Service Manual

Model
1044C-54
Series II

31200079

Revised
July 1, 2005
EFFECTIVITY PAGE

March 18, 2005 - A - Original Issue Of Manual

July 1, 2005 - Revised Manual

31200079 i
EFFECTIVITY PAGE

-ii 31200079
Table of Contents
Section 1 — Safety
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Servicing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Coolant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Tire and Wheels Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) . . . . . . . . . . . 1-6
Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cleaning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Attaching Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Section 2 — Identification and Specifications

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Serial Number, John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Attachment Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
John Deere 4045T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Section 3 — General Maintenance

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Preparation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service And Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Attaching Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Preparing the Machine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Preparing the Machine After Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
General Torques for Standard Bolts, Capscrews, and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Fitting Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Jump Starting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Section 4 — Reference Diagrams

Mid-Inlet Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-1
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-3

Section 5 — Supply, Pressure, and Return Hydraulics

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Major System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
General Hydraulic Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Filling Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Reservoir Drain and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

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Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Checking Filter Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Replacing Return Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Hydraulic Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Replacing Pressure Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Troubleshooting Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Checking Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Mid-Inlet Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Rear Axle Stabilizer Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Removal, Rear Axle Stabilizer Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Boom Extend Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Hydraulic Diagnostic Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Roll-Back Hose Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

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Section 6 — Boom and Transfer
Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Checking Cylinder Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Boom Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Front Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Rear Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Slide Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Slide Area Surface Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacing and Shimming Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Disconnecting an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Connecting an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

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Boom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Shimming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Boom Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Boom Extension Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129

Section 7 — Frame Tilt and Oscillation

Frame Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Frame Tilt Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Counterbalance Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

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Rear Oscillation Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
General Description, Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Theory of Operation and Circuit Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Testing Rear Oscillation Lock Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Rear Oscillation Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Oscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Boom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Section 8 — Transmission
Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission General Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Performance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Transmission Shift Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Section 9 — Axles and Brakes

Axle and Drive Shaft Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Axle Inspection, Internal Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

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Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
DriveShaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Transmission-to-Axle Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Service Brake Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Pre-Charging Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Checking Pre-charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Section 10 — Outriggers
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Differential Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Boom Extension Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

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List of Figures
Fig. 1-1: Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fig. 1-2: Instrument Panel Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fig. 1-3: Control Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fig. 1-5: Steer Selector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 1-7: Fork Carriage Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 2-1: Machine Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fig. 2-2: Engine Serial Number — John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fig. 2-3: Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fig. 2-4: Attachment Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fig. 2-5: Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fig. 2-6: Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fig. 3-1: SAE Grade Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Fig. 3-4: Metric Class Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Fig. 5-1: Major Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fig. 5-2: Mid-Inlet Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fig. 5-3: Hydraulic Reservoir Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fig. 5-4: Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fig. 5-5: Recommended Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Fig. 5-6: Alternate Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fig. 5-7: Hydraulic Reservoir Drain and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fig. 5-8: Hydraulic Reservoir/Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fig. 5-9: Hydraulic Reservoir Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Fig. 5-10: Reservoir Sight Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Fig. 5-11: Suction Strainer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fig. 5-12: Hydraulic Return Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fig. 5-13: Return Filter Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fig. 5-14: Filter Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Fig. 5-15: Filter Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Fig. 5-16: Return Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Fig. 5-17: Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Fig. 5-18: Hydraulic Pressure Filter – Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Fig. 5-19: Hydraulic Pressure Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fig. 5-20: Hydraulic Pressure Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Fig. 5-21: Hydraulic Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Fig. 5-23: Hydraulic Pump Installation – Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

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List of Figures
Fig. 5-24: Checking Hydraulic Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Fig. 5-25: Mid-Inlet Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Fig. 5-26: Mid-Inlet Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Fig. 5-27: Mid-Inlet Control Valve Configurations,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Fig. 5-28: Mid-Inlet Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Fig. 5-29: Rear Axle Stabilizer Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Fig. 5-30: Rear Axle Stabilizer Control Valve Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Fig. 5-31: Rear Axle Stabilizer Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Fig. 5-32: Boom Extend Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Fig. 5-33: Hydraulic Diagnostic Ports - Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 5-49
Fig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . 5-51
Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Fig. 6-1: Major Boom and Transfer Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fig. 6-2: Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fig. 6-3: Joystick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Fig. 6-4: Joystick Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fig. 6-5: Pilot Pressure Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fig. 6-6: Pilot Pressure Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Fig. 6-7: Boom Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Fig. 6-8: Boom Hoist Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Fig. 6-9: Boom Hoist Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Fig. 6-10: Front Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fig. 6-11: Front Carriage Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Fig. 6-12: Front Carriage Tilt Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Fig. 6-13: Rear Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Fig. 6-14: Rear Carriage Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Fig. 6-15: Rear Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Fig. 6-16: Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Fig. 6-17: Selector Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Fig. 6-18: Selector Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Fig. 6-19: Load Bearing Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Fig. 6-20: Pad Worn, But Still OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-21: Pad Must Be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-22: Bolted Boom Slide Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Fig. 6-24: Damaged Slide Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Fig. 6-25: Slide Surface Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Fig. 6-26: Slide Pad Installation (2-Section Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

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List of Figures
Fig. 6-27: Positioning Retaining Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Fig. 6-28: Determining Capscrew Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Fig. 6-29: Correctly Installed Capscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Fig. 6-30: Quick Attach Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fig. 6-31: Release Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fig. 6-32: Lock Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-33: Rotating Quick Attach Downwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-34: Lowering Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-35: Retracting Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-36: Extending Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-37: Raising Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-38: Rotating Quick Attach Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Fig. 6-39: Lock Plate Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Fig. 6-40: Lower Pivot of Carriage Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Fig. 6-41: Quick Attach Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Fig. 6-42: Boom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Fig. 6-43: Boom Angle Inclinometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Fig. 6-44: 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Fig. 6-45: Boom Slide Pad Locations – 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Fig. 6-46: Boom Section Gaps – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Fig. 6-47: Lower Shim Installation – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fig. 6-48: Upper Shim Installation – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Fig. 6-50: Lower Shim Installation - Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Fig. 6-51: Upper Shim Installation – Rear of 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Fig. 6-52: Clearances Between Boom Sections – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . 6-51
Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Fig. 6-54: Clearances Between Boom Sections – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . 6-52
Fig. 6-55: Gaps Between Pads and Boom – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Fig. 6-56: Inner Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fig. 6-57: Middle (Forward) Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fig. 6-58: Middle (Forward) Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Fig. 6-59: 4-Section Boom Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Fig. 6-60: Hose Connections, 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Fig. 6-61: Cylinder Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Fig. 6-62: Upper Rear Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . 6-58
Fig. 6-63: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . 6-59
Fig. 6-64: Upper Rear Slide Pad Removal – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

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List of Figures
Fig. 6-65: Locations for Chain Attachment – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Fig. 6-66: 4-Section Boom Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Fig. 6-67: Slide Pad Removal – Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Fig. 6-68: Lower Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . 6-65
Fig. 6-69: Disconnecting Hoses Between Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Fig. 6-70: Extension Cylinder Removal – 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Fig. 6-71: Upper Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . 6-68
Fig. 6-72: Upper Front Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . 6-69
Fig. 6-73: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . . . 6-69
Fig. 6-74: Upper Chain Roller Assembly – Middle (Forward) Boom Section. . . . . . . . . . . . . . . . . . . . . 6-70
Fig. 6-75: Disconnecting Chains at Rear of Inner Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Fig. 6-76: Disconnecting Chains at Rear of Middle (Forward) Boom . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Fig. 6-77: Slide Pad Removal – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Fig. 6-79: Grease Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-75
Fig. 6-81: Hose and Tube Removal – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Fig. 6-82: Upper Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Fig. 6-83: Upper Chain Roller Assembly – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-77
Fig. 6-84: Removing Lower Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Fig. 6-85: Slide Pads – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Fig. 6-86: Chain and Hose Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Fig. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . 6-81
Fig. 6-88: Side Slide Pads – Outer Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Fig. 6-89: Outer Boom Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Fig. 6-90: Outer Boom Tube and Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Fig. 6-91: Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Fig. 6-92: Lower Chains on Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Fig. 6-93: Lower Rear Slide Pad Installation - Middle (Rear) Boom Section. . . . . . . . . . . . . . . . . . . . . 6-88
Fig. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Fig. 6-95: Chain and Hose Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Fig. 6-96: Installation of Lower Chain – Middle (Rear) Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-92
Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Fig. 6-99: Slide Pad Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Fig. 6-100: Hydraulic Hose and Tube Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-95
Fig. 6-101: Slide Pad Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Fig. 6-102: Grease Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96

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List of Figures
Fig. 6-103: Upper Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section . . . . . . . . . . . . . . 6-98
Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom . . . . . . . . . . . . . . . . . . . 6-99
Fig. 6-106: Rear Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Fig. 6-107: Front Slide Pad Installation – Outer and Middle (Rear) Boom Sections . . . . . . . . . . . . . . 6-100
Fig. 6-108: Lower Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Fig. 6-109: Lower Chain Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-101
Fig. 6-110: Upper Chains – Middle (Rear) to Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Fig. 6-111: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-103
Fig. 6-112: Securing Lower Chains – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . 6-103
Fig. 6-113: Securing Boom Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Fig. 6-114: Connecting Hoses Between Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Fig. 6-115: Boom Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Fig. 6-116: 4-Section Boom Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Fig. 6-117: 4-Section Boom Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Fig. 6-118: 4-Section Boom Extension Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Fig. 6-119: Boom Extension Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Fig. 6-120: Boom Extension Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Fig. 6-121: Boom Extension Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Fig. 6-122: Boom Extension Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Fig. 6-123: Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Fig. 6-124: Disconnecting Transfer Cylinder from Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
Fig. 6-125: Boom Elevation Proximity Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Fig. 6-126: Boom Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Fig. 6-127: Boom Extension Proximity Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Fig. 6-129: Transfer Carriage with Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125
Fig. 6-130: Transfer Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Fig. 6-131: Transfer Carriage – Front Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Fig. 6-132: Shims for Front Transfer Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Fig. 6-133: Scraper Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
Fig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Fig. 6-135: Spacer Washers for Rear Transfer Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
Fig. 6-136: Rear Slide Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Fig. 7-1: Frame Tilt System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Fig. 7-2: Frame Tilt Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fig. 7-3: Frame Tilt Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Fig. 7-4: Frame Tilt Control Valve (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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Fig. 7-5: Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Fig. 7-6: Frame Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Fig. 7-7: Frame Tilt Cylinder (Exploded View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fig. 7-9: Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Fig. 7-10: Leveling the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Fig. 7-11: Circuit Operation Below 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Fig. 7-12: Circuit Operation Above 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Fig. 7-13: Circuit Operation Above 20° Below 40°. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Fig. 7-14: Circuit Operation Above 20° Below 40° with Service Brake Applied. . . . . . . . . . . . . . . . . . . 7-21
Fig. 7-15: Circuit Operation Below 20° With the Service Brake Applied . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Fig. 7-16: Rear Oscillation Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Fig. 7-17: Rear Oscillation Lock Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Fig. 7-18: Rear Oscillation Lock Cylinder (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Fig. 7-19: Oscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Fig. 7-20: Oscillation Control Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Fig. 7-21: Oscillation Control Block (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Fig. 7-22: Boom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Fig. 7-23: Boom Elevation Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Fig. 7-24: Boom Elevation Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Fig. 7-25: Boom Elevation Proximity Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Fig. 8-1: ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fig. 8-2: Transmission Serial Number Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fig. 8-3: The Lubrication and Maintenance Flip Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Fig. 8-4: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Fig. 8-5: Disconnect the Battery Negative (-) Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fig. 8-6: Drain Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Fig. 8-7: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Fig. 8-8: Remove Transmission from Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Fig. 8-9: Transmission External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Fig. 8-10: Install the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Fig. 8-11: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Fig. 8-12: Transmission Shift Logic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Fig. 9-1: Axle and Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Fig. 9-2: Service Brake Pedal Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fig. 9-3: Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Fig. 9-4: Accumulator Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Fig. 9-5: Park Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

31200079 13
List of Figures
Fig. 10-1: Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Fig. 10-2: Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Fig. 10-3: Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Fig. 10-4: Outrigger Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Fig. 10-5: Outrigger Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Fig. 10-6: Boom Extension Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Fig. 10-7: Boom Extension Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Fig. 10-8: Boom Extension Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Fig. 10-9: Boom Extension Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Fig. 10-10: Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fig. 10-11: Outrigger Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

14 31200079
List of Tables
Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Table 3-3: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Table 3-4: Torque for JIC and SAE Female Swivel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Table 3-5: Torque for Non-adjustable O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Table 3-6: Torque for Adjustable O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Table 3-7: Torque for O-ring Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Table 3-8: Pipe Thread Fittings (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Table 3-10: Miscellaneous Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Table 5-1: Rear Axle Stabilizer Control Valve Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Table 7-1: Rear Oscillation Lock Circuit Test Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

31200079 15
List of Tables

16 31200079
Section 1 — Safety

Table of Contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Before Servicing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine Coolant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire and Wheels Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) . . . . . . . . . . . . . 6
Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attaching Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

List of Figures

Fig. 1-1: Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Fig. 1-2: Instrument Panel Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fig. 1-3: Control Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fig. 1-5: Steer Selector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 1-7: Fork Carriage Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

31200079 i
Section 1 — Safety

General
Observing basic safety rules and precautions can eliminate accidents
when operating, maintaining, and repairing the forklift. The Operator’s
Manual contains detailed information regarding safety practices when
driving and operating the forklift. Always be alert to potential hazardous
situations that could result in injury to yourself or bystanders. Care should
also be taken to avoid damage to the equipment. Maintenance should
always be done by trained personnel using proper tools.

Caution, Warning, and Danger

W1049
Hazards are identified by the “Safety Alert Symbol” and followed by a
signal word: Caution, Warning, or Danger.

CAUTION: Means that a situation COULD be hazardous and MAY result

in personal injury if not avoided. CAUTION is also used to
alert against unsafe practices that could result in equipment
damage.

WARNING: Means that a situation COULD be hazardous and MAY result

in serious injury or death if not avoided.

DANGER: Means that a situation IS HAZARDOUS and WILL result in

serious injury or death if not avoided.

31200079 1-1
Safety

Safety Standard
The ASME/ANSI B56.6 safety standard for rough terrain forklift trucks
defines safety requirements relating to the design, operation, and
maintenance of these vehicles. For a copy of this standard write to:
The American Society of Mechanical Engineers
United Engineering Center
345 East 47th Street
New York, NY 10017

Maintenance Safety

General
DO NOT attempt machine operation or maintenance until you have read
and fully understand the safety instructions in this section. Only trained
and authorized personnel should be permitted to operate or maintain the
machine.

Mounting and Dismounting

Mount and dismount the machine only where steps and handholds are
provided. Keep steps, handholds and the cab floor free of debris, mud, and
other foreign matter. Replace damaged, loose, or excessively worn no-slip
surfacing on cab floor.
Face the machine when mounting and dismounting. Do not attempt to get
off the machine while it is moving. Never jump off the machine. Do not
mount or dismount the machine when carrying tools, equipment, etc.

Before Servicing the Machine

Before servicing the machine, position the forklift in a level area out of any
traffic lanes and follow safe shutdown procedures as described in the
Owners/Operators Manual supplied with each machine.
Wear all the protective clothing and personal safety gear necessary to
perform the job safely. This may include:
• Aprons
• Heavy gloves
• Safety glasses or goggles
• Safety shoes
• Welding helmet
• Filter mask or respirator.
Check the following items:
• If the forklift should not be started, attach a “DO NOT OPERATE”
warning tag to the steering wheel and remove the ignition key.

1-2 31200079
Safety

• Make certain there is adequate light and ventilation.

• Remove any foreign substances (i.e. oil, grease, water, snow, ice) to
eliminate any slippery surfaces and to remove all contaminants from
the area.
• Use only the correct tools to perform the maintenance or repair.
• Make sure all jacks, hoists, jack stands, or blocks are stable and strong
enough to handle the weight of the forklift or component that you will
be working on.
• Remove only the guards or covers that provide access to the area
being serviced and replace all guards or covers when work is
complete.

Note: Keep bystanders away if access doors are open or guards are removed.
NEVER leave the forklift unattended with open access doors or any guards
removed.

Fuel Hazards
Observe the following practices to reduce the possibility of an explosion
when working with fuel.
• Never fill the tank with the engine running. Shut off engine and ignition
during refueling.
• Make sure you have adequate ventilation during refueling.
• Do not permit anyone to be on the machine during refueling.
• Always ground the fuel nozzle against the filler neck to avoid sparks.
• Never use an open flame when checking the fuel level in the tank.
• Keep sparks and open flames away from fuel.
• Do not smoke while refueling or when handling fuel containers.
• Never cut or weld on or near fuel lines, tanks, or containers.
• Never overfill the tank or spill fuel. If you spill fuel, clean it up immedi-
ately. Spilled fuel must be completely absorbed or evaporated before
starting the engine.
• Make sure the fuel cap is in place before starting the engine.

Engine Coolant Hazards

Liquid cooling systems build up extreme heat and pressure as the engine
gets hot. Use care when servicing the system.
Take the following precautions before removing the radiator cap:
• Stop the engine and wait for the system to cool down.
• Wear protective clothing and safety glasses.
• Turn the radiator cap slowly to the first stop position to allow the pres-
sure to escape before removing the cap completely.

31200079 1-3
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

W1047
good repair.

The hydraulic system is under pressure whenever the engine is running

and can hold pressure after the engine is shut down. After forks or
attachments are resting on the ground or support, make sure pressure is
relieved from all hydraulic lines and components before removing them
from the circuit.
Remember the following during inspection of the hydraulic system:
• Wait for fluid to cool down before disconnecting lines.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or
paper to search for leaks.
• Wear appropriate eye protection.
• If any hydraulic fluid is injected into the skin, get medical attention
immediately.
• When venting or filling the hydraulic system, loosen the filler cap slowly
and remove it gradually.
• NEVER reset any relief valve in the hydraulic system to a pressure
higher than that specified in this manual.

Electrical System Hazards

Be aware of the following safety issues when working with batteries.
Explosive gases are always present around batteries. This is especially
true when the battery is being charged.
To avoid explosion…
• DO NOT use smoking materials near batteries.
• Keep arcs, sparks, and open flames away from batteries.
• Provide adequate ventilation.

1-4 31200079
Safety

To avoid personal injury…

• Electrolyte in batteries contains sulfuric acid which is a poison and can
cause severe chemical burns. Wear a face shield and safety glasses to
prevent contact with your eyes and face.
• Wear chemical resistant gloves and clothing to keep acid off your skin
and regular clothing.
Important: If electrolyte is ever ingested or splashed into your eyes, get medical
attention immediately. NEVER give fluids that would induce vomiting.
Eyes should be flushed with clean water as soon as possible. If
electrolyte comes in contact with your skin or clothing, immediately
wash it off with a large quantity of clean water.
• Before working on the electrical system, disconnect the battery
cable(s). NEVER check the battery by placing a metal object across
the battery posts; the resulting spark could ignite anything flammable,
causing a fire or an explosion.
• Always disconnect the battery before welding on the machine.

CAUTION: When removing the battery, always remove the negative (–)
cable first. When installing, connect the positive (+) cable first.

Tire and Wheels Hazards

The stability of the forklift can be dramatically affected by incorrect inflation
or the lack of ballast fill. It is good practice to check your tires and wheels
on a daily basis.
Check tires for…
• The correct pressure
• Cuts or bulges
• Nails or punctures
• The proper ballast required
• Uneven or excessive wear.
Check wheels for…
• Condition of valve stems and caps, making sure valve caps are kept on
• Damage to the rims
• Missing or loose lug nuts or bolts
• Obvious misalignment.
All tire service should be performed by a qualified tire service center or by
an authorized person. This person must be properly trained in the
procedures and use of safety equipment designed for tire servicing.
When servicing wheels and tires, remember…
• NEVER over inflate a tire. Over inflation could result in an explosion.
• Punctures that could have allowed the ballast fill in a tire to leak out
must be repaired and the tire refilled with ballast before the forklift is
put back in operation.

31200079 1-5
Safety

• NEVER reinflate a tire that has been run flat or seriously under inflated
WITHOUT removing the tire from the wheel. Have the tire and rim
closely inspected for damage before remounting.
• Clean the area around all wheel lug nuts or bolts. Periodically check
the torque per the specifications until the torque value stabilizes; then
check at regularly scheduled intervals.

Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS)
The machines are equipped with a Rollover Protective Structure (ROPS)
to guard the operator if the machine tips over. The Falling Object
Protective Structure (FOPS) is built into the ROPS. The FOPS protects the
operator from falling objects.
Despite the protection of the ROPS/FOPS, it cannot protect the operator
from every possible hazard. Do not consider the ROPS/FOPS a substitute
for safe practices and good common sense.
Any modification to a ROPS/FOPS, such as welding or drilling holes in the
structural members for mounting brackets, will affect the ROPS/FOPS
capability to provide the required protection.
Any modification or repair without the specific written approval of JLG will
void the ROPS/FOPS certification. Contact your authorized JLG dealer
before making any modifications or repairs. Failure to do so may void the
ROPS/FOPS certification.

Decals and Placards

General
The decals on the machine provide instructions for safe and correct
operation. Never make modifications affecting safe operation or capacity
without the expressed written approval of JLG. When approved
modifications are made, the user is responsible for seeing that appropriate
decals, load charts, and instructions are changed.
All plates and decals must be in place and legible at all times. Damaged
placards and decals should be replaced. Clean dirty decals.
In California, the machine MUST be equipped with a Proposition 65
Warning decal.

Cleaning Decals
If soiled with dirt, clean decals with mild soap. Use a mild alcohol solution if
soiled with grease. Do not use solvents that may damage the decal.
Replace all damaged, missing, or painted decals that cannot be read. On
refurbished or replaced parts, all missing decals must be replaced. See
your JLG dealer for replacement decals and placards.

1-6 31200079
Safety

Attaching Decals
The surface on which a decal is to be attached must be dry and free of all
dirt and grease. Remove the backing from the decal and apply decal in its
correct location. Once in place, rub entire surface of the decal with your
thumb, applying sufficient pressure to ensure good adhesion of the decal
to the mounting surface.

Decal Locations
Decals and placards that provide information, instructions, and address
safety issues include the following:
• Attachment Capacity Plate (Fig. 1-7)
• Boom Extension Indicator Decal (Fig. 1-1)
• Boom Movement Control Decal (Fig. 1-3)
• Cab Transfer Extension Decal (Fig. 1-1)
• California Proposition 65 Warning Decal (Fig. 1-1)
• Carriage Safety Decal (Fig. 1-7)
• Carry Load Low Caution Decal (Fig. 1-2)
• Caution Plate (Fig. 1-1)
• Diesel Fuel Only Decal (Fig. 1-6)
• Disconnect Battery Decal (Fig. 1-4)
• Don’t Be Careless Decal (Fig. 1-2)
• Forklift Signals Decal (Fig. 1-1)
• Frame Tilt Control Decal (Fig. 1-3)
• Frame Transfer Extension Decal (Fig. 1-1)
• Hydraulic Breather Decal (Fig. 1-6)
• Hydraulic Oil Only Decal (Fig. 1-6)
• Load Chart Capacities Flip Card (Fig. 1-1)
• Low Brake Pressure Decal (Fig. 1-2)
• Lubrication Schedule Flip Card (Fig. 1-1)
• Notice Decal (General Operating Instructions) (Fig. 1-1)
• Outrigger Caution Decal (Fig. 1-2)
• Outrigger Control Decal (Fig. 1-3)
• Parking Brake Decal (Fig. 1-2)
• Pressure Test Ports Decal (Fig. 1-1)
• Rear Oscillation Lock Light Decal (Fig. 1-2)
• Slow Moving Vehicle Sign (Fig. 1-4)
• Steer Selector Plate (Fig. 1-5)
• Tire Ballast Required Decal (Fig. 1-1)
• Transfer and Fork Tilt Control Decal (Fig. 1-3)
• Transmission Declutch Decal (Fig. 1-2)

31200079 1-7
Safety

Load Chart
Cab Transfer Forklift Capacities and
Boom Don’t Be
Extension Signals Lubrication Schedule Careless
Extension
Indicator Flip Cards
Notice

3 FT
2 FT

FORKLIFT SIGNALS

NOTICE
S
TOP R
AIS
ELOAD LOWERLOAD

45 MAX M
I U
M BOOMLOADC APAC
ITIE
SA T
13 24
"L O A
DC E
NTER,FORLF
I TA
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INDI CATES REAR POSIT IO
NSINPOUNDSAN DFEETW ITH
METR ICCO NVER
SIO
NS.

12 40 OSCIL L ATIO N L OCK

M
AN U
FA CT UR
ER 'SRECOMME NDED
ENGAGED C
A PACI
T IESAREINC ON
FO RMANCE
WITHAN SIA
/ S
MEB 56
.6ST
AB IL
ITYTES
TS
TILTFOR
KSR
IGHT TILTFOR
KSLEFT TILTFOR
KSU
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35 MAN U
FACTURER'SRE COM MEND ED
10 LOADSANDA NGLESS H OWNA REA T
THEHORIZONTALCEN TERO F GR A
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ITIESSHO WNARE
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7
INST RUCTI ONS T O SIGN ALM AN 70°
1. On lyon ep er son to be signalman. 6 20 60°
2. Make sur e the operator can see you and is able to acknowled get he sig nalg iven.
3. Signalman must watch the load, the oper at or is watchin g yo u.
4. Never r aise or lower the load over the other wor km en .Warn them to keep out of the way. 50°
5
5. Watch for over head lines or other o bstructions. 39617
B
15 40°
4
30°
3 10
20°
2
CALIFORNIA 5 10°
1
0°
-5°
Proposition 65 Warning 0 0
F E D C B A CAPACIT IES SHOWN DEPICT FULL BOOM EXTENSIONPRIORTO
I H G
O N M L K J TRANSFER. AT FULL TRANSFER EXTENSION, CAPACITIES AT ANY
-1 DIS TANCE OUT ARE 70% OF RETRACTED TRANSFER VALUES.
Diesel engine exhaust and some of its
constituents are known to the State of
F EET 35 30 25 20 15 10 5 0
MET ERS
California to cause cancer, birth 10 9 8 7 6 5 4 3 2 1 0
defects, and other reproductive harm.

3903 9B

DON'T BE
CARELESS
SHUT DOWN ENGINE
BEFORE ANYSERVICE

T IR E B A L L A S T
R E Q U IR E D
T IR E B A L L A S T REFER TO LUBRICATION SCHEDULE
R E Q U IR E D
REFER TO LUBRICATION SCHEDULE

CAUTION

REAR OSC. REAR OSC.

PUMP 1 PUMP 2 LOCK (G1) LOCK (G2) BRAKES STEERING PILOT ACCUM.

California
Proposition 65
Caution
Warning

R1046
Plate

Tire Ballast Frame Transfer Pressure Tire Ballast

Required Extension Test Ports Required
(Both Sides) (Both Sides)

Fig. 1-1: Decals and Placards

Low Brake
Pressure
Warning

Transmission
Declutch

Carry
Load Low
R1047

Rear
Oscillation
Lock Light
Outrigger Parking
Caution Brake

Fig. 1-2: Instrument Panel Decals

1-8 31200079
Safety

Transfer
and Fork
Tilt Control

Outrigger
Control

Boom
Movement
Control
Frame
Tilt Control

V1087
Fig. 1-3: Control Decals

Disconnect
Battery

MV0490

Fig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign

31200079 1-9
Safety

OBLIQUE STEER
FRONT WHEEL STEER
Operator’s Seat

ROUND STEER
Steer
Selector
Plate

R1049

Fig. 1-5: Steer Selector Plate

Hydraulic
Oil Only Hydraulic
Breather

Diesel
Fuel Only

R1050
Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals

Attachment
Capacity
Plate

Carriage
Safety
Decal
R1051

Fig. 1-7: Fork Carriage Decals

1-10 31200079
Section 2 — Identification and Specifications

Table of Contents

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Serial Number, John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Attachment Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
John Deere 4045T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

List of Figures

Fig. 2-1: Machine Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Fig. 2-2: Engine Serial Number — John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fig. 2-3: Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fig. 2-4: Attachment Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fig. 2-5: Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fig. 2-6: Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

31200079 i
ii 31200079
Section 2 — Identification and Specifications

Serial Number Locations

Machine Serial Number

Serial
TIRE BALLAST
REQUIRED
Number
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.

31200079 2-1
Identification and Specifications

Engine Serial Number, John Deere

Serial
Number
Plate

Fuel
Pump

Starter

V1006
Fig. 2-2: Engine Serial Number — John Deere
(Ref. Fig. 2-2) The engine serial number plate is located on the left side of
the engine near the starter and fuel pump.
John Deere engines include an options code decal located on top of the
engine manifold cover. Do not damage, remove, or paint over this decal. It
is recommended that this information be written down for future reference.

2-2 31200079
Identification and Specifications

Axle Serial Number

SERIAL NUMBER
PLATE

MV0360

Fig. 2-3: Axle Serial Number

(Ref. Fig. 2-3) The front axle serial number plate is located on the left front
side of the axle housing. The rear axle serial number plate is located on
the right rear side of the axle housing.

Attachment Serial Number Plate

MV0480

Fig. 2-4: Attachment Serial Number Plate

(Ref. Fig. 2-4) The location of this plate varies with each attachment.

31200079 2-3
Identification and Specifications

Identification

R1026
Fig. 2-5: Top View

R1052

Fig. 2-6: Left Side View

2-4 31200079
Identification and Specifications

Specifications

General Operating Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,000 lbs.

Specifications Maximum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Feet
Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +69°
TransAction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Inches
Maximum Horizontal Forward Reach:. . . . . . . . . . . . . . . . . . . . . . . 45 Feet
Maximum Reach at Maximum Lift . . . . . . . . . . . . . . . . . . . . . . . . . 14 Feet
Capacity at Maximum Reach:. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 lbs
Below Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Inches
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-Wheel
Steer Modes . . . . . . . . . . . Front Wheel, 4-Wheel Round, 4-Wheel Oblique
Frame Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° Right and Left
Empty Vehicle Weight: . . . . . . . . . . . . . . . . . . . . Approximately 32,000lbs.

Dimensions Note: Dimensions listed are for forklift with all components fully retracted in travel
mode.
Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Inches
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Inches
Overall Length. . . . . . . . . . . . . . . . . . . . . . 24 Feet, 10 Inches (w/42” Fork)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Inches
Outside Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Feet, 2Inches
Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 Inches

Capacities Hydraulic System (Including Reservoir) . . . . . . . . . . . . . . . . . . . 65 Gallons

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Gallons
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Gallons
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Quarts
Engine Crankcase Oil w/Filter (John Deere) . . . . . . . . . . . . . . . 14 Quarts
Transmission Drain and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Quarts
Front Axle
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Quarts
Planetary Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Ounces
Rear Axle
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Quarts
Planetary Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.5 Ounces

31200079 2-5
Identification and Specifications

Pressures Hydraulic:
Boom Hoist and Extend Valve Relief . . . . . . . . . . . . . . . . 3000 psi
4- or 5-Section Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 3150 psi
Carriage Tilt Valve Section, Up Port Relief . . . . . . . . . . . . 2800 psi
Carriage Tilt Valve Section, Down Port Relief. . . . . . . . . . 2800 psi
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2355 psi
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425psi
Joystick Control Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 psi
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–15 psi
Accumulator:
Dry Nitrogen Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . .400 psi
Accumulator Charge Valve . . . 1000 (Low Limit), 1125 (High Limit)

Transmission Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF)

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4WG-98TC
Type . . . . . . . . . . . . . . 4-Speed Electric Powershift with Torque Converter
Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Forward, 3 Reverse
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-On

Travel Speeds 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 mph (5,6 km/hr)

2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mph (9,7 km/hr)
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 mph (24,5 km/hr)
4th Gear (Forward Only). . . . . . . . . . . . . . . . . . . . . . . . . 22 mph (35 km/hr)

Axles Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF)

Model
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MS-T-3060
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MS-T-3055
Type . . . . . . . . . . . . . . . . . Off-Highway with Drive and Steering Functions

2-6 31200079
Identification and Specifications

Wheels/Tires Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 (Torque to 320 ft-lbs)

14 × 24 Tires (Bias & Radial):
Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 × 24
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Gallons
Calcium Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 lbs
Foam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 psi
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 psi

Service Brakes Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF)

Type . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated, Internal, Wet Disc

Parking Brake Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAHR) Spring Applied
Hydraulically Released

Engine Models (See “Engine Specifications” on page 2-8)

John Deere 4045T F 275 . . . . . . . . . . . . . . . . . . . . . . 115 HP @ 2500 rpm

Hydraulic Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear

Electrical System System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 12-Volt, Negative Ground

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-Volt, 925CCA
Alternator:
Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Amp

Working Temperatures Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140–180°F

Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104–230°F
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Engine Manual
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180–185°F

31200079 2-7
Identification and Specifications

Engine Specifications

John Deere 4045T

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 HP @ 2500 rpm
Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 291 ft-lbs @ 1400 rpm
Piston Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Cubic Inches
Number of Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vertical In-Line
Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stroke
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct Injection
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6:1
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-On
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry Cartridge
High rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2650-2750
Idle rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890-910

2-8 31200079
Section 3 — General Maintenance

Table of Contents

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Service Preparation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service And Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Attaching Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Preparing the Machine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Preparing the Machine After Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
General Torques for Standard Bolts, Capscrews, and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Fitting Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Jump Starting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

List of Figures

Fig. 3-1: SAE Grade Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Fig. 3-4: Metric Class Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

31200079 i
List of Tables

Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Table 3-3: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Table 3-4: Torque for JIC and SAE Female Swivel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Table 3-5: Torque for Non-adjustable O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Table 3-6: Torque for Adjustable O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Table 3-7: Torque for O-ring Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Table 3-8: Pipe Thread Fittings (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Table 3-10: Miscellaneous Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

ii 31200079
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. The machine must not continue to operate under any
circumstances as serious damage to the machine or personal injury may
result.
Attach a warning tag to the steering wheel of the forklift. If the forklift
should not be started, remove the ignition key.
Before doing any maintenance or repair work, get permission. Do not
perform any maintenance without authorization.
If you have been authorized to do maintenance, read the service manual,
study the instructions, and examine all the instructions and messages on
the machine.
When performing inspection, maintenance, lubrication, or adjustments to
the machine, be alert to evidence of excessive wear including odors and
noises that may indicate damage, malfunction, or other maintenance
problems.

Service Preparation Procedures

• Choose a clean, level work area. Check clearances and make sure you
have sufficient room. Make certain there is adequate light and
ventilation.
• Park machine on level surface, set the parking brake, level the frame,
and shut off the engine.
• Clean the walking and working surfaces. Remove oil, grease, ice,
snow, mud, and water to eliminate slippery areas. Sand any remaining
slippery areas.
• Make sure you have the correct tools. Keep tools clean and inspect
power cords.
• Make sure jacks and hoists are available and in good condition. Never
use jacks with cracked, bent, or twisted parts. Never use frayed,
twisted, or pinched cables. Never use bent or distorted hooks.
• Make use of mechanical assists. To protect your back from possible
injury, use proper lifting methods.

31200079 3-1
General Maintenance

Service And Repair Procedures

CAUTION: Unless specifically told not to, lower the boom to the ground,
apply the parking brake, and stop the engine before servicing,
adjusting, or repairing the machine.

WARNING: Release all hydraulic pressure before doing any maintenance

or repairs to the hydraulic system.

WARNING: Liquid cooling systems build up pressure as the engine gets

hot. Before removing the radiator cap, stop the engine and let
the system cool. Remove the radiator cap only after the
coolant is cold.

• Be careful not to damage machined and polished surfaces.

• Tighten all bolts, fittings and connections to specifications.
• Avoid fires and explosive hazards.
• Handle all solvents and dry chemicals according to procedures identi-
fied on manufacturers' containers. Work in a well-ventilated area. Make
sure you know where fire extinguishers are kept and how to use them.
• Use an approved solvent to clean parts. Never use gasoline or diesel
fuel.
• Shut off the engine and electrical equipment while filling the fuel tank.
Use extra caution when fueling while the engine is hot. Always ground
the fuel nozzle against the filler neck to avoid sparks.

WARNING: Never smoke while handling fuel or working on the fuel

system. The fumes in an empty fuel container are explosive.
Never cut or weld on fuel lines, tanks, or containers.

• Avoid spilling fuel. If a spill occurs, wipe it up immediately.

• Never 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.
• Refill systems with approved or recommended fluids. Start the engine
and check for leaks

WARNING: Diesel fuel or hydraulic fluid under pressure can penetrate the
skin or damage eyes. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to find leaks but do
not use your hand. Wear appropriate eye protection. If fluid
enters skin or eye, get medical attention immediately.

• Operate all controls and make sure the forklift is functioning properly.
Road test the machine if necessary. After testing, shut down and
recheck the work you performed. Recheck all fluid levels before releas-
ing machine for operation.

3-2 31200079
General Maintenance

Replacement Parts

General
Record the machine model, serial number, and component serial numbers
for reference when ordering replacement parts. See “Serial Number
Locations” in Section 2.
Use only JLG authorized replacement parts and fluids. Use of parts other
than JLG authorized parts may adversely effect machine reliability,
performance, and safety and may void the warranty.
JLG assumes no liability for equipment damages caused by the use of
unauthorized replacement parts.

Lubrication

General
For best machine performance, follow the instructions found on the
machine’s service lubrication schedule.
• Clean around all oil fill holes before checking or adding oil.
• Keep all lubricants and lubricating equipment clean and free of foreign
matter both while in use and while in storage.
• Wipe off any excess lubricants that spill or overflow. Oily or greasy sur-
faces tend to collect dirt and foreign matter which can work its way into
bearings and gears.

31200079 3-3
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 1 See "Fuel Requirements"

Hydraulic System Tractor Hydraulic Mobilfluid ®424

Fluid
Engine Cooling See engine manufacturer's operator's
System 1 manual.
Engine Oil 1 See “Engine Oil Specifications”

Transmission See “Transmission Oil

Specifications”
Differential Tractor Hydraulic Mobilfluid ®424
(Front & Rear) Fluid
Planetary Hub Tractor Hydraulic Mobilfluid ®424
Fluid
Grease Points Grease Lithium-based

1 Consult engine manufacturer's operator manual for additional information.

MV0500

Engine Oil Specifications

John Deere Engines Use the table below to select the oil viscosity based on expected air
temperature range during the period between oil changes. Consult the
John Deere Operator’s Manual for additional information.

Note: New John Deere engines use special break-in oil for the initial period of
operation. Consult engine Operator’s Manual for additional information.

3-4 31200079
General Maintenance

Table 3-2: John Deere Engine Oil Specifications

ENGINE OIL, DEERE

Temperature Temperature
Oil Grade
Range °F Range °C

SAE 5W-30 -22 to +86 °F -30 to +30 °C

SAE 10W-30 -4 to +86 °F -20 to +30 °C
SAE 15W-40 +5 to +122 °F -15 to +50 °C
SAE 30W +32 to +86 °F 0 to +30 °C
SAE 40W -50 to +104 °F +10 to +40 °C
Arctic oil (e.g. Below -30 °F
Below -22 °F
MIL-L-46167B)
Approved Engine Oil Specifications

API CD/CE
CCMC Specifications D4, D5
SAE 5W-30
SAE 10W-30
SAE 15W-40
SAE 30W
SAE 40W
MIL-46167B
MV0510

Transmission Oil Specifications

The following table shows approved lubricants and associated
temperature ranges for use with ZF 4WG series transmissions.
Table 3-3: ZF Transmission Oil Specifications

ZF 4WG-98TC TRANSMISSIONS
Minimum Oil
Minimum Oil Temperature for
Oil Grade Temperature for Engaging
Starting Engine Transmission
Recommended
Mobilfluid ®424 -4 °F (-20 °C) +86 °F (+30 °C)
Engine Oils
SAE 20W-20 +14 °F (-10 °C) +41 °F (+5 °C)
SAE 15W-40 +5 °F (-15 °C) +32 °F (0 °C)
SAE 10W, -4 °F (-20 °C) +23 °F (-5 °C)
10W-30,
10W-40

Automatic Transmission Fluid (ATF)

ATF -22 °F (-30 °C) +14 °F (-10 °C)
Approved Lubricants (Engine Oils)
API CD/ CE/ CF/ SF/ SG
MIL-L-2104 C/ D/ E
MIL-L-46152 C/ D/ E
SAE 10W
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-20
Automatic Transmission Fluid (ATF) may only be used at
ambient temperatures below +14 °F (-10 °C)

MV0520

31200079 3-5
General Maintenance

Fuel Requirements
Diesel fuels are blended to meet the local temperature requirements. The
standard grades are:
1. 1D for temperatures -22 to +86 °F (-30 to +30 °C)
2. 2D for temperatures +14 to +122 °F (-10 to +50 °C).
There are two main classifications of diesel fuel in general use:
1. Low-sulphur, “on-highway” diesel fuel
2. Medium-sulfur, “off-highway” diesel fuel. This fuel contains blue dye.
The engine manufacturer specifies the diesel fuel requirements. Additional
information can be found in the engine manufacturer’s Operator’s Manual.
Consult your local fuel distributor for the properties of the diesel fuels
available in your area

Grease
• Use a lithium base grease with E.P. additives and rust inhibitors. A #2
grade should be used at temperatures above 32° F (0° C) and #1
grade at or below 32° F (0° C).
• Wipe off all fittings before applying grease. Dirt on the fitting can be
forced through the opening in the fitting and cause premature bearing
failure.
• Lubricate all grease fittings with the specified grease.

3-6 31200079
General Maintenance

Care and Cleaning

Wash the machine regularly. A clean well-maintained machine helps
prevent safety hazards and makes problem areas more recognizable.
Remove all items that do not belong on the machine. Secure all loose
items such as lunch boxes, tools, and additional equipment.

Cleaning Exterior Surfaces

• High pressure water or steam may be used to clean the exterior. Give
extra attention to the underside.
• DO NOT damage or wash off decals when using high pressure water
or steam. See “Cleaning Decals” below.
• Clean the mirror carefully.
• DO NOT allow mud or snow to accumulate on engine or transmission.
• Make sure radiator and transmission oil cooler fins are clean.
• Commercial engine degreasers may be used to clean the engine and
transmission. Follow the product instructions closely.
• NEVER spray water or cleaner on a hot engine or transmission, espe-
cially on a hot turbocharger.
• Commercial general purpose degreasers and detergents may be used
to help clean thick deposits. Do not use chemicals that can damage
paint or decals.
• Avoid spraying water on electrical components such as the alternator,
starter, gauges, and electrical items under the dash.
• Be careful around the fuel fill and hydraulic reservoir breather. Water
may get into tanks and damage fuel and/or hydraulic components.
• To help prevent freezing, allow water to drain or dry before operating in
cold weather.

Cleaning the Cab

• Clean dust and dirt from all areas of the cab. Be careful to keep water
spray away from electrical components under the dash.
• Clean vinyl items with commercial vinyl cleaner. Treat with vinyl pro-
tectant to guard against ultraviolet damage. Do not use vinyl protectant
on rubber or plastic controls if it will leave them slippery.
• Clean the windows inside and out. Remove any decals from windows
that are not original equipment.
• Carefully clean plastic gauge and indicator lenses. Use a soft cloth and
a cleaner suitable for plastic. Dust and dirt can scratch the clear
plastic.
• Make sure step and hand holds are clean.
• Remove accumulated dirt from brake and accelerator pedals.

31200079 3-7
General Maintenance

Cleaning Decals
If soiled with dirt, clean decals with mild soap. Use a mild alcohol solution if
soiled with grease. Do not use solvents that may damage the decal.
Replace all damaged, missing, or painted decals that cannot be read. On
refurbished or replaced parts, all missing decals must be replaced.
See your JLG dealer for replacement decals and placards.

Attaching Decals
The surface on which a decal is to be attached must be dry and free of all
dirt and grease. 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.

Storage
The following procedures are to be used if the machine will not be
operated for a long period of time.

Preparing the Machine for Long-Term Storage

Prior to placing the machine into storage, perform the following:
1. Wash off the entire machine.
2. Lubricate all grease fittings as instructed in “Grease” on page 3-6 of
this section
3. Change engine oil according to specifications described in Table 3-2
on page 5.
4. Apply grease to all exposed hydraulic cylinder rod areas.
5. Disconnect battery cables. If the machine is to be stored under cold
conditions, remove the battery and store it in a heated area.
6. Check engine coolant level and make sure it has an adequate coolant-
to-water ratio for the conditions it will be stored in.
7. Check transmission fluid level and fill if necessary according to the
guidelines described in Table 3-3 on page 5 of this section.
8. Preferable, store the machine inside where it will remain dry. If it must
be stored outside, park it on a concrete slab or on lumber laid on flat,
level ground and cover it with a tarp.

3-8 31200079
General Maintenance

Preparing the Machine After Long-Term Storage

After removing the machine from storage and before placing it back in
service, perform the following:
1. If covered with a tarp, remove it.
2. Wipe off grease from cylinder rods.
3. Loosen drain plug from bottom of fuel tank and drain into suitable
container until fluid is clean.
4. Loosen drain plug on bottom of hydraulic oil reservoir and drain into
suitable container until fluid is clean.
5. Loosen drain on fuel/water separator on engine and drain into suitable
container until fluid is clean.
6. Check nitrogen recharge.
7. Check engine coolant and hydraulic fluid levels. Add fluids if
necessary.
8. If battery was stored separately from the machine, install it.
9. Connect battery cables.
10. Start engine using start safety procedures as described in the
Owner/Operator Manual.
11. After the engine has warmed up, test all hydraulic functions and
controls.
12. Check transmission operation.
13. Shut the machine down and check for any hydraulic leaks and repair,
as necessary.

WARNING: Hydraulic fluid under pressure can penetrate the skin or

damage eyes. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks but do not use
your hand. Wear appropriate eye protection. If fluid enters skin
or eye, get medical attention immediately.

14. Check for any other leaks and repair as necessary.

15. Check other fluid levels and replenish as necessary. Refer to your
service/lubrication charts.

31200079 3-9
General Maintenance

Torque Specifications

General Torques for Standard Bolts, Capscrews, and Nuts

Figure 3-2 and Figure 3-3 lists torque values for standard bolts and nuts.
They are intended as a guide for typical applications. Values for specific
applications take precedence over those in the following tables.

Note: Values are for plated or lubricated bolts and nuts.

SAE BOLT HEAD MARKINGS SAE NUT MARKINGS

SAE GRADE 2
SAE GRADE 2 (NO MARK)

SAE GRADE 5 SAE GRADE 5.1 SAE GRADE 5.2

SAE GRADE 5

Y1000
Y1001

SAE GRADE 8 SAE GRADE 8.2 SAE GRADE 8

Fig. 3-1: SAE Grade Identification

3-10 31200079
General Maintenance

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

31200079 3-11
3-12
VALUES FOR ZINC PLATED BOLTS ONLY UNPLATED CAP SCREWS
General Maintenance

Fig. 3-3: General Torques for Metric Bolts, Capscrews, and Nuts
Note: These torque values do not apply to cadium plated fasteners.

SAE GRADE 5 SAE GRADE 8

31200079
General Maintenance

PROPERTY CLASS PROPERTY CLASS

AND HEAD MARKINGS AND NUT MARKINGS

4.8 5
4.8

5
5
4.8

8.8 9.8 10
8.8 9.8

10
10
8.8 9.8

10.9 10

10.9

10
10

12.9 12
12.9

12
12
12.9
12.9

Y1--2
Fig. 3-4: Metric Class Identification

31200079 3-13
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. Min.
Size
Thread Size Torque
Max. Torque Flats1

-4 7/16-20 130 in-lbs 150 in-lbs 2

-5 1/2-20 165 " 195 " 2
-6 9/16-18 235 " 265 " 1 1/4
-8 3/4-16 44 ft-lbs 48 ft-lbs 1
-10 7/8-14 50 " 58 " 1
-12 1 1/16-12 79 " 88 " 1
-16 1 5/16-12 117 " 125 " 1
-20 1 5/8-12 158 " 175 " 1
-24 1 7/8-12 188 " 213 " 1
-32 2 1/2-12 250 " 283 " 1
1. Number of flats on nut to be turned past finger tight. This
method will produce the approximate torque.

Non-adjustable O-ring To install straight thread, non-adjustable O-ring fittings:

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 and torque per Table 3-5.
Table 3-5: Torque for Non-adjustable O-ring Fittings
SAE Port
Size Min. Torque Max. Torque
Thread Size
-2 5/16-24 85 in-lbs 95 in-lbs
-4 7/16-20 205 " 235 "
-6 9/16-18 25 ft-lbs 29 ft-lbs
-8 3/4-16 46 " 50 "
-10 7/8-14 85 " 95 "
-12 1 1/16-12 105 " 115 "
-16 1 5/16-12 154 " 166 "
-20 1 5/8-12 213 " 237 "
-24 1 7/8-12 238 " 262 "

3-14 31200079
General Maintenance

Adjustable O-ring Fittings To install straight thread, adjustable O-ring fittings:

1. Check condition of O-ring and replace as necessary. Do not install a
fitting with a damaged O-ring.
2. Lubricate O-ring with clean hydraulic fluid.
3. Back off the locknut fully.
4. Screw fitting into port until backup washer contacts face of port.
5. Position fitting by unscrewing a maximum of one turn.
6. Hold the fitting in position with a wrench and torque locknut per Table
3-6.
Table 3-6: Torque for Adjustable O-ring Fittings
SAE Port
Size Min. Torque Max. Torque
Thread Size
-2 5/16-24 60 in-lbs 70 in-lbs
-4 7/16-20 160 " 180 "
-6 9/16-18 25 ft-lbs 29 ft-lbs
-8 3/4-16 40 " 44 "
-10 7/8-14 58 " 63 "
-12 1 1/16-12 75 " 85 "
-16 1 5/16-12 109 " 121 "
-20 1 5/8-12 213 " 237 "
-24 1 7/8-12 238 " 262 "

O-ring Plugs To install straight thread O-ring plugs:

1. Check condition of O-ring and replace as necessary. Do not install a
plug with a damaged O-ring.
2. Lubricate O-ring with clean hydraulic fluid and torque per Table 3-7.
Table 3-7: Torque for O-ring Plugs
SAE Port Hollow Hex Head Hex Head
Size Thread Size Min. Torque Max. Torque Min. Torque Max. Torque
-2 5/16-24 30 in-lbs 40 in-lbs 85 in-lbs 95 in-lbs
-4 7/16-20 125 " 145 " 205 " 235 "
-6 9/16-18 210 " 230 " 25 ft-lbs 29 ft-lbs
-8 3/4-16 44 ft-lbs 48 ft-lbs 46 " 50 "
-10 7/8-14 70 " 80 " 85 " 95 "
-12 1 1/16-12 80 " 90 " 105 " 115 "
-16 1 5/16-12 129 " 141 " 154 " 166 "
-20 1 5/8-12 213 " 237 " 213 " 237 "
-24 1 7/8-12 238 " 262 " 238 " 262 "

31200079 3-15
General Maintenance

Pipe Thread Fittings To install National Pipe Thread (NPT) fittings:

1. Apply sealant sparingly to male pipe threads only, avoiding the first few
threads at the end of the fitting.

Note: Do not use Teflon tape or excessive amounts of sealant. System

contamination will result.
2. Install fitting and tighten per Table 3-8.
Table 3-8: Pipe Thread Fittings (Steel)
Fitting Thread Size
Size (NPT) Turns1

-2 1/8-27 2–3
-4 1/8-27 2–3
-6 1/4-18 1.5–3
-8 3/8-18 2–3
-10 1/2-14 2–3
-12 3/4-14 2–3
-16 1-11.5 1.5–2.5
-20 1 1/4-11.5 1.5–2.5
-24 1 1/2-11.5 1.5–2.5
1.Turns past finger tight

Jump Starting Procedures

CAUTION:

• Improper jump starting procedures can cause an explosion resulting in

personal injury.
• Sparks near batteries can cause explosions.
• Do not allow jump cable ends to touch each other or the machine.
• Battery acid can cause personal injury if it contacts skin or eyes.
Always wear eye protection when jump starting a machine.
• Always connect battery positive (+) to battery positive (+) and battery
negative (-) to ground on the machine. Make the final ground connec-
tion away from the battery.
• Allowing the two machines to touch during jump starting can cause
damage to bearings and electrical circuits.
• This machine has a 12 volt starting system. Use the same voltage (12
volts) for jump starting. Use of higher voltage can damage the electri-
cal system.
• Never charge a frozen battery.

