JLG Lull 1044C-54 II Series Service Manual

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

31200079-ii

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

Table of Contents

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

6 31200079

Table of Contents

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

31200079 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

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

8 31200079

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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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

12 31200079

List of Figures

Fig. 7-5: Frame Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Fig. 7-6: Frame Tilt Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Fig. 7-7: Frame Tilt Cylinder (Exploded View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Fig. 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

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.

W1049

31200079

1-1

Safety

Safety Standard

Maintenance Safety

General

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

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.

1-2

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.

31200079

Fuel Hazards

Safety

• Make certain there is adequate light and ventilation.

• Remove any foreign substances (i.e. oil, grease, water, snow, ice) to
eliminate any slippery surfaces and to remove all contaminants from
the area.

• Use only the correct tools to perform the maintenance or repair.

• 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.

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 immedi­ately. 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

31200079

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 pres­sure to escape before removing the cap completely.

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

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.

W1047

Electrical System Hazards

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.

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.
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.

NEVER

give fluids that would induce vomiting.

• 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.

31200079

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.

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.

Decals and Placards

General

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.

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

1-6

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.

31200079

Attaching Decals

Decal Locations

Safety

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.

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

0

1

2

3

4

5

6

7

8

10

9

11

12

13

-1

01234567810 9

METERS

Boom

Extension

Indicator

T IRE B A LL AS T

R EQ UI RE D

REFER TO LUBRICATION SCHEDULE

Tire Ballast

Required

(Both Sides)

Cab Transfer

Extension

Notice

California

Proposition 65

Warning

Frame Transfer

Extension

Fig. 1-1: Decals and Placards

Forklift

Signals

FT

2

3

FORKLIFT SIGNALS

NOTICE

STOPRAISE LOAD LOWER LOAD

TILT FORKS RIGHTTILT FORKS LEFTTILT FORKS UP

TILT FORKS DOWN

MOVE LOAD BACKWARD

INSTRUCTIONS TO SIGNALMAN

1. Only one person to be signalman.

2. Make sure the operator can see you and is able to acknowledge the signal given.

3. Signalman must watch the load, the operator is watching you.

4. Never raise or lower the load over the other workmen. Warn them to keep out of the way.

5. Watch for overhead lines or other obstructions.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.

REAR OSC.

REAR OSC.

PUMP 1 PUMP 2 BRAKES STEERING PILOT ACCUM.

LOCK (G1)

LOCK (G2)

Te st Po r t s

FT

45

MAXIMUM BOOM LOAD CAPACITIES AT
24" LOAD CENTER, FOR LIFT AND REACH
POSITIONS IN POUNDS AND FEET WITH

INDICATES REAR

METRIC CONVERSIONS.

OSCILLATION LOCK

40

MANUFACTURER'S RECOMMENDED
CAPACITIES ARE IN CONFORMANCE

ENGAGED

WITH ANSI/ASME B56.6 STABILITY TESTS
USING STANDARD HOMOGENEOUS
CUBES 4' × 4' × 4'.

35

MANUFACTURER'S RECOMMENDED
LOADS AND ANGLES SHOWN ARE AT
THE HORIZONTAL CENTER OF GRAVITY
OF THE ABOVE CUBE. CAPACITY
ADJUSTMENT MUST BE MADE FOR

30

EXTENDED LOAD CENTERS AND OTHER
VARIATIONS OF LOAD SIZE, ETC.

RATED LIFT CAPACITIES SHOWN ARE
WITH MACHINE ON A FIRM, LEVEL

25

SURFACE WITH UNDAMAGED, PROPERLY

MOVE LOAD FORWARD

INFLATED, BALLAST-FILLED TIRES.

70°

20

60°

50°

39617B

15

40°

30°

10

20°

10°

5

0°

-5°

0

AB

CD

EF

CAPACITIES SHOWN DEPICT FU LL B OOM EXTENSION PRIOR TO
G
HI

JK

LM

TRANSFER. AT FULL TRANSFER EXTENSION, CA PA CI T IE S AT ANY

NO

DISTANCE OUT ARE 70% OF RETRACTED TRANSFER VALUES.

FEET

05101520253035

39039B

CAUTION

Pressure

Load Chart

Capacities and

Lubrication Schedule

Flip Cards

Caution

Plate

Don’t Be
Careless

DON'T BE
CARELESS

SHUT DOWN ENGINE
BEFORE ANY SERVICE

T IRE B A LL AS T

R EQ UI RE D

REFER TO LUBRICATION SCHEDULE

Tire Ballast

Required

(Both Sides)

R1046

Carry

Load Low

Rear
Oscillation
Lock Light

Outrigger

Caution

Low Brake

Pressure

Warning

Transmission

Declutch

R1047

Parking

Brake

Fig. 1-2: Instrument Panel Decals

1-8

31200079

Boom

Movement

Control

Safety

Tr a n sf e r

and Fork

Tilt Control

Outrigger

Control

Frame

Tilt Control

Fig. 1-3: Control Decals

V1087

31200079

Disconnect

Battery

MV0490

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

1-9

Safety

Operator’s Seat

FRONT WHEEL STEER

ROUND STEER OBLIQUE 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

1-10

Carriage

Safety

Decal

R1051

Fig. 1-7: Fork Carriage Decals

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

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

Serial

Number

Plate

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

(Ref. Fig. 2-2) The engine serial number plate is located on the left side of
the engine near the starter and fuel pump.

Serial

Number

Plate

Fuel

Pump

Starter

V1006

Fig. 2-2: Engine Serial Number — John Deere

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

Axle Serial Number

Identification and Specifications

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

31200079

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

2-3

Identification and Specifications

Identification

R1026

Fig. 2-5: Top View

R1052

2-4

Fig. 2-6: Left Side View

31200079

Specifications

Identification and Specifications

General Operating
Specifications

Dimensions

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

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.

