Lull 1044C-54 Series II Service Manual User Manual

Service ManualModel1044C-54Series II31200079RevisedJuly 1, 2005

6 31200079Table of ContentsRear Oscillation Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-18312000796. Remove the sight gauge (Item 1) along with the two (2) hollow hex head bolts (Item 2). 7. Clean

Supply, Pressure, and Return Hydraulics312000795-19Suction StrainerDescriptionFig. 5-11: Suction Strainer Installation(Ref. Fig. 5-11) The suction str

Supply, Pressure, and Return Hydraulics5-2031200079Removal and CleaningSuction Strainer(Ref. Fig. 5-11) The following procedures describes removal of

Supply, Pressure, and Return Hydraulics312000795-21Hydraulic Return FilterDescriptionFig. 5-12: Hydraulic Return Filter(Ref. Fig. 5-12) The hydraulic

Supply, Pressure, and Return Hydraulics5-2231200079The return filter pressure gauge is located on the side of the return filter housing.The gauge indi

Supply, Pressure, and Return Hydraulics312000795-232. Loosen four (4) flange nuts (Item 2) that secure cover (Item 3) to return filter housing (Item 1

Supply, Pressure, and Return Hydraulics5-2431200079Replacement, Return Filter Element(Ref. Fig. 5-15) The following procedure describes replacing the

Supply, Pressure, and Return Hydraulics312000795-25RemovalReturn Filter AssemblyFig. 5-16: Return Filter Assembly(Ref. Fig. 5-16) The following proced

Supply, Pressure, and Return Hydraulics5-26312000796. Remove the diffuser (Item 7) and clean with solvent. Dry with compressed air.InstallationReturn

Supply, Pressure, and Return Hydraulics312000795-27Removal and InstallationReservoir Breather1. Loosen and remove breather, using tool on hex portion

31200079 7Table of ContentsAxle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-2831200079Replacing Pressure Filter ElementFig. 5-19: Hydraulic Pressure Filter Element(Ref. Fig. 5-19) The f

Supply, Pressure, and Return Hydraulics312000795-297. Insert a new filter element into bowl. Lubricate bowl O-ring with hydraulic oil and install it o

Supply, Pressure, and Return Hydraulics5-30312000795. Remove the pressure filter assembly from the hole in the filter mounting bracket.InstallationPre

Supply, Pressure, and Return Hydraulics312000795-31(Ref. Fig. 5-21) The hydraulic pump is located on the transmission towards the back of the machine.

Supply, Pressure, and Return Hydraulics5-3231200079C. Disconnected or broken pump driveInspect and repair or replace.4. Loss of fluid A. Ruptured hydr

Supply, Pressure, and Return Hydraulics312000795-33RemovalHydraulic Pump.Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics(Ref. Fig. 5-22) The fo

Supply, Pressure, and Return Hydraulics5-34312000793. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Re

Supply, Pressure, and Return Hydraulics312000795-35Fig. 5-23: Hydraulic Pump Installation – Mid-Inlet Hydraulics(Ref. Fig. 5-23) The following procedu

Supply, Pressure, and Return Hydraulics5-3631200079CAUTION: Before removing support bracket or loosening capscrews that secure the hydraulic pump to t

Supply, Pressure, and Return Hydraulics312000795-37InstallationHydraulic Pump(Ref. Fig. 5-22 and Fig. 5-23) The following procedure is for the install

8 31200079List of FiguresFig. 1-1: Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-3831200079Checking Pump Flow RateFig. 5-24: Checking Hydraulic Pump Flow Rate(Ref. Fig. 5-24) If the pump(s)

Supply, Pressure, and Return Hydraulics312000795-396. Adjust pressure relief valve setting to 100 psi over that of system's maximum rated pressur

Supply, Pressure, and Return Hydraulics5-4031200079Mid-Inlet Control ValveDescriptionFig. 5-25: Mid-Inlet Control Valve LocationFig. 5-26: Mid-Inlet C

Supply, Pressure, and Return Hydraulics312000795-41(Ref. Fig. 5-25 and Fig. 5-26)The mid-inlet control valve is located on the valve plate, near the m

Supply, Pressure, and Return Hydraulics5-4231200079Fig. 5-27: Mid-Inlet Control Valve Configurations, 1138Transfer CarriageAuxiliaryFrame TiltCarriage

Supply, Pressure, and Return Hydraulics312000795-43RemovalMid-Inlet Control ValveFig. 5-28: Mid-Inlet Control Valve Installation(Ref. Fig. 5-28) The f

Supply, Pressure, and Return Hydraulics5-4431200079InstallationMid-Inlet Control Valve1. (Ref. Fig. 5-28) Position the control valve on the valve plat

Supply, Pressure, and Return Hydraulics312000795-45Fig. 5-30 illustrates views of the control valve, showing port locations and markings. Table 5-1 is

Supply, Pressure, and Return Hydraulics5-4631200079Table 5-1: Rear Axle Stabilizer Control Valve MarkingsView Marking DescriptionA - Top View G2 Gauge

Supply, Pressure, and Return Hydraulics312000795-47Removal, Rear Axle Stabilizer Control ValveFig. 5-31: Rear Axle Stabilizer Control Valve.MV07201234

31200079 9List of FiguresFig. 5-24: Checking Hydraulic Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-4831200079WARNING: Hot hydraulic fluid can cause severe burns. Wait for the hydraulic fluid to cool before se

Supply, Pressure, and Return Hydraulics312000795-49Boom Extend Lockout ValveDescriptionFig. 5-32: Boom Extend Lockout Valve(Ref. Fig. 5-32) The boom e

Supply, Pressure, and Return Hydraulics5-5031200079• Pump 1 – Used for reading pressure of the hydraulic pump #1. Pressure limit is 3000 psi.• Pump 2

Supply, Pressure, and Return Hydraulics312000795-51Roll-Back Hose Tray GeneralFig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics(R

Supply, Pressure, and Return Hydraulics5-5231200079Mid-Inlet Hydraulic SystemFig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics(Ref. Fig. 5

Supply, Pressure, and Return Hydraulics312000795-53InstallationRoll-Back Hose Tray(Ref. Fig. 5-35) The following procedure describes installation of t

Supply, Pressure, and Return Hydraulics5-5431200079

31200079 iSection 6 — Boom and TransferTable of ContentsBoom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii 31200079Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 iiiFig. 6-10: Front Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 31200079List of FiguresFig. 6-27: Positioning Retaining Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv 31200079Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50Fig. 6-50:

31200079 vFig. 6-88: Side Slide Pads – Outer Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82Fig. 6

vi 31200079Fig. 6-127: Boom Extension Proximity Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123Fig. 6-1

