V 1200SJP, 1350SJP JLG Service English

Service and Maintenance Manual
Models
1200SJP
1350SJP
PN - 3121142
April 22, 2019 - Rev V
AS/NZS GB
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
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 personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
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.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
The specific precautions to be observed during maintenance SECURE AT ALL OTHER TIMES.
are inserted at the appropriate point in the manual. These pre-
cautions are, for the most part, those that apply when servic- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
ing hydraulic and larger machine component parts. FORMING ANY MAINTENANCE.
Your safety, and that of others, is the first consideration when • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
engaging in the maintenance of equipment. Always be con- TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
scious of weight. Never attempt to move heavy parts without CAUGHT ON OR ENTANGLED IN EQUIPMENT.
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
equipment, ensure that adequate support is provided. MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

SURFACES AND HAND HOLDS.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL- • USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ITY OF THE OWNER/OPERATOR. ANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

B HYDRAULIC SYSTEM SAFETY BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
It should be noted that the machines hydraulic systems oper- HAS BEEN ENGAGED.
ate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
disconnecting or removing any portion of the system. FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
POWER CONTROLS.
Do not use your hand to check for leaks. Use a piece of card-
board or paper to search for leaks. Wear gloves to help protect • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
hands from spraying fluid. REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

VENTS.
3121142 A-1
INTRODUCTION
REVISON LOG
Original Issue A - June 5, 2002

Revised B - January 15, 2003
Revised C - May 23, 2003
Revised D - August 30, 2004
Revised E - January 12, 2006
Revised F - July 12, 2006
Revised G - November 30, 2006
Revised H - January 18, 2007
Revised I - November 9, 2007
Revised J - April 9, 2008
Revised K - August 27, 2008
Revised L - January 22, 2009
Revised M - October 27, 2011
Revised N - March 28, 2012
Revised O - January 23, 2013
Revised P - July 22, 2014
Revised Q - June 17, 2015
Revised R - November 8, 2016
Revised S - May 23, 2017
Revised T - May 30, 2018
Revised U - June 29, 2018 - Revised Covers
Revised V - April 22, 2019
A-2 3121142
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz Prior to SN 0300127698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz SN 0300127698 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz TCD 2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz TCD 2.9 GUOIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Specifications and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3121142 i
TABLE OF CONTENTS

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do NOT Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Extending Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Axle Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.10 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.11 Wheel Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.12 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.13 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.14 Drive Hub (Prior to SN 100131). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly of Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly of the First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly of Second Stage Planet Gears (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Assembly of First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly of End Cover Unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Initial Start-up And After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.15 Drive Hub - Bonfiglioli (SN 100128 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installation of the Wheel Drive on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Start Up and Running In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Connecting the Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Filling-up the Gearbox with Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Gearbox Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Changing the Lubricating oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Inspection of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Final Test and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
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3.16 Drive Hub - Reggiana Riduttori (SN 134389 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.17 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Roll and Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3.18 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
3.19 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3.20 Procedure For Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.21 Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.22 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3.23 Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3.24 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3.25 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3.26 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3.27 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.28 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3.29 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
Cleaning the Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
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TABLE OF CONTENTS

3.30 Deutz Engine - TD2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Replacing Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Replacing the Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Replacing the Primary Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Replacing the Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Water in Fuel Sensing System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Draining Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Auxiliary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.31 Deutz TD2011 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3.32 Deutz 2.9 L4 (Guo Iii) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3.33 Deutz 2.9l4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3.34 Deutz EMR 2 (SN 87579 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3.35 Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
3.36 Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Platform Control Enable System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jib Stow System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Envelope Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Controlled Arc System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Controlled Boom Angle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Slow Down System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Dual Capacity System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Control Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3 Boom Removal, Disassembly/Assembly, & Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.4 Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.5 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.6 Boom Shimming Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.7 Jib Rotator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4.8 Jib Lift End of Stroke Dampening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4.9 Load Sensing Pin Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4.10 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
One Piece Bracket Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Two Piece Bracket Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
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4.11 Hose Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.12 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Additional Inspection Required If:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
12 Year or 7000 Hour Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Additional Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.13 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Boom Section Re-Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.14 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4.15 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4.16 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Testing the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Bleeding After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
4.17 Bolt-on External Fall Arrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4.18 Skyguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Connection Assembly and Torque Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tapered Thread Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Tube and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Flange Connection Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Assembly And Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections. . . . . . . . . 5-6
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections . . . . . . . . . . . . 5-7
Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . . . . . . . . . . . . . . . . . . . . 5-16
Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends . . . . . . . . . . . . . . . . . . . . . . 5-38
Assembly instructions for Adjustable Port End (BSPP) Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
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FFWR and TFFT Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5.3 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Cleaning And Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.4 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5.5 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Set Up of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Adjustments made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Adjustments Made at the Platform Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5.6 Drive Pumps (Rexroth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5.7 Function Pump (Rexroth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Sealing the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Disassembly and Assembly of the Complete Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
Tightening Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
Pump Control Disassembly For Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.8 Drive Pumps (SAUER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
Port Locations and Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
Initial Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
Removing The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Electric Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
Shaft, Seal, and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125
Charge Check / HPRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
Control Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
5.9 Function Pump (SAUER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5.10 Gear pump (Sauer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144
Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5.11 Drive & Function Pump Start Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
5.12 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
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SECTION 6 - JLG CONTROL SYSTEM
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.5 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.6 Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.7 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.8 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.9 Machine Personality Settings/Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.10 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.11 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.12 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6.13 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6.14 LSS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6.15 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6.16 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Platform Leveling Fault Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Fault Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
CAN Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Additional Platform and Jib Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Platform Leveling Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
6.17 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Step 1: Setting The Platform Valve Minimums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Step 2: Calibrating The Platform Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Step 3: Bleeding The Platform Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Step 4: Calibrating The Platform Level Up And Down Valve Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6.18 Calibrating Lift Crack Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
6.19 Calibrating Telescope Crack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
6.20 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6.21 Calibrating the Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Boom Control System Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
6.22 CANbus Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142
CANbus Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Load Moment Pin Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-162
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SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Brad Harrison/phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Control Unit Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Sealed Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
MIL-C-5015 Spec Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
MOLEX CMC Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.6 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Telematics-Ready (TCU) Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.7 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
viii 3121142
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Lubrication and Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Axle Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Conventional Two Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Coordinated Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-5. Chassis Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Chassis Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-7. Turntable and Boom Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-8. Turntable and Boom Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-9. Axle Installation - Oscillating (SN 0300196322 through 0300207700) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 3-10
3-10. Axle Installation - Oscillating (SN 0300196322 through 0300207700) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 3-11
3-11. Axle Installation - Oscillating (SN 0300207701 to Present, SN B300002238 to Present) - Sheet 1 of 2 . . . 3-12
3-12. Axle Installation - Oscillating (SN 0300207701 to Present, SN B300002238 to Present) - Sheet 2 of 2 . . . 3-13
3-13. Axle Installation - Fixed (SN 0300201016 through SN 0300207700) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . 3-14
3-14. Axle Installation - Fixed (SN 0300201016 through SN 0300207700) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . 3-15
3-15. Axle Installation - Fixed (SN 0300207701 to Present, SN B30002238 to Present) - Sheet 1 of 2 . . . . . . . . . 3-16
3-16. Axle Installation - Fixed (SN 0300207701 to Present, SN B30002238 to Present) - Sheet 2 of 2 . . . . . . . . . 3-17
3-17. Axle Loctite Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-18. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-19. Wheel Drive Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-20. Drive Hub Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-21. Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-22. Drive Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-23. Drive Hub - Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-24. Drive Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-25. Drive Hub Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-26. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-27. Gearbox engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-28. Gearbox Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-29. Drive Hub S/N 100128 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-30. Drive Hub Special Tools - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-34. Bearing Track Spacer Mounting C016117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-35. Oil Seal Spacer Mounting C125049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-36. Bearing Spacer Mountng CO16117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-37. Assembly Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-38. Wrench For Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-39. Anti-rotation Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-40. Anti-rotation Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-41. Anti-rotation Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-42. Assembly Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3-43. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-44. Reggiana Riduttori Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-45. Reggiana Riduttori Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-46. Swing System (SN 0300201016 through 0300254466, SN B300002238 to Present) . . . . . . . . . . . . . . . . . . . . 3-74
3-47. Swing System SN 0300254467 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3-48. Swing Drive - Motor Control Valve Disassembly
(SN 0300201016 through 0300254466, SN B300002238 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3121142 ix
LIST OF FIGURES

3-49. Swing Drive - Motor and Brake Disassembly
(SN 0300201016 through 0300254466, SN B300002238 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3-50. Swing Drive - Main Disassembly
3-51. Swing Drive - Hub Shaft Disassembly
3-52. Swing Drive - Carrier Disassembly
3-53. Swing Motor (SN 0300254467 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
3-54. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3-55. Swing Brake 8 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3-56. Swing Brake 12 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3-57. Swing Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3-58. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3-59. Swing Drive Ports (SN 0300201016 through 0300254466, SN B300002238 to Present) . . . . . . . . . . . . . . . . 3-108
3-60. Swing Drive Ports (SN0300254467 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3-61. Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3-62. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
3-63. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3-64. Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
3-65. Swing Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
3-66. Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-67. Rotary Coupling Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3-68. Rotary Coupling Cutaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3-69. Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3-70. Rotary Coupling Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3-71. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
3-72. Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3-73. Cold Weather Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3-75. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3-77. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3-78. Location of the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3-79. Location of the Primary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3-80. Location of Fuel Pre-Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3-81. Components of Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3-82. Components of Auxiliary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3-83. Detuz TD2011 L040 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-84. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3-85. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
3-86. Detuz TCD2.9L4 Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3-87. Detuz TCD2.9L4 Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139
3-88. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
3-89. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
3-90. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
3-91. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3-92. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
3-93. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3-94. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
3-95. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
x 3121142
LIST OF FIGURES

4-1. Boom Assembly - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-8. Boom Assembly Torque Values - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-9. Boom Assembly Torque Values - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4-10. Locations for Threadlocker Application - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4-14. Platform Rotator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4-15. Measuring Boom Section Sweep. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4-16. Jib Rotator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-17. Load Pin Removal Tool, JLG PN 4846765 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4-18. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4-26. Boom Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4-27. Pivot Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-28. Powertrack Installation - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4-34. Torque Sequence for Fly Extend Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-35. Wire Rope Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4-36. Outer Mid Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-37. Fly Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4-38. Wire Rope Adjustment Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4-39. Broken Boom Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-40. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4-41. Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4-42. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
4-43. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
4-44. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4-45. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
5-1. NPTF Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. BSPT Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3. JIC Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-4. SAE Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-5. ORFS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-6. MTBL-MBTS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-7. Bulkhead Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-8. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-9. MFF-BSPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-10. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-11. Torque Wrench Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-12. Double Wrench Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
3121142 xi
LIST OF FIGURES

5-13. FFWR Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-14. Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-15. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-16. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-17. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-18. Axle Extension Cylinder (SN 0300196322 through 0300238565,
SN B300002238 through B300002404, SN 0300238566 to Present, SN B300002405 to Present) . . . . . . . . 5-55
5-19. Axle Lockout Cylinder
(SN 0300207701 through 0300239161, SN B300002238 through B300002449). . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-20. Axle Lockout Cylinder (SN 0300239162 to Present, SN B300002450 to Present) . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-21. Level Cylinder (Without Cold Weather Plus Package - SN 0300201016 through 0300239161,
SN B300002238 through B300002449) and (With Cold Weather Plus Package -
SN 0300201016 through 0300239980) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-22. Level Cylinder (Without Cold Weather Plus Package - SN 0300239162 to Present,
SN B300002450 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-23. Lift Cylinder (SN 0300201016 through 0300239470, SN B300002238 through B300002473) . . . . . . . . . . . 5-60
5-24. Lift Cylinder (SN 0300239471 to Present, SN B300002474 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-25. Jib Cylinder (SN 0300201016 through 0300239161, SN B300002238 through B300002449). . . . . . . . . . . . 5-62
5-26. Jib Cylinder (SN 0300239162 to Present, SN B300002450 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-27. Telescope Cylinder(1200SJP - SN 0300201016 through 0300243437,
SN B300002238 through B300002718) and (1350SJP - SN 0300201016 through 0300243473,
SN B300002238 through B300002646)B300002646) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5-28. Telescope Cylinder -1200SJP (SN 0300243438 to Present, SN B300002719 to Present)
and 1350SJP (SN 0300243474 to Present, SN B300002647 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-30. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-31. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-32. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-33. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-34. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-35. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-36. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-37. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-38. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-39. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-40. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-41. Cylinder cap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-42. Cylinder cap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-43. Steer Cylinder (Prior to S/N 0300073367) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5-44. Steer Cylinder (SN 0300073367 through 0300238011, SN B300002238 through B300002376) . . . . . . . . . 5-73
5-45. Steer Cylinder (SN 0300238012 to Present, SN B300002377 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
5-47. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-48. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-49. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-50. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-51. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-52. Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5-53. Chassis Control Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5-54. Platform Valve Identification - JLG PN 4641266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-55. Platform Valve Identification - JLG PN 4641460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5-56. Main Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-57. Main Valve Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-58. Main Valve Plug Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5-59. Hydraulic Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-60. Steer Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-61. Function Pump - Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
xii 3121142
LIST OF FIGURES

5-62. Function Pump, Pressure and Flow Control - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5-65. Piston Pump Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-66. Port locations - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-67. Port locations - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5-68. Charge Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
5-69. Control Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-119
5-70. Servo and System Pressure Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
5-71. Control Module And Solenoid Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
5-72. Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5-73. Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
5-74. Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
5-75. Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
5-76. Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
5-77. Control Cutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
5-78. Fastener and Plug Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131
5-79. Hydraulic Schematic - Boom Functions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
5-80. Hydraulic Schematic - Boom Functions - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5-81. Hydraulic Schematic - Axle/Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-156
5-82. Hydraulic Schematic - Axle/Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5-83. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158
5-84. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-159
5-85. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-160
5-86. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-161
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Control System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-4. Analyzer Flow Chart - Personalities (Software Version 7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6. Analyzer Flow Chart - Calibrations (Software Version 7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.29) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-10. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-11. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-12. Platform Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-13. Ground control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-14. BLAM Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-15. System Test Flow Chart - Platform Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-16. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6-17. Boom Sensor Calibration Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6-26. Boom Sensor Calibration Position 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
6-27. Fault Code Light Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
6-28. CANbus Connections Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142
3121142 xiii
LIST OF FIGURES

6-29. CANbus Connections - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
6-34. CANbus Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148
6-35. Moment Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Applying Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7. Application to plug/male connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-8. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9. AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10. DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-11. Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-12. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-13. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-16. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-17. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-18. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-19. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-20. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-21. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-22. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-23. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-24. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-27. Chassis Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-28. Chassis Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-29. Turntable Electrical Components - Prior to S/N 87579 - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-30. Turntable Electrical Components - Prior to S/N 87579 - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-31. Turntable Electrical Components - SN 87579 to Present - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-32. Turntable Electrical Components - SN 87579 to Present - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-33. Electrical Schematic - Deutz EMR2 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
xiv 3121142
LIST OF FIGURES

7-39. Electrical Schematic - Sheet 1 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7-48. Electrical Schematic - Sheet 10 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
3121142 xv
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Deutz TCD 2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-6 Deutz TCD 2.9L4 GUOIII Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Reach Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-10 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Mobil DTE 10 Excel 32 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-15 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-16 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-17 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-18 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-19 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Steering Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-3 Brake Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-4 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade . . . . . . . . . . . . . . . . . . . . . . 3-33
3-5 Drive Hub Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7 Coupling Port Information Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3-8 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
4-1 Hose/Cable Pull Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-2 Hose/Cable Pull Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-3 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
5-1 NPTF Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-2 BSPT Pipe Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-3 37° Flare (JIC)Thread - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 37° Flare (JIC)Thread - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 45° Flare (SAE) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6 45° Flare (SAE) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 O-ring Face Seal (ORFS) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-8 O-ring Face Seal (ORFS) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-9 DIN 24°Cone (MBTL & MBTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-10 Bulkhead Fittings (BH) - INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-11 Bulkhead Fittings (BH) - METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-12 O-ring Boss (ORB) - Table 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-24 Metric Pipe Parallel O-Ring Boss (MPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
xvi 3121142
LIST OF TABLES

5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-33 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-34 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-35 Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-36 Plug Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5-37 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5-38 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-39 Port information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-40 Electrical troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-41 Neutral difficult or impossible to find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-42 System operating hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-43 System will not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5-44 System noise or vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5-45 Sluggish system response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5-46 Displacement Limiter Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-119
5-47 Fastener Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
5-48 Plug Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
5-49 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
6-1 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2 Machine Configuration Programming Information - Version P7.29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-3 Machine Configuration Programming Settings - Version P7.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-4 Machine Configuration Programming Settings - Version P7.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-5 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-7 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
6-9 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6-10 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
6-11 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
6-12 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6-13 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
6-14 Troubleshooting: Platform Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
6-15 Troubleshooting: BLAM Can Communications Lost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157
6-16 Troubleshooting: Chassis Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-161
6-17 Load Moment Pin Troubleshooting: Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-162
6-18 Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range . . . . . . . . . . . . . . . . . . . . . 6-163
6-19 Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range . . . . . . . . . . . . . . . . . . . . . . . . 6-164
6-20 Load Moment Pin Troubleshooting: Moment Pin Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165
6-21 Load Moment Pin Troubleshooting: New Moment Pin Detected Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165
3121142 xvii
LIST OF TABLES
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xviii 3121142
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES Deutz SN 0300127698 to Present

Table 1-1. Capacities Table 1-4. Deutz TD2011L4 Specifications
Hydraulic Tank 55 gallons (208 liters) Type Liquid Cooled

Fuel Tank Number of Cylinders 4
Standard 31 gallons (117 liters) Bore 3.7 in. (94 mm)
Optional 52.8 gallons (200 liters)
Stroke 4.4 in. (112 mm)
Hydraulic System 66 gallons (250 liters)
Total Displacement 190 cu. in. (3108 cm³)
Compression Ratio 17.5
1.2 TIRES Firing Order 1-3-4-2
Table 1-2. Tire Specifications Output 75 hp (56 kW)
Oil Capacity
Size 445/50D710 Cooling System 5 Quarts (4.5 L)
Load Range J w/Filter 11 Quarts (10.5 L)
Ply Rating 18 Total Capacity 16 Quarts (15 L)
Load Rating 26,500 lbs. @ 100 psi (12020 kg @ 6.9 Bar) Average Fuel Consumption 1.1 gph (4.1 lph)
Foam Fill Poly urethane HD (55 Durometer) Foam Idle Engine RPM 1200
Max Tire Load Mid Engine RPM 1800
1200SJP 25,000 lbs. (11,340 kg) High Engine RPM 2475
1350SJP 26,250 lbs. (11,907 kg)
Max Tire Load (Non-Marking Tire)
@6 km/h 33,000 lbs. (15,000 kg) Deutz TCD 2.9
@10km/h 29,700 lbs. (13,500 kg) Table 1-5. Deutz TCD 2.9L4 Specifications
@25km/h 25,300 lbs. (11,500 kg)
Type Liquid Cooled
Output Power 74.2hp (55.4 kW)
1.3 ENGINE DATA Output Torque 192 ft.lbs. (260 Nm) @ 1800 rpm
Max High Engine RPM 2500
Deutz Prior to SN 0300127698
Min Low Engine RPM 900
Table 1-3. Deutz BF4M2011 Specifications
High RPM set 2500 ±50 RPM
Type Liquid Cooled Low RPM set 1200 ± 50 RPM
Number of Cylinders 4 Engine Oil Capacity 2.4 gal. (8.9 L)
Bore 3.7 in. (94 mm) Coolant Capacity (Engine Only) 0.79 gal. (3 L)
Stroke 4.4 in. (112 mm) Average Fuel Consumption 1.2 gph (4.1 lph)
Total Displacement 190 cu. in. (3108 cm³) Acceptable Fuel Grades Ultra Low Sulfur (15 ppm)
Compression Ratio 17.5 (Dependent upon Regulated Area) Up to 5% Biodiesel
Firing Order 1-3-4-2
Output 87 hp (65 kW)
Oil Capacity
Cooling System 5 Quarts (4.5 L)
w/Filter 11 Quarts (10.5 L)
Total Capacity 16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475
3121142 1-1
Deutz TCD 2.9 GUOIII Dimensional Data

Table 1-6. Deutz TCD 2.9L4 GUOIII Specifications
Table 1-8. Dimensional Data
Type Liquid Cooled
Overall Width
Output Power 74.2 hp (55.4 kW) Axles Retracted 8 ft. 2 in. (2.49 m)
Output Torque 192 ft.lbs. (260 Nm) @ 1800 rpm Axles Extended 12 ft. 6 in. (3.8 m)
Max High Engine RPM 2600 Stowed Height 10 ft. (3.04 m)
Min Low Engine RPM 900 Stowed Length (Transport Mode)
High RPM set 2500 ±50 RPM 1200SJP 34 ft. 11in. (10.64 m)
1350SJP 38 ft. 11in. (11.86 m)
Low RPM set 1200 ± 50 RPM
Stowed Length (Working Mode)
Engine Oil Capacity 2.11 gal. (8.0 L)
1200SJP 44 ft. 11in. (13.69 m)
Coolant Capacity (Engine Only) 0.9 2 gal. (3.5 L) 1350SJP 48 ft. 11in. (14.91 m)
Average Fuel Consumption 1.2 gph (4.1 lph) Wheelbase 12 ft. 6 in. (3.81 m)
Acceptable Fuel Grades Ultra Low Sulfur (15 ppm) Tailswing 5 ft. 6 in. (1.6 m)
(Dependent upon Regulated Area) Up to 5% Biodiesel
Ground Clearance (Axle) 12 in. (30.4 cm)
Ground Clearance (Chassis) 25.5 in. (64.7 cm)
1.4 SPECIFICATIONS AND PERFORMANCE DATA

Chassis
Table 1-9. Chassis Specifications
Reach Specifications
Maximum Travel Grade With boom in stowed 45%
Table 1-7. Reach Specifications position (Gradeability)
Maximum Travel Grade With boom in stowed 5°
Maximum Work Load (Capacity) position (Side Slope)
Unrestricted 500 lb (230 kg)
Restricted 1000 lb (450 kg) Turning Radius (Axles Retracted)
Outside 22 ft. 6 in. (6.8 m)
Max.Vertical Platform Height (Unrestricted) Inside 14 ft. 5 in. (4.4 m)
1200SJP 120 ft. 6 in. (36.73 m)
1350SJP 135 ft. 6 in. (41.3 m) Turning Radius (Axles Extended)
Inside 8 ft. (2.4 m)
Max.Vertical Platform Height (Restricted) Outside 19 ft. 4 in. (5.9 m)
1200SJP 115 ft. 8 in. (35.26 m)
1350SJP 125 ft. 10 in. (38.35 m) Max Tire Load
1200SJP 25,000 lbs. (11,340 kg)
Max.Horizontal Platform Reach (Unrestricted) 1350SJP 26,250 lbs. (11,907 kg)
1200SJP 75 ft. (22.9 m)
1350SJP 80 ft. (24.4 m) Max Ground Bearing Pressure
1200SJP 100 psi (7.03 kg/cm2)
Max.Horizontal Platform Reach (Restricted) 1350SJP
1200SJP 65 ft. (19.8 m) 105 psi (7.38 kg/cm2)
1350SJP 70 ft. (21.3 m) Maximum Drive Speed 3.25 mph (5.2 kph)
JibPLUS Max. Hydraulic System Pressure 4600 psi (317 bar)
Length 8 ft. (2.44m) Maximum Wind Speed 28 mph (12.5 m/s)
Horizontal Motion 180° working, 244°
stowed Maximum Manual Force 400 N
Vertical Motion 130° (+75/-55) Electrical System Voltage 12 Volts
Gross Machine Weight (Platform Empty)
1200SJP 41,100 lb (18,650 kg)
1350SJP 44,750 lb (20,300 kg)
1-2 3121142
1.5 TORQUE REQUIREMENTS

Table 1-12. Mobilfluid 424 Specs
Table 1-10. Torque Requirements
SAE Grade 10W30
Description Torque Value (Dry) Interval Hours Gravity, API 29.0
Density, Lb/Gal. 60°F 7.35
Wheel Bolts 180 ft. lbs. 150
Pour Point, Max -46°F (-43°C)
(252 Nm)
Flash Point, Min. 442°F (228°C)
Swing Bearing Bolts 190 ft. lbs. 50/600* Viscosity
(258 Nm)
Brookfield, at -18°C 2700 cP
Tele Cylinder 13 ft. lbs. As required at 40° C 55 cSt
Regen Valve Mounting Bolts (18 Nm) at 100° C 9.3 cSt
Starter Solenoid Viscosity Index 152
Contacts 95 in. lbs. (9.5 Nm) As required
Coil 40 in. lbs. (4 Nm) Table 1-13. Mobil DTE 10 Excel 32 Specs
*Check swing bearing bolts for security after first 50 hours of operation and every 600 ISO Viscosity Grade #32
hours thereafter. (See Swing Bearing in Section 3.)
Specific Gravity 0.877
NOTE: When maintenance becomes necessary or a fastener has Pour Point, Max -65.2°F (-54°C)
loosened, refer to the Torque Chart to determine proper
Flash Point, Min. 482°F (250°C)
torque value.
Viscosity
at 40° C 32cSt
1.6 HYDRAULIC OIL at 100° C 6.6 cSt
Table 1-11. Hydraulic Oil Specifications
at 100° F 32.7 cSt
Hydraulic System at 212° F 6.63 cSt
S.A.E. Viscosity
Operating at -30° F 6,200 cp
Grade
Temperature Range
Viscosity Index 164
+0° to + 180° F 10W
(-18° to +83° C)
Table 1-14. UCon Hydrolube HP-5046
+0° to + 210° F 10W-20, 10W30
(-18° to +99° C) Type Synthetic Biodegradable
+50° to + 210° F 20W-20 Specific Gravity 1.082
(+10° to +99° C)
Pour Point, Max -58°F (-50°C)
pH 9.1
NOTE: Hydraulic oils must have anti-wear qualities at least to API Viscosity
Service Classification GL-3, and sufficient chemical stabil-
at 0° C (32° F) 340 cSt (1600SUS)
ity for mobile hydraulic system service. JLG Industries rec-
ommends Mobilfluid 424 hydraulic oil, which has an SAE at 40° C (104° F) 46 cSt (215SUS)
viscosity index of 152. at 65° C (150° F) 22 cSt (106SUS)
Viscosity Index 170
NOTE: When temperatures remain consistently below 20 degrees
F. (-7 degrees C.), JLG Industries recommends the use of
Mobil DTE13.
NOTE: Aside from JLG recommendations, it is not advisable to mix

oils of different brands or types, as they may not contain
the same required additives or be of comparable viscosi-
ties.
3121142 1-3
1.7 MAJOR COMPONENT WEIGHTS

Table 1-15. Mobil EAL H 46 Specs
Type Synthetic Biodegradable Table 1-17. Component Weights
ISO Viscosity Grade 46 Component Pounds Kilograms

Specific Gravity .910 Tire & Wheel (Foam Filled) 867 393
Pour Point -49°F (-45°C) Tire & Wheel (Solid) 990 449
Flash Point 500°F (260°C) Drive Hub & Motor 275.5 123
Operating Temp. -20 to 200°F (-29 to 93°C) Swing Drive 290 132
Weight 7.64 lb. per gal. Engine Assembly 1275 579
(0.9 kg per liter) 1350 Boom (Complete) 11850 5375
Viscosity 1200 Boom (Complete) 11100 5035
at 40° C 45 cSt Lift Cylinder 787 357
at 100° C 8.0 cSt 1350 Tele Cylinder 1322 600
Viscosity Index 153 1200 Tele Cylinder 1170 531
Jib Cylinder 69 31
Table 1-16. Exxon Univis HVI 26 Specs Axle Oscillation Cylinder 74 34
Specific Gravity 32.1 Axle Extend Cylinder 92 42
Pour Point -76°F (-60°C) Level Cylinder 89 40
Flash Point 217°F (103°C) Platform 36 x 96 245 111
Viscosity Platform 36 x 72 195 89
at 40° C 25.8 cSt 1350 Counterweight 8500 3856
at 100° C 9.3 cSt 1200 Counterweight 5494 2492
Viscosity Index 376 T/T Assy. (less Cwt) 9450 4286
NOTE: Mobil/Exxon recommends that this oil be checked on
a yearly basis for viscosity.
1-4 3121142
1.8 PRESSURE SETTINGS

Table 1-18. Pressure Settings
Circuit PSI Bar
Function Pump, High 3400 234.4
Function Pump, Low 300 20.6
Drive, Pre-Set 5000 344.7
Lift Up 2750 189.6
Lift Down 1500 103.4
Swing 1500 103.4
Tele Out 3000 206.8
Telescope In 3200 220.6
Steer Right 2000 137.9
Steer Left 2600 172.3
Platform Level Up 2500 172.3
Platform Level Down 1500 103.4
Jib Up 2750 189.6
Jib Down 2750 189.6
Extendable Axles 2500 172.3
3121142 1-5
12
15
18
16
14 9B
5 4
10,11
7
8 13 9A
1
2,3
4 4
17
Figure 1-1. Lubrication and Maintenance Diagram
1-6 3121142
1.9 LUBRICATION AND MAINTENANCE 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1., a. Swing Gearbox (SN 0300201016 through
Lubrication and Maintenance Diagram. 0300254466, SN B300002238 to Present)
Table 1-19. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/
CD class, MIL-L-2104B/MIL-L-2104C.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ b. Swing Gearbox (SN 0300254467 to Present)
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
NOTE: It is recommended as a good practice to replace all filters at

the same time.
1. Swing Bearing - Remote Lube
Lube Point(s) - 2 Grease Fitting

Capacity - A/R
Lube - MPG MAE36090
Interval - Every 3 months or 150 hours of operation.

Lube Point(s) - Fill Plug
Capacity - 79 ounces (2.3 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.
3121142 1-7
3. Swing Brake NOTE: After S/N 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs.
a. Swing Brake (SN 0300201016 through 0300254466,
SN B300002238 to Present)
4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128)
Lube Point(s) - Level/Fill Plug

Capacity - 0.5 liters (1/2 full)
Lube - EPGL
Interval - Change after first 150 hours then every 1200
hours of operation
b. Swing Brake (SN 0300254467 to Present)
Comments - Place Fill port at 12 o’clock position and
Check port at 3 o’clock position. Pour lubricant into fill
port until it just starts to flow out of check port.
B: Wheel Drive Hub - Bonfiglioli (S/N 100131 to Present)

Capacity - 2.1 quarts (2 liters) ± 10%
Lube - EPGL
MAE36100 hours of operation
Lube Point(s) - Fill Plug Check port at 8 o’clock position. Pour lubricant into fill
Capacity - 2.7 ounces (80 ml) port until it just starts to flow out of check port.
Lube - DTE24
Interval - Check level every 150 hrs/Change every 1200
hours of operation.
1-8 3121142
C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to 7. Hydraulic Oil

Present)
FULL LEVEL (HOT OIL)
FULL LEVEL (COLD OIL)

Capacity - 0.5 quarts (0.5 liters) ± 10%
Lube - EPGL
hours of operation
Lube Point(s) - Fill Cap
Capacity - 55 gallons (208 liters) Tank
Check port at 3 o’clock position. Pour lubricant into fill
Lube - HO
port until it just starts to flow out of check port.
Interval - Check level daily. Change every 2 years or 1200
5. Hydraulic Return Filter hours of operation.
8. Suction Strainers (In Tank)
Lube Point(s) - Replaceable Element

Interval - Change after first 50 hours and every 300
hours thereafter or as indicated by condition indicator.
6. Hydraulic Charge Filter
Lube Point(s) - Replaceable Element Lube Point(s) - 2
Interval - Change after first 50 hours and every 300 Interval - Every 2 years or 1200 hours of operation.
hours thereafter or as indicated by condition indicator. Remove and clean at time of hydraulic oil change.
3121142 1-9
9. A. Oil Change w/Filter - Deutz 2011
MINIMUM OIL
LEVEL
MAXIMUM OIL
LEVEL
MINIMUM LEVEL,
OIL HOT
MAXIMUM LEVEL,
Lube Point(s) - Fill Cap/Spin-on Element OIL HOT
Capacity -
5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
MINIMUM LEVEL,
16 Quarts (15 L) Total Capacity OIL COLD
MAXIMUM LEVEL,
Lube - EO OIL COLD
Interval - Check level daily; change every 500 hours or
six months, whichever comes first. Adjust final oil level NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.
by mark on dipstick.
B. Oil Change w/Filter - Deutz TCD2.9 Figure 1-2. Deutz Engine Dipstick
10. A. Fuel Filter - Deutz 2011
Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.4 Gallon (8.9 L)
Lube - EO
Interval - Every year or 600 hours of operation.
six months, whichever comes first. Adjust final oil level
by mark on dipstick.
1-10 3121142
B. Fuel Filter - Deutz TCD2.9 12. Fuel Pre-Filter TCD2.9

Interval - Drain water daily; Change every year or 600
hours of operation.
Lube Point(s) - Replaceable Element 13. Radiator Coolant TCD2.9

11. Fuel Strainer - Deutz 2011
Lube Point(s) - Fill Cap

Capacity - 3.2Gallon (12.1 L)
Lube - Anti-Freeze
2 years, whichever comes first.

3121142 1-11
14. A. Air Filter - Deutz 2011 15. Platform Filter
Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or as Interval - Change after first 50 hours and then every year
indicated by the condition indicator. or 600 hours of operation thereafter.
B. Air Filter - Deutz TCD2.9 16. Optional Fuel Filter/Water Separator

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check Dust Valve daily.
Interval - Drain water daily; Change every year or 600
hours of operation.
1-12 3121142
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
3121142 1-13
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
1-14 3121142
Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
3121142 1-15
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
1-16 3121142
To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
3121142 1-17
NOTES:
1-18 3121142
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventative Maintenance Schedule
MAINTENANCE for items requiring inspection during the performance of
these inspections. Reference the appropriate areas of this
General manual for servicing and maintenance procedures.
This section provides the necessary information needed by
those personnel that are responsible to place the machine in Annual Machine Inspection
operation readiness and maintain its safe operating condition.
The Annual Machine Inspection must be performed on an
For maximum service life and safe operation, ensure that all
annual basis, no later than thirteen (13) months from the date
the necessary inspections and maintenance have been com-
pleted before placing the machine into service. With proper of the prior Annual Machine Inspection. JLG Industries recom-
care, maintenance, and inspections performed per JLG's rec- mends this task be performed by a Factory-Trained Service
ommendations, and with any and all discrepancies corrected, Technician. JLG Industries, Inc. recognizes a Factory-Trained
this product will be fit for continued use. Service Technician as a person who has successfully com-
pleted the JLG Service Training School for the subject JLG
product model. Reference the machine Service and Mainte-
Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor-
It is important to establish and conform to a comprehensive mance of this inspection.
inspection and preventive maintenance program. The follow-
ing table outlines the periodic machine inspections and main- Reference the JLG Annual Machine Inspection Form and the
tenance recommended by JLG Industries, Inc. Consult your Inspection and Preventative Maintenance Schedule for items
national, regional, or local regulations for further requirements requiring inspection during the performance of this inspec-
for aerial work platforms. The frequency of inspections and tion. Reference the appropriate areas of this manual for servic-
maintenance must be increased as environment, severity and ing and maintenance procedures.
frequency of usage requires.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
Pre-Start Inspection information for each machine. When performing each Annual
It is the User’s or Operator’s primary responsibility to perform a Machine Inspection, notify JLG Industries, Inc. of the current
Pre-Start Inspection of the machine prior to use daily or at machine ownership.
each change of operator. Reference the Operator’s and Safety
Manual for completion procedures for the Pre-Start Inspec-
tion. The Operator and Safety Manual must be read in its Preventative Maintenance
entirety and understood prior to performing the Pre-Start In conjunction with the specified inspections, maintenance
Inspection. shall be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
Pre-Delivery Inspection and Frequent Inspection mechanic as a person who, by possession of a recognized
degree, certificate, extensive knowledge, training, or experi-
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus- ence, has successfully demonstrated the ability and profi-
tries, Inc. recognizes a qualified JLG equipment mechanic as a ciency to service, repair, and maintain the subject JLG product
person who, by possession of a recognized degree, certificate, model.
extensive knowledge, training, or experience, has successfully
Reference the Preventative Maintenance Schedule and the
demonstrated the ability and proficiency to service, repair, and
appropriate areas of this manual for servicing and mainte-
maintain the subject JLG product model.
nance procedures. The frequency of service and maintenance
The Pre-Delivery Inspection and Frequent Inspection proce- must be increased as environment, severity and frequency of
dures are performed in the same manner, but at different usage requires.
times. The Pre-Delivery Inspection shall be performed prior to
each sale, lease, or rental delivery. The Frequent Inspection
shall be accomplished for each machine in service 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 environ-
ment, severity and frequency of usage requires.
3121142 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
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 Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory Trained Service Service and Maintenance Manual
tion the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventive At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 3. Clean and inspect all parts during servicing or mainte-
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
General sure all parts are clean before they are installed. New
parts should remain in their containers until they are
The following information is provided to assist you in the use ready to be used.
and application of servicing and maintenance procedures
contained in this book.
Components Removal and Installation
1. Use adjustable lifting devices, whenever possible, if
Safety and Workmanship mechanical assistance is required. All slings (chains,
Your safety, and that of others, is the first consideration when cables, etc.) should be parallel to each other and as near
engaging in the maintenance of equipment. Always be con- perpendicular as possible to top of part being lifted.
scious of weight. Never attempt to move heavy parts without 2. Should it be necessary to remove a component on an
the aid of a mechanical device. Do not allow heavy objects to angle, keep in mind that the capacity of an eyebolt or
rest in an unstable position. When raising a portion of the similar bracket lessens, as the angle between the sup-
equipment, ensure that adequate support is provided. porting structure and the component becomes less
than 90 degrees.
Cleanliness 3. If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
1. The most important single item in preserving the long and that no adjacent parts are interfering.
service life of a machine is to keep dirt and foreign mate-
rials out of the vital components. Precautions have been
taken to safeguard against this. Shields, covers, seals,
and filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a
scheduled basis in order to function properly.
2. At any time when air, fuel, or oil lines are disconnected,

clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
nected, cap or cover all openings to prevent entry of for-
eign matter.
2-2 3121142
SECTION 2 - GENERAL
Component Disassembly and Reassembly Bolt Usage and Torque Application

When disassembling or reassembling a component, complete
the procedural steps in sequence. Do not partially disassemble
or assemble one part, then start on another. Always recheck
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
your work to assure that nothing has been overlooked. Do not
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
make any adjustments, other than those recommended, with-
out obtaining proper approval.
1. Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If
Pressure-Fit Parts a bolt is too short, there will not be enough thread area
When assembling pressure-fit parts, use an anti-seize or to engage and hold the part properly. When replacing
molybdenum disulfide base compound to lubricate the mat- bolts, use only those having the same specifications of
ing surface. the original, or one which is equivalent.
2. Unless specific torque requirements are given within the
Bearings text, standard torque values should be used on heat-
treated bolts, studs, and steel nuts, in accordance with
1. When a bearing is removed, cover it to keep out dirt and
recommended shop practices. (See Torque Chart Sec-
abrasives. Clean bearings in nonflammable cleaning sol-
tion 1.)
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing.
Hydraulic Lines and Electrical Wiring
2. Discard bearings if the races and balls (or rollers) are pit-
Clearly mark or tag hydraulic lines and electrical wiring, as well
ted, scored, or burned.
as their receptacles, when disconnecting or removing them
3. If bearing is found to be serviceable, apply a light coat of from the unit. This will assure that they are correctly rein-
oil and wrap it in clean (waxed) paper. Do not unwrap stalled.
reusable or new bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before Hydraulic System
installation. When pressing a bearing into a retainer or 1. Keep the system clean. If evidence of metal or rubber
bore, apply pressure to the outer race. If the bearing is to particles are found in the hydraulic system, drain and
be installed on a shaft, apply pressure to the inner race. flush the entire system.
Gaskets 2. Disassemble and reassemble parts on clean work sur-

face. Clean all metal parts with non-flammable cleaning
Check that holes in gaskets align with openings in the mating
solvent. Lubricate components, as required, to aid
parts. If it becomes necessary to hand-fabricate a gasket, use
assembly.
gasket material or stock of equivalent material and thickness.
Be sure to cut holes in the right location, as blank gaskets can
cause serious system damage.
3121142 2-3
SECTION 2 - GENERAL
Lubrication Hydraulic Oil

Service applicable components with the amount, type, and
1. Refer to Section 1 for recommendations for viscosity
grade of lubricant recommended in this manual, at the speci-
ranges.
fied intervals. When recommended lubricants are not avail-
able, consult your local supplier for an equivalent that meets 2. JLG recommends Mobilfluid 424 hydraulic oil, which has
or exceeds the specifications listed. an SAE viscosity of 10W-30 and a viscosity index of 152.
Battery NOTE: Start-up of hydraulic system with oil temperatures below -

15 degrees F (-26 degrees C) is not recommended. If it is
Clean battery, using a non-metallic brush and a solution of necessary to start the system in a sub-zero environment, it
baking soda and water. Rinse with clean water. After cleaning, will be necessary to heat the oil with a low density, 100VAC
thoroughly dry battery and coat terminals with an anti corro- heater to a minimum temperature of -15 degrees F (-26
sion compound. degrees C).
Lubrication and Servicing 3. The only exception to the above is to drain and fill the
Components and assemblies requiring lubrication and servic- system with Mobil DTE 13 oil or its equivalent. This will
ing are shown in the Lubrication Chart in Section 1. allow start up at temperatures down to -20 degrees F (-
29 degrees C). However, use of this oil will give poor per-
formance at temperatures above 120 degrees F (49
2.3 LUBRICATION AND INFORMATION degrees C). Systems using DTE 13 oil should not be oper-
ated at temperatures above 200 degrees F (94 degrees
C) under any condition.
Hydraulic System
1. The primary enemy of a hydraulic system is contamina-
Changing Hydraulic Oil
tion. Contaminants enter the system by various means,
1. Filter elements must be changed after the first 50 hours
e.g., using inadequate hydraulic oil, allowing moisture,
of operation and every 300 hours (unless specified oth-
grease, filings, sealing components, sand, etc., to enter
erwise) thereafter. If it is necessary to change the oil, use
when performing maintenance, or by permitting the
only those oils meeting or exceeding the specifications
pump to cavitate due to insufficient system warm-up or
appearing in this manual. If unable to obtain the same
leaks in the pump supply (suction) lines.
type of oil supplied with the machine, consult local sup-
2. The design and manufacturing tolerances of the compo- plier for assistance in selecting the proper equivalent.
nent working parts are very close, therefore, even the Avoid mixing petroleum and synthetic base oils.
smallest amount of dirt or foreign matter entering a sys-
tem can cause wear or damage to the components and 2. Use every precaution to keep the hydraulic oil clean. If
generally results in faulty operation. Every precaution the oil must be poured from the original container into
must be taken to keep hydraulic oil clean, including another, be sure to clean all possible contaminants from
reserve oil in storage. Hydraulic system filters should be the service container. Always clean the mesh element of
checked, cleaned, and/or replaced as necessary, at the the filter and replace the cartridge any time the system
specified intervals required in the Lubrication Chart in oil is changed.
Section 1. Always examine filters for evidence of metal 3. While the unit is shut down, a good preventive mainte-
particles. nance measure is to make a thorough inspection of all
3. Cloudy oils indicate a high moisture content which per- hydraulic components, lines, fittings, etc., as well as a
mits organic growth, resulting in oxidation or corrosion. functional check of each system, before placing the
If this condition occurs, the system must be drained, machine back in service.
flushed, and refilled with clean oil.
Lubrication Specifications
4. It is not advisable to mix oils of different brands or types,
as they may not contain the same required additives or Specified lubricants, as recommended by the component
be of comparable viscosities. Good grade mineral oils, manufacturers, are always the best choice, however, multi-pur-
with viscosities suited to the ambient temperatures in pose greases usually have the qualities which meet a variety of
which the machine is operating, are recommended for single purpose grease requirements. Should any question
use. arise, regarding the use of greases in maintenance stock, con-
sult your local supplier for evaluation. Refer to Section 1 for an
NOTE: Metal particles may appear in the oil or filters of new explanation of the lubricant key designations appearing in the
machines due to the wear-in of meshing components. Lubrication Chart.
2-4 3121142
SECTION 2 - GENERAL
2.4 CYLINDER DRIFT Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature
Theory before beginning this test.
When a hydraulic cylinder is supporting a load, cylinder drift
may occur as a result of any of the circumstances below: Measure drift at cylinder rod with a calibrated dial indicator.
• Normal leakage of load holding valves or malfunction of In an area free of obstructions, cylinder must have load
load holding valves. See Cylinder Leakage Test and Table 2- applied and appropriately positioned to detect drift.
2, Cylinder Drift below for evaluation.
Cylinder leakage is acceptable if it passes this test.
• Damaged or worn piston seals.
• Normal thermal expansion or contraction of the hydraulic Table 2-2. Cylinder Drift
oil within cylinders (See Cylinder Thermal Drift below).
Max. Acceptable Drift
The first two circumstances may result in cylinder movement Cylinder Bore Diameter
in 10 Minutes
due to oil leaking out of the cylinder externally or by leaking
back to tank or due to oil leaking internally from one cylinder inches mm inches mm
chamber to the other. 3 76.2 0.026 0.66
Thermal expansion or contraction of oil in hydraulic cylinders 3.5 89 0.019 0.48

is a normal occurrence and does not result in oil leaking out of 4 101.6 0.015 0.38
the cylinder or leaking internally from one cylinder chamber 5 127 0.009 0.22
to the other. Thermal expansion or contraction is the tendency
6 152.4 0.006 0.15
for materials to change size in response to a change in temper-
ature. 7 177.8 0.005 0.13
8 203.2 0.004 0.10
9 228.6 0.003 0.08
NOTE: This information is based on 6 drops per minute cylinder
leakage.
Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station-
ary. These effects occur as the cylinder oil changes tempera-
ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these
effects are related to several factors including cylinder length
and change in temperature over the time the cylinder remains
stationary.
3121142 2-5
SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to the
Filament wound bearings. machine and to welding performed from the machine on
an external structure, or component,
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG
a. Excessive sloppiness in joints.
Equipment
b. Noise originating from the joint during operation. • Disconnect the battery.
2. Filament wound bearings should be replaced if any of • Disconnect the moment pin connection (where fitted)
the following is observed:
• Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing. Do NOT Do the Following When Welding on JLG
c. Bearings that have moved or spun in their housing. Equipment
d. Debris embedded in liner surface. • Ground on frame and weld on any other area than the
3. Pins should be replaced if any of the following is chassis.
observed (pin should be properly cleaned prior to • Ground on turntable and weld on any other area than the
inspection): turntable.
a. Detectable wear in the bearing area. • Ground on the platform/support and weld on any other
b. Flaking, pealing, scoring, or scratches on the pin sur- area than the platform/support.
face. • Ground on a specific boom section and weld on any other
c. Rusting of the pin in the bearing area. area than that specific boom section.
4. Re-assembly of pinned joints using filament wound • Allow pins, wear pads, wire ropes, bearings, gearing, seals,
bearings. valves, electrical wiring, or hoses to be between the
grounding position and the welded area.
a. Housing should be blown out to remove all dirt and
debris bearings and bearing housings must be free
of all contamination.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Bearing / pins should be cleaned with a solvent to
PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil filament wound bearing
RING, BOOM WIRE ROPES ETC.)
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
ing during installation and operation.
2-6 3121142
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Pre-Delivery2 Annual4

or Frequent3 (Yearly)
Inspection Inspection
Boom Assembly 9
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 9
Platform 1,2 1,2
Railing 1,2 1,2
Gate 1,5 1,5
Floor 1,2 1,2
Rotator 9,5,15 9,5,15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14
Oil Coupling
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly 9
Tires 1,16,17,18 16,17,18
Wheel Nuts/Bolts 1,15 15
Wheel Bearings 14,24 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Drive Motors
Drive Hubs 11 11
3121142 2-7
SECTION 2 - GENERAL
INTERVAL

Functions/Controls 9
Platform Controls 5,6 6
Ground Controls 5,6 6
Function Control Locks, Guards, or Detents 1,5 5
Footswitch 1,5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Capacity Indicator 5
Drive Brakes 5 5
Swing Brakes 5 5
Boom Synchronization/Sequencing Systems 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
Air/Fuel Filter 1,7 7
Exhaust System 1,9 9
Batteries 1,5,9 19
Battery Fluid 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 1,2,5,9,11 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,2,9 1,2,9
Hydraulic Cylinders 1,2,7,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,2,9 1,2
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,2,5,9,11 1,5
Hydraulic Filter 1,7,9 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1,20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operators and Safety Manuals in Storage Box 21 21
ANSI and EMI Manuals/Handbooks Installed 21
2-8 3121142
SECTION 2 - GENERAL
INTERVAL

Capacity Decals Installed, Secure, Legible 21 21

All Decals/Placards Installed, Secure, Legible 21 21
Walk-Around Inspection Performed 21 21
Annual Machine Inspection Due 21 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
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
3121142 2-9
SECTION 2 - GENERAL
1001159163 B
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-10 3121142
SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES & WHEELS ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
Tire Inflation dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
The air pressure for pneumatic tires must be equal to the air
the mounting stud holes in the wheels.
pressure that is stenciled on the side of the JLG product or rim
decal for safe and proper operational characteristics. The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
Tire Damage NOT use a lubricant on threads or nuts.
For pneumatic tires, JLG Industries, Inc. recommends that
when any cut, rip, or tear is discovered that exposes sidewall or 2. Tighten nuts in the following sequence:
tread area cords in the tire, measures must be taken to remove
the JLG product from service immediately. Arrangements
must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom-

mends that when any of the following are discovered, mea-
sures must be taken to remove the JLG product from service
immediately and arrangements must be made for replace-
ment of the tire or tire assembly.
• a smooth, even cut through the cord plies which exceeds 3

inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the

tire must be inspected on a daily basis to insure the damage
hasn’t propagated beyond the allowable criteria.
Wheel and Tire Replacement 3. The tightening of the nuts should be done in stages. Fol-
lowing the recommended sequence, tighten nuts per
The rims installed on each product model have been designed
wheel torque chart.
for stability requirements which consist of track width, tire
pressure, and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc., without
Table 3-1. Wheel Torque Chart
written factory recommendations, may result in an unsafe
condition regarding stability. TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
Wheel Installation
45 ft. lbs. 100 ft. lbs. 180 ft. lbs.
It is extremely important to apply and maintain proper wheel
(60 Nm) (140 Nm) (252 Nm)
mounting torque.
4. Wheel nuts should be torqued before first road use and

after each wheel removal. Check and torque every 3
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE months or 150 hours of operation.
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
MATCHED TO THE CONE ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels
from coming loose. Use a torque wrench to tighten the fasten-
3121142 3-1
3.2 EXTENDING AXLES NOTE: For more detailed information concerning system adjust-
ment and operation, refer to Section 6 - JLG Control Sys-
The Axle Extension System allows each of the four axles to be tem.
extended and retracted together while maintaining full steer-
ing control as the machine is driven. The system allows the
axles to extend or retract only while the boom is in the trans- 3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
port position and in order to minimize wheel scrubbing during
axle movement, a minimum drive speed must be attained 1. Fully extend the axles.
before axle extension/retraction will be permitted. The system 2. Initially position the limit switch arm straight.
uses four limit switches (one at each axle) to sense when the
axles are fully extended. If any of the switches are not made, 3. Select the mounting plate bolt pattern to position the
the control system considers the axles retracted. To extend/ switch roller within 0.125 inches (3.1 mm) from the edge
retract the axles, the user engages the axle extend/retract of the axle cutout. It may be necessary to reposition the
switch on the platform console and the drive control at the switch arm ±10° to accomplish this.
same time. The axle set indicator will be off when the axles are
4. Ensure the arm will clear the axle (without bottoming
not fully extended and the axle extend/retract switch is not
out to 70° stroke of the switch) in the retracted position.
engaged. It will flash while the axles are extending or retract-
ing and will be on constantly when the axles are fully 5. Check for proper operation. Axle set light is to deacti-
extended. With the axles not fully extended, the boom is vate when the axle is retracted 0.625 inches (16 mm)
restricted to operation within the transport position. If a signal maximum from fully extended.
from any axle extend sensing switch is lost when the boom
beyond the transport position, the axle set indicator will flash
and drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
will be automatically limited to +/- 25 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/
- 25 degrees when the axle retract command is engaged, the
control system will automatically reduce the wheel angle to 25
degrees during axle retraction.
Figure 3-1. Axle Limit Switch Adjustment
3-2 3121142
3.4 DRIVE SYSTEM

The drive system utilizes 2 traction pumps so each side is pow-
ered individually. This produces maximum tractive effort to
wheels by minimizing flow divider losses. The maximum drive
speed is modulated with the steered angle of the wheels to
eliminate the whiplash effect of driving at full speed and maxi-
mum steering lock.
3.5 STEERING CONTROL SYSTEM

Each wheel is individually steered by means of a closed circuit
control system utilizing a steer sensor on each wheel, 4 steer
cylinders, and proportional valves.
Figure 3-4. Coordinated Steer Mode
The control system senses the wheel position in relation to the Each wheel has its own steer cylinder, wheel angle sensor, and
steering command (direction and steering mode) and auto- proportional valve, allowing the control system to position
matically synchronizes the movement of all 4 wheels to the each wheel to the ideal angle for all steering modes and all
desired position. steering commands. Changes in steering modes while the
There are three different modes of steering selectable by the footswitch is depressed causes the wheels to automatically
position of the steer select switch on the platform control adjust to the appropriate angle for the selected steering mode
panel: conventional two wheel steering, crab and coordinated. based on the position of the inside front wheel. If the steer
These are shown below. select switch is changed without the footswitch depressed or
the EMS is off, the wheels will not move until the footswitch is
depressed and a steering or drive command has been initi-
ated. The steering angles are limited to +/- 25 degrees anytime
the axles are not fully extended. If a wheel cannot achieve its
commanded angle within a specified time, it is considered
jammed. When a wheel is considered jammed during steering,
a fault is reported and the remaining wheels will continue to
their commanded position. The fault is cleared when the foot-
switch is cycled. If a wheel is jammed making it significantly
out of position, with regard to the other wheels, the drive
motors are restricted to their maximum displacement (slow
speed). Wheel angle sensor failures will result in an approxi-
mated steering control logic that will allow the operator to
move the machine until it can be repaired. The wheel at the
Figure 3-2. Conventional Two Wheel Steer Mode failed sensor will be driven based on the information available
from the other sensors. This wheel will not track perfectly and
will become farther out of position over time. When the wheel
becomes prohibitively out of position, the wheels can be re
synchronized by fully steering against the mechanical stops.
NOTE: For more detailed information concerning system adjust-

tem.
Figure 3-3. Crab Steer Mode
3121142 3-3
3.6 DRIVE/STEERING SPEED CONTROL 3.8 DRIVE ORIENTATION SYSTEM

The Drive/Steering Speed Control system uses the steering The Drive Orientation System (DOS) is intended to indicate to
sensors from the steering control system to increase operator the operator conditions that could make the direction of
control and comfort by reducing the effect of turning the movement of the chassis different than the direction of move-
chassis on the resulting lateral platform speed. The system ment of the drive/steer control handle. The system indicates to
proportionally varies the drive speed based on the predicted the operator the need to match the black and white direc-
turning radius of the chassis for both coordinated and conventional arrows on the platform control panel to the arrows on
tional two wheel steer modes. The tighter the turn the slower the chassis. The system uses a proximity switch mounted on
the allowable drive speed. As crab steer does not steer on a the hydraulic swivel, an indicator light and an override switch
radius, full drive speed is maintained regardless of steer angle. on the platform display panel. The proximity switch trips when
the turntable is swung +/- 45 degrees off center of the normal
NOTE: For more detailed information concerning system adjust- driving position. This occurs roughly when the boom is swung
ment and operation, refer to Section 6 - JLG Control Sys- past a rear tire. When the turntable is in the normal drive posi-
tem. tion with the boom between the rear tires, no indications or
interlocks are made. When the machine is actively driving
when the turntable is swung past the switch point, the system
3.7 TRACTION CONTROL SYSTEM is ignored until drive/steer is released. When drive is initiated
The traction control system uses the steering sensors from the with the boom swung past the switch point, the DOS indicator
steering control system to optimize the performance of the will flash and the drive/steer functions will be disabled. The
drive system. This is especially important due to the disparity operator must engage the DOS override switch to enable
of wheel speeds generated between the inside and outside Drive/steer (high drive will remain disabled). When the DOS is
wheels of the extended axle chassis with large steering angle enabled, the DOS indicator will be illuminated continuously
capability. The steering sensors are used to predict the rolling and a 3-second enable timer will be started and will continue
path and therefore the required wheel speed of each wheel as for 3 seconds after the end the last drive/steer command. If the
the steering angles change and steering modes change. The timer expires, the DOS override switch must be re-engaged to
control system can then command the ideal flow from each of enable drive/steer.
the two drive pumps, one for the right side of the machine and
one for he left side. Two flow dividers, one for the right side
front to back and one for the left side front to back absorb the
tem.
variation in wheel speed front to back.

tem.
3-4 3121142
3121142 3-5
Figure 3-5. Chassis Component Location - Sheet 1 of 2
3-6 3121142
1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear)
2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear)
3. Steer Valve (Front) 11. Chassis Module
4. Axle Lockout Valve 12. Swivel/Collector Ring
5. Traction Valve 13. Axle Lockout Pressure Switch
6. Steer Valve (Rear) 14. Steer Angle Sensor (Left Front)
7. Steer Angle Sensor (Right Rear) 15. Axle Limit Switch (Left Front)
8. Axle Limit Switch (Right Rear)
Figure 3-6. Chassis Component Location - Sheet 2 of 2
3121142 3-7
Figure 3-7. Turntable and Boom Component Location - Sheet 1 of 2
3-8 3121142
1. Platform Control Valve 23. Headlight

2. Jib Stow Switch 24. Deutz EMR2 Module
3. Platform Level Sensor (Secondary - Left) 25. 110V / 220V Generator
4. Tail Lights 26. Generator Control Box
5. Skypower Generator 27. Alternator
6. Alarm 28. Throttle Actuator
7. Main Control Valve 29. Oil Temperature Switch
8. Auxiliary Power Pump 30. Oil Pressure Switch
9. Auxiliary Power Relay 31. Intake Heaters
10. Chassis Power Distribution Relay 32. In Head Glow Plug
11. Headlight/Tail Light Relay 33. Engine Speed Sensor
12. Horn 34. Starter
13. Lift Cylinder Pivot Pin 35. Drive Pump (Right Side)
14. Fuel Level Sensor 36. Drive Pump (Left Side)
15. B.L.A.M. Module 37. Function Pump
16. Strobe Light 38. Starter Relay
17. Headlight 39. Glow Plug Relay
18. Ground Control Box 40. Swivel/Collector Ring
19. Boom Angle Sensor (Left) 41. Transport Limit Switch
20. Broken Cable Proximity Switch 42. Platform Level Sensor (Primary - Right)
21. Boom Length Sensor 43. Dual Capacity Jib Position Switch
22. Boom Angle Sensor (Right)
Figure 3-8. Turntable and Boom Component Location - Sheet 2 of 2
3121142 3-9
3
1 DETAIL A
6 * AXLE STOP SHIMMING PROCEDURE:

2 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL
SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME.
2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST
SHIM.
DETAIL B
Figure 3-9. Axle Installation - Oscillating (SN 0300196322 through 0300207700) - Sheet 1 of 2
3-10 3121142
9
3
11,12,B,G
6
11,12,A,G
8
10
11,12,C,G DETAIL A
11,12,D,G
11,12,E,G
11,12,F,G
2
4
A - Assemble to Axle Box Mid Plate; Typical 8 Places
B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 DETAIL B
inches (12.7 ± 1.587 mm) thread engagement.
C - Assemble to Side Plates of Axle Weldments; Typical 16 Places.
D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
E - Assemble to Top Plate of Axle Weldment; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5
±0.062 inches (12.7 ± 1.587 mm) thread engagement.
F - Assemble to Bottom Plate of Axle Box Weldment; Typical 8 Places.
G - See Axle Stop Shimming Procedure on Sheet 1
1. Axle Oscillation Cylinder 5. Axle Pivot Pin 9. Hose Clamp

2. Axle 6. Axle Limit Switch 10. Stop Block
3. Axle Powertrack 7. Axle Stop Pin 11. Wear Pad
4. Extension Cylinder 8. Rubber Pad 12. Shim
Figure 3-10. Axle Installation - Oscillating

(SN 0300196322 through 0300207700) - Sheet 2 of 2
3121142 3-11
SEE DETAIL A
3 8
1
SEE DETAIL B
-ASSEMBLE TO TOP PLATE OF AXLE WELDMENT

5 -TYP 4 PLACES, 4 AXLES
-TORQUE GRADE 8 PER JLG SPEC 5000059
-SELECT APPROPRIATE BOLT (ITEM 14 OR 15)
TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT
1001173913-H
MAE35920H
Figure 3-11. Axle Installation - Oscillating (SN 0300207701 to Present, SN B300002238 to Present) - Sheet 1 of 2
3-12 3121142
ASSEMBLE TO AXLE 3 -ASSEMBLE TO TOP PLATE OF

BOX MID PLATE AXLE BOXES
-TYP 4 PLACES, 2 AXLE BOXES
TYP 8 PLACES, -TORQUE GRADE 8 PER
2 AXLE BOXES JLG SPEC 5000059
-SELECT APPROPRIATE BOLT
(ITEM 15, 16, OR 17) TO ENSURE
1/2" 1/16" THREAD ENGAGEMNET
PLUG (4) 1/2-13

TAPPED HOLES
ASSEMBLE TO SIDE PLATES

OF AXLE WELDMENTS
TYP 16 PLACES, 4 AXLES
ASSEMBLE TO FRONT AND REAR

PLATES OF AXLE BOXES
7 TYP 8 PLACES, 2 AXLE BOXES
1
ASSEMBLE TO BOTTOM PLATE
OF AXLE BOX WELDMENT
TYP 8 PLACES, 2 AXLE BOXES
DETAIL A
DETAIL B
5
1001173913-H
MAE35930H
1. Axle 3. Axle Limit Switch 5. Extension Cylinder 7. Bracket

2. Sleeve 4. Axle Pivot Pin 6. Axle Stop Pin 8. Axle Pivot Weldment
Figure 3-12. Axle Installation - Oscillating (SN 0300207701 to Present, SN B300002238 to Present) - Sheet 2 of 2
3121142 3-13
SEE DETAIL A
AXLE STOP SHIMMING PROCEDURE:
1) ALL 4 WHEELS OF THE MACHINE SHOULD
BE ON A LEVEL SURFACE WITH THE
TURNTABLE SQUARE TO THE FRAME.
2) SHIM AXLE STOPS TO WITHIN THE THICKNESS
OF THE THINNEST SHIM.
3
1
4
SEE DETAIL B
5 0271934-M
MAE36110M
Figure 3-13. Axle Installation - Fixed (SN 0300201016 through SN 0300207700) - Sheet 1 of 2
3-14 3121142
ASSEMBLE TO AXLE
BOX MID PLATE 3 -ASSEMBLE TO TOP PLATE OF
TYP 8 PLACES, AXLE BOXES
2 AXLE BOXES -TYP 4 PLACES, 2 AXLE BOXES
-TORQUE GRADE 8 PER
JLG SPEC 5000059
(ITEM 15, 16, OR 17) TO ENSURE
1/2" 1/16" THREAD ENGAGEMNET

OF AXLE WELDMENTS


-TYP 4 PLACES, 4 AXLES
-TORQUE GRADE 8 PER JLG SPEC 5000059
-SELECT APPROPRIATE BOLT (ITEM 52 OR 53)
1 ASSEMBLE TO BOTTOM PLATE
DETAIL A
DETAIL B
5
0271934-M
MAE36120M
1. Axle 5. Extension Cylinder

2. Axle Power Track 6. Axle Pivot Weldment
3. Axle Limit Switch 7. Axle Stop Pin
4. Axle Pivot Pin 8. Rubber Pad
Figure 3-14. Axle Installation - Fixed

(SN 0300201016 through SN 0300207700) - Sheet 2 of 2
3121142 3-15
SEE DETAIL A
AXLE STOP SHIMMING PROCEDURE:

1) ALL 4 WHEELS OF THE MACHINE SHOULD
BE ON A LEVEL SURFACE WITH THE
TURNTABLE SQUARE TO THE FRAME.
2) SHIM AXLE STOPS TO WITHIN THE THICKNESS
OF THE THINNEST SHIM.
1 3 6
SEE DETAIL B

AXLE AND AXLE BOX FRONT PLATES -TYP 4 PLACES, 4 AXLES
5 -TORQUE GRADE 8 PER JLG SPEC 5000059
-SELECT APPROPRIATE BOLT (ITEM #15 OR #16)
1001173914-I
MAE35940I
Figure 3-15. Axle Installation - Fixed (SN 0300207701 to Present, SN B30002238 to Present) - Sheet 1 of 2
3-16 3121142
-ASSEMBLE TO TOP PLATE OF

3 AXLE BOXES
-TYP 4 PLACES, 2 AXLE BOXES
-TORQUE GRADE 8 PER
JLG SPEC 5000059
(ITEM #16, #17, OR #18) TO ENSURE
1/2" 1/16" THREAD ENGAGEMENT

OF AXLE WELDMENTS

ASSEMBLE TO BOTTOM PLATE

1
9
8
2 DETAIL A
5 DETAIL B 1001173914-I
MAE35950I
1. Axle 5. Extension Cylinder

2. Axle Power Track 6. Axle Pivot Weldment
3. Axle Limit Switch 7. Axle Stop Pin
4. Axle Pivot Pin 8. Rubber Pad
Figure 3-16. Axle Installation - Fixed (SN 0300207701 to Present,

SN B30002238 to Present) - Sheet 2 of 2
3121142 3-17
Figure 3-17. Axle Loctite Application
3-18 3121142
Table 3-2. Steering Assembly Notes
A Apply JLG Threadlocker PN 0100011
B Apply JLG Threadlocker PN 0100019
C Apply Loctite #222
D Preload Torque 100-300 ft. lb. (140-420 Nm)

on Slot Nut
1. Spindle 4. Steer Cylinder Pivot Pin

2. Angle Sensor Assembly 5. King Pin
3. Steer Cylinder 6. Axle
Figure 3-18. Steering Installation
3121142 3-19
3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND
The oscillating front axle is attached to the frame by a pivot LOCKOUT TEST
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. The oscillating axle also Lockout Cylinder Bleeding
incorporates two lockout cylinders connected between the
To start the test, the axle must be fully oscillated in one direc-
frame and the axle. The lockout cylinders permit axle oscilla-
tion. Start with oscillating the axle so that the left lock-out cyl.
tion when the boom is in the transport position and drive is
is fully retracted (left front tire up), and the right lock-out cyl. Is
commanded. The lockout cylinders will lock and hold the axle
fully extended (right front tire down).
when drive is not commanded or when the boom is outside
the transport position. The cylinders unlock when pilot pres-
sure is applied to the holding valves mounted on the cylinders
and lock when pilot pressure is removed. Pilot pressure is avail-
ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR
able from brake pressure and is controlled by a solenoid oper-
AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. MAKING SURE MACHINE
ated NC lockout valve mounted in the frame. To ensure the
IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS
lockout valve is functioning correctly, a NO pressure switch is
DISCONNECTED.
mounted between the lockout valve and the holding valves.
The system is “healthy” when pressure trips the pressure
switch when the lockout valve is commanded to be open and 1. Making sure machine is on a level surface and rear
conversely is healthy when the lack of pressure resets the pres- wheels are blocked, machine is in transport mode.
sure switch when the lockout valve is commanded to be
2. Disengage the drive hubs.
closed. Failures in the oscillating axle system will cause the
control system to disallow lift up and telescope out when the 3. Use suitable container to catch any residual hydraulic
boom is within the transport position and will disallow drive/ fluid, place container under the lockout cylinder.
steer, lift up and telescope out when the boom is beyond the
transport position. 4. With the left lock-out cyl. retracted, open the bleeder on
top of the cylinder, then have an operator from the plat-
NOTE: For more detailed information concerning system adjust- form (on high engine) feather drive. Activate drive fully.
5. Close the bleeder when there is a steady stream of oil
tem.
and not air.
6. With the axle in the same position, go to the right lock-
out cyl. and open the bleeder at the rod end. Activate
drive in the same manner and close when all air has
been purged.
7. Close the bleeder when there is a steady stream of oil
and not air.
8. Oscillate the axle the other direction, left lock-out cyl.
extended (tire down), right lock-out cyl. retracted (tire
up). Use the same procedure for the bleeder in the rod
end of the left lock-out cyl., Then the piston end of the
right lock-out cyl. then close.
9. Repeat this process one more time to ensure that all air
has been purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
NOTE: Bleeding of the oscillating axles is an infrequent operation

performed after hydraulic line failure and or lock-out cylin-
der repair.
3-20 3121142
Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position.
The front axles will oscillate when the boom is in the transport 12. Drive machine off of block and ramp back onto the level
position (i.e. when the boom is less than 15° above horizontal surface.
and not extended beyond 12" [30.4 cm] on the1350SJP or 24"
[60.9 cm] on the 1200SJP) and drive is selected. 13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Retract the boom back in to the transport position. Acti-
vate drive and the lockout cylinders should release.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS 15. If lockout cylinders do not function properly, have quali-
SUSPECTED. fied personnel correct the malfunction prior to any fur-
ther operation.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test. The axles must also be fully extended.
1. Place a 6 inch (15.2 cm) high block with ascension ramp

in front of left front wheel.
2. From platform control station, activate machine hydrau-
lic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/
TORQUE SELECT control switches to their respective
LOW positions.
4. Place DRIVE control lever to FORWARD position and
carefully drive machine up ascension ramp until left
front wheel is on top of block.
5. Telescope the boom out of the transport position.
6. Drive machine off of block and ramp back onto the level
surface.
7. Have an assistant check to see that left front wheel
remains locked in position off of ground.
8. Retract the boom back in to the transport position. Acti-
vate drive and the lockout cylinders should release.
9. Place the 6 inch (15.2 cm) high block with ascension
ramp in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully
drive machine up ascension ramp until right front wheel
is on top of block.
3121142 3-21
3.11 WHEEL DRIVE ASSEMBLY 2. Remove hardware securing wheel and remove wheel
assembly.
Removal 3. Using suitable lifting device lift the wheel assembly and
place in a suitable area.
NOTE: The drive motor can be removed through the axle flange as
part of the wheel drive assembly or they can be removed Installation
separately through the bottom of the frame while leaving
the torque hub bolted to the axle. 1. Use a jack to lift the frame enough so the tire and wheel
assembly is off of the ground. Place blocking strong
1. Use a jack to lift the frame enough so the tire and wheel enough to support the weight of the machine under the
assembly is off of the ground. Place blocking strong frame and remove the jack.
enough to support the weight of the machine under the
2. Using adequate support, install wheel into wheel
frame and remove the jack.
assembly and secure with bolts and washers.
NOTE: The solid tire & wheel assembly weighs approximately
NOTE: Torque the bolts to 180 ft. lbs. (244 Nm).
990 lbs. (449 kg). The foam-filled tire & wheel assembly
weighs approximately 867 lbs. (393 kg).
WHEEL
WASHER
BOLT
MAE35900
Figure 3-19. Wheel Drive Removal and Installation
3-22 3121142
3.12 DRIVE HUB Installation

1. Use suitable lifting device to support the drive hub.
Removal
NOTE: The drive hub weighs approximately 267 lbs. (121 kg).
1. Place machine on the firm level surface.
2. Disconnect the battery power and all electrical connec- 2. Install the drive hub to the machine.
tions from the drive motor assembly. 3. Use six bolts and attach the drive hub to the machine.
3. Use suitable lifting device to support the drive hub. 4. Install previously removed hydraulic hoses to drive
motor.
NOTE: The drive hub weighs approximately 267 lbs. (121 kg).
4. Remove twelve bolts attached drive hub to the frame.

5. Remove the hub from machine and place in a clean
work area.
DRIVE MOTOR
DRIVE HUB
BOLT
WASHER
MAE35910
Figure 3-20. Drive Hub Removal and Installation
3121142 3-23
3.13 DRIVE MOTOR Installation

1. Use suitable lifting device to support the drive motor.
Removal
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg).
1. Place machine on the firm level surface.
2. Disconnect the battery power and all electrical connec- 2. Install the drive motor to the drive hub.
tions from the drive motor.
3. Use suitable lifting device to support the drive motor.
INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT,
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg). BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE.
4. Remove two bolts attached drive motor to the drive 3. Make sure that the pump shaft is properly aligned.
hub.
4. Use the bolts and attach the drive motor to the machine.
5. Remove the motor from machine and place in a clean
5. Reconnect all electrical connections to the drive motor.
work area.
6. Start the machine and check the motor for proper func-
6. Clean the motor for dirt. Remove rust or corrosion from
tioning.
coupling shaft.
BOLT
WASHER
DRIVE MOTOR
DRIVE HUB
BOLT
WASHER
MAE37610
Figure 3-21. Drive Motor Removal and Installation
3-24 3121142
5
4
6
3
1
9
3 10
11
2 7 12
13
8
14
15
20 16
17
18
19 21
22
23
24
26
30
25
27
31
29
28
32
33
34
35
36
34
MAE37590B
1. Bolt 9. Snap ring 17. Cylinder Piston 25. Gasket 33. Snap ring
2. End cap motor 10. Spring Retainer 18. Piston Ring 26. Plug 34. Snap ring
3. Locating pin 11. Spring 19. O- ring 27. O-ring 35. Seal
4. O- ring 12. Washer 20. Piston 28. Plug 36. Washer
5. Plug 13. Cylinder block 21. Spring 29. O- ring
6. Dower pin 14. Slipper Pin 22. Pin 30. Housing
7. Needle Bearing 15. Guide 23. Swash Plate 31. Shaft
8. Valve Plate 16. Slip Retainer 24. Kit Bearing 32. Bearing
Figure 3-22. Drive Motor Assembly
3121142 3-25
3.14 DRIVE HUB (PRIOR TO SN 100131) 14. Inspect the planetary stage assemblies as complete
units. Thoroughly clean and check both the gearing and
The final drive consists of two planetary stages with an inte- the bearings for damage and apply new oil. If the gears
grated disconnect mechanism. Each stage incorporates a set or bearings need replacing, they must be replaced as
of matched planetary gears, which provide an equal load dis- complete sets.
tribution. All torque transmitting components are made of
forged quenched and tempered high-alloy steels. External 15. The first stage planetary gears (2) must be changed in
gears are carburized. Precision roller bearings support the sets of three pieces.
sprocket or wheel loads. A shaft seal protects the unit against 16. The first stage planetary gears (2) must be changed as a
contamination. complete set of three and JLG recommends changing
the sun gear shaft (43) along with this set of planets.
Disassembly 17. The second stage planetary bearings (11) must be
1. Position drive so that one of the fill holes is at the bot- replaced in sets of four pieces.
tom of the end cover and drain the oil. 18. The second stage planetary gears (1) must be changed
2. Remove all bolts holding the motor and Remove motor as a complete set of four and JLG recommends changing
from drive. the sun gear (3) along with this set of planets.
3. Compress the spring (55) using a simple fixture or other

suitable device.
Disassembly of Cover
Loosen and remove hex head bolts (53) to remove cover (51).
4. Remove snap ring (66) and release pressure on the
spring (55) until loose.
Disassembly of the First Stage Planetary
5. Remove the spring (55). Assembly (7)
6. Turn unit so that cover (8) is in the up position.
1. Push sun gear shaft (43) out of the first stage.
7. Remove the screw plugs (21) and seal rings (22).
2. Remove snap rings (14).
8. Remove “o” ring (33).
3. Press planet pins (5) out of the planet gears (2).
9. Remove the first stage planetary assembly (7).
4. Pull cylindrical roller bearing (10) out of the planet gears
10. Remove hex bolts (23). (2).
11. Remove ring gear (30) and “o” ring (19). 5. Remove snap ring (16) from sun gear (3) and Remove
planet carrier (7) from sun gear (3).
12. Remove snap rings (15).
13. Pull off planet gears (1) together with cylindrical roller Disassembly of Second Stage Planet Gears (1)
bearings (11) from spindle (60). Press cylindrical roller bearings out of planet gears (1).
NOTE: Further disassembly of the hub is discouraged. reinstalla-
tion of the shaft nut (4) requires a special tool and a torque
of 626 ft./ lbs. (876 Nm) for proper reassembly. These com-
ponents Will Fail if not properly reassembled.
3-26 3121142
Assembly of First Stage Planetary Assembly (7) 6. Before installation of motor, CHECK THAT THERE IS 1-2
mm OF CLEARANCE BETWEEN THE MOTOR SPLINE
1. Pre-freeze planet pins (5) and install into planet carrier SHAFT SHOULDER AND THE COUPLER (62).
(7).
7. Install the motor and reconnect hydraulic lines.
2. Install planet carrier (7) together with planet pins (5) on
8. Roll motor so that one fill plug is at 12 o’clock position,
sun gear (3), and install snap ring (16).
and the other is at 3 o’clock. Fill to bottom of 3 o’ clock
3. Put sun gear shaft (43) into sun gear (3). plug with gear oil. reinstall plugs.
4. Pre-heat stay rings (17) and install onto planet pins (5).
Initial Start-up And After Repairs
5. Pre-heat cylindrical roller bearings (10) and install onto Before operating the machine, make sure that the drive is filled
planet pins (5) and fix bearings with snap rings (14). with clean oil, approximately 0.2 US gallons(0.8 L). An accurate
oil level is determined by the oil level plug, which should be
Assembly of End Cover Unit (8) removed before oil fill.
1. Install “o” ring (54) into groove of cover (8). With the gear case filled to their proper levels, start the
2. Install the cover (51) into cover (8) and fix cover (51) with machine and allow sufficient time for run-in at moderate pres-
hex bolts (53). Tighten bolts with torque wrench to 6.3 sure and speed before running at full speed. After 4 hours of
ft. lbs. (8.5 Nm). operation, recheck oil level.Maintenance
Daily: - Check for oil leakage
Final Assembly
Weekly: - Check oil level
1. Install planet gears (1) onto planet pins which are part of
Monthly: - Check mounting bolt torque
spindle (60).
2. Install snap rings (15) on planet pins of spindle (60) in Oil Change Interval-Gear Drive
order to fix the planet gears (1).
1. Perform the first oil change after approximately 150
3. Insert the first stage planetary assembly (7) into drive. hours.
4. Install “o” ring (33) in groove of ring gear (30). 2. Subsequent changes, every 1500 hours or annually,
5. Install seal rings (22) and screw plugs (21). whichever occurs first.
NOTE: Flush the drive before filling with new oil.
3121142 3-27
Figure 3-23. Drive Hub - Sheet 1 of 2)
3-28 3121142
3121142
1. Planet Gear 16. Snap Ring 31. Not Used 51. Cover 68. Retaining Ring
2. Planet Gear 17. Stay Rings 32. Not Used 52. Thrust Washer 69. Bolt
3. Sun Gear 18. Not Used 33. O-ring 53. Bolt 70. Not Used
4. Shaft Nut 19. O-ring 34. thru 40. Not Used 54. O-ring 71. Not Used
5. Planet Pin 20. Shaft Seal 41. Planet Carrier 55. Spring 72. Brake Disc
6. Not Used 21. Plug 42. Sun Gear 56. thru 59. Not Used 73. Brake Disc
7. Planet Carrier 22. Seal Ring 43. Sun Gear 60. Spindle 74. Spring
8. Cover 23. Bolt 44. Not Used 61. Piston 75. Backup Ring
9. Thrust Button 24. Detent Ball 45. Planet Pin 62. Coupler 76. Seal
10. Roller Bearing 25. Not Used 46. Roller Bearing 63. Ring Locator 77. Backup Ring
11. Roller Bearing 26. Not Used 47. Retaining Ring 64. Backup Plate 78. Seal
12. Ball Bearing 27. Bolt 48. Retaining Ring 65. Backup Plate 79. Not Used
13. Hex Bolt 28. Washer 49. Not Used 66. Retaining Ring 80. Not Used
14. Snap Ring 29. Not Used 50. Not Used 67. Retaining Ring 81. O-ring
15. Snap Ring 30. Ring Gear
Figure 3-24. Drive Hub - Sheet 2 of 2
3-29
3.15 DRIVE HUB - BONFIGLIOLI (SN 100128 TO Installation of the Wheel Drive on the Machine
PRESENT) 1. Clean the mating surfaces from oils or paint and fit the
wheel drive on the machine frame.
NOTE: After S/N 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec- 2. Attach the gearbox to the machine frame with the
tion 3.16, Drive Hub - Reggiana Riduttori (SN 134389 to mounting bolts and torque to 178 ft.lbs. (241 Nm).
Present). Do not use different hubs on the same machine.
Product Identification Start Up and Running In

The identification data of the hub is shown on a name plates on If new hubs are being installed, it is advised to follow the
the hub. Figure 3-25., Drive Hub Identification Plate shows measures given below:
how the information is displayed.
1. Bleed air from every part of the hydraulic and add oil in
The informations stamped on the name plates must always be the tank if necessary.
readable. Use the identification data (at least serial number)
for spare part enquiries, information and service, etc.
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL BE REC-
Hydraulic Motor Installation OGNIZED BY THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A
The mating areas and the pilot diameter of the gearbox JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE
where the motor is to be mounted must be clean and without MOTOR AND THE VALVES.
burrs.
2. Start the gearmotor at a low speed and gradually
Before assembling the hydraulic motor, verify by a depth slide increase it after having verified that it is functioning cor-
gauge the correct assembly of the unit checking the axial dis- rectly without any noises or vibrations.
tance as shown in the scheme below as shown in the scheme
below.
1. Fit the O-ring seal, supplied with the gearbox, in its seat DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN
in the hydraulic motor, and assemble it to the gearbox FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
being careful not to damage the seal already fitted.
NOTE: During the running-in stage follow the steps given
2. Torque the bolts to 63.5 ft.lbs. (86 Nm) torque.
below.
3. Check the correct revolution and direction of rota-

tion.
4. Make sure that the functioning is regular and without
any excessive noises and vibrations.
Figure 3-25. Drive Hub Identification Plate
3-30 3121142
5. Make sure that the oil temperature does not exceed Connecting the Brake
values listed previously.
The gearbox is fitted with a negative multi disk safety brake
After having finished running-in the gearbox, follow the steps with hydraulic control release (parking brake). For information
given below. regarding the characteristics of the brake refer to the installa-
tion drawing.
6. Check that there are no oil leaks. If leaks are present,
fix them before proceeding. Table 3-3. Brake Technical Data
7. Check the level of oil in the gearmotor. Brake Release Pressure (16 bar)
8. It possible that the presence of air in the system Maximum Operating Pressure Brake (50 bar)
during the first start up could cause the application of Braking Torque (265 ± 10% Nm)
the brake to be slowed down. It is advised to
repeat the application and release functions of the
brake to purge air from the brake. Filling-up the Gearbox with Lubricating Oil
The motor and the gearbox have separate lubrication. The
9. Check that there are no other problems in general. gearbox is lubricated by oil splashing. The recommended type
of oil is SAE 80W/90 or SAE 85W/140 with EP features comply-
General Information ing with MIL-L-2105 C & API GL5. Refer to Table 3-4, Suggested
The gearbox is designed and built for wheel drive. Lubricants According SAE 80W/90 and SAE 85W/140 API GL5
Grade.
The unit includes planetary gearbox, 3 stages, rotating hous-
ing type. NOTE: During operation the oil temperature must not exceed 85-
90° C intermittent.
The illustrations show the parts and the main functions of the
gearbox.
A strict and consistent compliance with the specifications of
this technical manual ensure the minimum operating costs
and a longer unit life.
Photographic documentation and drawings are supplied for
educational purposes, so as to safely and properly carry out
maintenance operations.
Minor deviations from pictures of this manual may appear on
the actual gearbox. However, these discrepancies are not rele-
vant to the main parameters, or maintenance functions.
3121142 3-31
1= M18x1,5..........................Filling, draining and oil level plugs

2= 7/16" - 20 UNF - 2B..........Brake port
Figure 3-26. Hub Assembly
3-32 3121142
Table 3-4. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade
Ambient temperature -20°C / +30°C +10°C / +45°C

Oil viscosity SAE 80W/90 SAE 85W/140
Manufacturer Oil Brand
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP
ARAL GETRIEBEOL HYP GETRIEBEOL HYP
BP-MACH HYPOGEAR EP HYPOGEAR EP
CASTROL HYPOY HYPOY
CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT
ELF TRANSELF B TRANSELF B
ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
NOTE: Do not mix together oils of different brands or characteris- 4. Tighten the fill and level oil plug (B) and let the gearbox
tics. run. After a few minutes, stop and check the oil level.
5. If necessary, refill with lubricant oil. Approximate oil
NOTE: The gearbox is supplied without oil; before putting the
capacity = 2 liters ±10%
gearbox into operation, it is necessary to fill it with oil.
This procedure is undertaken following the indications given Gearbox Disengagement

below. The gearbox is supplied with mechanical disengagement.
1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug (A) is on the bot-
tom on the vertical axis of the end cover. THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY
WHEN THE GEARBOX IS STOPPED ON FLAT GROUND.
2. Unscrew the fill and level oil plug (B).
3. Fill from the hole until the lubricant flows out.
3121142 3-33
3. Take out the cap nut (5).
THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25
REV/MIN.
4. Turn the cap nut (5) upside down. As result the pin (3)
will be pushed inside in order to permit disengagement
of the gearbox.
Figure 3-27. Gearbox engaged
1. Unscrew the 2 socket head screws M8x16 (4), grade 8.8,

of the end cover (7) with a male hex head wrench.
5. Rotate the cap nut (5).
2. Rotate the cap nut (5).
3-34 3121142
6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to
hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade-
quate solution.
If unsuccessful, it may be necessary to partially or completely
disassemble the gearbox.
Table 3-5. Drive Hub Maintenance Schedule
Inspection Frequency Action

Tightening bolts After the first 50 operating hours Bolt tightening torque
of the gearbox check
Oil level Every 150 operating hours of the Refill oil if necessary
gearbox
1st oil change At 150 operating hours of the Oil replacement
gearbox
Next oil change Every 1200 operating hours Oil replacement
Changing the Lubricating oil

1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug is on the bottom of
the vertical axis of the end cover.
Figure 3-28. Gearbox Disengaged
7. Repeat the above steps to engage the gearbox again.
Operation:
a. Engaged gearbox 2. Unscrew the both plugs (Fill and Drain) and let the oil
flow in a large enough container; in order to facilitate
At this condition the motion is transmitted from the draining the oil must still be warm.
hydraulic motor to the gearbox.
3. Wait a few minutes until all the oil is drained and then
b. Disengaged gearbox proceed to screw on the plugs.
4. Proceed with the oil fill-up. Refer to Filling-up the Gear-
box with Lubricating Oil.
AT THIS CONDITION THE HYDRAULIC MOTOR AND THE BRAKE ARE DISCON-
NECTED TO THE GEARBOX: THE WHEEL IS IDLE. NOTE: Never mix mineral oils with synthetic oils and vice versa.
Maintenance Information
PERIODIC MAINTENANCE DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT. BE CAREFUL TO
The gearbox only requires the scheduled maintenance proce- ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS
dures set out by the manufacturer (see Table 3-5). THAT GOVERN LOCALLY.
Good maintenance will ensure an ongoing functioning in time

as well as maximum reliability.
3121142 3-35
Troubleshooting
The following table is provided to help locate problems in the
gearbox.
Table 3-6. Troubleshooting
Symptom Causes Remedies

External oil leakage:
From the lifetime seal a)Lifetime seal damaged a)Replace lifetime seal
From the end cover a)O-ring seal damaged a)Replace O-ring seals
From the plugs a)Plug seal damaged a)Replace plug seal
b)Plugs or screws loose b)Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down a)Hydraulic circuit malfunctioning a)Verify hydraulic circuit
of the motor speed)
Inside the gearmotor (reductions) a)Internal damage a)Check the gearbox
Other:
Overheating a)Insufficient oil level a)Check the oil level and refill if necessary
b)Hydraulic oil too warm b)Check the hydraulic circuit
c)Brake not fully released c)Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a)Brake discs worn a)Replace brake disc pack
b)Damaged parts b)Check brake components
Wheel Locked a)Parking brake locked a)Check the complete brake release
b)Mechanical components damaged b)Replace damaged parts
Disassembly Information 2. Making sure that the coupling surfaces are not dam-
aged.
It is also important that this procedure is undertaken in a
workshop that is equipped with the proper tools. As well as 3. Handle with care so as to be sure that there are no risks
normal workshop tools it will be necessary to use special tools for personnel safety and to guarantee the reliability of
that can be made (see special tools attachment) or may be the gearbox.
requested from the manufacturer.
4. Making available a work area that is in line with work
Special Tools: and health safety in the workplace guidelines.
Puller...............................................Code/: 6689960240
Disassembly Procedure
Tool for lifetime seal assembly........Code/: 6689960300
NOTE: Below are all the steps to follow during Disassembly and
Puller for brake disassembly..........Code/: 6689960310
Assembly. Numbers in brackets in the text correspond to
Torque multiplier............................Code/: ATZ.09.016.0 the references in the exploded view.
To be able to produce these special tools refer to Figure 3-30.
Initial inspection can be made without disassembling the hub
thru Figure 3-33.
from the machine. Before wheel drive disassembling, make
It is important to strictly adhere to all the procedures for disas- sure that the oil is drained from the hub.
sembling and reassembling the gearbox. Proceed with these
Unscrew and remove the nos. 2 screws M12, grade 8,8, and
instructions using all the necessary safety measures, for exam-
remove the hydraulic motor and its O-ring seal (48).
ple:
1. Plug all the Hydraulic ports on the gearbox to avoid the
introduction of any foreign particles in the circuit and
the gearbox.
3-36 3121142
1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for
(31) and turn the screw until it compresses the springs the reassembly.
(45).
5. Remove the springs (45) from their seats in the brake

2. Remove the circlip (47) and remove the special tool. piston (44).
3. Remove the spring retainer disc (46). 6. By using pliers remove the circlip (36) from its seat in the
brake shaft (35).
3121142 3-37
1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring
2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring
3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43. Backup Ring
4. Screw 14. Splined Shaft 24. Bearing 34. Spacer 44. Brake Piston
5. Cap Nut 15. Disengagement Shaft 25. Spacer 35. Brake Shaft 45. Springs
6. Oil Plug 16. 1st Reduction Assembly 26. Spacer 36. Circlip 46. Retainer Disc
7. End Cover 17. 2nd Stage Sun Gear 27. O-ring 37. Backup Ring 47. Circlip
8. Pad 18. 2nd Reduction Assembly 28. Spacer 38. O-ring 48. O- ring
9. O-ring 19. Circlip 29. Half Seal 39. Spacer
10. 1st Stage Sun Gear 20. 3rd Reduction Assembly 30. Seal Ring 40. Backup Ring
Figure 3-29. Drive Hub S/N 100128 to Present
3-38 3121142
7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup
piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39).
11. Remove the O-ring seal (42) and the backup ring (43)
from their seats in the flanged hub (31).
8. Remove the spacer (39) from the brake piston (44).
12. Remove brake discs pack (32-33).

