Service Manual Model 1044C-54 Series II 31200079 Revised July 1, 2005
EFFECTIVITY PAGE March 18, 2005 - A - Original Issue Of Manual July 1, 2005 - Revised Manual 31200079 i
EFFECTIVITY PAGE -ii 31200079
Table of Contents Section 1 — Safety General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Transmission Oil Specifications . . . . . . . . . . . . .
Table of Contents Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Installation . . . . . . .
Table of Contents Section 6 — Boom and Transfer Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Boom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 4-Section Boom . . . . . . . . . . . . . . .
Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Drive Shaft Maintenance . . . . . . . . .
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.
List of Figures Fig. 5-24: Checking Hydraulic Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Fig. 5-25: Mid-Inlet Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Fig. 5-26: Mid-Inlet Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Fig. 5-27: Mid-Inlet Control Valve Configurations,. . . . . . . . . . . . . . . . . .
List of Figures 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 . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 6-65: Locations for Chain Attachment – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 Fig. 6-66: 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 . . . . . . . . . . . . . .
List of Figures Fig. 6-103: Upper Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section . . . . . . . . . . . . . . 6-98 Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom . . . . . . . . . . . . . . . . . . . 6-99 Fig. 6-106: Rear Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 7-5: Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Fig. 7-6: Frame Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Fig. 7-7: Frame Tilt Cylinder (Exploded View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Fig.
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 . .
List of Tables Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Table 3-3: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Table 3-4: Torque for JIC and SAE Female Swivel Nuts . . . . . . . . . . . . . . . . .
List of Tables 16 31200079
Section 1 — Safety Table of Contents General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 — Safety General Observing basic safety rules and precautions can eliminate accidents when operating, maintaining, and repairing the forklift. The Operator’s Manual contains detailed information regarding safety practices when driving and operating the forklift. Always be alert to potential hazardous situations that could result in injury to yourself or bystanders. Care should also be taken to avoid damage to the equipment.
Safety Safety Standard The ASME/ANSI B56.6 safety standard for rough terrain forklift trucks defines safety requirements relating to the design, operation, and maintenance of these vehicles. For a copy of this standard write to: The American Society of Mechanical Engineers United Engineering Center 345 East 47th Street New York, NY 10017 Maintenance Safety General DO NOT attempt machine operation or maintenance until you have read and fully understand the safety instructions in this section.
Safety • Make certain there is adequate light and ventilation. • Remove any foreign substances (i.e. oil, grease, water, snow, ice) to eliminate any slippery surfaces and to remove all contaminants from the area. • Use only the correct tools to perform the maintenance or repair. • Make sure all jacks, hoists, jack stands, or blocks are stable and strong enough to handle the weight of the forklift or component that you will be working on.
Safety Hydraulic System Hazards WARNING HIGH PRESSURE FLUID HAZARD To prevent serious personal injury or death: • Relieve system pressure W1047 before adjusting, repairing, or disconnecting components. • Wear proper hand and eye protection. Use cardboard to search for leaks. • Keep all components in good repair. The hydraulic system is under pressure whenever the engine is running and can hold pressure after the engine is shut down.
Safety To avoid personal injury… • Electrolyte in batteries contains sulfuric acid which is a poison and can cause severe chemical burns. Wear a face shield and safety glasses to prevent contact with your eyes and face. • Wear chemical resistant gloves and clothing to keep acid off your skin and regular clothing. Important: If electrolyte is ever ingested or splashed into your eyes, get medical attention immediately. NEVER give fluids that would induce vomiting.
Safety • NEVER reinflate a tire that has been run flat or seriously under inflated WITHOUT removing the tire from the wheel. Have the tire and rim closely inspected for damage before remounting. • Clean the area around all wheel lug nuts or bolts. Periodically check the torque per the specifications until the torque value stabilizes; then check at regularly scheduled intervals.
Safety Attaching Decals The surface on which a decal is to be attached must be dry and free of all dirt and grease. Remove the backing from the decal and apply decal in its correct location. Once in place, rub entire surface of the decal with your thumb, applying sufficient pressure to ensure good adhesion of the decal to the mounting surface. Decal Locations Decals and placards that provide information, instructions, and address safety issues include the following: • Attachment Capacity Plate (Fig.
Safety Boom Extension Indicator Forklift Signals Cab Transfer Extension Load Chart Capacities and Don’t Be Lubrication Schedule Careless Flip Cards Notice 3 2 FT FT FORKLIFT SIGNALS NOTICE S T O P R AIS EL O AD L O W E RL O AD 45 M AX M I U M BO O M L O A DC A P A C IT IE SA T 24 "L O A DC E N T E R ,F O RL F I TA N DR E AC H P O S IT IO N SINP O U N DS AN DF E E T W IT H M E T R ICC O N V E R S IO N S .
Safety Transfer and Fork Tilt Control Outrigger Control Boom Movement Control V1087 Frame Tilt Control Fig. 1-3: Control Decals Disconnect Battery MV0490 Fig.
ROUND STEER OBLIQUE STEER FRONT WHEEL STEER Safety Operator’s Seat Steer Selector Plate R1049 Fig. 1-5: Steer Selector Plate Hydraulic Oil Only Hydraulic Breather R1050 Diesel Fuel Only Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals Attachment Capacity Plate R1051 Carriage Safety Decal Fig.
Section 2 — Identification and Specifications Table of Contents Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Engine Serial Number, John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 31200079
Section 2 — Identification and Specifications Serial Number Locations Machine Serial Number Serial Number Plate TIRE BALLAST REQUIRED REFER TO LUBRICATION SCHEDULE MV0290 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.
Identification and Specifications Engine Serial Number, John Deere Serial Number Plate Fuel Pump V1006 Starter Fig. 2-2: Engine Serial Number — John Deere (Ref. Fig. 2-2) The engine serial 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.
Identification and Specifications Axle Serial Number SERIAL NUMBER PLATE MV0360 Fig. 2-3: Axle Serial Number (Ref. Fig. 2-3) The front axle serial 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 MV0480 Fig. 2-4: Attachment Serial Number Plate (Ref. Fig. 2-4) The location of this plate varies with each attachment.
Identification and Specifications R1026 Identification R1052 Fig. 2-5: Top View Fig.
Identification and Specifications Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,000 lbs. Maximum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +69° TransAction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Pressures Hydraulic: Boom Hoist and Extend Valve Relief . . . . . . . . . . . . . . . . 3000 psi 4- or 5-Section Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 3150 psi Carriage Tilt Valve Section, Up Port Relief . . . . . . . . . . . . 2800 psi Carriage Tilt Valve Section, Down Port Relief. . . . . . . . . . 2800 psi Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2355 psi Brakes. . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Wheels/Tires Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 (Torque to 320 ft-lbs) 14 × 24 Tires (Bias & Radial): Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 × 24 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Gallons Calcium Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 lbs Foam. . . . . . . . . . . . . . . .
Identification and Specifications Engine Specifications John Deere 4045T Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 HP @ 2500 rpm Maximum Torque . . . .
Section 3 — General Maintenance Table of Contents General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Service Preparation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Service And Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Replacement Parts . . . . . . .
List of Tables Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Table 3-3: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Table 3-4: Torque for JIC and SAE Female Swivel Nuts . . . . . . . . . . . . . . . . .
Section 3 — General Maintenance General Instructions Performance of your machine is dependent on proper maintenance and lubrication at designated intervals. Proper operating procedures and a regularly scheduled maintenance and lubrication program will increase the life of machine components and reduce machine down time. Should a defect or failure occur to your machine, take it out of service immediately.
General Maintenance Service And Repair Procedures CAUTION: Unless specifically told not to, lower the boom to the ground, apply the parking brake, and stop the engine before servicing, adjusting, or repairing the machine. WARNING: Release all hydraulic pressure before doing any maintenance or repairs to the hydraulic system. WARNING: Liquid cooling systems build up pressure as the engine gets hot. Before removing the radiator cap, stop the engine and let the system cool.
General Maintenance Replacement Parts General Record the machine model, serial number, and component serial numbers for reference when ordering replacement parts. See “Serial Number Locations” in Section 2. Use only JLG authorized replacement parts and fluids. Use of parts other than JLG authorized parts may adversely effect machine reliability, performance, and safety and may void the warranty. JLG assumes no liability for equipment damages caused by the use of unauthorized replacement parts.
General Maintenance Fluid and Lubricant Specifications General Specifications Table 3-1: General Fluid and Lubricant Specifications SYSTEM OR COMPONENT 1 FLUID OR LUBRICATION SPECIFICATION Fuel System 1 See "Fuel Requirements" Hydraulic System Tractor Hydraulic Fluid Engine Cooling System 1 See engine manufacturer's operator's manual.
General Maintenance Table 3-2: John Deere Engine Oil Specifications ENGINE OIL, DEERE Oil Grade Temperature Range °F Temperature Range °C SAE 5W-30 -22 to +86 °F -30 to +30 °C SAE 10W-30 -4 to +86 °F -20 to +30 °C SAE 15W-40 +5 to +122 °F -15 to +50 °C SAE 30W +32 to +86 °F 0 to +30 °C SAE 40W -50 to +104 °F +10 to +40 °C Arctic oil (e.g.
General Maintenance Fuel Requirements Diesel fuels are blended to meet the local temperature requirements. The standard grades are: 1. 1D for temperatures -22 to +86 °F (-30 to +30 °C) 2. 2D for temperatures +14 to +122 °F (-10 to +50 °C). There are two main classifications of diesel fuel in general use: 1. Low-sulphur, “on-highway” diesel fuel 2. Medium-sulfur, “off-highway” diesel fuel. This fuel contains blue dye. The engine manufacturer specifies the diesel fuel requirements.
General Maintenance Care and Cleaning Wash the machine regularly. A clean well-maintained machine helps prevent safety hazards and makes problem areas more recognizable. Remove all items that do not belong on the machine. Secure all loose items such as lunch boxes, tools, and additional equipment. Cleaning Exterior Surfaces • High pressure water or steam may be used to clean the exterior. Give extra attention to the underside. • DO NOT damage or wash off decals when using high pressure water or steam.
General Maintenance Cleaning Decals If soiled with dirt, clean decals with mild soap. Use a mild alcohol solution if soiled with grease. Do not use solvents that may damage the decal. Replace all damaged, missing, or painted decals that cannot be read. On refurbished or replaced parts, all missing decals must be replaced. See your JLG dealer for replacement decals and placards. Attaching Decals The surface on which a decal is to be attached must be dry and free of all dirt and grease.
General Maintenance Preparing the Machine After Long-Term Storage After removing the machine from storage and before placing it back in service, perform the following: 1. If covered with a tarp, remove it. 2. Wipe off grease from cylinder rods. 3. Loosen drain plug from bottom of fuel tank and drain into suitable container until fluid is clean. 4. Loosen drain plug on bottom of hydraulic oil reservoir and drain into suitable container until fluid is clean. 5.
General Maintenance Torque Specifications General Torques for Standard Bolts, Capscrews, and Nuts Figure 3-2 and Figure 3-3 lists torque values for standard bolts and nuts. They are 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. SAE BOLT HEAD MARKINGS SAE NUT MARKINGS SAE GRADE 2 SAE GRADE 2 (NO MARK) SAE GRADE 5 SAE GRADE 5.1 SAE GRADE 5.
General Maintenance Fig.
Note: 3-12 These torque values do not apply to cadium plated fasteners. VALUES FOR ZINC PLATED BOLTS ONLY SAE GRADE 5 SAE GRADE 8 UNPLATED CAP SCREWS General Maintenance Fig.
General Maintenance PROPERTY CLASS AND HEAD MARKINGS PROPERTY CLASS AND NUT MARKINGS 4.8 5 8.8 9.8 8.8 9.8 8.8 9.8 5 10 10 4.8 5 4.8 10 10.9 10 10 10.9 10 12.9 12 12.9 12 12.9 12 12.9 Y1--2 Fig.
General Maintenance Hydraulic Fitting Torques JIC and SAE Female Swivel Nuts It is recommended that the nut be torqued to the approximate minimum value. If leakage occurs, tighten nut without exceeding maximum torque value. Note: Use two wrenches to tighten hydraulic line nuts. Table 3-4: Torque for JIC and SAE Female Swivel Nuts Size SAE Port Approx. Min. Max.
General Maintenance Adjustable O-ring Fittings To install straight thread, adjustable O-ring fittings: 1. Check condition of O-ring and replace as necessary. Do not install a fitting with a damaged O-ring. 2. Lubricate O-ring with clean hydraulic fluid. 3. Back off the locknut fully. 4. Screw fitting into port until backup washer contacts face of port. 5. Position fitting by unscrewing a maximum of one turn. 6. Hold the fitting in position with a wrench and torque locknut per Table 3-6.
General Maintenance Pipe Thread Fittings To install National Pipe Thread (NPT) fittings: 1. Apply sealant sparingly to male pipe threads only, avoiding the first few threads at the end of the fitting. Note: Do not use Teflon tape or excessive amounts of sealant. System contamination will result. 2. Install fitting and tighten per Table 3-8. Table 3-8: Pipe Thread Fittings (Steel) Fitting Size Thread Size (NPT) Turns1 -2 1/8-27 2–3 -4 1/8-27 2–3 -6 1/4-18 1.
General Maintenance 1. Move the boost start machine (or auxiliary power source) close enough to the stalled machine for the cables to reach without allowing the machines to touch. Place the transmission shift selector in NEUTRAL, engage the park brake, and turn off engine (or shut off auxiliary power source). 2. On the stalled machine, turn the ignition switch to OFF. 3. Connect the positive (+) jumper cable to the positive (+) cable terminal of the discharged battery on the stalled machine.
General Maintenance Conversion Charts V1070 Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart 3-18 Inch Fract. Inch Dec. 1/64 0.0156 1/32 0.0313 3/64 0.0469 1/16 0.0625 5/64 0.0781 3/32 0.0938 7/64 0.1094 1/8 0.1250 9/64 0.1406 5/32 0.1563 11/64 0.1719 3/16 0.1875 13/64 0.2031 7/32 0.2188 15/64 0.2344 1/4 0.2500 17/64 0.2656 9/32 0.2813 19/64 0.2969 5/16 0.3125 21/64 0.3281 11/32 0.3438 23/64 0.3594 3/8 0.3750 25/64 0.3906 13/32 0.4063 27/64 0.4219 7/16 0.4375 29/64 0.4531 15/32 0.
General Maintenance Table 3-10: Miscellaneous Conversions Multiply By International System Conversion (IS) Unit Factor To Get or Multiply By To Get Non-IS Unit Conversion Factor IS Unit x 0.113 x 1.36 = Nm = Nm x 0.249 x 3.38 x 6.89 x 0.069 x 0.0069 = kPa = kPa = kPa = bar = bar x 0.00689 = MPa x 0.736 x 0.746 x 1.055 x 1.36 = kW = kW = kW =W x 1.055 x 4.19 = kJ =J x 0.305 x 0.305 x 1.61 = m/s2 = m/s = km/h x 3.785 = L/min Torque Newton Meter (N•m) m) Newton Meter (N•m) m) x 8.
General Maintenance 3-20 31200079
Section 4 — Reference Diagrams Table of Contents Mid-Inlet Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-1 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31200079 ii
Reference Diagrams Section 4 — Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic QUICK DISCONNECTS BOOM TELESCOPE CYLINDER C.B. VALVE AUX. 1 OPTIONS C.B. VALVE QUICK DISCONNECTS AUX. 2 OPTIONS BOOM ROLL BACK HOSES FRONT CARRIAGE TILT CYLINDER FRONT OF MACHINE SW UPPER HYDRAULICS EF CV ACC UP ARROW FILTER 50 MICRON 0R1 CF LS LS SV OR3 T OR2 RV PIL P FILTER EC ORBITROL STEER VALVE P T C.B. VALVES 4000 PSI 2 1 92 PSI DIFF.
Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) BOOM HOIST CYLINDER C.B. VALVE C.B. VALVE REAR CARR. TILT CYLINDER TRANSFER CYLINDER BOOM HOIST CYLINDER REAR CARR. TILT CYLINDER BOOM TELESCOPE BOOM HOIST A6 A3 A A B B B AUX. 1 (OPTION) AUX. 2 A4 A1 A A A A B B B B (OPTION) L.H. OUTRIGGER A7 A8 A A B B 3150 PSI 2800 PSI 3000 PSI B2 R.H.
Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) NOTES 31200079 4-3
Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) NOTES 4-4 31200079
Reference Diagrams Diagram 4-2 — Control Valve Mid-Inlet Control Valve BOOM TELESCOPE BOOM HOIST A6 A3 A A B AUX. 1 (OPTION) AUX. 2 B B A4 A1 A A B B A A B B (OPTION) R.H. OUTRIGGER L.H.