312000796-1Section 6 — Boom and TransferBoom and Transfer HydraulicsGeneral DescriptionFig. 6-1: Major Boom and Transfer Hydraulic Components(Ref. Fig

Boom and Transfer6-231200079Joystick ControlsGeneral DescriptionFig. 6-2: Joystick(Ref. Fig. 6-2) The joysticks control hydraulic flow to the associat

Boom and Transfer312000796-3RemovalJoystickFig. 6-3: Joystick Installation(Ref. Fig. 6-3) The following steps are required to remove the joystick.1. F

Boom and Transfer6-4312000793. Tag, loosen, and remove two (2) swivel tees (Item 11) from connectors (Item 9) on bottom of joystick.4. Tag, loosen, an

Boom and Transfer312000796-5DisassemblyJoystickFig. 6-4: Joystick Components(Ref. Fig. 6-4) The following steps are required to disassemble and repair

Boom and Transfer6-6312000791. Pull back boot (Item 17) so that access to retainer (Item 19) and flange (Item 20) can be made.2. Loosen and remove fou

Boom and Transfer312000796-7e. Clean all remaining parts of joystick body assembly, including the body’s center port, with solvent. Dry with compresse

31200079 11List of FiguresFig. 6-65: Locations for Chain Attachment – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Boom and Transfer6-8312000797. 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. R

Boom and Transfer312000796-9Fig. 6-6: Pilot Pressure Plugc. (Ref. Fig. 6-6) If the pilot pressure is not within the recommended range, adjust pressure

Boom and Transfer6-1031200079WARNING: Do not remove counterbalance valves from cylinders on the machine while the cylinder is under load (extended). I

Boom and Transfer312000796-114. Remove the hose at the base end of the cylinder and plug the hose.5. Start the engine and activate the control that wi

Boom and Transfer6-1231200079Boom Hoist CylinderDescriptionFig. 6-7: Boom Hoist Cylinders(Ref. Fig. 6-7) Two (2) boom hoist cylinders are used to rais

Boom and Transfer312000796-13RemovalBoom Hoist CylinderFig. 6-8: Boom Hoist Cylinder Installation(Ref. Fig. 6-8) The following steps are required to r

Boom and Transfer6-1431200079WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blo

Boom and Transfer312000796-15OverhaulBoom Hoist CylinderFig. 6-9: Boom Hoist Cylinder Assembly(Ref. Fig. 6-9) The following steps are required to over

Boom and Transfer6-1631200079a. Place socket wrench over counterbalance valve cartridge (Item 8). Wrap a clean shop rag around the socket to cover the

Boom and Transfer312000796-1716. Inspect counterbalance valve cartridge (Item 8), including O-rings, for condition and replace as necessary. Do not di

12 31200079List of FiguresFig. 6-103: Upper Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-1831200079Front Carriage Tilt CylinderDescriptionFig. 6-10: Front Carriage Tilt CylinderThe front carriage tilt cylinder is located

Boom and Transfer312000796-19RemovalFront Carriage Tilt CylinderFig. 6-11: Front Carriage Tilt Cylinder Installation(Ref. Fig. 6-11) The following ste

Boom and Transfer6-2031200079WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blo

Boom and Transfer312000796-21OverhaulFront Carriage Tilt CylinderFig. 6-12: Front Carriage Tilt Cylinder Assembly(Ref. Fig. 6-12) The following steps

Boom and Transfer6-2231200079WARNING: The counterbalance valve cartridge traps hydraulic pressure in the cylinder. Wear proper eye and hand protection

Boom and Transfer312000796-2314. Inspect counterbalance valve cartridge (Item 5), including O-rings, for condition and replace as necessary. Do not di

Boom and Transfer6-2431200079Rear Carriage Tilt CylinderDescriptionFig. 6-13: Rear Carriage Tilt CylinderTwo rear carriage tilt cylinders are located

Boom and Transfer312000796-25RemovalRear Carriage Tilt CylinderFig. 6-14: Rear Carriage Tilt Cylinder Installation(Ref. Fig. 6-14) The following steps

Boom and Transfer6-26312000793. Tag and disconnect two (2) hydraulic hoses (Item 7) from elbows on both cylinders (Item 6). Cap fittings and hoses.4.

Boom and Transfer312000796-275. Clean hydraulic hose ends with solvent. Attach two (2) hoses (Item 7) to elbows on each cylinder. Torque hose swivel n

31200079 13List of FiguresFig. 7-5: Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-28312000795. Remove the cylinder rod assembly from cylinder barrel.CAUTION: To prevent possible damage to components, support cylin

Boom and Transfer312000796-2918. Install cylinder rod assembly in cylinder barrel. Install a spanner wrench in two (2) holes of rod bearing head and t

Boom and Transfer6-3031200079RemovalSelector Valve Fig. 6-17: Selector Valve Installation(Ref. Fig. 6-17) The following steps are required to remove t

Boom and Transfer312000796-31InstallationSelector Valve (Ref. Fig. 6-17) The following steps are required to install the selector valve in models with

Boom and Transfer6-32312000794. Remove coil (Item 2) from solenoid valve.5. Loosen and remove solenoid valve from valve body.6. Remove O-rings and bac

Boom and Transfer312000796-33TroubleshootingProblem Probable Cause Solution Reference1. Boom fails to extend or retractA. Broken hydraulic line(s) and

Boom and Transfer6-3431200079Boom Slide Pads — GeneralDescriptionWithin the slide boom assemblies, there art two classifications of slide pads:• Load

Boom and Transfer312000796-35Slide Pads with ChamfersFig. 6-20: Pad Worn, But Still OK(Ref. Fig. 6-20) Inspect all pads weekly for condition and amoun

Boom and Transfer6-3631200079Slide Pads without ChamfersFig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom(Ref. Fig. 6-23) The lower slide p

Boom and Transfer312000796-37Another option is to install/replace boom wear strips. Contact the JLG Service Department or your dealer for information

14 31200079List of FiguresFig. 10-1: Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-3831200079Replacing and Shimming Boom Slide Pads — GeneralFig. 6-26: Slide Pad Installation (2-Section Shown)(Ref. Fig. 6-26) As bo

Boom and Transfer312000796-39Adding or removing shims from bolted pads may require a different capscrew length or washer selection.Fig. 6-28: Determin

Boom and Transfer6-4031200079Quick AttachDescriptionFig. 6-30: Quick Attach Rear View(Ref. Fig. 6-30) The quick attach is designed for easy connection

Boom and Transfer312000796-418. Pull release handle (1) back.Fig. 6-32: Lock Plate9. The lock pin (2) should engage the attachment, clearing the lock

Boom and Transfer6-4231200079Fig. 6-35: Retracting Boom12. Retract the boom until quick attach (5) is clear of attachment (7).Connecting an Attachment

