Service and Maintenance Manual: Model 1850SJ

Service and Maintenance Manual
Model
1850SJ
3121619
May 27, 2019 - Rev K
AS/NZS
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.
3121619 A-1
INTRODUCTION
REVISON LOG
Original Issue A - June 18, 2014

Revised B - September 25, 2014
Revised C - May 15, 2015
Revised D - November 5, 2015
Revised E - January 27, 2016
Revised F - June 8, 2016
Revised G - November 8, 2016
Revised H - May 23, 2017
Revised I - May 30, 2018
Revised J - June 29, 2018 - Revised Covers
Revised K - May 27, 2019
A-2 3121619
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 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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
Preventive 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
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
3121619 i
TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Axle Extension System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Ground Control Keyswitch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Jib Lift End of Stroke Dampening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Ground Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.10 Hydraulic System Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.11 Function Speed Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.12 Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.13 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.14 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Engage Drive Motors & Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.15 Gear Hub Oil Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Change Gear Hub Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.16 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.17 Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.18 Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.19 Swing Bearing Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.20 Swing Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.21 Chassis Tilt Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.22 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.23 Water in Fuel Sensing System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.24 Deutz Turbocharger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.25 Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Cleaning and Flushing the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.26 Deutz Engine with Diesel Exhaust Fluid (DEF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.27 Selective Catalytic Reduction (SCR) - Machines Using Diesel Exhaust Fluid (DEF) . . . . . . . . . . . . . . . . . . . . . . 3-62
Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Maintenance Standstill Cleaning Initiation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Cancelling Maintenance Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Unsuccessful Cleaning Event. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
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SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer - Boom Function Interlock System (CE/AUS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Jib Stow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Envelope Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controlled Arc System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controlled Boom Angle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Slow Down System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Dual Capacity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Platform Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Control Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Recovery Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Platform/Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Platform/Support Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3 Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.4 Boom Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.5 Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.6 Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.7 Boom Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.8 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.9 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.10 Hose Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.11 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4.12 JIB Shimming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Jib Straight Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Stowed Jib Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.13 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Additional Inspection Required If:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
12 Year or 7000 Hour Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Additional Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.14 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Boom Preparation for Section Repositioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Confirm Proper Boom Deployment Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Boom Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
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4.15 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.16 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
One Piece Bracket Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Two Piece Bracket Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
4.17 SkyGuard® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
4.18 Bolt-on External Fall Arrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
FFWR and TFFT Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5.3 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Axle Extend Cylinder (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Axle Extend Cylinder (SN 0300239676 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Jib Level (Slave) Cylinder (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Jib Level (Slave) Cylinder (SN 0300239676 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Platform Level Cylinder (Prior to SN 0300239170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Platform Level Cylinder (SN 0300239170 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Boom Lift Cylinder (Prior to SN 0300239676). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Boom Lift Cylinder (SN 0300239676 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Jib Lift Cylinder (Prior to SN 0300239676). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
Jib Lift Cylinder (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
Steer Cylinder (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Steer Cylinder (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131
Jib Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
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Boom Telescope Cylinder (SN 0300190128 through 0300244677). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Boom Telescope Cylinder (SN 0300244678 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5.4 Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
5.5 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
5.6 Pressure setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-163
1. Setup of the Function Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-163
2. Adjustments Made at the Main Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-164
3. Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-170
4. Adjustments Made at the Platform Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-171
5. Adjustments Made at Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-172
6. Adjustments Made in Traction Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-178
5.7 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
Port Locations and Gauge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
Initial Startup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-182
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-182
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-186
Removing The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-190
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-190
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-190
Electric Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-191
Shaft, Seal, and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-192
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193
Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195
Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
Control Cutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
5.8 Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-202
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-205
5.9 Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-209
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-209
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-212
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-219
5.10 Drive & Function Pump Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-220
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-220
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Ground Control Console Display Gauge - Machines using Diesel Exhaust Fluid (DEF) . . . . . . . . . . . . 6-6
6.2 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
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6.6 Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Sensor #1 - Load Pin (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Sensor #2 - Main Boom Angle Sensors (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Sensor #3 - Main Boom Length Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Sensor #4 - Main Boom Cylinder Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Sensor #5 - Main Boom Transport Length Switch (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Sensor #6 - Jib Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Sensor #7 - Jib Lock Pin Proximity Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Sensor #8 - Jib Stow Angle Sensor (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Sensor #9 - Jib Lift Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Sensor #10 - Dual Capacity / Jib Transport Length Switches (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Sensor #11 - Platform Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Sensor #12 - Platform Level Angle Gravity Sensors (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #13 - Turntable Swing Angle (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #14 - Steer Angle Sensor (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #15 - Axle extend/retract Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #16 - Brake-Two Speed Pressure Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #17 - Chassis Tilt Sensor (Externally mounted) (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #18 - Tilt Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #19 - Warm up Switch (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #20 - Main Valve Pressure Transducer (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Sensor #21 - Main Lift Cylinder Pressure Transducer (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
6.7 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6.8 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Axle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Boom Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6.9 Jib Sensor Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Calibrating the Jib Level Up and Down Valve Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
6.10 Boom Unlock Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Initial Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
6.11 Setting Crackpoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Platform Level Up and Down Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Jib Level Up and Down Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Main Lift Up and Down Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Main Telescope Out and In Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
6.12 LSS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
6.13 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
6.14 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Platform Leveling Fault Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Fault Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
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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
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
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viii 3121619
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-2. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3-1. Crab Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Coordinated Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Conventional Two Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Axle Hose Routing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5. Axle Hose Routing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-6. Steering/Axle Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7. Drive System Hydraulic Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-8. Drive System Hydraulic Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-9. Turntable Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-10. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-11. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-12. Disengaging Drive Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-13. Gear Hub Oil Fill and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-14. Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-15. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-16. Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-17. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-19. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-20. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-21. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-22. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-23. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-24. Shaft & Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-25. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-26. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-27. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-28. Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-29. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-30. Cylinder Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-31. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-32. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-33. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-34. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-35. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-37. Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-38. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3-39. Swing Bearing Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-40. Swing Bearing Removal - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-44. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-45. Diesel Exhaust Fluid (DEF) Tank - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-46. Engine Installation and Diesel Exhaust Fluid (DEF) System - Sheet 1 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3121619 ix
LIST OF FIGURES

3-50. Engine Installation and Diesel Exhaust Fluid (DEF) System - Sheet 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-53. Diesel Exhaust Fluid (DEF) System - Sheet 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3-54. Engine Electrical Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-55. Mixing Petroleum With Summer Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
4-1. Location of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-2. Platform Support Torque Values (without LSS and with 4 Cell LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-3. Platform Support Torque Values (with 1 Cell LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-4. Rotator Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-5. Boom Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-6. Boom Assembly - Sheet 1 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-15. Locations for Threadlocker Application - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-20. Boom Assembly Torque Values - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-24. Hose Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-25. Section 3 Boom Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-28. Jib Hydraulics - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-35. Jib Assembly - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4-39. Jib Stow Shimming Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4-40. Fully Retracted Boom Section Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
4-41. Initial Exposed Thread Length for Wire Rope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-42. Boom Wire Rope Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-43. Broken Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-44. Powertrack Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4-48. Powertrack Shimming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4-49. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-80
x 3121619
LIST OF FIGURES

4-53. Powertrack Hose Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4-57. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
4-58. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-13. FFWR Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-14. Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-15. Turntable Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-16. Hydraulic Hose Installation - Sheet 1 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-24. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-25. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-26. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-27. Axle Extend Cylinder Assembly (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-28. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-29. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-30. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-31. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-32. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-33. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-34. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-38. Axle Extend Cylinder Assembly (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5-41. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
5-49. Jib Level (Slave) Cylinder Assembly (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
3121619 xi
LIST OF FIGURES

5-51. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5-52. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5-54. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-55. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-56. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5-57. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5-59. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-60. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-61. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-62. Jib Level (Slave) Cylinder Assembly (SN 0300239676 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-63. Piston Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5-64. Piston Seal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5-67. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5-68. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5-69. Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5-70. Cylinder Head Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5-71. Caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5-74. Cylinder Length Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-75. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-76. Platform Level Cylinder Assembly (Prior to SN 0300239170). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5-78. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-81. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-82. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-86. Rod and Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5-89. Cylinder Length Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-90. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-91. Platform Level Cylinder Assembly (SN 0300239170 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5-96. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5-101. Rod and Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5-106. Boom Lift Cylinder Assembly (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
xii 3121619
LIST OF FIGURES

5-108. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-111. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5-112. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-119. Boom Lift Cylinder Assembly (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-120. Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5-124. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5-125. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-126. Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-129. Cylinder Length Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-131. Jib Lift Cylinder Assembly (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-136. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5-137. Cylinder Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-143. Cylinder Length Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5-145. Jib Lift Cylinder Assembly (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
5-149. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
5-150. Cylinder Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
5-155. Jib Lock Cylinder Assembly (Prior to SN 0300239170). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5-156. Jib Lock Cylinder Assembly (SN 0300239170 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125
5-160. Steer Cylinder Assembly (Prior to SN 0300239676) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
5-161. Piston and Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
5-162. Cylinder Head and Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
3121619 xiii
LIST OF FIGURES

5-164. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131
5-166. Steer Cylinder Assembly (SN 0300239676 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
5-167. Piston and Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
5-168. Cylinder Head and Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
5-170. Cylinder Head and Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
5-172. Jib Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
5-173. Piston and Spacer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5-175. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-176. Piston and Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-178. Cylinder Head Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
5-179. Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
5-181. Port Block And Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
5-183. Boom Telescope Cylinder Assembly (SN 0300190128 through 0300244677) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
5-188. Cylinder Head and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144
5-192. Rod Assembly And Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-194. Port Block And Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5-196. Boom Telescope Cylinder Assembly (SN 0300244678 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5-201. Rod Assembly And Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-202. Cylinder Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5-203. Oil Sampling Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
5-204. Main Valve Identification (Prior to SN 0300247849) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5-205. Main Valve Identification (Prior to SN 0300247849) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-156
5-206. Main Valve Torque Values (Prior to SN 0300247849) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5-207. Main Valve Torque Values (Prior to SN 0300247849) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158
5-208. Main Valve Torque Values (SN 0300247850 to Present) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-159
5-212. Piston Pump Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
5-213. Port locations - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-180
5-214. Port locations - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-181
5-215. Charge Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-186
5-216. Control Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-187
5-217. Servo and System Pressure Gauge Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-189
5-218. Control Module And Solenoid Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-191
5-219. Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-192
xiv 3121619
LIST OF FIGURES

5-220. Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194
5-221. Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195
5-222. Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
5-223. Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
5-224. Control Cutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-198
5-225. Fastener and Plug Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
5-226. Hydraulic Schematic - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-222
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3. Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4. Engine Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5. Ground Control Console Display Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6. Control System CAN Circuit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-7. Control System CAN Circuit 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-8. Analyzer Flow Chart - Sheet 1 of 5 (Software Version P7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-10. Analyzer Flow Chart - Sheet 3 of 5 (Software VersionP 7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-13. Ground Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-14. Platform Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-15. Chassis Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-16. BLAM Control Module (Prior to SN 0300248234). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-17. BLAM Control Module (SN 0300248235 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-18. Ultra Boom Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-19. Jib Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6-20. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-21. Main Boom Angle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
6-22. Main Boom Cylinder Angle (Protractor) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
6-23. Main Boom Transport Length Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6-24. Jib Lock Pin Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
6-25. Jib Level Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
6-26. Jib Stow Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6-27. Jib Transport Length Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
6-28. Platform Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6-29. System Test Flow Chart - Platform Tests - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-30. System Test Flow Chart - Platform Tests - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
6-31. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
6-32. LSS Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
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. Application to plug/male connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-7. Brad-Harrison M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-8. Phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
3121619 xv
LIST OF FIGURES

7-9. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-10. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-14. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-15. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-17. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-18. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-19. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-20. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-21. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-22. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-25. Platform Box Wiring Harness (without SKYGUARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-26. Platform Box Wiring Harness (with SKYGUARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-27. Platform Valve Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-28. Jib Valve Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7-29. BLAM Module Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
7-30. Load Sensing Pin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7-31. Base Boom Sensor Cable (Prior to SN 0300224828) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-32. Base Boom Harness (Prior to SN 0300224828) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7-33. Base Boom Harness (Prior to SN 0300224828) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
7-34. Base Boom Harness (SN 0300224828 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
7-35. Beacon/Strobe Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
7-36. Fuel Pump & Water-In-Fuel Harness (Prior to SN 0300237158) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7-37. Fuel Pump & Water-In-Fuel Harness (SN 0300237158 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
7-38. Turntable Wiring Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
7-41. Ground Console Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
7-42. Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
7-43. Hydraulic Valve Bank Harness (Prior to SN 0300201023). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-44. Hydraulic Valve Bank Harness (SN 0300201023 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
7-45. Drive Pump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
7-46. T4i Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
7-47. CAN Engine Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
7-48. CAN Engine Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105
7-49. Generator Enable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
7-50. T4F Engine Harness - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
7-57. Urea Tank/Supply Module Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
7-58. Platform Interface Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
7-59. Cribbing Module Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
7-60. Cribbing Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132
7-61. Electrical Installation - Sheet 1 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134
xvi 3121619
LIST OF FIGURES

7-66. Electrical Installation - Sheet 6 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
7-70. Electrical Installation - Sheet 10 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-143
7-71. Battery Jump-Start Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144
7-72. Battery Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145
7-73. Battery Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
7-74. Electrical Schematic (SN 0300224828 through SN 0300243454) - Sheet 1 of 21 . . . . . . . . . . . . . . . . . . . . . . . 7-147
7-83. Electrical Schematic (SN 0300224828 through SN 0300243454) - Sheet 10 of 21 . . . . . . . . . . . . . . . . . . . . . . 7-156
7-95. Electrical Schematic (SN 0300243455 to Present) - Sheet 1 of 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-169
7-104. Electrical Schematic (SN 0300243455 to Present) - Sheet 10 of 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-178
3121619 xvii
LIST OF FIGURES
xviii 3121619
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3121619 xix
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Engine Data - Deutz TCD 3.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 Mobil DTE 10 Excel 32 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Mobil SHC 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-14 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-3 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-7 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-8 Maintenance Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-9 Cleaning When Crystallization is Detected During SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-10 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
4-1 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-6 45° Flare (SAE) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
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
5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
xx 3121619
LIST OF TABLES

5-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-33 Port information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
5-34 Electrical troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-183
5-35 Neutral difficult or impossible to find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-183
5-36 System operating hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-183
5-37 System will not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
5-38 System noise or vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
5-39 Sluggish system response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-185
5-40 Displacement Limiter Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-187
5-41 Fastener Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-198
5-42 Plug Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-198
5-43 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-219
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-2 Machine Configuration Programming Information (Software Version P7.29). . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-3 Machine Configuration Programming Settings (Software Version P7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-4 Machine Personality Settings and Function Speeds (Software Version P7.29) . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
6-8 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
6-9 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
6-10 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
6-11 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
6-12 Diagnostic Fault Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
6-13 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
3121619 xxi
LIST OF TABLES
xxii 3121619
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data
Horizontal Reach over end

Table 1-1. Operating Specifications
Unrestricted Capacity 70 ft. 6 in. (21.50 m)
Capacity - ANSI Restricted Capacity 59 ft. 6 in. (18.13 m)
Unrestricted 500 lbs (227 kg) Horizontal Reach over side
Restricted 1000 lbs (454 kg) Unrestricted Capacity 71 ft. 9 in. (21.86 m)
Capacity - CE & Australia Restricted Capacity 60 ft. 8 in. (18.49 m)
Unrestricted 500 lbs (230 kg) Overall Width
Restricted 1000 lbs (450 kg) Axles Retracted 8 ft. 2 in. (2.48 m)
Maximum Travel Grade, stowed 40% Axles Deployed 16 ft. 6.5 in. (5.04 m)
Position (Gradeability) Wheelbase
Maximum Travel Grade, stowed 5° Axles Retracted 17 ft. 1.5 in. (5.22 m)
Position (Side Slope) 4° - CE/Aus Axles Deployed 15 ft. 0.5 in. (4.59 m)
Drive Speed 2.8 mph (4.5 kph) Tailswing 7 ft. 7.5 in. (2.32 m)
Drive Speed at Elevation 0.3 mph (0.48 kph) Ground Clearance (Axle) 9.75 in. (0.25 m)
Gross Machine Weight - Approximate 59,900 lb. (27170 kg.) Ground Clearance (Chassis) 1 ft. 4.25 in. (0.41 m)
Ground Bearing Pressure - Maximum 119.6 psi (8.41 kg/cm2) 1.3 CAPACITIES
Maximum Wind Speed 28 mph (12.5 m/s) Table 1-3. Capacities
Maximum Manual Force 90 lbs (400N) Hydraulic Oil Tank 75.1 Gal. (284.2 L)
Maximum System Voltage 12 volts Fuel Tank 45 Gal. (170 L)
Maximum Main Relief Hyd. Pressure 5000 psi (345 Bar) Drive Hub 2.6 quarts (2.5 liters)
Swing Gearbox 3 qt. (2.8 L)

1.2 DIMENSIONAL DATA
Table 1-2. Dimensional Data 1.4 TIRES
Table 1-4. Tire Specifications
Turning Radius (Axles Retracted)
Outside 31 ft. 2.75 in. (9.52 m) Size 445/50D710
Inside 23 ft. 4.25 in. (7.12 m)
Load Range N
Turning Radius (Axles Extended) Ply Rating 24
Inside 7 ft. 6.75 in. (2.3 m) Foam Fill Polyurethane HD (55 Durometer) Foam
Outside 21 ft. 7.75 in. (6.6 m)
Diameter 46.45 in. (117.9 cm)
Machine Height (stowed) 10 ft. 0.5 in. (3.06 m) Width 16.81 in. (427 mm)
Machine Length (stowed) 47 ft. 9.5 in. (14.57 m) Rim Size 15x28
Tire & Wheel Weight 1025 lbs. (465 kg)
Platform Height (500 lb./230 kg. capacity) 185 ft. 7 in. (56.56 m)
Max Tire Load 36000 lbs. (16,329 kg)
Platform Height (1000 lb./450 kg. capacity) 165 ft. 2 in. (50.34 m)
Horizontal Reach from centerline of rota-

tion
Unrestricted Capacity 80 ft. (24.38 m)
Restricted Capacity 68 ft. 11 in. (21.01 m)
3121619 1-1
1.5 ENGINE DATA 1.7 HYDRAULIC OIL

Table 1-5. Engine Data - Deutz TCD 3.6L Table 1-7. Hydraulic Oil
Type Turbo-charged Diesel Hydraulic System

S.A.E. Viscosity
Number of Cylinders 4 Operating
Grade
Temperature Range
Bore 3.9 in. (98 mm)
Stroke 4.7 in. (120 mm) +0° to + 180° F 10W
(-18° to +83° C)
Total Displacement 221 cu.in. (3.6 L)
+0° to + 210° F 10W-20, 10W30
Firing Order 1-3-4-2 (-18° to +99° C)
Output 99.8 hp (74.4 kW) +50° to + 210° F 20W-20
Low Idle Engine RPM 1000 ±50 (+10° to +99° C
High Engine RPM 2300±50
Average Fuel Consumption 2.73 gph (10.3 lph) NOTE: Hydraulic oils require anti-wear qualities at least API Ser-
vice Classification GL-3, and sufficient chemical stability
Acceptable Fuel Grades Ultra Low Sulfur (15 ppm)
for mobile hydraulic system service.
HRC Up to 5% BioDiesel
LRC Max Sulfur Content (2000 ppm) NOTE: Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con-
tain the same required additives or be of comparable vis-
1.6 MAJOR COMPONENT WEIGHTS cosities.
OIL SAMPLING
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT This machine is equipped with an oil sampling valve to
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT- allow for verification of hydraulic oil condition. Refer to
FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Section 5 - Hydraulics for Oil Sampling procedures.
Table 1-6. Critical Stability Weights Table 1-8. Mobilfluid 424 Specs
Components LBS. KG. SAE Grade 10W30

Gravity, API 29.0
Tire & Wheel 1025 465
Density, Lb/Gal. 60°F 7.35
Drive Hub & Motor 337 153
Pour Point, Max -46°F (-43°C)
Swing Drive 223 101.2 Flash Point, Min. 442°F (228°C)
Engine Assembly 822 373 Viscosity
Brookfield, cP at -18°C 2700
Complete Boom (including jib & platform) 23,600 10705
at 40° C 55 cSt
Main Boom Assembly 21,600 9798 at 100° C 9.3 cSt
Jib Assembly 1493 677 Viscosity Index 152
1-2 3121619
Table 1-9. Mobil DTE 10 Excel 32 Specs Table 1-12. Quintolubric 888-46
ISO Viscosity Grade #32 Density 0.92 g/cm3

Pour Point, Max. -54°C (-65°F) Pour Point <-30°C (<-22°F)
Flash Point, Min. 250°C (482°F) Flash Point 300°C (572°F)
Viscosity Fire Point 360°C (680°F)
at 40° C 32.7 cSt
Autoignition Temperature >450°C (842°F)
at 100° C 6.6 3 cSt
Viscosity
at 100° F 32.7 cSt
at 0° C (32°F) 320 cSt
at 212° F 6.63 cSt
at 20° C (68°F) 109 cSt
cp at -30° F -
at 40° C (104°F) 47.5 cSt
Viscosity Index 164
at 100° C (212°F) 9.5 cSt
Density (Kg/l) @ 15°C 0.8468
Viscosity Index 190
Density (lb/in³) @ 60°F 0.0305
Table 1-13. Mobil SHC 46 Specs
Table 1-10. Mobil EAL H 46 Specs Type Synthetic Biodegradable
Type Synthetic Biodegradable ISO Viscosity Grade 46

ISO Viscosity Grade 46 Density @15°C 0.93
Density @15°C 0.874 Pour Point -27°F (-33°C)
Pour Point -49°F (-45°C) Flash Point 568°F (298°C)
Flash Point 500°F (260°C) Operating Temp. -20 to 200°F (-29 to 93°C)
Operating Temp. -20 to 200°F (-29 to 93°C)
Viscosity
Viscosity
at 40° C 43.3
at 40° C 48.8 cSt
at 100° C 7.7
at 100° C 7.8 cSt
Viscosity Index 149
Viscosity Index 145
Table 1-11. Exxon Univis HVI 26 Specs
Specific Gravity 32.1

Pour Point -76°F (-60°C)
Flash Point 217°F (103°C)
Viscosity
at 40° C 25.8 cSt
at 100° C 9.3 cSt
Viscosity Index 376
NOTE: Mobil/Exxon recommends that this oil be checked on
a yearly basis for viscosity.
3121619 1-3
12
13
18
15
17
16 11
8 10
3 3
9 6
3 3
1
14
Figure 1-1. Maintenance and Lubrication Diagram
1-4 3121619
1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1.,

Maintenance and Lubrication Diagram.
Table 1-14. 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) API CJ-4
Lube Point(s) - Fill Plug

Capacity - 3 qt. (2.8 L)
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- Lube - GL-5
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ Interval - Check level every 150 hrs/Change every 1200
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION hours of operation. Fill to cover ring gear.
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
3. Wheel Drive Hub
1. Swing Bearing - Remote Lube
Lube Point(s) - 3 Grease Fitting Lube Point(s) - Level/Fill Plug

Capacity - A/R Capacity - 2.6 quarts (2.5 liters) ± 10%
Lube - MPG Interval - Check level every 3 months or 150 hrs of oper-
Interval - Every 3 months or 150 hours of operation ation; change every 2 years or 1200 hours of operation
Comments - Apply grease and rotate in 45 degree inter-
vals until bearing is completely lubricated.
3121619 1-5
4. Hydraulic Return Filter 6. Hydraulic Charge Filter
Lube Point(s) - Replaceable Element

Interval - Change after first 50 hours and every 6 months
Lube Point(s) - Replaceable Element or 300 hours thereafter.
or 300 hours thereafter. 7. High Pressure Filter
5. Hydraulic Tank Breather

or 300 hours thereafter.
Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter.
Comments - Remove wing nut and cover to replace.
Under certain conditions, it may be necessary to replace
on a more frequent basis.
1-6 3121619
8. Hydraulic Oil 10. Oil Change w/Filter - Deutz
Lube Point(s) - Fill Cap

Capacity - 75 Gallons (208 liters) Tank to Full Mark
82 Gallons (310.4 L) System Lube Point(s) - Fill Cap/Spin-on Element
Lube - HO Capacity - 9.6 Quarts (9.1 L)
Interval - Check level daily. Change every 2 years or 1200 Lube - EO
hours of operation. Interval - Check level daily; change every 500 hours or
yearly, whichever comes first. Adjust final oil level by
9. Main Valve Filter mark on dipstick.

or 300 hours thereafter.
3121619 1-7
11. Fuel Filter - Deutz 13. Air Filter

Interval - Every year or 500 hours of operation
12. Fuel Pre-Filter

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check dust valve for dirt daily
14. Boom
Lube Point(s) - Apply to wear pad contact paths
Lube - Super Lube®
Interval - As needed. Refer to the Service Manual for
detailed procedures
15. Radiator
Lube Point(s) - Fill Cap
Interval - Every year or 500 hours of operation
Lube - Anti-Freeze Coolant (Refer to Engine Manual for
compatible coolants)
Capacity - 13.2 qt. (12.5 L)
1-8 3121619
16. Diesel Exhaust Fluid (DEF) (If Equipped) 18. Optional Fuel Filter/Water Separator

Interval - Drain water daily; Change every year or 600
hours of operation
Lube Point - Fill Cap

Lube - DEF
Capacity - 5.7 gal. (21.5 L)
17. DEF Supply Module Filter (If Equipped)
Interval - 500 hours or 2 years, whichever comes first
3121619 1-9
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
1-10 3121619
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
3121619 1-11
Torq ue
Tor que
Torqu e
Torq ue
Cl amp L oa d
To rqu e
To rque
1-12 3121619
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
3121619 1-13
To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
1-14 3121619
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 Preventive Maintenance Schedule for
MAINTENANCE items requiring inspection during the performance of these
inspections. Reference the appropriate areas of this manual for
General 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
the necessary inspections and maintenance have been com- annual basis, no later than thirteen (13) months from the date
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
Preparation, Inspection, and Maintenance product model. Reference the machine Service and Mainte-
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 Preventive 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
Pre-Start Inspection important that JLG Industries, Inc. has updated ownership
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- Preventive Maintenance
tion. The Operator and Safety Manual must be read in its
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
ence, has successfully demonstrated the ability and profi-
performed by a qualified JLG equipment mechanic. JLG Indus-
ciency to service, repair, and maintain the subject JLG product
tries, Inc. recognizes a qualified JLG equipment mechanic as a
model.
person who, by possession of a recognized degree, certificate,
extensive knowledge, training, or experience, has successfully Reference the Preventive 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.
3121619 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 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-
General nected, cap or cover all openings to prevent entry of for-
The following information is provided to assist you in the use eign matter.
and application of servicing and maintenance procedures
contained in this book. 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
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when
ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to Components Removal and Installation
rest in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided. 1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Cleanliness cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.
1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate- 2. Should it be necessary to remove a component on an
rials out of the vital components. Precautions have been angle, keep in mind that the capacity of an eyebolt or
taken to safeguard against this. Shields, covers, seals, similar bracket lessens, as the angle between the sup-
and filters are provided to keep air, fuel, and oil supplies porting structure and the component becomes less
clean; however, these items must be maintained on a than 90 degrees.
scheduled basis in order to function properly.
3. If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
2-2 3121619
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
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
or assemble one part, then start on another. Always recheck
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
your work to assure that nothing has been overlooked. Do not
make any adjustments, other than those recommended, with- 1. Always use new replacement hardware when installing
out obtaining proper approval. locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
Pressure-Fit Parts against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
When assembling pressure-fit parts, use a molybdenum disul- properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
fide base compound or equivalent to lubricate the mating sur-
equivalent.
face.
2. Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
Bearings treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Chart Sec-
1. When a bearing is removed, cover it to keep out dirt and tion 1.)
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used Hydraulic Lines and Electrical Wiring
but do not spin the bearing.
Clearly mark or tag hydraulic lines and electrical wiring, as well
2. Discard bearings if the races and balls (or rollers) are pit- as their receptacles, when disconnecting or removing them
ted, scored, or burned. from the unit. This will assure that they are correctly rein-
stalled.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap Hydraulic System
reusable or new bearings until they are ready to install. 1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
4. Lubricate new or used serviceable bearings before
flush the entire system.
installation. When pressing a bearing into a retainer or
bore, apply pressure to the outer race. If the bearing is to 2. Disassemble and reassemble parts on clean work sur-
be installed on a shaft, apply pressure to the inner race. face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid
assembly.
Gaskets
Check that holes in gaskets align with openings in the mating
parts. If it becomes necessary to hand-fabricate a gasket, use
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.
3121619 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 Changing Hydraulic Oil
or exceeds the specifications listed.
1. Filter elements must be changed after the first 50 hours
of operation and every 300 hours (unless specified oth-
Battery erwise) thereafter. If it is necessary to change the oil, use
only those oils meeting or exceeding the specifications
Clean battery using a non-metallic brush and a solution of
appearing in this manual. If unable to obtain the same
baking soda and water. Rinse with clean water. After cleaning,
type of oil supplied with the machine, consult local sup-
thoroughly dry battery and coat terminals with an anti corro-
plier for assistance in selecting the proper equivalent.
sion compound.
Avoid mixing petroleum and synthetic base oils.
Lubrication and Servicing 2. Use every precaution to keep the hydraulic oil clean. If
the oil must be poured from the original container into
Components and assemblies requiring lubrication and servic- another, be sure to clean all possible contaminants from
ing are shown in the Lubrication Chart in Section 1. the service container. Always clean the mesh element of
the filter and replace the cartridge any time the system
2.3 LUBRICATION AND INFORMATION oil is changed.
3. While the unit is shut down, a good preventive mainte-
Hydraulic System nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
1. The primary enemy of a hydraulic system is contamina- functional check of each system, before placing the
tion. Contaminants enter the system by various means, machine back in service.
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter Lubrication Specifications
when performing maintenance, or by permitting the
Specified lubricants, as recommended by the component
pump to cavitate due to insufficient system warm-up or
manufacturers, are always the best choice, however, multi-pur-
leaks in the pump supply (suction) lines.
pose greases usually have the qualities which meet a variety of
2. The design and manufacturing tolerances of the compo- single purpose grease requirements. Should any question
nent working parts are very close, therefore, even the arise, regarding the use of greases in maintenance stock, con-
smallest amount of dirt or foreign matter entering a sys- sult your local supplier for evaluation. Refer to Section 1 for an
tem can cause wear or damage to the components and explanation of the lubricant key designations appearing in the
generally results in faulty operation. Every precaution Lubrication Chart.
must be taken to keep hydraulic oil clean, including
reserve oil in storage. Hydraulic system filters should be
checked, cleaned, and/or replaced as necessary, at the
specified intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of metal
particles.
3. Cloudy oils indicate a high moisture content which per-

mits organic growth, resulting in oxidation or corrosion.
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil.
4. 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 viscosities. Good grade mineral oils,
with viscosities suited to the ambient temperatures in
which the machine is operating, are recommended for
use.
NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.
2-4 3121619
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.
3121619 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
machine and to welding performed from the machine on
Filament wound bearings.
an external structure, or component.
1. Pinned joints should be disassembled and inspected if
the following occurs: Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints. • Disconnect the battery.
b. Noise originating from the joint during operation. • Disconnect the moment pin connection (where fitted).
2. Filament wound bearings should be replaced if any of • Ground only to structure being welded.
the following is observed:
Do NOT Do the Following When Welding on JLG
a. Frayed or separated fibers on the liner surface. Equipment
b. Cracked or damaged liner backing.
• Ground on frame and weld on any other area than the
c. Bearings that have moved or spun in their housing. chassis.
d. Debris embedded in liner surface. • Ground on turntable and weld on any other area than the
turntable.
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to • Ground on the platform/support and weld on any other
inspection): area than the platform/support.
• Ground on a specific boom section and weld on any other
a. Detectable wear in the bearing area.
area than that specific boom section.
b. Flaking, pealing, scoring, or scratches on the pin sur-
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
face.
valves, electrical wiring, or hoses to be between the
c. Rusting of the pin in the bearing area. grounding position and the welded area.
4. Re-assembly of pinned joints using filament wound

bearings.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
a. Housing should be blown out to remove all dirt and PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
debris...bearings and bearing housings must be free RING, BOOM WIRE ROPES, ETC.)
of all contamination.
b. Bearing / pins should be cleaned with a solvent to
remove all grease and oil...filament wound bearing
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 3121619
SECTION 2 - GENERAL
NOTE: Refer the Operation and Safety Manual for completion procedures for the Pre-Start Inspection.
Table 2-3. Inspection and Preventive Maintenance Schedule
Inspections
AREA Pre-Delivery1 or Frequent 2 Annual3

(Quarterly) (Yearly)
Inspection Inspection
Boom Assembly
Boom Weldments 1, 2 1, 2
Hose/Cable Carrier Installations 1, 2 1, 2
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 Systems4 1, 2 1, 2
Platform Assembly
Railing 2 2
Gate 1, 2, 3 1, 2, 3
Floor 2 2
Rotator 1, 2, 3, 4 1, 2, 3, 4
Lanyard Anchorage Point 1, 2, 6 1, 2, 6
Turntable Assembly
Swing Bearing or Worm Gear 150, 2 150, 2
Oil Coupling 4 4
Swing Drive System 1, 4 1, 4
Turntable Lock 1, 2, 3 1, 2, 3
Hood, Hood Props, Hood Latches 3 3
Chassis Assembly
Tires 1, 2 1, 2
Wheel Nuts/Bolts 150 150
Wheel Bearings 1, 2, 4, 5
Oscillating Axle/Lockout Cylinder Systems 1, 2, 4, 5
Extendable Axle Systems 3 3
Steer Components 1, 2
Spindle Thrust Bearing/Washers 1, 2
Drive Hubs 1, 4 1, 4
3121619 2-7
SECTION 2 - GENERAL
Inspections

Functions/Controls
Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9
Ground Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9
Function Control Locks, Guards, or Detents 1, 3, 9 1, 3, 9
Footswitch (shuts off function when released) 1, 3, 9 1, 3, 9
Emergency Stop Switches (Ground & Platform) arrest all platform movement 1, 3, 6 1, 3, 6
Function Limit or Cutout Switch Systems 1, 3, 9 1, 3, 9
Capacity Indicator 1, 3, 9 1, 3, 9
Drive Brakes 1, 3, 9 1, 3, 9
Swing Brakes 1, 3, 9 1, 3, 9
Auxiliary Power 1, 3, 9 1, 3, 9
Power System
Engine Idle, Throttle, and RPM 1, 3, 7 1, 3, 7
Engine Fluids: Oil 4 4
Engine Fluids: Coolant 1, 4, 7 1, 4, 7
Air Filter 1, 4 1, 4
Fuel Filter(s) 1, 5 1, 5
Drain Oil Build Up in 2-Stage Vaporizer (LP Only) 1, 4 1, 4
Exhaust System 1, 4 1, 4
Batteries 1, 4 1, 4
Battery Fluid 4 4
Battery Charger 1, 3 1, 3
Intake System 1, 2 1, 2
Glow Plug (Diesel Only) 1, 2, 3 1, 2, 3
Serpentine Belt, Tensioner, Pulleys 1, 2, 3 1, 2, 3
Fuel Reservoir, Cap, and Breather 1, 2, 4 1, 2, 4
Hydraulic/Electric System
Hydraulic Pumps 1, 2, 4 1, 2, 4
Hydraulic Cylinders 1, 2, 4, 5 1, 2, 4, 5
Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2
Hydraulic Hoses, Lines, and Fittings 1, 2, 4 1,2,3,4
Hydraulic Reservoir, Cap, and Breather 1, 2, 3, 4, 5 1, 2, 3, 4, 5
Hydraulic Filter(s) 1, 4, 5 1, 4, 5
Hydraulic Fluid 4, 5 4, 5
Electrical Connections 1, 2 1, 2
Instruments, Gauges, Switches, Lights, Horn 1, 3
2-8 3121619
SECTION 2 - GENERAL
Inspections

General
All Decals/Placards Installed, Secure, Legible 9 9
Annual Machine Inspection Due 9
No Unauthorized Modifications or Additions 9 9
All Relevant Safety Publications Incorporated 9 9
General Structural Condition and Welds 2 2
All Fasteners, Pins, Shields, and Covers 1, 2 1, 2
Grease and Lubricate to Specifications 9 9
Function Test of All Systems 9 9
Paint and Appearance 5 5
Stamp Inspection Date on Frame 9
Notify JLG of Machine Ownership 9
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months; Out of service for 3 months or more; Purchased used
3 Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body
4 Replace every 12 years or 7,000 hours
50 Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life
250 Indicates a 250 hour interval required to perform task after initial use of machine. This only occurs once in machine life
Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris
6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform
3121619 2-9
SECTION 2 - GENERAL
ENGINE OIL OPERATION CHART

DEUTZ 2.9 L04 T4F AND 3.6L4 TCD
RECOMMENDED JLG COLD WEATHER PACKAGE
RECOMMENDED JLG ARCTIC PACKAGE (IF APPLICABLE)
NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN
PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
1001159163-B
MAF09020B
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-10 3121619
SECTION 2 - GENERAL
HYDRAULIC FLUID OPERATION CHART
MACHINE OPERAT ION USING NON-JLG APPROVED

HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF
T HE T EMPERATURE BOUNDARIES OUT LINED IN
T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY
RESULT IN PREMAT URE WEAR OR DAMAGE TO
COMPONENT S OF T HE HYDRAULIC SYST EM.
Fluid Properties Base Classifications

Viscosity at 40° C (cSt, Typical)
Readily Biodegradable*
Synthetic Polyol Esters
Virtually Non-toxic**
Fire Resistant***
Viscosity Index
Vegetable Oils
Mineral Oils
Description
Synthetic
Mobilfluid 424 55 145 X

Mobil DTE 10 Excel 32 32 164 X X
Univis HVI 26 26 376 X
Mobil EAL Hydraulic Oil 47 176 X X X
Mobil EAL Envirosyn H46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/6-82-003
CO2 Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
4150740 B
Figure 2-2. Hydraulic Oil Operating Temperature Specifications
3121619 2-11
SECTION 2 - GENERAL
NOTES:
2-12 3121619
SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES AND WHEELS 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
2. Tighten nuts in the following sequence:
when any cut, rip, or tear is discovered that exposes sidewall or
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 16 10
14
immediately and arrangements must be made for replace- 5 8
ment of the tire or tire assembly. 12 19
18 4
• a smooth, even cut through the cord plies which exceeds 3
inches (7.5 cm) in total length 3 17
20 11
• any tears or rips (ragged edges) in the cord plies which
7 6
exceeds 1 inch (2.5 cm) in any direction 13 9 2 15
• 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
TORQUE SEQUENCE
condition regarding stability.
1st Stage 2nd Stage 3rd Stage
Wheel Installation 35 ft. lbs. 80 ft. lbs. 140 ft. lbs.
It is extremely important to apply and maintain proper wheel (45 Nm) (100 Nm) (185 Nm)
mounting torque.
NOTE: Ensure all mating surface are clean and free from damage
or debris.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE
4. Wheel nuts should be torqued before first road use and
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS after each wheel removal. Check and torque every 3
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS months or 150 hours of operation.
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-
ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
the mounting stud holes in the wheels.
3121619 3-1
3.2 AXLE EXTENSION SYSTEM 3.3 DRIVE ORIENTATION SYSTEM

NOTE: The boom must be oriented between the rear wheels to The Drive Orientation System (DOS) is intended to indicate to
extend or retract the axles. the operator conditions that could make the direction of
movement of the chassis different than the direction of move-
The Axle Extension System allows each of the four axles to be ment of the drive/steer control handle. The system indicates to
extended and retracted together while maintaining full steer- the operator the need to match the black and white direc-
ing control as the machine is driven. The system allows the tional arrows on the platform control panel to the arrows on
axles to extend or retract only while the boom is in the trans- the chassis for the intended direction of travel. The system
port position (see Transport Position Sensing System in Sec- uses a proximity switch mounted on the hydraulic swivel, an
tion 4) and in order to minimize wheel scrubbing during axle indicator light and an override switch on the platform display
movement, a minimum drive speed must be attained before panel. The proximity switch trips when the turntable is swung
axle extension/retraction will be permitted. The system uses +/- 45 degrees off center of the normal driving position. This
four linear sensors (one at each axle) to sense when the axles occurs roughly when the boom is swung past a rear tire. When
are fully extended. If any of the linear sensors detect an out of the turntable is in the normal drive position with the boom
range value for axle set, the control system considers the axles between the rear tires, no indications or interlocks are made.
retracted. To extend/retract the axles, the user engages the When the machine is actively driving when the turntable is
axle extend/retract switch on the platform console and the swung past the switch point, the system is ignored until drive/
drive control at the same time. The axle set indicator will be off steer is released. When drive is initiated with the boom swung
when the axles are not fully extended and the axle extend/ past the switch point, the DOS indicator will flash and the
retract switch is not engaged. It will flash while the axles are drive/steer functions will be disabled. The operator must
extending or retracting and will be on constantly when the engage the DOS override switch to enable Drive/steer (high
axles are fully extended. With the axles not fully extended, the drive will remain disabled). When the DOS is enabled, the DOS
boom is restricted to operation within the transport position indicator will be illuminated continuously and a 3-second
(see Transport Position Sensing System in Section 4). If a signal enable timer will be started and will continue for 3 seconds
from any axle linear sensor is lost when the boom is beyond after the end the last drive/steer command. If the timer
the transport position, the axle set indicator will flash and expires, the DOS override switch must be re-engaged to
drive/steer functions will be disabled until the boom is enable drive/steer.
brought back into the transport position. The steering angle
will be automatically limited to +/- 20 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/
- 20 degrees when the axle retract command is engaged, the
control system will automatically reduce the wheel angle to 20
degrees during axle retraction.
3-2 3121619
3.4 STEERING CONTROL SYSTEM

There are three different modes of steering selectable by the
position of the steer select switch on the platform control
panel: crab, coordinated, and conventional two wheel steer-
ing. These are shown below.
Figure 3-3. Conventional Two Wheel Steer
Each wheel has its own steer cylinder, wheel angle sensor, axle
extend linear sensor, and proportional valve, allowing the con-
trol system to position each wheel to the ideal angle for all
steering modes and all steering commands. This is done
Figure 3-1. Crab Steer whether the axle is retracted, extended, or somewhere in
between. Changes in steering modes while drive is engaged
requires the operator to return the joystick to the neutral posi-
tion before the steer cylinders are adjusted. Once the foot-
switch is depressed and drive or steer is engaged, the wheels
automatically adjust to the appropriate angle for the selected
steering mode based on the position of the inside front wheel.
If the steer 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 initiated. The steering angles are limited to +/- 20
degrees anytime the axles are not fully extended. See the Axle
Extension System for interaction with the axle extension sys-
tem. If a wheel cannot achieve its commanded angle within a
specified time, it is considered jammed. When a wheel is con-
sidered jammed during steering, a fault is reported and the
remaining wheels will continue to their commanded position.
The fault is cleared when the footswitch 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 maxi-
mum displacement (slow speed). Wheel angle sensor failures
will result in an approximated steering control logic that will
allow the operator to move the machine until it can be
repaired. The wheel at the failed sensor will be driven based
Figure 3-2. Coordinated Steer 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 resynchronized by fully steering
against the mechanical stops.
3121619 3-3
Axle extend sensor failures will result in an approximated 3.9 GROUND CONTROL ENABLE SYSTEM
steering control logic that will allow the operator to move the
machine until it can be repaired. The axle at the failed sensor The ground controls include the use of a function enable sys-
will be driven based on the information available from the tem for the operation of directional functions from the ground
other sensors. This axle will not track perfectly and will control panel. To operate any directional function, the func-
become farther out of position over time. When the wheel tion enable switch must be held in combination with the
becomes prohibitively out of position, the wheels can be directional function switch. This switch doubles as the auxil-
resynchronized by fully steering against the mechanical stops. iary power switch. When the engine is not running, activating
Coordinated and crab steer modes are limited to low speed this switch will operate auxiliary power. When the engine in
drive, regardless of speed select switch position. running, activating this switch will enable directional func-
tions. Releasing this switch during function commands will
stop the function movement. Unlike the platform enable, no
3.5 DRIVE/STEERING SPEED CONTROL timer or sequence logic is imposed on the use of the function
enable.
The Drive/Steering Speed Control system uses the steering
sensors from the steering control system to increase operator
control and comfort by reducing the effect of turning the
chassis on the resulting lateral platform speed. The system
3.10 HYDRAULIC SYSTEM WARM UP
proportionally varies the drive speed based on the predicted For optimal life and performance of the hydraulic system in
turning radius of the chassis for conventional two wheel steer extremely cold temperatures, the control system monitors the
mode. The tighter the turn the slower the allowable drive hydraulic system temperature and automatically limits the
speed. As crab steer does not steer on a radius, low speed function speeds of the high demand functions.
drive is maintained regardless of steer angle.
While the system is cold and in the warm up mode, the main
lift and main telescope functions are limited to creep speeds
3.6 TRACTION CONTROL SYSTEM and is indicated to the operator by flashing the creep light on
the platform control panel.
The traction control system uses the steering sensors from the
steering control system to optimize the performance of the Operating the machine while in the warm up mode will gener-
drive system. This is especially important due to the disparity ate sufficient heat to bring the hydraulic temperature up to
of wheel speeds generated between the inside and outside allowable temperatures and the warm up mode will be auto-
wheels of the extended axle chassis with large steering angle matically turned off.
capability. The steering sensors are used to predict the rolling
path and therefore the required wheel speed of each wheel as This system is activated when the hydraulic oil temperature in
the steering angles change and steering modes change. The the main valve is below 30°F (-1°C) and the engine coolant
control system can then command the ideal flow from each of temperature is below 150°F (65°C). In warm up, the engine
the two drive pumps, one for the right side of the machine and operates at mid engine speed and a valve is energized which
one for he left side. Two flow dividers, one for the right side, loads the pump to build heat. This valve is active only when no
front to back and one for the left side, front to back absorb the function is selected. Warm up ends when the main valve tem-
variation in wheel speed, front to back. perature reaches 50°F (10°C) or the engine coolant reaches
150°F (65°C). Functions being operated when the warm up
mode turns off will remain in the creep speed until the func-
3.7 GROUND CONTROL KEYSWITCH SYSTEM tion is re-initiated.
The ground control keyswitch is used for selecting the active

control of the machine between the platform or ground con- 3.11 FUNCTION SPEED CONTROL SYSTEM
trol stations and as another shut off switch for machine power.
On the standard keyswitch, the key is removable only in the off The platform controls for the platform rotate, jib lift, main
position. This allows the ground control station to have ulti- boom telescope and jib telescope functions are controlled
mate priority over the platform control. through a common variable speed control knob. This knob
allows a smooth ramp up, controlled maximum output speed,
and ramp down. Each function has its own personality settings
3.8 JIB LIFT END OF STROKE DAMPENING allowing the characteristics of each function to be modified
using the standard analyzer. Not all functions will respond the
The jib lift cylinder is outfitted with a linear position sensor same to the changes in the function speed knob position. Full
and end of stroke dampening is achieved through the elec- counter-clockwise rotation of this knob to the detent position
tronic control system. This system slows the jib speed within places all functions into creep speed including lift, swing, and
the last 5° before minimum and maximum jib elevation. This drive.
reduction in speed occurs only while approaching the end of
stroke limits. Speeds in the opposite direction are not altered.
3-4 3121619
This page left blank intentionally.
3121619 3-5
Figure 3-4. Axle Hose Routing - Sheet 1 of 2
3-6 3121619
Figure 3-5. Axle Hose Routing - Sheet 2 of 2
3121619 3-7
3-8
Figure 3-6. Steering/Axle Hydraulic Circuit
3121619
FRONT
3121619
TO TO TO TO TO
SWIVEL PORT 7 SWIVEL PORT 6 SWIVEL PORT 5 SWIVEL PORT 4 SWIVEL PORT 3
B X A
X
A
B
X
X HU B/D RIV E MOTOR
LEFT FR ONT
H UB /D R IV E MOTOR
X B1
BR
A1
X
TOP VIE W OF
TR AC TION VALVE
RIGHT
A6
B5
B6 A5
TS
D A4
A3 B2 X R IGHT VIEW OF
LEFT LE FT V IE W OF TR AC TION VALV E
B4
TRA CTION VA LVE B3
FR ON T VIE W OF
TR AC TION VALV E
A2
X
BOTTOM V IE W OF
TR AC TION VALVE
X B
X
A R IGH T RE AR
X H U B/DR IVE M OTOR
B
LEFT R EAR
H UB/D R IV E MOTOR REAR
Figure 3-7. Drive System Hydraulic Circuit - Sheet 1 of 2
3-9
3-10
FRO NT
TO
SWIVEL PORT 7
BR X1
LEFT FRONT RIGHT FRONT
HUB/DRIVE MOTOR HUB/DRIVE MOTOR
L1 X L1
X
X
X1
BR
CASE DRAIN MANIFOLD

BR
X X
TOP VIEW OF
TRACTION VALVE
X X
X X
L EFT RIGHT
TS
X
X
TRACTION VALVE
X1
BR
X L1 L1
X
BR
X1
LEFT REAR RIGHT REAR
HUB/DRIVE MOTOR HUB/DRIVE MOTOR
REA R
Figure 3-8. Drive System Hydraulic Circuit - Sheet 2 of 2
3121619
Figure 3-9. Turntable Hydraulic System
3121619 3-11
3.12 DRIVE ASSEMBLY
5 7
4
6
3
1. Drive Hub 3. Drive motor 5. Bolt 7. Bolt

2. O-Ring 4. Washer 6. Washer
Figure 3-10. Drive Assembly
3-12 3121619
3.13 DRIVE HUB
1
22
2 20 23
3 38
4 21 24
5 39
6
25
39
7 41
8 40
26 42
9
10 27 43
28
44
11
29 45
12
46
30
47
13
48
49
14
31
50
15
51
32
16 49
48
33
52
17
33
53
34
54
18
35
55
36
19 56
37
1001149921
1. Ring 9. Pin 17. Pinion 25. Flange 33. Seal 41. Plastic Plug 49. O-Ring
2. Screw 10. O-Ring 18. Hub Housing 26. O-Ring 34. Coupling 42. Input Shaft 50. Brake Piston
3. Cover 11. Pinion 19. Screw 27. Ring Nut 35. Spring 43. Iron Disc 51. Brake Spring
4. Gasket 12. Retaining Ring 20. Screw 28. Set Screw 36. Retaining Ring 44. Brake Disc 52. Spacer
5. Plug 13. Gear Reduction Assy 21. Plug 29. Bearing 37. Bearing 45. Spacer 53. Retaining Ring
6. Cover 14. Pinion 22. Retaining Ring 30. Hub Support 38. Axle 46. Seal 54. O-Ring
7. O-Ring 15. Ring 23. Bearing 31. O-Ring 39. Plug 47. O-Ring 55. Motor Support
8. Shim 16. Gear Reduction Assy 24. Planet Wheel 32. Bearing 40. Plug 48. Seal 56. Screw
Figure 3-11. Drive Hub
3121619 3-13
Disassembly 4. Remove, Ring (1), Cover (6), O-Ring (7), Shim (8) and O-
Ring (10). Do not damage O-Rings. Check and remove
1. Remove plugs (5) and pour lubricant in a container. Gasket (4) if damaged.
Reinstall plugs.
2. Remove six screws (56), motor flange(55), and O-Ring
(54). Do not damage O-Ring.
55 10
54 6
56 1
7 8
18
5. Remove Pinion (11), Gear Reduction Assembly (13) and

Gear Reduction Assembly (16).
3. Remove two screws (2), cover (3), and pin (9).
16
13
11
9
3
2
MAF09970
3-14 3121619
6. Remove two Screws (19), Hub Housing (18) and O-Ring 8. Remove three snap rings (22) and planet wheel (24)
(26). Do not damage O-Ring. from spindles on Flange (25).
25
26
24
18
22
19
7. Remove Coupling (34) and Spring (35). 9. Remove two Set Screws (28) from Ring Nut (27). Remove
Ring Nut from Flange (25).
25
35
28
34 27
3121619 3-15
10. Remove Hub Support (30), Bearing (29), O-Ring (31), 12. Remove Snap Ring (53), Spacer (52), Seal (48), O-Ring
Bearing (32), and two Seals (33) from Axle (38). (49), and Brake Piston (50) from Axle (38). Remove five
Brake Springs (51) from Brake Piston (50). Use com-
pressed air to remove Brake Piston from Axle.
38
33
32
31 51
30
49
48
29
52
53
50 38
11. Remove six screws (20), Plug (21), and Flange (25) from
Axle (38)., 13. Remove O-Ring (49), Seal (48), O-Ring (47), Seal (46),
Spacer (45), nine Brake Discs (44) and eight Iron Discs
(43) from Axle (38).
25
44
45
47
38 48
49 38
21
20 43
46
3-16 3121619
14. Remove Split Ring (36), Input Shaft (42), and Bearing (37) 3. Install Seal (46), O-Ring (47), Seal (48), and O-Ring (49) in
from Axle (38). Axle (38). Starting with Brake Disk (44) alternate with
Iron Disk (43) until a total of eight Brake Disks and nine
Iron Discs are installed on Input Shaft (42 - not shown) in
Axle.
38
42
37 44
36
45
47
48
49 38
43
46
Assembly
NOTE: Thoroughly clean and coat all parts with grease before
assembling. 4. Install Brake Piston (50) in Axle (38). Install five Brake
Springs (51) Piston holes. Install O-Ring (49) and Seal
1. Check parts are free of damage, burrs, or other defects. (48) in Axle. Install Spacer (52) against Piston and secure
with Split Ring (53).
2. Install Bearing (37) in Axle (38). Install Input Shaft (42) in
Axle and Bearing. Secure with Split Ring (36).
38
42
51
49
48
52
53
37
36
50 38
3121619 3-17
5. Install Flange (25) on Axle (38), with Plug (21) and six NOTE: Install Ring Nut with convex part facing bearing.
screws (20).
7. Install Ring Nut (27) on Flange (25). Prevent Flange from
turning and torque Ring Nut to 295 ft-lb (400 Nm).
Tighten and back off two times to completely seat bear-
ings. Tighten to final torque of 221 ft-lb (300 Nm). Check
roll torque with seal is within 7 - 11 ft-lb (10 - 15 Nm).
25 Apply JLG Threadlocker or equivalent to two Setscrews
(28). Install and torque Setscrews to 7.4 ft-lb (10 Nm).
38
21
20
NOTE: Flat surface of bearings face toward inside of Hub Support.
6. Install two seals (33) on Axle (38). Install O-Ring (31) in

25
Hub Support (30). Install Bearing (32) and Bearing (29) in
Hub Support. Install assembled Hub Support on Axle as
shown below. 28
27
38
8. Install three planet wheel (24) on Flange spindles (25).
Secure with Snap Rings (22). Lubricate planetary gear
33 bearings.
32
31 25
30
29
24
22
3-18 3121619
9. Install Spring (35) and Coupling (34). 11. Install Gear Reduction Assembly (16), Gear Reduction
Assembly (13), and Pinion (11) in Planetary Housing.
Lubricate all bearings.
16
13
11
35
34
10. Install O-Ring (26). Install Planet wheel (18) with two 12. Install O-Ring (7) and O-Ring (10) in Cover (6). Liberally
Screws (19). Torque Screws to 36.8 ft-lb (50 Nm). coat Shim (8) with grease and center on hole at center of
Cover. Install Cover on Planetary Ring Assembly (18) and
secure with Ring (1). Replace Gasket (4) as needed.
26
18
10
6
1
7 8
18
19 4
3121619 3-19
13. Install O-Ring (54) and Motor Support (55). Apply JLG 15. Install Pin (9) and Cover (3). Secure with two Screws (2).
Threadlocker or equivalent to six Screws (56). Install and Torque to 7 ft-lb (10 Nm).
torque Screws to 177 ft-lb (240 Nm).
55
54
56
3
2
14. Check completed Drive Hub assembly rotates freely.
FAILURE TO PROPERLY FILL DRIVE HUB WITH OIL BEFORE OPERATION WILL
RESULT IN EQUIPMENT FAILURE AND COULD CAUSE DEATH, SERIOUS INJURY,
OR DAMAGE TO PROPERTY AND EQUIPMENT.
16. Follow oil change procedures and refill Drive Hub before
operating equipment.
3-20 3121619
3.14 FREE WHEELING OPTION 3.15 GEAR HUB OIL SERVICE

Disengage Drive Motors & Brakes for Towing, etc. Check Oil Level
(Free Wheel) 1. Position hub as shown in Figure 3-13.
1. Chock wheels. 2. Remove Level Plug (3) and check oil is level with plug
opening. Add oil as needed.
2. Removing screws and invert cover so center tip presses
on disengagement pin in hub. Reinstall screws. 3. Reinstall plug.
3. Remove chocks.
Change Gear Hub Oil
Engage Drive Motors & Brakes (Normal Operation) NOTE: Change oil when reduction gear is hot.
1. Chock wheels.
1. Position hub as shown in Figure 3-13.
2. Removing screws and invert cover so center tip faces
out. Reinstall screws. 2. Place suitable tray underneath to collect waste oil.
3. Remove chocks. 3. Remove three plugs.

4. Flush gear hub with appropriate solvent.
5. Reinstall Drain Plug (2).
6. Fill with oil until level reaches level hole.
7. Reinstall Level Plug (3) and Fill Plug (1).l
DISENGAGEMENT
COVER
1
DRIVE Drive Hub Engaged

HUB
DISENGAGEMENT
COVER (REVERSED)
DRIVE
HUB 2
Drive Hub Disengaged
Figure 3-13. Gear Hub Oil Fill and Drain
Figure 3-12. Disengaging Drive Hubs
3121619 3-21
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
29 31
32 28
33
34
35
36
34
3160339
1. Bolt 7. Needle Bearing 13. Cylinder Block 19. O-Ring 25. Gasket 31. Shaft
2. Motor End cap 8. Valve Plate 14. Slipper Pin 20. Servo Piston 26. Plug 32. Bearing
3. Locating Pin 9. Snap Ring 15. Guide 21. Spring 27. O-Ring 33. Snap Ring
4. O-Ring 10. Spring Retainer 16. Slipper Retainer 22. Pin 28. Plug 34. Snap Ring
5. Plug 11. Spring 17. Cylinder Piston 23. Swashplate 29. O-Ring 35. Seal
6. Dowel Pin 12. Washer 18. Piston Ring 24. Bearing Kit 30. Housing 36. Seal Support Washer
Figure 3-14. Drive Motor
3-22 3121619
3.16 DRIVE MOTOR Shaft Seal Replacement

NOTE: Drive motor servicing is similar for all Series 45 hydraulic REMOVAL
motors. The physical appearance of your motor may be
slightly different than shown. 1. Remove snap ring (1) retaining shaft seal, and support
washer.
Description
Drive motors are low to medium power, two-position axial pis-
ton motors incorporating an integral servo piston. They are
1
designed for operation in open and closed circuit applications.
The standard control is a direct acting single line hydraulic
control. The integral servo piston controls motor displace-
ment. 2
Motors are spring biased to maximum displacement and
hydraulically shifted to minimum displacement. Minimum and
maximum displacement can be set with fixed internal stops. 3
The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.
1
2
12 3
11
4
1. Snap Ring
2. Support Washer
3. Shaft Seal
10
5 Figure 3-16. Removing Shaft Seal
2. Remove support washer (2).
9 7 6
8 3. Carefully pry out shaft seal (3).
NOTE: To avoid damaging shaft during removal, install a large

37. Bias Spring 41. Shaft Seal 45. Valve Plate sheet metal screw in chuck of a slide hammer. Drive screw
38. Servo Piston 42. Bearing 46. End Cap in seal surface and use slide hammer to pull seal.
39. Swashplate 43. Slipper 47. Cylinder Block
40. Output Shaft 44. Piston 48. Minimum Angle Stop 4. Discard seal.
Figure 3-15. Drive Motor Cross Section
3121619 3-23
INSPECTION 2. Using a 1/4 in hex wrench remove plug (3).

Inspect new seal, motor housing seal bore, and sealing area on 3. Remove O-rings (4, 5, and 6).
shaft for rust, wear, and contamination. Polish shaft and clean
4. Using pliers, remove centering springs (7, 8, and 9).
housing if necessary.
5. Remove spring retaining washers (10 and 11).
INSTALLATION 6. Remove shift spool (12).
1. Cover shaft splines with an installation sleeve to protect 7. Remove orifice poppet (13).
shaft seal during installation.
INSPECTION
2. Install new shaft seal with cupped side facing motor. 1. Inspect new O-rings and the sealing area for rust, wear,
Press seal into housing until it bottoms out. Press evenly or contamination.
to avoid binding and damaging the seal.
2. Check springs and poppet for wear.
3. Install seal support washer.
INSTALLATION
4. Install snap ring.
1. Install orifice poppet (13).
5. Remove installation sleeve. 2. Install shift spool (12).
3. Install spring retaining washers on springs (10 and 11).
Loop Flushing Valve
4. Carefully install centering springs (7, 8, and 9).
REMOVAL 5. Install new O-rings (6, 4, and 5).

6. Using a 1/4 in hex wrench torque plug (3) to 20 ft. lbs.
1. Using a 11/16 in internal hex wrench remove plug (1)
(27 Nm).
and (2).
7. Using a 11/16 in internal hex, torque plugs (2 and 1) to
27 ft.lbs. (37 Nm).
6
9
11 2
11/16 in
27 ft-lb
(37 Nm)
10 12
8
4
11/16 in
1 13
27 ft-lb
(37 Nm)
7
5/8 in
5 3
20 ft-lb (27 Nm)
1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer
Figure 3-17. Loop Flushing Spool
3-24 3121619
Troubleshooting
Table 3-2. Excessive Noise and/or Vibration
Item Description Action

Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level. Ensure oil supply to motor is adequate and
supply to motor. tem noise. lines are unobstructed.
Check for air in system. Air trapped in system lines or motor could result in cavitation that would Ensure all system lines and components are purged of air.
cause system noise.
Inspect output shaft couplings. A loose or incorrect shaft coupling will produce vibrations that could result Ensure correct coupling is used and that it fits properly on shaft.
in system noise.
Inspect output shaft alignment. Misaligned shafts create excessive frictional vibration that could result in Ensure shafts are properly aligned.
system noise.
Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead Replace hydraulic oil with appropriate fluid for operating conditions.
to system noise.
Table 3-3. System Operating Hot

Check oil level in reservoir and oil Insufficient amount of hydraulic fluid will not meet system cooling Fill reservoir to proper level.
supply to pump. demands.
Inspect heat exchanger, (if If heat exchanger fails, or becomes obstructed, it may not meet system Ensure heat exchanger is receiving adequate air flow and is in good operat-
equipped). cooling demands. ing condition. Repair or replace as necessary.
Check system relief valves. If a system relief valve becomes unseated for an extended period of time or Repair or replace any malfunctioning relief valves as applicable and verify
fails for any other reason, system could become overheated. loads on machine are not excessive.
Table 3-4. Won’t Shift or Slow to Start

Check signal line to servo control Obstructed or restricted flow through servo control signal lines could Ensure signal lines are not obstructed or restricted and signal pressure is
port. result in slow shift or no shift motor conditions. adequate to shift motor.
Check correct supply and drain ori- Supply and drain orifices determine motor shift. The smaller the orifice, Ensure proper control orifices are installed in motor and not obstructed.
fices are properly installed and not the longer the time it takes to shift the motor. Obstruction also increases Clean or replace as necessary.
obstructed. shift times.
3121619 3-25
Disassembly
NOTE: Removal of endcap voids warranty.
17
19
During assembly, coat all moving parts with a film of clean
hydraulic oil. This ensures parts will be lubricated during
start-up.
Replace all O-Rings and gaskets. 15
It is recommended that all O-rings be replaced. Lightly 14

lubricate all O-rings with clean petroleum jelly prior to
assembly.
6
21
9
5 11
2
7
13
3 18
10 12
16
8
4 16
1
20
14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
16. Control Line Plug 20. Drain Plug
17. Control Line Plug 21. Work Port Plug
1. Plug 5. O-ring 9. Spring 12. Shift Spool

2. Plug 6. O-ring 10. Washer 13. Orifice Poppet Figure 3-19. Plugs, Fittings, and Speed Sensor
3. Plug 7. Spring 11. Washer
8. Remove all fittings from unit. Discard any O-rings on fit-
4. O-ring 8. Spring
tings.
Figure 3-18. Loop Flushing Spool 9. Using an 11/16 inch hex wrench, loosen speed sensor
lock nut (14) if equipped. Remove speed sensor using a
1. Using a 11/16 in wrench remove plug (1) and (2).
Vi inch hex wrench. Units without speed sensor have an
2. Using a 5/8 in hex wrench remove plug (3). O-ring plug (15) installed in that location; remove it with
3. Remove O-rings (4, 5, and 6). a Va inch internal hex wrench.
4. Using pliers, remove centering springs (7, 8, and 9). 10. Using a 1/4 inch internal hex wrench, remove control
5. Remove spring retaining washers (10 and 11). line plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18, if equipped with two-
6. Remove shift spool (12). line control) from X2 cavity.
7. Remove orifice poppet (13).
11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.
12. Using a 9/16 inch internal hex wrench, remove work

port plugs (21, if equipped with axial ports). Discard O-
rings.
3-26 3121619
22 25
30 27
29
29
23 26
28
24
25. Valve Plate 28. O-ring

26. End Cap 29. Angle Stop
27. O-ring 30. Servo Spring
22. Screw
23. End Cap Figure 3-21. Valve Plate & Rear Shaft Bearing
24. O-ring
Figure 3-20. End Cap

DO NOT SCRATCH VALVE PLATE SURFACE. DO NOT DRIVE BEARING PAST REAR
13. Using an 8 mm internal hex wrench, remove endcap SHAFT JOURNAL. BEARING MAY BECOME TRAPPED ON SHAFT AND DAMAGED.
screws (22).
14. Remove endcap (23). Remove O-ring (24) from housing 15. Remove valve plate (25) and timing pin (26) from end-
or endcap. When endcap screws are removed, pressure cap. Each displacement has a unique valve plate. For
from servo spring will cause endcap to bind on shaft. identification, the last two digits of the valve plate part
Press down on portion of endcap covering servo piston number are stamped on its surface.
and hold endcap level while removing. 16. Remove and discard O-rings (27, 28).
17. Remove rear shaft bearing from end cap with a bearing
puller. Bearing may be difficult to remove with a puller.
Try this as an alternative: Pack bearing cavity with heavy
grease. After shaft is removed, insert it into bearing cav-
ity and tap splined end lightly with a soft mallet. Grease
will force the bearing out. Remove minimum angle stop
(29) and servo spring (30) from housing.
3121619 3-27
34 33 32
31
32. Snap Ring

31. Cylinder Kit Assembly 33. Support Washer
34. Shaft Seal
Figure 3-22. Cylinder Kit
Figure 3-23. Shaft Seal
18. Turn housing on its side and remove cylinder kit assem-
bly (31). Set assembly aside. Do not to scratch running
surface.
TO AVOID DAMAGING SHAFT DURING SEAL REMOVAL, INSTALL A LARGE
NOTE: Grooves on surface of cylinder kit identify its displacement: SHEET METAL SCREW IN CHUCK OF SLIDE HAMMER. DRIVE SCREW INTO SEAL
SURFACE AND USE SLIDE HAMMER TO PULL SEAL.
Table 3-5. Displacement Identifiers
19. Turn housing over and remove snap ring (32) retaining
# of Grooves Frame L Frame K
shaft seal and support washer. Remove support washer
1 25 38 (33) and carefully pry out shaft seal (34). Discard seal.
2 30 45
3 35 --
3-28 3121619
Lift Here
36 39
35
37
38 40
43
42
41
35. Inner Snap Ring 37. Bearing

36. Snap Ring 38. Shaft
Figure 3-24. Shaft & Front Bearing

20. Remove inner snap ring (35) and shaft/bearing assembly.
21. Remove snap-ring (36) retaining shaft front bearing. Pull
bearing (37) off shaft (38). 39. Swashplate 42. O-ring
40. Servo Piston 43. Journal Bearings
41. Piston Seal
Figure 3-25. Swash Plate & Servo Piston

22. Turn housing over and remove swashplate (39) by lifting
on end opposite servo lever.
23. Remove servo piston (40). Remove piston seal (41) and
O-ring (42) from servo piston. Discard seal and O-ring.
24. Remove journal bearings (43) from housing. Note loca-
tion and orientation of each bearing for reassembly.
3121619 3-29
27. Turn block over. Using a press, apply pressure on block

spring washer (50) to compress block spring. Compress
spring enough to safely remove spiral retaining ring
(51). While maintaining pressure, unwind spiral retaining
44 ring (51). Carefully release pressure and remove outer
block spring washer (50), block spring (52), and inner
block spring washer (53) from cylinder block.
45
Inspection
After disassembly, wash all parts (including end-cap and hous-
47 ing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air.
Conduct inspection in a clean area and keep all parts free from
48
53 contamination. Clean and dry parts again after any rework or
49
resurfacing.
52
PISTON
Inspect pistons for damage and discoloration. Discolored pis-
tons may indicate excessive heat; do not reuse.
46 50
51
Slipper
Maximum End Play
44. Piston 49. Retaining Ring Minimum Slipper Foot Thickness

45. Slipper Retainer 50. Block Spring Washer
46. Cylinder Block 51. Spiral Retaining Ring
47. Ball Guide 52. Block Spring
48. Holddown Pins 53. Inner Block Spring Washer SLIPPERS
Inspect slipper running surfaces. Replace piston assemblies
Figure 3-26. Cylinder Kit Disassembly with scored or excessively rounded slipper edges. Measure
slipper foot thickness. Replace piston assemblies with exces-
25. Remove pistons (44) and slipper retainer (45) from cylin- sively worn slippers. Check slipper axial end-play. Replace pis-
der block (46). ton assemblies with excessive end-play.
NOTE: Pistons are not selectively fitted. However, units with high Table 3-6. Slipper Foot Thickness & End Play
hourly usage may develop wear patterns. Number pistons
and bores for reassembly if they are to be reused. Measurement L Frame K Frame
Slipper Foot Thickness 2.71 mm (0.11 in.) 4.07 mm (0.16 in.)
26. Remove ball guide (47), hold-down pins (48), and retain- Piston/Slipper End Play 0.15 mm (0.006 in.)
ing ring (49) from cylinder block.
NOTE: Most repairs do not require block spring removal. Perform

this procedure only if you suspect problems with the block
spring.
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES

FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED.
3-30 3121619
CYLINDER BLOCK
Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface.
Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing
will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements.
Table 3-7. Cylinder Block Measurements
Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079)
BALL GUIDE AND SLIPPER RETAINER SWASHPLATE AND JOURNAL BEARINGS

Inspect ball guide and slipper retainer for damage, discolor- Inspect running face, servo ball-joint, and swashplate journal
ation, or excessive wear. A discolored ball guide or slipper
surfaces for damage or excessive wear. Some material transfer
retainer indicates excessive heat. Do not reuse.
may appear on these surfaces and is acceptable if surface con-
dition meets specifications shown. Measure swashplate thick-
Slipper Retainer ness from journals running face. Replace swashplate if
damaged or worn beyond minimum specification. Replace
swashplate if difference in thickness from one side to the other
exceeds specification.
Ball Guide
VALVE PLATE
Valve Plate condition is critical to efficiency of the motor.
Inspect valve plate surfaces carefully for excessive wear, 0.0025 mm
(0.0001 in)
grooves, or scratches. Replace or resurface grooved or
scratched valve plates. Measure valve plate thickness and
replace if worn beyond minimum specification. Valve plates
may be resurfaced, provided resurfacing will not reduce thick- 25.8 mm
LV
ness below minimum specification.
24.6 mm
KV (0.969 in)
3.83 mm (0.151 in) Min
Thickness equality side to side:
0.05 mm (0.002 in)
0.025 mm
(0.001 in)
0.0076 mm
(0.00030 in)
Convex Max
Inspect journal bearings for damage or excessive wear.

Replace journal bearings if scratched, warped, or excessively
worn. Polymer wear layer must be smooth and intact.
3121619 3-31
SHAFT BEARINGS Assembly

Inspect bearings for excessive wear or contamination. Rotate
bearings while feeling for uneven movement. Bearings should 1. Install new O-ring (1) and piston seal (2) to servo piston
spin smoothly and freely. Replace bearings that appear worn (3). Install piston seal over O-ring.
or do not rotate smoothly.
NOTE: Installing piston seal stretches it, making it difficult to
install servo piston in its bore. Allow 30 minutes for seal to
relax after installation. To speed up seal relaxation, com-
press seal by installing piston head in end-cap servo cavity
and let it stand for at least five minutes.
SHAFT
Inspect motor shaft for damage or excessive wear on output
and block splines. Inspect bearing surfaces and sealing sur-
face. Replace shafts with damaged or excessively worn splines,
bearing surfaces, or sealing surfaces.
2
SERVO PISTON AND MINIMUM ANGLE STOP
Inspect minimum angle stop, servo piston head, and servo pis-
ton ball-socket for damage or excessive wear. Replace as
required.
3
1
1. O-ring
2. Piston Seal
3. Servo Piston
LOOP FLUSHING SPOOL
Inspect loop flushing spool for cracks or damage. Replace as
Figure 3-27. Servo Piston
required.
2. After piston seal has relaxed, lubricate and install servo
piston in housing bore. Align piston with ball socket fac-
ing inside of housing.
3-32 3121619
6. Install journal bearings (13) in housing seats. Use assem-

bly grease to keep bearings seated during assembly.
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES Ensure locating nubs drop into seat cavities. If reusing
ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO bearings, install in original location and orientation.
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS Lubricate journal bearings.
SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING.
RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS INSTALLED.
14
3. Install inner block spring washer (4), block spring (5), 13
and outer washer (6) in cylinder block (6A). Using a
press, compress block spring enough to expose retain-
ing ring groove. Wind spiral retaining ring (7) in cylinder
block groove.
11 13
12
10
9
4 13. Journal Bearings
8
14. Swash Plate
Figure 3-28. Swash Plate and Journal Bearing

5
7. Install swashplate (14) in housing. Tilt swashplate and
guide servo lever ball into its socket in the servo piston
6A 6
rod. Ensure swashplate seats into journal bearings and
moves freely. Lubricate running surface of swashplate.
7
4. Block Spring Washer 8. Retaining Ring

5. Block Spring 9. Holddown Pins
6. Outer Washer 10. Ball Guide
6A. Cylinder Block 11. Piston
7. Spiral Retaining Ring 12. Slipper Retainer
4. Turn block over and install retaining ring (8), hold-down

pins (9), and ball guide (10) to cylinder block.
5. Install pistons (11) to slipper retainer (12). Install piston/

retainer assembly in cylinder block. Ensure concave sur-
face of retainer seats on ball guide. If reusing pistons,
install them in original block bores. Lubricate pistons,
slippers, retainer, and ball guide before assembly. Set
cylinder kit aside on a clean surface until needed.
3121619 3-33
8. Press front shaft bearing (15) on shaft (16). Press bearing 11. Lubricate and install servo spring (20) and minimum
on shaft with lettering facing out. Lubricate bearing roll- angle stop (21) in housing bore.
ers. Install snap-ring (17) on shaft.
21
20
15
16
17
18
15. Front Shaft Bearing 17. Snap Ring

16. Shaft 18. Snap Ring
Figure 3-29. Shaft and Front Bearing
9. While holding swashplate in place, turn housing on its

side. Install the install shaft/bearing assembly into hous-
ing from flange end. Install snap-ring (18).
10. Verify swashplate and bearings are properly seated.

Install cylinder kit (19) on shaft. Install with slippers fac-
ing swashplate. Rock the shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,
20. Servo Spring
journal bearings, and servo piston are properly installed.
21. Minimum Angle Stop
19 Figure 3-31. Servo Spring and Minimum Angle Stop
19. Cylinder Kit
Figure 3-30. Cylinder Kit Installation
3-34 3121619
12. Press rear shaft bearing (22) in endcap. Install bearing 15. Install endcap (25) on housing with endcap screws (26).
with letters facing out. Press until bearing surface is 0.08 Ensure endcap will properly seat to housing without
±0.01 in (2 ±0.25 mm) above endcap surface. interference. Improper assembly of internal compo-
nents may prevent endcap from seating properly.
Ensure O-rings seat properly when installing endcap.
22 0.12 in
0.08 in 23 (3 mm)
26
8 mm
35-45 ft-lbs
23 (47-61 Nm)
22
24
25
23
22. Rear Shaft Bearing

23. Timing Pin
24. Valve Plate
Figure 3-32. Valve Plate and Rear Bearing 25. End Cap
13. Install timing pin (23) into its bore in the endcap. Install 26. Screw
pin with groove facing toward or away from shaft. Press
Figure 3-33. End Cap
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
above endcap surface. 16. Using an 8 mm internal hex wrench, tighten endcap
screws. Tighten screws in opposite corners slowly and
14. Install valve plate (24) on endcap. Install valve plate with
evenly to compress the servo spring and properly seat
yellow surface toward cylinder block. Align slot in valve
the endcap. Torque endcap screws 35-45 ft-lb (47-61
plate with timing pin. Apply a liberal coat of assembly
Nm).
grease to endcap side of valve plate to keep it in place
during installation. 17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, dis-
assemble and check unit.
3121619 3-35
18. Cover shaft splines with an installation sleeve. Install a 20. Install orifice poppet (30).
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer 37
(28) and snap ring (29). 36
39 33 41
34 11/16 in
30
27 ft-lb
40 (37 Nm)
5/8 in
27 28 29 20 ft-lb
(27 Nm)
32 31
35
38
42
11/16 in
27 ft-lb
(37 Nm)
27. Shaft Seal

28. Seal Support Washer 30. Orifice Poppet 34. Spring 37. O-ring 40. Plug
29. Snap Ring 31. Shift Spool 35. Spring 38. O-ring 41. Plug
32. Spring 36. Spring 39. O-ring 42. Plug
Figure 3-34. Shaft Seal 33. Spring
19. Install remaining plugs and fittings to housing. Refer to Figure 3-36. Loop Flushing Spool
drawing below for wrench sizes and installation torques.
21. Install shift spool (31).
5/16 in 22. Install spring retaining washers on springs (32 and 33).
63 ft-lb (85 Nm)
1/4 in 23. Carefully install centering springs (34, 35, and 36).
33 ft-lb (45 Nm) 24. Install new O-rings (37, 38, and 39).
25. Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27
Nm).
26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27
ft-lb (37 Nm).
9/16 in
125 ft-lb
(170 Nm)
3 mm
1.5 - 2.5 ft-lb
(2 - 3 Nm)
1/4 in
33 ft-lb (45 Nm)
5/16 in
63 ft-lb (85 Nm)
Figure 3-35. Plugs and Fittings Installation
3-36 3121619
Initial Start-up 2. Place shim between pinion and bearing on bearing high
spot.
Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.
INSPECT MOTOR FOR DAMAGE BEFORE INSTALLATION. MAKE CERTAIN ALL

SYSTEM COMPONENTS (RESERVOIR, HOSES, VALVES, FITTINGS, HEAT
EXCHANGER, ETC.) ARE CLEAN BEFORE FILLING WITH FLUID.
1. Fill reservoir with recommended hydraulic fluid. Always

filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid. SU R FAC E BEL OW TEETH
WITH "X" AN D BL U E PAIN T
ON TH R EE TEETH
2. Fill inlet line leading from pump to reservoir. Check inlet
line for properly tightened fittings and be certain it is
free of restrictions and air leaks.
3. Fill pump and motor housing with clean hydraulic fluid.
Pour filtered oil directly in upper most case drain port.
4. To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres-
sure gauge port of pump to monitor system pressure 3. Apply JLG Thread locking compound P/N 0100019 to
during start up. bolt. Torque pivot spacer screw to 340 ft-lb (47 kgm).
6. Watching pressure gauge and run engine at lowest pos-
sible speed until system pressure builds to normal levels
(minimum 160 psi [11 bar]). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained, shut down engine, deter-
mine cause, and take corrective action.
7. Operate hydraulic system for at least fifteen minutes
under light load conditions.
8. Check and adjust control settings as necessary after
installation.
9. Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.
3.17 SETTING SWING GEAR BACKLASH

Set backlash 0.10 to 0.15" (0.254 to 0.381 mm) using the fol-
lowing procedure.
1. Place machine on firm, level ground. NOTE: Make sure turntable is properly supported during the fol-
lowing step. The turntable can swing a few degrees when
turntable lock is removed if turntable is not balanced.
4. Remove turntable lock pin.
3121619 3-37
5. Apply JLG Thread locking compound P/N 0100019 to 10. Discard shim.
the bolts. Pre-torque the five bolts to 45 ft-lb (6 kgm).
11. Rotate bearing high spot 15° to the second drive hub.
Repeat procedure.
6. Tighten setscrew until pinion is completely snug against
shim and bearing. Back off setscrew. Turntable Bearing Mounting Bolt Condition
Check
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL

LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.
NOTE: This check is designed to replace the existing bearing bolt

torque checks on JLG Lifts in service. This check must be
performed after the first 50 hours of machine operation
and every 600 hours of machine operation thereafter. If
during this check any bolts are found to be missing or
loose, replace missing or loose bolts with new bolts and
torque to the value specified in the torque chart, after
applying JLG Threadlocker PN 0100019 to the bolt threads.
After replacing and retorquing bolt or bolts recheck all
existing bolts for looseness.
7. Torque setscrew to 50 ft-lb (7 kgm).
8. Apply JLG Thread locking compound P/N 0100019. 1. Check the frame to bearing attach bolts as follows:
Tighten jam nut. a. Fully elevate the main boom. See Position 2, Figure
3-39.
9. Torque bolts to 340 ft-lb (47 kgm).
b. At the position indicated on Figure 3-39., try to
insert a 0.0015" feeler gauge between the bolt and
hardened washer at the arrow indicated position.
3-38 3121619
c. Ensure that the 0.0015” feeler gauge will not pene- d. At the position indicated on Position 1, Figure 3-39.,
trate under the bolt head to the bolt shank. try and insert the 0.0015” feeler gauge between the
d. Swing the turntable 90 degrees, and check some bolt head and hardened washer at the arrow indi-
selected bolts at the new position. cated position.
e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.
2. Check the turntable to bearing attach bolts as follows:
a. Elevate the fully retracted main boom to full eleva-
tion.
b. At the position indicated on Figure 3-37. try to insert
the 0.0015” feeler gauge between the bolt head and
hardened washer at the arrow indicated position.
c. Lower the boom to horizontal and fully extend the
boom.
Figure 3-37. Swing Bolt Feeler Gauge Check
3.18 SWING BEARING TORQUE VALUES

1. Outer Race - 708 ft.lbs. (960 Nm) w/ JLG Threadlocker
P/N 0100019.
2. Inner Race - 708 ft.lbs. (960 Nm) w/ JLG Threadlocker
P/N 0100019.
3. See Swing Bearing Torquing Sequence.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.
3121619 3-39
6 2 10
14 18
22 26
30 32
24 4 8 29
12 16
20 34
34
28 21
24
33 30
16
22 13
27
19 14
8 5
11 6
36 3 2 1
7 10
4 9
15 18
23 26
12 17
31 32
20 35 29 25
25 21
17 13
28 9 5 35
1
33 31
27 23
19 15
11 3 7
Figure 3-38. Swing Bearing Torquing Sequence
3-40 3121619
3.19 SWING BEARING WEAR TOLERANCE 5. Position the machine as follows and as seen in Figure 3-
30., Swing Bearing Wear Tolerance, Position 2:
See Figure 3-39., Swing Bearing Wear Tolerance.
a. Do not rotate the turntable
1. Position the machine as follows and as seen in Figure 3-
b. The tower boom needs to be stowed
39., Swing Bearing Wear Tolerance, Position 1:
c. Raise the main boom to be fully elevated and
a. Ensure the axles are extended retracted
b. The turntable needs to be centered between the d. Raise the jib to be fully elevated and centered
rear wheels
e. Center the platform and keep it unloaded
c. Fully elevate the tower boom
6. Verify the dial indicator has not shifted. Record the value
d. Lower the main boom to be horizontal
for bearing play.
e. Extend the main boom until it stops
7. Return the machine to Figure 3-39., Swing Bearing Wear
f. Lower the jib to horizontal
Tolerance, Position 1. The dial indicator should to return
g. Keep the jib and platform centered and unloaded to zero. If the dial indicator does not return to zero, take
2. Set up a dial indicator as follows: corrective action and repeat the test.
a. The dial indicator location is to be at the front center 8. If the measurement is more than 0.165 in. (4.2 mm),
of the machine, next to the bearing, opposite of the replace the bearing. If the measurement is less than
tower pivot pin. 0.165 in. (4.2 mm), and any of the following conditions
exist, the bearing should be removed, disassembled,
b. The magnetic base of the indicator should be posi- and inspected.
tioned on the frame
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
9. If bearing inspection shows no defects, reassemble and
return to service.
c. The indicator point needs positioned to measure

the turntable base plate 2.5 inches from the root of
the gear tooth. Refer to Figure 3-39., Swing Bearing
Wear Tolerance.
3. Zero the dial indicator.
4. Check dial indicator accuracy once positioned, using a
feeler gauge and ensure the dial indicator reading, is the
same as the feeler gauge thickness.
3121619 3-41
Figure 3-39. Swing Bearing Wear Tolerance
3-42 3121619
3121619
Upperstructure - 39,000 lbs (17,690 kg)
31 .7 " (8 0 cm)
CEN TER
OF
GRAVITY
Figure 3-40. Swing Bearing Removal - Sheet 1 of 4
3-43
3-44
3121619
B oom Assembly - 21,650 lbs ( 9,82 0 kg)
3121619
CENTER
OF
GRAVITY
Main Boo m Pivot
3-45
3-46
83.3" (212 cm) Turntable - 15,350 lbs (6,963 kg)
Note: Attach Lifting Device to

Turntable Cutouts Closest to
This Side of Turntable
3121619
3.20 SWING CONTROL SYSTEM main boom length is less than 1477.7 inches in the 500 lb
mode or 1442.8 inches in the 1000 lb mode.
The swing control system uses the turntable swing angle sen-
sor in addition to the DOS proximity switch to prevent turnta- The 8.0º angle is used exclusively for the purpose of automati-
ble swing while the axles are retracted. Swing will be allowed cally shifting the drive motors to the maximum displacement
to +/- 35 degrees (before the DOS proximity switch trips) to position (slow speed).
facilitate positioning the turntable for transport of the The control system responds to indicated angle readings 0.3º
machine. Attempts to swing past this position will be disal- smaller than the required angles to account for calibration and
lowed by the control system and the operator will be sensor variation.
prompted via the LCD display to swing in the opposite direc-
tion to return the boom behind the rear wheels. Once the
axles are extended the boom has 360 degree continuous turn- 3.22 AUXILIARY POWER SYSTEM
table swing. If the turntable is swung past +/- 35° when the
boom is lowered into the transport position, the operator will The auxiliary power system is intended as a secondary means
have to swing the turntable back within the rear wheels before of moving the boom in the event of primary power loss. This
attempting to retract the axles. The DOS will work as described system uses an electric motor/pump unit powered by two12V
below when the axles are extended. batteries capable of operating all functions except drive, con-
trolled arc, controlled boom angle, and envelope tracking.
During main lift up or down functions, no other functions are
3.21 CHASSIS TILT INDICATOR SYSTEM permitted and during main lift up functions, automatic plat-
The Chassis Tilt Indicator System measures the turntable angle form leveling is not active but jib leveling is active. To reduce
with respect to level ground. The tilt sensor (mounted to a the demand on the battery and therefore extend the run time
bracket on the side of the turntable near the boom pivot pin) of the system, the auxiliary power functionality differs from
has three settings; 3.0° side tilt, 5.0 degree omni directional tilt, the primary power functionality. The auxiliary power main lift
and an 8.0° omni directional tilt. down function supplies pilot pressure to the main lift cylinder.
This allows gravity to lower the boom. The system redirects
discharge oil from the main lift cylinder to retract the main
telescope cylinder. At high main boom angles the envelope
may be encroached during lift down requiring the operator to
use main telescope in.
When the main boom is retracted to the transport length, the
main telescope in valve is dropped out and lift down is oper-
ated alone allowing the platform to reach the ground. This not
only greatly reduces the power required for these functions
but also lowers the boom within the envelope regardless of
starting position. Jib lift down function may then be operated
allowing the platform to reach ground level. Envelope control
and moment control remain active during the auxiliary power
function.
The 5.0° omni directional angle setting 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 Beyond Transport - Drive Speed Cutback System, the
tilt sensor will cause an alarm to sound and automatically put
all functions in the creep speed mode and drive will be cut
out. With the exception of the drive being cut out, this is a
warning system only indicating to the operator that the
machine has reached the out of level limit. The machine will
continue to function. The operator is responsible to prevent
the machine from attaining an unstable position.
The 3.0° side tilt setting is used in conjunction with the main
boom length and when exceeded, imposes the same func-
tionality as the 5.0° omni directional setting plus prevents
boom telescope out. The side tilt setting is ignored when the
3121619 3-47
3.23 WATER IN FUEL SENSING SYSTEM (OPTIONAL) AFTER SERVICING

After servicing the engine or turbocharger, ensure the turbo-
The Water in Fuel Sensing System detects when there is an charger is pre-lubed by adding clean engine oil into the turbo-
excessive amount of water in the fuel and sets a DTC code in charger oil inlet until full. After pre-lubing, crank the engine
the JLG Control System to alert the operator and/or service without firing (engine/fuel pump stop out) to allow oil to cir-
technician. culate through the full system under pressure. On starting the
engine, run at idle for a few minutes to ensure the oil and bear-
When a Water in Fuel condition occurs, the machine will
ing systems are operating satisfactorily.
respond in the following way:
• The engine will shut down automatically. LOW AIR TEMPERATURES & INACTIVE OPERATION
If the engine has been inactive for some time or the air tem-
• The JLG Control System will set DTC 4375 - Water in Fuel perature is very low, crank the engine first and then run at idle.
This allows the oil to circulate throughout the full system
• An alarm will sound from the active control station (ground
before high loads and speeds are applied to engine and turbo-
or platform)
charger.
• If in platform mode, the Low Fuel Indicator will flash
SHUT DOWN
Engine Restart will be permitted after the machine senses the Before shutting the engine down, let the turbocharger cool
Water in Fuel condition, but will only run for 2 minutes and the down. When an engine runs at maximum power/high torque,
engine will shut down again. This restart process will continue the turbocharger is operating at very high temperatures and
until the Water in Fuel condition is corrected. speeds. Hot shut down can cause reduced service life which is
avoidable by a minute or two of idling. Most mobile equip-
ment applications include an adequate cooling period during
3.24 DEUTZ TURBOCHARGER OPERATION parking or mooring procedures.
Good engine operating procedures are essential to prolong Allow the engine to idle for 1-5 minutes to allow the high tem-
turbocharger life. peratures and speed to reduce and thus prolong the life of the
turbocharger.
Particular attention to oil system and air system will eliminate
the two main causes of turbocharger failure. To prevent this ENGINE IDLE
Operators/Owners must ensure that:- Avoid running the engine for long periods in idle mode
(greater than 20-30 minutes). Under idling conditions low
1. Air and oil filters are checked regularly to the manufac-
pressures are generated in the turbocharger which can cause
turer's specifications.
oil mist to leak past seals into the two end housings. Although
2. Engine maintenance intervals are adhered to. no real harm is done to the turbocharger, as load is applied
temperatures increase and the oil will start to burn off and
3. Engine and equipment are operated in such a way that cause blue smoke emission problems.
is not harmful to the life of the turbocharger.
In the picture above you can see discoloration on the shaft
Operating Practices caused only by heat. If the engine is allowed to Idle for a
period of time, lube oil will continue to flow cooling the tur-
Operators and owners can get maximum service life from their bine shaft.
turbochargers if a few good practices are followed: You can also see spots on the turbo where grooves have been
“worn” in to the turbine shaft at the point where the radial
START UP bearing sits. Dirty oil/contaminates in the oil can become
When starting the engine use minimum throttle and run in trapped in between the radial bearing and the surface of the
idle mode for approximately one minute. Full working oil pres- shaft becoming abrasive and ultimately grinding away the
sure builds up within seconds but it is useful to allow the tur- material.
bocharger moving parts to warm up under good lubricating
conditions. Revving the engine within the first few seconds of
start up causes the turbocharger to rotate at high speeds with
marginal lubrication which can lead to early failure of the tur-
bocharger.
3-48 3121619
3.25 DIESEL EXHAUST FLUID (DEF) TANK Cleaning and Flushing the Tank
Refer to Figure 3-44. and Figure 3-45. If contaminated fluid or foreign material is found in the tank,
the tank must be cleaned. Use the following procedure for
Diesel exhaust fluid (DEF) is a urea solution consisting of 32.5%
cleaning.
urea and 67.5% deionized water. DEF is used in selective cata-
lytic reduction (SCR) to lower nitrogen oxide (NOx) concentra- 1. Remove the DEF tank drain plug, and drain any fluid into
tion in exhaust emissions. a suitable container. Dispose of fluid properly.
DEF is temperature sensitive in storage. If stored between 75°F 2. Clean the header with a mixture of warm water and a
(24°C) and 12°F (-10°C), it can be stored for 2 years. In the light petroleum based soap.
machine’s DEF tank, the storage life is 4 months. After 4
months, the DEF must be drained from the tank, properly dis- 3. Clean DEF tank with a high pressure washer, or flush
posed of, and the tank cleaned and flushed. If the machine has tank with hot water for five minutes and drain water.
been idle in an extreme cold environment (-40° to 32°F [-40° to 4. If DEF fluid lines are contaminated, tag and remove the
0°C]), the interval is reduced to 2 months. lines from the DEF pump module and flush with a mix-
ture of warm water and a light petroleum based soap.
NOTE: DEF freezes at 12°F (-11°C).
5. Refill DEF tank with water until it overflows. Completely
flush tank with water.
6. Empty DEF tank, and dispose of contaminated water
properly.
7. Rinse the tank and all soap residue with deionized or
distilled water and allow to air dry.
3121619 3-49
Figure 3-44. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2
3-50 3121619
1. Coolant Tube 13. Header