Reference Diagrams NOTES 4-6 31200079
Reference Diagrams Diagram 4-3 — Electrical Schematic H 9 FUEL 6 7 5 8 BOOM TRANS EXTEND LOCK WATER FAULT 36804X HOURMETER POWER 4 9 3 REAR OSC LOCK 10 GRD 2 PARK BRAKE 7 10 11 BRAKE PRESS TRANS DISC 11 ENGINE WATER TEMP 5 FUEL 36830B CLUSTER GAUGE 6 I 1 ENGINE OIL PRESSURE G TRANS OIL TEMP S 4 BATTERY VOLTAGE - G R E E N 1 6 R E D 1 6 B L A C K 1 6 G R A Y 1 6 1 12 Y E L L O W 1 6 V I O L E T 1 6 W H I T E 1 6 T A N 1 6 P I N K 1 6 ORANGE-16 A A BLACK-16
Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) 38200C-4 GROUND ENGINE TO MAINFRAME FUEL LEVEL GA SEND P29317 CONNECT BATT GRD TO LOWER STARTER MOUNTING BOLT STARTER MOTOR SOLENOID 65724A NEG. CABLE 35646A POS. CABLE BATTERY 12V 2/0 RED BLACK-10 WHITE-10 STARTER RELAY 67789A YELLOW-14 + 2/0 BLACK 30 38200C-5 S RED-14 PIN 86 IS GROUND ON ALL RELAYS 38200C-3 GROUND OPER COMP TO MAINFRAME R E D 6 86 B+ 4923247 WIRE W/DIODE RELAY SOCKET TOP VIEW WHITE-12 67062A SPST-N.
Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) 85 86 N/C IGN POWER SOLENOID Y2 RELAY GND REVERSE SGN D1 PLUGGED PLUGGED PLUGGED IGN POWER 87 87a 30 85 86 87 87a 30 RELAY K17 N/C IGN POWER SOLENOID Y1 RELAY GND FORWARD SGN 85 86 87 87a 30 'A' OF CIRCUIT BOARD & SHIFTER HARNESS) A B C D ON WHEN REVERSE SELECTED RELAY K16 SOLENOID Y6 SHIFTER Y6 A N/C RELAY GND JUMPER 2 85 86 RELAY K15 JUMPER 2 JUMPER 1 N/C RELAY GND SHIFTER Y5 87 87a 30 ON WHEN FORWARD SELECTED ON W
Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) NOTES 4-10 31200079
Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) NOTES 31200079 4-11
Reference Diagrams 4-12 31200079
Section 5 — Supply, Pressure, and Return Hydraulics Table of Contents General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Major System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Checking Pump Flow Rate . . . . . . . . . . . .
Fig. 5-19: Hydraulic Pressure Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Fig. 5-20: Hydraulic Pressure Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Fig. 5-21: Hydraulic Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . .
iv 31200079
Section 5 — Supply, Pressure, and Return Hydraulics General Major System Components Hydraulic Reservoir/ Fuel Tank Hydraulic Oil Return Filter Hydraulic Pump K1099 Hydraulic Control Valve Fig. 5-1: Major Hydraulic Components General Description (Ref. Fig.
Supply, Pressure, and Return Hydraulics These circuits are supplied by a two-section, gear-type hydraulic pump, driven directly from the transmission power takeoff. The closest to the shaft pump supplies flow to all circuits except steering and the steer selector valve. The second pump supplies flow to all circuits via the steering priority valve. The boom extension and hoist circuits are controlled by a two-spool valve with pressure relief.
Supply, Pressure, and Return Hydraulics Hydraulic Systems Mid-Inlet Hydraulic System Rear Axle Stabilizer Control Valve Mid-Inlet Directional Control Valve Assembly MV0030 Fig. 5-2: Mid-Inlet Hydraulic Components The term “mid-inlet hydraulic system” is used to reference and differentiate the types of components used in the hydraulic system. This system was designed to simplify the hydraulic system and improve overall reliability.
Supply, Pressure, and Return Hydraulics • The hydraulic system is under pressure whenever the engine is running and can hold pressure after the engine is shut down. After forks or attachments are resting on the ground or support, make sure pressure is relieved from all hydraulic lines and components before removing them from the circuit. Remember the following during inspection and maintenance of the hydraulic system: • Wait for fluid to cool down before disconnecting lines.
Supply, Pressure, and Return Hydraulics as the oil passes through. A high quality hydraulic oil contains many additives which work to keep contaminants from damaging the system. However, these additives lose their effectiveness after a period of time. Therefore, change the oil at recommended intervals to make sure the additives do their job. The system filter can absorb only a limited amount of dirt particles and other contaminants from the oil.
Supply, Pressure, and Return Hydraulics Hydraulic Reservoir K1090 Description Fig. 5-3: Hydraulic Reservoir Location (Ref. Fig. 5-3) The hydraulic reservoir is mounted 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.
Supply, Pressure, and Return Hydraulics 2 3 4 1 5 6 7 MV0010 # Description 1 Hydraulic Tank Breather (Models with Mid-Inlet Hydraulics) 2 Hydraulic Tank Sight Gauge 3 Pressure Gauge 4 Return Filter Assembly # Description 5 Hydraulic Oil Tank 6 Hydraulic Oil Strainer (Models with Mid-Inlet Hydraulics) 7 Suction Line Fig. 5-4: Hydraulic Reservoir (Ref. Fig.
Supply, Pressure, and Return Hydraulics Filling Hydraulic Reservoir Preferred Method CAUTION: Do not fill reservoir through the 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. 1 3 2 K1015 4 # 1 2 Description Hex Cap Cover # 3 4 Description Hydraulic Hose Male JIC (37°) Filler Fitting Fig.
Supply, Pressure, and Return Hydraulics 7. Start engine and allow hydraulic system to warm up. Operate controls gradually until you fully extend and retract each cylinder, including steering cylinders. This procedure removes air from the system. 8. Level the frame, retract all cylinders except frame tilt cylinder, and stop the engine. Recheck oil level and add oil as required. 9. Loosen and remove hose (Item 3) from reservoir filler fitting (Item 4). Install hex cap (Item 1) and torque to 70 ft-lbs.
Supply, Pressure, and Return Hydraulics 1. The machine must be parked on a level surface and the frame must be level. 2. Retract all cylinders except frame tilt cylinder, apply the park brake, and stop the engine. 3. Clean return filter housing (Item 1) and surrounding area. 4. Remove four (4) flange nuts (Item 2) that secure the filter housing cover (Item 3). Set hardware aside on a clean surface. 5. Lift the cover (Item 3) and spring (Item 4) from housing (Item 1) and set aside on a clean surface. 6.
Supply, Pressure, and Return Hydraulics Reservoir Drain and Refill 2 1 3 4 MV0070 # Description # 1 2 Breather Filter Return Filter Assembly 3 4 Description Hydraulic Oil Suction Strainer Drain Plug Fig. 5-7: Hydraulic Reservoir Drain and Refill (Ref. Fig. 5-7) The following procedure describes draining and refilling the hydraulic reservoir. 1. Lower the boom to the ground, apply the parking brake, and stop the engine. CAUTION: Do not place hands in hot hydraulic oil.
Supply, Pressure, and Return Hydraulics 6. Clean the strainer (Item 2) by back flushing with solvent. Dry the strainer element thoroughly with compressed air. Install it as described under “Installation” on page 5-20. 7. Install the reservoir drain plug (Item 4). Tighten 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.
Supply, Pressure, and Return Hydraulics Removal Hydraulic Reservoir and Fuel Tank 6 1 2 3 4 7 8 10 9 5 11 12 15 14 28 13 16 17 19 22 20 27 26 21 18 25 23 24 23 24 MV0060 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Tank Hold-Down Strap Chemprene Belting Pipe Adapter Hose Clamp Fuel Supply Hose Flatwasher Nut Wiring Harness JIC Pipe Connector Return Manifold Tube Hydraulic Oil Return Filter Hydraulic Reservoir/Fuel Tank Swivel Branch Tee Check Valve # 15 16 17 18 19 20 21 22 23 24 2
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-8) The following procedure describes removal of the hydraulic reservoir/fuel tank. 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-3. 2. Remove the hydraulic reservoir drain plug (Item 19) and drain hydraulic fluid into a suitable container. Dispose of drained fluid properly. Temporarily reinstall drain plug. 3.
Supply, Pressure, and Return Hydraulics 14. Perform steps 6 through 9 under “Reservoir Drain and Refill” on page 5-11. 15. Install the fuel tank drain plug (Item 18). Tighten two or three turns past finger tight. If it is necessary to use thread sealant to stop fluid leakage, make sure that the sealant is applied only to the last few threads close to the drain plug head. CAUTION: To avoid contamination of the fuel system, do not apply thread sealant to the end threads of the drain plug.
Supply, Pressure, and Return Hydraulics Sight Gauge Description H I G H K1005 L O W Fig. 5-9: Hydraulic Reservoir Sight Gauge Note: When checking oil quantity, the machine must be on a level surface and the frame must be level. The hydraulic reservoir sight gauge is located on the side of the reservoir (see Fig. 5-10, Item 1).
Supply, Pressure, and Return Hydraulics Removal Sight Gauge 6 5 4 3 8 7 2 1 9 K1093 10 # 1 2 3 4 5 Description Hydraulic Sight Gauge Hollow Hex Head Bolt O-Ring Lockwasher Capscrew # 6 7 8 9 10 Description Hydraulic Oil Return Filter Assy JIC Pipe Connector Return Manifold Tube Hydraulic Reservoir Nut Fig. 5-10: Reservoir Sight Gauge Installation (Ref. Fig. 5-10) The following procedures describes removal of the reservoir sight gauge. 1.
Supply, Pressure, and Return Hydraulics 6. Remove the sight gauge (Item 1) along with the two (2) hollow hex head bolts (Item 2). 7. Clean the two openings in the side of the hydraulic reservoir with appropriate solvent. Plug openings. Installation Sight Gauge (Ref. Fig. 5-10) The following procedures describes installation of the reservoir sight gauge. 1. Remove the four (4) O-rings (Item 3) from the sight gauge and clean O-rings with appropriate solvent. Dry with compressed air.
Supply, Pressure, and Return Hydraulics Suction Strainer Description 2 3 4 7 8 1 5 # 1 2 3 4 Description Drain Plug O-Ring Hydraulic Oil Strainer Flange Half 6 MV0080 # Description 5 6 7 8 Lockwasher Capscrew O-Ring Hydraulic Suction Hose Fig. 5-11: Suction Strainer Installation (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.
Supply, Pressure, and Return Hydraulics Removal and Cleaning Suction Strainer (Ref. Fig. 5-11) The following procedures describes removal of the suction strainer on models with mid-inlet hydraulics. 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-3. 2. Remove the hydraulic reservoir drain plug (Item 1) and drain hydraulic fluid into a suitable container.
Supply, Pressure, and Return Hydraulics Hydraulic Return Filter K1100 Description Fig. 5-12: Hydraulic Return Filter (Ref. Fig. 5-12) The hydraulic return 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 3 2 15 10 1 4 20 psi 5 25 psi K1009 30 0 Fig.
Supply, Pressure, and Return Hydraulics The return filter pressure gauge is located on the side of the return filter housing. The gauge indicates hydraulic fluid pressure entering the return filter element. As contamination accumulates in the filter element, pressure rises. The acceptable operating pressure range is 0–15 psi and is indicated by needle (1) positioned in green arc (2). Pressures above 15 psi, orange arc (3) and red arc (4), indicate that the return filter element must be serviced.
Supply, Pressure, and Return Hydraulics 2. Loosen four (4) flange nuts (Item 2) that secure cover (Item 3) to return filter housing (Item 1). Loosen them only enough to be able to rotate cover. While applying pressure to cover, rotate cover clockwise so that recessed areas of cover line up to flange nuts. Slowly release pressure and remove cover. CAUTION: Care must be taken to avoid injury when removing cover. Do not remove flange nuts. There is pressure under cover from spring (Item 5). 3.
Supply, Pressure, and Return Hydraulics Replacement, Return Filter Element (Ref. Fig. 5-15) The following procedure describes replacing the return filter element. 1. To avoid contamination, place all parts on clean paper or cloth. 2. Loosen and remove lock nut (Item 1) that secures trestle (Item 2) to filter element (Item 7). 3. Remove trestle and flatwasher (Item 3). 4. Loosen bypass spring assembly (Item 8) by turning it counterclockwise.
Supply, Pressure, and Return Hydraulics Removal Return Filter Assembly 3 2 5 4 6 7 8 K1097 1 # Description # 1 2 3 4 Hydraulic Oil Reservoir Lockwasher Capscrew Return Manifold Tube 5 6 7 8 Description Connector Return Hydraulic Oil Filter Diffuser Rubber Gasket Fig. 5-16: Return Filter Assembly (Ref. Fig. 5-16) The following procedure describes disassembly of the return filter assembly. 1. Follow preparation procedures as outlined in Section 3 of this manual.
Supply, Pressure, and Return Hydraulics 6. Remove the diffuser (Item 7) and clean with solvent. Dry with compressed air. Installation Return Filter Assembly (Ref. Fig. 5-16) The following procedures describes installation of the return filter assembly. 1. Reassemble the diffuser (Item 7) and the rubber gasket (Item 8) with the hydraulic return assembly (Item 6). 2. Install the return filter assembly on the hydraulic reservoir with the four (4) lockwashers (Item 2) and capscrews (Item 3).
Supply, Pressure, and Return Hydraulics Removal and Installation Reservoir Breather 1. Loosen and remove breather, using tool on hex portion of breather. 2. Replace breather per the maintenance schedule found on the machine or if damaged. 3. Install breather on tank and tighten as necessary. CAUTION: To avoid contamination of the hydraulic system, do not use thread sealant or Teflon tape.
Replacing Pressure Filter Element Supply, Pressure, and Return Hydraulics 1 2 3 4 MV0040 # 1 2 Description Filter Head Bowl O-Ring # 3 4 Description Filter Element Bowl Fig. 5-19: Hydraulic Pressure Filter Element (Ref. Fig. 5-19) The following procedure describes replacement of the hydraulic pressure filter element. 1. Follow preparation procedures as outlined in Section 3 of this manual.
Supply, Pressure, and Return Hydraulics 7. Insert a new filter element into bowl. Lubricate bowl O-ring with hydraulic oil and install it on bowl. 8. Screw bowl into filter head and tighten until snug. Removal Pressure Filter Assembly 1 4 7 2 3 5 6 MV0050 # Description # 1 Filter Mounting Bracket 2 Capscrew 3 Lockwasher 4 90° O-Ring Hose Elbow 5 6 7 Description Pressure Filter Assembly 90° O-Ring Hose Elbow Swivel Tee Fig. 5-20: Hydraulic Pressure Filter Assembly (Ref. Fig.
Supply, Pressure, and Return Hydraulics 5. Remove the pressure filter assembly from the hole in the filter mounting bracket. Installation Pressure Filter Assembly (Ref. Fig. 5-20) The following procedure describes installation of the hydraulic pressure filter assembly. 1. Insert the pressure filter assembly through the hole in the filter mounting bracket, making sure that the bypass indicator is closest to back of the mounting bracket. 2.
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-21) The hydraulic pump is located on the transmission towards the back of the machine.The hydraulic pump used is a two-section gear type, driven directly from the transmission power takeoff. PUMP SPECIFICATIONS: Type - Gear Sections - Two Manufacturer - Vickers Model - G2020 GPM - 18 at 2500 RPM (Cover End - Pump 1) GPM - 26 at 2500 RPM (Shaft End - Pump 2) Troubleshooting Pump Problems Problem 1. Excessive pump noise Probable Cause Solution A.
Supply, Pressure, and Return Hydraulics Problem Probable Cause Solution C. Disconnected or broken pump Inspect and repair or replace. drive 4. Loss 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.
Supply, Pressure, and Return Hydraulics Removal Hydraulic Pump .
Supply, Pressure, and Return Hydraulics 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 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.
Supply, Pressure, and Return Hydraulics 3 4 7 2 6 5 1 2 1 10 13 14 15 8 11 9 12 17 22 16 23 24 18 21 20 19 26 25 # Description # 1 2 3 4 5 6 7 8 9 10 11 12 13 Hydraulic Hose Elbow Capscrew Lockwasher Hydraulic Pump O-Ring Transmission O-ring Flange Half Lockwasher Capscrew Hydraulic Suction Hose Nut 14 15 16 17 18 19 20 21 22 23 24 25 26 MV0320 Description Lockwasher Flatwasher Nut Lockwasher Lower Pump Support Bracket Capscrew Lockwasher Flatwasher Upper Pump Support Bracket Flat
Supply, Pressure, and Return Hydraulics CAUTION: Before removing support bracket or loosening capscrews that secure the hydraulic pump to the transmission (Item 7), support the pump to ensure that it does not twist or fall. 3. Remove capscrews (Item 19), lockwashers (Item 20), and flatwashers (Item 21) securing upper pump support bracket (Item 22) to the pump. 4. Remove two (2) capscrews (Item 3) and lockwashers (Item 4) securing the hydraulic pump to the transmission. 5.
Supply, Pressure, and Return Hydraulics Installation Hydraulic Pump (Ref. Fig. 5-22 and Fig. 5-23) The following procedure is for the installation of the hydraulic pump. Step 1 thru Step 5 refer to Fig. 5-23. 1. If the pump support brackets were removed, a. Install lower pump support bracket on park brake cylinder mount with two (2) capscrews (Item 26), flatwashers (Item 15), lockwashers (Item 14), and nuts (Item 13). b.
