2 6 Description 1 Chain Anchor 2 Jam Nut 3 Lockwasher Description 4 Nut 5 Outer Boom S...

Page 245: ... chain anchor with lockwasher Item 3 and nut Item 4 Torque nut to 374 ft lbs Fig 6 112 Securing Lower Chains Middle Rear and Outer Boom Sections 43 Ref Fig 6 112 Align notch in head of adjustment rod Item 3 with threaded hole in anchor base Item 4 of middle rear Item 5 and outer boom Item 6 sections Secure adjustment rod with lockwasher Item 2 and capscrew Item 1 Torque capscrews to 50 in lbs Desc...

Page 246: ...nsion cylinder Item 4 to front of middle rear boom section with extension cylinder rod boss Item 3 and rod nut Item 1 Torque rod nut to 733 ft lbs Secure rod nut with two 2 setscrews Item 2 0 80 6 0 4 0 2 0 20 J1253 1 2 3 4 Description 1 2 Setscrew Description 3 Cylinder Rod Boss 4 Boom Extension Cylinder ...

Page 247: ...tion 4 Hose Guard 5 Lockwasher 6 Capscrew 7 Auxiliary Tilt Hydraulic Hose 8 Carriage Tilt Hydraulic Hose 9 Middle Rear Boom Section 10 Auxiliary Hydraulic Tube Description 11 Carriage Tilt Hydraulic Tube 12 Half Clamp 13 Round Head Screw 14 Auxiliary Hydraulic Hose 15 Carriage Tilt Hydraulic Hose 16 Lockwasher 17 Nut 18 Outer Boom Section 19 Hose Reels 20 Hose Rollers 12 4 5 6 1 2 8 13 J1241 3 17 ...

Page 248: ...es to the hydraulic tubes Items 10 and 11 at the rear of the middle rear boom section Torque swivel nut on hydraulic hoses to 50 58 ft lbs 46 Install assembled 4 section boom on machine as described on page 6 62 Boom Extend and Retract Chains Boom Chain Inspection WARNING Worn pins stretched or cracked links or cracked links or corrosive enviroments can cause chain failure A chain failure could re...

Page 249: ... chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain If during the inspection any chain is found to be damaged or stretched the chain must be replaced It is recommended that when any chain is replaced that all the chains and clevis be replaced at the same time Note DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part...

Page 250: ... the vehicle on level ground Place the travel select lever in N NEUTRAL place the neutral lock lever in the N NEUTRAL LOCK position engage the parking brake switch and raise the boom to a horizontal level position 3 Lower both outriggers completely 4 Slowly fully extend the boom and retract it about halfway Fully extend the boom again then retract it 3 51 mm one inch per section Turn the engine OF...

Page 251: ...ARNING Escaping hydraulic fluid under pressure can penetrate the skin causing death or serious injury Relieve hydraulic pressure before serving any hydraulic component 5 Extend the boom to the letter C to gain access to remove hose sheave pins through rear boom service access Remove the hose sheave pins left and right Then remove the hose sheaves WARNING DO NOT perform service or maintenance on th...

Page 252: ... hoses at rear of outer boom and cap the left side hoses to prevent the left side hoses from expelling fluid when the boom is raised or lowered to access the rear tube hose hold down clamps 15 Fully extend the transfer carriage and partially extend the boom Loosen and remove the forward most tube clamps on the outer boom Remove the fastening hardware securing the hydraulic manifold to the front an...

Page 253: ...on Cylinder The 4 section boom extension cylinder is located beneath the boom assembly It is attached from the middle rear to the outer boom section Its operating pressure is 3000 psi and weighs 650 pounds When completely retracted it is 149 3 4 long When fully extended it is 280 3 4 long 0 80 60 40 2 0 20 J1137 ...

Page 254: ... park brake retract the cylinder and shut the engine off 3 Support the boom and extension cylinder with sling s and crane or other suitable means Make sure support items have sufficient capacity to support the weight of the boom and cylinder the combined weight of the boom and extension cylinder is approximately 6650 pounds 10 MV0160 1 2 3 4 5 6 7 8 9 11 12 13 14 15 0 80 60 40 20 20 Description 1 ...

Page 255: ...the shim s Items 12 and 13 8 Slowly remove the cylinder from the machine and take it to a location suitable for inspection and disassembly 9 Clean remaining parts with solvent and dry with compressed air Inspect for damage and replace as necessary Installation Extension Cylinder The following steps are required to install the boom extension cylinder Ref Fig 6 117 1 Using sling s crane or other sui...

Page 256: ...a suitable pan or tray under the cylinder 3 Release pressure in counterbalance valve cartridges Items 5 and 6 as follows WARNING Counterbalance valve cartridges trap hydraulic pressure in the cylinder Wear proper eye and hand protection when removing counterbalance valve cartridges Hydraulic fluid under pressure can be injected under skin or into eyes resulting in serious personal injury or death ...

Page 257: ...l O rings wear rings and backup rings from cylinder components and discard 12 Thoroughly clean components with solvent and dry with compressed air Inspect and replace if damaged 13 Inspect inner surface of barrel outer surface of piston and length of rod for scratches and scoring If barrel piston or rod is damaged it must be replaced 14 Check condition of threads on rod nut and capscrews Do not at...

Page 258: ...Lubricate threads on rod with hydraulic oil and install rod nut Item 9 Torque rod nut to 1460 ft lbs 24 Apply removable blue thread locking adhesive to threads on 1 set screw Item 12 Coat inside of barrel Item 8 with hydraulic oil To avoid damaging seals during assembly carefully insert rod and head into barrel 25 Install two 2 elbows Item 7 on cylinder barrel 26 Install the extension cylinder bas...

Page 259: ...ance approximately 21 feet with tilting tower or 25 feet with standard carriage The proximity switch then opens as it no longer senses metal At this point the left and right outriggers must both be lowered to the ground to allow the boom or transfer carriage to be extended any further Normally open differential pressure switches in the outrigger cylinders close when the base end pressure exceeds t...

Page 260: ...hese eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop A sensor in the switch detects if the oscillator is on or off and this gives the switch its on off function Removal Boom Extension Proximity Switch Fig 6 121 Boom Extension Proximity Switch Assembly Proximity Switch Outer Boom Section Middle Rear Boom Section J1259 Magnetic Flux Lines Oscillator 0 80 6 ...