3-16 31200079
General Maintenance

1. Move the boost start machine (or auxiliary power source) close enough
to the stalled machine for the cables to reach without allowing the
machines to touch. Place the transmission shift selector in NEUTRAL,
engage the park brake, and turn off engine (or shut off auxiliary power
source).
2. On the stalled machine, turn the ignition switch to OFF.
3. Connect the positive (+) jumper cable to the positive (+) cable terminal
of the discharged battery on the stalled machine. Ensure a solid
connection. DO NOT allow positive cable clamps to touch ANYTHING
other than the battery terminal.
4. Connect the other end of the positive (+) jumper cable to the positive
(+) terminal of the boost battery (or auxiliary power source).
5. Connect one end of the negative (–) jumper cable to the negative (–)
terminal of the boost battery (or auxiliary power source).
6. Make the final connection of the negative (–) jumper cable to the frame
of the stalled machine away from the battery, fuel and hydraulic lines,
and moving parts.
7. Start the engine on the boost machine or energize the auxiliary power
source.
8. Wait at least two minutes for the battery in the stalled machine to
partially charge.
9. Attempt to start the stalled machine (see “Starting Procedures” in your
Owner/Operator Manual).
10. Immediately after the stalled machine starts, disconnect the jumper
cables in reverse order.

31200079 3-17
General Maintenance

Conversion Charts
Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart

Inch Fract. Inch Dec. mm Inch Fract. Inch Dec. mm

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 0.5625 14.29
5/64 0.0781 1.98 37/64 0.5781 14.68
3/32 0.0938 2.38 19/32 0.5938 15.08
7/64 0.1094 2.78 39/64 0.6094 15.48
1/8 0.1250 3.18 5/8 0.6250 15.88
9/64 0.1406 3.57 41/64 0.6406 16.27
5/32 0.1563 3.97 21/32 0.6563 16.67
11/64 0.1719 4.37 43/64 0.6719 17.07
3/16 0.1875 4.76 11/16 0.6875 17.46
13/64 0.2031 5.16 45/64 0.7031 17.86
7/32 0.2188 5.56 23/32 0.7188 18.26
15/64 0.2344 5.95 47/64 0.7344 18.65
1/4 0.2500 6.35 3/4 0.7500 19.05
17/64 0.2656 6.75 49/64 0.7656 19.45
9/32 0.2813 7.14 25/32 0.7813 19.84
19/64 0.2969 7.54 51/64 0.7969 20.24
5/16 0.3125 7.94 13/16 0.8125 20.64
21/64 0.3281 8.33 53/64 0.8281 21.03
11/32 0.3438 8.73 27/32 0.8438 21.43
23/64 0.3594 9.13 55/64 0.8594 21.83
3/8 0.3750 9.53 7/8 0.8750 22.23
25/64 0.3906 9.92 57/64 0.8906 22.62
13/32 0.4063 10.32 29/32 0.9063 23.02
27/64 0.4219 10.72 59/64 0.9219 23.42
7/16 0.4375 11.11 15/16 0.9375 23.81
29/64 0.4531 11.51 61/64 0.9531 24.21
15/32 0.4688 11.91 31/32 0.9688 24.61
31/64 0.4844 12.30 63/64 0.9844 25.00
V1070

1/2 0.5000 12.70 1 1.0000 25.40

3-18 31200079
General Maintenance

Table 3-10: Miscellaneous Conversions

To Get or
Multiply By By To Get
Multiply
International System Conversion Conversion
Non-IS Unit IS Unit
(IS) Unit Factor Factor
Torque
Newton Meter (N•m)
m) x 8.9 = in-lb. x 0.113 = Nm
Newton Meter (N•m)
m) x 0.74 = ft-lb. x 1.36 = Nm
Pressure (Pa = N/m2)
Kilopascal (kPa) x 4.0 = in H2O x 0.249 = kPa
Kilopascal (kPa) x 0.30 = in. Hg x 3.38 = kPa
Kilopascal (kPa) x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
Newton/mm2 x 145.04 = psi x 0.0069 = bar
Stress (Pa = N/m2)
Megapascal (mPa) x 145 = psi x 0.00689 = MPa
Power (W = J/s)
Kilowatt (kW) x 1.36 = PS(cv) x 0.736 = kW
Kilowatt (kW) x 1.34 = HP x 0.746 = kW
Kilowatt (kW) x 0.948 = Btu/s x 1.055 = kW
Watt (W) x 0.74 = ft-lb/s x 1.36 =W
Energy (J = (N•m)
m)
Kilojoulè (kJ) x 0.948 = Btu x 1.055 = kJ
Joule (J) x 0.239 = calorie x 4.19 =J
Velocity and Acceleration
Meter per sec2 (m/s2) x 3.28 = ft/s2 x 0.305 = m/s2
Meter per sec (m/s) x 3.28 = ft/s x 0.305 = m/s
Kilometer per hour x 0.62 = mph x 1.61 = km/h
(km/h)
Flow Rate
3 x 0.264 = US gal/min x 3.785 = L/min
Leter/mn (dm /mn)
Horse Power/Torque
(BHP x 5252) ÷ rpm = TQ (ft-lb.) (TQ x R.P.M.) ÷ 5252 = B.H.P.
Metric HP x 0.9863 = U.S. HP
U.S. HP x 1.014 = Metric HP
Temperature
°C = (°F-32) ÷ 1.8 °F = (°C x 1.8) + 32
Miles
Nautical Mile x 1.15078 = Statute Mile
Statute Mile x 0.86897 = Nautical Mile

31200079 3-19
General Maintenance

3-20 31200079
Section 4 — Reference Diagrams

Table of Contents

Mid-Inlet Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-1

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-2
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4-3

31200079 i
31200079 ii
Reference Diagrams

Section 4 — Reference Diagrams

Diagram 4-1 — Mid-Inlet Hydraulic Schematic

QUICK DISCONNECTS

C.B. BOOM TELESCOPE CYLINDER C.B.

AUX. 1 VALVE VALVE
OPTIONS

QUICK DISCONNECTS

AUX. 2
OPTIONS

FRONT CARRIAGE BOOM ROLL BACK HOSES

TILT CYLINDER UPPER HYDRAULICS

FRONT OF MACHINE SW EF
ARROW FILTER
ACC CV 50 MICRON
CF
P
0R1 FILTER
UP LS LS

T
SV
OR3 OR2

RV
EC ORBITROL STEER
PIL T P
VALVE
C.B. VALVES
4000 PSI

1 2
92 PSI B1
P1
DIFF.
B3
PRESSURE
SWITCH ACCUMULATOR .020

400 PSI .020

PRECHARGE A1
P2
A3

R.H. OUTRIGGER
CYLINDER SELECTOR
VALVE

FRAME TILT
CYLINDER
PRESSURE OUTRIGGER CONTROL VALVE
FILTER B7 B8

(2X) RH LH
#4
.080 P #4 P1 P B2

ORFICES X
FRONT STEER CYL

X
HYDRAULICALLY RELEASED BRAKE

A4 B4 A5 B5
FRONT BRAKES

#1 #3 #1 #3 OUTRIGGERS
C.B. VALVES S1
PARK BRAKE CYLS

T T
3500 PSI S3
SPRING APPLIED /

S2

#2 P2 #2 A2

FORK TILT/TRANSFER HOIST/TELESCOPE

1ST AUX. 2ND AUX. A7 A8
JOYSTICK CONTROL VALVES
VIEWED FROM THE TOP

P
A

BRAKE PARK BRAKE PRESS. SWITCH

VALVE CLOSED BELOW 100 PSI
OPEN ABOVE 100 PSI
ACCUMULATOR PRESSURE SWITCH
400 PSI PRE-CHARGE

CLOSED BELOW 850 PSI

B
BRAKES

CLOSED ABOVE 250 PSI

ACCUMULATOR
PUMP 1

PUMP 2

STEERING

PILOT
BRAKE PRESSURE SWITCH

1075 PSI LOW LIMIT

SEE SERVICE MANUAL

SEE SERVICE MANUAL

OPEN BELOW 250 PSI

1950 PSI HIGH LIMIT

OPEN ABOVE 850 PSI

330 PSI

450 PSI
3000 PSI

3150 PSI

2375 PSI
STABILIZER "G1"

STABILIZER "G2"

C A
PARK BRAKE VALVE
PULL TO APPLY BRAKE
C.B. VALVES
PUSH TO RELEASE
4000 PSI BRAKE

92 PSI
DIFF.
PRESSURE
SWITCH

L.H. OUTRIGGER
MV0400 CYLINDER

31200079 4-1
Reference Diagrams

Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)

C.B. BOOM HOIST CYLINDER

VALVE REAR CARR.
TILT CYLINDER

C.B. TRANSFER CYLINDER

VALVE BOOM HOIST CYLINDER
REAR CARR.
TILT CYLINDER

BOOM FRAME (OPTION) CARRIAGE R.H. L.H.

TELESCOPE BOOM HOIST TILT AUX. 1 AUX. 2 TRANSFER TILT OUTRIGGER OUTRIGGER
A2 A5

A6 A3 A1 A4 A7 A8

A A A A A A A A A
B B B 3150
B B B B B B PSI
(OPTION) 2800
PSI
3000
PSI
B6 B3 B1 2800 B4
PSI B7 B8
B2 B5
P

STABILIZER CONTROL VALVE

FB SW RB ACC
X BOOM EXTEND/TRANSFER
BR OR1 LOCK-OUT VALVE
OR2 .043 (B1)
G3 .043
GAGE .040
A6 PORT OR3
60 (B2) V PC1
X PSI
A PD1 RCB OR4
V
.040
T
60 RCR PC2 OR3
SV1 PB
PSI .040
REAR STEER CYL

P
S1 PS1 250 100 PSI
B PSI CV2
SV3
REAR BRAKES

SV2 CBP
FRAME TILT CBP
CB CV1
.08
PD4 PS2
G2 T OR2

PC3 (270 PSI) 60 PSI

S4 OR4 CV3 CV4
.043 T 3500
OR5 (.043) OR5
B PSI
.040
B6
RCR
G1 230 230 SYS PR .130
PSI PSI 150
.03
PD2 PD3 PSI
OR1
RCB PIL

PIL FCB FTB

GAGE PORT
225 PSI .18 DIA.

REAR AXLE STABILIZER VALVE

NOTE: HUSCO VALVE ASSEMBLY IS ORIENTATED

STEER
MODE
SO THAT THE "A" PORTS ARE FRONT
SELECTOR FORWARD OF THE "B" PORTS.

MV0420

4-2 31200079
Reference Diagrams

Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)

NOTES

31200079 4-3
Reference Diagrams

Diagram 4-1 — Mid-Inlet Hydraulic Schematic (cont’d)

NOTES

4-4 31200079
Reference Diagrams

Diagram 4-2 — Control Valve

Mid-Inlet
Control
Valve

BOOM FRAME (OPTION) CARRIAGE R.H. L.H.

TELESCOPE BOOM HOIST TILT AUX. 1 AUX. 2 TRANSFER TILT OUTRIGGER OUTRIGGER
A2 A5

A6 A3 A1 A4 A7 A8

A A A A A A A A A
B B B 3150
B B B B B B PSI
(OPTION) 2800
PSI
3000
PSI
B6 B3 B1 2800 B4
PSI B7 B8
B2 B5
P

MV0410

31200079 4-5
Reference Diagrams

NOTES

4-6 31200079
Reference Diagrams

Diagram 4-3 — Electrical Schematic

ORANGE-16 A A ORANGE-16

H 36830B
CLUSTER GAUGE
BLACK-16 B B BLACK-16

FUEL

6 7
9
BOOM
8
CHECK
ENGINE ENGINE
5
FUEL
6
INCLUDED IN UPPER
P INCLUDED IN INTERMEDIATE
WATER FAULT
TRANS
EXTEND PARK WATER I G HARNESS 66944D HARNESS 66961D
LOCK BRAKE TEMP CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX
5 8 7
36804X POWER
TRANS OIL
HOURMETER TEMP
4 9 12 1 4 S
LAMPS
REAR
BRAKE
PRESS
ENGINE BATTERY
3 10 OIL VOLTAGE 66982A
D
OSC
LOCK
GRD
TRANS
DISC PRESSURE TRANSMISSION TEMP 4923233 DASH HARNESS 'O' 4923232 ENGINE HARNESS 'A'
2 11 10 11 CONNECTS TO ENGINE HARNESS CONNECTS UNDER SEAT BOX
OIL UNDER THE SEAT BOX PINS 18 - 29 PLUGGED
HOUR
METER 1 12
G R B G Y V W T P O
+ - R E L R E I H A I R 1 SEE SHEET 3
E D A A L O I N N A
E 1 C Y L L T 1 K N 2 SEE SHEET 3
F N 6 K 1 O E E 6 1 G 3 SEE SHEET 3
1 1 6 W T 1 6 E 4 PLUGGED
6 6 1 1 6 1
5 SEE SHEET 3
6 6 6
6 PLUGGED
7 SEE SHEET 3
8 SEE SHEET 3
9
10 SEE SHEET 3
11 SEE SHEET 3
12 SEE SHEET 3
13 PLUGGED
14 SEE SHEET 3
15 SEE SHEET 3
16 SEE SHEET 3
17 SEE SHEET 3

PINS 4,
ENGINE 38094A THROTTLE 6, 13 &
3 3
R
WILLIAMS
FAULT O/R TRANSMISSION (SUSPENDED) 18 - 29
2 (RESET) 2 DISCONNECT PLUGGED
A
SWITCH 7 SWITCH B

Q B C
D PLUGGED
- + 66679A SPST-N.O., 250 PSI
BRAKE PRESSURE SWITCH
N
E PLUGGED
F PLUGGED
ON DIAGNOSTIC PANEL

TAN-16 B BLACK-16 67063A SPST-N.O., 1000 PSI

ON MACHINES W/DRY DISC BRAKES
RED-16 A RED-16

WHITE-16 D BLUE-16
RED-16 66680A DPST-N.C. SWITCH, 850 PSI
C BLACK-16
LOW BRAKE PRESSURE SWITCH
BLACK-16 B YELLOW-16
- ON DIAGNOSTIC PANEL
YELLOW-16 A BROWN-16 +
USE 67065A SPST-N.C. SWITCH, 1800 PSI
+ -
M ON MACHINES WITH DRY DISC BRAKES

10 AMP

A IGN. P11092
ACC. IGNITION
ST. SWITCH
10 AMP BAT.

TO PARKING BRAKE
RELAY TERM 85
(SEE SHEET 2).
E2
RED-16 A
BLUE-16 B

66941A DPST-N.C. SWITCH,100 PSI - +

PARKING BRAKE PRESSURE SWITCH
UNDER DASH PANEL + -
PINK-16 A TRANSMISSION BOOM/ TRANSFER
REAR OSC.
LOCK DISCONNECT EXTEND LOCKOUT
BLACK-16 B
TO PARKING BRAKE 4 SECTION BOOM ONLY
E1 RELAY TERM 86
(SEE SHEET 2).
LAMP #10 LAMP #11 LAMP #9

WHITE-16 A LAMP #10 A WHITE-16

VIOLET-16 B LAMP #11 B VIOLET-16
TAN-16 C LAMP #9 C TAN-16
BLUE-16 D DECLUTCH D BLUE-16

'K' J8

4923233 DASH HARNESS

CONNECTS TO CIRCUIT
BOARD UNDER THE DASH BOOM BOOM
OVER 20° OVER 40°
BACK-UP
NEUTRAL
ALARM
START
66906A HARNESS
66466X FOOT SWITCH,CONNECTS 86 30 86 30 86 30 R 86 30 R
MOMENTARY SWITCH UNDER DASH
TRANSMISSION ENGAGE/
AXLE UNLOCK
R 85 87A 87 85 87A 87 85 87A 87 85 87A 87
J9
YELLOW-16 B ~1.5 AMPS B YELLOW-16
WHITE-16 A ~1.5 AMPS A WHITE-16

85 30
85 30
R
4TH SPEED
86 87A 87
LOCKOUT RELAY
TRANS. 86 87A 87
CUT-OUT
TO CIRCUIT BOARD &
SHIFTER HARNESS J10
(SEE SHT 2)
A RED-16
B YELLOW-16
C PINK-16
D GRAY-16

A BROWN-16
B GREEN-16
TO CIRCUIT BOARD & C BLUE-16
SHIFTER HARNESS D VIOLET-16
(SEE SHT 2)
J11

J16
WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER

WHITE-14
L
YELLOW-16 A NEUTRAL START RELAY .41-.48 AMPS A YELLOW-16
VIOLET-16 B IGN. SWITCH RELAY RELAY CURRENT B VIOLET-16
FUSES FOR CIRCUIT BOARD
BLACK-16 C HORN RELAY RELAY CURRENT C
7.5 AMP: BROWN-LULL#66827X
B IGN. 10 AMP: RED-LULL#66828X
J12
I
85 30
L SWITCH 15 AMP: BLUE-LULL#66829X
A R RELAY
C
4923233 DASH HARNESS K 86 87A 87
HORN BUTTON CONNECTS TO CIRCUIT 1
KIT P18141 BOARD UNDER THE DASH 6

7.5 AMP
86 30 R F3
HORN
TRANS. & PROXIMITY SWITCHES.
RELAY

F 85 87A 87
F4
10 AMP
R BACK-UP ALARM

15 AMP
F5
R
BOOM PROX. SWITCH RELAYS
J
RED-16 A A RED-16 10 AMP 10 AMP
WHITE-16 F6 F1
B B WHITE-16 LOW BRAKE R JOYSTICK
GAGE PANEL/ NEUTRAL START
PRESSURE
J13 BUZZER

4923233 DASH HARNESS

CONNECTS TO CIRCUIT
BOARD UNDER THE DASH

MV0430

31200079 4-7
Reference Diagrams

Diagram 4-3 — Electrical Schematic (cont’d)

38200C-4
GROUND
ENGINE TO
MAINFRAME
FUEL LEVEL
GA SEND CONNECT BATT GRD
P29317 TO LOWER STARTER
MOUNTING BOLT
STARTER 65724A
MOTOR NEG. CABLE 2/0 BLACK

SOLENOID
35646A + BATTERY -
POS. CABLE 12V

BLACK-10 2/0 RED

38200C-3 PIN 86 IS GROUND ON ALL RELAYS

WHITE-10 GROUND
R OPER COMP TO
E MAINFRAME
D
6 30
YELLOW-14 STARTER 38200C-5
RELAY
67789A

RED-14 S B+ 86 87A 85
ALTERNATOR
BOSCH 87
95 AMP
D+

4923247
WIRE W/DIODE
RELAY SOCKET
WHITE-12 TOP VIEW
67062A SPST-N.O., 250 PSI RED-12
ON MACHINES W/ROADWAY LIGHTS

67064A SPST-N.O., 1000 PSI

CIRCUIT
ON MACHINES W/DRY DISC BRAKES BREAKERS
& ROADWAY LIGHTS 40 AMP
P29694
T
BACK-UP
ALARM
+ -
P13774

66891C (10366981)
CIRCUIT BOARD 38329A COIL
2-WAY SOLENOID VALVE ON
A BOOM ANGLE GREATER THAN 40° NO
VIOLET-14 SV3 REAR AXLE STABILIZER VALVE
BLACK-14 ON REAR STABILIZER CYLINDER BOOM ANGLE LESS THAN 40° NC
B
ENERGIZED W/BOOM BELOW 40° 37115X PROXIMITY SENSOR IS N. O.
ON TRANSFER CARRIAGE

VIOLET-16 1 STAB. SOL. SV3 (1.2 AMP INRUSH) VIOLET-16

38329A COIL
PINK-16 2 BACK-UP ALARM (.6 AMPS) PINK-16 SOLENOID VALVE ON BROWN BLACK
J14 A REAR AXLE STABILIZER
BLACK-16 3 GROUND (9.6 AMPS AT INRUSH) BLACK-16 POWER
SV1 POWER
CONTROL VALVE(ENERGIZED IN
B OUT
YELLOW-14 4 START RELAY(.41-.48 AMPS) YELLOW-14 W/BOOM BELOW 20°)
ORANGE-16 5 STAB. SOL. SV1 (1.2 AMP INRUSH) ORANGE-16 BLACK-14 GROUND
38329A COIL BLUE
BLACK-16 6 GROUND (2.4 AMPS) BLACK-16
J15 A 3-WAY SOLENOID VALVE ON
BLUE-16 7 STAB. SOL. SV2 (1.2 AMP INRUSH) BLUE-16 REAR AXLE STABILIZER CONTROL
SV2
VALVE ON VALVE PLATE
GRAY-14 8 HORN (6 AMPS MAX.) GRAY-14 B
ENERGIZED W/BOOM BELOW 40° OR
GREEN-16 9 40° SWITCH POWER OUT BLACK-14 BOOM ABOVE 40° & FOOT BOOM ANGLE GREATER THAN 20° NO
SWITCH DEPRESSED BOOM ANGLE LESS THAN 20° NC
RED-16 10 12 VOLTS 37115X PROXIMITY SENSOR IS N. O.
J2 ON TRANSFER CARRIAGE
BLACK-16 11 PROXIMITY SWITCH GROUND
HORN
WHITE-16 12 20° SWITCH POWER OUT P13707
13 BROWN BLACK
14 POWER
POWER
IN
OUT
GREEN-16 D GREEN-16 D
RED-16 C RED-16 C GROUND
INTERMEDIATE HARNESS, 66961D BLACK-16
BLACK-16 B B BLUE
CONNECTS UNDER SEAT BOX
WHITE-16 A WHITE-16 A

65923A PROXIMITY 65924A PROXIMITY SWITCH HARNESS

SWITCH HARNESS,THRU ON TRANSFER CARRIAGE BOOM EXTEND GREATER THAN 20' NO
TRANSFER CARRIAGE BOOM EXTEND LESS THAN 20' NC
37115X PROXIMITY SENSOR IS N. O.
FOOT ON OUTER BOOM
SWITCH
BOOM/TRANSFER EXTEND
CUTOUT HARNESS, 66809C
CONNECTS UNDER SEAT BOX BROWN BLACK
39351A PROXIMITY
J1 SWITCH HARNESS,THRU POWER POWER
86 30
BOOM TRANSFER CARRIAGE IN OUT
EXTEND YELLOW-16 D D YELLOW-16
RED-16 C C RED-16 RED-16 C RED-16 C
85 87A 87 R BLACK-16 GROUND
B B BLACK-16 BLACK-16 B BLACK-16 B BLUE
WHITE-16 A A WHITE-16 WHITE-16 A WHITE-16 A
R
85 30 E 38329A COIL 38231A PROXIMITY SWITCH HARNESS
D WHITE-16
A ON OUTER BOOM
YELLOW-16
SV4
86 87A 87 BLACK-16 SOLENOID VALVE
B
BLACK-16 BOOM/TRANSFER EXTEND CUTOUT
VALVE ON VALVE PLATE
ENERGIZED WITH BOOM EXTENDED LESS
(USED ON 4 SECTION ONLY) A B B A THAN 20' OR OUTRIGGERS DOWN
REMOVE RELAY ON ALL
OTHER MACHINES BLACK WHITE BLACK

BLACK-16 A
YELLOW-16 B
PINK-16 C
BLUE-16 D TO CIRCUIT BOARD RIGHT LEFT
GRAY-16 E & SHIFTER HARNESS
GREEN-16 F (SEE SHT 2) 68441A SPST-NO
DIFFERENTIAL PRESSURE SWITCH
J3 OUTRIGGER CYLINDERS-BASE END
CLOSED ABOVE 92 PSI DIFFERENTIAL
OPEN BELOW 92 PSI DIFFERENTIAL

STUD ON BOARD

RELAYS FOR CIRCUIT BOARD J5

ALL ARE THE SAME RED-12 FROM ENGINE HARNESS, UNSWITCHED POWER
30/40 AMP-LULL#66820X
S PUSHBUTTON
SWITCH
P31598

15 AMP FRONT REAR

10 AMP

F2 JOYSTICK JOYSTICK
HORN (OPTION ON
6K MACHINES)

RED-16
J7 STUD ON BOARD BLUE-16
SWITCHED POWER FOR OPTIONS A B A B
39510B HARNESS

J4 38329A COIL

SELECTOR VALVE
R
39076C

MV0440

4-8 31200079
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° Y5 IS ON BOOM IS 21-40° SELECTED SELECTED

RELAY K11 RELAY K12 RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17

87a

87a

87a

87a

87a

87a

87a
30

87
86
85

30

87
86
85

30

87
86
85

30

87
86
85

30

87
86
85

30

87
86
85

30

87
86
85
FORWARD SGN

REVERSE SGN
BOOM OVER 40

BOOM OVER 20

BOOM OVER 40
SHIFTER PWR

SOLENOID Y6

SOLENOID Y1

SOLENOID Y2
IGN POWER

IGN POWER

IGN POWER

IGN POWER
RELAY GND

RELAY GND

RELAY GND

RELAY GND

RELAY GND

RELAY GND

RELAY GND
SHIFTER Y6 A
SHIFT TO 1ST

BOOM 21-40

BOOM 21-40

SHIFTER Y5
JUMPER 1

JUMPER 2
JUMPER 1

JUMPER 2
N/C

N/C

N/C

N/C

N/C

N/C
'A' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
D1 D2 D3 D4 D5
A PLUGGED
B PLUGGED
C PLUGGED
D IGN POWER UPPER KOSTAL
TRANSMISSION
CONNECTOR
FROM CIRCUIT
('B' OF TRANS
BOARD J11
SOLENOID HARNESS)
(SEE SHT 1)

SOLENOID Y1 1
SOLENOID Y2 2
'B' OF CIRCUIT SOLENOID Y3 3
BOARD & DASH GND
SHIFTER HARNESS) 7

RELAY GND ONLY 4 OF 16

A PINS SHOWN
B FORWARD SGN (OTHERS NOT USED)
C REVERSE SGN
D BOOM OVER 40
E PLUGGED
DIODE
F BOOM OVER 20 MODULE
#1
FROM CIRCUIT
BOARD J3
(SEE SHT 1)

RELAY K18
'E' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
87a
30

87
86
85

A DIRECTION INPUT
B FORWARD
C REVERSE
D NEUTRAL A UPPER KOSTAL
D10 TRANSMISSION
NEUTRAL A
NEUTRAL

FROM CIRCUIT CONNECTOR

BOARD J10 ('C' OF TRANS
(SEE SHT 1) SOLENOID HARNESS)
FROM E2 A (SEE SHT. 1)
FROM E1 A (SEE SHT. 1)

SOLENOID Y4 4
SOLENOID Y5 5
SOLENOID Y6 6
DASH GND 7
'C' OF CIRCUIT
BOARD & ONLY 4 OF 16
SHIFTER HARNESS) PINS SHOWN
DIRECTION INPUT (OTHERS NOT USED)
1
2 FORWARD
3 REVERSE
NEUTRAL DIODE
4 MODULE
5 SHIFTER Y5 D6 #2
6 SHIFTER Y4 D7
7 SHIFTER Y3 D8
8 SHIFTER Y6 D9
9 SHIFTER PWR
10 PLUGGED
11 PLUGGED
12 PLUGGED

FROM SHIFTER
CONNECTOR
(SEE SHT 1)

TO DASH
GND STUD

MV0450
MANIFOLD AIR COOLANT TEMP FUEL TEMP CRANK OIL PRESSURE INJECTOR
TEMP SENSOR SENSOR SENSOR SENSOR SENSOR PUMP

A B A B A B A B A B C A B

R Q P N F E
MAN TMP/463

FUEL TMP/428

CRANK B/448

OVR SUP/911
CRANK A/447
THR RTN/914

THR RTN/914

THR RTN/914

THR RTN/914

OIL PRS/467
CLT/461

INJ B/493
INJ A/491

NOTES:
12 TURNS
PER FOOT 1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
TWIST ENGINE ECU HARNESS (4923232).

A
1 ECU IGN/012
2 ECU BAT/022
3 ECU GND/050
4 PLUGGED
5
6
CLT TMP
PLUGGED
CLT TMP CLT TEMP
SENDER Q
7 OVR SGN/918 P23222
8 FAULT LT/473
ALT EXC OIL PSI OIL PRESS
L
TO DASH HARNESS (UNDER SEAT)

9 SEE SHT 1
10 OVR SUP/911 SENDER
11 THR SGN/915 P23217
12 THR RTN/914
13 PLUGGED
HR MTR
HD36-24-29SE

14
15 OIL PSI

K
GAGE PWR GAGE PWR 5 PSI ENGINE OIL
16 A
TRANS TEMP HR MTR PRESSURE
17 B
SWITCH
18 PLUGGED
19 PLUGGED
20 PLUGGED
21 PLUGGED
22
23
PLUGGED
PLUGGED
PLUGGED
TRANS TEMP TRANS TEMP
SENDER V
24 P19472
25 PLUGGED
26 PLUGGED
27 PLUGGED
28 PLUGGED
29 PLUGGED

390 OHM, 1W
SHTDN/941

SHIELDED
CAN TERMINATOR CABLE

A (CAN H/904, YELLOW)

D 120 OHM
B
C
(CAN L/905, GREEN)
(SHIELD/020)

SHIELDED
CAN TERMINATOR CABLE

A (CAN H/904, YELLOW)

H 120 OHM
B
C
(CAN L/905, GREEN)
(SHIELD/020)

12 TURNS
PER FOOT SHIELDED
TWIST CABLE
OVR SGN/918

ECU GND/050
MAN TMP/463
FUEL TMP/428

THR SGN/915
CRANK B/448

OVR SUP/911
CRANK A/447

THR RTN/914
PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED

PLUGGED

PLUGGED
ECU BAT/022
ECU IGN/012
SHTDN/941

FAULT LT/473
OIL PRS/467
CAN H/904
CAN L/905
HI LO/947
CLT/461
INJ B/493

INJ A/491

(CAN H/904, YELLOW)

(CAN L/905, GREEN)
ECU GND/050
ECU IGN/012

(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED

J
G1
G2
G3
C1
C2
C3
D1
D2
D3

H1
H2
H3
A1
A2
A3
B1
B2
B3

E1
E2
E3

K1
K2
K3
F1
F2
F3

J1
J2
J3

G
A B C D E F G H J

DEERE ENGINE ECU DIAGNOSTIC

CONNECTOR
MV0460

31200079 4-9
Reference Diagrams

Diagram 4-3 — Electrical Schematic (cont’d)

NOTES

4-10 31200079
Reference Diagrams

Diagram 4-3 — Electrical Schematic (cont’d)

NOTES

31200079 4-11
Reference Diagrams

4-12 31200079
Section 5 — Supply, Pressure, and Return Hydraulics

Table of Contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Major System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
General Hydraulic Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Filling Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Reservoir Drain and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Checking Filter Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Replacing Return Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Hydraulic Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Replacing Pressure Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Troubleshooting Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

31200079 i
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Checking Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Mid-Inlet Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Rear Axle Stabilizer Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Removal, Rear Axle Stabilizer Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Boom Extend Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Hydraulic Diagnostic Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Roll-Back Hose Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

List of Figures

Fig. 5-1: Major Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fig. 5-2: Mid-Inlet Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Fig. 5-3: Hydraulic Reservoir Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fig. 5-4: Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fig. 5-5: Recommended Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Fig. 5-6: Alternate Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fig. 5-7: Hydraulic Reservoir Drain and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fig. 5-8: Hydraulic Reservoir/Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fig. 5-9: Hydraulic Reservoir Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Fig. 5-10: Reservoir Sight Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Fig. 5-11: Suction Strainer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fig. 5-12: Hydraulic Return Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fig. 5-13: Return Filter Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fig. 5-14: Filter Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Fig. 5-15: Filter Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Fig. 5-16: Return Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Fig. 5-17: Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Fig. 5-18: Hydraulic Pressure Filter – Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

ii 31200079
Fig. 5-19: Hydraulic Pressure Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fig. 5-20: Hydraulic Pressure Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Fig. 5-21: Hydraulic Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Fig. 5-23: Hydraulic Pump Installation – Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Fig. 5-24: Checking Hydraulic Pump Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Fig. 5-25: Mid-Inlet Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Fig. 5-26: Mid-Inlet Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Fig. 5-27: Mid-Inlet Control Valve Configurations,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Fig. 5-28: Mid-Inlet Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Fig. 5-29: Rear Axle Stabilizer Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Fig. 5-30: Rear Axle Stabilizer Control Valve Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Fig. 5-31: Rear Axle Stabilizer Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Fig. 5-32: Boom Extend Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Fig. 5-33: Hydraulic Diagnostic Ports - Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 5-49
Fig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . 5-51
Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

List of Tables

Table 5-1: Rear Axle Stabilizer Control Valve Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

31200079 iii
iv 31200079
Section 5 — Supply, Pressure, and Return Hydraulics

General

Major System Components

Hydraulic
Oil Return
Hydraulic
Filter
Reservoir/
Fuel Tank

Hydraulic
Pump

Hydraulic
Control
Valve

K1099
Fig. 5-1: Major Hydraulic Components

General Description
(Ref. Fig. 5-1) The hydraulic system consists of the following circuits:
• Boom Extension (See Section 6)
• Boom Hoist (See Section 6)
• Carriage Tilt (See Section 6)
• Transfer Carriage (See Section 6)
• Frame Tilt (See Section 7)
• Auxiliary — 1st - Standard, 2nd - Optional (See Section 6)
• Steering
• Service Brakes (See Section 9)
• Rear Axle Oscillation Lock (See Section 6)
• Outriggers

31200079 5-1
Supply, Pressure, and Return Hydraulics

These circuits are supplied by a two-section, gear-type hydraulic pump,

driven directly from the transmission power takeoff. The closest to the
shaft pump supplies flow to all circuits except steering and the steer
selector valve. The second pump supplies flow to all circuits via the
steering priority valve.
The boom extension and hoist circuits are controlled by a two-spool valve
with pressure relief. The frame tilt, carriage tilt, transfer carriage, and
auxiliary circuits are controlled by a four-spool valve (five-spool optional)
with pressure relief. The carriage tilt circuits are also equipped with two
work port relief valves. The outrigger circuits are controlled by two
additional valve sections with no-relief plugs. The steering circuit is
controlled by a steering control unit and steering mode selector valve. The
service brake circuit is controlled by a hydraulic power brake valve and
includes an accumulator.
The boom extension, boom hoist, carriage tilt, outrigger, and frame tilt
cylinders are equipped with externally mounted counterbalance valves.
The counterbalance valves prevent movement of the cylinders in event of
downstream hydraulic line failure, leakage through the main control valve
or fittings. The counterbalance valves prevent movement of the cylinders
when the engine is off, even if the control valve levers are operated. The
counterbalance valves also provide over-load relief protection.
The hydraulic reservoir is mounted on the right-hand side of the machine.
The hydraulic system return filter/magnetic separator is located at the top
of the reservoir. The strainer and suction line is located at the bottom of the
back side of the reservoir.

5-2 31200079
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. It
uses a rear axle stabilizer control valve along with a mid-inlet directional
control valve assembly to control all hydraulic functions.

General Hydraulic Maintenance Practices

Safe Maintenance Practices

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
W1047

good repair.

31200079 5-3
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.
Remember the following during inspection and maintenance of the
hydraulic system:
• Wait for fluid to cool down before disconnecting lines.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or
paper to search for leaks.
• Wear appropriate eye protection.
• If anyone is injured by or if any hydraulic fluid is injected into the skin,
get medical attention immediately.
• When venting or filling the hydraulic system, loosen the filler cap slowly
and remove it gradually.
• NEVER reset any relief valve in the hydraulic system to a pressure
higher than that shown in the Specifications Section of this manual.

Cleanliness
Cleanliness is critical when servicing hydraulic systems.
KEEP DIRT AND OTHER CONTAMINANTS OUT OF THE SYSTEM!
Small particles can score valves, seize pumps and clog orifices, causing
expensive repair jobs.
Steam clean or use solvents to clean the area of the machine around a
hydraulic component before it is removed.
When steam cleaning or using water to clean a machine, be sure the
reservoir breather filter is protected to keep water out of the system.
Use caps or plugs to cover ends of disconnected lines, or to plug openings
when working on a hydraulic system.
When removing parts for service, clean them with a suitable solvent and
store them in plastic bags or other clean containers until they are installed
again.
Thoroughly rinse the cleaned parts, and dry them using compressed air.
Protect the parts immediately with a coating of rust preventive oil.
A clean work bench is an absolute must when servicing hydraulic
components. An industrial-type vacuum cleaner is a valuable aid in
removing dust, dirt, and tiny metal particles from the work area.
Check the condition of the tools you use and make sure they are clean.
Use hammers made of plastic or leather so there is no danger of metal
chips getting into components.
Despite all the precautions you take when working with a hydraulic system,
some contaminants will get into the system anyway. High quality hydraulic
oils keep these contaminants in suspension and the filters will collect them

5-4 31200079
Supply, Pressure, and Return Hydraulics

as the oil passes through. A high quality hydraulic oil contains many
additives which work to keep contaminants from damaging the system.
However, these additives lose their effectiveness after a period of time.
Therefore, change the oil at recommended intervals to make sure the
additives do their job.
The system filter can absorb only a limited amount of dirt particles and
other contaminants from the oil. Therefore, replace the filter element at the
recommended intervals so the cleaning process can be maintained.

Checking Hydraulic Lines

Inspect hydraulic lines and fittings for gouges, nicks, kinks, leaks, and
collapsed or deteriorating hoses.

Note: Even small leaks can be detected by oil stains or build-up of dirt or other
foreign material in a suspect area.
Replace any tube lines that are pinched or dented.
Replace a hose if any of the following conditions exist:
• Any evidence of hydraulic oil leakage at the surface of the hose or its
junction with the metal end couplings.
• Any blistering or abnormal deformation to the outer covering of the
hose.
• Hydraulic oil leakage at any threaded or clamped joint that cannot be
eliminated by normal tightening.
• Evidence of excessive abrasion or scrubbing on the outer surface of
hose or hoses.
Important: When tightening loose lines or connections, use two wrenches to
avoid twisting hose or tubes. Tighten loose connections only until the
leak stops. An over-tightened fitting may result in overstressing and/or
cracking. Replace any connectors that continue to leak. See
“Hydraulic Fitting Torques” in Section 3 for torque specifications for
hydraulic fittings and hydraulic line connections.

31200079 5-5
Supply, Pressure, and Return Hydraulics

Hydraulic Reservoir

Description

K1090
Fig. 5-3: Hydraulic Reservoir Location
(Ref. Fig. 5-3) The hydraulic reservoir is mounted on the right-hand side of
the machine and is located next to the fuel tank. It has a capacity of 47
gallons. The major components associated with the hydraulic reservoir are:
• Hydraulic Tank Breather
• Hydraulic Tank Sight Gauge
• Pressure Gauge
• Hydraulic Oil Return Filter
• Hydraulic Oil Strainer.
A breakdown of hydraulic reservoir parts is shown in Fig. 5-4.

5-6 31200079
Supply, Pressure, and Return Hydraulics

2 3

6
7

MV0010

# Description # Description
1 Hydraulic Tank Breather (Models 5 Hydraulic Oil Tank
with Mid-Inlet Hydraulics) 6 Hydraulic Oil Strainer (Models with
2 Hydraulic Tank Sight Gauge Mid-Inlet Hydraulics)
3 Pressure Gauge 7 Suction Line
4 Return Filter Assembly

Fig. 5-4: Hydraulic Reservoir

(Ref. Fig. 5-4) The hydraulic system return filter assembly (Item 4), along
with the pressure gauge (Item 3), is located within the return filter housing,
located at the top of the reservoir (Item 5).
The strainer (Item 6) and suction line (Item 7) are located at the bottom of
the back side of the reservoir.
A pressure differential gauge (Item 3) is fitted to the return filter housing to
monitor filter condition.
A breather filter assembly (Item 1) is threaded into the top of the reservoir. It
allows for expansion of fluid and prevents vacuum in the tank.
Check the hydraulic reservoir daily for the proper oil level. Maintain oil level
at the full mark on the sight gauge (Item 2) with all cylinders retracted.
Important: Do not operate the machine if the oil level falls below the low mark on
the sight gauge. Low oil level could damage the pump and other
components.

31200079 5-7
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.

3
2

K1015
# Description # Description
1 Hex Cap 3 Hydraulic Hose
2 Cover 4 Male JIC (37°) Filler Fitting

Fig. 5-5: Recommended Reservoir Filling Method

(Ref. Fig. 5-5) The following is the recommended filling procedure for the
hydraulic reservoir:
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 area around hex cap (Item 1) on the cover (Item 2). Loosen and
remove the hex cap.
4. Provide a hydraulic hose of suitable length to run between hydraulic oil
fill pump and male JIC (37°) filler fitting (Item 4), in return filter housing
cover. The reservoir end of the hose must be fitted with a 1-1/16-12 JIC
(37°) female hose fitting.
5. Assemble hose (Item 3) to reservoir filler fitting (Item 4) and tighten.
6. Fill reservoir until oil level in sight gauge is at HIGH mark. Use
hydraulic oil as specified in “Fluid and Lubricant Specifications” in
Section 3.

5-8 31200079
Supply, Pressure, and Return Hydraulics

7. Start engine and allow hydraulic system to warm up. Operate controls
gradually until you fully extend and retract each cylinder, including
steering cylinders. This procedure removes air from the system.
8. Level the frame, retract all cylinders except frame tilt cylinder, and stop
the engine. Recheck oil level and add oil as required.
9. Loosen and remove hose (Item 3) from reservoir filler fitting (Item 4).
Install hex cap (Item 1) and torque to 70 ft-lbs.

Filling Hydraulic Reservoir

Alternate Method

CAUTION: Do not fill reservoir through breather opening. The hydraulic

system can become contaminated.

Oil must be filtered through the return filter to ensure purity.

Contamination, even small amounts, can permanently damage hydraulic
system components and void the warranty.

K1016

# Description # Description
1 Return Filter Housing 4 Spring
2 Flange Nut 5 Hydraulic Filter Element
3 Cover

Fig. 5-6: Alternate Reservoir Filling Method

(Ref. Fig. 5-6) The following is an alternate filling procedure for the
hydraulic reservoir.

31200079 5-9
Supply, Pressure, and Return Hydraulics

1. The machine must be parked on a level surface and the frame must be
level.
2. Retract all cylinders except frame tilt cylinder, apply the park brake,
and stop the engine.
3. Clean return filter housing (Item 1) and surrounding area.
4. Remove four (4) flange nuts (Item 2) that secure the filter housing
cover (Item 3). Set hardware aside on a clean surface.
5. Lift the cover (Item 3) and spring (Item 4) from housing (Item 1) and set
aside on a clean surface.
6. SLOWLY pour hydraulic oil into filter element (Item 5). It takes several
moments for oil to drain through the element. Continue to add oil until
HIGH mark is reached on hydraulic reservoir sight gauge.
7. Make sure the cover (Item 3) and spring (Item 4) are clean.
8. Place spring (Item 4) in position on filter element assembly (Item 5).
9. Place the cover (Item 3) in position and secure it to the filter housing
(Item 1) with four (4) flange nuts (Item 2). Torque nuts to 35 ft-lbs.
10. Start the engine and allow hydraulic system to warm up. Operate
controls gradually until you can fully extend and retract each cylinder,
including steering cylinders. This procedure removes air from the
system.
11. Retract all cylinders and stop the engine.
12. Recheck oil level and add oil as necessary.

5-10 31200079
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.
1. Lower the boom to the ground, apply the parking brake, and stop the
engine.

CAUTION: Do not place hands in hot hydraulic oil. Hot hydraulic oil can
cause severe burns and skin irritation.

2. Remove hydraulic reservoir drain plug (Item 4) and drain hydraulic oil
into an appropriate container. Dispose of drained oil properly.
3. To remove the return filter assembly (Item 2), see “Removal” on
page 5-25.
4. To remove the suction strainer (Item 3), see “Removal and Cleaning”
on page 5-20.
5. Clean inside of reservoir of rust, sludge, scale, metallic particles,
deposits, and other residue with solvent. Drain into suitable container
and wipe clean with dry, lint-free wipes. Dry with compressed air and
use a shop vacuum to remove any remaining particles.

31200079 5-11
Supply, Pressure, and Return Hydraulics

6. Clean the strainer (Item 2) by back flushing with solvent. Dry the
strainer element thoroughly with compressed air. Install it as described
under “Installation” on page 5-20.
7. Install the reservoir drain plug (Item 4). Tighten two or three turns past
finger tight. If it is necessary to use thread sealant to stop fluid leakage,
apply sealant only to last few threads close to the drain plug head.

CAUTION: To avoid contamination of hydraulic system, do not apply

thread sealant to end threads of drain plug.

8. To install return filter assembly (Item 2), see “Installation” on

page 5-26.
9. Install a new breather filter assembly (Item 1).
10. Fill hydraulic reservoir. see “Filling Hydraulic Reservoir” on page 5-8.

5-12 31200079
Supply, Pressure, and Return Hydraulics

Removal

Hydraulic Reservoir and

Fuel Tank

7
6 10
8 9
5
4 11
1
3
2 12
15 14
28
13
16 17
20
27 26 21
19
18
22
25

23
24 24
23

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
6 Flatwasher 20 Flange Halve
7 Nut 21 Hydraulic Suction Hose
8 Wiring Harness 22 Tank Support Mount
9 JIC Pipe Connector 23 Lockwasher
10 Return Manifold Tube 24 Nut
11 Hydraulic Oil Return Filter 25 Main Frame (Front End)
12 Hydraulic Reservoir/Fuel Tank 26 Capscrew
13 Swivel Branch Tee 27 Lockwasher
14 Check Valve 28 Hydraulic Oil Strainer

Fig. 5-8: Hydraulic Reservoir/Fuel Tank Installation

31200079 5-13
Supply, Pressure, and Return Hydraulics

(Ref. Fig. 5-8) The following procedure describes removal of the hydraulic
reservoir/fuel tank.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Remove the hydraulic reservoir drain plug (Item 19) and drain hydraulic
fluid into a suitable container. Dispose of drained fluid properly.
Temporarily reinstall drain plug.
3. Remove fuel tank drain plug (Item 18) and drain the fuel into an
suitable container. Dispose of drained fuel properly. Temporarily
reinstall drain plug.

WARNING: Fuel is highly combustible. Avoid all possibilities of sparks that

could ignite the fuel. Drain the fuel tank in a well ventilated
area, away from smoking materials, open flames, or exposed
heater parts.

4. Remove two (2) nuts (Item 7) and flatwashers (Item 6) securing wiring
harness (Item 8) to fuel sender.
5. Loosen and disconnect swivel nut of swivel branch tee (Item 13) from
check valve (Item 14).
6. Tag fuel lines (Items 17 and 5). Remove hose clamps (Items 4 and 16)
on fuel lines. Cap elbow (Item 15) and pipe adapter (Item 3).
7. Remove the four (4) capscrews (Item 26) and lockwashers (Item 27)
securing the two (2) flange halves (Item 20) and the hydraulic suction
hose (Item 21) to the hydraulic strainer (Item 28). Remove the flange
halves.
8. Loosen and remove the return manifold tube (Item 10) connected to
the JIC pipe connector (Item 9) on the hydraulic oil return filter
(Item 11).

CAUTION: To avoid personal injury and/or damage to the equipment,

support the hydraulic tank to ensure that it does not twist or
fall when removing or installing it.

9. After ensuring that the tank is properly supported, remove the four (4)
each nuts (Item 24) and lockwashers (Item 23) that secure the two (2)
tank hold-down straps (Item 1) to the tank support mount (Item 22).
10. Remove the hydraulic reservoir/fuel tank (Item 12) to an appropriate
area for cleaning/inspection.
11. Inspect reservoir/fuel tank for damage and replace if necessary.
12. Remove hydraulic reservoir drain plug and perform steps 3 thru 5
under “Reservoir Drain and Refill” on page 5-11.
13. Remove the fuel tank drain plug. Clean the inside of the fuel tank with
high-pressure jet spray of diesel fuel to ensure it is free of rust, sludge,
scale, metallic particles, deposits, and other residue. Drain into suitable
container and hand wipe clean with dry rags.

5-14 31200079
Supply, Pressure, and Return Hydraulics

14. Perform steps 6 through 9 under “Reservoir Drain and Refill” on

page 5-11.
15. Install the fuel tank drain plug (Item 18). Tighten two or three turns past
finger tight. If it is necessary to use thread sealant to stop fluid leakage,
make sure that the sealant is applied only to the last few threads close
to the drain plug head.

CAUTION: To avoid contamination of the fuel system, do not apply thread

sealant to the end threads of the drain plug.

Installation

Hydraulic Reservoir and (Ref. Fig. 5-8) The following procedure describes installation of the
Fuel Tank hydraulic reservoir/fuel tank.
1. Inspect the two (2) pieces of chemprene belting (Item 2) and replace if
necessary.

CAUTION: To avoid personal injury and/or damage to the equipment,

support the hydraulic tank to ensure that it does not twist or
fall when removing or installing it.

2. While ensuring that the hydraulic reservoir/fuel tank is properly

supported and in the proper position, attach the two (2) tank hold-down
straps (Item 1) over the two pieces of chemprene belting and to the
tank support mount (Item 22) using four (4) each nuts (Item 24) and
lockwashers (Item 23). For final tightening, torque nuts to 35 ft-lbs.
3. Reconnect the suction tube elbow (Item 21) to the JIC pipe connector
(Item 20).
4. Reconnect swivel nut of swivel branch tee (Item 13) to check valve
(Item 14). For final tightening, torque to 44–48 ft-lbs.
5. Reconnect return manifold tube (Item 10) to JIC pipe connector
(Item 9) on hydraulic oil return filter (Item 11). For final tightening,
torque connector on return manifold tube to 188–213 ft-lbs.
6. Reconnect fuel lines (Items 17 and 5) to elbow (Item 15) and pipe
adapter (Item 3). Secure the fuel lines to the fittings with hose clamps
(Items 4 and 16) and tighten as necessary.
7. Install wiring harness (Item 8) on fuel sender with two (2) flatwashers
(Item 6) and nuts (Item 7). Tighten nuts until snug.
8. Fill hydraulic reservoir according to the preferred method on page 5-8.
9. Fill fuel tank as outlined in Section 3.