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

Travel Speeds

Axles

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

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4WG-98TC

Type . . . . . . . . . . . . . . 4-Speed Electric Powershift with Torque Converter

Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Forward, 3 Reverse

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-On

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)

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

Service Brakes

Parking Brake

Engine Models

Hydraulic Pump

Electrical System

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

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

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

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

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAHR) Spring Applied

Hydraulically Released

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

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

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear

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,

WARNING: Release all hydraulic pressure before doing any maintenance

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

• 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 identi­fied 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.

apply the parking brake, and stop the engine before servicing,
adjusting, or repairing the machine.

or repairs to the hydraulic system.

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

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 releas­ing machine for operation.

3-2

31200079

Replacement Parts

General

Lubrication

General

General Maintenance

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.

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 sur­faces 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

COMPONENT

Fuel System

1

Hydraulic System

FLUID OR

LUBRICATION

See "Fuel Requirements"

Tractor Hydraulic

Mobilfluid 424

SPECIFICATION

®

Fluid

Engine Cooling
System

Engine Oil

1

1

See engine manufacturer's operator's
manual.

See Engine Oil Specifications

Transmission See Transmission Oil

Specifications

Differential
(Front & Rear)

Planetary Hub

Tractor Hydraulic
Fluid

Tractor Hydraulic

Mobilfluid 424

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.

New John Deere engines use special break-in oil for the initial period of

Note:

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

Oil Grade

Temperature

Range °F

Temperature

Range °C

Transmission Oil Specifications

The following table shows approved lubricants and associated
temperature ranges for use with ZF 4WG series transmissions.

SAE 5W-30

SAE 10W-30

SAE 15W-40

SAE 30W

SAE 40W

Arctic oil (e.g.
MIL-L-46167B)

-22 to +86 °F -30 to +30 °C

-4 to +86 °F

+5 to +122 °F

+32 to +86 °F

-50 to +104 °F

Below -22 °F

-20 to +30 °C

-15 to +50 °C

0 to +30 °C

+10 to +40 °C

Below -30 °F

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

Table 3-3: ZF Transmission Oil Specifications

ZF 4WG-98TC TRANSMISSIONS

Oil Grade

Recommended

Mobilfluid 424

Engine Oils

Automatic Transmission Fluid (ATF)

AT F

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)

®

SAE 20W-20 +14 °F (-10 °C)

SAE 15W-40

SAE 10W,
10W-30,
10W-40

Minimum Oil

Temperature for

Starting Engine

-4 °F (-20 °C) +86 °F (+30 °C)

+5 °F (-15 °C)

-4 °F (-20 °C)

-22 °F (-30 °C) +14 °F (-10 °C)

Minimum Oil

Temperature for

Engaging

Transmission

+41 °F (+5 °C)

+32 °F (0 °C)

+23 °F (-5 °C)

MV0520

31200079

3-5

General Maintenance

Fuel Requirements

Grease

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

• 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

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

General Maintenance

• 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, espe­cially 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

31200079

• 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 pro­tectant 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.

3-7

General Maintenance

Cleaning Decals

Attaching Decals

Storage

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.

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.

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 coolant­to-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.

3-8

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.

31200079

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.

General Maintenance

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.

Values are for plated or lubricated bolts and nuts.

Note:

SAE BOLT HEAD MARKINGS

SAE GRADE 2

SAE GRADE 5 SAE GRADE 5.1 SAE GRADE 5.2

Y1001

SAE GRADE 8.2SAE GRADE 8

Fig. 3-1: SAE Grade Identification

SAE NUT MARKINGS

SAE GRADE 2 (NO MARK)

SAE GRADE 5

Y1000

SAE GRADE 8

3-10

31200079

General Maintenance

31200079

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

3-11

General Maintenance

S

G

5S

G

8

RADE

UNPLATED CAP SCREWS

VALUES FOR ZINC PLATED BOLTS ONLY

AE

RADE

AE

3-12

Note: These torque values do not apply to cadium plated fasteners.

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

31200079

General Maintenance

PROPERTY CLASS

AND HEAD MARKINGS

4.8

4.8

4.8

8.8

8.8

9.8

9.88.8

9.8

10.9 10

10.9

12.9 12

PROPERTY CLASS

AND NUT MARKINGS

5

5

5

10

10

10

10

10

12.9

12.9

12

12.9

12

Fig. 3-4: Metric Class Identification

Y1--2

31200079

3-13

General Maintenance

Hydraulic Fitting Torques

JIC and SAE Female
Swivel Nuts

It is recommended that the nut be torqued to the approximate minimum
value. If leakage occurs, tighten nut without exceeding maximum torque
value.

Use two wrenches to tighten hydraulic line nuts.

Note:

Table 3-4: Torque for JIC and SAE Female Swivel Nuts

Size

-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.

SAE Port

Thread Size

Approx. Min.

Torque

Max. Torque

Flats

1

Non-adjustable O-ring
Fittings

To install straight thread, non-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 and torque per Table 3-5.

Table 3-5: Torque for Non-adjustable O-ring Fittings

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 "

SAE Port

Thread Size

Min. Torque Max. Torque

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

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 "

SAE Port

Thread Size

Min. Torque Max. Torque

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 "

-107/8-1470"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.

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

Note:

contamination will result.

2. Install fitting and tighten per Table 3-8.

Table 3-8: Pipe Thread Fittings (Steel)

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 connec­tion 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 electri­cal system.

• Never charge a frozen battery.