2. Level Tube 14. Metallic Flange
3. DEF Filter 15. Cover
4. Tie-Wrap 16. Screw
5. Rubber Bushing 17. Spring Tube
6. Float Assembly 18. Urea Quality Sensor
7. Suction Tube 19. DEF Electric Assembly
8. Suction Strengthening Plate 20. Breather
9. Return Tube 21. Cap
10. Return Strengthening Plate 22. Drain Plug
11. Connector 23. Tank
12. Rubber Header
Figure 3-45. Diesel Exhaust Fluid (DEF) Tank - Sheet 2 of 2
3121619 3-51
3-52
TANK VENT PORT
FUEL RETURN
FUEL SUPPLY PORT FROM ENGINE
SUPPLY FUEL LINE
TANK TO PRE-FILTER
SEE DETAIL C
SEE DETAIL A SEE DETAIL B
AIR FILTER
GEAR PUMP
SCR SURGE TANK

FUNCTION PUMP
DOC
DRIVE PUMP
1001192266 F
Figure 3-46. Engine Installation and Diesel Exhaust Fluid (DEF) System - Sheet 1 of 8
3121619
SUPPLY FUEL LINE
3121619
FROM TANK
FUEL PUMP
ENGINE HARNESS
SUPPLY FUEL LINE

(INBOARD)
DETAIL B RETURN FUEL LINE

(OUTBOARD)
DETAIL C
EMR4
HARNESS
SUPPLY AND
RETURN FUEL LINE
140 AMP
BATTERY
1001192266 F
ISOLATOR
3-53
3-54
DEF SUPPLY OUTLET
BACKFLOW TO TO DOSING MODULE
DEF TANK
INLET FROM
F DEF TANK
SUPPLY PREFILTER
TO FUEL PUMP DEF SUPPLY MODULE
1001192266-F
3121619
3121619
COOLANT SUPPLY TO
TEE FITTING UNDER ENGINE
COOLANT SUPPLY PORT
COOLANT RETURN PORT
COOLANT RETURN FROM

DOSING MODULE
COOLANT RETURN
FROM DEF TANK
1001192266-F
3-55
3-56
DEF FLUID SUPPLY
SUPPLY FUEL LINE RETURN FUEL LINE
L-L
DEF COOLANT RETURN LINE
DEF COOLANT SUPPLY LINE
1001192266-F
3121619
3121619
TANK VENT HOSE COOLANT RETURN LINE
TO TEE FITTING OUTBOARD COOLANT SUPPLY
SUPPLY FUEL LINE SIDE OF ENGINE LINE FROM DEF
TO SECONDARY FUEL DEF SUPPLY FROM
COOLANT VALVE
FILTER ON ENGINE OUTLET PORT ON
SUPPLY MODULE
INSTALL FUEL PUMP

SUPPLIED WITH ENGINE
DEF LINE TO DEF LINE TO

COOLANT SUPPLY TO SUPPLY MODULE
COOLANT RETURN TO SUPPLY MODULE
DOSING MODULE FROM BACKFLOW PORT INLET PORT
TEE FITTING ON OUTBOARD TEE FITTING UNDER ENGINE
SIDE OF ENGINE
DEF DOSING MODULE N-N
J-J
M-M
1001192266-F
3-57
3-58
COOLANT SUPPLY FROM

ENG SUPPLY PORT
COOLANT SUPPLY TO
DOSING MODULE
COOLANT SUPPLY
TO DEF COOLANT
SUPPLY VALVE
COOLANT SUPPLY
TO DEF TANK DEF COOLANT RETURN LINE
DEF COOLANT SUPPLY VALVE
- VALVE TO BE ORIENTED WITH THE FLOW FACING
THE FRONT (CCW END) OF THE MACHINE
1001192266-F
3121619
O2 SENSOR GLOW PLUG
CONNECTION:
3121619
PRESSURE SENSOR
MIXING PIPE EXH GAS

TEMP CONNECTION
DOC TEMP
SENSOR
PRE-SCR NOx
SENSOR
ENGINE ECU
CONNECTION
O2 SENSOR
NOx SENSOR AFTER SCR
STARTER
CONNECTION:
1001176371 G
Figure 3-53. Diesel Exhaust Fluid (DEF) System - Sheet 8 of 8
3-59
Figure 3-54. Engine Electrical Circuit
3-60 3121619
3.26 DEUTZ ENGINE WITH DIESEL EXHAUST FLUID WINTER OPERATION WITH DIESEL FUEL
Special demands are placed on the cold behavior (tempera-
(DEF) ture limit value of the filtrability) for winter operation. Suitable
fuels are available in winter.
Engine Oil Mixing with petrol is not permissible for safety and technical
Engines equipped with Exhaust After Treatment (EAT) systems reasons (cavitation in the injection system).
require the use of low-ash engine lubricating oils. Diesel fuels up to -44 °C are available for an Arctic climate. The
addition of flow improvers to the diesel fuel is only allowed in
Lubricating oil that is not "low-ash" rated can contain sulphate exceptional cases. The choice of a suitable additive and the
and oxide ashes from metal-organic additives which will sig- necessary dosing and mixing procedure must be discussed
nificantly shorten the life span of diesel particle filters. Phos- with the fuel supplier. If only summer diesel fuel is available,
phor from wear-protection additives as well as sulphur and petroleum or kerosene can be added to the diesel fuel up to
sulphur compounds negatively influence the catalyst activity 30% ( V/V ) at low temperatures as shown in the diagram
in exhaust gas post-treatment systems. below.
LOW-ASH ENGINE LUBRICATING OILS ARE RECOMMENDED FOR SCR EXHAUST

AFTER TREATMENT SYSTEMS.
USE OF NON-APPROVED LUBRICATING OIL WILL RESULT IN VOIDED WAR-

RANTY COVERAGE.
Diesel Fuel
Engines equipped with an SCR system (Selective Catalytic Figure 3-55. Mixing Petroleum With Summer Diesel Fuel
Reduction) may only be operated with sulphur-free diesel
fuels (EN 590, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1- The mixing should take place in the engine tank. First pour in
D S15 or heating oil in EN 590 quality). Otherwise compliance the necessary amount of petroleum or kerosene, and then add
with the emission requirements and durability is not guaran- the diesel fuel.
teed.
In a warranty case the customer must prove by a certificate

from the fuel supplier that a released fuel was used.
HIGH SULPHUR CONTENT IN THE FUEL

Fuels with a sulphur content > 0.5% (m/m) (5,000 mg/kg)
demand a shorter lubricating oil change interval. Fuels with a
high sulphur content may not be used in engines with exhaust
gas after-treatment. Fuels with a sulphur content > 1.0% (m/
m) are not permissible due to high corrosion and considerable
shortening of the engine life. Low-ash / low SAPS engine lubri-
cating oils (sulphate ash max. 1.0% (m/m)) may only be used in
engines without exhaust after-treatment systems if the sul-
phur content in the fuel does not exceed 50 mg/kg. However,
low-ash lubricating oils may be used in engines without
exhaust gas after-treatment systems up to sulphur contents of
500 mg/kg if the base number (TBN) is at least 9 mg KOH/g.
3121619 3-61
3.27 SELECTIVE CATALYTIC REDUCTION (SCR) - 1. The Selective Catalytic Reduction Indica-
tor will flash when standstill cleaning is
MACHINES USING DIESEL EXHAUST FLUID (DEF) required.
Selective Catalytic Reduction (SCR) is an emissions control
used in diesel engines and requires operator interaction to
ensure proper operation of the system.
The system injects liquid through a special catalyst into the
exhaust stream of a diesel engine. The liquid is automotive-
grade urea, otherwise known as Diesel Exhaust Fluid (DEF). 2. Move the machine to an suitable area free of flamma-
The DEF sets off a chemical reaction that converts nitrogen bles and personnel that could be exposed to hot
oxides into nitrogen, water and carbon dioxide (CO2), which is exhaust. Launch the cleaning process by pressing the
then expelled through the engine exhaust pipe. SCR button on the Ground Console for 3 seconds. The
Indicator Gauge will display the following screen.
For peak operation, the SCR system must be cleaned using
one of two methods, Standstill Cleaning and Maintenance
Standstill Cleaning. Standstill Cleaning is any cleaning
requested by the engine outside of the regular maintenance
window (for example, if the system detects crystallization in
the DEF solution). Maintenance Standstill Cleaning is cleaning
requested by the engine on the regular maintenance interval.
SCR technology is designed to permit nitrogen oxide (NOx)
reduction reactions to take place in an oxidizing atmosphere.
It is called “selective” because it reduces levels of NOx using
ammonia as a reductant within a catalyst system. The chemi-
cal reaction is known as “reduction” where the DEF is the
reducing agent that reacts with NOx to convert the pollutants
into nitrogen, water and tiny amounts of CO2. The DEF can be
rapidly broken down to produce the oxidizing ammonia in the 3. The Main Cleaning process will begin and last for
exhaust stream. SCR technology alone can achieve NOx reduc- approximately 30 to 60 minutes. The following screen
tions up to 90 percent. will show that the process has begun and includes a sta-
NOTE: The system will reset the maintenance interval back to 0 tus bar that indicates the progress of the cleaning pro-
hours after Standstill or Maintenance Standstill cleaning cess.
events are performed.
Standstill Cleaning
The following conditions must be met to perform Standstill
Cleaning.
• Machine must be stationary
• Boom in the stowed position
• No personnel in platform
• Engine must be idling
• Coolant temperature must be above 167° F (75° C)
• Diesel Exhaust Fluid (DEF) tank must not be frozen
• Machine in Ground Station mode
NOTE: Every standstill regenration slightly dilutes the engine oil

with fuel.The number of standstill regenration is therefore
monitored.
3-62 3121619
Unsuccessful Cleaning Event

If there is an unsuccessful cleaning event, The SCR icon will
show on the display gauge. Possible causes of an Unsuccessful
Cleaning Event are:
• Engine is not warmed up
• DEF tank is frozen
• Machine functions operated during cleaning event in
progress
• Other engine faults are active
The Indicator Gauge will display the “Regen Failed” screen as
shown. If the cleaning event has failed, it must be run again.
4. After the cleaning process is complete, the engine will
run for approximately 5 minutes to allow the Engine and
Exhaust After Treatment (EAT) to cool down. The Indica-
tor Gauge will display the “Regen Complete" screen as
shown and the HEST indicator will no longer be illumi-
nated.
Maintenance Standstill Cleaning Initiation

Methods
Maintenance Standstill Cleaning can be started by one of two
methods, by using the Analyzer or SCR button on the Ground
Console. All the same conditions as outlined under Standstill
Cleaning must be met.
Cancelling Maintenance Standstill

Maintenance Standstill Cleaning will be stopped immediately
if:
• The Platform/Ground Select switch is switched from
Ground to Platform mode
• Function switch is enabled to perform a boom function
• The Engine is powered down
If Maintenance Standstill Cleaning is interrupted, it must be re-
initiated.
If Maintenance Standstill Cleaning is interrupted, it must be re-
initiated and the Indicator Gauge will display the "Regen
Failed” screen as shown.
3121619 3-63
Table 3-8. Maintenance Standstill Cleaning
Machine Hours
Standstill Cleaning System Distress SCR Cleaning
Since Last Derate Comments
Levels Light Light
Cleaning
0-500 Between 500 and 1000 hours, clean-
Normal
0 -- -- None ing cycle can be initiated with JLG
Operation 500-1000 analyzer.
Standstill
1 1000-1100 -- None
Required
0.5 Hz Engine coolant temperature must
be >40° C and DEF should be thawed
Machine placed in before cleaning can be initiated.
Warning
2 1100-1125 Creep and DTC
Level
active
Continuous 0.5 Hz
Idle Lock. Boom Contact Deutz Dealer.
Shut Off Functions Locked
3 >1125
Level Out and Trapped in
Blinking 3 Hz Transport.
Table 3-9. Cleaning When Crystallization is Detected During SCR
Machine Hours
Cleaning
Crystallization after System Distress SCR Cleaning
Initiation Derate
Levels Crystallization Light Light
Methods
No Crystallization
Normal Operation -- -- -- None
Detected
Crystallization Detected SCR Switch

0-5 -- None
Standstill Required or Analyzer
0.5 Hz
Machine placed in
Crystallization Detected SCR Switch
5-600 Creep and DTC
Warning Level 1 or Analyzer
active
Continuous 0.5 Hz
Idle Lock. Boom

Crystallization Detected Contact Deutz Functions Locked
>600
Shut Off Level Dealer. Out and Trapped in
Blinking 3 Hz Transport.
3-64 3121619
Table 3-10. Engine Fault Codes
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523927 3 40 7-3-3 UB5; Short circuit to battery error of actuator Suspected Components: ECU PIN A04, A05 Check wiring harness and connected loads on
relay 5. Short circuit to battery error of actua- Because the assignment of PINs is different pins A04, A05.
tor relay 5. Components on Pin A04, A05 can- between the engine series, check the con-
not be activated. Internal ECU power stage nected loads in the motor circuit diagram.
switched off.
523924 4 42 1-6-7 UB2; Short circuit to ground actuator relay 2. Suspected Components: ECU PIN A01, K74 and Threshold for error detection is an internal ECU
Components on Pin A01, K74 and K91 cannot K91. Because the assignment of PINs is different threshold. Check wiring harness and connected
be activated. Internal ECU power stage between the engine series, check the con- loads on pins A04, A05. If error is still present,
switched off. nected loads in the motor circuit diagram. exchange ECU.
523925 4 43 7-3-1 Short circuit to ground actuator relay 3 Com- Suspected Components: ECU PIN A88 and K57. Threshold for error detection is an internal ECU
ponents on Pin A88 and K57 cannot be acti- Because the assignment of PINs is different threshold. Check wiring harness and connected
vated. Internal ECU power stage switched between the engine series, check the con- loads on pinsA88, K57. If error is still present,
off. nected loads in the motor circuit diagram . exchange ECU.
523926 4 44 7-3-2 UB4; Short circuit to ground actuator relay 4. Suspected Components: ECU PIN A90 Threshold for error detection is an internal ECU
Components on Pin A90 cannot be activated. Because the assignment of PINs is different threshold. Check wiring harness and connected
Internal ECU power stage switched off. between the engine series, check the con- loads on pin A90. If error is still present,
nected loads in the motor circuit diagram. exchange ECU.
168 3 45 3-1-8 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.
168 4 46 3-1-8 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.
168 2 47 3-1-8 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 mor than =0.5sec a warning is generated.
reaction is initiated. Battery voltage above warning threshold.
523912 4 73 7-2-2 @ engines < 4l: Throttle valve error, Open The sensed raw voltage value is below the mini- The sensed raw voltage value
Load or Short cut to Battery, blocked valve or mum threshold. DPM_uRawBrnDVDsP is above the minimum
wrong control signal for valve. @ engines threshold DPM_SRCBrnDVDsP.uMin_C @ CRT
with Burner T4i: Pressure Sensor error after < 4l: check throttle valve @ engines with Burner
valve (DV2), lower limit reached. T4i: check back-pressure valve.
639 14 84 2-7-1 CAN bus 0: the ECU is not allowed to send CAN Bus Off error; CAN 0 (Customer CAN). Threshold for error detection is an internal ECU
messages, because the status "BusOff"is threshold. Bus Off bit for CAN A node is set.
detected. 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).
1231 14 85 2-7-1 CAN bus 1: the ECU is not allowed to send CAN Bus Off error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold. Bus Off bit for CAN B node is set.
detected Warning, no diagnostic with Check wiring of CAN bus and if necessary repair
SERDIA2010 possible. it, check connection cable and if necessary
repair or replace it, check resistance in CAN lines
(120 Ohm).
1235 14 86 2-7-1 CAN bus 2: the ECU is not allowed to send CAN Bus Off error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold. BusOff bit for CAN C node is set. Check
detected. Warning, depends on engine, EAT. 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).
3121619 3-65
Deutz Blink
Code Code
102 2 89 2-2-3 Charge air pressure messured by sensor is Charge air pressure above shut off 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 necessery.!! If an error
occurs, always check the delta P sensor and the
Venturi tube for damage or contamination
because problems at this point can lead to this
result error.!!
110 1 93 2-2-5 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.
110 3 96 2-2-5 Coolant temperature sensor: the voltage of Short cut to power supply 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 repair or
get range (signal range check high) replace it.
110 4 97 2-2-5 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 repair or
get range (signal range check low) replace it Measure Voltage at Coolant Tempera-
ture Sensor and renew harness if needed.
110 0 98 2-3-2 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, check
range; the ECU activates a system reaction thermostat function, check water pump
110 0 99 2-3-2 Coolant temperature: the coolant Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
temperature calculated by ECU is above the level, check cooling system in general, check
target range. The ECU activates a system thermostat function, check water pump
reaction
111 1 101 2-3-5 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
3224 9 130 5-9-7 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)
3234 2 138 1-1-4 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
3234 9 139 1-1-7 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)
523942 9 141 7-6-7 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 & Sensorcali-
bration for NOX Sensor (SCR-system down-
stream cat, DPF-system downstream cat)
523943 9 142 7-6-7 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 down-
stream cat)
523211 9 164 3-3-1 Timeout Error of CAN-Receive-Frame EBC1 not used not used
523704 12 167 6-1-5 Timeout Error of CAN-Transmit-Frame EEC3 Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
3-66 3121619
Deutz Blink
Code Code
523935 12 168 7-6-3 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.
523936 12 169 7-6-4 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
523240 9 179 5-2-7 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.
523216 9 198 3-3-7 Timeout Error of CAN-Receive-Frame PrHt- Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
EnCmd; pre-heat command, engine com-
mand
523766 9 281 1-1-8 Timeout Error of CAN-Receive-Frame Active not used not used
TSC1AE
523769 9 284 1-1-9 not used No detail informationen!
523776 9 291 1-1-9 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 shedul-
ing, polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
523777 9 292 1-1-9 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 protocol
of receiver, check CAN functional range, check
actuator
523778 9 293 1-1-8 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling, polar-
TSC1TR; control signal ity, short circuit, power interrupt), test protocol
actuator
523779 9 294 1-1-8 Message TSC1-TR has been missing (pas- Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sive) sage) ity, short circuit, power interrupt), test protocol
actuator
523605 9 300 1-1-8 No detail informationen! No detail informationen!
523982 1 361 7-3-7 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is to low. to too low battery voltage. repair or replace if necessary.
630 12 376 2-8-1 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. There is no healing possible for the
memory or works with an alternative value error. In the every new initialization phase, the
debounce level is set to zero. If not pro-
grammed, EEPROM is defect --> ECU is defect,
reprogramm ECU and if necessary replace it.
630 12 377 2-8-1 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, Threshold for error detection is an internal ECU
an error during the access to its EEPROM EEPROM has Checksum Error threshold. There is no healing possible for the
memory or works with an alternative value error. In the every new initialization phase, the
debounce level is set to zero. If not pro-
grammed, EEPROM is defect -->ECU is defect,
reprogramm ECU and if necessary replace it
630 12 378 2-8-1 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. If not programmed, EEPROM is
memory or works with an alternative value defect --> ECU is defect, reprogramm ECU and if
necessary replace it.
3121619 3-67
Deutz Blink
Code Code
411 4 381 6-9-3 Range check cannot be done or interrupted. Defect EGR differential Pressure sensor or defect Check wiring harness and connected EGR. !!If an
wiring error occurs, always check the delta P sensor
and the Venturi tube for damage or contamina-
tion because problems at this point can lead to
this result error.!!
523612 12 387 5-5-5 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- threshold. Caution ! Sequence error, check error
nally; no item will be created in error mem- memory for other errors.
ory
190 0 389 2-1-4 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 was
activates a system reaction over Limit.
190 11 390 2-1-4 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC Check powertrainsettingsregarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed was
activates a system reaction over limit.
190 14 391 2-1-4 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 limit
activates a system reaction
171 3 417 3-1-2 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 and if necessary
signal range check high replace it, check connection cable and if neces-
sary repair or replace it.
190 8 419 2-1-2 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 camshaft signal.
speed sensor as alternative to calculate the Check increment wheel position, clean and
engine speed adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
190 2 421 2-1-3 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 adjust if necessary, check sensor
postition. Check Camshaft and Crankshaft senor
or wiring.
190 8 422 2-1-2 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Crankshaft sensor Threshold for error detection is an internal ECU
defect. threshold, occurs by disturbed crankshaft sig-
nal. Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Crankshaft Sensor or wiring.
190 12 423 2-1-2 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 Crankshaft
speed sensor as alternative to calculate the signal. Check increment wheel position, clean
engine speed. and adjust if necessary, check Crankshaft sensor
postition or wiring.
97 3 464 2-2-8 Fuel filter water level sensor: the voltage of Fuel filter water level sensor: the voltage of sen- Check of wiring and water in fuel sensor. Check
sensor measured by ECU is out of the target sor measured by ECU is out of the target range cabling, if charge Water in Fuel sensor is not
range working, check sensor and if necessary replace
repair or replace it.
3-68 3121619
Deutz Blink
Code Code
97 4 465 2-2-8 Fuel filter water level sensor: the voltage of Fuel filter water level sensor: the voltage of sen- Check wiring, sensor, ECU
sensor measured by ECU is out of the target sor measured by ECU is out of the target range.
range.
94 3 472 2-1-6 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 Short cut to battery sor and if necessary replace it, check connection
range or open loop cable and if necessary repair or replace it
94 4 473 2-1-6 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 short cut to ground sor and if necessary replace it, check connection
range cable and if necessary repair or replace it
94 1 474 2-1-6 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 neces-
range; the ECU activates a system reaction sary repair or replace it.
676 11 543 2-6-3 Cold start device relay error Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold. check wire harness, replace relay
676 11 544 2-6-3 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold. check wire harness, replace relay
729 5 545 2-6-3 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
729 3 549 2-6-3 Intake Air Heater Device; Short circuit to bat- wiring to the intake air heater device is faulty. Threshold for error detection is an internal ECU
tery threshold. Electrical error, Check wiring to the
intake air heater device.
729 4 551 2-6-3 Air intake heater; Short circuit to ground Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
error for powerstage on CJ945. ground. threshold. Electrical error, check wiring to the
air intake heater.
523895 13 559 1-5-8 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. Check correct injector adjustment
order). value (IMA). Use SERDIA UseCase to check it.
programming (IMA) injector 2 (in firing cyl. 2 threshold. check dataset and flash correct injec-
order). tor adjustement value (IMA). Use SERDIA Use-
Case to check it.
523897 13 561 1-5-8 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. Check correct injector adjustment
programming (IMA) injector 6 (in firing cyl. 6. threshold. Check correct injector adjustment
523350 4 565 1-5-1 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.
523352 4 566 1-5-2 Injector cylinder bank 2: the current drop Short circuit injection bank2 (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
523354 12 567 1-5-3 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. If error is not removable, change ECU.
output. Chip of CY33x defect power stage
components
3121619 3-69
Deutz Blink
Code Code
651 5 568 1-5-4 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 1 threshold. Check wiring harness, injectors and if
651 3 580 1-5-4 Injector cyl. 1: the current drop measured by Suspected Components: injector cylinder 1 wir- Threshold for error detection is an internal ECU
ECU is above the target range ing harness, cable break or short circuit, sensor threshold. Check wiring harness, injectors and if
defective, connection cable damaged necessary repair/replace it. Use SerDia Injector
test for diagnosis.
test for diagnosis.
test for diagnosis.
ECU is above the target range ing harness, cable break or short circuit, sensor threshold. Check wiring harness, injectors and
defective, connection cable damaged if necessary repair/replace it. Use SerDia Injec-
tor test for diagnosis.
test for diagnosis.
test for diagnosis.
523615 5 592 1-3-5 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 necessary repair/replace it.
523615 3 594 1-3-5 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. Check wiring harness and metering
3-70 3121619
Deutz Blink
Code Code
523615 4 595 1-3-5 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
523615 3 596 1-3-5 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
523615 4 597 1-3-5 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
523615 4 599 1-3-5 Metering unit, short circuit to ground not used not used
523612 12 612 5-5-5 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. If error is still present, exchange ECU.
nally; no item will be created in error mem-
ory.
523612 12 613 5-5-5 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. Check wiring, check connected sen-
nally; no item will be created in error mem- sors actuators. If error is still present, exchange
ory ECU.
523612 12 614 5-5-5 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. Check wiring, check connected sen-
nally; no item will be created in error mem- sors actuators. If error is still present, exchange
ory ECU.
523612 12 618 5-5-5 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 error). Loss threshold. If error is still present, exchange ECU.
nally; no item will be created in error mem- of synchronization sending bytes to the moni-
ory toring memory from CPU
523612 12 619 5-5-5 Injection system,electrical error injectors Suspected components: Injector ECU wiring Threshold for error detection is an internal ECU
harness/connector threshold. If error is still present, exchange ECU.
523612 12 620 5-5-5 Internal hardware monitoring: the CPU of Error trying to set MM Response time(ECU inter- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged internal error) threshold. If error is still present, exchange ECU.
ory
523612 12 621 5-5-5 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 MoCSOP execu- threshold. If error is still present, exchange ECU.
nally; no item will be created in error mem- tion
ory
523612 12 623 5-5-5 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 error). threshold. If error is still present, exchange ECU.
nally; no item will be created in error mem- Diagnostic fault check to report the error in
ory undervoltage monitoring
523612 12 624 5-5-5 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. If error is still present, exchange ECU.
ory
523612 12 625 5-5-5 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 setting threshold. If error is still present, exchange ECU.
nally; no item will be created in error mem- the alarm task period
ory
523612 12 630 5-5-5 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. If error is still present, exchange ECU.
3121619 3-71
Deutz Blink
Code Code
523612 12 631 5-5-5 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. If error is still present, exchange ECU.
and level 2 information
523612 12 632 5-5-5 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. If error is still present, exchange ECU.
523612 12 633 5-5-5 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. (-> ECU threshold. If error is still present, exchange ECU.
internal error)
523612 12 634 5-5-5 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold. If error is still present, exchange ECU.
523612 12 635 5-5-5 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
523612 12 636 5-5-5 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
523612 12 637 5-5-5 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. If error is still present, exchange ECU.
activates a system reaction time. Diagnostic fault check to report the error
due to Over Run
523612 12 638 5-5-5 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. If error is still present, exchange ECU.
523612 12 639 5-5-5 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 min threshold. Check metering unit or cable. Check
threshold. Rail metering unit defect. Leakge in Rail pressure. Check the Rail System of leakage.
the Rail System.
523612 12 640 5-5-5 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 current threshold. If error is still present, exchange ECU.
torque plausible actual torque.
523612 12 641 5-5-5 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. If error is still present, exchange ECU.
523612 3 644 5-5-5 supply voltage to high not used Threshold for error detection is an internal ECU
threshold.
523612 4 646 5-5-5 supply voltage to low not used Threshold for error detection is an internal ECU
threshold.
523612 12 714 5-5-5 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.
523612 12 715 5-5-5 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 autobat- threshold. Software reset.
tery) should not lead the ECU OCWDA's diag-
nose to enter an error in the fault memory due
to an undervoltage recognition.
523612 12 716 5-5-5 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.
523612 12 717 5-5-5 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 autobat- threshold. Software reset.
tery) should not lead the ECU OCWDA's diag-
nose to enter an error in the fault memory due
to an undervoltage recognition.
3-72 3121619
Deutz Blink
Code Code
100 3 732 2-2-4 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring Check cabling. If sen-
measured by ECU is out of the target range sor not working, check sensor and if necessary
replace it, check connection cable and if neces-
100 4 733 2-2-4 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 sensor and
if necessary replace it, check connection cable
and if necessary repair or replace it
100 0 735 2-3-1 High oil pressure; shut off threshold not used not used
exceeded
100 1 736 2-3-1 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 evalu-
ate sensor value
100 1 737 2-3-1 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 evalu-
ate sensor value.
107 3 750 1-3-6 short circuit to battery or cable break No detail informationen! If the signal PAirFltD_uRaw is below the appli-
catable threshold PAirFltD_uSRCMax_C, a sig-
nal range violation is reset after the healing
debouncing. No detail informationen!
107 0 751 1-3-6 short circuit to ground No detail informationen! If the signal PAirFltD_uRaw is above the appli-
catable threshold PAirFltD_uSRCMin_C, a sig-
nal range violation is reset after the healing
debouncing No detail informationen!
107 0 752 1-3-6 Air filter differential pressure: the pressure Pressure loss above target range, air filter Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter clogged or defective, sensor not working, con- check cabling, check sensor and if necessary
inlet and outlet calculated by ECU is above nection cable damaged Pressure value above replace it, check connection cable and if neces-
the target range and the ECU activates a sys- warning threshold sary repair or replace it
tem reaction
102 2 772 2-2-3 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 running 2) Exchange ECU
ronment pressure. Which sensor is not okay engine to high
can not be said.
102 1 774 2-2-3 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.
102 3 776 2-2-3 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 and if
range necessary replace it, check connection cable
and if necessary repair or replace it.
102 4 777 2-2-3 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 and if
range. necessary replace it, check connection cable
and if necessary repair or replace it
3121619 3-73
Deutz Blink
Code Code
411 3 795 6-9-3 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure
Air_uRawPEGRDeltaP is above the maxi- sensor is not working, check sensor and if neces-
mum threshold. sary replace it, check connection cable and if
necessary repair or replace it.
411 4 796 6-9-3 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure
Air_uRawPEGRDeltaP is above the mini- sensor is not working, check sensor and if
mum threshold. necessary replace it, check connection cable
3253 2 807 6-9-2 The difference pressure sensor value exceeds sensed differential pressure across DPF > limit Check tubes from exhaust line to sensor =>
an applicable not plausible threshold. course strictly rising Could sensor be frozen?
Cold enough? => Warm-up engine and check
whether failure heals (needs ignition cycle)
Water in sensor or lines to sensor? => dry & Re-
Check system Exchange differental pressure
sensor. Trigger Conditions: If the differential
pressure sensor over the DOC + DPF system
detects a pressure difference higher than 18hPa
AND ignition is off for more than 2s AND engine
is not in cranking this diagnostic will detect an
error.
3251 0 809 6-9-2 The difference pressure sensor value exceeds sensensed differential pressure across DPF > Check soot load level. DPF Check DPF condition.
an applicable upper shutoff limit high limit f(exhaust volume flow) Check DPF differential sensor .
If still allowed run stand-still
If failure healed after stand-still check engine
regarding too high soot emissions at engine
out: Check complete air path of engine => Tur-
bocharger, throttle, EGR-Valve, EGR-Cooler, all
pipes.
If stand-still is not allowed to run check engine
regarding too high soot emissions at engine out
Replace DPF!
! If an error occurs, always check the delta P sen-
sor and the Venturi tube for damage or contam-
ination because problems at this point can lead
to this result error.!!
3251 0 810 6-9-2 The difference pressure sensor value exceeds sensed differential pressure across DPF > warn- Check soot load level. Check DPF condition.
an applicable upper warning threshold. ing high limit f(exhaust volume flow) Check DPF differential sensor. If still allowed run
stand-still
If failure healed after stand-still check engine
regarding too high soot emissions at engine
out: Check complete air path of engine => Tur-
bocharger, throttle, EGR-Valve, EGR-Cooler, all
pipes If stand-still is not allowed to run check
engine regarding too high soot emissions at
engine out Replace DPF !!
If an error occurs, always check the delta P sen-
3-74 3121619
Deutz Blink
Code Code
3251 1 812 6-9-2 The difference pressure sensor value exceeds sensed differential pressure across DPF < shut- Check tubes from exhaust line to DPF differen-
an applicable lower shutoff threshold. off low limit f(exhaust volume flow) tial sensor Check flange between DOC & DPF for
leakage Check Exhaust pipe upstream DPF for
leakage Check engine exhaust mass flow /
exhaust volume flow Visual inspection of dis-
mounted DPF exchange DPF differential sensor
exchange DPF
3251 1 813 6-9-2 The difference pressure sensor value drops sensed differential pressure across DPF< warn- Check tubes from exhaust line to DPF differen-
below an applicable warning threshold. ing low limit f(exhaust volume flow) tial sensor Check flange between DOC & DPF for
leakage Check Exhaust pipe upstream DPF for
leakage Check engine exhaust mass flow /
exhaust volume flow Visual inspection of dis-
mounted DPF exchange DPF differential sensor
exchange DPF
3253 3 814 6-9-2 Electrical error differential pressure B58 sensor voltage > high limit Check wiring (terminal diagram engine side).
(DPF) The measured voltage is above the Exchange differential sensor DPF.
preset upper limit value.
3253 4 815 6-9-2 Electrical error differential pressure (DPF) sensor voltage < low limit Check wiring Exchange differential sensor DPF
The measured voltage is below the set lower
limit value. Short circuit to ground
523009 9 825 2-5-3 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.
523470 2 826 1-4-6 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 injection system.
523470 2 827 1-4-6 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 injection system.
523470 12 828 1-4-6 Rail pressure relief valve: is open. Shutoff Shut Off after PRV Open Threshold for error detection is an internal ECU
conditions. threshold. Check PRV opening counter and if
necessary replace PRV, check rail-pressure sen-
sor for plausibility and if necessary replace it,
check FCU and if necessary replace it.
523470 12 829 1-4-6 Rail pressure relief valve is open. Warning Warning PRV open Threshold for error detection is an internal ECU
conditions. threshold. Check PRV opening counter and if
necessary replace PRV, check rail-pressure sen-
sor for plausibility and if necessary replace it,
check FCU and if necessary replace it.
523470 14 830 1-4-6 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold. Only after ECU reset. Check PRV
opening counter and if necessary replace it,
check rail-pressure sensor for plausibility and if
necessary replace it, check FCU and if necessary
replace it.
523470 11 831 1-4-6 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 operating threshold. Check railpressure, check rail pres-
point) sure sensor for plausibility, check FCU.
523470 11 832 1-4-6 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. The PRV can not be opened at this tolerance range. threshold. Check PRV and replace if necessary.
operating point with a pressure shock.
3121619 3-75
Deutz Blink
Code Code
523009 10 833 2-5-3 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.
1176 0 847 1-3-9 Pressure above upper limit. Pressure sensor sensed pressure upstream turbine > limit Check function of waste gate => tube
upstream turbine, Physical Range Check connected / actuator okay
high. The physical value is above the set Check exhaust pipe blockage
threshold. Check for crystallisation downstream of DEF
injector
Check EGR-Valve functionality
Check rail pressure & injectors: injector stuck?
Check free rotation of turbocharger
1176 3 849 1-4-1 Signal range check (SRC) with the pressure Short cut to battery. Damaged Turbine Check cabling, check turbine upstream pressure
sensor has exceeded the upper limit of the upstream sensor. sensor and if necessary replace it, check connec-
voltage signal. tion cable and if necessary repair or replace it.
1176 4 850 1-4-1 In signal range check (SRC) has the voltage Short cut to ground. Damagedturbine Check cabling, check turbine upstream pressure
signal of the pressure sensor the lower limit upstream pressure sensor. sensor and if necessary replace it, check connec-
below. tion cable and if necessary repair or replace it.
523613 0 856 1-3-4 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
523613 0 857 1-3-4 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
523613 0 858 1-3-4 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity Threshold for error detection is an internal ECU
lated by ECU is above the target range which balance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit,
injector) if necessary
523613 0 859 1-3-4 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 below the target range which metering unit on lower limit is exceeded. threshold.
(C) Change components (metering unit, injec-
tor) if necessary
523613 1 861 1-3-4 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 which based on the engine speed. threshold.
(C) Change components (metering unit, injec-
tor) if necessary
3-76 3121619
Deutz Blink
Code Code
523613 0 862 1-3-4 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
523613 2 864 1-3-4 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 pressure. threshold.
ble. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
523470 7 876 1-4-6 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. PRV can not be opened. necessary.
(B) Check high pressure pumps, pressure relief
valve and metering unit.
157 3 877 1-4-7 Rail pressure sensor: the voltage of sensor Short cut to battery. Damaged rail pressure sen- Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. sor. necessary replace it, check connection cable
157 4 878 1-4-7 Rail pressure sensor: the voltage of sensor Short cut to ground. Damaged rail pressure sen- Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. sor. necessary replace it, check connection cable
523720 8 925 1-4-8 Supply module heater: Duration of switch on Duty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out of perature duty cycle SCR_rSMT is out of the
range; Supply modul defect, fault in the wiring. failurerange (SCR_rSMFailMax_C <
SCR_rSMHtrT < SCR_rSMFailMin_C) Supply
module check and replace if necessary. Check
the wiring.
523720 8 926 1-4-8 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 valid. cycle SCR_rSMHtrT is in the valid range (SCR_r-
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
523721 11 927 6-8-9 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 avail- threshold. No erasing in the current driving
able. Supply modul defect, fault in the wiring. cycle. Supply module check and replace if nec-
essary. Check the wiring.
523722 8 928 6-9-1 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 range. SCR_tiSMPerPwm is within the specified range
Supply modul defect, fault in the wiring. of150ms to 250ms Supply module check and
replace if necessary. Check the wiring.
523722 8 929 6-9-1 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. Sup- threshold. When valid Sync followed by tem-
ply modul defect, fault in the wiring. perature information signal is received AND
valid sync and temperaturesignal for both infor-
mation is received one after the other. Supply
module check and replace if necessary. Check
the wiring.
523721 8 930 6-8-9 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 range. Sup- Check the wiring.
ply modul defect, fault in the wiring.
3121619 3-77
Deutz Blink
Code Code
523721 8 931 6-8-9 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. Supply SCR_rSMT is in the valid range (SCR_rSMTVld-
modul defect, fault in the wiring. Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure range
(SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C) Supply module check and
replace if necessary. Check wiring.
29 3 932 1-2-6 Analog accelerator pedal 2 (hand pedal): the "Sensor defect. Short cut to battery or open If the signal is below the applicatable threshold
voltage measured by ECU is out of the target loop." APP_uRawSRCHiHTLIS_C, the signal range
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 is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset after debouncing.
91 3 935 2-2-6 Analog accelerator pedal sensor 1 or double Sensor defect. Short cut to battery or open loop. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check connection
sured by ECU is out of the target range or the cable and if necessary repair or replace it. If the
calculated pedal position is implausible signal is below the applicatable threshold
compared with the position of the second APP_uRaw1SRCHigh_C, the signal range vio-
pedal lation is reset after the healing debouncing.
29 4 937 1-2-6 Analog accelerator pedal 2 (hand pedal): the Sensor defect. Short circuit to Ground. If the signal exceeds the applicatable threshold
voltage measured by ECU is out of the target APP_uRawSRCLoHTLIS_C, the signal range
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.
91 4 940 2-2-6 Analog accelerator pedal 1: the voltage Sensor defect. Short circuit to Ground. Check cabling, check accelerator pedal sensor
measured by ECU is out of the target range. and if necessary replace it, check connection
cable and if necessary repair or replace it If the
signal exceeds the applicatable threshold
APP_uRaw1SRCLow_C, the signal range viola-
tion is reset after the healing
3532 3 943 1-2-7 DEF tank level sensor: the voltage measured Short circuit to battery, broken wiring DEF tank level sensor check, wiring check The
by ECU is out of the target range. sensed raw voltage value SCR_uRawUTnkLvl is
below SCR_SRCUTnkLvl.uMax_C
3532 4 945 1-2-7 DEF tank level sensor: the voltage measured Short circuit to ground The sensed raw voltage value
by ECU is out of the target range. SCR_uRawUTnkLvl is above
SCR_SRCUTnkLvl.uMin_C DEF tank level sensor
check, wiring check
3-78 3121619
Deutz Blink
Code Code
1079 13 946 2-8-2 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 it,
power supply voltage of sensor output 1. Air Pump PresS/BrnFuelPressAfterDV2Pin K19: check connection cable and if necessary repair
Fan Speed Sensor or replace it, if error is not removable, change
Pin A21: LDF6T / OilPress / LowFuelPressPin ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speedPin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal Suspected compo-
nents EDC17cv56
Pin A21: Cam speedPin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPressPin
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 it,
power supply voltage of sensor output 2. Pin K18: Pressure DS DPF check connection cable and if necessary repair
Pin A20: Exh.PressAfterTurb/DPFDiffPress/ or replace it, if error is not removable, change
BrnDV1Press/HCIPressDV1DV2 Suspected com- ECU.
ponents EDC17cv54
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal Suspected components
EDC17cv56
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 it,
power supply voltage of sensor output 3. throttle flap check connection cable and if necessary repair
Pin K20: First footpedal or replace it, if error is not removable, change
Pin K21: Air FilterDiffPress Suspected compo- ECU.
nents EDC17cv54 and cv56
Pin A07: Rail pressure
677 3 956 5-1-2 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. Check cabling and start relay and if
get range. necessary replace it, check connection cable
677 4 957 5-1-2 Start relay (high side power stage): the cur- Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold. Check cabling and start relay and if
get range. necessary replace it, check connection cable
677 5 958 5-1-2 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
get range necessary replace it, check connection cable
3121619 3-79
Deutz Blink
Code Code
677 3 960 5-1-2 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 threshold. Check cabling and start relay and if
target range. necessary replace it, check connection cable
677 4 961 5-1-2 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
get range. necessary replace it, check connection cable of
terminal 50 and if necessary repair or replace it.
523612 14 973 5-5-5 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.
523612 14 974 5-5-5 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.
523612 14 975 5-5-5 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. If possible the software update has to
nally; no item will be created in be done. Replace the ECU.
error memory
91 11 976 2-2-6 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
repair or replace it. When the PWM period
APP_tiPWMPer is in between
APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
29 2 978 1-2-6 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.
523550 12 980 5-1-5 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. Check cabling, if sensor not working,
battery or wrong usage of Terminal 50. check start switch and if necessary replace it,
Starter control is disabled until this error is check connection cable and if necessary repair
healed. or replace it.
105 3 994 1-2-8 Charge air temperature sensor: the voltage Short circuit to battery. sensor voltage > limit The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- age) >Air_SRCTCACDs.uMin_C. Check CAC-
get range. sensor and if necessary replace it, check connec-
tion cable and if necessary repair or replace it.
105 4 995 1-2-8 Charge air temperature sensor: the voltage Short circuit to ground or open load. sensor volt- The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- age <limit. age) is below Air_SRCTCACDs.uMin_C. Check
get range. CAC-sensor and if necessary replace it, check
connection cable and if necessary repair or
replace it
3-80 3121619
Deutz Blink
Code Code
105 0 996 2-3-3 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. The warning threshold. tionality. Check cooling perfomance with tem-
ECU activates a system reaction. perature measurement.
!! If an error occurs, always check the delta P sen-
105 0 997 2-3-3 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is over the shut off threshold. shut off threshold. tionality. Check cooling perfomance with tem-
The ECU activates a system reaction. perature measurement.
412 3 1007 6-8-2 EGR downstream temperature sensor: the Short circuit to battery. sensor voltage > limit Check wiring harness to TEGR-sensor. Exchange
voltage of sensor measured by ECU is out of TEGR-sensor.
the target range.
412 4 1008 6-8-2 EGR downstream temperature sensor: the Short circuit to ground or open load. sensor Check wiring harness to TEGR-sensor. Exchange
voltage of sensor measured by ECU is out of voltage <limit TEGR-sensor.
the target range.
523960 0 1011 7-7-1 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect Intake throttle blocked in
closed position
Exhaust pressure too high Check Nox-sensor
upstream SCR catalyst dp venturi sensor defect
5763 6 1014 5-9-4 Actuator error EGR-Valve. Signal range check Short cut to batterie. Check wiring and repair or replace if necessary,
high. check actuator with SERDIA test for EGR and if
520521 5 1015 5-9-4 Actuator error EGR-Valve. Signal range check Short cut to ground. Check wiring and repair or replace if necessary,
low. check actuator with SERDIA test for EGR and if
5763 7 1016 5-9-4 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. Threshold for error detection, devia-
the flap. tion from setpoint > 7%. Troubleshooting with
SERDIA 2010 Use Case "EGR Diagnostic".
5763 6 1022 5-9-4 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 connection
cable and if necessary repair or replace it.
5763 5 1023 5-9-4 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.
5763 3 1024 5-9-4 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 connection
load. cable and if necessary repair or replace it.
3121619 3-81
Deutz Blink
Code Code
5763 4 1025 5-9-4 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 connection
cable and if necessary repair or replace it.
4769 2 1026 6-8-4 Static plausibility check: The exhaust tem- static plausibility check: sensed temperature Check ambient temaperature => value plausi-
perature value from the sensor after DOC, downstream DOC differ too much from sensed ble? T downstream DOC sensor mounted within
the exhaust temperature value from the temperature upstream DOC or sensed tempera- exhaust line?
sensor before DOC, the temperature value ture upstream SCR catalyst=> check is done if T downstream DOC sensor physically mounted
from the sensor before SCR-Cat-Cat, the difference temperature of EngDa_tEng- in correct position downstream DOC? (not
environment temperature and the coolant Air_tAFS < limit & Exh_tOxiCatUs - upstream SCR or upstream DOC?) Other T-sen-
engine temperature their ratios to each SCR_tAdapUCatUsT < Limit& Exh_tOxiCatUs- sors show plausible values?
other exceed their related thresholds. Air_tAFS < Limit & SCR_stWrmUpLstDrvCyc = No errors on them?
(difference temprature between sensor 1 & TOxiCatDs_stStatChkEna_mp = 1 in words: Check temperature difference across DOC by
befor DOC and sensor after DOC > threshold engine cold start and EAT-system had reached Exh_tSensOxiCatDs-Exh_tSensOxiCatUs: <
1 difference temperature between sensor SCR-dosing-state at least once in the last driv- 100 K?
after DOC and sensor before SCR >threshold ing cycle before that start or dynamic plausibil- Check exhaust pipe downstream turbo charger
2 difference temperature between sensor ity check against environmental temperature: for oil?
befor DOC and sensor befor SCR < threshold engine running and sensed temperature down- Too many hydrocarbons in exhaust? White
3 difference temperature between sensor stream DOC > ambient temperature + offset smoke (at hot EAT system, not at cold start)?
befor DOC and sensor environment < TOxiCatDs_tDsEnvOffsThres_C or dynamic Check air path of engine: EGR-Valve, Intake-
threshold 4 difference temperature plausibility check of temperature difference Throttle, Turbocharger, Piping for leakage and
betweenengine temperature and environ- across DOC: Exh_tSensTOxiCatDs- correct function check injectors: is an injector
ment < threshold 5) Exh_tOxiCatUs > limit, separate limits for got stuck?
Dynamic plausibility check with exhaust nomal mode, heatmode or Stand-still. Engine
temperature sensor value before DOC: The must be in operation.Which conditions sets the
difference between the exhaust tempera- D
ture sensor befor- and after DOC is large
4766 0 1029 6-8-4 The exhaust temperature value from the Sensed temperature downstream DOC > Check temperature difference across DOC by
sensor after DOC is above an applicable threshold Exh_tSensOxiCatDs-Exh_tSensOxiCatUs: <
upper shutoff threshold 100 K?
Check exhaust pipe downstream turbo charger
for oil? 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 leak-
age and correct function Check injectors: is an
injector got stuck?
Exchange temperature sensor downstream
DOC
4766 0 1030 6-8-4 The exhaust temperature value from the Suspected Components: Sensor after DOC Check temperature sensor after DOC
sensor after DOC is above an applicable defect Check the exhaust path before DOC
upper warning threshold Problems in the exhaust path before DOC DOC is Check the DOC
defect
4769 3 1034 6-8-4 Sensor error exhaust gas temperature The sensed raw voltage value Check wiring harness to temperature sensor
downstream (DOC); signal range check high Exh_uRawTOxiCatDs > downstream DOC
Exh_SRCTOxiCatDs.uMax_C Exchangetemperature sensor downstream DOC
Shortcut to battery
4769 4 1035 6-8-4 Sensor error exhaust gas temperature The sensed raw voltage value Check wiring harness to temperature sensor
downstream (DOC); signal range check low Exh_uRawTOxiCatDs < downstream DOC
Exh_SRCTOxiCatDs.uMin_C Exchangetemperature sensor downstream DOC
Shortcut to ground
3-82 3121619
Deutz Blink
Code Code
4768 2 1036 6-8-3 Static plausibility check: The exhaust tem- Static plausibility check: The exhaust tempera- Check ambient temperature => value plausi-
perature value from the sensor before DOC, ture value from the sensor before DOC, the ble? upstream DOC sensor mounted within
the exhaust temperature value from the exhaust temperature value from the sensor exhaust line?
sensor after DOC, the temperature value after DOC, the temperature value from the sen- T upstream DOC sensor physically mounted in
from the sensor before SCR-Cat, the environ- sor before SCR-Cat, the environment tempera- correct position upstream DOC? (not upstream
ment temperature and the coolant engine ture and the coolant engine temperature their SCR or downstream DOC?)
temperature their ratios to each other ratios to each other exceed their related thresh- Check T upstream DOC sensor
exceed their related thresholds. Dynamic olds. (difference between temperature after Check other T-sensors within EAT-system
plausibility check with environment tem- DOC and temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
perature sensor value: The exhaust temper- difference between temperature befor DOC and plausible values? No errors on them?
ature value from the sensor before DOC is before SCR > Threshold 2
lower than an applicable environment tem- difference between temperature after DOC and
perature 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 environ-
ment tempe
4765 0 1039 6-8-3 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC is above an applicable limit Throttle,
upper shutoff threshold Check Turbocharger and Piping each for leakage
TOxiCatUs_tShOffThresHiAds_C = Thresh- and correct function
old 1 in Normal and Heatmodes Check injectors: is an injector got stuck?
(TOxiCatUs_tShOffThresHiRgn_C = Thresh- Exchange temperature sensor upstream DOC
old 2 in stand-still)
4765 0 1040 6-8-3 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC is above an applicable limit Throttle, Turbocharger and Piping each for leak-
upper warning threshold age and correct function
TOxiCatUs_tWarnThresHi_C = Threshold Check injectors: is an injector got stuck?
Exchange temperature sensor upstream DOC
4768 3 1044 6-8-3 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 Exchangetemperature sensor upstream DOC
Shortcut to battery
4768 4 1045 6-8-3 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 below upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMin_C Exchangetemperature sensor upstream DOC
Shortcut to ground
3121619 3-83
Deutz Blink
Code Code
4360 0 1069 6-6-8 The filtered DEF cat upstream temperature is Sensed temperature upstream SCR > physical Check temperature difference across DOC
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: =>
age 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) => Dis-
mount DPF and check it visually exchange tem-
perature sensor upstream SCR
4361 3 1072 6-6-8 DEF 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
4361 4 1073 6-6-8 DEF 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
3361 6 1075 6-7-7 DEF dosing valve: the currentmeasured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect DEF dosing injection valve Check the DEF dosing injection valve
high
3361 3 1077 6-7-7 DEF dosing valve (low side power stage): the Fault in the wiring Threshold for error detection is an internal ECU
current drain measured by ECU is above the threshold
target range See substitute function
Check the wiring
3361 3 1078 6-7-7 DEF dosing valve (high 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 Check the wiring
3361 4 1079 6-7-7 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
3361 4 1080 6-7-7 DEF dosing valve (high 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 Check the wiring
4345 5 1090 6-7-4 DEF backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range Broken wiring, broken heating element in back- threshold
flow line If this error detected during the heat- Check wiring
ing phase KWP 1089 can be a result error Check heating element
4345 3 1092 6-7-4 DEF backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range Short cut to battery or broken wiring, broken threshold
heating element in backflow line Check wiring
If this error detected during the heating phase Check heating element
KWP 1089 can be a result error
4345 4 1093 6-7-4 DEF backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range Short cut to ground or broken wiring, broken threshold
heating element in backflow line Check wiring
3-84 3121619
Deutz Blink
Code Code
4343 5 1094 6-7-3 DEF pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range Broken wiring, broken heating element in pres- threshold
sure line If this error detected during the heat- Check wiring
ing phase KWP 1089 can be a result error Check heating element
4343 3 1096 6-7-3 DEF pressure line heater: the current drain shortcut to battery broken heating element in Threshold for error detection is an internal ECU
measured by ECU is above the target range pressure line If this error detected during the threshold
heating phase KWP 1089 can be a result error Check wiring
Check heating element
4343 4 1097 6-7-3 DEF pressure line heater:the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range Short cut to ground or broken wiring, broken threshold
heating element in pressure line Check wiring
523718 5 1098 6-7-6 tank heating valve: the current drain mea- Open load Threshold for error detection is an internal ECU
sured by ECU is above the target range Broken wiring, broken Valve threshold
If this error detected during the heating phase Test tank heating valve
KWP 1089 can be a result error Check cabling, if necessary replace relay.
523718 3 1100 6-7-6 DEF heater relay: the current drain measured Shortcut to battery Threshold for error detection is an internal ECU
by ECU is above the target range Broken wiring, broken relay threshold
If this error detected during the heating phase Check wiring
KWP 1089 can be a result error Check SCR main relay
523718 4 1101 6-7-6 DEF heater relay: the current drain measured Shortcut to ground Threshold for error detection is an internal ECU
by ECU is above the target range Broken wiring, broken relay threshold
If this error detected during the heating phase Check wiring
KWP 1089 can be a result error Check SCR main relay
4341 5 1102 6-7-5 DEF heater supply line: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range Broken wiring threshold
If this error detected during the heating phase Check wire harness
KWP 1089 can be a result error Check supply line
4341 3 1104 6-7-5 DEF heater supply line: the current drain Shortcut to battery Threshold for error detection is an internal ECU
4341 4 1105 6-7-5 DEF heater supply line: the current drain short cut to ground Threshold for error detection is an internal ECU
523719 5 1106 6-7-2 DEF supply module heater: the current drain Open load Threshold for error detection is an internal ECU
Heating element in supply module defect Check wiring
Check cabling, if necessary replace supply mod-
ule
523719 3 1108 6-7-2 DEF supply module heater: the current drain Short circuit to battery Threshold for error detection is an internal ECU
If this error detected during the heating phase Check cabling, if necessary replace supply mod-
KWP 1089 can be a result error ule
3121619 3-85
Deutz Blink
Code Code
523719 4 1109 6-7-2 DEF supply module heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
If this error detected during the heating phase Check cabling, if necessary replace supply mod-
KWP 1089 can be a result error ule
4366 5 1110 6-7-1 DEF tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
Urea tank heating valve defect Check wiring
If this error detected during the heating phase Check urea tank heating valve
523632 11 1117 6-6-6 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 measure-
ment has been carried out.
4375 5 1118 6-6-6 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 The hardware detects the presence of
Pump in urea supply module defect load on the PWM output power stage for the
urea pump module actuator. Check wiring.
Check pump in the urea supply module
4375 3 1120 6-6-6 Urea supply module pump: the current drain Shortcut to battery 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 The hardware detects absence of any
a result error: KWP 1089 Broken wiring Pump in short circuit to battery on the PWM output
urea supply module defect power stage for the urea pump module actuator
Check wiring.
Check pump in the urea supply module
523632 3 1127 6-6-5 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 DEF supply module defect
523632 4 1128 6-6-5 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 DEF supply module
target range. The sensed raw voltage value Pressure sensor in urea supply module defect
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
4376 5 1129 6-6-7 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 DEF supply module defect Check wiring
Check urea supply modul
3-86 3121619
Deutz Blink
Code Code
3031 0 1135 6-6-9 DEF temperature in DEF tank is to high.The Sensed urea tank temperature > physical range Case "CANBUS sensor":
DEF tank temperature sensor detects a value high limit Check urea tank temperature: really hot?
above the maximum allowed threshold Check CANBus-messageof DEF sensor urea tank
temperature Com_dRxSCR2Byt2 Compare it to
Com_dRxSCR1Byt1 (urea temperature at qual-
ity sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor Case "ana-
log DEF T & Level sensor": Check urea tank tem-
perature: 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
3031 1 1136 6-6-9 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor": Check ambient temper-
value lower than the minimum allowed low limit ature EnvT_t => About -40 °C?
threshold. If yes Error could be plausible Check CANBus-
message of DEF sensor urea tank temperature
Com_dRxSCR2Byt2 Compare it to
Com_dRxSCR1Byt1 (urea temperature at qual-
ity 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
4365 3 1138 6-6-9 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. The Sensed raw voltage value
range. SCR_uRawUTnkT is below
SCR_SRCUTnkT.uMax_C. Check wiring.
4365 4 1139 6-6-9 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. The sensed raw voltage value
range. SCR_uRawUTnkT is above
SCR_SRCUTnkT.uMin_C. Check wiring.
523612 12 1170 5-5-5 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 positive threshold.
nally; no item will be created in error mem- test failed Reflash ECU. If error is still activ replace ECU.
ory
168 1 1181 3-1-8 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, check
battery pole and if necessary c
3121619 3-87
Deutz Blink
Code Code
5763 4 1229 5-9-4 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 6 1230 5-9-4 Actuator error EGR-valve; Overload by short- Short Circuit over Load Threshold for error detection is an internal ECU
circuit threshold.
Check wiring, component
5763 11 1231 5-9-4 Actuator error EGR valve (2.9;3.6) or throttle Temperature dependent Over Current Threshold for error detection is an internal ECU
valve (4.1;6.1;7.8); Power stage overtem- threshold.
perature due to high current 3.6) throttle Check wiring, component
valve (4.1;6.1;7.8); Power stage overtem-
perature due to high current;
5763 4 1232 5-9-4 _Actuator error EGR-Valve (2.9;3.6) or Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
Throttle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold 3.6) Drosselklappe (4.1;6.1;7.8); Check wiring, component
Voltage below threshold;
523984 3 1239 7-8-8 UB7; Short circuit to battery error of actuator Suspected Components: ECU PIN A03 Because Threshold for error detection is an internal ECU
relay 7Components onPin A03 cannot be the assignment of PINs is different between the threshold.
activated. Internal ECU power stage engine series, check the connected loads in the Check wiring harness and connected loads on
switched off. motor circuit diagram pin A03. If error is still present, exchange ECU.
523986 4 1241 1-7-6 UB6; Short circuit to ground actuator relais 6 Suspected Components: ECU PIN A04 and A05 Threshold for error detection is an internal ECU
Components onPin A04 and A05 cannot be Because the assignment of PINs is different threshold.
activated. Internal ECU power stage between the engine series, check the conected Check wiring harness and connected loads on
switched off. loads in the motor circuit diagram pin A04 and A05. If error is still present,
exchange ECU.
523987 4 1242 7-9-1 UB7; Short circuit to ground actuator relay 7 Suspected Components: ECU PIN A03 Because Threshold for error detection is an internal ECU
Components onPin A03 cannot be activated. the assignment of PINs is different between the threshold.
Internal ECU power stage switched off. engine series, check the connected loads in the Check wiring harness and connected loads on
motor circuit diagram pin A03. If error is still present, exchange ECU.
2797 4 1337 5-6-5 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.
Check wiring, component, ECU Note: affected
injector has to be evaluated according to firing
order
2798 4 1338 5-6-6 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.
Check wiring, component, ECU Note: affected
injector has to be evaluated according to firing
order
2797 4 1339 5-6-5 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU Note: affected
bank 0 injector has to be evaluated according to firing
order
2798 4 1340 5-6-6 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU Note: affected
bank 1 injector has to be evaluated according to firing
order
164 2 1381 8-3-9 Rail pressure control: error during afterrun Rail pressure is still above threshold. Threshold for error detection is an internal ECU
(appears only at 2000 bar system) threshold. Reset the fault and at reappearance
check ECU and injection system
1136 0 1398 6-8-1 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
3-88 3121619
Deutz Blink
Code Code
3711 12 1455 7-1-1 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above the target tem- Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted perature towards the end of the stand-still main °C? If not: => Check air path of engine: EGR-
DPF temperature > Threshold 2 towards the phase. Valve, Intake-Throttle, Turbocharger and Piping
end of the stand-still main phase. 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)?
age 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
524057 2 1505 8-4-3 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 neces-
524074 9 1533 2-4-6 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 sensor.
Check mounting position of sensor and judge it
regarding condense water formation / agglom-
eration.
Check wiring harness Exchange sensor
524075 11 1534 2-4-7 Short circuit sensor internally at NOx-sensor Short circuit 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?
eration?
Rearrange if critical and possible
3121619 3-89
Deutz Blink
Code Code
524076 9 1535 2-4-8 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR NOx Sensors are CAN Sen- downstream SCR threshold.
sors --> no HW Pin on the ECU Check NOx-Sensor upstream SCR catalyst:
water inside?
eration.
524077 11 1536 2-4-9 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR NOx Sensors are CAN Sen- downstream SCR threshold.
sors --> no HW Pin on the ECU Check NOx-Sensor upstream SCR catalyst:
water inside?
eration.
524078 9 1537 2-5-5 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. When the filtered stream SCR catalyst is > physical high limit catalyst is physically mounted within the
Lambda concentration value at the sensor ComRxSCR_rCanLamDs_mp > threshold exhaust line
(ComRxSCR_rFltLamDs_mp) is greater than Check Lambda values of NOx-sensor down-
the physical range check max. lambda stream SCR catalystat at idle conditions,
threshold ComRxSCR_rCanLamDs_mp > 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 cat-
alyst
524079 9 1538 2-5-6 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamUs_mp.ComRxSCR_rCan
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold LamDs_mp must be 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 down-
stream SCR catalyst Check NOx-sensor down-
stream SCR catalyst wiring
itself Replace NOx-sensor downstream SCR cat-
alyst
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Deutz Blink
Code Code
524080 9 1539 2-5-7 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 exhaust
limit ComRxSCR_rCanLamUs_mp > ComRxSCR_rCanLamUs_mp > Threshold line
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
524081 9 1540 2-5-8 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 for leak-
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold age and correct function
Check injection system of engine. Injector
stuck? Check CANBus of NOx-sensor upstream
SCR catalyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524063 5 1557 8-6-9 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 3 1558 8-6-9 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
2
524063 4 1559 8-6-9 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 Load side SCR defective heating valve (Y31), broken element reset fault. If fault is still present you have to
heater main relay (K31) is a short cut to in heating. look in the wiring of Y31 to the control unit Pin
ground. Threshold 1 < A:92. If error is no longer present, you have to
SCRHtr_rUHtrMeasRatio_mp < Threshold check the wiring of Y31 via relay K31 and possi-
2 bly the heating cables and relay (K27-K30).
524063 5 1560 8-6-9 SCR relay for suction line not connected relay defect relay not connected wiring harness Check wiring, component
Threshold 1 < broken problems with supply voltage
2
524065 4 1570 8-9-2 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 sensor upstream
SCR catalyst
3121619 3-91
Deutz Blink
Code Code
524065 2 1598 8-9-2 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 environ- connector type used? pressure exchange from
ence should not exceed a certain limit mental pressure > limit inside electrical connector with the environemt
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold possible? water in sensor? sensor frozen?
old Check wiring of pressure sensor upstream SCR
catalyst Exchange pressure sensor upstream
SCR catalyst
Check intake manifold pressure sensor
(Air_pCACDs) Check ambient pressure sensor
(EnvP_p)
1761 14 1655 1-3-8 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 val-
ueor it's implausible.
2791 7 1752 4-1-5 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.
2791 2 1753 4-1-5 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 message is sent, fix the wiring. If o.k.
exchange EGR actuaror.
2791 13 1754 4-1-5 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. Start Serdia Usecase to reset EGR
failures occure. actuator. Check EGR valve and mounting situa-
tion. If o.k. change EGR actuator.
2791 12 1755 4-1-5 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.
2791 13 1756 4-1-5 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.
2791 6 1757 4-1-5 Overcurrent to EGR actuator. High voltage from battery. EGR actuator is Check battery voltage. Check if EGR is blocked or
blocked or moving very hard. not running smoothly. If everything is o.k.
change EGR actuator.
2791 3 1758 4-1-5 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
2791 4 1759 4-1-5 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
2791 13 1760 4-1-5 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. EGR valve Threshold for error detection is an internal ECU
is blocked or moving very hard. threshold. Start Serdia Usecase to reset EGR
actuator.
2791 7 1761 4-1-5 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold. Exchange EGR actuator.
2791 16 1762 4-1-5 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
2791 0 1763 4-1-5 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.
3-92 3121619
Deutz Blink
Code Code
523612 12 1857 5-5-5 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 low threshold. check other active errors and fix
released in level 2 which leads to no fuel battery voltage during start malfunction of them. check all needed engine start conditions,
injection. starter e.g. neutral switch. check the engine speed dur-
ing starting of the engine. If it's too low, then
check the battery voltage and then check the
starter for malfunction.
524147 7 1858 9-6-6 During Afterrun and draining of DEF lines, Urea pressure sensor is defect. Reverting valve is Run SERDIA use-case "injection test" to ensure
the reverting valve in the DEF supply module blocked. Urea injector is blocked. the urea injector works properly. Run SERDIA
is opened but the urea pump pressure use-case "pressure test" to ensure the lines are
increases instead of decrease, which means filled with urea and supply module is working
that the reverting valve is not working. Run SERDIA use-case "empty service". The urea
pump ressure, SCR_pAbsAdapUPmpP,must
decrease below the urea pump pressure before
the reverting valve was opened. Observe
SCR_pAbsAdapUPmpP & SCR_stURevVlv (0 =
closed, 1 = open) & SCR_rDycUdosVlv The error
heals each time after SCR system status "emp-
tying" (64) is successfully ended => debounce
time 30 s. If the error is still active, then
exchange supply module.
524175 0 1859 9-9-3 Tailpipe Nox-emissions are higher than NTE- - no DEF injection ijection of DEF with low qual - Check DEF level in tank which should be higner
Limit (2 g/kWh) and/or NRTC-Limit (0.9 g/ -ity (normal quality = 32.5%) than 12%.
kWh) - injection of non-DEF fluid - Check DEF quality ComRxSCR_rAdBlu which
shall be above 32.5%. If it's below 24, then it's
diluted urea in tank or even water => Exchange
the fluid in the tank with right DEF quality.
-Check DEF supply module: perform pressure
test => Replace supply module
-Check DEF dosing valve => perform injector
test => Clean injector with water => Repeat
injector test => Replace injector
-Check NOx sensor downstream SCR catayst:
check wiring and sensor itself. At warm engine
and warm EAT-system (SCRT_tCatAvrgExhGs >
250°C) in steady state, check sensed Nox-val-
ues: at ComRxSCR_stNOxRdyUs
&ComRxSCR_stNOxRdyDs,
ComRxSCR_rNOxUs must be >
ComRxSCR_rNOxDs. ComRxSCR_rNOxDs shall
be< 100 ppm in steady state operation. =>
Exchange NOx-Sensor downstream of SCR
catalyst
-Check engine air path: dp venturi sensor, EGR
cooler, EGR-Valve, Intake
3121619 3-93
Deutz Blink
Code Code
524178 7 1864 9-9-6 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 bar due frozen.
to malfunction in the SCR system. Suspected Check for DEF level in the tank
components: DEF pump broken Reverting valve Check DEF lines: All lines connected?
continously open Urea suction line, backflow The right lines connected to the correct places?
line broken or connection swapped PWM Pow- Suction line blocked? Is there any leakage? Not
erstage has a defect Pump Pressure sensor bro- also urea to the outside but also air into the
ken lines, especially 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
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check reverting valve Check DEF pump fil-
ter:dirt inside?
Suspected components: DEF pump broken
Reverting valve continously open DEF suction
line, backflow line broken or connection
swapped PWM Powerstage has a defect
4360 2 1865 6-6-8 Error at static plausibility check: absolut Error at static plausibility check: absolut tem- Check whether temperature sensor upstream of
temperature difference of sensed tempera- perature difference of sensed temperature SCR catalyst is physically mounted within
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient tempera- exhaust pipe
temperature > as static plausibility limit at ture > as static plausibility limit at engine cold If cold start condition can be made sure (engine
engine cold start (engine was off for at least start (engine was off for at least 8 h), tempera- was off for at least 8 h)compare values of
8 h), temperature upstream of SCR catalyst is ture upstream of SCR catalyst is expected to be EnvT_t, EngDa_tEng,Exh_TOxiCatUs,
expected to be identical to ambient temper- identical to ambient temperature => see Exh_tOxiCatDs and SCR_tSensUCatUsT at igni-
ature => see enable conditions for details. enable conditions for details. Error at dynamic tion on, without starting the engine. All identi-
Error at dynamic plausibility check: temper- plausibility check: temperature difference of cal?
ature difference of sensed temperature sensed temperature upstream SCR catalyst and Compare values of Exh_TOxiCatUs,
upstream SCR catalyst and ambient temper- ambient temperature < as dynamic plausibility Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
ature < as dynamic plausibility limit limit dynamic check is blocked if static plausibil- min in constant operation point: show all simi-
dynamic check is blocked if static plausibility ity check is already faulty => Temperature lar values (30 K tolerance width).
check is already faulty => Temperature upstream SCR catalyst must be by 40°C higher Are ambient temperature and (EnvT_t), cooling
upstream SCR catalyst must be by 40°C than ambient temperature if engine runs and a water temperature (EngDa_tEng) plausible?
higher than ambient temperature if engine certain delay time has expired. Sensor coated with urea crystalls? Dismount
runs and a certain delay time has expired. urea injector and inspect temperature sensor
upstream SCR catalyst visually Check wiring of
sensor Replace sensor
524067 2 1867 8-9-4 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 ambi- and CEngTds_tand SCR_tAdapUTnkT => All
ambient temperature ent temperature identical?
UPmpT_tDiffPmpHtrAmb_mp >threshold UPmpT_tDiffPmpHtrAmb_mp > threshold If not: Has the machine been brought from cold
environment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect Cool-
ant temperature sensor defect
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
3-94 3121619
Deutz Blink
Code Code
524067 2 1868 8-9-4 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 tem- and CEngTds_tand SCR_tAdapUTnkT => All
temperature> threshold perature UPmpT_tDiffPmpAmb_mp > thresh- identical? If not: Has the machine been brought
old from cold environment into a warm one or vice
versa without engine running, e.g. at work-
shop? Environment temperature sensor defect
Coolant temperature sensor defect
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
1761 2 1869 1-2-9 In the case the system is calucalating an DEF Suspected components: - suction unit sensor Check the suction unit sensor for communi-
injection demand and the filling level of the defect - mechanical defect at the float gauge cated values on CAN bus.
tankdoesn´t change, the diagnostic func- Check the level sensor for plausible values.
tion will detect an implausible behavior. Check mechanical damage on the floater of the
level gauge.
524152 2 1874 9-7-1 CAN message is not received for a 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 message is sor
is received the error heals. received the error heals. Check engine CAN bus
Check urea quality sensor itself Exchange urea
quality sensor
524153 2 1875 9-9-7 CAN message is not recieved for a definite CAN message is not received for a defined time Check electrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the message is sor (combined sensor with tank level and tank
is received again the error is healed. received again the error is healed. temperature)
Check engine CAN bus
Check level sensor itself Exchange suction unit
4768 2 1881 6-8-3 At engine cold start conditions the Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
sensedexhaust gas temperature down- ature downstream DOC and fixed ambient tem- sensors within the EAT system are mounted
stream DOC (Exh_tSensTOxiCatDs) has perature at ignition on exceeds a certain limit properly: Within the exhaust line and at correct
exceeded the sum of ambient temperature earlier than the difference temperature of positions.
(EnvT_t) + offset (40°C) earlier than the exhaust gas temperature upstream DOC and Check the position of the sensor upstream SCR
sensed exhaust gas temperature upstream fixed ambient temperature at ignition on. which might be physically mounted in the
of DOC (Exh_tSensTOxiCatUs). The check is wrong position. If cold start condition can be
only performed once each ignition cycle and made sure (engine was off for at least 8 h) com-
only if the start is judged a cold start. Error pare values of EnvT_t,
status is frozen for that ignition cycle. No EngDa_tEng,Exh_TOxiCatUs, Exh_tOxiCatDs
healing possible. and SCR_tSensUCatUsT at ignition on, without
starting the engine. All identical? Then the sen-
sors itself are okay. Check exhaust piping for
leakage. Check wiring of sensors Replace sen-
sors Check DOC => physicallly intact?
524190 14 1891 2-7-2 Inducement level 1 activ Not enough urea in Low DEF tank level Check DEF level in tank. If there is no DEF, refill
tank or low urea quality or hardware tam- Low DEF quality Hardware Tampering is active up to volume above the warning threshold.
pering failure is detected or hardware failure Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is detected is filled, refill with proper DEF. Check other errors
based on hardware malfunctions.
524191 14 1892 2-7-3 Inducement level 2 activ. A low DEF tank Low DEF tank level Threshold for error detection is an internal ECU
level or a low DEF quality is detected or hard- Low DEF quality Hardware Tampering is active threshold.
ware tampering(system components are Hardware Failure is active Check the DEF level in tank. If there is no DEF,
pinched off) or hardware failures as shortcut refill up above the warning level.
to battery, shortcut to ground etc. are Check DEF quality filled in the tank.
detected. Check other errors based on hardware tamper-
ing or failure.
3121619 3-95
Deutz Blink
Code Code
524193 8 1893 2-7-5 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. Stand-still mode does not reach manual: Stand-still operation finished or often
within last 500h total engine run time. The required temperature level and regeneration interrupted by driver / engine shut-off? =>
error is activated if the engine runs to many level is therefore reached after a short time Run stand-still and instruct operator Stand-still
times in Standstill regeneartion. Change oil again operation required often by soot load =>Check
and reset counter. dp DPF pressure sensor Stand-still mode does
not reach required temperature 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 system:
upstream DOC, downstream DOC If soot load
level of DPf allow it: Perform Stand-still and
check reached temperature level upstream and
downstream DOC: T upstream DOCin the range
of 480-550°C?Downstream DOC after 25 min
stand-still main phase 590°C are reached? Tem-
erature traces are steady and even? Tempera-
ture downstream DOC higher than upstream
DOC but difference does not exceed100 K?
524194 8 1894 2-7-6 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 Stand-still is required too manual: Stand-still operation finished or often
stand-still operation within 50h total motor often due to miscalculation in the soot model interrupted by driver / engine shut-off? =>
run time. The error is activated if the engine Stand-still mode does not reache temperature Run stand-still and instruct operator Stand-still
runs to much time in short Standstill level and regeneration level is therefore operation required often by soot load =>Check
regeneartion. Change oil and reset counter. reached after a short time again. dp DPF pressure sensor Stand-still mode does
not reach required temperature 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 system:
upstream DOC, downstream DOC
If soot load level of DPF allows it: Perform
Stand-still and check reached temperature
level upstream and downstream DOC: T
upstream DOCin 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 down-
stream DOC higher than upstream DOC but dif-
ference does not exceed100 K?
3-96 3121619
Deutz Blink
Code Code
3519 12 1895 2-7-7 The integrated temperature sensor of the Temperature sensor inside the UQS defect. CAN Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- Communication corrupted. Overheating of the bility. In case of improper signal, exchange the
perature than threshold DEF tank due to malfunction of the heating suction unit in the tank.
valve. Flow direction is of coolant is wrong due Check CAN bus communication for proper sig-
to mixed up the hoses routed to the heating nal. In case of improper signal, exchange the
valve. Overheating of the DEF tank due to heat suction unit in the tank.
transfer from neighbor parts. Check the function of heating valve and routing
of the hoses. The coolant flow through the heat-
ing valve must be observed according to the
shown arrow. In case all actions above are OK,
check the real temperature in the DEF tank dur-
ing worst case condition and improve the instal-
lation of the DEF tank.
3520 3 1896 2-7-8 The integrated diagnostic of the DEF quality wiring harness of UQS corrupted CAN Commu- Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery nication 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.
3520 4 1897 2-7-8 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 CAN Communication cor- threshold. Check the wiring to the suction unit
rupted in the DEF tank. Check the CAN bus communica-
tion. In case the communication is corrupt,
exchange the suction unit in the DEF tank.
3519 3 1898 2-7-7 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 CAN tank. Check the CAN bus communication of the
nized a short circuit to battery. The UQS Communication corrupted suction unit. In case the communication is cor-
Sensor is an combined sensor of tank tem- rupt, exchange the suction unit.
perature, filling grade and DEF quality and it
is also an CAN sensor --> no PIN
3519 4 1899 2-7-7 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 CAN Communication corrupted tank.Check the CAN bus communication from
nized a short circuit to ground the suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3121619 3-97
Deutz Blink
Code Code
524195 14 1900 2-7-9 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 crystallisation inspect visually the injector andthe exhaust line
5h(>300min) inside of exhaust line. The error detection for urea crystallisation upstream of SCR cata-
This will be activated if there is a standstill depends on the sensed pressure upstream of lyst: If crystallisation can be clearly seen, then
request activated by Crystalisation Monitor- the SCR catalyst and the calculated exhaust vol- stand-still must be processed. Has the engine
ing. ume flow through the mixer pipe. In case of been operated in low load for longer time? If
error is set, but no crystallisation can be found in yes, then it could be the reaoson for crystallisa-
the mixing pipe, a possible reason can be the tion. Does the NOx-Sensors work properly?
defect sensors: - exhaust pressure & tempera- Compare ComRxSCR_rNOxUs to
ture upstream of the SCR catalyst, - the ambient ComRxSCR_rNOxDs, when
pressure - the exhaust mass flow => Check air ComRxSCR_stNOxRdyUs = 1 &
path system at the engine. ComRxSCR_stNOxRdyDs = 1 (Warm 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 status "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 tub
3520 13 1907 2-7-8 Urea quality at UQS out of range the speci- Suspected components DEF quality sensor DEF Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea
qualiy
3519 13 1908 2-7-7 Temperature at UQS out of range the Suspected Components Tank heater DEF sensor Check temperature system and/or DEF quality
specified thresholds; invalid quality of the sensor
temperature
3532 3 1911 1-2-7 The DEF level value from the sensor is higher Suspected Components: UQS defect Check DEF quality and/or sensor.
than the maximum physical range threshold
Comment: tank level, temperature and
quality are measured by the UQS sensor
3532 4 1912 1-2-7 The urea quality value from the sensor is Suspected Components: UQS defect Check DEF quality and/or Sensor.
lower than the minimum physical range
threshold.
4365 3 1914 6-6-9 Internal error of DEF qualitysensor. Suspected componentes: DEF qualitysensor Check wiring harness and DEF qualitysensor
Wiring harness
4365 4 1915 6-6-9 Internal error of DEF qualitysensor. Suspected componentes: DEF qualitysensor Check wiring harness and DEF qualitysensor
Wiring harness
3936 14 1917 2-8-6 Standstill escalation by time.In case the Stand-still request ignored by the operator. Dis- Perform Stand-still. If soot load level of DPF has
standstill request will not be released within play / stand-still request lamp broken. increased too high already call service to per-
50 h by the driver this fault code will be set. form stand-still. In case the DPF soot load level
remove DPF => Exchange DPF.
3936 14 1918 2-8-6 Standstill escalation by time.In case the
standstill request will not be released within
75h by the driver this fault code will be set
and the next step for power reduction (50%
power reduction) will be activated.
Debounce Time: 0ms
3-98 3121619
Deutz Blink
Code Code
524267 14 2007 2-8-7 Announcement triggers the Inducement not used not used
Level 2
524025 8 2008 8-4-5 Max. launch time for stand still exceeded not used not used
(60min).
4171 2 2011 6-6-8 Dynamic temperatur check of temp before not used not used
SCR
524147 13 2013 9-9-6 Set together with DFC_SCRCoBldUpLoPres. Look at KWP 1639 (DFC_SCRCoBldUpLoPres) See KWP 1639 (DFC_SCRCoBldUpLoPres) In
DFC_SCRCoBldUpLoPresRst is only used for addition for See DFC_SCRCoBldUpLoPresRst:
inducement purposes. It ensures that legal Fix supply module. DFC_SCRCoBldUpLoPres &
inducement is working correctly. See DFC_SCRCoBldUpLoPresRst heal by them-
selfs if proper urea pressure was build up once If
that is not possible for some reason run service
routine number 216 to reset all DFC2Restore-
blocks
3121619 3-99
NOTES:
3-100 3121619
SECTION 4. BOOM & PLATFORM

4.1 BOOM SYSTEMS Beyond Transport - Drive Speed Cutback System
When boom is positioned beyond the Transport Position as
described in The transport position sensing system, the drive
Broken Cable Indicator System motors are automatically restricted to their maximum dis-
The boom on this model is a 5 section proportionally driven placement position (slow speed). See the Tilt Indicator System
telescopic boom. Section #2 is driven directly by the telescope for interaction with the tilt sensor.
cylinder. Section #3, #4, and #5 (fly boom) are each driven by
separate wire rope systems. Each rope system contains redun- Drive/Steer - Boom Function Interlock System
dant ropes that are capable of allowing the operator to
unknowingly continue use of the machine with a single rope (CE/AUS ONLY)
failure. These kinds of failures with the extend ropes are self The Drive/Steer - Boom Function Interlock System uses the
revealing to the operator so proper action can be taken. Fail- Transport Position Sensing System to sense when the boom
ures within section #4 and section #5 extend ropes are self and jib are out of the transport position. All controls are simul-
revealing as they are exposed on the exterior of the boom taneously functional when the booms are within the transport
where a broken rope would be obvious. Failures within section position as on the standard machine. When the boom/jib are
#3 ropes require the addition of the Broken Cable Indicator beyond the transport position, the control functions are inter-
System in order to be self-revealing to the operator. This sys- locked to prevent simultaneous operation of any boom func-
tem uses a proximity sensor to detect excessive movement of tion with drive/steer. The first function set to be operated in
the sensed rope as would be expected with a rope failure. this mode, becomes the master function set. In other words,
A broken rope detection results in illuminating the Cable while operating drive/steer functions the boom functions are
Break indicator on the platform control panel. No restrictions inoperable. Likewise, while operating boom functions drive/
are made to the functionality of the control system. It is the steer functions are inoperable.
responsibility of the operator to take the appropriate action.
Jib Stow System
Transport Position Sensing System The machine's stowed length can be reduced to facilitate
transportation on standard trailers by swinging the jib to the
The transport position sensing system uses the main boom
right using the hydraulic power of the jib stow rotator. The
angle sensors, the main boom length sensor mounted in the
control system will prevent swinging the jib unless the axles
pivot end of the main section #1boom in addition to the boom
are retracted, the boom and jib are in the transport position. If
length switch mounted on the platform end of the main base
the transport criteria are met and the operator commands jib
boom and transport proximity switches mounted to the jib fly
swing right via the jib swing function switch. The control sys-
boom to sense when the main boom and jib boom are in the
tem will retract the jib lock pin and begin to swing the jib into
position associated with high speed travel. Above transport
the stowed position. When the jib is stowed, automatic plat-
angle is recognized when the main boom (using the cylinder
form leveling is disabled, the boom is restricted to the trans-
angle sensors) is more than 5º with respect to the turntable
port position, and axle extension is disabled. This system is
and resets to within transport position when both main boom
functional only in the 500# mode of the Dual Capacity System.
angle sensors read less than 3º with respect to the turntable.
Jib telescope function will resume when the jib is nearly fully
Transport length is recognized when the main boom length
stowed alongside the main boom. Conversely, the jib must be
switch and main boom length sensor read less than 17" exten-
retracted into the transport position before the jib is allowed
sion for the main boom. Transport position is also determined
to swing left into the locked position. Once the jib reaches the
when the jib boom length switches indicate the jib is fully
inline position, and the operator is maintaining the jib swing
retracted. During failures of either the main boom length
left function switch the control system will attempt to lock the
transport switch or the main boom length sensor the main
jib lock pin. If successful, the jib lock pin lamp will illuminate
boom transport length will be determined by the remaining
continuously after the operator releases jib swing function
sensor or switch. In addition, for a failure of either jib transport
switch.
length switch, jib length will be determined by the remaining
switch.
This system is used to control the following systems:
• Beyond Transport - Drive Speed Cutback System
• Drive/Steer - Boom Function Interlock System - CE Only
• Jib Stow System
• Axle Extension System
3121619 4-1
Envelope Control System tions due to moment system violations related to forward
reach are disallowing jib functions, lift down, telescope out,
The Envelope Control System is the primary means of control-
swing, drive, and steer. The restricted functions due to
ling the stability of the machine by restricting the working
moment system violations related to backward reach are disal-
envelope of the main boom. The envelope shape, is such that,
lowing jib functions, lift up, telescope in, swing, drive and
positions of stability and structural integrity can be controlled
steer. Recognized failures within this system will result in con-
including the restriction of forward and rearward reach of the
trol by the Envelope Control System, reduced function speeds,
platform. This system uses the two main boom angle sensors,
and BCS warning light illumination. The boom will be
the main boom length sensor, and the main boom transport
restricted from leaving the transport position until the failure
length switch to continuously measure the position of the
is resolved.
main boom and control its position within the predetermined
envelope. The two main boom angle sensors measure the
angle of the main boom relative to gravity and are continu- Boom Control System (BCS) Functional Check
ously monitored for mutual agreement. The main boom (Push to Test) System
length sensor measures the length of the main boom and is
monitored for response to main telescope command and for The machine is equipped with a system for the operator to
agreement with the fixed position length switch (Main boom daily verify the proper functioning of the Boom Control Sys-
length transport switch). Violations of the main boom position tem (Envelope Control System and the Moment Control Sys-
to allowable envelope positions will result in reduced function tem). The operator is instructed to position the boom in the
speeds, BCS warning light illumination, and restriction of func- position described by the instruction decal and to then verify
tions. The platform alarm will sound and the BCS light will the control system cut out the main telescope movement at
flash with attempts to operate restricted functions. The the correct length. When the operator pushes the button
restricted functions due to envelope violations related to for- mounted on the ground control panel, the control system
ward reach are disallowing main lift down, main telescope out, compares the current moment reading in the moment system
swing, drive and steer. The restricted functions due to enve- to the moment expected for this position. If the current
lope violations related to backward reach are disallowing main moment is within allowable tolerance for the test position, the
lift up, main telescope in, swing, drive, and steer. Recognized green BCS indicator will illuminate indicating the system is
failures within this system will result in control by the Moment working properly. If the current moment is not within the
Control System, reduced function speeds, and BCS warning allowable tolerance for the test position, the red BCS indicator
light illumination. The unit will be restricted from leaving the will illuminate indicating the machine requires service by JLG
transport position until the failure is resolved. authorized service personnel before the system is used. Failure
of this test will not restrict the functionality of the machine
and will not cause a system fault. It is the operators responsi-
Moment Control System bility to take proper action. The machine can be in either
The Moment Control System is the secondary means of con- capacity mode of the dual capacity system for this system
trolling the stability of the machine. This system uses a load check.
cell pin to attach the lift cylinder of the main boom to the turn-
table. This pin is instrumented with gauges allowing the forces
in the pin to be monitored. These forces are used to compare
Controlled Arc System
the actual boom moment (force at a distance) to a predeter- The Controlled Arc System uses the envelope control sensors
mined allowable boom moment. In controlling the boom to enhance the control of the main boom within the working
moment, the position and load of the boom is controlled. The envelope. The purpose of the controlled arc system is to mini-
moment control system will detect moments larger than mize the interaction of lift functions with envelope edges and
expected as well as those smaller than expected. This effec- to increase user efficiency. This minimizes the effect of a long
tively controls the forward and rearward positions of the boom working in a comparatively narrow envelope. Because
boom. The moment control system varies the maximum the boom is permitted to extend to longer lengths at high
allowable moment based on ground slope. On level ground angles than at it is low angles, lift commands would normally
and with rated load in the platform, the allowable moments cause the boom to violate the permitted envelope while lifting
establish a working envelope slightly larger than the Envelope down or conversely require the operator to frequently com-
Control System's envelope to minimize interaction of the sys- mand telescope out while lifting to high heights. The con-
tems. With increasing ground slopes and rated load in the trolled arc system optimizes the envelope shape by
platform, the allowable moments may establish a working automatically introducing telescope in or out during “lift only”
envelope smaller than the Envelope Control System's enve- commands. Telescope flow is regulated during lift commands
lope and may result in moment violations at the extreme plat- to maintain a constant percentage of available boom length
form positions. Violations of the moment control systems (0% is always fully retracted, 100% is variable as the permitted
allowable moment will result in reduced function speeds, BCS length changes when the boom is raised). The target percent-
warning light illumination, and restriction of functions. The age will be maintained throughout the lift command whether
platform alarm will sound and the BCS light will flash with it is maintaining 0%, 100%, or any percentage in between. The
attempts to operate restricted functions. The restricted func- target percentage is established at the start of lift command or
4-2 3121619
end of manual telescope commands when using multiple not used elsewhere within the envelope or when telescoping
functions with lift. The telescope command can be used inde- out. Envelope tracking is disabled with any envelope or
pendently or in combination with other functions. Manual moment violations or failures. The envelope tracking function-
introduction of telescope will override the controlled arc sys- ality can be turned off using the manual position of the boom
tem and result in conventional control. Controlled arc will be control select switch.
disabled with any sensor failure, any moment violation, any
envelope violation, or with auxiliary power functions. The con-
trolled arc functionality can be turned off using the manual Slow Down System
position of the boom control select switch.When selected, this
When the main boom approaches the edges of the working
system active at all boom angles and lengths.
envelope, all functions (except jib and platform functions, tele-
scope in or out on the rearward edge and telescope in on the
forward edge) are automatically slowed down by the control
system to reduce the machine dynamics and improve opera-
tor control. The slow down starts within 4 feet of all edges and
is at the fully reduced speeds 2 feet from all edges. The control
system indicates to the operator this automatic introduction
of slow down by flashing the creep light on the platform dis-
play panel. This feature applies to both platform and ground
controls, however, no indication is made on the ground con-
trol panel. This is not adjustable using the analyzer.
Dual Capacity System

The Dual Capacity System on this machine is a multiple enve-
lope control system as opposed to an indication system. The
Controlled Arc Boom Movements
control system changes the working envelope and moment
limits to match the capacity select mode to either the 500#
mode or the 1000# mode. It then displays the capacity mode
Controlled Boom Angle System
on the platform and ground display panel and controls the
The Controlled Boom Angle System uses the envelope control positions of the boom within the allowable envelope for that
sensors to enhance the control of the boom by minimizing the mode. This mode is selectable by the operator with the dual
interaction of swing and drive functions with the envelope capacity select switch on the platform control panel. The 500#
edges. This interaction is due to two factors. First, the envelope
mode has the largest envelope. The 1000# mode has a smaller
is controlled relative to gravity regardless of ground slope and
envelope and requires the jib to be retracted fully. To select
second, the turntable/boom mounting is effected by swing
and drive functions when the ground slope varies. This can the 1000# mode the boom must already be in the smaller
cause the boom position to vary within the envelope or even 1000# envelope. When the operator selects the 1000# mode
violate the envelope edges when swinging or driving without and this condition is met, the capacity light changes from 500#
intentionally moving the boom. The controlled boom angle to 1000# and the envelope and permitted moment values are
system minimizes this effect by automatically introducing lift changed accordingly. When the operator selects the 1000#
up or down during swing and drive commands to maintain a mode and this condition is not met, both capacity lights will
constant boom angle relative to gravity for all boom angles flash, the platform alarm will sound, and all functions will be
greater than 8 degrees. Controlled boom angle is disabled disabled until the capacity select switch is put back into the
with any envelope or moment violations or failures. The con- 500# position.
trolled boom angle functionality can be turned off using the
manual position of the boom control select switch.
Swing Speed Proportioning
Envelope Tracking Swing Speed Proportioning uses the boom length and angle
sensors to improve the comfort, speed and control of the turn-
The Envelope Tracking System uses the envelope control sen-
sors to enhance the control of the boom within the working table swing function. Turntable swing speed is increased as
envelope. Due to the shape of the working envelope, the max- the distance of the platform to the center of rotation is
imum boom angle varies with telescope length. To maintain decreased. This results in approximately constant platform
unrestricted operation of the boom, the lift down function is speeds regardless of boom position. Swing speed proportion-
automatically introduced while telescoping in only when the ing is disabled with any envelope sensors failure. Disabling of
boom is on the rearward edge of the envelope. This only swing speed proportioning will default to the slowest swing
occurs when telescoping in along the rearward edge and is speed setting.
3121619 4-3
Platform Load Sensing System Boom Control Select

The Platform Load Sensing System (LSS) consists of 1 load cell The boom control select switch is mounted on the platform
and 2 linkages mounted to the platform rotator and replaces control panel and allows the operator the ability to select
the platform support on machines that get this optional instal- between two different modes of boom control functionality:
lation. The load cell includes a sealed circuit and is connected automatic and manual. While in either mode, the envelope
directly to a CAN-based platform control panel within the plat- control system and moment control system remains active.
form box. This system compares the capacity mode (500# or
When the boom control is selected to the automatic boom
1000#) recognized by the dual capacity system to the mea-
control position, lift and telescope movements are coordi-
sured weight in the platform. When the capacity is exceeded,
nated by the control system as described in the controlled arc,
or when there is a fault in the system, the platform overload
controlled boom angle, and envelope tracking descriptions.
indicator will flash, the platform alarm will sound at the rate of
These systems will remain active to automatically assist the
5 sec on, 2 sec off and all platform controls (except auxiliary
operator in keeping the boom within the envelope boundar-
power) will be disabled. For CE Market, the ground controls are
ies. When operating in the automatic mode, the following
also affected.
functionality characteristics should be noted.
Electronic Platform Leveling • While operating Lift Up, the boom may also telescope out
The electronic platform leveling system uses two tilt sensors (controlled arc)
(mounted on either side of the platform rotator), a control • While operating Lift Down, the boom may also telescope in
valve (mounted to the platform support), a level cylinder, and (controlled arc)
the platform control module (mounted in the platform control
• While operating Swing or Drive, the boom may lift up or lift
box) to automatically measure and control the incline of the
down (controlled boom angle)
platform with respect to gravity. While in the automatic posi-
tion of the boom control select platform leveling is active • While operating Telescope In, the boom may lift down
while operating drive, telescope, main lift, jib lift or swing and when at high boom angles and the creep light is flashing
is not active while operating any other function (e.g. rotate, jib, (envelope tracking)
or steer). While in the manual position of the boom control
In addition, when the boom control is selected to the auto-
select platform leveling is active while operating main lift and
matic position, the automatic platform leveling feature is
jib lift only. The system controls the platform angle relative to
active during lift, telescope, swing, and drive movements as
gravity using a set point established during power-up (cycling
described in the electronic platform leveling system descrip-
of the EMS) or at the conclusion of a manual platform level
tion.
override by the operator using the platform level override
switch from either the platform or the ground control. In other When the boom control is selected to the manual position, lift
words the operator can choose a platform incline other than and telescope movements are controlled separately by the
level with gravity and the system will maintain that incline operator effectively turning off the controlled arc, controlled
automatically. If a fault occurs in the platform leveling system boom angle, and envelope tracking systems. Without these
the following will occur: systems being active, the control system will stop the move-
ments of the boom when the envelope boundaries are
• Automatic platform leveling will stop (except when there is
reached and the functions that could violate the envelope will
a fault in only one sensor)
be restricted. The platform alarm will sound and the BCS light
• The platform level fault indicator will flash will flash with attempts to operate a restricted function. In
addition, when the boom control is selected to the manual
• The platform alarm will sound
position, the automatic platform leveling feature is active only
• All functions will default to creep speed if in platform mode during lift movements.
and the boom is out of the transport position
To reset the fault the emergency stop switch should be recy-
cled.
4-4 3121619
Platform Control Enable System Boom Recovery Mode

The platform controls make use of a time dependent enable Boom Recovery Mode allows the boom to be lifted down and
circuit to limit the time availability of “live” or enabled controls. telescoped in, in the event CAN bus communication is lost to
To operate any directional function, the footswitch must be both the Jib Control Module and the Platform Module.
depressed before activation of the function. When the foot-
Boom Recovery Override is only available in the event the
switch is depressed, the controls are enabled and the operator
ground module loses CAN communication with both the Jib
has 7 seconds to operate any function. The controls will
Control Module and the Platform module, in the case of a sev-
remain enabled as long as the operator continues to use any
ered boom cable for example. This mode allows the boom to
function and will remain enabled 7 seconds after the last func-
be lifted down and telescoped in.
tion has been used. While the controls are “live”, the enabled
light will be illuminated in the platform display panel. When Boom Recovery override is accessible in Access Level 1. Using
the time limit has been reached, the enabled light will turn off
and the controls will be “dead” or disabled. To continue use of
the Left and Right arrow keys until the screen
the machine the controls must be re-enabled to start the timer
shown below is reached.
system over again. This is done by releasing all functions, then
releasing and re-depressing the footswitch.
3121619 4-5
Press ENTER , the screen should read: Use the Left or Right arrow key until you see:
To enable the override mode 58237 must be entered as the

code. When the code is entered, the screen will show:
Press Enter . Once Enter is pressed using the Up
or Down arrow key will turn the boom recovery

on or off. Once turned on, main boom lift down will be
enabled and main telescope in will be enabled to recover the
boom. After the boom is brought down it will be trapped into
transport. Reset or turning it off is achieved by escaping out of
the service mode, by cycling power to the machine, or re-
entering the service mode and manually turning it off.
4-6 3121619
4.2 PLATFORM NOTE: The platform support weighs approximately 125 lbs.
(56.8 kg).
Platform/Support Removal 3. Using a suitable device, support the platform support.

