Service Manual Models 644B, 6K, 844C, 8K, 1044C, 10K 10709790 Revised February 18, 2005 An Oshkosh Truck Corporation Company
Quick Reference Section No. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Identification and Specifications . . . . . . . . . . . . . . . . . . . . . . 2 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Reference Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Supply, Pressure, and Return Hydraulics . . . . . . . . . . . . . . . 5 Boom and Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision Record Rev. No. Inserted By Date 001 Lull (initial release) 12/97 B JLG(replace branding with JLG) 02/05 Rev. No.
Table of Contents Section 1 — Safety General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 John Deere 4039D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 John Deere 4039T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 John Deere 4045T . . . . . . . . . . . . . . . .
Table of Contents Section 4 — Reference Diagrams Schematic, Model 644B w/ Naturally Aspirated Engine, Control Manifold Hydraulic System . . . . . . . . . Diagram 1 Schematic, Model 644B w/ Naturally Aspirated Engine, Mid-Inlet Hydraulic System . . . . . . . . . . . . . . . . Diagram 2 Pump Unloader Valve Operation, Mid-Inlet Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 3 Schematic, Models 644B, 844C, 1044C-42 w/ Turbocharged Engine, Mid-Inlet Hydraulic Sys. . .
Table of Contents Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Hydraulic Pressure Filter . . . . . . . .
Table of Contents Section 6 — Boom and Transfer Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Slide Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Lubrication . . . . . . . . . . . . . . . . . . .
Table of Contents Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-217 Installation . . . . . . . . . . .
Table of Contents Oscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Installation . . . . . . . . . . . .
Table of Contents Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 Pre-Charging Accumulator . . .
List of Figures Fig. 1-1: Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Fig. 1-2: Instrument Panel Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Fig. 1-3: Control Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Fig.
List of Figures Fig. 5-14: Return Filter Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Fig. 5-15: Filter Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Fig. 5-16: Filter Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Fig. 5-17: Return Filter Assembly . . . . . . . . . . . . . . .
List of Figures Fig. 5-52: Mid-Inlet Control Valve Configurations, Models 6K, 8K, 10K . . . . . . . . . . . . . . . . . . . . . . . . 5-84 Fig. 5-53: Mid-Inlet Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85 Fig. 5-54: Rear Axle Stabilizer Control Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86 Fig. 5-55: Rear Axle Stabilizer Control Valve Ports. . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 6-28: Selector Valve Assembly – Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Fig. 6-29: Load Bearing Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Fig. 6-30: Pad Worn, But Still OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Fig. 6-31: Pad Must Be Replaced . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 6-66: Inner Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 Fig. 6-67: View at Rear of 2-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 Fig. 6-68: Hose Connections, 2-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Fig. 6-69: Cylinder Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 6-104: Upper Chains - Third Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101 Fig. 6-105: Upper Chain Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Fig. 6-106: Boom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Fig. 6-107: Rear Hose Connections, Inner Boom . . . . . . . . .
List of Figures Fig. 6-142: Front Slide Pads Installation, Outer Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132 Fig. 6-143: Securing Lower Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133 Fig. 6-144: Upper Chains - First Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134 Fig. 6-145: Upper Chains - Second Type . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 6-180: Upper Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . 6-167 Fig. 6-181: Upper Front Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . 6-167 Fig. 6-182: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-168 Fig. 6-183: Upper Chain Roller Assembly – Middle (Forward) Boom Section. . . . . . . . . . . . . . . . . . . 6-168 Fig.
List of Figures Fig. 6-218: Lower Chain Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-201 Fig. 6-219: Upper Chains – Middle (Rear) to Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202 Fig. 6-220: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-203 Fig. 6-221: Securing Lower Chains – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . 6-203 Fig.
List of Figures Fig. 6-256: Transfer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-243 Fig. 6-257: Transfer Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244 Fig. 6-258: Transfer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246 Fig. 7-1: Frame Tilt System Components . . . . . . . . . . . . . . .
List of Figures Fig. 8-7: Typical Shunt Diode Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Fig. 8-8: Shunt Diode Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Fig. 8-9: Rear Oscillation Lock Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Fig. 8-10: Connection Guide and Pin Positions. . . . . . . . . . . .
List of Figures Fig. 10-11: Outrigger Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Table 3-3: Cummins Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Table 3-4: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . .
Section 1 — Safety Table of Contents General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Caution, Warning, and Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 — Safety General Observing basic safety rules and precautions can eliminate accidents when operating, maintaining, and repairing the forklift. The Operator’s Manual contains detailed information regarding safety practices when driving and operating the forklift. Always be alert to potential hazardous situations that could result in injury to yourself or bystanders. Care should also be taken to avoid damage to the equipment.
Safety Safety Standard The ASME/ANSI B56.6 safety standard for rough terrain forklift trucks defines safety requirements relating to the design, operation, and maintenance of these vehicles. For a copy of this standard write to: The American Society of Mechanical Engineers United Engineering Center 345 East 47th Street New York, NY 10017 Maintenance Safety General DO NOT attempt machine operation or maintenance until you have read and fully understand the safety instructions in this section.
Safety • Make certain there is adequate light and ventilation. • Remove any foreign substances (i.e. oil, grease, water, snow, ice) to eliminate any slippery surfaces and to remove all contaminants from the area. • Use only the correct tools to perform the maintenance or repair. • Make sure all jacks, hoists, jack stands, or blocks are stable and strong enough to handle the weight of the forklift or component that you will be working on.
Safety Hydraulic System Hazards WARNING HIGH PRESSURE FLUID HAZARD To prevent serious personal injury or death: 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 • Relieve system pressure The hydraulic system is under pressure whenever the engine is running and can hold pressure after the engine is shut down.
Safety To avoid personal injury… • Electrolyte in batteries contains sulfuric acid which is a poison and can cause severe chemical burns. Wear a face shield and safety glasses to prevent contact with your eyes and face. • Wear chemical resistant gloves and clothing to keep acid off your skin and regular clothing. Important: If electrolyte is ever ingested or splashed into your eyes, get medical attention immediately. NEVER give fluids that would induce vomiting.
Safety • NEVER reinflate a tire that has been run flat or seriously under inflated WITHOUT removing the tire from the wheel. Have the tire and rim closely inspected for damage before remounting. • Clean the area around all wheel lug nuts or bolts. Periodically check the torque per the specifications until the torque value stabilizes; then check at regularly scheduled intervals.
Safety Attaching Decals The surface on which a decal is to be attached must be dry and free of all dirt and grease. Remove the backing from the decal and apply decal in its correct location. Once in place, rub entire surface of the decal with your thumb, applying sufficient pressure to ensure good adhesion of the decal to the mounting surface. Decal Locations Decals and placards that provide information, instructions, and address safety issues include the following: • Attachment Capacity Plate (Fig.
Safety Boom Extension Indicator Forklift Signals Cab Transfer Extension Load Chart Capacities and Don’t Be Lubrication Schedule Careless Flip Cards Notice 3 2 FT FT FORKLIFT SIGNALS NOTICE S T O P R AIS EL O AD L O W E RL O AD 45 M AX M I U M BO O M L O A DC A P A C IT IE SA T 24 "L O A DC E N T E R ,F O RL F I TA N DR E AC H P O S IT IO N SINP O U N DS AN DF E E T W IT H M E T R ICC O N V E R S IO N S .
Safety Transfer and Fork Tilt Control Outrigger Control Boom Movement Control V1087 Frame Tilt Control Fig. 1-3: Control Decals Slow Moving Vehicle Sign R1053 Disconnect Battery Fig.
ROUND STEER OBLIQUE STEER FRONT WHEEL STEER Safety Operator’s Seat Steer Selector Plate R1049 Fig. 1-5: Steer Selector Plate Hydraulic Oil Only Hydraulic Breather R1050 Diesel Fuel Only Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals Attachment Capacity Plate R1051 Carriage Safety Decal Fig.
Section 2 — Identification and Specifications Table of Contents Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Engine Serial Number, John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Fig. 2-1: Machine Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fig. 2-2: Stamped Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fig. 2-3: Engine Serial Number — John Deere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Fig. 2-4: Engine Serial Number — Cummins . . . . . . . . . . . . . . . . . . . .
Section 2 — Identification and Specifications Serial Number Locations Machine Serial Number V1005 Serial Number Plate Fig. 2-1: Machine Serial Number Plate (Ref. Fig. 2-1) The machine serial number plate is mounted in the cab below the seat. V1008 Machine Serial Number Fig. 2-2: Stamped Machine Serial Number (Ref. Fig. 2-2) The machine serial number is also stamped into the frame on the left rear corner of the machine.
Identification and Specifications Engine Serial Number, John Deere Serial Number Plate Fuel Pump V1006 Starter Fig. 2-3: Engine Serial Number — John Deere (Ref. Fig. 2-3) The engine serial number plate is located on the left side of the engine near the starter and fuel pump. John Deere engines include an options code decal located on top of the engine manifold cover. Do not damage, remove, or paint over this decal. It is recommended that this information be written down for future reference.
Identification and Specifications Axle Serial Number V1007 Front Axle Serial Number Plate Fig. 2-5: Axle Serial Number (Ref. Fig. 2-5) 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 MODEL SERIAL NUMBER MAX. HYDR. PRESS. WEIGHT CAPACITY OF ROUGH TERRAIN FORKLIFT TRUCK AND ATTACHMENT COMBINATION MAY BE LESS THAN CAPACITY SHOWN ON ATTACHMENT.
Identification and Specifications Models 644B-37 and 6K-37 R1026 Identification R1027 Fig. 2-7: Top View — Models 644B-37 and 6K-37 Fig.
Identification and Specifications Models 644B-37 and 6K-37 (cont’d.) Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 lbs. Maximum Lift Height (and “Landing Height” for 644B-37) . . . . . . . 37 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +70° TransAction (644B-37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 644B-37 and 6K-37 (cont’d.) Pressures Hydraulic: Control Manifold System: Boom Hoist and Extend Valve Relief . . . . . . . . . . . . . . . . .2650 psi 4- or 5-Section Relief Valve . . . . . . . . . . . . . . . . . . . . . . . .2800 psi Carriage Tilt Valve Section, Up Port Relief . . . . . . . . . . . . .2800 psi Carriage Tilt Valve Section, Down Port Relief. . . . . . . . . . .2800 psi Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 644B-37 and 6K-37 (cont’d.) Service Brakes Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Spicer Type . . . . . . . . . . . . . . . . . . .Hydraulically Actuated, Wheel End, Wet Disc Parking Brake Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF) Type . . . . . . . . . . . . . . . . .
Identification and Specifications Models 644B-42 and 6K-42 R1026 Identification R1028 Fig. 2-9: Top View — Models 644B-42 and 6K-42 Fig.
Identification and Specifications Models 644B-42 and 6K-42 (cont’d.) Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 lbs. Maximum Lift Height (and “Landing Height” for 644B-42) . . . . . . . 42 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +70° TransAction (644B-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 644B-42 and 6K-42 (cont’d.) Pressures Hydraulic: Control Manifold System: Boom Hoist and Extend Valve Relief . . . . . . . . . . . . . . . . .2650 psi 4- or 5-Section Relief Valve . . . . . . . . . . . . . . . . . . . . . . . .2800 psi Carriage Tilt Valve Section, Up Port Relief . . . . . . . . . . . . .2800 psi Carriage Tilt Valve Section, Down Port Relief. . . . . . . . . . .2800 psi Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 644B-42 and 6K-42 (cont’d.) Service Brakes Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Spicer Type . . . . . . . . . . . . . . . . . . .Hydraulically Actuated, Wheel End, Wet Disc Parking Brake Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF) Type . . . . . . . . . . . . . . . . .
Identification and Specifications Models 844C-42 and 8K-42 R1026 Identification R1028 Fig. 2-11: Top View — Models 844C-42 and 8K-42 Fig.
Identification and Specifications Models 844C-42 and 8K-42 (cont’d.) Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000 lbs. Maximum Lift Height (and “Landing Height” for 844C-42) . . . . . . . 42 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +70° TransAction (844C-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 844C-42 and 8K-42 (cont’d.) Pressures Hydraulic: Control Manifold System: 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 844C-42 and 8K-42 (cont’d.) Service Brakes Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Spicer Type . . . . . . . . . . . . . . . . . . .Hydraulically Actuated, Wheel End, Wet Disc Parking Brake Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zahnradfabrik (ZF) Type . . . . . . . . . . . . . . . . .
Identification and Specifications Models 1044C-42 and 10K-42 R1026 Identification R1028 Fig. 2-13: Top View — Models 1044C-42 and 10K-42 Fig.
Identification and Specifications Models 1044C-42 and 10K-42 (cont’d.) Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,000 lbs. Maximum Lift Height (and “Landing Height” for 1044C-42) . . . . . . 42 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +70° TransAction (1044C-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 1044C-42 and 10K-42 (cont’d.) Pressures Hydraulic: Control Manifold System: 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 1044C-42 and 10K-42 (cont’d.) Wheels/Tires Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 (Torque to 320 ft-lbs) Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 × 24 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gallons Sodium Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 lbs Pressure .
Identification and Specifications Models 1044C-54 and 10K-54 R1026 Identification R1052 Fig. 2-15: Top View — Models 1044C-54 and 10K-54 Fig.
Identification and Specifications Models 1044C-54 and 10K-54 (cont’d.) Specifications General Operating Specifications Lift and Carry Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,000 lbs. Maximum Lift Height (and “Landing Height” for 1044C-54) . . . . . . 54 Feet Boom Elevation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5° to +69° TransAction (1044C-54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 1044C-54 and 10K-54 (cont’d.) Pressures Hydraulic: Control Manifold System: 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Models 1044C-54 and 10K-54 (cont’d.) Wheels/Tires Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 (Torque to 320 ft-lbs) 14 × 24 Tires: Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 × 24 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gallons Sodium Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 lbs Pressure . .
Identification and Specifications Engine Specifications John Deere 4039D Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally Aspirated Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 HP @ 2500 rpm Maximum Torque . . . .
Identification and Specifications Engine Specifications (cont’d.) John Deere 6068D Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally Aspirated Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications Engine Specifications (cont’d.) Cummins 4BT3.9 (EPA) Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 — General Maintenance Table of Contents General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Service Preparation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Service And Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Replacement Parts . . . . . . .
List of Tables Table 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Table 3-2: John Deere Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Table 3-3: Cummins Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Table 3-4: ZF Transmission Oil Specifications . . . . . . . . . . . . . . . . . . . . . .
Section 3 — General Maintenance General Instructions Performance of your machine is dependent on proper maintenance and lubrication at designated intervals. Proper operating procedures and a regularly scheduled maintenance and lubrication program will increase the life of machine components and reduce machine down time. Should a defect or failure occur to your machine, take it out of service immediately.
General Maintenance Service And Repair Procedures CAUTION: Unless specifically told not to, lower the boom to the ground, apply the parking brake, and stop the engine before servicing, adjusting, or repairing the machine. WARNING: Release all hydraulic pressure before doing any maintenance or repairs to the hydraulic system. WARNING: Liquid cooling systems build up pressure as the engine gets hot. Before removing the radiator cap, stop the engine and let the system cool.
General Maintenance Replacement Parts General Record the machine model, serial number, and component serial numbers for reference when ordering replacement parts. See “Serial Number Locations” in Section 2. Use only JLG authorized replacement parts and fluids. Use of parts other than JLG authorized parts may adversely effect machine reliability, performance, and safety and may void the warranty. JLG assumes no liability for equipment damages caused by the use of unauthorized replacement parts.
General Maintenance Fluid and Lubricant Specifications General Specifications Table 3-1: General Fluid and Lubricant Specifications 1 FLUID OR LUBRICATION SPECIFICATION Fuel System1 See "Fuel Requirements" Hydraulic System Heavy Duty Hydraulic Fluid Engine Cooling System1 See engine manufacturer's operator's manual. Engine Oil1 See "Engine Oil Specifications" Transmission See "Transmission Oil Selection Chart" Differential (Front & Rear) Gear Lubrication Planetary Hub (Each) Use 58 oz.
General Maintenance Table 3-2: John Deere Engine Oil Specifications ENGINE OIL, DEERE Oil Grade Temperature Range °F Temperature Range °C SAE 5W-30 -22 to +86 °F -30 to +30 °C SAE 10W-30 -4 to +86 °F -20 to +30 °C SAE 15W-40 +5 to +122 °F -15 to +50 °C SAE 30W +32 to +86 °F 0 to +30 °C SAE 40W -50 to +104 °F +10 to +40 °C Arctic oil (e.g.
General Maintenance Table 3-4: ZF Transmission Oil Specifications ZF 3WG-100 & 4WG-100 TRANSMISSIONS Oil Grade Minimum Oil Temperature for Starting Engine Minimum Oil Temperature for Engaging Transmission SAE 20W-20 +14 °F (-10 °C) +41 °F (+5 °C) SAE 15W-40 +5 °F (-15 °C) +32 °F (0 °C) SAE 10W, 10W-30, 10W-40 -4 °F (-20 °C) +23 °F (-5 °C) Engine Oils Automatic Transmission Fluid (ATF) ATF -22 °F (-30 °C) +14 °F (-10 °C) Approved Lubricants (Engine Oils) API CD/ CE/ CF/ SF/ SG MIL-L-2104 C/
General Maintenance • Lubricate all grease fittings with the specified grease. Hydraulic Oil Hydraulic oil selected for use with JLG forklifts should be a premium quality anti-wear hydraulic oil.
General Maintenance • Avoid spraying water on electrical components such as the alternator, starter, gauges, and electrical items under the dash. • Be careful around the fuel fill and hydraulic reservoir breather. Water may get into tanks and damage fuel and/or hydraulic components. • To help prevent freezing, allow water to drain or dry before operating in cold weather. Cleaning the Cab • Clean dust and dirt from all areas of the cab.
General Maintenance 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 or Table 3-3 on page 5. 4. Apply grease to all exposed hydraulic cylinder rod areas. 5. Disconnect battery cables.
General Maintenance 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.
General Maintenance Table 3-5: General Torques for Standard Bolts, Capscrews, and Nuts SAE Grade 5, 5.1, 5.2 SAE Grade 8, 8.
General Maintenance PROPERTY CLASS AND HEAD MARKINGS PROPERTY CLASS AND NUT MARKINGS 4.8 5 5 4.8 5 4.8 9.8 8.8 9.8 8.8 9.8 10 10 8.8 10 10.9 10 10 10.9 10 12.9 12 12.9 12 12.9 12 12.9 Y1--2 Fig. 3-2: Metric Class Identification Table 3-6: General Torques for Metric Bolts, Capscrews, and Nuts Size 3-12 Class 4.8 Class 8.8 or 9.8 Ft-lbs Nm Ft-lbs M6 3.5 4.8 M8 8.5 12 M10 17 M12 29 M14 47 M16 73 M18 100 M20 Class 10.9 Class 12.9 Nm Ft-lbs Nm Ft-lbs Nm 6.
General Maintenance Hydraulic Fitting Torques JIC and SAE Female Swivel Nuts It is recommended that the nut be torqued to the approximate minimum value. If leakage occurs, tighten nut without exceeding maximum torque value. Note: Use two wrenches to tighten hydraulic line nuts. Table 3-7: Torque for JIC and SAE Female Swivel Nuts Size SAE Port Approx. Min. Max.
General Maintenance Adjustable O-ring Fittings To install straight thread, adjustable O-ring fittings: 1. Check condition of O-ring and replace as necessary. Do not install a fitting with a damaged O-ring. 2. Lubricate O-ring with clean hydraulic fluid. 3. Back off the locknut fully. 4. Screw fitting into port until backup washer contacts face of port. 5. Position fitting by unscrewing a maximum of one turn. 6. Hold the fitting in position with a wrench and torque locknut per Table 3-9.
General Maintenance Pipe Thread Fittings To install National Pipe Thread (NPT) fittings: 1. Apply sealant sparingly to male pipe threads only, avoiding the first few threads at the end of the fitting. Note: Do not use Teflon tape or excessive amounts of sealant. System contamination will result. 2. Install fitting and tighten per Table 3-11. Table 3-11: Pipe Thread Fittings (Steel) Fitting Size Thread Size (NPT) Turns1 -2 1/8-27 2–3 -4 1/8-27 2–3 -6 1/4-18 1.
General Maintenance 1. Move the boost start machine (or auxiliary power source) close enough to the stalled machine for the cables to reach without allowing the machines to touch. Place the transmission shift selector in NEUTRAL, engage the park brake, and turn off engine (or shut off auxiliary power source). 2. On the stalled machine, turn the ignition switch to OFF. 3. Connect the positive (+) jumper cable to the positive (+) cable terminal of the discharged battery on the stalled machine.
General Maintenance Conversion Charts V1070 Table 3-12: Inch Fraction, Decimal, and Metric Conversion Chart Inch Fract. Inch Dec. 1/64 0.0156 1/32 0.0313 3/64 0.0469 1/16 0.0625 5/64 0.0781 3/32 0.0938 7/64 0.1094 1/8 0.1250 9/64 0.1406 5/32 0.1563 11/64 0.1719 3/16 0.1875 13/64 0.2031 7/32 0.2188 15/64 0.2344 1/4 0.2500 17/64 0.2656 9/32 0.2813 19/64 0.2969 5/16 0.3125 21/64 0.3281 11/32 0.3438 23/64 0.3594 3/8 0.3750 25/64 0.3906 13/32 0.4063 27/64 0.4219 7/16 0.4375 29/64 0.4531 15/32 0.4688 31/64 0.
General Maintenance Table 3-13: Miscellaneous Conversions Multiply By International System Conversion (IS) Unit Factor To Get or Multiply By To Get Non-IS Unit Conversion Factor IS Unit x 0.113 x 1.36 = Nm = Nm x 0.249 x 3.38 x 6.89 x 0.069 x 0.0069 = kPa = kPa = kPa = bar = bar x 0.00689 = MPa x 0.736 x 0.746 x 1.055 x 1.36 = kW = kW = kW =W x 1.055 x 4.19 = kJ =J x 0.305 x 0.305 x 1.61 = m/s2 = m/s = km/h x 3.785 = L/min Torque Newton Meter (N•m) m) Newton Meter (N•m) m) x 8.
Section 4 — Reference Diagrams Table of Contents Schematic, Model 644B w/ Naturally Aspirated Engine, Control Manifold Hydraulic System . . . . . . . . . Diagram 1 Schematic, Model 644B w/ Naturally Aspirated Engine, Mid-Inlet Hydraulic System . . . . . . . . . . . . . . . . Diagram 2 Pump Unloader Valve Operation, Mid-Inlet Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 3 Schematic, Models 644B, 844C, 1044C-42 w/ Turbocharged Engine, Mid-Inlet Hydraulic Sys. . .
Section 4 — Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Control Manifold Hydraulic System-Diagram 1 4-1 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Control Manifold Hydraulic System-Diagram 1 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-2
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Control Manifold Hydraulic System-Diagram 1 PG STP OR1 .040 OR2 .040 F PR ACG PD B OUT 450 PSI SW PLT CV P2 HR B5 T PU LC CS 1200/1600 PSI P1 HL A5 IN 2 3 AC PF STB 1 RET A2 T EF P1G 2200 PSI ST LS CF PSG This diagram applies to the following Model(s) and serial numbers: 644B-37 ....... S/N: 428, 429, 485-590, 592-666 644B-42 ........
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Control Manifold Hydraulic System-Diagram 1 B C A D F A – Left Side View Cartridge Identification CS Compensator Valve CV Check Valve LC Logic Valve PD Pilot Directional Valve PF Priority Flow Control PR Pressure Reducing Valve PU Pilot Unloading Valve E F – Front View B – Top View D – Right Side View C – Back View E – Bottom View Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-4
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Mid-Inlet Hydraulic System - Diagram 2 QUICK DISCONNECTS BOOM TELESCOPE CYLINDER C.B. VALVE AUX. 1 OPTIONS UPPER HYDRAULICS BOOM ROLL BACK HOSES FRONT CARRIAGE TILT CYLINDER CLOSED BELOW 850 PSI OPEN ABOVE 850 PSI 12V LOW BRAKE PRESSURE SW WARNING SWITCH PARK BRAKE PRESS.
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Mid-Inlet Hydraulic System - Diagram 2 REAR CARRIAGE TILT CYLINDER BOOM HOIST CYLINDER C.B. VALVE C.B. VALVE TRANSFER CYLINDER C.B. VALVE BOOM HOIST CYLINDER REAR CARRIAGE TILT CYLINDER X BOOM TELESCOPE BOOM HOIST X FRAME TILT UNLOADER AUX.
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Mid-Inlet Hydraulic System - Diagram 2 Mid-Inlet Control Valve BOOM TELESCOPE BOOM HOIST UNLOADER FRAME TILT AUX. 1 CARRIAGE TILT TRANSFER A5 A2 A2 A A B B A A6 A1 A3 A4 A A A A B B B B B 2800 PSI 2750 PSI B2 3170 PSI B2 B5 B6 B3 B1 2800 PSI B4 P Mid-Inlet Port Schematic Symbol for Mid-Inlet Control Valve This diagram applies to the following Model(s) and serial numbers: 644B-37 .......
Reference Diagrams Schematic, Model 644B w/Naturally Aspirated Engine, Mid-Inlet Hydraulic System - Diagram 2 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-8
Reference Diagrams Pump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3 4-9 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Pump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-10
Reference Diagrams Pump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3 4-11 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Pump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3 This page intentionally left blank Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-12
Reference Diagrams Schematic, Models 644B, 844C, 1044C-42 w/Turbocharged Engine, Mid-Inlet Hydraulic Sys.-Diagram 4 QUICK DISCONNECTS C.B. VALVE AUX. 1 OPTIONS BOOM TELESCOPE CYLINDER QUICK DISCONNECTS AUX. 2 OPTIONS UPPER HYDRAULICS BOOM ROLL BACK HOSES FRONT CARRIAGE TILT CYLINDER CLOSED BELOW 850 PSI OPEN ABOVE 850 PSI 12V LOW BRAKE SW PRESSURE WARNING SWITCH PARK BRAKE PRESS.
Reference Diagrams Schematic, Models 644B, 844C, 1044C-42 w/Turbocharged Engine, Mid-Inlet Hydraulic Sys.-Diagram 4 REAR CARRIAGE TILT CYLINDER BOOM HOIST CYLINDER C.B. VALVE C.B. VALVE TRANSFER CYLINDER C.B. VALVE BOOM HOIST CYLINDER REAR CARRIAGE TILT CYLINDER BOOM TELESCOPE FRAME TILT BOOM HOIST (OPTION) AUX. 2 AUX. 1 CARRIAGE TILT TRANSFER A5 A2 A6 A A A3 A A A A B B B B B B B (OPTION) (OPTION) A A B B 3175 PSI 2800 PSI 3050 PSI B3 B6 B5 B2 L.H.
Reference Diagrams Schematic, Models 644B, 844C, 1044C-42 w/Turbocharged Engine, Mid-Inlet Hydraulic Sys.-Diagram 4 Mid-Inlet Control Valve BOOM TELESCOPE FRAME TILT BOOM HOIST A2 AUX. 1 CARRIAGE TILT TRANSFER A5 A6 A A (OPTION) AUX. 2 A A3 A A B B B B B B B (OPTION) A A B B 3175 PSI 2800 PSI 3050 PSI B2 L.H. OUTRIGGER (OPTION) A4 A1 A A R.H. OUTRIGGER B6 B5 B3 B1 2800 PSI B4 P This diagram applies to the following Model(s) and serial numbers: 644B-37 .......
Reference Diagrams Schematic, Models 644B, 844C, 1044C-42 w/Turbocharged Engine, Mid-Inlet Hydraulic Sys.
Reference Diagrams Schematic, Model 1044C-54, Mid-Inlet Hydraulic System - Diagram 5 QUICK DISCONNECTS C.B. VALVE AUX. 1 OPTIONS BOOM TELESCOPE CYLINDER QUICK DISCONNECTS AUX. 2 OPTIONS UPPER HYDRAULICS BOOM ROLL BACK HOSES FRONT CARRIAGE TILT CYLINDER CLOSED BELOW 850 PSI OPEN ABOVE 850 PSI 12V LOW BRAKE SW PRESSURE WARNING SWITCH PARK BRAKE PRESS.
Reference Diagrams Schematic, Model 1044C-54, Mid-Inlet Hydraulic System - Diagram 5 REAR CARRIAGE TILT CYLINDER C.B. VALVE C.B. VALVE BOOM HOIST CYLINDER TRANSFER CYLINDER C.B. VALVE BOOM HOIST CYLINDER REAR CARRIAGE TILT CYLINDER BOOM TELESCOPE FRAME TILT BOOM HOIST (OPTION) AUX. 2 AUX. 1 CARRIAGE TILT TRANSFER L.H. OUTRIGGER R.H.
Reference Diagrams Schematic, Model 1044C-54, Mid-Inlet Hydraulic System - Diagram 5 Mid-Inlet Control Valve BOOM TELESCOPE FRAME TILT BOOM HOIST AUX. 1 CARRIAGE TILT TRANSFER A6 A A A3 A A B B B A A B B A A B B 3175 PSI 2800 PSI 3050 PSI B2 L.H. OUTRIGGER A4 A1 B B R.H. OUTRIGGER A5 A2 A (OPTION) AUX. 2 B6 B5 B3 B1 2800 PSI B4 P This diagram applies to the following Model(s) and serial numbers: 1044C-54 ......
Reference Diagrams Schematic, Model 1044C-54, Mid-Inlet Hydraulic System - Diagram 5 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-20
Reference Diagrams Electrical Diagram, Models 644B and 6K w/Control Manifold Hydraulic System - Diagram 6 9 8 FUEL 6 6 B A T T E R Y V O L T A G E 4 I 8 12 POWER 9 4 REAR OSC LOCK LAMPS 10 3 10 GRD E N G IN E O IL P R E S S U R E LOW BRAKE PRESS 1 G TRANS OIL TEMP S L 11 11 2 IGNITION SWITCH RELAY 37383X SPST 50A F U E L 7 WATER 5 E N G IN E 5 W A T E R T E M P E R A T U R E PARK BRAKE 7 OIL 1 12 HOUR METER + 86 85 30 87 38072D UPPER HA VIOLET-16 WHITE-12 RED
Reference Diagrams Electrical Diagram, Models 644B and 6K w/Control Manifold Hydraulic System - Diagram 6 35646A POS. CABLE STARTER MOTOR SOLENOID + BATTERY – 12V 925 CCA P30712 1/0 RED BLACK-8 1/0 BLACK WHITE-8 35532A NEG. CABLE RED-6 STARTER RELAY P21777 WHITE-12 RED-12 P28569 HARNESS 38073D INTERMEDIATE HARNESS O. 38074C LOWER HARNESS PIN NO.
Reference Diagrams Electrical Diagram, Models 644B and 6K w/Control Manifold Hydraulic System - Diagram 6 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ...... 644B-42 ...... 6K-37 .......... 6K-42 ..........
Reference Diagrams Electrical Diagram, Models 644B and 6K w/Control Manifold Hydraulic System - Diagram 6 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-24
Reference Diagrams Rear Oscillation Lock System Operation, Control Manifold Hydraulic System - Diagram 7 9 8 6 PARK BRAKE 7 8 12 POWER 4 9 10 10 GRD 2 LOW BRAKE PRESS REAR OSC LOCK LAMPS 3 GAUGE MODULE AND CONNECTOR FUEL 7 WATER 5 6 5 ENGINE WATER TEMPERATURE FUEL ENGINE OIL PRESSURE 4 1 BATTERY VOLTAGE 11 11 OIL 1 12 PINK-14 11 TAN-14 4 WHITE-14 R1 PROXIMITY SWITCH RELAY B C R3 30 86 85 30 86 85 87A 87 30 86 85 87A 87 OSC.
Reference Diagrams Rear Oscillation Lock System Operation, Control Manifold Hydraulic System - Diagram 7 PUMP SYSTEM PRESSURE ACCUMULATOR PRESSURE SHOWN WITH AXLE LOCKED (PILOT SPOOLS VENTED TO TANK) SYS TAN-14 150 PSI 2 V1 .030 T 1 .
Reference Diagrams Rear Oscillation Lock System Operation, Control Manifold Hydraulic System - Diagram 7 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 101–590, 592–666 644B-42 ........ S/N: 101–207 844C-42 ........ S/N: 101-621 1044C-42 ...... S/N: 101-116 1044C-54 ...... S/N: 101-154 6K-37 ............ S/N: 101–317 6K-42 ........... S/N: 101–119 8K-42 ........... S/N: 101-220 10K-42 ......... S/N: 101-106 10K-54 .........