Page 261: ... body Item 2 at previously marked position 2 Install boom extension proximity switch in outer boom Install inner jam nut Item 1 Check gap between end of proximity switch and boom See Fig 6 122 3 Connect wire harness Item 4 to proximity switch 4 Check operation of proximity switch by extending the boom The boom extension proximity light must come on at specified distance approximately 21 feet with ...

Page 262: ...eet with standard carriage adjust proximity switch to slightly reduce the gap Do not exceed gap tolerances specified in Fig 6 122 Snug jam nuts to hold switch in position 4 Extend boom and check operation of boom extension proximity light The light must come on when boom is extended to specified distance approximately 21 feet with tilting tower or 25 feet with standard carriage If light does not i...

Page 263: ...move the transfer carriage 1 Follow preparation procedures as outlined in Section 3 of this manual 2 Lower the boom to the ground apply the park brake retract the transfer cylinder and stop the engine Fig 6 124 Disconnecting Transfer Cylinder from Transfer Carriage 3 Ref Fig 6 124 Loosen two 2 socket setscrews in rod nut securing transfer cylinder to the transfer carriage 4 Ref Fig 6 124 Remove tr...

Page 264: ...ubes and hoses so that it is completely separated from the transfer carriage Fig 6 126 Boom Cover Installation 7 Ref Fig 6 126 Remove the boom cover on models with 3 section booms see Step a or 4 section booms see Step b a Remove four 4 each nuts Item 3 lockwashers Item 1 and flatwashers Item 2 securing boom cover Item 4 to boom Remove boom cover J1149 Wiring Harness Connection Proximity Switch Wi...

Page 265: ...twashers Item 2 and J clamps Item 1 that secure the boom extension proximity switch wiring to the boom b Disconnect the proximity switch connection wire Item 6 from the proximity switch Item 8 and the wiring harness Item 5 c Remove all wire ties that secure the wiring harness to hydraulic tubes and hoses so that it is completely separated from the transfer carriage 0 80 6 0 4 0 2 0 J1147 4 3 1 5 3...

Page 266: ...along with the hose cover Item 2 10 Ref Fig 6 128 Disconnect hydraulic hoses Item 1 from the hydraulic tube elbows 11 If the boom and transfer carriage are being removed as an assembly go to Step 12 If the boom is being removed separately from the transfer carriage go to Step 13 J1142 1 Description 1 Hydraulic Hoses 2 Hose Cover Description 3 Lockwasher 4 Capscrew 2 3 4 ...

Page 267: ...emoving heavy machine components b Remove the four 4 each nuts Item 1 and lockwashers Item 2 securing the front slide blocks Item 4 to the transfer carriage Item 5 Remove the four 4 capscrews Item 3 and the two 2 slide blocks c Loosen the two 2 setscrews Item 6 in each spindle nut Item 7 d Remove the two 2 each spindle nuts spacer washers Item 8 thrust washers Item 9 spindles Item 10 roller bushin...

Page 268: ...embly WARNING To avoid personal and or equipment damage support the transfer carriage assembly before removing any additional mounting hardware Use suitable blocking and lifting devices when removing heavy machine components e Ref Fig 6 130 Remove the four 4 each nuts Item 1 and lockwashers Item 2 securing the two 2 front slide blocks Item 4 to the transfer carriage Item 5 Remove the four 4 capscr...

Page 269: ... up and unto its proper position on the machine WARNING To avoid personal and or equipment damage supporting the boom and transfer carriage assembly is essential when lifting and reinstalling it back on the machine Make sure that the boom and transfer carriage assembly is supported until it is completely installed b Install the transfer carriage Item 5 to rear of the main frame using the two 2 eac...

Page 270: ...t of transfer cylinder rod can be inserted in its mounting hole 5 Ref Fig 6 124 Install transfer cylinder rod nut and washer Torque cylinder rod nut to 1641 ft lbs Secure rod nut with two 2 setscrews 6 Ref Fig 6 128 Reconnect hydraulic hoses Item 1 to the hydraulic tube elbows Torque the swivel nuts on the hoses 79 88 ft lbs 7 Ref Fig 6 128 Install the hose cover Item 2 on the transfer carriage wi...

Page 271: ...r Item 4 on boom and secure it with six 6 each flatwashers Item 2 lockwashers Item 1 and nuts Item 3 Torque nuts to 180 in lbs Rollers Bushings and Shims Transfer Carriage The following procedures describe replacement of transfer rollers and bushings for the transfer carriage along with shimming procedures and replacement of scraper plates Front Mount Rollers Bushings and Shims Fig 6 131 Transfer ...

Page 272: ... rollers Item 13 and roller bushings Item 14 6 Discard transfer rollers and bushings Clean remaining parts with solvent and dry with compressed air Replace any damaged parts 7 Install new bushings so that each is centered in each transfer roller 8 Install transfer roller roller shims roller spacer and roller pin on each side of transfer carriage 9 Secure roller pins with lock pins and secure lock ...

Page 273: ... to replace scraper plates 1 Follow preparation procedures as outlined in Section 3 of this manual 2 Lower the boom to the ground apply the park brake retract the transfer cylinder and stop the engine 3 Remove two 2 each capscrews Item 8 lockwashers Item 9 and flatwashers Item 10 securing each of the two 2 scraper plates Item 7 to the front of the transfer carriage Remove scraper plates Clean insp...

Page 274: ...em 4 in each spindle nut Item 3 Remove two 2 spindle nuts 4 Remove spacer washer s Item 5 thrust washer Item 6 spindle Item 7 roller bushing Item 8 and transfer roller Item 9 from each side of transfer carriage 5 Discard transfer rollers and bushings Clean remaining parts with solvent and dry with compressed air Replace any damaged parts 6 Install new bushings so that each is centered in transfer ...

Page 275: ...urement is reached 10 Secure front transfer roller assembly to transfer carriage by tightening spindle nut Item 3 to3466 ft lbs 11 Remove two 2 grease fitting cover caps Item 1 and lubricate grease fittings Item 2 with EP lithium based grease Transfer Carriage Boom Pivot Bushings Ref Fig 6 134 The following steps are required to replace transfer carriage boom pivot bushings 1 Remove boom and shims...