9. Remove the internal O-Ring seal (41) and the backup
ring (40) from their seat in the spacer (39).
3121142 3-39
13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the
splined shaft (14).
14. Place the disengagement shaft kit (15) inside the special
tool (6689960240). 17. Remove the special tool and remove the spring (13) and
the washers (12).
15. Tighten the 2 screws M5x16, grade 8.8, of the cover by a

torque wrench to 18.4 ft.lbs. (25 Nm). 18. Turn the gearbox upside down and unscrew the 2
screws M8x16 (4), grade 8.8, of the end cover (7).
3-40 3121142
19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male
hex head wrench.
20. Remove the pin (3).

23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the
end cover (7).
21. Remove the O-ring seal (2) from its seat in the end cover
(7).
24. Remove the end cover (7).
3121142 3-41
25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17).
(7).
29. Remove the 2nd reduction assembly (18).

26. Remove the 1st stage sun gear (10).
30. By using pliers remove the circlips (19) from their seats
27. Remove the 1st reduction assembly (16). in the flanged hub's pins (31).
3-42 3121142
31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier
3rd reduction (20). (ATZ.09.016.0) on the ring nut (22).
32. Remove the spacer (21) from their seats in the pins of 35. By using the torque multiplier (ATZ.09.016.0) loosen the
the flanged hub (31). ring nut (22).
NOTE: In order to proceed with the gearbox disassembly, it is now 36. Take out the ring nut (22).
necessary to remove it from the machine and bring it to a
properly equipped workshop.
33. By using a drill remove the caulkings on the ring nut

(22).
3121142 3-43
37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29)
flanged hub (31) from the gearbox housing (23). from the flanged hub (31).
38. By using a tackle remove the gearbox housing (23) from 41. By using a screwdriver, remove the 2nd half-seal (29)
the flanged hub (31). from the gearbox housing (23).
39. Remove the seal ring (30) from its seat in the flanged NOTE: The gearbox disassembly ends with the above operation.
hub (31). All items are now available for the necessary inspections.
Inspection of Parts
The pieces that are subject to general wear and tear are the
following:
- Gears.
- Bearings.
- All the seals
Replace the used or irregular parts using the following steps:
1. Remove dirt, and in particular properly clean the seals,
bearings and locking rings seating.
2. Lubricate the parts before connecting them.
NOTE: In case of oil leaks, it may be necessary to check and even- 3. In the case of damaged gears, for example a planetary,
tually replace the lifetime seal (29), which means both the do not proceed to replace the individual gear but the
metal rings parts and the O-ring seals. entire reduction assembly.
3-44 3121142
4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings
involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate
seals to make reassembly easier. them with a thin oil film, taking care not to oil the
other components.
5. Replace all the damaged parts with original spare parts.
2. Assemble the half seal (29) on the tool (6689960300).
Assembly
Apply grease TECNOLUBE SEAL GS730 on the gearbox hous-
ing (23).
3. Assemble the 1st half seal (29) on the gearbox housing

(23).
1. Follow the steps below to prepare the lifetime seal for

assembly:
a. Carefully clean the seats (A and B) using, if neces-
sary, metallic brushes or solvent (surfaces in contact
with or (C) must be perfectly clean and dry).
b. Make sure that sealing surfaces (D) of metal rings (E)

are free from scratches, dinges or foreign sub-
stances; metallic ring surfaces must be perfectly
clean and dry. We suggest to dip the metallic rings
in volatile solvent or industrial degreasing alcohol.
3121142 3-45
4. Using the same tool (6689960300), assemble the 2nd 7. Apply grease TECNOLUBE SEAL GS730 on the seal ring
half seal (29) on the flanged hub (31). (30).
5. Carefully clean the metallic faces of the lifetime seal (29)

and lube the surfaces with oil.
AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29)
8. By using a hoist, place the gearbox housing (23) on the

flanged hub (31).
6. Insert the seal ring (30) in its seat in the flanged hub (31).
3-46 3121142
9. By using a press and a metallic stopper, push the gear- 11. By using the mutiplier (ATZ.09.016.0), tighten the ring
box housing (23) against the shoulder on the flanged nut (22), using a torque wrench with an input multiplier
hub (31) until assembling of the unit is complete. torque of 71 ± 3 ft.lbs.(96,5 ± 4, 5 Nm) corresponding to
an output multiplier torque of 3688 ± 184 ft.lbs. (5000 ±
250 Nm).
SCREW THE NUT (22) ON PARTIALLY IN ORDER TO PREVENT THE FLANGED 12. Stake the ring nut (22) near 2 seats at 180° of the flanged
HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE hub (31) on the right side.
FOLLOWING STEPS.
NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm).

10. By using a hoist place the torque multiplier
(ATZ.09.016.0) on the ring nut (22).
3121142 3-47
13. Assemble correctly the spacers (21) on the pins of the 16. By using pliers, assemble the circlips (19) in the flanged
flanged hub (31). hub pin seats (31).
14. Place the 5 planet assemblies of the 3rd reduction (20) in 17. Assemble the 2nd reduction assembly (18).
the flanged hub's pin (31).
18. Insert the 2nd stage sun gear (17).

15. By using a rubber hammer and a metal stopper push the
planet assemblies of the 3rd reduction (20) against the
shoulder until assembly is complete.
3-48 3121142
19. Assemble the 1st reduction assembly (16). 22. Place the end cover (7) on the gearbox housing (23).
20. Insert the 1st stage sun gear (10). 23. Tighten the 10 socket head screws M10x25 (1),grade
12,9, by a torque wrench at 62.7 ft.lbs. torque (85 Nm).
21. Assemble the O-ring seal (9) into its seat in the end
cover (7). 24. Insert the plugs (6) into the oil draining-filling holes of
the end cover (7). Torque the plugs to 52 ± 7 ft.lbs.
(70±10 Nm).
3121142 3-49
25. Assemble the O-ring seal (2) into its seat in the end 28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs.
cover (7). (25 Nm).
26. Protect the seat and the pin (3) with grease type 29. Insert the 1st washer (12) in the splined shaft (14).
MOLYKOTE G6000. Wait 15 minutes for it to completely
dry. Insert the pin (3) in its seat in the end cover (7).
30. Insert the spring (13) in the splined shaft (14).
27. Assemble the cap nut (5).
3-50 3121142
31. Insert the splined shaft (14) in the equipment 34. By using pliers, assemble the elastic ring (11) into its seat
(6689960240). in the splined shaft (14).
32. Insert the 2nd washer (12) correctly in the splined shaft
(14).
35. Insert the disengagement shaft kit (15) in the flanged

hub (31).
33. Torque the 2 screws M5x16, grade 8.8, of the cover to

18.4 ft.lbs. (25 Nm).
3121142 3-51
36. By using pliers assemble the circlip (36) into its seat in 39. Then insert an internally toothed steel disc (32). Repeat
the brake shaft (35). the operation until all 5 sintered bronze discs and 4 steel
discs have been assembled.
37. Turn the gearbox upside down and assemble the brake
shaft (35) inside the flanged hub (31). 40. Fit the internal O-ring seal (41) and the backup ring (40)
into their seats in the spacer (39).
38. Assemble the brake discs package according to the fol-

lowing order: first, insert one sintered bronze disc with 41. Fit the external O-ring seal (38) and the backup ring (37)
external teeth (33). into their seats in the spacer (39).
3-52 3121142
42. Insert the spacer (39) inside the flanged hub (31), paying 44. Lube the seal seats into the flanged hub (31) and assem-
attention not to damage the seals already fitted. ble the O-ring seal (42) and the backup ring (43).
43. By using a rubber hammer and a metal stopper push the NOTE: The O-ring seals (A) and backup rings (B) must be fitted in
spacer (39) against the flanged hub (31), paying atten- the seats according the mutual position as shown in the
tion not to damage the seals already fitted. scheme.
3121142 3-53
45. Insert the brake piston (44) inside the flanged hub (31), 47. Insert the springs (45) into the holes in the brake piston
paying attention not to damage the seals already fitted. (44) marked previously.
46. By using a rubber hammer and a metal stopper push the 48. Insert the spring retainer disc (46).
brake piston (44) against the flanged hub (31), paying
attention not to damage the seals already fitted.
3-54 3121142
49. Install the special tool (6689960310) on the flanged hub Final Test and Reinstallation
(31) and turn the screw until it compresses the springs
Check the product by remounting it to the machine.
(45).
Check the function of the drive hub following all the checks
shown in Startup and Running In.
If work on the brake was undertaken, it is important to check
that there are no oil leaks. Follow the procedure below:
1. Connect the pressure pilot line with the manometer
(with a base scale of 100 bars) to the brake release port.
50. Assemble the circlip (47) in its seat and remove the spe-
cial tool.
2. Open the flow valve and release the brake with the pilot
pressure of 50 bar.
NOTE: Before assembling the hydraulic motor, verify by a depth
slide gauge the correct assembly of the unit checking the 3. Close the flow valve and keep the brake released 3 min-
axial distance as shown below. utes or longer.
4. Using the manometer, check that the pressure remains
constant.
NOTE: If the pressure drops it may mean that the brake seals are
not tight and consequently they must be replaced or it may
mean that the reassembling was not completed properly.
5. After having reassembled the gearbox, install the

hydraulic motor.
6. Fill the gearmotor with the lubricant oil.
3121142 3-55
Figure 3-30. Drive Hub Special Tools - Sheet 1 of 4
3-56 3121142
3121142 3-57
3-58 3121142
3121142 3-59
3.16 DRIVE HUB - REGGIANA RIDUTTORI (SN 134389 8. Wrench for M6, M8, M10 socket head screws and 1/4"G
plug.
TO PRESENT)
9. Socket wrench for M6 hexagonal screw.
NOTE: After S/N 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
tion 3.15, Drive Hub - Bonfiglioli (SN 100128 to Present). Do
not use different hubs on the same machine. M- 1326
Symbol Nomenclature Ø240
Ø130
Ø30 5x45°
35
= ADHESIVE °
15
R5
Ø224
10
5
Ø233
Ø240
= LUBRICANT 60°
°
60
60
°
A A
= GREASE
N° 6 Hole to 120° Ø30
= TORQUE WRENCH
Figure 3-34. Bearing Track Spacer Mounting C016117
= DISPOSAL
M- 1537
Ø249
Ø130
Tools
Ø30
Tools required for assembling and disassembling the wheel N° 4 Hole to 90° Ø30
gear RRTD1701TB
29.5
1. Hammer;
2. Clamps for inner retention rings;
Ø210
14.5
10
3. Clamps for outer retention rings; Ø219

4. Electric or pneumatic screwdriver;
5. Special spacer mounting; Figure 3-35. Oil Seal Spacer Mounting C125049
6. Torque wrench;
7. Hydraulic press;
3-60 3121142
Ø210
5x45°
Ø130
25
Ø30
M- 1321
LOCTITE 2701
N° 4 Hole to 90° Ø40
110
M- 1320
Ø197.5
Ø210
Figure 3-36. Bearing Spacer Mountng CO16117
Figure 3-37. Assembly Diagram 1
3121142 3-61
M- 1316 M- 1020
30
Ø34 35 35
10
10 10
M- 1317
45°
45°
8 M- 1317
N° 4 R
35
45°
45°
70
A A
35
50
M- 1317
70
50
216.5
Ø
12
10
Ø11
Ø230
20
M- 1316 10x45°
60
Ø16
90
70
Ø17
55
38
11
M- 1317
M- 1317
M- 1317 Figure 3-40. Anti-rotation Block
16 n° 8 Routing to 45°
Ø205
Figure 3-38. Wrench For Ring Nut

M- 1126
Ø20
Ø12
M- 1125
T.U.9
Ø180
n° 12 Fori a 30° Ø35
Ø80
30
50
Ø20 H7 (+0.021) n°12 Hole to 30°

10.5
0
20
n° 12 Hole to 30° Ø6.5

M6
32
n° 12 Spot-facing to 30° Ø10.5

T.U.15
Figure 3-41. Anti-rotation Pin

6.5
n° 4 Hole to 90° M10

Ø50
Ø275
Ø305
30° 30°
0
°
30
3
°
30°
30°
A A
Figure 3-39. Anti-rotation Flange
3-62 3121142
M- 1126 M- 1126
M- 1125 VTCEI M6X12 n°12
M- 1020
VTCEI M10X60 n°4
Figure 3-42. Assembly Diagram 2
3121142 3-63
Ø105 M- 1546 M- 1548

Ø93.5
+0.1
Ø48
Ø20+0.2 Ø46
5
5
9
80
70
50
8.5
20
Ø8.5
Ø13.5 Ø40.5
5
Ø46
2.5x15° M- 1547
Ø39.5
t.u. 12
88.5
3.5
0 M8
Ø20 -0.1
VTCEI M8X16 n°1
Figure 3-43. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3-64 3121142
Disassembly 3. Release the screws from the release cover and pull the
pin out.
1. Remove the plugs and pour the lubricant in a container.
4. Remove the BR250 ring and pull the cover out avoiding
to damage the O-Ring.
2. Release the screws to disassemble the motor flange tak-

ing care not to damage the O-Ring.
5. Pull the reduction gears out.
3121142 3-65
3-66
Figure 3-44. Reggiana Riduttori Hub - Sheet 1 of 2
3121142
3121142
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Tablet
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring
10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
Figure 3-45. Reggiana Riduttori Hub - Sheet 2 of 2
3-67
6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also
the planetary ring without damaging the O-Ring. remove the 3/16" balls.
7. Remove the release joint together with the spring. 10. Loosen the ring nut using the special wrench.
8. Disassemble the Ø40 outer snap rings and using an 11. Remove the hub support together with the roller bear-
extractor remove the planetary gears from the spindle ing inner track.
pins.
3-68 3121142
12. Disassemble the Ø160 inner snap ring and pull the Assembly
spring holder spacer out. Remove the springs and using
a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are
piston out of the spindle. devoid of burrs, machining residues and that they are
correctly washed.
2. Fit the ball bearing in the input shaft and lock with a Ø40
outer snap ring.
13. Remove the brake discs and seals.

3. Mount the motor shaft in the spindle and lock with BR68
ring. Lubricate the bearing.
14. Fit the ball bearing into the input shaft and lock it with a
Ø40 outer snap ring. Then mount the motor shaft in the
spindle and lock with a BR68 ring. Lubricate the bearing.
3121142 3-69
4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller
cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner
the brake discs making sure to centre them on the spin- track.
dle and on the input shaft.
7. Fit the oil seal lubricated with grease onto the support
5. Insert the brake piston and place the springs into the with the special spacer mounting (see figure A).
piston holes. Close the brake fitting the spring holder
plate, then lock with the Ø160 inner snap ring. Check the
brake leakage, if any, as well as the static torque and Fig.A
minimum opening pressure.
8. Place the hub support already assembled on the spindle

making sure that the first roller bearing inner track goes
correctly against it; then fit the second roller bearing
inner track by means of the spacer mounting. Tighten
the ring nut.
3-70 3121142
9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on
lowing order: the spindle thread by the M6 holes of the ring nut.
10. 7.) By keeping the spindle locked, apply a setting pre-
load by tightening the ring nut at 40daNm, turn com-
pletely the hub support twice using the special wrench
to recover any bearing cage misalignments. Release and
tighten the ring nut at the final torque of 30daNm (alter-
nate tightening and some setting turns). Check the roll
torque with seal which must be within 1÷1,5 daNm.
12. Fit the 4 3/16" balls and tighten with LOCTITE 243 the 4
M6x6 socket headless screws at the torque of 1daNm.
NOTE: Place the ring nut with its convex part facing the roller
bearing as shown below.
3121142 3-71
13. Fit the bearings onto the 3rd stage planetary gears and 15. Place the hub onto the support making the two holes
using a spacer mounting mount everything on the spin- coincide for tightening the M10x25 flathead socket
dle pins. Lock with a ÿ40 outer snap ring. Lubricate the screws at the torque of 5daNm.
bearings.
16. Fit the reduction gears and the pinion in the unit.
14. Using a marking pen, make a mark between the snap

ring and the bearing. Fit the greased spring and the
release joint. Use grease to fit the O-Ring 2-275 in the
hub support seat.
3-72 3121142
17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor
ably greased and lock it with the shimming ring. Lubri- coupling flange S-D LC/KC. Mount the flange on the
cate the bearings. spindle with 6 M8x25 socket cap screws at the torque of
2.4daNm with LOCTITE 243 Insert the pin and carry out
the rotation test according to PGQ-22 standard.
18. Fit the O-Ring 2-177 suitably greased, mount the cover
locking it with the BR250 ring.
20. Mount the release cover fastening it with 2 M6x20 hex-
agonal screws at the torque of 1daNm. Mount the 1/
4"GAS plugs on the cover at the torque of 1daNm.
3121142 3-73
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-46. Swing System (SN 0300201016 through 0300254466,

3-74 3121142
4
MAE36280
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-47. Swing System (SN 0300254467 to Present)
3121142 3-75
3.17 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
Roll and Leak Testing should be taken to ensure that the bolts are not tightened
beyond their specified torque.
Torque-Hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the unit's The following steps describe how to tighten and torque bolts
gears, bearings and seals are working properly. The following or socket head cap screws in a bolt circle.
information briefly outlines what to look for when performing
these tests.
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure)
NOTE: Bolts must be removed while performing brake release test
Roll Test
The purpose of the roll test is to determine if the unit's gears
are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency.
LEAK TEST (MAIN UNIT) 1. Tighten (but do not torque) bolt “A" until snug.
The purpose of a leak test is to make sure the unit is air tight. 2. Go to the opposite side of the bolt circle and tighten
You can tell if your unit has a leak if the pressure gauge read- bolt °B" until equally snug.
ing on your air checker starts to fall after the unit has been
pressurized and allowed to equalize. Leaks will most likely 3. Crisscross around the bolt circle and tighten remaining
occur at the pipe plugs, the main seal or wherever o-rings or bolts.
gaskets are located. The exact location of a leak can usually be 4. Now use a torque wrench to apply the specified torque
detected by brushing a soap and water solution around the to bolt "A".
main seal and where the o-rings or gaskets meet on the exte-
rior of the unit, then checking for air bubbles. If a leak is 5. Using the same sequence, crisscross around the bolt cir-
detected in a seal, o-ring or gasket, the part must be replaced, cle and apply an equal torque to the remaining bolts.
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.
3-76 3121142
Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36)
and remove fittings from Brake (26) and Motor Control
1. Place unit on bench with the motor end up. Valve (32).
2. Remove O-ring Plug (1J) and drain the oil from the gear- 5. Remove O-ring Plugs (21) from Motor Control Valve (32).
box.
6. Remove Motor Control Valve (32) from Motor (10) by
3. Remove Hydraulic Tubing Assembly (35) by loosening removing the four Bolts (34) and washers (33).
fittings on both ends of tube with a wrench.
1J. O-Ring Plug 32. Motor Control Valve

10. Hydraulic Motor 33. Lockwasher
21. Plug 34. Hex Bolt
24. ID Plate 35. Hydraulic Tubing
25. Drive Screw 36. Elbow
26. Hydraulic Brake
Figure 3-48. Swing Drive - Motor Control Valve Disassembly (SN 0300201016 through
0300254466, SN B300002238 to Present)
3121142 3-77
Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor
(10).
1. With unit resting on bench with Motor (10) end up,
4. Remove Brake (26) from Main Torque-Hub Assembly
loosen Hex Bolts (29) and remove Lift Lugs (28) from the
and dump oil out of Brake (26).
Motor (10).
5. Remove O-ring (27) from between Motor (10) and Brake
2. Pull Motor (10) straight up and remove Motor (10) from
(26).
Brake (26).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-49. Swing Drive - Motor and Brake Disassembly (SN 0300201016 through
0300254466, SN B300002238 to Present)
3-78 3121142
Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15)
from between Input Cover (6) and Carrier (3A) Subas-
1. With the unit resting on the Output Shaft (Pinion) (1A), sembly.
remove the eight Bolts (17), four Shoulder Bolts (18) and
7. Remove Ring Gear (4) from Housing (1G).
four Lock Washers (19) from the Input Cover (6).
8. Remove O-ring (5) from between Ring Gear (4) and
2. Thread either 1/2-13 UNC eye bolts or motor mounting
Housing (1G).
Bolts (29) into threaded holes in Input Cover (6) and pull
Input Cover (6) off on the main assembly. 9. Remove Carrier (3A) Subassembly.
3. Remove O-ring (5) from between Input Cover (6) and 10. Remove Thrust Washers (16) and Thrust Bearing (15)
Ring Gear (4). from between Carrier (3A) Subassembly and Internal
Gear (2).
4. Remove Thrust Washer (8) from end of Sun Gear (13).
11. Remove Internal Gear (2).
5. Remove Sun Gear (13).
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-50. Swing Drive - Main Disassembly (SN 0300201016 through

0300254466, SN B300002238 to Present)
3121142 3-79
Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G).
5. Invert the Housing (1G) and remove the Lip Seal (1B) if
1. Using retaining ring pliers, remove Retaining Ring (1I)
not already removed when Output Shaft (1A) was
from groove in Output Shaft (1A) and discard.
pressed out of Housing (1G).
6. Remove the Bearing Cone (1D).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Bearing Cups (1C & 1E) will remain in Housing (1G).
2. Remove Thrust Washer (1H). NOTE: If bearing replacement is necessary, the Bearing Cups (1C &
1E) can be removed with a slide hammer puller or driven
3. While supporting the Housing (1G) on the Output Shaft out with a punch.
(1A) end, press the Output Shaft (1A) out of the Housing
(1G).
NOTE: The Lip Seal (1B) may or may not be pressed out of the
Housing (1G) by the Bearing Cone (1D) during this step.
1A. Output Shaft 1F. Tapered Bearing Cone

1B. Lip Seal 1G. Housing
1C. Tapered Bearing Cup 1H. Thrust Washer
1D. Tapered Bearing Cone 1I. Retaining Ring
1E. Tapered Bearing Cup 1J. O-Ring Plug
Figure 3-51. Swing Drive - Hub Shaft Disassembly (SN 0300201016 through 0300254466,
3-80 3121142
Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust
Washers (3H) and the two Thrust Washers (3B) out of the
1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).
holds the Planet Shaft (3E) in the Carrier (3A) down into
4. Remove both rows of Needle Bearings (3C) and the
the Planet Shaft (3E) until it bottoms.
Spacer (3D) from the bore of the Planet Gear (3F).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-
5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is
Gears(3F).
removed.
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3G) from the Planet
Shaft (3E).
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-52. Swing Drive - Carrier Disassembly (SN 0300201016 through

0300254466, SN B300002238 to Present)
3121142 3-81
Hub-Shaft Sub-Assembly Carrier Sub-Assembly

NOTE: Refer to Figure 3-51., Swing Drive - Hub Shaft Disassembly NOTE: Refer to Figure 3-52., Swing Drive - Carrier Disassembly (SN
(SN 0300201016 through 0300254466, SN B300002238 to 0300201016 through 0300254466, SN B300002238 to Pres-
Present). ent).
1. Press Bearing Cone (1D) onto Shaft (1A). 1. Apply a liberal coat of grease to the bore of Cluster Gear
(3F). This will enable the Needle Rollers (3C) to be held in
2. Press Bearing Cup (1C) into Housing (1G), take care to
place during assembly.
insure cup starts square with bore of Hub (1G).
2. Install the first row of 14 Needle Rollers (3C) into the
3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
bore of Cluster Gear (3F).
1G).
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
4. Press or tap Seal (1B) into the counterbore of Housing
the Needle Rollers (3C).
(1G) to the point where it becomes flush with the Hous-
ing (1G) face. Care should be taken to insure Seal (1B) is 4. Place second row of Needle Rollers (3C) into bore of
being correctly installed (smooth face up). Cluster Gear (3F) against Spacer (3D) and remove Planet
Shaft (3E).
5. Invert Hub (1G) and press Bearing Cup (1E) into counter-
bore of Housing (1G). 5. Place Carrier (3A) into tool fixture so that one of the roll
pin holes is straight up.
6. Carefully lower Housing (1G) onto the Output Shaft (1A).
6. Start Planet Shaft (3E) through the hole in Carrier (3A).
7. Start the Bearing Cone (1F) onto the Output Shaft (1A).
Using ample grease to hold it in position, slide one
8. Press or tap the Bearing Cone (1F) onto the Output Shaft Thrust Washer (3B) over the Planet Shaft (3E) with the
(1A) until it is seated in the Bearing Cup (1E). tang resting in the cast slot of the Carrier (3A). Place Ball-
Indented Thrust Washer (3H) on the Planet Shaft (3E)
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and with the indents against the first washer.
against Bearing Cone (1F).
7. With large end of Cluster Gear (3F) facing the roll pin
10. Install Retaining Ring (1I) into the groove in the Output hole in the carrier, place the cluster gear into position in
Shaft (1A). This Retaining Ring (1I) should never be Carrier (3A) and push Planet Shaft (3E) through the Clus-
reused in a repair or rebuild. ter Gear (3F) without going all the way through.
8. Slide the second Thrust Washer (3E) between the Cluster
Gear (3F) and the Carrier (3A) with the tang of the
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. washer located in the cast slot of the Carrier (3A). Slide
ball-indented Thrust Washer (3H) onto the end of the
11. Tap the Retaining Ring (1I) with a soft metal punch to Planet Shaft with the indents against the second thrust
ensure that the Retaining Ring (1I) is completely seated Washer. Finish sliding the Planet Shaft (3E) through the
in the groove of the Output Shaft (1A). Thrust Washers (3H) & (3B) and into the Carrier (3A).
9. Position the non-chamfered side on the Planet Shaft (3E)
roll pin hole so that it is in line with the hole in the Car-
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. rier (3A) using a 1/8" (3 mm) diameter punch.
12. Install O-ring Plug (1J) and torque 23 to 24 ft-lbs.(32 - 10. After using a 3/16" (5 mm) punch to align the two roll
33.5 Nm). pin holes. Drive the Roll Pin (3G) through Carrier (3A)
and into the Planet Shaft (3E) until the Roll Pin (3G) is
flush with the bottom of the cast tang slot in the Carrier
(3A). Use a 1/4" (6 mm) pin punch to make sure the Roll
Pin (3G) is flush in the slot.
11. Repeat Steps 1 thru 10 for the remaining two Cluster
Gears(3F).
3-82 3121142
Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
NOTE: Refer to Figure 3-50., Swing Drive - Main Disassembly (SN with the Internal Gear (2) and Input Gear (13). On the
0300201016 through 0300254466, SN B300002238 to Pres- Ring Gear (4) locate the hole marked "X", or punch
ent). marked, over one of the marked counter-bored holes
(Step 5) in Hub (1G). Check timing through the slots in
1. With the Hub Shaft Sub-Assembly resting on the Shaft the carrier. Rotate carrier in assembly to check for free-
(1A) install Internal Gear (2). The spline of the Internal dom of rotation.
Gear (2) bore will mesh with the spline of the Output
NOTE: NOTE: If gears do not mesh easily or Carrier Assembly does
Shaft (1A).
not rotate freely, then remove the Carrier and Ring Gear
2. Inspect the location of the Internal Gear (2) on the Out- and check the Cluster Gear timing
put Shaft (1A). The portion of the Output Shaft (1A),
which does not have full spline, should protrude 10. Install Thrust Washer (15)/Thrust Bearing (16) set into
through the Internal Gear (2) bore. the counter-bore in the face of the carrier. Use grease to
hold in place.
3. Install two Thrust Washers (15) and one Thrust Bearing
(16) on the portion of Output Shaft (1A) which protrudes 11. Place O-ring (5) into Cover (6) counter-bore. Use grease
through Internal Gear (2). to hold O-Ring in place.
4. Center the Input Gear (13) on the end of the Output
Shaft (1A) opposite the gear with the large diameter
down. CAUTION: BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING
THIS O-RING.
5. Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place.
12. Using sufficient grease to hold in place, install Thrust
Washer (8) into the counter-bore of the interface of the
Cover (6).
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O-
13. The Cover (6) is now installed, taking care to correctly
RING.
align Pipe Plug hole (20) with those in the Hub (1J).
Check timing sheet.
6. Also at this time locate and mark the four counter
reamed holes in the face of the Hub (1G). This is for iden- 14. Locate the 4 counter-bored holes in Hub (1G) [marked in
tification later in the assembly. Step 5] and install 4 Shoulder Bolts (18) with Lockwash-
ers (19). Start the shoulder bolts by hand.
7. Place Carrier (3A) Subassembly on bench with the large
end of Cluster Gears (3F) up with one at the 12 o clock 15. Install Grade 8 Bolts (17) with Lockwashers (19) into
position. Find the punch marked tooth on each gear at remaining holes.
the large end and locate at 12 o'clock (straight up) from
16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65 Nm)
each planet pin. Marked tooth will be located just under
and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to 65 Nm).
the Carrier on upper two gears. Check the timing
Roll and leak test the assembly.
through the slots in the carrier.
17. With gearbox standing on the pinion end fill gearbox
8. With large shoulder side of Ring Gear (4) facing down,
with GEAROIL 80W90, to bottom of plug hole in cover at
place Ring Gear (4) over (into mesh with) large end of
Pipe Plug (20).
gears. Be sure that punch marks remain in correct loca-
tion during Ring Gear (4) installation. The side of the 18. Install Pipe Plug (20) into Cover (6) using thread sealant.
Ring Gear (4) with an "X" or punch mark stamped on it
should be up.
3121142 3-83
Motor and Brake Assembly Motor Control Valve Assembly

NOTE: Refer to Figure 3-49., Swing Drive - Motor and Brake Disas- NOTE: Refer to Figure 3-48., Swing Drive - Motor Control Valve Dis-
sembly (SN 0300201016 through 0300254466, SN assembly (SN 0300201016 through 0300254466, SN
B300002238 to Present). B300002238 to Present).
1. Place O-ring (27) onto end of Brake (26) and locate brake 1. Lay assembly down with motor ports facing up. Remove
into pilot of cover. the two plastic plugs in the motor ports, being careful
not to loose the O-ring in each port. Assemble the Motor
2. Place Gasket (31) onto the brake face and line up the
control Valve (32) onto the Motor (10) with Bolt (34) and
holes.
Lock Washers (33). Torque Bolts (33) 23 to 27 ft-lbs. (32 to
3. Place Motor (10) into Brake pilot against the Gasket (31). 38 Nm).
4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble NOTE: Be sure to align the holes in the control valve with the
Hex Bolts (29) with Lift Lugs through the Motor (10) and motor ports.
Brake (26) against the motor flange. Torque to 35 ft-lbs.
2. Install Elbow Fittings (36) into Brake (26) and torque 13
5. Fill Brake (26) with 2.7 oz. (80cc) of BRAKOILVG32
to 15 ft-lbs. (18 to 21 Nm).
(DTE24).
3. Install Elbow Fittings (36) into Motor Control Valve (32)
and torque to 13 to 15 ft-lbs. (18 to 21 Nm).
4. Assemble Tube (35) into Elbow Fittings (36) and torque
13 to 15 ft-lbs. (18 to 21 Nm).
5. Install O-ring Plugs (21) into Motor Control Valve (32)
and torque 30 to 31 ft-lbs. (42 to 43 Nm).
6. Pressure test brake, tube and control valve connections
by applying 3000 psi (207 bar) pressure to the brake
bleed port and holding for 1 minute. Check for leaks at
the control-valve-motor interface and the tube connec-
tions. Release pressure.
7. Place I.D. Plate (24) onto Housing (1G) with two Drive
Screws (25). I.D. Plate (24) is to be inline with O-ring Plug
(1J) as shown on assembly print.
3-84 3121142
3121142 3-85
15
11
9 10
12
13
17
12
14
16
8
5 6
4
4
3
2 7 40
30
6 27
1
26
25
20
18 28
19
29
18
24 7
27
23
22
21 49
20 48
18
19
18 43 47
46
45
44
42
41
31
32
39
38
37
36
35
32
31
34
33 1001228488-B
MAE37600B
Figure 3-53. Swing Motor (SN 0300254467 to Present)- Sheet 1 of 2
3-86 3121142
1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring

2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover
3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw
4. Bearing 14. Spacer 24. Spacer 34. Disc 44. O-ring
5. Support 15. O-Ring Plug 25. Pinion 35. Disc 45. Motor
6. O-ring Plug 16. Spring 26. Ring 36. Seal 46. Lung Lifting
7. O- ring Plug 17. Capscrew 27. Washer 37. O-ring 47. Capscrew
8. Nut Ring 18. O-ring 28. Brake Housing 38. Piston Brake 48. Brake valve adapter
9. Reduction Gear 19. Planetory Ring 29. Plug 39. Spring Brake 49. Valve
10. Pinion 20. Reduction Gear 30. Capscrew 40. Shaft Input
Figure 3-54. Swing Motor (SN 0300254467 to Present)- Sheet 2 of 2
3121142 3-87
3.18 SWING BRAKE HYDRAULIC/MECHANICAL

To check brake release, connect an appropriate hydraulic pres-
Pre-Installation Checks sure supply set to the required level up to a maximum of 3000
MECHANICAL psi (200bar) and check that brake shaft (1) is free to rotate.
Check, That in the handling prior to assembly, the mounting Remove hydraulic supply from brake, checking to ensure that
features and other parts of the brake are undamaged. Ensure the friction plates (3 & 6) have engaged thus preventing rota-
that the shaft to which the brake is mounted are clean and free tion of brake shaft (1)
from burrs and swellings.
RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIMITED TO 2000

PSI (138 BAR) UNLESS BRAKE IS FULLY INSTALLED USING 2-OFF 1/2” UNC
MOUNTING BOLTS IN THE THROUGH (MOUNTING) HOLES.
1. Brake Shaft 9. Piston 17. O-Ring

2. Housing 10. Deep Groove Ball Bearing 18. Backing Ring
3. Inner Friction Plate 11. Internal Retaining Ring 19. Dowel Pin
4. Pressure Plate 12. Rotary Shaft Seal 20. Hexagon Plug
5. Gasket 13. Socket Head Cap Screw 21. Plastic Plug
6. Outer Plate 14. Shakeproof Washer 21A. Socket Pressure Plug
7. Gasket 15. O-Ring 22. Spring (Natural)
8. Cylinder 16. Backing Ring 23. Spring (Blue)
Figure 3-55. Swing Brake
3-88 3121142
Installation 5. Remove 2-off dowel pins (19).

Position 1-off gasket (5) over male pilot on brake housing (4). 6. Remove springs (8). Take note of quantity and orienta-
Locate brake shaft (1) and secure brake in position using 2-off tion of springs.
1/2” UNC mounting bolts in the through mounting (fixing)
holes provided. 7. Should it be necessary to replace ball bearing (10) or
Connect hydraulic pressure supply to brake pressure inlet shaft seal (12), reverse remainder of brake sub-assembly,
port. Ensure that the hydraulic pressure is set to the required supporting on face “c” of housing (2).
level up to a maximum of 3000 psi (200 bar) and check that the 8. Remove internal retaining ring (11).
brake disengages and re-engages correctly.
9. Using arbor press or similar to break Loctite seal, remove
brake shaft (1) from housing (2) and lay aside.
Maintenance
The brake is required to be kept in good working order and 10. Reverse housing (2) and press out ball bearing (10).
must be included in the planned maintenance program for the Shaft seal (12) can also be removed if necessary.
equipment to which the brake is installed.
This must include torque testing together with inspection and Examination
replacement of the working parts such as friction plates (3 & 6) All components can now be examined and inspected, paying
and, springs (22 & 23). The frequency of inspection depends particular attention to the following.
on the duty demanded of the brake.
1. Inspect friction plates (3 & 6) and friction surface on
Disassembly pressure plate (4) for wear or damage.
To remove brake from its installed position, reverse procedure 2. Examine friction plates (3) and brake shaft (1) for wear or
previously described in the installation instructions. damage to splines.
Place the complete brake assembly on a clean, dry work
bench. 3. Examine input and output splines of brake shaft (1) for
wear or damage.
Remove external gasket (5) as necessary.
4. Examine compression springs (22 & 23) for damage or
NOTE: Refer to Diagrams for the following. fatigue.
5. Check ball bearing (10) for axial float or wear.
1. Supporting brake face “A”, remove the six socket head
cap screws and washers (items 13 & 14) in equal incre- 6. Examine O-ring seals (15 & 17) and backing rings (16 &
ments to ensure the spring pressure within the brake is 18) for damage.
reduced gradually and evenly.
7. Obtain replacement parts as required.
Alternatively, if press is available, the cylinder housing
(8) can be restrained on face “B” while removing the six
socket head cap screws and washers (13 & 14). Assembly
The brake assembly can now be fully dismantled and Clean all parts thoroughly.
parts examined. Reverse procedure previously outlined in Dismantling instruc-
tions taking particular care with.
2. Remove cylinder housing (8) and piston (9) subassembly
and dismantle if required, removing O-ring seals (15 & a. Assembly of shaft seal (12).
17) and backing rings (16 & 18) as necessary.
b. Assembly of bearing (10).
3. Remove gasket (7) from housing (2). c. Quantity and orientation of springs (8).
4. Remove friction plates (3 & 6) and pressure plate (4). d. Assembly sequence of friction plates (3 & 6).
1. Lightly lubricate rotary shaft seal (12) and assemble to
housing (2) taking care not to damage seal lip.
3121142 3-89
2. Apply ring of Loctite 641 or equivalent adhesive to full 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
circumference of housing (2) bearing recess adjacent to equivalent) silicone grease and assemble together with
shoulder. backing rings (16 & 18) to piston (9). To ensure correct
Apply complete coverage of Loctite 641 to outside brake operation, it is important that the backing rings
diameter of bearing (10) and assemble fully in housing are assembled opposite ti the pressurized side of piston
(2), retaining with internal retaining ring (11). Remove (9).
excess adhesive with clean cloth.
5. Correctly orientate piston (9) aligning spaces with the
Press shaft (1) through bearing (10), ensuring bearing
two dowel pin holes and, assemble into cylinder hous-
inner ring is adequately supported.
ing (2) taking care not to damage seals and carefully lay
3. Assemble correct quantity of springs (8) in orientation aside.
required. Refer to (See Figure 3-56.) and (See Figure 3-
6. Loctite 2-off pins (19) in housing (2) followed by pres-
57.).
sure plate (4) and friction plates i.e. an inner (3) followed
by an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off socket head cap screws and
washers (13 & 14). Torque to 55ft/lbs. (75 Nm).
NOTE: The use of a suitable press (hydraulic or arbor) Pressing

down on cylinder end face “B” will ease assembly of the
socket head cap screws (13).
Figure 3-56. Swing Brake 8 Spring Orientation
Figure 3-57. Swing Brake 12 Spring Orientation
3-90 3121142
1. Brake Shaft 8. Cylinder 15. O-Ring

2. Housing 9. Piston 16. Backing Ring
3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring
4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring
5. Gasket 12. Rotary Shaft Seal 19. Dowel Pin
6. Outer Plate 13. Socket Head Cap Screw 20. Hexagon Plug
7. Gasket 14. Shakeproof Washer 21. Plastic Plug
21A. Socket Pressure Plug
Figure 3-58. Swing Brake Assembly
3121142 3-91
3.19 SWING MOTOR
Disassembly and inspection

1. Place the Torqlink™ in a soft jawed vice, with coupling
shaft (12) pointed down and the vise jaws clamping
firmly on the sides of the housing (18) mounting flange
or port bosses. Remove manifold port O-Rings (18A) if
applicable.
3. Remove the five, six, or seven special ring head bolts (1)
using an appropriate 1/2 or 9/16 inch size socket.
Inspect bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts.
IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED

DURINGTHE SERVICE PROCEDURES, CAUSING INJURY.
2. Scribe an alignment mark down and across the Torq-

link™ components from end cover (2) to housing (18) to
facilitate reassembly orientation where required. Loosen
two shuttle or relief valve plugs (21) for disassembly
later if included in end cover. 3/16 or 3/8 inch Allen 4. Remove end cover assembly (2) and seal ring (4). Discard
wrench or 1 inch hex socket required. seal ring.
NOTE: Refer to the appropriate “alternate cover construction” on

the exploded view to determine the end cover construction
being serviced.
3-92 3121142
1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing

2. End Cover 8C. Vane 16. Seal
3. Seal Ring-Commutator 8D. Stator Half 17. Backup Washer
4. Seal Ring 9. Wear Plate 18. Housing
5. Commutator Ring 10. Drive Link 18A. O-Ring
6. Commutator Ring 11. Not Used 19. Bearing/Bushing, Outer
7. Manifold 12. Coupling Shaft 20. Dirt & Water Seal
8. Rotor Set 13. Bearing/Bushing, Inner 21. Plug
8A. Rotor 14. Thrust Washer
Figure 3-59. Swing Drive Motor
5. If the end cover (2) is equipped with shuttle valve com-

ponents, remove the two previously loosened plugs
(21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE
REMOVED.
NOTE: The insert and if included the orifice plug in the end cover
(2) must not be removed as they are serviced as an integral
part of the end cover.
3121142 3-93
6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal
blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into
ing the internal orifice plug, are free of contamination. ring groove until seal ring is lifted out and discard seal
Inspect end cover for cracks and the bolt head recesses ring. Inspect commutator for cracks or burrs, wear, scor-
for good bolt head sealing surfaces. Replace end cover ing, spalling or brinelling. If any of these conditions exist,
as necessary. replace commutator and commutator ring as a matched
set.
NOTE: A polished pattern (not scratches) on the cover from rota-

tion of the commutator (5) is normal. Discoloration would
indicate excess fluid temperature, thermal shock, or excess
speed and require system investigation for cause and close
inspection of end cover, commutator, manifold, and rotor
set.
7. Remove commutator ring (6). Inspect commutator ring

for cracks, or burrs.
9. Remove manifold (7) and inspect for cracks surface scor-

ing, brinelling or spalling. Replace manifold if any of
these conditions exist. A polished pattern on the ground
surface from commutator or rotor rotation is normal.
Remove and discard the seal rings (4) that are on both
sides of the manifold.
3-94 3121142
NOTE: The manifold is constructed of plates bonded together to

form an integral component not subject to further disas-
sembly for service. Compare configuration of both sides oft
hem an if old to ensure that same surface is reassembled
against the rotor set.
10. Remove rotor set (8) and warplane (9), together to retain
the rotor set in its assembled form, maintaining the
same rotor vane (8C) to stator (8B) contact surfaces. The
drive link (10) may come away from the coupling shaft
(12) with the rotor set, and wearplate.You may have to
shift the rotor set on the warplane to work the drive link
out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on
any surface and for broken or worn splines. If the rotor NOTE: Series TG Torqlinks™ may have a rotor set with two stator
set component requires replacement, the complete halves (8B) with a seal ring (4) between them and two sets
rotor set must be replaced as it is a matched set. Inspect of seven vanes (8C). Discard seal ring only if stator halves
the warplane for cracks, brinelling, or scoring. Discard become disassembled during the service procedures.
seal ring (4) that is between the rotor set and wearplate.
NOTE: A polished pattern on the wear plate from rotor rotation is
normal.
11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor (8A) in stator (8B) such that two
rotor lobes (180 degrees apart) and a roller vane
(8C) centerline 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.
NOTE: The rotor set (8) components may become disassembled

during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pen-
cil before removal from Torqlink™ will ensure correct reas-
sembly of rotor into stator and rotor set
intoTorqlink™.Marking all rotor components and mating
spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
andTorqlink™.
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets
of seven vanes (8C & 8E) as shown in the alternate con-
struction TG rotor set assembly view, check the rotor lobe
to roller vane clearance at both ends of rotor.
3121142 3-95
12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output
not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur-
link for cracks and worn or damaged splines. No percep- faces for spalling, nicks, grooves, severe wear or corro-
tible lash (play) should be noted between mating spline sion and discoloration. Inspect for damaged or worn
parts. Remove and discard seal ring (4) from housing internal and external splines or keyway. Replace cou-
(18). pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion and a full
complement of retained rollers.
NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020 inches (0.51 mm) diametrically, replace cou-
pling shaft.
14. Check exposed portion of coupling shaft (12) to be sure
you have removed all signs of rust and corrosion which
NOTE: A slight “polish” is permissible in the shaft bearing areas.
might prevent its withdrawal through the seal and bear-
Anything more would require coupling shaft replacement.
ing. Crocus cloth or fine emery paper may be used.
16. Remove and discard seal ring (4) from housing (18).
3-96 3121142
17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and
Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is
ment of retained rollers. required.
18. Remove seal (16) and back up washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.
3121142 3-97
21. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to
this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location
and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of
the two thrust washers (14) and thrust bearing (15). The bearing/bushing counter bore should be measured and
bearing rollers must be firmly retained in the bearing noted before removing the bearings/ bushings. This will
cages, but must rotate and orbit freely. All rollers and facilitate the correct reassembly of new bearings/bushings.
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
this inspection the disassembly of the Torqlink™ is com-
pleted.
22. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) with-
out damaging the housing. Remove thrust washers (14)
and thrust bearing (15) if they were previously retained
in the housing by bearing (13).
3-98 3121142
Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqlink™ unit. Lubricate all seals and seal rings
with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal

kit are available. The parts should be available through
most OEM parts distributors or Parker approved Torqlink™
distributors. (Contact your local dealer for availability).
NOTE: Unless otherwise indicated, do not oil or grease parts

before assembly.
Wash all parts in clean petroleum-based solvents before NOTE: Bearing mandrel must be pressed against the lettered end
assembly. Blow them dry with compressed air. Remove any of bearing shell. Take care that the housing bore is square
paint chips from mating surfaces of the end cover, commuta- with the press base and the bearing/bushing is not cocked
tor set, manifold rotor set, wear plate and housing and from when pressing a bearing/bushing into the housing.
port and sealing areas.
IF THE BEARING MANDREL SPECIFIED IN THE “TOOLS AND MATERIALS

SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE
DEATH. BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
PONENTS WHEN ASSEMBLED.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-
IMUM AIR PRESSURE REQUIREMENTS.
BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
1. If the housing (18) bearing components were removed HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
for replacement, thoroughly coat and pack a new outer REUSED.
bearing/bushing (19) with clean corrosion resistant
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel

to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
3121142 3-99
2. The Torqlink™ inner housing bearing/bushing (13) can

now be pressed into its counterbore in housing (18)
flush to 0.03 inch (.76 mm) below the housing wear
plate contact face. Use the opposite end of the bearing
mandrel that was used to press in the outer bearing/
bushing (19).
3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqlink™ dirt and water seal (20) must be pressed in

until its’ flange is flush against the housing.
3-100 3121142
4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the that was removed from the Torqlink™.
mounting flange.
NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17) ing (15).The coupling shaft will be seated directly against
and new seal (16) with the seal lip facing toward the the thrust
inside of Torqlink™, into their respective counterbores in
housing (18) if they were not assembled in procedure 2. 7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.
8. Be sure that a generous amount of clean corrosion resis-

tant grease has been applied to the lower (outer) hous-
ing bearing/bushing (19). Install the coupling shaft (12)
into housing (18), seating it against the thrust bearing
(15) in the housings.
ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
3121142 3-101
9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT
#K-70M.
NOTE: Mobil Mobilith SHC ® 460
NOTE: A 102Tube (PN 406010) is included in each seal kit.
NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqlinks™ when properly seated.
The coupling shaft must rotate smoothly on the thrust
bearing package.
NOTE: One or two alignment studs screwed finger tight into

housing (18) bolt holes, approximately 180 degrees apart,
will facilitate the assembly and alignment of components
as required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqlink™.
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.
NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.
3-102 3121142
11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against
alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without
a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate (9).
14. Apply clean grease to a new seal ring (4) and assemble it
in the seal ring groove in the rotor set contact side of
manifold (7).
12. Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear
plate side of the rotor set stator (8B).
NOTE: The manifold (7) is made up of several plates bonded

together permanently to form an integral component.The
manifold surface that must contact the rotor set has it’s
series of irregular shaped cavities on the largest circumfer-
ence or circle around the inside diameter.The polished
impression left on the manifold by the rotor set is another
indication of which surface must contact the rotor set.
13. Install the assembled rotor set (8) onto wear plate (9)
with rotor (8A) counterbore and seal ring side down and
15. Assemble the manifold (7) over the alignment studs and
the splines into mesh with the drive link splines.
drive link (10) and onto the rotor set. Be sure the correct
manifold surface is against the rotor set.
NOTE: It may be necessary to turn one alignment stud out of the

housing (18) temporarily to assemble rotor set (8) or mani-
fold (7) over the drive link.
NOTE: If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”
3121142 3-103
16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.
19. If shuttle valve components items #21, were removed

17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one
onto the manifold. end of the valve cavity in the end cover. A 3/16 inch
Allen wrench is required.
20. 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.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
3-104 3121142
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.
21. Assemble the 5 or 7 special bolts (1) and screw in finger

tight. Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and NOTE: The special bolts required for use with the relief or shuttle
progressively tighten the bolts to pull the end cover and valve (24) end cover assembly (2) are longer than the bolts
other components into place with a final torque of 22-26 required with standard and cover assembly. Refer to the
ft. lbs. 45-55 ft. lbs.(61-75 N m) for the seven 3/8-24 individual service parts lists or parts list charts for correct
threaded bolts. service part number if replacement is required.
22. Torque the two shuttle valve plug assemblies (21) in end
cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so
equipped.
Torque the two relief valve plug assemblies (21) in end

cover assembly to 45-55 ft. lbs.(61-75 Nm) if cover is so
equipped.
3121142 3-105
One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
ily assemble into the stator vane pockets.
A disassembled rotor (8A) stator (8B) and vanes (8C) that can-
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
5. Grasp the output end of coupling shaft (12) with locking

2. If assembly alignment studs are not being utilized, align pliers or other appropriate turning device and rotate
stator bolt holes with wear plate and housing bolt holes coupling shaft, drive link and rotor to seat the rotor and
and turn two bolts (1) finger tight into bolt holes the assembled vanes (8C) into stator (8B), creating the
approximately 180 degrees apart to retain stator and necessary clearance to assemble the seventh or full
wear plate stationary. complement of seven vanes. Assemble the seven vanes
using minimum force.
3. Assemble the rotor (8A), counterbore down if applica-
ble, into stator (8B), and onto wear plate (9) with rotor
splines into mesh with drive link (10) splines.
NOTE: If the manifold side of the rotor was etched during Torqlink
disassembly, this side should be up. If the rotor is not
etched and does not have a counterbore, use the drive link
spline contact pattern apparent on the rotor splines to
determine the rotor side that must be against the wear
plate. 6. Remove the two assembled bolts (1) if used to retain sta-
tor and wear plate.
7. Tighten the jam nut (shown below) with JLG Thread-
locker PN 0100019.
3-106 3121142
3.20 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 ft-lbs
(122 Nm) with JLG Threadlocker PN 0100019.
1. Set backlash to 0.010" to 0.015" using the following pro-
cedure.
2. Place shim (JLG PN 4071041) between pinion and bear-
ing on the bearing high spot. The bearing high spot
should be stamped with an "X" on the surface below the
teeth and marked with yellow paint in the tooth space.
3. Torque the shoulder screw (shown below) to 660 foot-

pounds (896 Nm) with JLG Threadlocker PN 0100019. 6. Tighten the setscrew (shown below) until the pinion is
completely snug against the shim and bearing and then
back off the setscrew.
4. Remove the turntable lock pin.
3121142 3-107
7. Torque the setscrew to 50 foot-pounds (68 Nm).
MAE37630
1 Gearbox Fill Port

2 Gearbox Drain Port
8. Torque the capscrews shown in step 5 to 660 foot-
pounds (896 Nm). Figure 3-61. Swing Drive Ports (SN0300254467 to Present)
9. Remove shim and discard. The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API
Service Classification GL-5 Extreme Pressure Gear Lube. Fill to
cover the ring gear.
3.21 SWING DRIVE LUBRICATION
1.195 IN. (30.35 mm) TOP OF HOUSING TO TOP

OF RING GEAR. TO BE FILLED TO COVER RING
GEAR.
1 Brake Bleed Port

2 Brake Fill Port
3 Gearbox Fill Port Figure 3-62. Swing Drive Lubrication
4 Gearbox Drain Port
The Swing Brake is to be filled half full, 2.7 ounces (80 ml), with
Figure 3-60. Swing Drive Ports (SN 0300201016 through DTE24 oil.
0300254466, SN B300002238 to Present)
3-108 3121142
3.22 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check some
Turntable Bearing Mounting Bolt Condition selected bolts at the new position.
Check e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL 2. Check the turntable to bearing Attach bolts as follows:
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE a. Elevate the fully retracted main boom to full eleva-
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. tion.
b. At the position indicated on Figure 3-65. try to insert
NOTE: This check is designed to replace the existing bearing bolt the 0.0015” feeler gauge between the bolt head and
torque checks on JLG Lifts in service. This check must be hardened washer at the arrow indicated position.
performed after the first 50 hours of machine operation c. Lower the boom to horizontal and fully extend the
and every 600 hours of machine operation thereafter. If boom.
during this check any bolts are found to be missing or
loose, replace missing or loose bolts with new bolts and d. At the position indicated on Figure 3-64., try and
torque to the value specified in the torque chart, after insert the 0.0015” feeler gauge between the bolt
applying JLG Threadlocker PN 0100019 to the bolt threads. head and hardened washer at the arrow indicated
After replacing and retorquing bolt or bolts recheck all position.
existing bolts for looseness.
1. Check the frame to bearing attach bolts as follows:

a. Fully elevate the main boom. (See Figure 3-63.)
b. At the position indicated on Figure 3-63., try to
insert a 0.0015 feeler gauge between the bolt and
hardened washer at the arrow indicated position.
3121142 3-109
BOOM
FULLYELEVATED
FEELERGAUGE DIAL INDICATOR

MEASURING POINT MEASURING POINT
Figure 3-63. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
3-110 3121142
3121142
TELESCOPE
FULLYEXTENDED
DIAL INDICATOR&
FEELERGAUGE
MEASURING POINT
Figure 3-64. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
3-111
3. If the measurement is greater than 0.094 in. (2.387 mm),

the swing bearing should be replaced.
4. If the measurement is less than 0.094 in. (2.387 mm), and
any of the following conditions exist, the bearing should
be removed, disassembled, and inspected for the fol-
lowing:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble and
Figure 3-65. Swing Bolt Feeler Gauge Check return to service.
Wear Tolerance Swing Bearing Removal

1. From the underside of the machine, at rear center, with 1. From Ground Control station, operate the boom ade-
the main boom fully elevated and fully retracted, as quately to provide access to frame opening to rotary
shown in Figure 3-63., Swing Bearing Tolerance Boom coupling.
Placement - Sheet 1 of 2, set up a magnetic base dial
indicator as shown below and set the indicator to 0
(zero).
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK-
ING.
2. Attach an adequate support sling to the boom and draw

all slack from sling. Prop or block the boom if feasible.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
TEM.
3. Tag and disconnect the hydraulic lines from the fittings

on the top of the rotary coupling. Use a suitable con-
tainer to retain any residual hydraulic fluid. Immediately
cap lines and ports.
2. Next, position the main boom fully extended and hori-

zontal as shown in Figure 3-64., Swing Bearing Tolerance
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
Boom Placement - Sheet 2 of 2. Read the measurement
CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
recorded on the dial indicator gauge.
TEM.
4. From inside turntable, remove mounting hardware

which attach rotary coupling retaining yoke brackets to
turntable.
3-112 3121142
3121142
1350SJP Upperstructure - 30,250 lbs. (13,721 kg)
1200SJP Upperstructure - 26,150 lbs. (11,861 kg)
13” (33 cm)-1350SJP 18” (45 cm)-1200SJP
CENTER
OF
GRAVITY
C
L ROTATION
Figure 3-66. Swing Bearing Removal
3-113
5. At the rear of the main valve, remove the lift hose from Swing Bearing Installation
port #4. Immediately cap the line and port.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
BACK OF VALVE 1. Using suitable lifting equipment, carefully lower the

swing bearing into position on the frame. Ensure the
scribed line of the outer race of the bearing aligns with
the scribed line on the frame. If a new swing bearing is
used, ensure that the spot with minimum gear backlash
(marked with yellow paint) is towards the centerline of
the swing drive (as close as the bolt pattern will allow).
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS-

CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE
ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER-
ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.
USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
6. Attach suitable overhead lifting equipment to the
machine. Refer to Figure 3-66., Swing Bearing Removal. 2. Apply a light coating of Loctite #271 to the new bearing
bolts, and loosely install the bolts and washers through
7. Use a suitable tool to scribe a line on the inner race of the frame and outer race of bearing.
the swing bearing and on the underside of the turnta-
ble. This will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which attach the
turntable to the bearing inner race. Discard the bolts. IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING
8. Use the lifting equipment to carefully lift the complete ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.
turntable assembly from the bearing. Ensure that no
damage occurs to the turntable, bearing or frame-
mounted components.
9. Carefully place the turntable on a suitably supported
trestle.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
10. Use a suitable tool to scribe a line on the outer race of

the swing bearing and the frame. This line will aid in
aligning the bearing upon installation. Remove the bolts
and washers which attach the outer race of the bearing
to the frame. Discard the bolts. Use suitable lifting
equipment to remove the bearing from the frame, then
move the bearing to a clean, suitably supported work
area.
3-114 3121142
3. Refer to the Torque Sequence diagram as shown in Fig- 9. Connect the hydraulic lines to the rotary coupling as
ure 3-67., Swing Bearing Torque Sequence. Spray a light tagged prior to removal.
coat of Safety Solvent 13 on the new bearing bolts. Then
10. Install the rotary coupling retaining yoke brackets, apply
apply a light coating of JLG Threadlocker PN 0100019 to
a light coating of JLG Threadlocker 0100011 to the
the new bearing bolts, and install the bolts and washers
attaching bolts and secure the yoke to the turntable
through the frame and outer race of the bearing.
with the mounting hardware.
Tighten the bolts to an initial torque of 190 ft. lbs. (258
Nm) w/Loctite. 11. Connect the hydraulic line disconnected during removal
back to port #4 on the back of the main hydraulic valve.
4. Remove the lifting equipment from the bearing.
12. Remove the lifting equipment.
5. Using suitable lifting equipment, carefully position the
turntable assembly above the machine frame. 13. At ground control station, use boom lift control to lower
boom to stowed position.
6. Carefully lower the turntable onto the swing bearing,
ensuring that the scribed line of the inner race of the 14. Using all applicable safety precautions, activate the
bearing aligns with scribed line on the turntable. If a hydraulic system and check the swing system for proper
new swing bearing is used, ensure that the filler plug fit- and safe operation.
ting is at 90 degrees from the fore and aft center line of
the turntable. Swing Bearing Torque Values
7. Spray a light coat of Safety Solvent 13 on the new bear-
1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite.
ing bolts. Then apply a light coating of JLG Threadlocker
PN 0100019 to the new bearing bolts, and install the 2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite.
bolts and washers through the turntable and inner race
of the bearing. 3. See Swing Bearing Torquing Sequence.
8. Following the Torque Sequence diagram shown in Fig-

ure 3-67., Swing Bearing Torque Sequence, tighten the
bolts to a torque of 190 ft. lbs. (258 Nm) w/Loctite. CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.
3121142 3-115
NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.
Figure 3-67. Swing Bearing Torque Sequence
3.23 SWING SPEED PROPORTIONING Beyond Transport - Drive Speed Cutback System, the tilt sen-
sor will cause an alarm to sound, and automatically put all
Swing Speed Proportioning uses the boom length and angle functions in the creep speed mode. With the exception of the
sensors to improve the comfort, speed and control of the turn- speed cutback, this is a warning system only. The machine will
table swing function. Turntable swing speed is increased as continue to function. The operator is responsible to prevent
the distance of the platform to the center of rotation is the machine from attaining an unstable position. The 8.0
decreased. This results in approximately constant platform degree angle is used exclusively for the purpose of automati-
speeds regardless of boom position. Swing speed proportion- cally shifting the drive motors to the maximum displacement
ing is disabled with any envelope sensors failure. Disabling of position (slow speed). The control system responds to indi-
swing speed proportioning will default to the slowest swing cated angle readings 0.5 degrees smaller than the required
speed setting. angles to account for calibration and sensor variation.
NOTE: For more detailed information concerning system adjust- NOTE: For more detailed information concerning system adjust-
ment and operation, refer to Section 6 - JLG Control Sys- ment and operation, refer to Section 6 - JLG Control Sys-
tem. tem.
3.24 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the turntable angle
with respect to level ground. The tilt sensor (which is an inte-
gral part of the ground module) has two settings; 5.0 and 8.0
degrees. The smaller angle is used for the purpose of warning
the operator by means of the chassis tilt light in the platform
display panel. Additionally when used in conjunction with the
3-116 3121142
3.25 ROTARY COUPLING 6. Reassemble O-ring (4).
Use the following procedure to for installing the seal kit. 7. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F
(149° C).
1. Remove snap ring (7) from end.
8. Assemble cap seals over O-rings
2. Remove thrust ring (3) from same end.
9. Reinsert center body into housing (lube with hydraulic
3. Remove center body (1) from housing (3). oil).
4. Cut off old seals (2,3,5). 10. Replace thrust ring and snap ring.
5. Assemble lip seals (2) in direction shown in Figure 3-68.,
Rotary Coupling Seal Installation.
Figure 3-68. Rotary Coupling Seal Installation
3121142 3-117
1. Center Body 5. Seal

2. Seal 6. Thrust Ring
3. Housing 7. Snap Ring
4. O-ring
Figure 3-69. Rotary Coupling Cutaway
3-118 3121142
5 1,2
6 8
8
1,9
8
5A
5B
1. JLG Threadlocker PN 0100011 5B. Rotary Circuit Contactor

2. Bolt 6. Locknut
3. Bolt 7. Not Used
4. Swivel Bracket 8. Flatwasher
5. Rotary Coupling & Collector Ring Assembly 9. Nut
5A. Rotary Coupling
Figure 3-70. Rotary Coupling Installation
3121142 3-119
6
2 1
6
4
7 1
5
4 2
5 3
1 2
3
1
2 1
3 2
3
4
5
6
7 7 7
Figure 3-71. Rotary Coupling Port Location
3-120 3121142
Every 500 hours

Table 3-7. Coupling Port Information Table
Every 500 hours of operation, service the generator brushes
Operating Proof and slip rings. Hostile environments may require more fre-
Port Port quent service.
Outlets Description Pressure Pressure
No. Size
PSI (Bar) PSI (Bar)
1 2 -12 Steer/Axle Extend 250 (17) 375 (26)
(Tank)
2 2 -10 Steer/Axle Extend (Pres- 3000 (207) 4500 (310)
sure)
3 1 -10 Drive A 3000 (207) 4500 (310)
4 1 -10 Drive B 3000 (207) 4500 (310)
5 1 -10 Drive A 3000 (207) 4500 (310)
6 1 -10 Drive B 3000 (207) 4500 (310) Every 500 hours of service, blow out the inside of the genera-
7 2 -12 Case Drain 250 (17) 375 (26) tor. If operating in a hostile environment, clean monthly.
3.26 GENERATOR
Every 250 hours
Every 250 hours of operation, check the drive belt for proper
tension.
1/2 in.
(13 mm)
3121142 3-121
Overload Protection Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-72., Inspecting Generator Brushes, Replacing
STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings.
BREAKER.
INSPECTING BRUSH POSITION
The circuit breaker protects the generator windings from over-
load. If the circuit breaker opens, generator output stops. If the Inspect brush alignment with slip rings. View alignment
circuit breaker continues to open, check for faulty equipment through the air vents in the stator barrel. The brushes must
connected to the platform receptacles. ride completely on the slip rings.
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near

minimum length.
Circuit
Breaker CLEANING SLIP RINGS
Visually inspect the slip rings. Under normal use, the rings turn
dark brown.
If the slip rings are corroded or their surface is uneven, remove

the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
3-122 3121142
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-72. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3121142 3-123
3.27 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres-
sure to the lift cylinder allowing gravity to lower the boom.
The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to
of moving the boom in the event of primary power loss. This retract the telescope cylinder. When the boom is retracted to
system uses an electric motor/pump unit powered by a 12V the transport length, the telescope in valve is dropped out and
battery capable of operating all functions except drive, con- lift down is operated alone allowing the platform to reach the
trolled arc, controlled boom angle, and envelope tracking. ground. This not only greatly reduces the power required for
During lift up or down functions, no other functions are per- these functions but also lowers the boom within the envelope
mitted and during lift up functions, automatic platform level- regardless of starting position. Envelope control and moment
ing is not active. To reduce the demand on the battery and control remain active during the auxiliary power function.
therefore extend the run time of the system, the auxiliary
power functionality differs from the primary power functional-
1. Auxiliary Pump
2. Power Relay
3. Battery
Figure 3-73. Auxiliary Pump Installation
3-124 3121142
HYDRAULIC OIL
TANK HEATERCABLE
BATTERYHEATERCABLE
BATTERYHEATERCABLE
BATTERY
REF AUXPUMP
BATTERYHEATER BATTERYHEATER
VIEWA-A
A A
B B
TANK HEATER
VIEW B-B
Figure 3-74. Cold Weather Package
3121142 3-125
3.28 COLD WEATHER PACKAGE Check the oil level, and if necessary, top the oil level up
to the MAX mark with an approved grade and type of
As an option, a cold weather package is available to allow the oil as outlined in the engine manufacturer’s opera-
machine to be operated in lower temperatures. The package tor’s manual. Refer to Figure 3-75., Deutz Engine Dip-
consists of battery heaters, a hydraulic tank heater, Exxon Uni- stick.
vis hydraulic oil, and diesel fuel conditioner. See Figure 3-74.,
Cold Weather Package.
MINIMUM OIL
3.29 ENGINE LEVEL
NOTE: Refer to the engine manufacturer’s manual for detailed

operating and maintenance instructions.
Glow Plugs MAXIMUM OIL

If the glow plug option is enabled in the JLG Control System, LEVEL
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG MINIMUM LEVEL,
Control System. Engine start shall be disabled during this OIL HOT
MAXIMUM LEVEL,
period. On Deutz engines, the glow plugs will continue (post OIL HOT
glow) after the engine has started for three times the machine
digit setting.
MINIMUM LEVEL,
Checking Oil Level OIL COLD
MAXIMUM LEVEL,
1. Switch the engine off before checking oil level. OIL COLD
NOTE: Hot oil checks should not be made until the engine
2. Make sure the machine and engine are level. has been shut down for a period of 5 minutes.
3. Remove the oil dipstick.

Figure 3-75. Deutz Engine Dipstick
4. Wipe the dipstick with non-fibrous, clean cloth.
6. Replace the dipstick making sure that it is fully seated in
5. Insert the dipstick to the stop and remove again.
the dipstick tube to seal off the crankcase.
Changing Engine Oil

1. Allow the engine to warm up. The engine oil should
reach approximately 176° F (80° C).
2. Make sure the machine and engine are level.
3. Switch off the engine.
4. Place an oil tray under the engine.
3-126 3121142
5. Open the oil drain valve. Changing the Oil Filter
WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING. 1. Wipe the area around the filter to clean any dirt from the
area.
2. Using a suitable oil filter removal tool, loosen the lube oil
DO NOT LET USED OIL RUN INTO THE SOIL; COLLECT THE USED OIL IN A CON- filter cartridge and spin off.
TAINER SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF THE USED
ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
6. Drain the oil.

7. Close the oil drain valve.
8. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-76., Engine Oil Viscosity for the
proper grade.
3. Catch any escaping oil.

4. Clean any dirt from the filter carrier sealing surface.
5. Lightly oil the rubber gasket on the new oil filter.
Figure 3-76. Engine Oil Viscosity
3121142 3-127
6. Manually screw in the new filter until the gasket is flush. 8. Open the fuel shut-off valve.
9. Check for leaks.
Cleaning the Fuel Strainer
7. Tighten the filter another half-turn.

8. Check the oil level.
9. Check the oil pressure.
10. Check the oil filter cartridge and make sure there are no
leaks.
Replacing the Fuel Filter WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM.
1. Unscrew the hexagonal nut (1).
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FUEL SYSTEM.
1. Wipe the area around the filter to clean any dirt from the
area.
2. Undo the fuel filter cartridge and spin off. 2. Remove the fuel strainer cover (2).
3. Catch any escaping fuel. 3. Clean the fuel strainer with diesel fuel, replace if neces-
sary.
4. Clean any dirt from the filter carrier sealing surface.
4. Place the seal (3) in position.
5. Apply a light film of oil or diesel fuel to the rubber gas-
ket of the new filter cartridge. 5. Install the fuel strainer cover (2) in position and tighten
the hexagonal screw (1).
6. Manually screw in the new filter until the gasket is flush.
6. Check for leaks.
7. Tighten the fuel filter cartridge with a final half-turn.
3-128 3121142
3.30 DEUTZ ENGINE - TD2.9L4 Replacing Engine Oil

NOTE: Refer to engine manufacturer's manual for detailed oper- 1. Allow engine to warm up. Engine oil should reach
ating and maintenance instructions. Limited engine main- approximately 176° F (80° C).
tenance items are presented here for convenience but
2. Make sure machine and engine are level.
detailed engine maintenance items and schedule are
included in the engine manufacturer's manual. 3. Switch off engine.
4. Place oil tray under engine.
Glow Plugs
If the glow plug option is enabled in the JLG Control System,
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
temperature is less than 50° F (10° C) and the engine coolant DRAINING.
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has
been pulled on. The lamp and glow plugs will remain ene-
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
gized for the period of time specified by the setting in the JLG
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
Control System. Engine start shall be disabled during this
LATIONS.
period. On Deutz engines, the glow plugs will continue (post
glow) after the engine has started for three times the machine
5. Open oil drain valve and drain oil.
digit setting.
6. Close oil drain valve.
Check Oil Level 7. Pour in new engine oil. Refer to Section 1 for capacity
1. Make sure machine and engine are level and switch and Figure 3-78., Engine Oil Viscosity.
engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.
Figure 3-78. Engine Oil Viscosity
Figure 3-77. Deutz Engine Dipstick
5. Replace dipstick until fully seated.
3121142 3-129
Replacing the Oil Filter Replacing the Primary Fuel Filters
Figure 3-80. Location of the Primary Fuel Filter
Figure 3-79. Location of the oil filter
1. Wipe area around filter to clean any dirt from area. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
2. Using a suitable oil filter removal tool, loosen lube oil fil-
SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEMS.
ter element and spin off.
1. Wipe area around filter to clean any dirt from area.
2. Fuel supply from the fuel tank may need to be blocked
to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.
4. Catch any escaping fuel.
3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil.
6. Screw in new filter by hand until gasket is flush.
7. Hand-tighten filter another half-turn.
5. Clean dirt from filter carrier sealing surface.

6. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
7. Screw in new filter by hand until gasket is flush. Hand-
8. Check oil level. tighten filter another 3/4 turn.
9. Check oil pressure.

10. Check oil filter cartridge for leaks.
3-130 3121142
8. Check for leaks.
Replacing the Fuel Pre-Filter

1. Fuel Supply Flow to the Pump 4. Drain Plug
2. Venting Screw 5. Filter Element
3. Electrical Connection for Water 6. Fuel Inlet from the Fuel Tank
Level Sensor
Figure 3-82. Components of Fuel Pre-Filter
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FUEL SYSTEM.

to prevent fuel flow from the tank.
3. Place suitable collecting container under drain plug.
4. Disconnect electrical connections from water sensor.
5. Loosen drain plug and drain liquid.
6. Remove filter element.
7. Catch any escaping fuel.
Figure 3-81. Location of Fuel Pre-Filter 8. Clean any dirt of the sealing surfaces of the new filter
element and opposite side of filter head.
NOTE: Refer Figure 3-82., Components of Fuel Pre-Filters. 9. Wet the sealing surfaces of new filter element slightly
with fuel.
10. Install new filter onto the filter head in clockwise direc-
tion. Torque to 12.5-13.3 ft. lbs. (17-18 Nm).
11. Install the drain plug and tighten to torque 1-1.4 ft. lbs.
(1.3-1.9 Nm).
12. Connect electrical connection to water sensor.
13. Check for leaks after starting engine.
3121142 3-131
Water in Fuel Sensing System (Optional) Auxiliary Fuel Filter

The Water in Fuel Sensing System detects when there is an
excessive amount of water in the fuel and sets a DTC code in
the JLG Control System to alert the operator and/or service 1
technician.
When Water in Fuel condition occurs, the machine will
respond in the following way:
• The engine will shut down automatically.
• The JLG Control System will set DTC 4375 - Water in Fuel.
• An alarm will sound from the active control station (ground
or platform).
• If in platform mode, the Low Fuel Indicator will flash.
• Engine Restart will be permitted after the machine senses
the Water in Fuel condition, but will only run for 2 minutes
and the engine will shut down again. This restart process
will continue until the Water in Fuel condition is corrected.
Draining Water
Frequency of water draining is determined by the contamina-
tion level of the fuel. Inspect or drain the collection bowl of
water daily or as necessary. The collection bowl must be
1. T-handle 3. Lid
drained before contaminants reach the top of the turbine or
2. Filter Element 4. Drain Plug
when the Water Detection Module (optional) indicates it’s
time to drain water. Figure 3-83. Components of Auxiliary Fuel Filter
PRESSURE APPLICATIONS / INSTALLATIONS:

1. Open the drain plug on the bottom of the bowl to evac- WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
uate water and contaminants with a suitable collection FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
container in place. FUEL SYSTEM.
2. Close the drain after all the water and contaminants
have been evacuated.
NOTE: Do not leave the drain open too long as it may completely
drain the entire filter assembly of water and fuel.
3-132 3121142
ELEMENT REPLACEMENT DRAINING WATER

Frequency of element replacement is determined by the con- Frequency of water draining is determined by the contamina-
tamination level of the fuel. Replace the elements every 500 tion level of the fuel. Inspect or drain the collection bowl of
hours, if power loss is noticed or annually, which ever comes water daily or as necessary. The collection bowl must be
first. drained before contaminants reach the top of the turbine or
when the Water Detection Module (optional) indicates it’s
time to drain water.
to prevent fuel flow from the tank. PRESSURE APPLICATIONS / INSTALLATIONS:
3. Wipe the area around the filter to clean any dirt from the 1. Open the self-venting drain plug on the bottom of the
area. bowl to evacuate water and contaminants with a sui
able collection container in place. Head pressure will
4. Remove the T-handle and lid. push any water and contaminants out of the drain while
5. Remove the element by holding the bail handles and keeping the filter primed.
slowly pulling upward with a twisting motion. Dispose 2. Close the drain after all the water and contaminants
of properly. have been evacuated.
6. Replace old lid gasket and T-handle O-ring with new 3. If necessary, follow priming of auxiliary fuel filter.
seals (supplied with new element). Lubricate both seals
with motor oil or diesel fuel before installation. NOTE: Do not leave the drain open too long as it may completely
drain the entire filter assembly of water and fuel.
7. Refer to Priming of auxiliary fuel filter or fill the unit with
clean fuel, then replace the lid and T-handle then
tighten snugly by hand only.
NOTE: Do not use any tool for removal and installation of T-han-
dle.
PRIMING OF AUXILIARY FUEL FILTER

1. Remove the T-handle and lid from the top of the filter
assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and T-handle O-ring with clean fuel
or motor oil.
4. Replace the lid and T-handle and tighten snugly by hand
only.
NOTE: Do not use any tool for removal and installation of T-han-
dle.
5. Start engine and check for fuel system leaks.

6. Correct as necessary with engine off and pressure
relieved from filter assembly.
3121142 3-133
3.31 DEUTZ TD2011 ENGINE
4
16
8
19
15
1
5
17 11
18 2
12
14
10
13
20
1001116015-D
MAE35960D
1. Fan 6. Oil Cooler 11. Oil Drain 16. Muffler Bracket

2. Rod 7. Muffler 12. Lanyard 17. Motor Mount
3. Exhaust 8. Air Cleaner Assembly 13. Front Engine Mounting Plate 18. Generator Mount
4. Air Intake 9. Pump Assembly 14. Rear Engine Mounting Plate 19. Pump Coupling Kit
5. Heater 10. Cooler 15. Pulley 20. Engine Tray
Figure 3-84. Detuz TD2011 L040 Engine Installation
3-134 3121142
3121142 3-135
3.32 DEUTZ 2.9 L4 (GUO III) ENGINE
8
4
7
1001221259-C
MAE35970C
1. Surge Tank 5. Muffler

2. Radiator 6. Exhaust Tail Pipe
3. Fan 7. Engine Mount
4. Alternator 8. Fuel Filter
Figure 3-85. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 1 of 2
3-136 3121142
8
7
1
6
5
1001221259-C
MAE36230C
1. Generator Mount 5. Air Filter

2. Lower Radiatpr Hose 6. Coolant Level Sensor
3. Air Intake Hose 7. Upper Radiator Hose
4. Air Filter Indicator 8. Pipe Flex Assembly
Figure 3-86. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 2 of 2
3121142 3-137
3.33 DEUTZ 2.9L4 ENGINE
3 4
1001141744-L
MAE36140L
1. Fan 5. Muffler
2. Fuel Tank 6. Engine Mount
3. Alternator 7. Radiator
4. Air Fuel Filter
Figure 3-87. Detuz TCD2.9L4 Engine Installation - Sheet 1 of 2
3-138 3121142
1
1001141744-L
MAE36270L
1. Air Filter 5. Sensor Coolant Level

2. Air Intake 6. Generator Mount
3. Fuel Filter Service Indicator 7. Heater Enfine Block
4. Pipe Exhaust 8. Engine Tray
Figure 3-88. Detuz TCD2.9L4 Engine Installation - Sheet 2 of 2
3121142 3-139
3.34 DEUTZ EMR 2 (SN 87579 TO PRESENT) The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
NOTE: S/N 87532 also incorporates EMR2. S/N 87765 incorporates (Limp home) functions.
old Engine controls.
In order to switch the engine off, the EMR2 is switched in a de-
energized fashion over the ignition switch. A strong spring in
The EMR2 consists of the sensors, the control unit and the
the actuator presses the control rod in the de-energized con-
actuator. Engine-side controls as well as the JLG Control Sys-
dition into the zero position. As a redundancy measure, an
tem are connected by means of separate cable harnesses to
additional solenoid serves for switching off and this, indepen-
the EMR control unit.
dently of the actuator, also moves the control rod in the de-
The sensors attached to the engine provide the electronics in energized condition into the zero position.
the control unit with all the relevant physical parameters In
After the programming, that is carried out over the ISO9141
accordance with the information of the current condition of
interface, the EMR2 is possesses a motor-specific data set and
the engine and the preconditions (throttle position etc.), the
this is then fixedly assigned to the engine. Included in this are
EMR2 controls an actuator that operates the control rod of the
the various application cases as well as the customer’s wishes
injection pump and thus doses the fuel quantity in accordance
regarding a particular scope of function.
with the performance requirements.
Each EMR2 module is matched by serial number to the engine.
The exact position of the regulating rod is reported back and,
Modules cannot be swapped between engines.
if necessary, is corrected, by means of the control rod travel
sensor, situated together with the rotation magnets in a hous-
ing of the actuator.
3-140 3121142
CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE FLYWHEEL SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/STOP; EMR2

TAKES CONTROL OF THE ENGINE AT 700RPM
GLOW PLUG
JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS

OIL PRESSURE TO CONTROL THE ENGINE & FAULT REPORTING.
SENSOR
Figure 3-89. EMR 2 Engine Side Equipment
3121142 3-141
3-142
Deutz EMR2;
Fails to Start/
Runs Abnormally
Does the machine Add fuel or

have fuel and a NO replace/
charged battery? recharge
battery.
YES
The starter and/
Connect or starter solenoid
Verify the needs replaced
JLG starter relay
Analyzer is getting
12Vwhen
the start
Cycle Power YES switch is YES
engaged.
Unplug the vehicle NO
side engine module
Are there any Does the fault connector. Verify On the analyzer, are
faults listed since indicate the engine there is 12Vacross Can you start there faults indicating Does the
the power was YES module is not YES pins 1 (Ground) & 14 the engine? NO Cycle Power NO starter crank?
(Battery +). Verify an open circuit on
cycled? detected? the starter relay?
there is 60 Ohms
across pins 12 & 13
NO (CAN High & Low)
YES
NO
Does the
engine operate YES
correctly?
The EMR2 needs
NO replaced.
Contact
Deutz
Service
Department
Connect Does the fault

Laptop to Replace/Repair
use Deutz indicate a Deutz the faulty
Diagnostic NO fault code YES wiring/
Software number? component(s)
YES
Does the
diagnostic software
indicate a problem?
Figure 3-90. Deutz EMR 2 Troubleshooting Flow Chart
3121142
3121142
Figure 3-91. Deutz EMR 2 Vehicle Side Connection Diagram
3-143
3-144
Figure 3-92. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3121142
3121142
Figure 3-93. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-145
Figure 3-94. EMR 2 Engine Plug Pin Identification
3-146 3121142
Figure 3-95. EMR 2 Vehicle Plug Pin Identification
3121142 3-147
3-148
Figure 3-96. EMR2 Fault Codes - Sheet 1 of 5
3121142
3121142
3-149
3-150
3121142
3121142
3-151
3-152
3121142
3.35 BIO FUEL IN DEUTZ ENGINES The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
General
comply with the ASTM D6751-07a (B100) standard.
Use of bio fuels is permitted for the compact engines made by
APPROVED ENGINES
DEUTZ.
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and
Distillate fuels with residue oil percentages or mixed fuels may 513 series are approved for bio-diesel from year of manufac-
not be used in DEUTZ compact engines. ture 1993 under compliance with the basic conditions speci-
The DEUTZ vehicle engines are designed for diesel fuels in fied below.
accordance with EN 590 with a cetane number of at least 51. BASIC CONDITIONS TO BE OBSERVED
DEUTZ engines for mobile machinery are designed for a cetane
number of at least 45. When using fuels of a low cetane num- • A power loss of 5-9 % in relation to diesel fuel in accor-
ber, disturbing white smoke and ignition misfires are to be dance with EN 590 is possible due to the lower heating
expected under some circumstances. value. Blocking of the fuel injector is not allowed.
• The lubricating oil quality must correspond to TR 0199-
A cetane number of at least 40 is permissible for the US market,
99-3002. The lubricating oil change interval must be
therefore special engine models have been developed to
halved in relation to operation with diesel fuel in accor-
avoid starting difficulties, extreme white smoke or increased
dance with EN 590.
hydrocarbon emissions (EPA specification - US EPA REGULA-
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION • Standstills of longer than 4 to 6 weeks must be avoided
ENGINES). with bio-diesel. Otherwise the engine must be started and
stopped with diesel fuel.
If the white smoke behavior is unacceptable when using a very
low cetane number, the use of ignition improvers is to be rec- • Bio-diesels can be mixed with normal diesel fuel but the
ommended as a later remedial measure. basic conditions described in this subsection apply for mix-
tures. Mixtures with up to 5 % (m/m) bio-diesel (B5) which
The certification measurements for compliance with the legal have recently been on sale at European fuel stations are
emission limits are carried out with the test fuels prescribed by excepted. These fuels must be treated like normal diesel
law. These correspond to the diesel fuels in accordance with fuels because EN 590 expressly permits adding up to 5 %
EN 590 and ASTM D 975. No emission values are guaranteed (m/m) bio-diesel in accordance with EN 14214.
with the other fuels described. It is the obligation of the owner
to check the permission for use of the fuels in accordance with • Approx. 30-50 hours after changing over from diesel fuel to
regional regulations. bio-diesel, the fuel filter should be changed as a preventive
measure to avoid a drop in performance due to clogged fuel
Bio Fuel filters. Deposited fuel ageing products are dissolved by bio-
diesel and transported into the fuel filter. They should not
PERMITTED BIO-DIESEL FUELS be changed immediately but after approx. 30 to 50 hours
Originally only rape seed oil methylester (RME) was sold as a because the dissolving of dirt takes a certain amount of
bio-diesel fuel in Europe but fatty acid methylester (FAME) time.
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Man-
agement Biodiesel e.V.).
3121142 3-153
PLANT OIL PREVENTIVE MEASURES

• Keep the storage tank clean, regular cleaning of the tank
by specialist companies
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high
ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH percentage of water.
VISCOSITY, POOR EVAPORATION BEHAVIOR.
If the fuel system and storage tank have already been attacked
The conversion of DEUTZ engines to rape seed oil fuel opera- by micro-organisms. The biocide must be dosed according to
tion with conversion kits and modified tanks systems of vari- the manufacturer's specifications.
ous manufacturers is not allowed and leads to loss of warranty • Avoid direct exposure of the storage tank to sunlight
rights.
• Use smaller storage tanks with corresponding low dwell
Biological Contamination In Fuels times of the stored fuel
FUEL ADDITIVES
SYMPTOMS
The use of fuel additives is not permitted. The flow improvers
The following symptoms may indicate that a fuel tank is con-
mentioned above are an exception. Use of unsuitable additives
taminated by micro-organisms:
will result in loss of warranty.
• Internal tank corrosion,
• Filter blockage and the associated loss of power due to gel-
like deposits on the fuel filter (especially after long stand-
stills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of the
water in the air. Water does not dissolve in fuel so that the pene-
trating water collects at the bottom of the tank. The bacteria and
funguses grow in the watery phase, at the phase boundary to
the fuel phase, from which they draw their nutrition. There is an
increased risk especially with bio-diesel (FAME).
3-154 3121142
3.36 DEUTZ ENGINE FAULT CODES