Boom and Transfer312000796-43Fig. 6-38: Rotating Quick Attach Forward3. Rotate the quick attach (5) upwards to engage the attachment (7).4. Shut off e

Boom and Transfer6-4431200079RemovalQuick Attach1. Disconnect attachment from quick attach.2. Fully retract boom and transfer carriage (if equipped),

Boom and Transfer312000796-45Fig. 6-41: Quick Attach Pivot5. (Ref. Fig. 6-41) Remove nut (Item 4), lockwasher (Item 3), and capscrew (Item 2) from qui

Boom and Transfer6-4631200079Boom Angle InclinometerDescriptionFig. 6-42: Boom Angle Inclinometer(Ref. Fig. 6-42) The boom angle inclinometer is locat

Boom and Transfer312000796-474-Section BoomDescriptionFig. 6-44: 4-Section BoomThe 4-section boom is used on 1044C-54 models. It is a fully synchroniz

31200079 15List of TablesTable 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-4831200079Shimming Procedures4-Section BoomFig. 6-45: Boom Slide Pad Locations – 4-Section Boom1. Park machine on firm, level surfa

Boom and Transfer312000796-493. (Ref. Fig. 6-46) Measure the gap between boom sections at all upper front pads. If the dimensions are not within the s

Boom and Transfer6-50312000795. (Ref. Fig. 6-48) Install/remove shim(s) under indicated pads to obtain specified clearances.Fig. 6-49: Boom Section Ga

Boom and Transfer312000796-51Fig. 6-51: Upper Shim Installation – Rear of 4-Section Boom8. (Ref. Fig. 6-51) Install/remove shim(s) under indicated pad

Boom and Transfer6-5231200079Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom10. (Ref. Fig. 6-53) Install/remove shim(s) under indicated

Boom and Transfer312000796-5311. (Ref. Fig. 6-54) Adjust boom positions to obtain clearances between boom sections as shown. Measure these clearances

Boom and Transfer6-5431200079Fig. 6-56: Inner Boom Cross-Section at Window2. (Ref. Fig. 6-56) Place a straight edge against the bottom surface of the

Boom and Transfer312000796-554. (Ref. Fig. 6-57) Place a straight edge against the bottom surface of the middle (forward) boom section. Measure the di

Boom and Transfer6-5631200079Fig. 6-59: 4-Section Boom Cover Installation5. (Ref. Fig. 6-59) Remove six (6) each nuts (Item 1), lockwashers (Item 2),

Boom and Transfer312000796-578. (Ref. Fig. 6-60) Tag and disconnect two (2) hoses at boom extension cylinder lines (Item 3). Cap lines and hoses9. Tag

16 31200079List of Tables

Boom and Transfer6-5831200079CAUTION: Make sure each cylinder is fully supported so it does not fall and cause personal or equipment damage when it is

Boom and Transfer312000796-59Fig. 6-63: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section16. (Ref. Fig. 6-63) Remove upper rear slide pads

Boom and Transfer6-603120007917. (Ref. Fig. 6-64) Remove upper rear slide pads from inner boom section as follows:a. Remove two (2) each capscrews (It

Boom and Transfer312000796-61Fig. 6-66: 4-Section Boom Pivot Pins19. (Ref. Fig. 6-66) Remove two (2) each nuts (Item 1), lockwashers (Item 2), and cap

Boom and Transfer6-6231200079installation4-Section Boom1. Prepare replacement boom for installation by removing strapping and blocks used for shipment

Boom and Transfer312000796-63a. With the outriggers up, extend the boom, noting that Boom Extension proximity light illuminates when the boom is exten

Boom and Transfer6-6431200079Fig. 6-67: Slide Pad Removal – Outer Boom Section3. (Ref. Fig. 6-67) Remove the lower slide pads from outer boom section

Boom and Transfer312000796-65Fig. 6-68: Lower Front Slide Pad Removal – Middle (Rear) Boom Section4. (Ref. Fig. 6-68) Remove lower front slide pads fr

Boom and Transfer6-6631200079Fig. 6-69: Disconnecting Hoses Between Sections5. (Ref. Fig. 6-69) Disconnect hoses between sections as follows:a. Remove

Boom and Transfer312000796-67CAUTION: Be sure to note orientation of the hose guard during removal. Your hose guard may be different from that shown a

31200079 iSection 1 — SafetyTable of ContentsGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-68312000796. (Ref. Fig. 6-70) Remove extension cylinder as follows:a. Support the extension cylinder with sling(s) or other suitabl

Boom and Transfer312000796-699. (Ref. Fig. 6-71) Remove upper front slide pads from middle (rear) boom section as follows:a. Remove two (2) each capsc

Boom and Transfer6-703120007911. (Ref. Fig. 6-73) Remove jam nut (Item 2) and lockwasher (Item 3) securing upper chain adjustment anchor (Item 1) to m

Boom and Transfer312000796-71Fig. 6-75: Disconnecting Chains at Rear of Inner Boom15. (Ref. Fig. 6-75) Disconnect chains from rear of inner boom as fo

Boom and Transfer6-7231200079a. Remove two (2) lock nuts (Item 2), chain anchor rod (Item 6), and upper chain (Item 1).b. Remove capscrew (Item 4), lo

Boom and Transfer312000796-73Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section20. (Ref. Fig. 6-78) Remove remaining slide pads from middle

Boom and Transfer6-7431200079c. (Ref. Fig. 6-78) Remove lower slide pads from front of middle (forward) boom section as follows:1). Remove two (2) soc

Boom and Transfer312000796-75Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section27. (Ref. Fig. 6-80) Remove rear chain roller assembl

Boom and Transfer6-7631200079Fig. 6-81: Hose and Tube Removal – Inner Boom Section30. (Ref. Fig. 6-81) Remove tubes and hoses from inner boom section

Boom and Transfer312000796-77Fig. 6-82: Upper Chain Assembly31. (Ref. Fig. 6-82) Remove nut (Item 4) and lockwasher (Item 3) securing upper chain anch

Boom and Transfer6-783120007932. (Ref. Fig. 6-83) Remove capscrew (Item 9), lockwasher (Item 8), and lock pin (Item 7) from chain roller pin (Item 10)

Boom and Transfer312000796-79Fig. 6-85: Slide Pads – Middle (Rear) Boom Section36. (Ref. Fig. 6-85) Remove remaining slide pads from middle (rear) boo

Boom and Transfer6-8031200079Fig. 6-86: Chain and Hose Guide Assembly37. (Ref. Fig. 6-86) Remove chain and hose guide assembly from rear of middle (re

Boom and Transfer312000796-81Fig. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections38. (Ref. Fig. 6-87) Remove middle (rear) boom section