Page 276: ... and shims 4 Discard worn slide block Clean and inspect remaining parts replace as necessary Fig 6 136 Rear Slide Block Installation 5 Ref Fig 6 136 Make sure that the correct number of shims will be installed a Check to see that the rear transfer roller is up against the bottom of the rail It may be necessary to start the engine and relocate the weight of the boom until the transfer roller is snu...

Page 277: ...Boom and Transfer 31200079 6 135 ...

Page 278: ...Boom and Transfer 6 136 31200079 ...

Page 279: ... 14 Frame Level Indicator 7 16 Description 7 16 Adjustment 7 16 Rear Oscillation Lock System 7 17 General Description Models with Control Manifold Hydraulics 7 17 Theory of Operation and Circuit Logic 7 18 Testing Rear Oscillation Lock Circuit 7 23 Rear Oscillation Lock Cylinder 7 24 Description 7 24 Removal 7 25 Installation 7 26 Overhaul 7 28 Oscillation Control Block 7 31 Description 7 31 Remov...

Page 280: ... 7 20 Fig 7 14 Circuit Operation Above 20 Below 40 with Service Brake Applied 7 21 Fig 7 15 Circuit Operation Below 20 With the Service Brake Applied 7 22 Fig 7 16 Rear Oscillation Lock Cylinder 7 24 Fig 7 17 Rear Oscillation Lock Cylinder Installation 7 25 Fig 7 18 Rear Oscillation Lock Cylinder Exploded View 7 28 Fig 7 19 Head Capscrew Torque Sequence 7 30 Fig 7 20 Oscillation Control Block 7 31...

Page 281: ...31200079 iii ...

Page 282: ......

Page 283: ...me level indicator When hydraulic pressure is applied to the frame tilt cylinder the frame pivots around each axle Two counterbalance valves one on the rod end and one on the base end are used to inhibit hydraulic fluid from exiting the frame tilt cylinder Function is controlled by the frame tilt control valve see page 7 3 located in the operator s compartment Circuit Description Reference Fig 7 1...

Page 284: ... shifted away from port A6 allowing pump flow to be routed through port A to the rod end of the frame tilt cylinder Pressure is sufficient to pilot the counterbalance valves open allowing fluid to enter and leave the cylinder As the cylinder retracts the frame tilts to the right and fluid from the base end of the cylinder is routed through port B of the frame tilt section and on to the filtered ta...

Page 285: ...icator See Frame Level Indicator on page 7 16 The control is functional only while the engine is running The control lever is equipped with a safety lock to prevent unintentional operation Lifting the lock ring to unlock the lever allows it to be moved left or right tilting the frame accordingly Returning the control lever to center position and releasing the lock ring secures the lever To level t...

Page 286: ...s compartment Lift up rear of control panel to expose lower portion of frame tilt control valve Item 5 3 Tag and disconnect six 12 hydraulic hoses Items 4 and 9 at frame tilt control valve Cap hoses and fittings 4 Note Position of two 2 tee fittings Item 8 on back side of valve body Remove fittings 5 Remove two 6 capscrews Item 7 and starwashers Item 6 retaining control valve to control panel 6 Li...

Page 287: ...gs to 300 340 in lbs 25 29 ft lbs 4 Install hydraulic hoses Items 4 and 9 onto fittings Torque nuts on 3 8 hoses to 235 265 in lbs 20 22 ft lbs Torque nuts on 1 4 hoses to 130 150 in lbs 5 Position control panel in operator s compartment and secure with six 6 flatwashers Item 1 and screws Item 2 6 Start engine and raise boom slightly Tilt frame fully left and right several times to purge trapped a...

Page 288: ...28 29 30 31 32 33 Description 1 Capscrew 2 Washer 3 Body 4 Plug 5 Knob 6 Lever 7 Rubber Boot 8 Cam 9 Metric Jam Nut 10 Capscrew 11 Pivot Pin 12 CirClip 13 Flange 14 Guide Assy 15 Spring Pack 16 Spring 17 O Ring Description 18 O Ring 19 Ported Guide 20 Knob 21 Lever Assy 22 Rubber Boot 23 Cam 24 Pin 25 Pivot Pin 26 CirClip 27 Flange 28 Guide Assy 29 Spring Pack 30 Spring 31 O Ring 32 O Ring 33 O Ri...

Page 289: ...for scratches and damage Scoring on the spool may also indicate damage to the ported guides If damage is evident replace with new parts Check fit of spools in ported guides The spools must fit snugly with no sticking A stuck spool can cause unintentional operation of a hydraulic circuit Excessive play or sticking means that the spool and its ported guide must be replaced 4 Check surface of each pl...

Page 290: ...ounted to the front axle With the engine running moving the frame tilt control valve handle see page 7 3 to the right causes the cylinder to retract and the frame tilts to the right Moving the tilt control handle to the left causes the cylinder to extend and the frame will tilt to the left There are conditions during normal machine operation when the frame tilt cylinder cannot be actuated See Rear...

Page 291: ...arning and procedures on page 7 15 for releasing hydraulic pressure in cylinder 5 Remove nut Item 18 lockwasher Item 17 and capscrew Item 16 securing cylinder upper pivot pin Item 15 to frame 6 Remove capscrew Item 14 lockwasher Item 12 and lock pin Item 11 securing cylinder lower pivot pin Item 13 G1022 2 1 3 2 1 19 9 13 11 12 14 15 16 17 18 View B Description 1 Grease Fitting Cover 2 Grease Fitt...

Page 292: ...able lifting equipment position upper cylinder pivot at frame pivot Install upper pivot pin so hole in pin is aligned with hole in frame boss Secure upper pivot pin with capscrew Item 16 lockwasher Item 17 and nut Item 18 Torque nut to 180 in lbs 4 If necessary models with the cylinder illustrated in View A install mounting blocks on front axle as follows a Install mounting block Item 5 to front o...

Page 293: ...ne and cycle frame tilt fully left and right several times to purge air from hydraulic system Lower boom and shut off engine 11 Inspect for hydraulic leaks and repair as necessary 12 Check oil level in hydraulic reservoir Add oil as necessary See Filling Hydraulic Reservoir in Section 5 for procedures ...

Page 294: ...Cylinder Fig 7 7 Frame Tilt Cylinder Exploded View MV0300 1 11 12 8 9 10 4 1 1 2 3 4 3 5 6 7 Description 1 Bushing 2 Barrel 3 Counterbalance Valve Cartridge 4 O Ring Plug 5 Orifice 6 Fitting O Ring 7 Set Screw Description 8 Tube 9 Piston 10 Rod Nut 11 Rod 12 Head ...