31200079 5-15
Supply, Pressure, and Return Hydraulics

Sight Gauge

Description

H
I
G
H

L
O
W

K1005
Fig. 5-9: Hydraulic Reservoir Sight Gauge

Note: When checking oil quantity, the machine must be on a level surface and the
frame must be level.
The hydraulic reservoir sight gauge is located on the side of the reservoir
(see Fig. 5-10, Item 1).
The hydraulic fluid level in the reservoir changes considerably during
operation and a reading should not be taken until the boom is lowered to
the ground, the parking brake is applied, the engine is stopped, and all
hydraulic pressure is released in the system. The hydraulic reservoir sight
gauge should then show the fluid level being near the high level. If
necessary, add hydraulic fluid, being careful not to overfill.

5-16 31200079
Supply, Pressure, and Return Hydraulics

Removal

Sight Gauge 6
5

4
8
3 7
2

1 9

10

K1093
# 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. 5-10: Reservoir Sight Gauge Installation

(Ref. Fig. 5-10) The following procedures describes removal of the
reservoir sight gauge.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Remove the hydraulic reservoir drain plug (Item 19) and drain hydraulic
fluid into a suitable container. Dispose of drained fluid properly.
3. Disconnect return manifold tube (Item 8) connected to the JIC pipe
connector (Item 7) on the hydraulic oil return filter assembly (Item 6).
4. Remove four (4) each capscrews (Item 5) and lockwashers (Item 4)
that secure the hydraulic oil return filter assembly (Item 6) to the
hydraulic reservoir (Item 9). Remove the hydraulic oil return filter
assembly.
5. Reaching inside the opening for the hydraulic oil return filter assembly
in the hydraulic fluid reservoir, remove the two (2) nuts (Item 10) that
secure the sight gauge to the hydraulic reservoir.

31200079 5-17
Supply, Pressure, and Return Hydraulics

6. Remove the sight gauge (Item 1) along with the two (2) hollow hex
head bolts (Item 2).
7. Clean the two openings in the side of the hydraulic reservoir with
appropriate solvent. Plug openings.

Installation

Sight Gauge (Ref. Fig. 5-10) The following procedures describes installation of the
reservoir sight gauge.
1. Remove the four (4) O-rings (Item 3) from the sight gauge and clean
O-rings with appropriate solvent. Dry with compressed air. Check for
and replace any damaged O-rings.
2. Inspect sight gauge for damage and replace if necessary. Clean sight
gauge with appropriate solvent and dry with compressed air.
3. Install four (4) O-rings (Item 3) in sight gauge. Lubricate each O-ring
before installing it.
4. Clean the two (2) hollow hex head bolts (Item 2) with appropriate
solvent; inspect and replace if damaged.
5. Install sight gauge (Item 1) on hydraulic reservoir (Item 9) with hollow
hex head bolts (Item 2) and nuts (Item 10). Tighten as necessary.
6. Install hydraulic oil return filter assembly (Item 6) as per instructions on
page 5-26.
7. Reconnect return manifold tube (Item 8) to the JIC pipe connector
(Item 7) on the hydraulic oil return filter assembly (Item 6). For final
tightening, torque hex head connector on return manifold tube to
188–213 ft-lbs.
8. lean the inside of the reservoir of rust, sludge, scale, metallic particles,
deposits, and other residue with high pressure jet spray of diesel fuel.
Drain into suitable container and hand wipe clean with dry rags.
Dispose of contaminated diesel fuel properly.
9. Install the reservoir drain plug (Item 4). Tighten two or three turns past
finger tight. If it is necessary to use thread sealant to stop fluid leakage,
apply sealant only to the last few threads close to the drain plug head.

CAUTION: To avoid contamination of the hydraulic system, do not apply

thread sealant to the end threads of the drain plug.

10. Fill hydraulic reservoir. (See page 5-8.)

5-18 31200079
Supply, Pressure, and Return Hydraulics

Suction Strainer

Description

2
3
4
8
7
1

5
6 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. It removes contaminants as oil is pumped out of the hydraulic
reservoir.

31200079 5-19
Supply, Pressure, and Return Hydraulics

Removal and Cleaning

Suction Strainer
(Ref. Fig. 5-11) The following procedures describes removal of the suction
strainer on models with mid-inlet hydraulics.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Remove the hydraulic reservoir drain plug (Item 1) and drain hydraulic
fluid into a suitable container. Dispose of drained fluid properly.
3. Remove the four (4) capscrews (Item 6) and lockwashers (Item 5)
securing the two (2) flange halves (Item 4) and the hydraulic suction
hose (Item 8) to the hydraulic strainer (Item 3). Remove the flange
halves.
4. Remove and discard the O-ring (Item 7) from the hydraulic suction
hose.
5. Loosen and remove the strainer (Item 3) from the reservoir. Take the
strainer to an appropriate area for further cleaning.
6. Clean the strainer (Item 3) by back flushing with solvent. Dry the
strainer element thoroughly with compressed air.

Installation

Suction Strainer
(Ref. Fig. 5-11) The following procedures describes installation of the
suction strainer on models with mid-inlet hydraulics.
1. Insert hydraulic oil strainer (Item 3) into cavity in hydraulic reservoir
and tighten until snug.
2. Install a new O-ring (Item 7) on the hydraulic suction hose (Item 8).
3. Install the hydraulic suction hose on the hydraulic oil strainer using the
two flange halves (Item 4) and the four (4) lockwashers (Item 5) and
capscrews (Item 6). 4
4. Apply thread sealant to few threads near the head of drain plug (Item
1). Install the drain plug. Tighten 2–3 turns past finger tight.
5. Fill hydraulic reservoir according to the preferred method on page 5-8.

5-20 31200079
Supply, Pressure, and Return Hydraulics

Hydraulic Return Filter

Description

K1100
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

2 3

15

1 10 20 4
psi

5 25

0 30

psi
K1009

Fig. 5-13: Return Filter Pressure Gauge

Note: Check indicator with engine at idle, after thirty minutes of operation.

31200079 5-21
Supply, Pressure, and Return Hydraulics

The return filter pressure gauge is located on the side of the return filter
housing.
The gauge indicates hydraulic fluid pressure entering the return filter
element. As contamination accumulates in the filter element, pressure
rises.
The acceptable operating pressure range is 0–15 psi and is indicated by
needle (1) positioned in green arc (2). Pressures above 15 psi, orange arc
(3) and red arc (4), indicate that the return filter element must be serviced.

Replacing Return Filter Element

2
3

K1095
# Description # Description
1 Return Filter Housing 4 O-Ring
2 Flange Nut 5 Spring
3 Filter Housing Cover 6 Hydraulic Filter Element

Fig. 5-14: Filter Housing Cover

Disassembly, Return Filter Element

(Ref. Fig. 5-14) The following procedure describes removal of the return
filter element.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.

5-22 31200079
Supply, Pressure, and Return Hydraulics

2. Loosen four (4) flange nuts (Item 2) that secure cover (Item 3) to return
filter housing (Item 1). Loosen them only enough to be able to rotate
cover. While applying pressure to cover, rotate cover clockwise so that
recessed areas of cover line up to flange nuts. Slowly release
pressure and remove cover.

CAUTION: Care must be taken to avoid injury when removing cover. Do

not remove flange nuts. There is pressure under cover from
spring (Item 5).

3. Remove spring (Item 5) and return filter element assembly (Item 6)

and take to a suitable location for further inspection and cleaning.
4. To protect system from contamination while working on filter element
assembly, place cover (Item 3) back on return filter housing (Item 1)
and tighten flange nuts (Item 2).
1

5 7

K1098

# Description # Description
1 Lock Nut 5 Filter Element O-Ring
2 Trestle 6 Tie Rod
3 Flatwasher 7 Filter Element
4 O-Ring 8 Bypass Spring Assembly

Fig. 5-15: Filter Element Assembly

31200079 5-23
Supply, Pressure, and Return Hydraulics

Replacement, Return Filter Element

(Ref. Fig. 5-15) The following procedure describes replacing the return
filter element.
1. To avoid contamination, place all parts on clean paper or cloth.
2. Loosen and remove lock nut (Item 1) that secures trestle (Item 2) to
filter element (Item 7).
3. Remove trestle and flatwasher (Item 3).
4. Loosen bypass spring assembly (Item 8) by turning it counter-
clockwise. Remove bypass spring assembly and tie rod (Item 6) from
filter element (Item 7). Discard contaminated filter element.
5. Remove and inspect two (2) trestle O-rings (Items 4 and 5). Clean
trestle and O-rings with solvent. Dry with compressed air. Lubricate
O-rings with hydraulic oil and install.
6. Clean washer, lock nut, bypass spring assembly, and tie rod with
solvent. Dry with compressed air.
7. Insert short end of tie rod (Item 6) through new filter element (Item 7).
Connect bypass spring assembly (Item 8) to end of tie rod. Tighten by
turning bypass spring assembly clockwise until snug and completely
engaged on tie rod.
8. Reassemble flatwasher (Item 3), trestle (Item 2), and lock nut (Item 1)
on other end of tie rod.

Reassembly, Return Filter Element

(Ref. Fig. 5-14) The following procedure describes installation of the return
filter element.
1. Loosen four (4) flange nuts (Item 2) enough so cover (Item 3) can be
removed from filter assembly head (Item 1). Twist cover clockwise so
that recessed areas of cover line up to flange nuts before removing it.
2. Inspect and clean cover O-ring (Item 4) and replace if necessary.
Lubricate O-ring with hydraulic oil and install on cover.
3. Insert filter element assembly (Item 6) into return filter housing
(Item 1).
4. Place spring (Item 5) so it rests vertically on top of trestle.
5. Place cover (Item 3) on filter assembly head making sure recessed
areas of cover line up with flange nuts.
6. Press down on cover until it can be rotated counter clockwise and slide
under flange nuts (Item 2). Torque flange nuts to 35 ft-lbs.

5-24 31200079
Supply, Pressure, and Return Hydraulics

Removal

Return Filter Assembly

3

2
5
4
6

1 8

K1097
# Description # Description
1 Hydraulic Oil Reservoir 5 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.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Clean the area around the return filter housing (Item 6).
3. Loosen and remove the return manifold tube (Item 4) connected to the
connector (Item 5) on the hydraulic oil return filter assembly (Item 6).
4. Loosen and remove four (4) capscrews (Item 3) and lockwashers
(Item 2) that secure the hydraulic oil return filter assembly (Item 6) to
the hydraulic oil reservoir (Item 1). Remove the hydraulic oil return filter
assembly. To avoid contamination, place all parts on a clean surface.
5. Remove the rubber gasket (Item 8) and clean it with an appropriate
solvent. Inspect condition of the gasket and replace it if necessary.

31200079 5-25
Supply, Pressure, and Return Hydraulics

6. Remove the diffuser (Item 7) and clean with solvent. Dry with
compressed air.

Installation

Return Filter Assembly (Ref. Fig. 5-16) The following procedures describes installation of the
return filter assembly.
1. Reassemble the diffuser (Item 7) and the rubber gasket (Item 8) with
the hydraulic return assembly (Item 6).
2. Install the return filter assembly on the hydraulic reservoir with the four
(4) lockwashers (Item 2) and capscrews (Item 3). Torque the
capscrews evenly to 276 in-lbs.
3. Connect the return manifold tube (Item 4) to the connector (Item 5) on
the hydraulic oil return filter assembly (Item 6). Torque the nut on the
return manifold tube to 188–213 ft-lbs.

Reservoir Breather

Description

MV0020

Fig. 5-17: Reservoir Breather

(Ref. Fig. 5-17) The reservoir breather is located on the top of the
hydraulic reservoir near the return filter. It allows for expansion of fluid and
prevents vacuum in the tank.

5-26 31200079
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.

CAUTION: To avoid the possibility of the hydraulic system being

contaminated, do not fill the reservoir through the breather
opening.

Hydraulic Pressure Filter

Description

K1101

Fig. 5-18: Hydraulic Pressure Filter – Control Manifold Hydraulics

The hydraulic pressure filter is located on the mounting bracket for the
pressure filter and accumulator which is attached to the valve plate. While
Fig. 5-18 illustrates the hydraulic pressure filter. The function of the
pressure filter is to remove contaminants from the oil traveling to the
joystick controls.

31200079 5-27
Replacing Pressure Filter Element
Supply, Pressure, and Return Hydraulics

1
2
3
4

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. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Clean hydraulic pressure filter assembly to avoid contamination of
system while removing hydraulic pressure filter assembly.
3. Unscrew and remove filter element bowl (Item 4) from filter head
(Item 1).
4. Remove filter element (Item 3) and discard it.
5. Remove bowl O-ring (Item 2), clean with an solvent, and dry with
compressed air. Replace it if damaged.
6. Clean filter element bowl and filter head with solvent and dry with
compressed air.

5-28 31200079
Supply, Pressure, and Return Hydraulics

7. Insert a new filter element into bowl. Lubricate bowl O-ring with
hydraulic oil and install it on bowl.
8. Screw bowl into filter head and tighten until snug.

Removal

Pressure Filter Assembly

1 7
4
2
3
5
6

MV0050

# Description # Description
1 Filter Mounting Bracket 5 Pressure Filter Assembly
2 Capscrew 6 90° O-Ring Hose Elbow
3 Lockwasher 7 Swivel Tee
4 90° O-Ring Hose Elbow

Fig. 5-20: Hydraulic Pressure Filter Assembly

(Ref. Fig. 5-20) The following procedure describes removal of the hydraulic
pressure filter assembly.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Clean the hydraulic pressure assembly to avoid contamination of the
system while removing the hydraulic pressure filter assembly.
3. Tag and slowly loosen the three (3) fittings (Items 4, 6 and 7) from the
pressure filter assembly and bleed any remaining oil. Cap fittings.
4. While securing the hydraulic pressure filter assembly (Item 5), loosen
and remove the four (4) each capscrews (Item 2) and lockwashers
(Item 3) that connect the pressure filter assembly to the filter mounting
bracket (Item 1).

31200079 5-29
Supply, Pressure, and Return Hydraulics

5. Remove the pressure filter assembly from the hole in the filter
mounting bracket.

Installation

Pressure Filter Assembly (Ref. Fig. 5-20) The following procedure describes installation of the
hydraulic pressure filter assembly.
1. Insert the pressure filter assembly through the hole in the filter
mounting bracket, making sure that the bypass indicator is closest to
back of the mounting bracket.
2. Secure the pressure filter assembly to the mounting bracket with the
four (4) each capscrews and lockwashers. For final tightening, torque
the capscrews to 75 in-lbs.
3. Connect the three (3) fittings (Items 4,6 and 7) to the pressure filter
assembly. For final tightening, torque to 75–85 ft-lbs.

Hydraulic Pump

Description
60 80
40
20

0
-20

K1066

Fig. 5-21: Hydraulic Pump Location

5-30 31200079
Supply, Pressure, and Return Hydraulics

(Ref. Fig. 5-21) The hydraulic pump is located on the transmission towards
the back of the machine.The hydraulic pump used is a two-section gear
type, driven directly from the transmission power takeoff.
PUMP SPECIFICATIONS:
Type - Gear
Sections - Two
Manufacturer - Vickers
Model - G2020
GPM - 18 at 2500 RPM (Cover End - Pump 1)
GPM - 26 at 2500 RPM (Shaft End - Pump 2)

Troubleshooting Pump Problems

Problem Probable Cause Solution

1. Excessive pump noise A. Low oil level in the hydraulic Fill reservoir to proper level with the recommended
reservoir hydraulic fluid. DO NOT overfill.
B. Air in the system 1. Operate hydraulic system until purged.
2. Check inlet (suction) lines and fittings for air
leaks.
C. Vacuum condition 1. Check inlet (suction) lines and fittings for
restrictions.
2. Check reservoir breather filter conditions.
D. Oil too thick Be certain correct type of oil is used for refilling or
adding to the system. Viscosity must be correct for
ambient temperatures.
E. Cold weather Run hydraulic system until unit is warm to the
touch and noise disappears. Check oil viscosity.
2. Pump Overheating A. Internal leakage Return vehicle to maintenance shop for evaluation
and repair.
B. Low fluid level Add oil to operating level.
3. System not developing A. Relief valve open Replace or repair the relief valve.
pressure
B. Loss of fluid internally Return the vehicle to the maintenance shop for
(slippage) repair of hydraulic system.

31200079 5-31
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
B. Loose fittings hoses. Tighten connections and replace any
ruptured tubes or hoses.
C. Leaking gaskets or seals in
pump or circuit 2. Observe mating sections of pump for leaks.
3. Replace seals or gaskets if possible.

5-32 31200079
Supply, Pressure, and Return Hydraulics

Removal

Hydraulic Pump
.

1
17

2 16

3
4 5 15
14
13
6 12

8
11
9
10

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
5 Branch Tee Axle Stabilizer Valve
6 Elbow 15 Connector
7 Hydraulic Hose to Steer Motor 16 Hyd. Hose to Connector on Rear
8 Hydraulic Hose to Steer Motor Axle Stabilizer Valve
9 Hydraulic Hose to Accumulator 17 Run Tee
10 Hydraulic Hose to Steer Motor

Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics

(Ref. Fig. 5-22) The following describes initial steps for removal of the
hydraulic pump.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Install brake pressure diagnostic port test gauge into brake diagnostic
port (see page 5-49).

31200079 5-33
Supply, Pressure, and Return Hydraulics

3. While watching test gauge, press brake pedal numerous times until
pressure gauge reads 0 psi. Remove test gauge from diagnostic port.
4. Thoroughly clean the hydraulic pump to ensure that dirt will not get into
the system/transmission.
5. Tag and slowly loosen the ten (10) hydraulic hoses shown in Fig. 5-22
(Items 1, 2, 3, 7 thru 11, 14 and 16) and the two (2) hydraulic hoses
shown in Fig. 5-24 (Items 1 & 12). Bleed any remaining oil into
appropriate container. Disconnect hoses. Cap fittings and hoses.

5-34 31200079
Supply, Pressure, and Return Hydraulics

4 7
3

2
6
5
1
2 10

1 13 8
9 11
14
15 12
17
16 22
18 23
24
21 20
19

26 25
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 22 Upper Pump Support Bracket
10 Lockwasher 23 Flatwasher
11 Capscrew 24 Capscrew
12 Hydraulic Suction Hose 25 Transmission Mount
13 Nut 26 Capscrew

Fig. 5-23: Hydraulic Pump Installation – Mid-Inlet Hydraulics

(Ref. Fig. 5-23) The following procedures completes the steps necessary
for removal of the hydraulic pump.
1. Tag and slowly loosen two (2) hydraulic hoses (Item 1) and bleed any
remaining oil. Disconnect hoses from connectors (Item 2). Cap fittings
and hoses.
2. Remove four (4) capscrews (Item 11) and lockwashers (Item 10)
securing the two (2) flange halves (Item 9) to the hydraulic suction
hose (Item 12). Remove the flange halves.

31200079 5-35
Supply, Pressure, and Return Hydraulics

CAUTION: Before removing support bracket or loosening capscrews that

secure the hydraulic pump to the transmission (Item 7),
support the pump to ensure that it does not twist or fall.

3. Remove capscrews (Item 19), lockwashers (Item 20), and flatwashers

(Item 21) securing upper pump support bracket (Item 22) to the pump.
4. Remove two (2) capscrews (Item 3) and lockwashers (Item 4) securing
the hydraulic pump to the transmission.
5. Pull the pump straight out from the transmission and take it to an
appropriate area for further inspection.

CAUTION: To avoid contamination of system, cap hoses and cover

opening in transmission after pump is removed.

Inspection and Maintenance, Hydraulic Pump

The following steps describe cleaning and replacement of fittings and

O-rings for the hydraulic pump after it has been removed.
1. (Ref. Fig. 5-23) Remove and discard O-rings (Items 6 and 8).
2. Make notes of positions of hydraulic fittings shown in Fig. 5-22 and
Fig. 5-23. Tag and remove all fittings. Clean with appropriate solvent
and dry with compressed air. Inspect and replace if damaged.
3. Clean exposed areas of hydraulic pump with appropriate solvent and
dry with compressed air.
4. (Ref. Fig. 5-23) Lubricate and install new O-rings on pump.
5. Lubricate threaded portion of each fitting, including the O-ring.
Steps 6 thru 14 apply to Fig. 5-22. Refer to notes made earlier for correct
positioning of all fittings.
6. Install connector (Item 6) in lower port on front of pump.
7. Install run tee (Item 17) on top of pump.
8. Install branch tee (Item 5) on side of pump.
9. Install reducer adapter (Item 4) on the branch tee (Item 5).
10. Install connector (Item 15) on side of pump.
11. Install swivel run tee (Item 12) on side of pump.
12. Install elbow (Item 13) on side of pump.

5-36 31200079
Supply, Pressure, and Return Hydraulics

Installation

Hydraulic Pump
(Ref. Fig. 5-22 and Fig. 5-23) The following procedure is for the installation
of the hydraulic pump.
Step 1 thru Step 5 refer to Fig. 5-23.
1. If the pump support brackets were removed,
a. Install lower pump support bracket on park brake cylinder mount
with two (2) capscrews (Item 26), flatwashers (Item 15),
lockwashers (Item 14), and nuts (Item 13).
b. Install upper pump support bracket on lower pump support bracket
with three (3) capscrews (Item 24), flatwashers (Item 23),
lockwashers (Item 17), and nuts (Item 16).
2. Insert assembled hydraulic pump straight into the transmission making
sure the pump is supported so it cannot twist and cause damage.
Install the pump on the transmission with the two (2) capscrews
(Item 3) and lockwashers (Item 4).
3. Secure upper pump support bracket to pump with two (2) each
flatwashers (Item 21), lockwashers (Item 20), and capscrews
(Item 19).
4. Connect hydraulic suction hose (Item 12) to pump by installing two (2)
flange halves (Item 9) and four (4) lockwashers (Item 10) and
capscrews (Item 11).
5. Connect two (2) hydraulic hoses (Item 1) on connectors (Item 2) on
side of pump.
Step 6 thru Step 16 refer to Fig. 5-23.
6. Install hydraulic hose (Item 3) from Pump 1 test port to reducer adapter
(Item 4).
7. Install hydraulic hose (Item 1) from test port to branch tee (Item 17).
8. Install hydraulic hose (Item 2) from accumulator to run tee (Item 17).
9. Install hydraulic hose (Item 16) from rear axle stabilizer valve to run tee
(Item 5).
10. Install hydraulic hose (Item 7) from steer motor to hydraulic pump.
11. Install hydraulic hose (Item 8) from steer motor to elbow (Item 6).
12. Install hydraulic hose (Item 9) from accumulator to elbow (Item 13).
13. Install hydraulic hose (Item 10) from steer motor to run tee (Item 12) on
side of pump.
14. Install hydraulic hose (Item 11) from test port to run tee (Item 12).
15. Install hydraulic hose (Item 14) from rear axle stabilizer valve to
connector (Item 15).
16. Start the engine and check for hydraulic leaks. Correct as necessary.

31200079 5-37
Supply, Pressure, and Return Hydraulics

Checking Pump Flow Rate

4
3

2
4
5

6
6

# 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. Fig. 5-24) If the pump(s) is suspected of delivering below rated
capacity, use the following procedure to check pump flow rate:
1. Lower boom to the ground, apply parking brake and stop engine.
Release all hydraulic pressure in the system (See warning and
procedure under “General Hydraulic Maintenance Practices” on
page 5-3 of this section).
2. Loosen and remove pressure line hose (Item 6) from pressure port of
pump (Item 5) to be tested.
3. Loosen and remove hex cap (Item 2) from top of return filter housing
(Item 1).
4. Assemble a hydraulic tester (Item 3) in a test loop between the pump
and return filter. Use hydraulic hose (Item 4) with a minimum burst
pressure rating of 12,000 psi. Hose end fittings for the pump and return
filter must be 1 1/16-12 JIC (37°) female.
5. Determine the system's maximum rated pressure (which is the
specified-relief setting for boom hoist and extend control valve). See
Fluid Pressures under “Specifications” for your model forklift in section
2.

5-38 31200079
Supply, Pressure, and Return Hydraulics

6. Adjust pressure relief valve setting to 100 psi over that of system's
maximum rated pressure.
Important: Be sure the load valve is open before starting the engine.
7. Start the engine and, when it is at normal operating temperature, open
the throttle control all the way. Slowly close the load valve to load the
system. (Do not exceed system's maximum rated pressure). Continue
loading until normal operating temperature of the system is reached
(see “Hydraulic Oil Working Temperature @ under Specifications @ for
your model forklift in Section 2).
8. Open load valve. Record maximum pump flow at zero pressure.
9. Slowly close the load valve until the system is at the maximum rated
pressure. Record the pump flow.
10. Open load valve until pump pressure is again at zero.
11. Shut off the engine.
12. Disconnect test loop from pump and return filter housing. Reconnect
pump pressure hose (Item 6) and install hex cap (Item 2) atop return
filter housing.
Pump flow at maximum pressure should be at least 75 percent of the rated
pump flow. For rated pump flow, see “Hydraulic Pump”, under
“Specifications”, in Section 2.
Repair or replace pump if pump flow rate is less than 75 percent of rated
capacity. see “Hydraulic Pump” on page 5-30 for replacement pump
procedures.

31200079 5-39
Supply, Pressure, and Return Hydraulics

Mid-Inlet Control Valve

Description

6 0 8 0
4 0
2 0
0
-2 0

K1140
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)
K1141

Inlet Section
Relief Valve

Fig. 5-26: Mid-Inlet Control Valve Components

5-40 31200079
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
• Carriage Fork Tilt
• Transfer Carriage
• 1st Auxiliary Hydraulics
• 2nd Auxiliary Hydraulics
• Frame Tilt
To the right of the mid-inlet section, there are two boom-controlling
sections for the following circuits:
• Boom Hoist
• Boom Extension (Telescope)
The presence of these circuits, and the controlling valve sections, depends
upon the machine model and installed options (see Fig. 5-27 and Fig. 5-
29).

31200079 5-41
Supply, Pressure, and Return Hydraulics

Boom Extend
Boom Extend Boom Hoist
Boom Hoist Mid-Inlet
Mid-Inlet Unloader
Frame Tilt Frame Tilt
Auxiliary Auxiliary
Transfer Carriage Transfer Carriage
Carriage Tilt Carriage Tilt

6-Spool Valve 7-Spool Valve

For Models without Outriggers For Models with Unloader
(Natural Engine)

Boom Extend
Boom Extend Boom Hoist
Boom Hoist Mid-Inlet
Mid-Inlet Frame Tilt
Frame Tilt 2nd Auxiliary
Auxiliary 1st Auxiliary
Transfer Carriage Transfer Carriage
Carriage Tilt Carriage Tilt
R.H. Outrigger R.H. Outrigger
L.H. Outrigger L.H. Outrigger

1138

8-Spool Valve 9-Spool Valve

For Models with Outriggers Only For Models with Outriggers and
Optional 2nd Auxiliary Hydraulics

Fig. 5-27: Mid-Inlet Control Valve Configurations,

5-42 31200079
Supply, Pressure, and Return Hydraulics

Removal

Mid-Inlet Control Valve

Control Valve

Valve Plate

K1142
Lockwasher
Capscrew

Fig. 5-28: Mid-Inlet Control Valve Installation

(Ref. Fig. 5-28) The following procedure describes removal of the mid-inlet
control valve.
1. Follow preparation procedures as outlined in Section 3.
2. Install a brake pressure diagnostic test gauge onto the “Brakes”
diagnostic port.
3. While watching the test gauge, press the brake pedal numerous times
until the pressure gauge reads 0 psi. Remove the test gauge and cap
the diagnostic port.
4. Tag and disconnect all hydraulic lines from control valve fittings. Cap all
hoses, tubes, and fittings. Tag all fittings.
5. Remove three (3) capscrews and lockwashers securing the mid-inlet
control valve to the valve plate.
6. Using appropriate lifting devices, lift the control valve from valve plate
and take to an appropriate location for disassembly and cleaning.

31200079 5-43
Supply, Pressure, and Return Hydraulics

Installation

Mid-Inlet Control Valve 1. (Ref. Fig. 5-28) Position the control valve on the valve plate. Secure
with three (3) lockwashers and capscrews.
2. Connect all hydraulic hoses and tubes to fittings on the control valve.
Torque per instructions in Section 3.
3. Start the engine and repeatedly cycle all hydraulic circuits controlled by
the valve to remove air from the system.
4. Stop engine and check for hydraulic leaks. Tighten connections as
necessary.

Rear Axle Stabilizer Control Valve

Description
6 0 8 0
4 0
2 0

0
-2 0

K1153

Fig. 5-29: Rear Axle Stabilizer Control Valve Location

(Ref. Fig. 5-29) The rear axle stabilizer control valve is located on the valve
plate near the middle of the machine. This valve controls hydraulic
functions using the following valves:
• Solenoid Valve
• Piloted 3-Way Cartridge Valve
• Sequence Cartridge Valve
• Piloted 2-Way Cartridge Valve
• Shuttle Cartridge Valve
• Boom Extend Lockout Valve - Used on models with outriggers

5-44 31200079
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.

RCR CBP
F PIL
PB
S1

BR T
RB SV2

B-Back View

C
E

G2
PS1

PD4

PD3 PD2
PC3
A-Top View

OR5 G1 G3
RCR A B
FTB
OR1
PD1 ACC
OR3 SV1 OR4 OR2
T RCB
FCB FB
F-Left View C-Right View
E-Front View

MV0730

Fig. 5-30: Rear Axle Stabilizer Control Valve Ports

31200079 5-45
Supply, Pressure, and Return Hydraulics

Table 5-1: Rear Axle Stabilizer Control Valve Markings

View Marking Description
A - Top View G2 Gauge #1 - Test Port (Rear Osc. Lock)
PS1 Piloted Sequence Valve
PC3 Cartridge Valve
PD2 Piloted CartridgeValve
PD3 Piloted CartridgeValve
PD4 Piloted Cartridge Valve
B - Back View S1 Shuttle Cartridge Valve
RB Rear Brakes
SV2 Solenoid Valve
PS2 Sequence Valve
BR Brake
CBP Stabilizer Lock Valve
PB Power Brake
PIL Stabilizer Lock Valve
T Tank
C - Right View A Port A
B Port B
G3 Gauge #3 - Test Port (Rear Osc. Lock)
FB Front Brakes
OR2 Orifice #2
OR4 Orifice #3
E - Front View RCR Stabilizer Lock Valve
G1 Gauge #1
FTB Piloted Sequence Valve
FCB Frame Tilt Cylinder
RCB Stabilizer Lock Valve
F - Left View OR3 Orifice #3
SV1 Solenoid Valve
PD1 Piloted Cartridge Valve

5-46 31200079
Supply, Pressure, and Return Hydraulics

Removal, Rear Axle Stabilizer Control Valve

20
19
17

21 18
22 16

15
23
1
14
13

12
6
11
2 10

3 5 7
8 9
4 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 16 Hose for Elbow at RB Port
5 Hose for Elbow at ACC Port 17 Hose for Connector at PB Port
6 Hose for Elbow at RCR Port 18 Hose for Connector at FB Port
7 Hose for Connector at FB Port 19 Hose for Run Tee at PB Port
8 Hose for Run Tee at A Port 20 Hose for Connector at G2 Port
9 Hose for Run Tee at A Port 21 Capscrew
10 Hose for Connector at B Port 22 Lockwasher
11 Hose for Connector on Boom 23 Valve
Extend Lockout Valve
12 Hose for Connector on Boom
Extend Lockout Valve

Fig. 5-31: Rear Axle Stabilizer Control Valve.

31200079 5-47
Supply, Pressure, and Return Hydraulics

WARNING: Hot hydraulic fluid can cause severe burns. Wait for the
hydraulic fluid to cool before servicing any hydraulic
component.

WARNING: Relieve hydraulic pressure before servicing any hydraulic

component. Escaping hydraulic fluid under pressure can
penetrate the skin, causing death or serious injury.

(Ref. Fig. 5-31) The following procedure describes removal of the rear axle
stabilizer control valve.
1. Follow preparation procedures as outlined in Section 3 of this manual.
Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.
2. Install brake pressure diagnostic port test gauge into brake diagnostic
port (see page 5-49).
3. While watching test gauge, press brake pedal numerous times until
pressure gauge reads 0 psi. Remove test gauge from diagnostic port.
4. Thoroughly clean the rear axle stabilizer control valve.
5. Disconnect intermediate wiring harness from the low brake pressure
switch and solenoid valve.
6. Tag and slowly loosen all hydraulic hoses. Disconnect hoses and
bleed any remaining oil into appropriate container. Cap fittings and
hoses.
7. Remove the three (3) each capscrews (Item 21) and lockwashers (Item
22) securing the rear axle stabilizer control valve (Item 23) to the valve
plate.
8. Remove the rear axle stabilizer control valve from the machine and
take it to a clean area appropriate for further disassembly, cleaning,
and overhauling.

5-48 31200079
Supply, Pressure, and Return Hydraulics

Boom Extend Lockout Valve

Description

C D

SV1
PD1

K1154
OR3
Front View

Fig. 5-32: Boom Extend Lockout Valve

(Ref. Fig. 5-32) The boom extend lockout valve is used on models with
outriggers and is standard equipment on 1044C-54 models. It is located on
top of the rear axle stabilizer control valve.

Hydraulic Diagnostic Ports

General
The eight (8) hydraulic diagnostic ports are located beneath the operator’s
compartment and can be accessed through the opening in the operator’s
step.

REAR OSC. REAR OSC.

PUMP 1 PUMP 2 LOCK (G1) LOCK (G2) BRAKES STEERING PILOT ACCUM.
K1168

Fig. 5-33: Hydraulic Diagnostic Ports - Models with Mid-Inlet Hydraulics

(Ref. Fig. 5-33) The hydraulic ports on models with mid-inlet hydraulics
are:

31200079 5-49
Supply, Pressure, and Return Hydraulics

• Pump 1 – Used for reading pressure of the hydraulic pump #1.

Pressure limit is 3000 psi.
• Pump 2 – Used for reading pressure of the hydraulic pump #2.
Pressure limit is 3150 psi.
• Rear Osc. Lock (G1) – Used for reading output pressure of the sole-
noid valve SV1. It is useful when diagnosing service malfunctions in
the rear axle stabilizer circuit.
• Rear Osc. Lock (G2) – Used for reading pressure in the rear oscilla-
tion lock circuit.
• Brakes – Used for reading pressure of the brake circuit and is used to
indicate when pressure is eliminated from the system prior to discon-
necting hydraulic hoses. Pressure limit is 425 psi.
• Steering – Used for reading pressure of the steering circuit. Pressure
limit is 2355 psi.
• Pilot – Used for reading pressure of the joystick circuit. Pressure limit
is 500 psi.
• Accum. – Used for reading of pressure in the accumulator charging
circuit. Pre-charge pressure is 400 psi. The low pressure limit is 1000
psi and the high pressure limit is 1125 psi.

CAUTION: To ensure that system is kept free of dirt and contamination,

always cap all ports when not in use.

5-50 31200079
Supply, Pressure, and Return Hydraulics

Roll-Back Hose Tray

General

60 80
40
20
0
-20

K1069
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

31200079 5-51
Supply, Pressure, and Return Hydraulics

Mid-Inlet Hydraulic System

9
10
8 11

6
5 7

12
4

2
1

K1152
# 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

Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics

(Ref. Fig. 5-35) The following procedure describes removal of the roll-back
hose tray used in models with a mid-inlet hydraulic system.
1. Remove the two (2) each button head socket capscrews (Item 6) and
lockwashers (Item 7) securing the roll-back hose tray (Item 8) to the
front hose tray support bracket (Item 3).
2. Remove the two (2) each button head socket capscrews (Item 9),
lockwashers (Item 10), and flatwashers (Item 11) securing the roll-
back hose tray to the rear hose tray support bracket (Item 12).
3. Remove the roll-back hose tray from the machine.

5-52 31200079
Supply, Pressure, and Return Hydraulics

Installation

Roll-Back Hose Tray

(Ref. Fig. 5-35) The following procedure describes installation of the
roll-back hose tray used in models with mid-inlet hydraulics.
1. Inspect and clean the roll-back hose tray.
2. Place the roll-back hose tray on the two support brackets making sure
it is in the same position as when removed.
3. Secure the roll-back hose tray (Item 8) to the rear hose tray support
bracket with two (2) each flatwashers (Item 11), lockwashers (Item 10),
and button head socket capscrews (Item 9). Tighten as necessary.
4. Secure the roll-back hose tray to the front hose tray support bracket
(Item 3) with two (2) lockwashers (Item 7) and button head socket
capscrews (Item 6). Tighten as necessary.

31200079 5-53
Supply, Pressure, and Return Hydraulics

5-54 31200079
Section 6 — Boom and Transfer

Table of Contents

Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Checking Cylinder Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Boom Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Front Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Rear Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Slide Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Slide Area Surface Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacing and Shimming Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

31200079 i
Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Disconnecting an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Connecting an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Boom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Shimming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Boom Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Boom Extension Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129

List of Figures

Fig. 6-1: Major Boom and Transfer Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Fig. 6-2: Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fig. 6-3: Joystick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Fig. 6-4: Joystick Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fig. 6-5: Pilot Pressure Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fig. 6-6: Pilot Pressure Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Fig. 6-7: Boom Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Fig. 6-8: Boom Hoist Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Fig. 6-9: Boom Hoist Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

ii 31200079
Fig. 6-10: Front Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fig. 6-11: Front Carriage Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Fig. 6-12: Front Carriage Tilt Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Fig. 6-13: Rear Carriage Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Fig. 6-14: Rear Carriage Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Fig. 6-15: Rear Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Fig. 6-16: Selector Valve – Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Fig. 6-17: Selector Valve Installation – Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 6-30
Fig. 6-18: Selector Valve Assembly – Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Fig. 6-19: Load Bearing Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Fig. 6-20: Pad Worn, But Still OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-21: Pad Must Be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-22: Bolted Boom Slide Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Fig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Fig. 6-24: Damaged Slide Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Fig. 6-25: Slide Surface Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Fig. 6-26: Slide Pad Installation (2-Section Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Fig. 6-27: Positioning Retaining Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Fig. 6-28: Determining Capscrew Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Fig. 6-29: Correctly Installed Capscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Fig. 6-30: Quick Attach Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fig. 6-31: Release Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fig. 6-32: Lock Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-33: Rotating Quick Attach Downwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-34: Lowering Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Fig. 6-35: Retracting Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-36: Extending Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-37: Raising Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Fig. 6-38: Rotating Quick Attach Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Fig. 6-39: Lock Plate Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Fig. 6-40: Lower Pivot of Carriage Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Fig. 6-41: Quick Attach Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Fig. 6-42: Boom Angle Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Fig. 6-43: Boom Angle Inclinometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Fig. 6-44: 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Fig. 6-45: Boom Slide Pad Locations – 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Fig. 6-46: Boom Section Gaps – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Fig. 6-47: Lower Shim Installation – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fig. 6-48: Upper Shim Installation – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

31200079 iii
Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Fig. 6-50: Lower Shim Installation - Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Fig. 6-51: Upper Shim Installation – Rear of 4-Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Fig. 6-52: Clearances Between Boom Sections – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . 6-51
Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Fig. 6-54: Clearances Between Boom Sections – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . 6-52
Fig. 6-55: Gaps Between Pads and Boom – Front of 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Fig. 6-56: Inner Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fig. 6-57: Middle (Forward) Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fig. 6-58: Middle (Forward) Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Fig. 6-59: 4-Section Boom Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Fig. 6-60: Hose Connections, 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Fig. 6-61: Cylinder Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Fig. 6-62: Upper Rear Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . 6-58
Fig. 6-63: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . 6-59
Fig. 6-64: Upper Rear Slide Pad Removal – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Fig. 6-65: Locations for Chain Attachment – Inner Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Fig. 6-66: 4-Section Boom Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Fig. 6-67: Slide Pad Removal – Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Fig. 6-68: Lower Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . 6-65
Fig. 6-69: Disconnecting Hoses Between Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Fig. 6-70: Extension Cylinder Removal – 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Fig. 6-71: Upper Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . 6-68
Fig. 6-72: Upper Front Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . 6-69
Fig. 6-73: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . . . 6-69
Fig. 6-74: Upper Chain Roller Assembly – Middle (Forward) Boom Section. . . . . . . . . . . . . . . . . . . . . 6-70
Fig. 6-75: Disconnecting Chains at Rear of Inner Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Fig. 6-76: Disconnecting Chains at Rear of Middle (Forward) Boom . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Fig. 6-77: Slide Pad Removal – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Fig. 6-79: Grease Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-75
Fig. 6-81: Hose and Tube Removal – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Fig. 6-82: Upper Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Fig. 6-83: Upper Chain Roller Assembly – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-77
Fig. 6-84: Removing Lower Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Fig. 6-85: Slide Pads – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Fig. 6-86: Chain and Hose Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Fig. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . 6-81

iv 31200079
Fig. 6-88: Side Slide Pads – Outer Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Fig. 6-89: Outer Boom Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Fig. 6-90: Outer Boom Tube and Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Fig. 6-91: Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Fig. 6-92: Lower Chains on Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Fig. 6-93: Lower Rear Slide Pad Installation - Middle (Rear) Boom Section. . . . . . . . . . . . . . . . . . . . . 6-88
Fig. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Fig. 6-95: Chain and Hose Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Fig. 6-96: Installation of Lower Chain – Middle (Rear) Boom Section. . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-92
Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Fig. 6-99: Slide Pad Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Fig. 6-100: Hydraulic Hose and Tube Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-95
Fig. 6-101: Slide Pad Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Fig. 6-102: Grease Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Fig. 6-103: Upper Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section . . . . . . . . . . . . . . 6-98
Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom . . . . . . . . . . . . . . . . . . . 6-99
Fig. 6-106: Rear Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Fig. 6-107: Front Slide Pad Installation – Outer and Middle (Rear) Boom Sections . . . . . . . . . . . . . . 6-100
Fig. 6-108: Lower Chain Installation – Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Fig. 6-109: Lower Chain Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-101
Fig. 6-110: Upper Chains – Middle (Rear) to Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Fig. 6-111: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-103
Fig. 6-112: Securing Lower Chains – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . 6-103
Fig. 6-113: Securing Boom Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Fig. 6-114: Connecting Hoses Between Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Fig. 6-115: Boom Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Fig. 6-116: 4-Section Boom Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Fig. 6-117: 4-Section Boom Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Fig. 6-118: 4-Section Boom Extension Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Fig. 6-119: Boom Extension Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Fig. 6-120: Boom Extension Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Fig. 6-121: Boom Extension Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Fig. 6-122: Boom Extension Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Fig. 6-123: Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Fig. 6-124: Disconnecting Transfer Cylinder from Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
Fig. 6-125: Boom Elevation Proximity Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Fig. 6-126: Boom Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122

31200079 v
Fig. 6-127: Boom Extension Proximity Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Fig. 6-129: Transfer Carriage with Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125
Fig. 6-130: Transfer Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Fig. 6-131: Transfer Carriage – Front Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Fig. 6-132: Shims for Front Transfer Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Fig. 6-133: Scraper Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
Fig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Fig. 6-135: Spacer Washers for Rear Transfer Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
Fig. 6-136: Rear Slide Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134

vi 31200079
Section 6 — Boom and Transfer

Boom and Transfer Hydraulics

General Description

Boom

Rear Carriage
Tilt Cylinder

Transfer
Carriage
Front Carriage
Tilt Cylinder

60 80
40
20
0
-20

Hoist
Cylinder

Joystick
Controls

J1116
Fig. 6-1: Major Boom and Transfer Hydraulic Components
(Ref. Fig. 6-1) The following are major boom and transfer components:
• Boom - 2, 3, or 4 Sections
• Boom Extension Cylinder (not visible in illustration)
• Front Carriage Tilt Cylinder
• Boom Hoist Cylinder
• Rear Carriage Tilt Cylinder
• Joystick Controls
• Transfer Carriage
Further information on the hydraulic system can be found in Section 4.

31200079 6-1
Boom and Transfer

Joystick Controls

General Description

V1018
Fig. 6-2: Joystick
(Ref. Fig. 6-2) The joysticks control hydraulic flow to the associated
cylinders.
Control is proportional: The more joystick movement, the greater the
action. The speed of cylinder action is also affected by engine/hydraulic
pump speed. Action is quicker at higher engine speeds.
Joysticks can be moved in any direction and are not limited to front/back,
left/right movement. Moving a joystick in a diagonal direction will cause a
combination of actions.
A switch is located on the top of the front joystick, under a protective
rubber cap. Pressing this switch down with your thumb activates the
auxiliary function.

Note: Releasing the switch while moving the joystick left or right changes the
function of the joystick back to transfer carriage control.

6-2 31200079
Boom and Transfer

Removal

Joystick 2
1
7

5
6
3
4 8

14
15

13

10 9

9 10
11
11

J1120
12 12
# 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 15 Lockwasher
8 Control Panel

Fig. 6-3: Joystick Installation

(Ref. Fig. 6-3) The following steps are required to remove the joystick.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Remove two (2) capscrews (Item 14) and lockwashers (Item 15)
securing side panel (Item 13) to control panel (Item 8). Remove side
panel.

31200079 6-3
Boom and Transfer

3. Tag, loosen, and remove two (2) swivel tees (Item 11) from connectors
(Item 9) on bottom of joystick.
4. Tag, loosen, and remove remaining four (4) hydraulic hoses (Item 12)
from connectors (Item 10).
5. Tag and disconnect two (2) lead connectors (Item 6) from wiring
harness (Item 5).
6. Loosen and remove four (4) each capscrews (Item 1) and lockwashers
(Item 2) securing joystick (Item 7) to control panel.
7. Remove joystick and take it to a suitable area for further disassembly
and cleaning.
8. Remove six connectors (Items 9 and 10) from bottom of joystick and
manifold. Clean with solvent. Dry with compressed air and inspect for
damage. Replace if necessary.

Installation

Joystick (Ref. Fig. 6-3) The following steps are required to install the joystick.
1. Install two (2) connectors (Item 9): one in center port in bottom of
joystick (Item 7) and the other in the bottom of the manifold. Torque
connectors to 25–29 ft-lbs.
2. Install remaining four (4) connectors (Item 10) in ported guides in
bottom of joystick body. Torque connectors to 25–29 ft-lbs.
3. Install assembled joystick on control panel (Item 8) with four (4) each
capscrews (Item 1) and lockwashers (Item 2). Torque capscrews to
50 in-lbs.
4. Reconnect two (2) lead connectors (Item 6) to wiring harness (Item 5).
5. Clean swivel nuts on hoses and tees with solvent.
6. Reconnect swivel tees/hydraulic hoses (Item 11) to connectors
(Item 9). Torque swivel nuts to 130–150 in-lbs.
7. Reconnect remaining four (4) hydraulic hoses (Item 12) to connectors
(Item 10). Torque swivel nuts on hoses to 235–265 in-lbs.
8. Reconnect two (2) lead connectors (Item 6) to wiring harness (Item 5).
9. Install side panel (Item 13) on control panel with two (2) lockwashers
(Item 15) and capscrews (Item 14). Torque capscrews to 96 in-lbs.

6-4 31200079
Boom and Transfer

Disassembly

Joystick
4 25
2
17 26
3
5 27
28
6 29
1 8
30
7 18
31
24
3 16
9
10
19 22 23
15
11
12 13 16

14
20
32
21

33

34
35

J1121
36

# 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 26 Guide
9 Hex Nut 27 O-ring
10 Seal 28 Seal
11 Setscrew 29 Spreader
12 Lever Joint 30 Plunger
13 Retaining Nut 31 240
14 Stem 32 Spool
15 Clip 33 Spring
16 Socket Head Capscrew 34 O-ring
17 Boot 35 O-ring
18 Cam 36 Ported Guide

Fig. 6-4: Joystick Components

(Ref. Fig. 6-4) The following steps are required to disassemble and repair
the joystick.

31200079 6-5
Boom and Transfer

1. Pull back boot (Item 17) so that access to retainer (Item 19) and flange
(Item 20) can be made.
2. Loosen and remove four (4) socket head capscrews (Item 16) and one
(1) clip (Item 15) that secure retainer and flange to joystick body
(Item 24). Separate body from joystick handle assembly.
3. Disassemble joystick body assembly as follows:
a. Loosen and remove three (3) socket head capscrews (Item 21)
securing manifold (Item 22) to body.
b. Remove O-ring (Item 23) from manifold. Discard O-ring.
c. The following steps are required to remove parts (Items 25 thru 36)
located in each port:

Note: Because the spools (Item 32) may differ from each other, it is
strongly recommended that when they are removed, they should
be removed one at a time and then reinstalled before another is
removed.
1). Loosen and remove one (1) of the four (4) ported guides
(Item 36) from body.
2). Remove two (2) O-rings (Items 34 and 35) from ported guide.
Discard O-rings.
3). Remove spool (Item 32) and spring (Item 33) from body.
4). Remove guide assembly (Items 25 thru 31) from body.
5). Remove O-ring (Item 27) from guide (Item 26). Discard O-ring.
6). Clean remaining parts with solvent. Dry with compressed air.
Inspect and replace if damaged.

Note: Items 25 thru 31 cannot be purchased individually. The O-ring

(Item 27) can only be purchased as a part of a seal kit. If any of the
remaining parts become damaged, it will be necessary to purchase
a complete new guide assembly.
7). Inspect open port in body and clean as necessary.
8). Obtain O-ring (Item 27) from seal kit. Lubricate O-ring before
installing it.
9). Install new O-ring on guide (Item 26). Lubricate and install
guide assembly (Items 21 thru 36) in body.
10). Lubricate and install spring (Item 33) and spool (Item 32) in
body.
11). Obtain new O-rings from seal kit. Install large O-ring (Item 35)
and then smaller O-ring (Item 34) on ported guide (Item 36).
12). Install ported guide in body. Torque guide to 260 in-lbs.
d. Repeat Step c for each of the remaining three (3) ports, one port at
a time.

6-6 31200079
Boom and Transfer

e. Clean all remaining parts of joystick body assembly, including the

body’s center port, with solvent. Dry with compressed air. Inspect
and replace any damaged parts.