Supply, Pressure, and Return Hydraulics Checking Pump Flow Rate 4 3 2 4 5 1 6 6 # 1 2 3 Description Return Filter Housing Hex Cap Hydraulic Tester # 4 5 6 Description Test Loop Hose (2) Hydraulic Pump Pressure Hose (2) Fig. 5-24: Checking Hydraulic Pump Flow Rate (Ref. Fig. 5-24) If the pump(s) is suspected of delivering below rated capacity, use the following procedure to check pump flow rate: 1. Lower boom to the ground, apply parking brake and stop engine.
Supply, Pressure, and Return Hydraulics 6. Adjust pressure relief valve setting to 100 psi over that of system's maximum rated pressure. Important: Be sure the load valve is open before starting the engine. 7. Start the engine and, when it is at normal operating temperature, open the throttle control all the way. Slowly close the load valve to load the system. (Do not exceed system's maximum rated pressure).
Supply, Pressure, and Return Hydraulics Mid-Inlet Control Valve 2 0 4 0 6 0 8 0 Description 0 K1140 -2 0 Fig. 5-25: Mid-Inlet Control Valve Location Boom Extension Outlet Section Outlet (Return to Tank) Boom Hoist Mid-Inlet Valve Sections Relief Valve Work Ports Inlet From Pump 2 “Pump 2” Test Port K1141 Inlet (From Priority Valve on Pump) Relief Valve Inlet Section Fig.
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-25 and Fig. 5-26)The mid-inlet control valve is located on the valve plate, near the middle of the machine. This valve controls hydraulic functions for the following circuits: • L.H. Outrigger • R.H.
Supply, Pressure, and Return Hydraulics Boom Extend Boom Hoist Mid-Inlet Frame Tilt Auxiliary Transfer Carriage Carriage Tilt Boom Extend Boom Hoist Mid-Inlet Unloader Frame Tilt Auxiliary Transfer Carriage Carriage Tilt 6-Spool Valve For Models without Outriggers 7-Spool Valve For Models with Unloader (Natural Engine) Boom Extend Boom Hoist 1138 Boom Extend Mid-Inlet Boom Hoist Mid-Inlet Frame Tilt Frame Tilt 2nd Auxiliary Auxiliary 1st Auxiliary Transfer Carriage Transfer Carriage Carriage Tilt Carr
Supply, Pressure, and Return Hydraulics Removal Mid-Inlet Control Valve Control Valve K1142 Valve Plate Lockwasher Capscrew Fig. 5-28: Mid-Inlet Control Valve Installation (Ref. Fig. 5-28) The following procedure describes removal of the mid-inlet control valve. 1. Follow preparation procedures as outlined in Section 3. 2. Install a brake pressure diagnostic test gauge onto the “Brakes” diagnostic port. 3.
Supply, Pressure, and Return Hydraulics Installation Mid-Inlet Control Valve 1. (Ref. Fig. 5-28) Position the control valve on the valve plate. Secure with three (3) lockwashers and capscrews. 2. Connect all hydraulic hoses and tubes to fittings on the control valve. Torque per instructions in Section 3. 3. Start the engine and repeatedly cycle all hydraulic circuits controlled by the valve to remove air from the system. 4. Stop engine and check for hydraulic leaks. Tighten connections as necessary.
Supply, Pressure, and Return Hydraulics Fig. 5-30 illustrates views of the control valve, showing port locations and markings. Table 5-1 is a list of markings for each side of these valves. A B RCR F CBP S1 PB PIL T BR SV2 RB B-Back View C E D G2 PS1 PD4 PD3 PD2 PC3 A-Top View OR5 RCR PD1 OR3 SV1 OR1 ACC G1 FTB T RCB FCB F-Left View E-Front View A G3 B OR4 OR2 FB C-Right View MV0730 Fig.
Supply, Pressure, and Return Hydraulics Table 5-1: Rear Axle Stabilizer Control Valve Markings View A - Top View B - Back View C - Right View E - Front View F - Left View 5-46 Marking Description G2 Gauge #1 - Test Port (Rear Osc.
Supply, Pressure, and Return Hydraulics Removal, Rear Axle Stabilizer Control Valve 20 19 17 21 22 18 15 23 1 14 13 12 6 11 2 3 5 1 2 3 4 5 6 7 8 9 10 11 Description Hose for Connector at FTB Port Hose at FCB Port Hose for Connector at G1 Port Hose for Connector at RCB Port Hose for Elbow at ACC Port Hose for Elbow at RCR Port Hose for Connector at FB Port Hose for Run Tee at A Port Hose for Run Tee at A Port Hose for Connector at B Port Hose for Connector on Boom Extend Lockout Valve 12 Ho
Supply, Pressure, and Return Hydraulics WARNING: Hot hydraulic fluid can cause severe burns. Wait for the hydraulic fluid to cool before servicing any hydraulic component. WARNING: Relieve hydraulic pressure before servicing any hydraulic component. Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. (Ref. Fig. 5-31) The following procedure describes removal of the rear axle stabilizer control valve. 1.
Supply, Pressure, and Return Hydraulics Boom Extend Lockout Valve Description D SV1 PD1 K1154 C OR3 Front View Fig. 5-32: Boom Extend Lockout Valve (Ref. Fig. 5-32) The boom extend lockout valve is used on models with outriggers and is standard equipment on 1044C-54 models. It is located on top of the rear axle stabilizer control valve.
Supply, Pressure, and Return Hydraulics • Pump 1 – Used for reading pressure of the hydraulic pump #1. Pressure limit is 3000 psi. • Pump 2 – Used for reading pressure of the hydraulic pump #2. Pressure limit is 3150 psi. • Rear Osc. Lock (G1) – Used for reading output pressure of the solenoid valve SV1. It is useful when diagnosing service malfunctions in the rear axle stabilizer circuit. • Rear Osc. Lock (G2) – Used for reading pressure in the rear oscillation lock circuit.
Supply, Pressure, and Return Hydraulics Roll-Back Hose Tray 20 40 60 80 General 0 K1069 -20 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.
Supply, Pressure, and Return Hydraulics Mid-Inlet Hydraulic System 9 10 11 8 6 7 5 12 4 3 K1152 2 1 # Description # 1 2 3 4 5 6 Nut Lockwasher Front Hose Tray Support Bracket Hose Mount Button Head Socket Capscrew Button Head Socket Capscrew 7 8 9 10 11 12 Description Lockwasher Roll-Back Hose Tray Button Head Socket Capscrew Lockwasher Flatwasher Rear Hose Tray Support Bracket Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics (Ref. Fig.
Supply, Pressure, and Return Hydraulics Installation Roll-Back Hose Tray (Ref. Fig. 5-35) The following procedure describes installation of the roll-back hose tray used in models with mid-inlet hydraulics. 1. Inspect and clean the roll-back hose tray. 2. Place the roll-back hose tray on the two support brackets making sure it is in the same position as when removed. 3.
Supply, Pressure, and Return Hydraulics 5-54 31200079
Section 6 — Boom and Transfer Table of Contents Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Disconnecting an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Connecting an Attachment . . . . . . . . . . . . . . . . . .
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 Fig. 6-13: Rear Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Fig. 6-88: Side Slide Pads – Outer Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Fig. 6-89: Outer Boom Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Fig. 6-90: Outer Boom Tube and Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Fig. 6-91: Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 6-127: Boom Extension Proximity Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123 Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124 Fig. 6-129: Transfer Carriage with Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125 Fig. 6-130: Transfer Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6 — Boom and Transfer Boom and Transfer Hydraulics General Description Boom Rear Carriage Tilt Cylinder Transfer Carriage 20 40 60 80 Front Carriage Tilt Cylinder -20 0 Hoist Cylinder J1116 Joystick Controls Fig. 6-1: Major Boom and Transfer Hydraulic Components (Ref. Fig.
Boom and Transfer Joystick Controls V1018 General Description Fig. 6-2: Joystick (Ref. Fig. 6-2) The joysticks control hydraulic flow to the associated cylinders. Control is proportional: The more joystick movement, the greater the action. The speed of cylinder action is also affected by engine/hydraulic pump speed. Action is quicker at higher engine speeds. Joysticks can be moved in any direction and are not limited to front/back, left/right movement.
Boom and Transfer Removal Joystick 2 1 7 5 6 3 4 8 14 15 13 9 10 10 9 11 J1120 11 12 # 1 2 3 4 5 6 7 8 Description Button Head Socket Capscrew Lockwasher with Internal Teeth Phillips Truss Head Screw Flatwasher Wiring Harness Lead Connector Joystick Control Panel 12 # 9 10 11 12 13 14 15 Description Connector Connector Swivel Tee Hydraulic Hose Side Panel Capscrew Lockwasher Fig. 6-3: Joystick Installation (Ref. Fig. 6-3) The following steps are required to remove the joystick. 1.
Boom and Transfer 3. Tag, loosen, and remove two (2) swivel tees (Item 11) from connectors (Item 9) on bottom of joystick. 4. Tag, loosen, and remove remaining four (4) hydraulic hoses (Item 12) from connectors (Item 10). 5. Tag and disconnect two (2) lead connectors (Item 6) from wiring harness (Item 5). 6. Loosen and remove four (4) each capscrews (Item 1) and lockwashers (Item 2) securing joystick (Item 7) to control panel. 7.
Boom and Transfer Disassembly Joystick 25 4 2 3 17 6 1 26 27 28 29 30 5 8 7 18 31 24 3 9 10 16 22 23 19 15 11 12 16 13 14 20 32 21 33 36 # Description # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Socket Head Capscrew Socket Head Capscrew Half Handle Cap Push Button Switch Guide Hex Nut Hex Nut Seal Setscrew Lever Joint Retaining Nut Stem Clip Socket Head Capscrew Boot Cam 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Retainer Flange Socket Head Capscrew Man
Boom and Transfer 1. Pull back boot (Item 17) so that access to retainer (Item 19) and flange (Item 20) can be made. 2. Loosen and remove four (4) socket head capscrews (Item 16) and one (1) clip (Item 15) that secure retainer and flange to joystick body (Item 24). Separate body from joystick handle assembly. 3. Disassemble joystick body assembly as follows: a. Loosen and remove three (3) socket head capscrews (Item 21) securing manifold (Item 22) to body. b. Remove O-ring (Item 23) from manifold.
Boom and Transfer e. Clean all remaining parts of joystick body assembly, including the body’s center port, with solvent. Dry with compressed air. Inspect and replace any damaged parts. Note: The body (Item 24) cannot be purchased individually. If it becomes damaged, it will be necessary to replace the entire joystick assembly. f. Lubricate and install new O-ring (Item 23) in manifold (Item 22). g. Install manifold on body with three (3) capscrews (Item 21). Torque capscrews to 22 in-lbs. 4.
Boom and Transfer 7. Install boot (Item 17) on stem (Item 14) making sure that the top lip of the boot rests in the channel in the stem. 8. Roll back boot and install cam (Item 18), retainer (Item 19), and flange (Item 20) on stem. 9. Install flange on joystick body with two (2) capscrews (Item 16). Install retainer on flange with remaining two (2) capscrews, ensuring that one capscrew also secures the wire to the retainer with the clip (Item 15). Torque capscrews to 28 in-lbs. 10.
Boom and Transfer O-ring Plug Pressure Reducing Valve Pressure Reducing Valve O-ring Plug MV0610 Mid-Inlet Hydraulics Fig. 6-6: Pilot Pressure Plug c. (Ref. Fig. 6-6) If the pilot pressure is not within the recommended range, adjust pressure as follows: 1). For models with mid-inlet hydraulics, remove the O-ring plug from the pressure reducing cartridge with a 5/16" Allen wrench.
Boom and Transfer WARNING: Do not remove counterbalance valves from cylinders on the machine while the cylinder is under load (extended). If a counterbalance valve must be removed, first retract the cylinder and remove all hydraulic pressure in the cylinder. Wear eye protection when removing counterbalance valves. WARNING: Hydraulic cylinders equipped with counterbalance valves may have hydraulic pressure stored within the cylinder even after the cylinder is removed from the machine.
Boom and Transfer 4. Remove the hose at the base end of the cylinder and plug the hose. 5. Start the engine 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).
Boom and Transfer Boom Hoist Cylinder 20 40 60 80 Description 0 J1126 -20 Fig. 6-7: Boom Hoist Cylinders REV. 001 (Ref. Fig. 6-7) Two (2) boom 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.
Boom and Transfer Removal Boom Hoist Cylinder 1 3 2 5 6 4 1 7 20 40 60 80 2 -20 0 8 J1122 10 11 12 9 # 1 2 3 4 5 6 Description Hydraulic Hose Hoist Cylinder Outer Boom Pivot Pin - Rod End Lock Pin Hex Capscrew # 7 8 9 10 11 12 Description Lockwasher Transfer Carriage/Boom Cradle Lock Pin Pivot Pin - Base End Lockwasher Hex Capscrew Fig. 6-8: Boom Hoist Cylinder Installation (Ref. Fig. 6-8) The following steps are required to remove boom hoist cylinders. 1.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. Note: Cylinder pins are designed to be removed with a slide hammer. 5. Remove lock pin from rod end pivot pin (Item 4). 6. Remove rod end hoist cylinder pin from outer boom (Item 3). 7. Slowly lower supported cylinder until it rests on main frame. 8.
Boom and Transfer Overhaul Boom Hoist Cylinder 8 1 7 9 2 16 3 15 13 14 6 4 11 5 12 10 MV0620 # Description # 1 2 3 4 5 6 7 8 45 Degree Elbow Grease Fitting Cover Grease Fitting Self-Aligning Bushing - Base End Cylinder Barrel Hollow Hex O-ring Plug Hollow Hex O-ring Plug Counterbalance Valve Cartridge 9 10 11 12 13 14 15 16 Description Rod Nut Piston Set Screw Rod Bearing Head Cylinder Rod Self-Aligning Bushing - Rod End Grease Fitting Grease Fitting Cover Fig.
Boom and Transfer a. Place socket wrench over counterbalance valve cartridge (Item 8). Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b. Carefully and slowly, turn cartridge out of manifold block to release pressure in cylinder. 3. Remove the counterbalance valve cartridge. 4. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 5. Remove one (1) set screw (Item 11) securing rod bearing head (Item 12) to barrel. 6.
Boom and Transfer 16. Inspect counterbalance valve cartridge (Item 8), including O-rings, for condition and replace as necessary. Do not disassemble the cartridge. Service to counterbalance valve cartridges is limited to installing new O-rings or replacing the entire cartridge. 17. Lubricate counterbalance valve cartridge O-rings with clean hydraulic oil. 18. Install cartridge in manifold block. 19. Install O-ring plug (Item 6) in manifold block. 20. Install O-ring plug (Item 7) in manifold block. 21.
Boom and Transfer Front Carriage Tilt Cylinder 20 40 60 80 Description 0 J1126 -20 Fig. 6-10: Front Carriage Tilt Cylinder The front carriage tilt cylinder 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.
Boom and Transfer Removal Front Carriage Tilt Cylinder 1 2 3 4 5 6 7 J1070 8 # 1 2 3 4 Description Inner Boom Section Pin Boss Lock Pin Lockwasher Capscrew # 5 6 7 8 Description Upper Pivot Pin Hydraulic Hose Front Carriage Tilt Cylinder O-ring Connector Fig. 6-11: Front Carriage Tilt Cylinder Installation (Ref. Fig. 6-11) The following steps are required to remove the front carriage tilt cylinder. 1. Remove quick attach assembly. See page 6-44 2.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. 4. Remove capscrew (Item 4), lockwasher (Item 3), and lock pin (Item 2) from upper pivot pin (Item 5) of front carriage tilt cylinder. Remove pivot pin. 5. Carefully remove cylinder from boom nose (Item 1). 6. Clean with solvent and dry with compressed air. Inspect all components for condition and wear.
Boom and Transfer Overhaul Front Carriage Tilt Cylinder 6 5 1 2 8 4 7 3 10 9 8 2 13 12 MV0630 11 # 1 2 3 4 5 6 7 8 9 Description O-ring Connector Bushing Set Screw Grease Fitting Counterbalance Valve Cartridge Rod Nut Cylinder Barrel Bushing Cylinder Rod # 10 11 12 13 Description Grease Fitting Piston Tube Rod Bearing Head Fig. 6-12: Front Carriage Tilt Cylinder Assembly (Ref. Fig. 6-12) The following steps are required to overhaul the front carriage tilt cylinder. 1.
Boom and Transfer 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. a. Place socket wrench over counterbalance valve cartridge (Item 5). Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b.
Boom and Transfer 14. Inspect counterbalance valve cartridge (Item 5), including O-rings, for condition and replace as necessary. Do not disassemble the cartridge. Service to counterbalance valve cartridges is limited to installing new O-rings and replacing the entire cartridge. 15. Lubricate counterbalance valve cartridge O-rings with clean hydraulic oil. 16. Install cartridge in manifold block. 17. Lubricate new O-ring with hydraulic oil and install inside piston (seals rod to piston). 18.
Boom and Transfer Rear Carriage Tilt Cylinder 20 40 60 80 Description 0 J1128 -20 Fig. 6-13: Rear Carriage Tilt Cylinder Two rear carriage tilt cylinders 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.