Fitting

Size

-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

Thread Size

(NPT)

1.Turns past finger tight

Turn s

1

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

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

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

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

3-18

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

31200079

Table 3-10: Miscellaneous Conversions

General Maintenance

Multiply By

International System

(IS) Unit

Conversion

Factor

To Ge t or

Non-IS Unit

Torque

Newton Meter (N•m)m)
Newton Meter (N•m)m)

x 8.9

x 0.74

Pressure (Pa = N/m

Kilopascal (kPa)
Kilopascal (kPa)
Kilopascal (kPa)
bar

Newton/mm

2

x 4.0

x 0.30

x 0.145

x 14.5

x 145.04

Stress (Pa = N/m

Megapascal (mPa)

x 145 = psi x 0.00689 = MPa

Power (W = J/s)

Kilowatt (kW)
Kilowatt (kW)
Kilowatt (kW)
Watt (W)

x 1.36
x 1.34

x 0.948

x 0.74

Energy (J = (N•m)m)

Kilojoulè (kJ)
Joule (J)

x 0.948
x 0.239

Velocity and Acceleration

Meter per sec
Meter per sec (m/s)
Kilometer per hour

2

(m/s2)

x 3.28
x 3.28
x 0.62

(km/h)

Flow Rate

Leter/mn (dm

3

/mn)

x 0.264 = US gal/min x 3.785 = L/min

Horse Power/Torque

(BHP x 5252) ÷ rpm = TQ (ft-lb.)
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

Multiply

By To Get

Conversion

Factor

= in-lb.
= ft-lb.

= in H

2

= in. Hg
= psi
= psi
= psi

2

= PS(cv)
= HP
= Btu/s
= ft-lb/s

= Btu
= calorie

2

= ft/s
= ft/s
= mph

2

O

)

x 0.113

x 1.36

)

x 0.249

x 3.38
x 6.89

x 0.069

x 0.0069

x 0.736
x 0.746
x 1.055

x 1.36

x 1.055

x 4.19

x 0.305
x 0.305

x 1.61

(TQ x R.P.M.) ÷ 5252 = B.H.P.

IS Unit

= Nm
= Nm

= kPa
= kPa
= kPa

= bar
= bar

= kW
= kW
= kW

= W

= kJ

= J

= m/s

= m/s

= km/h

2

31200079

Nautical Mile
Statute Mile

x 1.15078
x 0.86897

Miles

= Statute Mile
= Nautical Mile

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

Section 4 — Reference Diagrams

Diagram 4-1 — Mid-Inlet Hydraulic Schematic

QUICK DISCONNECTS

C.B.

AUX. 1

OPTIONS

QUICK DISCONNECTS

AUX. 2

OPTIONS

FRONT CARRIAGE

TILT CYLINDER

VALV E

BOOM ROLL BACK HOSES

BOOM TELESCOPE CYLINDER

UPPER HYDRAULICS

Reference Diagrams

C.B.

VALV E

FRONT OF MACHINE

C.B. VALVES

4000 PSI

R.H. OUTRIGGER

CYLINDER

FRONT STEER CYL

FRONT BRAKES

PARK BRAKE CYLS

SPRING APPLIED /

HYDRAULICALLY RELEASED BRAKE

C.B. VALVES

4000 PSI

92 PSI

DIFF.

PRESSURE

SWITCH

92 PSI
DIFF.
PRESSURE
SWITCH

ACCUMULATOR

400 PSI

PRECHARGE

FRAME TILT
CYLINDER

C.B. VALVES

A

BRAKE
VALVE

3500 PSI

P

T

ACC

(2X)
.080
ORFICES

SW

ARROW FILTER

CV

0R1

UP

OR3

RV

PIL

T

FORK TILT/TRANSFER

PUMP 1

PUMP 2

3000 PSI

3150 PSI

50 MICRON

FILTER

SV

OR2

P

A4

#1

1ST AUX.

STABILIZER "G1"

STABILIZER "G2"

SEE SERVICE MANUAL

EF

EC

P

2

1

PRESSURE

FILTER

#4

P1

P2

#2

JOYSTICK

BRAKES

330 PSI

CLOSED ABOVE 250 PSI

SEE SERVICE MANUAL

BRAKE PRESSURE SWITCH

CF

LS

#4

P

A5

B4

#1

#3

T

#2

HOIST/TELESCOPE

2ND AUX.

CONTROL

VALVE S

VIEWED FROM THE TOP

PILOT

450 PSI

2375 PSI

STEERING

ACCUMULATOR

OPEN BELOW 250 PSI

400 PSI PRE-CHARGE

P

LS

T

ORBITROL STEER

VALV E

P1

.020

.020

P2

SELECTOR

VALV E

OUTRIGGER CONTROL VALVE

B2

B5

#3

T

A2

1075 PSI LOW LIMIT

1950 PSI HIGH LIMIT

OPEN ABOVE 850 PSI

CLOSED BELOW 850 PSI

ACCUMULATOR PRESSURE SWITCH

B7

RH LH

X
X

OUTRIGGERS

S1

A7

PARK BRAKE PRESS. SWITCH

CLOSED BELOW 100 PSI

OPEN ABOVE 100 PSI

B

A

C

PARK BRAKE VALVE
PULL TO APPLY BRAKE
PUSH TO RELEASE
BRAKE

B1

B3

A1

A3

B8

S3

S2

A8

31200079

MV0400

L.H. OUTRIGGER

CYLINDER

4-1

Reference Diagrams

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

(OPTION)

BOOM

TELESCOPE

A2

A

B

B2

C.B.
VALV E

C.B.

VALV E

BOOM HOIST

A5

A

B

B5

BOOM HOIST CYLINDER

BOOM HOIST CYLINDER

FRAME

TILT

A6

B

3000
PSI

B6

P

REAR CARR.

TILT CYLINDER

REAR CARR.

TILT CYLINDER

(OPTION)

AUX. 1

AUX. 2

A3

AA AA

B

A

B

B3

TRANSFER

A1

B

B1

2800
PSI

2800
PSI

B

CARRIAGE

TILT

A4

B4

TRANSFER CYLINDER

R.H.

OUTRIGGER

A7

A

B

B7

L.H.