Boom and Transfer6-8231200079a. Remove two (2) each nuts (Item 7), lockwashers (Item 8), and tube clamps (Item 9) securing each set of auxiliary and c

Boom and Transfer312000796-83Fig. 6-89: Outer Boom Tubes and Hoses42. (Ref. Fig. 6-89) Remove outer boom hydraulic hoses as follows:a. Loosen and remo

Boom and Transfer6-8431200079b. Remove two (2) each nuts (Item 5), lockwashers (Item 6), and clamps (Item 7) securing each set of hydraulic tubes to b

Boom and Transfer312000796-85Fig. 6-90: Outer Boom Tube and Hose Assembly2. (Ref. Fig. 6-90) Install auxiliary and front carriage tilt hydraulic tubes

Boom and Transfer6-8631200079d. Install a cushion clamp (Item 8) on each hydraulic tube as follows:1). Install plastic cushion (Item 15) on hydraulic

Boom and Transfer312000796-87WARNING: To avoid personal and/or equipment damage, make sure the cylinder is properly supported until it is completely i

312000791-1Section 1 — SafetyGeneralObserving basic safety rules and precautions can eliminate accidents when operating, maintaining, and repairing th

Boom and Transfer6-8831200079b. Install chain adjustment block (Item 5) on other end of lower chain with shoulder bolt (Item 6) and lock nut (Item 8).

Boom and Transfer312000796-89Fig. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections9. (Ref. Fig. 6-94) Install hydraulic tubes and hoses on middle (

Boom and Transfer6-9031200079Fig. 6-95: Chain and Hose Guide Assembly10. (Ref. Fig. 6-95) Install chain and hose guide assembly on rear of middle (rea

Boom and Transfer312000796-9111. Turn middle (rear) boom section over to upright position on work stands.Fig. 6-96: Installation of Lower Chain – Midd

Boom and Transfer6-9231200079Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section13. (Ref. Fig. 6-97) Install upper chain roller assemb

Boom and Transfer312000796-93Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section17. (Ref. Fig. 6-98) Install chain roller assemblies on

Boom and Transfer6-9431200079Fig. 6-99: Slide Pad Installation – Middle (Forward) Boom SectionNote: Apply thread locking compound to all slide pad mou

Boom and Transfer312000796-95a. Install two (2) bottom slide pads (Item 1) and shims (Item 2) to front of boom section with four (4) each lockwashers

Boom and Transfer6-9631200079c. Install auxiliary and front carriage tilt hydraulic tubes on channels (Item 6) in inside of inner boom section with cu

Boom and Transfer312000796-9727. (Ref. Fig. 6-102) Install grease hose assembly on rear of inner boom section as follows:a. Install two (2) elbows (It

Safety1-231200079Safety StandardThe ASME/ANSI B56.6 safety standard for rough terrain forklift trucks defines safety requirements relating to the desi

Boom and Transfer6-9831200079d. Lay upper chain flat on top of inner boom section.30. Lift inner boom section and slide it into middle (front) boom se

Boom and Transfer312000796-99Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom33. (Ref. Fig. 6-105) Install upper chains and hose

Boom and Transfer6-1003120007935. (Ref. Fig. 6-106) Install slide pad retainers (Item 3) with flatwashers (Item 4), lockwashers (Item 5), and capscrew

Boom and Transfer312000796-101Fig. 6-108: Lower Chain Installation – Inner Boom Section39. Install lower chain (Item 2) from inside middle (rear) boom

Boom and Transfer6-10231200079Fig. 6-110: Upper Chains – Middle (Rear) to Outer Boom Sections41. (Ref. Fig. 6-110) Secure upper chain to outer boom se

Boom and Transfer312000796-103Fig. 6-111: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections42. (Ref. Fig. 6-111) Secure upper chain to mid

Boom and Transfer6-10431200079Fig. 6-113: Securing Boom Extension Cylinder44. (Ref. Fig. 6-113) Secure extension cylinder (Item 4) to front of middle

Boom and Transfer312000796-105Fig. 6-114: Connecting Hoses Between Sections45. (Ref. Fig. 6-114) Connect hydraulic hoses between boom sections as foll

Boom and Transfer6-10631200079a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from inside the middle (rear) boom section (Item 9) up

Boom and Transfer312000796-107The extend chains will be visible for inspection with the machine in this state.While doing the chain inspection, check

Safety312000791-3• Make certain there is adequate light and ventilation.• Remove any foreign substances (i.e. oil, grease, water, snow, ice) to elimin

Boom and Transfer6-10831200079Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extre

Boom and Transfer312000796-1097. Make sure the service ovals are lined up on the side rear of boom. If not, adjust forward middle boom section first.

Boom and Transfer6-1103120007911. Install new hose sheaves with existing sheave retaining pins. Pull hoses up around sheave and reattach to tubes. Avo

Boom and Transfer312000796-111Extension Cylinder4-Section BoomDescriptionFig. 6-116: 4-Section Boom Extension CylinderThe 4-section boom extension cyl

Boom and Transfer6-11231200079Removal, Extension CylinderFig. 6-117: 4-Section Boom Extension Cylinder Installation(Ref. Fig. 6-117) The following ste

Boom and Transfer312000796-113DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. To avoid pers

Boom and Transfer6-11431200079Overhaul, Extension CylinderFig. 6-118: 4-Section Boom Extension Cylinder Assembly(Ref. Fig. 6-118) The following steps

Boom and Transfer312000796-115a. Place socket wrench over counterbalance valve cartridge. Wrap a clean shop rag around the socket to cover the area of

Boom and Transfer6-1163120007922. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic oil and install on head. Using a seal driver

Boom and Transfer312000796-117Boom Extension Proximity SwitchDescriptionFig. 6-119: Boom Extension Proximity Switch(Ref. Fig. 6-119) The boom extensio

Safety1-431200079Hydraulic System HazardsThe hydraulic system is under pressure whenever the engine is running and can hold pressure after the engine

Boom and Transfer6-11831200079Fig. 6-120: Boom Extension Proximity Switch Operation(Ref. Fig. 6-120) The switch operates by sending out a constant, hi

Boom and Transfer312000796-119(Ref. Fig. 6-121) The following procedure describes removal of the boom extension proximity switch.1. Disconnect wire ha

Boom and Transfer6-120312000791. Loosen, but do not remove the two (2) jam nuts on the proximity switch body.2. Check gap between switch and boom. Gap

Boom and Transfer312000796-121The transfer carriage, along with the transfer cylinder, make up the “Trans-Action” feature. This feature makes it possi

