JLG Lull 1044C-54 II Series Service Manual

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Service Manual

Model

1044C-54

Series II

31200079

Revised

July 1, 2005

Table of Contents

Troubleshooting

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Do you have a question about the Lull 1044C-54 II Series and is the answer not in the manual?

Questions and answers

Bill Sullivan

March 29, 2025

How do you replace the rollers on the transfer carriage 2005 year

1 comments:

Mr. Anderson

March 29, 2025

To replace the rollers on the transfer carriage of a JLG Lull 1044C-54 II Series (2005), follow these steps:

1. Preparation: Lower the boom to the ground, apply the park brake, retract the transfer cylinder, and stop the engine. Support the boom and transfer carriage with suitable blocking and lifting devices to prevent shifting.

2. Remove Old Components:
- Loosen two setscrews in each spindle nut and remove the spindle nuts.
- Remove spacer washers, thrust washers, spindles, roller bushings, and transfer rollers from both sides of the transfer carriage.
- Discard the used rollers and bushings.
- Clean all remaining parts with solvent and dry with compressed air. Replace any damaged parts.

3. Install New Components:
- Install new bushings centered in each transfer roller.
- Reinstall the transfer roller, spindle, thrust washer, and spacer washers on each side.
- Secure the spindle.

4. Shim Adjustment (Front Rollers):
- Check the number of shims.
- Move the transfer carriage to the narrowest point between rails.
- Measure the gap between the roller lip and rail edge. It should be 1/16".
- If not, remove the roller assembly and adjust shims to achieve the correct gap.

5. Secure Assembly:
- Install roller shims, spacers, and pins.
- Secure roller pins with lock pins, lockwashers, and capscrews.

6. Scraper Plate (if applicable):
- Install scraper plate with flatwashers, lockwashers, and capscrews.
- Maintain the specified distance between scraper plate and rail.
- Torque capscrews to 156 in-lbs.

This answer is automatically generated

Waldemar Cruz

January 29, 2025

how to locate, remove and replace the 4 transmission filter for the JLG Lull 1044c-54 II series