Reference Diagrams Rear Oscillation Lock System Operation, Control Manifold Hydraulic System - Diagram 7 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-28
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Control Manifold Hydraulic System - Diagram 8 S6 39321A DIFFERENTIAL PRESSURE SWITCH (39321A) DIFFERENTIAL RH OUTRIGGER BLACK - 16 CLOSED ABOVE 9 OPEN BELOW 92 P S5 39321A DIFFERENTIAL PRESSURE SWITCH LH OUTRIGGER - BASE END CLOSED ABOVE 92 PSI DIFFERENTIAL OPEN BELOW 92 PSI DIFFERENTIAL R4 RELAY R5 RELAY INSTR PARKIN IGNITION SWITCH RELAY BOOM/TRANSFER EXTEND LOCKOUT CIRCUIT OPERATION OPERATING PARAMETERS S4 S6 S6 R4 R5 PROX
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Control Manifold Hydraulic System - Diagram 8 S4 WHITE - 16 A BLACK RED - 16 C BROWN RED - 16 POWER POWER OUT IN - PROXIMITY SWITCH RELAY - BOOM EXTEND (P30796) GROUND R5 L PRESSURE SWITCH ER - BASE END 86 30 86 87A 85 87 87A 6 87 7 WATER 5 8 9 8 BOOM/ TRANSFER EXTEND LOCK PARK BRAKE 6 5 ENGINE WATER TEMPERATURE FUEL POWER 4 9 7 10 12 LAMPS 3 GRD 2 - BOOM EXTEND WARNING LIGHT RELAY (P30796) 30 9
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Control Manifold Hydraulic System - Diagram 8 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 101–590, 592–666 644B-42 ........ S/N: 101–207 844C-42 ........ S/N: 101-621 1044C-42 ...... S/N: 101-116 1044C-54 ...... S/N: 101-154 6K-37 ............ S/N: 101–317 6K-42 ........... S/N: 101–119 8K-42 ........... S/N: 101-220 10K-42 ......... S/N: 101-106 10K-54 .........
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Control Manifold Hydraulic System - Diagram 8 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-32
Reference Diagrams Rear Oscillation Lock System Operation, Mid-Inlet Hysraulic System - Diagram 9 9 8 6 7 PARK BRAKE WATER 5 12 9 10 GRD 2 LOW BRAKE PRESS REAR OSC LOCK LAMPS 3 FUEL 7 8 POWER 4 GAUGE MODULE AND CONNECTOR 6 5 ENGINE WATER TEMPERATURE FUEL 10 11 ENGINE OIL PRESSURE 1 4 BATTERY VOLTAGE 11 OIL 1 12 PINK-14 11 WHITE-14 R1 - PROXIMITY SWITCH RELAY B C R3 85 OSC. LOCK RELAYS P30796 30 86 87A 87 30 86 85 - OSC.
Reference Diagrams Rear Oscillation Lock System Operation, Mid-Inlet Hysraulic System - Diagram 9 PROXIMITY SENSOR 37115X CLOSED WITH BOOM ANGLE LESS THAN 40° OPEN WITH BOOM ANGLE GREATER THAN 40° S1 BLACK POWER OUT BROWN POWER IN GROUND C B A RED-16 BLACK-16 WHITE-16 BLUE SOLENOID VALVE ON REAR AXLE STABILIZER CONTROL VALVE COIL 38329A 150-3000 PSI SV1 A B 1 2 150 PSI BLACK-14 2 TAN-14 SYS S2 T PIL PRESSURE SWITCH SERVICE BRAKE (39505A) ESSURE SWITCH (37139A) PSI STABILIZER LOCK VA
Reference Diagrams Rear Oscillation Lock System Operation, Mid-Inlet Hysraulic System - Diagram 9 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 591, 667644B-42 ........ S/N: 208844C-42 ........ S/N: 6221044C-42 ...... S/N: 1171044C-54 ...... S/N: 1556K-37 ............ S/N: 3186K-42 ........... S/N: 1208K-42 ........... S/N: 22110K-42 ......... S/N: 10710K-54 .........
Reference Diagrams Rear Oscillation Lock System Operation, Mid-Inlet Hysraulic System - Diagram 9 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-36
Reference Diagrams Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System - Diagram 10 4-37 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System - Diagram 10 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-38
Reference Diagrams Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System - Diagram 10 4-39 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System - Diagram 10 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-40
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Mid-Inlet Hydraulic System - Diagram 11 18" S6 DIFFERENTIAL PRESSURE SWITCH (39321A) BLACK - 16 39321A DIFFERENTIA RH OUTRIGG S5 39321A DIFFERENTIAL LH OUTRIGGE R4 RELAY R5 RELAY INSTRUMENT PAN PARKING BRAKE VA IGNITION SWITCH RELAY BOOM/TRANSFER EXTEND LOCKOUT CIRCUIT OPERATION OPERATING PARAMETERS 4-41 S4 S5 S6 R4 R5 PROXIMITY SWITCH LH OUTRIGGER SWITCH RH OUTRIGGER SWITCH RELAY #4 PIN #86 RELAY #5 PIN #86 BOOM/TRANS
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Mid-Inlet Hydraulic System - Diagram 11 PROXIMITY SWITCH POSITION FOR MACHINES EQUIPPED W/ OPTIONAL 8 FT.
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Mid-Inlet Hydraulic System - Diagram 11 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 591, 667644B-42 ........ S/N: 208844C-42 ........ S/N: 6221044C-42 ...... S/N: 1171044C-54 ...... S/N: 1556K-37 ............ S/N: 3186K-42 ........... S/N: 1208K-42 ............ S/N: 22110K-42 .......... S/N: 10710K-54 ..........
Reference Diagrams Boom/Transfer Extend Lockout Circuit Operation, Mid-Inlet Hydraulic System - Diagram 11 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-44
Reference Diagrams Electrical Diagram, ZF DW-2/EST-19 System Harness - Diagram 12 EST-19 Connector Pin Position 666 35 464 446 N/A 612 434 32 442 31 430 30 616 N/A 29 674 14 Pin 19 500 A Pin 23 504 B Pin 5 508 C Pin 29 512 D Male Pins 13 N/A 580 11 520 A Pin 8 524 B Pin 25 27 460 Pin 26 528 C 26 528 Pin 24 532 D Red B Yellow C Pink D Gray To Shifter A Black B Green C Blue D N/A 8 24 662 N/A 23 504 22 596 21 640 N/A Pin 21 640 A N/A
Reference Diagrams Electrical Diagram, ZF DW-2/EST-19 System Harness - Diagram 12 EST-19 Harness Plug Pin Wire Position Number 1. 2. 3. 4. 5. mission onnector A F E D Sensor nector 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
Reference Diagrams Electrical Diagram, ZF DW-2/EST-19 System Harness - Diagram 12 This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 101-880 644B-42 ........ S/N: 101-241 844C-42 ........ S/N: 101-783 1044C-42 ...... S/N: 101-121 1044C-54 ...... S/N: 101-215 6K-37 ............ S/N: 101-397 6K-42 ........... S/N: 101-131 8K-42 ........... S/N: 101-261 10K-42 ......... S/N: 101-107 10K-54 .........
Reference Diagrams Electrical Diagram, ZF DW-2/EST-19 System Harness - Diagram 12 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-48
Reference Diagrams Electrical Diagram, ZF DW-3 System Harness - Diagram 13 4-49 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Reference Diagrams Electrical Diagram, ZF DW-3 System Harness - Diagram 13 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-50
Reference Diagrams Electrical Diagram, ZF DW-3 System Harness - Diagram 13 NOTES This diagram applies to the following Model(s) and serial numbers: 644B-37 ........ S/N: 101-880 644B-42 ........ S/N: 101-241 844C-42 ........ S/N: 101-783 1044C-42 ...... S/N: 101-121 1044C-54 ...... S/N: 101-215 6K-37 ............ S/N: 101-397 6K-42 ........... S/N: 101-131 8K-42 ........... S/N: 101-261 10K-42 ......... S/N: 101-107 10K-54 .........
Reference Diagrams Electrical Diagram, ZF DW-3 System Harness - Diagram 13 NOTES Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 4-52
Section 5 — Supply, Pressure, and Return Hydraulics Table of Contents General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Major System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Troubleshooting Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 5-4: Hydraulic Reservoir Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fig. 5-5: Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Fig. 5-6: Recommended Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Fig. 5-7: Alternate Reservoir Filling Method . . . . . . . . . . . . . . . . . . . . .
Fig. 5-43: Hydraulic Control Manifold Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71 Fig. 5-44: Hydraulic Control Manifold Block Fittings Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 5-73 Fig. 5-45: Hydraulic Control Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74 Fig. 5-46: Pump Unloader Valve Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5 — Supply, Pressure, and Return Hydraulics General Major System Components Hydraulic Reservoir/ Fuel Tank Hydraulic Oil Return Filter Hydraulic Control Manifold Hydraulic Pump K1099 Hydraulic Control Valve Fig. 5-1: Major Hydraulic Components General Description (Ref. Fig.
Supply, Pressure, and Return Hydraulics These circuits are supplied by a two-section, gear-type hydraulic pump, driven directly from the transmission power takeoff. The first pump supplies flow to all circuits except steering and the steer selector valve. The second pump supplies flow to all circuits via the steering priority valve. The boom extension and hoist circuits are controlled by a two-spool valve with pressure relief.
Supply, Pressure, and Return Hydraulics Hydraulic Systems Control Manifold Hydraulic System 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) Control Manifold Boom Function Control Valve Assembly K1161 Multi-Spool Control Valve Assembly Fig. 5-2: Control Manifold Hydraulic Components (Ref. Fig.
Supply, Pressure, and Return Hydraulics 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.
Supply, Pressure, and Return Hydraulics 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.
Supply, Pressure, and Return Hydraulics • 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.
Supply, Pressure, and Return Hydraulics 3 4 5 2 1 6 7 8 9 10 12 # Description 1 Hydraulic Tank Breather (Models with Mid-Inlet Hydraulics) 2 Hydraulic Tank Breather (Models with Control Manifold Hydraulics) 3 Hydraulic Tank Sight Gauge 4 Pressure Gauge 5 Return Filter Assembly 6 Hydraulic Oil Tank K1092 11 # Description 7 Hydraulic Oil Strainer (Models with Control Manifold Hydraulics) 8 Connector 9 Suction Tube 10 Suction Hose 11 Hydraulic Oil Strainer (Models with Mid-Inlet Hydraulics) 12
Supply, Pressure, and Return Hydraulics Filling Hydraulic Reservoir Preferred Method CAUTION: Do not fill reservoir through the breather opening. The hydraulic system can become contaminated. Oil must be filtered through the return filter to ensure purity. Contamination, even small amounts, can permanently damage hydraulic system components and void the warranty. 1 3 2 K1015 4 # 1 2 Description Hex Cap Cover # 3 4 Description Hydraulic Hose Male JIC (37°) Filler Fitting Fig.
Supply, Pressure, and Return Hydraulics 7. Start engine and allow hydraulic system to warm up. Operate controls gradually until you fully extend and retract each cylinder, including steering cylinders. This procedure removes air from the system. 8. Level the frame, retract all cylinders except frame tilt cylinder, and stop the engine. Recheck oil level and add oil as required. 9. Loosen and remove hose (Item 3) from reservoir filler fitting (Item 4). Install hex cap (Item 1) and torque to 70 ft-lbs.
Supply, Pressure, and Return Hydraulics 1. The machine must be parked on a level surface and the frame must be level. 2. Retract all cylinders except frame tilt cylinder, apply the park brake, and stop the engine. 3. Clean return filter housing (Item 1) and surrounding area. 4. Remove four (4) flange nuts (Item 2) that secure the filter housing cover (Item 3). Set hardware aside on a clean surface. 5. Lift the cover (Item 3) and spring (Item 4) from housing (Item 1) and set aside on a clean surface. 6.
Supply, Pressure, and Return Hydraulics Reservoir Drain and Refill 2 1 3 K1092 4 # Description # 1 2 Breather Filter Return Filter Assembly 3 4 Description Hydraulic Oil Suction Strainer Drain Plug Fig. 5-8: Hydraulic Reservoir Drain and Refill (Ref. Fig. 5-8) The following procedure describes draining and refilling the hydraulic reservoir. 1. Lower the boom to the ground, apply the parking brake, and stop the engine. CAUTION: Do not place hands in hot hydraulic oil.
Supply, Pressure, and Return Hydraulics 6. Clean the strainer (Item 2) by back flushing with solvent. Dry the strainer element thoroughly with compressed air. Install it as described under “Installation” on page 5-21. 7. Install the reservoir drain plug (Item 4). Tighten two or three turns past finger tight. If it is necessary to use thread sealant to stop fluid leakage, apply sealant only to last few threads close to the drain plug head.
Supply, Pressure, and Return Hydraulics Removal Hydraulic Reservoir and Fuel Tank 8 7 6 4 1 2 9 10 5 11 12 3 15 14 16 17 13 28 20 29 30 19 21 27 26 18 25 22 23 24 23 K1091 24 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Tank Hold-Down Strap Chemprene Belting Pipe Adapter Hose Clamp Fuel Supply Hose Flatwasher Nut Wiring Harness JIC Pipe Connector Return Manifold Tube Hydraulic Oil Return Filter Hydraulic Reservoir/Fuel Tank Swivel Branch Tee Check Valve 90° Elbow # 16 17 18 19
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-9) The following procedure describes removal of the hydraulic reservoir/fuel tank. 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-4. 2. Remove the hydraulic reservoir drain plug (Item 19) and drain hydraulic fluid into a suitable container. Dispose of drained fluid properly. Temporarily reinstall drain plug. 3.
Supply, Pressure, and Return Hydraulics 14. 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. 15. Perform steps 6 through 9 under “Reservoir Drain and Refill” on page 5-11. 16. Install the fuel tank drain plug (Item 18). Tighten two or three turns past finger tight.
Supply, Pressure, and Return Hydraulics Sight Gauge Description H I G H K1005 L O W Fig. 5-10: 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. 5-11, Item 1).
Supply, Pressure, and Return Hydraulics Removal Sight Gauge 6 5 4 3 8 7 2 1 9 K1093 10 # 1 2 3 4 5 Description Hydraulic Sight Gauge Hollow Hex Head Bolt O-Ring Lockwasher Capscrew # 6 7 8 9 10 Description Hydraulic Oil Return Filter Assy JIC Pipe Connector Return Manifold Tube Hydraulic Reservoir Nut Fig. 5-11: Reservoir Sight Gauge Installation (Ref. Fig. 5-11) The following procedures describes removal of the reservoir sight gauge. 1.
Supply, Pressure, and Return Hydraulics 6. Remove the sight gauge (Item 1) along with the two (2) hollow hex head bolts (Item 2). 7. Clean the two openings in the side of the hydraulic reservoir with appropriate solvent. Plug openings. Installation Sight Gauge (Ref. Fig. 5-11) The following procedures describes installation of the reservoir sight gauge. 1. Remove the four (4) O-rings (Item 3) from the sight gauge and clean O-rings with appropriate solvent. Dry with compressed air.
Supply, Pressure, and Return Hydraulics Suction Strainer Description 2 3 4 5 6 1 7 9 # 1 2 3 4 5 6 7 Description Drain Plug Hydraulic Oil Strainer - Control Manifold Hydraulics JIC Pipe Connector Suction Tube Elbow Hose Clamp Suction Hose O-Ring 10 11 12 # 8 9 10 11 12 13 K1094 8 13 Description Hydraulic Oil Strainer - Mid-Inlet Hydraulics Flange Half Lockwasher Capscrew O-Ring Hydraulic Suction Hose Fig. 5-12: Suction Strainer Installation (Ref. Fig.
Supply, Pressure, and Return Hydraulics Removal and Cleaning Suction Strainer Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) (Ref. Fig. 5-12) The following procedures describes removal of the suction strainer on models with control manifold hydraulics. 1.
Supply, Pressure, and Return Hydraulics Installation Suction Strainer Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) (Ref. Fig. 5-12) The following procedures describes installation of the suction strainer on models with control manifold hydraulics. 1.
Supply, Pressure, and Return Hydraulics Hydraulic Return Filter K1100 Description Fig. 5-13: Hydraulic Return Filter (Ref. Fig. 5-13) The hydraulic return filter assembly is located on the hydraulic reservoir. Its function are to filter return hydraulic oil entering the reservoir and provide a means to fill the reservoir. Checking Filter Condition 3 2 15 10 1 4 20 psi 5 25 psi K1009 30 0 Fig.
Supply, Pressure, and Return Hydraulics The return filter pressure gauge is located on the side of the return filter housing. The gauge indicates hydraulic fluid pressure entering the return filter element. As contamination accumulates in the filter element, pressure rises. The acceptable operating pressure range is 0–15 psi and is indicated by needle (1) positioned in green arc (2). Pressures above 15 psi, orange arc (3) and red arc (4), indicate that the return filter element must be serviced.
Supply, Pressure, and Return Hydraulics 2. Loosen four (4) flange nuts (Item 2) that secure cover (Item 3) to return filter housing (Item 1). Loosen them only enough to be able to rotate cover. While applying pressure to cover, rotate cover clockwise so that recessed areas of cover line up to flange nuts. Slowly release pressure and remove cover. CAUTION: Care must be taken to avoid injury when removing cover. Do not remove flange nuts. There is pressure under cover from spring (Item 5). 3.
Supply, Pressure, and Return Hydraulics Replacement, Return Filter Element (Ref. Fig. 5-16) The following procedure describes replacing the return filter element. 1. To avoid contamination, place all parts on clean paper or cloth. 2. Loosen and remove lock nut (Item 1) that secures trestle (Item 2) to filter element (Item 7). 3. Remove trestle and flatwasher (Item 3). 4. Loosen bypass spring assembly (Item 8) by turning it counterclockwise.
Supply, Pressure, and Return Hydraulics Removal Return Filter Assembly 3 2 5 4 6 7 8 K1097 1 # Description # 1 2 3 4 Hydraulic Oil Reservoir Lockwasher Capscrew Return Manifold Tube 5 6 7 8 Description Connector Return Hydraulic Oil Filter Diffuser Rubber Gasket Fig. 5-17: Return Filter Assembly (Ref. Fig. 5-17) The following procedure describes disassembly of the return filter assembly. 1. Follow preparation procedures as outlined in Section 3 of this manual.
Supply, Pressure, and Return Hydraulics 6. Remove the diffuser (Item 7) and clean with solvent. Dry with compressed air. Installation Return Filter Assembly (Ref. Fig. 5-17) The following procedures describes installation of the return filter assembly. 1. Reassemble the diffuser (Item 7) and the rubber gasket (Item 8) with the hydraulic return assembly (Item 6). 2. Install the return filter assembly on the hydraulic reservoir with the four (4) lockwashers (Item 2) and capscrews (Item 3).
Supply, Pressure, and Return Hydraulics Removal and Installation Reservoir Breather 1. Loosen and remove breather, using tool on hex portion of breather. 2. Replace breather per the maintenance schedule found on the machine or if damaged. 3. Install breather on tank and tighten as necessary. CAUTION: To avoid contamination of the hydraulic system, do not use thread sealant or Teflon tape.
Supply, Pressure, and Return Hydraulics Checking Filter Element Condition 2 2 3 4 3 1 FILTER OK SERVICE NEEDED K1010 K1011 Fig. 5-20: Pressure Filter Service Indicator Note: Not all pressure filter assemblies have a pressure filter service indicator. Note: Check indicator with the engine on. The pressure filter service indicator (1) is located on the top of the pressure filter assembly. The indicator shows the relative amount of restriction in the pressure filter element.
Supply, Pressure, and Return Hydraulics Replacing Pressure Filter Element Control Manifold Hydraulics: 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 2 3 K1102 4 1 2 3 K1135 4 Mid-Inlet Hydraulics: 6K-37 (S/N 318–) 6K-42 (S/N 120–) 8K-42 (S/N 221–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 644B-37 (S/N 591, 667–) 644B-42 (S/N 20
Supply, Pressure, and Return Hydraulics 2. Clean hydraulic pressure filter assembly to avoid contamination of system while removing hydraulic pressure filter assembly. 3. Unscrew and remove filter element bowl (Item 4) from filter head (Item 1). 4. Remove filter element (Item 3) and discard it. 5. Remove bowl O-ring (Item 2), clean with an solvent, and dry with compressed air. Replace it if damaged. 6. Clean filter element bowl and filter head with solvent and dry with compressed air. 7.
Supply, Pressure, and Return Hydraulics 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-4. 2. For models 644B, 844C, and 1044C, refer to roll-back hose tray removal procedures on page 5-92. 3. Clean the hydraulic pressure assembly to avoid contamination of the system while removing the hydraulic pressure filter assembly. 4.
Supply, Pressure, and Return Hydraulics Hydraulic Pump 20 40 60 80 Description 0 K1066 -20 Fig. 5-23: Hydraulic Pump Location (Ref. Fig. 5-23) The hydraulic pump is located on the transmission towards the back of the machine.The hydraulic pump used is a two-section gear type, driven directly from the transmission power takeoff.
Supply, Pressure, and Return Hydraulics Troubleshooting Pump Problems Problem 1. Excessive pump noise Probable Cause Solution A. Low oil level in the hydraulic reservoir Fill reservoir to proper level with the recommended hydraulic fluid. DO NOT overfill. B. Air in the system 1. Operate hydraulic system until purged. 2. Check inlet (suction) lines and fittings for air leaks. C. Vacuum condition 1. Check inlet (suction) lines and fittings for restrictions. 2.
Supply, Pressure, and Return Hydraulics Removal Hydraulic Pump Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 8 7 2 3 5 6 4 1 10 9 16 11 15 14 12 K1065 13 # 1 2 3 4 5 6 7 8 Description Elbow Flange Head Connector Capscrew Lockwasher Flange Half Hydraulic Hose Hydraulic Hose Capscre
Supply, Pressure, and Return Hydraulics 3. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Remove test gauge from diagnostic port. 4. For models 644B, 844C, and 1044C, refer to roll-back hose tray removal procedures on page 5-92. 5. Thoroughly clean the hydraulic pump (Item 15) to ensure that dirt will not get into the system/transmission. 6. Tag and slowly loosen four (4) hydraulic hoses (Items 5, 6, 12, and 13) and bleed any remaining oil. Disconnect hoses.
Supply, Pressure, and Return Hydraulics Models with Mid-Inlet Hydraulics 6K-37 (S/N 318–) 6K-42 (S/N 120–) 8K-42 (S/N 221–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 844C-42 (S/N 622–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) Fig. 5-25 and Fig. 5-26 describe procedures for removal of the hydraulic pump for models with a mid-inlet hydraulic system.
Supply, Pressure, and Return Hydraulics 4. For models 644B, 844C, and 1044C, refer to roll-back hose tray removal procedures on page 5-92. 5. Disconnect wiring harness (Item 10) from pressure switch (Item 9). 6. Thoroughly clean the hydraulic pump to ensure that dirt will not get into the system/transmission. 7. Tag and slowly loosen the ten (10) hydraulic hoses shown in Fig. 5-25 (Items 1 thru 5, 7, 11, 12, 14, and 18). Bleed any remaining oil into appropriate container. Disconnect hoses.
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-26) The following procedures completes the steps necessary for removal of the hydraulic pump. 1. Tag and slowly loosen two (2) hydraulic hoses (Item 1) and bleed any remaining oil. Disconnect hoses from elbows (Item 2). Cap fittings and hoses. 2. Remove four (4) capscrews (Item 11) and lockwashers (Item 10) securing the two (2) flange halves (Item 9) to the hydraulic suction hose (Item 12). Remove the flange halves.
Supply, Pressure, and Return Hydraulics 4. Clean exposed areas of hydraulic pump with appropriate solvent and dry with compressed air. 5. (Ref. Fig. 5-26) Lubricate and install new O-rings on pump. 6. Lubricate threaded portion of each fitting, including the O-ring. Steps 7 thru 14 apply to Fig. 5-25. Refer to notes made earlier for correct positioning of all fittings. 7. Install connector (Item 13) in lower port on front of pump. Torque the connector to 25–29 ft-lbs. 8.
Supply, Pressure, and Return Hydraulics 4. Remove caps and clean hydraulic hose ends (Items 5, 6, 12, and 13) with appropriate solvent. Dry with compressed air. 5. Reconnect hydraulic hoses to fittings as instructed in Chapter 3 of this manual. Refer to the sketches and notes made earlier and adjust fittings as necessary so that they are in the same position as prior to being disconnected.
Supply, Pressure, and Return Hydraulics 7. Install hydraulic hose (Item 18) from check valve on rear oscillation lock control block to branch tee (Item 8). For final tightening, torque swivel nut on hose to 44–48 ft-lbs. 8. Install hydraulic hose (Item 5) from accumulator to run tee (Item 17). For final tightening, torque swivel nut on hose to 130–150 in-lbs. 9. Install hydraulic hose (Item 4) from Pilot test port to run tee (Item 17). For final tightening, torque swivel nut on hose to 130–150 in-lbs. 10.
Supply, Pressure, and Return Hydraulics Checking Pump Flow Rate 4 3 2 4 5 1 6 6 # 1 2 3 Description Return Filter Housing Hex Cap Hydraulic Tester # 4 5 6 Description Test Loop Hose (2) Hydraulic Pump Pressure Hose (2) Fig. 5-27: Checking Hydraulic Pump Flow Rate (Ref. Fig. 5-27) If the pump(s) is suspected of delivering below rated capacity, use the following procedure to check pump flow rate: 1. Lower boom to the ground, apply parking brake and stop engine.
Supply, Pressure, and Return Hydraulics 6. Adjust pressure relief valve setting to 100 psi over that of system's maximum rated pressure. Important: Be sure the load valve is open before starting the engine. 7. Start the engine and, when it is at normal operating temperature, open the throttle control all the way. Slowly close the load valve to load the system. (Do not exceed system's maximum rated pressure).
Supply, Pressure, and Return Hydraulics 20 40 60 80 Multi-Spool Control Valve Description -20 0 K1046 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) Fig. 5-28: Multi-Spool Control Valve Location (Ref. Fig. 5-28) The multi-spool control valve is used on models with control manifold hydraulics.
Supply, Pressure, and Return Hydraulics Multi-Spool Control Valve Configurations, Models 644B, 844C, and 1044C 2nd Auxiliary Transfer Carriage Frame Tilt Auxiliary Carriage Tilt Transfer Carriage Frame Tilt Auxiliary Carriage Tilt 4-Spool Valve For Models without Optional 2nd Auxiliary Hydraulics or Outriggers R.H. Outrigger L.H.
Supply, Pressure, and Return Hydraulics Multi-Spool Control Valve Configurations, Models 6K, 8K, and 10K Frame Tilt Carriage Tilt 2-Spool Valve For Models without Outriggers or Optional Auxiliary Hydraulics R.H. Outrigger L.H. Outrigger Frame Tilt Carriage Tilt K1045 4-Spool Valve For Models with Outriggers Only Auxiliary Frame Tilt Carriage Tilt 3-Spool Valve For Models with Optional Auxiliary Hydraulics R.H. Outrigger L.H.
Supply, Pressure, and Return Hydraulics Control Valve Operation Work Ports Valve Sections CRA Assembly Power-Beyond Sleeve Bonnet Assembly Load Check Assembly Main Relief Positioner Assembly CRA Assembly Inlet (From Pump #2) K1047 Outlet (Return to Tank) Fig. 5-31: Multi-Spool Control Valve Components Each hydraulic circuit is controlled by a separate valve section (Fig. 5-31). The valve sections are 4-way, 3-position with an open center.
Supply, Pressure, and Return Hydraulics Removal Multi-Spool Control Valve Capscrew Control Valve Lockwasher K1056 Valve Plate Fig. 5-32: Multi-Spool Control Valve Installation (Ref. Fig. 5-32) The following procedure describes removal of the multi-spool control valve. 1. Follow preparation procedures as outlined in Section 3. 2. Install brake pressure diagnostic port test gauge onto “Brakes” diagnostic port (see Fig. 5-58). 3.
Supply, Pressure, and Return Hydraulics 4. Stop engine and check for hydraulic leaks. Tighten connections as necessary. Overhaul Multi-Spool Control Valve Disassembly, Multi-Spool Control Valve Po we (Se r-Bey e p ond ag e 5 Slee -60 ve ) Ou (Se tle e p t Co ag ver e5 -58 ) Capscrew Spool Assembly (See page 5-51) O-Rings required for outlet cover and each valve section.
Supply, Pressure, and Return Hydraulics Assembly, Multi-Spool Control Valve (Ref. Fig. 5-33) To assembly the control valve, 1. Place valve sections, inlet cover, and outlet cover together in the same order as they were disassembled. 2. Install three (3) capscrews and nuts. Torque nuts to 180 in-lbs.
Supply, Pressure, and Return Hydraulics 1. Loosen and remove four (4) each socket head capscrews (Item 18), lockwashers (Item 17), and bearing washers (Item 16) that secure bonnet housing (Item 15) to valve housing (Item 13). 2. Remove bonnet housing. Tag or mark housing; note location of fitting port(s). 3. Loosen and remove four (4) each socket head capscrews (Item 1), lockwashers (Item 2) and bearing washers (Item 3) that secure positioner housing (Item 4) to valve housing. 4. Remove positioner housing.
Supply, Pressure, and Return Hydraulics 4. Apply type II, grade O, thread locking compound on threaded portion of positioner screw (Item 5). Install positioner screw on spool. Torque screw 10–12 ft-lbs. 5. Install spool assembly (Items 5 thru 11) in valve housing. 6. Install positioner housing (Item 4) on valve housing with four (4) each socket head capscrews (Item 1), lockwashers (Item 2) and bearing washers (Item 3).
Supply, Pressure, and Return Hydraulics 4. Remove O-ring (Item 5) and backup washer (Item 4) from middle of load check plug. 5. Remove remaining O-ring (Item 3) near head of load check plug. 6. Discard all O-rings and backup washers. 7. Clean remaining parts with solvent and dry with compressed air. Inspect and replace any damaged parts. Note: Only the O-rings and backup washers of the load check valve are replaceable. If other parts become damaged, it will be necessary to purchase a new load check valve.
Supply, Pressure, and Return Hydraulics Disassembly, CRA Assembly 7 8 9 1 10 2 11 3 12 13 4 14 15 5 16 17 18 6 19 20 21 22 23 24 26 25 27 K1070 28 # Description # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Socket Head Capscrew Lockwasher Bearing Washer Positioner Housing Square Cut Seal Housing Acorn Nut Jam Nut Adjustable Stem Adjustable Relief Cap O-Ring Piston O-Ring Spring 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Description Shim Relief Poppet Piston Ring Relief Body O-Ring Backup Washer O-R
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-36) The following procedure describes disassembly of the Combination Relief and Anti-Cavitation Check Assembly (CRA). 1. Loosen and remove four (4) each socket head capscrews, 33 lockwashers (Item 2), and bearing washers (Item 3). 2. Remove positioner housing (Item 4). Tag or mark housing; note location of fitting port(s). 3. Remove square cut seal (Item 5) from housing (Item 6). Discard square cut seal. 4.
Supply, Pressure, and Return Hydraulics Assembly, CRA Assembly (Ref. Fig. 5-36) The following procedure describes reassembly of the CRA assembly. 1. Obtain seal kit and new square cut seal. Lubricate each seal, backup washer, and other internal parts, with hydraulic oil before installing them. 2. Install new O-ring (Item 19) near head of relief body (Item 18). 3. Install new backup washer (Item 20) and O-ring (Item 21) near middle of relief body. 4.
Supply, Pressure, and Return Hydraulics Inlet and Outlet Covers 2 1 3 4 5 6 8 7 9 K1071 10 11 # 1 2 3 4 5 6 Description Long O-Ring Connector Hollow Hex O-Ring Plug Outlet Cover O-Ring O-Ring Diagnostic Plug # Description 7 8 9 10 11 Hollow Plug Hex O-Ring Plug (105-115 ft-lbs) Inlet Cover Adjustable Elbow Connector Fig.
Supply, Pressure, and Return Hydraulics Disassembly, Outlet Cover (Ref. Fig. 5-37) The following procedure describes disassembly of the outlet cover. 1. Loosen and remove long connector (Item 1) from outlet cover (Item 3). 2. Loosen and remove hollow hex plug (Item 2) from outlet cover. 3. Remove four (4) O-rings (Items 4 and 5) from outlet cover. Discard O-rings. 4. Clean remaining parts with solvent and dry with compressed air. Inspect for damage and replace, if necessary. Assembly, Outlet Cover (Ref.
Supply, Pressure, and Return Hydraulics Assembly, Inlet Cover (Ref. Fig. 5-37) The following procedure describes reassembly of the inlet cover. 1. Lubricate threaded portion, including the O-ring, on each fitting and plug with hydraulic oil before installing them. 2. Install hollow plug (Item 7) and hex plug (Item 8) on inlet cover. Torque each to 105–115 ft-lbs. 3. Install diagnostic plug (Item 6) on hollow plug and torque to 205–235 in-lbs. 4. Install connector (Item 11) on inlet cover.
Supply, Pressure, and Return Hydraulics 3. Remove O-ring (Item 5) and backup ring (Item 4) from cover housing. 4. Remove O-ring (Item 3) near head of power-beyond sleeve. 5. Discard O-rings and backup ring. 6. Clean remaining parts with solvent and dry with compressed air. Inspect remaining parts for damage, including O-ring on connector. Replace as necessary.
Supply, Pressure, and Return Hydraulics Disassembly, Main Relief Assembly 19 16 17 20 18 15 14 13 78 9 11 10 12 56 4 3 1 2 K1073 21 # 1 2 3 4 5 6 7 8 9 10 11 Description O-Ring Backup Ring O-Ring Relief Valve Body O-Ring Backup Ring Retaining Ring Filter Main Poppet Backup Ring O-Ring # 12 13 14 15 16 17 18 19 20 21 Description Spring O-Ring Pilot Assembly Body Relief Poppet Pilot Spring O-Ring Adjustment Screw Washer Jam Nut Cover Assembly Fig. 5-39: Main Relief Valve (Ref. Fig.