Boom and Transfer6-12231200079Fig. 6-125: Boom Elevation Proximity Switch Wiring6. (Ref. Fig. 6-125) Remove boom elevation proximity switch as follows

Boom and Transfer312000796-123b. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwashers (Item 2) securing boom cover (Item 4) to boo

Boom and Transfer6-12431200079Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage9. (Ref. Fig. 6-128) Remove four (4) each capscrews (Ite

Boom and Transfer312000796-125Fig. 6-129: Transfer Carriage with Boom Installation12. (Ref. Fig. 6-129) The following steps are necessary if the boom

Boom and Transfer6-12631200079e. Slowly lift the boom and transfer carriage assembly up and away from the machine. Place the assembly on support block

Boom and Transfer312000796-127g. (Ref. Fig. 6-130) Remove the two (2) spindle nuts. Remove spacer washer (Item 8), thrust washer (Item 9), spindle (It

Safety312000791-5To avoid personal injury…• Electrolyte in batteries contains sulfuric acid which is a poison and can cause severe chemical burns. Wea

Boom and Transfer6-12831200079WARNING: To avoid personal and/or equipment damage, support the transfer carriage assembly when lifting and reinstalling

Boom and Transfer312000796-129d. Secure the wiring harness and switch connection wire to the boom with six (6) each (five on top of the boom and one i

Boom and Transfer6-130312000791. Follow preparation procedures as outlined in Section 3 of this manual.2. Lower the boom to the ground, apply the park

Boom and Transfer312000796-131c. Measure the gap between the lip of the transfer roller and the inner edge of the rail. If this measurement is not 1/1

Boom and Transfer6-13231200079Rear Mount Rollers, Bushings, and Spacer WashersFig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims(Ref. F

Boom and Transfer312000796-1338. Secure spindle to transfer carriage with spindle nut.Fig. 6-135: Spacer Washers for Rear Transfer Rollers9. (Ref. Fig

Boom and Transfer6-134312000794. Reinstall boom and shims as described earlier in this section.5. Remove two (2) grease fitting cover caps (Item 15) a

Boom and Transfer312000796-135

Boom and Transfer6-13631200079

31200079 iSection 7 — Frame Tilt and OscillationTable of ContentsFrame Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety1-631200079• NEVER reinflate a tire that has been run flat or seriously under inflated WITHOUT removing the tire from the wheel. Have the tire a

ii 31200079List of FiguresFig. 7-1: Frame Tilt System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 iii

312000797-1Section 7 — Frame Tilt and OscillationFrame Tilt SystemGeneral DescriptionFig. 7-1: Frame Tilt System Components(Ref. Fig. 7-1) The frame t

Frame Tilt and Oscillation7-231200079The frame tilt system works in combination with the rear oscillation lock system. The frame tilt system is explai

Frame Tilt and Oscillation312000797-3frame tilt lockout valve is a component of the rear oscillation lock system and its function is explained under “

Frame Tilt and Oscillation7-431200079RemovalFrame Tilt Control ValveFig. 7-3: Frame Tilt Control Valve Installation(Ref. Fig. 7-3) The following proce

Frame Tilt and Oscillation312000797-5InstallationFrame Tilt Control Valve1. (Ref. Fig. 7-3) Insert frame tilt control valve (Item 5) into control pane

Frame Tilt and Oscillation7-631200079OverhaulFrame Tilt Control ValveFig. 7-4: Frame Tilt Control Valve (Exploded View)MV06905678104312913141511121617

Frame Tilt and Oscillation312000797-7(Ref. Fig. 7-4) The following procedures are for the disassembly, cleaning, and assembly of the frame tilt contro

Safety312000791-7Attaching DecalsThe surface on which a decal is to be attached must be dry and free of all dirt and grease. Remove the backing from t

Frame Tilt and Oscillation7-831200079Frame Tilt CylinderDescriptionFig. 7-5: Frame Tilt Cylinder(Ref. Fig. 7-5) The frame tilt cylinder is located nea

Frame Tilt and Oscillation312000797-9RemovalFrame Tilt CylinderFig. 7-6: Frame Tilt Cylinder Installation(Ref. Fig. 7-6) The following procedures are

Frame Tilt and Oscillation7-10312000797. Place a sling around the cylinder and attach the sling to suitable lifting equipment. Make sure sling and lif

Frame Tilt and Oscillation312000797-119. Lubricate upper and lower pivots with grease.10. Start engine and cycle frame tilt fully left and right sever

Frame Tilt and Oscillation7-1231200079OverhaulFrame Tilt CylinderFig. 7-7: Frame Tilt Cylinder (Exploded View)MV03001111289104112343567# Description1

Frame Tilt and Oscillation312000797-13Disassembly, Frame Tilt Cylinder(Ref. Fig. 7-7) The following steps are required to disassemble the frame tilt c

Frame Tilt and Oscillation7-1431200079Bushing Replacement1. Fig. 7-7 shows both types of rod end configurations and bushing locations. Remove pivot bu

Frame Tilt and Oscillation312000797-15Counterbalance Valve CartridgeFig. 7-8: Counterbalance Valve Cartridges, Frame Tilt CylinderWARNING: The counter

Frame Tilt and Oscillation7-1631200079Frame Level IndicatorDescriptionFig. 7-9: Frame Level Indicator(Ref. Fig. 7-9) The Frame Level Indicator shows t

Frame Tilt and Oscillation312000797-173. Adjust frame level indicator so ball is centered over 0° mark. Tighten indicator screws.Rear Oscillation Lock

EFFECTIVITY PAGE31200079 iMarch 18, 2005 - A - Original Issue Of Manual July 1, 2005 - Revised Manual

Safety1-831200079Fig. 1-1: Decals and PlacardsFig. 1-2: Instrument Panel Decals3FT2FTNOTICEFORKLIFT SIGNALSSTOPRAISE LOAD LOWER LOADTILT FORKS RIGHTTI

Frame Tilt and Oscillation7-1831200079Theory of Operation and Circuit LogicFig. 7-11: Circuit Operation Below 40°(Reference Fig. 7-11) Major component

Frame Tilt and Oscillation312000797-19Boom Positioned Above 40°Fig. 7-12: Circuit Operation Above 40°(Ref. Fig. 7-12) The following describes the rear

Frame Tilt and Oscillation7-2031200079Boom Positioned Above 20° Below 40°Fig. 7-13: Circuit Operation Above 20° Below 40°(Ref. Fig. 7-13) The followin

Frame Tilt and Oscillation312000797-21Boom Positioned Above 20° Below 40° With the Service Brake AppliedFig. 7-14: Circuit Operation Above 20° Below 4

Frame Tilt and Oscillation7-2231200079Boom Positioned Below 20° With the Service Brake AppliedFig. 7-15: Circuit Operation Below 20° With the Service