OUTRIGGER

A8

A

B

B8

3150
PSI

A6

FRAME TILT

B6

S4

T

P

B

BR

G3
GAGE
PORT

X

A

B

G2

G1

PIL

STEER

MODE

SELECTOR

.040

OR3

S1

PC3 (270 PSI)

FB

X

OR2

.043

60
PSI

PD1

PS1

OR5 (.043)

FCB

SV1

230

PSI

PD2

FTB

OR1

.043

60

PSI

PS2

PD4

OR4

.043

230

PSI

PD3

BOOM EXTEND/TRANSFER

LOCK-OUT VALVE

(B1)

(B2)

PB
250
PSI

SV2

CBP

T

RCR

RCB

RCB

RCR

V

PC1

V

PC2

OR3

.040

3500

SV3

CB

OR5

PSI

.040

PR
150
PSI

225 PSI

CBP

T

SYS

PIL

OR4

.040

100 PSI

CV2

CV1

.08

OR2

60 PSI

CV3

CV4

.130

.03

OR1

GAGE PORT

.18 DIA.

REAR STEER CYL

REAR BRAKES

STABILIZER CONTROL VALVE

ACC

RB

SW

REAR AXLE STABILIZER VALVE

NOTE: HUSCO VALVE ASSEMBLY IS ORIENTATED

SO THAT THE "A" PORTS ARE FRONT

FORWARD OF THE "B" PORTS.

MV0420

4-2

31200079

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

NOTES

Reference Diagrams

31200079

4-3

Reference Diagrams

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

NOTES

4-4

31200079

Diagram 4-2 — Control Valve

Reference Diagrams

Mid-Inlet

Control

Val ve

(OPTION)

BOOM

TELESCOPE

A2

A

B

B2

BOOM HOIST

A5

A

B

B5

3000
PSI

FRAME

TILT

A6

B6

P

AUX. 1

AAAA

B

(OPTION)

AUX. 2

A3

A

B

B3

TRANSFER

A1

B

B1

2800
PSI

2800
PSI

B

CARRIAGE

TILT

A4

B4

R.H.

OUTRIGGER

A7

A

BB

B7

L.H.

OUTRIGGER

A8

A

B

B8

3150
PSI

MV0410

31200079

4-5

Reference Diagrams

NOTES

4-6

31200079

Diagram 4-3 — Electrical Schematic

Reference Diagrams

36804X
HOURMETER

HOUR
METER

+ -

F

H

FUEL

67

WATER

FAULT

5

8

POWER

9

4

LAMPS

10

3

GRD

2

11

OIL

1

12

V

G

B

R

G
R
E

E
N
1
6

Y

R

L

E
D
1
6

I

E

O

A

A

L

L

Y

C

L

E

1

K

O

T

6

1

W

1

6

1

6

6

9

8

5

CHECK

ENGINE

ENGINE

BOOM
TRANS

WATER

PARK

EXTEND

BRAKE

LOCK

TEMP

7

12

1

BRAKE

ENGINE

PRESS

REAR
OSC

OIL

LOCK

TRANS

PRESSURE

DISC

10

W

T

H

A

I

N

T

1

E

6
1
6

11

P

O

I

R

N

A

K

N

1

G

6

E
1
6

ENGINE

3

FAULT O/R

2

(RESET)
SWITCH

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

PARKING BRAKE PRESSURE SWITCH
UNDER DASH PANEL

TO CIRCUIT BOARD &

TO CIRCUIT BOARD &

YELLOW-16

VIOLET-16
BLACK-16

HORN BUTTON
KIT P18141

36830B
CLUSTER GAUGE

6

FUEL

BATTERY
VOLTAG E

3

2

7

RED-16

BLUE-16

PINK-16

BLACK-16

4923233 DASH HARNESS
CONNECTS TO CIRCUIT
BOARD UNDER THE DASH

66466X
MOMENTARY SWITCH
TRANSMISSION ENGAGE/

AXLE UNLOCK

YELLOW-16
WHITE-16

SHIFTER HARNESS

(SEE SHT 2)

SHIFTER HARNESS

(SEE SHT 2)

WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER

WHITE-14

A

NEUTRAL START RELAY

B

IGN. SWITCH RELAY

C

HORN RELAY

I

TRANS OIL
TEMP

4

S

D

38094A
TRANSMISSION
DISCONNECT
SWITCH

BQ

10 AMP

A

10 AMP

E2

A

B

A

B

E1

4923233 DASH HARNESS
CONNECTS TO CIRCUIT
BOARD UNDER THE DASH

GI

THROTTLE

IGN.

A

ST.

BAT.

WHITE-16

VIOLET-16

TAN-16

BLUE-16

66906A HARNESS
FOOT SWITCH,CONNECTS
UNDER DASH

B

66982A
TRANSMISSION TEMP

WILLIAMS

(SUSPENDED)

P11092
IGNITION

.

C

C

SWITCH

TO PARKING BRAKE
RELAY TERM 85
(SEE SHEET 2).

-

+

TO PARKING BRAKE
RELAY TERM 86
(SEE SHEET 2).

LAMP #10

A

LAMP #11

B

C

LAMP #9

D

DECLUTCH

'K'

~1.5 AMPS

A

~1.5 AMPS

.41-.48 AMPS

RELAY CURRENT
RELAY CURRENT

R

A
B
C
D

PLUGGED

E

PLUGGED

F

PLUGGED

+

-

A
B

C

D

J8

J9

B
A

J10

A
B
C
D

A
B
C
D

J11

J12

F

J

A
B

4923233 DASH HARNESS
CONNECTS TO CIRCUIT
BOARD UNDER THE DASH

RED-16
WHITE-16

ORANGE-16

BLACK-16

INCLUDED IN UPPER
HARNESS 66944D
CONNECTS UNDER SEAT BOX

4923233 DASH HARNESS 'O'
CONNECTS TO ENGINE HARNESS
UNDER THE SEAT BOX

TAN-16

RED-16

WHITE-16
RED-16

BLACK-16

YELLOW-16

REAR OSC.
LOCK

WHITE-16

VIOLET-16

TAN-16

BLUE-16

YELLOW-16

WHITE-16

85

R

TRANS.