Table 3-8. Engine Fault Codes
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
38 731 523925 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
activated. Warn Coolant Temp/Level, Warn Oil,
Internal ECU power stage switched off. Warn Boost Air, Warn Air Filter, Warn Water in
Fuel, SCR, Regeneration, Engine
Running.
2- Relay Preheat A88
3- Exhaust Flap A88
40 733 523927 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A04, A05 cannot be 1- Urea Pump A04 pins A04, A05.
activated. 2- SCR Heater A05
Internal ECU power stage switched off.
42 167 523924 4 Overload at Pins O_V_RH2x: A01, K74, K91. Suspected components: Threshold for error detection is an internal ECU
Components on A01, K74, K91 cannot be 1- Pin K91: threshold.
activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
43 731 523925 4 Short circuit to ground actuator relais 3 Suspected components: Threshold for error detection is an internal ECU
Overload at Pins O_V_RH3x: A88, K57 1- Pin A88: threshold.
Preheat relay, Exhaust flap Check wiring harness and connected loads on
2- Pin K 57: pinsA88, K57.
- control lamps: If error is still present, exchange ECU.
- OBD, preheat lamp, warning temp., warning
oil, maintenance lamp, regeneration
indicator, alternator management, engine run-
ning, diagnostic
44 732 523926 4 Short circuit to ground aktuator relais 4. Suspected components:Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
If error is still present, exchange ECU.
45 318 168 3 Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected alternator.
ECU is out of the target range, system reac- (~38,9Volt), Short cut to battery possible.
tion is initiated
46 318 168 4 Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected alternator.
ECU is out of the target range, system reac- Short cut to ground
tion is initiated
47 318 168 2 Battery voltage: the voltage measured by If Batteryvoltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected alternator.
ECU is out of the target range, system reac- mor than =0.5sec a warning is generated
tion is initiated Battery voltage above warning threshold
3121142 3-155
Deutz Blink
Code Code
73 7-2-2 523912 4 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value
Throttle valve error, Open Load or Short cut mum threshold. DPM_uRawBrnDVDsP is above the minimum
to Battery, blocked valve or wrong control threshold
signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve (DV2), @ engines with Burner T4i: check back-pressure
lower limit reached valve
84 271 639 14 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
85 271 1231 14 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary repair
possible it, check connection cable and if
CAN lines (120 Ohm)
86 271 1235 14 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if necessary repair
it, check connection cable and if
CAN lines (120 Ohm)
88 223 102 2 Charge air pressure messured by sensor is Charged air cooler pressure below threshold. Check waste gate system if necessary replace
above the shut off threshold. TC,
check CAC if all channels are clean,check charge
air piping if nececery.
89 223 102 2 Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary replace
above the warning threshold TC, check CAC if all channels are clean,
check charge air piping if necessery.
93 225 110 1 Coolant temperature sensor: the voltage of Suspected components:wiring harness, cool- Check wiring harness and connected Coolant
the sensor measured by ECU is out of the tar- ant temperature sensor. Temp Sens.
get range.
96 225 110 3 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- connection cable and if necessary
get range repair or replace it.
97 225 110 4 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- Ground at Coolant Temperatur Sensor. connection cable and if necessary
get range repair or replace it
Measure Voltage at Coolant Temperature Sen-
sor and renew harness if needed.
98 232 110 0 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant temper- Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target ature above warning threshold level, check cooling system in general,
range; the ECU activates a system reaction check thermostat function, check water pump
3-156 3121142
Deutz Blink
Code Code
99 232 110 0 Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target level, check cooling system in general,
range. check thermostat function, check water pump
The ECU activates a system reaction
101 235 111 1 Coolant level: the coolant level calculated by Coolant level too low, leakage in cooling sys- Check coolant level, inspect cooling system for
ECU is underneath the allowed minimum. tem, sensor defective, wiring damaged. leakage and if necessary repair it,
check sensor and wiring
121 341 1109 2 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within an the user
allowed period.
122 591 523698 11 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function threshold.
Check error memory for additional errorcode to
find root cause.
Depending on additional error follow the docu-
mented "Take action for repair".
129 596 3224 2 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; DPF- threshold.
system downstream cat); length of frame Check Nox-Sensor and the wiring from CAN-
incorrect BUS.
130 597 3224 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
upstream cat; DPF-system downstream cat)
133 766 523938 9 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat)
134 766 523939 9 Broadcast Announce Message of the calibra- Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
tion message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
(SCR-system upstream cat, DPF-system
downstream cat).
135 766 523940 9 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat)
138 114 3234 2 DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor connection
NOX Sensor (SCR-system downstream cat; check
DPF-system downstream cat); length of
frame incorrect
139 117 3234 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor connection
AT1OG1Vol; NOX sensor (SCR-system down- check
stream cat; DPF-system downstream cat)
3121142 3-157
Deutz Blink
Code Code
140 767 523941 9 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information; check
(SCR-system downstream cat; DPF-system
downstream cat)
141 767 523942 9 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information, check.
Calibration message 1 of the after catalyst
NOx sensor has failed.
Factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
142 767 523943 9 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor connection
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. check
Sensorcalibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)
168 763 523935 12 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes
EEC3VOL1; Engine send messages frame has occured.
169 764 523936 12 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
171 3-3-3 523212 9 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
ComEngPrt; Engine Protection
179 527 523240 9 Timeout CAN-message FunModCtl; Func- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
tion Mode Control short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
291 119 523776 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
- active threshold.
Check CAN Bus cabling (Bus sheduling, polarity,
short circuit, power interrupt), test
range.
292 119 523777 9 Message TSC1-TE has been missing (passive) Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sage) ity, short circuit, power interrupt), test
range, check actuator
305 118 898 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
- active short circuit, power interrupt), test
range.
360 737 523982 0 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not high. to too high battery voltage. repair or replace if necessary.
361 737 523982 1 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not low. to too low battery voltage. repair or replace if necessary.
3-158 3121142
Deutz Blink
Code Code
376 281 630 12 Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU
an error during the access to its EEPROM threshold.
memory or works with an alternative value There is no healing possible for the error. In the
every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
377 281 630 12 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, There is no healing possible for the error. In the
an error during the access to its EEPROM EEPROM has Checksum Error every new initialization phase, the
memory or works with an alternative value debounce level is set to zero.
If not programmed, EEPROM is defect -->ECU is
necessary replace it
378 281 630 12 Internal hardware monitoring: the ECU finds Block could not be written for minimum 3 times Threshold for error detection is an internal ECU
an error during the access to it's EEPROM threshold.
memory or works with an alternative value If not programmed, EEPROM is defect --> ECU is
necessary replace it.
381 693 411 4 Range check cannot be done or interrupted. EGR or wiring defect Check wiring harness and connected EGR.
387 555 523612 12 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO coordinator Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- System responses: threshold.
nally; no item will be created in error mem- not Caution ! Sequence error, check error memory
ory for other errors.
389 214 190 0 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over Limit.
390 214 190 11 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over limit.
391 214 190 14 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding overspeed
by ECU is above the target range; the ECU conditions) if engine speed was over
activates a system reaction 2900rpm
417 312 171 3 Sensor error SCR-System environment tem- open loop to sensor Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
418 312 171 4 Sensor error SCR-System environment tem- short circuit to Ground Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
419 212 190 8 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
3121142 3-159
Deutz Blink
Code Code
420 212 190 12 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
421 213 190 2 ECU measures a deviation between cam- Offset error between crankshaft and camshaft. Threshold for error detection is an internal ECU
shaft and crankshaft angle to target. threshold, occurs by offset between
crankshaft and camshaft.
Check increment wheel position, clean and
Check Camshaft and Crankshaft senor or wiring.
422 212 190 8 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Threshold for error detection is an internal ECU
Crankshaft sensor defect. threshold, occurs by disturbed
crankshaft signal.
Check increment wheel position, clean and
Check Crankshaft Sensor or wiring.
423 212 190 12 Crankshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the Crankshaft signal.
engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor postition or wiring.
464 228 97 3 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
check connection cable and if necessary repair
or replace it.
465 228 97 4 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
472 216 94 3 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
473 216 94 4 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
474 216 94 1 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
culated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
543 263 676 11 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
544 263 676 11 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
3-160 3121142
Deutz Blink
Code Code
545 263 729 5 The cold start aid relay is according to wiring Relay defect or wire harness problem Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, check wires
547 263 729 12 The cold start aid relay is overheated, which High temperature around the cold start relay. Check the functionality of relay and replace it if
causes this error needed.
Check the temperature around the cold start
relay during worst case operation.
549 263 729 3 wiring to the intake air heater device is Intake Air Heater Device: overload, short-circuit Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, Check wiring to the intake air
heater device.
551 263 729 4 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.
559 1-5-8 523895 13 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 1 (in firing cyl. 1. threshold.
order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
programming (IMA) injector 2 (in firing cyl. 2 threshold.
order). check dataset and flash correct injector adjuste-
ment value (IMA). Use SERDIA
UseCase to check it.
561 1-5-8 523897 13 Missing or wrong injector adjustment value Missing or wrong parametrisation of injector Threshold for error detection is an internal ECU
programming (IMA) injector 3 (in firing adjustment cyl. 3. threshold.
565 151 523350 4 Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
566 152 523352 4 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
repair/replace it.
567 153 523354 12 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
3121142 3-161
Deutz Blink
Code Code
568 154 651 5 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 1 threshold.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
580 154 651 3 Injector cyl. 1: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 1 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
test for diagnosis.
test for diagnosis.
3-162 3121142
Deutz Blink
Code Code
test for diagnosis.
592 135 523615 5 Detecting an open load fault in the metering wiring harness defective, cable break Threshold for error detection is an internal ECU
unit threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
593 135 523615 12 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of overheating.
594 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
595 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
596 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
597 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
612 555 523612 12 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- higher than MoCADC_uNTPMax_C). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory.
613 555 523612 12 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- get -> ECU internal error) threshold.
nally; no item will be created in error mem- Check wiring, check connected sensors actua-
ory tors.
614 555 523612 12 Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- out of the target -> ECU internal error) threshold.
nally; Check wiring, check connected sensors actua-
no item will be created in error memory tors.
615 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an error in the plausbility of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Function Coordination(FC) and threshold.
nally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory
3121142 3-163
Deutz Blink
Code Code
616 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
ory
617 555 523612 12 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- postdrive detected (ECU internal error) threshold.
ory
618 555 523612 12 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- from CPU as response (ECU internal threshold.
nally; no item will be created in error mem- error). Loss of synchronization sending bytes to If error is still present, exchange ECU.
ory the monitoring memory from CPU
619 555 523612 12 Internal hardware monitoring: the CPU of Suspected components: Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Injector threshold.
nally; no item will be created in error mem- ECU If error is still present, exchange ECU.
ory wiring harness/connector
620 555 523612 12 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- internal error) threshold.
ory
621 555 523612 12 Internal hardware monitoring: the CPU of Error detected in the internal ECU communica- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- tion, Too many SPI errors during threshold.
nally; no item will be created in error mem- MoCSOP execution If error is still present, exchange ECU.
ory
623 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- under voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in undervoltage monitoring
624 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- monitoring module (ECU internal error). threshold.
ory
625 555 523612 12 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- alarm task (ECU internal error). Failure threshold.
nally; no item will be created in error mem- setting the alarm task period If error is still present, exchange ECU.
ory
627 555 523612 12 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- test (ECU internal error). Diagnostic fault threshold.
nally; no item will be created in error mem- check to report the timeout in the shut If error is still present, exchange ECU.
ory off path test
628 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- over voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in overvoltage monitoring
629 555 523612 12 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
3-164 3121142
Deutz Blink
Code Code
630 555 523612 12 Impermissible offset between the engine Calculated engine speed in level 1/2 implausi- Threshold for error detection is an internal ECU
speed of level 2 and level 1 ble (-> ECU internal error). threshold.
631 555 523612 12 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU
bility error between level 1 energizing time PiIx or MI1 or PoIx. threshold.
and level 2 information If error is still present, exchange ECU.
632 555 523612 12 Error in the plausibility of the start of ener- Implausible start of energising of either PiIx or Threshold for error detection is an internal ECU
gising angles MI1 or PoIx. threshold.
633 555 523612 12 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
634 555 523612 12 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
635 555 523612 12 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
636 555 523612 12 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
637 555 523612 12 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to Over
Run
638 555 523612 12 Error in the plausibility of the wave correc- Error in the plausibility of the wave correction Threshold for error detection is an internal ECU
tion parts parts threshold.
639 555 523612 12 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger than Threshold for error detection is an internal ECU
the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Check Rail pressure. Check the Rail System of
Leakge in the Rail System. leakage.
640 555 523612 12 Error in the torque comparison between per- Error in the torque comparison between the Threshold for error detection is an internal ECU
missible engine torque and current actual permissible inner engine torque and the threshold.
torque current plausible actual torque. If error is still present, exchange ECU.
641 555 523612 12 Diagnosis of curr path limitation forced by The torque comparison is not plausible with the Threshold for error detection is an internal ECU
ECU monitoring level 2 torque monitoring. threshold.
642 555 523612 12 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited by Threshold for error detection is an internal ECU
ECU monitoring level 2 the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
643 555 523612 12 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
644 555 523612 3 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.
3121142 3-165
Deutz Blink
Code Code
646 555 523612 4 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.
714 555 523612 12 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU
defect query/response communication threshold.
Software reset.
715 555 523612 12 Error report "ABE wire is active" due to The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
undervoltage detection electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
716 555 523612 12 Error report "ABE wire is active" due to over- If the ABE/WDA powerstage shut-off is active Threshold for error detection is an internal ECU
voltage detection due to an overvoltage detection. threshold.
software reset.
717 555 523612 12 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
unknown reason electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
732 224 100 3 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check sen-
sor and if necessary replace it,
or replace it.
733 224 100 4 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_uRawPSwmp
measured by ECU is out of the target range is above Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check sen-
sor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail informationen!
736 231 100 1 Oil pressure is below the target range (warn- Oilpressure too low (pressure below warning Threshold for error detection is an internal ECU
ing threshold) threshold) threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value
737 231 100 1 Oil pressure is below the target range (shut Oilpressure too low (pressure below shut off Threshold for error detection is an internal ECU
off threshold) threshold). threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value.
747 145 1237 2 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
replace it.
3-166 3121142
Deutz Blink
Code Code
752 136 107 0 Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if
inlet and outlet calculated by ECU is above sensor not working, connection cable damaged necessary replace it, check connection cable
the target range and the ECU activates a Pressure value above warning threshold and if necessary repair or replace it
system reaction
772 223 102 2 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to envi- and charge air pressure sensor at not 2) Exchange ECU
ronment pressure. Which sensor is not okay running engine to high
can not be said.
774 223 102 1 charge air pressure below lower limit measured charge air pressure below the thresh- Check complete air system of engine for mas-
old. sive leakage, especially from compressor
to intake air manifold.
Check air filter.
Exchange charge air presure sensor.
776 223 102 3 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and if necessary replace it, check connection
cable and if necessary repair or replace it.
777 223 102 4 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and
if necessary replace it, check connection cable
and if necessary repair or replace it
791 693 411 0 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
792 693 411 1 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
3121142 3-167
Deutz Blink
Code Code
793 693 411 11 DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU
check is allowed intake air manifold threshold.
to be carried out again and the real O2-concentration within intake air EGR-Valve mechanically blocked open or closed
DFC can be reset by service routine 216 manifold > limit EGR-pipe blocked with metall plate instead
sealing downstream EGR-Valve
EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
795 693 411 3 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the maxi- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
796 693 411 4 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the mini- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
825 253 523009 9 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the number of allowed activations. old of the pressure limiting valve. fault with Serdia.
826 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
827 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
828 146 523470 12 Rail pressure relief valve: is open. Shut Off after PRV Open Threshold for error detection is an internal ECU
Shutoff conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
check FCU and if necessary replace it.
829 146 523470 12 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an internal ECU
Warning conditions. threshold.
replace PRV,
3-168 3121142
Deutz Blink
Code Code
830 146 523470 14 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
replace it,
831 146 523470 11 Rail pressure relief valve can not be opened Railpressure out of tolerance range (PRV can not Threshold for error detection is an internal ECU
due to the railpressure. be opened by a pressure peak in this threshold.
operating point) Check railpressure, check rail pressure sensor for
plausibility, check FCU.
832 146 523470 11 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this operating Check PRV and replace if necessary.
point with a pressure shock.
833 2-5-3 523009 10 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the allowed opening time. old of the pressure limiting valve. fault with Serdia.
839 1-4-3 523450 4 Diagnostic fault check for min error of COM The sensed raw value is less than the threshold. Check cabling, check sensor and if necessary
message. replace it,
or replace it.
856 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Pressure governor deviation exceeds the limit- Threshold for error detection is an internal ECU
lated by ECU is below the target range which ing value based on the engine speed. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
857 134 523613 0 Rail pressure: the fuel pressure in rail calcu- maximum positive deviation of rail pressure Threshold for error detection is an internal ECU
lated by ECU is below the target range which exceeded concerning set flow of fuel. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
858 134 523613 0 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU
lated by ECU is above the target range which ance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
859 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation with Threshold for error detection is an internal ECU
lated by ECU is above the target range which metering unit on lower limit is exceeded. threshold.
is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
3121142 3-169
Deutz Blink
Code Code
861 134 523613 1 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
862 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure
lated by ECU is above the target range. (B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
864 134 523613 2 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the threshold.
ble. pressure. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
876 146 523470 7 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check railpressure relief valve and replace if
range. range. necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
877 147 157 3 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
or replace it.
878 147 157 4 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
925 148 523720 8 Supply module heater: Duration of switch on uty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out perature duty cycle SCR_rSMT is out of
of range; Supply modul defect, fault in the wir- the failurerange (SCR_rSMFailMax_C <
ing. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
926 148 523720 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply When the received supply module heater duty
over error threshold. module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
927 689 523721 11 Supply module heater: temperature mea- Duty cycle for temperature readout from supply Threshold for detection is an internal ECU
surement not available. module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Check the wiring.
928 928 691 8 Supply module heater: PWM time periode PWM signal for temperature readout from sup- The Time period of the received PWM signal
out of valid range. ply module to the control unit is out of SCR_tiSMPerPwm is within the specified
range. range of150ms to 250ms
Check the wiring.
3-170 3121142
Deutz Blink
Code Code
929 691 523722 8 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU
from supply module. ply module to the control unit is not valid. threshold.
Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperaturesignal for both information is
received one after the other.
Check the wiring.
930 689 523721 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply Supply module check and replace if necessary.
over error threshold. module to the control unit is out of Check the wiring.
range.
Supply modul defect, fault in the wiring.
931 689 523721 8 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle
of valid range. module to the control unit is not valid. SCR_rSMT is in the valid range
Supply modul defect, fault in the wiring. (SCR_rSMTVld-Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Check wiring.
932 1-2-6 29 3 Diagnostic fault check of short circuit to sup- The signal exceeds the applicatable threshold; If the signal is below the applicatable threshold
ply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal
(signal range check high) of acceleration range violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset
after debouncing.
935 2-2-6 91 3 Analog accelerator pedal sensor 1 or double Sensor defect. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- Short cut to battery or open loop. and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it.
compared with the position of the second If the signal is below the applicatable threshold
pedal APP_uRaw1SRCHigh_C, the signal
range violation is reset after
the healing debouncing.
937 1-2-6 29 4 Diagnostic fault check of short circuit to The signal is below the applicatable threshold; If the signal exceeds the applicatable threshold
ground (signal range check low) of accelera- signal range violation APP_uRawSRCLoHTLIS_C, the signal
tion pedal signal range violation is reset
after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range violation
is reset
after debouncing.
3121142 3-171
Deutz Blink
Code Code
940 2-2-6 91 4 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it
compared with the position of the second If the signal exceeds the applicatable threshold
pedal APP_uRaw1SRCLow_C, the signal
range violation is reset after the
healing
946 282 1079 13 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct
power supply voltage of sensor output 1. Air Pump Press it,
/BrnFuelPressAfterDV2 Pin K19: Fan Speed Sen- check connection cable and if necessary repair
sor or replace it,
Pin A21: LDF6T / OilPress / LowFuelPress Pin if error is not removable, change ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal
Pin A21: Cam speed Pin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPress Pin
K43: second footpedal
Pin A09: Delta Press Venturi
detects a deviation of the target range of the Pin K16: second footpedal working voltage and if necessary correct
power supply voltage of sensor output 2. Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
BrnDV1Press/HCIPressDV1DV2 repair or replace it, if error is not removable,
Suspected components EDC17cv54 change ECU.
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal
detects a deviation of the target range of the Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
power supply voltage of sensor output 3. throttle flap it,
Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
956 512 677 3 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
or replace it.
3-172 3121142
Deutz Blink
Code Code
957 512 677 4 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
or replace it.
958 512 677 5 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
get range Check cabling and start relay and if necessary
replace it,
or replace it.
959 512 677 12 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
replace it,
or replace it.
960 512 677 3 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold.
replace it,
or replace it.
961 512 677 4 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
replace it,
check connection cable of terminal 50 and if
necessary repair or replace it.
973 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally;
no item will be created in error memory.
974 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
nally;
no item will be created in error memory.
975 555 523612 14 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
nally; If possible the software update has to be done.
no item will be created in error memory Replace the ECU.
976 2-2-6 91 11 Diagnostic fault check of synchronism of sin- Measured voltage of accelerator pedal 1 is out of Threshold for error detection is an internal ECU
gle potentiometer and Low idle switch(LIS). plausible range. threshold.
Check cabling, check accelerator pedal and
pedal sensor and if necessary replace it,
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
3121142 3-173
Deutz Blink
Code Code
978 1-2-6 29 2 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU
hand throttle and Low idle switch(LIS). switch threshold.
The accelerator pedal must have detected full
load and idle plausibility at least once.
980 515 523550 12 Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal ECU
minutes. This may happen due to short to erratic/defect. threshold.
battery or wrong usage of Terminal 50. Check cabling, if sensor not working, check start
Starter control is disabled until this error is switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
992 128 105 1 Charged Air cooler down stream tempera- Sensed temperature within intake air manifold actual temperature below -40°C?
ture. < threshold. exchange sensor
Temperature below lower physical thresh-
old.
994 128 105 3 Charge air temperature sensor: the voltage Short circuit to battery. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage > limit age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
995 128 105 4 Charge air temperature sensor: the voltage Short circuit to ground or open load. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it
996 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func-
lated by ECU is above the target range. warning threshold. tionality.
The ECU activates a system reaction. Check cooling perfomance with temperature
measurement.
997 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is under the shut down thresh- low threshold. tionality. Check cooling perfomance
old. with temperature measurement.
The ECU activates a system reaction.
1007 682 412 3 EGR downstream temperature sensor: the Short circuit to battery. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage > limit Exchange TEGR-sensor.
the target range.
1008 682 412 4 EGR downstream temperature sensor: the Short circuit to ground or open load. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage < limit Exchange TEGR-sensor.
the target range.
1011 771 523960 0 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
3-174 3121142
Deutz Blink
Code Code
1012 771 523960 1 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
1014 594 5763 6 Actuator error EGR-Valve. Short cut to batterie. Check wiring and repair or replace if necessary,
Signal range check high. check actuator with SERDIA test for
EGR and if necessary replace it.
1015 594 520521 5 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if necessary,
Signal range check low. check actuator with SERDIA test for
EGR and if necessary replace it.
1016 594 5763 7 Actuator position for EGR valve is not plausi- Position error of throttle flap (deviation > 7%). Threshold for error detection is an internal ECU
ble, internal error, angular misalignement of threshold.
the flap. Threshold for error detection, deviation from
setpoint > 7%.
Troubleshooting with SERDIA 2010 Use Case
"EGR Diagnostic".
1022 5-9-4 5763 6 Actuator error EGR-Valve; signal range check Short circuit to battery or open circuit. Check cabling, actuator defect, check actuator
high, measured current by ECU is over target and if necessary replace it, check
replace it.
1023 5-9-4 5763 5 Actuator error EGR-Valve; signal range check Short circuit to ground. Check wiring, check cabels and repair or replace
low, measured current is below target if necessary, check actuator with
SERDIA 2010 test for EGR and if necessary
replace it.
1024 594 5763 3 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
1025 594 5763 4 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
replace it.
3121142 3-175
Deutz Blink
Code Code
1036 683 4768 2 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi-
The exhaust temperature value from the The exhaust temperature value from the sensor ble?
sensor before DOC, the exhaust temperature before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
value from the sensor after DOC, the temper- value from the sensor after DOC, the tempera- line?
ature value from the sensor before ture value from the sensor before T upstream DOC sensor physically mounted in
SCR-Cat, the environment temperature and SCR-Cat, the environment temperature and the correct position upstream DOC? (not
the coolant engine temperature their ratios coolant engine temperature their ratios upstream SCR or downstream DOC?)
to each other exceed their related thresh- to each other exceed their related thresholds. Check T upstream DOC sensor
olds. (difference between temperature after DOC and Check other T-sensors within EAT-system
Dynamic plausibility check with environ- temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
ment temperature sensor value: difference between temperature befor DOC and plausible values? No errors on them?
The exhaust temperature value from the before SCR > Threshold 2
sensor before DOC is lower than an applica- difference between temperature after DOC and
ble environment temperature threshold before SCR < Threshold 3
difference between temperature after DOC and
ambinet temperature < Threshold 4
differnece between temperatur ambient tem-
perature and engine temperature <
Threshold 5)
Dynamic plausibility check with environment
temperature sensor value:
The exhaust temperature value from the sensor
before DOC is lower than an applicable
environment temperature threshold (< envi-
ronmental temperature + Threshold 6)
1039 683 4765 0 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle,
is above an applicable upper shutoff thresh- Check Turbocharger and Piping each for leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C = Thresh-
old 2
in stand-still)
1040 683 4765 0 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle, Turbocharger and Piping each
is above an applicable upper warning for leakage and correct function
threshold Check injectors: is an injector got stuck?
TOxiCatUs_tWarnThresHi_C = Threshold Exchange temperature sensor upstream DOC
1044 683 4768 3 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Exchange temperature sensor upstream DOC
Shortcut to battery
1045 683 4768 4 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor upstream DOC
Shortcut to ground
3-176 3121142
Deutz Blink
Code Code
1069 668 4360 0 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
perature threshold engine load => high difference > 100 K?
If yes, the engine emitts too many Hydrocar-
bons => check injectors: is an injector got
stuck?
=> Check EGR Valve
If difference normal the exhaust out of the engie
itself is too hot:
=> Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
If that error was set while stand-still operation
the error source could be exothermal
soot burn off in DPF (which should not happen)
=> Dismount DPF and check it visually
exchange temperature sensor upstream SCR
1070 668 4360 1 The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature < Thresh-
less than an applicable minimum tempera- than physical low limit old? Missdetection?
ture threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
1072 668 4361 3 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst > maximum limit Check wiring
of the target range Short circuit to battery Replace UCatUsT-sensor
1073 668 4361 4 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst < minimum limit Check wiring
of the target range Short circuit to ground Replace UCatUsT-sensor
1075 677 3361 6 Urea dosing valve: the current measured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect urea dosing injection valve Check the urea dosing injection valve
high
1077 677 3361 3 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
1078 677 3361 3 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1079 677 3361 4 Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
the current drain measured by ECU is above
the target range
1080 677 3361 4 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1090 674 4345 5 Urea backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in back- Check heating element
flow line
3121142 3-177
Deutz Blink
Code Code
1092 674 4345 3 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
1093 674 4345 4 Urea backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
1094 673 4343 5 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in pres- Check heating element
sure line
1096 673 4343 3 Urea pressure line heater: the current drain shortcut to battery Threshold for error detection is an internal ECU
broken heating element in pressure line Check heating element
1097 673 4343 4 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
1098 676 523718 5 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay
1100 676 523718 3 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1101 676 523718 4 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1102 675 4341 5 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
Check wire harness
Check supply line
Check wire harness
Check supply line
3-178 3121142
Deutz Blink
Code Code
1106 672 523719 5 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase is threshold
range a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
1108 672 5232719 3 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error:KWP 1089 Check wiring
1109 672 523719 4 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error: KWP 1089 Check wiring
1110 671 4366 5 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
1112 671 4366 3 Urea tank heating valve: the current drain Shortcut to battery Threshold for error detection is an internal ECU
1113 671 4366 4 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
1117 666 523632 11 Urea supply module pump: the current drain When the pump motor does not switch to pump Threshold for error is an internal ECU threshold
measured by ECU is above the target range actuation mode after temperature
measurement has
been carried out.
1118 666 4375 5 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator.
Check wiring
Check pump in the urea supply module
1120 666 4375 3 Urea supply module pump: the current drain Shortcut to battery Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects absence of any short cir-
Broken wiring cuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
3121142 3-179
Deutz Blink
Code Code
1121 666 4375 4 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects a short circuit to ground
Broken wiring error on the PWM output power stage
Pump in urea supply module defect for the UreaPump Module Motor Actuator. The
error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
1122 665 4334 0 The absolute pressure value of the urea Suspected Components: Check the urea pump
pump is greater than an applicable maximal Urea pump defect Check the supply module pressur sensor
filtered pressure threshold Supply module pressure sensor defect Clean the urea pump (filter)
Pump contains dirty parts
1123 665 4334 1 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
1127 665 523632 3 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
1128 665 523632 4 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
1129 667 4376 5 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
1131 667 4376 3 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
1132 667 4376 4 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
3-180 3121142
Deutz Blink
Code Code
1135 669 3031 0 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor":
value above the maximum allowed thresh- high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_tSensUTnkT
Compare urea tank temperature to EnvT_t or to
SCR_tSMT (the urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
1136 669 3031 1 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor":
value lower than the minimum allowed low limit Check ambient temperature EnvT_t => About
threshold. -40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature SCR_tSensUTnkT
Check wiring of analog DEF T & Level sensor
Check analog DEF T & Level sensor
1137 6-6-9 4365 2 Signal error in case of Urea tank temperature CAN message is not send properly. Check sensor connector
trnasmitted via CAN-signal Com_tUTnkT. Check CANbus
1138 6-6-9 4365 3 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The Sensed raw voltage value SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C.
Check wiring.
1139 6-6-9 4365 4 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The sensed raw voltage value SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C.
Check wiring.
1157 228 97 12 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over limit Measure Voltage at Water in Fuel Sensor and
level is exceeded (bad fuel quality) renew harness if needed.
1170 555 523612 12 Internal hardware monitoring: the CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Diagnostic fault check to report that the threshold.
nally; no item will be created in error mem- positive test failed Reflash ECU. If error is still activ replace ECU.
ory
3121142 3-181
Deutz Blink
Code Code
1180 318 168 0 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
1181 318 168 1 Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact resistance,
ECU is out of the target range safety fuses, too high load in energy
system, check battery and if necessary replace it
1183 226 172 1 sensed air temperature within air intake sensed air temperature within air intake path of Cold start and ambient temperature < thresh-
path of engine below physical low limit engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
1222 2-1-2 190 14 Camshaft- and Crankshaft speed sensor sig- Sensors for engine speed are defect. Threshold for error detection is an internal ECU
nal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or replace
if necessary.
1223 594 5763 6 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
1224 594 5763 6 Actuator EGR-valve: too high curent is going Overload on component wiring Threshold for error detection is an internal ECU
into the actuator. Output is switched off threshold.
1226 594 5763 3 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
1227 594 5763 3 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
1228 594 5763 4 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
1229 594 5763 4 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
1230 5-9-4 5763 6 Actuator error EGR-valve; Overload by short- Short Circuit over Load Threshold for error detection is an internal ECU
circuit threshold.
Check wiring, component
1231 5-9-4 5763 11 Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
1232 5-9-4 5763 4 Actuator error EGR-Valve (2.9;3.6) or Throt- Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
tle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
3-182 3121142
Deutz Blink
Code Code
1239 788 523984 3 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
1241 176 523986 4 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
1242 791 523987 4 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
1337 565 2797 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 0 threshold.
Note: affected injector has to be evaluated
according to firing order
1338 566 2798 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 1 threshold.
Note: affected injector has to be evaluated
1339 565 2797 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 0 Note: affected injector has to be evaluated
1340 566 2798 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 1 Note: affected injector has to be evaluated
1381 839 164 2 Rail pressure safety function is not executed Rail pressure is still above threshold. Threshold for error detection is an internal ECU
correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
1398 681 1136 0 ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
measured by ECU is out of the target range
1425 226 172 0 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake air
system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to adapt
limits
if not check sensor and wiring harness
exchange sensor
1434 8-3-6 524050 11 CAN; not used not used not used
1435 8-3-7 524051 11 CAN; not used not used not used
3121142 3-183
Deutz Blink
Code Code
1455 711 3711 12 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If
DPF temperature > Threshold 2 stand-still main phase. not:
towards the end of the stand-still main => Check air path of engine: EGR-Valve,
phase. Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
Check temperature difference across DOC by
Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-still: <
100°C? If not:
Check exhaust pipe downstream turbo charger
for oil?
check injectors: is an injector got stuck?
Too many hydrocarbons in exhaust? White
smoke (at hot EAT system, not at cold
start)?
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check exhaust gas temperature sensors within
EAT-system: T upstream DOCC, T
downstream DOC & T upstream SCR catalyst
all three of them can influence Phy_tPfWgh
1505 8-4-3 524057 2 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Threshold for error detection is an internal ECU
culated by ECU is underneath the target threshold.
range; the ECU activates a system reaction Check low fuel pressure system (fuel feed
pump, relay , fuse, wiring, sensor) and if
1533 246 524074 9 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
1534 247 524075 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
sor.
agglomeration? Rearrange if critical and possi-
ble
Exchange sensor
3-184 3121142
Deutz Blink
Code Code
1535 248 524076 9 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1536 249 524077 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1537 255 524078 9 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater than stream SCR catalystat at idle conditions,
the physical range check max. lambda ComRxSCR_rCanLamDs_mp > threshold?
threshold Compare to ComRxSCR_rCanLamUs_mp. Val-
ues must be almost identical
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
itself
Replace NOx-sensor downstream SCR catalyst
3121142 3-185
Deutz Blink
Code Code
1538 256 524079 9 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold almost identical!
If almost identical,
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check injection system of engine. Injector
stuck?
if sensed lambda upstream SCR higher
(ComRxSCR_rCanLamUs_mp) : Diesel in
Urea-tank?
Check CANBus of NOx-sensor downstream SCR
catalyst
wiring
itself
1539 257 524080 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata-
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit lyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp. Must
be almost identical
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
1540 258 524081 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low limit SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR cat-
alyst
1542 261 524083 9 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
wiring
itself
3-186 3121142
Deutz Blink
Code Code
1544 912 524085 9 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat-
SCR catalyst < Threshold catalyst < physical low limit alyst
1555 869 524063 5 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
1556 869 524063 5 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
1557 869 524063 5 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
2
1558 869 524063 3 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
2
1559 869 524063 4 Connection between heating valve (Y31) on Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
the control unit Pin A:92 and defective heating valve (Y31), reset fault.
Load side SCR heater main relay (K31) is a broken element in heating. If fault is still present you have to look in the wir-
short cut to ground. ing of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay (K27-
K30).
1560 869 524063 5 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
1561 869 524063 5 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
2
1562 869 524063 5 SCR heater tank; open load Open load on wiring to component Check wiring, component
3121142 3-187
Deutz Blink
Code Code
1565 892 524065 0 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line
from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector
sensor is greater than an applicable maxi- flow) Check correct connection from exhaust line to
mum pressure threshold UCatUsP_pRelFlt_mp > UCatUsP_pMax_mp pressure sensor upstream SCR catalyst:
syphons?, water in tube?, water in sensor?
Check that exhaust pipe outlet is free (down-
stream SCR catalyst)
Check wiring of pressure sensor upstream SCR
catalyst
Check pressure sensor upstream SCR catalyst:
sensor has no connection to vehicle body? =>
Ensure that sensor is free
Does sensor oscillate heavely at engine low idle
/ high idle? => try to supress the
oscillating
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
1566 892 524065 1 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check correct connection from exhaust line to
from the urea cat upstream sensor is less cal high range limit f(exhaust volume pressure sensor upstream SCR catalyst:
than an applicable minimum pressure flow) leakage?
threshold UCatUsP_pRelFlt_mp < UCatUsP_pMin_mp Check electric connector: 4h pin open / new
connector type used? pressure exchange
from inside electrical connector with the envi-
ronemt possible
Check exhaust line: any leakages upstream of
SCR catalyst?
catalyst
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
1569 892 524065 3 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > volt- Check wiring of pressure sensor upstream SCR
voltage high limit age high limit catalyst
Check pressure sensor upstream SCR catalyst
lyst
3-188 3121142
Deutz Blink
Code Code
1570 892 524065 4 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR
voltage low limit age low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure sen-
sor upstream SCR catalyst
1581 894 524067 0 Filtered urea supply module heater temper- sensed temperature of supply module heater > Compare SCR_tSMT with SCR_tSMHtrT. Both
ature value is above an applicable maximum physical high range limit show the same value?
heater temperature threshold of the supply Check urea tank temperature
module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM sig- tank heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
1582 894 524067 1 Filtered urea supply module heater temper- sensed temperature of supply module heater < Check ambient temperature EnvT_t < Thresh-
ature value is below an applicable minimum threshold old?
heater temperature threshold of the supply Compare SCR_tSMT with SCR_tSMHtrT
module Check wiring with regard to supply modul
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module heater temperature sensor
tion was switched on. When that state is defect
left the sensed temperature value is frozen. Supply module defect
1585 894 524067 0 Filtered urea supply module temperature sensed temperature of urea within supply mod- Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable ule > physical high range limit show the same value?
maximum temperature threshold of the Check urea tank temperature
supply module (SCR_tAdapUTnkT). Very hot (> 70°C), ure tank
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
3121142 3-189
Deutz Blink
Code Code
1586 894 524067 1 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable ule < physical low range limit old?
minimum temperature threshold of the sup- Compare SCR_tSMT with SCR_tSMHtrT
ply module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module temperature sensor defect
tion was switched on. When that state is Supply module defect
left the sensed temperature value is frozen.
1593 129 1761 0 The urea tank level sensor detects a value Suspected components: Check level sensor and float gauge
higher than the maximum allowed thresh- Urea Quality Sensor defect
old mechanical defect at the float gauge
1594 129 1761 1 The DEF tank level sensor detects a value Suspected components: Check level sensor and float gauge
lower than the minimum allowed threshold Urea Quality Sensor defect
mechanical defect at the float gauge
1598 892 524065 2 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the differ- pressure upstream SCR catalyst and connector type used?
ence should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical con-
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold nector with the environemt possible?
old water in sensor?
sensor frozen?
catalyst
lyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
3-190 3121142
Deutz Blink
Code Code
1639 966 524147 13 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be
up within the SCR system state "Fill Lines" level could be build up within the SCR excluded!
=> SCRCo_stStatus_mp = 1 within some system state "Fill Lines" => Check whether there is urea in the urea tank
miuntes SCRCo_stStatus_mp = 1 within some minutes Check urea lines:
Once the urea pump pressure has exceeded the All lines connected? The right lines connected to
threshold the error is declared as the correct places?
okay. Suction line blocked?
Suspected components: No leakage? Not also urea to the outside but also
Suction line blocked air into the lines, especially in the
PWM Powerstage has a defect and a default suction line!
value which leads not to a rising pressure Perform service routine "pressure test":
Pump Pressure sensor defect Does the urea pump work? => check wiring
pump filter contains dirty parts harness & PWM signal for pump
reverting valve continously open Does the urea pressure rise?
DFC already healed?
If all unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check reverting valve => see
DFC_SCRCoRevVlvBlk
Check pump filter: dirt inside?
Suspected components:
Urea pump broken
Reverting valve continously open
Urea suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
1646 869 524063 12 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the given
defrosting time limit, an error will be
detected. Is the temperature reached in time
the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental temper-
ature 0°C --> defrosting time limit 6000s --
> if the clock counter reaches 6000s the error
will
be detected
3121142 3-191
Deutz Blink
Code Code
1655 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <5% below applicable threshold 5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of value
or it's implausible.
1656 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <2.5% below 2.5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
Exchange DEF level sensor, if no change of value
or it's implausible.
1666 924 524100 9 Timeout error of CAN-Transmit-Frame Com- Open load on CANBUS wiring. Check wiring, component.
DPFHisDat.
1672 9-4-2 524118 9 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus sheduling, polarity,
ComRxCM1 successfully short circuit, power interrupt), test
range.
1676 928 524104 9 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Receive Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Recieve Message, PGN65348. threshold.
Message. The message is not received. Check CANBUS EAT Control Receive Message,
PGN65348.
CM1 Module Customer Recieve Message.
1683 9-4-5 524121 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
RxTrbChActr short circuit, power interrupt), test
range.
1687 9-4-9 524125 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
TxTrbChActr short circuit, power interrupt), test
range.
1705 972 524156 9 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. short circuit, power interrupt), test
range.
Replace the wheel speed sensor.
1752 415 2791 7 EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal ECU
threshold.
Check the EGR actuator and EGR valve to
mechanical blockage / clean.
Check for free movement of the valve. If it'S
blocked, then exchange the EGR valve.
1753 415 2791 2 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuaror.
3-192 3121142
Deutz Blink
Code Code
1754 415 2791 13 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If o.k.
change EGR actuator.
1755 415 2791 12 Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to high Threshold for error detection is an internal ECU
temperature or electrical wiring issue. threshold.
Exchange EGR actuator.
1756 415 2791 13 EGR actuator can not learn stop positions Interruption of learning process due to mechan- Threshold for error detection is an internal ECU
because procedure was interrupted. ical damage. threshold.
Start Serdia Usecase to reset EGR actuator.
1757 415 2791 6 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked or
EGR actuator is blocked or moving very hard. not running smoothly.
If everything is o.k. change EGR actuator.
1758 415 2791 3 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
1759 415 2791 4 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
1760 415 2791 13 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
1761 415 2791 7 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold.
Exchange EGR actuator.
1762 415 2791 16 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
1763 415 2791 0 Internal actuator temperature is above Overheating of EGR actuator during operation. Let EGR actuator cool down and check heat
threshold. accumulation during worst case operation.
1827 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
1857 555 523612 12 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
3121142 3-193
Deutz Blink
Code Code
1858 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
1863 995 524177 7 The error shows up, if no proper urea presure This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are not
could be build up within the SCR system could be build up within the SCR system frozen.
state "Fill Lines" => SCRCo_stStatus_mp = state "Fill Lines" => SCRCo_stStatus_mp = 1. Check for DEF level in the tank.
1. 3 cases can lead to the error: Check DEF lines:
Case A: increasing pressure is detected within Are all DEF lines connected?
15s the check has passed => no error Is the suction line blocked?
Case B: The pressure threshold was not reached Is ther any leakage? Not only urea to the outside
within the 60s but case A was not but also air into the lines, especially in
positiv. the suction line!
Case C: The minimum pressure of 3000 hPa was Perform SERDIA usecase "pressure test":
not reached within the 60s. Does the DEF pump work? => check wiring har-
ness & PWM signal for pump.
Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
Check DEF pump filter: Is any dirt inside?
Suction line
PWM Powerstage has a defect and a default
value which leads not to a rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
3-194 3121142
Deutz Blink
Code Code
1864 996 524178 7 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not
pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 frozen.
bar due to malfunction in the SCR system. Check for DEF level in the tank
Suspected components: Check DEF lines:
- DEF pump broken All lines connected? The right lines connected to
- Reverting valve continously open the correct places?
- Urea suction line, backflow line broken or con- Suction line blocked?
nection swapped Is there any leakage? Not also urea to the out-
- PWM Powerstage has a defect side but also air into the lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure test":
Does the DEF pump work properly? => check
wiring harness & PWM signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At ignition on and
- Check reverting valve
- Check DEF pump filter: dirt inside?
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
1865 668 4360 2 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream of
absolut temperature difference of sensed absolut temperature difference of sensed tem- SCR catalyst is physically mounted
temperature upstream SCR catalyst and perature upstream SCR catalyst and within exhaust pipe
ambient temperature > as static plausibility ambient temperature > as static plausibility If cold start condition can be made sure (engine
limit limit was off for at least 8 h) compare
at engine cold start (engine was off for at at engine cold start (engine was off for at least 8 values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
least 8 h), temperature upstream of SCR cat- h), temperature upstream of SCR Exh_tOxiCatDs and
alyst is expected to be identical to ambient catalyst is expected to be identical to ambient SCR_tSensUCatUsT at ignition on, without
temperature => see enable conditions for temperature => see enable conditions for starting the engine. All identical?
details. details. Compare values of Exh_TOxiCatUs,
Error at dynamic plausibility check: Error at dynamic plausibility check: Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
temperature difference of sensed tempera- temperature difference of sensed temperature min in constant operation point: show all simi-
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient lar values (30 K tolerance width). Are
temperature < as dynamic plausibility limit temperature < as dynamic plausibility limit ambient temperature and (EnvT_t), cooling
dynamic check is blocked if static plausibility dynamic check is blocked if static plausibility water temperature (EngDa_tEng) plausible?
check is already faulty check is already faulty Sensor coated with urea crystalls? Dismount
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must urea injector and inspect temperature
must be by 40°C higher than ambient tem- be by 40°C higher than ambient sensor upstream SCR catalyst visually
perature if engine runs and a certain delay temperature if engine runs and a certain delay Check wiring of sensor
time has expired. time has expired. Replace sensor
3121142 3-195
Deutz Blink
Code Code
1866 665 4334 2 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and => plausible value?
ent pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
1867 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module heater temperature and supply module heater temperature and and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > threshold UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1868 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module temperature and ambient supply module temperature and ambient and CEngTds_t and
temperature > threshold temperature UPmpT_tDiffPmpAmb_mp > SCR_tAdapUTnkT => All identical? If not:
threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1874 971 524152 2 CAN message is not received fora definite CAN message is not received for a definite time Check eletrical connection oif urea quality sen-
time => error is set. As soon as the message => error is set. As soon as the sor
is received the error heals. message is received the error heals. Check engine CAN bus
Check urea quality sensor itself
Exchange urea quality sensor
1875 997 524153 2 CAN message is not reseived for a definite CAN message is not reseived for a definite time Check eletrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the sor (combined sensor with tank level and
is received the error heals. message is received the error heals. tank temperature)
Check engine CAN bus
Check level sensor itself
Exchange suction unit
3-196 3121142
Deutz Blink
Code Code
1880 138 1761 14 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill
below the threshold Check DEF level sensor.
If there is urea in the tank loose the sensor and
move it. The floater must be free and
move if you lift the sensor body.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level sen-
sor.
1881 683 4768 2 At engine cold start conditions the sensed Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC ature downstream DOC and fixed sensors within the EAT system are
(Exh_tSensTOxiCatDs) ambient temperature at ignition on exceeds a mounted properly: Within the exhaust line and
has exceeded the sum of ambient tempera- certain limit earlier than the difference at correct positions.
ture (EnvT_t) + offset (40°C) earlier than the temperature of exhaust gas temperature Check the position of the sensor upstream SCR
sensed exhaust gas upstream DOC and fixed ambient temperature which might be physically mounted in
temperature upstream of DOC at ignition on. the wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure (engine
The check is only performed once each igni- was off for at least 8 h) compare
tion cycle and only if the start is judged a cold values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
start. Exh_tOxiCatDs and
Error status is frozen for that ignition cycle. SCR_tSensUCatUsT at ignition on, without
No healing possible. starting the engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physicallly intact?
1891 272 524190 14 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected or Low DEF quality up to volume above the warning
hardware failure is detected Hardware Tampering is active threshold.
Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is filled, refill with proper DEF.
Check other errors based on hardware malfunc-
tions.
1892 273 524191 14 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering(system Low DEF quality threshold.
components are pinched off) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware tamper-
ing or failure.
3121142 3-197
Deutz Blink
Code Code
1893 275 524193 8 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. Stand-still mode does not reach required tem- Stand-still operation finished or often inter-
The error is activated if the engine runs to perature level and regeneration level is rupted by driver / engine shut-off? => Run
many times in Standstill regeneartion. therefore reached after a short time again stand-still and instruct operator
Stand-still operation required often by soot
load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3-198 3121142
Deutz Blink
Code Code
1894 276 524194 8 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: 2,5h often by the operator manual:
stand-still operation within 50h total motor Stand-still is required too often due to miscalcu- Stand-still operation finished or often inter-
run time. lation in the soot model rupted by driver / engine shut-off? => Run
The error is activated if the engine runs to Stand-still mode does not reache temperature stand-still and instruct operator
much time in short Standstill regeneartion. level and regeneration level is therefore Stand-still operation required often by soot
reached after a short time again. load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
1895 277 3519 12 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- CAN Communication corrupted. bility. In case of improper signal,
perature than threshold Overheating of the DEF tank due to malfunction exchange the suction unit in the tank.
of the heating valve. Check CAN bus communication for proper sig-
Flow direction is of coolant is wrong due to nal. In case of improper signal, exchange
mixed up the hoses routed to the heating the suction unit in the tank.
valve. Check the function of heating valve and routing
Overheating of the DEF tank due to heat transfer of the hoses. The coolant flow through
from neighbor parts. the heating valve must be observed according
to the shown arrow.
In case all actions above are OK, check the real
temperature in the DEF tank during
worst case condition and improve the installa-
tion of the DEF tank.
1896 278 3520 3 The integrated diagnostic of the Urea Quality wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery CAN Communication corrupted threshold.
Check the wiring harness from the ECU to the
suction unit of the DEF tank
Check the CAN bus communication. If the signal
is corrupt, then exchange the suction
unit.
3121142 3-199
Deutz Blink
Code Code
1897 278 3520 4 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Sensor recognized a short circuit to ground. tank is corrupted threshold.
CAN Communication corrupted Check the wiring to the suction unit in the DEF
tank.
Check the CAN bus communication. In case the
communication is corrupt, exchange
the suction unit in the DEF tank.
1898 277 3519 3 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor recog- inside the temperature sensor of the UQS tank.
nized a short circuit to battery. CAN Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
1899 277 3519 4 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the DEF Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor recog- tank is defect tank.
nized a short circuit to ground CAN Communication corrupted Check the CAN bus communication from the
suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3-200 3121142
Deutz Blink
Code Code
1900 279 524195 14 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
zation is ignored for more than reached a level which indicates inspect visually the injector and the
5h(>300min) crystallisation inside of exhaust line. exhaust line for urea crystallisation upstream of
This will be activated if there is a standstill The error detection depends on the sensed pres- SCR catalyst:
request activated by Crystalisation Monitor- sure upstream of the SCR catalyst and If crystallisation can be clearly seen, then stand-
ing. the calculated exhaust volume flow through still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallisation can longer time? If yes, then it could be the
be found in the mixing pipe, a possible reaoson for crystallisation.
reason can be the defect sensors: Does the NOx-Sensors work properly? Compare
- exhaust pressure & temperature upstream of ComRxSCR_rNOxUs to
the SCR catalyst, ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path sys- ComRxSCR_stNOxRdyDs = 1 (Warm engine
tem at the engine. and EAT-system,
SCRT_tCatAvrgExhGs_mp > 250°C,
SCR_stStatus = "Dosing" = 8): sensed NOx
upstream of SCR catalyst must be higher than
downstream of SCR catalyst.
Go to idle and wait until SCR system enters sta-
tus "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi tube, EGR cooler, EGR-Valve,
Reed-Valve, Intake throttle regarding function
and leakage. Does the EGR-cooler leak
water in the exhaust?
Check air path for leakage
Check turbocharger
No crystallisation can be seen in the mixing
pipe:
Check exhaust pressure sensor upstream of SCR
catalyst (SCR_pSensUCatUsP):
tube, water in sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
Check exhaust temperature sensor upstream of
SCR-catalyst (SCR_tSensUCatUsT):
plausible compared to Exh_tOxiCatUs &
Exh_tOxiCatDs e.g. when engine has idled for
20 minutes?
=> Run stand-still to remove crystallisation
and to reset the DFC
3121142 3-201
Deutz Blink
Code Code
1904 2-7-8 3520 2 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality
Quality value received from UQS is < 22 % for Urea quality sensor defect in the tank first
a certain time and a certain number or for Wrong installation (measuring air) Check urea tank level. Add urea until level is at
measuring conditions not observed for a cer- Urea level sensor defect least 10 cm above sensor.
tain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea is
CANBUS problems liquid
Evaluation conditions for new quality check not Check Sensor: Are urea tank temperature and
fulfilled after one previous mal detection level displayed? Changes the level if you
refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value.
It should be about 33 %
Exchange quality sensor
1907 278 3520 13 Urea quality at UQS out of range the speci- Suspected components Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea DEF quality sensor
qualiy DEF
1908 277 3519 13 Temperature at UQS out of range the speci- Suspected Components Check temperature system and/or DEF quality
fied thresholds; invalid quality of the tem- Tank heater sensor
perature DEF sensor
1911 127 3532 3 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or sensor.
greater than the maximum physical range UQS defect
threshold
Comment: tank temperature is measured by
the UQS sensor
1912 127 3532 4 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or Sensor.
lower than the minimum physical range UQS defect
threshold.
1914 669 4365 3 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1915 6-6-9 4365 4 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1917 2-8-6 3936 14 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF has
standstill request will not be released within Display / stand-still request lamp broken. increased too high already call service
50 h by the driver this fault code will be set. to perform stand-still.
In case the DPF soot load level remove DPF =>
Exchange DPF.
3-202 3121142
SECTION 4. BOOM & PLATFORM
4.1 BOOM SYSTEMS Transport Position Sensing System

The transport position sensing system uses the boom angle
Broken Cable Indicator System sensors and the boom length sensor mounted in the pivot end
of the base boom in addition to the boom length switch
The boom on this model is a 4 section proportionally driven
mounted on the platform end of the base boom to sense
telescopic boom. The inner mid boom is driven directly by the
when the boom is in the position associated with high speed
telescope cylinder. The outer mid and fly booms are each
travel. Above transport angle is recognized when one angle
driven by separate wire rope systems. Each rope system con-
sensor reads more than 15° with respect to gravity and resets
tains redundant ropes that are capable of allowing the opera-
to within transport position when both angle sensors read less
tor to unknowingly continue use of the machine with a single
than 10° with respect to gravity. Transport length is recog-
rope failure. These kinds of failures with the extend ropes are
nized when both the length switch and length sensor read less
self revealing to the operator so proper action can be taken.
than 1 ft extension for the 1350SJP (2 ft extension for the
Failures within the fly extend ropes are self revealing as they
1200SJP). During failures of either the length switch or length
are exposed on the exterior of the boom where a broken rope
sensor, the transport length will be determined by the remain-
would be obvious. Failures within the outer mid ropes require
ing sensor or switch. The position of the articulated jib is not
the addition of the Broken Cable Indicator System in order to
considered.
be self-revealing to the operator. This system uses a proximity
sensor to detect excessive movement of the sensed rope as This system is used to control the following systems:
would be expected with a rope failure. A broken rope detec-
tion results in illuminating the Cable Break indicator on the • Beyond Transport - Drive Speed Cutback System
platform control panel. No restrictions are made to the func- • Drive/Steer – Boom Function Interlock System – CE Only
tionality of the control system. It is the responsibility of the
• Jib Stow System
operator to take the appropriate action.
• Axle Extension System
ment and operation, refer to Section 6 - JLG Control Sys- • Oscillating Axle System
tem.
Platform Control Enable System tem.
The platform controls make use of a time dependent enable
circuit to limit the time availability of “live” or enabled controls. Beyond Transport - Drive Speed Cutback System
When the footswitch is depressed, the controls are enabled
When boom is positioned beyond the Transport Position, the
and the operator has 7 seconds to operate any control. The
drive motors are automatically restricted to their maximum
controls will remain enabled as long as the operator continues
displacement position (slow speed).
to use any function and will remain enabled 7 seconds after
the last function has been used. While the controls are “live”, NOTE: For more detailed information concerning system adjust-
the enabled light will be illuminated in the platform display ment and operation, refer to Section 6 - JLG Control Sys-
panel. When the time limit has been reached, the enabled tem.
light will turn off and the controls will be “dead” or disabled. To
continue use of the machine the controls must be re-enabled
to start the timer system over again. This is done by releasing
all functions, then releasing and re-depressing the footswitch.

tem.
3121142 4-1
Drive/Steer – Boom Function Interlock System Envelope Tracking System

(CE ONLY) The Envelope Tracking System uses the envelope control sen-
sors to enhance the control of the boom within the working
The Drive/Steer – Boom Function Interlock System uses the
envelope. Due to the shape of the working envelope, the max-
Transport Position Sensing System to sense when the boom is
imum boom angle varies with telescope length. To maintain
out of the transport position. All controls are simultaneously
unrestricted operation of the boom, the lift down function is
functional when the booms are within the transport position
automatically introduced while telescoping in only when the
as on the standard machine. When the boom is beyond the
boom is on the rearward edge of the envelope. This only
transport position, the control functions are interlocked to
occurs when telescoping in along the rearward edge and is
prevent simultaneous operation of any boom function with
not used elsewhere within the envelope or when telescoping
drive/steer. The first function set to be operated in this mode,
out. Envelope tracking is disabled with any envelope or
becomes the master function set. In other words, while oper-
moment violations or failures. The envelope tracking function-
ating drive/steer functions the boom functions are inoperable.
ality and be turned off using the manual position of the boom
Likewise, while operating boom functions drive/steer func-
control select switch. Refer to Boom Control Select.
tions are inoperable.
tem.
tem.
Jib Stow System

This machine is equipped with a full function side swing rota-
tor that is mechanically limited to 90 degree rotation to the
left and electrically limited to 90 degrees to the right through
the use of a positive action limit switch mounted on the rota-
tor assembly. The machines stowed length can be reduced to
facilitate transportation on standard trailers by swinging the
jib further to the right using the hydraulic power of the side
swing rotator. The control system will prevent swinging the jib
past the 90 degree position unless the axles are retracted, the
boom is in the transport position, and the jib stow override
button on the platform control panel is held in combination
with the jib swing function switch. When the jib is stowed,
automatic platform leveling is disabled, the boom is restricted
to the transport position, and axle extension is disabled. This
system is functional only in the 500 lb. (230 kg) mode of the
Dual Capacity System.

tem.
4-2 3121142
Moment Control System Boom Control System (BCS) Functional Check

The Moment Control System is the secondary means of con- (Push to Test) System
trolling the stability of the machine. This system uses a load
The machine is equipped with a system for the operator to
moment pin to attach the lift cylinder of the boom to the turn-
daily verify the proper functioning of the Boom Control Sys-
table. This pin is instrumented with gauges allowing the forces
tem (Envelope Control System and the Moment Control Sys-
in the pin to be monitored. These forces are used to compare
tem). The operator is instructed to position the boom in the
the actual boom moment (force at a distance) to a predeter-
position described by the instruction decal and to then verify
mined allowable boom moment. In controlling the boom
the control system cut out the telescope movement at the cor-
moment, the position and load of the boom is controlled. The
rect length. When the operator pushes the push button
moment control system will detect moments larger than
mounted on the ground control panel, the control system
expected as well as those smaller than expected. This effec-
compares the current moment reading in the moment system
tively controls the forward and rearward positions of the
and compares it to the moment expected for this position. If
boom. The moment control system varies the maximum
the current moment is within allowable tolerance for the test
allowable moment based on ground slope. On level ground
position, the green BCS indicator will illuminate indicating the
and with rated load in the platform, the allowable moments
system is working properly. If the current moment is not
establish a working envelope slightly larger than the Envelope
within the allowable tolerance for the test position, the red
Control System’s envelope to minimize interaction of the sys-
BCS indicator will illuminate indicating the machine requires
tems. With increasing ground slopes and rated load in the
service by JLG authorized service personnel before the system
platform, the allowable moments may establish a working
is used. Failure of this test will not restrict the functionality of
envelope smaller than the Envelope Control System’s enve-
the machine and will not cause a system fault. It is the opera-
lope and may result in moment violations at the extreme plat-
tors responsibility to take proper action. The machine can be
form positions. Violations of the moment control systems
in either capacity mode of the dual capacity system for this
allowable moment will result in reduced function speeds, BCS
system check.
warning light illumination, restriction of functions, and sound-
ing of the platform alarm and the flashing of the BCS light with NOTE: For more detailed information concerning system adjust-
attempts to operate restricted functions. The restricted func- ment and operation, refer to Section 6 - JLG Control Sys-
tions due to moment system violations related to forward tem.
reach are disallowing jib functions, lift down, telescope out,
swing, drive, and steer. The restricted functions due to Controlled Arc System
moment system violations related to backward reach are disal-
The Controlled Arc System uses the envelope control sensors
lowing jib functions, lift up, telescope in, swing, drive, and
to enhance the control of the boom within the working enve-
steer. Recognized failures within this system will result in con-
lope. The purpose of the controlled arc system is to minimize
trol by the Envelope Control System, reduced function speeds,
the interaction of lift functions with envelope edges and to
BCS warning light illumination. The boom will be restricted
increase user efficiency. This minimizes the effect of a long
from leaving the transport position until the failure is resolved.
boom working in a comparatively narrow envelope. Because
NOTE: For more detailed information concerning system adjust- the boom is permitted to extend to longer lengths at high
ment and operation, refer to Section 6 - JLG Control Sys- angles than at it is low angles, lift commands would normally
tem. cause the boom to violate the permitted envelope while lifting
down or conversely require the operator to frequently com-
mand telescope out while lifting to high heights. The con-
trolled arc system optimizes the envelope shape by
automatically introducing telescope in or out during "lift only"
commands. Telescope flow is regulated during lift commands
to maintain a constant percentage of available boom length
(0% is always fully retracted, 100% is variable as the permitted
length changes when the boom is raised). The target percent-
age will be maintained throughout the lift command whether
it is maintaining 0%, 100%, or any percentage in between. The
target percentage is established at the start of lift command or
end of manual telescope commands when using multiple
functions with lift. The telescope command can be used inde-
pendently or in combination with other functions. Manual
introduction of telescope will override the controlled arc sys-
tem and result in conventional control. Controlled arc will be
disabled with any sensor failure, any moment violation, any
envelope violation, or with auxiliary power functions. The con-
trolled arc functionality and be turned off using the manual
3121142 4-3
position of the boom control select switch. Refer to Boom Envelope Tracking
Control system.
The Envelope Tracking System uses the envelope control sen-
sors to enhance the control of the boom within the working
envelope. Due to the shape of the working envelope, the max-
imum boom angle varies with telescope length. To maintain
unrestricted operation of the boom, the lift down function is
automatically introduced while telescoping in only when the
boom is on the rearward edge of the envelope. This only
occurs when telescoping in along the rearward edge and is
not used elsewhere within the envelope or when telescoping
out. Envelope tracking is disabled with any envelope or
moment violations or failures. The envelope tracking function-
ality and be turned off using the manual position of the boom
control select switch. Refer to Boom Control Select.

Controlled Arc Boom tem.
Movement
Slow Down System
NOTE: For more detailed information concerning system adjust- When the boom approaches the edges of the working enve-
ment and operation, refer to Section 6 - JLG Control Sys- lope, all functions (except jib and platform functions, tele-
tem. scope in or out on the rearward edge and telescope in on the
forward edge) are automatically slowed down by the control
Controlled Boom Angle System system to reduce the machine dynamics and improve opera-
tor control. The slow down starts within 4 feet of all edges and
The Controlled Boom Angle System uses the envelope control
is at the fully reduced speeds 2 feet from all edges. The control
sensors to enhance the control of the boom by minimizing the
system indicates to the operator this automatic introduction
interaction of swing and drive functions with the envelope
of slow down by flashing the creep light on the platform dis-
edges. This interaction is due to two factors. First, the envelope
play panel. This feature applies to both platform and ground
is controlled relative to gravity regardless of ground slope and
controls, however, no indication is made on the ground con-
second, the turntable/boom mounting is effected by swing
trol panel.
and drive functions when the ground slope varies. This can
cause the boom position to vary within the envelope or even NOTE: For more detailed information concerning system adjust-
violate the envelope edges when swinging or driving without ment and operation, refer to Section 6 - JLG Control Sys-
intentionally moving the boom. The controlled boom angle tem.
system minimizes this effect by automatically introducing lift
up or down during swing and drive commands to maintain a
constant boom angle relative to gravity for all boom angles
greater than 9 degrees. Controlled boom angle is disabled
with any envelope or moment violations or failures. The con-
trolled boom angle functionality and be turned off using the
manual position of the boom control select switch. Refer to
Boom Control Select.

tem.
4-4 3121142
Dual Capacity System Electronic Platform Leveling

The Dual Capacity System on this machine is a multiple enve- The electronic platform leveling system uses two tilt sensors
lope control system as opposed to an indication system. The (mounted on either side of the pivot weldment), a control
control system changes the working envelope and moment valve (mounted to the platform support), a level cylinder, and
limits to match the capacity select mode to either the 500 lb. the platform control module (mounted in the platform control
(230 kg) mode or the 1000 lb. (450 kg) mode. It then displays box) to automatically measure and control the incline of the
the capacity mode on the platform and ground display panel platform with respect to gravity. While in the automatic posi-
and controls the positions of the boom within the allowable tion of the boom control select (item 33) platform leveling is
envelope for that mode. This mode is selectable by the opera- active while operating drive, telescope, lift or swing and is not
tor with the dual capacity select switch on the platform con- active while operating any other function (e.g. rotate, jib, or
trol panel. The 500 lb. (230 kg) mode has the largest envelope steer). While in the manual position of the boom control
and allows the use of the side swing jib. The 1000 lb. (450 kg) select, platform leveling is active while operating lift only. The
mode has a smaller envelope and requires the jib to be fixed in system controls the platform angle relative to gravity using a
the centered position. To select the 1000 lb. (450 kg) mode the set point established during power-up (cycling of the EMS) or
boom must already be in the smaller 1000 lb. (450 kg) enve- at the conclusion of a manual platform level override by the
lope and the jib must be centered (+/-10 degrees) verified to operator using the platform level override switch from either
the control system by the jib centered limit switch mounted the platform or the ground control. In other words the opera-
on the side swing rotator. When the operator selects the 1000 tor can chose a platform incline other than level with gravity
lb. (450 kg) mode and these conditions are met, the capacity and the system will maintain that incline automatically.
light changes from 500 lb. (230 kg) to 1000#, jib swing is disal-
If a fault occurs in the platform leveling system the following
lowed, and the envelope and permitted moment values are
will occur:
changed accordingly. When the operator selects the 1000 lb.
(450 kg) mode and these conditions are not met, both capac- • Automatic platform leveling will stop (except when there is
ity lights will flash, the platform alarm will sound, and all func- a fault in only one sensor)
tions except jib swing will be disabled until the capacity select
• The platform level fault indicator will flash
switch is put back into the 500 lb. (230 kg) position. Operation
of jib swing in this condition can be used to find the center • The platform alarm will sound
position of the jib as the jib swing function will stop when the
• All functions will default to creep speed if in platform mode
center position is reached.
and the boom is out of the transport position. Refer to
NOTE: For more detailed information concerning system adjust- Transport Position Sensing System.
ment and operation, refer to Section 6 - JLG Control Sys- To reset the fault the emergency stop switch should be recy-
tem. cled.

tem.
3121142 4-5
Boom Control Select In addition, when the boom control is selected to the auto-
matic position, the automatic platform leveling feature is
The boom control select switch is mounted on the platform
active during lift, telescope, swing, and drive movements as
control panel and allows the operator the ability to select
described in the Electronic Platform Leveling System descrip-
between two different modes of boom control functionality:
tion.
automatic and manual. While in either mode, the Envelope
Control System and Moment Control System remains active. When the boom control is selected to the manual position, lift
and telescope movements are controlled separately by the
When the boom control is selected to the automatic boom
operator effectively turning off the controlled arc, controlled
control position, lift and telescope movements are coordi-
boom angle, and envelope tracking systems. Without these
nated by the control system as described in the Controlled Arc,
systems being active, the control system will stop the move-
Controlled Boom Angle, and Envelope Tracking descriptions.
ments of the boom when the envelope boundaries are
These systems will remain active to automatically assist the
reached and the functions that could violate the envelope will
operator in keeping the boom within the envelope boundar-
be restricted. The platform alarm will sound and the BCS light
ies.
will flash with attempts to operate a restricted function. In
When operating in the automatic mode, the following func- addition, when the boom control is selected to the manual
tionality characteristics should be noted. position, the automatic platform leveling feature is active only
during lift movements.
• While operating Lift Up, the boom may also telescope out
(Controlled Arc) NOTE: For more detailed information concerning system adjust-
• While operating Lift Down, the boom may also telescope in ment and operation, refer to Section 6 - JLG Control Sys-
(Controlled Arc) tem.
• While operating Swing or Drive, the boom may lift up or lift

down (Controlled Boom Angle)
• While operating Telescope In, the boom may lift down
when at high boom angles and the creep light is flashing
(Envelope Tracking)
4-6 3121142
4.2 PLATFORM NOTE: The platform support weighs approximately 81.6 lbs.
(35 kg).
Support Removal 4. Remove the bolts securing the support to the rotator.
BOLTS
1. Disconnect electrical cables from control console.

5. Using a suitable brass drift and hammer, remove the
2. Remove the bolts securing the platform to the platform center bolt and locknut.
support, then remove the platform.
NOTE: The platform weighs approximately 132.2 lbs. (60 kg).
6. Remove the platform support from rotator.
3. Using a suitable lifting device, support the platform sup-

port.
3121142 4-7
Support Installation 5. Position the platform on the platform support and

install the bolts securing the platform to the platform
1. Using a suitable device, support the platform support support.
and position it on the rotator.
NOTE: The platform support weighs approximately 81.6 lbs.

(57 kg).
2. Install the rotator center bolt and locknut.
6. Connect the electrical cables to the platform control

3. Apply JLG Threadlocker PN 0100011 to the eight bolts console.
securing the support to the rotator and install the bolts.
4. Torque the nut on the rotator center bolt to 586 ft. lbs.
(795 Nm). Torque the retaining bolts to 340 ft. lbs.
(460 Nm).
4-8 3121142
4.3 BOOM REMOVAL, DISASSEMBLY/ASSEMBLY, & 6. Tag and disconnect the telescope, tank, and pressure
hoses as indicated below from the main valve and cap
CABLE REPLACEMENT ends.
Removal
1. Place machine on firm, level ground.
2. Slightly elevate the boom and support the fly boom
with a crane or an adequate lifting device capable of
handling 6 - 7 tons.
3. Place blocking under lift cylinder to hold it in place.

4. Remove lift cylinder pin securing the lift cylinder rod to
the boom.
1. Pivot Pin
2. Bolt
3. Keeper Pin
5. Remove the boom end cover.
3121142 4-9
4-10
3
4 5 6 7
1
A B 2
A B
1001139517-F
MAE35330F
1. Boom Base 5. Jib Rotator

2. Boom Inner Mid 6. Jib Assembly
3. Boom Outer Mid 7. Platform Rotator
4. Boom Fly
Figure 4-1. Boom Assembly - Sheet 1 of 7
3121142
3121142
1
9
4
6
5 8
SECTION A-A SECTION B-B
1001139517-F
MAE35340F
1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pad
4-11
4-12
1,2
3 7
5,6
4
8,9
1001139517-F
MAE35350F
1. Upper Rear Wear Pad 6. Shim

2. Shim 7. Tele Cylinder Pulley Assembly
3. Telescope Cylinder 8. Bottom Rear Wear Pad
4. Trunnion Keeper Block 9. Shim
5. Lower Rear Wear Pad
3121142
3121142
7
6
4
3
2
1001139517-F
MAE35360F
1. Sheave Deflector 6. Rope Retainer Block

2. Sheave Deflector 7. Level Cylinder
3. Rope Retainer Block 8. Front Lower Wear Pad
4. Fly Extension Sheave 9. Lock Plate
5. Rope Retainer Block
4-13
4-14
4
3
1,2
5
6
7
8
4
11
9,10
6
5
12
1001139517-F
MAE35370F
1. Front Upper Wear Pad 7. Jib Rotator

2. Shim 8. Jib Rotator Cam
3. Pivot Assembly 9. Front Side Wear Pad
4. Platform Rotator 10. Shim
5. Jib Cylinder 11. Shim
6. Lower Jib Link 12. Lock Plate
3121142
8.0 ± 0.5”
3121142
203 ± 13 mm 9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
4 3
2
4 3
6 5
1001139517-F
MAE35380F
1. Outer Mid Extend Rope 4. Outer Mid Retract Rope

2. Fly Extend Rope 5. Proximity Switch Spring
3. Fly Retract Rope 6. Switch Adjustment Block
4-15
A B
4-16
A B
1.375 .062
1.375 .062
1.125 .062
1.125 .062
1.438 .062
1.438 .062
VIEW A-A SECTION D-D
1001139517-F
MAE35390F
3121142
7. Tag and disconnect the three electrical wires that run to 13. Using the lifting device, remove boom from chassis.
the power track and the wire that goes to the proximity
switch.
14. Place boom on saw horses or other adequate supports.
Disassembly
It is not necessary to completely remove the entire boom
assembly from the machine to replace the cables. In the fol-
lowing procedure, the base boom section will remain on the
8. Unbolt the power track.
machine.
9. Remove the bolt securing the keeper pin and remove
the keeper pin from boom pivot pin.
10. Using the lifting device, support the rear of the boom to NEVER HANDLE WIRE ROPE WITH BARE HANDS.
remove the load from the pivot pin.
1. Position the boom so that it is horizontal. If the boom is
below horizontal, ensure that the boom is not on the
boom rest.
2. Use an adequate lifting device to support the weight of
the jib and platform assembly.
3. Tag and disconnect the hoses and electrical harnesses
that run to the platform. Cap or plug all openings.
4. Pull the hoses and harnesses through the jib and lay
them off to the side of the boom.
5. Remove the bolt and keeper pin securing the platform
level pivot pin and remove the pin.
11. Remove the boom pivot pin.

12. Move all of the hydraulic hoses and electrical wires so
they are free from chassis.
3121142 4-17
6. Remove the bolt and keeper pin securing the jib pivot 9. Pull the disconnected tube back to allow room to dis-
pin and remove the pin. connect the lower tube.
7. Remove the jib and platform assembly from the boom.
8. Attach a lifting device to the powertrack for support and

unbolt the upper powertrack tube from the fly boom.
4-18 3121142
10. Unbolt the lower powertrack tube from the outer mid 12. Remove the bolts securing the side wear pads to the
boom section and the mounting bracket from the inner front of the base boom and remove the pads and shims.
mid boom section.
13. Remove the boom length plate.
11. Attach a strap or other similar device around the pow-

ertrack and boom to keep the powertrack secure
throughout the cable replacement procedure.
3121142 4-19
14. Remove the cover over the boom length limit switch at 16. Tag and disconnect the wiring harness running to the
the front of the boom base section. Remove the switch. boom length sensor. Remove all the bolts and washers
securing the sensor, including those that secure the
measuring cable to the telescope cylinder, and remove
the length sensor.
17. Tag and disconnect the hydraulic hoses from the tele-
scope cylinder. Cap or plug all openings.
15. Remove the rear boom cover.
18. Remove the front side, top, and lower wear pads from
the boom base section.
4-20 3121142
19. Remove the keepers for the outer mid retract cable 22. Remove the adjustment nuts for the for the outer mid
adjustment nuts at the front of the boom base section. extend cables along with the Broken Cable proximity
switch, spring, and adjustment plate.
23. Remove the cable mounting plate.

20. Loosen and remove the outer mid retract cable adjust-
ment nuts.
21. Remove the adjustment bolt keepers for the outer mid
extend cable adjustment nuts at the rear of the boom.
3121142 4-21
24. Remove the cover plate from the bottom of the boom 26. Remove the outer mid retract cables from the attach-
and remove the sheave blocks. ment fixtures at the front of the boom base section.
27. Attach an auxiliary hydraulic power source to the tele-

scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
25. Remove the trunnion blocks that secure the telescope

cylinder rod to the boom base section.
4-22 3121142
28. Pull the inner mid, outer mid, and fly boom sections out 29. Remove the trunnion blocks that secure the telescope
of the base boom section. Use additional lifting devices cylinder barrel to the inner mid boom section.
and reposition any lifting straps as necessary as the sec-
tions are withdrawn. It will be helpful during this step to
pull the outer mid retract cable out from the front of the
base section as the other sections are being pulled out.
This will prevent the cables from tangling as the sections
are withdrawn.
30. Attach a lifting device to the telescope cylinder and pull

the cylinder, along with the outer mid extend cables out
of the inner mid boom section. Reposition the lifting
device as necessary to balance the cylinder.
3121142 4-23
31. Remove the hardware attaching the outer mid extend 33. Remove the rear bottom wear pad.
block and remove the block and outer mid extend
cables.
34. Remove the lock plates from the fly boom retract cable
adjustment nuts and remove the adjustment nuts from
the fly boom retract cables and from the fly boom
extend cables at the front of the inner mid boom sec-
tion.
32. Remove the cable retainer plate, cable retainer block,
bushing, and sheave.
4-24 3121142
35. Pull the fly boom extend cables from their mounting of the inner mid boom section so it doesn’t move as the
receptacles. other sections are withdrawn.
36. Remove the top, side, and bottom wear pads from the
front of the inner mid boom sections.
38. Pull the sections out enough to allow easy removal of

the cable retainer blocks and sheave blocks for the fly
boom retract cables at the front of the inner mid boom
section.
37. Attach a strap to pull the outer mid and fly boom sec-
tions out of the inner mid boom section. Secure the rear
NOTE: When pulling the outer mid and fly boom sections out of
the inner mid boom section, make sure the outer mid
retract cables do not catch at the rear of the boom section.
3121142 4-25
39. Pull the sections the rest of the way out of the inner mid 41. Remove the cable retract retainer plates, cable retainer
boom section, pulling the fly boom retract cables out at blocks, sheaves, and bushings from the rear of the outer
the same time. mid boom section.
40. Remove the outer mid retract cables from the rear of the
inner mid boom section.
42. Remove the front wear pads from the outer mid boom
section.
4-26 3121142
43. Remove the upper rear wear pads from the fly boom ing bolt, keeper pin, pin, bushings, and sheave from the
section. front of the outer mid boom section.
44. Remove the cable retainer blocks and shims.
45. Pull the fly boom extend cables out enough to have
clearance to remove the sheave, and remove the retain-
3121142 4-27
NOTE: When pulling the fly boom section out of the outer mid 48. Remove the fly boom extend cables from the bottom of
boom section, make sure the fly boom retract cables do not the fly boom section.
catch at the rear of the boom section.
46. Attach a lifting device to the fly boom section and pull
the section and fly boom extend cables from the outer
mid boom section. Secure the rear of the outer mid
boom section so it doesn’t move when the fly boom sec-
tion is withdrawn.
49. Thoroughly clean the boom sections.
Assembly
NEVER HANDLE WIRE ROPE WITH BARE HANDS.

47. Remove the tape from the fly boom section and remove
the fly boom retract cables. NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all
four inner surfaces of both ends of each boom section to a
minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom
section only needs Super Lube applied to the insertion end.
Super Lube is also to be moderately applied to all outer sur-

faces of interior wear pads after they are installed to the
insertion end of boom sections. Care should be taken to
avoid application on exposed painted surfaces of the fully
extended boom. Refer to Section 1 - Remove the Platform
Support. Refer to Section 4.2, Platform.
WIRE ROPE NUTS ARE CLOSE IN SIZE AND CAN BE SWITCHED. REFER TO THE
JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF
BASE BOOM, WILL BE BLACK IN COLOR.
4-28 3121142
wire rope and place them into the fly boom, tape the
slots to keep the rope from jumping out.
TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY
PROCEDURE.
1. Install the fly extend wire rope button ends into the slots
on the bottom of the fly boom section. Place tape over
the wire ends to keep them in place during assembly.
2. Fabricate a special fixture as shown below to keep four

extend wire ropes from crossing over each other.
3. Install the fly retract wire rope button ends into the slots
in the side of the fly boom, coil the remaining lengths of
3121142 4-29
Ft-Lbs. Nm
A 190 260
B 190 260
C 35 48
D 40 55
Figure 4-8. Boom Assembly Torque Values - Sheet 1 of 2
4-30 3121142
E F
NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued. Check
torque on the bolts every 150 hours of
operation.
Ft-Lbs. Nm
E 340 460
F 480 651
G 190 260
Figure 4-9. Boom Assembly Torque Values - Sheet 2 of 2
3121142 4-31
4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain-
boom section. ing bolt to the front of the outer mid boom section.
DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES
8. Install the cable retainer blocks and shims.
WHILE INSERTING IT INTO THE OUTER MID BOOM.
5. Apply JLG Threadlocker PN 0100011 to the bolts and

install the front lower wear pads and shims to the outer
mid boom as marked during disassembly. Torque the
bolts to 50 ft.lbs. (68 Nm).

install the front upper, and side wear pads on the outer
mid boom section as marked during disassembly.
Torque the bolts to 50 ft.lbs. (68 Nm).
6. Install the fly boom section most of the way into the
outer mid boom section, leaving enough of the fly out
so there is adequate slack in the fly boom extend cables
to allow for installation of the front sheave.
4-32 3121142
10. Apply JLG Threadlocker PN 0100011 to the bolts and 12. Apply a thin coat of moly paste lubricant to the inside
install the rear upper and side wear pads on the outer diameter of the sheave composite bearings. Install the
mid boom section as marked during disassembly. fly retract sheaves and bushings while guiding the wire
Torque the bolts to 50 ft.lbs. (68 Nm). ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
PN 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retract retainer
plates and cable retainer blocks.
11. Uncoil the fly retract wire ropes from the fly boom.
Route the threaded ends of the wire ropes through the
holes in the outer mid boom plates at the retract sheave
locations.

install the lower rear wear pad onto the outer mid boom
section. Torque the bolts to 50 ft.lbs. (68 Nm).

install the side and upper wear pads on the rear of the
inner mid boom section. Torque the bolts to 50 ft.lbs.
(68 Nm).
15. Lubricate the wear surfaces on the inside of the inner
mid boom section with Super Lube.
3121142 4-33
16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid
section from the front. boom section to the receptacles at the rear of the outer
mid boom section.
19. Put tape over the holes to keep the cable ends from
jumping out.
17. Using an adequate lifting device, align the outer mid

boom section with the inner mid boom section.
20. Push the outer mid assembly part way into the inner
mid boom section. Apply JLG Threadlocker PN 0100011
to the bolts and install the front bottom wear pad into
the inner mid boom section. Torque the bolts to
50 ft.lbs. (68 Nm).
4-34 3121142
21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the
pulling the boom cables out the back fo the inner mid inner mid boom section.
section at the same time. Leave 3 to 4 feet of the outer
mid section sticking out of the inner mid section.
24. Install the cable retainer blocks over the fly boom retract
cables and insert the fly boom extend cable into the
22. Push the retract cable ends into the mounting recepta- mounting receptacles.
cles and install the cable sheaves and adjustment nuts.
3121142 4-35
25. Apply JLG Threadlocker PN 0100011 to the bolts and 27. Apply a thin coat of moly paste lubricant to the inside
install the side and top wear pads into the inner mid diameter of the sheave composite bearings. Install the
boom section. Torque the bolts to 50 ft.lbs. (68 Nm). retract sheaves and bushings while guiding the wire
ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
PN 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retainer blocks and
cable retainer plates.
26. Put moly paste on the sheave mounts at the rear of the
inner mid boom section and install the sheaves.

install the rear bottom wear pad on the rear of the inner
mid boom section. Torque the bolts to 50 ft.lbs. (68 Nm).
4-36 3121142
29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and
install the cable retainer block.
30. Install the outer mid extend cables into the cable pulley
at the rod end of the telescope cylinder. 33. Using an adequate lifting device, insert the cylinder and
cables part way into the inner mid boom.
31. Install the other end of the outer mid extend cables into
the cable guide block.
3121142 4-37
34. Apply JLG Threadlocker PN 0100019 to the bolts and 37. Using Super Lube®, lubricate all wear surfaces on the
attach the cable guide to the inner mid boom section inside of the boom base section and the outside of the
with the mounting hardware. Torque the bolts to inner mid boom section.
165 ft.lbs. (224 Nm).
38. Insert the inner mid boom section part way into the
boom base section enough to be able to pull the outer
mid retract cables out through the hole at the bottom
front of the boom base section.
35. Push the cylinder the rest of the way into the inner mid
boom assembly.
36. Install the cylinder trunnion blocks and shims. 39. Apply JLG Threadlocker PN 0100011 to the bolts and
install the front lower wear pads into the boom base
40. Push the inner mid boom assembly the rest of the way
into the boom base section, adjusting the lifting device
as necessary to keep the weight balanced.
4-38 3121142
41. Apply JLG Threadlocker PN 0100011 to the bolts and 46. Install the outer mid retract cable adjustment nuts at the
install the side and upper wear pads into the boom base front of the boom base section.
42. Install the boom transport length sensor on the side of
the boom base section.
43. Attach the powertrack tubes.
44. If necessary, attach a source of auxiliary hydraulic power
and retract the boom enough to allow installation of the
cable adjustment plate at the rear of the base boom sec-
tion and install the plate.
47. Install the boom length sensors and angle sensors as

tagged during removal.
45. Install the broken cable sensor and the outer mid extend
cable adjustment nuts.
48. Connect the hydraulic hoses to the telescope cylinder as

49. Adjust the boom cables. Refer to Section 4.13 - Wire
Rope Tensioning Adjustment.
50. Perform a boom calibration as described in Section 6
under Calibrating the Boom Sensors.
3121142 4-39
#0100019
#0100011
#0100011
#0100011
#0100019
#0100019
#0100011
A
A
#0100011
SECTION A-A
1001139517-F
MAE36190F
Figure 4-10. Locations for Threadlocker Application - Sheet 1 of 4
4-40 3121142
#0100011
#0100011
#0100011
#0100011
#0100011
1001139517-F
MAE36200F
3121142 4-41
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
1001139517-F
MAE39201F
4-42 3121142
#0100011
#0100011
#0100011
#0100011 #0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100019
#0100019
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
1001139517-F1001139517-F
MAE36220F MAE36220F
3121142 4-43
4.4 ROTATOR Installation

1. Supporting the rotator and jib lift cylinder, align rotator
Removal with jib lift cylinder and jib. Using a soft head mallet,
install pin (1) to the jib assembly. Install hardware secur-
1. Remove the Platform Support. Refer to Section 4.2, Plat-
ing pin (1).
form.
2. Tag and disconnect hydraulic lines to rotator. Use suit- NOTE: The rotator approximately weighs 50 lbs. (23 kg).
able container to retain any residual hydraulic fluid. Cap
or plug all openings of hydraulic lines and ports. 2. Using a soft head mallet install pin (2) to jib assembly
and install the rotator. Install hardware securing pin (2).
NOTE: The rotator approximately weighs 50 lbs. (23 kg).
3. Install the platform and platform support. Refer Section
4.2, Platform.
3. Supporting the rotator and jib lift cylinder, remove hard-
ware from pin (1). Using a suitable brass drift and ham- 4. Remove cap or plugs from openings of hydraulic lines
mer remove pin (1). and ports and connect hydraulic lines to the rotator as
4. Remove the hardware from pin (2). Using a suitable
brass drift and hammer, remove pin (2) and remove the
rotator.
JIB LIFT CYLINDER
ROTATOR
2
MAE37620
Figure 4-14. Platform Rotator Removal and Installation
4-44 3121142
4.5 BOOM LUBRICATION APPLICATION 4.6 BOOM SHIMMING PROCEDURE

This procedure applies to booms after assembly or during 1. Measure and record the dimension and direction of any
annual application using Super Lube® lubricant (JLG sweep found in the fly boom section. Measure and
PN 3020042). record the inside width and inside height of the outer
1. Position the boom on the boom rest using the 500lb mid boom opening.
capacity setting.
2. Telescope main boom section as far as it will extend at
this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moder-
ately apply lubricant to the interior surfaces of the base
boom, inner mid boom, and outer mid boom. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
4. At the rear of the machine, apply lubricant to the side,
top and bottom surfaces of the fly boom, outer mid, and
inner mid specifically to wear pad contact paths. To pre- SWEEP
vent misdiagnosis of hydraulic leaks, take care to pre- MEASUREMENT
vent excessive application of lubrication.
5. After application of the lubricant is complete, cycle the
boom through its full range of travel 2 times.
TOP VIEWOF BOOM SECTION
Figure 4-15. Measuring Boom Section Sweep
NOTE: Wear Pad bolt lengths should be flush to one thread below
the surface of the insert. When installing wear pads in the
following steps, the wear pad bolt lengths may need to be
adjusted as shim thicknesses are adjusted.
2. Install the side wear pads on the fly boom sides. Shim as
necessary to match the outer mid boom dimension
recorded in step 1 ± 1/32” (± 0.8 mm). Shims should be
divided as evenly as possible between the side pads
unless corrections are needed to compensate for sweep
recorded in step 1. If the sweep is to the left the internal
side pads on the left should have more shims than the
right side pads and vise versa.
3. Install the bottom wear pad(s) and shims if applicable
on the fly boom.
3121142 4-45
4. Install the top wear pad(s) on the fly boom and shim as 4.7 JIB ROTATOR ORIENTATION
necessary to obtain 0 - 1/16” (0 - 1.6 mm) less than the
corresponding dimension recorded in step 2. In order for the Jib Rotator to rotate properly, it must be
installed with the timing marks running parallel to the flat
5. Slide the fly into the outer mid boom leaving 2 - 6 feet rotator mounting plate as shown below.
(0.6-1.8 m) exposed.
6. Install the bottom wear pad(s) and shims if necessary
into the end of the outer mid boom.
7. Temporarily insert the side pads on one side and slide
the fly boom to that side. Insert the other side pads and
using shims, measure how many will be required to fill
the remaining space. Install the total amount of shims
as evenly as possible between the two sides unless cor-
rections are needed to compensate for out-of-square
booms or for corrections due to sweep recorded in step
1. Care should be taken to keep the bottom pads evenly
loaded while shimming the side pads.
NOTE: Do not install more shims than will fit because this may
result in a boom being shimmed too tight. The use of pry
bars or wedges should only be used to finish installing a
shim that can be installed by hand more than ½ of its
length. Figure 4-16. Jib Rotator Orientation
8. Install the top wear pads and shims into the end of the
outer mid boom leaving a gap of 0” to 1/16” between
the top of the fly boom and inside of the outer mid 4.8 JIB LIFT END OF STROKE DAMPENING
boom.
The jib lift cylinder is constructed in a way that causes the jib
9. Repeat steps 1-7 to install the fly/outer mid assembly lift cylinder oil flow to be restricted by an orifice while raising
into the inner mid boom. the jib within 5 degrees of maximum elevation. This restriction
slows the jib lift speed while raising the jib. The oil flow is not
10. Repeat steps 1-7 to assemble the fly/out mid/inner mid
restricted while lowering the jib and therefore the speed is not
assembly into the base boom.
altered.
11. Complete the boom assembly. The boom should be
functionally tested and evaluated for boom sweep.
Boom sweep should be limited to no more than 5/16" (8
mm). If necessary, the boom may be re-shimmed by
moving shims from one side to the other to further cor-
rect any remaining boom sweep. There may be some
instances where no shims are used under a given side
pad to pass the criteria for boom sweep at final inspec-
tion of machine.
4-46 3121142
4.9 LOAD SENSING PIN REMOVAL AND 6. Use the Load Pin Removal Tool (JLG PN 4846765) to pre-
vent the pin from being damaged, and use a hammer to
INSTALLATION remove the pin. To make the tool refer to Figure 4-17.,
Load Pin Removal Tool, JLG PN 4846765. If the Load Pin
1. Place the machine on a firm, level surface.
Removal Tool is not available, use an arbor of the proper
NOTE: Replacing the load sensing pin requires the boom sensors size (as shown below). If excessive force is necessary to
be re-calibrated. Make sure the machine is in an area move the pin, it may be necessary to carefully activate
where this can be accomplished after installation of the lift using the auxiliary power switch to relieve lift cylin-
new pin. der weight from the load sensing pin.
2. Swing the engine tray out to gain access to the sensing

pin and retaining pin.
NOTE: The lift cylinder weighs 787 lbs. (357 kg.)
3. Run a nylon strap capable of supporting the weight of

the lift cylinder around the bottom of the cylinder. Lift
up on the strap to relieve the weight of the lift cylinder
on the load sensing pin.
7. When installing a new pin, make sure all of the holes in

the turntable and lift cylinder are aligned. If the new
load sensing pin does not push 1/2 to 3/4 of the way in
by hand, remove the pin and align the holes better. Also
make sure the pin is installed with the strain relief con-
nector opposing the pin orientation bar as shown. Refer
to Figure 4-27., Pivot Pin Installation.
4. Loosen and remove the bolt that secures the retaining

pin and remove the retaining pin.
8. Using an oak block, carefully tap the pin until it is fully

installed. Secure the pin in place with the retaining pin
and retaining pin bolt.
5. Disconnect the wiring harness from the strain relief con-

nector at the opposite side of the load sensing pin. DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
9. Connect the wiring harness to the strain relief connector

and re-calibrate the boom sensors.
3121142 4-47
Figure 4-17. Load Pin Removal Tool, JLG PN 4846765
4-48 3121142
Figure 4-18. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4
3121142 4-49
4-50 3121142
3121142 4-51
4-52 3121142
SEE DETAIL A
SEE DETAIL C
BOOM LENGTH
SENSOR
DETAIL C
ANGLE SENSOR INSTALLATION

TYPICAL ON LEFT & RIGHT SIDES
OF BOOM
0273696-H
MAE36150H
3121142 4-53
SEE DETAIL D
SEE DETAIL E
DETAIL D
SENSOR #1 SENSOR #1
PIN # DESC SENSOR HARNESS PIN # DESC SENSOR HARNESS
PIN #1 POWER RED RED PIN #1 POWER RED RED
PIN #2 OUTPUT WHITE BLUE PIN #2 PWM OUT WHITE BLUE
PIN #3 GROUND BLACK BLACK PIN #3 GROUND BLACK BLACK
SENSOR #2 SENSOR #2
PIN # DESC SENSOR HARNESS PIN # DESC SENSOR HARNESS
PIN #1 POWER RED ORANGE PIN #1 POWER RED ORANGE
PIN #2 OUTPUT WHITE YELLOW PIN #2 PWM OUT WHITE YELLOW
PIN #3 GROUND BLACK BLACK PIN #3 GROUND BLACK BLACK
0273696-H
MAE36160H
4-54 3121142
JIB STOW SWITCH TO