Page 295: ...m 7 securing head Item 12 to barrel Item 2 5 Pull rod Item 11 out to help remove head Support rod and head during removal to prevent damage Do not wiggle rod or head back and forth to remove this may damage the components 6 Remove rod nut Item 10 piston Item 9 tube Item 8 and head from rod 7 Remove two 2 O ring plugs Item 4 8 Remove fittings Item 6 9 Using a large flat bladed screw driver remove t...

Page 296: ...with hydraulic oil and install inside piston seals rod to piston 4 Lubricate new O ring backup ring seals and wear rings with hydraulic oil and install on head Item 12 Using a seal driver install new wiper seal in head Lubricate wiper seal with hydraulic oil 5 Slide head Item 12 stroke limiter Item 8 and piston Item 9 onto rod Item 11 Lubricate threads on rod with hydraulic oil and install rod nut...

Page 297: ...Carefully and slowly turn cartridge out of manifold block to release pressure in cylinder Repeat for other cartridge to release pressure from other end of cylinder 3 After pressure has been released tighten cartridges If cartridges will not be removed then torque counterbalance valve cartridges to 30 35 ft lbs Removal and Service Counterbalance Valve 1 Remove both cartridges and cap ports in manif...

Page 298: ...red 0 the machine is laterally level The frame tilt feature may be used to correct machine angles up to 12 5 to the left or right See Frame Tilt Control Valve on page 7 3 Adjustment Fig 7 10 Leveling the Frame 1 Ref Fig 7 10 Park the machine on a firm level surface Place a carpenter s level across the frame rails 2 Loosen screws securing frame level indicator to its mounting bracket Start the engi...

Page 299: ...s above 40 the following conditions apply Rear axle cylinder locks preventing the frame from rotating on the rear axle Note Rear oscillation lock cylinder can be unlocked by the drive lockout override switch See Drive Lockout Override in the Operator Safety Manual Transmission is inoperative Frame tilt function is disengaged REAR OSC LOCK light in the instrument cluster illuminates When the frame ...

Page 300: ... rear stabilizer cylinder along with Solenoid Valve SV3 7 Solenoid Valve SV3 controls rear stabilizer cylinder along with Solenoid Valve SV2 8 Service Brake Valve not shown locks the rear stabilizer cylinder when applied regardless of the status of SV2 and SV3 MV0540 VALVE ON VALVE PLATE REAR AXLE STABILIZER CONTROL 3 WAY SOLENOID VALVE ON ON REAR STABILIZER CYLINDER REAR AXLE STABILIZER VALVE 2 W...

Page 301: ...lamp in the instrument cluster 4 An additional effect of the Boom Over 40 relay not being energized is theTransmission Disconnect Override Footswitch is enabled Pressing the Transmission Disconnect Override Footswitch when the boom is over 40 reengages the transmission first gear only and allows very slow restricted oscillation of the frame on the rear axle This allows the machine to be moved This...

Page 302: ...Boom Over 20 relay is not energized Solenoid Valve SV1 is not energized which restricts movement of the rear stabilizer cylinder so that the frame may oscillate on the rear axle only in a slow or restricted mode The Boom Over 20 relay also illuminates the Rear Oscillation Lock lamp in the instrument cluster 4 The frame tilt is also restricted when Solenoid Valve SV1 is not energized MV0560 VALVE O...

Page 303: ...and Solenoid Valve SV1 is not energized which restricts the frame tilt 3 Applying the service brake locks the rear stabilizer cylinder hydraulically which prevents the frame from rotating on the rear axle MV0570 VALVE ON VALVE PLATE REAR AXLE STABILIZER CONTROL 3 WAY SOLENOID VALVE ON ENERGIZED ON REAR STABILIZER CYLINDER REAR AXLE STABILIZER VALVE 2 WAY SOLENOID VALVE ON ENERGIZED SOLENOID VALVE ...

Page 304: ...ylinder hydraulically which prevents the frame from rotating on the rear axle 4 Releasing the service brake unlocks the rear stabilizer cylinder hydraulically which allows the frame to rotate freely on the rear axle MV0580 ON REAR STABILIZER CYLINDER REAR AXLE STABILIZER VALVE 2 WAY SOLENOID VALVE ON ENERGIZED VALVE ON VALVE PLATE REAR AXLE STABILIZER CONTROL 3 WAY SOLENOID VALVE ON ENERGIZED SOLE...

Page 305: ...nergized Energized Boom below 20 Service brake applied Operating Frame Tilt Closed Closed Energized Energized Off Off Floating While Frame Tilt ing Energized Energized Energized Boom above 20 Service brake released Open Closed De energized Energized On Off Slow Restricted Oscillation De energized Energized Energized Boom above 20 Service brake applied Open Closed De energized Energized On Off Lock...

Page 306: ...o the rear axle The oscillation control block is mounted to the inboard side of the cylinder and controls hydraulic flow to and from the cylinder When hydraulic fluid is trapped in the cylinder the frame is prevented from rotating around the rear axle The rear oscillation lock cylinder and the oscillation control block are components of the rear oscillation lock system See Rear Oscillation Lock Sy...

Page 307: ...rt 5 Place a suitable drip pan under rear oscillation lock cylinder WARNING Residual hydraulic pressure may be trapped in rear oscillation lock cylinder Wear proper eye and hand protection when releasing pressure from cylinder Hydraulic fluid under pressure can be injected under skin or into eyes resulting in serious personal injury or death G1025 15 14 13 9 4 2 8 20 19 18 6 5 1 2 3 4 16 View B 21...

Page 308: ...r 1 Prior to installation lubricate upper and lower pivot pins with a light coating of grease 2 Using suitable lifting equipment position upper cylinder pivot at frame pivot Install upper pivot pin Item 3 so hole in pin is aligned with hole in frame boss Secure upper pivot pin with capscrew Item 4 lockwasher Item 2 and nut Item 1 Torque nut to 180 in lbs 3 If necessary models with a cylinder as il...

Page 309: ...fully left and right several times to purge air from hydraulic system Lower boom and shut off engine 10 Inspect for hydraulic leaks and repair as necessary 11 Check oil level in hydraulic reservoir and add as necessary See Filling Hydraulic Reservoir in Section 5 for procedures ...