4. Remove the bolts and locknuts securing the support to
the rotator.
CENTER BOLT
BOLT
ROTATOR
LOCKNUT
MAF09580
MAF09600
Figure 4-1. Location of Components
1. Disconnect electrical cable from control console. 5. Using a suitable brass drift and hammer, remove the
center bolt and locknut.
NOTE: The platform weighs approximately 441 lbs. (200 kg).
2. Remove the bolts securing the platform to the platform

support, then remove the platform.
MAF09610
6. Remove the platform support from rotator.

MAF09590
3121619 4-7
Platform/Support Installation 5. Using a suitable lifting device., position the platform on

the platform support and install the bolts securing the
NOTE: The platform support weighs approximately 125 lbs. platform to the platform support. See Figure 4-2. and
(56.8 kg). Figure 4-3.
1. Using a suitable device, support the platform support

and position it on the rotator.
2. Install the rotator center bolt and locknut.
MAF09590
6. Connect the electrical cable to the platform control con-

sole.
MAF09610
3. Apply JLG Threadlocker P/N 0100011 to the eight bolts

securing the support to the rotator and install the bolts.
MAF09600
4. Torque the nut on the rotator center bolt and the retain-
ing bolts. See Figure 4-2. and Figure 4-3.
NOTE: The platform weighs approximately 441 lbs. (200 kg).
4-8 3121619
NOTE: If any rotator bolts are replaced, all bolts on the

rotator should be retorqued.
A,B,D
C,D
MAF09620
A Torque to 35 ft. lbs. (50 Nm)

B JLG Threadlocker P/N 0100011
C Torque to 480 ft. lbs. (651 Nm)
D Check torque every 150 hours of operation
E Torque to 85 ft. lbs. (116 Nm)
F Torque to 50 ft. lbs. (68 Nm)
Figure 4-2. Platform Support Torque Values (without LSS and with 4 Cell LSS)
3121619 4-9
NOTE: If any rotator bolts are replaced, all bolts on the

rotator should be retorqued.
A,B,D
C,D
MAF09630
A Torque to 35 ft. lbs. (50 Nm)

B JLG Threadlocker P/N 0100011
C Torque to 586 ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque to 74 ft. lbs. (100 Nm)
Figure 4-3. Platform Support Torque Values (with 1 Cell LSS)
4-10 3121619
4.3 ROTATOR Installation

NOTE: The rotator approximately weighs 230 lbs. (104 kg).
Removal
1. Remove the Platform and Platform Support. Refer to NOTE: The jib lift cylinder approximately weighs 194.7 lbs.
Section 4.2, Platform. (87.6 kg).
2. Tag and disconnect hydraulic lines to rotator. Use 1. Supporting the rotator and jib lift cylinder, align rotator
suitable container to retain any residual hydraulic fluid. with jib lift cylinder and jib. Using a soft head mallet,
Cap or plug all openings of hydraulic lines and ports. install pin #1 to the jib assembly. Install hardware secur-
ing pin #1.
NOTE: The rotator approximately weighs 230 lbs. (104 kg).
2. Using a soft head mallet install pin #2 to jib assembly
NOTE: The jib lift cylinder approximately weighs 194.7 lbs. and install the rotator. Install hardware securing pin #2.
(87.6 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
tagged during removal.
4. Remove the hardware from pin #2. Using a suitable
brass drift and hammer, remove pin #2 and remove the
rotator.
3121619 4-11
JIB LIFT CYLINDER
PIN 1
PIN 2
ROTATOR
MAF09640
Figure 4-4. Rotator Removal/Installation
4-12 3121619
4.4 BOOM REMOVAL AND INSTALLATION
Removal
1. If necessary, remove the platform.
2. If necessary, remove the jib.
3. Tag and disconnect hoses T2 T3, 7, 8, and Pressure Filter
lines from the main valve. Cap or plug all openings.
3121619 4-13
Figure 4-5. Boom Hydraulic System
4-14 3121619
4. Tag and disconnect all electrical lines from the limit 9. Carefully lift the boom from the machine, taking care to
switches and generator that go to from the turntable to feed the hydraulic and electrical lines up alongside the
the powertrack. boom as it is raised.
Installation
1. Lift the boom almost into position.
2. Feed the hydraulic hoses and electrical lines down
alongside the hood.
3. Loosely connect the powertrack end. Remember to
5. Elevate the boom enough to remove the upper lift cylin- tighten the bolts the rest of the way when installation is
der pin. Use an overhead crane or similar lifting device complete.
to support the weight of the boom.
6. Using an adequate lifting device, support the weight of
the lift cylinder and remove the lift cylinder pin. Lower
the lift cylinder down until it rests on the boom rest.
4. Lower the boom into position and install the boom

pivot pin.
7. Use an overhead crane or similar lifting device to sup-

port the rear of the boom.
8. Remove the boom pivot pin.
3121619 4-15
5. Raise the front of the boom enough to allow connection 4.5 BOOM ASSEMBLY
of the lift cylinder.
Assembly
NOTE: Throughout this procedure, boom sections are identified
numerically, 1-5. Boom Section 1 is at the base, Boom Sec-
tion 5 is the fly.
NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042)

is to be moderately applied to all four inner surfaces of
both ends of each boom section to a minimum depth of
three to four feet and also to the end of section 5 that is
inserted into section 4.
NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042)

is to be moderately applied to all outer surfaces of interior
wear pads after they are assembled to the insertion end of
boom sections. Care should be taken to avoid application
6. Attach a lifting strap to the lift cylinder. Raise the lift cyl- on exposed painted surfaces of the fully extended boom.
inder into place and install the lift cylinder pin.
AVOID APPLICATION
ON EXPOSED
PAINTED SURFACES
WEAR PAD
SURFACES
NOTE: Boom section 5 weighs approximately 1682 lbs. (763 kg).
7. Connect the hydraulic lines as tagged during removal. 1. Place boom section 5 on a proper supporting device.
8. Connect the electrical lines as tagged during removal.
9. If removed, install the jib.
10. If removed install the platform.
4-16 3121619
2. Install the side rear wear pads and shims. Coat the 5. Install the section 5 extend ropes into the mounting
retaining bolts with JLG threadlocking compound P/N holes in the bottom of section 5. Place tape over the
0100011 and secure the wear pads with the bolts and holes to keep the cables in place during assembly as
washers. Torque the bolts to 40.5 ft.lbs. (55 Nm). shown.
3. Install the top and bottom rear wear pads and shims.
Coat the retaining bolts with JLG threadlocking com-
pound P/N 0100011 and secure the wear pads with the
bolts and washers. Torque the bolts to 40.5 ft.lbs. (55
Nm).
4. Install the section 5 retract ropes to into the holes in the

side of section 5. Place tape over the holes to keep the
cables in place during assembly as shown.
3121619 4-17
4-18
Figure 4-6. Boom Assembly - Sheet 1 of 9
3121619
3121619
4-19
4-20
3121619
3121619
4-21
4-22
3121619
3121619
4-23
4-24
3121619
3121619
4-25
4-26
3121619
3121619
Figure 4-15. Locations for Threadlocker Application - Sheet 1 of 5
4-27
4-28
3121619
3121619
4-29
4-30
3121619
3121619
4-31
4-32
Figure 4-20. Boom Assembly Torque Values - Sheet 1 of 4
3121619
3121619
4-33
4-34
3121619
3121619
4-35
6. Place boom section 4 on a proper supporting device. 10. Install the wire rope retainer blocks to the front of sec-
tion 4 boom using the washers, bolts, and nuts.
7. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4

sides of the boom approximately 3 to 4 feet on both
ends. Apply Super Lube® to section 5 on the end that
will go into section 4 only. Apply super lube to all outer 11. Install the bottom front wear pads and shims to section
surfaces of interior wear pads after they are installed. 4. Coat the retaining bolts with JLG threadlocking com-
8. Avoid getting super lube on painted surfaces. Slide sec- pound P/N 0100011 and secure the wear pads with the
tion 5 into section 4 using adequate lifting equipment. bolts and washers. Torque the bolts to 43 ft.lbs. (58 Nm).
12. Install the front side wear pads and shims to section 4.
bolts and washers. Torque the bolts to 28 ft.lbs. (38 Nm).
13. Install the front bottom wear pad and shims to section 4.
14. Install the front top wear pads and shims to section 4.
15. Install the rear top wear pads and shims to section 4.
NOTE: Apply a thin coat of moly paste (JLG P/N 3020039) on the pound P/N 0100011 and secure the wear pads with the
inside diameter of the sheave bearing before installation of bolts and washers. Torque the bolts to 28 ft.lbs. (38 Nm).
sheaves.
16. Install the section 4 retract wire ropes to the rear of sec-
NOTE: Ensure the wire ropes remain untwisted through boom section 4.
tion 4.
NOTE: The retract wire ropes must be installed before side wear
9. Install the sheaves to the front of section 4. Apply JLG pads are installed.
threadlocking compound P/N 0100011to the bolts and
use the bolts, pins, keepers, and washers to secure the 17. Install the rear side wear pads and shims to the outside
sheaves. Route the wire rope around the sheaves. of section 4. Coat the retaining bolts with JLG thread-
locking compound P/N 0100011 and secure the wear
pads with the bolts and washers. Torque the bolts to
40.5 ft.lbs. (55 Nm).
18. Install the rear side wear pads to the inside of section 4.
4-36 3121619
19. Install the rear bottom wear pads to the outside of sec- 22. Install the section 4 extend ropes to section 4.
tion 4. Coat the retaining bolts with JLG threadlocking
compound P/N 0100011 and secure the wear pads with
the bolts and washers. Torque the bolts to 28 ft.lbs. (38
Nm).
20. Coat the inside diameter of the sheave bushings with
moly paste and install the wire rope sheaves to the rear
of section 4 boom using the bushings.
23. Place boom section 3 on a proper supporting device.
21. Coat the sheave retaining bolts with JLG Threadlocker P/

N 0100019 and the sheave plate/retainer block retaining
bolts with JLG Threadlocker P/N 0100011. Install the
sheave plate and rope retainer blocks to the rear of sec-
tion 4 using the retaining bolts. Torque the sheave
retaining bolts to 178 ft.lbs. (241 Nm). Torque the sheave
plate/retainer block bolts to 40.5 ft.lbs. (55 Nm)
ends. Apply Super Lube® only to the insertion end of
section 4. Apply Super Lube® to all outer surfaces of inte-
rior wear pads after they are installed. Avoid getting
Super Lube® on painted surfaces. Slide the section 4/
section 5 assembly into section 3 using proper lifting
procedures. The section 5 end of the section 4/5 assem-
bly must be raised after section 4 is inserted in section 3
to allow the four extend rope anchors to clear the top of
the four extend sheave mounts at the section 5 end of
section 3.
3121619 4-37
25. Install the fixed sheave shields, and deflector sheaves 27. Coat the bolts with JLG Threadlocker P/N 0100011 and
using the retaining bolts and washers. Coat the bolts install the section 5 extend ropes to section 3 using nuts,
with JLG Threadlocker P/N 0100011 before installation. keeper plates, bolts, and washers.
Torque the bolts to 28 ft.lbs. (38 Nm).
28. Coat the bolts with JLG Threadlocker P/N 0100011 and
install the front bottom wear pads to section 3 using
washers, bolts, and shims. Torque the bolts to 43 ft.lbs.
26. Coat the bolts with JLG Threadlocker P/N 0100011 and (58 Nm)
install the section 5 retract ropes to section 3 using the
nuts, keeper plates, bolts, and washers.
4-38 3121619
29. Apply a thin coat of moly paste on I.D. of sheave bear- washers, bolts, and shims. Torque the bolts to 28 ft.lbs.
ings. Coat the bolts with JLG Threadlocker P/N 0100011 (38 Nm))
and install the sheaves to the front of section 3 using the
pin, keeper, bolt, and washer.
30. Coat the bolts with JLG Threadlocker P/N 0100011.
Install the rope retaining blocks to the front of section 3
using washers, bolts, and nuts.

Install the front side wear pads to section 3 using wash-
ers, bolts, and shims. Torque the bolts to 28 ft.lbs. (38
Nm).

Install the front upper wear pads to section 3 using
3121619 4-39
33. Coat the bolts with JLG Threadlocker P/N 0100011. 43. Install the adjustment nuts and lock nuts to the section
Install the rear upper wear pads to section 3 using wash- 4 extend ropes.
44. Install the rope adjustment bracket to section 2 using
Nm).
washers, bolts, and nuts as shown.
Install the outer rear side wear pads to section 3 using
Install the section 4 return ropes to the rope adjustment
bracket on section 2 using washers, bolts, keepers, and
(38 Nm).
nuts.
Install the rear inner side wear pads to section 3 using
Install the sheave deflectors to the rope adjustment
washers, and bolts. Torque the bolts to 28 ft.lbs. (38 Nm)
bracket on section 2 using nuts, bolts, and washers.
Install the bottom rear wear pad to section 3 using
Install the front side wear pads to section 2 using wash-
washers and bolts. Torque the bolts to 28 ft.lbs. (38 Nm).
37. Apply moly paste to the I.D. of the sheave bearings. Nm)
Install the sheaves to section 3.
38. Coat the two sheave center bolts with JLG Threadlocker Install front top wear pads to section 2 using washers,
P/N 0100019 and the sheave plate retaining bolts with bolts, and shims. Torque the bolts to 28 ft.lbs. (38 Nm)
JLG Threadlocker P/N 0100011. Install the sheave plates
and rope retainer blocks to section 3 using the retaining
Install the rear top wear pads to section 3 using washers,
bolts. Torque the sheave center bolts to 178 ft.lbs. (241
bolts, and shims. Torque the bolts to 28 ft.lbs. (38 Nm).
Nm). Torque the sheave plate retaining bolts to 41 ft.lbs.
(55 Nm) 50. Coat the bolts with JLG Threadlocker P/N 0100011.
Install the rear side wear pads to section 2 using wash-
ers, bolts, and shims. Torque to 28 ft.lbs. (38 Nm).
Install the section 3 retract ropes to the rear of section 3
using washers, bolts, and pads. Torque the bolts to 28
ft.lbs. (38 Nm).

will go into section 2 only. Apply super lube to all outer
surfaces of interior wear pads after they are installed.
Slide sections 3,4, and 5 as an assembly into section 2
using proper lifting procedures.
Install the wear pads to section 2 using the bolts and
washers. Torque the bolts to 43 ft.lbs. (58 Nm).
4-40 3121619
51. Apply moly paste to the I.D. of the sheave bearings. 57. Coat the bolts with JLG Threadlocker P/N 0100011.
Install the sheaves to section 2 boom. Install the front bottom wear pads to section 1 using
52. Coat the two sheave center bolts with JLG Threadlocker
(55 Nm).
P/N 0100019 and the sheave plate retaining bolts with
JLG Threadlocker P/N 0100011. Install the sheave plates 58. Coat the bolts with JLG Threadlocker P/N 0100011.
and rope retainer blocks to section 2 using the retaining Install the front side wear pads to section 1 using wash-
bolts. Torque the sheave center bolts to 178 ft.lbs. (241 ers, bolts, and shims. Torque the bolts to 43 ft.lbs. (58
Nm). Torque the sheave plate retaining bolts to 41 ft.lbs. Nm).
(55 Nm)
53. Coat the bolts with JLG Threadlocker P/N 0100011. Install the front top wear pads to section 1 using wash-
Install the bottom rear wear pad to section 2 using ers, bolts, and shims. Torque the bolts to 28 ft.lbs. (38
washers, and bolts. Torque the bolts to 28 ft.lbs. (38 Nm).
Nm)
NOTE: Boom section 1 weighs approximately 6045 lbs. (2742 kg). Install the cover to the section 1.
NOTE: Center the cover over the hole in section 1.

61. Install the cover to side section 1 boom.
62. Coat the bolts with JLG Threadlocker P/N 0100011 and
install the boom length bracket.
63. Route cables and hose’s out thru the power track.

will go into section 1 only. Apply super lube to all outer
surfaces of interior wear pads after they are installed.
Slide sections 2.3,4, and 5 as an assembly into section 1
using proper lifting procedures.
NOTE: Position the deflectors so the surface is 3-4 mm from the

section 2 bottom plate.

Install the section 3 retract ropes to section 1 using
deflectors, bolts, nuts, washers, and keepers.
3121619 4-41
4.6 TELESCOPE CYLINDER 4. Remove the bolts securing the adjustment mount and
disconnect the adjustment mount from boom section 1.
Removal
1. Remove the boom from the machine. Refer to Section -
Boom Recovery Mode.
2. Remove the bolts and shims securing the telescope cyl-
inder rod trunnion blocks to boom section 1 and
remove the trunnion blocks. Using a hydraulic power
supply, extend the telescope cylinder out of boom sec-
tion 1.
5. Carefully pull the cylinder and ropes from the boom

assembly until there is access to the extend rope sup-
port. As the cylinder and ropes are removed from the
assembled boom, do not allow slack to accumulate in
the ropes between the rope support and the sheaves on
the cylinder assembly. The rope adjuster mount must
travel at twice the rate the cylinder is extracted to con-
trol slack.
3. Remove the bolts and shims securing the telescope cyl-

inder barrel trunnion blocks to boom section 2 and
remove the trunnion blocks.
4-42 3121619
6. Remove the bolts securing the extend rope support and 4.7 BOOM SHIMMING PROCEDURE
disconnect the support from boom section 3.
NOTE: Throughout this procedure, boom sections are identified
numerically, 1-5. Boom Section 1 is at the base, Boom Sec-
tion 5 is the fly.
1. Measure and record any sweep dimension and direction

of Boom Section 5 per spec drawing 1280284 and
record in Quality logbook. Measure and record the
inside width and inside height of the Boom Section 4
opening.
2. Install the Internal Side wear pads on the Section 5 sides

and shim as required to match the corresponding
dimension recorded in step 1 within plus or minus 1/32”.
Shims should be divided as evenly as possible between
the side pads unless corrections are needed to compen-
sate for any sweep recorded in step 1. If the sweep is to
the left the internal side pads on the right should have
more shims than the left side pads and vice-versa.
NOTE: When installing wear pads in the following steps, the wear
pad bolt lengths may need to be adjusted as shim thick-
nesses are adjusted. Bolt lengths should be flush to one
thread below the surface of the insert.
3. Install the bottom wear pad(s) on Section 5 boom as

specified on the boom assembly drawing.
4. Install the top wear pad(s) on Section 5 boom and shim

as required to obtain the total dimension 0” to1/16”
under the corresponding dimension in step 1.
7. Carefully remove the telescope cylinder and ropes from 5. Slide Section 5 into Section 4 with 2 to 6 feet exposed.
the boom assembly.
6. Install the bottom wear pad(s) onto the end of Section 4
as specified on the boom assembly drawing.
7. Temporarily insert the External Side pads on one side

and slide Section 5 boom to that side. Insert the other
side pads using shims measure how many will be
required to fill the remaining space. Once this is estab-
lished, install the total amount of shims as evenly as pos-
sible between the two sides unless corrections are
needed to compensate for out of square booms or for
additional corrections for any sweep recorded in step 1.
Care should be taken to keep the bottom pads evenly
loaded while shimming the side pads. If the sweep is to
the left the external side pads on the left should have
more shims than the right side pads and vice-versa.
NOTE: Do not use a wedge to install more shims than will fit with
the use of a pry bar. This may result in a boom being
shimmed too tight. The use of pry bars should only be used
to finish installing a shim that can be installed by hand
more than ½ of its length.
8. Install the top wear pads and shims into the end of Sec-
tion 4 leaving a gap of 0” to 1/16” between the top of
the Section 5 and the pad inside Section 4.
3121619 4-43
9. Repeat steps 1-7 above to install the Section 5/4 assem- 4.9 BOOM CLEANLINESS GUIDELINES
bly into boom Section 3.
The following are guidelines for internal boom cleanliness for
10. Repeat steps 1-7 above to assemble the Section 5/4/3 machines that are used in excessively dirty environments.
assembly into Section 2.
1. JLG recommends the use of the JLG Hostile Environment
11. Repeat steps 1-7 above to assemble the Section 5/4/3/2
Package if available to keep the internal portions of a
assembly into Section 1.
boom cleaner and to help prevent dirt and debris from
12. Complete the boom and machine assembly. The boom entering the boom. This package reduces the amount of
should be functionally tested and evaluated for boom contamination which can enter the boom but does not
sweep. If necessary, the boom may be re-shimmed by eliminate the need for more frequent inspections and
moving shims from one side to the other to further cor- maintenance when used in these types of environ-
rect any remaining boom sweep. There may be some ments.
instances where no shims are used under a given side
pad to pass the criteria for boom sweep at final inspec- 2. JLG recommends that you follow all guidelines for ser-
tion of machine. vicing your equipment in accordance with the instruc-
tions outlined in the JLG Service & Maintenance Manual
for your machine. Periodic maintenance and inspection
4.8 BOOM LUBRICATION APPLICATION is vital to the proper operation of the machine. The fre-
quency of service and maintenance must be increased
This procedure applies to booms after assembly or as neces-
as environment, severity and frequency of usage
sary using Super Lube® lubricant (JLG p/n 3020042).
requires.
NOTE: This procedure should also be performed when the tele-
3. Debris and foreign matter inside of the boom can cause
scope in or telescope out functions are not operating
premature failure of components and should be
smoothly.
removed. Methods to remove debris should always be
done using all applicable safety precautions outlined in
1. Position the boom on the boom rest using the 500lb the JLG Service & Maintenance Manuals.
capacity setting.
4. The first attempt to remove debris from inside the boom
2. Telescope main boom section as far as it will extend at
must be to utilize pressurized air to blow the debris
this position, approximately 3 ft. (0.9 m).
toward the nearest exiting point from the boom. Make
3. From the front of the machine (boom pivot end), moder- sure that all debris is removed before operating the
ately apply lubricant to the interior surfaces of boom machine.
sections 1, 2, 3, and 4. To prevent misdiagnosis of
hydraulic leaks, take care to prevent excessive applica- 5. If pressurized air cannot dislodge the debris, then water
tion of lubrication. with mild solvents applied via a pressure washer can be
used. Again the method is to wash the debris toward the
4. At the rear of the machine, apply lubricant to the side, nearest exiting point from the boom. Make sure that all
top and bottom surfaces of boom sections 5, 4, 3, and 2 debris is removed, that no “puddling” of water has
specifically to wear pad contact paths. To prevent misdi- occurred, and that the boom internal components are
agnosis of hydraulic leaks, take care to prevent excessive dry prior to operating the machine. Make sure you com-
application of lubrication. ply with all federal and local laws for disposing of the
wash water and debris.
5. After application of the lubricant is complete, cycle the
boom through its full range of travel 2 times. 6. If neither pressurized air nor washing of the boom dis-
lodges and removes the debris, then disassemble the
boom in accordance to the instructions outlined in the
JLG Service & Maintenance Manual to remove the
debris.
4-44 3121619
4.10 HOSE ADJUSTMENT PROCEDURE 5. With clamp D set, pull the hoses and cables until they
are resting against the flat bars on the outside radius of
1. Load the hoses and cables into the powertracks and the power track. Force additional hydraulic hose slack
push tubes according to Figure 4-56., Powertrack Hose into the power track by pushing the hoses from the
Installation - Sheet 4 of 4. Location E. Tighten the clamp at location E.
6. While maintaining the hose and cable configuration
2. Adjust the hose and cable lengths at the fly nose clamp shown in Figure 4-56., Powertrack Hose Installation -
(Location A) per their respective drawings and install Sheet 4 of 4, insert a tool to ensure the minimum bend
clamp. Tighten the clamp at the end of the top push radius of 4 inches is not being violated as the hoses are
tube (Location B). Each clamp is considered tight when routed into the trays at location E. Once adjusted,
the contained hoses and cables cannot be moved. tighten the clamp at Location F and remove the tool.
Check additional lengths of the hoses and cables
3. With clamp B set, pull the hoses and cables until they are against the pull lengths listed on their respective draw-
resting against the flat bars on the outside radius of the ings.
power track. Force additional hydraulic hose slack into
the power track by pushing the hoses from the Location 7. Attach all hydraulic hoses and pressurize the hoses by
C. Tighten the clamp at location C. dead heading a function. Check hose clearance in both
power tracks. There should be clearance between the
4. While maintaining the hose and cable configuration hoses and the inside rollers or flat bars. Release the func-
listed in Figure 4-56., Powertrack Hose Installation - tion.
Sheet 4 of 4, insert a tool to ensure the minimum bend
8. If the hoses were in contact, loosen the clamps and pull
radius of 4 inches is not being violated as the hoses are
additional length from the lower clamp (additional
routed into the push tube at location C. Once adjusted,
length at location B should be pulled through clamp C,
tighten the clamp at Location D and remove the tool.
additional length at location D should be pulled
through clamp E). Steps 3 thru 7 should be followed
when adjusting the hoses.
9. Repeat steps 7 and 8 until there is no contact between
the hoses and the inside radius of the power track.
3121619 4-45
Figure 4-24. Hose Adjustment
4-46 3121619
Figure 4-25. Section 3 Boom Cables
3121619 4-47
4-48 3121619
3121619 4-49
Figure 4-28. Jib Hydraulics - Sheet 1 of 7
1001157243-D
MAF09080D
4-50 3121619
3121619
PLATFORM LEVEL
V2 V1 CYLINDER
JIB TELESCOPIC CYLINDER
V2 V1
V2 V1
JIB LIFT CYLINDER
V1
V2
T
FRONT VIEW OF
PLATFORM CONTROL VALVE
TB JB
P
JA
TA
JIB STOW ROTATOR T2 L2

T2 L1
T3
R1 R2
P2
T1 S1 S2
SA LA
SB LB
V1
T
V2
FRONT VIEW
JIB CONTROL VALVE
X X
PLATFORM
V1 ROTATOR
V2
JIB LEVEL CYLINDER
JIB LOCK CYLINDER
MAF09090D
1001157243-D
4-51
JIB TELE CYLINDER
4-52
PORT BLOCK
JIB LOCK CYLINDER
JIB CONTROL VALVE
PL ATFORM VALVE
PLATFORM ROTATOR
PLATFORM LEVEL
CYLINDER
MAF09100D
1001157243-D
3121619
3121619
JIB LOCK CYLINDER
JIB LOCK CYLINDER
MAF09110D
1001157243-D
4-53
4-54
PLATFORM VALVE
JIB ROTATOR
MAF09120D
1001157243-D
3121619
0.7" CONTROL CABLE
3121619
0.75" AIR LINE
.25" POWER CABLE
0.815" GEN CABLE
.25" POWER CABLE
0.7" CONTROL CABLE
0.75" AIR LINE
0.815" GEN CABLE
MAF09130D
1001157243-D
4-55
4-56
187 303
272 269
VIEW A-A
A A
389 382 362 324 379 423 382 313 401 271 459
319
195
300 MAINTAIN HOSE LOOP

AT THIS DIMENSION
1600 PULLED LENGTH OF HOSES

STRETCH HOSE OUT AND MEASURE IN A STRAIGHT LINE
NOTE: ALL DIMENSIONS IN MM.
MAF09140D
1001157243-D
3121619
4.11 JIB 8. Remove the bolt and keeper pin securing the jib level
pivot pin and remove the pin. Place blocking under the
cylinder rod or a soft material under the cylinder rod to
Removal protect the rod from being scratched.
1. Lower the platform to the ground or onto blocking to

support the weight of the jib.
2. Tag and disconnect the electrical harnesses that run to

the jib. If necessary, loosen the guide block to allow the
harnesses and hoses to move more freely.
3. Remove the jib valve protection plate.
4. Have a container or absorption material ready to catch

residual hydraulic fluid. Tag and disconnect the hydrau-
lic hoses that run from the boom to the jib control valve.
It may be necessary to disconnect additional lines to
gain access to certain fittings. Cap or plug all openings.
5. Unbolt the valve from the boom.
6. Lay the jib control valve aside on the jib. Secure it in

place so it does not fall. NOTE: The jib and platform assembly weighs approximately 2100
lbs. (953 kg.).
7. Disconnect the jib protractor sensor linkage from the
boom.
3121619 4-57
9. Attach an adequate supporting device to the jib to sup- threads and secure the pin in place with the keeper pin
port its weight. Remove the bolt and keeper pin secur- and bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
ing the jib pivot pin and remove the pin.
5. Place the mounting bracket on the jib valve and bolt the
jib valve to the fly boom section.
10. Remove the jib and platform assembly from the boom.
6. Install the wiring harnesses and hydraulic hoses on the
Installation jib valve as tagged during removal.
7. Install the jib valve protection plate.

1. Attach an adequate lifting device to the jib and position
it in front of the boom. 8. Perform a boom calibration as described in Section 6
2. Place something under the front of the jib that will allow under Calibrating the Boom Sensors.
it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to 4.12 JIB SHIMMING PROCEDURES
pivot on the ground.
3. Lift the jib into position on the boom fly section and Jib Straight Shimming Procedure
install the jib pivot pin. Secure the pin in place with the
keeper pin and bolt. 1. Install the Jib Lock Cylinder and fully extend the rod
through the bearing housings in the jib rotator and jib
pivot.
2. Alight the jib pivot straight with the jib assembly.
3. Insert shims (16 and 20 gauge) between the wear pad

and the pivot pad mount.
4. Add enough shims as required to fill the gap between

the wear pad and the edge of the bottom plate of the jib
rotator.
5. Only shim until the thinnest shim can not fit. Do not
over shim. This will cause jib pivot and jib assembly mis-
alignment.
6. When shimmed properly, the jib pivot should line up

straight with the jib assembly as shown below.
4. Attach a lifting device to the front of the jib and align
WITH JIB ASSEMBLY AS SHOWN
the jib level cylinder attachment fittings. Install the pivot
pin. Apply JLG Threadlocker P/N 0100019 to the bolt
4-58 3121619
RUBBER PAD
Adhesive PN# 0100081
HOSE CLAMP
BOLT KEEPER PIN

TORQUE 60 FT.LBS. (82 Nm)
JLG Threadlocker
PN# 0100011
BOLT KEEPER PIN

JLG Threadlocker
PN# 0100011
BOLT KEEPER PIN

JLG Threadlocker
PN# 0100011
PLATFORM ROTATOR
BAR CLAMP PLATFORM LEVEL
CYLINDER
RUBBER PAD
Adhesive PN# 0100081
BOLT KEEPER PIN

1001158944-K
MAF09030K
Figure 4-35. Jib Assembly - Sheet 1 of 4
3121619 4-59
BOLT
TORQUE 190 FT.LBS. (260 NM)
JLG THREADLOCKER PN# 0100011
JLG THREADLOCKER
PN# 0100019
BOLT
JIB PIVOT
JIB LIFT CYLINDER
BOLT KEEPER PIN

TORQUE 120 FT.LBS. (163 NM)
JLG THREADLOCKER
SHIMS
PN# 0100011 BOLT
TORQUE340 FT.LBS.
JIB ROTATE ACTUATOR (460 NM)
1001158944-K
MAF09040K
4-60 3121619
BOLT
ALIGN CUTOUT IN CAP LOCKPIN CYLINDER CAP

INWARD AS SHOWN
(SEE SECTION A-A BELOW)
ALIGN LOCK CYL WITH PROTRUSIONS CAP

JIB LOCK CYLINDER (SEE SECTION A-A BELOW)
LOCKNUT
LOCKPIN
CYLINDER CAP
ALIGN HOLES IN LOCK CYL

WITH PROTRUSIONS
IN CAP AS SHOWN ALIGN CUTOUT IN CAP
AS SHOWN
A
JIB PIVOT
BEARING HOUSING
BEARING
(PRESS FIT)
FLANGE BEARING
(PRESS FIT)
INTERNALS OF ACTUATOR
JIB ROTATOR NOT SHOWN FOR CLARITY
BEARING HOUSING
BEARING
(PRESS FIT)
JIB PIVOT
BEARING HOUSING
SECTION A-A 1001158944-K

MAF09060K
3121619 4-61
SCREW NUT
WASHERS
CABLE GUIDE
PAD
GUIDE BLOCK
BRACKET
JIB ROTATE
ACTUATOR
PIVOT PAD MOUNT
JIB ROTATOR
BEARING BOTTOM PLATE
Loctite RC 609 Threadlocker
JIB PIVOT BEARING

Loctite RC 609 Thread-
locker
BEARING
Loctite RC 609 Threadlocker
WEAR PADS
BOLT SHIMS
1001158944-K
MAF09070K
4-62 3121619
Stowed Jib Shimming Procedure 2. Insert a shim between the wear pad and pivot pad
mount.
1. Rotate the jib to the appropriate position as shown
below.
3. Add shims as required to fill the gap between the wear

pad and the edge of the side plate of the jib rotator.
4. Shim until the distance between the jib and the side of
the base boom reaches the dimension shown in Figure
4-39., Jib Stow Shimming Measurements.
Figure 4-39. Jib Stow Shimming Measurements
3121619 4-63
4.13 WIRE ROPE 6. Inspect sheaves with a groove wearout gauge for exces-
sive wear.
WIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER
HANDLE WIRE ROPE WITH BARE HANDS.
Each day before using machine:
1. Raise main boom approximately horizontal.
2. Extend and retract the boom sections.

Observe the groove so that it may be clearly seen
3. Check for delayed movement of fly section which indi- whether the contour of the gauge matches the
cates loose wire ropes. contour of the bottom of the groove.
7. Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.
IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER
PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE Three Month Inspection
ROPES INSPECTED/SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR
MISADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH. 1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays, abuse, or
Inspection any signs of abnormalities.
2. Check rope tension by deflecting the ropes by

NOTE: The pictures in this paragraph are just samples to show the hand...properly tensioned ropes should have little or no
replacement criteria of the rope. movement.
1. Inspect ropes for broken wires, particularly valley wire NOTE: Delayed movement of the fly boom indicates loose wire
breaks and breaks at end terminations. ropes.
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-
den in valleys between strands. 3. Machine is idle for an extended period.
4. Boom is overloaded or sustained a shock load.

2. Inspect ropes for corrosion.
5. Boom exposed to electrical arc. Wires may be fused
3. Inspect ropes for kinks or abuse. internally.
12 Year or 7000 Hour Replacement

1. Mandatory wire rope and sheave replacement.
Additional Replacement Criteria

A kink is caused by pulling down a loop
in a slack line during improper handling, 1. Sheaves and wire rope must be replaced as sets.
installation, or operation.
2. Rusted or corroded wire ropes.
4. Inspect sheaves for condition of bearings/pins. (See
3. Kinked, “bird caged”, or crushed ropes.
Dimension Of Sheaves for proper dimension.)
4. Ropes at end of adjustment range.
5. Inspect sheaves for condition of flanges. (See Dimension
Of Sheaves for proper dimension.) 5. Sheaves failing wearout gage inspection.
4-64 3121619
6. Ropes with 6 total broken wires in one rope lay, 3 in one 1. Before making any adjustments, confirm the boom
strand in one rope lay, 1 valley break, or 1 break at any assembly is in the fully retracted position (See Figure 4-
end termination. 40., Fully Retracted Boom Section Positions).
2. Take preliminary measurements of the position of each
4.14 WIRE ROPE TENSIONING ADJUSTMENT boom section with the boom in the fully retracted posi-
tion and compare them to Figure 4-40., Fully Retracted
If new wire ropes are installed, there is a general starting point Boom Section Positions.
for the initial exposed thread length for each wire rope
adjuster stud. Refer to Figure 4-40., Fully Retracted Boom Sec- 3. If the measurements fall within tolerance shown on Fig-
tion Positions for these dimensions. The proper position of the ure 4-40., proceed to the Wire Rope Tensioning Proce-
boom sections (See Figure 4-40.) must be achieved with wire dure.
rope equalized on both sides of the sheaves and ropes prop-
NOTE: Proper boom position does not confirm that rope tension is
erly seated in sheave grooves prior to tensioning. This will
correct, at this point.
allow for proper tensioning of the wire ropes.
There are two major steps to this procedure: 4. If the measurements do not fall within the tolerances in
Figure 4-40., adjust the position using the re-position
• Positioning the boom sections so proper tensioning can be procedures in this sub-section
achieved
BOOM SECTION #2 REPOSITIONING:
• Tensioning the wire rope
NOTE: Boom Section #2 is positioned by the telescope cylinder. No
adjustments to this section are necessary. The wire ropes
Boom Preparation for Section Repositioning within this assembly only control the movement of the
remaining smaller sections.
NOTE: Because each rope actuated section controls the move-
ment of the next smaller section, any repositioning of the
larger will affect the position of the next smaller. Correctly
position Section #3 before setting the position of Section
#4, followed by section #5.
Use the Boom Telescope function to position the boom sec-

tions. Using the wire rope adjustment nuts to position the
boom sections will cause damage to the wire rope adjust-
ers.
Figure 4-40. Fully Retracted Boom Section Positions
3121619 4-65
4-66
Figure 4-41. Initial Exposed Thread Length for Wire Rope Adjustment
3121619
BOOM SECTION #3 REPOSITIONING: needs to move to be within tolerance (for example,

if the section must move 0.5 inches to fall within the
1. If Boom Section #3 falls within the dimension and toler-
dimension shown, tighten the nut so it moves 0.5
ance shown in Figure 4-40. with the boom fully
retracted, proceed to Boom Section #4 Repositioning inches further from the exposed end of the adjust-
procedure in this section. ment stud).
2. If Boom Section #3 does not fall within the dimension f. Fully retract the boom.
and tolerance shown in Figure 4-40. with the boom fully
g. To remove slack resulting from the adjustment in
retracted, perform the following procedure:
step e., tighten the Section #4 Extend adjustment.
3. If the Section needs to be RETRACTED (measured
dimension is greater than dimension shown in Figure 4- h. To remove slack resulting from the adjustment in
40.): step d., tighten the Section #4 Retract Adjustment
Nuts shown below until they contact the rope
a. Remove any covers necessary to access the wire mount plate.
rope adjustment nuts.
b. Remove lock plates and nylon collar locknuts from

wire rope adjustment studs.
c. Loosen the Section #3 Extend Adjustment Nuts,
moving them a distance equal to twice what the
section needs to move to be within tolerance. (E.g. If
the section must move ½” to fall within the dimen-
sion shown, loosen the nut such that it moves 1”
closer to the exposed end of the adjustment stud.) i. Extend the boom assembly so the platform moves 4
to 5 feet, then fully retract.
j. Repeat step i three times to equalize rope position.
k. Go to step 5.
4. If the Section needs to be EXTENDED (measured dimen-

sion is less than dimension shown in Figure 4-40.):
a. Remove any covers necessary to access the wire


c. Extend the boom assembly such that the platform

moves 4 to 5 feet (1.2m-1.5m) from the fully
retracted position.
d. Loosen the Section #3 Retract Adjustment Nuts,

d. Extend the boom assembly such that the platform moving them a distance equal to twice what the
moves 4 to 5 feet (1.2m-1.5m) from the fully section needs to move to be within tolerance. (E.g. If
retracted position. the section must move ½” to fall within the dimen-
e. Tighten the Section #3 Retract Adjustment Nuts, sion shown, loosen the nut such that it moves 1”
moving them a distance equal to what the section closer to the exposed end of the adjustment stud.)
3121619 4-67
6. Verify that the exposed boom section dimensions meet

the dimension and tolerance of Figure 4-40..
a. If Section #3 still does not fall within the dimension

and tolerance of Figure 4-40., repeat the steps out-
lined in 3. Boom Section #3 Repositioning.
b. If Section #3 does fall within the dimension and tol-
erance of Figure 4-40., proceed to 4. Boom Section
#4 Repositioning.

retracted, proceed to Boom Section #5 Repositioning
procedure in this section.
2. If Boom Section #4 does not fall within the dimension

e. Retract the boom assembly such that the platform 3. If the Section needs to be RETRACTED (measured
moves 2 to 3 feet (0.6m-0.9m) from the previous dimension is greater than dimension shown in Figure 4-
extended position in Step c. 40.):
f. Tighten the Section #3 Extend Adjustment Nuts a. Remove any covers necessary to access the wire
shown below, moving them a distance equal to rope adjustment nuts.
what the section needs to move to be within toler-
ance. (For example, if the section must move 0.5 b. Remove lock plates and nylon collar locknuts from
inches to fall within the dimension shown, tighten wire rope adjustment studs.
the nut such that it moves 0.5 inches further from c. Loosen the Section #4 Extend Adjustment Nuts,
the exposed end of the adjustment stud.) moving them a distance equal to twice what the
section needs to move to be within tolerance. (E.g. If
the section must move ½” to fall within the dimen-
sion shown, loosen the nut such that it moves 1”
closer to the exposed end of the adjustment stud.)
d. Extend the boom assembly such that the platform
retracted position.
e. Tighten the Section #4 Retract Adjustment Nuts
shown below, moving them a distance equal to
what the section needs to move to be within toler-
ance. (E.g. If the section must move ½” to fall within
the dimension shown, tighten the nut such that it
moves ½” farther from the exposed end of the
adjustment stud.)

Step d., tighten the Section #4 Extend Adjustment
Nuts until they contact the rope mount plate.
h. Extend the boom assembly so the platform moves 4
i. Repeat Step h. three times to equalize rope position.
j. Go to Step 5.
f. Fully retract the boom.
5. Fully retract the boom sections.
4-68 3121619
g. To remove slack resulting from the adjustment in c, f. Tighten the Section #4 Extend Adjustment Nuts
tighten the Section #4 Extend Adjustment Nuts shown below, moving them a distance equal to
shown below until they contact the rope mount what the section needs to move to be within toler-
plate. ance. (E.g. If the section must move ½” to fall within
the dimension shown, tighten the nut such that it
moves ½” farther from the exposed end of the
adjustment stud.)
h. Extend the boom assembly so the platform moves 4

i. Repeat step h three times to equalize rope position.
j. Go to step 5. g. To remove slack resulting from the adjustment in
step d, tighten the Section #4 Retract Adjustment
4. If the Section needs to be EXTENDED (measured dimen- Nuts shown below until they contact the rope
mount plate.
c. Extend the boom assembly such that the platform
retracted position.
d. Loosen the Section #4 Retract Adjustment Nuts
twice what the section needs to move to be within
h. Extend the boom assembly such that the platform
tolerance. (E.g. If the section must move ½” to fall
moves 4 to 5 feet, then fully retract.
within the dimension shown, loosen the nut such
that it moves 1” closer to the exposed end of the i. Repeat step h three times to equalize rope position.
adjustment stud.)
j. Go to step 5.
5. Fully retract the boom sections.

the dimension and tolerance of Figure 4-40.

lined in 4. Boom Section #4 Repositioning.
e. Retract the boom assembly such that the platform b. If Section #4 does fall within the dimension and tol-
moves 2 to 3 feet (0.6m-0.9m) from the previous erance of Figure 4-40., proceed to 5. Boom Section
extended position in step c. #5 Repositioning.
3121619 4-69

retracted, proceed to Wire Rope Tensioning procedure
in Section 6 of this document.
2. If Boom Section #5 does not fall within the dimension

3. If the Section needs to be RETRACTED (measured f. Fully retract the boom.

dimension is greater than dimension shown in Figure 4-
40.):
step c, tighten the Section #5 Retract Adjustment
Nuts shown below until they contact the rope
mount plate.

c. Loosen the Section #5 Extend Adjustment Nuts,

twice what the section needs to move to be within
tolerance. (E.g. If the section must move ½” to fall
within the dimension shown, loosen the nut such
that it moves 1” closer to the exposed end of the
adjustment stud.)
h. Extend the boom assembly such that the platform

moves 4 to 5 feet, then fully retract.
i. Repeat h three times to equalize rope position
j. Go to Step 5.
4. If the Section needs to be EXTENDED (measured dimen-


d. Extend the boom assembly such that the platform wire rope adjustment studs.
moves 4 to 5 feet (1.2m-1.5m) from the fully c. Extend the boom assembly so the platform moves 4
retracted position. to 5 feet (1.2m-1.5m) from the fully retracted posi-
tion.
e. Tighten the Section #5 Retract Adjustment Nuts
d. Loosen the Section #5 Retract Adjustment Nuts,
what the section needs to move to be within toler- twice what the section needs to move to be within
ance. (E.g. If the section must move ½” to fall within tolerance. (E.g. If the section must move ½” to fall
the dimension shown, tighten the nut such that it within the dimension shown, loosen the nut such
moves ½” farther from the exposed end of the that it moves 1” closer to the exposed end of the
adjustment stud.) adjustment stud.)
4-70 3121619
has been consumed. Do not continue with the remainder

of this procedure. Replace all wire ropes and sheaves.
1. Remove any covers necessary to access the wire rope

adjustment nuts.
e. Retract the boom assembly such that the platform

moves 2 to 3 feet (0.6m-0.9m) from the previous
extended position in Boom Section #3 Positioning,
Step 4c.
f. To remove slack resulting from the adjustment in
Step 3d, tighten the Section #4 Extend Adjustment 2. Remove lock plates and nylon collar nuts from wire rope
Nuts shown below until they contact the rope adjustment studs.
mount plate. 3. Position the boom so that it is horizontal within +/- 5º,
and not supported by the boom rest.
4. Extend the boom assembly such that the platform
moves 4 to 5 feet (1.2m-1.5m) from the fully retracted
position. The purpose of this step is to position the
boom sections such that the ropes to be tensioned are
not under load. If the extending boom reaches end of
stroke and then automatically retracts a small amount,
the ropes may still be under load. In such case, the fol-
lowing additional steps are necessary:
a. Note where the boom reached end of stroke.
g. Go to Step 5. b. Retract 3 to 4 feet (1m-1.3m).
c. Extend the boom, stopping just before end of stroke
5. Fully retract the boom sections. is reached.
the dimension and tolerance of Figure 4-40..

lined in Boom Section #5 Repositioning.
b. If Section #5 does fall within the dimension and tol-
erance of Figure 4-40., proceed to Wire Rope Ten-
sioning Procedure.
Wire Rope Tensioning Procedure

NOTE: NOTE: Repeat Wire Rope Tensioning Procedure only as nec-
essary to achieve proper tension.
Verification of the rope tension should be determined by

proper deployment function of the boom assembly and by
the dimensions and tolerances shown in Figure 4-40..
If the boom sections have been properly positioned but

there is not enough adjustment travel remaining on a wire 5. Using tool, JLG p/n 1001162217, torque Section #3
rope to achieve proper torque, the service life of the rope Retract Adjustment Nuts to 38 ft-lb (51.5 Nm), alternat-
3121619 4-71
ing between the two ropes until both maintain the 10. Using tool, JLG p/n 1001162216, torque Section #4
required torque. Extend Adjustment Nuts to 17 ft-lb (23 Newton meters),
alternating between the two ropes until both maintain
the required torque.
6. Using tool, JLG p/n 1001162217, torque Section #4

Retract Adjustment Nuts to 38 ft-lb (51.5 Newton
meters), alternating between the two ropes until both
maintain the required torque.

Extend Adjustment Nuts to 17 ft-lb (23 Newton meters),

Retract Adjustment Nuts to 38 ft-lb (51.5 Newton
meters), alternating between the two ropes until both
maintain the required torque.
8. Retract the boom 2-3 feet (.6m – 1.0m) Do NOT fully

retract the boom or bottom out any section.

Extend Adjustment Nuts to 17 ft-lb (23 Newton meters),
12. Equalize the rope tension across the sheaves by exercis-

ing the boom telescope position:
a. Fully retract the boom

b. Extend the boom 4 to 5 feet (1.2m-1.5m) from the
fully retracted position or to the stroke limit identi-
fied in 6.4.
c. Repeat 12a and 12b for a minimum of three cycles,
stopping with the boom extended 4 to 5 feet (1.2m-
1.5m) from the fully retracted position or to the
stroke limit identified in Step 4.
13. Verify wire rope torque values for retract ropes.
4-72 3121619
14. Retract the boom 2-3 feet (.6m – 1.0m) Do NOT fully Re-Assembly
retract the boom or bottom out any section.
1. Install nylon collar locknuts on Section #4 extend wire
15. Verify wire rope torque values for extend ropes.
rope fittings.
16. If the torque values are NOT correct, repeat the Wire
a. Do not re-use the nylon collar lock nuts. Replace
Rope Tensioning Procedure.
with new nylon collar lock nuts.
17. If the torque values are correct, proceed to Confirm b. Torque locknuts to 10 ft-lb (13.5 Nm).
Proper Boom Deployment Function.
2. Reinstall lock plates to remaining adjuster nuts.
Confirm Proper Boom Deployment Function 3. Install all covers.
Exercise the boom telescope function. When wire ropes are
properly torqued, all traveling sections will move simultane- Boom Calibration
ously when extending and retracting. Any adjustment of wire rope tension should be immediately
followed by Boom Calibration. For Boom calibration Refer Sec-
tion 6, JLG Control System.
Figure 4-42. Boom Wire Rope Torques
3121619 4-73
4.15 BROKEN BOOM CABLE PROXIMITY SWITCH 3. Tighten the jam nut.
This system uses a proximity switch to detect excessive move-

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-
tem. It is the responsibility of the operator to take immediate
action.
To avoid damaging the proximity switch, install and adjust

after assembling the switch block, compression spring, and
torquing the wire ropes.
Adjusting the Proximity Switch

1. Thread the switch in until it contacts the adjuster block.
2. Thread the switch out 1/8 to 1/2 turn to achieve proper
sensing range.
NOTE: The LED light on the sensor illuminates when power is

applied and the sensor is within the proper range.
Figure 4-43. Broken Cable Proximity Switch Location
4-74 3121619
3 4
2
3121619
5
6
DO NOT DRAW TRACK MOUNTING

FOOT TO MATCH UNLEVEL PUSH TUBE.
USE WASHERS UNDER TRACK
MOUNTING FOOT TO SHIM
AS REQUIRED TO KEEP JOINT IN
1 RELAXED POSITION. INSTALL WASHERS
EVENLY FRONT TO BACK.
MAF09350L
1001159687-L
1. Powertrack 4. Rubber Pad 6. Clamp Plate
2. Powertrack 5. Powertrack 7. Rubber Pad
3. Clamp Plate
Figure 4-44. Powertrack Installation - Sheet 1 of 4
4-75
4-76
3
4
1
6
MAF09360L
1001159687-L
1. Clamp Plate 3. Clamp Plate 5. Bracket 7. Rubber Pad
2. Rubber Pad 4. Rubber Pad 6. Clamp Plate
3121619
3121619
14 15
8
7
6 9
4 5
2 3
1
10
16
11
12
13
MAF09370L
1001159687-L
1. Clamp Bar 5. Track Support Cover 9. Power Track Support 13. Support Bracket
2. Rubber Pad 6. Spacer Tube 10. Track Support Cover 14. Hose Cover
3. Spacer Tube 7. Power Track Support 11. Support Bracket 15. Track Support Cover
4. Power Track Support 8. Track Support Cover 12. Support Bracket 16. Support Bracket
4-77
4-78
4
3
12
1
5
6
7
8 9
10
11
MAF09380L
1001159687-L
1. Support Bracket 4. Upper Push Tube Assembly 7. Adjusting Shims 10. Mounting Plate
2. Push Tube Pad 5. Adjusting Shims 8. Lower Push Tube Assembly 11. Adjusting Shims
3. Push Tube Pad 6. Mounting Plate 9. Adjusting Shims 12. Support Bracket
3121619
NOTE: USE SHIMS AS REQUIRED TO SHIM UPPER PUSH TUBE ASSEMBLY
SO THERE IS A 6MM ± 3MM CLEARANCE BETWEEN THE PUSH TUBE AND
POWER TRACK ROLLERS. ADJUST AT THE RETRACTED POSITION.
3121619
NOTE: IF THE QUANTITY OF SHIMS IS MORE THAN 3 OR THE TOTAL
SHIM THIKNESS EXCEEDS 10MM, USE A BOLT 5MM LONGER
THAN WHAT IS SPECIFIED.
NOTE: USE SHIMS TO SHIM MOUNTING PLATE SO THERE IS

2MM GAP ON THE LEFT AND RIGHT SIDES OF UPPER PUSH
TUBE ASSEMBLY. ADJUST IN THE RETRACTED POSITION.

NOTE: USE SHIMS TO SHIM MOUNTING PLATE SO THERE IS THAN WHAT IS SPECIFIED.
2MM GAP ON THE LEFT AND RIGHT SIDES OF UPPER PUSH
TUBE ASSEMBLY. ADJUST IN THE RETRACTED POSITION.
NOTE: IF THE QUANTITY OF SHIMS IS MORE THAN 3 OR THE TOTAL NOTE: USE SHIMS AS REQUIRED TO SHIM UPPER PUSH TUBE ASSEMBLY
SHIM THIKNESS EXCEEDS 10MM, USE A BOLT 5MM LONGER SO THERE IS A 6MM ± 3MM CLEARANCE BETWEEN THE PUSH TUBE AND
THAN WHAT IS SPECIFIED. POWER TRACK ROLLERS. ADJUST AT THE RETRACTED POSITION.

THAN WHAT IS SPECIFIED.
MAF09390L
1001159687-L
Figure 4-48. Powertrack Shimming Instructions
4-79
4-80
#0100081
#0100081
MAF09400L
1001159687-L
Figure 4-49. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 of 4
3121619
#0100081
3121619
#0100011 #0100081
#0100081
MAF09410L
1001159687-L
4-81
4-82
#0100011
#0100011
#0100011
#0100011 #0100011
#0100011
#0100081
#0100011
#0100011
49 ft.lbs.
(66 Nm)
#0100011
#0100011
#0100011
49 ft.lbs.
(66 Nm)
MAF09420L
1001159687-L
3121619
3121619
38 ft.lbs. (52 Nm)
#0100011
38 ft.lbs. (52 Nm)

#0100011
25 ft.lbs. (34 Nm)

#0100011
#0100011
38 ft.lbs. (52 Nm)
#0100011
#0100011 38 ft.lbs. (52 Nm)
49 ft.lbs. (66 Nm)
MAF09430L
1001159687-L
4-83
4-84
Figure 4-53. Powertrack Hose Installation - Sheet 1 of 4
3121619
3121619
4-85
4-86
3121619
3121619
4-87
4.16 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.
4-88 3121619
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.
3121619 4-89
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.
4-90 3121619
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
3121619 4-91
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.
4-92 3121619
4.17 SKYGUARD® Function Test

Operation SKYGUARD ONLY
SkyGuard provides enhanced control panel protection. Perform this function test if SkyGuard only is selected in
When the SkyGuard sensor is activated, functions in use at machine setup (refer to Table 6-2).
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
of SkyGuard the machine is equipped with. Regardless of 1. Operate the telescope out function, then activate Sky-
the type, SkyGuard function according to the SkyGuard Guard sensor.
Function Table does not change.
2. Once sensor has been activated, ensure telescope out
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-

0"$
cle footswitch. Ensure normal operation available.
SkyGuard
In Ground Mode:
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:
0"%
NOTE: Machine will treat Soft Touch/SkyGuard override switch as
if it is a Soft Touch and SkyGuard switch.
SkyGuard SkyLine™
1. Operate the telescope out function, then activate Sky-
Guard sensor.
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.
0"$
SkyGuard SkyEye™ 4. Disengage SkyGuard sensor, release controls, and recy-
cle footswitch. Ensure sure normal operation is available.
In Ground Mode:
THE MACHINE OPERATOR IS REQUIRED TO PERFORM A DAILY FUNCTION TEST
TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM. 1. Operation is allowed regardless of SkyGuard activation.
3121619 4-93
SOFT TOUCH ONLY

If Soft Touch only is selected in machine setup (refer to Table
Engage the SkyGuard sensor and observe the Analyzer to
6-2), machine will treat the Soft Touch/SkyGuard override
determine if the switch/relay closes.
switch as if it is a Soft Touch switch.
If the status of the switch/relay remains OPEN while the Sky-
SKYGUARD NOT SELECTED IN MACHINE SETUP Guard sensor is actively engaged, it is possible the sensor has
If the SkyGuard system is installed on the machine, but no failed and should be replaced immediately.
option is selected in the machine setup (refer to Table 6-2),
SkyGuard sensor status will be ignored. No function cutout or If the status of the switch/relay remains CLOSED while the Sky-
reversal will be implemented. Guard sensor is actively engaged, a power or ground wire may
not be making good contact or may be loose or broken. Addi-
Diagnostics & Troubleshooting tionally, there is a low probability that both relays may have
failed.
If SkyGuard does not function when the sensor is engaged,
If the switch/relay status is in disagreement, then one may
first verify the configuration under the
have failed or is not installed correctly. In this case, the
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
machine will be inoperable.
held Analyzer. Ensure the selected configuration matches the
actual system installed on the machine. If not, select the cor-
FAULT CODES
rect configuration, then verify operation.
Refer to Table 6-12 for more fault code information
Additionally, use the handheld analyzer to navigate to the
• 0039 - SkyGuard switch activation fault
DIAGNOSTICS: FEATURES  SKYGUARD INPUTS menu to
determine additional SkyGuard fault information. • 2563 - switch disagreement fault
Table 4-1. SkyGuard Function Table
Boom Boom
Drive Drive Boom Boom Jib Basket Basket
Steer Swing Lift Tel e Jib Lift Jib Tele
Forward Reverse Lift Up Tele In Swing Level Rotate
Down O ut
R*/C** R C R R R R C 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.
4-94 3121619
4.18 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
The 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 4-57. 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.
Inspection Before Use

The bolt-on external fall arrest system must be inspected
before each use of the aerial work platform. Replace compo-
nents if there are any signs of wear or damage.
Before each use, perform a visual inspection of the following

components:
3121619 4-95
Installation nuts onto the cable finger tight so the mark on the cable
does not move.
1. Install the retaining hardware (bolts, nuts, and washers)
and secure the brackets to the platform rail. Tighten the WASHER
nuts but do not torque them yet. BELLEVILLE
NUT WASHER
BOLT
WASHER
JAM NUT
5. Use the two jam nuts to prevent the cable from rotating
while the nut is tightened. Tighten the nut until the bel-
leville washers are fully compressed and no gap is pres-
ent at the outside diameter of the washers. Ensure the
WASHER cable has not rotated during tightening.
NUT
2. Attach the fall arrest cable to the right hand bracket

Using the attaching bolt and nut. Orient the bolt as
shown below. Do not tighten the nut so cable can still
rotate.
BOLT
NUT
6. Tighten the first jam nut against the retaining nut to

keep the nut from loosening. Tighten the remaining jam
nut against the first jam nut.
7. Torque the nuts and bolts securing the brackets to 15
ft.lbs. (20 Nm).
3. Install the Attachment Ring onto the cable.

4. Without twisting the fall arrest cable, pull it thru the left
hand bracket and mark the top of the swaged cable end.
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
4-96 3121619
7
1,2,3,4
1. Belleville Washer
2. Washer
6 3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal
Figure 4-58. Bolt-On External Fall Arrest System
3121619 4-97
NOTES:
4-98 3121619
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-
rated.
When assembling connectors in the hydraulic that use o-ring
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 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
• Small paint brush 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.
3121619 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 3121619
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
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
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
Figure 5-2. BSPT Thread Figure 5-6. MTBL-MBTS Thread
Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514
Figure 5-3. JIC Thread

Figure 5-7. Bulkhead Thread
3121619 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 preload
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 3121619
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
steel.
1. Take precautions to ensure that fittings and mating
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.
3121619 5-5
Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE
ALIGNMENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST
Thread Tapered (NPTF) Connections. TURN FOR 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 JLG Thread-
NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
locker, to the male pipe threads if not already applied.
applicable for the following material configurations:
Ensure the first 1 to 2 threads are uncovered to prevent
system contamination.
• 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
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 3121619
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 JLG Thread- • STEEL fittings with STEEL mating components
locker, to the male pipe threads if not already applied.
Ensure the first 1 to 2 threads are uncovered to prevent • STEEL fittings with ALUMINUM or BRASS mating compo-
system contamination. nents
3. Assemble connection hand tight. • ALUMINUM or BRASS fittings with STEEL mating compo-
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

ALIGNMENT. 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.
3121619 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
LEAKAGE. 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:
• STEEL fittings with ALUMINUM or BRASS mating compo-
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.
mating components.
5-8 3121619
Table 5-3. 37° Flare (JIC)Thread - Steel
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 --
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
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.
3121619 5-9
Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
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 3121619
3121619 5-11
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 ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
LEAKAGE. 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.
5-12 3121619
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.
3121619 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).
NOTE: Torque values provided in Table 5-7, O-ring Face Seal
2. Ensure surface is smooth, free of rust, weld and brazing (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
splatter, splits, dirt, foreign matter, or burrs. If necessary minum/Brass are segregated based on the material config-
uration of the connection.
replace fitting or adapter.
COMPONENTS’ indicate either the following material configu-
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO rations:
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD • STEEL fittings with ALUMINUM or BRASS mating compo-
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. Place the tube assembly against the fitting body so that • ALUMINUM or BRASS fittings with ALUMINUM or
the flat face comes in contact with the O-ring. Hand BRASS mating components
thread the nut onto the fitting body.
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
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 MATING COMPONENTS;
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 3121619
Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

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

Dash Size Tube
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

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
ALUMINUM/BRASS FITTINGS OR
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

MATING COMPONENTS;
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.
3121619 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 3121619
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 method of fitting assembly. 1.5 to 1.75
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application
15 M22 x 1.5 20.50 22.00 7.00 15.20 specific due to variability in the 1.5 to 1.75
18 M26 x 1.5 24.50 26.00 7.50 18.20 fitting supplier, coating, 1.5 to 1.75
lubrication, and other physical
22 M30 x 2 27.90 30.00 7.50 22.20 characteristics of the connection. 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75

Refer to the specific procedure
35 M45 x 2 42.90 45.00 10.50 35.30 in the 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
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 method of fitting assembly. 1.5 to 1.75
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
Torque values are application
14 M22 x 1.5 20.50 22.00 8.00 14.20 specific due to variability in the 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 fitting supplier, coating, 1.5 to 1.75
lubrication, and other physical
20 M30 x 2 27.90 30.00 10.50 20.20 characteristics of the connection. 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 1.5 to 1.75
Refer to the specific procedure
30 M42 x 2 39.90 42.00 13.50 30.20 in the 1.5 to 1.75
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121619 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 3121619
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
TYPE
Dash Size [Ft-Lb] [N-m]

STEEL FITTINGS
(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
3121619 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
10 M16 x 1.5 22 23 24 30 31 33
(MBTL) BULKHEAD FITTING
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
Thread M Size
Tube O.D.
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
[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 3121619
3121619 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 • STEEL fittings with ALUMINUM or BRASS mating compo-
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD nents
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. For Non-Adjustable and Plugs, thread the fitting by mating components.
hand until contact.
7. Inspect to ensure the O-ring is not pinched and the
5. For Adjustable fittings, refer to Adjustable Stud End washer is seated flat on the counter bore of the port.
Assembly for proper assembly.
5-22 3121619
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
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
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.
3121619 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 3121619
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
3121619 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 3121619
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
3121619 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 3121619
3121619 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.
b. Torque values provided in Table 5-18, Table 5-19,
2. If O-ring is not pre-installed, install proper size, taking Table 5-20, Table 5-21, Table 5-22, and Table 5-23
care not to damage it. See O-ring Installation (Replace- are segregated based on the material configuration
ment) for instructions. of the connection. ‘ALUMINUM/BRASS FITTINGS OR
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
5-30 3121619
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
3121619 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 3121619
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
3121619 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 3121619
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
3121619 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 3121619
3121619 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
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD • ALUMINUM or BRASS fittings with STEEL mating compo-
CAUSE 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.

5-38 3121619
Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
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
3121619 5-39
Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
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 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
5-40 3121619
3121619 5-41
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.
b. Torque values provided in Table 5-25, Table 5-26,
2. If O-ring is not preinstalled, install proper size, taking Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
care not to damage it. See O-ring Installation (Replace- segregated based on the material configuration of
ment) for instructions. the connection. ‘ALUMINUM/BRASS FITTINGS OR
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5-42 3121619
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
3121619 5-43
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
5-44 3121619
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
3121619 5-45
Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
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
5-46 3121619
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
3121619 5-47
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
JLG applications. Refer to the specific
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133
procedure in this Service Manual.
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254
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
JLG applications. Refer to the specific
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87
procedure in this Service Manual.
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165
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
5-48 3121619
3121619 5-49
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.
5-50 3121619
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
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
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.
3121619 5-51
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.
5-52 3121619
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
3121619 5-53
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 2. Position #1 – The o-ring should be located in the groove
tight condition. adjacent to the face of the back-up washer. The washer
and o-ring should be positioned at the extreme top end
2. Mark a dot on one of the swivel hex nut flats and of the groove as shown.
another dot in line on the connecting tube adapter. See
Figure B.1. 3. Position #2 – Position the locknut to just touch the back-
up washer as shown. The locknut in this position will
3. Use the double wrench method per Appendix A, turn eliminate potential back up washer damage during the
the swivel nut to tighten as shown in Figure B.1. The nut next step.
is to be rotated clockwise the number of hex flats as
4. Position #3 – Install the connector into the straight
defined by the applicable Table in Section 5.0.
thread box port until the metal back-up washer contacts
the face of the port as shown.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering 5. Position #4 – Adjust the connector to the proper posi-
the dots, to indicate the connection has been properly tion by turning out (counterclockwise) up to a maxi-
tightened. See Figure 5-13. 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
flat against the face of the port.
Figure 5-13. FFWR Method
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.
5-54 3121619
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 5. Inspect O-ring for any visible nicks or tears. Replace if
or torn. A damaged O-ring could lead to leakage problems. 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.
3121619 5-55
Figure 5-15. Turntable Hydraulic System
5-56 3121619
Figure 5-16. Hydraulic Hose Installation - Sheet 1 of 8
3121619 5-57
5-58 3121619
3121619 5-59
5-60 3121619
3121619 5-61
5-62 3121619
3121619 5-63
5-64 3121619
5.3 HYDRAULIC CYLINDERS 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove the capscrews (4).
Axle Extend Cylinder (Prior to SN 0300239676)
Refer to Figure 5-27.
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

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

cylinder port block fitting.
Figure 5-25. Capscrew Removal

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
SURE. 6. Attach a suitable pulling device to the cylinder rod end.
2. Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately
support cylinder rod. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
3. Remove cartridge-type counterbalance valve and fittings ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
from cylinder port block. Discard O-rings. PISTON AND CYLINDER BARREL SURFACES.
4. Place cylinder barrel in a suitable holding fixture. Tap
7. With the barrel clamped securely, carefully withdraw the
around outside of cylinder head retainer with a suitable
complete rod assembly from the cylinder barrel (2).
hammer to break thread-locking compound.
ROD SUPPORT
ROD SUPPORT
PROTECTED ROD CLAMP SUPPORT TABLE
BARREL CLAMP
SUPPORT TABLE
Figure 5-24. Cylinder Barrel Support Figure 5-26. Cylinder Rod Support
8. Using suitable protection, clamp the cylinder rod (21) in

a vise or holding fixture as close to the piston (15) as
possible.
3121619 5-65
1. Bushing 6. Wiper Seal 10. O-Ring 14. O-Ring 18. Tapered Bushing
2. Barrel 7. Seal 11. Wear Ring 15. Piston 19. Bolt
3. Counterbalance Valve 8. Cylinder Head 12. Spacer 16. Lock Ring 20. Bushing
4. Capscrew 9. Backup Ring 13. Backup Ring 17. Seal 21. Rod
5. Washer Ring
Figure 5-27. Axle Extend Cylinder Assembly (Prior to SN 0300239676)
5-66 3121619
9. Loosen and remove bolts from tapered bushing (18) and CLEANING AND INSPECTION
piston (15).
1. Clean parts thoroughly with approved cleaning solvent.
10. Insert bolts in threaded holes in outer piece of tapered
2. Inspect cylinder rod for scoring, tapering, ovality, or
bushing (18). Progressively tighten bolts until bushing is
other damage. If necessary, dress rod with Scotch Brite
loose. Remove tapered bushing (18) from piston (15).
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.
6. Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress
8. Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
Figure 5-28. Tapered Bushing Removal
9. Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
11. By hand, screw the piston (15) counterclockwise and necessary.
remove it from cylinder rod (21).
10. Inspect threaded portion of head for damage. Dress
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, 11. Inspect seal and O-ring grooves in head for burrs and
SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION sharp edges. Dress applicable surfaces as necessary.
BEFORE REMOVING FOR PROPER INSTALLATION. 12. Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.
12. Remove and discard backup ring, o-ring, and backup
ring from inside grooves of piston (15). Remove and dis- 13. Inspect rod and barrel bearings for signs of correct
card two lock rings and seals from outer grooves of pis- excessive wear or damage. Replace as necessary.
ton (15). a. Thoroughly clean hole, (steel bushing) of burrs, dirt
13. Remove piston spacer from rod. etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
14. Remove rod (21) from holding fixture. Remove cylinder steel bushing is worn or damaged, rod/barrel must
head (8) and washer ring (5). be replaced.
15. Remove and discard two wear rings (11), wiper seal (6) c. Lubricate inside of the steel bushing with WD40
and rod seal (7) from inside of cylinder head (8). Remove prior to bearing installation.
and discard O-ring and backup ring (9) from outer
groves of cylinder head (8). NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
3121619 5-67
d. Press bushing in barrel or rod bushing with correct

size arbor.
Composite Barrel or
Bushing Rod Bushing
Composite
Bushing
Arbor
Figure 5-29. Bushing Installation
14. Inspect spacer for burrs and sharp edges. If necessary,

dress inside diameter surface with Scotch Brite or equiv-
alent.
15. Inspect port block fittings and holding valves. Replace
as necessary.
16. Inspect oil ports for blockage or presence of dirt or other Figure 5-30. Cylinder Head Seal Installation
foreign material. Repair as necessary.
3. Slide washer ring on rod. Install cylinder head assembly
ASSEMBLY
(8) on rod. Do not damage or dislodge wiper (6) and rod
seals (7). Push cylinder head (8) to rod end (21).
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER 4. Install spacer (12) on rod (21).
CYLINDER OPERATION.
5. Install backup ring (13), O-ring (14), and backup ring (13)
NOTE: Use proper cylinder seal kit for cylinder assembly. See your in inside grooves of piston (15).
JLG Parts Manual.
6. Install hydrolock seals (17) and guidelock rings (16) in
Apply a light film of hydraulic oil to all components before outer grooves of piston (15).
assembly.
1. Install backup ring (9) and o-ring (10) in outside diame-

ter grooves of cylinder head (8).
2. Install rod seal (7), wiper ring (6), and wear rings (11) in
cylinder head (8) as shown.
Figure 5-31. Piston Seal Kit Installation
7. Using suitable protection, clamp cylinder rod in a vise or

similar holding fixture as close to piston as possible.
5-68 3121619
8. Thread piston (15) on cylinder rod (21) hand tight.

Ensure O-ring (14) and back-up rings (13) are not dam-
aged or dislodged.
NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.
9. Assemble the tapered bushing (18) loosely into the pis-

ton (15) and insert capscrews (19) through the drilled
holes in the bushing and into the tapped holes in the
piston (15).
Figure 5-33. Seating the Tapered Bearing
12. Retorque the capscrews (4) evenly and progressively in

rotation to 9 ft.lbs (12 Nm).
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
13. Clamp barrel (2) securely and support rod. Insert piston
Figure 5-32. Tapered Bushing Installation
end into barrel cylinder. Do not damage or dislodge pis-
ton O-ring and seal ring.
10. Tighten the capscrews (19) evenly and progressively in
rotation to 9 ft.lbs (12 Nm). 14. Continue pushing rod (21) in barrel (2) until cylinder
head (8) can be inserted into barrel cylinder.
11. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011)
(approximately 3/4" in diameter) as follows; to capscrews.
a. Place the shaft against the cylinder rod and in con-
tact with the bushing in the spaces between the
capscrews.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
the capscrews.
3121619 5-69
15. Secure cylinder head (8) and washer ring (5) with eight
capscrews (4).
16. Install two counterbalance valves with new O-rings in
valve block. Torque to 30-35 ft-lb (40-47 Nm).
Figure 5-34. Rod Assembly Installation
5-70 3121619
Axle Extend Cylinder (SN 0300239676 to Present) 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove the capscrews (4).
DISASSEMBLY



SURE.
2. Operate hydraulic power source and extend cylinder. 6. Attach a suitable pulling device to the cylinder rod end.
support cylinder rod.
3. Remove cartridge-type counterbalance valve and fittings EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
from cylinder port block. Discard O-rings. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
4. Place cylinder barrel in a suitable holding fixture. Tap ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
around outside of cylinder head retainer with a suitable PISTON AND CYLINDER BARREL SURFACES.
7. With the barrel clamped securely, carefully withdraw the
complete rod assembly from the cylinder barrel (2).
ROD SUPPORT
PROTECTED ROD CLAMP ROD SUPPORT
BARREL CLAMP SUPPORT TABLE
SUPPORT TABLE
Figure 5-35. Cylinder Barrel Support
Figure 5-37. Cylinder Rod Support
8. Using suitable protection, clamp the cylinder rod (21) in

a vise or holding fixture as close to the piston (15) as
possible.
3121619 5-71
1
5 2
3*
3*
5 5
5
18 5
5
15 13
14
13
19**
11
12 4
16
17
17
16
8
10
9
7
21
*Torque to 30.24- 35 ft-lbs (41-47 Nm)
**Torque to 9.59 ft-lbs (13 Nm)
20
1001228066-A
MAF08310A
1. Bushing 6. Wiper Seal 10. O-Ring 14. O-Ring 18. Tapered Bushing
2. Barrel 7. Seal 11. Wear Ring 15. Piston 19. Bolt
3. Counterbalance Valve 8. Cylinder Head 12. Spacer 16. Lock Ring 20. Bushing
4. Capscrew 9. Backup Ring 13. Backup Ring 17. Seal 21. Rod
5. O-Ring
Figure 5-38. Axle Extend Cylinder Assembly (SN 0300239676 to Present)
5-72 3121619
9. Loosen and remove bolts from tapered bushing (18) and CLEANING AND INSPECTION
piston (15).
bushing (18). Progressively tighten bolts until bushing is
loose. Remove tapered bushing (18) from piston (15).
11. By hand, screw the piston (15) counterclockwise and necessary.
remove it from cylinder rod (21). 10. Inspect threaded portion of head for damage. Dress
11. Inspect seal and O-ring grooves in head for burrs and
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, sharp edges. Dress applicable surfaces as necessary.
SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
BEFORE REMOVING FOR PROPER INSTALLATION. 12. Inspect cylinder head outside diameter for scoring,
12. Remove and discard backup ring, o-ring, and backup 13. Inspect rod and barrel bearings for signs of correct
ring from inside grooves of piston (15). Remove and dis- excessive wear or damage. Replace as necessary.
card two lock rings and seals from outer grooves of pis-
ton (15). a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
13. Remove piston spacer from rod. b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
14. Remove rod (21) from holding fixture.
be replaced.
15. Remove and discard two wear rings (11), wiper seal (6) c. Lubricate inside of the steel bushing with WD40
and rod seal (7) from inside of cylinder head (8). Remove prior to bearing installation.
and discard O-ring and backup ring (9) from outer
groves of cylinder head (8). NOTE: Lubrication is not required with nickel plated pins and
3121619 5-73
d. Press bushing in barrel or rod bushing with correct

size arbor.
Composite Barrel or
Bushing Rod Bushing
Composite
Bushing
Arbor

dress inside diameter surface with Scotch Brite or equiv-
alent.
as necessary.
16. Inspect oil ports for blockage or presence of dirt or other Figure 5-41. Cylinder Head Seal Installation
3. Install cylinder head assembly (8) on rod. Do not dam-
ASSEMBLY age or dislodge wiper (6) and rod seals (7). Push cylinder
head (8) to rod end (21).
4. Install spacer (12) on rod (21).
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
5. Install backup ring (13), O-ring (14), and backup ring (13)
CYLINDER OPERATION.
in inside grooves of piston (15).
NOTE: Use proper cylinder seal kit for cylinder assembly. See your 6. Install hydrolock seals (17) and guidelock rings (16) in
JLG Parts Manual. outer grooves of piston (15).
Apply a light film of hydraulic oil to all components before

assembly.
1. Install backup ring (9) and o-ring (10) in outside diame-

2. Install rod seal (7), wiper ring (6), and wear rings (11) in
5-74 3121619
7. Using suitable protection, clamp cylinder rod (21) in a

vise or similar holding fixture as close to piston (15) as
possible.
Ensure O-ring (14) and back-up rings (13) are not dam-
aged or dislodged.

9. Assemble the tapered bushing (18) loosely into the pis-

ton (15) and insert capscrews (19) through the drilled
piston (15).

rotation to 9 ft.lbs (12 Nm).

AND PISTON.
13. Clamp barrel (2) securely and support rod. Insert piston
end into barrel cylinder. Do not damage or dislodge pis-
Figure 5-43. Tapered Bushing Installation 14. Continue pushing rod (21) in barrel (2) until cylinder
NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011)
rotation to 9.59 ft.lbs (13 Nm).
to capscrews.
bushing with a hammer (16 to 24 oz.) and brass shaft 15. Secure cylinder head (8) with capscrews (4).
(approximately 3/4" in diameter) as follows;
16. Install two counterbalance valves (3) with new O-rings in
a. Place the shaft against the cylinder rod and in con- valve block. Torque to 30.24-35 ft-lbs (41-47 Nm).
capscrews. CYLINDER
BARREL
the capscrews.
CAPSCREW
COUNTERBALANCE
VALVE
ROD
HEAD
ROD
MAF08330
3121619 5-75
Jib Level (Slave) Cylinder (Prior to SN 0300239676) 5. Mark cylinder head and barrel with center punch marks
(3) for later realignment. Remove eight cylinder head
Refer to Figure 5-49. capscrews
DISASSEMBLY



SURE.
3. Remove cartridge-type counterbalance valve and fittings PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
from cylinder port block. Discard O-rings. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.
6. Clamp barrel securely. Unscrew cylinder head and pull
rod assembly from barrel.
7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
holding fixture as close to piston as possible.
PROTECTED ROD CLAMP
ROD SUPPORT
BARREL CLAMP
SUPPORT TABLE
SUPPORT TABLE
5-76 3121619
3*
1
2
3*
17**
16 13 14
15 13
8 6
12
18
5
19
18 4
11
10
*Torque to 50-55 ft-lb (67-75 Nm) 21

**Torque to 30 ft-lb (41 Nm)
20
20
1001155834-C
MAF07670C
1. Bushing 5. Washer Ring 9. Wear Ring 13. Back-Up Ring 17. Bolt
2. Barrel 6. Wiper Seal 10. Backup Ring 14. O-Ring 18. Lock Ring
3. Counterbalance Valve 7. Rod Seal 11. O-Ring 15. Piston 19. Seal
4. Capscrew 8. Cylinder Head 12. Spacer 16. Tapered Bushing 20. Bushing
21. Rod
Figure 5-49. Jib Level (Slave) Cylinder Assembly (Prior to SN 0300239676)
3121619 5-77
8. Using suitable protection, clamp cylinder rod in a vise or 13. Remove and discard two lock rings (18) and seals (19)
similar holding fixture as close to piston as possible. from outside grooves of piston.
9. Loosen and remove bolts from tapered bushing and pis-
ton. 15
bushing. Progressively tighten bolts until bushing is
18
loose. Remove tapered bushing from piston.
14
11. Screw piston counter-clockwise by hand and remove
from cylinder rod.
13
19
18
Figure 5-51. Piston Disassembly
14. Remove piston spacer (12) from rod (7).

15. Remove rod from holding fixture. Remove cylinder head
(8) and washer ring (5)
16. Remove and discard three wear rings (9), wiper seal (6),
Figure 5-50. Tapered Bushing Removal and rod seal (7) from inside of cylinder head (8). Remove
and discard O-ring (11) and backup ring (10) from outer
groves of cylinder head.
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, 9
8 6
BEFORE REMOVING FOR PROPER INSTALLATION.
12. Remove and discard backup ring (13), O-ring (14), and
backup ring (13) from inside grooves of piston (15).
11
10
7
Figure 5-52. Cylinder Head Disassembly
5-78 3121619
CLEANING AND INSPECTION d. Press bushing in barrel or rod bushing with correct
size arbor.
2. Inspect cylinder rod for scoring, tapering, ovality, or Composite Barrel or
other damage. If necessary, dress rod with Scotch Brite Bushing Rod Bushing
or equivalent. Replace rod if necessary. Composite
Bushing
or other damage. Check inside diameter for tapering or Arbor
6. Inspect piston surface for damage, scoring, or distortion. dress inside diameter surface with Scotch Brite or equiv-
Dress piston surface or replace piston as necessary. alent.
7. Inspect threaded portion of piston for damage. Dress 15. Inspect port block fittings and holding valves. Replace
threads as necessary. as necessary.
8. Inspect seal and O-ring grooves in piston for burrs and 16. Inspect oil ports for blockage or presence of dirt or other
sharp edges. Dress surfaces as necessary. foreign material. Repair as necessary.
necessary.
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring,
13. 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
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and

3121619 5-79
ASSEMBLY 5. Install backup ring (13), O-ring (14), and backup ring (13)
in inside grooves of piston (15).
6. Install two seals (13) and lock rings (14) in outer grooves
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER of piston.
CYLINDER OPERATION.
NOTE: Use proper cylinder seal kit for cylinder assembly. See your 3
JLG Parts Manual.
15
Apply a light film of hydraulic oil to all components before 16
assembly.
1. Install backup ring (10) and O-ring (11) in outside diame-

2. Install rod seal (7), wiper seal (6), and three wear rings (9) 14
in cylinder head as shown. 13
17
21 13
4
14

8. Thread piston on cylinder rod hand tight. Ensure O-ring

and back-up rings are not damaged or dislodged.
NOTE: Piston and mating end of rod must be free of oil when
18 installing tapered bushing.
20
9. Thread piston on rod until it aligns with spacer end and
Figure 5-54. Cylinder Head Assembly install tapered bushing.
3. Slide washer ring (5) on rod (21). Install cylinder head

assembly (8) on rod. Do not damage or dislodge wiper
and rod seals. Push cylinder head to rod end.
4. Install spacer (12) on rod (21).
5-80 3121619
NOTE: Apply JLG Threadlocker (P/N 0100011) to tapered bushing

bolts.
10. Assemble the tapered bushing loosely into the piston SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
and insert capscrews through the drilled holes in the AND PISTON.
bushing and into the tapped holes in the piston.
14. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge piston
O-ring and seal ring.
15. Continue pushing rod (21) in barrel (2) until cylinder
NOTE: Apply locking primer and medium strength (Blue) Locking

Compound (JLG P/N 0100011 or equivalent to capscrews.
16. Secure cylinder head (8) and washer ring (5) with eight
capscrews (4).

3*
11. Tighten the capscrews evenly and progressively in rota-

tion to 30 ft-lb (41 Nm). 3* 8
5
bushing with a hammer (16 to 24 oz.) and brass shaft 2 4
21
capscrews.
the capscrews. Figure 5-58. Rod Assembly Installation
13. Re-torque capscrews evenly and progressively in rota-

tion to 30 ft-lb (41 Nm).
3121619 5-81
Jib Level (Slave) Cylinder (SN 0300239676 to 5. Unscrew cylinder head with hook spanner wrench.
Present) CYLINDER BARREL

SPANNER NUT
DISASSEMBLY
HOOK SPANNER
ROD
MAF07790
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. Figure 5-60. Cylinder Head Removal
SURE. 6. Attach a suitable pulling device to the cylinder rod port-
2. Operate hydraulic power source and extend cylinder. block end or cylinder rod end, as applicable.
3. Remove cartridge-type counterbalance valve and fittings PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
from cylinder port block. Discard O-rings. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.
around outside of cylinder head retainer with a suitable 7. Clamp barrel securely. Unscrew cylinder head and pull
hammer to break thread-locking compound. rod assembly from barrel.
ROD SUPPORT holding fixture as close to piston as possible.
PROTECTED ROD CLAMP
ROD SUPPORT
BARREL CLAMP
SUPPORT TABLE
SUPPORT TABLE
5-82 3121619
17
19 19
18*
19
19
17
19
1 18*
8
9 7
5
6
11
4
10
13
16
12**
15***
14
2
*Torque to 50-55 ft-lb (67-75 Nm)
**Torque to 1032 ft-lb (1400 Nm)
***Torque to 15 ft-lb (20 Nm)
17
17
1001228064-C
MAF07680C
1. Barrel 5. Rod Seal 9. Backup Ring 13. Seal, Piston 17. Bushing
2. Rod 6. Backup Ring 10. Retainer 14. O-Ring 18. Counterbalance Valve
3. Head 7. Wear Ring 11. O-Ring 15. Setscrew 19. Plug
4. Wiper Seal 8. O-Ring 12. Piston 16. Steel Ball
Figure 5-62. Jib Level (Slave) Cylinder Assembly (SN 0300239676 to Present)
3121619 5-83
9. Using suitable protection, clamp cylinder rod in a vise or 13. Remove and discard the o-ring (14) from inside grooves
similar holding fixture as close to piston as possible. of piston (12).
10. Loosen and remove the setscrew (15) and ball (16) 12
which attaches the piston to the rod.
13
11. Screw the piston (12) counterclockwise and remove the
piston from cylinder rod (2).
14
ROD
PISTON
MAF07720
Figure 5-64. Piston Seal Disassembly
14. Remove rod from holding fixture and remove

STEEL BALL cylinder head (3).
SETSCREW 15. Remove and discard wear ring (7), wiper seals (4),
MAF07710
retainer ring (10), backup ring (6) and rod seal (5) from
Figure 5-63. Piston Removal inside of cylinder head (3).
16. Remove and discard O-ring (8), backup ring (9) and O-
ring (11) from outside groves of cylinder head (3).
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
12. Remove and discard the piston seal (13) from outside
grooves of piston (12).
8
9 7
5
6
3
11 4
10
MAF07730
5-84 3121619
CLEANING AND INSPECTION d. Press bushing in barrel or rod bushing with correct
size arbor.
2. Inspect cylinder rod for scoring, tapering, ovality, or Composite Barrel or
other damage. If necessary, dress rod with Scotch Brite Bushing Rod Bushing
or equivalent. Replace rod if necessary. Composite
Bushing
or other damage. Check inside diameter for tapering or Arbor
6. Inspect piston surface for damage, scoring, or distortion. dress inside diameter surface with Scotch Brite or equiv-
Dress piston surface or replace piston as necessary. alent.
7. Inspect threaded portion of piston for damage. Dress 15. Inspect port block fittings and holding valves. Replace
threads as necessary. as necessary.
8. Inspect seal and O-ring grooves in piston for burrs and 16. Inspect oil ports for blockage or presence of dirt or other
sharp edges. Dress surfaces as necessary. foreign material. Repair as necessary.
necessary.
13. Inspect rod and barrel bearings for signs of correct
be replaced.