ACTIVATE WHEN JIB ROTATES
90˚ CCW FROM CENTER
POSITION SWITCH MOUNT

TO ACHIEVE 0.000" - 0.030"
CLEARANCE BETWEEN SWITCH
ROTATOR ROLLERS AND ROTATOR CAM
CAM
SWITCH TO ACTIVATE WHEN

DUAL CAPACITY - JIB POSITION
JIB IS ROTATED 5˚ ± 1˚ BOTH
DIRECTIONS FROM CENTER
DETAIL E
NOTE:
PUSH NUT
ASSEMBLE COMPONENTS AS SHOWN TO
FORM A SUBASSEMBLY WHICH WILL MOUNT
TO JIB PIVOT
SENSOR MOUNT
ENSURE THE PUSHNUTS HOLD SENSOR SENSOR COVER
MOUNT FIRMLY TO SENSOR COVER SO
ALL WIRES ARE CONTAINED IN THE
SUBASSEMBLY PRIOR TO INSTALL ON
THE JIB PIVOT.
MOUNTING BOLT
0273696-H
MAE36170H
3121142 4-55
SEE DETAIL F BOOM LENGTH LIMIT SWITCH TO ACTIVATE WHEN

FLY BOOM IS EXTENDED 12" ± 1.5" (1350SJP)
or 24" ± 1.5" (1200SJP)
[30.5 cm ± 3.8 cm (1350SJP)
or 60.96 cm ± 3.8 cm (1200SJP)]
DETAIL F
DETAIL B
SEE DETAIL B
PROXIMITY SWITCH
TO AVOID DAMAGING PROXIMITY , INSTALL AND ADJUST AFTER ASSEMBLING

SWITCH BLOCK, COMPRESSION SPRING AND TORQING WIRE ROPES.
TO ADJUST PROXIMITY SWITCH:

1. THREAD SWITCH IN UNTIL IT CONTACTS ADJUSTER BLOCK.
2. THREAD SWITCH OUT 1/8 TO 1/2 TURN TO ACHIEVE PROPER SENSING RANGE.
3. TIGHTEN JAM NUT
0273696-H
MAE36180H
4-56 3121142
0271875 D
1. Bar
2. Blade
3. Mount
A Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate
B Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate
C Apply Threadlocker PN 0100019 & torque to 50 ft.lbs. (70 Nm)
Figure 4-26. Boom Wiper Installation
3121142 4-57
1 Pivot Pin
2 Bolt
3 Keeper Rod
4 Load Sensing Pin
5 Pin Orientation Bar
* Position the Load Sensing Pin with the strain relief connector opposite the pin
orientation bar as shown
CAUTION: Pounding on the Load Sensing Pin for removal can destroy the internal
strain gauge. Use care when removing the pin.
Figure 4-27. Pivot Pin Installation
4-58 3121142
4.10 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
4. Pull up on the loose side of the round bar to allow the

poly roller to slide off.
2. Remove the screws from the bars on one side of the

powertrack on the first link.
3121142 4-59
5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
4-60 3121142
10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
11. Repeat the previous step on the other side.
2. Slide the roller off the bar.
12. Slide the bracket off of the powertrack.
3. Hold the bar tightly and remove the other screw.
3121142 4-61
4. Hold the flat bar and remove the screws. 7. Slide the link out.
5. Remove the snap rings and pins. Snap Rings and Screws
WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO

DISCARD AND REPLACE ALL OLD SCREWS.
Make sure screws are tight and installed properly.
6. Remove the screws from the bar. Remove the snap ring
and pin. LOOSE SCREW TIGHT SCREW
4-62 3121142
Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below.
CLOSED
OPEN
10-24 x 0.812 button torx socket head with blue locking patch:
An open snap ring is shown below. • Tighten to 45-50 in.lbs. (5-5.6 Nm).
• Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new
one.
A snap ring that is not seated is shown below.
3121142 4-63
4-64
TIE ELECTRIC CABLES TOGETHER
EVERY 8" (20cm) WITHIN T/T TO BOOM POWERTRACK
CONTINUE TYING ELECTRIC CABLES
UNTIL THEY PASS THRU HOSE CLAMP
(CUT OFF EXCESS STRAP AT EACH TIE POINT)
SEE DETAIL C
SEE DETAIL E
B B
62
2
SEE DETAIL D
SEE DETAIL F
A A
0271570-R
0271800-Q
MAE35400
Figure 4-28. Powertrack Installation - Sheet 1 of 6
3121142
3121142
APPLY RUBBER PAD AFTER BUTTON HEAD SCREWS
HAVE BEEN ASSEMBLED AND TIGHTENED
APPLY LOCTITE #454 TO SURFACE OF
RUBBER PAD AND ASSEMBLE TO APPLY RUBBER PAD AFTER BUTTON HEAD SCREWS
CORRESPONDING PART AS SHOWN HAVE BEEN ASSEMBLED AND TIGHTENED
RUBBER PAD AND ASSEMBLE TO
CORRESPONDING PART AS SHOWN
DETAIL D

RUBBER PAD AND ASSEMBLE TO
CORRESPONDING PART AS SHOWN
USE WASHER AS A SHIM

MAX OF (4) ON EACH MTG BOLT
TYPICAL, LEFT OR RIGHT SIDE
OF MOUNTING FLANGE
DETAIL C
APPLY LOCTITE #454 UNDERNEATH THE HEAD

OF BUTTON HEAD SCREW PRIOR TO ASSEMBLING
T/T TO BOOM POWERTRACK TO THE POWERTRACK/HOOD BRACKET
0271570-R
0271800-Q
MAE35410
4-65
4-66
APPLY LOCTITE #454 TO SURFACE
OF RUBBER PAD AND ASSEMBLE TO
CORRESPONDING PARTAS SHOWN
DETAIL E
ROUTE HOSES/CABLES THROUGH LOOP

ON ROTATOR SUPPORT AS SHOWN
TRIM EXCESS
AS REQUIRED

RUBBER CLAMP PAD AND ASSEMBLE AS SHOWN

RUBBER CLAMP PAD AND ASSEMBLE
AS SHOWN
ASSEMBLE STAUFF CLAMPS TO

TWO TAPPED BLOCKS ON THE
BOTTOM SIDE OF THE UPPER
JIB LINK
0271570-R
0271800-Q
MAE35420
3121142
3121142
ADJUST POWERTRACK POSITION SO THAT
THERE IS A 1/4" ±1/8" CLEARANCE BETWEEN THE PUSH
TUBES AND POWERTRACK ROLLERS AT THESE
TWO LOCATIONS. ADJUST IN THE RETRACTED POSITION

RUBBER PAD AND ASSEMBLE AS SHOWN
VIEW A-A
VIEW B-B
ROUTE TIE STRAPPED HARNESSES BETWEEN
TELESCOPE CYLINDER HOSES AS SHOWN BELOW
TELESCOPE RETRACT HOSE

TELESCOPE EXTEND HOSE (OUTSIDE OF BEND RADIUS)
(INSIDE OF BEND RADIUS)
HARNESS BUNDLE
0271570-R
0271800-Q
MAE35430
4-67
4-68
Table 4-2. Hose/Cable Pull Chart
LETTER DESCRIPTION DIM "X"
IN. CM
P LEVEL UP HOSE (PORT L1) 64 162.5
Q LEVEL DOWN HOSE (PORT L2) 64 162.5
R SWING RIGHT HOSE (PORT S1) 64 162.5
S SWING LEFT HOSE (PORT S2) 64 162.5
T JIB LIFT UP HOSE (PORT J1) 64 162.5
U JIB LIFT DOWN HOSE (PORT J2) 64 162.5
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
DIM "Z"
MAINTAIN 63" OF HOSE/CABLE BETWEEN END STRETCH HOSE OUT AND
OF UPPER PUSH TUBE AND JIB CLAMP MEASURE IN A STRAIGHT LINE
P
SEE DETAIL H
B Table 4-1. Hose/Cable Pull Chart

C
LETTER DESCRIPTION DIM "X"
D
FT. (IN.) CM
E
A HARNESS, TRANSPORT LIMIT SWITCH (18/3 CABLE) 6 (72) 182.8
F
B HARNESS, BOOM ANGLE SENSOR (LEFT) (18/3 CABLE) 1.5 (18) 45.8
G
C HARNESS, BOOM ANGLE SENSOR (RIGHT) (18/3 CABLE) 1.5 (18) 45.8
H
D HARNESS, BOOM LENGTH SENSOR (18/3 CABLE) 1.5 (18) 45.8
I
E BROKEN CABLE PROXIMITY SENSOR (YELLOW CABLE) 5 (60) 152.4
J F AC CABLE (10/3) 13 (156) 396.2
K G CONTROL CABLE (18/8) 6 (72) 182.8
L H TELESCOPE EXTEND HOSE (5/8 10M3K) 7 (84) 213.3
M I TELESCOPE RETRACT HOSE (1/2 8M3K) 7 (84) 213.3
N J PRESSURE HOSE TO PLATFORM VALVE (3/8 6M4K) 6 (72) 182.8
DIM "X"
K RETURN HOSE TO PLATFORM VALVE (1/2 8M3K) 6 (72) 182.8
STRETCH HOSE/CABLE OUT AND
MEASURE IN A STRIGHT LINE L AIR LINE (1/2 8LOLA) OPTIONAL 10 (120) 304.8
M WELD LEAD (3/0 CABLE) OPTIONAL 10 (120) 304.8
N 7500W GENERATOR (8/5 CABLE) OPTIONAL 10 (120) 304.8
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
0271570-R
0271800-Q
MAE35440
3121142
3121142
7" (17.8 CM)
MAINTAIN HOSE/CABLE LOOP
ROUTE HOSES TO INBOARD SIDE AT THIS DIMENSION
OF CENTER POWERTRACK DIVIDER 7" (17.8 CM)
MAINTAIN HOSE/CABLE LOOP
AT THIS DIMENSION
DETAIL H
RETURN HOSE TO PLATFORM VALVE
ROUTE CABLES AND OPTIONAL AIRLINE/WELD LEAD/ PRESSURE HOSE TO PLATFORM VALVE
7500W GEN. CABLE TO OUTBOARD SIDE OF CENTER AC CABLE
POWERTRACK DIVIDER
CONTROL CABLE
VIEW SHOWING POWERTRACK LOADING 0271570-R

(PUSH TUBES NOT SHOWN FOR CLARITY) 0271800-Q
MAE35450
4-69
4.11 HOSE ROUTING PROCEDURE 4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)
For proper hose routing and cable wrap placement and
clamping, refer to Figure 4-28., Figure 4-29., Figure 4-30., Fig- 5. Inspect sheaves for condition of flanges. (See Dimension
ure 4-31., Figure 4-32., and Figure 4-33. It is important to peri- Of Sheaves for proper dimension.)
odically inspect hoses, wraps and clamps for proper slack 6. Inspect sheaves with a groove wearout gauge for exces-
adjustments and clamping integrity (pull check). Any sive wear.
changes as a result of inspection should be verified by per-
forming full strokes of boom functions especially lift, tele-
scope, jib, and platform rotate.
4.12 WIRE ROPE
IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER

PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE
ROPES INSPECTED/SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR
MISADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH.
Observe the groove so that it may be clearly seen
Each day before using the machine: whether the contour of the gauge matches the
contour of the bottom of the groove.
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections. 7. Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.
3. Check for delayed movement of the fly section, which
indicates loose wire ropes. Three Month Inspection
Inspection 1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays, abuse, or
NOTE: The pictures in this paragraph are just samples to show the any signs of abnormalities.
replacement criteria of the rope.
2. Check rope tension by deflecting the ropes by hand
properly tensioned ropes should have little or no move-
1. Inspect ropes for broken wires, particularly valley wire
ment.
breaks and breaks at end terminations.
Additional Inspection Required If:

1. Machine is exposed to hostile environment or condi-
tions.
2. Erratic boom operation or unusual noise exists.
Flexing a wire rope can often expose broken wires hid-
3. Machine is idle for an extended period.
den in valleys between strands.
4. Boom is overloaded or sustained a shock load.
2. Inspect ropes for corrosion. 5. Boom exposed to electrical arc. Wires may be fused
internally.
3. Inspect ropes for kinks or abuse.
12 Year or 7000 Hour Replacement
1. Mandatory wire rope and sheave replacement.
A kink is caused by pulling down a loop

in a slack line during improper handling,
installation, or operation.
4-70 3121142
Additional Replacement Criteria

1. Sheaves and wire rope must be replaced as sets. PROPER BOOM POSITIONS DO NOT MEAN THAT THE WIRE ROPE TENSIONS
ARE CORRECT.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes. If the measurements do not fall within the tolerances in Figure
4-35., Wire Rope Tensioning, adjust the booms using the re-
4. Ropes at end of adjustment range. positioning procedures that follow.
5. Sheaves failing wearout gage inspection.
INNER MID BOOM SECTION REPOSITIONING
6. Ropes with 6 total broken wires in one rope lay, 3 in one The inner mid section of the boom is positioned by the
strand in one rope lay, 1 valley break, or 1 break at any hydraulic cylinder. No adjustments can be made to this sec-
end termination. tion. The wire ropes within the assembly only control the
movement of the Outer Mid Boom and Fly Boom sections.
4.13 WIRE ROPE TENSIONING ADJUSTMENT OUTER MID BOOM SECTION REPOSITIONING
If the Outer Mid Boom falls within the dimension and toler-
ance of Figure 4-35., Wire Rope Tensioning, proceed to the Fly
Boom Section Positioning procedure in this section. If the
ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALI-
Outer Mid Boom section is outside of the tolerance as shown,
BRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD.
perform the following procedure.
Before adjusting wire rope tension, the boom sections must 1. Extend the boom assembly so the platform moves
be in the proper position as shown in Figure 4-35., Wire Rope 5 to 6 feet (1.5 to 1.8 m) from the fully retracted position.
Tensioning. This is so the wire ropes are equalized on both
2. Remove any covers necessary to access the wire rope
sides of the sheaves and are seated properly in the sheave
adjustment nuts.
grooves. This is necessary for proper tensioning of the wire
ropes.
This section covers the two major operations in tensioning the
wire ropes which are as follows:
• Positioning the boom sections (so that proper tensioning
can be achieved).
• Tensioning the wire rope.
Boom Section Re-Positioning

NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom section will also affect the position of the Fly Boom
section. Correctly position the Outer Mid Boom before
repositioning the Fly Boom.
NOTE: Use the Telescope function of the machine to position the

boom sections. Do not use the wire rope adjustment nuts
to position the booms. This may cause damage to the wire
rope adjustment threads.
1. Ensure the machine is placed on firm, level ground.

2. Before making any adjustments, position the boom
assembly in the fully retracted position.
3. Take preliminary measurements of the position of each
boom section and compare them to Figure 4-35., Wire
Rope Tensioning. If the measurements fall within the tol-
erances in the figure, proceed to Wire Rope Tensioning
in this section.
3121142 4-71
3. Remove the lock plates and nylon collar locknuts from a. If the Outer Mid Boom still does not fall within the
the wire rope adjustment nuts. dimension and tolerance of Figure 4-35., repeat the
Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension
and tolerance of Figure 4-35., proceed to the Fly
Boom Section Positioning procedure in this section.
NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom Section will also affect the position of the Fly Boom
section. After repositioning the Outer Mid Boom, always
check the Fly Boom position per Figure 4-35.
FLY BOOM SECTION REPOSITIONING

If the Fly Boom section location and the Outer Mid Boom sec-
tion location are both within the dimensions and tolerances in
Figure 4-35., proceed to the Wire Rope Tensioning Procedure
Outer Mid Retract Adjusting in this section.
Nuts and Lock Plates
If the Fly Boom section is outside of the tolerance as shown in
Figure 4-35. while the boom assembly is fully retracted, per-
form the following procedure:
1. Extend the boom assembly such that the platform
moves 5 to 6 feet (1.5-1.8 m) from the fully retracted
position.
2. Remove the lock plates and nylon collar locknuts from
the wire rope adjustment nuts.
3. If the Fly Boom needs to be retracted farther in:
a. Loosen the Fly Boom Extend Adjustment Nuts by an
Outer Mid Extend Adjusting amount equal to twice the distance the boom needs
Nuts and Lock Plates to move to be in tolerance.
4. If the Outer Mid Boom needs to be retracted:

a. Loosen the Outer Mid Boom Extend Adjustment
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance.
b. Fully retract the boom.
c. To remove the slack caused by the previous step,
tighten the Outer Mid Boom Extend Adjustment
Nuts until they just contact the plate.
5. If the Outer Mid Boom needs to be extended out:
a. Loosen the Outer Mid Boom Retract Adjustment Fly Boom Extend Adjusting
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance
b. Fully retract the boom.
b. Extend the boom 3-4 feet (1-1.5m).
c. To remove the slack caused by the previous step, tighten the Fly Boom Extend Adjustment Nuts until
tighten the Outer Mid Boom Retract Adjustment they just contact the plate.
Nuts until they just contact the plate.
6. Fully retract the boom sections.
7. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-35., Wire
Rope Tensioning.
4-72 3121142
4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope
adjustment nuts.
a. Loosen the Fly Boom Retract Adjustment Nuts by an
amount equal to twice the distance the boom needs
to move to be in tolerance.
Fly Boom Retract Adjusting

b. Extend the boom 3-4 feet (1-1.5m).
tighten the Fly Boom Retract Adjustment Nuts until
they just contact the plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-35., Wire
Rope Tensioning.
a. If the Fly Boom still does not fall within the dimen-
sion and tolerance of Figure 4-35., repeat the Fly 2. If not already done, remove the lock plates and nylon
Boom Section Repositioning procedure. collar locknuts from the wire rope adjustment nuts.
b. If the Fly Boom falls within the dimension and toler- 3. Position the boom so that it is horizontal within ±5°. If
ance of Figure 4-35., proceed to the Wire Rope Ten- the boom is below horizontal, ensure that the boom is
sioning Procedure. not on the boom rest.
Wire Rope Tensioning Procedure 4. Extend the boom so the platform moves 5 to 6 feet (1.5-
1.8 m) from the fully retracted position. This is done to
NOTE: Verification of the rope tension should be determined by position the boom so the ropes to be tensioned are not
proper function of the boom assembly and by the dimen- under load.
sions and tolerances of Figure 4-35., Wire Rope Tensioning. 5. When extending the boom in the previous step, if the
boom reaches the end of travel and then automatically
retracts a small amount, the ropes may still be under
load. If so, perform the following steps:
REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO
ACHIEVE PROPER TENSION. a. Note where the boom hits the end of stroke.
b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT hits the end of stroke.
ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
3121142 4-73
6. Using tool JLG PN 4120043, torque the Outer Mid Boom 9. Using tool JLG PN 4120043, torque the Outer Mid Boom
Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton
ing between the two ropes until both maintain the meters), alternating between the two ropes until both
required torque. maintain the required torque.
Outer Mid Extend Adjusting

Outer Mid Retract Adjusting
Nuts and Lock Plates 10. Using tool JLG PN 4120040, torque the Fly Extend
Adjustment Nuts to 10 ft-lb (13.5 Nm), starting with the
inside ropes and doing the outside ropes last. Refer to
7. Using tool JLG PN 4120043, torque the Fly Boom Retract
Figure 4-34., Torque Sequence for Fly Extend Rope.
Adjuster Nuts to 80 ft-lb (108 Nm), alternating between
Alternate between the four ropes until all maintain the
the two ropes until both maintain the required torque.
required torque.
Fly Boom Retract Adjusting Fly Boom Extend Adjusting

Nuts and Lock Plates Nuts and Lock Plates
8. Retract the boom 2-3 feet (0.6-1.0 m). Do not fully retract
or bottom out the booms.
3 1 2 4
Figure 4-34. Torque Sequence for Fly Extend Rope
4-74 3121142
11. Repeat the following boom movement steps three 18. Install all covers.
times. This is to ensure that the wire rope tension has
equalized on both sides of the sheaves and the ropes are
seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 5 to
6 feet (1.5-1.8 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
13. Retract the boom 2-3 feet (0.5-1 m). Do not fully retract
or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
15. Check for proper function of the boom assembly. When
properly torqued and positioned, all three moving
boom sections will move simultaneously.
16. Install new nylon collar locknuts to the Fly Boom Extend
wire rope fittings. Do not re-use the old nylon collar lock
nuts. Torque the locknuts to 10 ft-lb (13.5 Nm)
17. Reinstall the lock plates to the remaining adjuster nuts.
3121142 4-75
9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
FLYBOOM
BASE BOOM OUTERMID BOOM
INNERMID BOOM
NOTE: Boom shown in fully retracted position.
Figure 4-35. Wire Rope Tensioning
4-76 3121142
3121142
Figure 4-36. Outer Mid Boom Extend/Retract Cables
4-77
4-78
Figure 4-37. Fly Boom Extend/Retract Cables
3121142
1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
Figure 4-38. Wire Rope Adjustment Tools (Optional)
3121142 4-79
4.14 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust
after assembling the switch block, compression spring, and
This system uses a proximity switch to detect excessive move- torquing the wire ropes.
ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
Adjusting the Proximity Switch
tem. It is the responsibility of the operator to take immediate 1. Thread the switch in until it contacts the adjuster block.
action.
2. Thread the switch out 1/8 to 1/2 turn to achieve proper
sensing range.
3. Tighten the jam nut.
Figure 4-39. Broken Boom Cable Proximity Switch Location
4.15 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR INTERACTION
The secondary tilt sensor is used as a backup to the primary tilt
sensor. Any time a tilt set point is reset, a value from each sen-
sor shall be set.
tem.
If a fault occurs with the primary sensor, control will revert to
Description the secondary sensor. (This is discussed in more detail in the
error response section.)
Electronic platform leveling replaces the conventional hydrau-
lic method of platform leveling. Because of the mounting orientation of the tilt sensors, the
primary tilt sensor will output ascending voltage values with
To control electronic platform leveling the platform is
increases in positive platform tilt angle. The backup or second-
equipped with a pair of tilt sensors, one primary and one sec-
ary tilt sensor will output descending voltage values with
ondary, mounted to the non-rotating portion of the platform
increases in positive platform angle.
rotator. The tilt sensors are monitored regularly and the plat-
form level up and down valves are automatically controlled to
maintain set point as the machine is operated.
4-80 3121142
PLATFORM VALVES In order to obtain acceptable performance while performing

all hydraulic functions, five sets of parameters are used. These
The platform specific valves are located in a manifold at the
“zones” allow compensation for differences in how the basket
platform.
level changes when doing different functions. These zones are
There are individual proportional control valves that control as follows:
each of the four platform functions; Platform Level, Platform
1. Lift up
Rotate, Jib Lift, and Jib Swing.
2. Lift down
There is also a Platform Dump Valve, located in the platform
valve manifold, which is used to hydraulically isolate the con- 3. Other boom functions
trol valves and to improve hydraulic response.
4. Drive
The Ground Module controls this valve to provide manual
5. Auxiliary
platform leveling in the event that the Platform Module is
inoperable. The other boom functions zone includes Swing, Telescope, Jib
swing (It is not necessary to level with jib lift, since the
In ground mode, the platform dump valve is turned on when-
mechanical linkage keeps the basket level).
ever any platform or jib valve output is turned on. Whenever
all platform and jib valves are turned off, the platform dump These zones are prioritized when multiple functions are active.
valve is turned off. The priorities are as follows.
In platform mode, the platform dump valve is turned on 1. Auxiliary power and any other function, zone = auxiliary
whenever the footswitch is depressed. power
2. Drive and any other function, zone = Drive
Normal Operation
AUTOMATIC LEVELING 3. Lift up and any other function, zone = Lift up
Two tilt sensors, mounted on either side of the platform sup- 4. Lift down and any other function, zone = Lift down
port, are used to measure the incline of the platform with 5. Other boom functions, zone = Other boom functions
respect to gravity and control the automatic leveling function,
one is used as the primary sensor and one as a secondary back During the power-up procedure, function enable, in both Plat-
up sensor. form and Ground Mode, is delayed during the 1.5 second
startup lamp test. During this 1.5 second startup period, the
The level system shall assume a new fixed set point (fixed basket level up valve will be energized at 100% duty cycle for
incline of the platform with respect to gravity) each time the 0.5 second, and then the basket level down valve energized at
control system is powered up (cycling of the EMS). 100% duty cycle for 0.5 second. This will help to keep the
Automatic platform leveling only functions while operating valves from sticking.
drive, telescope, lift or swing. It does not operate while operat- PLATFORM LEVEL MANUAL OVERRIDE
ing any other function (e.g. rotate, jib, or steer).
In addition to automatic leveling the operator is able to manu-
The proportional control for these valves varies. This is depen- ally adjust the platform level position by means of the level
dant on the tilt variance from target as well as on the impact override switches located at the platform and ground control
coil temperature is having on the current to the valves. positions (similar to a Master/Slave hydraulic system).
If a command from the Platform Level Up and Down toggle The level system assumes a new set point after a level over-
switch on either the platform or the ground is received, auto- ride switch is operated. In other words the operator can chose
matic platform leveling will cease and the appropriate output a platform level incline other than level with gravity and the
will be commanded to turn on. system will maintain this set point during automatic leveling.
When the toggle switch is released, after ¼ second, the current
filtered value of tilt angle will be taken as the new set point.
3121142 4-81
4.16 ROTARY ACTUATOR Required Tools

Upon assembly and disassembly of the actuator there are
Theory of Operation basic tools required. The tools and their intended functions are
The L20 Series rotary actuator is a simple mechanism that uses as follows:
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation. Each actuator is com-
posed of a housing with integrated gear teeth (01) and only
two moving parts: the central shaft with integrated bearing
tube and mounting flange (02), and the annular piston sleeve
(03). Helical spline teeth machined on the shaft engage
matching splines on the inside diameter of the piston. The
outside diameter of the piston carries a second set of splines,
of opposite hand, which engage with matching splines in the
housing. As hydraulic pressure is applied, the piston is dis-
placed axially within the housing - similar to the operation of a
hydraulic cylinder - while the splines cause the shaft to rotate.
When the control valve is closed, oil is trapped inside the actu-
ator, preventing piston movement and locking the shaft in
position.
1. Flashlight - helps examine timing marks, component

failure and overall condition.
2. Felt Marker - match mark the timing marks and outline
troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and wear
guides.
6. Pry bar - removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and pis-
ton sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end cap
(sold with Helac seal kit).
The seal tool is merely a customized standard flat head screw-
Bars indicate starting positions As fluid pressure is applied, the driver. To make this tool you will need to heat the flat end with
of piston and shaft. Arrows indi- piston is displaced axially while
a torch. Secure the heated end of the screwdriver in a vice and
cate direction they will rotate. the helical gearing causes the
The housing with integral ring piston and shaft to rotate simul-
physically bend the heated end to a slight radius. Once the
gear remains stationary. taneously. The double helix radius is achieved round off all sharp edges of the heated end
design compounds rotation: by using a grinder. There may be some slight modifications for
shaft rotation is about twice that your own personal preference.
of the piston.
The shaft is supported radially by the large upper radial bear-

ing and the lower radial bearing. Axially, the shaft is separated
from the housing by the upper and lower thrust washers. The
end cap is adjusted for axial clearance and locked in position
by set screws or pins.
4-82 3121142
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-40. Rotary Actuator - Exploded View
3121142 4-83
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-41. Rotary Actuator - Assembly Drawing
4-84 3121142
Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is

shown).
1. Remove the cap screws (113) over end cap lock pins
(109).
If the pin will not come out with the ”Easy Out”, use 5/1
6” drill bit to a depth of 1/2” (12.7mm) to drill out the
entire pin.
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center
of each lock pin to a depth of approximately 3/16” 4. Install the end cap (4) removal tools provided with the
(4.76mm). Helac seal kit.
5. Using a metal bar, or something similar, unscrew the end

cap (4) by turning it counter clockwise.
3121142 4-85
6. Remove the end cap (4) and set aside for later inspec- 8. Every actuator has timing marks for proper engage-
tion. ment.
7. Remove the stop tube if included. The stop tube is an

available option to limit the rotation of the actuator.
9. Prior to removing the shaft, (2), use a felt marker to

clearly indicate the timing marks between shaft and pis-
ton. This will greatly simplify timing during assembly.
4-86 3121142
10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of
threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis-
ton and housing with a marker as shown.
11. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There should 14. Remove the o-ring (204) and backup ring (207) from end
now be timing marks on the housing (1) ring gear, the cap (4) and set aside for inspection.
piston (3) and the shaft (2).
15. Remove the wear guides (302) from the end cap (4) and
12. To remove the piston (3) use a rubber mallet and a plas- shaft (2).
tic mandrel so the piston is not damaged.
3121142 4-87
16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202).
cut them using a sharp razor blade being careful not to
damage the seal groove.
20. Remove the piston I.D. seal (200). You may now proceed
to the inspection process.
17. Remove the thrust washers (304), from the end cap (4)
and shaft (2).
18. Remove the wiper seal (304.1) from its groove in the end
cap (4) and shaft (2).
4-88 3121142
Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air prior to inspecting. Carefully inspect all criti-
cal areas for any surface finish abnormalities: Seal
grooves, bearing grooves, thrust surfaces, rod surface,
housing bore and gear teeth.
Assembly
1. Gather all the components and tools into one location
prior to re-assembly. Use the cut away drawing to refer-
2. Inspect the thrust washers (304) for rough or worn ence the seal orientations.
edges and surfaces. Measure it’s thickness to make sure
it is within specifications (Not less than 0.092” or 2.34
mm).
3121142 4-89
2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto
(4). shaft (2) and end cap (4). Use the seal tool in a circular
motion.
3. Install the wiper seal (304.1/green 0-ring) into it’s groove 5. Install the wear guide (302) on the end cap (4) and shaft
on the shaft (2) and end cap (4) around the outside edge (2).
of the thrust washer (304).
6. Install the inner T-seal (200) into the piston (3) using a
circular motion.
Install the outer T-seal (202) by stretching it around the

groove in a circular motion.
4-90 3121142
Each T-seal has 2 Backup rings (see drawing for orienta- 7. Insert the piston (3) into the housing (1) as shown, until
tion). the outer piston seal (202) is touching inside the hous-
ing bore.
Beginning with the inner seal (200) insert one end of b/u
ring in the lower groove and feed the rest in using a cir- 8. Looking from the angle shown, rotate the piston (3) until
cular motion. Make sure the wedged ends overlap cor- the marks you put on the piston and the housing (1)
rectly. during disassembly line up as shown. Using a rubber
Repeat this step for the outer seal (202). mallet, tap the piston into the housing up to the point
where the gear teeth meet.
3121142 4-91
9. Looking from the opposite end of the housing (1) you 11. Looking from the view shown, use the existing timing
can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the
tap the piston (3) in until the gear teeth mesh together. gear teeth on the inside of the piston (3). Now tap the
Tap the piston into the housing the rest of the way until flange end of the shaft with a rubber mallet until the
it bottoms out. gear teeth engage.
10. Install the shaft (2) into the piston (3). Be careful not to 12. Install 2 bolts in the threaded holes in the flange. Using a
damage the seals. Do not engage the piston gear teeth bar, rotate the shaft in a clockwise direction until the
yet. wear guides are seated inside the housing bore.
13. Install the stop tube onto the shaft end. Stop tube is an
available option to limit the rotation of an actuator.
4-92 3121142
14. Coat the threads on the end of the shaft with anti-seize 17. Tighten the end cap (4). In most cases the original holes
grease to prevent galling. for the lock pins will line up.
18. Place the lock pins (109) provided in the Helac seal kit in
15. Install the 0-ring (204) and Backup ring (207) into the
the holes with the dimple side up. Then, using a punch,
inner seal groove on the end cap (4).
tap the lock pins to the bottom of the hole.
16. Thread the end cap (4) onto the shaft (2) end. Make sure
the wear guide stays in place on the end cap as it is 19. Insert the set screws (113) over the lock pins. Tighten
threaded into the housing (1). them to 25 in. lbs. (2.825 Nm).
3121142 4-93
Installing Counterbalance Valve Bleeding After Installation

Refer to Figure 4-42., Rotator Counterbalance Valve. NOTE: Bleeding will be necessary if excessive backlash is displayed
1. Make sure the surface of the actuator is clean, free of any after the actuator is installed. To do this, bleeder valves
contamination and foreign debris including old Loctite. must be installed in the actuator at the locations shown
below. The following steps are recommended when a mini-
2. Make sure the new valve has the O-rings in the counter- mum of two gallons (8 liters) is purged.
bores of the valve to seal it to the actuator housing.
3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. JLG
Threadlocker PN 0100011 should be applied to the
shank of the three bolts at the time of installation.
4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4
to 13.5 Nm). Do not torque over 125 inch pounds (14.1
Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8
Nm). Do not torque over 145 inch pounds (16.3 Nm).
Testing the Actuator

If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
pressure to 4500 psi (315 bar) to check for leaks and cracks. 1. Connect a 5 foot (1.5 m) long 3/16" inside diameter, 5/
Perform the test again at the end of the rotation in the oppo- 16" outside diameter clear vinyl drain tube to each of
site direction. the two bleeder valves. Secure the tubes in place with
hose clamps.
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
2. Place the end of the tubes in a clean 5 gallon (19 L) con-
If the actuator is equipped with with a counterbalance valve,
tainer to collect the purged oil. The oil can be returned
plug the valve ports. Connect the hydraulic lines to the hous-
to the reservoir when the procedure is complete.
ing ports. Bleed all air from the actuator (see Installation and
Bleeding) Rotate the shaft to the end of rotation at 3000 psi 3. Open both bleeder valves 1/4 turn. Using the hydraulic
(210 bar) and maintain pressure. Remove the hydraulic line system, rotate the platform to the end of rotation and
from the non-pressurized side. maintain hydraulic pressure. Oil with small air bubbles
should be seen flowing through the tubes. Allow 1/2
Continuous oil flow from the open housing port indicates
gallon (2 L) of oil to be purged from the actuator.
internal leakage across the piston. Replace the line and rotate
the shaft to the end of rotation in the opposite direction. 4. Keep the bleeder valves open and rotate the platform in
Repeat the test procedure outlined above for the other port. If the opposite direction to the end of rotation. Maintain
there is an internal leak, disassemble, inspect and repair. hydraulic pressure until an additional 1/2 gallon (2 L) of
oil is pumped out.
5. Repeat steps 3 and 4. After the last 1/2 gallon (2 L) of oil
is purged, close both bleed nipples before rotating away
from the end of rotation.
4-94 3121142
Figure 4-42. Rotator Counterbalance Valve
3121142 4-95
A,B,D
C,D
A Torque to 50 ft.lbs. (68 Nm)

B JLG Threadlocker PN 0100019
C Torque to 586ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque to 75 ft. lbs. (102 Nm)
Figure 4-43. Platform Support Torque Values
4-96 3121142
4.17 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The bolt-on external fall arrest system is designed to provide a
lanyard attach point while allowing the operator to access GAP
GAPSHOWING:
SHOWING:
areas outside the platform. Exit/Enter the platform through INCORRECT
INCORRECT
the gate area only. The system is designed for use by one per-
son.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs. (408
kg). NO GAP:
NO GAP: CORRECT
CORRECT
Bolt-On External Fall Arrest System capacity is 310 lb (140 kg) -
one (1) person maximum.
Do not move the platform during use of the bolt-on external

fall arrest system.
DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM.

BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION. Figure 4-44. Bolt-On External Fall Arrest Cable Tension
• Fittings & Brackets: Ensure all fittings are tight and there are
no signs of fractures. Inspect brackets for any damage.
IF THE BOLT-ON EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL • Attachment Ring: No cracks or signs of wear are accept-
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND able. Any signs of corrosion requires replacement.
THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO
• Attaching Hardware: Inspect all attaching hardware to
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
ensure there are no missing components and hardware is
THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPEC- properly tightened.
TION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION
• Platform Rails: No visible damage is acceptable.
MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
Installation
Inspection Before Use
1. Install the retaining hardware (bolts, nuts, and washers)
The bolt-on external fall arrest system must be inspected and secure the brackets to the platform rail. Tighten the
before each use of the aerial work platform. Replace compo- nuts but do not torque them yet.
nents if there are any signs of wear or damage.
BOLT
Before each use, perform a visual inspection of the following
components:
WASHER
WASHER
NUT
3121142 4-97
2. Attach the fall arrest cable to the right hand bracket 5. Use the two jam nuts to prevent the cable from rotating
Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel-
shown below. Do not tighten the nut so cable can still leville washers are fully compressed and no gap is pres-
rotate. ent at the outside diameter of the washers. Ensure the
cable has not rotated during tightening.
BOLT
NUT
6. Tighten the first jam nut against the retaining nut to

keep the nut from loosening. Tighten the remaining jam
3. Install the Attachment Ring onto the cable. nut against the first jam nut.
4. Without twisting the fall arrest cable, pull it thru the left 7. Torque the nuts and bolts securing the brackets to
hand bracket and mark the top of the swaged cable end. 15 ft.lbs. (20 Nm).
Install the fall arrest cable through the left hand bracket
and secure it using the belleville washers, washer, retain-
ing nut, and jam nuts. Orient the hardware as shown
below and with the belleville washers so the gap is pres-
ent at the outside diameter of the washers. install the
nuts onto the cable finger tight so the mark on the cable
does not move.
WASHER
BELLEVILLE
NUT WASHER
JAM NUT
4-98 3121142
7
1,2,3,4
9 1. Belleville Washer
2. Washer
5 3. Hex Nut
4. Jam Nut
5. LH Bracket
6 6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal
Figure 4-45. Bolt-On External Fall Arrest System
3121142 4-99
4.18 SKYGUARD Function Test

Operation SKYGUARD ONLY
Perform this function test if SkyGuard only is selected in
SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2).
When the SkyGuard sensor is activated, functions in use at
the time of actuation will reverse or cutout. The SkyGuard From the Platform Control Console in an area free from obstruc-
Function Table provides more details on these functions. tions:
Consult the following illustrations to determine which type 1. Operate the telescope out function, then activate Sky-
of SkyGuard the machine is equipped with. Regardless of Guard sensor.
the type, SkyGuard function according to the SkyGuard 2. Once sensor has been activated, ensure telescope out
Function Table does not change. function stops then telescope in function operates for a
short duration. Additionally, verify Soft Touch/SkyGuard
indicator light flashes and horn sounds. If machine is
equipped with SkyGuard beacon, ensure it flashes when
sensor activates.
3. With SkyGuard sensor still engaged, press and hold yel-
low Soft Touch/SkyGuard override button. Operate a
function to verify operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recy-
cle footswitch. Ensure normal operation available.
0"$
In Ground Mode:
SkyGuard
1. Operation is allowed regardless of SkyGuard activation.
BOTH SKYGUARD AND SOFT TOUCH

Perform this procedure if both SkyGuard and Soft Touch are
selected in machine setup (refer to Table 6-2).
From the Platform Control Console in an area free from
obstructions:
NOTE: Machine will treat Soft Touch/SkyGuard override switch as

if it is a Soft Touch and SkyGuard switch.
1. Operate the telescope out function, then activate Sky-

0"%
Guard sensor.
SkyGuard SkyLine™
2. Once sensor has been activated, ensure telescope out
function stops. Additionally, verify Soft Touch/SkyGuard
indicator light flashes and horn sounds. If machine is
equipped with SkyGuard beacon, ensure it flashes when
sensor activates.
3. With SkyGuard sensor still engaged, press and hold yel-
low Soft Touch/SkyGuard override button. Operate a
function to verify operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recy-
cle footswitch. Ensure sure normal operation is available.
0"$
In Ground Mode:
SkyGuard SkyEye™ 1. Operation is allowed regardless of SkyGuard activation.
THE MACHINE OPERATOR IS REQUIRED TO PERFORM A DAILY FUNCTION TEST

TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM.
4-100 3121142
SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup (refer to Table determine if the switch/relay closes.
6-2), machine will treat the Soft Touch/SkyGuard override
If the status of the switch/relay remains OPEN while the Sky-
switch as if it is a Soft Touch switch.
Guard sensor is actively engaged, it is possible the sensor has
failed and should be replaced immediately.
SKYGUARD NOT SELECTED IN MACHINE SETUP
If the SkyGuard system is installed on the machine, but no If the status of the switch/relay remains CLOSED while the Sky-
option is selected in the machine setup (refer to Table 6-2), Guard sensor is actively engaged, a power or ground wire may
SkyGuard sensor status will be ignored. No function cutout or not be making good contact or may be loose or broken. Addi-
reversal will be implemented. tionally, there is a low probability that both relays may have
failed.
Diagnostics & Troubleshooting
If the switch/relay status is in disagreement, then one may
If SkyGuard does not function when the sensor is engaged, have failed or is not installed correctly. In this case, the
first verify the configuration under the machine will be inoperable.
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
held Analyzer. Ensure the selected configuration matches the FAULT CODES
actual system installed on the machine. If not, select the cor- Refer to Table 6-9 for more fault code information
rect configuration, then verify operation.
• 0039 - SkyGuard switch activation fault
Additionally, use the handheld analyzer to navigate to the • 2563 - switch disagreement fault
DIAGNOSTICS: FEATURES  SKYGUARD INPUTS menu to
determine additional SkyGuard fault information.
Table 4-3. SkyGuard Function Table
Boom
Drive Drive Boom Boom Boom Jib Basket Basket
Steer Swing Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Swing Level Rotate
Down
R*/C** R C R R R R C C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active
Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing
3121142 4-101
NOTES:
4-102 3121142
SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
When assembling connectors in the hydraulic that use o-ring rated.
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:
• A small container for hydraulic oil

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121142 5-1
Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but will This method requires a pump or trigger spray bottle.
work for all o-ring fitting types.
1. Fill the spray bottle with hydraulic oil.
The following is needed to correctly oil the o-ring in this man- 2. Hold the fitting over a suitable catch can.
ner:
3. Spray the entire o-ring surface with a medium coat of
• A small leak proof container oil.
• Sponge cut to fit inside the container
• A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add hydraulic
oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and drip
from the bottom of the fitting. This should signify an
even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
3. O-ring Boss type fittings will require more pressure in even coat of oil.
able to immerse more of the fitting into the saturated
sponge. This will also cause more oil to be dispersed
from the sponge.
5-2 3121142
5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types

NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
60°
30°
Figure 5-4. SAE Thread
ORFS = o-ring face seal per SAE J1453
Figure 5-1. NPTF Thread

BSPT = British standard pipe tapered per ISO7-1
55°
Figure 5-5. ORFS Thread
MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353
Thread
O.D.
Figure 5-2. BSPT Thread

Figure 5-6. MTBL-MBTS Thread
Straight Thread Types, Tube and Hose BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
Connections
JIC = 37° flare per SAE J514
Figure 5-3. JIC Thread Figure 5-7. Bulkhead Thread
3121142 5-3
Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852
Figure 5-10. ORB-MPP Thread
Tightening Methods
Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
torque wrench).
MFF = metric flat face port per ISO 9974-1
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2 gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’
Figure 5-9. MFF-BSPP Thread
5-4 3121142
Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY
be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
1. Take precautions to ensure that fittings and mating steel.
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci-
Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system.
6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.
3121142 5-5
Assembly Instructions for American Standard NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-
MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
Pipe Thread Tapered (NPTF) Connections. ALIGNMENT.
1. Inspect components to ensure male and female port
5. Rotate male fitting the number of turns per Table 5-1,
threads are free of rust, splits, dirt, foreign matter, or
NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs.
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight.
• STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. mating components.
Table 5-1. NPTF Pipe Thread
60° ØA dimension is measured

30° on the 4th pitch of the thread
TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C
4 1/4 - 18 0.54 13.61 2 to 3

6 3/8 - 18 0.67 17.05 2 to 3
8 1/2 - 14 0.84 21.22 2 to 3
OMPONENTS
12 3/4 - 14 1.05 26.56 2 to 3

16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
* ØA thread dimension for reference only.

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.
5-6 3121142
Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2,
BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
Thread Tapered (BSPT) Connections procedure requirements.
1. Inspect components to ensure male and female port NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
threads are free of rust, splits, dirt, foreign matter, or applicable for the following material configurations:
burrs.
2. Apply a suitable thread sealant, such as Loctite 567, to • STEEL fittings with STEEL mating components
the male pipe threads if not already applied. Ensure the • STEEL fittings with ALUMINUM or BRASS mating compo-
first 1 to 2 threads are uncovered to prevent system con- nents
tamination.
3. Assemble connection hand tight. nents
4. Mark fittings, male and female. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND

DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR.
NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-

MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
ALIGNMENT.
Table 5-2. BSPT Pipe Thread
Turns From
Thread Size ØA* Finger Tight
MATERIAL Dash Size (TFFT)**
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
4 1/4 - 19 0.52 13.16 2 to 3

STEEL, ALUMINUM, OR BRASS
6 3/8 - 19 0.66 16.66 2 to 3

MATING COMPONENTS
8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
16 1 - 11 1.31 33.25 1.5 to 2.5
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.
3121142 5-7
Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37°
Flare (JIC)Thread - Steel or Table 5-4, 37° Flare
1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double
centricity issues with the tube OD. Ensure surface is Wrench Method per Double Wrench Method. Refer to
smooth, free of rust, weld and brazing splatter, splits, FFWR and TFFT Methods for procedure requirements if
dirt, foreign matter, or burrs. If necessary replace fitting using the FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT configuration of the connection.
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK-
AGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
nents
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
5-8 3121142
Table 5-3. 37° Flare (JIC)Thread - Steel
Thread OD
A
B
37°
Type/Fitting Identification Torque

Flats from
Thread Wrench
MATERIAL
ØA* ØB* [Ft-Lb] [N-m]

Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --

4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
UN-LUBRICATED THREADS
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121142 5-9
Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
Thread OD
A
B
37°
TYPE/FITTING IDENTIFICATION Torque

Flats from
Thread Wrench
MATERIAL

Dash Size Size Resistance
(F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --

4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
COMPONENTS; UN-LUBRICATED THREADS
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2

6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

** See FFWR and TFFT Methodsfor FFWR procedure requirements.
5-10 3121142
Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK- ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
AGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting.
3. Tighten fitting by hand until hand tight. nents
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. mating components.
3121142 5-11
Table 5-5. 45° Flare (SAE) - Steel

Thread
MATERIAL

Dash Size Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
STEEL MATING COMPONENTS;
STEEL FITTINGS WITH
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33

8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125

Table 5-6. 45° Flare (SAE) - Aluminum/Brass

Thread
MATERIAL

Dash Size Size
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
MATING COMPONENTS;
OR ALUMINUM/BRASS
ALUMINUM/BRASS
6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20

FITTINGS
8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83

** See FFWR and TFFT Methods for TFFT procedure requirements.
5-12 3121142
3121142 5-13
Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing
ments if using the FFWR method.
install per O-ring Installation (Replacement).
2. Ensure surface is smooth, free of rust, weld and brazing NOTE: Torque values provided in Table 5-7, O-ring Face Seal
splatter, splits, dirt, foreign matter, or burrs. If necessary (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
replace fitting or adapter. minum/Brass are segregated based on the material config-
uration of the connection.

CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE COMPONENTS’ indicate either the following material configu-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE rations:
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. Place the tube assembly against the fitting body so that
nents
the flat face comes in contact with the O-ring. Hand
thread the nut onto the fitting body. • ALUMINUM or BRASS fittings with ALUMINUM or
BRASS mating components
Table 5-7. O-ring Face Seal (ORFS) - Steel
Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
MATERIAL
Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Tube
Dash Size Hose
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Nuts
Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

STEEL FITTINGS WITH
10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
5-14 3121142
Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
Thread Swivel &
MATERIAL
Dash ØA* ØB* [Ft-Lb] [N-m] Tube

Size Hose
Size Nuts
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS FITTINGS OR
6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS
10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
** See FFWR and TFFT Methods for FFWR procedure requirements.
3121142 5-15
Assembly Instructions for DIN 24° Flare Bite Type

Fittings (MBTL and MBTS)
A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND

LEAKAGE.
1. Inspect the components to ensure free of contamina-

tion, external damage, rust, splits, dirt, foreign matter, or
burrs. Ensure tube end is visibly square. If necessary
replace fitting or tube.
2. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
3. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
4. Push the tube end into the coupling body.
5. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed in Table Table 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.
5-16 3121142
Table 5-9. DIN 24°Cone (MBTL & MBTS)
DIN 24° CONE FLARELESS BITE FITTING

(With or Without O-Ring)
Tube Thread M Torque Flats from

MATERIAL
ØA* ØB* C* ØD* Wrench

TYPE
O.D. Size [Ft-Lb] [N-m]

Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTL) FITTING
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75

FFWR is the recommended
10 M16 x 1.5 14.50 16.00 7.00 10.20 1.5 to 1.75
method of fitting assembly.
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
15 M22 x 1.5 20.50 22.00 7.00 15.20 Torque values are application 1.5 to 1.75
18 M26 x 1.5 24.50 26.00 7.50 18.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
22 M30 x 2 27.90 30.00 7.50 22.20 lubrication, and other physical 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS
28 M36 x 2 33.90 36.00 7.50 28.20 characteristics of the connection. 1.5 to 1.75
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
Refer to the specific procedure
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in the
Tube Thread M Torque Flats from
ØA* ØB* C* ØD* Wrench
TYPE
O.D. Size [Ft-Lb] [N-m]

Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTS) FITTING
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

FFWR is the recommended
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
method of fitting assembly.
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
20 M30 x 2 27.90 30.00 10.50 20.20 lubrication, and other physical 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 characteristics of the connection. 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
Refer to the specific procedure
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
in the
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121142 5-17
Assembly Instructions for Bulkhead (BH) Fittings

1. Ensure threads and surface are free of rust, weld and
brazing splatter, splits, burrs or other foreign material. If
necessary replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting per Table 5-10 and Table 5-11
while using the Double Wrench Method.
5-18 3121142
Table 5-10. Bulkhead Fittings (BH) - INCH
FASTENING JAM NUT

for Bulkhead Connectors
Torque
MATERIAL
Thread Size
TYPE
Dash Size [Ft-Lb] [N-m]

(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
O-RING FACE SEAL (ORFS) BULKHEAD FITTING
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
10 1-14 85 90 94 115 122 127
12 1 3/16-12 135 142 149 183 193 202
14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Torque
Thread Size
STEEL FITTINGS
TYPE
Dash Size [Ft-Lb] [N-m]

(UNF) Min Nom Max Min Nom Max
3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
3121142 5-19
Table 5-11. Bulkhead Fittings (BH) - METRIC
FASTENING JAM NUT

for Bulkhead Connectors
Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
Thread M Size
Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
5-20 3121142
3121142 5-21
Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
nents
4. For Non-Adjustable and Plugs, thread the fitting by • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
hand until contact. mating components.
5. For Adjustable fittings, refer to Adjustable Stud End 7. Inspect to ensure the O-ring is not pinched and the
Assembly for proper assembly. washer is seated flat on the counter bore of the port.
5-22 3121142
Table 5-12. O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
STEEL FITTINGS WITH STEEL MATING
5 1/2-20 0.50 12.70 23 25 26 32 34 35

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
HEX TYPE PLUGS & STUD ENDS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13

MATING COMPONENTS; UN-LUBRICATED THREADS
4 7/16-20 0.44 11.11 14 15 16 19 20 22

5 1/2-20 0.50 12.70 15 16 17 20 22 23
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
3121142 5-23
STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
5 1/2-20 0.50 12.70 30 32 33 40 43 45

6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
STUD ENDS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --

4 7/16-20 0.44 11.11 17 18 18 23 24 24

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-24 3121142
ADJUSTABLE STUD END

MATERIAL Dash Size
2 5/16-24 0.31 7.93 (60) (63) (66) 7 7 7
3 3/8-24 0.37 9.52 (100) (105) (110) 11 12 12
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 21 22 23 28 30 31

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (39) (41) (43) 4 5 5
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8

4 7/16-20 0.44 11.11 10 11 11 14 15 15

5 1/2-20 0.50 12.70 14 15 15 19 20 20
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121142 5-25
ADJUSTABLE STUD END

MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45

6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --

4 7/16-20 0.44 11.11 10 11 11 14 15 15

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-26 3121142
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

MATERIAL Dash Size
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22

6 9/16-18 0.56 14.28 34 36 38 46 49 52
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5

4 7/16-20 0.44 11.11 6 7 7 8 9 9

5 1/2-20 0.50 12.70 9 10 10 12 14 14
6 9/16-18 0.56 14.28 22 24 25 30 33 34
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121142 5-27
ZERO LEAK GOLD®

HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15

6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
ZERO LEAK GOLD®
HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7

4 7/16-20 0.44 11.11 7 8 9 9 11 12

5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
5-28 3121142
3121142 5-29
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. mating components.
5-30 3121142
Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end
Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694

M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
3121142 5-31


M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
5-32 3121142
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Thread Connecting Torque Torque Torque

MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397

M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
3121142 5-33
Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3

with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end

M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770

M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
5-34 3121142
Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3
FORM E (EOLASTIC SEALING RING)

FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS
STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
3121142 5-35
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
5-36 3121142
3121142 5-37
Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter, or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
nents
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • ALUMINUM or BRASS fittings with STEEL mating compo-
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil.
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
7. Inspect to ensure the O-ring is not pinched and the
by hand until contact.
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.
5-38 3121142
Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
Note: Metric O-ring

only style (ISO 6149)
requires o-ring
chamfer in the port,
similar to ISO 11926
(SAE ORB),but is not
interchangeable.
STUD ENDS STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Thread Connecting Torque Torque

MATERIAL
M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
3121142 5-39
Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the BSPP port.
2. If O-ring is not preinstalled, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. mating components.
5-40 3121142
Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

BSPP Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 42 139 146 153 188 198 207 302 318 333 409 431 451
* Typical for JLG Straight Male Stud Fittings

** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
3121142 5-41
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386

5-42 3121142
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321

3121142 5-43
Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
Bonded Washer
Seal
Bonded
Washer
Bonded Washer
(e.g. Dowty) Seal
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500

5-44 3121142
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386

3121142 5-45
Note: BSPP O-ring only

style (ISO 228-1) requires
o-ring chamfer in the
port, similar to ISO
11926 (SAE ORB),but is
not interchangeable.
Not typically used on
JLG machines.
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS

TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
Connecting
Thread G
Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
Fitting type not typically specified on
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133
JLG applications. Refer to the specific
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure in this Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
Connecting
Thread G
Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
Fitting type not typically specified on
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87
JLG applications. Refer to the specific
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 procedure in this Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499

5-46 3121142
3121142 5-47
Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter, or burrs.
2. See Figure for O-ring installation instructions.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table Table 5-31and Table
5-32.
5-48 3121142
Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners
STEEL 4-BOLT FLANGE SAE J518

(INCH FASTENERS)
Bolt Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66

20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66

16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.
3121142 5-49
Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners
STEEL 4-BOLT FLANGE SAE J518

(INCH FASTENERS)
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55

20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77

16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
* A dimension for reference only.
5-50 3121142
Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two
is twisted. See Figure 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one Backup
ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
Figure 5-12. Double Wrench Method
3121142 5-51
FFWR and TFFT Methods Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly
FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed:
1. Tighten the swivel nut to the mating fitting until no lat- 1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger
tight condition. 2. Position #1 – The o-ring should be located in the groove
adjacent to the face of the Backup washer. The washer
2. Mark a dot on one of the swivel hex nut flats and and o-ring should be positioned at the extreme top end
another dot in line on the connecting tube adapter. See of the groove as shown.
Figure B.1.
3. Position #2 – Position the locknut to just touch the
3. Use the double wrench method per Appendix A, turn Backup washer as shown. The locknut in this position
the swivel nut to tighten as shown in Figure B.1. The nut will eliminate potential back up washer damage during
is to be rotated clockwise the number of hex flats as the next step.
defined by the applicable Table in Section 5.0.
4. Position #3 – Install the connector into the straight
4. After the connection has been properly tightened, mark thread box port until the metal Backup washer contacts
a straight line across the connecting parts, not covering the face of the port as shown.
the dots, to indicate the connection has been properly
tightened. See Figure 5-13. 5. Position #4 – Adjust the connector to the proper posi-
tion by turning out (counterclockwise) up to a maxi-
mum of one turn as shown to provide proper alignment
with the mating connector, tube assembly, or hose
assembly.
6. Position #5 – Using two wrenches, use the backup
wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the
o-ring is not pinched or bulging out from under the
washer and that the backup washer is properly seated
Figure 5-13. FFWR Method flat against the face of the port.
TFFT (TURNS FROM FINGER TIGHT METHOD)

1. Tighten the swivel nut to the mating fitting until no lat-
eral movement of the swivel nut can be detected; finger
tight condition.
2. Mark a dot on one of the swivel hex nut flats and
another dot in line on the connecting tube adapter.
3. Use the double wrench method per Appendix A, turn
the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.
5-52 3121142
Position #1 Position #2 Position #4

Locknut and Washer Locknut in position to Position #3 Connector backed Position #5
backed off with o-ring protect the back-up Hand tightened into port Connector tightened
off for alignment
in position washer from damage until back-up to mating connector, to ?nal position
during installation washer contacts tube assembly or
into the port port face hose assembly
Adjustable Stud End Assembly Positions
Locknut
O-Ring
Back-up Washer
Figure 5-14. Adjustable Stud End Assembly
O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On

straight threads, ensure O-ring is seated all the way past
Care must be taken when installing O-rings over threads dur-
the threads prior to installation.
ing replacement or installation. O-rings could become nicked
or torn. A damaged O-ring could lead to leakage problems. 5. Inspect O-ring for any visible nicks or tears. Replace if
found.
1. Inspect O-ring for tears or nicks. If any are found replace
O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look
the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing O-rings on fit-
tings.
3121142 5-53
5.3 CYLINDER REPAIR

NOTE: The following are general procedures that apply to all of
the cylinders on this machine. Procedures that apply to a
specific cylinder will be so noted.
Disassembly
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to

the cylinder port block fitting.
Figure 5-16. Cap Screw Removal

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the cyl- EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
inder. Shut down and disconnect the power source. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
Adequately support the cylinder rod, if applicable. CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
3. If applicable, remove the cartridge-type holding valve 6. With the barrel clamped securely, apply pressure to the
and fittings from the cylinder port block. Discard o- rod pulling device and carefully withdraw the complete
rings. rod assembly from the cylinder barrel.
4. Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.

Figure 5-17. Cylinder Rod Support
Figure 5-15. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for

easy realignment. Using an allen wrench, loosen the
eight (8) cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.
5-54 3121142
1
18**
19
17*
16
3
18
9 19
17
10
14 11
15
14
13
12
4 5
6
7
8
*Torque to 9 ft-lbs (12 Nm)

**Torque to 50-55 ft-lbs(67-74 Nm)
1684102-E
1001228020-A
MAE35980E
1. Barrel 6. Rod Wiper 11. Wear Ring 16. Tapered Bushing

2. Rod 7. Washer Ring 12. Backup Ring 17. Capscrew
3. Piston 8. Capscrew 13. O- Ring 18. Holding Valves
4. Head 9. O- Ring 14. Wear Ring 19. O-Ring Plug
5. Seal 10. Backup Ring 15. T- Seal
Figure 5-18. Axle Extension Cylinder (SN 0300196322 through 0300238565,

SN B300002238 through B300002404, SN 0300238566 to Present,
3121142 5-55
8
6
20*
20*
8
1
7
4
3
7 15
16
12
5
14
13 11
19
18
13 17
10
21 2
8
*Torque to 12-15 ft-lbs (16-20 Nm) 1684081-F

MAE35990F
1. Barrel 7. Capscrew 13. Lock ring 19. Rod Seal

2. Rod 8. Bushing 14. Backup ring 20. Bleeder Valve
3. Piston 9. O- ring Plug 15. O-ring 21. Ring washer
4. Tapered Bushing 10. Capscrew 16. O- ring
5. Head 11. Wear ring 17. Wiper
6. Counterbalance Valve 12. Backup ring 18. Seal
Figure 5-19. Axle Lockout Cylinder (SN 0300207701 through 0300239161,

SN B300002238 through B300002449)
5-56 3121142
11
6****
19 19***
11 1
4
18** 12
3
14
15
14
17
13
16
17 10
9
5
8
7
20*
2
11
11
*Torque to 84 ft-lbs (113 Nm) 1001228019-A

**Torque to 9.5 ft-lbs (13 Nm) MAE35830A
***Torque to 13-15 ft-lbs (17-20Nm)(

****Torque to 30-35 ft-lbs (40-47 Nm)
1. Barrel 6. Counterbalance Valve 11. Bushing 16. Seal

2. Rod 7. Wiper 12. O-ring Plug 17. Lock Ring
3. Piston 8. Rod Seal 13. Wear Ring 18. Capscrew.
4. Tapered Bushing 9. Backup ring 14. Backup ring 19. Bleeder Valve
5. Head 10. O- ring 15. O- ring 20. Capscrew
Figure 5-20. Axle Lockout Cylinder (SN 0300239162 to Present, SN B300002450 to Present)
3121142 5-57
8*
23
1
11
7*
10
12 4
14
15
3
15
14
18
17
18
6
20
16
13** 19
5
22
21
9 2
*Torque to 50-55 ft-lbs (67-74 Nm)

**Torque to 9 ft-lbs (12 Nm)
23
1684149-G
1001138802-B
MAE36000
1. Barrel 7. Holding Valve 13. Capscrew 19. Wear Ring

2. Rod 8. Counterbalance Valve 14. Lock Ring 20. O-Ring
3. Piston 9. Ring Washer 15. Guide Ring 21. Wiper,
4. Tapered Bushing 10. Capscrew 16. Backup Ring 22. Rod Seal
5. Head 11. O-Ring Plug 17. O- ring 23. Bushing
6. Spacer 12. O-Ring Plug 18. Ring, Backup
Figure 5-21. Level Cylinder (Without Cold Weather Plus Package - SN 0300201016 through 0300239161,
SN B300002238 through B300002449) and (With Cold Weather Plus Package - SN 0300201016 through
0300239980)
5-58 3121142
21
22 24
20***
21
24 23
15 19***
11
1
10
9
16**
10
11
13
12
13
14
7
8
6
3
5
4
18
17*
21
**Torque to 9ft-lbs (12 Nm)
***Torque to 50-54 ft-lbs (67-73 Nm) 21 1001228023-A
MAE35840A
1. Barrel 7. O-Ring 13. Backup Ring 19. Counterbalance valve

2. Rod 8. Backup Ring 14. Spacer 20. Cartridge Valve
3. Head 9. Piston 15. Tapered Bushing 21. Bushing
4. Wiper 10. Guide Ring 16. Capscrew 22. O-Ring
5. Rod seal 11. Lock Ring 17. Capscrew 23. O-Ring
6. Wear Ring 12. O-Ring 18. Ring washer 24. O-Ring
Figure 5-22. Level Cylinder (Without Cold Weather Plus Package - SN 0300239162 to Present,
3121142 5-59
24
22***
23****
19*
18
21**
15
17
20 1
4
16
17
15
14
13
14
9
13
12
11
10
3
5
6 2
7
8
* Torque to 60 ft-lbs (81 Nm)

** Torque to 50-55 ft-lbs (67-74 Nm)
***Torque to 30-35 ft- lbs (40-47 Nm)
24
1684162-I
MAE36010I
1. Barrel 7. Washer Ring 13. O-Ring 19. Capscrew

2. Rod 8. Capscrew 14. Back Up Ring 20. O-Ring Plug
3. Head 9. Spacer 15. Lock Ring 21. Check Valve Cartidge
4. Piston 10. Wear Ring 16. Wear Ring 22. Holding Valve Cartridge
5. Rod Seal 11. Backup Ring 17. Guide Ring 23. Pressure Regulator Valve
6. Rod Wiper 12. O- Ring 18. Tapered Bushing 24. Bushing
Figure 5-23. Lift Cylinder (SN 0300201016 through 0300239470, SN B300002238 through B300002473)
5-60 3121142
22
26****
22 25
24
1
20*****
24 23
16
21***
17**
10
11
12
9
11
10 14
13
14
15
13
6
7
19 8
18* 3 5
4
2 22
***Torque to 30-34 ft-lbs (41-47 Nm) 22
****Torque to 25 ft-lbs (34 Nm)
*****Torque to 50-55 ft-lbs (68-75 Nm) 1001228024-B
MAE35850B
1. Barrel 7. O-Ring 13. O-Ring 19. Ring washer 25. O-ring Plug
2. Rod 8. Backup Ring 14. Back Up Ring 20. Holding Valve 26. Pressure Regulator Valve
3. Head 9. Piston 15. Spacer 21. Check Valve
4. Wiper 10. Lock Ring 16. Tapered Bushing 22. Bushing
5. Rod Seal 11. Guide Ring 17. Capscrew 23. O-ring Plug
6. Wear Ring 12. Wear Ring 18. Capscrew 24. O-ring Plug
Figure 5-24. Lift Cylinder (SN 0300239471 to Present, SN B300002474 to Present)
3121142 5-61
20**
21
21
20**
23
23
1
21
13 8*
22
11***
3
14
11***
6 13
16
17
18 15
19 12 4
18 5
7
8
9
10
23
* Torque to 18-20 ft-lbs (24-27 Nm)

**Torque to 30-35 ft-lbs (40-47 Nm)
***Torque to 5 ft-lbs (6 Nm) 23
1684173-H
MAE36050H
1. Barrel 7. Seal 13. O- ring 19. Seal

2. Rod 8. Rod Wiper 14. Seal 20. Cartridge Valve
3. Piston 9. Washer Ring 15. Wear Ring 21. O-ring Plug
4. Head 10. Capscrew 16. O- ring 22. O-ring Plug
5. Spacer 11. Capscrew 17. Backup Ring 23. Bushing
6. Tapered Bushing 12. Backup Ring 18. Wear Ring
Figure 5-25. Jib Cylinder (SN 0300201016 through 0300239161, SN B300002238 through B300002449)
5-62 3121142
21***
24
23
24
20 24
23
1
24
22****
16 24
11 25
10
11
17** 13
9
14
13
12
13
12 15
7
8
6
3
5
4
19
18*
23

**Torque to 5 ft-lbs (6.7 Nm)
***Torque to 30-35ft-lbs (40-47 Nm) 23
1001228025-B
MAE35860B
1. Barrel 7. O-Ring 13. Backup Ring 19. Ring Washer 25. O-Ring
2. Rod 8. Backup Rig 14. Seal 20. Counterbalance valve
3. Head 9. Piston 15. Spacer 21. Cartridge Valve
4. Rod Wiper 10. Seal 16. Tapered Bushing 22. Cartridge Valve
5. Seal 11. Wear Ring 17. Capscrew 23. Bushing
6. Wear Ring 12. O-Ring 18. Capscrew 24. O-ring
Figure 5-26. Jib Cylinder (SN 0300239162 to Present, SN B300002450 to Present)
3121142 5-63
20
21
22
28
21
20
22
5
4
7* 17 19
18 28
23 16
24
23
13
15
14 6
10
9
8
12
11
2
27
26
25
* Torque to 30 ft-lbs (40.6 Nm)
1684108-M
MAE36130M
1. Barrel 8. Retaining Ring 15. O-Ring 22. Bolt

2. Rod 9. Rod Wiper 16. Backup Ring 23. Wear Ring
3. Head 10. Rod Seal 17. O- ring 24. T - Seal
4. Piston 11. Capscrew 18. Spacer 25. Capscrew
5. Tapered Bushing 12. Compound Locking 19. Capscrew 26. Valve Assembly
6. Bracket 13. Wear Ring 20. Washer 27. O-ring
7. Capscrew 14. Backup ring 21. Wear Pad 28. Primer Locking
Figure 5-27. Telescope Cylinder(1200SJP - SN 0300201016 through 0300243437,

SN B300002238 through B300002718) and (1350SJP - SN 0300201016 through 0300243473,
SN B300002238 through B300002646)
5-64 3121142
25
18
24
26
18
25
24
15
10
21** 13 17
16 26
12 14
11
12
7
8
9 20
6
4
5
22*
2
28
19
23
* Torque to 30 ft.lbs (42 Nm)
** Torque to 115 ft.lbs (85 Nm)
27 1001228021-A
1001228026-A
MAE35890A
1. Barrel 8. O-Ring 15. Tapered Bushing 22. Capscrew

2. Rod 9. Backup Ring 16. Spacer 23. Capscrew
3. Head 10. Piston 17. Capscrew 24. Bolt
4. Wiper 11. Seal 18. Wear Pad 25. Washer
5. Retaining Ring 12. Wear Ring 19. Valve Assembly 26. O-Ring
6. Rod seal 13. O-Ring 20. Bracket 27. O-Ring
7. Wear Ring 14. Backup Ring 21. Capscrew 28. O-Ring
Figure 5-28. Telescope Cylinder -1200SJP (SN 0300243438 to Present, SN B300002719 to Present)
and 1350SJP (SN 0300243474 to Present, SN B300002647 to Present)
3121142 5-65
.
14. Remove the rod from the holding fixture. Remove the
cylinder head gland and retainer plate, if applicable. Dis-
card the o-rings, Backup rings, rod seals, and wiper seals.
Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
7. Using suitable protection, clamp the cylinder rod in a 6. Inspect piston surface for damage and scoring and for
vise or similar holding fixture as close to the piston as distortion. Dress piston surface or replace piston as nec-
possible. essary.
8. Loosen and remove the cap screw(s), if applicable, 7. Inspect threaded portion of piston for damage. Dress
which attach the tapered bushing to the piston. threads as necessary.
9. Insert the cap screw(s) in the threaded holes in the outer 8. Inspect seal and o-ring grooves in piston for burrs and
piece of the tapered bushing. Progressively tighten the sharp edges. Dress applicable surfaces as necessary.
cap screw(s) until the bushing is loose on the piston.
9. Inspect cylinder head inside diameter for scoring or
10. Remove the tapered bushing from the piston. other damage and for ovality and tapering. Replace as
necessary.
10. Inspect threaded portion of head for damage. Dress
11. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
essary.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
Figure 5-30. Tapered Bushing Removal be replaced.
c. Lubricate inside of the steel bushing with WD40
11. Screw the piston CCW, by hand, and remove the piston prior to bearing installation.
from cylinder rod. d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
12. Remove and discard the piston o-rings, seal rings, and
backup rings.
13. Remove piston spacer, if applicable, from the rod.
5-66 3121142
NOTE: Install pin into the composite bearing dry. Lubrication is Assembly
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to

assembly.
1. A special tool is used to install a new rod seal into the

applicable cylinder head gland groove.
Figure 5-31. Composite Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other Figure 5-32. Rod Seal Installation
damage. Replace as necessary.
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED

PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAK-
AGE AND IMPROPER CYLINDER OPERATION.
3121142 5-67
2. Use a soft mallet to tap a new wiper seal into the appli- 6. If applicable, correctly place new o-ring in the inner pis-
cable cylinder head gland groove. Install a new wear ton diameter groove. (The backup ring side facing the
ring into the applicable cylinder head gland groove. O-ring is grooved.)
7. If applicable, correctly place new seals and guide lock
rings in the outer piston diameter groove. (A tube, with
I.D. slightly larger than the O.D.of the piston is recom-
mended to install the solid seal.)
NOTE: The backup rings for the solid seal have a radius on one
side. This side faces the solid seal.(See magnified insert in
Figure 5-36.)The split of seals and backup rings are to be
positioned so as not to be in alignment with each other.
Figure 5-33. Poly-Pak Piston Seal Installation
Figure 5-34. Wiper Seal Installation
3. Place a new O-ring and Backup seal in the applicable

outside diameter groove of the cylinder head.
Figure 5-36. Piston Seal Kit Installation
8. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi-
ble.
9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and Backup rings are not
damaged or dislodged.
Figure 5-35. Installation of Head Seal Kit
10. Thread piston onto rod until it abuts the spacer end and
4. Install washer ring onto rod, carefully install the head install the tapered bushing.
gland on the rod, ensuring that the wiper and rod seals
NOTE: When installing the tapered bushing, piston and mating
are not damaged or dislodged. Push the head along the
end of rod must be free of oil.
rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
NOTE: Main telescope cylinder piston has an o-ring installed

inside the spacer.
5-68 3121142
b. Tap each space once; this means the tapered bush-

ing is tapped 3 times as there are 3 spaces between
WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE the capscrews.
EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-33)
11. Assemble the tapered bushing loosely into the piston

and insert JLG capscrews (not vendor capscrews)
through the drilled holes in the bushing and into the
tapped holes in the piston.
Figure 5-38. Seating the Tapered Bearing
14. Retorque the capscrews evenly and progressively in

rotation to the specified torque value. (See Table 5-33,
Cylinder Head and Tapered Bushing Torque Specifica-
tions).
Figure 5-37. Tapered Bushing Installation 15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable out-
12. Tighten the capscrews evenly and progressively in rota- side diameter grooves of the cylinder piston. (See Figure
tion to the specified torque value. (See Table 5-33, Cylin- 5-36., Piston Seal Kit Installation)
der Head and Tapered Bushing Torque Specifications).
17. Position the cylinder barrel in a suitable holding fixture.
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
a. Place the shaft against the cylinder rod and in con- HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
tact with the bushing in the spaces between the CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
capscrews.
18. With barrel clamped securely, and while adequately sup-
porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
3121142 5-69
20. Secure the cylinder head gland using the washer ring Table 5-33. Cylinder Head and Tapered Bushing Torque
and socket head bolts. (See Table 5-33, Cylinder Head Specifications
and Tapered Bushing Torque Specifications and Table 5-
34, Holding Valve Torque Specifications) Tapered
Head Torque Value
Description Bushing Torque
(Wet)
Value (Wet)
Tele Cylinder (1200SJP) 120 ft. lbs. 30 ft. lbs.

(163 Nm) (40.5 Nm)
Tele Cylinder (1350SJP) 120 ft. lbs. 45 ft. lbs.

(163 Nm) (63 Nm)
Level Cylinder 120 ft. lbs. 9 ft. lb.s

(163 Nm) (12.6 Nm)
Jib Cylinder 30 ft. lbs. 5 ft. lbs.

(41 Nm) (9 Nm)
Figure 5-39. Rod Assembly Installation
Lift Cylinder 300 ft. lbs. 120 ft. lbs.
(410 Nm) (168 Nm)
21. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the Axle Oscillation 120 ft. lbs. 9 ft. lb.s
reinstallation of any holding valve or valves. Cylinder (163 Nm) (12.6 Nm)
22. If applicable, install the cartridge-type holding valve and
Axle Extend 50 ft. lbs. 9 ft. lb.s
fittings in the rod port block, using new o-rings as appli-
Cylinder (70 Nm) (12.6 Nm)
cable. (See Table 5-34, Holding Valve Torque Specifica-
tions).
Table 5-34. Holding Valve Torque Specifications
Description Torque Value
SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

(68-75 Nm)

(102-109 Nm)

(136-149 Nm)
5-70 3121142
Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for
easy realignment. Unscrew the cylinder cap from the
DISASSEMBLY barrel.
5. Using a hook spanner, loosen the cylinder cap on Barrel.
Remove the cylinder head from the barrel and the rod.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to

the cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER

SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the cyl-

inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound. Figure 5-41. Cylinder cap removal

Figure 5-42. Cylinder cap removal

Figure 5-40. Cylinder Barrel Support
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,

HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
6. Clamp barrel securely. Pull rod assembly and cylinder

head from barrel.
7. Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
3121142 5-71
1. Barrel 7. Not Used 13. Wear Ring

2. Rod 8. Rod End Bushing 14. Piston Seal
3. Head 9. Barrel End Bushing 15. Wear Ring
4. Piston 10. Not Used 16. O-ring
5. Nut 11. Wiper 17. Back Up Ring
6. Loctite #222(not shown) 12. Rod Seal 18. O-ring
Figure 5-43. Steer Cylinder (Prior to S/N 0300073367)
5-72 3121142
15
15 4
9
6
5* 9
12
3
1
10 14
11
7
13
15
*Torque to 400 ft-lbs (542 Nm) 15

1684314-F
MAE36060F
1. Cylinder Cap 6. Piston 11. O-ring

2. Rod 7. Backup Ring 12. Wiper
3. Head 8. Wear Ring 13. Seal
4. Barrel 9. Wear Ring 14. Piston Seal
5. Nut 10. O-ring 15. Bushing
Figure 5-44. Steer Cylinder (SN 0300073367 through 0300238011,

SN B300002238 through B300002376)
3121142 5-73
15
15 1
17
11* 12
17
10
5
7
3
4**
13 14
9
6
2 16
16

1001228031-B
MAE35870B
1. Barrel 6. Piston Seal 11. Nut 16. Bushing

2. Rod 7. Wear Ring 12. Wiper 17. Plug
3. Head 8. O-Ring 13. Wear Ring
4. Cylinder Cap 9. Backup Ring 14. O-Ring
5. Wiper 10. Piston 15. Bushing
Figure 5-45. Steer Cylinder (SN 0300238012 to Present, SN B300002377 to Present)
5-74 3121142
9. Inspect cylinder head inside diameter for scoring or

other damage and for ovality and tapering. Replace as
necessary.
10. Inspect threaded portion of head for damage. Dress

11. Inspect seal and o-ring grooves in head for burrs and
12. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
essary.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
8. Using suitable protection, clamp the cylinder rod in a prior to bearing installation.
vise or holding fixture as close to the piston as possible. d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
9. Loosen and remove the lock nut that secures the piston
to the cylinder rod. NOTE: Install pin into the composite bearing dry. Lubrication is
not required with nickel plated pins and bearings.
10. Remove the piston from the cylinder rod.
11. Remove and discard the piston o-rings, seal rings.
12. Remove the rod from the holding fixture. Remove the
cylinder head. Discard all seals on the cylinder head.
Cleaning And Inspection

1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-47. Composite Bearing Installation
3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
14. Inspect the oil ports for blockage or the presence of dirt
4. Inspect inner surface of cylinder barrel tube for scoring or other foreign material. Repair as necessary.
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary. 15. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
5. Inspect threaded portion of barrel for damage. Dress
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary.
7. Inspect threaded portion of piston for damage. Dress
8. Inspect seal and o-ring grooves in piston for burrs and
3121142 5-75
Assembly 2. Use a soft mallet to tap a new wiper seal into the cylin-
der head gland groove. Install new wear rings into the
NOTE: Prior to cylinder assembly, ensure that the proper cylinder cylinder head gland groove.
seal kit is used. See your JLG Parts Manual.
NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.
1. A special tool is used to install a new rod seal into the

applicable cylinder head gland groove.
Figure 5-49. Poly-Pak Piston Seal Installation
8&"3
3*/(
Figure 5-48. Rod Seal Installation

8*1&3
4&"-
$:-*/%&3
."--&5 )&"%
WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.
IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
Figure 5-50. Wiper Seal Installation
3. Place a new O-ring and backup ring in the outside diam-

eter groove of the cylinder head.
25,1* &</,1'(5
+($'
%$&.83
5,1*
Figure 5-51. Installation of Head Seal Kit
5-76 3121142
4. Place the cylinder cap over the rod and carefully install
the head gland on the rod, ensuring that the wiper and
rod seals are not damaged or dislodged. Push the head EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
along the rod to the rod end. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
5. Place a new O-ring in the inner piston diameter groove.
6. Using suitable protection, clamp the cylinder rod in a 12. With barrel clamped securely, and while adequately sup-
vise or similar holding fixture as close to the piston porting the rod, insert the piston end into the barrel cyl-
threads as possible. inder. Ensure that the piston seals are not damaged or
dislodged.
7. Install the piston on the cylinder rod hand tight, ensur-
ing that the o-ring and Backup rings are not damaged or 13. Continue pushing the rod into the barrel until the cylin-
dislodged. der head gland can be inserted into the barrel cylinder.
8. Place a new wear ring in the outer piston diameter 14. Secure the cylinder head using JLG Threadlocker (PN
grooves. 0100035 and the cylinder cap.
9. Carefully thread the lock nut onto the rod to secure the 15. After the cylinder has been reassembled, the rod should
piston in place. be pushed all the way in (fully retracted).
10. Remove the cylinder rod from the holding fixture.