Page 310: ... 7 28 31200079 Overhaul Rear Oscillation Lock Cylinder Fig 7 18 Rear Oscillation Lock Cylinder Exploded View MV0310 1 6 7 1 1 2 3 4 5 Description 1 Bushing 2 Barrel 3 Rod Nut 4 Piston Description 5 Tube 6 Rod 7 Set screw 8 Head ...

Page 311: ... Rear Oscillation Lock Cylinder 1 Remove all O rings wear rings and backup rings from cylinder components and discard 2 Thoroughly wash components in solvent and dry with compressed air 3 Inspect inner surface of barrel the outer surface of piston and rod for scratches and scoring If barrel piston or rod is damaged the component must be replaced 4 Check condition of threads on rod nut and capscrew...

Page 312: ...lide head Item 8 tube Item 5 and piston Item 4 onto rod Item 6 Lubricate threads on rod with hydraulic oil and install rod nut Item 3 Torque rod nut to 1540 1675 ft lbs 4 Lubricate new seal and wear rings with hydraulic oil and install on piston 5 Apply removable blue thread locking adhesive to threads on 1 set screw Item 7 Coat inside of barrel Item 2 with hydraulic oil Carefully insert rod and h...

Page 313: ...ock cylinder When the oscillation lock system is in UNLOCK mode the control block allows hydraulic fluid to freely pass into and out of the cylinder When the oscillation lock system is in LOCK mode the control block traps hydraulic fluid in both the rod end and base end of the cylinder This hydraulic lock in the cylinder prevents the frame from rotating on the rear axle MV0750 Rear Oscillation Loc...

Page 314: ...outlined in Section 3 2 Place blocks between frame and top of rear axle This will hold the frame in place when the control block is removed 3 Install brake pressure diagnostic port test gauge onto brake diagnostic port 4 While watching test gauge press brake pedal numerous times until pressure gauge reads 0 psi Remove test gauge from diagnostic port MV0470 1 9 4 3 5 8 26 29 1 1 6 7 10 1 2 Descript...

Page 315: ...crews Item 3 and lockwashers Item 4 securing control block to cylinder Item 8 Remove control block 10 Plug ports in cylinder Rear Oscillation Lock Cylinder Removed from Machine Ref Fig 7 20 Use the following control block removal procedures when the rear oscillation lock cylinder is removed from the machine For removal procedures when the cylinder is installed on the machine see page 7 32 1 Suppor...

Page 316: ... hoses to fittings on oscillation control block Item 6 5 For models with control manifold hydraulics connect electrical lead Item 9 at control block 6 Start engine and tilt frame fully left and right several times to purge air from the hydraulic system Shut off engine and check for leaks Rear Oscillation Lock Cylinder Removed from Machine Ref Fig 7 20 Use the following control block installation p...

Page 317: ...n control block MV0660 6 5 4 3 2 1 16 15 14 13 11 12 11 10 9 8 18 9 19 17 4 20 7 7 Description 1 Nut 2 Coil 3 Solenoid Valve 4 Seal Kit 5 Counter Balance Valve Cartridge 6 PO Check Valve PC1 PC2 7 Orifice Plug 040 8 O Ring 9 Hollow Hex O Ring Plug 4 10 Hollow Hex O Ring Plug 10 11 Backup Ring Description 12 O Ring 13 Check Valve Cartridge CV3 CV4 14 Piston Assy 15 Pressure Reducing Valve Car tridg...

Page 318: ...aining components except solenoid coil with solvent and dry with compressed air 4 Inspect orifice plugs Items 17 and 19 for blockage and clean as necessary Assembly Oscillation Control Block 1 If orifice plug Item 19 was removed install in block body so it is finger tight Tighten orifice plug 2 3 turns past finger tight 2 Install two 2 SAE 6 plugs Item 4 Torque plugs to 210 230 in lbs 3 Install on...

Page 319: ...YS port and torque to 46 50 ft lbs 14 Install adjustable fitting in T port Position fitting as previously noted and torque to 300 340 in lbs 25 29 ft lbs 15 Two 2 O rings Item 8 are installed when control block is installed on rear oscillation lock cylinder See Installation on page 7 34 Boom Elevation Proximity Switch Description Fig 7 22 Boom Elevation Proximity Switch Ref Fig 7 22 The boom eleva...

Page 320: ...e switch detects if the oscillator is on or off and this gives the switch its on off function Removal Boom Elevation Proximity Switch Fig 7 24 Boom Elevation Proximity Switch Assembly 1 Ref Fig 7 24 Disconnect wire harness Item 5 at boom proximity switch Item 3 2 Place a piece of masking tape around proximity switch body at the outer jam nut Item 4 this will serve as a guide during re installation...

Page 321: ...n If the light does not illuminate stop and lower boom Proceed to Adjustment below Adjustment Boom Elevation Proximity Switch Fig 7 25 Boom Elevation Proximity Switch Adjustment 1 Loosen but do not remove the two 2 jam nuts on the proximity switch body 2 Check gap between switch and boom Gap must be within the range specified in Fig 7 25 3 If Rear Osc Lock light does not illuminate when boom is at...

Page 322: ...Frame Tilt and Oscillation 7 40 31200079 ...

Page 323: ...ement 8 12 Transmission Shift Logic 8 13 Troubleshooting 8 15 Transmission Troubleshooting 8 16 List of Figures Fig 8 1 ZF Transmission 8 1 Fig 8 2 Transmission Serial Number Plate Location 8 3 Fig 8 3 The Lubrication and Maintenance Flip Chart 8 4 Fig 8 4 Transmission Oil Cooler Hose Connections 8 5 Fig 8 5 Disconnect the Battery Negative Cable 8 6 Fig 8 6 Drain Transmission Oil 8 7 Fig 8 7 Trans...

Page 324: ......

Page 325: ...referred to throughout this section Fig 8 1 ZF Transmission Transmission Description Instructions in this section pertain mainly to general specifications towing maintenance information and transmission removal and installation procedures Internal transmission service instructions and detailed specifications are provided in the ZF 4 WG 98 TC Transmission Repair Manual P N 8990455 ZF P N 5871 135 0...

Page 326: ... supplied by a pump located at the rear of the transmission The pump is driven by the central shaft which in turn is connected to the impeller of the torque converter The vehicle is equipped with an external oil cooler to cool the transmission oil The transmission gear speed select lever an electric shift control is located on the left side of the steering column in the operator s cab Movement of ...