Supply, Pressure, and Return Hydraulics 5. Remove relief poppet (Item 15) and pilot spring (Item 16) from adjustment screw. 6. Remove O-ring (Item 17) from adjustment screw. 7. Remove pilot assembly body (Item 14) from relief valve body (Item 4). 8. Remove O-ring (Item 13) from pilot assembly body. 9. Remove spring (Item 12), main poppet (Item 9), filter (Item 8), and retaining ring (Item 7) from relief valve body. 10. Remove O-ring (Item 11) and backup ring (Item 10) from main poppet. 11.
Supply, Pressure, and Return Hydraulics Hydraulic Control Manifold Description 20 40 60 80 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 0 K1064 -20 Fig. 5-40: Hydraulic Control Manifold Location (Ref. Fig. 5-40) The hydraulic control manifold is located on the valve plate, near the middle of the machine.
Supply, Pressure, and Return Hydraulics B C A D F A – Left Side View E B – Top View D – Right Side View E – Bottom View C – Back View K1060 F – Front View Fig. 5-42: Hydraulic Control Manifold Ports Fig. 5-42 illustrates views of the manifold that show port locations and manifold markings. The manifold includes 7 valve and 20 port markings. Table 5-1 is a list of markings for each side of the manifold.
Supply, Pressure, and Return Hydraulics Table 5-1: Manifold Markings View A - Left Side View B - Top View C - Back View D - Right Side View F - Front View 5-66 Marking Description OR1 Orifice #1 SW Switch, Low Brake Pressure AC Accumulator P2 Port #2 LC Logic Valve PF Priority Flow Valve STP Stabilizer Pilot PLT Pilot (From Hydraulic Pump) PD Pilot Directional Valve P1G Pump 1 (Gauge) STB Stabilizer (System Pressure from Pump 1) PU Pilot Unloading Valve PR Pressure Reducin
Supply, Pressure, and Return Hydraulics Control Valve Functions The following is a description of the seven control valves in the control manifold assembly and their function. Compensator Valve The Compensator (CS) valve is a load sensing bypass type with priority relief. It allows hydraulic fluid to flow to steering on demand. It limits pressure in the steering circuit to 2200 psi. Pressure can be checked at the Steering Pressure Gauge (PSG) port.
Supply, Pressure, and Return Hydraulics Logic Valve The Logic (LC) valve opens and closes dependent upon a pilot signal from the Pilot Unloading (PU) valve.
Supply, Pressure, and Return Hydraulics Pilot Unloading Valve (PU) The Pilot Unloading (PU) valve is one of three valves used to recharge the accumulator. When pressure is below 1200 psi, the valve energizes, closing off the logic valve, and fills the accumulator to 1600 psi. At 1600 psi, the PU valve opens the Logic (LC) valve allowing the 3 gpm to go to the Excess Flow (EF) port.
Supply, Pressure, and Return Hydraulics Hydraulic Manifold Assembly Functions Accumulator Charging Hydraulic fluid is taken from hydraulic reservoir and flows through the hydraulic pump, through the control valve, through the pump unloader, and on to the hydraulic control manifold. Flow comes in P2 port and goes through the Priority Flow (PF) valve. Three gpm of flow is split off and flows through the Logic (LC) element and back to the PF valve. The circuit is then combined with input flow (P2).
Supply, Pressure, and Return Hydraulics Removal Control Manifold 7 8 1 13 6 12 9 11 2 10 14 15 4 3 16 5 25 24 23 17 22 20 18 19 K1061 21 # Description 1 Intermediate Wiring Harness 2 Hose for Elbow at P2 Port 3 Hose for Elbow at ST Port (CS Valve) 4 Hose for Elbow at AC Port 5 Hose for Elbow at PSG Port 6 Hose for Elbow at P1G Port 7 Hose for Connector at STP Port 8 Hose for Connector at STB Port 9 Hose for Elbow at PLT Port (PD Valve) 10 Hose for Elbow at PG Port 11 Hose for Tee at F Port
Supply, Pressure, and Return Hydraulics 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-4. 2. Install brake pressure diagnostic port test gauge into brake diagnostic port (see page 5-90). 3. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Remove test gauge from diagnostic port. 4.
Supply, Pressure, and Return Hydraulics 5. Inspect and replace any damaged fittings or O-rings. Lubricate each O-ring with hydraulic oil before installing it on fitting or low brake pressure switch.
Supply, Pressure, and Return Hydraulics 6. Clean valve cartridges using an solvent. Dry with compressed air. 7. Make sure that you have the correct O-ring kit for each cartridge valve ensuring they are not damaged. Lubricate each O-ring with hydraulic oil before installing it on cartridge valve. Install the largest (black) O-ring first. Install remaining O-rings in descending order, making sure largest is installed first and smallest last.
Supply, Pressure, and Return Hydraulics Installation, Hydraulic Control Manifold Plugs and Cartridge Valves (Ref. Fig. 5-45) The following procedure describes installation of the hydraulic control manifold plugs and cartridge valves. 1. Visually inspect the hydraulic control manifold block to make sure all cavities are free of contamination including machine burrs and chips as well as pieces of O-rings. 2. Check two (2) 1/8” hex orifice plugs (Item 20) to make sure they are free of visible contamination.
Supply, Pressure, and Return Hydraulics 1. Install low brake pressure switch (Item 1) into SW port and torque to 205–235 in-lbs. Apply torque to hex closest to port. Do not apply torque to body of switch or large hex (if equipped). 2. Install each fitting in its proper location. Use the following torque specifications: Table 5-4: Torque Specifications for Hydraulic Fittings on Control Manifold Assembly Fig. 5-44 Fitting Ref. # Fitting Description Torque Spec. Fig. 5-43 Hose Ref.
Supply, Pressure, and Return Hydraulics Pump Unloader Valve General 20 40 60 80 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 6K -37 (S/N 101–317) 6K-42 (S/N 101–119) With Naturally Aspirated Engines 0 K1111 -20 Fig. 5-46: Pump Unloader Valve Location (Ref. Fig. 5-46) The pump unloader valve is located on the valve plate near the center of the machine. It is used on 644B and 6K models with naturally aspirated engines and control manifold hydraulics.
Supply, Pressure, and Return Hydraulics Removal Pump Unloader Valve 5 4 8 7 9 10 2 3 1 14 11 12 13 6 16 15 K1112 17 # 1 2 3 4 5 6 7 8 9 Description Capscrew Mounting Bracket Hydraulic Hose Elbow Hydraulic Hose Elbow Hydraulic Hose Elbow Elbow # 10 11 12 13 14 15 16 17 Description Hydraulic Hose Nut Lockwasher Pump Unloader Valve Hydraulic Hose Elbow Elbow Hydraulic Hose Fig. 5-47: Pump Unloader Valve Installation - Control Manifold Hydraulics (Ref. Fig.
Supply, Pressure, and Return Hydraulics 6. Tag and slowly loosen six (6) hydraulic hoses (Items 3, 5, 7, 10, 14, and 17) and bleed any remaining oil into appropriate container. Disconnect hoses. Cap fittings and hoses. 7. Loosen and remove the two (2) each nuts (Item 11) and lockwashers (Item 12) that secure the pump unloader valve (Item 13) to the mounting bracket (Item 2). 8. Remove the two (2) capscrews (Item 1) and the pump unloader valve assembly.
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-48) The following procedures describes overhaul of the pump unloader valve. 1. Loosen and remove shuttle valve cartridge (Item 1). 2. Loosen and remove piloted valve cartridge (Item 10). 3. Loosen and remove check valve cartridge (Item 8). 4. Remove hollow hex plug (Item 9). 5. Remove and discard all O-rings and backup rings from the three valve cartridges. 6.
Supply, Pressure, and Return Hydraulics Boom Extension Outlet Section Outlet (Return to Tank) Boom Hoist Mid-Inlet Valve Sections Relief Valve Work Ports Inlet From Pump 2 “Pump 2” Test Port K1141 Inlet (From Priority Valve on Pump) Relief Valve Inlet Section Fig. 5-50: Mid-Inlet Control Valve Components (Ref. Fig. 5-49 and Fig. 5-50)The mid-inlet control valve is located on the valve plate, near the middle of the machine. This valve controls hydraulic functions for the following circuits: • L.H.
Supply, Pressure, and Return Hydraulics Boom Extend Boom Hoist Mid-Inlet Frame Tilt Auxiliary Transfer Carriage Carriage Tilt Boom Extend Boom Hoist Mid-Inlet Unloader Frame Tilt Auxiliary Transfer Carriage Carriage Tilt 6-Spool Valve For Models without Outriggers 7-Spool Valve For Models with Unloader (Natural Engine) Boom Extend Boom Hoist 1138 Boom Extend Mid-Inlet Boom Hoist Mid-Inlet Frame Tilt Frame Tilt 2nd Auxiliary Auxiliary 1st Auxiliary Transfer Carriage Transfer Carriage Carriage Tilt Carr
Supply, Pressure, and Return Hydraulics Boom Extend Boom Hoist Mid-Inlet Unloader Frame Tilt Carriage Tilt 4-Spool Valve For Models without Outriggers or Optional Auxiliary Hydraulics Boom Extend Boom Hoist Mid-Inlet Frame Tilt Carriage Tilt R.H. Outrigger L.H.
Supply, Pressure, and Return Hydraulics Removal Mid-Inlet Control Valve Control Valve K1142 Valve Plate Lockwasher Capscrew Fig. 5-53: Mid-Inlet Control Valve Installation (Ref. Fig. 5-53) The following procedure describes removal of the mid-inlet control valve. 1. Follow preparation procedures as outlined in Section 3. 2. Install a brake pressure diagnostic test gauge onto the “Brakes” diagnostic port (see Fig. 5-58). 3.
Supply, Pressure, and Return Hydraulics Installation Mid-Inlet Control Valve 1. (Ref. Fig. 5-53) Position the control valve on the valve plate. Secure with three (3) lockwashers and capscrews. 2. Connect all hydraulic hoses and tubes to fittings on the control valve. Torque per instructions in Section 3. 3. Start the engine and repeatedly cycle all hydraulic circuits controlled by the valve to remove air from the system. 4. Stop engine and check for hydraulic leaks. Tighten connections as necessary.
Supply, Pressure, and Return Hydraulics Fig. 5-55 illustrates views of the control valve, showing port locations and markings. Table 5-5 is a list of markings for each side of these valves. B A C SW OR2 A – Left Side View D F OR1 E FB T1 B – Top View PS1 SV1 PD1 T2 PD2 ACC B PIL OR3 F – Front View RB SH D – Right Side View A C – Back View G2 G1 BR K1137 G3 E – Bottom View Fig.
Supply, Pressure, and Return Hydraulics Table 5-5: Rear Axle Stabilizer Control Valve Markings View A - Left Side View Marking Description OR2 Orifice #2 SW Service Brake Pressure Switch T1 Tank FB Front Brakes OR1 Orifice #1 RB Rear Brakes A Port A B Port B ACC Accumulator PS1 Piloted Sequence Valve PIL Pilot PD2 2-Way Pilot Operated Directional Valve SH Shuttle Valve G1 Gauge #1 - Test Port (Carr. Tilt, Base End) G2 Gauge #2 - Test Port (Carr.
Supply, Pressure, and Return Hydraulics Removal, Rear Axle Stabilizer Control Valve 5 6 4 7 2 3 1 8 25 9 10 26 11 24 12 22 23 13 14 21 20 15 17 16 1155 19 18 # 1 2 3 4 5 6 7 8 9 10 11 12 13 5-88 Description Boom Extend Lockout Valve Hose for Connector on Boom Extend Lockout Valve Lockwasher Capscrew Hose for Tee at T1 Port Boom Extend Wire Harness Hose for Tee at T1 Port Hose for Elbow at FB Port Hose for Elbow at RB Port Hose for Tee at A Port Hose for Fitting at B Port Hose for Tee at A
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-56) The following procedure describes removal of the rear axle stabilizer control valve. 1. Follow preparation procedures as outlined in Section 3 of this manual. Be sure to follow the guidelines in this section detailed under “General Hydraulic Maintenance Practices” on page 5-4. 2. Install brake pressure diagnostic port test gauge into brake diagnostic port (see page 5-90). 3.
Supply, Pressure, and Return Hydraulics Boom Extend Lockout Valve Description SV1 D PD1 OR3 K1154 C Front View Fig. 5-57: Boom Extend Lockout Valve (Ref. Fig. 5-57) The boom extend lockout valve is used on models with outriggers and is standard equipment on 10K-54 and 1044C-54 models. It is located on top of the rear axle stabilizer control valve.
Supply, Pressure, and Return Hydraulics (Ref. Fig. 5-58) The hydraulic ports on models with control manifold hydraulics are: • Pump 1 – Used for reading pressure of the hydraulic pump #1. Pressure limit is 2650 psi. • Pump 2 – Used for reading pressure of the hydraulic pump #2. Pressure limit is 2800 psi. • Carr. Tilt (Base End) – Used for reading pressure for the base end of the carriage tilt cylinder. Pressure limit is 2800 psi. • Carr.
Supply, Pressure, and Return Hydraulics • Brakes – Used for reading pressure of the brake circuit and is used to indicate when pressure is eliminated from the system prior to disconnecting hydraulic hoses. Pressure limit is 330 psi. • Steering – Used for reading pressure of the steering circuit. Pressure limit is 2200 psi. • Pilot – Used for reading pressure of the joystick circuit. Pressure limit is 450 psi. • Accum. – Used for reading of pressure in the accumulator charging circuit.
Supply, Pressure, and Return Hydraulics Removal Roll-Back Hose Tray Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) (Ref. Fig. 5-61) The following procedure describes removal of the roll-back hose tray used in models with control manifold hydraulics. 1.
Supply, Pressure, and Return Hydraulics A B C D E 5 F G 4 4 H 3 3 2 2 1 A B C D E F G 8 H 6 K1068 7 # 1 2 3 4 Description Valve Plate Hose Tray Support Bracket Lockwasher Truss Head Screw # 5 6 7 8 Description Roll-Back Hose Tray Self-Locking Nut Cushion Clamp (1” Hose) Cushion Clamp (1-1/8” Hose) Fig.
Supply, Pressure, and Return Hydraulics Models with a Mid-Inlet Hydraulic System 6K-37 (S/N 318–) 6K-42 (S/N 120–) 8K-42 (S/N 221–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 844C-42 (S/N 622–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) 9 10 11 8 6 7 5 12 4 3 K1152 2 1 # Description # 1 2 3 4 5 6 Nut Lockwasher Front Hose Tray Support Bracket Hose Mount Button Head Socket Capscrew Button Head Socket Capscrew 7 8 9 10 11 12 Description Lockwasher Roll-Back Hos
Supply, Pressure, and Return Hydraulics Installation Roll-Back Hose Tray Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) (Ref. Fig. 5-61) The following procedure describes installation of the roll-back hose tray used in models with control manifold hydraulics. 1.
Section 6 — Boom and Transfer Table of Contents Boom and Transfer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Boom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Slide Pad Inspection . . . . . . . . . . . . . . . . . . . . .
Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-217 Installation . . . . . . . . . . . . . . . . . . . .
Fig. 6-23: Selector Valve – Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Fig. 6-24: Selector Valve Installation – Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . 6-39 Fig. 6-25: Selector Valve Assembly – Models with Control Manifold Hydraulics. . . . . . . . . . . . . . . . . . 6-41 Fig. 6-26: Selector Valve – Models with Mid-Inlet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Fig.
Fig. 6-62: Clearances Between Boom Sections Rear of 2-Section Boom. . . . . . . . . . . . . . . . . . . . . . . 6-65 Fig. 6-63: Gaps Between Pads and Boom – Rear of 2-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Fig. 6-64: Clearances Between Boom Sections – Front of 2-Section Boom . . . . . . . . . . . . . . . . . . . . . 6-66 Fig. 6-65: Gaps Between Pads and Boom – Front of 2-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 Fig.
Fig. 6-101: Middle Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Fig. 6-102: Upper Chains - First Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 Fig. 6-103: Upper Chains - Second Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 Fig. 6-104: Upper Chains - Third Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 6-140: Rod End of Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131 Fig. 6-141: Anchor Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131 Fig. 6-142: Front Slide Pads Installation, Outer Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132 Fig. 6-143: Securing Lower Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 6-179: Extension Cylinder Removal – 4-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165 Fig. 6-180: Upper Front Slide Pad Removal – Middle (Rear) Boom Section . . . . . . . . . . . . . . . . . . . 6-167 Fig. 6-181: Upper Front Slide Pad Removal – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . 6-167 Fig. 6-182: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-168 Fig.
Fig. 6-218: Lower Chain Installation – Middle (Forward) Boom Section . . . . . . . . . . . . . . . . . . . . . . . 6-201 Fig. 6-219: Upper Chains – Middle (Rear) to Outer Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202 Fig. 6-220: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections . . . . . . . . . . . . . . . . . . 6-203 Fig. 6-221: Securing Lower Chains – Middle (Rear) and Outer Boom Sections . . . . . . . . . . . . . . . . . 6-203 Fig.
Fig. 6-257: Transfer Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244 Fig. 6-258: Transfer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6 — Boom and Transfer Boom and Transfer Hydraulics General Description Boom Rear Carriage Tilt Cylinder Transfer Carriage/ Boom Cradle 20 40 60 80 Front Carriage Tilt Cylinder -20 0 Hoist Cylinder J1116 Joystick Controls Fig. 6-1: Major Boom and Transfer Hydraulic Components (Ref. Fig.
Boom and Transfer Joystick Controls V1018 General Description Fig. 6-2: Joystick (Ref. Fig. 6-2) The joysticks control hydraulic flow to the associated cylinders. Control is proportional: The more joystick movement, the greater the action. The speed of cylinder action is also affected by engine/hydraulic pump speed. Action is quicker at higher engine speeds. Joysticks can be moved in any direction and are not limited to front/back, left/right movement.
Boom and Transfer Removal Joystick 2 1 7 5 6 3 4 8 14 15 13 9 10 10 9 11 J1120 11 12 # 1 2 3 4 5 6 7 8 Description Button Head Socket Capscrew Lockwasher with Internal Teeth Phillips Truss Head Screw Flatwasher Wiring Harness Lead Connector Joystick Control Panel 12 # 9 10 11 12 13 14 15 Description Connector Connector Swivel Tee Hydraulic Hose Side Panel Capscrew Lockwasher Fig. 6-3: Joystick Installation (Ref. Fig. 6-3) The following steps are required to remove the joystick. 1.
Boom and Transfer 3. Tag, loosen, and remove two (2) swivel tees (Item 11) from connectors (Item 9) on bottom of joystick. Note: On models with two joysticks (644B, 844C, and 1044C), hydraulic hoses attach directly to the connectors on the front joystick and the swivel tees (Item 11) are not used. Swivel tees as shown in Fig. 6-3 are used with models 6K, 8K, and 10K and are also used with the rear joystick of models 644B, 844C, and 1044C. 4.
Boom and Transfer Disassembly Joystick 25 4 2 17 3 26 27 28 29 30 5 6 1 8 7 18 31 24 3 9 10 16 22 23 19 15 11 12 16 13 14 20 32 21 33 36 # Description # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Socket Head Capscrew Socket Head Capscrew Half Handle Cap Push Button Switch Guide Hex Nut Hex Nut Seal Setscrew Lever Joint Retaining Nut Stem Clip Socket Head Capscrew Boot Cam 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Retainer Flange Socket Head Capscrew Ma
Boom and Transfer 1. Pull back boot (Item 17) so that access to retainer (Item 19) and flange (Item 20) can be made. 2. Loosen and remove four (4) socket head capscrews (Item 16) and one (1) clip (Item 15) that secure retainer and flange to joystick body (Item 24). Separate body from joystick handle assembly. 3. Disassemble joystick body assembly as follows: a. Loosen and remove three (3) socket head capscrews (Item 21) securing manifold (Item 22) to body. b. Remove O-ring (Item 23) from manifold.
Boom and Transfer e. Clean all remaining parts of joystick body assembly, including the body’s center port, with solvent. Dry with compressed air. Inspect and replace any damaged parts. Note: The body (Item 24) cannot be purchased individually. If it becomes damaged, it will be necessary to replace the entire joystick assembly. f. Lubricate and install new O-ring (Item 23) in manifold (Item 22). g. Install manifold on body with three (3) capscrews (Item 21). Torque capscrews to 22 in-lbs. 4.
Boom and Transfer 7. Install boot (Item 17) on stem (Item 14) making sure that the top lip of the boot rests in the channel in the stem. 8. Roll back boot and install cam (Item 18), retainer (Item 19), and flange (Item 20) on stem. 9. Install flange on joystick body with two (2) capscrews (Item 16). Install retainer on flange with remaining two (2) capscrews, ensuring that one capscrew also secures the wire to the retainer with the clip (Item 15). Torque capscrews to 28 in-lbs. 10.
Boom and Transfer O-ring Plug Pressure Reducing Valve Control Manifold Hydraulics O-ring Plug K1134 Pressure Reducing Valve Mid-Inlet Hydraulics Fig. 6-6: Pilot Pressure Plug c. (Ref. Fig. 6-6) If the pilot pressure is not within the recommended range, adjust pressure as follows: 1). For models with control manifold hydraulics, remove the O-ring plug from the pressure reducing cartridge with a 1/4" Allen wrench.
Boom and Transfer downstream hydraulic line failure or leakage through the control valves or fittings. Counterbalance valves prevent movement of the cylinders when the engine is off, even if the control valve levers are operated. Counterbalance valves also provide relief valve overpressure protection. WARNING: Do not remove counterbalance valves from cylinders on the machine while the cylinder is under load (extended).
Boom and Transfer 2. Install brake pressure diagnostic port test gauge into brake diagnostic port. 3. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Remove test gauge and cap diagnostic port. 4. Remove the hose at the base end of the cylinder and plug the hose. 5. Start the engine and activate the control that will supply hydraulic oil to the rod end of the cylinder. 6.
Boom and Transfer Removal Boom Hoist Cylinder 1 3 2 5 6 4 1 7 20 40 60 80 2 -20 0 8 J1122 10 11 12 9 # 1 2 3 4 5 6 Description Hydraulic Hose Hoist Cylinder Outer Boom Pivot Pin - Rod End Lock Pin Hex Capscrew # 7 8 9 10 11 12 Description Lockwasher Transfer Carriage/Boom Cradle Lock Pin Pivot Pin - Base End Lockwasher Hex Capscrew Fig. 6-8: Boom Hoist Cylinder Installation (Ref. Fig. 6-8) The following steps are required to remove boom hoist cylinders. 2.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. Note: Cylinder pins are designed to be removed with a slide hammer. 5. Remove lock pin from rod end pivot pin (Item 4). 6. Remove rod end hoist cylinder pin from outer boom (Item 3). 7. Slowly lower supported cylinder until it rests on main frame. 8.
Boom and Transfer Overhaul Boom Hoist Cylinder 1 8 7 9 2 13 3 14 6 4 11 15 5 16 10 J1124 12 # Description # 1 2 3 4 5 6 7 8 45 Degree Elbow Grease Fitting Cover Grease Fitting Self-Aligning Bushing - Base End Cylinder Barrel Hollow Hex O-ring Plug Hollow Hex O-ring Plug Counterbalance Valve Cartridge 9 10 11 12 13 14 15 16 Description Rod Nut Piston Hex Head Capscrew Rod Bearing Head Cylinder Rod Self-Aligning Bushing - Rod End Grease Fitting Grease Fitting Cover Fig.
Boom and Transfer a. Place socket wrench over counterbalance valve cartridge (Item 8). Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b. Carefully and slowly, turn cartridge out of manifold block to release pressure in cylinder. 3. Remove the counterbalance valve cartridge. 4. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 5. Remove eight (8) capscrews (Item 11) securing rod bearing head (Item 12) to barrel. 6.
Boom and Transfer 16. Inspect counterbalance valve cartridge (Item 8), including O-rings, for condition and replace as necessary. Do not disassemble the cartridge. Service to counterbalance valve cartridges is limited to installing new O-rings or replacing the entire cartridge. 17. Lubricate counterbalance valve cartridge O-rings with clean hydraulic oil. 18. Install cartridge in manifold block and torque to 30–35 ft-lbs. 19. Install O-ring plug (Item 6) in manifold block and torque to 70–80 ft-lbs. 20.
Boom and Transfer Front Carriage Tilt Cylinder 20 40 60 80 Description 0 J1126 -20 Fig. 6-11: Front Carriage Tilt Cylinder The front carriage tilt cylinder is located inside the inner boom section at the front of the machine connecting to the inner boom and to the quick attach assembly. It controls attachment tilt when the appropriate joystick handle is activated. Maximum operating pressure is at approximately 3175 psi. Daily lubrication of the two grease fittings is required.
Boom and Transfer Removal Front Carriage Tilt Cylinder 1 2 3 4 5 6 7 J1070 8 # 1 2 3 4 Description Inner Boom Section Pin Boss Lock Pin Lockwasher Capscrew # 5 6 7 8 Description Upper Pivot Pin Hydraulic Hose Front Carriage Tilt Cylinder O-ring Connector Fig. 6-12: Front Carriage Tilt Cylinder Installation (Ref. Fig. 6-12) The following steps are required to remove the front carriage tilt cylinder. 1. Remove quick attach assembly. See page 6-58 2.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. 4. Remove capscrew (Item 4), lockwasher (Item 3), and lock pin (Item 2) from upper pivot pin (Item 5) of front carriage tilt cylinder. Remove pivot pin. 5. Carefully remove cylinder from boom nose (Item 1). 6. Clean with solvent and dry with compressed air. Inspect all components for condition and wear.
Boom and Transfer Overhaul Front Carriage Tilt Cylinder 4 3 2 5 6 1 17 18 16 7 8 15 9 10 16 14 8 13 J1127 12 11 # 1 2 3 4 5 6 7 8 9 Description O-ring Connector Manifold Block Lockwasher Capscrew Counterbalance Valve Cartridge Rod Nut Cylinder Barrel Bushing Grease Fitting Cover # 10 11 12 13 14 15 16 17 18 Description Grease Fitting Piston Stroke Limiter Rod Bearing Head Cylinder Rod Capscrew Bushing Grease Fitting Cover Grease Fitting Fig.
Boom and Transfer a. Place socket wrench over counterbalance valve cartridge (Item 5). Wrap a clean shop rag around the socket to cover the area of the counterbalance valve cartridge. b. Carefully and slowly, turn cartridge out of manifold block (Item 2) to release pressure in cylinder. 3. Remove the counterbalance valve cartridge.
Boom and Transfer 13. Inspect inner surface of barrel, outer surface of piston, and length of rod for scratches and scoring. If barrel, piston, or rod is damaged, it must be replaced. 14. Check condition of threads on rod, nut, and capscrews. Do not attempt to repair damaged threads. 15. Inspect counterbalance valve cartridge (Item 5), including O-rings, for condition and replace as necessary. Do not disassemble the cartridge.
Boom and Transfer Rear Carriage Tilt Cylinder 20 40 60 80 Description 0 J1128 -20 Fig. 6-14: Rear Carriage Tilt Cylinder Two rear carriage tilt cylinders are located at the rear of the outer boom section, one on each side. These cylinders maintain the attachment tilt position as the boom is raised and lowered. As boom elevation changes, a specific amount of oil in the cylinders moves to the front carriage tilt cylinder, automatically adjusting the attachment tilt.
Boom and Transfer Removal Rear Carriage Tilt Cylinder 1 2 3 5 7 4 6 8 9 14 13 10 11 J1129 12 # 1 2 3 4 5 6 7 Description Outer Boom Lock Pin Lockwasher Hex Head Capscrew Cylinder Pivot Pin - Rod End Rear Carriage Tilt Cylinder Hydraulic Hose # 8 9 10 11 12 13 14 Description Grease Fitting Cover Grease Fitting Lock Pin Lockwasher Hex Head Capscrew Cylinder Pivot Pin - Base End Transfer Carriage/Boom Cradle Fig. 6-15: Rear Carriage Tilt Cylinder Installation (Ref. Fig.
Boom and Transfer 3. Tag and disconnect two (2) hydraulic hoses (Item 7) from elbows on both cylinders (Item 6). Cap fittings and hoses. 4. Support each cylinder with sling(s) and crane, or other suitable means. Make sure equipment has sufficient capacity to support weight of cylinder. WARNING: To avoid personal and/or equipment damage, support hydraulic cylinders before removing pins. Use suitable blocking and lifting devices when removing heavy machine components. 5.
Boom and Transfer 5. Clean hydraulic hose ends with solvent. Attach two (2) hoses (Item 7) to elbows on each cylinder. Torque hose swivel nuts to 44–48 ft-lbs. 6. If necessary, remove grease fitting cover(s) (Item 8) and grease fitting(s) (Item 9). Clean and inspect for damage; replace if necessary. Install grease fitting(s) and covers; torque fitting(s) 1.5 to 3 turns past finger tight. 7. Lubricate grease fittings with EP lithium based grease.
Boom and Transfer Note: 10K and 1044C models have three (3) holes in the side of the rod bearing head. 5. Remove the cylinder rod assembly from cylinder barrel. CAUTION: To prevent possible damage to components, support cylinder rod assembly; do not wiggle rod or head back and forth during removal. 6. Remove rod nut (Item 4), piston (Item 5), stroke limiter (Item 6), and rod bearing head from rod (Item 8).
Boom and Transfer 644B-37 (S/N 101–434), 644B-42 (S/N 101–130), 6K-37 (S/N 101–229), 6K-42 (S/N 101–109), 844C-42 (S/N 101–319), and 8K-42 (S/N 101–180) 745 ft-lbs. 644B-37 (S/N 435–), 644B-42 (S/N 131–), 6K-37 (S/N 230–), 6K-42 (S/N 110–), 844C-42 (S/N 320–), and 8K-42 (S/N 181–) 1508 ft-lbs. 1044C -42 (S/N 101–), 1044C-54 (S/N 101–), 10K-42 (S/N 101–), and 10K-54 (S/N 101–) 550 ft-lbs. 16. Lubricate new seal and wear rings with hydraulic oil and install on piston. 17.
Boom and Transfer The boom hydraulic control valve is located near the middle of the machine on the valve plate. It controls fluid flow to the boom hoist and telescope cylinders when operating the hoist/telescope joystick control.
Boom and Transfer (Ref. Fig. 6-18) The following procedures describes disassembly for the boom hydraulic control valve. 1. Follow preparation procedures as outlined in Section 3. 2. Install a 0–600 psi gauge into the brake diagnostic test port marked “BRAKES” located behind the cab step. 3. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Remove test gauge and cap diagnostic port. 4. For models 644B, 844C, and 1044C, remove roll-back hose tray. 5.
Boom and Transfer Installation Boom Hydraulic Control Valve (Control Manifold System) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 844C-42 (S/N 101–621) 8K-42 (S/N 101–220) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) (Ref. Fig. 6-18) The following procedures describes installation of the boom control valve. 1.
Boom and Transfer Fitting Removal 3 4 6K-37 – S/N 101–317 2 6K-42 – S/N 101–119 644B-37 – S/N 101–590, 592–666 644B-42 – S/N 101–207 8K-42 – S/N 101–220 844C-42 – S/N 101–621 10K-42 – S/N 101–106 1 10K-54 – S/N 101–103 1044C-42 – S/N 101–116 1044C-54 – S/N 101–154 5 6 K1110 7 9 8 # 1 2 3 4 5 Description Boom Control Valve Assembly Connector Long Connector Elbow (Hydraulic Return Hose) Elbow* # 6 7 8 9 Description Elbow* Connector (Hydraulic Tube) Elbow* Elbow * This fitting is a tee on models wi
Boom and Transfer Boom Control Valve Disassembly 15 13 11 16 14 12 17 10 9 8 7 6 5 4 3 K1109 1 2 # Description # Description 1 2 3 4 5 6 7 8 9 Socket Head Capscrew Retainer Spool Cap Socket Head Shoulder Capscrew Flatwasher Spring Spacer Flatwasher Spool 10 11 12 13 14 15 16 17 O-ring Spool Retainer O-ring Spool Housing O-ring Spool Cap Retainer Socket Head Capscrew Fig. 6-20: Control Valve Components (Ref. Fig. 6-20) The following procedure describes disassembly of the control valve.
Boom and Transfer 6. Remove the two (2) O-rings (Items 10 and 12) from the spool retainer (Item 11) and the O-ring (Item 14) from the spool cap (Item 15). Discard all O-rings. 7. Clean all removed parts with solvent and dry with compressed air. Inspect for damage and replace if necessary. Note: The spool (Item 9) and the spool housing (Item 13) cannot be purchased separately. If they are damaged, purchase of an entire valve section is necessary. 8.
Boom and Transfer (Ref. Fig. 6-21) The following procedure describes disassembly and overhaul of the boom hydraulic control valve assembly. 1. Loosen and remove three (3) hex nuts (Items 14 and 15). 2. Remove three (3) tie rods (Items 3 and 4) with remaining three (3) hex nuts (Items 1 and 2). 3. Separate the four (4) sections — outlet housing (Item 5), two (2) spool housings (Item 9) and inlet housing (Item 12). 4. Remove the two (2) each springs (Item 7) and poppets (Item 8). 5.