11. Position the cylinder barrel in a suitable holding fixture.
3121142 5-77
1. Return Filter
2. Vented Fill Cap
3. Sight/Temperature Gauge
4. Suction Strainer
5. Magnetic Drain Plug
Figure 5-52. Hydraulic Tank
5-78 3121142
A. Front Steer Valve/Axle Extend

B. Traction Valve
C. Rear Steer Valve/Axle Extend
D. Chassis Module Controller
E. Junction Manifold Valve
F. Axle Oscillation Valve
Figure 5-53. Chassis Control Valve Locations
3121142 5-79
1. Level Up 6. Jib Swing Left 10. Level Up Relief 14. Main Pressure Check Port
2. Rotate Right 7. Jib Up 11. Jib Up/Down Relief 15. Level Up Test Port
3. Level Down 8. Jib Swing Right 12. Level Down Relief 16. Level Down Test Port
4. Rotate Left 9. Platform Dump 13. Filter or Plug 17. Jib Up/Down Test Port
5. Jib Down
Figure 5-54. Platform Valve Identification - JLG PN 4641266
5-80 3121142
1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
Figure 5-55. Platform Valve Identification - JLG PN 4641460
3121142 5-81
1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
Figure 5-56. Main Valve Identification
5-82 3121142
Table 5-35. Cartridge Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 25-30 33.9-40.6 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
Figure 5-57. Main Valve Cartridge Torque Values
3121142 5-83
4 3
Table 5-36. Plug Torque Values
Ft-Lbs. Nm
1 115 156
2 100 135.5
3 40 54
4 13 17.5
Figure 5-58. Main Valve Plug Torque Values
5-84 3121142
5.4 HYDRAULIC TANK 5.5 PRESSURE SETTING PROCEDURE

The hydraulic tank has a capacity of 55 gallons (208 liters) and Cold temperatures have a significant impact on pressure read-
includes the hydraulic return filter and two suction strainers. It ings. JLG Industries Inc. recommends operating the machine
is normal for the oil level to appear low when the boom is until the hydraulic system has warmed to normal operating
raised and should only be checked with the machine on level temperatures prior to checking pressures. JLG Industries Inc.
ground and with the boom fully retracted and lowered. The also recommends the use of a calibrated gauge. Pressure read-
hydraulic oil should be maintained at the full level as shown by ings are acceptable if they are within ± 5% of specified pres-
the decal and hydraulic oil level gauge located on the side of sures.
the tank as shown in Figure 5-59., Hydraulic Oil Level Gauge.
This decal shows the proper full level for both hot and cold oil. To ensure all pressures are set correctly, the following proce-
Do not fill the hydraulic tank past the appropriate full mark. dures must be followed in order.
Overfilling can cause the oil to overflow from the top of the
1. All applicable steps in Section 5.11, Drive & Function
hydraulic tank during emergency lowering operations.
Pump Start Up Procedures must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
Set Up of the Function Pump

HIGH PRESSURE RELIEF - 3400 PSI (234.4 BAR)
1. Install a high pressure gauge at the MP port of the main
valve block.
2. Using a screwdriver, remove the Din connector from the
lift down coil.
FULL LEVEL (HOT OIL)

3. Activate lift down. The gauge should read 3400 psi (234
bar).
FULL LEVEL (COLD OIL)
Figure 5-59. Hydraulic Oil Level Gauge
3121142 5-85
4. To make an adjustment to this pressure, go back to the 3. To make an adjustment to this pressure, go to the
engine compartment to the function pump which is the engine compartment, locate the function pump. The
back pump. The high pressure relief adjustment is the stand by adjustment is the adjustment outside adjust-
adjustment closest to the pump. Using a 17 mm wrench, ment, closest to the turntable. Use the same tools that
remove the cover nut. Be careful not to lose the O-ring were used in the Hi pressure adjustment procedure.
washer inside the cover nut.
5. Loosen the jam nut at the setscrew with the 17 mm Adjustments made at the Main Valve Bank
wrench. Using a 3 mm allen wrench, adjust clockwise to LIFT UP - 2750 PSI (189.6 BAR)
increase, or counterclockwise to decrease. 1. Install a high pressure gauge at the M5 port of the main
6. After adjusting the pressure, tighten the jam nut and the valve block. Plug and cap the hose on port 5.
cover nut. This is the maximum relief pressure for all the 2. Activate lift up. The gauge should read 2750 psi (189.6
functions governed by this pump. Bar).
STAND BY PRESSURE OR LOW PRESSURE RELIEF - 300 PSI 3. The adjustment cartridge is located below the M5
(20.6 BAR) gauge port. Turn clockwise to increase, counterclock-
1. Install a low pressure gauge at port MP of the main valve wise to decrease.
block capable of reading 300 psi (20.6 bar). LIFT DOWN - 1500 PSI (103.4 BAR)
2. Start the engine, the gauge should read 300 psi (20.6 1. Install a high pressure gauge at the M4 port of the main
bar). valve block.
2. Activate lift down to the end of the stroke. The gauge
should read 1500 psi (103.4 bar).
3. The adjustment cartridge is located to the left of the M4
gauge port. Turn clockwise to increase, counterclock-
wise to decrease.
5-86 3121142
SWING - 1500 PSI (103.4 BAR) STEERING, FRONT AND REAR

NOTE: Left and right are done with one adjustment. NOTE: The following procedure requires 2 people to perform. One
is needed for verifying / adjusting pressure readings and
1. Install a high pressure gauge at port MS. wheel spindle alignment the other for operating the steer
functions and using the Analyzer from the platform.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4 The Analyzer is required to perform the pressure check proce-
Bar). The adjustment cartridge is located below the MS dure through access of the calibration menu. The calibration
gauge port. menu will allow for extending and retracting the steer cylin-
ders individually, verifying pressures, and proper steer sensor
4. Turn clockwise to increase, counterclockwise to calibration. Verification of the steer sensor calibration will
decrease. require one of two types of measuring methods; using a
TELESCOPE OUT - 3000 PSI (206.8 Bar) square and ruler or using string as explained in Section 6 - JLG
Control System. The purpose of these measuring tools is to
1. Install a high pressure gauge at the M8 port of the main assure that the wheel spindle is aligned “straight” with the
valve bank. Plug the telescope out hose either at the extended axle weldment.
valve bank (port #8) or at the inlet of the telescope cylin-
der (V1). 1. Position the machine with both front and rear axles fully
extended.
2. Activate telescope out. The gauge should read 3000 psi
(206.8 Bar). 2. Install the Analyzer in the platform control box and scroll
menu’s to Access Level 2 and insert password (33271) to
3. The adjustment cartridge is located below the M8 get into Access Level 1.
wise to decrease.
TELESCOPE IN - 3200 PSI (220.6 BAR)
1. Install a high pressure gauge at the M7 port of the main
valve block.
2. Activate Telescope In. The gauge should read 3200 psi
(220.6 Bar).
3. The adjustment cartridge is located to the left of the M7
wise to decrease.
Adjustments Made at the Frame Valve Bank

AXLE EXTEND AND RETRACT, FRONT AND REAR - 2500 PSI
(172.3 BAR)
1. To extend the axles, drive the machine back and forth
3. Scroll to the calibration mode. Once in the calibration
until extended. A machine that cannot be driven must
mode, press “ENTER” and scroll to steer. Once in the
be jacked up.
steer calibration mode, the Analyzer is going to ask to
2. On both the front and rear frame valve banks, install a calibrate the steer sensors, this is going to allow extend-
high pressure gauge on ports MA1 for extend and MA2 ing and retracting each steer cylinder individually dur-
for retract. The gauge should read 2500 psi (172.3 Bar) in ing this process. The JLG control system will ask to
both directions. calibrate the left front sensor, the left rear sensor, the
right front sensor and finally the right rear sensor in that
3. The axle extend/retract cylinders are connected hydrau- order. During this calibration mode each individual steer
lically in parallel. In order to get the correct pressure of cylinder will be extended and retracted to verify correct
the circuit being adjusted, unscrew the solenoid coil pressures with the marked MS (Measure Steer) ports on
from the circuit not being adjusted and pull it away from the steer / axle valve that pertains to that steer cylinder.
the valve. Refer to the Hydraulic Schematic in Section 7 - Schemat-
4. Turn clockwise to increase, counterclockwise to ics.
decrease.
3121142 5-87
Figure 5-60. Steer Pressure Adjustments
5-88 3121142
4. Remove the front circular steer/axle access covers at the 6. Remove the pressure gauge from MS2 port and install
front of the chassis, and the rear square cover at the top on the MS1 port, which is on the right side of the front
rear of the chassis to gain access to the axle/steer valves. axle/steer valve, closest to the right front wheel spindle.
Position the steer switch to activate the left front steer
cylinder until the rod is in the fully retracted position
and hold the switch for a few seconds after the rod has
stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to
MS1 port, CW to increase or CCW to decrease.
7. This step involves aligning the left front wheel spindle

with the axle weldment. Position the left front wheel
spindle “straight” using a square and rule or string for
proper alignment (Refer to Section 6 - JLG Control Sys-
5. Install a pressure gauge at the front axle/steer valve at
tem). Once the left front wheel spindle has been prop-
MS2 port. This should be located on the left side of the
erly measured, press “ENTER” on the Analyzer. This is
valve closest to the left front wheel spindle. Position the
calibrating data to the JLG Control System that the left
steer switch to activate the left front steer cylinder until
front steer sensor is centered.
the rod is in the fully extended position and hold the
switch for a few seconds after the rod has been fully
extended. The MS2 port should read 2000 psi (138 Bar).
If the pressure is not 2000 psi (138 Bar) adjust relief valve
mounted next to the MS2 port, CW to increase or CCW
to decrease.
3121142 5-89
8. Checking the left rear steer cylinder is identical to the 9. Remove the gauge from MS1 port and install on MS2
procedure for left front steer cylinder, except now we are port, which is on the right side of the rear axle/steer
checking pressures at the rear axle/steer valve location. valve, closest to the right rear wheel spindle. Position
Install pressure gauge at MS1 port. This should be the steer switch to activate the left rear steer cylinder
located on the left side of the valve closest to the left until the rod is in the fully extended position and hold
rear wheel spindle. MS1 port should read 2600 psi (179 the steer switch for a few seconds after the rod has been
Bar) when the left rear steer cylinder is activated with fully extended. The MS2 port should read 2000 psi (179
the rod in the fully retracted position. If the pressure is Bar). If the pressure is not correct, adjust the relief valve
not 2600 psi (179 Bar) adjust relief valve mounted next mounted next to MS2 port CW to increase or CCW to
to MS1 port CW to increase or CCW to decrease. decrease.
5-90 3121142
10. The next step is identical to the left front step men- 16. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is tioned above, make sure the right rear wheel spindle is
straight and press “ENTER” to accept the new calibration straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right settings, now escape out of the calibration menu and
front steer calibration step. remove the Analyzer and pressure gauge.
11. Checking the right front steer cylinder is identical to the
procedure laid out for the left front steer cylinder, except Adjustments Made at the Platform Valve Bank
the pressures are now checked at MS3 port of the front PLATFORM LEVEL UP - 2500 PSI (172.3 BAR)
axle/steer valve. This should be at the right side of the
1. Install a high pressure gauge at the gauge port M1.
valve closest to the right front wheel spindle. Install the
gauge at MS3 port. Position the steer switch to activate 2. Activate level up to the end of stroke, it should read
the right front steer cylinder until the rod is in the fully 2500 psi (172.3 Bar).
retracted position and hold the steer switch for a few
3. All the relief valves are located on the same face. The
seconds after the rod has been fully retracted. If the
level up relief valve is located closest to the M1 gauge
pressure is not 2600 psi (179 Bar), adjust the relief valve
port. Turn clockwise to increase, counterclockwise to
mounted next to the MS3 port CW to increase or CCW to
decrease.
decrease.
PLATFORM LEVEL DOWN - 1500 PSI (103.4 BAR)
12. Remove the gauge from MS3 port and install on MS4
port, which is on the left side of the front axle/steer 1. Install a high pressure gauge at gauge port M2.
valve, closest to the left front wheel spindle. Position the
steer switch to activate the right front steer cylinder 2. Activate level down to the end of stroke, it should read
until the rod is in the fully extended position and hold 1500 psi (103.4 Bar).
the steer switch for a few seconds after the rod has 3. The level down relief valve is located to the left of the
stopped extending. The MS4 port should read 2000 psi level up relief valve. Turn clockwise to increase, counter-
(138 Bar). If the pressure is not correct, adjust relief valve clockwise to decrease.
mounted next to the MS4 port CW to increase or CCW to
decrease. ARTICULATING JIB UP AND DOWN - 2750 PSI (189.6 BAR)
13. The next step is identical to the left front step men- 1. Install a high pressure gauge on gauge port M3. The jib
tioned above. Make sure the right front wheel spindle is relief valve is located below the level down relief valve.
straight and press “ENTER” to accept the new calibration Activate jib up or down, it should read 2750 psi (189.6
settings. Scroll over to right rear steer calibration step. Bar). Turn clockwise to increase, counterclockwise to
decrease.
14. Checking the right rear steer cylinder is identical to the
procedure laid out for the left rear steer cylinder. Install
gauge at MS4 port of the rear axle/steer valve. This
should be at the right side of the valve closest to the
right rear wheel spindle. Position the steer switch to acti-
vate the right rear steer cylinder until the rod is in the
fully extended position and hold the steer switch for a
few seconds after the rod has stopped extending. The
MS4 port should read 2000 psi (138 Bar. If the pressure is
not correct, adjust relief valve next to the MS4 port CCW
to increase or CCW to decrease.
15. Remove gauge from MS4 port and install on MS3 port,
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer
switch to activate the right rear steer cylinder until the
rod is in the fully retracted position and hold the steer
switch for a few seconds after the rod stops retracting. If
the pressure is not 2600 psi (179 Bar), adjust the relief
valve mounted next to the MS3 port CW to increase or
CCW to decrease.
3121142 5-91
5.6 DRIVE PUMPS (REXROTH) 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated

by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0-
at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210
No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou-
Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
tem fault. c. Can the charge pressure be raised by removing dirt/
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel removing shims from the charge pressure relief
engine running properly valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram? engine running and propelling the machine forward or
reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
d. Is the pump direction of rotation correct? (clockwise tridge (#130). The brake release pressure must be 25 psi less
as looking at the shaft) than the charge pump pressure. Measure pressure at port
"MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
No - Fit pump having the correct direction of rota-
d. Is the transmission pumps suction hose pinched
tion
shut?
Yes - If yes, proceed to step 1.e
No - Proceed to step 2e
e. Are there "O"-rings missing from fittings (as exam- Yes - Repair damaged hose
ple - suction leak), pinched hoses, broken tubing,
e. Is the charge pump suction pressure/vacuum within
etc?
recommended limits? (0.8 bar absolute or 6.3 inches
of mercury)
No - Proceed to step 1.f
Yes - Repair damage or fault
Yes - Proceed to step 2.g
f. Are the electrical connectors/wiring intact and
f. Is the suction strainer inside the reservoir blocked,
secure to the pump control solenoids?
clogged, restricted?
No - Repair damage or fault
No - Proceed to step 2.g
Yes - If yes, proceed to step 1.g
Yes - Repair/replace with a clean suction strainer
g. Does the engine "labor" when attempting drive, are
g. Is the reservoir air breather blocked or restricted?
the brakes released?
No - Proceed to step 2.h
No - Proceed to step 1.h
Yes - Clean or replace air breather
Yes - Check brake release circuit, measure pressure
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
5-92 3121142
h. Remove charge pressure relief valve from the mid- f. Stroke pump in both directions, while measuring
dle pump and inspect. Is it damaged? pressure at Ma & Mb ports of the pump. Does any
No - Refit cartridge and proceed to step 2.i pressure greater than charge pressure alternate
Yes - Clean & inspect cartridge, poppet, springs, between ports Ma & Mb?
seals to determine cause of damage. Repair or fit a No - Verify that loading the pump will cause system
new cartridge and return to step 2.a pressure to increase above charge pressure. Proceed
i. Remove and inspect charge pump assemblies. Are to step 3.a
they damaged? Yes - Proceed to step 3.g
No - Proceed to step 2.j g. Is it possible to adjust high pressure relief valves
Yes - Repair and/or replace damaged components using 0-6000 psi (0 - 415 bar) gauges to monitor
and return to step 2.a pressure at Ma & Mb? (Refer to relief valve adjust-
j. Is the charge pump installed for the clockwise rota- ment)
tion? No - Replace high pressure relief valve and return to
No - Refit charge pump. Return to step 2.a step 3.c
Yes - With proper charge pressure and transmission Yes - Adjust high pressure relief valves to 5000 psi
still does not operate, proceed to step 3.a +50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
3. Transmission does not propel the machine, diesel h. Actuate control in both directions. Does transmis-
engine running properly - Pump Control: (Insure Gener- sion operate?
ator Drive option is not turned "on") No - Check that minimum displacement stops on
the wheel drive motors are adjusted properly, check
a. Are the electrical connectors & wiring connected that the motors stroke between maximum to mini-
properly to the pump control solenoids? mum.
No - Connect a ammeter in series with solenoid wir- Yes - Operate the transmission
ing. Is a current of 400 mA to 1060 mA being
applied. (Current signal varies with joystick position) 4. Transmission Drive is Sluggish or Erratic
Yes - Proceed to step 3.b a. Does the "EP" proportional pump control current
b. Are all four of the two-speed motors, mounted in vary with joystick movement?
the wheel drive planetary reduction gearboxes, No - Rectify the problem - broken wires, electrical
shifted to maximum displacement (high torque - connector, open solenoid coil, etc.
low speed)? Yes - Proceed to step 4.b
No - Select maximum displacement b. Are all four (4) brakes fully released?
Yes - Proceed to step 3.c No - Check brake release pressure and insure each
c. Actuate the pump control in both directions. Do the wheel receives correct release pressure.
pumps stroke? Do they go to full stroke? Yes - Proceed to step 4.c
No - Refer to the pump service manual and then c. Are the pumps stroking time orifices installed tight
proceed to step 3.d and clean?
Yes - Operate the transmission No - Remove the Plugs in ports X1 and X2. Remove
d. Remove stroking orifices in X1 and X2. Install pres- orifices with a 3mm allen wrench. Check that orifices
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). are clean & re-install.
Stroke the pump in both directions. Do the pres- Yes - Proceed to step 4.d
sures at X1 and X2 alternate between 30 & 250 psi (2 d. Is an motor displacement stroking time orifice
& 17 bar)? plugged or is the two-speed shift hose pinched?
No - Remove the EP control module & replace it with Yes - Inspect and clean stroking orifice, check two-
a new unit. Repeat step 3.c speed hose routing
Yes - Proceed to step 3.e. e. Is a flow divider/combiner cartridge stuck in the
e. Is the pressure at port "R", case pressure, less than 15 Traction Control Manifold? Flow divider/combiner
psi (1 bar) gauge pressure? cartridge # 111 controls the right side wheels, # 112
No - Correct problem restricting case drain oil flow controls the left side wheels. Also check to insure
(oil cooler blockage, pinched hoses, etc) bypass orifices #151 (right side) and # 152 (left side
Yes - Proceed to step 3.f are not plugged.
3121142 5-93
5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge "O"-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
c. Inspect "Make-Up" check valve cartridges, #190.1- No - Apply 12 volts to opposite solenoid & recheck.
190.4, installed in the Traction Control Manifold. Is a No - Replace pump control module, repeat step 7.a
cartridge "stuck" open with debris or is an "O"-ring Yes - Possibly dirt was dislodged from control mod-
failed? ule, re-check thoroughly to determine problem has
No - Proceed to step 5.d definitely been resolved.
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
tridge. 8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission. a. Are the wheel drive planetary reduction gearboxes
Does the transmission drive in the other direction? filled to the correct level and do they have the
No - Proceed to step 5.e proper lubricant?
Yes - Repair/clean/adjust or replace high pressure No - Fill gearbox with correct grade of oil to the pre-
relief valve on the non-driving side scribed level.
e. Replace "EP" control module. Does pump operate Yes - Proceed to step 8.b
properly? b. Is the engine flex plate and drive coupling correctly
No - Replace or repair pump installed and aligned with the transmission pump?
Yes - Operate the transmission No - Install flex plate and bell housing per manufac-
6. Transmission Drives in Wrong Direction turer's instructions
Yes - proceed to step 8.c
a. Check to see if electrical connectors or wiring have
been swapped on the pump. c. Is a rigid item or object contacting the resilient
mounted engine/pump assembly?
b. Check to determine want end of the machine the No - Proceed to step 8.d
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
ting air borne noise.
d. Is the suction pressure/vacuum at the charge
pumps inlets within recommended limits?
No - Return to step 1.h
Yes - Proceed to step 8.e
e. Is there air in the hydraulic fluid? This may be indi-
cated by foaming or milky colored oil.
Yes - Deaerate the oil and inspect system for cause
of air induction. Check for loose or missing "O"-rings
on face seal connections.
5-94 3121142
f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or more No - Return to step 2.a
motors "stuck" at minimum displacement, check for Yes - Proceed to step 11.b
plugged/blocked two-speed stroking orifice(s). b. Does the pump case pressure exceed 15 psi gauge
pressure?
9. Transmission Operates at a Higher than Normal Temper-
ature
Yes - Check case drain hoses, oil cooler, etc. for
a. Is the reservoir temperature above 195oF (90.5° C)? pinched or restricted oil flow
No - 195oF (90.5° C) is the upper limit. If temperature c. Are the pump(s) high pressure cross port relief
is over 195oF (90.5° C), the oil cooler may need to be valves adjusted to the required pressure (5000 psi)
cleaned. so they do not bypass prematurely?
Yes - Proceed to step 9.c No - Inspect/clean/adjust and or replace valve car-
tridge
b. Are the hydraulic motor(s) stalling (wheels not turn-
Yes - Replace the pump, after blocking the "A" & "B"
ing) intermittently?
ports, running the pump and measuring pressure
developed at "A" & "B". This must be done to insure
Yes - Hydraulic fluid is being heated through system
that flow & pressure loss in not elsewhere in the sys-
pressure relief valves. Shut down system and rectify
tem. (motors, swivel coupling, etc)
the cause of motor stall.
d. Is the diesel engine capable of developing horse-
c. Does oil temperature remain above 195oF (90.5° C), power at design rpm?
after cleaning the oil cooler? Follow recommended troubleshooting procedures
No - Operate transmission. Check oil cooler more to insure the engine is developing full power at
often. specified rpms.
Yes - Proceed to step 8.a
10. Transmission Operates at a Higher than Normal Temper- Charge Pressure Relief Valve Adjustment
ature
a. Check for differential temperature across the oil
cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve
(10 psi [0.7 bar] crack pressure) is stuck open. Check
to determine if the oil cooler is restricted internally,
causing oil flow to pass across the bypass check
valve.
Yes - Proceed to step 8.b
NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge
pressure. Higher pressure will prematurely damage pump
shaft seals CHARGE RELIEF
b. Disconnect pump case drain from oil cooler & check With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
flow rate from charge pumps. Is the flow rate 3.8 tee’d into the ”G” port or two (2) low pressure gauges installed
GPM (14.4 LPM) with diesel idle speed of 1200 rpm? into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
No - Refer to charge pump removal & inspection place the pump on stroke – low pressure gauges installed in
procedure ”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
3121142 5-95
NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT
When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
Mechanical Centering of Pump

PREPARATION FOR ADJUSTMENT
The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw effect, and could cause damage to the eccentric pin.
opposite direction until 1000 psi is read on other pressure Pump Size Tool Required Wrench
port. Turn the screw back, splitting the distance between the
28 Screwdriver 10 mm
previous two positions. This should be the neutral position.
Pressure on MA, and MB should be equal.
CENTERING THE EP CONTROL MODULE
With no electrical signal to solenoids A and B, (remove both
plug-in connectors), the EP control module is correctly
adjusted when any or all of the following conditions exist:
1. Approximately, when equal control pressures are
obtained at control pressure ports X1 and X2.
2. The hydraulic motor does not turn when the brake is
released.
3. Charge pressure is registered equally at ports MA and
MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
Tighten jam nut, stop the pump drive, remove the hose con-
necting ports X1 and X2.
5-96 3121142
If difficulties are encountered in obtaining neutral position of Removal and inspection of charge pump
the HD or EP control modules, check that the ends of the con-
trol spring are correctly located in the grooves near the end of Before removing cap screws, mark the position of the charge
the feedback lever arms. pump housing and separator plate in relation to the port
block.
High Pressure Relief Valve Adjustments

Loosen screws with metric allen wrench.
1. Remove relief valve cover from pump (ref. item 1).
Pump Size Allen Wrench
28 8 mm
2. Loosen jam screw (ref. item 2).

3. Holding spring loading nut (ref. item 4) rotate valve
spindle (ref. item 3). For high range relief valve, one turn
equals approximately 630 psi (44 bar). For low range
relief valve, one turn equals approximately 377 psi (26
bar). Remove charge pump housing and inspect for wear or dam-
4. After adjustment is completed torque jam screw (ref. age to gear set and 0-ring seals. Grease 0-rings prior to reas-
item 4) to 5 ft.lb. (7 Nm). sembly. Make sure 0-rings are completely seated in their
grooves.
5. Install relief valve assembly into pump, reinstall cover
(ref. item 1) to proper torque.
Table 5-37. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
3121142 5-97
Routine Maintenance
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
a. After commissioning or re-build.
b. At every 500 operating hours or when filter indica-
tor shows a dirty element.
c. With the suction strainer, the strainer should be
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
d. Only JLG recommended filter elements are to be
Withdraw pinion shaft and inspect gear teeth and bearing sur- used. Paper elements cannot be cleaned; use throw-
faces for abnormal wear. away cartridges.
When reassembling, make sure chamfer (on outer edge of 2. Hydraulic Fluid Change
driven gear and drive gear) is installed into housing per illus-
tration. a. After 2000 operating hours (1st oil change)
b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
c. Oil change should be performed with the system in
warm running condition. Before re-filling, the reser-
voir interior should be inspected and cleaned to
remove any sludge.
d. Rags or threaded material must not be used.
e. This machine has been designed & manufactured to
operate on an Exxon-Mobil Oil Co. hydraulic fluid,
Mobilfluid #424, Product #52233-4. Consult JLG
Industries prior to introducing any other type of
fluid to prevent interaction or possible contamina-
tion.
Torque value for bolts when replacing charge pump. f. The recommended interval between oil changes is
based on various factors and should be carried out
Pump Size Torque according to the degree of aging, contamination
28 18 ft.lb. (24 Nm) and water content.
g. Under application conditions with a heavy occur-
NOTE: If serious wear or damage has occurred to one component, rence of dust or severe temperature fluctuations,
the complete charge pump assembly must be replaced the intervals between fluid maintenance should be
because they are matched components. shortened accordingly.
5-98 3121142
5. Oil Level Inspection

a. Inspect oil level in the reservoir daily.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAINTENANCE ERRORS
OCCUR DURING AN OIL CHANGE DUE TO: b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
• USE OF AN UNSUITABLE HYDRAULIC FLUID c. Do Not Mix Fluids.
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES 6. Hydraulic Fluid - The "Life Blood" of the Machine
• FAILURE TO CLEAN THE RESERVOIR a. The type of hydraulic fluid supplied in the machine
from the factory was selected after extensive testing
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY and development. The fluid was selected to perform
DRUMS, CONTAINERS, WATER, ETC) under "most" applications and conditions. Should
3. Leakage Inspection this machine be in service for extended time peri-
ods at the extremes (hot or cold), JLG should be con-
a. After commissioning
sulted for assistance in selection of the most
b. The complete transmission drive system (pumps, suitable fluid type and grade for your application.
motors, hosing, filters, valves, etc) should be
checked for leakage at regular intervals. b. When operating at temperatures below 0oF, allow a
warm-up period, if at all possible, to a temperature
c. Leaking joints & connections must only be tight-
ened when pressureless. of 40oF.
4. Cleanliness Inspection c. When beginning motion of a "cold" machine, oper-

ate all functions at reduced speeds until the "cold"
a. The oil tank breather should be regularly cleaned of oil has circulated out of the drive loop.
dirt and dust to prevent clogging. With each cylin-
der movement, gallons of oil pumped, an equal
amount of air exchange occurs across the reservoir
breather. A dirty or clogged breather will affect all
machine functions!
b. The air/oil cooler surfaces and engine radiator
should be cleaned at the same time.
c. If hose connections are disassembled, it is impera-
tive that the utmost care be taken that no foreign
bodies infiltrate the oil circuit. Catastrophic compo-
nent failure may occur.
3121142 5-99
Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
5-100 3121142
5.7 FUNCTION PUMP (REXROTH)
Figure 5-61. Function Pump - Sectional View
Spare Parts 2. Drive Shaft
1. Sealing kit, existing spare parts: shaft sealing ring, o-

rings, and a circlip.
3. Bearing set, miscellaneous parts.
3121142 5-101
4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE

REMOVAL OF THE SHAFT SEALING RING.
1. Remove the snap ring.
5. Swash Plate.
2. Change the shaft seal and check its’ sliding surface

(drive shaft) and housing. Grease the sealing ring.
6. Parts of the control valve: control piston, piston rod,

plug, spring stopper max flow, hex nut, and hex head
nut.
3. Be careful while you seal the drive shaft. Use an adhesive

tape to prevent the shaft splines from damaging the
seal.
7. DFR pilot valve.
5-102 3121142
4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
(hold the valve plate so the plate can’t fall down).
6. Assemble the snap ring in the correct position.

4. Remove the o-ring.
Disassembly and Assembly of the Complete Unit 5. Disassemble the taper roller bearing (nearby port plate).
1. Disassemble the pilot valve.
3121142 5-103
6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
5-104 3121142
14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble
the piston rod.
20. Disassemble the snap ring.
16. Remove the swash plate.
21. Disassemble the sealing ring.
17. Remove the spring.
3121142 5-105
22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
23. Remove the o-ring. Lifting of the valve plate isn’t shown.
Assembly
1. Measurement of the taper roller bearing pretention.
24. A bearing puller is used to disassemble the external

bearing ring of the taper roller bearing inside the port
plate. Take care of the surface of the port plate. 2. Ensure there is a correct connection of the piston rod
and the swash plate.
5-106 3121142
3. Pumps clockwise driven must have a position of the Adjustments

valve plate 4 degrees out of center in the same direction
TAPER ROLLER BEARING INITIAL TENSION
decentered like drive direction.
Cast Iron pump housing must have initial tension of the bear-
ings: 0 to 0.05 mm.
4. Pumps counterclockwise driven must have a position of

the valve plate 4 degrees decentered in the ccw posi-
tion.
MECHANICAL FLOW LIMITER

Differential volume if you are rotating the threaded pin - each
rotation is approximately 3.1 cm3.
5. Note the correct position of the drilling that connects
high pressure to the control valve. Check control valve Tightening Torques
drilling position at the pump housing and fit together. For break-off plugs, use Loctite #601.
For all other parts, use JLG Threadlocker PN 0100011.
Table 5-38. Tightening Torques
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
3121142 5-107
Figure 5-62. Function Pump, Pressure and Flow Control - Sheet 1
5-108 3121142
Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur-
face clean and installing some adhesive tape should pre-
NOTE: If the Function Pump does not perform correctly after
vent oil from seeping from the pump control.
following the pre-start start-up procedures, it is possible that a
contaminate particle has lodged in the pump control prevent- 4. Work on a clean, lint free area.
ing proper operation. The pump control’s internal parts are
not provided as spare parts due to the close tolerances NOTE: The pump control can be equipped with either O-rings or a
required between the mating parts. However, the control can sealing plate. These components are NOT interchangeable.
be disassembled, cleaned and placed back in service should 5. Remove the three (3) ”0”-rings (Parker # 2-011, Viton 90
the only problem prove to be contamination. Disassembly, shore)
inspection, cleaning and reassembly MUST BE done in a clean
well-illuminated area. 6. Remove both the adjustment hex caps and bonded seal
rings. (17 mm wrench)
Pump Control removal:
7. Remove both the adjustment lock nuts and bonded seal
1. Disconnect plug the hose attached to the pump control rings. (17 mm wrench)
Port ”X”.
8. Remove both the adjusting screws. (3-mm Allen
2. Remove the four (4) socket head cap screws that attach wrench)
the control to the pump. Insure that the three (3) ”0”-
rings are also removed with the control.
9. Remove the spring cover hex cap for the ”outer” flow regulation adjustment this requires a 19-mm wrench.
3121142 5-109
10. Remove the spring disc. 21. Inspect the housing for contamination or plugged ori-
fices. Clean orifices carefully with a dead soft steel wire
11. Remove the adjusting springs (two springs, one
to insure they are open. Inspect all parts for burrs, scor-
”nested” inside the other) and spring follower.
ing, debris, etc.
12. The flow regulation spool should slide from the control
NOTE: On the mounting surface of the control housing, between
housing, (a magnet should aid in removal). If it does not,
the oil ports is what appears to be a slotted head screw. IT
remove the hollow hex head plug at the rear of the flow
IS NOT A SCREW. This is a bleed orifice, which must be ori-
regulation spool and carefully push the spool from the
entated to allow proper control operation. The slot in the
housing - do not scratch/mar the spool’s bore.
head should be oriented to fall in-line with the oil ports,
13. Remove the spring cover hex cap for the ”inner” pres- NOT PERPENDICULAR to the oil ports. If the slot is oriented
sure compensation adjustment – this requires a 30-mm perpendicular to the three ports, the pump pressure will
wrench. not return from load pressure to stand-by pressure at the
end of operating a function! The pump pressure will
14. Remove the spring disc.
remain at the last highest pressure generated.)
15. Remove the adjusting springs (two springs, one
”nested” inside the other). 22. After all parts are clean and dry, lightly oil a control
spool and install in its bore. The spool must slide
16. Remove the spring follower. smoothly and easily within the housing. If it does not,
17. The pressure compensation spool should slide from the check for contamination. If contamination cannot be
control housing, (a magnet should aid in removal). If it found check for ”scoring” or ”burring” of the control
does not, remove the hollow hex head plug at the rear housing. If the spool does not slide smoothly & freely,
of the flow regulation spool and carefully push the spool the control must be replaced with a new unit.
from the housing - do not scratch/mar the spool’s bore. 23. Lightly oil and check operation of the second spool. The
18. The spools are identical. spools are installed correctly when there ”pointed” end
faces the spring followers
19. Wash the housing and all parts in a clean JLG approved
solvent such as non-chlorinated brake cleaner, Stoddard 24. Re-assemble in reverse order.
solvent, etc. 25. Bench set the pressure adjustments as described in ”C.
20. Blow off all the parts with clean, dry compressed air. 4” of the Operating Instructions.
NOTE: The pump control can be equipped with either O-rings or a

sealing plate. These components are NOT interchangeable.
26. Re-install on the Function Pump, insure the ”0”-rings are

installed properly and tighten the four (4) M6 socket
head cap screws to 105 inch pounds.
5-110 3121142
5.8 DRIVE PUMPS (SAUER)
Electric displacement control Electric displacement control
Servo piston Servo piston
Swashplate feedback pin Swashplate feedback pin

Valve plates
Piston
Piston Slipper
Slipper Front shaft bearing
Rear shaft bearin

g
Shaft seal
Rear shaft Front shaft
Swashplate bearing Shaft coupling Swashplate bearing
Swashplate Cylinder block Center shaft bearings Cylinder block Swashplate
Figure 5-65. Piston Pump Cross Sectional View
Port Locations and Gauge Installation
Table 5-39. Port information
Port identifier Port size Wrench size Reading Gauge size, bar [psi]
L1, L2, L3 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 bar [100 psi]
MA, MB, MC, MD 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]
X7 9/16-18 UNF 2B 1/4 internal hex Brake pressure 50 bar [1000 psi]
3121142 5-111
Servo gauge port M5 Charge inlet port E

ISO 11926-1 - 7/16-20 ISO 11926-1 - 1 5/16-12
Case drain port L3 Servo gauge port M4
ISO 11926-1 - 1 1/16-12 ISO 11926-1 - 7/16-20
Case drain port L1

ISO 11926-1 - 1 1/16-12
System port B
System port C ISO 11926-1 - 1 5/16-12
ISO 11926-1 - 1 5/16-12
System port D System port MD
ISO 11926-1 - 1 5/16-12 ISO 11926-1 - 9/16-18
System port A System gauge port MA
ISO 11926-1 - 1 5/16-12 ISO 11926-1 - 9/16-18
Figure 5-66. Port locations - Sheet 1 of 2
5-112 3121142
System gauge port MB System gauge port MC

ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18
Brake gage port X7

ISO 11926-1 - 9/16-18 Charge constr port M3
ISO 11926-1 - 9/16-18
Servo gauge port M5 Servo gauge port M4

ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
Charge pressure gauge port M3

ISO 11926-1 - 9/16-18
Case drain port L2

ISO 11926-1 - 1 1/16-12
Figure 5-67. Port locations - Sheet 2 of 2
3121142 5-113
Initial Startup Procedures tions and listen for cavitation. Check for proper fluid
level in reservoir.
Follow this procedure when starting-up a new pump or when
restarting a pump that has been removed. Ensure the pump is 9. When adequate charge pressure is established (as
thoroughly tested on a test stand before installing. shown in model code), increase engine speed to normal
operating rpm to further purge residual air from the sys-
Prior to installing the pump, inspect for damage that may have tem.
occurred during shipping.
10. Shut the off engine. Connect the pump control signal.
1. Ensure that the machine hydraulic oil and system com- Start the engine, checking to be certain the pump
ponents (reservoir, hoses, valves, fittings, and heat remains in neutral. Run the engine at normal operating
exchanger) are clean and free of any foreign material. speed and carefully check for forward and reverse con-
trol operation.
2. Install new system filter element(s) if necessary. Check
that inlet line fittings are properly tightened and free of 11. Continue to cycle between forward and reverse for at
air leaks. least five minutes to bleed all air and flush system con-
taminants out of the system loop.
3. Install the pump. Install a 50 bar [1000 psi] gauge in the
charge pressure gauge port M3. NOTE: Normal charge pressure fluctuation may occur during for-
4. Fill the housing by adding filtered hydraulic fluid to the ward and reverse operation.
upper case drain port. If the controls are installed on top,
open the construction plugs in the top of the controls to 12. Check that the reservoir is full. Remove charge pressure
assist in air bleed. gauge and cap port. The pump is now ready for opera-
tion.
5. Fill the reservoir with hydraulic fluid of the recom-
mended type and viscosity. Use a 10-micron filler filter. Troubleshooting
Ensure construction plug is closed after filling is com-
plete.
6. Disconnect the pump from all control input signals. HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE INTERNAL
PUMP COMPONENTS.
AFTER START-UP THE FLUID LEVEL IN THE RESERVOIR MAY DROP DUE TO
SYSTEM COMPONENTS FILLING DAMAGE TO HYDRAULIC COMPONENTS MAY
OCCUR IF THE FLUID SUPPLY RUNS OUT. ENSURE RESERVOIR REMAINS ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE
FULL OF FLUID DURING START-UP. SUFFICIENT FORCE TO PENETRATE YOUR SKIN CAUSING
SERIOUS INJURY AND/OR INFECTION AND MAY BE HOT
ENOUGH TO CAUSE BURNS. RELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES, FITTINGS, GAUGES,
AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAMAGE HYDRAU- OR COMPONENTS. SEEK IMMEDIATE MEDICAL ATTENTION
LIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS. IF YOU ARE CUT OR BURNED BY HYDRAULIC FLUID.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS. TAKE PRECAU-

DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REIN-
FLUID HAS BEEN THOROUGHLY FILTERED. STALLING SYSTEM COMPONENTS AND LINES
7. Use a common method to disable the engine to prevent

it from starting. Crank the starter for several seconds. Do
not to exceed the engine manufacturer’s recommenda-
tion. Wait 30 seconds and then crank the engine a sec-
ond time as stated above. This operation helps remove
air from the system lines. Refill the reservoir to recom-
mended full oil level.
8. When the gauge begins to register charge pressure,
enable and start engine. Let the engine run for a mini-
mum of 30 seconds at low idle to allow the air to work
itself out of the system. Check for leaks at all line connec-
5-114 3121142
Table 5-40. Electrical troubleshooting
Item Description Action

Control operates pump in one direction only Control coil failure. Measure resistance at coil pins. Resistance
should be 14.2W (24V) or 3.66W (12V) at 20° C
[70° F]. Replace coil.
No pump function No power to controller. Restore power to controller.
Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, recon-
nect wires.
Erratic or no machine function External controller malfunction or Verify external controller problem using spare
hydraulic system problem. controller. Replace controller. Check hydraulic
system fluid level/pressures/filters/etc. Fix
hydraulic system problems.
Table 5-41. Neutral difficult or impossible to find

Input to pump control Input to control module is operating Disconnect input and check to see if pump comes back to neu-
improperly. tral. If Yes, input fault, replace/repair external controller. If No,
go to next step.
Pump control neutral Neutral set improperly. Shunt servo gauge ports M4 and M5 together with external
hose and see if pump comes back to neutral. If Yes: control neu-
tral improperly set. If no: balance swashplate (see Mechanical
neutral adjustment). If you still cannot set neutral, replace con-
trol.
Table 5-42. System operating hot

Oil level in reservoir Insufficient hydraulic fluid will not meet cooling Fill reservoir to proper level.
demands of system.
Heat exchanger Heat exchanger not sufficiently cooling the system. Check air flow and input air temperature for heat
exchanger. Clean, repair or replace heat exchanger.
Charge pressure Low charge pressure will overwork system. Measure charge pressure. Inspect and adjust or
replace charge relief valve. Inspect charge pump.
Repair or replace charge pump.
Charge pump inlet vacuum High inlet vacuum will overwork system. A dirty fil- Check charge inlet vacuum. If high, inspect inlet filter
ter will increase the inlet vacuum. Inadequate line and replace as necessary. Check for adequate line
size will restrict flow. size, length or other restrictions.
System relief pressure settings If the system relief valves are worn, contaminated, or Verify settings of high pressure relief valves and
valve settings are too low, the relief valves will be replace valves as necessary.
overworked.
System pressure Frequent or long term operation over system relief Measure system pressure. If pressure is too high,
setting will create heat in system. reduce loads.
3121142 5-115
Table 5-43. System will not operate

Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level.
Control orifices Control orifices are blocked. Clean control orifices.
Control screens Control screens are blocked. Clean or replace control screens.
Charge pressure with pump in neutral Low charge pressure insufficient to recharge sys- Measure charge pressure with the pump in neu-
tem loop. tral. If pressure is low, go to next step.
Pump charge relief valve A pump charge relief valve that is leaky, contami- Adjust or replace pump charge relief valve as nec-
nated, or set too low will depressurize the sys- essary.
tem.
Charge pump inlet filter A clogged filter will under supply system loop. Inspect filter and replace if necessary.
Charge pump A malfunctioning charge pump will provide Repair or replace the charge pump.
insufficient charge flow.
System pressure Low system pressure does not provide enough Measure system pressure. Continue to next step.
power to move load.
Charge check / HPRVs Defective charge check / HPRVs cause system Repair or replace charge check / HPRVs.
pressure to be low.
Input to control Input to control module is operating improperly. Repair or replace control.
Optional control cutoff valve Control cutoff valve coil not energized. Ensure charge pressure to control via port X7. If
none, confirm control cutoff valve coil is ener-
gized. If still no pressure, repair or replace control
cutoff valve.
Table 5-44. System noise or vibration

Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump inlet vacuum Air in system decreases efficiency of units and con- Find location where air is entering into the system
trols. Air in system is indicated by excessive noise in and repair. Check that inlet line is not restricted and
pump, foaming in oil, and hot oil. is proper size.
Cold oil If oil is cold, it may be too viscous for proper function Allow the oil to warm up to its normal operating
and pump cavitates. temperature with engine at idle speed.
Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is proper
size. Check filter and bypass switch.
Shaft couplings A loose input shaft to prime mover coupling will Replace loose shaft coupling.
cause excessive noise.
Shaft alignment Misaligned input and prime mover shafts create Correct misalignment.
noise.
Charge/system relief valves Unusual noise may indicate sticking valves. Possible Clean/replace valves and test pump. May be a nor-
contamination. mal condition.
5-116 3121142
Table 5-45. Sluggish system response

Oil level in reservoir Low oil level will cause sluggish response. Fill reservoir.
Charge check / HPRVs Incorrect pressure settings will affect system Replace charge check / HPRVs.
reaction time.
Low prime mover speed Low engine speed will reduce system perfor- Adjust engine speed.
mance.
Charge and control pressures Incorrect pressures will affect system perfor- Measure and adjust charge and control pres-
mance. sures.
Air in system Air in system will produce sluggish system Fill tank to proper level. Cycle system slowly for
response. several minutes to remove air from system.
Contaminated control orifices Control orifices are plugged. Clean control orifices.
Contaminated control screens Control screens are plugged. Clean or replace control screens.
Pump inlet vacuum Inlet vacuum is too high resulting in reduced Measure charge inlet vacuum. Inspect line for
system pressure. proper sizing. Replace filter. Confirm proper
bypass operation.
3121142 5-117
Adjustments NOTE: Listed pressures assume a pump speed of 1800 min-1 (rpm)
and charge flow of 26.5 l/min [7 US gal/min]. At higher
pump speeds or higher charge flows the charge pressure
will rise over the rated setting.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR
WARRANTY. TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN 3. Loosen the locknut and rotate the adjusting screw
REMOVING AND REINSTALLING SYSTEM LINES clockwise to increase the setting; counterclockwise to
decrease it. Subtract the case pressure reading to com-
1. Thoroughly clean the outside of the pump. pute the actual charge pressure.
2. If removing the pump, tag each hydraulic line. When you NOTE: Pressure change per turn is dependent on charge flow
disconnect hydraulic lines, cap them and plug each entering pump.
open port to prevent contamination.
4. While holding the adjusting screw, torque locknut to 12
3. Ensure the surrounding area is clean and free of contam-
Nm [9 lbft].
inants like dirt and grime.
5. When you achieve the desired charge pressure setting,
4. Inspect the system for contamination.
remove the gauges and plug the ports.
5. Check the hydraulic fluid for signs of contamination: oil
discoloration, foam in the oil, sludge, or metal particles. DISPLACEMENT LIMITER ADJUSTMENT
6. If there are signs of contamination in the hydraulic fluid, 1. Mark servo cylinder location in case it rotates during dis-
replace all filters and drain the hydraulic system. Flush placement limiter adjustment.
the lines and refill the reservoir with the correct filtered
2. Loosen the locknut (E550).
hydraulic fluid.
7. Before reinstalling the pump, test for leaks.
CHARGE PRESSURE RELIEF VALVE.

1. Install a 50 bar [1000 psi] pressure gauge in charge pres-
sure gauge port M3. Install a 10 bar [100 psi] gauge at
case pressure port L1, L2, or L3. Operate the system with E450
4 mm
the pump in neutral (zero displacement) when measur-
ing charge pressure.
E550
2. The table below shows the acceptable pump charge 13 mm
pressure range for some nominal charge relief valve set- 23 N•m
tings (refer to model code located on serial number [17 lbf•ft]
plate). These pressures assume 1800 min-1 (rpm) pump
speed and a reservoir temperature of 50°C [120°F], and 3. Rotate the adjusting screw (E450) based on the follow-
are referenced to case pressure. ing table. Rotating the adjusting screw clockwise
decreases the maximum displacement of the pump
while rotating the adjusting screw counterclockwise
increases the maximum displacement.
Charge pressure gauge port M3

0 - 50 bar [0 - 1000 psi]
1/4 in
24 N•m [17 lbf•ft]
Locknut Case drain port L2

19 mm
12 N•m 0 - 10 bar [0 - 100 psi]
[9 lbf•ft] 9/16 in
115 N•m [85 lbf•ft]
Adjusting screw
5 mm
Figure 5-68. Charge Pressure Adjustment
5-118 3121142
4. After establishing the desired maximum displacement 3. Observe pressure gauges. If necessary, turn adjusting
setting, hold adjusting screw in place and tighten the screw to reduce any pressure differential.
locknut. Torque to 23 Nm [17 lbft]. C
NOTE: Adjustment of the EDC is very sensitive. Be sure to hold the
hex wrench steady while loosening the locknut. Total
adjustment is less than 120 degrees.
BE SURE SERVO CYLINDER DOES NOT ROTATE WHEN DISPLACEMENT LIM-
ITER LOCKNUT (E550) IS TORQUED. 4. Rotate the neutral adjusting screw clockwise until the
pressure increases on the gauge. Note the angular posi-
5. One turn of the adjusting screw will change the maxi- tion of the wrench. Then rotate the neutral adjusting
mum displacement approximately as follows. screw counterclockwise until the pressure increases by
an equal amount on the other gauge. Again note the
Table 5-46. Displacement Limiter Adjustment Data angular position of the wrench.
Approximate Solenoid shaft
displacement Control spool
Locknut wrench Adjusting screw
Displacement change per
size and torque size
revolution of
adjusting screw
45 13 mm 23 Nm [17 lbft] 4 mm internal hex 5.1 cc / turn
CONTROL NEUTRAL ADJUSTMENT

All functions of the Electric Displacement Control (EDC) are
preset at the factory. Adjust the pump to neutral with the
pump running on a test stand or on the vehicle/machine with
the prime mover operating. If adjustment fails to give satisfac-
tory results, you may need to replace the control or coils. Adjusting
screw
1. Install a 50 bar [1000 psi] gauge in each of the two servo (cam)
gauge ports (M4 and M5). Disconnect the external con- Feedback pin
trol input (electrical connections) from the control. Start Maximum

the prime mover and operate at normal speed. adjustment
less than 120°
2. Use a 4mm internal hex wrench to hold the neutral
adjusting screw stationary while loosening the locknut
with a 13mm wrench.
Illustration shows how eccentric cam on
adjusting screw rotates to adjust neutral.
Neutral adjusting screw

4 mm
Servo pressure gauge port M4
0 - 50 bar [0 - 1000 psi]
Locknut 3/16 in
13 mm 12 N•m [9 lbf•ft]
10 N•m
[7 lbf•ft]
Servo pressure gauge port M5 0 - 50 bar [0 - 1000 psi]
3/16 in
0 - 50 bar [0 - 1000 psi] 12 N•m [9 lbf•ft]
3/16 in
12 N•m [9 lbf•ft]

0 - 50 bar [0 - 1000 psi]
3/16 in
12 N•m [9 lbf•ft]
Figure 5-69. Control Neutral Adjustment
3121142 5-119
5. Rotate the neutral adjusting screw clockwise half the PUMP SETUP
distance between the wrench positions noted above.
The gauges should read the same pressure, indicating 1. Attach a 50 bar [1000 psi] gauge to each servo pressure
that the control is in its neutral position. port M4 and M5.
6. Hold the neutral adjusting screw stationary and tighten 2. Attach a 600 bar [10 000 psi] gauge to each system pres-
the lock nut. Torque to 10.Nm [7 lbft]. Do not over sure port (MA and MB for front pump, MC and MD for
torque the nut. rear pump).
7. When the neutral position is set, stop the prime mover, 3. Remove servo cylinder locking screws (E350) and plates
remove the gauges, and install the gauge port plugs. (E300) from both sides of the pump.
Reconnect the external control input. 4. Disconnect the control solenoids from the vehicle wir-
ing harness.
NOTE: A small pressure differential of 1.5 bar [22 psi] or less is
acceptable. Zero differential is usually not possible. 5. If using a PWM signal to set mechanical neutral, connect
the control solenoids C1 and C2 to the signal source.
MECHANICAL NEUTRAL ADJUSTMENT Ensure the source supplies no current to the solenoids
Mechanical neutral is set with the pump running at 1800 min until required in the following procedure.
(rpm). To set neutral, you must stroke the pump in each direc-
tion.
This procedure details setting neutral for the entire pump, one
side at a time. The procedure is the same for each side of each
pump so you will need to repeat it four times to set mechani-
cal neutral for both the front and rear sections. Alternate M4/
M5 and MA/MB to zero out forward and reverse directions of
the front unit, then move the gauges to M4/M5 of the rear unit
and MC/MD (system gauge ports for the rear unit). Refer to the
drawing that follows to identify all ports. The front and rear
sections are basically mirror images of each other. The control
solenoids C1 and C2 are marked on each control.
While performing this adjustment, you monitor the following
pressures.:
• Servo pressure at M4 and M5
• System pressure at MA and MB or MC and MD
• Pressure differential between M4 and M5 (optional)
• Pressure differential between A and B or C and D (optional)
5-120 3121142
System gauge port MC System gauge port MB

ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18
Rear servo gauge port M5 Front servo gauge port M4

Servo cylinder (4 pl.) ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
E300 Servo cylinder

locking clip
E350 Servo cylinder
locking screw
10mm
14.5 N•m [11 lbf•f t]
System port B
System port C
ISO 11926-1 - 1 5/16-12
ISO 11926-1 - 1 5/16-12
System port D
ISO 11926-1 - 1 5/16-12 System port MD
System port A ISO 11926-1 - 9/16-18
ISO 11926-1 - 1 5/16-12 System gauge port MA
ISO 11926-1 - 9/16-18
Rear servo gauge port M4 Front servo gauge port M5

ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
Figure 5-70. Servo and System Pressure Gauge Port Locations
3121142 5-121
SERVO ADJUSTMENT Removing The Pump

6. Run prime mover at 1800 min (rpm). Before working on the pump, thoroughly clean the outside. If
7. If using a PWM signal, ensure the signal is off. Check the the pump has an auxiliary pump attached, remove both
servo pressure gauges. Ensure the differential between pumps as a single unit. Tag and cap all hydraulic lines as you
M4 and M5 is less than 1.5 bar [22 psi]. disconnect them, and plug all open ports to ensure that dirt
and contamination do not get into the system.
8. Using a 3/4 in deep socket, unthread both servo cylin-
ders 2-3 turns. This step ensures the servo cylinders have
no contact with the servo piston.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS. TAKE PRECAU-
9. Stroke the pump by turning the control eccentric screw TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND INSTALL-
(or supplying current to solenoid C1) until the servo ING SYSTEM LINES.
pressure at port M4 is 1 to 2 bar [14 -29 psi] greater than
at port M5 and the system pressure gauges indicate dis- 1. Thoroughly clean all dirt and grime from the outside of
placement. Pressure should be greater at port MA for the pump.
clockwise rotation, or MB for counterclockwise rotation.
This also indicates the servo piston is in contact with the 2. Tag, disconnect, and cap each hydraulic line connected
servo cylinder on side M5. to the pump. As hydraulic lines are disconnected, plug
each open port, to ensure that dirt and contamination
10. Slowly thread the servo cylinder on the M5 side in until do not get into the pump.
the system pressure differential starts to decrease. Main-
tain servo pressure differential between 1-2 bar [14-29 3. Remove the pump and its auxiliary pump (if applicable)
psi] during this step. Continue turning the servo cylinder as a single unit.
in until the system pressure differential (between ports NOTE: Be careful, do not damage solenoids and electrical connec-
MA/MB or MC/MD) is less than 1.5 bar [22 psi]. This pro- tions when using straps or chains to support the pump.
cedure sets the servo and swashplate to mechanical
neutral on the M5 side.
Inspection
11. To complete setting neutral, repeat steps 1-5 but stroke
the pump in the opposite direction by turning the 1. Ensure the work surface and surrounding area are clean
eccentric screw in the opposite direction, or by supply- and free of contaminants such as dirt and grime.
ing current to solenoid C2. Reverse gauge locations (M4 2. Inspect the system for contamination.
for M5, MB for MA etc.) from those stated above since
the pump is now stroking the other direction. 3. Look at the hydraulic fluid for signs of system contami-
nation, oil discoloration, foam in the oil, sludge, or metal
12. Set neutral for the rear pump by repeating steps 1-6 on particles.
the rear pump. Remember that the rear pump is a mirror
image of the front pump and therefore the locations of Replacement
the servo gauge ports (M4/M5) and the control sole-
noids (C1/C2) are opposite. 1. Before replacing the pump, replace all filters and drain
the hydraulic system. Flush the system lines and fill the
13. Remove all gauges and replace gauge port plugs.
reservoir with the correct, filtered hydraulic fluid.
2. Fill the pump with clean, filtered hydraulic fluid.
3. Attach the pump to the prime mover. Torque mounting
screws according to the manufacturers recommenda-
tion.
4. Replace all hydraulic lines. Ensure the charge inlet line is
filled with fluid.
5-122 3121142
Electric Control Module REASSEMBLY

NOTE: Ensure you install dowel pins (D300) in housing before
REMOVAL installing control.
Refer to exploded diagram, next page.
1. Using a 5 mm internal hex wrench, remove the six cap 1. Install a new gasket (D150).
screws (D250). 2. If you removed screen (D084), install a new one. Install
2. Remove the control module and gasket (D150). Discard with the mesh facing outward.
the gasket. D084
D084
3. If necessary, remove orifices (F100) using a 3 mm inter-

nal hex wrench. Tag and number them for reinstallation. Incorrect screen
Correct screen
orientation orientation
4. Inspection
5. Inspect the machined surfaces on the control and top of
the pump. If you find any nicks or scratches, replace the
component. 3. If previously removed, install orifices (F100) using a 3
mm internal hex wrench. Torque to 2.5 Nm [1.8 lbft].
NOTE: Remove plug on top of control to ensure the swashplate
feedback pin is properly positioned in the center of the con- 4. Install the control module and six cap screws (D250).
trol module when installing control. 5. Using a 5 mm internal hex wrench, torque the cap
screws (D250) to 13.5 Nm [10.lbft].
D050 (3X)
4 mm
5 N•m [4 lbf•f t] D1
D025A D250
5 mm
13.5 N•m
[10 lbf•ft]
D025A D050 (3X)

D084 4 mm
5 N•m
Torque sequence
[4 lbf•ft]
2 1 D150
6 5 F100 (2X)
3 mm
2.5 N•m
4 3 [1.8 lbf•ft]
D300 (2X)
Figure 5-71. Control Module And Solenoid Removal/installation
3121142 5-123
CONTROL SOLENOIDS REMOVAL Shaft, Seal, and Bearing

1. Disconnect electrical connection and remove the three The front pump input shaft assembly is serviceable without
cap screws (D050) using a 4.mm internal hex wrench. disassembling the pump, the rear shaft is not. Orient the
2. Remove the solenoid (D025) and O-ring (D025A). Dis- pump on the work surface so the shaft is pointing to the side.
card the O-ring.
REMOVAL
3. If necessary, remove the coil using a 12 point 26 mm
socket. 1. Unwind the spiral ring (J300) from the housing to
release the shaft/seal/bearing subassembly.
CONTROL SOLENOIDS INSPECTION 2. Pry on the lip of the seal carrier (J275) to remove it from
1. Inspect the machined surface on the control. If you find the pump. Remove the seal carrier. Remove and discard
any nicks or scratches, replace the component. O-ring (J260). Press the seal (J250) out of the carrier and
discard.
CONTROL SOLENOIDS REASSEMBLY 3. Pull the shaft (J100) with bearing (J150) out of the
1. Lubricate new O-ring (D025A) using petroleum jelly and pump. If necessary, tap lightly on the shaft to dislodge it
install. from the cylinder block. C
2. Install solenoid with three cap screws (D050) using a 4

mm internal hex wrench. Torque screws to 5 Nm [4 lbft].
DO NOT DAMAGE THE HOUSING BORE, SHAFT OR BEARING WHEN REMOV-
3. Install coil using a 12 point 26 mm socket. Torque coil ING THE SHAFT AND BEARING.
nut to 5 Nm [3.7 lbft].
4. Reconnect electrical connections and test the pump for 4. Remove the retaining ring (J200) using retaining ring
proper operation. pliers. Press the bearing off the shaft.
Protective
sleeve
J100
J150
J200
J250
J260
J150
J275
J300
Figure 5-72. Shaft Assembly
5-124 3121142
INSPECTION Charge Pump

1. Inspect the shaft journals for wear, scratching, and pits. Position pump with front shaft pointing downward. Attach
Check the splines for fretting; replace if damaged. securely to a proper work stand. If an auxiliary pump is
Rotate the bearing, if it does not rotate smoothly, attached, remove auxiliary pump before servicing charge
replace it. pump.
REASSEMBLY REMOVAL
1. Press the bearing (J150) onto the shaft (J100) and 1. Remove screws (K351), and hangers (K975).
replace the retaining ring (J200). Ensure the retaining
ring diameter is less than 38.84 mm [1.53.in] when 2. Remove running cover (K301). Remove and discard seal
installed on the shaft. ring (K250).
2. Install the shaft/bearing assembly into the pump. 3. Using a 10 mm internal hex, remove screws (K400).
Remove cover (K101).
3. Lubricate and install a new O-ring (J260) onto seal car-
rier (J275). Press a new seal (J250) into the seal carrier. 4. Remove charge pump assembly with shaft.
Press the seal until it is flush within +0.12mm [0.005 in]
NOTE: Note position of alignment pin (S500) in housing. Align-
or -0.72 mm [0.0028 in] of the inside lip of the carrier: see
ment pin position will change for clockwise or counter-
illustration.
clockwise rotation.
Press ?ush to this sur face
+0.12 mm [ 0.005 in] / -0.72 mm [ 0.028 in] 5. Remove and discard seal (S300).
6. Using a snap ring pliers, remove two clips (K205).
Seal
7. Remove geroter cover (S200). Remove geroter assembly
(S100).
4. Cover the shaft with a protective sleeve while installing
the seal carrier. Hand press the seal carrier into the hous- 8. Remove and discard gasket (K151). Remove alignment
ing. Ensure the seal carrier clears the spiral ring groove pins (K450).
in the housing. Remove the protective sleeve.
9. If it is necessary to remove housing (K300), use a 10 mm
5. Wind the spiral ring into the housing. Ensure the inside internal hex to remove screws (K350).
diameter of the spiral ring is greater than 68 mm [2.677
10. Remove housing (K300).
in] after installation.
11. Remove and discard seal (K150).
INSPECTION
1. Inspect all machined surfaces. If you find any nicks or
scratches, replace the component.
2. Inspect geroter and cover for wear or damage. If wear or
damage is found, replace geroter kit.
3. Inspect shaft for wear or damage. If found, replace shaft.
4. Inspect journal bearings in aux pad and housing. If worn
or damaged, replace journal bearings or aux pad or
housing assembly.
3121142 5-125
Figure 5-73. Charge Pump
5-126 3121142
REPLACING CHARGE PUMP JOURNAL BEARINGS 10. Install screws (K351) and brackets (K975). Torque screws
Use a suitable press to remove and replace the journal bear- per listing in the table.
ings. Refer to the drawings below for installation dimensions.
Charge Check / HPRV
The high pressure relief and charge check valve assembly may
be removed for cleaning and replacement of the O-rings.
These valves are factory set and are not field adjustable. Refer
to the pump model code for the factory setting when ordering
replacements.
REMOVAL
1. Using an 8 mm internal hex wrench, remove the valve
seat plugs (K007).
ASSEMBLY 2. Carefully lift the valve (H002) and spring (H003) assem-
blies from the center section using a magnet.
1. Lubricate and install new seal (K150).
2. Install housing (K300). Install screws (K350). Using a 10 INSPECTION
mm internal hex, torque screws per listing in table. 1. Inspect the valves and mating seats in the valve seat
3. Install alignment pins (K450). Install new gasket (K151). plugs (K007) for damage or foreign material.
4. Lubricate and reassemble charge pump assembly [shaft REASSEMBLY

(K201), pin (S500), geroter (S100), cover (S200), two clips
(K205)]. 1. Lubricate and install new O-rings (K008, K010) and
backup ring (K009) on valve seat plug (K007).
5. Install charge pump assembly into housing in original
position. 2. Verify that the conical springs (H003) are properly
retained on the check relief valves (H002). Install the
6. Lubricate and install seal (S300). valve assemblies into the center section. Ensure each
7. Install aux pad (K101). valve assembly moves freely in its bore.
8. Using a 10 mm internal hex, install screws (K400). Torque 3. Install the valve seat plugs into the center section and
screws per listing in table. torque to 80 Nm [59.lbft].
9. Lubricate and install seal (K250). Install running cover 4. Operate machine through full range of controls to
(K301). ensure proper operation. Check for leaks.
Figure 5-74. Charge Check / HPRV
3121142 5-127
Figure 5-75. Charge Check / HPRV
Charge Pressure Relief Valve REASSEMBLY
Replace the charge pressure relief valve (V10-1) or (V10-2) as a 1. Lubricate and install new O-rings (V10A).
complete unit. Do not attempt to repair the internal compo- 2. Install the charge pressure relief valve (V10). Torque to
nents of the valve. 52 Nm [38 lbft].
REMOVAL 3. Operate vehicle/machine through full range of controls
to ensure proper operation.
1. Using a 27 mm (V10-1) or a 1 in (V10-2) wrench, remove
the charge pressure relief valve. Discard the O-rings
(V10A).
INSPECTION
1. Inspect the sealing surfaces of the pump and charge
pressure relief valve for nicks or scratches, replace com-
ponents as necessary.
5-128 3121142
Figure 5-76. Charge Pressure Relief Valve
Control Cutoff Valve REASSEMBLY
Replace the control cutoff valve as a complete unit. Do not 1. Lubricate and install new O-rings (G10A) onto the valve.
attempt to repair the internal components of the valve. 2. Install the control cutoff valve (G10). Torque to 46 Nm
[34 lbft]. Slide the coil (G20) onto the valve.
REMOVAL
3. Install the coil nut (G30). Torque to 9 Nm [7.lbft]. Do not
1. Disconnect the coil from the vehicle/machine wire har- overtorque.
ness.
4. Operate vehicle/machine through full range of controls
2. Using a 24 mm hex wrench, remove the control cutoff to ensure proper operation
valve coil nut (G30). Remove the coil (G20).
3. Use a 1 1/16 in hex wrench to remove the control cutoff
valve (G10). Remove and discard the O-rings and backup
rings (G10A).
INSPECTION
1. Inspect the sealing surfaces of the pump and control
cutoff valve for nicks or scratches. Replace components
as necessary.
3121142 5-129
Figure 5-77. Control Cutoff Valve
Table 5-47. Fastener Size and Torque Chart
Item Fastener Wrench size Torque

D015 Neutral adjust screw 4 mm internal hex NA
D050 Control coil mounting screw 4 mm internal hex 8 Nm [5.9 lbft]
D060 Neutral adjust locking nut 13 mm hex 10 Nm [7 lbft]
D200 Swash plate feedback pin (not shown) 13 mm hex 25 Nm [18.4 lbft]
D250 Electric control mounting screw 5 mm internal hex 13 Nm [9.5 lbft]
E350 Servo cylinder locking screw 10 mm hex 14.5 Nm [11 lbft]
G10 Control cutoff valve 1 1/16 in hex 45 Nm [33 lbft]
G10B Control cutoff valve coil nut 24 mm hex 9 Nm [7 lbft]
K007 Charge check / HPRV 8 mm internal hex 80 Nm [60 lbft]
K350 A pad cover mounting screw 17 mm hex 70 Nm [52 lbft]
B pad cover mounting screw 8 mm hex 111 Nm [82 lbft]
V10-1 Charge relief valve 27 mm hex 52 Nm [38 lbft]
V10-2 Charge relief valve 1 in hex 52 Nm [38 lbft]
Table 5-48. Plug Size and Torque Chart
Item O-ring plug Wrench size Torque

B015 7/16 - 20 3/16 internal hex 20 Nm [15 lbft]
B020 1-1/16 - 12 9/16 internal hex 48 Nm [35 lbft]
D065 7/16 - 20 3/16 internal hex 12 Nm [9 lbft]
G250 9/16 - 18 1/4 internal hex (hardened plug) 45 Nm [33 lbft]
5-130 3121142
Figure 5-78. Fastener and Plug Locations
3121142 5-131
5.9 FUNCTION PUMP (SAUER) 6. Remove the bearing cup (B010), bearing cone (B020)
and housing O-ring (K060). Discard the O-ring.
Disassembly 7. Tilt the housing on its side to allow fluid to drain.
1. Remove the control from the endcap by removing the 4 8. Remove the cylinder block kit while holding onto the
control bolts (C300), using a 4 mm internal hex wrench. front shaft.
C200
s K041
C300
I4 mm
2. Remove and discard the 4 O-rings (C200). P101 368
3. Remove the 4 endcap screws (J030) using a 10 mm 9. Set cylinder block on a clean dry surface.
internal hex wrench.
10. Rotate pump back to a position so that the shaft is
J030 pointing down.
10 mm 11. Pull the shaft (J010) from the shaft seal.
J020
pJ010 P020
B090
B010 B025
B020 B044
B040
K060
B043 K030
E101 17 E101 176
4. Carefully remove the endcap (J020). Prevent the valve 12. Compress the bias spring (B025) and rotate the servo
(B090) plate from falling off. piston assembly (P020) towards the swashplate (B040).
5. Place the endcap and valve plate in a clean area, pro- 13. Lift the swashplate/servo piston assembly up at an
tecting them from contamination. angle and remove it from the housing.
5-132 3121142
14. Remove the servo piston (P020) and bias spring (B025) rings. Remove the 2 set screws (C102). Remove the
from the swashplate by removing the clevis pin (B043) spools (C112, C132). Note which bore each spool came
and snap ring (B044). Discard the snap ring. out of. Also note the orientation of each spool for rein-
sertion. There may be differences in reinserting into the
15. Pull to remove the front tapered roller bearing cup
same bore.
(B060) and cone (B070).
C104
B071
C104A
C103
C103A
C112
R C132
pB070
C105
pB060
C106A C106 C105A
C113
E101 178
C102
C115
C133 C114
16. Examine the cradle bearings (B030) to determine if they C117
need replacement. C135
C116
NOTE: Removing the pins (B071) will likely damage the cradle
bearings, so make sure you have replacement bearings C134 C117 d
before you remove them. C118
dC138A
17. If cradle bearings need replacing, remove the 2 pins
C138 E101 180
(B071) holding the cradle bearings, and then remove the
cradle bearings. Note the location and orientation of the
22. Remove the adjusting screw (C138) and the O-ring
bearings for re-installation.
(C138A). Discard the O-ring. Remove the springs (C134,
18. Orient the housing with the flange facing up. C135) and spring guide (C133).
19. Using snap-ring pliers, remove the snap ring (K010). 23. Remove the adjusting screw (C118), O-ring (C116) and 2
backup rings (C117). Discard the O-ring and backup
K010 rings. Remove the springs (C114, C115) and spring guide
(C113).
K020
24. Pull to remove the slipper retainer (K049) with the pis-
tons (K050) from the cylinder kit.
20. Carefully pry out the shaft seal (K020).
If you are unable to pull the shaft seal out, try to push
the seal out by going through the inside of the housing.
21. Remove the 4 plugs (C103, C104, C105, C106) and their
O-rings (C103A, C104A, C105A, C106A). Discard the O-
3121142 5-133
NOTE: The pistons are not selectively fitted, however units with pressed air. Conduct inspection in a clean area and keep all
high hourly usage may develop wear patterns. Number the parts free from contamination. Clean and dry parts again after
pistons and bores for reassembly if they are to be reused. any rework or resurfacing.
PISTONS AND SLIPPERS

K050 Inspect the pistons for damage and discoloration. Discolored
pistons may indicate excessive heat; do not reuse.
K049 Inspect the running surface of the slippers. Replace any piston
assemblies with scored or excessively rounded slipper edges.
K047 Measure the slipper foot thickness. Replace any piston assem-
blies with excessively worn slippers. Check the slipper axial
end-play. Replace any piston assemblies with excessive end-
K046 play.
P010 Maximum end play
K041
Minimum Slipper
slipper foot
K042 thickness
K050
K043
K044
Minimum slipper foot thickness and maximum axial end-play
K045
are given in the table below.
J Frame
25. Remove the ball guide (K047).
Slipperfoot thickness 3.23 mm
26. Remove the 3 pins (K046).
[0.127 in]
NOTE: Most repairs do not require block spring removal. Perform Piston/slipper end play 0.05 mm
this procedure only if you suspect problems with the block [0.002 in]
spring.
27. Turn the block over. Using a press, apply pressure on the BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN
block spring washer (K044) to compress the block spring PINS
(K043). Compress the spring enough to safely remove The ball guide should be free of nicks and scratches, and
the spiral retaining ring (K045). While maintaining pres- should not be excessively scored. Examine for discoloration
sure, unwind the spiral retaining ring. Carefully release that may indicate excessive heat or lack of lubrication. The slip-
the pressure and remove the outer block spring washer, per retainer should be flat, and slippers should fit in the
block spring, and inner block spring washer (K042) from retainer with minimal side play. Place the hold-down pins on a
the cylinder block. flat surface and roll them to make sure they are straight. Dis-
card and replace any damaged parts.
Slipper
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK retainer
SPRING REQUIRES ABOUT 350 TO 400 N [80 TO 90.LBF ].
USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH
REASONABLE EFFORT. ENSURE THE SPRING IS SECURE
BEFORE ATTEMPTING TO REMOVE. THE SPIRAL RETAINING Ball guide
R I N G. R EL E A S E T H E P RE S S U RE S L O W L Y A F T E R T H E
RETAINING.RING IS REMOVED.
Hold down pins
Inspection
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 com-
5-134 3121142
BLOCK SPRING, AND WASHERS for scratches and / or burrs. Clean and coat all spools, bores,
If cylinder kit was fully dissembled, visual inspection of the cyl- and seals with a light coating of hydraulic oil.
inder block, spring, and washers should indicate minimal wear. C104
Replace if cracks or other damage is present.
C103
C104A
C103A
Washer
C112i
C132
Cylinder block spring
Spring retainer
C105
Retaining ring C106A
C105A
C106
CYLINDER BLOCK
C113
Examine the running face of the cylinder block. The surface C102
should be smooth and free of nicks and burrs. Ensure that no C115
scratches or grooves exist; these may drastically reduce output
C133 C114
flow.
B C117
C135
C116
K041 C117
C134
C118
A C138A
C138
?at to 0.002 mm
[0.000079 in]
INPUT SHAFT
Check to see that the shaft (J010) and its splines are straight
J Frame 45-60 cc 65-75 cc and free of damage or heavy wear. Inspect the shaft surface
where it meets the shaft seal. Replace the shaft if a groove
Minimum cylinder block height (A) 62.25 mm exists at the sealing land surface that may let dirt into or
[2.45 in] hydraulic fluid out of the unit. Clean the sealing area with a
Maximum block bore diameter (B) 19.8 mm 21.57 mm nonabrasive material if necessary. Lubricate the shaft with a
[0.785 in] [0.85 in] light coat of hydraulic fluid.
J010
CONTROL
Carefully examine the plug(s) for signs of wear. Also check the
small tip of the plug(s) for heavy wear and replace if necessary.
Inspect each spool’s springs to make sure they are intact.
Check the inside and outside surfaces of the springs for wear
and replace if necessary. Check the spool’s outside diameter
3121142 5-135
SWASHPLATE Measure the thickness of the valve plate. Ensure that valve
Carefully inspect each surface of the swashplate for wear. All plate parallelism is equal to or less than 0.025 mm [0.001 in].
swashplate surfaces should be smooth. Inspect the swash- Appearance should be flat and smooth on both the running
plate’s slipper running surface for damage and brass transfer. face and the bottom surface. The valve plate should be flat to
Excessive brass transfer from slippers may indicate that the 0.005 mm [0.0002.in] convex. A magnetic particle inspection is
slippers should be replaced. Finally, check the swashplate recommended to detect cracks. The valve plate must be
bearing journal for scratches. Replace swashplate if necessary. replaced if any cracks exist.
3.88 mm [0.153 in] min.
B040
B090 0.025 mm
[0.001 in]
0.005 mm
JOURNAL BEARINGS [0.0002 in]
convex max
Inspect the journal bearings for damage or excessive wear.
Replace journal bearings if scratched, warped, or excessively
worn. The polymer wear layer must be smooth and intact.
ENDCAP
Inspect the endcap. Remove the check valve (B092) to expose
B030 the spring (B091). Check and record orientation of the timing
pin (J050) The split in the timing pin should be facing into or
out of the slot in the valve plate. Inspect the check valve for
wear on its sealing face and replace if necessary. Make sure the
spring is undamaged. Replace any components if excess wear
VALVE PLATE is present.
Inspect the valve plate for scratches and grooves. Check the
plate for evidence of any cavitation along the running face of
the valve plate. If pitting from cavitation exists, replace the
valve plate. Check for excess wear on the brass running face. If
any discoloration or burn marks are observed, replace the
valve plate.
Run a fingernail or pencil tip across the diameter of the sealing
J050
land surface (see illustration). No deep or outstanding grooves
should be felt, as these may decrease pump flow. Lap or
replace if grooves or nicks are present. Inspect the mating sur-
faces of the endcap and valve plate for any possible contami-
nation; even a few thousandths of an inch may affect pump
operation. B091
B092
SERVO PISTON
Check the servo piston assembly (P020) for any obvious wear
or damage. Check the corresponding endcap bore for galling
or excessive wear. Discard the piston if damaged. Replace the
servo piston-rings.
P020
5-136 3121142
HOUSING NOTE: If journal bearings are reused, reinstall them in their origi-
Inspect the housing to ensure that it is clean and free of for- nal orientation and position.
eign material. Inspect the swashplate bearing surfaces, and
endcap mating surfaces.
P020
J010
B025
lB040
B044
SHAFT BEARING KITS

The tapered roller bearing kit consists of a cup and cone. Make B071
sure the cup and cone are free of excessive wear or contamina- B043
tion. Rotate the bearings to check for smoothness. If a contam-
inated bearing is suspected, clean with a solvent and lubricate
with hydraulic fluid.
NOTE: Replace the bearing if the problem is not remedied by lB030

cleaning.
Inspect for uneven wear. If abnormal wear is found, replace the B070
bearing kit.
B060
Assembly
1. Coat the journal bearings (B030) with hydraulic fluid and
install them into the pump housing. Punch in retaining
pins (B071) a minimum of 0.5 mm [0.002 in] below the
bearing surface.
2. Reinstall shaft bearing cup (B060) and cone (B070).

Before replacing the bias spring (B025), coat the curved
surface of the swashplate with hydraulic fluid.
3121142 5-137
3. Reinstall the swashplate/servo piston/bias spring 8. Install the pistons (K050) to the slipper retainer (K049).
assembly in its original orientation in the housing. Install the piston/retainer assembly into the cylinder
Rotate the servo piston perpendicular to the swash- block. Ensure the concave surface of the retainer seats
plate, and at the same time compress the bias spring to on the ball guide. If you’re reusing the pistons, install
fit into housing pocket. Lubricate all sides of the servo them to the original block bores. Lubricate the pistons,
piston and its respective bore liberally with hydraulic oil. slippers, retainer, and ball guide before assembly. Set
Also, lubricate the flat face of the swashplate to prevent the cylinder kit aside on a clean surface until needed.
premature wear during start-up.
NOTE: Be sure to install the slipper retainer so it mates correctly
4. Insert the input shaft (J010) through the bearing into with the ball guide (concave side of the slipper retainer
the housing. You may need to push on the servo piston against the convex side of the ball guide).
to rotate the swashplate in order to put the shaft in
properly. 9. Set the pump on its side. Secure the end of the shaft
with one hand and keep it horizontal. Insert the cylinder
5. Coat all parts with hydraulic fluid prior to reassembly.
kit onto the shaft. While holding the shaft still, slightly
rotate the cylinder block kit to help start the shaft
splines over the ball guide and align it with the block
COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 350 splines. When the cylinder block kit slides completely
TO 400 N [80 TO 90 LBF ]. USE A PRESS SUFFICIENT TO over the shaft splines, reposition the unit with the flange
MAINTAIN THIS FORCE WITH REASONABLE EFFOR T. facing downward.
ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO Fix the shaft
INSTALL.THE SPIRAL RETAINING RING. RELEASE THE PRES- on this end
SURE SLOWLY AFTER THE RETAINING RING IS INSTALLED.
6. Install the inner block spring washer (K042), block spring
(K043), and outer washer (K044) into the cylinder block.
Using a press, compress the block spring enough to
expose the retaining ring groove. Wind the spiral retain- Slightly rotate
ing ring (K045) into the groove in the cylinder block. cylinder block
K050
K049
K047
K046
P010
K041
K042
K043
K044
K045
7. Turn the block over and install the hold-down pins

(K046), and ball guide (K047) to the cylinder block.
5-138 3121142
10. Clean the valve plate (B090) and endcap. Install the tim- 11. Install the bearing cone (B020) onto the shaft. Using
ing pin (J050) in the endcap and verify that it is properly assembly grease to hold the seal (K060), install the end-
oriented with the split facing into or out of the slot in the cap to the housing. Ensure that seals remain properly
valve plate. The timing pin should be installed to 3.61 ? seated and are not pinched during assembly. With a 10
0.25.mm [0.14.?.0.01 in] above the valve plate surface. mm internal hex wrench, install and torque endcap
Apply a liberal amount of assembly grease to the back- screws at 127 to 155 Nm [94.to.114.lbft], using the criss
side of the valve plate surface to hold it in position. cross pattern. Retorque the first screw to ensure proper
Install the valve plate over the timing pin, check valve torque retention.
(B092), and bearing cup (B010).
J030
B090 10 mm
127 to 155 N·m
[94 to 114 lbf·ft]
J050
B092 J020
B010
B091
B020
K060
NOTE: To insure proper pump operation, it is extremely important

to ensure that there is no contamination between the end-
cap and valve plate.
12. Lubricate the lip of the new shaft seal (K020) with clean
hydraulic fluid. Place a protective sleeve over the shaft
end to prevent damage to the seal during installation.
Keeping the seal perpendicular to the shaft, press the
new seal into the housing just far enough to clear the
retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal dur-
ing installation. Using the appropriate snap ring pliers,
install the seal retaining ring (K010). Remove the instal-
lation sleeve.
3121142 5-139
15. Hold the control in a horizontal position. Install the

K010 spherical end of the LS spool (C112) into the LS bore (see
illustration). Using a new O-ring, install the LS plug
K020 (C104), torque at 10.8 to 13.5 Nm [8 to 10 lbft]. Place the
2 LS springs (C114, C115) onto the LS spring guide
(C113) and install into the LS bore. Place a new O-ring
(C116) and Backup rings (C117) onto the LS adjustment
screw (C118). Install the LS plug assembly so that it sits
one turn below the surface of the control housing.
Install and tighten set screw (C102) at 7.5 to 10.8 Nm
[5.5.to 8.0 lbft]. Also, install the plugs (C105, C106) with
new O-rings. Torque the plugs at 10.8 to 13.5 Nm [8 to
10 lbft].
C103 C104
C103A C104A
13. Clean all control parts and cover with a light coating of
hydraulic fluid prior to reassembly. C132 C112
14. Install the spherical end of the PC spool (C132) into the
PC bore (refer to illustration). Install the PC plug (C103) C105
using a new O-ring (C103A). Torque at 10.8 to 13.5 Nm
[8.to.10.lbft]. Place the two PC springs (C134, C135) onto C106A
the PC spring guide (C133) and install into the PC bore.
C105A
Place a new O-ring onto the PC plug and install it so that C106
it sits one turn below the surface of the control housing.
Install and tighten set screw (C102) at 7.5 to 10.8 Nm [5.5
to 8.0 lbft] to retain the adjusting plug. C113
C102
10.8 to 13.5 N•m C115
[8.0 to 10.0 lbf•f
t]
C133 C114
C103
C103A C117
C135
C116
C132
C134 C117
C118
C136
7.5 to 10.8 N•m
C138
[5.5 to 8.0 lbf•f
t]
C102
NOTE: PC and LS spools need to be adjusted to proper setting
according to tag nomenclature.
C133
C135
C134
C136
C138
5-140 3121142
16. Using petroleum jelly to retain them, install 4 new seal PROCEDURE
rings (C200) in the recesses on the control housing.
Install the control assembly onto the endcap using the 4 1. Clamp the unit.
screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 lbft]
using a criss cross pattern and retorque the first screw to Clamp the unit in a vice from the flange side.
ensure proper torque retention.
Make sure the vice jaws are clean and have smooth sur-
faces to prevent damage to the pump.
5.4 to 7.5 N• m C200

[4 to 5.5 lbf•f
t]
4 mm
C300
5.10 GEAR PUMP (SAUER)

Disassembly NOTE: Clamping the pump on the body is not recommended
because serious damage to the surfaces, on which the
Prior to proceeding it may be necessary to prepare some sub- ports are located, may occur.
assemblies separately.
2. Remove capscrews. (Except Units with 03 Flange).
The details for preparing each subassembly are given in the
following section.
Use a 17 mm socket wrench and loosen the four cap-
Also, some general recommendations are given below. screws on the cover. Next completely unscrew the cap-
screws and remove them.
CLEANLINESS
Cleanliness is a primary factor for reliable pump performance. Inspect the threads of the capscrews for damage.
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 adequate.
LUBRICATION OF MOVING PARTS

During assembly, it is imperative to provide lubrication with
clean hydraulic oil to all the running parts of the pump.
It is also necessary to coat the seals with grease. The absence
of lubrication during assembly can cause the unit to seize after
a few minutes of running.
CARE OF SURFACE TREATMENT

Be careful when handling all the internal surfaces, especially
bearings, gears, and body faces. Do not touch or score them
with metal tools or cutting edges.
MARKING THE PARTS

Mark the parts before completely disassembling a pump. The
marks allow components to be reassembled in the same rela-
tive position. This action should be applied to the body, bear-
ings, and gears. Scribing, bluing, or using a felt tip pen to mark
the outside of the body on the inlet side is suggested to indi-
cate the relative position of the front flange and the rear cover
to the body. Mark the bearing blocks also on the inlet side and
the gears position relative to each other. DO NOT scribe inter-
nal surfaces.
3121142 5-141
3. Remove socket head capscrews. (03 Flange or Multiple 4. Remove front flange.
Pump Stages Only).
Place the pump on the table and slowly remove the
Using a 4 mm internal hex wrench, loosen and remove front flange.
the two small socket screws placed in the center of the
cover. Repeat the same operation for the corresponding Be careful not to damage the shaft seal when removing
screws on the rear flange. the flange. Avoid contact of the shaft seal lips with key-
way edges (in tapered and parallel shafts) or splined
shaft teeth.
Inspect the front flange and seal area.
Clean with shop solvent, dry, and set aside.
5. Remove rear cover.
Remover rear cover. Clean with shop solvent, dry, and

set aside. Visually inspect rear cover and seal area.
5-142 3121142
6. Remove bearing blocks and gears. 8. Remove Outer O-Ring Seal
Place the pump on its side and carefully remove the Check the quality of this seal. If necessary, replace it. Fol-
bearing block and gear set. To accomplish this, hold the low the same removal recommenda?tions given in step
pump body and push with your fingers on the rear bear- 7.
ing block.
After removal, discard the damaged seal.
Mark the relative positions of the gear mesh (drive gear
tooth to idler gear tooth) and the bearing blocks to the Do not use tools with sharp edges to remove the seals,
body so they can be reassembled in the same position. as damage to the cover can result.
7. Remove pressure seals. 9. Remove the snap ring.
Check the seal quality. Replacement is recommended Place the flange on the work surface. Using internal snap
whenever there are burrs, evidence of extrusion, or ring pliers, remove the snap ring.
marks caused by overheating. If the seals need to be
replaced, carefully remove them from the flange cover,
beginning with the backup ring and then the pressure
seal.
Do not use tools with sharp edges to remove the seals,

as damage to the cover can result.
After removal, dispose of damaged seals.
3121142 5-143
10. Remove the shaft seal. 2. Install shaft seal into front flange.
Check the shaft seal quality and remove if necessary. Prepare the flange and shaft seal by lightly lubricating
with grease.
To remove, pry the bottom of the shaft seal and force it
out while rotating the flange to lift it out evenly. Seat the seal in the flange by hand. Then, using the shaft
seal installation tool, press the seal until the tool stops
Do not use the flange pilot to gain leverage, damage on the flange. This will insure the seal is inserted to the
may result. Use a plastic rod or wooden dowel as a ful- proper depth.
crum.
After removal, dispose of damaged seal.
3. Install snap ring.
Install the snap ring using internal snap ring pliers.

Ensure the snap ring fits securely in its groove. This is
Assembly necessary to retain the shaft seal.
1. Prepare the seals.
Have the entire seal kit available.
Lightly coat all seals with seal grease. The grease is

needed to adhere the seals to their grooves.
Do not install dry seals.
5-144 3121142
4. Install pressure seals. 6. Install outer seal.
Prepare the pressure seals by lightly lubricating them Prepare the outer seal by lightly lubricating with grease.
with grease.
Install outer seals in the grooves on both sides of the
Install pressure seals into the grooves on the front flange body.
and rear cover. Then install the teflon backup ring.
Ensure that the seals are located in the grooves, as

shown.
5. Prepare the body.
Clean the body.
Inspect the internal and mating surfaces. Ensure the sur-

faces are free of burrs and scratches. Check both the
bearing block mating surface and the cut-in path. The
cut-in path should be no deeper than 0.1 mm (0.004 in).
3121142 5-145
7. Prepare the gears. 8. Prepare the bearing blocks.
Clean the two bearing blocks.