Frame Tilt and Oscillation312000797-23Testing Rear Oscillation Lock Circuit Use Table 7-1 for testing the rear oscillation lock circuit. Table 7-1: Re

Frame Tilt and Oscillation7-2431200079Rear Oscillation Lock CylinderDescriptionFig. 7-16: Rear Oscillation Lock Cylinder(Ref. Fig. 7-16) The rear osci

Frame Tilt and Oscillation312000797-25RemovalFig. 7-17: Rear Oscillation Lock Cylinder Installation(Ref. Fig. 7-17) The following steps are required t

Frame Tilt and Oscillation7-26312000796. Slowly loosen each check valve (Item 16) on control block (labeled 3.1 and 3.2) to allow residual pressure to

Frame Tilt and Oscillation312000797-279. Start engine and cycle frame tilt fully left and right several times to purge air from hydraulic system. Lowe

Safety312000791-9Fig. 1-3: Control DecalsFig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle SignV1087OutriggerFrameTilt ControlTr an s fe rand

Frame Tilt and Oscillation7-2831200079OverhaulRear Oscillation Lock CylinderFig. 7-18: Rear Oscillation Lock Cylinder (Exploded View)MV0310167112345#

Frame Tilt and Oscillation312000797-29Disassembly, Rear Oscillation Lock Cylinder(Ref. Fig. 7-18) Disassembly procedures for the rear oscillation lock

Frame Tilt and Oscillation7-30312000792. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic oil and install on head (Item 8). Usi

Frame Tilt and Oscillation312000797-31Oscillation Control BlockDescriptionFig. 7-19: Oscillation Control Block(Ref. Fig. 7-19) The oscillation control

Frame Tilt and Oscillation7-3231200079RemovalOscillation Control BlockFig. 7-20: Oscillation Control Block InstallationRear Oscillation Lock Cylinder

Frame Tilt and Oscillation312000797-335. Place a suitable drip pan under rear oscillation lock cylinder.WARNING: Residual hydraulic pressure may be tr

Frame Tilt and Oscillation7-3431200079InstallationOscillation Control BlockRear Oscillation Lock Cylinder Installed on Machine(Ref. Fig. 7-20) Use the

Frame Tilt and Oscillation312000797-35OverhaulOscillation Control Block Fig. 7-21: Oscillation Control Block (Exploded View)(Ref. Fig. 7-21) Follow th

Frame Tilt and Oscillation7-3631200079Disassembly, Oscillation Control BlockCheck Valve1. Note position of hydraulic fittings installed in block body

Frame Tilt and Oscillation312000797-37Solenoid Valve9. Install two (2) backup rings and O-ring on each pilot piston (Item 14) so O-ring is between bac

Safety1-1031200079Fig. 1-5: Steer Selector PlateFig. 1-6: Hydraulic Reservoir/Fuel Tank DecalsFig. 1-7: Fork Carriage DecalsFRONT WHEEL STEERROUND STE

Frame Tilt and Oscillation7-3831200079Fig. 7-23: Boom Elevation Proximity Switch Operation(Ref. Fig. 7-23) The switch operates by sending out a consta

Frame Tilt and Oscillation312000797-393. Remove inner jam nut (Item 2) and proximity switch form transfer carriage/boom cradle (Item 1). Re-install in

Frame Tilt and Oscillation7-4031200079

31200079 iSection 8 — TransmissionTable of ContentsTransmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 8-1Section 8 — TransmissionTransmission Assembly Component TerminologyTo understand the safety, operation and maintenance information present

Transmission8-2 31200079The ZF 4 WG-98 TC Transmission used in this vehicle is a four-speed configuration. The “intermediate drop” designation refers

Transmission31200079 8-3Fig. 8-2: Transmission Serial Number Plate LocationTransmission SpecificationsTransmission General SpecificationGeneral transm

Transmission8-4 31200079Transmission MaintenanceWARNING: To help avoid severe burns, DO NOT attempt this procedure when the engine, cooling, and hydr

Transmission31200079 8-5• At ten hour intervals, check the transmission oil level. Refer to the appro-priate operators & safety manual.• When the

31200079 iSection 2 — Identification and SpecificationsTable of ContentsSerial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission8-6 31200079Important:To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate p

Transmission31200079 8-7Fig. 8-5: Disconnect the Battery Negative (-) Cable7. Thoroughly clean the transmission and surrounding area, including all ho

Transmission8-8 3120007913. Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors.14. Remove

Transmission31200079 8-9WARNING: Risk of personal injury. The transmission may move while hoisting it out of the chassis. Carefully move the transmis

Transmission8-10 31200079Fig. 8-9: Transmission External ComponentsThe transmission is now ready for inspection and/or further service. Refer to the Z

Transmission31200079 8-112. Attach the transmission to the rear mounting bracket (6) with two capscrews (4) and two lockwashers (5). Torque the capscr

Transmission8-12 31200079Fig. 8-11: Transmission Oil Cooler Hose Connections9. Install the transmission-to-axle drive shafts.10. Clean the transmissio

Transmission31200079 8-138. Back flush the transmission oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil an

Transmission8-14 31200079Normal Operation of the transmission is as follows:When the boom is not above 20°, the transmission shifts normally (i.e., th

Transmission31200079 8-15Fig. 8-12: Transmission Shift Logic SchematicTroubleshootingThis section provides an easy reference guide covering the most c

ii 31200079

Transmission8-16 31200079Note:Contact the JLG Service Department at 1-877-554-5438 or 1-717-485-6657, if internal transmission repair is required duri

Transmission31200079 8-173. Low clutch pressure. 1. Incorrect oil level.2. Main pressure valve stuck open.3. Broken or worn coupling shaft or piston o

Transmission8-18 312000796. Grinding or “clunking” noise from transmission.1. Oil level too low.2. Transmission filled with incorrect oil.3. Incorrect

31200079 iSection 9 — Axles and BrakesTable of ContentsAxle and Drive Shaft Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . .

ii 31200079

312000799-1Section 9 — Axles and BrakesAxle and Drive Shaft Component TerminologyTo understand the safety, operation and maintenance information prese

Axles and Brakes9-231200079Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker a

Axles and Brakes312000799-3• DO NOT pound, beat or hammer on end yokes and flanges to remove or to install them. Damage to axle components can occur.