Page 327: ...Transmission Performance Specification Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable Travel Speed standard tires no load First gear 3 5 mph 5 6 km hr Second gear 6 mph 9 7 km hr Third gear 15 2 mph 24 5 km hr Fourth gear 22 mph 35 km hr Transmission Lubrication a Transmission Fluid Complete transmission fluid information is found in Sectio...

Page 328: ...rs thoroughly clean the exterior of the transmission to help prevent dirt from entering while performing maintenance checks and procedures Transmission Maintenance Schedule provides a suggested maintenance schedule with references to pertinent procedures and instructions in this manual To help prevent transmission problems before they occur follow the maintenance schedule Note Lubrication and Main...

Page 329: ...outlet hose 3 routed to the lower oil cooler fitting is located on the top of the transmission The transmission oil cooler inlet hose 4 routed to the upper oil cooler fitting is located on the top of the transmission CAUTION DO NOT exceed 165 psi 39 6 bar when back flushing the oil cooler Applying too much pressure may damage the oil cooler radiator Disconnect and back flush the oil cooler portion...

Page 330: ...r in the N NEUTRAL position engage the parking brake and shut the engine OFF 2 Place an Accident Prevention Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Refer to Section 1 5 Accident Prevention Tags WARNING DO NOT get under a raised boom unless the boom is blocked up ALWAYS block the boom before doing any servicing that requires the boom to...

Page 331: ...ission drain plug 2 and allow the transmission oil to drain into the receptacle 9 Transfer the used transmission oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the transmission drain plug Fig 8 6 Drain Transmission Oil 10 Remove the engine to transmission drive shaft 11 Remove the transmission to a...

Page 332: ...ooler inlet hose routed to the upper radiator fitting is located on top of the transmission 17 Wipe up any spilled hydraulic and transmission oil Fig 8 7 Transmission Oil Cooler Hose Connections 18 Connect a lifting strap or chain to the top of the transmission 18 and to a suitable hoist or overhead crane Operate the hoist or crane to remove slack from the chain but DO NOT raise the transmission a...

Page 333: ... clear of the vehicle and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service Secure the transmission so that it will not move or fall Fig 8 8 Remove Transmission from Frame 27 Remove any external transmission components as required including the transmission temperature switch 20 and inlet 21 and outlet 22 cooler hose fittings Cover all tran...

Page 334: ...nce Manual P N 8990449 ZF part number 5872 134 002 for information on transmission diagnosis and internal schematics If replacing the entire transmission transfer the transmission temperature switch to the replacement transmission The gear shift solenoids are included with a new transmission WARNING Risk of severe personal injury NEVER lift a transmission alone enlist the help of at least one assi...

Page 335: ...m 4 Install the two rubber mounts 1 and the rear transmission mounting bracket 2 on the transmission with two capscrews 7 two mounting washers 17 two flat washers 8 two lockwashers 9 and two hex nuts 10 5 Remove the hoist or overhead crane and sling Fig 8 10 Install the Transmission 6 Secure the wiring harness to the transmission housing 7 Connect the transmission oil cooler inlet 18 and outlet 19...

Page 336: ...ry After Transmission Service or Replacement Refer to the ZF 4 WG 98 TC Transmission Repair Manual P N 8990455 ZF P N 5871 135 002 for information on servicing the transmission after overhaul or repair In general 1 Check the transmission oil level and add oil as required 2 Install a new transmission filter 3 Check the torque on the drive shaft yoke capscrews 4 Wear suitable eye protection When an ...

Page 337: ...l level when it reaches operating temperature 180 200 F or 83 94 C 13 Recheck all drain plugs lines connections etc for leaks and tighten where necessary Transmission Shift Logic There are 8 relays 9 diodes and 2 diode modules which make up the transmission shift logic circuit Fig 8 12 The relays are labeled K11 through K17 Relay K18 is not part of the transmission shift logic Relays K11 through K...

Page 338: ...mp transmission fuse F3 on the circuit board in the cab If the fuse is blown replace it with another 7 5 amp fuse If it blows again immediately there is an electrical short somewhere in the system that must be corrected Never replace the fuse with one of a larger amp rating or a fire or other permanent damage to the electrical system may occur 2 Check that power is being supplied to the Transmissi...

Page 339: ...D Y4 PLUGGED PLUGGED PLUGGED SHIFTER PWR SHIFTER Y6 SHIFTER Y3 BOOM 21 40 BOOM OVER 20 N C BOOM OVER 40 N C IGN POWER JUMPER 1 BOOM 21 40 SOLENOID Y6 SHIFTER Y6 A N C N C IGN POWER SOLENOID Y1 FORWARD SGN N C IGN POWER SOLENOID Y2 REVERSE SGN RELAY GND RELAY GND RELAY GND RELAY GND RELAY GND RELAY GND JUMPER 2 JUMPER 1 N C SHIFTER Y5 JUMPER 2 D5 D4 D3 D1 D2 D6 D7 D8 D9 SHIFTER Y4 SHIFTER Y5 NEUTRA...

Page 340: ...iston o rings damaged 7 Clutch discs worn or damaged 8 Coupling shafts or gear teeth damaged 1 Fill transmission to correct level with Universal Tractor Fluid Refer to the appropriate owners operators manual 2 Refer to Section 9 14 7 a Travel Select Lever and Wiring Harness Testing 3 Refer to Section 9 14 7 b Upper and Lower Transmission Valve Body Solenoid Testing 4 Clean the valve spool and hous...

Page 341: ...n Transmission Troubleshooting Problem 2 Low or no pump flow or pressure 4 Replace clutch discs 5 Refer to Section Transmission Troubleshooting Problem 5 Transmission overheating oil above 248 F 120 C 5 Transmission overheating oil above 248 F 120 C 1 Low oil level 2 Clogged radiator 3 Transmission filled with incorrect oil or oil contaminated 4 Excessive roading 5 Restriction in oil cooler hoses ...

Page 342: ...aking at valve bodies possible valve body gaskets damaged or missing and or mounting capscrews not tight 5 Housing capscrews loose 6 Oil leaking at pump possible pump to housing o rings missing or damaged and or pump mounting capscrews not tight 7 Oil leaking at converter bell possible converter leak and or input shaft seal damage 8 Oil leaking at output shaft output shaft seal damaged 9 Housing d...

