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340AJ Service 3121259 Jan-2012 Global English PDF
340AJ Service 3121259 Jan-2012 Global English PDF
340AJ Service 3121259 Jan-2012 Global English PDF
Model
340AJ
P/N - 3121259
A GENERAL C MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
tions to avoid possible injury to themselves or others, or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM ING ELECTRICAL STORMS. ENSURE THAT FUEL
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE CAP IS CLOSED AND SECURE AT ALL OTHER
MANUFACTURER. TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
The specific precautions to be observed during mainte-
WHEN PERFORMING ANY MAINTENANCE.
nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
when servicing hydraulic and larger machine component LOOSE-FITTING CLOTHING AND NECKTIES WHICH
parts. ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always • OBSERVE AND OBEY ALL WARNINGS AND CAU-
be conscious of weight. Never attempt to move heavy TIONS ON MACHINE AND IN SERVICE MANUAL.
parts without the aid of a mechanical device. Do not allow • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
heavy objects to rest in an unstable position. When raising STANDING SURFACES AND HAND HOLDS.
a portion of the equipment, ensure that adequate support
is provided. • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- MOVEMENT BY BLOCKING OR OVERHEAD SLING,
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY OR BOOM SAFETY PROP HAS BEEN ENGAGED.
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
B HYDRAULIC SYSTEM SAFETY OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED-
It should be noted that the machines hydraulic systems DURING REPLACEMENT OF ELECTRICAL COMPO-
operate at extremely high potentially dangerous pres- NENTS.
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
the system. MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
REVISON LOG
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data
Platform Height
Table 1-1. Operating Specifications
ANSI 33’ 9" (10.29 m)
Capacity: Unrestricted: CE & Australia 33’ 10.5" (10.33 m)
ANSI 500 lbs. (227 kg)
Ground Clearance 10.1" (23.7 cm)
CE & Australia 500 lbs. (230 kg)
5
5
6,8
7
3
5 5
KEY SPECIFICATIONS
BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA
460.
HO Hydraulic Oil. API service classification GL-4, e.g. Mobil-
fluid 424. Lube Point(s) - Grease Fitting
EPGL Extreme Pressure Gear Lube (oil) meeting API Service Capacity - A/R
Classification GL-5 or Mil-Spec Mil-L-2105. Lube - BG
MPG Multipurpose Grease having a minimum dripping point of Interval - A/R
350° F (177° C). Excellent water resistance and adhesive
qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-
L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-
2104C.
*MPG may be substituted for these lubricants, if necessary, but ser-
vice intervals will be reduced.
Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)
Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18
Torque
Torque
Torque (Lub OR Loctite®
Tensile (Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
Size PITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe Annual Machine Inspection
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and The Annual Machine Inspection must be performed by a
maintenance have been completed before placing the Factory-Trained Service Technician on an annual basis,
machine into service. no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. rec-
Preparation, Inspection, and Maintenance ognizes a Factory-Trained Service Technician as a person
who has successfully completed the JLG Service Training
It is important to establish and conform to a comprehen- School for the subject JLG product model. Reference the
sive inspection and preventive maintenance program. The machine Service and Maintenance Manual and appropri-
following table outlines the periodic machine inspections ate JLG inspection form for performance of this inspec-
and maintenance recommended by JLG Industries, Inc. tion.
Consult your national, regional, or local regulations for fur-
ther requirements for aerial work platforms. The frequency Reference the JLG Annual Machine Inspection Form and
of inspections and maintenance must be increased as the Inspection and Preventative Maintenance Schedule for
environment, severity and frequency of usage requires. items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man-
Pre-Start Inspection ual for servicing and maintenance procedures.
It is the User’s or Operator’s primary responsibility to per- For the purpose of receiving safety-related bulletins, it is
form a Pre-Start Inspection of the machine prior to use important that JLG Industries, Inc. has updated ownership
daily or at each change of operator. Reference the Opera- information for each machine. When performing each
tion and Safety Manual for completion procedures for the Annual Machine Inspection, notify JLG Industries, Inc. of
Pre-Start Inspection. The Operator and Safety Manual the current machine ownership.
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Preventative Maintenance
Pre-Delivery Inspection and Frequent
In conjunction with the specified inspections, mainte-
Inspection nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
The Pre-Delivery Inspection and Frequent Inspection shall
equipment mechanic as a person who, by possession of a
be performed by a qualified JLG equipment mechanic.
recognized degree, certificate, extensive knowledge, train-
JLG Industries, Inc. recognizes a qualified JLG equipment
ing, or experience, has successfully demonstrated the
mechanic as a person who, by possession of a recog-
ability and proficiency to service, repair, and maintain the
nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and subject JLG product model.
proficiency to service, repair, and maintain the subject
Reference the Preventative Maintenance Schedule and
JLG product model.
the appropriate areas of this manual for servicing and
The Pre-Delivery Inspection and Frequent Inspection pro- maintenance procedures. The frequency of service and
cedures are performed in the same manner, but at differ- maintenance must be increased as environment, severity
ent times. The Pre-Delivery Inspection shall be performed and frequency of usage requires.
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspec- Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
tion rental delivery. Mechanic Manual and applicable JLG
inspection form.
Frequent Inspection In service for 3 months or 150 hours, Owner, Dealer, or User Qualified JLG Service and Maintenance
whichever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
purchased used.
Annual Machine Annually, no later than 13 months from Owner, Dealer, or User Factory-Trained Service and Maintenance
Inspection the date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General nent is disconnected, cap or cover all openings to
The following information is provided to assist you in the prevent entry of foreign matter.
use and application of servicing and maintenance proce- 3. Clean and inspect all parts during servicing or main-
dures contained in this book. tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
Safety and Workmanship clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain-
Your safety, and that of others, is the first consideration ers until they are ready to be used.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Components Removal and Installation
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising 1. Use adjustable lifting devices, whenever possible, if
a portion of the equipment, ensure that adequate support mechanical assistance is required. All slings (chains,
is provided. cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
Cleanliness lifted.
2. Should it be necessary to remove a component on
1. The most important single item in preserving the
an angle, keep in mind that the capacity of an eye-
long service life of a machine is to keep dirt and for-
bolt or similar bracket lessens, as the angle between
eign materials out of the vital components. Precau-
the supporting structure and the component
tions have been taken to safeguard against this.
becomes less than 90 degrees.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these 3. If a part resists removal, check to see whether all
items must be maintained on a scheduled basis in nuts, bolts, cables, brackets, wiring, etc., have been
order to function properly. removed and that no adjacent parts are interfering.
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com- heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially dance with recommended shop practices. (See
disassemble or assemble one part, then start on another. Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than Hydraulic Lines and Electrical Wiring
those recommended, without obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
Pressure-Fit Parts them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use a molybdenum reinstalled.
disulfide base compound or equivalent to lubricate the
mating surface. Hydraulic System
1. Keep the system clean. If evidence of metal or rub-
Bearings ber particles are found in the hydraulic system, drain
and flush the entire system.
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable 2. Disassemble and reassemble parts on clean work
cleaning solvent and allow to drip dry. Compressed surface. Clean all metal parts with non-flammable
air can be used but do not spin the bearing. cleaning solvent. Lubricate components, as
required, to aid assembly.
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.
Lubrication
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not Service applicable components with the amount, type,
unwrap reusable or new bearings until they are and grade of lubricant recommended in this manual, at
ready to install. the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
4. Lubricate new or used serviceable bearings before that meets or exceeds the specifications listed.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear- Battery
ing is to be installed on a shaft, apply pressure to the
inner race. Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
Gaskets cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a Lubrication and Servicing
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as Components and assemblies requiring lubrication and
blank gaskets can cause serious system damage. servicing are shown in the Lubrication Chart in Section 1.
Platform Drift
Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, main boom fully
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
If the machine does not pass this test, proceed with the
following.
a. Frayed or separated fibers on the liner surface. • Ground on the platform/support and weld on any other
b. Cracked or damaged liner backing. area than the platform/support.
c. Bearings that have moved or spun in their hous- • Ground on a specific boom section and weld on any
ing. other area than that specific boom section.
d. Debris embedded in liner surface.
• Allow pins, wear pads, wire ropes, bearings, gearing,
3. Pins should be replaced if any of the following is seals, valves, electrical wiring, or hoses to be between
observed (pin should be properly cleaned prior to the grounding position and the welded area.
inspection):
a. Detectable wear in the bearing area.
b. Flaking, pealing, scoring, or scratches on the pin FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
surface. RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
c. Rusting of the pin in the bearing area. SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
INTERVAL
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 5 1 1,5
Floor 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Motors
Drive Hubs 11 11
INTERVAL
Functions/Controls
Platform Controls 5 6 6
Ground Controls 5 6 6
Function Control Locks, Guards, or Detents 1,5 5 5
Footswitch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Capacity Indicator 5
Drive Brakes 5
Swing Brakes 5
Manual Descent or Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 2 1,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21 21
Capacity Decals Installed, Secure, Legible 21 21
INTERVAL
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
NOTICE:
Readily Biodegradable*
Synthetic Polyol Esters
Virtually Non-toxic**
Fire Resistant***
Viscosity Index
Vegetable Oils
Mineral Oils
Description
Synthetic
NOTICE:
1001120074-A
NOTICE:
1001120075-A
3.1 TIRES AND WHEELS the fasteners with a lug wrench, then immediately have a
service garage or dealer tighten the lug nuts to the proper
Tire Replacement torque. Over-tightening will result in breaking the studs or
permanently deforming the mounting stud holes in the
JLG recommends a replacement tire be the same size, ply wheels. The proper procedure for attaching wheels is as
and brand as originally installed on the machine. Please follows:
refer to the JLG Parts Manual for the part number of the
approved tires for a particular machine model. If not using 1. Start all nuts by hand to prevent cross threading.
a JLG approved replacement tire, we recommend that DO NOT use a lubricant on threads or nuts.
replacement tires have the following characteristics:
2. Tighten nuts in the following sequence.
• Equal or greater ply/load rating and size of origi-
nal
• Tire tread contact width equal or greater than
original 1
6
• Wheel diameter, width, and offset dimensions 9
equal to the original
4
3
• Approved for the application by the tire manufac- 8
turer (including inflation pressure and maximum 7
2 5
tire load)
TORQUE SEQUENCE
The rims installed on each product model have been
designed for stability requirements which consist of track 1st Stage 2nd Stage 3rd Stage
width, tire pressure, and load capacity. Size changes such 55 ft lbs (75 Nm) 135 ft lbs (180 Nm) 240 ft lbs (325 Nm)
as rim width, center piece location, larger or smaller diam-
eter, etc., without written factory recommendations, may
result in an unsafe condition regarding stability. 4. Wheel nuts should be torqued after each wheel
removal. Check and torque every 3 months or 150
Wheel Installation hours of operation.
3.2 DRIVE ORIENTATION SYSTEM and see Chassis Tilt Indicator System in this section for
interaction with the tilt sensor.
The Drive Orientation System (DOS) is intended to indi-
cate to the operator conditions that could make the direc-
tion of movement of the chassis different than the 3.4 DRIVE/STEER - BOOM FUNCTION
direction of movement of the drive/steer control handle.
The system indicates to the operator the need to match
INTERLOCK SYSTEM (CE ONLY)
the black and white directional arrows on the platform The Drive/Steer - Boom Function Interlock System uses
control panel to the arrows on the chassis. The system the Transport Position Sensing System to sense when the
uses a limit switch mounted on the underside of the turn- boom is out of the transport position. Drive and Boom
table, an indicator light and an override switch on the plat- functions are simultaneously functional when the booms
form display panel. The limit switch trips when the are within the transport position, as on the standard
turntable is swung +/- 42 degrees off center of the normal machine. When the boom is beyond the transport posi-
driving position. This occurs approximately when the tion, the control functions are interlocked to prevent simul-
boom is swung past a rear tire. When the turntable is in taneous operation of any boom function with drive/steer
the normal drive position with the boom between the rear functions. While operating drive/steer functions the boom
tires, no indications or interlocks are made. When the functions are inoperable, likewise, while operating boom
machine is actively driving when the turntable is swung functions drive/steer functions are inoperable.
past the switch point, the system is ignored until drive/
steer is released. When drive is initiated with the boom
swung past the switch point, the DOS indicator will flash 3.5 DRIVE SYSTEM
and the drive/steer functions will be disabled. The opera-
tor must engage the DOS override switch to enable drive/ The Drive system consists of a variable displacement
steer (High Speed drive will remain disabled). When the closed loop pump, four low speed high torque orbital type
DOS is enabled, the DOS indicator will be illuminated con- motors, directional control valves, and a series of flow
tinuously and a 3-second enable timer will be started and dividers.
will continue for 3 seconds after the end of the last drive/ Drive Speed is controlled by a combination of engine RPM
steer command. If the timer expires, the DOS override and drive pump displacement. Traction and torque are
switch must be re-engaged to enable drive/steer. controlled through the flow divider system which is
engaged or bypassed depending on the drive mode
selected. There are three drive modes selectable at the
3.3 BEYOND TRANSPORT POSITION - DRIVE platform control box, and the functionality of the drive sys-
SPEED CUTBACK SYSTEM tem is dependent on the position of the boom (in or out of
transport, see Transport Position Sensing System in Sec-
When the boom is positioned beyond the Transport Posi-
tion 4 and Beyond Transport Position - Drive Cutback Sys-
tion as described in the Transport Position Sensing Sys-
tem in this section). The following chart describes how
tem in Section 4, the drive pump is automatically
the system works in each drive mode.
restricted to approximately 0.75 mph (1.2 kph). See Drive
System in this section for more detail on the drive speeds,
Engine Speed
Drive Pump Flow Max. Speed
Boom Position Drive Selection when Drive is
Displacement Dividers MPH (kph)
Actuated
Engine Speed
Drive Pump Flow Max. Speed
Boom Position Drive Selection when Drive is
Displacement Dividers MPH (kph)
Actuated
Out of Transport Min. Engine Noise Mid-1800 RPM 46% Engaged 0.6 (1.0)
Disassembly 1. Carefully lift from under the gear set to prevent parts
from falling out. Lay the gearwheel set so the o-ring
1. Remove the drain plug (13) and washer (14). groove is upwards. Mark the wheel of the gearwheel
set at the point where the bottom of an internal tooth
2. Carefully place the motor in a vise and remove the is opposite the bottom of an external tooth.
two seal plugs (33) from the end cover (32).
4. Lifting from below the port plate (23), carefully lift the
components from the port plate (23) up from the
motor assembly as a unit.
10. Pour oil into the spacer hole and use a 0.56 in.
(14.25 mm) mandrel as a piston to press up the
pressure plate(26).
11. Remove the guide pin (27). 2. Mark the tip of a spline tooth on the end of the valve
12. Remove the o-rings (28 & 29). drive (22) with the widest splines. Line up the mark
on the rotor and valve drive (22). The end with the
13. Remove the crinkle washer (31). widest splines must point upwards.
14. Remove the valve drive (22). 3. Grease the o-ring (19) with petroleum jelly. Install it
in the gearwheel (20) and channel plate groove.
15. Carefully lifting from under the gear set (20) to pre-
vent parts from dropping out, remove the gear set
4. Fit the channel plate (23) so the o-ring groove is
(20).
upwards and the check valve holes line up with the
16. Remove the o-ring (19). through hole in the gear set.
17. Remove the cardan shaft (18). 5. Install the balls (35).
6. Align the mark on the valve drive (22) with a hole in 11. Grease the spacer (30) with petroleum jelly to pre-
the outer rim. Turn the disc valve (25) counterclock- vent it from dropping out.
wise until the splines in the two parts engage.
12. Install the valve housing (32) on the motor assembly.
7. Place the crinkle washer in the end cover (32). The ports should face in the dame direction as the
8. Grease the two o-rings (28 & 29) with petroleum jelly drain port.
and install them in the balance plate grooves. 13. Secure the assembly together by installing the bolts
9. Install the guide pin (27) in the end cover (32). (34) and torquing 55 to 59 ft.lbs. (75 to 80 Nm).
13
14
17
16
18
19
22 20
23
35 19
24
19
25
26
27
28
29 33
30
31
32
34
13. Drain Plug 18. Cardan Shaft 23. Pressure Plate 28. O-ring 33. Seal Plug
14. Washer 19. O-ring 24. Guide Pin 29. O-ring 34. Bolt
15. Not Used 20. Gear Set 25. Channel Plate 30. Spacer 35. Ball
16. Mounting Flange 21. Not Used 26. Stop Ring 31. Crinkle Washer
17. O-ring 22. Valve Drive 27. Disc Valve 32. End Cover
DRIVE MOTOR
PORT "BRAKE"
PORT "B" ( TORQUE HUB)
(DRIVE MOTOR)
PORT "A" PORT #10
(DRIVE MOTOR) PORT #6
PORT #16
PORT #4
SECTION 3 - CHASSIS & TURNTABLE
PORT "B"
(DRIVE MOTOR)
– JLG Lift –
PORT "A"
(DRIVE MOTOR)
3121259
3121259
DRIVE MOTOR
PORT "CASE"
(DRIVE MOTOR)
PORT "B"
(DRIVE MOTOR)
PORT "A"
(DRIVE MOTOR)
TORQUE HUB "BRAKE" PORT
(TORQUE HUB)
– JLG Lift –
PORT #15 PORT #11
PORT "A"
(DRIVE MOTOR)
PORT "B"
(DRIVE MOTOR)
3-7
SECTION 3 - CHASSIS & TURNTABLE
3-8
PORT "B"
(DRIVE MOTOR) PORT #17
PORT #5
TORQUE HUB
PORT, BRAKE
(TORQUE HUB)
FLOW DIVIDER VALVE PORT #7
SECTION 3 - CHASSIS & TURNTABLE
DRIVE MOTOR
PORT "CASE"
(MOTOR, DRIVE)
– JLG Lift –
PORT "A"
(MOTOR, DRIVE)
PORT "B"
(MOTOR, DRIVE)
3121259
3121259
PORT "B"
PORT #13
(DRIVE MOTOR)
PORT "A"
(DRIVE MOTOR)
PORT #18
PORT #7 PORT #5
FLOW DIVIDER VALVE
TORQUE HUB DRIVE MOTOR
PORT, BRAKE
(DRIVE MOTOR)
– JLG Lift –
CASE PORT
(DRIVE MOTOR)
PORT "A"
(DRIVE MOTOR)
PORT "B"
(DRIVE MOTOR)
3-9
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE
Measuring Rolling Torque 4. Remove the Cover Subassembly (6) from the unit.
The unit can be carefully pressurized with air to pop
1. Screw one bolt down into the housing and rotate the the cover subassembly out of the unit.
housing so that the bolt is at twelve o’clock.
5. Remove O-Ring (17) from groove in Cover Subas-
2. Position the torque wrench so that it is perpendicular sembly (6).
to the vertical centerline as shown. 6. Remove the Sun Gear (11).
3. The correct reading can only be made if the torque 7. Loosen and remove the three Flat Head Bolts (19)
wrench is pulled slowly (approximately 3.5 rpm) and that retain the Ring Gear (1E) to the Housing (1D).
smoothly towards you.
8. Lift the Ring Gear (1E) off of the Housing (1D).
9. Remove the O-Ring (18) from between the Housing
(1D) and the Ring Gear (1E).
10. Using a 1/8" diameter punch, drive the Roll Pin (4G)
into the Planet Shaft (4E) until it bottoms against the
Spindle (1 A).
11. Grasp the Roll Pin (4G) using needle nosed pliers or
some sort of hooked tool, and pull the Planet Shaft
(4E) out of the Spindle (1A).
12. Using a 1/8" diameter punch, drive the Roll Pin (4G)
out of the Planet Shaft (4E).
Main Disassembly
1. Perform Roll Check, Leak Check and Brake Check if
applicable prior to disassembling the unit.
6. Cover
6G. Retaining Ring
15. ID Plate
17. O-ring
15. Repeat Steps 12 though 14 for the remaining two 4. Lift Housing (1D) off of Spindle (1 A).
Planet Gears Subassemblies (4F).
5. If necessary, press Studs (1H) out of Housing (1D).
16. Remove the Thrust Washer (4H) from the counter-
6. Remove Lip Seal (1B) from Housing (1D).
bore in the Spindle (1 A).
NOTE: The lip seal should NOT be reused when reassem-
17. Remove the Input Shaft (9).
bling the unit.
Housing-Spindle Disassembly 7. Using a soft steel rod, carefully knock both Ball
1. Secure the unit in a fixture with Spindle (1 A) flange Bearings (1C) out of Housing (1D).
end down.
2. Remove the Set Screws (1G) from Bearing Nut (1F).
Then loosen the Bearing Nut (1F) using the Bearing
Nut Wrench. It may be necessary to heat the Bear-
ing Nut (1F) to break down the Loctite that was used
to secure the bearing nut on to the Spindle (1 A).
NOTE: The holes in the bearing nut for the set screws were
staked for retention of the set screws. The holes will
need to be cleaned up prior to removing the set
screws.
1A. Spindle
1B. Lip Seal
1C. Ball Bearing
1D. Housing
1F. Bearing Nut
1G. Setscrew
1H. Stud
1A. Spindle
8A. Brake Piston
8B. Ball Bearing
8D. O-ring
8E. Backup Ring
8F. O-ring
8H. Backup Ring
8J. Brake Rotor
8K. Brake Stator
8L. Spring
8M. Spring
21. Bolt
5. Remove Coupling (7) from brake cavity in Spindle 5. Remove O-Ring Pipe Plugs (6F) from Cover (6A).
(1A). NOTE: O-Ring (6K) can be discarded unless cover subas-
sembly needs to be repainted.
6. Remove Backup Ring (8E) and O-Ring (8D) from
grooves in Spindle (1A).
1L. Spring
1M. Thrust Washer
5. Internal Retaining Ring
7. Coupling
11. Remove Pressure Plug (22) and Pipe Plug (12) from
Spindle (1 A) if applicable. This completes the Spin-
dle-Brake Subassembly Disassembly.
2. Thrust Spacer
6A. Cover
6B. Disengage Cap
6C. Bolt
6D. Dowel Pin
6E. O-ring
6F. Pipe Plug
6K. O-ring
Planet Gear Subassembly 3. Place Spacer (4D) into the bore of the Planet Gear
(4F).
1. Apply a liberal coat of grease to the bore of one of
Planet Gears (4F). 4. Repeat Step 2 to put in second roll of Needle Rollers
(4C).
2. Line the inside of the Planet Gear (4F) with Needle
Rollers (4C). 5. Apply grease to hold Thrust Washers (4B) together
and onto Planet Gear (4F) counterbore. Do the
NOTE: The last roller installed must be installed end wise. same to the other side.
That is, the end of the last roller must be placed in
between the ends of the two rollers which form the 6. Repeat Steps 1-5 to finish the assembly of the two
space, and then slid, parallel to the other rollers, into remaining Planet Gears Subassemblies (4F).
place.
Spindle-Brake Subassembly 3. Place Brake Rotor (8J) on top of Brake Stator (8K).
NOTE: Use an air gun to clean the brake port and make 4. Repeat steps 2 and 3 until there are a total of nine
sure there is no debris inside. Brake Stators (8K) and eight Brake Rotors (8J)
installed.
1. Place Spindle (1 A) with the flange side up. Press
Ball Bearing (8B) into the small counterbore of the 5. Place Spring (1L) into counterbore of the Coupling
spindle. (7), then place Thrust Washer (1M) on top of the
spring.
2. Place Brake Stator (8K) into the Spindle (1A) align-
ing with the scallop cuts.
1A. Spindle
8A. Brake Piston
8B. Ball Bearing
8D. O-ring
8E. Backup Ring
8F. O-ring
8H. Backup Ring
8J. Brake Rotor
8K. Brake Stator
8L. Spring
8M. Spring
21. Bolt
6. Use Truarc #0100 or equivalent pliers to install (8M) into the Springs (8L) already installed into the
Retaining Ring (5) into the retaining ring groove in brake piston.
the counterbore the Coupling (7).
15. Press Ball Bearing (8B) in the Mounting Adaptor
(1N) and then install Retaining Ring (8C) into the
retaining ring groove of the mounting adaptor.
12. Install large O-Ring (8F) in the large-diameter groove 21. Disconnect Brake Tester and install O-Ring Plug (12)
at the bottom of the Brake Piston (8A), on top of the and tighten according to DIN standard if applicable.
large Backup Ring (8H).
Housing-Spindle Subassembly NOTE: Use enough pressure to press in studs. Don’t use
excessively high pressures to press in studs or the
NOTE: Spray a light film of oil on all component parts during housing may crack.
assembly. Spray a generous amount of oil on bear-
ings during installation. 5. Secure Spindle-Brake Subassembly with the flange
down and then lower the Housing (1D) onto Spindle
1. With housing flange side up and press outbound (1A).
Ball Bearing (1C) into Housing (1D) using Bearing
6. Apply Loctite 272 on Bearing Nut (1F) threads.
Pressing Tool.
Install the Bearing Nut (1F) onto Spindle (1 A) with a
2. Turn housing over and press inbound Ball Bearing nut torque of 100-110 in-lbs. Make sure the bearings
(1C) into Housing (1D) using Bearing Pressing Tool. have 0.001 - 0.005 inches end play with a dial indica-
tor sitting on the spindle and dial on the housing
3. Grease Lip Seal (1B) and then press lip seal into with prying bars.
Housing (1D) using Seal Pressing Tool until seal is
flush with end of housing. 7. Install Set Screws (1G) into Bearing Nut (1F)
threaded holes. Make sure Set Screw (1G) is driven
4. Secure Housing (1D) and press Studs (1H) into into the spindle threads. Tighten the set screws to
housing. damage the threads and stake the edge of the nut
around the Set Screws (1G) so the nut will not
loosen.
1A. Spindle
1B. Lip Seal
1C. Ball Bearing
1D. Housing
1F. Bearing Nut
1G. Setscrew
1H. Stud
Housing-Ring Gear Subassembly the planet shaft that does NOT have the roll pin hole
should be inserted into the spindle FIRST.
1. Insert Input Shaft (9) into mesh with Coupling’s (7) 4. Now insert Planet Shaft (4E) through the first set of
internal splines and place the Thrust Washer (4H) Thrust Washers (4B), Planet gear, then the second
into counterbore of Spindle (1A). set of Thrust Washers (4B). Use an alignment punch
or similar tool to align roll pin holes on Spindle (1A)
2. Place one of the Planet Gear Subassemblies (4F) and Planet Shaft (4E).
into Spindle (1 A) through gap between two Studs
(1H). Align the planet gear bore with one of the NOTE: Be sure not to hit the planet gears when driving in
planet shaft holes on the Spindle-Brake Subassem- the roll pins.
bly using the Drift Pin Assembly Tool.
5. Drive Roll Pin (4G) down into the aligned roll pin
3. Insert Planet Shaft (4E) into the planet shaft hole holes. Pin should be flush with OD of spindle.
described in Step (2) on Spindle (1A). The end of
6. Repeat Steps (2-6) for the installation of the two 9. Install three Shipping Cap Screws (19) into Ring
remaining Planet Gears (4F). Gear (1E) and Housing (1G). Torque them to15-20 ft-
lbs.
NOTE: All components should receive a generous amount
10. With the non-toothed end facing up, place the Sun
of lubricant oil as they are being assembled.
Gear (11) into mesh with the planet gears from the
Housing-Spindle Subassembly.
7. Grease O-Ring (18) and place it into groove of
Housing (1D). Cover Subassembly
8. Place Ring Gear (1E) onto Housing (1D). Align the 1. Grease O-Ring (6E) and insert into internal groove in
three shipping cap screw holes on Housing (1D) Cover (6A).
and Ring Gear (1E).
2. Thrust Spacer
6A. Cover
6B. Disengage Cap
6C. Bolt
6D. Dowel Pin
6E. O-ring
6F. Pipe Plug
6K. O-ring
2. Assemble Disengage Cap (6B) onto Cover (6A) 5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The
using two Hex Head Bolts (6C). Torque bolts to 70- plugs should be hand tight. The Cover Subassembly
80 in-lbs. is now complete.
NOTE: It is not necessary to reinstall the larger O-Ring (6K) Main Assembly
unless cover subassembly needs repainted.
1. Grease O-Ring (17) and insert into groove in Cover
3. Insert Disengage Rod (6D) into hole in Cover (6A) Subassembly (6).
until it touches the inside of the Disengage Cap (6B).
2. Install Cover Subassembly (6) into Ring Gear (1E)
NOTE: The disengage rod can be inserted in either end first. counterbore and install Retaining Ring (6G) into
groove in Ring Gear (1E).
4. Grease face of Thrust Washer (2) that mates with
3. Attach ID Plate (15) onto unit using Drive Screws
pocket side of the Cover (6A), making sure that
(16) if needed.
tangs on washer seats into pockets.
4. Check disconnect, roll and air check unit. The Main
Assembly is now complete.
6. Cover
6G. Retaining Ring
15. ID Plate
17. O-ring
K 240-260
1F 1G
1A 1B 1C 1D 1E 4F 1H 4D 4C 4B 4E
4G
12
6A
22
8A
19
1N
4H
1K
8C 2
8B 6K
1L 6F
6B
15 16
6D
7
6C
1M
5 6E
8M 9
8L
8F 11
8H 6G
8D
8E 17
8J 8K
18
Figure 3-26. Drift Pin for Lining Up Thrustwashers with Output Planet Gear
3.8 OSCILLATING AXLE SYSTEM tires, two control valves are actuated to supply charge
pressure to the lock-out cylinder holding valves. This
The oscillating front axle is attached to the frame by a allows the cylinders to unlock which allows the axle to
pivot pin, which allows all four wheels to remain on the float. The first valve is normally closed and opens when
ground when traveling on rough terrain. The oscillating actuated to allow flow to the lock-out cylinder circuit. The
axle incorporates two lockout cylinders connected second valve (located between the first valve and the lock-
between the frame and the axle. The lockout cylinders out cylinders) is normally open to tank. This valve closes
permit axle oscillation when the main boom is in Transport when actuated to block the tank path and force the flow to
Position (see Section 4), and when the boom is oriented the lock-out cylinders. If either of these valves is in its nor-
between the rear tires as described under Drive Orienta- mal state, the axle will be locked.
tion System. In this system, both of these boom positions
(swing and main boom elevation) are sensed by two Oscillating Axle Bleeding Procedure
switches. One switch in each position is normally closed
and positively opens in the unsafe state (these are the 1. Start the engine.
same switches described in the Transport Position Sens-
ing System (see Section 4) and in the Drive Orientation 2. Position the turntable to the normal stowed position.
System. The other switch for each position is normally
open and closes in the safe state. 3. Position a small container suitable for containing
hydraulic oil in front of the lockout cylinder bleeder.
The lockout cylinders will lock and hold the axle when the
boom is in a position as described above (Main boom 4. Using a 3/8" wrench, loosen the bleeder by slowly
above horizontal or swung beyond the rear tires). The cyl- turning counterclockwise.
inders unlock when pilot pressure is applied to the hold-
ing valves mounted on the cylinders and lock when pilot 5. Bleed approximately 2 cups (0.2 L) of fluid from the
pressure is removed. bleeder in the cylinder. Tighten the bleeder while the
machine is running.
Pilot pressure is supplied via Drive Pump charge pres-
sure. When the control system detects that the Main 6. Locate the bleeder on the opposite lockout cylinder
Boom is below horizontal and swung between the rear and repeat steps 3 thru 5.