Axles and Brakes9-431200079from the machine. NEVER check for leaks using any part of the human body; use a piece of cardboard or wood instead. Wear he

Axles and Brakes312000799-58. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the ma

312000792-1Section 2 — Identification and SpecificationsSerial Number LocationsMachine Serial NumberFig. 2-1: Machine Serial Number Plate(Ref. Fig. 2-

Axles and Brakes9-6312000793. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the

Axles and Brakes312000799-7Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reas

Axles and Brakes9-831200079Drive Shaft MaintenanceRefer to the appropriate Operator/Safety Manual for information regarding the lubrication of the gre

Axles and Brakes312000799-9Transmission-to-Axle Drive Shaft1. Level the machine, ground the carriage, place the travel select lever in the (N) NEUTRAL

Axles and Brakes9-10312000794. Use a soft, round drive pin with a flat face approximately 1/32" (0,8 mm) smaller than the hole diameter in the yo

Axles and Brakes312000799-116. Apply grease to grease fitting on slip yoke.Drive Shaft InstallationImportant: To help ensure optimum performance, the

Axles and Brakes9-1231200079Service BrakesService Brake Pressure Switch ReplacementMid-Inlet HydraulicsFig. 9-2: Service Brake Pedal Pressure Switch T

Axles and Brakes312000799-13AccumulatorGeneralThe accumulator is a 3000 psi piston-type accumulator. It has a oil volume of 116 cubic inches and gas v

Axles and Brakes9-1431200079Precautions WARNING: Never fill an accumulator with oxygen! An explosion could result if oil and oxygen mix under pressure

Axles and Brakes312000799-15Fig. 9-4: Accumulator ChargingPre-charge the accumulator using the following steps (see Fig. 9-4):1. Follow preparation pr

Identification and Specifications2-231200079Engine Serial Number, John DeereFig. 2-2: Engine Serial Number — John Deere(Ref. Fig. 2-2) The engine seri

Axles and Brakes9-163120007910. Turn “T” handle all the way down. This will depress (open) the core in the gas valve.11. Crack open nitrogen bottle va

Axles and Brakes312000799-175. Record the lowest pressure observed before the accumulator recharges. The pressure should be 950–1200 psi. This reading

Axles and Brakes9-1831200079Manually Releasing the Park BrakeIf it is necessary to tow the vehicle a short distance to avoid a potentially hazardous s

31200079 iSection 10 — OutriggersTable of ContentsOutriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120007910-1Section 10 — OutriggersOutriggersGeneral Fig. 10-1: OutriggersOutriggers increase the stability of the machine when lifting and placing lo

Outriggers10-231200079RemovalOutriggersFig. 10-2: Outrigger Installation(Ref. Fig. 10-2) The following procedure describes removal of the outrigger.1.

Outriggers3120007910-3DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. Use suitable blocking

Outriggers10-4312000795. Install as many shims (Item 7) as needed on shaft assembly to fill the gap measured in Step 3.Note: Shims are available in th

Outriggers3120007910-5The outrigger cylinders have an operating pressure of 3000 psi and have a 15.63” stroke. Each cylinder includes four bushings.Re

Identification and Specifications312000792-3Axle Serial NumberFig. 2-3: Axle Serial Number(Ref. Fig. 2-3) The front axle serial number plate is locate

Outriggers10-631200079CAUTION: Use suitable blocking and lifting devices when removing the cylinders. Care must be taken when removing and lifting the

Outriggers3120007910-7OverhaulOutrigger CylindersFig. 10-5: Outrigger Cylinder Assembly(Ref. Fig. 10-4) The following procedure describes removal of t

Outriggers10-831200079a. Place a socket wrench over each counterbalance valve cartridge (Items 3 and 8). Wrap a clean shop rag around the socket to co

Outriggers3120007910-918. Lubricate counterbalance valve cartridges O-rings with clean hydraulic oil.19. Install cartridges in the manifold block.20.

Outriggers10-1031200079Boom Extension Proximity SwitchDescriptionFig. 10-6: Boom Extension Proximity Switch(Ref. Fig. 10-6) The boom extension proximi

Outriggers3120007910-11Fig. 10-7: Boom Extension Proximity Switch Operation(Ref. Fig. 10-7) The switch operates by sending out a constant, high freque

Outriggers10-1231200079(Ref. Fig. 10-8) The following procedure describes removal of the boom extension proximity switch.1. Disconnect the wire harnes

Outriggers3120007910-131. Loosen, but do not remove the two (2) jam nuts on the proximity switch body.2. Check the gap between switch and boom. The ga

Outriggers10-1431200079RemovalOutrigger Control ValveFig. 10-11: Outrigger Control Valve Installation(Ref. Fig. 10-11) The following procedure describ

Outriggers3120007910-156. Remove the two (2) nuts (Item 13), lockwashers (Item 12), and capscrews (Item 5) securing each valve section to the control

Identification and Specifications2-431200079IdentificationFig. 2-5: Top View Fig. 2-6: Left Side ViewR1026R1052

Outriggers10-1631200079

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

Identification and Specifications312000792-5SpecificationsGeneral Operating SpecificationsLift and Carry Capacity . . . . . . . . . . . . . . . . . .

EFFECTIVITY PAGE31200079-ii

Identification and Specifications2-631200079Pressures Hydraulic:Boom Hoist and Extend Valve Relief . . . . . . . . . . . . . . . . 3000 psi4- or 5-S

Identification and Specifications312000792-7Wheels/TiresLugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 (Torque to 320

Identification and Specifications2-831200079Engine SpecificationsJohn Deere 4045TFuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 iSection 3 — General MaintenanceTable of ContentsGeneral Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii 31200079List of TablesTable 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

312000793-1Section 3 — General MaintenanceGeneral InstructionsPerformance of your machine is dependent on proper maintenance and lubrication at design

General Maintenance3-231200079Service And Repair ProceduresCAUTION: Unless specifically told not to, lower the boom to the ground, apply the parking b

General Maintenance312000793-3Replacement PartsGeneralRecord the machine model, serial number, and component serial numbers for reference when orderin

General Maintenance3-431200079Fluid and Lubricant SpecificationsGeneral SpecificationsTable 3-1: General Fluid and Lubricant SpecificationsEngine Oil

General Maintenance312000793-5Table 3-2: John Deere Engine Oil SpecificationsTransmission Oil SpecificationsThe following table shows approved lubrica

31200079 1Table of ContentsSection 1 — SafetyGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Maintenance3-631200079Fuel RequirementsDiesel fuels are blended to meet the local temperature requirements. The standard grades are:1. 1D for

General Maintenance312000793-7Care and CleaningWash the machine regularly. A clean well-maintained machine helps prevent safety hazards and makes prob

General Maintenance3-831200079Cleaning DecalsIf soiled with dirt, clean decals with mild soap. Use a mild alcohol solution if soiled with grease. Do n

General Maintenance312000793-9Preparing the Machine After Long-Term StorageAfter removing the machine from storage and before placing it back in servi