THE GEAR SURFACES ARE SUPER-FINISHED. RESIDUE ON HANDS AND FIN-
Inspect the flat surfaces of the bearing blocks for burrs
GERS MAY BE CORROSIVE TO THIS SURFACE. DO NOT TOUCH.
or scratches on the edges. If necessary, remove burrs
with very fine emery paper. Then rewash the bearings.
Carefully clean the two gears. If the gears are new, wash
them with shop solvent to remove any anticorrosive
Inspect the DU bushings for wear. There should be no
grease on the surfaces.
bronze showing.
Inspect the journals and the flat faces on the top and
Using clean hydraulic oil, lubricate the internal and
bottom of the gears. Ensure these surfaces are free from
external surfaces of the bearing blocks.
burrs or scratches. If scratches or burrs are found, clean
them with a flat stone and/or very fine emery paper.
Rewash the gears after this operation.
5-146 3121142
9. Assemble the bearing blocks and gears. 11. Clean the mating surfaces.
Lubricate the journals and the gear faces. Remove any excess lubrication and grease from the mat-
ing surfaces of the pump body. Ensure that these sur-
Assemble the bearing blocks and gears. Ensure that the faces are dry and free of contamination before moving
recessed bearing faces are installed adjacent to the gear on to the next step.
faces. Align all assembly marks made during disassem-
bly. Ensure the front and rear bearing blocks occupy the
same location with respect to the housing as before dis-
assembly. Ensure that the relative position of the gear
mesh is maintained as before disassembly. Misalign-
ment of the gear teeth may increase operating noise.
10. Install the gear block assembly.
Install the bearing block and gear assembly into the

body cavity. Align the assembly marks to ensure that the
gear block assembly is installed with the same orienta-
tion as before disassembly.
3121142 5-147
12. Install the dowel pins. 13. Clean the mating surfaces.
Install four 5 mm dowel pins into the proper cavities on Remove any excess lubrication and grease from the mat-
both sides of the body (refer to the illustration). Swab ing surfaces of the front flange and rear cover. Ensure
the pins with assembly grease or petroleum jelly to that these surfaces are dry and free of contamination
retain them during assembly. before moving on to the next step.
Do not install dowel pins to the rear cover or flange, as Ensure the pressure seals are seated properly after this
one of them may drop inside the pump during assem- operation.
bly.
14. Install Rear Cover.
Mount the cover on the body. Ensure the arrow on the

back is oriented properly. The arrow should be In the
same direction as the flow.
Ensure that all the pressure seals stay in place during

this operation.
5-148 3121142
15. Prepare pump for front flange assembly. Ensure that the seals remain seated in their grooves dur-
ing this operation.
Place the pump with the rear cover downwards.
Ensure that the assembly marks on the bearing block /

body are properly aligned.
16. Install the front flange.
Install a protective sleeve over the shaft. The sleeve is

used to protect the shaft seal from damage by the shaft 17. Torque sequence.
splines / keyway during front flange assembly.
When assembling units with 01 flange and short cou-
Install the flange onto the body, then remove the pro- pled tandems, wash the capscrews and apply JLG
tective sleeve. Threadlocker PN 0100011 or equivalent thread lock
compound to the threads before assembly.
Install capscrews. While observing the torque sequence

shown, pre tighten the capscrews. Then, using a torque
wrench, tighten them to the proper torque.
Torque 44-54 Nm (32-40 ft.lbs.).
3121142 5-149
18. Install socket head capscrews. (03 flange and first stage 20. Prepare the unit for shipment or storage.
of multiple).
Clean the exterior of the pump and install the following:
Using a 4 mm internal hex wrench, install the socket
a. Port Plugs
head capscrews to the front flange and rear cover.
b. Key (CI and CO shafts)
Torque 2.5-3.4 Nm (22-30 ft.lbs.). c. Shaft protective cap (CI and CO shafts)
d. Nut and washer (CO shaft)
If used, install new o-ring to flange pilot.
19. Testing
After pump has been disassembled and reassembled, it

is suggested that the pump be run in and tested on an
appropriate test stand. This is done to verify the volu-
metric efficiency and the integrity of the unit.
Test specifications and procedure are given in Testing

the Pump.
5-150 3121142
Trouble Shooting
Table 5-49. Troubleshooting
Low or No Flow From Gear Pump

1. Check oil level in reservoir. Description 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. Recommended inlet pres- Clogged suction filter or inlet screen. Replace filter or clean suction screen.
sure: 0.8 to 3.0 bar absolute. 0.6 Minimum at cold start.
4. Check condition of gear faces and bearing blocks. Scored bearing block and gear faces will reduce pump effi- Repair or replace gear pump.
ciency.
5. Check bushings. Overpressure of gear pump will cause idler gear bushing to Repair or replace gear pump.
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. Recommended inlet pres- Lower than normal inlet pressure causes excessive pump Return inlet pressure to recommended levels.
sure: 0.8 to 3.0 bar absolute. 0.6 Minimum at cold start. noise.
External Leakage
1. Check for pinched o-rings or backup ring seal. Pinched seal will allow leakage. Replace pinched seal.
2. Check pressure seals. Damage to pressure seals is typically caused by reduced Inspect condition of bearing blocks. If they are found to be
stack-up in the pump assembly. This may be due to under- worn, repair or replace the pump.
torqued assembly fasteners, or more commonly is attrib- If bearing blocks are not worn, replace pressure seals and re-
uted to excessive wear on the bearing blocks. Reduced stack- torque pump assembly fasteners.
up will affect seal efficiency possibly to the point of seal
extrusion.
3121142 5-151
5.11 DRIVE & FUNCTION PUMP START UP The middle transmission pump also supplies oil to a hot oil
flushing valve cartridge, #120, in the Traction Control Mani-
PROCEDURES fold. This cartridge provides a means to obtain brake release
oil pressure. The brake release pressure is controlled by a pres-
Start-Up Procedure sure relief valve cartridge # 130 and a solenoid operated brake
release directional control cartridge, #170, also located in the
The 1200/1350 Boom Lift utilizes a Triple Combination Pump Traction Control Manifold. This is important to note as the
coupled to the Deutz diesel engine. The pumps are connected brake release oil pressure must be set 25 psi (1.7 bar) below
in-line to each other as follows: the boost oil pressure relief valve. If the brake release pressure
1. The front hydrostatic transmission pump, or drive pump, is set too low, brake drag and pump control will be affected. If
is coupled directly to the diesel engine and provides oil set too high, damage to the wheel drive parking brakes could
flow to operate the machine's right side wheels. result. Prior to start, connect appropriate pressure gauges to
2. The middle hydrostatic transmission pump, or drive the unit.
pump, is coupled to the back of the front pump and pro- FOR THE START-UP OF NEW OR OVERHAULED INSTALLA-
vides oil flow to operate the machine's left side wheels. TIONS:
3. The third or rear pump is the function pump. It is cou- 1. Insure all electrical checks have been performed & the
pled to the back of the middle pump and provides oil machine is set up correctly with the JLG Analyzer.
flow to operate the boom, axle, steer and platform func- 2. Insure the machine has all four wheels jacked & blocked
tions. off the ground per JLG procedures.
The transmission pumps share some common connections. 3. Insure the triple pump assembly is installed and con-
Each pumps charge oil suction ports are connected by steel nected correctly per the hydraulic circuit diagram.
tubing, the charge pumps discharge oil flows are connected
and flow to a common charge pump inline oil filter, cleaned & 4. Disconnect the electrical connector from the diesel's
filtered oil flows back to the transmission pumps "G" ports. The throttle actuator, to prevent engine start.
pumps case drain ports are connected (T1 & T2), oil flow from 5. Crank the engine until charge pressure reaches 50 psi or
the middle pumps T1 port also provides flows to the oil cooler. more.
The charge pumps oil pressure is regulated by a single boost 6. Re-connect throttle actuator electrical connector and
oil pressure relief valve installed in the middle pump. The front start engine. Allow engine to run at idle speed only for at
pump has an orifice cartridge (0.047" diameter) installed in least 5 minutes. This will allow the hydrostatic system to
place of a charge oil pressure relief cartridge. This insures that filled.
only one valve controls charge pressure & provides an amount
of charge oil flow to the front pump's case to insure flushing & 7. Listen for any abnormal noises.
removal of hot oil. 8. Check for oil leaks.
Each pump has its own separate electrical proportional direc- 9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
tional control valve to control oil flow and direction. The sig- +3.4 bar, - 0 bar]). Pressure can be measured a pump
nals or command values to each pump are similar except ports Ma & Mb or by "teeing" into the inlet for the
when steering. During steering and propel of the machine the charge oil filter. Charge pressure is checked with the joy-
pump supplying oil to the "inside turning radius" has a com- stick in neutral. A 0-1000 psi (0-70 bar) pressure gauge
mand less than the pump supplying oil flow to the "outside must be used. (If pressure gauges were installed in Ma &
turning radius" pump. Mb to check charge pressure, disconnect the gauges
"Posi-Traction" control, front to rear on a given side of the installed in Ma & Mb, as they will be damaged if loop
machine, is accomplished by a flow divider/combiner car- pressure rises above 1000 psi [34.4 bar].)
tridge installed in the Traction Control Manifold. There is a flow
divider/combiner for each side. Each flow divider/combiner
also has a "bleed orifice" to limit the amount of flow splitting
or combining.
5-152 3121142
10. Operate the drive system in the "turtle mode", forward

and reverse.
11. De-aerate the system by bleeding fluid from the Ma &
Mb ports.
12. Switch the drive mode speed control from "turtle" to
"rabbit". Gradually increase drive speed forward &
reverse, still with no load - wheels off the ground.
13. With the joystick in neutral, check for creep in neutral. If
evident, most likely dirt is present in the proportional
pump control, an incorrect electrical signal is present on
the pump's electrical control(s) or the control was not
centered properly when overhauled. See service manual
for centering instructions.
14. Check that the controls are connected so that the trans-
missions operate in the correct direction related to con-
trol input.
15. Continue to monitor all pressure gauges & correct any
irregularities.
16. Remove the brake coil (leaving the electrical connection
intact) from the brake release solenoid cartridge located
on the Traction Manifold. This disables the machine's
ability to release the brakes! Stroke the transmission
pumps slightly (less than 20%) and check the setting of
the high pressure cross port relief valves. Setting should
be 5000 psi +50 psi, - 0 psi (344.7 bar +3.4 bar, -0 bar).
Install 0-6000 psi (0 - 415 bar) gauges on Pump ports Ma
& Mb.
17. Check oil level & temperature.
18. Remove and inspect charge pressure oil filter, replace
with new element.
19. Operate the transmission under no load conditions for
about 15 minutes to stabilize the temperature and
remove any residual air from the fluid.
20. Set the machine back on the ground. Operate the trans-
missions under full and normal conditions.
21. Erratic operation may indicate there is still air trapped in
the system. By working the pump controls forward and
reverse the remaining air can be eliminated. The system
is free of air when all functions can be operated
smoothly and when the oil in the reservoir is no longer
aerated. (Usually less than one hour of operation)
NOTE: If the transmissions do not perform correctly after follow-

ing the pre-start & start-up procedures, refer to the relevant
sections of the trouble-shooting procedures.
3121142 5-153
5.12 HYDRAULIC SCHEMATICS
Figure 5-79. Hydraulic Schematic - Boom Functions - Sheet 1 of 2
5-154 3121142
1001110749-C
Figure 5-80. Hydraulic Schematic - Boom Functions - Sheet 2 of 2
3121142 5-155
Figure 5-81. Hydraulic Schematic - Axle/Steer Control - Sheet 1 of 2
5-156 3121142
1001110749-C
Figure 5-82. Hydraulic Schematic - Axle/Steer Control - Sheet 2 of 2
3121142 5-157
Figure 5-83. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 1 of 2
5-158 3121142
1001110749-C
Figure 5-84. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 2 of 2
3121142 5-159
Figure 5-85. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2
5-160 3121142
1001110749-C
Figure 5-86. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2
3121142 5-161
NOTES:
5-162 3121142
SECTION 6. JLG CONTROL SYSTEM
6.1 INTRODUCTION smooth control of: acceleration, deceleration, creep, min

speed, and max.-speed for all boom, drive, and steering func-
tions.
WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT The main lift, swing, and drive are controlled by individual joy-
WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER sticks, with steering being controlled by a rocker switch built
MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATE into the top the drive joystick. To activate Drive, Lift, and Swing
THE TILT SENSOR. simply pull up on the slide lock location on the joystick and
move the handle into the direction desired.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation and
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- maximum cycle time. Ground control speeds for all boom
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH functions can also be programmed into the control system.
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS-
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A The JLG Control System controller has a built in LED to indicate
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- any faults. The system stores recent faults which may be
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING accessed for troubleshooting. Optional equipment includes a
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- soft touch system, head and tail lights, and ground alarm.
URATION. These options may be added later but must be programmed
into the control system when installed.
The JLG designed Control System is a 12 volt based control The Control System may be accessed utilizing a custom
unit installed on the boom lift. designed, hand held analyzer (Analyzer Kit, JLG part no.
The JLG Control System has reduced the need for exposed ter- 2901443) which will display two lines of information at a time,
minal strips, diodes and trimpots and provides simplicity in by scrolling through the program.
viewing and adjusting the various personality settings for
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub Level,
To return home or access previ-
and item menus
ous menu
Left & Right Arrow Keys

Up & Down Arrow Keys Used to move between Top Level, Sub
Value Selector Level, and item menus
Figure 6-1. Hand Held Analyzer
3121142 6-1
6.2 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform Module, Ground Module, Platform Level: The GROUND MODULE stores the default val-
Boom Length Angle Module and the Chassis Module provid- ues and handles interlocks. The PLATFORM MODULE reads the
ing bi-directional communications. sensors mounted on the platform assembly and controls the
Level Up / Down valves to maintain setpoint sent from the
Two-wire: One wire (red) is driven high (5v) and the other low GROUND MODULE.
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
signal is being sent. Steer: The GROUND MODULE stores crack points, sends
desired drive direction, sends steering mode and sends axle
Differential: Any electrical line noise can affect the high or the extend / retract commands. The PLATFORM MODULE reports
low wires but never both, so communications is not corrupted. the steering switch position to the GROUND MODULE. The
CHASSIS MODULE modulates each steer left / right valve to
Serial Link: Messages are being sent bit by bit along the wires; maintain commanded wheel position.
the high bus speed allow all modules to be constantly Drive: The GROUND MODULE stores crack points, sends com-
updated around 20 times per second. Typical traffic is 300 - mands for each drive pump to the BLAM. (Command is com-
500 messages per second. puted from drive joystick input, interlocks, wheel angle, etc).
BLAM maintains proper current for the drive pumps by modu-
A complete CANbus circuit is approximately 60 ohms, which lating PWM outputs.
can be verified at the ”T” fitting inside the ground station or
below the BLAM. Each individual circuit from the modules is Lift, Tele, & Swing: The GROUND MODULE stores default val-
approximately 120 ohms. ues, handles interlocks and calibration information. Lift, Tele-
scope and Swing commands are dependent upon interlocks
The GROUND MODULE is the master system controller. Most through out the machine. Boom angle, length and swing are
functions are dispatched and coordinated from this module, controlled by the GROUND MODULE. The BLAM monitors and
all other system modules (PLATFORM, BLAM L CHASSIS) han- communicates (CANbus) to the GROUND MODULE boom
dle sub-tasks. All characterized information (values) are stored angle and boom length via two angle sensors, a length sensor
into the ground module (i.e., Personalities or Calibrations). and a load moment pin.
6-2 3121142
Figure 6-2. Control System Block Diagram
3121142 6-3
6.3 CALIBRATION INSTRUCTIONS Table 6-1. Calibration Instructions
This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement
degree of function interaction. For safety and proper machine bration Telescope proportional valve replacement
functionality, the calibration procedures must be repeated for Erratic controlled arc operation
any control module replacement, system calibration related Erratic controlled boom angle operation
fault, or removal or replacement of any sensors, valves, coils,
motors, or pumps. The chart below lists the calibrations Chassis Tilt Ground module removal or replacement
required and potential reasons for re-calibration. All calibra- Calibration Main terminal box removal or replacement
tion procedures are menu driven through the use of the stan- Tilt indication inaccuracy
dard analyzer. With the exception of steering calibration, no
Boom Sensors Ground module removal or replacement
external tools are required to complete the calibration proce-
Calibration BLAM module removal or replacement
dures. The user is prompted to exercise the machine in a spe-
Boom angle sensor removal or replacement
cific order to use the machines physical properties to
Boom length sensor removal or replacement
consistently establish sensor response and the interaction of
Moment pin removal or replacement
valves, pumps, and motors. Steering calibration also uses the
Boom angle sensor calibration fault
analyzer and is performed on one side of the machine at a
Boom length sensor calibration fault
time requiring the use of a string or other means to determine
Moment pin fault
when the tires are in line with each other. With the exception
Failed BCS functional check
of the load control calibration, all calibrations are accessed by
Boom control system inaccuracies
connecting the analyzer into the control system inside the
Installing or removing approved accessories
main terminal box or on the bottom of the platform control
Changing Platform Size
box.
Table 6-1. Calibration Instructions
Calibration Reasons for Re-calibration

Procedure
Steering Calibration Ground module replacement
Chassis module replacement
Steer sensor removal or replacement
Persistent wheel misalignment
Drive Calibration Ground module replacement

BLAM module replacement
Drive pump/coil replacement
Drive pulls to one side
Drive lugs engine
Poor slow speed control
Platform Leveling Ground module replacement

Calibration Platform module replacement
Platform level sensor removal or replacement
Platform level sensor calibration fault
Platform Level Crack Point Platform module replacement

Calibration Ground module replacement
Platform level valve/coil replacement
Erratic platform leveling
Lift Crack Point Ground module replacement

Calibration Lift proportional valve/coil replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
6-4 3121142
3121142
(See Figure 6-4.) (See Figure 6-5.) (See Figure 6-6.)
(See Figure 6-7.)
or
(See Figure 6-8.)
or
(See Figure 6-9.)
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine con-
figuration.
Figure 6-3. Analyzer Flow Chart
6-5
ACCESS LEVEL:
6-6
CODE 33271
MENU: ACCESS LEVEL:

ACCESS LEVEL 1 CODE 0000
MENU: PERSONALITIES : PERSONALITIES: PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES :

PERSONALITIES DRIVE STEER MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE
TO: DRIVE : STEER : MAIN LIFT : SWING : TOWER LIFT : MAIN TELESCOPE : TOWER TELESCOPE :
MACHINE SETUP ACCEL X.X S MAX SPEED X% ACCEL X.X S ACCEL X.X S ACCEL X.X S ACCEL X.X S ACCEL X.X S
DRIVE : MAIN LIFT : SWING : TOWER LIFT : MAIN TELESCOPE : TOWER TELESCOPE :
DECEL X.X S DECEL X.X S DECEL X.X S X.X S
DECEL MEDIUM DECEL X.X S DECEL X.X S
MIN FORWARD X% MIN UP X% MIN LEFT X% MIN UP X% MIN IN X% MIN IN X%
MAX FORWARD X% MAX UP X% MAX LEFT X% MAX UP X% MAX IN X% MAX IN X%
MIN REVERSE X% CREEP UP X% CREEP LEFT X% MIN DOWN X% MIN OUT X% MIN OUT X%
MAX REVERSE X% MIN DOWN X% MIN RIGHT X% MAX DOWN X% MAX OUT X% MAX OUT X%
DRIVE : MAIN LIFT: SWING :

ELEV MAX X% MAX DOWN X% MAX RIGHT X%
DRIVE : MAIN LIFT: SWING :

CREEP MAX X% CREEP DOWN X% CREEP RIGHT X%
PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES :

PLATFORM LEVEL PLATFORM ROTATE JIB LIFT JIB SWING GROUND MODE GEN SET /WELDER TEMPERATURE CUT
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE : GEN SET/WELDER: LOW TEMPERATURE
ACCEL X.X S ACCEL X.X S ACCEL X.X S ACCEL X.X S MAIN UP : XXX % ENGINE RPM 1800 CUTOUT SET : XXXC
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE :
DECEL X.X S DECEL X.X S DECEL X.X S DECEL X.X S MAIN DOWN : XXX %
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE :
MIN UP X% MIN LEFT X% MIN UP X% MIN LEFT X% SWING : XXX %
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE : NOTE: The layout shown includes all
MAX UP X% MAX LEFT X% MAX UP X% MAX LEFT X% PLT LEVEL : XXX % possible analyzer screens. Please
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE : note that some screens may not
MIN DOWN X% MIN RIGHT X% MIN DOWN X% MIN RIGHT X% PLT ROTATE : XXX %
be available depending upon
PLATFORM LEVEL : PLATFORM ROTATE : JIB LIFT : JIB LIFT : GROUND MODE : machine configuration.
MAX DOWN X% MAX RIGHT X% MAX DOWN X% MAX RIGHT X% MAIN TELE : XXX %
GROUND MODE :
TOWER TELE : XXX %
GROUND MODE :
TOWER UP : XXX %
GROUND MODE : GROUND MODE : GROUND MODE :

TOWER DOWN : XXX % JIB (U/D): XXX % JIB (L/R): XXX %
1001110093-P
MAE35170P
Figure 6-4. Analyzer Flow Chart - Personalities (Software Version 7.29)
3121142
3121142
FROM:
PERSONALITIES
MENU: MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: FUEL CUTOUT:
MACHINESETUP 1100S 1350S: 135' MAX ANSI USA DEUTZ F4 TIER1 NO GLOW PLUGS DISABLED ENABLED RESTART
MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: FUEL CUTOUT:
TO: 1200S 1350S: 125' MAX ANSI EXPORT DEUTZ F4 TIER2 AIR INTAKE ENABLED DISABLED ONE RESTART
CALIBRATIONS
MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: FUEL CUTOUT:
1350S 1350S: 120' MAX CSA CAT ECM T4I IN CYLINDER* ENGINE STOP
ENVELOPE HEIGHT: MARKET: ENGINE:

1350S: 110' MAX CE DEUTZ ECM*
ENVELOPE HEIGHT: MARKET: ENGINE:

1200S: 120' MAX AUSTRALIA DEUTZ ECM T4F
ENVELOPE HEIGHT: MARKET:

1200S: 110' MAX JAPAN
ENVELOPE HEIGHT:
1100S: 110' MAX
CHASIS TILT: STOUCH/SKYGUARD: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM:
5 DEG + DRV CUT NONE NO MOTION ENABLED NO NO CAN LSS NO NO
CHASIS TILT: STOUCH/SKYGUARD: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM:
4 DEG + DRV CUT SOFT TOUCH BELT DRIVE MOTION CUTOUT YES WARN ONLY NO CAN LSS BOOM CUTOUT DRIVE
CHASIS TILT: STOUCH/SKYGUARD: GEN SET/WELDER: LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:
3 DEG + DRV CUT SKYGUARD HYDRAULIC DRIVE CUTOUT PLATFORM DRIVE CUTOUT DESCENT
CHASIS TILT: STOUCH/SKYGUARD: LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:

3 DEG + CUT BOTH(CUTOUT) CUTOUT ALL DRIVE CUT E&T MOTION
CHASIS TILT: LOAD SYSTEM:
4 DEG + CUT SPECIAL 1
CHASIS TILT:
2 DEG + CUT
FLYWHEEL TEETH: OSCILLATING: DISPLAY UNITS: LEVELING MODE: CLEARSKY: FUEL TANK SIZE: ALERT BEACON: TEMP CUTOUT: PLAT LVL OVR CUT: CRIBBING OPTION: WATER IN FUEL:
110 TEETH AXLE: YES IMPERIAL LEVELING ALL NO 31 GALLON OFF FOR CREEP NO NO NO SENSOR: NO
FLYWHEEL TEETH: OSCILLATING: DISPLAY UNITS: LEVELING MODE: CLEARSKY: FUEL TANK SIZE: ALERT BEACON: TEMP CUTOUT: PLAT LVL OVR CUT: CRIBBING OPTION: WATER IN FUEL:
133 TEETH AXLE: NO METRIC LEVELING LIFT YES 52 GALLON 20FPM FOR CREEP YES YES YES SENSOR: YES
FLYWHEEL TEETH:
112 TEETH
1001110093-P
MAE35180P
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
Figure 6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.29)
6-7
6-8
FROM:
MACHINE SETUP
MENU: CALIBRATIONS: C ALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

CALIBRATIONS STEER DRIVE BOOM VALVES LEVEL UP CRKPT LEVEL DOWN CRKPT MAIN LIFT CRKPT MAIN TELE CRKPT
CALIBRATE CALIBRATE CALIBRATE CALIBRATE LEVEL C ALIBRATE LEVEL CALIBRATE MAIN CALIBRATE MAIN
TO:
STEER? DRIVE? BOOM VALVES? UP CRACKPOINT ? DOWN CRACKPOINT ? LIFT CRACKPOINT ? TELECRACKPOINT ?
SERVICE MODE
CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

TILT SENSOR BOOM SENSORS LOAD SENSING UNLOCK BOOM DEUTZ SETUP: PLTLVLCUTOUT MSSO NONE AVAILABLE
POSITION 1: POSITION 1: LOAD SENSING: UNLOCK BOOM: DEUTZ SETUP: TILT SENSOR: MSSO RESET
CHECK SYSTEM? CHECK SYSTEM? CALIBR ATE? CHECK SYSTEM? SETUP 1 CALIBRATE? CONFIRM?
LOAD SENSING: DEUTZ SETUP:

PLATFORM EMPTY? SETUP 2
LO AD SENSING: DEUTZ SETUP:

ACCESSORY XXX LBS SETUP 3
LOAD SENSING: DEUTZ SETUP:

CALIBRATING... SETUP 4
LOAD SENSING:
SKY GLAZIER N
LOAD SENSING:
PIPE RACKS N
LOAD SENSING:
UNRSTRICT XXXLBS
LOAD SENSING:
RSTRICT XXXLBS
LOAD SENSING:
CAL COMPLETE
1001110093-P
MAE35190P
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
Figure 6-6. Analyzer Flow Chart - Calibrations (Software Version 7.29)
3121142
FROM:
CALIBRATION
3121142
MENU: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE:
SERVICE MODE TWR TELE ONLY? TWR LIFT ONLY? MAIN LIFT? MAIN TELE? SET PRESSURES? PRODUCTION TEST?
MENU: HELP:
HELP:PRESS ENTER GROUND MODE OK
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: TO: DIAGNOSTICS:
DIAGNOSTICS DRIVE BOOM FUNCTIONS ENGINE SYSTEM TRANSPORT DATA BCS ENVELOPE BOOM SWITCHES
JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE SKYGUARD INPUT 1 TRANSPORT MODE: BCS STATUS: MAIN BOOM
FORWARD XXX % MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV OPEN OUT OF TRANSPORT NORMAL LENGTH: XXX.X"
JOYSTICK STEER: JOYSTICK SWING: BATTERY VOLTAGE: PLATFORM MODULE SKYGUARD INPUT 2 TOWER LIFT ELEC. RETRIEVAL: MAIN BOOM
LEFT XXX % LEFT XXX % XX.XV BATTERY: XX.XV OPEN STATUS: STOWED NOT ACTIVE ANGLE1: XX.X DEG
DRIVE OUTPUT: LIFT OUTPUT: COOLANT UGM ST/ SG INPUTS: TOWER TELESCOPE HYD. RETRIEVAL: MAIN BOOM
FORWARD XXX % MAIN UP XXX% TEMPERATURE: XXXC TEMPERATURE: XXXC OPEN STATUS:RETRACTED NOT ACTIVE ANGLE2: XX.X DEG
ENGINE OIL PLATFORM SELECT ST / SG INPUT 1 MAIN ENVELOPE
STEER OUTPUT: SWING OUTPUT: MAIN LIFT MAIN BOOM A/D
PRESSURE: XXXXPSI KEYSWITCH:CLOSED OPEN STATUS: NOMINAL LENGTH: XXXXX
LEFT XXX % LEFT XXX% STATUS: ELEVATED
ST / SG INPUT 2
STEER TYPE: PLATFORM LEVEL: AMBIENT GROUND SELECT MAIN TELESCOPE MAIN ENVELOPE MAIN BOOM A/D
OPEN
NORMAL UP XXX% TEMPERATURE: XXXC KEYSWITCH: OPEN STATUS:RETRACTED LOW: NOMINAL ANGLE1: XXX.X
ST OVERRIDE:
BRAKES STATUS: PLATFORM ROTATE: FUEL LEVEL STATION CONTROL: MAIN IN LIMIT TOWER ENVELOPE MAIN BOOM A/D
OPEN
LOCKED LEFT XXX% SENSOR: OK GROUND SWITCH 1: OPEN STATUS: NOMINAL ANGLE2: XXX.X
SG OVERRIDE SW:
CREEP MAIN TELESCOPE: STARTER FOOTSWITCH INPUT OPEN MAIN IN LIMIT MAIN BOOM ANGLE BOOM CONTROL:
SWITCH: CLOSED IN XXX % CRANK TIME: XX S GROUND: OPEN SWITCH 2: OPEN ZONE: 4 AUTOMATIC
SG/ ST OVRRIDE SW
CREEP MODE: TOWER TELESCOPE: ENGINE SPEED FOOTSWITCH INPUT OPEN PLATFORM MAIN BOOM LENGTH BOOM CONTROL:
OFF IN XXX % ACTUAL:XXXX RPM PLATFORM: CLOSED STOWED: NO ZONE: A MODE SW: OPEN
GENSET /WELDER
2-SPEED TOWER LIFT: ENGINE SPEED TRANSPORT MODE: SWITCH: OPEN AXLE STATUS:
SWITCH: CLOSED UP XXX % TARGET: XXXX RPM OUT OF TRANSPORT EXTENDED
LIGHTS
2-SPEED VALVE JIB LIFT: CABLE BREAK SWITCH: OPEN FRONT AXLE :
OUTPUT: OFF UP XXX % SWITCH: CLOSED SWITCH: CLOSED
PLATFORM TILT1
HIGH ENGINE JIB SWING: CREEP ANGLE: XX.X DEG REAR AXLE :
SWITCH: OPEN LEFT XXX % SWITCH: CLOSED SWITCH: CLOSED
PLATFORM TILT2
DRIVE MODE: PLATFORM CONTROL CREEP MODE: ANGLE: XX.X DEG JIB STOWED LIMIT
MID ENGINE VALVE: OFF OFF SWITCH: CLOSED
PLATFORM TILT1
L FRONT WHEEL FUNCTION SPEED: CHASSIS TILT: RAW: XXXX JIB STOWED LIMIT
ANGLE: XX.X PUMP POT XXX% XX.X DEGREES OVERRIDE: OPEN
PLATFORM TILT2
R FRONT WHEEL CREEP CHASSIS TILT RAW: XXXX AXLE INPUT SW.:
ANGLE: XX.X SWITCH: CLOSED X-AXIS: X.X EXTEND CLOSED
OSCILATING AXLE
L REAR WHEEL CREEP MODE: CHASSIS TILT PRES.SW.: OPEN
ANGLE: XX.X OFF Y-AXIS: X.X
HYDRAULIC OIL
R REAR WHEEL AUXILIARY POWER TEMP.SW.: OPEN
ANGLE: XX.X SWITCH: OPEN
HYDRAULIC OIL:
DRV.ORIENTATION HORN WARM UP NOT DONE
SWITCH: CLOSED SWITCH: OPEN
MAIN LIFT PILOT
DRV. ORIENTATION SOFT TOUCH LIMIT PRES. SW.: OPEN
OVERRIDE: OPEN SWITCH: OPEN
MODEL ID
DRV. ORIENTATION SOFT TOUCH INPUT:OPEN NOTE: The layout shown includes all possible analyzer
STATUS: REQUIRED OVERRIDE: OPEN
AMBIENT TEMP screens. Please note that some screens may not be
CRIBBING OPTION: SOFT TOUCH LIMIT
XXXC
ENABLED SWITCH: OPEN available depending upon machine configuration.
LOW TEMPERATURE
SKYGUARD INPUTS:
CRIBBING OPTION: CUTOUT: INACTIVE
OPEN
DISABLED
1001110093-P
MAE35200P
Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.29) - Sheet 1 of 3
6-9
6-10
FROM:DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: TO:DIAGNOSTICS:
ENVELOPE BOOM SWITCHES BOOM SENSORS LOAD PIN MOMENT PLATFORM LOAD CAN STATISTICS
MAIN BOOM LENGTH: TOWER LENGTH 1 TOWER TRIP POINT LOAD PIN MOMENT: ACTUAL MOMENT: PLATFORM LOAD
SWITCH NC : OPEN SENSOR: X.X” LENGTH: XXXX.X” LOAD PIN XXXXXXXX LB*IN STATE: OK
MAIN BOOM LENGTH: TOWER LENGTH 2 TOWER ANGLE 1 LOAD PIN RATIO: OVER MOMENT: PLATFORM LOAD:
SWITCH NO : CLOSED SENSOR: X.X” LOW CAL: XXX.X VALUE: XX.XXX XXXXXXXX LB*IN ACTUAL XXXLBS
MAIN BOOM LENGTH: TOWER ANGLE 1 TOWER ANGLE 2 LOAD PIN ANGLE: UNDER MOMENT: PLATFORM LOAD:
ZONE: A/D SENSOR: XX.X LOW CAL: XXX.X FORCE: XXXXXX XXXXXXXX LB*IN GROSS XXXLBS
DUAL CAPACITY: TOWER ANGLE 2 TOWER ANGLE 1 LOAD PIN VECTOR: UNDER MOMENT CAL PLATFORM LOAD:
SWITCH NC: OPEN SENSOR: XX.X HIGH CAL: XXX.X FORCE: XXXXXX POINT: X OFFSET 1 XXXLBS
DUAL CAPACITY: TOWER CYLINDER TOWER ANGLE 2 LOAD PIN MOMENT: YELLOW WITNESS PLATFORM LOAD:
SWITCH NO: CLOSED SENSOR: XX.X HIGH CAL: XXX.X RAW: XXXXXX CAL: XXXXXXXXX OFFSET 2 XXXLBS
DUAL CAPACITY: TOWER CYLINDER TOWER CYLINDER LOAD PIN RATIO: GREEN WITNESS PLATFORM LOAD:
LENGTH ZONE: A/B ANGLE: XX.X LOW CAL: XXXXXX RAW: XX.XXX CAL: XXXXXXXXX ACCESSORY XXXLBS
TOWER TELESCOPE: MAIN ANGLE 2 TO TOWER CYLINDER LOAD PIN ANGLE: LOAD PIN RATIO PLATFORM LOAD:
SWICTH NC: OPEN TOWER: XX.X HIGH CAL: XXXXXX RAW: XXX.X VALUE: XX.XXX
UNRSTRICT XXXLBS
TOWER TELESCOPE: MAIN ANGLE L TO MAIN ANGLE 1 LOAD PIN V-FORCE LOAD PIN ERROR PLATFORM LOAD:
SWICTH NO: CLOSED GRAVITY: XXX.X LOW CAL: XXXXXX RAW: XXXXXXXX FLAGS: 0X0000 RSTRICT XXXLBS
TOWER TELESCOPE: MAIN ANGLE H TO MAIN ANGLE 2 LOAD PIN ANGLE SKY WELDER PLATFORM LOAD:
STATUS: RETRACTED GRAVITY: XXX.X LOW CAL: XXXXXX CAL POINT: XXX.X INSTALLED: NO RAW 1 XXXLBS
TOWER TELESCOPE: TOWER LENGTH 1 MAIN ANGLE 1 LOAD PIN V-FORCE SKY CUTTER PLATFORM LOAD:
SWITCH: OPEN A/D: XXXXX HIGH CAL: XXXXXX CAL: XXXXX INSTALLED: NO
RAW 2 XXXLBS
MAIN LIFT ANGLE: TOWER LENGTH 2 MAIN ANGLE 2 LOAD PIN MOMENT SKY GLAZIER
SWITCH NC: OPEN A/D: XXXXX HIGH CAL: XXXXXX CAL POINT: XXXXX INSTALLED: NO
MAIN LIFT ANGLE: TOWER ANGLE 1 MAIN TRIP POINT LOAD PIN ERROR SKY BRIGHT
SWITCH NO: CLOSED A/D: XX.X ANGLE: XXX.X FLAGS: 0X0000 INSTALLED: NO
MAIN LIFT ANGLE: TOWER ANGLE 2 LOAD PIN X-AXIS SKY RACKS
STATUS: TRANSPORT A/D: XX.X VALUE: XXX INSTALLED: NO
TOWER CYLINDER LOAD PIN Y-AXIS CAMERA MOUNT

ANGLE A/D: XXXXX VALUE: XXX INSTALLED: NO
MAIN LIFT 1 LOAD PIN X-AXIS

ANGLE A/D: XXXXX RAW VALUE: XXX
MAIN LIFT 2 LOAD PIN Y-AXIS

ANGLE A/D: XXXXX RAW VALUE: XXX
MAIN LIFT 1 RAW

ANGLE: XXX.X
MAIN LIFT 2 RAW

ANGLE: XXX.X
TOWER RETRACTED
LENGTH 1: XXXXXX
TOWER RETRACTED NOTE: The layout shown includes all possible analyzer screens. Please note that some
LENGTH 2: XXXXXX
screens may not be available depending upon machine configuration.
TOWER EXTENDED
LENGTH 1: XXXXXX
TOWER EXTENDED
LENGTH 2: XXXXXX
1001110093-P
MAE35210P
3121142
FROM: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
CAN STATISTICS CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
3121142
CAN STATISTICS PLATFORM UP DATALOG : GROUND MODULE
RX/SEC: X CAL: X ON XXH XXM SOFTWARE: PX.X
CAN STATISTICS PLATFORM DOWN DATALOG : GROUND MODULE

TX/SEC: X CAL: X ENGINE XH XM CNST DATA: PX.X
CAN STATISTICS LEFT FORWARD DATALOG : GROUND MODULE

BUS OFF X DRIVE CAL: XXXX DRIVE XH XM HARDWARE: REV X
CAN STATISTICS RIGHT FORWARD DATALOG : GROUND MODULE

PASSIVE XXXXX DRIVE CAL: XXXX LIFT XH XM S/N: XXXXXX
CAN STATISTICS LEFT REVERSE DATALOG : PLATFORM MODULE
MSGERROR: XXXX DRIVE CAL: XXXX SWING XH XM SOFTWARE: PX.X
RIGHT REVERSE DATALOG : PLATFORM MODULE

DRIVE CAL: XXXX TELE XH XM HARDWARE: REV X
L FRONT STEER DATALOG : PLATFORM MODULE

CAL: XXXXX MAX TEMP XXC S/N: XXXXXX
R FRONT STEER DATALOG : CHASSIS MODULE
CAL: XXXXX MIN TEMP XXC SOFTWARE: PX.X
L REAR STEER DATALOG : B.L.A. MODULE

CAL: XXXXX MAX VOLTS XX.XV SOFTWARE: PX.X
R REAR STEER DATALOG : CYLINDER PIN

CAL: XXXXX RENTAL XH XM SOFTWARE: RX.XX
MAIN LIFT UP DATALOG : CYLINDER PIN

CAL: XXXXX ERASE RENTAL? S/N: XXXXXX
MAIN LIFT DOWN MAIN ANGLE 1
CAL: XXXX S/N: XXXXXX
MAIN TELESCOPE MAIN ANGLE 1
IN CAL: XXXXX REVX.X
MAIN TELESCOPE MAIN ANGLE 2

OUT CAL: XXXXX S/N: XXXXXX
MAIN ANGLE 1 MAIN ANGLE 2
LOCAL: X REV X.X
MAIN ANGLE 1 CRIB MODULE

HI CAL: X SOFTWARE: PX.X
MAIN ANGLE 2
CRIB MODULE
LOCAL: X
HARDWARE: REV X
MAIN ANGLE 2
HICAL: X VERSIONS:
ANALYZER V6.3
NOTE: The layout shown includes all possible analyzer LENGTH RETRACTED
screens. Please note that some screens may not be CAL: XXXXX
available depending upon machine configuration. LENGTH EXTENDED

CAL: XXXXX
YELLOW WITNESS
MARK CAL: X
LENGTH SWITCH
CAL: XXXXX
1001110093-P
MAE35220P
6-11
Figure 6-10. Control Module Location
6-12 3121142
PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-11. Analyzer Connecting Points
3121142 6-13
J5 J2
NATURAL 8 PIN BLUE 35 PIN
J6
BLACK 8 PIN
J8
POWER
J7
BLACK 35 PIN
J1
NATURAL 35 PIN
1600343-Q
MAE35100Q
Figure 6-12. Platform Control Module
6-14 3121142
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 TOWER LIFT UP HSDIGITAL INPUT 1 SPARE PIN HS DIGITAL INPUT
2 TOWER LIFT DOWN HSDIGITAL INPUT 2 SPARE PIN HS DIGITAL INPUT
3 TOWER TELESC OPEIN HSDIGITAL INPUT 3 BATTERY VOLTAGE BATTERY VOLTAGE
4 TOWER TELESCOPE OUT HSDIGITAL INPUT DRIVE ORIENTATION SYSTEM OVERRIDE
4 HS DIGITAL INPUT
5 MAIN TELESCOPE IN HSDIGITAL INPUT SWITCH
6 MAIN TELESCOPEOUT HSDIGITAL INPUT 5 PLATFORM STOWED HS DIGITAL INPUT
7 PLATFORM ROTATE RIGHT HSDIGITAL INPUT 6 CHASSIS TILTED INDICATOR LAMP OUTPUT
8 PLATFORM ROTATE LEFT HSDIGITAL INPUT 7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
9 PLATFORM LEVEL UP HSDIGITAL INPUT 8 VEHICLE SYSTEM DISTRESS INDICATOR LAMP OUTPUT
10 PLATFORM LEVEL DOWN HSDIGITAL INPUT 9 CREEP SPEED INDICATOR LAMP OUTPUT
11 JIB UP HSDIGITAL INPUT 10 BROKEN CABLE INDICATOR LAMP OUTPUT
12 JIB DOWN HSDIGITAL INPUT 11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
13 SPEED PUMP POTENTIOMETER GROUND GROUND 12 500LB CAPACITY INDICATOR LAMP OUTPUT
14 ENGINE START HSDIGITAL INPUT 13 1000LB CAPACITY INDICATOR LAMP OUTPUT
15 AUXILIARY POWER HSDIGITAL INPUT 14 DRIVE ORIENTATION SYSTEM INDICATOR LAMP OUTPUT
16 CRAB STEER SELECT HSDIGITAL INPUT 15 GENERATOR ON INDICATOR LAMP OUTPUT
17 COORDINATED STEER SELECT HSDIGITAL INPUT 16 SOFT TOUCHT RIGGERED INDICATOR LAMP OUTPUT
18 SWITCH POWER BATTERY VOLTAGE 17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
19 JIB 1000LB ENABLE HSDIGITAL INPUT 18 LAMP RETURN GROUND
20 EIM PLATFORMOVER LOAD HSDIGITAL INPUT 19 SPARE PIN LAMP OUTPUT
21 500/1000LB.CAPACITY SELECT HSDIGITAL INPUT 20 UPRIGHTTILTED INDICATOR LAMP OUTPUT
DRIVE ORIENTATION SYSTEM FEATURE 21 LOW FUEL INDICATOR LAMP OUTPUT
22 HSDIGITAL INPUT
ENABLE 22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
23 SPARE PIN HSDIGITAL INPUT 23 3/4 FUEL LEVEL INDICATOR LAMP OUTPUT
24 SPARE PIN HSDIGITAL INPUT J2BLUE 24 1/2 FUEL LEVEL INDICATOR LAMP OUTPUT
J1NATURAL 25 LEVEL SENSOR1 SIGNAL HSDIGITAL INPUT 25 FUEL LEVEL INDICATORS RETURN GROUND
26 LEVEL SENSOR2 SIGNAL HSDIGITAL INPUT 26 ANALYZER POWER ANALYZER POWER
27 TWO SPEED VALVE(HIGH ENGINE) HSDIGITAL INPUT 27 ANALYZER GROUND ANALYZER GROUND
28 TORQUEMODE HSDIGITAL INPUT 28 ANALYZER RX ANALYZER RX
29 SOFTTOUCH OVERRIDE HSDIGITAL INPUT 29 ANALYZER TX ANALYZER TX
30 HEAD/TAILLIGHT HSDIGITAL INPUT 30 SPARE PIN LAMP OUTPUT
31 HORN HSDIGITAL INPUT 31 SPARE PIN DIGITAL OUTPUT
32 CREEPMODE HSDIGITAL INPUT 32 BATTERY VOLTAGE BATTERY VOLTAGE
33 DUAL-FUELSELECT HSDIGITAL INPUT 33 BATTERY VOLTAGE BATTERY VOLTAGE
SPEED PUMP POTENTIOMETER REFERENCE +7REFERENCE 34 SWITCH POWER BATTERY VOLTAGE
34
VOLTAGE VOLTAGE 35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT
35 SPEED PUMPPOTENTIOMETER ANALOG INPUT
3121142 6-15
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 LIFT/SWINGJOYSTICKSUPPLYVOLTAGE SUPPLYVOLTAGE 1 GROUND MODE GROUND MODE
2 LIFTCENTERTAP ANALOGINPUT 2 PLATFORM EMS PLATFORM EMS
3 LIFTSIGNAL ANALOGINPUT 3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
4 SWINGSIGNAL ANALOGINPUT FOOT SWITCH (FUNCTION ENABLE
4 BATTERY VOLTAGE
5 SWINGCENTERTAP ANALOGINPUT SWITCH)POWER
J5 6 NOTCONNECTED ANALOGINPUT ME DIGITAL
NATURAL 5 PLATFORM ROTAT ELEFT
OUTPUT
7 LIFT/SWINGJOYSTICKRETURN GROUND
ME DIGITAL
8 SPAREPIN BLANK 6 PLATFORM ROTATE RIGHT
OUTPUT
7 SOFTTOUCH LIMITSWITCH POWER BATTERY VOLTAGE
8 FOOT SWITCH SIGNAL DIGITAL INPUT
CONNECTOR PIN ASSIGNMENT FUNCTION
9 GENERATOR ON SIGNAL DIGITAL INPUT
1 DRIVE/STEERJOYSTICKSUPPLYVOLTAGE SUPPLYVOLTAGE
+7 REFERENCE
2 DRIVECENTERTAP ANALOGINPUT 10 +7 REFERENCE VOLTAGE
VOLTAGE
3 DRIVESIGNAL ANALOGINPUT +5V REFERENCE
4 STEERSIGNAL ANALOGINPUT 11 SPARE PIN
VOLTAGE
5 STEERLEFT ANALOGINPUT +5V REFERENCE
J6 12 SPARE PIN
6 STEERRIGHT ANALOGINPUT VOLTAGE
BLACK
7 DRIVE/STEERJOYSTICKRETURN GROUND 13 SPARE PIN ANALOG INPUT
8 SPAREPIN BLANK 14 GROUND RETURN GROUND
15 PLATFORMLEVEL UP HS DIGITAL OUTPUT
16 PLATFORMLEVEL DOWN HS DIGITAL OUTPUT
CONNECTOR PIN ASSIGNMENT FUNCTION 17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
1 MODULEGROUND GROUND 18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
J8 2 MODULEPOWER BATTERYVOLTAGE 19 PLATFORM ALARM LAMPOUTPUT
20 ALARM RETURN GROUND
21 SPARE PIN GROUND
22 SPARE PIN GROUND
23 SPARE PIN ANALOG INPUT
24 SPARE PIN DIGITAL OUTPUT
J7 ME DIGITAL
BLACK 25 JIB UP
OUTPUT
ME DIGITAL
26 JIB DOWN
OUTPUT
ME DIGITAL
27 JIB RIGHT
OUTPUT
ME DIGITAL
28 JIB LEFT
OUTPUT
29 GROUND RETURN GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 CAN SHIELD CAN SHIELD
33 SPARE PIN GROUND
34 SPARE PIN GROUND
35 SPARE PIN ANALOG INPUT
6-16 3121142
3121142 6-17
J8
BLACK 4 PIN
J1
NATURAL 35 PIN
J7
BLACK 35 PIN
J12
BLACK 8 PIN
J2
GRAY 35 PIN
J3
BLACK 14 PIN J4
BLUE 35 PIN
1001110084-R
MAE35130R
Figure 6-13. Ground control module
6-18 3121142
Connector Pin Function Type Connector Pin Function Type

1 THROTTLE ACTUATOR (DIESELONLY) DIGITAL OUTPUT 1 SPARE VAVLE RETURN 1 GROUND INPUT
2 SPARE (LPNOTUSED) DIGITAL OUTPUT 2 SPARE VAVLE RETURN 2 GROUND INPUT
3 TOWER BOOM LIFT POWER DIGITAL OUTPUT 3 GROUND GROUND INPUT
4 GROUND GROUND INPUT 4 SPARE VAVLE RETURN 4 GROUND INPUT
5 GROUND GROUND INPUT 5 SPARE VAVLE RETURN 5 GROUND INPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT 6 SPARE VAVLE RETURN 6 GROUND INPUT
7 SPARE (LPNOTUSED) DIGITAL OUTPUT 7 VBAT VBAT OUTPUT
8 GROUND GROUND INPUT 8 SPARE HS DIGITALIN(FREQ.CAPABLE) DIGITAL INPUT
9 GROUND GROUND INPUT 9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT
10 IGNITION ON RELAY DIGITAL OUTPUT SPARE HS SWITCH INPUT
J3 10 DIGITAL INPUT
11 START SOLENOID (DIESELONLY) DIGITAL OUTPUT (MODELINPUTFOR1100S)
(Black)
12 GLOW PLUG (DIESELONLYOPTION) DIGITAL OUTPUT 11 SPARE LS DIGITAL INPUT DIGITAL INPUT
13 AUXILIARY POWER DIGITAL OUTPUT 12 ANALOG REF.VOLTAGE VOLTAGE OUTPUT
14 COOLAN TTEMP (DIESELONLY) ANALOG INPUT 13 SPARE ANALOG INPUT 8 ANALOG INPUT
15 OIL PRESSURE (DIESELONLY) ANALOG INPUT 14 SPARE VALVE RETURN 3 GROUND INPUT
16 FLY WHEEL SPEED PICKUP(DIESELONLY) FREQUENCY INPUT
17 GROUND GROUND INPUT
Connector Pin Function Type
18 SPARE GROUND GROUND INPUT
1 FREQUENCY INPUT 2 FREQUENCY INPUT
19 SPARE GROUND GROUND INPUT
20 TWO SPEED DIGITAL OUTPUT 2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
21 MAIN LIFT PILOT PRESSURE SWITCH DIGITAL INPUT 3 CAN 2H SERIAL I/O
22 GENERATOR/WELDER(OPTION) DIGITAL OUTPUT 4 CAN 2L SERIAL I/O
23 PARKING BRAKE DIGITAL OUTPUT 5 CAN 2SHIELD GROUND INPUT
J12
24 CONSTANT BATTERY N/C N/C 6 CAN2 TERMINATOR TERM I/O
(Black)
25 RS-485HI SERIAL I/O 7 CAN2 TERMINATOR TERM I/O
26 RS-485LO SERIAL I/O 8 SPARE LS DIGITAL INPUT DIGITAL INPUT
J1
(Natural)
28 ANALYZER POWER VOLTAGE OUTPUT
29 ANALYZER RS-232Rx SERIAL INPUT
30 ANALYZER RS-232Tx SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT
34 SPARE DIGITAL INPUT
35 HYDRAULIC OIL TEMPERATURE SWITCH DIGITAL INPUT
3121142 6-19

1 MAIN LIFT PILOT DIGITAL OUTPUT 1 AXLES SET LAMP DIGITAL OUTPUT
2 HORN DIGITAL OUTPUT 2 500# CAPACITY LAMP DIGITAL OUTPUT
3 PLATFORM CONTROL VALVE DIGITAL OUTPUT 3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT
4 UPPER TELESCOPE IN DIGITAL OUTPUT 4 START SWITCH DIGITAL INPUT
5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT 5 BASKET LEVEL DOWN DIGITAL INPUT
6 GROUND GROUND INPUT 6 BASKET LEVEL DOWN DIGITAL INPUT
7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT 7 UPPER TELESC OPEIN DIGITAL INPUT
8 TOWER TELESCOPE POWER DIGITAL OUTPUT 8 JIB DOWN DIGITAL INPUT
9 TELESCOPEF LOW CONTROL DIGITAL OUTPUT 9 JIB LEFT DIGITAL INPUT
10 LIFT PILOT DIGITAL OUTPUT 10 TOWER UP DIGITAL INPUT
11 UPPER LIFT UP DIGITAL OUTPUT 11 MAIN TOWER TRANSPORT ANGLE OPEN DIGITAL INPUT
12 LIFT DOWN AUXILIARY DIGITAL OUTPUT 12 HOUR METER DIGITAL OUTPUT
13 MAIN DUMP DIGITAL OUTPUT 13 BCS CALIBRATED LAMP DIGITAL OUTPUT
14 GROUND GROUND INPUT 14 OVERLOAD LAMP DIGITAL OUTPUT
NOT CONNECTEDRS232 BACKUP 15 SPARE DIGITAL OUTPUT
15 DIGITAL OUTPUT
COMM.ENABLE 16 AUXILIARY POWER DIGITAL INPUT
16 UPPER TELESCOPE OUT DIGITAL OUTPUT
17 BASKET LEVEL UP DIGITAL INPUT
18 BASKET ROTATE RIGHT DIGITAL INPUT
18 SPARE PIN GROUND INPUT
19 JIB UP DIGITAL INPUT
19 LIFT FLOW CONTROL DIGITAL OUTPUT
20 JIB RIGHT DIGITAL INPUT
20 SPARE OUTPUT DIGITAL OUTPUT
21 TOWER DOWN DIGITAL INPUT
21 MAIN BOOM ANGLE SENSOR#2 POWER DIGITAL OUTPUT
22 MAIN BOOM TRANSPORTANGLECLOSED DIGITAL INPUT
22 UPPER LIFT DOWN DIGITAL OUTPUT
23 UPPER LIFT UP DIGITAL INPUT
23 MAIN BOOM LIFTENABLE DIGITAL OUTPUT
24 V BAT VBAT OUTPUT
24 TOWER CYLINDER TYPE DIGITAL INPUT
25 FUEL SENSOR ANALOG INPUT
26 NO CHARGE LAMP DIGITAL OUTPUT
26 HEAD/TAILLIGHT DIGITAL OUTPUT J4
J2 27 1000#CAPACITY LAMP DIGITAL OUTPUT
27 ALARM DIGITAL OUTPUT (Blue)
(Gray) 28 ENGINE HIGH TEMPERATURE LENGTH DIGITAL OUTPUT
28 SPAREPIN GROUND INPUT
29 ENGINE LOW OIL PRESSURE LAMP DIGITAL OUTPUT
30 UPPER TELESCOPE OUT DIGITAL INPUT
31 PVGENABLE DIGITAL OUTPUT
32 SPAREPIN GROUND INPUT
32 TOWER BOOM TELESCOPEPILOT DIGITAL OUTPUT
33 UPPER LIFT DOWN DIGITAL INPUT
33 TOWER BOOM LIFT ENABLE DIGITAL OUTPUT
34 SWING LEFT DIGITAL INPUT
34 SWING LEFT DIGITAL OUTPUT
35 SWING RIGHT DIGITAL INPUT
35 SWING RIGHT DIGITAL OUTPUT
6-20 3121142

1 PLATFORM EMS DIGITAL INPUT 1 GROUND FROM BATTERY GROUND INPUT
2 PLATFORM MODE DIGITAL INPUT 2 GROUND EMS GROUND INPUT
J8
3 GROUND MODE DIGITAL INPUT (Black) 3 GROUND TO PLATFORM GROUND OUTPUT
4 TOWER CYLINDER PRESSURE ANALOG INPUT 4 GROUND EMS OUT TO PLATFORM GROUND OUTPUT
5 REFERENCE VOLTAGE VOLTAGE OUTPUT
6 CAN TERMINATION TERM I/O
7 SPARE ANALOG INPUT
8 SPARE ANALOGINPUT 2 ANALOG INPUT
11 BOOM RETRACTED CLOSED DIGITAL INPUT
12 BROKEN CABLE SWITCH INPUT
13 CANHI SERIAL I/O
14 GROUND MODEOUT TO PLATFORM DIGITAL INPUT
15 FOOT SWITCH ENGAGE DIGITAL INPUT
17 CAN TERMINATION TERM I/O
18 CANSHEILD GROUND INPUT
19 SPARE PIN GROUND INPUT
20 SPARE ANA LOGINPUT 1 ANALOG INPUT
21 PUSH TO TEST DIGITAL INPUT
22 TOWER BOOMTRANSPORTANGLE DIGITAL INPUT
23 GROUND CONTROLE NABLE DIGITAL INPUT
24 CAN LO SERIAL I/O
J7 27 REFERENCE VOLTAGE VOLTAGE OUTPUT
(Black)
28 GROUND(RESERVEDFORCRIBBINGOPTION) GROUND INPUT
33 V BAT(RESERVEDFORCRIBBINGOPTION) VBAT OUTPUT
34 CLEARSKY POWER(VBAT) VBAT OUTPUT
35 BOOM RETRACT OPEN DIGITAL INPUT
3121142 6-21
J1 J4 J2
GREY GREY BLACK
12 PIN 8 PIN 12 PIN
J3 J5
GREEN BROWN
12 PIN 12 PIN
1001227960-D
MAE37570D
Figure 6-14. BLAM Controller
6-22 3121142
Function
Connector Pin 1100/1200/1350 1250 1500 Type
1 PowerFeedThrutoJ2-1 PowerFeedThrutoJ2-1 PowerFeedThrutoJ2-1 Power I/O
3 SignalFeedThrutoJ2-4 SignalFeedThrutoJ2-4 SignalFeedThrutoJ2-4 Digital Input
4 MasterGroundConnect MasterGroundConnect MasterGroundConnect Power Input
5 MasterIgnitionConnect MasterIgnitionConnect MasterIgnitionConnect Power Input
6 CANbusHigh CANbusHigh CANbusHigh Serial I/O
7 CANbusLow CANbusLow CANbusLow Serial I/O
8 CANbusShield CANbusShield CANbusShield Serial I/O
J1(Grey) 9 CANbusTerminator CANbusTerminator CANbusTerminator Serial I/O
10 CANbusTerminator CANbusTerminator CANbusTerminator Serial I/O
11 Ignition Ignition Ignition Power Output
12 Ground Ground Ground Power Output
4 SpareInput LoadPinPushtoTest SpareInput Digital Input
5 SpareInput PlatformRotateRight SpareInput Digital Input
6 SpareInput PlatformRotateLeft SpareInput Digital Input
7 SpareInput SpareInput SpareInput Digital Input
8 MainBoomAng1(Gravity) TowerBoomAng1(Gravity) MainBoomAng1(Gravity) Digital Input
J2(Black) 9 MainBoomAng2(Gravity) TowerBoomAng2(Gravity) MainBoomAng2(Gravity) Digital Input
10 SpareAnalogInput SpareAnalog SpareAnalog Analog Input
11 RightDrivePumpForward RightDrivePumpForward RightDrivePumpForward Digital Output
12 RightDrivePumpReverse RightDrivePumpReverse RightDrivePumpReverse Digital Output
1 +5VAnalogReference +5VAnalogReference +5VAnalogReference Power Output
2 RefVoltagefromJ3-1 RefVoltagefromJ3-1 RefVoltagefromJ3-1 Analog Input
5 SpareAnalogInput TowerBoomCylinderAngle MainCylAngle#1(Absolute) Analog Input
8 BoomLengthSensor TowerBoomLengthSnsr#1 BoomLengthSensor Analog Input
J3(Green) 9 Ground Ground Ground Power Output
11 SpareAnalogInput TowerBoomLengthSnsr#2 MainCylAngle#2(Absolute) Analog Input
3121142 6-23
6.4 TO CONNECT THE JLG CONTROL SYSTEM The top level menus are as follows:
ANALYZER HELP
DIAGNOSTICS
1. Connect the cable supplied with the analyzer, to the SYSTEM TEST
controller module located in the platform box or at the ACCESS LEVEL
controller module in the ground control box and con- PERSONALITIES
nect the remaining end of the cable to the analyzer. MACHINE SETUP
CALIBRATIONS (view only)
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards. If you press ENTER, at the HELP: PRESS ENTER display, and a
fault is present, the analyzer display will scroll the fault across
2. Power up the Control System by turning the key to the the screen. If there was no fault detected, the display will read:
platform or ground position and pulling both emer- HELP: EVERYTHING OK. If powered up at the ground station,
gency stop buttons on. the display will read: GROUND OK.
If ENTER is pressed again, the display moves to the following
6.5 USING THE ANALYZER display:
With the machine power on and the analyzer connected prop-

erly, the analyzer will display the following:
HELP:
1: STARTUP (2/1)
MENU:
ESC ENTER
HELP: PRESS ENTER
ESC ENTER
MAE19060
LOGGED HELP
MAE19060 1: POWER CYCLE (0/0)
HELP: At this point, the analyzer will display the last fault the system
PRESS ENTER 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
At this point, using the RIGHT and LEFT arrow keys, you can arrow keys to scroll through the fault logs. To return to the
move between the top level menu items. To select a displayed beginning, press ESC. two times. POWER CYCLE (0/0) indi-
menu item, press ENTER. To cancel a selected menu item, cates a power up.
press ESC.; then you will be able to scroll using the right and
left arrow keys to select a different menu item.
6-24 3121142
When a top level menu is selected, a new set of menu items Then using the RIGHT arrow key, position the cursor to the
may be offered: for example: right one space to enter the second digit of the password.
DRIVE Use the UP or DOWN arrow key to enter the second digit of
BOOM the password which is 33271.
SYSTEM
Continue using the arrow keys until all the remaining digits of
DATALOG
the password is shown.
VERSIONS
Pressing ENTER with any of the above displayed menus, will
Once the correct password is displayed, press ENTER. The
display additional sub-menus within the selected menu. In
access level should display the following, if the password was
some cases, such as DRIVE, the next level is the parameter or
entered correctly:
information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may only
view the personality settings for selected menus while in
access level 2. Remember, you may always cancel a selected
menu item by pressing the ESC. key.
MENU:
ACCESS LEVEL 1
6.6 CHANGING THE ACCESS LEVEL OF THE HAND
HELD ANALYZER ESC ENTER
When the analyzer is first connected, you will be in access level

2 which enables you to only view most settings which cannot
be changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:
MENU:
ACCESS LEVEL 2 MAE19060
MENU:
ESC ENTER ACCESS LEVEL 1
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.
MAE19060
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of the
password, 3.
3121142 6-25
6.7 ADJUSTING PARAMETERS USING THE HAND 6.8 MACHINE SETUP

HELD ANALYZER When a machine digit item is selected, press the UP or DOWN
arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personality item
is selected, press the UP or DOWN arrow keys to adjust its
value, for example:
GROUND ALARAM:
2 = LIFT DOWN
PERSONALITIES:
DRIVE ACCEL 1.05 ESC ENTER
ESC ENTER
MAE19060
GROUND ALARM:
MAE19060
2 = LIFT DOWN
PERSONALITIES: The effect of the machine digit value is displayed along with
DRIVE ACCEL 1.0s its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
There will be a minimum and maximum for the value to
sound when lifting down. There are certain settings allowed to
ensure efficient operation. The Value will not increase if the UP
install optional features or select the machine model.
arrow is pressed when at the maximum value nor will the
value decrease if the DOWN arrow is pressed and the value is When selection the machine model to match the size of the
at the minimum value for any particular personality. If the machine, the personality settings will all default to the factory
value does not change when pressing the up and down recommended setting.
arrows, check the access level to ensure you are at access level
1. NOTE: Refer to Table 6-5, Personality Ranges/Defaults, and in this
Service Manual for the recommended factory settings.
NOTE: Password 33271 will give you access to level 1, which will
permit you to change all machine personality settings.
There is a setting that JLG strongly recommends that you do

not change. This setting is so noted below:
ELEVATION CUTBACK
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF

YOUR MACHINE.
6-26 3121142
Table 6-2. Machine Configuration Programming Information - Version P7.29
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default
MODEL NUMBER: 1 1200S 1

1
2 1250A
3 1350S
4 1100S
ENVELOPE HEIGHT: 1 1350S: 135' MAX 5

2
2 1350S: 125' MAX
3 1350S: 120' MAX
4 1350S: 110' MAX
5 1200S: 120' MAX
6 1200S: 110' MAX
7 1250A: 125' MAX
8 1250A: 100' MAX
9 1250A: 80' MAX
Note: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting.
MARKET: 0 ANSI USA 0

3
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
ENGINE: 1 DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1) 3

4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
4 CAT ECM: Engine Control Module
5 DEUTZ ECM T4F: Engine Control Module (Tier 4 Final)
3121142 6-27
Default
Number
GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 0
6 can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil
pressure is less than 8 PSI.
FUEL CUTOUT: 0 RESTART: Engine allowed to be restarted multiple times when very low fuel level is reached 0
8*
1 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel level is reached.
2 ENGINE STOP: Engine not able to restart when very low fuel level is reached.
* This menu item is only visible if non dual fuel engines are selected.
CHASSIS TILT: 1 5 DEGREES + DRV CUT: Reduces the maximum speed of all boom functions to creep when 1
9 tilted more than 5 degrees and above elevation; also cuts out drive
2 4 DEGREES + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted more
than 4 degrees and above elevation; also cuts out drive
3 3 DEGREES + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted more
than 3 degrees and above elevation; also cuts out drive
4 5 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
and main lift up.
and main lift up.
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.
6-28 3121142
Default
Number
JIB: 0 NO: No Jib installed. 2

10
1 YES: Jib installed.
2 SIDESWING: Jib with Sideswing installed
4WS: 0 NO: 2WS mode enabled. 1

11
1 YES: 4WS mode enabled.
DRIVE: 0 2WD drive mode enabled. 1

12
1 4WD drive mode enabled.
STOUCH/SKYGUARD: 0 None: No soft touch or SkyGuard system installed. 2

13
1 SOFT TOUCH - Soft touch only installed
2 SKYGUARD - Skyguard only installed
3 BOTH(CUTOUT) - Soft touch and Skyguard installed
GEN SET/WELDER: 0 NO: No generator installed. 1

14
1 BELT DRIVE: Belt driven setup.
2 HYDRAULIC DRIVE: Hydraulic driven setup.
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
15*
1 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS: 0 NO: No head and tail lights installed. 0

16
1 YES: Head and tail lights installed.
3121142 6-29
Default
Number
LOAD SYSTEM: 0 NO: No load sensor installed. 0

17*
1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main 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.
LOAD TYPE: 0 NON CAN LSS: Non CAN based LSS installed 1
18
1 CAN LSS: CAN based LSS is installed.
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

19*
1 BOOM CUTOUT: Boom function cutout while driving above elevation.
2 DRIVE CUTOUT: Drive cutout above elevation.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.
* Certain market selections will limit function cutout options or alter default setting.
GROUND ALARM: 0 NO: No ground alarm installed. 0

20*
1 DRIVE: Travel alarm sounds when the drive function is active (Option).
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
* Certain market selections will alter default setting.
FLYWHEEL TEETH: 0 110 TEETH - The engine is configured to calculate speed using 110 teeth 0
21*
1 133 TEETH - The engine is configured to calculate speed using 133 teeth
2 112 TEETH - The engine is configured to calculate speed using 112 teeth.
* Only visible when Engine Setup is DEUTZ F4 Tier 1 or Tier 2.
6-30 3121142
Default
Number
OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1

22
1 YES: Oscillating axle system installed.
DISPLAY UNITS: 0 IMPERIAL: DEG F, PSI, LBS. 0

23*
1 METRIC: DEG C, KPA, KGS.
* Certain market selections will alter default setting.
LEVELING MODE: 0 LIFT: Platform leveling during lift only. 1

24
1 ALL: Platform leveling during all functions.
CLEARSKY: 0 NO: ClearSky Telematics system not installed. 0

25
1 YES: ClearSky Telematics system installed
FUEL TANK: 0 31 Gallon Fuel Tank 0

26
1 52 Gallon Fuel Tank
2 62 Gallon Fuel Tank
ALERT BEACON: 0 OFF FOR CREEP 0

27
1 20FPS FOR CREEP
TEMP CUTOUT: 0 NO: Temp Cutout is Disabled 0

28
1 YES: Temp Cutout is Enabled
3121142 6-31
Default
Number
PLAT LVL OVR CUT: 0 NO: Platform Level Override will always be functional 0
29
1 YES: Platform Level Override will only be functional when In Transport
CRIBBING OPTION: 0 NO: Cribbing Option is disabled. 0

30
1 YES: Cribbing Option is enabled.
WATER IN FUEL SENSOR: 0 NO: Water in fuel sensor Disabled. 0

31
1 YES: Water in fuel sensor Enabled.
4150364-X
6-32 3121142
Table 6-3. Machine Configuration Programming Settings -

Table 6-3. Machine Configuration Programming Settings - Version P7.29
Version P7.29
ANSI Export
Australia
ANSI USA
Japan
CSA
ANSI Export
1200SJP
CE
ANSI USA
Australia
Japan
CSA
1200SJP
CE
Load System 0 0 0 0 0 0
Model Number 1 1 1 1 1 1 X 1 X X X 1
Envelope Height 5 5 5 5 5 5 X 2 X 2 2 2
Market 0 1 2 3 4 5 X 3 X 3 X 3
Engine 3 3 3 3 3 3 X 4 X X X 4
Glow Plug 0 0 0 0 0 0 Load Type 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 Function Cutout 0 0 0 0 0 0
Starter Lockout 0 0 0 0 0 0 X 1 1 1 1 1
1 1 1 1 1 1 X 2 2 X 2 2
Engine Shutdown 0 0 0 0 0 0 X 3 3 X 3 3
1 1 1 1 1 1 Ground Alarm 0 0 0 0 0 0
Fuel Cutout 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 2 2 2 2 2 2
2 2 2 2 2 2 3 3 3 3 3 3
Tilt 1 1 1 1 1 1 Flywheel Teeth 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
3 3 3 3 3 3 2 2 2 2 2 2
4 4 4 4 4 4 Oscillating Axle 0 0 0 0 0 0
5 5 5 5 5 5 1 1 1 1 1 1
6 6 6 6 6 6 Display Units 0 0 0 0 0 0
Jib 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Leveling Mode 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
4 Wheel Steer 0 0 0 0 0 0 ClearSky 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 Fuel Tank 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Soft Touch/SkyGuard 0 0 0 0 0 0 2 2 2 2 2 2
1 1 1 1 1 1 Alert Beacon 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
3 3 3 3 3 3 Temperature Cutout X 0 X 0 X X
Gen Set / Welder 0 0 0 0 0 0 X 1 X 1 X X
1 1 1 1 1 1 Platform Cutout 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
Gen Set Cutout 0 0 0 0 0 0 Cribbing Option 0 0 0 X X 0
1 1 1 1 1 1 1 1 1 X X 1
Head & Taillights 0 0 0 0 0 0 Water In Level Sensor 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
3121142 6-33
Table 6-3. Machine Configuration Programming Settings - Table 6-4. Machine Configuration Programming Settings -
Version P7.29 Version P7.29
ANSI Export
ANSI Export
Australia
Australia
ANSI USA
ANSI USA
Japan
Japan
CSA
CSA
1200SJP 1350SJP
CE
CE
Water In Level Sensor 0 0 0 0 0 0 Soft Touch/SkyGuard 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
BOLD TEXT indicates the default setting. Plain text indicates another available selec- 2 2 2 2 2 2
tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS 3 3 3 3 3 3
indicate hidden menu or selection.
Gen Set / Welder 0 0 0 0 0 0
Table 6-4. Machine Configuration Programming Settings - 1 1 1 1 1 1
Version P7.29 2 2 2 2 2 2
Gen Set Cutout 0 0 0 0 0 0
ANSI Export
Australia
ANSI USA
Japan
1 1 1 1 1 1
CSA
1350SJP
CE
Head & Taillights 0 0 0 0 0 0

1 1 1 1 1 1
Model Number 3 3 3 3 3 3
Load System 0 0 0 0 0 0
Envelope Height 1 1 1 1 1 1
X 1 X X X 1
Market 0 1 2 3 4 5
X 2 X 2 2 2
Engine 3 3 3 3 3 3
X 3 X 3 X 3
Glow Plug 0 0 0 0 0 0
X 4 X X X 4
1 1 1 1 1 1
Load Type 0 0 0 0 0 0
2 2 2 2 2 2
1 1 1 1 1 1
Starter Lockout 0 0 0 0 0 0
Function Cutout 0 0 0 0 0 0
1 1 1 1 1 1
X 1 1 1 1 1
Engine Shutdown 0 0 0 0 0 0
X 2 2 X 2 2
1 1 1 1 1 1
X 3 3 X 3 3
Fuel Cutout 0 0 0 0 0 0
Ground Alarm 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
2 2 2 2 2 2
Tilt 1 1 1 1 1 1
3 3 3 3 3 3
2 2 2 2 2 2
Fly Wheel Teeth 0 0 0 0 0 0
3 3 3 3 3 3
1 1 1 1 1 1
4 4 4 4 4 4
2 2 2 2 2 2
5 5 5 5 5 5
Oscillating Axle 0 0 0 0 0 0
6 6 6 6 6 6
1 1 1 1 1 1
Jib 0 0 0 0 0 0
Display Units 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Leveling Mode 0 0 0 0 0 0
4 Wheel Steer 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
ClearSky 0 0 0 0 0 0
Drive Type 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Fuel Tank 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
6-34 3121142
Table 6-4. Machine Configuration Programming Settings -

Version P7.29
ANSI Export
Australia
ANSI USA
Japan
CSA
1350SJP
CE
Alert Beacon 0 0 0 0 0 0
1 1 1 1 1 1
Temperature Cutout X 0 X 0 X X
X 1 X 1 X X
Platform Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Cribbing Option 0 0 0 X X 0
1 1 1 X X 1
Water In Level Sensor 0 0 0 0 0 0
1 1 1 1 1 1
BOLD TEXT indicates the default setting. Plain text indicates another available selec-
tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS
indicate hidden menu or selection.
3121142 6-35
6.9 MACHINE PERSONALITY SETTINGS/FUNCTION NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
SPEEDS
Table 6-5. Personality Ranges/Defaults
TIME RANGE (SEC) (SEE

SUBMENU PARAMETER SECTION 6.10 FOR
DEFAULT VALUES
(DISPLAYED ON (DISPLAYED ON ANALYZER 2ND DESCRIPTION RANGE MACHINE ORIENTATION
ANALYZER 1ST LINE) LINE) WHEN SETTING SPEEDS)
1200 1350 1200S 1350S
DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3 1.3
MIN forward XX% Displays/adjusts minimum forward drive 0 to 35% 1 1
speed
MAX forward XXX% Displays/adjusts maximum forward drive 0 to 100% 100 100 44-48 44-48
speed
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100 100
ELEV. MAX XX% Displays/adjusts maximum drive speed 0 to 50% 25 25 93-104 93-104
NOTE: used when elevation cutout switches are
limiting maximum speed
CREEP MAX XX% Displays/adjusts maximum drive speed 0 to 50% 35 35 79-87 79-87
NOTE: used when creep switch on pump pot is
active
STEER: max SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100 100
MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN Up XX% Displays/adjusts minimum main lift up speed 0 to 60% 20 20
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 100% 50 50 75-100 75-100
MIN DOWN XX% Displays/adjusts minimum main lift down 0 to 60% 10 10
speed
MAX DOWN XXX% Displays/adjusts maximum main lift down 0 to 100% 50 50 85-110 85-110
speed
CREEP UP XX% Displays/adjusts maximum main lift up speed 0 to 65% 50 50
active
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45 45
speed
active
6-36 3121142

DEFAULT VALUES
1200 1350 1200S 1350S
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 40 40
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 65 65 115-125 115-125
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 40 40
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 65 65 115-125 115-125
CREEP LEFT XX% Displays/adjusts maximum swing left speed 0 to 65% 50 50
active
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 50 50
active
MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1.0 1.0
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15 15
speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 65 58-68 65-75
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 15 15
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 60 45-55 50-60
speed
BASKET LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5 0.5
MIN UP XX% Displays/adjusts minimum basket level up 0 to 65% 40 40
MAX UP XXX% Displays/adjusts maximum basket level up 0 to 100% 70 70
speed
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 40 40
MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70 70
speed
3121142 6-37

DEFAULT VALUES
1200 1350 1200S 1350S
BASKET ROTATE: ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60 60
MAX LEFT XXX% Displays/adjusts maximum basket rotate left 0 to 100% 60 60 24-30 24-30
speed (180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 60 24-30 24-30
speed (180°) (180°)
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN UP XX% Displays/adjusts minimum jib up speed. Same 0 to 65% 40 40
as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 65 30-36 30-36
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 40 40
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 60 60 30-36 30-36
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same 0 to 65% 40 40
as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. 0 to 65% 40 40
Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
6-38 3121142

DEFAULT VALUES
1200 1350 1200S 1350S
GROUND U. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60 60
MODE: U. LIFT DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60 60
BASKET LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75 75
BASKET ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 60 60
TOWER TELE XXX% Displays/adjusts fixed tower telescope speed 0 to 100% 100 100
Not displayed if TOWER TELE=NO
T. LIFT UP XXX% Displays/adjusts fixed tower lift up speed 0 to 100% 100 100
Not displayed if TOWER LIFT=NO
T. LIFT DN XXX% Displays/adjusts fixed tower lift down speed 0 to 100% 100 100
Not displayed if TOWER LIFT=NO
JIB (U/D) XXX% Displays/adjusts jib lift speed 0 to 100% 60 60
Not displayed if JIB = 0
JIB (L/R) XXX% Displays/adjusts jib swing speed 0 to 100% 70 70
Displayed if JIB = 2
GEN SET/WELDER: ENGINE XXXX RPM Control generator/welder RPM. Not displayed if 1200-2800 1800 1800
GEN SET/WELDER = 0
4150453-H
3121142 6-39
6.10 MACHINE ORIENTATION WHEN SETTING Test Notes

FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within
Lift Up: From platform control, lowest elevation up to maxi- the adjustment range in order to achieve optimum
mum elevation, boom retracted. machine performance.
2. Stop watch should be started when the function is acti-
Lift Down: From platform control, maximum elevation down vated.
to minimum elevation, boom retracted.
3. Unless noted, all speed tests are run from the platform.
Swing Right (Max): 360 Degrees, from platform control, boom These speeds do not reflect the ground control opera-
approximately 45° elevation, boom retracted. tion.
Swing Left (Max): 360 Degrees, from platform control, boom 4. The platform speed knob control must be at full speed
approximately 45° elevation, boom retracted. (turned clockwise completely).
Telescope Out: From platform control, boom horizontal, 500 5. Function speeds may vary due to cold, thick hydraulic
lb. (230 kg) capacity selected. oil. Test should be run with the oil temperature above
100° F (38° C).
Telescope In: From platform control, boom horizontal, 500 lb.
(230 kg) capacity selected.
Drive Forward (Max): Test should be done on a smooth level
surface. High Speed - Low Torque setting, drive 200 ft. (61 m)
front wheels to front wheels. Timed after machine has
obtained maximum speed.
Drive Reverse (Max): Test should be done on a smooth level

surface. High Speed - Low Torque setting, drive 200 ft. (61 m)
front wheels to front wheels. Timed after machine has
obtained maximum speed.
Drive Forward (Creep Max): Test should be done on a

smooth level surface. High Torque - Low Speed setting, plat-
form speed knob at full creep.
Drive Reverse (Creep Max): Test should be done on a smooth

level surface. High Torque - Low Speed setting, platform speed
knob at full creep.
Drive Forward (Elevated Max - Boom Beyond Transport):

Test should be done on a smooth level surface. High speed -
Low Torque setting, platform speed knob out of creep, Lift
boom above transport, drive forward 50 ft. (15.2 m).
Drive Reverse (Elevated Max - Boom Beyond Transport):

Test should be done on a smooth level surface. High speed -
Low Torque setting, platform speed knob out of creep, Lift
boom above transport, drive forward 50 ft. (15.2 m).
Platform Rotate: Platform level and completely rotated one

direction. Rotate the opposite direction, Record Time. Rotate
the other direction, Record Time.
Articulating Jib: Platform level and centered with the boom.
Start with the Jib down. Jib Up, Record Time. Jib Down, Record
Time.
6-40 3121142
6.11 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat-
form console are in the following positions:
The Control System Incorporates a built-in system test to
check the system components and functions. To use this func- a. Drive speed switch is in the Middle position. (Turtle
tion, use the following procedures. Icon)
b. 4WS switch is in the Middle position. (2WS mode)
Test from the Platform c. Capacity select switch in the 1000 lb. (450 kg) mode.
d. Function speed potentiometer out of creep mode
1. Position the Platform/Ground select switch to the Plat-
switch.
form position.
e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Plug the analyzer into the connector at the base of the

platform control box.
3121142 6-41
4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-15., System Test Flow
Chart - Platform Tests and go through the component
tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
5. The analyzer screen should read:
HELP - PRESS ENTER
ESC ENTER
MAE19060
6-42 3121142
3121142
Figure 6-15. System Test Flow Chart - Platform Tests
6-43
Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the
engine.
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the Ground

control box.
HELP - PRESS ENTER
ESC ENTER
MAE19060
5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
6. Follow the flow path in Figure 6-16., System Test Flow
Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
6-44 3121142
3121142
Figure 6-16. System Test Flow Chart - Ground Station Tests
6-45
Table 6-6. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be
reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and
ground modules. The system test cannot run in ground mode unless data is being received from
the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor.
HOT ENGINE The engine temperature exceeds 100°C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also
detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is displayed; the footswitch
MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One
footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the
platform module. Check footswitch and wiring.
6-46 3121142

Description
Analyzer Analyzer
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized;
checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if
TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT
AXLES=NO. Four wheel steer valves are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly. Check valve
wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-circuited. Check valve
wiring.
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wir-
ing.
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor-
mal” position; function switches should be open, cutout switches should be closed, joysticks
should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are
reported.
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep
to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for con-
firmation that the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine
digit.
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for con-
firmation that the alarm is sounding.
ENTER must be pressed or clicked to continue the test.
NOTE: The platform alarm and the horn are only tested in platform mode.
NOTE: The ground alarm is not tested if GROUND ALARM = NO.
3121142 6-47

Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
If ENTER is pressed or clicked, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.
6-48 3121142
Table 6-7. Machine Diagnostics Parameters
Diagnostics Submenu
Parameter (Displayed on Parameter Value
(Displayed on Analyzer Description
Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
1st Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL NUMBER = 7 or
8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch. (Displayed if
MODEL NUMBER = 7 or 8)
3121142 6-49
Diagnostics Submenu
1st Line)
BOOM:
U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand is controlled
by the pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE: demand is con-
trolled by the pump pot
U TELE IN/OUT XXX% Displays main telescope switch direction & demand. NOTE: demand is con-
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE: demand is con-
Not displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is controlled by
the pump pot
Not displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is controlled by the
pump pot
Not displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is controlled by
the pump pot
Displayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models equipped
with the Jib Stow System
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models equipped with
Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601 (machine digit =
4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
6-50 3121142
Diagnostics Submenu
1st Line)
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL
NUMBER = 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUMBER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ¼ / ½ / ¾ / FULL or LOW / OK Displays measured fuel level
XXXx rpm Engine RPM
3121142 6-51
Diagnostics Submenu
1st Line)
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature
FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform module.
ABOVE ELEV. OP/CL/YES/NO Displays above elevation cutout switch status or above angle status
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL NUMBER = 7 or
8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN CABLE SWITCH =
1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL = 601
(machine digit = 4)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUMBER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is configured)
6-52 3121142
Diagnostics Submenu
1st Line)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input
R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed
ONLY if MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch. Displayed ONLY
if MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Displays jib block limit switch status. Not displayed if associated configuration
digit = 0
BASKET STOWD YES/NO Displays status of basket stowed mode. (Displayed if MODEL NUMBER = 7 or 8)
SOFT LIMIT OP/CL Displays status of soft touch limit switch. Not displayed if associated configu-
ration digit = 0
SOFT O/R OP/CL Displays status of soft touch override switch. Not displayed if associated con-
figuration digit = 0
GEN SET/WELDER OP/CL Displays generator/welder switch input status. Not displayed if associated
configuration digit = 0
LIGHTS OP/CL Displays head and tail light switch input status. Not displayed if associated
configuration digit = 0
BSK TILT1 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
BSK TILT2 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
AXLE RET SW OP/CL Displays status of axle extension user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE EXT SW OP/CL Displays status of axle retraction user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE LIM SW RET/EXT Displays status of axle extension limit switches. (Displayed if MODEL NUMBER
= 7 or 8)
DOS LIM SW OP/CL Displays status of Drive Orientation System Limit Switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R SW OP/CL Displays status of Drive Orientation System Override switch. (Displayed if
MODEL NUMBER = 7 or 8)
CAPACITY SW 500/1000 Displays status of capacity selection switch. (Displayed if MODEL NUMBER = 7
or 8)
3121142 6-53
Diagnostics Submenu
1st Line)
OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING
AXLE = 1)
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO (machine digits =

0)
LENGTH OP /CL Displays measured length, NOTE: Not displayed if MODEL NUMBER = 7 or 8
ANGLE OP / CL Displays measured angle, NOTE: Not displayed if MODEL NUMBER = 7 or 8
WEIGHT XXXX% Percentage of maximum calibrated weight on the platform. An uncalibrated

load cell will read 1000% Displayed if LOAD is not 0 and LOAD TYPE is 0.
OK/OVERLOADED Displayed if LOAD is not 0 and LOAD TYPE is 1.
6-54 3121142
Diagnostics Submenu
1st Line)
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Displays current moment value
(LB-IN) XXXXXXXX Displays current over moment setpoint.

OVER
(LB-IN) XXXXXXXX Displays current under moment setpoint.

UNDER
CAL PT XXXXXXXX Displays the under moment value recorded during boom sensor calibration.
UNDER
CAL PT XXXXXXXX Displays the yellow witness mark moment value recorded during boom sen-
WIT YEL sor calibration.
CAL PT XXXXXXXX Displays the green witness mark moment value recorded during boom sensor
WIT GRN calibration.
CYL PIN X.XXX Displays the current cylinder moment pin ratio of X and Y forces.
RATIO
PIN 0xXXXX Displays the current error flag status of the cylinder moment pin.
E FLAGS
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
3121142 6-55
Diagnostics Submenu
1st Line)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Displays the current indicated boom length in inches.
ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Displays the current indicated boom length in A/D counts.
A/D ANG1 XXXXX Displays the current indicated boom angle 1 in A/D counts or raw angle if cali-
brated.
A/D ANG2 XXXXX Displays the current indicated boom angle 2 in A/D counts or raw angel if cali-
brated.
CAN STATISTICS: CAN Statistics as detected by the Ground Module
RX/SEC XXX Displays the number of received messages per second
TX/SEC XXX Displays the number of transmitted messages per second
BUS OFF XX Displays the number of bus off occurrences
PASSIVE XX Displays the number of bus passive occurrences
6-56 3121142
Diagnostics Submenu
1st Line)
CALIBRATION DATA
BASKET UP XXX Displays the basket up calibration point
BASKET DOWN XXX Displays the basket down calibration point
L FWD DRIVE XXX Displays the left forward drive calibration point
R FWD DRIVE XXX Displays the right forward drive calibration point
L REV DRIVE XXX Displays the left reverse drive calibration point
R REV DRIVE XXX Displays the right reverse drive calibration point
F LT STEER XXX Displays the forward left steer calibration point
F RT STEER XXX Displays the forward right steer calibration point
R LT STEER XXX Displays the reverse left steer calibration point
R RT STEER XXX Displays the reverse right steer calibration point
U LIFT UP XXX Displays the main lift up calibration point
U LIFT DOWN XXX Displays the main lift down calibration point
U TELE IN XXX Displays the main telescope in calibration point
U TELE OUT XXX Displays the main telescope out calibration point
BM ANG 1 LO XXX Displays the boom angle 1 low calibration point
BM ANG 1 HI XXX Displays the boom angle 1 high calibration point
BM ANG 2 LO XXX Displays the boom angle 2 low calibration point
BM ANG 2 HI XXX Displays the boom angle 2 high calibration point
LEN RETRACT XXX Displays the length sensor retracted calibration point
LEN EXTEND XXXXX Displays the length sensor extended calibration point
LEN WIT XXXXX Displays the witness mark calibration point
LEN SWITCH XXXX Displays the length switch calibration point
3121142 6-57
Diagnostics Submenu
1st Line)
DATALOG:
ON XXXXhXXm Displays total controller on (EMS) time
ENGINE XXXXhXXm Display engine run time
DRIVE XXXXhXXm Displays total controller drive operation time
LIFT XXXXhXXm Displays total controller lift operation time
SWING XXXXhXXm Displays total controller swing operation time
TELE XXXXhXXm Displays total controller telescope operation time
MAX TEMP XXC Displays maximum measured ambient temp.
MIN TEMP XXC Displays minimum measured ambient temp.
MAX VOLTS XX.XV Displays maximum measured battery voltage
RENTAL XXXXhXXm Displays total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at Access Level 2.

ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Displays ground module software version
GM HW REV XXXX Displays ground module hardware revision
GM SN XXXXXX Displays ground module serial number
PM SW PX.X Displays platform module software version
PM HW REV XXXX Displays platform module hardware revision
PM SN XXXXXX Displays platform module serial number
CM SW PX.X Displays chassis module software version
BM SW PX.X Displays BLAM module software version
C PIN SW Displayed if cylinder moment load pin transmits software version.
C PIN SN Displayed if cylinder moment load pin transmits serial number.
ANALYZER VX.XXXX Displays Analyzer software version
6-58 3121142
6.12 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat-
form position.
When calibrating steering, each individual wheel must be cali-
brated in order to make the tire and wheel parallel with the
frame. Two methods to help ensure proper calibration are the
use of a carpenter’s square to square the spindle to the axle or
aligning the two wheels on one side using a stretched string.

platform control box.
3121142 6-59
3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read:
engine.
CALIBRATION:
STEER
ESC ENTER
MAE19060
9. Hit Enter. The screen will read:

HELP - PRESS ENTER
ESC ENTER
STEER CAL:
CALIBRATE?
ESC ENTER
MAE19060
5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.

6. Enter the Access Code, 33271.
MAE19060
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
6-60 3121142
10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
LT STEER CAL: FRONT LT STEER:

FRONT LT STEER CAL. COMPLETE
ESC ENTER ESC ENTER
MAE19060 MAE19060
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right For-
ward Steer Calibration which will be followed by Right
Rear Steer Calibration.
FRONT LT STEER:
16. After completing all the Steer Calibrations, hit ESC twice
VALuE = XX
to go back to CALIBRATIONS.
ESC ENTER
MAE19060
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave off
the control. The display will read FRT LEFT = and show
the numeric calibration value for that wheel.
3121142 6-61
6.13 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the
engine.
form position.

platform control box. HELP - PRESS ENTER
ESC ENTER
MAE19060

Enter.
6-62 3121142
8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
CALIBRATION: DRIVE CAL:

DRIVE LT FWD DRIVE
ESC ENTER ESC ENTER
MAE19060 MAE19060
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
DRIVe CAL: LT FWD DRIVE:

CALIBRATE? CRK PT = 0
ESC ENTER ESC ENTER
MAE19060 MAE19060
12. Activate the Drive Joystick forward full stroke until the
machine just begins to move, then leave off the joystick
immediately. The display will read CRK PT = and show
the numeric crack point value.
3121142 6-63
13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
the crack point is set to. The screen will show:
DRIVE CAl:
LT FWD DRIVE: LT REV.DRIVE
CAL COMPLETE
ESC ENTER
ESC ENTER
MAE19060
MAE19060
15. Repeat steps 10 thru 12 for left reverse drive.
16. Left Reverse Drive Calibration will be followed by Right
Forward Drive Calibration which will be followed by
Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC twice
6-64 3121142
6.14 LSS SYSTEM

The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF
form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR:
ture.
a. LSS Sensor removal or replacement
There have been two different types of LSS system used on
this machine; b. Addition or removal of certain platform mounted
accessories. (Refer to Calibration)
NON CAN LSS - 4-pin Load Sensing System that does not
c. Platform is removed, replaced, repaired or shows
directly communicate system knowledge to the UGM via CAN-
evidence of impact.
bus. This system sends an overload signal from the LSS mod-
ule to the Platform Module. Configuration and Calibration of
the load sensing system occurs through the load sensing sys-
tem module analyzer connection. THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFICATION
NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. REFER TO TEST-
CAN LSS - This system can be 1-pin or 4-cell CAN based load
ING & EVALUATION.
sensing. The CAN systems communicate knowledge of the
load sensing system and pins via CANbus to the UGM directly.
All calibration procedures are menu driven through the use of
Configuration and Calibration of the load sensing system
a JLG Analyzer.
occurs through the analyzer connection at the UGM.
The LOAD TYPE menu is available at software revision level
If the actual platform load exceeds the selected Rated Load,
P7.25 and higher so machines equipped with 4-cell NON CAN
the following will occur:
LSS can remain functional if new software that supports 1-cell
1. The Overload Visual Warning Indicator will LSS is downloaded onto the machine. The LOAD TYPE menu is
flash at the selected control position (plat- defaulted to CAN LSS and must be changed to NON CAN LSS
form or ground). on machines that are equipped with the 4-cell NON CAN ver-
sion of LSS. If equipped with 4-cell NON CAN LSS and LOAD
TYPE is left at CAN LSS, the machine will behave as if over-
2. The Platform and Ground Alarms will sound 5 seconds loaded.
On, and 2 seconds Off.
3. All normal movement will be prevented from the plat-
form control position (optional - ground control func-
tions may be prevented).
4. Further movement is permitted by:
a. Removing the excess platform load until actual plat-
form load is less than Rated Load.
b. Operation of the overriding emergency system
(Auxiliary Power Unit).
c. By an authorized person at the ground control posi-
tion (optional - ground control functions may be
prevented).
3121142 6-65
Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and
select the various sub-menus. To access a sub-menu, press the
The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT
Load Sensing System. Sensor and status information is pre- Arrow keys to view the various displays (just like a Top Level
sented in real-time for the technician. Several sub-menus exist
to organize the data.
menu). To exit a sub-menu, press the ESC key .
Table 6-8, Diagnostic Menu Descriptions details the structure
To access the Diagnostic Menu, use the LEFT and RIGHT of the Diagnostic Menu, and describes the meaning of each
piece of information presented.
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to view the menu.
Table 6-8. Diagnostic Menu Descriptions
Diagnostics Menu Parameter (Displayed on Parameter Value

Description
(Displayed on Analyzer 1st Line) Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.
??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by Machine Con-
figuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as defined by Machine Config-
uration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.
??? if Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.
??? if Unhealthy**.
* Indicates only visible in service view mode
** Typically indicates a DTC is active
6-66 3121142
Calibration Procedure
5. Press the ENTER key to view the menu. Upon
1. Remove everything from the platform, except perma-
entry to the Calibration Menu, the JLG Control System
nently fixed JLG Accessories, to allow the Load Sensing
will link to the Analyzer and the screen will read:
System to record its’ weight during calibration. This
includes all tools, debris, and customer-installed devices.
2. Plug the JLG Analyzer into the Machine at the Ground
Station and enter Service Access Password 33271.
3. The platform should be approximately level for calibra- CALIBRATION:
tion. Level the platform from ground control (if neces- LOAD SENSING
sary) to within +/- 5°.
ESC ENTER
4. To access the Calibration Menu, use the LEFT and RIGHT
Arrow keys to select CALIBRATION from the Top Level
Menu. The screen will read:
MENu:
CALIBRATION
ESC ENTER
MAE19060
6. Press Enter . The Screen will read:
LOAD SENSING:
CALIBRATE?
MAE19060
ESC ENTER
NOTE: The Calibration Menu is not available in OPERATOR
ACCESS.
MAE19060
NOTE: Calibration will auto fail if LSS DTC's are active (443, 444,
4479, 4480, 663, 821, 822, 823, 824, 8218, 8222 -> 8238,
991, 992, 993, 994 or 99285).
3121142 6-67
Pressing the ESC key after starting calibration and 8. If the platform is empty, press ENTER . The screen
before calibration is complete will display the CAL FAILED will read:
message. This will not disturb the prior calibration infor-
mation.
7. Press ENTER . The analyzer screen will read: LOAD SENSING

ACCESSORY XXXLBS:
ESC ENTER
LOAD SENSOR:
PLATFORM EMPTY?
ESC ENTER
MAE19060
NOTE: Accessory weight will reset to 0 lbs. each time the machine
is re-calibrated and will need to be re-entered.
MAE19060 NOTE: The Accessory weight will be temporarily stored in the Con-
trol System until calibration has been completed success-
fully.
Refer to Table 6-9, Accessory Weights. Use the up and

down analyzer keys to enter the accessory weight(s) (in
6-68 3121142
lbs). When all the accessory weights are entered, press 9. The control system will calculate the load cell readings
and ensure it is greater than 130 lbs. (59 kg), but less
than 575 lbs.(261 kg).
ENTER . The screen will read:
If the platform weight is not within the allowed range,
the calibration attempt will be unsuccessful and the
Analyzer will show the following:
LOAD SENSING:
CALIBRATING....
LOAD SENSING:
ESC ENTER
CAL FAILED
ESC ENTER
MAE19060
Table 6-9. Accessory Weights

MAE19060
Accessory Weight
SkyWelder (stick welder) 70 lb (32 kg)
SkyWelder Prep Prep only = 15 lb (7 kg) 10. Press ENTER . The control system will ask for
Full install = 70 lb (32 kg) installed accessories. The screen will show the following:
SkyCutter (plasma cutter) 70 lb (32 kg)
SkCutter / SkyWelder Combo 140 lb (64 kg)
Fire Extinguisher 45 lb (20 kg)
Overhead SoftTouch 80 lb (36 kg) LOAD SENSING:
SKY GLAZIER?
Work Surface 20 lb (9 kg)
NOTE: Not all Accessories are available on every JLG model.
Some Accessory combinations are prohibited due to ESC ENTER
excessive weight and/or load restriction. If any installed
JLG Accessories are labeled with weight decals but are
not listed in the table above, include their weight when
entering the ACC WEIGHT value.
MAE19060
3121142 6-69
11. Use the analyzer keys to select N for no or Y for yes. Press Table 6-10. SkyGlazier Capacity Reductions
ENTER . The screen will read: PLATFORM OVRLD

Capacity PLATFORM OVRLD
RESTRICT
500 lb (227 kg) 400 lb (181 kg) n/a
550 lb (250 kg) 400 lb (181 kg) n/a
600 lb (272 kg) 400 lb (181 kg) n/a
LOAD SENSING:
750 lb (340 kg) n/a 590 lb (268 kg)
PIPE RACKS?
1000 lb (454 kg) n/a 750 lb (340 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
ESC ENTER
two values.
Table 6-11. Pipe Rack Capacity Reductions
PLATFORM OVRLD
Capacity PLATFORM OVRLD
RESTRICT
500 lb (227 kg) 400 lb (181 kg) n/a
550 lb (250 kg) 450 lb (204 kg) n/a
600 lb (272 kg) 500 lb (227 kg) n/a
750 lb (340 kg) n/a 650 lb (295 kg)
1000 lb (454 kg) n/a 900 lb (408 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
MAE19060
two values.
12. Use the analyzer keys to select N for no or Y for yes. Press
ENTER . The control system will default to an esti-

mate of unrestricted capacity, which can be adjusted if
necessary. Refer to Table 6-10, SkyGlazier Capacity
Reductions and Table 6-11, Pipe Rack Capacity Reduc-
tions.The screen will read:
PLATFORM OVRLD:
UNRSTRICT XXXLBS
ESC ENTER
MAE19060
6-70 3121142
13. Press ENTER . The following screen will be dis- 14. Press ENTER . If calibration is successful, the screen
played for restricted capacity, which can be adjusted if will read:
necessary. Refer to Table 6-10, SkyGlazier Capacity
Reductions and Table 6-11, Pipe Rack Capacity Reduc-
tions.
LOAD SENSING:
CAL COMPLETE
PLATFORM OVRLD:
ESC ENTER
RSTRICT XXXLBS
ESC ENTER
MAE19060
MAE19060
3121142 6-71
Testing & Evaluation 6. Confirm Control System Capacity Indication (optional

for vehicles with Dual Capacity Ratings). For vehicles
Refer to Troubleshooting if the Load Sensing System fails to equipped with a Capacity Select switch on the Platform
meet these guidelines. Console Box, it is necessary to examine an additional
interface between the Load Sensing System and the
1. Connect the JLG Analyzer.
Control System. Using the keyswitch, select Platform
2. Level the Platform. The platform should be approxi- Mode and power-up. If necessary, put the boom in the
mately level for analysis, or the guidelines below will not transport position (completely stowed) and center the
be applicable. Level the platform from Ground Control Jib Plus (if equipped). Place the Capacity Select switch in
(if necessary) to within ±5 degrees. the unrestricted position and ensure that the proper
indicator illuminates on the Platform Console Box. Plug
3. Observe the Empty Platform Weight. Proceed to the
the JLG Analyzer into the Analyzer connection and pro-
DIAGNOSTICS, PLTLOAD sub-menu and observe the
ceed to the DIAGNOSTICS, SYSTEM submenu. Ensure
measured platform load. All tools, debris, and customer-
that the CAPACITY displays indicate OFF. Place the
installed devices shall be removed during evaluation.
Capacity Select switch in the unrestricted position (if so
Ideally, the PLTLOAD should be zero but can vary ±15lbs
equipped) and ensure that the proper indicator illumi-
(± 7kg). Further, the reading should be stable and
nates on the Platform Console Box (but does not flash).
should not vary by more than ±2lbs (±1kg) (unless there
For vehicles with unrestricted capacity, ensure that the
is heavy influence from wind or vibration).
unrestricted CAPACITY display indicates ON but the
4. Use the Technician’s Weight to Evaluate. The technician restricted CAPACITY indicates OFF. For vehicles with
should enter the platform and record the PLTLOAD read- restricted capacity, ensure that the unrestricted CAPAC-
ing while standing in the center of the platform. ITY display indicates OFF but the restricted CAPACITY
indicates ON.
5. Confirm Control System Warnings and Interlocks. Using
the keyswitch, select Platform Mode and power-up. 7. Confirm Load Sensing System Performance with Cali-
Start the vehicle’s engine and ensure that all controls are brated Weights. Operate the vehicle from Ground Con-
functional and the Load Sensing System’s Overload trol and place the boom in the transport position (fully
Visual and Audible Warnings are not active. Simulate an stowed) for safety. Plug the JLG Analyzer into the control
Overload by unplugging the Shear Beam Load Cell. The system connection and proceed to the DIAGNOSTICS,
Overload Visual Warning should flash, and the Audible PLTLOAD display. Place 500lbs (230kg) in the platform
Warning (at Platform and Ground) should sound for 5 and ensure that PLTLOAD is with ±5% of the actual
seconds On, and 2 seconds Off. With the engine run- weight. For Dual Capacity vehicles, do the same for the
ning, all control should be prevented. Cycle the Platform alternate capacity (unrestricted or restricted).
EMS to stop the engine and then power-up again. The
Overload Visual and Audible Warning should continue.
Confirm that controls are responsive when using the
Auxiliary Power Unit for emergency movement. Recon-
nect the Load Cell. The Overload Visual and Audible
Warnings should cease and normal control function
should return. Switch the vehicle’s keyswitch to Ground
Mode and repeat the above procedure. The Overload
Visual Warning at the Ground Controls should flash, and
the Audible Warning (at Platform and Ground) should
sound for 5 seconds On, 2 seconds Off. However, the
controls should remain functional when using the
engine and the Auxiliary Power Unit (if the Control Sys-
tem’s MACHINE SETUP, LOAD is set to “2=CUTOUT PLT”. If
set to “3=CUTOUT ALL”, then Ground Controls will be
prevented when using the engine as in the platform).
6-72 3121142
Troubleshooting
The following tables are furnished to provide possible resolu-
tions for common difficulties. Difficulties are classified as Gen-
eral, Calibration, Measurement Performance, and Host System
Functionality.
Table 6-12. LSS Troubleshooting Chart
Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.
FORM LOAD) is not within ±15lbs (±7kg) of
zero. 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
or
Platform Load readings (DIAGNOTICS, PLTLOAD) 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of damage.
are unstable by more than ±2lbs (±1kg) (with- Inspect wiring where damage to the channel is apparent.
out the influence of vibration or wind).
or 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAG-
There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pressure above the
(DIAGNOSTICS, PLTLOAD) based on the location sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted upside-down).
of the load. Tolerance to variations is 20lbs for
an evaluation using the technician’s weight, 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS,
and +5% of Rated Load when using calibrated CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2lbs (±1kg) (without the influ-
weights. ence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug the connector and inspect for dirt or
moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away
with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or
accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of
the connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself will require replacement of the sensor.
5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be replaced
immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000lbs [>2722kg]).
The Visual and Audible Overload Warnings fail The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
to sound when platform is loaded beyond Rated
Load, or when simulated by unplugging the 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the Access
Load Cell. Controls remain functional at Plat- Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should be displayed (plat-
form and Ground Control positions. form controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstance, the selec-
tion “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
The Ground Audible Warning fails to sound, but The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and
the Platform Audible Warning sounds properly. Ground Module.
Controls remain functional at the Ground Con- The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System can be
trol position during an overload, or when simu- configured to prevent ground and platform controls for country- or customer-specific circumstances.
lated by unplugging the Load Cell. The Controls Using the JLG Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to
at the Platform Control position are prevented “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and
when using the engine, but not when using the ground controls in the event of overload.
Auxiliary Power Unit.
3121142 6-73
6.15 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu.
The screen should read:
1. Use the following procedure to reset the MSSO system.
desired position.
3. Plug the analyzer into the connector coming from the CALIBRATIOn:
ground control module or from the platform console. LOAD SENSING
NOTE: If performing the procedure from the platform console, the

Emergency Stop switch on the ground console must also ESC ENTER
be pulled out.
4. Pull out the Emergency Stop switch.