Page 343: ...xle Drive Shaft 9 9 Drive Shaft Disassembly 9 9 Drive Shaft Assembly 9 10 Service Brakes 9 12 Service Brake Pressure Switch Replacement 9 12 Accumulator 9 13 General 9 13 Precautions 9 14 Pre Charging Accumulator 9 14 Checking Pre charge 9 16 Towing a Disabled Machine 9 17 Manually Releasing the Park Brake 9 18 Manually Resetting the Park Brake 9 18 List of Figures Fig 9 1 Axle and Drive Shaft 9 1...

Page 344: ...ii 31200079 ...

Page 345: ...sure optimum performance the drive shaft assemblies are specially balanced as a unit at the factory When servicing any flange yoke slip yoke or drive shaft tube order a complete assembly if components are bent or damaged Refer to the appropriate parts manual for ordering information Before performing any inspection maintenance or service operation thoroughly clean the unit The axles and drive shaf...

Page 346: ...ng snap rings or spring loaded retention devices WARNING Risk of death or serious personal injury if components are assembled improperly if components are assembled improperly if incompatible worn or damaged components are used or if components are used in a non approved application Obtain proper training follow recommended procedures and use proper tools and safety equipment Wear safety glasses a...

Page 347: ...ying lightly coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize ...

Page 348: ...other electrical components If using a steam cleaner seal all openings before steam cleaning IMPORTANT Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park the machine on a firm level surface level the machine ground the attachment place the travel select lever in the N NEUTRAL position engage the parking brake straig...

Page 349: ...nt it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand Axle Inspection Internal Service and Repair Detailed axle service instructions covering the axle differential brakes and wheel end safety repair disassembly reassembly adjustment and troubleshooting information are provided in the Axle Repair Manuals Refer to The Z...

Page 350: ... axle note the position of the driveshaft yoke at the transmission Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission 10 Install the wheel and tire assemblies 11 Carefully remove the jack hoist or overhead crane and sling supporting the axle 12 Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the ma...

Page 351: ...both directions Look for excessive looseness missing parts cracks or other damage Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise Individually inspect each cross the needle bearings and cap for signs of wear or for missing parts Note Replace the cross and bearings as a complete assembly if any parts are worn or missing If all parts ...

Page 352: ... or damaged Refer to the appropriate parts manual for ordering information Note The drive shaft assemblies are balanced assemblies Mark the yoke and axle transmission transfer case and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration 7 2 3...

Page 353: ...ge 7 Remove the four capscrews and two straps securing the bearing crosses to the axle 8 Remove the front drive shaft assembly 9 Repeat the above procedure on the rear drive shaft Drive Shaft Disassembly Important To help ensure optimum performance the drive shaft assemblies are specially balanced as a unit at the factory When servicing any flange yoke slip yoke or drive shaft tube order a complet...

Page 354: ...bly 1 Install the dust cap split retaining ring and felt seal onto the splines of the drive shaft tube assembly Important Ensure that the reference marks made before removal on the drive shaft and slip yoke are aligned The drive shaft and yokes must be in the same plane to help prevent excessive vibration 2 Align the reference marks made previously on the drive shaft and slip yoke 3 Slide the slip...

Page 355: ...appropriate parts manual for ordering information Transmission to Axle Drive Shafts 1 Raise the drive shaft assembly into position The slip yoke end of the drive shaft mounts toward the axle If reinstalling a drive shaft previously removed align the flange yokes according to the alignment marks made during removal Important Yokes at both ends of the drive shaft must be in the same plane to help pr...

Page 356: ...preparation procedures as outlined in Section 3 and in Section 5 of this manual 2 Tag and disconnect the wiring harness connector Item 1 from the connector on the brake pressure switch Item 2 3 Remove the brake pressure switch from the connector tee Item 3 Discard the pressure switch 4 Install a new brake pressure switch 5 Reconnect the wiring harness connector Item 1 to the connector on the brake...

Page 357: ... floating piston see Fig 9 3 This prevents mixing of gas and oil and keeps gas out of the hydraulic system The piston Item 4 fits into a smooth bore and uses seals Item 6 to separate gas Item 3 from oil Item 5 O rings Item 2 in the end caps prevent leakage of gas oil The accumulator must be pre charged with gas before use in a system This is done by filling the gas chamber with dry nitrogen to a p...

Page 358: ... hydraulic pressure before removing an accumulator from the system CAUTION Before disassembling an accumulator release both gas and hydraulic pressure When disassembling an accumulator make sure that dirt and abrasive materials do not enter any openings Pre Charging Accumulator Note Replacement accumulators shipped from the factory are not pre charged Make sure the nitrogen bottle as well as the c...

Page 359: ...e Item 5 all the way out counterclockwise The pressure gauge must have 2500 psi capacity correctly calibrated 6 Mount test gauge on accumulator gas valve Item 9 and tighten Be sure of an air tight connection when mounting gauge 7 Close turn in bleed valve Item 4 8 Remove gauge cap Item 6 from test valve 9 While making sure not to loop or twist the hose attach swivel nut on nitrogen hose Item 7 to ...

Page 360: ... test valve Remove test gauge and replace gas cap on valve Item 3 Torque gas cap to 10 15 in lbs Gas cap acts as a secondary seal 16 Install gas valve guard and two 2 capscrews on the accumulator gas end cap Torque capscrews to 35 ft lbs Checking Pre charge Gas Leaks If an external gas leak is suspected apply soapy water to the gas valve and seams of the gas end cap If bubbles form there is a leak...

Page 361: ...eadings are outside the recommended ranges contact the JLG Service Department Towing a Disabled Machine Towing a disabled machine should only be attempted as a last resort after exhausting all other options Make every effort to repair the machine and move it under its own power before using the emergency towing procedure outlined below Important In the event the vehicle is disabled and cannot be m...

Page 362: ...10 Turn the ignition switch to the ON position with the engine not running release the park brake park brake switch OFF 11 Pressurize the park brake with the pressurizing unit Pump pressure into the park brake system DO NOT exceed 425 psi 12 Watch the pressure gauge on the pressurizing unit to ensure that the pressure in the park brake system does not drop during the towing operation 13 Carefully ...