Boom and Transfer Relief Valve Assembly 11 12 10 9 8 7 5 6 4 3 2 19 1 18 17 16 15 06-9006 14 13 # 1 2 3 4 5 6 7 8 9 10 Description O-ring Valve Body Poppet Poppet Backup Ring O-ring Piston Spring O-ring Backup Ring # 11 12 13 14 15 16 17 18 19 Description O-ring Plug Poppet Spring Adjusting Screw O-ring Hex Nut O-ring Rounded End Nut Fig. 6-22: Relief Valve Assembly (Ref. Fig. 6-22) The following steps are required to overhaul the relief valve assembly. 1.
Boom and Transfer 7. Remove piston (Item 7) and poppet (Item 4) from poppet (Item 3). 8. Remove O-ring (Item 1) from valve body (Item 2), the backup ring (Item 5) and O-ring (Item 6) from the poppet (Item 4), and the two O-rings (Items 9 and 11) and backup ring (Item 10) from the plug (Item 12). 9. Discard all O-rings, backup rings, and springs. 10. Clean all remaining parts with solvent and dry with compressed air. Inspect and replace any damaged parts.
Boom and Transfer 1. Install the four (4) elbows/tees (Items 5, 6, 8, and 9) on the ends of the valves sections in the control valve assembly (Item 1), making sure that they are positioned vertically so that the hydraulic hoses can be easily reconnected through the holes in the valve plate. Torque to 25–29 ft-lbs. 2. Install the hydraulic return elbow (Item 4) and torque to109–121 ft-lbs. 3.
Boom and Transfer Removal Selector Valve (Control Manifold System) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 844C-42 (S/N 101–621) 8K-42 (S/N 101–220) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 11 10 8 7 9 6 5 4 1 3 J1179 2 # 1 2 3 4 5 6 Description Hydraulic Hose Hydraulic Hose (Joystick) Hydraulic Hose Capscrew Selector Valve Mounting Bracket # 7 8 9 10 11 Description Lockwasher Nut Lockwasher Capscre
Boom and Transfer 8. Remove two (2) each nuts (Item 8), lockwashers (Item 7), and capscrews (Item 4) securing selector valve (Item 5) to the mounting bracket (Item 6). 9. Take selector valve and mounting hardware to a suitable area for cleaning and further disassembly. 10. Clean mounting hardware with solvent. Dry with compressed air, inspect for damage, and replace as necessary.
Boom and Transfer Overhaul Selector Valve (Control Manifold System) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 844C-42 (S/N 101–621) 8K-42 (S/N 101–220) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 1 16 2 15 14 13 12 11 3 4 7 10 5 9 # 1 2 3 4 5 6 7 8 7 Description Nut Name Plate Coil Housing Solenoid Coil Cover Plate Long Elbow Elbow O-ring Plug # 9 10 11 12 13 14 15 16 8 J1180 6 Description Orific
Boom and Transfer 6. Remove O-rings and backup rings (Items 11, thru 15) from solenoid cartridge. Discard O-rings and backup rings. 7. Repeat Step 4 thru Step 6 for the other solenoid valve assembly. 8. Clean all remaining parts with solvent and dry with compressed air. Visually inspect the valve body to make sure all cavities are free of contamination including burrs and chips as well as pieces of O-rings. Inspect for all parts for damage and contamination; replace as necessary.
Boom and Transfer Selector Valve (Mid-Inlet System) Description J1181 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 6K-37 (S/N 318–) 6K-42 (S/N 120–) 844C-42 (S/N 622–) 8K-42 (S/N 221–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) Fig. 6-26: Selector Valve – Models with Mid-Inlet Hydraulics The 6-port circuit selector valve (directional control valve) is located on the valve plate near the center of the machine.
Boom and Transfer Removal Selector Valve (Mid-Inlet System) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 6K-37 (S/N 318–) 6K-42 (S/N 120–) 844C-42 (S/N 622–) 8K-42 (S/N 221–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 8 7 6 5 1 2 J1182 3 4 # 1 2 3 4 Description Lockwasher Nut Hydraulic Hoses Hydraulic Hoses # 5 6 7 8 Description Selector Valve Hydraulic Hoses (Joystick) Capscrew Joystick Wiring Harness Fig.
Boom and Transfer Installation Selector Valve (Mid-Inlet System) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 6K-37 (S/N 318–) 6K-42 (S/N 120–) 844C-42 (S/N 622–) 8K-42 (S/N 221–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) (Ref. Fig. 6-27) The following steps are required to install the selector valve in models with a mid-inlet hydraulic system. 1.
Boom and Transfer 1. Loosen and remove four (4) connectors (Item 9) from valve body (Item 10). 2. Loosen and remove two (2) each O-ring plugs (Item 12) and orifices (Item 11). 3. Loosen and remove nut (Item 1) from solenoid valve (Item 3). 4. Remove coil (Item 2) from solenoid valve. 5. Loosen and remove solenoid valve from valve body. 6. Remove O-rings and backup rings (Items 4 thru 8) from solenoid valve. Discard O-rings and backup rings. 7. Repeat Step 3 thru Step 6 for the other solenoid valve. 8.
Boom and Transfer Troubleshooting Problem 1. Boom fails to extend or retract Probable Cause A. Broken hydraulic line(s) and/or connection leaks A. Replace hydraulic tube(s)/hose(s) and/or tighten loose connections. B. Faulty extension cylinder B. Repair extension cylinder seals. C. Broken chains or chain connections 2. Boom fails to raise or lower A. Replace hydraulic hose(s)/tube(s) and/or tighten loose connections. B. Faulty hoist cylinder(s) B. Repair cylinder seals. C.
Boom and Transfer Boom Slide Pads — General Description Within the slide boom assemblies, there art two classifications of slide pads: • Load Bearing Slide Pads Load bearing slide pads are located at the front and on the bottom of any boom section that contains another section. Load bearing pads are also located on the top rear of a boom section that is placed inside another section.
Boom and Transfer Slide Pads with Chamfers Less Chamfer J1036 Fig. 6-30: Pad Worn, But Still OK (Ref. Fig. 6-30) Inspect all pads weekly for condition and amount of chamfer wear. As a pad wears, the chamfer will get smaller. As long as a portion of the chamfer is visible, the pad is OK and does not need to be replaced. No Chamfer J1037 Fig. 6-31: Pad Must Be Replaced (Ref. Fig. 6-31) When the chamfer is gone, the pad must be replaced.
Boom and Transfer Slide Pads without Chamfers New Slide Pad 3/4" Worn Pad 9/16" Minimum J1184 Fig. 6-33: Slide Pad Without Chamfers – 3 and 4-Section Boom (Ref. Fig. 6-33) The lower slide pads, located at the rear of the middle boom on 3-section booms and at the rear of the middle (rear) boom on 4-section booms, do not have chamfers. It will be necessary to measure the thickness of these slide pads to ensure that they are a minimum of 9/16".
Boom and Transfer Another option is to install/replace boom wear strips. Contact the JLG Service Department or your dealer for information about available wear strips. 0.030" Max. J1040 Fig. 6-34: Damaged Slide Surface 0.030" Max. J1041 Fig.
Boom and Transfer Replacing and Shimming Boom Slide Pads — General Shims Bolted Pad Pad Cage Caged Pad Lockwas her Retaining Block Pad Capscrew J1019 Fig. 6-36: Slide Pad Installation (2-Section Shown) (Ref. Fig. 6-36) As boom pads wear, it becomes necessary to install or remove shims to maintain the correct clearances. Specific instructions and clearances for 2-section, 3-section, and 4-section booms are provided on following pages.
Boom and Transfer Adding or removing shims from bolted pads may require a different capscrew length or washer selection. Boom Bolted Pad Washer Lockwasher Capscrew Nut Insert Pad Number Dimension A 39023A 39024A 39530A 39594A 39604A 0.28"–0.33" 0.39"–0.44" 0.39"–0.44" 0.39"–0.44" 0.21"–0.26" Dimension A J1034 Fig. 6-38: Determining Capscrew Length (Ref. Fig.
Boom and Transfer Quick Attach Description J1004 Fig. 6-40: Quick Attach Rear View (Ref. Fig. 6-40) The quick attach is designed for easy connection and disconnection of various attachments. By pulling the release handle, attachments can be easily interchanged. Disconnecting an Attachment 1. Come to a complete stop on flat, level ground. 2. Set the park brake. 3. Raise the boom so attachment clears the ground. 4. Extend the boom a short distance. 5.
Boom and Transfer 8. Pull release handle (1) back. J1013 Fig. 6-42: Lock Plate 9. The lock pin (2) should engage the attachment, clearing the lock plate (3) from the attachment stop (4). J1007 Fig. 6-43: Rotating Quick Attach Downwards 10. Start the engine. Fully rotate quick attach (5) downwards by using the attachment tilt control. J1008 Fig. 6-44: Lowering Boom 11. Lower boom enough to clear quick attach pivot pin (6) from attachment (7).
Boom and Transfer J1009 Fig. 6-45: Retracting Boom 12. Retract the boom until quick attach (5) is clear of attachment (7). Connecting an Attachment J1015 Fig. 6-46: Extending Boom 1. With quick attach (5) rotated fully downwards, extend the boom until quick attach pivot pin (6) is properly aligned underneath the attachment (7). J1016 Fig. 6-47: Raising Boom 2. Raise the boom to engage the quick attach pivot pin (6) with the attachment (7).
Boom and Transfer J1017 Fig. 6-48: Rotating Quick Attach Forward 3. Rotate the quick attach (5) upwards to engage the attachment (7). 4. Shut off engine. J1014 Fig. 6-49: Lock Plate Engaged 5. Check to see that the lock plate (3) is engaged ahead of the attachment stop (4). MAKE SURE ATTACHMENT IS SECURELY CONNECTED TO QUICK ATTACH. ATTACHMENT MAY FALL AND CAUSE SERIOUS PERSONAL INJURY OR DEATH! W1048 WARNING 6. Connect attachment hydraulic hoses (if equipped).
Boom and Transfer Removal Quick Attach 1. Disconnect attachment from quick attach. 2. Fully retract boom and transfer carriage (if equipped), level quick attach and lower boom to ground. 3. Set park brake, lock shift selector in NEUTRAL position, shut off engine and remove ignition key from switch. Block all wheels. 6 1 5 4 3 2 J1067 # 1 2 3 Description Quick Attach Pivot Pin capscrew # 4 5 6 Description Lockwasher Lock Pin Front Carriage Tilt Cylinder Fig.
Boom and Transfer 5 1 3 4 5 2 6 J1068 # 1 2 3 Description Pivot Pin Capscrew Lockwasher # 4 5 6 Description Nut Shim Quick Attach Fig. 6-51: Quick Attach Pivot 5. (Ref. Fig. 6-51) Remove nut (Item 4), lockwasher (Item 3), and capscrew (Item 2) from quick attach pivot pin (Item 1). 6. Remove quick attach pivot pin and shims (Item 5) (if installed). 7. Clean and inspect all parts for condition and wear. Replace as necessary. Installation Quick Attach 1. Align quick attach (Item 6) to boom.
Boom and Transfer Boom Angle Inclinometer DEGREES 60 80 60 0 -20 0 20 4 H1045 60 80 80 Description 20 -20 0 20 J1177 0 40 0 4 -20 Fig. 6-52: Boom Angle Inclinometer (Ref. Fig. 6-52) The boom angle inclinometer is located near the front of the outer boom section. The boom angle inclinometer shows the angle of the boom relative to level ground.
Boom and Transfer 2-Section Boom 20 40 60 80 Description -20 0 J1150 Fig. 6-54: 2-Section Boom The 2-section boom is used on 644B-37 and 6K-37 models. It is a slide boom with a 37 foot maximum lift height. The maximum forward reach on the 644B-37 is 27 feet and the 6K-37 has a maximum reach of 20 feet.
Boom and Transfer 1. Park machine on firm, level surface and apply park brake. Level the frame. Level and fully retract the boom. Shut off engine. 2. Determine if all boom slide pads are serviceable. (See “Slide Pad Inspection” on page 6-48) Have replacement pads ready as required. 0.625"–0.688" (5/8"–11/16") J1045 Fig. 6-56: Boom Section Gaps – Front of 2-Section Boom 3. (Ref. Fig. 6-56) Measure the gap between boom sections at both upper pads.
Boom and Transfer Install shim(s) under these pads J1046 Fig. 6-57: Lower Shim Installation – Front of 2-Section Boom 4. (Ref. Fig. 6-57) Install/remove shim(s) under indicated pads to obtain clearance specified in Step 3. 0.063"–0.125" (1/16"–1/8") gap between boom and pads Install shim(s) under these pads J1050 Fig. 6-58: Upper Shim Installation – Front of 2-Section Boom 5. (Ref. Fig. 6-58) Install/remove shim(s) under indicated pads to obtain specified clearance.
Boom and Transfer 0.813"–0.875" (13/16"–7/8") J1047 Fig. 6-59: Boom Section Gaps – Rear of 2-Section Boom 6. (Ref. Fig. 6-59) Measure the gap between boom sections at both upper pads. If the dimensions are not within the specified range, proceed to Step 7. If the dimensions are within the specified range, proceed to Step 8. Install shim(s) under these pads J1048 Fig. 6-60: Lower Shim Installation – Rear of 2-Section Boom 7. (Ref. Fig.
Boom and Transfer Install shim(s) under these pads 0.063"–0.125" (1/16"–1/8") gap between boom and pads J1049 Fig. 6-61: Upper Shim Installation – Rear of 2-Section Boom 8. (Ref. Fig. 6-61) Install/remove shim(s) under indicated pads to obtain specified clearance. 0.688"–0.750" (11/16"–3/4") gap between boom sections Rear of Boom, Looking Forward J1051 Fig. 6-62: Clearances Between Boom Sections Rear of 2-Section Boom 9. (Ref. Fig.
Boom and Transfer 0.030"–0.063" (1/32"–1/16") gap between pads and boom Rear of Boom, Looking Forward J1052 Fig. 6-63: Gaps Between Pads and Boom – Rear of 2-Section Boom 10. (Ref. Fig. 6-63) Install/remove shim(s) under indicated pads to obtain specified clearances. 0.688"–0.750" (11/16"–3/4") gap between boom sections Front of Boom, Looking Rearward J1053 Fig.
Boom and Transfer 11. (Ref. Fig. 6-64) Position inner boom section to obtain the indicated dimensions. 0.030"–0.063" (1/32"–1/16") gap between pads and boom Front of Boom, Looking Rearward J1054 Fig. 6-65: Gaps Between Pads and Boom – Front of 2-Section Boom 12. (Ref. Fig. 6-65) Install/remove shim(s) under indicated pads to obtain specified clearances. 13. Extend boom and lubricate per previous instructions. 14. Check boom extension and retraction for binding against slide pads.
Boom and Transfer 12 3/8" (12.38") Max. 3/16" (0.19") 1/4" (0.25") Max. J1085 Fig. 6-66: Inner Boom Cross-Section at Window 2. (Ref. Fig. 6-66) Place a straight edge against the bottom surface of the inner boom section. Measure the distance from the straight edge to the bottom surface of the boom tube. This distance should not exceed 1/4" (0.25"). The maximum deflection will be found just in front of the outer boom section. 3. (Ref. Fig.
Boom and Transfer 5. (Ref. Fig. 6-67) Look through the rear of the boom. Using a 12-inch straight edge, measure the top surface of the rear of the inner boom section. Maximum allowable deflection at the center, top of the inner boom section is 1/4" (0.25"). Removal 2-Section Boom 1. Remove Quick Attach. See page 6-58. 2. Fully retract boom and transfer carriage (if equipped), lower boom to ground. 3. Park machine on firm, level surface.
Boom and Transfer 8. Place sling around inner boom section, at the front. Chains with hooks may be attached to the rear of the outer boom section, near the pivot pin bosses (Ref. Fig. 6-69). Attach sling and chains to crane hook and lift crane to support weight of boom. CAUTION: Make sure crane, slings, and chains have sufficient capacity to support the weight of the boom. A 2-section boom assembly weighs approximately 4,200 pounds.
Boom and Transfer CAUTION: Use suitable blocking to support the cylinder and prevent damage to the surrounding structure. 11. (Ref. Fig. 6-69) Repeat Step 10 for the remaining rear carriage tilt cylinder. 12. (Ref. Fig. 6-69) Continue with each of the two (2) the hoist cylinders (Item 7) by using a slide hammer puller threaded into pivot pin to remove it. After the pivot pin has been removed, allow the cylinder to swing down and away from the boom.
Boom and Transfer CAUTION: Make sure slings and chains are secure and crane is supporting the weight of the boom. 14. (Ref. Fig. 6-70) Using the slide hammer puller, remove the two (2) boom pivot pins and shims (Item 5). 15. (Ref. Fig. 6-70) Carefully lift the boom assembly (Item 7) clear of the transfer carriage/boom cradle (Item 6). 16. Swing the boom away from the machine and position it above a firm, level surface. Installation 2-Section Boom 1.
Boom and Transfer 12. Cycle all boom hydraulics several times to remove air from system. Retract and lower boom to ground and shut off engine. 13. Inspect hydraulic connections for leaks and tighten as necessary. Disassembly 2-Section Boom 1. Remove boom assembly from machine. See page 6-69. 2. Remove the front carriage tilt cylinder. See page 6-18. J1078 3. Place the boom assembly on work stands in an upright position. Fig. 6-71: Front Slide Pads, Outer Boom 4. (Ref. Fig.
Boom and Transfer These pads are removed at Step 7 J1078 Remove these pads Fig. 6-72: Rear Slide Pads, Inner Boom 5. (Ref. Fig. 6-72) Remove four (4) upper slide pads from the rear of the inner boom section. Leave the lower rear pads installed to protect the outer boom section during separation.
Boom and Transfer 1 3 2 J1079 4 # 1 2 Description Extension Cylinder Rear Support # 3 4 Description Lockwasher Capscrew Fig. 6-73: Extension Cylinder Rear Support 6. (Ref. Fig. 6-73) Place a block between the extension cylinder (Item 1) and the inner boom. Remove two (2) capscrews (Item 4) and lockwashers (Item 3) securing the extension cylinder to the rear support (Item 2). 7.
Boom and Transfer 3 4 2 1 5 J1080 6 # 1 2 3 Description Nut Setscrew Washer # 4 5 6 Description Cotter Pin Mounting Block Extension Cylinder Fig. 6-74: Extension Cylinder Rod End 10. (Ref. Fig. 6-74) Loosen the two (2) setscrews (Item 2) in the extension cylinder nut (Item 1). Remove the nut and washer (Item 3). 11. (Ref. Fig. 6-74) For models with a 2" diameter rod in the boom extension cylinder (Item 6), remove the cotter pin (Item 4). Models with a 2.
Boom and Transfer Capscrew Lockwasher Flatwasher J1276 Rear Mount Support Fig. 6-76: Rear Boom Extension Cylinder Mount Support Installation 12. (Ref. Fig. 6-76) Support the boom extension cylinder and remove the two (2) capscrews, lockwashers, and flatwashers securing the rear mount support to the outer boom. 13. (Ref. Fig. 6-75) Slide the extension cylinder back about a foot. Tag and disconnect two (2) carriage tilt and two (2) auxiliary hydraulics hoses from the fittings at the extension cylinder.
Boom and Transfer 15. Remove the extension cylinder from the inner boom section. 16. Rotate the inner boom section upside down. Auxiliary Hydraulic Hoses J1083 Carriage Tilt Hoses Fittings Fig. 6-78: Hose Connections in Inner Boom 17. (Ref. Fig. 6-78) Tag and disconnect two (2) carriage tilt and two (2) auxiliary hydraulics hoses from the fittings in the boom. Cap hoses and fittings. Capscrew Lockwasher Flatwasher Hose Carrier Mounting Block J1084 Hose Carrier Fig.
Boom and Transfer Assembly 2-Section Boom 1. (Ref. Fig. 6-79) With the inner boom section lying upside down, position two (2) hose carriers (with hoses) in the boom, secure each carrier with four (4) screws, lockwashers, and washers. Apply thread locking compound to the screws before installing them. 2. (Ref. Fig. 6-78) Connect two (2) carriage tilt and two (2) auxiliary hydraulics hoses to the fittings in the boom. 3.
Boom and Transfer Extension Cylinder 2-Section Boom 20 40 60 80 Description 0 J1123 -20 Fig. 6-80: 2-Section Boom Extension Cylinder (Ref. Fig. 6-80) The boom extension cylinder controls extension and retraction of the boom. For models with a 2-section boom, it is located inside the boom. Operating pressure is at 3000 psi. Removal, Boom Extension Cylinder The following procedure describes removal of the boom extension cylinder. 1. Follow safety guidelines as outlined in Section 1 of this manual.
Boom and Transfer 3 4 2 1 5 # 1 2 3 Description # Nut Setscrew Washer J1080 6 Description 4 5 6 Cotter Pin Mounting Block Extension Cylinder Fig. 6-81: Extension Cylinder Rod End 5. (Ref. Fig. 6-81) Level the boom. Then loosen the two (2) setscrews (Item 2) in the extension cylinder nut (Item 1). Remove the nut and washer (Item 3). 6. (Ref. Fig. 6-81) For models with a 2" diameter rod in the boom extension cylinder (Item 6), remove the cotter pin (Item 4). Models with a 2.
Boom and Transfer 7. (Ref. Fig. 6-82) Tag and disconnect two (2) hoses (Item 3) at the boom extension cylinder (Item 4). Cap hoses and fittings. 8. (Ref. Fig. 6-82) Tag and disconnect two (2) carriage tilt hoses (Item 2), and two (2) auxiliary hydraulics hoses (Item 1) at the boom. Cap hoses and fittings. Note: “K” Model machines are not equipped with auxiliary hydraulics. For these models, disregard procedures that refer to auxiliary hydraulic components.
Boom and Transfer 10. (Ref. Fig. 6-84) Remove four (4) capscrews, lockwashers, and flatwashers securing each hose carrier to the boom section. Remove the hose carrier(s) and hoses from the boom. Capscrew Lockwasher Flatwasher J1276 Rear Mount Support Fig. 6-85: Rear Boom Extension Cylinder Mount Support 11. (Ref. Fig. 6-85) Support the boom extension cylinder and remove the two (2) capscrews, lockwashers, and flatwashers securing the rear mount support to the outer boom.
Boom and Transfer 5 6 7 9 18 8 1 17 2 3 4 21 22 20 1 12 14 19 2 13 3 16 10 23 11 15 27 24 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Capscrew Lockwasher Flatwasher Rear Hose Tray - R.H.
Boom and Transfer 14. (Ref. Fig. 6-86) Remove the hardware securing the hose tray assembly(ies) (Items 4 and 9 and Items 22 and 23) to the boom extension cylinder. This includes capscrews (Item 1), lockwashers (Item 2), and flatwashers (Item 3). Remove the hose tray assemblies. Note: The 6K-37 has one hose tray assembly and seventeen (17) sets of hardware while the 644B-37 has two hose tray assemblies and thirty-four sets of hardware. 15. (Ref. Fig.
Boom and Transfer 11. (Ref. Fig. 6-81) Secure the extension cylinder to the mounting block with a washer (Item 3) and extension cylinder nut (Item 1). Torque the nut to 1640 ft-lbs. Tighten the two (2) setscrews (Item 2) in the extension cylinder nut. 12. (Ref. Fig. 6-81) For models with a 2" diameter rod in the boom extension cylinder (Item 6), install the cotter pin (Item 4). Models with a 2.25" diameter rod do not have a cotter pin; proceed to Step 13. 13. Install the front carriage tilt cylinder.
Boom and Transfer Overhaul, Boom Extension Cylinder 6 5 7 9 18 8 1 17 2 3 4 21 22 20 1 12 14 19 2 13 3 16 10 23 11 15 27 24 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Capscrew Lockwasher Flatwasher Rear Hose Tray - R.H.
Boom and Transfer 2. Mount or support the cylinder vertically with the rod end down. Hydraulic oil in cylinder will drain out during disassembly. Place a suitable pan or tray under the cylinder. 3. Release pressure in the cylinder as follows: WARNING: Counterbalance valve cartridges trap hydraulic pressure in the cylinder. Wear proper eye and hand protection when removing counterbalance valve cartridges.
Boom and Transfer 15. Inspect counterbalance valve cartridges (Items 14 and 16), including O-rings, for condition and replace as necessary. Do not disassemble cartridges. Service to counterbalance valve cartridges is limited to installing new O-rings and replacing the entire cartridge. 16. Lubricate a new O-ring with hydraulic oil and install it inside the piston (seals the rod to the piston). 17. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic oil and install them on the head.
Boom and Transfer 3-Section Boom 20 40 60 80 Description -20 0 J1151 Fig. 6-88: 3-Section Boom The 3-section boom is used on 644B-42, 6K-42, 844C-42, 8K-42, 1044C42, and 10K-42 models. It is a fully synchronized slide boom with a 42 foot maximum lift height. The maximum forward reach on the 644B-42, 844C-42, and 1044C-42 is 32 feet. The 6K-42, 8K-42, and 10K-42 have a maximum reach of 25 feet, 6 inches.
Boom and Transfer Shimming Procedures 3-Section Boom NOTE: Items 1, 3, 6, and 7 are load bearing pads. 1 2 2 2 2 2 2 3 1 2 2 or 4 2 2 2 5 6 or 7 J1022 NOTE: Items 4 and 7 were used with early production units.
Boom and Transfer 0.938"–1.000" (15/16"–1") 0.625"–.688" (5/8"–11/16") J1056 Fig. 6-90: Boom Section Gaps – Front of 3-Section Boom 3. (Ref. Fig. 6-90) Measure the gap between boom sections at all upper pads. If the dimensions are not within the specified range, proceed to Step 4. If the dimensions are within the specified range, proceed to Step 5. Install shim(s) under these pads J1057 Fig. 6-91: Lower Shim Installation – Front of 3-Section Boom 4. (Ref. Fig.
Boom and Transfer 0.063"–0.125" (1/16"–1/8") gap between boom and pad 0.063"–0.125" (1/16"–1/8") gap between boom and pad Install shim(s) under these pads J1058 Fig. 6-92: Upper Shim Installation – Front of 3-Section Boom 5. (Ref. Fig. 6-92) Install/remove shim(s) under the indicated pads to obtain specified clearances. 1.063"–1.125" (1 1/16"– 1 1/8") This dimension cannot be adjusted J1059 Fig.
Boom and Transfer 6. (Ref. Fig. 6-93) Measure the gaps between the inner and middle boom sections at the upper pads. Spacing between the middle and outer boom section cannot be adjusted. If the dimensions are not within the specified range, proceed to Step 7. If the dimensions are within the specified range, proceed to Step 8. Install shim(s) under these pads J1060 Fig. 6-94: Lower Shim Installation – Rear of 3-Section Boom 7. (Ref. Fig.
Boom and Transfer 0.938"–1.063" (15/16"–1 1/16") 1.063"–1.125" (1 1/16"–1 1/8") Rear of Boom, Looking Forward J1062 Fig. 6-96: Clearances Between Boom Sections – Rear of 3-Section Boom 9. Adjust boom positions to obtain clearances between boom sections as shown in Fig. 6-96. Measure these clearances at the slide pad locations. 0.030"–0.063" (1/32"–1/16") gap between pads and boom Rear of Boom, Looking Forward J1063 Fig. 6-97: Gaps Between Pads and Boom – Rear of 3-Section Boom 10. (Ref. Fig.
Boom and Transfer 0.750"–0.813" (3/4"–13/16") 0.688"–0.750" (11/16"–3/4") J1064 Fig. 6-98: Clearances Between Boom Sections – Front of 3-Section Boom 11. Adjust boom positions to obtain clearances between boom sections as shown in Fig. 6-98. Measure these clearances at the slide pad locations. 0.030"–0.063" (1/32"–1/16") gap between pads and boom J1065 Fig.
Boom and Transfer 12. (Ref. Fig. 6-99) Install/remove shim(s) under the indicated pads to obtain specified clearances. 13. Extend the boom and lubricate as per previous instructions. 14. Check the boom extension and retraction for binding against slide pads. Inspection Procedures 3-Section Boom These procedures are intended to determine if localized deformation has occurred on the inner and middle boom sections. 1. Extend the boom and lower the forks to the ground. 12 3/8" (12.38") Max. 3/16" (0.
Boom and Transfer 14 3/8" (14.38") Max. 3/16" (0.19") 1/4" (0.25") Max. J1085 Fig. 6-101: Middle Boom Cross-Section at Window 4. (Ref. Fig. 6-101) Place a straight edge against the bottom surface of the middle boom section. Measure the distance from the straight edge to the bottom surface of the boom tube. This distance should not exceed 1/4" (0.25"). The maximum deflection will be found just in front of the outer boom section. 5. (Ref. Fig.
Boom and Transfer 644B-42 (S/N 101–141) 844C-42 (S/N 101–433) 1044C-42 (S/N 101–110) 6K-42 (S/N 101–113) 8K-42 (S/N 101–192) 2 6 3 7 1 10 9 5 J1279 4 8 # 1 2 3 4 5 Description Upper Chain Locknut Flatwasher Chain Anchor Rod Locknut # 6 7 8 9 10 Description Chain Adjustment Anchor Flatwasher Nut Lockwasher Jam Nut Fig. 6-102: Upper Chains - First Type First Type (Ref. Fig. 6-102) a.
Boom and Transfer 644B-42 (S/N 142–264) 844C-42 (S/N 434–856) 1044C-42 (S/N 111–120) 6K-42 (S/N 114–137) 8K-42 (S/N 193–)273 10K-42 (S/N 101–108) 3 8 4 7 6 10 11 12 2 9 1 6 J1278 5 # 1 2 3 4 5 6 Description Upper Chain Locknut Chain Anchor Shoulder Bolt Locknut Chain Equalizer # 7 8 9 10 11 12 Description Flatwasher Shoulder Bolt Chain Adjustment Anchor Jam Nut Lockwasher Nut Fig. 6-103: Upper Chains - Second Type Second Type (Ref. Fig. 6-103) a.
Boom and Transfer 644B-42 (S/N 265–) 844C-42 (S/N 857–) 1044C-42 (S/N 121–) 6K-42 (S/N 138–) 8K-42 (S/N 274–) 10K-42 (S/N 109–) 3 11 7 8 9 6 5 2 12 13 4 10 14 16 15 J1277 1 # 1 2 3 4 5 6 7 8 Description Upper Chain Locknut Chain Anchor Shoulder Bolt Flatwasher Shoulder Bolt Shoulder Bolt Flatwasher # 9 10 11 12 13 14 15 16 Description Chain Equalizer Chain Adjustment Anchor Jam Nut Lockwasher Nut Chain Equalizer Locknut Locknut Fig. 6-104: Upper Chains - Third Type Third Type (Ref. Fig.
Boom and Transfer 1 2 3 2 1 6 4 # Description # 1 2 3 4 Shim Guide Washer Chain Roller Assembly Chain Roller Pin 5 6 7 8 8 J1088 7 5 Description Middle Boom Section Lock Pin Lockwasher Bolt Fig. 6-105: Upper Chain Roller 7. (Ref. Fig. 6-105) Remove the capscrew (Item 8), lockwasher (Item 7), and lock pin (Item 6) from the chain roller pin (Item 4). Remove the chain roller pin, shims (Item 1), guide washers (Item 2), and chain roller assembly (Item 3).
Boom and Transfer 1 2 J1098 3 # 1 2 Description Auxiliary Hydraulic Hoses Carriage Tilt Hoses # 3 Description Hydraulic Tubes Fig. 6-107: Rear Hose Connections, Inner Boom 9. (Ref. Fig. 6-107) Tag and disconnect carriage tilt (Item 2) and auxiliary hydraulic hoses (Item 1) from hydraulic tubes (Item 3) at rear of the inner boom section. Cap hoses and tubes. Lay the hoses down at the rear of the outer boom section.
Boom and Transfer 1 2 2 0 4 0 6 0 8 0 3 0 J1091 4 J1280 -2 0 # 1 2 Description # Button Head Socket Capscrew Lockwasher 3 4 Description Shim Slide Pad Fig. 6-108: Front Slide Pads, Outer Boom 12. (Ref. Fig. 6-108) Remove the slide pads, shims, and attaching hardware (Items 1 thru 4) from the top and sides of the outer boom section. 1 2 4 J1095 3 # 1 2 Description Outer Boom Section Anchor Base # 3 4 Description Capscrew Lockwasher Fig.
Boom and Transfer 13. (Ref. Fig. 6-109) Remove six (6) capscrews (Item 3) and lockwashers (Item 4) securing the anchor base (Item 2) to the outer boom section (Item 1). 1 2 3 # 1 2 Description Anchor Base Capscrew J1094 4 # Description 3 4 Lockwasher Chain Adjustment Rod Fig. 6-110: Lower Chain Adjustment Rod 14. (Ref. Fig. 6-110) Remove capscrew (Item 2) and lockwasher (Item 3). Remove chain adjustment rod (Item 4) by turning counterclockwise until free. Remove the anchor base (Item 1).
Boom and Transfer 1 2 3 6 J1093 5 4 # 1 2 3 Description Inner Boom Section Setscrew Extension Cylinder # 4 5 6 Description Nut Washer Support Bracket Fig. 6-111: Rod End of Extension Cylinder 15. (Ref. Fig. 6-111) Loosen two (2) setscrews (Item 2) and remove extension cylinder nut (Item 4) and washer (Item 5). Place blocks between extension cylinder (Item 3) and support bracket (Item 6) to prevent damage to cylinder during disassembly. 16.