SWITCH #2 LOCATED
FARTHEST FROM BEARING,
ARM WILL BE ON THE RAMP
WHEN THE MACHINE IS IN
THE STOWED POSITION
3121259
KEEPER
PIVOT PIN
B B
BEARING THRUST WASHER
DETAIL A B B
LOCKOUT CYLINDER
A
A
SEE DETAIL A
AXLE
– JLG Lift –
SECTION A-A A
A
TORQUE 35 FT. LB. (47 NM) TORQUE 40.5 FT. LB. (55 NM)
WEAR PAD
SHIMS
SECTION B-B
WEAR PAD DETAIL
3-31
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE
3.9 CHASSIS TILT INDICATOR SYSTEM switch into Max Torque mode. This condition will be
cleared if the chassis tilt reading is less than 5 degrees for
The Chassis Tilt Indicator System measures the turntable a period of 1 second or longer.
angle with regard to level ground. The tilt sensor has two
settings; 5.0°/3.0° (depending on market) and 6.0° The JLG Control System responds to indicated angle
degrees. The 5.0°/3.0° angle is set by choosing the readings 0.5 degree smaller than the required angles to
desired market selection for the machine based on account for calibration and sensor variation.
machine setup using the JLG Analyzer.
The machine’s chassis tilt is measured by a pair of fluid-
The 5.0°/3.0° angle is used to warn the operator of an based sensors imbedded within the Ground Module.
excessive slope by means of the chassis tilt light on the These sensors measure chassis tilt from side-to-side and
platform display panel. The tilted condition exists when from front-to-back. The ground module uses one tilt sen-
the chassis tilt reading is greater than or equal to the set- sor to measure machine angle and uses the second sen-
ting selected in the analyzer for a period of 4 seconds or sor to compare against the first one to ensure the angle
longer. The tilted condition will be cleared if the tilt reading reading is reliable.
is less than the selected setting for a period of 1 second.
When used in conjunction with the Beyond Transport -
Drive Speed Cutback System, the tilt sensor will cause an 3.10 SWING MOTOR
alarm to sound and automatically put all functions in the
creep speed mode. The operator is responsible for pre-
venting the machine from reaching an unstable position.
IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN
The 6° angle is used only for the purpose of automatically EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN
slowing drive speed when this angle is reached and the SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING
boom is in Transport position. When the boom is in Trans- ABILITY.
port Position and the chassis is at or above 6° for a period
of 1 second or longer, the drive system will automatically
2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.
3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing (a) Loosen then tighten single bolt to torque specification.
area deteriorated by corrosion. (b) Replace bolt.
4. Internal shaft seal (16) worn or damaged. Replace seal. Disassembly of motor unit necessary.
5. Worn coupling shaft (12) and internal seal (16). Replace coupling shaft and seal by disassembling unit.
Significant loss of speed under load 1. Lack of sufficient oil supply (a) Check for faulty relief valve and adjust or replace as
required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for temperature of opera-
tion.
2. High internal motor leakage Replace worn rotor set by disassembling unit.
3. Severely worn or damaged internal splines. Replace rotor set, drive link and coupling shaft by disas-
sembling unit.
4. Excessive binding or loading in system external to Locate source and eliminate cause.
motor unit.
4. Remove the bolts securing the swing motor to the • Remove the motor from system, drain it of fluid and
swing drive assembly. take it to a clean work surface.
20
18
8
25
8C 17
16
8E 14
15 19
14
8B
13
4 12
8A
4
8D
10
9
4
8
4
7
5
4
6
3
4
2
1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used
2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used
3. Seal Ring 8. Rotor Set 9. Wear Plate 14. Thrust Washer 19. Outer Bushing 24. Not Used
4. Seal Ring 8A. Rotor 10. Drive Link 15. Thrust Bearing 20. Dirt & Water Seal 25. Backup Washer
5. Commutator 8B. Stator Half 11. Thrust Bearing 16. Seal 21. Not Used
4. Remove end cover assembly (2) and seal ring (4). 6. Remove commutator ring (6). Inspect commutator
Discard seal ring. ring for cracks, or burrs.
5. Thoroughly wash end cover (2) in proper solvent 7. Remove commutator (5) and seal ring (3) Remove
and blow dry. Be sure the end cover valve apertures seal ring from commutator, using an air hose to blow
are free of contamination. Inspect end cover for air into ring groove until seal ring is lifted out and dis-
cracks and the bolt head recesses for good bolt card seal ring. Inspect commutator for cracks or
head sealing surfaces. Replace end cover as neces- burrs, wear, scoring, spalling or brinelling. If any of
sary. these conditions exist, replace commutator and
commutator ring as a matched set.
8. Remove manifold (7) and inspect for cracks surface plate for cracks, brinelling, or scoring. Discard seal
scoring, brinelling or spalling. Replace manifold if ring (4) that is between the rotor set and wearplate.
any of these conditions exist. A polished pattern on
the ground surface from commutator or rotor rota-
tion is normal. Remove and discard the seal rings (4)
that are on both sides of the manifold.
10. Place rotor set (8) and wear plate (9) on a flat sur- 12. Remove thrust bearing (11) from top of coupling
face and center rotor in stator such that two rotor shaft (12). Inspect for wear, brinelling, corrosion and
lobes (180 degrees apart) and a roller vane center- a full complement of retained rollers.
line are on the same stator centerline. Check the
rotor lobe to roller vane clearance with a feeler gage
at this common centerline. If there is more than
0.005 inches (0.13 mm) of clearance, replace rotor
set.
14. Remove coupling shaft (12), by pushing on the out- 16. Remove thrust bearing (15) and thrust washer (14).
put end of shaft. Inspect coupling shaft bearing and Inspect for wear, brinelling, corrosion and a full com-
seal surfaces for spalling, nicks, grooves, severe plement of retained rollers.
wear or corrosion and discoloration. Inspect for
damaged or worn internal and external splines or
keyway. Replace coupling shaft if any of these con-
ditions exist.
17. Remove seal (16) and back up ring (17) from hous-
ing (18) and backup washer (25). Discard both.
15. Remove and discard seal ring (4) from housing (18).
19. Inspect housing (18) assembly for cracks, the replaced. If the housing has passed this inspection
machined surfaces for nicks, burrs, brinelling or cor- the disassembly of the motor is completed.
rosion. Remove burrs that can be removed without
changing dimensional characteristics. Inspect
tapped holes for thread damage. If the housing is
defective in these areas, discard the housing assem-
bly.
Assembly
NOTE: Bearing mandrel must be pressed against the let-
Replace all seals and seal rings with new ones each time tered end of bearing shell. Take care that the hous-
you reassemble the motor unit. Lubricate all seals and ing bore is square with the press base and the
seal rings with SAE 10W40 oil or clean grease before bearing/ bushing is not cocked when pressing a
assembly. bearing/bushing into the housing.
NOTE: Unless otherwise indicated, do not oil or grease
parts before assembly.
3. Press a new dirt and water seal (20) into the housing
(18) outer bearing counterbore. The dirt and water
IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE seal (20) must be pressed in until its’ flange is flush
METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND against the housing.
(19) THE BEARING/BUSHING DEPTHS SPECIFIED MUST BE
ACHIEVED TO INSURE ADEQUATE BEARING SUPPORT AND COR-
RECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN
ASSEMBLED.
6. Assemble thrust washer (14) then thrust bearing (15) coupling shaft (12) into housing (18), seating it
that was removed from the motor. against the thrust bearing (15).
9. Apply a small amount of clean grease to a new seal 11. Assemble wear plate (9) over the drive link (10) and
ring (4) and insert it into the housing (18) seal ring alignment studs onto the housing (18).
groove.
10. Install drive link (10) the long splined end down into
the coupling shaft (12) and engage the drive link
splines into mesh with the coupling shaft splines.
13. Install the assembled rotor set (8) onto wear plate
(9) with rotor counterbore and seal ring side down
and the splines into mesh with the drive link splines.
NOTE: It may be necessary to turn one alignment stud out 15. Assemble the manifold (7) over the alignment studs
of the housing (18) temporarily to assemble rotor set and drive link (10) and onto the rotor set. Be sure the
(8) or manifold (7) over the drive link. correct manifold surface is against the rotor set.
18. Assemble a new seal ring (3) flat side up, into com-
mutator (5) and assemble commutator over the end
of drive link (10) onto manifold (7) with seal ring side
up.
19. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and
onto the commutator set. If the end cover has only 5
bolt holes be sure the cover holes are aligned with
the 5 threaded holes in housing (18). The correct 5
bolt end cover bolt hole relationship to housing port
bosses is shown below.
NOTE: If the end cover has a valve (24) or has five bolt
holes, use the line you previously scribed on the
cover to radially align the end cover into its original
position.
20. Assemble the bolts (1) and screw in finger tight. One Piece Stator Construction
Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately A disassembled rotor stator and vanes that cannot be
and progressively tighten the bolts to pull the end readily assembled by hand can be assembled by the fol-
cover and other components into place with a final lowing procedures.
torque of 25-30 ft. lbs. (34-41 N m).
1. Place stator onto wear plate (9) with seal ring (4)
side down, after following assembly procedures 1
through 13. Be sure the seal ring is in place.
4. Assemble six vanes, or as many vanes that will read- Two Piece Stator Construction
ily assemble into the stator vane pockets.
A disassembled rotor set (8) that cannot be readily assem-
bled by hand and has a two piece stator can be assem-
bled by the following procedures.
1. Place stator half onto wear plate (9) with
seal ring (4) side down, after following motor assem-
bly procedures 1 through 13. Be sure the seal ring is
in place.
2. Align stator bolt holes with wear plate and
housing bolts and turn two alignment studs
finger tight into bolt holes approximately 180
degrees apart to retain stator half and wear plate
stationary.
3. Assemble rotor, counterbore down if applicable, into
stator half, and onto wear plate (9) with rotor splines
into mesh with drive link (10) splines.
5. Grasp the output end of coupling shaft (12) with 4. Assemble six vanes, or as many vanes that will read-
locking pliers or other appropriate turning device ily assemble into the stator vane pockets.
and rotate coupling shaft, drive link and rotor to seat
the rotor and the assembled vanes into stator, creat-
ing the necessary clearance to assemble the sev-
enth or full complement of seven vanes. Assemble EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO
the seven vanes using minimum force. PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA-
TOR VANE POCKETS.
6. Remove the two assembled bolts (1) if used to retain IF THE STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS)
stator and wear plate. THAN STATOR HALF (8D) THE STATOR VANES (8C) OR (8E)OF
THE SAME LENGTH (HEIGHT) AS THE STATOR HALF MUST BE
Go to assembly procedure #15, to continue assem- REASSEMBLED IN THEIR RESPECTIVE STATOR HALF FOR THE
bly. ROTOR SET TO FUNCTION PROPERLY.
8. Assemble six vanes, or as many vanes that will read- 4. Operate the swing function in both directions to
ily assemble into the stator vane pockets. ensure proper operation. Inspect the hose connec-
tions for any leakage.
9. Grasp the output end of coupling shaft (12)
with locking pliers or other appropriate turning
device and rotate coupling shaft, drive link and rotor 3.11 SWING DRIVE
to seat the rotor and the assembled vanes into sta-
tor, creating the necessary clearance to assemble The swing drive assembly has five major components.
the seventh or full complement of seven vanes. They are the housing, worm, worm gear, output pinion
Assemble the seven vanes using minimum force. and gear /pinion cap. The unit cannot be serviced while
mounted on the machine.
Go to assembly procedure #15, to continue assem-
bly. Removal
1. Remove the hardware securing the battery cover
Final Checks and remove the battery cover.
1. Pressurize the motor with 100 p.s.i. dry air or nitro- 2. Disconnect the negative terminal on the battery.
gen and submerge in solvent to check for external
leaks.
2. Check motor for rotation. Torque required to rotate
coupling shaft should not be more than 50 ft. lbs.
(68 N m)
3. Pressure port with "A" cast under it on housing (18)
is for clockwise coupling shaft rotation as viewed
from the output end of coupling shaft. Pressure port
with "B" cast under it is for counter clockwise cou-
pling shaft rotation.
4. Use test stand if available, to check operation of the
motor.
Installation
Refer to Figure 3-31., Swing Motor Removal and Installa-
tion.
1. Carefully insert the swing motor into the swing drive,
making sure the swing motor shaft key is aligned
correctly. MAKE SURE THE EYEBOLTS HAVE A RATED WORK LOAD SUFFI-
2. Secure the swing motor to the swing drive assembly CIENT TO HANDLE THE LOAD OF THE UPPERSTRUCTURE OF THE
with the retaining bolts. Apply threadlocker JLG P/N MACHINE. THE UPPERSTRUCTURE WEIGHS APPROXIMATELY
0100019 to the threads of the retaining bolts and 7,000 LBS. (3175 KG).
torque to 85 ft.lbs. (115 Nm).
TORQUE
81 35
41 20
135
M20x2.5Thread
40
7. Pull out the engine tray as far as it will go. Unbolt the more working area.
charge filter bracket so it can be moved aside for
8. Loosen and remove all but a few of the bolts secur- 11. Swing the engine tray back into position and secure
ing the turntable to the swing bearing. it in place with the retaining bolt.
12. Attach chains and slings to support the upperstruc-
ture. Begin with the chain at the approximate lengths
as shown below and adjust as necessary to main-
tain the turntable in a level position during lifiting.
2. Install the bearing in the position shown in Figure 3- 16. Connect the negative terminal on the battery.
36., Bearing Placement. Coat the bearing bolts with
17. Install the battery cover.
JLG Threadlocker P/N 0100019 and secure the
bearing assembly to the frame with the bolts. Follow- 18. Push the engine tray back into place and secure it.
ing the torque sequence diagram in Figure 3-37.,
Swing Bearing Torque Sequence, tighten the bolts 19. Start the machine and run it through several operat-
to an initial torque of 95 ft.lbs. (130 Nm). Next, fol- ing cycles. Swing the machine in both directions.
lowing the same sequence, tighten to a final torque
of 133 ft.lbs. (180 Nm). 20. Check for any leaks and that all functions are operat-
ing properly. Top off the hydraulic oil level if neces-
3. If any hydraulic hoses were disconnected to remove sary.
the swing bearing assembly, reconnect them as
tagged during removal.
Turntable Bearing Mounting Bolt Condition 4. At the position indicated on Figure 2-30. try and
insert the 0.0015" feeler gauge between the bolt
Check head and hardened washer at the arrow indicated
NOTE: This check is designed to replace the existing bear- position.
ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of Wear Tolerance
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or TURNTABLE REF.
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for MEASURING SWING
looseness. POINT BEARING
2. At the positions indicated on the figure titled Swing Figure 3-35. Swing Bearing Tolerance Measuring Point
Bearing Tolerance Boom Placement. Try and insert
the 0.0015" feeler gauge between the bolt head and
hardened washer at the arrow indicated position. 1. With the boom positioned over the side of the
3. Assure that the 0.0015" feeler gauge will not pene- machine, the Upper Boom horizontal with telescope
trate under the bolt head to the bolt shank. fully extended and Mid/Lower Boom stowed, using a
4. Swing the turntable 90 degrees, and check some magnetic base dial indicator, measure and record
selected bolts at the new position. the distance between the swing bearing and turnta-
ble.
5. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in 2. At the same point, with the boom positioned over
all quadrants. the side of the machine, the Upper Boom fully ele-
Check the turntable to bearing. Attach bolts as follows: vated and the Mid/Lower Boom fully elevated, using
a magnetic base dial indicator, measure and record
1. Elevate the fully retracted boom to 70 degrees (full the distance between the swing bearing and turnta-
elevation).
ble.
2. At the positions indicated in the figure below, try and
insert the 0.0015" feeler gauge between the bolt 3. If a difference greater than 0.057 in. (1.40 mm) is
head and hardened washer at the arrow indicated determined, the swing bearing should be replaced.
position.
4. If a difference less than 0.057 in. (1.40 mm) is deter-
mined, and any of the following conditions exist, the
bearing should be removed.
c. Noise.
d. Rough rotation.
Figure 3-34. Swing Bearing Feeler Gauge Check Swing Bearing Torque Value
3. Lower the boom to horizontal and fully extend the Install bolts with JLG Threadlocker P/N 0100019; Torque
boom. to 133 ft.lbs. (180 Nm).
(90°)
1. Washer 7. Bolt 13. Grease Fitting 19. Cover Plate 25. Housing 31. Worm Gear
2. Bearing 8. Pressure Vent 14. Slew Ring 20. Worm Cap 26. Cap Shim 32. Worm
3. Oil Seal 9. Oil Seal 15. Bearing 21. Output Pinion 27. Cover Shim
4. Capscrew 10. Pipe Plug 16. Grease Ring 22. Motor Adapter 28. Gasket
5. Bolt 11. Grease Fitting 17. Bearing 23. Face Seal 29. Gasket
6. Bolt 12. Grease Fitting 18. Gear Cap 24. Washer Spacer 30. Screw
7. Remove bearing (15) and Nilos Ring (16) from pin- 7. Install bearing (2) on bore end of worm (32) only.
ion (21) using external bearing puller or press. This is almost a slip fit, may have to be lightly tapped
with soft hammer.
8. Remove motor and motor adapter (22) and shims
(28). 8. Install worm (32) into housing (25), hex end first.
9. Remove ¾" bolts (7) from Worm Cap (20) using ¾" 9. On bore end of worm, install bearing cup (2) into
socket. Remove shim (29) and seal (9) and discard. worm bore of housing. Also on bore end of worm
(32) install motor adapter (22) and 1 shim (28 yel-
10. Remove worm (32) from housing (25) by pushing low) to housing using ¾-13 x 1" bolts (6) and seal-
worm from motor end using steel rod and hammer. ant. Torque to 75 ft-lbs. (3.1 Nm) (these bolts will be
Bearing cup (3) on hex end of worm will be forced replaced with motor bolts when motor is mounted).
out of housing. Once the bearing cup (2) has come
out of housing use soft hammer to tap worm on hex 10. Install bearing cone (2) on hex end of worm (32).
end to remove other bearing cup (2) out the other Place bearing cup (2) over bearing and lightly tap
end of housing. cup into bore using soft hammer.
11. Remove both bearings (2) from worm (32) from 11. Install worm cap (20) using proper shims (29) to
worm using external bearing puller or press. achieve 0.000 to 0.001" (0.0000 to 0.0254 mm) end
play. Apply LocTite 242 to end of ¾-13 x 1.25" grade
12. Bearing cup (17) can be removed from housing (25) 5 bolts (7) and LocTite #515 sealant to shims.
by lifting out (this is not a press fit just a close slip Torque bolts to 75 ft-lbs. (3.1 Nm).
fit).
12. Place pinion/gear assembly into housing so gear
13. Bearing cup (15) can be removed from cap (18) teeth mesh with worm gear teeth. May have to turn
using small pry bar. Or by welding a small bead of worm or gear set by hand to achieve this.
weld on internal diameter of cup, this is a press fit.
13. Apply LocTite #515 to surfaces of housing where
cap assembly will touch. This includes the vertical
Assembly surfaces.
1. Press bearing cup (15) into cap (18). 14. Place gear cap assembly and shims set aside in
2. Place bearing cup (17) into housing (25). step 6, over pinion assembly.
15. Apply LocTite 242 to end of eight 5/16" 12 point
3. Put face seal (23) on to hub of worm gear (31) with
screws (4) and torque to 20 ft-lbs. (0.84 Nm)
flap of seal pointing away from gear.
16. Install 4 small screws (30) through cover plate (18)
4. Place worm gear (31) on press with face seal up and
and into housing (25) tighten screws take care not
press pinion (21) into worm gear. Place Nilos Ring
the twist these screws off.
(16) on to pinion so that cup shape is up and press
bearing (15) on to pinion tight to Nilos Ring. 17. Install seal (9) in worm cap at hex end of worm.
5. Turn assembly over and place spacer (24) on pinion 18. Install slew ring (14) using two 1/4" bolts (5) and
against gear hub so that large chamfer on I.D. of washer (1). Adjust backlash with pinion to 0.008/
spacer is against Bronze gear. Press Bearing (17) on 0.012" (0.203/0.305 mm) and torque bolts to 10 ft-
to pinion tight to spacer and gear. lbs. (0.42 Nm).
6. Place pinion/gear assembly into housing. Place gear 19. Fill unit with SHC 007 grease and grease pinion
cap (18) and shims (26) over gear/pinion assembly bearing (15) thru fitting (11) with Mobil SHC 460
to achieve a slight preload on pinion bearings. grease.
Remove cap and shims and set shims aside. Install
new cover plate (19) on to cap using 6 screws (30)
and shims (26) equal to or close to equal to total
thickness of shims just set aside. Apply sealant (Loc-
Tite #515) to both sides of each of these shims and
tighten screws take care not to twist these screws
off. Clean extra sealant from surfaces of cover plate.
Apply a small amount of grease to this flap. Set this
assembly to the side.
C BOOM CABLE
C AIRLINE (IF EQUIPPED)
ROUTE HOSES/ CABLES AC CABLE
THROUGH GUIDE ROD
ON BASE BOOM
HOSE & CABLE CLAMP BLOCK
SECTION C-C
UPPER UPRIGHT ROTATED 75° CW
SECTION A-A
ROTATED 33° CCW
(ORIENTATION LOOKING
TOWARDS UPPER UPRIGHT)
WIRE BUNDLE
TO UPRIGHT
HYDRAULIC
MANIFOLD SYSTEM PRESSURE
MAIN LIFT CYLINDER
18/6 CABLE PRESSURE
TO MAIN SYSTEM TANK
BOOM LIMIT
SWITCHES BOOM CABLE
AC CABLE
TOWER LIFT CYLINDER PRESSURE 18/6 CABLE TO MAIN BOOM LIMIT SWITCHES
TOWER LIFT CYLINDER TANK 18/2 CABLE TO TOWER CYLINDER MANIFOLD
SYSTEM TANK 18/6 CABLE TO UPRIGHT HYDRAULIC MANIFOLD
AC CABLE
BOOM CABLE
UPPER UPRIGHT A
A
SYSTEM PRESSURE
MAIN LIFT CYLINDER PRESSURE
SECTION B-B
ROTATED 28.5° CW
(ORIENTATION LOOKING TOWARDS
LOWER UPRIGHT)
LOWER UPRIGHT
HOSES AND CABLES SHOULD NOT BE HOSES AND CABLES SHOULD BE AGAINST
PULLED TIGHT AGAINST THE INSIDE THE OUTSIDE RADIUS OF THE POWER TRACK
RADIUS OF THE POWERTRACK
INCORRECT CORRECT
SEE DETAIL D
50 12
MAINTAIN HOSE/
110 10 FROM CABLE LOOP AT
CYLINDER THIS DIMENSION
ENDCAP
DETAIL D
JIB LINK CUT AWAY
SEE DETAIL E
DETAIL E
SEE DETAIL F
MEASURE LOWER BOOM LOWER UPRIGHT
PULL LENGTHS FROM HERE
AC CABLE
BOOM CABLE
LEVEL TO LEVEL CYL PORT V1
LEVEL TO LEVEL CYL PORT V2
SYSTEM TANK
SYSTEM PRESSURE
DETAIL K
SWITCH SW242 OF
LOWER BOOM HARNESS
DETAIL R
LOWER BOOM LIMIT SWITCH
LOWER BOOM TO BE 2° TO 5° ABOVE HORIZONTAL TO TRIP SWITCH,
1° BELOW HORIZONTAL TO 5° ABOVE HORIZONTAL TO RESET SWITCH
SEE DETAILQ
SEE DETAILR
DETAIL Q
MAIN BOOM LIMIT SWITCHES
MAIN BOOM TO BE 1° BELOW HORIZONTAL TO 3° ABOVE HORIZONTAL TO TRIP SWITCH,
1° TO 4° BELOW HORIZONTAL TO RESET SWITCH
DETAILS
SEE DETAIL S
CONNECTOR V60 OF
UPPER BOOM HARNESS
CONNECTOR V61 OF
UPPER BOOM HARNESS
CONNECTOR V62 OF
UPPER BOOM HARNESS CONNECTOR V59 OF
UPPER BOOM HARNESS
DETAIL T
UPRIGHT BACK PLATE SHOWN TRANSPARENT
SEE DETAIL T
CONNECTOR V57 OF
UPPER BOOM HARNESS
CONNECTOR V56 OF
UPPER BOOM HARNESS SEE DETAIL U
CONNECTOR V55 OF
UPPER BOOM HARNESS
DETAIL U
FLY VALVE COVER SHOWN TRANSPARENT
ENGINE ENGINE
STOPPED (Engine RPM = 0) CRANKING
2. The selected Operating Station must have all of its The engine operates at different RPM levels in order to
control switches in the neutral position since power properly operate the machine and the functions com-
up and remain in the neutral position prior to select- manded by the operator. The following lists the possible
ing the Start Switch. RPM levels and the operating conditions that control
them.
3. If operating from the Platform Station, the footswitch
must not be depressed (Ground Module J7-15
deenergized; Platform Module J7-8 energized)
Engine Stop RPM
before selecting the Start Switch.
Engine Stop RPM is always zero (0) and occurs when the
4. If operating from the platform, the Auxiliary Power engine operating state is Engine Stopped or when the
Switch must not be selected before selecting the operator shuts down the engine.
Start Switch.
Idle RPM
5. If operating from the ground station, the Function
Enable Switch must not be selected before selecting Idle RPM occurs when all of the following conditions exist;
the Start Switch.
1. The Engine State is Engine Running, Engine Crank-
6. If the Engine Starter was disengaged because the ing, or Engine Starting.
Start Switch was released, more than 3 seconds
must pass with the Start Switch in the released posi- 2. The operator is not shutting down the engine.
tion.
3. The control system is not commanding a higher
7. If the Engine Starter has been cranking without the engine RPM (Mid-Engine, Multi-function, or High
engine starting for the Engine Starter Engaged Time Engine).
Limit, the control system deenergizes the Engine
Starter for the Engine Restart Wait Period. The Start 4. The control system is not calling for Generator RPM.
Switch must be in the deselected position after the
Wait Period is over. Mid Engine RPM
Table 3-4. Engine Starter Limits Mid Engine RPM occurs when all of the following condi-
tions exist;
Starter Engage Restart Attempt
Engine
Time Limit Wait Time 1. The Engine State is Engine Running.
Kubota 20 10
2. The operator is not shutting down the engine.
GM Indefinite Indefinite
3. The control system is not commanding a higher
8. The engine must be in the Engine Stopped or engine RPM (Multi-function or High Engine).
Engine Cranking state.
4. The control system is not calling for Generator RPM.
9. The Engine Shutdown switch must not be activated.
5. Platform mode is active with the controls enabled or
10. The Start Switch has been in the deselected position Ground mode is active with any function enabled
after the Engine State changes to Engine Stopped except for Lift Down, Tower Lift Down, or Jib Lift
from Engine Running or Engine Starting. Down.
Generator RPM
Generator RPM occurs when all of the following condi-
tions exist;
1. The Engine State is Engine Running.
2. The operator is not shutting down the engine.
3. The Control System is configured for a generator.
4. The Platform Generator Switch is Enabled and
Selected.
Ground Module
Ground
J1-17
Ground Module
J1-15 Input
Engine Block
Ground
Ground Module
Glow Plugs
VBatt
- +
J1-12 Output
Glow Plug Relay
Ground Module
J1-15 Input
Engine Block
Ground
The Ground Module calculates the length of time the glow Engine Speed Actuators
plugs are energized prior to startup based upon ambient
temperature, engine coolant temperature, and battery Engine speed on the Kubota engine is controlled by two
voltage. Refer to Table 3-6, Glow Plug Conditions. actuators; a throttle actuator that is On/Off operated
(moves the throttle arm between the Idle and High Engine
Table 3-6. Glow Plug Conditions positions) and a proportional fuel rack actuator that limits
the opening of the fuel rack to control speeds between the
Engine Coolant Battery Ambient Glow Plug Idle and High Engine positions. The two actuators func-
Temperature Voltage Temperature Time On tion together to achieve smooth engine speed transitions.
Greater than or -- -- Off Refer to Table 3-7, Engine Actuator Conditions.
equal to
122 º F (50 º C) Table 3-7. Engine Actuator Conditions
-- Less than 11V -- Off Engine RPM Throttle
Fuel Rack Actuator
Less than Greater than Greater than Off Level Actuator
122 º F (50 º C) 11V 59ºF(15ºC) Idle Off Energized/Fully
Less than Greater than Temp Between On for Retracted
122 º F (50 º C) 11V 23ºF and 59ºF 10 sec. Between Idle RPM On Energized/Control Loop
(-5ºC and 15ºC) and
Less than Greater than Temp Between On for High Engine RPM
122 º F (50 º C) 11V 5ºF and 23ºF 15 sec. High Engine On Energized/Fully
(-15ºC and -5ºC) Retracted
Less than Greater than Temp Less On for
122 º F (50 º C) 11V Than 20 sec.
ENGINE THROTTLE ACTUATOR
5ºF (-15ºC)
The Ground Module energizes the Throttle Actuator Relay
through terminal J1-2 if the engine is cranking or starting
The glow plugs are deenergized if: and the Control System is calling for Idle RPM.
• The Engine State is Engine Cranking, Engine Starting,
Engine running
or
• The Emergency Descent Mode is activated and Lift Ground Module
Down, Tower Lift Down, or Jib Lift Down are active.
Throttle
If the STARTER LOCKOUT option is enabled in the VBatt Actuator
- +
Machine Setup, the Ground Module will not allow an
engine start attempt until the glow plug time has expired. 30A Fuse
If this option is not enabled, the glow plug time can be
interrupted and an engine start attempt can be made.
Starter Lockout is only applicable for the first glow plug J1-2 Output
cycle. Throttle
Actuator Relay
Ground Module
J3-1
Current VBatt
Fuel Rack Ground Module
Sense Actuator
VBatt
J1-1 Output
D+
J1-32 Output
Proportional Fuel Rack Actuator Alternator
Shutdown
If the JLG Control System determines that the engine
should be shut down and not allowed to run, the Ground
Starter
Ground Module Module takes the following steps to shut down the engine.
VBatt
- + 1. Remove power and prevent power from flowing to
the Proportional Fuel Rack Actuator by turning off
VBatt
output terminal J1-1.
2. Remove power and prevent power from flowing to
the Engine Throttle Actuator by turning off output
terminal J1-2.
J1-11 Start Relay
Output
1
12
11
10 13
2
3
8
7
6
11
10
6
7
13 12
1
11
10
9
2
POSITIVE TERMINAL
3
11
10
6,7,8
4,5
1. Radiator 4. Mid Engine Harness 7. Full Speed Relay 10. Gear Pump 12. Muffler
2. Radiator Mount 5. Engine Harness 8. Glow Plug Relay 11. Main Pump 13. Coolant Recovery Tank
3. Engine Oil Filter 6. Starter Relay 9. Starter
13
12
4,5
7,8
6
11
10
Engine Start
The Ground Module energizes terminal J1-11 to engage
the starter. The engine ECU considers the engine started
when RPMs are greater than 800 and continues in the Run
mode unless engine RPM drops below 200. The ECU
establishes a maximum crank time of 7.5 seconds before
a 20 second wait time is required. The ECU also requires
that power is cycled after 60 seconds of cranking time.