Note: The body (Item 24) cannot be purchased individually. If it becomes

damaged, it will be necessary to replace the entire joystick
assembly.
f. Lubricate and install new O-ring (Item 23) in manifold (Item 22).
g. Install manifold on body with three (3) capscrews (Item 21). Torque
capscrews to 22 in-lbs.
4. Remove flange (Item 20) from stem (Item 14). Separate flange,
retainer (Item 19), cam (Item 18), and boot (Item 17) from stem.
5. Clean items 15 thru 20 with solvent. Inspect and replace if damaged.
6. Disassemble handle assembly (Items 1 thru 14) as follows:
a. Remove joystick cap (Item 4).
b. Loosen and remove two (2) each hex nuts (Item 1) and capscrews
(Item 9) near bottom of joystick handle.
c. Loosen and remove two (2) each hex nuts (Item 8) and capscrews
(Item 2) near top of joystick handle.
d. Separate the two (2) half handles (Item 3) and remove the push
button (Item 5).
e. Remove switch (Item 6) from guide (Item 7) if damaged.
f. If the switch is damaged, remove connecting wires and discard
switch. Solder wires to outside tabs on new switch. Install switch in
guide.
g. Inspect remaining parts and replace if damaged.

Note: Unless they are damaged, it will not be necessary to remove lever
joint (Item 12) and retaining nut (Item 13) from stem (Item 14), to
remove setscrew (Item 11) from lever joint, or to remove seal
(Item 10) from handle half.

Note: Only the handle halves (Item 3), cap (Item 4), push button (Item 5),
and switch (Item 6) can be purchased individually. If any of the
remaining items become damaged, it will be necessary replace the
entire handle assembly.
h. Install push button in guide while installing guide and lever joint in
one (1) half handle ensuring that each is placed in the correct slot
of half handle.
i. Secure the two (2) half handles together with two (2) each hex nuts
(Item 8) and capscrews (Item 2) near top of joystick handle.
j. Install remaining two (2) each hex nuts (Item 1) and capscrews
(Item 9) near bottom of joystick handle. Tighten the four (4) screws
until snug.
k. Reinstall cap on joystick.

31200079 6-7
Boom and Transfer

7. Install boot (Item 17) on stem (Item 14) making sure that the top lip of
the boot rests in the channel in the stem.
8. Roll back boot and install cam (Item 18), retainer (Item 19), and flange
(Item 20) on stem.
9. Install flange on joystick body with two (2) capscrews (Item 16). Install
retainer on flange with remaining two (2) capscrews, ensuring that one
capscrew also secures the wire to the retainer with the clip (Item 15).
Torque capscrews to 28 in-lbs.
10. Make final adjustment of cam and flange as follows:
a. Make sure the cam is backed off enough to ensure that all four (4)
plungers (Item 30) are in the spring-offset position.
b. Apply thread locking compound to flange thread.
c. Screw cam and stem on flange until cam just touches the plungers.
d. Screw cam a maximum of 1/4 turn and then torque back cam
against stem to 160 in-lbs.
11. Return boot to correct position, covering retainer.

PUMP 1 PUMP 2 CARR. TILT CARR. TILT BRAKES STEERING PILOT ACCUM.
(BASE END) (ROD END)

K1067
Fig. 6-5: Pilot Pressure Diagnostic Port
12. Test pilot pressure as follows:
a. (Ref. Fig. 6-5) Connect a 600 psi gauge to the pilot pressure test
port located behind the cab step.
b. Start the machine and check pilot pressure. While the engine is
idling, the pilot pressure should read 510 ±25 psi.

6-8 31200079
Boom and Transfer

O-ring
O-ring Pressure Plug
Plug Reducing
Valve
Pressure
Reducing
Valve

MV0610

Mid-Inlet Hydraulics

Fig. 6-6: Pilot Pressure Plug

c. (Ref. Fig. 6-6) If the pilot pressure is not within the recommended
range, adjust pressure as follows:
1). For models with mid-inlet hydraulics, remove the O-ring plug
from the pressure reducing cartridge with a 5/16" Allen wrench.
Use a 1/4" Allen wrench to adjust the reducing valve by turning
clockwise to increase pressure and counterclockwise to
decrease pressure.

Note: This pressure reducing cartridge is located on the hydraulic pump.

2). Install O-ring plug.
3). Retest pilot pressure, and make any additional valve
adjustments as required.

Hydraulic Cylinders

Description
All hydraulic cylinders used on JLG forklifts are a double-acting,
non-cushioned type with chromed rods.
The boom hoist, carriage tilt, boom extension, and frame tilt cylinders are
equipped with externally mounted counterbalance valves. These
counterbalance valves prevent movement of the cylinders in the event of
downstream hydraulic line failure or leakage through the control valves or
fittings. Counterbalance valves prevent movement of the cylinders when
the engine is off, even if the control valve levers are operated.
Counterbalance valves also provide relief valve over pressure protection.

31200079 6-9
Boom and Transfer

WARNING: Do not remove counterbalance valves from cylinders on the

machine while the cylinder is under load (extended). If a
counterbalance valve must be removed, first retract the
cylinder and remove all hydraulic pressure in the cylinder.
Wear eye protection when removing counterbalance valves.

WARNING: Hydraulic cylinders equipped with counterbalance valves may

have hydraulic pressure stored within the cylinder even after
the cylinder is removed from the machine. If a counterbalance
valve must be removed, do so carefully while wearing eye
protection.

Checking Cylinder Condition

Exposed piston rods can be damaged by impact with hard objects. If the
smooth surface of the rod is marred, the rod seal may be damaged.
Cylinders need to be inspected periodically to check for excessive play at
the cylinder pivot ends. Excessive play is an indication of worn bushings
that will need to be replaced.

Note: When the machine or cylinders are stored, retract the cylinder rods to
protect them.
Cylinder maintenance requires periodic inspection for wear and checks for
leakage.

External Leakage

If a cylinder end cap is leaking or if the cylinder leaks around the rod, the
seals must be replaced.

WARNING: DO NOT use your hand to check for leaks. Use a piece of
cardboard or paper to search for leaks.

Internal Leakage

Leakage past the piston seals inside the cylinder can cause sluggish
movement or settling under load. Piston leakage can be caused by worn
piston seals or scored cylinder walls. Scored cylinder walls may be caused
by hydraulic oil contamination. Check hydraulic cylinders for internal
leakage using the following procedure:
1. Lower the boom to the ground, apply the park brake, retract the
cylinder, and stop the engine.
2. Install brake pressure diagnostic port test gauge into brake diagnostic
port.
3. While watching test gauge, press brake pedal numerous times until
pressure gauge reads 0 psi. Remove test gauge and cap diagnostic
port.

6-10 31200079
Boom and Transfer

4. Remove the hose at the base end of the cylinder and plug the hose.
5. Start the engine and activate the control that will supply hydraulic oil to
the rod end of the cylinder.
6. If there is leakage from the disconnected end of the cylinder, remove
the cylinder and make repairs. If there is no leakage, reconnect the
hose and tighten (see installation procedures for each cylinder for
torque specifications).

31200079 6-11
Boom and Transfer

Boom Hoist Cylinder

Description

60 80
40
20

0
-20

J1126
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. Daily lubrication of the two grease fittings on
each cylinder is required.

REV. 001

6-12 31200079
Boom and Transfer

Removal

Boom Hoist Cylinder

1 2 3

5
6
7
4

1 2

60 80
40
20
0
-20

10
11

J1122
12
9

# 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

Fig. 6-8: Boom Hoist Cylinder Installation

(Ref. Fig. 6-8) The following steps are required to remove boom hoist
cylinders.
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
cylinder, and stop the engine.
3. Loosen and remove hydraulic hoses (Item 1) from fittings on hoist
cylinder (Item 2). Bleed any remaining oil into a suitable container. Cap
fittings and hoses.
4. Loosen and remove capscrew (Item 6) and lockwasher (Item 7) from
rod end lock pin (Item 5).

31200079 6-13
Boom and Transfer

WARNING: To avoid personal and/or equipment damage, support the

hydraulic cylinder before removing pins. Use suitable blocking
and lifting devices when removing heavy machine
components.

Note: Cylinder pins are designed to be removed with a slide hammer.

5. Remove lock pin from rod end pivot pin (Item 4).
6. Remove rod end hoist cylinder pin from outer boom (Item 3).
7. Slowly lower supported cylinder until it rests on main frame.
8. Loosen and remove capscrew (Item 12) and lockwasher (Item 11) from
base end lock pin (Item 9).
9. Remove lock pin from base end pivot pin (Item 10).
10. Remove base end hoist cylinder pin from transfer carriage/boom
cradle (Item 8).
11. Slowly remove the cylinder from the machine and take it to a location
suitable for inspection and disassembly.

Installation

Boom Hoist Cylinder (Ref. Fig. 6-8) The following steps are required to install boom hoist
cylinders.
1. Using sling(s), crane, or other suitable means, position base end of
cylinder (Item 2) in its proper location on the transfer carriage/boom
cradle (Item 8).

WARNING: To avoid personal and/or equipment damage, make sure the

cylinder is properly supported until it is completely installed.

Note: Be sure to apply thread locking compound to the threads of the capscrews
before installing them.
2. Align cylinder with pin bosses in transfer carriage/boom cradle and
install pivot pin (Item 10). Secure pivot pin with lock pin (Item 5),
lockwasher (Item 11), and capscrew (Item 12). Torque capscrew to
55 ft-lbs.
3. Place rod end of cylinder in its proper location and insert rod end pivot
pin (Item 4) to secure the cylinder to outer boom (Item 3).
4. Secure pivot pin with lock pin (Item 9), lockwasher (Item 7) and
capscrew (Item 6). Torque capscrew to 55 ft-lbs.
5. Clean hydraulic hose ends with solvent and reconnect them to fittings
on each hoist cylinder. Torque hose swivel nuts to 50–58 ft-lbs.
6. Lubricate grease fittings with EP lithium based grease.

6-14 31200079
Boom and Transfer

Overhaul

Boom Hoist Cylinder

8

1
7
9
2 16
3
13
15

14
6
4
11
5

12

10 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
7 Hollow Hex O-ring Plug 15 Grease Fitting
8 Counterbalance Valve Cartridge 16 Grease Fitting Cover

Fig. 6-9: Boom Hoist Cylinder Assembly

(Ref. Fig. 6-9) The following steps are required to overhaul boom hoist
cylinders.
1. Mount or support cylinder vertically with rod end down. Hydraulic oil in
cylinder will drain out during disassembly. Place a suitable pan or tray
under the cylinder.
2. Release oil pressure in the cylinder as follows:

WARNING: The counterbalance valve cartridge traps hydraulic oil in the

cylinder which may be under pressure. Wear proper eye and
hand protection when removing counterbalance valve
cartridges. Hydraulic fluid under pressure can be injected
under skin or into eyes, resulting in serious personal injury or
death.

31200079 6-15
Boom and Transfer

a. Place socket wrench over counterbalance valve cartridge (Item 8).

Wrap a clean shop rag around the socket to cover the area of the
counterbalance valve cartridge.
b. Carefully and slowly, turn cartridge out of manifold block to release
pressure in cylinder.
3. Remove the counterbalance valve cartridge.
4. Slowly extend and retract cylinder by hand to remove most of the
hydraulic oil.
5. Remove one (1) set screw (Item 11) securing rod bearing head
(Item 12) to barrel.
6. Remove cylinder rod (Item 13) from cylinder barrel (Item 5).

CAUTION: To prevent possible damage to components, support rod and

head; do not wiggle rod or head back and forth during
removal.

7. Remove rod nut (Item 9), piston (Item 10), and rod bearing head from
cylinder rod.
8. Remove two (2) O-ring plugs (Items 6 and 7).
9. Remove the two elbows (Item 1) from the cylinder manifold block.
10. Inspect bushings for damage. The following steps are necessary if
bushing(s) need to be replaced:
a. Remove bushing (Item 4) from cylinder barrel (Item 5) and/or
remove bushing (Item 14) from cylinder rod (Item 13) using a
bushing driver and hammer or press.
b. Install new bushing so that it is centered in axle boss.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting(s) after cylinder is reinstalled
on machine.
11. If necessary, remove grease fitting covers (Items 2 and 16) and grease
fittings (Items 3 and 15) on the cylinder. Inspect and replace if
damaged. Install and tighten fittings 1.5 to 3 turns past finger tight.
12. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
13. Thoroughly clean components with solvent and dry with compressed
air.
14. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
15. Check condition of threads on rod, nut, and capscrews. Do not attempt
to repair damaged threads.

6-16 31200079
Boom and Transfer

16. Inspect counterbalance valve cartridge (Item 8), including O-rings, for
condition and replace as necessary. Do not disassemble the cartridge.
Service to counterbalance valve cartridges is limited to installing new
O-rings or replacing the entire cartridge.
17. Lubricate counterbalance valve cartridge O-rings with clean hydraulic
oil.
18. Install cartridge in manifold block.
19. Install O-ring plug (Item 6) in manifold block.
20. Install O-ring plug (Item 7) in manifold block.
21. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
22. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on head. Using a seal driver, install new wiper seal in
head. Lubricate wiper seal with hydraulic oil.
23. Slide head (Item 12) and piston (Item 10) onto rod (Item 13). Lubricate
threads on rod with hydraulic oil and install rod nut (Item 9). Torque rod
nut to 2600-2800 ft-lbs.
24. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
25. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (Item 11). Coat inside of barrel (Item 5) with hydraulic oil. To
avoid damaging seals during assembly, carefully insert rod and head
into barrel. Install set screw until snug.
26. Install two (2) elbows (Item 1) on cylinder manifold.
27. Lubricate grease fittings with EP lithium based grease.

31200079 6-17
Boom and Transfer

Front Carriage Tilt Cylinder

Description

60 80
40
20
0
-20

J1126
Fig. 6-10: Front Carriage Tilt Cylinder
The front carriage tilt cylinder is located inside the inner boom section at
the front of the machine connecting to the inner boom and to the quick
attach assembly. It controls attachment tilt when the appropriate joystick
handle is activated. Maximum operating pressure is at approximately
3175 psi. Daily lubrication of the two grease fittings is required.

6-18 31200079
Boom and Transfer

Removal

Front Carriage Tilt

Cylinder

1 2
3
4

J1070
# 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. Fig. 6-11) The following steps are required to remove the front
carriage tilt cylinder.
1. Remove quick attach assembly. See page 6-44
2. Tag and disconnect two (2) hydraulic hoses (Item 6) from connectors
(Item 8). Cap fittings and hoses.
3. Support cylinder (Item 7) with sling(s) and crane, or other suitable
means. Make sure equipment has sufficient capacity to support weight
of cylinder; the cylinder weighs approximately 200 pounds.

31200079 6-19
Boom and Transfer

WARNING: To avoid personal and/or equipment damage, support the

hydraulic cylinder before removing pins. Use suitable blocking
and lifting devices when removing heavy machine
components.

4. Remove capscrew (Item 4), lockwasher (Item 3), and lock pin (Item 2)
from upper pivot pin (Item 5) of front carriage tilt cylinder. Remove pivot
pin.
5. Carefully remove cylinder from boom nose (Item 1).
6. Clean with solvent and dry with compressed air. Inspect all
components for condition and wear. Replace as necessary.

Installation

Front Carriage Tilt (Ref. Fig. 6-11) The following steps are required to install the front carriage
Cylinder tilt cylinder.
1. Using sling(s), crane, or other suitable means, position cylinder in
boom nose. Align cylinder with pin bosses in boom and install pivot pin.
Secure pin with lock pin, lockwasher, and capscrew. Torque capscrew
to 55 ft-lbs.

Note: Be sure to apply thread locking compound to the threads of the capscrew
before installing it.
2. Attach two (2) hoses to cylinder. Tighten swivel nuts on hoses (Item 6)
to 50–58 ft-lbs.
3. Lubricate grease fitting at each end of the cylinder with EP lithium
based grease.

6-20 31200079
Boom and Transfer

Overhaul

Front Carriage Tilt

Cylinder

6
5
1
2 4
8 7

2
10 8 9

13
12

11 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

Fig. 6-12: Front Carriage Tilt Cylinder Assembly

(Ref. Fig. 6-12) The following steps are required to overhaul the front
carriage tilt cylinder.
1. Mount or support cylinder vertically with rod end down. Hydraulic oil in
cylinder will drain out during disassembly. Place a suitable pan or tray
under the cylinder.
2. Release oil pressure in the cylinder as follows:

31200079 6-21
Boom and Transfer

WARNING: The counterbalance valve cartridge traps hydraulic pressure

in the cylinder. Wear proper eye and hand protection when
removing counterbalance valve cartridges. Hydraulic fluid
under pressure can be injected under skin or into eyes,
resulting in serious personal injury or death.

a. Place socket wrench over counterbalance valve cartridge (Item 5).

Wrap a clean shop rag around the socket to cover the area of the
counterbalance valve cartridge.
b. Carefully and slowly, turn cartridge out of manifold block (Item 2) to
release pressure in cylinder.
3. Remove the counterbalance valve cartridge.
4. Slowly extend and retract cylinder by hand to remove most of the
hydraulic oil.
5. Remove one (1) set screw (Item 3) securing rod bearing head
(Item 13) to barrel.
6. Remove cylinder rod (Item 9) from cylinder barrel (Item 7).

CAUTION: To prevent possible damage to components, support rod and

head; do not wiggle rod or head back and forth during
removal.

7. Remove rod nut (Item 6), piston (Item 11), tube (Item 12), and rod
bearing head from cylinder rod.
8. Remove the two (2) connectors (Item 1) from the cylinder manifold
block (Item 2).
9. Inspect bushings for damage. The following steps are necessary if
bushing(s) need to be replaced:
a. Remove bushing (Item 8) from cylinder barrel and/or remove
bushing (Item 2) from cylinder rod using a bushing driver and
hammer or press. Drive one bushing all the way through to remove
other bushing.
b. Install new bushings so they are flush with outer edge boss to 0.02"
below.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting(s) after cylinder is reinstalled
on machine.
10. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
11. Thoroughly clean components with solvent and dry with compressed
air.
12. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
13. Check condition of threads on rod, nut, and setscrew. Do not attempt to
repair damaged threads.

6-22 31200079
Boom and Transfer

14. Inspect counterbalance valve cartridge (Item 5), including O-rings, for
condition and replace as necessary. Do not disassemble the cartridge.
Service to counterbalance valve cartridges is limited to installing new
O-rings and replacing the entire cartridge.
15. Lubricate counterbalance valve cartridge O-rings with clean hydraulic
oil.
16. Install cartridge in manifold block.
17. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
18. 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.
19. Slide head (Item 13), tube (Item 12), and piston (Item 11) onto rod
(Item 9). Lubricate threads on rod with hydraulic oil and install rod nut
(Item 6). Torque rod nut to 2600-2800 ft-lbs.
20. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
21. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (Item 3). Coat inside of barrel (Item 7) with hydraulic oil. To avoid
damaging seals during assembly, carefully insert rod and head into
barrel.
22. Install two (2) connectors (Item 1) on cylinder manifold.
23. If necessary, grease fittings (Items 4 and 10) from cylinder. Inspect and
replace if damaged. Install and tighten fittings 1.5 to 3 turns past finger
tight.
24. Lubricate grease fittings with EP lithium based grease.

31200079 6-23
Boom and Transfer

Rear Carriage Tilt Cylinder

Description

60 80
40
20

0
-20

J1128
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.

6-24 31200079
Boom and Transfer

Removal

Rear Carriage Tilt Cylinder

2 3

4
5

7 6

9
14

13
10

11
12

J1129
# 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
7 Hydraulic Hose 14 Transfer Carriage/Boom Cradle

Fig. 6-14: Rear Carriage Tilt Cylinder Installation

(Ref. Fig. 6-14) The following steps are required to remove rear carriage
tilt cylinders.
1. Follow preparation procedures as outlined in Section 3.
2. Lower the boom to the ground, apply the park brake, retract the
cylinder, and stop the engine.

31200079 6-25
Boom and Transfer

3. Tag and disconnect two (2) hydraulic hoses (Item 7) from elbows on
both cylinders (Item 6). Cap fittings and hoses.
4. Support each cylinder with sling(s) and crane, or other suitable means.
Make sure equipment has sufficient capacity to support weight of
cylinder.

WARNING: To avoid personal and/or equipment damage, support

hydraulic cylinders before removing pins. Use suitable
blocking and lifting devices when removing heavy machine
components.

5. Loosen and remove capscrew (Item 4) and lockwasher (Item 3) from

rod end lock pin (Item 2).
6. Remove lock pin from rod end cylinder pivot pin (Item 5).
7. Remove rod end cylinder pin from outer boom (Item 1).
8. Slowly lower supported cylinder until it rests on main frame.
9. Loosen and remove capscrew (Item 12) and lockwasher (Item 11) from
base end lock pin (Item 10).
10. Remove lock pin from base end cylinder pivot pin (Item 13).
11. Remove base end cylinder pin from transfer carriage/boom cradle
(Item 14).
12. Slowly remove the cylinder from the machine and take it to a location
suitable for inspection and disassembly.

Installation

Rear Carriage Tilt Cylinder (Ref. Fig. 6-14) The following steps are required to install rear carriage tilt
cylinders.
1. Using sling(s), crane, or other suitable means, position base end of
cylinder (Item 6) in its proper location on the transfer carriage/boom
cradle (Item 14).

WARNING: To avoid personal and/or equipment damage, make sure each

cylinder is properly supported until it is completely installed.

Note: Be sure to apply thread locking compound to the threads of the capscrews
before installing them.
2. Align cylinder with pin bosses in transfer carriage/boom cradle and
install pivot pin (Item 13). Secure pivot pin with lock pin (Item 10),
lockwasher (Item 11), and capscrew (Item 12). Torque capscrew to
55 ft-lbs.
3. Place rod end of cylinder in its proper location and insert rod end pivot
pin (Item 5) to secure the cylinder to the outer boom (Item 1).
4. Secure pivot pin with lock pin (Item 2), lockwasher (Item 3), and
capscrew (Item 4). Torque capscrew to 55 ft-lbs.

6-26 31200079
Boom and Transfer

5. Clean hydraulic hose ends with solvent. Attach two (2) hoses (Item 7)
to elbows on each cylinder. Torque hose swivel nuts to 44–48 ft-lbs.
6. If necessary, remove grease fitting cover(s) (Item 8) and grease
fitting(s) (Item 9). Clean and inspect for damage; replace if necessary.
Install grease fitting(s) and covers; torque fitting(s) 1.5 to 3 turns past
finger tight.
7. Lubricate grease fittings with EP lithium based grease.

Overhaul

Rear Carriage Tilt Cylinder

4

2
1

3
9
8
10

7 11
6
MV0740
5

# Description # Description
1 45° O-ring Elbow 7 Rod Bearing Head
2 Cylinder Barrel 8 Rod
3 Setscrew 9 Self-Aligned Bushing
4 Rod Nut 10 Grease Fitting
5 Piston 11 Grease Fitting Cover
6 Tube

Fig. 6-15: Rear Carriage Tilt Cylinder Assembly

(Ref. Fig. 6-15) The following steps are required to overhaul the rear
carriage tilt cylinder.
1. Lay cylinder horizontally in a vice or hold it down with a strap wrench.
Hydraulic oil in cylinder will drain out during disassembly. Place a
suitable pan or tray under the cylinder.
2. Remove the two (2) elbows (Item 1) from the manifold block on the
cylinder barrel (Item 2).
3. Remove the setscrew (Item 3).
4. Install a spanner wrench in the two (2) holes in the end of the rod
bearing head (Item 7). Unscrew the rod bearing head.

31200079 6-27
Boom and Transfer

5. Remove the cylinder rod assembly from cylinder barrel.

CAUTION: To prevent possible damage to components, support cylinder

rod assembly; do not wiggle rod or head back and forth during
removal.

6. Remove rod nut (Item 4), piston (Item 5), tube (Item 6), and rod
bearing head from rod (Item 8).
7. Inspect bushings for damage. The following steps are necessary if
bushing(s) need to be replaced:
a. Remove bushing (Item 9) from cylinder rod using a bushing driver
and hammer or press.
b. Install new bushing so that it is centered in rod end opening.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting after cylinder is reinstalled on
machine.
8. If necessary, remove grease fitting cover (Item 11) and grease fitting
(Item 10) from cylinder. Inspect and replace if damaged. Install and
tighten fitting 1.5 to 3 turns past finger tight.
9. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
10. Thoroughly clean components with solvent and dry with compressed
air.
11. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
12. Check condition of threads on rod and rod nut. Do not attempt to repair
damaged threads.
13. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
14. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on rod bearing head. Using a seal driver, install new
wiper seal in head. Lubricate wiper seal with hydraulic oil.
15. Slide rod bearing head (Item 7), tube (Item 6) (see note after Step 6),
and piston (Item 5) onto rod (Item 8). Lubricate threads on rod with
hydraulic oil and install rod nut (Item 4). Torque rod nut as follows:
550 ft-lbs.
16. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
17. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (item 3) Coat inside of cylinder barrel (Item 2) with hydraulic oil.
To avoid damaging seals during assembly, carefully insert cylinder rod
assembly into cylinder barrel.

6-28 31200079
Boom and Transfer

18. Install cylinder rod assembly in cylinder barrel. Install a spanner

wrench in two (2) holes of rod bearing head and tighten until it is snug
against the cylinder barrel.
19. Install two (2) elbows (Item 1) on cylinder manifold. Torque connectors
to 40–44 ft-lbs.
20. Lubricate grease fittings with EP lithium based grease.

Selector Valve

Description

J1181
Fig. 6-16: Selector Valve
The 6-port circuit selector valve (directional control valve) is located on the
valve plate near the center of the machine. It directs fluid to the control
valve when the joystick is activated. The 6-port selector valve directs the
flow of hydraulic oil from the joystick controller to the appropriate control
valve section. The solenoids are used to change the flow of oil from one
control valve section to the other.

31200079 6-29
Boom and Transfer

Removal

Selector Valve

8 7 6

5
1
3

J1182
2
4
# 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.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Install brake pressure diagnostic port test gauge into brake diagnostic
port.
3. While watching test gauge, press and release brake pedal numerous
times until pressure gauge reads 0 psi. Remove test gauge from
diagnostic port.
4. Remove roll-back hose tray.
5. To avoid contamination of the system, clean selector valve.
6. Disconnect joystick wiring harness (Item 8) from selector valve.
7. Tag and loosen six (6) hydraulic hoses (Items 3, 4, and 6) and bleed
any remaining oil into a suitable container. Disconnect hoses. Cap
fittings and hoses.
8. Remove two (2) each nuts (Item 1), lockwashers (Item 2), and
capscrews (Item 7) securing selector valve (Item 5) to the valve plate.
9. Take selector valve and mounting hardware to a suitable area for
cleaning and further disassembly.
10. Clean mounting hardware with solvent. Dry with compressed air,
inspect for damage, and replace as necessary.

6-30 31200079
Boom and Transfer

Installation

Selector Valve (Ref. Fig. 6-17) The following steps are required to install the selector
valve in models with a mid-inlet hydraulic system.
1. Secured the selector valve (Item 5) to the valve plate with two (2) each
capscrews (Item 7), lockwashers (Item 2), and nuts (Item 1). Torque
nuts to 50 in-lbs.
2. Reconnect four (4) hydraulic hoses (Items 3 and 6) to respective
elbows at ports A3, B3, P1, and P2 on selector valve. Torque hydraulic
hose swivel nuts to 130–150 in-lbs.
3. Install two (2) hydraulic hoses (Item 4) to ports A1 and B1 on selector
valve and torque hose swivel nuts to 130–150 in-lbs.
4. Reconnect joystick wiring harness (Item 8) to selector valve.

Overhaul

Selector Valve
2
1 3
4
12
5
7
9
11

6
8

J1183
10

# Description # Description
1 Nut 7 Backup Rings
2 Coil 8 O-ring
3 Solenoid Valve 9 Connector
4 O-ring 10 Valve Body
5 Backup Rings 11 Orifice
6 O-ring 12 O-ring Plug

Fig. 6-18: Selector Valve Assembly

(Ref. Fig. 6-18) The following steps describe disassembly and overhaul of
the selector valve assembly in models with a mid-inlet hydraulic system.
1. Loosen and remove four (4) connectors (Item 9) from valve body
(Item 10).
2. Loosen and remove two (2) each O-ring plugs (Item 12) and orifices
(Item 11).
3. Loosen and remove nut (Item 1) from solenoid valve (Item 3).

31200079 6-31
Boom and Transfer

4. Remove coil (Item 2) from solenoid valve.

5. Loosen and remove solenoid valve from valve body.
6. Remove O-rings and backup rings (Items 4 thru 8) from solenoid valve.
Discard O-rings and backup rings.
7. Repeat Step 3 thru Step 6 for the other solenoid valve.
8. Clean all remaining parts with solvent and dry with compressed air.
Visually inspect the valve body to make sure all cavities are free of
contamination including burrs and chips as well as pieces of O-rings.
Inspect for all parts for damage and replace as necessary.
9. Obtain seal kit. Lubricate each O-ring and backup ring before installing
it. Install O-rings on each solenoid valve in descending order, making
sure the largest is installed first and the smallest last. Make sure that
O-rings (Items 6 and 8) are installed between their backup rings.
10. Check valves for any visible contamination. Dip each valve in clean oil
up to the largest O-ring (Item 4) before installing it in the valve body.
11. Install valves on valve body (Item 10). Torque each valve to 20 ft-lbs.
12. Install coil (Item 2) on solenoid valve with nut (Item 1). Torque nut to
5 ft-lbs.
13. Install two (2) orifices in the valve body. Torque orifices to 30–40 in-lbs.
14. Install two (2) O-ring plugs in valve body. Torque plugs to
125–145 in-lbs.
15. Install four (4) connectors in ports A3, B3, P1, and P2. Torque
connectors to 160–180 in-lbs.

6-32 31200079
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
C. Broken chains or chain seals.
connections C. Repair or replace chains.
D. Check pump pressure
2. Boom fails to raise A. Broken hydraulic line(s) A. Replace hydraulic
or lower and/or connection leaks hose(s)/tube(s) and/or
tighten loose connections.
B. Faulty hoist cylinder(s) B. Repair cylinder seals.
C. Faulty components in C. Repair or replace damaged
raise/lower hydraulic components.
circuitry D. Check pump pressure
3. Excessive boom A. Failure to grease at regular A. Replace worn pins and
pivot pin or cylinder intervals lubricate at recommended
pivot pin wear intervals.

B. Worn bushings B. Replace bushings and

lubricate at recommended
intervals.
4. Excessive Slide A. Improper shimming of slide A. Make proper shim See page 6-38, and
Pad Wear pads adjustments. page 6-48 (4-section).

B. Contaminated or rusted B. Clean and lubricate slide See page 6-36.

slide pad sliding surfaces pad sliding surfaces.
after long term storage
5. Jerky boom extend A. Chains out of adjustment A. Readjust chains.
or retract functions
6. Excessive Chain A. Chains out of adjustment A. Replace and readjust
Wear B. Improper chain lubrication chains.
B. Replace chain(s) and
lubricate at recommended
intervals.

31200079 6-33
Boom and Transfer

Boom Slide Pads — General

Description
Within the slide boom assemblies, there art two classifications of slide
pads:
• Load Bearing Slide Pads
Load bearing slide pads are located at the front and on the bottom of
any boom section that contains another section. Load bearing pads
are also located on the top rear of a boom section that is placed inside
another section.
• Non-Load Bearing Slide Pads
Non-load bearing slide pads are located at the front and on the top of a
boom section that contains another section. Pads that are located at
the rear and on the bottom of a boom that fits inside of another or any
pads that are located on a side of any boom section are also non-load
bearing slide pads.

Slide Pad Inspection

Full Chamfer
of New Pad

J1035

Fig. 6-19: Load Bearing Pad

(Ref. Fig. 6-19) Except for the lower slide pads located at the rear of the
middle boom on 3-section booms, all other slide pads have a chamfer on
each end of the top side (the side that wears). The depth of this chamfer
varies, depending on the part number, and shows the amount of usable
pad remaining.

6-34 31200079
Boom and Transfer

Slide Pads with Chamfers

Less Chamfer

J1036

Fig. 6-20: Pad Worn, But Still OK

(Ref. Fig. 6-20) Inspect all pads weekly for condition and amount of
chamfer wear. As a pad wears, the chamfer will get smaller. As long as a
portion of the chamfer is visible, the pad is OK and does not need to be
replaced.

No Chamfer

J1037

Fig. 6-21: Pad Must Be Replaced

(Ref. Fig. 6-21) When the chamfer is gone, the pad must be replaced.
Important: Never use a boom slide pad that has worn past the chamfer. The
boom will be damaged.

Nut Inserts

J1038

Fig. 6-22: Bolted Boom Slide Pad

(Ref. Fig. 6-22) Chamfered slide pads that have nut inserts are secured to
the boom with capscrews, lockwashers (spring and/or star), and
flatwashers (if needed).

31200079 6-35
Boom and Transfer

Slide Pads without Chamfers

New Slide Pad

3/4"

Worn Pad

9/16" Minimum

J1184

Fig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom

(Ref. Fig. 6-23) The lower slide pads, located at the rear of the middle
boom on 3-section booms and at the rear of the middle (rear) boom on
4-section booms, do not have chamfers. It will be necessary to measure
the thickness of these slide pads to ensure that they are a minimum of
9/16".

Lubrication
Load bearing pad slide areas must be greased at least monthly. Working
conditions and heavy usage may warrant greasing more often.
Fully extend and lower the boom, then apply a thin coat of EP Lithium
based grease on exposed pad slide areas. Retract the boom fully and use
the grease fittings provided at the rear of the boom section(s) for
lubricating those areas.

Slide Area Surface Finish

The areas on each boom section where the main load bearing pads slide
must be smooth and free of nicks and scratches. Rough surfaces will
greatly reduce the service life of slide pads. The general rule is: if you can
catch your fingernail on a scratch, it must be repaired.
Damaged areas that are 0.030" deep or less may be repaired by blending
the area smooth. Grind just enough material away to remove the damage,
then blend the area using fine sand paper. See Fig. 6-24 and Fig. 6-25.
Damage greater than 0.030" deep must be filled with weld and ground
smooth.

6-36 31200079
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

31200079 6-37
Boom and Transfer

Replacing and Shimming Boom Slide Pads — General

Shims

Bolted Pad
Pad Cage

Caged Pad
Lockwas
her
Retaining Block
Pad
Capscrew

J1019

Fig. 6-26: Slide Pad Installation (2-Section Shown)

(Ref. Fig. 6-26) As boom pads wear, it becomes necessary to install or
remove shims to maintain the correct clearances. Specific instructions and
clearances for 2-section, 3-section, and 4-section booms are provided on
following pages.
Usually, the main load bearing pads (caged pads) are the only pads that
will need shimming. The other pads are not normally subjected to heavy
wear.
Position this edge just below
lower limit of pad chamfer.
Lower Limit of Pad
Chamfer
Pad

Retaining Block

J1042

Fig. 6-27: Positioning Retaining Block

(Ref. Fig. 6-27) After shimming caged pads, the retaining block must be
correctly positioned to prevent possible damage to the boom.

6-38 31200079
Boom and Transfer

Adding or removing shims from bolted pads may require a different

capscrew length or washer selection.
Boom

Bolted Pad
Washer
Lockwasher
Capscrew
Nut Insert

Pad Number Dimension A

39023A 0.28"–0.33"
39024A 0.39"–0.44"
39530A 0.39"–0.44"
39594A 0.39"–0.44"
39604A 0.21"–0.26"

Dimension A
J1034

Fig. 6-28: Determining Capscrew Length

(Ref. Fig. 6-28) Select a combination of capscrew length, flatwasher (if
needed), and lockwasher (spring and/or star) to obtain the required
dimension (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").
Clearance is measured from under the capscrew head to the lockwasher.
A lockwasher must always be used under the capscrew head.
Apply nonpermanent thread locking compound to the first few threads of
the capscrew before final installation.
Boom

Bolted Pad

Bolt
Nut Insert

J1034

Fig. 6-29: Correctly Installed Capscrew

(Ref. Fig. 6-29) The end of the installed capscrew should be flush with, or
just beneath, the inner edge of the nut insert.

31200079 6-39
Boom and Transfer

Quick Attach

Description

J1004

Fig. 6-30: Quick Attach Rear View

(Ref. Fig. 6-30) The quick attach is designed for easy connection and
disconnection of various attachments. By pulling the release handle,
attachments can be easily interchanged.

Disconnecting an Attachment
1. Come to a complete stop on flat, level ground.
2. Set the park brake.
3. Raise the boom so attachment clears the ground.
4. Extend the boom a short distance.
5. Lower the boom to rest the attachment on level ground.
6. Shut off engine.
7. Disconnect attachment hydraulic lines (if equipped).

J1014

Fig. 6-31: Release Handle

6-40 31200079
Boom and Transfer

8. Pull release handle (1) back.

J1013

Fig. 6-32: Lock Plate

9. The lock pin (2) should engage the attachment, clearing the lock plate
(3) from the attachment stop (4).

J1007

Fig. 6-33: Rotating Quick Attach Downwards

10. Start the engine. Fully rotate quick attach (5) downwards by using the
attachment tilt control.

J1008

Fig. 6-34: Lowering Boom

11. Lower boom enough to clear quick attach pivot pin (6) from attachment
(7).

31200079 6-41
Boom and Transfer

J1009

Fig. 6-35: Retracting Boom

12. Retract the boom until quick attach (5) is clear of attachment (7).

Connecting an Attachment

J1015

Fig. 6-36: Extending Boom

1. With quick attach (5) rotated fully downwards, extend the boom until
quick attach pivot pin (6) is properly aligned underneath the
attachment (7).

J1016

Fig. 6-37: Raising Boom

2. Raise the boom to engage the quick attach pivot pin (6) with the
attachment (7).

6-42 31200079
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).

WARNING
MAKE SURE
ATTACHMENT IS
SECURELY CONNECTED
TO QUICK ATTACH.
ATTACHMENT MAY FALL
AND CAUSE SERIOUS
PERSONAL INJURY OR
W1048

DEATH!

6. Connect attachment hydraulic hoses (if equipped).

31200079 6-43
Boom and Transfer

Removal

Quick Attach 1. Disconnect attachment from quick attach.

2. Fully retract boom and transfer carriage (if equipped), level quick
attach and lower boom to ground.
3. Set park brake, lock shift selector in NEUTRAL position, shut off
engine and remove ignition key from switch. Block all wheels.
6

5
4
3

2
J1067

# Description # Description
1 Quick Attach 4 Lockwasher
2 Pivot Pin 5 Lock Pin
3 capscrew 6 Front Carriage Tilt Cylinder

Fig. 6-40: Lower Pivot of Carriage Tilt Cylinder

4. (Ref. Fig. 6-40) Remove capscrew (Item 3), lockwasher (Item 4), and
lock pin (Item 5) from lower pivot pin (Item 2) of front carriage tilt
cylinder (Item 6). Remove pivot pin from quick attach (Item 1).

6-44 31200079
Boom and Transfer

1 5

3
4

5
2

6
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. Remove quick attach pivot pin and shims (Item 5) (if installed).
7. Clean and inspect all parts for condition and wear. Replace as
necessary.

Installation

Quick Attach 1. Align quick attach (Item 6) to boom. Check gaps between quick attach
and boom. Select shims to center quick attach on boom.
2. (Ref. Fig. 6-41) Install quick attach pivot pin (Item 1) and shims
(Item 5). Secure pivot pin with capscrew (Item 2), lockwasher (Item 3),
and nut (Item 4).
3. (Ref. Fig. 6-40) Align rod-end of front carriage tilt cylinder with quick
attach. Install pivot pin and secure with lock pin, lockwasher, and
capscrew.
4. Lubricate grease fittings with EP lithium based grease.

31200079 6-45
Boom and Transfer

Boom Angle Inclinometer

Description

80

80
60
0
-20 0 20 4

60

H1045
DEGREES

60 80
0

40
4

20
0
-20

-20
20
0

J1177
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. This indicator is used with the boom extension indicator, transfer
carriage extension indicator (if equipped), and machine load chart to
determine correct boom lifting capacities.

Replacement

1
60 80

2
40
20

-20
0
3 J1176
4

# Description # Description
1 Boom Angle Inclinometer 3 Starwasher
2 Flatwasher 4 Round Head Screw

Fig. 6-43: Boom Angle Inclinometer Installation

1. Remove two (2) each round head screws (Item 4), starwashers
(Item 3), and flatwashers (Item 2) along with the boom angle indicator
(Item 1) from the boom.
2. Discard old boom angle inclinometer.
3. Clean and inspect hardware for damage and replace as necessary.
4. Install new boom angle inclinometer with two (2) each flatwashers,
starwashers, and round head screws. Tighten screws until snug.

6-46 31200079
Boom and Transfer

4-Section Boom

Description

60 80
40
20
0
-20

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.

31200079 6-47
Boom and Transfer

Shimming Procedures

4-Section Boom

2 2

60 80
40
20
0
-20

2 1 2

1
2

60 80
40
3

20
0
-20

2
2 2

1 2 1
4
2
1
2
2

J1160
2

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"
2 Boom Pad, 9/16" Thick x 2" Wide Wide
3 Boom Pad, 3/4" Thick x 3" Wide

Fig. 6-45: Boom Slide Pad Locations – 4-Section Boom

1. Park machine on firm, level surface and apply park brake. Level the
frame. Level and fully retract the boom. Shut off engine.
2. Determine if all boom slide pads are serviceable. (See “Slide Pad
Inspection” on page 6-34). Have replacement pads ready as required.

0.62"–0.74"
(5/8"–3/4")

0.67"–0.82"
(11/16"–13/16")

0.75"–1.00"
(3/4"–1")
J1161

Fig. 6-46: Boom Section Gaps – Front of 4-Section Boom

6-48 31200079
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)

J1162
under these pads

Fig. 6-47: Lower Shim Installation – Front of 4-Section Boom

4. (Ref. Fig. 6-47) Install/remove shim(s) under indicated pads to obtain
clearances specified in Step 3.
0.06"–0.12"
(1/16"–1/8")
gap between
boom and pad

0.05"–0.11"
(3/64"–7/64")
gap between
boom and pad

0.03"–0.09"
(1/32"–3/32")
gap between
boom and pad
J1155

Fig. 6-48: Upper Shim Installation – Front of 4-Section Boom

31200079 6-49
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")

J1156
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. Spacing between the
middle (rear) and outer boom section cannot be adjusted. If the
dimensions are not within the specified range, proceed to Step 7. If the
dimensions are within the specified range, proceed to Step 8.

J1157

Install shim(s) under these pads

Fig. 6-50: Lower Shim Installation - Rear of 4-Section Boom

7. (Ref. Fig. 6-50)Install/remove shim(s) under indicated pads to obtain
clearance specified in Step 6.

6-50 31200079
Boom and Transfer

0.06" (1/16")
0.07" (1/16")

J1158
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"
0.595"–0.655" (19/32"–
(19/32"– 21/32")
21/32")
J1187

Rear of Boom, Looking Forward

Fig. 6-52: Clearances Between Boom Sections – Rear of 4-Section Boom

9. (Ref. Fig. 6-52) Adjust boom positions to obtain clearances between
boom sections as shown. Measure these clearances at the slide pad
locations.

31200079 6-51
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")

J1188
Rear of Boom, Looking Forward

Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom
10. (Ref. Fig. 6-53) Install/remove shim(s) under indicated pads to obtain
specified clearances making sure clearances on both sides of each
boom section are the same.

0.47–0.53" 0.595"–0.655" 0.47–0.53"

0.72"–0.78" 0.72"–0.78"
(15/32"– (19/32"– (15/32"–
(23/32"– (23/32"–
17/32") 21/32") 17/32")
25/32") 25/32")
J1189

Front of Boom, Looking Rearward

Fig. 6-54: Clearances Between Boom Sections – Front of 4-Section Boom

6-52 31200079
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"

J1190
(1/16"–1/8") (1/16"–1/8")
Front of Boom, Looking Rearward

Fig. 6-55: Gaps Between Pads and Boom – Front of 4-Section Boom
12. (Ref. Fig. 6-55) Install/remove shim(s) under indicated pads to obtain
specified clearances making sure clearances on both sides of each
boom section are the same.
13. Extend boom and lubricate as described under “Lubrication” on
page 6-36.
14. Check boom extension and retraction for binding against slide pads.

Inspection Procedures

4-Section Boom These procedures are intended to determine if localized deformation has
occurred on the inner, middle (forward), and middle (rear) boom sections.
1. Extend the boom and lower the forks to the ground.

31200079 6-53
Boom and Transfer

10 5/8" (10.625")

3/16" (0.19")

1/4" (0.25") Max.

J1085
Fig. 6-56: Inner Boom Cross-Section at Window
2. (Ref. Fig. 6-56) Place a straight edge against the bottom surface of the
inner boom section. Measure the distance from the straight edge to the
bottom surface of the boom tube. This distance should not exceed 1/4"
(0.25"). The maximum deflection will be found just in front of the middle
(forward) boom section.
3. (Ref. Fig. 6-56) The side walls may also deflect outward at the window
areas. Take this measurement across the inner boom tube, through the
windows. Maximum allowable deflection is 3/16" (0.19) per side. The
maximum allowable inner boom tube width is 10-5/8" (10.625"),
measured through the windows.

12 7/8" (12.875")

3/16" (0.19")

1/4" (0.25") Max.

J1085

Fig. 6-57: Middle (Forward) Boom Cross-Section at Window

6-54 31200079
Boom and Transfer

4. (Ref. Fig. 6-57) Place a straight edge against the bottom surface of the
middle (forward) boom section. Measure the distance from the straight
edge to the bottom surface of the boom tube. This distance should not
exceed 1/4" (0.25"). The maximum deflection will be found just in front
of the middle (rear) boom section.
5. (Ref. Fig. 6-57) The side walls may also deflect outward at the window
areas. Take this measurement across the middle (forward) boom tube,
through the windows. Maximum allowable deflection is 3/16" (0.19")
per side. The maximum allowable middle (forward) boom tube width is
12-7/8" (12.875"), measured through the windows.

14 1/2" (14.5") Max.

3/16" (0.19")

1/4" (0.25") Max.

J1085
Fig. 6-58: Middle (Forward) Boom Cross-Section at Window
6. (Ref. Fig. 6-58) Place a straight edge against the bottom surface of the
middle (rear) boom section. Measure the distance from the straight
edge to the bottom surface of the boom tube. This distance should not
exceed 1/4" (0.25"). The maximum deflection will be found just in front
of the outer boom section.
7. (Ref. Fig. 6-58) The side walls may also deflect outward at the window
areas. Take this measurement across the middle (rear) boom tube,
through the windows. Maximum allowable deflection is 3/16" (0.19) per
side. The maximum allowable middle (forward) boom tube width is 14-
1/2" (14.5"), measured through the windows.

Boom Removal

4-Section Boom 1. Remove Quick Attach. See page 6-44.

2. Park machine on firm, level surface. If so equipped, fully retract transfer
carriage. Fully retract boom before lowering it to the ground.
3. Set park brake, lock shift selector in NEUTRAL position, shut off
engine and remove ignition key from switch. Block all wheels.
4. Position crane next to machine.

31200079 6-55
Boom and Transfer

1
2
3
4

J1169B
# 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. Remove boom cover.
6. Remove boom elevation proximity switch. See “Boom Elevation
Proximity Switch” in Section 7.
7. Remove boom extension proximity switch. See Step 8 on page 6-123.

2
1

4 3

J1220

# Description # Description
1 Auxiliary Hydraulic Hoses 3 Boom Extension Hoses
2 Carriage Tilt Hoses 4 Boom Extension Cylinder

Fig. 6-60: Hose Connections, 4-Section Boom

6-56 31200079
Boom and Transfer

8. (Ref. Fig. 6-60) Tag and disconnect two (2) hoses at boom extension
cylinder lines (Item 3). Cap lines and hoses
9. Tag and disconnect two (2) carriage tilt hoses (Item 2), and two (2)
auxiliary hydraulics hoses (Item 1) at the boom. Cap hoses and lines.
10. Place sling around inner boom section, at the front. Chains with hooks
may be attached to the rear of the outer boom section, near the pivot
pin bosses (Ref. Fig. 6-61). Attach sling and chains to crane hook and
lift crane to support weight of boom.

CAUTION: Make sure crane, slings, and chains have sufficient capacity to
support the weight of the boom. A 4-section boom assembly,
including boom extension cylinder, weighs approximately
6,650 pounds.

Hook chains at
these areas

1
2
3

1 4

8 2
3
5

J1221
# Description # Description
1 Lock Pin 5 Pivot Pin, Boom Hoist Cylinder
2 Lockwasher 6 Rear Carriage Tilt Cylinder
3 Bolt 7 Boom Hoist Cylinder
4 Pivot Pin, Rear Carriage Tilt Cyl. 8 Boom

Fig. 6-61: Cylinder Pivot Pins

11. (Ref. Fig. 6-61) Remove four (4) capscrews (Item 3) and lockwashers
(Item 2) from lock pins (Item 1) securing rear carriage tilt cylinders
(Item 6) and boom hoist cylinders (Item 7) to the boom (Item 8).
Remove four (4) lock pins from pivot pins (Items 4 and 5).

31200079 6-57
Boom and Transfer

CAUTION: Make sure each cylinder is fully supported so it does not fall
and cause personal or equipment damage when it is being
removed.

12. (Ref. Fig. 6-61) Starting at a rear carriage tilt cylinder (Item 6), use a
slide hammer puller threaded into the pivot pin (Item 4) to remove the
pivot pin from boom. After the pivot pin has been removed, allow the
cylinder to swing down and away from the boom.

CAUTION: Use suitable blocking to support cylinders and prevent

damage to the surrounding structure.

13. (Ref. Fig. 6-61) Repeat Step 12 for the remaining rear carriage tilt
cylinder.
14. (Ref. Fig. 6-61) Continue with each of the two (2) hoist cylinders
(Item 7) by using a slide hammer puller threaded into pivot pin (Item 5)
to remove it. After the pivot pin has been removed, allow the cylinder to
swing down and away from the boom.

5
3 4
6
2

7
1
8

J1270
# Description # Description
1 Shim 5 Lockwasher
2 Upper Rear Slide Pad 6 Capscrew
3 Pad Retainer 7 Lockwasher
4 Flatwasher 8 Button-Head Socket Capscrew

Fig. 6-62: Upper Rear Slide Pad Removal – Middle (Rear) Boom Section
15. (Ref. Fig. 6-62) Remove upper rear slide pads from middle (rear) boom
section as follows:
a. Remove two (2) each capscrews (Item 6), lockwashers (Item 5),
flatwashers (Item 4), and pad retainers (Item 3) from rear of middle
(rear) boom section.
b. Remove four (4) capscrews (Item 8) and lockwashers (Item 7)
securing upper slide pads to rear of middle (rear) boom section.
Remove two (2) slide pads (Item 2) and shims (Item 1).