Boom and Transfer 2 1 4 5 1 2 3 Description Bulkhead Elbows Auxiliary Hydraulic Hoses Carriage Tilt Hoses # 4 5 6 J1092 5 6 # 3 6 Description Access Cover Lockwasher Capscrew Fig. 6-112: Hose Connections, Outer Boom 17. (Ref. Fig. 6-112) Remove three (3) capscrews (Item 6) and lockwashers (Item 5) from each access cover (Item 4) to the outer boom section. Remove the access covers. 18. Park the machine on a firm, level surface.
Boom and Transfer 1 2 3 4 J1077 # 1 2 Description Auxiliary Hydraulic Hoses Carriage Tilt Hoses # 3 4 Description Boom Extension Hoses Boom Extension Cylinder Fig. 6-113: Hose Connections, 3-Section Boom 21. (Ref. Fig. 6-113) Disconnect hoses from the tubes at the rear of the outer boom section as follows. a. Tag and disconnect two (2) boom extension hoses (Item 3) at the rear of the inner boom. Cap the tubes and hoses. b.
Boom and Transfer Hook chains at these areas 1 1 2 3 4 8 2 5 3 7 6 J1072 # 1 2 3 4 Description Lock Pin Lockwasher Capscrew Pivot Pin, Rear Carriage Tilt Cyl. # 5 6 7 8 Description Pivot Pin, Boom Hoist Cylinder Rear Carriage Tilt Cylinder Boom Hoist Cylinder Boom Fig. 6-114: Cylinder Pivot Pins 23. (Ref. Fig.
Boom and Transfer 26. (Ref. Fig. 6-114) Continue with each of the two (2) hoist cylinders (Item 7) by using a slide hammer puller threaded into the pivot pin (Item 5) to remove it. After the pivot pin has been removed, allow the cylinder to swing down and away from the boom. 3 4 1 2 4 1 2 3 7 5 6 5 J1076 # 1 2 3 4 Description Nut Lockwasher Boom Pivot Pin Capscrew # 5 6 7 Description Shims Transfer Carriage/Boom Cradle Outer Boom Section Fig. 6-115: 3-Section Boom Pivot Pins 27. (Ref. Fig.
Boom and Transfer 29. (Ref. Fig. 6-115) Carefully lift the outer boom (Item 7) clear of the transfer carriage/boom cradle (Item 6). 30. Swing the boom away from the machine and position it above a firm, level surface. 31. (Ref. Fig. 6-112) Tag and disconnect the carriage tilt (Item 3) and auxiliary hydraulic hoses (Item 2) at the bulkhead elbows (Item 1). Cap hoses and fittings. 2 3 J1092 1 # 1 2 Description Swivel Elbows Auxiliary Hydraulic Tubes # 3 Description Carriage Tilt Tubes Fig.
Boom and Transfer 3 5 5 6 7 16 View A – Models with Outriggers (Early Production Models) 4 0 6 0 8 0 17 18 2 0 -2 0 15 0 J1290 1 2 11 12 13 14 8 9 10 # 1 2 3 4 5 6 7 8 9 Description Capscrew Cylinder Stop Lockwasher Nut Capscrew Lockwasher Nut Cylinder Support Bracket Lockwasher View B – Models with Outriggers # 10 11 12 13 14 15 16 17 18 Description Capscrew Cylinder Stop Capscrew Lockwasher Nut Capscrew Lockwasher Hydraulic Tube Boom Extension Cylinder Fig.
Boom and Transfer 5 9 6 8 7 7 8 6 5 1 2 4 3 J1089 10 # 1 2 3 4 5 Description Nut Lockwasher Tube in Boom Bolt Bolt # 6 7 8 9 10 Description Lockwasher Special Washer Guide Washer Hose Tensioner Middle Boom Section Fig. 6-118: Hose Tensioner 35. (Ref. Fig. 6-118) Remove the hose tensioner from the middle boom section as follows: a. Take care during this step; the hose tensioner is spring-loaded.
Boom and Transfer 4 1 2 J1104 3 # 1 2 Description # Lock Nut Rear Chain Anchor 3 4 Description Shoulder Bolt Lower Chain Fig. 6-119: Attaching Chain to Rear Anchor 36. (Ref. Fig. 6-119) Remove the lower chain (Item 4) from the rear anchor (Item 2) at the rear of the inner boom section by removing the lock nut (Item 1) and shoulder bolt (Item 3).
Boom and Transfer J1090 37. (Ref. Fig. 6-120) Remove the rear chain roller assembly from the rear of the middle boom section. Fig. 6-121: Rear Slide Pads, Middle Boom Section 38. (Ref. Fig. 6-121) Remove slide pads, shims, and attaching hardware at the rear of the middle boom section. 39. Support the inner boom section. J1099 W Fig. 6-122: Front Slide Pads, Middle Boom 40. (Ref. Fig. 6-122) Remove eight (8) slide pads and attaching hardware from the front of the middle boom section. 41.
Boom and Transfer 5 6 7 8 1 9 10 2 3 J1100 4 # 1 2 3 4 5 Description Upper Chains Lock Nut Rear Chain Anchor Shoulder Bolt Lock Nut # 6 7 8 9 10 Description Lockwasher Capscrew Lower Chain Chain Anchor Rod Lock Nut Fig. 6-123: Rear Chain Anchor 42. (Ref. Fig. 6-123) Remove the upper and lower chains from the inner boom section as follows: a. Remove a lock nut (Item 5) from the upper chain anchor rod (Item 9). Remove the anchor rod from rear chain anchor (Item 3).
Boom and Transfer 1 2 3 4 6 5 7 10 J1283 9 8 # 1 2 3 4 5 Description Upper Slide Pad Shim Pad Retainer Flatwasher Lockwasher # 6 7 8 9 10 Description Capscrew Shim Slide Pad Lockwasher Button Head Socket Capscrew Fig. 6-124: Rear Slide Pads, Inner Boom 43. (Ref. Fig. 6-124) Remove slide pads from the rear of the inner boom section as follows: a.
Boom and Transfer 2 3 1 5 4 12 2 13 10 11 89 6 14 15 7 16 J1284 16 # 1 2 3 4 5 6 7 8 Description Auxiliary Hydraulic Hoses Cushion Clamp Auxiliary Hydraulic Tubes Carriage Tilt Hydraulic Hoses Carriage Tilt Hydraulic Tubes Capscrew Quick Disconnect Coupler Lockwasher # Description 9 10 11 12 13 14 15 16 Nut Front Carriage Tilt Cylinder Base End Pin Lock Pin Lockwasher Capscrew Inner Boom Section Quick Attach Pivot Boom Bushing Fig. 6-125: Front Carriage Tilt Cylinder 44. (Ref. Fig.
Boom and Transfer 50. Turn the inner boom upside down. 51. (Ref. Fig. 6-125) Remove the capscrew (Item 14), lockwasher (Item 13), and lock pin (Item 12) securing the base end pin (Item 11) to the inner boom section. 52. (Ref. Fig. 6-125) Remove the base end pin and the front carriage tilt cylinder. 53. (Ref. Fig. 6-125) Remove the two (2) quick attach pivot pin bushings (Item 16) from the inner boom section. Assembly and Installation 3-Section Boom 1.
Boom and Transfer 5 6 7 8 1 9 10 2 3 J1100 4 # 1 2 3 4 5 Description Upper Chains Lock Nut Rear Chain Anchor Shoulder Bolt Lock Nut # 6 7 8 9 10 Description Lockwasher Capscrew Lower Chain Chain Anchor Rod Lock Nut Fig. 6-126: Rear Chain Anchor 10. (Ref. Fig. 6-126) Install the upper chains to the inner boom section as follows: a. Install three (3) lockwashers (Item 6) and capscrews (Item 7) to secure the rear chain anchor (Item 3) to the rear of the inner boom section.
Boom and Transfer 12 3 4 5 6 8 7 J1287 10 9 # 1 2 3 4 5 Description # Button Head Socket Capscrew Lockwasher Side Slide Pad Shim Lower Slide Pad 6 7 8 9 10 Description Shim Pad Retainer Flatwasher Lockwasher Capscrew Fig. 6-127: Front Slide Pads, Middle Boom 13. (Ref. Fig. 6-127) Install the front slide pads and shims in the middle boom section according to drawing specifications. See “Shimming Procedures” on page 6-91 for details. a. Install the lower shims (Item 6) and slide pads (Item 5).
Boom and Transfer 14. (Ref. Fig. 6-128) Install rear slide pads and shims on the inner boom section according to drawing specifications. See “Shimming Procedures” on page 6-91 for details. a. Install the upper shims (Item 2) and slide pads (Item 1). Install each pad retainer (Item 3) with a flatwasher (Item 4), lockwasher (Item 5), and capscrew (Item 6). Torque the capscrew to 200 ft-lbs. b.
Boom and Transfer 1 2 3 4 5 4 3 2 1 7 9 J1289 8 6 # 1 2 3 4 5 Description Shim Chain Guide Washer Chain Roller Bushing Hardened Bushing Chain Roller # 6 7 8 9 Description Chain Roller Pin Lock Pin Lockwasher Capscrew Fig. 6-130: Chain Roller Installation, Middle Boom 16. (Ref. Fig. 6-130) Install the chain roller assembly on the front of the middle boom section as follows: a.
Boom and Transfer 5 6 7 8 1 9 10 2 3 J1100 4 # 1 2 3 4 5 Description Upper Chains Lock Nut Rear Chain Anchor Shoulder Bolt Lock Nut # 6 7 8 9 10 Description Lockwasher Capscrew Lower Chain Chain Anchor Rod Lock Nut Fig. 6-131: Lower Chain Installation 17. (Ref. Fig. 6-131) Install the lower chain to the inner boom section as follows: a. Unless a new chain is being installed, lubricate the lower chain with EP lithium based grease. b.
Boom and Transfer Right Hand Side Slot 2 6 3 5 4 J1106 1 # 1 2 3 Description # Middle Boom Section Nut Lockwasher 4 5 6 Description Tube in Boom Bolt Hose Tensioner Fig. 6-132: Hose Tensioner Mounting 18. (Ref. Fig. 6-132) Install the hose tensioner on the rear of the middle boom section as follows: a. Orient the hose tensioner (Item 6) with slot to the right and insert tensioner into tube (Item 4) in middle boom section (Item 1). b.
Boom and Transfer 19. (Ref. Fig. 6-133) Position chain adjustment block (Item 3) tight against back of anchor base (Item 2) as shown. Thread the chain adjustment rod (Item 1) into the block until the specified measurement is obtained. Push the adjustment rod fully into the anchor base. 20. With the outer boom still upside down, install the inclinometer. See page 6-60.
Boom and Transfer 2). Secure cylinder stop to extension cylinder with capscrew (Item 1), lockwasher (Item 3), and nut (Item 4) Torque nut to 276 in-lbs. 3). Torque the two (2) cylinder stop nuts (Item 7) to 276 in-lbs. For all other models (see View B), 1). Install the cylinder stop (Item 11) on the boom extension cylinder with a capscrew (Item 12), lockwasher (Item 13), and nut (Item 14). 2). Torque the cylinder stop nut (Item 14) to 276 in-lbs. b.
Boom and Transfer 23. (Ref. Fig. 6-135) Install the auxiliary and carriage tilt hydraulic tubes (Items 2 and 3) on the swivel elbows (Item 1) in the outer boom. Torque the auxiliary tube swivel nuts to 50–58 ft-lbs and the carriage tilt tube swivel nuts to 79–88 ft-lbs. Secure the hydraulic tubes to the boom section with cushion clamps.
Boom and Transfer 3 4 1 2 4 1 2 3 7 5 6 5 J1076 # 1 2 3 4 Description Nut Lockwasher Boom Pivot Pin Capscrew # 5 6 7 Description Shims Transfer Carriage/Boom Cradle Outer Boom Section Fig. 6-137: 3-Section Outer Boom Installation 27. (Ref. Fig. 6-137) Partially insert two (2) boom pivot pins (Item 3) to temporarily secure the boom pivot. Check gaps between the boom pivot boss and the matching bosses in the transfer carriage/boom cradle.
Boom and Transfer Hook chains at these areas 1 1 2 3 4 8 2 5 3 7 6 J1072 # 1 2 3 4 Description Lock Pin Lockwasher Capscrew Pivot Pin, Rear Carriage Tilt Cyl. # 5 6 7 8 Description Pivot Pin, Boom Hoist Cylinder Rear Carriage Tilt Cylinder Boom Hoist Cylinder Boom Fig. 6-138: Cylinder Pivot Pin Installation 29. (Ref. Fig. 6-138) Align the rod-end of a boom hoist cylinder (Item 7) with the matching boss on the boom.
Boom and Transfer 1 2 3 4 J1077 # 1 2 Description Auxiliary Hydraulic Hoses Carriage Tilt Hoses # 3 4 Description Boom Extension Hoses Boom Extension Cylinder Fig. 6-139: Hose Connections, 3-Section Boom 31. (Ref. Fig. 6-139) Connect the two (2) auxiliary hydraulic hoses (Item 1) and two (2) carriage tilt hoses (Item 2) to the rear of the boom. Torque the hose swivel nuts to 79–88 ft-lbs. 32. (Ref. Fig. 6-139) Connect the two (2) boom extension hoses (Item 3) to the boom extension cylinder lines.
Boom and Transfer 1 2 3 6 J1093 5 4 # 1 2 3 Description # Inner Boom Section Setscrew Extension Cylinder 4 5 6 Description Extension Cylinder Rod Nut Washer Support Bracket Fig. 6-140: Rod End of Extension Cylinder 37. (Ref. Fig. 6-140) Install the washer (Item 5) and extension cylinder rod nut (Item 4) on the boom extension cylinder rod (Item 3). Torque the nut to 1,641 ft-lbs. Secure the nut with two setscrews (Item 2).
Boom and Transfer 38. (Ref. Fig. 6-141) Install the anchor base assembly to the bottom of the middle boom section with six (6) lockwashers and capscrews. Install the shortest capscrew in the hole illustrated above. Torque this capscrew to 280 ft-lbs. Torque the other five (5) capscrews to 200 ftlbs. 1 2 2 0 4 0 6 0 8 0 3 0 J1280 -2 0 J1091 4 # 1 2 Description Button Head Socket Capscrew Lockwasher # 3 4 Description Shim Slide Pad Fig. 6-142: Front Slide Pads Installation, Outer Boom 39. (Ref.
Boom and Transfer 4 3 2 J1105 1 # 1 2 Description Capscrew Lockwasher # Description 3 4 Chain Adjustment Rod Anchor Base Fig. 6-143: Securing Lower Chain 40. (Ref. Fig. 6-143) Adjust the lower chain by tightening the chain adjustment rod (Item 3). Stop tightening just prior to the chain being taunt. Align the notch in the head of adjustment rod (Item 3) with the threaded hole in anchor base (Item 4). Secure the adjustment rod with a lockwasher (Item 2) and capscrew (Item 1).
Boom and Transfer 644B-42 (S/N 101–141) 844C-42 (S/N 101–433) 1044C-42 (S/N 101–110) 6K-42 (S/N 101–113) 8K-42 (S/N 101–192) 2 6 3 7 1 10 9 5 J1279 4 8 # 1 2 3 4 5 Description Upper Chain Locknut Flatwasher Chain Anchor Rod Locknut # 6 7 8 9 10 Description Chain Adjustment Anchor Flatwasher Nut Lockwasher Jam Nut Fig. 6-144: Upper Chains - First Type First Type (Ref. Fig. 6-144) a.
Boom and Transfer 644B-42 (S/N 142–264) 844C-42 (S/N 434–856) 1044C-42 (S/N 111–120) 6K-42 (S/N 114–137) 8K-42 (S/N 193–)273 10K-42 (S/N 101–108) 3 8 4 7 6 10 11 12 2 9 1 6 J1278 5 # 1 2 3 4 5 6 Description Upper Chain Locknut Chain Anchor Shoulder Bolt Locknut Chain Equalizer # 7 8 9 10 11 12 Description Flatwasher Shoulder Bolt Chain Adjustment Anchor Jam Nut Lockwasher Nut Fig. 6-145: Upper Chains - Second Type Second Type (Ref. Fig. 6-145) a.
Boom and Transfer 644B-42 (S/N 265–) 844C-42 (S/N 857–) 1044C-42 (S/N 121–) 6K-42 (S/N 138–) 8K-42 (S/N 274–) 10K-42 (S/N 109–) 3 11 7 8 9 6 5 2 12 13 4 10 14 16 15 J1277 1 # 1 2 3 4 5 6 7 8 Description Upper Chain Locknut Chain Anchor Shoulder Bolt Flatwasher Shoulder Bolt Shoulder Bolt Flatwasher # 9 10 11 12 13 14 15 16 Description Chain Equalizer Chain Adjustment Anchor Jam Nut Lockwasher Nut Chain Equalizer Locknut Locknut Fig. 6-146: Upper Chains - Third Type Third Type (Ref. Fig.
Boom and Transfer 1 2 J1098 3 # 1 2 Description Auxiliary Hydraulic Hoses Carriage Tilt Hydraulic Hoses # 3 Description Hydraulic Tubes Fig. 6-147: Rear Hose Connections, Inner Boom 42. (Ref. Fig. 6-147) Install the auxiliary (Item 1) and carriage tilt (Item 2) hydraulic hoses to the hydraulic tubes (Item 3) at the rear of the inner boom section. Torque the auxiliary hose swivel nuts to 50–58 ft-lbs. Torque the carriage tilt hose swivel nuts to 79–88 ft-lbs. 43.
Boom and Transfer 2 1 4 5 1 2 3 Description Bulkhead Elbows Auxiliary Hydraulic Hoses Carriage Tilt Hydraulic Hoses # 4 5 6 J1092 5 6 # 3 6 Description Access Cover Lockwasher Capscrew Fig. 6-148: Access Cover Installation, Outer Boom 49. (Ref. Fig. 6-148) Install each access cover (Item 4) on the outer boom section with three (3) lockwashers (Item 5) and capscrews (Item 6). Torque the capscrews to 276 in-lbs.
Boom and Transfer Extension Cylinder 3-Section Boom 20 40 60 80 Description 0 J1133 -20 Fig. 6-150: 3-Section Boom Extension Cylinder (Ref. Fig. 6-150) The boom extension cylinder controls extension and retraction of the boom. For models with a 3-section boom, it is located beneath the outer boom. Operating pressure is 3000 psi.
Boom and Transfer Removal, Boom Extension Cylinder 17 13 14 5 14 18 15 16 19 View A – Models with Outriggers (Early Production Models) 12 11 10 20 J1131 40 60 80 4 -20 0 1 20 9 8 7 3 2 6 23 22 21 View B – Models with Outriggers # 1 2 3 4 5 6 7 8 9 10 11 12 Description Washer Extension Cylinder Rod Nut Socket Setscrew Middle Boom Section Outer Boom Section Capscrew Lockwasher Cylinder Support Bracket Boom Extension Cylinder Hydraulic Tube Lockwasher Capscrew # 13 14 15 16 17 18 19 20 21
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing support bracket and other hardware that secure the cylinder to the boom. Use suitable blocking and lifting devices when removing heavy machine components. 6. Place blocks between the extension cylinder and the support bracket (Item 8) to prevent damage to the cylinder during removal. 7. Retract the extension cylinder. 8.
Boom and Transfer 1). Install cylinder stop halves (Item 14) on extension cylinder with two (2) each capscrews (Item 17), lockwashers (Item 18), and nuts (Item 19). Partially tighten the nuts. 2). Secure cylinder stop to extension cylinder with capscrew (Item 13), lockwasher (Item 15), and nut (Item 16) Torque nut to 276 in-lbs. 3). Torque the two (2) cylinder stop nuts (Item 19) to 276 in-lbs. b. For all other models (see View B), 1).
Boom and Transfer Overhaul, Extension Cylinder 4 5 3 10 2 9 6 7 J1132 1 8 # 1 2 3 4 5 Description Hollow Hex O-ring Plug Counterbalance Valve Cartridge Counterbalance Valve Cartridge Cylinder Barrel Rod Nut # 6 7 8 9 10 Description 90° O-ring Elbow Piston Rod Bearing Head Capscrew Cylinder Rod Fig. 6-152: 3-Section Boom Extension Cylinder Assembly (Ref. Fig. 6-152) The following steps are required to overhaul the boom extension cylinder. 1.
Boom and Transfer 5. Remove eight (8) capscrews (Item 9) securing rod bearing head (Item 8) to cylinder barrel. 6. Remove cylinder rod (Item 10) from cylinder barrel (Item 4). CAUTION: To prevent possible damage to components, support rod and head; do not wiggle rod or head back and forth during removal. 7. Remove rod nut (Item 5), piston (Item 7), and rod bearing head from cylinder rod. 8. Remove the two (2) elbows (Item 6) from the cylinder manifold block. 9.
Boom and Transfer 23. Lubricate threads on eight (8) capscrews (Item 9) with hydraulic oil. Coat inside of barrel (Item 4) with hydraulic oil. To avoid damaging seals during assembly, carefully insert rod and head into barrel. Install capscrews until snug. Do not torque capscrews (instructions follow). 24. Following sequence shown in Fig. 6-10, torque capscrews to an initial value of 30 ft-lbs. Follow sequence again and torque capscrews to a final value of 90 ft-lbs. 25.
Boom and Transfer Shimming Procedures 4-Section Boom 2 20 40 60 80 2 -20 2 0 1 1 2 40 60 80 2 3 20 -20 0 2 2 2 2 1 1 4 2 1 2 J1160 2 2 NOTES: Items 1 and 3 are load bearing pads Item 4 is included with the following models only: 1044C-54 (S/N 117–) and 10K-54 (S/N 104–) # Description # 1 2 3 Boom Pad, 1" Thick x 3" Wide Boom Pad, 9/16" Thick x 2" Wide Boom Pad, 3/4" Thick x 3" Wide 4 Description Boom Pad, 3/4" Thick x 1-1/4" Wide Fig.
Boom and Transfer Install shim(s) under these pads J1162 3. (Ref. Fig. 6-155) Measure the gap between boom sections at all upper front pads. If the dimensions are not within the specified range, proceed to Step 4. If the dimensions are within the specified range, proceed to Step 5. Fig. 6-156: Lower Shim Installation – Front of 4-Section Boom 4. (Ref. Fig. 6-156) Install/remove shim(s) under indicated pads to obtain clearances specified in Step 3. 0.06"–0.12" (1/16"–1/8") gap between boom and pad 0.
Boom and Transfer 5. (Ref. Fig. 6-157) Install/remove shim(s) under indicated pads to obtain specified clearances. This dimension cannot be adjusted 1.22"–1.47" (1-7/32"–1-15/32") J1156 1.04"–1.10" (1-3/64"–1-7/64") Fig. 6-158: Boom Section Gaps – Rear of 4-Section Boom Install shim(s) under these pads J1157 6. (Ref. Fig. 6-158) Measure the gaps between the inner, middle (forward), and middle (rear) sections at the upper pads.
Boom and Transfer 0.06" (1/16") J1158 0.07" (1/16") Fig. 6-160: Upper Shim Installation – Rear of 4-Section Boom 8. (Ref. Fig. 6-160) Install/remove shim(s) under indicated pads to obtain specified clearances. 0.47–0.53" (15/32"– 17/32") 0.47–0.53" (15/32"– 17/32") 0.72"–0.78" (23/32"– 25/32") 0.72"–0.78" (23/32"– 25/32") 0.595"–0.655" (19/32"– 21/32") J1187 0.595"–0.655" (19/32"– 21/32") Rear of Boom, Looking Forward Fig. 6-161: Clearances Between Boom Sections – Rear of 4-Section Boom 9.
Boom and Transfer 0.02"–0.08" (1/64"–5/64") 0.02"–0.08" (1/64"–5/64") 0.03"–0.09" (1/32"–3/32") 0.03"–0.09" (1/32"–3/32") 0.03"–0.09" (1/32"–3/32") J1188 0.03"–0.09" (1/32"–3/32") Rear of Boom, Looking Forward Fig. 6-162: Gaps Between Pads and Boom – Rear of 4-Section Boom 10. (Ref. Fig. 6-162) Install/remove shim(s) under indicated pads to obtain specified clearances making sure clearances on both sides of each boom section are the same. 0.47–0.53" (15/32"– 17/32") 0.595"–0.
Boom and Transfer 11. (Ref. Fig. 6-163) Adjust boom positions to obtain clearances between boom sections as shown. Measure these clearances at the slide pad locations. 0.06"–0.12" (1/16"–1/8") 0.02"–0.08" (1/64"–5/64") 0.04"–0.10" (3/64"–7/64") 0.06"–0.12" (1/16"–1/8") Front of Boom, Looking Rearward 0.06"–0.12" (1/16"–1/8") J1190 0.02"–0.08" (1/64"–5/64") 0.06"–0.12" (1/16"–1/8") Fig. 6-164: Gaps Between Pads and Boom – Front of 4-Section Boom 12. (Ref. Fig.
Boom and Transfer 10 5/8" (10.625") 3/16" (0.19") J1085 1/4" (0.25") Max. Fig. 6-165: Inner Boom Cross-Section at Window 2. (Ref. Fig. 6-165) Place a straight edge against the bottom surface of the inner boom section. Measure the distance from the straight edge to the bottom surface of the boom tube. This distance should not exceed 1/4" (0.25"). The maximum deflection will be found just in front of the middle (forward) boom section. 3. (Ref. Fig.
Boom and Transfer 4. (Ref. Fig. 6-166) Place a straight edge against the bottom surface of the middle (forward) boom section. Measure the distance from the straight edge to the bottom surface of the boom tube. This distance should not exceed 1/4" (0.25"). The maximum deflection will be found just in front of the middle (rear) boom section. 5. (Ref. Fig. 6-166) The side walls may also deflect outward at the window areas. Take this measurement across the middle (forward) boom tube, through the windows.
Boom and Transfer 1 2 3 J1169B 4 # 1 2 Description # Nut Lockwasher 3 4 Description Flatwasher Boom Cover Fig. 6-168: 4-Section Boom Cover Installation 5. (Ref. Fig. 6-168) Remove six (6) each nuts (Item 1), lockwashers (Item 2), and flatwashers (Item 3) securing boom cover (Item 4) to boom. Remove boom cover. 6. Remove boom elevation proximity switch. See “Boom Elevation Proximity Switch” in Section 7. 7. Remove boom extension proximity switch. See Step 8 on page 6-220.
Boom and Transfer 8. (Ref. Fig. 6-169) Tag and disconnect two (2) hoses at boom extension cylinder lines (Item 3). Cap lines and hoses. Note: “K” Model machines are not equipped with auxiliary hydraulics. For these models, disregard procedures that refer to auxiliary hydraulic components. 9. Tag and disconnect two (2) carriage tilt hoses (Item 2), and two (2) auxiliary hydraulics hoses (Item 1) at the boom. Cap hoses and lines. 10. Place sling around inner boom section, at the front.
Boom and Transfer CAUTION: Make sure each cylinder is fully supported so it does not fall and cause personal or equipment damage when it is being removed. 12. (Ref. Fig. 6-170) Starting at a rear carriage tilt cylinder (Item 6), use a slide hammer puller threaded into the pivot pin (Item 4) to remove the pivot pin from boom. After the pivot pin has been removed, allow the cylinder to swing down and away from the boom.
Boom and Transfer 2 4 3 1 6 5 7 J1245 8 # 1 2 3 4 Description # Shim Rear Upper Slide Pad Pad Retainer Lockwasher 5 6 7 8 Description Flatwasher Capscrew Lockwasher Button-Head Socket Capscrew Fig. 6-172: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section 16. (Ref. Fig. 6-172) Remove upper rear slide pads from middle (front) boom section as follows: a.
Boom and Transfer 17. (Ref. Fig. 6-173) Remove upper rear slide pads from inner boom section as follows: a. Remove two (2) each capscrews (Item 6), lockwashers (Item 5), flatwashers (Item 4), and pad retainers (Item 3) from rear of inner boom section. 20 -20 0 J1268 Locations for Chain Attachment 40 60 80 b. Remove four (4) capscrews (Item 8) and lockwashers (Item 7) securing upper slide pads (Item 2) to rear of inner boom section. Remove the two (2) slide pads. Fig.
Boom and Transfer 3 2 4 1 1 2 5 4 3 5 5 7 J1222 6 # 1 2 3 4 Description Nut Lockwasher Boom Pivot Pin Bolt # 5 6 7 Description Shims Transfer Carriage/Boom Cradle Boom Assembly Fig. 6-175: 4-Section Boom Pivot Pins 19. (Ref. Fig. 6-175) Remove two (2) each nuts (Item 1), lockwashers (Item 2), and capscrews (Item 4) from boom pivot pins (Item 3). CAUTION: Make sure slings and chains are secure and crane is supporting the weight of the boom. 20. (Ref. Fig.
Boom and Transfer installation 4-Section Boom 1. Prepare replacement boom for installation by removing strapping and blocks used for shipment. Note location of straps and blocks for use on the previously removed boom. 2. With the replacement boom still lying upside down, the front carriage tilt cylinder should be installed at this point. It is easier to install when the boom is in this position. See page 6-19 3. Attach slings/chains to the boom and crane.
Boom and Transfer a. With the outriggers up, extend the boom, noting that Boom Extension proximity light illuminates when the boom is extended to specified distance (approximately 21 feet with tilting tower or 25 feet with standard carriage). If light does not illuminate, stop and retract the boom. See page 6-216 for adjustment procedures. b. Retract and lower boom to ground and shut off engine. c. Complete proximity switch adjustment before proceeding to Step 18. 18.
Boom and Transfer 16 15 1 2 6 5 4 3 7 13 11 10 9 12 11 10 8 5 9 4 14 J1271 6 7 # 1 2 3 4 5 6 7 8 Description Lower Slide Pad Shim Right Hand Retainer Block Pad Retainer Flatwasher Lockwasher Capscrew Left Hand Retainer Block # 9 10 11 12 13 14 15 16 Description Lockwasher Capscrew Lockwasher Upper Slide Pad Shim Capscrew Lockwasher Button-Head Socket Capscrew Fig. 6-176: Slide Pad Removal – Outer Boom Section 3. (Ref. Fig.
Boom and Transfer 1 2 3 4 5 6 # 1 2 3 4 Description Lower Front Slide Pad Shim Capscrew Lockwasher J1270 7 # 5 6 7 Description Pad Retainer Lockwasher Button-Head Socket Capscrew Fig. 6-177: Lower Front Slide Pad Removal – Middle (Rear) Boom Section 4. (Ref. Fig. 6-177) Remove lower front slide pads from middle (rear) boom section as follows: a. Remove two (2) each capscrews (Item 3), lockwashers (Item 4), and pad retainers (Item 5) from rear of middle (rear) boom section. b.
Boom and Transfer 4 5 6 7 8 3 13 14 15 12 1 11 10 2 16 17 9 20 40 60 80 J1227 18 -20 0 1 and 2 7 and 8 10 and 11 J1241 14 and 15 Side View # 1 2 3 4 5 6 7 8 9 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Middle (Front) Boom Section Hose Guard Lockwasher Capscrew Auxiliary Tilt Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section # 10 11 12 13 14 15 16 17 18 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Half Clamp Round Head
Boom and Transfer CAUTION: Be sure to note orientation of the hose guard during removal. Your hose guard may be different from that shown above. If the hose guard is reversed at assembly, equipment damage may occur during operation of machine. b. Loosen and remove hydraulic hoses (two (2) each auxiliary and carriage tilt) (Items 7 and 8) from hydraulic tubes (Items 1 and 2) at rear of middle (front) boom section. Bleed any remaining oil into a suitable container. Tag and cap hoses and tubes. c.
Boom and Transfer 6. (Ref. Fig. 6-179) Remove extension cylinder as follows: a. Support the extension cylinder with sling(s) or other suitable means. Make sure support items have sufficient capacity to support the weight of the cylinder. The extension cylinder weighs 650 pounds. b. Loosen and remove two (2) hydraulic tubes (Item 9) from elbows (Item 8) on boom extension cylinder (Item 5). Bleed any remaining oil into a suitable container. Tag and cap fittings and tubes. c.
Boom and Transfer 1 J1272 2 3 4 # 1 2 Description # Button-Head Socket Capscrew Lockwasher 3 4 Description Shim Upper Front Slide Pad Fig. 6-180: Upper Front Slide Pad Removal – Middle (Rear) Boom Section 9. (Ref. Fig. 6-180) Remove upper front slide pads from middle (rear) boom section as follows: a. Remove two (2) each capscrews (Item 1), lockwashers (Item 2), from front of middle (rear) boom section. b. Remove two (2) slide pads (Item 4) and shims (Item 3).
Boom and Transfer 4 3 2 20 40 60 80 1 0 J1223 -20 # 1 2 Description # Chain Adjustment Anchor Jam Nut Description 3 4 Lockwasher Nut Fig. 6-182: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections 11. (Ref. Fig. 6-182) Remove jam nut (Item 2) and lockwasher (Item 3) securing upper chain adjustment anchor (Item 1) to middle (rear) boom section. 12. Remove chain adjustment anchor from bracket at top of middle (rear) boom section and lay chain over top of inner boom section.