Boom and Transfer Removal Rear Carriage Tilt Cylinder 1 2 3 5 7 4 6 8 9 14 13 10 11 J1129 12 # 1 2 3 4 5 6 7 Description Outer Boom Lock Pin Lockwasher Hex Head Capscrew Cylinder Pivot Pin - Rod End Rear Carriage Tilt Cylinder Hydraulic Hose # 8 9 10 11 12 13 14 Description Grease Fitting Cover Grease Fitting Lock Pin Lockwasher Hex Head Capscrew Cylinder Pivot Pin - Base End Transfer Carriage/Boom Cradle Fig. 6-14: Rear Carriage Tilt Cylinder Installation (Ref. Fig.
Boom and Transfer 3. Tag and disconnect two (2) hydraulic hoses (Item 7) from elbows on both cylinders (Item 6). Cap fittings and hoses. 4. Support each cylinder with sling(s) and crane, or other suitable means. Make sure equipment has sufficient capacity to support weight of cylinder. WARNING: To avoid personal and/or equipment damage, support hydraulic cylinders before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. 5.
Boom and Transfer 5. Clean hydraulic hose ends with solvent. Attach two (2) hoses (Item 7) to elbows on each cylinder. Torque hose swivel nuts to 44–48 ft-lbs. 6. If necessary, remove grease fitting cover(s) (Item 8) and grease fitting(s) (Item 9). Clean and inspect for damage; replace if necessary. Install grease fitting(s) and covers; torque fitting(s) 1.5 to 3 turns past finger tight. 7. Lubricate grease fittings with EP lithium based grease.
Boom and Transfer 5. Remove the cylinder rod assembly from cylinder barrel. CAUTION: To prevent possible damage to components, support cylinder rod assembly; do not wiggle rod or head back and forth during removal. 6. Remove rod nut (Item 4), piston (Item 5), tube (Item 6), and rod bearing head from rod (Item 8). 7. Inspect bushings for damage. The following steps are necessary if bushing(s) need to be replaced: a. Remove bushing (Item 9) from cylinder rod using a bushing driver and hammer or press. b.
Boom and Transfer 18. Install cylinder rod assembly in cylinder barrel. Install a spanner wrench in two (2) holes of rod bearing head and tighten until it is snug against the cylinder barrel. 19. Install two (2) elbows (Item 1) on cylinder manifold. Torque connectors to 40–44 ft-lbs. 20. Lubricate grease fittings with EP lithium based grease. Selector Valve J1181 Description Fig.
Boom and Transfer Removal Selector Valve 8 6 7 5 1 2 J1182 3 4 # 1 2 3 4 Description Lockwasher Nut Hydraulic Hoses Hydraulic Hoses # 5 6 7 8 Description Selector Valve Hydraulic Hoses (Joystick) Capscrew Joystick Wiring Harness Fig. 6-17: Selector Valve Installation (Ref. Fig. 6-17) The following steps are required to remove the selector valve in models with a mid-inlet hydraulic system. 1. Follow preparation procedures as outlined in Section 3 of this manual. 2.
Boom and Transfer Installation Selector Valve (Ref. Fig. 6-17) The following steps are required to install the selector valve in models with a mid-inlet hydraulic system. 1. Secured the selector valve (Item 5) to the valve plate with two (2) each capscrews (Item 7), lockwashers (Item 2), and nuts (Item 1). Torque nuts to 50 in-lbs. 2. Reconnect four (4) hydraulic hoses (Items 3 and 6) to respective elbows at ports A3, B3, P1, and P2 on selector valve. Torque hydraulic hose swivel nuts to 130–150 in-lbs.
Boom and Transfer 4. Remove coil (Item 2) from solenoid valve. 5. Loosen and remove solenoid valve from valve body. 6. Remove O-rings and backup rings (Items 4 thru 8) from solenoid valve. Discard O-rings and backup rings. 7. Repeat Step 3 thru Step 6 for the other solenoid valve. 8. Clean all remaining parts with solvent and dry with compressed air. Visually inspect the valve body to make sure all cavities are free of contamination including burrs and chips as well as pieces of O-rings.
Boom and Transfer Troubleshooting Problem 1. Boom fails to extend or retract Probable Cause Solution A. Broken hydraulic line(s) and/or connection leaks A. Replace hydraulic tube(s)/hose(s) and/or tighten loose connections. B. Faulty extension cylinder B. Repair extension cylinder seals. C. Broken chains or chain connections Reference C. Repair or replace chains. D. Check pump pressure 2. Boom fails to raise or lower A. Broken hydraulic line(s) and/or connection leaks A.
Boom and Transfer Boom Slide Pads — General Description Within the slide boom assemblies, there art two classifications of slide pads: • Load Bearing Slide Pads Load bearing slide pads are located at the front and on the bottom of any boom section that contains another section. Load bearing pads are also located on the top rear of a boom section that is placed inside another section.
Boom and Transfer Slide Pads with Chamfers Less Chamfer J1036 Fig. 6-20: Pad Worn, But Still OK (Ref. Fig. 6-20) Inspect all pads weekly for condition and amount of chamfer wear. As a pad wears, the chamfer will get smaller. As long as a portion of the chamfer is visible, the pad is OK and does not need to be replaced. No Chamfer J1037 Fig. 6-21: Pad Must Be Replaced (Ref. Fig. 6-21) When the chamfer is gone, the pad must be replaced.
Boom and Transfer Slide Pads without Chamfers New Slide Pad 3/4" Worn Pad 9/16" Minimum J1184 Fig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom (Ref. Fig. 6-23) The lower slide pads, located at the rear of the middle boom on 3-section booms and at the rear of the middle (rear) boom on 4-section booms, do not have chamfers. It will be necessary to measure the thickness of these slide pads to ensure that they are a minimum of 9/16".
Boom and Transfer Another option is to install/replace boom wear strips. Contact the JLG Service Department or your dealer for information about available wear strips. 0.030" Max. J1040 Fig. 6-24: Damaged Slide Surface 0.030" Max. J1041 Fig.
Boom and Transfer Replacing and Shimming Boom Slide Pads — General Shims Bolted Pad Pad Cage Caged Pad Lockwas her Retaining Block Pad Capscrew J1019 Fig. 6-26: Slide Pad Installation (2-Section Shown) (Ref. Fig. 6-26) As boom pads wear, it becomes necessary to install or remove shims to maintain the correct clearances. Specific instructions and clearances for 2-section, 3-section, and 4-section booms are provided on following pages.
Boom and Transfer Adding or removing shims from bolted pads may require a different capscrew length or washer selection. Boom Bolted Pad Washer Lockwasher Capscrew Nut Insert Pad Number Dimension A 39023A 39024A 39530A 39594A 39604A 0.28"–0.33" 0.39"–0.44" 0.39"–0.44" 0.39"–0.44" 0.21"–0.26" Dimension A J1034 Fig. 6-28: Determining Capscrew Length (Ref. Fig.
Boom and Transfer Quick Attach Description J1004 Fig. 6-30: Quick Attach Rear View (Ref. Fig. 6-30) The quick attach is designed for easy connection and disconnection of various attachments. By pulling 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.
Boom and Transfer 8. Pull release handle (1) back. J1013 Fig. 6-32: Lock Plate 9. The lock pin (2) should engage the attachment, clearing the lock plate (3) from the attachment stop (4). J1007 Fig. 6-33: Rotating Quick Attach Downwards 10. Start the engine. Fully rotate quick attach (5) downwards by using the attachment tilt control. J1008 Fig. 6-34: Lowering Boom 11. Lower boom enough to clear quick attach pivot pin (6) from attachment (7).
Boom and Transfer J1009 Fig. 6-35: Retracting Boom 12. Retract the boom until quick attach (5) is clear of attachment (7). Connecting an Attachment J1015 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). J1016 Fig. 6-37: Raising Boom 2. Raise the boom to engage the quick attach pivot pin (6) with the attachment (7).
Boom and Transfer J1017 Fig. 6-38: Rotating Quick Attach Forward 3. Rotate the quick attach (5) upwards to engage the attachment (7). 4. Shut off engine. J1014 Fig. 6-39: Lock Plate Engaged 5. Check to see that the lock plate (3) is engaged ahead of the attachment stop (4). MAKE SURE ATTACHMENT IS SECURELY CONNECTED TO QUICK ATTACH. ATTACHMENT MAY FALL AND CAUSE SERIOUS PERSONAL INJURY OR DEATH! W1048 WARNING 6. Connect attachment hydraulic hoses (if equipped).
Boom and Transfer Removal Quick Attach 1. Disconnect attachment from quick attach. 2. Fully retract boom and transfer carriage (if equipped), level quick attach and lower boom to ground. 3. Set park brake, lock shift selector in NEUTRAL position, shut off engine and remove ignition key from switch. Block all wheels. 6 1 5 4 3 2 J1067 # 1 2 3 Description Quick Attach Pivot Pin capscrew # 4 5 6 Description Lockwasher Lock Pin Front Carriage Tilt Cylinder Fig.
Boom and Transfer 5 1 3 4 5 2 6 J1068 # 1 2 3 Description Pivot Pin Capscrew Lockwasher # 4 5 6 Description Nut Shim Quick Attach Fig. 6-41: Quick Attach Pivot 5. (Ref. Fig. 6-41) Remove nut (Item 4), lockwasher (Item 3), and capscrew (Item 2) from quick attach pivot pin (Item 1). 6. Remove quick attach pivot pin and shims (Item 5) (if installed). 7. Clean and inspect all parts for condition and wear. Replace as necessary. Installation Quick Attach 1. Align quick attach (Item 6) to boom.
Boom and Transfer Boom Angle Inclinometer DEGREES 60 80 60 0 -20 0 20 4 H1045 60 80 80 Description 20 -20 0 20 J1177 0 40 0 4 -20 Fig. 6-42: Boom Angle Inclinometer (Ref. Fig. 6-42) The boom angle inclinometer is located near the front of the outer boom section. The boom angle inclinometer shows the angle of the boom relative to level ground.
Boom and Transfer 4-Section Boom 20 40 60 80 Description -20 0 J1152 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.
Boom and Transfer Shimming Procedures 4-Section Boom 2 20 40 60 80 2 -20 2 0 1 1 2 40 60 80 2 3 20 -20 0 2 2 2 2 1 1 4 2 1 2 J1160 2 2 NOTE: Items 1 and 3 are load bearing pads # Description # 1 2 3 Boom Pad, 1" Thick x 3" Wide Boom Pad, 9/16" Thick x 2" Wide Boom Pad, 3/4" Thick x 3" Wide 4 Description Boom Pad, 3/4" Thick x 1-1/4" Wide Fig. 6-45: Boom Slide Pad Locations – 4-Section Boom 1. Park machine on firm, level surface and apply park brake. Level the frame.
Boom and Transfer 3. (Ref. Fig. 6-46) Measure the gap between boom sections at all upper front pads. If the dimensions are not within the specified range, proceed to Step 4. If the dimensions are within the specified range, proceed to Step 5. J1162 Install shim(s) under these pads 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. 0.06"–0.12" (1/16"–1/8") gap between boom and pad 0.05"–0.
Boom and Transfer 5. (Ref. Fig. 6-48) Install/remove shim(s) under indicated pads to obtain specified clearances. This dimension cannot be adjusted 1.22"–1.47" (1-7/32"–1-15/32") J1156 1.04"–1.10" (1-3/64"–1-7/64") Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom J1157 6. (Ref. Fig. 6-49) Measure the gaps between the inner, middle (forward), and middle (rear) sections at the upper pads. Spacing between the middle (rear) and outer boom section cannot be adjusted.
Boom and Transfer 0.06" (1/16") J1158 0.07" (1/16") Fig. 6-51: Upper Shim Installation – Rear of 4-Section Boom 8. (Ref. Fig. 6-51) Install/remove shim(s) under indicated pads to obtain specified clearances. 0.47–0.53" (15/32"– 17/32") 0.47–0.53" (15/32"– 17/32") 0.72"–0.78" (23/32"– 25/32") 0.72"–0.78" (23/32"– 25/32") 0.595"–0.655" (19/32"– 21/32") J1187 0.595"–0.655" (19/32"– 21/32") Rear of Boom, Looking Forward Fig. 6-52: Clearances Between Boom Sections – Rear of 4-Section Boom 9. (Ref.
Boom and Transfer 0.02"–0.08" (1/64"–5/64") 0.02"–0.08" (1/64"–5/64") 0.03"–0.09" (1/32"–3/32") 0.03"–0.09" (1/32"–3/32") 0.03"–0.09" (1/32"–3/32") J1188 0.03"–0.09" (1/32"–3/32") Rear of Boom, Looking Forward Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom 10. (Ref. Fig. 6-53) Install/remove shim(s) under indicated pads to obtain specified clearances making sure clearances on both sides of each boom section are the same. 0.47–0.53" (15/32"– 17/32") 0.595"–0.
Boom and Transfer 11. (Ref. Fig. 6-54) Adjust boom positions to obtain clearances between boom sections as shown. Measure these clearances at the slide pad locations. 0.02"–0.08" (1/64"–5/64") 0.06"–0.12" (1/16"–1/8") 0.02"–0.08" (1/64"–5/64") 0.04"–0.10" (3/64"–7/64") 0.06"–0.12" (1/16"–1/8") Front of Boom, Looking Rearward 0.06"–0.12" (1/16"–1/8") J1190 0.06"–0.12" (1/16"–1/8") Fig. 6-55: Gaps Between Pads and Boom – Front of 4-Section Boom 12. (Ref. Fig.
Boom and Transfer 10 5/8" (10.625") 3/16" (0.19") J1085 1/4" (0.25") Max. Fig. 6-56: Inner Boom Cross-Section at Window 2. (Ref. Fig. 6-56) Place a straight edge against the bottom surface of the inner 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 middle (forward) boom section. 3. (Ref. Fig.
Boom and Transfer 4. (Ref. Fig. 6-57) Place a straight edge against the bottom surface of the middle (forward) 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 middle (rear) boom section. 5. (Ref. Fig. 6-57) The side walls may also deflect outward at the window areas. Take this measurement across the middle (forward) boom tube, through the windows.
Boom and Transfer 1 2 3 J1169B 4 # 1 2 Description # Nut Lockwasher 3 4 Description Flatwasher Boom Cover Fig. 6-59: 4-Section Boom Cover Installation 5. (Ref. Fig. 6-59) Remove six (6) each nuts (Item 1), lockwashers (Item 2), and flatwashers (Item 3) securing boom cover (Item 4) to boom. Remove boom cover. 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.
Boom and Transfer 8. (Ref. Fig. 6-60) Tag and disconnect two (2) hoses at boom extension cylinder lines (Item 3). Cap lines and hoses 9. Tag and disconnect two (2) carriage tilt hoses (Item 2), and two (2) auxiliary hydraulics hoses (Item 1) at the boom. Cap hoses and lines. 10. Place sling around inner boom section, at the front. Chains with hooks may be attached to the rear of the outer boom section, near the pivot pin bosses (Ref. Fig. 6-61).
Boom and Transfer CAUTION: Make sure each cylinder is fully supported so it does not fall and cause personal or equipment damage when it is being removed. 12. (Ref. Fig. 6-61) Starting at a rear carriage tilt cylinder (Item 6), use a slide hammer puller threaded into the pivot pin (Item 4) to remove the pivot pin from boom. After the pivot pin has been removed, allow the cylinder to swing down and away from the boom.
Boom and Transfer 2 4 3 1 6 5 7 J1245 8 # 1 2 3 4 Description # Shim Rear Upper Slide Pad Pad Retainer Lockwasher 5 6 7 8 Description Flatwasher Capscrew Lockwasher Button-Head Socket Capscrew Fig. 6-63: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section 16. (Ref. Fig. 6-63) Remove upper rear slide pads from middle (front) boom section as follows: a.
Boom and Transfer 17. (Ref. Fig. 6-64) Remove upper rear slide pads from inner boom section as follows: a. Remove two (2) each capscrews (Item 6), lockwashers (Item 5), flatwashers (Item 4), and pad retainers (Item 3) from rear of inner boom section. 20 -20 0 J1268 Locations for Chain Attachment 40 60 80 b. Remove four (4) capscrews (Item 8) and lockwashers (Item 7) securing upper slide pads (Item 2) to rear of inner boom section. Remove the two (2) slide pads. Fig.
Boom and Transfer 3 2 4 1 1 2 5 4 3 5 5 7 J1222 6 # 1 2 3 4 Description Nut Lockwasher Boom Pivot Pin Bolt # 5 6 7 Description Shims Transfer Carriage/Boom Cradle Boom Assembly Fig. 6-66: 4-Section Boom Pivot Pins 19. (Ref. Fig. 6-66) Remove two (2) each nuts (Item 1), lockwashers (Item 2), and capscrews (Item 4) from boom pivot pins (Item 3). CAUTION: Make sure slings and chains are secure and crane is supporting the weight of the boom. 20. (Ref. Fig.