10
4
8
6 7
10
5
3
3
10
7
4
1
18
17 16
15
2
14
13
12
4 11
6,7 9,10
1. Dipstick 6. Negative Battery Cable 11. Air/Fuel Mixer 16. Fuel Tank
2. Relays 7. Negative Battery Post 12. Air Filter 17. Fuel Lock-off Valve
3. Muffler 8. Battery 13. Fuel Pump 18. Engine Oil Fill Cap
4. Main Pump 9. Positive Battery Cable 14. Fuel Mixer
5. Gear Pump 10. Positive Battery Post 15. Fuel Level Sensor
1 10
8
2 9
EC210 - NEGATIVE
TERMINAL ON FUEL PUMP
EC210-POSITIVE
TERMINAL ON FUEL PUMP
3
12
11
1
LP MIXER PURGE POINT,
HOSE FROM CARBON CANISTER
13 9
12 11
10
2 8
4
7
3.19 FUEL RESERVE / CUT-OUT SYSTEM 3.20 COLD START SYSTEM (DIESEL ENGINE)
The Fuel Shutoff System senses when the fuel level is get- The machine control system monitors the engine coolant
ting low and automatically shuts the engine down before and ambient temperature to make an estimate of cylinder
the fuel tank is emptied. When the fuel level gets below preheating requirements. If the coolant temperature is
1.3 gallons (4.9 L), the fault light will flash at the platform below 50° C (122° F) and the battery has sufficient voltage
controls and the control system will report fault 0031 when control power is turned on, the glow plugs will be
"FUEL LEVEL LOW - ENGINE SHUTDOWN" on the ana- automatically fired for a duration that is based on the
lyzer. ambient temperature. During this preheat period, the glow
plug indicators will flash. The glow plugs will be turned off
There is an analyzer personality setting in the control sys-
before the engine begins to crank.
tem to control the machines response to this fault. If this
personality setting is set to "ENGINE STOP", the machine
will remain in this fault mode until the fuel level is returned
to a level above 1.3 gallons (4.9 L). If the personality set-
3.21 GENERATOR
ting is set to "1 RESTART", the operator will be able to start See Figure 3-72., Generator.
the engine and run for 1 minute. After 1 minute, the engine
will shut off for a second time and the machine will return An optional generator is available to supply electrical
to the "Engine Shutdown" fault mode. The machine will power to the platform. It is controlled by a switch in the
then stay in this mode until the fuel level is returned to a platform.
level above 1.3 gallons (4.9 L).
CONTROL BOX
GENERATOR
ASSEMBLY
VOLTAGE REGULATOR
3.22 COUNTERWEIGHT
If the counterweight has been removed, ensure the retain-
ing bolts are torqued to the proper value as shown in Fig-
ure 3-73., Counterweight Bolt Torque.
*
*
*
*
* Torque to 150 ft.lbs. (204 Nm) ± 3%
Figure 3-73. Counterweight Bolt Torque
NOTES:
NOTE: When removing the retaining pin from the rod end of
the telescope cylinder, make sure the cylinder is
properly supported.
4. Remove the retaining ring and pin securing the tele- 6. Using a suitable lifting device, remove telescope cyl-
scope cylinder rod end to the fly boom section. inder from the rear of the boom sections.
5. Remove the bolts and washers securing telescope 7. Remove hardware securing the front wear pads on
cylinder to the rear of the base boom section. base boom section, remove wear pads and shims,
noting the location and amount of shims to aid in
reassembly.
5. Align the telescope cylinder rod end with the corre- 6. Using JLG P/N 0100011 thread locking compound
sponding hole in the fly boom section. If necessary, or equivalent, secure the rear of the telescope cylin-
attach a portable power supply to the cylinder to der to the base boom section with the attaching
extend or retract the cylinder for alignment. Install bolts and washers. Torque the bolts 95 ft.lbs. (129
the retaining pin and secure it in place with the Nm).
retaining ring.
4
1
6 8
2
7
4.4 BOOM CLEANLINESS GUIDELINES 5. If pressurized air cannot dislodge the debris, then
water with mild solvents applied via a pressure
The following are guidelines for internal boom cleanliness washer can be used. Again the method is to wash
for machines that are used in excessively dirty environ- the debris toward the nearest exiting point from the
ments. boom. Make sure that all debris is removed, that no
“puddling” of water has occurred, and that the
1. JLG recommends the use of the JLG Hostile Envi-
boom internal components are dry prior to operating
ronment Package if available to keep the internal
the machine. Make sure you comply with all federal
portions of a boom cleaner and to help prevent dirt
and local laws for disposing of the wash water and
and debris from entering the boom. This package
debris.
reduces the amount of contamination which can
enter the boom but does not eliminate the need for 6. If neither pressurized air nor washing of the boom
more frequent inspections and maintenance when dislodges and removes the debris, then disassem-
used in these types of environments. ble the boom in accordance to the instructions out-
lined in the JLG Service & Maintenance Manual to
2. JLG recommends that you follow all guidelines for
remove the debris.
servicing your equipment in accordance with the
instructions outlined in the JLG Service & Mainte-
nance Manual for your machine. Periodic mainte-
nance and inspection is vital to the proper operation
of the machine. The frequency of service and main-
tenance must be increased as environment, severity
and frequency of usage requires.
3. Debris and foreign matter inside of the boom can
cause premature failure of components and should
be removed. Methods to remove debris should
always be done using all applicable safety precau-
tions outlined in the JLG Service & Maintenance
Manuals.
4. The first attempt to remove debris from inside the
boom must be to utilize pressurized air to blow the
debris toward the nearest exiting point from the
boom. Make sure that all debris is removed before
operating the machine.
PORT T1
(UPRIGHT
VALVE)
SECTION 4 - BOOM & PLATFORM
PORT T2
(UPRIGHT
VALVE)
PORT P1
(UPRIGHT UPRIGHT VALVE TO
VALVE) TELE/LIFT CYL
– JLG Lift –
HYDRAULIC TANK
RETURN FILTER PORT
(HYD TANK)
PORT P4 PORT V2
(MAIN VALVE) (TELE CYL)
3121259
PORT R1 PORT P2
PORT V2 (FLY BOOM VALVE) (HELAC)
(LEVEL CYL)
3121259
ROD END
(MASTER CYL)
PORT V1 PORT V2
PORT J1 PORT J2
(FLY BOOM VALVE) (FLY BOOM VALVE)
PORT V1 PORT R2 PORT P1
(LEVEL CYL) (FLY BOOM VALVE) (HELAC)
BARREL END
(MASTER CYL)
MASTER CYL.
– JLG Lift –
PORT "L2"
(VALVE, UPRIGHT)
4-9
SECTION 4 - BOOM & PLATFORM
SECTION 4 - BOOM & PLATFORM
Bars indicate starting positions of piston and shaft. Arrows indicate Applying fluid pressure will displace the piston axially while the heli-
direction they will rotate. The housing with integral ring gear cal gearing causes the piston and shaft to rotate simultaneously.
remains stationary. For clarity, the shaft flange, bearings, and end The double helix design compounds rotation: shaft rotation is about
cap are not shown. twice that of the piston. Applying pressure to the opposite port will
return the piston and shaft to their original starting positions.
2. Remove the cap screws (113) that cover the end cap
lock pins (109).
7. Remove the end cap (4) and carefully set aside for marker before disassembly as outlined in the steps
later inspection. below.
11. Remove the shaft (2) by rotating counterclockwise. 14. At the point when the piston gear teeth come out of
As the shaft is rotated, it will disengage from the pis- engagement with the housing gear teeth, mark the
ton sleeve (3) and can be removed. It may be neces- piston and housing with a marker as shown.
sary to strike the threaded end of the shaft with a
rubber mallet.
15. Remove the O-ring (204) and backup ring (207) from
12. As in step 9, before removing the piston (3), mark end cap (4).
the housing (1) ring gear in relation to the piston out-
side diameter gear. There should now be timing
marks on the housing (1) ring gear, the piston (3)
and the shaft (2).
17. Remove the main pressure seal (205). 20. Remove the outside diameter piston seal (202) from
the piston.
18. Remove the thrust washer (304) from the end cap
(4) and shaft (2). 21. Remove the inside diameter piston seal (200).
19. Remove the O-ring (304.1) from its groove in the end
cap (4) and shaft (2).
Inspection
Assembly 4. Using a seal tool install the main pressure seal (205)
onto shaft (2) and end cap (4). Use the seal tool in a
1. Gather all the components and tools into one loca- circular motion.
tion prior to re-assembly. Use the cut away drawing
to reference the seal orientations.
5. Install the wear guide (302) on the end cap (4) and
shaft (2).
2. Coat the thrust washers (304) with a generous
amount of Lithium grease. Install the thrust washer
(304) onto shaft (2) and end cap (4).
7. Install the inner T-seal (200) into the appropriate 8. Insert the piston (3) into the housing (1) as shown,
groove in the piston (3). Use a circular motion to until the outer piston seal (202) contacts the inside
ensure the seal is correctly seated in the groove. housing bore.
10. Looking into the bore from the opposite end of the 12. Looking at the actuator from the end opposite the
housing (1) be sure the timing marks align correctly. shaft flange, use the existing timing marks to align
Rotate the piston as necessary until aligned, then the gear teeth on the shaft (2) with the gear teeth on
gently tap the piston (3) into the housing until the the inside of the piston (3). When the marks align,
gear teeth mesh together. Tap the piston into the gently tap the flange end of the shaft with a rubber
housing until it completely bottoms out against the mallet until the gear teeth engage.
ring gear.
14. Install the stop tube (400) onto the shaft end if nec- 17. Tighten the end cap (4) using a metal bar. In most
essary. Stop tubes are an available option to limit the cases the original holes for the lock pins will align.
rotation of an actuator.
15. Coat the threads on the end of the shaft with anti- 18. Insert the lock pins (109) provided with the Helac
seize grease to prevent galling. seal kit into the holes with the dimple side up. Then,
using a punch, tap the lock pins to the bottom of the
hole.
16. Thread the end cap (4) onto the shaft (2). Make sure
the wear guide remains in place on the end cap as it
is threaded into the housing (1). 19. Insert the set screws (113) over the lock pins.
Tighten to 25 in-lbs. (2.8 Nm).
TYPICAL CONFIGURATION
OF ACTUATOR
Troubleshooting
Table 4-1. Troubleshooting
b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic
lines for restrictions and leaks.
c. Control or counterbalance valve has internal c. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.
e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then pol-
ish. Replacement parts may be needed.
f. Swollen seals and composite bearings caused f. Re-build the actuator. Use fluid that is compati-
by incompatible hydraulic fluid ble with seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding proce-
dures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth a. Check for gear binding. Actuator may not be
able to be re-built and may need to be replaced.
Damage could be a result of overload or shock.
b. Port fittings are obstructing the piston b. Check thread length of port fittings. Fittings
should during stroke not reach inside the housing
bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal a. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.
C,D
SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in
HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com-
When assembling connectors in the hydraulic that use o- pletely saturated.
ring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.
Brush-on Method
This method requires a sealed bottle brush.
5.2 HYDRAULIC CYLINDERS cylinder can be secured firmly in place during disas-
sembly.
Holding (counterbalance) valves are used in the Lift,
Level, Jib, Telescope, and Axle Lockout circuits to prevent 2. Prepare all the necessary tools and replacement
retraction of the cylinder rod should a hydraulic line rup- parts. Refer to Table 5-2, Required Tools.
ture or a leak develop between the cylinder and its’ related
holding valve. General Information
NOTE: The steer cylinder weighs approximately 37.2 lbs 1. Clean any burrs or contamination from the surface
(16.9 kg). of the cylinder before disassembly.
Operation Inspection With- There is no problem when fully extended 5 times without load
out Load
Dimension Check the retracted length and stroke
Inspection of the Surface When each of the cylinders are pressurized with test pressure on the piston end, it should not be loose and have no
change in pressure or external leakage
Inspection of external leak- Check the oil leakage at the rod area. Refer to Figure 5-1., Acceptable Oil Leakage on Cylinder Rod.
age
Inspection of internal leak- Leakage Unit: ml/ 10 minutes
age Bore (mm) Leakage (ml) Bore (mm) Leakage (ml) Bore (mm) Leakage (ml) Remark
32 0.4 100 4 160 10
40 0.6 125 5.6 180 12.6
50 1 140 6 200 15.6
63 1.6 220 20
80 2.3 250 22
Check the oil leakage status on the rod surface with a flow of 20cc - 40cc. Oil leakage in an amount as
shown in example A is unacceptable. Examples B-G are acceptable.
2mm
OIL RING 1mm
A B C D E F G
Flat-head Screwdriver
2 1 Set
Vise
4 1 Set
Spanner Wrench
5 1
Punch
6 1 Set
Torque Wrench
7 1
Plastic Hammer
8 1
Crescent Wrench
Disassembly Procedure
Table 5-3. Special Tools 1. Remove the oil from the cylinder.
Name of Tool Description 2. Fix the cylinder in a vertical or horizontal position.
Bushing for Disassembly Vertical position is convenient for disassembly and
assembly. Fix the base by inserting the pin not to be
rotated. Remove any hoses, valves, or fittings that
may be in the way.
c. After the Rod assembly is pulled from the barrel, 5. Place the Rod assembly on blocking as shown
unscrew the head using a spanner wrench. below. Use the pin hole to keep it from rotating.
8. Piston nut, piston, gland disassembly. d. The du bushing is pressed in and must be
removed by using a tool as shown below.
TAKE CARE NOT TO LET ANY PAINT CHIPS OR DIRT FALL INSIDE
PART 2
THE CYLINDER. THIS COULD CAUSE LEAKAGE.
PART 1
BAR
c. Install du bushing assembly and dust wiper c. Using a proper tool, press the piston seal onto
assembly as shown below. the piston. When installing the piston seal, it is
stretched while passing over the head.
JIG FOR
PRESS
TOOL
O-RING
JIG
DU BUSHING
TOOL
c. Assemble Piston.
6. Gland assembly.
**
***
*
* Torque 19-21 ft.lbs. (25.7-28.5 Nm) Max
** Torque 14.4 ft.lbs. (19.6 Nm) Max
*** Torque 25 ft.lbs. (34.3 Nm) Max
*****
**** Torque 48-60 in.lbs. (5.3-6.7 Nm)
***** 8.8 Ohms **** 1001122527-D
**
***
*
* Torque 19-21 ft.lbs. (25.7-28.5 Nm) Max
** Torque 14.4 ft.lbs. (19.6 Nm) Max *****
*** Torque 25 ft.lbs. (34.3 Nm) Max
**** Torque 48-60 in.lbs. (5.3-6.7 Nm) ****
***** 8.8 Ohms
1001117640 F
1001120976-A
**
*
***
****
**
*
*****
******
* Torque 19-21 ft.lbs. (25.7-28.5 Nm) Max
** Torque 14.4 ft.lbs. (19.6 Nm) Max
*** Torque 30-37 ft.lbs. (40.2-50 Nm) Max
**** Torque 25 ft.lbs. (34.3 Nm) Max
***** Torque 43-60 in.lbs. (5.3-6.7 Nm)
****** 8.8 Ohms
1001123004-B
1. Tube 7. Backup Ring 13. Piston Seal 19. MRP Bearing 25. Orifice
2. Rod 8. Dry Bearing 14. Wear Ring 20. Poppet Valve 26. Plug
3. Gland 9. O-ring 15. O-ring 21. Check Valve 27. O-ring
4. Dust Wiper 10. Backup Ring 16. Piston Ring 22. Counterbalance Valve
5. Retaining Ring 11. O-ring 17. Hex Nut 23. Plug
6. Rod Seal 12. Piston 18. MRP Bearing 24. O-ring
1001116788-C
*
**
1. Tube Assembly 6. Rod Seal 11. O-ring 16. Hex Nut 21. Load Shuttle Valve
2. Rod 7. Backup Ring 12. Piston 17. Spacer 22. Plug
3. Gland 8. Dry Bearing 13. Piston Seal 18. O-ring 23. Plug
4. Dust Wiper 9. O-ring 14. Wear Ring 19. Counterbalance Valve 24. Plug
5. Retaining Ring 10. Backup Ring 15. O-ring 20. Counterbalance Valve 25. MRP Bearing
1001116361-D
2
3 1
1. Return Filter
2. Breather
3. Fill Cap
4. Internal Baffle
5 5. Drain Plug
6. Oil Level Gauge
FLY BOOM
CONTROL
VALVE
UPRIGHT
CONTROL
VALVE
ASSEMBLE TO BRACKET
WITH MARKING ORIENTED FLY BOOM
AS SHOWN CONTROL
VALVE
MANUAL PUMP
THREADLOCKER
P/N 0100011
THREADLOCKER
P/N 0100011
FLOW DIVIDER
VALVE
3121259
GAUGE PORT "MA"
PUMP, MAIN (MAIN PUMP)
"OUTLET SIDE"
CHARGE PUMP FILTER PORT "B"
(MAIN PUMP)
– JLG Lift –
PORT #14
PORT #3
5-23
SECTION 5 - HYDRAULICS
5-24
PORT #1
(MAIN VALVE)
PORT #2
PORT #19
PORT #2 PORT #1
PORT "M4"
PORT #2
(MAIN VALVE) FLOW DIVIDER VALVE
HYDRAULIC TANK
PORT #20
SECTION 5 - HYDRAULICS
VALVE BOTTOM
RETURN PORT
(HYD TANK)
MAIN VALVE
RETURN PORT
(HYDRAULIC TANK)
PORT M4
(MAIN VALVE)
PORT #1
(MAIN VALVE)
– JLG Lift –
PORT #2
(MAIN VALVE)
3121259
PORT B PORT, A
(SWING MOTOR) (SWING MOTOR)
3121259
SWING MOTOR
PORT L1
(MAIN PUMP) OUTLET PORT (CHARGE PUMP FILTER)
PORT "S"
(PUMP, MAIN)
PORT P2
(MAIN VALVE)
– JLG Lift –
CHARGE PUMP FILTER
MAIN PUMP
PORT A
PORT "M14" (MAIN VALVE) (SWING MOTOR)
PORT MS PORT #4 (MAIN VALVE)
PORT "F" OUTLET (MAIN PUMP) (MAIN VALVE) PORT B (SWING MOTOR)
PORT,"OUTLET" (FILTER CHARGE PUMP) PORT #5 (MAIN VALVE)
PORT E INLET (MAIN PUMP)
5-25
SECTION 5 - HYDRAULICS
SECTION 5 - HYDRAULICS
12 14
14
16
11 2
11 1 14
16
16
6 6 9
5 15
7 9
12 Table 5-6. Main Control Valve Specifications
16 Torque
# Item Ohms
ft.lbs. Nm
1 Solenoid /w Integral 24-26 32.7-35.4 --
Relief Valve
2 Solenoid /w Integral 24-26 32.7-35.4 --
10 Relief Valve
13 10 10 3 3 Solenoid Valve 16-20 24.4-27.1 --
10
4 Solenoid Valve 16-20 24.4-27.1 --
4 5 Relief Valve 19-21 25.8-28.6 --
6 Flow Control Valve 19-21 25.8-28.6 --
7 Flow Control Valve 19-21 25.8-28.6 --
8 Load Shuttle Valve 19-21 25.8-28.6 --
9 Coil 5-7 6.8-9.5 5.4
10 Coil 5-7 6.8-9.5 9.8
11 Coil 5-7 6.8-9.5 7.2
12 Pressure Compensated 19-21 25.8-28.6 --
8 Flow Regulator Valve
13 Pressure Compensator 24-26 32.7-35.4 --
16 14 Check Valve 12-14 16.3-19 --
15 Relief Valve 19-21 25.8-28.6 --
16 Plug 12-14 16.3-19 --
1001116487-E
V75
LIFT UP V79
TOWER LIFT UP
V72
FLOW CONTROL
V74
V80 SWING LEFT
STEER LEFT
V73
SWING RIGHT
V81
STEER RIGHT
V70
HIGH FLOW DUMP
V240
LOW FLOW DUMP
11 4 6
7
10
3 2 9
11 4 9
Torque
# Item Ohms
ft.lbs. Nm
1 Solenoid Valve 4-5 5.4-6.8 --
2 Solenoid Valve 4-5 5.4-6.8 --
3 Solenoid Valve 4-5 5.4-6.8 --
4 Pilot/Directional Valve 46-54 62.6-73.4 --
5 Flow Divider Valve 73-77 99-104 --
6 Flow Divider Valve 48-52 65-70 --
11 7 Check Valve 24-26 32.5-35.25 --
8 Coil 4-5 5.4-6.8 8.8
9 Coil 4-5 5.4-6.8 8.8
10 Plug 24-26 32.5-35.25 --
1 1
11 Plug 12-14 16.3-19 --
8 8
1001118029-D
PORT "B"
(MOTOR, DRIVE) PORT #17
PORT #12
PORT "A"
(MOTOR, DRIVE)
PORT #5
PORT #7 TRACTION
BRAKE LOCK
VALVE VALVE
PORT #1
(VALVE, MAIN)
PORT #2
PORT #19
PORT #2
(VALVE, MAIN)
PORT #20
PORT "B"
PORT #14 (MOTOR, DRIVE) PORT #13
PORT "A"
(MOTOR, DRIVE) PORT #18
PRIMARY PORT #3
OSCILLATING
AXLE VALVE
TRACTION
SECONDARY BRAKE LOCK
OSCILLATING VALVE
PORT #5 VALVE
AXLE VALVE PORT #7
PORT #21
PORT #22
PRIMARY
OSCILLATING SECONDARY
AXLE VALVE OSCILLATING
AXLE VALVE
PORT #8
PORT #9
PRIMARY SECONDARY
OSCILLATING OSCILLATING
AXLE VALVE AXLE VALVE
PORT #16
PORT #4
PORT "B"
PORT "B" (MOTOR, DRIVE)
(MOTOR, DRIVE)
PORT "A"
(MOTOR, PORT "A"
DRIVE) (MOTOR, DRIVE)
SECONDARY PRIMARY
PRIMARY OSCILLATING OSCILLATING SECONDARY
OSCILLATING AXLE VALVE AXLE VALVE OSCILLATING
AXLE VALVE AXLE VALVE
V213
BYPASS V212
BRAKE
V212
BRAKE
V97
OSC AXLE #2
SECONDARY
V96
OSC AXLE #1
PRIMARY
V213
BYPASS
To PORT "P1"
(HELAC)
PORT "R2"
PORT "R1”
To PORT "V2"
(JIB LIFT CYL)
PORT "J2"
To PORT "V1"
(JIB LIFT CYL)
PORT "P" PORT "J1"
To PORT "P2"
(VALVE, UPRIGHT)
ROTATE
JIB
1001116228-C
PORT "V1"
(LIFT CYL)
PORT "V2"
PORT "V1" PORT "V2"
(TELE CYL)
(TELE CYL) (LIFT CYL)
PORT "T1"
(VALVE,
UPRIGHT)
PORT "T2"
(VALVE,
UPRIGHT)
PORT "P1"
(VALVE,
UPRIGHT)
TELESCOPE
PORT "V1"
(VALVE, UPRIGHT)
VALVE, UPRIGHT
PORT "V1"
(TELE CYL) PORT "M2"
(VALVE, UPRIGHT)
PORT "M1"
(VALVE, UPRIGHT)
PORT "V2"
(VALVE, UPRIGHT)
PORT "V2"
(TELE CYL)
1001116229-D
5.3 DRIVE PUMP independent porting in the center section. As each piston
cycles in and out of its bore, fluid is drawn from one port
Description and displaced to the other thereby imparting hydraulic
power into the system. A small amount of fluid is allowed
Sauer-Danfoss H1 tandem closed circuit piston pumps to flow from the cylinder block/ valve plate and slipper/
convert input torque to hydraulic power.The tandem swashplate interfaces for lubrication and cooling.Case
design powers two independent drive trains for dual-path drain ports return this fluid to the reservoir. An external
propel applications.The two-piece input shaft transmits charge pump (not shown) provides clean, cool fluid to
rotational force to the cylinder block. A splined coupling makeup this lubricating flow and to maintain minimum
connects the front and rear shafts. Bearings at the front, loop pressure.
rear, and center of the pump support the shaft. Splines
connect each shaft to a cylinder block. A lip-seal at the The angle of each swashplate controls the volume and
front end of the pump prevents leakage where the shaft direction of fluid displaced into the system.The servo pis-
exits the pump housing.The spinning cylinder block con- tons control the angle of the swashplates. Each pump
tains nine reciprocating pistons. Each piston has a brass control, by varying the pressure at the servo pistons, con-
slipper connected at one end by a ball joint. The block trols each piston's position. An electric signal to the con-
spring, ball guide, and slipper retainer hold the slippers to trol coils transmits the command from the operator to the
the swash plate. The reciprocating movement of the pis- pump. Mechanical feedback of the swashplate position to
tons occurs as the slippers slide against the inclined the control through the feedback pins allows for very pre-
swashplates during rotation.Via the valve plates, one half cise displacement control and increases overall system
of each cylinder block is connected to port A or C and the stability. Non-feedback control options do not use the
other half to port B or D. Front and rear sections have mechanical feedback link.
The System Circuit flow will cause a pressure rise with flow above the
valve setting.
THE BASIC CLOSED CIRCUIT
Hydraulic lines connect the main ports of the pump to the
main ports of the motor. Fluid flows in either direction from
the pump to the motor and back. Either of the hydraulic
lines can be under high pressure. In pumping mode the
position of the pump swashplate determines which line is
high pressure as well as the direction of fluid flow.
M14
X3 MA
A
C2 C1
M5 X
E
M3
M4
DRIVE
B
PUMP
L2 L1 S MB
Charge Pressure Relief Valve Typically charge pressure increases from 1.2-1.5 bar per
10 l/min [17.4-21.8 psi per 2.64 US gal/min].
The charge pressure relief valve maintains charge pres-
sure at a designated level above case pressure.The
charge pressure relief valve is a direct acting poppet valve
that opens and discharges fluid to the pump case when
pressure exceeds a designated level. This level is nomi-
nally set with the pump running at 1800 min-1 (rpm). For
external charge flow, the CPRV is set with a flow of 30 l/
min [8 US gal/min]. In forward or reverse, charge pressure
will be slightly lower than in neutral position. The model
code of the pump specifies the charge relief setting.
When the control input signal is either lost or removed, or efficiency), is dependent only on the prime mover speed
if there is a loss of charge pressure, the spring-loaded or motor displacement.
servo piston automatically returns the pump to neutral
position.
The EDC is a displacement (flow) control. Pump swash-
plate position is proportional to the input command and
therefore vehicle or load speed (excluding influence of
NOTE: These symbols are used throughout the Drive Pump illustrations.
Disassembly
DO NOT DAMAGE THE HOUSING BORE, SHAFT OR BEARING
SHAFT SEAL REMOVAL WHEN REMOVING THE SHAFT AND SHAFT SEAL.
1. Orient pump with the shaft pointing up.
2. Remove the snap ring (J200) using snap ring pliers.
2. Remove the spiral ring (J300) from the front housing 3. Use an adequate press to remove the bearing from
to release the shaft seal carrier (J275). the shaft.
EDC CONTROL DISASSEMBLY 1. Position pump so end cover (K100) or auxiliary pad
is on top.
ALIGNMENT PINS (G450) ARE IN END COVER. THEY MAY DIS- Using a 22 mm wrench, remove the charge pressure relief
LODGE DURING DISASSEMBLY. valve (VI0). Discard O-ring (V024).
NOTE: If charge pump requires replacement, replace as a NOTE: Charge pressure relief valve (VI0) is available as
kit. Kit includes (S300), (S250), (S100), and(S200). complete unit only. Seal (V024) is available sepa-
rately.
PRESSURE LIMITER REMOVAL
1. Using a 14 mm wrench, remove pressure limiter car- HIGH PRESSURE RELIEF VALVE REMOVAL
tridges (L300) and (L400). Using a 22 mm wrench, remove the HPRV valves (LI00 /
L200). Discard O-rings (L060) and seals (L068).
2. Remove and discard O-ring (L022). NOTE: HPRV valves may not have the same pressure set-
ting. Tag each valve for reassembly.
NOTE: Right and left pressure settings are different. Tag
each valve for later re-assembly
2. Remove the locking screws (E350) with a 10 mm SWASHPLATE AND SWASHPLATE BEARING
hex wrench. Remove the locking plates (E300). REMOVAL
NOTE: Servo (E100) is available as an assembly only. Seals 3. Remove the three pins (C25).
(E025) and slider block (E015) are available as
repair items. BLOCK SPRING REMOVAL
CYLINDER KIT NOTE: Most repairs do not require block spring removal.
Perform the following only if you suspect problems
1. Pull to remove the slipper retainer (C20) with the pis- with the block spring.
tons (C10) from the cylinder kit.
NOTE: The pistons are not selectively fitted, however units 1. Turn the block over. Using a press, apply pressure
with high hourly usage may develop wear patterns. on the block spring washer (C35) to compress the
Number the pistons and bores for reassembly if they block spring (C30). Compress the spring enough to
are to be reused. safely remove the spiral retaining ring (C45).While
maintaining pressure, unwind the spiral retaining
ring. Carefully release the pressure and remove the
outer block spring washer, block spring, and inner
block spring washer (C40) from the cylinder block.
Inspection
OVERVIEW
After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow to
air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area
and keep all parts free from contamination. Clean and dry
parts again after any rework or resurfacing.
SHAFT BEARING
BLOCK SPRING, AND WASHERS Clean bearing with a solvent and lubricate with hydraulic
fluid. Inspect for wear, or pitting. Rotate the bearing in your
If cylinder kit was fully disassembled, visual inspection of
hand. Replace if it does not rotate smoothly.
the cylinder block, spring, and washers should indicate
minimal wear. Replace if cracks or other damage are pres-
ent.
SWASHPLATE
Carefully inspect each machined surface of the swash-
plate for wear. Ensure all swashplate surfaces are smooth.
Inspect the swashplate's slipper running surface for flat-
ness and brass transfer. Excessive brass transfer from
slippers may indicate you should replace the slippers.
Check the journals for scratches. Replace swashplate if
CYLINDER BLOCK necessary.
Examine the running face of the cylinder block. The sur-
face should be smooth and free of nicks and burrs.
Ensure that no scratches or grooves exist; these may
drastically reduce output flow.
VALVE PLATE
Inspect the valve plate for scratches and grooves. Check
the plate for pitting along the running face. If pitting from
cavitation exists, replace the valve plate. Check for excess
wear on the brass running face. If you observe any discol- HOUSING
oration or burn marks, replace the valve plate. Inspect the housing to ensure that it is clean and free of
foreign material. Inspect the swashplate bearing surfaces,
Run a fingernail or pencil tip across the diameter of the and endcap and control mating surfaces.
sealing land surface (see illustration).You should feel no
deep or outstanding grooves.These may decrease pump
flow. Lap or replace if grooves or nicks are present.
Inspect the mating surfaces of the endcap and valve plate
for any possible contamination; even a few thousandths of
an inch may affect pump operation.
PRESSURE LIMITER
Pressure limiter valves are available as complete units
only. If you suspect valve malfunction, replace the valve(s)
and test pump operation. Replace O-rings before reas-
sembly.
ENDCAP
Inspect the endcap. Inspect all machined surfaces for
scratches or pits. Carefully check the bearing surface for
wear. Inspect valve seats carefully for wear or cracks.
Replace if damaged.
CONTROL
NOTE: If you suspect a coil malfunction, remove the coil by
removing the plastic nut with a 26 mm 12 point
CHARGE PRESSURE RELIEF VALVE socket. Install a new coil. Torque nut to 5 Nm [3.7
ft.Ibs.].
Charge pressure relief valve is available as a complete
unit only. If you suspect valve malfunction, replace the
Inspect sealing surfaces of control. If you find nicks or
valve and test pump operation. Replace O-rings before
scratches that may allow fluid leakage, replace control.
assembly.
Inspect feedback spring and linkage. Control is available
as a complete unit only. If you suspect control operation
problems, replace control with a new unit and test pump.
If necessary, you may remove and clean the control ori-
fices. Use a 3 mm internal hex. wrench Torque to 2.5 Nm
[1.8 Ib.ft.]. Remove and replace the screen if contami-
nated. Screen is not serviceable.