Boom and Transfer 14. (Ref. Fig. 6-183) Remove chain roller pin, two (2) guide washers (Item 1), bushing (Item 2), chain roller (Item 3), and chain roller bushing (Item 4). 5 4 1 3 2 6 8 J1229 7 # 1 2 3 4 Description # Inner Boom Upper Chain Lock Nut Lockwasher 5 6 7 8 Description Capscrew Lower Chain Shoulder Bolt Rear Chain Anchor Fig. 6-184: Disconnecting Chains at Rear of Inner Boom 15. (Ref. Fig. 6-184) Disconnect chains from rear of inner boom as follows: a.
Boom and Transfer 16. (Ref. Fig. 6-185) Disconnect chains from rear of middle (forward) boom as follows: a. Remove two (2) lock nuts (Item 2), chain anchor rod (Item 6), and upper chain (Item 1). b. Remove capscrew (Item 4), lockwasher (Item 5), and upper chain anchor (Item 3). c. Remove capscrew (Item 14), lockwasher (Item 15), and hose reel pin (Item 16) securing each of the two (2) hose reels (Item 13) to the rear of the middle (forward) boom section. Remove hose reels. d.
Boom and Transfer 18 11 12 14 15 20 9 19 7 View A 1044C-54 (S/N 101–154) 10K-54 (S/N 101–103) 16 17 1 2 3 12 54 10 9 11 8 J1231 6 13 7 # 1 2 3 4 5 6 7 8 9 10 Description Front Bottom Slide Pad Shim Pad Retainer Flatwasher Lockwasher Capscrew Side Slide Pad Shim Button-Head Socket Capscrew Lockwasher # 11 12 13 14 15 16 17 18 19 20 Description Button-Head Socket Capscrew Lockwasher Middle (Forward) Boom Assy Button-Head Socket Capscrew Lockwasher Shim Rear Bottom Slide Pad Pad Retainer Capsc
Boom and Transfer c. (Ref. Fig. 6-187) Remove lower slide pads from front of middle (forward) boom section as follows: For Models 1044C-54 (S/N 101–154) and 10K-54 (S/N 101–103): 1). Remove two (2) each capscrews (Item 19) and lockwashers (Item 20) along with the pad retainer (Item 18) (see View A). 2). Remove two (2) socket capscrews (Item 9) and lockwashers (Item 10) securing lower slide pads (Item 1) to front of boom section. 3). Remove slide pads and shims (Item 2).
Boom and Transfer 7 8 9 1 10 2 7 3 4 5 J1233 6 # 1 2 3 4 5 Description Grease Fitting Cover Grease Fitting Chain Roller Pin Lock Pin Lockwasher # 6 7 8 9 10 Description Capscrew Chain Guide Washer Bushing Chain Roller Chain Roller Bushing Fig. 6-189: Rear Chain Roller Removal - Middle (Forward) Boom Section 27. (Ref. Fig. 6-189) Remove rear chain roller assembly as follows: a. Remove capscrew (Item 6), lockwasher, (Item 5) and lock pin (Item 4) from chain roller pin (Item 3). b.
Boom and Transfer 6 4 3 5 J1246 2 1 # 1 2 3 Description Auxiliary Hydraulic Hoses Carriage Tilt Hydraulic Hoses Cushion Clamp # 4 5 6 Description Auxiliary Hydraulic Tubes Carriage Tilt Hydraulic Tubes Mounting Channel Fig. 6-190: Hose and Tube Removal – Inner Boom Section 30. (Ref. Fig. 6-190) Remove tubes and hoses from inner boom section as follows: a.
Boom and Transfer 4 3 2 40 60 80 1 5 20 0 J1225 -20 # 1 2 3 Description # Chain Anchor Jam Nut Lockwasher 4 5 Description Nut Outer Boom Section Fig. 6-191: Upper Chain Assembly 31. (Ref. Fig. 6-191) Remove nut (Item 4) and lockwasher (Item 3) securing upper chain anchor (Item 1) to outer boom section (Item 5). Remove upper chain assembly from boom.
Boom and Transfer 32. (Ref. Fig. 6-192) Remove capscrew (Item 9), lockwasher (Item 8), and lock pin (Item 7) from chain roller pin (Item 10). 33. (Ref. Fig. 6-192) Remove chain roller pin along with two (2) each chain guide washers (Item 1), chain roller bushings (Item 2), hardened bushings (Item 3), and the chain roller (Item 4).
Boom and Transfer 7 6 5 8 9 10 11 12 J1232 1 2 3 4 # 1 2 3 4 5 6 Description Front Side Slide Pad Shim Lockwasher Button-Head Socket Capscrew Button-Head Socket Capscrew Lockwasher # 7 8 9 10 11 12 Description Button-Head Socket Capscrew Lockwasher Shim Rear Side Slide Pad Shim Rear Lower Slide Pad Fig. 6-194: Slide Pads – Middle (Rear) Boom Section 36. (Ref. Fig. 6-194) Remove remaining slide pads from middle (rear) boom section as follows: a.
Boom and Transfer 4 3 5 6 7 9 8 10 2 11 12 10 9 4 1 7 5 6 1 2 8 J1238 3 13 14 15 # Description # 1 2 3 4 5 6 7 8 Roller Bushing Washer Capscrew Right Hand Hose Guide Hose Guide Spacer Hose Spacer Plastic Bushing Left Hand Hose Guide 9 10 11 12 13 14 15 Description Lock Nut Chain Roller Washer Hardened Bushing Chain and Hose Roller Chain and Hose Roller Shaft Grease Fitting Grease Fitting Cover Fig. 6-195: Chain and Hose Guide Assembly 37. (Ref. Fig.
Boom and Transfer 1 2 10 3 5 9 8 7 6 4 4 1044C-54 (S/N 101–144 and 148) 10K-54 (S/N 101–102) 1 2 10 5 3 9 8 11 J1239 7 6 1044C-54 (S/N 145–147 and 149–) 10K-54 (S/N 103–) # 1 2 3 4 5 6 Description Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Elbow Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube # 7 8 9 10 11 Description Nut Lockwasher Clamp Cushion Clamp Hydraulic Manifold Block Fig. 6-196: Tubes and Hoses – Middle (Rear) and Outer Boom Sections 38.
Boom and Transfer b. Bleed any remaining oil into a suitable container and remove hoses from inside middle (rear) boom section (Item 3). Tag and cap hoses and fittings. 39. Flip middle (rear) boom section upside down and place on work stands. 40. (Ref. Fig. 6-196) Remove hydraulic tubes from bottom of middle (rear) boom section as follows: a.
Boom and Transfer 3 2 10 9 1 8 7 6 5 4 1044C-54 (S/N 101–144 and 148) 10K-54 (S/N 101–102) 3 2 4 10 9 12 1 13 11 1044C-54 (S/N 145–147, and 149–) 10K-54 (S/N 103–) # 1 2 3 4 5 6 7 Description Outer Boom Section Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Elbow Nut Lockwasher Clamp # 8 9 10 11 12 13 J1240 8 7 6 5 Description Cushion Clamp Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Hydraulic Manifold Block Lockwasher Capscrew Fig. 6-198: Outer Boom Tubes and Hoses 42.
Boom and Transfer b. Remove hoses from inside outer boom section (Item 1). Cap and tag hoses and open ports on manifold blocks. 43. Turn outer boom section over and place it upside down on work stands. 44. (Ref. Fig. 6-198) Remove outer boom hydraulic tubes as follows: For Models 1044C-54 (S/N 101–144 and 148) and 10K-54 S/N 101–102): a. Remove four (4) elbows (Item 4) from auxiliary and front carriage tilt hydraulic tubes (Items 9 and 10). Bleed any remaining oil from tubes into a suitable container.
Boom and Transfer Note: This procedure assumes that the boom has been completely disassembled. In certain areas, references are made to other locations in this manual where specific subjects are covered in detail. Note: “K” Model machines are not equipped with auxiliary hydraulics. For these models, disregard procedures that refer to auxiliary hydraulic components.
Boom and Transfer a. Install two (2) each auxiliary and front carriage tilt hydraulic hoses (Items 2 and 3) on elbows (Item 4). Torque swivel nuts on hoses to 50–58 ft-lbs. b. Install two (2) each auxiliary and front carriage tilt hydraulic tubes (Items 9 and 10) on elbows. Make sure the tube is positioned so that the longest portion of each tube will be close to the bottom of the boom section. Torque swivel nuts on tubes to 50–58 ft-lbs. c. Place hoses through openings in bottom and outer boom section. d.
Boom and Transfer 13 12 14 11 40 60 80 10 20 -20 6 0 9 7 8 4 18 1 2 3 15 16 17 View A 1044C-54 (S/N 101–143) 10K-54 (S/N 101–103) # 1 2 3 4 5 6 7 8 9 Description Rod Nut Socket Setscrew Extension Cylinder Rod Boss Middle (Rear) Boom Section Boom Extension Cylinder Capscrew Flatwasher Elbow Hydraulic Tube # 10 11 12 13 14 15 16 17 18 J1136 5 Description Cushion Clamp Extension Cylinder Base Mount Shim Shim Nut Capscrew Lockwasher Flatwasher Extension Cylinder Base Mount Fig.
Boom and Transfer For Models 1044C-54 (S/N 144–) and 10K-54 (S/N 104–): Use two (2) each nuts (Item 14), flatwashers (Item 7), and capscrews (Item 6) to secure extension cylinder base mount (Item 11) to rear of outer boom section. Install as many shims (Items 12 and 13) as necessary before installing the nuts. Torque nuts to 680 ft-lbs. c. Install two (2) hydraulic tubes (Item 9) on extension cylinder elbows (Item 8). Torque swivel nuts on hydraulic tubes to 79–88 ft-lbs. d.
Boom and Transfer c. Position chain adjustment block tight against back of anchor base (Item 4) at bottom of outer boom section as shown in View A. d. Thread chain adjustment rod (Item 3) into block until specified measurement is obtained. e. Push adjustment rod fully into anchor base. f. Lay chain flat inside of outer boom section. Attach a cord or wire to end of chain for ease in handling after all four sections are assembled. 7. Place middle (rear) boom section upside down on work stands.
Boom and Transfer 1 2 10 3 5 9 8 7 4 4 6 1044C-54 (S/N 101–144 and 148) 10K-54 (S/N 101–102) 1 2 10 5 3 8 7 11 6 12 # 1 2 3 4 5 6 7 Description Auxiliary Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Elbow Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Nut J1239 9 13 1044C-54 (S/N 145–147, and 149–) 10K-54 (S/N 103–) # 8 9 10 11 12 13 Description Lockwasher Clamp Cushion Clamp Hydraulic Manifold Block Lockwasher Capscrew Fig.
Boom and Transfer For Models 1044C-54 (S/N 145–147 and 149–) and 10K-54 (S/N 103–): a. Install auxiliary and front carriage tilt hydraulic tubes (Items 5 and 6) on hydraulic manifold blocks (Item 11). Make sure the tube is positioned so that the longest portion of each tube will be close to bottom of the boom section (Item 3). Torque swivel nut on tubes to 50–58 ft-lbs. b. Install two (2) manifold block on middle (rear) boom section with four (4) lockwashers (Item 12) and capscrews (Item 13).
Boom and Transfer 10. (Ref. Fig. 6-204) Install chain and hose guide assembly on rear of middle (rear) boom section as follows: a. Install two (2) roller bushings (Item 1) inside chain and hose roller (Item 12) — one in each end. b. Install hardened bushing (Item 11) and two (2) chain roller washers (Item 10) on the chain and hose roller. c.
Boom and Transfer a. Install chain adjustment block (Item 5) on lower chain with shoulder bolt (Item 6) and lock nut (Item 7). Torque lock nut to 108 in-lbs. b. Position chain adjustment block tight against back of anchor base (Item 4) at bottom of middle (rear) boom section as shown in View A. c. Thread chain adjustment rod (Item 3) into block until specified measurement is obtained. d. Push adjustment rod fully into anchor base. e. Lay chain flat inside of middle (rear) section.
Boom and Transfer e. Install grease fitting (Item 6) and grease fitting cover (Item 5) on chain roller pin. Tighten the grease fitting 2–3 turns past finger tight. 14. Lift and slide middle (rear) boom section into outer boom section. Release strap securing extension cylinder to outer boom section and install cylinder end through orifice of middle (rear) section. 15. Apply EP lithium based grease to the inside bottom surfaces of middle (rear) boom section (slide pad slide areas). 16.
Boom and Transfer f. Repeat the preceding steps to install chain roller assembly to the rear of the boom section. g. Install upper chain anchor (Item 3) on upper chains (Item 1) with chain anchor rod (Item 6) and two (2) lock nuts (Item 2). Torque lock nuts to 108 in-lbs. h. Install upper chain anchor to rear of boom section with lockwasher (Item 5) and capscrew (Item 4). Make sure the hole in the anchor (where the anchor rod was installed) is positioned toward the front of the boom.
Boom and Transfer a. Install bottom slide pad (Item 17) and shim(s) (Item 16) to rear of boom section with two (2) lockwashers (Item 15) and capscrews (Item 14) according to drawing specifications. Torque capscrews to 180 in-lbs. b. Install two (2) side slide pads (Item 7) and shim(s) (Item 8) to rear of boom section with two (2) each lockwashers (Item 12) and capscrews (Item 11) according to drawing specifications. Torque capscrews to 180 in-lbs. 19. (Ref. Fig.
Boom and Transfer 6 4 3 5 J1246 2 1 # 1 2 3 Description Auxiliary Hydraulic Hoses Carriage Tilt Hydraulic Hoses Cushion Clamp # 4 5 6 Description Auxiliary Hydraulic Tubes Carriage Tilt Hydraulic Tubes Mounting Channel Fig. 6-209: Hydraulic Hose and Tube Installation – Inner Boom Section 23. (Ref. Fig. 6-209) Install auxiliary and front carriage tilt cylinder hydraulic hoses and tubes as follows: a. Connect hydraulic hoses (Item 1) to carriage tilt hydraulic tubes (Item 4).
Boom and Transfer 3 4 3 4 2 J1247 1 # 1 2 Description # Lower Slide Pad Side Slide Pad 3 4 Description Lockwasher Button-Head Socket Capscrew Fig. 6-210: Slide Pad Installation – Inner Boom Section 26. (Ref. Fig. 6-210) After applying thread locking compound to the capscrews, install two (2) lower and two (2) side slide pads (Items 1 and 2) on inner boom section according to drawing specifications with lockwashers (Item 3) and capscrews (Item 4). Torque capscrews to 180 in-lbs.
Boom and Transfer b. Install two (2) bulkhead adapters (Item 4) on rear of inner boom section (Item 2). c. Connect two (2) grease hoses (Item 1) to bulkhead adapters. Torque swivel nuts on grease hoses to 130–150 in-lbs. d. Connect grease hoses to elbows. Torque swivel nuts on grease hose to 130–150 in-lbs. e. Install grease fittings (Item 5) and grease fitting covers (Item 6) on bulkhead adapters (Item 2). Torque grease fittings 2–3 turns past finger tight. 28.
Boom and Transfer 1 2 # 1 2 J1245 3 4 Description # Button-Head Socket Capscrew Lockwasher Description 3 4 Shim Front Upper Slide Pad Fig. 6-213: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section 31. (Ref. Fig. 6-213) After applying thread locking compound to the capscrews, install two (2) upper slide pads (Item 4) and shims (Item 3) on front of middle (forward) boom section with lockwashers (Item 2) and capscrews (Item 1) according to drawing specifications.
Boom and Transfer 33. (Ref. Fig. 6-214) Install upper chains and hose reel assembly on middle (forward) boom section as follows: a. Install two (2) hose reels (Item 7) to rear of boom section with hose reel pins (Item 10). Secure each pin to boom section with lockwasher (Item 9) and capscrew (Item 8). Torque capscrews to 216 in-lbs.
Boom and Transfer 8 9 8 9 6 5 4 3 7 13 14 6 5 6 5 6 10 7 11 1 2 34 8 9 5 10 12 10 11 4 10 2 1 8 5 6 9 6 10 11 J1258 1 2 5 # 1 2 3 4 5 6 7 Description Capscrew Lockwasher Flatwasher Slide Pad Retainer Shim Slide Pad Retainer Block # 8 9 10 11 12 13 14 Description Button-Head Socket Capscrew Lockwasher Lockwasher Capscrew Capscrew Outer Boom Section Middle (Rear) Boom Section Fig. 6-216: Front Slide Pad Installation – Outer and Middle (Rear) Boom Sections 36. (Ref. Fig.
Boom and Transfer 1 2 3 J1255 4 # 1 2 Description # Lock Nut Lower Chain 3 4 Description Shoulder Bolt Rear Chain Anchor Fig. 6-217: Lower Chain Installation – Inner Boom Section 39. Install lower chain (Item 2) from inside middle (rear) boom section to rear chain anchor (Item 4) at rear of inner boom section with shoulder bolt (Item 3) and lock nut (Item 1). Torque lock nut to 108 in-lbs.
Boom and Transfer 4 3 2 60 80 1 40 5 20 -20 0 # 1 2 3 J1225 6 Description # Chain Anchor Jam Nut Lockwasher Description 4 5 6 Nut Outer Boom Section Upper Chain Roller Assembly Fig. 6-219: Upper Chains – Middle (Rear) to Outer Boom Sections 41. (Ref. Fig. 6-219) Secure upper chain to outer boom section as follows: a. Bring upper chain lying on top of middle (front) boom section up and around the upper chain roller assembly (Item 6) on the middle (rear) boom section (Item 5). b.
Boom and Transfer # 1 2 3 Description # Chain Adjustment Anchor Jam Nut Lockwasher 4 5 6 Description Nut Upper Chain Roller Assembly Middle (Forward) Boom Section Fig. 6-220: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections 42. (Ref. Fig. 6-220) Secure upper chain to middle (rear) boom section as follows: a. Bring upper chain lying on top of inner boom section up and around the upper chain roller assembly (Item 5) on the middle (forward) boom section (Item 6). b.
20 40 60 80 Boom and Transfer -20 0 4 1 # 1 2 Description J1253 3 2 # 3 4 Setscrew Description Cylinder Rod Boss Boom Extension Cylinder Fig. 6-222: Securing Boom Extension Cylinder 44. (Ref. Fig. 6-222) Secure extension cylinder (Item 4) to front of middle (rear) boom section with extension cylinder rod boss (Item 3) and rod nut (Item 1). Torque rod nut to 733 ft-lbs. Secure rod nut with two (2) setscrews (Item 2).
Boom and Transfer 4 5 6 7 8 3 13 14 15 12 1 11 10 2 16 17 9 20 40 60 80 J1227 18 -20 0 1 and 2 7 and 8 19 10 and 11 14 and 15 J1241 20 Side View # 1 2 3 4 5 6 7 8 9 10 Description Auxiliary Hydraulic Tube Carriage Tilt Hydraulic Tube Middle (Front) Boom Section Hose Guard Lockwasher Capscrew Auxiliary Tilt Hydraulic Hose Carriage Tilt Hydraulic Hose Middle (Rear) Boom Section Auxiliary Hydraulic Tube # 11 12 13 14 15 16 17 18 19 20 Description Carriage Tilt Hydraulic Tube Half Clamp
Boom and Transfer a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from inside the middle (rear) boom section (Item 9) up and around the two (2) hose reels (Item 19) at the rear of the middle (forward) boom section (Item 3). b. Connect the hydraulic hoses to the hydraulic tubes (Items 1 and 2) at the rear of the inner boom section. Torque swivel nut on hydraulic hoses to 50–58 ft-lbs. c.
Boom and Transfer Extension Cylinder 4-Section Boom 20 40 60 80 Description 0 J1137 -20 Fig. 6-224: 4-Section Boom Extension Cylinder The 4-section boom extension cylinder is located beneath the boom assembly. It is attached from the middle (rear) to the outer boom section. Its operating pressure is 3000 psi and weighs 650 pounds. When completely retracted, it is 149-3/4" long. When fully extended, it is 280-3/4" long.
Boom and Transfer Removal, Extension Cylinder 13 14 20 40 60 80 11 12 0 10 6 7 4 8 9 5 1 2 3 15 16 17 18 J1136 -20 View A 1044C-54 (S/N 101–143) 10K-54 (S/N 101–103) # 1 2 3 4 5 6 7 8 9 Description Rod Nut Socket Setscrew Extension Cylinder Rod Boss Middle (Rear) Boom Section Boom Extension Cylinder Outer Boom Section Capscrew Flatwasher Elbow # 10 11 12 13 14 15 16 17 18 Description Hydraulic Tube Extension Cylinder Base Mount Shim Shim Nut Capscrew Lockwasher Flatwasher Extension Cy
Boom and Transfer DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. To avoid personal and/or equipment damage, support the hydraulic cylinder before removing any additional hardware securing cylinder to the boom. Use suitable blocking and lifting devices when removing heavy machine components. 4. Loosen and remove two (2) hydraulic tubes (Item 10) from elbows (Item 9) on boom extension cylinder (Item 5).
Boom and Transfer 3. Secure cylinder to outer boom section with hardware as follows. For Models 1044C-54 (S/N 101–143) and 10K-54 (S/N 101–103) (See View A): Use two (2) each flatwashers (Item 17), lockwashers (Item 16), and capscrews (Item 15). Torque capscrews to 200 ft-lbs. For Models 1044C-54 (S/N 144–) and 10K-54 (S/N 104–): Use two (2) each nuts (Item 14), flatwashers (Item 8), and capscrews (Item 7). Install as many shims (Items 12 and 13) as necessary before installing the nuts.
Boom and Transfer 1. Remove base mount from the cylinder barrel as follows: For Models 1044C-54 (S/N 101–143) and 10K-54 (S/N 101–103) Remove three (3) each capscrews (Item 1) and flatwashers (Item 2) along with the extension cylinder base mount (Item 3) from the cylinder barrel (Item 8). For Models 1044C-54 (S/N 144–) and 10K-54 (S/N 104–): Remove two (2) each capscrews (Item 1) and flatwashers (Item 2) along with the extension cylinder base mount (Item 3) from the cylinder barrel (Item 8). 2.
Boom and Transfer 13. Inspect inner surface of barrel, outer surface of piston, and length of rod for scratches and scoring. If barrel, piston, or rod is damaged, it must be replaced. 14. Check condition of threads on rod, nut, and capscrews. Do not attempt to repair damaged threads. 15. Inspect counterbalance valve cartridges (Items 5 and 6), including O-rings, for condition and replace as necessary. Do not disassemble cartridges.
Boom and Transfer Boom Extension Proximity Switch (Models 1044C-54 and 10K-54 Only) Description J1146 Proximity Switch 20 40 60 80 Fig. 6-227: Boom Extension Proximity Switch 0 (Ref. Fig. 6-227) The boom extension proximity switch is located on the left side of the outer boom section on machines with a 4-section boom. The boom extend/lockout circuit is designed to increase stability of the machine by limiting how far the boom can be extended with the outriggers up.
Boom and Transfer Outer Boom Section Middle Rear) Boom Section Magnetic Flux Lines Proximity Switch J1259 Oscillator Fig. 6-228: Boom Extension Proximity Switch Operation (Ref. Fig. 6-228) The switch operates by sending out a constant, high frequency magnetic field a short distance from the oscillator end of the switch. Eddy currents are produced in metal when the magnetic flux lines pass through it. These eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop.
Boom and Transfer (Ref. Fig. 6-229) The following procedure describes removal of the boom extension proximity switch. 1. Disconnect wire harness (Item 4) at boom extension proximity switch (Item 2). 2. Place a piece of masking tape around proximity switch body at the outer jam nut (Item 3) (this will serve as a guide during reinstallation). 3. Remove inner jam nut (Item 1) and proximity switch. Reinstall inner jam nut on proximity switch for safekeeping. Installation Boom Extension Proximity Switch (Ref.
Boom and Transfer 1. Loosen, but do not remove the two (2) jam nuts on the proximity switch body. 2. Check gap between switch and boom. Gap must be within the range specified in Fig. 6-230. 3. If boom extension proximity light does not illuminate when boom is extended to specified distance (approximately 21 feet with tilting tower or 25 feet with standard carriage), adjust proximity switch to slightly reduce the gap. Do not exceed gap tolerances specified in Fig. 6-230.
Boom and Transfer The transfer carriage, along with the transfer cylinder, make up the “TransAction” feature. This feature makes it possible to land materials from a parked, level machine by driving the boom load forward at any height. The operator can then retract the boom and forks by moving the entire upper assembly rearward without driving the machine on uneven terrain. Removal Transfer Carriage The following steps are required to remove the transfer carriage. 1.
Boom and Transfer Proximity Switch Connection Wire J1149 Wiring Harness Fig. 6-233: Boom Elevation Proximity Switch Wiring 6. (Ref. Fig. 6-233) Remove boom elevation proximity switch as follows: a. Disconnect connection wire from boom proximity switch. b. Disconnect connection wire from wiring harness. c. Remove all wire ties that secure the wiring harness to hydraulic tubes and hoses so that it is completely separated from the transfer carriage.
Boom and Transfer b. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwashers (Item 2) securing boom cover (Item 4) to boom. Remove boom cover. 4 3 2 1 3 2 1 5 4 3 2 1 6 8 9 10 J1147 7 20 40 60 80 # 0 1 2 3 4 5 Description JClamp Flatwasher Lockwasher Nut Proximity Switch Wiring Harness # Description 6 7 8 9 10 Proximity Switch Connection Wire Proximity Mounting Plate Boom Extension Proximity Switch Lockwasher Capscrew Fig. 6-235: Boom Extension Proximity Switch Wiring 8.
Boom and Transfer 1 2 3 # 1 2 Description Hydraulic Hoses Hose Cover J1142 4 # 3 4 Description Lockwasher Capscrew Fig. 6-236: Disconnecting Hydraulic Hoses from Transfer Carriage 9. (Ref. Fig. 6-236) Remove four (4) each capscrews (Item 4) and lockwashers (Item 3) along with the hose cover (Item 2). 10. (Ref. Fig. 6-236) Disconnect hydraulic hoses (Item 1) from the hydraulic tube elbows. 11. If the boom and transfer carriage are being removed as an assembly, go to Step 12.
Boom and Transfer 8 9 10 11 12 6 7 5 4 40 60 80 3 20 1 0 J1153 -20 2 # 1 2 3 4 5 6 Description Nut Lockwasher Capscrew Front Slide Block Transfer Carriage Setscrew # 7 8 9 10 11 12 Description Spindle Nut Spacer Washer Thrust Washer Spindle Roller Bushing Transfer Roller Fig. 6-237: Transfer Carriage with Boom Installation 12. (Ref. Fig. 6-237) The following steps are necessary if the boom and transfer carriage are to be removed as an assembly. a.
Boom and Transfer e. Slowly lift the boom and transfer carriage assembly up and away from the machine. Place the assembly on support blocks on a firm level surface. 8 9 10 11 12 6 7 5 4 J1154 3 1 2 # 1 2 3 4 5 6 Description Nut Lockwasher Capscrew Front Slide Block Transfer Carriage Setscrew # 7 8 9 10 11 12 Description Spindle Nut Spacer Washer Thrust Washer Spindle Roller Bushing Transfer Roller Fig. 6-238: Transfer Carriage Installation 13.
Boom and Transfer g. (Ref. Fig. 6-238) Remove the two (2) spindle nuts. Remove spacer washer (Item 8), thrust washer (Item 9), spindle (Item 10), roller bushing (Item 11), and transfer roller (Item 12) from each side of the rear transfer carriage mount. Note: The quantity of spacer washers used with each machine may vary. h. Slowly lift the transfer carriage assembly up and away from the machine. Place the assembly on support blocks on a firm level surface.
Boom and Transfer WARNING: To avoid personal and/or equipment damage, support the transfer carriage assembly when lifting and reinstalling it back on the machine. Make sure that the transfer carriage assembly is supported until it is completely installed. b. Install the transfer carriage (Item 5) to rear of the main frame using the two (2) each transfer rollers (Item 12), roller bushings (Item 11), spindles (Item 10), thrust washers (Item 9), spacer washers (Item 8), and spindle nuts (Item 7).
Boom and Transfer d. Secure the wiring harness and switch connection wire to the boom with six (6) each (five on top of the boom and one inside of the back left side of the boom) nuts (Item 4), lockwashers, (Item 3), flatwashers (Item 2), and J-clamps (Item 1). Tighten nuts until snug. e. Secure the wire harness to the hydraulic tubes and hoses with wire tires. 10. (Ref. Fig. 6-234) Install the boom cover on models with 3-section (see Step a) or 4-section booms (see Step b). a.
Boom and Transfer 1. Follow preparation procedures as outlined in Section 3 of this manual. 2. Lower the boom to the ground, apply the park brake, retract the transfer cylinder, and stop the engine. 3. Remove capscrew (Item 1) and lockwasher (Item 3) securing the two (2) lock pins (Item 4) to transfer carriage. CAUTION: To avoid personal and/or equipment damage, support the boom and transfer carriage before removing the transfer roller assembly.
Boom and Transfer c. Measure the gap between the lip of the transfer roller and the inner edge of the rail. If this measurement is not 1/16", remove the transfer roller assembly and install or remove shims until the required measurement is reached. 11. Secure front transfer roller assembly to transfer carriage by tightening capscrew (Item 1) to 55 ft-lbs. 12. Remove two (2) grease fitting cover caps (Item 6) and lubricate grease fittings (Item 5) with EP lithium based grease. Scraper Plate (Ref. Fig.
Boom and Transfer Rear Mount Rollers, Bushings, and Spacer Washers 16 15 14 13 12 11 10 4 5 6 1 7 8 2 J1144 9 3 # 1 2 3 4 5 6 7 8 Description Grease Fitting Cover Grease Fitting Spindle Nut Setscrew Spacer Washer Thrust Washer Spindle Rear Roller Bushing # 9 10 11 12 13 14 15 16 Description Rear Transfer Roller Rear Slide Block Slide Block Shim Lockwasher Capscrew Boom Pivot Bushing Grease Fitting Cover Grease Fitting Fig. 6-242: Transfer Carriage – Rear Rollers, Bushings, and Shims (Ref. Fig.
Boom and Transfer 8. Secure spindle to transfer carriage with spindle nut. Distance Between Rails Transfer Roller 1/16" Transfer Carriage Nut Roller Spindle Spacer Washer(s) Rail J1143 Thrust Washer Fig. 6-243: Spacer Washers for Rear Transfer Rollers 9. (Ref. Fig. 6-243) Check to see if the number of spacer washers installed is correct. a. Locate the point that is the shortest distance between the two rails (usually near the center of the rails). b.
Boom and Transfer 4. Reinstall boom and shims as described earlier in this section. 5. Remove two (2) grease fitting cover caps (Item 15) and lubricate grease fittings (Item 16) with EP lithium based grease. Rear Slide Block and Shims (Ref. Fig. 6-242) The following steps are required to replace worn rear slide blocks. 1. Follow preparation procedures as outlined in Section 3 of this manual. 2. Lower the boom to the ground, apply the park brake, retract the transfer cylinder, and stop the engine. 3.
Boom and Transfer Boom Cradle (Models 6K, 8K and 10K Onl 20 40 60 80 Description 0 J1141 -20 Fig. 6-245: Boom Cradle The boom cradle is a stationary structure, similar to a transfer carriage. It is only found on “K” Models: 6K, 8K, 10K. Unlike the transfer carriage found on Models 644B, 844C, and 1044C, the boom cradle does not allow for boom “Tans-Action” (see page 6-217). Removal Boom Cradle The following steps are required to remove the boom cradle. 1.
Boom and Transfer Proximity Switch Connection Wire J1149 Wiring Harness Fig. 6-246: Boom Elevation Proximity Switch Wiring 3. (Ref. Fig. 6-246) Remove boom elevation proximity switch as follows: a. Disconnect connection wire from boom proximity switch. b. Disconnect connection wire from wiring harness. c. Remove all wire ties that secure the wiring harness to hydraulic tubes and hoses so that it is completely separated from the transfer carriage.
Boom and Transfer b. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwashers (Item 2) securing boom cover (Item 4) to boom. Remove boom cover. 4 3 2 1 3 2 1 5 4 3 2 1 6 J1147 7 20 40 60 80 # 0 1 2 3 4 Description J-Clamp Flatwasher Lockwasher Nut # Description 5 6 7 Proximity Switch Wiring Harness Proximity Switch Connection Wire Boom Extension Proximity Switch Fig. 6-248: Boom Extension Proximity Switch Wiring 5. (Ref. Fig.
Boom and Transfer 1 2 3 # 1 2 Description Hydraulic Hoses Hose Cover J1167 4 # 3 4 Description Lockwasher Capscrew Fig. 6-249: Disconnecting Hydraulic Hoses from Boom Cradle 6. (Ref. Fig. 6-249) Remove the four (4) each capscrews (Item 4) and lockwashers (Item 3) along with the hose cover (Item 2). 7. (Ref. Fig. 6-249) Disconnect hydraulic hoses (Item 1) from the hydraulic tube elbows. 8. If the boom and boom cradle are being removed as an assembly, go to Step 9.
Boom and Transfer 17 16 15 14 13 6 7 5 4 8 9 10 11 12 -20 0 1 J1168 20 40 60 80 3 2 # 1 2 3 4 5 6 7 8 9 Description Nut Lockwasher Capscrew Front Slide Block Boom Cradle Setscrew Spindle Nut Sleeve Shim # 10 11 12 13 14 15 16 17 Description Spacer Block Flatwasher Capscrew Rear Support Block Spacer (1/4" Thick) Shim (22 Gauge) Lockwasher Capscrew Fig. 6-250: Boom Cradle with Boom Installation 9. (Ref. Fig.