86

87A

CUT-OUT

RED-16

YELLOW-16
PINK-16
GRAY-16

BROWN-16
GREEN-16
BLUE-16
VIOLET-16

J16

L

A

YELLOW-16

B

VIOLET-16

C

B

85

L
A

R

C

86

87A

K
1
6

86

85

87A

RED-16

A

WHITE-16

B

J13

A

B

P

4923232 ENGINE HARNESS 'A'
CONNECTS UNDER SEAT BOX
PINS 18 - 29 PLUGGED

SEE SHEET 3

1

SEE SHEET 3

2

SEE SHEET 3

3

PLUGGED

4

SEE SHEET 3

5

PLUGGED

6

SEE SHEET 3

7

SEE SHEET 3

8

9

SEE SHEET 3

10

SEE SHEET 3

11

SEE SHEET 3

12

PLUGGED

13

SEE SHEET 3

14

15

SEE SHEET 3

SEE SHEET 3

16

SEE SHEET 3

17

PINS 4,
6, 13 &
18 - 29

PLUGGED

N

B

BLACK-16

A

RED-16

BLUE-16

D

BLACK-16

C

YELLOW-16

B

A

BROWN-16

M

LAMP #10

30

87

IGN.

30

SWITCH
RELAY

87

30

HORN
RELAY

87

LOW BRAKE
PRESSURE
BUZZER

TRANSMISSION

DISCONNECT

NEUTRAL
START

86

85

87A

R

LAMP #11

30

87

-

+

+ -

BACK-UP

ALARM

+

-

86

30

85

87A

87

ORANGE-16

A

BLACK-16

B

INCLUDED IN INTERMEDIATE
HARNESS 66961D
CONNECTS UNDER SEAT BOX

66679A SPST-N.O., 250 PSI

BRAKE PRESSURE SWITCH
ON DIAGNOSTIC PANEL

67063A SPST-N.O., 1000 PSI

ON MACHINES W/DRY DISC BRAKES

66680A DPST-N.C. SWITCH, 850 PSI

LOW BRAKE PRESSURE SWITCH
ON DIAGNOSTIC PANEL

USE 67065A SPST-N.C. SWITCH, 1800 PSI

ON MACHINES WITH DRY DISC BRAKES

BOOM/ TRANSFER

EXTEND LOCKOUT

4 SECTION BOOM ONLY

LAMP #9

BOOM

OVER 20°

86

30

R R

85

87A

87

85

30

86

87A

87

FUSES FOR CIRCUIT BOARD

7.5 AMP: BROWN-LULL#66827X
10 AMP: RED-LULL#66828X
15 AMP: BLUE-LULL#66829X

7.5 AMP

F3

R

TRANS. & PROXIMITY SWITCHES.

10 AMP

F4

R

BACK-UP ALARM

15 AMP

F5

R

BOOM PROX. SWITCH RELAYS

10 AMP

F6

R

GAGE PANEL/ NEUTRAL START

BOOM
OVER 40°

86

30

85

87A

87

4TH SPEED
LOCKOUT RELAY

10 AMP

F1

JOYSTICK

31200079

MV0430

4-7

Reference Diagrams

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

FUEL LEVEL
GA SEND
P29317

BLACK-10

YELLOW-14

67062A SPST-N.O., 250 PSI

ON MACHINES W/ROADWAY LIGHTS

67064A SPST-N.O., 1000 PSI

ON MACHINES W/DRY DISC BRAKES
& ROADWAY LIGHTS

66891C (10366981)
CIRCUIT BOARD

STAB. SOL. SV3 (1.2 AMP INRUSH)

YELLOW-16

RED-16
BLACK-16
WHITE-16

BLACK-16
YELLOW-16
PINK-16
BLUE-16
GRAY-16
GREEN-16

1

BACK-UP ALARM (.6 AMPS)

2

J14

J15

J2

3

4

5

6

8

9

10

11

12

13

14

J1

D

C
B
A

A
B
C
D
E
F

J3

GROUND (9.6 AMPS AT INRUSH)

START RELAY(.41-.48 AMPS)

STAB. SOL. SV1 (1.2 AMP INRUSH)

GROUND (2.4 AMPS)

STAB. SOL. SV2 (1.2 AMP INRUSH)

7

HORN (6 AMPS MAX.)

40° SWITCH POWER OUT

12 VOLTS

PROXIMITY SWITCH GROUND

20° SWITCH POWER OUT

INTERMEDIATE HARNESS, 66961D
CONNECTS UNDER SEAT BOX

BOOM/TRANSFER EXTEND
CUTOUT HARNESS, 66809C
CONNECTS UNDER SEAT BOX

D

C
B
A

TO CIRCUIT BOARD
& SHIFTER HARNESS
(SEE SHT 2)

YELLOW-16

RED-16
BLACK-16

WHITE-16

VIOLET-16

PINK-16

BLACK-16

YELLOW-14

ORANGE-16

BLACK-16

BLUE-16

GRAY-14

GREEN-16

RED-16

BLACK-16

WHITE-16

FOOT
SWITCH

30

86

85

87A 87

R

BOOM

EXTEND

30

85

86

8787A

(USED ON 4 SECTION ONLY)