3. Install the swashplate and bearings into the housing. SERVO PISTON INSTALLATION
Ensure swashplate is in neutral position.
Install servo piston assembly (E100). Ensure swashplate
4. If removed, install new filter screens (B040) into pin fits properly in servo slider block (EOT5).
housing. Install screens in same orientation as when
removed.
NOTE: After pump assembly is complete, mount pump on the spiral retaining ring (C45) into the groove in the
test stand. Perform mechanical neutral adjustment cylinder block.
and control neutral adjustment. Refer to HI Closed
Circuit Axial Piston Pumps 078/147/165 Service
Manual 520L0848 for adjustment procedures.
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING
REQUIRES ABOUT 350 TO 400 N [80 TO 90 LB.F.]. USE A PRESS
CYLINDER KIT REASSEMBLY
SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
1. Coat all parts with hydraulic fluid prior to reassem- EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING
bly. TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRES-
SURE SLOWLY AFTER THE RETAINING RING IS INSTALLED.
TIMING PIN AND ENDCAP BUSHING VALVE PLATE AND ENDCAP INSTALLATION
INSTALLATION
1. Install the alignment pins (B010) in housing.
1. Install timing pin (C020) in endcap as shown. Orient
slot away from valve plate. Install the alignment pins
(B010) in housing. Measure pin insertion depth to
verify proper pin insertion.
NOTE: For proper pump operation, it is extremely important CHARGE PUMP INSTALLATION
to ensure that there is no contamination between the
end cap and valve plate. NOTE: Charge pump components are available as a com-
plete kit only. Kit includes (S300), (S250), (SI 00), (SI
4. Install new gasket (G150). 50), and (S200).
NOTE: Do not bend or warp the gasket in an attempt to 1. Install new seal (S300) to valve plate (S250). Lubri-
straighten it.This may damage the embossing which cate valve plate (S250) and install in same orienta-
is not visible under the rubber coating. tion as when it was removed.
Approximate
Locknut wrench displacement change
Adjusting screw size
size and torque per revolution of
adjusting screw
13 mm 23 Nm 4 mm internal hex 5.1 cm3 [0.31 in3]
[17 ft.lbs.]
Port Locations and Gauge Installation calibrate pressure gauges frequently to ensure accuracy.
Use snubbers to protect gauges.
PORT LOCATIONS AND GAUGE INSTALLATION
The following table and drawing show the port locations
and gauge sizes needed. When testing system pressures,
Table 5-7. Port information
Port identifier Port size Wrench size Pressure obtained Gauge size, bar [psi]
L1,L2 1 1/16-12 UNF28 9/16 internal hex Case drain 10bar[100psi]
MA, MB 9/16-18 UNF 1/4 internal hex System pressure 600 bar [10,000 psi]
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure 50 bar [1000 psi]
M4,M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 bar [1000 psi]
PRECAUTIONS
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND
VOID THE MANUFACTURER'S WARRANTY. TAKE PRECAUTIONS
TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND
HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE REINSTALLING SYSTEM COMPONENTS AND LINES.
INTERNAL PUMP COMPONENTS.
PRESSURE LIMITER ADJUSTMENT 2. Start the prime mover and operate at normal speed.
Lock motor output shaft to adjust the pressure limiter set-
3. Use a 17mm wrench to loosen the locking nut
ting. Lock the vehicle's brakes or rigidly fix the work func-
(L024).
tion so it cannot rotate.
4. Activate the control input until pressure in the high
NOTE: Ensure charge pressure is properly set before
side of the system loop stops rising. This pressure is
checking pressure limiter.
the PL setting.
NOTE: If you change pressure limiter settings, you must 5. Return the pump to neutral and adjust the PL setting
also change the HPRV valve to maintain proper PL using an internal hex wrench. Wrench size is in the
function. Refer to the table for corresponding set- diagram on the previous page. Turn the adjusting
tings. screw clockwise to increase the PL setting, counter
clockwise to decrease it.The adjustment is very sen-
1. Install 600 bar [10,000 psi] pressure gauges in the sitive. Change per turn is approximately 150 bar
high pressure gauge ports (MA and MB). Install a 50 [2176 psi].
bar [1000 psi] pressure gauge in the charge pres-
sure gauge port (M3). NOTE: Change per turn is 150 bar/rev [2176 psi/rev].
NOTE: The model code on the serial plate gives the factory
setting of the PL (Pressure Limiter).The PL setting is
referenced to charge pressure. Subtract charge
pressure from system pressure gauge readings to
compute the effective PL setting.
6. Repeat steps four and five until you reach the Table 5-15. Pressure Limiter Settings
desired PL setting. After adjustment, torque the lock-
nut (L024) to 12 Nm [9 ft.lbs.]. Do not over torque. Pressure limiter setting HPRV setting
350 400
7. Shut down the prime mover. Remove gauges and
replace plugs. 380 420
400 450
Table 5-15. Pressure Limiter Settings
410
Pressure limiter setting HPRV setting 420
150 200 430 480
180 230 440
200 250 450
230 280 460 510
250 300 470
280 330 480
300 350
330 380
approximate
displacement
Locknut wrench Adjusting Screw
Displacement change per
size and torque Size
revolution of
adjusting screw
45 13 mm 4 mm internal hex 5.1 cm3 [0.31 in3]
23Nm[17lb.ft.]
53 13 mm 23Nm 4 mm internal hex 6.0 cm3 [0.37 in3]
[17 lb.ft.]
Control Neutral Adjustment 4. Rotate the neutral adjusting screw (D015) clockwise
until the pressure increases on the gauge. Note the
angular position of the wrench. Then rotate the neu-
tral adjusting screw counter clockwise until the pres-
ADJUSTMENT OF THE EDC IS VERY SENSITIVE. BE SURE TO sure increases by an equal amount on the other
HOLD THE HEX WRENCH STEADY WHILE LOOSENING THE LOCK- gauge. Again note the angular position of the
NUT. TOTAL ADJUSTMENT IS LESS THAN 120 DEGREES. wrench.
Mechanical Neutral Adjustment 7. Remove all gauges and replace gauge port plugs.
You can find wrench sizes and plug torques in the
Plug size and torque chart.
SERVO ADJUSTMENT
SERVO ADJUSTMENT SIDE M4
1. Run prime mover at 1800 min rpm.
1. Run prime mover at 1800 rpm.
2. If using a PWM signal, ensure the signal is off.
Check the servo pressure gauges. Ensure the differ- 2. If using a PWM signal to set mechanical neutral,
ential between M4 and M5 is less than 1.5 bar [22 start with the electronic control testing tool off (no
psi]. current to either solenoid). Check to be sure the
servo pressure differential is less than 1.5 bar [22
3. Using a 3/4 in hex deep socket, unthread both servo psi]. Reference Control Neutral Adjustment.
cylinders 2-3 turns.This step ensures the servo cylin-
3. Turn neutral adjust excenter screw (or supply current
ders have no contact with the servo piston.
to solenoid C2) until the servo pressure at port M5 is
1 - 2 bar [14- 29 psi] greater than at port M4.
4. The system pressure differential must be greater
than zero and the pressure at port A (B for clockwise
rotation) must be greater than the pressure at port B
(A for clockwise rotation). This step ensures the
servo is in contact with the servo cylinder on side
M4.
5. Slowly turn in the servo cylinder on the M4 side until
the system pressure differential starts to decrease.
The servo pressure differential must be maintained
between 1-2 bar [14-29 psi] during this step. Con-
tinue turning in the servo cylinder until the system
pressure differential is less than 1.5 bar [22 psi]. This
procedure sets the servo and swashplate to
mechanical neutral.
4. Stroke the pump by turning the control eccentric VERIFY NEUTRAL SETTING
screw (or supplying current to solenoid C1) until the
servo pressure at port M4 is 1 to 2 bar [14- 29 psi] 1. If using a PWM signal to set mechanical neutral,
greater than at port M5 and the system pressure check that servo pressure differential is less than 1.5
gauges indicate displacement. Pressure should be bar [22 psi]. Refer to Control Neutral Adjustment.
greater at port MA for clockwise rotation, or MB for
2. To verify mechanical neutral, provide current to sole-
counter clockwise rotation. This also indicates the
noid C1,or turn neutral adjust excenter screw, until
servo piston is in contact with the servo cylinder on
the servo pressure differential is 3 bar [43 psi]. The
side M5.
system pressure differential must be below 1.5 bar
5. Slowly thread the servo cylinder on the M5 side in [22 psi]. Repeat test on solenoid C2 side.
until the system pressure differential starts to 3. The current required to set the servo pressure differ-
decrease. Maintain servo pressure differential ential to 3 bar [43 psi] should be the same for each
between 1-2 bar [14-29 psi] during this step. Con- solenoid. Refer to TS-392.
tinue turning the servo cylinder in until the system
pressure differential (between ports MA/MB) is less 4. If using neutral adjust excenter screw to set mechan-
than 1.5 bar [22 psi]. This procedure sets the servo ical neutral, reset control neutral.
and swashplate to mechanical neutral on the M5
side.
3. Pull the shaft (J100) with bearing (J150) out of the carrier. Press the seal until it is flush within +0.12mm
pump. If necessary, tap lightly on the shaft to dis- [0.005 in] or -0.72 mm [0.0028 in] of the inside lip of
lodge it from the cylinder block. C the carrier as shown below.
4. Remove the retaining ring (J200) using retaining ring
pliers. Press the bearing off the shaft.
5. Inspect the shaft journals for wear, scratching, and
pits. Check the splines for fretting; replace if dam-
aged. Rotate the bearing, if it does not rotate
smoothly, replace it.
9. Cover the shaft with a protective sleeve while install-
6. Press the bearing (J150) onto the shaft (J100) and ing the seal carrier. Hand press the seal carrier into
replace the retaining ring (J200). Ensure the retain- the housing. Ensure the seal carrier clears the spiral
ing ring diameter is less than 38.84 mm [1.53 in] ring groove in the housing. Remove the protective
when installed on the shaft. sleeve.
7. Install the shaft/bearing assembly into the pump.
10. Wind the spiral ring into the housing. Ensure the
8. Lubricate and install a new O-ring (J260) onto seal inside diameter of the spiral ring is greater than 68
carrier (J275). Press a new seal (J250) into the seal mm [2.677 in] after installation.
CLEANLINESS
Cleanliness is a primary factor for reliable pump perfor-
mance. Wash the outside of the pump thoroughly before
disassembly and all pieces prior to assembly. Cleaning
parts with clean shop solvent and air drying is usually ade-
quate.
PROCEDURE
1. Clamp the unit.
Make sure the vice jaws are clean and have smooth
surfaces to prevent damage to the pump.
2. Remove capscrews.
Place the pump on the table and slowly remove the Place the pump on its side and carefully remove the
front flange. bearing block and gear set. To accomplish this, hold
the pump body and push with your fingers on the
Be careful not to damage the shaft seal when remov- rear bearing block.
ing the flange. Avoid contact of the shaft seal lips
with keyway edges (in tapered and parallel shafts) or Mark the relative positions of the gear mesh (drive
splined shaft teeth. gear tooth to idler gear tooth) and the bearing
blocks to the body so they can be reassembled in
Inspect the front flange and seal area. the same position.
Visually inspect rear cover and seal area. IMPORTANT: DO NOT USE TOOLS WITH SHARP EDGES TO
REMOVE THE SEALS, AS DAMAGE TO THE COVER CAN RESULT.
Check the quality of this seal. If necessary, replace it. Check the shaft seal quality and remove if neces-
Follow the same removal recommendations given in sary.
step 7.}
To remove, pry the bottom of the shaft seal and force
After removal, discard the damaged seal. it out while rotating the flange to lift it out evenly.
Prepare the flange and shaft seal by lightly. Prepare the pressure seals by lightly lubricating
them with grease.
lubricating with grease.
Install pressure seals into the grooves on the front
Seat the seal in the flange by hand. Then, using the flange and rear cover. Then install the teflon backup
shaft seal installation tool (shown on page 52), press ring.
the seal until the tool stops on the flange. This will
insure the seal is inserted to the proper depth. Ensure that the seals are located in the grooves, as
shown.
Prepare the outer seal by lightly lubricating with Clean the two bearing blocks.
grease.
Inspect the flat surfaces of the bearing blocks for
Install outer seals in the grooves on both sides of the burrs or scratches on the edges. If necessary,
body. remove burrs with very fine emery paper. Then
rewash the bearings.
10. Install the gear block assembly. 12. Install the dowel pins.
Install the bearing block and gear assembly into the Install four 5 mm dowel pins into the proper cavities
body cavity. Align the assembly marks to ensure that on both sides of the body (refer to the illustration
the gear block assembly is installed with the same below). Swab the pins with assembly grease or
orientation as before disassembly. petroleum jelly to retain them during assembly.
13. Clean the mating surfaces. 15. Prepare pump for front flange assembly.
Remove any excess lubrication and grease from the Place the pump with the rear cover downwards.
mating surfaces of the front flange and rear cover.
Ensure that these surfaces are dry and free of con- Ensure that the assembly marks on the bearing
tamination before moving on to the next step. block / body are properly aligned.
• In the same direction as the flow if the unit is a Ensure that the seals remain seated in their grooves
pump. during this operation.
Install capscrews. While observing the torque Using a 4 mm internal hex wrench, install the socket
sequence shown, pre tighten the capscrews. Then, head capscrews to the front flange and rear cover.
using a torque wrench, tighten them to the proper
torque. Torque 2.5-3.4 Nm (22-30 ft.lbs.).
Torque 44-54 Nm (32-40 ft.lbs.). If used, install new o-ring to flange pilot.
Troubleshooting
1. Check oil level in reservoir. Insufficient oil to supply gear pump. Fill reservoir to proper level.
2. Check input spline condition. Input shaft broken or stripped. Repair or replace gear pump.
3. Check pressure at pump inlet. Recom- Clogged suction filter or inlet screen. Replace filter or clean suction screen.
mended inlet pressure: 0.8 to 3.0 bar abso-
lute. 0.6 Minimum at cold start.
4. Check condition of gear faces and bearing Scored bearing block and gear faces will reduce Repair or replace gear pump.
blocks. pump efficiency.
5. Check bushings. Overpressure of gear pump will cause idler gear Repair or replace gear pump.
bushing to fail.
Excessive Noise
1. Check oil level in reservoir. Excessive air will cause cavitation sound. Fill reservoir to proper level.
2. Check inlet line for leaks. Excessive air will cause cavitation sound. Repair inlet line.
3. Check pressure at pump inlet. Lower than normal inlet pressure causes Return inlet pressure to recommended levels.
excessive pump noise.
Recommended inlet pressure: 0.8 to 3.0 bar
absolute. 0.6 Minimum at cold start.
External Leakage
1. Check for pinched o-rings or backup ring Pinched seal will allow leakage. Replace pinched seal.
seal.
2. Check pressure seals. Damage to pressure seals is typically caused Inspect condition of bearing blocks. If they are
by reduced "stack-up" in the pump assembly. found to be worn, repair or replace the pump.
This may be due to under-torqued assembly
fasteners, or more commonly is attributed to If bearing blocks are not worn, replace pressure
excessive wear on the bearing blocks. Reduced seals and re-torque pump assembly fasteners.
"stack-up" will affect seal efficiency possibly to
the point of seal extrusion.
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON The upper lift, swing, and drive are controlled by individual
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- joysticks, with steering being controlled by a rocker switch
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- built into the top the drive joystick. To activate Drive, Lift,
ING OPTIONS. and Swing simply pull up on the slide lock location on the
joystick and move the handle into the direction desired.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level,
To return home or
Sub Level, and item menus
access previous menu
The JLG Control System controller has a built in LED to 4. ACCESS LEVEL
indicate any faults. The system stores recent faults which This menu allows the technician to navigate
may be accessed for troubleshooting. Optional equip- between access levels; Operator Access or Service
ment includes a beacon light, function cutout, and ground Access. To enter the Service access level, a five-digit
alarm. These options may be added later but some must code must be entered. Powering down returns the
be programmed into the controller when installed. Analyzer to Operator Access.
The Control System may be accessed by using a custom
5. PERSONALITIES
designed, hand held analyzer (Analyzer Kit, JLG P/N
This menu contains performance settings specific to
2901443 or separately, Analyzer, JLG P/N 1600244 &
the machine. These settings are necessary to main-
Cable, JLG P/N 1600633) which will display two lines of
tain functions such as solenoid breakpoints and joy-
information at a time, by scrolling through the program.
stick engagement percentages and are organized in
NOTE: Each module has a label with the JLG part number an outline format (see Figure 6-10., Analyzer Person-
and a serial number which contains a date code. alities Menu). These settings can be modified in the
Service access level.
6.2 ANALYZER MENU STRUCTURE
6. MACHINE SETUP
There are seven levels within the Analyzer menu structure This menu contains machine configuration informa-
and they are as follows; tion for the JLG Control System. Selections in this
menu can change interlock functionality and cause
1. HELP: PRESS ENTER some Personality and Machine Setup entries to be
This is the default menu that appears at power up of visible or hidden. These settings can be modified in
the Analyzer. This menu displays the current Help the Service access level.
(fault) message. This is intended to quickly guide
the technician in the event of a fault in the JLG Con- 7. CALIBRATIONS
trol System. This menu also displays functional inter- This menu allows the operator to interact with the
locks. Pressing ENTER shows Logged Help which is sensors on the machine. These settings can be
a record of the last 25 Help (fault) messages. Editing modified in the Service access level.
of information in this menu is not possible.
2. DIAGNOSTICS
This menu provides real-time status information
about the control system as a diagnostic aid.
3. SYSTEM TEST
This menu is used to activate and then interact with
the Control System’s self-test functionality. Starting
the System Test will cause the functionality of each
device to be tested. Outputs are energized to detect
short or open circuit conditions and digital inputs are
stimulated to simulate switching conditions. Editing
of information in this menu is not possible.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
The top level menus are as follows: When a top level menu is selected, a new set of menu
items may be offered: for example:
HELP
DIAGNOSTICS SYSTEM
SYSTEM TEST DATALOG
OPERATOR ACCESS VERSIONS
PERSONALITIES ENGINE
MACHINE SETUP OPER CONTROLS
CALIBRATIONS (Service Access only) Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
If you press ENTER, at the HELP: PRESS ENTER display,
menu. In some cases, such as DRIVE, the next level is the
and a fault is present, the analyzer display will scroll the
parameter or information to be changed. Refer to the flow
fault across the screen. If there was no fault detected, the
chart for what menus are available within the top level
display will read: HELP: EVERYTHING OK. If powered up
menus. You may only view the personality settings for
at the ground station, the display will read: GROUND OK. selected menus while in Operator Access level. Remem-
If ENTER is pressed again, the display moves to the fol- ber, you may always cancel a selected menu item by
lowing display: pressing the ESC. key.
LOG (211)
1: POWER CYCLE
At this point, the analyzer will display the last fault the sys-
tem has seen, if any are present. You may scroll through
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To
return to the beginning, press ESC. two times. POWER
CYCLE (211) indicates a power up.
ACCESS LEVEL:
CODE 00000
Press ENTER to select the ACCESS LEVEL menu. Adjusting Parameters Using the Hand Held
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Analyzer
Then using the RIGHT arrow key, position the cursor to Once you have gained Service Access, and a personality
the right one space to enter the second digit of the pass- item is selected, press the UP or DOWN arrow keys to
word. adjust its value, for example:
SWING:
ACCEL 1.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
MENU: the value is at the minimum value for any particular per-
SERVICE ACCESS sonality. If the value does not change when pressing the
Repeat the above steps if the correct access level is not up and down arrows, check the access level to ensure
displayed or you can not adjust the personality settings. you are at Service Access.
Machine Setup There are two settings that JLG strongly recommends that
you do not change. These settings are so noted below:
When a machine digit item is selected, press the UP or DRIVE MT ELEV MAX (Driving with engine at Max
DOWN arrow keys to adjust its value, for example: Torque and machine at maximum elevation)
DRIVE ME ELEV MAX (Driving with engine at Mid
Engine and machine at maximum elevation)
G R O U N D A LA R M :
CHANGING THESE SETTINGS COULD ADVERSELY AFFECT THE
2 =D R IV E
STABILITY OF YOUR MACHINE.
LE V E L V E H IC LE
Y E S :E N T E R , N O :E S C
GROUND ALARM:
2 = DRIVE
PLATFORM MODULE
GROUND MODULE
PROPORTIONAL JOYSTICKS
Platform
Control Function Module
Input
Lift/Swing Joystick Lift J5-3
Swing J5-4
Drive/Steer Joystick Drive J6-3
Steer Left J6-5
Steer Right J6-6
6.5 CONTROL SYSTEM STARTUP CHECKS • Energize all Ground and Platform Station indicators
and energize the Platform Alarm.
The following actions and checks are performed during • Perform assessments as shown in Table 6-5, System
system startup: Startup Checks.
• Inhibit all hydraulic functions
MENU: MENU: 2
MENU: MENU: MENU: MENU: MENU:
HELP: PRESS CALIBRATIONS
DIAGNOSTICS SYSTEM TEST OPERATOR ACCESS PERSONALITIES MACHINE SETUP
ENTER
CALIBRATIONS: CALIBRATIONS:
HELP: SYSTEM TEST: ACCESS LEVEL:
TILT SENSOR LOAD SENSING
EVERYTHING OK ACTIVATE ? CODE XXXXX
SECTION 6 - JLG CONTROL SYSTEM
– JLG Lift –
TILT SENSOR: LOAD SENSING
SWING 180 & ENTER CALIBRATING…
or
LEVEL VEHICLE?
or
CAL FAILED LOAD SENSING
CAL FAILED
or
CAL COMPLETE
TILT SENSOR:
LEVEL VEHICLE?
then
CAL FAILED
or
CAL COMPLETE
1001120432 B
3121259
MENU:
PERSONALITIES
3121259
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES: PERSONALITIES: PERSONALITIES:
DRIVE TOWER LIFT JIB LIFT PLATFORM PLATFORM GROUND MODE ENGINE RPM
STEER SWING LIFT TELESCOPE
LEVEL ROTATE
DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND ENGINE RPM
ACCEL 275mA/s ACCEL 0.8s ACCEL 2.2s ACCEL 3.0s ACCEL 2.0s ACCEL 1.0s ACCEL 1.2s ACCEL 0.0s ACCEL 0.0s SWING 750mA GEN SET 1800RPM
DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND
DECEL 175mA/S DECEL 0.1s DECEL 1.2s DECEL 1.0s DECEL 1.0s DECEL 1.0s DECEL 0.5s DECEL 0.0s DECEL 0.0s TOWER UP 1250mA
DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND
MIN 640mA MIN LEFT 35% MIN LEFT 400mA MIN UP 400mA MIN UP 400mA MIN IN 400mA MIN UP 400mA MIN UP 400mA MIN LEFT 400mA TWR DOWN 750mA
DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND
MAX 1500mA MAX LEFT 80% MAX LEFT 880mA MAX UP 1250mA MAX UP 1250mA MAX IN 1250mA MAX UP 1075mA MAX UP 1250mA MAX LEFT 1250mA LIFT UP 1250mA
DRIVE ME/MT STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND
ACCEL 300mA/s CREEP LEFT 50% CREEP LT 600mA CREEP UP 600mA CREEP UP 525mA CREEP IN 675mA CREEP UP 575mA CREEP UP 550mA CREEP LT 1250mA LIFT DOWN 750mA
DRIVE ME/MT STEER SWING TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND
DECEL 100mA/s MIN RIGHT 35% MIN RIGHT 400mA MIN DOWN 400mA MIN DOWN 400mA MIN OUT 400mA MIN DOWN 32% MIN DOWN 400mA MIN RIGHT 400mA TELESCOPE 1250mA
– JLG Lift –
MAX RIGHT 80% MAX OUT 1250mA MAX DOWN 53% MAX RIGHT 1250mA
MAX RIGHT 880mA 750mA 850mA 1250mA
DRIVE MT ELEV
MAX 790mA
DRIVE ME ELEV
MAX 900mA
6-21
SECTION 6 - JLG CONTROL SYSTEM
6-22
MENU:
MACHINE
SETUP
MARKET
TILT
MODEL ANSI USA ENGINE FLYWHEEL GLOW PLUGS START LOCKOUT ENGINE SHUTDOWN FUEL CUTOUT
5 DEGREES
ANSI EXPORT TEETH 4 DEGREES
NO MODEL CSA KUBOTA D 1105 NO GLOW PLUGS DISABLED DISABLED ONE RESTART
3 DEGREES
340AJ CE DUAL FUEL ECM 98 TEETH IN CYLINDER ENABLED ENABLED ENGINE STOP
4 DEGREES + CUT
AUSTRALIA
3 DEGREES + CUT
JAPAN
SECTION 6 - JLG CONTROL SYSTEM
LOAD SYSTEM
FUNCTION CUTOUT GROUND ALARM
GEN SET/WELDER GEN SET CUTOUT H&T LIGHTS
JIB NO
NO NO
NO WARN ONLY
NO MOTION ENABLED NO BOOM CUTOUT DRIVE
YES CUTOUT PLATFORM
BELT DRIVE MOTION CUTOUT YES DRIVE CUTOUT DESCENT
– JLG Lift –
CUTOUT ALL
DRIVE CUT E&T MOTION
SPECIAL 1
METRIC NO NO
IMPERIAL YES YES
3121259
MENU:
DIAGNOSTICS * To Sheet 2
3121259
*
DRIVE/STEER BOOM FUNCTIONS ENGINE SYSTEM OPER CONTROLS
*
TRANSPORT MODE JOYSTICK DRIVE
SWING DEMAND TELE OUTPUT ENGINE SPEED UGM BATTERY
DRIVE DEMAND IN TRANSPORT /OUT FORWARD /
DRV ORNT OVR SW LEFT/RIGHT XXX % IN/OUT XXX% OPERATING STATE TARGET XXXXRPM XX.XV
FORWARD / OF TRANSPORT REVERSE XXX %
CLOSED/OPEN STOPPED /
REVERSE XXX % CRANKIING /
JIB LIFT DEMAND STARTING / CREEP SW
SWING OUTPUT PLATFORM MODULE JOYSTICK STEER
CRIBBING MODE UP/DOWN XXX % RUNNING OPEN/CLOSED
DRIVE OUTPUT LEFT/RIGHT XXX % BATTERY XX .XV LEFT /RIGHT
SW FUEL ACTUATOR
FORWARD / OUTPUT XXXXmA XXX%
CLOSED/OPEN
REVERSE XXX %
JIB LIFT OUTPUT GLOW PLUG AMBIENT TEMP CREEP MODE
SWING OUTPUT mA
UP/DOWN XXX % NOT ACTIVE / XXXC/XXXF ON/OFF JOYSTICK SWING
LEFT/RIGHT XXXXmA
DRIVE OUT mA CRIBBING MODE PREGLOW ACTIVE FUEL ACTUATOR LEFT /RIGHT
FORWARD / DISABLED /ENABLED FDBK XXXXmA XXX%
PLATFORM SELECT CHASSIS TILT
REVERSE XXXXmA PLAT LVL DEMAND
KEYSWITCH : OPEN XX.XDEG
SWING FDBK mA UP/DOWN XXX %
KEYSWITCH : CLOSED JOYSTICK LIFT
XXXXmA COOLANT TEMP UP/DOWN XXX %
XXXC /XXXF THROTTLE OUTPUT GROUND SELECT
DRIVE FDBK mA PLAT LVL OUTPUT CHASSIS TILT
XXXXmA TWR LIFT UP/DOWN XXX % OFF/ON KEYSWITCH : OPEN X-AXIS XX .XDEG
DEMAND KEYSWITCH : CLOSED START SWITCH
UP/DOWN XXX% ENGINE OIL OPEN/CLOSED
PLAT ROT DEMAND PRESS CHASSIS TILT
STATION CONTROL
STEER DEMAND LEFT/RIGHT XXX % OK Y-AXIS XX .XDEG
TWR LIFT OUTPUT GROUND/PLATFORM AUX DESCENT SW
LEFT/RIGHT XXX % XXXXPSI /
UP/DOWN XXX% XXXXKPA OPEN/CLOSED
PLAT ROT OUTPUT FOOTSWITCH INPUT GENSET/WELDER SW
TWR LIFT OUT mA LEFT/RIGHT XXX % GROUND: OPEN OPEN/CLOSED
STEER OUTPUT GROUND: CLOSED SWING LEFT SW
UP/DOWN FUEL SELECTION
LEFT/RIGHT XXX % OPEN/CLOSED
XXXXmA STATUS GAS /LP
FLW CNTRL OUT mA FOOTSWITCH INPUT GENSET ENABLE
– JLG Lift –
TWR LIFT FDBK XXXXmA PLATFORM : OPEN OUTPUT: ON/OFF
PLATFORM : CLOSED SWING RIGHT SW
BRAKES STATUS mA
OPEN/CLOSED
LOCKED/ XXXX mA AMBIENT TEMP
RELEASED FLW CNTRL FBK mA BM ELEV SW 1 H&T LIGHTS SW
XXXC /XXXF
XXXXmA UNKNOWN /OPEN/ OPEN/CLOSED
LIFT DEMAND CLOSED TOWER LIFT UP
UP/DOWN XXX% OPEN/CLOSED
TRACTION LOCK
BM ELEV SW 2 H&T LIGHTS OUT
OUTPUT ON /OFF FUNCTION SPEED FUEL LEVEL UNKNOWN /OPEN/ ON/OFF
SETTING: XXX% FULL;¾ ;½ ;¼; TOWER LIFT DN SW
LIFT OUTPUT CLOSED
UP/DOWN XXX% LOW, EMPTY, OPEN/CLOSED
ERROR
DRIVE MODE TOWER ELEV SW
CREEP SW
MAX SPEED/MAX UNKNOWN /OPEN/
OPEN/CLOSED LIFT UP SW
TORQUE /MID LIFT OUTPUT mA CLOSED
OPEN/CLOSED
ENGINE UP/DOWN XXXX mA ALLOWED
STARTER OSC AXLE SW 1
CREEP MODE CRANK TIME : XXs UNKNOWN /OPEN/
ON/OFF CLOSED LIFT DN SW
DRV ORIENT TT SW LIFT FDBK mA
XXXX mA OPEN/CLOSED
OPEN-INLINE/
CLOSED-DOS OSC AXLE SW 2
ENGINE SPEED UNKNOWN /OPEN/
ACTUAL XXXXRPM CLOSED TELE IN SW
TELE DEMAND
OPEN/CLOSED
IN/OUT XXX %
DRV ORIENT STATE
CONFIRM / ELEVATION MODE
REQUIRED ABOVE/NOT ABOVE
6-23
SECTION 6 - JLG CONTROL SYSTEM
6-24
MENU:
* From Sheet 1 DIAGNOSTICS
* 2 Only Available in Access Level 2
2 DIAGNOSTICS : 2 2
PLATFORM LOAD CAN STATISTICS CALIBRATION DATALOG VERSIONS
DATA
*
TELE OUT SW PLATFORM LOAD UGM
UGM TILT 1 X DATALOG TIME
OPEN/CLOSED STATE : OK/ CAN 1 STATISTICS DATALOG CYCLES SOFTWARE PX .X
XXXXX COUNTS ON XXXXH XXM
OVERLOAD RX/SEC: XXX LEVEL UP XXXXXXX
DATALOG CYCLES
DATALOG TIME UGM
JIB LIFT UP SW DRIVE FWD XXXXXXX
ENGINE XXXXH DATALOG CYCLES CNST DATA PX .X
OPEN/CLOSED PLATFORM LOAD
UGM TILT 1 Y XXM LEVEL DN XXXXXXX
ACTUAL : XXX.XKG CAN 1 STATISTICS
TX/SEC: XXX XXXXX COUNTS DATALOG CYCLES
DATALOG TIME UGM
JIB LIFT DN SW DRIVE REV XXXXXXX
2 ENABLD XXXXH DATALOG CYCLES HARDWARE REV X
OPEN/CLOSED ROT LEFT XXXXXXX
PLATFORM LOAD XXM
GROSS: XXX.XKG UGM TILT 2 X
CAN 1 STATISTICS DATALOG CYCLES
XXXXX COUNTS UGM
PLAT LEVEL UP SW BUS OFF : XXX DATALOG TIME STEER LT XXXXXXX DATALOG CYCLES
S/N XXXXXXX
OPEN/CLOSED AUX XXXXH XXM ROT RGHT XXXXXXX
2
PLATFORM LOAD
OFFSET : XXX.XKG UGM TILT 2 Y DATALOG CYCLES UGM
DATALOG TIME DATALOG CYCLES
PLAT LEVEL DN SW CAN 1 STATISTICS XXXXX COUNTS STEER RT XXXXXXX P/N XXXXXXXXXX
UGM ON XXXXXXX
SECTION 6 - JLG CONTROL SYSTEM
– JLG Lift –
OPEN/CLOSED DATALOG CYCLES
2
PLATFORM LOAD CAN 2 STATISTICS DATALOG TIME GEN ON XXXXXXX LSS MODULE
DATALOG CYCLES SOFTWARE PX .X
CELL3: XXX.XKG TX/SEC: XXX LIFT XXXXH XXM
MAX TORQUE SW TOWER DN XXXXXXX
OPEN/CLOSED DATALOG : MAX
UGM TEMP XXXC LSS MODULE
2 DATALOG TIME UGM TEMP XXXF
CAN 2 STATISTICS DATALOG CYCLES HARDWARE REV X
PLATFORM LOAD TELE XXXXH XXM
CREEP SW BUS OFF : XXX LIFT UP XXXXXXX
OPEN/CLOSED CELL4: XXX.XKG DATALOG : MIN
DATALOG TIME UGM TEMP XXXC TCU MODULE
JIB XXXXH XXM DATALOG CYCLES UGM TEMP XXXF SOFTWARE PX .X
HORN SW CAN 2 STATISTICS LIFT DN XXXXXXX
OPEN/CLOSED PASSIVE : XXX DATALOG : MAX TCU MODULE
DATALOG TIME DATALOG CYCLES UGM VOLT XX .XV
LEVEL XXXXH XXM HARDWARE REV X
TELE IN XXXXXXX
FUEL SELECT SW
OPEN/CLOSED CAN 2 STATISTICS DATALOG : MACHINE
DATALOG TIME DATALOG CYCLES TCU MODULE
MSG ERROR : XXXX RENTAL XXXXH XXM
ROTATE XXXXH XXM TELE OUT XXXXXXX S/N XXXXXXX
H&T LIGHTS SW
OPEN/CLOSED DATALOG : ERASE
DATALOG CYCLES MACHINE RENTAL ? ANALYZER
DATALOG TIME JIB UP XXXXXXX ANALYZER vX .X
GEN XXXXH XXM
GENSET /WELDER SW
OPEN/CLOSED DATALOG CYCLES
JIB DOWN XXXXXXX
3121259
SECTION 6 - JLG CONTROL SYSTEM
4150365-A
Default
Configuration Label/Digit Number Description
Number
The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then chang-
ing the model number of the machine configuration will cause the personality settings to return to default.