Summary of Contents for JLG Lull 1044C-54 II Series

Page 1 Service Manual Model 1044C-54 Series II 31200079 Revised July 1, 2005...
Page 3: July
EFFECTIVITY PAGE March 18, 2005 - A - Original Issue Of Manual July 1, 2005 - Revised Manual 31200079...
Page 4 EFFECTIVITY PAGE 31200079...
Page 5: Table Of Contents
Table of Contents Section 1 — Safety General ................1-1 Caution, Warning, and Danger .
Page 6 Table of Contents Fluid and Lubricant Specifications ..........3-4 General Specifications .
Page 7 Table of Contents Sight Gauge ..............5-16 Description .
Page 8 Table of Contents Section 6 — Boom and Transfer Boom and Transfer Hydraulics ........... . . 6-1 General Description .
Page 9 Table of Contents Boom Angle Inclinometer ............6-46 Description .
Page 10 Table of Contents Rear Oscillation Lock System ........... . . 7-17 General Description, Models with Control Manifold Hydraulics .
Page 11 Table of Contents Axle Installation ..............9-5 Axle Service and Troubleshooting .
Page 12 List of Figures Fig. 1-1: Decals and Placards ............1-8 Fig.
Page 13 List of Figures Fig. 5-24: Checking Hydraulic Pump Flow Rate ......... . 5-38 Fig.
Page 14 List of Figures Fig. 6-27: Positioning Retaining Block..........6-38 Fig.
Page 15 List of Figures Fig. 6-65: Locations for Chain Attachment – Inner Boom Section......6-60 Fig.
Page 16 List of Figures Fig. 6-103: Upper Chain Installation – Inner Boom Section ....... . . 6-97 Fig.
Page 17 List of Figures Fig. 7-5: Frame Tilt Cylinder ............7-8 Fig.
Page 18 List of Figures Fig. 10-1: Outriggers ............. . . 10-1 Fig.
Page 19 List of Tables Table 3-1: General Fluid and Lubricant Specifications ........3-1 Table 3-2: John Deere Engine Oil Specifications .
Page 20 List of Tables 31200079...
Page 21 Section 1 — Safety Table of Contents General ................1 Caution, Warning, and Danger .
Page 23: General
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.
Page 24: Safety Standard
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...
Page 25: Fuel Hazards
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. •...
Page 26: Hydraulic System Hazards
Safety Hydraulic System Hazards WARNING HIGH PRESSURE FLUID HAZARD To prevent serious personal injury or death: • Relieve system pressure before adjusting, repairing, or disconnecting components. • Wear proper hand and eye protection. Use cardboard to search for leaks. • Keep all components in good repair.
Page 27: Tire And Wheels Hazards
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.
Page 28: Rollover Protective Structure (Rops) And Falling Object Protective Structure (Fops)
ROPS/FOPS capability to provide the required protection. Any modification or repair without the specific written approval of JLG will void the ROPS/FOPS certification. Contact your authorized JLG dealer before making any modifications or repairs. Failure to do so may void the ROPS/FOPS certification.
Page 29: Attaching Decals
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.
Page 30: Fig. 1-1: Decals And Placards
Safety Load Chart Forklift Cab Transfer Capacities and Don’t Be Boom Signals Extension Lubrication Schedule Careless Extension Flip Cards Indicator Notice FORKLIFT SIGNALS NOTICE S T O P R A I S E L O A D L O W E R L O A D M A X I M U M B O O M L O A D C A P A C I T I E S A T 2 4 "...
Page 31: Fig. 1-3: Control Decals
Safety Transfer and Fork Tilt Control Outrigger Control Boom Movement Control Frame Tilt Control Fig. 1-3: Control Decals Disconnect Battery MV0490 Fig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign 31200079...
Page 32: Fig. 1-5: Steer Selector Plate
Safety Operator’s Seat Steer Selector Plate R1049 Fig. 1-5: Steer Selector Plate Hydraulic Hydraulic Oil Only Breather Diesel Fuel Only Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals Attachment Capacity Plate Carriage Safety Decal Fig. 1-7: Fork Carriage Decals 1-10 31200079...
Page 33: Section 2 - Identification And Specifications
Section 2 — Identification and Specifications Table of Contents Serial Number Locations ............2-1 Machine Serial Number .
Page 34 31200079...
Page 35: Serial Number Locations
Section 2 — Identification and Specifications Serial Number Locations Machine Serial Number Serial Number TIRE BALLAST REQUIRED Plate 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.
Page 36: Engine Serial Number, John Deere
Identification and Specifications Engine Serial Number, John Deere Serial Number Plate Fuel Pump 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.
Page 37: Axle Serial Number
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.
Page 38: Identification
Identification and Specifications Identification Fig. 2-5: Top View Fig. 2-6: Left Side View 31200079...
Page 39: Specifications
Identification and Specifications Specifications General Operating Lift and Carry Capacity ....... .10,000 lbs. Specifications Maximum Lift Height .
Page 40 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 .
Page 41 Identification and Specifications Wheels/Tires Lugs ........10 (Torque to 320 ft-lbs) 14 ×...
Page 42: Engine Specifications
Identification and Specifications Engine Specifications John Deere 4045T Fuel..........Diesel Aspiration .
Page 43: Section 3 - General Maintenance
Section 3 — General Maintenance Table of Contents General Instructions ............. . . 3-1 Service Preparation Procedures .
Page 44 List of Tables Table 3-1: General Fluid and Lubricant Specifications ........3-1 Table 3-2: John Deere Engine Oil Specifications .
Page 45: General Instructions
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.
Page 46: Service And Repair Procedures
• Avoid spilling fuel. If a spill occurs, wipe it up immediately. • Never weld on forks, boom, support frame or overhead guard without written consent from JLG. • Install all guards, covers and shields after servicing. Repair or replace any that are damaged.
Page 47: 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.
Page 48: Fluid And Lubricant Specifications
General Maintenance Fluid and Lubricant Specifications General Specifications Table 3-1: General Fluid and Lubricant Specifications SYSTEM OR FLUID OR SPECIFICATION COMPONENT LUBRICATION Fuel System See "Fuel Requirements" Hydraulic System Tractor Hydraulic Mobilfluid 424 ® Fluid Engine Cooling See engine manufacturer's operator's System manual.
Page 49: Transmission Oil Specifications
General Maintenance Table 3-2: John Deere Engine Oil Specifications ENGINE OIL, DEERE Temperature Temperature Oil Grade Range °F Range °C -22 to +86 °F -30 to +30 °C SAE 5W-30 -4 to +86 °F -20 to +30 °C SAE 10W-30 +5 to +122 °F -15 to +50 °C SAE 15W-40...
Page 50: Fuel Requirements
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.
Page 51: Care And Cleaning
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 •...
Page 52: Cleaning Decals
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.
Page 53: Preparing The Machine After Long-Term Storage
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.
Page 54: Torque Specifications
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.
Page 55 General Maintenance Fig. 3-2: General Torques for Standard Bolts, Capscrews, and Nuts 3-11 31200079...
Page 56 General Maintenance Fig. 3-3: General Torques for Metric Bolts, Capscrews, and Nuts 3-12 31200079...
Page 57: Fig. 3-4: Metric Class Identification
General Maintenance PROPERTY CLASS PROPERTY CLASS AND HEAD MARKINGS AND NUT MARKINGS 10.9 10.9 12.9 12.9 12.9 12.9 Fig. 3-4: Metric Class Identification 3-13 31200079...
Page 58: Hydraulic Fitting Torques
General Maintenance Hydraulic Fitting Torques JIC and SAE Female It is recommended that the nut be torqued to the approximate minimum Swivel Nuts 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 SAE Port Approx.
Page 59: Table 3-6: Torque For Adjustable O-Ring Fittings
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.
Page 60: Jump Starting Procedures
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.
Page 61 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).
Page 62: Conversion Charts
General Maintenance Conversion Charts Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart Inch Fract. Inch Dec. Inch Fract. Inch Dec. 1/64 0.0156 0.40 33/64 0.5156 13.10 1/32 0.0313 0.79 17/32 0.5313 13.49 3/64 0.0469 1.19 35/64 0.5469 13.89 1/16 0.0625 1.59 9/16...
Page 63: Table 3-10: Miscellaneous Conversions
General Maintenance Table 3-10: Miscellaneous Conversions To Get or Multiply To Get Multiply International System Conversion Conversion Non-IS Unit IS Unit (IS) Unit Factor Factor Torque Newton Meter (N•m) x 8.9 = in-lb. x 0.113 = Nm Newton Meter (N•m) x 0.74 = ft-lb.
Page 64 General Maintenance 3-20 31200079...
Page 65: Mid-Inlet Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram
Section 4 — Reference Diagrams Table of Contents Mid-Inlet Hydraulic Schematic ............Diagram 4-1 Control Valve .
Page 66 31200079...
Page 67: Section 4 - Reference Diagrams
Reference Diagrams Section 4 — Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic QUICK DISCONNECTS C.B. BOOM TELESCOPE CYLINDER C.B. VALVE VALVE AUX. 1 OPTIONS QUICK DISCONNECTS AUX. 2 OPTIONS BOOM ROLL BACK HOSES FRONT CARRIAGE UPPER HYDRAULICS TILT CYLINDER FRONT OF MACHINE ARROW FILTER 50 MICRON...
Page 68 Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) BOOM HOIST CYLINDER C.B. VALVE REAR CARR. TILT CYLINDER TRANSFER CYLINDER C.B. VALVE BOOM HOIST CYLINDER REAR CARR. TILT CYLINDER BOOM (OPTION) FRAME CARRIAGE R.H. L.H. BOOM HOIST TELESCOPE TILT AUX. 1 AUX.
Page 69 Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) NOTES 31200079...
Page 70 Reference Diagrams Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d) NOTES 31200079...
Page 71 Reference Diagrams Diagram 4-2 — Control Valve Mid-Inlet Control Valve BOOM (OPTION) FRAME CARRIAGE R.H. L.H. BOOM HOIST TELESCOPE TILT AUX. 1 AUX. 2 TRANSFER TILT OUTRIGGER OUTRIGGER 3150 (OPTION) 2800 3000 2800 MV0410 31200079...
Page 72 Reference Diagrams NOTES 31200079...
Page 73 Reference Diagrams Diagram 4-3 — Electrical Schematic ORANGE-16 ORANGE-16 36830B BLACK-16 BLACK-16 CLUSTER GAUGE FUEL CHECK ENGINE FUEL INCLUDED IN UPPER INCLUDED IN INTERMEDIATE BOOM ENGINE WATER HARNESS 66944D HARNESS 66961D TRANS WATER FAULT EXTEND PARK CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX TEMP LOCK...