HELp - PRESS ENTER
ESC ENTER
MAE19060
10. Press ENTER .
11. Use the Down arrow to reach MSSO RESET.
MAE19060
6. Use the arrow button to reach OPERATOR ACCESS. Press
Enter .
8. Use the right Arrow key to reach MENU: CALIBRATIONS.
Press Enter .
6-74 3121142
12. Press Enter . The screen will read: 13. Press Enter . The JLG Control System will reset an
active 873 DTC and the MSSO System will be reset. Press
Escape to return to the CALIBRATIONS menu.

MSSO RESET:
CONFIRM?
ESC ENTER
MAE19060
3121142 6-75
6.16 ELECTRONIC PLATFORM LEVELING allow the operator to operate the machine as a new level set-
point is taken.
Platform Leveling Fault Warning VALVE DRIVER ERRORS

The JLG Control System takes a snapshot of the two sensor val- There are three possible level valve driver errors, short to bat-
ues and records the difference once on each power up. The tery, short to ground, and open circuit.
Control system allows a ±5 degree difference from those val-
ues. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at 1. In the case of a short to ground or an open circuit, the
11 degrees, the difference is 6 degrees and the DTC is trig- platform valve cannot be turned on and the following
gered when the sensors are 1 degree (or less) apart or 11 will occur:
degrees (or more) apart. a. All interactions with platform leveling shall cease
If a fault occurs in the platform leveling system the following b. The Electronic Leveling System Fault Lamp shall
will occur: flash (to indicate that the leveling function has been
lost).
1. Automatic platform leveling will stop (except when
there is a fault in only one sensor automatic leveling will c. The platform alarm will sound.
remain active as the control system will use the other d. A system fault will be logged.
sensor to control leveling) e. All function speeds (lift, swing, telescope and drive)
2. The level fault lamp will flash will be placed in creep mode (except when the plat-
form is in the transport position).
3. The audible alarm will sound
2. In the case of a short to battery on one of the platform
4. All functions will default to creep speed if the platform is leveling valves, the valve cannot be turned off and the
out of the transport position (extended more than 12” following will occur:
[51 cm] 1350SJP; 24" [60.9 cm] 1200SJP, or elevated
above the horizontal position). a. The platform dump valve will be turned off to pre-
vent unintended tilting of the platform.
To reset the fault the emergency stop switch should be recy-
b. All interactions with platform leveling shall cease.
cled.
c. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has been
lost).
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION,
d. The platform alarm will sound.
SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESEN-
TATIVE TO INVESTIGATE THE FAULT. e. A system fault will be logged.
f. All function speeds (lift, swing, telescope and drive)
Fault Response will be placed in creep mode (except when the plat-
ERROR RESPONSE form is in the transport position)
If basket level varies from the current setpoint by ± 5.5º for 3. In the case of a short to battery on the platform dump
more than 1.5 seconds when the platform is not in the trans- valve, the valve cannot be turned off. The controllability
port position, the following events will occur: of the platform leveling function will be impaired and
the following will occur:
1. The platform dump valve will be disabled (level, rotate
and jib functions disabled). a. All interactions with platform leveling shall cease.
b. The Electronic Leveling System Fault Lamp shall
2. The level system fault lamp will flash (to indicate that flash (to indicate that the leveling function has been
the leveling function has been lost). lost).
3. The platform alarm will sound. c. The platform alarm will sound.
4. A system fault will be logged. d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive)
5. All function speeds (lift, swing, telescope and drive) will
will be placed in creep mode (except when the plat-
be placed in creep mode (except when the platform is in
form is in the transport position).
the transport position see below).
Lift, swing, drive and telescope will continue to operate
When the unit is in the transport position and driving and the
current setpoint varies by ± 5.5º for more than 8 seconds the In each of the cases above it shall be necessary to re-cycle the
events 1,2,3 & 4 above will occur. (note function speeds will EMS to clear the fault. Operable functions shall be in the creep
operate normally). Cycling the EMS will clear the fault and mode except while below elevation.
6-76 3121142
TILT SENSOR ERRORS CAN Errors

If the secondary tilt sensor is faulty, the control system will The Ground Module has two direct outputs dedicated to over-
continue to utilize information from the primary sensor. riding the Platform Module’s control of the leveling valves. The
Ground Module “Platform Level Up/Down” outputs are used
If the primary sensor is faulty, the control system will switch to to control the platform level up and down valves.
the backup sensor for control.
When in ground mode, if the Ground Module reads a platform
In both cases above the following will occur: leveling switch command, the switch command is communi-
1. The Electronic Leveling System Fault Lamp will flash (to cated over CAN to the Platform Module where it is handled
indicate that there is a leveling fault). normally.
2. The platform alarm will sound. If Ground Module determines that CAN communication is
inoperable, it turns on the platform control valve and the
3. A system fault will be logged. appropriate platform leveling override outputs while the
4. All function speeds (lift, swing, telescope, jib and drive) switch is engaged.
will be placed in creep mode (except when the platform If the Platform Module is still running when CAN is down noth-
is in the transport position). ing will operate when in platform mode. When the operator
5. Automatic leveling remains active. switches to ground mode, the platform will not control any of
its valve outputs and a CAN error message is signaled.
Lift, swing, drive and telescope will continue to operate.
In each of the cases above it will be necessary to re-cycle the Additional Platform and Jib Valves
EMS to clear the fault. Operable functions shall be in the creep The high side drivers for the platform left and right and the jib
mode except while below elevation. up and down valves are be located in the Platform Module and
are proportional. Flow through the valves is individually con-
When both sensors appear to be working but have measure-
trollable. The individually controlled duty cycle will be the
ments that disagree by ±5.5º The following will occur:
same as would otherwise have been commanded to the flow
1. All interactions with platform leveling shall cease. control valve.
2. The Electronic Leveling System Fault Lamp shall flash (to Only one platform or jib function is allowed at one time to
indicate that the leveling function has been lost). limit the amount of current draw, minimizing the voltage drop
on the supply to the Platform Module.
3. The platform alarm will sound.
The function is enabled first shall remain active until it is
4. A system fault will be logged.
released. Any other function commanded while another func-
5. All function speeds (lift, swing, telescope and drive) will tion is active is ignored.
be placed in creep mode (except when the platform is in
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3121142 6-77
Platform Leveling Calibration Procedure STEP 3: BLEEDING THE PLATFORM VALVES

STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 1. Put machine into “Ground Mode”.
1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer.
2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen.
3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode.
4. Enter “33271” to get into Access Level 1 mode. 5. Go to the "Personalities" menu.
5. Go to the "Personalities" menu and adjust the following 6. Using the left arrow button, go to the "Ground Mode"
personalities. Refer to the Personality Ranges/Defaults menu.
table in Section 6 - JLG Control System for proper setting 7. Hit ENTER.
values.
8. Using the UP/DOWN arrows, adjust the following per-
Basket Level Up Min sonalities to 100%.
Basket Level Up Max
Basket Level Down Max Basket Rotate
Jib Up Min Basket Level
Jib Down Min Jib U/D (if configured)
6. Recycle EMS. Start up the machine and exercise each above platform
STEP 2: CALIBRATING THE PLATFORM LEVEL function (from the ground) eight (8) to ten (10) times for
SENSORS 5 seconds in each direction.
1. Put machine into “Ground Mode”. 9. Return the personality settings back to the values as
shown in the Personality Ranges/Defaults table in Sec-
2. Start machine and plug in Analyzer. tion 6 - JLG Control System.
3. Manually level the platform with the switch on the MTB. 10. Recycle EMS.
4. Go to the “Access Level 2” screen. STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
5. Enter “33271” to get into Access Level 1 mode.
1. Put machine into “Ground Mode”.
6. Go to the “Calibrations” menu and hit ENTER.
2. Start machine and plug in Analyzer.
7. Use RIGHT ARROW go to “Plat. Leveling” screen.
3. Go to the “Access Level 2” screen.
8. Hit ENTER. “Calibrate?” prompt should appear.
4. Enter “33271” to get into Access Level 1 mode.
9. Hit ENTER again to calibrate level sensors.
5. Go to the “Calibrations” menu and hit ENTER.
10. When calibration has been successful “Cal. Complete”
should appear. 6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
11. Cycle power to the machine. 7. “Calibrate?” prompt should appear. Hit ENTER again.
8. You will hear engine go to 1800 rpm.
9. Using UP ARROW, increase the value until you see the
basket up movement.
6-78 3121142
10. Hit ENTER again. “Cal. Complete” message should 2. Plug the analyzer into the connector inside the Ground
appear control box.
11. Engine should again return to idle.
12. Hit ESC should return to “Basket U Crkpt” screen.
13. Hit RIGHT ARROW to get to the “Basket D Crkpt” screen.
Hit ENTER.
14. “Calibrate?” prompt should appear. Hit ENTER again.
Using UP ARROW, decrease the value until you see the basket
down movement.
Hit ENTER again. “Cal. Complete” message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
3. Pull out the Emergency Stop switch and start the
engine.
6.17 CALIBRATING PLATFORM LEVEL
Step 1: Setting The Platform Valve Minimums

Ground position.
HELP - PRESS ENTER
ESC ENTER
MAE19060

3121142 6-79
7. Use the arrow button to reach PERSONALITIES adjust 5. The analyzer screen should read:
the following personalities. Refer to the Personality
Ranges/Defaults table for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max HELP - PRESS ENTER
Jib Up Min
Jib Down Min
8. Recycle EMS. ESC ENTER
Step 2: Calibrating The Platform Level Sensors

Ground position.
MAE19060

8. Use the arrow button to reach CALIBRATIONS menu and
hit ENTER.
9. Use right arrow go to PLAT. LEVELING screen.
10. Hit ENTER. The screen should read:
control box.
PLAT LEVELING:
CALIBRATE?
ESC ENTER
3. Pull out the Emergency Stop switch and start the

engine.
MAE19060
4. Manually level the platform with the switch on the Main
Terminal Box. 11. Hit ENTER again to calibrate level sensors.
6-80 3121142
12. When calibration has been successful CAL. COMPLETE 4. The analyzer screen should read:
should appear.
13. Cycle power to the machine.
Step 3: Bleeding The Platform Valves HELp - PRESS ENTER

Ground position.
ESC ENTER
MAE19060
2. Plug the analyzer into the connector inside the Ground 6. Enter the Access Code, 33271.
control box. 7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND MODE
menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following per-
sonalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform

function (from the ground) eight (8) to ten (10) times for
5 seconds in each direction.
11. Return the personality settings back to the values as
shown in the Personality Ranges/Defaults table in Sec-
3. Pull out the Emergency Stop switch and start the tion 6 - JLG Control System.
engine. 12. Recycle EMS.
3121142 6-81
Step 4: Calibrating The Platform Level Up And 4. The analyzer screen should read:
Down Valve Crackpoints

Ground position.
HELp - PRESS ENTER
ESC ENTER
MAE19060
control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER again.
11. Using UP ARROW, increase the value until you see the
basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
3. Pull out the Emergency Stop switch and start the screen. Hit ENTER.
engine.
16. CALIBRATE? prompt should appear. Hit ENTER again.
Using UP ARROW, increase the value until you see the basket
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
6-82 3121142
6.18 CALIBRATING LIFT CRACK POINT 3. Pull out the Emergency Stop switch and Start the
engine.
form position.

platform control box. HELp - PRESS ENTER
ESC ENTER
MAE19060

Enter.
3121142 6-83
8. Use the arrow keys to reach Upper Lift Crack Point 10. Hit Enter. The screen will read:
(UPPER LIFT CRKPT). The screen will read:
U LIFT U CRK PT:

UPPER LIFT CAL: CRK PT = 0
UPPER LIFt CRKPT
ESC ENTER
ESC ENTER
MAE19060
MAE19060
11. Hit Enter again. The screen will read:
9. Hit enter. The screen will read:
U LIFT U CRk PT:

UPPER LIFT CAL: CRK PT = XX
CALIBRATE?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
12. Activate the Lift Up function by fully stroking the joy-
stick until the boom starts to move, then leave off imme-
diately. The display will read CRK PT = and show the
numeric crack point value.
6-84 3121142
13. Hit enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
UPPER LIFT CAL:

CAL VALUE: UPPER LIFT DN
CRK PT = XX
ESC ENTER
ESC ENTER
MAE19060
MAE19060
15. Repeat steps 10 thru 12 for the Lift Down function.
16. After completing all the Tele Calibrations, hit ESC twice
3121142 6-85
6.19 CALIBRATING TELESCOPE CRACK POINT 3. Pull out the Emergency Stop switch and Start the
engine.
form position.

platform control box. HELp - PRESS ENTER
ESC ENTER
MAE19060

Enter.
6-86 3121142
8. Use the arrow keys to reach Upper Telescope Crack Point 10. Hit Enter. The screen will read:
(UPPER TELE CRKPT). The screen will read:
UPPER TELE CAL:

CALIBRATIONS: UPPER TELE OUT
UPPER TELE CRKPT?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
11. Hit enter again. The screen will read:
9. Hit Enter. The screen will read:
UT OUT CRK PT:

UPPER TELE CAL: CRK PT = 0
CALIBRATE?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
12. Activate the Tele Out function until the boom starts to
move, then leave off immediately. The display will read
CRK PT = and show the numeric crack point value.
3121142 6-87
13. Hit enter. The number displayed will be the value that 15. Hit Enter. The screen will read:
UPPER TELE CAL

CAL VALUE: UPPER TELE In
CRK PT = XX
ESC ENTER
ESC ENTER
MAE19060
MAE19060
16. Repeat steps 10 thru 12 for the Tele In function.
14. Hit Enter. The screen will read: 17. After completing all the Tele Calibrations, hit ESC twice
UPPER TELE:
CAL COMPLETE
ESC ENTER
MAE19060
6-88 3121142
6.20 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground
control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE
FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following

conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
d. Turntable centered. 4. Pull out the Emergency Stop switch and start the
e. Boom fully retracted. engine.
f. Boom angle is less than 45°. 5. The analyzer screen should read:
g. Machine on firm, level ground.
Ground position.
HELP - PRESS ENTER
ESC ENTER
MAE19060

Enter.
3121142 6-89
9. Use the arrow keys to reach the TILT SENSOR. The screen 6.21 CALIBRATING THE BOOM SENSORS
should read:
DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR

THE REAR WHEEL TO LIFT FROM THE GROUND APPROXIMATELY 1 INCH (2.5
CALIBRATION: CM). IF THE WHEEL RAISES APPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10
TILT SENSOR CM] OR MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER OPERA-
TION OR THE NEED FOR BLEEDING, THEN PROCEED WITH THE BOOM SENSOR
CALIBRATION PROCEDURE.
ESC ENTER
Use the following step-by-step procedure to calibrate the

boom sensors.
1. Before the boom sensors can be calibrated, the follow-

ing conditions must be met:
a. Steering, telescope crack points, and tilt previously
calibrated
b. Axles Extended
c. Wheels Straight
d. Platform Unloaded
e. Jib Horizontal
MAE19060
f. Jib Swing Centered
10. Press ENTER. g. Platform Level
11. When prompted, swing turntable 180° to opposite end h. Platform Centered
of chassis. i. Turntable Centered
12. Press ENTER. The screen should read: j. Boom Fully Retracted
k. Level Ground (within 1.5°)
CAL COMPLETE?
ESC ENTER Figure 6-17. Boom Sensor Calibration Position 1
MAE19060
13. Upon completing swing calibration, swing turntable

180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
6-90 3121142
2. Position the Platform/Ground select switch to the 5. The analyzer screen should read:
Ground position.
HELp - PRESS ENTER
ESC ENTER

control box.
MAE19060

Enter.
9. Use the arrow keys to reach BOOM SENSORS. The screen
should read:
CALIBRATIONS:
BOOM SENSORS
4. Pull out the Emergency Stop switch and start the ESC ENTER
engine.
MAE19060
3121142 6-91
10. Hit Enter. The screen will read: 12. After verifying all load (personnel or material) is
removed from the platform, hit Enter. The screen will
read:
CAL POSITION 1:
CHECK SYSTEM?
CAL POSITION 1:
ESC ENTER
JIB HORIZONTAL?
ESC ENTER
MAE19060
11. After verifying all the conditions listed in step 1 are met,
MAE19060
hit Enter. The screen will read:
13. After visually verifying that the jib is horizontal, hit Enter.
The screen will read:
CAL POSITIon 1:
UNLOAD PLATFORM?
CAL POSITION 1:
LEVEL PLATFORM?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
6-92 3121142
14. After visually verifying the platform is level, hit Enter. The 16. After operating telescope in to verify the boom is fully
screen will read: retracted, hit Enter. The screen will read:
CAL POSITIOn 1: CAL POSITION 1:

CENTER PLATFORM? SKY WELDER YES/NO?
ESC ENTER ESC ENTER
MAE19060 MAE19060
15. After visually verifying the platform is centered, hit 17. Use the up/down arrows to select YES if the accessory is
Enter. The screen will read: installed, NO if it is not installed and hit enter. The screen
will read:
CAL POSITION 1:
TELE IN TO STOP? CAL POSITION 1:
SKY CUTTER YES/NO?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
3121142 6-93
18. Use the up/down arrows to select YES if the accessory is 20. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter. The screen
will read: will read:
CAL POSITION 1: CAL POSITION 1:

SKY GLAZIER YES/NO? PIPE RACKS YES/No?
ESC ENTER ESC ENTER
MAE19060 MAE19060
19. Use the up/down arrows to select YES if the accessory is 21. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter. The screen
will read: will read:

SKY BRIGHT YES/NO? CAMERA MOUNT YES/No?
ESC ENTER ESC ENTER
MAE19060 MAE19060
6-94 3121142
22. Use the up/down arrows to select yes if the accessory is 24. Lift up to stop (full stroke of cylinder) for Calibration
installed, no if it is not installed and hit Enter. The screen Position 2. When the machine is in that position, hit
will read: Enter.
CAL POSITIOn1:
CALIBRATE?
ESC ENTER
Figure 6-18. Boom Sensor Calibration Position 2

MAE19060
23. After making sure the machine is in Calibration Position

1, hit Enter. The screen will read: The screen will read:
CAL POSITION 3:
CAL POSITION 2:
SWING 180 DEG.
LIFT UP TO STOP
ESC ENTER
ESC ENTER
MAE19060
MAE19060
3121142 6-95
25. Swing 180 degrees (centered over opposite end of chas- When Position 3 calibrating is complete the screen will
sis) for Calibration Position 3. read:
CAL POSITION 3:
PRESS ENTER
ESC ENTER
When the machine is in the proper position, hit Enter.

The screen will read: MAE19060
26. Press Enter. The screen will read:
CAL POSITION 3:
CALIBRATING....
CAL POSITION 4:
ESC ENTER
SWING 180 DEG
ESC ENTER
MAE19060
MAE19060
6-96 3121142
Swing the machine back 180 degrees (centered over When Position 4 calibrating is complete, the screen will
original end of chassis) for Calibration Position 4. read:
CAL POSITION 4:
PRESS ENTER
ESC ENTER
When the machine is in the proper position, hit Enter. MAE19060

CAL POSITION 4:
CALIBRATING....
ESC ENTER
MAE19060
3121142 6-97
27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.

TELE OUT TO STOP TELE IN TO STOP
ESC ENTER ESC ENTER
MAE19060 MAE19060
Telescope out to stop (boom must be fully extended) for

Calibration Position 5.
6-98 3121142
28. Retract to stop (boom must be fully retracted) for Cali- 29. Lift down to stop (boom must be on boom rest) for Cali-
bration Position 6. bration Position 7.

The screen will read as follows:
CAL POSITION 7:
CALIBRATING....
ESC ENTER

CAL POSITION 7:
LIFT ON TO STOP
ESC ENTER
MAE19060
MAE19060
3121142 6-99
When Position 7 Calibrating is complete, the screen will 30. Lift until the function stops (controller will stop at 5
read: degrees above horizontal) for Calibration Position 8.
CAL POSITION 7:
PRESS ENTER
ESC ENTER Figure 6-24. Boom Sensor Calibration Position 8

CAL POSITION 8:
PRESS ENTER
ESC ENTER
MAE19060
Press Enter. The screen will read:
CAL POSITION 8:
LIFT UP
ESC ENTER
MAE19060
MAE19060
6-100 3121142
Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The
screen will read:
CAL POSITION 9:
TELE TO YELLOW CAL POSITION 9:
CALIBRATING......
ESC ENTER
ESC ENTER
MAE19060
MAE19060
31. Telescope to the yellow witness mark (controller will be
close - operator must position the pointer to center line When Position 9 calibrating is complete, the screen will
on decal within 0.25" [6 mm]) for Calibration Position 9. read:
CAL POSITION 9:
Figure 6-25. Boom Sensor Calibration Position 9 PRESS ENTER
ESC ENTER
MAE19060
3121142 6-101
Press Enter. The screen will read: When the boom is in the proper position, the screen will
read:
CAL POSITION 10:

TELE TO GREEN CAl POSITION: 10
PRESS ENTER
ESC ENTER
ESC ENTER
MAE19060
MAE19060
32. Telescope in to green witness mark (controller will find
the position - operator must visually verify the position). Press Enter. The screen will read:
BOOM SENSORS:
Figure 6-26. Boom Sensor Calibration Position 10 CAL COMPLETE
ESC ENTER
MAE19060
33. After completing all the Boom Sensors Calibrations, hit

ESC twice to go back to Calibrations.
34. Cycle the emergency stop switch.
6-102 3121142
Boom Control System Check Procedure

Perform the following check with no load (personnel or mate-
rial) in the platform from the ground control station.
1. With the boom fully retracted, raise the boom off the
boom rest to horizontal.
2. Position the jib horizontal, jib straight, and platform
level.
3. Extend the boom until it stops.
4. Boom must stop on colored stripe matching the capac-
ity indicator. If the boom does not stop on the correct
stripe, the system must be repaired by JLG authorized
Service Personnel before the machine can be used.
5. Push and hold the gray Boom Control System Test But-
ton on the ground control panel. The lighting of the
green Boom Control System Calibrated indicator indi-
cates the system is functioning properly. No indicator
light or the lighting of the red Boom Control System
Warning indicator indicates the system must be repaired
by JLG authorized Service Personnel before the machine
can be used.
3121142 6-103
Figure 6-27. Fault Code Light Location
6-104 3121142
Table 6-13. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
001 0 1 EVERYTHING OK The normal help message in
Platform Mode.
002 0 2 GROUND MODE OK The normal help message in
Ground Mode.
0010 0 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-
VATED MAX" while the vehicle is
out of transport position.
000 0 0 <<< HELP COMMENT >>>
0011 0 11 FSW OPEN A drive / boom function was
selected with the Footswitch
open.
0012 0 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
0013 0 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the
Platform is elevated and the
Chassis is tilted.
0014 0 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 - Not reported during power-up.
degrees for more then 4 sec-
onds.
0015 0 15 LOAD SENSOR READING UNDER WEIGHT LSS has been calibrated and the Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
less than -50lbs for 2 seconds. If
the load sensing system deter- Re-calibrate the load sensing sys-
mines that the reading is greater tem if the above items are not a
than -50lbs for 5 seconds this factor.
fault will no longer be annunci-
ated.
No control system interlocks

present when DTC is active.
0016 0 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control system
equipped vehicle only.
0017 0 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment viola- - Envelope control system
tion. equipped vehicle only.
0018 0 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment viola- - Envelope control system
0019 0 19 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a main envelope viola- - Main envelope system equipped
tion. vehicle only.
0020 0 20 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a tower envelope viola- - Tower envelope system
210 2 1 <<< POWER-UP >>>
211 2 1 POWER CYCLE The normal help message is
issued at each power cycle.
212 2 1 KEYSWITCH FAULTY Both Platform and Ground
modes are selected simultane-
ously.
3121142 6-105
Flash
Code
213 2 1 FSW FAULTY Both Footswitches are closed for
more then one second.
220 2 2 <<< PLATFORM CONTROLS >>>
227 2 2 STEER SWITCHES FAULTY Both Steer Left and Steer Right
inputs are closed simultane-
ously.
2211 2 2 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power-
more then seven seconds. up.
2212 2 2 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected - Can be reported during power-
with Footswitch open. up.
2213 2 2 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected
with Footswitch open.
2215 2 2 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2216 2 2 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2217 2 2 D/S JOY. CENTER TAP BAD The D/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2218 2 2 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2219 2 2 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2220 2 2 L/S JOY. CENTER TAP BAD The L/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2221 2 2 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was
selected with Footswitch open.
2222 2 2 WAITING FOR FSW TO BE OPEN The Footswitch was closed dur- - Can be reported during power-
ing Platform selection. up.
2223 2 2 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected
with Footswitch open.
2224 2 2 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed dur-
ing engine start.
230 2 3 <<< GROUND CONTROLS >>>
234 2 3 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both direc-
tions selected together.
235 2 3 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER A boom function was selected
before aux power.
6-106 3121142
Flash
Code
236 2 3 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected
before engine start.
237 2 3 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed dur-
ing power-up.
250 2 5 <<< FUNCTION PREVENTED >>>
259 2 5 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been
changed.
2513 2 5 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the
vehicle generator is running
AND is configured to prevent
drive.
2514 2 5 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible
while the vehicle is being driven
AND is configured to not allow
simultaneous drive & boom
operation.
2515 2 5 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the
vehicle above elevation AND is
configured to prevent drive
while above elevation.
2516 2 5 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while
Boom functions are selected
AND is configured to not allow
simultaneous drive & boom
operation.
2517 2 5 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the
vehicle is tilted and above eleva-
tion AND is configured to pre-
vent drive while tilted and
above elevation.
2521 2 5 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while
the vehicle is in 1000 LB Mode.
2522 2 5 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very lim-
ited restrictions for all hydrau-
lics systems.
2523 2 5 BACKUP BLAM COMMUNICATIONS ACTIVE RS232 serial backup communi-
cations link to the BLAM is
active.
2524 2 5 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL RS232 serial backup communi-
cations link to the BLAM is
needed but an analyzer is con-
nected.
2587 2 5 RUNNING AT CREEP - PLATFORM LEVELED UNDER The control system has deter-
mined that the platform is lev-
eled under and is being
considered to be in a loading/
unloading position. Boom,
Tower, and Level Override func-
tions will operate at creep
speed.
3121142 6-107
Flash
Code
330 3 3 <<< GROUND OUTPUT DRIVER >>>
331 3 3 BRAKE - SHORT TO BATTERY There is a Short to Battery to the
Brake Valve.
332 3 3 BRAKE - OPEN CIRCUIT There is an Open Circuit to the
Brake Valve.
3311 3 3 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3316 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Forward Drive Valve. cles only.
3317 3 3 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3318 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3320 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Reverse Drive Valve. cles only.
3321 3 3 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3322 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3324 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3325 3 3 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3326 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3328 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
3329 3 3 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3330 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3336 3 3 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 3 3 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
6-108 3121142
Flash
Code
3339 3 3 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 3 3 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 3 3 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the
3342 3 3 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
3343 3 3 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Cold Start Advance Solenoid.
3344 3 3 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
3345 3 3 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
3349 3 3 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 3 3 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3351 3 3 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 3 3 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 3 3 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 3 3 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 3 3 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 3 3 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 3 3 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 3 3 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3368 3 3 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3369 3 3 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the
Two Speed Valve.
3370 3 3 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 3 3 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3121142 6-109
Flash
Code
3372 3 3 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3373 3 3 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped
Generator Relay. vehicles only.
3374 3 3 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the - Generator / Welder equipped
3375 3 3 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the - Generator / Welder equipped
3376 3 3 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the - Head Light equipped vehicles
Head Light Relay. only.
3377 3 3 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles
3378 3 3 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the - Head Light equipped vehicles
3379 3 3 HOUR METER - SHORT TO GROUND There is a Short to Ground to the
Hour Meter.
3380 3 3 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the - Can be reported during power-
Hour Meter. up.
3381 3 3 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the
Hour Meter.
3385 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Up Override equipped vehicles only.
Valve.
3386 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3387 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3391 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Down Override equipped vehicles only.
Valve.
3392 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3393 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3394 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 3 3 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3396 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
6-110 3121142
Flash
Code
3397 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 3 3 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3399 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
33100 3 3 JIB LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Up Valve.
33101 3 3 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Up Valve.
33102 3 3 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Up Valve.
33103 3 3 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Down Valve.
33104 3 3 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Down Valve.
33105 3 3 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Down Valve.
33118 3 3 SWING RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Right Valve.
33119 3 3 SWING RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Right Valve.
33120 3 3 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope In Valve.
33121 3 3 SWING RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Right Valve.
33122 3 3 SWING LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Left Valve.
33123 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope Out Valve.
33130 3 3 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 3 3 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the
Throttle Actuator.
33132 3 3 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 3 3 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Control Valve. equipped vehicles only.
33134 3 3 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
3121142 6-111
Flash
Code
33135 3 3 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
33136 3 3 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift APU Valve.
33137 3 3 MAIN LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33138 3 3 MAIN LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33139 3 3 MAIN LIFT PILOT - PRESSURE FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Failure.
33140 3 3 MAIN LIFT PILOT - NO PRESSURE The Main Lift Pilot has No Pres- - 1250AJP only.
sure.
33141 3 3 MAIN LIFT PILOT - PRESSURE SWITCH FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Switch Failure.
33142 3 3 TOWER LIFT APU VALVE - STUCK OPEN The Tower Lift APU Valve is Stuck - 1250AJP only.
Open
33143 3 3 TOWER LIFT ENABLE VALVE - STUCK OPEN The Tower Lift Enable Valve is - 1250AJP only.
Stuck Open
33144 3 3 TOWER LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift Enable Valve.
33145 3 3 TOWER LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33146 3 3 TOWER LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33147 3 3 TOWER TELESCOPE APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Telescope APU Valve.
33148 3 3 TOWER TELESCOPE APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33149 3 3 TOWER TELESCOPE APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33150 3 3 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33151 3 3 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33152 3 3 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33153 3 3 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
6-112 3121142
Flash
Code
33154 3 3 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33155 3 3 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33156 3 3 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift APU Valve.
33157 3 3 TOWER LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33158 3 3 TOWER LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33159 3 3 MAIN LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift Enable Valve.
33160 3 3 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33161 3 3 MAIN LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33162 3 3 TOWER TELESCOPE APU VALVE - STUCK OPEN The Tower Telescope APU Valve - 1250AJP only.
is Stuck Open
33163 3 3 TOWER TELESCOPE ENABLE VALVE - STUCK OPEN The Tower Telescope Enable - 1250AJP only.
Valve is Stuck Open
33164 3 3 TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
33165 3 3 TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33166 3 3 TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33167 3 3 PVG ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
PVG Valve.
33168 3 3 PVG ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
PVG Valve.
33169 3 3 PVG ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
PVG Valve.
33173 3 3 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY There is a Short to Battery or an
OR OPEN CIRCUIT Open Circuit to the Axle Lockout
Valve.
33174 3 3 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- There is a Short to Battery or an
CUIT Open Circuit to the Brake.
3121142 6-113
Flash
Code
33175 3 3 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Left Valve.
33176 3 3 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Left Valve.
33177 3 3 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Left Valve.
33178 3 3 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Right Valve.
33179 3 3 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Right Valve.
33180 3 3 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Right Valve.
33181 3 3 MAIN LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Up Valve.
33183 3 3 MAIN LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Up Valve.
33184 3 3 MAIN LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Down Valve.
33185 3 3 MAIN LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
33186 3 3 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the
33188 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the
33189 3 3 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the
33190 3 3 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the
33207 3 3 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 3 3 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 3 3 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
33279 3 3 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles
Glow Plugs. only.
33280 3 3 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles
Glow Plugs. only.
33281 3 3 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles
Glow Plugs. only.
33295 3 3 SWING LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Left Valve.
6-114 3121142
Flash
Code
33306 3 3 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Left Valve.
33307 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Telescope Flow Control
Valve.
33308 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
Valve.
33309 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
Valve.
33310 3 3 MAIN LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
33311 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Flow Control Valve.
33312 3 3 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
33313 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
33329 3 3 MAIN LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Lift Up Valve.
340 3 4 <<< PLATFORM OUTPUT DRIVER >>>
343 3 4 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
344 3 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Open Circuit to the Platform equipped vehicles only.
Level Up Valve.
347 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Level Down Valve.
430 4 3 <<< ENGINE >>>
431 4 3 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is >
4.3V.
432 4 3 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is <
0.2V.
433 4 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading - Deutz engine only.
is > 6.6V.
3121142 6-115
Flash
Code
434 4 3 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only.
is < 0.1V for more then 5 sec- - Not reported during engine
onds. start.
435 4 3 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sen- - Deutz engine only.
sor reading is < 0.1V.
437 4 3 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 4 3 HIGH ENGINE TEMP (Ford engine only) The engine - Ford / Deutz engine only.
temperature is > 117 C.
(Deutz engine only) The engine
temperature is > 130 C.
439 4 3 AIR FILTER BYPASSED The Air Filter is clogged.
4310 4 3 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts
for more then 15 seconds after
engine start.
4311 4 3 LOW OIL PRESSURE (Ford engine only) The ECM has - Ford / Deutz engine only.
reported a low oil pressure fault.
(Deutz engine only) Oil pressure
is < 8 PSI for more then 10 sec-
onds after engine start.
4313 4 3 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for
more then XX seconds.
4314 4 3 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-
ECM type engine selected.
4322 4 3 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indi- - Diesel engine only.
cates 0 RPM AND the Oil Pressure
Sensor indicates > 8 PSI for
three seconds.
4323 4 3 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indi- - Diesel engine only.
cates > 4000 RPM.
4375 4 3 WATER IN FUEL The engine has shut down Water in fuel filter for water or in
because an unacceptable fuel or water in fuel sensor.
amount of water has been
detected in the fuel or there is an
issue with the water in fuel sen-
sor.
If operating in platform mode,

platform alarm will sound con-
tinuously and low fuel indicator
will flash.
If operating in ground mode, the

ground alarm will sound
6-116 3121142
Flash
Code
4376 4 3 FUNCTIONS PREVENTED - ENGINE OIL WARM UP ACTIVE Engine Oil Warm Up is active
because the engine was started
when the engine coolant was
less than 32 deg F. Engine Oil
Warm Up will remain active
until the engine coolant is
greater than 32 deg F or the
engine has been running for 60s
and the engine coolant is less
than 32 deg F.
Machine functions will be pre-

vented until Engine Oil Warm Up
is complete.
440 4 4 <<< BATTERY SUPPLY >>>
441 4 4 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 4 4 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
443 4 4 LSS BATTERY VOLTAGE TOO HIGH The load sensor has determined Check for issue with sensor supply
that its supply voltage is too voltage.
high (> 16V).
The machine will assume the

platform is overloaded.
444 4 4 LSS BATTERY VOLTAGE TOO LOW The load sensor has determined Check for issue with sensor supply
that its supply voltage is too low voltage.
(> 8V).

445 4 4 BATTERY VOLTAGE LOW Battery voltage is < 11V for
more then 5 seconds.
4479 4 4 LSS BATTERY VOLTAGE - INITIALIZATION ERROR The shear beam is reporting a Possible sensor hardware issue.
Sensor Supply Voltage Initial-
ization Error

This fault, once annunciated is

latched within a given key cycle.
4480 4 4 LSS BATTERY VOLTAGE - NOT CALIBRATED The shear beam is reporting a Possible sensor hardware issue.
Sensor Supply Voltage calibra-
tion error.


3121142 6-117
Flash
Code
450 4 5 <<< CAN CONTROLLED VALVES >>>
451 4 5 MAIN LIFT PVG VALVE - INTERNAL FAULT The Main Lift PVG Valve has an - 1250AJP only.
internal fault.
452 4 5 TOWER LIFT PVG VALVE - INTERNAL FAULT The Tower Lift PVG Valve has an - 1250AJP only.
internal fault.
453 4 5 TOWER TELESCOPE PVG VALVE - INTERNAL FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an internal fault.
454 4 5 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is high.
455 4 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is high.
456 4 5 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is high.
457 4 5 MAIN LIFT PVG VALVE - LOW VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is low.
458 4 5 TOWER LIFT PVG VALVE - LOW VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is low.
459 4 5 TOWER TELESCOPE PVG VALVE - LOW VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is low.
4510 4 5 MAIN LIFT PVG VALVE - STUCK NEUTRAL The Main Lift PVG Valve is stuck - 1250AJP only.
in its neutral position.
4511 4 5 TOWER LIFT PVG VALVE - STUCK NEUTRAL The Tower Lift PVG Valve is stuck - 1250AJP only.
in its neutral position.
4512 4 5 TOWER TELESCOPE PVG VALVE - STUCK NEUTRAL The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its neutral position.
4513 4 5 MAIN LIFT PVG VALVE - STUCK EXTENDED The Main Lift PVG Valve is stuck - 1250AJP only.
in its extended position.
4514 4 5 TOWER LIFT PVG VALVE - STUCK EXTENDED The Tower Lift PVG Valve is stuck - 1250AJP only.
in its extended position.
4515 4 5 TOWER TELESCOPE PVG VALVE - STUCK EXTENDED The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its extended position.
4516 4 5 MAIN LIFT PVG VALVE - STUCK RETRACTED The Main Lift PVG Valve is stuck - 1250AJP only.
in its retracted position.
4517 4 5 TOWER LIFT PVG VALVE - STUCK RETRACTED The Tower Lift PVG Valve is stuck - 1250AJP only.
in its retracted position.
4518 4 5 TOWER TELESCOPE PVG VALVE - STUCK RETRACTED The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its retracted position.
4519 4 5 MAIN LIFT PVG VALVE - OBSTRUCTED The Main Lift PVG Valve is - 1250AJP only.
obstructed
4520 4 5 TOWER LIFT PVG VALVE - OBSTRUCTED The Tower Lift PVG Valve is - 1250AJP only.
obstructed
4521 4 5 TOWER TELESCOPE PVG VALVE - OBSTRUCTED The Tower Telescope PVG Valve - 1250AJP only.
is obstructed
4522 4 5 MAIN LIFT PVG VALVE - COMMAND IMPROPER The Main Lift PVG Valve com- - 1250AJP only.
mand is improper.
4523 4 5 TOWER LIFT PVG VALVE - COMMAND IMPROPER The Tower Lift PVG Valve com- - 1250AJP only.
mand is improper.
6-118 3121142
Flash
Code
4524 4 5 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
command is improper.
4525 4 5 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has - 1250AJP only.
timed out.
4526 4 5 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has - 1250AJP only.
timed out.
4527 4 5 TOWER TELESCOPE PVG VALVE - TIMEOUT The Tower Telescope PVG Valve - 1250AJP only.
has timed out.
4528 4 5 MAIN LIFT PVG VALVE - SETUP FAULT The Main Lift PVG Valve has a - 1250AJP only.
setup fault.
4529 4 5 TOWER LIFT PVG VALVE - SETUP FAULT The Tower Lift PVG Valve has a - 1250AJP only.
setup fault.
4530 4 5 TOWER TELESCOPE PVG VALVE - SETUP FAULT The Tower Telescope PVG Valve - 1250AJP only.
has a setup fault.
4531 4 5 MAIN LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Main Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4532 4 5 TOWER LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4533 4 5 TOWER TELESCOPE PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an unrecognized fault.
4534 4 5 MAIN LIFT PVG VALVE - PARAMETERS INCORRECT The Main Lift PVG Valve parame- - 1250AJP only.
ters are incorrect.
4535 4 5 TOWER LIFT PVG VALVE - PARAMETERS INCORRECT The Tower Lift PVG Valve param- - 1250AJP only.
eters are incorrect.
4536 4 5 TOWER TELESCOPE PVG VALVE - PARAMETERS INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
parameters are incorrect.
4537 4 5 MAIN LIFT PVG VALVE - LOCATION IMPROPER The Main Lift PVG Valve is in the - 1250AJP only.
wrong location.
4538 4 5 TOWER LIFT PVG VALVE - LOCATION IMPROPER The Tower Lift PVG Valve is in the - 1250AJP only.
wrong location.
4539 4 5 TOWER TELESCOPE PVG VALVE - LOCATION IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
is in the wrong location.
4540 4 5 MAIN LIFT PVG VALVE - WIRING INCORRECT The Main Lift PVG Valve has - 1250AJP only.
incorrect wiring.
4541 4 5 TOWER LIFT PVG VALVE - WIRING INCORRECT The Tower Lift PVG Valve has - 1250AJP only.
incorrect wiring.
4542 4 5 TOWER TELESCOPE PVG VALVE - WIRING INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
has incorrect wiring.
4543 4 5 MAIN LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4544 4 5 TOWER LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4545 4 5 TOWER TELESCOPE PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
3121142 6-119
Flash
Code
660 6 6 <<< COMMUNICATION >>>
662 6 6 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN commu-
nication lost.
663 6 6 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE The control system has lost com- Check wiring to load sensor.
munication with the load sens-
ing system load pin.

666 6 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication lost.
667 6 6 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communica- - 1250AJP only.
tion lost.
668 6 6 CANBUS FAILURE - TOWER LIFT PVG Tower Lift PVG CAN communica- - 1250AJP only.
tion lost.
669 6 6 CANBUS FAILURE - TOWER TELESCOPE PVG Tower Telescope PVG CAN com- - 1250AJP only.
munication lost.
6610 6 6 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 6 6 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped engine only.
communication lost.
6612 6 6 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN commu- - Cylinder Load Pin equipped
nication lost. engine only.
6613 6 6 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off
errors or >500 Bus Passive
Errors.
6614 6 6 CANBUS FAILURE - MAIN ANGLE SENSOR #1 Angle Sensor #1 CAN communi- - 1250AJP only.
cation lost.
6615 6 6 CANBUS FAILURE - MAIN ANGLE SENSOR #2 Angle Sensor #2 CAN communi- - 1250AJP only.
cation lost.
6622 6 6 CANBUS FAILURE - TCU MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6623 6 6 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6629 6 6 CANBUS FAILURE - TELEMATICS CANBUS LOADING X -Telematics only
TOO HIGH
680 6 8 <<< TELEMATICS >>>
681 6 8 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP X -Telematics only
810 8 1 <<< TILT SENSOR >>>
813 8 1 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not
been calibrated.
815 8 1 CHASSIS TILT SENSOR DISAGREEMENT X
6-120 3121142
Flash
Code
820 8 2 <<< PLATFORM LOAD SENSE >>>
8211 8 2 LSS READING UNDER WEIGHT LSS has been calibrated and the Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
underweight while a period of
time while operating drive or Re-calibrate the load sensing sys-
boom lift up at speeds greater tem if the above items are not a
than creep OR the UGM has factor.
determined that the load sens-
ing system reading is less than -
1.5 x Gross Platform Weight.

8218 8 2 LSS SENSOR DISAGREEMENT The control system has deter- Attempt to re-calibrate the load
mined that the difference sensing system.
between the calculated load for
sensor 1 and sensor 2 differ by Possible sensor hardware issue.
more than 50lbs OR the internal
strain gauge sensor 1 gross plat-
form weight reading and the
internal strain gauge sensor 2
gross platform weight reading
differ by more than 200lbs.
If the platform is not considered

to be overloaded boom func-
tions will be restricted to creep.

822 8 2 LSS CELL #2 ERROR822822
8222 8 2 LSS STRAIN GAUGE 1 - STAGNANT The control system has deter- Possible sensor hardware issue.
mined that the strain gauge 1
reading in the load sensor is
stagnant (not changing).

tions will be restricted to creep..
If DTC 8223 is active in combina-

tion with DTC 8222 the machine
will assume the platform is
overloaded.

3121142 6-121
Flash
Code
8223 8 2 LSS STRAIN GAUGE 2 - STAGNANT The control system has deter- Possible sensor hardware issue.
mined that the strain gauge 2
reading in the load sensor is
stagnant (not changing).

tions will be restricted to creep.
If DTC 8222 is active in combina-

tion with DTC 8223 the machine
will assume the platform is
overloaded.

8224 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE LOW The shear beam is reporting an Possible sensor hardware issue.
out of range low issue with the
strain gauge 1 reading.
If the platform is not overloaded

the machine will be placed in to
creep.
If DTC 8225 is also active the

machine will assume the plat-
form is overloaded.

8225 8 2 LSS STRAIN GAUGE 2 - OUT OF RANGE LOW The shear beam is reporting an Possible sensor hardware issue.
out of range low issue with the

creep.

form is overloaded.

6-122 3121142
Flash
Code
8228 8 2 LSS STRAIN GAUGE 1 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor hardware issue.
initialization issue with the
strain gauge 1 sensor.

creep.

form is overloaded.

8229 8 2 LSS STRAIN GAUGE 2 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor hardware issue.
initialization issue with the

creep.

form is overloaded.

8230 8 2 LSS STRAIN GAUGE 1 - NOT CALIBRATED The shear beam is reporting a Possible sensor hardware issue.
calibration issue with the strain
gauge 1 sensor.

creep.

form is overloaded.

823 8 2 LSS CELL #3 ERROR823823
3121142 6-123
Flash
Code
8231 8 2 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a Possible sensor hardware issue.
calibration issue with the strain
gauge 2 sensor.

creep.

form is overloaded.

8226 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE HIGH The shear beam is reporting an Possible sensor hardware issue.
out of range high issue with the

creep.

form is overloaded.

8227 8 2 LSS STRAIN GAUGE 2 - OUT OF RANGE HIGH The shear beam is reporting an Possible sensor hardware issue.
out of range high issue with the

creep.

form is overloaded.

6-124 3121142
Flash
Code
8232 8 2 LSS STRAIN GAUGE 1 - SENSOR DEFECT The shear beam is reporting a Possible sensor hardware issue.
sensor defect issue with the

creep.

form is overloaded.

8233 8 2 LSS STRAIN GAUGE 2 - SENSOR DEFECT The shear beam is reporting a Possible sensor hardware issue.
sensor defect issue with the

creep.

form is overloaded.

8234 8 2 LSS STRAIN GAUGE 1 - NOT INSTALLED The shear beam is reporting a Possible sensor hardware issue.
not installed issue with the

creep.

form is overloaded.

3121142 6-125
Flash
Code
8235 8 2 LSS STRAIN GAUGE 2 - NOT INSTALLED The shear beam is reporting a Possible sensor hardware issue.
not installed issue with the

creep.

form is overloaded.

8236 8 2 LSS NOT DETECTING CHANGE The control system has deter- Possible sensor hardware issue.
mined that the load sensor
reading has not deviated by
more than 1lb for 5s while oper-
ating drive or boom functions at
greater than creep speed.

8237 8 2 LSS STRAIN GAUGE 1 - A/D DEFECT The shear beam is reporting an Possible sensor hardware issue.
internal issue with the strain
gauge 1 sensor.

creep.

form is overloaded.

8238 8 2 LSS STRAIN GAUGE 2 - A/D DEFECT The shear beam is reporting an Possible sensor hardware issue.
internal issue with the strain
gauge 2 sensor.

creep.

form is overloaded.

824 8 2 LSS CELL #4 ERROR824824
6-126 3121142
Flash
Code
825 8 2 LSS HAS NOT BEEN CALIBRATED The load sensing system is con- Calibrate the load sensing system.
figured but has not been cali-
brated.

826 8 2 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load
Sensing System indicates the
Platform is overloaded AND is
configured to warn only while
the Platform is overloaded.
827 8 2 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are
not possible while the Load
Sensing System indicates the
Platform is overloaded AND is
configured to prevent drive and
boom functions while the Plat-
form is overloaded.
828 8 2 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not
possible while the Load Sensing
System indicates the Platform is
overloaded AND is configured to
prevent Lift up and telescope
out while the Platform is over-
loaded.
830 8 3 <<< PLATFORM LEVELING >>>
831 8 3 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on
with Access Level 0 selection.
832 8 3 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off
with Access Level 0 selection.
833 8 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
834 8 3 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
837 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #1. equipped vehicles only.
838 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #1.
8311 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #2. equipped vehicles only.
8312 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #2.
3121142 6-127
Flash
Code
8313 8 3 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8314 8 3 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8315 8 3 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the - Electronic leveling system
sensor values at power-up. The equipped vehicles only.
fault is triggered when there is a
± 5 degree difference from the
initial reading.
8316 8 3 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial - 1200S and 1350S only.
communication lost.
8317 8 3 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial - 1200S and 1350S only.
communication lost.
8318 8 3 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to
maintain desired level within
range for the allotted time.
840 8 4 <<< ENVELOPE >>>
841 8 4 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Angle Sen- cles only.
sors.
842 8 4 BOOM LENGTH SWITCH FAILED The Boom Length Switches are - Envelope Control equipped vehi-
reporting the same state. cles only.
843 8 4 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Length cles only.
Switch and the Boom Length
Sensor.
844 8 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi-
changing during a boom tele- cles only.
scope command.
845 8 4 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of - Envelope Control equipped vehi-
range high. cles only.
-1200/1350 only
846 8 4 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of - Envelope Control equipped vehi-
range low. cles only.
-1200/1350 only
847 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
848 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
6-128 3121142
Flash
Code
849 8 4 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8410 8 4 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8411 8 4 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
8412 8 4 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
8413 8 4 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control equipped vehi-
opposite direction of the com- cles only.
mand.
8414 8 4 WRONG LIFT RESPONSE Boom lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
8415 8 4 TOWER ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Angle Sen- cles only.
sors. -1250
3121142 6-129
Flash
Code
84151 8 4 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) Check Hardware, Wiring
that these faults can be set:
(a)
If the length sensor voltage
changes more than 0.0168 volts
within 40 milliseconds a counter
for the respective length sensor
shall be incremented to aid ser-
vice in diagnosing bad sensor
performance. The counter
below shall be incremented
anytime the description above is
met. It is cleared/reset by a
power cycle
TwrLenSnsr(1/
2)FaultCounter_PowerCycle >
30
(b)
The counter below shall be
incremented every time
TwrLenSnsr(1/
2)FaultCounter_PowerCycle
(described above) reached its
threshold. This value is stored in
EEPROM in order to track the his-
tory of the issue. (A successful
Boom Sensor Calibration will
reset this counter – this is
reflected in the boom sensor
calibration document)
TwrLenSnsr(1/
2)FaultCounter_EEPROM > 3
(c)
The fault counter below shall be
incremented every time the
trigger condition described in
section (a) is observed during
certain steps during Boom Sen-
sor Calibration (please see that
document section for further
details)
TwrLenSnsr(1/
2)FaultCounter_BmSnsrCal >
20
If (a) or (b) or (c) are met (fault

triggered) the machine will be
put into Electrical Retrieval
Fault, once triggered, is main-
tained within a given key-cycle
Machine will be trapped in
transport
6-130 3121142
Flash
Code
84152 8 4 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) Check Hardware, Wiring
(a)
power cycle
TwrLenSnsr(1/
30
(b)
TwrLenSnsr(1/
TwrLenSnsr(1/
(c)
details)
TwrLenSnsr(1/
20

transport
3121142 6-131
Flash
Code
84153 8 4 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) Check wiring and hardware
(a)
power cycle
BmLenSnsr(1/
30
(b)
BmLenSnsr(1/
BmLenSnsr(1/
(c)
details)
BmLenSnsr(1/
20

transport
6-132 3121142
Flash
Code
84154 8 4 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) Check wiring and hardware
(a)
power cycle
BmLenSnsr(1/
30
(b)
BmLenSnsr(1/
BmLenSnsr(1/
(c)
details)
BmLenSnsr(1/
20

transport
3121142 6-133
Flash
Code
8416 8 4 TOWER LENGTH SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Length Sen- cles only.
sors. -1250
8417 8 4 MAIN ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Angle cles only.
Sensors. -1250
8418 8 4 TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range high. cles only.
-1250
8419 8 4 TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range low. cles only.
-1250
-1250
-1250
8422 8 4 TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE The Tower Length Sensor is not - Envelope Control equipped vehi-
changing during a tower tele- cles only.
scope command. -1250
8423 8 4 TOWER LENGTH MOVEMENT WITHOUT COMMAND The Tower Length Sensor is - Envelope Control equipped vehi-
changing without a tower tele- cles only.
scope command. -1250
-1250
-1250
-1250
-1250
8428 8 4 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range. cles only.
-1250
8429 8 4 TOWER ANGLE SENSOR #2 - INVALID ANGLE Tower Boom Angle Sensor #2 - Envelope Control equipped vehi-
out of range. cles only.
-1250
8430 8 4 TOWER ANGLE SENSOR #1 - INVALID MODEL Wrong Tower Boom Angle Sen- - Envelope Control equipped vehi-
sor #1 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
6-134 3121142
Flash
Code
8431 8 4 TOWER ANGLE SENSOR #2 - INVALID MODEL Wrong Tower Boom Angle Sen- - Envelope Control equipped vehi-
sor #2 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
8432 8 4 MAIN ANGLE SENSOR #1 - INVALID ANGLE Main Boom Angle Sensor #1 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8433 8 4 MAIN ANGLE SENSOR #2 - INVALID ANGLE Main Boom Angle Sensor #2 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8434 8 4 MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE The Main Boom Angle Sensor is - Envelope Control equipped vehi-
not changing during a main lift cles only.
command. -1250
8435 8 4 MAIN ANGLE MOVEMENT WITHOUT CMD The Main Boom Angle Sensor is - Envelope Control equipped vehi-
changing without a main lift cles only.
command. -1250
8436 8 4 WRONG TOWER TELESCOPE RESPONSE Tower telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8437 8 4 WRONG TOWER LIFT RESPONSE Tower lift is moving in the oppo- - Envelope Control equipped vehi-
-1250
8438 8 4 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is < 4721 A/D counts. cles only.
-1250
8439 8 4 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is > 29535 A/D counts. cles only.
-1250
8440 8 4 TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is not changing during a tower cles only.
lift command. -1250
8441 8 4 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is changing without a tower lift cles only.
command. -1250
8442 8 4 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is - Envelope Control equipped vehi-
bad. cles only.
-1250
8443 8 4 TWR TRANSPORT SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Boom cles only.
Length Switch and the Tower -1250
Length Sensor.
8444 8 4 TRANSPORT DUAL CAPACITY SWITCHES BAD Both the Dual Capacity Switch - Envelope Control equipped vehi-
and the Transport Switch are cles only.
bad. -1250
8445 8 4 TRANSPORT DUAL CAPACITY BAD TRANSITION The Dual Capacity Switch and - Envelope Control equipped vehi-
the Transport Switch changed cles only.
state out of order. -1250
3121142 6-135
Flash
Code
8446 8 4 MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Trans- cles only.
port Length Switches. -1250
8447 8 4 MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Dual cles only.
Capacity Length Switches. -1250
8448 8 4 MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Angle cles only.
Switch and the Main Boom -1250
Angle Sensor.
8449 8 4 TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Boom Angle cles only.
Switch and the Tower Cylinder -1250
Angle Sensor.
8450 8 4 NEW MAIN ANGLE SENSOR #1 DETECTED A new Main Angle Sensor 1 has -1250
been detected.
8451 8 4 NEW MAIN ANGLE SENSOR #2 DETECTED A new Main Angle Sensor 2 has -1250
been detected.
8452 8 4 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Length cles only.
Switch and the Tower Length -1250
Sensor.
8453 8 4 WRONG MAIN TELE RESPONSE Main telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8454 8 4 WRONG MAIN LIFT RESPONSE Main lift is moving in the oppo- - Envelope Control equipped vehi-
-1250
8482 8 4 TOWER ENVELOPE MASSIVELY ENCROACHED X
8483 8 4 TOWER ENVELOPE MULTIPLE ENCROACHMENTS X
8484 8 4 BCS VIOLATION - BOOM LOCKED X
8485 8 4 BCS - HYDRAULIC RETRIEVAL ACTIVE X
8486 8 4 BCS - ELECTRICAL RETRIEVAL ACTIVE X
8487 8 4 BCS - MULTIPLE FAILURES ACTIVE X
850 8 5 <<< MOMENT / LOAD PINS >>>
851 8 5 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal
force is out of range.
852 8 5 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is
out of range.
853 8 5 LOAD PIN - HORIZONTAL FORCE OUT OF RANGE The Load Pin horizontal force is -1250
out of range.
854 8 5 LOAD PIN - VERTICAL FORCE OUT OF RANGE The Load Pin vertical force is out -1250
of range.
855 8 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a
fault.
856 8 5 LOAD PIN - SENSOR FAULT The Load Pin has reported a -1250
fault.
6-136 3121142
Flash
Code
857 8 5 NEW MOMENT PIN DETECTED A new Moment Pin has been
detected.
858 8 5 NEW LOAD PIN DETECTED A new Load Pin has been -1250
detected.
859 8 5 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT There is a disagreement -1250
between the Load Pin and the
Tower Lift cylinder Angle.
8510 8 5 LOAD PIN - FORCE VALUES NOT CHANGING The Load Pin is not changing. -1250
8511 8 5 LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE X -1250
8512 8 5 LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE X -1250
8513 8 5 LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION X -1250
860 8 6 <<< STEERING / AXLE >>>
861 8 6 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- The Oscillating Axle Pressure - Electrically released Oscillated
AGREEMENT Switch indicates pressure while Axles equipped vehicles only.
not driving or does not indicate
pressure while driving and
restricted to transport.
862 8 6 AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Extend
Valve.
863 8 6 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
864 8 6 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Retract
Valve.
865 8 6 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Right Valve.
867 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Right Valve.
868 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Left Valve.
869 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Left Valve.
8610 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Right Valve.
8611 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Right Valve.
8612 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Left Valve.
8613 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Left Valve.
3121142 6-137
Flash
Code
8614 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Right Valve.
8615 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Right Valve.
8616 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Left Valve.
8617 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Left Valve.
8618 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Right Valve.
8619 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Right Valve.
8620 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Left Valve.
8621 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Left Valve.
8622 8 6 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has
become decoupled.
8623 8 6 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has
become decoupled.
8624 8 6 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has
become decoupled.
8625 8 6 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has
become decoupled.
8626 8 6 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is
not responding to steer com-
mands.
8627 8 6 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
responding to steer commands.
8628 8 6 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is
not responding to steer com-
mands.
8629 8 6 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
responding to steer commands.
8630 8 6 FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Right
Steer Sensor.
8631 8 6 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Right Steer Sensor.
8632 8 6 FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Left
Steer Sensor.
8633 8 6 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Left Steer Sensor.
6-138 3121142
Flash
Code
8634 8 6 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Right
Steer Sensor.
8635 8 6 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Right Steer Sensor.
8636 8 6 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Left
Steer Sensor.
8637 8 6 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Left Steer Sensor.
8651 8 6 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while
there is an Oscillating Axle fault
and vehicle is out of transport
position
876 87 6 WIRE ROPE SERVICE REQUIRED MACHINE SETUP → CABLE
SWITCH = YES;
Wire Rope Service = Enabled
990 99 9 <<< HARDWARE >>>
998 9 9 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has
reported an EEPROM failure.
9910 9 9 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION The Platform Module software
IMPROPER version is not compatible with
the rest of the system.
9914 9 9 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software
requires an updated.
9915 9 9 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain cali-
bration has been lost.
9916 9 9 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain cali-
bration has become corrupted.
9917 9 9 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has
reported that its ADS1213 chip
has stopped asserting its inter-
rupt.
9918 9 9 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has
reported that its ADS1213 chip
had to be reset 3 or more times.
9919 9 9 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9920 9 9 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
3121142 6-139
Flash
Code
9921 9 9 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has
reported that its high side driver
cutout failed.
9922 9 9 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has
reported that the V(Low) FET
has failed.
9923 9 9 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has
reported that the V(Low) FET
has failed.
9925 9 9 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software
IMPROPER version is not compatible with
the rest of the system.
9926 9 9 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER The BLAM software version is
not compatible with the rest of
the system.
9927 9 9 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant
data requires an updated.
9928 9 9 ENVELOPE CONTROL DISABLED Envelope Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
99285 9 9 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a Possible sensor hardware issue.
factor calibration issue (internal
error)


9929 9 9 MOMENT CONTROL DISABLED Moment Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9930 9 9 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been - Chassis Module equipped vehi-
calibrated. cles only.
9931 9 9 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not - BLAM equipped vehicles only.
been calibrated.
9932 9 9 LIFT CRACKPOINTS NOT CALIBRATED The Lift Valves have not been - 1200S and 1350S only.
calibrated.
9933 9 9 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Valves have not - 1200S and 1350S only.
been calibrated.
9934 9 9 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Valves have not been - 1200S and 1350S only.
calibrated.
9935 9 9 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is high.
9936 9 9 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is low.
9937 9 9 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors sup-
ply voltage is high.
6-140 3121142
Flash
Code
9938 9 9 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors sup-
ply voltage is low.
9939 9 9 BLAM HIGH RES A/D FAILURE The BLAM high resolution ana- - BLAM equipped vehicles only.
log to digital converter has
failed.
9940 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply volt-
age is high.
9941 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt-
age is low.
9942 9 9 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communica- - BLAM equipped vehicles only.
tions link test was activated at -1250
startup, but no communication
connection established/main-
tained.
9943 9 9 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED The BLAM backup communica- - BLAM equipped vehicles only.
tions link was activated, but no -1250
communication connection
established/maintained.
9944 9 9 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback
gains are out of range.
9945 9 9 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
9975 9 9 LOAD PIN NOT CALIBRATED The Load Pin has not been cali- -1250
brated.
9979 9 9 FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION Temporary fault for the telemat-
IMPROPER ics project. The model needs to
be a 600S or 1350S if not this
fault will be generated and Plat-
form controls will be prevented.
This fault was to insure that the
software will only work for
these two models.
3121142 6-141
Figure 6-28. CANbus Connections Diagram
6.22 CANBUS TROUBLESHOOTING

The PLATFORM MODULE and the CHASSIS MODULE have ”Ter-
minator Resistors” located inside the modules, these resistors
squelch high speed signal reflections in the CANbus transmis-
sion lines. The value of the terminators is determined by wire
properties, this includes the type of insulation and geometry,
combined to determine the perfect value for bus termination.
Improper values or missing terminators allow bus ringing. A
complete CANbus circuit (wired in parallel) is approximately
60 Ohms at the ”T” fitting inside the Ground Station or at the
Boom Length & Angle Module. Each individual circuit from
their respective Module should read approximately 120 Ohm.
For CANbus connections, refer to Figure 6-28., Figure 6-29.,
Figure 6-30., Figure 6-31., Figure 6-32., and Figure 6-33.
6-142 3121142
A B
PLATFORM MODULE
CANbus Link
C
Figure 6-29. CANbus Connections - Sheet 1 of 5
3121142 6-143
1. Chassis Module CANbus Link

2. Ground Module CANbus Link
3. Boom Length & Angle Module
4. BLAM J1 (Gray) Plug
* Remove BLAM J1 Plug and measure the A & B pin of the T fitting.
This should measure approximately 60 Ohms for a complete CANbus
Circuit.
6-144 3121142
Remove Ground Module J7 plug

and measure the A & B pin of the T
Boom Length &
fitting. This should measure
Angle Module
approximately 60 Ohms for a com-
CANbus Link
plete CANbus Circuit.
Ground Module J7 Platform Module J7

(Black) plug (Black) plug
3121142 6-145
"BEFORE" Slip Ring

Connection
"AFTER" Slip Ring

Connection
6-146 3121142
Chassis Module J1
(Gray) Plug
Chassis Module
CANbus Link
3121142 6-147
Figure 6-34. CANbus Circuit
6-148 3121142
CANbus Communication Failure 4. The analyzer screen should read:

If a problem in the CANbus system is suspected, use the fol-
lowing step-by-step procedure to verify which part of the
CANbus communication system has failed.
CANBUS LINK FROM THE PLATFORM MODULE LOST

Ground position.
2. Plug the analyzer into the connector inside the Ground 5. Press enter twice to reach Logged Help. The screen will
control box. read:
6. Hit ESC to get back to the HELP screen and then use the
arrow button to reach VERSIONS. Hit Enter.
3121142 6-149
7. If the CANbus link from the platform module is lost, you TROUBLESHOOTING: PLATFORM CAN COMMUNICATIONS
will see the Ground Module SW version, Ground Module LOST
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the NOTE: PLATFORM CAN COMMUNICATIONS LOST (6/6) (Help Fault
Platform Module SW version or the Platform Module HW Code 6-6) basically means all communication linked to the
version. The Analyzer screen will read: Platform Module is lost. This does not mean that the Plat-
form Module Link only is affected, this means the commu-
nication link between the Platform Module down to the
Chassis Module has been broken, therefore all Canbus links
have to be checked. Remember this link is wired in parallel,
so the Ground Module has lost all MSA communication.
8. Hit the right arrow button once. The screen will read:
6-150 3121142
Table 6-14. Troubleshooting: Platform Can Communications Lost
STEP ACTION REQUIRED SPEC YES NO

1 Install the Analyzer at the ground station, scroll to the ”Diag- See Diagnostics / Version Chart See step 2 See step 2
nostics” sub level menu, press ”enter” then scroll to the ”Ver-
sions” menu item press ”enter” and view the screen,
reference the Diagnostics / Version Chart to assist you in
determining which module has lost it’s communication link.
In some cases the module that shows up with a question may
be defective if all other CANbus links check OK.
2 Disconnect the Ground Module J7 deutsche plug connection Approximately 60 ohms. CANbus circuit is Reconnect plug and go to step 3
at the "T" fitting inside of the ground control station. Perform complete. Platform
an ohms check at the ”A” and ”B” pins of the "T" fitting. Module suspected
Inspect the shield wire ”C” for shorts. defective
3 Make sure the CANbus link wires are installed correctly at the See Electrical Schematic in Section 7 Go to step 4 Wire per Electrical Schematic
Platform Module.
4 Disconnect the platform cannon plug and ground cannon Continuity Reconnect plug and go to step 5 Repair or replace platform har-
plug that holds the CANbus link. Red (3) Black (2) and Shield ness.
(1) perform a continuity test.
5 Disconnect the deutsche plug connection from the Platform Approximately 120 ohms. Reconnect plug and go to step 6 Suspected defective Platform
Module at the ”T” fitting inside of the ground station. Per- Module.
form an ohms check at the ”A” and ”B” sockets of the
deutsche plug. Inspect the shield wire ”C” for shorts.
6 Inspect the Platform Module harness connection at the Continuity Reconnect harness and go to Repair or replace harness inside
ground cannon plug and at the ”T”’ fitting inside of the step 7 the ground control station.
ground control station.
7 Disconnect the deutsche plug connection from the Boom Approximately 120 ohms Reconnect plug and go to step 8 Verify step 7, inspect the BLAM
Length & Angle Module at the ”T’ fitting inside of the ground to Ground Module harness con-
station. Perform an ohms check at the ”A” and ”B” sockets of nection s at both ”T" fitting con-
the deutsche plug. Inspect the shield wire ”C” for shorts. nections for proper continuity
and correct wiring per Electrical
schematic.
8 Disconnect all deutsche plug connections at the "T” fitting in Continuity (NO OHM VALUES) Reconnect all deutsche plugs at Replace defective ”T" fitting
the ground station and the BLAM, perform a continuity test the "T” fitting and go to step 9 plug.
on all ”A” ”B” and ”C” pins use the singular end of the fitting
and cross probe the corresponding letters of the other two
connections.
9 Disconnect the Chassis Module deutsche plug at the ”T’ fit- Approximately 120 ohms Reconnect deutsche plug and Inspect the harness from the
ting below the Boom Length & Angle Module. Perform an go to step 10 ”T” fitting at the BLAM to the
ohms check at the ”A” and ”B” sockets of the deutsche plug. Chassis Module plug connec-
Inspect the shield wire ”C” for shorts. tion at the battery. Assure
proper continuity and correct
wiring per Electrical Schematic.
3121142 6-151
Table 6-14. Troubleshooting: Platform Can Communications Lost

10 Disconnect the Chassis Module connection at the right side of Approximately 120 ohms Reconnect plug and go to step Inspect the harness from the
the battery at the turntable lock pin. Perform an ohms check 11 slip ring connections at the top
at the #1 and #2 connections of the plug. Inspect shield wire and bottom plug connections of
#3 for possible short. the swivel. Assure proper conti-
nuity and correct wiring per
Electrical Schematic.
11 Disconnect the Chassis Module connection below the swivel Approximately 120 ohms Reconnect plug and go to step Inspect the harness from the
under the machine. Perform an ohms check at the #1 and #2 12 bottom of the swivel into the
connections of the plug that is routed to the Chassis Module. Chassis Module. Assure proper
Inspect shield wire #3 for possible short. continuity and wiring r sche-
matic 1870149A.
12 Make sure the Chassis Module CANbus link wires are installed Electrical Schematic Stop Replace the Chassis Module.
correctly at the plug near the battery, the plug below the
swivel and 31 plug at the Chassis Module.
6-152 3121142
CANBUS LINK FROM THE GROUND MODULE LOST 4. The analyzer screen should read:
Ground position.
HELp - PRESS ENTER
ESC ENTER

control box. MAE19060
5. Press enter twice to reach Logged Help. The screen will

read:
3121142 6-153
7. If the CANbus link from the ground module is lost, you 8. Hit the right arrow button once. The screen will read:
will see the Ground Module SW version, Ground Module
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the
Platform Module SW version or the Platform Module HW
version. The Analyzer screen will read:
6-154 3121142
CANBUS LINK FROM THE BOOM LENGTH & ANGLE MOD- 4. The analyzer screen should read:
ULE (BLAM) LOST
Ground position.

control box.

read:
3121142 6-155
7. If the CANbus link from the Boom Length & Angle Mod- TROUBLESHOOTING: BLAM CAN COMMUNICATIONS LOST
ule is lost, you will see the Platform Module SW version,
Platform Module HW Rev, Platform Module SN, Ground NOTE: BLAM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code
Module SW version, Ground Module HW Revision, 6-6) basically means all communication linked from the
Ground Module SN, Chassis SW version, but you will not Ground Module to the Boom Length &: Angle Module is
see the Boom Length & Angle Module SW revision. The lost. This also includes the lift cylinder load moment pin as
Analyzer screen will read: well.
6-156 3121142
Table 6-15. Troubleshooting: BLAM Can Communications Lost

2 Disconnect the BLAM J 1 deutsche plug connection at the "T” Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go to step 3
fitting just above the fuel tank. Perform an ohms check at the plete.
”A” and ”B” pins of the "T” fitting. Inspect the shield wire ”C” BLAM suspected defec-
for possible short. tive.
3 Disconnect the Ground Module deutsche plug from ”T” fit- Approximately 120 Ohms Reconnect harness and go to Repair or replace the Ground
ting at the BLAM above the fuel tank. Perform an ohm check step 4 Module to BLAM harness.
at the ”A” and ”B” sockets of the deutsche plug. Inspect the
shield wire ”C ” for possible short.
4 Verify the CANbus link signal wires are installed correctly at Electrical Schematic Reconnect plug and go to step 5 Wire per Electrical Schematic
the ’T” fitting at the Ground Module.
5 Verify the lift cylinder load moment harness has good conti- Continuity Reconnect plug and go to step 6 Repair or replace Chassis Mod-
nuity and wired correctly at the J4 plug on the BLAM. ule harness.
6 Disconnect the Chassis Module plug connection at the bat- Approximately l 20 Ohms Reconnect plug and stop Inspect harness and connec-
tery and perform an ohm check at the #1 and #2 socket of the tions to the Chassis Module.
deutsche plug. Inspect the shield wire #3 for possible short.
3121142 6-157
CANBUS LINK FROM THE CHASSIS MODULE LOST 4. The analyzer screen should read:
Ground position.

control box.

read:
6-158 3121142
7. If the CANbus link from the Chassis Module is lost, you 9. Hit the right arrow button once. The screen will read:
will NOT see the Platform Module SW version, Platform
Module HW rev, Platform Module SN, Chassis SW ver-
sion, Boom Length & Angle Module SW version, but you
WILL see the Ground Module SW version, Ground Mod-
ule HW rev, and the Ground Module SN. The analyzer
screen will read:
3121142 6-159
11. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS
LOST
NOTE: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault

Code 6-6) basically means all communication linked from
the Ground Module to the Chassis Module is lost.
6-160 3121142
Table 6-16. Troubleshooting: Chassis Can Communications Lost

2 Disconnect the BLAM J1 deutsche plug connection at the "T" Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go to step 3
fitting just above the fuel tank. Perform an ohms check at the plete. Chassis Module
”A” and ”B” pins of the ”T” fitting. Inspect the shield wire ”C” suspected defective.
for possible short.
3 Disconnect the Chassis Module communication harness from Continuity Reconnect harness and go to Repair or replace BLAM and
the BLAM ”T” fitting and Chassis Module plug connection at step 4 Chassis Module harness.
the battery. Perform a continuity test.
4 Verify the CANbus link signal wires are installed correctly at Electrical Schematic Reconnect plug and go to step 6 Wire per Electrical Schematic
the Chassis Module plug connection at the battery and at the
plug below the swivel.
5 Verify continuity at the Chassis Module harness from the plug Continuity Reconnect plug and go to step 6 Repair or replace Chassis Mod-
connection at the battery down to the plug connection ule harness.
below the swivel.
6 Disconnect the Chassis Module plug connection below the Approximately 120 Ohms Stop Replace Chassis Module
swivel and perform an ohms check at the #1 and #2 of the
plug. Inspect the shield wire #3 plug connection for possible
short.
3121142 6-161
Load Moment Pin Troubleshooting refer to Section 4 for information concerning replacement of
the Load Moment Pin.
The following Troubleshooting Charts outline diagnostic mea-
sures to be taken to diagnose problems within the Load
Moment Pin portion of the JLG Control System. If necessary,
Table 6-17. Load Moment Pin Troubleshooting: Can Communications Lost
STEP FAULT CODE/SYMPTOM REPAIR YES NO

1 6/6 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST Check for correct and tight wire connec- Go to step 2 Replace harness. (4922826)
tions at the deutsch and phoenix con-
nectors of the Load Sensing Pin harness
and perform a continuity check.
2 Check for loose pins in the potting of the Replace the BLAM & Go to step 3
Boom Length & Angle Module J4 con- Perform the Boom Sen-
nection. sor calibration process.
3 Inspect the CANbus link ”T” fitting con- Go to step 4 Replace ”T” fitting connector.
nections at the BLAM & Ground Module. (4460945)
Are the fittings dry?
4 Inspect the CANbus link ”T” fitting con- Go to step 5 Replace ”T” fitting connector.
nections at the BLAM & Ground Module. (4460945)
Perform a continuity check.
5 Check the J1 and J4 plug connections on Go to step 6 Position plug correctly.
the BLAM, make sure the notched plugs
line up with the plug sockets correctly.
6 Use the Analyzer, scroll – + to the DIAG- Go to step 6 Replace the load moment pin. &
NOSTICS menu, press ENTER, then scroll Perform the Boom Sensor cali-
to the MOMENT menu, and press ENTER, bration process.
check to see i f Actual / Over / Under
moment values are registering on the
screen display.
7 If they are, refer to Figure 6-35., If the problem still exists, verify Replace the load moment pin. &
Moment Chart for comparable values, if steps 1-7 again before contact- Perform the Boom Sensor cali-
the values are not close, try boom sen- ing the JLG Service Dept. bration process.
sor calibration to see if the values come
within the chart.
6-162 3121142
Table 6-18. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range

1 8/6 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE The Check to see if the platform is over- Remove excess weight Go to step 2
horizontal force is out of allowed range. loaded in the vertical position. Check
the rated capacity requirement.
2 Check to see if any additional accesso- Perform the Boom Sen- Go to step 3
ries have been added to the platform sor calibration process.
without proper calibration.
3 Perform the BCS daily check procedure Go to step 4 Perform the Boom Sensor cali-
to make sure the boom sections are bration process.
stopping correctly at the witness marks
matching their capacity selection.
4 Inspect the job the machine is perform- Go to step 5 Position machine correctly.
ing, making sure that there is no addi-
tional force applied when the boom
sections are in the horizontal position.
Also consider weather conditions
(Wind).
5 Use the Analyzer, scroll to the DIAGNOS- Go to step 6 Replace the load moment pin. &
TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process.
check to see if Actual / Over / Under
screen display.
within the chart.
3121142 6-163
Table 6-19. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range

1 8/6 MOMENT PIN VERTICAL FORCE OUT OF RANGE The vertical Check to see if the platform is over- Remove excess weight Go to step 2
force is out of allowed range. loaded in the vertical position. Check
the rated capacity requirement.
2 Check to see if any additional accesso- Perform the Boom Sen- Go to step 3
ries have been added to the platform sor calibration process.
without proper calibration.
3 Perform the BCS daily check procedure Go to step 4 Perform the Boom Sensor cali-
to make sure the boom sections are bration process.
stopping correctly at the witness marks
matching their capacity selection.
4 Inspect the job the machine is perform- Go to step 5 Position machine correctly.
ing, making sure that there is no addi-
tional force applied when the boom
sections are in the horizontal position.
Also consider weather conditions
(Wind).
5 Use the Analyzer, scroll to the DIAGNOS- Go to step 6 Replace the load moment pin. &
TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process.
check to see if Actual / Over / Under
screen display.
within the chart.
6-164 3121142
Table 6-20. Load Moment Pin Troubleshooting: Moment Pin Sensor Fault

1 8/6 MOMENT PIN SENSOR FAULT The moment pin has Use the Analyzer, scroll to the DIAGNOS- Replace load moment pin & Contact JLG Service Dept.
reported a fault flag TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process
check to see if PIN E FLAGS has any num-
bers on the screen display.
Table 6-21. Load Moment Pin Troubleshooting: New Moment Pin Detected Fault

1 8/6 NEW MOMENT PIN DETECTED FAULT A moment pin was Perform the Boom Sensor calibration Verify BCS check and review all Contact JLG Service Dept.
detected on the system different from the one used to cali- process to accept the new load moment faults prior to contacting JLG
brate the machine. pin. Service Dept.
3121142 6-165
Figure 6-35. Moment Chart
6-166 3121142
SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL or negative side of the signal and the lead on the other port
goes to the positive side of the signal.
This section contains basic electrical information and sche-
matics to be used for locating and correcting most of the oper- Scale
ating problems which may develop. If a problem should
M = Mega = 1,000,000 * (Displayed Number)
develop which is not presented in this section or which is not
corrected by listed corrective actions, technically qualified k = kilo = 1,000 * (Displayed Number)
guidance should be obtained before proceeding with any
maintenance. m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS
Example: 1.2 kW = 1200 W
A wide variety of multimeters or Volt Ohm Meters (VOM) can Example: 50 mA = 0.05 A
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM
Voltage Measurement
may vary. Please consult the meter operator’s manual for more
information.
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 cir-
cuit continuity this way. If the connector 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 technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen-
tle pull to ensure the wires are still attached to the contact and Figure 7-1. Voltage Measurement (DC)
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 of the "Min/Max" recording feature of some meters can • Use firm contact with meter leads
help when taking measurements of intermittent conditions
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.
Polarity
Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
3121142 7-1
Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable

audible continuity testing
• Circuit power must be turned OFF before testing conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
(See multimeter’s operation manual)
7-2 3121142
Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO

ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG PN 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERI-

ALAPPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connec-

tions:
• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the follow-
ing reasons:
• To prevent oxidation at the mechanical joint between male
and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
Figure 7-4. Current Measurement (DC)
pound to the electrical connectors. This procedure applies to
• Set up the meter for the expected current range all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
• Be sure to connect the meter leads to the correct jacks
for the current range you have selected 1. To prevent oxidation, silicone grease must be packed
completely around male and female pins on the inside
of the connector prior to assembly. This is most easily
(See multi meter’s operation manual)
achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.
NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
conductive than water.
3. Anderson connectors for the battery boxes and battery

chargers should have silicone grease applied to the con-
tacts only.
NOTE: Curing-type sealants might also be used to prevent short-

ing and would be less messy, but would make future pin
removal more difficult.
3121142 7-3
When applied to electrical connections, dielectric grease helps Deutsch HD, DT, DTM, DRC Series
prevent corrosion of electrical contacts and improper conduc-
The Deutsch connector system is commonly used for harsh
tivity between contacts from moisture intrusion. Open and
environments. Follow installation instructions.
sealed connectors benefit from application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).
Installation of Dielectric Grease

Before following these instructions, refer to excluded connec-
tor types (See Exclusions below).
1. Use dielectric grease in a tube for larger connection

points or apply with a syringe for small connectors.
2. Apply dielectric grease to plug/male connector housing
which typically contains sockets contact/female termi-
nals.
3. Leave a thin layer of dielectric grease on the face of the
connector.
4. Assemble connector system immediately to prevent Figure 7-6. Deutsch Connector
moisture or dust contamination.
5. Pierce one of the unused wire seals before assembly if
the connector system tends to trap air (i.e. AMP Seal) AMP Seal
and then install a seal plug. The AMP Seal connector system is used on Control ADE Plat-
form and Ground Modules.
Apply dielectric grease to the plug/male connector housing

which typically contains socket contacts/female terminals. If
trapped air prevents the connector from latching, pierce one
of the unused wire seals. After assembly, install a seal plug (JLG
#4460905) in that location to prevent moisture ingress.
Note that seal plugs may be installed by the wire harness man-
ufacturer if an unused wire seal becomes compromised (wire

inserted in the wrong cavity during assembly and the cor-

rected).