REMOVE RELAY ON ALL
OTHER MACHINES

RED-14

STARTER
RELAY
67789A

SOLENOID

WHITE-10

VIOLET-16

PINK-16

BLACK-16

YELLOW-14

ORANGE-16

BLACK-16

BLUE-16

GRAY-14

38200C-4
GROUND

ENGINE TO
MAINFRAME

STARTER

MOTOR

CONNECT BATT GRD
TO LOWER STARTER
MOUNTING BOLT

65724A
NEG. CABLE

35646A
POS. CABLE

2/0 RED

R
E
D
6

4923247
WIRE W/DIODE

WHITE-12

RED-12

GREEN-16
RED-16
BLACK-16
WHITE-16

2/0 BLACK

+

BATTERY

-

12V

38200C-3
GROUND

OPER COMP TO
MAINFRAME

38200C-5

S

B+

ALTERNATOR

BOSCH
95 AMP

D+

PIN 86 IS GROUND ON ALL RELAYS

30

87A
87

85

86

RELAY SOCKET

TOP VIEW

CIRCUIT
BREAKERS
40 AMP
P29694

T

VIOLET-14
BLACK-14

38329A COIL

R
E
D

BLACK-16

B

A

RIGHT

68441A SPST-NO
DIFFERENTIAL PRESSURE SWITCH
OUTRIGGER CYLINDERS-BASE END
CLOSED ABOVE 92 PSI DIFFERENTIAL
OPEN BELOW 92 PSI DIFFERENTIAL

A

B

A

B
BLACK-14

A

B

BLACK-14

GREEN-16

D
C

RED-16
BLACK-16

B
A

WHITE-16

65923A PROXIMITY
SWITCH HARNESS,THRU
TRANSFER CARRIAGE

RED-16
BLACK-16
WHITE-16

WHITE-16

B

WHITE

LEFT

38329A COIL

SV3

SV1

38329A COIL

SV2

C
B
A

YELLOW-16

BLACK-16

A

BLACKBLACK

2-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER VALVE
ON REAR STABILIZER CYLINDER
ENERGIZED W/BOOM BELOW 40°

SOLENOID VALVE ON
REAR AXLE STABILIZER
CONTROL VALVE(ENERGIZED
W/BOOM BELOW 20°)

3-WAY SOLENOID VALVE ON
REAR AXLE STABILIZER CONTROL
VALVE ON VALVE PLATE
ENERGIZED W/BOOM BELOW 40° OR
BOOM ABOVE 40° & FOOT
SWITCH DEPRESSED

HORN

P13707

D
C
B
A

65924A PROXIMITY SWITCH HARNESS
ON TRANSFER CARRIAGE

39351A PROXIMITY
SWITCH HARNESS,THRU
TRANSFER CARRIAGE

RED-16
BLACK-16
WHITE-16

A

SV4

B

38329A COIL

BACK-UP
ALARM

P13774

+

-

BOOM ANGLE GREATER THAN 40° NO
BOOM ANGLE LESS THAN 40° NC
37115X PROXIMITY SENSOR IS N. O.
ON TRANSFER CARRIAGE

BROWN
POWER
IN

GROUND

BLUE

BOOM ANGLE GREATER THAN 20° NO
BOOM ANGLE LESS THAN 20° NC
37115X PROXIMITY SENSOR IS N. O.
ON TRANSFER CARRIAGE

BROWN
POWER
IN

GROUND

BLUE

BOOM EXTEND GREATER THAN 20' NO
BOOM EXTEND LESS THAN 20' NC
37115X PROXIMITY SENSOR IS N. O.
ON OUTER BOOM

BROWN
POWER
IN

C
B
A

SOLENOID VALVE
BOOM/TRANSFER EXTEND CUTOUT
VALVE ON VALVE PLATE
ENERGIZED WITH BOOM EXTENDED LESS
THAN 20' OR OUTRIGGERS DOWN

GROUND

BLUE

38231A PROXIMITY SWITCH HARNESS
ON OUTER BOOM

BLACK

POWER
OUT

BLACK

POWER
OUT

BLACK

POWER
OUT

4-8

RELAYS FOR CIRCUIT BOARD
ALL ARE THE SAME
30/40 AMP-LULL#66820X

15 AMP

F2

HORN

J7

STUD ON BOARD
SWITCHED POWER FOR OPTIONS

R

STUD ON BOARD

J5

RED-12 FROM ENGINE HARNESS, UNSWITCHED POWER

S

FRONT
JOYSTICK

(OPTION ON

10 AMP

6K MACHINES)

J4

PUSHBUTTON
SWITCH
P31598

RED-16

39510B HARNESS

SELECTOR VALVE
39076C

REAR
JOYSTICK

BLUE-16

38329A COIL

A

BBA

MV0440

31200079

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

Reference Diagrams

'A' OF CIRCUIT

BOARD &

SHIFTER HARNESS)

A
B
C
D

FROM CIRCUIT

BOARD J11

(SEE SHT 1)

'B' OF CIRCUIT

BOARD &

SHIFTER HARNESS)

A
B
C
D
E
F

FROM CIRCUIT

BOARD J3

(SEE SHT 1)

'E' OF CIRCUIT

BOARD &

SHIFTER HARNESS)

A
B
C
D

FROM CIRCUIT

BOARD J10

(SEE SHT 1)

'C' OF CIRCUIT

BOARD &

SHIFTER HARNESS)

1
2
3
4
5
6
7
8

9
10
11
12

FROM SHIFTER

CONNECTOR

(SEE SHT 1)