Page 74: Control Valve
Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) 38200C-4 GROUND ENGINE TO MAINFRAME FUEL LEVEL GA SEND CONNECT BATT GRD TO LOWER STARTER P29317 MOUNTING BOLT STARTER 65724A MOTOR NEG. CABLE 2/0 BLACK SOLENOID 35646A BATTERY POS. CABLE 2/0 RED BLACK-10 PIN 86 IS GROUND ON ALL RELAYS 38200C-3...
Page 75 Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) ON WHEN BOOM ON WHEN ON WHEN SHIFTER ON WHEN ON WHEN ON WHEN BOOM ON WHEN BOOM OVER 20° AND SHIFTER Y5 IS OFF AND FORWARD REVERSE OVER 40° OVER 40° NOT OVER 40°...
Page 76 Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) NOTES 4-10 31200079...
Page 77 Reference Diagrams Diagram 4-3 — Electrical Schematic (cont’d) NOTES 4-11 31200079...
Page 78 Reference Diagrams 4-12 31200079...
Page 79: Section 5 - Supply, Pressure, And Return Hydraulics
Section 5 — Supply, Pressure, and Return Hydraulics Table of Contents General ................5-1 Major System Components .
Page 80 Removal ............... . . 5-33 Hydraulic Pump .
Page 81 Fig. 5-19: Hydraulic Pressure Filter Element..........5-28 Fig.
Page 82 31200079...
Page 83: General
Section 5 — Supply, Pressure, and Return Hydraulics General Major System Components Hydraulic Oil Return Hydraulic Filter Reservoir/ Fuel Tank Hydraulic Pump Hydraulic Control Valve Fig. 5-1: Major Hydraulic Components General Description (Ref. Fig. 5-1) The hydraulic system consists of the following circuits: •...
Page 84 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.
Page 85: Hydraulic Systems
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.
Page 86: Cleanliness
Supply, Pressure, and Return Hydraulics • The hydraulic system is under pressure whenever the engine is run- ning 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.
Page 87: Checking Hydraulic 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.
Page 88: Hydraulic Reservoir
Supply, Pressure, and Return Hydraulics Hydraulic Reservoir 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.
Page 89: Fig. 5-4: Hydraulic Reservoir
Supply, Pressure, and Return Hydraulics MV0010 Description Description 1 Hydraulic Tank Breather (Models 5 Hydraulic Oil Tank with Mid-Inlet Hydraulics) 6 Hydraulic Oil Strainer (Models with Mid-Inlet Hydraulics) 2 Hydraulic Tank Sight Gauge 7 Suction Line 3 Pressure Gauge 4 Return Filter Assembly Fig.
Page 90: Filling Hydraulic Reservoir
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.
Page 91: Fig. 5-6: Alternate Reservoir Filling Method
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.
Page 92 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.
Page 93: Reservoir Drain And Refill
Supply, Pressure, and Return Hydraulics Reservoir Drain and Refill MV0070 Description Description 1 Breather Filter 3 Hydraulic Oil Suction Strainer 2 Return Filter Assembly 4 Drain Plug Fig. 5-7: Hydraulic Reservoir Drain and Refill (Ref. Fig. 5-7) The following procedure describes draining and refilling the hydraulic reservoir.
Page 94 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.
Page 95: Removal
Supply, Pressure, and Return Hydraulics Removal Hydraulic Reservoir and Fuel Tank 16 17 27 26 MV0060 Description Description 1 Tank Hold-Down Strap 15 90° Elbow 2 Chemprene Belting 16 Hose Clamp 3 Pipe Adapter 17 Fuel Return Hose 4 Hose Clamp 18 Fuel Tank Drain Plug 5 Fuel Supply Hose 19 Hydraulic Reservoir Drain Plug...
Page 96 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”...
Page 97: Installation
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.
Page 98: Sight Gauge
Supply, Pressure, and Return Hydraulics Sight Gauge Description 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.
Page 99: Removal
Supply, Pressure, and Return Hydraulics Removal Sight Gauge Description Description 1 Hydraulic Sight Gauge 6 Hydraulic Oil Return Filter Assy 2 Hollow Hex Head Bolt 7 JIC Pipe Connector 3 O-Ring 8 Return Manifold Tube 4 Lockwasher 9 Hydraulic Reservoir 5 Capscrew 10 Nut Fig.
Page 100: Installation
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.
Page 101: Suction Strainer
Supply, Pressure, and Return Hydraulics Suction Strainer Description MV0080 Description Description 1 Drain Plug 5 Lockwasher 2 O-Ring 6 Capscrew 3 Hydraulic Oil Strainer 7 O-Ring 4 Flange Half 8 Hydraulic Suction Hose Fig. 5-11: Suction Strainer Installation (Ref. Fig. 5-11) The suction strainer is located behind the hydraulic reservoir.
Page 102: Removal And Cleaning
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”...
Page 103: Hydraulic Return Filter
Supply, Pressure, and Return Hydraulics Hydraulic Return Filter 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 Fig.
Page 104: Replacing Return Filter Element
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) .
Page 105: Fig. 5-15: Filter Element Assembly
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.
Page 106 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).
Page 107: Removal
Supply, Pressure, and Return Hydraulics Removal Return Filter Assembly Description Description 1 Hydraulic Oil Reservoir Connector 2 Lockwasher 6 Return Hydraulic Oil Filter 3 Capscrew 7 Diffuser 4 Return Manifold Tube 8 Rubber Gasket Fig. 5-16: Return Filter Assembly (Ref. Fig. 5-16) The following procedure describes disassembly of the return filter assembly.
Page 108: Installation
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).
Page 109: Removal And Installation
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.
Page 110: Replacing Pressure Filter Element
Replacing Pressure Filter Element Supply, Pressure, and Return Hydraulics MV0040 Description Description 1 Filter Head 3 Filter Element 2 Bowl O-Ring 4 Bowl Fig. 5-19: Hydraulic Pressure Filter Element (Ref. Fig. 5-19) The following procedure describes replacement of the hydraulic pressure filter element. 1.
Page 111: Removal
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 MV0050 Description Description Filter Mounting Bracket 5 Pressure Filter Assembly...
Page 112: Installation
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.
Page 113: Troubleshooting Pump Problems
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...
Page 114 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 1. Check all external connections, tubing, and hoses. Tighten connections and replace any B.
Page 115: Removal
Supply, Pressure, and Return Hydraulics Removal Hydraulic Pump MV0330 Description Description 1 Hydraulic Hose to Test Port 11 Hydraulic Hose to Test Port 2 Hydraulic Hose to Accumulator 12 Run Tee 3 Hydraulic Hose to Test Port 13 Elbow 4 Reducer Adapter 14 Hydraulic Hose to Elbow on Rear Axle Stabilizer Valve 5 Branch Tee...
Page 116 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.
Page 117: Fig. 5-23: Hydraulic Pump Installation - Mid-Inlet Hydraulics
Supply, Pressure, and Return Hydraulics MV0320 Description Description 1 Hydraulic Hose 14 Lockwasher 2 Elbow 15 Flatwasher 3 Capscrew 16 Nut 4 Lockwasher 17 Lockwasher 5 Hydraulic Pump 18 Lower Pump Support Bracket 6 O-Ring 19 Capscrew 7 Transmission 20 Lockwasher 8 O-ring 21 Flatwasher 9 Flange Half...
Page 118 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.
Page 119: Installation
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.
Page 120: Checking Pump Flow Rate
Supply, Pressure, and Return Hydraulics Checking Pump Flow Rate Description Description 1 Return Filter Housing 4 Test Loop Hose (2) 2 Hex Cap 5 Hydraulic Pump 3 Hydraulic Tester 6 Pressure Hose (2) Fig. 5-24: Checking Hydraulic Pump Flow Rate (Ref.
Page 121 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.
Page 122: Mid-Inlet Control Valve
Supply, Pressure, and Return Hydraulics Mid-Inlet Control Valve Description Fig. 5-25: Mid-Inlet Control Valve Location Boom Extension Outlet Section Boom Hoist Outlet (Return to Tank) Mid-Inlet Valve Sections Relief Valve Work Ports Inlet From Pump 2 “Pump 2” Inlet (From Priority Test Port Valve on Pump) Inlet Section...
Page 123 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. Outrigger •...
Page 124: Fig. 5-27: Mid-Inlet Control Valve Configurations
Supply, Pressure, and Return Hydraulics Boom Extend Boom Hoist Boom Extend Mid-Inlet Boom Hoist Mid-Inlet Unloader Frame Tilt Frame Tilt Auxiliary Auxiliary Transfer Carriage Transfer Carriage Carriage Tilt Carriage Tilt 7-Spool Valve 6-Spool Valve For Models with Unloader For Models without Outriggers (Natural Engine) Boom Extend Boom Hoist...
Page 125: Removal
Supply, Pressure, and Return Hydraulics Removal Mid-Inlet Control Valve Control Valve 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.
Page 126: Installation
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.
Page 127: Fig. 5-30: Rear Axle Stabilizer Control Valve Ports
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. B-Back View PD3 PD2 A-Top View C-Right View F-Left View E-Front View MV0730 Fig.
Page 128: Table 5-1: Rear Axle Stabilizer Control Valve Markings
Supply, Pressure, and Return Hydraulics Table 5-1: Rear Axle Stabilizer Control Valve Markings View Marking Description A - Top View Gauge #1 - Test Port (Rear Osc. Lock) Piloted Sequence Valve Cartridge Valve Piloted CartridgeValve Piloted CartridgeValve Piloted Cartridge Valve B - Back View Shuttle Cartridge Valve Rear Brakes...
Page 129: Removal, Rear Axle Stabilizer Control Valve
Supply, Pressure, and Return Hydraulics Removal, Rear Axle Stabilizer Control Valve MV0720 Description Description 1 Hose for Connector at FTB Port 13 Hose for Elbow at BR Port 2 Hose at FCB Port 14 Hose for Elbow at PIL Port 3 Hose for Connector at G1 Port 15 Hose for Run Tee at T Port 4 Hose for Connector at RCB Port...
Page 130 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.
Page 131: Boom Extend Lockout Valve
Supply, Pressure, and Return Hydraulics Boom Extend Lockout Valve Description 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.
Page 132 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. •...
Page 133: Roll-Back Hose Tray
Supply, Pressure, and Return Hydraulics Roll-Back Hose Tray General Fig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics (Ref. Fig. 5-34) The roll-back hose tray is located near the middle of the machine, above the valve plate. Removal Roll-Back Hose Tray 5-51 31200079...