Boom and Transfer installation 4-Section Boom 1. Prepare replacement boom for installation by removing strapping and blocks used for shipment. Note location of straps and blocks for use on the previously removed boom. 2. With the replacement boom still lying upside down, the front carriage tilt cylinder should be installed at this point. It is easier to install when the boom is in this position. See page 6-20 3. Attach slings/chains to the boom and crane.
Boom and Transfer a. With the outriggers up, extend the boom, noting that Boom Extension proximity light illuminates when the boom is extended to specified distance (approximately 21 feet with tilting tower or 25 feet with standard carriage). If light does not illuminate, stop and retract the boom. See page 6-119 for adjustment procedures. b. Retract and lower boom to ground and shut off engine. c. Complete proximity switch adjustment before proceeding to Step 18. 18.
Boom and Transfer 16 15 1 2 6 5 4 3 7 13 11 10 9 12 11 10 8 5 9 4 14 J1271 6 7 # 1 2 3 4 5 6 7 8 Description Lower Slide Pad Shim Right Hand Retainer Block Pad Retainer Flatwasher Lockwasher Capscrew Left Hand Retainer Block # 9 10 11 12 13 14 15 16 Description Lockwasher Capscrew Lockwasher Upper Slide Pad Shim Capscrew Lockwasher Button-Head Socket Capscrew Fig. 6-67: Slide Pad Removal – Outer Boom Section 3. (Ref. Fig.
Boom and Transfer 1 2 3 4 5 6 # 1 2 3 4 Description Lower Front Slide Pad Shim Capscrew Lockwasher J1270 7 # 5 6 7 Description Pad Retainer Lockwasher Button-Head Socket Capscrew Fig. 6-68: Lower Front Slide Pad Removal – Middle (Rear) Boom Section 4. (Ref. Fig. 6-68) Remove lower front slide pads from middle (rear) boom section as follows: a. Remove two (2) each capscrews (Item 3), lockwashers (Item 4), and pad retainers (Item 5) from rear of middle (rear) boom section. b.
Boom and Transfer 4 5 6 7 8 3 13 14 15 12 1 11 10 2 16 17 9 20 40 60 80 J1227 18 -20 0 1 and 2 7 and 8 10 and 11 J1241 14 and 15 Side View # 1 2 3 4 5 6 7 8 9 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Middle (Front) Boom Section Hose Guard Lockwasher Capscrew Auxiliary Tilt Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section # 10 11 12 13 14 15 16 17 18 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Half Clamp Round Head
Boom and Transfer CAUTION: Be sure to note orientation of the hose guard during removal. Your hose guard may be different from that shown above. If the hose guard is reversed at assembly, equipment damage may occur during operation of machine. b. Loosen and remove hydraulic hoses (two (2) each auxiliary and carriage tilt) (Items 7 and 8) from hydraulic tubes (Items 1 and 2) at rear of middle (front) boom section. Bleed any remaining oil into a suitable container. Tag and cap hoses and tubes. c.
Boom and Transfer 6. (Ref. Fig. 6-70) Remove extension cylinder as follows: a. Support the extension cylinder with sling(s) or other suitable means. Make sure support items have sufficient capacity to support the weight of the cylinder. The extension cylinder weighs 650 pounds. b. Loosen and remove two (2) hydraulic tubes (Item 9) from elbows (Item 8) on boom extension cylinder (Item 5). Bleed any remaining oil into a suitable container. Tag and cap fittings and tubes. c.
Boom and Transfer 9. (Ref. Fig. 6-71) Remove upper front slide pads from middle (rear) boom section as follows: a. Remove two (2) each capscrews (Item 1), lockwashers (Item 2), from front of middle (rear) boom section. b. Remove two (2) slide pads (Item 4) and shims (Item 3). 1 2 # 1 2 Description J1245 3 4 # Button-Head Socket Capscrew Lockwasher 3 4 Description Shim Front Upper Slide Pad Fig. 6-72: Upper Front Slide Pad Removal – Middle (Forward) Boom Section 10. (Ref. Fig.
Boom and Transfer 11. (Ref. Fig. 6-73) Remove jam nut (Item 2) and lockwasher (Item 3) securing upper chain adjustment anchor (Item 1) to middle (rear) boom section. 12. Remove chain adjustment anchor from bracket at top of middle (rear) boom section and lay chain over top of inner boom section.
Boom and Transfer 5 4 1 3 2 6 8 J1229 7 # 1 2 3 4 Description # Inner Boom Upper Chain Lock Nut Lockwasher 5 6 7 8 Description Capscrew Lower Chain Shoulder Bolt Rear Chain Anchor Fig. 6-75: Disconnecting Chains at Rear of Inner Boom 15. (Ref. Fig. 6-75) Disconnect chains from rear of inner boom as follows: a. Remove two (2) lock nuts (Item 3) and shoulder bolts (Item 7) securing chains (Items 2 and 6) to rear chain anchor (Item 8). b.
Boom and Transfer a. Remove two (2) lock nuts (Item 2), chain anchor rod (Item 6), and upper chain (Item 1). b. Remove capscrew (Item 4), lockwasher (Item 5), and upper chain anchor (Item 3). c. Remove capscrew (Item 14), lockwasher (Item 15), and hose reel pin (Item 16) securing each of the two (2) hose reels (Item 13) to the rear of the middle (forward) boom section. Remove hose reels. d.
Boom and Transfer 11 12 14 15 9 7 16 17 1 2 13 3 12 5 4 6 10 9 7 11 8 MV0090 # 1 2 3 4 5 6 7 8 9 10 Description Front Bottom Slide Pad Shim Pad Retainer Flatwasher Lockwasher Capscrew Side Slide Pad Shim Button-Head Socket Capscrew Lockwasher # 11 12 13 14 15 16 17 18 Description Button-Head Socket Capscrew Lockwasher Middle (Forward) Boom Assy Button-Head Socket Capscrew Lockwasher Shim Rear Bottom Slide Pad Pad Retainer Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section 20. (Ref.
Boom and Transfer c. (Ref. Fig. 6-78) Remove lower slide pads from front of middle (forward) boom section as follows: 1). Remove two (2) socket capscrews (Item 9) and lockwashers (Item 10) securing lower slide pads (Item 1) to front of boom section. 2). Remove slide pads and shims (Item 2). 21. (Ref. Fig. 6-78) Remove two (2) capscrews (Item 14) and lockwashers (Item 15) securing bottom slide pad (Item 17) to rear of middle (forward) boom section. Remove slide pad and shim(s) (Item 16). 22.
Boom and Transfer 7 8 9 1 10 2 7 3 4 5 J1233 6 # 1 2 3 4 5 Description Grease Fitting Cover Grease Fitting Chain Roller Pin Lock Pin Lockwasher # 6 7 8 9 10 Description Capscrew Chain Guide Washer Bushing Chain Roller Chain Roller Bushing Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section 27. (Ref. Fig. 6-80) Remove rear chain roller assembly as follows: a. Remove capscrew (Item 6), lockwasher, (Item 5) and lock pin (Item 4) from chain roller pin (Item 3). b.
Boom and Transfer 6 4 3 5 J1246 2 1 # 1 2 3 Description Auxiliary Hydraulic Hoses Carriage Tilt Hydraulic Hoses Cushion Clamp # 4 5 6 Description Auxiliary Hydraulic Tubes Carriage Tilt Hydraulic Tubes Mounting Channel Fig. 6-81: Hose and Tube Removal – Inner Boom Section 30. (Ref. Fig. 6-81) Remove tubes and hoses from inner boom section as follows: a. Remove lock nuts from cushion clamps (Item 3) securing auxiliary and carriage tilt hydraulic tubes (Items 4 and 5) in mounting channels (Item 6).
Boom and Transfer 4 3 2 40 60 80 1 5 20 0 J1225 -20 # 1 2 3 Description # Chain Anchor Jam Nut Lockwasher 4 5 Description Nut Outer Boom Section Fig. 6-82: Upper Chain Assembly 31. (Ref. Fig. 6-82) Remove nut (Item 4) and lockwasher (Item 3) securing upper chain anchor (Item 1) to outer boom section (Item 5). Remove upper chain assembly from boom.
Boom and Transfer 32. (Ref. Fig. 6-83) Remove capscrew (Item 9), lockwasher (Item 8), and lock pin (Item 7) from chain roller pin (Item 10). 33. (Ref. Fig. 6-83) Remove chain roller pin along with two (2) each chain guide washers (Item 1), chain roller bushings (Item 2), hardened bushings (Item 3), and the chain roller (Item 4).
Boom and Transfer 7 6 5 8 9 10 11 12 J1232 1 2 3 4 # 1 2 3 4 5 6 Description Front Side Slide Pad Shim Lockwasher Button-Head Socket Capscrew Button-Head Socket Capscrew Lockwasher # 7 8 9 10 11 12 Description Button-Head Socket Capscrew Lockwasher Shim Rear Side Slide Pad Shim Rear Lower Slide Pad Fig. 6-85: Slide Pads – Middle (Rear) Boom Section 36. (Ref. Fig. 6-85) Remove remaining slide pads from middle (rear) boom section as follows: a.
Boom and Transfer 4 3 5 6 7 9 8 10 2 11 12 10 9 4 1 7 5 6 1 2 8 J1238 3 13 14 15 # Description # 1 2 3 4 5 6 7 8 Roller Bushing Washer Capscrew Right Hand Hose Guide Hose Guide Spacer Hose Spacer Plastic Bushing Left Hand Hose Guide 9 10 11 12 13 14 15 Description Lock Nut Chain Roller Washer Hardened Bushing Chain and Hose Roller Chain and Hose Roller Shaft Grease Fitting Grease Fitting Cover Fig. 6-86: Chain and Hose Guide Assembly 37. (Ref. Fig.
Boom and Transfer 1 10 2 5 3 9 8 4 6 7 MV0100 # 1 2 3 4 5 6 Description Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Hydraulic Manifold Block Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube # 7 8 9 10 Description Nut Lockwasher Clamp Cushion Clamp Fig. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections 38. (Ref. Fig. 6-87) Remove middle (rear) boom section hoses as follows: a.
Boom and Transfer a. Remove two (2) each nuts (Item 7), lockwashers (Item 8), and tube clamps (Item 9) securing each set of auxiliary and carriage tilt hydraulic tubes (Items 5 and 6) to bottom of middle (rear) boom section. b. Loosen screw on cushion clamps (Item 10). Slide cushion clamps out of channel and remove hydraulic tubes from boom section. 1 J1237 2 3 4 # 1 2 Description Button-Head Socket Capscrew Lockwasher # 3 4 Description Shim Side Slide Pad Fig.
Boom and Transfer 2 3 10 9 8 4 1 12 7 6 5 11 MV0110 # 1 2 3 4 5 6 7 Description Outer Boom Section Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Capscrew Nut Lockwasher Clamp # 8 9 10 11 12 Description Cushion Clamp Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Hydraulic Manifold Block Lockwasher Fig. 6-89: Outer Boom Tubes and Hoses 42. (Ref. Fig. 6-89) Remove outer boom hydraulic hoses as follows: a.
Boom and Transfer b. Remove two (2) each nuts (Item 5), lockwashers (Item 6), and clamps (Item 7) securing each set of hydraulic tubes to bottom of outer boom section. c. Loosen screws on cushion clamps (Item 8). Slide cushion clamps out of channel and remove hydraulic tubes. d. Remove two (2) capscrews (Item 4) and lockwashers (Item 12) securing each manifold block to the outer boom. Remove the manifold blocks. Note: If damaged, further disassembly of chain assemblies may become necessary.
Boom and Transfer 14 15 16 4 2 3 10 9 13 1 12 8 11 7 6 5 MV0120 # 1 2 3 4 5 6 7 8 9 Description Outer Boom Section Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Lock Nut Nut Lockwasher Clamp Cushion Clamp Auxiliary Hydraulic Tube # 10 11 12 13 14 15 16 Description Carriage Tilt Hydraulic Tube Hydraulic Manifold Block Lockwasher Capscrew Left Clamp Half Plastic Cushion Right Clamp Half Fig. 6-90: Outer Boom Tube and Hose Assembly 2. (Ref. Fig.
Boom and Transfer d. Install a cushion clamp (Item 8) on each hydraulic tube as follows: 1). Install plastic cushion (Item 15) on hydraulic tube. 2). Slide left cushion clamp half (Item 14) to correct position in channel on bottom of outer boom (Item 1). 3). Position tube with cushion next to left cushion half and slide right cushion half (Item 16) into channel. 4). Secure two halves of clamp together with lock nut (Item 4). Tighten lock nut until snug. e.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, make sure the cylinder is properly supported until it is completely installed. b. Secure cylinder to outer boom section with hardware as follows. Use two (2) each nuts (Item 14), flatwashers (Item 7), and capscrews (Item 6) to secure extension cylinder base mount (Item 11) to rear of outer boom section. Install as many shims (Items 12 and 13) as necessary before installing the nuts. Torque nuts to 680 ft-lbs. c.
Boom and Transfer b. Install chain adjustment block (Item 5) on other end of lower chain with shoulder bolt (Item 6) and lock nut (Item 8). Torque lock nut to 108 in-lbs. c. Position chain adjustment block tight against back of anchor base (Item 4) at bottom of outer boom section as shown in View A. d. Thread chain adjustment rod (Item 3) into block until specified measurement is obtained. e. Push adjustment rod fully into anchor base. f. Lay chain flat inside of outer boom section.
Boom and Transfer 1 10 2 5 3 9 8 11 6 7 12 13 MV0140 # 1 2 3 4 5 6 Description Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Capscrew Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube # 7 8 9 10 11 12 Description Nut Lockwasher Clamp Cushion Clamp Hydraulic Manifold Block Lockwasher Fig. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections 9. (Ref. Fig. 6-94) Install hydraulic tubes and hoses on middle (rear) boom section as follows: a.
Boom and Transfer 4 3 5 6 7 9 8 10 2 11 12 10 9 4 7 5 1 6 1 2 8 3 13 15 # Description # 1 2 3 4 5 6 7 8 Roller Bushing Washer Capscrew Right Hand Hose Guide Hose Guide Spacer Hose Spacer Plastic Bushing Left Hand Hose Guide 9 10 11 12 13 14 15 J1238 14 Description Lock Nut Chain Roller Washer Hardened Bushing Chain and Hose Roller Chain and Hose Roller Shaft Grease Fitting Grease Fitting Cover Fig. 6-95: Chain and Hose Guide Assembly 10. (Ref. Fig.
Boom and Transfer 11. Turn middle (rear) boom section over to upright position on work stands. 3.13" (3-1/8") 7 3 4 View A 8 7 3 1 4 6 J1250 5 2 # 1 2 3 4 Description Button-Head Socket Capscrew Lockwasher Chain Adjustment Rod Anchor Base # 5 6 7 8 Description Chain Adjustment Block Shoulder Bolt Lock Nut Chain Fig. 6-96: Installation of Lower Chain – Middle (Rear) Boom Section 12. Install lower chain on bottom of middle (rear) boom section as follows: a.
Boom and Transfer 1 2 3 4 5 3 2 1 6 7 8 J1254 9 10 # 1 2 3 4 5 Description Chain Guide Washer Chain Roller Bushing Hardened Bushing Chain Roller Grease Fitting Cover # 6 7 8 9 10 Description Grease Fitting Lock Pin Lockwasher Capscrew Chain Roller Pin Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section 13. (Ref. Fig. 6-97) Install upper chain roller assembly on middle (rear) boom section as follows: a. Install two (2) chain roller bushings (Item 2) into chain roller (Item 4).
Boom and Transfer 7 8 1 9 10 2 7 7 8 9 4 10 5 7 6 3 1 2 5 6 J1243 4 3 # 1 2 3 4 5 Description Grease Fitting Cover Grease Fitting Chain Roller Pin Lock Pin Lockwasher # 6 7 8 9 10 Description Capscrew Chain Guide Washer Bushing Chain Roller Chain Roller Bushing Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section 17. (Ref. Fig. 6-98) Install chain roller assemblies on middle (forward) boom section as follows: a.
Boom and Transfer 11 12 14 15 8 7 16 1 17 13 2 6 5 12 4 11 10 3 7 9 8 MV0150 # 1 2 3 4 5 6 7 8 9 Description Front Bottom Slide Pad Shim Pad Retainer Flatwasher Lockwasher Capscrew Side Slide Pad Shim Button-Head Socket Capscrew # 10 11 12 13 14 15 16 17 Description Lockwasher Button-Head Socket Capscrew Lockwasher Middle (Forward) Boom Assy Button-Head Socket Capscrew Lockwasher Shim Rear Bottom Slide Pad Fig.
Boom and Transfer a. Install two (2) bottom slide pads (Item 1) and shims (Item 2) to front of boom section with four (4) each lockwashers (Item 10) and capscrews (Item 9) according to drawing specifications. Torque capscrews to 180 in-lbs. b. Install two (2) pad retainers (Item 3) on front of boom section with flatwashers (Item 4), lockwashers, (Item 5) and capscrews (Item 6). Torque capscrews to 200 ft-lbs. c.