6-58 31200079
Boom and Transfer

2 4
3
1
6
5

7
8

J1245
# 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. Remove two (2) each capscrews (Item 6), lockwashers (Item 4),
flatwashers (Item 5), and pad retainers (Item 3) securing upper
slide pads to rear of middle (forward) boom section.
b. Remove four (4) capscrews (Item 8) and lockwashers (Item 7)
securing slide pads (Item 2) to top rear of middle (forward) boom
section. Remove slide pads and shims (Item 1).
5 6
4
3
2

1 7
8

J1269

# Description # Description
1 Inner Boom Section 5 Lockwasher
2 Upper Slide Pad 6 Capscrew
3 Pad Retainer 7 Lockwasher
4 Flatwasher 8 Button-Head Socket Capscrew

Fig. 6-64: Upper Rear Slide Pad Removal – Inner Boom Section

31200079 6-59
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.
b. Remove four (4) capscrews (Item 8) and lockwashers (Item 7)
securing upper slide pads (Item 2) to rear of inner boom section.
Remove the two (2) slide pads.

60 80
Locations for

40
Chain Attachment

20
0
-20

J1268
Fig. 6-65: Locations for Chain Attachment – Inner Boom Section
18. (Ref. Fig. 6-65) Because the chain and hose guide assembly interferes
with removal of the boom pivot pins, it will be necessary to extend the
boom approximately eight (8) inches. To do so, attach a chain to one of
the openings either on the front or top of the inner boom section and
pull the sections straight out.

6-60 31200079
Boom and Transfer

3 1
2
4

1
2

5 4 3
5
5

7
6

J1222
# 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).

CAUTION: Make sure slings and chains are secure and crane is
supporting the weight of the boom.

20. (Ref. Fig. 6-66) Using the slide hammer puller, remove the two (2)
boom pivot pins and shims (Item 5).
21. (Ref. Fig. 6-66) Carefully lift the boom assembly (Item 7) clear of the
transfer carriage/boom cradle (Item 6).
22. Swing the boom away from the machine and position it above a firm,
level surface. Rotate the boom upside down and lower it onto support
blocks.
23. Remove the front carriage tilt cylinder. See page 6-19.

31200079 6-61
Boom and Transfer

installation

4-Section Boom 1. Prepare replacement boom for installation by removing strapping and
blocks used for shipment. Note location of straps and blocks for use on
the previously removed boom.
2. With the replacement boom still lying upside down, the front carriage
tilt cylinder should be installed at this point. It is easier to install when
the boom is in this position. See page 6-20
3. Attach slings/chains to the boom and crane. Lift the boom and rotate it
to the upright position.
4. Position the boom over the transfer carriage/boom cradle. Carefully
lower boom and align boom pivot boss with the matching bosses in the
transfer carriage/boom cradle.
5. (Ref. Fig. 6-66) Partially insert two (2) boom pivot pins to temporarily
secure the boom pivot. Check gaps between boom pivot boss and the
matching bosses in the transfer carriage/boom cradle. Select
appropriate shim sizes to center the boom in the transfer
carriage/boom cradle.
6. (Ref. Fig. 6-66) Slide the boom pivot pins out one at a time and insert
the required shims. Fully insert the boom pivot pins.
7. (Ref. Fig. 6-61) Align rod-end of a boom hoist cylinder with the
matching boss on the boom. Insert pivot pin and secure with lock pin,
lockwasher, and capscrew. Repeat this procedure for the other hoist
cylinder and rear carriage tilt cylinders.
8. The slings/chains and crane may be removed at this point.
9. (Ref. Fig. 6-61) Connect the two (2) auxiliary hydraulic hoses and two
(2) carriage tilt hoses to the rear of the boom.
10. Connect the two (2) hoses to the boom extension cylinder lines.
11. Lubricate all pivot grease fittings with EP lithium based grease.
12. Install boom extension proximity switch. See Step 9 on page 6-128.
13. Install boom elevation proximity switch in transfer carriage/boom
cradle. See “Boom Elevation Proximity Switch” in Section 7.
14. Install quick attach assembly to boom. See page 6-45.
15. (Ref. Fig. 6-66) Start engine and extend the boom approximately eight
inches. Shut engine off. Secure pivot pins with two (2) capscrews,
lockwashers, and nuts. Torque nuts to 110 ft-lbs.
16. Start engine and cycle the frame tilt fully several times.
a. Raise the boom, noting that Rear Osc Lock light illuminates when
boom is at about 40° elevation. If light does not illuminate, stop and
lower the boom. Follow procedures for under “Boom Elevation
Proximity Switch” in Section 7.
b. Complete proximity switch adjustment before proceeding to
Step 17.
17. Cycle all boom hydraulics several times to remove air from system.

6-62 31200079
Boom and Transfer

a. With the outriggers up, extend the boom, noting that Boom
Extension proximity light illuminates when the boom is extended to
specified distance (approximately 21 feet with tilting tower or 25
feet with standard carriage). If light does not illuminate, stop and
retract the boom. See page 6-119 for adjustment procedures.
b. Retract and lower boom to ground and shut off engine.
c. Complete proximity switch adjustment before proceeding to
Step 18.
18. Inspect hydraulic connections for leaks and tighten as necessary.
19. (Ref. Fig. 6-59) Install boom cover (Item 4) with six (6) each
flatwashers (Item 3), lockwashers (Item 2), and nuts (Item 1). Tighten
nuts to 180 in-lbs.

Boom Disassembly

4-Section Boom 1. Remove boom assembly from machine.

2. Place boom assembly on work stands in upside down position.

CAUTION: To avoid personal and equipment damage, make sure that the
boom is properly supported through this entire procedure.

31200079 6-63
Boom and Transfer

16
15
1
2
3
4
5
6
7

13
11
12 10
11
9
10
9
8 14
4
5
6

J1271
7

# 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. 6-67: Slide Pad Removal – Outer Boom Section

3. (Ref. Fig. 6-67) Remove the lower slide pads from outer boom section
as follows:
a. Remove two (2) each capscrews (Item 7), lockwashers (Item 6),
flatwashers (Item 5), and pad retainers (Item 4) from retainer
blocks (Items 3 and 8).
b. Remove four (4) capscrews (Items 10 and 14) and lockwashers
(Items 9 and 11) securing retainer blocks to outer boom section.
Remove two (2) each lower slide pads (Item 1), shims (Item 2) and
retainer blocks.

6-64 31200079
Boom and Transfer

1
2

4 5
3 6

J1270
# 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. Remove two (2) each capscrews (Item 3), lockwashers (Item 4),
and pad retainers (Item 5) from rear of middle (rear) boom section.
b. Remove four (4) capscrews (Item 7) and lockwashers (Item 6)
securing upper slide pads to rear of middle (rear) boom section.
Remove two (2) slide pads (Item 1) and shims (Item 2).

31200079 6-65
Boom and Transfer

4 6
5
13
3 7
14 15
8
12
1

11
10
16
2 9 17

18

J1227
60 80
40
20

0
-20

1 and 2 7 and 8
10 and 11

14 and 15

J1241
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
5 Lockwasher 14 Auxiliary Hydraulic Hose
6 Capscrew 15 Carriage Tilt Hydraulic Hose
7 Auxiliary Tilt Hydraulic Hose 16 Lockwasher
8 Carriage Tilt Hydraulic Hose 17 Nut
9 Middle (Rear) Boom Section 18 Outer Boom Section

Fig. 6-69: Disconnecting Hoses Between Sections

5. (Ref. Fig. 6-69) Disconnect hoses between sections as follows:
a. Remove two (2) capscrews (Item 6), lockwashers (Item 5), and the
hose guard (Item 4) from the rear of the middle (front) boom
section (Item 3).

6-66 31200079
Boom and Transfer

CAUTION: Be sure to note orientation of the hose guard during removal.

Your hose guard may be different from that shown above. If
the hose guard is reversed at assembly, equipment damage
may occur during operation of machine.

b. Loosen and remove hydraulic hoses (two (2) each auxiliary and
carriage tilt) (Items 7 and 8) from hydraulic tubes (Items 1 and 2) at
rear of middle (front) boom section. Bleed any remaining oil into a
suitable container. Tag and cap hoses and tubes.
c. Loosen and remove hydraulic hoses (two (2) each auxiliary and
carriage tilt) (Items 14 and 15) from hydraulic tubes (Items 10 and
11) at rear of outer boom section (Item 18). Bleed any remaining oil
into a suitable container. Tag and cap hoses and tubes.
d. For early production models, remove four (4) each nuts (Item 17),
lockwashers (Item 16), round head screws (Item 13), and half
clamps (Item 12).

14
12 13
11

6 10
60 80

9
40
20

0
-20

7
8
4

5
3
1 2

MV0390

# Description # Description
1 Rod Nut 10 Cushion Clamp
2 Socket Setscrew 11 Extension Cylinder Base Mount
3 Extension Cylinder Rod Boss 12 Shim
4 Middle (Rear) Boom Section 13 Shim
5 Boom Extension Cylinder 14 Nut
6 Capscrew 15 Capscrew
7 Flatwasher 16 Lockwasher
8 Elbow 17 Flatwasher
9 Hydraulic Tube 18 Extension Cylinder Base Mount

Fig. 6-70: Extension Cylinder Removal – 4-Section Boom

31200079 6-67
Boom and Transfer

6. (Ref. Fig. 6-70) Remove extension cylinder as follows:

a. Support the extension cylinder with sling(s) or other suitable
means. Make sure support items have sufficient capacity to
support the weight of the cylinder. The extension cylinder weighs
650 pounds.
b. Loosen and remove two (2) hydraulic tubes (Item 9) from elbows
(Item 8) on boom extension cylinder (Item 5). Bleed any remaining
oil into a suitable container. Tag and cap fittings and tubes.
c. Loosen nut on two (2) cushion clamps (Item 10) and remove
clamps and hydraulic tubes from mounting channel on outer boom
section.
d. Loosen two (2) socket setscrews (Item 2) in rod nut (Item 1).
e. Loosen and remove rod nut and rod boss (Item 3) securing boom
extension cylinder to front of middle (rear) boom section (Item 4).
f. Loosen and remove hardware securing extension cylinder to outer
boom section as follows:
Remove two (2) each nuts (Item 14), capscrews (Item 6), and
flatwashers (Item 7) securing extension cylinder base mount
(Item 11) to outer boom section. Remove the shim(s) (Items 12
and 13).
g. Remove the extension cylinder.
7. Turn boom assembly over and place it on work stands in upright
position.
8. (Ref. Fig. 6-67) Remove upper slide pads on outer boom as follows:
a. Remove four (4) capscrews (Item 16) and lockwashers (Item 15)
securing top slide pads (Item 12) to outer boom.
b. Remove the two (2) slide pads and shims (Item 13).

1
2

J1272

3
4

# Description # Description
1 Button-Head Socket Capscrew 3 Shim
2 Lockwasher 4 Upper Front Slide Pad

Fig. 6-71: Upper Front Slide Pad Removal – Middle (Rear) Boom Section

6-68 31200079
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).

J1245
4

# Description # Description
1 Button-Head Socket Capscrew 3 Shim
2 Lockwasher 4 Front Upper Slide Pad

Fig. 6-72: Upper Front Slide Pad Removal – Middle (Forward) Boom Section
10. (Ref. Fig. 6-72) Remove upper front slide pads from middle (front)
boom section as follows:
a. Remove two (2) capscrews (Item 1) and lockwashers (Item 2)
securing each of the two (2) upper slide pads to the front of the
middle (forward) boom section.
b. Remove two (2) slide pads (Item 4) and shims (Item 3).
4
3

2
1
60 80
40
20

0
-20 J1223

# Description # Description
1 Chain Adjustment Anchor 3 Lockwasher
2 Jam Nut 4 Nut

Fig. 6-73: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections

31200079 6-69
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.
1
2
3
4
1

5 6

60 80
40
20
0
-20

8
9
10

J1224
7

# Description # Description
1 Chain Guide Washer 6 Grease Fitting
2 Bushing 7 Chain Roller Pin
3 Chain Roller 8 Lock Pin
4 Chain Roller Bushing 9 Lockwasher
5 Grease Fitting Cover 10 Capscrew

Fig. 6-74: Upper Chain Roller Assembly – Middle (Forward) Boom Section
13. (Ref. Fig. 6-74) Remove capscrew (Item 10), lockwasher (Item 9), and
lock pin (Item 8) from chain roller pin (Item 7).
14. (Ref. Fig. 6-74) Remove chain roller pin, two (2) guide washers
(Item 1), bushing (Item 2), chain roller (Item 3), and chain roller
bushing (Item 4).

6-70 31200079
Boom and Transfer

5
4
1 3

2
6

8
7

J1229
# 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. Remove two (2) lock nuts (Item 3) and shoulder bolts (Item 7)
securing chains (Items 2 and 6) to rear chain anchor (Item 8).
b. Remove two (2) capscrews (Item 5), lockwashers (Item 4), and
rear chain anchor from rear of inner boom (Item 1).
3 7
8
2
4
1 5

9 10
6
2 12 11
13

14
15

J1228
16

# Description # Description
1 Upper Chain 9 Lockwasher
2 Lock Nut 10 Lower Chain
3 Upper Chain Anchor 11 Shoulder Bolt
4 Capscrew 12 Lower Chain Anchor
5 Lockwasher 13 Hose Reel
6 Chain Anchor Rod 14 Capscrew
7 Lock Nut 15 Lockwasher
8 Capscrew 16 Hose Reel Pin

Fig. 6-76: Disconnecting Chains at Rear of Middle (Forward) Boom

16. (Ref. Fig. 6-76) Disconnect chains from rear of middle (forward) boom
as follows:

31200079 6-71
Boom and Transfer

a. Remove two (2) lock nuts (Item 2), chain anchor rod (Item 6), and
upper chain (Item 1).
b. Remove capscrew (Item 4), lockwasher (Item 5), and upper chain
anchor (Item 3).
c. Remove capscrew (Item 14), lockwasher (Item 15), and hose reel
pin (Item 16) securing each of the two (2) hose reels (Item 13) to
the rear of the middle (forward) boom section. Remove hose reels.
d. Remove two (2) each capscrews (Item 7) and lockwashers (Item 8)
securing lower chain anchor (Item 12) to middle (forward) boom
section.
e. Remove lock nut (Item 9), shoulder bolt (Item 11), and lower chain
anchor from lower chain (Item 10).
17. (Ref. Fig. 6-75) Pull upper chain (Item 2) out through front of boom.
18. Slide inner and middle (forward) boom sections out of middle (rear)
boom section. Place middle (forward) section (with inner) on work
stands upside down.

3
2 4

J1236
# Description # Description
1 Button-Head Socket Capscrew 4 Lockwasher
2 Lockwasher 5 Side Slide Pad
3 Button-Head Socket Capscrew 6 Bottom Slide Pad

Fig. 6-77: Slide Pad Removal – Inner Boom Section

19. (Ref. Fig. 6-77) Remove eight (8) capscrews (Items 1 and 3) and
lockwashers (Items 2 and 4) securing two (2) side and two (2) bottom
slide pads (Items 5 and 6) to rear of inner boom section. Remove slide
pads.

6-72 31200079
Boom and Transfer

11 12

14
15
9
7

16
17
1
2

3 13

12
5 4 11
6 10
9
8
7
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
8 Shim 18 Pad Retainer
9 Button-Head Socket Capscrew
10 Lockwasher

Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section

20. (Ref. Fig. 6-78) Remove remaining slide pads from middle (forward)
boom section as follows:
a. Remove four (4) capscrews (Item 11) and lockwashers (Item 12)
securing two (2) side slide pads (Item 7) to front of middle (forward)
boom section (Item 13). Remove slide pads and shims (Item 8).
Repeat this step for the rear side slide pads.
b. (Ref. Fig. 6-78) Remove two (2) each capscrews (Item 6),
lockwashers (Item 5), flatwashers (Item 4), and pad retainers
(Item 3) from front of middle (forward) boom section.

31200079 6-73
Boom and Transfer

c. (Ref. Fig. 6-78) Remove lower slide pads from front of middle
(forward) boom section as follows:
1). Remove two (2) socket capscrews (Item 9) and lockwashers
(Item 10) securing lower slide pads (Item 1) to front of boom
section.
2). Remove slide pads and shims (Item 2).
21. (Ref. Fig. 6-78) Remove two (2) capscrews (Item 14) and lockwashers
(Item 15) securing bottom slide pad (Item 17) to rear of middle
(forward) boom section. Remove slide pad and shim(s) (Item 16).
22. Slide inner boom section out of middle (forward) boom section. Place
inner boom on work stands in upright position.
23. Remove auxiliary hydraulic quick disconnects from inner boom.

6
1
5
4

J1235
# Description # Description
1 Grease Hose 4 Bulkhead Adapter
2 Inner Boom Section 5 Grease Fitting
3 Elbow 6 Grease Fitting Cover

Fig. 6-79: Grease Hose Assembly

24. (Ref. Fig. 6-79) Remove bulkhead adapter (Item 4) from rear of inner
boom section (Item 2).
25. (Ref. Fig. 6-79) Loosen and remove grease hose (Item 1) and elbow
(Item 3) from inside of inner boom section.
26. Flip middle (forward) boom section to upright position.

6-74 31200079
Boom and Transfer

7
8
9
1 10
2 7

4
3 5
6

J1233
# 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. (Ref. Fig. 6-80) Remove rear chain roller assembly as follows:
a. Remove capscrew (Item 6), lockwasher, (Item 5) and lock pin
(Item 4) from chain roller pin (Item 3).
b. Remove chain roller pin, two (2) chain guide washers (Item 7),
bushing (Item 8), chain roller (Item 9), and chain roller bushing
(Item 10).
28. Turn over inner boom section and place on work stands in upside down
position.
29. Remove front carriage tilt cylinder from inner boom (See page 6-19,
Steps 2–6).

31200079 6-75
Boom and Transfer

3
5

J1246
1

# 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. Remove lock nuts from cushion clamps (Item 3) securing auxiliary
and carriage tilt hydraulic tubes (Items 4 and 5) in mounting
channels (Item 6).
b. Slide cushion clamps from mounting channel and remove hydraulic
tubes from inner boom section.
c. Remove hydraulic hoses (Items 1 and 2) from tubes.

6-76 31200079
Boom and Transfer

4
3

2
1

60 80
5

40
20
0
-20

J1225
# 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.
1
2
3
4
3
2
1

5 6
60 80
40
20

0
-20

7
8
9

10
J1226

# 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. 6-83: Upper Chain Roller Assembly – Middle (Rear) Boom Section

31200079 6-77
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).

5 5
4 4

60 80
40
1

20
0
-20

1
7
6 7 6

J1230
3
2 3
Middle (Rear) Boom Section 2 Outer Boom Section

# Description # Description
1 Lockwasher 5 Chain
2 Button Head Capscrew 6 Chain Adjustment Block
3 Chain Adjustment Rod 7 Shoulder Bolt
4 Lock Nut

Fig. 6-84: Removing Lower Chains

34. (Ref. Fig. 6-84) Remove lower chains from the middle (rear) and outer
boom sections as follows:
a. Remove capscrew (Item 2) and lockwasher (Item 1).
b. Remove chain adjustment rod (Item 3).
c. Pull the chain assembly (Items 4 thru 7) out through rear of boom.
35. Slide middle (rear) boom out of outer boom section and place it on
work stands in upright position.

6-78 31200079
Boom and Transfer

7
8
9
10

11
6 12
5

1 2

J1232
3
4

# 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. 6-85: Slide Pads – Middle (Rear) Boom Section

36. (Ref. Fig. 6-85) Remove remaining slide pads from middle (rear) boom
section as follows:
a. Remove eight (8) each capscrews (Item 4) and lockwashers
(Item 3) securing side slide pads to front of middle (rear) boom
section. Remove four (4) slide pads (Item 1) and shims (Item 2).
b. Remove four (4) each capscrews (Item 7) and lockwashers
(Item 8) securing side slide pads to rear of middle (rear) boom
section. Remove two (2) slide pads (Item 10) and shims (Item 9).
c. Remove four (4) each capscrews (Item 5) and lockwashers
(Item 6) securing lower slide pads to rear of middle (rear) boom
section. Remove two (2) slide pads (Item 12) and shims (Item 11).

31200079 6-79
Boom and Transfer

4
3 5
6
7 9
8
2 10
11

12 9
10
4
7
1 5
6
1
2
8
3

J1238
13
14
15

# 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 15 Grease Fitting Cover
8 Left Hand Hose Guide

Fig. 6-86: Chain and Hose Guide Assembly

37. (Ref. Fig. 6-86) Remove chain and hose guide assembly from rear of
middle (rear) boom section as follows:
a. Remove chain and hose roller shaft (Item 13) from rear of middle
(rear) boom section. Remove chain and hose roller assembly.
b. Remove two (2) lock nuts (Item 9) and capscrews (Item 3).
c. Separate two (2) each right hand hose guides (Item 4), washers
(Item 2), roller bushings (Item 1), hose guide spacers (Item 5),
hose spacers (Item 6), plastic bushings (Item 7), and left hand
hose guides (Item 8) from chain and hose roller (Item 12).
d. Remove two (2) chain roller washers (Item 10) and the hardened
bushing (Item 11) from the chain and hose roller.

6-80 31200079
Boom and Transfer

10
1 2

5
3

9
8
4
6 7

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. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections
38. (Ref. Fig. 6-87) Remove middle (rear) boom section hoses as follows:
a. Loosen and remove two (2) auxiliary and two (2) carriage tilt
hydraulic hoses (Items 1 and 2) from hydraulic manifold block
(Item 4).
b. Bleed any remaining oil into a suitable container and remove hoses
from inside middle (rear) boom section (Item 3). Tag and cap hoses
and fittings.
39. Flip middle (rear) boom section upside down and place on work
stands.
40. (Ref. Fig. 6-87) Remove hydraulic tubes from bottom of middle (rear)
boom section as follows:

31200079 6-81
Boom and Transfer

a. Remove two (2) each nuts (Item 7), lockwashers (Item 8), and tube
clamps (Item 9) securing each set of auxiliary and carriage tilt
hydraulic tubes (Items 5 and 6) to bottom of middle (rear) boom
section.
b. Loosen screw on cushion clamps (Item 10). Slide cushion clamps
out of channel and remove hydraulic tubes from boom section.

1
2

J1237
3
4

# Description # Description
1 Button-Head Socket Capscrew 3 Shim
2 Lockwasher 4 Side Slide Pad

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

41. (Ref. Fig. 6-88) Remove side slide pads from outer boom section as
follows:
a. Remove four (4) capscrews (Item 1) and lockwashers (Item 2)
securing side slide pads to outer boom.
b. Remove the two (2) slide pads (Item 4) and shims (Item 3).

6-82 31200079
Boom and Transfer

3
2

10
9

4 8
1 12
7
6
5

11

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. 6-89: Outer Boom Tubes and Hoses

42. (Ref. Fig. 6-89) Remove outer boom hydraulic hoses as follows:
a. Loosen and remove auxiliary and front carriage tilt hydraulic hoses
(Items 2 and 3) from hydraulic manifold blocks (Item 11). Bleed any
remaining oil into a suitable container.
b. Remove hoses from inside outer boom section (Item 1). Cap and
tag hoses and open ports on manifold blocks.
43. Turn outer boom section over and place it upside down on work
stands.
a. Loosen and remove four (4) auxiliary and front carriage tilt
hydraulic tubes (Items 9 and 10) from hydraulic manifold blocks
(Item 11). Bleed any remaining oil from tubes into a suitable
container. Tag and cap hydraulic tubes and open ports on hydraulic
manifold blocks.

31200079 6-83
Boom and Transfer

b. Remove two (2) each nuts (Item 5), lockwashers (Item 6), and
clamps (Item 7) securing each set of hydraulic tubes to bottom of
outer boom section.
c. Loosen screws on cushion clamps (Item 8). Slide cushion clamps
out of channel and remove hydraulic tubes.
d. Remove two (2) capscrews (Item 4) and lockwashers (Item 12)
securing each manifold block to the outer boom. Remove the
manifold blocks.

Note: If damaged, further disassembly of chain assemblies may become

necessary. If required, information on the removal and installation of
additional items such as the boom angle indicator is covered elsewhere in
this manual. Additional information of removal and installation of the boom
elevation proximity switch and the boom extension proximity switch is also
covered in this manual.

Assembly

4-Section Boom 1. Use crane, chains, and slings to lift and place outer boom section on
work stands in upside down position.

CAUTION: To avoid personal and equipment damage, make sure that

major boom components are properly supported through this
entire procedure.

Note: This procedure assumes that the boom has been completely
disassembled. In certain areas, references are made to other
locations in this manual where specific subjects are covered in
detail.

6-84 31200079
Boom and Transfer

14
15

16

3
2

10
9

13
1 12
8

11
7
6
5

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 16 Right Clamp Half
8 Cushion Clamp
9 Auxiliary Hydraulic Tube

Fig. 6-90: Outer Boom Tube and Hose Assembly

2. (Ref. Fig. 6-90) Install auxiliary and front carriage tilt hydraulic tubes
and hoses on outer boom section as follows:
a. Install auxiliary and hydraulic hoses (Items 2 and 3) to two (2)
hydraulic manifold blocks (Item 11). Torque swivel nuts on hoses to
50–58 ft-lbs.
b. Install auxiliary and front carriage tilt hydraulic tubes (Items 9 and
10) on manifold blocks. Make sure the tube is positioned so that the
longest portion of each tube will be close to bottom of the boom
section (Item 1). Torque swivel nut on tubes to 50–58 ft-lbs.
c. Place hoses through openings in bottom of outer boom section
(Item 1) and install hydraulic manifold blocks on outer section with
lockwashers (Item 12) and capscrews (Item 13). Torque capscrews
to 55 ft-lbs.

31200079 6-85
Boom and Transfer

d. Install a cushion clamp (Item 8) on each hydraulic tube as follows:

1). Install plastic cushion (Item 15) on hydraulic tube.
2). Slide left cushion clamp half (Item 14) to correct position in
channel on bottom of outer boom (Item 1).
3). Position tube with cushion next to left cushion half and slide
right cushion half (Item 16) into channel.
4). Secure two halves of clamp together with lock nut (Item 4).
Tighten lock nut until snug.
e. Secure hydraulic tubes to bottom of boom section with two (2) each
clamps (Item 7), lockwashers (Item 6), and nuts (Item 5). Torque
nuts to 96 in-lbs.

14
13
12
11
10
60 80

6
40
20

0
-20

9
7
8
4
5
3
1 2

MV0130

# Description # Description
1 Rod Nut 8 Elbow
2 Socket Setscrew 9 Hydraulic Tube
3 Extension Cylinder Rod Boss 10 Cushion Clamp
4 Middle (Rear) Boom Section 11 Extension Cylinder Base Mount
5 Boom Extension Cylinder 12 Shim
6 Capscrew 13 Shim
7 Flatwasher 14 Nut

Fig. 6-91: Extension Cylinder Installation

3. (Ref. Fig. 6-91) Install extension cylinder on outer boom section as
follows:
a. Using sling(s), crane, or other suitable means, position rod end of
cylinder (Item 5) in its proper location on the middle (rear) boom
section (Item 4).

6-86 31200079
Boom and Transfer

WARNING: To avoid personal and/or equipment damage, make sure the

cylinder is properly supported until it is completely installed.

b. Secure cylinder to outer boom section with hardware as follows.

Use two (2) each nuts (Item 14), flatwashers (Item 7), and
capscrews (Item 6) to secure extension cylinder base mount
(Item 11) to rear of outer boom section. Install as many shims
(Items 12 and 13) as necessary before installing the nuts. Torque
nuts to 680 ft-lbs.
c. Install two (2) hydraulic tubes (Item 9)on extension cylinder elbows
(Item 8). Torque swivel nuts on hydraulic tubes to 79–88 ft-lbs.
d. Install cushion clamp (Item 10) on each hydraulic tube as
described in Substep d under Step 2 on Page 68.
4. Apply EP lithium based grease to the inside top surfaces of outer boom
section (slide pad slide areas).
5. Turn outer boom section over and place it in upright position on work
stands.
9 10
View A

3.13" 6
(3-1/8")
11
7

3 4 8
8
60 80
40
20

3 -20
0

7
2
1 6
5

J1242
4

# Description # Description
1 Capscrew 7 Lower Chain
2 Lockwasher 8 Lock Nut
3 Chain Adjustment Rod 9 Lock Nut
4 Anchor Base 10 Lower Chain Anchor
5 Chain Adjustment Block 11 Shoulder Bolt
6 Shoulder Bolt

Fig. 6-92: Lower Chains on Outer Boom Section

6. (Ref. Fig. 6-92) Add lower chain to inside of outer boom section as
follows:
a. Install lower chain anchor (Item 10) on lower chain (Item 7) with
lock nut (Item 9) and shoulder bolt (Item 11). Torque lock nut to 108
in-lbs.

31200079 6-87
Boom and Transfer

b. Install chain adjustment block (Item 5) on other end of lower chain

with shoulder bolt (Item 6) and lock nut (Item 8). Torque lock nut to
108 in-lbs.
c. Position chain adjustment block tight against back of anchor base
(Item 4) at bottom of outer boom section as shown in View A.
d. Thread chain adjustment rod (Item 3) into block until specified
measurement is obtained.
e. Push adjustment rod fully into anchor base.
f. Lay chain flat inside of outer boom section. Attach a cord or wire to
end of chain for ease in handling after all four sections are
assembled.
7. Place middle (rear) boom section upside down on work stands.

2
1

3
4

J1234
# Description # Description
1 Lower Rear Slide Pad 3 Lockwasher
2 Shim 4 Button-Head Socket Capscrew

Fig. 6-93: Lower Rear Slide Pad Installation - Middle (Rear) Boom Section
8. (Ref. Fig. 6-93) After applying thread locking compound to the
capscrews, install two (2) lower, rear slide pads (Item 1) and shim(s)
(Item 2) to bottom of middle (rear) boom section with lockwashers
(Item 3) and capscrews (Item 4) according to drawing specifications.
Torque capscrews to 180 in-lbs.

6-88 31200079
Boom and Transfer

10
1 2

5
3

9
8
11
6 7

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. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections

9. (Ref. Fig. 6-94) Install hydraulic tubes and hoses on middle (rear)
boom section as follows:
a. Install auxiliary and front carriage tilt hydraulic tubes (Items 5 and
6) on hydraulic manifold blocks (Item 11). Make sure the tube is
positioned so that the longest portion of each tube will be close to
bottom of the boom section (Item 3). Torque swivel nut on tubes to
50–58 ft-lbs.
b. Install two (2) manifold block on middle (rear) boom section with
four (4) lockwashers (Item 12) and capscrews (Item 4). Torque
capscrews to 55 ft-lbs.
c. Install cushion clamp (Item 10) on each hydraulic tube and secured
in mounting channel as described in Substep d under Step 2 on
page 6-85.
d. Securing hydraulic tubes to bottom of boom section with two (2)
each clamps (Item 9), lockwashers (Item 8), and nuts (Item 7).
Torque nuts to 96 in-lbs.
e. Install auxiliary and hydraulic hoses (Items 1 and 2) to hydraulic
manifold blocks. Torque swivel nuts on hoses to 50–58 ft-lbs.

31200079 6-89
Boom and Transfer

4
3 5
6
7 9
8
2 10
11

12 9
10
4
7 5
1 6
1
2
8
3

13
14
15

J1238
# 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 15 Grease Fitting Cover
8 Left Hand Hose Guide

Fig. 6-95: Chain and Hose Guide Assembly

10. (Ref. Fig. 6-95) Install chain and hose guide assembly on rear of
middle (rear) boom section as follows:
a. Install two (2) roller bushings (Item 1) inside chain and hose roller
(Item 12) — one in each end.
b. Install hardened bushing (Item 11) and two (2) chain roller washers
(Item 10) on the chain and hose roller.
c. Install two (2) each left hand hose guides (Item 8), plastic bushings
(Item 7), hose spacers (Item 6), washers (Item 2), and right hand
hose guides (Item 4) on chain and hose roller.
d. Install two hose guide spacers (Item 5) between left and right hand
hose guides with two (2) lock nuts (Item 9) and capscrews (Item 3).
Torque the lock nuts to 180 in-lbs.
e. Install chain and hose roller assembly on rear of boom section with
chain and hose roller shaft (Item 13).
f. Install two (2) grease fittings (Item 14) and grease fittings covers
(Item 15) on chain and hose roller shaft.

6-90 31200079
Boom and Transfer

11. Turn middle (rear) boom section over to upright position on work
stands.

3.13"
(3-1/8") 3 7

View A

8
7
3
1
4
6

J1250
5
2

# 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. 6-96: Installation of Lower Chain – Middle (Rear) Boom Section

12. Install lower chain on bottom of middle (rear) boom section as follows:
a. Install chain adjustment block (Item 5) on lower chain with shoulder
bolt (Item 6) and lock nut (Item 7). Torque lock nut to 108 in-lbs.
b. Position chain adjustment block tight against back of anchor base
(Item 4) at bottom of middle (rear) boom section as shown in View
A.
c. Thread chain adjustment rod (Item 3) into block until specified
measurement is obtained.
d. Push adjustment rod fully into anchor base.
e. Lay chain flat inside of middle (rear) section. Attach a cord or wire
to end of chain for ease in handling after all four sections are
assembled.

31200079 6-91
Boom and Transfer

1 2
3
4
3
2
1

5 6

7
8
9

J1254
10

# 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. (Ref. Fig. 6-97) Install upper chain roller assembly on middle (rear)
boom section as follows:
a. Install two (2) chain roller bushings (Item 2) into chain roller
(Item 4).
b. Install two (2) hardened bushings (Item 3) on chain roller.
c. Install bushings and chain roller and two (2) chain guide washers
(Item 1) on front of middle (forward) boom section with chain roller
pin (Item 10).
d. Secure chain roller pin with lock pin (Item 7), lockwasher (Item 8),
and capscrew (Item 9). Torque capscrew to 110 ft-lbs.
e. Install grease fitting (Item 6) and grease fitting cover (Item 5) on
chain roller pin. Tighten the grease fitting 2–3 turns past finger
tight.
14. Lift and slide middle (rear) boom section into outer boom section.
Release strap securing extension cylinder to outer boom section and
install cylinder end through orifice of middle (rear) section.
15. Apply EP lithium based grease to the inside bottom surfaces of middle
(rear) boom section (slide pad slide areas).
16. Place middle (forward) boom section on work stands upside down.

6-92 31200079
Boom and Transfer

7
8
9
1 10
2 7
7
8
9 4
10 5
7 6

3
1 2

4
5
6

J1243
3
# 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. (Ref. Fig. 6-98) Install chain roller assemblies on middle (forward)
boom section as follows:
a. Install chain roller bushing (Item 10) in chain roller (Item 9).
b. Install chain roller in bushing (Item 8).
c. Install chain roller and two (2) chain guide washers (Item 7) on
front of boom section with chain roller pin (Item 3).
d. Secure the chain roller pin to the boom section with lock pin
(Item 4), lockwasher (Item 5), and capscrew (Item 6). Torque the
capscrew to 110 ft-lbs.
e. Install grease fitting (Item 2) and grease fitting cover (Item 1) on
chain roller pin. Tighten grease fitting 2–3 turns past finger tight.
f. Repeat the preceding steps to install chain roller assembly to the
rear of the boom section.
g. Install upper chain anchor (Item 3) on upper chains (Item 1) with
chain anchor rod (Item 6) and two (2) lock nuts (Item 2). Torque
lock nuts to 108 in-lbs.
h. Install upper chain anchor to rear of boom section with lockwasher
(Item 5) and capscrew (Item 4). Make sure the hole in the anchor
(where the anchor rod was installed) is positioned toward the front
of the boom. Torque capscrew to 280 ft-lbs.
i. Lay upper chain on top of middle (forward) boom section.

31200079 6-93
Boom and Transfer

11
12
14
15

16
17
1

2 13

12
4
5 11
6
10
3 8
9
7
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 17 Rear Bottom Slide Pad
9 Button-Head Socket Capscrew

Fig. 6-99: Slide Pad Installation – Middle (Forward) Boom Section

Note: Apply thread locking compound to all slide pad mounting capscrews before
installing them.
18. (Ref. Fig. 6-99) Install shim pads on middle (forward) boom section as
follows:
a. Install bottom slide pad (Item 17) and shim(s) (Item 16) to rear of
boom section with two (2) lockwashers (Item 15) and capscrews
(Item 14) according to drawing specifications. Torque capscrews to
180 in-lbs.
b. Install two (2) side slide pads (Item 7) and shim(s) (Item 8) to rear
of boom section with two (2) each lockwashers (Item 12) and
capscrews (Item 11) according to drawing specifications. Torque
capscrews to 180 in-lbs.
19. (Ref. Fig. 6-99) Install bottom slide pads and shims on front of boom
section as follows:

6-94 31200079
Boom and Transfer

a. Install two (2) bottom slide pads (Item 1) and shims (Item 2) to front
of boom section with four (4) each lockwashers (Item 10) and
capscrews (Item 9) according to drawing specifications. Torque
capscrews to 180 in-lbs.
b. Install two (2) pad retainers (Item 3) on front of boom section with
flatwashers (Item 4), lockwashers, (Item 5) and capscrews
(Item 6). Torque capscrews to 200 ft-lbs.
c. Install two (2) side slide pads (Item 7) and shims (Item 8) on front
of boom section with four (4) each lockwashers (Item 12) and
capscrews (Item 11). Torque capscrews to 180 in-lbs.
20. Apply EP lithium based grease to the inside top surfaces of middle
(forward) boom section (slide pad slide areas).
21. Turn middle (forward) boom section over to upright position on work
stands.
22. Place inner boom section upside down on work stands.
6

3
5

J1246
1

# 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. 6-100: Hydraulic Hose and Tube Installation – Inner Boom Section
23. (Ref. Fig. 6-100) Install auxiliary and front carriage tilt cylinder
hydraulic hoses and tubes as follows:
a. Connect hydraulic hoses (Item 1) to carriage tilt hydraulic tubes
(Item 4). Torque swivel nuts on hydraulic tubes to 50–58 ft-lbs.
b. Connect hydraulic hoses (Item 2) to auxiliary hydraulic tubes
(Item 5). Torque swivel nuts on hydraulic tubes to 50–58 ft-lbs.

31200079 6-95
Boom and Transfer

c. Install auxiliary and front carriage tilt hydraulic tubes on channels

(Item 6) in inside of inner boom section with cushion clamps
(Item 3) as described in Substep d under Step 2 on page 6-68.
24. Install front carriage tilt cylinder in inner boom (See page 6-20).
25. Install auxiliary hydraulic quick disconnects
3

4
3

J1247
# Description # Description
1 Lower Slide Pad 3 Lockwasher
2 Side Slide Pad 4 Button-Head Socket Capscrew

Fig. 6-101: Slide Pad Installation – Inner Boom Section

26. (Ref. Fig. 6-101) After applying thread locking compound to the
capscrews, install two (2) lower and two (2) side slide pads (Items 1
and 2) on inner boom section according to drawing specifications with
lockwashers (Item 3) and capscrews (Item 4). Torque capscrews to
180 in-lbs.

6
1
5
4

2
J1235

# Description # Description
1 Grease Hose 4 Bulkhead Adapter
2 Inner Boom Section 5 Grease Fitting
3 Elbow 6 Grease Fitting Cover

Fig. 6-102: Grease Hose Installation

6-96 31200079
Boom and Transfer

27. (Ref. Fig. 6-102) Install grease hose assembly on rear of inner boom
section as follows:
a. Install two (2) elbows (Item 3) on inside of inner boom section
making sure elbows are in correct position for grease hose to be
connected.
b. Install two (2) bulkhead adapters (Item 4) on rear of inner boom
section (Item 2).
c. Connect two (2) grease hoses (Item 1) to bulkhead adapters.
Torque swivel nuts on grease hoses to 130–150 in-lbs.
d. Connect grease hoses to elbows. Torque swivel nuts on grease
hose to 130–150 in-lbs.
e. Install grease fittings (Item 5) and grease fitting covers (Item 6) on
bulkhead adapters (Item 2). Torque grease fittings 2–3 turns past
finger tight.
28. Turn inner boom section over and place it on work stands in upright
position.
7
6

5
4 4 8
2

1 9

J1248
# Description # Description
1 Chain Adjustment Anchor 6 Lockwasher
2 Lock Nut 7 Capscrew
3 Shoulder Bolt 8 Shoulder Bolt
4 Upper Chain 9 Rear Chain Anchor
5 Lock Nut

Fig. 6-103: Upper Chain Installation – Inner Boom Section

29. (Ref. Fig. 6-103) Install upper chain assembly on inner boom section
as follows:
a. Install rear chain anchor (Item 9) on inner boom section with two
(2) lockwashers (Item 6) and capscrews (Item 7). Torque
capscrews to 280 ft-lbs.
b. Install upper chain (Item 4) on chain anchor with shoulder bolt
(Item 8) and lock nut (Item 5). Torque lock nut to 108 in-lbs.
c. Install chain adjustment anchor (Item 1) on upper chain with
shoulder bolt (Item 3) and lock nut (Item 2). Torque lock nut to 108
in-lbs.

31200079 6-97
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.

3
4

J1245
# Description # Description
1 Button-Head Socket Capscrew 3 Shim
2 Lockwasher 4 Front Upper Slide Pad

Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom
Section
31. (Ref. Fig. 6-104) After applying thread locking compound to the
capscrews, install two (2) upper slide pads (Item 4) and shims (Item 3)
on front of middle (forward) boom section with lockwashers (Item 2)
and capscrews (Item 1) according to drawing specifications. Torque
capscrews to 180 in-lbs.
32. Lift middle (forward) and inner boom sections and slide them into
middle (rear) boom section.
3
2
4
5

6
2
1
7

8
9
10
J1244

6-98 31200079
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. (Ref. Fig. 6-105) Install upper chains and hose reel assembly on
middle (forward) boom section as follows:
a. Install two (2) hose reels (Item 7) to rear of boom section with hose
reel pins (Item 10). Secure each pin to boom section with
lockwasher (Item 9) and capscrew (Item 8). Torque capscrews to
216 in-lbs.

4 4
3 2 3
2
6 10 6
5 5
1 7
8
9
7
8

6
5
3 4

2
7
8 8
10
7
11 10
12

J1257
# Description # Description
1 Inner Boom Section 7 Lockwasher
2 Upper Slide Pad 8 Button-Head Socket Capscrew
3 Slide Pad Retainer 9 Middle (Forward) Boom Section
4 Flatwasher 10 Shim
5 Lockwasher 11 Middle (Rear) Boom Section
6 Capscrew 12 Side Slide Pad

Fig. 6-106: Rear Slide Pad Installation

34. (Ref. Fig. 6-106) After applying thread locking compound to the
capscrews, install remaining slide pads (Items 2 and 12) and shims
(Item 10) on rear of boom sections with lockwashers (Item 7) and
capscrews (Item 8). Torque slide pad capscrews to 180 in-lbs.

Note: See “Shimming Procedures” on page 6-48 for details in

determining the number of shims that will be required when
performing Steps 34 and 37.

31200079 6-99
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.

8
9
6 8
9
5
4 7
3 13
2
1
14
6
8
5 5 9
6 10
5 12
6 10
10
11
7 11 10 4 8
2 9
1
4
23 5 6
1
6
10

J1258
11
5
# Description # Description
1 Capscrew 8 Button-Head Socket Capscrew
2 Lockwasher 9 Lockwasher
3 Flatwasher 10 Lockwasher
4 Slide Pad Retainer 11 Capscrew
5 Shim 12 Capscrew
6 Slide Pad 13 Outer Boom Section
7 Retainer Block 14 Middle (Rear) Boom Section

Fig. 6-107: Front Slide Pad Installation – Outer and Middle (Rear) Boom
Sections
36. (Ref. Fig. 6-106) Install two (2) retainer blocks (Item 7) on front of outer
boom section (Item 13) with lockwashers (Item 10) and capscrews
(Items 11 and 12). Torque capscrews (Item 11) to 90 ft-lbs and
capscrew (Item 12) to 200 ft-lbs.
37. (Ref. Fig. 6-106) After applying thread locking compound to the
capscrews, install remaining slide pads (Item 6) and shims (Item 5) on
front of outer and middle (rear) boom sections with lockwashers
(Item 9) and capscrews (Item 8). Torque capscrews to 180 in-lbs.
38. (Ref. Fig. 6-106) Install remaining slide pad retainers (Item 4) with
flatwashers (Item 3), lockwashers (Item 2), and capscrews (Item 1).
Torque capscrews to 200 ft-lbs.

6-100 31200079
Boom and Transfer

1 2

J1255
# 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). Torque lock nut to 108 in-lbs.
2
3

1 4

J1256
# Description # Description
1 Lock Nut 4 Lower Chain
2 Capscrew 5 Shoulder Bolt
3 Lockwasher 6 Lower Chain Anchor

Fig. 6-109: Lower Chain Installation – Middle (Forward) Boom Section

40. Install lower chain assembly from inside outer boom section to middle
(front) boom section as follows:
a. Install lower chain anchor (Item 6) on lower chain (Item 4) with
shoulder bolt (Item 5) and lock nut (Item 1). Torque lock nut to 108
in-lbs.
b. Install lower chain anchor on rear of boom section with two (2)
lockwashers (Item 3) and capscrews (Item 2). Torque capscrews to
280 ft-lbs.

31200079 6-101
Boom and Transfer

4
3

2
1

60 80
40
5

20
0
-20

J1225
# 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. Bring upper chain lying on top of middle (front) boom section up
and around the upper chain roller assembly (Item 6) on the middle
(rear) boom section (Item 5).
b. Install jam nut (Item 2) on chain anchor (Item 1) and insert
threaded portion of chain anchor through opening in bracket at top
of outer boom section.
c. Secure chain anchor with lockwasher (Item 3) and nut (Item 4).
Torque anchor nut to 120 ft-lbs.

4
3

1 2
60 80
40
20

0
-20
J1223

6
5

6-102 31200079
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. Bring upper chain lying on top of inner boom section up and around
the upper chain roller assembly (Item 5) on the middle (forward)
boom section (Item 6).
b. Install jam nut (Item 2) on chain adjustment anchor (Item 1). Insert
threaded portion of chain adjustment anchor through opening in
bracket at top of middle (rear) boom section.
c. Secure chain anchor with lockwasher (Item 3) and nut (Item 4).
Torque nut to 374 ft-lbs.

2
1

60 80
40
20
0
2 -20

5
1 6
4
3
4

J1252
3

# Description # Description
1 Capscrew 4 Anchor Base
2 Lockwasher 5 Middle (Rear) Boom Section
3 Adjustment Rod 6 Outer Boom Section

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

31200079 6-103
Boom and Transfer

60 80
40
20
0
-20

J1253
2
1

# Description # Description
1 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). Torque rod nut to 733 ft-lbs. Secure rod nut with two (2)
setscrews (Item 2).

6-104 31200079
Boom and Transfer

4 6
5
13
3 7
14 15
8
12
1

11
10
16
2 9 17

18

J1227
60 80
40
20

0
-20

1 and 2 7 and 8 19
10 and 11
14 and 15

20

J1241
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
5 Lockwasher 15 Carriage Tilt Hydraulic Hose
6 Capscrew 16 Lockwasher
7 Auxiliary Tilt Hydraulic Hose 17 Nut
8 Carriage Tilt Hydraulic Hose 18 Outer Boom Section
9 Middle (Rear) Boom Section 19 Hose Reels
10 Auxiliary Hydraulic Tube 20 Hose Rollers

Fig. 6-114: Connecting Hoses Between Sections

45. (Ref. Fig. 6-114) Connect hydraulic hoses between boom sections as
follows:

31200079 6-105
Boom and Transfer

a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from
inside the middle (rear) boom section (Item 9) up and around the
two (2) hose reels (Item 19) at the rear of the middle (forward)
boom section (Item 3).
b. Connect the hydraulic hoses to the hydraulic tubes (Items 1 and 2)
at the rear of the inner boom section. Torque swivel nut on
hydraulic hoses to 50–58 ft-lbs.
c. Install hose guard (Item 4) on rear of inner boom section with two
(2) each lockwashers (Item 5) and capscrews (Item 6). Torque
capscrews to 280 ft-lbs.

CAUTION: Make sure hose guard is installed in the same orientation as it

was before being removed. The hose guard may be different
from that shown above. If hose guard is reversed, equipment
damage may occur during operation of machine.

d. Bring auxiliary and front carriage tilt hoses (Items 14 and 15) from
inside the outer boom section (Item 18) up and around the hose
rollers (Item 20) at the rear of the middle (rear) boom section.
e. Connect the hydraulic hoses to the hydraulic tubes (Items 10 and
11) at the rear of the middle (rear) boom section. Torque swivel nut
on hydraulic hoses to 50–58 ft-lbs.
46. Install assembled 4-section boom on machine as described on
page 6-62.

Boom Extend and Retract Chains

Boom Chain Inspection

WARNING: Worn pins, stretched or cracked links or cracked links or

corrosive enviroments can cause chain failure.A chain failure
could result in uncontrolled boom movement, loss of load or
machine instabiltity, and could cause death or serious injury
and/or property damage.

Under normal operating conditions the extend chains will need to be inspected
every 250 hours of operation. The retract chain will need to be exposed and
inspected every 1000 hours of operation. Environmental conditions and dynamic
impulse/shock loads can drastically affect normal operating conditions and require
more frequent inspection intervals.
a. Expose Extend Chains for Inspection
1. Park the machine on level ground. Place the travel select lever in (N)
NEUTRAL, engage the parking brake switch and raise the boom to a
horizontal (level) position.
2. Lower both outriggers completely
3. Fully extend the boom until both extend chains are taut. Shut the
engine OFF.

6-106 31200079
Boom and Transfer

The extend chains will be visible for inspection with the machine in this
state.
While doing the chain inspection, check all chain clevis ends for distortion
or cracking and sheaves for bearing wear or grooving from the chain.
If during the inspection, any chain is found to be damaged or stretched, the chain
must be replaced. It is recommended that when any chain is replaced, that all the
chains and clevis’ be replaced at the same time.

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain

with a new part. Always replace both the chain and the clevis. It is
recommended that when any chain is replaced, that all the chains and
clevis’ be replaced at the same time.
b. Expose Retract Chains for Inspection

Note: The three retract chains are only partially visible through the rear of the
boom with all the sections retracted. It is possible to see a section of the
retract chain as the boom is slowly extended. If there is ANY question that
one or all the retract chains are damaged, the boom should be removed
and disassembled with the retract chains being inspected and replaced if
necessary.
c. Removing Extend and Retract Chains for Inspection
The four extend chains and the three retract chains can only be removed
during a complete boom teardown.
While doing the chain inspection, check all chain clevis ends for distortion
or cracking and sheaves for bearing wear or grooving from the chain.
If during the inspection, any chain is found to be damaged or stretched, the
chain must be replaced. It is recommended that when any chain is
replaced, that all the chains and clevis’ be replaced at the same time.

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain

with a new part. Always replace both the chain and the clevis. It is
recommended that when any chain is replaced, that all chains and clevis’
be replaced at the same time.