Page 363: ... Valves 10 13 Description 10 13 Removal 10 14 Installation 10 15 List of Figures Fig 10 1 Outriggers 10 1 Fig 10 2 Outrigger Installation 10 2 Fig 10 3 Outrigger Cylinders 10 4 Fig 10 4 Outrigger Cylinder Installation 10 5 Fig 10 5 Outrigger Cylinder Assembly 10 7 Fig 10 6 Boom Extension Proximity Switch 10 10 Fig 10 7 Boom Extension Proximity Switch Operation 10 11 Fig 10 8 Boom Extension Proximi...

Page 364: ......

Page 365: ...31200079 10 1 Section 10 Outriggers Outriggers General Fig 10 1 Outriggers Outriggers increase the stability of the machine when lifting and placing loads V1083 0 80 60 40 20 20 ...

Page 366: ...Support the boom and extension cylinder with sling s and crane or other suitable means Make sure support items have sufficient capacity to support the weight of the boom and cylinder the combined weight of the boom and extension cylinder is approximately 6650 pounds MV0170 1 2 3 4 6 5 9 10 11 12 13 14 15 16 7 17 18 19 20 21 8 Description 1 Outrigger Cylinder 2 Differential Pressure Switch 3 Tie 4 ...

Page 367: ... to the clamp plate Item 13 on each side of the machine 10 Remove four 4 each nuts Item 16 starwashers Item 15 jam nuts Item 14 and capscrews Item 9 securing each of the clamp plates and the outrigger assembly to the axle Remove the clamp plates 11 Remove the wiring harness and hoses from outrigger and secure them to the main frame 12 Start the engine and slowly back the machine away from the outr...

Page 368: ...arwashers Item 15 and nuts Item 16 Torque nuts to 320 ft lbs 8 Install two 2 hydraulic hoses Item 6 on the two 2 elbows Item 5 on each outrigger cylinder Item 1 For final tightening torque swivel nuts on hoses to 44 48 ft lbs 9 Connect the wiring harness Item 4 on the differential pressure switch Item 2 Install a tie Item 3 to secure the pressure switch wires to the wiring harness or the hydraulic...

Page 369: ...raise the outrigger foot pads completely and shut the engine off 3 Disconnect the wiring harness Item 1 from the differential pressure switch Item 3 on both cylinders Remove the ties Item 2 securing the pressure switch wires to the wiring harness or the hydraulic hoses 4 Loosen two 2 hydraulic hoses Item 6 from the elbows Item 5 on both outrigger cylinders Item 4 V1084 Description 1 Wiring Harness...

Page 370: ...lifting device to place the outrigger cylinder in its proper location Secure the cylinder to the outrigger by installing the lower pin Item 7 2 Secure the cylinder to outrigger with the upper pin Item 11 Note Be sure to apply blue thread sealant to the threads of the capscrews before installing them 3 Secure the upper pin by installing a lock pin Item 14 lockwasher Item 13 and capscrew Item 12 Tor...

Page 371: ...pressure in each cylinder as follows WARNING The counterbalance valve cartridge traps hydraulic pressure in the cylinder Wear proper eye and hand protection when removing counterbalance valve cartridges Hydraulic fluid under pressure can be injected under skin or into eyes resulting in serious personal injury or death 12 14 13 12 15 17 16 11 10 9 8 7 6 5 4 3 2 1 4 MV0680 Description 1 Grease Fitti...

Page 372: ...e cylinder rod end using a bushing driver and hammer or press Drive one bushing all the way through to remove other bushing b Install new bushings so they are flush with outer edge boss to 0 02 below c To ensure proper lubrication make sure an adequate amount of grease is applied to the grease fitting s after the cylinder is reinstalled on the machine 12 If necessary remove the grease fitting cove...

Page 373: ... and install the rod nut Item 10 23 Install the rod assembly in the cylinder barrel Tighten the cylinder cap and secure with a setscrew Item 17 24 Install two 2 elbows Item 7 on the cylinder manifold block Torque the elbows to 40 44 ft lbs 25 For models with an O ring plug Item 5 install the plug in the control manifold block Torque the plug to 85 95 ft lbs 26 Install the differential pressure swi...

Page 374: ...ce approximately 21 feet with tilting tower or 25 feet with standard carriage The proximity switch then opens as it no longer senses metal At this point the left and right outriggers must both be lowered to the ground to allow the boom or transfer carriage to be extended any further Normally open differential pressure switches in the outrigger cylinders close when the base end pressure exceeds the...

Page 375: ... eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop A sensor in the switch detects if the oscillator is on or off and this gives the switch its on off function Removal Boom Extension Proximity Switch Fig 10 8 Boom Extension Proximity Switch Assembly Proximity Switch Outer Boom Section Middle Rear Boom Section J1259 Magnetic Flux Lines Oscillator 0 80 6 0 4 0...

Page 376: ...2 at the previously marked position 2 Install the boom extension proximity switch in the outer boom Install the inner jam nut Item 1 Check the gap between the end of the proximity switch and boom See Fig 10 9 3 Connect the wire harness Item 4 to the proximity switch 4 Check operation of the proximity switch by extending the boom The boom extension proximity light must come on at specified distance...

Page 377: ...peration of the boom extension proximity light The light must come on when the boom is extended to specified distance approximately 21 feet with tilting tower or 25 feet with standard carriage If the light does not illuminate stop and retract the boom Repeat Step 3 5 Tighten the jam nuts Outrigger Control Valves Description Fig 10 10 Outrigger Controls Ref Fig 10 9 The remote controls are located ...

Page 378: ...nd remove four 4 hydraulic hoses Item 10 from the connectors Item 9 on the bottom of the outrigger control valves Item 4 Bleed any remaining oil into a suitable container Tag and cap the hoses and fittings 5 Remove the nut Item 1 and lockwasher Item 2 from each of the three 3 tie rods Item 3 Remove the tie rods along with lockwashers Item 7 and nuts Item 8 securing the control valve sections toget...

Page 379: ... valve Item 6 with three 3 tie rods Item 3 Install lockwashers Items 2 and 7 and nuts Items 1 and 8 on each end of both tie rods 2 Install each outrigger control valve on the control panel Item 11 with two 2 capscrews Item 5 lockwashers Item 12 and nuts Item 13 Torque the nuts to 50 in lbs 3 Install the hydraulic hoses Item 10 on the connectors Item 9 on the bottom of each control valve For final ...

Page 380: ...Outriggers 10 16 31200079 ...

Page 381: ......

Page 382: ... Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 20...

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