3121619 5-85
ASSEMBLY 4. Install o-ring (8), backup ring (9) and o-ring (11) in
outside groves of cylinder head (3).

CYLINDER OPERATION.
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
8
9 7
NOTE: Apply a light film of hydraulic oil to all components before 5
assembly. 6
3
1. A special tool is used to install a new rod seal into the
applicable cylinder head groove.
11 4
10
MAF07730
WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. Figure 5-68. Cylinder Head Assembly
IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
5. Carefully install the cylinder head (3) on the rod (2),
ensuring that the wiper seal (4), wear ring (7),
2. Use a soft mallet to tap a new wiper seal into the appli-
backup rings (6), rod seal (5) and backup rings (9) are not
cable cylinder head groove. Install a new bearing into
damaged or dislodged. Push the head (3) along the rod
the applicable inside diameter of the cylinder head
(2) to the rod end, as applicable.
groove.
6. Using suitable protection, clamp the cylinder rod (2) in a
vise or similar holding fixture as close to piston
as possible.
WEAR
RING 7. Place new o-ring (14) in the inside diameter of the
piston (12).
WIPER 8. Carefully thread the piston (12) on the cylinder rod (2),
SEAL ensuring that the o-ring (14) and seal (13) are not
CYLINDER damaged or dislodged.
MALLET HEAD
Torque piston (12) to 1032 ft-lb (1400 Nm).
NOTE: When installing wiper seals, ensure the seals are installed properly. 9. Install the setscrew (15) and ball (16) on the piston and
Install the seal so the flat part of the seal is facing into the cylinder head. attach the piston on the rod.
MAE32860 Torque setscrew (15) to 15 ft-lb (20 Nm).
Figure 5-67. Wiper Seal Installation 10. Remove the cylinder rod (2) from the holding fixture.
3. Install wear ring (7), wiper seals (4), retainer ring (10),
backup ring (6) and rod seal (5) in inside groves of
cylinder head (3).
5-86 3121619
11. Place new piston seal (13) in the outer diameter of 16. Caulk at the machined area of the cylinder barrel end so
piston (12) groove. (A tube, with I.D. slightly larger than that it locks the cylinder head in place and it does not
the O.D. of the piston is recommended to install the unscrew from the barrel.
solid seal).
12
13
14
MAF00120
Figure 5-71. Caulking
17. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
MAF07720
reinstallation of any plugs.
Figure 5-69. Piston Seal Installation 18. Install the plugs (19) in the cylinder ports.
12. Position the cylinder barrel in a suitable holding fixture.
19 19
19 19
18
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
19
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 1 12
18
13. With barrel clamped secured and adequately support- 3
ing the rod, insert the piston end into the barrel cylinder.
Ensure that the piston loading o-ring and piston seal is
not damaged or dislodged. 2
14. Continue pushing the rod into the barrel until the cylin-
der head can be inserted into the barrel cylinder. MAF07770
15. Screw the cylinder head into the barrel using a hook Figure 5-72. Rod Assembly Installation
spanner wrench.
HOOK SPANNER
ROD
CYLINDER
BARREL
SAPANNER NUT
Figure 5-70. Cylinder Head Tightening
3121619 5-87
Platform Level Cylinder (Prior to SN 0300239170) Remove cylinder length sensor assembly (6) from barrel
(3).
DISASSEMBLY
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A 5 8

3
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 7
6
1. Connect a suitable auxiliary hydraulic power source to 9
10
cylinder port fitting.
support cylinder rod, if applicable.
11
3. Place cylinder barrel in a suitable holding fixture. 12
Figure 5-74. Cylinder Length Sensor Removal


7. Mark cylinder head and barrel with a center punch for
realignment.
8. Remove setscrew (1) from barrel (3). Unscrew cylinder
head with pin-face spanner wrench.

4. Remove cartridge-type counterbalance valve and fit-

tings from cylinder port block. Discard O-rings.
5. If necessary, remove eight capscrews (8) and retainer
cap (7). Remove O-Ring plug (12) and setscrew (11). . .
Mark For Reassembly
Figure 5-75. Cylinder Head Removal
5-88 3121619
6
4
5 8
3 9
10
2*
4
11**
12
1
2*
13***
14
15
16
17
16
15
18
19
18 21
20
22
23
24****
25
26
27

28 **Torque to 4 in-lb (.4 Nm)
29
****Torque to 200 ft-lb (271 Nm)
29 1001139999-D
MAF07820D
1. Screw 6. Length Sensor 11. Setscrew 16. Seal 21. Backup Ring 26. Seal
2. Counterbalance Valve 7. Retainer Cap 12. Plug 17. Piston 22. O-Ring 27. Rod Wiper
3. Barrel 8. Capscrew 13. Capscrew 18. Backup Ring 23. O-Ring 28. Rod
4. Bushing 9. Retaining Ring 14. Tapered Bushing 19. O-Ring 24. Head 29. Bushing
5. Spacer Sleeve 10. Sensor Magnet 15. Lock Ring 20. Spacer 25. Wear Ring
Figure 5-76. Platform Level Cylinder Assembly (Prior to SN 0300239170)
3121619 5-89
OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
9. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel. 14. Remove and discard two lock rings (15), seals (16),
backup ring (18), O-ring (19), and backup ring (18) from
10. Protect cylinder rod from damage and clamp in a vise or piston (17).
holding fixture as close to piston as possible. 15. Remove piston spacer (20) from rod.
ROD SUPPORT 15
16
SUPPORT TABLE 15
17
18
19
18
20
11. Loosen and remove bolts from tapered bushing and pis-
16. Remove rod from holding fixture. Remove cylinder head
ton.
(24).
12. Insert bolts in threaded holes in outer piece of tapered 17. Remove and discard backup ring (21), O-ring (22), O-ring
bushing. Progressively tighten bolts until bushing is (23), rod wiper (27), seal (26), and two wear rings (25),
loose. Remove tapered bushing from piston. from cylinder head (24).
21
22
23
24
25
Figure 5-78. Tapered Bushing Removal 26
27
13. Screw piston counter-clockwise by hand and remove Figure 5-80. Cylinder Head Disassembly
from cylinder rod.
5-90 3121619
CLEANING AND INSPECTION d. Press bushing into barrel or rod bushing with cor-
rect size arbor.
Composite Barrel or
2. Inspect cylinder rod for scoring, tapering, ovality, or Bushing Rod Bushing
other damage. If necessary, dress rod with Scotch Brite Composite
or equivalent. Replace rod if necessary. Bushing

Arbor
or other damage. Check inside diameter for tapering or Figure 5-81. Composite Bushing Installation
15. Inspect port block fittings and holding valve. Replace as
5. Inspect threaded portion of barrel for damage. Dress necessary.
16. Inspect oil ports for blockage or presence of dirt or other
6. Inspect piston surface for damage, scoring, or distortion. foreign material. Repair as necessary.
ASSEMBLY
JLG Parts Manual.
assembly.
necessary. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION.
threads as necessary. 1. Install O-ring (23), O-ring (22), and backup ring (21) in
outside diameter grooves of cylinder head (24).
sharp edges. Dress applicable surfaces as necessary. 2. Install two wear rings (25) seal (26), and rod wiper (27), in
cylinder head as shown.
21
13. Inspect cylinder length sensor components for damage. 22
Replace as needed.
23
14. Inspect rod and barrel bearings for signs of excessive
wear or damage. Replace as necessary.

24
be replaced.
25
c. Lubricate inside of steel bushing with WD40 before 26
installing bushings. 27
NOTE: Lubrication is not required with nickel plated pins and Figure 5-82. Cylinder Head Seal Kit Installation
3121619 5-91
3. Install cylinder head assembly on rod. Do not damage or through the drilled holes in the bushing and into the
dislodge wiper and rod seals. Push head along rod to tapped holes in the piston.
rod end.
4. Install piston spacer (20) on rod.
5. Install backup ring (18), O-ring (19) and backup ring (18)
in inner diameter grooves of piston (17). Install two seals
(16) and lock rings (15) in outer grooves of piston.
15
16
15

17 tion to 9 ft.lbs. (12 Nm).
18
19
18 11. After the screws have been torqued, tap the tapered
20 bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4” in diameter) as follows;
6. Using suitable protection, clamp cylinder rod in a vise or tact with the bushing in the spaces between the
similar holding fixture as close to piston as possible. capscrews.
7. Thread piston on cylinder rod hand tight. Ensure O-ring b. Tap each space once; this means the tapered bush-
and back-up rings are not damaged or dislodged. ing is tapped 3 times as there are 3 spaces between
the capscrews.
installing tapered bushing.
8. Thread piston on rod until it aligns with spacer end and

install tapered bushing.
9. Apply JLG Threadlocker (P/N 0100011) or equivalent to
tapered bushing capscrews and assemble the tapered
bushing loosely into the piston. Insert capscrews
12. Retorque the capscrews evenly and progressively in

rotation to 9 ft.lbs. (12 Nm).

5-92 3121619
14. If removed, install the cylinder length sensor. See Sec- 18. Tighten cylinder head with pin spanner wrench. Torque
tion 5.4, Cylinder Length Sensor. to 200 ft-lb (271 Nm).

AND PISTON.
15. Clamp barrel securely and support rod.
NOTE: Apply locking primer and JLG Threadlocker01 (P/N

0100011) to cylinder head threads.
16. Insert piston end into barrel cylinder. Do not damage or

dislodge piston loading O-ring and seal ring. . .
17. Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
1
24 19. Secure cylinder head (24) with setscrew (1).

3
28
28
Figure 5-86. Rod and Cylinder Head Installation
3121619 5-93
Platform Level Cylinder (SN 0300239170 to

Present) 8
Refer to Figure 5-91. 7
9 6
DISASSEMBLY 5
10
5
11
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

12
MAF07840
Figure 5-89. Cylinder Length Sensor Removal
3. Place cylinder barrel in a suitable holding fixture.

7. Mark cylinder head and barrel with center punch marks

for later realignment. Unscrew cylinder head with hook
spanner wrench.
CYLINDER BARREL
SPANNER NUT
HOOK SPANNER

Figure 5-88. Cylinder Barrel Support ROD

MAF07850
cap (7). Remove O-Ring plug (12). Remove cylinder Figure 5-90. Cylinder Head Installation
length sensor assembly (6) from barrel (3).
5-94 3121619
9 6
4 5
10
5
11
12 12
2* 12
12
3
4
2*
13**
14
15
16
17
16 21
15 22
18 23
19
18
20 24
25
26
27
1
**Torque to 9.59 in-lb (13 Nm)
28
1
1001228057-D
MAF07830D
1. Bushing 6. Length Sensor 11. Setscrew 16. Lock Ring 21. Backup Ring 26. Seal
2. Counterbalance Valve 7. Retainer Cap 12. Plug 17. Piston 22. O-Ring 27. Rod Wiper
3. Barrel 8. Capscrew 13. Capscrew 18. Backup Ring 23. O-Ring 28. Rod
4. Bushing 9. Retaining Ring 14. Tapered Bushing 19. O-Ring 24. Head
5. Spacer Sleeve 10. Sensor Magnet 15. Guidelock Ring 20. Spacer 25. Wear Ring
Figure 5-91. Platform Level Cylinder Assembly (SN 0300239170 to Present)
3121619 5-95
OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
head from barrel. 13. Remove and discard two guidelock ring (15), lock rings
(16), backup rings (18), O-ring (19) from piston (17).
9. Protect cylinder rod (28) from damage and clamp in a
vise or holding fixture as close to piston (17) as possible. 14. Remove piston spacer (20) from cylinder rod (28).
ROD SUPPORT 15
16
SUPPORT TABLE 15
17
18
19
18
20
10. Loosen and remove Capscrews (13) from tapered bush-
ing (14) and piston (17). 15. Remove cylinder rod (28) from holding fixture. Remove
cylinder head (24).
11. Insert capscrews (13) in threaded holes in outer piece of
tapered bushing (14). Progressively tighten capscrews 16. Remove and discard backup ring (21), O-ring (22), O-ring
(13) until tapered bushing (14) is loose. Remove tapered (23), rod wiper (27), seal (26), and two wear rings (25),
bushing (14) from piston (17). from cylinder head (24).
TAPERED BUSHING
21
ROD
22
PISTON 23
24
CAPSCREWS
25
MAF09940
26
Figure 5-93. Tapered Bushing Removal 27 MAF08020
12. Screw piston (17) counter-clockwise by hand and Figure 5-95. Cylinder Head Disassembly
remove from cylinder rod (28).
5-96 3121619
rect size arbor.
Composite Barrel or

Arbor
ASSEMBLY
JLG Parts Manual.
assembly.
necessary. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION.
threads as necessary. 1. Install O-ring (23), O-ring (22), and backup ring (21) in
outside diameter grooves of cylinder head (24).
sharp edges. Dress applicable surfaces as necessary. 2. Install two wear rings (25), seal (26), and rod wiper (27),
into cylinder head (24).
13. Inspect cylinder length sensor components for damage.

Replace as needed.

wear or damage. Replace as necessary. 21
a. Thoroughly clean hole, (steel bushing) of burrs, dirt 22

etc. to facilitate bearing installation. 23

steel bushing is worn or damaged, rod/barrel must 24
be replaced. 25
26
c. Lubricate inside of steel bushing with WD40 before 27 MAF08020
installing bushings.
NOTE: Lubrication is not required with nickel plated pins and Figure 5-97. Cylinder Head Seal Kit Installation
3121619 5-97
3. Install cylinder head assembly on rod. Do not damage or

dislodge wiper and rod seals. Push head along rod to
rod end.
4. Install piston spacer (20) on cylinder rod (28).
5. Install backup rings (18), O-ring (19) in inner diameter
grooves of piston (17). Install two guidelock rings (15),
lock rings (16) in outer grooves of piston (17).
15
16
15

rotation to 9.59 ft. lbs. (13 Nm).
17 11. After the screws have been torqued, tap the tapered
18 bushing with a hammer (16 to 24 oz.) and brass shaft
19
18 (approximately 3/4" in diameter) as follows;
20
Figure 5-98. Piston Seal Kit Installation tact with the bushing in the spaces between the
capscrews.
6. Using suitable protection, clamp cylinder rod (28) in a b. Tap each space once; this means the tapered bush-
vise or similar holding fixture as close to piston (17) as ing is tapped 3 times as there are 3 spaces between
possible. the capscrews.
Ensure O-ring and back-up rings are not damaged or
dislodged.
8. Thread piston (17) on cylinder rod (28) until it aligns with

spacer (20) end and install tapered bushing (14).
9. Apply JLG Threadlocker (P/N 0100011) or equivalent to
tapered bushing capscrews (13) and assemble the
tapered bushing (14) loosely into the piston (17. Insert
capscrews (13) through the drilled holes in the tapered
bushing (14) and into the tapped holes in the piston
(17). Insert capscrews (13) through the drilled holes in
the tapered bushing (14) and into the tapped holes in
the piston (17).
rotation to 9.59 ft. lbs. (13 Nm).

14. If removed, install the cylinder length sensor. See Sec-

tion 5.4, Cylinder Length Sensor.
5-98 3121619
18. Tighten cylinder head with hook spanner wrench.

Torque cylinder head to 180-220 ft. lbs. (244-298 Nm).
AND PISTON. HOOK SPANNER
15. Clamp barrel (3) securely and support cylinder rod (28).
NOTE: Apply locking primer and JLG Threadlocker01 (P/N

0100011) to cylinder head threads.
ROD
16. Insert piston (17) end into cylinder barrel (3). Do not
damage or dislodge piston loading O-ring and seal ring. CYLINDER
BARREL
17. Continue pushing cylinder rod (28) into cylinder barrel
(3) until cylinder head (24) gland can be inserted into
SAPANNER NUT
cylinder barrel (3).
3
19. Install the plugs (12) in the cylinder ports.
24
28
MAF08030
Figure 5-101. Rod and Cylinder Head Installation
3121619 5-99
Boom Lift Cylinder (Prior to SN 0300239676) 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove cylinder head cap screws.
DISASSEMBLY



SURE.
support cylinder rod, if applicable. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
3. If applicable, remove cartridge-type counterbalance SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
valve and fittings from cylinder port block. Discard O- PISTON.
rings.
4. Place cylinder barrel in a suitable holding fixture. Tap rod assembly from barrel.
hammer to break thread-locking compound. 7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
ROD SUPPORT
PROTECTED ROD CLAMP
SUPPORT TABLE
BARREL CLAMP
SUPPORT TABLE

5-100 3121619
2* 3*
4*
22** 21
17 16 15
14
10
13 9
8
18
19
20
19 7
18
6
12
11
24
*Torque to 30-35 ft-lb (41-Nm) 23

**Torque to 60 ft-lb (81-Nm)
23
1001158853-H
MAF07690H
1. Bearing 6. Capscrew 11. Wiper Seal 16. Backup Ring 21. Bushing
2. Counterbalance Valve 7. Washer Ring 12. Rod Seal 17. Piston 22. Bolt
3. Counterbalance Valve 8. Wear Ring 13. Head 18. Lock Ring 23. Bushing
4. Counterbalance Valve 9. Backup Ring 14. Backup Ring 19. Seal 24. Rod
5. Barrel 10. O-Ring 15. O-Ring 20. Wear Ring
Figure 5-106. Boom Lift Cylinder Assembly (Prior to SN 0300239676)
3121619 5-101
8. Remove three bolts attaching tapered bushing to pis- 12. Remove rod from holding fixture. Remove cylinder head
ton. (13) and washer ring (7) from rod.
9. Insert bolts in threaded holes in outer piece of Tapered 13. Remove and discard wiper seal (11), rod seal (12), wear
ring (8), back-up ring (9), and O-ring (10).
Bushing. Alternately tighten bolts until bushing is loose
on piston. Remove tapered bushing from piston.
10. Screw the piston counterclockwise by hand and remove

piston from cylinder rod.

CLEANING AND INSPECTION

BEFORE REMOVING FOR PROPER INSTALLATION. 2. Inspect cylinder rod for scoring, tapering, ovality, or
11. Remove and discard backup ring (14), O-ring (15), and
backup ring (16) from inside of piston (17). Remove and 3. Inspect threaded portion of rod for excessive damage.
discard two lock rings (18), seals (19), and wear ring (20) Dress threads as necessary.
from outside of piston.
necessary.
Figure 5-108. Piston Disassembly 10. Inspect threaded portion of head for damage. Dress
5-102 3121619
11. Inspect seal and O-ring grooves in head for burrs and ASSEMBLY
12. Inspect cylinder head outside diameter for scoring, JLG Parts Manual.
13. Inspect rod and barrel bearings for signs of correct assembly.

etc. to facilitate bearing installation. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
b. Inspect steel bushing for wear or other damage. If CYLINDER OPERATION.
be replaced. 1. Install O-ring (10), backup ring (9), wear ring (8), rod seal
(12), and wiper seal (11) in cylinder head (13).

d. Press bushing into barrel or rod bushing with cor-

rect size arbor.
Composite Barrel or
Bushing Rod Bushing
Composite
Bushing
Arbor

as necessary. Figure 5-111. Cylinder Head Assembly
foreign material. Repair as necessary. 2. Slide washer ring (7) and cylinder head Assembly (13) on
rod (26).
3121619 5-103
3. Install backup ring (16), O-ring (15), and backup ring (14) 7. Tighten the capscrews evenly and progressively in rota-
to inside groves of piston (17). tion to 60 ft-lb (81 Nm).
4. Install wear ring (20), two seals ring (19), and lock rings 8. After the screws have been torqued, tap the tapered
(18) to outside grooves of piston (17). bushing with a hammer (16 to 24 oz.) and brass shaft
capscrews.
the capscrews.
Figure 5-112. Piston Assembly
5. Install piston assembly (17) and tapered bushing (23) on Figure 5-114. Seating the Tapered Bearing
rod (26).
9. Re-torque the capscrews evenly and progressively in
NOTE: When installing the tapered bushing, piston and mating rotation to 60 ft-lb (81 Nm).
6. Apply JLG Threadlocker (P/N 0100011) to tapered bush-

ing capscrews. Assemble the tapered bushing loosely
into the piston and insert capscrews through the drilled
piston.
5-104 3121619
10. Remove cylinder rod from holding fixture. 15. Apply primer and medium-strength locking compound
JLG P/N 0100011or equivalent to eight capscrews (6).
11. Position cylinder barrel in a suitable holding fixture. Secure cylinder head assembly (13) and washer ring (7)
to barrel (5)with capscrews.

AND PISTON.
12. Clamp barrel (5) securely and support rod (24). Insert
piston (17) end in barrel. Do not damage or dislodge pis-
ton O-rings or seal rings.
13. Continue pushing rod in barrel until cylinder head (13)

can be inserted in barrel.
14. Install cylinder head until tight and marks made during
disassembly are aligned.
3121619 5-105
Boom Lift Cylinder (SN 0300239676 to Present) 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove cylinder head cap screws.
DISASSEMBLY



SURE.
support cylinder rod, if applicable. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
3. If applicable, remove cartridge-type counterbalance SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
valve and fittings from cylinder port block. Discard O- PISTON.
rings.
4. Place cylinder barrel in a suitable holding fixture. Tap rod assembly from barrel.
hammer to break thread-locking compound. 7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
ROD SUPPORT
PROTECTED ROD CLAMP
SUPPORT TABLE
BARREL CLAMP
SUPPORT TABLE

5-106 3121619
21
17***
21 21
15
21
16***
21
21
16***
8
9
22
6
7
3
4 14
20** 13
19*
5
12
10
18
11
*Torque to 24 ft-lb (33-Nm) 15

**Torque to 197 ft-lb (267-Nm)
***Torque to 30-34 ft-lb (41-47-Nm)
15
1001228072-B
MAF07700B
1. Barrel 6. Rod Seal 11. Rod, O-Ring 16. Counterbalance Valve 20. Capscrew
2. Rod 7. Backup Ring 12. Piston Seal 17. Shuttle Valve 21. Plug
3. Head 8. Wear Ring 13. Stell Ball 18. Spacer 22. Back-up Ring
4. Wiper Seal 9. O-Ring 14. Setscrew 19. Capscrew
5. Retainer Ring 10. Piston 15. Bushing
Figure 5-119. Boom Lift Cylinder Assembly (SN 0300239676 to Present)
3121619 5-107
8. Using suitable protection, clamp cylinder rod in a vise or 13. Remove rod (2) from holding fixture.
similar holding fixture as close to piston as possible. Remove cylinder head (3) from rod (2).
9. Remove setscrews attaching piston to cylinder rod. 14. Remove and discard wear rings (8), wiper seal (4),
retaining ring (5), rod seal (6), backup ring (7) from inside
10. Screw the piston counterclockwise by hand and remove
of cylinder head (3).
piston from cylinder rod.
ROD
CAPSCREW
SETSCREW
STEEL BALL
8
9
22
ROD END 6
7
SPACER
3
4
PISTON 5
MAF07740
MAF07760
Figure 5-120. Piston Removal

15. Remove and discard O-ring (9) and backup ring (22)
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, from outside grooves of cylinder head (3).
BEFORE REMOVING FOR PROPER INSTALLATION. CLEANING AND INSPECTION
11. Remove and discard piston seal (12) from outside
grooves of piston (10). 2. Inspect cylinder rod for scoring, tapering, ovality, or
12. Remove spacer (18) from rod (2). Remove and discard
O-ring (11).
11 Dress threads as necessary.
19
18 4. Inspect inner surface of cylinder barrel tube for scoring
12 5. Inspect threaded portion of barrel for damage. Dress
14
10 13
MAF07750
Figure 5-121. Piston Disassembly other damage, and for ovality and tapering. Replace as
necessary.
5-108 3121619
11. Inspect seal and O-ring grooves in head for burrs and ASSEMBLY
12. Inspect cylinder head outside diameter for scoring, JLG Parts Manual.
13. Inspect rod and barrel bearings for signs of correct assembly.

etc. to facilitate bearing installation. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
b. Inspect steel bushing for wear or other damage. If CYLINDER OPERATION.
be replaced. 1. Install wear rings (8), wiper seal (4), retaining ring (5),
rod seal (6), backup ring (7) in inside grooves of
c. Lubricate inside of the steel bushing with WD40 cylinder head (3).
2. Install O-ring (9) and backup ring (22) in outside grooves
NOTE: Lubrication is not required with nickel plated pins and of cylinder head (3).
d. Press bushing into barrel or rod bushing with cor-

rect size arbor.
Composite Barrel or 8
Bushing Rod Bushing
Composite 9
22
Bushing
6
7
3
Arbor 4
5
Figure 5-123. Bushing Installation MAF07760
Figure 5-124. Cylinder Head Assembly

as necessary.
3. Carefully install cylinder head assembly (3) on rod (2).
15. Inspect oil ports for blockage or presence of dirt or other Do not damage or dislodge wiper and rod seals. Push
foreign material. Repair as necessary. head along rod to rod end.
4. Install O-ring (11) into the spacer (18) and Carefully slide
spacer (18) onto rod (2) with O-ring (11) end facing
cylinder head. Ensure that O-ring not damage and dis-
lodge.
3121619 5-109
5. Install piston seal (12) in outside grooves of piston (10).

6. Using suitable protection, clamp cylinder rod (2) in a INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
vise or similar holding fixture as close to piston SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
as possible. AND PISTON.
11
19 10. Clamp barrel (1) securely and support rod (2).
18 Insert piston (10) end in barrel. Do not damage or dis-
lodge piston O-rings or seal rings.
11. Continue pushing rod in barrel until cylinder head (3)
12 can be inserted in barrel.
14
10 12. Install cylinder head (3) until tight and marks made dur-
13
ing disassembly are aligned.
13. Secure cylinder head assembly (3) to barrel (1) with cap-
screws (20). Torque to 197 ft-lb (267-Nm).
17 21
21 21
MAF07750
21
Figure 5-125. Piston Assembly 16
16
21
NOTE: Piston and mating end of rod must be free of oil when 1
7. Carefully thread piston (10) on cylinder rod (2) hand 10

tight. Do not damaged or dislodge O-ring and
backup rings.
8. Install the setscrew (14) and stell ball (13) on the piston
(10) and attach the piston (10) on the rod (2). 2
9. Position cylinder barrel (1) in a suitable holding fixture.

3
ROD 20
MAF07780

CAPSCREW
SETSCREW
14. Install the plugs (21) in the cylinder ports.
STEEL BALL
15. Install two counterbalance valves (16) in valve block.
Torque to 30-34 ft-lb (41-47-Nm).
ROD END
16. Install shuttle valves (17) valve block.
Torque to 30-34 ft-lb (41-47-Nm).
SPACER
PISTON
MAF07740
Figure 5-126. Piston Removal
5-110 3121619
Jib Lift Cylinder (Prior to SN 0300239676)

DISASSEMBLY 5
4
6 11
1
10
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A 9
7

SURE. Figure 5-129. Cylinder Length Sensor Removal
Shut down and disconnect power source. Adequately 6. Tap around outside of cylinder head retainer with a suit-
support cylinder rod, if applicable. able hammer to break thread-locking compound.
for later realignment. Remove eight cylinder head cap
screws.




cap (10). Remove O-Ring plug (5) and setscrew (4).
Remove cylinder length sensor assembly (9) from barrel
(1).
3121619 5-111
5
4**
3
6 11
10
9
2*
7 8
1
3
2*
12***
13
14
15
16
15
14
18 17
17
20
18
21
19
22
23
24
25
26
27
* Torque to 50-55ft-lb (67-75 Nm)

* *Torque to 4 in-lb (0.9 Nm)
29 * **Torque to 9.95 ft-lb (13 Nm)
28
1001140104-D
MAF08180D
28
1. Barrel 7. Sensor Magnet 13. Tapered Bushing 19. Spacer 25. Rod Wiper
2. Counterbalance Valve 8. Internal Retaining Ring 14. Lock Ring 20. O-Ring 26. Washer Ring
3. Bushing 9. Cylinder Length Sensor 15. Seal 21. Backup Ring 27. Capscrew
4. Setscrew 10. Retainer Cap 16. Piston 22. Cylinder Head 28. Bushing
5. O-Ring Plug 11. Capscrew 17. Backup Ring 23. Wear Ring 29. Rod
6. Spacer 12. Capscrew 18. O-Ring 24. Seal
Figure 5-131. Jib Lift Cylinder Assembly (Prior to SN 0300239676)
5-112 3121619
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.

head from barrel.
ROD SUPPORT
SUPPORT TABLE
13. Remove and discard two lock rings (14), seals (15),
backup ring (17), O-ring (18), and backup ring (17) from
piston (16).
Figure 5-132. Cylinder Rod Support 14. Remove piston spacer (19) from rod (29). Remove and
discard O-ring (18) from inside of spacer.
10. Loosen and remove bolts from tapered bushing and
piston.
11. Insert Capscrews (12) in threaded holes in outer piece of
tapered bushing (13). Progressively tighten bolts until
14
bushing isloose. Remove tapered bushing (13) from
15
piston (16).
16
12. Screw piston counter-clockwise by hand and remove
15
from cylinder rod.
14
18 17
17
18
19
MAF08200
3121619 5-113
15. Remove rod from holding fixture. 12. Inspect cylinder head outside diameter for scoring,
16. Remove cylinder head (22) and washer ring (26).
17. Remove and discard O-ring (20), backup ring (21), Replace as needed.
rod wiper (25), seal (24), and two wear rings (23), from
cylinder head (22). 14. Inspect rod and barrel bearings for signs of excessive
20 be replaced.
21 c. Lubricate inside of steel bushing with WD40 before
22
23 bearings. Install pin in composite bushing dry.
24
25 d. Press bushing (3) into barrel (1) or rod bushing with
correct size arbor.
MAF08190
Composite Barrel or
Figure 5-135. Cylinder Head Disassembly Bushing Rod Bushing
Composite
Bushing
2. Inspect cylinder rod for scoring, tapering, ovality, or Arbor

or equivalent. Replace rod if necessary. Figure 5-136. Composite Bushing Installation
necessary.
4. Inspect inner surface of cylinder barrel tube for scoring 16. Inspect oil ports for blockage or presence of dirt or other
or other damage. Check inside diameter for tapering or foreign material. Repair as necessary.





necessary.

5-114 3121619
ASSEMBLY
JLG Parts Manual.

assembly.
14
15
16
15
CYLINDER OPERATION.
14
1. Install backup ring (21) and O-ring (20) in outside diame- 18 17
ter grooves of cylinder head (22). 17
18
2. Install two wear rings (23), seal (24) and rod wiper (25) in 19
MAF08200
20 6. Using suitable protection, clamp cylinder rod in a vise or

21
7. Thread piston on cylinder rod hand tight. Ensure O-ring
22 and back-up rings are not damaged or dislodged.
23 NOTE: Piston and mating end of rod must be free of oil when
25
8. Thread piston (16) on rod (29) until it aligns with spacer
end and install tapered bushing (13).
MAF08190

Figure 5-137. Cylinder Head Seal Kit Installation
3. Install washer ring (26) on rod (29). Install cylinder head

assembly on rod. Do not damage or dislodge wiper and
rod seals. Push head along rod to rod end.
4. Install O-ring (18) in spacer (19). Slide piston spacer on
rod (29).
5. Install backup ring (17), O-ring (18) and backup ring (17)
(15) and lock rings (14) in outer grooves of piston (16).
3121619 5-115

ing bolts. Assemble the tapered bushing (13) loosely
into the piston (16) and insert capscrews (12) through INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
the drilled holes in the bushing and into the tapped SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
holes in the piston (16). AND PISTON.
loading O-ring and seal ring.
NOTE: Apply JLG Threadlocker (P/N 0100011) or equivalent to

capscrews.

29
rotation to 9 ft.lb (12 Nm). 22
26
11. After the screws have been torqued, tap the tapered 27
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows; 29
MAF08210
tact with the bushing in the spaces between the Figure 5-141. Rod Assembly Installation
capscrews.

15. Secure cylinder head (22) and washer ring (26) with
eight capscrews (27).
the capscrews.
16. Install two counterbalance valve (3) with new O-rings
17. If removed, install the cylinder length sensor.
See Section 5.4, Cylinder Length Sensor.

rotation to 9 ft.lb (12 Nm).
5-116 3121619
Jib Lift Cylinder (SN 0300239676 to Present) 5. If necessary, remove eight capscrews (11) and retainer
cap (10). Remove O-Ring plug (5) and setscrew (4).
Refer to Figure 5-145. Remove cylinder length sensor assembly (9) from barrel
(1).
DISASSEMBLY
5
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 6 11
1
10
cylinder port block fitting. 8
7

SURE.

Shut down and disconnect power source. Adequately Figure 5-143. Cylinder Length Sensor Removal
6. Tap around outside of cylinder head retainer with a suit-
3. Place cylinder barrel in a suitable holding fixture. able hammer to break thread-locking compound.
for later realignment. Remove eight cylinder head cap
screws.



3121619 5-117
5 8
4** 7 11
3 10
5 9
5 6
2* 5
6
1 5
3
2*
12***
13
14
15
16
15
14
17
18
17
18
19
20
21
22
23
24
25
26
27
* Torque to 55-55ft-lb (67-75 Nm)

* *Torque to 4 in-lb (0.9 Nm)
* **Torque to 9.95 ft-lb (13 Nm)
29
28
1001228058-D
28 MAF08220D
1. Barrel 7. Sensor Magnet 13. Tapered Bushing 19. Spacer 25. Rod Wiper
2. Counterbalance Valve 8. Internal Retaining Ring 14. Lock Ring 20. O-Ring 26. Washer Ring
3. Bushing 9. Cylinder Length Sensor 15. Seal 21. Backup Ring 27. Capscrew
4. Setscrew 10. Retainer Cap 16. Piston 22. Cylinder Head 28. Bushing
5. O-Ring Plug 11. Capscrew 17. Backup Ring 23. Wear Ring 29. Rod
6. Spacer 12. Capscrew 18. O-Ring 24. Seal
Figure 5-145. Jib Lift Cylinder Assembly (SN 0300239676 to Present)
5-118 3121619
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
PISTON. BEFORE REMOVING FOR PROPER INSTALLATION.
8. Clamp barrel (1) securely. Pull rod assembly and cylinder 1. Remove and discard two lock rings (14), seals (15),
head from barrel. backup ring (17), O-ring (18), and backup ring (17) from
piston (16).
9. Protect cylinder rod (29) from damage and clamp in a
vise or holding fixture as close to piston (16) as possible. 2. Remove piston spacer (19) from rod (29). Remove and
discard O-ring (18) from inside of spacer.
ROD SUPPORT
SUPPORT TABLE
14
15
16
15
14
17
18
17
18
19
MAF08240
Figure 5-146. Cylinder Rod Support 3. Remove rod from holding fixture. Remove cylinder head
(22) and washer ring (26).
10. Loosen and remove Capscrews (12) from tapered bush-
4. Remove and discard O-ring (20), backup ring (21), rod
ing (13) and piston (16).
wiper (25), seal (24) and two wear rings (23) from cylin-
11. Insert Capscrews (12) in threaded holes in outer piece of der head (22).
tapered bushing (13). Progressively tighten bolts until
bushing is loose. Remove tapered bushing (13) from pis-
ton (16).
12. Screw piston(16) counter-clockwise by hand and

remove from cylinder rod (29). 20
21
22
23
24
CAPSCREWS 25
ROD
MAF08230
PISTON
TAPERED
BUSHING
MAF08250
3121619 5-119
rect size arbor.
Composite Barrel or

Arbor



necessary.



Replace as needed.


be replaced.
c. Lubricate inside of steel bushing with WD40 before


5-120 3121619
ASSEMBLY
JLG Parts Manual.
assembly. 14
15
16
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER 15
CYLINDER OPERATION. 14
17
18
17
1. Install backup ring (21) and O-ring (20) in outside diame- 18
ter grooves of cylinder head (22). 19
2. Install two wear rings (23) seal (24) and rod wiper (25) in
MAF08240
cylinder head as shown.

similar holding fixture as close to piston (16) as possible.

20 Ensure O-ring and back-up rings are not damaged or
21 dislodged.
22 NOTE: Piston and mating end of rod must be free of oil when
24
25 8. Thread piston on rod until it aligns with spacer end and
MAF08230
Figure 5-150. Cylinder Head Seal Kit Installation
3. Install washer ring (26) on rod (29). Install cylinder head 9. Apply JLG Threadlocker (P/N 0100011) to tapered cap-
assembly on rod. Do not damage or dislodge wiper and screws (12). Assemble the tapered bushing (13) loosely
rod seals. Push head along rod to rod end. into the piston (16) and insert capscrews through the
4. Install O-ring (18) in spacer (19). Slide piston spacer on drilled holes in the bushing and into the tapped holes in
rod (29). the piston (16).
5. Install backup ring (17), O-ring (18) and backup ring (17) PISTON
(15) and lock rings (14) in outer grooves of piston.
CAPSCREWS
ROD
TAPERED
BUSHING
MAF08250

3121619 5-121

(approximately 3/4" in diameter) as follows; INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
a. Place the shaft against the cylinder rod and in con- AND PISTON.
capscrews. 4. Clamp barrel securely and support rod. Insert piston end
b. Tap each space once; this means the tapered bush- into barrel cylinder. Do not damage or dislodge piston
ing is tapped 3 times as there are 3 spaces between loading O-ring and seal ring.
the capscrews.
5. Continue pushing cylinder rod (29) into barrel (1) until
cylinder head (23) gland can be inserted into cylinder
barrel (1).
NOTE: Apply JLG Threadlocker (P/N 0100011) or equivalent to

capscrews
6. Secure cylinder head (22) and washer ring (26) with

eight capscrews (27).

29
22
26
27
29
MAF08260

8. If removed, install the cylinder length sensor.
See Section 5.4, Cylinder Length Sensor.
5-122 3121619
Jib Lock Cylinder 5. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
Refer to Figure 5-155. and Figure 5-156.
holding fixture.
DISASSEMBLY
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. BEFORE REMOVING FOR PROPER INSTALLATION.
7. Remove and discard seal (2) and wear ring (3) from rod
(1).
8. Remove and discard rod wiper (11), seal (10), and two
wear rings (9) from inside of cylinder head (8).
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. 9. Remove and discard O-ring (5), backup ring (6), and O-
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES- ring (7) from outer groves of cylinder head.
SURE.

Shut down and disconnect power source.

4. Mark cylinder head and barrel with a center punch for

realignment. Unscrew cylinder head with pin-face span-
ner wrench.
. .
Mark For Reassembly

PISTON.
3121619 5-123
3
2
5
6
10
11 1001119313-C
MAF07800C
1. Rod 4. Barrel 7. O-Ring 10. Seal

2. Seal 5. O-Ring 8. Head 11. Rod Wiper
3. Wear Ring 6. Backup Ring 9. Wear Ring
Figure 5-155. Jib Lock Cylinder Assembly (Prior to SN 0300239170)
5-124 3121619
10
11 1001228046-B
MAF07810B
1. Rod 4. Barrel 7. O-Ring 10. Seal

2. Seal 5. O-Ring 8. Head 11. Rod Wiper
3. Wear Ring 6. Backup Ring 9. Wear Ring
Figure 5-156. Jib Lock Cylinder Assembly (SN 0300239170 to Present)
3121619 5-125
CLEANING AND INSPECTION 3. Install two wear rings (9), seal (10), and rod wiper (11) to
inside grooves of cylinder head.
4. Install seal (2) and wear ring (3) to piston end of rod (1).
2. Inspect rod for scoring, tapering, ovality, or other dam-
age. If necessary, dress rod with Scotch Brite or equiva-
lent. Replace rod if necessary.
3. Inspect inner surface of barrel for scoring or other dam- SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
age. Check inside diameter for tapering or ovality. AND PISTON.
Replace if necessary.
NOTE: Apply anti-seize compound to cylinder head threads.
threads as necessary. 5. Insert piston end into barrel cylinder. Do not damage or
5. Inspect piston surface for damage, scoring, or distortion. dislodge piston loading O-ring and seal ring. Push rod in
Dress piston surface or replace piston as necessary. barrel as far as possible without excess force.
6. Inspect seal and O-ring grooves in piston for burrs and 6. Slide cylinder head assembly (8) over rod and screw into
sharp edges. Dress surfaces as necessary. barrel. Tighten cylinder head with pin spanner wrench.

necessary.



11. Inspect oil ports for blockage or presence of dirt or other . .

ASSEMBLY
JLG Parts Manual.

assembly. Figure 5-157. Cylinder Head Installation
1. Position cylinder barrel in a suitable holding fixture.
2. Use seal tool to install new rod seal into applicable cylin-
der head gland groove.

CYLINDER OPERATION.
3. Install O-ring (7), back-up ring (6), and O-ring (5) in appli-
cable outside diameter groove of cylinder head (8).
5-126 3121619
Steer Cylinder (Prior to SN 0300239676) 7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
DISASSEMBLY
SUPPORT TABLE



SURE.
Shut down and disconnect power source. Figure 5-159. Cylinder Rod Support
4. Remove self-tapping screw (9) from cylinder head (5)
and barrel (2). REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
5. Unscrew cylinder head with pin-face spanner wrench. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
8. Remove setscrew (13) from piston (12). remove piston

(12) from rod (17).
9. Remove and discard O-ring (11), seal (15), and wear ring
(14) from piston (12). Remove rod (17) from clamp or
vise.

PISTON.

head from barrel.
3121619 5-127
1001155986
1. Bushing 4. Seal 7. Backup Ring 10. Wear Ring 13. Setscrew 16. Bushing
2. Barrel 5. Head 8. O-Ring 11. O-Ring 14. Wear Ring 17. Rod
3. Wiper Seal 6. O-Ring 9. Screw 12. Piston 15. Seal
Figure 5-160. Steer Cylinder Assembly (Prior to SN 0300239676)
5-128 3121619
10. Remove cylinder head assembly (5) from rod (17). 12. Inspect cylinder head outside diameter for scoring,
Remove and discard two wear rings (10), seal (4), wiper damage, ovality, and tapering. Replace as necessary.
seal (3), O-ring (8), backup ring (7), and O-ring (6) from
cylinder head.
ASSEMBLY
JLG Parts Manual.

assembly.

CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION.
1. Install seal (4) and wiper seal (3) to inside grooves of cyl-
inder head (5).
Figure 5-161. Piston and Cylinder Head Disassembly 2. Install two wear rings (10) in cylinder head.
3. Install O-Ring (6), backup ring (7), and O-ring (8) to out-
side grooves of cylinder head.
4. Slide cylinder head assembly on rod.
5. Install O-ring (11) to inside groove of piston (12).
other damage. If necessary, dress rod with Scotch Brite 6. Install wear ring (14) and seal (15) in outside grooves of
or equivalent. Replace rod if necessary. piston.
8. Apply medium-high strength (red) thread-locking com-
4. Inspect inner surface of cylinder barrel tube for scoring pound JLG P/N 0100071 or equivalent to rod threads.
ovality. Replace if necessary. 9. Thread piston assembly on rod. Do not dislodge or dam-
age O-ring. Torque piston to 30 ft-lb (40 Nm).




necessary.

3121619 5-129
10. Install setscrew (13) in piston. Torque to 90 in-lb (10 Nm). 15. Adjust cylinder head until screw hole aligns with barrel.
Install screw (9).
5
Figure 5-162. Cylinder Head and Piston Assembly
Figure 5-163. Cylinder Head Installation

AND PISTON.
11. Clamp barrel securely in suitable fixture and support

rod. Insert piston end into barrel cylinder. Do not dam-
age or dislodge piston O-rings or seal rings.
12. Apply ant-seize compound to cylinder head threads.
13. Continue pushing rod into barrel until cylinder head can
be inserted into barrel cylinder.
14. Screw in cylinder head (5) to barrel (2). Torque to 100 ft-
lb (135 Nm).
5-130 3121619
Steer Cylinder (SN 0300239676 to Present) 7. Protect cylinder rod from damage and clamp in a vise or
DISASSEMBLY ROD SUPPORT
SUPPORT TABLE



SURE.
for later realignment.
5. Unscrew cylinder head with hook spanner wrench. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
CYLINDER HEAD
8. Remove setscrew (13) from piston (12). remove piston
(12) from Cylinder rod (16).
ROD 9. Remove and discard O-ring (11), seal (15), and wear ring
BARREL (14) from piston (12). Remove cylinder rod (16) from
clamp or vise.
HOOK SPANNER
MAF08280

PISTON.

head from barrel.
3121619 5-131
2
1
10
11*
9
6
3
12**
14
13 5
4
8
7
*Torque to 30.24 ft-lbs (41 Nm)

**Torque to 7.38 ft-lbs (10 Nm)
16
15
15 1001228065-A
MAF08290A
1. Bushing 4. Seal 7. Backup Ring 10. O-Ring 13. Wear Ring 15. Bushing
2. Barrel 5. Head 8. O-Ring 11. Piston 14. Seal 16. Rod
3. Wiper Seal 6. O-Ring 9. Wear Ring 12. Setscrew
Figure 5-166. Steer Cylinder Assembly (SN 0300239676 to Present)
5-132 3121619
10. Remove cylinder head assembly (5) from rod (16). CLEANING AND INSPECTION
10. Remove and discard two wear rings (9), seal (4), wiper 1. Clean parts thoroughly with approved cleaning solvent.
seal (3), O-ring (8), backup ring (7), and O-ring (6) from
cylinder head (5). 2. Inspect cylinder rod for scoring, tapering, ovality, or
11 10 or equivalent. Replace rod if necessary.
9
6
3 4. Inspect inner surface of cylinder barrel tube for scoring
12 5. Inspect threaded portion of barrel for damage. Dress
14
13 5 6. Inspect piston surface for damage, scoring, or distortion.
4
8 7. Inspect threaded portion of piston for damage. Dress
7
MAF08300
Figure 5-167. Piston and Cylinder Head Disassembly 8. Inspect seal and O-ring grooves in piston for burrs and
necessary.
3121619 5-133
ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
JLG Parts Manual. SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
assembly. 11. Clamp barrel (2) securely in suitable fixture and support
rod. Insert piston (5) end into barrel cylinder. Do not
damage or dislodge piston O-rings or seal rings.
12. Apply ant-seize compound to cylinder head threads.
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY 13. Continue pushing rod into barrel until cylinder head can
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN- be inserted into barrel cylinder.
TATION.
14. Screw in cylinder head (5) to barrel (2).
1. Install two wear rings (9) in cylinder head (5). 15. Adjust cylinder head until Mark up of Center Punch hole
aligns with barrel.
2. Install two wear rings (10) in cylinder head.
3. Install O-Ring (6), backup ring (7), and O-ring (8) to out-
side grooves of cylinder head (5).
HOOK SPANNER
4. Slide cylinder head assembly (5) on cylinder rod (16).
5. Install O-ring (10) to inside groove of piston (11).

ROD
6. Install wear ring (13) and seal (14) in outside grooves of
piston (11).
7. Using suitable protection, clamp cylinder rod (16) in a BARREL

vise or similar holding fixture as close to piston (5) as
possible.
CYLINDER HEAD
8. Apply medium-high strength (red) thread-locking com-
pound JLG P/N 0100071 or equivalent to rod threads.
9. Thread piston (5) assembly on cylinder rod (16). Do not

dislodge or damage O-ring. Torque piston to 30.24 ft-lbs Figure 5-169. Cylinder Head Installation
(41 Nm).
10. Install setscrew (12) in piston. Torque to 7.38 ft-lbs

(10 Nm).
11 10
9
6
3
12
14
13 5
4
8
7
MAF08300
Figure 5-168. Cylinder Head and Piston Assembly
5-134 3121619
Jib Telescope Cylinder

Refer to Figure 5-172. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
PISTON.
DISASSEMBLY
8. Clamp barrel securely. Pull rod assembly out until piston
bottoms to cylinder head.
9. Remove capscrew and pull rod assembly and cylinder
head from barrel.
1. Connect a suitable auxiliary hydraulic power source to holding fixture as close to piston as possible.
ROD SUPPORT
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. SUPPORT TABLE

SURE.

3. Place cylinder barrel in a suitable holding fixture. Clean

outside of cylinder to prevent contamination.
4. Remove two bolts (3), four washers (4), two nuts (9) and
wear pad (5) from bracket (7). Repeat for remaining wear
pad.
5. Remove eight socket head screws (6) and two pad sup- Figure 5-171. Cylinder Rod Support
ports (7) from cylinder head (12). Reinstall one socket
head screw finger-tight. 11. Remove piston assembly (19) from rod (22) with spanner
wrench.
6. Remove three cartridge valves from valve block.
12. Remove spacer assembly (16) from rod (22).
7. Tap around outside of cylinder head retainer with a suit-
13. Remove cylinder head assembly (12) from rod (22).
able hammer to break thread-locking compound.
2 12
9
8
7
22
4
3
7
6
Figure 5-170. Cylinder Head and Wear Pads
3121619 5-135
2**
2** 3
20***
19
18
21 16
22
21 13
11
17
10
9
8
15
14 6
12 5
4
8
7*
23
*Torque to 20 ft-lb (27 Nm)

**Torque to 25-30 ft-lb (33-40 Nm)
1001158991
1. Shuttle Valve 5. Washer 9. Washer 13. Cylinder Head 17. Spacer 21. Wear Ring
2. Counterbalance Valve 6. Wear Pad 10. Nut 14. Backup Ring 18. O-Ring 22. Seal
3. Barrel 7. Capscrew 11. Wiper 15. O- Ring 19. O-Ring 23. Rod
4. Bolt 8. Support Pad 12. Seal 16. Wear Ring 20. Piston
Figure 5-172. Jib Telescope Cylinder Assembly
5-136 3121619
BEFORE REMOVING FOR PROPER INSTALLATION. CLEAN PARTS THOROUGHLY WITH WATER AND A RUST PREVENTATIVE ONLY.
DO NOT USE ANY FORM OF DETERGENT OR SOAP.
14. Remove and discard O-ring (19), two wear rings (21),
and seal (22) from piston (20). 1. Inspect cylinder rod for scoring, tapering, ovality, or
15. Remove and discard O-ring (18) from spacer (17). or equivalent. Replace rod if necessary.

20
19
18

21
22
21
17
Figure 5-173. Piston and Spacer Disassembly other damage, and for ovality and tapering. Replace as
necessary.
16. Remove rod from holding fixture and remove cylinder
head.
17. Remove and discard wiper (11), seal (12), wear ring (16),
O-ring (15), and backup ring (14) from cylinder head 9. Inspect seal and O-ring grooves in head for burrs and
(13). sharp edges. Dress applicable surfaces as necessary.

16
13
11 dress inside diameter surface with Scotch Brite or equiv-
alent.
12. Inspect port block fittings and cartridge valves. Replace

15 as necessary.

14 12
3121619 5-137
ASSEMBLY 5. Install O-ring (18) in spacer (17). Slide spacer on rod.
NOTE: Use proper cylinder seal kit for cylinder assembly. See your 6. Install O-ring (19) to inside groove of piston (20).
JLG Parts Manual. 7. Install seal (22) and two wear rings in outer grooves of
piston.
assembly.
20
19

CYLINDER OPERATION. 18
1. Install new wear ring (16) in cylinder head (13).

2. Install seal (12) and wiper (11) in cylinder head. 21
3. Install backup ring (14) and O-ring (15) in outside diame- 22
ter grooves of cylinder head. 21
16 17
13 Figure 5-176. Piston and Spacer Assembly

11

15
9. Apply medium-strength locking compound JLG P/N
0100011or equivalent to rod threads.
10. Install piston on cylinder rod. Do not damage or dis-
lodge O-ring. Torque to 100 ft-lb (135 Nm).
14 12 11. Remove cylinder rod from holding fixture.
Figure 5-175. Cylinder Head Assembly

4. Install cylinder head assembly on rod. Do not damage or
dislodge wiper and rod seals. Push head along rod to
AND PISTON.
rod end.
O-rings and seals.
5-138 3121619
NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011) 17. Install shuttle valve (1) with new O-ring in valve block.
or equivalent to capscrew threads. Torque to 20 ft-lb (27 Nm).
15. Install two pad supports (7) to cylinder head (12) and
barrel (2) with eight capscrews (6). Torque capscrews to
20 ft-lb (27 Nm) following sequence shown in Figure 5-
178.
2
2 12
9
8
7
22
4
3
2
7
6
Figure 5-179. Valve Installation
5 1
3 7
8
4
2 6
Figure 5-178. Cylinder Head Torque Sequence
16. Install each wear pad (5) with two bolts (3), four washers
(4) and two bolts (9).
3121619 5-139
Boom Telescope Cylinder (SN 0300190128 through 7. Tap around outside of Cylinder Head with a suitable
hammer to break thread-locking compound. Unscrew
0300244677) Cylinder Head (23).
DISASSEMBLY
27
25
28
DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER Figure 5-181. Port Block And Rod Removal
SLIGHTLY TO AVOID TRAPPING PRESSURE.

Shut down and disconnect power source. Adequately PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
support cylinder rod. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.
head from barrel.
ROD SUPPORT
PROTECTED ROD CLAMP
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
4. Remove check valves (3), counterbalance valves (4), and

fittings from valve block (2). Discard O-rings. Remove
four capscrews (1) and valve block from rod (7). Discard Figure 5-182. Cylinder Rod Support
O-rings (5, 6).
5. Mark cylinder head (23) and barrel (28) with center

punch marks for later realignment. Remove two cap-
screws (27) and bracket (26).
6. Remove six remaining capscrews (25) and washers (24).
5-140 3121619
1 3 4
2
3 5
6
4
27
26
25
24
23
22
21
20
19 18 11 12
17 13
11
16
15 14
10
9
8*
28
* Torque to 30 ft-lb (41Nm)
1001178592-E
MAF09050E
1. Capscrew 6. O-Ring 11. Wear Ring 16. Spacer 21. Wiper Seal 26. Bracket
2. Valve Block 7. Rod 12. Seal 17. Wear Ring 22. Retaining Ring 27. Capscrew
3. Check Cartridge 8. Bolt 13. Backup Ring 18. O-Ring 23. Cylinder Head 28. Barrel
4. Counterbalance Valve 9. Tapered Bushing 14. Washer Ring 19. Back-Up Ring 24. Washer
5. O-Ring 10. Piston 15. Capscrew 20. Rod Seal 25. Capscrew
Figure 5-183. Boom Telescope Cylinder Assembly (SN 0300190128 through 0300244677)
3121619 5-141
10. Remove three bolts attaching tapered bushing to pis- 14. Remove capscrew (15) and spacer (16) from rod (7).
ton.
15. Remove rod from holding fixture.
NOTE: Record orientation of rings for reassembly.
bushing. Alternately tighten bolts until bushing is loose
on piston. Remove tapered bushing from piston.
16. Remove cylinder head (23) from rod (7). Remove and
12. Remove piston from cylinder rod. discard O-Ring (18), backup ring (19), retaining ring (22),
wiper seal (21), rod seal (20), and two wear rings (17).
22
19
18
21
20
23

17
13. Remove and discard two backup rings (13), washer ring
(14), two wear rings (11), and seal (12) from piston (10).
13
14
11
11
5-142 3121619
CLEANING AND INSPECTION ASSEMBLY
1. Clean parts thoroughly with approved cleaning solvent. NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
other damage. If necessary, dress rod with Scotch Brite Apply a light film of hydraulic oil to all components before
or equivalent. Replace rod if necessary. assembly.

ovality. Replace if necessary. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. WIPER SEAL ROUNDED SURFACE MUST FACE TOWARD
4. Inspect threaded portion of barrel for damage. Dress PISTON AS NOTED DURING DISASSEMBLY.
1. Install rod seal (20), wiper seal (21), and locking ring (22)
in cylinder head (23).
2. Install two wear rings (17) in cylinder head.
threads as necessary. 3. Install backup ring (19) and O-ring (18) on cylinder head.

sharp edges. Dress surfaces as necessary. 22
19
necessary.
9. Inspect threaded portion of cylinder head for damage. 18

21
10. Inspect seal and O-ring grooves in head for burrs and 20

damage, ovality, and tapering. Replace as necessary. 23
12. Inspect spacer for burrs and sharp edges. Dress inside 17
diameter surface with Scotch Brite or equivalent.
13. Inspect port block fittings and cartridge valves. Replace Figure 5-187. Cylinder Head Seal Kit Installation
as necessary.
4. Install cylinder head assembly (23) on rod (7). Do not
damage or dislodge wiper and rod seals. Push cylinder
head along rod to rod end.
3121619 5-143
5. Install Spacer (16) on Rod (7) with screw hole facing NOTE: Piston and mating end of rod must be free of oil when
toward piston end. Align hole in spacer and rod. Apply installing tapered bushing.
locking primer and medium strength (Blue) locking
compound JLG P/N 0100011 or equivalent to socket 10. Thread piston on rod until it aligns with spacer end and
head capscrew (10). Install capscrew.
ing bolts. Assemble the tapered bushing loosely into the
piston and insert capscrews through the drilled holes in
the bushing and into the tapped holes in the piston.
23
16
15
Figure 5-188. Cylinder Head and Spacer Installation
6. Install backup ring (13), washer ring (14), and backup

ring (13) in piston (11).
7. Install seal (12), and two wear rings (11) on piston.
tion to 30 ft-lb (41 Nm).
13
14 capscrews.
11
11

9. Carefully thread piston on cylinder rod hand tight,

Ensure O-ring and back-up rings are not damaged or
dislodged.
5-144 3121619
b. Tap each space once; this means the tapered bush- 19. Install cylinder head (23) in barrel (28) and align marks
ing is tapped 3 times as there are 3 spaces between made during disassembly.
the capscrews.
NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011
to capscrews.
20. Install bracket (26) with two capscrews (27).

21. Install six washers (24) and capscrews (25). Tighten all
capscrews.
22. Install small O-ring (5) and large O-ring (6) in valve block
(2). Install valve block to rod (7) with four capscrews (1).
23. Install two check cartridges (3) and two counterbalance
valves (4) with new O-rings in valve block (2).

27
26
rotation to 30 ft-lb (41 Nm). 23
15. Remove cylinder rod from holding fixture.
25
16. Position cylinder barrel in a suitable holding fixture. 24
28
AND PISTON. Figure 5-192. Rod Assembly And Valve Installation
17. Clamp barrel clamped securely and support rod. Insert

piston end into barrel. Do not damage or dislodge pis-
18. Push rod in barrel until cylinder head can be inserted.
3121619 5-145
Boom Telescope Cylinder (SN 0300244678 to 8. Tap around outside of Cylinder Head with a suitable
hammer to break thread-locking compound. Unscrew
Present) Cylinder Head (23).
Refer to Figure 5-196. 1

3 4
DISASSEMBLY 5
6
7
27
4
26
cylinder port block fitting. 24
28
DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER MAF09460
SLIGHTLY TO AVOID TRAPPING PRESSURE.
Figure 5-194. Port Block And Rod Removal
3. Remove the plugs from the cylinder ports. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
4. Place cylinder barrel in a suitable holding fixture. PISTON.
ROD SUPPORT 9. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
PROTECTED ROD CLAMP
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5. Remove check valves (3), counterbalance valves (4), and

fittings from valve block (2). Discard O-rings. Remove
four capscrews (1) and valve block from rod (7). Discard
O-rings (5, 6).
6. Mark cylinder head (21) and barrel (25) with center
punch marks for later realignment. Remove two cap-
screws (23) and bracket (24).
7. Remove remaining capscrews (23) and washers (22).
5-146 3121619
4
3
5
1
2 6
4
27
7
23
26
25 21
19
24
22 17
15
20
18
15
16 11
15
13
12
8
14
9
10
9
28
1001228082-C
MAF08940C
1. Capscrew 6. O-Ring 11. Setscrew 16. Rod Seal 21. Cylinder Head
2. Valve Block 7. Rod 12. Spacer 17. Back-Up Ring 22. Washer
3. Check Cartridge 8. Piston 13. Wear Ring 18. Head Back-Up Ring 23. Capscrew
4. Counterbalance Valve 9. Wear Ring 14. O-Ring 19. Wiper Seal 24. Bracket
5. O-Ring 10. Piston Seal 15. O-Ring 20. Retaining Ring 25. Barrel
Figure 5-196. Boom Telescope Cylinder Assembly (SN 0300244678 to Present)
3121619 5-147
11. Loosen and remove the setscrew which attaches the pis- 19. Remove cylinder head (21) from rod (7). Remove and
ton to the rod. discard O-Ring (14 and 15), backup ring (17), head
backup ring (18), wiper seal (19), rod seal (16), retaining
12. Screw the piston counterclockwise and remove the pis-
ring (20), and wear rings (13).
ton from cylinder rod.
13. Remove and discard the piston seal and O-ring.
14. Remove spacer from the rod. 23
15. Remove the rod from the holding fixture. Remove the
cylinder head. Discard the o-rings, backup rings, rod 21
seal, wearing, retaining ring, and wiper seal. 19
24
22
15 17
20
BEFORE REMOVING FOR PROPER INSTALLATION. 18
15
16. Remove and discard piston seal (10) and piston wear 16
ring (9) from piston (8). 15
MAF09450
13
8
14
10
9
MAF09440
17. Remove spacer (12) from rod (7).

18. Remove rod from holding fixture.
NOTE: Record orientation of rings for reassembly.
5-148 3121619
CLEANING AND INSPECTION ASSEMBLY
1. Clean parts thoroughly with approved cleaning solvent. NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
other damage. If necessary, dress rod with Scotch Brite Apply a light film of hydraulic oil to all components before
or equivalent. Replace rod if necessary. assembly.

ovality. Replace if necessary. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. WIPER SEAL ROUNDED SURFACE MUST FACE TOWARD
4. Inspect threaded portion of barrel for damage. Dress PISTON AS NOTED DURING DISASSEMBLY.
1. Install O-Ring (14), backup ring (17), wiper seal (19), rod
seal (16), retaining ring (20) in cylinder head (23).
2. Install wear rings (13) in cylinder head (21).
threads as necessary. 3. Install head backup ring (18) and O-ring (15) on cylinder
head (21).
23
other damage, and for ovality and tapering. Replace as 21
necessary.
19
24
9. Inspect threaded portion of cylinder head for damage. 22
Dress threads as necessary. 15 17
10. Inspect seal and O-ring grooves in head for burrs and 20
sharp edges. Dress applicable surfaces as necessary. 18
15
damage, ovality, and tapering. Replace as necessary. 16
15
12. Inspect spacer for burrs and sharp edges. Dress inside MAF09450
diameter surface with Scotch Brite or equivalent.
13. Inspect port block fittings and cartridge valves. Replace

as necessary. Figure 5-199. Cylinder Head Seal Kit Installation

4. Install cylinder head assembly (21) on rod (7). Do not
damage or dislodge wiper and rod seals. Push cylinder
head along rod to rod end.
3121619 5-149
5. Install Spacer (12) on Rod (7) with screw hole facing 15. Install cylinder head (21) in barrel (25) and align marks
toward piston end. Align hole in spacer and rod. made during disassembly
6. Install piston seal (10) in piston (8). 16. Install bracket (24) with capscrews (23).
7. Install piston wear rings (9) on piston (8). 17. Install washers (22) and capscrews (23). Tighten all cap-
screws.
18. Install small O-ring (5) and large O-ring (6) in valve block
(2). Install valve block (2) to rod (7) with capscrews (1).
13
19. Install two check cartridges (3) and two counterbalance
valves (4) with new O-rings in valve block (2).
8
1
14 3 4
5
6
9
7
10 27
4
9
MAF09440
26
25
24
8. Using suitable protection, clamp cylinder rod in a vise or 28

similar holding fixture as close to piston as possible. MAF09460
9. Carefully thread piston on cylinder rod hand tight,

Ensure O-ring and back-up rings are not damaged or Figure 5-201. Rod Assembly And Valve Installation
dislodged.
10. Thread piston on rod until it aligns with spacer end.

11. Remove cylinder rod from holding fixture.

AND PISTON.
13. Clamp barrel clamped securely and support rod. Insert

piston end into barrel. Do not damage or dislodge pis-
14. Push rod in barrel until cylinder head can be inserted.
5-150 3121619
5.4 CYLINDER LENGTH SENSOR 5. Remove the plug that is over the setscrew that secures
the sensor in place.
Both the jib lift cylinder and the platform level cylinder utilize
a cylinder length sensor which communicates with the JLG
control system. These sensors can be removed from without
the cylinder being disassembled.
6. Using an allen wrench, remove the setscrew.
Figure 5-202. Cylinder Length Sensor
Removal
1. Lower the platform to the ground or on suitable block-
ing.
NOTE: The jib lift cylinder weighs approximately 186 lbs.(84 kg)
and the platform level cylinder weighs approximately
76 lbs. (34 kg)
2. Support the weight of the jib cylinder and remove the

bolt and keeper pin that secure the cylinder barrel
retaining pin. Remove the pin.
3. Lower the cylinder to a horizontal position to gain
access to the rear of the cylinder.
4. Place a catch pan under the cylinder to capture any oil
that may drain out of the cylinder. If the cylinder is
removed from the machine, drain the oil out of the cylin-
der.
3121619 5-151
7. Using an allen wrench, remove the bolts securing the 8. Pull sensor out of the cylinder. DO NOT use the wiring
retaining cap and remove the cap. harness to pull the sensor out as this will cause damage
to the wiring.
5-152 3121619
Installation 3. Apply lubricant JLG P/N 3020039 to the setscrew and

install the setscrew. Torque the setscrew to 4 in. lbs. (0.45
1. Carefully insert the sensor into the cylinder. It may be Nm).
necessary to gently tap the end of the sensor to seat the
o-ring into the sensor bore. DO NOT tap on the wiring
harness.
4. Install the plug over the setscrew.
2. Install the cap and secure in place with the retaining

bolts.
5. Raise the cylinder back in place and install the retaining

pin.
6. Install the keeper pin and retaining bolt.
7. Check the cylinder for proper operation.
3121619 5-153
5.5 OIL SAMPLING 4. Unscrew the knurled end which is attached to the chain.
See Figure 5-203., Oil Sampling Valve Location.
This machine is equipped with an oil sampling valve to

allow for verification of hydraulic oil condition.
Procedure
1. Function the machine for approximately 15 minutes
operating all functions.
2. Switch the select switch to the ground controls and start
the engine.
3. Locate the oil sampling valve on the front of the main
control valve.
5. Place a drip pan under the spout and push in for approx-
imately 10 seconds. This should flush out the valve.
6. Open and place the sample bottle under the spout.
7. Push in on the end of the valve and fill up the bottle.
8. Cap the bottle immediately.
9. Thread the knurled cap back onto the valve.
10. The sample is complete.
Figure 5-203. Oil Sampling Valve Location
5-154 3121619
MP
OIL TEMP SENSOR

MAIN DUMP
REDUCED PRESSURE
RELIEF MP4
PRESSURE REDUCING
VALVE
M8 MAIN TELE OUT
PORT 7
MAIN LIFT UP
PORT 8
TELE OUT RELIEF

PORT 4 SWING RIGHT
PORT 5
LIFT DOWN AUX
LIFT UP RELIEF
LIFT PILOT
SWING LEFT RELIEF MP5
Figure 5-204. Main Valve Identification (Prior to SN 0300247849) - Sheet 1 of 2
3121619 5-155
MP
CHASSIS ENABLE
WARM-UP
MAIN DUMP
MP4
TELE CNTL
M7
TELE OUT RELIEF

MAIN TELE IN LIFT CNTL
M4
LIFT DOWN RELIEF
MAIN LIFT DOWN SWING CNTL
MS2
SWING LEFT
LIFT PILOT
LIFT DOWN AUX MS3 M5
SWING RIGHT RELIEF
Figure 5-205. Main Valve Identification (Prior to SN 0300247849) - Sheet 2 of 2
5-156 3121619
Item Ft.Lbs. Nm
1 60-70 81-95
2 25-30 34-40.5
3 40-49 54-66
4 2.2-3 3-4
5 30-35 40.5-47
6 122-133 165-180
7 3.7-5.2 5-7
8 28.8-37.6 39-51
9 46 62
10 30-37 40.5-50
11 13 17.5
Figure 5-206. Main Valve Torque Values (Prior to SN 0300247849) - Sheet 1 of 2
3121619 5-157
Figure 5-207. Main Valve Torque Values (Prior to SN 0300247849) - Sheet 2 of 2
5-158 3121619
MP
OIL TEMP SENSOR
PRESSURE REDUCING VALVE

MAIN DUMP
MP4
CHECK VALVE
M8 MAIN TELE OUT
PORT 7
MAIN LIFT UP
PORT 8
TELE OUT RELIEF
SWING RIGHT
PORT 4
PORT 5
LIFT DOWN AUX
LIFT UP RELIEF LIFT PILOT
SWING LEFT RELIEF
1001234548-A
MAF08040A
Figure 5-208. Main Valve Torque Values (SN 0300247850 to Present) - Sheet 1 of 2
3121619 5-159
MP
CHASSIS ENABLE
WARM-UP
MAIN DUMP
MP4
CHECK VALVE
TELE CNTL
MAIN TELE IN
M7
MAIN LIFT DOWN TELE OUT RELIEF
LIFT CNTL
M4
SWING CNTL
SWING LEFT
LIFT DOWN RELIEF
MS2
SWING RIGHT RELIEF

LIFT PILOT
M5
LIFT DOWN AUX MS3
MP5
1001234548-A
MAF08050A
5-160 3121619
11
3
5
5
11
1 12
11
5
Item Ft.Lbs. Nm
1 60-70 81-95
2 25-30 34-40.5
5 3 40-49 54-66
4 2.2-3 3-4
5 30-35 40.5-47
6 122-133 165-180
7 3.7-5.2 5-7
8 28.8-37.6 39-51
2
4 46 62
9
10 30-37 40.5-50
10 2 11 13 17.5
4 12 33-37 40.5-50
2
1001234548-A
MAF08060A
3121619 5-161
11
4
12
6
5 1
7
11
5
6
7
11
5
11
9
10
11
8
1001234548-A
MAF08070A
5-162 3121619
5.6 PRESSURE SETTING PROCEDURE 3. Using the Analyzer, go to service mode - set pressures -
passcode:14605, select Boom Lift. Activate boom lift
Cold temperatures have a significant impact on pressure read- down.
ings. JLG Industries Inc. recommends operating the machine 4. Activate lift down. The gauge should read 4000 psi. (275
until the hydraulic system has warmed to normal operating bar).
temperatures prior to checking pressures. JLG Industries Inc.
5. To make an adjustment to this pressure, go back to the
also recommends the use of a calibrated gauge. Pressure read-
engine compartment to the function pump which is the
ings are acceptable if they are within ± 5% of specified pres- rear pump. The high pressure relief adjustment is the
sures. adjustment closest to the pump case.
To ensure all pressures are set correctly, the following proce-

dures must be followed in order.
1. Setup of the Function Pump
PRESSURE COMPENSATOR (PC) SETTING
1. Install a high pressure gauge 5000 psi (345 bar) at the

“MP” port of the main valve block.
6. Loosen the locking set screw at the side of the adjust-

ment. Adjust the PC to obtain 4000 psi (275 bar), clock-
wise increases pressure.
7. If a pressure increase is necessary and the adjustment
described above does not result in a change, then Per-
form “Lift Down Procedure” before repeating “Pressure
Compensator (PC) Setting”.
8. After adjusting the pressure, tighten the locking set
screw, and reconnect the Lift Down coil.
2. Remove the Deutsch connector from the lift down coil.
LIFT DOWN
COIL
3121619 5-163
STAND BY PRESSURE OR LOAD (LS) SENSE PRESSURE 2. Adjustments Made at the Main Valve Bank
1. Install a low pressure gauge at port “MP” of the main
valve block. The gauge must be capable of reading 500 REDUCED PRESSURE SECTION
psi (34.5 bar). 1. Relief Valve: Install pressure 5000 psi (345 bar) gauge at
port MP5. Using the Analyzer, go to service mode - Hyd
warm up - passcode: 12671. An alternative method is to
unplug the temperature and switch on the tank mani-
fold with the engine temperature less than normal oper-
ating temperature. Adjust the relief valve located at 5 o'
clock adjacent port P4 to obtain gauge reading of 3600
psi (248 bar) After adjusting the pressure, tighten the
locking set screw and Exit hydraulic warm up mode.
2. Start the engine, the gauge should read 500psi (34.5

bar).
3. To make an adjustment to this pressure, go to the
engine compartment, locate the function pump which
is the rear pump.
4. The stand by adjustment is the outside adjustment.
Using the same procedure as in the (PC) setting above MP5
adjust (LS) to 500psi (34.5 bar). PORT
5-164 3121619
2. Pressures Reducing Valve: Install pressure 5000 psi (345

bar) gauge at port MP5. Using the Analyzer, go to service
mode - set pressures - passcode: 14605. select Boom Lift.
Activate boom lift down and the gauge should read
3200 psi (221 bar). Adjust the pressure reducing value,
located at 3 o' clock behind port P5 until gauge reads
3200 psi (221 bar). If a pressure increase is necessary and
the adjustment described above does not result in a
change, then Perform “Pressure Compensator (PC) Set-
ting'' and “Relief Valve'' before repeating “Pressure
Reducing Valve'' procedure.
LIFT UP
1. Install a high pressure gauge at the “M5” port of the
LIFT DOWN main valve block.
COIL
PRESSURE
REDUCING
VALVE
3121619 5-165
2. Plug and cap the hose on port 5. Activate lift up. The LIFT DOWN
gauge should read 3700 psi. (255 bar).
1. Install a high pressure 5000 psi (345 bar) gauge at the
“M4” port of the main valve block.
3. The adjustment cartridge is located to the right of port

5. Turn clockwise to increase pressure, counter clockwise
to decrease. 2. Install pressure gauge (5000 psi) at port “M4''. Using the
Analyzer, go to service mode – set pressures - passcode:
14605, select Boom Lift. Activate boom lift down. The
gauge should read 2850 psi (196 bar). The adjustment
cartridge is located to the left of the “M4'' gauge port.
Turn clockwise to increase, counterclockwise to
decrease.
5-166 3121619
SWING 4. Install gauge at MS3, Activate swing left, the gauge

should read 2000 psi. (138 bar), The adjustment is
1. Install a high pressure gauge at port “MS2”.
located at 9 o’clock beside port 3, Turn clockwise to
increase pressure, counter clockwise to decrease pres-
sure.
2. Install the Turntable lock pin.
3. Activate swing right, the gauge should read 2000 psi.

The adjustment cartridge is located at beside the “MS2”
gauge port. Turn clockwise to increase, counterclock-
wise to decrease.
3121619 5-167
TELESCOPE OUT
NOTE: NEVER increase telescope out pressure to achieve desired
telescope length.

main valve bank.
TELESCOPE IN
main valve block.
2. Plug the telescope out hose either at the valve bank

(port #8) or at the inlet of the telescope cylinder (V1).
Activate telescope out. The gauge should read 3000 psi
(207 Bar). The adjustment cartridge is located at 2
o’clock adjacent to M8 gauge port. Turn clockwise to
increase, counter clockwise to decrease.
5-168 3121619
2. Plug the telescope in hose either at the valve bank (port

#7) or at the inlet of the telescope cylinder (V2).
3. Activate telescope in. The gauge should read 3300 psi.

(227 bar). The adjustment cartridge is located at 3
o’clock adjacent to “M7” gauge port. Turn clockwise to
increase, counterclockwise to decrease.
3121619 5-169
3. Adjustments Made at the Frame Valve Bank 3. Turn clockwise to increase, counterclockwise to
decrease.
AXLE EXTEND AND RETRACT, FRONT AND REAR
1. To extend the axles drive the machine back and forth
until extended. A machine that cannot be driven must
be jacked up.
2. On both the front and rear frame valve banks install a
high pressure gauge on ports “MA1” for retract and
“MA2” for extend. The gauge should read 2500 psi. for
both directions.
5-170 3121619
STEERING, FRONT AND REAR 4. Adjustments Made at the Platform Valve Bank
1. The axles must be extended to set the steer pressures.
PLATFORM LEVEL UP
2. Install a high pressure gauge at “MS2” and “MS4” gauge
ports for steer right (extend), adjust to 2000 psi, and 1. Install a high pressure gauge at gauge port “ML1”.
“MS1 and “MS3” for steer left (retract), adjust to 2600 psi,
on both the front and rear valves. Each relief valve is
located next to its own gauge port. Turn clockwise to
2. Activate level up to the end of stroke, the gauge should

read 2500 psi.(172bar).
3. All the relief valves are located on the same face. The
level up relief valve is on the top. Turn clockwise to
PLATFORM LEVEL DOWN

1. Install a high pressure gauge at gauge port “ML2”.
3121619 5-171
2. Activate level down to the end of stroke, the gauge 5. Adjustments Made at Jib Valve
should read 2000 psi. (138bar). The level down relief
valve is the second from the top. Turn clockwise to JIB LEVEL UP
NOTE: To check or adjust the jib level up pressure setting the JLG
Analyzer must be used to override the automatic jib level
function.
1. Install a high pressure gauge at MLB.
JIB PIN EXTEND (2500 PSI [172BAR]) PRESET

1. Install a high pressure gauge at port MS1.
2. Connect the analyzer to the ground control connector.

3. Position the main boom on the boom rest and the jib to
horizontal.
4. Using the analyzer, press the RIGHT or LEFT

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
2. Using the analyzer and “set pressures” menu, select jib
lock pin extend. This is the bottom relief valve on the
platform valve. Turn CW to increase and CCW to ENTER .
decrease pressure.
5-172 3121619
6. Using the arrow keys scroll until MENU: SERVICE MODE is

8. Enter code 58237 and Press ENTER . The screen
reached. Press ENTER . should read SERVICE MODE: JIB & SWING AND JIB LEVEL.
7. The analyzer should read JIB & SWING. Press ENTER
9. Press ENTER again. The screen will read JIB LEVEL

.
OVERRIDE: OFF. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
10. Once turned on, operate the Jib Lift Up function. This
will activate the jib level up function.
3121619 5-173
11. When the function bottoms out, pressure should read 6. Using the arrow keys scroll until MENU: SERVICE MODE is
2600 psi.(180bar).
12. If necessary to adjust pressure, CW increases and CCW reached. Press ENTER .
decreases setting. Jib level up adjustment is adjacent to
MLB.
13. Make sure to reset Jib override to off after pressure is set,
and cycle machine power.
JIB LEVEL DOWN

1. Install high pressure gauge at MLA.
7. The analyzer should read JIB & SWING. Press ENTER
2. Connect the analyzer to the ground control connector.

3. Position the main boom on the boom rest and the jib
fully elevated.
4. Using the analyzer, press the RIGHT or LEFT

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
ENTER .
5-174 3121619
10. Once turned on, operate the Jib Lift Down function. This
will activate the Jib Level Down function.
8. Enter code 58237 and Press ENTER . The screen
should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 11. When the cylinder is completely retracted, the pressure
should be 1500 psi. (104bar). CW increases and CCW
decreases setting. Jib level down adjustment is adjacent
to MLA.
and cycle machine power.
NOTE: Steps 13 thru 17 are only necessary if the Jib Leveling Sys-
tem Fault has been set.
13. To adjust the jib back to level, go into override mode for
jib leveling. Turn the override mode to “On” and press
9. Press ENTER again. The screen will read JIB LEVEL
the ESCAPE key until out of the Service Modes

OVERRIDE: OFF. Use the UP or DOWN arrow menu.
keys to toggle the override from Off to On.
14. Go to the Diagnostics/Boom Sensors menu. Use the
Right arrow key until reaching the “Jib Level CNTL: Angle
0.0" screen.
NOTE: Using this override may set the Jib Leveling System Fault,
depending upon how far out of level the jib is moved.
3121619 5-175
15. Adjust the jib level using the JIB TELESCOPE IN

Jib Lift function switch until
the jib level control angle 1. Install high pressure gauge at MTA.
reads zero (0).
16. After the control angle is set, use the UP or DOWN
arrow keys to toggle the override from On to Off.

and cycle machine power. Operate the main boom to
verify jib level is working properly. 2. Retract jib telescope fully.
JIB TELESCOPE OUT 3. Set pressure at 2850 psi.(197bar). CW increases and CCW
decreases setting. Adjustment is the one closest to MTA.
1. Install high pressure gauge at MTB.
2. Extend jib telescope fully.

3. Set pressure at 2850 psi. (197bar). CW increases and
CCW decreases setting. Adjustment is the one closest to
MTB.
5-176 3121619
JIB LIFT UP JIB LIFT DOWN

1. Install high pressure gauge at port MJB. 1. Install high pressure gauge at port MJA.
2. Fully extend jib lift cylinder or cap port JB. 2. Fully retract jib lift cylinder or cap port JA. Set pressure
to 1200 psi (83bar).
3. Set pressure to 2800 psi.(193bar). Clockwise increases

and Counterclockwise decreases setting. Adjustment is 3. CW increases and CCW decreases setting. Adjustment is
on the boom side of MJB. on the boom side of MJA.
3121619 5-177
6. Adjustments Made in Traction Circuit 3. Adjust the charge relief valve to obtain reading of 400psi
(28bar). The charge relief is located on the turntable side
of the pump above M3. Clockwise increases pressure,
CHARGE PRESSURE RELIEF Counterclockwise decreases pressure.
1. Install gauge 1000psi (69bar)) at port M3 on traction

pump.
LOOP FLUSHING RELIEF

1. Install pressure gauge at port MP on traction valve.
2. With the drive hubs disconnected, start the engine.
2. With hubs still disconnected energize Drive, adjust loop
flushing valve to obtain gauge reading of 350psi (24bar).
Clockwise increases pressure, counter clockwise
decreases.
5-178 3121619
5.7 DRIVE PUMPS
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 5-212. Piston Pump Cross Sectional View
Port Locations and Gauge Installation
Table 5-33. 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]
3121619 5-179
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 5-213. Port locations - Sheet 1 of 2
5-180 3121619
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 5-214. Port locations - Sheet 2 of 2
3121619 5-181
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
9. When adequate charge pressure is established (as
restarting a pump that has been removed. Ensure the pump is
shown in model code), increase engine speed to normal
thoroughly tested on a test stand before installing.
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-
ward and reverse operation.
4. Fill the housing by adding filtered hydraulic fluid to the
upper case drain port. If the controls are installed on top, 12. Check that the reservoir is full. Remove charge pressure
open the construction plugs in the top of the controls to gauge and cap port. The pump is now ready for opera-
assist in air bleed. tion.
5. Fill the reservoir with hydraulic fluid of the recom- Troubleshooting

mended type and viscosity. Use a 10-micron filler filter.
Ensure construction plug is closed after filling is com-
plete.
HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE INTERNAL
6. Disconnect the pump from all control input signals.
PUMP COMPONENTS.
AFTER START-UP THE FLUID LEVEL IN THE RESERVOIR MAY DROP DUE TO
SYSTEM COMPONENTS FILLING DAMAGE TO HYDRAULIC COMPONENTS MAY ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE
OCCUR IF THE FLUID SUPPLY RUNS OUT. ENSURE RESERVOIR REMAINS SUFFICIENT FORCE TO PENETRATE YOUR SKIN CAUSING
FULL OF FLUID DURING START-UP. SERIOUS INJURY AND/OR INFECTION AND MAY BE HOT
ENOUGH TO CAUSE BURNS. RELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES, FITTINGS, GAUGES,
OR COMPONENTS. SEEK IMMEDIATE MEDICAL ATTENTION
AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAMAGE HYDRAU- IF YOU ARE CUT OR BURNED BY HYDRAULIC FLUID.
LIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS. TAKE PRECAU-

TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REIN-
DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND STALLING SYSTEM COMPONENTS AND LINES
FLUID HAS BEEN THOROUGHLY FILTERED.
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-
5-182 3121619
Table 5-34. Electrical troubleshooting

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 5-35. 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 5-36. 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.
3121619 5-183
Table 5-37. 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 5-38. 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.
5-184 3121619
Table 5-39. 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.
3121619 5-185
Adjustments pump speeds or higher charge flows the charge pressure

will rise over the rated setting.
3. Loosen the locknut and rotate the adjusting screw

CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR clockwise to increase the setting; counterclockwise to
WARRANTY. TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN decrease it. Subtract the case pressure reading to com-
REMOVING AND REINSTALLING SYSTEM LINES pute the actual charge pressure.
1. Thoroughly clean the outside of the pump. NOTE: Pressure change per turn is dependent on charge flow
entering pump.
2. If removing the pump, tag each hydraulic line. When you
disconnect hydraulic lines, cap them and plug each
open port to prevent contamination. 4. While holding the adjusting screw, torque locknut to 12
Nm [9 lbft].
3. Ensure the surrounding area is clean and free of contam-
inants like dirt and grime. 5. When you achieve the desired charge pressure setting,
remove the gauges and plug the ports.
4. Inspect the system for contamination.
5. Check the hydraulic fluid for signs of contamination: oil DISPLACEMENT LIMITER ADJUSTMENT
discoloration, foam in the oil, sludge, or metal particles.
1. Mark servo cylinder location in case it rotates during dis-
6. If there are signs of contamination in the hydraulic fluid, placement limiter adjustment.
replace all filters and drain the hydraulic system. Flush
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
E450
case pressure port L1, L2, or L3. Operate the system with 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
[17 lbf•ft]
tings (refer to model code located on serial number
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
NOTE: Listed pressures assume a pump speed of 1800 min-1 (rpm) while rotating the adjusting screw counterclockwise
and charge flow of 26.5 l/min [7 US gal/min]. At higher 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 5-215. Charge Pressure Adjustment
5-186 3121619
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-
tion of the wrench. Then rotate the neutral adjusting
5. One turn of the adjusting screw will change the maxi-
screw counterclockwise until the pressure increases by
mum displacement approximately as follows.
an equal amount on the other gauge. Again note the
Table 5-40. Displacement Limiter Adjustment Data angular position of the wrench.
Solenoid shaft
Approximate Control spool
displacement
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- Adjusting
screw
tory results, you may need to replace the control or coils. (cam)
Feedback pin
1. Install a 50 bar [1000 psi] gauge in each of the two servo
Maximum
gauge ports (M4 and M5). Disconnect the external con-
adjustment
trol input (electrical connections) from the control. Start less than 120°
the prime mover and operate at normal speed.
2. Use a 4mm internal hex wrench to hold the neutral

Illustration shows how eccentric cam on
adjusting screw stationary while loosening the locknut
adjusting screw rotates to adjust neutral.
with a 13mm wrench.
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 5-216. Control Neutral Adjustment
3121619 5-187
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.
2. Attach a 600 bar [10 000 psi] gauge to each system pres-
6. Hold the neutral adjusting screw stationary and tighten
sure port (MA and MB for front pump, MC and MD for
the lock nut. Torque to 10.Nm [7 lbft]. Do not over
rear pump).
torque the nut.
3. Remove servo cylinder locking screws (E350) and plates
7. When the neutral position is set, stop the prime mover, (E300) from both sides of the pump.
remove the gauges, and install the gauge port plugs.
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
5. If using a PWM signal to set mechanical neutral, connect
acceptable. Zero differential is usually not possible.
the control solenoids C1 and C2 to the signal source.
Ensure the source supplies no current to the solenoids
MECHANICAL NEUTRAL ADJUSTMENT until required in the following procedure.
Mechanical neutral is set with the pump running at 1800 min
(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)
5-188 3121619
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 5-217. Servo and System Pressure Gauge Port Locations
3121619 5-189
SERVO ADJUSTMENT Removing The Pump

6. Run prime mover at 1800 min (rpm). Before working on the pump, thoroughly clean the outside. If
the pump has an auxiliary pump attached, remove both
7. If using a PWM signal, ensure the signal is off. Check the pumps as a single unit. Tag and cap all hydraulic lines as you
servo pressure gauges. Ensure the differential between disconnect them, and plug all open ports to ensure that dirt
M4 and M5 is less than 1.5 bar [22 psi]. 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-
TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND INSTALL-
9. Stroke the pump by turning the control eccentric screw ING SYSTEM LINES.
(or supplying current to solenoid C1) until the servo
pressure at port M4 is 1 to 2 bar [14 -29 psi] greater than 1. Thoroughly clean all dirt and grime from the outside of
at port M5 and the system pressure gauges indicate dis- the pump.
placement. Pressure should be greater at port MA for 2. Tag, disconnect, and cap each hydraulic line connected
clockwise rotation, or MB for counterclockwise rotation. to the pump. As hydraulic lines are disconnected, plug
This also indicates the servo piston is in contact with the each open port, to ensure that dirt and contamination
servo cylinder on side M5. do not get into the pump.
10. Slowly thread the servo cylinder on the M5 side in until 3. Remove the pump and its auxiliary pump (if applicable)
the system pressure differential starts to decrease. Main- as a single unit.
tain servo pressure differential between 1-2 bar [14-29
psi] during this step. Continue turning the servo cylinder NOTE: Be careful, do not damage solenoids and electrical connec-
in until the system pressure differential (between ports tions when using straps or chains to support the pump.
MA/MB or MC/MD) is less than 1.5 bar [22 psi]. This pro-
cedure sets the servo and swashplate to mechanical Inspection
neutral on the M5 side.
1. Ensure the work surface and surrounding area are clean
11. To complete setting neutral, repeat steps 1-5 but stroke and free of contaminants such as dirt and grime.
the pump in the opposite direction by turning the 2. Inspect the system for contamination.
eccentric screw in the opposite direction, or by supply-
ing current to solenoid C2. Reverse gauge locations (M4 3. Look at the hydraulic fluid for signs of system contami-
for M5, MB for MA etc.) from those stated above since nation, oil discoloration, foam in the oil, sludge, or metal
the pump is now stroking the other direction. particles.
12. Set neutral for the rear pump by repeating steps 1-6 on Replacement
the rear pump. Remember that the rear pump is a mirror
image of the front pump and therefore the locations of 1. Before replacing the pump, replace all filters and drain
the servo gauge ports (M4/M5) and the control sole- the hydraulic system. Flush the system lines and fill the
noids (C1/C2) are opposite. reservoir with the correct, filtered hydraulic fluid.
2. Fill the pump with clean, filtered hydraulic fluid.
13. Remove all gauges and replace gauge port plugs.
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.
5-190 3121619
Electric Control Module REASSEMBLY

NOTE: Ensure you install dowel pins (D300) in housing before
REMOVAL installing control.
Refer to exploded diagram, next page.
1. Install a new gasket (D150).
1. Using a 5 mm internal hex wrench, remove the six cap 2. If you removed screen (D084), install a new one. Install
screws (D250). with the mesh facing outward.
D084
2. Remove the control module and gasket (D150). Discard D084
the gasket.
Correct screen Incorrect screen
3. If necessary, remove orifices (F100) using a 3 mm inter- orientation orientation
nal hex wrench. Tag and number them for reinstallation.
4. Inspection
3. If previously removed, install orifices (F100) using a 3
5. Inspect the machined surfaces on the control and top of mm internal hex wrench. Torque to 2.5 Nm [1.8 lbft].
the pump. If you find any nicks or scratches, replace the
component. 4. Install the control module and six cap screws (D250).
5. Using a 5 mm internal hex wrench, torque the cap
NOTE: Remove plug on top of control to ensure the swashplate
screws (D250) to 13.5 Nm [10.lbft].
feedback pin is properly positioned in the center of the con-
trol module when installing control.
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 5-218. Control Module And Solenoid Removal/installation
3121619 5-191
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
pump on the work surface so the shaft is pointing to the side.
2. Remove the solenoid (D025) and O-ring (D025A). Dis-
card the O-ring. REMOVAL
3. If necessary, remove the coil using a 12 point 26 mm 1. Unwind the spiral ring (J300) from the housing to
socket. release the shaft/seal/bearing subassembly.
CONTROL SOLENOIDS INSPECTION 2. Pry on the lip of the seal carrier (J275) to remove it from
the pump. Remove the seal carrier. Remove and discard
1. Inspect the machined surface on the control. If you find O-ring (J260). Press the seal (J250) out of the carrier and
any nicks or scratches, replace the component. discard.
CONTROL SOLENOIDS REASSEMBLY 3. Pull the shaft (J100) with bearing (J150) out of the
pump. If necessary, tap lightly on the shaft to dislodge it
1. Lubricate new O-ring (D025A) using petroleum jelly and from the cylinder block. C
install.
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-
ING THE SHAFT AND BEARING.
3. Install coil using a 12 point 26 mm socket. Torque coil
nut to 5 Nm [3.7 lbft]. 4. Remove the retaining ring (J200) using retaining ring
pliers. Press the bearing off the shaft.
4. Reconnect electrical connections and test the pump for
proper operation.
Protective
sleeve
J100
J150
J200
J250
J260
J150
J275
J300
Figure 5-219. Shaft Assembly
5-192 3121619
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.
REMOVAL
REASSEMBLY
1. Remove screws (K351), and hangers (K975).
1. Press the bearing (J150) onto the shaft (J100) and
2. Remove running cover (K301). Remove and discard seal
replace the retaining ring (J200). Ensure the retaining
ring (K250).
ring diameter is less than 38.84 mm [1.53.in] when
installed on the shaft. 3. Using a 10 mm internal hex, remove screws (K400).
Remove cover (K101).
2. Install the shaft/bearing assembly into the pump.
4. Remove charge pump assembly with shaft.
3. Lubricate and install a new O-ring (J260) onto seal car- NOTE: Note position of alignment pin (S500) in housing. Align-
rier (J275). Press a new seal (J250) into the seal carrier. ment pin position will change for clockwise or counter-
Press the seal until it is flush within +0.12mm [0.005 in] clockwise rotation.
or -0.72 mm [0.0028 in] of the inside lip of the carrier: see
illustration. 5. Remove and discard seal (S300).
Press ?ush to this sur face
6. Using a snap ring pliers, remove two clips (K205).
+0.12 mm [ 0.005 in] / -0.72 mm [ 0.028 in]
7. Remove geroter cover (S200). Remove geroter assembly
(S100).
Seal
8. Remove and discard gasket (K151). Remove alignment
pins (K450).
4. Cover the shaft with a protective sleeve while installing
the seal carrier. Hand press the seal carrier into the hous- 9. If it is necessary to remove housing (K300), use a 10 mm
ing. Ensure the seal carrier clears the spiral ring groove internal hex to remove screws (K350).
in the housing. Remove the protective sleeve. 10. Remove housing (K300).
5. Wind the spiral ring into the housing. Ensure the inside 11. Remove and discard seal (K150).
diameter of the spiral ring is greater than 68 mm [2.677
in] after installation. 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.
3121619 5-193
Figure 5-220. Charge Pump
5-194 3121619
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).
INSPECTION
2. Install housing (K300). Install screws (K350). Using a 10
mm internal hex, torque screws per listing in table. 1. Inspect the valves and mating seats in the valve seat
plugs (K007) for damage or foreign material.
3. Install alignment pins (K450). Install new gasket (K151).
REASSEMBLY
4. Lubricate and reassemble charge pump assembly [shaft
(K201), pin (S500), geroter (S100), cover (S200), two clips 1. Lubricate and install new O-rings (K008, K010) and
(K205)]. backup ring (K009) on valve seat plug (K007).
5. Install charge pump assembly into housing in original 2. Verify that the conical springs (H003) are properly
position. retained on the check relief valves (H002). Install the
valve assemblies into the center section. Ensure each
6. Lubricate and install seal (S300). valve assembly moves freely in its bore.
7. Install aux pad (K101). 3. Install the valve seat plugs into the center section and
torque to 80 Nm [59.lbft].
8. Using a 10 mm internal hex, install screws (K400). Torque
screws per listing in table. 4. Operate machine through full range of controls to
ensure proper operation. Check for leaks.
9. Lubricate and install seal (K250). Install running cover
(K301).
Figure 5-221. Charge Check / HPRV
3121619 5-195
Figure 5-222. Charge Check / HPRV
Charge Pressure Relief Valve REASSEMBLY

1. Lubricate and install new O-rings (V10A).
Replace the charge pressure relief valve (V10-1) or (V10-2) as a
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].
3. Operate vehicle/machine through full range of controls
REMOVAL 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.
5-196 3121619
Figure 5-223. Charge Pressure Relief Valve
Control Cutoff Valve REASSEMBLY

1. Lubricate and install new O-rings (G10A) onto the valve.
Replace the control cutoff valve as a complete unit. Do not
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
overtorque.
1. Disconnect the coil from the vehicle/machine wire har-
ness. 4. Operate vehicle/machine through full range of controls
to ensure proper operation
2. Using a 24 mm hex wrench, remove the control cutoff
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.
3121619 5-197
Figure 5-224. Control Cutoff Valve
Table 5-41. 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 5-42. 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]
5-198 3121619
Figure 5-225. Fastener and Plug Locations
3121619 5-199
5.8 FUNCTION PUMP 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
P101 368
2. Remove and discard the 4 O-rings (C200).
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.
5-200 3121619
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
C102
E101 178 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
C134 C117 d
bearings, so make sure you have replacement bearings
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-
3121619 5-201
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.
K050 PISTONS AND SLIPPERS

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

K047
assemblies with scored or excessively rounded slipper edges.
Measure the slipper foot thickness. Replace any piston assem-
K046
blies with excessively worn slippers. Check the slipper axial
end-play. Replace any piston assemblies with excessive end-
P010 play.
K041
Maximum end play
K042 Minimum Slipper

slipper foot
thickness
K043 K050
K044
K045
Minimum slipper foot thickness and maximum axial end-play

are given in the table below.
25. Remove the ball guide (K047).
26. Remove the 3 pins (K046). J Frame

NOTE: Most repairs do not require block spring removal. Perform Slipper foot thickness 3.23 mm
this procedure only if you suspect problems with the block [0.127 in]
spring. Piston/slipper end play 0.05 mm
[0.002 in]
27. Turn the block over. Using a press, apply pressure on the
block spring washer (K044) to compress the block spring
(K043). Compress the spring enough to safely remove BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN
the spiral retaining ring (K045). While maintaining pres- PINS
sure, unwind the spiral retaining ring. Carefully release
The ball guide should be free of nicks and scratches, and
the pressure and remove the outer block spring washer,
block spring, and inner block spring washer (K042) from should not be excessively scored. Examine for discoloration
the cylinder block. that may indicate excessive heat or lack of lubrication. The slip-
per retainer should be flat, and slippers should fit in the
retainer with minimal side play. Place the hold-down pins on a
flat surface and roll them to make sure they are straight. Dis-
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK card and replace any damaged parts.
SPRING REQUIRES ABOUT 350 TO 400 N [80 TO 90.LBF ].
USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH
Slipper
REASONABLE EFFORT. ENSURE THE SPRING IS SECURE
retainer
BEFORE ATTEMPTING TO REMOVE. THE SPIRAL RETAINING
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.
Ball guide
Inspection
After disassembly, wash all parts (including the end-cap and Hold down pins
housing) thoroughly with clean solvent and allow to air dry.
Blow out oil passages in the housing and endcap with com-
5-202 3121619
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
3121619 5-203
SWASHPLATE recommended to detect cracks. The valve plate must be

Carefully inspect each surface of the swashplate for wear. All replaced if any cracks exist.
swashplate surfaces should be smooth. Inspect the swash- 3.88 mm [0.153 in] min.
plate’s slipper running surface for damage and brass transfer.