Chain Lubrication
After inspection and before being returned to service, chains must be lubricated
with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or
equivalent).
The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to
the external surfaces will prevent rust, but the chains should be articulated to make
sure the lubricant penetrates to the working surfaces between the pins and links.
To prepare the chain for lubrication, the chain plates should be brushed with a stiff
brush or wire brush to clear the space between the plates so that the lubricant can
penetrate to the working surfaces.
Lubricant may be applied with a narrow paint brush or directly poured on, but the
chain should be well flooded with lubricant, and the boom should be extended and
retracted to be sure that the lubricant penetrates to the working surfaces. All
surplus lubricant should be wiped away from the external surfaces. DO NOT use a
solvent for this wiping operation.

31200079 6-107
Boom and Transfer

Regular application of lubricant is necessary to make sure that all working surfaces
are adequately lubricated. In extremely dusty conditions, it may be necessary to
lubricate the chains more often.
Lubrication of chains on vehicles working consistently in extreme hot or cold
conditions requires special consideration. It is important that a reputable
lubrication specialist, consult the local distributor or the JLG Service Department at
1-877-554-5438 or 1-717-485-6657, for guidance.

Boom Chain Tension Check

1. Make sure the carriage is attached to the gooseneck before doing the
tension check.
2. Start the engine. If necessary, attach carriage to gooseneck. Park the
vehicle on level ground. Place the travel select lever in (N) NEUTRAL,
place the neutral lock lever in the (N) NEUTRAL LOCK position,
engage the parking brake switch and raise the boom to a horizontal
(level) position.
3. Lower both outriggers completely.
4. Slowly, fully extend the boom and retract it about halfway. Fully extend
the boom again, then retract it 3" (51 mm) (one inch per section). Turn
the engine OFF.
5. Measure the sag in each of the three boom extend chains (1) between
the bottom of the extend chains and the top of the boom at their closest
point (2). Acceptable boom chain sag (3) is between 1.5" (38 mm) and
2.5" (64 mm). If the measurement is either less than, or greater than
the range given, the boom chains need to be adjusted.
6. Start the engine, retract the boom completely and turn the engine OFF.
Then look at the service oval window at the rear of boom.

1 2

MV0600

Fig. 6-115: Boom Tension Check

6-108 31200079
Boom and Transfer

7. Make sure the service ovals are lined up on the side rear of boom. If
not, adjust forward middle boom section first. Tighten the extend chain
to move the forward middle boom forward, or tighten the retract chain
to move the forward middle boom towards the rear. recheck chain
tension.
8. Then adjust the inner boom, retract the boom all the way and check the
clearance at the gooseneck. Adjust as needed

Note: If boom is too far to the rear, the gooseneck can hit the slide pad retainers.

Boom Hose Replacement

WARNING: Fall Hazard. Use extreme caution when checking items

beyond your normal reach. Use an approved ladder. Failure to
comply could result in death or serious injury.

1. Lower both outriggers completely.

2. Remove the cover from the rear of the outer boom.
3. Loosen the tube clamps at the front and rear of the inner boom.
4. Remove hoses from tubes. From the rear of the boom, pull the
disconnected hose ends off the hose sheaves and out the rear of the
boom.

WARNING: Escaping hydraulic fluid under pressure can penetrate the

skin causing death or serious injury. Relieve hydraulic
pressure before serving any hydraulic component.

5. Extend the boom to the letter “C” to gain access to remove hose
sheave pins through rear boom service access. Remove the hose
sheave pins left and right. Then remove the hose sheaves.

WARNING: DO NOT perform service or maintenance on the vehicle with

the engine running, with the exception of the transmission
level check. Contact with moving parts can cause death or
serious personal injury.

6. Connect new hoses to the old hoses at the rear of the boom.
7. Extend the boom until you can remove the first tube clamp on the rear
middle boom.
8. Remove bolts that secure the manifolds to the boom and remove
hoses from the manifolds. (For machines with 2nd aux. hydraulic lines,
you will have to remove the tubes from the manifold to remove the
hoses).
9. Pull the new hoses into the boom and secure the hoses and or the
tubes to the manifolds. Then reconnect the manifolds to the boom.
10. Reinstall the tube clamps to the rear middle boom and retract the
boom to position the hose sheave pins for reinstallation from the rear
service access.

31200079 6-109
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. tube and connect the outer hose on the hose sheave to the upper
outer tube.
12. At the front of the boom, pull the tubes forward until the ferrules of the
tubes butt up against the hose clamps at the rear of the inner boom. At
the front of the inner boom, install and secure tube stops against hose
clamp channel. At the rear of the inner boom align and secure the
upper tube clamps with the hoses on the hose sheaves. Secure tube
clamps at the front of the inner boom. Do not secure tube clamps at the
front of the inner boom. Do not secure tube clamps on 2 aux. units, see
step 12.
13. This is a change in the hose routing for 2nd aux. units only. Take the
hose that is connected to the tube marked 2 and transfer to the tube
marked 3, take the hose from tube 3 and connect it to the tube marked
2. Repeat the procedure for tubes 4 and 5.
14. Retract the boom. Disconnect outer hoses at rear of outer boom and
cap the left side hoses, to prevent the left side hoses from expelling
fluid when the boom is raised or lowered to access the rear tube/hose
hold down clamps.
15. Fully extend the transfer carriage and partially extend the boom.
Loosen and remove the forward most tube clamps on the outer boom.
Remove the fastening hardware securing the hydraulic manifold to the
front and bottom of the outer boom. Disconnect the hoses from the
manifold, and the tubes if necessary.
16. Remove the fastening hardware from the most rear tube/hose clamps
on the under side of the outer boom. Remove the hose hold down
clamp from the boom. Remove hoses from boom at the rear. Pull the
hose sleeve over the hose ends that connect to the tubes at the rear of
the outer boom, leaving 2” of the hose end exposed. Use the tie wraps
at 12” intervals to secure the hose sleeve. Keep the locking
mechanism of the tie wrap to the inside radius on the hoses.
17. Re-install the hoses. Connect the hoses to the hydraulic manifold at
the front of the outer boom. Secure the manifold to the boom. Connect
the tubes to the manifold. Fasten the forward most tube holder to the
boom. Install the hose hold down clamp into the outer boom. Put the
white plastic bushing p/n 11001518 onto the hose hold down clamp.
Attach and secure the tube holder to the hose hold clamp, avoid over-
tightening as this could crush the hoses. Reconnect the hoses to the
tubes at the rear of the outer boom. Be careful not to twist the hoses
while tightening.

6-110 31200079
Boom and Transfer

Extension Cylinder

4-Section Boom

Description

60 80
40
20
0
-20

J1137
Fig. 6-116: 4-Section Boom Extension Cylinder
The 4-section boom extension cylinder is located beneath the boom
assembly. It is attached from the middle (rear) to the outer boom section.
Its operating pressure is 3000 psi and weighs 650 pounds. When
completely retracted, it is 149-3/4" long. When fully extended, it is 280-3/4"
long.

31200079 6-111
Boom and Transfer

Removal, Extension Cylinder

12 13 14
11

60 80
40
20
0
-20

6 10
8 9
4 7

1 2 3
15
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
7 Capscrew 15 Lead Ball
8 Flatwasher

Fig. 6-117: 4-Section Boom Extension Cylinder Installation

(Ref. Fig. 6-117) The following steps are required to remove the boom
extension cylinder.
1. Follow preparation procedures as outlined in Section 3 and “General
Hydraulic Maintenance Practices” on page 5-3 of this manual.
2. Disconnect any attachments and raise the boom enough so that
access to the rear of the extension cylinder is possible. Apply the park
brake, retract the cylinder, and shut the engine off.
3. Support the boom and extension cylinder with sling(s) and crane or
other suitable means. Make sure support items have sufficient capacity
to support the weight of the boom and cylinder; the combined weight of
the boom and extension cylinder is approximately 6650 pounds.

6-112 31200079
Boom and Transfer

DANGER: Support of the boom is essential to avoid the possibility of

injury or death should the boom fall. To avoid personal and/or
equipment damage, support the hydraulic cylinder before
removing any additional hardware securing cylinder to the
boom. Use suitable blocking and lifting devices when
removing heavy machine components.

4. Loosen and remove two (2) hydraulic tubes (Item 10) from elbows
(Item 9) on boom extension cylinder (Item 5). Bleed any remaining oil
into a suitable container. Cap fittings and tubes.
5. Loosen two (2) socket setscrews (Item 2) in rod nut (Item 1).
6. Loosen and remove rod nut and rod boss (Item 3) securing boom
extension cylinder to front of middle (rear) boom section (Item 4).
7. Loosen and remove hardware securing extension cylinder to outer
boom section (Item 6) as follows.
Remove two (2) each nuts (Item 14), capscrews (Item 7), and
flatwashers (Item 8) securing extension cylinder base mount (Item 11)
to outer boom section. Also, remove the shim(s) (Items 12 and 13).
8. Slowly remove the cylinder from the machine and take it to a location
suitable for inspection and disassembly.
9. Clean remaining parts with solvent and dry with compressed air.
Inspect for damage and replace as necessary.

Installation, Extension Cylinder

The following steps are required to install the boom extension cylinder
(Ref. Fig. 6-117).
1. Using sling(s), crane, or other suitable means, position rod end of
cylinder (Item 5) in its proper location on the middle (rear) boom
section (Item 4).

WARNING: To avoid personal and/or equipment damage, make sure the

cylinder is properly supported until it is completely installed.

2. Secure cylinder to middle (rear) boom section with rod boss (Item 3)
and rod nut (Item 1).
3. Secure cylinder to outer boom section with hardware as follows.
Use two (2) each nuts (Item 14), flatwashers (Item 8), and capscrews
(Item 7). Install as many shims (Items 12 and 13) as necessary before
installing the nuts. Torque nuts to 680 ft-lbs.
4. Torque rod nut to 733 ft-lbs.
5. If socket setscrews (Item 2) were removed, install them in rod nut.
6. Reconnect two (2) hydraulic tubes (Item 10) to elbows on extension
cylinder. Torque tube swivel nuts to 79–88 ft-lbs.

31200079 6-113
Boom and Transfer

Overhaul, Extension Cylinder

7 8

6 9
4

5
3 4
12

2 13
1

11
14
10 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
7 90° O-ring Elbow 14 Tube

Fig. 6-118: 4-Section Boom Extension Cylinder Assembly

(Ref. Fig. 6-118) The following steps are required to overhaul the boom
extension cylinder.
1. Remove base mount from the cylinder barrel as follows:
Remove two (2) each capscrews (Item 1) and flatwashers (Item 2)
along with the extension cylinder base mount (Item 3) from the cylinder
barrel (Item 8).
2. 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.
3. Release pressure in counterbalance valve cartridges (Items 5 and 6)
as follows:

WARNING: Counterbalance valve cartridges trap hydraulic pressure in the

cylinder. Wear proper eye and hand protection when removing
counterbalance valve cartridges. Hydraulic fluid under
pressure can be injected under skin or into eyes, resulting in
serious personal injury or death.

6-114 31200079
Boom and Transfer

a. Place socket wrench over counterbalance valve cartridge. Wrap a

clean shop rag around the socket to cover the area of the
counterbalance valve cartridge.
b. Carefully and slowly, turn cartridge out of manifold block to release
pressure in cylinder.
4. Remove the counterbalance valve cartridges.
5. Slowly extend and retract cylinder by hand to remove most of the
hydraulic oil.
6. Remove one (1) setscrew (Item 12) securing rod bearing head
(Item 11) to cylinder barrel.
7. Remove cylinder rod (Item 13) from cylinder barrel.

CAUTION: To prevent possible damage to components, support rod and

head; do not wiggle rod or head back and forth during
removal.

8. Remove rod nut (Item 9), piston (Item 10), tube (Item 14) and rod
bearing head from cylinder rod.
9. Remove the two (2) elbows (Item 7) from cylinder barrel.
10. Remove four (4) O-ring plugs (Item 4) from cylinder manifold block.
11. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
12. Thoroughly clean components with solvent and dry with compressed
air. Inspect and replace if damaged.
13. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
14. Check condition of threads on rod, nut, and capscrews. Do not attempt
to repair damaged threads.
15. Inspect counterbalance valve cartridges (Items 5 and 6), including
O-rings, for condition and replace as necessary. Do not disassemble
cartridges. Service to counterbalance valve cartridges is limited to
installing new O-rings and replacing the entire cartridge.
16. Lubricate counterbalance valve cartridge O-rings with clean hydraulic
oil.
17. Install valve cartridge (Item 5) in manifold block.
18. Install valve cartridge (Item 6) in manifold block.
19. Install four O-ring plugs (Item 4) in manifold block.
20. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
21. Lubricate new seal and wear rings with hydraulic oil and install on
piston.

31200079 6-115
Boom and Transfer

22. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on head. Using a seal driver, install new wiper seal in
head. Lubricate wiper seal with hydraulic oil.
23. Slide rod bearing head (Item 11), tube (Item 14) and piston (Item 10)
onto rod (Item 13). Lubricate threads on rod with hydraulic oil and
install rod nut (Item 9). Torque rod nut to 1460 ft-lbs.
24. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (Item 12). Coat inside of barrel (Item 8) with hydraulic oil. To
avoid damaging seals during assembly, carefully insert rod and head
into barrel.
25. Install two (2) elbows (Item 7) on cylinder barrel.
26. Install the extension cylinder base mount (Item 3) to the cylinder barrel.
27. Install with two (2) each flatwashers (Item 2) and capscrews (Item 1).

6-116 31200079
Boom and Transfer

Boom Extension Proximity Switch

Description

Proximity Switch

J1146
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. The
system will disable the boom extend and transfer extend functions and the
60 80

warning lamp will come on when the boom is extended to specified

40
20

0
distance (approximately 21 feet with tilting tower or 25 feet with standard
carriage). The proximity switch then opens as it no longer senses metal. At
this point, the left and right outriggers must both be lowered to the ground
to allow the boom or transfer carriage to be extended any further.
Normally-open differential pressure switches in the outrigger cylinders
close when the base end pressure exceeds the rod end pressure by
approximately 90–95 psi. When both pressure switches close, this
completes the circuit, allowing the boom and transfer carriage to be
extended, and the lamp turns off. The system is fail-safe in that it requires
an electrical signal to enable the boom to be extended beyond the
specified distance.

31200079 6-117
Boom and Transfer

Outer Boom Section Middle Rear)

Magnetic Boom Section
Flux Lines

Proximity Switch Oscillator

J1259
Fig. 6-120: Boom Extension Proximity Switch Operation
(Ref. Fig. 6-120) The switch operates by sending out a constant, high
frequency magnetic field a short distance from the oscillator end of the
switch. Eddy currents are produced in metal when the magnetic flux lines
pass through it. These eddy currents oppose the oscillations of the
magnetic flux lines and the oscillations stop. A sensor in the switch detects
if the oscillator is on or off and this gives the switch its on/off function.

Removal

Boom Extension
Proximity Switch

2
3
4
60 80

1
40

J1145
20

# Description # Description
1 Inner Jam Nut 3 Outer Jam Nut
2 Proximity Switch 4 Wire Harness

Fig. 6-121: Boom Extension Proximity Switch Assembly

6-118 31200079
Boom and Transfer

(Ref. Fig. 6-121) The following procedure describes removal of the boom
extension proximity switch.
1. Disconnect wire harness (Item 4) at boom extension proximity switch
(Item 2).
2. Place a piece of masking tape around proximity switch body at the
outer jam nut (Item 3) (this will serve as a guide during reinstallation).
3. Remove inner jam nut (Item 1) and proximity switch. Reinstall inner
jam nut on proximity switch for safekeeping.

Installation

Boom Extension (Ref. Fig. 6-121) The following procedure describes installation of the
Proximity Switch boom extension proximity switch.
1. Position outer jam nut (Item 3) on switch body (Item 2) at previously
marked position.
2. Install boom extension proximity switch in outer boom. Install inner jam
nut (Item 1). Check gap between end of proximity switch and boom.
See Fig. 6-122.
3. Connect wire harness (Item 4) to proximity switch.
4. Check operation of proximity switch by extending the boom. The boom
extension proximity light must come on at specified distance
(approximately 21 feet with tilting tower or 25 feet with standard
carriage). If the light does not illuminate, stop and retract boom.
Proceed to “Adjustments” below.

Adjustments

Boom Extension
Proximity Switch

Outer Boom Section Middle Rear

Boom Section
0.19" to
Proximity Switch 0.25" Gap

Outer Jam Nut Inner Jam

Nut
J1262

Fig. 6-122: Boom Extension Proximity Switch Adjustment

(Ref. Fig. 6-122) The following procedure describes adjustments to the
boom extension proximity switch.

31200079 6-119
Boom and Transfer

1. Loosen, but do not remove the two (2) jam nuts on the proximity switch
body.
2. Check gap between switch and boom. Gap must be within the range
specified in Fig. 6-122.
3. If boom extension proximity light does not illuminate when boom is
extended to specified distance (approximately 21 feet with tilting tower
or 25 feet with standard carriage), adjust proximity switch to slightly
reduce the gap. Do not exceed gap tolerances specified in Fig. 6-122.
Snug jam nuts to hold switch in position.
4. Extend boom and check operation of boom extension proximity light.
The light must come on when boom is extended to specified distance
(approximately 21 feet with tilting tower or 25 feet with standard
carriage). If light does not illuminate, stop and retract boom. Repeat
Step 3.
5. Tighten jam nuts.

Transfer Carriage

Description
60 80
40
20

0
-20
J1141

Fig. 6-123: Transfer Carriage

6-120 31200079
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.

Removal

Transfer Carriage The following steps are required to remove the transfer carriage.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Lower the boom to the ground, apply the park brake, retract the
transfer cylinder, and stop the engine.

Washer

Setscrew

Lead Ball

Rod Nut

Fig. 6-124: Disconnecting Transfer Cylinder from Transfer Carriage

3. (Ref. Fig. 6-124) Loosen two (2) socket setscrews in rod nut securing
transfer cylinder to the transfer carriage.
4. (Ref. Fig. 6-124) Remove transfer cylinder rod nut and washer.
5. Move transfer carriage forward enough so that the threaded port of
transfer cylinder rod comes clear from its mounting hole. Block and
secure the transfer cylinder to the main frame.

31200079 6-121
Boom and Transfer

Proximity
Switch

Connection
Wire

Wiring Harness

J1149
Fig. 6-125: Boom Elevation Proximity Switch Wiring
6. (Ref. Fig. 6-125) Remove boom elevation proximity switch as follows:
a. Disconnect connection wire from boom proximity switch.
b. Disconnect connection wire from wiring harness.
c. Remove all wire ties that secure the wiring harness to hydraulic
tubes and hoses so that it is completely separated from the transfer
carriage.
3-Section Boom 4-Section Boom
1 3 3 1
2 4 2

J1169

# Description # Description
1 Lockwasher 3 Nut
2 Flatwasher 4 Boom Cover

Fig. 6-126: Boom Cover Installation

7. (Ref. Fig. 6-126) Remove the boom cover on models with 3-section
booms (see Step a) or 4-section booms (see Step b).
a. Remove four (4) each nuts (Item 3), lockwashers (Item 1), and
flatwashers (Item 2) securing boom cover (Item 4) to boom.
Remove boom cover.

6-122 31200079
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.
3 4
2 3
1 2
1

5
4
3
2
1

8
9
7 10

J1147
# Description # Description
1 JClamp 6 Proximity Switch Connection Wire
60 80
40

2 Flatwasher 7 Proximity Mounting Plate

20

3 Lockwasher 8 Boom Extension Proximity Switch

4 Nut 9 Lockwasher
5 Proximity Switch Wiring Harness 10 Capscrew

Fig. 6-127: Boom Extension Proximity Switch Wiring

8. (Ref. Fig. 6-127) For models with a 4-section boom, remove the boom
extension proximity switch as follows:
a. Remove the 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) that secure the boom
extension proximity switch wiring to the boom.
b. Disconnect the proximity switch connection wire (Item 6) from the
proximity switch (Item 8) and the wiring harness (Item 5).
c. Remove all wire ties that secure the wiring harness to hydraulic
tubes and hoses so that it is completely separated from the transfer
carriage.

31200079 6-123
Boom and Transfer

3
4

J1142
# 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. (Ref. Fig. 6-128) Disconnect hydraulic hoses (Item 1) from the
hydraulic tube elbows.
11. If the boom and transfer carriage are being removed as an assembly,
go to Step 12. If the boom is being removed separately from the
transfer carriage, go to Step 13.

6-124 31200079
Boom and Transfer

8 9
10
11
12
6

7
5

4
3
60 80
40
20

-20
0
1

J1153
2

# 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. (Ref. Fig. 6-129) The following steps are necessary if the boom and
transfer carriage are to be removed as an assembly.
a. Use sling(s), crane, or other suitable means to support the boom
and transfer carriage assembly. It will be necessary to fully secure
the transfer carriage securely to the boom before removal.

WARNING: To avoid personal and/or equipment damage, supporting the

boom and transfer carriage is essential before removing any
additional mounting hardware. Use suitable blocking and
lifting devices when removing heavy machine components.

b. Remove the four (4) each nuts (Item 1) and lockwashers (Item 2)
securing the front slide blocks (Item 4) to the transfer carriage
(Item 5). Remove the four (4) capscrews (Item 3) and the two (2)
slide blocks.
c. Loosen the two (2) setscrews (Item 6) in each spindle nut (Item 7).
d. Remove the two (2) each spindle nuts, spacer washers (Item 8),
thrust washers (Item 9), spindles (Item 10), roller bushings
(Item 11), and transfer rollers (Item 12) from the rear transfer
carriage mount.

Note: The quantity of spacer washers used with each machine may vary.

31200079 6-125
Boom and Transfer

e. Slowly lift the boom and transfer carriage assembly up and away
from the machine. Place the assembly on support blocks on a firm
level surface.

8
9
10
11
12
6

7
5

4
3

J1154
1
2
# 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. 6-130: Transfer Carriage Installation

13. The following steps are required if the boom is being removed
separately from the transfer carriage.
a. Remove the boom hoist cylinder (See page 6-13).
b. Remove the rear carriage tilt cylinder (See page 6-25).
c. Remove the boom (see this section).
d. Use sling(s), crane, or other suitable means to support the transfer
carriage assembly.

WARNING: To avoid personal and/or equipment damage, support the

transfer carriage assembly before removing any additional
mounting hardware. Use suitable blocking and lifting devices
when removing heavy machine components.

e. (Ref. Fig. 6-130) Remove the four (4) each nuts (Item 1) and
lockwashers (Item 2) securing the two (2) front slide blocks (Item 4)
to the transfer carriage (Item 5). Remove the four (4) capscrews
(Item 3) and the slide blocks.
f. (Ref. Fig. 6-130) Loosen the two (2) setscrews (Item 6) in each
spindle nut (Item 7).

6-126 31200079
Boom and Transfer

g. (Ref. Fig. 6-130) Remove the two (2) spindle nuts. Remove spacer
washer (Item 8), thrust washer (Item 9), spindle (Item 10), roller
bushing (Item 11), and transfer roller (Item 12) from each side of
the rear transfer carriage mount.

Note: The quantity of spacer washers used with each machine may vary.
h. Slowly lift the transfer carriage assembly up and away from the
machine. Place the assembly on support blocks on a firm level
surface.

Installation

Transfer Carriage The following steps are required to install the transfer carriage.
1. If the boom and transfer carriage were removed as an assembly, go to
Step 2. If the boom was removed separately from the transfer carriage,
go to Step 3.
2. (Ref. Fig. 6-129) The following steps are necessary to reinstall the
boom and transfer carriage assembly.
a. Using sling(s), crane, or other suitable means of support, slowly lift
the boom and transfer carriage assembly up and unto its proper
position on the machine.

WARNING: To avoid personal and/or equipment damage, supporting the

boom and transfer carriage assembly is essential when lifting
and reinstalling it back on the machine. Make sure that the
boom and transfer carriage assembly is supported until it is
completely installed.

b. Install the transfer carriage (Item 5) to rear of the main frame using
the two (2) 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). Torque spindle nuts to 3466 ft-
lbs.

Note: The quantity of spacer washers used with each machine may vary.
c. Secure each spindle nut with two (2) setscrews (Item 6).
d. Install the two (2) slide blocks (Item 4) to the front of the transfer
carriage with four (4) each capscrews, (Item 3) lockwashers
(Item 2), and nuts (Item 1). Torque the nuts to 130 ft-lbs.
3. (Ref. Fig. 6-130) The following steps are necessary to reinstall the
transfer carriage assembly.
a. Using sling(s), crane, or other suitable means of support, slowly lift
the transfer carriage assembly up and unto its proper position on
the machine.

31200079 6-127
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). Torque spindle nuts to
3466 ft-lbs.

Note: The quantity of spacer washers used with each machine may vary.
c. Secure each spindle nut with two (2) setscrews (Item 6).
d. Install the two (2) slide blocks (Item 4) to the front of the transfer
carriage with four (4) each capscrews, (Item 3) lockwashers
(Item 2), and nuts (Item 1). Torque the nuts to 130 ft-lbs.
e. Install the boom as described elsewhere in this section.
f. Install the rear carriage tilt cylinder (See page 6-26).
g. Install the boom hoist cylinder (See page 6-14).
4. Move transfer carriage backward until the threaded port of transfer
cylinder rod can be inserted in its mounting hole.
5. (Ref. Fig. 6-124) Install transfer cylinder rod nut and washer. Torque
cylinder rod nut to 1641 ft-lbs. Secure rod nut with two (2) setscrews.
6. (Ref. Fig. 6-128) Reconnect hydraulic hoses (Item 1) to the hydraulic
tube elbows. Torque the swivel nuts on the hoses 79–88 ft-lbs.
7. (Ref. Fig. 6-128) Install the hose cover (Item 2) on the transfer carriage
with four (4) each capscrews (Item 4) and lockwashers (Item 3).
Torque the capscrews to 75 in-lbs.
8. (Ref. Fig. 6-125) Install boom elevation proximity switch as follows:
a. Work the wiring harness along the hydraulic tubes on the transfer
carriage.
b. Reconnect connection wire to boom proximity switch and wiring
harness.
c. Secure wiring harness to hydraulic tubes with wire ties.
9. (Ref. Fig. 6-127) For models with a 4-section boom, install the boom
extension proximity switch as follows:
a. If necessary, install the proximity mounting plate (Item 7) with two
(2) each lockwashers (Item 9) and capscrews (Item 10). Torque the
capscrews to 276 in-lbs.
b. Work the wiring harness along the hydraulic tube s on the transfer
carriage and up to the top of the boom.
c. Connect the proximity switch connection wire (Item 6) to the
proximity switch (Item 8) and the wiring harness (Item 5).

6-128 31200079
Boom and Transfer

d. Secure the wiring harness and switch connection wire to the boom
with six (6) each (five on top of the boom and one inside of the
back left side of the boom) nuts (Item 4), lockwashers, (Item 3),
flatwashers (Item 2), and J-clamps (Item 1). Tighten nuts until
snug.
e. Secure the wire harness to the hydraulic tubes and hoses with wire
tires.
10. (Ref. Fig. 6-126) Install the boom cover on models with 3-section (see
Step a) or 4-section booms (see Step b).
a. Install boom cover (Item 4) on boom and secure it with four (4)
each flatwashers (Item 2), lockwashers (Item 1), and nuts (Item 3).
Torque nuts to 180 in-lbs.
b. Install boom cover (Item 4) on boom and secure it with six (6) each
flatwashers (Item 2), lockwashers (Item 1), and nuts (Item 3).
Torque nuts to 180 in-lbs.

Rollers, Bushings, and Shims

Transfer Carriage The following procedures describe replacement of transfer rollers and
bushings for the transfer carriage along with shimming procedures and
replacement of scraper plates.

Front Mount Rollers, Bushings, and Shims

1 2

3 7
4 5
6

10
8 9
11

J1144
12
13
14
# Description # Description
1 Capscrew 8 Capscrew
2 Front Roller Pin 9 Lockwasher
3 Lockwasher 10 Flatwasher
4 Lock Pin 11 Roller Spacer
5 Grease Fitting 12 Roller Shims
6 Grease Fitting Cover 13 Front Transfer Roller
7 Scraper Plate 14 Front Roller Bushing

Fig. 6-131: Transfer Carriage – Front Rollers, Bushings, and Shims

(Ref. Fig. 6-131) The following steps are required to replace the front
transfer rollers and bushings.

31200079 6-129
Boom and Transfer

1. Follow preparation procedures as outlined in Section 3 of this manual.

2. Lower the boom to the ground, apply the park brake, retract the
transfer cylinder, and stop the engine.
3. Remove capscrew (Item 1) and lockwasher (Item 3) securing the two
(2) lock pins (Item 4) to transfer carriage.

CAUTION: To avoid personal and/or equipment damage, support the

boom and transfer carriage before removing the transfer roller
assembly. Use suitable blocking and lifting devices to prevent
the transfer carriage from dropping.

4. Remove lock pins from front roller pins (Item 2).

5. Raise the boom and transfer carriage slightly to remove roller pins,
roller spacers (Item 11), roller shims (Item 12), transfer rollers
(Item 13), and roller bushings (Item 14).
6. Discard transfer rollers and bushings. Clean remaining parts with
solvent and dry with compressed air. Replace any damaged parts.
7. Install new bushings so that each is centered in each transfer roller.
8. Install transfer roller, roller shims, roller spacer, and roller pin on each
side of transfer carriage.
9. Secure roller pins with lock pins and secure lock pins to transfer
carriage with lockwashers and capscrews.

Transfer Roller
Distance Between Rails
1/16"

Roller Pin

Roller Spacer
Transfer Carriage
Roller Shim(s)
J1171

Rail

Fig. 6-132: Shims for Front Transfer Rollers

10. (Ref. Fig. 6-132) Check to see if correct number of shims are installed.
a. Locate the point that is the shortest distance between the two rails
(usually near the center of the rails).
b. Start the engine and slowly move the transfer carriage forward until
the front transfer rollers are at this point.

6-130 31200079
Boom and Transfer

c. Measure the gap between the lip of the transfer roller and the inner
edge of the rail. If this measurement is not 1/16", remove the
transfer roller assembly and install or remove shims until the
required measurement is reached.
11. Secure front transfer roller assembly to transfer carriage by tightening
capscrew (Item 1) to 55 ft-lbs.
12. Remove two (2) grease fitting cover caps (Item 6) and lubricate grease
fittings (Item 5) with EP lithium based grease.

Scraper Plate

(Ref. Fig. 6-131) The following steps are required to replace scraper
plates.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Lower the boom to the ground, apply the park brake, retract the
transfer cylinder, and stop the engine.
3. Remove two (2) each capscrews (Item 8), lockwashers (Item 9), and
flatwashers (Item 10) securing each of the two (2) scraper plates
(Item 7) to the front of the transfer carriage. Remove scraper plates.
Clean, inspect for damage, and replace as necessary.

Transfer Carriage

Scraper Plate
1/8"

Rail (Main Frame)

Front Slide Block

J1170

Fig. 6-133: Scraper Plate

4. Install each scraper plate with two (2) each flatwashers, lockwashers,
and capscrews. Make sure that the distance from the scraper plate to
the rail is as shown in Fig. 6-133. Torque capscrews to 156 in-lbs.

31200079 6-131
Boom and Transfer

Rear Mount Rollers, Bushings, and Spacer Washers

16 15
14

13
12
11
10

4
5
6
7
1 8
2 9

J1144
3

# 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 14 Boom Pivot Bushing
7 Spindle 15 Grease Fitting Cover
8 Rear Roller Bushing 16 Grease Fitting

Fig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims

(Ref. Fig. 6-134) The following steps are required to replace rear transfer
rollers and bushings.
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.

CAUTION: To avoid personal and/or equipment damage, support the

boom and transfer carriage before removing the transfer roller
assembly. Use suitable blocking and lifting devices to prevent
the transfer carriage from shifting.

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

6-132 31200079
Boom and Transfer

8. Secure spindle to transfer carriage with spindle nut.

Distance Between Rails

Transfer Roller

1/16"
Transfer
Carriage

Nut

Roller Spindle
Spacer Washer(s)

Thrust Washer

J1143
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.
a. Locate the point that is the shortest distance between the two rails
(usually near the center of the rails).
b. Move the transfer carriage forward until the rear transfer rollers are
at this point.
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 spacer washers until
the required measurement is reached.
10. Secure front transfer roller assembly to transfer carriage by tightening
spindle nut (Item 3) to3466 ft-lbs.
11. Remove two (2) grease fitting cover caps (Item 1) and lubricate grease
fittings (Item 2) with EP lithium based grease.

Transfer Carriage/Boom Pivot Bushings

(Ref. Fig. 6-134) The following steps are required to replace transfer
carriage/boom pivot bushings.
1. Remove boom and shims as in this section.
2. Remove two (2) boom pivot bushings (Item 14) using a bushing driver
and hammer. Discard bushings.

Note: It may be necessary to cut out the old bushing.

3. Install new bushings so that each is centered in transfer carriage boss.

Note: It may be necessary to freeze the new bushing before installing it.

31200079 6-133
Boom and Transfer

4. Reinstall boom and shims as described earlier in this section.

5. Remove two (2) grease fitting cover caps (Item 15) and lubricate
grease fittings (Item 16) with EP lithium based grease.

Rear Slide Block and Shims

(Ref. Fig. 6-134) The following steps are required to replace worn rear
slide blocks.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Lower the boom to the ground, apply the park brake, retract the
transfer cylinder, and stop the engine.
3. Remove two (2) each capscrews (Item 13) and lockwashers (Item 12)
securing each of the two rear slide blocks (Item 10) and shims
(Item 11) to the transfer carriage. Remove slide blocks and shims.
4. Discard worn slide block. Clean and inspect remaining parts; replace
as necessary.

Capscrew
Lockwasher

Less than 1/16"

Shims

Rear Slide Block

Rail and Main Frame

Transfer Roller Assembly

J1172
Fig. 6-136: Rear Slide Block Installation
5. (Ref. Fig. 6-136) Make sure that the correct number of shims will be
installed.
a. Check to see that the rear transfer roller is up against the bottom of
the rail. It may be necessary to start the engine and relocate the
weight of the boom until the transfer roller is snug against the rail.
b. Place slide block and shims on the rail beneath the transfer
carriage.
c. Measure the space between the stack to the transfer carriage. Add
or subtract shims until the remaining gap is less than 1/16".
6. Install new slide block and shims on each side of the transfer carriage
with two (2) each lockwashers and capscrews. Torque capscrews to 55
ft-lbs.

6-134 31200079
Boom and Transfer

31200079 6-135
Boom and Transfer

6-136 31200079
Section 7 — Frame Tilt and Oscillation

Table of Contents

Frame Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Frame Tilt Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Counterbalance Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Oscillation Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
General Description, Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Theory of Operation and Circuit Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Testing Rear Oscillation Lock Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Rear Oscillation Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Oscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Boom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

31200079 i
List of Figures

Fig. 7-1: Frame Tilt System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Fig. 7-2: Frame Tilt Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fig. 7-3: Frame Tilt Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Fig. 7-4: Frame Tilt Control Valve (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fig. 7-5: Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Fig. 7-6: Frame Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Fig. 7-7: Frame Tilt Cylinder (Exploded View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Fig. 7-9: Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Fig. 7-10: Leveling the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Fig. 7-11: Circuit Operation Below 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Fig. 7-12: Circuit Operation Above 40° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Fig. 7-13: Circuit Operation Above 20° Below 40°. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Fig. 7-14: Circuit Operation Above 20° Below 40° with Service Brake Applied. . . . . . . . . . . . . . . . . . . 7-21
Fig. 7-15: Circuit Operation Below 20° With the Service Brake Applied . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Fig. 7-16: Rear Oscillation Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Fig. 7-17: Rear Oscillation Lock Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Fig. 7-18: Rear Oscillation Lock Cylinder (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Fig. 7-19: Head Capscrew Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Fig. 7-20: Oscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Fig. 7-21: Oscillation Control Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Fig. 7-22: Oscillation Control Block (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Fig. 7-23: Boom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Fig. 7-24: Boom Elevation Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Fig. 7-25: Boom Elevation Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Fig. 7-26: Boom Elevation Proximity Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

List of Tables

Table 7-1: Rear Oscillation Lock Circuit Test Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

ii 31200079
31200079 iii
Section 7 — Frame Tilt and Oscillation

Frame Tilt System

General Description

Frame Tilt
Cylinder

Multi-Spool
Control Valve Frame Tilt
Control Valve

G1020
Fig. 7-1: Frame Tilt System Components
(Ref. Fig. 7-1) The frame tilt system allows the machine to be levelled
laterally (side-to-side) up to 10°, left or right. The lateral angle of the
machine, relative to level ground, is shown on the frame level indicator.
When hydraulic pressure is applied to the frame tilt cylinder the frame
pivots around each axle. Two counterbalance valves (one on the rod end
and one on the base end) are used to inhibit hydraulic fluid from exiting the
frame tilt cylinder.
Function is controlled by the frame tilt control valve (see page 7-3) located
in the operator’s compartment.

Circuit Description
Reference Fig. 7-1 above and Section 4-1, “Reference Diagrams”.

31200079 7-1
Frame Tilt and Oscillation

The frame tilt system works in combination with the rear oscillation lock
system. The frame tilt system is explained here. See “Rear Oscillation
Lock System” on page 7-17 for detailed information concerning that
system.

Control Centered

With the engine on and the boom below 40° elevation, the frame tilt system
is enabled. The frame tilt control valve (see page 7-3) is normally centered
and no pilot pressure is supplied to ports A6 or B6 of the frame tilt section
of the multi-spool control valve. In this condition, the spool in the frame tilt
section remains centered and no pressure is supplied to the frame tilt
cylinder.
Two (2) counterbalance valves on the frame tilt cylinder prevent fluid
escaping from the cylinder. This mechanically locks the cylinder in position
and prevents the frame from rotating on the front axle.

Control to Right

Moving the frame tilt control handle to the right allows pilot pressure to flow
from port #2 of the control valve. This pilot pressure is routed to port A6 of
the frame tilt section of the multi-spool control valve. The spool is shifted
away from port A6, allowing pump flow to be routed through port A to the
rod end of the frame tilt cylinder. Pressure is sufficient to pilot the
counterbalance valves open, allowing fluid to enter and leave the cylinder.
As the cylinder retracts, the frame tilts to the right and fluid from the base
end of the cylinder is routed through port B of the frame tilt section and on
to the filtered tank return.

Control to Left

Moving the frame tilt control handle to the left allows pilot pressure to flow
from port #1 of the control valve. This pilot flow is routed to port B6 of the
frame tilt section of the multi-spool control valve. The spool is shifted away
from port B6, allowing pump flow to be routed through port B to the base
end of the frame tilt cylinder. Pressure is sufficient to pilot the
counterbalance valves open, allowing fluid to enter and leave the cylinder.
As the cylinder extends, the frame tilts to the left and fluid from the rod end
of the cylinder is routed through port A of the frame tilt section and on to
the filtered tank return.

Frame Tilt Disabled

Under certain conditions the frame tilt system is disabled by the frame tilt
lockout valve. The lockout valve prevents or allows pilot flow to be routed to
ports A6 and B6 on the frame tilt section of the multi-spool valve. The

7-2 31200079
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

Frame Tilt
Control Valve

H1046
Fig. 7-2: Frame Tilt Control Valve

The frame tilt control lever is located immediately to the right of the driver’s
seat on the control panel. It is used to level the machine laterally (side-to-
side) up to 10°, left or right. The lateral angle of the machine, relative to
level ground, is shown on the frame level indicator (See “Frame Level
Indicator” on page 7-16). The control is functional only while the engine is
running.
The control lever is equipped with a safety lock to prevent unintentional
operation. Lifting the lock ring to unlock the lever allows it to be moved left
or right tilting the frame accordingly. Returning the control lever to center
position and releasing the lock ring secures the lever.
To level the frame, move the lever in the direction you want the ball in the
frame level indicator to move. Control is proportional: a small amount of
movement causes the frame to tilt slowly, while full movement of the
control causes faster frame movement.

31200079 7-3
Frame Tilt and Oscillation

Removal

Frame Tilt Control Valve 8

7
6

4
1
2 3

p p 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. Fig. 7-3) The following procedure describes removal of the frame tilt
control valve.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Remove six (6) screws (Item 2) and flatwashers (Item 1) securing
control panel (Item 3) to operator’s compartment. Lift up rear of control
panel to expose lower portion of frame tilt control valve (Item 5).
3. Tag and disconnect six (12) hydraulic hoses (Items 4 and 9) at frame
tilt control valve. Cap hoses and fittings.
4. Note Position of two (2) tee fittings (Item 8) on back side of valve body.
Remove fittings.
5. Remove two (6) capscrews (Item 7) and starwashers (Item 6) retaining
control valve to control panel.
6. Lift valve up to remove.

7-4 31200079
Frame Tilt and Oscillation

Installation

Frame Tilt Control Valve 1. (Ref. Fig. 7-3) Insert frame tilt control valve (Item 5) into control panel
(Item 3) with plugged ports on front of valve body facing forward.
2. Install two (6) starwashers (Item 6) and capscrews (Item 7) to secure
valve to control panel.
3. Install two (2) fittings (Item 8) into rear of valve body and position them
as previously noted. Torque fittings to 300–340 in-lbs (25–29 ft-lbs).
4. Install hydraulic hoses (Items 4 and 9) onto fittings. Torque nuts on 3/8”
hoses to 235–265 in-lbs (20–22 ft-lbs). Torque nuts on 1/4” hoses to
130–150 in-lbs.
5. Position control panel in operator’s compartment and secure with six
(6) flatwashers (Item 1) and screws (Item 2).
6. Start engine and raise boom slightly. Tilt frame fully left and right
several times to purge trapped air from frame tilt hydraulic system.
7. Level frame, and cycle remaining controls to purge air from those
control circuits. Lower boom to ground, and shut off engine. Inspect for
hydraulic leaks and repair as necessary.

31200079 7-5
Frame Tilt and Oscillation

Overhaul

Frame Tilt Control Valve

20

21

5 22

6
23
24
7
25

26
8
9
10
27

13 1 28
11 2
12
3 29

4
14 30
31

17 32
15 18 33
19
16
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
9 Metric Jam Nut 26 CirClip
10 Capscrew 27 Flange
11 Pivot Pin 28 Guide Assy
12 CirClip 29 Spring Pack
13 Flange 30 Spring
14 Guide Assy 31 O-Ring
15 Spring Pack 32 O-Ring
16 Spring 33 O-Ring
17 O-Ring

Fig. 7-4: Frame Tilt Control Valve (Exploded View)

7-6 31200079
Frame Tilt and Oscillation

(Ref. Fig. 7-4) The following procedures are for the disassembly, cleaning,
and assembly of the frame tilt control valve. Follow the guidelines for
cleanliness as stated in Section 3 of this manual.

Cleaning and Inspection, Frame Tilt Control Valve

1. Thoroughly clean all parts, except for the lever assembly, in clean
solvent and dry with compressed air. Do not immerse the lever
assembly in solvent. Solvent can become trapped in the assembly and
will be difficult to remove.
2. Pay particular attention to the porting in the valve body. Flush valve
body with clean solvent and use compressed air to dry.
3. Inspect each spool for scratches and damage. Scoring on the spool
may also indicate damage to the ported guides . If damage is evident,
replace with new parts. Check fit of spools in ported guides. The
spools must fit snugly with no sticking. A stuck spool can cause
unintentional operation of a hydraulic circuit. Excessive play or sticking
means that the spool and its ported guide must be replaced.
4. Check surface of each plunger and guide for wear and damage. Check
fit of plunger in guide to make sure no sticking occurs. Like the spools,
a stuck plunger can cause unintentional operation of a hydraulic circuit.
5. Inspect each spool cavity in the valve body for scratches.
6. Check condition of lever assembly, cam, pivot pin, springs, and flange .
Replace as necessary.
7. Replace O-rings and seals as necessary. Lubricate O-rings and seals
with clean hydraulic oil before installing them.

31200079 7-7
Frame Tilt and Oscillation

Frame Tilt Cylinder

Description

Frame Tilt
Cylinder

G1020
Fig. 7-5: Frame Tilt Cylinder
(Ref. Fig. 7-5) The frame tilt cylinder is located near the front of the
machine, on the right side. The cylinder is mounted vertically with the base
end secured to the frame and the rod end mounted to the front axle.
With the engine running, moving the frame tilt control valve handle (see
page 7-3) to the right causes the cylinder to retract and the frame tilts to
the right. Moving the tilt control handle to the left causes the cylinder to
extend and the frame will tilt to the left.
There are conditions during normal machine operation when the frame tilt
cylinder cannot be actuated. See “Rear Oscillation Lock System” on
page 7-17 for further information.

7-8 31200079
Frame Tilt and Oscillation

Removal

Frame Tilt Cylinder

1
2
14 15 16
12
3 11 17

13 18
2
1

19

G1022
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 17 Lockwasher
8 Shim 18 Nut
9 Hydraulic Hose 19 Lower Cylinder Bushing
10 Mounting Block w/Lock Pin Hole

Fig. 7-6: Frame Tilt Cylinder Installation

(Ref. Fig. 7-6) The following procedures are required to remove the frame
tilt cylinder.
1. Follow preparation procedures as outlined in Section 3.
2. Place blocks between frame and top of front axle. These will hold the
frame in place when the cylinder is removed.
3. Tag and disconnect two (2) hydraulic hoses (Item 9) at frame tilt
cylinder (Item 3). Cap hoses and fittings.
4. See warning and procedures on page 7-15 for releasing hydraulic
pressure in cylinder.
5. Remove nut (Item 18), lockwasher (Item 17), and capscrew (Item 16)
securing cylinder upper pivot pin (Item 15) to frame.
6. Remove capscrew (Item 14), lockwasher (Item 12), and lock pin
(Item 11) securing cylinder lower pivot pin (Item 13).

31200079 7-9
Frame Tilt and Oscillation

7. Place a sling around the cylinder and attach the sling to suitable lifting
equipment. Make sure sling and lifting equipment have sufficient
capacity. The frame tilt cylinder weighs approximately 200 pounds.
Using the lifting equipment, support the weight of the cylinder.
8. Remove upper pivot pin.
9. Remove lower pivot pin and shims (Item 8) (early production models
only).
10. Move cylinder out and up from the machine.
11. For models with the cylinder illustrated in View B, remove lower
bushing (Item 19) from front axle using bushing driver and hammer or
press. Inspect and, if damaged, discard bushing.

Installation

Frame Tilt Cylinder (Ref. Fig. 7-6) The following procedures are required to install the frame tilt
cylinder.
1. Prior to installation, lubricate upper and lower pivot pins with a light
coating of grease.
2. For models with the cylinder illustrated in View B, install new lower
bushing (Item 19) on front axle. Install bushing so that it is centered in
axle boss.
3. Using suitable lifting equipment, position upper cylinder pivot at frame
pivot. Install upper pivot pin so hole in pin is aligned with hole in frame
boss. Secure upper pivot pin with capscrew (Item 16), lockwasher
(Item 17), and nut (Item 18). Torque nut to 180 in-lbs.
4. If necessary (models with the cylinder illustrated in View A), install
mounting blocks on front axle as follows:
a. Install mounting block (Item 5) to front of axle with two (2)
capscrews (Item 4), lockwashers (Item 6) and nuts (Item 7). Torque
nuts to 150 ft-lbs.
b. Install mounting block (with lock pin hole) (Item 10) to rear of axle
with two (2) capscrews (Item 4), lockwashers (Item 6), and nuts
(Item 7). Make sure the lock pin hole is to the rear of the machine.
Torque nut to 150 ft-lbs.
5. Position lower cylinder pivot on axle to install lower pivot pin. Install
lower pivot pin (Item 13) and shims (Item 8) (early production models
only).
6. Secure pin with lock pin (Item 11), lockwasher (Item 12), and capscrew
(Item 14). Torque capscrew to 55 ft-lbs.
7. Attach hydraulic hoses (Item 9) to fittings on cylinder. Torque hose
swivel nuts to 235–265 in-lbs.
8. If necessary, install grease fittings (Item 2) and grease fitting covers
(Item 1) as shown in Fig. 7-6. Torque grease fitting 1.5–3 turns past
finger tight.

7-10 31200079
Frame Tilt and Oscillation

9. Lubricate upper and lower pivots with grease.

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

31200079 7-11
Frame Tilt and Oscillation

Overhaul

Frame Tilt Cylinder

3
6
5
4
8
3
9
10
2
4

1
11

7
12

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. 7-7: Frame Tilt Cylinder (Exploded View)

7-12 31200079
Frame Tilt and Oscillation

Disassembly, Frame Tilt Cylinder

(Ref. Fig. 7-7) The following steps are required to disassemble the frame
tilt cylinder.
1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in
cylinder will drain out during disassembly. Place a suitable pan or tray
under the cylinder.
2. Remove counterbalance valve (Item 3).

WARNING: The counterbalance valve cartridges trap hydraulic pressure

in the frame tilt cylinder. 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.

3. Slowly extend and retract cylinder by hand to remove most of the

hydraulic oil.
4. Remove one (1) set screw (Item 7) securing head (Item 12) to barrel
(Item 2).
5. Pull rod (Item 11) out to help remove head. Support rod and head
during removal to prevent damage. Do not wiggle rod or head back and
forth to remove; this may damage the components.
6. Remove rod nut (Item 10), piston (Item 9), tube (Item 8), and head
from rod.
7. Remove two (2) O-ring plugs (Item 4).
8. Remove fittings (Item 6).
9. Using a large, flat bladed screw driver, remove two (2) orifices (Item 5).
10. If the bushings need to be replaced, see “Bushing Replacement”
below.

Cleaning and Inspection, Frame Tilt Cylinder

1. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
2. Thoroughly wash components in solvent and dry with compressed air.
3. Inspect inner surface of barrel, outer surface of piston, and length of
the rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
4. Check condition of threads on rod, nut, and capscrews. Replace as
necessary. Do not attempt to repair damaged threads.

31200079 7-13
Frame Tilt and Oscillation

Bushing Replacement

1. Fig. 7-7 shows both types of rod end configurations and bushing
locations. Remove pivot bushings (Item 1) using a bushing driver and
hammer or press. Drive one bushing all the way through to remove
other bushing.
2. Install new bushings so they are flush with outer edge boss to 0.02"
below. For machines with lower (rod end) pivot bushing installed in
front axle: Install bushing so that it is centered in axle boss.

Assembly, Frame Tilt Cylinder

1. (Ref. Fig. 7-7) Install two (2) orifices (Item 5) using a large, flat bladed
screw driver.
2. Install two (2) O-ring plugs (Item 4).
3. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
4. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on head (Item 12). Using a seal driver, install new wiper
seal in head. Lubricate wiper seal with hydraulic oil.
5. Slide head (Item 12), stroke limiter (Item 8) and piston (Item 9) onto
rod (Item 11). Lubricate threads on rod with hydraulic oil and install rod
nut (Item 10). Torque rod nut to 1540-1675 ft-lbs.
6. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
7. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (Item 7). Coat inside of barrel (Item 2) with hydraulic oil.
Carefully insert rod and head into barrel. Do not damage seals during
assembly. Install and snug set screw (Item 7).
8. Install two (2) O-ring fittings (Item 6).
9. Install counterbalance valve cartridges.