Figure 7-5. Applying Dielectric Grease
Figure 7-7. Application to plug/male connector housing
7-4 3121142
DIN Connectors
This connector is typically used on hydraulic valves. Follow
manufacturer installation instructions.
Figure 7-10. DIN Connector
Figure 7-8. Use of Seal Plugs
AMP Mate-N-Lok
Follow manufacturer installation instructions.
Figure 7-9. AMP Mate-N-Lok Connector
3121142 7-5
Exclusions Engine Control Unit Connectors

A limited number of connectors do not benefit from dielectric Many times, these types of connectors use back-seals for mois-
grease, or may be permanently damaged by application. ture integrity. However, the low-force contacts cannot displace
Dielectric grease may not be required in properly sealed dielectric grease and create electrical contact. It is possible to
enclosures. use solvents (i.e. contact cleaner or mineral spirits) for the
removal of improperly applied dielectric grease. The EMR4
Brad Harrison/phoenix Contact M12 engine control module from Deutz employs this connector
system (for example).
The connector uses gold contact material to resist corrosion
and an o-ring seal for moisture integrity. If dielectric grease is
mistakenly applied to this connector system, the low-force
contacts cannot displace the grease to achieve electrical con-
tact. Once contaminated, there is no practical way to remove
the dielectric grease (replacement of female contacts
required).
7-6 3121142
Sealed Enclosures MOLEX CMC Series Connectors

Application of dielectric grease is not required in properly The CMC connector family is a sealed, high-density connec-
sealed enclosures. To meet criteria, the enclosure must be tion system using matte-seal technology for CP 0.635 and 1.50
rated to at least IP66 (dust tight; protected from powerful jets mm terminals. To guarantee IP6K7 and IP6K9 sealing, a seal
of water). The enclosure must be fitted with a high quality, plug option is used. However, the low-force contacts cannot
continuous gasket and all wiring must pass through cable displace dielectric grease and create electrical contact. It is
entrances. possible to use solvents (i.e. contact cleaner or mineral spirits)
for the removal of improperly applied dielectric grease. The
flexbox control modules from JDES employ this connector sys-
tem (for example).
MIL-C-5015 Spec Connectors

Crown Connector Inc’s recommendation is to not use dielec-
tric grease for this series connector. For similar model series
connectors, the manufacturer should be contacted for confir-
mation before applying dielectric grease. A typical application
for this connector is on David Clark Intercom connections in
Aerial Work Platforms.
3121142 7-7
7.4 AMP CONNECTOR Assembly

Check to be sure the wedge lock is in the open, or as-shipped,
Applying Silicone Dielectric Compound to AMP position (See Figure 7-11.). Proceed as follows:
Connectors
Silicone Dielectric Compound must be used on the AMP con-
nections for the following reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone
dielectric grease must be packed completely around
male and female pins on the inside of the connector
after the mating of the housing to the header. This is
easily achieved by using a syringe to fill the header with
silicone dielectric compound, to a point just above the
top of the male pins inside the header. When assem-
bling the housing to the header, it is possible that the
housing will become air locked, thus preventing the Figure 7-11. Connector Assembly
housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped
1. To insert a contact, push it straight into the appropriate
air inside the housing to escape.
circuit cavity as far as it will go (See Figure 7-13.).
3. Install a hole plug into this and/or any unused wire seal
2. Pull back on the contact wire with a force of 1 or 2 lbs. to
that has silicone dielectric compound escaping from it.
be sure the retention fingers are holding the contact
(See Figure 7-13.).
Figure 7-12. AMP Connector
7-8 3121142
Figure 7-13. Connector Assembly Figure 2
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 7-15.).
Release the locking latches by squeezing them inward
(See Figure 7-14.).
3121142 7-9
Figure 7-16. Connector Disassembly
Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16") wide screwdriver blade between DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
the mating seal and one of the red wedge lock tabs.
It has been common practice in electrical troubleshooting to
2. Pry open the wedge lock to the open position.
probe wires by piercing the insulation with a sharp point. This
3. While rotating the wire back and forth over a half turn practice should be discouraged when dealing with the
(1/4 turn in each direction), gently pull the wire until the AMPSEAL plug assembly, or any other sealed connector sys-
contact is removed. tem. The resulting pinholes in the insulation will allow mois-
ture to invade the system by traveling along the wire strands.
NOTE: The wedge lock should never be removed from the housing This nullifies the effectiveness of the connector seals and
for insertion or removal of the contacts. could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
7-10 3121142
Figure 7-17. Connector Installation
3121142 7-11
7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly
DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-19. DT/DTP Contact Removal
Figure 7-18. DT/DTP Contact Installation
1. Remove wedgelock using needlenose pliers or a hook
1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
barrel.
2. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger by
moving it away from the contact with a screwdriver.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly 3. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
7-12 3121142
HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-20. HD/HDP Contact Installation Figure 7-22. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact crimp

1. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
2. Hold connector with rear grommet facing you.
2. Slide tool along into the insert cavity until it engages
3. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
3. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-23. HD/HDP Unlocking Contacts

Figure 7-21. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing
3121142 7-13
7.6 TELEMATICS GATEWAY

Personnel using machines equipped with an optional telemat-
ics gateway will be able to view the following data through
their telematics device:
JLG LABEL DESCRIPTION UNIT
Engine Speed Actual engine speed. RPM
Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is
DEF Tank Level (If equipped with DEF tank.
• 0% = Empty Percentage (%)
Equipped)
• 100% = Full
• 00 - No Machine Faults
JLG Machine Faults: • 01 - Active Machine Fault

Bit
Active / Not-Active • 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel
limit switch is present, the fuel level will indicate "full" until the switch opens, which will
then indicate 10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel stor-
age containers. When Fuel Level 2 is used, Fuel Level 1 represents the fuel level in the pri-
mary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
7-14 3121142
DIAGNOSTICS PLUG GATEWAY MODULE
TELEMATICS-READY PLUG
Telematics-Ready (TCU) Plug

The telematics-ready (TCU) plug is a standard 12-pin Deutsch
connector. Pin-out locations are shown below:
12 1 - BATTERY
11 2 - GROUND
CAN-HI 2 - 10 3
CAN-LO 2 - 9 4 - IGNITION
8 5
7 6
3121142 7-15
7-16
MS1619-3 MS1619-1
MS1619-2
X1609
MS1620-1
S1614
MS1618-2
S1615
MS1620-3
MS1620-2
MS1618-3
CO1613-J2
CO1613-J1
X1606
Figure 7-24. Telematics Gateway Harness - Sheet 1 of 3
3121142
X1609 (TCU) MS1620-3 (CAN-T 2)

CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
1 RED 1-0 BAT 16 AWG GXL X1606 (B) A YEL CANH2 18 AWG GXL CO1613-J2 (10)
2 BLK 0-0 GND 16 AWG GXL S1615 (1) B GRN CANL2 18 AWG GXL CO1613-J2 (9)
4 ORN 2-0 IGN 16 AWG GXL S1614 (1)

S1614
9 GRN CANL2 18 AWG GXL MS1619-2 (B)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
10 YEL CANH2 18 AWG GXL MS1619-2 (A)
1 ORN 2-0 IGN 16 AWG GXL X1609 (4)
MS1619-2 (CAN-T 2) 2 ORN 2-1 IGN 16 AWG GXL X1606 (H)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)
A YEL CANH2 18 AWG GXL X1609 (10)
B GRN CANL2 18 AWG GXL X1609 (9)

S1615
MS1619-3 (CAN-T 2) 1 BLK 0-0 GND 16 AWG GXL X1609 (2)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 BLK 0-1 GND 16 AWG GXL X1606 (A)
A YEL CANH2 18 AWG GXL MS1620-2 (A) 2 BLK 0-2 GND 16 AWG GXL CO1613-J1 (11)
B GRN CANL2 18 AWG GXL MS1620-2 (B)
MS1618-2 (CAN-T 1)
CO1613-J1 (GATEWAY 1)
A YEL CANH1 18 AWG GXL CO1613-J1 (10)
9 GRN CAN1 18 AWG GXL MS1618-2 (B)
B GRN CANL1 18 AWG GXL CO1613-J1 (9)
11 BLK 0-2 GND 16 AWG GXL S1615 (2) MS1618-3 (CAN-T 1)

12 ORN 2-2 IGN 16 AWG GXL S1614 (2) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
A YEL CANH1 18 AWG GXL X1606 (C)

CO1613-J2 (GATEWAY 2)
B GRN CANL1 18 AWG GXL X1606 (D)
9 GRN CANL2 18 AWG GXL MS1620-3 (B) X1606 (DIAG)

A BLK 0-1 GND 16 AWG GXL S1615 (2)

MS1620-2 (CAN-T 2)
B RED 1-0 BAT 16 AWG GXL X1609 (1)
C YEL CANH1 18 AWG GXL MS1618-3 (A)
A YEL CANH2 18 AWG GXL MS1619-3 (A)
D GRN CANL1 18 AWG GXL MS1618-3 (B)
B GRN CANL2 18 AWG GXL MS1619-3 (B)
H ORN 2-1 IGN 16 AWG GXL S1614 (2)
3121142 7-17
FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
CAN L2 GRN 18 AWG 1151 GXL MS1619-3 B MS1620-2 B
CAN L2 GRN 18 AWG 151 GXL X1609 9 MS1619-2 B
CAN L1 GRN 18 AWG 157 GXL MS1618-2 B CO1613-J1 9
CAN L2 GRN 18 AWG 225 GXL MS1620-3 B CO1613-J2 9
CAN L1 GRN 18 AWG 1076 GXL MS1618-3 B X1606 D
CAN H2 YEL 18 AWG 155 GXL X1609 10 MS1619-2 A
CAN H2 YEL 18 AWG 233 GXL MS1620-3 A CO1613-J2 10
CAN H1 YEL 18 AWG 157 GXL MS1618-2 A CO1613-J1 10
CAN H2 YEL 18 AWG 1150 GXL MS1619-3 A MS1620-2 A
CAN H1 YEL 18 AWG 1079 GXL MS1618-3 A X1606 C
0-0 GND BLK 16 AWG 1006 GXL X1609 2 S1615 1
0-1 GND BLK 16 AWG 1145 GXL X1606 A S1615 2
0-2 GND BLK 16 AWG 223 GXL CO1613-J1 11 S1615 2
1-0 BAT RED 16 AWG 2150 GXL X1609 1 X1606 B
2-0 IGN ORN 16 AWG 939 GXL X1609 4 S1614 1
2-1 IGN ORN 16 AWG 1212 GXL S1614 2 X1606 H
2-2 IGN ORN 16 AWG 287 GXL CO1613-J1 12 S1614 2
7-18 3121142
3121142 7-19
Figure 7-27. Chassis Electrical Components - Sheet 1 of 2
7-20 3121142
0274660 D
Figure 7-28. Chassis Electrical Components - Sheet 2 of 2
3121142 7-21
Figure 7-29. Turntable Electrical Components - Prior to S/N 87579 - Sheet 1 of 2
7-22 3121142
0272445-E
Figure 7-30. Turntable Electrical Components - Prior to S/N 87579 - Sheet 2 of 2
3121142 7-23
Figure 7-31. Turntable Electrical Components - SN 87579 to Present - Sheet 1 of 2
7-24 3121142
0274660-D
Figure 7-32. Turntable Electrical Components - SN 87579 to Present - Sheet 2 of 2
3121142 7-25
7.7 ELECTRICAL SCHEMATICS
18 BLACK (12)
13 YEL/RED 2-5 2 B1
YEL/RED 2-4 (12)
4
10 YEL/RED 2-2 (12) 1 YEL/RED 2-1 (12)
YEL/RED 2-30 3 B2
YEL/RED 2-30-4
YEL/RED 2-4-1
YEL/RED 2-1-1(12)
4 YEL/RED 2-3-1
87a 87
9 IGN. ON
85 86 RELAY
7 30
5
87 87a
POWER DOWN
86 85
RELAY 30 YEL/RED 2-1-3 (12)
BLACK
BLACK
TO BATTERY NEG.
GROUND CONTROL BOX
24
IN BROWN 13-2 7 17 HORN GND YEL/RED 2-6-2
MAIN TELE
OUT BROWN 14-2 30 2 BLU/ORN 52-2 HORN OUTPUT
GRAY 24-2 18
ROTATE RIGHT
RED 1-1 (12)

LEFT GRAY 23-2 6 3 RED/WHT 50-2-1
PINK 25-2 17
LEVEL UP 7 PINK 26-3-1
DOWN PINK 26-2 5 5 PINK 25-3-1
START SWITCH WHT/YEL 48-1 4
13 RED/WHT 50-1 MAIN DUMP
J4 (BLUE)
AUX POWER/ENABLE BRN/ORN 53-2 16 1

JIB UP BLUE 27-2 19 9 BROWN 55-10 TELE. FLOW CONTROL
DOWN BLUE 28-2 8
TAN 3-2 23 33
UP
J2 (GRAY)
MAIN LIFT 4 BROWN 13-3 IN MAIN TELE.

DOWN TAN 4-2 33 16 BROWN 14-3 OUT
YEL/RED 2-70 (14)

RIGHT WHITE 22-2 35 LIFT DOWN AUX. SELECT
SWING 10 TAN 55-21
LEFT WHITE 21-2 34 12 TAN 55-22 LIFT DOWN AUX.
JIB RIGHT WHITE 60-2 20 UP MAIN LIFT
11 TAN 3-3
BLACK
SWING LEFT WHITE 59-2 9 22 TAN 4-3 DOWN
11 35 WHITE 22-3 RIGHT
22 34 WHITE 21-3 SWING
LEFT YEL/RED 2-1-99
2-40 25
19 TAN 55-20 LIFT FLOW CONTROL
32 20
HOURMETER
BLACK (10)
BRN/WHT 47-8 12 14
ENGINE LOW
OIL PRESSURE BRN/WHT 47-5-1 29 30
ENGINE HIGH HEAD/TAIL
CAN LO
BRN/WHT 47-6-1 28 27 BLU/ORN 52-10 ALARM LIGHTS
TEMPERATURE
29 BLACK
YEL/RED 2-40-9
CAN HI
NO CHARGE 87 87a
BRN/WHT 47-8-1 26
26 BLU/ORN 52-12 86 85
15 30
MOMENT CONTROL
TEST ORN/RED 49-103 13 18
CAN SHIELD
BLACK (18)
AXLES SET 1 24
WHT/YEL 39-1-1
RED (18)
PLATFORM 28
OVERLOAD ORN/RED 49-100 14 25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL)
500# CAP RED/YEL 54-2-1 2 6 BLACK SENSOR (GROUND)
1000# CAP RED/YEL 54-3-1 27
BOOM SYSTEM 11 WHT/YEL 48-3
CONTROL ORN/RED 49-101 3 12 WHT/YEL 48-9 A B C
BLACK 31 10
8
GND FROM BATTERY
1 3
MTB EMS input
BLACK
2 6
GND TO PLATFORM 3
16 BLACK (12)
J8
5 A B C
12 YEL/RED 2-1-2(12) MTB EMS TO PLATFORM 4
24 YEL/RED 20-70-1
5 RED A A
YEL/RED 2-3-2 1 18
BLACK B B
YEL/RED 2-2-1 2 19
4 SHIELD C C
27
2
YEL/RED 2-21 FOOTSWITCH 15 9
6 MTB MODE SELECT
YEL/RED 2-30 3 1
J1 (WHITE)
2 6
MTB MODE OUTPUT ANALYZER POWER 1
11 YEL/RED 2-30-1 14 28 RED
4 29 GREEN ANALYZER RECEIVE 2
16 30 ANALYZER TRANSMIT3 4
WHITE
ORN/RED 49-102 21 ANALYZER GROUND 4
31 BLACK/SHIELD
BOOM CONTROL SYSTEM 26
TEST SWITCH 9 10
17
30 14 2
15 3
YEL/RED 2-40-10 23
31 22 BLU/ORN 52-5
10 16
BROKEN CABLE BLACK 4 ORN/RED 49-88 12 7
PROX. SWITCH 4 1 BROWN 5 YEL/RED 2-61 32 25
YEL/RED 2-70-5
CAN SHIELD
16
YEL/RED 2-70-4
23
BLACK (18)
3
BLUE 3 BLACK 19 27
RED (18)
22 20
BOOM LENGTH LIMIT SWITCH 34 BLACK (14)
17
13 14 33
19 34
35 5
20
32
ORANGE 55-45
YEL/RED 2-60 29
ORANGE 55-47
WHITE 1 33
21
YELLOW
22
BLACK 2 ORN/RED 49-64 11 19
13 BRN/ORN 53-3
RED 6 ORN/RED 49-65 35
25 87
J7 (BLACK)
2 87a
7 86 85
4 8 4 6 7 30
5 1 2 3
3 RED(18) A A RED CAN HI 13 8
2 BLACK B B BLACK CAN LO 24 SLIP RING CONNECTOR TO CHASSIS
9
1 SHIELD C C SHIELD CAN SHIELD 18 6
5 7 BLU/ORN 52-6 (12)
C B A 8 13
87 87a
28 14 86 85
3 GENERATOR
30
10 RED 1-3 (12)
V REF 11
7500 W GENERATOR
1
5 BLU/ORN 52-6 B
BLACK
V BAT GENERATOR
12 YEL/RED 2-20 A CONTROL
BLACK C BOX
RED
SHEILD
87 87a
86 85
30
RED
BLACK (14)
87 87a
86 85
30
RED
Figure 7-33. Electrical Schematic - Deutz EMR2 - Sheet 1 of 6
7-26 3121142
14 GA. FUSE LINK
2 B1 MTB
YEL/RED 2-4 (12) EMS
4 STARTER
1 YEL/RED 2-1 (12) MOTOR DEUTZ ENGINE
3 B2 RED 1-2(10) SOL.
30 AMP
STARTER
MOTOR
YEL/RED 2-4-1
BLACK (16) RECTIFER

87 B+
87a IGN. ON
WHT/YEL
48-12(12)
COOLANT 2 8 GRD(TempAll) FUSIBLE
85 86 RELAY STATOR
30 TEMPERATURE1 1 LINK
9 ADC7(TEMP3)
EMR2 ENGINE CONTROL TO ENGINE
BRN/WHT 47-8
13 SPEED 2
ENGINE 2
WHT/YEL 48-13 (8)

SPEED
RED 1-1(10)
CAMSHAFT 1 12 GRD (SPEED) 10 sol.
IN HEAD GLOW PLUG
YEL/RED 2-1-3 (12) 1 23 GRD (ACD2) 11 ALTERNATOR
NOTE: ENGINE WILL ONLY
12
MTB TO EMR2 ENGINE CONTROL

BLACK CHARGE 2 4 ADC5(TEMP1) HAVE INTAKE HEATERS OR REGULATOR
AIR GLOW PLUGS NOT BOTH. SENSING AND
3 25 +5Vref(ADC2) 13
SWITCHING
WHT/YEL 48-3
PRESSURE
CIRCUITS D+
4 24 ADC2 WHT/YEL 48-11 (10)
14
YEL/RED 2-6-2 sol. WHT/YEL 48-10 (10)
1 22 +5Vref(ADC4)
ENGINE OIL 2 21 ADC4
PRESSURE
3 INTAKE HEATERS
20 GND (ADC4)
1 14 ActorOut
2 15 ActorOut
EMR
ACTUATOR 3 17 RackMeasCom
4 19 RackMeasSignal
WHT/YEL 48-9
5 18 RackMeasRef
YEL/RED 2-1-99
CAN SHIELD BLACK 0-1 B
DEUTZ
BLACK (18)
CAN LO ORN/RED 49-199 L DIANOSTICS
RED (18) CAN HI ORN/RED 49-198 K PLUG
YEL/RED 2-1-98 A
CAN LO
J3 GREEN BOOM LENGTH ANGLE MODULE

CAN HI
1 ORN/RED 5
2
6
7 YEL/RED 2-80 1 RED A
BOOM LENGTH SENSOR
CAN SHIELD
BLACK (18)
8 ORN/RED 49-110 3 BLUE C STRING POT

9 BLACK 2 BLACK B
RED (18)
BRN/BLK 4 BRN/BLK
12
23 J5 BROWN 6
A B C 5
1 ORANGE 8-3 2 ORANGE 8-3 LEFT FORWARD DRIVE PUMP
2 ORANGE 8-2 1 ORANGE 8-2 LEFT REVERSE DRIVE PUMP
12
23 3 ORANGE 7-2 RIGHT REVERSE DRIVE PUMP
J1 GRAY 4 ORANGE 7-3 RIGHT FORWARD DRIVE PUMP
A B C 1
2
A A RED CAN HI 6 9 RED ANALYZER POWER 1
B B BLACK CAN LO 7 10 GREEN ANALYZER RECEIVE 2
C C SHIELD CAN SHIELD 8 11 WHITE ANALYZER TRANSMIT3
9 12 BLACK/SHIELDANALYZER GROUND 4
ORN/RED 10 3
1 YEL/RED 2-70-2 (14) 5
6 BLACK (16) 4
3
4 ORANGE 60-1
V-BAT + J2 BLACK
BATTERY CABLE (1 GA.)

12 ORANGE 7-2
11 ORANGE 7-3
2 YEL/RED 2-70-3 (14)
3 YEL/RED 2-70-4 (14) YEL/RED 2-82 1 ORANGE 1 RED #2 LEFT SIDE BOOM
9 ORN/RED 49-112 2 YELLOW 2 WHITE ANGLE SENSOR
BLACK 3 BLACK 3 BLACK SERIAL OUTPUT
BRN/BLK 4 BRN/BLK
12
YEL/RED 2-81 1 RED 1 RED #1 RIGHT SIDE BOOM
YEL/RED 2-70-5
CAN SHIELD
YEL/RED 2-70-4
GND -
ANGLE SENSOR
BLACK (18)
8 ORN/RED 49-111 2 BLUE 2 WHITE

BLACK SERIAL OUTPUT
RED (18)
3 BLACK 3 BLACK
BRN/BLK 4 BRN/BLK
J4 GRAY
DEUTZ ENGINE
5 BLACK 5 (16) 1 RED A A

2 BLACK B B LIFT
ORANGE 55-45
ORANGE 55-47
3 GREEN D D CYL. PIN

YELLOW
4 WHITE E E
5 SHIELD
87
87a CHASSIS POWER
86 85 DISTRIBUTION
30 RELAY AUXILIARY POWER
8 4 5 6 7 1 2 3 PUMP MOTOR
M B+
SLIP RING CONNECTOR TO CHASSIS 30 AMP
GROUND CONTROL SCH.
2500W
BLU/ORN 52-6 (12)
GENERATOR
87 87a 12 VDC
86 85 BATTERY
GENERATOR
30
RED 1-3 (12) 14 GA. FUSE LINK
B 5 AMP
GENERATOR
A CONTROL BRN/WHT 47-20
C BOX
87 87a
86 85
30
RED
1870214 H
87 87a
86 85
30
RED
3121142 7-27
JIB STOW LIMIT SWITCH
ORN/RED 49-1014 ORN/RED 49-122

YEL/RED 2-11-11
YEL/RED 2-11 13 YEL/RED 2-11
YEL/RED 2-11-21
ORN/RED 49-1221 ORN/RED 49-112

JIB INLINE LIMIT SWITCH
YEL/RED 2-12-1
YEL/RED 2-12-2
ORN/RED 49-80
ORN/RED 49-63
BASKET LEVEL SENSOR #1
V REF.
25 17
26 7 1 RED 1 RED
19 2 BLUE 2 WHITE
IN BROWN 13-1 5 21 ORN/RED 49-68 3 BLACK 3 BLACK
MAIN TELE OUT BROWN 14-1 6 BRAIDED SHIELD BRN/BLK (18)
GRAY 24-1 7
ROTATE RIGHT
LEFT GRAY 23-1 8
UP PINK 25-1 9 4 BASKET LEVEL SENSOR #2
LEVEL
DOWN PINK 26-1 10
4 ORANGE 1 RED
UP BLUE 27-1 11 35
JIB 34 5 YELLOW 2 WHITE
DOWN BLUE 28-1 12
33
33 ORN/RED 49-81 6 BLACK 3 BLACK
PUMP Ref.V 4 RED/WHT 55-30 BRAIDED SHIELD BRN/BLK (18)
34
POTENTIOMETER
WIPER 6 35 19
RED/WHT 55-31
5 BLACK 13 10
GND
CREEP 11 PINK 26-3-1
3 2 ORN/RED 49-11 32
12 PINK 25-3-1
YEL/RED 2-10 18
13 RED/WHT 50-2-1
TAN 5-1 1
14
TAN 6-1 2 RED/WHT 50-2-3 5 RED/WHT 50-2-3
3 15 PINK 25-3-2 PINK 25-3-3 7
4
J1 (WHITE)
CRAB STEER YELLOW 55-16 16 16 PINK 26-3-2 PINK 26-3-3 6

COORDINATED STEER YELLOW 55-17 17 5 GRAY 23-3 8
500# 15 YEL/RED 2-37 20 6 GRAY 24-3 9
CAPACITY RED/YEL 54-1 21 25 BLUE 27-3
1000# J7 (BLACK) 10
BOOM CONTROL SELECT ORN/RED 49-120 22 26 BLUE 28-3 11
YEL/WHT 43-1 23
AXLE SET EXT 27 WHITE 60-3 19
RET YEL/WHT 44-1 24 28 WHITE 59-3 20
29 BLACK 12
START SWITCH WHT/YEL 48-1 14 2 PTF EMS
AUX POWER BRN/ORN 53-1 15 31 CAN HI
ENGINE SPEED WHT/YEL 48-5 28 30 CAN LO
TWO SPEED ORN 55-46 27 32 CAN SHIELD
31 3 EMS PTF TO MTB
HORN BLU/ORN 52-1
SOFT TOUCH OVERIDE 29 1 GND MODE
ORN/RED 49-40
HEAD/TAIL LIGHTS BLU/ORN 52-12 30 8 ORN/RED 49-70
19 ORN/RED 49-4
ALARM
20 BLACK
18 ORN/RED 49-69 3
9 BLU/ORN 52-4 1 BLU/ORN 52-4 GENERATOR

32 22
6 BRN/WHT 47-4 35 23
BLU/ORN 52-3
J1 3 BRN/WHT 47-3 23 24
FULL
FUEL GAGE
2 BRN/WHT 47-2 24
3/4
1/2 1 BRN/WHT 47-1 22
1/4 4 BLACK 25
5 SOFT TOUCH ORN/RED 49-42 16
2
J8 (BLACK)
4
J2 (GRAY)
5 GND FROM GND MODULE

1
CREEP 1 ORN/RED 49-15 9 GND EMS
2
FOOTSWITCH/ENABLE 2 YEL/RED 2-21 7
J2
3 BRN/WHT 47-13 21
6 BLACK 18
BOOM CONTROL SYSTEM 1 ORN/RED 49-1000 19
AXLE SET 2 WHT/YEL 39-1 14

J3
DRIVE ORIENTATION 3 ORANGE 55-51 30
453KG/1000# CAPACITY 4 RED/YEL 54-3-1 RED/YEL 54-3 13
BROKEN CABLE 5 ORN/RED 49-101 10
SWING
SYSTEM DISTRESS 6 BRN/WHT 47-12 8
5K
8
AUTO LEVEL SYSTEM 1 BRN/WHT 47-10 20 6
GENERATOR ON 2 BLU/ORN 52-4-1 15 5
1
OVERLOAD J4
J5 (WHITE)
3 ORN/RED 49-100 11
4
226KG/500# CAPACITY 4 RED/YEL 54-2 12 2
TILT 5 ORN/RED 49-3 6 LIFT
GLOW PLUG 6 WHT/YEL 48-6 17 3 5K
7
BLU/ORN 52-3 33
31 8
5 LEFT
STEER
6 RIGHT
1 ANALYZER POWER
RED ORN/RED 49-92
J6 (BLACK)
11 26
4
2 ANALYZER RECEIVE
GREEN 10 ORN/RED 49-91 28
2
3 WHITE
ANALYZER TRANSMIT 9 ORN/RED 49-90 29 1
4 BLACK/SHIELD
ANALYZER GROUND 8 ORN/RED 49-89 27 DRIVE
3
14 YEL/RED 2-36 7
LEFT WHITE 59-1 2
JIB SWING YEL/RED 2-10-14 34
RIGHT
WHITE 60-1 1
ORANGE 55-504
DRIVE ORIENTATION OVERIDE
YEL/RED 2-16 3
YEL/RED 2-16-1
JIB STOW V BAT.
WHITE 59-60 5
YEL/RED 2-16-2 8
6 YEL/RED 2-16-3
SOFT TOUCH LIMIT SWITCHS BLACK WHITE ORN/RED 49-67 4 BLACK WHITE
5
7-28 3121142
JIB STOW LIMIT SWITCH
7 BROWN(18)TO MTB
9 RED/BLK
JIB INLINE LIMIT SWITCH
5 BLUE(18)
8 BLACK (12) 8
18 BLK/WHT (12) 18
RED
WHITE MOUNTED ON RIGHT STROBE LIGHT
BLACK SIDE OF BOOM
BRN/BLK (18) MTB
BLU/ORN 52-11 15 YEL/BLK(18) 15 BLU/ORN 52-111
SELECT
2 SWITCH
RED
WHITE MOUNTED ON LEFT
BLACK SIDE OF BOOM
BRN/BLK (18)
PLATFORM DUMP PLATFORM

EMS
PINK 25-3-3 UP
LEVEL YEL/RED
2-5
13 ORN/BLK(18) 13
DOWN
PINK 26-3-3
YEL/RED 10
GRAY 23-3 LEFT ORN(12) 10
ROTATE 2-2(12)
GRAY 24-3 RIGHT
BLUE 27-3 UP YEL/RED

JIB 2-3(16)
BLUE 28-3 DOWN
WHITE 60-3 RIGHT

JIB SWING
WHITE 59-3 LEFT
BLACK
RED (18) 3 RED (18) 3

BLACK (18) 2 BLACK (18) 2
1 SHIELD 1
output YEL/RED 2-3-1 4 ORN (18) 4
YEL/RED 2-30-1
7 BLACK FOOTSWITCH
YEL/RED 2-16-2 8 WHITE GREEN 6 YELLOW (18) 6
GENERATOR
BLU/ORN 52-3
11 BLU/BLK 11
14 HOLE PLUG (12) 14
2
BLACK (12) 16 BLACK (12) 16

YEL/RED 2-1-2 (12) 12 RED (12) 12
PLATFORM WORK LIGHTS OPTION #1

GREEN
CONNECT TO
RED BATTERY PLUS AT
BLACK RED AUXILIARY POWER
20 AMP PUMP MOTOR RELAY
10/3
BLACK
RED
BLACK
GREEN
GREEN
CONNECT TO
RED BATTERY PLUS AT
14 GA FUSE LINK
PUMP MOTOR RELAY
10/3
BLACK
RED
BLACK 15 AMP
GREEN
PLATFORM SCH.
12 = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
12 = 19 POSITION DEUTSCH CONNECTOR TO MAIN TERMINAL/GROUND BOX
= TERMINAL STRIP IN PLATFORM BOX
= 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.)
1870214 H
3121142 7-29
ORANGE (16)
YELLOW (16)
RED 14GA
BLK 14GA
SHIELD
VIOLET
RED
BLK
RED 1
BLK 2
SHIELD 3
YEL/BLK 14GA 4
BLK 14GA 5
ORANGE 55-47 6
ORANGE 55-45 7
ORANGE 60-2 8
1
2 LEFT FRONT AXLE
EXTEND LIMIT SWITCH
RIGHT FRONT AXLE
EXTEND LIMIT SWITCH
BLK WHT BLK WHT YEL/RED 2-1-3
3
4 ORN/RED 49-104
5 ORN/RED 49-105 LEFT REAR AXLE RIGHT REAR AXLE
J2 BLACK
EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH
6 ORN/RED 49-106
7 ORN/RED 49-107
8
9 2
SPD
BRAKE
VALVE
VALVE
10 YEL/WHT 39-2 FRONT AXLE EXTEND
11 YEL/WHT 39-2-43-1 YEL/WHT 43-1 REAR AXLE EXTEND
12 YEL/WHT 40-2-44-1 YEL/WHT 44-1 REAR AXLE RETRACT
YEL/WHT 40-2 FRONT AXLE RETRACT
YEL/RED 2-1-1 (14GA)
1 YEL 10-2 RIGHT FRONT STEER RIGHT
2 YEL 9-2 RIGHT FRONT STEER LEFT

BLK 14GA
3 YEL 10-1 LEFT FRONT STEER RIGHT
4 YEL 9-1 LEFT FRONT STEER LEFT
5 YEL 12-2 RIGHT REAR STEER RIGHT

J5 RUST
6 YEL 11-2 RIGHT REAR STEER LEFT
7 YEL 12-1 LEFT REAR STEER RIGHT

YEL/RED 2-1-5
YEL/RED 2-1-6
8 YEL 11-1 LEFT REAR STEER LEFT

ORN/RED
9
SHIELD
RED
BLACK
RED
BLK
10 GRN
11 WHT
10
12
11
1
2
3
4
5
6
7
8
9
12 BLK
J1 GRAY
4 3 2 1
7-30 3121142
DRIVE ORIENTATION
SWITCH
ORANGE (16)
YELLOW (16)
RED 14GA
BLK 14GA
1
SHIELD
VIOLET YEL/RED 2-1-7

BLK
ORN/RED 49-10612 BLK

YEL/RED11 BLK
BLACK 2
10
BLK 2
SHIELD 3
YEL/BLK 14GA 4
BLK 14GA 5
ORANGE 55-47 6
ORANGE 55-45 7
ORANGE 60-2 8
OSC. AXLE 3
J4 GRAY
LOCK-OUT
PRESSURE
OSC. AXLE
SWITCH 4
LOCK-OUT
VALVE 5
ORN/RED 6
ORN/RED 7
8
1
2
6 PIN
BRAKE 3
2 VALVE BUSS
SPD 4
VALVE CONNECTOR
5
6
1 RED 1 RED A
RIGHT FRONT
2 WHT 2 BLUE B
STEER SENSOR
3 BLK 3 BLK C
BLK BRN/BLK 4 BRN/BLK
4 RED 1 RED A
LEFT FRONT
5 WHT 2 BLUE B
STEER SENSOR
J3 GREEN
6 BLK 3 BLK C
7 RED 1 RED A
RIGHT REAR
8 WHT 2 BLUE B
STEER SENSOR
9 BLK 3 BLK C
10 RED 1 RED A
YEL/RED 2-1-6
LEFT REAR
11 WHT 2 BLUE B
STEER SENSOR
ORN/RED
12
SHIELD
BLK 3 BLK C
BLK
10
12
11
8
9
7
CHASSIS SCH.
J1 GRAY
1870214 H
3121142 7-31
7-32 3121142
Page 1: TABLE OF CONTENTS
Page 2: GROUND CONTROL & BLAM

(Boom Length Angle Module)
Page 3: PLATFORM
Page 4: CHASSIS
Page 5: CAT ENGINE
Page 6: DEUTZ ENGINE
Page 7: DEUTZ TIER 4 FINAL ENGINE
Page 8: SOFT TOUCH/PLATFORM SENSOR/

TEMP SENSOR
Page 9: CRIBBING HARNESS/ALERT BEACON

OPTION GEN 2 PLAT INTERFACE
1001119860-O
Figure 7-39. Electrical Schematic - Sheet 1 of 17
3121142 7-33
8 7 6 5 4
18 BLACK (12)
13 YEL/RED 2-5 2 B1 MTB

4
10 YEL/RED 2-2 (12) 1 YEL/RED 2-1 (12)
YEL/RED 2-30 3 B2
H 30 AMP
YEL/RED 2-30-4
5 AMP
YEL/RED 2-1-1(12)
5 AMP
4 YEL/RED 2-3-1 RED 1-4
9
7
5
87 87a
POWER DOWN 86
RELAY 85
30 YEL/RED 2-1-3 (12)
BLACK
TO BATTERY NEG.
GROUND CONTROL BOX
8
24 15
G BROWN 13-2 7 17 HORN GND
IN
TO J12-3
TO J12-4
TO J12-5
MAIN TELE 2 BLU/ORN 52-2
OUT BROWN 14-2 30 HORN OUTPUT
GRAY 24-2 18 21
ROTATE RIGHT 23
LEFT GRAY 23-2 6
RED 1-1 (12)

3 RED/WHT 50-2-1 BLACK A
UP PINK 25-2 17 7 PINK 26-3-1 12
LEVEL RED 1-3 B
DOWN PINK 26-2 5 1 RED C
5 PINK 25-3-1
START SWITCH WHT/YEL 48-1 4 11 BLACK D ADVANCED
13 RED/WHT 50-1 MAIN DUMP
AUX POWER/ENABLE BRN/ORN 53-2 16 4 SHIELD E DIAGNOSTIC
J4 (BLUE)
1 CONNECTOR
UP BLUE 27-2 19 8 PLUGGED F
JIB 9 BROWN 55-10 TELE. FLOW CONTROL
9 PLUGGED G
DOWN BLUE 28-2 8
TAN 3-2 23 33 2 YEL/RED 2-1-4 H
MAIN LIFT UP 4 BROWN 13-3 IN MAIN TELE. 3 PLUGGED J
J2 (GRAY)
DOWN TAN 4-2 33 16 BROWN 14-3 OUT 10

RIGHT WHITE 22-2 35 LIFT DOWN AUX. SELECT
SWING 10 TAN 55-21
YEL/RED 2-70 (14)

LEFT WHITE 21-2 34 12 TAN 55-22 LIFT DOWN AUX.
JIB RIGHT WHITE 60-2 20 UP
11 TAN 3-3 MAIN LIFT
BLACK
F SWING LEFT WHITE 59-2 9 22 TAN 4-3 5 AMP
DOWN
(NOT ON 1100S) 11 YEL/RED 2-1-4 J7-34, ZONE C7
35 WHITE 22-3 RIGHT
22 SWING
34 WHITE 21-3 LEFT
}
2-40 25 CAN SHIELD SHIELD
21 19 TAN 55-20 LIFT FLOW CONTROL
BLK CAN LO BLACK (18)
32 20
HOURMETER RED CAN HI RED (18)
BLACK (10)
12 14
SEE SHEET 5, ZONE B3

BRN/WHT 47-8
ENGINE LOW 31 YEL/RED 2-1-99 SEE
OIL PRESSURE BRN/WHT 47-5-1 29 30
ENGINE HIGH HEAD/TAIL SHEET 5, ZONE C7
BRN/WHT 47-6-1 28 27 BLU/ORN 52-10 ALARM LIGHTS SHEET 6, ZONE D3 J3 GREEN
TEMPERATURE
29 BLACK 87 1
NO CHARGE BRN/WHT 47-8-3 26 87a
YEL/RED 2-40-9
26 BLU/ORN 52-12 86 85 2
15 30
10 32
MOMENT CONTROL
ORN/RED 49-103 13 18 7
TEST
AXLES SET 24 8
WHT/YEL 39-1-1 1 9 BLACK
PLATFORM 28
OVERLOAD ORN/RED 49-100 14 25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL)
E 500# CAP 6 SENSOR (GROUND) 12
RED/YEL 54-2-1 2 BLACK
BLACK (18) CAN LO

23
RED (18) CAN HI

1000# CAP RED/YEL 54-3-1 27
CAN SHIELD
BOOM SYSTEM 11
ORN/RED 49-101 3
YEL/RED 2-20
CONTROL 12
BLACK 31 10
GND FROM BATTERY
1 3
MTB EMS INPUT 2 6 J1 GRAY
BLACK
BLACK (12) GND TO PLATFORM

16 3 A B C
5
J8
MTB EMS TO PLATFORM A B C 1

12 YEL/RED 2-1-2(12) 4 24 YEL/RED 20-70-1
2
8 RED A A RED CAN HI 6
YEL/RED 2-3-2 1 18
BLACK B B BLACK CAN LO 7
YEL/RED 2-2-1 2 19
SHIELD C C SHIELD CAN SHIELD 8
27 4
2 9
FOOTSWITCH ORN/RED 10
D 6 YEL/RED 2-21 15 9
MTB MODE SELECT 1 YEL/RED 2-70-2 (14) 5
YEL/RED 2-30 3 1
6 6 BLACK (16) 4
J1 (WHITE)
MTB MODE OUTPUT ANALYZER POWER 3

11 YEL/RED 2-30-1 14 28 RED 1
4 29 GREEN ANALYZER RECEIVE 2
16 30 ANALYZER TRANSMIT 3 4 ORANGE 60-1
WHITE
ORN/RED 49-102 21 ANALYZER GROUND 4
31 BLACK/SHIELD
BOOM CONTROL SYSTEM 26
TEST SWITCH 9 21
17
30 14 2 YEL/RED 2-70-3 (14)
15 3 YEL/RED 2-70-4 (14)
YEL/RED 2-40-10 23
31 22
10 16
BROKEN CABLE BLACK 4 ORN/RED 49-88 12 7
PROX. SWITCH 4 1 BROWN 5 YEL/RED 2-61 32 25
CAN SHIELD
23
C 3
YEL/RED 2-70-5
YEL/RED 2-70-4
BLUE BLACK
BLACK (18)
3 19 27
22
RED (18)
20
BOOM LENGTH LIMIT SWITCH CRIBBING OPTION 34 BLACK (14)
17
13 14 33
SEE SHEET 9, ZONE G2 RED 118 34
SEE SHEET 9, ZONE G2 35 5
20 BLACK 5 (16)
32 BRN/WHT 47-8-1
WHITE 1 YEL/RED 2-60 29 33 ORN 100-1
21 22
ORANGE 55-45
ORANGE 55-47
26
YELLOW
BLACK 2 ORN/RED 49-64 11

13 BRN/ORN 53-3
RED 6 ORN/RED 49-65 35
25 2 87
87a CHASSIS POWER
7 86 85
J7 (BLACK)
DISTRIBUTION
4 8 4 6 7 30 RELAY
5 1 2 3
J3 (BLACK)
3 A A RED CAN HIGH 13 8

2 B B BLACK CAN LOW 24 9 BRN/WHT 47-8-2
B 1 C C SHIELD CAN SHIELD 18 6
5 7
SHIELD
RED(18)
C B A
BLACK
8 13
SHIELD
BLACK
28
RED
BLK 117 14
BRN/WHT 47-8 SEE SHEET 5, ZONE C7
3 SEE SHEET 6, ZONE C3
10
C B A V REF 11 ORN 100-3
ORN 100-2
A A 1
1
B B 5
2 V BAT
C C 3 12 CE MARKET ONLY
SEE ZONE MDI
J12 (BLACK)
G5 4
5 CE MARKET ONLY
MSSO
6
7
8 3
4
SHIELD
BLACK
ORN 101-1
RED
A BLACK 5
RED 6
BLU 102-1 1
BROWN 103-1 2
BLACK (14)
SHEET 2
8 7 6 5 4
7-34 3121142
5 4 3 2 1
14 GA. FUSE LINK

GENERATOR
YEL/RED 2-5 2 B1 MTB CONTROL
4 7500 W BOX
YEL/RED 2-2 (12) 1 YEL/RED 2-1 (12) GENERATOR B A C
YEL/RED 2-30 3 B2 RED 1-2(10)
30 AMP H
YEL/RED 2-30-4
5 AMP
BLU/ORN 52-5
RED 1-3
YEL/RED 2-20
BLACK
5 AMP
RED 1-4 BATTERY +
SHEET 5, ZONE B6
SHEET 6, ZONE E6
SHEET 7, ZONE H2

87 87a BLU/ORN 52-5
POWER DOWN 86 SEE SHEET 6, ZONE B6
RELAY 85
30 YEL/RED 2-1-3 (12)
4000 W GENERATOR GENERATOR

CONTROL 5 AMP
BOX SEE SHEET 5, ZONE B3
B A C SEE SHEET 6, ZONE B6 YEL/RED 2-20
G
TO J12-3
TO J12-4
TO J12-5
BLACK
BLU/ORN 52-5
POWERMITE
2500 W
RED 1-1 (12)
BLACK A GENERATOR
GENERATOR
14 GA FUSE LINK
12 RED 1-3 B
1 RED C
11 BLACK D ADVANCED
4 SHIELD E DIAGNOSTIC SEE SHEET 5, ZONE B3

BLU/ORN 52-5 87 87a
8 PLUGGED F CONNECTOR SEE SHEET 6, ZONE B6 SEE SHEET 5, ZONE B3
9 PLUGGED G SEE SHEET 6, ZONE B6 BLU/ORN 52-5 86 85
2 YEL/RED 2-1-4 H 30
3 PLUGGED J
10
YEL/RED 2-70 (14)
RED 1-3 (12)

BLACK
5 AMP F
YEL/RED 2-1-4 J7-34, ZONE C7
}
CAN SHIELD SHIELD
TELEMATICS
BLK CAN LO BLACK (18) SEE SHEET 5, ZONE C7 RED 1-4
1 BAT 5A
RED CAN HI RED (18) SEE SHEET 6, ZONE D3 BLACK GND
2
YEL/RED 2-71 3 KEY ON/ ENGINE
YEL/RED 2-1-99 SEE YEL/RED 2-2A 4 PLATFORM ENABLE
SHEET 5, ZONE C7
SHEET 6, ZONE D3 J3 GREEN BOOM LENGTH ANGLE MODULE
1 ORN/RED 5
2
6
7 YEL/RED 2-80 1 RED A
BOOM LENGTH SENSOR
8 ORN/RED 49-110 3 BLUE C STRING POT
9 BLACK 2 BLACK B
BRN/BLK 4 BRN/BLK
12 E
BLACK (18) CAN LO
23 J5 BROWN
RED (18) CAN HI
6
CAN SHIELD
5
YEL/RED 2-20
1 ORANGE 8-3 2 ORANGE 8-3 LEFT FORWARD DRIVE PUMP

2 ORANGE 8-2 1 ORANGE 8-2 LEFT REVERSE DRIVE PUMP
12
23 3 ORANGE 7-2 RIGHT REVERSE DRIVE PUMP
J1 GRAY 4 ORANGE 7-3 RIGHT FORWARD DRIVE PUMP
A B C A B C
1
2
RED A A RED CAN HI 6 9 RED ANALYZER POWER 1
BLACK B B BLACK CAN LO 7 10 GREEN ANALYZER RECEIVE 2
SHIELD C C SHIELD CAN SHIELD 8 11 WHITE ANALYZER TRANSMIT 3
9 12 BLACK/SHIELD ANALYZER GROUND 4
ORN/RED 10 3
1 YEL/RED 2-70-2 (14) 5 D
6 BLACK (16) 4
1 3
2
3 4 ORANGE 60-1
4 V-BAT + J2 BLACK
12 ORANGE 7-2
11 ORANGE 7-3
2 YEL/RED 2-70-3 (14)
3 YEL/RED 2-70-4 (14) YEL/RED 2-82 1 ORANGE 1 RED #2 LEFT SIDE BOOM
9 ORN/RED 49-112 2 YELLOW 2 WHITE ANGLE SENSOR
BRN/BLK 4 BRN/BLK
12
YEL/RED 2-81 1 RED 1 RED #1 RIGHT SIDE BOOM
CAN SHIELD
GND -
8 ORN/RED 49-111 2 BLUE 2 WHITE ANGLE SENSOR C
YEL/RED 2-70-5
YEL/RED 2-70-4
BLACK (18)

RED (18)
BRN/BLK 4 BRN/BLK
BLACK (14)
J4 GRAY
5 BLACK 5 (16) 1 RED A A
2 BLACK B B LIFT
3 GREEN D D CYL. PIN
ORANGE 55-45
ORANGE 55-47
YELLOW
4 WHITE E E
5 SHIELD
87
87a CHASSIS POWER
86 85 DISTRIBUTION
30 RELAY AUXILIARY POWER
8 4 5 6 7 1 2 3 PUMP MOTOR
M B+
GROUND CONTROL SCH.
B
12 VDC
BRN/WHT 47-8 SEE SHEET 5, ZONE C7 BATTERY
SEE SHEET 6, ZONE C3
CE MARKET ONLY
MDI
3
4
5 A
6
1
2
SHEET 2 1001119860-O
5 4 3 2 1
3121142 7-35
8 7 6 5 4
ORN/RED 49-10 14 ORN/RED 49-12 2 JIB STOW LIMIT SWITCH

ZONE E1 WHITE
YEL/RED 2-11-1 1
LA
YEL/RED 2-11 13 YEL/RED 2-11
1 JIB INLINE LIMIT SWITCH
YEL/RED 2-11-2
ORN/RED 49-12 21 ORN/RED 49-11 2

H
YEL/RED 2-12-1
YEL/RED 2-12-2
ORN/RED 49-80
ORN/RED 49-63
V REF. BASKET LEVEL SENSOR #1

25 17
26 7 1 RED 1 RED
19 2 BLUE 2 WHITE MOUNTED ON RIGHT
IN BROWN 13-1 5 21 ORN/RED 49-68 3 BLACK 3 BLACK SIDE OF BOOM
MAIN TELE OUT BROWN 14-1 6 BRAIDED SHIELD BRN/BLK (18)
RIGHT GRAY 24-1 7
ROTATE
G LEFT GRAY 23-1 8
UP PINK 25-1 9 4 BASKET LEVEL SENSOR #2
LEVEL
DOWN PINK 26-1 10
4 ORANGE 1 RED
UP BLUE 27-1 11
JIB 5 YELLOW 2 WHITE MOUNTED ON LEFT
DOWN BLUE 28-1 12
33 ORN/RED 49-81 6 BLACK 3 BLACK SIDE OF BOOM
33
PUMP Ref.V 4 RED/WHT 55-30 BRAIDED SHIELD BRN/BLK (18)
34 SEE SHEET 8 SEE SHEET 9
POTENTIOMETER WIPER 6 RED/WHT 55-31 35 19 ZONE E2 OR ZONE B5
5 BLACK 13 10
GND
CREEP 11 PINK 26-3-1
3 2 ORN/RED 49-11 32
12 PINK 25-3-1
YEL/RED 2-10 18
13 RED/WHT 50-2-1
TAN 5-1 1
14 BLACK P6
TAN 6-1 2 RED/WHT 50-2-3 5 RED/WHT 50-2-3
SEE SHEET 9 OR SEE SHEET 8 3
ZONE B5 ZONE G6 15 PINK 25-3-2 PINK 25-3-3 7 PINK 25-3-3 UP
LEVEL
4
16 PINK 26-3-2 6 DOWN
YELLOW 55-16 16 PINK 26-3-3 PINK 26-3-3
J1 (WHITE)
CRAB STEER
F COORDINATED STEER 17 GRAY 23-3
YELLOW 55-17 5 8 GRAY 23-3 LEFT
ROTATE
500# 15 YEL/RED 2-37 20 6 GRAY 24-3 9 GRAY 24-3 RIGHT
CAPACITY RED/YEL 54-1 21 25 BLUE 27-3 10
1000# BLUE 27-3 UP
JIB
J7 (BLACK)
BOOM CONTROL SELECT ORN/RED 49-120 22 26 BLUE 28-3 11 BLUE 28-3 DOWN
EXT YEL/WHT 43-1 23 27 WHITE 60-3 19
AXLE SET WHITE 60-3 RIGHT
RET YEL/WHT 44-1 24 JIB SWING
28 WHITE 59-3 20 WHITE 59-3 LEFT
29 BLACK 12 BLACK
START SWITCH WHT/YEL 48-1 14 2 PTF EMS
AUX POWER BRN/ORN 53-1 15 31 CAN HI
ENGINE SPEED WHT/YEL 48-5 28 30 CAN LO
TWO SPEED ORN 55-46 27 32 CAN SHIELD
31 3 EMS PTF TO MTB
HORN BLU/ORN 52-1
SOFT TOUCH OVERIDE 29 1 GND MODE
ORN/RED 49-40
E HEAD/TAIL LIGHTS BLU/ORN 52-12 30 8 ORN/RED 49-70
SEE SHEET 9
3 ORN/RED 49-69-1 ZONE B5
19 ORN/RED 49-4
ALARM
BLUE 20 BLACK
ZONE E1 SEE SHEET 8
18 ORN/RED 49-69
ZONE H8, F8
9 BLU/ORN 52-4 1 BLU/ORN 52-4 GENERATOR
32 22
6 BRN/WHT 47-4 35 23 YEL/RED 2-16-3
3 BRN/WHT 47-3 23 24
BLU/ORN 52-3
FULL J1
FUEL GAGE
2 BRN/WHT 47-2 24 34
3/4
1/2 1 BRN/WHT 47-1 22
BLACK LB
1/4 4 25
5 SOFT TOUCH ORN/RED 49-42 16
4 2
D
J8 (BLACK)
5 GND FROM GND MODULE

1
J2 (GRAY)
CREEP 1 ORN/RED 49-15 9 GND EMS

2
FOOTSWITCH/ENABLE 2 YEL/RED 2-21 7
J2
3 BRN/WHT 47-13 21
6 BLACK 18
BOOM CONTROL SYSTEM 1 ORN/RED 49-1000 19
AXLE SET 2 WHT/YEL 39-1 14

J3
DRIVE ORIENTATION 3 ORANGE 55-51 30
453KG/1000# CAPACITY 4 RED/YEL 54-3-1 RED/YEL 54-3 13
BROKEN CABLE 5 ORN/RED 49-101 10
SWING
SYSTEM DISTRESS 6 BRN/WHT 47-12 8
C 5K
8
AUTO LEVEL SYSTEM 1 BRN/WHT 47-10 20 6
GENERATOR ON 2 BLU/ORN 52-4-1 15 5
J4 1
OVERLOAD 3 ORN/RED 49-100 11
4
J5 (WHITE)
226KG/500# CAPACITY 4 RED/YEL 54-2 12 2

TILT 5 ORN/RED 49-3 6 LIFT
GLOW PLUG 6 WHT/YEL 48-6 17 3 5K
7
BLU/ORN 52-3 33
31 8
5 LEFT
STEER
6 RIGHT
1 ANALYZER POWER RED 11 ORN/RED 49-92 26
B 2 ANALYZER RECEIVE GREEN 4
J6 (BLACK)
10 ORN/RED 49-91 28
2
3 ANALYZER TRANSMIT WHITE 9 ORN/RED 49-90 29 1
4 ANALYZER GROUND BLACK/SHIELD 8 ORN/RED 49-89 27 DRIVE
3
14 YEL/RED 2-36 7
LEFT WHITE 59-1 2
JIB SWING YEL/RED 2-10-14 34
RIGHT
WHITE 60-1 1
ORANGE 55-50 4
DRIVE ORIENTATION OVERIDE
YEL/RED 2-16 3
YEL/RED 2-16-1
JIB STOW V BAT.
WHITE 59-60 5
YEL/RED 2-16-2 8 SHEET 3

A SEE SHEET 8
ZONE H8, F8 12 = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
8 7 6 5 4
7-36 3121142
5 4 3 2 1
ORN/RED 49-12 2 JIB STOW LIMIT SWITCH
YEL/RED 2-11-1 1 7 BROWN(18) TO MTB

YEL/RED 2-11 9 RED/BLK
1 JIB INLINE LIMIT SWITCH
YEL/RED 2-11-2 5 BLUE(18)
ORN/RED 49-11 2
H
8 BLACK (12) 8
18 BLK/WHT (12) 18
1 RED 1 RED
2 BLUE 2 WHITE MOUNTED ON RIGHT STROBE LIGHT
3 BLACK 3 BLACK SIDE OF BOOM
BRAIDED SHIELD BRN/BLK (18) MTB
BLU/ORN 52-11 15 YEL/BLK(18) 15 BLU/ORN 52-11 1
SELECT
2 SWITCH G
BASKET LEVEL SENSOR #2 PLATFORM
EMS
4 ORANGE 1 RED YEL/RED
13 ORN/BLK(18) 13
5 YELLOW 2 WHITE MOUNTED ON LEFT 2-5
6 BLACK 3 BLACK SIDE OF BOOM YEL/RED 10 ORN(12) 10
BRAIDED SHIELD BRN/BLK (18) 2-2(12)
RED (18) 1
RED (18) 2
11
BLACK 12
RED/WHT 50-2-1 BLACK (18) 3
RED/WHT 50-2-3 5 RED/WHT 50-2-3 PLATFORM DUMP BLACK (18) MS509
4
PINK 25-3-3 7 PINK 25-3-3 UP CANBUS
LEVEL 9
6 DOWN GRAY 10
PINK 26-3-3 PINK 26-3-3
SHIELD (18) F
YEL/RED 2-3(16)
8 GRAY 23-3 LEFT 5
ROTATE SHIELD (18)
9 6
GRAY 24-3 RIGHT
7
10 BLUE 27-3 UP
JIB 8
11 BLUE 28-3 DOWN
19 WHITE 60-3 RIGHT

JIB SWING GRAY 5
20 WHITE 59-3 LEFT
BLACK 4
12 BLACK X1002 BLUE
X1001 ZONE E8 3 CO99
WHITE LSS
RED (18) A 3 RED (18) 3 ZONE H7 2
BLACK (18) B 2 2 1
BLACK (18)
C 1 SHIELD 1
output YEL/RED 2-3-1 4 ORN (18) 4
YEL/RED 2-30-1
7 BLACK FOOTSWITCH E
SEE SHEET 9 YEL/RED 2-16-2 8 WHITE GREEN 6 YELLOW (18) 6
3 ORN/RED 49-69-1 ZONE B5
ALARM
SEE SHEET 8
ZONE H8, F8
1 BLU/ORN 52-4 GENERATOR
YEL/RED 2-16-3 YEL/RED 2-16-3-1 SEE SHEET 9

6
ZONE B5
BLU/ORN 52-3
11 BLU/BLK 11
2
D
BLACK (12) 16 BLACK (12) 16
YEL/RED 2-1-2 (12) 12 RED (12) 12

GREEN
CONNECT TO
RED BATTERY PLUS AT
SWING 20 AMP PUMP MOTOR RELAY
10/3
5K BLACK C
RED
BLACK
GREEN
GREEN
CONNECT TO
RED BATTERY PLUS AT
LIFT BLACK RED AUXILIARY POWER
14 GA FUSE LINK
5K PUMP MOTOR RELAY
10/3
BLACK
RED
BLACK 15 AMP
GREEN
B
PLATFORM SCH.
SHEET 3 1001119860-O
5 4 3 2 1
3121142 7-37
8 7 6 5 4
ORANGE (16)
YELLOW (16)
RED 14GA
BLK 14GA
SHIELD
VIOLET
RED
BLK
10
1
RED 1
BLK 2
SHIELD 3
YEL/BLK 14GA 4
BLK 14GA 5
ORANGE 55-47 6
ORANGE 55-45 7
ORANGE 60-2 8
9
G
2 LEFT FRONT AXLE
EXTEND LIMIT SWITCH
RIGHT FRONT AXLE
EXTEND LIMIT SWITCH
OSC. AXLE
3
LOCK-OUT
VALVE
4 ORN/RED 49-104
5 ORN/RED 49-105 LEFT REAR AXLE
EXTEND LIMIT SWITCH
RIGHT REAR AXLE
EXTEND LIMIT SWITCH
J2 BLACK
6 ORN/RED 49-106
F 7 ORN/RED 49-107
8
9 2
SPD
BRAKE
VALVE
VALVE
10 YEL/WHT 39-2 FRONT AXLE EXTEND
11 YEL/WHT 39-2-43-1 YEL/WHT 43-1 REAR AXLE EXTEND
E 12 YEL/WHT 40-2-44-1 YEL/WHT 44-1 REAR AXLE RETRACT
YEL/WHT 40-2 FRONT AXLE RETRACT
D
1 YEL 10-2 RIGHT FRONT STEER RIGHT
2 YEL 9-2 RIGHT FRONT STEER LEFT
3 YEL 10-1 LEFT FRONT STEER RIGHT

BLK 14GA
4 YEL 9-1 LEFT FRONT STEER LEFT
5 YEL 12-2 RIGHT REAR STEER RIGHT

J5 RUST
C
6 YEL 11-2 RIGHT REAR STEER LEFT
7 YEL 12-1 LEFT REAR STEER RIGHT
8 YEL 11-1 LEFT REAR STEER LEFT

YEL/RED 2-1-5
YEL/RED 2-1-6
9
ORN/RED
RED
SHIELD
BLACK
RED
BLK
10 GRN
B
11 WHT
10
12
11
1
2
3
4
5
6
7
8
9
12 BLK
J1 GRAY
4 3 2 1
SHEET 4
8 7 6 5 4
7-38 3121142
5 4 3 2 1
DRIVE ORIENTATION
SWITCH
ORANGE (16)
YELLOW (16)
RED 14GA
1
BLK 14GA
YEL/RED 2-1-7
SHIELD
VIOLET
RED
YEL/RED 11 BLK
BLK
ORN/RED 49-106 12 BLK

BLACK 2
10
RED 1
BLK 2
SHIELD 3
YEL/BLK 14GA 4
BLK 14GA 5
ORANGE 55-47 6
ORANGE 55-45 7
ORANGE 60-2 8
9 OSC. AXLE
LOCK-OUT
3
J4 GRAY
G
4
PRESSURE
SWITCH
OSC. AXLE
LOCK-OUT
VALVE 5
ORN/RED 6
ORN/RED 7
8
F
1
2
6 PIN
BRAKE 3
2 VALVE BUSS
SPD 4
VALVE CONNECTOR
5
6
1 RED 1 RED A
RIGHT FRONT
2 WHT 2 BLUE B
STEER SENSOR
3 BLK 3 BLK C
BLK BRN/BLK 4 BRN/BLK D
4 RED 1 RED A
LEFT FRONT
5 WHT 2 BLUE B
STEER SENSOR
J3 GREEN
6 BLK 3 BLK C
BLK 14GA

7 RED 1 RED A
RIGHT REAR
8 WHT 2 BLUE B
STEER SENSOR
C
9 BLK 3 BLK C
10 RED 1 RED A
LEFT REAR
11 WHT 2 BLUE B
YEL/RED 2-1-5
YEL/RED 2-1-6
STEER SENSOR
ORN/RED
12 BLK 3 BLK C
SHIELD
BLACK

RED
BLK
B
10
12
11
4
5
6
7
8
9
CHASSIS SCH.
J1 GRAY
SHEET 4 1001119860-O
5 4 3 2 1
3121142 7-39
8 7 6 5 4
H
VENDOR SCHEMATIC BOSCH GPA-S ACTUATOR
CAT ENGINE HARNESS
PURPLE/LT GREEN 18
1 SENSOR OUT
BLACK/LT GREEN 18
2 5V RTN
TAN/ORANGE 18
3 DBW +
PINK/WHITE 18
4 DBW -
LT GREEN/RED 18
5 5V EXT
BOSCH_872-860-521 CONN
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
OIL BOSCH_1 99 00 44435 2 SEAL
PRESSURE RED/BLACK 18
G BLACK/LT GREEN 18 2
LT BLUE 18 BLACK/RED 18
1
RED 18
DEUTSCH_DT06-2S CONN
PINK/TAN 18
AMP23
DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_W2S LOCK GROUND
PINK/WHITE 18 BLACK 14 13MM RING W/
DBW + 1 STAR WASHER
DBW - 2 TAN/ORANGE 18
BLACK 18
STARTER LOCKOUT 3
RED/BLACK 18 PINK/TAN 18
GLOW CONTROL 4
WHITE/BLACK 18
SHUT OFF CONTROL 5
LT GRN/WHT 18 ECM
COLD START CONTROL 6
RED/TAN 16 F2 RED 16
7
10A
8
9
GROUND 10 BLACK 16 WHITE 16
F VBAT 11
RED/TAN 16
TPS 12 PURPLE/LT BLUE 18
13 LT BLUE/PINK 18
LT BLUE 18
OIL PRESSURE 14
PINK/TAN 18
VSW 15 BLACK 18
LT GREEN/RED 18
5V EXT 16
17 COLD START SOLENOID
TAN/WHITE 18 LT GRN/WHT 18 F5 WHITE 16
ECT 18
BLACK/LT GREEN 18 10A
5V RTN 19 TYCO_172128-1 CONNECTOR
BLUE/PINK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAN + 20
CAN - 21
BLUE/WHITE 18
TYCO_63648-1 TERMINAL
COLD START
WHITE/PURPLE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CRANK - 22
PURPLE/WHITE 18
CRANK + 23
TAN/WHITE 18 A
LT GRN/WHT 18
AMP_770680_1 CONNECTOR
AMP_770520_1 TERMINAL (TIN PLATED)
BLACK/LT GREEN 18 B ECT
E PINK/TAN 18
PED_12162193 CONNECTOR
PED_12124075 TERMINAL
LT GRN/WHT 18
DIAGNOSTIC CONNECTOR
UNUSED 1 ANA RTN
UNUSED 2 5V REF
UNUSED 3 PC TX
UNUSED 4 PC RX
UNUSED 5 VBAT EPC_1F1T-14A624-AA-004 CONN
GTS_0330-930009 TERM (18-29)
UNUSED 6 GROUND GTS_0330-940001 TERM (14-16)
BLUE/PINK 18
7 CAN1 + EPC_E6DB-14A468-DA LOCK
BLUE/WHITE 18
8 CAN1 - EPC_F5AB-14A666-AA CAP
DEUTSCH_0413-204-2005 PLUG
JLG WIRING
D FOR SHUT OFF SOLENOID
CAT ENGINE BK/W 18 F4
CRANK SENSOR TYCO_172128-1 CONNECTOR 10A
WHITE/PURPLE 18
PURPLE/WHITE 18
2 CRANK -
1 CRANK +
SHUT OFF
DEUTSCH_DT04-6P CONN SEE
DEUTSCH_0460-202-16141 TERMINAL SHEET 2
ZONE F4 DEUTSCH_DT06-2S CONN
DEUTSCH_W6P LOCK
DEUTSCH_114017 CAVITY PLUG
DEUTSCH_W2S LOCK
1 YEL/RED 2-1-99 (16)
J1-11 ON SHEET 2, ZONE E6
}
2 WHT/YEL 48-3
VEHICLE 3 RED CAN HI
INTERFACE 1 4 BLK CAN LO SEE SHEET 2, ZONE F3
5 BRN/WHT 47-8 SHIELD
6
C
STARTER B+
RED 1-10
GLOWPLUG
87a
SHEET 5, ZONE G3
(VENDOR WIRING) 86 RELAY 30
BLACK RED 1-10
85 WHT/YEL 48-15 87
86
B BLACK
TO GLOW PLUG RAIL
SHEET 5, ZONE H2 85
(VENDOR WIRING)
SEE SHEET 2, ZONE H3 RED
VEHICLE FUEL PUMP RELAY
INTERFACE 2 (LOCATED ON CAT ENGINE)
DEUTSCH_DT04-8PA CONN
DEUTSCH_W8P LOCK
1 YEL/RED 2-1-88 J1-10 ON SHEET 2, ZONE E6

BLACK
2
2 BLACK (16) J1-8 ON SHEET 2, ZONE E6

CONNECT TO 3 BLU/ORG 52-5 J1-22 ON SHEET 2, ZONE C6
FUEL PUMP
4 WHT/YEL 48-9 J1-12 ON SHEET 2, ZONE E6
HARNESS FOR FUEL
CAT ENGINE 5 YEL/RED 2-20 SEE SHEET 2, ZONE E5 PUMP
6 BLACK
A 7 WHT/YEL 48-15 J1-7 ON SHEET 2, ZONE E6
8 WHT/YEL 48-8 WHT/YEL 48-8
1
SHEET 5
8 7 6 5
7-40 3121142
5 4 3 2 1
GLOW PLUG GLOW PLUG

SOLENOID RAIL
RED 8
H
5MM RING
BOSCH GPA-S ACTUATOR 8MM RING
GLOW PLUG
PURPLE/LT GREEN 18
1 SENSOR OUT
SOLENOID ALTERNATOR
BLACK/LT GREEN 18
2 5V RTN
TAN/ORANGE 18
3 DBW + F3 BLACK/RED 18 UNUSED
PINK/WHITE 18 1
4 DBW - 10A BROWN/WHITE 18 CAT 1073134 CONNECTOR
LT GREEN/RED 18 2
5 5V EXT BROWN/WHITE 18 CAT 1073135 TERMINAL
GLOW 5MM RING 3
BOSCH_872-860-521 CONN
PLUGS
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
BOSCH_1 99 00 44435 2 SEAL
RED/BLACK 18 2 18-22 GAUGE INSULATED BUTT CONNECTOR
G
BLACK/RED 18 3
RED 18 5 STARTER B+
PINK/TAN 18 1
GROUND 4 RED 14 10MM RING
RED 8
BLACK 14 13MM RING W/
STAR WASHER
GLOW CONTROL
BLACK 18
PINK/TAN 18 F1 PINK 18
5A
ECM ALTERNATOR +
RED/TAN 16 F2 RED 16 VSW RED 16
10A RED 8 7MM RING
87a
30
WHITE 16
87 RED 16 F
LT BLUE/PINK 18 86
STARTER
BLACK 18
85
RELAY
COLD START SOLENOID
LT GRN/WHT 18 F5 WHITE 16 STARTER
TYCO_172128-1 CONNECTOR 10A
SOLENOID VEHICLE INTERFACE 1
COLD START 7MM RING
PINK 18 1
VSW
LT BLUE/PINK 18 2
START
BLUE/PINK 18 3
CAN +
TAN/WHITE 18 A 87a BLUE/WHITE 18 4
LT GRN/WHT 18 30 CAN -
BROWN/WHITE 18 5
BLACK/LT GREEN 18 B ECT 87 RED 18
6
ALT. EXCITE
UNUSED
PINK/TAN 18 86 DEUTSCH_DT06-6S CONN E
PED_12162193 CONNECTOR
PED_12124075 TERMINAL COLD DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_W6S LOCK
LT GRN/WHT 18
85
START DEUTSCH_114017 CAVITY PLUG
DIAGNOSTIC CONNECTOR RELAY

UNUSED 1 ANA RTN
UNUSED 2 5V REF
UNUSED 3 PC TX
UNUSED 4 PC RX
UNUSED 5 VBAT EPC_1F1T-14A624-AA-004 CONN
GTS_0330-930009 TERM (18-29)
UNUSED 6 GROUND GTS_0330-940001 TERM (14-16)
BLUE/PINK 18
7 CAN1 + EPC_E6DB-14A468-DA LOCK
BLUE/WHITE 18
8 CAN1 - EPC_F5AB-14A666-AA CAP
DEUTSCH_0413-204-2005 PLUG
WHITE/BLACK 18 2 SEE VENDOR B+ D

SHUT OFF SOLENOID SCHEMATIC DETAIL
D+
BK/W 18 F4 BLACK/WHITE 18 3 CAT ENGINE HARNESS
SHEET 5
REGULATOR
CRANK SENSOR TYCO_172128-1 CONNECTOR 10A ZONE G/E2
RED 18 5
WHITE/PURPLE 18
2 CRANK -
SHUT OFF PINK/TAN 18 1
PURPLE/WHITE 18
1 CRANK + 4
SHUT OFF RELAY W
DEUTSCH_W2S LOCK
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
STARTER B+
RED 1-10
VEHICLE INTERFACE 2
10MM RING
1
UNUSED
2
GROUND
SEE SHEET 2, ZONE G2 BLU/ORG 52-5 3
SEE SHEET 2, ZONE F2 GENERATOR ENABLE
YEL/RED 2-20
4
5
PLUGGED JLG WIRING
SEE SHEET 2, ZONE G2 GENERATOR POWER
87a SEE SHEET 2, ZONE G1
BLACK 6
GENERATOR GROUND
FOR CAT
WHT/YEL 48-15
30 WHT/YEL 48-8
7
8
FUEL PUMP ENABLE FUEL PUMP
RED 1-10 WHT/YEL 48-8 FUEL PUMP POWER
WHT/YEL 48-15 87 15 AMP
86 SLOW BLO
BLACK FUSE DEUTSCH_DT06-8SA CONN B
85 DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_W8S LOCK
FUEL PUMP RELAY
(LOCATED ON CAT ENGINE)
SHEET 5 1001119860-O
5 4 3 2 1
3121142 7-41
8 7 6 5 4
RECTIFER
H B+ FUSIBLE
LINK
STATOR
RED 1-1 (8)

STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
STARTER SENSING AND
MOTOR SWITCHING
CIRCUITS D+
G WHT/YEL 48-13 (8)

WHT/YEL 48-12(12)
BRN/WHT 47-8
IN HEAD GLOW PLUGS
BATTERY CABLE (1 GA.)

sol.
sol. DEUTZ EMR2 ENGINE
11
WHT/YEL 48-3
F
WHT/YEL 48-9
BATTERY +
SHEET 2
ZONE H3
2 8 GRD(TempAll)
MTB TO EMR2 ENGINE CONTROL
COOLANT BLACK (16)

E TEMPERATURE
1 9 ADC7(TEMP3) 1
BLACK 0-1 BLACK 0-1
EMR2 ENGINE CONTROL TO ENGINE
DIANOSTICS
2
A K L B
ENGINE 2 13 SPEED ORN/RED 49-198 ORN/RED 49-199
SPEED 10
1 12 GRD (SPEED) ORN/RED 49-198
DEUTZ
CAMSHAFT ORN/RED 49-199
PLUG
11
1 YEL/RED 2-1-98
23 GRD (ACD2)
CHARGE AIR2 4 ADC5(TEMP1) CAN HI
PRESSURE 3 25 +5Vref(ADC2) 12
4 24 ADC2 CAN LO
13
1 22 +5Vref(ADC4)
ENGINE OIL
PRESSURE 2 21 ADC4 14
YEL/RED 2-1-99
3 20 GND (ADC4)
1 14 ActorOut
EMR 2 15 ActorOut
ACTUATOR 3 17 RackMeasCom
4 19 RackMeasSignal
D 5 18 RackMeasRef
VEHICLE INTERFACE I
YEL/RED 2-1-99 1
WHT/YEL 48-3 VSW
2
RED (18) START
CAN HI 3
CAN LO BLACK (18) CAN +
4
BRN/WHT 47-8 CAN -
5
ALT. EXCITE
6
UNUSED
DEUTSCH_W6S LOCK
VEHICLE
INTERFACE 2
VEHICLE INTERFACE 2
1
UNUSED 1 YEL/RED 2-1-88 J1-10 ON SHEET 2, ZONE E6
BLACK (16) 2
GROUND 2 BLACK (16) J1-8 ON SHEET 2, ZONE E6
SEE SHEET 2, ZONE G2 BLU/ORG 52-5 3
SEE SHEET 2, ZONE F2 GENERATOR ENABLE 3 BLU/ORG 52-5 J1-22 ON SHEET 2, ZONE C6
WHT/YEL 48-9 4
GLOW 4 WHT/YEL 48-9 J1-12 ON SHEET 2, ZONE E6
RED 2-20 5
SEE SHEET 2, ZONE G2 GENERATOR POWER 5 YEL/RED 2-20
BLACK 6
SEE SHEET 2, ZONE G1 GENERATOR GROUND 6 BLACK
7
PLUGGED 7 WHT/YEL 48-15 J1-7 ON SHEET 2, ZONE E6
8
B PLUGGED 8 WHT/YEL 48-8
DEUTSCH_DT06-8SA CONN
DEUTSCH_0462-201-16141 TERMINAL DEUTSCH_DT04-8PA CONN
DEUTSCH_W8S LOCK DEUTSCH_0460-202-16141 TERMINAL
DEUTSCH_114017 CAVITY PLUG DEUTSCH_W8P LOCK
SHEET 6
8 7 6 5 4
7-42 3121142
DRAWING NUMBER REV.

5 4 3 2 1 1001119860 G
E
BLACK 0-1
DIANOSTICS
A K L B
ORN/RED 49-199
ORN/RED 49-198
DEUTZ
PLUG
YEL/RED 2-1-98
VEHICLE
INTERFACE 1
DEUTSCH_DT04-6P CONN SEE

DEUTSCH_0460-202-16141 TERMINAL SHEET 2 D
VEHICLE INTERFACE I DEUTSCH_W6P LOCK
ZONE F4
YEL/RED 2-1-99 1
WHT/YEL 48-3 VSW
2 1 YEL/RED 2-1-99 (16)
RED (18) START
3 J1-11 ON SHEET 2, ZONE E6
}
2 WHT/YEL 48-3
BLACK (18) CAN +
4 3 RED CAN HI
BRN/WHT 47-8 CAN -
5 4 BLK CAN LO SEE SHEET 2, ZONE F3
ALT. EXCITE
6 5 BRN/WHT 47-8 SHIELD
UNUSED
6
DEUTSCH_0462-201-16141 TERMINAL SEE SHEET 2, ZONE B5
DEUTSCH_W6S LOCK
VEHICLE
INTERFACE 2
VEHICLE INTERFACE 2
1
UNUSED 1 YEL/RED 2-1-88 J1-10 ON SHEET 2, ZONE E6
2 BLACK
2
GROUND 2 BLACK (16) J1-8 ON SHEET 2, ZONE E6

3
GENERATOR ENABLE 3 BLU/ORG 52-5 J1-22 ON SHEET 2, ZONE C6
4
GLOW 4 WHT/YEL 48-9 J1-12 ON SHEET 2, ZONE E6 NOT PRESENT
5 FUEL
GENERATOR POWER 5 YEL/RED 2-20 SEE SHEET 2, ZONE E5 PUMP WITH
6
GENERATOR GROUND 6 BLACK DEUTZ ENGINE
7
PLUGGED 7 WHT/YEL 48-15 J1-7 ON SHEET 2, ZONE E6
8
PLUGGED 8 WHT/YEL 48-8 WHT/YEL 48-8 B
1
DEUTSCH_DT06-8SA CONN
DEUTSCH_0462-201-16141 TERMINAL DEUTSCH_DT04-8PA CONN
DEUTSCH_W8S LOCK DEUTSCH_0460-202-16141 TERMINAL
DEUTSCH_114017 CAVITY PLUG DEUTSCH_W8P LOCK
SHEET 6 1001119860-O
5 3 2 1
3121142 7-43
8 7 6 5 4
ECM-J2 X999 X1003 EIC BUSSMANN DIODE PACK FUEL PUMP 20A (SW), ECM 30A (CONT)
BLK 248-33 INJECTOR 1 BLK 248-33 INJECTOR 1 1.5mm²
33 1 1 62 (BLUE) YELLOW CONNECTOR
16 2 2 35 GENERIC
48 3 3 42 RELAY, POWER MODULE
18 4 4 37
32 5 5 38
BLK 248-2 INJECTOR 3 BLK 248-2 INJECTOR 3 1.5mm² 5A 10A
2 6 6 61
46 7 7 40
3 8 8 41
H 6
BLK 248-5 MPROP ACTUATOR
BLK 248-4 MPROP ACTUATOR
9 9
BLK 248-5 MPROP ACTUATOR 1.5mm²
2
5 10 10 20
RL930-B+
MS932
RL930-1
BLK 248-19 EXH GAS RECIRC BLK 248-4 MPROP ACTUATOR 1.5mm²
G
C
D
H
B
A
RL930
F
1
2
1
4 11 11 19
BLK 248-20 EXH GAS RECIRC BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 12 12 14
BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²
52 13
BLK 248-23 GLOW SENSE 0.75mm²
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

YEL 2-1-99 IGNITION 18AWG
SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²

ORG 248-23-1 GLOW SENSE 18AWG
53 9
WHT 48-96 FUEL PUMP 14AWG

BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²
39 15
BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²

54 X1000 X1004 21
BLK 248-37 ENG CAM SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²
38 1 1 1
BLK 148-7 RAIL PRESSURE FUEL BLK 248-52 ENG CAM BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 2 2 32
SHLD 248-53 ENG CAM
8 3 3 57
BLK 248-39 ENG CRANK
9 4 4 3
BLK 248-54 ENG CRANK
10 5 5 4
SHLD 248-38 ENG CRANK
11 6 6 5
12 7 7 6
EIC (ENGINE INTERFACE CONNECTION)

13 8 8 7
14 9 9 8
A [J2] 15 10 10 10
17 11 11 11
ECM CONNECTOR 19 12 12
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
20 48
G 21 12
22 59
BLK 248-23 GLOW SENSE
S946
23 X1001 X1005 16
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm² BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
24 1 1 22
BLK 248-25 RAIL PRESSURE FUEL 0.75mm² BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 2 2 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm² BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 3 3 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm² BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 4 4 29
BLK 248-28 COOLING TEMPERATURE 0.75mm² BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 5 5 24
BLK 248-29 OIL PRESSURE 0.75mm² BLK 248-29 OIL PRESSURE 0.75mm²
29 6 6 27
30 7 7 33
31 8 8 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 9 9 17
BLK 248-35 GLOW RELAY CONTROL GND
35 10 10 18
36 11 11 58
1 12 12 30
BLK 248-40 AIR INLET TEMP BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
BLK 248-43 OIL PRESSURE BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE BLK 248-44 OIL PRESSURE 0.75mm²
44 26
F 45
47
39
43
49 44
50 45
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
58 51
59 53
60 54
55
56
ECM-J1
1.5MM (7,29,51,73) 7
8
9
10
11
E 12
BLK 148-13 COOLANT LEVEL SIG
13
S951
14
BLK 148-15-68 CLUTCH SWITCH
15
16
17
S952
18
19
20
21
22
23
24
25
BLK 148-26 FUEL PUMP RELAY CONTROL GND
26
27
28
1.5MM (7,29,51,73) BLK 148-29 COOLANT LEVEL PWR
29
30
31
32
D 33
34
35
36
37 X1002 X1006
BLK 148-38 THROTTLE FLAP 4
38 1 1
39 2 2
40 3 3
41 4 4
42 5 5
43 6 6
BLK 148-44 EXH GAS RECIRC
44 7 7
45 8 8
46 9 9
47 10 10
48 11 11
49 12 12
50
1.5MM (7,29,51,73) 51
52
GRN CAN 2 LO DIAG CAN LOW S968
C 53
YEL CAN 1 HI CUSTOMER CAN HIGH
54
55 S953
BLK 148-56 AIR INLET TEMP
56
BLK 148-57 WATER IN FUEL SW RTN
57
K [J1] 58 X965
YEL CAN 2 HI 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO
B B
BLK 148-61 FUEL LOW PRESSURE
61 C C
62 X966
63
BLK 148-64 WATER IN FUEL SW
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH YEL CAN 1 HI 120 OHM
68 A A
GRN CAN 1 LO
69 B B
70 C C
71 X956
BLK 148-72 THROTTLE FLAP 3
72
1.5MM (7,29,51,73) 73
B 74 S969
YEL CAN 2 HI DIAG CAN HIGH
75
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954
X1008 X1010
YEL CAN 2 HI
78 1 1
GRN CAN 2 LO
79 2 2
80 3 3
YEL CAN 1 HI
81 4 4
BLK 148-82 EXH GAS RECIRC GRN CAN 1 LO
82 5 5
SHLD CAN 1 SHLD
83 6 6
84 7 7
BLK 148-85 EXH GAS RECIRC
85 8 8
86
BLK 148-87 COOLANT LEVEL GND
87
BLK 148-88 IGNITION
88
89
90
91
92
93
A 94
5
RED 148-5 ECM PWR 2.5mm²
X1007
RED 148-3 ECM PWR 2.5mm² S944
3 1 1
RED 148-1 ECM PWR 2.5mm² X1009
1
2.5MM (1-6) BLK 148-2 ECM GND 2.5mm²
2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
NC
SHLD CAN 1 SHLD
SHEET 7
8 7 6 5 4
7-44 3121142
5 4 3 2 1
EIC BUSSMANN DIODE PACK
FUEL PUMP 20A (SW), ECM 30A (CONT)
62 (BLUE)
YELLOW CONNECTOR GLOWPLUG SOLENOID GLOWPLUGS
35
GENERIC 150 AMP
42
RELAY, POWER MODULE
37
38
5A 10A
61
40
GENERIC
41
87
30
86
85
2
GENERIC
ALTERNATOR
H
20
RL930-B+
RL931-85
MS932
RL931-87
RL931-87
RL931-87
RL931-30
RL931-86
B+
RL930-1
RL930-2
W
G
C
D
H
B
A
E
F
RL930
1
1
2
1
2
L
19
EC18
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
14
EC241-B+
EC241-W
BUSBAR
EC241-L
1
1
13
BLK 248-23 GLOW SENSE 0.75mm²
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²


RED 1-148-135 ECM PWR 8AWG
BATTERY +
150A
15
SHEET 2
RED 48-13 GLOW 8AWG
RED 48-13 GLOW 8AWG

RED 48-14 GLOW 8AWG
RED 48-14 GLOW 8AWG

21

ZONE H3
RED - - 4AWG
RED 47-8 ALT EXCITE 16AWG

1
32
BUSBAR
57
3
4 BUSBAR
5
RED - - 2/0AWG
RED - - 2/0AWG
6
X923
EIC (ENGINE INTERFACE CONNECTION)
1
8
150A
10
11
47
48
G
BUSBAR
12 EC971-B+
59 1 M
S946
GENERIC
GENERIC
16 EC971
22 1
31 EC971-B-
25 1
29
24 RL974
WHT 48-3 START 18AWG
27 1 DEUTZ PROVIDED
BLK 000-48-4 ENG GND
33 2
START RELAY
60
17
18
58
30 X901
28 1 VSW
WHT 48-3 START 18AWG
34 2 START
36 3 CAN + (HI)
GRN CAN 1 LO CUSTOMER CAN LO
23
RED 47-8 ALT EXCITE 16AWG
4 CAN - (LOW) VEHICLE INTERFACE 1
26 5
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
ALT EXCITE
(SEE SHEET 6, ZONE C3)
39
43
6 CAN SHIELD
F
44
45 X902
46 1 EMR4 IGNITION
49 2 GROUND
50 3 GENERATOR ENABLE
52 4 GLOW
51 5 GENERATOR POWER VEHICLE INTERFACE 2

53 6 GENERATOR GROUND
(SEE SHEET 6, ZONE B4)
54 7 PLUGGED
55 8 PLUGGED
56
E
S951
S952
X950
YEL 2-48-2 IGNITION
A
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
F
GRN CAN 2 LO DIAG CAN LOW
G DEUTZ DIAGNOSTIC D
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
H
J
K
L
M
X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
GRN CAN 2 LO DIAG CAN LOW
B B
C C
X961
C
NORMALLY CLOSED
SN939 PWR
COOLANT LEVEL
BLK 148-29 COOLANT LEVEL PWR 0.75mm²

1
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
WIF SWITCH
X941 X942
BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
2 2
2
SN959
WATER IN FUEL
3 3
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
4 4
120 OHM
FUEL PUMP
A
B 1
M
C 2 FUEL PUMP
X956 EC958
X958A EC958+
FUEL PUMP
WHT 48-96 FUEL PUMP

1 1
2 EC958- M B
1
X1008 X1010
BLK 000-48-2 ENG GND T920 2 x 5mm 14 AWG RING
YEL CAN 2 HI
1 1
BLK 000-48-1 ENG GND 14AWG
1 GND
GRN CAN 2 LO
2 2
3 3 3/8" 10-12 AWG RING
YEL CAN 1 HI
4 4 X1011
GRN CAN 1 LO BLK 000-148-246 ECM GND 8AWG
5 5 1
SHLD CAN 1 SHLD
6 6
7 7 3/8" 8 AWG RING
8 8
SHEET 7 1001119860-O
5 4 3 2 1
3121142 7-45
8 7 6 5 4
DRAWING NUMBER
1001119860
PLATFORM SENSOR
H
ORN/RED 49-69
SEE
SHT 3
ZONE E6, A7 YEL/RED 2-16-3
3 YEL/RED P1 ZONE D6
PLATFORM SENSOR
6 YEL/RED P8
13
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 9
ZONE B5
G
SOFT TOUCH AND PLATFORM SENSOR

SEE
SHT 3
YEL/RED P3
ORN/RED 49-69 ZONE F8
SEE 3 YEL/RED P1 ZONE D6
SHT 3
ZONE E6, A7
YEL/RED 2-16-3
6 BLK L WHT 5
SOFT
F
13 BLK BLK 4 TOUCH
R
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 9
ZONE B5
PLATFORM SENSOR
WHT ORN/RED P4
4
BLK ORN/RED P5
3
E BLK BLK P6
2
WHT YEL/RED P10
1
YEL/RED P1
YEL/RED P9
D
LOW TEMPERATURE CUTOUT OPTION P-J8A

X3
C
YEL/RED EMS GND 2-1-3
2 CONNECT TO P8
BLK GND
1 (MATING CONNECTOR OF J8)
MOLEX SHT 1 ZONE D-7
042818-0212
PARKER SENSOR
X1 YEL/RED EMS GND 2-1-3
YEL/RED EMS GND 2-1-5 YEL/RED EMS GND 2-1-4
1
BLK GND S531
2
3
BLK CAN L
RED CAN H BLK GND
BLK GND
BLK GND
X4
4 B
CONNECT TO X1002
NC S532 A
C SHT 1 ZONE F-6
BLK CAN L
B
BLK CAN L BLK CAN L DEUTSCH
S533 RED CAN H
RED CAN H RED CAN H JLG PN 4460536
S534
SHIELD CANSHD X5
SHIELD CANSHD SHIELD CANSHD B
CONNECT TO X1001
X2 S535
A
C SHT 1 ZONE F-6
CONNECT TO J8 2
BLK GND
SHT 1 ZONE D-7 1 DEUTSCH
JLG PN 4460539
P-J8
MOLEX
A 042816-0212
LTC OPTION BOOM HARNESS

SHEET 8
8 7 6 5 4
7-46 3121142
DRAWING NUMBER REV.

5 4 3 2 1 1001119860 O
PLATFORM SENSOR
YEL/RED P3 YEL/RED P3 87
1
YEL/RED P9-1 30
1
RELAY, 12V
87a F
1
ORN/RED P5 85
1
ORN/RED P5-1
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
WHT ORN/RED P4
4
BLK ORN/RED P5
3
BLK BLK P6 SEE
E
2 SHT 3
WHT YEL/RED P10 YEL/RED P2 ZONE G6

1
18 ohm 25W
YEL/RED P1 YEL/RED P1 87
1
YEL/RED P9 YEL/RED P9
D
YEL/RED P9-1 30
1
RELAY, 12V
87a
1
ORN/RED P5-1 85
1
P-J8A ORN/RED P4-1 86
1
X3
2 CONNECT TO P8 C
BLK GND
1 (MATING CONNECTOR OF J8)
MOLEX SHT 1 ZONE D-7 NOTE:
SKYGUARD RELAYS LOCATED ON THE RIGHT SIDE OF THE CONTROL PLATFORM BOX.
042818-0212 IF SKYGUARD RELAYS ARE ON THE LEFT SIDE, SEE SHEET 9.
X4
B
A
CONNECT TO X1002
C SHT 1 ZONE F-6
B
DEUTSCH
JLG PN 4460536
X5
B
CONNECT TO X1001
A
C SHT 1 ZONE F-6
DEUTSCH
JLG PN 4460539
SHEET 8 1001119860-O
5 4 3 2 1
3121142 7-47
8 7 6 5 4
H ALERT BEACON OPTION

HARNESS P/N 1001142736 12
11
10
9
8
RED - BEACON PWR
7
6
BEACON MODULE
5
4
3
BLK - GROUND
X3 2
RED - BEACON PWR WHT - IGNITION
1 1
BLK - GROUND S1
2 X1
BLK - GROUND
G
S3
S2
TO ENG DIAG CONN (ORIGINAL)
F
WHT - CAN SHIELD
RED - CAN HIGH

BLK - CAN LOW
TO ENG DIAG CONN (NEW)

WHT - CAN SHIELD
WHT - CAN SHIELD
WHT - CAN SHIELD
WHT - CAN SHIELD
WHT - CAN SHIELD
WHT - CAN SHIELD
WHT - CAN SHIELD

RED - CAN HIGH
RED - CAN HIGH
RED - CAN HIGH
RED - CAN HIGH
RED - CAN HIGH
RED - CAN HIGH
RED - CAN HIGH

WHT - IGNITION
WHT - IGNITION
RED - BATTERY
RED - BATTERY
BLK - CAN LOW
BLK - CAN LOW
BLK - CAN LOW
BLK - CAN LOW
BLK - CAN LOW
BLK - CAN LOW
BLK - CAN LOW

BLK - GROUND
BLK - GROUND
BEACON MODULE
CAN TERMINATOR
X2
X5
X9
X7
X4
J
J
G
F
G
F
12
11
10
9
8
7
6
5
4
3
2
1
1
3
5
2
4
6
11
9
7
12
10
8
D
C
D
C
E
B
A
B
A
B
A
E
HARNESS,GEN 2 PLAT INTERFACE

P/N: 1001225580
D
PLTFM SNSR
PLTFM SNSR PLTFM SNSR
RELAY #1 RELAY #2
87a
87a
87
30
85
86
86
85
30
87
4
3
2
1
RL503
RL502
X500
4
3
2
1
C
WHT P1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P4-2
WHT P5-2
WHT P9-2
WHT P3
WHT P5
WHT P4
WHT P6
WHT P10
NOTE:
6 PIN CONNECTOR AND RELAYS LOCATED
ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX.
IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 8.
S191 INTERFACE
X5B KL
S192
WHT P6 BLACK P6
2 SEE SHT 3 ZONE F6
WHT P1 ORN/RED 49-69-1

4 SEE SHT 3 ZONE E4
WHT P3 YEL/RED P3
B 5 SEE SHT 3 ZONE F8
18 OHM
IP144 WHT P2 YEL/RED 2-16-3-1
1 SEE SHT 3 ZONE D3
YEL/RED P2
3 SEE SHT 8 ZONE F6 OR G6
SHEET 9
8 7 6 5 4
7-48 3121142
5 4 3 2 1
CRIBBING HARNESS OPTION

TO CRIBBING MODULE - J2 TO CRIBBING MODULE- J1
H
10
12
11
1
2
3
4
5
6
7
8
9
10
12
11
1
2
3
4
5
6
7
8
9
X383
X878
CRIBBING ENABLE LAMP
GRN CANL_7
YEL CANH_5
RED/ORN 116
BLK/ORN 114
1
2
LB373
RED 103
BLK 102
BLK/ORN 114
BLK 113
CRIBBING ENABLE SW
SW374 G
RED 115
S369 BLK 117
BLK 102
J7 28
CONNECT TO
RED 103 BLK BLK RED 118
J7 33 GROUND CONTROLLER (SHEET 2)
S370 S371
IP914
MS377-3 INLINE FUSE 5A
GRN CANL_7
1
YEL CANH_5
2
2 YEL CANH_6 YEL CANH_6 J7 13 CONNECT TO
GRN CAN LOW
MS377-2 1 GRN CANL_8 GRN CANL_8 J7 24 GROUND CONTROLLER (SHEET 2)
1
YEL CAN HIGH
2 MS377-1
EXTRACT WIRES FROM F
GROUND CONTROLLER J7-13 & J7-24
AND CONNECT AS SHOWN
(SEE SHEET 2)
(EXISTING HARNESS)
1001210632 CRIBBING HARNESS

1001210633 CRIBBING HARNESS
SHEET 9 1001119860-O
5 4 3 2 1
3121142 7-49
NOTES:
7-50 3121142
3121142
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations

www.jlg.com

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Service and Maintenance Manual

April 22, 2019 - Rev V

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

Original Issue A - June 5, 2002

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TABLE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

This Page Left Blank Intentionally

1.1 CAPACITIES Deutz SN 0300127698 to Present

Hydraulic Tank 55 gallons (208 liters) Type Liquid Cooled

Deutz TCD 2.9 GUOIII Dimensional Data

1.4 SPECIFICATIONS AND PERFORMANCE DATA

1.5 TORQUE REQUIREMENTS

NOTE: Aside from JLG recommendations, it is not advisable to mix

1.7 MAJOR COMPONENT WEIGHTS

Type Synthetic Biodegradable Table 1-17. Component Weights

ISO Viscosity Grade 46 Component Pounds Kilograms

1.8 PRESSURE SETTINGS

Circuit PSI Bar

Function Pump, High 3400 234.4

Function Pump, Low 300 20.6

Drive, Pre-Set 5000 344.7

Lift Up 2750 189.6

Lift Down 1500 103.4

Swing 1500 103.4

Tele Out 3000 206.8

Telescope In 3200 220.6

Steer Right 2000 137.9

Steer Left 2600 172.3

Platform Level Up 2500 172.3

Platform Level Down 1500 103.4

Jib Up 2750 189.6

Jib Down 2750 189.6

Extendable Axles 2500 172.3

Figure 1-1. Lubrication and Maintenance Diagram

1.9 LUBRICATION AND MAINTENANCE 2. Swing Gearbox

Table 1-19. Lubrication Specifications

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

NOTE: It is recommended as a good practice to replace all filters at