JLG Lull 1044C-54 II Series Service Manual Download

Page: 252 / 382

Boom and Transfer

6-110

31200079

11. Install new hose sheaves with existing sheave retaining pins. Pull

hoses up around sheave and reattach to tubes. Avoid crossing or
twisting hoses when reconnecting and tightening.

Note:

There is a change in the hose routing. Please follow the instructions below.

For units with 2nd aux., connect the inner hose on the hose sheave to the
upper inner tube, connect the middle hose on the hose sheave to the lower
2nd aux. tube and connect the outer hose on the hose sheave to the upper
outer tube.

12. At the front of the boom, pull the tubes forward until the ferrules of the

tubes butt up against the hose clamps at the rear of the inner boom. At
the front of the inner boom, install and secure tube stops against hose
clamp channel. At the rear of the inner boom align and secure the
upper tube clamps with the hoses on the hose sheaves. Secure tube
clamps at the front of the inner boom. Do not secure tube clamps at the
front of the inner boom. Do not secure tube clamps on 2 aux. units, see
step 12.

13. This is a change in the hose routing for 2nd aux. units only. Take the

hose that is connected to the tube marked 2 and transfer to the tube
marked 3, take the hose from tube 3 and connect it to the tube marked
2. Repeat the procedure for tubes 4 and 5.

14. Retract the boom. Disconnect outer hoses at rear of outer boom and

cap the left side hoses, to prevent the left side hoses from expelling
fluid when the boom is raised or lowered to access the rear tube/hose
hold down clamps.

15. Fully extend the transfer carriage and partially extend the boom.

Loosen and remove the forward most tube clamps on the outer boom.
Remove the fastening hardware securing the hydraulic manifold to the
front and bottom of the outer boom. Disconnect the hoses from the
manifold, and the tubes if necessary.

16. Remove the fastening hardware from the most rear tube/hose clamps

on the under side of the outer boom. Remove the hose hold down
clamp from the boom. Remove hoses from boom at the rear. Pull the
hose sleeve over the hose ends that connect to the tubes at the rear of
the outer boom, leaving 2” of the hose end exposed. Use the tie wraps
at 12” intervals to secure the hose sleeve. Keep the locking
mechanism of the tie wrap to the inside radius on the hoses.

17. Re-install the hoses. Connect the hoses to the hydraulic manifold at

the front of the outer boom. Secure the manifold to the boom. Connect
the tubes to the manifold. Fasten the forward most tube holder to the
boom. Install the hose hold down clamp into the outer boom. Put the
white plastic bushing p/n 11001518 onto the hose hold down clamp.
Attach and secure the tube holder to the hose hold clamp, avoid over-
tightening as this could crush the hoses. Reconnect the hoses to the
tubes at the rear of the outer boom. Be careful not to twist the hoses
while tightening.

JLG Lull 1044C-54 II Series, Service Manual

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