Page 134: Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics
Supply, Pressure, and Return Hydraulics Mid-Inlet Hydraulic System Description Description 1 Nut 7 Lockwasher 2 Lockwasher 8 Roll-Back Hose Tray 3 Front Hose Tray Support Bracket 9 Button Head Socket Capscrew 4 Hose Mount 10 Lockwasher 5 Button Head Socket Capscrew 11 Flatwasher 6 Button Head Socket Capscrew 12 Rear Hose Tray Support Bracket...
Page 135: Installation
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.
Page 136 Supply, Pressure, and Return Hydraulics 5-54 31200079...
Page 137 Section 6 — Boom and Transfer Table of Contents Boom and Transfer Hydraulics ........... . . 6-1 General Description .
Page 138 Quick Attach ..............6-40 Description .
Page 139 Fig. 6-10: Front Carriage Tilt Cylinder ..........6-18 Fig.
Page 140 Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom ........6-50 Fig.
Page 141 Fig. 6-88: Side Slide Pads – Outer Boom Section......... 6-82 Fig.
Page 142 Fig. 6-127: Boom Extension Proximity Switch Wiring ........6-123 Fig.
Page 143: Boom And Transfer Hydraulics
Section 6 — Boom and Transfer Boom and Transfer Hydraulics General Description Boom Rear Carriage Tilt Cylinder Transfer Carriage Front Carriage Tilt Cylinder Hoist Cylinder Joystick Controls Fig. 6-1: Major Boom and Transfer Hydraulic Components (Ref. Fig. 6-1) The following are major boom and transfer components: •...
Page 144: Joystick Controls
Boom and Transfer Joystick Controls 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.
Page 145: Removal
Boom and Transfer Removal Joystick Description Description 1 Button Head Socket Capscrew 9 Connector 2 Lockwasher with Internal Teeth 10 Connector 3 Phillips Truss Head Screw 11 Swivel Tee 4 Flatwasher 12 Hydraulic Hose 5 Wiring Harness 13 Side Panel 6 Lead Connector 14 Capscrew 7 Joystick...
Page 146: Installation
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).
Page 147: Disassembly
Boom and Transfer Disassembly Joystick 22 23 Description Description 1 Socket Head Capscrew 19 Retainer 2 Socket Head Capscrew 20 Flange 3 Half Handle 21 Socket Head Capscrew 4 Cap 22 Manifold 5 Push Button 23 O-ring 6 Switch 24 Body 7 Guide 25 Wiper 8 Hex Nut...
Page 148 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).
Page 149 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.
Page 150: Fig. 6-5: Pilot Pressure Diagnostic Port
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.
Page 151: Hydraulic Cylinders
Hydraulic Cylinders Description All hydraulic cylinders used on JLG forklifts are a double-acting, non-cushioned type with chromed rods. The boom hoist, carriage tilt, boom extension, and frame tilt cylinders are equipped with externally mounted counterbalance valves. These...
Page 152: Checking Cylinder Condition
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.
Page 153 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.
Page 154: Boom Hoist Cylinder
Boom and Transfer Boom Hoist Cylinder Description Fig. 6-7: Boom Hoist Cylinders (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.
Page 155: Removal
Boom and Transfer Removal Boom Hoist Cylinder Description Description 1 Hydraulic Hose 7 Lockwasher 2 Hoist Cylinder 8 Transfer Carriage/Boom Cradle 3 Outer Boom 9 Lock Pin 4 Pivot Pin - Rod End 10 Pivot Pin - Base End 5 Lock Pin 11 Lockwasher 6 Hex Capscrew 12 Hex Capscrew...
Page 156: Installation
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.
Page 157: Overhaul
Boom and Transfer Overhaul Boom Hoist Cylinder MV0620 Description Description 1 45 Degree Elbow 9 Rod Nut 2 Grease Fitting Cover 10 Piston 3 Grease Fitting 11 Set Screw 4 Self-Aligning Bushing - Base End 12 Rod Bearing Head 5 Cylinder Barrel 13 Cylinder Rod 6 Hollow Hex O-ring Plug 14 Self-Aligning Bushing - Rod End...
Page 158 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.
Page 159 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.
Page 160: Front Carriage Tilt Cylinder
Boom and Transfer Front Carriage Tilt Cylinder Description 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.
Page 161: Removal
Boom and Transfer Removal Front Carriage Tilt Cylinder Description Description 1 Inner Boom Section Pin Boss 5 Upper Pivot Pin 2 Lock Pin 6 Hydraulic Hose 3 Lockwasher 7 Front Carriage Tilt Cylinder 4 Capscrew 8 O-ring Connector Fig. 6-11: Front Carriage Tilt Cylinder Installation (Ref.
Page 162: Installation
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.
Page 163: Overhaul
Boom and Transfer Overhaul Front Carriage Tilt Cylinder MV0630 Description Description 1 O-ring Connector 10 Grease Fitting 2 Bushing 11 Piston 3 Set Screw 12 Tube 4 Grease Fitting 13 Rod Bearing Head 5 Counterbalance Valve Cartridge 6 Rod Nut 7 Cylinder Barrel 8 Bushing 9 Cylinder Rod...
Page 164 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.
Page 165 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.
Page 166: Rear Carriage Tilt Cylinder
Boom and Transfer Rear Carriage Tilt Cylinder Description 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.
Page 167: Removal
Boom and Transfer Removal Rear Carriage Tilt Cylinder Description Description 1 Outer Boom 8 Grease Fitting Cover 2 Lock Pin 9 Grease Fitting 3 Lockwasher 10 Lock Pin 4 Hex Head Capscrew 11 Lockwasher 5 Cylinder Pivot Pin - Rod End 12 Hex Head Capscrew 6 Rear Carriage Tilt Cylinder 13 Cylinder Pivot Pin - Base End...
Page 168: Installation
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.
Page 169: Overhaul
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;...
Page 170 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).
Page 171: Selector Valve
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.
Page 172: Removal
Boom and Transfer Removal Selector Valve Description Description 1 Lockwasher 5 Selector Valve 2 Nut 6 Hydraulic Hoses (Joystick) 3 Hydraulic Hoses 7 Capscrew 4 Hydraulic Hoses 8 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.
Page 173: Installation
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).
Page 174 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.
Page 175: Troubleshooting
Boom and Transfer Troubleshooting Problem Probable Cause Solution Reference 1. Boom fails to A. Broken hydraulic line(s) A. Replace hydraulic extend or retract and/or connection leaks tube(s)/hose(s) and/or tighten loose connections. B. Faulty extension cylinder B. Repair extension cylinder seals. C.
Page 176: Boom Slide Pads - General
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.
Page 177: Fig. 6-20: Pad Worn, But Still Ok
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.
Page 178: Lubrication
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.
Page 179: Fig. 6-24: Damaged Slide Surface
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. 6-25: Slide Surface Repair...
Page 180: Replacing And Shimming Boom Slide Pads - General
Boom and Transfer Replacing and Shimming Boom Slide Pads — General Shims Bolted Cage Caged Pad Lockwas Retaining Block 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.
Page 181: Fig. 6-28: Determining Capscrew Length
(Dimension A). This dimension will ensure that the capscrew will not protrude past the nut insert and cause boom damage. See Fig. 6-29. Capscrews that can be purchased from JLG come in three (3) lengths (3/4", 1", and 1-1/4").
Page 182: Quick Attach
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.
Page 183: Fig. 6-32: Lock Plate
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.
Page 184: Connecting An Attachment
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) .
Page 185: Fig. 6-38: Rotating Quick Attach Forward
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) .
Page 186: Removal
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.
Page 187: Installation
Boom and Transfer J1068 Description Description 1 Pivot Pin 4 Nut 2 Capscrew 5 Shim 3 Lockwasher 6 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.
Page 188: Boom Angle Inclinometer
Boom and Transfer Boom Angle Inclinometer Description DEGREES 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.
Page 189: 4-Section Boom
Boom and Transfer 4-Section Boom Description 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. 6-47 31200079...
Page 190: Shimming Procedures
Boom and Transfer Shimming Procedures 4-Section Boom NOTE: Items 1 and 3 are load bearing pads Description Description 1 Boom Pad, 1" Thick x 3" Wide 4 Boom Pad, 3/4" Thick x 1-1/4" Wide 2 Boom Pad, 9/16" Thick x 2" Wide 3 Boom Pad, 3/4"...
Page 191: Fig. 6-47: Lower Shim Installation - Front Of 4-Section Boom
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. Install shim(s) under these pads Fig.
Page 192: Fig. 6-49: Boom Section Gaps - Rear Of 4-Section Boom
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") 1.04"–1.10" (1-3/64"–1-7/64") Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom 6. (Ref. Fig. 6-49) Measure the gaps between the inner, middle (forward), and middle (rear) sections at the upper pads.
Page 193: Fig. 6-51: Upper Shim Installation - Rear Of 4-Section Boom
Boom and Transfer 0.06" (1/16") 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" 0.47–0.53" (15/32"– (15/32"– 17/32") 17/32") 0.72"–0.78" 0.72"–0.78" (23/32"– (23/32"– 25/32") 25/32") 0.595"–0.655"...
Page 194: Fig. 6-53: Gaps Between Pads And Boom - Rear Of 4-Section Boom
Boom and Transfer 0.02"–0.08" 0.02"–0.08" (1/64"–5/64") (1/64"–5/64") 0.03"–0.09" 0.03"–0.09" (1/32"–3/32") (1/32"–3/32") 0.03"–0.09" 0.03"–0.09" (1/32"–3/32") (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.
Page 195: Inspection Procedures
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. 0.06"–0.12" 0.06"–0.12" (1/16"–1/8") (1/16"–1/8") 0.02"–0.08" 0.04"–0.10" 0.02"–0.08" (1/64"–5/64") (3/64"–7/64") (1/64"–5/64") 0.06"–0.12" 0.06"–0.12" (1/16"–1/8") (1/16"–1/8") Front of Boom, Looking Rearward Fig.
Page 196: Fig. 6-56: Inner Boom Cross-Section At Window
Boom and Transfer 10 5/8" (10.625") 3/16" (0.19") 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.
Page 197: Boom Removal
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"...
Page 198: Fig. 6-59: 4-Section Boom Cover Installation
Boom and Transfer Description Description 1 Nut 3 Flatwasher 2 Lockwasher 4 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.
Page 199: Fig. 6-61: Cylinder Pivot Pins
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.