7-14 31200079
Frame Tilt and Oscillation

Counterbalance Valve Cartridge

Counterbalance Valve
Cartridge

Manifold Block

Counterbalance Valve
Cartridge

K1025
Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder

WARNING: The counterbalance valve cartridges trap hydraulic pressure

in the frame tilt cylinder. Wear proper eye and hand protection
when removing counterbalance valve cartridges. Hydraulic
fluid under pressure can be injected under skin or into eyes,
resulting in serious personal injury or death.

The following procedures refer to Fig. 7-8.

Releasing Pressure in Cylinder

1. Place socket wrench over a counterbalance valve cartridge. Wrap a

clean shop rag around the socket to cover the area of the
counterbalance valve cartridge.
2. Carefully and slowly, turn cartridge out of manifold block to release
pressure in cylinder. Repeat for other cartridge to release pressure
from other end of cylinder.
3. After pressure has been released, tighten cartridges. If cartridges will
not be removed, then torque counterbalance valve cartridges to
30–35 ft-lbs.

Removal and Service, Counterbalance Valve

1. Remove both cartridges and cap ports in manifold block. Inspect

cartridge O-rings for condition and replace as necessary.
2. Do not disassemble the cartridge. Service to a counterbalance valve
cartridge is limited to installing a new O-ring and replacing the entire
cartridge.

Installation, Counterbalance Valve

1. Lubricate O-rings with clean hydraulic oil.

2. Install each cartridge in manifold block and torque to 30–35 ft-lbs.

31200079 7-15
Frame Tilt and Oscillation

Frame Level Indicator

Description

10 10
5 0 5
H1004

Fig. 7-9: Frame Level Indicator

(Ref. Fig. 7-9) The Frame Level Indicator shows the lateral (side-to-side)
angle of the frame relative to level ground. Indicator range is from 0° to 10°
left or right, in increments of one degree. When the ball is centered (0°),
the machine is laterally level. The frame tilt feature may be used to correct
machine angles up to 12.5° to the left or right. See “Frame Tilt Control
Valve” on page 7-3.

Adjustment

Carpenter’s Level
K1026

Fig. 7-10: Leveling the Frame

1. (Ref. Fig. 7-10) Park the machine on a firm, level surface. Place a
carpenter’s level across the frame rails.
2. Loosen screws securing frame level indicator to its mounting bracket.
Start the engine and adjust frame tilt so the carpenter’s level shows the
frame is level.

7-16 31200079
Frame Tilt and Oscillation

3. Adjust frame level indicator so ball is centered over 0° mark. Tighten

indicator screws.

Rear Oscillation Lock System

General Description, Models with Control Manifold Hydraulics

The Rear Oscillation Lock System provides safety and stability by
preventing the frame from rotating on the rear axle.
The rear oscillation lock will be operational when any or all of the following
conditions apply:
• When the boom angle exceeds 40°.
• When the service brakes are applied.
• If a system component fails.
When the boom angle is above 40°, the following conditions apply:
• Rear axle cylinder locks, preventing the frame from rotating on the rear
axle.

Note: Rear oscillation lock cylinder can be unlocked by the drive lockout override
switch. See Drive Lockout Override in the Operator & Safety Manual.
• Transmission is inoperative.
• Frame tilt function is disengaged.
• REAR OSC LOCK light in the instrument cluster illuminates.
• When the frame tilt function is disengaged, it CANNOT be overridden
by the operator unless the boom angle is below 40°.
When the service brakes are applied, the following conditions apply:
• Rear axle cylinder locks, preventing the frame from rotating on the rear
axle.
• The rear oscillation lock cylinder can be unlocked by the frame tilt func-
tion when the boom is below 40°.

31200079 7-17
Frame Tilt and Oscillation

Theory of Operation and Circuit Logic

BOOM ANGLE GREATER THAN 40 - OPEN

BOOM ANGLE LESS THAN 40 - CLOSED
3-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER CONTROL
VALVE ON VALVE PLATE
A
S2 SV2
B
86 30
BOOM
OVER 40° 2-WAY SOLENOID VALVE ON
RELAY REAR AXLE STABILIZER VALVE
85 87A 87
ON REAR STABILIZER CYLINDER
+12 VOLTS
FROM A
FUSE PANEL SV3
B
TO ENABLE FOOT
BOOM ANGLE GREATER THAN 20 - OPEN SWITCH AND TO
BOOM ANGLE LESS THAN 20 - CLOSED DISABLE
TRANSMISSION

SOLENOID VALVE ON
REAR AXLE STABILIZER
S1 CONTROL VALVE
86 30 A
BOOM SV1
OVER 20°
RELAY B
85 87A 87

TO RESTRICT
TRANSMISSION
TO 1ST & 2ND
GEARS

MV0540

Fig. 7-11: Circuit Operation Below 40°

(Reference Fig. 7-11) Major components of the rear oscillation lock system
are:
1. Boom Over 20° Elevation Proximity Switch (S1)-senses when boom
position is above 20°.
2. Boom Over 40° Elevation Proximity Switch (S2)-senses when boom
position is above 40°.
3. Boom Over 20° Relay-receives signal from the Boom Over 20°
Elevation Proximity Switch (S1).
4. Boom Over 40° Relay-receives signal from the Boom Over 40°
Elevation Proximity Switch (S2).
5. Solenoid Valve (SV1)-controls frame tilt functions.
6. Solenoid Valve (SV2)-controls rear stabilizer cylinder along with
Solenoid Valve (SV3).
7. Solenoid Valve (SV3)-controls rear stabilizer cylinder along with
Solenoid Valve (SV2).
8. Service Brake Valve (not shown)-locks the rear stabilizer cylinder when
applied regardless of the status of SV2 and SV3.

7-18 31200079
Frame Tilt and Oscillation

Boom Positioned Above 40°

BOOM ANGLE GREATER THAN 40 - OPEN

BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER CONTROL
VALVE ON VALVE PLATE
(NOT ENERGIZED)
A
S2 SV2
B
86 30
BOOM 2-WAY SOLENOID VALVE ON
NOT ENERGIZED OVER 40° REAR AXLE STABILIZER VALVE
RELAY ON REAR STABILIZER CYLINDER
85 87A 87
+12 VOLTS (NOT ENERGIZED)
FROM A
FUSE PANEL SV3
TO ENABLE FOOT B
SWITCH AND TO
BOOM ANGLE GREATER THAN 20 - OPEN DISABLE
BOOM ANGLE LESS THAN 20 - CLOSED TRANSMISSION

SOLENOID VALVE ON
REAR AXLE STABILIZER
CONTROL VALVE
S1 (NOT ENERGIZED)
86 30 A
BOOM SV1
NOT ENERGIZED OVER 20°
RELAY B
85 87A 87

TO RESTRICT
TRANSMISSION MV0550
TO 1ST & 2ND
GEARS

Fig. 7-12: Circuit Operation Above 40°

(Ref. Fig. 7-12) The following describes the rear axle stabilizer circuit logic
when the boom is positioned above 40° elevation.
1. When the boom is above 40°, the proximity switch (S2) is not sensing
the boom. Therefore, the proximity switch (S1) opens and is also not
sensing the boom.
2. When the proximity switch (S2) is open, the Boom Over 40° relay is not
energized and power is directed to the coil of Relay K11 of the
transmission logic (see Transmission Section 8). When K11 is
energized, power is removed from all of the transmission solenoids,
which puts the transmission into Neutral and illuminates the
Transmission Disconnect Lamp in the instrument cluster.
3. Additionally, when the Boom Over 40° relay is not energized, Solenoid
Valves SV2 and SV3 are energized, which locks the rear stabilizer
cylinder. This prevents the frame from rotating on the rear axle and
illuminates the Rear Oscillation Lock lamp in the instrument cluster.
4. An additional effect of the Boom Over 40° relay not being energized is
theTransmission Disconnect Override Footswitch is enabled. Pressing
the Transmission Disconnect Override Footswitch, when the boom is
over 40°, reengages the transmission (first gear only) and allows very
slow, restricted oscillation of the frame on the rear axle. This allows
the machine to be moved. This is an extremely dangerous operation –
see the Operator's Manual.
5. The frame tilt is also restricted when the boom is over 40° because
Solenoid Valve (SV1) is energized.

31200079 7-19
Frame Tilt and Oscillation

Boom Positioned Above 20° Below 40°

BOOM ANGLE GREATER THAN 40 - OPEN

BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER CONTROL
VALVE ON VALVE PLATE
(ENERGIZED)
A
S2 SV2
B
86 30
BOOM 2-WAY SOLENOID VALVE ON
ENERGIZED OVER 40° REAR AXLE STABILIZER VALVE
RELAY ON REAR STABILIZER CYLINDER
85 87A 87
(ENERGIZED)
+12 VOLTS
FROM A
FUSE PANEL SV3
TO ENABLE FOOT B
SWITCH AND TO
BOOM ANGLE GREATER THAN 20 - OPEN DISABLE
BOOM ANGLE LESS THAN 20 - CLOSED TRANSMISSION

SOLENOID VALVE ON
REAR AXLE STABILIZER
S1 CONTROL VALVE
(NOT ENERGIZED)
86 30 A
BOOM SV1
NOT ENERGIZED OVER 20°
RELAY B
85 87A 87

TO RESTRICT
TRANSMISSION TO
1ST & 2ND GEARS MV0560

Fig. 7-13: Circuit Operation Above 20° Below 40°

(Ref. Fig. 7-13) The following describes the rear axle stabilizer circuit logic
when the boom is positioned above 20° below 40° elevation.
1. When the boom is above 20° and below 40°, the proximity switch (S2)
is sensing the boom, so the (S2) proximity switch closes. Proximity
switch (S1) is not sensing the boom, so it opens when boom is above
20°.
2. When the proximity switch (S1) is open, the Boom Over 20° relay is not
energized and power is directed to the coil of relay K13 of the
transmission logic (see Transmission Section 8). When K13 is
energized, the transmission is restricted to first and second gears only,
regardless of the gear selected with the transmission shifter.
3. Additionally, when the Boom Over 20° relay is not energized, Solenoid
Valve (SV1) is not energized, which restricts movement of the rear
stabilizer cylinder so that the frame may oscillate on the rear axle only
in a slow or restricted mode. The Boom Over 20° relay also illuminates
the Rear Oscillation Lock lamp in the instrument cluster.
4. The frame tilt is also restricted when Solenoid Valve (SV1) is not
energized.

7-20 31200079
Frame Tilt and Oscillation

Boom Positioned Above 20° Below 40° With the Service Brake Applied

BOOM ANGLE GREATER THAN 40 - OPEN

BOOM ANGLE LESS THAN 40 - CLOSED 3-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER CONTROL
VALVE ON VALVE PLATE
(ENERGIZED)
A
S2 SV2
B
86 30
BOOM 2-WAY SOLENOID VALVE ON
ENERGIZED OVER 40° REAR AXLE STABILIZER VALVE
RELAY ON REAR STABILIZER CYLINDER
85 87A 87
+12 VOLTS (ENERGIZED)
FROM A
FUSE PANEL SV3
TO ENABLE B
BOOM ANGLE GREATER THAN 20 - OPEN FOOT SWITCH
AND TO
BOOM ANGLE LESS THAN 20 - CLOSED DISABLE
TRANSMISSION
SOLENOID VALVE ON
REAR AXLE STABILIZER
CONTROL VALVE
S1 (NOT ENERGIZED)
86 30 A
BOOM SV1
NOT ENERGIZED OVER 20°
RELAY B
85 87A 87

TO RESTRICT
TRANSMISSION
TO 1ST & 2ND
GEARS MV0570

Fig. 7-14: Circuit Operation Above 20° Below 40° with Service Brake Applied
(Ref. Fig. 7-14) The following describes the rear axle stabilizer circuit logic
when the boom is positioned above 20° below 40° elevation with the
service brake applied.
1. When the boom is above 20° and below 40°, the proximity switch (S2)
is sensing the boom, so the (S2) proximity switch closes. Proximity
switch (S1) is not sensing the boom, so it opens when boom is above
20°.
2. When the proximity switch (S1) is open, the Boom Over 20° relay is not
energized and Solenoid Valve (SV1) is not energized, which restricts
the frame tilt.
3. Applying the service brake locks the rear stabilizer cylinder
hydraulically, which prevents the frame from rotating on the rear axle.

31200079 7-21
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)

A
S2 SV2
B
86 30
BOOM 2-WAY SOLENOID VALVE ON
ENERGIZED OVER 40° REAR AXLE STABILIZER VALVE
RELAY ON REAR STABILIZER CYLINDER
85 87A 87
+12 VOLTS (ENERGIZED)
FROM A
FUSE PANEL SV3
B
TO ENABLE
BOOM ANGLE GREATER THAN 20 - OPEN FOOT SWITCH
BOOM ANGLE LESS THAN 20 - CLOSED AND TO
DISABLE
TRANSMISSION
SOLENOID VALVE ON
REAR AXLE STABILIZER
CONTROL VALVE
S1 (ENERGIZED)
86 30 A
BOOM SV1
ENERGIZED OVER 20°
RELAY B
85 87A 87

TO RESTRICT
TRANSMISSION
TO 1ST & 2ND
GEARS
MV0580

Fig. 7-15: Circuit Operation Below 20° With the Service Brake Applied
(Ref. Fig. 7-15) The following describes the rear axle stabilizer circuit logic
when the boom is positioned above 20° with the service brake applied.
1. When the boom is below 20°, the proximity switch (S1) is sensing the
boom, so the (S1) proximity switch closes.
2. When the proximity switch (S1) is closed, the Boom Over 20° relay is
energized and Solenoid Valve (SV1) is energized, which allows
unrestricted frame tilt.
3. Applying the service brake locks the rear stabilizer cylinder
hydraulically, which prevents the frame from rotating on the rear axle.
4. Releasing the service brake unlocks the rear stabilizer cylinder
hydraulically, which allows the frame to rotate freely on the rear axle.

7-22 31200079
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
S1 S2 Boom Boom Osc. Trans. Rear SV1 SV2 SV3
OPERATING Proximity Proximity Over 20° Over 40° Locked Disconnect Stabilizer Solenoid Solenoid Solenoid
PARAMETERS Switch Switch Relay Relay Lamp Lamp Cylinder Valve Valve Valve

Boom below 20° Closed Closed Energized Energized Off Off Floating Energized Energized Energized
Service brake
released

Boom below 20° Closed Closed Energized Energized Off Off Locked Energized Energized Energized
Service brake applied

Boom below 20° Closed Closed Energized Energized Off Off Floating Energized Energized Energized
Service brake applied While
Operating Frame Tilt Frame Tilt-
ing

Boom above 20° Open Closed De- Energized On Off Slow De- Energized Energized
Service brake energized Restricted energized
released Oscillation

Boom above 20° Open Closed De- Energized On Off Locked De- Energized Energized
Service brake applied energized energized

Boom above 40° Open Open De- De- On On Locked De- De- De-
Service Brake energized energized energized energized energized
Released

Boom above 40° Open Open De- De- On On Locked De- De- De-
Service Brake energized energized energized energized energized
Applied

Boom above 40° Open Open De- De- On On Very Slow De- Energized De-
Footswitch energized energized Restricted energized energized
Depressed Oscillation

31200079 7-23
Frame Tilt and Oscillation

Rear Oscillation Lock Cylinder

Description

20
60 80
40
Rear Oscillation
-20
0

Lock Cylinder

Rear Oscillation

G1023
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.
The oscillation control block is mounted to the inboard side of the cylinder
and controls hydraulic flow to and from the cylinder. When hydraulic fluid is
trapped in the cylinder the frame is prevented from rotating around the rear
axle.
The rear oscillation lock cylinder and the oscillation control block are
components of the rear oscillation lock system. See “Rear Oscillation Lock
System” on page 7-17 for more information.

7-24 31200079
Frame Tilt and Oscillation

Removal

6 19
1 18
2
3 5 21
4
16
8 15
2
4
14
13

9
20

G1025
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
5 #6 Hydraulic Hose 16 Check Valve
6 #8 Hydraulic Hose 17 Wiring Harness
7 Capscrew 18 Grease Fitting Cover
8 Lock Pin 19 Grease Fitting
9 Lower Pivot Pin 20 Bushing
10 Lockwasher 21 Pressure Reducing Valve
11 Nut

Fig. 7-17: Rear Oscillation Lock Cylinder Installation

(Ref. Fig. 7-17) The following steps are required to remove the rear
oscillation lock cylinder:
1. Follow preparation procedures as outlined in Section 3.
2. Place blocks between frame and top of rear axle. These will hold the
frame in place when the cylinder is removed.
3. Install brake pressure diagnostic port test gauge onto brake diagnostic
port.
4. While watching test gauge, press brake pedal numerous times until
pressure gauge reads 0 psi. Remove test gauge from diagnostic port.
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.

31200079 7-25
Frame Tilt and Oscillation

6. Slowly loosen each check valve (Item 16) on control block (labeled 3.1
and 3.2) to allow residual pressure to escape. After pressure has been
released, torque check valves to 50 ft-lbs.
7. Tag and disconnect three (3) hydraulic hoses (Items 5 and 6) at
oscillation control block. Cap hoses and fittings.
8. For models with control manifold hydraulics, disconnect wiring harness
electrical connection (Item 17) at oscillation control block.
9. Remove nut (Item 1), lockwasher (Item 2), and capscrew (Item 4)
securing cylinder upper pivot pin (Item 3) to frame.
10. Remove capscrew (Item 4), lockwasher (Item 2), and lock pin (Item 8)
securing cylinder lower pivot pin (Item 9).
11. Place a sling around cylinder (Item 15) and attach sling to suitable
lifting equipment. Make sure sling and lifting equipment have sufficient
capacity. The rear oscillation lock cylinder weighs approximately 200
pounds. Using lifting equipment, support weight of cylinder.
12. Remove upper and lower pivot pins (Items 3 and 9). Move cylinder out
and up from machine.

Installation

Rear Oscillation Lock (Ref. Fig. 7-17) The following steps are required to install the rear
Cylinder oscillation lock cylinder:
1. Prior to installation, lubricate upper and lower pivot pins with a light
coating of grease.
2. Using suitable lifting equipment, position upper cylinder pivot at frame
pivot. Install upper pivot pin (Item 3) so hole in pin is aligned with hole
in frame boss. Secure upper pivot pin with capscrew (Item 4),
lockwasher (Item 2), and nut (Item 1). Torque nut to 180 in-lbs.
3. If necessary (models with a cylinder as illustrated in View A), install
mounting base (Item 12) with four (4) each capscrews (Item 7),
lockwashers (Item 10), and nuts (Item 11). Torque nuts to 280 ft-lbs.
4. If necessary (models with a cylinder as illustrated in View A), install
bushing (Item 20) in rear axle boss. Install bushing so that it is
centered in axle boss
5. Position lower cylinder pivot on axle and install lower pivot pin. Secure
pin with lock pin (Item 8), lockwasher (Item 2), and capscrew (Item 4).
Torque capscrew to 55 ft-lbs.
6. Attach hydraulic hoses to fittings on oscillation control block. Torque
nut on #8 hose (Item 6) to 44–48 ft-lbs. Torque nuts on #6 hoses
(Item 5) to 235–265 in-lbs (20–22 ft-lbs).
7. For models with a cylinder as illustrated in View A, connect electrical
lead from wiring harness (Item 17) at oscillation control block.
8. If necessary, install grease fittings (Items 13 and 19) and grease fitting
covers (Items 14 and 18). Torque grease fittings 1.5–3 turns past finger
tight. Lubricate upper and lower pivots with grease.

7-26 31200079
Frame Tilt and Oscillation

9. Start engine and cycle frame tilt fully left and right several times to
purge air from hydraulic system. Lower boom and shut off engine.
10. Inspect for hydraulic leaks and repair as necessary.
11. Check oil level in hydraulic reservoir and add as necessary. See “Filling
Hydraulic Reservoir” in Section 5 for procedures.

31200079 7-27
Frame Tilt and Oscillation

Overhaul

Rear Oscillation Lock

Cylinder

5
4

1 6

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
Frame Tilt and Oscillation

Disassembly, Rear Oscillation Lock Cylinder

(Ref. Fig. 7-18) Disassembly procedures for the rear oscillation lock
cylinder are as follows:
1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in
cylinder will drain out during disassembly. Place a suitable pan or tray
under cylinder.
2. Slowly extend and retract cylinder by hand to remove most of the
hydraulic oil.
3. Remove one (1) set screw (Item 7) securing head (Item 8) to barrel
(Item 2).
4. Pull rod (Item 6) out to help remove head. Support rod and head
during removal to prevent damage. Do not wiggle the rod or head back
and forth to remove; this may damage the components.
5. Remove rod nut (Item 3), piston (Item 4), tube (Item 5), and head from
rod.
6. If the bushings need to be replaced, see “Bushing Replacement, Rear
Oscillation Lock Cylinder” below.

Cleaning and Inspection, Rear Oscillation Lock Cylinder

1. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
2. Thoroughly wash components in solvent and dry with compressed air.
3. Inspect inner surface of barrel, the outer surface of piston, and rod for
scratches and scoring. If barrel, piston, or rod is damaged, the
component must be replaced.
4. Check condition of threads on rod, nut, and capscrews. Replace as
necessary. Do not attempt to repair damaged threads.

Bushing Replacement, Rear Oscillation Lock Cylinder

1. Fig. 7-18 shows both types of rod end configurations and bushing
locations. Remove pivot bushings (Item 1) using a bushing driver and
hammer or press. Drive one bushing all the way through to remove
other bushing.
2. Install new bushings so they are flush with outer edge of boss to 0.02"
below. For machines with lower (rod end) pivot bushing installed in rear
axle: Install bushing so that it is centered in axle boss.

Assembly, Rear Oscillation Lock Cylinder

1. Lubricate new O-ring with hydraulic oil and install inside piston (seals
the rod to the piston).

31200079 7-29
Frame Tilt and Oscillation

2. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on head (Item 8). Using a seal driver, install new wiper
seal in head. Lubricate wiper seal with hydraulic oil.
3. (Ref. Fig. 7-18) Slide head (Item 8), tube (Item 5) and piston (Item 4)
onto rod (Item 6). Lubricate threads on rod with hydraulic oil and install
rod nut (Item 3). Torque rod nut to 1540-1675 ft-lbs.
4. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
5. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (Item 7). Coat inside of barrel (Item 2) with hydraulic oil.
Carefully insert rod and head into barrel.
6. Install oscillation control block.

7-30 31200079
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.
When the oscillation lock system is in LOCK mode, the control block traps
hydraulic fluid in both the rod-end and base-end of the cylinder. This
hydraulic lock in the cylinder prevents the frame from rotating on the rear
axle.

31200079 7-31
Frame Tilt and Oscillation

Removal

Oscillation Control Block

1
1

29

1 26

9
10
1
5
6
3 7
4

MV0470
8

# 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. 7-20: Oscillation Control Block Installation

Rear Oscillation Lock Cylinder Installed on Machine

(Ref. Fig. 7-20) Use the following control block removal procedures when
the rear oscillation lock cylinder is installed on the machine. For removal
procedures when the cylinder has been removed, see page 7-33.
1. Follow preparation procedures as outlined in Section 3.
2. Place blocks between frame and top of rear axle. This will hold the
frame in place when the control block is removed.
3. Install brake pressure diagnostic port test gauge onto brake diagnostic
port.
4. While watching test gauge, press brake pedal numerous times until
pressure gauge reads 0 psi. Remove test gauge from diagnostic port.

7-32 31200079
Frame Tilt and Oscillation

5. Place a suitable drip pan under rear oscillation lock cylinder.

WARNING: Residual hydraulic pressure may be trapped in rear oscillation

lock cylinder. Wear proper eye and hand protection when
releasing pressure from cylinder. Hydraulic fluid under
pressure can be injected under skin or into eyes, resulting in
serious personal injury or death.

6. Slowly loosen each check valve cartridge (Item 5) on control block

(labeled 3.1 and 3.2) to allow residual pressure to escape. After
pressure has been released, tighten check valves. If control block
(Item 6) will not be overhauled, torque check valves to 45–50 ft-lbs.
7. For models with control manifold hydraulics, disconnect electrical
connection (Item 9) at oscillation control block.
8. Tag and disconnect three (5) hydraulic hoses (Items 1 and 2) from the
fittings at the oscillation control block. Cap hoses and fittings.
9. Remove three (3) capscrews (Item 3) and lockwashers (Item 4)
securing control block to cylinder (Item 8). Remove control block.
10. Plug ports in cylinder.

Rear Oscillation Lock Cylinder Removed from Machine

(Ref. Fig. 7-20) Use the following control block removal procedures when
the rear oscillation lock cylinder is removed from the machine. For removal
procedures when the cylinder is installed on the machine, see page 7-32.
1. Support cylinder in a vice. Place a suitable pan or tray under 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.

2. Slowly loosen each check valve cartridge (Item 5) on control block

(labeled 3.1 and 3.2) to allow residual pressure to escape. After
pressure has been released, tighten check valves. If control block
(Item 6) will not be overhauled, torque check valves to 45–50 ft-lbs.
3. Remove three (3) capscrews (Item 3) and lockwashers (Item 4)
securing control block to cylinder. Remove control block.

31200079 7-33
Frame Tilt and Oscillation

Installation

Oscillation Control Block

Rear Oscillation Lock Cylinder Installed on Machine

(Ref. Fig. 7-20) Use the following control block installation procedures
when the rear oscillation lock cylinder is installed on the machine. For
installation procedures when the cylinder has been removed, see below.
1. Clean mating surfaces of rear oscillation lock cylinder and oscillation
control block.
2. Lubricate two (2) O-rings (Item 7) with hydraulic oil and install in control
block.
3. Position control block on cylinder and secure with three (3) capscrews
(Item 3) and lockwashers (Item 4). Torque capscrews evenly to 80
ft-lbs.
4. Attach hydraulic hoses to fittings on oscillation control block (Item 6).
5. For models with control manifold hydraulics, connect electrical lead
(Item 9) at control block.
6. Start engine and tilt frame fully left and right several times to purge air
from the hydraulic system. Shut off engine and check for leaks.

Rear Oscillation Lock Cylinder Removed from Machine

(Ref. Fig. 7-20) Use the following control block installation procedures
when the rear oscillation lock cylinder is removed from the machine. For
installation procedures when the cylinder is installed on the machine, see
above.
1. Clean mating surfaces of rear oscillation lock cylinder and oscillation
control block.
2. Lubricate two (2) O-rings (Item 7) with hydraulic oil and install in control
block.
3. Position control block on cylinder and secure with three (3) capscrews
(Item 3) and lockwashers (Item 4). Torque capscrews evenly to 80
ft-lbs.

7-34 31200079
Frame Tilt and Oscillation

Overhaul

Oscillation Control Block

1
2 4 5
3

6
7
4
9 19 17
7
16

20

15 18

14
8
11
13 12
11

9
10
MV0660

# Description # Description
1 Nut 12 O-Ring
2 Coil 13 Check Valve Cartridge, (CV3 &
3 Solenoid Valve CV4)
4 Seal Kit 14 Piston Assy
5 Counter Balance Valve Cartridge 15 Pressure Reducing Valve Car-
6 PO Check Valve (PC1 & PC2) tridge, (PR)
16 Check Valve
7 Orifice Plug, .040
17 Orifice Plug
8 O-Ring
18 Hollow Hex O-Ring Plug, #2
9 Hollow Hex O-Ring Plug, #4 19 Orifice Plug, .080
10 Hollow Hex O-Ring Plug, #10 20 Orifice Disc, .130
11 Backup Ring

Fig. 7-21: Oscillation Control Block (Exploded View)

(Ref. Fig. 7-21) Follow the guidelines for cleanliness as stated in Section 5
of this manual. The following procedures are for the disassembly, cleaning,
and assembly of the oscillation control block.

31200079 7-35
Frame Tilt and Oscillation

Disassembly, Oscillation Control Block

Check Valve 1. Note position of hydraulic fittings installed in block body then remove
fittings.
Pressure Reducing Cartridge 2. Remove pressure reducing cartridge (Item 15) and two (2) check valve
cartridges (Item 13).
3. Remove two (2) pilot pistons (Item 14).
Solenoid Valve 4. Remove the one (1) SAE #2 plugs (Item 18), three (3) SAE #4 plugs
(Item 9), two (2) SAE #6 plug (Item 4), and SAE #10 plug (Item 10).
5. Orifice plug (Item 19) does not usually require removal. It will be
cleaned when the block body is flushed.

Cleaning and Inspection, Oscillation Control Block

1. Remove O-rings and backup rings from pressure reducing valve

cartridge (Item 15), two (2) check valve cartridges (Item 13), counter
balance valve cartridge (Item 5), and PO Check Valve (Item 6). Clean
these components with solvent and dry with compressed air. Inspect
components for condition and cleanliness.
2. Thoroughly flush block body with solvent and dry with compressed air.
3. Clean remaining components (except solenoid coil) with solvent and
dry with compressed air.
4. Inspect orifice plugs (Items 17 and 19) for blockage and clean as
necessary.

Assembly, Oscillation Control Block

1. If orifice plug (Item 19) was removed, install in block body so it is finger
tight. Tighten orifice plug 2–3 turns past finger tight.
2. Install two (2) SAE #6 plugs (Item 4). Torque plugs to 210–230 in-lbs.
3. Install one (1) SAE #2 plugs (Items 18). Torque plugs to 30–40 in-lbs.
4. Install three (3) SAE #4 plug (Item 9). Torque plug to 125–145 in-lbs.
5. Install SAE #10 plug (Item 10). Torque plug to 71–79 ft-lbs
(850–950 in-lbs).
6. Obtain new O-rings and backup rings for pressure reducing cartridge
(Item 15), two (2) check valve cartridges (Item 13), two (2) pilot pistons
(Item 14), counter balance valve cartridge (Item 5), and PO Check
Valve (Item 6). Lubricate all O-rings and backup rings with hydraulic oil
before installing on components.
Pressure Reducing Cartridge 7. Install large O-ring on pressure reducing valve cartridge (Item 15).
Install backup ring and O-ring on cartridge so backup ring is behind O-
ring.
8. Lubricate all O-rings and backup rings on pressure reducing cartridge
(Item 15). Install cartridge and torque to 270–300 in-lbs.

7-36 31200079
Frame Tilt and Oscillation

Solenoid Valve 9. Install two (2) backup rings and O-ring on each pilot piston (Item 14) so
O-ring is between backup rings. (Ref. Fig. 7-21).
10. Lubricate backup rings and O-ring on each pilot piston and install
pistons in block body. Tapered end of pistons must face out as shown
in Fig. 7-21.
11. Install large O-ring , O-ring , and backup ring on each check valve
cartridge (Item 13).
12. Lubricate O-rings and backup ring on each check valve cartridge (Item
13). Install cartridges and torque to 45–50 ft-lbs (540–600 in-lbs).
Check Valve 13. Install check valve in SYS port and torque to 46–50 ft-lbs.
14. Install adjustable fitting in T port. Position fitting as previously noted
and torque to 300–340 in-lbs (25–29 ft-lbs).
15. Two (2) O-rings (Item 8) are installed when control block is installed on
rear oscillation lock cylinder. See “Installation” on page 7-34.

Boom Elevation Proximity Switch

Description
Boom

Proximity Switch

Transfer Carriage/Boom Cradle

Fig. 7-22: Boom Elevation Proximity Switch

(Ref. Fig. 7-22) The boom elevation proximity switch is located on the left
side of the transfer carriage/boom cradle. This normally open switch
closes when the boom is below 20° elevation. This normally open switch
closes when the boom is below 40° elevation.The switch is a component of
the rear oscillation lock system. See “Rear Oscillation Lock System” on
page 7-17.

31200079 7-37
Frame Tilt and Oscillation

Transfer Carriage/Boom Cradle Boom

Magnetic Flux
Lines

Proximity Switch Oscillator

J1108
Fig. 7-23: Boom Elevation Proximity Switch Operation
(Ref. Fig. 7-23) The switch operates by sending out a constant, high
frequency magnetic field a short distance from the oscillator end of the
switch. Eddy currents are produced in metal when the magnetic flux lines
pass through it. These eddy currents oppose the oscillations of the
magnetic flux lines and the oscillations stop. A sensor in the switch detects
if the oscillator is on or off and this gives the switch its on/off function.

Removal

Boom Elevation Proximity

Switch 2 1
3
4
5

MV0670

# Description # Description
1 Transfer Carriage/Boom Cradle 4 Outer Jam Nut
2 Inner Jam Nut 5 Wire Harness
3 Proximity Switch

Fig. 7-24: Boom Elevation Proximity Switch Assembly

1. (Ref. Fig. 7-24) Disconnect wire harness (Item 5) at boom proximity
switch (Item 3).
2. Place a piece of masking tape around proximity switch body at the
outer jam nut (Item 4) (this will serve as a guide during re-installation).

7-38 31200079
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.
2. Install boom proximity switch in transfer carriage/boom cradle (Item 1).
Install inner jam nut (Item 2). Check gap between end of proximity
switch and boom. See Fig. 7-25.
3. Connect wire harness (Item 5) to proximity switch.
4. Check operation of proximity switch by raising the boom. The Rear
Osc Lock light must come on at approximately 20° of boom elevation.
If the light does not illuminate, stop and lower boom. Proceed to
“Adjustment” below.

Adjustment

Boom Elevation Proximity

Switch Transfer Carriage/Boom Cradle Boom
0.19” to
0.25” Gap
Proximity Switch

Outer Jam Nut Inner Jam

Nut

J1075
Fig. 7-25: Boom Elevation Proximity Switch Adjustment
1. Loosen, but do not remove the two (2) jam nuts on the proximity switch
body.
2. Check gap between switch and boom. Gap must be within the range
specified in Fig. 7-25.
3. If Rear Osc Lock light does not illuminate when boom is at
approximately 20° elevation, adjust proximity switch to slightly reduce
the gap. Do not exceed gap tolerances specified in Fig. 7-25. Snug jam
nuts to hold switch in position.
4. Raise boom and check operation of Rear Osc Lock light. The light
must come on at approximately 20° of boom elevation. If light does not
illuminate, stop and lower boom. Repeat Step 3.
5. Tighten jam nuts.

31200079 7-39
Frame Tilt and Oscillation

7-40 31200079
Section 8 — Transmission

Table of Contents

Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission General Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Performance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Transmission Shift Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

List of Figures

Fig. 8-1: ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Fig. 8-2: Transmission Serial Number Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fig. 8-3: The Lubrication and Maintenance Flip Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Fig. 8-4: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Fig. 8-5: Disconnect the Battery Negative (-) Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fig. 8-6: Drain Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Fig. 8-7: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Fig. 8-8: Remove Transmission from Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Fig. 8-9: Transmission External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Fig. 8-10: Install the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Fig. 8-11: Transmission Oil Cooler Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Fig. 8-12: Transmission Shift Logic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

31200079 i
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.

Oil Cooler

Dipstick and
Fill Inlet (Cooler)
Hose
Valve Block
Outlet (Cooler)
Oil Filter Hose
Torque Converter
Housing

Output Shaft

Vehicle Frame
(Reference)

MV0210

Fig. 8-1: ZF Transmission

Transmission Description
Instructions in this section pertain mainly to general specifications, towing,
maintenance information, and transmission removal and installation procedures.
Internal transmission service instructions and detailed specifications are provided in
the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135
002).

31200079 8-1
Transmission

The ZF 4 WG-98 TC Transmission used in this vehicle is a four-speed

configuration. The “intermediate drop” designation refers to the relative top-to-bottom
length of the transmission case, chosen for its compatibility with vehicle chassis
and operating requirements. Intermediate drop does not refer to an operational rpm
shift or drop.

Transmission Operation
The transmission is mounted to the frame by front and rear mounting brackets and
rubber isolator pads. Power from the engine is transmitted to the transmission by
means of a drive shaft, bolted to the engine flywheel and a torque converter at the
transmission input. The transmission in turn transmits power to the drive shafts,
driving the front and rear axles.
The torque converter consists of three main components: the impeller (driver),
stator and turbine (driven) in an oil-filled, enclosed housing. As the torque converter
is driven by the engine flywheel, the impeller (pump) wheel rotates, forcing oil
through the stator, which is held stationary by the stator shaft bolted to the
transmission housing. This directs the moving oil onto the vanes of the turbine
(driven) wheel, causing the turbine wheel to rotate. The turbine wheel is connected
to the transmission input shaft, and transfers power to the transmission. Oil from
the turbine wheel is then returned to the impeller wheel to repeat the process. This
process results in an increase in the torque available at the transmission input
shaft.
The transmission and torque converter are powered by their own internal hydraulic
(“transmission fluid”) system, separate from the vehicle hydraulic system.
Pressurized oil for the valve control circuits and torque converter is supplied by a
pump located at the rear of the transmission. The pump is driven by the central shaft,
which in turn is connected to the impeller of the torque converter. The vehicle is
equipped with an external oil cooler to cool the transmission oil.
The transmission gear (“speed”) select lever, an electric shift control, is located on
the left side of the steering column in the operator’s cab. Movement of the gear
select lever energizes the selected transmission shift solenoid valves, which, in
turn, direct the transmission fluid under pressure to the selected forward or reverse
valve and to the designated range (gear or “speed”) clutch. Several factors,
including terrain, loading, engine rpm, axle/wheel-end gearing and the selected
transmission gear, determine actual vehicle speed.
To engage the clutch, the gear select lever is placed in the desired direction
(forward or reverse) and range (gear or “speed”) position. The gear select lever
movement energizes the selected direction and range (gear) solenoids, allowing
transmission fluid under pressure to flow through tubes and passages to the
selected clutch shafts. Oil sealing rings are located on the clutch shaft; these rings
direct oil under pressure through a drilled passageway in the shaft to a desired
clutch. Hydraulic pressure forces the piston and discs against the back-up plate.
Discs, with edge tangs, clamp against toothed discs on the inner diameter,
enabling the hub and the clutch shaft to lock together and drive as a unit,
providing output power.Transmission Serial Number
The transmission serial number plate (1) is located on the pump side (front) of
the transmission at the bottom right, toward the vehicle frame. Information
specified on the serial number plate includes the transmission model number,
the transmission serial number and other data. Information on the serial
number plate is required in correspondence regarding the transmission.

8-2 31200079
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.
Travel Speed (standard tires, no load)
First gear...........................................3.5 mph (5,6 km/hr)
Second gear ........................................6 mph (9,7 km/hr)
Third gear ....................................15.2 mph (24,5 km/hr)
Fourth gear .........................................22 mph (35 km/hr)

Transmission Lubrication
a. Transmission Fluid
Complete transmission fluid information is found in Section 3-3, “ZF Transmission
Oil Specifications.”.
b. Transmission Fluid (Oil) Capacity
Capacity w/ filter change................... 19 quarts (18 liters)

31200079 8-3
Transmission

Transmission Maintenance

WARNING: To help avoid severe burns, DO NOT attempt this procedure

when the engine, cooling, and hydraulic systems are hot. Wait until they
have cooled before proceeding.
• Follow the manufacturer’s instructions to avoid health hazards when
using solvents and caustic cleaners.
• Exercise extreme care when using a steam cleaner to help avoid
burns.
IMPORTANT: These instructions cover only the routine maintenance of the
transmission. Refer to the
ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135
002), for information on transmission internal component replacement.
Refer to the ZF 4 WG-98 TC Transmission Technical Data and Maintenance Manual,
P/N 8990449 (ZF P/N 5872 134 002), for information on transmission diagnosis
and internal schematics.
Cleanliness is of extreme importance. Before attempting any repairs, thoroughly
clean the exterior of the transmission to help prevent dirt from entering while
performing maintenance checks and procedures.
Transmission Maintenance Schedule provides a suggested maintenance
schedule with references to pertinent procedures and instructions in this manual.
To help prevent transmission problems before they occur, follow the maintenance
schedule.

Note:Lubrication and Maintenance Flip Card is (1) located inside the Cab.
These decals contain a general maintenance schedule that should
be followed to maintain the vehicle in good operating condition.
Refer to Section 2, “ General Information and Specifications.”The
same schedule information is presented in the appropriate
owners/operators manual, with a detailed account of how to perform
the procedures.

PRESSURE TEST PORTS

REAR OSC. REAR OSC.
PUMP 1 PUMP 2 LOCK (G1) LOCK (G2) BRAKES STEERING PILOT ACCUM.

MV0220

Fig. 8-3: The Lubrication and Maintenance Flip Chart

Transmission Maintenance Schedule

Complete transmission maintenance information is located in the appropriate
operators & safety manual.

8-4 31200079
Transmission

• At ten hour intervals, check the transmission oil level. Refer to the appro-
priate operators & safety manual.
• When the vehicle completes its first 50 hours of use, change the transmis-
sion filter. Change the filter only; DO NOT change the transmission oil at
the first 50 hour maintenance level. Refer to the appropriate operators &
safety manual.
• At 1,000 hour intervals, change the transmission oil and filter. Refer to the
appropriate operators & safety manual.
Periodically, depending on operating conditions and other factors, back flush the
transmission oil cooler (2), which is located in or behind the radiator. ALWAYS
back flush the transmission oil cooler after removing the transmission for repair or
replacement.
The transmission oil cooler outlet hose (3), routed to the lower oil cooler fitting, is
located on the top of the transmission. The transmission oil cooler inlet hose (4),
routed to the upper oil cooler fitting, is located on the top of the transmission.

CAUTION: DO NOT exceed 165 psi (39.6 bar) when back flushing the oil
cooler. Applying too much pressure may damage the oil
cooler/radiator.

Disconnect and back flush the oil cooler portion of the radiator or the oil cooler
(located behind the radiator) with oil and compressed air until all foreign material is
removed. If necessary, remove the radiator or oil cooler from the vehicle, and clean
the oil cooler circuit using oil, compressed air and steam.
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 8-5
Transmission

Important:To help ensure safety and optimum performance, replace the

transmission if it is damaged. Refer to the appropriate parts
manual for ordering information.
Cleanliness is of extreme importance. Before attempting to remove the
transmission, thoroughly clean the exterior of the transmission to help prevent dirt
from entering during the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and other electrical
components.

Transmission Removal

WARNING: Risk of severe personal injury. NEVER lift a transmission alone;

enlist the help of at least one assistant or use a suitable hoist or overhead crane
and sling.
1. Park the machine on a firm, level surface, fully retract the boom, raise
the boom, place the travel select lever in the (N) NEUTRAL position,
engage the parking brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the ignition key switch and
steering wheel, stating that the machine should not be operated. Refer
to Section 1.5, “Accident Prevention Tags.”

WARNING: DO NOT get under a raised boom unless the boom is blocked up.
ALWAYS block the boom before doing any servicing that requires the boom to be
up. Unexpected lowering of the boom may cause death or serious injury.
3. Temporarily block up or support the boom.

WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic
fluid to cool before servicing any hydraulic component.
4. Open the rear door. Allow the engine, transmission and hydraulic fluid to
cool.
5. Drain the hydraulic oil reservoir. (Refer to the appropriate operators &
safety manual for information concerning the hydraulic oil and filter
change.)
6. Disconnect the battery negative (-) cable (1) or cables at the battery
negative (-) terminal, to prevent the engine from starting accidentally.

8-6 31200079
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.
9. Transfer the used transmission oil into a suitable, covered container,
and label the container as “Used Oil.” Dispose of used oil at an
approved recycling facility. Clean and reinstall the transmission drain
plug.

MV0200

Fig. 8-6: Drain Transmission Oil

10. Remove the engine-to-transmission drive shaft.
11. Remove the transmission-to-axle drive shafts.
12. Remove the hydraulic pump.

31200079 8-7
Transmission

13. Label and disconnect the transmission temperature switch connector

and shift solenoid wiring harness connectors.
14. Remove the capscrew securing the black wire to the transmission
housing, and disconnect the wire. DO NOT reinstall the capscrew at
this time.
15. Remove the capscrew securing the clamp and wiring harness to the
transmission housing, and move the wiring harness safely out of the
way. DO NOT reinstall the capscrew at this time.
16. Label, disconnect and cap the transmission oil cooler inlet (3) and
outlet (4) hoses at the transmission. The transmission oil cooler outlet
hose, routed to the lower radiator fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose, routed to the
upper radiator fitting, is located on top of the transmission.
17. Wipe up any spilled hydraulic and transmission oil.

MV0240

Fig. 8-7: Transmission Oil Cooler Hose Connections

18. Connect a lifting strap or chain to the top of the transmission (18), and
to a suitable hoist or overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the transmission at this
time.
19. Place jack under the transmission to help support it during removal.
20. Remove the two capscrews (19) and two lockwashers (5) securing the
front transmission mount (6) to the transmission.
21. Remove the two capscrews (7), two mount washers (17), two flat
washers (8), two lockwasher (9) and two hex nut (10).
22. Remove the four capscrews (11), four flat washer (12), four lockwasher
(13), and four hex locknuts (14).
23. Remove transmission mount weldment (15).
24. Inspect the rubber mounts (16). Replace the mounts if damaged.

8-8 31200079
Transmission

WARNING: Risk of personal injury. The transmission may move while

hoisting it out of the chassis. Carefully move the transmission and adjust
the sling as needed. Keep fingers, hands, legs and other body parts clear
of the transmission.
25. Carefully remove the transmission from the vehicle. Avoid causing
damage to the transmission or surrounding parts.
26. Lift the transmission clear of the vehicle, and lower it onto suitable
supports or secure it to a stand built especially for transmission or
engine service. Secure the transmission so that it will not move or fall.

7
17

11

18
5
19 6

16

12 8 15
13 9
14 10
MV0250

Fig. 8-8: Remove Transmission from Frame

27. Remove any external transmission components as required, including
the transmission temperature switch (20), and inlet (21) and outlet (22)
cooler hose fittings. Cover all transmission openings.
28. Remove the transmission oil filter (23) and dispose of properly. Clean
the filter mounting surface. Cover or cap the oil filter mount.

31200079 8-9
Transmission

22
20

21

23

MV0260

Fig. 8-9: Transmission External Components

The transmission is now ready for inspection and/or further service. Refer to the
ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135
002) for information on transmission diagnosis, and internal component repair or
replacement.

Transmission Inspection and Internal Repair

Refer to the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455
(ZF P/N 5871 135 002) for information on internal component repair or
replacement. Refer to the ZF 4 WG-98 TC Transmission Technical Data
Manual and Maintenance Manual, P/N 8990449 (ZF part number 5872 134
002) for information on transmission diagnosis and internal schematics.
If replacing the entire transmission, transfer the transmission temperature
switch to the replacement transmission. The gear shift solenoids are
included with a new transmission.

WARNING: Risk of severe personal injury. NEVER lift a transmission

alone; enlist the help of at least one assistant or use a suitable hoist or
overhead crane and sling.

WARNING: The transmission must be properly installed using fasteners

of the correct size and grade, and torqued to their specified values.

Transmission Installation
1. Use a hoist or overhead crane and sling attached to the top of the
transmission. Raise and position the transmission within the chassis.

8-10 31200079
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. Install the two rubber mounts (1) and the rear transmission mounting
bracket (2) on the transmission with two capscrews (7), two mounting
washers (17), two flat washers (8), two lockwashers (9) and two hex
nuts (10)
5. Remove the hoist or overhead crane and sling.

7
17

11

3
5
4 6

12 8 2
13 9
14 10
MV0270

Fig. 8-10: Install the Transmission

6. Secure the wiring harness to the transmission housing.
7. Connect the transmission oil cooler inlet (18) and outlet (19) hose at
the transmission.
8. Install the hydraulic pump.

31200079 8-11
Transmission

19

18

MV0280

Fig. 8-11: Transmission Oil Cooler Hose Connections

9. Install the transmission-to-axle drive shafts.
10. Clean the transmission oil filter mounting surface.
11. Apply a thin film of clean Mobil 424 Tractor/Hydraulic Fluid to the new
transmission filter gasket. Install the new filter and torque to 20-25 lb-ft
(27-34 Nm).
12. Transmission oil may be added through the dipstick tube. Remove the
dipstick and add approximately 3 gallons (11,4 liters) of Mobil 424
Tractor/Hydraulic Fluid. Check the oil level by taking intermittent
dipstick readings as outlined in the appropriate operators & safety
manual. DO NOT overfill. Reinstall the dipstick when finished.
13. Connect the battery negative (-) cable at the battery.

After Transmission Service or Replacement

Refer to the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N
5871 135 002) for information on servicing the transmission after overhaul or
repair. In general:
1. Check the transmission oil level and add oil as required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
4. Wear suitable eye protection. When an overhauled or repaired
transmission is installed, thoroughly clean the oil cooler lines to and
from the transmission.
5. Drain and flush the entire system.
6. Disconnect and clean all transmission cooler hoses. When possible,
remove transmission lines from the machine for cleaning.
7. Thoroughly clean transmission filter screens and cases, and replace
transmission filter elements.

CAUTION: DO NOT exceed 165 psi (11,4 bar) when back flushing the oil cooler.
Applying too much pressure may damage the oil cooler/radiator.

8-12 31200079
Transmission

8. Back flush the transmission oil cooler portion of the radiator or the oil
cooler (located behind the radiator) with oil and compressed air until all
foreign material is removed. Flushing in the direction of normal oil flow
does not adequately clean the cooler. If needed, remove the radiator or
oil cooler from the machine.

IMPORTANT: DO NOT use flushing compounds for cleaning purposes.

9. Reassemble all components and fill the transmission with clean, fresh
Mobil 424 Tractor/Hydraulic Fluid through the dipstick tube opening.
Remove the dipstick and fill with approximately 19 quarts (18 liters) of
Mobil 424 Tractor/Hydraulic Fluid. Check the level by taking intermittent
dipstick readings as outlined in the appropriate Operator/Safety
Manual. DO NOT overfill. Reinstall the dipstick when finished.

10. Run the engine for two minutes at idle to help prime the torque converter
and the transmission oil lines.
11. Recheck the level of the fluid in the transmission with the engine
running at idle.
12. Add Mobil 424 Tractor/Hydraulic Fluid as necessary to bring the fluid
level up until it reaches the FULL mark on the dipstick. Recheck the oil
level when it reaches operating temperature (180-200° F or 83-94° C).
13. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten
where necessary.