MODEL NUMBER: 0 ????: Visible only on a Non-Configured UGM 1
1 1 340AJ
2 NO MODEL
STARTER LOCKOUT: 1 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine 1
6* start can be attempted at any time during pre-glow.
FUEL CUTOUT: ONE START: One start with limited run time when near Empty. 1
8*
ENGINE STOP: No starting permitted when near Empty.
* This menu item is visible only if Engine = Kubota D1105
Default
Configuration Label/Digit Number Description
Number
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted 1
9* more than 5 degrees and above elevation; also reduces drive speed to creep.12
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 4 degrees and above elevation; also disallows tower lift up, drive, tele-
scope out and lift up.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, drive, tele-
scope out and lift up.
* Certain market selections will limit tilt options and alter default setting.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the
machine is also above elevation.
GEN SET CUTOUT: 1 MOTION ENABLED: Motion enabled when generator is ON. 1
14*
2 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder = Belt Drive.
Default
Configuration Label/Digit Number Description
Number
CABLE SWITCH: 1 NO: No broken cable switch installed. 1
16*
2 YES: Broken cable switch installed.
* This item not visible.
3 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
beeps (5 sec ON, 2 sec OFF).
4 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off),
platform alarm beeps (5 sec ON, 2 sec OFF).
5 SPECIAL 1: Functions in creep, overload lamp lit, disables telescope out & lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
4 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
* Only visible under certain market selections.
* Certain market selections will limit function cutout options or alter default setting.
Default
Configuration Label/Digit Number Description
Number
LEVELING MODE: 1 ALL FUNCTIONS: Platform level with all functions. 1
22*
2 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
* This item not visible.
4150364-A
Table 6-8. Machine Configuration Programming Settings Table 6-8. Machine Configuration Programming Settings
ANSI Export
ANSI USA
ANSI Export
Australia
ANSI USA
Australia
Japan
CSA
Japan
CE
340AJ
CSA
CE
340AJ
Engine 1 1 1 1 1 1 2 2 2 2 2 2
2 2 2 X X 2 Leveling Mode 1 1 1 1 1 1
Glow Plug 3 3 3 3 3 3 2 2 2 2 2 2
2 2 2 2 2 2 2 X X X X X
Engine Shutdown 2 2 2 2 2 2 BOLD TEXT indicates the default setting. Plain text indicates another
available selection. ITALIC TEXT indicates the default when option is
1 1 1 1 1 1 factory installed. SHADED CELLS indicate hidden menu or selection.
Fuel Cutout 1 1 1 1 1 1
2 2 2 2 2 2
Tilt 1 1 1 X X 1
2 2 2 X X 2
3 3 3 3 3 3
4 4 4 4 4 4
5 5 5 5 5 5
Jib 2 2 2 2 2 2
4 Wheel Steer 1 1 1 1 1 1
Soft Touch 1 1 1 1 1 1
Gen Set / Welder 1 1 1 1 1 1
2 2 2 2 2 2
Gen Set Cutout 1 1 1 1 1 1
2 2 2 2 2 2
Head & Taillights 1 1 1 1 1 1
2 2 2 2 2 2
Cable Break Switch 1 1 1 1 1 1
Load System 1 1 1 1 1 1
X 2 X X X 2
X 3 X 3 3 3
X 4 X 4 X 4
X 5 X X X X
Function Cutout 1 1 1 1 1 1
X 2 2 2 2 2
3 3 3 X 3 3
X 4 4 X 4 4
Ground Alarm 1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
4 4 4 4 4 4
6.6 SYSTEM FAULT MESSAGES Pressing ENTER again will cause the Analyzer to display
the current Help description followed by its’ Diagnostic
The Help Message display on the JLG Analyzer provides Trouble Code (DTC). Help Messages larger than the Ana-
diagnostic feedback to explain vehicle operation and lyzer’s display are scrolled across the screen and
interlocks. After the Analyzer is connected to the Ground repeated. Using the up arrow will increase the scroll
Module or Platform Module, the Control System shall speed. If the Fault is active, an asterisk will appear beside
receives an “Initialize Analyzer” command from the Ana- the DTC. If the operator enters Logged Help, the Control
lyzer and the Control System commands the Analyzer to System will show the previous 25 logged DTCs along with
display the top menu item: the Fault description on the analyzer screen.
Table 6-9, System Fault Code Listing lists the fault codes
applicable for this machine and the analyzer message that
accompanies the fault code. Table 6-10, Fault Code Trou-
bleshooting Information contains evaluation, response,
H E LP :
PRESS ENTER display, and operational requirements for each Fault con-
dition.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
EVERYTHING OK or 0011 The platform station (EVERYTHING OK) or ground sta- No response required. -
GROUND MODE OK tion (GROUND MODE OK) is selected and the system
detects no problems exist.
RUNNING AT CUTBACK 00101 Tower Elevation Switch shows tower is elevated out of Machine is considered Lower boom into trans-
– OUT OF TRANSPORT transport position Out Of Transport Position port position
POSITION or
Boom Elevation Switch #1 shows boom elevated out of
transport position
or
Boom Elevation Switch #2 shows boom elevated out of
transport position
FSW OPEN 00111 Machine is in Platform Mode Machine is not allowed to Release controls, Engage
Drive/Steer or Boom function control is activated when enter the Machine Footswitch and reacti-
Footswitch not engaged Enabled state vate Drive/Steer and/or
Boom function control
RUNNING AT CREEP - 00121 Machine is in Platform Mode Creep Mode is active Turn Platform creep
CREEP SWITCH OPEN Platform creep switch is turned on switch off
RUNNING AT CREEP - 00131 Fault RUNNING AT CREEP - CREEP SWITCH OPEN Creep Mode is active Lower Machine and
TILTED AND ABOVE (DTC 0012) is not active place on firm, level sur-
ELEVATION Machine is Out Of Transport Position face
Machine chassis is considered Tilted
RUNNING AT CREEP – 00301 Platform is in Stowed Position Lift Down and Level Raise Platform from
PLATFORM STOWED Down function speed Stowed Position
maximums are limited to
Ground Creep
FUEL LEVEL LOW – 0031 Engine Shutdown has occurred due to Fuel Level being Machine prohibits engine Add fuel to fuel tank
ENGINE SHUTDOWN EMPTY cranking and throttle
functions
APU ACTIVE 0035 Emergency Descent Mode is active Operation specified in Stop using Emergency
Emergency Descent Descent Mode
Mode section
KEYSWITCH FAULTY 212 Both Ground and Platform Keyswitches are energized at The Control System On Analyzer under DIAG-
the same time assumes a station selec- NOSTICS-->SYSTEM--
tion of Ground >PLATFORM SELECT
(and GROUND SELECT),
activate Platform and
Ground keyswitches to
determine fault location;
then troubleshoot wiring
and/or keyswitch.
FSW FAULTY 213 The ground footswitch input and platform footswitch Machine does not allow Use the Emergency Stop
input have been both engaged or disengaged for a time any functions Switch to cycle power
period greater than or equal to 1 second
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 224 The machine is in Platform mode and the Steer Left Machine enters Creep Enable machine and on
STEER LEFT PERMA- switch is energized at startup Mode and Steer Left and Analyzer under DIAG-
NENTLY SELECTED Right are prohibited NOSTICS-->DRIVE/
STEER-->STEER
DEMAND, observe Steer
Left and Right com-
mands; open Platform
box and troubleshoot wir-
ing or replace joystick.
FUNCTION PROBLEM - 225 The machine is in Platform mode and the Steer Right Machine enters Creep Enable machine and on
STEER RIGHT PERMA- switch is energized at startup Mode and Steer Left and Analyzer under DIAG-
NENTLY SELECTED Right are prohibited NOSTICS-->DRIVE/
STEER-->STEER
DEMAND, observe Steer
Left and Right com-
mands; open Platform
box and troubleshoot wir-
ing or replace joystick.
STEER SWITCHES 227 Both steer switch inputs on the Drive/Steer joystick are Drive and Steer are pro- Enable machine and on
FAULTY energized at startup (Platform or Ground mode). hibited. Analyzer under DIAG-
NOSTICS-->DRIVE/
STEER-->STEER
DEMAND, observe Steer
Left and Right com-
mands; open Platform
box and troubleshoot wir-
ing or replace joystick.
FSW INTERLOCK 2211 Machine is in Platform Mode. The Machine Enabled Release the footswitch
TRIPPED The footswitch is depressed for a time period greater function is disabled
than or equal to 7 seconds without activation of any
functions
DRIVE LOCKED - JOY- 2212 The Control System detects one of the following condi- If caused by the drive joy- If caused by the drive joy-
STICK MOVED BEFORE tions: stick not being in the neu- stick not being in the neu-
FOOTSWITCH tral position immediately tral position immediately
The machine is in Platform Mode and the drive joystick following the startup following Start Up, then
is not in the neutral position immediately following Start period then disable drive return Drive joystick to its
Up. and steer neutral position before
depressing footswitch
The machine is in Platform Mode and the footswitch is If caused by engaging
depressed or DTC 2213, 2221, or 2223 are active while footswitch while the drive If caused by footswitch
the drive joystick is not in the neutral position. joystick is not in the neu- being depressed while
tral position, then do not the drive joystick is not in
allow the machine to the neutral position then
enter the Machine release the footswitch,
Enabled state return the Drive joystick
to neutral and depress the
footswitch again
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
STEER LOCKED - 2213 The Ground Module detects that the machine is in Plat- Do not allow the machine Steer controls are
SELECTED BEFORE form Mode and the footswitch is depressed or DTC to enter the Machine returned to neutral and
FOOTSWITCH 2212, 2221 or 2223 is active while the steer controls Enabled state the footswitch is released
are not in the neutral position.
D/S JOY. OUT OF 2216 The Platform Module detects that the drive/steer joy- The Control System dis- The Platform Module
RANGE HIGH stick voltage is out of range ables Drive; Brake detects the voltage is in
release and Steer still per- range and no longer
mitted reports the fault. Move
joystick through range of
motion and check voltage
(should be approximately
0.7-6.3V).
D/S JOY. CENTER TAP 2217 The Platform Module detects that the drive/steer center The Control System dis- The Platform Module
BAD tap voltage is out of range ables Drive; Brake detects the voltage is in
release and Steer still per- range and no longer
mitted reports the fault
L/S JOY. OUT OF RANGE 2219 The Platform Module detects that the Lift/Swing joy- Disable Lift and Swing in The Platform Module no
HIGH stick reference voltage is high Platform Mode longer reports the fault
L/S JOY. CENTER TAP 2220 The Platform Module detects that the Lift/Swing center Disable Lift and Swing in The Platform Module
BAD tap voltage is out of range Platform Mode. detects that the lift/swing
center tap voltage is in
range and no longer
reports the fault
LIFT/SWING LOCKED - 2221 The Ground Module detects one of the following condi- If fault occurs at startup, Return Lift/Swing con-
JOYSTICK MOVED tions: disable Lift and Swing in trols to neutral while not
BEFORE FOOTSWITCH Platform Mode in the Enabled state.
The machine is in Platform Mode and the Lift and/or
Swing controls are not in the neutral position immedi- If fault occurs by engag- Return Lift/Swing con-
ately following Start Up. ing the footswitch after trols to neutral and
the control, then machine release the footswitch
The machine is in Platform Mode and the footswitch is is not permitted to enter
depressed or DTC 2212, 2213 or 2223 are active while the Machine Enabled
the Lift/Swing joystick is not in the neutral position. state.
WAITING FOR FSW TO 2222 Machine is in Platform Mode Machine is not allowed to Release the Footswitch
BE OPEN Footswitch has been engaged since Start Up enter the Machine
Enabled state
FUNCTION SWITCHES 2223 The machine is in Platform Mode and the footswitch is Machine is not allowed to Release engaged control
LOCKED - SELECTED depressed or DTC 2212, 2213, or 2221 is active while enter the Machine switch and then depress
BEFORE ENABLE any of the following boom control inputs are engaged: Enabled state footswitch
Tower Lift
Telescope
Platform Level
Platform Rotate
Jib Lift
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FOOTSWITCH 2224 Machine is in Platform mode Disable engine start Release the footswitch
SELECTED BEFORE The footswitch is already engaged when an engine start before attempting to start
START is attempted from the platform controls the engine
FUNCTION PROBLEM - 2247 The machine is in Platform mode and the platform rotate Machine enters Creep Release the footswitch
PLATFORM ROTATE switch is sending a continual left rotate signal. Mode and Platform and return the platform
LEFT PERMANENTLY Rotate Left and Right pro- rotate switch to neutral.
SELECTED hibited. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
FUNCTION PROBLEM - 2248 The machine is in Platform mode and the platform rotate Machine enters Creep Release the footswitch
PLATFORM ROTATE switch is sending a continual right rotate signal. Mode and Platform and return the platform
RIGHT PERMANENTLY Rotate Left and Right pro- rotate switch to neutral.
SELECTED hibited. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
FUNCTION PROBLEM - 2249 The machine is in Platform mode and the jib lift switch is Machine enters Creep Release the footswitch
JIB LIFT UP PERMA- sending a continual lift up signal. Mode and Platform Jib and return the platform jib
NENTLY SELECTED Lift Up and Down prohib- lift switch to neutral.
ited. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
FUNCTION PROBLEM - 2250 The machine is in Platform mode and the jib lift switch is Machine enters Creep Release the footswitch
JIB LIFT DOWN PER- sending a continual lift down signal. Mode and Platform Jib and return the platform jib
MANENTLY SELECTED Lift Up and Down prohib- lift switch to neutral.
ited. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 2251 The machine is in Platform mode and the telescope Machine enters Creep Release the footswitch
TELESCOPE IN PERMA- switch is sending a continual telescope in signal. Mode and Tele In and Out and return the telescope
NENTLY SELECTED prohibited. switch to neutral. Actuate
switch while monitoring
state changes under
appropriate menu in
DIAGNOSTICS-->OPER
CONTROLS on Analyzer.
Replace the switch if
faulty.
FUNCTION PROBLEM - 2252 The machine is in Platform mode and the telescope Machine enters Creep Release the footswitch
TELESCOPE OUT PER- switch is sending a continual telescope out signal. Mode and Tele In and Out and return the telescope
MANENTLY SELECTED prohibited. switch to neutral.
Replace the switch if
faulty.
FUNCTION PROBLEM - 2257 The machine is in Platform mode and the tower lift Machine enters Creep Release the footswitch
TOWER LIFT UP PER- switch is sending a continual tower lift up signal. Mode and Tower Lift Up and return the telescope
MANENTLY SELECTED and Down prohibited. switch to neutral. Actuate
switch while monitoring
state changes under
appropriate menu in
DIAGNOSTICS-->OPER
CONTROLS on Analyzer.
Replace the switch if
faulty.
FUNCTION PROBLEM - 2258 The machine is in Platform mode and the tower lift Machine enters Creep Release the footswitch
TOWER LIFT DOWN switch is sending a continual tower lift down signal. Mode and Tower Lift Up and return the telescope
PERMANENTLY and Down prohibited. switch to neutral. Actuate
SELECTED switch while monitoring
state changes under
appropriate menu in
DIAGNOSTICS-->OPER
CONTROLS on Ana-
lyzer.Replace the switch
if faulty.
FUNCTION PROBLEM - 2262 The machine is in Platform mode and the platform level Machine enters Creep Release the footswitch
PLATFORM LEVEL UP up switch is sending a continual level up signal. Mode and Platform Level and return the platform
PERMANENTLY Up and Down prohibited. level switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 2263 The machine is in Platform mode and the platform level Machine enters Creep Release the footswitch
PLATFORM LEVEL down switch is sending a continual level up signal. Mode and Platform Level and return the platform
DOWN PERMANENTLY Up and Down prohibited. level switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if faulty.
FUNCTION SWITCHES 234 The Ground Module detects one of the following condi- The boom function that is Check the switch for the
FAULTY - CHECK DIAG- tions: triggering the fault is dis- applicable function.
NOSTICS/BOOM abled. NOTE: If Engine Actuate switch while
The machine is in Ground Mode and both direction
inputs of the following boom controls are energized Start/Aux Power is at monitoring state changes
at the same time: Engine Start/Aux, Telescope, Plat- fault, Emergency under appropriate menu
form Level, Platform Rotate, Jib Lift, Tower Lift, Lift, Descent will still be per- in DIAGNOSTICS--
or Swing. mitted. >OPER CONTROLS on
Analyzer. Replace if
The machine is in Platform Mode and both direction faulty.
inputs of the following boom controls are energized
at the same time: Engine Start/Aux, Telescope, Plat-
form Level, Platform Rotate, Jib Lift, Tower Lift
FUNCTION SWITCHES 235 The Ground Module detects one of the following condi- Emergency Descent Release all function
LOCKED - SELECTED tions: mode is disabled switches. Activate the
BEFORE AUX POWER The machine is in Ground Mode, the engine is Auxiliary Descent switch
stopped, and the ground Auxiliary Descent switch is before any other applica-
selected after a Ground control switch has been ble control switches or
selected. start the engine
FUNCTION SWITCHES 236 The Ground Module detects one of the following condi- Engine start is disabled Release all function
LOCKED - SELECTED tions: switches. Start the
BEFORE START The machine is in Ground Mode, the engine is engine before any other
SWITCH stopped, and any boom control is selected before applicable function
the ground engine start switch is selected. switches are selected.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
START SWITCH 237 The engine start switch for the selected station is Engine start is disabled Release the engine start
LOCKED - SELECTED engaged during the Ground Module startup sequence. switch. Position the
BEFORE KEYSWITCH Ground/Platform Select
switch to the opposite
operating station to verify
the engine can be started.
View switch state on
Analyzer under DIAG-
NOSTICS-->OPER
CONTROLS-->START
SWITCH.
FUNCTION PROBLEM - 2310 The machine is in Ground mode and the Enable switch is Disable Start and Boom Return the switch to the
GROUND ENABLE PER- in the selected position. functions, including off position. View switch
MANENTLY SELECTED Emergency Descent. state on Analyzer under
DIAGNOSTICS-->OPER
CONTROLS-->AUX
DESCENT SW. Replace
the switch if defective.
FUNCTION PROBLEM - 2370 The machine is in Ground mode and the Jib Lift switch is Jib Lift Up and Down pro- With the machine con-
JIB LIFT UP PERMA- selected and trying to activate the Jib Lift Up function at hibited. trols not enabled, return
NENTLY SELECTED startup. the Jib Lift switch to neu-
tral. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 2371 The machine is in Ground mode and the Jib Lift switch is Jib Lift Up and Down pro- With the machine con-
JIB LIFT DOWN PER- selected and trying to activate the Jib Lift Down function hibited. trols not enabled, return
MANENTLY SELECTED at startup. the Jib Lift switch to neu-
tral. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 2372 The machine is in Ground mode and the Swing switch is Swing Left and Right pro- With the machine con-
SWING LEFT PERMA- selected and trying to activate the Swing Left function at hibited. trols not enabled, return
NENTLY SELECTED startup. the Swing switch to neu-
tral. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 2373 The machine is in Ground mode and the Swing switch is Swing Left and Right pro- With the machine con-
SWING RIGHT PERMA- selected and trying to activate the Swing Right function hibited. trols not enabled, return
NENTLY SELECTED at startup. the Swing switch to neu-
tral. Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
BOOM TRANSPORT 23104 The Ground Module detects that Boom Elevation switch The Ground Module Verify that the two boom
SWITCH DISAGREE- #1 and switch #2 are not in agreement for more than 4 assumes an "Above Ele- angle switches are
MENT seconds while lifting. vation" condition and adjusted to actuate
does not allow Axle Oscil- simultaneously. Cycle
lation. Power.
FUNCTION PROBLEM – 23105 The machine is in Ground mode and the Tower Lift Tower Lift Up and Down With the machine con-
TOWER LIFT UP PER- switch is selected and trying to activate the Tower Lift prohibited. trols not enabled, return
MANENTLY SELECTED Up function at startup. the Tower Lift switch to
neutral. Actuate switch
while monitoring state
changes under appropri-
ate menu in DIAGNOS-
TICS-->OPER
CONTROLS on Analyzer.
Replace the switch if
defective.
FUNCTION PROBLEM – 23106 The machine is in Ground mode and the Tower Lift Tower Lift Up and Down With the machine con-
TOWER LIFT DOWN switch is selected and trying to activate the Tower Lift prohibited. trols not enabled, return
PERMANENTLY Down function at startup. the Tower Lift switch to
SELECTED neutral. Actuate switch
while monitoring state
changes under appropri-
ate menu in DIAGNOS-
TICS-->OPER
CONTROLS on Analyzer.
Replace the switch if
defective.
FUNCTION PROBLEM - 23107 The machine is in Ground mode and the Lift switch is Lift Up and Down prohib- With the machine con-
LIFT UP PERMANENTLY selected and trying to activate the Lift Up function at ited. trols not enabled, return
SELECTED startup. the Lift switch to neutral.
Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 23108 The machine is in Ground mode and the Lift switch is Lift Up and Down prohib- With the machine con-
LIFT DOWN PERMA- selected and trying to activate the Lift Down function at ited. trols not enabled, return
NENTLY SELECTED startup. the Lift switch to neutral.
Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 23109 The machine is in Ground mode and the Telescope Tele In and Out prohibited. With the machine con-
TELESCOPE IN PERMA- switch is selected and trying to activate the Telescope In trols not enabled, return
NENTLY SELECTED function at startup. the Lift switch to neutral.
Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 23110 The machine is in Ground mode and the Telescope Tele In and Out prohibited. With the machine con-
TELESCOPE OUT PER- switch is selected and trying to activate the Telescope trols not enabled, return
MANENTLY SELECTED Out function at startup. the Lift switch to neutral.
Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 23111 The machine is in Ground mode and the Platform Level Platform Level Up and With the machine con-
PLATFORM LEVEL UP switch is selected and trying to activate the Platform Down prohibited. trols not enabled, return
PERMANENTLY Level Up function at startup. the Lift switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUNCTION PROBLEM - 23112 The machine is in Ground mode and the Platform Level Platform Level Up and With the machine con-
PLATFORM LEVEL switch is selected and trying to activate the Platform Down prohibited. trols not enabled, return
DOWN PERMANENTLY Level Down function at startup. the Lift switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 23113 The machine is in Ground mode and the Platform Rotate Platform Rotate Right With the machine con-
PLATFORM ROTATE switch is selected and trying to activate the Platform and Left prohibited. trols not enabled, return
LEFT PERMANENTLY Rotate Left function at startup. the Lift switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
FUNCTION PROBLEM - 23114 The machine is in Ground mode and the Platform Rotate Platform Rotate Right With the machine con-
PLATFORM ROTATE switch is selected and trying to activate the Platform and Left prohibited. trols not enabled, return
RIGHT PERMANENTLY Rotate Right function at startup. the Lift switch to neutral.
SELECTED Actuate switch while
monitoring state changes
under appropriate menu
in DIAGNOSTICS--
>OPER CONTROLS on
Analyzer. Replace the
switch if defective.
MODEL CHANGED – 259 The MACHINE SETUP MODEL is changed using the All of the boom, drive, Cycle Power.
HYDRAULICS SUS- analyzer and steer functions are
PENDED – CYCLE EMS disabled; the engine will
be shut down.
GENERATOR MOTION 2513 MACHINE SETUP GEN SET = BELT DRIVE and GEN All of the boom, drive, Motion is no longer
CUTOUT ACTIVE SET CUTOUT = MOTION CUTOUT and steer functions are attempted or generator is
The machine is being operated in Platform mode and the disabled. turned off.
footswitch and Generator Enable switch are engaged
while any of the configured boom, drive, or steer func-
tions are attempting to be activated.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
BOOM PREVENTED – 2514 The machine is set up to cut out boom functions when All boom functions are Stop operating any Drive
DRIVE SELECTED the drive or steer is being operated. The machine is in disabled. or Steer functions. Acti-
the Out of Transport position and the operator is operat- vate the Boom function.
ing a Drive or Steer function and attempts to activate a
boom function.
Note: DTC 2514 supercedes DTC 2518 if drive/steer
and boom functions are both active when the machine
changes from Below Elevation to Above Elevation.
DRIVE PREVENTED – 2516 The machine is set up to cut out drive and steer when the Disable Drive and Steer Place the machine in the
ABOVE ELEVATION boom is above elevation. The machine is in the Out of transport position before
Transport position. The Control System senses the attempting to drive or
boom is above elevation and the operator is attempting steer.
to activate Drive or Steer
DRIVE PREVENTED – 2517 The machine is set up to cut out drive and steer when the Disable Drive and Steer Place the machine in the
TILTED & ABOVE ELE- chassis is tilted and boom is above elevation. The transport position before
VATION machine is in the Out Of Transport position. The Control attempting to drive or
System senses the chassis is tilted and the operator is steer.
attempting to activate Drive or Steer
DRIVE PREVENTED – 2518 The machine is set up to cut out functions when the Disable Drive and Steer Stop operating any boom
BOOM SELECTED boom is being operated. The machine is in the Out Of functions. Activate the
Transport position. The operator is operating a boom Drive or Steer function.
function and tries to activate the Drive or Steer controls.
FUNCTIONS LOCKED 2520 The Ground Module detects a mismatch between pro- Disable all machine and Reprogram the software
OUT – CONSTANT DATA grammed sections of the processor memory. engine functions (i.e., so that the memory val-
VERSION IMPROPER command engine shut- ues match.
down and do not permit Cycle Power.
start).
BRAKE – SHORT TO 331 The Ground Module detects a short to battery at the Disable Drive and Brake Inspect wiring for physi-
BATTERY brake output. outputs. cal damage and check for
wire continuity. Cycle
power to clear the fault.
BRAKE – OPEN CIR- 332 The Ground Module detects an open circuit at the brake No response required. Inspect wiring for physi-
CUIT output. cal damage. Check for a
good connection at the
solenoid and for wire
continuity through this
circuit. Cycle power to
clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
LIFT UP VALVE – OPEN 334 The Ground Module detects an open circuit at the lift up The Ground Module sus- Inspect wiring for physi-
CIRCUIT valve output. pends the Lift Up/Down cal damage. Check for a
command and reverts to good connection at the
Open Loop Current con- solenoid and for continu-
trol for Lift; Lift speed is ity through the circuit.
limited to Creep after both With the solenoid discon-
Lift Up/Down controls nected, an open circuit
are returned to neutral voltage of nearly 8.0V
and the machine controls exists on the Ground
are not Enabled. Module output pin for
diagnostic purposes.
Cycle power to clear the
fault.
LIFT DOWN VALVE – 335 The Ground Module detects a short to ground at the Lift Ground Module Lift Up Inspect wiring for physi-
SHORT TO GROUND Down valve output. and Down outputs are cal damage and check for
disabled. wire continuity. Cycle
power to clear the fault.
LIFT DOWN VALVE – 336 The Ground Module detects an open circuit at the Lift The Ground Module sus- Check for a good con-
OPEN CIRCUIT Down valve output. pends Lift Up/Down nection at the solenoid
commands and reverts and for continuity
to Open Loop Current through this circuit. With
control for Lift; Lift speed the solenoid discon-
is limited to Creep after nected, an open circuit
both Lift Up/Down con- voltage of nearly 8.0V
trols have been returned exists on the Ground
to neutral and machine is Module output pin for
not Enabled. diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
GROUND ALARM – 3311 The Ground Module detects a short to battery at the No response required. Inspect wiring for physi-
SHORT TO BATTERY Ground Alarm output. cal damage and check for
wire continuity. Cycle
power to clear the fault.
MAIN DUMP VALVE – 3358 The Ground Module detects a short to ground at the The Main Dump Valve Inspect wiring for physi-
SHORT TO GROUND Main Dump Valve output. output is disabled. cal damage and check for
wire continuity. Cycle
power to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
MAIN DUMP VALVE – 3359 The Ground Module detects an open circuit at the Main No response required. Check for a good con-
OPEN CIRCUIT Dump Valve output. nection at the solenoid
and for continuity
through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
MAIN DUMP VALVE – 3360 The Ground Module detects a short to battery at the Ground Module Main Inspect wiring for physi-
SHORT TO BATTERY Main Dump Valve output. Dump, Swing Left/Right, cal damage and check for
Tower Lift Up, and Lift Up wire continuity. Cycle
outputs are disabled. power to clear the fault.