Boom and Transfer c. Install auxiliary and front carriage tilt hydraulic tubes on channels (Item 6) in inside of inner boom section with cushion clamps (Item 3) as described in Substep d under Step 2 on page 6-68. 24. Install front carriage tilt cylinder in inner boom (See page 6-20). 25. Install auxiliary hydraulic quick disconnects 3 4 3 4 2 J1247 1 # 1 2 Description # Lower Slide Pad Side Slide Pad 3 4 Description Lockwasher Button-Head Socket Capscrew Fig.
Boom and Transfer 27. (Ref. Fig. 6-102) Install grease hose assembly on rear of inner boom section as follows: a. Install two (2) elbows (Item 3) on inside of inner boom section making sure elbows are in correct position for grease hose to be connected. b. Install two (2) bulkhead adapters (Item 4) on rear of inner boom section (Item 2). c. Connect two (2) grease hoses (Item 1) to bulkhead adapters. Torque swivel nuts on grease hoses to 130–150 in-lbs. d. Connect grease hoses to elbows.
Boom and Transfer d. Lay upper chain flat on top of inner boom section. 30. Lift inner boom section and slide it into middle (front) boom section. 1 2 # 1 2 J1245 3 4 Description # Button-Head Socket Capscrew Lockwasher Description 3 4 Shim Front Upper Slide Pad Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section 31. (Ref. Fig.
Boom and Transfer # 1 2 3 4 5 Description # Upper Chains Lock Nut Upper Chain Anchor Capscrew Lockwasher 6 7 8 9 10 Description Chain Anchor Rod Hose Reel Capscrew Lockwasher Hose Reel Pin Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom 33. (Ref. Fig. 6-105) Install upper chains and hose reel assembly on middle (forward) boom section as follows: a. Install two (2) hose reels (Item 7) to rear of boom section with hose reel pins (Item 10).
Boom and Transfer 35. (Ref. Fig. 6-106) Install slide pad retainers (Item 3) with flatwashers (Item 4), lockwashers (Item 5), and capscrews (Item 6). Torque capscrews to 200 ft-lbs.
Boom and Transfer 1 2 3 J1255 4 # 1 2 Description # Lock Nut Lower Chain 3 4 Description Shoulder Bolt Rear Chain Anchor Fig. 6-108: Lower Chain Installation – Inner Boom Section 39. Install lower chain (Item 2) from inside middle (rear) boom section to rear chain anchor (Item 4) at rear of inner boom section with shoulder bolt (Item 3) and lock nut (Item 1). Torque lock nut to 108 in-lbs.
Boom and Transfer 4 3 2 60 80 1 40 5 20 -20 0 # 1 2 3 J1225 6 Description # Chain Anchor Jam Nut Lockwasher Description 4 5 6 Nut Outer Boom Section Upper Chain Roller Assembly Fig. 6-110: Upper Chains – Middle (Rear) to Outer Boom Sections 41. (Ref. Fig. 6-110) Secure upper chain to outer boom section as follows: a. Bring upper chain lying on top of middle (front) boom section up and around the upper chain roller assembly (Item 6) on the middle (rear) boom section (Item 5). b.
Boom and Transfer # 1 2 3 Description # Chain Adjustment Anchor Jam Nut Lockwasher 4 5 6 Description Nut Upper Chain Roller Assembly Middle (Forward) Boom Section Fig. 6-111: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections 42. (Ref. Fig. 6-111) Secure upper chain to middle (rear) boom section as follows: a. Bring upper chain lying on top of inner boom section up and around the upper chain roller assembly (Item 5) on the middle (forward) boom section (Item 6). b.
20 40 60 80 Boom and Transfer -20 0 4 1 # 1 2 Description Setscrew J1253 3 2 # 3 4 Description Cylinder Rod Boss Boom Extension Cylinder Fig. 6-113: Securing Boom Extension Cylinder 44. (Ref. Fig. 6-113) Secure extension 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).
Boom and Transfer 4 5 6 7 8 3 13 14 15 12 1 11 10 2 16 17 9 20 40 60 80 J1227 18 -20 0 1 and 2 7 and 8 19 10 and 11 14 and 15 J1241 20 Side View # 1 2 3 4 5 6 7 8 9 10 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Middle (Front) Boom Section Hose Guard Lockwasher Capscrew Auxiliary Tilt Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Auxiliary Hydraulic Tube # 11 12 13 14 15 16 17 18 19 20 Description Carriage Tilt Hydraulic Tube Half Clamp
Boom and Transfer a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from inside the middle (rear) boom section (Item 9) up and around the two (2) hose reels (Item 19) at the rear of the middle (forward) boom section (Item 3). b. Connect the hydraulic hoses to the hydraulic tubes (Items 1 and 2) at the rear of the inner boom section. Torque swivel nut on hydraulic hoses to 50–58 ft-lbs. c.
Boom and Transfer The extend chains will be visible for inspection with the machine in this state. While doing the chain inspection, check all 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.
Boom and Transfer Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often. Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, consult the local distributor or the JLG Service Department at 1-877-554-5438 or 1-717-485-6657, for guidance.
Boom and Transfer 7. Make sure the service ovals are lined up on the side rear of boom. If not, adjust forward middle boom section first. Tighten the extend chain to move the forward middle boom forward, or tighten the retract chain to move the forward middle boom towards the rear. recheck chain tension. 8. Then adjust the inner boom, retract the boom all the way and check the clearance at the gooseneck. Adjust as needed Note: If boom is too far to the rear, the gooseneck can hit the slide pad retainers.
Boom and Transfer 11. Install new hose sheaves with existing sheave retaining pins. Pull hoses up around sheave and reattach to tubes. Avoid crossing or twisting hoses when reconnecting and tightening. Note: There is a change in the hose routing. Please follow the instructions below. For units with 2nd aux., connect the inner hose on the hose sheave to the upper inner tube, connect the middle hose on the hose sheave to the lower 2nd aux.
Boom and Transfer Extension Cylinder 4-Section Boom 20 40 60 80 Description 0 J1137 -20 Fig. 6-116: 4-Section Boom Extension 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.
Boom and Transfer Removal, Extension Cylinder 14 12 13 20 40 60 80 11 -20 0 10 6 7 4 8 9 5 2 3 1 15 MV0160 # Description 1 Rod Nut 2 Socket Setscrew 3 Extension Cylinder Rod Boss 4 Middle (Rear) Boom Section 5 Boom Extension Cylinder 6 Outer Boom Section 7 Capscrew 8 Flatwasher # 9 10 11 12 13 14 15 Description Elbow Hydraulic Tube Extension Cylinder Base Mount Shim Shim Nut Lead Ball Fig. 6-117: 4-Section Boom Extension Cylinder Installation (Ref. Fig.
Boom and Transfer DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. To avoid personal and/or equipment damage, support the hydraulic cylinder before removing any additional hardware securing cylinder to the boom. Use suitable blocking and lifting devices when removing heavy machine components. 4. Loosen and remove two (2) hydraulic tubes (Item 10) from elbows (Item 9) on boom extension cylinder (Item 5).
Boom and Transfer Overhaul, Extension Cylinder 7 8 9 6 4 5 3 4 12 2 13 1 11 14 MV0640 10 # 1 2 3 4 5 6 7 Description Bolt Flatwasher Extension Cylinder Base Mount Hollow Hex O-ring Plug Counterbalance Valve Cartridge Counterbalance Valve Cartridge 90° O-ring Elbow # 8 9 10 11 12 13 14 Description Cylinder Barrel Rod Nut Piston Rod Bearing Head Capscrew Rod Bearing Head Tube Fig. 6-118: 4-Section Boom Extension Cylinder Assembly (Ref. Fig.
Boom and Transfer a. Place socket wrench over counterbalance valve cartridge. Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b. Carefully and slowly, turn cartridge out of manifold block to release pressure in cylinder. 4. Remove the counterbalance valve cartridges. 5. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 6. Remove one (1) setscrew (Item 12) securing rod bearing head (Item 11) to cylinder barrel. 7.
Boom and Transfer 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 rod bearing head (Item 11), tube (Item 14) 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 1460 ft-lbs. 24. Apply removable (blue) thread locking adhesive to threads on (1) set screw (Item 12).
Boom and Transfer Boom Extension Proximity Switch Description J1146 Proximity Switch 20 40 60 80 Fig. 6-119: Boom Extension Proximity Switch 0 (Ref. Fig. 6-119) The boom extension proximity switch is located on the left side of the outer boom section on machines with a 4-section boom. The boom extend/lockout circuit is designed to increase stability of the machine by limiting how far the boom can be extended with the outriggers up.
Boom and Transfer Outer Boom Section Middle Rear) Boom Section Magnetic Flux Lines Proximity Switch J1259 Oscillator Fig. 6-120: Boom Extension Proximity Switch Operation (Ref. Fig. 6-120) The switch operates by sending out a constant, high frequency magnetic field a short distance from the oscillator end of the switch. Eddy currents are produced in metal when the magnetic flux lines pass through it. These eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop.
Boom and Transfer (Ref. Fig. 6-121) The following procedure describes removal of the boom extension proximity switch. 1. Disconnect wire harness (Item 4) at boom extension proximity switch (Item 2). 2. Place a piece of masking tape around proximity switch body at the outer jam nut (Item 3) (this will serve as a guide during reinstallation). 3. Remove inner jam nut (Item 1) and proximity switch. Reinstall inner jam nut on proximity switch for safekeeping. Installation Boom Extension Proximity Switch (Ref.
Boom and Transfer 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. 6-122. 3. If boom extension proximity light does not illuminate when boom is extended to specified distance (approximately 21 feet with tilting tower or 25 feet with standard carriage), adjust proximity switch to slightly reduce the gap. Do not exceed gap tolerances specified in Fig. 6-122.
Boom and Transfer The transfer carriage, along with the transfer cylinder, make up the “TransAction” feature. This feature makes it possible to land materials from a parked, level machine by driving the boom load forward at any height. The operator can then retract the boom and forks by moving the entire upper assembly rearward without driving the machine on uneven terrain. Removal Transfer Carriage The following steps are required to remove the transfer carriage. 1.
Boom and Transfer Proximity Switch Connection Wire J1149 Wiring Harness Fig. 6-125: Boom Elevation Proximity Switch Wiring 6. (Ref. Fig. 6-125) Remove boom elevation proximity switch as follows: a. Disconnect connection wire from boom proximity switch. b. Disconnect connection wire from wiring harness. 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.
Boom and Transfer b. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwashers (Item 2) securing boom cover (Item 4) to boom. Remove boom cover. 4 3 2 1 3 2 1 5 4 3 2 1 6 8 9 10 J1147 7 20 40 60 80 # 0 1 2 3 4 5 Description JClamp Flatwasher Lockwasher Nut Proximity Switch Wiring Harness # Description 6 7 8 9 10 Proximity Switch Connection Wire Proximity Mounting Plate Boom Extension Proximity Switch Lockwasher Capscrew Fig. 6-127: Boom Extension Proximity Switch Wiring 8.
Boom and Transfer 1 2 3 # 1 2 Description Hydraulic Hoses Hose Cover J1142 4 # 3 4 Description Lockwasher Capscrew Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage 9. (Ref. Fig. 6-128) Remove four (4) each capscrews (Item 4) and lockwashers (Item 3) 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.
Boom and Transfer 8 9 10 11 12 6 7 5 4 40 60 80 3 20 1 0 J1153 -20 2 # 1 2 3 4 5 6 Description Nut Lockwasher Capscrew Front Slide Block Transfer Carriage Setscrew # 7 8 9 10 11 12 Description Spindle Nut Spacer Washer Thrust Washer Spindle Roller Bushing Transfer Roller Fig. 6-129: Transfer Carriage with Boom Installation 12. (Ref. Fig. 6-129) The following steps are necessary if the boom and transfer carriage are to be removed as an assembly. a.
Boom and Transfer e. Slowly lift the boom and transfer carriage assembly up and away from the machine. Place the assembly on support blocks on a firm level surface. 8 9 10 11 12 6 7 5 4 J1154 3 1 2 # 1 2 3 4 5 6 Description Nut Lockwasher Capscrew Front Slide Block Transfer Carriage Setscrew # 7 8 9 10 11 12 Description Spindle Nut Spacer Washer Thrust Washer Spindle Roller Bushing Transfer Roller Fig. 6-130: Transfer Carriage Installation 13.
Boom and Transfer g. (Ref. Fig. 6-130) Remove the two (2) spindle nuts. Remove spacer washer (Item 8), thrust washer (Item 9), spindle (Item 10), roller bushing (Item 11), and transfer roller (Item 12) from each side of the rear transfer carriage mount. Note: The quantity of spacer washers used with each machine may vary. h. Slowly lift the transfer carriage assembly up and away from the machine. Place the assembly on support blocks on a firm level surface.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the transfer carriage assembly when lifting and reinstalling it back on the machine. Make sure that the 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) each transfer rollers (Item 12), roller bushings (Item 11), spindles (Item 10), thrust washers (Item 9), spacer washers (Item 8), and spindle nuts (Item 7).
Boom and Transfer d. Secure the wiring harness and switch connection wire to the boom with six (6) each (five on top of the boom and one inside of the back left side of the boom) nuts (Item 4), lockwashers, (Item 3), flatwashers (Item 2), and J-clamps (Item 1). Tighten nuts until snug. e. Secure the wire harness to the hydraulic tubes and hoses with wire tires. 10. (Ref. Fig. 6-126) Install the boom cover on models with 3-section (see Step a) or 4-section booms (see Step b). a.
Boom and Transfer 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 capscrew (Item 1) and lockwasher (Item 3) securing the two (2) lock pins (Item 4) to transfer carriage. CAUTION: To avoid personal and/or equipment damage, support the boom and transfer carriage before removing the transfer roller assembly.
Boom and Transfer c. Measure the gap between the lip of the transfer roller and the inner edge of the rail. If this measurement is not 1/16", remove the transfer roller assembly and install or remove shims until the required measurement is reached. 11. Secure front transfer roller assembly to transfer carriage by tightening capscrew (Item 1) to 55 ft-lbs. 12. Remove two (2) grease fitting cover caps (Item 6) and lubricate grease fittings (Item 5) with EP lithium based grease. Scraper Plate (Ref. Fig.
Boom and Transfer Rear Mount Rollers, Bushings, and Spacer Washers 16 15 14 13 12 11 10 4 5 6 1 7 8 2 J1144 9 3 # 1 2 3 4 5 6 7 8 Description Grease Fitting Cover Grease Fitting Spindle Nut Setscrew Spacer Washer Thrust Washer Spindle Rear Roller Bushing # 9 10 11 12 13 14 15 16 Description Rear Transfer Roller Rear Slide Block Slide Block Shim Lockwasher Capscrew Boom Pivot Bushing Grease Fitting Cover Grease Fitting Fig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims (Ref. Fig.
Boom and Transfer 8. Secure spindle to transfer carriage with spindle nut. Distance Between Rails Transfer Roller 1/16" Transfer Carriage Nut Roller Spindle Spacer Washer(s) Rail J1143 Thrust Washer Fig. 6-135: Spacer Washers for Rear Transfer Rollers 9. (Ref. Fig. 6-135) Check to see if the number of spacer washers installed is correct. a. Locate the point that is the shortest distance between the two rails (usually near the center of the rails). b.
Boom and Transfer 4. Reinstall boom and shims as described earlier in this section. 5. Remove two (2) grease fitting cover caps (Item 15) and lubricate grease fittings (Item 16) with EP lithium based grease. Rear Slide Block and Shims (Ref. Fig. 6-134) The following steps are required to replace worn rear slide blocks. 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.
Boom and Transfer 31200079 6-135
Boom and Transfer 6-136 31200079
Section 7 — Frame Tilt and Oscillation Table of Contents Frame Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 7-1: Frame Tilt System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Fig. 7-2: Frame Tilt Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fig. 7-3: Frame Tilt Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Fig. 7-4: Frame Tilt Control Valve (Exploded View) . . . . . . . . .
31200079 iii
Section 7 — Frame Tilt and Oscillation Frame Tilt System General Description Multi-Spool Control Valve Frame Tilt Control Valve G1020 Frame Tilt Cylinder Fig. 7-1: Frame Tilt System Components (Ref. Fig. 7-1) The frame tilt system allows the machine to be levelled laterally (side-to-side) up to 10°, left or right. The lateral angle of the machine, relative to level ground, is shown on the frame level indicator.
Frame Tilt and Oscillation The frame tilt system works in combination with the rear oscillation lock system. The frame tilt system is explained here. See “Rear Oscillation Lock System” on page 7-17 for detailed information concerning that system. Control Centered With the engine on and the boom below 40° elevation, the frame tilt system is enabled.
Frame Tilt and Oscillation frame tilt lockout valve is a component of the rear oscillation lock system and its function is explained under “Rear Oscillation Lock System” on page 7-17. Frame Tilt Control Valve Description Frame Tilt Control Lever Outrigger Control Valve Safety Lock Ring H1046 Frame Tilt Control Valve Fig. 7-2: Frame Tilt Control Valve The frame tilt control lever is located immediately to the right of the driver’s seat on the control panel.