General Maintenance3-1031200079Torque SpecificationsGeneral Torques for Standard Bolts, Capscrews, and NutsFigure 3-2 and Figure 3-3 lists torque valu

General Maintenance312000793-11Fig. 3-2: General Torques for Standard Bolts, Capscrews, and Nuts

General Maintenance3-1231200079Fig. 3-3: General Torques for Metric Bolts, Capscrews, and NutsSAE GRADE 5SAE GRADE 8Note: These torque values do no

General Maintenance312000793-13Fig. 3-4: Metric Class IdentificationY1--24.84.84.89.88.89.88.812.910.912.912.912101012101055AND HEAD MARKINGSPROPERTY

General Maintenance3-1431200079Hydraulic Fitting TorquesJIC and SAE Female Swivel NutsIt is recommended that the nut be torqued to the approximate min

General Maintenance312000793-15Adjustable O-ring FittingsTo install straight thread, adjustable O-ring fittings:1. Check condition of O-ring and repla

2 31200079Table of ContentsFluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Maintenance3-1631200079Pipe Thread Fittings To install National Pipe Thread (NPT) fittings:1. Apply sealant sparingly to male pipe threads onl

General Maintenance312000793-171. Move the boost start machine (or auxiliary power source) close enough to the stalled machine for the cables to reach

General Maintenance3-1831200079Conversion ChartsTable 3-9: Inch Fraction, Decimal, and Metric Conversion ChartInch Fract. Inch Dec. mm Inch Fract. Inc

General Maintenance312000793-19Table 3-10: Miscellaneous ConversionsMultiply ByTo Get or MultiplyBy To GetInternational System (IS) UnitConversion Fac

General Maintenance3-2031200079

31200079 iSection 4 — Reference DiagramsTable of ContentsMid-Inlet Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 ii

Reference Diagrams312000794-1Section 4 — Reference DiagramsDiagram 4-1 — Mid-Inlet Hydraulic SchematicMV0400FILTERECARROW FILTER50 MICRONEFLSCFPILACCO

Reference Diagrams4-231200079Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)(OPTION)MV04203150PSIL.H.OUTRIGGERR.H.OUTRIGGERFRAMETILTTRANSFERCARRI

Reference Diagrams312000794-3Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)NOTES

31200079 3Table of ContentsSight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Diagrams4-431200079Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)NOTES

Reference Diagrams312000794-5Diagram 4-2 — Control ValveMid-Inlet Control ValveMV0410(OPTION)3150PSIL.H.OUTRIGGERR.H.OUTRIGGERFRAMETILTTRANSFERCARRIAG

Reference Diagrams4-631200079NOTES

Reference Diagrams312000794-7Diagram 4-3 — Electrical SchematicMETER+ -HOURTEMPTRANS OILNMTO PARKING BRAKERELAY TERM 85(SEE SHEET 2).TO PARKING BRAKER

Reference Diagrams4-831200079Diagram 4-3 — Electrical Schematic (cont’d)MV0440RRPIN 86 IS GROUND ON ALL RELAYS15 AMPEFABCD(USED ON 4 SECTION ONLY)EXTE

Reference Diagrams312000794-9Diagram 4-3 — Electrical Schematic (cont’d)MV0450RELAY K188787a308586NEUTRALNEUTRAL AFROM E2 A (SEE SHT. 1)FROM E1 A (SEE

Reference Diagrams4-1031200079Diagram 4-3 — Electrical Schematic (cont’d)NOTES

Reference Diagrams312000794-11Diagram 4-3 — Electrical Schematic (cont’d)NOTES

Reference Diagrams4-1231200079

31200079 iSection 5 — Supply, Pressure, and Return HydraulicsTable of ContentsGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 31200079Table of ContentsSection 6 — Boom and TransferBoom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii 31200079Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200079 iiiFig. 5-19: Hydraulic Pressure Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

iv 31200079

312000795-1Section 5 — Supply, Pressure, and Return HydraulicsGeneralMajor System ComponentsFig. 5-1: Major Hydraulic ComponentsGeneral Description(Re

Supply, Pressure, and Return Hydraulics5-231200079These circuits are supplied by a two-section, gear-type hydraulic pump, driven directly from the tra

Supply, Pressure, and Return Hydraulics312000795-3Hydraulic SystemsMid-Inlet Hydraulic SystemFig. 5-2: Mid-Inlet Hydraulic ComponentsThe term “mid-inl

Supply, Pressure, and Return Hydraulics5-431200079• The hydraulic system is under pressure whenever the engine is run-ning and can hold pressure after

Supply, Pressure, and Return Hydraulics312000795-5as the oil passes through. A high quality hydraulic oil contains many additives which work to keep c

Supply, Pressure, and Return Hydraulics5-631200079Hydraulic ReservoirDescriptionFig. 5-3: Hydraulic Reservoir Location(Ref. Fig. 5-3) The hydraulic re

Supply, Pressure, and Return Hydraulics312000795-7Fig. 5-4: Hydraulic Reservoir(Ref. Fig. 5-4) The hydraulic system return filter assembly (Item 4), a

31200079 5Table of ContentsBoom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-831200079Filling Hydraulic ReservoirPreferred MethodCAUTION: Do not fill reservoir through the breather openi

Supply, Pressure, and Return Hydraulics312000795-97. Start engine and allow hydraulic system to warm up. Operate controls gradually until you fully ex

Supply, Pressure, and Return Hydraulics5-10312000791. The machine must be parked on a level surface and the frame must be level.2. Retract all cylinde

Supply, Pressure, and Return Hydraulics312000795-11Reservoir Drain and RefillFig. 5-7: Hydraulic Reservoir Drain and Refill(Ref. Fig. 5-7) The followi

Supply, Pressure, and Return Hydraulics5-12312000796. Clean the strainer (Item 2) by back flushing with solvent. Dry the strainer element thoroughly w

Supply, Pressure, and Return Hydraulics312000795-13RemovalHydraulic Reservoir and Fuel TankFig. 5-8: Hydraulic Reservoir/Fuel Tank InstallationMV00601

Supply, Pressure, and Return Hydraulics5-1431200079(Ref. Fig. 5-8) The following procedure describes removal of the hydraulic reservoir/fuel tank.1. F

Supply, Pressure, and Return Hydraulics312000795-1514. Perform steps 6 through 9 under “Reservoir Drain and Refill” on page 5-11.15. Install the fuel

Supply, Pressure, and Return Hydraulics5-1631200079Sight GaugeDescriptionFig. 5-9: Hydraulic Reservoir Sight GaugeNote: When checking oil quantity, th

Supply, Pressure, and Return Hydraulics312000795-17RemovalSight GaugeFig. 5-10: Reservoir Sight Gauge Installation(Ref. Fig. 5-10) The following proce