B090 0.025 mm
Excessive brass transfer from slippers may indicate that the [0.001 in]
slippers should be replaced. Finally, check the swashplate
bearing journal for scratches. Replace swashplate if necessary.
B040
0.005 mm
[0.0002 in]
convex max
JOURNAL BEARINGS
Inspect the journal bearings for damage or excessive wear. ENDCAP
Replace journal bearings if scratched, warped, or excessively Inspect the endcap. Remove the check valve (B092) to expose
worn. The polymer wear layer must be smooth and intact. 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
B030 is present.
VALVE PLATE
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 J050
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
land surface (see illustration). No deep or outstanding grooves B091
should be felt, as these may decrease pump flow. Lap or B092
replace if grooves or nicks are present. Inspect the mating sur-
faces of the endcap and valve plate for any possible contami-
SERVO PISTON
nation; even a few thousandths of an inch may affect pump
Check the servo piston assembly (P020) for any obvious wear
operation.
or damage. Check the corresponding endcap bore for galling
Measure the thickness of the valve plate. Ensure that valve or excessive wear. Discard the piston if damaged. Replace the
plate parallelism is equal to or less than 0.025 mm [0.001 in]. servo piston-rings.
Appearance should be flat and smooth on both the running P020
face and the bottom surface. The valve plate should be flat to
0.005 mm [0.0002.in] convex. A magnetic particle inspection is
5-204 3121619
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.
3121619 5-205
3. Reinstall the swashplate/servo piston/bias spring them to the original block bores. Lubricate the pistons,
assembly in its original orientation in the housing. slippers, retainer, and ball guide before assembly. Set
Rotate the servo piston perpendicular to the swash- the cylinder kit aside on a clean surface until needed.
plate, and at the same time compress the bias spring to
fit into housing pocket. Lubricate all sides of the servo NOTE: Be sure to install the slipper retainer so it mates correctly
piston and its respective bore liberally with hydraulic oil. with the ball guide (concave side of the slipper retainer
Also, lubricate the flat face of the swashplate to prevent against the convex side of the ball guide).
premature wear during start-up.
4. Insert the input shaft (J010) through the bearing into 9. Set the pump on its side. Secure the end of the shaft
the housing. You may need to push on the servo piston with one hand and keep it horizontal. Insert the cylinder
to rotate the swashplate in order to put the shaft in kit onto the shaft. While holding the shaft still, slightly
properly. rotate the cylinder block kit to help start the shaft
splines over the ball guide and align it with the block
5. Coat all parts with hydraulic fluid prior to reassembly. splines. When the cylinder block kit slides completely
over the shaft splines, reposition the unit with the flange
facing downward.
COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 350 Fix the shaft
TO 400 N [80 TO 90 LBF ]. USE A PRESS SUFFICIENT TO on this end
MAINTAIN THIS FORCE WITH REASONABLE EFFOR T.
ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO
INSTALL.THE SPIRAL RETAINING RING. RELEASE THE PRES-
SURE SLOWLY AFTER THE RETAINING RING IS INSTALLED.
6. Install the inner block spring washer (K042), block spring Slightly rotate
cylinder block
(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-
ing ring (K045) into the groove in the cylinder block.
K050
10. Clean the valve plate (B090) and endcap. Install the tim-
K049 ing pin (J050) in the endcap and verify that it is properly
oriented with the split facing into or out of the slot in the
valve plate. The timing pin should be installed to 3.61 ?
K047
0.25.mm [0.14.?.0.01 in] above the valve plate surface.
Apply a liberal amount of assembly grease to the back-
side of the valve plate surface to hold it in position.
K046
Install the valve plate over the timing pin, check valve
P010 (B092), and bearing cup (B010).
K041 B090
K042
K043 J050
B092
K044 B010
K045
B091
7. Turn the block over and install the hold-down pins

(K046), and ball guide (K047) to the cylinder block.
8. Install the pistons (K050) to the slipper retainer (K049).
Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer seats
on the ball guide. If you’re reusing the pistons, install
5-206 3121619
NOTE: To insure proper pump operation, it is extremely important install the seal retaining ring (K010). Remove the instal-
to ensure that there is no contamination between the end- lation sleeve.
cap and valve plate. K010
11. Install the bearing cone (B020) onto the shaft. Using K020
assembly grease to hold the seal (K060), install the end-
cap to the housing. Ensure that seals remain properly
seated and are not pinched during assembly. With a 10
mm internal hex wrench, install and torque endcap
screws at 127 to 155 Nm [94.to.114.lbft], using the criss
cross pattern. Retorque the first screw to ensure proper
torque retention.
J030
10 mm
127 to 155 N·m
[94 to 114 lbf·ft]
13. Clean all control parts and cover with a light coating of
hydraulic fluid prior to reassembly.
J020
14. Install the spherical end of the PC spool (C132) into the
PC bore (refer to illustration). Install the PC plug (C103)
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
B020 the PC spring guide (C133) and install into the PC bore.
Place a new O-ring onto the PC plug and install it so that
it sits one turn below the surface of the control housing.
K060 Install and tighten set screw (C102) at 7.5 to 10.8 Nm [5.5
to 8.0 lbft] to retain the adjusting plug.
10.8 to 13.5 N•m
[8.0 to 10.0 lbf•f
t]
C103
C103A
C132
7.5 to 10.8 N•m

[5.5 to 8.0 lbf•f
t]
12. Lubricate the lip of the new shaft seal (K020) with clean
hydraulic fluid. Place a protective sleeve over the shaft C102
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 C133
retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal dur- C135
ing installation. Using the appropriate snap ring pliers,
C134
C136
C138
3121619 5-207
15. Hold the control in a horizontal position. Install the using a criss cross pattern and retorque the first screw to
spherical end of the LS spool (C112) into the LS bore (see ensure proper torque retention.
illustration). Using a new O-ring, install the LS plug
(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 C200
5.4 to 7.5 N• m
(C116) and back-up rings (C117) onto the LS adjustment [4 to 5.5 lbf•f
t]
screw (C118). Install the LS plug assembly so that it sits 4 mm
one turn below the surface of the control housing. C300
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
C132 C112
C105
C106A
C105A
C106
C113
C102
C115
C133 C114
C117
C135
C116
C134 C117
C118
C136
C138
NOTE: PC and LS spools need to be adjusted to proper setting

according to tag nomenclature.
16. Using petroleum jelly to retain them, install 4 new seal

rings (C200) in the recesses on the control housing.
Install the control assembly onto the endcap using the 4
screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 lbft]
5-208 3121619
5.9 GEAR PUMP PROCEDURE

1. Clamp the unit.
Disassembly
Clamp the unit in a vice from the flange side.
Prior to proceeding it may be necessary to prepare some sub-
assemblies separately.
Make sure the vice jaws are clean and have smooth sur-
The details for preparing each subassembly are given in the faces to prevent damage to the pump.
following section.
Also, some general recommendations are given below.
CLEANLINESS
Cleanliness is a primary factor for reliable pump performance.
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 NOTE: Clamping the pump on the body is not recommended
of lubrication during assembly can cause the unit to seize after because serious damage to the surfaces, on which the
a few minutes of running. ports are located, may occur.
CARE OF SURFACE TREATMENT 2. Remove capscrews. (Except Units with 03 Flange).
Be careful when handling all the internal surfaces, especially
bearings, gears, and body faces. Do not touch or score them Use a 17 mm socket wrench and loosen the four cap-
with metal tools or cutting edges. screws on the cover. Next completely unscrew the cap-
screws and remove them.
MARKING THE PARTS
Mark the parts before completely disassembling a pump. The
Inspect the threads of the capscrews for damage.
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.
3121619 5-209
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.
5-210 3121619
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 Do not use tools with sharp edges to remove the seals,
tooth to idler gear tooth) and the bearing blocks to the as damage to the cover can result.
body so they can be reas?sembled in the same position.
9. Remove the snap ring.

7. Remove pressure seals.
Place the flange on the work surface. Using internal snap
ring pliers, remove the snap ring.
Check the seal quality. Replacement is recommended
whenever there are burrs, evidence of extrusion, or
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.
3121619 5-211
10. Remove the shaft seal. Prepare the flange and shaft seal by lightly lubricating
with grease.
Check the shaft seal quality and remove if necessary.
Seat the seal in the flange by hand. Then, using the shaft
To remove, pry the bottom of the shaft seal and force it seal installation tool, press the seal until the tool stops
out while rotating the flange to lift it out evenly. on the flange. This will insure the seal is inserted to the
proper depth.
Do not use the flange pilot to gain leverage, damage
may result. Use a plastic rod or wooden dowel as a ful-
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
necessary to retain the shaft seal.
Assembly
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.
2. Install shaft seal into front flange.
5-212 3121619
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).
3121619 5-213
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.
5-214 3121619
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.
3121619 5-215
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
one of them may drop inside the pump during assem- Ensure the pressure seals are seated properly after this
bly. operation.
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.
5-216 3121619
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.).
3121619 5-217
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.
5-218 3121619
Trouble Shooting
Table 5-43. 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.
3121619 5-219
5.10 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 Boom Lift utilizes a Triple Combination Pump coupled to Traction Control Manifold. This is important to note as the
the Deutz diesel engine. The pumps are connected in-line to brake release oil pressure must be set 25 psi (1.7 bar) below
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
the unit.
2. The middle hydrostatic transmission pump, or drive
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
oil pressure relief valve installed in the middle pump. The front 6. Re-connect throttle actuator electrical connector and
pump has an orifice cartridge (0.047" diameter) installed in start engine. Allow engine to run at idle speed only for at
place of a charge oil pressure relief cartridge. This insures that least 5 minutes. This will allow the hydrostatic system to
only one valve controls charge pressure & provides an amount filled.
of charge oil flow to the front pump's case to insure flushing &
removal of hot oil. 7. Listen for any abnormal noises.
Each pump has its own separate electrical proportional direc- 8. Check for oil leaks.
tional control valve to control oil flow and direction. The sig- 9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
nals or command values to each pump are similar except +3.4 bar, - 0 bar]). Pressure can be measured a pump
when steering. During steering and propel of the machine the ports Ma & Mb or by “teeing” into the inlet for the
pump supplying oil to the “inside turning radius” has a com- charge oil filter. Charge pressure is checked with the joy-
mand less than the pump supplying oil flow to the “outside stick in neutral. A 0-1000 psi (0-70 bar) pressure gauge
turning radius” pump. must be used. (If pressure gauges were installed in Ma &
“Posi-Traction” control, front to rear on a given side of the Mb to check charge pressure, disconnect the gauges
machine, is accomplished by a flow divider/combiner car- installed in Ma & Mb, as they will be damaged if loop
tridge installed in the Traction Control Manifold. There is a flow pressure rises above 1000 psi [34.4 bar].)
divider/combiner for each side. Each flow divider/combiner
also has a “bleed orifice” to limit the amount of flow splitting
or combining.
5-220 3121619
10. Operate the drive system in the “turtle mode”, forward 17. Check oil level & temperature.
and reverse. 18. Remove and inspect charge pressure oil filter, replace
11. De-aerate the system by bleeding fluid from the Ma & with new element.
Mb ports. 19. Operate the transmission under no load conditions for
12. Switch the drive mode speed control from “turtle” to about 15 minutes to stabilize the temperature and
“rabbit”. Gradually increase drive speed forward & remove any residual air from the fluid.
reverse, still with no load - wheels off the ground. 20. Set the machine back on the ground. Operate the trans-
13. With the joystick in neutral, check for creep in neutral. If missions under full and normal conditions.
evident, most likely dirt is present in the proportional
21. Erratic operation may indicate there is still air trapped in
pump control, an incorrect electrical signal is present on the system. By working the pump controls forward and
the pump's electrical control(s) or the control was not reverse the remaining air can be eliminated. The system
centered properly when overhauled. See service manual
is free of air when all functions can be operated
for centering instructions. smoothly and when the oil in the reservoir is no longer
14. Check that the controls are connected so that the trans- aerated. (Usually less than one hour of operation)
missions operate in the correct direction related to con-
trol input. NOTE: If the transmissions do not perform correctly after follow-
ing the pre-start & start-up procedures, refer to the relevant
15. Continue to monitor all pressure gauges & correct any sections of the trouble-shooting procedures.
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.
3121619 5-221
8 7 6 5 4
TELE CYL LIFT CYL
TELESCOPE
BORE: 5.5 IN
ROD: 4.5 IN SWING
STROKE 333.15 BORE: 8.0 IN DRIVES
ROD: 7.0 IN
STROKE 84.9 SWING
B A
LIFT SWING
D B A
EXH RET EXT
V2 V1 MD
T2 7 M7 8 M8 4 M4 5 M5 5A 2 2A MS2 MS3 3 3A
3300 PSI 3000 PSI 7 PSI

(227.5BAR) (206.8BAR) 0.5BAR
A B
2850 PSI
P T (196.5BAR)
TELE LIFT 2000PSI
DIRECTIONAL DIRECTIONAL A B (138BAR)
RETURN P T 3700 PSI

PLATFORM (258.5BAR)
2000PSI
T3
(138BAR)
C 115 PSI 5 PSI SWING
0.3BAR DIRECTIONAL
(7.9BAR) A B
a b
P T
AUX
15 PSI LIFT
AUX PILOT
TELE SWING RELIEF

FLOW FLOW 3550 PSI
CONTROL 15 PSI (245 BAR)
LIFT CONTROL
FLOW
MAIN
CONTROL
DUMP
REDUCING
3200 PSI
15 PSI
(220.7 BAR)
15 PSI 15 PSI
(1.03BAR)
(1.03BAR)
B LS PT1 MP5
MP P1 P2 T1 T4 MAIN
CONTROL
VALVE
SWIVEL
PORT #1
RETURN FILTER IN
B10>=1000
TANK
43 PSI(3BAR) B6>=200
BYPASS 45PSI(3.1BAR)
500PSI
(34.5BAR)
4000PSI L1
(275.9BAR) APU
2800PSI
B L
(193BAR)
VARIABLE PUMP
3.1 in3(51CC)
LOAD SENSE 500PSI
A PRESSURE COMP
SHEET 1
8 7 6 5 4
Figure 5-226. Hydraulic Schematic - Sheet 1 of 8
5-222 3121619
5 4 3 2
SWING
DRIVES
SWING
B A
SWING
BRAKES
SWING
B A D
2 2A MS2 MS3 3 3A
7 PSI
0.5 BAR
2850 PSI
(196.5BAR)
2000PSI
(138BAR)
3700 PSI
(258.5BAR)
2000PSI
(138BAR)
SWING C
DIRECTIONAL A B
P TO JIB
a b
P T
VALVE
AUX
LIFT
PILOT
PLATFORM
FILTER
SWING RELIEF
3500 PSI B10>=1000
FLOW
(245 BAR) 43 PSI(3BAR)
15 PSI CONTROL
BYPASS
MP4
P4
PLATFORM
15 PSI SUPPLY
CHASSIS
ENABLE
PT1 MP5 P3
B
T1 T4 MAIN SWIVEL
CONTROL PORT 2
VALVE
SWIVEL
PORT #1
RETURN FILTER IN
TANK
B6>=200
45PSI(3.1BAR)
SHEET 1 1001149709-E
5 4 3 2 1
MAF07980E
3121619 5-223
8 7 6 5 4
SWIVEL SWIVEL FRONT DEPLOY CYLS

PORT#2 PORT# 1
P T
2500 PSI V2
(172.4BAR) MA1
D A3
A1 V2
P A
V1
V1
T B 2500 PSI
(172.4BAR)
MA2
2600 PSI
(179.3BAR)
S1
A MS1
P
LEFT
MS2 FRONT
T B STEER
S2 A7
2000 PSI
(138BAR)
2600 PSI
C (179.3BAR)
S3
P A MS3
LEFT
REAR
T B MS4 STEER
S4 A8
2000 PSI
(138BAR)
LEFT VALVE
AXLE EXTENSION STEERING CYLINDERS

CYLINDERS BORE: 4.75 IN 17.72 SQ.IN
BORE: 5 IN 19.63 SQ.IN ROD: 1.75 IN 2.4 SQ.IN
ROD:2 IN 3.14 SQ.IN ANNULAR: 15.32 SQ.IN
ANNULAR: 16.49 SQ.IN STROKE: 9.8 IN
STROKE: 14.24 IN
B
SHEET 2
8 7 6 5 4
5-224 3121619
5 4 3 2 1
SWIVEL SWIVEL
PORT#2 PORT#1 REAR DEPLOY CYLS
P T
D
2500 PSI V2
MA1
(172.4BAR)
A3
A1 V2
P A V1
V1 A14
T B
MA2
A2
2600 PSI
(179.3BAR)
S1
MS1
P A
RIGHT
T B MS2 FRONT
STEER
S2
A9
C
2000 PSI
(138BAR)
2600 PSI
(179.3BAR)
S3
MS3
P A
RIGHT
T B MS4 REAR
STEER
S4
A10
2000 PSI
(138BAR)
RIGHT VALVE
SHEET 2 1001149709-E
5 4 3 2 1
MAF07990E
3121619 5-225
8 7 6 5 4
M14 M14
C1
C2
C1 C2 REAR
FRONT DRIVE
DRIVE PUMP
PUMP
MB MC
D F00B F00A
M3 E
FCOB FCOA
L1
L3
CW
CW
M5 M4 L2 MA A B C D MD M5 M4
TO PORT P3,MAIN TO PORT T4,MAIN

CONTROL, CONTROL,
VALVE PAGE 1 VALVE PAGE 1
PORT PORT
PORT PORT PORT #2 #1 SWIVEL PORT PORT
#7 #6 #5 PORTS #4 #3
D MP B2 A2 FRONT AXLE
REAR AXLE
A3 A4
300 PSI
LEFT (20.7BAR)
G B LEFT
G
A G1
G1 A
B3
B4
TRACTION MANIFOLD
A5
A6
RIGHT B RIGHT
B
G
G
A
G1 G1 A
B1
B BRAKE 2 SPEED
B6
B5 TS
MBR BR TS A1
FRONT DRIVE
REAR DRIVE
BRAKES
BRAKES
SHEET 3
8 7 6 5 4
5-226 3121619
5 4 3 2 1
M14
C1 CHARGE PUMP FILTER
C1 C2 REAR B6>=200
DRIVE BYPASS 50 PSI
PUMP CHARGE PUMP
1.025 IN3
OIL COOLER OPTION

MB MC
PORT L3 OF THE PUMP
M3 E
FCOB FCOA
TO THE INLET OF THE D
COOLER, COOLER OUTLET
BACK TO TANK
L3
CW
CW
L2 MA A B C D MD M5 M4
SWIVEL PORT PORT

PORTS #4 #3
B2 A2 FRONT AXLE
A4
B LEFT
G
G1 A
B4
A6
B RIGHT
G
G1 A
B6
TS
TS A1
FRONT DRIVE
BRAKES
SHEET 3 1001149709-E
5 4 3 2 1
MAF08000E
3121619 5-227
8 7 6 5 4
JIB STOP ROTATOR

66 CU IN
D JIB LEVEL CYLINDERS
10:1 PILOT RATIO
SPRING 3300 PSI
BORE: 5.5" 23.76 SQ.IN
ROD: 2.5" 4.91 SQ.IN
ANNULAR: 18.85 SQ.IN
JIB TELESCOPIC
STROKE: 16.59"
CYLINDERS
RATIO 1.26:1
BORE: 2.5" 4.91 SQ.IN
ROD: 1.5" 1.78 SQ.IN
ANNULAR: 3.14 SQ.IN
V1 T V2
STROKE: 84.06"
V2 TELESCOPIC V2
JIB LIFT CYLINDERS
BORE: 5" 19.63 SQ.IN
ROD: 2.5" 4.91 SQ.IN
ANNULAR: 14.73 SQ.IN
STROKE: 25.15"
RATIO 1.33:1
V1
V1
V2 V1
MLA LA LB MLB MTA TA TB MTB SA SB MJA JA JB MJB
C 2850 PSI 1200 PSI

1500 PSI 2600 PSI 2800 PSI
(103.59BAR)
(196.6BAR) 2850 PSI (82.8BAR)
(179.3BAR) (193.1BAR)
(196.6BAR)
T3
TOGR T2
0.3
PORT ON GPM 2.0
MAIN CONTROL GPM
VALVE T1
MP
TO PORT ON
HIGH PRESSURE
FILTER
P1
P2
JIB CONTROL VALVE
SHEET 4
8 7 6 5 4
5-228 3121619
5 4 3 2 1
PLATFORM ROTATOR
PLATFORM LEVEL
CYLINDER
14.1 CU IN D
3:1 PILOT RATIO
BORE: 3.55" 9.62 SQ.IN SPRING 3000 PSI
ROD: 1.5" 1.76 SQ.IN
ANNULAR: 7.65 SQ.IN
STROKE: 14.79"
JIB LOCK CYLINDER

BORE: 2.5" 4.91 SQ.IN
ROD: 1.75" 2.41 SQ.IN
V1 T V2 ANNULAR: 2.50 SQ.IN
STROKE: 13.375"
RATIO 1.96:1
V1 V2
ML1 L1 L2 ML2 R1 R2 S1 S2
2000 PSI 2500 PSI

2500 PSI (172.4BAR)
(172.4BAR) (138BAR)
T2
T1
0.2
GPM
MP
2.0
GPM
P
PLAT FORM CONTROL
SHEET 4 1001149709-E
5 4 3 2 1
MAF08010E
3121619 5-229
NOTES:
5-230 3121619
SECTION 6. JLG CONTROL SYSTEM
6.1 JLG CONTROL SYSTEM ANALYZER KIT viewing and adjusting the various personality settings for
smooth control of: acceleration, deceleration, creep, min
INSTRUCTIONS speed, and max.-speed for all boom, drive, and steering func-
tions.
Introduction
The main lift, swing, and drive are controlled by individual joy-
sticks, with steering being controlled by a rocker switch built
into the top the drive joystick. To activate Drive, Lift, and Swing
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT simply pull up on the slide lock location on the joystick and
WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER move the handle into the direction desired.
MACHINE CONFIGURATION, INCLUDING OPTIONS.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation and
maximum cycle time. Ground control speeds for all boom
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- functions can also be programmed into the control system.
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- The JLG Control System controller has a built in LED to indicate
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A any faults. The system stores recent faults which may be
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- accessed for troubleshooting. Optional equipment includes a
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING soft touch system, head and tail lights, and ground alarm.
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- These options may be added later but must be programmed
URATION. into the control system when installed.
The Control System may be accessed utilizing a custom

The JLG designed Control System is a 12 volt based control designed, hand held analyzer (Analyzer Kit, JLG part no.
unit installed on the boom lift. 2901443) which will display two lines of information at a time,
The JLG Control System has reduced the need for exposed ter- by scrolling through the program.
minal strips, diodes and trimpots and provides simplicity in
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or access pre-
Level, and item menus
vious 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
3121619 6-1
To Connect the JLG Control System Analyzer Using the Analyzer

1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop-
analyzer, to the motor controller module located in the erly, the analyzer will display the following:
platform box or at the power module and connect the
remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.
2. Power up the Control System by turning the lower key to

the platform or ground position and pulling both emer-
gency stop buttons on.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow

keys, you can move between the top level menu items. To
select a displayed menu item, press ENTER . To cancel a
selected menu item, press Escape ; then you will be able

to scroll using the right and left arrow keys to select a different
menu item.
6-2 3121619
The top level menus are as follows: When a top level menu is selected, a new set of menu items
may be offered: for example:
HELP
DIAGNOSTICS DRIVE
ACTIVATE TEST BOOM
ACCESS LEVEL SYSTEM
PERSONALITIES DATALOG
MACHINE SETUP VERSIONS
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only)
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected menu. In
If you press ENTER , at the HELP: PRESS ENTER display, some cases, such as DRIVE, the next level is the parameter or
and a fault is present, the analyzer display will scroll the fault information to be changed. Refer to the flow chart for what
across the screen. If there was no fault detected, the display menus are available within the top level menus. You may only
will read: HELP: EVERYTHING OK. If powered up at the view the personality settings for selected menus while in
ground station, the display will read: GROUND OK. OPERATOR ACCESS. Remember, you may always cancel a
If ENTER is pressed again, the display moves to the fol- selected menu item by pressing the ESCAPE key.
lowing display:
Changing the Access Level of the Hand Held
Analyzer
When the analyzer is first connected, you will be in OPERATOR
ACCESS 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:
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
beginning, press ESCAPE two times. STARTUP (2/1)

indicates a power up.
ACCESS LEVEL:
CODE 00000
3121619 6-3
Adjusting Parameters Using the Hand Held

Press ENTER to select the ACCESS LEVEL menu. Analyzer
Once you have gained access to level 1, and a personality item
Using the UP or DOWN arrow keys, enter the first
digit of the password, 3.
is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the sec-

ond digit of the password which is 33271.
Once the correct password is displayed, press ENTER .

The access level should display the following, if the password
was entered correctly:
DRIVE:
ACCEL 1.5s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP
arrow is pressed when at the maximum value nor will
the value decrease if the DOWN arrow is pressed and

the value is at the minimum value for any particular personal-
ity. If the value does not change when pressing the up and
MENU:
down arrows, check the access level to ensure you are at
ACCESS LEVEL 1
access level 1.
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.
6-4 3121619
Machine Setup There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF
YOUR MACHINE.
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-

TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI-
MUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
Level Vehicle Description
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults 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.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2 ENTER confirms that

vehicle is currently level, and zeroes the tilt sensor measure-
ments
3121619 6-5
Ground Control Console Display Gauge - Machines The Engine Diagnostics Screen will show SPN (Suspect
Parameter Number), FMI (Failure Mode Identifier), and
using Diesel Exhaust Fluid (DEF) Occurrence count information. Engine SPN text is not scrol-
lable. If there is more than one engine trouble code, the
(See Figure 6-5., Ground Control Console Display Gauge) operator must exit from the Engine DTC Screen to see
other SPN and FMI information.
The Display Gauge shows engine hours, fuel level (if appli-
cable), and Diagnostic Trouble Codes (DTCs) from both the
JLG Control System and the engine control system. During
machine start up, with no active DTCs in the control sys-
tem, the splash screen will show for 3 seconds and then
switch to main screen. If there is an active DTC while pow-
ering up the machine, the splash screen will show for 3 sec-
onds, and then launch the Diagnostics Screen. The
indicator lamp will light when there is an active DTC in the
Fault Log.
Figure 6-4. Engine Diagnostic Screen
Figure 6-2. Splash Screen
The Diagnostic Screen will show active and inactive faults

from the JLG Control System on the screen. An asterisk (*)
will be displayed to show active faults.
DIAGNOSTIC CODES
Figure 6-3. Diagnostic Screen
6-6 3121619
INDICATOR LAMP
ENGINE HOURS FUEL LEVEL
NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW
NAVIGATION BUTTONS
Figure 6-5. Ground Control Console Display Gauge
3121619 6-7
Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations
ABBREVIATION MEANING ABBREVIATION MEANING

ACCEL ACCELERATE GND GROUND
ACT ACTIVE GRN GREEN
A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE
AMB. AMBIENT H HOURS
ANG ANGLE HW HARDWARE
AUX AUXILIARY HWFS HARDWARE FAILSAFE
BCS BOOM CONTROL SYSTEM I IN or CURRENT
BM BOOM LENGTH ANGLE MODULE JOY JOYSTICK
BLAM BOOM LENGTH ANGLE MODULE L LEFT
BR BROKEN LB POUND
BSK BASKET LEN LENGTH
CAL CALIBRATION LIM LIMIT
CL CLOSED LT LEFT
CM CHASSIS MODULE LVL LEVEL
CNTL CONTROL M MINUTES
CNTRL CONTROL MIN MINIMUM
C/O CUT OUT MAX MAXIMUM
CONT(S) CONTRACTOR(S) M MAIN
COOR COORDINATED MN MAIN
CRK PT CRACK POINT NO NORMALLY OPEN or NO
CRP CREEP NC NORMALLY CLOSED
CUT CUTOUT O OUT
CYL CYLINDER O/C OPEN CIRCUIT
DECEL DECELERATE OP OPEN
D DOWN O/R OVERRIDE or OUTRIGGER
DN DOWN O//R OVERRIDE
DWN DOWN OSC OSCILLATING
DEG. DEGREE OVRD OVERRIDE
DOS DRIVE ORIENTATION SYSTEM P PLATFORM
DRV DRIVE P PRESSURE
E ERROR PCV PROPORTIONAL CONTROL VALVE
E&T ELEVATED & TILTED PLAT PLATFORM
ELEV ELEVATION PLT PLATFORM
ENG ENGINE PM PLATFORM MODULE
EXT EXTEND POT POTENTIOMETER
F FRONT PRES PRESSURE
FL FLOW PRS PRESSURE
FNT FRONT PT POINT
FOR FORWARD R REAR or RIGHT
FWD FORWARD REV REVERSE or REVISION
FSW FOOT SWITCH RET RETRACT
FUNC FUNCTION ROT. ROTATE
G GROUND RT RIGHT
6-8 3121619
Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING
S/C SHORT CIRCUIT
SEL SELECTOR
SN SERIAL NUMBER
SPD SPEED
STOW STOWED
STOWD STOWED
SW SWITCH or SOFTWARE
TELE TELESCOPE
TEMP TEMPERATURE
TORQ. TORQUE
TRN TRANSPORT
T/T TURNTABLE
T TOWER
TURNTBL TURNTABLE
TWR TOWER
U UPPER or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW
3121619 6-9
Table 6-2. Machine Configuration Programming Information (Software 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
personality settings first and then changing the model number of the machine configuration will cause the personality
settings to return to default values.
The items marked in BOLD bold text on this sheet represent a new board that has never been configured.
MODEL NUMBER: 0 No Model 0

1
1 1500SJ
2 1850SJ
ENVELOPE HEIGHT: 0 1500SJ: 150' MAX 0

2
1 1850SJ: 185’ MAX
Note: The default settings (bold) will vary depending on the model selection with selection #0 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) 6

4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
4 CAT Engine
5 DEUTZ ECM T4i: Engine Control Module (Tier 4 Interim)
6 DEUTZ ECM T4F: Engine Control Module (Tier 4 Final)
6-10 3121619
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
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 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also disallows tower lift up, 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.
* Certain market selections will alter default setting.
3121619 6-11
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.
6-12 3121619
Default
Number
LOAD SYSTEM: 0 0
NO: No load sensor installed.
17*
1
WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2
CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
3
SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
4
* 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 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).
FLYWHEEL TEETH 0 110 TEETH: Engine speed is calculated using 110 flywheel teeth 0
21*
1 133 TEETH: Engine speed is calculated using 110 flywheel teeth
2 112 TEETH: Engine speed is calculated using 110 flywheel teeth
* Only visible when Deutz F4 Tier 1 or Tier 2 engines selected
3121619 6-13
Default
Number
OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1

22
1 YES: Oscillating axle system installed.
Note: The default settings (bold) will vary depending on the model selection with selection #0 being the initial default setting.
DISPLAY UNITS: 0 METRIC: units selection. (Deg. C, KPA, Kg.) 1

23*
1 IMPERIAL: units selection. (Deg. F, PSI, Lbs.)
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 52 Gallon Fuel tank. 0

26
1 31 Gallon Fuel tank.
1 45 Gallon Fuel tank.
ALERT BEACON: 0 OFF FOR CREEP. 0

27
1 20FPS FOR CREEP.
LANGUAGE: 0 ENGLISH 0
28
1 SPANISH
2 EURO PORTUGUESE
3 BRAZILIAN PORTUGUESE
4 FRENCH
5 GERMAN
6 DUTCH
7 ITALIAN
8 SIMPLIFIED CHINESE
9 JAPANESE
10 KOREAN
6-14 3121619
Default
Number
TEMP CUTOUT: 0 NO: No temperature cutout 0

29*
1 YES: Temperature cutout enab led
PLAT LVL OVR CUT: 0 NO: No platform cutout 0

30
1 YES: Platform cutout enabled
CRIBBING: 0 NO: No temperature cutout 0

31
1 YES: Cribbing is installed
WATER IN FUELSENSOR: 0 NO: Water in fuel sensor option not installed 0

32
1 YES: Water in fuel sensor option installed
*Only visible under certain market selections.
ALARM/HORN: 0 COMBINED: The white noise alarm option is not installed 0

33
1 SEPARATE: The white noise alarm option is installed
1001128802-H
3121619 6-15
Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings
(Software Version P7.29) (Software Version P7.29)
ANSI Export
ANSI Export
Australia
ANSI USA
Australia
ANSI USA
Japan
CSA
Japan
1850SJ
CE
CSA
1850SJ
CE
Model Number 2 2 2 2 2 2 Gen Set / Welder 0 0 0 0 0 0
Envelope Height 1 1 1 1 1 1 1 1 1 1 1 1
Market 0 1 2 3 4 5 2 2 2 2 2 2
Engine 1 1 1 1 1 1 Gen Set Cutout 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
3 3 3 3 3 3 Head & Taillights 0 0 0 0 0 0
4 4 4 4 4 4 1 1 1 1 1 1
5 5 5 5 5 5 Load System 0 0 0 0 0 0
6 6 6 6 6 6 X 1 X 2 2 1
Glow Plug 0 0 0 0 0 0 X 2 X 2 2 2
1 1 1 1 1 1 X 3 X 3 3 3
2 2 2 2 2 2 X 4 X X 4 4
Starter Lockout 0 0 0 0 0 0 Load Type X 0 X 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Engine Shutdown 0 0 0 0 0 0 Function Cutout X 0 0 1 0 0
1 1 1 1 1 1 X 1 1 X 1 1
Fuel Cutout 0 0 0 0 0 0 X 2 2 X 2 2
1 1 1 1 1 1 3 3 3 X 3 3
2 2 2 2 2 2 Ground Alarm 0 0 0 0 0 0
Chassis Tilt 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 3 3 3 3 3 3
4 4 4 4 4 4 Flywheel Teeth 0 0 0 0 0 0
5 5 5 5 5 5 1 1 1 1 1 1
Jib 0 0 0 0 0 0 2 2 2 2 2 2
1 1 1 1 1 1 Oscillating Axle 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 Display Units 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 Leveling Mode 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 Clearsky 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 Fuel Tank 0 0 0 0 0 0
3 3 3 3 3 3 1 1 1 1 1 1
2 2 2 2 2 2
Alert Beacon 0 0 0 0 0 0
1 1 1 1 1 1
6-16 3121619
Table 6-3. Machine Configuration Programming Settings

(Software Version P7.29)
ANSI Export
Australia
ANSI USA
Japan
CSA
1850SJ
CE
Language 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
4 4 4 4 4 4
5 5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
8 8 8 8 8 8
9 9 9 9 9 9
10 10 10 10 10 10
Platform Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Temp Cutout X 0 X 0 X X
X 1 X 1 X X
Cribbing 0 0 0 X X 0
0 0 0 X X 1
Water In Fuel Sensor X 0 X X X X
X 1 X X X X
Alarm/Horn 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.
3121619 6-17
6.2 MACHINE PERSONALITY SETTINGS AND

FUNCTION SPEEDS
NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance.
Table 6-4. Machine Personality Settings and Function Speeds (Software Version P7.29)
SUBMENU PARAMETER
DEFAULT TIME RANGE
(DISPLAYED ON (DISPLAYED ON ANALYZER 2ND DESCRIPTION RANGE
VALUES (SEC)
ANALYZER 1ST LINE) LINE)
DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3
MIN forward XX% Displays/adjusts minimum forward drive speed 0 to 35% 1
MAX forward XXX% Displays/adjusts maximum forward drive speed 0 to 100% 100 54-58 (see orientation)
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100
ELEV. MAX XX% Displays/adjusts maximum drive speed 0 to 50% 25 110-112 (see orientation)
NOTE: used when elevation cutout switches are

limiting maximum speed
CREEP MAX XX% Displays/adjusts maximum drive speed 0 to 50% 35 79-87 (see orientation)
NOTE: used when creep switch on pump pot is

active
STEER: MAX SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100
MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum main lift up speed 0 to 60% 20
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 100% 80 130-160 (see orientation)
CREEP UP XX% Displays/adjusts maximum main lift up speed 0 to 65% 50
active
MIN DOWN XX% Displays/adjusts minimum main lift down 0 to 60% 10
speed
MAX DOWN XXX% Displays/adjusts maximum main lift down 0 to 100% 60 145-175 (see orientation)
speed
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45
speed
6-18 3121619
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 3

DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 15
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 75 110-130 (see orientation)
CREEP LEFT XX% Displays/adjusts maximum swing left speed 0 to 65% 40

active
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 22
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 81 110-130 (see orientation)
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 47
MAN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15
speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 45-65 (see orientation)
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 15
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 45-65 (see orientation)
speed
PLATFORM ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5
LEVEL: DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum basket level up 0 to 65% 55
MAX UP XXX% Displays/adjusts maximum basket level up 0 to 100% 70
speed
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 50
MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70
speed
3121619 6-19
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
PLATFORM ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1
ROTATE: DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60
MAX LEFT XXX% Displays/adjusts maximum basket rotate left 0 to 100% 60 15-20 (180)
speed
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 15-20 (180)
speed
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum jib up speed. Same 0 to 65% 46
as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 70-120
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 46
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 76 65-100
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same 0 to 65% 48
as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 60-68 (180)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. 0 to 65% 55
Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 60-68 (180)
JIB TELESCOPE: ACCEL X.Xs Displays/adjusts jib tele acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib tele deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum jib tele in speed. 0 to 65% 45
Same as Creep speed
MAX IN XXX% Displays/adjusts maximum jib tele in speed 0 to 100% 70 20-25 (see orientation)
MIN OUT XX% Displays/adjusts minimum jib right speed. 0 to 65% 40
Same as Creep speed
MAX OUT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 20-25 (see orientation)
6-20 3121619
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum jib level up speed. 0 to 65% 60
Same as Creep speed
MAX UP XXX% Displays/adjusts maximum jib level up speed 0 to 100% 100
MIN DOWN XX% Displays/adjusts minimum jib level down 0 to 65% 60
MAX DOWN XXX% Displays/adjusts maximum jib level down 0 to 100% 100
speed
GROUND M. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 50% 50

MODE: M. lift DN XXX% Displays/adjusts main lift down speed 0 to 100% 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60
PLATFORM LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75
PLATFORM ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 60
JIB (U/D) XXX% Displays/adjusts jib lift speed 0 to 100% 80
Not displayed if JIB = 0
JIB (L/R) XXX% Displays/adjusts jib swing speed 0 to 100% 80
Displayed if JIB = 2
JIB TELE XXX% Displays/adjusts jib tele speed 0 to 100% 80
JIB LEVEL XXX% Displays/adjusts jib level speed 0 to 100% 100
GEN SET/WELDER: Engine XXXX RPM Control generator/welder RPM. Not displayed if 1200-2800 1800 1800 for 60Hz,1900 for 50Hz
GEN SET/WELDER = 0
1001172159-D
3121619 6-21
6.3 MACHINE ORIENTATION WHEN SETTING DRIVE REVERSE (Creep Max), high torque - low
FUNCTION SPEEDS speed setting, platform speed knob at full creep,
drive reverse 50 ft.
LIFT UP, from platform control, lowest elevation
up to maximum elevation, boom retracted, jib DRIVE FORWARD (Elevated Max - Boom Beyond
retracted. Transport), high speed - low torque setting, plat-
form speed knob out of creep, Lift boom above
LIFT DOWN, from platform control, maximum ele- transport, drive forward 50 ft.
vation down to minimum elevation, boom
retracted, jib retracted. DRIVE REVERSE (Elevated Max - Boom Beyond
Transport), high speed - low torque setting, plat-
JIB LIFT UP, from platform control, lowest jib ele- form speed knob out of creep, Lift boom above
vation up to maximum jib elevation, boom transport, drive backward 50 ft.
retracted, jib retracted.
Test Notes
JIB LIFT DOWN, from platform control, maximum
jib elevation down to minimum jib elevation, 1. Personality settings can be adjusted anywhere within
boom retracted, jib retracted. the adjustment range in order to achieve optimum
machine performance
SWING RIGHT(Max),360 Degrees, from platform 2. Stop watch should start when the function is acti-
control, boom approximately 45° elevation, boom vated.Not with the controller or switch.
retracted, jib retracted.
3. Unless noted, function speeds should be measured from
SWING LEFT(Max),360 Degrees, from platform platform.
control, boom approximately 45° elevation, boom 4. Platform speed knob must be at full speed (fully clock-
retracted, jib retracted. wise).
TELESCOPE OUT, from platform control, boom @ 5. All test should be done with the oil temp above 100° F
0 degrees, 500 lb. capacity selected. (38° C).
TELESCOPE IN, from platform control, boom @ 0

degrees, 500 lb. capacity selected.
JIB TELESCOPE IN, from platform control, boom
horizontal, jib horizontal, 500 lb. capacity selected.
JIB TELESCOPE OUT, from platform control, boom
horizontal, jib horizontal, 500 lb. capacity selected.
DRIVE FORWARD (Max), high speed - low torque
setting, drive 200 ft. front wheels to front wheels.
Timed after machine has obtained maximum
speed.
DRIVE REVERSE (Max), high speed - low torque
setting,drive 200 ft. front wheels to front wheels
Timed after machine has obtained maximum
speed.
DRIVE FORWARD (Creep Max), high torque - low
speed setting, platform speed knob at full creep,
drive forward 50 ft.
6-22 3121619
3121619 6-23
6.4 CANBUS COMMUNICATIONS The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
CANbus: CAN (Control Area Network) is a two wire differential module, all other system modules (PLATFORM, JIB, BLAM,
serial link between the Platform Module, Jib Module, Ground CHASSIS) handle sub-tasks. All characterized information (val-
Module, Boom Length Angle Module and the Chassis Module ues) are stored into the ground module (i.e., Personalities or
providing bi-directional communications. Calibrations).
Two-wire: One wire (yellow) is driven high (5v) and the other Interlocks: Any device that sends an electrical input. (For an
low (green) (0v) to send a signal; both wires ”float” (2.5v) when example a limit switch, proximity switch, etc;)
no signal is being sent. Platform Level: The GROUND MODULE stores the default val-
ues and handles interlocks. The PLATFORM MODULE reads the
Differential: Any electrical line noise can affect the high or the sensors mounted on the platform assembly and controls the
low wires but never both, so communications is not corrupted. Level Up / Down valves to maintain setpoint sent from the
GROUND MODULE.
Serial Link: Messages are being sent bit by bit along the wires;
the high bus speed allow all modules to be constantly Steer: The GROUND MODULE stores crack points, sends
updated around 20 times per second. Typical traffic is 300 - desired drive direction, sends steering mode and sends axle
500 messages per second. extend / retract commands. The PLATFORM MODULE reports
the steering switch position to the GROUND MODULE. The
A complete CANbus circuit is approximately 60 ohms, which CHASSIS MODULE modulates each steer left / right valve to
can be verified at the ”T” fitting below the BLAM. Each individ- maintain commanded wheel position.
ual circuit from the modules is approximately 120 ohms.
Drive: The GROUND MODULE stores crack points, sends com-
This machine has 3 CAN Networks. The UGM and BLAM are on
mands for each drive pump to the CHASSIS MODULE. (Com-
the side sheet.
mand is computed from drive joystick input, interlocks, wheel
• CAN1 - Unplug MDI and check for 60 Ohms angle, etc). CHASSIS MODULE maintains proper current for the
drive pumps by modulating PWM outputs.
• CAN2 - Verify 60 Ohm at Diagnostic connector.
Lift, Tele, & Swing: The GROUND MODULE stores default val-
• CAN3 - Verify 60 Ohm at Deutz Diagnostic Connector ues, handles interlocks and calibration information. Lift, Tele-
scope and Swing commands are dependent upon interlocks
through out the machine. Boom angle, length and swing are
controlled by the GROUND MODULE. The BLAM monitors and
communicates (CANbus) to the GROUND MODULE boom
angle and boom length via two angle sensors, a length sensor
and a load moment pin.
6-24 3121619
MS83
3X4 B us s Bar
Be low U GM
C hassi s LSS Module
U GM Shie ld
6 Groun d X468
YEL Ca n Hig h
J2 -4
J2 -9
J2 -5
2
GRN C an Lo C an 2 Buss Bar
J7 -24 4 MS83 She et 5 , D1
Broken C abl e Prox

Sen sor 1 Sh ee t 4, G2
Gr aphic Display
YEL C an Hi gh
MDI 4 8 1 BL U Hig h 5 8
GR N Can L o 10 3 12
X77 3 7 3
X327 a t UGM Chas sis Module 9 BLK Lo 4 10
M12 Te e with
X43
Shie ld 5 J7-6
YEL Can H igh 120 OHM LSS Option
11 J7-1 7
GRN C an Lo White
9
J7-1 8
Ma in Boom
1 3 2 J7-2 4
Cable X 81 SN29 2 Pla tfor m
J7-1 3
Le vel Cylinder
RED C an Hi gh
BLK Ca n Lo
Angle Se ns or
Shie ld
10 Gra y Shi eld

12 5 5 YEL Hig h 7
Bl ue
7 Swivel 3 3 GRN Lo 11
Bla ck
YEL C an Hi gh 4 4 9
A A 1 1
X44
B B GRN Ca n Lo 2 2
X2 31 1 3 2 Shi eld
C C 3 3
MS158 -3
MS15 8-2
YEL Ca n Hig h
GRN Can Lo
RED Ca n Hig h
BLK Ca n Lo
Shie ld
Shie ld
A B C SN26 0 Jib Lift

MS158 -1 Cy linde r Angle
Sensor 3 4 5
J1 -7
Platf orm Module

J1-6
YEL Ca n Hig h
GRN C an Lo
X23 0 1 3 2 Sh iel d
J7-32 6
Shi eld
YEL Can H igh

J4 -4 WHT C an Lo J7-31 GRN C an Lo 2
D 12 0 OH M 4
J4-3 GRN Ca n Hig h J7-30
E
B LA M Module SN 129 A B C MS261 -2

Load
Pin
GR N Can L o J1-7 J4-4 GR N Lo 2 RED Hi gh 2 GRN Can L o

B B 3
YEL Can H igh J1-6 J4-3 A A YEL Hi gh 3 BLK Lo 3 YEL Can H igh 1
Shi eld J1-8 J4-5 Sh ie ld Sh iel d
C C 1 1 5
MS261 -1
MS26 2-3
X2 28
X3 3
MS41
J ib Module 3x 4 Buss
Bar
Figure 6-6. Control System CAN Circuit 1
3121619 6-25
120 OHM
MS83
3X4 Buss Bar
Below UGM MS1000-3 A B C
UGM MODULE
MS1000-1
MS1000-2
YEL Can High
12 Deutz ECM
120 OHM
GRN Can Lo
54
76
53
75
J12-4 10 J1 Connector
6
J12-7 Shield from Can A A
J12-6 White 1 Bus Bar Sheet B B
5 Zone H3 C C
Tee Connector
under ECM
MS1001-1 AB C
A A
120 OHM
B B
Tee Connector Tee Connector
JLG Diagnostic E Shiel d 7 A C C
120 OHM be hind Drive
GRN Can Lo under De utz
MS1002-1
B
MS1002-3
Connector D 4 Pumps
YEL Can High C ECM
Beside UGM C 11
MS1001-3
A B C MS1002-2
MS10 01-2A B C
GRN Can Lo
YEL Can High
Shield
Sh ield
5
GRN Can Lo
3
YEL Can Hi gh
1
MS999-2 AB C
G
H
YEL Ca n High YEL Can High
3 A A 1 M
GRN Can Lo GRN Can Lo
4 B B 2 F
Shi eld Shield
6 C C 3
Engine Deutz
MS999 -1
MS999 -3
Connector #1 Te e Connector Diagnostic

X218 under drive Connector
On T/T side pumps Behind Engine
shee t behind
char ge pump
Figure 6-7. Control System CAN Circuit 2 & 3
6-26 3121619
6.5 CALIBRATION INSTRUCTIONS Table 6-5. Calibration Instructions
This machine incorporates a variety of sensors and a high Lift Crack Point Ground module replacement
Calibration Lift proportional valve/coil replacement
degree of function interaction. For safety and proper machine
Erratic controlled arc operation
functionality, the calibration procedures must be repeated for
Erratic controlled boom angle operation
any control module replacement, system calibration related
fault, or removal or replacement of any sensors, valves, coils, Telescope Crack Point Cali- Ground module replacement
motors, or pumps. The chart below lists the calibrations bration Telescope proportional valve replacement
required and potential reasons for re-calibration. All calibra- Erratic controlled arc operation
Erratic controlled boom angle operation
tion procedures are menu driven through the use of the stan-
dard analyzer. With the exception of steering calibration, no Jib Level Crack Point Jib Control Module replacement
external tools are required to complete the calibration proce- Calibration Jib level proportional valve replacement
dures. The user is prompted to exercise the machine in a spe-
Chassis Tilt Ground module removal or replacement
cific order to use the machines physical properties to
Calibration Main terminal box removal or replacement
consistently establish sensor response and the interaction of Tilt indication inaccuracy
valves, pumps, and motors. Steering calibration also uses the External tilt sensor removal or replacement
analyzer and is performed on one side of the machine at a
time requiring the use of a string or other means to determine Boom Sensors Ground module removal or replacement
Calibration BLAM module removal or replacement
when the tires are in line with each other. With the exception
Main Boom angle sensor removal or replacement
of the load control calibration, all calibrations are accessed by Main Boom length sensor removal or replacement
connecting the analyzer into the control system inside the Moment pin removal or replacement
main terminal box or on the bottom of the platform control Main Boom angle sensor calibration fault
box. Main Boom length sensor calibration fault
Moment pin fault
Table 6-5. Calibration Instructions Failed BCS functional check
Boom control system inaccuracies
Calibration Reasons for Re-calibration Jib Sensor Calibration Ground module removal or replacement
Procedure Replacement of any Jib sensor
Replacement of the Jib Control Module
Steering Calibration Ground module replacement
Chassis module replacement Platform Load Control LSS module replacement
Steer sensor removal or replacement Calibration Load cell removal or replacement
Persistent wheel misalignment Load control inaccuracy
Drive Calibration Ground module replacement Axle Extend/Retract Ground module replacement
BLAM module replacement Sensors Calibration Chassis module replacement
Drive pump/coil replacement Axle extend/retract sensor removal or replacement
Drive pulls to one side Axle extend out of range fault
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
Jib Level Crack Point Ground Module replacement

Calibration Jib Control Module replacement
Jib Level Sensor replacement
Jib Level valve/coil replacement
Erratic Jib leveling
3121619 6-27
6-28
ANALYZER MENU
STRUCTURE
ACCESS LEVEL: 2
CODE 33271
MENU: 2 ACCESS LEVEL: 2

ACCESS LEVEL 2 CODE 00000
MENU: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2
PERSONALITIES DRIVE STEER MAIN LIFT SWING MAIN TELESCOPE PLATFORM LEVEL PLATFORM ROTATE JIB LIFT JIB SWING
DRIVE: 2 STEER: 2 MAIN LIFT: 2 SWING: 2 MAIN TELESCOPE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE: 2 JIB LIFT: 2 JIB SWING: 2
ACCEL X.XS MAX SPEED XXX% ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS
DRIVE: 2 MAIN LIFT: 2 SWING: 2 MAIN TELESCOPE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE: 2 JIB LIFT: 2 JIB SWING: 2
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS
MIN FORWARD XXX% MIN UP XXX% MIN LEFT XXX% MIN IN XXX% MIN UP XXX% MIN LEFT XXX% MIN UP XXX% MIN LEFT XXX%
MAX FORWARD XXX% MAX UP XXX% MAX LEFT XXX% MAX IN XXX% MAX UP XXX% MAX LEFT XXX% MAX UP XXX% MAX LEFT XXX%
MIN REVERSE XXX% CREEP UP XXX% CREEP LEFT XXX% MIN OUT XXX% MIN DOWN XXX% MIN RIGHT XXX% MIN DOWN XXX% MIN RIGHT XXX%
MAX REVERSE XXX% MIN DOWN XXX% MIN RIGHT XXX% MAX OUT XXX% MAX DOWN XXX% MAX RIGHT XXX% MAX DOWN XXX% MAX RIGHT XXX%
DRIVE: 2 MAIN LIFT: 2 SWING: 2

ELEV. MAX XXX% MAX DOWN XXX% MAX RIGHT XXX%
DRIVE: 2 MAIN LIFT: 2 SWING: 2

CREEP MAX XXX% CREEP DOWN XXX% CREEP RIGHT XXX%
PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2 PERSONALITIES: 2

JIB TELESCOPE JIB LEVEL GROUND MODE GEN SET/WELDER AXLE DEPLOY LOW TEMP CUTOUT
JIB TELESCOPE: 2 JIB LEVEL: 2 GROUND MODE: 2 GEN SET/WELDER: 2 AXLE DEPLOY: 2 LOW TEMPERATURE 2
ACCEL X.XS ACCEL X.XS MAIN UP: XXX% ENGINE 1800 RPM ALL CUTOUT SET: XX C
JIB TELESCOPE: 2 JIB LEVEL: 2 GROUND MODE: 2

DECEL X.XS DECEL X.XS MAIN DOWN: XXX%
TO JIB TELESCOPE: 2 JIB LEVEL: 2 GROUND MODE: 2

MENU: MIN IN XXX% MIN UP XXX% SWING: XXX%
MACHINE SETUP
JIB TELESCOPE: 2 JIB LEVEL: 2 GROUND MODE: 2 GROUND MODE: 2

MAX IN XXX% MAX UP XXX% PLT LEVEL: XXX% JIB (L/R): XXX%

MIN OUT XXX% MIN DOWN XXX% PLT ROTATE: XXX% JIB TELE: XXX%

MAX OUT XXX% MAX DOWN XXX% MAIN TELE: XXX% JIB LEVEL: XXX%
GROUND MODE: 2
JIB (U/D): XXX%
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine con-
figuration.
1001119511-P
MAF09890P
Figure 6-8. Analyzer Flow Chart - Sheet 1 of 5 (Software Version P7.29)
3121619
FROM
3121619
MENU:
PERSONALITIES
MENU: 2 MODEL NUMBER: 2 ENVELOPE HEIGHT: 2 MARKET: 2 ENGINE: 1 GLOW PLUGS: 1 STARTER LOCKOUT: 1 FUEL CUTOUT: 2 CHASSIS TILT: 2 STOUCH/SKYGUARD: 2 GEN SET/WELDER: 2
MACHINE SETUP 1850SJ 1850S: 185' MAX ANSI USA DEUTZ ECM T4F IN-CYLINDER DISABLED RESTART 5 DEG + DRV CUT NONE NO
GEN SET CUTOUT: 2 H & T LIGHTS: 2 LOAD SYSTEM: 2 LOAD TYPE: 2 FUNCTION CUTOUT: 2 GROUND ALARM: 2 OSCILLATING AXLE 2 DISPLAY UNITS: 2
MOTION ENABLED NO NO CAN LSS NO NO YES IMPERIAL
LEVELING MODE: 2 CLEARSKY: 2 FUEL TANK SIZE: 2 ALERT BEACON: 2 DISPLAY LANGUAGE 2 TEMP CUTOUT: NO 2 PLAT LVL OVR 2 CRIBBING OPTION: 2 WATER IN FUEL 2 ALARM/HORN: 2
LEVEL ALL NO 31 GALLON OFF FOR CREEP ENGLISH CUT: NO NO SENSOR: NO COMBINED
MENU: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1

CALIBRATIONS STEER DRIVE LEVEL UP CRKPT LEVEL DOWN CRKPT JIB LVL UP CRKPT JIB LVL DN CRKPT MAIN LIFT CRKPT MAIN TELE CRKPT
CALIBRATE 1 CALIBRATE 1 CALIBRATE 1 CALIBRATE 1 CALIBRATE LEVEL 1 CALIBRATE LEVEL 1 CALIBRATE JIB 1 CALIBRATE JIB 1 CALIBRATE MAIN 1 CALIBRATE MAIN 1
STEER? FRONT LT STEER DRIVE? LT FWD DRIVE UP CRACKPOINT? DOWN CRACKPOINT? LEVEL UP CRKPNT? LEVEL DN CRKPNT? LIFT CRACKPOINT? TELE CRACKPOINT?
CALIBRATE 1 CALIBRATE 1
REAR LT STEER LT REV DRIVE CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1
TILT SENSOR BOOM SENSORS JIB SENSORS LOAD SENSING
FRONT RT STEER RT FWD DRIVE POSITION 1: 1 POSITION 1: 1 JIB CALIBRATION 1 LSS CALIBRATION 1
CHECK SYSTEM? CHECK SYSTEM? CHECK SYSTEM? CHECK SYSTEM?
REAR RT STEER RT REV DRIVE
LOAD SENSING: 1
PLATFORM EMPTY?
CALIBRATIONS: 1 CALIBRATIONS: 1 MSSO 1 CALIBRATIONS: 1
TO UNLOCK BOOM AXLE SWING PLAT LVL CUTOUT
MENU: LOAD SENSING 1
SERVICE MODE ACCESSORY XXXLB
UNLOCK BOOM: 1 CALIBRATION AXLE 1 MSSO RESET 1 TILT SENSOR: 1
CHECK SYSTEM? SWING? CONFIRM? CALIBRATE?
LOAD SENSING: 1
CALIBRATING
LOAD SENSING: 1
SKY GLAZIER N
LOAD SENSING: 1
PIPE RACKS N
LOAD SENSING: 1
UNRSTRICT XXLBS
LOAD SENSING: 1
RSTRICT XXXLBS
LOAD SENSING: 1
CAL COMPLETE
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
1001119511-P
MAF09900P
6-29
FROM
MENU:
6-30
CALIBRATIONS
MENU: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1
SERVICE MODE JIB & SWING? PRODUCTION TEST? AXLES? ENGINE HYD WARMUP SET PRESSURES
JIB & SWING 1 AXLE SERVICE: 1 ENGINE: 1 ACTIVATE REGEN? 1 HYD WARMUP: 1 HYD WARMUP: 1 SET PRESSURES: 1 BOOM LIFT: 1
CODE 00000 OFF REGNERATION? CODE 00000 ACTIVATE? BOOM LIFT? WARNING/MOVEMENT
JIB & SWING: 1 JIB & SWING: 1 AXLE SERVICE: 1 CANCEL REGEN? 1 HYD WARMUP: 1 BOOM LIFT: 1
JIB LEVEL JIB LOCK PIN? FRNT SWNG EXT ACTIVE BOOM ON REST?
AXLE SERVICE: 1 BOOM LIFT: 1

FRNT SWNG RET BOOM LIFT
2 2 AXLE SERVICE: 1
MENU: HELP:
HELP:PRESS ENTER GROUND MODE OK REAR SWNG EXT
AXLE SERVICE: 1
REAR SWNG RET
TO
MENU: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2
DIAGONOSTICS:
DIAGNOSTICS DRIVE/STEER BOOM FUNCTIONS ENGINE SYSTEM TRANSPORT DATA
JOYSTICK DRIVE: 2 JOYSTICK LIFT: 2 START SEQUENCE: 2 GROUND MODULE: 2

FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV
JOYSTICK STEER: 2 LIFT OUTPUT: 2 BATTERY VOLTAGE: 2 PLATFORM MODULE: 2

LEFT XXX% MAIN UP XXX% XX.XV BATTERY: XX.XV
DRIVE OUTPUT: 2 LIFT OUTPUT 2 COOLANT 2 UGM 2

PLATFORM TILT2 2
FORWARD XXX% COMMANDED:XXXXMA TEMPERATURE:XXXF TEMPERATURE:XXXC RAW: XXXX
STEER OUTPUT: 2 LIFT OUTPUT 2 ENGINE OIL 2 PLATFORM SELECT 2

OSCILLATING AXLE 2
LEFT XXX% ACTUAL:XXXXMA PRESSURE:XXX PSI KEYSWITCH CLOSED PRES. SW.: OPEN
STEER TYPE: 2 LIFT ENABLE 2 AMBIENT 2 GROUND SELECT 2

MODEL ID 2
NORMAL COMMANDED:XXXXMA TEMPERATURE:XXXC KEYSWITCH: OPEN INPUT: OPEN
BRAKES STATUS: 2 LIFT ENABLE 2 FUEL LEVEL 2 STATION CONTROL: 2

HYDRAULIC OIL 2
LOCKED ACTUAL:XXXXMA SENSOR: OK GROUND TEMP. SW.: OPEN
CREEP: 2 JOYSTICK SWING: 2 PLATFORM ROTATE: 2 STARTER 2 TRANSPORT MODE: 2

EXTERNAL TILT X- 2 HYDRAULIC OIL: 2
SWITCH: CLOSED LEFT XXX% LEFT XXX% CRANK TIME: XX S OUT OF TRANSPORT AXIS: XX.X WARM UP NOT DONE
MENU: 2 SYSTEM TEST: 2 CREEP MODE: 2 SWING OUTPUT: 2 JIB LIFT: UP 2 ENGINE SPEED 2 CABLE BREAK 2
EXTERNAL TILT Y- 2 CHASSIS ENABLE 2
SYSTEM TEST ACTIVATE? OFF LEFT XXX% XXX% ACTUAL: XXXX RPM SWITCH: CLOSED AXIS: XX.X VALVE: OFF
2-SPEED: 2 L REAR WHEEL 2 SWING OUTPUT 2 JIB SWING LEFT 2 ENGINE SPEED 2 CREEP 2
AUXILIARY POWER 2 MODEL ID INPUT: 2
SWITCH: OPEN ANGLE: XX.X COMMANDED:XXXXMA XXX% TARGET: XXXX RPM SWITCH: CLOSED SWITCH: OPEN OPEN
2-SPEED VALVE 2 R REAR WHEEL 2 SWING OUTPUT: 2 JIB TELESCOPE: 2 TIME FROM REGEN: 2 CREEP MODE: 2
HORN 2 AMBIENT TEMP 2
OUTPUT: OFF ANGLE: XX.X ACTUAL:XXXXMA IN XXX% XXXXHRS XXMINS OFF SWITCH: OPEN XXX C
HIGH ENGINE 2 DRV. ORIENTATION 2 MAIN TELESCOPE: 2 PLATFORM CONTROL 2 REMAIN REGEN TMR 1 CHASSIS TILT: 2 2
GENSET.WELDER LOW TEMPERATURE 2
SWITCH: OPEN SWITCH: CLOSED IN XXX% VALVE: OFF XXXX MINS XX.X DEGREES SWITCH: OPEN CUTOUT: INACTIVE
DRIVE MODE: 2 DRV. ORIENTATION 2 TELE OUPUT 2 FUNCTION SPEED: 2 REGEN STATUS: 1 CHASSIS TILT 2
PLATFORM TILT1 2 MSSO SW: 2
MID ENGINE OVERRIDE: OPEN COMMANDED:XXXXMA PUMP POT XXX% INACTIVE X-AXIS: XX.X ANGLE: XX.X DEG OPEN
L FRONT WHEEL 2 DRV. ORIENTATION 2 TELE OUPUT 2 CREEP SWITCH: 2 REGEN REQUEST 1 CHASSIS TILT 2
PLATFORM TILT2 2 MSSO: 2
ANGLE: XX.X STATUS: REQUIRED ACTUAL:XXXXMA CLOSED NONE Y-AXIS: XX.X ANGLE: XX.X DEG INACTIVE
R FRONT WHEEL 2 CRIBBING OPTION: 2 PLATFORM LEVEL: 2 CREEP MODE: 2 DEF LEVEL: 2 EXTERNAL TILT: 2
PLATFORM TILT1 2 REGEN SW: 2
ANGLE: XX.X DISABLED UP XXX% OFF XX% XX.X DEGREES RAW: XXXX OPEN
MAF09910P
1001119511-P
Figure 6-10. Analyzer Flow Chart - Sheet 3 of 5 (Software VersionP 7.29)
3121619
FROM TO
DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS: 2 DIAGNOSTICS:
DIAGNOSTICS:
TRANSPORT DATA ENVELOPE BOOM SWITCHES BOOM SENSORS MOMENT PLATFORM LOAD CAN STATISTICS
SYSTEM
3121619
TRANSPORT MODE: 2 MAIN BOOM 2 JIB LOCK PIN 2 MAIN CYL ANGLE 1 2 1 ACTUAL MOMENT 2 PLATFORM LOAD 2
JIB SWING 1 RAW
OUT OF TRANSPORT LENGTH: XXX.X" SWITCH NO: OPEN ANGLE:XX.X COUNT:XXXX XXXXXXXX LB*IN STATE: OK
MAIN LIFT 2 MAIN BOOM 2 JIB LOCK PIN 2 MAIN CYL ANGLE 2 2 1 OVER MOMENT 2 PLATFORM LOAD 2
JIB SWING 2 RAW
STATUS: ELEVATED ANGLE1: XX.X DEG SWITCH NC:CLOSED ANGLE:XX.X COUNT:XXXX XXXXXXXX LB*IN ACTUAL: XXXLBS
MAIN TELESCOPE 2 MAIN BOOM 2 JIB TRANSPORT 1 2 MAIN CYL ANGLE 1 2 2 UNDER MOMENT 2 PLATFORM LOAD 2
JIB SWING 1
STATUS:RETRACTED ANGLE2: XX.X DEG SWITCH NO: OPEN ANGLE A/D:XXXX ANGLE:XX.X DEG XXXXXXXX LB*IN GROSS: XXXXLBS
MAIN IN LIMIT 2 MAIN BOOM A/D 2 JIB TRANSPORT 1 2 MAIN CYL ANGLE 2 2 2 UNDER MOMENT CAL 2 PLATFORM LOAD 2
JIB SWING 2
SWITCH 1: OPEN LENGTH: XXXXX SWITCH NC CLOSED ANGLE A/D:XXXX ANGLE:XX.X DEG POINT: X OFFSET 1: XXXXLB
MAIN IN LIMIT 2 MAIN BOOM A/D 2 JIB TRANSPORT 2 2 TURNTABLE 1 RAW 1 1 YELLOW WITNESS 2 PLATFORM LOAD 2
JIB LIFT LENGTH
SWITCH 2: OPEN ANGLE1: XXX.X SWITCH NO: OPEN ANGLE: XX.X DEG RAW:XXX.X MM CAL: XXXXXXXX OFFSET 2: XXXXLB
PLATFORM STOWED: 2 MAIN BOOM A/D 2 JIB TRANSPORT 2 2 TURNTABLE 2 RAW 1 1 GREEN WITNESS 2 PLATFORM LOAD 2
JIB LIFT VEL.
NO ANGLE2: XXX.X SWITCH NC CLOSED ANGLE: XX.X DEG RAW:XXXX MM/S CAL: XXXXXXXX ACC'Y: XXXXLBS
AXLE STATUS: 2 BOOM CONTROL: 2 TURNTABLE 1 2 2 500# VER CAL: 2 PLATFORM LOAD: 2
JIB LIFT ANGLE
EXTENDED AUTOMATIC ANGLE: XX.X DEG ANGLE: XX.X DEG XXXXXXX UNRSTRICT XXXLBS
FRONT AXLE 2 BOOM CONTROL: 2 TURNTABLE 2 2 1 1000# VER CAL: 2 PLATFORM LOAD 2
PLT LVL LENGTH
SWITCH: CLOSED MODE SW: OPEN ANGLE: XX.X DEG RAW: XXX.X MM XXXXXXX RAW 1: XXXXLBS
REAR AXLE 2 JIB LEVEL 1 RAW 1 1 LOAD PIN RATIO 2 PLATFORM LOAD 2
PLT LVL VEL.
SWITCH: CLOSED COUNT:XXXX RAW:XXX MM/S VALUE: XX.XXX RAW 2: XXXXLBS
FRONT LEFT AXLE 2 JIB LEVEL 2 RAW 1 2 LOAD PIN ERROR 2

PLT LVL ANGLE
ANGLE: XX.X DEG COUNT:XXXX ANGLE:XX.X DEG FLAGS: 0X0000
FRONT RIGHT AXLE 2 JIB LEVEL 1 2 SKY WELDER 2

PRESS. REDUCTION 2
ANGLE: XX.X DEG ANGLE:XX.X DEG PRESS: XXX PSI INSTALLED: NO
REAR LEFT AXLE 2 AXLE INPUT SW: 2 JIB LEVEL 2 2 2 SKY CUTTER 2
LIFT PRESSURE
ANGLE: XX.X DEG OPEN ANGLE:XX.X DEG PRESS: XXX PSI INSTALLED: NO
REAR RIGHT AXLE 2 JIB LOCK PIN: 2 JIB LEVEL CNTL 2 SKY GLAZIER 2
CHASSIS PRESSURE 2
ANGLE: XX.X DEG SWITCH: OPEN ANGLE:XX.X DEG SWITCH: OPEN INSTALLED: NO
FRONT LEFT AXLE 1 JIB STATUS: 2 SKY BRIGHT 2

ANGLE A/D: ??? LOCKED INLINE INSTALLED: NO
FRONT RIGHT AXLE 1 JIB TRANSPORT: 2 PIPE RACKS 2

ANGLE A/D: ??? SWITCH 1: OPEN INSTALLED: NO
REAR LEFT AXLE 1 JIB TRANSPORT: 2 CAMERA MOUNT 2

ANGLE A/D: ??? SWITCH 2: OPEN INSTALLED: NO
REAR RIGHT AXLE 1 JIB TELESCOPE: 2

ANGLE A/D: ??? STATUS RETRACTED
MAF09920P
1001119511-P
6-31
FROM 2 2 2 2
DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS:
6-32
CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
PLATFORM LOAD
CAN1 STATISTICS 2 PLATFORM UP CAL: 2 DATALOG: 2 GROUND MODULE 2

RX/SEC: X X ON: XXH XXM SOFTWARE: PX.X
2 2 YELLOW WITNESS 2 2 2
CAN1 STATISTICS PLATFORM DOWN DATALOG: GROUND MODULE
TX/SEC: X CAL: X CAL: X ENGINE: Xh Xm CNST. DATA: PX.X
2 2 LENGTH SWITCH 2 2 2
CAN1 STATISTICS LEFT FORWARD DATALOG: GROUND MODULE
BUS OFF: X DRIVE CAL: XXXX CAL: XXXXX DRIVE: XH XM HARDWARE: REV X
2 2 MAIN CYL ANGLE 1 2 2 2

CAN1 STATISTICS RIGHT FORWARD DATALOG: GROUND MODULE
PASSIVE: XXXXX DRIVE CAL: XXXX LO CAL:XXXXX LIFT: XH XM S/N: XXXXXX

CAN1 STATISTICS LEFT REVERSE JIB LIFT ANGLE 2 DATALOG: PLATFORM MODULE
MSG ERROR: XXXX DRIVE CAL: XXXX HI CAL:XXXXX SWING: XH XM SOFTWARE: PX.X
HI CAL:XXXX

CAN2 STATISTICS RIGHT REVERSE PLT LEVEL ANGLE 2 DATALOG: PLATFORM MODULE
RX/SEC: X DRIVE CAL: XXXX LO CAL:XXXXX TELE: XH XM HARDWARE: REV X
HI CAL:XXXX

CAN2 STATISTICS L FRONT STEER LSS EMPTY PLTFRM 2 DATALOG: PLATFORM MODULE
TX/SEC: X CAL: XXXXX HI CAL:XXXXX MAX TEMP: XXC S/N: XXXXXX
CAL (LBS): XXXXX
2 2 TURNTABLE ANGLE1 2 2
CAN2 STATISTICS R FRONT STEER FRONT LEFT AXLE 1 DATALOG: CHASSIS MODULE
BUS OFF: X CAL: XXXXX CAL:XXXXX MIN TEMP: XXC SOFTWARE: PX.X
RET CAL: XXX
2 2 TURNTABLE ANGLE2 2 2
CAN2 STATISTICS L REAR STEER FRONT RIGHT AXLE 1 DATALOG: B.L.A MODULE
PASSIVE: XXXXX CAL: XXXXX CAL:XXXXX MAX VOLTS: XX.XV SOFTWARE: PX.X
RET CAL: XXX
2 2 JIB LVL UP CRCK 2 2

CAN2 STATISTICS R REAR STEER REAR LEFT AXLE 1 DATALOG: JCM MODULE
MSG ERROR: XXXX CAL: XXXXX CAL:XXXX RENTAL: XH XM SOFTWARE: PX.X
RET CAL: XXX
2 JIB LVL DN CRCK 2 1

MAIN LIFT UP REAR RIGHT AXLE 1 DATALOG: JCM MODULE
CAL: XXXXX CAL:XXXX ERASE RENTAL? HARDWARE: REV X
RET CAL: XXX
2 JIB LVL ANGLE 1 2 2

MAIN LIFT DOWN FRONT LEFT AXLE 1 TCU MODULE
CAL: XXXX LO CAL:XXXX SOFTWARE:X.XXP
EXT CAL: XXX

MAIN LIFT ENABLE FRONT RIGHT AXLE 1 TCU MODULE
CAL: XXXX HI CAL:XXXX HARDWARE REV: X
EXT CAL: XXX

MAIN TELESCOPE REAR LEFT AXLE 1 TCU MODULE:
IN CAL: XXXXX LO CAL:XXXX S/N: XXXXXX
EXT CAL: XXX

MAIN TELESCOPE REAR RIGHT AXLE 1 GATEWAY MODULE
OUT CAL: XXXXX HI CAL:XXXX SOFTWARE: XXX
EXT CAL: XXX
2 JIB SWING ANGLE1 2 2

MAIN ANGLE 1 LO GATEWAY MODULE
CAL: X LO CAL:XXXX HARDWARE REV:XXX

MAIN ANGLE 1 HI LSS MODULE
CAL: X HI CAL:XXXX SOFTWARE: PX.XX

MAIN ANGLE 2 LO LSS MODULE
CAL: X LO CAL:XXXX HARDWARE REV: X

MAIN ANGLE 2 HI VERSIONS:
CAL: X HI CAL:XXXX ANALYZER V6.5
LENGTH RETRACTED 2 CRIBBING MODULE 2

CAL: XXXXX SOFTWARE: PX.XX
LENGTH EXTENDED 2 CRIBBING MODULE 2

CAL: XXXXX HARDWARE: REV X
1001119511-P
MAF09930P
3121619
3121619 6-33
J8
J1
J7
J12
J2
J3 J4
1001119509-T
MAF07260T
Figure 6-13. Ground Control Module
6-34 3121619
Connector Pin Function Type Connector Pin Function Type

1 THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT 1 MAIN LIFT PILOT DIGITAL OUTPUT
2 SPARE (LP NOT USED) DIGITAL OUTPUT 2 HORN DIGITAL OUTPUT
3 TOWER BOOM LIFT POWER DIGITAL OUTPUT 3 PLATFORM CONTROL VALVE DIGITAL OUTPUT
4 GROUND GROUND INPUT 4 UPPER TELESCOPE IN DIGITAL OUTPUT
5 GROUND GROUND INPUT 5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT 6 GROUND GROUND INPUT
7 SPARE (LP NOT USED) DIGITAL OUTPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT
8 GROUND GROUND INPUT 8 TOWER TELESCOPE POWER DIGITAL OUTPUT
9 GROUND GROUND INPUT 9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT
10 IGNITION ON RELAY DIGITAL OUTPUT 10 LIFT PILOT DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT 11 UPPER LIFT UP DIGITAL OUTPUT
12 GLOW PLUG (DIESEL ONLY OPTION) DIGITAL OUTPUT 12 LIFT DOWN AUXILIARY DIGITAL OUTPUT
13 AUXILIARY POWER DIGITAL OUTPUT 13 MAIN DUMP DIGITAL OUTPUT
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT 14 GROUND GROUND INPUT
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT NOT CONNECTEDRS232 BACKUP
15 DIGITAL OUTPUT
FLYWHEEL SPEED PICKUP COMM. ENABLE
16 FREQUENCY INPUT 16 UPPER TELESCOPE OUT DIGITAL OUTPUT
(DIESEL ONLY)
17 GROUND GROUND INPUT J2 17 GROUND GROUND INPUT
J1 18 SPARE PIN GROUND INPUT
18 SPARE GROUND GROUND INPUT (Gray)
(Natural) 19 SPARE GROUND GROUND INPUT 19 LIFT FLOW CONTROL DIGITAL OUTPUT
20 TWO SPEED DIGITAL OUTPUT 20 SPARE OUTPUT DIGITAL OUTPUT
21 MAIN LIFT PILOT PRESSURE SWITCH DIGITAL INPUT MAIN BOOM ANGLE SENSOR #2
21 DIGITAL OUTPUT
22 GENERATOR/WELDER (OPTION) DIGITAL OUTPUT POWER
23 PARKING BRAKE DIGITAL OUTPUT 22 UPPER LIFT DOWN DIGITAL OUTPUT
24 CONSTANT BATTERY N/C N/C 23 MAIN BOOM LIFT ENABLE DIGITAL OUTPUT
25 RS-485 HI SERIAL I/O 24 TOWER CYLINDER TYPE DIGITAL INPUT
26 RS-485 LO SERIAL I/O 25 FUEL SENSOR ANALOG INPUT
27 GROUND GROUND INPUT 26 HEAD/TAIL LIGHT DIGITAL OUTPUT
28 ANALYZER POWER VOLTAGE OUTPUT 27 ALARM DIGITAL OUTPUT
29 ANALYZER RS-232 Rx SERIAL INPUT 28 SPARE PIN GROUND INPUT
30 ANALYZER RS-232 Tx SERIAL OUTPUT 29 GROUND GROUND INPUT
31 ANALYZER GROUND GROUND INPUT 30 GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT 31 PVG ENABLE DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT 32 TOWER BOOM TELESCOPE PILOT DIGITAL OUTPUT
34 SPARE DIGITAL INPUT 33 TOWER BOOM LIFT ENABLE DIGITAL OUTPUT
HYDRAULIC OIL TEMPERATURE 34 SWING LEFT DIGITAL OUTPUT
35 DIGITAL INPUT 35 SWING RIGHT DIGITAL OUTPUT
SWITCH
Connector Pin Function Type
1 FREQUENCY INPUT 2 FREQUENCY INPUT
1 GROUND FROM BATTERY GROUND OUTPUT 2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
2 GROUND EMS VBAT INPUT 3 CAN 2 H SERIAL I/O
J8
3 GROUND TO PLATFORM GROUND INPUT J12 4 CAN 2 L SERIAL I/O
(Black)
(Black) 5 CAN 2 SHIELD GROUND INPUT
4 GROUND EMS OUT TO PLATFORM VBAT OUTPUT 6 CAN 2 TERMINATOR TERM I/O
7 CAN 2 TERMINATOR TERM I/O
8 SPARE LS DIGITAL INPUT DIGITAL INPUT
3121619 6-35

1 SPARE VAVLE RETURN 1 GROUND INPUT 1 PLATFORM EMS DIGITAL INPUT
2 SPARE VAVLE RETURN 2 GROUND INPUT 2 PLATFORM MODE DIGITAL INPUT
3 GROUND GROUND INPUT 3 GROUND MODE DIGITAL INPUT
4 SPARE VAVLE RETURN 4 GROUND INPUT 4 TOWER CYLINDER PRESSURE ANALOG INPUT
5 SPARE VAVLE RETURN 5 GROUND INPUT 5 REFERENCE VOLTAGE VOLTAGE OUTPUT
6 SPARE VAVLE RETURN 6 GROUND INPUT 6 CAN TERMINATION TERM I/O
7 VBAT VBAT OUTPUT 7 SPARE ANALOG INPUT
J3 SPARE HS DIGITAL IN (FREQ. 8 SPARE ANALOG INPUT 2 ANALOG INPUT
8 DIGITAL INPUT 9 GROUND GROUND INPUT
(Black) CAPABLE)
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT 10 GROUND GROUND INPUT
SPARE HS SWITCH INPUT (MODEL 11 BOOM RETRACTED CLOSED DIGITAL INPUT
10 DIGITAL INPUT 12 BROKEN CABLE SWITCH DIGITAL IPUT
INPUT FOR 1100S)
11 SPARE LS DIGITAL INPUT DIGITAL INPUT 13 CAN HI SERIAL I/O
12 ANALOG REF. VOLTAGE VOLTAGE OUTPUT 14 GROUND MODE OUT TO PLATFORM DIGITAL INPUT
13 SPARE ANALOG INPUT 8 ANALOG INPUT 15 FOOTSWITCH ENGAGE DIGITAL INPUT
14 SPARE VALVE RETURN 3 GROUND INPUT 16 REFERENCE VOLTAGE VOLTAGE OUTPUT
17 CAN TERMINATION TERM I/O
Connector Pin Function Type 18 CAN SHEILD GROUND INPUT
1 AXLES SET LAMP DIGITAL OUTPUT J7 19 SPARE PIN GROUND INPUT
2 500# CAPACITY LAMP DIGITAL OUTPUT (Black) 20 SPARE ANALOG INPUT 1 ANALOG INPUT
3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT 21 PUSH TO TEST DIGITAL INPUT
4 START SWITCH DIGITAL INPUT 22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT
5 BASKET LEVEL DOWN DIGITAL INPUT 23 GROUND CONTROL ENABLE DIGITAL INPUT
6 BASKET LEVEL DOWN DIGITAL INPUT 24 CAN LO SERIAL I/O
7 UPPER TELESCOPE IN DIGITAL INPUT 25 GROUND GROUND INPUT
8 JIB DOWN DIGITAL INPUT 26 REFERENCE VOLTAGE VOLTAGE OUTPUT
9 JIB LEFT DIGITAL INPUT 27 REFERENCE VOLTAGE VOLTAGE OUTPUT
10 TOWER UP DIGITAL INPUT GROUND (RESERVED FOR CRIBBING
MAIN TOWER TRANSPORT ANGLE 28 GROUND INPUT
11 DIGITAL INPUT OPTION)
OPEN 29 VBAT VBAT OUTPUT
12 HOUR METER DIGITAL OUTPUT 30 VBAT VBAT OUTPUT
13 BCS CALIBRATED LAMP DIGITAL OUTPUT 31 VBAT VBAT OUTPUT
14 OVERLOAD LAMP DIGITAL OUTPUT 32 VBAT VBAT OUTPUT
15 SPARE DIGITAL OUTPUT VBAT (RESERVED FOR CRIBBING
16 AUXILIARY POWER DIGITAL INPUT 33 VBAT OUTPUT
OPTION)
17 BASKET LEVEL UP DIGITAL INPUT 34 CLEARSKY POWER (VBAT) VBAT OUTPUT
J4 18 BASKET ROTATE RIGHT DIGITAL INPUT 35 BOOM RETRACT OPEN DIGITAL INPUT
(Blue) 19 JIB UP DIGITAL INPUT
20 JIB RIGHT DIGITAL INPUT
21 TOWER DOWN DIGITAL INPUT
MAIN BOOM TRANSPORT ANGLE
22 DIGITAL INPUT
CLOSED
23 UPPER LIFT UP DIGITAL INPUT
24 VBAT VBAT OUTPUT
25 VBAT VBAT OUTPUT
26 NO CHARGE LAMP DIGITAL OUTPUT
27 1000# CAPACITY LAMP DIGITAL OUTPUT
ENGINE HIGH TEMPERATURE
28 DIGITAL OUTPUT
LENGTH’
29 ENGINE LOW OIL PRESSURE LAMP DIGITAL OUTPUT
30 UPPER TELESCOPE OUT DIGITAL INPUT
31 GROUND GROUND INPUT
32 SPARE PIN GROUND INPUT
33 UPPER LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT
6-36 3121619
3121619 6-37
J5
J2
J8
J6
J7
J1
1600343-R
MAF07630R
Figure 6-14. Platform Control Module
6-38 3121619
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 TOWER LIFT UP HS DIGITAL INPUT 1 SPARE PIN HS DIGITAL INPUT
2 TOWER LIFT DOWN HS DIGITAL INPUT 2 SPARE PIN HS DIGITAL INPUT
3 TOWER TELESCOPE IN HS DIGITAL INPUT 3 BATTERY VOLTAGE BATTERY VOLTAGE
4 TOWER TELESCOPE OUT HS DIGITAL INPUT DRIVE ORIENTATION SYSTEM
5 MAIN TELESCOPE IN HS DIGITAL INPUT 4 HS DIGITAL INPUT
OVERRIDE SWITCH
6 MAIN TELESCOPE OUT HS DIGITAL INPUT 5 PLATFORM STOWED HS DIGITAL INPUT
7 PLATFORM ROTATE RIGHT HS DIGITAL INPUT 6 CHASSIS TILTED INDICATOR LAMP OUTPUT
8 PLATFORM ROTATE LEFT HS DIGITAL INPUT 7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
9 PLATFORM LEVEL UP HS DIGITAL INPUT 8 VEHICLE SYSTEM DISTRESS INDICATOR LAMP OUTPUT
10 PLATFORM LEVEL DOWN HS DIGITAL INPUT 9 CREEP SPEED INDICATOR LAMP OUTPUT
11 JIB UP HS DIGITAL INPUT 10 BROKEN CABLE INDICATOR LAMP OUTPUT
12 JIB DOWN HS DIGITAL INPUT 11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
SPEED PUMP POTENTIOMETER 12 500 LB CAPACITY INDICATOR LAMP OUTPUT
13 GROUND
GROUND 13 1000 LB CAPACITY INDICATOR LAMP OUTPUT
14 ENGINE START HS DIGITAL INPUT DRIVE ORIENTATION SYSTEM
15 AUXILIARY POWER HS DIGITAL INPUT 14 LAMP OUTPUT
INDICATOR
16 CRAB STEER SELECT HS DIGITAL INPUT 15 GENERATOR ON INDICATOR LAMP OUTPUT
17 COORDINATED STEER SELECT HS DIGITAL INPUT J2 16 SOFT TOUCH TRIGGERED INDICATOR LAMP OUTPUT
J1 18 SWITCH POWER BATTERY VOLTAGE 17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
19 JIB 1000LB ENABLE HS DIGITAL INPUT (BLUE)
(NATURAL) 18 LAMP RETURN GROUND
20 EIM PLATFORM OVERLOAD HS DIGITAL INPUT 19 SPARE PIN LAMP OUTPUT
21 500/1000 LB. CAPACITY SELECT HS DIGITAL INPUT 20 UPRIGHT TILTED INDICATOR LAMP OUTPUT
DRIVE ORIENTATION SYSTEM FEATURE 21 LOW FUEL INDICATOR LAMP OUTPUT
22 HS DIGITAL INPUT
ENABLE 22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
23 SPARE PIN HS DIGITAL INPUT 23 3/4 FUEL LEVEL INDICATOR LAMP OUTPUT
24 SPARE PIN HS DIGITAL INPUT 24 1/2 FUEL LEVEL INDICATOR LAMP OUTPUT
25 LEVEL SENSOR 1 SIGNAL HS DIGITAL INPUT 25 FUEL LEVEL INDICATORS RETURN GROUND
26 LEVEL SENSOR 2 SIGNAL HS DIGITAL INPUT 26 ANALYZER POWER ANALYZER POWER
27 TWO SPEED VALVE (HIGH ENGINE) HS DIGITAL INPUT 27 ANALYZER GROUND ANALYZER GROUND
28 TORQUE MODE HS DIGITAL INPUT 28 ANALYZER RX ANALYZER RX
29 SOFT TOUCH OVERRIDE HS DIGITAL INPUT 29 ANALYZER TX ANALYZER TX
30 HEAD/TAIL LIGHT HS DIGITAL INPUT 30 SPARE PIN LAMP OUTPUT
31 HORN HS DIGITAL INPUT 31 SPARE PIN DIGITAL OUTPUT
32 CREEP MODE HS DIGITAL INPUT 32 BATTERY VOLTAGE BATTERY VOLTAGE
33 DUAL-FUEL SELECT HS DIGITAL INPUT 33 BATTERY VOLTAGE BATTERY VOLTAGE
SPEED PUMP POTENTIOMETER +7 REFERENCE 34 SWITCH POWER BATTERY VOLTAGE
34 35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT
REFERENCE VOLTAGE VOLTAGE
35 SPEED PUMP POTENTIOMETER ANALOG INPUT CONNECTOR PIN ASSIGNMENT FUNCTION
CONNECTOR PIN ASSIGNMENT FUNCTION LIFT / SWING JOYSTICK SUPPLY
1 SUPPLY VOLTAGE
DRIVE / STEER JOYSTICK SUPPLY VOLTAGE
1 SUPPLY VOLTAGE 2 LIFT CENTER TAP ANALOG INPUT
VOLTAGE
2 DRIVE CENTER TAP ANALOG INPUT J5 3 LIFT SIGNAL ANALOG INPUT
3 DRIVE SIGNAL ANALOG INPUT 4 SWING SIGNAL ANALOG INPUT
J6 (NATURAL)
4 STEER SIGNAL ANALOG INPUT 5 SWING CENTER TAP ANALOG INPUT
(BLACK) 6 NOT CONNECTED ANALOG INPUT
5 STEER LEFT ANALOG INPUT
6 STEER RIGHT ANALOG INPUT 7 LIFT / SWING JOYSTICK RETURN GRPOUND
7 DRIVE / STEER JOYSTICK RETURN GROUND 8 SPARE PIN BLANK
8 SPARE PIN BLANK
CONNECTOR PIN ASSIGNMENT FUNCTION
1 MODULE GROUND GROUND
J8
2 MODULE POWER BATTERY VOLTAGE
3121619 6-39
CONNECTOR PIN ASSIGNMENT FUNCTION