Frame Tilt and Oscillation Removal Frame Tilt Control Valve 8 7 6 5 4 1 2 3 9 p 1 2 3 4 5 Flatwasher Screw Control Panel 1/4” Hoses Frame Tilt Control Valve p 6 7 8 9 MV0650 Starwasher Capscrew Fittings 3/8” Hoses Fig. 7-3: Frame Tilt Control Valve Installation (Ref. Fig. 7-3) The following procedure describes removal of the frame tilt control valve. 1. Follow preparation procedures as outlined in Section 3 of this manual. 2.
Frame Tilt and Oscillation Installation Frame Tilt Control Valve 1. (Ref. Fig. 7-3) Insert frame tilt control valve (Item 5) into control panel (Item 3) with plugged ports on front of valve body facing forward. 2. Install two (6) starwashers (Item 6) and capscrews (Item 7) to secure valve to control panel. 3. Install two (2) fittings (Item 8) into rear of valve body and position them as previously noted. Torque fittings to 300–340 in-lbs (25–29 ft-lbs). 4.
Frame Tilt and Oscillation Overhaul Frame Tilt Control Valve 20 21 22 5 6 23 24 7 25 10 9 26 8 27 13 12 11 1 2 28 3 4 14 15 16 31 17 19 29 30 32 33 18 MV0690 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Capscrew Washer Body Plug Knob Lever Rubber Boot Cam Metric Jam Nut Capscrew Pivot Pin CirClip Flange Guide Assy Spring Pack Spring O-Ring # 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Description O-Ring Ported Guide Knob Lever Assy Rubber Boot Cam Pin Pivot Pin CirCl
Frame Tilt and Oscillation (Ref. Fig. 7-4) The following procedures are for the disassembly, cleaning, and assembly of the frame tilt control valve. Follow the guidelines for cleanliness as stated in Section 3 of this manual. Cleaning and Inspection, Frame Tilt Control Valve 1. Thoroughly clean all parts, except for the lever assembly, in clean solvent and dry with compressed air. Do not immerse the lever assembly in solvent. Solvent can become trapped in the assembly and will be difficult to remove. 2.
Frame Tilt and Oscillation Frame Tilt Cylinder Description G1020 Frame Tilt Cylinder Fig. 7-5: Frame Tilt Cylinder (Ref. Fig. 7-5) The frame tilt cylinder is located near the front of the machine, on the right side. The cylinder is mounted vertically with the base end secured to the frame and the rod end mounted 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.
Frame Tilt and Oscillation Removal Frame Tilt Cylinder 1 2 3 12 11 15 14 16 17 18 13 2 1 9 G1022 19 View B # 1 2 3 4 5 6 7 8 9 10 Description Grease Fitting Cover Grease Fitting Frame Tilt Cylinder Capscrew Mounting Block Lockwasher Nut Shim Hydraulic Hose Mounting Block w/Lock Pin Hole # Description 11 12 13 14 15 16 17 18 19 Lock Pin Lockwasher Lower Pivot Pin Capscrew Upper Pivot Pin Capscrew Lockwasher Nut Lower Cylinder Bushing Fig. 7-6: Frame Tilt Cylinder Installation (Ref. Fig.
Frame Tilt and Oscillation 7. Place a sling around the cylinder and attach the sling to suitable lifting equipment. Make sure sling and lifting equipment have sufficient capacity. The frame tilt cylinder weighs approximately 200 pounds. Using the lifting equipment, support the weight of the cylinder. 8. Remove upper pivot pin. 9. Remove lower pivot pin and shims (Item 8) (early production models only). 10. Move cylinder out and up from the machine. 11.
Frame Tilt and Oscillation 9. Lubricate upper and lower pivots with grease. 10. Start engine 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.
Frame Tilt and Oscillation Overhaul Frame Tilt Cylinder 3 6 5 4 8 3 10 9 2 4 1 1 11 7 12 1 MV0300 # 1 2 3 4 5 6 7 Description Bushing Barrel Counterbalance Valve Cartridge O-Ring Plug Orifice Fitting, O-Ring Set Screw # 8 9 10 11 12 Description Tube Piston Rod Nut Rod Head Fig.
Frame Tilt and Oscillation Disassembly, Frame Tilt Cylinder (Ref. Fig. 7-7) The following steps are required to disassemble the frame tilt cylinder. 1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in cylinder will drain out during disassembly. Place a suitable pan or tray under the cylinder. 2. Remove counterbalance valve (Item 3). WARNING: The counterbalance valve cartridges trap hydraulic pressure in the frame tilt cylinder.
Frame Tilt and Oscillation Bushing Replacement 1. Fig. 7-7 shows both types of rod end configurations and bushing locations. Remove pivot bushings (Item 1) using a bushing driver and hammer or press. Drive one bushing all the way through to remove other bushing. 2. Install new bushings so they are flush with outer edge boss to 0.02" below. For machines with lower (rod end) pivot bushing installed in front axle: Install bushing so that it is centered in axle boss. Assembly, Frame Tilt Cylinder 1. (Ref.
Frame Tilt and Oscillation Counterbalance Valve Cartridge Counterbalance Valve Cartridge Manifold Block K1025 Counterbalance Valve Cartridge Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder WARNING: The counterbalance valve cartridges trap hydraulic pressure in the frame tilt 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.
Frame Tilt and Oscillation Frame Level Indicator Description 10 5 0 5 10 H1004 Fig. 7-9: Frame Level Indicator (Ref. Fig. 7-9) The Frame Level Indicator shows the lateral (side-to-side) angle of the frame relative to level ground. Indicator range is from 0° to 10° left or right, in increments of one degree. When the ball is centered (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.
Frame Tilt and Oscillation 3. Adjust frame level indicator so ball is centered over 0° mark. Tighten indicator screws. Rear Oscillation Lock System General Description, Models with Control Manifold Hydraulics The Rear Oscillation Lock System provides safety and stability by preventing the frame from rotating on the rear axle. The rear oscillation lock will be operational when any or all of the following conditions apply: • When the boom angle exceeds 40°. • When the service brakes are applied.
Frame Tilt and Oscillation Theory of Operation and Circuit Logic BOOM ANGLE GREATER THAN 40 - OPEN BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE A S2 86 30 85 87A 87 +12 VOLTS FROM FUSE PANEL TO ENABLE FOOT SWITCH AND TO DISABLE TRANSMISSION BOOM ANGLE GREATER THAN 20 - OPEN BOOM ANGLE LESS THAN 20 - CLOSED SV2 B BOOM OVER 40° RELAY 2-WAY SOLENOID VALVE ON REAR AXLE STABILIZER VALVE ON REAR STABILIZER CYLINDER A SV3 B SOLENOID VALVE
Frame Tilt and Oscillation Boom Positioned Above 40° BOOM ANGLE GREATER THAN 40 - OPEN BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (NOT ENERGIZED) A SV2 B S2 86 30 NOT ENERGIZED 85 87A 87 +12 VOLTS FROM FUSE PANEL BOOM OVER 40° RELAY TO ENABLE FOOT SWITCH AND TO DISABLE TRANSMISSION BOOM ANGLE GREATER THAN 20 - OPEN BOOM ANGLE LESS THAN 20 - CLOSED 2-WAY SOLENOID VALVE ON REAR AXLE STABILIZER VALVE ON REAR STABILIZER CYLINDER (NOT ENE
Frame Tilt and Oscillation Boom Positioned Above 20° Below 40° BOOM ANGLE GREATER THAN 40 - OPEN BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) A S2 86 30 ENERGIZED 85 87A 87 +12 VOLTS FROM FUSE PANEL BOOM OVER 40° RELAY TO ENABLE FOOT SWITCH AND TO DISABLE TRANSMISSION BOOM ANGLE GREATER THAN 20 - OPEN BOOM ANGLE LESS THAN 20 - CLOSED S1 86 30 NOT ENERGIZED 85 87A 87 BOOM OVER 20° RELAY SV2 B 2-WAY SOLENOID VALVE ON REAR
Frame Tilt and Oscillation Boom Positioned Above 20° Below 40° With the Service Brake Applied BOOM ANGLE GREATER THAN 40 - OPEN BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) A S2 86 30 ENERGIZED 85 87A 87 +12 VOLTS FROM FUSE PANEL TO ENABLE FOOT SWITCH AND TO DISABLE TRANSMISSION BOOM ANGLE GREATER THAN 20 - OPEN BOOM ANGLE LESS THAN 20 - CLOSED S1 86 30 NOT ENERGIZED 85 87A 87 SV2 B BOOM OVER 40° RELAY BOOM OVER 20° RE
Frame Tilt and Oscillation Boom Positioned Below 20° With the Service Brake Applied BOOM ANGLE GREATER THAN 40 - OPEN BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) A S2 86 30 ENERGIZED 85 87A 87 +12 VOLTS FROM FUSE PANEL TO ENABLE FOOT SWITCH AND TO DISABLE TRANSMISSION BOOM ANGLE GREATER THAN 20 - OPEN BOOM ANGLE LESS THAN 20 - CLOSED S1 86 30 ENERGIZED 85 87A 87 SV2 B BOOM OVER 40° RELAY BOOM OVER 20° RELAY TO RESTRI
Frame Tilt and Oscillation Testing Rear Oscillation Lock Circuit Use Table 7-1 for testing the rear oscillation lock circuit. Table 7-1: Rear Oscillation Lock Circuit Test Matrix OPERATING PARAMETERS S1 Proximity Switch S2 Proximity Switch Boom Over 20° Relay Boom Over 40° Relay Rear Osc. Locked Lamp Trans.
Frame Tilt and Oscillation Rear Oscillation Lock Cylinder Description 0 Rear Oscillation Lock Control Block G1023 40 60 80 Rear Oscillation Lock Cylinder 20 -20 Fig. 7-16: Rear Oscillation Lock Cylinder (Ref. Fig. 7-16) The rear oscillation lock cylinder is located near the rear of the machine, on the left side. The cylinder is mounted vertically with the base end secured to the frame and the rod end mounted to the rear axle.
Frame Tilt and Oscillation Removal 19 6 1 2 3 5 21 16 8 2 4 4 18 15 14 13 9 G1025 20 View B # 1 2 3 4 5 6 7 8 9 10 11 Description Nut Lockwasher Upper Pivot Pin Capscrew #6 Hydraulic Hose #8 Hydraulic Hose Capscrew Lock Pin Lower Pivot Pin Lockwasher Nut # 12 13 14 15 16 17 18 19 20 21 Description Mounting Base Grease Fitting Grease Fitting Cover Rear Carriage Tilt Cylinder Check Valve Wiring Harness Grease Fitting Cover Grease Fitting Bushing Pressure Reducing Valve Fig.
Frame Tilt and Oscillation 6. Slowly loosen each check valve (Item 16) on control block (labeled 3.1 and 3.2) to allow residual pressure to escape. After pressure has been released, torque check valves to 50 ft-lbs. 7. Tag and disconnect three (3) hydraulic hoses (Items 5 and 6) at oscillation control block. Cap hoses and fittings. 8. For models with control manifold hydraulics, disconnect wiring harness electrical connection (Item 17) at oscillation control block. 9.
Frame Tilt and Oscillation 9. Start engine and cycle frame tilt 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.
Frame Tilt and Oscillation Overhaul Rear Oscillation Lock Cylinder 5 4 3 2 1 1 6 7 1 MV0310 # 1 2 3 4 Description Bushing Barrel Rod Nut Piston # 5 6 7 8 Description Tube Rod Set screw Head Fig.
Frame Tilt and Oscillation Disassembly, Rear Oscillation Lock Cylinder (Ref. Fig. 7-18) Disassembly procedures for the rear oscillation lock cylinder are as follows: 1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in cylinder will drain out during disassembly. Place a suitable pan or tray under cylinder. 2. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 3. Remove one (1) set screw (Item 7) securing head (Item 8) to barrel (Item 2). 4.
Frame Tilt and Oscillation 2. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic oil and install on head (Item 8). Using a seal driver, install new wiper seal in head. Lubricate wiper seal with hydraulic oil. 3. (Ref. Fig. 7-18) Slide 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.
Frame Tilt and Oscillation Oscillation Control Block Description Rear Oscillation Lock Control Block MV0750 Fig. 7-19: Oscillation Control Block (Ref. Fig. 7-19) The oscillation control block assembly controls the function of the rear oscillation lock 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.
Frame Tilt and Oscillation Removal Oscillation Control Block 1 1 29 2 26 1 9 1 10 5 3 6 7 4 8 # Description # 1 2 3 4 5 #6 Hydraulic Hose #8 Hydraulic Hose Capscrew Lockwasher Check Valve Cartridge 6 7 8 9 10 MV0470 Description Oscillation Control Block O-Ring Rear Oscillation Lock Cylinder Electrical Lead Pressure Reducing Valve Fig. 7-20: Oscillation Control Block Installation Rear Oscillation Lock Cylinder Installed on Machine (Ref. Fig.
Frame Tilt and Oscillation 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. 6. Slowly loosen each check valve cartridge (Item 5) on control block (labeled 3.1 and 3.2) to allow residual pressure to escape.
Frame Tilt and Oscillation Installation Oscillation Control Block Rear Oscillation Lock Cylinder Installed on Machine (Ref. Fig. 7-20) Use the following control block installation procedures when the rear oscillation lock cylinder is installed on the machine. For installation procedures when the cylinder has been removed, see below. 1. Clean mating surfaces of rear oscillation lock cylinder and oscillation control block. 2.
Frame Tilt and Oscillation Overhaul Oscillation Control Block 1 2 4 3 9 19 5 6 7 4 17 7 16 20 18 15 14 13 11 12 8 11 10 9 MV0660 # Description 1 2 3 4 5 6 7 8 9 10 11 Nut Coil Solenoid Valve Seal Kit Counter Balance Valve Cartridge PO Check Valve (PC1 & PC2) Orifice Plug, .
Frame Tilt and Oscillation Disassembly, Oscillation Control Block Check Valve 1. Note position of hydraulic fittings installed in block body then remove fittings. Pressure Reducing Cartridge 2. Remove pressure reducing cartridge (Item 15) and two (2) check valve cartridges (Item 13). 3. Remove two (2) pilot pistons (Item 14). Solenoid Valve 4. Remove the one (1) SAE #2 plugs (Item 18), three (3) SAE #4 plugs (Item 9), two (2) SAE #6 plug (Item 4), and SAE #10 plug (Item 10). 5.
Frame Tilt and Oscillation Solenoid Valve 9. Install two (2) backup rings and O-ring on each pilot piston (Item 14) so O-ring is between backup rings. (Ref. Fig. 7-21). 10. Lubricate backup rings and O-ring on each pilot piston and install pistons in block body. Tapered end of pistons must face out as shown in Fig. 7-21. 11. Install large O-ring , O-ring , and backup ring on each check valve cartridge (Item 13). 12. Lubricate O-rings and backup ring on each check valve cartridge (Item 13).
Frame Tilt and Oscillation Boom Transfer Carriage/Boom Cradle Magnetic Flux Lines Proximity Switch J1108 Oscillator Fig. 7-23: Boom Elevation Proximity Switch Operation (Ref. Fig. 7-23) The switch operates by sending out a constant, high frequency magnetic field a short distance from the oscillator end of the switch. Eddy currents are produced in metal when the magnetic flux lines pass through it. These eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop.
Frame Tilt and Oscillation 3. Remove inner jam nut (Item 2) and proximity switch form transfer carriage/boom cradle (Item 1). Re-install inner jam nut on proximity switch for safekeeping. Installation Boom Elevation Proximity Switch 1. Position outer jam nut (Item 4) on switch body (Item 3) at previously marked position. 2. Install boom proximity switch in transfer carriage/boom cradle (Item 1). Install inner jam nut (Item 2). Check gap between end of proximity switch and boom. See Fig. 7-25. 3.
Frame Tilt and Oscillation 7-40 31200079
Section 8 — Transmission Table of Contents Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Transmission Specifications . . . . . . . . . . . . . .
Section 8 — Transmission Transmission Assembly Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
Transmission The ZF 4 WG-98 TC Transmission used in this vehicle is a four-speed configuration. The “intermediate drop” designation refers to the relative top-to-bottom length of the transmission case, chosen for its compatibility with vehicle chassis and operating requirements. Intermediate drop does not refer to an operational rpm shift or drop. Transmission Operation The transmission is mounted to the frame by front and rear mounting brackets and rubber isolator pads.
Transmission 1 MV0180 Fig. 8-2: Transmission Serial Number Plate Location Transmission Specifications Transmission General Specification General transmission specifications are found in Section 2, “General Information and Specifications.” Transmission fluid information is found in Section 3-3, “ZF Transmission Oil Specifications.”. Transmission Performance Specification Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable.
Transmission Transmission Maintenance WARNING: To help avoid severe burns, DO NOT attempt this procedure when the engine, cooling, and hydraulic systems are hot. Wait until they have cooled before proceeding. • Follow the manufacturer’s instructions to avoid health hazards when using solvents and caustic cleaners. • Exercise extreme care when using a steam cleaner to help avoid burns. IMPORTANT: These instructions cover only the routine maintenance of the transmission.
Transmission • At ten hour intervals, check the transmission oil level. Refer to the appropriate operators & safety manual. • When the vehicle completes its first 50 hours of use, change the transmission filter. Change the filter only; DO NOT change the transmission oil at the first 50 hour maintenance level. Refer to the appropriate operators & safety manual. • At 1,000 hour intervals, change the transmission oil and filter. Refer to the appropriate operators & safety manual.