BRAKE – SHORT TO 3361 The Ground Module detects a short to ground at the Ground Module Drive/ Inspect wiring for physi-
GROUND Brake output. Steer and Brake outputs cal damage and check for
are disabled. wire continuity. Cycle
power to clear the fault.
START SOLENOID – 3362 The Ground Module detects a short to ground at the Engine Start attempt is Inspect wiring for physi-
SHORT TO GROUND Engine Starter Solenoid. not permitted. cal damage and check for
wire continuity. Cycle
power to clear the fault.
START SOLENOID – 3363 Ground Module detects an open circuit at this output; if No response required. Inspect wiring for physi-
OPEN CIRCUIT machine is equipped with a Dual Fuel ECU, ground mod- cal damage and check for
ule will only evaluate for open circuit conditions until wire continuity. Cycle
first Start is attempted for each power cycle due to pos- power to clear the fault.
sibility of ECU opening ground solenoid return path to
disable Start and causing erroneous diagnostics.
START SOLENOID – 3364 The Ground Module detects a short to battery at the Ground Module Engine Inspect wiring for physi-
SHORT TO BATTERY Engine Starter Solenoid. Start is disabled by de- cal damage and check for
energizing the Fuel Actu- wire continuity. Cycle
ator (Kubota) or sending power to clear the fault.
an Engine Shutdown
command (Dual Fuel
ECU)
STEER DUMP VALVE – 3365 The Ground Module detects a short to ground at the Ground Module Steer Inspect wiring for physi-
SHORT TO GROUND Steer Dump Valve output. Dump output is disabled. cal damage and check for
wire continuity. Cycle
power to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
STEER DUMP VALVE – 3366 The Ground Module detects an open circuit at the Steer No response required. Check for a good con-
OPEN CIRCUIT Dump Valve output. nection at the solenoid
and for continuity
through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
STEER DUMP VALVE – 3367 The Ground Module detects a short to battery at the Ground Module Steer Inspect wiring for physi-
SHORT TO BATTERY Steer Dump Valve output. Dump, Steer, and Flow cal damage and check for
Control outputs are dis- wire continuity. Cycle
abled; Steer, Tele In/Out, power to clear the fault.
Jib Up (permitted if oper-
ating in Emergency
Descent mode), Level
Up/Down, and Rotate
Left/Right functions are
disallowed.
GEN SET/WELDER – 3373 The Ground Module detects a short to ground at the Gen Ground Module Genera- Inspect wiring for physi-
SHORT TO GROUND Set/Welder output. tor relay output is dis- cal damage and check for
abled thereby disabling wire continuity. Cycle
generator functionality. power to clear the fault.
GEN SET/WELDER – 3374 The Ground Module detects an open circuit at the Gen No response required. Check for a good con-
OPEN CIRCUIT Set/Welder output. nection at the relay and
for continuity through this
circuit. With the relay dis-
connected, an open cir-
cuit voltage of nearly
8.0V exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
GEN SET/WELDER – 3375 The Ground Module detects a short to battery at the Gen The Ground Module Gen- Inspect wiring for physi-
SHORT TO BATTERY Set/Welder output. erator relay output is dis- cal damage and check for
abled, but the Ground wire continuity. Cycle
Module considers the power to clear the fault.
Generator always
enabled and restricts
engine speed to Genera-
tor RPM. If MACHINE
SETUP GENSET CUT-
OUT = MOTION CUT-
OUT, disregard cutout
and permit motion.
HEAD TAIL LIGHT – 3376 The Ground Module detects a short to ground at the Ground Module H&T Inspect wiring for physi-
SHORT TO GROUND Head-Tail Light output. Light relay output is dis- cal damage and check for
abled. wire continuity. Cycle
power to clear the fault.
HEAD TAIL LIGHT – 3377 The Ground Module detects an open circuit at the Head- No response required. Check for a good con-
OPEN CIRCUIT Tail Light output. nection at the relay and
for continuity through this
circuit. With the relay dis-
connected, an open cir-
cuit voltage of nearly
8.0V exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Fault cleared
with power cycle.
HEAD TAIL LIGHT – 3378 The Ground Module detects a short to battery at the Disable Ground Module Inspect wiring for physi-
SHORT TO BATTERY Head-Tail Light output. H&T Light relay output is cal damage and check for
disabled. wire continuity. Cycle
power to clear the fault.
HOUR METER – SHORT 3379 The Ground Module detects a short to ground at the Ground Module Hourme- Inspect wiring for physi-
TO GROUND Hourmeter output. ter output is disabled. cal damage and check for
wire continuity. Confirm
high resistance reading
across hourmeter. Cycle
power to clear the fault.
HOUR METER – SHORT 3381 The Ground Module detects a short to battery at the Ground Module Hourme- Inspect wiring for physi-
TO BATTERY Hourmeter output. ter output is disabled. cal damage and check for
wire continuity. Cycle
power to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
PLATFORM LEVEL UP 3382 The Ground Module detects a short to ground at the Ground Module Platform Inspect wiring for physi-
VALVE – SHORT TO Platform Level Up Valve output. Level Up is disabled; cal damage and check for
GROUND Level Down speed is lim- wire continuity. Check for
ited to Creep. coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
PLATFORM LEVEL UP 3383 The Ground Module detects an open circuit at the Plat- Platform Level speed is Check for a good con-
VALVE – OPEN CIRCUIT form Level Up Valve output. limited to Creep. nection at the solenoid
and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
PLATFORM LEVEL UP 3384 The Ground Module detects a short to battery at the Ground Module Platform Inspect wiring for physi-
VALVE – SHORT TO Platform Level Up Valve output. Level Up, Level Down, cal damage and check for
BATTERY and Flow Control Valve wire continuity. Cycle
outputs are disabled. power to clear the fault.
PLATFORM LEVEL 3388 The Ground Module detects a short to ground at the Ground Module Platform Inspect wiring for physi-
DOWN VALVE – SHORT Platform Level Down Valve output. Level Up and Down valve cal damage and check for
TO GROUND outputs are disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
PLATFORM LEVEL 3389 The Ground Module detects an open circuit at the Plat- Platform Level speed is Check for a good con-
DOWN VALVE – OPEN form Level Down Valve output. limited to Creep. nection at the solenoid
CIRCUIT and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
PLATFORM LEVEL 3390 The Ground Module detects a short to battery at the Ground Module Platform Inspect wiring for physi-
DOWN VALVE – SHORT Platform Level Down Valve output. Level Up, Level Down, cal damage and check for
TO BATTERY and Flow Control Valve wire continuity. Cycle
outputs are disabled. power to clear the fault.
TOWER LIFT UP VALVE 33106 The Ground Module detects a short to ground at the Ground Module Tower Inspect wiring for physi-
– SHORT TO GROUND Tower Lift Up Valve output. Lift Up output is disabled; cal damage and check for
Tower Lift Down speed is wire continuity. Check for
limited to Creep coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
TOWER LIFT UP VALVE 33107 The Ground Module detects an open circuit at the Tower The Ground Module sus- Check for a good con-
– OPEN CIRCUIT Lift Up Valve output. pends Tower Lift Up/ nection at the solenoid
Down commands and and for continuity
reverts to Open Loop through this circuit. With
Current control for Tower the solenoid discon-
Lift; Tower Lift speed is nected, an open circuit
limited to Creep after both voltage of nearly 8.0V
Tower Lift Up/Down con- exists on the Ground
trols have been returned Module output pin for
to neutral and machine is diagnostic purposes.
not Enabled Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
TOWER LIFT DOWN 33109 The Ground Module detects a short to ground at the Ground Module Tower Inspect wiring for physi-
VALVE – SHORT TO Tower Lift Down Valve output. Lift Up and Down outputs cal damage and check for
GROUND are disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
TOWER LIFT DOWN 33110 The Ground Module detects an open circuit at the Tower The Ground Module sus- Check for a good con-
VALVE – OPEN CIRCUIT Lift Down Valve output. pends Tower Lift Up/ nection at the solenoid
Down commands and and for continuity
reverts to Open Loop through this circuit. With
Current control for Tower the solenoid discon-
Lift; Tower Lift speed is nected, an open circuit
limited to Creep after both voltage of nearly 8.0V
Tower Lift Up/Down con- exists on the Ground
trols have been returned Module output pin for
to neutral and machine is diagnostic purposes.
not Enabled Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
SWING RIGHT VALVE – 33118 The Ground Module detects a short to ground at the Swing Left and Right out- Inspect wiring for physi-
SHORT TO GROUND Swing Right Valve output. puts are disabled. cal damage and check for
wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
SWING RIGHT VALVE – 33119 The Ground Module detects an open circuit at the Swing The Ground Module sus- Check for a good con-
OPEN CIRCUIT Right Valve output. pends Swing Left/Right nection at the solenoid
commands and reverts and for continuity
to Open Loop Current through this circuit. With
control for Swing; Swing the solenoid discon-
speed is limited to Creep nected, an open circuit
after both Swing Left/ voltage of nearly 8.0V
Right controls are exists on the Ground
returned to neutral and Module output pin for
machine is not Enabled diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
TELESCOPE IN VALVE – 33120 The Ground Module detects a short to battery at the Ground Module Tele- Inspect wiring for physi-
SHORT TO BATTERY Telescope In Valve output. scope In, Telescope Out, cal damage and check for
and Flow Control Valve wire continuity. Cycle
outputs are disabled. power to clear the fault.
SWING LEFT VALVE – 33122 The Ground Module detects a short to ground at the Ground Module Swing Inspect wiring for physi-
SHORT TO GROUND Swing Left Valve output. Left and Right outputs are cal damage and check for
disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
TELESCOPE OUT 33123 The Ground Module detects a short to battery at the Ground Module Tele- Inspect wiring for physi-
VALVE – SHORT TO Telescope Out Valve output. scope In, Telescope Out, cal damage and check for
BATTERY and Flow Control Valve wire continuity. Cycle
outputs are disabled. power to clear the fault.
THROTTLE ACTUATOR 33130 The Ground Module detects a short to ground at the The Ground Module Inspect wiring for physi-
– SHORT TO GROUND Throttle Actuator output (Kubota). Throttle Actuator output cal damage and check for
is disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
THROTTLE ACTUATOR 33131 The Ground Module detects an open circuit at the Throt- No response required Check for a good con-
– OPEN CIRCUIT tle Actuator output (Kubota). nection at the solenoid
and for continuity
through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
THROTTLE ACTUATOR 33132 The Ground Module detects a short to battery at the The Ground Module Inspect wiring for physi-
– SHORT TO BATTERY Throttle Actuator output (Kubota). Throttle Actuator output cal damage and check for
is disabled; functions are wire continuity. Cycle
set to Creep speed. power to clear the fault.
LIFT VALVES – SHORT 33182 The Ground Module detects a short to battery at either The Ground Module Lift Inspect wiring for physi-
TO BATTERY the Lift Up or Lift Down valve Up and Down outputs are cal damage and check for
disabled and ground cur- wire continuity. Cycle
rent return path is open power to clear the fault.
circuited.
TELESCOPE OUT 33186 The Ground Module detects an open circuit at the Tele- Tele speed is limited to Check for a good con-
VALVE – OPEN CIRCUIT scope Out Valve output. Creep nection at the solenoid
and for continuity
through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
TELESCOPE OUT 33188 The Ground Module detects a short to ground at the Ground Module Tele- Inspect wiring for physi-
VALVE – SHORT TO Telescope Out Valve output. scope Out output is dis- cal damage and check for
GROUND abled; Tele In speed is wire continuity. Check for
limited to Creep. coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
TELESCOPE IN VALVE – 33189 The Ground Module detects an open circuit at the Tele- Tele speed is limited to Check for a good con-
OPEN CIRCUIT scope In Valve output. Creep nection at the solenoid
and for continuity
through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
TELESCOPE IN VALVE – 33190 The Ground Module detects a short to ground at the Ground Module Tele- Inspect wiring for physi-
SHORT TO GROUND Telescope In Valve output. scope In and Out outputs cal damage and check for
are disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
GLOWPLUG – OPEN 33279 The Ground Module detects an open circuit at the Glow No response required Check for a good con-
CIRCUIT Plug output. (Kubota) nection at the relay and
for continuity through this
circuit. With the relay dis-
connected, an open cir-
cuit voltage of nearly
8.0V exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
GLOWPLUG – SHORT 33280 The Ground Module detects a short to battery at the Ground Module Glow Inspect wiring for physi-
TO BATTERY Glow Plug output. (Kubota) Plug relay output is dis- cal damage and check for
abled. wire continuity. Cycle
power to clear the fault.
GLOWPLUG – SHORT 33281 The Ground Module detects a short to ground at the Ground Module Glow Inspect wiring for physi-
TO GROUND Glow Plug output. (Kubota) Plug relay output is dis- cal damage and check for
abled. wire continuity. Check for
relay damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
LIFT – CURRENT FEED- 33287 The Ground Module calls for current greater than The Ground Module sus- Part of the commanded
BACK READING TOO 250mA, but the actual current is at least 125mA less pends Lift Up/Down current is being divided
LOW than the called for current for more than 1 second commands and reverts either prior to the sole-
to Open Loop Current noid connection or on the
control for Lift; Lift speed ground return path.
is limited to Creep after Inspect wiring for physi-
both Lift Up/Down con- cal damage and check for
trols have been returned wire continuity and a low
to neutral and the resistance return path.
machine is not Enabled Cycle power to clear the
fault.
SWING LEFT VALVE – 33295 The Ground Module detects an open circuit at the Swing The Ground Module sus- Check for a good con-
OPEN CIRCUIT Left Valve output. pends Swing Left/Right nection at the solenoid
commands and reverts and for continuity
to Open Loop Current through this circuit. With
control for Swing; Swing the solenoid discon-
speed is limited to Creep nected, an open circuit
after both Swing Left/ voltage of nearly 8.0V
Right controls have been exists on the Ground
returned to neutral and Module output pin for
the machine is not diagnostic purposes.
Enabled Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
FLOW CONTROL VALVE 33314 The Ground Module detects an open circuit at the Flow The Ground Module sus- Check for a good con-
– OPEN CIRCUIT Control Valve output. pends output commands nection at the solenoid
and reverts to Open Cur- and for continuity
rent loop control for Flow through this circuit. With
Control Valve; Tele In/Out, the solenoid discon-
Jib Up, Rotate Right/Left, nected, an open circuit
and Level Up/Down voltage of nearly 8.0V
speed are limited to exists on the Ground
Creep after controls for Module output pin for
those functions have all diagnostic purposes.
been simultaneously Inspect wiring for physi-
returned to neutral and cal damage. Cycle power
the machine is not to clear the fault.
Enabled.
FLOW CONTROL VALVE 33315 The Ground Module detects a short to battery at the Disable Ground Module Inspect wiring for physi-
– SHORT TO BATTERY Flow Control Valve output. Flow Control Valve output cal damage and check for
and open the ground cur- wire continuity. Cycle
rent return path; disallow power to clear the fault.
energization of valves for
Tele In/Out, Jib Up (per-
mitted if operating in
Emergency Descent
mode), Level Up/Down,
or Rotate Right/Left.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FLOW CONTROL VALVE 33316 The Ground Module detects a short to ground at the Ground Module Flow Inspect wiring for physi-
– SHORT TO GROUND Flow Control Valve output. Control Valve output is cal damage and check for
disabled; disallows ener- wire continuity. Check for
gization of valves for Tele coil damage or shorting
In/Out, Jib Up (permitted condition in connector.
if operating in Emergency Cycle power to clear the
Descent mode), Level fault.
Up/Down, or Rotate
Right/Left.
DRIVE FORWARD 33317 The Ground Module detects an open circuit at the Drive The Ground Module sus- Check for a good con-
VALVE – OPEN CIRCUIT Forward Valve output. pends Drive Forward/ nection at the solenoid
Reverse commands and and for continuity
reverts to Open Current through this circuit. With
loop control for Drive; the solenoid discon-
Drive speed is limited to nected, an open circuit
Creep after both Drive voltage of nearly 8.0V
Forward/Reverse con- exists on the Ground
trols have been returned Module output pin for
to neutral and the diagnostic purposes.
machine is not Enabled. Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
DRIVE VALVES – 33318 The Ground Module detects a short to battery at either Ground Module Drive Inspect wiring for physi-
SHORT TO BATTERY the Drive Forward or Drive Reverse valve. Forward and Reverse cal damage and check for
outputs are disabled and wire continuity. Cycle
open the ground current power to clear the fault.
return path.
DRIVE FORWARD 33319 The Ground Module detects a short to ground at the Ground Module Drive Inspect wiring for physi-
VALVE – SHORT TO Drive Forward Valve output. Forward and Reverse cal damage and check for
GROUND outputs are disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
DRIVE REVERSE VALVE 33320 The Ground Module detects an open circuit at the Drive The Ground Module sus- Check for a good con-
– OPEN CIRCUIT Reverse Valve output. pends Drive Forward/ nection at the solenoid
Reverse commands and and for continuity
reverts to Open Current through this circuit. With
loop control for Drive; the solenoid discon-
Drive speed is limited to nected, an open circuit
Creep after both Drive voltage of nearly 8.0V
Forward/Reverse con- exists on the Ground
trols have been returned Module output pin for
to neutral and the diagnostic purposes.
machine is not Enabled. Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
DRIVE REVERSE VALVE 33322 The Ground Module detects a short to ground at the Ground Module Drive Inspect wiring for physi-
– SHORT TO GROUND Drive Reverse Valve output. Forward and Reverse cal damage and check for
outputs are disabled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
DRIVE – CURRENT 33331 The Ground Module calls for current greater than The Ground Module sus- Part of the commanded
FEEDBACK READING 250mA, but the actual current is at least 125mA less pends Drive Forward/ current is being divided
TOO LOW than the called for current for more than 1 second Reverse commands and either prior to the sole-
reverts to Open Current noid connection or on the
loop control for Drive; ground return path.
Drive speed is limited to Inspect wiring for physi-
Creep after both Drive cal damage and check for
Forward/Reverse con- wire continuity and a low
trols have been returned resistance return path.
to neutral and the Cycle power to clear the
machine is not Enabled. fault.
LIFT UP VALVE – 33406 The Ground Module detects a short to ground at the Lift Lift Up is disabled; Lift Inspect wiring for physi-
SHORT TO GROUND Up Valve output. Down speed is limited to cal damage and check for
Creep wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
DRIVE – LOSS OF CUR- 33410 Measured feedback current is less than 225mA while The Ground Module sus- Part or all of the com-
RENT FEEDBACK Ground Module output is greater than 40% (Displayed pends Drive Forward/ manded current is being
on Analyzer DIAGNOSTICS menu). Reverse commands and diverted from the ground
reverts to Open Current return path. Inspect wir-
loop control for Drive; ing for physical damage
Drive speed is limited to and check for wire conti-
Creep after both Drive nuity and a low resis-
Forward/Reverse con- tance return path. Cycle
trols have been returned power to clear the fault.
to neutral and the
machine is not Enabled.
SWING VALVES – 33412 The Ground Module detects a short to battery at either Ground Module Swing Inspect wiring for physi-
SHORT TO BATTERY the Swing Right or Swing Left valve Left and Right outputs are cal damage and check for
disabled and open the wire continuity. Cycle
ground current return power to clear the fault.
path is open circuited.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
TOWER LIFT – CUR- 33413 The Ground Module calls for current greater than The Ground Module sus- Part of the commanded
RENT FEEDBACK 250mA, but the actual current is at least 125mA less pends Tower Lift com- current is being divided
READING TOO LOW than the called for current for more than 1 second mands and reverts to either prior to the sole-
Open Current loop con- noid connection or on the
trol for Tower Lift; Tower ground return path.
Lift speed is limited to Inspect wiring for physi-
Creep after both Tower cal damage and check for
Lift Up/Down controls wire continuity and a low
have been returned to resistance return path.
neutral and the machine Cycle power to clear the
is not Enabled. fault.
SWING – CURRENT 33414 The Ground Module calls for current greater than The Ground Module sus- Part of the commanded
FEEDBACK READING 250mA, but the actual current is at least 125mA less pends Swing Left/Right current is being divided
TOO LOW than the called for current for more than 1 second commands and reverts either prior to the sole-
to Open Loop Current noid connection or on the
control for Swing; Swing ground return path.
speed is limited to Creep Inspect wiring for physi-
after both Swing Left/ cal damage and check for
Right have been returned wire continuity and a low
to neutral and the resistance return path.
machine is not Enabled Cycle power to clear the
fault.
FLOW CONTROL VALVE 33415 The Ground Module calls for current greater than The Ground Module sus- Part of the commanded
– CURRENT FEEDBACK 250mA, but the actual current is at least 125mA less pends and reverts to current is being divided
READING TOO LOW than the called for current for more than 1 second Open Current loop con- either prior to the sole-
trol for Flow Control noid connection or on the
Valve; Tele In/Out, Jib Up, ground return path.
Rotate Right/Left, and Inspect wiring for physi-
Level Up/Down speed is cal damage and check for
limited to Creep after wire continuity and a low
controls for those func- resistance return path.
tions have all been simul- Cycle power to clear the
taneously returned to fault.
neutral and the machine
is not Enabled
TOWER LIFT – CUR- 33416 Measured feedback current is less than 225mA while The Ground Module sus- Part or all of the com-
RENT FEEDBACK Ground Module output is greater than 40% (Displayed pends commands and manded current is being
READING LOST on Analyzer DIAGNOSTICS menu). reverts to Open Current diverted from the ground
loop control for Tower return path. Inspect wir-
Lift; Tower Lift speed is ing for physical damage
limited to Creep after both and check for wire conti-
Lift Up/Down controls nuity and a low resis-
have been returned to tance return path. Cycle
neutral and the machine power to clear the fault.
is not Enabled.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
LIFT – CURRENT FEED- 33417 Measured feedback current is less than 225mA while The Ground Module sus- Part or all of the com-
BACK READING LOST Ground Module output is greater than 40% (Displayed pends Lift Up/Down manded current is being
on Analyzer DIAGNOSTICS menu). commands and reverts diverted from the ground
to Open Loop Current return path. Inspect wir-
control for Lift; Lift speed ing for physical damage
is limited to Creep after and check for wire conti-
both Lift Up/Down con- nuity and a low resis-
trols have been returned tance return path. Cycle
to neutral and the power to clear the fault.
machine is not Enabled.
SWING – CURRENT 33418 Measured feedback current is less than 225mA while The Ground Module sus- Part or all of the com-
FEEDBACK READING Ground Module output is greater than 40% (Displayed pends Swing Left/Right manded current is being
LOST on Analyzer DIAGNOSTICS menu). commands and reverts diverted from the ground
to Open Loop Current return path. Inspect wir-
control for Swing; Swing ing for physical damage
speed is limited to Creep and check for wire conti-
after both Swing Left/ nuity and a low resis-
Right have been returned tance return path. Cycle
to neutral and the power to clear the fault.
machine is not Enabled.
FLOW CONTROL VALVE 33419 Measured feedback current is less than 225mA while The Ground Module sus- Part or all of the com-
– CURRENT FEEDBACK Ground Module output is greater than 40% (Displayed pends and reverts to manded current is being
READING LOST on Analyzer DIAGNOSTICS menu). Open Current loop con- diverted from the ground
trol for Flow Control return path. Inspect wir-
Valve; Tele In/Out, Jib Up, ing for physical damage
Rotate Right/Left, and and check for wire conti-
Level Up/Down speed is nuity and a low resis-
limited to Creep after tance return path. Cycle
controls for those func- power to clear the fault.
tions have all been simul-
taneously returned to
neutral and the machine
is not Enabled
TRACTION LOCK VALVE 33420 The Ground Module detects a short to battery at the If in Max Speed drive Inspect wiring for physi-
– SHORT TO BATTERY Traction Lock valve output. mode, the machine cal damage and check for
switches to Max Torque; wire continuity. Cycle
Max Speed drive mode is power to clear the fault.
disabled.
TRACTION LOCK VALVE 33421 The Ground Module detects an open circuit at the Trac- If in Max Speed drive Check for a good con-
– OPEN CIRCUIT tion Lock valve output. mode, the machine nection at the solenoid
switches to Max Torque; and for continuity
Max Speed drive mode is through this circuit.
disabled. Inspect wiring for physi-
cal damage.Cycle power
to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
TRACTION LOCK VALVE 33422 The Ground Module detects a short to ground at the Traction Lock valve out- Inspect wiring for physi-
– SHORT TO GROUND Traction Lock valve output. put is disabled. If in Max cal damage and check for
Speed drive mode, the wire continuity. Check for
machine switches to Max coil damage or shorting
Torque; Max Speed drive condition in connector.
mode is disabled. Cycle power to clear the
fault.
OSCILLATING AXLE 33423 The Ground Module detects a short to battery condition The Ground Module Inspect wiring for physi-
VALVES – SHORT TO on the J1-7 output. assumes an Above Ele- cal damage and check for
BATTERY vation State and de-ener- wire continuity. Cycle
gizes the J1-7 Oscillating power to clear the fault.
Axle output.
OSCILLATING AXLE 33424 The Ground Module detects a short to ground condition The Ground Module to Inspect wiring for physi-
VALVES – SHORT TO on the J1-7 output. assumes an Above Ele- cal damage and check for
GROUND vation State and de-ener- wire continuity. Check for
gizes J1-7 Oscillating shorting condition in
Axle output. connector. Cycle power
to clear the fault.
TOWER LIFT VALVES – 33425 The Ground Module detects a short to battery at either Ground Module Tower Inspect wiring for physi-
SHORT TO BATTERY the Tower Lift Up or Tower Lift Down valve. Lift Up and Down outputs cal damage and check for
are disabled and open the wire continuity. Cycle
ground current return power to clear the fault.
path.
PLATFORM ROTATE 349 The Platform Module detects an open circuit at the Plat- Platform Rotate speed is Check for a good con-
LEFT VALVE – OPEN form Rotate Left Valve output and reports it to the limited to Creep nection at the solenoid
CIRCUIT Ground Module. and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
PLATFORM ROTATE 3410 The Platform Module detects a short to battery at the Platform Module are dis- Inspect wiring for physi-
LEFT VALVE – SHORT Platform Rotate Left Valve output and reports it to the abled for Platform Rotate cal damage and check for
TO BATTERY Ground Module. Right, Rotate Left, and wire continuity. Cycle
Flow Control Valve out- power to clear the fault.
puts are disabled.
PLATFORM ROTATE 3411 The Platform Module detects a short to ground at the Platform Rotate Right Inspect wiring for physi-
LEFT VALVE – SHORT Platform Rotate Left Valve output and reports it to the and Left outputs are dis- cal damage and check for
TO GROUND Ground Module. abled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
PLATFORM ROTATE 3412 The Platform Module detects an open circuit at the Plat- Platform Rotate speed is Check for a good con-
RIGHT VALVE – OPEN form Rotate Right Valve output and reports it to the limited to Creep nection at the solenoid
CIRCUIT Ground Module. and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
PLATFORM ROTATE 3413 The Platform Module detects a short to battery at the Platform Rotate Right, Inspect wiring for physi-
RIGHT VALVE – SHORT Platform Rotate Right Valve output and reports it to the Rotate Left, and Flow cal damage and check for
TO BATTERY Ground Module. Control Valve outputs. wire continuity. Cycle
power to clear the fault.
PLATFORM ROTATE 3414 The Platform Module detects a short to ground at the Platform Rotate Right Inspect wiring for physi-
RIGHT VALVE – SHORT Platform Rotate Right Valve output and reports it to the and Left outputs are dis- cal damage and check for
TO GROUND Ground Module. abled. wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
JIB LIFT UP VALVE – 3415 The Platform Module detects an open circuit at the Jib Jib Lift speed is limited to Check for a good con-
OPEN CIRCUIT Lift Up Valve output and reports it to the Ground Module. Creep. nection at the solenoid
and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
JIB LIFT UP VALVE – 3416 The Platform Module detects a short to battery at the Jib Jib Lift Up and Flow Con- Check for a good con-
SHORT TO BATTERY Lift Up Valve output and reports it to the Ground Module. trol Valve outputs are dis- nection at the solenoid
abled; Jib Lift Down and for continuity
speed is limited to Creep through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
JIB LIFT UP VALVE – 3417 The Platform Module detects a short to ground at the Jib Jib Lift Up output is dis- Inspect wiring for physi-
SHORT TO GROUND Lift Up Valve output and reports it to the Ground Module. abled; Jib Lift Down cal damage and check for
speed is limited to Creep wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
JIB LIFT DOWN VALVE – 3418 The Platform Module detects an open circuit at the Jib Jib Lift speed is limited to Check for a good con-
OPEN CIRCUIT Lift Down Valve output and reports it to the Ground Mod- Creep. nection at the solenoid
ule. and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
JIB LIFT DOWN VALVE – 3419 The Platform Module detects a short to battery at the Jib Jib Lift Up and Down out- Check for a good con-
SHORT TO BATTERY Lift Down Valve output and reports it to the Ground Mod- puts are disabled. nection at the solenoid
ule. and for continuity
through this circuit.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
JIB LIFT DOWN VALVE – 3420 The Platform Module detects a short to ground at this Jib Lift Up and Down out- Inspect wiring for physi-
SHORT TO GROUND output and reports it to the Ground Module. puts are disabled. cal damage and check for
wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
FUEL SENSOR SHORT 431 Ground Module fuel sensor input (J2-25) detects a volt- The Control System Disconnect fuel sender
TO BATTERY age higher than 2.50 volts shuts down all fuel level and verify resistance
indicators in Platform readings can range from
and Ground stations. approximately 30ohms
(full) to 240ohms
(empty). If not, replace
sender. With fuel sender
connected, backprobe
J2-25 and verify voltage
range from approxi-
mately 0.5V to 2.3V.
Troubleshoot wiring or
connections.
FUEL SENSOR SHORT 432 Ground Module fuel sensor input (J2-25) detects a volt- The Control System Disconnect fuel sender
TO GROUND age less than or equal to 0.3 volts shuts down all fuel level and verify resistance
indicators in Platform readings can range from
and Ground stations. approximately 30ohms
(full) to 240ohms
(empty). If not okay,
replace sender. With fuel
sender connected, back-
probe J2-25 and verify
voltage range from
approximately 0.5V to
2.3V. Troubleshoot wiring
or connections.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
OIL PRESSURE SHORT 433 MACHINE SETUP ENGINE = KUBOTA D1105 If MACHINE SETUP Verify wire is connected
TO BATTERY Oil Pressure reads a high value at Startup even though ENGINE SHUTDOWN = to oil pressure switch.
the engine has not been started (occurs for STB or OC – ENABLED then engine With engine off, switch
wire off pressure switch) start is not permitted; should show low imped-
Low Oil Pressure indica- ance to ground or replace
tor will be activated switch. Observe state
change on Analyzer
under DIAGNOSTICS--
>ENGINE-->ENGINE
OIL PRESS
COOLANT TEMPERA- 435 MACHINE SETUP ENGINE = KUBOTA D1105 If MACHINE SETUP Disconnect temperature
TURE SHORT TO Ground Module coolant temperature input (J1-14) ENGINE SHUTDOWN = sender and verify resis-
GROUND detects a voltage less than or equal to 0.05 volts ENABLED then engine tance reading >
will be shutdown 0.15ohms (up to
High Engine Temperature 50kohms is acceptable);
indicator will be activated then troubleshoot wiring.
With system on, back-
probe J1-14 and verify
voltage > 1.5V.
ENGINE TROUBLE 437 The engine controller reports a J1939 fault Engine will operate at Cycle power to clear the
CODE 1800RPM until power fault.
cycle.