1 GROUND MODE GROUND MODE
2 PLATFORM EMS PLATFORM EMS
3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
FOOTSWITCH (FUNCTION ENABLE
4 BATTERY VOLTAGE
SWITCH) POWER
5 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
6 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT
7 SOFT TOUCH LIMIT SWITCH POWER BATTERY VOLTAGE
8 FOOTSWITCH SIGNAL DIGITAL INPUT
9 GENERATOR ON SIGNAL DIGITAL INPUT
+7 REFERENCE
10 +7 REFERENCE VOLTAGE
VOLTAGE
+5V REFERENCE
11 SPARE PIN
VOLTAGE
+5V REFERENCE
12 SPARE PIN
VOLTAGE
13 SPARE PIN ANALOG INPUT
14 GROUND RETURN GROUND
J7 15 PLATFORM LEVEL UP HS DIGITAL OUTPUT
(BLACK) 16 PLATFORM LEVEL DOWN HS DIGITAL OUTPUT
17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
19 PLATFORM ALARM LAMP OUTPUT
20 ALARM RETURN GROUND
21 SPARE PIN GROUND
22 SPARE PIN GROUND
24 SPARE PIN DIGITAL OUTPUT
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 JIB RIGHT ME DIGITAL OUTPUT
28 JIB LEFT ME DIGITAL 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
6-40 3121619
3121619 6-41
J1 J2
J4
J3 J5
1001112758-I
MAF07890I
Figure 6-15. Chassis Control Module
6-42 3121619

1 POWER FEED THRU TO J2-1 POWER I/O 1 RIGHT FRONT STEER RIGHT DIGITAL OUTPUT
2 POWER FEED THRU TO J2-2 POWER I/O 2 RIGHT FRONT STEER LEFT DIGITAL OUTPUT
3 SIGNAL FEED THRU TO J2-4 DIGITAL I/O 3 LEFT FRONT STEER RIGHT DIGITAL OUTPUT
4 MASTER GROUND CONNECT POWER INPUT 4 LEFT FRONT STEER LEFT DIGITAL OUTPUT
5 MASTER IGNITION CONNECT POWER INPUT 5 RIGHT REAR STEER RIGHT DIGITAL OUTPUT
J1 6 CANBUS HIGH SERIAL I/O J5 6 RIGHT REAR STEER LEFT DIGITAL OUTPUT
(Gray) 7 CANBUS LOW SERIAL I/O (Brown) 7 LEFT REAR STEER RIGHT DIGITAL OUTPUT
8 CANBUS SHIELD SERIAL I/O 8 LEFT REAR STEER LEFT DIGITAL OUTPUT
9 CANBUS TERMINATOR SERIAL I/O 9 IGNITION POWER OUTPUT
10 CANBUS TERMINATOR SERIAL I/O 10 RS232 RECEIVE SERIAL INPUT
11 IGNITION POWER OUTPUT 11 RS232 TRANSMIT SERIAL OUTPUT
12 GROUND POWER OUTPUT 12 GROUND POWER OUTPUT
1 POWER FEED THRU TO J1-1 POWER I/O
3 GROUND POWER OUTPUT
4 FRONT AXLES LIMIT SWITCH DIGITAL INPUT
5 REAR AXLES LIMIT SWITCH DIGITAL INPUT
J2 6 DRIVE ORIENTATION SWITCH DIGITAL INPUT
(Black) 7 OSCILLATING AXLE PRES SW DIGITAL INPUT
8 TURNTABLE ANGLE SENSOR #1 DIGITAL INPUT
9 TURNTABLE ANGLE SENSOR #2 DIGITAL INPUT
10 SPARE ANALOG ANALOG INPUT
11 FRONT/REAR AXLE EXTEND DIGITAL OUTPUT
12 FRONT/REAR AXLE RETRACT DIGITAL OUTPUT
1 +5V ANALOG REFERENCE POWER OUTPUT
2 FRONT RIGHT STEER ANGLE ANALOG INPUT
5 FRONT LEFT STEER ANGLE ANALOG INPUT
J3 6 GROUND POWER OUTPUT
(Green) 7 +5V ANALOG REFERENCE POWER OUTPUT
8 REAR RIGHT STEER ANGLE ANALOG INPUT
11 REAR LEFT STEER ANGLE ANALOG INPUT
1 IGNITION POWER OUTPUT
3 CANBUS HIGH POWER I/O
J4 4 CANBUS LOW SERIAL I/O
(Gray) 5 CANBUS SHIELD SERIAL INPUT
6 BOOTSTRAP MODE POWER INPUT
7 IGNITION DIGITAL OUTPUT
3121619 6-43
J1 J2
J4
J3 J5
1001112757-I
MAF07870I
Figure 6-16. BLAM Control Module (Prior to SN 0300248234)
6-44 3121619

1 POWER FEED THRU TO J2-1 POWER I/O 1 LEFT DRIVE PUMP FORWARD DIGITAL OUTPUT
3 SIGNAL FEED THRU TO J2-4 DIGITAL INPUT 3 OSCILLATING AXLES DIGITAL OUTPUT
4 MASTER GROUND CONNECT POWER INPUT 4 SPARE OUTPUT - D005 DIGITAL OUTPUT
5 MASTER IGNITION CONNECT POWER INPUT 5 SPARE OUTPUT - D006 DIGITAL OUTPUT
J1 6 CANBUS HIGH SERIAL I/O J5 6 SPARE OUTPUT - D007 DIGITAL OUTPUT
(Gray) 7 CANBUS LOW SERIAL I/O (Brown) 7 SPARE OUTPUT - D008 DIGITAL OUTPUT
8 CANBUS SHIELD SERIAL I/O 8 SPARE OUTPUT - D009 DIGITAL OUTPUT
9 CANBUS TERMINATOR SERIAL I/O 9 IGNITION POWER OUTPUT
4 SPARE INPUT DIGITAL INPUT
J2 6 SPARE INPUT DIGITAL INPUT
(Black) 7 SPARE INPUT DIGITAL INPUT
8 MAIN BOOM ANG 1 (GRAVITY) DIGITAL INPUT
11 RIGHT DRIVE PUMP FORWARD DIGITAL OUTPUT
12 RIGHT DRIVE PUMP REVERSE DIGITAL OUTPUT
2 REF VOLTAGE FROM J3-1 ANALOG INPUT
5 MAIN CYL ANGLE #1(ABSOLUTE) ANALOG INPUT
8 BOOM LENGTH SENSOR ANALOG INPUT
3 CANBUS HIGH SERIAL I/O
(Gray) 5 CANBUS SHIELD POWER INPUT
6 BOOTSTRAP MODE DIGITAL INPUT
3121619 6-45
J1 J2
J4
J3 J5
1001227960-C
MAF07920C
Figure 6-17. BLAM Control Module (SN 0300248235 to Present)
6-46 3121619

3 SIGNAL FEED THRU TO J2-4 DIGITAL INPUT 3 OSCILLATING AXLES DIGITAL OUTPUT
4 MASTER GROUND CONNECT POWER INPUT 4 SPARE OUTPUT - D005 DIGITAL OUTPUT
5 MASTER IGNITION CONNECT POWER INPUT 5 SPARE OUTPUT - D006 DIGITAL OUTPUT
J1 6 CANBUS HIGH SERIAL I/O J5 6 SPARE OUTPUT - D007 DIGITAL OUTPUT
(Gray) 7 CANBUS LOW SERIAL I/O (Brown) 7 SPARE OUTPUT - D008 DIGITAL OUTPUT
8 CANBUS SHIELD SERIAL I/O 8 SPARE OUTPUT - D009 DIGITAL OUTPUT
9 CANBUS TERMINATOR SERIAL I/O 9 IGNITION DIGITAL OUTPUT
J2 6 SPARE INPUT DIGITAL INPUT
(Black) 7 SPARE INPUT DIGITAL INPUT
11 RIGHT DRIVE PUMP FORWARD DIGITAL OUTPUT
12 RIGHT DRIVE PUMP REVERSE DIGITAL OUTPUT
2 REF VOLTAGE FROM J3-1 ANALOG INPUT
8 BOOM LENGTH SENSOR ANALOG INPUT
3 CANBUS HIGH SERIAL I/O
(Gray) 5 CANBUS SHIELD POWER INPUT
6 BOOTSTRAP MODE DIGITAL INPUT
3121619 6-47
J8
J1
J7
J12
J2
J3 J4
1001150162-G
MAF07650G
Figure 6-18. Ultra Boom Control Module
6-48 3121619

1 SPARE DIGITAL OUTPUT 1 TWO SPEED DIGITAL OUTPUT
2 SPARE DIGITAL OUTPUT 2 SPARE DIGITAL OUTPUT
4 SPARE GROUND INPUT 4 FRONT AXLE SWING EXTEND DIGITAL OUTPUT
5 SPARE GROUND INPUT 5 REAR AXLE SWING EXTEND DIGITAL OUTPUT
6 SPARE DIGITAL OUTPUT 6 GROUND GROUND INPUT
7 SPARE DIGITAL OUTPUT 7 REAR AXLE SWING RETRACT DIGITAL OUTPUT
8 GROUND GROUND INPUT 8 RIGHT REAR STEER RIGHT DIGITAL OUTPUT
9 GROUND GROUND INPUT 9 LEFT REAR STEER RIGHT DIGITAL OUTPUT
11 SPARE DIGITAL OUTPUT 11 RIGHT FRONT STEER RIGHT DIGITAL OUTPUT
13 SPARE DIGITAL OUTPUT 13 BRAKE DIGITAL OUTPUT
14 LEFT FRONT AXLE SWING ANALOG INPUT 14 GROUND GROUND INPUT
15 RIGHT REAR AXLE SWING ANALOG INPUT 15 SPARE DIGITAL OUTPUT
16 TURNTABLE ANGLE #1 FREQUENCY INPUT 16 FRONT AXLE SWING RETRACT DIGITAL OUTPUT
J1 17 SPARE GROUND INPUT J2 17 GROUND GROUND INPUT
18 SPARE GROUND INPUT 18 GROUND GROUND INPUT
(Natural) 19 SPARE GROUND INPUT (Gray) 19 RIGHT REAR STEER LEFT DIGITAL OUTPUT
20 SPARE DIGITAL OUTPUT 20 LEFT REAR STEER LEFT DIGITAL OUTPUT
21 SPARE DIGITAL INPUT 21 SPARE DIGITAL OUTPUT
22 SPARE DIGITAL OUTPUT 22 RIGHT FRONT STEER LEFT DIGITAL OUTPUT
24 SPARE N/C N/C 24 SPARE DIGITAL INPUT
25 SPARE SERIAL I/O 25 FRONT RIGHT AXLE SWING ANALOG INPUT
26 SPARE SERIAL I/O 26 SPARE DIGITAL OUTPUT
27 SPARE GROUND INPUT 27 SPARE DIGITAL OUTPUT
28 ANALYZER POWER VOLTAGE OUTPUT 28 GROUND GROUND INPUT
29 ANALYZER RS-232 Rx SERIAL INPUT 29 SPARE GROUND INPUT
30 ANALYZER RS-232 Rx SERIAL OUTPUT 30 GROUND GROUND INPUT
31 ANALYZER GROUND GROUND INPUT 31 SPARE DIGITAL OUTPUT
33 SPARE GROUND INPUT 33 SPARE DIGITAL OUTPUT
34 SPARE DIGITAL INPUT 34 LEFT FRONT STEER LEFT DIGITAL OUTPUT
35 SPARE DIGITAL INPUT 35 LEFT FRONT STEER RIGHT DIGITAL OUTPUT
1 GROUND FROM BATTERY GROUND INPUT 1 FRONT AXLE SWING RETURN GROUND INPUT
J8 2 POWER FROM BATTERY POWER INPUT 2 REAR AXLE SWING RETURN GROUND INPUT
(Black) 3 SENSOR SHIELD GROUND OUTPUT 3 GROUND GROUND INPUT
4 SPARE POWER OUTPUT 4 SPARE GROUND INPUT
5 SPARE GROUND INPUT
Connector Pin Function Type 6 SPARE GROUND INPUT
1 TURNTABLE ANGLE #2 FREQUENCY INPUT J3 7 SPARE VBAT OUTPUT
2 GROUND FREQUENCY INPUT 8 SPARE DIGITAL INPUT
(Black)
3 SPARE SERIAL I/O 9 SPARE DIGITAL INPUT
J12 4 SPARE SERIAL I/O 10 SPARE DIGITAL INPUT
(Black) 5 SPARE GROUND INPUT 11 SPARE DIGITAL INPUT
6 SPARE TERM I/O 12 ANALOG REF. VOLTAGE VOLTAGE OUTPUT
7 SPARE TERM I/O 13 LEFT REAR AXLE SWING ANALOG INPUT
8 SPARE DIGITAL INPUT 14 SPARE GROUND INPUT
3121619 6-49

1 SPARE DIGITAL OUTPUT 1 SPARE DIGITAL INPUT
4 SPARE DIGITAL INPUT 4 RIGHT FRONT STEER ANALOG INPUT
5 SPARE DIGITAL INPUT 5 REFERENCE VOLTAGE VOLTAGE OUTPUT
6 SPARE DIGITAL INPUT 6 CAN TERMINATION TERM I/O
7 SPARE DIGITAL INPUT 7 LEFT FRONT STEER ANALOG INPUT
8 SPARE DIGITAL INPUT 8 LEFT REAR STEER ANALOG INPUT
9 SPARE DIGITAL INPUT 9 GROUND GROUND INPUT
10 SPARE DIGITAL INPUT 10 GROUND GROUND INPUT
11 SPARE DIGITAL INPUT 11 DRIVE ORIENTATION SWITCH DIGITAL INPUT
12 SPARE DIGITAL INPUT 12 SPARE INPUT
13 SPARE DIGITAL OUTPUT 13 CAN HI SERIAL I/O
15 SPARE DIGITAL OUTPUT 15 BRAKE RELEASE FROM UGM DIGITAL INPUT
16 SPARE DIGITAL OUTPUT 16 REFERENCE VOLTAGE VOLTAGE OUTPUT
J4 17 SPARE DIGITAL INPUT J7 17 CAN TERMINATION TERM I/O
18 SPARE DIGITAL INPUT 18 CAN SHEILD GROUND INPUT
(Blue) 19 SPARE DIGITAL INPUT (Black) 19 SPARE GROUND INPUT
20 SPARE DIGITAL INPUT 20 RIGHT REAR STEER ANALOG INPUT
21 SPARE DIGITAL INPUT 21 SPARE DIGITAL INPUT
24 SPARE VBAT OUTPUT 24 CAN LO SERIAL I/O
25 SPARE VBAT OUTPUT 25 GROUND GROUND INPUT
28 SPARE DIGITAL OUTPUT 28 GROUND GROUND INPUT
29 SPARE DIGITAL OUTPUT 29 VBAT VBAT OUTPUT
30 SPARE DIGITAL INPUT 30 SPARE VBAT OUTPUT
31 SPARE GROUND INPUT 31 SPARE VBAT OUTPUT
32 SPARE GROUND INPUT 32 SPARE VBAT OUTPUT
6-50 3121619
3121619 6-51
J1 J2
J4
J3 J5
1001119262-C
MAF07910C
Figure 6-19. Jib Control Module
6-52 3121619

1 Power Feed Thru to J2-1 Power I/O 1 Jib Lift Up Digital Output
2 Power Feed Thru to J2-2 Power I/O 2 Jib Lift Down Digital Output
3 Signal Feed Thru to J2-4 Digital Input 3 Jib Swing Right Digital Output
4 Master Ground Connect Power Input 4 Jib Swing Left Digital Output
5 Master Ignition Connect Power Input 5 Jib Telescope In Digital Output
J1 6 CANbus High Serial I/O J5 6 Jib Telescope Out Digital Output
(Gray) 7 CANbus Low Serial I/O (Brown) 7 Spare Output Digital Output
8 CANbus Shield Serial I/O 8 Spare Output Digital Output
9 CANbus Terminator Serial I/O 9 Ignition Power Output
10 CANbus Terminator Serial I/O 10 RS232 Receive Serial Input
11 Ignition Power Output 11 RS232 Transmit Serial Output
12 Ground Power Output 12 Ground Power Output
1 Power Feed Thru to J1-1 Power I/O
2 Power Feed Thru to J1-2 Power I/O
3 Ground Power Output
4 Lock Pin NO Contact Digital Input
5 Lock Pin NC Contact Digital Input
J2 6 Jib Transport #1 NO Contact Digital Input
(Black) 7 Jib Transport #1 NC Contact Digital Input
8 Spare Input Digital Input
9 Spare Input Digital Input
10 Spare Analog Input Analog Input
11 Jib Level Up Digital Output
12 Jib Level Down Digital Output
1 +5V Analog Reference Power Output
2 Jib Level Angle #1 Analog Input
5 Jib level Angle #2 Analog Input
J3 6 Ground Power Output
(Green) 7 +5V Analog Reference Power Output
8 Jib Swing Angle #1 Analog Input
11 Jib Swing Angle #2 Analog Input
1 Ignition Power Output
3 CANbus High Serial I/O
J4 4 CANbus Low Serial I/O
(Gray) 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input
7 Ignition Power Output
3121619 6-53
PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-20. Analyzer Connecting Points
6-54 3121619
6.6 CONTROL SYSTEM BOOM SENSORS Sensor #3 - Main Boom Length Sensor (1)
The Boom Control System (BCS) requires the use of multiple
sensors to measure the position of the boom. The sensors
used to determine main boom and jib boom position are
shown in the following figures.
THE CONTROL SYSTEM MUST BE RECALIBRATED AFTER REPLACING OF ANY

SENSOR.
Sensor #1 - Load Pin (1)
The Main Lift Cylinder is attached to the Turntable with a load

This sensor is used to measure total stroke of the Main Boom.
cell pin. This pin is fixed to the Turntable so as to allow mea-
It is located in the rear of the Base Boom and consists of a wire
surement of the force exerted by the cylinder regardless of the
rope attached to a rotating drum.
cylinder orientation.
Sensor #2 - Main Boom Angle Sensors (2)

See (See Figure 6-21.)
These sensors measure Main Boom angle with respect to grav-
ity. They are located in the rear of the Section #1boom and
mounted such that they generate opposing signals with
respect to boom movement.
3121619 6-55
SENSOR ORIENTATION
LEFT SIDE VIEW
SENSOR ORIENTATION
RIGHT SIDE VIEW
SENSOR INSTALLATION ON LEFT

& RIGHT SIDES OF PLATE
(LEFT SIDE, SENSOR #2, SHOWN)
1001155440-L
MAF09570L
Figure 6-21. Main Boom Angle Sensors
6-56 3121619
ANGLE SENSOR #1 (RIGHT)

PIN # DESC SENSOR HARNESS
PIN #1 POWER RED RED
PIN #2 OUTPUT WHITE BLUE
PIN #3 GROUND BLACK BLACK
ANGLE SENSOR #2 (LEFT)

PIN # DESC SENSOR HARNESS
PIN #1 POWER RED ORANGE
PIN #2 OUTPUT WHITE YELLOW
PIN #3 GROUND BLACK BLACK
3121619 6-57
Sensor #4 - Main Boom Cylinder Angle Sensor (1)

This sensor's function is to measure Main Boom angle relative to the Turntable. A rotary type sensor is mounted to the Turntable and
attached to the Main Lift cylinder of the base boom. It is a dual output sensor in a single mechanical body with electrically opposing
signals.
ANGLE SENSOR
LINK
ADAPTER
BASE TERMINAL
BEI ANGLE
SENSOR ANGLE SENSOR
PIN
BOLT,
BOLT, THREADLOCKER
P/N-0100035
THREADLOCKER
P/N-0100011
Torque 12 Nm BOLT,
THREADLOCKER
P/N-0100035
ANGLE SENSOR
Torque 3.4 Nm
ANGLE SENSOR LINK
PIN WASHER RING
ADAPTER
BEI ANGLE
SENSOR
Figure 6-22. Main Boom Cylinder Angle (Protractor) Sensor
Sensor #5 - Main Boom Transport Length Switch (1)

This switch is used to indicate Main Boom retracted position
for transport. This is a mechanical limit switch.
6-58 3121619
TRANSPORT LIMIT SWITCH WIRING
13 14
21 22
BL ACK
WHITE
TOP OF SENSOR
R ED
LIMIT SWITCH
BLACK
+1°
RED 90° -10°
WHITE
SECTION E-E
LIMIT SWITCH ADJUSTMENT
LIMIT SWITCH COVER

RUBBER PAD, BOLT, WASHER,
ADHESIVE LIMIT SWITCH THREADLOCKER
P/N-0100081 P/N-0100011
Torque 25ft.lbs. (34 Nm)
TORQUE BOLT TO 55 NM
CABLE
BOLT,
ADHESIVE
P/N-0100035
Figure 6-23. Main Boom Transport Length Switch
3121619 6-59
Sensor #6 - Jib Level Angle Sensor (1) ing bracket. The LED on the sensor will light when power is
applied and the sensor is within range.
This sensor is used to measure Jib Level angle relative to the
20
Main Boom. A rotary type sensor is mounted between the
Main Boom Fly nose and the Jib Pivot weldment. It is a dual
output sensor in a single mechanical body with electrically
opposing signals.
SENSOR INSTALLATION
1. Attach the sensor to the mounting plate.
2. Attach the link to the sensor arm.
3. Install the sensor subassembly onto the boom.
4. Connect the sensor wiring.
Sensor #7 - Jib Lock Pin Proximity Sensor (1)
BOLT, WASHER, BOTTOM VIEW OF ROTATOR

THREADLOCKER
P/N-0100011
PROXMITY SENSOR
BRACKET
Figure 6-24. Jib Lock Pin Proximity Sensor
This sensor is used to indicate the Jib Lock Pin is fully engaged.
This is a proximity switch mounted to the Jib Pivot weldment.
LOCK PIN SENSOR ADJUSTMENT

Adjust the proximity sensor to 20 mm from the front face of
the proximity sensor to the front mounting face of the mount-
6-60 3121619
SPACER
NUT
BOLT SCREW, WASHER,

ANGLE THREADLOCKER
SENSOR P/N-0100035
SCREW,
THREADLOCKER
P/N-0100011
ANGLE
SENSOR
WASHER
INSTALL BETWEEN
LINK AND ARM
DETAIL B BOLT, WASHER,

SCREW, NUT THREADLOCKER
TORQUE UNTIL SNUG P/N-0100011
5 NM MAX
SENSOR
MOUNT
SENSOR
LINK
SENSOR COVER
SHOWN IN PHANTOM
FOR CLARITY
Figure 6-25. Jib Level Angle Sensor
3121619 6-61
Sensor #8 - Jib Stow Angle Sensor (1)

This sensor is used to measure Jib swing angle. This is a rotary
sensor mounted to the underside of the Jib Pivot weldment. It
is a dual output sensor in a single mechanical body with elec-
trically opposing signals.
Sensor #9 - Jib Lift Angle Sensor (1)

This sensor's function is to measure the Jib angle relative to
the Main Boom Pivot weldment. A linear position sensor is
located inside the Jib lift cylinder to measure cylinder stroke.
SCREW, WASHER,
THREADLOCKER
P/N-0100035
ANGLE
SENSOR
ADAPTER
SENSOR
BRACKET
BOLT, WASHER
THREADLOCKER
P/N-0100011
ANGLE Torque 34 Nm
SENSOR PIN
SCREW,
THREADLOCKER
P/N-0100035
SENSOR MOUNT
Figure 6-26. Jib Stow Angle Sensor
6-62 3121619
Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Angle Sensor (1)
Switches (2) This sensor is used to measure Platform angle relative to the
Jib. A linear position sensor is located inside the Platform Level
See (See Figure 6-27.) cylinder to measure cylinder stroke.
These switches are located on the Jib Base Boom and are used
to measure transport position and 1000# length limit. These
are proximity switches mounted such that they generate
opposing signals.
ADJUSTMENT
Adjust the Proximity Sensors so the front sensing face is flush
to 0.75 mm below the surface of the mounting face.
PROX SENSOR
BELOW MOUNT FACE
SENSOR
COVER
PROXIMITY SENSOR
SENSOR
MOUNT
BOLT, WASHER
THREADLOCKER
P/N-0100011
Figure 6-27. Jib Transport Length Sensors
3121619 6-63
Sensor #12 - Platform Level Angle Gravity Sensors Sensor #17 - Chassis Tilt Sensor (Externally
(2) mounted) (1)
See (See Figure 6-28.) This sensor is the primary tilt sensor and measures the tilted
angle of the turntable relative to gravity. It is mounted on a
These sensors are located on the Platform Support and are bracket on the left side of the turntable adjacent to the UGM
used to measure platform angle with respect to gravity. They and BLAM module. It is a dual axis output sensor in a single
are mounted such that they generate opposing signals. body.
Sensor #13 - Turntable Swing Angle (1) Sensor #18 - Tilt Sensor (1)
This sensor is used to determine turntable swing angle. It is This sensor is integral to the UGM. This sensor is the secondary
used for turntable swing control when the boom is in trans- tilt sensor and measures the tilted angle of the chassis relative
port position (Axles Retracted). It is a dual output sensor in a to gravity. It is used to check plausibility of the primary chassis
single mechanical body with electrically opposing signals tilt sensor reading (See Sensor #17).
mounted integral to the electrical collector ring.
Sensor #19 - Warm up Switch (1)
Sensor #14 - Steer Angle Sensor (4) This switch is located on Main Control valve. It monitors the
temperature of the main control valve.
These sensors are used to measure wheel steer angles. These
rotary sensors are mounted on top of each king pin. Sensor #20 - Main Valve Pressure Transducer (1)
Sensor #15 - Axle extend/retract Sensor (4) This pressure transducer is located on the main control valve.
It is used to monitor pressure of the lower pressure functions
These sensors are used to measure axle rotation between the of the machine (all control valve functions except Lift and Tele-
retracted and extended positions. Each sensor is mounted scope), to assure that they are within the regulated range.
between the frame and an axle.
Sensor #16 - Brake-Two Speed Pressure Sensor (1)

This pressure switch monitors that there is no pressure present
when the associated valves are not activated.
PUSH NUTS
BOLT, WASHER,
PUSH NUT,
MOUNTING
THREADLOCKER
P/N-0100011 SENSOR BOLT
Torque 34 Nm MOUNT
BOLT,
THREADLOCKER
P/N-0100035
SENSOR COVER
SENSOR
COVER SENSOR
MOUNT
SENSOR INSTALLATION ON LEFT

& RIGHT SIDES OF ROTATOR
(LEFT SIDE, SENSOR #2 SHOWN)
PIN # D ESC SEN SOR H AR N ESS

P IN #1 P OWE R RE D RE D
P IN #2 P WM OUT WHITE B LUE
P IN #3 GROUND B LA CK B LA CK
ANGLE SENSOR AN GL E SEN SOR # 2 (L EFT)

PIN # D ESC SEN SOR H AR N ESS
P IN #1 P OWE R RE D ORA NGE
P IN #2 P WM OUT WHITE Y E LLOW
P IN #3 GROUND B LA CK B LA CK
Figure 6-28. Platform Level Sensor
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Sensor #21 - Main Lift Cylinder Pressure Transducer 3. Plug the analyzer into the connector at the base of the
platform control box.
(1)
This pressure transducer is located on the port block of the
main boom lift cylinder. This is used for the diagnostics of the
lift cylinder.
6.7 SYSTEM TEST

The Control System Incorporates a built-in system test to
check the system components and functions. To use this func-
tion, use the following procedures.
Test from the Platform

1. Position the Platform/Ground select switch to the Plat-
form position.
4. Before proceeding, ensure that the switches on the plat-

form console are in the following positions:
a. Drive speed switch is in the Middle position. (Turtle
Icon)
b. 4WS switch is in the Middle position. (2WS mode)
c. Capacity select switch in the 1000 lb. (450 kg) mode.
d. Function speed potentiometer out of creep mode
switch.
e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Pull out the Emergency Stop switch at the Ground Con-

trol Station.
3121619 6-65
5. Pull out the Emergency Stop switch and Start the 7. 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.
8. Follow the flow path in Figure 6-29., System Test Flow
Chart - Platform Tests - Sheet 1 of 2 and Figure 6-30., Sys-
tem Test Flow Chart - Platform Tests - Sheet 2 of 2 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).
6. The analyzer screen should read:
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Figure 6-29. System Test Flow Chart - Platform Tests - Sheet 1 of 2
3121619 6-67
Figure 6-30. System Test Flow Chart - Platform Tests - Sheet 2 of 2
6-68 3121619
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.
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 6-31., 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).
3121619 6-69
Figure 6-31. System Test Flow Chart - Ground Station Tests
6-70 3121619
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.
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.
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Description
Analyzer Analyzer
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.
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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.
3121619 6-73
6.8 CALIBRATION PROCEDURES General notes:

During all controller lag times the controller should display
Axle Calibration “CALIBRATING…”
The axle angle sensors need to be calibrated to ensure that the After each operator “ENTER” input preceding the recording of
axle angle can be accurately calculated. The machine must be sensor values, the controller will wait 10 seconds for the boom
in transport position to perform an axle calibration. If the steer dynamics to settle down before readings are taken.
sensors have not been calibrated, they will be calibrated as
part of the axle calibration procedure. During the calibration if the ESC key is pressed after the cali-
bration procedure is started, the calibration will be aborted
Axle Calibration is available under AXLE SWING under the CAL- and “CAL FAILED” will be displayed on the bottom line of the
IBRATIONS menu using the analyzer. analyzer and the previous calibration values will be used for
the boom sensors.
When performing a calibration, the first prompt will be to
RETRACT AXLES. 1. With the analyzer, put the vehicle into Access Level 1
and enter the “BOOM SENSORS” calibration. The Con-
The analyzer will prompt to move to the next sequence once
troller will display “CAL. POSITION 1” on the top line and
the axle retract conditions are met and retract values are
“CHECK SYSTEM?” on the bottom line.
stored in the Control System.
2. After the operator presses the ENTER key, the controller
If the steer sensors have not been calibrated when an axle cali-
will verify:
bration is attempted, the system shall require the steer sensors
be calibrated. If this is the case, the analyzer prompt shall auto- • the angle sensors and length sensors are reporting valid
matically redirect to the steer sensor calibration section after data,
the axle retract position is calibrated (Refer to steer sensor cali-
bration). If the steer sensors have been calibrated, this step • the axles are completely extended,
shall be skipped. • the wheels are straight within 10°,
The analyzer will prompt to EXTEND AXLES. • the Boom Length Limit switch is in the retracted position,
The analyzer shall prompt to move after the extend conditions • the drive orientation switch is indicating the turntable is
are met and extend values are stored in the Control System. between the rear tires,
The axle calibration is complete at this point.
• the Jib aligned switch is on if equipped,
Boom Sensor Calibration • the chassis tilt sensor reads less than 1.5° out of level,
Initial conditions prior to initiating boom sensor calibration: • the machine is in Ground Mode and the steering, tilt sensor
calibrations have been successfully completed,
• Steering sensor, tilt sensor, and telescope crack point cali-
brations are complete • Jib Transport sensors are healthy,
• Axle calibration is complete • the Jib Level, Jib Swing, Main Cylinder Angle, Jib Lift, Plat-
form Level Cylinder Position and turntable sensors are
• Chassis tilt calibration is complete healthy,
• Ensure the axles are completely extended and axle set • the Jib is fully retracted and the Jib Pin is Locked,
lamp is ON
• if Model 1850 the axle calibration has been performed.
• Ensure the wheels are straight
• Ensure the platform is unloaded and boom is clean
• Ensure the jib is horizontal
• Ensure the jib swing is centered if Jib swing is configured
• Ensure the platform is level
• Ensure the platform is not rotated
• Ensure the turntable is centered between the rear tires
• Ensure the boom is fully retracted
• Ensure the machine indicates that it is on a level surface +/-
1.5°
• Ensure Ground Mode is selected
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3. If the initial conditions are not met, the controller will 6. The controller shall display “LIFT UP TO STOP”. After the
prompt the operator with analyzer messages “BLAM operator presses the ENTER key, the controller shall dis-
CAN LOST”, “AXLE VALVE FAULT”, OSC AXL SW FAULT”, play “CAL POSITION 3” and “SWING 180 DEG”. After the
“PARK BRAKE FAULT”, “ANGL SNSR1 FAULT”, “ANGL SNSR2 operator presses the ENTER key, the controller must see
FAULT”, “MOMENT PIN FAULT”, “LEN SNSR FAULT”, “CAL a change in the drive orientation switch or “CAL FAILED”
STEERING”, “CAL TILT SENSOR”, “CAL UPPER TELE”, and “DRIVE ORNT SW” shall be displayed. The boom
“EXTEND AXLES”, “LEVEL MACHINE”, “CENTER WHEELS”, angle sensors must also be within 10° of 40.6° (80.6° -
“TELE IN”, “ALIGN TURNTABLE”, “CENTER JIB SWING”, 40.0° = 40.6° equals rough angle sensor mounting off-
“SELECT GRND MODE”, “JIB TRANSPORT SENSOR FAULT”, set) or “CAL FAILED” and “ANGL SNSR# FAULT” will be
“JIB LEVEL SENOSR FAULT”, JIB SWING SENSOR FAULT”, displayed. The controller shall also check that the Main
“MAIN CYL ANGLE SENSOR FAULT”, “JIB LIFT SENSOR Cylinder Angle 1 sensor counts are between 15000 and
FAULT”, “PLATFORM LEVEL SENSOR FAULT”, “TURN TABLE 32767 and that sensor 2 is between 100 and 14000
SENSOR FAULT”, “JIB TELE IN”, “LOCK JIB PIN” and counts or “CAL FAILED” and “CYLN SNSR1 FAULT” or
“REMOVE DONGLE” to satisfy the initial conditions. The “CYLN SNSR2 FAULT” will be displayed.
controller will then prompt with “UNLOAD PLATFORM?”,
7. The controller at this point shall disable lift down. The
“JIB HORIZONTAL?”, “LEVEL PLATFORM?”, “CENTER PLAT- controller will record the following: moment value
FORM?” and “TELE IN TO STOP?”. based on load-pin output, both boom angle sensor raw
outputs, both main cylinder angle counts and the
4. Once the initial conditions are verified, the controller will
retracted length of the boom. The retracted length will
display “SKY WELDER NO”. If a sky welder is installed, the
be set at 539.7”. The raw length sensor A/D counts must
operator presses an ARROW key to switch to “SKY between 100 and 1311 counts or “CAL FAILED” and “LEN
WELDER YES. A similar set of menus will prompt the SNSR FAULT” shall be displayed.
operator to select sky cutter, sky glazier, sky bright, pipe
racks and camera mount. 8. The controller will display “CAL POSITION 4” on the first
line and “SWING 180 DEG”. After the operator presses
5. If the operator selects sky bright the controller will dis- the ENTER key, the controller must see a change in the
play “CAL FAILED” and “REMOVE SKYBRIGHT”. If more drive orientation switch or “CAL FAILED” and “DRIVE
than one accessory is selected except for the combina- ORNT SW” will be displayed. The controller will record
tion of sky welder/sky cutter the controller will display moment value based on load-pin output and both
“CAL FAILED” and “# OF ACCESSORIES”. If a valid acces- boom angle sensor raw outputs. If the change in right
sory option has been selected after the camera mount boom angle sensor readings is more than 1.0° from the
selection and the operator presses the ENTER key, the change in left boom angle sensor readings, “CAL
controller will display “CALIBRATE?”. After the operator FAILED” and “ANGL SNSR FAILED” will be displayed. If
presses the ENTER key, the controller will check that the this moment falls outside the expected calibration
Main Cylinder Angle 1 sensor counts are between 100 moment range of 1.288E+06 to 1.932E+06, “CAL FAILED”
and 14000 counts and that Main Cylinder Angle 2 sensor and “MOMENT PIN FAULT” will be displayed.
counts are between 15000 and 32767 counts. If they are
not in the given ranges, the controller shall display “CAL 9. If no failures have occurred, The controller will enable
FAILED” and “CYLN SNSR1 FAULT” or “CYLN SNSR2 telescope out, disable swing, and display “CAL POSITION
FAULT”. If the sensors are in range, the controller will dis- 5” on the first line and “TELE OUT TO STOP”.
able Envelope and Moment control, Telescope out, Jib
10. After the operator presses the ENTER key, the controller
Lift/Swing, Jib Telescope and Basket Level/Rotate func-
will establish this length as 1911.7”. The raw length sen-
tions and display “CAL POSITION 2” on the first line. sor A/D counts must between 29220 and 31220 counts
or “CAL FAILED” and “LEN SNSR FAULT” will be displayed.
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11. The controller will disable telescope out, enable tele- 17. The controller shall display “CAL POSITION 9” on the first
scope in and display “CAL POSITION 6” on the first line line and “JIB OUT TO STOP” on the second. When the
and “TELE IN TO STOP”. The controller will monitor the operator reaches the stopping point with the Jib and
length sensor reading at which the length limit switch is presses enter, the controller will record the moment for
tripped. The switch should change state at 553 +3.5”/- the 500# forward calibration. If this moment falls outside
5.5”. If the switch changes state in the wrong length the expected calibration moment range of 8.11E+06 to
range for the selected model, “CAL FAILED” and “CHECK 10.81E+06 lb-in “CAL FAILED” and “MOMENT PIN FAULT”
MODEL” will be displayed. If the switch does not change shall be displayed.
state at all, the calibration should be aborted and “CAL
18. The controller shall then display “CAL POSITION 10” on
FAILED” and “LENGTH SW FAILED” will be displayed.
the first line and “JIB IN TO STOP” on the second. When
The length sensor reading at the precise switch trip
the operator reaches the retracted position for the Jib,
point will be recorded for operational length calibration
the menu will automatically advance.
checks each time the boom passes through that point.
19. The controller will enable telescope in and display “CAL
12. If no failures have occurred, the controller will enable lift POSITION 10” on the first line and “TELE IN TO GREEN”.
functions, disable telescope out functions and display When Telescope In is commanded, boom length will be
“CAL POSITION 7” on the first line and “LIFT DN TO controlled to 762.0” +/-0.5”.
STOP”.
20. When the operator presses the ENTER key, the controller
13. When operator presses ENTER controller will record will verify the measured length matches the expected
angle 7. The controller must see a moment reading less green witness mark location, otherwise the controller
than 50,000 lb-in, or “CAL FAILED” and “LIFT DN TO will display “CAL FAILED” and “TELE TO GREEN” each
STOP” will be displayed each time the ENTER key is time the ENTER key is pressed and the measured length
pressed and the moment reading is too high. does not match the expected length. The controller will
calculate and record the 1000# forward calibration
14. The Control system establishes the low angle calibration moment and validate the moment is within the
point by taking into account ground slope in the direc- expected range of 7.658E+06 to 10.21E+06 lb-in. If the
tion of the boom. Low Angle Calibration value = -1.3° +/- Moment is not in this range the controller shall display
Ground Slope. If either of the angle sensors are not “CAL FAILED” and “MOMENT PIN FAULT”. The controller
within 10.0° of –39.3° (-1.3° - 38.0° = –39.3° equals rough will also revalidate the length switch trip point using the
angle sensor mounting offset) then “CAL FAILED” and retracted and yellow witness mark to calculate length. If
“ANGL SNSR# FAULT” will be displayed. the length switch trip point is not 553 +3.5”/-5.5”, the
controller shall display “CAL FAILED” and “LEN SNSR
15. The controller shall enable telescope out and display FAULT”. Otherwise, the controller shall display “BOOM
“CAL POSITION 8” on the first line and “LIFT UNTIL STOP”. SENSORS” on the first line and “CAL COMPLETE” on the
The controller will disable Lift functions when the boom second line.
angle reaches 0°. When the operator presses the ENTER
key, the controller will verify the measured angle is 0° +/
-1°. If not, The controller will display “CAL FAILED” and
“LIFT UP(DOWN) STOP” each time the ENTER key is
pressed and the angle does not match 0° +/-1°.
16. The controller shall display “CAL POSITION 9” on the first

line and “TELE TO YELLOW”. The swing function will be
enabled and the telescope functions will be disabled
when the measured length reaches 810.0” until the
function is cycled. While the boom is in this state the
telescope functions will be allowed to extend or retract
the boom 1.0” at a time. This can be repeated until the
length reading deviates from the expected witness mark
by more than +/-14”, when “CAL FAILED” and “LENGTH
FAILED” will be displayed. When the operator presses
the ENTER key, the controller will calculate and record
the 500# verification moment value. If this moment falls
outside the expected calibration moment value of
10.720E+06 lb-in, “CAL FAILED” and “MOMENT PIN
FAULT” will be displayed. The raw length sensor A/D
counts must between 5220 and 7220 counts or “CAL
FAILED” and “LEN SNSR FAULT” will be displayed.
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6.9 JIB SENSOR CALIBRATIONS 4. The analyzer screen should read:
To calibrate the jib sensors, the analyzer must be in access

level 1. All jib sensors can be calibrated at one time or each cal-
ibration can be performed on an individual basis.
Ground position.
2. Plug the analyzer into the connector inside the Ground

control box. 5. Use the arrow button to reach OPERATOR ACCESS. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
3. Pull out the Emergency Stop switch and start the

engine.
3121619 6-77
8. Use the arrow keys to reach the JIB SENSORS. The screen 10. Press ENTER. The screen should read as shown below.
should read: When it does, activate boom lift until the control system
stops it at 20 degrees boom angle.
9. Press ENTER. The screen should read:
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11. Press ENTER. The screen should read as shown below. 12. If the operator presses enter at the jib lift sensor calibra-
When it does, the operator can either press enter to tion prompt, the screen shown below will be displayed.
begin the jib lift sensor calibration, or use the right or At this point, lift the jib up to the mechanical stop.
left arrow key to locate the desired jib sensor calibration.
The available sensor calibrations are:
JIB LIFT
JIB LEVEL
JIB SWING
PLATFORM LEVEL
13. When the jib is at the mechanical stop, press ENTER. The
screen shown below will be displayed. At that point, jib
lift down until the control system stops the jib.
3121619 6-79
14. Once the jib is stopped the screen shown below will be 16. Hitting the ENTER key at this point will take the operator
displayed. to the next jib sensor calibration. The screen will show:
15. Hitting the escape key (ESC) will take the system back to 17. Press Enter. The screen will show:
the initial jib lift calibration display.
NOTE: At this point the left or right arrow key may be used to skip
to any of the other jib sensor calibrations.
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18. Operate jib lift down until the jib stops. When the jib is 20. Press ENTER. The screen should read:
at the mechanical stop the operator must hit ENTER
again. The screen will show:
21. Operate jib lift up until the jib stops. When the jib is at
the mechanical stop, Hit ENTER again. The screen will
show:
19. When the system completes this step, the next screen
will show:
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22. When the system completes this step, the next screen 24. When the system completes the previous step, the
will show: screen will read:
23. Press ENTER. The screen should read as shown below. 25. Hitting the escape key (ESC) will take the system back to
The control system will jib level down and stop the jib the initial jib lift calibration display.
leveling command.
NOTE: At this point the left or right arrow key may be used to skip
to any of the other jib sensor calibrations.
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26. Hitting the ENTER key at this point will take the operator 28. When the jib reaches the mechanical stop, press ENTER.
to the next jib sensor calibration. The screen will show: The screen will show:
27. Press Enter. The screen shown below will be displayed. 29. When the system is complete with this step, the screen
At this point, use the platform rotate right function below will be displayed.
switch to swing the jib right.
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30. Press Enter. The screen shown below will be displayed. 32. At the finish of the jib swing lift calibration the jib lock
At this point, use the platform rotate left function switch pin will be locked by the control system. The screen will
to swing the jib left. read:
31. When the jib is at the mechanical stop, press ENTER. The 33. Press ENTER. The screen will show:
screen will show:
34. Hitting the escape key (ESC) will take the system back to
the initial jib lift calibration display.
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NOTE: At this point the left or right arrow key may be used to skip 37. When the platform level up is at mechanical stop, Press
to any of the other jib sensor calibrations. ENTER. The screen will show:
35. Hitting the ENTER key at this point will continue the cali-
bration sequence. The screen will show:
38. When the system is complete with this step, the screen
below will be displayed.
36. Press Enter. The screen shown below will be displayed.

At this point, use the platform level up function switch
to level up.
3121619 6-85
39. Press ENTER. The display will then show: 40. The control system will stop the platform level and the
screen will show:
41. Pressing ENTER will take you back to the beginning and
escape (ESC) will take you to the initial screen.
Calibrating the Jib Level Up and Down Valve

Crackpoints
Ground position.
6-86 3121619
2. Plug the analyzer into the connector inside the Ground 5. Use the arrow button to reach OPERATOR ACCESS. Hit
control box. Enter.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the JIB LVL UP CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER again.
10. You will hear engine go to 1800 rpm.
11. Using UP ARROW, increase the value until you see the jib
level movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to JIB LVL UP CRKPT screen.
15. Hit RIGHT ARROW to get to the JIB LVL DN CRKPT screen.
Hit ENTER.
3. Pull out the Emergency Stop switch and start the
engine. 16. CALIBRATE? prompt should appear. Hit ENTER again.
4. The analyzer screen should read: 17. You will hear engine go to 1800 rpm.
Using UP ARROW, increase the value until you see the jib level
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.
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6.10 BOOM UNLOCK PROCEDURE 2. Once the operator selects the UNLOCK BOOM option,
the screen will read:
If the fault “LIFT CYLINDER OVER PRESSURE” or “WRONG TELE
RESPONSE” is active, then the boom will be trapped in trans-
port.
To clear these faults, the Boom Unlock Procedure must be fol-
lowed.
Initial Conditions
Before performing the Boom Unlock Procedure, the following
conditions must be met:
• Booms Sensors, Jib Sensors, Axle Sensor and tilt sensor cal-
ibrations must be successfully completed
• The Boom is operating in the BCS Normal Mode
• The parking brake is not reporting a short to battery from
the UGM or the UCM
• The main boom sensor is reading less than 600”
• The jib is fully retracted
• The main boom sensor is reading less than 7 degrees
• The axles are completely extended
• The machine control system indicates that it is not tilted
• The turntable is centered between the rear tires Pressing will cause the boom to check the initial
• Ground Mode is selected conditions listed above. If any of the calibrations have
not been completed “CAL. BOOM” will be displayed. If
Procedure there is a problem with the envelope, moment or any of
the supporting sensors (including loss of communica-
NOTE: During the calibration, if the ESC key is pressed after the tions) “CHECK FAULTS” will be displayed. If the parking
procedure is started, the calibration will be aborted and brake is shorted anywhere in the system “PARK BRAKE
exit back to the “UNLOCK BOOM” prompt. FAULT” will be displayed. If the jib is not fully retracted
“JIB TELE IN” will be displayed. If the telescope is reading
NOTE: The envelope, moment and appropriate faults will continu- more than 600”, “MAIN TELE IN” will be displayed. If the
ously be monitored after the initial conditions are satisfied. main boom angle sensors are reading more than 7
If at any time during the test these conditions change to an degrees, “MAIN LIFT DOWN” will be displayed, if the
unsafe state (communications lost, envelope violation, axles are not extended “EXTEND AXLES” will be dis-
moment violation etc.) the Calibration will abort and the played. If the DOS switch is not indicating in line and the
analyzer will display “ENVLP VIOLATION”. angles are not within 10° of inline “ALIGN TURNTABLE”
will be displayed. If the chassis tilt is tilted “LEVEL
1. Using the analyzer, enter access level 1. Unlock Boom MACHINE” will be displayed. If the machine is in plat-
can be found under the Calibrations menu. form mode. “SELECT GRND MODE” will be displayed. If
none of the above faults are present, the test will move
on to the next step. As each fault is cleared, the system
will make sure no other faults are active. During this
time the latched faults from If the fault “LIFT CYLINDER
OVER PRESSURE” or “WRONG TELE RESPONSE” is active,
then the boom will be trapped in transport. These faults
will be latched through key-cycle.
6-88 3121619
3. If all of the initial conditions are passed, the analyzer will 4. After the machine has reached the set point in step 3,
display: Lift up and down functionality will be cut out and Tele-
scope in and out functionality will be restored. The ana-
lyzer menu will display:
The control system will suppress the latched faults (“LIFT

CYLINDER OVER PRESSURE” or “WRONG TELE
RESPONSE”) to allow the boom out of transport position Engage Tele Out until the control system cuts it out. The
until the boom is unlocked or the test is cancelled. system will cut out at 60.0”. After the machine reaches
Engage main lift until the control system cuts it out. The the set point, the menu will automatically advance and
system will cut out at 7°. Only lift up and lift down will be Telescope in and out will be cut out. During this test, the
available while on this menu, all other functions will be telescope response will be tested. Telescope out will
cut out. After the machine reaches the stop point, the have to be commanded for at least 3 seconds, and meet
menu will automatically advance. the requirements for movement and for the correct
direction. If the machine reaches the telescope set point
without 3 seconds of continuous operation, it will be
assumed that the telescope response was correct and
the menu will advance. If the machine does not move, or
moves in the wrong direction, the menu “CHECK FAILED
WRONG TELE DIR.” will be displayed and the test will
end. The WRONG TELE RESPONSE fault will still be active,
and the boom unlock procedure will have to be
attempted again.
3121619 6-89
5. As soon as the machine had reached the set point in analyzer will display “CHECK FAILED PRESS ENTER”. If the
step 4, Telescope in and out functionality will be cut out. check passes the analyzer will display “CHECK PASSED
The analyzer menu will display: PRESS ENTER”.
7. The next test to be performed will be the Lift Pressure
over pressure check. The system will monitor the lift
pressure input. If the reported PSI is above the over pres-
sure limit then the analyzer will display:
The menu will not change until the telescope controls

have returned to neutral and the machine had been dis-
abled.
6. After Step 5, the system will check the boom. The ana-
If the lift pressure is under the pressure limit, then the
lyzer will display:
fault will clear at the end of the test.
This screen will remain until the boom check has com-
pleted, the check fails, or the routine is interrupted by an
attempted command. If the check is interrupted the
6-90 3121619
8. Regardless if the check passed or failed in Step 7, after 9. After the boom is retracted, the analyzer menu will
advance to:
the status of the test has been reported, press the
menu will advance to:
The operator will have to bring the boom down to

below elevation before the menu will advance, all
hydraulics are enabled, but the fault cutout rules will still
The first part of this step will be the second part of the
apply.
machine response test. Telescope in and out will be the
only hydraulics available. Telescope in will have to be 10. Once the boom is in transport position again the ana-
commanded for at least 3 seconds, and meet the lyzer will display:
requirements in for movement and for the correct direc-
tion. If the machine reaches the retracted point without
3 seconds of continuous operation, it will be assumed
that the telescope response was correct and the menu
will advance. If the machine does not move, or moves in
the wrong direction, the menu “CHECK FAILED WRONG
TELE DIR.” will be displayed and the test will end. The
WRONG TELE RESPONSE fault will still be active, and the
boom unlock procedure will have to be attempted
again. If the test passes, all hydraulics will be enabled,
but if the boom was not fully unlocked then the cutouts
from the faults will be applied. The operator will have to
tele in until the boom is retracted to advance to the next
menu.
3121619 6-91
6.11 SETTING CRACKPOINTS 2. Scroll to MENU: OPERATOR ACCESS and press ENTER
Crackpoints, the point at which a valve is opened enough to

.
induce movement, must be set for a variety of reasons: when-
ever related valves or cartridges are changed, software is
updated, the UGM is changed, or the boom envelope control
does not seem to be functioning properly.
The crackpoints covered in this section are:
• Platform Level Up and Down,

• Jib Level Up and Down,
• Main Lift Up and Down,
• Main Telescope Out and In.
THE JLG ANALYZER WILL PROMPT USERS FOR A CODE UPON REACHING MENU:
OPERATOR ACCESS. THIS FIVE-DIGIT CODE (33271) WILL DISABLE THE BOOM
ENVELOPE CONTROL. WHEN THE BOOM ENVELOPE CONTROL IS DISABLED,
THE MACHINE MAY TIP IF USED INCORRECTLY.
DO NOT ATTACH THE ANALYZER TO THE CONNECTION PORT IN THE PLAT-

FORM. DO NOT CONDUCT ANY CRACKPOINT SETTINGS FROM THE PLATFORM.
3. Enter code 33271 and press ENTER .
NOTE: Cycle the boom functions (8 to 10 times, 5 seconds in each
direction) prior to setting the crackpoints to ensure the
hydraulic oil is at operating temperature.
NOTE: If ESC is pressed while calibration readings are being

taken, the calibration will abort, and CAL FAILED will
appear on the analyzer. The previous calibration values
will be used instead. Only press ESC when instructed

to do so.
During all Control System lag times, the analyzer will dis-
play CALIBRATING...
Platform Level Up and Down Crackpoints

NOTE: To set crackpoints for Platform Level Up and Down, a JLG
analyzer is needed. Have an assistant on hand to help ver-
ify that movement occurs.
1. Connect the JLG analyzer to the machine at the Ground

Controls. Start the engine.
6-92 3121619
4. Scroll to MENU: CALIBRATIONS and press ENTER . 6. Press ENTER to calibrate Platform Level Up crack-
point.
5. Scroll to LEVEL UP CRKPT and press ENTER . NOTE: Have an assistant help verify that movement occurs.
7. Using the analyzer, press and hold the Up Arrow

until the function starts moving, then press ENTER
. Release the Up Arrow ..
3121619 6-93
8. This completes the Platform Level Up crackpoint pro-

10. Press ENTER to calibrate Platform Level Down
cedure. Press ESC to return to the calibrations crackpoint.
menu.
NOTE: Have an assistant help verify that movement occurs.
9. Scroll to LEVEL DOWN CRKPT and press ENTER .

until the function starts moving, then press
ENTER . Release the Up Arrow .
6-94 3121619
12. This completes the Platform Level Down crackpoint pro- 2. Scroll to MENU: OPERATOR ACCESS and press ENTER
cedure. Press ESC to return to the calibrations .

menu.
13. The crackpoint setting procedure for Platform Level Up

and Down is complete. Press ESC to exit calibra-

tions.
14. Push in Power/Emergency stop switch to save the cali-
bration changes.
Jib Level Up and Down Crackpoints

NOTE: To set crackpoints for the Jib Level Up and Down, a JLG

3121619 6-95
4. Scroll to MENU: CALIBRATIONS and press ENTER . 6. Press ENTER to calibrate Jib Level Up crackpoint.

5. Scroll to JIB LVL UP CRKPT and press ENTER .

. Release the Up Arrow .
6-96 3121619
8. This completes the Jib Level Up crackpoint procedure.

10. Press ENTER to calibrate Jib Level Down crack-
Press ESC to return to the calibrations menu. point.

9. Scroll to JIB LVL DN CRKPT and press ENTER .

. Release the Up Arrow .
3121619 6-97
12. This completes the Jib Level Down crackpoint proce- 2. Scroll to MENU: OPERATOR ACCESS and press ENTER
dure. Press ESC to return to the calibrations menu. .
13. The crackpoint setting procedure for Jib Level Up and

Down is complete. Press ESC to exit calibrations.
14. Push in Power/Emergency Stop switch to
save the calibration changes.
Main Lift Up and Down Crackpoints

NOTE: To set crackpoints for the Main Lift Up and Down, a JLG

6-98 3121619
4. Scroll to MENU: CALIBRATIONS and press ENTER . 6. Press ENTER .
5. Scroll to MAIN LIFT CRKPT and press ENTER . 7. Press ENTER to calibrate Main Lift Up crackpoint.
3121619 6-99
NOTE: Have an assistant help verify that movement occurs. 9. This completes the Main Lift Up crackpoint procedure.
8. At the Ground Controls, press

Press ENTER .
and hold the Lift Up toggle
switch until the function starts
moving, then press ENTER
. Release the Lift Up toggle

switch.
10. Press ENTER to calibrate Main Lift Down crack-

point.
6-100 3121619
NOTE: Have an assistant help verify that movement occurs. 12. This completes the Main Lift Down crackpoint proce-

dure. Press ENTER .
and hold the Lift Down toggle
switch until the function starts
moving, then press ENTER
. Release the Lift Down

toggle switch.
13. Press ENTER to calibrate Main Lift Enable crack-

point.
3121619 6-101

and hold the Lift Down toggle
FOR THE FOLLOWING STEP, ELEVATE THE BOOM UNTIL IT STOPS IN ORDER TO switch until the function starts
CORRECTLY CALIBRATE THE MAIN LIFT ENABLE CRACKPOINT. moving, then press ENTER

. Release the Lift Down
and hold the Lift Up toggle
toggle switch.
switch until the engine goes to
idle speed (lift should not be
moving), then press ENTER
. Release the Lift Up tog-

gle switch.
16. This completes the Main Lift Enable crackpoint proce-
dure. Press ESC to return to the calibrations menu.
17. The crackpoint setting procedure for Main Lift Up and
Down is complete. Press ESC to exit calibrations.
6-102 3121619
18. Push in Power/Emergency Stop button to

save the calibration changes.
Main Telescope Out and In Crackpoints
THE BOOM MUST BE FULLY RETRACTED AND HORIZONTAL BEFORE STARTING

THE MAIN TELESCOPE OUT AND IN CRACKPOINT PROCEDURE.
NOTE: To set crackpoints for the Main Telescope Out and In, a JLG

2. Scroll to MENU: OPERATOR ACCESS and press ENTER
.
4. Scroll to MENU: CALIBRATIONS and press ENTER .
3121619 6-103
5. Scroll to MAIN TELE CRKPT and press ENTER . 7. Press ENTER to calibrate Main Telescope Out
crackpoint.
6. Press ENTER .
6-104 3121619
NOTE: Have an assistant help verify that movement occurs. 9. This completes the Main Telescope Out crackpoint pro-

cedure. Press ENTER .
and hold the Telescope Out
toggle switch until the func-
tion starts moving, then
press ENTER . Release

the Telescope Out toggle
switch.
10. Press ENTER to calibrate Main Telescope In crack-

point.
3121619 6-105
NOTE: Have an assistant help verify that movement occurs. 12. The crackpoint setting procedure for Main Telescope

Out and In is complete. Press ESC to exit calibra-
and hold the Telescope In
tions.
toggle switch until the func-
tion starts moving, then
press ENTER . Release

the Telescope In toggle
switch.
13. Push in Power/Emergency Stop switch to save the cali-

bration changes.
6-106 3121619
6.12 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. If the actual platform load exceeds the selected Rated
Load, the following will occur: a. LSS Sensor removal or replacement
1. The Overload Visual Warning Indicator will b. Addition or removal of certain platform mounted
flash at the selected control position (plat- accessories. (Refer to Calibration)
form or ground). c. Platform is removed, replaced, repaired or shows
evidence of impact.
2. The Platform and Ground Alarms will sound 5 seconds
On, and 2 seconds Off.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFICATION
3. All normal movement will be prevented from the plat-
NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. REFER TO TEST-
form control position (optional - ground control func-
ING & EVALUATION.
tions may be prevented).
4. Further movement is permitted by: All calibration procedures are menu driven through the use of
a JLG Analyzer.
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).
3121619 6-107
E
D THRUST BEARING THRUST BEARING
B LINK
C
C
A A
LINK ROTATRY
SIDE PIN SECTION D-D
D
E
BOLT, WASHER, NUT *

Torque to 72 ft.lbs. (97Nm)
PLATFORM SUPPORT LINK
LINK
SEE DETAIL G
LINK
LINK PLATE
SIDE PIN
SECTION E-E
WEAR PAD
LOCKNUT PLATFORM
SUPPORT SECTION A-A
WASHER
BOLT BOLT, NUT *

Torque to 72 ft.lbs. (97 Nm)
REST BUTTON*
Torque to 18.5 ft.lbs. (25 Nm) LOAD
SECTION B-B SENSING
CELL
CENTER BOLT BOLT, WASHER*
Torque to 48 ft.lbs. (65Nm)
Torque Nut
To 565 lb.ft. (766 Nm)
NUT, WASHER DETAIL G
SECTION C-C 1001207388-F
MAF09650F
Figure 6-32. LSS Installation - Sheet 1 of 4
6-108 3121619
DO NOT APPLY MOLY PASTE

ON PINS OR IN PIN BORES (8+)
BOLT, WASHER, NUT, KEEPER*

*BOLT, WASHER, NUT, KEEPER
Torque to 40.5 ft.lbs. (55 Nm)
LOAD SENSING
GAUGE
BOLT, WEAR PAD

PLATFORM
ROTATOR
*BOLT, WASHER, NUT, KEEPER

BOLT, WASHER, NUT, KEEPER*

BOLT, WASHER, NUT
BOLT, WASHER, NUT

BOLT, WASHER, NUT

BOLT, WASHER, NUT

*Apply JLG THREDLOCKER P/N 0100011 1001207388-F
MAF09660F
3121619 6-109
N
W
VIE
ROUTE LOAD CELL CABLE THROUGH P-CLAMP

BETWEEN THE TOP LINK AND THE TOP PLATE
AND CONNECT TO PLATFORM BOX
BOLT, WASHER, NUT *

LOAD SENSING GAUGE
VIEW N

MAF09670F
6-110 3121619
CARRIAGE BOLT
1. USE SEQ # AS SHIM TO CENTER ASSEMBLY

2. REFINW AIGMENT OF SEQ #22 USING SLOTTED
ADJUSTMENT OF SEQ #16 BOLTS
3. SEQ #23 MUST REST FULLY CENTERED O SEQ #21.
4. ARROW ON SEQ #22 MUST POINT AWAY DROM SEQ #23.
BOLTS
RESET BUTTON SCREW
THRUST BEARING
LOAD
SENSING
CELL

MAF09680F
3121619 6-111
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 6-7, 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 6-7. 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
6-112 3121619
Calibration Procedure
5. Press the ENTER key to view the menu. Upon entry
1. Remove everything from the platform, except perma- to the Calibration Menu, the JLG Control System will link
nently fixed JLG Accessories, to allow the Load Sensing 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-
tion. Level the platform from ground control (if neces-
sary) to within +/- 5°.
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:
6. Press Enter . The Screen will read:
NOTE: The Calibration Menu is not available in OPERATOR

ACCESS.
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).
3121619 6-113
NOTE: Accessory weight will reset to 0 lbs. each time the machine
Pressing the ESC key after starting calibration and is re-calibrated and will need to be re-entered.
before calibration is complete will display the CAL FAILED
message. This will not disturb the prior calibration infor- NOTE: The Accessory weight will be temporarily stored in the Con-
mation. trol System until calibration has been completed success-
fully.
Refer to Table 6-8, Accessory Weights. Use the up and

7. Press ENTER . The analyzer screen will read: down analyzer keys to enter the accessory weight(s) (in
lbs). When all the accessory weights are entered, press
ENTER . The screen will read:
8. If the platform is empty, press ENTER . The screen

will read:
Table 6-8. Accessory Weights
Accessory Weight
LOAD SENSI NG: SkyWelder (stick welder) 70 lb (32 kg)

accessory xxxlbs: SkyWelder Prep Prep only = 15 lb (7 kg)
Full install = 70 lb (32 kg)
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)
Work Surface 20 lb (9 kg)
NOTE: Not all Accessories are available on every JLG model.
Some Accessory combinations are prohibited due to
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.
6-114 3121619
9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press
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:
10. Press ENTER . The control system will ask for

installed accessories. The screen will show the following:
3121619 6-115
12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-10. Pipe Rack Capacity Reductions
ENTER . The control system will default to an esti- PLATFORM OVRLD

Capacity PLATFORM OVRLD
mate of unrestricted capacity, which can be adjusted if RESTRICT
necessary. Refer to Table 6-9, SkyGlazier Capacity Reduc- 500 lb (227 kg) 400 lb (181 kg) n/a
tions and Table 6-10, Pipe Rack Capacity Reductions. 550 lb (250 kg) 450 lb (204 kg) n/a
The screen will read: 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
two values.
13. Press ENTER . The following screen will be dis-

played for restricted capacity, which can be adjusted if
necessary. Refer to Table 6-9, SkyGlazier Capacity Reduc-
tions and Table 6-10, Pipe Rack Capacity Reductions.
Table 6-9. SkyGlazier Capacity Reductions
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
750 lb (340 kg) n/a 590 lb (268 kg)
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
two values.
6-116 3121619
14. Press ENTER . If calibration is successful, the screen

will read:
3121619 6-117
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).
6-118 3121619
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 6-11. 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.
3121619 6-119
6.13 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
ground control module or from the platform console.
NOTE: If performing the procedure from the platform console, the

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

10. Press ENTER .
11. Use the Down arrow to reach MSSO RESET.
6. Use the arrow button to reach OPERATOR ACCESS. Press
Enter .
8. Use the right Arrow key to reach MENU: CALIBRATIONS.
Press Enter .
6-120 3121619
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.
3121619 6-121
6.14 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS

There are three possible level valve driver errors, short to bat-
Platform Leveling Fault Warning tery, short to ground, and open circuit.
The JLG Control System takes a snapshot of the two sensor val- 1. In the case of a short to ground or an open circuit, the
ues and records the difference once on each power up. The platform valve cannot be turned on and the following
will occur:
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 a. All interactions with platform leveling shall cease
11 degrees, the difference is 6 degrees and the DTC is trig-
b. The Electronic Leveling System Fault Lamp shall
gered when the sensors are 1 degree (or less) apart or 11
flash (to indicate that the leveling function has been
degrees (or more) apart.
lost).
If a fault occurs in the platform leveling system the following c. The platform alarm will sound.
will occur:
d. A system fault will be logged.
1. Automatic platform leveling will stop (except when e. All function speeds (lift, swing, telescope and drive)
there is a fault in only one sensor automatic leveling will will be placed in creep mode (except when the plat-
remain active as the control system will use the other form is in the transport position).
sensor to control leveling)
2. In the case of a short to battery on one of the platform
2. The level fault lamp will flash
leveling valves, the valve cannot be turned off and the
3. The audible alarm will sound following will occur:
4. All functions will default to creep speed if the platform is a. The platform dump valve will be turned off to pre-
out of the transport position. 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
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- e. A system fault will be logged.
TATIVE TO INVESTIGATE THE FAULT.
f. All function speeds (lift, swing, telescope and drive)
will be placed in creep mode (except when the plat-
Fault Response form is in the transport position)
ERROR RESPONSE 3. In the case of a short to battery on the platform dump

If basket level varies from the current setpoint by ± 5.5º for valve, the valve cannot be turned off. The controllability
more than 1.5 seconds when the platform is not in the trans- of the platform leveling function will be impaired and
port position, the following events will occur: the following will occur:
1. The platform dump valve will be disabled (level, rotate a. All interactions with platform leveling shall cease.
and jib functions disabled). b. The Electronic Leveling System Fault Lamp shall
2. The level system fault lamp will flash (to indicate that lost).
the leveling function has been lost).
c. The platform alarm will sound.
3. The platform alarm will sound.
d. A system fault will be logged.
4. 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 In each of the cases above it shall be necessary to re-cycle the
current setpoint varies by ± 5.5º for more than 8 seconds the EMS to clear the fault. Operable functions shall be in the creep
events 1,2,3 & 4 above will occur. (note function speeds will mode except while below elevation.
operate normally). Cycling the EMS will clear the fault and
allow the operator to operate the machine as a new level set-
point is taken.
6-122 3121619
TILT SENSOR ERRORS In each of the cases above it will be necessary to re-cycle the
EMS to clear the fault. Operable functions shall be in the creep
If the secondary tilt sensor is faulty, the control system will mode except while below elevation.
continue to utilize information from the primary sensor.
When both sensors appear to be working but have measure-
If the primary sensor is faulty, the control system will switch to ments that disagree by ±5.5º The following will occur:
the backup sensor for control.
1. All interactions with platform leveling shall cease.
In both cases above the following will occur: 2. The Electronic Leveling System Fault Lamp shall flash (to
indicate that the leveling function has been lost).
1. The Electronic Leveling System Fault Lamp will flash (to
indicate that there is a leveling fault). 3. The platform alarm will sound.
2. The platform alarm will sound. 4. A system fault will be logged.

5. All function speeds (lift, swing, telescope and drive) will
3. A system fault will be logged.
be placed in creep mode (except when the platform is in
4. All function speeds (lift, swing, telescope, jib and drive) the transport position)
will be placed in creep mode (except when the platform At this point, the operator must use the level up and down
is in the transport position). toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
5. Automatic leveling remains active.
Lift, swing, drive and telescope will continue to operate.
3121619 6-123
Table 6-12. Diagnostic Fault Code Chart
Fault Text Flash 1 Flash 2 DTC 1350 1200 1250 1500 1850
EVERYTHING OK 0 0 1 ✔ ✔ ✔ ✔ ✔
RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0 0 10 ✔ ✔ ✔ ✔ ✔
FSW OPEN 0 0 11 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - CREEP SWITCH OPEN 0 0 12 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION 0 0 13 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR OUT OF RANGE 0 0 14 ✔ ✔ ✔ ✔ ✔
LOAD SENSOR READING UNDER WEIGHT 0 0 15 ✔ ✔ ✔ ✔ ✔
ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 16 ✔ ✔ ✔ ✔ ✔
OVER MOMENT - HYDRAULICS SUSPENDED 0 0 17 ✔ ✔ ✔ ✔ ✔
UNDER MOMENT - HYDRAULICS SUSPENDED 0 0 18 ✔ ✔ ✔ ✔ ✔
MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 19 ✔ ✔ ✔ ✔ ✔
TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 20 -- -- ✔ -- --
ADS1213 REINITIALIZED 0 0 21 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - PLATFORM STOWED 0 0 30 ✔ ✔ ✔ ✔ ✔
FUEL LEVEL LOW - ENGINE SHUTDOWN 0 0 31 ✔ ✔ ✔ ✔ ✔
APU ACTIVE 0 0 35 ✔ ✔ ✔ ✔ ✔
JIB UNLOCKED OUT OF TRANSPORT - HYDRAULICS SUSPENDED 0 0 37 -- -- -- ✔ ✔
SWING ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 38 -- -- -- ✔ ✔
SKYGUARD ACTIVE - FUNCTIONS CUTOUT 0 0 39 ✔ ✔ ✔ ✔ ✔
KEYSWITCH FAULTY 2 1 212 ✔ ✔ ✔ ✔ ✔
FSW FAULTY 2 1 213 ✔ ✔ ✔ ✔ ✔
STEER SWITCHES FAULTY 2 2 227 ✔ ✔ ✔ ✔ ✔
FSW INTERLOCK TRIPPED 2 2 2211 ✔ ✔ ✔ ✔ ✔
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH 2 2 2212 ✔ ✔ ✔ ✔ ✔
STEER LOCKED - SELECTED BEFORE FOOTSWITCH 2 2 2213 ✔ ✔ ✔ ✔ ✔
D/S JOY. OUT OF RANGE LOW 2 2 2215 ✔ ✔ ✔ ✔ ✔
D/S JOY. OUT OF RANGE HIGH 2 2 2216 ✔ ✔ ✔ ✔ ✔
D/S JOY. CENTER TAP BAD 2 2 2217 ✔ ✔ ✔ ✔ ✔
L/S JOY. OUT OF RANGE LOW 2 2 2218 ✔ ✔ ✔ ✔ ✔
L/S JOY. OUT OF RANGE HIGH 2 2 2219 ✔ ✔ ✔ ✔ ✔
L/S JOY. CENTER TAP BAD 2 2 2220 ✔ ✔ ✔ ✔ ✔
LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH 2 2 2221 ✔ ✔ ✔ ✔ ✔
WAITING FOR FSW TO BE OPEN 2 2 2222 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE 2 2 2223 ✔ ✔ ✔ ✔ ✔
FOOTSWITCH SELECTED BEFORE START 2 2 2224 ✔ ✔ ✔ ✔ ✔
6-124 3121619
FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM 2 3 234 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER 2 3 235 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH 2 3 236 ✔ ✔ ✔ ✔ ✔
START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH 2 3 237 ✔ ✔ ✔ ✔ ✔
TOWER LIFT PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23100 -- -- ✔ -- --
TOWER LIFT PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23101 -- -- ✔ -- --
TOWER LIFT PRESSURE SENSOR - NOT DETECTING CHANGE 2 3 23102 -- -- ✔ -- --
TOWER LIFT CYLINDER - OVER PRESSURE 2 3 23103 -- -- ✔ -- --
LIFT PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23124 -- -- -- -- ✔
LIFT PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23125 -- -- -- -- ✔
LIFT PRESSURE SENSOR - NOT DETECTING CHANGE 2 3 23126 -- -- -- -- ✔
LIFT CYLINDER - OVER PRESSURE 2 3 23127 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23128 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23129 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - HIGH 2 3 23130 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - LOW 2 3 23131 -- -- -- -- ✔
MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS 2 5 259 ✔ ✔ ✔ ✔ ✔
GENERATOR MOTION CUTOUT ACTIVE 2 5 2513 ✔ ✔ ✔ ✔ ✔
BOOM PREVENTED - DRIVE SELECTED 2 5 2514 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - BOOM SELECTED 2 5 2515 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - ABOVE ELEVATION 2 5 2516 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - TILTED & ABOVE ELEVATION 2 5 2517 ✔ ✔ ✔ ✔ ✔
JIB SWING PREVENTED - IN 1000# MODE 2 5 2521 ✔ ✔ ✔ ✔ ✔
CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED 2 5 2522 ✔ ✔ ✔ ✔ ✔
BACKUP BLAM COMMUNICATIONS ACTIVE 2 5 2523 -- -- ✔ -- --
DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL 2 5 2524 -- -- ✔ -- --
MACHINE SETUP FAULT - JIB SWING 2 5 2546 ✔ ✔ ✔ ✔ ✔
MACHINE SETUP FAULT - MODEL 2 5 2547 ✔ ✔ ✔ ✔ ✔
SYSTEM TEST MODE ACTIVE 2 5 2548 ✔ ✔ ✔ ✔ ✔
SKYGUARD SW - DISAGREEMENT 2 5 2563 ✔ ✔ ✔ ✔ ✔
FRONT LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 261 -- -- -- -- ✔
FRONT LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 262 -- -- -- -- ✔
FRONT RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 263 -- -- -- -- ✔
FRONT RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 264 -- -- -- -- ✔
REAR LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 265 -- -- -- -- ✔
3121619 6-125
REAR LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 266 -- -- -- -- ✔
REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 267 -- -- -- -- ✔
REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 268 -- -- -- -- ✔
FRONT LEFT AXLE SENSOR - NOT RESPONDING 2 6 2611 -- -- -- -- ✔
FRONT RIGHT AXLE SENSOR - NOT RESPONDING 2 6 2612 -- -- -- -- ✔
REAR LEFT AXLE SENSOR - NOT RESPONDING 2 6 2613 -- -- -- -- ✔
REAR RIGHT AXLE SENSOR - NOT RESPONDING 2 6 2614 -- -- -- -- ✔
AXLE RETRACT POSITION - NOT CALIBRATED 2 6 2615 -- -- -- -- ✔
AXLE DEPLOY POSITION - NOT CALIBRATED 2 6 2616 -- -- -- -- ✔
BRAKE - SHORT TO BATTERY 3 3 331 ✔ ✔ ✔ ✔ ✔
BRAKE - OPEN CIRCUIT 3 3 332 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - SHORT TO BATTERY 3 3 3311 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND 3 3 3316 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT 3 3 3317 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY 3 3 3318 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND 3 3 3320 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT 3 3 3321 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY 3 3 3322 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - SHORT TO GROUND 3 3 3324 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT 3 3 3325 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY 3 3 3326 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - SHORT TO GROUND 3 3 3328 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT 3 3 3329 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY 3 3 3330 ✔ ✔ ✔ ✔ ✔
ALTERNATOR/ECM POWER - SHORT TO GROUND 3 3 3336 ✔ ✔ ✔ ✔ ✔
ALTERNATOR POWER - OPEN CIRCUIT 3 3 3338 ✔ ✔ ✔ ✔ ✔
ALTERNATOR POWER - SHORT TO BATTERY 3 3 3339 ✔ ✔ ✔ ✔ ✔
AUX POWER - SHORT TO GROUND 3 3 3340 ✔ ✔ ✔ ✔ ✔
AUX POWER - OPEN CIRCUIT 3 3 3341 ✔ ✔ ✔ ✔ ✔
AUX POWER - SHORT TO BATTERY 3 3 3342 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - SHORT TO GROUND 3 3 3343 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - OPEN CIRCUIT 3 3 3344 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - SHORT TO BATTERY 3 3 3345 ✔ ✔ ✔ ✔ ✔
ELECTRIC PUMP - SHORT TO GROUND 3 3 3349 ✔ ✔ ✔ ✔ ✔
ELECTRIC PUMP - OPEN CIRCUIT 3 3 3350 ✔ ✔ ✔ ✔ ✔
6-126 3121619
ELECTRIC PUMP - SHORT TO BATTERY 3 3 3351 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - SHORT TO GROUND 3 3 3358 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - OPEN CIRCUIT 3 3 3359 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - SHORT TO BATTERY 3 3 3360 ✔ ✔ ✔ ✔ ✔
BRAKE - SHORT TO GROUND 3 3 3361 ✔ ✔ ✔ ✔ ✔
START SOLENOID - SHORT TO GROUND 3 3 3362 ✔ ✔ ✔ ✔ ✔
START SOLENOID - OPEN CIRCUIT 3 3 3363 ✔ ✔ ✔ ✔ ✔
START SOLENOID - SHORT TO BATTERY 3 3 3364 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - SHORT TO GROUND 3 3 3368 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - OPEN CIRCUIT 3 3 3369 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - SHORT TO BATTERY 3 3 3370 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - SHORT TO GROUND 3 3 3371 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - OPEN CIRCUIT 3 3 3372 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - SHORT TO GROUND 3 3 3373 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - OPEN CIRCUIT 3 3 3374 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - SHORT TO BATTERY 3 3 3375 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - SHORT TO GROUND 3 3 3376 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - OPEN CIRCUIT 3 3 3377 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - SHORT TO BATTERY 3 3 3378 ✔ ✔ ✔ ✔ ✔
HOUR METER - SHORT TO GROUND 3 3 3379 ✔ ✔ ✔ ✔ ✔
HOUR METER - OPEN CIRCUIT 3 3 3380 ✔ ✔ ✔ ✔ ✔
HOUR METER - SHORT TO BATTERY 3 3 3381 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND 3 3 3385 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT 3 3 3386 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY 3 3 3387 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND 3 3 3391 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT 3 3 3392 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY 3 3 3393 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND 3 3 3394 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT 3 3 3395 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY 3 3 3396 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND 3 3 3397 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT 3 3 3398 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY 3 3 3399 ✔ ✔ ✔ ✔ ✔
JIB LIFT UP VALVE - SHORT TO GROUND 3 3 33100 ✔ ✔ ✔ -- --
3121619 6-127
JIB LIFT UP VALVE - OPEN CIRCUIT 3 3 33101 ✔ ✔ ✔ -- --
JIB LIFT UP VALVE - SHORT TO BATTERY 3 3 33102 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - SHORT TO GROUND 3 3 33103 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - OPEN CIRCUIT 3 3 33104 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - SHORT TO BATTERY 3 3 33105 ✔ ✔ ✔ -- --
SWING RIGHT VALVE - SHORT TO GROUND 3 3 33118 ✔ ✔ ✔ ✔ ✔
SWING RIGHT VALVE - OPEN CIRCUIT 3 3 33119 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - SHORT TO BATTERY 3 3 33120 ✔ ✔ ✔ ✔ ✔
SWING RIGHT VALVE - SHORT TO BATTERY 3 3 33121 ✔ ✔ ✔ ✔ ✔

SWING LEFT VALVE - SHORT TO GROUND 3 3 33122 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY 3 3 33123 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - SHORT TO GROUND 3 3 33130 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - OPEN CIRCUIT 3 3 33131 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - SHORT TO BATTERY 3 3 33132 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - SHORT TO GROUND 3 3 33133 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - OPEN CIRCUIT 3 3 33134 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - SHORT TO BATTERY 3 3 33135 ✔ ✔ ✔ ✔ ✔
MAIN LIFT APU VALVE - SHORT TO GROUND 3 3 33136 -- -- ✔ -- --
MAIN LIFT APU VALVE - OPEN CIRCUIT 3 3 33137 -- -- ✔ -- --
MAIN LIFT APU VALVE - SHORT TO BATTERY 3 3 33138 -- -- ✔ -- --
MAIN LIFT PILOT - PRESSURE FAILURE 3 3 33139 -- -- ✔ -- --
MAIN LIFT PILOT - NO PRESSURE 3 3 33140 -- -- ✔ -- --
MAIN LIFT PILOT - PRESSURE SWITCH FAILURE 3 3 33141 -- -- ✔ -- --
TOWER LIFT APU VALVE - STUCK OPEN 3 3 33142 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - STUCK OPEN 3 3 33143 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - SHORT TO GROUND 3 3 33144 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - OPEN CIRCUIT 3 3 33145 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - SHORT TO BATTERY 3 3 33146 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - SHORT TO GROUND 3 3 33147 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - OPEN CIRCUIT 3 3 33148 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - SHORT TO BATTERY 3 3 33149 -- -- ✔ -- --
LIFT PILOT VALVE - SHORT TO GROUND 3 3 33150 ✔ ✔ -- ✔ ✔
LIFT PILOT VALVE - OPEN CIRCUIT 3 3 33151 ✔ ✔ -- ✔ ✔
LIFT PILOT VALVE - SHORT TO BATTERY 3 3 33152 ✔ ✔ -- ✔ ✔
LIFT DOWN AUX VALVE - SHORT TO GROUND 3 3 33153 ✔ ✔ -- ✔ ✔
6-128 3121619
LIFT DOWN AUX VALVE - OPEN CIRCUIT 3 3 33154 ✔ ✔ -- ✔ ✔
LIFT DOWN AUX VALVE - SHORT TO BATTERY 3 3 33155 ✔ ✔ -- ✔ ✔
TOWER LIFT APU VALVE - SHORT TO GROUND 3 3 33156 -- -- ✔ -- --
TOWER LIFT APU VALVE - OPEN CIRCUIT 3 3 33157 -- -- ✔ -- --
TOWER LIFT APU VALVE - SHORT TO BATTERY 3 3 33158 -- -- ✔ -- --
MAIN LIFT ENABLE VALVE - SHORT TO GROUND 3 3 33159 -- -- ✔ -- ✔
MAIN LIFT ENABLE VALVE - OPEN CIRCUIT 3 3 33160 -- -- ✔ -- ✔
MAIN LIFT ENABLE VALVE - SHORT TO BATTERY 3 3 33161 -- -- ✔ -- ✔
TOWER TELESCOPE APU VALVE - STUCK OPEN 3 3 33162 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - STUCK OPEN 3 3 33163 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND 3 3 33164 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT 3 3 33165 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY 3 3 33166 -- -- ✔ -- --
PVG ENABLE VALVE - SHORT TO GROUND 3 3 33167 -- -- ✔ -- --
PVG ENABLE VALVE - OPEN CIRCUIT 3 3 33168 -- -- ✔ -- --
PVG ENABLE VALVE - SHORT TO BATTERY 3 3 33169 -- -- ✔ -- --
RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY 3 3 33173 ✔ ✔ ✔ ✔ ✔
OR OPEN CIRCUIT
RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- 3 3 33174 ✔ ✔ ✔ ✔ ✔
CUIT
JIB ROTATE LEFT VALVE - OPEN CIRCUIT 3 3 33175 ✔ ✔ ✔ -- --
JIB ROTATE LEFT VALVE - SHORT TO BATTERY 3 3 33176 ✔ ✔ ✔ -- --
JIB ROTATE LEFT VALVE - SHORT TO GROUND 3 3 33177 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - OPEN CIRCUIT 3 3 33178 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - SHORT TO BATTERY 3 3 33179 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - SHORT TO GROUND 3 3 33180 ✔ ✔ ✔ -- --
MAIN LIFT UP VALVE - OPEN CIRCUIT 3 3 33181 ✔ ✔ -- ✔ ✔
MAIN LIFT UP VALVE - SHORT TO BATTERY 3 3 33329 ✔ ✔ -- ✔ ✔
MAIN LIFT UP VALVE - SHORT TO GROUND 3 3 33183 ✔ ✔ -- ✔ ✔
MAIN LIFT DOWN VALVE - OPEN CIRCUIT 3 3 33184 ✔ ✔ -- ✔ ✔
MAIN LIFT DOWN VALVE - SHORT TO GROUND 3 3 33185 ✔ ✔ -- ✔ ✔
MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT 3 3 33186 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE OUT VALVE - SHORT TO GROUND 3 3 33188 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - OPEN CIRCUIT 3 3 33189 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - SHORT TO GROUND 3 3 33190 ✔ ✔ ✔ ✔ ✔
HORN - OPEN CIRCUIT 3 3 33207 ✔ ✔ ✔ ✔ ✔
3121619 6-129
HORN - SHORT TO BATTERY 3 3 33208 ✔ ✔ ✔ ✔ ✔
HORN - SHORT TO GROUND 3 3 33209 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - OPEN CIRCUIT 3 3 33279 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - SHORT TO BATTERY 3 3 33280 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - SHORT TO GROUND 3 3 33281 ✔ ✔ ✔ ✔ ✔
ALTERNATOR EXCITATION LINE - SHORT TO BATTERY 3 3 33285 ✔ ✔ ✔ ✔ ✔
SWING LEFT VALVE - OPEN CIRCUIT 3 3 33295 ✔ ✔ ✔ ✔ ✔
SWING LEFT VALVE - SHORT TO BATTERY 3 3 33306 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33307 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33308 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33309 ✔ ✔ ✔ ✔ ✔
MAIN LIFT DOWN VALVE - SHORT TO BATTERY 3 3 33310 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33311 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33312 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33313 ✔ ✔ -- ✔ ✔
LIFT UP VALVE - SHORT TO BATTERY 3 3 33329 -- -- -- -- ✔
SWING - CURRENT FEEDBACK READING TOO LOW 3 3 33414 -- -- -- -- ✔
SWING - CURRENT FEEDBACK READING LOST 3 3 33418 -- -- -- -- ✔
JIB LIFT UP OVERRIDE VALVE - SHORT TO GROUND 3 3 33429 -- -- -- ✔ ✔
JIB LIFT UP OVERRIDE VALVE - OPEN CIRCUIT 3 3 33430 -- -- -- ✔ ✔
JIB LIFT UP OVERRIDE VALVE - SHORT TO BATTERY 3 3 33431 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - SHORT TO GROUND 3 3 33432 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - OPEN CIRCUIT 3 3 33433 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - SHORT TO BATTERY 3 3 33434 -- -- -- ✔ ✔
JIB CONTROL VALVE - SHORT TO GROUND 3 3 33435 -- -- -- ✔ ✔
JIB CONTROL VALVE - OPEN CIRCUIT 3 3 33436 -- -- -- ✔ ✔
JIB CONTROL VALVE - SHORT TO BATTERY 3 3 33437 -- -- -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST 3 3 33456 -- -- -- -- ✔
MAIN LIFT FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO 3 3 33457 -- -- -- -- ✔
LOW
TELESCOPE FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST 3 3 33460 -- -- -- -- ✔
TELESCOPE FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO 3 3 33461 -- -- -- -- ✔
LOW
WARM UP VALVE - SHORT TO BATTERY 3 3 33462 -- -- -- -- ✔
WARM UP VALVE - OPEN CIRCUIT 3 3 33463 -- -- -- -- ✔
WARM UP VALVE - SHORT TO GROUND 3 3 33464 -- -- -- -- ✔
6-130 3121619
CHASSIS ENABLE VALVE - SHORT TO BATTERY 3 3 33465 -- -- -- -- ✔
CHASSIS ENABLE VALVE - OPEN CIRCUIT 3 3 33466 -- -- -- -- ✔
CHASSIS ENABLE VALVE - SHORT TO GROUND 3 3 33467 -- -- -- -- ✔
TWO SPEED OR BRAKE VALVE - STUCK OPEN 3 3 33487 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33488 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33489 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33490 -- -- -- -- ✔
LIFT ENABLE VALVE - STUCK OPEN 3 3 33563 -- -- -- -- ✔
COUNTER BALANCE VALVE - STUCK OPEN 3 3 33564 -- -- -- -- ✔
LIFT ENABLE - CURRENT FEEDBACK READING LOST 3 3 33565 -- -- -- -- ✔
LIFT ENABLE - CURRENT FEEDBACK READING TOO LOW 3 3 33566 -- -- -- -- ✔
JIB LOCK VALVE - OPEN CIRCUIT 3 4 3427 -- -- -- ✔ ✔
JIB LOCK VALVE - SHORT TO BATTERY 3 4 3428 -- -- -- ✔ ✔
JIB LOCK VALVE - SHORT TO GROUND 3 4 3429 -- -- -- ✔ ✔
JIB UNLOCK VALVE - OPEN CIRCUIT 3 4 3430 -- -- -- ✔ ✔
JIB UNLOCK VALVE - SHORT TO BATTERY 3 4 3431 -- -- -- ✔ ✔
JIB UNLOCK VALVE - SHORT TO GROUND 3 4 3432 -- -- -- ✔ ✔
PLATFORM LEVEL UP VALVE - SHORT TO GROUND 3 4 343 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 4 344 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND 3 4 347 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 4 348 ✔ ✔ ✔ ✔ ✔
JIB LEVEL UP VALVE - SHORT TO GROUND 3 5 351 -- -- -- ✔ ✔
JIB LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 352 -- -- -- ✔ ✔
JIB LEVEL DOWN VALVE - SHORT TO GROUND 3 5 353 -- -- -- ✔ ✔
JIB LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 354 -- -- -- ✔ ✔
JIB LIFT UP VALVE - SHORT TO GROUND 3 5 355 -- -- -- ✔ ✔
JIB LIFT UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 356 -- -- -- ✔ ✔
JIB LIFT DOWN VALVE - SHORT TO GROUND 3 5 357 -- -- -- ✔ ✔
JIB LIFT DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 358 -- -- -- ✔ ✔
JIB ROTATE LEFT VALVE - SHORT TO GROUND 3 5 359 -- -- -- ✔ ✔
JIB ROTATE LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3510 -- -- -- ✔ ✔
JIB ROTATE RIGHT VALVE - SHORT TO GROUND 3 5 3511 -- -- -- ✔ ✔
JIB ROTATE RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3512 -- -- -- ✔ ✔
JIB TELESCOPE IN VALVE - SHORT TO GROUND 3 5 3513 -- -- -- ✔ ✔
JIB TELESCOPE IN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3514 -- -- -- ✔ ✔
3121619 6-131
JIB TELESCOPE OUT VALVE - SHORT TO GROUND 3 5 3515 -- -- -- ✔ ✔
JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3516 -- -- -- ✔ ✔
FRONT AXLE EXTEND VALVE - SHORT TO BATTERY 3 6 361 -- -- -- -- ✔
FRONT AXLE EXTEND VALVE - SHORT TO GROUND 3 6 362 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - SHORT TO BATTERY 3 6 363 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - SHORT TO GROUND 3 6 364 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - SHORT TO BATTERY 3 6 365 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - SHORT TO GROUND 3 6 366 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - SHORT TO BATTERY 3 6 367 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - SHORT TO GROUND 3 6 368 -- -- -- -- ✔
FRONT AXLE EXTEND VALVE - OPEN CIRCUIT 3 6 369 -- -- -- -- ✔
FRONT AXLE VALVE - CURRENT FEEDBACK READING LOST 3 6 3610 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - OPEN CIRCUIT 3 6 3611 -- -- -- -- ✔
REAR AXLE VALVE - CURRENT FEEDBACK READING LOST 3 6 3612 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - OPEN CIRCUIT 3 6 3613 -- -- -- -- ✔
FRONT AXLE VALVE - CURRENT FEEDBACK READING TOO LOW 3 6 3514 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - OPEN CIRCUIT 3 6 3615 -- -- -- -- ✔
REAR AXLE VALVE - CURRENT FEEDBACK READING TOO LOW 3 6 3616 -- -- -- -- ✔
CHASSIS BRAKE - OPEN CIRCUIT 3 6 3617 -- -- -- -- ✔
CHASSIS BRAKE - SHORT TO BATTERY 3 6 3618 -- -- -- -- ✔
CHASSIS BRAKE - SHORT TO GROUND 3 6 3619 -- -- -- -- ✔
FRONT AXLE VALVE - SHORT TO BATTERY 3 6 3620 -- -- -- -- ✔
REAR AXLE VAVE - SHORT TO BATTERY 3 6 3621 -- -- -- -- ✔
FUEL SENSOR SHORT TO BATTERY 4 3 431 ✔ ✔ ✔ ✔ ✔
FUEL SENSOR SHORT TO GROUND 4 3 432 ✔ ✔ ✔ ✔ ✔
OIL PRESSURE SHORT TO BATTERY 4 3 433 ✔ ✔ ✔ ✔ ✔
OIL PRESSURE SHORT TO GROUND 4 3 434 ✔ ✔ ✔ ✔ ✔
COOLANT TEMPERATURE SHORT TO GROUND 4 3 435 ✔ ✔ ✔ ✔ ✔
ENGINE TROUBLE CODE 4 3 437 ✔ ✔ ✔ ✔ ✔
HIGH ENGINE TEMP 4 3 438 ✔ ✔ ✔ ✔ ✔
AIR FILTER BYPASSED 4 3 439 ✔ ✔ ✔ ✔ ✔
NO ALTERNATOR OUTPUT 4 3 4310 ✔ ✔ ✔ ✔ ✔
LOW OIL PRESSURE 4 3 4311 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR FAILURE 4 3 4313 ✔ ✔ ✔ ✔ ✔
WRONG ENGINE SELECTED - ECM DETECTED 4 3 4314 ✔ ✔ ✔ ✔ ✔
6-132 3121619
LOSS OF ENGINE SPEED SENSOR 4 3 4322 ✔ ✔ ✔ ✔ ✔
SPEED SENSOR READING INVALID SPEED 4 3 4323 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - LOW 4 3 4331 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - HIGH 4 3 4332 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - SEVERE 4 3 4333 ✔ ✔ ✔ ✔ ✔
ENGINE COOLANT - LOW LEVEL 4 3 4334 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN 4 4 441 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN 4 4 442 ✔ ✔ ✔ ✔ ✔
LSS BATTERY VOLTAGE TOO HIGH 4 4 443 ✔ ✔ ✔ ✔ ✔
LSS BATTERY VOLTAGE TOO LOW 4 4 444 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE LOW 4 4 445 ✔ ✔ ✔ ✔ ✔
MAIN LIFT PVG VALVE - INTERNAL FAULT 4 5 451 -- -- ✔ -- --
TOWER LIFT PVG VALVE - INTERNAL FAULT 4 5 452 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - INTERNAL FAULT 4 5 453 -- -- ✔ -- --
MAIN LIFT PVG VALVE - HIGH VOLTAGE 4 5 454 -- -- ✔ -- --
TOWER LIFT PVG VALVE - HIGH VOLTAGE 4 5 455 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE 4 5 456 -- -- ✔ -- --
MAIN LIFT PVG VALVE - LOW VOLTAGE 4 5 457 -- -- ✔ -- --