Transmission Shift Logic

There are 8 relays, 9 diodes and 2 diode modules which make up the
transmission shift logic circuit. Fig. 8-12.The relays are labeled K11
through K17 (Relay K18 is not part of the transmission shift logic).
Relays K11 through K17 are part of harness assembly part number
4923246.Diodes D1 through D9 are also a part of harness assembly part
number 4923246. Relays K11 through K17 and Diodes D1 through D9 are
located in the cab in a small metal box behind the operator's seat on the
right side of the machine.The 2 diode modules are part of harness
assembly part number 4923243.The purpose of the diode modules is to
allow the solenoids to be energized and de-energized without adverse
effects on the rest of the transmission circuits only. They do not control
how the transmission shifts.The purpose of Diodes D1 through D9 is to
allow current flow in only one direction in a given wire or circuit. It is
extremely important that the polarity of the diodes in the circuit is correct or
the transmission will not shift as it was designed to.
The purpose of the relays is to control how the transmission shifts.
See Fig. 8-12 to determine when each of the relays is supposed to be
energized.

31200079 8-13
Transmission

Normal Operation of the transmission is as follows:

When the boom is not above 20°, the transmission shifts normally (i.e., the
gear selected using the Transmission Shifter is the gear the transmission
shifts to).
When the boom is above 20° and not above 40°, the transmission is limited
to first and second gears. Selecting first gear will put the transmission in
first gear and selecting any other gear will put the transmission in second
gear.
When the boom is above 40°, the transmission is disabled.
When the boom is above 40° and the Transmission Disconnect Override
Footswitch is activated, the transmission will operate in first gear only
regardless of the gear selected with the Transmission Shifter. This is an
extremely dangerous operation – see the Operator's Manual for more
information on this.

Troubleshooting the transmission: If the transmission is not operating as described above, check the
following items:

1. Check the 7.5 amp transmission fuse (F3) on the circuit board in the
cab. If the fuse is blown, replace it with another 7.5 amp fuse. If it blows
again immediately, there is an electrical short somewhere in the
system that must be corrected. Never replace the fuse with one of a
larger amp rating or a fire or other permanent damage to the electrical
system may occur.
2. Check that power is being supplied to the Transmission Shifter at pins
1 and 9.
3. Check that Diodes D1 through D9 are installed in the proper direction
and are functioning properly (they can be tested using a digital
multimeter with a diode mode).Replace any failed diodes that are
found.
4. Check that Relays K11 through K17 are operating properly. Replace
any failed relays that are found.
5. Check the Diode Modules on the harness assembly part number
4923243. If there are failed diodes in the diode module, replace the
internal circuit board with the diodes on it.
6. Check the condition of the wires on each of the harnesses that make
up the transmission shift circuits. See part numbers 4923246, 4923242
and 4923243. If there are damaged wires or loose connections, repair
as necessary or replace the harness.

8-14 31200079
31200079
Troubleshooting
RELAY K11 RELAY K12 RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17

30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85

87a
87a
87a
87a
87a
87a
87a

N/C
N/C
N/C
N/C
N/C
N/C

JUMPER 1
JUMPER 1
JUMPER 2
JUMPER 2

RELAY GND
RELAY GND
RELAY GND
RELAY GND
RELAY GND
RELAY GND
RELAY GND

IGN POWER
IGN POWER
IGN POWER
IGN POWER

SHIFTER Y5
SOLENOID Y1

SOLENOID Y6
SOLENOID Y2

SHIFTER PWR
BOOM 21-40
BOOM 21-40
REVERSE SGN

SHIFT TO 1ST
SHIFTER Y6 A
FORWARD SGN

BOOM OVER 40
BOOM OVER 20
BOOM OVER 40
D1 D2 D3 D4 D5
PLUGGED
A
PLUGGED
B
PLUGGED
C
IGN POWER
D

SOLENOID Y1
1
SOLENOID Y2
2
SOLENOID Y3
3
DASH GND
7

RELAY GND
A
FORWARD SGN
B
REVERSE SGN
C
BOOM OVER 40
D
PLUGGED
E
BOOM OVER 20
F

RELAY K18
30
87
86
85

87a

DIRECTION INPUT
A
FORWARD
B
REVERSE
C
NEUTRAL A
D
N/C
NEUTRAL
NEUTRAL A
FROM E1.A (SHT 1)
FROM E2.A (SHT 1)

SOLENOID Y4
4
SOLENOID Y5
5
D10 SOLENOID Y6
6
DASH GND
7

DIRECTION INPUT
1
FORWARD
2
REVERSE
3
NEUTRAL
4

Fig. 8-12: Transmission Shift Logic Schematic

SHIFTER Y5 D6
5
SHIFTER Y4 D7
6
SHIFTER Y3 D8

problems that may occur during operation of the transmission.

7
SHIFTER Y6 D9
8
SHIFTER PWR
9
PLUGGED
10
PLUGGED
11
PLUGGED
12

MV0590

This section provides an easy reference guide covering the most common
Transmission

8-15
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).
The transmission should be checked, serviced and repaired only by experienced
service technicians who are aware of all safety instructions and particular
component features.

Transmission Troubleshooting

Problem Cause Remedy

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with Universal Tractor Fluid.
(Refer to the appropriate
owners/operators manual.)
2. Travel select lever not 2. Refer to Section 9.14.7, a.
functioning properly and/or a “Travel Select Lever and Wiring
fault in the wiring harness. Harness Testing.”
3. Transmission valve body 3. Refer to Section 9.14.7, b.
solenoids not functioning “Upper and Lower Transmission
properly. Valve Body Solenoid Testing.”
4. Pilot-operated shift valves not 4. Clean the valve spool and
operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section , “Transmission
Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.
damaged.

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with Universal Tractor Fluid.
(Refer to the appropriate
owners/operators manual.)
2. Transmission filled with incorrect 2. Drain transmission and fill to
oil, or oil contaminated. correct level with Universal
Tractor Fluid. (Refer to the
appropriate owners/operators
manual.)
3. Pump suction pipe screen 3. Clean, repair and/or replace
clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump
assembly.

8-16 31200079
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.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.
piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and
open. housing.

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.8, “Hydraulic
Circuits and Troubleshooting.”
2. Low engine rpm causes 2. Adjust the engine rpm to
converter stall. specifications. Refer to
Cummins Service Manual.
3. Pump output pressure is low. 3. Refer to Section , “Transmission
Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section , “Transmission
Troubleshooting,” Problem 5.
“Transmission overheating (oil
above 248° F [120° C]).”

5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level

(oil above 248° F [120° C]). with Universal Tractor Fluid.
Refer to the appropriate
owners/operators manual.
2. Clogged radiator. 2. Remove debris from the
radiator.
3. Transmission filled with incorrect 3. Drain transmission and fill to
oil, or oil contaminated. correct level with Universal
Tractor Fluid. Refer to the
appropriate owners/operators
manual.
4. Excessive “roading.” 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump
assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat.
Refer to Section 7B.6.2, b.
“Thermostat Installation.”

31200079 8-17
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. Transmission filled with incorrect 2. Drain transmission and fill to
oil. correct level with Universal
Tractor Fluid. Refer to the
appropriate owners/operators
manual.
3. Incorrect clutch engagement. 3. Refer to Section 9.14.7,
“Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as
needed.
5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).
Refer to Section , “Transmission
Removal.”
6. Loose diaphragm (flex plate) 6. Tighten capscrews.
mounting capscrews.

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to the appropriate
owners/operators manual).
Replace o-rings as needed and
tighten plugs to 96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and
damaged or missing. tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten
(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft
(46 Nm).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten
pump-to-housing o-rings capscrews to 85 lb-ft (115 Nm).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input
(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft 8. Replace output shaft seal.
(output shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.

8-18 31200079
Section 9 — Axles and Brakes

Table of Contents

Axle and Drive Shaft Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Axle Inspection, Internal Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
DriveShaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Transmission-to-Axle Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Service Brake Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Pre-Charging Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Checking Pre-charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

List of Figures

Fig. 9-1: Axle and Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Fig. 9-2: Service Brake Pedal Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fig. 9-3: Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Fig. 9-4: Accumulator Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Fig. 9-5: Park Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

31200079 i
ii 31200079
Section 9 — Axles and Brakes

Axle and Drive Shaft Component Terminology

To understand the safety, operation and maintenance information
presented in this section, it is necessary that the operator/mechanic be
familiar with the names and locations of the major assemblies of the axles
and drive shafts. The following illustration identifies the components that
are referred to throughout this section.

REAR STEERING
CYLINDER

TRANSMISSION
DROP BOX

FRONT STEERING
CYLINDER
REAR DRIVE
SHAFT

FRONT DRIVE
SHAFT

FRONT AXLE
ASSEMBLY MV0350

Fig. 9-1: Axle and Drive Shaft

General Information
IMPORTANT: To help ensure optimum performance, the drive shaft assemblies
are specially balanced as a unit at the factory. When servicing any flange yoke,
slip yoke or drive shaft tube, order a complete assembly if components are bent or
damaged. Refer to the appropriate parts manual for ordering information.
Before performing any inspection, maintenance or service operation,
thoroughly clean the unit. The axles and drive shafts should be checked
and repaired only by experienced service technicians who are aware of all
safety instructions and particular component features.

31200079 9-1
Axles and Brakes

Use suitable products to thoroughly clean all disassembled mechanical

parts to help prevent personal injury to the worker and prevent damage to
the parts. Carefully inspect the integrity of all moving parts (bearings,
yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.)
as they are subject to major stress and wear. Always replace elastic
locknuts and any damaged, worn, cracked, seized or otherwise improper
parts that could affect the safe and proper functioning of the machine,
axles and drive shafts.

Axle Assembly

Axle Maintenance

Note: Detailed axle service instructions (covering the axle, differential, brakes and
wheel-end safety, repair, disassembly, reassembly, adjustment and
troubleshooting information) are provided in the Zahnradfabrik (ZF) Repair
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.

WARNING: Risk of death or serious personal injury if components are

assembled improperly, if components are assembled
improperly, if incompatible, worn or damaged components are
used, or if components are used in a non-approved
application. Obtain proper training, follow recommended
procedures, and use proper tools and safety equipment. Wear
safety glasses at all times when working on the machine and
machine components.

WARNING: An improperly supported machine can fall, causing death or

serious injury. When removing the axle assembly from the
machine, properly support the machine. If servicing axle
components with the axle attached to the machine, securely
support the carrier, differential, pinion assemblies and wheel
ends.

Important:When replacing a fastener, replace it with one of equal or

higher grade and quality. Torque fasteners to the specified
value for the application.
Important:The use of replacement parts provided by other than the original
manufacturer is not recommended, as such use may cause axle
failure and affect machine safety.
• Some service operations require the use of tools specifically designed
for the purpose. Use the special tools when and as recommended.

9-2 31200079
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 Zahnradfabrik (ZF) axle service manual.
• DO NOT attempt carrier and differential removal and installation, and
differential and pinion disassembly and assembly, without thoroughly
understanding the instructions in the appropriate Zahnradfabrik (ZF)
publications.
• Before disassembling any parts inside the carrier, remove the entire
axle assembly from the machine and securely support it with the pinion
facing up in an appropriate stand or rack.
• DO NOT reuse oil or grease seals.
CLEANING: Clean parts with machined or ground surfaces (such as
gears, bearings and shafts) with emulsion cleaners or petroleum-based
cleaners. DO NOT steam clean internal components and the interior of the
planetary hub and axle housing. Water can cause corrosion of critical
parts. Rust contamination in the lubricant can cause gear and bearing
failure. Remove old gasket material from all surfaces.
DRYING: Use clean, lint less towels to dry components after cleaning. DO
NOT dry bearings by spinning them with compressed air; this can damage
mating surfaces due to lack of lubrication. After drying, lightly coat
components with oil or a rust-preventive chemical to help protect them
from corrosion. If storing components for a prolonged period, wrap them in
wax paper.
PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the
machine far enough to cause the drive-train components to make several
complete revolutions. This will help ensure that internal components
receive lubrication to minimize deterioration caused by environmental
factors such as high humidity.
SUBMERSION: If the machine has been exposed to water deep enough
to cover the hubs, disassemble the wheel ends and inspect for water
damage and contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent tube (breather),
drain the axle and inspect internal parts for water damage and
contamination. Before assembling and refilling the unit with the specified
lubricant(s), clean, examine and replace damaged parts as necessary.

Note:Use a suitable puller for bearing removal. Clean, inspect and

lubricate all bearings just prior to reassembly. If replacement of a
damaged bearing cup or cone is necessary, replace the cup and
cone as a set.

WARNING: Avoid prolonged engine operation in closed areas without

adequate ventilation. Failure to properly ventilate exhaust
fumes can result in death or severe personal injury.

WARNING: Escaping hydraulic fluid under pressure can penetrate the

skin, causing death or serious injury. Before starting the
engine, tighten all hydraulic connections and remove all tools

31200079 9-3
Axles and Brakes

from the machine. NEVER check for leaks using any part of
the human body; use a piece of cardboard or wood instead.
Wear heavy, protective gloves and eye protection.

WARNING: An improperly supported machine can fall, causing death or

severe personal injury. Safely raise and adequately support
the machine so that it will remain stable and in place before
attempting to remove an axle.

WARNING: Hot hydraulic fluid can cause severe burns. 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.

The front and rear axle assemblies differ in that the front axle assembly is
equipped with a parking brake mechanism and a limited-slip feature; the
rear axle has neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle assembly.
Cleanliness is extremely important. Before attempting to remove the axle,
thoroughly clean the machine. Avoid spraying water or cleaning solution on
the stabilizer solenoids and other electrical components. If using a steam
cleaner, seal all openings before steam cleaning.
IMPORTANT: Clear the work area of all debris, unnecessary personnel,
etc. Allow sufficient space to raise the machine and to remove the axle.
1. Park the machine on a firm, level surface, level the machine, ground the
attachment, place the travel select lever in the (N) NEUTRAL position,
engage the parking brake, straighten all wheels 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.
3. Open the engine compartment cover. Allow the engine, transmission
and hydraulic fluid to cool.
4. Disconnect the battery negative (-) cable at the battery negative (-)
terminal to prevent the engine from starting accidentally.
5. If the axle will be disassembled after removal, place a suitable
receptacle under the axle drain plug. Remove the drain plug and allow
the axle oil to drain into the receptacle. Transfer the used axle oil into a
suitable covered container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.
6. Label, disconnect and cap the steering and brake lines at the axle.
Wipe up any spilled oil.
7. Block the front and rear of both tires on the axle that is not being
removed. Ensure that the machine will remain in place during axle
removal before proceeding.

9-4 31200079
Axles and Brakes

8. Raise the machine using a suitable jack or hoist. Place suitable

supports under both sides of the frame and lower the machine onto the
supports. Ensure that the machine will remain in place during axle
removal.
9. Support the axle that is being removed with a suitable jack, hoist or
overhead crane and sling. DO NOT raise the axle or the machine.
10. Mark and remove both wheel and tire assemblies from the axle that is
being removed.
Note: The wheel and tire assemblies must be re-installed later with the
directional tread pattern “arrows” facing in the direction of forward travel.
11. Remove the drive shaft assemblies.
12. On the front axle remove the capscrew and locknuts securing the lower
position cylinder-mount pin to the front cylinder. Tap the cylinder mount
pin out, and move the cylinder to prevent it from interfering with axle
removal.
13. Remove the four bolts and locknuts securing the axle to the frame.
14. Remove the axles from the machine using the jack, hoist or overhead
crane and sling supporting the axle. DO NOT raise or otherwise disturb
the machine while removing the axle. Balance the axle and prevent it
from tipping, turning or falling while removing it from beneath the
machine. Place the axle on a suitable support or holding stand.

Axle Inspection, Internal Service and Repair

Detailed axle service instructions (covering the axle, differential, brakes
and wheel-end safety, repair, disassembly, reassembly, adjustment and
troubleshooting information) are provided in the Axle Repair Manuals.
(Refer to The 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.

Axle Installation
The front and rear axle assemblies differ in that the front axle assembly is
equipped with a parking brake mechanism and limited-slip feature; the rear
axle has neither. The steps below outline a typical axle installation
procedure, suitable for either the front or the rear axle assembly.
1. Before proceeding, ensure that the machine will remain in place during
axle installation. Block the front and rear of both tires on the axle that is
already installed on the machine.
2. If applicable, raise the machine using a suitable jack or hoist. Place
suitable supports beneath the frame and lower the machine onto the
supports, allowing enough room for axle installation. Ensure that the
machine will remain in place during axle installation.

31200079 9-5
Axles and Brakes

3. Using a suitable jack, hoist or overhead crane and sling, remove the
axle from its support or holding stand. Balance the axle and prevent it
from tipping, turning or falling while positioning it beneath the machine.
DO NOT raise or otherwise disturb the machine while installing the
axle. Keep the axle supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation procedure.
4. Position the axle under the frame, and align the axle housings with the
holes in the frame.
5. Install the four axle bolts and nuts.
6. Move the cylinder into position on the axle cylinder anchor. Insert a
cylinder-mount pin through the cylinder and cylinder anchor. Secure
the cylinder-mount pin with one capscrew and a new locknut.
7. Apply multi-purpose grease through the self-tapping lube fitting to
lubricate the self-align bearing and the cylinder-mount pin.
8. Install the drive shaft assemblies.
9. If reinstalling an axle previously removed from the machine, position
the driveshaft yoke on the axle according to the alignment marks made
earlier. If installing a new axle, note the position of the driveshaft yoke
at the transmission. Align the driveshaft yoke on the axle in the same
plane as the yoke on the transmission.
10. Install the wheel and tire assemblies.
11. Carefully remove the jack, hoist or overhead crane and sling
supporting the axle.
12. Carefully raise the machine using a suitable jack or hoist. Remove the
supports from beneath the frame and lower the machine to the ground.
13. Remove the blocks from the front and rear of both tires on the other
axle.
Note: ALWAYS use new o-rings when servicing the machine.
14. Install new o-rings into the fittings. Lubricate the o-rings with clean
hydraulic oil.
15. Uncap and connect the steering and brake lines at their axle fittings.
16. Check the hydraulic reservoir oil level.
17. Start the engine. Turn the steering wheel several times lock to lock,
operate the frame tilt function several times in both directions and
check the function of the brakes. Check for hydraulic leaks, and tighten
or repair as necessary.

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.

9-6 31200079
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.

Drive Shafts

Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual inspection of the drive

shafts and cross and bearing assemblies (universal joints, or U-joints). A
few moments spent doing this can help prevent further problems and down
time later.
Inspect areas where the drive shaft flange yokes and slip yokes mount to
the drive shafts. Attempt to turn each drive shaft in both directions. Look
for excessive looseness, missing parts, cracks or other damage. Worn or
damaged drive shafts and cross and bearing assemblies may cause an
excessive amount of vibration or noise.
Individually inspect each cross the needle bearings and cap for signs of
wear or for missing parts.

Note: Replace the cross and bearings as a complete assembly if any parts are
worn or missing. If all parts of the cross and bearing assemblies are in good
condition, pack the bearing caps with a premium grade of multi-purpose
wheel-bearing grease. Reattach the bearing cap to the cross, assuring that
all needle bearings are present. Then, reassemble the cross and bearing
assembly into the drive shaft yoke.
1. Replace the felt seal if worn or damaged.
2. Replace the entire drive shaft assembly if any flange yoke, slip yoke or
drive shaft tube is severely dented or damaged.
Cross assemblies should flex and be free from excessive binding. A slight
amount of drag or resistance is desirable on a new cross and bearing
assembly. Excessive looseness causes unbalance.

31200079 9-7
Axles and Brakes

7
2
3
4

8
9 5
6
7

1
11 9
10

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.

DriveShaft Removal
Important: To help ensure optimum performance, the drive shaft assemblies are
specially balanced as a unit at the factory. When servicing any flange
yoke, slip yoke or drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the appropriate parts manual
for ordering information.

Note: The drive shaft assemblies are balanced assemblies. Mark the yoke and
axle, transmission, transfer case, and the shaft and slip yoke so that these
components can be returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the same plane to help
prevent excessive vibration.

9-8 31200079
Axles and Brakes

Transmission-to-Axle Drive Shaft

1. Level the machine, ground the carriage, place the travel select lever in
the (N) NEUTRAL position, engage the parking brake switch and shut
the engine OFF.
2. Place an Accident Prevention Tag on both the ignition key switch and
steering wheel, stating that the machine should not be operated.
(Refer to Section 1.5, “Accident Prevention Tags.”)
3. Open the engine compartment access door. Allow the engine,
transmission and hydraulic fluid to cool.
4. Disconnect the battery negative (-) ground cable at the battery
negative (-) terminal to prevent the engine from starting accidentally.
5. The drive shaft assembly is a balanced assembly. Mark the yoke and
axle, transmission and the shaft and slip yoke so that these components
can be returned to their original positions when reinstalled. Yokes at
both ends of the drive shaft must be in the same plane to help prevent
excessive vibration.
6. Remove the four capscrews and two straps securing the bearing cross
to the transmission output shaft flange.
7. Remove the four capscrews and two straps securing the bearing
crosses to the axle.
8. Remove the front drive shaft assembly.
9. Repeat the above procedure on the rear drive shaft.

Drive Shaft Disassembly

Important: To help ensure optimum performance, the drive shaft assemblies are
specially balanced as a unit at the factory. When servicing any flange
yoke, slip yoke, or drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the appropriate Parts
Manual for ordering information.
1. Use an approved, non-flammable cleaning fluid to thoroughly clean the
drive shaft assembly with a brush. Wipe dry before disassembling.

CAUTION: Avoid using excess force when clamping the drive shaft in a
vise. Apply only enough force to hold the drive shaft securely.
Excessive force can damage the drive shaft, resulting in an
unbalanced condition.

2. Place the drive shaft assembly in a bench vise.

3. Use a pair of pliers to pinch the ends of the snap rings securing the
cross and bearing assemblies to the yoke. Remove the snap rings from
their grooves in the yoke.

Note: If the snap rings fail to readily snap out of their grooves in the yokes, tap the
end of the bearing cap lightly to help relieve pressure against the snap
rings.

31200079 9-9
Axles and Brakes

MV0380

4. Use a soft, round drive pin with a flat face approximately 1/32" (0,8
mm) smaller than the hole diameter in the yoke to drive on one end of
the cross and bearing assembly until the opposite bearing assembly
comes out of the yoke.
5. Turn the yoke over and tap on the exposed end of the cross until the
opposite bearing assembly comes out of the yoke.
6. Remove the cross from the yoke.
7. Repeat Steps 2 thru 6 to remove the cross and bearing assembly on
the other end of the drive shaft.

Drive Shaft Assembly

1. Install the dust cap, split retaining ring and felt seal onto the splines of
the drive shaft tube assembly.
Important: Ensure that the reference marks made before removal on the drive
shaft and slip yoke are aligned. The drive shaft and yokes must be in
the same plane to help prevent excessive vibration.
2. Align the reference marks made previously on the drive shaft and slip
yoke.
3. Slide the slip yoke onto the splines of the drive shaft and tighten the
dust cap securely. DO NOT overtighten or the cap will break.
4. Install the cross and bearing assembly into the yoke.
5. Secure the cross and bearing assembly into the yoke with snap rings.
Pinch each snap ring with a pliers and insert them into their grooves in
the yoke.

9-10 31200079
Axles and Brakes

6. Apply grease to grease fitting on slip yoke.

Drive Shaft Installation

Important: To help ensure optimum performance, the drive shaft assemblies are
specially balanced as a unit at the factory. When servicing any flange
yoke, slip yoke or drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the appropriate parts
manual for ordering information.

Transmission-to-Axle Drive Shafts

1. Raise the drive shaft assembly into position. The slip-yoke end of the
drive shaft mounts toward the axle. If reinstalling a drive shaft
previously removed, align the flange yokes according to the alignment
marks made during removal.
Important: Yokes at both ends of the drive shaft must be in the same plane to
help prevent excessive vibration.
2. Install the four capscrews and two straps securing the bearing crosses
to the transmission. Torque the capscrews to 60 lb-ft (81 Nm).

31200079 9-11
Axles and Brakes

Service Brakes

Service Brake Pressure Switch Replacement

Mid-Inlet Hydraulics

1
2

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. 9-2). This switch is normally open and is set to
close above 250 psi.
1. Follow preparation procedures as outlined in Section 3 and in
Section 5 of this manual.
2. Tag and disconnect the wiring harness connector (Item 1) from the
connector on the brake pressure switch (Item 2).
3. Remove the brake pressure switch from the connector tee (Item 3).
Discard the pressure switch.
4. Install a new brake pressure switch.
5. Reconnect the wiring harness connector (Item 1) to the connector on
the brake pressure switch.

9-12 31200079
Axles and Brakes

Accumulator

General
The accumulator is a 3000 psi piston-type accumulator. It has a oil volume
of 116 cubic inches and gas volume of 126 cubic inches, with a bore size
of four inches.
The pneumatic accumulator is operated by compressed gas. Gas and
hydraulic oil occupy the same container. When oil pressure rises, incoming
oil compresses the gas. When oil pressure drops, the gas expands, forcing
oil out. The gas is separated from the oil by a “free floating” piston (see
Fig. 9-3). This prevents mixing of gas and oil and keeps gas out of the
hydraulic system. The piston (Item 4) fits into a smooth bore and uses
seals (Item 6) to separate gas (Item 3) from oil (Item 5). O-rings (Item 2) in
the end caps prevent leakage of gas/oil.
The accumulator must be “pre-charged” with gas before use in a system.
This is done by filling the gas chamber with dry nitrogen to a pressure of
400 psi. The gas valve (Item 1) is used for pre-charging and testing the
accumulator.

4
6

2
K1117

To Hydraulic System
# Description # Description
1 Gas Valve 4 “Free-Floating” Piston
2 End Cap O-Rings 5 Oil Chamber
3 Gas Chamber 6 Piston Seals

Fig. 9-3: Accumulator

31200079 9-13
Axles and Brakes

Precautions

WARNING: Never fill an accumulator with oxygen! An explosion could

result if oil and oxygen mix under pressure. Always fill an
accumulator with dry nitrogen. Nitrogen gas is free of water
vapor and oxygen which makes it harmless to parts and is
safe to use.

CAUTION: Never fill an accumulator with air. When air is compressed,

water vapor condenses and can cause corrosion. This may
damage seals and ruin the accumulator.

CAUTION: Never charge an accumulator to a pressure more than that

specified. Pressure should be 375–425 psi.

WARNING: Always release all hydraulic pressure before removing an

accumulator from the system.

CAUTION: Before disassembling an accumulator, release both gas and

hydraulic pressure. When disassembling an accumulator,
make sure that dirt and abrasive materials do not enter any
openings.

Pre-Charging Accumulator

Note: Replacement accumulators shipped from the factory are not pre-charged.
Make sure the nitrogen bottle, as well as the charging and gauging
assembly used, is compatible with the gas valve assembly. The nitrogen
source and all components must be rated for a pressure at least as high as
the nitrogen source. It is strongly recommended that the nitrogen bottle
has a high pressure regulator. Nitrogen gas bottles for water-pumped
nitrogen have right-hand valve threads and are used with accumulators up
to 3000 psi.

9-14 31200079
Axles and Brakes

5
1
4
6
2
3 7

8
9

10

K1018
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. 9-4):
1. Follow preparation procedures as outlined in Section 3 and in
Section 5 of this manual.
2. Make sure nitrogen supply is shut off.
3. Attach hose (Item 7) to nitrogen bottle.
4. Remove two (2) capscrews (Item 1), valve guard (Item 2), and gas
valve cap (Item 3).
5. Back “T” handle (Item 8) on accumulator test gauge (Item 5) all the
way out (counterclockwise). The pressure gauge must have 2500 psi
capacity (correctly calibrated).
6. Mount test gauge on accumulator gas valve (Item 9) and tighten. Be
sure of an air-tight connection when mounting gauge.
7. Close (turn in) bleed valve (Item 4).
8. Remove gauge cap (Item 6) from test valve.
9. While making sure not to loop or twist the hose, attach swivel nut on
nitrogen hose (Item 7) to gas valve.

31200079 9-15
Axles and Brakes

10. Turn “T” handle all the way down. This will depress (open) the core in
the gas valve.
11. Crack open nitrogen bottle valve and slowly fill the accumulator. Close
the nitrogen bottle valve when gauge indicates desired pre-charge
pressure (400 psi).
12. Let the pre-charge set for 10–15 minutes. This will allow the gas
temperature to stabilize. If the desired pre-charge range (375–425) is
exceeded, close nitrogen bottle valve, then slowly open the bleed valve
(Item 4) until desired pressure is reached.

CAUTION: Do not reduce pre-charge by depressing valve core with a

foreign object. High pressure may rupture rubber valve seat.

13. When finished pre-charging accumulator, turn “T” handle all the way
out, then open (turn out) bleed valve.
14. While holding the gas valve to keep it from turning, loosen and remove
swivel nut on nitrogen hose (Item 7).
15. Install gauge cap on test valve. Remove test gauge and replace gas
cap on valve (Item 3). Torque gas cap to 10–15 in-lbs. (Gas cap acts
as a secondary seal.)
16. Install gas valve guard and two (2) capscrews on the accumulator gas
end cap. Torque capscrews to 35 ft-lbs.

Checking Pre-charge

Gas Leaks

If an external gas leak is suspected, apply soapy water to the gas valve
and seams of the gas end cap. If bubbles form, there is a leak.
If and internal gas leak is suspected, check for foaming oil in the hydraulic
reservoir and/or no accumulator action. These signs usually mean faulty
piston seals inside the accumulator.

Checking Accumulator Recharge Pressure and Nitrogen Pre-Charge

1. Park the vehicle on a level surface, lower boom to the ground, and
engage park brake.
2. While the engine is off, pump brake pedal repeatedly until accumulator
is discharged. This will allow the “free-floating” piston to bottom against
the hydraulic end cap.
3. Connect a high pressure gauge to the test port marked “ACCUM.”
located behind the cab step.
4. Start the engine and slowly pump the brake pedal while closely
watching the test gauge.

9-16 31200079
Axles and Brakes

5. Record the lowest pressure observed before the accumulator

recharges. The pressure should be 950–1200 psi. This reading is the
accumulator recharge pressure.
6. Shut the engine off.
7. Slowly pump the brake pedal while closely watching the pressure
gauge.
8. Record the lowest pressure observed before the pressure drops to
nearly zero. This reading is the nitrogen pre-charge. This pressure
should be 375–425 psi.
9. If either of the recorded readings are outside the recommended
ranges, contact the JLG Service Department.

Towing a Disabled Machine

Towing a disabled machine should only be attempted as a last resort, after
exhausting all other options. Make every effort to repair the machine, and
move it under its own power, before using the emergency towing
procedure outlined below.
Important: In the event the vehicle is disabled and cannot be 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.

MV0340

Fig. 9-5: Park Brake Hoses

31200079 9-17
Axles and Brakes

Manually Releasing the Park Brake

If it is necessary to tow the vehicle a short distance to avoid a potentially
hazardous situation such as being in an unsafe area on the worksite or on
a roadway, prepare the vehicle for towing as follows;
1. Remove the load from the vehicle.
2. Fully retract the transfer carriage.
3. Fully retract the boom. Position the forks approximately 24" above the
ground.
4. Block all four wheels to prevent any unexpected movement of the
vehicle after the parking brake is disabled.
5. Position the towing vehicle in place. Attach a rigid tow bar to the
disabled vehicle.
6. Disconnect hose (2) from elbow (1) that is located on front of frame.
7. Attach a remote portable hydraulic pressurizing unit to elbow (1).
8. Clear the area of any unnecessary personnel.
9. Have an operator seated in the seat.
10. Turn the ignition switch to the ON position (with the engine not
running), release the park brake (park brake switch OFF).
11. Pressurize the park brake with the pressurizing unit. Pump pressure
into the park brake system. DO NOT exceed 425 psi.
12. Watch the pressure gauge on the pressurizing unit to ensure that the
pressure in the park brake system does not drop during the towing
operation.
13. Carefully remove the blocks from the four wheels of the vehicle.
14. The vehicle can now be towed or pushed out of the way. Tow or push
the vehicle at a very slow speed!

Manually Resetting the Park Brake

Important: Block the wheels of the machine BEFORE attempting to reset the
machine’s park brake. Once the park brake is released the machine’s
park brake AND service brakes are inoperable.
1. Disconnect remote portable hydraulic pressurizing unit from elbow (1).
2. Connect hose (2) to elbow (1) that is located on front of frame.
3. After repairs to the machine have been made, start the machine and
check the park brake and service brakes for proper function.

9-18 31200079
Section 10 — Outriggers

Table of Contents

Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Differential Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Boom Extension Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

List of Figures

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

Fig. 10-2: Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Fig. 10-3: Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Fig. 10-4: Outrigger Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Fig. 10-5: Outrigger Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Fig. 10-6: Boom Extension Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Fig. 10-7: Boom Extension Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Fig. 10-8: Boom Extension Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Fig. 10-9: Boom Extension Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Fig. 10-10: Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fig. 10-11: Outrigger Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

31200079 i
Section 10 — Outriggers

Outriggers

General

60 80
40
20
0
-20

V1083
Fig. 10-1: Outriggers
Outriggers increase the stability of the machine when lifting and placing
loads.

31200079 10-1
Outriggers

Removal

Outriggers
1
9
3
2
5 10
11
12
6 4 13
7

14
8
20 21 15
16
19
17
18

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 19 Lockwasher
9 Capscrew 20 Capscrew
10 Capscrew 21 Grease Fitting
11 Lockwasher

Fig. 10-2: Outrigger Installation

(Ref. Fig. 10-2) The following procedure describes removal of the
outrigger.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Disconnect any attachments and raise the boom enough so easy
access can be made to the outrigger. Apply the parking brake and fully
retract the boom extension cylinder. Raise the outrigger foot pads
completely and shut the engine off.
3. Support the boom and extension cylinder with sling(s) and crane or
other suitable means. Make sure support items have sufficient capacity
to support the weight of the boom and cylinder; the combined weight of
the boom and extension cylinder is approximately 6650 pounds.

10-2 31200079
Outriggers

DANGER: Support of the boom is essential to avoid the possibility of

injury or death should the boom fall. Use suitable blocking and
lifting devices when removing heavy machine components.

4. Place blocks or other means of support under the front and rear
corners of the outrigger frame. Make sure supports are adequate to
support the weight of the outrigger; the outrigger weighs approximately
2585 pounds.
5. Disconnect the wiring harness (Item 4) from the differential pressure
switch (Item 2) from both cylinders. Remove the ties (Item 3) securing
pressure switch wires to wiring harness or hydraulic hoses.
6. Loosen and remove two (2) hydraulic hoses (Item 6) from elbows
(Item 5) on both outrigger cylinders (Item 1). Tag hoses and fittings.
Bleed any remaining oil into a suitable container.
7. Remove the nut (Item 18), lockwasher (Item 19), and capscrew
(Item 20) from the shaft assembly (Item 17).
8. Remove all ties around hydraulic hoses and wiring harness.
9. Remove the capscrew (Item 10), lockwasher (Item 11), and double
tube clamp (Item 12) securing the hydraulic tubes to the clamp plate
(Item 13) on each side of the machine.
10. Remove four (4) each nuts (Item 16), starwashers (Item 15), jam nuts
(Item 14), and capscrews (Item 9) securing each of the clamp plates
and the outrigger assembly to the axle. Remove the clamp plates.
11. Remove the wiring harness and hoses from outrigger and secure them
to the main frame.
12. Start the engine and slowly back the machine away from the outrigger.

Installation

Outriggers (Ref. Fig. 10-2) The following procedure describes installation of the
outrigger.
1. If the bushing and shaft assembly were removed,
a. Install the shaft assembly (Item 17) on the bushing, making sure
the port for a grease fitting is on the rights side of the machine.
b. Install a grease fitting (Item 21) on the shaft assembly. Torque the
grease fitting to 1.5–3 turns past finger tight. Install a grease fitting
cover (Item 8) on the grease fitting.
2. With the boom raised and fully supported, use sling(s), crane or other
suitable means of support to position the outrigger until it can be slid
onto the shaft assembly (Item 17).
3. Temporarily install a capscrew (Item 20) into the orifice in the shaft
assembly (Item 17). Measure the gap between the outrigger assembly
and the support plate boss on the main frame.
4. Remove the capscrew and outrigger assembly.

31200079 10-3
Outriggers

5. Install as many shims (Item 7) as needed on shaft assembly to fill the

gap measured in Step 3.

Note: Shims are available in three different sizes – 16, 20, and 24 gauge.
6. Reinstall the outrigger on the shaft assembly and secure it with a
capscrew (Item 20), lockwasher (Item 19), and nut (Item 18). Torque
the nut to 130 ft-lbs.
7. Secure the outrigger to each side of the axle with a clamp plate
(Item 13) and four (4) capscrews (Item 10), jam nuts (Item 14),
starwashers (Item 15), and nuts (Item 16). Torque nuts to 320 ft-lbs.
8. Install two (2) hydraulic hoses (Item 6) on the two (2) elbows (Item 5)
on each outrigger cylinder (Item 1). For final tightening, torque swivel
nuts on hoses to 44–48 ft-lbs.
9. Connect the wiring harness (Item 4) on the differential pressure switch
(Item 2). Install a tie (Item 3) to secure the pressure switch wires to the
wiring harness or the hydraulic hoses.
10. Secure the wiring harness and hydraulic hoses to the clamp plate with
a double tube clamp (Item 12), lockwasher (Item 11), and capscrew
(Item 10). Torque the capscrew to 276 in-lbs.

Outrigger Cylinders

60 80
40
20
0
-20

General

V1082

Fig. 10-3: Outrigger Cylinders

10-4 31200079
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

23 4
1

11
10
9
8

14
13
12

V1084
# 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 12 Capscrew
6 Hydraulic Hose 13 Lockwasher
7 Pin 14 Lock Pin

Fig. 10-4: Outrigger Cylinder Installation

(Ref. Fig. 10-4) The following procedure describes removal of the outrigger
cylinders.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Lower the boom, apply the parking brake, raise the outrigger foot pads
completely, and shut the engine off.
3. Disconnect the wiring harness (Item 1) from the differential pressure
switch (Item 3) on both cylinders. Remove the ties (Item 2) securing
the pressure switch wires to the wiring harness or the hydraulic hoses.
4. Loosen two (2) hydraulic hoses (Item 6) from the elbows (Item 5) on
both outrigger cylinders (Item 4).

31200079 10-5
Outriggers

CAUTION: Use suitable blocking and lifting devices when removing the
cylinders. Care must be taken when removing and lifting the
cylinders to prevent personal injury or equipment damage.

5. Place blocking device under the top of the outrigger cylinder. Remove
the capscrew (Item 12) and lockwasher (Item 13) from the lock pin
(Item 14). Remove the lock pin and upper pin (Item 11).
6. Remove a capscrew (Item 8) and lockwasher (Item 9) from the lock pin
(Item 10). Remove the lock pin and lower pin (Item 7).
7. Remove the outrigger cylinder.
8. Repeat Steps 5–7 for the remaining outrigger cylinder.

Installation

Outrigger Cylinders (Ref. Fig. 10-4) The following procedure describes installation of the
outrigger cylinders.
1. Use a suitable lifting device to place the outrigger cylinder in its proper
location. Secure the cylinder to the outrigger by installing the lower pin
(Item 7).
2. Secure the cylinder to outrigger with the upper pin (Item 11).

Note: Be sure to apply blue thread sealant to the threads of the capscrews before
installing them.
3. Secure the upper pin by installing a lock pin (Item 14), lockwasher
(Item 13), and capscrew (Item 12). Torque the capscrew to 55 ft-lbs.
4. Secure the lower pin by installing a lock pin (Item 10), lockwasher
(Item 9), and capscrew (Item 8). Torque the capscrew to 55 ft-lbs.
5. Repeat Steps 1–4 for the remaining cylinder.
6. Install two (2) hydraulic hoses (Item 6) on elbows (Item 5) on both
outrigger cylinders (Item 1). For final tightening, torque the swivel nuts
on hoses to 44–48 ft-lbs.
7. Connect the wiring harness (Item 4) to the differential pressure switch
(Item 2). Install a tie (Item 3) to secure the pressure switch wires to
wiring harness or hydraulic hoses.

10-6 31200079
Outriggers

Overhaul

Outrigger Cylinders

11

10
6 9
5 8
7

14
12 13
4

15
3

2 17 12
1 4

16
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
8 Counterbalance Valve Cartridge 17 Setscrew
9 Cylinder Barrel 18

Fig. 10-5: Outrigger Cylinder Assembly

(Ref. Fig. 10-4) The following procedure describes removal of the outrigger
cylinders.
1. Mount or support the cylinder vertically with the rod end down.
Hydraulic oil in cylinder will drain out during disassembly. Place a
suitable pan or tray under the cylinder.
2. Remove the differential pressure switch (Item 6) from the cylinder
manifold block.
3. For models with an O-ring plug (Item 5), remove the plug.
4. Release pressure in each cylinder as follows:

WARNING: The counterbalance valve cartridge traps hydraulic pressure

in the cylinder. Wear proper eye and hand protection when
removing counterbalance valve cartridges. Hydraulic fluid
under pressure can be injected under skin or into eyes,
resulting in serious personal injury or death.

31200079 10-7
Outriggers

a. Place a socket wrench over each counterbalance valve cartridge

(Items 3 and 8). Wrap a clean shop rag around the socket to cover
the area of the counterbalance valve cartridge.
b. Carefully and slowly, turn the cartridge out of the manifold block to
release pressure in cylinder.
5. Remove the counterbalance valve cartridges.
6. Slowly extend and retract the cylinder by hand to remove most of the
hydraulic oil.
7. Remove two (2) elbows (Item 7) from the cylinder manifold block.
8. Loosen the setscrew (Item 17) and remove the cylinder head (Item 16)
from cylinder barrel (Item 9).
9. Remove the cylinder rod (Item 15) from the cylinder barrel.

CAUTION: To prevent possible damage to components, support the rod

and head; do not wiggle the rod or head back and forth during
removal.

10. Remove the rod nut (Item 10), piston (Item 11), and the cylinder head
(Item 16) from the cylinder rod.
11. Inspect bushings for damage. If necessary, replace the bushings as
follows:
a. Remove two (2) bushings (Item 4) from the cylinder barrel end
and/or remove two (2) bushings (Item 12) from the cylinder rod end
using a bushing driver and hammer or press. Drive one bushing all
the way through to remove other bushing.
b. Install new bushings so they are flush with outer edge boss to 0.02”
below.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting(s) after the cylinder is
reinstalled on the machine.
12. If necessary, remove the grease fitting covers (Items 2 and 14) and
grease fittings (Items 1 and 13) from the cylinder. Inspect and replace if
damaged. Install and tighten fittings 1.5 to 3 turns past finger tight.
13. Remove all O-rings, wear rings, and backup rings from the cylinder
components and discard.
14. Thoroughly clean components with solvent; dry with compressed air.
15. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If the barrel, piston, or rod are damaged,
they must be replaced.
16. Check the condition of the threads on the rod, nut, and capscrews. Do
not attempt to repair damaged threads.
17. Inspect the counterbalance valve cartridges (Items 3 and 8), including
O-rings, for condition and replace as necessary. Do not disassemble
cartridges. Service to counterbalance valve cartridges is limited to
installing new O-rings and replacing the entire cartridge.

10-8 31200079
Outriggers

18. Lubricate counterbalance valve cartridges O-rings with clean hydraulic

oil.
19. Install cartridges in the manifold block.
20. Lubricate a new O-ring with hydraulic oil and install it inside the piston
(seals rod to piston).
21. Lubricate new seal and wear rings with hydraulic oil and install them on
the piston.
22. Slide the cylinder head (Item 16), and piston (Item 11) onto the rod
(Item 15). Lubricate the threads on the rod with hydraulic oil and install
the rod nut (Item 10).
23. Install the rod assembly in the cylinder barrel. Tighten the cylinder cap
and secure with a setscrew (Item 17).
24. Install two (2) elbows (Item 7) on the cylinder manifold block. Torque
the elbows to 40–44 ft-lbs.
25. For models with an O-ring plug (Item 5), install the plug in the control
manifold block. Torque the plug to 85–95 ft-lbs.
26. Install the differential pressure switch (Item 6) on the cylinder manifold
block.

Differential Pressure Switch

Description
The differential pressure switch is a cartridge-style switch with a maximum
operating pressure of 6000 psi. It is a normally open circuit that is set to
close at 92 psi (+0, -18 psi).

31200079 10-9
Outriggers

Boom Extension Proximity Switch

Description

Proximity Switch

J1146
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.
The system will disable the boom extend and transfer extend functions and
60 80

the warning lamp will come on when the boom is extended to specified
40
20

0
distance (approximately 21 feet with tilting tower or 25 feet with standard
carriage). The proximity switch then opens as it no longer senses metal. At
this point, the left and right outriggers must both be lowered to the ground
to allow the boom or transfer carriage to be extended any further.
Normally open differential pressure switches in the outrigger cylinders
close when the base end pressure exceeds the rod end pressure by
approximately 90–95 psi. When both pressure switches close, this
completes the circuit, allowing the boom and transfer carriage to be
extended, and the lamp turns off. The system is fail-safe in that it requires
an electrical signal to enable the boom to be extended beyond the
specified distance.

10-10 31200079
Outriggers

Outer Boom Section Middle Rear)

Magnetic Boom Section
Flux Lines

Proximity Switch Oscillator

J1259
Fig. 10-7: Boom Extension Proximity Switch Operation
(Ref. Fig. 10-7) The switch operates by sending out a constant, high
frequency magnetic field a short distance from the oscillator end of the
switch. Eddy currents are produced in metal when the magnetic flux lines
pass through it. These eddy currents oppose the oscillations of the
magnetic flux lines and the oscillations stop. A sensor in the switch detects
if the oscillator is on or off and this gives the switch its on/off function.

Removal

Boom Extension
Proximity Switch

2
3
4
60 80

1
40

J1145
20

# Description # Description
1 Inner Jam Nut 3 Outer Jam Nut
2 Proximity Switch 4 Wire Harness

Fig. 10-8: Boom Extension Proximity Switch Assembly

31200079 10-11
Outriggers

(Ref. Fig. 10-8) The following procedure describes removal of the boom
extension proximity switch.
1. Disconnect the wire harness (Item 4) at the boom extension proximity
switch (Item 2).
2. Place a piece of masking tape around the proximity switch body at the
outer jam nut (Item 3). This will serve as a guide during reinstallation.
3. Remove the inner jam nut (Item 1) and proximity switch. Reinstall the
inner jam nut on the proximity switch for safekeeping.

Installation

Boom Extension (Ref. Fig. 10-8) The following procedure describes installation of the boom
Proximity Switch extension proximity switch.
1. Position the outer jam nut (Item 3) on the switch body (Item 2) at the
previously marked position.
2. Install the boom extension proximity switch in the outer boom. Install
the inner jam nut (Item 1). Check the gap between the end of the
proximity switch and boom. See Fig. 10-9.
3. Connect the wire harness (Item 4) to the proximity switch.
4. Check operation of the proximity switch by extending the boom. The
boom extension proximity light must come on at specified distance
(approximately 21 feet with a tilting tower or 25 feet with a standard
carriage). If the light does not illuminate, stop and retract the boom.
Proceed to “Adjustments” below.

Adjustments

Boom Extension
Proximity Switch

Outer Boom Section Middle Rear

Boom Section
0.19” to
Proximity Switch 0.25” Gap

Outer Jam Nut Inner Jam

Nut
J1262

Fig. 10-9: Boom Extension Proximity Switch Adjustment

(Ref. Fig. 10-9) The following procedure describes adjustments to the
boom extension proximity switch.

10-12 31200079
Outriggers

1. Loosen, but do not remove the two (2) jam nuts on the proximity switch
body.
2. Check the gap between switch and boom. The gap must be within the
range specified in Fig. 10-9.
3. If the boom extension proximity light does not illuminate when the
boom is extended to the specified distance (approximately 21 feet with
a tilting tower or 25 feet with a standard carriage), adjust the proximity
switch to slightly reduce the gap. Do not exceed gap tolerances
specified in Fig. 10-9. Snug jam nuts to hold switch in position.
4. Extend the boom and check operation of the boom extension proximity
light. The light must come on when the boom is extended to specified
distance (approximately 21 feet with tilting tower or 25 feet with
standard carriage). If the light does not illuminate, stop and retract the
boom. Repeat Step 3.
5. Tighten the jam nuts.

Outrigger Control Valves

Description
Right
Outrigger
Left
Outrigger
Frame
Tilt Control

V1087

Fig. 10-10: Outrigger Controls

(Ref. Fig. 10-9) The remote controls are located to the right of the seat and
consists of three sections. One section is used for frame tilt control (rear
control) and two are outrigger controls. The pressure range for each
section is 116–410 psi. The front control raises and lowers the right
outrigger and the middle control raises and lowers the left outrigger.

31200079 10-13
Outriggers

Removal

Outrigger Control Valve 6

5
7 8
4

3
2
1
9
14 16
15
10

11

12
13

V1088
# 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 16 Phillips Truss Head Screw

Fig. 10-11: Outrigger Control Valve Installation

(Ref. Fig. 10-11) The following procedure describes removal of the
outrigger control valves.
1. Follow preparation procedures as outlined in Section 3 of this manual.
2. Lower the boom, apply the parking brake, raise the outrigger foot pads
completely, and shut the engine off.
3. Remove four (4) screws (Item 16) and flatwashers (Item 15) securing
the rear cover (Item 14) to the operator’s compartment. Remove the
rear cover.
4. Loosen and remove four (4) hydraulic hoses (Item 10) from the
connectors (Item 9) on the bottom of the outrigger control valves
(Item 4). Bleed any remaining oil into a suitable container. Tag and cap
the hoses and fittings.
5. Remove the nut (Item 1) and lockwasher (Item 2) from each of the
three (3) tie rods (Item 3). Remove the tie rods, along with lockwashers
(Item 7) and nuts (Item 8), securing the control valve sections together.

10-14 31200079
Outriggers

6. Remove the two (2) nuts (Item 13), lockwashers (Item 12), and
capscrews (Item 5) securing each valve section to the control panel
(Item 11). Remove the outrigger valve sections.

Installation

Outrigger Control Valve (Ref. Fig. 10-11) The following procedure describes installation of the
outrigger control valves.
1. Secure the two (2) outrigger control valves (Item 4) to the frame tilt
control valve (Item 6) with three (3) tie rods (Item 3). Install
lockwashers (Items 2 and 7) and nuts (Items 1 and 8) on each end of
both tie rods.
2. Install each outrigger control valve on the control panel (Item 11) with
two (2) capscrews (Item 5), lockwashers (Item 12), and nuts (Item 13).
Torque the nuts to 50 in-lbs.
3. Install the hydraulic hoses (Item 10) on the connectors (Item 9) on the
bottom of each control valve. For final tightening, torque the hose
swivel nuts to 130–150 in-lbs.
4. Install the rear cover (Item 14) on the operators compartment with four
(4) flatwashers (Item 15) and screws (Item 16). Torque the screws to
96 in-lbs.

31200079 10-15
Outriggers

10-16 31200079
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 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. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025

JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762