HIGH ENGINE TEMP 438 For a machine configured with a Kubota D1105 engine, If MACHINE SETUP Reduce hydraulic loading
the engine has been running more than 10 seconds and ENGINE SHUTDOWN = of machine and inspect
the engine coolant temperature is greater than 110ºC: ENABLED then the engine radiator for blockage of
will be shut down and the air flow.
For a machine with electronic engine controls, the ECM High Engine Temperature
transmits an engine coolant high temperature critical indicator will be lit
fault (SPN:FMI 110:0)
NO ALTERNATOR OUT- 4310 The engine has been running more than 10 seconds and The No Charge indicator Ground Module system
PUT Ground Module system voltage is less than 11.5 volts will be lit voltage greater than 11.7
for 10 seconds volts
LOW OIL PRESSURE 4311 For a machine configured with a Kubota D1105 engine, If MACHINE SETUP Check engine oil level.
the engine has been running more than 10 seconds and ENGINE SHUTDOWN = Cycle power to clear the
the engine oil pressure is LOW (debounce 3s). ENABLED then the engine fault.
For a machine with electronic engine controls, the ECM will be shut down and the
transmits an engine oil low pressure critical fault Low Oil Pressure indica-
(SPN:FMI 100:1). tor will be lit
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
THROTTLE ACTUATOR 4313 For a machine configured with a Kubota D1105 engine: Disable Ground Module Cycle power to clear the
FAILURE THROTTLE ACTUATOR – OPEN CIRCUIT (33131) is not Throttle Actuator output fault.
active and call for full opening
THROTTLE ACTUATOR – SHORT TO GROUND (33130) (current = 1500mA) to
is not active Proportional Fuel Rack
LOSS OF ENGINE SPEED SENSOR (4322) is not active Actuator.
desired engine speed is greater than 1800 but actual
RPM is less than 1400 (debounce time = 3s) when no
fault exists with Proportional Fuel Rack actuator
WRONG ENGINE 4314 Machine is configured with a non-electronic controlled No function inhibits Cycle power to clear the
SELECTED – ECM Kubota D1105 engine and the Ground Module detects required fault.
DETECTED an electronic engine controller on the CAN bus
LOSS OF ENGINE 4322 Machine is configured with a Kubota D1105 engine and Ground Module to limit all Check proper seating/
SPEED SENSOR the engine is running: function speeds to creep, clearance of engine
LOW OIL PRESSURE fault (4311) is not active but run at High Engine speed sensor installa-
OIL PRESSURE SHORT TO BATTERY fault (433) is not speed until the oil pres- tion. Verify continuity of
active sure drops to a low value. wiring before replacing
No engine shutdown command exists Ground Module to dis- sensor. Fault cleared
Engine RPM is read as 0 for 1500ms and Engine oil able Generator relay out- when Engine RPM
pressure is not LOW put until generator greater than 0
operator switch cycled.
SPEED SENSOR READ- 4323 Machine is configured with a Kubota D1105 engine and The Ground Module Verify integrity of wiring,
ING INVALID SPEED the engine RPM reading is greater than 4000 commands High Engine particularly the ground,
speed and places all before replacing sensor.
functions in Creep. Fault cleared when
engine RPM reading <
4000
FUEL ACTUATOR – 4326 The Ground Module detects a short to ground at the fuel The Ground Module dis- Inspect wiring for physi-
SHORT TO GROUND actuator output. (Kubota) ables the Fuel Actuator cal damage and check for
output wire continuity. Check for
coil damage or shorting
condition in connector.
Cycle power to clear the
fault.
FUEL ACTUATOR – 4327 The Ground Module detects an open circuit at the fuel The Ground Module con- Check for a good con-
OPEN CIRCUIT actuator output. (Kubota) trols revert to Open Loop nection at the solenoid
and restrict machine and for continuity
speeds to Creep. through this circuit. With
the solenoid discon-
nected, an open circuit
voltage of nearly 8.0V
exists on the Ground
Module output pin for
diagnostic purposes.
Inspect wiring for physi-
cal damage. Cycle power
to clear the fault.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
FUEL ACTUATOR – 4328 The Ground Module detects a short to battery at the fuel Disable Ground Module Inspect wiring for physi-
SHORT TO BATTERY actuator output. (Kubota) Fuel Actuator output and cal damage and check for
open the ground current wire continuity. Cycle
return path. power to clear the fault.
FUEL ACTUATOR - 4329 The Ground Module calls for current greater than The Ground Module con- Part of the commanded
CURRENT FEEDBACK 250mA, but the actual current is at least 125mA less trols revert to Open Loop current is being divided
READING TOO LOW than the called for current for more than 1 second control and restricts all either prior to the sole-
machine speeds to noid connection or on the
Creep. ground return path.
Inspect wiring for physi-
cal damage and check for
wire continuity and a low
resistance return path.
Cycle power to clear the
fault.
FUEL ACTUATOR – 4330 Measured feedback current is less than 225mA while The Ground Module con- Part or all of the com-
CURRENT FEEDBACK Ground Module output is greater than 40% for a period trols revert to Open Loop manded current is being
READING LOST of 100ms (Displayed on Analyzer DIAGNOSTICS and restricts all machine diverted from the ground
menu). speeds to Creep. return path. Inspect wir-
ing for physical damage
and check for wire conti-
nuity and a low resis-
tance return path. Cycle
power to clear the fault.
BATTERY VOLTAGE 441 The Ground Module detects that its supply voltage is Disable all Ground Mod- Perform battery mainte-
TOO LOW – SYSTEM less than 9 volts ule valve outputs except nance. Fault cleared
SHUTDOWN those used during Emer- when voltage is greater
gency Descent (Tower than 9.25 volts
Lift Down, Lift Down, Jib
Up/Down). If MACHINE
SETUP H&T LIGHTS
= YES or ENGINE =
KUBOTA D1105 turn off
lights and disable glow
plugs.
BATTERY VOLTAGE 442 The Ground Module detects that its supply voltage is Disable all Ground Mod- Likely cause is poor alter-
TOO HIGH – SYSTEM greater than 16.0 volts. ule and Platform outputs nator regulation; check
SHUTDOWN until voltage is less than alternator. Cycle power to
15.75 volts clear the fault.
LSS BATTERY VOLTAGE 443 MACHINE SETUP LOAD SYSTEM NOT EQUAL Ground Module to set LSS reports voltage less
TOO HIGH The machine is configured with and Load Sensing Sys- Platform Load State = than 16.0V
tem and the Ground Module detects that the LSS reports Overloaded
supply voltage greater than 16.0 volts.
LSS BATTERY VOLTAGE 444 The machine is configured with and Load Sensing Sys- Ground Module to set LSS reports voltage
TOO LOW tem and the Ground Module detects that the LSS reports Platform Load State = greater than 9.0V
supply voltage less than 9.0 volts. Overloaded
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
BATTERY VOLTAGE 445 The Ground Module detects that its supply voltage < 11 No functions are inhibited Voltage is greater than
LOW volts for 5 seconds while none of the following condi- 11.25 volts
tions exist:
Engine is not cranking
Emergency Descent Mode is not active
Glow Plugs are not energized
CANBUS FAILURE – 662 Ground Module does not receive any CAN messages All functions will be With power off, discon-
PLATFORM MODULE from the Platform Module in 250ms decelerated to zero and nect the boom cable at
generator will be dis- the bottom of the Plat-
abled. If machine form box. With a multi-
equipped with Dual Fuel meter, verify that the
engine, state of Fuel resistance between the
Selection switch shall be CAN1H and CAN1L pins
retained until CAN Bus 1 of the boom cable is
is restored. Reactivation approximately 120ohms.
of Footswitch is required Verify the same at the
to resume operation. connector entering the
bottom of the box. If
Okay, connect cable at
platform and disconnect
cable at connection near
turntable. Check in the
same manner then con-
tinue splitting and mea-
suring in the manner over
remainder of machine
CAN Bus. When a bad
reading occurs, check
wire continuity on the
individual wire.
Fault is cleared when
CAN messages are
received from the Plat-
form Module
CANBUS FAILURE – 663 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
LOAD SENSING SYS- Ground Module does not receive any CAN messages assume Platform Load received from the LSS
TEM MODULE from the LSS module in 250ms State = Overloaded module
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
CANBUS FAILURE – 666 An engine with a CAN engine controller is configured in Ground Module shall With power off, discon-
ENGINE CONTROLLER MACHINE SETUP decel all functions, set nect the CAN2 cable
No CAN messages are received from the engine con- Target engine RPM = going to the engine at the
troller for more than 250ms Mid-Engine if Engine tee near the UGM. With a
State ENGINE STOPPED, multimeter, verify that the
and assume Engine Con- resistance between the
troller reporting mid- CAN2H and CAN2L pins
Engine; otherwise Engine is approximately
State = ENGINE 120ohms both in the path
STOPPED. If MACHINE to engine and path to
SETUP GENERATOR UGM. If a bad reading
= YES, Generator Relay occurs, check wire conti-
output to be turned off nuity on individual wires.
until re-enabled by opera- CAN messages are
tor. Reactivation of Foot- received from the engine
switch is required to controller. Ground Mod-
resume operation. ule shall require re-acti-
vation of Footswitch to
enable functions.
CANBUS FAILURE – 6613 More than 22 error frames per second for 4 seconds or No functions are inhib- Cycle power to clear the
EXCESSIVE CANBUS more than 500 Buss Off conditions since last power ited. fault.
ERRORS cycle.
CANBUS FAILURE – 6622 MACHINE SETUP CLEARSKY = YES No functions are inhib- CAN messages are
TCU MODULE No CAN2 messages are received from the TCU module ited. received from the TCU
for more than 30 seconds module.
REMOTE CONTRACT 681 MACHINE SETUP CLEARSKY = YES Puts the machine into Cleared by ClearSky TCU
MANAGEMENT OVER- Value set by ClearSky TCU Creep and locks into
RIDE – ALL FUNCTIONS Transport
IN CREEP
CHASSIS TILT SENSOR 813 The tilt sensor has not been calibrated The Ground Module Calibrate the Tilt sensor
NOT CALIBRATED reports a faulted chassis to clear the fault
tilt angle of 90 degrees
CHASSIS TILT SENSOR 814 Fault CHASSIS TILT SENSOR NOT CALIBRATED (813) No additional action Tilt sensor reads less
OUT OF RANGE is not present and Tilt sensor measurement greater than required beyond Tilted than 19º.
19º for 4 seconds. Note: Not to be reported during Tilt requirements specified
Sensor calibration. above. Ground Module
reports 90° angle.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
CHASSIS TILT SENSOR 815 The Ground Module detects one of the following condi- The Ground Module Cycle power to clear the
DISAGREEMENT tions: reports a faulted chassis fault.
tilt angle of 90 degrees
If a Drive, Steer, or Boom function is active or if the
engine is cranking or if the primary raw Tilt Sensor read-
ings greater than ±10 º then: if the two ground board tilt
sensors disagree by more than or equal to 3 degrees for
either the X axis or the Y axis for longer than 5 seconds
then the fault will be logged.
LSS CELL #1 ERROR 821 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
The Ground Module detects that LSS is reporting error assume Platform Load received from the LSS
with Cell #1 State = Overloaded module.
LSS CELL #2 ERROR 822 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
The Ground Module detects that LSS is reporting error assume Platform Load received from the LSS
with Cell #2 State = Overloaded module.
LSS CELL #3 ERROR 823 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
The Ground Module detects that LSS is reporting error assume Platform Load received from the LSS
with Cell #3 State = Overloaded module.
LSS CELL #4 ERROR 824 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
The Ground Module detects that LSS is reporting error assume Platform Load received from the LSS
with Cell #4. State = Overloaded module.
LSS HAS NOT BEEN 825 MACHINE SETUP LOAD SYSTEM is not set = NO Ground Module to CAN messages are
CALIBRATED The load sensor has not been calibrated assume Platform Load received from the LSS
State = Overloaded module.
RUNNING AT CREEP – 826 Machine Setup LOAD SYSTEM = WARN ONLY Refer to Table 6-11, Over- Not all of the trigger con-
PLATFORM OVER- The platform is Overloaded load Variations for ditions are met
LOADED Ground mode is active with Emergency Descent mode machine response.
not active or Platform mode is active
DRIVE & BOOM PRE- 827 The Platform is Overloaded and Refer to Table 6-11, Over- Not all of the trigger con-
VENTED – PLATFORM Machine Setup LOAD SYSTEM = CUTOUT PLAT- load Variations for ditions are met
OVERLOADED FORM, Platform Mode is active, and conditions of Table machine response.
6-11, Overload Variations apply.
-or-
The Platform is Overloaded and Machine Setup
LOAD SYSTEM = CUTOUT ALL and conditions of Table
6-11, Overload Variations apply.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
LIFT UP & TELE OUT 828 MACHINE SETUP LOAD SYSTEM = SPECIAL 1 Refer to Table 6-11, Over- Not all of the trigger con-
PREVENTED – PLAT- Platform Mode is active load Variations for ditions are met
FORM OVERLOADED The platform is Overloaded machine response.
LSS READING UNDER 8211 MACHINE SETUP LOAD SYSTEM NO Ground Module to set Not all of the trigger con-
WEIGHT The load sensor has been calibrated and Gross Platform Platform Load State = ditions are met
Weight < (0.5 * Empty Platform Weight). Overloaded
FRONT LEFT STEER 8639 The Ground Module detects an open circuit at the Front Steer Left and Right Cycle power to clear the
VALVE – OPEN CIRCUIT Left Steer Valve output. speed are limited to fault.
Creep
FRONT LEFT STEER 8640 The Ground Module detects a short to battery at the The Ground Module dis- Cycle power to clear the
VALVE – SHORT TO Front Left Steer Valve output. ables the Drive Forward/ fault.
BATTERY Reverse and Steer Left/
Right outputs.
FRONT LEFT STEER 8641 The Ground Module detects a short to ground at the The Ground Module dis- Cycle power to clear the
VALVE – SHORT TO Front Left Steer Valve output. ables the Steer Left and fault.
GROUND Right outputs.
FRONT RIGHT STEER 8642 The Ground Module detects an open circuit at the Front Steer Left and Right Cycle power to clear the
VALVE – OPEN CIRCUIT Right Steer Valve output. speed is limited to Creep fault.
FRONT RIGHT STEER 8643 The Ground Module detects a short to battery at the The Ground Module dis- Cycle power to clear the
VALVE – SHORT TO Front Right Steer Valve output. ables the Drive Forward/ fault.
BATTERY Reverse and Steer Left/
Right outputs
FRONT RIGHT STEER 8644 The Ground Module detects a short to ground at the The Ground Module dis- Cycle power to clear the
VALVE – SHORT TO Front Right Steer Valve output. ables the Steer Left and fault.
GROUND Right outputs
OSCILLATING AXLE 8669 The Ground Module detects that Oscillating Axle switch The Ground Module Cycle power to clear the
SWITCH DISAGREE- #1 and switch #2 are not in agreement. Note: This fault assumes an Above Ele- fault.
MENT will not to be reported if DTC 23104 BOOM TRANS- vation State and de-ener-
PORT SWITCH DISAGREEMENT is active. gizes J1-7 Oscillating
Axle output.
LSS WATCHDOG 991 The Ground Module detects an LSS report of an anom- The Ground Module sets Cycle power to clear the
RESET aly that has caused a WatchDog Timer reset. the Platform Load State fault.
to Overloaded
LSS EEPROM ERROR 992 The Ground Module detects an LSS report of an anom- The Ground Module sets Cycle power to clear the
aly that exists in the LSS EEPROM the Platform Load State fault.
to Overloaded
LSS INTERNAL ERROR 993 The Ground Module detects an LSS report of improper The Ground Module sets Cycle power to clear the
– PIN EXCITATION excitation voltage. the Platform Load State fault.
to Overloaded
LSS INTERNAL ERROR 994 The Ground Module detects an LSS report of an anom- The Ground Module sets Cycle power to clear the
– DRDY MISSING FROM aly that exists in the LSS A/D converter operations. the Platform Load State fault.
A/D to Overloaded
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
EEPROM FAILURE - 998 The Ground Module has detected an anomaly in the The Ground Module dis- Cycle power to clear the
CHECK ALL SETTINGS EEPROM ables all functions and fault.
resets the section of
EEPROM where the fail-
ure occurred back to the
defaults.
FUNCTIONS LOCKED 9910 The Ground Module software major version number The platform alarm Platform Module needs
OUT - PLATFORM MOD- does not match the major version number of the plat- sounds continuously reprogrammed with cor-
ULE SOFTWARE VER- form software and, Creep mode is rect version of software.
SION IMPROPER active. If the Platform
Mode is active all Drive,
Steer, and Boom func-
tions are disabled.
FUNCTION LOCKED 9911 The Ground Module determines that the LSS software The Ground Module sets Cycle power to clear the
OUT - LSS MODULE version is not compatible with existing code. the Platform Load State fault.
SOFTWARE VERSION to Overloaded
IMPROPER
CHASSIS TILT SENSOR 9915 The tilt sensor gain calibration values recorded to flash The Ground Module Valid values must be
NOT GAIN CALIBRATED memory during manufacturing are not present reports a faulted chassis present to reset.
tilt angle of 90 degrees
GROUND SENSOR REF 9919 The Ground Module has detected reference voltage is If MACHINE SETUP Cycle power to clear the
VOLTAGE OUT OF out of range (Reference Voltage is between 2.3V and Kubota D1105 and fault.
RANGE 2.7V). ENGINE SHUTDOWN
ENABLED, then call for
engine shutdown and
disable engine start oper-
ations; otherwise, no
interlocks required.
PLATFORM SENSOR 9920 The Platform Module detects that its reference voltage If in Platform mode, Lift/ Cycle power to clear the
REF VOLTAGE OUT OF is out of range and reports the fault to the Ground Mod- Swing and Drive are fault.
RANGE ule placed in Creep. All other
functions shall operate
normally.
GROUND MODULE 9921 The engine is not running All Drive/Steer and Boom Cycle power to clear the
FAILURE:HIGH SIDE The engine is not cranking functions except Tower fault.
DRIVER CUTOUT The Ground Module footswitch input (J7-15) is LOW Lift Down, Lift Down, and
FAULTY The machine is in Platform Mode Jib Lift Down are dis-
The Main Dump output (J2-13) is detected as HIGH via abled.
the analog feedback 300ms after it is attempted to be
activated during the one time startup test of the Ground
Module hardware shutoff circuitry
PLATFORM MODULE 9922 The Platform Module detects faulty hardware No response required. Cycle power to clear the
FAILURE: HWFS CODE fault; if faults remains,
1 replace board.
Corrective Action/
Control System Operational
Help Message DTC Condition Producing DTC Response or Machine Requirement for
Condition Function Movement and/
or to Clear Fault
GROUND MODULE 9923 The Ground Module detects faulty hardware. No response required. Cycle power to clear the
FAILURE: HWFS CODE fault; if faults remains,
1 replace board.
FUNCTIONS LOCKED 9924 The machine is powered up and no model has been Display??? or NO Cycle power to clear the
OUT - MACHINE NOT selected yet in the MACHINE SETUP menu MODEL at Analyzer fault.
CONFIGURED MACHINE SETUP menu
MACHINE SETUP-
>MODEL NUMBER
No other faults will be
reported.
All machine functions are
disabled and the engine is
not permitted to start.
CURRENT FEEDBACK 9944 One or more of the current feedback gains that are cal- A gain of 1 is used for the Cycle power to clear the
GAINS OUT OF RANGE culated and written to flash memory during manufactur- factory gain(s) that was fault.
ing are detected as being out of range out of range; all functions
are placed in Creep
mode.
CURRENT FEEDBACK 9945 The current feedback gains checksum that is calculated All machine and engine Cycle power to clear the
CALIBRATION CHECK- and written to flash memory during manufacturing is functions are disabled fault.
SUM INCORRECT detected as being incorrect (i.e., command engine
shutdown and do not per-
mit start).
MACHINE CONFIGURA- 9949 The Ground Module has detected an anomaly in stored The Ground Module Cycle Power and change
TION OUT OF RANGE – readings for the Machine Setup configuration. prompts the operator to the Machine Setup data.
CHECK ALL SETTINGS correct the issue via Ana-
lyzer and disable all func-
tions until stored data in
corrupted area is
changed.
LSS CORRUPT 9977 The Ground Module is advising that the LSS module has The Ground Module sets Cycle power to clear the
EEPROM detected faulty stored parameters. the Platform Load State fault.
to Overloaded
FUNCTIONS LOCKED 9979 Ground Module detects a disagreement with internal All machine and engine Cycle power to clear the
OUT - GROUND MOD- checks on the version of software. functions are disabled fault.
ULE SOFTWARE VER- (i.e., command engine
SION IMPROPER shutdown and do not per-
mit start)
GROUND MODULE 9986 Ground Module has determined a hardware fault exists All machine and engine Cycle power to clear the
VLOW FET FAILURE and is unable to read high-sensing inputs. functions are disabled fault.
(i.e., command engine
shutdown and do not per-
mit start)
1
Annotated DTCs do not flash a numeric code, sound an alarm, and are not stored in annotated DTCs in Logged Help queue (this applies to most DTCs <
0100).
SPECIAL 1
BROADCAST ONLY3 WARN ONLY CUTOUT ALL
(Access Industries)
CUTOUT PLATFORM
Platform
Activate visual overload light Activate visual overload light Activate System Distress and Activate visual overload light Activate System Distress
at Platform Station at Platform Station Overload lights at Platform at Platform Station and Overload lights at Plat-
station form station
Activate Platform and Activate Platform and Activate Platform and Activate Platform and Activate Platform and
Ground Alarm – 5 sec ON, 2 Ground Alarm – 5 sec ON, 2 Ground Alarm – 5 sec ON, 2 Ground Alarm – on continu- Ground Alarm – 5 sec ON,
sec OFF sec OFF sec OFF ously 2 sec OFF
Do not report Fault Activate creep mode all func- Do not permit Machine Activate creep mode all func- Do not permit Machine
tions, energize Creep light, Enable (no creep light) and tions, energize Creep light, Enable (no creep light) and
and report Fault report Fault and report Fault report Fault
Disable Telescope Out and
Lift Up
Ground
Activate visual overload light Activate visual overload light Activate visual overload light Activate visual overload light Activate visual Overload
(Ground Station) (Ground Station) (Ground Station) (Ground Station) light at Ground Station
Activate Platform and Activate Platform and Activate Platform and Activate Platform and Activate Platform and
Ground Alarm – 5 sec ON, 2 Ground Alarm – 5 sec ON, 2 Ground Alarm – 5 sec ON, 2 Ground Alarm – on continu- Ground Alarm – 5 sec ON,
sec OFF sec OFF sec OFF ously 2 sec OFF
Do not report Fault Report Fault Report Fault Do not report Fault Do not report fault.
Activate creep mode all func- Do not permit Machine Overload shall have no effect Overload shall have no
tions Enable (no creep light) on function speeds. effect on function speeds.
Auxiliary Power/Emergency Descent
Platform operation and Platform operation and Platform operation and Platform operation and Platform operation and
annunciation as Platform annunciation as Platform annunciation as Platform annunciation as Platform annunciation as Platform
Mode above Mode above Mode above, except do not Mode above Mode above, except do not
disable all functions report Fault or disable all
functions
Ground operation and annun- Ground operation and annun- Ground operation and annun- Ground operation and annun- Ground operation and
ciation as Ground Mode ciation as Ground Mode ciation as Ground Mode ciation as Ground Mode annunciation as Ground
above, except do not activate above, except do not activate above, except do not report above Mode above
creep mode creep mode Fault or disable all functions
Faults
No applicable fault When the platform is over- When the platform is over- When the platform is over- When the platform is over-
loaded, report “RUNNING AT loaded, report "DRIVE & loaded, report "LIFT UP & loaded, report the "DRIVE
CREEP - PLATFORM OVER- BOOM PREVENTED – PLAT- TELE OUT PREVENTED – & BOOM PREVENTED –
LOADED.” FORM OVERLOADED." PLATFORM OVERLOADED.” PLATFORM OVER-
LOADED."
Clarifications:
1. The term Report Fault is defined as logging the DTC on the Analyzer fault stack and flashing the System Distress lamp.
2. When specified, Ground Alarm energization shall only occur if MACHINE SETUP GROUND ALARM ? NO.
3. This selection is not Analyzer configurable in MACHINE SETUP LOAD SYSTEM but is shown here for completeness of the response table.
NOTES:
A wide variety of multimeters or Volt Ohm Meters (VOM) m = milli = (Displayed Number) / 1,000
can be used for troubleshooting your equipment. This µ = micro = (Displayed Number) / 1,000,000
section shows diagrams of a common, digital VOM con-
figured for several different circuit measurements. Instruc- Example: 1.2 k = 1200
tions for your VOM may vary. Please consult the meter Example: 50 mA = 0.05 A
operator’s manual for more information.
Voltage Measurement
Grounding
"Grounding the meter" means to take the black lead
(which is connected to the COM (common) or negative
port) and touch it to a good path to the negative side of
the Voltage source.
Backprobing
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the connec-
tor is the sealed type, great care must be taken to avoid
damaging the seal around the wire. It is best to use
probes or probe tips specifically designed for this tech-
nique, especially on sealed connectors. Whenever possi-
ble insert probes into the side of the connector such that
the test also checks both terminals of the connection. It is
possible to inspect a connection within a closed connec-
tor by backprobing both sides of a connector terminal and
measuring resistance. Do this after giving each wire a
gentle pull to ensure the wires are still attached to the con- Figure 7-1. Voltage Measurement (DC)
tact and contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct
range (See multimeter’s operation manual)
Min/Max
• Use firm contact with meter leads
Use of the "Min/Max" recording feature of some meters
can help when taking measurements of intermittent condi-
tions while alone. For example, you can read the Voltage
applied to a solenoid when it is only operational while a
switch, far from the solenoid and meter, is held down.
Figure 7-4. Current Measurement (DC) • To prevent oxidation at the mechanical joint between
male and female pins.
• Set up the meter for the expected current range
• To prevent electrical malfunction caused by low level
• Be sure to connect the meter leads to the correct conductivity between pins when wet.
jacks for the current range you have selected Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
• If meter is not auto ranging, set it to the correct
applies to all plug connections not enclosed in a box. Sili-
range (See multi meter’s operation manual)
cone grease should not be applied to connectors with
• Use firm contact with meter leads external seals.
3. Anderson connectors for the battery boxes and bat- Deutsch HD, DT, DTM, DRC Series
tery chargers should have silicone grease applied to
the contacts only. The Deutsch connector system is commonly used for
harsh environment interconnect. Follow the installation
NOTE: Curing-type sealants might also be used to prevent instructions.
shorting and would be less messy, but would make
future pin removal more difficult.
DIN Connectors
This connector is typically used on hydraulic valves. Fol-
low the installation instructions.
SEALED ENCLOSURES
Application of dielectric grease is not required in properly
sealed enclosures. To meet criteria, the enclosure must
be rated to at least IP66 (dust tight; protected from power-
ful jets of water). The enclosure must be fitted with a high
quality, continuous gasket and all wiring must pass
through cable entrances.
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).
Release the locking latches by squeezing them
inward (See Figure 7-10.).