TOWER LIFT PVG VALVE - LOW VOLTAGE 4 5 458 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - LOW VOLTAGE 4 5 459 -- -- ✔ -- --
MAIN LIFT PVG VALVE - STUCK NEUTRAL 4 5 4510 -- -- ✔ -- --

TOWER LIFT PVG VALVE - STUCK NEUTRAL 4 5 4511 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - STUCK NEUTRAL 4 5 4512 -- -- ✔ -- --
MAIN LIFT PVG VALVE - STUCK EXTENDED 4 5 4513 -- -- ✔ -- --

TOWER LIFT PVG VALVE - STUCK EXTENDED 4 5 4514 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - STUCK EXTENDED 4 5 4515 -- -- ✔ -- --
MAIN LIFT PVG VALVE - STUCK RETRACTED 4 5 4516 -- -- ✔ -- --

TOWER LIFT PVG VALVE - STUCK RETRACTED 4 5 4517 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - STUCK RETRACTED 4 5 4518 -- -- ✔ -- --
MAIN LIFT PVG VALVE - OBSTRUCTED 4 5 4519 -- -- ✔ -- --

TOWER LIFT PVG VALVE - OBSTRUCTED 4 5 4520 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - OBSTRUCTED 4 5 4521 -- -- ✔ -- --
MAIN LIFT PVG VALVE - COMMAND IMPROPER 4 5 4522 -- -- ✔ -- --
3121619 6-133
TOWER LIFT PVG VALVE - COMMAND IMPROPER 4 5 4523 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER 4 5 4524 -- -- ✔ -- --
MAIN LIFT PVG VALVE - TIMEOUT 4 5 4525 -- -- ✔ -- --

TOWER LIFT PVG VALVE - TIMEOUT 4 5 4526 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - TIMEOUT 4 5 4527 -- -- ✔ -- --
MAIN LIFT PVG VALVE - SETUP FAULT 4 5 4528 -- -- ✔ -- --
TOWER LIFT PVG VALVE - SETUP FAULT 4 5 4529 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - SETUP FAULT 4 5 4530 -- -- ✔ -- --
MAIN LIFT PVG VALVE - SENT UNRECOGNIZED FAULT 4 5 4531 -- -- ✔ -- --
TOWER LIFT PVG VALVE - SENT UNRECOGNIZED FAULT 4 5 4532 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - SENT UNRECOGNIZED FAULT 4 5 4533 -- -- ✔ -- --
MAIN LIFT PVG VALVE - PARAMETERS INCORRECT 4 5 4534 -- -- ✔ -- --
TOWER LIFT PVG VALVE - PARAMETERS INCORRECT 4 5 4535 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - PARAMETERS INCORRECT 4 5 4536 -- -- ✔ -- --
MAIN LIFT PVG VALVE - LOCATION IMPROPER 4 5 4537 -- -- ✔ -- --

TOWER LIFT PVG VALVE - LOCATION IMPROPER 4 5 4538 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - LOCATION IMPROPER 4 5 4539 -- -- ✔ -- --
MAIN LIFT PVG VALVE - WIRING INCORRECT 4 5 4540 -- -- ✔ -- --

TOWER LIFT PVG VALVE - WIRING INCORRECT 4 5 4541 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - WIRING INCORRECT 4 5 4542 -- -- ✔ -- --
MAIN LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL 4 5 4543 -- -- ✔ -- --
TOWER LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL 4 5 4544 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - SPOOL CANNOT REACH NEUTRAL 4 5 4545 -- -- ✔ -- --
CANBUS FAILURE - PLATFORM MODULE 6 6 662 ✔ ✔ ✔ ✔ ✔

CANBUS FAILURE - LOAD SENSING SYSTEM MODULE 6 6 663 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - ENGINE CONTROLLER 6 6 666 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - MAIN LIFT PVG 6 6 667 -- -- ✔ -- --
CANBUS FAILURE - TOWER LIFT PVG 6 6 668 -- -- ✔ -- --
CANBUS FAILURE - TOWER TELESCOPE PVG 6 6 669 -- -- ✔ -- --
6-134 3121619
CANBUS FAILURE - BLAM 6 6 6610 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - CHASSIS MODULE 6 6 6611 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - CYLINDER LOAD PIN 6 6 6612 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - EXCESSIVE CANBUS ERRORS 6 6 6613 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - MAIN ANGLE SENSOR #1 6 6 6614 -- -- ✔ -- --
CANBUS FAILURE - MAIN ANGLE SENSOR #2 6 6 6615 -- -- ✔ -- --
CANBUS FAILURE - TCU MODULE 6 6 6622 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - TELEMATICS CANBUS LOADING TOO HIGH 6 6 6629 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - GATEWAY MODULE 6 6 6623 ✔ ✔ ✔ ✔ ✔

CANBUS FAILURE - JIB CONTROL MODULE 6 6 6639 -- -- -- ✔ ✔
CANBUS FAILURE - JIB LIFT ANGLE SENSOR 6 6 6640 -- -- -- ✔ ✔
CANBUS FAILURE - PLATFORM LEVEL ANGLE SENSOR 6 6 6641 -- -- -- ✔ ✔
REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP 6 8 681 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR NOT CALIBRATED 8 1 813 ✔ ✔ ✔ ✔ ✔

CHASSIS TILT SENSOR OUT OF RANGE 8 1 814 -- -- -- -- ✔
CHASSIS TILT SENSOR DISAGREEMENT 8 1 815 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT READING DISAGREEMENT 8 1 8111 -- -- -- -- ✔
LSS CELL #1 ERROR 8 2 821 ✔ ✔ ✔ ✔ ✔
LSS CELL #2 ERROR 8 2 822 ✔ ✔ ✔ ✔ ✔
LSS CELL #3 ERROR 8 2 823 ✔ ✔ ✔ ✔ ✔
LSS CELL #4 ERROR 8 2 824 ✔ ✔ ✔ ✔ ✔
LSS HAS NOT BEEN CALIBRATED 8 2 825 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - PLATFORM OVERLOADED 8 2 826 ✔ ✔ ✔ ✔ ✔
DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED 8 2 827 ✔ ✔ ✔ ✔ ✔
LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED 8 2 828 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING OVERRIDE ON 8 3 831 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING OVERRIDE OFF 8 3 832 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED 8 3 833 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED 8 3 834 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY 8 3 8311 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT 8 3 8312 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE 8 3 8313 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE 8 3 8314 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING SENSOR - DISAGREEMENT 8 3 8315 ✔ ✔ ✔ ✔ ✔
3121619 6-135
PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST 8 3 8316 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST 8 3 8317 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING SYSTEM TIMEOUT 8 3 8318 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY 8 3 837 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT 8 3 838 ✔ ✔ ✔ ✔ ✔
JIB LEVEL SENSOR #1 - OUT OF RANGE LOW 8 3 8319 -- -- -- ✔ ✔
JIB LEVEL SENSOR #1 - OUT OF RANGE HIGH 8 3 8320 -- -- -- ✔ ✔
JIB LEVEL SENSOR #2 - OUT OF RANGE LOW 8 3 8321 -- -- -- ✔ ✔
JIB LEVEL SENSOR #2 - OUT OF RANGE HIGH 8 3 8322 -- -- -- ✔ ✔
JIB LEVEL SENSORS - NOT CALIBRATED 8 3 8323 -- -- -- ✔ ✔
JIB LEVEL SENSORS - DISAGREEMENT 8 3 8324 -- -- -- ✔ ✔
JIB SWING SENSOR #1 - OUT OF RANGE LOW 8 3 8325 -- -- -- ✔ ✔
JIB SWING SENSOR #1 - OUT OF RANGE HIGH 8 3 8326 -- -- -- ✔ ✔
JIB SWING SENSOR #2 - OUT OF RANGE LOW 8 3 8327 -- -- -- ✔ ✔
JIB SWING SENSOR #2 - OUT OF RANGE HIGH 8 3 8328 -- -- -- ✔ ✔
JIB SWING SENSORS - NOT CALIBRATED 8 3 8329 -- -- -- ✔ ✔
JIB SWING SENSORS - DISAGREEMENT 8 3 8330 -- -- -- ✔ ✔
JIB LOCK PIN SENSOR - DISAGREEMENT 8 3 8331 -- -- -- ✔ ✔
JIB TRANSPORT SENSOR #1 - DISAGREEMENT 8 3 8332 -- -- -- ✔ ✔
JIB TRANSPORT SENSOR #2 - DISAGREEMENT 8 3 8333 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - NOT CALIBRATED 8 3 8334 -- -- -- ✔ ✔
JIB LEVEL UP CRACKPOINT - NOT CALIBRATED 8 3 8335 -- -- -- ✔ ✔
JIB LEVEL DOWN CRACKPOINT - NOT CALIBRATED 8 3 8336 -- -- -- ✔ ✔
JIB LEVELING SYSTEM TIMEOUT 8 3 8337 -- -- -- ✔ ✔
WRONG JIB LOCK PIN RESPONSE 8 3 8338 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - NOT CALIBRATED 8 3 8339 -- -- -- ✔ ✔
BOOM ANGLE SENSOR DISAGREEMENT 8 4 841 ✔ ✔ -- ✔ ✔
BOOM LENGTH SWITCH FAILED 8 4 842 ✔ ✔ -- ✔ ✔
BOOM LENGTH SWITCH/SENSOR DISAGREEMENT 8 4 843 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE 8 4 844 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - OUT OF RANGE HIGH 8 4 845 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - OUT OF RANGE LOW 8 4 846 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH 8 4 847 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW 8 4 848 ✔ ✔ -- ✔ ✔
BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT 8 4 849 ✔ ✔ ✔ ✔ ✔
6-136 3121619
BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT 8 4 8410 ✔ ✔ ✔ ✔ ✔
BOOM ANGLE SENSOR #1 - INVALID ANGLE 8 4 8411 ✔ ✔ -- ✔ ✔
BOOM ANGLE SENSOR #2 - INVALID ANGLE 8 4 8412 ✔ ✔ -- ✔ ✔
WRONG TELESCOPE RESPONSE 8 4 8413 ✔ ✔ -- ✔ ✔
WRONG LIFT RESPONSE 8 4 8414 ✔ ✔ -- ✔ ✔
TOWER ANGLE SENSOR DISAGREEMENT 8 4 8415 -- -- ✔ -- --
TOWER LENGTH SENSOR DISAGREEMENT 8 4 8416 -- -- ✔ -- --
MAIN ANGLE SENSOR DISAGREEMENT 8 4 8417 -- -- ✔ -- --
TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH 8 4 8418 -- -- ✔ -- --
TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW 8 4 8419 -- -- ✔ -- --
TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE 8 4 8422 -- -- ✔ -- --
TOWER LENGTH MOVEMENT WITHOUT COMMAND 8 4 8423 -- -- ✔ -- --
TOWER ANGLE SENSOR #1 - INVALID ANGLE 8 4 8428 -- -- ✔ -- --
TOWER ANGLE SENSOR #2 - INVALID ANGLE 8 4 8429 -- -- ✔ -- --
TOWER ANGLE SENSOR #1 - INVALID MODEL 8 4 8430 -- -- ✔ -- --
TOWER ANGLE SENSOR #2 - INVALID MODEL 8 4 8431 -- -- ✔ -- --
MAIN ANGLE SENSOR #1 - INVALID ANGLE 8 4 8432 -- -- ✔ -- --
MAIN ANGLE SENSOR #2 - INVALID ANGLE 8 4 8433 -- -- ✔ -- --
MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE 8 4 8434 -- -- ✔ -- --
MAIN ANGLE MOVEMENT WITHOUT CMD 8 4 8435 -- -- ✔ -- --
WRONG TOWER TELESCOPE RESPONSE 8 4 8436 -- -- ✔ -- --
WRONG TOWER LIFT RESPONSE 8 4 8437 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH 8 4 8438 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW 8 4 8439 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE 8 4 8440 -- -- ✔ -- --
TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND 8 4 8441 -- -- ✔ -- --
MAIN TRANSPORT ANGLE SWITCH FAILED 8 4 8442 -- -- ✔ -- --
TWR TRANSPORT SWITCH DISAGREEMENT 8 4 8443 -- -- ✔ -- --
TRANSPORT DUAL CAPACITY SWITCHES BAD 8 4 8444 -- -- ✔ -- --
3121619 6-137
TRANSPORT DUAL CAPACITY BAD TRANSITION 8 4 8445 -- -- ✔ -- --
MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT 8 4 8446 -- -- ✔ -- --
MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT 8 4 8447 -- -- ✔ -- --
MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT 8 4 8448 -- -- ✔ -- --
TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT 8 4 8449 -- -- ✔ -- --
NEW MAIN ANGLE SENSOR #1 DETECTED 8 4 8450 -- -- ✔ -- --
NEW MAIN ANGLE SENSOR #2 DETECTED 8 4 8451 -- -- ✔ -- --
TOWER LENGTH SWITCH/SENSOR DISAGREEMENT 8 4 8452 -- -- ✔ -- --
WRONG MAIN TELE RESPONSE 8 4 8453 -- -- ✔ -- --
WRONG MAIN LIFT RESPONSE 8 4 8454 -- -- ✔ -- --
MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE LOW 8 4 8479 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE HIGH 8 4 8480 -- -- -- ✔ ✔
TOWER ENVELOPE MASSIVELY ENCROACHED 8 4 8482 -- -- ✔ -- --
TOWER ENVELOPE MULTIPLE ENCROACHMENTS 8 4 8483 -- -- ✔ -- --
BCS VIOLATION - BOOM LOCKED 8 4 8484 -- -- ✔ -- --
BCS - HYDRAULIC RETRIEVAL ACTIVE 8 4 8485 -- -- ✔ -- --
BCS - ELECTRICAL RETRIEVAL ACTIVE 8 4 8486 -- -- ✔ -- --
BCS - MULTIPLE FAILURES ACTIVE 8 4 8487 -- -- ✔ -- --
MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE LOW 8 4 8492 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE HIGH 8 4 8493 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSORS - DISAGREEMENT 8 4 8494 -- -- -- ✔ ✔
TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE LOW 8 4 8495 -- -- -- ✔ ✔
TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE HIGH 8 4 8496 -- -- -- ✔ ✔
TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE LOW 8 4 8497 -- -- -- ✔ ✔
TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE HIGH 8 4 8498 -- -- -- ✔ ✔
CHASSIS TURN TABLE SENSORS - DISAGREEMENT 8 4 8499 -- -- -- ✔ ✔
CHASSIS TURN TABLE SENSORS AND DRIVE ORIENTATION SWITCH - DIS- 8 4 84100 -- -- -- ✔ ✔
AGREEMENT
CHASSIS TURN TABLE SENSORS - NOT CALIBRATED 8 4 84101 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84102 -- -- -- ✔ ✔
JIB LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84103 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84104 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84105 -- -- -- ✔ ✔
JIB LEVEL MOVEMENT WITHOUT COMMAND 8 4 84106 -- -- -- ✔ ✔
JIB LIFT MOVEMENT WITHOUT COMMAND 8 4 84107 -- -- -- ✔ ✔
PLATFORM LEVEL MOVEMENT WITHOUT COMMAND 8 4 84108 -- -- -- ✔ ✔
6-138 3121619
WRONG SWING RESPONSE 8 4 84109 -- -- -- -- ✔
MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE 8 5 851 ✔ ✔ -- ✔ ✔
MOMENT PIN - VERTICAL FORCE OUT OF RANGE 8 5 852 ✔ ✔ -- ✔ ✔
LOAD PIN - HORIZONTAL FORCE OUT OF RANGE 8 5 853 -- -- ✔ -- --
LOAD PIN - VERTICAL FORCE OUT OF RANGE 8 5 854 -- -- ✔ -- --
MOMENT PIN - SENSOR FAULT 8 5 855 ✔ ✔ -- ✔ ✔
LOAD PIN - SENSOR FAULT 8 5 856 -- -- ✔ -- --
NEW MOMENT PIN DETECTED 8 5 857 ✔ ✔ -- ✔ ✔
NEW LOAD PIN DETECTED 8 5 858 -- -- ✔ -- --
LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT 8 5 859 -- -- ✔ -- --
LOAD PIN - FORCE VALUES NOT CHANGING 8 5 8510 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE 8 5 8511 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE 8 5 8512 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION 8 5 8513 -- -- ✔ -- --
RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- 8 6 861 ✔ ✔ ✔ ✔ ✔
AGREEMENT
AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 862 ✔ ✔ ✔ ✔ --
AXLE EXTEND VALVE - SHORT TO GROUND 8 6 863 ✔ ✔ ✔ ✔ --
AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 864 ✔ ✔ ✔ ✔ --
AXLE RETRACT VALVE - SHORT TO GROUND 8 6 865 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 866 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND 8 6 867 ✔ ✔ ✔ ✔ ✔
RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 868 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND 8 6 869 ✔ ✔ ✔ ✔ ✔
LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8610 ✔ ✔ ✔ ✔ --
LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND 8 6 8611 ✔ ✔ ✔ ✔ ✔
LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8612 ✔ ✔ ✔ ✔ --
LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND 8 6 8613 ✔ ✔ ✔ ✔ ✔
RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8614 ✔ ✔ ✔ ✔ --
RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND 8 6 8615 ✔ ✔ ✔ ✔ ✔
RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8616 ✔ ✔ ✔ ✔ --
RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND 8 6 8617 ✔ ✔ ✔ ✔ ✔
LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8618 ✔ ✔ ✔ ✔ --
LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND 8 6 8619 ✔ ✔ ✔ ✔ ✔
LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8620 ✔ ✔ ✔ ✔ --
LEFT REAR STEER LEFT VALVE - SHORT TO GROUND 8 6 8621 ✔ ✔ ✔ ✔ ✔
3121619 6-139
FRONT RIGHT STEER SENSOR - DECOUPLED 8 6 8622 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - DECOUPLED 8 6 8623 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - DECOUPLED 8 6 8624 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - DECOUPLED 8 6 8625 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - NOT RESPONDING 8 6 8626 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - NOT RESPONDING 8 6 8627 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - NOT RESPONDING 8 6 8628 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - NOT RESPONDING 8 6 8629 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8630 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - SHORT TO BATTERY 8 6 8631 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8632 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - SHORT TO BATTERY 8 6 8633 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8634 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - SHORT TO BATTERY 8 6 8635 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8636 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - SHORT TO BATTERY 8 6 8637 ✔ ✔ ✔ ✔ ✔
ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT 8 6 8651 ✔ ✔ ✔ ✔ ✔
RIGHT FRONT STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8670 -- -- -- -- ✔
RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8671 -- -- -- -- ✔
RIGHT FRONT STEER LEFT VALVE - OPEN CIRCUIT 8 6 8672 -- -- -- -- ✔
RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY 8 6 8673 -- -- -- -- ✔
LEFT FRONT STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8674 -- -- -- -- ✔
LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8675 -- -- -- -- ✔
LEFT FRONT STEER LEFT VALVE - OPEN CIRCUIT 8 6 8676 -- -- -- -- ✔
LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY 8 6 8677 -- -- -- -- ✔
RIGHT REAR STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8678 -- -- -- -- ✔
RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8679 -- -- -- -- ✔
RIGHT REAR STEER LEFT VALVE - OPEN CIRCUIT 8 6 8680 -- -- -- -- ✔
RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY 8 6 8681 -- -- -- -- ✔
LEFT REAR STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8682 -- -- -- -- ✔
LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8683 -- -- -- -- ✔
LEFT REAR STEER LEFT VALVE - OPEN CIRCUIT 8 6 8684 -- -- -- -- ✔
LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY 8 6 8685 -- -- -- -- ✔
FRONT LEFT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8686 -- -- -- -- ✔
FRONT RIGHT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8687 -- -- -- -- ✔
6-140 3121619
REAR RIGHT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8688 -- -- -- -- ✔
REAR LEFT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8689 -- -- -- -- ✔
MACHINE SAFTEY SYSTEM OVERRIDE OCCURRED 8 7 873 -- -- -- -- ✔
LSS WATCHDOG RESET 9 9 991 ✔ ✔ ✔ ✔ ✔
LSS EEPROM ERROR 9 9 992 ✔ ✔ ✔ ✔ ✔
LSS INTERNAL ERROR - PIN EXCITATION 9 9 993 ✔ ✔ ✔ ✔ ✔
LSS INTERNAL ERROR - DRDY MISSING FROM A/D 9 9 994 ✔ ✔ ✔ ✔ ✔
EEPROM FAILURE - CHECK ALL SETTINGS 9 9 998 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER 9 9 9911 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION 9 9 9910 ✔ ✔ ✔ ✔ ✔
IMPROPER
PLATFORM MODULE SOFTWARE UPDATE REQUIRED 9 9 9914 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR NOT GAIN CALIBRATED 9 9 9915 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR GAIN OUT OF RANGE 9 9 9916 ✔ ✔ ✔ ✔ ✔
HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST 9 9 9917 ✔ ✔ ✔ ✔ ✔
HIGH RESOLUTION A2D FAILURE - REINIT LIMIT 9 9 9918 ✔ ✔ ✔ ✔ ✔
GROUND SENSOR REF VOLTAGE OUT OF RANGE 9 9 9919 ✔ ✔ ✔ ✔ ✔
PLATFORM SENSOR REF VOLTAGE OUT OF RANGE 9 9 9920 ✔ ✔ ✔ ✔ ✔
GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY 9 9 9921 ✔ ✔ ✔ ✔ ✔
PLATFORM MODULE FAILURE - HWFS CODE 1 9 9 9922 ✔ ✔ ✔ ✔ ✔
GROUND MODULE FAILURE - HWFS CODE 1 9 9 9923 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED 9 9 9924 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION 9 9 9925 ✔ ✔ ✔ ✔ ✔
IMPROPER
FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION 9 9 9926 ✔ ✔ ✔ ✔ ✔
IMPROPER
GROUND MODULE CONSTANT DATA UPDATE REQUIRED 9 9 9927 ✔ ✔ ✔ ✔ ✔
ENVELOPE CONTROL DISABLED 9 9 9928 ✔ ✔ ✔ ✔ ✔
MOMENT CONTROL DISABLED 9 9 9929 ✔ ✔ ✔ ✔ ✔
STEER SENSORS NOT CALIBRATED 9 9 9930 ✔ ✔ ✔ ✔ ✔
BOOM SENSORS NOT CALIBRATED 9 9 9931 ✔ ✔ ✔ ✔ ✔
LIFT CRACKPOINTS NOT CALIBRATED 9 9 9932 ✔ ✔ -- ✔ ✔
TELESCOPE CRACKPOINTS NOT CALIBRATED 9 9 9933 ✔ ✔ -- ✔ ✔
DRIVE CRACKPOINTS NOT CALIBRATED 9 9 9934 ✔ ✔ ✔ ✔ ✔
BLAM SENSOR SUPPLY OUT OF RANGE HIGH 9 9 9935 ✔ ✔ ✔ ✔ ✔
BLAM SENSOR SUPPLY OUT OF RANGE LOW 9 9 9936 ✔ ✔ ✔ ✔ ✔
LENGTH SENSOR REF VOLTAGE HIGH 9 9 9937 ✔ ✔ ✔ ✔ ✔
3121619 6-141
LENGTH SENSOR REF VOLTAGE LOW 9 9 9938 ✔ ✔ ✔ ✔ ✔
BLAM HIGH RES A/D FAILURE 9 9 9939 ✔ ✔ ✔ ✔ ✔
CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH 9 9 9940 ✔ ✔ ✔ ✔ ✔
CHASSIS SENSOR SUPPLY OUT OF RANGE LOW 9 9 9941 ✔ ✔ ✔ ✔ ✔
BLAM BACKUP COMMUNICATIONS LINK FAULTY 9 9 9942 -- -- ✔ -- --
BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED 9 9 9943 -- -- ✔ -- --
CURRENT FEEDBACK GAINS OUT OF RANGE 9 9 9944 ✔ ✔ ✔ ✔ ✔
CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT 9 9 9945 ✔ ✔ ✔ ✔ ✔
LOAD PIN NOT CALIBRATED 9 9 9975 -- -- ✔ -- --
LSS CORRUPT EEPROM 9 9 9977 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION 9 9 9979 ✔ ✔ ✔ ✔ ✔
IMPROPER
JIB CONTROL MODULE - HIGH RESOLUTION A2D FAILURE 9 9 99155 -- -- -- ✔ ✔
JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE LOW 9 9 99156 -- -- -- ✔ ✔
JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE HIGH 9 9 99157 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - INTERNAL ERROR 9 9 99158 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - INTERNAL ERROR 9 9 99159 -- -- -- ✔ ✔
FUNCTIONS LOCKED OUT - JIB CONTROL MODULE SOFTWARE VERSION 9 9 99160 -- -- -- ✔ ✔
IMPROPER
6-142 3121619
Table 6-13. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
1 0 1 EVERYTHING OK The normal help message in Platform
Mode.
2 0 2 GROUND MODE OK The normal help message in Ground Mode.
10 0 10 RUNNING AT CUTBACK - OUT OF TRANSPORT Drive speed is limited to "ELEVATED MAX"
POSITION while the vehicle is out of transport posi-
tion.
49 0 0 SCR CLEANING REQUIRED SCR Cleaning for regular maintenance
(engine controlled)
50 0 0 BOOM UNLOCK REQUIRED Triggers if machine is 1850SJ and DTC 23127
and DTC 8413 become active
0 0 0 <<< HELP COMMENT >>>
11 0 11 FSW OPEN A drive / boom function was selected with
the Footswitch open.
12 0 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
13 0 13 RUNNING AT CREEP - TILTED AND ABOVE All functions at creep while the Platform is
ELEVATION elevated and the Chassis is tilted.
14 0 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 degrees for more - Not reported during power-up.
then 4 seconds.
0015 0 15 LOAD SENSOR READING UNDER WEIGHT LSS has been calibrated and the UGM has Ensure platform is not resting on the ground or is not
determined that the load sensing system leveled at an extreme negative angle.
reading is less than -50lbs for 2 seconds. If
the load sensing system determines that Re-calibrate the load sensing system if the above
the reading is greater than -50lbs for 5 sec- items are not a factor.
onds this fault will no longer be annunci-
ated.
No control system interlocks present when

DTC is active.
16 0 16 ENVELOPE ENCROACHED - HYDRAULICS There is an envelope violation. - Envelope control system equipped vehicle only.
SUSPENDED
17 0 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment violation. - Envelope control system equipped vehicle only.
18 0 18 UNDER MOMENT - HYDRAULICS SUS- There is an under moment violation. - Envelope control system equipped vehicle only.
PENDED
21 0 21 ADS 1213 REINITIALIZED
30 0 30 RUNNING AT CREEP - PLATFORM STOWED
31 0 31 FUEL LEVEL LOW - ENGINE SHUTDOWN
35 0 35 APU ACTIVE
37 0 37 JIB UNLOCKED OUT OF TRANSPORT -
HYDRAULICS SUSPENDED
38 0 38 SWING ENVELOPE ENCROACHED - HYDRAU-
LICS SUSPENDED
0039 0 0 SKYGUARD ACTIVE - FUNCTIONS CUTOUT The SkyGuard sensors have been activated.
Fault cleared when controls returned to
neutral and SkyGuard is no longer active.
210 2‘ 1 <<< POWER-UP >>>
3121619 6-143
Flash
Code
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 simultaneously.
213 2 1 FSW FAULTY Both Footswitches are closed for more then
one second.
220 22 0 <<< PLATFORM CONTROLS >>>
227 2 2 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are
closed simultaneously.
2211 2 2 FSW INTERLOCK TRIPPED The Footswitch was closed for more then - Can be reported during power- up.
seven seconds.
2212 2 2 DRIVE LOCKED - JOYSTICK MOVED BEFORE A drive function was selected with Foot- - Can be reported during power- up.
FOOTSWITCH switch open.
2213 2 2 STEER LOCKED - SELECTED BEFORE FOOT- A steer function was selected with Foot-
SWITCH switch open.
2215 2 2 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference voltage is low. - Resistive joysticks, these faults do not occur.
2216 2 2 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference voltage is > - Resistive joysticks.
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 voltage is < - Resistive joysticks.
3.08V or > 3.83V. - There is a +/- .1V range. around these values due to
resistor tolerances
2218 2 2 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference voltage is low. - Resistive joysticks, these faults do not occur.
2219 2 2 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference voltage is > - Resistive joysticks.
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 voltage is < - Resistive joysticks.
3.08V or > 3.83V. - There is a +/- .1V range. around these values due to
resistor tolerances
2221 2 2 LIFT/SWING LOCKED - JOYSTICK MOVED A lift / swing function was selected with
BEFORE FOOTSWITCH Footswitch open.
2222 2 2 WAITING FOR FSW TO BE OPEN The Footswitch was closed during Platform - Can be reported during power- up.
selection.
2223 2 2 FUNCTION SWITCHES LOCKED - SELECTED A boom function was selected with Foot-
BEFORE ENABLE switch open.
2224 2 2 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed during engine
start.
2286 2 2 FUNCTION PROBLEM - SOFT TOUCH/SKY- The Soft Touch/SkyGuard Override swtich is Check wiring and switch
GUARD OVERRIDE PERMANENTLY SELECTED engaged during system power up and Soft
Touch or SkyGuard is turned on in Machine
Setup. Fault cleared when switch is no lon-
ger enageged
230 2 0 <<<Ground Inputs >>>
23124 2 3 LIFT PRESSURE SENSOR - OUT OF RANGE Pressure transducer sensor voltage output Check sensor hardware and wiring
LOW < 0.4V for 240ms
6-144 3121619
Flash
Code
23125 2 3 LIFT PRESSURE SENSOR - OUT OF RANGE Pressure transducer sensor voltage output Check sensor hardware and wiring
HIGH > 4.5V for 240ms
23126 2 3 LIFT PRESSURE SENSOR - NOT DETECTING Lift down is commanded and pressure does Check sensor hardware and wiring
CHANGE not change by 20psi within 10seconds. This
is only evaluated when rod-side pressure
starts out below a threshold value
23127 2 3 LIFT CYLINDER - OVER PRESSURE At the end of a lift up event if pressure is Check lift cylinder seal across piston, fault detects a
greater than 2200 psi for 3seconds hardware failure
23128 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure sensor voltage output < 0.4V for Check sensor hardware and wiring
OUT OF RANGE LOW 240ms
23129 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure sensor voltage output > 4.5V for Check sensor hardware and wiring
OUT OF RANGE HIGH 240ms
23130 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure transducer reads > 3250 psi for 2 Check sensor hardware and wiring and check relief
HIGH seconds while main dump valve energized setttings
and engine is running
23131 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure transducer reads < 1500 psi for 2 Check sensor hardware and wiring and check relief
LOW seconds while main dump valve energized setttings
and engine is running
23253 2 3 MACHINE SETUP WIRING - ERROR An issue with the machine setup wiring has Check wiring on UGM J3-11 and BLAM J2-7 against
been detected. Electrical Schematic applicable to machine manufac-
turing date. Analyzer also provides status of the inputs
Fault cleared once issue resolved. under DIAGNOSTICS --> SYSTEM --> SETUP CONFIG 1
and DIAGNOSTICS --> SYSTEM --> SETUP CONFIG 2
(LOW = Open Circuit, HIGH = Closed Circuit)
240 24 0 <<< OTHER CONTROLS >>>
250 25 0 <<< FUNCTION PREVENTED >>>
259 2 5 MODEL CHANGED - HYDRAULICS SUS- The model selection has been changed.
PENDED - CYCLE EMS
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 oper-
ation.
2515 2 5 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the vehicle
above elevation AND is configured to pre-
vent drive while above elevation.
2516 2 5 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom func-
tions are selected AND is configured to not
allow simultaneous drive & boom opera-
tion.
2517 2 5 DRIVE PREVENTED - TILTED & ABOVE ELEVA- Driving is not possible while the vehicle is
TION tilted and above elevation AND is config-
ured to prevent 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.
3121619 6-145
Flash
Code
2522 2 5 CAN DONGLE ATTACHED - HYDRAULICS NOT CAN Dongle attached. Very limited restric-
RESTRICTED tions for all hydraulics systems.
2546 2 5 MACHINE SETUP FAULT - JIB SWING
2547 2 5 MACHINE SETUP FAULT - MODEL
2563 2 5 SKYGUARD SWITCH - DISAGREEMENT The UGM detects that Skyguard Input 1 and Check wiring, verify wiring to relays and relays are
Skyguard Input 2 states do not match for working correctly.
more than 160ms. Fault is cleared when
Skyguard input 1 and Skyguard Input 2
must match and controls are returned to
neutral.
2549 2 5 DRIVE & BOOM PREVENTED - SOFT TOUCH The Soft Touch sensor has been activated.
ACTIVE Fault cleared once controls are returned to
neutral and Soft Touch is not active.
2587 2 5 RUNNING AT CREEP - PLATFORM LEVELED The UGM has detected the platform is in the Level platform
UNDER leveled under position. Fault cleared when
platform is returned to level.
260 26 0 <<<Chassis Inputs >>>
261 2 6 FRONT LEFT AXLE SWING SENSOR - VOLTAGE Sensor output < 0.1V Check sensor hardware and wiring
OUT OF RANGE LOW
262 2 6 FRONT LEFT AXLE SWING SENSOR - VOLTAGE Sensor output >4.9V Check sensor hardware and wiring
OUT OF RANGE HIGH
263 2 6 FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output < 0.1V Check sensor hardware and wiring
AGE OUT OF RANGE LOW
264 2 6 FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output >4.9V Check sensor hardware and wiring
AGE OUT OF RANGE HIGH
265 2 6 REAR LEFT AXLE SWING SENSOR - VOLTAGE Sensor output < 0.1V Check sensor hardware and wiring
OUT OF RANGE LOW
266 2 6 REAR LEFT AXLE SWING SENSOR - VOLTAGE Sensor output >4.9V Check sensor hardware and wiring
OUT OF RANGE HIGH
267 2 6 REAR RIGHT AXLE SWING SENSOR - VOLT- Sensor output < 0.1V Check sensor hardware and wiring
AGE OUT OF RANGE LOW
268 2 6 REAR RIGHT AXLE SWING SENSOR - VOLT- Sensor output >4.9V Check sensor hardware and wiring
AGE OUT OF RANGE HIGH
269 2 6 REAR LEFT AXLE RETRACT SWITCH - Check sensor hardware and wiring
DISAGREEMENT
2610 2 6 REAR RIGHT AXLE RETRACT SWITCH - Check sensor hardware and wiring
DISAGREEMENT
2611 2 6 FRONT LEFT AXLE SENSOR - NOT RESPOND- < 0.4deg travel detected for 5 seconds with Check sensor hardware and wiring
ING a deploy or retract command
2612 2 6 FRONT RIGHT AXLE SENSOR - NOT Check sensor hardware and wiring
RESPONDING
2613 2 6 REAR LEFT AXLE SENSOR - NOT RESPONDING Check sensor hardware and wiring
2614 2 6 REAR RIGHT AXLE SENSOR - NOT RESPOND- Check sensor hardware and wiring
ING
2615 2 6 AXLE RETRACT POSITION - NOT CALIBRATED Axles are not calibrated Calibrate axles
2616 2 6 AXLE DEPLOY POSITION - NOT CALIBRATED Axles are not calibrated Calibrate axles
330 3 3 <<< GROUND OUTPUT DRIVER >>>
6-146 3121619
Flash
Code
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 - Ground Alarm equipped vehicles only.
Alarm.
3316 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Right Forward Drive Valve.
3317 3 3 RIGHT FORWARD DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Right Forward Drive Valve.
3318 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Right Forward Drive Valve.
3320 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Right Reverse Drive Valve.
3321 3 3 RIGHT REVERSE DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Right Reverse Drive Valve.
3322 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Right Reverse Drive Valve.
3324 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Left Forward Drive Valve.
3325 3 3 LEFT FORWARD DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Left Forward Drive Valve.
3326 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Left Forward Drive Valve.
3328 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Left Reverse Drive Valve.
3329 3 3 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehicles only.
Left Reverse Drive Valve.
3330 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO BAT- There is a Short to Battery to the - Chassis Module equipped vehicles only.
TERY Left Reverse Drive Valve.
3336 3 3 ALTERNATOR/ECM POWER - SHORT TO There is a Short to Ground to the
GROUND Alternator/ECM.
3338 3 3 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
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 There is a Short to Ground to the - CAT engines only.
TO GROUND Cold Start Advance Solenoid.
3344 3 3 COLD START ADVANCE SOLENOID - OPEN There is an Open Circuit to the - CAT engines only.
CIRCUIT Cold Start Advance Solenoid.
3345 3 3 COLD START ADVANCE SOLENOID - SHORT There is a Short to Battery to the - CAT engines only.
TO BATTERY Cold Start Advance Solenoid.
3121619 6-147
Flash
Code
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 - Ground Alarm equipped vehicles only.
Alarm.
3372 3 3 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground - Ground Alarm equipped vehicles only.
Alarm.
3373 3 3 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the Generator - Generator / Welder equipped vehicles only.
Relay.
3374 3 3 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator - Generator / Welder equipped vehicles only.
Relay.
3375 3 3 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the Generator - Generator / Welder equipped vehicles only.
Relay.
3376 3 3 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the Head Light - Head Light equipped vehicles only.
Relay.
3377 3 3 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the Head Light - Head Light equipped vehicles only.
Relay.
3378 3 3 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the Head Light - Head Light equipped vehicles only.
Relay.
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 Hour Meter. - Can be reported during power- up.
3381 3 3 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the Hour
Meter.
6-148 3121619
Flash
Code
3385 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO GROUND Level Up Override Valve.
3386 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - There is an Open Circuit to the Platform - Electronic leveling system equipped vehicles only.
OPEN CIRCUIT Level Up Override Valve.
3387 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO BATTERY Level Up Override Valve.
3391 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO GROUND Level Down Override Valve.
3392 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is an Open Circuit to the Platform - Electronic leveling system equipped vehicles only.
OPEN CIRCUIT Level Down Override Valve.
3393 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO BATTERY Level Down Override Valve.
3394 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO There is a Short to Ground to the Platform
GROUND Rotate Left Valve.
3395 3 3 PLATFORM ROTATE LEFT VALVE - OPEN CIR- There is an Open Circuit to the Platform
CUIT Rotate Left Valve.
3396 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO There is a Short to Battery to the Platform
BATTERY Rotate Left Valve.
3397 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO There is a Short to Ground to the Platform
GROUND Rotate Right Valve.
3398 3 3 PLATFORM ROTATE RIGHT VALVE - OPEN There is an Open Circuit to the Platform
CIRCUIT Rotate Right Valve.
3399 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO There is a Short to Battery to the Platform
BATTERY Rotate Right Valve.
33120 3 3 MAIN TELESCOPE IN VALVE - SHORT TO BAT- There is a Short to Battery to the Main Tele-
TERY scope In Valve.
33123 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO There is a Short to Battery to the Main Tele-
BATTERY scope 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 Actu-
ator.
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 There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
GROUND Control Valve.
33134 3 3 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Con- - Electronic leveling system equipped vehicles only.
trol Valve.
33135 3 3 PLATFORM CONTROL VALVE - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Control Valve.
33150 3 3 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
33151 3 3 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
33152 3 3 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
3121619 6-149
Flash
Code
33153 3 3 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33154 3 3 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33155 3 3 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33159 3 3 MAIN LIFT ENABLE VALVE - SHORT TO Short to Ground detected Check wiring
GROUND
33160 3 3 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33173 3 3 RESTRICTED TO TRANSPORT - AXLE LOCK- There is a Short to Battery or an Open Circuit
OUT VALVE - SHORT TO BATTERY OR OPEN to the Axle Lockout Valve.
CIRCUIT
33174 3 3 RESTRICTED TO TRANSPORT - BRAKE - There is a Short to Battery or an Open Circuit
SHORT TO BATTERY OR OPEN CIRCUIT to the Brake.
33182 3 3 LIFT VALVES - SHORT TO BATTERY
33186 3 3 MAIN TELESCOPE OUT VALVE - OPEN CIRUIT There is an Open Circuit to the Main Tele-
scope Out Valve.
33188 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO There is a Short to Ground to the Main Tele-
GROUND scope Out Valve.
33189 3 3 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Tele-
scope In Valve.
33190 3 3 MAIN TELESCOPE IN VALVE - SHORT TO There is a Short to Ground to the
GROUND Main Telescope In Valve.
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 only.
Glow Plugs.
33280 3 3 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles only.
Glow Plugs.
33281 3 3 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles only.
Glow Plugs.
33285 3 3 ALTERNATOR EXCITATION LINE - SHORT TO
BATTERY
33307 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - There is a Short to Ground to the Main Tele-
SHORT TO GROUND scope Flow Control Valve.
33308 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - There is an Open Circuit to the Main Tele-
OPEN CIRCUIT scope Flow Control Valve.
33309 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - There is a Short to Battery to the Main Tele-
SHORT TO BATTERY scope Flow Control Valve.
33311 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT There is a Short to Ground to the
TO GROUND Main Lift Flow Control Valve.
33312 3 3 MAIN LIFT FLOW CONTROL VALVE - OPEN There is an Open Circuit to the
CIRCUIT Main Lift Flow Control Valve.
6-150 3121619
Flash
Code
33313 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT There is a Short to Battery to the
TO BATTERY Main Lift Flow Control Valve.
33414 3 3 SWING - CURRENT FEEDBACK READING TOO Current feedback into controller is below Check wiring and coil
LOW threshold value
33418 3 3 SWING - CURRENT FEEDBACK READING Current feedback into controller not Check wiring and coil
LOST detected
33429 3 3 JIB LIFT UP OVERRIDE VALVE - SHORT TO
GROUND
33430 3 3 JIB LIFT UP OVERRIDE VALVE - OPEN CIRCUIT
33431 3 3 JIB LIFT UP OVERRIDE VALVE - SHORT TO
BATTERY
33432 3 3 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO
GROUND
33433 3 3 JIB LIFT DOWN OVERRRIDE VALVE - OPEN
CIRCUIT
33434 3 3 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO
BATTERY
33435 3 3 JIB CONTROL VALVE - SHORT TO GROUND
33436 3 3 JIB CONTROL VALVE - OPEN CIRCUIT
33437 3 3 JIB CONTROL VALVE - SHORT TO BATTERY
33456 3 3 MAIN LIFT FLOW CONTROL VALVE - CUR- Current feedback into controller not Check wiring and coil
RENT FEEDBACK READING LOST detected
33457 3 3 MAIN LIFT FLOW CONTROL VALVE - CUR- Current feedback into controller is below
RENT FEEDBACK READING TOO LOW threshold value
33460 3 3 TELESCOPE FLOW CONTROL VALVE - CUR- Current feedback into controller not
RENT FEEDBACK READING LOST detected
33461 3 3 TELESCOPE FLOW CONTROL VALVE - CUR- Current feedback into controller is below
RENT FEEDBACK READING TOO LOW threshold value
33462 3 3 WARM UP VALVE - SHORT TO BATTERY Short to Battery detected Check wiring
33463 3 3 WARM UP VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33464 3 3 WARM UP VALVE - SHORT TO GROUND Short to Ground detected Check wiring
33465 3 3 CHASSIS ENABLE VALVE - SHORT TO BAT- Short to Battery detected Check wiring
TERY
33466 3 3 CHASSIS ENABLE VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33467 3 3 CHASSIS ENABLE VALVE - SHORT TO Short to Ground detected Check wiring
GROUND
33487 3 3 TWO SPEED OR BRAKE VALVE - STUCK OPEN
33488 3 3 SWING FLOW CONTROL VALVE - SHORT TO Short to Ground detected Check wiring
GROUND
33489 3 3 SWING FLOW CONTROL VALVE - OPEN CIR- Open Circuit detected Check wiring
CUIT
33490 3 3 SWING FLOW CONTROL VALVE - SHORT TO Short to Battery detected Check wiring
BATTERY
3121619 6-151
Flash
Code
33563 3 3 LIFT ENABLE VALVE - STUCK OPEN Lift pilot valve is energized (during auxil- Check enable valve hardware
iary or gravity sequence) and 1deg of
motion is detected prior to the enable valve
being energized
33564 3 3 COUNTER BALANCE VALVE - STUCK OPEN Counterbalance valve test completed at the Check counterbalance valve hardware
end of a lift down command. If Lift Cylinder
angle sensor detects 2-deg motion, fault is
activated
33565 3 3 LIFT ENABLE - CURRENT FEEDBACK READ- Current feedback into controller not Check wiring and coil
ING LOST detected
33566 3 3 LIFT ENABLE - CURRENT FEEDBACK READ- Current feedback into controller is below Check wiring and coil
ING TOO LOW threshold value
340 3 4 <<< PLATFORM OUTPUT DRIVER >>>
343 3 4 PLATFORM LEVEL UP VALVE - SHORT TO There is a Short to Ground to the
GROUND Platform Level Up Valve.
344 3 4 PLATFORM LEVEL UP VALVE - SHORT TO BAT- There is a Short to Battery or an Open Circuit - Electronic leveling system equipped vehicles only.
TERY OR OPEN CIRCUIT to the Platform Level Up Valve.
347 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO There is a Short to Ground to the
GROUND Platform Level Down Valve.
348 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO There is a Short to Battery or an Open Circuit - Electronic leveling system equipped vehicles only.
BATTERY OR OPEN CIRCUIT to the Platform Level Down Valve.
3427 3 4 JIB LOCK VALVE - OPEN CIRCUIT
3428 3 4 JIB LOCK VALVE - SHORT TO BATTERY
3429 3 4 JIB LOCK VALVE - SHORT TO GROUND
3430 3 4 JIB UNLOCK VALVE - OPEN CIRCUIT
3431 3 4 JIB UNLOCK VALVE - SHORT TO BATTERY
3432 3 4 JIB UNLOCK VALVE - SHORT TO GROUND
350 3 5 <<< OTHER OUTPUT DRIVERS >>>
351 3 5 JIB LEVEL UP VALVE - SHORT TO GROUND
352 3 5 JIB LEVEL UP VALVE - SHORT TO BATTERY OR
OPEN CIRCUIT
353 3 5 JIB LEVEL DOWN VALVE - SHORT TO GROUND
354 3 5 JIB LEVEL DOWN VALVE - SHORT TO BATTERY
OR OPEN CIRCUIT
355 3 5 JIB LIFT UP VALVE - SHORT TO GROUND
356 3 5 JIB LIFT UP VALVE - SHORT TO BATTERY OR
OPEN CIRCUIT
357 3 5 JIB LIFT DOWN VALVE - SHORT TO GROUND
358 3 5 JIB LIFT DOWN VALVE - SHORT TO BATTERY
OR OPEN CIRCUIT
359 3 5 JIB ROTATE LEFT VALVE - SHORT TO GROUND
3510 3 5 JIB ROTATE LEFT VALVE - SHORT TO BATTERY
OR OPEN CIRCUIT
3511 3 5 JIB ROTATE RIGHT VALVE - SHORT TO
GROUND
6-152 3121619
Flash
Code
3512 3 5 JIB ROTATE RIGHT VALVE - SHORT TO BAT-
TERY OR OPEN CIRCUIT
3513 3 5 JIB TELESCOPE IN VALVE - SHORT TO
GROUND
3514 3 5 JIB TELESCOPE IN VALVE - SHORT TO BAT-
3515 3 5 JIB TELESCOPE OUT VALVE - SHORT TO
GROUND
3516 3 5 JIB TELESCOPE OUT VALVE - SHORT TO BAT-
360 3 6 <<<Chassis Output Driver >>>
361 3 6 FRONT AXLE EXTEND VALVE - SHORT TO BAT- Short to Battery detected Check wiring
TERY
362 3 6 FRONT AXLE EXTEND VALVE - SHORT TO Short to Ground detected
GROUND
363 3 6 FRONT AXLE RETRACT VALVE - SHORT TO Short to Battery detected
BATTERY
364 3 6 FRONT AXLE RETRACT VALVE - SHORT TO Short to Ground detected
GROUND
365 3 6 REAR AXLE EXTEND VALVE - SHORT TO BAT- Short to Battery detected
TERY
366 3 6 REAR AXLE EXTEND VALVE - SHORT TO Short to Ground detected
GROUND
367 3 6 REAR AXLE RETRACT VALVE - SHORT TO BAT- Short to Battery detected
TERY
368 3 6 REAR AXLE RETRACT VALVE - SHORT TO Short to Ground detected
GROUND
369 3 6 FRONT AXLE EXTEND VALVE - OPEN CIRCUIT Open Circuit detected
3610 3 6 FRONT AXLE VALVE - CURRENT FEEDBACK Current feedback into controller not Check wiring and coil
READING LOST detected
3611 3 6 FRONT AXLE RETRACT VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3612 3 6 REAR AXLE VALVE - CURRENT FEEDBACK Current feedback into controller not Check wiring and coil
READING LOST detected
3613 3 6 REAR AXLE EXTEND VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3514 3 6 FRONT AXLE VALVE - CURRENT FEEDBACK Current feedback into controller is below Check wiring and coil
READING TOO LOW threshold value
3615 3 6 REAR AXLE RETRACT VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3616 3 6 REAR AXLE VALVE - CURRENT FEEDBACK Current feedback into controller is below Check wiring and coil
READING TOO LOW threshold value
3617 3 6 CHASSIS BRAKE - OPEN CIRCUIT Open Circuit detected Check wiring
3618 3 6 CHASSIS BRAKE - SHORT TO BATTERY Short to Battery detected Check wiring
3619 3 6 CHASSIS BRAKE - SHORT TO GROUND Short to Ground detected Check wiring
3620 3 6 FRONT AXLE VALVE - SHORT TO BATTERY Short to Battery detected Check wiring
3621 3 6 REAR AXLE VAVE - SHORT TO BATTERY Short to Battery detected Check wiring
430 4 3 <<< ENGINE >>>
3121619 6-153
Flash
Code
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 is > 6.6V. - Deutz engine only.
434 4 3 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading is < 0.1V for - Deutz engine only.
more then 5 seconds. - Not reported during engine start.
435 4 3 COOLANT TEMPERATURE SHORT TO The Coolant Temperature Sensor reading is - Deutz engine only.
GROUND < 0.1V.
437 4 3 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 4 3 HIGH ENGINE TEMP (Ford engine only) The engine temperature - Ford / Deutz engine only.
is > 117 C.
(Deutz engine only) The engine tempera-
ture 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 reported a - Ford / Deutz engine only.
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 indicates 0 RPM - Diesel engine only.
AND the Oil Pressure Sensor indicates > 8
PSI for three seconds.
4323 4 3 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indicates > 4000 - Diesel engine only.
RPM.
4364 4 3 SCR CLEANING NOT INITIATED SCR Cleaning was requested bu not initi-
ated.
4365 4 3 RUNNING AT CREEP - ENGINE POWER Triggered by 524190:14 (engine con-
REDUCTION trolled)
4366 4 3 SCR CLEANING REQUIRED - SOOT DETECTED SCR Crystallization has been detected
(engine controlled)
4368 4 3 ALL FUNCTIONS PREVENTED - ENGINE Triggered by 524191:14 (engine con-
POWER REDUCTION SEVERE trolled)You
6-154 3121619
Flash
Code
4375 4 3 WATER IN FUEL The engine has shut down because an Water in fuel filter for water or in fuel or water in fuel
unacceptable amount of water has been sensor.
detected in the fuel or there is an issue with
the water in fuel sensor.
If operating in platform mode, platform

alarm will sound continuously and low fuel
indicator will flash.
If operating in ground mode, the ground

alarm will sound
4376 4 3 FUNCTIONS PREVENTED - ENGINE OIL The engine oil is not warm enough to run Let machine run until fault is cleared
WARM-UP ACTIVE the machine. Fault cleared once engine oil
temperature has reached temperature.
440 4 4 <<< BATTERY SUPPLY >>>
441 4 4 BATTERY VOLTAGE TOO LOW - SYSTEM Battery voltage is < 9V.
SHUTDOWN
442 4 4 BATTERY VOLTAGE TOO HIGH - SYSTEM Battery voltage is > 16V.
SHUTDOWN
443 4 4 LSS BATTERY VOLTAGE TOO HIGH The load sensor has determined that its Check for issue with sensor supply voltage.
supply voltage is too high (> 16V).
The machine will assume the platform is

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

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

overloaded.
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 Sensor Sup- Possible sensor hardware issue.
ply Voltage calibration error.

overloaded.

660 6 6 <<< COMMUNICATION >>>
662 6 6 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost.
3121619 6-155
Flash
Code
663 6 6 CANBUS FAILURE - LOAD SENSING SYSTEM The control system has lost communication Check wiring to load sensor.
MODULE with the load sensing system load pin.

overloaded.
666 6 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication 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 communication lost. - Cylinder Load Pin equipped engine only.
6613 6 6 CANBUS FAILURE - EXCESSIVE CANBUS There has been > 500 Bus Off errors or
ERRORS >500 Bus Passive Errors.
6622 6 6 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6623 6 6 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6629 6 6 CANBUS FAILURE - TELEMATICS CANBUS X -Telematics only
LOADING TOO HIGH
6639 6 6 CANBUS FAILURE - JIB CONTROL MODULE
6640 6 6 CANBUS FAILURE - JIB LIFT ANGLE SENSOR
6641 6 6 CANBUS FAILURE - PLATFORM LEVEL ANGLE
SENSOR
6654 6 6 CANBUS FAILURE - GROUND DISPLAY CANbus communications has been lost Verify CANbus wiring per electrical schematic, verify
between the UGM and the Ground Display CANbus resistance.
(only applicable to 1850SJ with a T4f
engine).
Fault cleared once communications has
been restored.
6667 6 6 CANBUS FAILURE - PLATFORM DISPLAY CANbus communications has been lost Verify CANbus wiring per electrical schematic, verify
between the UGM and the Platform Display CANbus resistance.
(only applicable to 1850SJ with a T4f
engine).
been restored.
6682 6 6 CANBUS FAILURE - GROUND LIGHT PANEL CANbus communications has been lost Verify CANbus wiring per electrical schematic, verify
between the UGM and the Ground Light CANbus resistance.
Panel.
been restored.
6683 6 6 CANBUS FAILURE - PLATFORM LIGHT PANEL CANbus communications has been lost Verify CANbus wiring per electrical schematic, verify
between the UGM and the Ground Light CANbus resistance.
Panel
been restored.
680 6 8 <<< TELEMATICS >>>
681 6 8 REMOTE CONTRACT MANAGEMENT OVER- X -Telematics only
RIDE - ALL FUNCTIONS IN CREEP
6-156 3121619
Flash
Code
810 8 1 <<< TILT SENSOR >>>
813 8 1 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not been cali-
brated.
814 8 1 CHASSIS TILT SENSOR OUT OF RANGE Tilt sensor out of range Check sensor hardware and wiring
815 8 1 CHASSIS TILT SENSOR DISAGREEMENT X
8111 8 1 CHASSIS TILT READING DISAGREEMENT Disagreement between internal (UGM) and Check external/internal sensor hardware and installa-
external chassis tilt sensors tion on machine
820 8 2 <<< PLATFORM LOAD SENSE >>>
821 8 2 LSS CELL #1 ERROR
8211 8 2 LSS READING UNDER WEIGHT LSS has been calibrated and the UGM has Ensure platform is not resting on the ground or is not
determined that the load sensing system leveled at an extreme negative angle.
reading is underweight while a period of
time while operating drive or boom lift up Re-calibrate the load sensing system if the above
at speeds greater than creep OR the UGM items are not a factor.
has determined that the load sensing sys-
tem reading is less than -1.5 x Gross Plat-
form Weight.

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

loaded boom functions will be restricted to
creep.

822 8 2 LSS CELL #2 ERROR822822
3121619 6-157
Flash
Code
8222 8 2 LSS STRAIN GAUGE 1 - STAGNANT The control system has determined that the Possible sensor hardware issue.
strain gauge 1 reading in the load sensor is
stagnant (not changing).

creep..
If DTC 8223 is active in combination with

DTC 8222 the machine will assume the plat-
form is overloaded.

8223 8 2 LSS STRAIN GAUGE 2 - STAGNANT The control system has determined that the Possible sensor hardware issue.
strain gauge 2 reading in the load sensor is
stagnant (not changing).

creep.
If DTC 8222 is active in combination with

DTC 8223 the machine will assume the plat-
form is overloaded.

8224 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE LOW The shear beam is reporting an out of range Possible sensor hardware issue.
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 platform is overloaded.

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



6-158 3121619
Flash
Code
8226 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE HIGH The shear beam is reporting an out of range Possible sensor hardware issue.
high issue with the strain gauge 1 reading.



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



8228 8 2 LSS STRAIN GAUGE 1 - INITIALIZATION The shear beam is reporting an initializa- Possible sensor hardware issue.
ERROR tion issue with the strain gauge 1 sensor.



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



3121619 6-159
Flash
Code
8230 8 2 LSS STRAIN GAUGE 1 - NOT CALIBRATED The shear beam is reporting a calibration Possible sensor hardware issue.
issue with the strain gauge 1 sensor.



823 8 2 LSS CELL #3 ERROR823823
8231 8 2 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a calibration Possible sensor hardware issue.



8232 8 2 LSS STRAIN GAUGE 1 - SENSOR DEFECT The shear beam is reporting a sensor defect Possible sensor hardware issue.



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



6-160 3121619
Flash
Code
8234 8 2 LSS STRAIN GAUGE 1 - NOT INSTALLED The shear beam is reporting a not installed Possible sensor hardware issue.



8235 8 2 LSS STRAIN GAUGE 2 - NOT INSTALLED The shear beam is reporting a not installed Possible sensor hardware issue.



8236 8 2 LSS NOT DETECTING CHANGE The control system has determined that the Possible sensor hardware issue.
load sensor reading has not deviated by
more than 1lb for 5s while operating 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 internal Possible sensor hardware issue.



8238 8 2 LSS STRAIN GAUGE 2 - A/D DEFECT The shear beam is reporting an internal Possible sensor hardware issue.



3121619 6-161
Flash
Code
824 8 2 LSS CELL #4 ERROR824824
825 8 2 LSS HAS NOT BEEN CALIBRATED The load sensing system is configured but Calibrate the load sensing system.
has not been calibrated.

overloaded.
826 8 2 RUNNING AT CREEP - PLATFORM OVER- All functions at creep, the Load Sensing Sys-
LOADED tem indicates the Platform is overloaded
AND is configured to warn only while the
Platform is overloaded.
827 8 2 DRIVE & BOOM PREVENTED - PLATFORM Driving and boom functions are not possi-
OVERLOADED ble while the Load Sensing System indi-
cates the Platform is overloaded AND is
configured to prevent drive and boom func-
tions while the Plat- form is overloaded.
828 8 2 LIFT UP & TELE OUT PREVENTED - PLAT- Lift up and telescope out are not possible
FORM OVERLOADED while the Load Sensing System indicates
the Platform is overloaded AND is config-
ured to prevent Lift up and telescope out
while the Platform is overloaded.
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 The Platform Level Up Valve Crackpoint has - Electronic leveling system equipped vehicles only.
CALIBRATED not been calibrated.
834 8 3 PLATFORM LEVEL DOWN CRACKPOINT - NOT The Platform Level Down Valve Crackpoint - Electronic leveling system equipped vehicles only.
CALIBRATED has not been calibrated.
837 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Level Sensor #1.
838 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO There is a Short to Ground or an Open Circuit - Electronic leveling system equipped vehicles only.
GROUND OR OPEN CIRCUIT to the Platform Level Sensor #1.
8311 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Level Sensor #2.
8312 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO There is a Short to Ground or an Open Circuit - Electronic leveling system equipped vehicles only.
GROUND OR OPEN CIRCUIT to the Platform Level Sensor #2.
8313 8 3 PLATFORM LEVEL SENSOR #1 - REFERENCE Platform Level Sensor #1 reference voltage - Electronic leveling system equipped vehicles only.
VOLTAGE OUT OF RANGE is outside acceptable range (4.9 to 5.1
volts).
8314 8 3 PLATFORM LEVEL SENSOR #2 - REFERENCE Platform Level Sensor #2 reference voltage - Electronic leveling system equipped vehicles only.
VOLTAGE OUT OF RANGE is outside acceptable range (4.9 to 5.1
volts).
8315 8 3 PLATFORM LEVELING SENSOR - DISAGREE- The Control System reads the sensor values - Electronic leveling system equipped vehicles only.
MENT at power-up. The fault is triggered when
there is a ± 5 degree difference from the ini-
tial reading.
8316 8 3 PLATFORM LEVEL SENSOR #1 - COMMUNI- Platform Level Sensor #1 serial communi-
CATIONS LOST cation lost.
6-162 3121619
Flash
Code
8317 8 3 PLATFORM LEVEL SENSOR #2 - COMMUNI- Platform Level Sensor #2 serial communi-
CATIONS LOST cation lost.
8318 8 3 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to maintain
desired level within range for the allotted
time.
8319 8 3 JIB LEVEL SENSOR #1 - OUT OF RANGE LOW
8320 8 3 JIB LEVEL SENSOR #1 - OUT OF RANGE HIGH
8321 8 3 JIB LEVEL SENSOR #2 - OUT OF RANGE LOW
8322 8 3 JIB LEVEL SENSOR #2 - OUT OF RANGE HIGH
8323 8 3 JIB LEVEL SENSORS - NOT CALIBRATED
8324 8 3 JIB LEVEL SENSORS - DISAGREEMENT
8325 8 3 JIB SWING SENSOR #1 - OUT OF RANGE LOW
8326 8 3 JIB SWING SENSOR #1 - OUT OF RANGE HIGH
8327 8 3 JIB SWING SENSOR #2 - OUT OF RANGE LOW
8328 8 3 JIB SWING SENSOR #2 - OUT OF RANGE HIGH
8329 8 3 JIB SWING SENSORS - NOT CALIBRATED
8330 8 3 JIB SWING SENSORS - DISAGREEMENT
8331 8 3 JIB LOCK PIN SENSOR - DISAGREEMENT
8332 8 3 JIB TRANSPORT SENSOR #1 - DISAGREE-
MENT
8333 8 3 JIB TRANSPORT SENSOR #2 - DISAGREE-
MENT
8334 8 3 JIB LIFT ANGLE SENSOR - NOT CALIBRATED
8335 8 3 JIB LEVEL UP CRACKPOINT - NOT CALI-
BRATED
8336 8 3 JIB LEVEL DOWN CRACKPOINT - NOT CALI-
BRATED
8337 8 3 JIB LEVELING SYSTEM TIMEOUT
8338 8 3 WRONG JIB LOCK PIN RESPONSE
8339 8 3 PLATFORM LEVEL ANGLE SENSOR - NOT
CALIBRATED
840 8 4 <<< ENVELOPE >>>
841 8 4 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement between the Boom - Envelope Control equipped vehicles only.
Angle Sensors.
842 8 4 BOOM LENGTH SWITCH FAILED The Boom Length Switches are reporting - Envelope Control equipped vehicles only.
the same state.
843 8 4 BOOM LENGTH SWITCH/SENSOR DISAGREE- There is a disagreement between the Boom - Envelope Control equipped vehicles only.
MENT Length Switch and the Boom Length Sen-
sor.
844 8 4 BOOM LENGTH SENSOR NOT DETECTING The Boom Length Sensor is not changing - Envelope Control equipped vehicles only.
LENGTH CHANGE during a boom telescope command.
845 8 4 BOOM LENGTH SENSOR - OUT OF RANGE Boom Length Sensor out of range high. - Envelope Control equipped vehicles only.
HIGH
846 8 4 BOOM LENGTH SENSOR - OUT OF RANGE Boom Length Sensor out of range low. - Envelope Control equipped vehicles only.
LOW
3121619 6-163
Flash
Code
847 8 4 BOOM LENGTH SENSOR - VALUE OUT OF Boom Length out of range high. - Envelope Control equipped vehicles only.
RANGE HIGH
848 8 4 BOOM LENGTH SENSOR - VALUE OUT OF Boom Length out of range low. - Envelope Control equipped vehicles only.
RANGE LOW
849 8 4 BOOM ANGLE SENSOR #1 - COMMUNICA- Boom Angle Sensor #1 communications - Envelope Control equipped vehicles only.
TIONS FAULT lost.
8410 8 4 BOOM ANGLE SENSOR #2 - COMMUNICA- Boom Angle Sensor #2 communications - Envelope Control equipped vehicles only.
TIONS FAULT lost.
8411 8 4 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of range. - Envelope Control equipped vehicles only.
8412 8 4 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of range. - Envelope Control equipped vehicles only.
8413 8 4 WRONG TELESCOPE RESPONSE Boom telescope is moving in the opposite - Envelope Control equipped vehicles only.
direction of the command.
8414 8 4 WRONG LIFT RESPONSE Boom lift is moving in the opposite direc- - Envelope Control equipped vehicles only.
tion of the command.
8479 8 4 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF
RANGE LOW
RANGE HIGH
RANGE LOW
RANGE HIGH
8494 8 4 MAIN CYLINDER ANGLE SENSORS - DIS-
AGREEMENT
8495 8 4 TURN TABLE SENSOR #1 - FREQUENCY OUT
OF RANGE LOW
OF RANGE HIGH
OF RANGE LOW
OF RANGE HIGH
8499 8 4 CHASSIS TURN TABLE SENSORS - DISAGREE-
MENT
84100 8 4 CHASSIS TURN TABLE SENSORS AND DRIVE
ORIENTATION SWITCH - DIS- AGREEMENT
84101 8 4 CHASSIS TURN TABLE SENSORS - NOT CALI-
BRATED
84102 8 4 MAIN CYLINDER ANGLE SENSOR - NOT
DETECTING CHANGE
84103 8 4 JIB LEVEL ANGLE SENSOR - NOT DETECTING
CHANGE
84104 8 4 JIB LIFT ANGLE SENSOR - NOT DETECTING
CHANGE
84105 8 4 PLATFORM LEVEL ANGLE SENSOR - NOT
DETECTING CHANGE
84106 8 4 JIB LEVEL MOVEMENT WITHOUT COMMAND
6-164 3121619
Flash
Code
84107 8 4 JIB LIFT MOVEMENT WITHOUT COMMAND
84108 8 4 PLATFORM LEVEL MOVEMENT WITHOUT
COMMAND
84151 8 4 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check Hardware, Wiring
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 service in diag-
nosing bad sensor performance. The coun-
ter 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 incre-
mented every time the trigger condition
described in section (a) is observed during
certain steps during Boom Sensor Calibra-
tion (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 maintained within
a given key-cycle
Machine will be trapped in transport
3121619 6-165
Flash
Code
84152 8 4 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check Hardware, Wiring
faults can be set:
(a)
by a power cycle
TwrLenSnsr(1/
2)FaultCounter_PowerCycle > 30
(b)
every time TwrLenSnsr(1/
document)
TwrLenSnsr(1/2)FaultCounter_EEPROM >
3
(c)
further details)
TwrLenSnsr(1/2)FaultCounter_BmSnsrCal
> 20

Retrieval
a given key-cycle
6-166 3121619
Flash
Code
84153 8 4 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check wiring and hardware
faults can be set:
(a)
by a power cycle
BmLenSnsr(1/2)FaultCounter_PowerCycle
> 30
(b)
every time BmLenSnsr(1/
document)
BmLenSnsr(1/2)FaultCounter_EEPROM >
3
(c)
further details)
BmLenSnsr(1/2)FaultCounter_BmSnsrCal
> 20

Retrieval
a given key-cycle
3121619 6-167
Flash
Code
84154 8 4 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check wiring and hardware
faults can be set:
(a)
by a power cycle
BmLenSnsr(1/2)FaultCounter_PowerCycle
> 30
(b)
every time BmLenSnsr(1/
document)
BmLenSnsr(1/2)FaultCounter_EEPROM >
3
(c)
further details)
BmLenSnsr(1/2)FaultCounter_BmSnsrCal
> 20

Retrieval
a given key-cycle
850 8 5 <<< MOMENT / LOAD PINS >>>
851 8 5 MOMENT PIN - HORIZONTAL FORCE OUT OF The Moment Pin horizontal force is out of
RANGE range.
852 8 5 MOMENT PIN - VERTICAL FORCE OUT OF The Moment Pin vertical force is out of
RANGE range.
855 8 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a fault.
857 8 5 NEW MOMENT PIN DETECTED A new Moment Pin has been detected.
6-168 3121619
Flash
Code
860 8 6 <<< STEERING / AXLE >>>
861 8 6 RESTRICTED TO TRANSPORT - OSCILLATING The Oscillating Axle Pressure Switch indi- - Electrically released Oscillated
AXLE PRESSURE SWITCH DIS- AGREEMENT cates pressure while not driving or does not Axles equipped vehicles only.
indicate pressure while driving and
restricted to transport.
862 8 6 AXLE EXTEND VALVE - SHORT TO BATTERY OR There is a Short to Battery or an Open Circuit
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 There is a Short to Battery or an Open Circuit
OR 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 There is a Short to Battery or an Open Circuit
TO BATTERY OR OPEN CIRCUIT to the Right Front Steer Right Valve.
867 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT There is a Short to Ground to the
TO GROUND Right Front Steer Right Valve.
868 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Front Steer Left Valve.
869 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Front Steer Left Valve.
8610 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Front Steer Right Valve.
8611 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Front Steer Right Valve.
8612 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Front Steer Left Valve.
8613 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Front Steer Left Valve.
8614 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Rear Steer Right Valve.
8615 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Rear Steer Right Valve.
8616 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Rear Steer Left Valve.
8617 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Rear Steer Left Valve.
8618 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Rear Steer Right Valve.
8619 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Rear Steer Right Valve.
8620 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Rear Steer Left Valve.
8621 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Rear Steer Left Valve.
8622 8 6 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has become
decoupled.
3121619 6-169
Flash
Code
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 RESPOND- The Front Right Steer Sensor is not respond-
ING ing to steer commands.
8627 8 6 FRONT RIGHT STEER SENSOR - NOT The Front Left Steer Sensor is not respond-
RESPONDING ing to steer commands.
8628 8 6 REAR LEFT STEER SENSOR - NOT RESPOND- The Rear Right Steer Sensor is not respond-
ING ing to steer commands.
8629 8 6 REAR RIGHT STEER SENSOR - NOT RESPOND- The Rear Left Steer Sensor is not responding
ING to steer commands.
8630 8 6 FRONT RIGHT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Front Right Steer Sensor.
8631 8 6 FRONT RIGHT STEER SENSOR - SHORT TO There is a Short to Battery to the
BATTERY Front Right Steer Sensor.
8632 8 6 FRONT LEFT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Front Left Steer Sensor.
8633 8 6 FRONT LEFT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Front Left Steer Sensor.
8634 8 6 REAR RIGHT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Rear Right Steer Sensor.
8635 8 6 REAR RIGHT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Rear Right Steer Sensor.
8636 8 6 REAR LEFT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Rear Left Steer Sensor.
8637 8 6 REAR LEFT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Rear Left Steer Sensor.
8651 8 6 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE Engine Start is prevented while there is an
FAULT Oscillating Axle fault and vehicle is out of
transport position
6-170 3121619
Flash
Code
8670 8 6 RIGHT FRONT STEER RIGHT VALVE - OPEN Open Circuit detected Check wiring
CIRCUIT
8671 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT Short to Battery detected
TO BATTERY
8672 8 6 RIGHT FRONT STEER LEFT VALVE - OPEN Open Circuit detected
CIRCUIT
8673 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8674 8 6 LEFT FRONT STEER RIGHT VALVE - OPEN Open Circuit detected
CIRCUIT
8675 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8676 8 6 LEFT FRONT STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8677 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8678 8 6 RIGHT REAR STEER RIGHT VALVE - OPEN Open Circuit detected
CIRCUIT
8679 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8680 8 6 RIGHT REAR STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8681 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8682 8 6 LEFT REAR STEER RIGHT VALVE - OPEN CIR- Open Circuit detected
CUIT
8683 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8684 8 6 LEFT REAR STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8685 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8686 8 6 FRONT LEFT AXLE - MOVEMENT WITHOUT Axle is set to extend position, no axle retract Check sensor hardware and hydraulics
COMMAND or extend is demanded by the operator and
8687 8 6 FRONT RIGHT AXLE - MOVEMENT WITHOUT one or more of the axle sensors detects
COMMAND motion
8688 8 6 REAR RIGHT AXLE - MOVEMENT WITHOUT
COMMAND
8689 8 6 REAR LEFT AXLE - MOVEMENT WITHOUT
COMMAND
876 87 6 WIRE ROPE SERVICE REQUIRED The Wire Rope Service Proximity sensor
detects slack in wire ropes. Fault cleared Check wire ropes per torque spec.
when proximity switch detects no more Check sensor wiring.
slack in wire ropes.
990 9 9 <<< HARDWARE >>>
991 9 9 LSS WATCHDOG RESET
992 9 9 LSS EEPROM ERROR
3121619 6-171
Flash
Code
993 9 9 LSS INTERNAL ERROR - PIN EXCITATION
994 9 9 LSS INTERNAL ERROR - DRDY MISSING
FROM A/D
998 9 9 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported an
EEPROM failure.
9910 9 9 FUNCTIONS LOCKED OUT - PLATFORM MOD- The Platform Module software version is
ULE SOFTWARE VERSION IMPROPER not compatible with the rest of the system.
9911 9 9 FUNCTIONS LOCKED OUT - LSS MODULE
SOFTWARE VERSION IMPROPER
9914 9 9 PLATFORM MODULE SOFTWARE UPDATE The Platform Module software requires an
REQUIRED updated.
9915 9 9 CHASSIS TILT SENSOR NOT GAIN CALI- The Chassis Tilt Sensor gain calibration has
BRATED been lost.
9916 9 9 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain calibration has
become corrupted.
9917 9 9 HIGH RESOLUTION A2D FAILURE - INTER- The Platform Module has reported that its
RUPT LOST ADS1213 chip has stopped asserting its
interrupt.
9918 9 9 HIGH RESOLUTION A2D FAILURE - REINIT The Platform Module has reported that its
LIMIT ADS1213 chip had to be reset 3 or more
times.
9919 9 9 GROUND SENSOR REF VOLTAGE OUT OF The Ground Module has reported that its - Not reported during power-up.
RANGE sensor reference voltage is outside accept-
able range.
9920 9 9 PLATFORM SENSOR REF VOLTAGE OUT OF The Platform Module has reported that its - Not reported during power-up.
RANGE sensor reference voltage is outside accept-
able range.
9921 9 9 GROUND MODULE FAILURE - HIGH SIDE The Ground Module has reported that its
DRIVER CUTOUT FAULTY high side driver cutout failed.
9922 9 9 PLATFORM MODULE FAILURE - HWFS CODE The Platform Module has reported that the
1 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.
9924 9 9 FUNCTIONS LOCKED OUT - MACHINE NOT
CONFIGURED
9925 9 9 FUNCTIONS LOCKED OUT - CHASSIS MOD- The Chassis Module software version is not
ULE SOFTWARE VERSION IMPROPER compatible with the rest of the system.
9926 9 9 FUNCTIONS LOCKED OUT - BLAM MODULE The BLAM software version is not compati-
SOFTWARE VERSION IMPROPER ble with the rest of the system.
9927 9 9 GROUND MODULE CONSTANT DATA UPDATE The Ground Module constant data requires
REQUIRED an updated.
9928 9 9 ENVELOPE CONTROL DISABLED Envelope Control has been disabled by the - Envelope Control equipped vehicles only.
user from Access Level 0.
99282 9 9 GROUND DISPLAY SOFTWARE VERSION IS The UGM has detected improper software Verify Machine Setup is correct and ground display
IMPROPER version on the ground display. software version is at least P1.1 or greater
Fault cleared once software has been
updated on the ground display
6-172 3121619
Flash
Code
99285 9 9 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a factor calibra- Possible sensor hardware issue.
tion issue (internal error)

overloaded.