Boom and Transfer e. Slowly lift the boom and boom cradle assembly up and away from the machine. Place the assembly on support blocks on a firm level surface. 17 16 15 14 13 6 7 5 8 9 1 3 2 # 1 2 3 4 5 6 7 8 9 11 Description Nut Lockwasher Capscrew Front Slide Block Boom Cradle Setscrew Spindle Nut Sleeve Shim # 10 11 12 13 14 15 16 17 12 J1166 10 4 Description Spacer Block Flatwasher Capscrew Rear Support Block Spacer (1/4" Thick) Shim (22 Gauge) Lockwasher Capscrew Fig.
Boom and Transfer g. Slowly lift the boom cradle assembly up and away from the machine. Place the assembly on support blocks on a firm level surface. Installation Boom Cradle 1. If the boom and boom cradle were removed as an assembly, go to Step 2. If the boom was removed separately from the boom cradle, go to Step 3. 2. (Ref. Fig. 6-250) The following steps are required to reinstall the boom and boom cradle assembly. a.
Boom and Transfer d. Install the two (2) slide blocks (Item 4) to the front of the transfer carriage with four (4) each capscrews, (Item 3) lockwashers (Item 2), and nuts (Item 1). Torque the nuts to 130 ft-lbs. e. Install the boom as described elsewhere in this section. f. Install the rear carriage tilt cylinder (See page 6-25). g. Install the boom hoist cylinder (See page 6-13). 4. (Ref. Fig. 6-249) Reconnect hydraulic hoses (Item 1) to the hydraulic tube elbows.
Boom and Transfer Front Support Blocks and Shims 8 1 2 3 4 J1173 5 6 7 # 1 2 3 4 Description Capscrew Lockwasher Lock Pin Front Roller Pin # 5 6 7 8 Description Spacer Shim Support Block Boom Cradle Fig. 6-252: Boom Cradle – Front Support Blocks and Shims (Ref. Fig. 6-252) The following steps are required to replace the front support blocks and shims. 1. Follow preparation procedures as outlined in Section 3 of this manual. 2.
Boom and Transfer Boom Cradle Spacer Shim(s) Support Block Rail J1175 Slide Block Fig. 6-253: Shims for Front Support Blocks 8. (Ref. Fig. 6-253) Check to see if the number of shims to be installed is correct. a. Place support block on rail so that the lower lip is resting snug against the inner side of the rail. b. Insert spacer and shims between support block and boom cradle. c. Add or remove as many 14 gauge shims as necessary to fill the gap.
Boom and Transfer Rear Spacer Blocks, Support Blocks, and Shims 16 15 14 13 12 11 10 9 1 8 3 7 4 5 J1173 2 6 # 1 2 3 4 5 6 7 8 Description Setscrew Spindle Nut Sleeve Shim (16 Gauge) Shim (10 Gauge) Spacer Block Capscrew Flatwasher # 9 10 11 12 13 14 15 16 Description Rear Support Block Spacer (1/4" Thick) Shim (22 Gauge) Lockwasher Capscrew Boom Pivot Bushing Grease Fitting Cover Grease Fitting Fig. 6-254: Boom Cradle – Rear Spacer Blocks, Bushings, and Shims (Ref. Fig.
Boom and Transfer 7. Remove capscrew (Item 7), flatwasher (Item 8), spacer block (Item 6), sleeve (Item 3), and shims (Items 4 and 5) from each side of the boom cradle. 8. Clean parts with solvent and dry with compressed air. Replace any damaged parts. Capscrew Lockwasher Spacer(s) (1/4") Shim(s) (22 Gauge) Rear Support Block Boom Cradle Spacer Block Shim(s) (16 Gauge) Frame J1174 Shim (10 Gauge) Fig. 6-255: Boom Cradle – Rear Shims 9. (Ref. Fig.
Boom and Transfer Boom Cradle/Boom Pivot Bushings (Ref. Fig. 6-254) The following steps are required to replace boom cradle/boom pivot bushings. 1. Remove boom and shims as described in this section. 2. Remove two (2) boom pivot bushings (Item 14) using a bushing driver and hammer. Discard bushings. Note: It may be necessary to cut out the old bushing. 3. Install new bushings so that each is centered in boom cradle boss. Note: It may be necessary to freeze the new bushing before installing it. 4.
Boom and Transfer Removal Transfer Cylinder 4 1 8 3 7 2 6 9 5 10 # 1 2 3 4 5 6 Description Setscrew Rod Nut Washer Transfer Carriage Transfer Cylinder Main Frame J1139 11 # 7 8 9 10 11 Description Lockwasher Capscrew 90° Elbow Hydraulic Tube Hydraulic Hose Fig. 6-257: Transfer Cylinder Installation (Ref. Fig. 6-257) The following steps are required to remove the transfer cylinder. 1. Follow preparation procedures as outlined in Section 3 of this manual. 2.
Boom and Transfer 4. Remove elbow (Item 9) from transfer cylinder. Cap cylinder orifice. 5. Loosen and remove hydraulic hose (Item 11) from connector on transfer cylinder. Bleed any remaining oil into a suitable container. Cap connector and hose end. 6. Loosen two (2) socket setscrews (Item 1) in rod nut (Item 2). WARNING: To avoid personal and/or equipment damage, support the hydraulic cylinder before removing any additional hardware securing cylinder to transfer carriage or main frame.
Boom and Transfer Overhaul Transfer Cylinder 3 2 4 1 8 J1140 7 6 5 # 1 2 3 4 Description Dowel Pin Cylinder Barrel Connector Rod Bearing Nut # 5 6 7 8 Description Piston Stroke Limiter Rod Rod Bearing Head Fig. 6-258: Transfer Cylinder Assembly (Ref. Fig. 6-258) The following steps are required to overhaul the transfer cylinder. 1. Remove the connector (Item 3) from the cylinder barrel (Item 2). 2. Remove dowel pin (Item 1) from cylinder barrel. 3.
Note: Older production models do not have a stroke limiter. This includes S/N 101–433 for 644B-37, S/N 101–130 for 644B-42, S/N 101–323 and 326–328 for 844C-42, S/N 101–109 for 1044C-42, and S/N 101–108 for 1044C-54. 7. Remove all O-rings, wear rings, and backup rings from cylinder components and discard. 8. Thoroughly clean components with solvent and dry with compressed air. Inspect and replace if damaged. 9.
Section 7 — Frame Tilt and Oscillation Table of Contents Frame Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables Table 7-1: Rear Oscillation Lock Circuit Test Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7 — Frame Tilt and Oscillation Frame Tilt System General Description Multi-Spool Control Valve Frame Tilt Control Valve G1020 Frame Tilt Cylinder Fig. 7-1: Frame Tilt System Components (Ref. Fig. 7-1) The frame tilt system allows the machine to be levelled laterally (side-to-side) up to 12.5°, left or right. The lateral angle of the machine, relative to level ground, is shown on the frame level indicator (See “Frame Level Indicator” on page 7-17).
Frame Tilt and Oscillation Circuit Description Reference Fig. 7-1 above and Section 4, “Reference Diagrams”. The frame tilt system works in combination with the rear oscillation lock system. The frame tilt system is explained here. See “Rear Oscillation Lock System” on page 7-18 for detailed information concerning that system. Control Centered With the engine on and the boom below 40° elevation, the frame tilt system is enabled.
Frame Tilt and Oscillation Frame Tilt Disabled Under certain conditions the frame tilt system is disabled by the frame tilt lockout valve. The lockout valve prevents or allows pilot flow to be routed to ports A6 and B6 on the frame tilt section of the multi-spool valve. The frame tilt lockout valve is a component of the rear oscillation lock system and its function is explained under “Rear Oscillation Lock System” on page 7-18.
Frame Tilt and Oscillation To level the frame, move the lever in the direction you want the ball in the frame level indicator to move. Control is proportional: a small amount of movement causes the frame to tilt slowly, while full movement of the control causes faster frame movement. Removal Frame Tilt Control Valve 8 7 6 5 4 3 1 2 K1027 9 # 1 2 3 4 5 Description Flatwasher Screw Control Panel 1/4” Hoses Frame Tilt Control Valve # 6 7 8 9 Description Starwasher Capscrew Fittings 3/8” Hoses Fig.
Frame Tilt and Oscillation Note: “K” Models have 90° elbows instead of tee fittings. 5. Remove two (2) capscrews (Item 7) and starwashers (Item 6) retaining control valve to control panel. 6. Lift valve up to remove. Installation Frame Tilt Control Valve 1. (Ref. Fig. 7-3) Insert frame tilt control valve (Item 5) into control panel (Item 3) with plugged ports on front of valve body facing forward. 2. Install two (2) starwashers (Item 6) and capscrews (Item 7) to secure valve to control panel. 3.
Frame Tilt and Oscillation Overhaul Frame Tilt Control Valve 11 12 13 10 14 15 2 16 17 18 4 3 19 1 5 7 20 9 21 6 7 22 8 23 24 K1022 25 # Description # 1 2 3 4 5 6 7 8 9 10 11 12 13 Lever Assembly Rubber Boot Cam Roll Pin Capscrew (4) Washer (4) Circlip (2) Pivot Pin Flange Guide Assembly (2) (Incl.
Frame Tilt and Oscillation Disassembly, Frame Tilt Control Valve 1. Note locations of fittings and plugs installed in valve body ports. Remove all fittings and plugs. Drain any residual oil into a suitable container. 2. Lift rubber boot (Item 2) from flange (Item 9) and slide it up lever assembly (Item 1). 3. Remove one of the circlips (Item 7) from pivot pin (Item 8). Push pin out of flange and remove lever assembly. 4.
Frame Tilt and Oscillation 4. Check surface of each plunger (Item 17) and guide (Item 12) for wear and damage. Check fit of plunger in guide to make sure no sticking occurs. Like the spools, a stuck plunger can cause unintentional operation of a hydraulic circuit. 5. Inspect each spool cavity in the valve body for scratches. 6. Check condition of lever assembly (Item 1), cam (Item 3), pivot pin (Item 8), springs (Item 19), and flange (Item 9). Replace as necessary. 7.
Frame Tilt and Oscillation Frame Tilt Cylinder Description G1020 Frame Tilt Cylinder Fig. 7-5: Frame Tilt Cylinder (Ref. Fig. 7-5) The frame tilt cylinder is located near the front of the machine, on the right side. The cylinder is mounted vertically with the base end secured to the frame and the rod end mounted to the front axle. With the engine running, moving the frame tilt control valve handle (see page 7-3) to the right causes the cylinder to retract and the frame tilts to the right.
Frame Tilt and Oscillation Removal Frame Tilt Cylinder 644B-37 (S/N 101–170) 6K-37 (S/N 101–144) 844C-42 (S/N 101–164) 8K-42 (S/N 101–125) 1 2 15 12 11 16 17 14 13 3 4 18 10 5 8 9 G1021 6 7 View A 1 644B-37 (S/N 171–) 6K-37 (S/N 145–) 644B-42 (S/N 101–) 6K-42 (S/N 101–) 844C-42 (S/N 165–) 8K-42 (S/N 26–) 1044C-42 (S/N 101–) 10K-42 (S/N 101–) 1044C-54 (S/N 101–) 10K-54 (S/N101–) 2 3 12 11 15 14 16 17 18 13 2 1 9 G1022 19 View B # 1 2 3 4 5 6 7 8 9 10 Description Grease Fitting Cove
Frame Tilt and Oscillation (Ref. Fig. 7-6) The following procedures are required to remove the frame tilt cylinder. 1. Follow preparation procedures as outlined in Section 3. 2. Place blocks between frame and top of front axle. These will hold the frame in place when the cylinder is removed. 3. Tag and disconnect two (2) hydraulic hoses (Item 9) at frame tilt cylinder (Item 3). Cap hoses and fittings. 4. See warning and procedures on page 7-16 for releasing hydraulic pressure in cylinder. 5.
Frame Tilt and Oscillation b. Install mounting block (with lock pin hole) (Item 10) to rear of axle with two (2) capscrews (Item 4), lockwashers (Item 6), and nuts (Item 7). Make sure the lock pin hole is to the rear of the machine. Torque nut to 150 ft-lbs. 5. Position lower cylinder pivot on axle to install lower pivot pin. Install lower pivot pin (Item 13) and shims (Item 8) (early production models only). 6. Secure pin with lock pin (Item 11), lockwasher (Item 12), and capscrew (Item 14).
Frame Tilt and Oscillation Overhaul Frame Tilt Cylinder 7 3 6 5 4 3 8 2 9 1 10 4 1 11 1 11 1 644B-37 6K-37 844C-42 8K-42 12 S/N S/N S/N S/N 101–170 101–144 101–164 101–125 13 644B-37 644B-42 6K-37 6K-42 844C-42 # 1 2 3 4 5 6 7 S/N S/N S/N S/N S/N 171– 101– 145– 101– 165– Description Bushing Barrel Counterbalance Valve Cartridge O-Ring Plug Orifice Fitting, O-Ring Swivel Fitting 8K-42 1044C-42 1044C-54 10K-42 10K-54 # 8 9 10 11 12 13 S/N S/N S/N S/N S/N 126– 101– 101– 101– 101– K1023
Frame Tilt and Oscillation Disassembly, Frame Tilt Cylinder (Ref. Fig. 7-7) The following steps are required to disassemble the frame tilt cylinder. 1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in cylinder will drain out during disassembly. Place a suitable pan or tray under the cylinder. 2. See warning and procedures on page 7-16 for counterbalance valve (Item 3) removal. 3. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 4.
Frame Tilt and Oscillation 2. Install new bushings so they are flush with outer edge boss to 0.02" below. For machines with lower (rod end) pivot bushing installed in front axle: Install bushing so that it is centered in axle boss. Assembly, Frame Tilt Cylinder 1. (Ref. Fig. 7-7) Install two (2) orifices (Item 5) using a large, flat bladed screw driver. 2. Install two (2) O-ring plugs (Item 4) and torque to 125–145 in-lbs. 3.
Frame Tilt and Oscillation Note: Swivel fittings are not used with the latest production models (e.g. 644B-37 (S/N 591, 667~) and 644B-42 (S/N 208~)). 11. Install counterbalance valve cartridges. See below. Counterbalance Valve Cartridge Counterbalance Valve Cartridge Manifold Block K1025 Counterbalance Valve Cartridge Fig. 7-9: Counterbalance Valve Cartridges, Frame Tilt Cylinder WARNING: The counterbalance valve cartridges trap hydraulic pressure in the frame tilt cylinder.
Frame Tilt and Oscillation Installation, Counterbalance Valve 1. Lubricate O-rings with clean hydraulic oil. 2. Install each cartridge in manifold block and torque to 30–35 ft-lbs. Frame Level Indicator Description 10 5 0 5 10 H1004 Fig. 7-10: Frame Level Indicator (Ref. Fig. 7-10) The Frame Level Indicator shows the lateral (side-to-side) angle of the frame relative to level ground. Indicator range is from 0° to 10° left or right, in increments of one degree.
Frame Tilt and Oscillation 1. (Ref. Fig. 7-11) Park the machine on a firm, level surface. Place a carpenter’s level across the frame rails. 2. Loosen screws securing frame level indicator to its mounting bracket. Start the engine and adjust frame tilt so the carpenter’s level shows the frame is level. 3. Adjust frame level indicator so ball is centered over 0° mark. Tighten indicator screws.
Frame Tilt and Oscillation Theory of Operation and Circuit Logic Solenoid Valve On Stabilizer Block A Dash Panel C B V1 B R2 R1 6 R3 1 S1 2 5 9 C C B B A A B A + D 4 5 6 1 2 3 Fuse Panel 3 A B C DE F 3 2 7 ECU Transmission 6 Pole Disconnect W/P Switch Conn. V2 + – Parking Brake Pressure Switch S2 7 S3 4 8 J1260 – Fig. 7-12: Rear Oscillation Lock Component Locations (Reference Fig.
Frame Tilt and Oscillation Boom Positioned Above 40° R1 = Proximity Switch Relay R2 = Service Brake Relay R3 = Oscillation Lock Warning Light Relay S1 = Proximity Switch S2 = Service Brake Pressure Switch S3 = Frame Tilt Override Pressure Switch V1 = Stabilizer Block Solenoid Valve V2 = Frame Tilt Lockout Solenoid Valve Solenoid Valve On Stabilizer Block A Dash Panel C B V1 B R2 R1 R3 S1 C C B B A A B A + D 4 5 6 1 2 3 Fuse Panel A B CDE F 3 2 7 ECU Transmission 6 Pole Disconnect W/P
Frame Tilt and Oscillation Boom Positioned Below 40° R1 = Proximity Switch Relay R2 = Service Brake Relay R3 = Oscillation Lock Warning Light Relay S1 = Proximity Switch S2 = Service Brake Pressure Switch S3 = Frame Tilt Override Pressure Switch V1 = Stabilizer Block Solenoid Valve V2 = Frame Tilt Lockout Solenoid Valve Solenoid Valve On Stabilizer Block A Dash Panel C B V1 B R2 R1 R3 S1 C C B B A A B A + D 4 5 6 1 2 3 Fuse Panel A B CDE F 3 2 7 ECU Transmission 6 Pole Disconnect W/P
Frame Tilt and Oscillation 5. When the proximity switch (S1) energizes the proximity switch relay (R1), power is also directed from relay (R1) to the rear oscillation lock warning light relay (R3). When the warning light relay is energized, the path to ground for the warning light is interrupted and the oscillation lock warning light goes out.
Frame Tilt and Oscillation 4. When the proximity switch (S1) energizes the proximity switch relay (R1), power is also directed from relay (R1) to the rear oscillation lock warning light relay (R3). When the warning light relay is energized, the path to ground for the warning light is interrupted and the oscillation lock warning light goes out. 5. As the service brake is applied, the normally open service brake pressure switch (S2) closes.
Frame Tilt and Oscillation Rear Oscillation Lock Cylinder Description 0 Rear Oscillation Lock Control Block G1023 40 60 80 Rear Oscillation Lock Cylinder 20 -20 Fig. 7-16: Rear Oscillation Lock Cylinder (Ref. Fig. 7-16) The rear oscillation lock cylinder is located near the rear of the machine, on the left side. The cylinder is mounted vertically with the base end secured to the frame and the rod end mounted to the rear axle.
Frame Tilt and Oscillation Removal 644B-37 (S/N 101–170) 6K-37 (S/N 101–144) 844C-42 (S/N 101–164) 8K-42 (S/N 101–125) 18 19 1 2 3 17 5 6 21 16 4 15 7 2 4 14 8 13 12 9 644B-37 (S/N 171–) 6K-37 (S/N 145–) 644B-42 (S/N 101–) 6K-42 (S/N 101–) 844C-42 (S/N 165–) 8K-42 (S/N 126–) 1044C-42 (S/N 101–) 10K-42 (S/N 101–) 1044C-54 (S/N 101–) 10K-54 (S/N 101–) 19 6 1 G1024 10 11 View A 2 3 5 21 16 8 2 4 4 18 15 14 13 20 G1025 9 View B # 1 2 3 4 5 6 7 8 9 10 11 Description Nut Lockwasher Uppe
Frame Tilt and Oscillation (Ref. Fig. 7-17) The following steps are required to remove the rear oscillation lock cylinder: 1. Follow preparation procedures as outlined in Section 3. 2. Place blocks between frame and top of rear axle. These will hold the frame in place when the cylinder is removed. 3. Install brake pressure diagnostic port test gauge onto brake diagnostic port. 4. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi.
Frame Tilt and Oscillation 3. If necessary (models with a cylinder as illustrated in View A), install mounting base (Item 12) with four (4) each capscrews (Item 7), lockwashers (Item 10), and nuts (Item 11). Torque nuts to 280 ft-lbs. 4. If necessary (models with a cylinder as illustrated in View A), install bushing (Item 20) in rear axle boss. Install bushing so that it is centered in axle boss 5. Position lower cylinder pivot on axle and install lower pivot pin.
Frame Tilt and Oscillation Overhaul Rear Oscillation Lock Cylinder 5 4 3 2 1 1 6 1 6 1 644B-37 S/N 101–170 6K-37 S/N 101–144 7 844C-42 8K-42 S/N 101–164 S/N 101–125 1 8 # 1 2 3 4 S/N S/N S/N S/N S/N 171– 101– 145– 101– 165– Description Bushing Barrel Rod Nut Piston 8K-42 1044C-42 1044C-54 10K-42 10K-54 # 5 6 7 8 S/N S/N S/N S/N S/N 126– 101– 101– 101– 101– K1028 644B-37 644B-42 6K-37 6K-42 844C-42 Description Stroke Limiter Rod Capscrew Head Fig.
Frame Tilt and Oscillation Disassembly, Rear Oscillation Lock Cylinder (Ref. Fig. 7-18) Disassembly procedures for the rear oscillation lock cylinder are as follows: 1. Mount or support cylinder vertically, with rod end down. Hydraulic oil in cylinder will drain out during disassembly. Place a suitable pan or tray under cylinder. 2. See warning and procedures on page 7-34 for removal of oscillation control block. 3. Slowly extend and retract cylinder by hand to remove most of the hydraulic oil. 4.
Frame Tilt and Oscillation Assembly, Rear Oscillation Lock Cylinder 1. Lubricate new O-ring with hydraulic oil and install inside piston (seals the rod to the piston). 2. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic oil and install on head (Item 8). Using a seal driver, install new wiper seal in head. Lubricate wiper seal with hydraulic oil. 3. (Ref. Fig. 7-18) Slide head (Item 8), stroke limiter (Item 5) and piston (Item 4) onto rod (Item 6).
Frame Tilt and Oscillation Oscillation Control Block Description G1026 Rear Oscillation Lock Control Block Fig. 7-20: Oscillation Control Block (Ref. Fig. 7-20) The oscillation control block assembly controls the function of the rear oscillation lock cylinder. When the oscillation lock system is in UNLOCK mode, the control block allows hydraulic fluid to freely pass into and out of the cylinder.
Frame Tilt and Oscillation The functions of these components depend upon the mode of the oscillation lock system: LOCKED or UNLOCKED. During LOCKED mode: 1. No electrical power is supplied to solenoid valve V1. Pilot pressure from port PIL does not reach the pilot pistons at check valves 3.1 and 3.2. 2. Check valves 3.1 and 3.2 keep hydraulic fluid trapped in the cylinder, locking the cylinder and preventing the frame from rotating on the rear axle. 3.
Frame Tilt and Oscillation Removal Oscillation Control Block 1 9 2 10 3 4 5 6 7 K1030 8 # Description # 1 2 3 4 5 #6 Hydraulic Hose #8 Hydraulic Hose Capscrew Lockwasher Check Valve Cartridge 6 7 8 9 10 Description Oscillation Control Block O-Ring Rear Oscillation Lock Cylinder Electrical Lead Pressure Reducing Valve Fig. 7-21: Oscillation Control Block Installation Rear Oscillation Lock Cylinder Installed on Machine (Ref. Fig.
Frame Tilt and Oscillation 5. Place a suitable drip pan under rear oscillation lock cylinder. WARNING: Residual hydraulic pressure may be trapped in rear oscillation lock cylinder. Wear proper eye and hand protection when releasing pressure from cylinder. Hydraulic fluid under pressure can be injected under skin or into eyes, resulting in serious personal injury or death. 6. Slowly loosen each check valve cartridge (Item 5) on control block (labeled 3.1 and 3.2) to allow residual pressure to escape.
Frame Tilt and Oscillation Installation Oscillation Control Block Rear Oscillation Lock Cylinder Installed on Machine (Ref. Fig. 7-21) Use the following control block installation procedures when the rear oscillation lock cylinder is installed on the machine. For installation procedures when the cylinder has been removed, see below. 1. Clean mating surfaces of rear oscillation lock cylinder and oscillation control block. 2.
Frame Tilt and Oscillation Overhaul Oscillation Control Block 6 5 4 7 3 1 1 8 11 14 11 13 12 2 15 16 33 31 9 9 10 32 29 8 30 17 28 25 22 23 26 27 26 18 24 21 19 K1029 20 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Plug, SAE #6 Orifice Plug Check Valve Swivel Fitting Elbow, Adjustable O-Ring Elbow w/ Orifice, O-Ring Orifice Plug Plug, SAE #2 Backup Ring O-Ring Backup Ring O-Ring O-Ring Solenoid Valve Solenoid Coil Nut Block Body # Description 18 O-Ring 19 Plug, SAE #4
Frame Tilt and Oscillation (Ref. Fig. 7-22) Follow the guidelines for cleanliness as stated in Section 5 of this manual. The following procedures are for the disassembly, cleaning, and assembly of the oscillation control block. Disassembly, Oscillation Control Block Check Valve 1. Note position of hydraulic fittings (Items 4–6) installed in block body (Item 17) then remove fittings. Remove the check valve (Item 3) from the SYS port.
Frame Tilt and Oscillation 3. Install two (2) SAE #2 plugs (Items 8 and 34). Torque plugs to 30–40 in-lbs. Note: Models with mid-inlet hydraulics do not have the SAE #2 plug (Item 8). 4. Install SAE #4 plug (Item 19). Torque plug to 125–145 in-lbs. 5. Install SAE #10 plug (Item 20). Torque plug to 71–79 ft-lbs (850–950 in-lbs). 6.
Frame Tilt and Oscillation 15. Lubricate O-rings and backup ring on each check valve cartridge (Item 21). Install cartridges and torque to 45–50 ft-lbs (540–600 in-lbs). Check Valve 16. Install check valve (Item 3) in SYS port and torque to 46–50 ft-lbs. 17. For models with control manifold hydraulics, install swivel fitting (Item 4) on check valve (Item 3). Position fitting as previously noted and torque to 44–48 ft-lbs. 18. Install adjustable fitting (Item 5) in T port.
Frame Tilt and Oscillation Removal Frame Tilt Lockout Valve 2 1 3 12 4 5 6 11 7 8 9 K1032 10 # 1 2 3 4 5 6 Description Electrical Leads Capscrew Frame Tilt Lockout Valve Capscrew Lockwasher Flatwasher # 7 8 9 10 11 12 Description Mounting Bracket Lockwasher Nut Valve Plate Hydraulic Hose Connector Fig. 7-24: Frame Tilt Lockout Valve Installation (Ref. Fig. 7-24) The following procedure describes removal of the frame tilt lockout valve. 1.
Frame Tilt and Oscillation Installation Frame Tilt Lockout Valve (Ref. Fig. 7-24) The following procedure describes installation of the frame tilt lockout valve. 1. Position frame tilt lockout valve (Item 3) on mounting bracket (Item 7) and secure with two (2) capscrews (Item 2), lockwashers (Item 8), and nuts (Item 9). Torque nuts to 50 in-lbs. 2. Position mounting bracket on valve plate. Secure with two (2) flatwashers (Item 6), lockwashers (Item 5), and capscrews (Item 4).
Frame Tilt and Oscillation (Ref. Fig. 7-25) Follow the guidelines for cleanliness as stated in Section 5 of this manual. The following procedures are for the disassembly, cleaning, and assembly of the frame tilt lockout valve. Disassembly, Frame Tilt Lockout Valve 1. Remove two (2) fittings (Item 8) from valve body (Item 9). Frame Tilt Override Press. Switch 2. Remove frame tilt override pressure switch (Item 7). Place wrench on hex fitting at base of switch. Do not apply torque to body of switch.
Frame Tilt and Oscillation Boom Elevation Proximity Switch Description Boom Proximity Switch J1109 Transfer Carriage/Boom Cradle Fig. 7-26: Boom Elevation Proximity Switch (Ref. Fig. 7-26) The boom elevation proximity switch is located on the left side of the transfer carriage/boom cradle. This normally open switch closes when the boom is below 40° elevation. The switch is a component of the rear oscillation lock system. See “Rear Oscillation Lock System” on page 7-18.
Frame Tilt and Oscillation Removal Boom Elevation Proximity Switch 1 2 3 4 J1074 5 # 1 2 3 Description Transfer Carriage/Boom Cradle Inner Jam Nut Proximity Switch # 4 5 Description Outer Jam Nut Wire Harness Fig. 7-28: Boom Elevation Proximity Switch Assembly 1. (Ref. Fig. 7-28) Disconnect wire harness (Item 5) at boom proximity switch (Item 3). 2. Place a piece of masking tape around proximity switch body at the outer jam nut (Item 4) (this will serve as a guide during re-installation). 3.
Frame Tilt and Oscillation Adjustment Transfer Carriage/Boom Cradle Proximity Switch Outer Jam Nut Boom 0.19” to 0.25” Gap Inner Jam Nut J1075 Boom Elevation Proximity Switch Fig. 7-29: Boom Elevation Proximity Switch Adjustment 1. Loosen, but do not remove the two (2) jam nuts on the proximity switch body. 2. Check gap between switch and boom. Gap must be within the range specified in Fig. 7-29. 3.
Section 8 — Transmission Table of Contents Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ZF Transmission with DW-2 Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ZF Transmission with DW-3 Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E1014 Section 8 — Transmission Fig. 8-1: ZF Transmission Description ZF Transmission with DW-2 Shifter 644B-37 (S/N 101–880) 6K-37 (S/N 101–397) 6K-42 (S/N 101–131) 644B-42 (S/N 101–241) 844C-42 (S/N 101–783) 8K-42 (S/N 101–261) 1044C-42 (S/N 101–121) 10K-42 (S/N 101–107) 1044C-54 (S/N 101–25) 10K-54 (S/N 101–107, 109) The ZF transmission system that uses a DW-2 shifter employs an EST-19 microprocessor control unit and contains the following six components: 1.
Transmission 3. 3- or 4-Speed Transmission a. 38369A — 3-Speed Transmission b. 38370A — 4-Speed Transmission The 3- and 4-speed transmission consists of a torque converter coupled to a multi-speed powershift transmission with an integrated transfer case. The 3-speed design has three forward and three reverse speeds. The 4-speed design has four forward and three reverse speeds. Speed ranges and direction can be engaged and disengaged under load with hydraulically-actuated multidisc clutches. 4.
Transmission The 3- or 4-speed WG100 transmission consists of a torque converter coupled to a multi-spool powershift transmission with an integrated transfer case. The 3-speed design has three forward and three reverse speeds. The 4-speed design has four forward and three reverse speeds. Speed ranges and direction can be engaged and disengaged under load with hydraulically-actuated multidisc clutches. 3. Transmission Harness Connection DW-3 Shifter to Transmission Solenoid Valve Assembly a.
Transmission Troubleshooting and Test Procedures Troubleshooting Options ZF Transmission with DW-2 Shifter 644B-37 (S/N 101–880) 6K-37 (S/N 101–397) 6K-42 (S/N 101–131) 644B-42 (S/N 101–241) 844C-42 (S/N 101–783) 8K-42 (S/N 101–261) 1044C-42 (S/N 101–121) 10K-42 (S/N 101–107) 1044C-54 (S/N 101–25) 10K-54 (S/N 101–107, 109) 1. Check for correct fluid and fluid level. Consult Service/Lubrication Schedule and see the Transmission Oil Selection Chart located in the Owner/Operator Manual. 2.
Transmission 9. Check short harness. It connects the solenoids to the transmission valve connector. It is accessible by removing the transmission valve assembly cover. a. Inspect harness and connections from solenoids to the transmission valve connector. b. Test continuity between plug ends and valve connector pins. 10. Check transmission pressure. Control pressure should be 230–260 psi (16–18 bar). See “ZF Transmission Pressure Checks” on page 8-23.
Transmission 9. Check transmission pressure. Control pressure should be 230–260 psi (16–18 bar). See “ZF Transmission Pressure Checks” on page 8-23.
Transmission ZF Transmission with DW-3 Shifter 6K-37 (S/N 398–) 6K-42 (S/N 132–) 644B-37 (S/N 881–) 644B-42 (S/N 242–) 8K-42 (S/N 262–) 844C-42 (S/N 784–) 10K-42 (S/N 108–) 10K-54 (S/N 108, 110–) 1044C-42 (S/N 122–) 1044C-54 (S/N 216–) If an electrical supply problem is suspected, the operator may also experience circuit failures, alternator/charging problems, or starting problems. These problems should be addressed and corrected prior to proceeding with diagnosis of the ZF transmission electrical system.
Transmission 2. Make sure the parking brake is disengaged and the service brake is not applied. 3. Transmission declutch switch must be in “OFF” position. 4. With the engine off, turn ignition switch to the “ON” position. Do not start the engine. 5. Wait five seconds before selecting a direction and speed range. This allows the EST-19 to perform self diagnostic checks. 6. Probe colored wires from shifter at the front of the sealed connectors.
Transmission 3. Because the proximity switch can also declutch the transmission, the boom elevation must be lower than 40°. 4. Remove cover at transmission valve to gain access to solenoids. 5. Turn ignition to “ON” position. 6. Wait five seconds before shifting. This allows the EST-19 to perform self-diagnostic testing. 7. Select direction and speed range. 8. Probe positive (+) contacts for voltage. 9. Test all direction and speed range combinations shown in Fig. 8-3. 10.