TO DASH
GND STUD

PLUGGED
PLUGGED
PLUGGED

IGN POWER

RELAY GND
FORWARD SGN
REVERSE SGN

BOOM OVER 40

PLUGGED

BOOM OVER 20

DIRECTION INPUT

FORWARD
REVERSE

NEUTRAL A

DIRECTION INPUT

FORWARD
REVERSE

NEUTRAL
SHIFTER Y5
SHIFTER Y4
SHIFTER Y3
SHIFTER Y6

SHIFTER PWR

PLUGGED

PLUGGED

PLUGGED

ON WHEN BOOM

OVER 40°

RELAY K11

87

308586

87a

IGN POWER

SHIFTER PWR

SHIFT TO 1ST

RELAY GND

BOOM OVER 40

ON WHEN BOOM

OVER 40°

RELAY K12

30

878685

87a

N/C

BOOM 21-40

BOOM OVER 20

RELAY GND

BOOM OVER 40

ON WHEN BOOM
OVER 20° AND
NOT OVER 40°

RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17

87

308586

87a

N/C

JUMPER 1

IGN POWER

RELAY GND

BOOM 21-40

ON WHEN
SHIFTER

Y5 IS ON

308586

87a

JUMPER 2

JUMPER 1

ON WHEN SHIFTER

Y5 IS OFF AND
BOOM IS 21-40°

87

N/C

RELAY GND

SHIFTER Y5

87a

SOLENOID Y6

308586

SHIFTER Y6 A

87

N/C

JUMPER 2

RELAY GND

ON WHEN
FORWARD
SELECTED

308586

87a

N/C

IGN POWER

ON WHEN
REVERSE

SELECTED

87

RELAY GND

SOLENOID Y1

FORWARD SGN

308586

87a

N/C

IGN POWER

87

RELAY GND

SOLENOID Y2

REVERSE SGN

D5D4D3D1 D2

UPPER KOSTAL
TRANSMISSION

CONNECTOR

('B' OF TRANS

SOLENOID HARNESS)

DIODE

MODULE

SOLENOID Y1
SOLENOID Y2
SOLENOID Y3

#1

DASH GND

(OTHERS NOT USED)

ONLY 4 OF 16

PINS SHOWN

1
2
3
7

RELAY K18

87

308586

87a

SOLENOID Y4
SOLENOID Y5
SOLENOID Y6

DASH GND

UPPER KOSTAL
TRANSMISSION

CONNECTOR

('C' OF TRANS

SOLENOID HARNESS)

ONLY 4 OF 16

PINS SHOWN

(OTHERS NOT USED)

4
5
6
7

D10

NEUTRAL

NEUTRAL A

FROM E2 A (SEE SHT. 1)

D6

FROM E1 A (SEE SHT. 1)

D7
D8
D9

DIODE

MODULE

#2

MV0450

MANIFOLD AIR

COOLANT TEMP

FUEL TEMP

CRANK

TEMP SENSOR

SENSOR

SENSOR

OIL PRESSURE INJECTOR

SENSOR SENSOR

PUMP

D

H

A

TO DASH HARNESS (UNDER SEAT)

CAN TERMINATOR

120 OHM

CAN TERMINATOR

120 OHM

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

HD36-24-29SE

18
19
20
21
22
23
24
25
26
27
28
29

A
B
C

A
B
C

ECU IGN/012
ECU BAT/022
ECU GND/050

PLUGGED
CLT TMP

PLUGGED
OVR SGN/918
FAULT LT/473

ALT EXC
OVR SUP/911
THR SGN/915
THR RTN/914

PLUGGED

HR MTR

OIL PSI

GAGE PWR

TRANS TEMP

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

SHTDN/941

(CAN H/904, YELLOW)
(CAN L/905, GREEN)

(CAN H/904, YELLOW)
(CAN L/905, GREEN)

(SHIELD/020)

(SHIELD/020)

PLUGGED

CRANK A/447

CRANK B/448

PLUGGED

ECU GND/050

BCAABABABABAB

INJ A/491

INJ B/493

OVR SUP/911

THR RTN/914

OIL PRS/467

12 TURNS
PER FOOT

TWIST

390 OHM, 1W

12 TURNS
PER FOOT

TWIST

PLUGGED

INJ A/491

ECU BAT/022

J

K3

NOTES:

1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
ENGINE ECU HARNESS (4923232).

SHIELDED

CABLE

ECU IGN/012

ECU GND/050

PLUGGED

PLUGGED

PLUGGED

PLUGGED

(SHIELD/020)

(CAN L/905, GREEN)

(CAN H/904, YELLOW)

G

CAB FDE HGJ

DIAGNOSTIC

CONNECTOR

GAGE PWR

HR MTR

CLT TEMP

CLT TMP

OIL PSI

A
B

Q

SENDER
P23222

OIL PRESS

L

SENDER
P23217

5 PSI

ENGINE OIL

PRESSURE

K

SWITCH

TRANS TEMPTRANS TEMP

V

SENDER
P19472

MV0460

RQPNF E

CLT/461

THR RTN/914

THR RTN/914

MAN TMP/463

SEE SHT 1

SHIELDED

CABLE

SHIELDED

CABLE

CLT/461

SHTDN/941

INJ B/493

HI LO/947

OVR SGN/918

ECU IGN/012

CRANK A/447

A2A1A3B1B2B3C2C1E3

THR RTN/914

FUEL TMP/428

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

CAN H/904

CAN L/905

OVR SUP/911

THR SGN/915

THR RTN/914

OIL PRS/467

MAN TMP/463

CRANK B/448

FUEL TMP/428

D1C3D2E1D3E2F3F1F2G2G1K1H2H1H3J2J1J3K2

FAULT LT/473

G3

DEERE ENGINE ECU

PLUGGED

PLUGGED

31200079

4-9

Reference Diagrams

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

NOTES

4-10

31200079

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

Reference Diagrams

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

Hydraulic

Reservoir/

Fuel Tank

Oil Return

Filter

General Description

Hydraulic

Pump

Hydraulic

Control

Val ve

K1099

Fig. 5-1: Major Hydraulic Components

(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

Hydraulic Systems

Mid-Inlet Hydraulic System

Supply, Pressure, and Return Hydraulics

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

good repair.

W1047

31200079

5-3

Supply, Pressure, and Return Hydraulics

• The hydraulic system is under pressure whenever the engine is run-

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

• Wear appropriate eye protection.

• If anyone is injured by or if any hydraulic fluid is injected into the skin,

• When venting or filling the hydraulic system, loosen the filler cap slowly

• NEVER reset any relief valve in the hydraulic system to a pressure

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.

paper to search for leaks.

get medical attention immediately.

and remove it gradually.

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.