Transmission Important:To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate parts manual for ordering information. Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.
Transmission 1 MV0190 Fig. 8-5: Disconnect the Battery Negative (-) Cable 7. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding. 8. Place a suitable receptacle under the transmission drain plug. Remove the transmission 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.
Transmission 13. Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors. 14. Remove the capscrew securing the black wire to the transmission housing, and disconnect the wire. DO NOT reinstall the capscrew at this time. 15. Remove the capscrew securing the clamp and wiring harness to the transmission housing, and move the wiring harness safely out of the way. DO NOT reinstall the capscrew at this time. 16.
Transmission WARNING: Risk of personal injury. The transmission may move while hoisting it out of the chassis. Carefully move the transmission and adjust the sling as needed. Keep fingers, hands, legs and other body parts clear of the transmission. 25. Carefully remove the transmission from the vehicle. Avoid causing damage to the transmission or surrounding parts. 26.
Transmission 22 20 21 23 MV0260 Fig. 8-9: Transmission External Components The transmission is now ready for inspection and/or further service. Refer to the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135 002) for information on transmission diagnosis, and internal component repair or replacement.
Transmission 2. Attach the transmission to the rear mounting bracket (6) with two capscrews (4) and two lockwashers (5). Torque the capscrews to 148 lb-ft (200 Nm). 3. Install four capscrews (11), four flat washer (12), four lockwashers (13) and four hex nuts (14). Torque the capscrews to 148 lb-ft (200 Nm). 4.
Transmission 19 18 MV0280 Fig. 8-11: Transmission Oil Cooler Hose Connections 9. Install the transmission-to-axle drive shafts. 10. Clean the transmission oil filter mounting surface. 11. Apply a thin film of clean Mobil 424 Tractor/Hydraulic Fluid to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm). 12. Transmission oil may be added through the dipstick tube.
Transmission 8. Back flush the transmission oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. Flushing in the direction of normal oil flow does not adequately clean the cooler. If needed, remove the radiator or oil cooler from the machine. IMPORTANT: DO NOT use flushing compounds for cleaning purposes. 9.
Transmission Normal Operation of the transmission is as follows: When the boom is not above 20°, the transmission shifts normally (i.e., the gear selected using the Transmission Shifter is the gear the transmission shifts to). When the boom is above 20° and not above 40°, the transmission is limited to first and second gears. Selecting first gear will put the transmission in first gear and selecting any other gear will put the transmission in second gear.
1 2 3 4 5 6 7 8 9 10 11 12 A B C D A B C D E F A B C D DIRECTION INPUT FORWARD REVERSE NEUTRAL SHIFTER Y5 SHIFTER Y4 SHIFTER Y3 SHIFTER Y6 SHIFTER PWR PLUGGED PLUGGED PLUGGED DIRECTION INPUT FORWARD REVERSE NEUTRAL A RELAY GND FORWARD SGN REVERSE SGN BOOM OVER 40 PLUGGED BOOM OVER 20 PLUGGED PLUGGED PLUGGED IGN POWER D6 D7 D8 D9 85 87a 30 86 87 SHIFTER PWR IGN POWER SHIFT TO 1ST RELAY GND BOOM OVER 40 85 87a 30 86 87 BOOM 21-40 BOOM OVER 20 N/C RELAY GND BOOM OVER 40 86 87 D10 86 87
Transmission Note:Contact the JLG Service Department at 1-877-554-5438 or 1-717-485-6657, if internal transmission repair is required during the warranty period. Detailed transmission service instructions (covering repair, disassembly, reassembly and adjustment information) are provided in the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135 002).
Transmission Transmission Troubleshooting (Continued) Problem 3. Low clutch pressure. 4. Lack of power. 5. Transmission overheating (oil above 248° F [120° C]). 31200079 Cause Remedy 1. Incorrect oil level. 1. Fill transmission to correct level with Universal Tractor Fluid. Refer to the appropriate owners/operators manual. 2. Main pressure valve stuck open. 2. Clean the valve spool and housing. 3. Broken or worn coupling shaft or piston o-rings. 3. Replace coupling and/or o-rings. 4.
Transmission Transmission Troubleshooting (Continued) Problem 6. Grinding or “clunking” noise from transmission. 7. Oil leaking from transmission. 8-18 Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to appropriate owners/operators manual. 2. Transmission filled with incorrect oil. 2. Drain transmission and fill to correct level with Universal Tractor Fluid. Refer to the appropriate owners/operators manual. 3. Incorrect clutch engagement. 3. Refer to Section 9.14.
Section 9 — Axles and Brakes Table of Contents Axle and Drive Shaft Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 31200079
Section 9 — Axles and Brakes Axle and Drive Shaft Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles and drive shafts. The following illustration identifies the components that are referred to throughout this section.
Axles and Brakes Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear.
Axles and Brakes • DO NOT pound, beat or hammer on end yokes and flanges to remove or to install them. Damage to axle components can occur. Remove and install end yokes and flanges by following the recommended procedures in the appropriate Zahnradfabrik (ZF) axle service manual. • DO NOT attempt carrier and differential removal and installation, and differential and pinion disassembly and assembly, without thoroughly understanding the instructions in the appropriate Zahnradfabrik (ZF) publications.
Axles and Brakes from the machine. NEVER check for leaks using any part of the human body; use a piece of cardboard or wood instead. Wear heavy, protective gloves and eye protection. WARNING: An improperly supported machine can fall, causing death or severe personal injury. Safely raise and adequately support the machine so that it will remain stable and in place before attempting to remove an axle. WARNING: Hot hydraulic fluid can cause severe burns.
Axles and Brakes 8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal. 9. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine. 10. Mark and remove both wheel and tire assemblies from the axle that is being removed.
Axles and Brakes 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure. 4.
Axles and Brakes 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 Zahnradfabrik (ZF) Repair Manual). The axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
Axles and Brakes 4 3 2 7 8 9 6 7 1 11 5 9 10 MV0370 # Description 1 Universal Joint Kit 2 Bearing Strap 3 Strap Bolt 4 Driveshaft 5 Transmission 6 Rear Driveshaft # 7 8 9 10 11 Description Universal Joint Kit Hex Head Capscrew Flat Washer Locknut Front Driveshaft Drive Shaft Maintenance Refer to the appropriate Operator/Safety Manual for information regarding the lubrication of the grease fittings on the drive shafts.
Axles and Brakes Transmission-to-Axle Drive Shaft 1. Level the machine, ground the carriage, place the travel select lever in the (N) NEUTRAL position, engage the parking brake switch 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.”) 3. Open the engine compartment access door. Allow the engine, transmission and hydraulic fluid to cool. 4.
Axles and Brakes MV0380 4. Use a soft, round drive pin with a flat face approximately 1/32" (0,8 mm) smaller than the hole diameter in the yoke to drive on one end of the cross and bearing assembly until the opposite bearing assembly comes out of the yoke. 5. Turn the yoke over and tap on the exposed end of the cross until the opposite bearing assembly comes out of the yoke. 6. Remove the cross from the yoke. 7.
Axles and Brakes 6. Apply grease to grease fitting on slip yoke. Drive Shaft Installation 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 complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information. Transmission-to-Axle Drive Shafts 1. Raise the drive shaft assembly into position.
Axles and Brakes Service Brakes Service Brake Pressure Switch Replacement Mid-Inlet Hydraulics 1 2 3 MV0710 # 1 2 Description Wiring Harness Connector Service Brake Pressure Switch # 3 Description Operators Step Fig. 9-2: Service Brake Pedal Pressure Switch The service brake pedal pressure switch is located behind pressure test port under the cab (see Fig. 9-2). This switch is normally open and is set to close above 250 psi. 1.
Axles and Brakes Accumulator General The accumulator is a 3000 psi piston-type accumulator. It has a oil volume of 116 cubic inches and gas volume of 126 cubic inches, with a bore size of four inches. The pneumatic accumulator is operated by compressed gas. Gas and hydraulic oil occupy the same container. When oil pressure rises, incoming oil compresses the gas. When oil pressure drops, the gas expands, forcing oil out. The gas is separated from the oil by a “free floating” piston (see Fig. 9-3).
Axles and Brakes Precautions WARNING: Never fill an accumulator with oxygen! An explosion could result if oil and oxygen mix under pressure. Always fill an accumulator with dry nitrogen. Nitrogen gas is free of water vapor and oxygen which makes it harmless to parts and is safe to use. CAUTION: Never fill an accumulator with air. When air is compressed, water vapor condenses and can cause corrosion. This may damage seals and ruin the accumulator.
Axles and Brakes 5 1 4 6 2 3 7 8 9 K1018 # 1 2 3 4 5 Description Capscrew Valve Guard Gas Valve Cap Gauge Bleed Valve Accumulator Test Gauge # 6 7 8 9 10 K1018 10 Description Gauge Cap Nitrogen Hose “T” Handle Gas Valve Accumulator Fig. 9-4: Accumulator Charging Pre-charge the accumulator using the following steps (see Fig. 9-4): 1. Follow preparation procedures as outlined in Section 3 and in Section 5 of this manual. 2. Make sure nitrogen supply is shut off. 3.
Axles and Brakes 10. Turn “T” handle all the way down. This will depress (open) the core in the gas valve. 11. Crack open nitrogen bottle valve and slowly fill the accumulator. Close the nitrogen bottle valve when gauge indicates desired pre-charge pressure (400 psi). 12. Let the pre-charge set for 10–15 minutes. This will allow the gas temperature to stabilize.
Axles and Brakes 5. Record the lowest pressure observed before the accumulator recharges. The pressure should be 950–1200 psi. This reading is the accumulator recharge pressure. 6. Shut the engine off. 7. Slowly pump the brake pedal while closely watching the pressure gauge. 8. Record the lowest pressure observed before the pressure drops to nearly zero. This reading is the nitrogen pre-charge. This pressure should be 375–425 psi. 9.
Axles and Brakes Manually Releasing the Park Brake If it is necessary to tow the vehicle a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the worksite or on a roadway, prepare the vehicle for towing as follows; 1. Remove the load from the vehicle. 2. Fully retract the transfer carriage. 3. Fully retract the boom. Position the forks approximately 24" above the ground. 4.
Section 10 — Outriggers Table of Contents Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 10 — Outriggers Outriggers 20 40 60 80 General 0 V1083 -20 Fig. 10-1: Outriggers Outriggers increase the stability of the machine when lifting and placing loads.
Outriggers Removal Outriggers 1 2 9 3 10 11 12 13 5 6 4 20 19 18 8 7 14 15 16 21 17 MV0170 # 1 2 3 4 5 6 7 8 9 10 11 Description Outrigger Cylinder Differential Pressure Switch Tie Wiring Harness Elbow Hydraulic Hose Shim(s) Grease Fitting Cover Capscrew Capscrew Lockwasher # 12 13 14 15 16 17 18 19 20 21 Description Double Tube Clamp Clamp Plate Jam Nut Starwasher Nut Shaft Assembly Nut Lockwasher Capscrew Grease Fitting Fig. 10-2: Outrigger Installation (Ref. Fig.
Outriggers DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. Use suitable blocking and lifting devices when removing heavy machine components. 4. Place blocks or other means of support under the front and rear corners of the outrigger frame. Make sure supports are adequate to support the weight of the outrigger; the outrigger weighs approximately 2585 pounds. 5.
Outriggers 5. Install as many shims (Item 7) as needed on shaft assembly to fill the gap measured in Step 3. Note: Shims are available in three different sizes – 16, 20, and 24 gauge. 6. Reinstall the outrigger on the shaft assembly and secure it with a capscrew (Item 20), lockwasher (Item 19), and nut (Item 18). Torque the nut to 130 ft-lbs. 7.
Outriggers The outrigger cylinders have an operating pressure of 3000 psi and have a 15.63” stroke. Each cylinder includes four bushings. Removal Outrigger Cylinders 1 4 23 5 6 7 10 8 11 9 14 V1084 12 13 # 1 2 3 4 5 6 7 Description Wiring Harness Tie Differential Pressure Switch Outrigger Cylinder Elbow Hydraulic Hose Pin # 8 9 10 11 12 13 14 Description Capscrew Lockwasher Lock Pin Pin Capscrew Lockwasher Lock Pin Fig. 10-4: Outrigger Cylinder Installation (Ref. Fig.
Outriggers CAUTION: Use suitable blocking and lifting devices when removing the cylinders. Care must be taken when removing and lifting the cylinders to prevent personal injury or equipment damage. 5. Place blocking device under the top of the outrigger cylinder. Remove the capscrew (Item 12) and lockwasher (Item 13) from the lock pin (Item 14). Remove the lock pin and upper pin (Item 11). 6. Remove a capscrew (Item 8) and lockwasher (Item 9) from the lock pin (Item 10).
Outriggers Overhaul Outrigger Cylinders 11 6 5 7 8 10 9 12 4 17 1 12 4 16 # 1 2 3 4 5 6 7 8 9 14 15 3 2 13 Description Grease Fitting Grease Fitting Cover Counterbalance Valve Cartridge Bushing O-ring Plug Differential Pressure Switch Elbow Counterbalance Valve Cartridge Cylinder Barrel # 10 11 12 13 14 15 16 17 18 MV0680 Description Rod Bearing Nut Piston Bushing Grease Fitting Grease Fitting Cover Rod Head Setscrew Fig. 10-5: Outrigger Cylinder Assembly (Ref. Fig.
Outriggers a. Place a socket wrench over each counterbalance valve cartridge (Items 3 and 8). Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b. Carefully and slowly, turn the cartridge out of the manifold block to release pressure in cylinder. 5. Remove the counterbalance valve cartridges. 6. Slowly extend and retract the cylinder by hand to remove most of the hydraulic oil. 7. Remove two (2) elbows (Item 7) from the cylinder manifold block. 8.
Outriggers 18. Lubricate counterbalance valve cartridges O-rings with clean hydraulic oil. 19. Install cartridges in the manifold block. 20. Lubricate a new O-ring with hydraulic oil and install it inside the piston (seals rod to piston). 21. Lubricate new seal and wear rings with hydraulic oil and install them on the piston. 22. Slide the cylinder head (Item 16), and piston (Item 11) onto the rod (Item 15). Lubricate the threads on the rod with hydraulic oil and install the rod nut (Item 10). 23.
Outriggers Boom Extension Proximity Switch Description J1146 Proximity Switch 20 40 60 80 Fig. 10-6: Boom Extension Proximity Switch 0 (Ref. Fig. 10-6) The boom extension proximity switch is located on the left side of the outer boom section on machines with a 4-section boom. The boom extend/lockout circuit is designed to increase stability of the machine by limiting how far the boom can be extended without the outriggers down.
Outriggers Outer Boom Section Middle Rear) Boom Section Magnetic Flux Lines Proximity Switch J1259 Oscillator Fig. 10-7: Boom Extension Proximity Switch Operation (Ref. Fig. 10-7) The switch operates by sending out a constant, high frequency magnetic field a short distance from the oscillator end of the switch. Eddy currents are produced in metal when the magnetic flux lines pass through it. These eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop.
Outriggers (Ref. Fig. 10-8) The following procedure describes removal of the boom extension proximity switch. 1. Disconnect the wire harness (Item 4) at the boom extension proximity switch (Item 2). 2. Place a piece of masking tape around the proximity switch body at the outer jam nut (Item 3). This will serve as a guide during reinstallation. 3. Remove the inner jam nut (Item 1) and proximity switch. Reinstall the inner jam nut on the proximity switch for safekeeping.
Outriggers 1. Loosen, but do not remove the two (2) jam nuts on the proximity switch body. 2. Check the gap between switch and boom. The gap must be within the range specified in Fig. 10-9. 3. If the boom extension proximity light does not illuminate when the boom is extended to the specified distance (approximately 21 feet with a tilting tower or 25 feet with a standard carriage), adjust the proximity switch to slightly reduce the gap. Do not exceed gap tolerances specified in Fig. 10-9.
Outriggers Removal Outrigger Control Valve 5 4 1 2 6 7 8 3 9 14 15 16 10 11 12 V1088 13 # 1 2 3 4 5 6 7 8 Description Nut Lockwasher Tie Rod Outrigger Control Valve Button Head Capscrew Frame Tilt Control Valve Lockwasher Nut # 9 10 11 12 13 14 15 16 Description Connector Hydraulic Hose Control Panel Lockwasher Nut Rear Cover Flatwasher Phillips Truss Head Screw Fig. 10-11: Outrigger Control Valve Installation (Ref. Fig.
Outriggers 6. Remove the two (2) nuts (Item 13), lockwashers (Item 12), and capscrews (Item 5) securing each valve section to the control panel (Item 11). Remove the outrigger valve sections. Installation Outrigger Control Valve (Ref. Fig. 10-11) The following procedure describes installation of the outrigger control valves. 1. Secure the two (2) outrigger control valves (Item 4) to the frame tilt control valve (Item 6) with three (3) tie rods (Item 3).
Outriggers 10-16 31200079
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