Transmission Inductive sensor failure can be eliminated as soon as the sensor signal is sensed by the microprocessor. Inductive sensor failure can be corrected with the following steps: 1. Check for pinched or severed wire(s) between the EST-19 and the ZF transmission system harness. Repair or replace, if necessary. 2. Check for a loose or separated plug connection at the transmitter on the transmission. 3. Check for a failed inductive transmitter by checking resistance. The correct resistance should be 1.
E1015 Transmission Fig. 8-4: DW-3 Signal/Wire Combinations for a 3WG-100 Transmission No power at Red or Violet Wires 7. If no power is present at Red or Violet wires, check for the following: a. Park brake is on or the park brake pressure switch is closed when it should be open. b. Transmission declutch switch is in the “ON” position and the service brake pressure switch is stuck closed. c. Boom is above 40° or the proximity switch relay is not being energized by proximity switch. d.
Transmission g. Ignition Relay (37383X): i. Check resistance between pin 86 and pin 85: 76 W ii. Check ground connection to pin 85 through the horn button ground. h. Ignition switch. i. Circuit breaker. j. Battery and cable connections. DW-3 Speed Range/Direction Signal Test for a 4WG-100 Transmission 1. Park the machine on level ground, lower the boom, and block the wheels. 2. Make sure the parking brake is disengaged and the service brake is not applied. 3.
E1011 Transmission Fig. 8-5: DW-3 Signal/Wire Combinations for a 4WG-100 Transmission No power at Red or Violet Wires 7. If no power is present at Red or Violet wires, check for the following: a. Park brake is on or the park brake pressure switch is closed when it should be open. b. Transmission declutch switch is in the “ON” position and the service brake pressure switch is stuck closed. c. Boom is above 40° or the proximity switch relay is not being energized by proximity switch. d.
Transmission ii. Check ground connection to pin 85 through the horn button ground. h. Ignition switch. i. Circuit breaker. j. Battery and cable connections. DW-3 Signals at Transmission Test Note:Signals from DW-3 Controller, when measured at the solenoids, are dependent upon correct voltage “IN” and “OUT” signals from the DW-3. It is necessary to confirm signal integrity from the DW-3 before proceeding with the following test.
Transmission 3WG-100, 3-SPEED TRANSMISSION DW-3 CONTROLLER SIGNALS MEASURED AT VALVE SOLENOIDS Forward, Declutch OFF 1st Gear — M3 M2 M4 M5 2nd Gear — M3 M4 M5 3rd Gear — M3 M5 Forward, Declutch ON 1st Gear — M2 M4 2nd Gear — M4 3rd Gear — — Reverse, Declutch OFF 1st Gear — M1 M2 M4 2nd Gear — M1 M4 3rd Gear — M1 Reverse, Declutch ON 1st Gear — M2 M4 2nd Gear — M4 3rd Gear — — Neutral 1st Gear — M2 M4 2nd Gear — M4 3rd Gear — — 4WG-100, 4-SPEED TRANSMISSION DW-3 CONTROLLER SIGNALS MEASURED AT VALVE S
Transmission Shunt Diodes E1016 Description Fig. 8-7: Typical Shunt Diode Application Fig. 8-7 represents a typical shunt diode application. When the switch is opened, the magnetic field surrounding the coil collapses and generates reverse polarity voltage. If enough voltage is present, it will jump (arc) the contacts in the switch and may cause damage. The diode protects the switch contacts from this reverse voltage by providing a path of lesser resistance for the electricity.
Transmission 2. Measure forward voltage by connecting the black DMM lead to the cathode side of the diode and the red DMM to the anode side of the diode. Typically the value registered on the DMM display will be 0.5V for a P21787 diode. 3. Measure reverse voltage by connecting the black DMM lead to the anode side of the diode and the red DMM lead to the cathode side of the diode. The DMM display should register “OL” for overrange. 4.
Transmission A symptom of a failed park brake (or service brake) pressure switch is a transmission that will not go into forward or reverse (loss of forward and reverse clutch packs). If this happens, check the pressure switch integrity (see below). Park Brake Pressure Switch Integrity Test 1. Apply the park brake. 2. Locate the park brake pressure switch and unplug both leads connecting the pressure switch to the vehicle’s harness. 3.
Transmission Machines w/ DW-3 Shifter For machines equipped with a DW-3 shifter, a closed pressure switch completes a circuit that sends an electric signal to the transmission declutch relay. The relay energizes and stops power to the DW-3 shifter. This prevents the shifter from sending the signals to the transmission solenoids that engage forward/reverse and this declutches the transmission.
Transmission Rear Oscillation Lock Proximity Switch and Relay General Wire Harness Inner Jam Nut Proximity Switch Outer Jam Nut j1074 Connection Wire Fig. 8-9: Rear Oscillation Lock Proximity Switch (Ref. Fig. 8-9) The rear oscillation lock proximity switch is located at the rear left side of the transfer carriage. This switch senses if the boom elevation is above or below 40°. When the boom elevation is below 40°, the proximity switch is closed and energizes the proximity switch relay (R1).
Transmission Rear Oscillation Lock Proximity Switch Integrity Test 1. Disconnect the plug connecting the wire harness at the proximity switch. 2. Remove the proximity switch from the transfer carriage by loosening and removing the jam nut on the inside of the transfer carriage. 3. Reference the wire harness end of the proximity switch to note the connection guide and the position of the four pins as shown in Fig. 8-10.
Transmission 3. Using a DMM set to meter resistance, test for resistance between blade 86 and blade 85. A Bosch brand relay should meter 85 ±5 W. A Potter & Brummfield brand relay should meter 90 ±10% W. 4. Connect a 12 volt lead to blade 86. Connect a ground lead to blade 85. Using a DMM set to test continuity, test for continuity between blade 30 and blade 87. Note:With 12 volts at blade 86 and blade 85 grounded, continuity between blade 30 and blade 87 must be present; if not, replace the relay. 5.
Transmission ZF Transmission Pressure Checks Control Pressure 232–261 PSI (16–18 Bar) Forward/Reverse 1, 2, 3, 4, Clutch Pressures 232–261 PSI (16–18 Bar) Reduced Pressure to Solenoids 145 PSI (10 Bar) 2nd (57) Reverse (55) 1st (56) 3rd (58) 4th (60) E1001 Control Pressure (65) Forward (53) Fig. 8-12: Transmission Pressure Check Ports (Ref. Fig. 8-12) Install 600 psi gauge at control pressure port (65). Check and record control pressure in neutral at idle rpm.
Section 9 — Brakes Table of Contents Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Description, Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Brake Testing and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Service Brake Pedal and Valve . . . . . .
Fig. 9-6: Service Brake and Valve Installation — Models with Control Manifold Hydraulics . . . . . . . . . . 9-9 Fig. 9-7: Service Brake and Valve Assembly – Models with Control Manifold Hydraulics . . . . . . . . . . 9-11 Fig. 9-8: Service Brake Adjustment – Models with Control Manifold Hydraulics . . . . . . . . . . . . . . . . . . 9-13 Fig. 9-9: Cab Front Cover Installation – Early Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Fig.
Section 9 — Brakes Service Brakes Description, Models with Control Manifold Hydraulics The service brakes are operated and controlled by hydraulic oil from the hydraulic system. Fluid flows from the brake port of the control manifold to the brake valve and on to the front and rear brakes.
Brakes Brake Testing and Bleeding The following procedure may be used to check brake components for failure or adjustment with the aid of test gauges. Test gauge kits sold by JLG are listed in Section 19. The bleeding procedure alone does not require use of test equipment. 5 1 4 6 2 3 7 8 9 K1018 # 1 2 3 4 5 Description # Capscrew Valve Guard Gas Valve Cap Gauge Bleed Valve Accumulator Test Gauge 6 7 8 9 10 K1018 10 Description Gauge Cap Nitrogen Hose “T” Handle Gas Valve Accumulator Fig.
Brakes 3. Remove the two (2) capscrews (Item 1), valve guard (Item 2), and gas valve cap (Item 3) from the accumulator (Item 10) (see Fig. 9-2). 4. Mount accumulator test gauge (Item 5) to the accumulator gas valve (Item 9). The pressure gauge must have a 2000 psi capacity (correctly calibrated) with 5/16-32 UNEF mounting nut threads. Before installing it, perform the following: a. The bleed valve (Item 4) must be tightly closed (turned in). b.
Brakes 9. Open bleeder screw at left rear wheel (see Fig. 9-4) and slowly apply brake pedal until air is bled out of the line. Then close the bleeder screw by torquing it to 20 ft-lbs. Repeat this step at each wheel in the following sequence: left rear, right rear, right front, left front. Bleeder Screw Fig. 9-4: Brake Bleeding 10. For testing brake line pressure, apply pressure on the brake pedal and hold. The gauge at the test port should read 310 to 350 psi.
Brakes The brake testing and bleeding procedure is complete. Accumulator Pre-charge 15. The following procedure is for adjusting accumulator pre-charge (from Step 7 above). a. If test gauge pressure reads too high, slowly turn out gauge bleeding valve (Item 4) to release pressure and tighten when 375–425 psi on accumulator gauge (Item 5) is indicated. b. If test gauge pressure reads too low, charge accumulator as described in “Pre-Charging Accumulator” on page 9-19 (through Step 12). c.
Brakes Service Brake Pedal and Valve Adjustment Service Brake Valve Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 8 9 1 10 2 11 4 12 2 5 13 14 3 15 16 17 7 6 18 22 23 # Description # 1 2 3 4 5 6 7 8 9 10 11 12 Brake Pedal Hex Nut U-Clamp Deadband Setscrew Socket Head Capscre
Brakes 1. With the engine off, connect a 0–600 psi gauge to the test port marked “BRAKES” located behind the cab step. Pump the brakes until the gauge reads 0 psi. 2. Remove the brake pedal assembly (Item 1) by loosening the four (4) 1/4” nuts (Item 2) on the two (2) U-clamps (Item 3) and pushing the pedal mounting pin (Item 7) out. 3. Remove the rubber boot (Item 9), being careful not to damage it. 4. Use a spanner wrench to remove the piston guide (Item 10) from the body (Item 19). 5.
Brakes 16. Install the rubber boot (Item 9) onto the body (Item 19). Apply a quality adhesive sealant to the boot and head of the flange head capscrew. 17. Repeat Step 9 and Step 10. 18. Adjust the deadband setscrew (Item 4) until it contacts the flange head capscrew. 19. Place a 0.010” shim between the actuator base (Item 6) and the pedal return stop. 20. Connect a 0–600 psi gauge to the brake test port behind the cab step and start the engine.
Brakes Removal Service Brake Pedal and Valve – Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 8 3 9 4 5 10 6 7 11 12 2 17 16 15 13 14 12 15 V1072 11 # 1 2 3 4 5 6 7 8 9 Description Cab Front Cover Phillips Truss Head Screw Hex Nut Lockwasher Large Flatwasher Flatwasher Phillips
Brakes The following service brake removal procedure refers to Fig. 9-6. 1. Follow preparation procedures as outlined in Section 3 and in Section 5 of this manual. 2. With the engine off, connect a 0–600 psi gauge to the test port located behind the cab step. 3. Pump the brake repeatedly until the gauge reads 0 psi. 4. Loosen and remove Phillips truss head screw (Item 7), flatwashers (Items 5 and 6), lockwasher (Item 4), and hex nut (Item 3) that secure cab front cover (Item 1) to cab step. 5.
Brakes Disassembly Service Brake Valve – Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 7 8 1 9 2 10 11 2 4 12 13 3 14 15 16 6 5 17 21 22 # Description # 1 2 3 4 5 6 7 8 9 10 11 Brake Pedal Hex Nut U-Clamp Socket Head Capscrew Actuator Base Pedal Mounting Pin Flange Head Capscr
Brakes 4. Discard rubber boot (Item 8), O-ring (Item 10), and seal (Item 11). 5. Clean remaining parts with solvent and dry with compressed air. Inspect all parts for damage and replace, if necessary. Note: The spool (Item 15) and valve body (Item 18) cannot be purchased separately. If these parts are damaged, it will be necessary to replace the entire valve assembly (Items 7–20).
Brakes Service Brake Adjustment Procedures Models with Control Manifold Hydraulics 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 7 8 2 3 9 10 2 4 11 Place a .
Brakes 1 2 3 H1049 4 5 # 1 2 3 Description Cab Front Cover Flatwasher Phillips Truss Head Screw # 4 5 Description Flatwasher Phillips Truss Head Screw Fig. 9-9: Cab Front Cover Installation – Early Production 3. (Ref. Fig. 9-9) Remove the cab front panel as follows: a. Remove the Phillips truss head screw (Item 3) and flatwasher (Item 2) securing the cab front cover (Item 1) to the cab step. b.
Brakes 11. Install the brake pedal (Item 1) onto the actuator base (Item 5) by pushing the pedal mounting pin (Item 6) through the U-clamps (Item 4) until centered in the actuator base (Item 5). 12. Tighten the four (4) ¼" nuts (Item 2) on the U-clamps. Adjust the deadband setscrew (Item 3) out so that it doesn’t contact the flange head capscrew (Item 7). 13. Connect a 0–600 psi gauge to the brake test port located behind the cab step. 14.
Brakes Service Brake Pressure Switch Replacement Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 2 3 4 5 V1073 6 # 1 2 3 Description Wiring Harness Connector Service Brake Pressure Switch Hydraulic Hose # 4 5 6 Description Adapter Fitting Brake Pedal Hydraulic Hose Hydraulic Hose Fig
Brakes Models with Mid-Inlet Hydraulics 6K-37 (S/N 318–) 6K-42 (S/N 120–) 8K-42 (S/N 221–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 844C-42 (S/N 622–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) A 1 2 V1102 3 # 1 2 Description Wiring Harness Connector Service Brake Pressure Switch # 3 Description Control Valve Fig.
Brakes Accumulator General The accumulator is a 3000 psi piston-type accumulator. It has a oil volume of 116 cubic inches and gas volume of 126 cubic inches, with a bore size of four inches. The pneumatic accumulator is operated by compressed gas. Gas and hydraulic oil occupy the same container. When oil pressure rises, incoming oil compresses the gas. When oil pressure drops, the gas expands, forcing oil out. The gas is separated from the oil by a “free floating” piston (see Fig. 9-12).
Brakes Precautions WARNING: Never fill an accumulator with oxygen! An explosion could result if oil and oxygen mix under pressure. Always fill an accumulator with dry nitrogen. Nitrogen gas is free of water vapor and oxygen which makes it harmless to parts and is safe to use. CAUTION: Never fill an accumulator with air. When air is compressed, water vapor condenses and can cause corrosion. This may damage seals and ruin the accumulator.
Brakes 5 1 4 6 2 3 7 8 9 K1018 # 1 2 3 4 5 Description Capscrew Valve Guard Gas Valve Cap Gauge Bleed Valve Accumulator Test Gauge # 6 7 8 9 10 K1018 10 Description Gauge Cap Nitrogen Hose “T” Handle Gas Valve Accumulator Fig. 9-13: Accumulator Charging Pre-charge the accumulator using the following steps (see Fig. 9-13): 1. Follow preparation procedures as outlined in Section 3 and in Section 5 of this manual. 2. Make sure nitrogen supply is shut off. 3.
Brakes 10. Turn “T” handle all the way down. This will depress (open) the core in the gas valve. 11. Crack open nitrogen bottle valve and slowly fill the accumulator. Close the nitrogen bottle valve when gauge indicates desired pre-charge pressure (400 psi). 12. Let the pre-charge set for 10–15 minutes. This will allow the gas temperature to stabilize.
Brakes 5. Record the lowest pressure observed before the accumulator recharges. The pressure should be 950–1200 psi. This reading is the accumulator recharge pressure. 6. Shut the engine off. 7. Slowly pump the brake pedal while closely watching the pressure gauge. 8. Record the lowest pressure observed before the pressure drops to nearly zero. This reading is the nitrogen pre-charge. This pressure should be 375–425 psi. 9.
Brakes Removal Accumulator Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C42 (S/N 101–521) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 2 3 4 5 6 7 8 12 10 K1115 9 13 11 # 1 2 3 4 5 6 7 Description Capscrew Gas Valve Guard Gas Valve Cap Gas Valve Accumulator Mounting Bracket Hex Nut # Description 8 Lockwasher 9 Capscrew 10 Hydraulic Hose to
Brakes 3. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. At this point, the “free-floating” piston will be bottomed at the hydraulic end cap. Remove test gauge and cap diagnostic port. 4. To release pre-charge pressure in accumulator, perform the following steps (see Fig. 9-2 on page 9-2): a. Remove two (2) capscrews (Item 1) and gas valve guard (Item 2). b. Remove gas valve cap (Item 3) from gas valve (Item 9). c.
Brakes Overhaul Accumulator 1 11 2 10 3 4 5 8 6 7 12 8 9 13 10 K1116 14 # 1 2 3 4 5 6 7 Description Hex Capscrew Valve Guard Gas Valve Cap Gas Valve O-Ring Gas End Cap O-Ring # 8 9 10 11 12 13 14 Description Teflon Ring Piston Backup Washer V-Ring Accumulator Body O-Ring Hydraulic End Cap Fig. 9-15: Accumulator Assembly The following procedure refers to Fig. 9-15. 1. Lay accumulator horizontally in a vice or hold it down with a strap wrench. 2.
Brakes 5. Remove piston (Item 9) by pushing it out with a bar from hydraulic end of accumulator. CAUTION: Never try to remove piston by applying compressed air to the opposite end. 6. Remove two (2) Teflon rings (Item 8) from piston. 7. Remove two (2) backup washers (Item 10) from piston. 8. To remove V-ring (Item 11) from piston, lift it with a small, smooth screw driver or similar tool. Move tool around the piston several times while using the other hand to work ring off piston. 9.
Brakes 18. Use a hammer and wood block to tap piston into the bore until it is about two inches below start of honed bore surface. To prevent piston from bouncing back and damaging the V-ring, keep force against piston while tapping piston through bore chamfer. Cover gas end opening of accumulator body to keep dirt out. 19. Install new O-rings (Items 7 and 13) on end caps (Items 6 and 14). Note: Care should be taken not to drag end cap O-rings over threads in body.
Brakes 20 40 60 80 Park Brake -20 0 1 Park Brake Cylinder Drum Brake H1007 V1078 Parking Brake Control Fig. 9-16: Park Brake The park brake is a drum type located on the output shaft of the transmission (see Fig. 9-16). The park brake cylinder, cylinder mount, and linkage assembly is located on the transmission behind the valve plate. The hydraulic cylinder has an internal compression spring that actuates the park brake.
Brakes The version used in latter production is shown in Fig. 9-22. This version includes a cylinder that is mounted vertically and has 600 pounds of spring force when the rod is fully extended and 300 pounds of spring force when the rod is fully retracted. It has a maximum hydraulic extend of 500 psi and a 2” bore by 2.62” stroke single-acting spring retract. Inspection 1. Inspection interval is every 100 hours of operation. 2. Check all hydraulic lines and fittings for leaks and damage. 3.
Brakes Park Brake Pressure Switch Removal Models with Control Manifold Hydraulics 6K-37 (S/N 101–317) 6K-42 (S/N 101–119) 8K-42 (S/N 101–220) 10K-42 (S/N 101–106) 10K-54 (S/N 101–103) 644B-37 (S/N 101–590, 592–666) 644B-42 (S/N 101–207) 844C-42 (S/N 101–621) 1044C-42 (S/N 101–116) 1044C-54 (S/N 101–154) 1 2 3 4 V1074 5 6 7 # 1 2 3 4 Description Wiring Harness Connector Park Brake Pressure Switch Reducer Bushing Adapter # 5 6 7 Description Hydraulic Hose to Brake Cylinder Swivel Branch Tee Hydraulic
Brakes 4. Remove the brake pressure switch from the reducer bushing (Item 3). Discard pressure switch. Models with Mid-Inlet Hydraulics 6K-37 (S/N 318–) 6K-42 (S/N 120–) 8K-42 (S/N 221–) 10K-42 (S/N 107–) 10K-54 (S/N 104–) 644B-37 (S/N 591, 667–) 644B-42 (S/N 208–) 844C-42 (S/N 622–) 1044C-42 (S/N 117–) 1044C-54 (S/N 155–) 1 V1105 2 # Description 1 Park Brake Pressure Switch # 2 Description Intermediate Wire Harness Fig. 9-18: Park Brake Pressure Switch - Models with Mid-Inlet Hydraulics (Ref.
Brakes Installation, Park Brake Pressure Switch Models with Control Manifold Hydraulics (Ref. Fig. 9-17) The following procedure describes installation of the park brake pressure switch used on models with control manifold hydraulics. 1. Install a new brake pressure switch (Item 2) on reducer bushing (Item 3). Tighten two or three turns past finger tight. 2. Reconnect wiring harness connectors (Item 1) to the connectors on the brake pressure switch. Models with Mid-Inlet Hydraulics (Ref. Fig.
Brakes Valve Removal, Park Brake 3 4 1 2 13 5 14 12 6 11 7 7 V1077 8 10 9 # 1 2 3 4 5 6 7 Description Capscrew Lockwasher Instrument Panel Park Brake Valve Elbow Hydraulic Hose Elbow # 8 9 10 11 12 13 14 Description Hydraulic Hose to Pressure Switch Hydraulic Hose to Control Manifold Elbow Hydraulic Hose Check Valve Connector Hydraulic Hose Fig. 9-19: Park Brake Assembly 1. Follow preparation procedures as outlined in Section 3 and in Section 5 of this manual. 2.
Brakes 6. Tag and slowly loosen hydraulic hoses (Items 6, 11 and 14) from elbow (Item 5), check valve (Item 12), and connector (Item 13). Bleed any remaining oil into appropriate container. Disconnect hoses. Cap hoses and fittings. 7. Loosen and remove the two (2) each capscrews (Item 1) and lockwashers (Item 2) that secure the park brake valve (Item 4) to the instrument panel (Item 3). 8. Remove the park brake valve and take it to a clean area appropriate for further cleaning and disassembly. 9.
Brakes f. Clean all remaining parts with appropriate solvent and dry with compressed air. Inspect and replace any damaged parts. Note: It may not be necessary to separate control knob (Item 1) and lockwasher (Item 2) from valve spool (Item 4). Disassemble only if they are damaged or extremely contaminated. Note: The valve spool (Item 4) and valve housing (Item 7) are not sold separately. If these parts are damaged, it will necessary to replace the entire park brake valve assembly. g.
Brakes Cylinder Removal Models with Horizontal Cylinder Mount 644B-37 (S/N 101–383) 644B-42 (S/N 101–119) 844C-42 (S/N 101–281) 1044C-42 (S/N 101–106) 1044C-54 (S/N 101–102) 6K-37 (S/N 101–211) 6K-42 (S/N 101–105) 8K-42 (S/N 101–162, 165) 10K-42 (S/N 101–106) 3 4 1 2 5 8 6 7 9 10 23 11 22 19 21 28 20 13 24 27 26 12 18 13 17 16 25 14 V1075 15 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Cotter Pin Brake Cylinder Pin Hydraulic Brake Hose Elbow Park Brake Cylinder Hex Jam Nut Lockwasher
Brakes 1. Follow preparation procedures as outlined in Section 3 and in Section 5 of this manual. 2. Block the wheels and make sure the park brake is released. 3. Install a brake pressure diagnostic port test gauge to the hose into the brake diagnostic port. 4. While watching test gauge, press brake pedal numerous times until pressure gauge reads 0 psi. Remove test gauge and cap diagnostic port. 5.
Brakes Models with Vertical Cylinder Mount 644B-37 (S/N 384–) 644B-42 (S/N 120–) 844C-42 (S/N 282–) 1044C-42 (S/N 107–) 1044C-54 (S/N 103–) 6K-37 (S/N 212–) 6K-42 (S/N 106–) 8K-42 (S/N 163–164, 166–) 10K-42 (S/N 107–) 10K-54 (S/N 101–) 1 4 5 7 6 2 8 12 11 3 9 10 13 V1076 14 # 1 2 3 4 5 6 7 Description Park Brake Cylinder Mount Hydraulic Brake Hose Elbow Clevis Pin Cotter Pin Park Brake Cylinder Brake Cam # 8 9 10 11 12 13 14 Description Cotter Pin Clevis Pin Clevis Lockwasher Jam Nut Park Bra
Brakes 8. Remove cotter pin (Item 5) and clevis pin (Item 4) securing the park brake cylinder (Item 6) to cylinder mount (Item 1). Remove park brake assembly. 9. Take park brake assembly, along with other disassembled parts, to an appropriate place for further inspection and cleaning. 10. Remove elbow (Item 3), clevis (Item 10), lockwasher (Item 11), and jam nut (Item 12) from park brake cylinder. 11. Discard park brake cylinder and cotter pins.
Brakes Note: With the park brake cylinder (Item 5) fully extended and the brake cam (Item 15) raised 1/16–1/8” from its lowest possible position, it should be possible to insert the clevis pin (Item 10) directly into the clevis (Item 8) and through the bell crank (Item 11). 6. Make any necessary adjustments in the position of the clevis on the cylinder rod to meet the guidelines described in the above note. 7. Install new cotter pin (Item 9) on clevis pin. 8.
Brakes Models with Horizontal Cylinder Mount 644B-37 (S/N 101–383) 644B-42 (S/N 101–119) 844C-42 (S/N 101–281) 1044C-42 (S/N 101–106) 1044C-54 (S/N 101–102) 6K-37 (S/N 101–211) 6K-42 (S/N 101–105) 8K-42 (S/N 101–162, 165) 10K-42 (S/N 101–106) The park brake cylinder used on models with a horizontal cylinder mount includes a clevis and jam nut whose position can be adjusted (see Fig. 9-21).
Brakes Models with Vertical Cylinder Mount 644B-37 (S/N 384–) 644B-42 (S/N 120–) 844C-42 (S/N 282–) 1044C-42 (S/N 107–) 1044C-54 (S/N 103–) 6K-37 (S/N 212–) 6K-42 (S/N 106–) 8K-42 (S/N 163–164, 166–) 10K-42 (S/N 107–) 10K-54 (S/N 101–) The park brake cylinder used on models with a vertical cylinder mount require only an adjustment to the position of the clevis and jam nut (see Fig. 9-22).
Section 10 — Outriggers Table of Contents Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 10 — Outriggers Outriggers 20 40 60 80 General 0 V1083 -20 Fig. 10-1: Outriggers Outriggers are standard on models with 4-section booms (1044C-54, 10K-54). and optional on other models. They increase the stability of the machine when lifting and placing loads.
Outriggers Removal Outriggers 1 9 2 3 4 10 11 12 13 5 78 6 22 14 21 15 20 16 17 V1085 19 18 # 1 2 3 4 5 6 7 8 9 10 11 Description Outrigger Cylinder Differential Pressure Switch Tie Wiring Harness Elbow Hydraulic Hose Shim(s) Outrigger Support Plate Bushing Capscrew Capscrew Lockwasher # 12 13 14 15 16 17 18 19 20 21 22 Description Double Tube Clamp Clamp Plate Jam Nut Starwasher Nut Shaft Assembly Nut Lockwasher Capscrew Grease Fitting Grease Fitting Cover Fig.
Outriggers DANGER: Support of the boom is essential to avoid the possibility of injury or death should the boom fall. Use suitable blocking and lifting devices when removing heavy machine components. 4. Place blocks or other means of support under the front and rear corners of the outrigger frame. Make sure supports are adequate to support the weight of the outrigger; the outrigger weighs approximately 2585 pounds. 5.
Outriggers 3. Temporarily install a capscrew (Item 20) into the orifice in the shaft assembly (Item 17). Measure the gap between the outrigger assembly and the support plate boss on the main frame. 4. Remove the capscrew and outrigger assembly. 5. Install as many shims (Item 7) as needed on shaft assembly to fill the gap measured in Step 3. Note: Shims are available in three different sizes – 16, 20, and 24 gauge. 6.
Outriggers 20 40 60 80 Outrigger Cylinders -20 0 V1082 General Fig. 10-3: Outrigger Cylinders The outrigger cylinders have an operating pressure of 3000 psi and have a 15.63” stroke. Each cylinder includes four bushings.
Outriggers Removal Outrigger Cylinders 1 4 23 5 6 7 10 8 11 9 14 V1084 12 13 # 1 2 3 4 5 6 7 Description Wiring Harness Tie Differential Pressure Switch Outrigger Cylinder Elbow Hydraulic Hose Pin # 8 9 10 11 12 13 14 Description Capscrew Lockwasher Lock Pin Pin Capscrew Lockwasher Lock Pin Fig. 10-4: Outrigger Cylinder Installation (Ref. Fig. 10-4) The following procedure describes removal of the outrigger cylinders. 1.
Outriggers 5. Place blocking device under the top of the outrigger cylinder. Remove the capscrew (Item 12) and lockwasher (Item 13) from the lock pin (Item 14). Remove the lock pin and upper pin (Item 11). 6. Remove a capscrew (Item 8) and lockwasher (Item 9) from the lock pin (Item 10). Remove the lock pin and lower pin (Item 7). 7. Remove the outrigger cylinder. 8. Repeat Steps 5–7 for the remaining outrigger cylinder. Installation Outrigger Cylinders (Ref. Fig.
Outriggers Overhaul Outrigger Cylinders 9 5 10 8 6 7 4 12 11 14 13 3 17 15 18 2 1 12 4 V1086 16 # 1 2 3 4 5 6 7 8 9 Description Grease Fitting Grease Fitting Cover Counterbalance Valve Cartridge Bushing O-ring Plug Differential Pressure Switch Elbow Counterbalance Valve Cartridge Cylinder Barrel # 10 11 12 13 14 15 16 17 18 Description Rod Bearing Nut Piston Bushing Grease Fitting Grease Fitting Cover Rod Cylinder Cap Setscrew Stroke Limiter Fig. 10-5: Outrigger Cylinder Assembly (Ref.
Outriggers 4. Release pressure in each cylinder as follows: WARNING: The counterbalance valve cartridge traps hydraulic pressure in the cylinder. Wear proper eye and hand protection when removing counterbalance valve cartridges. Hydraulic fluid under pressure can be injected under skin or into eyes, resulting in serious personal injury or death. a. Place a socket wrench over each counterbalance valve cartridge (Items 3 and 8).
Outriggers 15. Inspect inner surface of barrel, outer surface of piston, and length of rod for scratches and scoring. If the barrel, piston, or rod are damaged, they must be replaced. 16. Check the condition of the threads on the rod, nut, and capscrews. Do not attempt to repair damaged threads. 17. Inspect the counterbalance valve cartridges (Items 3 and 8), including O-rings, for condition and replace as necessary. Do not disassemble cartridges.
Outriggers Boom Extension Proximity Switch Description 1044C-54 10K-54 J1146 Proximity Switch 20 40 60 80 Fig. 10-6: Boom Extension Proximity Switch 0 (Ref. Fig. 10-6) The boom extension proximity switch is located on the left side of the outer boom section on machines with a 4-section boom. The boom extend/lockout circuit is designed to increase stability of the machine by limiting how far the boom can be extended without the outriggers down.
Outriggers Outer Boom Section Middle Rear) Boom Section Magnetic Flux Lines Proximity Switch J1259 Oscillator Fig. 10-7: Boom Extension Proximity Switch Operation (Ref. Fig. 10-7) The switch operates by sending out a constant, high frequency magnetic field a short distance from the oscillator end of the switch. Eddy currents are produced in metal when the magnetic flux lines pass through it. These eddy currents oppose the oscillations of the magnetic flux lines and the oscillations stop.
Outriggers (Ref. Fig. 10-8) The following procedure describes removal of the boom extension proximity switch. 1. Disconnect the wire harness (Item 4) at the boom extension proximity switch (Item 2). 2. Place a piece of masking tape around the proximity switch body at the outer jam nut (Item 3). This will serve as a guide during reinstallation. 3. Remove the inner jam nut (Item 1) and proximity switch. Reinstall the inner jam nut on the proximity switch for safekeeping.
Outriggers 1. Loosen, but do not remove the two (2) jam nuts on the proximity switch body. 2. Check the gap between switch and boom. The gap must be within the range specified in Fig. 10-9. 3. If the boom extension proximity light does not illuminate when the boom is extended to the specified distance (approximately 21 feet with a tilting tower or 25 feet with a standard carriage), adjust the proximity switch to slightly reduce the gap. Do not exceed gap tolerances specified in Fig. 10-9.
Outriggers Removal Outrigger Control Valve 5 4 1 2 6 7 8 3 9 14 15 16 10 11 12 V1088 13 # 1 2 3 4 5 6 7 8 Description Nut Lockwasher Tie Rod Outrigger Control Valve Button Head Capscrew Frame Tilt Control Valve Lockwasher Nut # 9 10 11 12 13 14 15 16 Description Connector Hydraulic Hose Control Panel Lockwasher Nut Rear Cover Flatwasher Phillips Truss Head Screw Fig. 10-11: Outrigger Control Valve Installation (Ref. Fig.
Outriggers 6. Remove the two (2) nuts (Item 13), lockwashers (Item 12), and capscrews (Item 5) securing each valve section to the control panel (Item 11). Remove the outrigger valve sections. Installation Outrigger Control Valve (Ref. Fig. 10-11) The following procedure describes installation of the outrigger control valves. 1. Secure the two (2) outrigger control valves (Item 4) to the frame tilt control valve (Item 6) with three (3) tie rods (Item 3).
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