Page 200: Fig. 6-62: Upper Rear Slide Pad Removal - Middle (Rear) Boom Section
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.
Page 201: Fig. 6-63: Upper Rear Slide Pad Removal - Middle (Forward) Boom Section
Boom and Transfer Description Description 1 Shim 5 Flatwasher 2 Rear Upper Slide Pad 6 Capscrew 3 Pad Retainer 7 Lockwasher 4 Lockwasher 8 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.
Page 202: Fig. 6-65: Locations For Chain Attachment - Inner Boom Section
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.
Page 203: Fig. 6-66: 4-Section Boom Pivot Pins
Boom and Transfer Description Description 1 Nut 5 Shims 2 Lockwasher 6 Transfer Carriage/Boom Cradle 3 Boom Pivot Pin 7 Boom Assembly 4 Bolt 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).
Page 204: Installation
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.
Page 205: Boom Disassembly
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.
Page 206: Fig. 6-67: Slide Pad Removal - Outer Boom Section
Boom and Transfer Description Description 1 Lower Slide Pad 9 Lockwasher 2 Shim 10 Capscrew 3 Right Hand Retainer Block 11 Lockwasher 4 Pad Retainer 12 Upper Slide Pad 5 Flatwasher 13 Shim 6 Lockwasher 14 Capscrew 7 Capscrew 15 Lockwasher 8 Left Hand Retainer Block 16 Button-Head Socket Capscrew Fig.
Page 207: Fig. 6-68: Lower Front Slide Pad Removal - Middle (Rear) Boom Section
Boom and Transfer Description Description 1 Lower Front Slide Pad 5 Pad Retainer 2 Shim 6 Lockwasher 3 Capscrew 7 Button-Head Socket Capscrew 4 Lockwasher 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.
Page 208: Fig. 6-69: Disconnecting Hoses Between Sections
Boom and Transfer 14 15 1 and 2 7 and 8 10 and 11 14 and 15 Side View Description Description 1 Auxiliary Hydraulic Tube 10 Auxiliary Hydraulic Tube 2 Carriage Tilt Hydraulic Tube 11 Carriage Tilt Hydraulic Tube 3 Middle (Front) Boom Section 12 Half Clamp 4 Hose Guard 13 Round Head Screw...
Page 209: Fig. 6-70: Extension Cylinder Removal - 4-Section Boom
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.
Page 210: Fig. 6-71: Upper Front Slide Pad Removal - Middle (Rear) Boom Section
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.
Page 211: Fig. 6-72: Upper Front Slide Pad Removal - Middle (Forward) Boom Section
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). Description Description 1 Button-Head Socket Capscrew...
Page 212: Fig. 6-74: Upper Chain Roller Assembly - Middle (Forward) Boom Section
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.
Page 213: Fig. 6-75: Disconnecting Chains At Rear Of Inner Boom
Boom and Transfer Description Description 1 Inner Boom 5 Capscrew 2 Upper Chain 6 Lower Chain 3 Lock Nut 7 Shoulder Bolt 4 Lockwasher 8 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.
Page 214: Fig. 6-77: Slide Pad Removal - Inner Boom Section
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.
Page 215: Fig. 6-78: Slide Pad Removal - Middle (Forward) Boom Section
Boom and Transfer 11 12 MV0090 Description Description 1 Front Bottom Slide Pad 11 Button-Head Socket Capscrew 2 Shim 12 Lockwasher 3 Pad Retainer 13 Middle (Forward) Boom Assy 4 Flatwasher 14 Button-Head Socket Capscrew 5 Lockwasher 15 Lockwasher 6 Capscrew 16 Shim 7 Side Slide Pad 17 Rear Bottom Slide Pad...
Page 216: Fig. 6-79: Grease Hose Assembly
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.
Page 217: Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section
Boom and Transfer Description Description 1 Grease Fitting Cover 6 Capscrew 2 Grease Fitting 7 Chain Guide Washer 3 Chain Roller Pin 8 Bushing 4 Lock Pin 9 Chain Roller 5 Lockwasher 10 Chain Roller Bushing Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section 27.
Page 218: Fig. 6-81: Hose And Tube Removal - Inner Boom Section
Boom and Transfer Description Description 1 Auxiliary Hydraulic Hoses 4 Auxiliary Hydraulic Tubes 2 Carriage Tilt Hydraulic Hoses 5 Carriage Tilt Hydraulic Tubes 3 Cushion Clamp 6 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.
Page 219: Fig. 6-82: Upper Chain Assembly
Boom and Transfer Description Description 1 Chain Anchor 4 Nut 2 Jam Nut 5 Outer Boom Section 3 Lockwasher 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.
Page 220: Fig. 6-84: Removing Lower Chains
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).
Page 221: Fig. 6-85: Slide Pads - Middle (Rear) Boom Section
Boom and Transfer Description Description 1 Front Side Slide Pad 7 Button-Head Socket Capscrew 2 Shim 8 Lockwasher 3 Lockwasher 9 Shim 4 Button-Head Socket Capscrew 10 Rear Side Slide Pad 5 Button-Head Socket Capscrew 11 Shim 6 Lockwasher 12 Rear Lower Slide Pad Fig.
Page 222: Fig. 6-86: Chain And Hose Guide Assembly
Boom and Transfer Description Description 1 Roller Bushing 9 Lock Nut 2 Washer 10 Chain Roller Washer 3 Capscrew 11 Hardened Bushing 4 Right Hand Hose Guide 12 Chain and Hose Roller 5 Hose Guide Spacer 13 Chain and Hose Roller Shaft 6 Hose Spacer 14 Grease Fitting 7 Plastic Bushing...
Page 223: Fig. 6-87: Tubes And Hoses - Middle (Rear) And Outer Boom Sections
Boom and Transfer MV0100 Description Description 1 Auxiliary Hydraulic Hose 7 Nut 2 Carriage Tilt Hydraulic Hose 8 Lockwasher 3 Middle (Rear) Boom Section 9 Clamp 4 Hydraulic Manifold Block 10 Cushion Clamp 5 Auxiliary Hydraulic Tube 6 Carriage Tilt Hydraulic Tube Fig.
Page 224: Fig. 6-88: Side Slide Pads - Outer Boom Section
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.
Page 225: Fig. 6-89: Outer Boom Tubes And Hoses
Boom and Transfer MV0110 Description Description 1 Outer Boom Section 8 Cushion Clamp 2 Auxiliary Hydraulic Hose 9 Auxiliary Hydraulic Tube 3 Carriage Tilt Hydraulic Hose 10 Carriage Tilt Hydraulic Tube 4 Capscrew 11 Hydraulic Manifold Block 5 Nut 12 Lockwasher 6 Lockwasher 7 Clamp Fig.
Page 226: Assembly
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.
Page 227: Fig. 6-90: Outer Boom Tube And Hose Assembly
Boom and Transfer MV0120 Description Description 1 Outer Boom Section 10 Carriage Tilt Hydraulic Tube 2 Auxiliary Hydraulic Hose 11 Hydraulic Manifold Block 3 Carriage Tilt Hydraulic Hose 12 Lockwasher 4 Lock Nut 13 Capscrew 5 Nut 14 Left Clamp Half 6 Lockwasher 15 Plastic Cushion 7 Clamp...
Page 228: Fig. 6-91: Extension Cylinder Installation
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).
Page 229: Fig. 6-92: Lower Chains On Outer Boom Section
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.
Page 230: Fig. 6-93: Lower Rear Slide Pad Installation - Middle (Rear) Boom Section
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.
Page 231: Fig. 6-94: Tubes And Hoses - Middle (Rear) Boom Sections
Boom and Transfer 12 13 MV0140 Description Description 1 Auxiliary Hydraulic Hose 7 Nut 2 Carriage Tilt Hydraulic Hose 8 Lockwasher 3 Middle (Rear) Boom Section 9 Clamp 4 Capscrew 10 Cushion Clamp 5 Auxiliary Hydraulic Tube 11 Hydraulic Manifold Block 6 Carriage Tilt Hydraulic Tube 12 Lockwasher Fig.
Page 232: Fig. 6-95: Chain And Hose Guide Assembly
Boom and Transfer Description Description 1 Roller Bushing 9 Lock Nut 2 Washer 10 Chain Roller Washer 3 Capscrew 11 Hardened Bushing 4 Right Hand Hose Guide 12 Chain and Hose Roller 5 Hose Guide Spacer 13 Chain and Hose Roller Shaft 6 Hose Spacer 14 Grease Fitting 7 Plastic Bushing...
Page 233: Fig. 6-96: Installation Of Lower Chain - Middle (Rear) Boom Section
Boom and Transfer 11. Turn middle (rear) boom section over to upright position on work stands. 3.13" (3-1/8") View A Description Description 1 Button-Head Socket Capscrew 5 Chain Adjustment Block 2 Lockwasher 6 Shoulder Bolt 3 Chain Adjustment Rod 7 Lock Nut 4 Anchor Base 8 Chain Fig.
Page 234: Fig. 6-97: Upper Chain Roller Assembly - Middle (Rear) Boom Section
Boom and Transfer Description Description 1 Chain Guide Washer 6 Grease Fitting 2 Chain Roller Bushing 7 Lock Pin 3 Hardened Bushing 8 Lockwasher 4 Chain Roller 9 Capscrew 5 Grease Fitting Cover 10 Chain Roller Pin Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section 13.
Page 235: Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section
Boom and Transfer Description Description 1 Grease Fitting Cover 6 Capscrew 2 Grease Fitting 7 Chain Guide Washer 3 Chain Roller Pin 8 Bushing 4 Lock Pin 9 Chain Roller 5 Lockwasher 10 Chain Roller Bushing Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section 17.
Page 236: Fig. 6-99: Slide Pad Installation - Middle (Forward) Boom Section
Boom and Transfer MV0150 Description Description 1 Front Bottom Slide Pad 10 Lockwasher 2 Shim 11 Button-Head Socket Capscrew 3 Pad Retainer 12 Lockwasher 4 Flatwasher 13 Middle (Forward) Boom Assy 5 Lockwasher 14 Button-Head Socket Capscrew 6 Capscrew 15 Lockwasher 7 Side Slide Pad 16 Shim 8 Shim...
Page 237: Fig. 6-100: Hydraulic Hose And Tube Installation - Inner Boom Section
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.
Page 238: Fig. 6-101: Slide Pad Installation - Inner Boom Section
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.
Page 239: Fig. 6-103: Upper Chain Installation - Inner Boom Section
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.
Page 240: Fig. 6-104: Upper Slide Pad Installation - Front Of Middle (Forward) Boom Section
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. Description Description 1 Button-Head Socket Capscrew 3 Shim 2 Lockwasher 4 Front Upper Slide Pad Fig.
Page 241: Fig. 6-105: Upper Chain And Hose Reel Assembly - Middle (Forward) Boom
Boom and Transfer Description Description 1 Upper Chains 6 Chain Anchor Rod 2 Lock Nut 7 Hose Reel 3 Upper Chain Anchor 8 Capscrew 4 Capscrew 9 Lockwasher 5 Lockwasher 10 Hose Reel Pin Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom 33.
Page 242: Fig. 6-107: Front Slide Pad Installation - Outer And Middle (Rear) Boom Sections
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. Description Description 1 Capscrew 8 Button-Head Socket Capscrew 2 Lockwasher 9 Lockwasher 3 Flatwasher 10 Lockwasher 4 Slide Pad Retainer...
Page 243: Fig. 6-108: Lower Chain Installation - Inner Boom Section
Boom and Transfer Description Description 1 Lock Nut 3 Shoulder Bolt 2 Lower Chain 4 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).
Page 244: Fig. 6-110: Upper Chains - Middle (Rear) To Outer Boom Sections