A B
A B
C
C D
Figure 7-14. DT/DTP Contact Installation Figure 7-15. DT/DTP Contact Removal
A B A B
C C
Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal
Figure 7-17. HD/HDP Locking Contacts Into Position Figure 7-19. HD/HDP Unlocking Contacts
NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do Not twist or insert tool at an angle.
environmental sealing
1 2 3 4 5
H GENERIC GENERIC
PLATFORM LEVEL ENGINE SPEED
HORN
PUSH BUTTON
SW224-1
SW224-2
SW09
SW10
1
1
2
3
4
5
6
1
2
3
4
5
6
WHT 25-1 PLAT LVL UP
WHT 2-17-2 SWITCH IGN
SW13
WHT 0-20 PUMP POT GND
5 CO01-J8
2
1
PUMP POT
6
4
WHT 40-1 PUMP POT REF CO01-J1
WHT 2-17-3 SWITCH IGN WHT 42-1 MAX SPEED
3 27 19
WHT 2-17-4 SWITCH IGN WHT 2-17 SWITCH IGN
1 18 20
WHT 55-1 CREEP MODE WHT 41-1 MAX TORQUE
2 28 9
WHT 25-1 PLAT LVL UP
9 5
WHT 26-1 PLAT LVL DN
10 18
WHT 35-1 HORN
31 PLATFORM MODULE 35
WHT 0-20 PUMP POT GND
13 28
WHT 40-2 PUMP POT CMD
35 7
WHT 40-1 PUMP POT REF
34 8
WHT 55-1 CREEP MODE
32 4
F SW12 3 11
PLATFORM ROTATE
6 4 12
5 16 16
GENERIC
4 17 15
WHT 24-1 PLAT ROT RT WHT 24-1 PLAT ROT RT
3 7 27
WHT 2-17-4 SWITCH IGN
2 19 29
WHT 23-1 PLAT ROT LFT WHT 23-1 PLAT ROT LFT
1 8 24
WHT 2-17-5 SWITCH IGN
20 17
21 14
23 13
SW14 24 10
6 25 6
TOWER LIFT
5 26 22
GENERIC
4 29 21
WHT 5-1 TWR LFT UP WHT 5-1 TWR LFT UP
3 1 33
WHT 2-17-5 SWITCH IGN WHT 29-1 HEAD/TAIL LT
2 30 34
WHT 6-1 TWR LFT DN WHT 6-1 TWR LFT DN
1 2 25
WHT 2-17-6 SWITCH IGN WHT 27-1 JIB UP
11 26
WHT 28-1 JIB DN
12 23
WHT 13-1 MAIN TELE IN
5 32
WHT 14-1 MAIN TELE OUT
6 30
HEAD/TAIL LIGHT
1 14 3
WHT 2-17-7 SWITCH IGN WHT 52-1 FUEL SELECT
33 1
WHT 29-1 HEAD/TAIL LT
1 22 2
SW280-1 CO01-J7
6
SW15 1
6 5
5 4
GENERIC
JIB LIFT
4 3
WHT 27-1 JIB UP
3 7
WHT 2-17-7 SWITCH IGN
2 2
WHT 28-1 JIB DN
1 8
WHT 2-17-8 SWITCH IGN
CO01-J6
SW16 5
MAIN TELESCOPE
6 4
5 7
GENERIC
4 8
D 3
WHT 13-1 MAIN TELE IN
6
WHT 2-17-8 SWITCH IGN
2 1
WHT 14-1 MAIN TELE OUT
1 3
WHT 2-17-9 SWITCH IGN
2
CO01-J5
SW17
START / AUX POWER
6
5
21
30
18
22
24
23
25
35
14
13
10
16
19
20
31
15
12
17
26
28
29
27
32
33
34
11
GENERIC
9
7
1
2
8
3
5
6
CO01-J2
4
WHT 53-1 AUX POWER
3
WHT 2-17-9 SWITCH IGN
2
WHT 45-1 START
1
WHT 2-18 LSS PWR
WHT 66-1 SYS DISTRESS
WHT 39-7 LOW FUEL
WHT 71-2 RX
WHT 71-3 TX
WHT 39-3 1/4 FUEL LVL
SW18
6
5
GENERIC
4
WHT 52-1 FUEL SELECT
C 3
WHT 2-17-10 SWITCH IGN
2
WHT 2-17-11 SWITCH IGN
1
SW19
DRIVE ORIENTATION
6
5
GENERIC
4
3
WHT 2-17-11 SWITCH IGN
WHT 66-1 SYS DISTRESS
WHT 39-6 FULL FUEL LVL
2
WHT 48-1 GLOW PLUGS
WHT 31-3 FUNC ENABLE
WHT 55-2 CREEP MODE
1
WHT 0-22 FUEL GND
GD20-J2
GD20-J4
GD20-J3
B
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
FUEL GND
CREEP
ENABLE
SYSTEM FAULT
TILT
FUEL 1/4
FUEL 1/2
FUEL 3/4
SPARE14
FUEL FULL
LOW FUEL
SPARE20
SPARE21
N/C
N/C
GROUND
DRIVE ORIENTATION
SPARE22
SPARE23
SPARE19
GENERATOR
SPARE24
GLOW PLUG
OVERLOAD
FUEL GAUGE
ORIENTATION FAULT
Y
SPARE20 SPARE21 DRIVE SPARE22 SPARE23 SYSTEM CREEP LOW FUEL
R G Y G R Y G Y G
PLUG
R G R Y R Y G G
G
GENERIC
DISPLAY BOARD
SHEET 2
1 2 3 4 5
4 5 6 7 8
AH02+
JLG ALARM
WHT 37-1 PLAT ALARM
GENERIC
1
1
BLK 0-6 PLAT GND 12 AWG
AH02-
X1
WHT 54-1 GEN ON
1
WHT 2-20 GEN SW IGN
2
3
WHT 31-1 FOOT PEDAL
CO01-J8 4
2
1
MS269
12
10
11
1
2
3
4
9
5
6
7
8
CO01-J7
STEER
ELECTRONIC JOYSTICK
RIGHT
WHT/YEL
6
WHT/RED LEFT
1
WHT/GRN
GENERIC
5
RED
4
DRIVE
BRN
3
BLK
7
2
BLU X3
5K
ORN/YEL
LIFT AND SWING
4 5
BLU/YEL WHT 2-8 PLAT EMS
7 4
GENERIC
19
18
10
WHT 2-11 STROBE
15
21
30
18
22
24
23
25
35
14
13
10
16
19
20
31
15
12
17
26
28
29
27
32
33
34
11
9
7
1
2
8
3
5
9
WHT 2-6 PLAT MODE
13
WHT 66-1 SYS DISTRESS
WHT 71-2 RX
SW21-1B
SW21-1A
WHT 2-6 PLAT MODE
1B
WHT 2-4 PLAT MODE
1A EMERGENCY
T7 MS220+
RED 1-7 B+ 12AWG RED 1-7 B+ 12AWG
1 1
AUX POWER
WHT 66-1 SYS DISTRESS
1 1
WHT 39-7 LOW FUEL
T8 MS220-
WHT 56-1 TILTED
WHT 71-2 RX
WHT 71-3 TX
GD20-J2
GD20-J4
GD20-J3
B
X4
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
TO ANALYZER PORT
SYSTEM FAULT
TILT
LOW FUEL
GLOW PLUG
N/C
N/C
GROUND
DRIVE ORIENTATION
GENERATOR
OVERLOAD
CREEP
ENABLE
SPARE20
SPARE21
SPARE22
SPARE23
SPARE19
SPARE24
FUEL GAUGE
FAULT
Y
SPARE22 SPARE23 SYSTEM CREEP LOW FUEL
G R Y G Y G
PLUG
SPARE24 TILT GLOW ENABLE SPARE14
G A
Y R Y G G
G
GENERIC
DISPLAY BOARD
00111963-G
SHEET 2
4 5 6 7 8
1 2 3 4 5
CO44-J2
CO44-J1
SW43
SW42
10
12
10
12
11
11
1
2
3
4
5
6
1
2
3
1
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
GRN
BLK
BLU/BLK
BLU/ORN 52-4
BLU/ORN 52-3
BLK/RED
WHT
X1
G 1
BLU/ORN 52-4
BLU/ORN 52-3
2
3
BLK
4
WHT
5
6
TO SHEET 2 7
X1 8
INSIDE PLATFORM BOX 9
10
11
12
13
14
15
GRN
Sheet_2-[7,D]
F X2
T2 BLU/BLK
1 1
2 X411
T3 ORN/BLK 1
3 1
2
4 T4 YEL/BLK 3
TO SHEET 2 5 1
4
X2 6
T5 BRN/BLK 5
7 T391 1
INSIDE PLATFORM BOX 8 1
RED - TP CAN CABLE 6
T6 BLK/RED X411
S64
9 T392 1
BLK - TP CAN CABLE
10 1
11
T393 SHLD TP CAN CABLE
12 1
T394 WHT 0-27 LSS GND
1
T395 WHT 2-18 LSS PWR
1
X3 X5 X5
RED 12AWG RED 12AWG
12 12 12
BLK 12AWG BLK 12AWG
16 16 16
SHLD SHLD
1 1 1
BLK 18AWG BLK 18AWG
2 2 2
RED 18AWG RED 18AWG
3 3 3
BLU 18AWG BLU 18AWG
5 5 5
ORN 18AWG ORN 18AWG
4 4 4
TO SHEET 2 6
YEL 18AWG
6 6
YEL 18AWG
BRN 18AWG BRN 18AWG
BOOM CABLE 7 7 7
X3 8
BLU/BLK 18AWG
8 8
BLU/BLK 18AWG
PLATFORM 11 11 11
14 14 14
BOX 17 17 17
19 19 19
D 18
BLK/WHT 12AWG
18 18
BLK/WHT 12AWG
ORN 12AWG ORN 12AWG
10 10 10
YEL/BLK 18AWG YEL/BLK 18AWG
15 15 15
RED/BLK 18AWG RED/BLK 18AWG
9 9 9
ORN/BLK 18AWG ORN/BLK 18AWG
13 13 13
JOINT BETWEEN
UPPER AND
LOWER BOOMS
1
2
1
2
1
2
1
2
1
2
LIMIT SWITCH
V71
V76
V59
V60
V61
V62
ORN/BLK
ORN/BLK
ORN/BLK
WHT CABLE 2
BLK CABLE 2
BLK/RED CABLE 4
BRN/BLK CABLE 4
BLU/BLK CABLE 3
YEL/BLK CABLE 3
BLK/RED CABLE 3
BLU/RED CABLE 3
ORN/BLK CABLE 4
21
YEL/BLK CABLE 4
22
13
14
SW152
LIMIT SWITCH
BOOM ANGLE SWITCH #2
WHT CABLE 1
21
BLK CABLE 1
22
13 X6
BLU/BLK CABLE 4
14 1
B BLU/RED CABLE 4
2
SW242 ORN/BLK CABLE 4
LIMIT SWITCH
YEL/BLK CABLE 4
3 TO SHEET 4
TOWER ELEV 4
WHT CABLE 1
5
X6
BLK CABLE 1
6
X17
BLU/RED CABLE 3
1
BLK/RED CABLE 3
2
YEL/BLK CABLE 3
3
BLU/BLK CABLE 3
4
ORN/BLK CABLE 3
BLK/RED CABLE 4
5 TO SHEET 4
S65 6
BRN/BLK CABLE 4
7 X17
WHT CABLE 2
A BLK CABLE 2
8
9
10
11
12
SHEET 3
1 2 3 4 5
4 5 6 7 8
CO44-J2
CO44-J1
10
12
11
10
12
11
1
2
1
2
1
2
1
2
3
4
5
6
7
8
9
V55
V57
V58
1
2
3
4
5
6
7
8
9
V56
RED - TP CAN CABLE
SHLD TP CAN CABLE
BLU/BLK
ORN/BLK
BRN/BLK
BLK/RED
BLK/RED
BLK/RED
BLK/RED
BLK - TP CAN CABLE
YEL/BLK
G
F
T2 BLU/BLK
1
X411
T3 ORN/BLK 1
1
2
T4 YEL/BLK 3
1
4
T5 BRN/BLK 5
1
6
T6 BLK/RED X411
S64
1
X5 X7
RED 12AWG
12 12
BLK 12AWG
16 16
SHLD
1 1
BLK 18AWG
2 2
RED 18AWG
3 3
BLU 18AWG
5 5
ORN 18AWG
4 4
YEL 18AWG
6 6
BRN 18AWG TO SHEET 4
7 7
8 8
BOOM CABLE
11
BLU/BLK 18AWG
11 X7
14 14
17 17
19 19
18
BLK/WHT 12AWG
18
D
ORN 12AWG
10 10
YEL/BLK 18AWG
15 15
RED/BLK 18AWG
9 9
ORN/BLK 18AWG
13 13
X6
BLU/BLK CABLE 4
1
BLU/RED CABLE 4
2
B
ORN/BLK CABLE 4
YEL/BLK CABLE 4
3 TO SHEET 4
4
WHT CABLE 1
5
X6
BLK CABLE 1
6
X17
BLU/RED CABLE 3
1
BLK/RED CABLE 3
2
YEL/BLK CABLE 3
3
BLU/BLK CABLE 3
4
ORN/BLK CABLE 3
BLK/RED CABLE 4
5 TO SHEET 4
6
BRN/BLK CABLE 4
7 X17
WHT CABLE 2
BLK CABLE 2
8 A
9
10
11
12
SHEET 3 1001119638-G
4 5 6 7 8
1 2 3 4 5
X166
X167
12
10
11
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
WHT 2-21 IGN 16AWG
1
2
3
4
CO66-J1
1
2
3
4
G 5 GROUND MODULE
6
7
8
9
10
11
12
13
14
DRIVE FORWARD
TO SHEET 8 15
V83
GENERIC
16
WHT 47-2 DRV VLV RTN CO66-J1 17
2
WHT 7-2 DRV FORWARD
1 18
19
20
21
DRIVE REVERSE
22
V82
GENERIC
S86 23
WHT 47-3 DRV VLV RTN
2 24
WHT 8-2 DRV REVERSE
F 1 25
26
27
28
STEER RIGHT
29
V81
GENERIC
30
WHT 0-12-2 STR VLV GND
2 31
WHT 10-2 STEER RT
1 32
33
34
35
STEER LEFT
V80 CO66-J2
GENERIC
S87
WHT 0-12-1 STR VLV GND WHT 25-3 PLAT LVL UP
2 5
WHT 9-2 STEER LFT WHT 26-3 PLAT LVL DN
1 7
WHT 13-3 TELE IN
4
WHT 14-3 TELE OUT
16
WHT 0-10 MID VLV GND
14
WHT 0-13-12 STEER DUMP GND
18
WHT 50-3 STEER DUMP
1
3
E
TOWER LIFT UP
32
V79
GENERIC
33
WHT 0-13-4 TWR VLV RTN
2 10
WHT 5-3 TWR LIFT UP WHT 10-2 STEER RT
1 8
WHT 9-2 STEER LFT
19
WHT 0-12 STR VLV GND
28
WHT 5-3 TWR LIFT UP
20
12
STEER DUMP
15
V240
GENERIC
S138 21
WHT 0-13-12 STEER DUMP GND
2 23
WHT 50-3 STEER DUMP WHT 6-3 TWR LIFT DN
1 9
24
WHT 51-1 NITE BRITE
26
WHT 0-13-6 MAIN DUMP GND
30
WHT 50-1 MAIN DUMP
13
WHT 50-2 FLOW VLV
31
MAIN DUMP
35
WHT 0-13-6 MAIN DUMP GND WHT 21-3 SWG LFT
2 34
WHT 50-1 MAIN DUMP WHT 3-3 LIFT UP
1 11
WHT 4-3 LIFT DN
22
D WHT 0-14 FUEL GND
6
WHT 39-1 FUEL LVL
25
FLOW CONTROL
27
WHT 0-13-7 FLOW VLV RTN
2 17
WHT 50-2 FLOW VLV
1 2
SWING RIGHT
V73
GENERIC
13
27
28
29
31
26
15
20
22
24
32
25
16
34
35
21
10
33
23
10
12
13
14
11
11
1
9
4
1
2
3
4
5
6
7
8
9
1
CO66-J3
CO66-J4
TO SHEET 5
WHT 36-1 GND ALARM B+
CO66-J4
SWING LEFT
V74
GENERIC
S78
TO SHEET 8 WHT 0-43
V75
GENERIC
LIFT UP
B
GENERIC
FUEL SENSOR
TO SHEET 8
X308
AH216
WHT 36-1 GND ALARM B+
GENERIC
1
ALARM
SHEET 4
1 2 3 4 5
4 5 6 7 8
12
10
X167
11
BLK 0-5 SYS GND 10AWG
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
BLK 0-7 GND 12AWG
1 TO GND (STARTER)
WHT 2-21 IGN 16AWG
CO66-J8 X7
1
2
3
4
WHT 2-10 PLAT IGN 12AWG
12
BLK 0-6 PLAT GND 12AWG
16
SHLD - TP CAN CABLE SHLD - TP CAN CABLE
1 18 1
BLK - TP CAN CABLE BLK - TP CAN CABLE
2 24 2
RED - TP CAN CABLE RED - TP CAN CABLE
3 13 3
4 9 5
5 GROUND MODULE 1
WHT 2-8-1 PLAT EMS S101 WHT 2-8 PLAT EMS
4 G
WHT 31-2 FOOT PEDAL WHT 31-2 FOOT PEDAL
6 15 6
7 34
WHT 63-6 OSC AXLE #2
7 TO SHEET 3
8 32 8
9 14
WHT 2-12 GND MODE WHT 2-12 GND MODE
11
BOOM CABLE
10 31 14
X7
11 30 17
12 27 19
BLK 0-7 GND 12AWG
13 26 18
IP218
33 12
15A
34 33
WHT 63-7 OSC AXLE #2 IP315
35 35
IP219
WHT 72-1 JUMPER
4 6
16 5
SHLD - TP CAN CABLE RL98
IGNITION RELAY
BLK TP CAN CABLE WHT 2-9 IGN 12AWG 87
14 4 4
RED TP CAN CABLE WHT 2-2 GND EMS 12AWG 30
GENERIC
18 3 1
87a
1 2 3
WHT 0-17 IGN GND 85
3 1 2
32
CO66-J12
WHT 2-5-4 SYS ON
5
86 E
33 S102
10
8 X6
WHT 63-3-1 BOOM ELEV SW
19 1
S147 WHT 63-4 BOOM ELEV SW
28 2
S349
WHT 63-3-2 BOOM ELEV SW
20 3 TO SHEET 3
WHT 63-5 BOOM ELEV SW
12
WHT 74-2 TRANSPORT SW
4 X6
15 5
WHT 74-1 TRANSPORT SW
21 6
23
9
S351
24
26
30
13
31
S352
35
34
11
22
6
D
25
29
27
17
2
WHT 63-4-1 BOOM ELEV SW
WHT 73-1 OSC AXLE #1 WHT 73-1-1 OSC AXLE #1
2 N.C.
3
S146 LOCATED
1
4
IN VOID
SW226 LIMIT SWITCH
TO SHEET 8
OSC AXLE #1
12
14
13
27
28
29
31
26
15
20
22
24
32
25
16
34
35
21
10
33
23
30
19
18
17
10
12
13
14
11
11
1
9
5
1
2
3
4
5
6
7
8
9
X175
CO66-J4
LIMIT SWITCH
X173
OSC AXLE #2
TO SHEET 8 WHT 0-43
C
C
C
A
B
A
B
OSC AXLE #1
WHT 73-1-2 OSC AXLE #1
PRIMARY
1
WHT 0-18-2 VLV GND
2
WHT 63-3 BOOM ELEV SW
Sheet_8-[2,E]
V96
X174
C
B
A
GENERIC
OSC AXLE #2
SECONDARY
V97
FC252
1
2
FC253
S143
1
2
RED 1-9-1 B+
TO ESTOP 1A2 1
T15
WHT 0-8 GND WHT 82-2 SPEED VCC
SHLD - TP CAN CABLE
WHT 7-2 DRV FORWARD
1 Sheet_8-[2,E]
WHT 8-2 DRV REVERSE
T14
WHT 49-1 CRIBBING
B
WHT 0-8 GND
RED 1-9 B+
X308
T16
X8
8
7
6
5
4
3
2
1
F
G
1
D
C
H
A
B
E
TO SHEET 8
X308 ADVANCED DIAGNOSTIC
SHEET 4 1001119638-G
4 5 6 7 8
1 2 3 4 5
SW105
SW107
SW106
SW108
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
WHT 2-14-8 SWITCH IGN
GENERIC
WHT 4-2 LIFT DN
3
LIFT
G 4
5
6
SW109
TOWER LIFT
2
GENERIC
WHT 6-2 TWR LIFT DN
3
4
5
6
SW110
GENERIC
SWING
WHT 21-2 SWING LFT
3
4
CO66-J4 5
WHT 26-2 PLAT LVL DN
5 6
WHT 25-2 PLAT LVL UP
17
WHT 23-2 PLAT ROT LFT SW111
6
WHT 24-2 PLAT ROT RT
18
WHT 27-2 JIB UP
19
WHT 28-2 JIB DOWN
8
WHT 2-14-1 SWITCH IGN
9
GENERIC
WHT 13-2 TELE IN WHT 45-2 START
7 3
WHT 3-2 LIFT UP
23 4
WHT 4-2 LIFT DN
33 5
WHT 5-2 TWR LIFT UP
10 6
WHT 6-2 TWR LIFT DN
21
WHT 22-2 SWING RT SW112
35
E 34
WHT 21-2 SWING LFT
TO SHEET 4 16
WHT 53-2 AUX / ENABLE
CO66-J4 25
WHT 2-14 SWITCH IGN
WHT 45-2 START
4
32
24
22
15
GENERIC
WHT 46-3 ALT WHT 46-3 ALT
26 1
WHT 0-17 LAMP GND WHT 0-17 LAMP GND
31 2
WHT 39-7 LOW FUEL WHT 0-17-1 LAMP GND
13
WHT 48-2 GLOW PLUGS
3
WHT 65-1 LOW OIL PR
29
28
WHT 65-2 HI TEMP LB114
GENERIC
WHT 66-2 SYS FAULT WHT 39-7 LOW FUEL
2 1
WHT 57-2 OVERLOAD WHT 0-17-1 LAMP GND
14 2
WHT 58-2 CRIBBING WHT 0-17-2 LAMP GND
1
WHT 32 HOUR METER
12
GLOW PLUGS
LB115
GENERIC
WHT 48-2 GLOW PLUGS
1
WHT 0-17-2 LAMP GND
2
WHT 0-17-3 LAMP GND
GENERIC
WHT 65-1 LOW OIL PR
1
WHT 0-17-3 LAMP GND
2
WHT 0-17-4 LAMP GND
HI COOLANT TEMP
LB117
GENERIC
WHT 65-2 HI TEMP
1
WHT 0-17-4 LAMP GND
2
WHT 0-17-5 LAMP GND
C
LB118 SYS FAULT
GENERIC
WHT 66-2 SYS FAULT
1
WHT 0-17-5 LAMP GND
2
WHT 0-17-6 LAMP GND
LB119
OVERLOAD
GENERIC
LB251
CRIBBING
GENERIC
GD121+
HOUR METER
GD121-
SHEET 5
1 2 3 4 5
4 5 6 7 8
GENERIC
TELESCOPE
H
SW108
1
2
3
4
5
6
GENERIC
WHT 2-23 CRIBBING PWR
T331 3
4
WHT 2-23 CRIBBING PWR
TO SHEET 4 X166 POS 4 1 5
6
T330
SW327
GENERIC
WHT 4-2 LIFT DN
3
LIFT
4 G
5
6
SW109
2
GENERIC
SW110
SW111
X23
RED 1-4-2 B+ 12AWG
1
LOW FUEL BATTERY CHARGING
LB115
GENERIC
LB116
GENERIC
1B: 1-4-2 B+
LB117
GENERIC
LB119
OVERLOAD
GENERIC
LB251
CRIBBING
GENERIC
GD121+
HOUR METER
GD121-
SHEET 5 1001119638-G
4 5 6 7 8
1
GENERIC
M
X170
FUSE HOLDER
T170-
STARTER
FC267
GENERIC
FUSE HOLDER
S259
87a
87a
WHT 0-46-1 GND 85
85
GENERIC
STARTER
RL30
2
WHT 46-1 ALT EXCITE 16AWG
1
X266
LAMP IGN
GENERIC
RL255
FULL SPEED RELAY
WHT 84-2 GLOW PLUGS 12AWG WHT 84-2 GLOW PLUGS 12AWG 87
1 87
EC228 RED 1-10-4 B+ 12AWG 30
ENGINE
30
87a
GLOW PLUGS
87a
WHT 0-46-3 GND 85
85
GENERIC
86
FIVE PIN RELAY
RL31
SW134
WHT 83-1 OIL PRESSURE
1
S260
GENERIC
PRESSURE SWITCH
3 GND
SENSOR
SN227
SENSOR, SPEED
S261
KUBOTA ENGINE HARNESS
SN262
WHT 81-1 COOLANT TEMP
1
WHT 0-41-5 GND
2
GENERIC
TEMP SENSOR
EC40
THROTTLE ACTUATOR
EC256+
WHT 86-1 FULL THROTTLE 14AWG
1
WHT 0-41-6 GND 14AWG
1
GENERIC
EC256-
FULL THROTTLE
C C
BLK CAN LO
B B
RED CAN HI
A A
X406 X407
120
BLK CAN LO
RED CAN HI
WHT 45-5 START
WHT 80-1 THROTTLE ACT
WHT 46-1 ALT EXCITE 16AWG
L
F
S
P
K
E
B
A
R
N
H
D
C
SHEET 6
X16
1001119638-G
TO SHEET 8
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3121259
TO VOLTAGE REGULATOR
5
4
3
2
1
X42
WHT 0-35 GND 12AWG
TO ENGINE BLOCK 1
T409
T355 GD359+
WHT 2-25-3 IGN S357 WHT 2-25-3 IGN
1 1
T30
WHT 2-24 IGN 12AWG
1 TO E-STOP 2A2
– JLG Lift –
WHT 2-25 IGN 12AWG 87
87
WHT 2-24 IGN 12AWG 30
30
87a
87a
WHT 0-30 GND 85
B 85
GENERIC
A 86
FIVE PIN RELAY
GENERATOR HARNESS
SHEET 6
1001119638-G
7-23
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
1 2 3 4 5
PED_12162193 CONNECTOR
ECM PED_12124075 TERMINAL
PED_12162193 CONNECTOR
PED_12124075 TERMINAL
PED_12162834
CONNECTOR
PED_12124075
TERMINAL
MOLEX 56 WAY
34576-0703 - 56 CIRCUIT POL G VERSION "0" CONNECTOR
33467-0005 - 0.64MM 18/20 AWG GOLD PLATED TERMINAL
34575-0003 - 56 WAY WIRE DRESS COVER
34586-0001 - 0.64MM CAVITY PLUG
D
AMP_1-967616-1 CONNECTOR 1/4" SPADE
AMP_965906-5 TERMINAL (FEMALE)
AMP_967067-1 SEAL
B
GM ENGINE HARNESS
SHEET 7
1 2 3 4 5
4 5 6 7 8
PED_12052641 CONNECTOR
PED_12048074 TERMINAL
PED_12052634 LOCK
PED_12048086 SEAL
1/4" SPADE
PED_12160825 CONNECTOR G
PED_12177150 TERM (GOLD)
(FEMALE)
PED_12160826 LOCK
PED_12089678 SEAL
PED_12103784 CONNECTOR
PED_12124580 TERM FEMALE (14/16 AWG)
PED_12089188 TERM FEMALE (18/20 AWG)
PED_12015323 SEAL
PED_12162193 CONNECTOR
PED_12124075 TERMINAL
PED_12162834
CONNECTOR
PED_12124075
TERMINAL
F
CONNECTOR 1
PED_15326868 CONNECTOR
TO SHEET 8 PED_15326269 TERMINAL
PED_12191153 SEAL
X16 PED_15305171 CAVITY PLUG
PED_15358639 CLIP
DJF7031A-6.3-20 CONN
CONNECTOR 2
PED_15326840 CONNECTOR E
PED_15326269 TERMINAL
TO SHEET 8 PED_12191153 SEAL
CAP CONNECTOR 2 WITH MATING CONNECTOR
PED_15326835, CAVITY PLUGS PED_15305171
PED_15305171 CAVITY PLUG
X40 PED_15358639 CLIP
AND TPA PED_15418415
PED_15317363 LOCK
PED_12052848 CONNECTOR
PED_12056198 CAVITY PLUG
PED_12052850 LOCK
PED_12124107 CONNECTOR
PED_15324973 SEAL
PED_12059168 CAVITY PLUG
PED_12045773 TERMINAL
PED_12052850 TPA
PED_12020833 CPA
EPC_1F1T-14A624-AA-004 TERM
GTS_0330-930009 TERM (18-20)
GTS_0330_940001 TERM (14-16)
EPC_E6DB-14A468-DA LOCK D
EPC_F5AB-14A666-AA CAP
AMP_1-967616-1 CONNECTOR 1/4" SPADE
AMP_965906-5 TERMINAL (FEMALE)
AMP_967067-1 SEAL
F4ZB-14A464-MA CONN
F3VB-14474-AA TERM
E93B-14A468-DA SPACER
GM ENGINE HARNESS B
SHEET 7 1001119638-G
4 5 6 7 8
1 2 3 4 5
GENERIC GENERIC
BRAKE BYPASS
V213
V212
1
2
1
2
H
E Sheet_4-[8,B]
WHT 82-2 SPEED VCC
X308
1 TO SHEET 5 WHT 49-1 CRIBBING
2 TO SHEET 9 WHT 51-1 NITE BRITE
3
TO SHEET 4 4
X308 5
6
WHT 7-2 DRV FORWARD
7
WHT 8-2 DRV REVERSE
8
X35
TO SHEET 6 B
WHT 54-2 GEN ON
X35 A
X175
SHLD
C
D TO SHEET 4 B
BLK - TP CAN CABLE
X175 A
RED - TP CAN CABLE
T34
RED 1-1 B+ 1/0AWG
TO STARTER B+ 1
T36
BLK 1-0 GND 1/0AWG
TO STARTER GND 1
C
WHT 65-4 FUEL PUMP
BLK 1-0 GND 1/0AWG
EC210+
BT209+
EC210-
BT209-
1
1
M
12V BATTERY
GENERIC FUEL PUMP
GENERIC
SHEET 8
1 2 3 4 5
4 5 6 7 8
X14
WHT 70-4 GND
4
WHT 70-3 TX
3
WHT 70-2 RX
2
ANALYZER PORT
WHT 70-1 PWR
1 G
X16
SHLD
NC
S
WHT 84-1 GLOW PLUGS
R
BLK - TP CAN CABLE
P
RED - TP CAN CABLE
N
WHT 0-42 SN GND
M
WHT 83-1 OIL PRESSURE
L
WHT 0-46 GND
K
WHT 0-43 THROTTLE RTN
J
WHT 81-1 COOLANT TEMP
WHT 82-1 SPEED SN
H TO KUBOTA (SHEET 6 , X16) / GM (SHEET 7, CONNECTOR 1) ENGINE HARNESS
G
WHT 45-3 START
F
WHT 80-1 THROTTLE ACT
E
WHT 82-2 SPEED VCC
D
WHT 85-1 FULL THROTTLE
C
WHT 46-1 ALT EXCITE 16AWG
B
WHT 2-21 IGN 16AWG
Sheet_4-[3,H] A F
X40
A
B
C
TO ESTOP 1B2 1
RED 1-11 B+ 16AWG RED 1-11 B+ 16AWG
TO LOCK - RED D
T362 S368
IP374 S373
WHT 87-1-1 LOCK 16AWG WHT 87-1 LOCK 16AWG
TO KEYSWITCH POS 1 1 TO LOCK - BLUE
T363 S369
IP375
WHT 87-1-2 LOCK 16AWG WHT 87-2-1 LOCK 16AWG
TO KEYSWITCH POS 3 1 TO LOCK - ORANGE
T364 S370
WHT 87-2 LOCK 16AWG WHT 87-2-2 LOCK 16AWG
TO WHT 0-17 IGN GND SIDE S376
TO LOCK - BLACK
S366 S371
WHT 87-3 LOCK 16AWG WHT 87-3 LOCK 16AWG
TO WHT 0-17 IGN GND, IGN RELAY SIDE TO LOCK - ORANGE
S367 S372
WIRE WHT 0-17 IGN GND MUST BE CUT NEAR IGN RELAY
EC210+
BT209+
EC210-
BT209-
1
M
FUEL PUMP
GENERIC
SHEET 8 1001119638-G
4 5 6 7 8
GENERIC GENERIC
LEFT FRONT LEFT REAR
LB391
LB390
2
1
2
1
WHT 51-2-1 LIGHT 16AWG
WHT 0-45-2 GND 16AWG
RL387
CHASSIS LIGHTS
2
85
3
87a RED 1-12 B+ 12AWG
1
30 WHT 51-2 LIGHT 12AWG WHT 51-2 LIGHT 12AWG
4
87 S385
LB392
LB393
2
1
2
1
RIGHT FRONT RIGHT REAR
GENERIC GENERIC
3A
IP396
IP395
BLK 16AWG
BLK 16AWG
LIGHTS
1
2
3
4
LIGHTS_1
1
2
3
4
BLK 16AWG
WHT 16AWG S401
S402
1
YEL/RED 16AWG
2
GENERIC
YEL/RED 16AWG
3
4
5
6
SWITCH
BLK 16AWG
FLOOD_1 FLOOD_2
YEL/RED 16AWG YEL/RED 16AWG
1 1
BLK 16AWG S400 BLK 16AWG
2 2
S399
MASTER CYLINDER
BARREL: 3.0" (75mm)
ROD: 1.3" (32mm) V1 X
STROKE: 11.5" (293mm) V1 V2
P1 P2 V1 V2
V2 V1
J2 J1 R2 R1 V1 V2 M1 L1 L2 M2
JIB ROTATE
MP
T2 T1
UPRIGHT VALVE
V V
P
P
9 2 3
Traction lock
Valve
Brake
valve
23
STEER CYLINDER
BARREL: 2.5" (65mm)
ROD: 1.75"(45mm)
STROKE: 5.5" (139mm)
19 21 20 22 10 11
Front Brakes
A A
RT MOTOR
LF MOTOR FRONT AXLE
B B
REAR BRAKES
A A
REAR AXLE RT MOTOR
LF MOTOR
B B
ORF
LOWER LIFT CYLINDER V2
BARREL: 2.95"(75mm)
ROD: 1.77"(45mm)
STROKE: 29.6" (751.8mm)
X V1
SWING DRIVE
MOTOR D: 2.2 cu in (36cc)
REDUCTION: 170.7:1
B A
MS
P2 M2 P1 M1 T CP
RETURN FILTER
MICRON LEVEL: 6
BYPASS VALVE: 45 PSI
M14
Reverse MA X3
A
C1 C2
1 4 5 8
X M5
Primary oscl axle valve E
M3
F
DRIVE VALVE
Secondary oscl axle valve M4
CHARGE FILTER
MICRON LEVEL: 5
BYPASS VALVE: 43 PSI (3 BAR)
Forward DRIVE
B
PUMP
MB S L1 L2
FUNCTION PUMP
1st Gear: 0.51 cu in (8.4cc) at 1800 RPM, 3.6 GPM
2nd Gear: 0.16 cu in (2.62cc) at 1800 RPM, 1.1 GPM
DRIVE MOTOR
Fixed 12.2 cu in (200CC)
Presurize port A = CW Rotation
Presurize port B = CCW Rotation
DRIVE GEAR BOX
Ratio: 4.25:1
Brake Torque 4300 in/lb
Brake Release 350 PSI (24 BAR)
Output Rotation Opposite Input Rotation
1001120020-C
NOTES:
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI Ltd
Germany Sheung Shui N. T. Italy 29 Tuas Ave 4,
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Jurong Industrial Estate
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 Singapore, 639379
(852) 2639 5797 +65-6591 9030
+65-6591 9031
www.jlg.com