5-4

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

31200079

Checking Hydraulic Lines

Supply, Pressure, and Return Hydraulics

as the oil passes through. A high quality hydraulic oil contains many
additives which work to keep contaminants from damaging the system.
However, these additives lose their effectiveness after a period of time.
Therefore, change the oil at recommended intervals to make sure the
additives do their job.

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.

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

3

2

4

1

5

6

7

MV0010

# Description

1 Hydraulic Tank Breather (Models

with Mid-Inlet Hydraulics)

2 Hydraulic Tank Sight Gauge
3 Pressure Gauge
4 Return Filter Assembly

# Description

5Hydraulic Oil Tank
6 Hydraulic Oil Strainer (Models with

Mid-Inlet Hydraulics)

7 Suction Line

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.

31200079

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.

5-7

Supply, Pressure, and Return Hydraulics

Filling Hydraulic Reservoir

Preferred Method

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

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.

hydraulic system can become contaminated.

1

3

2

4

# Description

1Hex Cap
2Cover

Fig. 5-5: Recommended Reservoir Filling Method

# Description

3Hydraulic Hose
4 Male JIC (37°) Filler Fitting

(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.

K1015

5-8

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.

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.

Filling Hydraulic Reservoir
Alternate Method

9. Loosen and remove hose (Item 3)

from reservoir filler fitting (Item 4).

Install hex cap (Item 1) and torque to 70 ft-lbs.

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.

2

3

4

5

1

# Description

1 Return Filter Housing
2 Flange Nut
3 Cover

# Description

4Spring
5 Hydraulic Filter Element

Fig. 5-6: Alternate Reservoir Filling Method

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

K1016

31200079

5-9

Supply, Pressure, and Return Hydraulics

1. The machine must be parked on a level surface and the frame must be

2. Retract all cylinders except frame tilt cylinder, apply the park brake,

3. Clean return filter housing (Item 1) and surrounding area.

4. Remove four (4) flange nuts (Item 2) that secure the filter housing

5. Lift the cover (Item 3) and spring (Item 4) from housing (Item 1) and set

6.

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

level.

and stop the engine.

cover (Item 3). Set hardware aside on a clean surface.

aside on a clean surface.

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.

(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

Reservoir Drain and Refill

Supply, Pressure, and Return Hydraulics

2

1

3

4

MV0070

# Description

1 Breather Filter
2 Return Filter Assembly

Fig. 5-7: Hydraulic Reservoir Drain and Refill

# Description

3 Hydraulic Oil Suction Strainer
4Drain Plug

(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.

31200079

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.

5-11

Supply, Pressure, and Return Hydraulics

6. Clean the strainer (Item 2) by back flushing with solvent. Dry the

7. Install the reservoir drain plug (Item 4). Tighten two or three turns past

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

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

9. Install a new breather filter assembly (Item 1).

10. Fill hydraulic reservoir. see “Filling Hydraulic Reservoir” on page 5-8.

strainer element thoroughly with compressed air. Install it as described
under “Installation” on page 5-20.

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.

thread sealant to end threads of drain plug.

page 5-26.

5-12

31200079

Removal

Hydraulic Reservoir and
Fuel Tank

Supply, Pressure, and Return Hydraulics

24

23

7

6

8

5

22

4

3

2

15

17

16

19

18

24

23

1

20

28

9

27

26

10

11

12

14

13

21

25

# Description

1 Tank Hold-Down Strap
2 Chemprene Belting
3 Pipe Adapter
4 Hose Clamp
5 Fuel Supply Hose
6 Flatwasher
7Nut
8 Wiring Harness

9 JIC Pipe Connector
10 Return Manifold Tube
11 Hydraulic Oil Return Filter
12 Hydraulic Reservoir/Fuel Tank
13 Swivel Branch Tee
14 Check Valve

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

MV0060

# Description

15 90° Elbow
16 Hose Clamp
17 Fuel Return Hose
18 Fuel Tank Drain Plug
19 Hydraulic Reservoir Drain Plug
20 Flange Halve
21 Hydraulic Suction Hose
22 Tank Support Mount
23 Lockwasher
24 Nut
25 Main Frame (Front End)
26 Capscrew
27 Lockwasher
28 Hydraulic Oil Strainer

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.

2. Remove the hydraulic reservoir drain plug (Item 19) and drain hydraulic

3. Remove fuel tank drain plug (Item 18) and drain the fuel into an

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

4. Remove two (2) nuts (Item 7) and flatwashers (Item 6) securing wiring

Be sure to follow the guidelines in this section detailed under “General
Hydraulic Maintenance Practices” on page 5-3.

fluid into a suitable container. Dispose of drained fluid properly.
Temporarily reinstall drain plug.

suitable container. Dispose of drained fuel properly. Temporarily
reinstall drain plug.

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

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.

5-14

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.

31200079

Installation

Supply, Pressure, and Return Hydraulics

14. Perform steps 6 through 9 under “Reservoir Drain and Refill” on
page 5-11.

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

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

sealant to the end threads of the drain plug.

Hydraulic Reservoir and
Fuel Tank

(Ref. Fig. 5-8) The following procedure describes installation of the
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.

31200079

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.

5-15

Supply, Pressure, and Return Hydraulics

L
O
W

H
I
G
H

Sight Gauge

Description

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

Removal

Supply, Pressure, and Return Hydraulics

Sight Gauge

5

4

3

2

1

6

8

7

9

10

K1093

# Description

1 Hydraulic Sight Gauge
2 Hollow Hex Head Bolt
3O-Ring
4 Lockwasher
5Capscrew

# Description

6 Hydraulic Oil Return Filter Assy
7 JIC Pipe Connector
8 Return Manifold Tube
9 Hydraulic Reservoir

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.

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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.

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Supply, Pressure, and Return Hydraulics

6. Remove the sight gauge (Item 1) along with the two (2) hollow hex

7. Clean the two openings in the side of the hydraulic reservoir with

Installation

head bolts (Item 2).

appropriate solvent. Plug openings.

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.)

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