Boom and Transfer Description Description 1 Chain Anchor 4 Nut 2 Jam Nut 5 Outer Boom Section 3 Lockwasher 6 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.
Page 245: Fig. 6-111: Upper Chain - Middle (Forward) To Middle (Rear) Boom Sections
Boom and Transfer Description Description 1 Chain Adjustment Anchor 4 Nut 2 Jam Nut 5 Upper Chain Roller Assembly 3 Lockwasher 6 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.
Page 246: Fig. 6-113: Securing Boom Extension Cylinder
Boom and Transfer Description Description 3 Cylinder Rod Boss 2 Setscrew 4 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).
Page 247: Fig. 6-114: Connecting Hoses Between Sections
Boom and Transfer 14 15 1 and 2 7 and 8 10 and 11 14 and 15 Side View Description Description 1 Auxiliary Hydraulic Tube 11 Carriage Tilt Hydraulic Tube 2 Carriage Tilt Hydraulic Tube 12 Half Clamp 3 Middle (Front) Boom Section 13 Round Head Screw 4 Hose Guard 14 Auxiliary Hydraulic Hose...
Page 248: Boom Extend And Retract Chains
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).
Page 249: Chain Lubrication
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.
Page 250: Boom Chain Tension Check
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 Chain Tension Check 1.
Page 251: Boom Hose Replacement
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.
Page 252 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.
Page 253: Extension Cylinder
Boom and Transfer Extension Cylinder 4-Section Boom Description 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"...
Page 254: Fig. 6-117: 4-Section Boom Extension Cylinder Installation
Boom and Transfer Removal, Extension Cylinder 12 13 MV0160 Description Description 1 Rod Nut 9 Elbow 2 Socket Setscrew 10 Hydraulic Tube 3 Extension Cylinder Rod Boss 11 Extension Cylinder Base Mount 4 Middle (Rear) Boom Section 12 Shim 5 Boom Extension Cylinder 13 Shim 6 Outer Boom Section 14 Nut...
Page 255 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.
Page 256: Fig. 6-118: 4-Section Boom Extension Cylinder Assembly
Boom and Transfer Overhaul, Extension Cylinder MV0640 Description Description 1 Bolt 8 Cylinder Barrel 2 Flatwasher 9 Rod Nut 3 Extension Cylinder Base Mount 10 Piston 4 Hollow Hex O-ring Plug 11 Rod Bearing Head 5 Counterbalance Valve Cartridge 12 Capscrew 6 Counterbalance Valve Cartridge 13 Rod Bearing Head 14 Tube...
Page 257 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.
Page 258 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).
Page 259: Boom Extension Proximity Switch
Boom and Transfer Boom Extension Proximity Switch Description Proximity Switch Fig. 6-119: Boom Extension Proximity Switch (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.
Page 260: Removal
Boom and Transfer Middle Rear) Outer Boom Section Magnetic Boom Section Flux Lines Proximity Switch 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.
Page 261: Installation
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).
Page 262: Transfer Carriage
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.
Page 263: Fig. 6-124: Disconnecting Transfer Cylinder From Transfer Carriage
Boom and Transfer The transfer carriage, along with the transfer cylinder, make up the “Trans- Action” 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.
Page 264: Fig. 6-125: Boom Elevation Proximity Switch Wiring
Boom and Transfer Proximity Switch Connection Wire 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.
Page 265: Fig. 6-127: Boom Extension Proximity Switch Wiring
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. Description Description 1 JClamp 6 Proximity Switch Connection Wire 2 Flatwasher 7 Proximity Mounting Plate 3 Lockwasher 8 Boom Extension Proximity Switch 4 Nut...
Page 266: Fig. 6-128: Disconnecting Hydraulic Hoses From Transfer Carriage
Boom and Transfer Description Description 1 Hydraulic Hoses 3 Lockwasher 2 Hose Cover 4 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.
Page 267: Fig. 6-129: Transfer Carriage With Boom Installation
Boom and Transfer Description Description 1 Nut 7 Spindle Nut 2 Lockwasher 8 Spacer Washer 3 Capscrew 9 Thrust Washer 4 Front Slide Block 10 Spindle 5 Transfer Carriage 11 Roller Bushing 6 Setscrew 12 Transfer Roller Fig. 6-129: Transfer Carriage with Boom Installation 12.
Page 268: Fig. 6-130: Transfer Carriage Installation
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. Description Description 1 Nut 7 Spindle Nut 2 Lockwasher 8 Spacer Washer 3 Capscrew 9 Thrust Washer 4 Front Slide Block...
Page 269: Installation
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.
Page 270 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).
Page 271: Rollers, Bushings, And Shims
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).
Page 272: Fig. 6-132: Shims For Front Transfer Rollers
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.
Page 273: Fig. 6-133: Scraper Plate
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.
Page 274: Fig. 6-134: Transfer Carriage - Rear Rollers, Bushings, And Shims
Boom and Transfer Rear Mount Rollers, Bushings, and Spacer Washers 16 15 Description Description 1 Grease Fitting Cover 9 Rear Transfer Roller 2 Grease Fitting 10 Rear Slide Block 3 Spindle Nut 11 Slide Block Shim 4 Setscrew 12 Lockwasher 5 Spacer Washer 13 Capscrew 6 Thrust Washer...
Page 275: Fig. 6-135: Spacer Washers For Rear Transfer Rollers
Boom and Transfer 8. Secure spindle to transfer carriage with spindle nut. Distance Between Rails Transfer Roller 1/16" Transfer Carriage Roller Spindle Spacer Washer(s) Thrust Washer Rail 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.
Page 276: Fig. 6-136: Rear Slide Block Installation
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.
Page 277 Boom and Transfer 6-135 31200079...
Page 278 Boom and Transfer 6-136 31200079...
Page 279: Section 7 - Frame Tilt And Oscillation
Section 7 — Frame Tilt and Oscillation Table of Contents Frame Tilt System ..............7-1 General Description .
Page 280 List of Figures Fig. 7-1: Frame Tilt System Components ..........7-1 Fig.
Page 281 31200079...
Page 283: Frame Tilt System
Section 7 — Frame Tilt and Oscillation Frame Tilt System General Description Frame Tilt Cylinder Multi-Spool Frame Tilt Control Valve Control Valve 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.
Page 284 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°...
Page 285: Frame Tilt Control Valve
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...
Page 286: Removal
Frame Tilt and Oscillation Removal Frame Tilt Control Valve MV0650 1 Flatwasher 6 Starwasher 2 Screw 7 Capscrew 3 Control Panel 8 Fittings 4 1/4” Hoses 9 3/8” Hoses 5 Frame Tilt Control Valve Fig. 7-3: Frame Tilt Control Valve Installation (Ref.
Page 287: Installation
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.
Page 288: Overhaul
Frame Tilt and Oscillation Overhaul Frame Tilt Control Valve MV0690 Description Description 1 Capscrew 18 O-Ring 2 Washer 19 Ported Guide 3 Body 20 Knob 4 Plug 21 Lever Assy 5 Knob 22 Rubber Boot 6 Lever 23 Cam 7 Rubber Boot 24 Pin 8 Cam 25 Pivot Pin...
Page 289 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.
Page 290: Frame Tilt Cylinder
Frame Tilt and Oscillation Frame Tilt Cylinder Description 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.
Page 291: Removal
Frame Tilt and Oscillation Removal Frame Tilt Cylinder View B Description Description 1 Grease Fitting Cover 11 Lock Pin 2 Grease Fitting 12 Lockwasher 3 Frame Tilt Cylinder 13 Lower Pivot Pin 4 Capscrew 14 Capscrew 5 Mounting Block 15 Upper Pivot Pin 6 Lockwasher 16 Capscrew 7 Nut...
Page 292: Installation
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.
Page 293 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.
Page 294: Overhaul
Frame Tilt and Oscillation Overhaul Frame Tilt Cylinder MV0300 Description Description 1 Bushing 8 Tube 2 Barrel 9 Piston 3 Counterbalance Valve Cartridge 10 Rod Nut 4 O-Ring Plug 11 Rod 5 Orifice 12 Head 6 Fitting, O-Ring 7 Set Screw Fig.
Page 295 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.
Page 296 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.
Page 297: Counterbalance Valve Cartridge
Frame Tilt and Oscillation Counterbalance Valve Cartridge Counterbalance Valve Cartridge Manifold Block 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.
Page 298: Frame Level Indicator
Frame Tilt and Oscillation Frame Level Indicator Description 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.
Page 299: Rear Oscillation Lock System
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.
Page 300: Theory Of Operation And Circuit Logic
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 BOOM OVER 40° 2-WAY SOLENOID VALVE ON RELAY REAR AXLE STABILIZER VALVE ON REAR STABILIZER CYLINDER...
Page 301: Fig. 7-12: Circuit Operation Above 40°
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) BOOM 2-WAY SOLENOID VALVE ON OVER 40°...
Page 302: Fig. 7-13: Circuit Operation Above 20° Below 40°
Frame Tilt and Oscillation Boom Positioned Above 20° Below 40° BOOM ANGLE GREATER THAN 40 - OPEN 3-WAY SOLENOID VALVE ON BOOM ANGLE LESS THAN 40 - CLOSED REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) BOOM 2-WAY SOLENOID VALVE ON OVER 40°...
Page 303: Fig. 7-14: Circuit Operation Above 20° Below 40° With Service Brake Applied
Frame Tilt and Oscillation Boom Positioned Above 20° Below 40° With the Service Brake Applied BOOM ANGLE GREATER THAN 40 - OPEN 3-WAY SOLENOID VALVE ON BOOM ANGLE LESS THAN 40 - CLOSED REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) BOOM 2-WAY SOLENOID VALVE ON...
Page 304 Frame Tilt and Oscillation Boom Positioned Below 20° With the Service Brake Applied BOOM ANGLE GREATER THAN 40 - OPEN 3-WAY SOLENOID VALVE ON BOOM ANGLE LESS THAN 40 - CLOSED REAR AXLE STABILIZER CONTROL VALVE ON VALVE PLATE (ENERGIZED) BOOM 2-WAY SOLENOID VALVE ON OVER 40°...
Page 305: Testing Rear Oscillation Lock Circuit
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 Rear Boom Boom Osc. Trans. Rear OPERATING Proximity Proximity Over 20° Over 40° Locked Solenoid Solenoid...
Page 306: Rear Oscillation Lock Cylinder
Frame Tilt and Oscillation Rear Oscillation Lock Cylinder Description Rear Oscillation Lock Cylinder Rear Oscillation Lock Control Block 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.
Page 307: Removal
Frame Tilt and Oscillation Removal View B Description Description 1 Nut 12 Mounting Base 2 Lockwasher 13 Grease Fitting 3 Upper Pivot Pin 14 Grease Fitting Cover 4 Capscrew 15 Rear Carriage Tilt Cylinder #6 Hydraulic Hose 16 Check Valve 6 #8 Hydraulic Hose 17 Wiring Harness 7 Capscrew...
Page 308: Installation
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.
Page 309 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”...
Page 310: Overhaul
Frame Tilt and Oscillation Overhaul Rear Oscillation Lock Cylinder MV0310 Description Description 1 Bushing 5 Tube 2 Barrel 6 Rod 3 Rod Nut 7 Set screw 4 Piston 8 Head Fig. 7-18: Rear Oscillation Lock Cylinder (Exploded View) 7-28 31200079...
Page 311 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.
Page 312 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).
Page 313: Oscillation Control Block
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.
Page 314: Removal
Frame Tilt and Oscillation Removal Oscillation Control Block MV0470 Description Description 1 #6 Hydraulic Hose 6 Oscillation Control Block 2 #8 Hydraulic Hose 7 O-Ring 3 Capscrew 8 Rear Oscillation Lock Cylinder 4 Lockwasher 9 Electrical Lead 5 Check Valve Cartridge 10 Pressure Reducing Valve Fig.
Page 315 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.
Page 316: Installation
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.
Page 317: Overhaul
Frame Tilt and Oscillation Overhaul Oscillation Control Block MV0660 Description Description 1 Nut 12 O-Ring 13 Check Valve Cartridge, (CV3 & 2 Coil CV4) 3 Solenoid Valve 14 Piston Assy 4 Seal Kit 15 Pressure Reducing Valve Car- 5 Counter Balance Valve Cartridge tridge, (PR) 6 PO Check Valve (PC1 &...
Page 318 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.
Page 319: Boom Elevation Proximity Switch
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.
Page 320: Removal
Frame Tilt and Oscillation Boom Transfer Carriage/Boom Cradle Magnetic Flux Lines Proximity Switch 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.
Page 321: Installation
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 1. Position outer jam nut (Item 4) on switch body (Item 3) at previously Switch marked position.
Page 322 Frame Tilt and Oscillation 7-40 31200079...
Page 323: Section 8 - Transmission
Section 8 — Transmission Table of Contents Transmission Assembly Component Terminology ........8-1 Transmission Description .
Page 325: Transmission Assembly Component Terminology
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.
Page 326: Transmission Operation
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.
Page 327: Transmission Specifications
Transmission 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.
Page 328: Transmission Maintenance
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.
Page 329: Fig. 8-4: Transmission Oil Cooler Hose Connections
IMPORTANT: DO NOT use flushing compounds for cleaning purposes MV0230 Fig. 8-4: Transmission Oil Cooler Hose Connections Transmission Replacement 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. 31200079...
Page 330: Transmission Removal
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.
Page 331: Fig. 8-5: Disconnect The Battery Negative (-) Cable
Transmission 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.
Page 332: Fig. 8-7: Transmission Oil Cooler Hose Connections
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.
Page 333: Fig. 8-8: Remove Transmission From Frame
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.
Page 334: Transmission Inspection And Internal Repair
Transmission 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.
Page 335: Fig. 8-10: Install The Transmission
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.
Page 336: After Transmission Service Or Replacement
Transmission 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).
Page 337: Transmission Shift Logic
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.
Page 338 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.
Page 339: Troubleshooting
Transmission MV0590 Fig. 8-12: Transmission Shift Logic Schematic Troubleshooting This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. 31200079 8-15...
Page 340: Transmission Troubleshooting
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).
Page 341 Transmission Transmission Troubleshooting (Continued) Problem Cause Remedy 3. Low clutch pressure. 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.
Page 342 Transmission Transmission Troubleshooting (Continued) Problem Cause Remedy 6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to from transmission. appropriate owners/operators manual. 2. Drain transmission and fill to 2. Transmission filled with incorrect correct level with Universal oil.
Page 343: Section 9 - Axles And Brakes
Section 9 — Axles and Brakes Table of Contents Axle and Drive Shaft Component Terminology ........9-1 General Information .
Page 344 31200079...
Page 345: Axle And Drive Shaft Component Terminology
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.
Page 346: Axle Assembly
Manuals. Note: Several special axle service tools are required to properly service the axle assemblies. Contact the local JLG parts distributor for ordering information. CAUTION: Risk of personal injury. Exercise extreme care when using snap rings or spring-loaded retention devices.
Page 347 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 proce- dures in the appropriate axle service manual.
Page 348 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.
Page 349: Axle Inspection, Internal Service And Repair
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.
Page 350: Axle Service And Troubleshooting
This section provides an easy reference guide covering the most common problems that may occur during operation of the axles. Note: Contact the JLG distributor or the JLG Service Department at 1-877-554-5438 ext.6657, if internal axle repair is required during the warranty period.
Page 351: Drive Shafts
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.
Page 352: Drive Shaft Maintenance
Axles and Brakes MV0370 Description Description 1 Universal Joint Kit 7 Universal Joint Kit 2 Bearing Strap 8 Hex Head Capscrew 3 Strap Bolt 9 Flat Washer 4 Driveshaft 10 Locknut 5 Transmission 11 Front Driveshaft 6 Rear Driveshaft Drive Shaft Maintenance Refer to the appropriate Operator/Safety Manual for information regarding the lubrication of the grease fittings on the drive shafts.
Page 353: Transmission-To-Axle Drive Shaft
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.
Page 354: Drive Shaft Assembly
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.
Page 355 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.
Page 356: Service Brakes
Axles and Brakes Service Brakes Service Brake Pressure Switch Replacement Mid-Inlet Hydraulics MV0710 Description Description 1 Wiring Harness Connector 3 Operators Step 2 Service Brake Pressure Switch 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.
Page 357: Accumulator
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.
Page 358: Precautions
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.
Page 359: Fig. 9-4: Accumulator Charging
Axles and Brakes K1018 Description Description 1 Capscrew 6 Gauge Cap 2 Valve Guard 7 Nitrogen Hose 3 Gas Valve Cap 8 “T” Handle 4 Gauge Bleed Valve 9 Gas Valve 5 Accumulator Test Gauge 10 Accumulator Fig. 9-4: Accumulator Charging Pre-charge the accumulator using the following steps (see Fig.
Page 360: Checking Pre-Charge
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).
Page 361: Towing A Disabled Machine
Important: In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.
Page 362: Manually Releasing The Park Brake
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.
Page 363 Section 10 — Outriggers Table of Contents Outriggers ............... 10-1 General .
Page 365: Outriggers
Section 10 — Outriggers Outriggers General Fig. 10-1: Outriggers Outriggers increase the stability of the machine when lifting and placing loads. 10-1 31200079...
Page 366: Removal
Outriggers Removal Outriggers MV0170 Description Description 1 Outrigger Cylinder 12 Double Tube Clamp 2 Differential Pressure Switch 13 Clamp Plate 3 Tie 14 Jam Nut 4 Wiring Harness 15 Starwasher 5 Elbow 16 Nut 6 Hydraulic Hose 17 Shaft Assembly 7 Shim(s) 18 Nut 8 Grease Fitting Cover...
Page 367: Installation
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.
Page 368: Outrigger Cylinders
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).
Page 369: Removal
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 Description Description 1 Wiring Harness 8 Capscrew 2 Tie 9 Lockwasher 3 Differential Pressure Switch 10 Lock Pin 4 Outrigger Cylinder 11 Pin 5 Elbow...
Page 370: Installation
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).
Page 371: Overhaul
Outriggers Overhaul Outrigger Cylinders MV0680 Description Description 1 Grease Fitting 10 Rod Bearing Nut 2 Grease Fitting Cover 11 Piston 3 Counterbalance Valve Cartridge 12 Bushing 4 Bushing 13 Grease Fitting 5 O-ring Plug 14 Grease Fitting Cover 6 Differential Pressure Switch 15 Rod 7 Elbow 16 Head...
Page 372 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.
Page 373: Differential Pressure Switch
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.
Page 374: Boom Extension Proximity Switch
Outriggers Boom Extension Proximity Switch Description Proximity Switch Fig. 10-6: Boom Extension Proximity Switch (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.
Page 375: Removal
Outriggers Middle Rear) Outer Boom Section Magnetic Boom Section Flux Lines Proximity Switch 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.
Page 376: Installation
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).
Page 377: Outrigger Control Valves
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.
Page 378: Removal
Outriggers Removal Outrigger Control Valve Description Description 1 Nut 9 Connector 2 Lockwasher 10 Hydraulic Hose 3 Tie Rod 11 Control Panel 4 Outrigger Control Valve 12 Lockwasher 5 Button Head Capscrew 13 Nut 6 Frame Tilt Control Valve 14 Rear Cover 7 Lockwasher 15 Flatwasher 8 Nut...
Page 379: Installation
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.
Page 380 Outriggers 10-16 31200079...
Page 382 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.

JLG Lull 1044C-54 II Series Service Manual

Section 1 - Safety

General

Maintenance Safety

Decals and Placards

Section 2 - Identification and Specifications

Serial Number Locations

Engine Specifications

Section 3 - General Maintenance

General Instructions

Service Preparation Procedures

Service and Repair Procedures

Replacement Parts

Lubrication

Section 4 - Reference Diagrams

Section 5 - Supply, Pressure, and Return Hydraulics

Sight Gauge

Suction Strainer

Hydraulic Return Filter

Reservoir Breather

Hydraulic Pressure Filter

Hydraulic Pump

Removal

MID-Inlet Control Valve

Rear Axle Stabilizer Control Valve

Boom Extend Lockout Valve

Hydraulic Diagnostic Ports

Roll-Back Hose Tray

Section 6 - Boom and Transfer

Boom and Transfer Hydraulics

Joystick Controls

Hydraulic Cylinders

Boom Hoist Cylinder

Front Carriage Tilt Cylinder

Rear Carriage Tilt Cylinder

Selector Valve

Troubleshooting

Boom Slide Pads - General

Quick Attach

Boom Angle Inclinometer

4-Section Boom

Boom Extension Proximity Switch

Boom Extension Proximity Switch

Transfer Carriage

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for JLG Lull 1044C-54 II Series