9929 9 9 MOMENT CONTROL DISABLED Moment Control has been disabled by the - Envelope Control equipped vehicles only.
user from Access Level 0.
9930 9 9 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been calibrated.
9931 9 9 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not been cali- - BLAM equipped vehicles only.
brated.
9932 9 9 LIFT CRACKPOINTS NOT CALIBRATED The Lift Crackpoints have not been cali-
brated.
9933 9 9 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Crackpoints have not been
calibrated.
9934 9 9 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Crackpoints have not been cali-
brated.
9935 9 9 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply voltage is - BLAM equipped vehicles only.
high.
9936 9 9 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply voltage is - BLAM equipped vehicles only.
low.
9937 9 9 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors supply voltage is
high.
9938 9 9 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors supply voltage is
low.
9939 9 9 BLAM HIGH RES A/D FAILURE The BLAM high resolution analog to digital - BLAM equipped vehicles only.
converter has failed.
9940 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE The Chassis Sensors supply voltage is high.
HIGH
9941 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE The Chassis Sensors supply voltage is low.
LOW
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 CHECK- The factory set current feedback checksum
SUM INCORRECT is not correct.
99155 9 9 JIB CONTROL MODULE - HIGH RESOLUTION
A2D FAILURE
A2D REFERENCE LOW
A2D REFERENCE HIGH
99158 9 9 PLATFORM LEVEL ANGLE SENSOR - INTER-
NAL ERROR
99159 9 9 JIB LIFT ANGLE SENSOR - INTERNAL ERROR
3121619 6-173
Flash
Code
99160 9 9 FUNCTIONS LOCKED OUT - JIB CONTROL
MODULE SOFTWARE VERSION IMPROPER
99296 9 9 PLATFORM DISPLAY SOFTWARE VERSION The UGM has detected improper software Verify Machine Setup is correct and platform display
IMPROPER version on the platform display. software version is at least 1.6 or greater
Fault cleared once software has been

updated on the platform display
6-174 3121619
SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port
matics to be used for locating and correcting most of the oper- goes to the positive side of the signal.
ating problems which may develop. If a problem should
develop which is not presented in this section or which is not Scale
corrected by listed corrective actions, technically qualified
guidance should be obtained before proceeding with any M = Mega = 1,000,000 * (Displayed Number)
maintenance. k = kilo = 1,000 * (Displayed Number)
NOTE: Some of the procedures/connectors shown in this section m = milli = (Displayed Number) / 1,000
may not be applicable to all models.
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS Example: 1.2 kW = 1200 W
Example: 50 mA = 0.05 A
A wide variety of multimeters or Volt Ohm Meters (VOM) can
be used for troubleshooting your equipment. This section Voltage Measurement
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM
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- Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent 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
3121619 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
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
7-2 3121619
Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED 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-

Figure 7-4. Current Measurement (DC) ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-

• Set up the meter for the expected current range
pound to the electrical connectors. This procedure applies to
• Be sure to connect the meter leads to the correct jacks all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
for the current range you have selected
1. To prevent oxidation, silicone grease must be packed
• If meter is not auto ranging, set it to the correct range
completely around male and female pins on the inside
(See multi meter’s operation manual) of the connector prior to assembly. This is most easily
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.
3121619 7-3
3. Anderson connectors for the battery boxes and battery Deutsch HD, DT, DTM, DRC Series
chargers should have silicone grease applied to the con-
tacts only. The Deutsch connector system is commonly used for harsh
environment interconnect. Follow the installation instructions.
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.
When applied to electrical connections, dielectric grease helps

to prevent corrosion of electrical contacts and improper con-
ductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from the 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 AMP Seal
points or apply with a syringe for small connectors.
The AMP Seal connector system is used on the Control ADE
2. Apply dielectric grease to the female contact (fill it Platform and Ground Modules.
approximately ½ full; see example below)
Apply dielectric grease to the female contact. If trapped air
3. Leave a thin layer of dielectric grease on the face of the prevents the connector from latching, pierce one of the
connector unused wire seals. After assembly, install a seal plug (JLG
4. Assemble the connector system immediately to prevent #4460905) in that location to prevent moisture ingress.
moisture ingress or dust contamination Note that seal plugs may be installed by the wire harness man-
5. Pierce one of the unused wire seals prior to assembly if ufacturer if an unused wire seal becomes compromised (wire
the connector system tends to trap air (i.e. AMP Seal) inserted in the wrong cavity during assembly and then cor-
and then install a seal plug. rected).
Figure 7-5. Application to plug/male connector housing
7-4 3121619
DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.
Figure 7-6. Use of Seal Plugs
AMP Mate-N-Lok
This connector system is widely used inside enclosures for
general purpose interconnect. Follow the installation instruc-
tions.
3121619 7-5
Exclusions ENGINE CONTROL UNIT CONNECTORS

These connectors use back-seals for moisture integrity. How-
A limited number of connectors do not benefit from dielectric ever, the low-force contacts cannot displace dielectric grease
grease, or may be permanently damaged by application. and create electrical contact. It is possible to use solvents (i.e.
Dielectric grease may not be required in properly sealed contact cleaner or mineral spirits) for the removal of improp-
erly applied dielectric grease. The EMR4 engine control mod-
enclosures.
ule from Deutz employs this connector system (for example).
BRAD HARRISON / PHOENIX CONTACT M12

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). The JLG Load Sensing System and Rotary Angle
Sensors are examples of components with the M12 connector
system.
SEALED ENCLOSURES
Figure 7-7. Brad-Harrison M12
Application of dielectric grease is not required in properly
sealed enclosures. To meet criteria, the enclosure must be
rated to at least IP66 (dust tight; protected from powerful jets
of water). The enclosure must be fitted with a high quality,
continuous gasket and all wiring must pass through cable
entrances.
Figure 7-8. Phoenix Contact M12
7-6 3121619
MIL-C-5015 SPEC CONNECTOR’S MOLEX CMC SERIES CONNECTORS

Crown Connector Inc’s recommendation is to not use The CMC connector family is a sealed, high-density connec-
dielectric grease for this series connector. For similar model tion system using matte-seal technology for CP 0.635 and 1.50
series connectors, the manufacturer should be contacted for mm terminals. To guarantee IP6K7 and IP6K9 sealing, a seal
confirmation before applying dielectric grease. A typical appli- plug option is used. However, the low-force contacts cannot
cation for this connector is on David Clark Intercom connec- displace dielectric grease and create electrical contact. It is
tions in Aerial Work Platforms. 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
system (for example).
3121619 7-7
7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to
be sure the retention fingers are holding the contact
Assembly (See Figure 7-11.).
Check to be sure the wedge lock is in the open, or as-shipped,

position (See Figure 7-9.). Proceed as follows:
Figure 7-9. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate

circuit cavity as far as it will go (See Figure 7-11.).
Figure 7-10. AMP Connector
7-8 3121619
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 7-13.).
Release the locking latches by squeezing them inward
(See Figure 7-12.).
3121619 7-9
Figure 7-14. Connector Disassembly
Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16") wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
2. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
3. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing
ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts.
This nullifies the effectiveness of the connector seals and
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 3121619
Figure 7-15. Connector Installation
3121619 7-11
7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-16. DT/DTP Contact Installation Figure 7-17. DT/DTP Contact Removal
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
3. Push contact straight into connector grommet until a moving it away from the contact with a screwdriver.
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 3121619
HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-18. HD/HDP Contact Installation Figure 7-20. 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 7-21. HD/HDP Unlocking Contacts

Figure 7-19. 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
3121619 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 equipped with DEF tank.
DEF Tank Level (If Equipped) • 0% = Empty Percentage (%)
• 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 storage containers. When Fuel Level
2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
DIAGNOSTICS PLUG GATEWAY MODULE

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
TELEMATICS-READY PLUG
7-14 3121619
3121619
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 7-22. Telematics Gateway Harness - Sheet 1 of 3
7-15
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)
7-16 3121619
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
3121619 7-17
7.7 WIRING HARNESS CONNECTOR LABELS Table 7-1. Wiring Harness Connector Labels
Connector Labels Component Category Label

Audible Alarms AH
Connectors between harnesses are identified by the prefix “X”
and a sequentially assigned number. An optional suffix (letters Horns
& numbers) may be added when multiple terminations occur Battery Batteries BT
at one device or when there are optional connections. Battery Terminals
Examples: Control Module Ground CO
X25 connects to X25 in another harness. LSS

Platform
X65A, X65B connect to different portions of one device
Engine Alternator EC
X163 connects to X163A in ANSI and X163B in CE machines Cold Start
Component Labels Controller
Coolant Temp
Every component on the vehicle has a unique identification. A
Fuel Pump
standard prefix letter is assigned according to the table below,
followed by a unique sequential number. An optional suffix Fuel Solenoid
(letters & numbers) may be added when multiple terminations Glow Plugs
occur at one device. Oil Pressure
Terminals that are not loaded into connectors are considered Starter
independent components and labeled in the same fashion. Fuse & CB Fuse FC Fuse FC
Fusible Link FC
Circuit Breaker CB
Gauge & Display Board GD
Cluster
Hour meter
LMI
Speedometer
Inline Resistor R
Diode D
Joystick & Steering Electronic JS
Hydraulic
Lights Dome LB
Headlights
Simple
Taillights
Membrane Panel MP
Miscellaneous Radio MS
Speakers
Splice Blocks
T-Connectors
7-18 3121619
Table 7-1. Wiring Harness Connector Labels
Component Category Label

Other Switches Disconnect SW
EMS
Foot
HVAC WH
Key SW
Park brake
Pump pot
Push
Shifter
Turn signal
Relay 5 Pin RL
4 Pin
Contactor
Power module
Rocker Switch SW
Sensor Angle SN
Fuel
Length
Limit
Load
Pressure
Proximity
Speed
Temperature
Terminals Pins T
Sockets
Male Blades
Female Blades
Rings
Forks
Toggle Switch DPDT SW
DPST
SPDT
SPST
Special
Valves Simple HV
Suppression
Examples:
T67 is a ring terminal connected during installation.
CO1-J3 is the J3 connector for a UGM control module.
EC9 is a glow plug supplied with the engine
3121619 7-19
7-20
SW23
MAIN BOOM TELE
SW22-2
SW22-1
SW21
JIB LIFT SW20-1
SW19 SW20-2
JIB SWING
SW14
JIB TELE MS41
LB12-
*MUST INCLUDE:
BUSSBAR
MOUNTING CLIP
SW13 LB12+
PLTFM ROTATE
X38A
LB320+ CO01-J7
X390 CO01-J8
LB320- X43A
GD04-J1 GD04-J3 SW10
SW35-1A
SW26
CAPACITY SEL SW08-2 X392
SW08-1 X385
X388
SW27
DRIVE ORIENT
SW25
STRT/AUX PWR SW35-2A
GD04-J2
X387 X44A
GD04-J4 AH30-
SW15
HIGH DRIVE CO01-J1
SW24 SW18
BOOM CONTROL AXLE EXT/RET AH30+ X36A
CO01-J2 *MUST INCLUDE:
X399
SW17 WASHER
PLTFM LEVEL X398
X32 NUT
SW16 X33A
STEER MODE *MUST INCLUDE:
WASHER
X391
NUT
X384
MAF08430F
1001149976-F
Figure 7-25. Platform Box Wiring Harness (without SKYGUARD)
3121619
SW16 X399
STEER MODE CONN WIRE
WIRE LABEL GAUGE JACKET TO
CONN WIRE POS COLOR
POS COLOR 1 YEL 2-26 12 AWG GXL S481 (1)
1 WHT 55-2 CRB STR 18 AWG GXL CO01-J1 (16)
X387
2 YEL 2-1-1 18 AWG GXL SW15 (2)
CONN WIRE
3 YEL 2-1-2 18 AWG GXL SW17 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
4 WHT 55-3 CRD STR 18 AWG GXL CO01-J1 (17)
1 YEL 2-25-1 12 AWG GXL CO01-J8 (2)
5
6 X388
CONN WIRE
SW15 WIRE LABEL GAUGE JACKET TO
POS COLOR
HIGH DRIVE
1 BLK 0-7 16 AWG TXL X36A (19)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 BLK 0-8 18 AWG GXL X36A (5)
POS COLOR
1 WHT 48-1 ENG SPD 18 AWG GXL CO01-J1 (28) X385
2 YEL 2-1 18 AWG GXL CO01-J1 (18) CONN WIRE
3 YEL 2-1-1 18 AWG GXL SW16 (2) POS COLOR
4 WHT 48-2 2 SPD 18 AWG GXL CO01-J1 (27) 1 BLK 0-40-3 16 AWG GXL X392 (1)
5 1 BLK 0-41-3 16 AWG GXL X392 (3)
6 X390
SW10 CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 BLK 0-41-2 12 AWG GXL CO01-J8 (1)
POS COLOR
1 X38A
2 WHT 49-14 CREEP 18 AWG GXL CO01-J1 (32) CONN WIRE
3 YEL 2-1-5 18 AWG GXL SW08-1 (1) POS COLOR
3 YEL 2-1-7 18 AWG GXL SW13 (2) 1 YEL 2-7 18 AWG GXL CO01-J2 (33)
4 WHT 55-4 POT REF 18 AWG GXL CO01-J1 (34) 1 YEL 2-8 18 AWG GXL CO01-J2 (3)
5 BLK 0-3 18 AWG GXL CO01-J1 (13) 1 WHT 49-24 SFTCH 18 AWG GXL CO01-J7 (18)
6 WHT 55-5 PUMP POT 18 AWG GXL CO01-J1 (35) 1 WHT 49-25 FTSW OPEN 18 AWG GXL CO01-J7 (8)
1 WHT 52-4 GEN 18 AWG GXL CO01-J7 (9)
X384
2
CONN WIRE
WIRE LABEL GAUGE JACKET TO 3
POS COLOR
1 BLK 0-40 12 AWG GXL X33A (16) 4
5 WHT 49-27 18 AWG GXL X38A (4)
X391
6 YEL 2-8-1 18 AWG GXL X38A (8)
CONN WIRE
POS COLOR
8
1 BLK 0-41 12 AWG GXL X33A (18)
AH30+
X398
CONN WIRE
CONN WIRE WIRE LABEL GAUGE JACKET TO
WIRE LABEL GAUGE JACKET TO POS COLOR
POS COLOR
1 WHT 49-26 ALARM 18 AWG GXL CO01-J7 (19)
1 YEL 2-25 12 AWG GXL S480 (1)
3121619 7-21
AH30- SN131
CONN WIRE LENGTH SENSOR
POS COLOR CONN WIRE
1 BLK 0-5 18 AWG GXL CO01-J7 (20) POS COLOR
A RED CABLEP/N1060616 18AWG CABLE X404A(1)
MS41
B BLK CABLEP/N1060616 18AWG CABLE X404A(3)
CONN WIRE
WIRE LABEL GAUGE JACKET TO C BLU CABLEP/N1060616 18AWG CABLE X404A(2)
POS COLOR
1 YEL CAN HI 20 AWG J1939 CABLE X33A (3) S166
2 YEL CAN HI 20 AWG J1939 CABLE CO01-J7 (31) CONN WIRE
3 GRN CAN LOW 20 AWG J1939 CABLE X33A (2) POS COLOR
4 GRN CAN LOW 20 AWG J1939 CABLE CO01-J7 (30) 1 BRN CABLEP/N1060616 22AWG CABLE X404A(7)
5 SHLD CAN SHIELD 20 AWG J1939 CABLE X33A (1) 2 BLK 18AWG GXL SN221(3)
6 SHLD CAN SHIELD 20 AWG J1939 CABLE CO01-J7 (32) 2 BLK 18AWG GXL SN401(3)
7 GRY CAN SHIELD 20 AWG CABLE X44A (5) SN401
8 GRY CAN SHIELD 20 AWG CABLE X43A (5) BROKEN CABLEP ROX2
9 BLK CAN LOW 20 AWG CABLE X44A (4) LEFTSIDE
10 BLK CAN LOW 20 AWG CABLE X43A (4) CONN WIRE
POS COLOR
11 BLK CAN HI 20 AWG CABLE X44A (3)
1 WHT 18AWG GXL SN221(2)
12 BLK CAN HI 20 AWG CABLE X43A (3)
2 ORG CABLEP/N1060616 18AWG CABLE X404A(6)
X32 3 BLK 18AWG GXL S166(2)
CONN WIRE 4
POS COLOR
1 YEL CAN HI 20 AWG J1939 CABLE X33A (3) SN221
BROKEN CABLE PROX1
2 YEL CAN HI 20 AWG J1939 CABLE CO01-J7 (31)
RIGHT SIDE
3 GRN CAN LOW 20 AWG J1939 CABLE X33A (2)
CONN WIRE
4 GRN CAN LOW 20 AWG J1939 CABLE CO01-J7 (30) WIRE LABEL GAUGE JACKET TO
POS COLOR
X404A 1 YEL CABLEP/N1060616 18AWG CABLE X404A(5)

CONN WIRE 2 WHT 18AWG GXL SN401(1)
WIRE LABEL 3 BLK 18AWG GXL S166(2)
POS COLOR GAUGE JACKET TO
1 RED CABLEP/N1060616 18AWG CABLE SN131(A) N.C SHIELD CABLEP/N1060616 18AWG SHLD X404A(8)
2 BLU CABLEP/N1060616 18AWG CABLE SN131(C) NC RED/BLK CABLEP/N1060616 18AWG TFFN X404A(4)
3 BLK CABLEP/N1060616 18AWG CABLE SN131(B)
SN137
4 RED/BLK CABLEP/N1060616 18AWG TFFN SN221(NC) BOOM ANG2 LEFT SIDE
5 YEL CABLEP/N1060616 18AWG CABLE SN221(1) CONN
WIRE COLOR WIRE LABEL GAUGE TO
6 ORG CABLEP/N1060616 18AWG CABLE SN401(2) POS
7 BRN CABLEP/N1060616 22AWG CABLE S166(1) 1 YEL CABLEP/N1060616 18AWG X406B(5)
8 SHIELD CABLEP/N1060616 18AWG SHLD SN221(N.C) 2 ORG CABLEP/N1060616 18AWG X406B(6)
3 BRN CABLEP/N1060616 22AWG X406B(7)
7-22 3121619
X422 X32
CONN WIREC CONN WIRE
WIRELABEL GAUGE JACKET TO WIRE LABEL GAUGE JACKET TO
POS OLOR POS COLOR
1 SHIELD CABLEP/N1060616 18AWG SHLD SN136(NC) 1 WHT 49-9ANALPWR 18AWG GXL CO01-J2(26)
2 WHT 49-8RX 18AWG GXL CO01-J2(28)
X406B
3 WHT 49-7TX 18AWG GXL CO01-J2(29)
CONN WIREC
WIRELABEL GAUGE JACKET TO 4 WHT 49-6ANALGND 18AWG GXL CO01-J2(27)
POS OLOR
1 RED CABLEP/N1060616 18AWG CABLE SN136(1) CO01-J8
2 BLU CABLEP/N1060616 18AWG CABLE SN136(2) CONN WIRE
3 BLK CABLEP/N1060616 18AWG CABLE SN136(3) POS COLOR
4 1 BLK 0-41-2 12AWG GXL X390(1)
5 YEL CABLEP/N1060616 18AWG CABLE SN137(1) 2 YEL 2-25-1 12AWG GXL X387(1)
6 ORG CABLEP/N1060616 18AWG CABLE SN137(2)
X43A
7 BRN CABLEP/N1060616 22AWG CABLE SN137(3)
CONN WIRE
8 WIRE LABEL GAUGE JACKET TO
POS COLOR
SN136 1 BRN 49-11X43PWR 20AWG CABLE CO01-J7(4)
BOOM ANG1 RIGHT SIDE 2 WHT 49-10X43GND 20AWG CABLE CO01-J7(14)
CONN WIREC 3 BLU CANHI 20AWG CABLE MS41(12)
WIRELABEL GAUGE JACKET TO
POS OLOR 4 BLK CANLOW 20AWG CABLE MS41(10)
1 RED CABLEP/N1060616 18AWG CABLE X406B(1) 5 GRY CANSHIELD 20AWG CABLE MS41(8)
2 BLU CABLEP/N1060616 18AWG CABLE X406B(2)
X44A
3 BLK CABLEP/N1060616 18AWG CABLE X406B(3)
CONN WIRE
NC SHIELD CABLEP/N1060616 18AWG SHLD X422(1) WIRE LABEL GAUGE JACKET TO
POS COLOR
MS41 1 BRN 49-13X44PWR 20AWG CABLE CO01-J7(7)
CONN WIRE 2 WHT 49-12X44GND 20AWG CABLE CO01-J7(14)
POS COLOR 3 BLU CANHI 20AWG CABLE MS41(11)
J1939CA 4 BLK CANLOW 20AWG CABLE MS41(9)
1 YEL CANHI 20AWG X33A(3)
BLE
5 GRY CANSHIELD 20AWG CABLE MS41(7)
J1939CA
2 YEL CANHI 20AWG CO01-J7(31)
BLE X392
J1939CA CONN WIRE
3 GRN CANLOW 20AWG X33A(2) WIRE LABEL GAUGE JACKET TO
BLE POS COLOR
J1939CA 1 BLK 0-40-3 16AWG GXL X385(1)
4 GRN CANLOW 20AWG CO01-J7(30)
BLE 2 ORG 1-7-1WKLTPWR 16AWG TXL X36A(13)
J1939CA 3 BLK 0-41-3 16AWG GXL X385(1)
5 SHLD CANSHIELD 20AWG X33A(1)
BLE
4 ORG 1-7-2WKLTPWR 16AWG TXL X36A(20)
J1939CA
6 SHLD CANSHIELD 20AWG CO01-J7(32)
BLE
7 GRY CANSHIELD 20AWG CABLE X44A(5)
8 GRY CANSHIELD 20AWG CABLE X43A(5)
9 BLK CANLOW 20AWG CABLE X44A(4)
10 BLK CANLOW 20AWG CABLE X43A(4)
11 BLU CANHI 20AWG CABLE X44A(3)
12 BLU CANHI 20AWG CABLE X43A(3)
3121619 7-23
X36A X33A
CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET TO WIRE LABEL GAUGE JACKET TO
POS COLOR POS COLOR
1 YEL 2-6-1 18AWG GXL S40(2) J1939CA
1 SHLD CANSHIELD 20AWG MS41(5)
2 WHT 49-18PLVL1 18AWG GXL CO01-J1(25) BLE
3 WHT 49-22GND 18AWG GXL CO01-J7(21) J1939CA
2 GRN CANLOW 20AWG MS41(3)
BLE
4 WHT 49-50PROXNC 18AWG GXL CO01-J1(20)
J1939CA
5 BLK 0-8 18AWG GXL X388(1) 3 YEL CANHI 20AWG MS41(1)
BLE
6 WHT 25-4-1PLVLDN 18AWG GXL S46(2)
4 YEL 2-4 18AWG GXL CO01-J7(3)
7 WHT 25-3-1PLVLUP 18AWG GXL S45(2)
5 RED 1-4-3 18AWG GXL SW35-2A(2A)
8 WHT 23-3PROTLT 18AWG GXL CO01-J7(5)
6
9 WHT 23-4PROTRT 18AWG GXL CO01-J7(6)
7 WHT 25-5PLVLDNO/R 18AWG GXL S46(2)
10 WHT 55-26JLOCKIN 18AWG GXL CO01-J7(25)
8
11 WHT 55-25JLOCKOUT 18AWG GXL CO01-J7(26)
9 WHT 25-6PLVLUPO/R 18AWG GXL S45(2)
12 BLK 0-4 18AWG GXL CO01-J7(29)
FUSIBLE
13 ORG 1-7-1WKLTPWR 16AWG TXL X392(2) 10 - 2-25FUSIBLELINK 12AWG S480(2)
LINK
14 11 YEL 2-5 18AWG GXL CO01-J7(1)
15 YEL 2-6-2 18AWG GXL S40(2) FUSIBLE
12 - 2-26FUSIBLELINK 12AWG S481(2)
16 WHT 49-17PLVL2 18AWG GXL CO01-J1(26) LINK
17 WHT 49-23GND 18AWG GXL CO01-J7(33) 13 WHT 49-19PROXNO 18AWG GXL CO01-J1(33)
18 WHT 50-2PDUMP 16AWG TXL X36A(14) 14
19 BLK 0-7 16AWG TXL X388(1) 15 WHT 49-20PROXNC 18AWG GXL CO01-J1(1)
20 ORG 1-7-2WKLTPWR 16AWG TXL X392(4) 16 BLK 0-40 12AWG GXL X384(1)
21 17
18 BLK 0-41 12AWG GXL X391(1)
19
7-24 3121619
CO01-J7 CO01-J1
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-5 18AWG GXL X33A(11) 1 WHT 49-20PROXNC 18AWG GXL X33A(15)
2 RED 1-4-3PLTFMODE 18AWG GXL SW35-1A(1A) 2
3 YEL 2-4 18AWG GXL X33A(4) 3 WHT 29-1JTELEIN 18AWG GXL SW14(1)
4 BRN 49-11X43PWR 20AWG CABLE X43A(1) 4 WHT 29-2JTELEOUT 18AWG GXL SW14(3)
5 WHT 23-3PROTLT 18AWG GXL X36A(8) 5 WHT 13-1MTELEIN 18AWG GXL SW23(1)
6 WHT 23-4PROTRT 18AWG GXL X36A(9) 6 WHT 13-2MTELEOUT 18AWG GXL SW23(3)
7 BRN 49-13X44PWR 20AWG CABLE X44A(1) 7 WHT 23-1PROTRT 18AWG GXL SW13(1)
8 WHT 49-25FTSWOPEN 18AWG GXL X38A(7) 8 WHT 23-2PROTLT 18AWG GXL SW13(3)
9 WHT 52-4GEN 18AWG GXL X38A(1) 9 WHT 25-1PLVLUP 18AWG GXL SW17(1)
10 10 WHT 25-2PLVLDN 18AWG GXL SW17(3)
11 11 WHT 27-1JIBUP 18AWG GXL SW21(1)
12 12 WHT 27-2JIBDN 18AWG GXL SW21(3)
13 13 BLK 0-3 18AWG GXL SW10(5)
14 WHT 49-10X43GND 20AWG CABLE X43A(2) 14 WHT 48-3STRT 18AWG GXL SW25(1)
14 WHT 49-12X44GND 20AWG CABLE X44A(2) 15 WHT 53-1AUX 18AWG GXL SW25(3)
15 WHT 25-3PLVLUP 18AWG GXL S45(1) 16 WHT 55-2CRBSTR 18AWG GXL SW16(1)
16 WHT 25-4PLVLDN 18AWG GXL S46(1) 17 WHT 55-3CRDSTR 18AWG GXL SW16(3)
17 18 YEL 2-1 18AWG GXL SW15(2)
18 WHT 49-24SFTCH 18AWG GXL X38A(3) 19
19 WHT 49-26ALARM 18AWG GXL AH30+(1) 20 WHT 49-50PROXNC 18AWG GXL X36A(4)
20 BLK 0-5 18AWG GXL AH30-(1) 21 WHT 54-3CPCITYSW 18AWG GXL SW26(3)
21 WHT 49-22GND 18AWG GXL X36A(3) 22 WHT 49-16ENVLP 18AWG GXL SW24(3)
22 23 WHT 39-2AXLEXT 18AWG GXL SW18(1)
23 24 WHT 39-3AXLRET 18AWG GXL SW18(3)
24 25 WHT 49-18PLVL1 18AWG GXL X36A(2)
25 WHT 55-26JLOCKIN 18AWG GXL X36A(10) 26 WHT 49-17PLVL2 18AWG GXL X36A(16)
26 WHT 55-25JLOCKOUT 18AWG GXL X36A(11) 27 WHT 48-22SPD 18AWG GXL SW15(3)
27 28 WHT 48-1ENGSPD 18AWG GXL SW15(1)
28 29 WHT 49-15SFTTOUCH 18AWG GXL SW20-2(1)
29 BLK 0-4 18AWG GXL X36A(12) 30 WHT 52-3HEAD/TAILLT 18AWG GXL SW22-2(1)
J1939CA 31 WHT 52-2HORN 18AWG GXL SW08-2(1)
30 GRN CANLOW 20AWG MS41(4)
BLE 32 WHT 49-14CREEP 18AWG GXL SW10(2)
J1939CA 33 WHT 49-19PROXNO 18AWG GXL X33A(13)
31 YEL CANHI 20AWG MS41(2)
BLE
34 WHT 55-4POTREF 18AWG GXL SW10(4)
J1939CA
32 SHLD CANSHIELD 20AWG MS41(6) 35 WHT 55-5PUMPPOT 18AWG GXL SW10(6)
BLE
33 WHT 49-23GND 18AWG GXL X36A(17)
34
35
3121619 7-25
CO01-J2 SW27
CONN WIRE DRIVE ORIENT
POS COLOR CONN WIRE
1 WHT 59-1JSWGRT 18AWG GXL SW19(1) POS COLOR
2 WHT 59-2JSWGLT 18AWG GXL SW19(3) 1 WHT 55-6 DOS 18 AWG GXL CO01-J2 (4)
3 YEL 2-8 18AWG GXL X38A(8) 2 YEL 2-1-17 18 AWG GXL SW26 (2)
4 WHT 55-6DOS 18AWG GXL SW27(1) 3
5 4
6 WHT 49-1TILT 18AWG GXL GD04-J4(5) 5
7 YEL 2-2ENABLE 18AWG GXL GD04-J2(2) 6
8 WHT 47-2SYSFAIL 18AWG GXL GD04-J3(6) SW26
9 WHT 49-5CREEP 18AWG GXL GD04-J2(1) CAPACITY SEL
10 WHT 49-3BRKNCABLE 18AWG GXL GD04-J3(5) CONN WIRE
11 WHT 49-2OVERLOAD 18AWG GXL GD04-J4(3) POS COLOR
12 WHT 54-1500LBMODE 18AWG GXL GD04-J4(4) 1
13 WHT 54-21000LBMODE 18AWG GXL GD04-J3(4) 2 YEL 2-1-16 18 AWG GXL SW25 (2)
14 WHT 39-1AXLSET 18AWG GXL GD04-J3(2) 2 YEL 2-1-17 18 AWG GXL SW27 (2)
15 WHT 52-1GEN 18AWG GXL GD04-J4(2) 3 YEL 54-3 CPCITY SW 18 AWG GXL CO01-J1 (21)
16 WHT 49-21SFTCHLT 18AWG GXL LB12+(1) 4
17 WHT 48-1ENGPREHEAT 18AWG GXL GD04-J4(6) 5
18 BLK 0-2 18AWG GXL GD04-J2(6) 6
19 WHT 49-4BCS 18AWG GXL GD04-J3(1) SW25
20 WHT 47-1PLTFMLVLFAIL 18AWG GXL GD04-J4(1) STRT/AUX PWR
21 WHT 47-5LOWFUL 18AWG GXL GD04-J2(3) CONN WIRE
22 WHT 47-1FUL1/4 18AWG GXL GD04-J1(1) POS COLOR
23 WHT 47-3FUL3/4 18AWG GXL GD04-J1(3) 1 WHT 48-3 STRT 18 AWG GXL CO01-J1 (14)
24 WHT 47-2FUL1/2 18AWG GXL GD04-J1(2) 2 YEL 2-1-15 18 AWG GXL SW24 (2)
25 BLK 0-1 18AWG GXL GD04-J1(4) 2 YEL 2-1-16 18 AWG GXL SW26 (2)
26 WHT 49-9ANALPWR 18AWG GXL X32(1) 3 WHT 53-1 AUX 18 AWG GXL CO01-J1 (15)
27 WHT 49-6ANALGND 18AWG GXL X32(4) 4
28 WHT 49-8RX 18AWG GXL X32(2) 5
29 WHT 49-7TX 18AWG GXL X32(3) 6
30 WHT 55-1DRVORNT 18AWG GXL GD04-J3(3) SW35-1A
31 WHT 59-6JIBLOK 18AWG GXL LB320+(1) CONN WIRE
32 YEL 2-6 18AWG GXL S40(1) POS COLOR
33 YEL 2-7 18AWG GXL X38A(2) 1A RED 1-4-3 PLTF MODE 18 AWG GXL CO01-J7 (2)
34
SW20-1
35 WHT 47-4FULFULL 18AWG GXL GD04-J1(6)
CONN WIRE
SW35-2A POS COLOR
CONN WIRE 1 YEL 2-1-10 18 AWG GXL SW19 (2)
POS COLOR 1 YEL 2-1-11 18 AWG GXL SW21 (2)
2A RED 1-4-3 18 AWG GXL X33A (5)
7-26 3121619
SW24 SW14
BOOM CONTROL JIB TELE
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 1 WHT 29-1 JTELE IN 18 AWG GXL CO01-J1 (3)
2 YEL 2-1-14 18 AWG GXL SW23 (2) 2 YEL 2-1-8 18 AWG GXL SW13 (2)
3 WHT 49-16 ENVLP 18 AWG GXL CO01-J1 (22) 3 WHT 29-2 JTELE OUT 18 AWG GXL CO01-J1 (4)
4 4
5 5
6 6
CONN WIRE SW19

POS COLOR JIB SWING
1 WHT 49-5 CREEP 18 AWG GXL CO01-J2 (9) CONN WIRE
2 YEL 2-2 ENABLE 18 AWG GXL CO01-J2 (7) POS COLOR
3 WHT 47-5 LOW FUL 18 AWG GXL CO01-J2 (21) 1 WHT 59-1 JSWG RT 18 AWG GXL CO01-J2 (1)
4 2 YEL 2-1-10 18 AWG GXL SW20-1 (1)
5 2 YEL 2-1-9 18 AWG GXL SW14 (2)
6 BLK 0-2 18 AWG GXL CO01-J2 (18) 3 WHT 59-2 JSWG LT 18 AWG GXL CO01-J2 (2)
4
GD04-J1
5
CONN WIRE
POS COLOR
1 WHT 47-1 FUL 1/4 18 AWG GXL CO01-J2 (22) SW21
2 WHT 47-2 FUL 1/2 18 AWG GXL CO01-J2 (24) JIB LIFT
3 WHT 47-3 FUL 3/4 18 AWG GXL CO01-J2 (23) CONN WIRE
POS COLOR
4 BLK 0-1 18 AWG GXL CO01-J2 (25)
1 WHT 27-1 JIB UP 18 AWG GXL CO01-J1 (11)
4 BLK 0-1-2 18 AWG GXL LB12- (1)
2 YEL 2-1-11 18 AWG GXL SW20-1 (1)
5
2 YEL 2-1-12 18 AWG GXL SW22-1 (1)
6 WHT 47-4 FUL FULL 18 AWG GXL CO01-J2 (35)
3 WHT 27-2 JIB DN 18 AWG GXL CO01-J1 (12)
SW13 4
PLTFM ROTATE
5
CONN WIRE
POS COLOR
1 WHT 23-1 P ROT RT 18 AWG GXL CO01-J1 (7) SW23
2 YEL 2-1-7 18 AWG GXL SW10 (3) MAIN BOOM TELE
3 YEL 2-1-8 18 AWG GXL SW14 (2) CONN WIRE
POS COLOR
4 WHT 23-2 P ROT LT 18 AWG GXL CO01-J1 (8)
1 WHT 13-1 MTELE IN 18 AWG GXL CO01-J1 (5)
5
2 YEL 2-1-13 18 AWG GXL SW22-1 (1)
6
2 YEL 2-1-14 18 AWG GXL SW24 (2)
3 WHT 13-2 MTELE OUT 18 AWG GXL CO01-J1 (6)
4
5
6
3121619 7-27
SW22-2 GD04-J3
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 52-3 HEAD/TAIL LT 18 AWG GXL CO01-J1 (30) 1 WHT 49-4 BCS 18 AWG GXL CO01-J2 (19)
2 WHT 39-1 AXL SET 18 AWG GXL CO01-J2 (14)
SW22-1
3 WHT 55-1 DRV ORNT 18 AWG GXL CO01-J2 (30)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 4 WHT 54-2 1000LB MODE 18 AWG GXL CO01-J2 (13)
POS COLOR
1 YEL 2-1-12 18 AWG GXL SW21 (2) 5 WHT 49-3 BRKN CABLE 18 AWG GXL CO01-J2 (10)
1 YEL 2-1-13 18 AWG GXL SW23 (2) 6 WHT 47-2 SYS FAIL 18 AWG GXL CO01-J2 (8)
SW20-2 SW08-2
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 49-15 SFT TOUCH 18 AWG GXL CO01-J1 (29) 1 WHT 52-2 HORN 18 AWG GXL CO01-J1 (31)
LB12- SW08-1
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-1-2 18 AWG GXL GD04-J1 (4) 1 YEL 2-1-4 18 AWG GXL CO01-J1 (31)
1 BLK 0-1-2-2 18 AWG GXL LB320- (1) 1 YEL 2-1-5 18 AWG GXL SW10 (3)
LB12+ SW18
AXLE EXT/RET
CONN WIRE
WIRE LABEL GAUGE JACKET TO CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET TO
POS COLOR
1 WHT 49-21 SFTCH LT 18 AWG GXL CO01-J2 (16)
1 WHT 39-2 AXL EXT 18 AWG GXL CO01-J1 (23)
LB320+ 2 YEL 2-1-3 18 AWG GXL SW17 (2)
CONN WIRE 2 YEL 2-1-4 18 AWG GXL SW08-1 (1)
POS COLOR
3 WHT 39-3 AXL RET 18 AWG GXL CO01-J1 (24)
1 WHT 59-6 JIB LOK 18 AWG GXL CO01-J2 (31)
4
LB320- 5
CONN WIRE 6
POS COLOR
SW17
1 BLK 0-1-2-2 18 AWG GXL LB12- (1)
PLTFM LEVEL
GD04-J4 CONN WIRE
CONN WIRE POS COLOR
POS COLOR 1 WHT 25-1 PLVL UP 18 AWG GXL CO01-J1 (9)
1 WHT 47-1 PLTFM LVL FAIL 18 AWG GXL CO01-J2 (20) 2 YEL 2-1-2 18 AWG GXL SW16 (2)
2 WHT 52-1 GEN 18 AWG GXL CO01-J2 (15) 2 YEL 2-1-3 18 AWG GXL SW18 (2)
3 WHT 49-2 OVERLOAD 18 AWG GXL CO01-J2 (11) 3 WHT 25-2 PLVL DN 18 AWG GXL CO01-J1 (10)
4 WHT 54-1 500LB MODE 18 AWG GXL CO01-J2 (12) 4
5 WHT 49-1 TILT 18 AWG GXL CO01-J2 (6) 5
6 WHT 48-1 ENG PREHEAT 18 AWG GXL CO01-J2 (17) 6
7-28 3121619
3121619 7-29
7-30
SW23
SW22-2
SW22-1
SW21 SW20-1
SW20-2
SW19
SW14
SW13 X38B CO01-J7

CO01-J8
SW35-1A X385
GD04-J1 X390 X38A
GD04-J3 SW10 X472B
SW26 SW08-2 X392
X388 X472A
SW08-1
SW27
X180
SW16
STEER MODE
SW25 GD04-J4 X43A
SW35-2A SW18
GD04-J2 X387
SW17 CO01-J2 X44A
SW24
CO01-J1
X32
SW15 X399 X398
HIGH DRIVE X33A
MS41 AH30-
ALARM
X391 X36A
MS169 AH30+
ALARM
X384
MAF09960D
1001220868-D
Figure 7-26. Platform Box Wiring Harness (with SKYGUARD)
3121619
X36A X44A
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-6-1 18 AWG GXL S40 (2) 1 BRN 49-13 X44 PWR 20 AWG CABLE CO01-J7 (7)
1 WHT 50-2 P DUMP 16 AWG TXL () 2 WHT 49-12 X44 GND 20 AWG CABLE CO01-J7 (14)
2 WHT 49-18 PLVL 1 18 AWG GXL CO01-J1 (25) 3 BLU CAN HI 20 AWG CABLE MS169 (2)
3 WHT 49-22 GND 18 AWG GXL CO01-J7 (21) 4 BLK CAN LOW 20 AWG CABLE MS169 (4)
4 WHT 49-50 PROX NC 18 AWG GXL CO01-J1 (20) 5 GRY CAN SHIELD 20 AWG CABLE MS169 (6)
5 BLK 0-8 18 AWG GXL X388 (1)
X33A
6 WHT 25-4-1 PLVL DN 18 AWG GXL S46 (2)
CONN WIRE
7 WHT 25-3-1 PLVL UP 18 AWG GXL S45 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
8 WHT 23-3 PROT LT 18 AWG GXL CO01-J7 (5) 1 SHLD CAN SHIELD 20 AWG J1939 CABLE X472A (3)
9 WHT 23-4 PROT RT 18 AWG GXL CO01-J7 (6) 2 GRN CAN LOW 20 AWG J1939 CABLE X472A (2)
10 WHT 55-26 JLOCK IN 18 AWG GXL CO01-J7 (25) 3 YEL CAN HI 20 AWG J1939 CABLE X472A (1)
11 WHT 55-25 JLOCK OUT 18 AWG GXL CO01-J7 (26) 4 YEL 2-4 18 AWG GXL CO01-J7 (3)
12 BLK 0-4 18 AWG GXL CO01-J7 (29) 5 RED 1-4-3 18 AWG GXL SW35-2A (2A)
13 ORG 1-7-1 WK LT PWR 16 AWG TXL X392 (2) 6
14 7 WHT 25-5 PLVL DN O/R 18 AWG GXL S46 (2)
15 YEL 2-6-2 18 AWG GXL S40 (2) 8
16 WHT 49-17 PLVL 2 18 AWG GXL CO01-J1 (26) 9 WHT 25-6 PLVL UP O/R 18 AWG GXL S45 (2)
17 WHT 49-23 GND 18 AWG GXL CO01-J7 (33) 10 2-25 FUSIBLE LINK 12 AWG FUSIBLE LINK S480 (2)
18 WHT 50-2 P DUMP 16 AWG TXL X36A (14) 11 YEL 2-5 18 AWG GXL CO01-J7 (1)
19 BLK 0-7 16 AWG TXL X388 (1) 12 2-26 FUSIBLE LINK 12 AWG FUSIBLE LINK S481 (2)
20 ORG 1-7-2 WK LT PWR 16 AWG TXL X392 (4) 13 WHT 49-19 PROX NO 18 AWG GXL CO01-J1 (33)
21 14
X392 15 WHT 49-20 PROX NC 18 AWG GXL CO01-J1 (1)
LIGHTS (OPTION) 16 BLK 0-40 12 AWG GXL X384 (1)
CONN WIRE 17
POS COLOR 18 BLK 0-41 12 AWG GXL X391 (1)
1 BLK 0-40-3 16 AWG GXL X385 (1) 19
2 ORG 1-7-1 WK LT PWR 16 AWG TXL X36A (13)
X180
3 BLK 0-41-3 16 AWG GXL X385 (1)
CONN WIRE
4 ORG 1-7-2 WK LT PWR 16 AWG TXL X36A (20) WIRE LABEL GAUGE JACKET TO
POS COLOR
X43A 1
CONN WIRE 2 WHT PWR 20 AWG CABLE X386 (1)
POS COLOR 3 BLU GND 20 AWG CABLE X397 (1)
1 BRN 49-11 X43 PWR 20 AWG CABLE CO01-J7 (4) 4 BLK CAN HI 20 AWG CABLE MS169 (1)
2 WHT 49-10 X43 GND 20 AWG CABLE CO01-J7 (34) 5 GRY CAN LOW 20 AWG CABLE MS169 (3)
3 BLU CAN HI 20 AWG CABLE MS41 (12)
X390
4 BLK CAN LOW 20 AWG CABLE MS41 (10)
CONN WIRE
5 GRY CAN SHIELD 20 AWG CABLE MS41 (8) WIRE LABEL GAUGE JACKET TO
POS COLOR
1 BLK 0-41-2 12 AWG GXL CO01-J8 (1)
3121619 7-31
X385 MS169
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-40-3 16 AWG GXL X392 (1) 1 BLK CAN HI 20 AWG CABLE X180 (4)
1 BLK 0-41-3 16 AWG GXL X392 (3) 2 BLU CAN HI 20 AWG CABLE X44A (3)
3 GRY CAN LOW 20 AWG CABLE X180 (5)
CO01-J8
4 GRY CAN LOW 20 AWG CABLE X44A (4)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 5 SHLD CAN SHIELD 20 AWG J1939 CABLE MS41 (7)
POS COLOR
1 BLK 0-41-2 12 AWG GXL X390 (1) 6 GRY CAN SHIELD 20 AWG CABLE X44A (5)
2 YEL 2-25-1 12 AWG GXL X387 (1) 7
8
X472B
9 GRN CAN LOW 20 AWG J1939 CABLE MS41 (9)
CONN WIRE
POS COLOR
11
1 YEL CAN HI 20 AWG J1939 CABLE MS41 (1)
12 YEL CAN HI 20 AWG J1939 CABLE MS41 (11)
2 GRN CAN LOW 20 AWG J1939 CABLE MS41 (3)
3 SHLD CAN SHIELD 20 AWG J1939 CABLE MS41 (5) X5A
PLATFORM SENSOR
X472A
CONN WIRE
POS COLOR
1 FUSIBLE LINK 14 AWG FUSIBLE LINK FC250 (1)
1 YEL CAN HI 20 AWG J1939 CABLE X33A (3)
2 BLK P6 SKYG GND 18 AWG GXL AH30 - (1)
2 GRN CAN LOW 20 AWG J1939 CABLE X33A (2)
3
3 SHLD CAN SHIELD 20 AWG J1939 CABLE X33A (1)
4 WHT P1 SKYG INPUT #1 20 AWG GXL CO01-J7 (18)
X386 5 WHT P3 SKYG INPUT #2 20 AWG GXL CO01-J1 (2)
CONN WIRE 6
POS COLOR
1 WHT PWR 20 AWG CABLE X180 (2)
X32
CONN WIRE
POS COLOR
1 WHT 49-9 ANALPWR 18 AWG GXL CO01-J2 (26)
2 WHT 49-8 RX 18 AWG GXL CO01-J2 (28)
3 WHT 49-7 TZX 18 AWG GXL CO01-J2 (29)
4 WHT 49-6 ANALGND 18 AWG GXL CO01-J2 (27)
7-32 3121619
CO01-J1 CO01-J2
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 49-20 PROX NC 18 AWG GXL X33A (15) 1 WHT 59-1 JSWG RT 18 AWG GXL SW19 (1)
2 WHT P3 SKYG INPUT #2 20 AWG GXL X5A (5) 2 WHT 59-2 JSWG LT 18 AWG GXL SW19 (3)
3 WHT 29-1 JTELE IN 18 AWG GXL SW14 (1) 3 YEL 2-8 18 AWG GXL X38A (8)
4 WHT 29-2 JTELE OUT 18 AWG GXL SW14 (3) 4 WHT 55-6 DOS 18 AWG GXL SW27 (1)
5 WHT 13-1 MTELE IN 18 AWG GXL SW23 (1) 5
6 WHT 13-2 MTELE OUT 18 AWG GXL SW23 (3) 6 WHT 49-1 TILT 18 AWG GXL GD04-J4 (5)
7 WHT 23-1 P ROT RT 18 AWG GXL SW13 (1) 7 YEL 2-2 ENABLE 18 AWG GXL GD04-J2 (2)
8 WHT 23-2 P ROT LT 18 AWG GXL SW13 (3) 8 WHT 47-2 SYS FAIL 18 AWG GXL GD04-J3 (6)
9 WHT 25-1 PLVL UP 18 AWG GXL SW17 (1) 9 WHT 49-5 CREEP 18 AWG GXL GD04-J2 (1)
10 WHT 25-2 PLVL DN 18 AWG GXL SW17 (3) 10 WHT 49-3 BRKN CABLE 18 AWG GXL GD04-J3 (5)
11 WHT 27-1 JIB UP 18 AWG GXL SW21 (1) 11 WHT 49-2 OVERLOAD 18 AWG GXL GD04-J4 (3)
12 WHT 27-2 JIB DN 18 AWG GXL SW21 (3) 12 WHT 54-1 500LB MODE 18 AWG GXL GD04-J4 (4)
13 BLK 0-3 18 AWG GXL SW10 (5) 13 WHT 54-2 1000LB MODE 18 AWG GXL GD04-J3 (4)
14 WHT 48-3 STRT 18 AWG GXL SW25 (1) 14 WHT 39-1 AXL SET 18 AWG GXL GD04-J3 (2)
15 WHT 53-1 AUX 18 AWG GXL SW25 (3) 15 WHT 52-1 GEN 18 AWG GXL GD04-J4 (2)
16 WHT 55-2 CRB STR 18 AWG GXL SW16 (1) 16 WHT 49-21 SFTCH LT 18 AWG GXL LB12+ (1)
17 WHT 55-3 CRD STR 18 AWG GXL SW16 (3) 17 WHT 48-1 ENG PREHEAT 18 AWG GXL GD04-J4 (6)
18 YEL 2-1 18 AWG GXL SW15 (2) 18 BLK 0-2 18 AWG GXL GD04-J2 (6)
19 19 WHT 49-4 BCS 18 AWG GXL GD04-J3 (1)
20 WHT 49-50 PROX NC 18 AWG GXL X36A (4) 20 WHT 47-1 PLTFM LVL FAIL 18 AWG GXL GD04-J4 (1)
21 WHT 54-3 CPCITY SW 18 AWG GXL SW26 (3) 21 WHT 47-5 LOW FUL 18 AWG GXL GD04-J2 (3)
22 WHT 49-16 ENVLP 18 AWG GXL SW24 (3) 22 WHT 47-1 FUL 1/4 18 AWG GXL GD04-J1 (1)
23 WHT 39-2 AXL EXT 18 AWG GXL SW18 (1) 23 WHT 47-3 FUL 3/4 18 AWG GXL GD04-J1 (3)
24 WHT 39-3 AXL RET 18 AWG GXL SW18 (3) 24 WHT 47-2 FUL 1/2 18 AWG GXL GD04-J1 (2)
25 WHT 49-18 PLVL 1 18 AWG GXL X36A (2) 25 BLK 0-1 18 AWG GXL GD04-J1 (4)
26 WHT 49-17 PLVL 2 18 AWG GXL X36A (16) 26 WHT 49-9 ANALPWR 18 AWG GXL X32 (1)
27 WHT 48-2 2 SPD 18 AWG GXL SW15 (3) 27 WHT 49-6 ANALGND 18 AWG GXL X32 (4)
28 WHT 48-1 ENG SPD 18 AWG GXL SW15 (1) 28 WHT 49-8 RX 18 AWG GXL X32 (2)
29 WHT 49-15 SFT TOUCH 18 AWG GXL SW20-2 (1) 29 WHT 49-7 TX 18 AWG GXL X32 (3)
30 WHT 52-3 HEAD/TAIL LT 18 AWG GXL SW22-2 (1) 30 WHT 55-1 DRV ORNT 18 AWG GXL GD04-J3 (3)
31 WHT 52-2 HORN 18 AWG GXL SW08-2 (1) 31 WHT 59-6 JIB LOK 18 AWG GXL LB320+ (1)
32 WHT 49-14 CREEP 18 AWG GXL SW10 (2) 32 YEL 2-6 18 AWG GXL S40 (1)
33 WHT 49-19 PROX NO 18 AWG GXL X33A (13) 33 YEL 2-7 18 AWG GXL X38A (2)
34 WHT 55-4 POT REF 18 AWG GXL SW10 (4) 34
35 WHT 55-5 PUMP POT 18 AWG GXL SW10 (6) 35 WHT 47-4 FUL FULL 18 AWG GXL GD04-J1 (6)
3121619 7-33
CO01-J7 AH30+
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-5 18 AWG GXL X33A (11) 1 WHT 49-26 ALARM 18 AWG GXL CO01- J7 (19)
2 RED 1-4-3 PLTF MODE 18 AWG GXL SW35-1A (1A)
AH30-
3 YEL 2-4 18 AWG GXL X33A (4)
CONN WIRE
4 BRN 49-11 X43 PWR 20 AWG CABLE X43A (1) WIRE LABEL GAUGE JACKET TO
POS COLOR
5 WHT 23-3 PROT LT 18 AWG GXL X36A (8) 1 BLK 0-5 18 AWG GXL CO01- J7 (20)
6 WHT 23-4 PROT RT 18 AWG GXL X36A (9) 1 BLK P6 SKYG GND 18 AWG GXL X54 (2)
7 BRN 49-13 X44 PWR 20 AWG CABLE X44A (1)
MS41
8 WHT 49-25 FTSW OPEN 18 AWG GXL X38A (7)
CONN WIRE
9 WHT 52-4 GEN 18 AWG GXL X38A (1) WIRE LABEL GAUGE JACKET TO
POS COLOR
10
1 YEL CAN HI 20 AWG J1 939 CABLE X472B (1)
11
2 YEL CAN HI 20 AWG J1 939 CABLE CO01- J7 (31)
12
3 GRN CAN LOW 20 AWG J1 939 CABLE X472B (2)
13
4 GRN CAN LOW 20 AWG J1 939 CABLE CO01- J7 (30)
14 WHT 49-12 X44 GND 20 AWG CABLE X44A (2)
5 SHLD CAN SHIELD 20 AWG J1 939 CABLE X472B (3)
15 WHT 25-3 PLVL UP 18 AWG GXL S45 (1)
6 SHLD CAN SHIELD 20 AWG J1 939 CABLE CO01- J7 (32)
16 WHT 25-4 PLVL DN 18 AWG GXL S46 (1)
7 SHLD CAN SHIELD 20 AWG J1 939 CABLE MS169 (5)
17
8 GRY CAN SHIELD 20 AWG CABLE X43A (5)
18 WHT P1 SKYG INPUT #1 20 AWG GXL X5A (4)
9 GRN CAN LOW 20 AWG J1 939 CABLE MS169 (9)
19 WHT 49-26 ALARM 18 AWG GXL AH30+ (1)
10 BLK CAN LOW 20 AWG CABLE X43A (4)
20 BLK 0-5 18 AWG GXL AH30- (1)
11 YEL CAN HI 20 AWG J1 939 CABLE MS169 (12)
21 WHT 49-22 GND 18 AWG GXL X36A (3)
12 BLU CAN HI 20 AWG CABLE X43A (3)
22
23 X384
24 CONN WIRE
POS COLOR
25 WHT 55-26 JLOCK IN 18 AWG GXL X36A (10)
1 BLK 0- 40 12 AWG GXL X33A (16)
26 WHT 55-25 JLOCK OUT 18 AWG GXL X36A (11)
27 X391
28 CONN WIRE
29 BLK 0-4 18 AWG GXL X36A (12) POS COLOR
30 GRN CAN LOW 20 AWG J1939 CABLE MS41 (4) 1 BLK 0- 41 12 AWG GXL X33A (18)
31 YEL CAN HI 20 AWG J1939 CABLE MS41 (2) X398
32 SHLD CAN SHIELD 20 AWG J1939 CABLE MS41 (6) CONN WIRE
33 WHT 49-23 GND 18 AWG GXL X36A (17) WIRE LABEL GAUGE JACKET TO
POS COLOR
34 WHT 49-10 X43 GND 20 AWG CABLE X43A (2) 1 YEL 2- 25 12 AWG GXL S480 (1)
35
X399
CONN WIRE WIRE LABEL
GAUGE JACKET TO
POS COLOR
1 YEL 2- 26 12 AWG GXL S481 (1)
7-34 3121619
X387 X388
CONN WIRE WIRE LABEL CONN WIRE WIRE LABEL
GAUGE JACKET TO GAUGE JACKET TO
POS COLOR POS COLOR
1 YEL 2- 25- 1 12 AWG GXL CO01- J8 (2) 1 BLK 0- 7 16 AWG TXL X36A (19)
1 BLK 0- 8 18 AWG GXL X36A (5)
X38A
CONN WIRE WIRE LABEL SW10
GAUGE JACKET TO
POS COLOR CONN WIRE WIRE LABEL
GAUGE JACKET TO
1 WHT 52-4 GEN 18 AWG GXL CO01- J7 (9) POS COLOR
2 YEL 2-7 18 AWG GXL CO01- J2 (33) 1
3 WHT 2- 8- 1 18 AWG GXL S301 (1) 2 WHT 49- 14 CREEP 18 AWG GXL CO01- J1 (32)
4 WHT 49- 27 18 AWG GXL X38A (5) 3 YEL 2- 1- 5 18 AWG GXL SW08- 1 (1)
5 WHT 49- 27 18 AWG GXL X38A (4) 3 YEL 2- 1- 7 18 AWG GXL SW13 (2)
6 YEL 2- 8- 1 18 AWG GXL X38A (8) 4 WHT 55- 4 POT REF 18 AWG GXL CO01- J1 (34)
7 WHT 49- 25 FTSW OPEN 18 AWG GXL CO01- J7 (8) 5 BLK 0- 3 18 AWG GXL CO01- J1 (13)
8 YEL 2- 8- 1 18 AWG GXL X38A (6) 6 WHT 55- 5 PUMP POT 18 AWG GXL CO01- J1 (35)
8 YEL 2- 8 18 AWG GXL CO01- J2 (3)
SW15
9 HIGH DRIVE
10 CONN WIRE WIRE LABEL
GAUGE JACKET TO
11 POS COLOR
12 1 WHT 48- 1 ENG SPD 18 AWG GXL CO01- J1 (28)
13 2 YEL 2- 1 18 AWG GXL CO01- J1 (18)
14 2 YEL 2- 1- 1 18 AWG GXL SW16 (2)
15 3 WHT 48- 2 2 SPD 18 AWG GXL CO01- J1 (27)
X38B SW16
CONN WIRE WIRE LABEL STEER MODE
GAUGE JACKET TO
GAUGE JACKET TO
1 POS COLOR
2 1 WHT 55- 2 CRB STR 18 AWG GXL CO01- J1 (16)
3 WHT P8 18 AWG GXL X38B (6) 2 YEL 2- 1 18 AWG GXL SW15 (2)
4 2 YEL 2- 1- 1 18 AWG GXL SW17 (2)
5 3 WHT 55- 3 CRD STR 18 AWG GXL CO01- J1 (17)
6 WHT P8 18 AWG GXL X38B (3) SW17
7 PLTFM LEVEL
8 CONN WIRE WIRE LABEL
GAUGE JACKET TO
8 POS COLOR
9 1 WHT 25- 1 PLVL UP 18 AWG GXL CO01- J1 (9)
10 2 YEL 2- 1- 2 18 AWG GXL SW16 (2)
11 2 YEL 2- 1- 3 18 AWG GXL SW18 (2)
12 3 WHT 25- 2 PLVL DN 18 AWG GXL CO01- J1 (10)
13
14
15
3121619 7-35
SW18 LB12+
AXLE EXT/ RET CONN WIRE WIRE LABEL
GAUGE JACKET TO
CONN WIRE WIRE LABEL POS COLOR
GAUGE JACKET TO
POS COLOR 1 WHT 49- 21 SFTCH LT 18 AWG GXL CO01- J2 (16)
1 WHT 39- 2 AXL EXT 18 AWG GXL CO01- J1 (23)
LB12-
2 YEL 2- 1- 3 18 AWG GXL SW17 (2)
2 YEL 2- 1- 4 18 AWG GXL SW08- 1 (1) GAUGE JACKET TO
POS COLOR
3 WHT 39- 3 AXL RET 18 AWG GXL CO01- J1 (24)
1 BLK 0- 1- 2 18 AWG GXL GD04- J1 (4)
SW08- 1 1 BLK 0- 1- 2- 2 18 AWG GXL LB320- (1)
GAUGE JACKET TO SW20- 2
POS COLOR
1 YEL 2- 1- 4 18 AWG GXL SW18 (2) GAUGE JACKET TO
POS COLOR
1 YEL 2- 1- 5 18 AWG GXL SW10 (3)
1 WHT 49- 15 SFT TOUCH 18 AWG GXL GD01- J1 (29)
SW08- 2
SW20- 1
GAUGE JACKET TO CONN WIRE WIRE LABEL
POS COLOR
1 WHT 52- 2 HORN 18 AWG GXL CO01- J1 (31)
1 YEL 2- 1- 10 18 AWG GXL SW19 (2)
GD04- J4 1 YEL 2- 1- 11 18 AWG GXL SW21 (2)
GAUGE JACKET TO SW22- 1
POS COLOR
1 WHT 47- 1 PLTFM LVL FAIL 18 AWG GXL CO01- J2 (20) GAUGE JACKET TO
POS COLOR
2 WHT 52- 1 GEN 18 AWG GXL CO01- J2 (15)
1 YEL 2- 1- 12 18 AWG GXL SW21 (2)
3 WHT 49- 2 OVERLOAD 18 AWG GXL CO01- J2 (11)
1 YEL 2- 1- 13 18 AWG GXL SW23 (2)
4 WHT 54- 1 500LB MODE 18 AWG GXL CO01- J2 (12)
5 WHT 49- 1 TILT 18 AWG GXL CO01- J2 (6) SW22- 2
6 WHT 48- 1 ENG PREHEAT 18 AWG GXL CO01- J2 (17) CONN WIRE WIRE LABEL
GAUGE JACKET TO
POS COLOR
GD04- J3 1 WHT 52- 3 HEAD/ TAIL LT 18 AWG GXL CO01- J1 (30)
GAUGE JACKET TO SW23
POS COLOR
MAIN BOOM TELE
1 WHT 49- 4 BCS 18 AWG GXL CO01- J2 (19)
2 WHT 39- 1 AXL SET 18 AWG GXL CO01- J2 (14) GAUGE JACKET TO
POS COLOR
3 WHT 55- 1 DRV ORNT 18 AWG GXL CO01- J2 (30)
1 WHT 13- 1 MTELE IN 18 AWG GXL CO01- J1 (5)
4 WHT 54- 2 1000LB MODE 18 AWG GXL CO01- J2 (13)
2 YEL 2-1- 13 18 AWG GXL SW22- 1 (1)
5 WHT 49- 3 BRKN CABLE 18 AWG GXL CO01- J2 (10)
2 YEL 2-1- 14 18 AWG GXL SW24 (2)
6 WHT 47- 2 SYS FAIL 18 AWG GXL CO01- J2 (8)
3 WHT 13- 2 MTELE OUT 18 AWG GXL CO01- J1 (6)
LB320-
SW21
CONN WIRE WIRE LABEL JIB LIFT
GAUGE JACKET TO
POS COLOR
1 BLK 0- 1- 2- 2 18 AWG GXL LB12- (1) GAUGE JACKET TO
POS COLOR
LB320+ 1 WHT 27- 1 JIB UP 18 AWG GXL CO01- J1 (11)
CONN WIRE WIRE LABEL 2 YEL 2-1- 11 18 AWG GXL SW20- 1 (1)
GAUGE JACKET TO
POS COLOR 2 YEL 2-1- 12 18 AWG GXL SW22- 1 (1)
1 WHT 59- 6 JIB LOK 18 AWG GXL CO01- J2 (31) 3 WHT 27- 2 JIB DN 18 AWG GXL CO01- J1 (12)
7-36 3121619
X397 SW24
CONN WIRE WIRE LABEL BOOM CONTROL
GAUGE JACKET TO
GAUGE JACKET TO
1 BLU GND 20 AWG CABLE X180 (3) POS COLOR
1
SW19
2 YEL 2- 1- 14 18 AWG GXL SW23 (2)
JIB SWING
2 YEL 2- 1- 15 18 AWG GXL SW25 (2)
GAUGE JACKET TO 3 WHT 49- 16 ENVLP 18 AWG GXL CO01- J1 (22)
POS COLOR
1 WHT 59- 1 JSWG RT 18 AWG GXL CO01- J2 (1) GD04- J1
2 YEL 2- 1- 10 18 AWG GXL SW20- 1 (1) CONN WIRE WIRE LABEL
GAUGE JACKET TO
2 YEL 2- 1- 9 18 AWG GXL SW14 (2) POS COLOR
3 WHT 59- 2 JSWG LT 18 AWG GXL CO01- J2 (2) 1 WHT 47- 1 FUL 1/4 18 AWG GXL CO01- J2 (22)
2 WHT 47- 2 FUL 1/2 18 AWG GXL CO01- J2 (24)
SW14
JIB TELE 3 WHT 47- 3 FUL 3/4 18 AWG GXL CO01- J2 (23)
CONN WIRE WIRE LABEL 4 BLK 0- 1 18 AWG GXL CO01- J2 (25)
GAUGE JACKET TO
POS COLOR 4 BLK 0- 1- 2 18 AWG GXL LB12- 1
1 WHT 29- 1 JTELE IN 18 AWG GXL CO01- J1 (3) 5
2 YEL 2- 1- 8 18 AWG GXL SW13 (2) 6 WHT 47- 4 FUL FULL 18 AWG GXL CO01- J2 (35)
2 YEL 2- 1- 9 18 AWG GXL SW19 (2)
SW35- 2A
3 WHT 29- 2 JTELE OUT 18 AWG GXL CO01- J1 (4)
GAUGE JACKET TO
SW13 POS COLOR
PLTFM ROTATE 2A RED 1- 4- 3 18 AWG GXL X33A (5)
GAUGE JACKET TO SW35- 1A
POS COLOR
1 WHT 23- 1 P ROT RT 18 AWG GXL CO01- J1 (7) GAUGE JACKET TO
POS COLOR
2 YEL 2- 1- 7 18 AWG GXL SW10 (3)
1A RED 1- 4- 3 PLTF MODE 18 AWG GXL CO01- J7 (2)
2 YEL 2- 1- 8 18 AWG GXL SW14 (2)
3 WHT 23- 2 P ROT LT 18 AWG GXL CO01- J1 (8)
GD04- J2
GAUGE JACKET TO
POS COLOR
1 WHT 49- 5 CREEP 18 AWG GXL CO01- J2 (9)
2 YEL 2- 2 ENABLE 18 AWG GXL CO01- J2 (7)
3 WHT 47- 5 LOW FUL 18 AWG GXL CO01- J2 (21)
4
5
6 BLK 0- 2 18 AWG GXL CO01- J2 (18)
3121619 7-37
7-38
SN274
MS437
X36B
X365B
HV343
JLOCK OUT
HV342
JLOCK IN
HV277
HV278 P-ROT LFT
P-ROT RHT
HV276 SN273
HV275 P-LVL DN
P-LVL UP
HV281
PLTFM ENABLE
MAF08440E
1001149977-E
Figure 7-27. Platform Valve Wiring Harness
3121619
X36B HV278
CONN WIRE P-ROT RHT
POS COLOR CONN WIRE
1 RED CABLE 18 AWG CABLE SN274 (1) POS COLOR
2 BLU CABLE 18 AWG CABLE SN274 (2) 1 WHT 23-4 PROT RT 18 AWG GXL X36B (9)
3 BLK CABLE 18 AWG CABLE SN274 (3) 2 BLK 0-4-4 18 AWG GXL MS437 (1)
4 BLU CABLE 16 AWG CABLE X365B (3) HV275
5 SHIELD SHIELD 18 AWG SHLD NC () P-LVL UP
6 WHT 25-4-2 PLVL DN 18 AWG GXL HV276 (1) CONN WIRE
7 WHT 25-3-2 PLVL UP 18 AWG GXL HV275 (1) POS COLOR
8 WHT 23-3 PROT LT 18 AWG GXL HV277 (1) 1 WHT 25-3-2 PLVL UP 18 AWG GXL X36B (7)
9 WHT 23-4 PROT RT 18 AWG GXL HV278 (1) 2 BLK 0-4-1 18 AWG GXL MS437 (3)
10 WHT 55-26 JLOCK IN 18 AWG GXL HV342 (1) HV343
11 WHT 55-25 JLOCK OUT 18 AWG GXL HV343 (1) JLOCK OUT
12 BLK 0-4 18 AWG GXL MS437 (8) CONN WIRE
13 ORG CABLE 16 AWG CABLE X365B (2) POS COLOR
14 BLK CABLE 16 AWG CABLE X365B (4) 1 WHT 55-25 JLOCK OUT 18 AWG GXL X36B (11)
15 ORG CABLE 18 AWG CABLE SN273 (1) 2 BLK 0-4-6 18 AWG GXL MS437 (6)
16 YEL CABLE 18 AWG CABLE SN273 (2) HV277
17 BLK CABLE 18 AWG CABLE SN273 (3) P-ROT LFT
18 WHT 25-5 PLTFRM DUMP 16 AWG GXL HV281 (1) CONN WIRE
19 BLK 0-7 16 AWG GXL HV281 (2) POS COLOR
20 RED CABLE 16 AWG CABLE X365B (1) 1 WHT 23-3 PROT LT 18 AWG GXL X36B (8)
21 2 BLK 0-4-3 18 AWG GXL MS437 (2)
MS437 SN274
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-4-4 18 AWG GXL HV278 (2) 1 RED CABLE 18 AWG CABLE X36B (1)
2 BLK 0-4-3 18 AWG GXL HV277 (2) 2 BLU CABLE 18 AWG CABLE X36B (2)
3 BLK 0-4-1 18 AWG GXL HV275 (2) 3 BLK CABLE 18 AWG CABLE X36B (3)
4 BLK 0-4-2 18 AWG GXL HV276 (2) X365B
5 CONN WIRE
6 BLK 0-4-6 18 AWG GXL HV343 (2) POS COLOR
7 BLK 0-4-5 18 AWG GXL HV342 (2) 1 RED CABLE 16 AWG CABLE X36B (20)
8 BLK 0-4 18 AWG GXL X36B (12) 2 ORG CABLE 16 AWG CABLE X36B (13)
3 BLU CABLE 16 AWG CABLE X36B (4)
HV342
JLOCK IN 4 BLK CABLE 16 AWG CABLE X36B (14)
CONN WIRE SN273
POS COLOR
CONN WIRE
1 WHT 55-26 JLOCK IN 18 AWG GXL X36B (10) WIRE LABEL GAUGE JACKET TO
POS COLOR
2 BLK 0-4-5 18 AWG GXL MS437 (7) 1 ORG CABLE 18 AWG CABLE X36B (15)
2 YEL CABLE 18 AWG CABLE X36B (16)
3 BLK CABLE 18 AWG CABLE X36B (17)
3121619 7-39
HV281
PLTFM ENABLE
CONN WIRE
POS COLOR
1 WHT 25-5 PLTFRM DUMP 16 AWG GXL X36B (18)
2 BLK 0-7 16 AWG GXL X36B (19)
HV276
P-LVL DN
CONN WIRE
POS COLOR
1 WHT 25-4-2 PLVL DN 18 AWG GXL X36B (6)
2 BLK 0-4-2 18 AWG GXL MS437 (4)
7-40 3121619
3121619 7-41
7-42
MS262-2
X230A
MS262-3
SN260 CO245-J5
CO245-J2
CO245-J4 SN259
CO245-J3 JIB TRANS 2
X228B MS262-1
SN246
S264 S383
S265
X365A CO245-J1 SN257
X364B SN258
JIB TRANS 1
MS380 SN247
MS347
HV249
JIB SWG LFT
HV256
JIB LVL UP
HV255
JIB LVL DN
HV250
JIB SWG RHT
HV248
JIB ENABLE
HV251
HV252 JIB TELE OUT
JIB TELE IN
HV254
JIB LIFT UP
HV253
JIB LIFT DN
MAF08340G
1001149978-G
Figure 7-28. Jib Valve Wiring Harness
3121619
S264 SN247
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 27-5-1 JIB UP 18AWG GXL CO245-J5(1) A BLK GROUND 18AWG CABLE CO245-J3(6)
1 WHT 27-6-1 J-UP O/R 18AWG GXL CO245-J2(2) B RED 5V PWR 18AWG CABLE CO245-J3(4)
2 WHT 27-5-2 JIB UP 18AWG GXL HV254(1) C BLU SIGNAL 18AWG CABLE CO245-J3(2)
D WHT SIGNAL 18AWG CABLE CO245-J3(5)
S265
E GRN GROUND 18AWG CABLE CO245-J3(3)
CONN WIREC
WIRE LABEL GAUGE JACKET TO F ORG 5V PWR 18AWG CABLE CO245-J3(1)
POS OLOR
1 WHT 27-3-1 JIB DN O/R 18AWG GXL CO245-J2(1) HV253
1 WHT 27-4-1 JIB DN 18AWG GXL CO245-J5(2) JIB LIFT DN
2 WHT 27-4-2 JIB DN 18AWG GXL HV253(1) CONN WIRE
POS COLOR
S383
1 WHT 27-4-2 JIB DN 18AWG GXL S265(2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 BLK 0-26-2 18AWG GXL MS347(9)
POS COLOR
1 BLK 0-27 18AWG GXL MS380(12) HV254
2 BLK 0-27-1 18AWG GXL SN259(3) JIB LIFT UP
2 BLK 0-47 16AWG GXL HV248(2) CONN WIRE
POS COLOR
SN246 1 WHT 27-5-2 JIB UP 18AWG GXL S264(2)
CONN WIRE 2 BLK 0-26-1 18AWG GXL MS347(10)
POS COLOR
A BLK GROUND 18AWG CABLE CO245-J3(12) HV251
JIB TELE OUT
B RED 5V PWR 18AWG CABLE CO245-J3(10)
CONN WIRE
C BLU SIGNAL 18AWG CABLE CO245-J3(8) WIRE LABEL GAUGE JACKET TO
POS COLOR
D WHT SIGNAL 18AWG CABLE CO245-J3(11)
1 WHT 29-4-1 JIB OUT 18AWG GXL CO245-J5(6)
E GRN GROUND 18AWG CABLE CO245-J3(9)
2 BLK 0-26-4 18AWG GXL MS347(3)
F ORG 5V PWR 18AWG CABLE CO245-J3(7)
HV248
SN257 JIB ENABLE
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-22 18AWG GXL CO245-J4(1) 1 WHT 50-3 JIB DUMP 16AWG GXL X364B(3)
2 WHT 49-42 LOCK NC 18AWG GXL CO245-J2(5) 2 BLK 0-47 16AWG GXL S383(2)
3 BLK 0-23 18AWG GXL CO245-J4(2)
HV249
4 WHT 49-41 LOCK NO 18AWG GXL CO245-J2(4)
JIB SWG LFT
HV252 (JIB TELE IN) CONN WIRE
CONN WIRE POS COLOR
POS COLOR 1 WHT 59-2-1 JSWG LT 18AWG GXL CO245-J5(4)
1 WHT 29-3-1 JIB IN 18AWG GXL CO245-J5(5) 2 BLK 0-26-6 18AWG GXL MS347(1)
2 BLK 0-26-3 18AWG GXL MS347(4)
HV255 (JIB LVL DN)
CONN WIRE
POS COLOR
1 WHT 55-19 JLVL DN 18AWG GXL CO245-J2(12)
2 BLK 0-25-2 18AWG GXL MS347(7)
3121619 7-43
HV256 MS262-3
JIB LVL UP CONN WIRE
CONN WIRE POS COLOR
POS COLOR A YEL CAN HI 20AWG J1939CABLE CO245-J4(3)
1 WHT 55-20 JLVL UP 18AWG GXL CO245-J2(11) B GRN CAN LOW 20AWG J1939CABLE CO245-J4(4)
2 BLK 0-25-1 18AWG GXL MS347(8) C SHLD SHIELD 20AWG J1939CABLE CO245-J4(5)
HV250 X364B
JIB SWG RHT
CONN WIRE
POS COLOR
1 RED 1-7-2 WK LT PWR 16AWG GXL X365A(1)
1 WHT 59-1-1 JSWG RT 18AWG GXL CO245-J5(3)
2 RED 1-7-1 WK LT PWR 16AWG GXL X365A(2)
2 BLK 0-26-5 18AWG GXL MS347(2)
3 WHT 50-3 JIB DUMP 16AWG GXL HV248(1)
SN258 4 WHT 50-2 PLTFM DUMP 16AWG GXL X365A(4)
JIB TRANS 1
X230A
CONN WIRE
POS COLOR
1 YEL 2-21 18AWG GXL CO245-J4(7)
1 SHLD SHIELD 20AWG J1939CABLE CO245-J1(8)
2 WHT 49-44 PROX 1NC 18AWG GXL CO245-J2(7)
2 GRN CAN LOW 20AWG J1939CABLE CO245-J1(7)
3 BLK 0-24 18AWG GXL CO245-J4(8)
3 YEL CAN HI 20AWG J1939CABLE CO245-J1(6)
4 WHT 49-43 PROX 1NO 18AWG GXL CO245-J2(6)
4 YEL 2-4 18AWG GXL X228B(4)
SN259 5 RED 1-4-3 18AWG GXL X228B(5)
JIB TRANS 2
6 YEL 2-15 18AWG GXL X228B(6)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 7 WHT 25-5PLVL DN O/R 18AWG GXL X228B(7)
POS COLOR
8
1 YEL 2-19 18AWG GXL MS380(9)
9 WHT 25-6PLVL UP O/R 18AWG GXL X228B(9)
2 WHT 49-20 PROX NC 18AWG GXL X228B(15)
10 YEL 2-25 12AWG GXL MS380(7)
3 BLK 0-27-1 18AWG GXL S383(2)
11 YEL 2-5 18AWG GXL X228B(11)
4 WHT 49-19 PROX NO 18AWG GXL X228B(13)
12 YEL 2-26 12AWG GXL MS380(6)
MS262-1 13 WHT 27-6 J-UP O/R 18AWG GXL CO245-J1(2)
CONN WIRE 14
POS COLOR
15 WHT 27-3 JIB DN O/R 18AWG GXL CO245-J1(1)
J1939CA
A YEL CAN HI 20AWG X228B(3) 16 BLK 0-40 12AWG GXL MS380(10)
BLE
17
J1939CA
B GRN CAN LOW 20AWG X228B(2) 18 BLK 0-41 12AWG GXL MS380(3)
BLE
J1939CA 19
C SHLD SHIELD 20AWG X228B(1)
BLE
MS262-2
CONN WIRE
POS COLOR
A BLU CAN HI 20AWG CABLE SN260(3)
B BLK CAN LOW 20AWG CABLE SN260(4)
C GRY SHIELD 20AWG CABLE SN260(5)
7-44 3121619
CO245-J3 CO245-J2
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 ORG 5V PWR 18AWG CABLE SN247(F) 1 WHT 27-3-1 JIB DN O/R 18AWG GXL S265(1)
2 BLU SIGNAL 18AWG CABLE SN247(C) 2 WHT 27-6-1 J-UP O/R 18AWG GXL S264(1)
3 GRN GROUND 18AWG CABLE SN247(E) 3 BLK 0-25 18AWG GXL MS347(11)
4 RED 5V PWR 18AWG CABLE SN247(B) 4 WHT 49-41 LOCK NO 18AWG GXL SN257(4)
5 WHT SIGNAL 18AWG CABLE SN247(D) 5 WHT 49-42 LOCK NC 18AWG GXL SN257(2)
6 BLK GROUND 18AWG CABLE SN247(A) 6 WHT 49-43 PROX 1NO 18AWG GXL SN258(4)
7 ORG 5V PWR 18AWG CABLE SN246(F) 7 WHT 49-44PROX1NC 18AWG GXL SN258(2)
8 BLU SIGNAL 18AWG CABLE SN246(C) 8
9 GRN GROUND 18AWG CABLE SN246(E) 9
10 RED 5V PWR 18AWG CABLE SN246(B) 10
11 WHT SIGNAL 18AWG CABLE SN246(D) 11 WHT 55-20 JLVL UP 18AWG GXL HV256(1)
12 BLK GROUND 18AWG CABLE SN246(A) 12 WHT 55-19 JLVL DN 18AWG GXL HV255(1)
MS347 CO245-J1
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-26-6 18AWG GXL HV249(2) 1 WHT 27-3 JIB DN O/R 18AWG GXL X230A(15)
2 BLK 0-26-5 18AWG GXL HV250(2) 2 WHT 27-6 J-UP O/R 18AWG GXL X230A(13)
3 BLK 0-26-4 18AWG GXL HV251(2) 3
4 BLK 0-26-3 18AWG GXL HV252(2) 4 BLK 0-28 14AWG GXL MS380(11)
5 5 YEL 2-18 14AWG GXL MS380(8)
6 6 YEL CAN HI 20AWG J1939CABLE X230A(3)
7 BLK 0-25-2 18AWG GXL HV255(2) 7 GRN CAN LOW 20AWG J1939CABLE X230A(2)
8 BLK 0-25-1 18AWG GXL HV256(2) 8 SHLD SHIELD 20AWG J1939CABLE X230A(1)
9 BLK 0-26-2 18AWG GXL HV253(2) 9
10 BLK 0-26-1 18AWG GXL HV254(2) 10
11 BLK 0-25 18AWG GXL CO245-J2(3) 11 BRN 2-20 20AWG CABLE SN260(1)
12 BLK 0-26 18AWG GXL CO245-J5(12) 12 WHT 0-29 20AWG CABLE SN260(2)
CO245-J4 SN260
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-22 18AWG GXL SN257(1) 1 BRN 2-20 20AWG CABLE CO245-J1(11)
2 BLK 0-23 18AWG GXL SN257(3) 2 WHT 0-29 20AWG CABLE CO245-J1(12)
3 YEL CAN HI 20AWG J1939CABLE MS262-3(A) 3 BLU CAN HI 20AWG CABLE MS262-2(A)
4 GRN CAN LOW 20AWG J1939CABLE MS262-3(B) 4 BLK CAN LOW 20AWG CABLE MS262-2(B)
5 SHLD SHIELD 20AWG J1939CABLE MS262-3(C) 5 GRY SHIELD 20AWG CABLE MS262-2(C)
6
7 YEL 2-21 18AWG GXL SN258(1)
8 BLK 0-24 18AWG GXL SN258(3)
3121619 7-45
CO245-J5 X228B
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 27-5-1 JIB UP 18AWG GXL S264(1) 1 SHLD SHIELD 20AWG J1939CABLE MS262-1(C)
2 WHT 27-4-1 JIB DN 18AWG GXL S265(1) 2 GRN CAN LOW 20AWG J1939CABLE MS262-1(B)
3 WHT 59-1-1 JSWG RT 18AWG GXL HV250(1) 3 YEL CAN HI 20AWG J1939CABLE MS262-1(A)
4 WHT 59-2-1 JSWG LT 18AWG GXL HV249(1) 4 YEL 2-4 18AWG GXL X230A(4)
5 WHT 29-3-1 JIB IN 18AWG GXL HV252(1) 5 RED 1-4-3 18AWG GXL X230A(5)
6 WHT 29-4-1 JIB OUT 18AWG GXL HV251(1) 6 YEL 2-15 18AWG GXL X230A(6)
7 7 WHT 25-5 PLVL DN O/R 18AWG GXL X230A(7)
8 8
9 9 WHT 25-6 PLVL UP O/R 18AWG GXL X230A(9)
10 10 YEL 2-25 12AWG GXL MS380(4)
11 11 YEL 2-5 18AWG GXL X230A(11)
12 BLK 0-26 18AWG GXL MS347(12) 12 YEL 2-26 12AWG GXL MS380(5)
13 WHT 49-19 PROX NO 18AWG GXL SN259(4)
MS380
14
CONN WIRE
WIRE LABEL GAUGE JACKET TO 15 WHT 49-20 PROX NC 18AWG GXL SN259(2)
POS COLOR
1 BLK 0-41 12AWG GXL X228B(18) 16 BLK 0-40 12AWG GXL MS380(2)
2 BLK 0-40 12AWG GXL X228B(16) 17
3 BLK 0-41 12AWG GXL X230A(18) 18 BLK 0-41 12AWG GXL MS380(1)
4 YEL 2-25 12AWG GXL X228B(10) 19
5 YEL 2-26 12AWG GXL X228B(12)
6 YEL 2-26 12AWG GXL X230A(12)
7 YEL 2-25 12AWG GXL X230A(10)
8 YEL 2-18 14AWG GXL CO245-J1(5)
9 YEL 2-19 18AWG GXL SN259(1)
10 BLK 0-40 12AWG GXL X230A(16)
11 BLK 0-28 14AWG GXL CO245-J1(4)
12 BLK 0-27 18AWG GXL S383(1)
X365A
CONN WIRE
POS COLOR
1 RED 1-7-2 WK LT PWR 16AWG GXL X364B(1)
2 RED 1-7-1 WK LT PWR 16AWG GXL X364B(2)
3
4 WHT 50-2 PLTFM DUMP 16AWG GXL X364B(4)
7-46 3121619
3121619 7-47
7-48
CO128-J1
CO128-J2
X406A
MS148-1
X222B
X404B
X411
X413
CO128-J5 X421
CO128-J3
SN130
MAF08450C
1001149979-C
Figure 7-29. BLAM Module Wiring Harness
3121619
X404B CO128-J5
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED B LNGTH 18AWG CABLE CO128-J3(7) 1 WHT 7-4 LDRV PFWD 18AWG GXL X222B(6)
2 BLU B LNGTH 18AWG CABLE CO128-J3(8) 2 WHT 7-3 LDRV PREV 18AWG GXL X222B(5)
3 BLK B LNGTH 18AWG CABLE CO128-J3(9) 3
4 4
5 RED BRKN CBL PROX 18AWG CABLE X411(5) 5
6 BLU BRKN CBL PROX 18AWG CABLE X411(3) 6
7 BLK BRKN CBL PROX 18AWG CABLE X411(4) 7
8 SHIELD BRKN CBL PROX 18AWG SHLD X411(6) 8
9 YEL 1-10 18AWG GXL X406A(1)
X406A
10
CONN WIRE
POS COLOR
1 YEL 1-10 18AWG GXL CO128-J5(9) 12 BLK 0-15 18AWG GXL X222B(3)
2 WHT 49-60 GRVTY SEN1 18AWG GXL CO128-J2(8) X222B
3 BLK 0-55 18AWG GXL CO128-J2(3) CONN WIRE
4 POS COLOR
5 YEL 1-11 18AWG GXL CO128-J2(1) 1 WHT 7-1 RDRV PFWD 18AWG GXL CO128-J2(11)
6 WHT 49-61 GRVTY SEN2 18AWG GXL CO128-J2(9) 2 WHT 7-2 RDRV PREV 18AWG GXL CO128-J2(12)
7 BLK 0-56 18AWG GXL CO128-J2(2) 3 BLK 0-15 18AWG GXL CO128-J5(12)
8 4
5 WHT 7-3 LDRV PREV 18AWG GXL CO128-J5(2)
CO128-J2
6 WHT 7-4 LDRV PFWD 18AWG GXL CO128-J5(1)
CONN WIRE
POS COLOR SN130
1 YEL 1-11 18AWG GXL X406A(5) CONN WIRE
2 BLK 0-56 18AWG GXL X406A(7) POS COLOR
3 BLK 0-55 18AWG GXL X406A(3) 1 BLK BANG 2 18AWG CABLE CO128-J3(12)
4 2 RED BANG 2 18AWG CABLE CO128-J3(10)
5 3 BLU BANG 2 18AWG CABLE CO128-J3(5)
6 4 BLK BANG 1 18AWG CABLE CO128-J3(6)
7 5 RED BANG 1 18AWG CABLE CO128-J3(4)
8 WHT 49-60 GRVTY SEN1 18AWG GXL X406A(2) 6 BLU BANG 1 18AWG CABLE CO128-J3(11)
9 WHT 49-61 GRVTY SEN2 18AWG GXL X406A(6)
X421
10
CONN WIRE
11 WHT 7-1 RDRV PFWD 18AWG GXL X222B(1) WIRE LABEL
12 WHT 7-2 RDRV PREV 18AWG GXL X222B(2) 1 SHIELD B LNGTH 18AWG SHLD X404B(NC)
X413 MS148-1
CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET TO
POS COLOR TO POS COLOR
1 SHIELD CABLE SHIELD 18AWG SHLD SN130(NC) A YEL CAN HIGH 18AWG GXL CO128-J1(6)
1 SHIELD CABLE SHIELD 18AWG SHLD SN130(NC2) B GRN CAN LOW 18AWG GXL CO128-J1(7)
C
3121619 7-49
X411
CONN WIRE
POS COLOR
1 BLK 0-22 14AWG GXL CO128-J1(4)
2 YEL 2-10 14AWG GXL CO128-J1(5)
3 BLU BRKN CBL PROX 18AWG CABLE X404B(6)
4 BLK BRKN CBL PROX 18AWG CABLE X404B(7)
5 RED BRKN CBL PROX 18AWG CABLE X404B(5)
6 SHIELD BRKN CBL PROX 18AWG SHLD X404B(8)
CO128-J3
CONN WIRE
POS COLOR
1 WHT 5V 18AWG GXL CO128-J3(2)
2 WHT 5V 18AWG GXL CO128-J3(1)
3
4 RED BANG 1 18AWG CABLE SN130(5)
5 BLU BANG 2 18AWG CABLE SN130(3)
6 BLK BANG 1 18AWG CABLE SN130(4)
7 RED B LNGTH 18AWG CABLE X404B(1)
8 BLU B LNGTH 18AWG CABLE X404B(2)
9 BLK B LNGTH 18AWG CABLE X404B(3)
10 RED BANG 2 18AWG CABLE SN130(2)
11 BLU BANG 1 18AWG CABLE SN130(6)
12 BLK BANG 2 18AWG CABLE SN130(1)
CO128-J1
CONN WIRE
POS COLOR
1 BLK GND JUMP 18AWG GXL ()
1 YEL IGN JUMP 18AWG GXL CO128-J1(11)
2 BLK GND JUMP 18AWG GXL CO128-J1(12)
2 YEL IGN JUMP 18AWG GXL ()
3
4 BLK 0-22 14AWG GXL X411(1)
5 YEL 2-10 14AWG GXL X411(2)
6 YEL CAN HIGH 18AWG GXL MS148-1(A)
7 GRN CAN LOW 18AWG GXL MS148-1(B)
8
9
10
11
12
7-50 3121619
3121619 7-51
SN129
CO128-J4
1001157646-A
MAF08460A
Figure 7-30. Load Sensing Pin Cable
7-52 3121619
SN129
CONN WIRE
WIRE LABEL GAUGE JACKET
POS COLOR
A RED +B PWR SUP 22 PVC

B BLK -B GND SUP 22 PVC
C
D GRN CAN HI 22 PVC
E WHT CAN LO 22 PVC
F
CO128-J4
CONN WIRE
WIRE LABEL GAUGE JACKET
POS COLOR
1 RED +B PWR SUP 22 PVC

2 BLK -B GND SUP 22 PVC
3 GRN CAN HI 22 PVC
4 WHT CAN LO 22 PVC
5 SHLD SHIELD 22 PVC
6
7
8
3121619 7-53
X422
SN137
X406B
SN136
X404A
ADHESIVE LINED HEAT SHRINK

100mm
X407A
1001158015-F
MAF08480F
Figure 7-31. Base Boom Sensor Cable (Prior to SN 0300224828)
7-54 3121619
X407A SN136
CONN BOOM ANGLE SENSOR #1 RIGHT SIDE
WIRE COLOR WIRE LABEL GAUGE JACKET
POS CONN
1 RED B LNTH PWR 18 AWG CABLE POS
2 BLUE B LNTH SIG 18 AWG CABLE A RED #1 ANGLE PWR 18 AWG CABLE
3 BLACK B LNTH GND 18 AWG CABLE B BLUE #1 ANGLE SIG 18 AWG CABLE
4 RED/BLACK 18 AWG CABLE C BLACK #1 ANGLE GND 18 AWG CABLE
5 YELLOW BRKN CBL PWR 18 AWG CABLE SN137
6 ORANGE BRKN CBL SIG 18 AWG CABLE BOOM ANGLE SENSOR #2 LEFT SIDE
7 BROWN BRKN CBL GND 18 AWG CABLE CONN
8 SHIELD CABLE SHIELD 18 AWG CABLE POS
A YELLOW #2 ANGLE PWR 18 AWG CABLE
X404A
B ORANGE #2 ANGLE SIG 18 AWG CABLE
CONN
WIRE COLOR WIRE LABEL GAUGE JACKET C BROWN #2 ANGLE GND 18 AWG CABLE
POS
1 RED B LNTH PWR 18 AWG CABLE
2 BLUE B LNTH SIG 18 AWG CABLE
3 BLACK B LNTH GND 18 AWG CABLE
4 RED/BLACK 18 AWG CABLE
5 YELLOW BRKN CBL PWR 18 AWG CABLE
6 ORANGE BRKN CBL SIG 18 AWG CABLE
7 BROWN BRKN CBL GND 18 AWG CABLE
8 SHIELD CABLE SHIELD 18 AWG CABLE
X406B
CONN
POS
1 RED #1 ANGLE PWR 18 AWG CABLE
2 BLUE #1 ANGLE SIG 18 AWG CABLE
3 BLACK #1 ANGLE GND 18 AWG CABLE
4 RED/BLACK 18 AWG CABLE
5 YELLOW #2 ANGLE PWR 18 AWG CABLE
6 ORANGE #2 ANGLE SIG 18 AWG CABLE
7 BROWN #2 ANGLE GND 18 AWG CABLE
8 BLUE/BLACK 18 AWG CABLE
X422
CONN
POS
1 BRN/BLK CABLE SHIELD 18 AWG CABLE
3121619 7-55
SN221
COVER THESE TWO BRANCHES WITH

ADHESIVE LINED HEAT SHRINK.
S409
S410
SN401
X407B
SN131
1001158411-E
MAF08500E
Figure 7-32. Base Boom Harness (Prior to SN 0300224828) - Sheet 1 of 2
7-56 3121619
3121619
SN221 SN401 SN131
1 4 3 2 1 4 3 2 A C B
BRKN CBL PWR 1

BRKN CBL GND 2
BRKN CBL GND 1
BRKN CBL SIG 1

S409
S410
BRKN CBL GND
BRKN CBL PWR

BRKN CBL SIG
B LNTH PWR
B LNTH SIG
B LNTH GND
5 8 7 6 4 1 2 3
MAF08510E
1001158411-E
X407B
Figure 7-33. Base Boom Harness (Prior to SN 0300224828) - Sheet 2 of 2
7-57
X407B SN401
CONN BROKEN CABLE PROX SENSOR #2
WIRE COLOR WIRE LABEL GAUGE JACKET LEFT SIDE
POS
1 RED B LNTH PWR 18 AWG CABLE CONN
POS
2 BLUE B LNTH SIG 18 AWG CABLE
1 BROWN BRKN CBL PWR 1 22 AWG CABLE
3 BLACK B LNTH GND 18 AWG CABLE
2 WHITE 22 AWG CABLE
4
3 BLUE BRKN CBL GND 2 22 AWG CABLE
5 BROWN BRKN CBL PWR 22 AWG CABLE
4 BLACK BRKN CBL SIG 22 AWG CABLE
6 BLACK BRKN CBL SIG 22 AWG CABLE
7 BLUE BRKN CBL GND 22 AWG CABLE
8
S410
CONN
POS
3 BLUE BRKN CBL GND 22 AWG CABLE
SN131
BOOM LENGTH SENSOR
CONN
POS
A RED B LNTH PWR 18 AWG CABLE
B BLUE B LNTH SIG 18 AWG CABLE
C BLACK B LNTH GND 18 AWG CABLE
S409
CONN
POS
1 BLACK BRKN CBL SIG 1 22 AWG CABLE
1 BROWN BRKN CBL PWR 1 22 AWG CABLE
SN221
BROKEN CABLE PROX SENSOR #1
RIGHT SIDE
CONN
POS
1 BROWN BRKN CBL PWR 22 AWG CABLE
2 WHITE 22 AWG CABLE
4 BLACK BRKN CBL SIG 1 22 AWG CABLE
7-58 3121619
3121619 7-59
S166 SN221
BROKEN CABLE PROX 1
X404A
SN401
BROKEN CABLE PROX 2
SN131
LENGTH SENSOR
SN136
X406B BOOM ANG 1
SN137
BOOM ANG 2
X422
1001215949-C
MAF08470C
Figure 7-34. Base Boom Harness (SN 0300224828 to Present)
7-60 3121619
X404A SN136 - BOOM ANG 1 RIGHT SIDE

CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED CABLE P/N 1060616 18 AWG CABLE SN131 (A) 1 RED CABLE P/N 1060616 18 AWG CABLE X406B (1)
2 BLU CABLE P/N 1060616 18 AWG CABLE SN131 (C) 2 BLU CABLE P/N 1060616 18 AWG CABLE X406B (2)
3 BLK CABLE P/N 1060616 18 AWG CABLE SN131 (B) 3 BLK CABLE P/N 1060616 18 AWG CABLE X406B (3)
4 RED/BLK CABLE P/N 1060616 18 AWG TFFN SN221 (NC) NC SHIELD CABLE P/N 1060616 18 AWG SHLD X422 (1)
5 YEL CABLE P/N 1060616 18 AWG CABLE SN221 (1)
SN401 - BROKEN CABLE PROX 2 LEFT SIDE
6 ORG CABLE P/N 1060616 18 AWG CABLE SN401 (2)
CONN WIRE
7 BRN CABLE P/N 1060616 22 AWG CABLE S166 (1) WIRE LABEL GAUGE JACKET TO
POS COLOR
8 SHIELD CABLE P/N 1060616 18 AWG CABLE SN221 (N.C) 1 WHT 18 AWG GXL SN221 (2)
SN131 - LENGTH SENSOR 2 ORG CABLE P/N 1060616 18 AWG CABLE X404A (6)
CONN WIRE 3 BLK 18 AWG GXL S166 (2)
POS COLOR 4
1 RED CABLE P/N 1060616 18 AWG CABLE X404A (1)
SN221 - BROKEN CABLE PROX 2 RIGHT SIDE
2 BLK CABLE P/N 1060616 18 AWG CABLE X404A (3)
CONN WIRE
3 BLU CABLE P/N 1060616 18 AWG CABLE X404A (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
SN137 - BOOM ANG 2 LEFT SIDE 1 YEL CABLE P/N 1060616 18 AWG CABLE X404A (5)
CONN WIRE 2 WHT 18 AWG GXL SN401 (1)
POS COLOR 3 BLK 18 AWG GXL S166 (2)
1 YEL CABLE P/N 1060616 18 AWG CABLE X406B (5) N.C SHIELD CABLE P/N 1060616 18 AWG SHLD X404A (8)
2 ORG CABLE P/N 1060616 18 AWG CABLE X406B (6) NC RED/BLK CABLE P/N 1060616 18 AWG TFFN X404A (4)
3 BRN CABLE P/N 1060616 22 AWG CABLE X406B (7)
X422
CONN WIRE
POS COLOR
1 SHIELD CABLE P/N 1060616 18 AWG SHLD SN136 (NC)
X406B
CONN WIRE
POS COLOR
1 RED CABLE P/N 1060616 18 AWG CABLE SN136 (1)
2 BLU CABLE P/N 1060616 18 AWG CABLE SN136 (2)
3 BLK CABLE P/N 1060616 18 AWG CABLE SN136 (3)
4
5 YEL CABLE P/N 1060616 18 AWG CABLE SN137 (1)
6 ORG CABLE P/N 1060616 18 AWG CABLE SN137 (2)
7 BRN CABLE P/N 1060616 22 AWG CABLE SN137 (3)
8
3121619 7-61
1001158989-A
MAF08520A
Figure 7-35. Beacon/Strobe Harness
7-62 3121619
BECON SIDE CONNECTION

CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
HARNESS SIDE
1 WHT BECON PWR 16 AWG CABLE
CONNECTION
HARNESS SIDE
2 BLK BECON GND 16 AWG CABLE
CONNECTION
HARNESS SIDE CONNECTION

CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
BECON SIDE
1 WHT BECON PWR 16 AWG CABLE
CONNECTION
BECON SIDE
2 BLK BECON GND 16 AWG CABLE
CONNECTION
3121619 7-63
7-64
EC958-
EC958-
EC958+
EC958+
X942
SN959
X942
SN959
1001156135-D
MAF08530D
MAF08530D
1001156135-D
Figure 7-36. Fuel Pump & Water-In-Fuel Harness (Prior to SN 0300237158)
3121619
SN959
CONN WIRE
POS COLOR
1 BLK 148-64 WTR/FUL SW 16 AWG GXL X942 (1)
2 BLK 148-57 WTR/FUL RTN 16 AWG GXL X942 (2)
X942
CONN WIRE
POS COLOR
1 BLK 148-64 WTR/FUL SW 16 AWG GXL SN959 (1)
2 BLK 148-57 WTR/FUL RTN 16 AWG GXL SN959 (2)
3 WHT 48-96 FUEL PUMP 14 AWG GXL EC958+ (1)
4 BLK 000-48-1 ENG GND 14 AWG GXL EC958- (1)
EC958-
CONN WIRE
POS COLOR
1 BLK 000-48-1 ENG GND 14 AWG GXL X942 (4)
EC958+
CONN WIRE
POS COLOR
1 WHT 48-96 FUEL PUMP 14 AWG GXL X942 (3)
3121619 7-65
7-66
X492
X492
SN262
WIF SENSOR
SN262
WIF SENSOR
EC263+
FUEL PUMP
EC263+
FUEL PUMP
EC263-
FUEL PUMP
EC263- 1001211885-A
FUEL PUMP MAF08540A
MAF08540A
1001211885-A
Figure 7-37. Fuel Pump & Water-In-Fuel Harness (SN 0300237158 to Present)
3121619
SN262
CONN WIRE
POS COLOR
1 WHT 148-64 WTR/FUL SW 16 AWG GXL X492 (1)
2 WHT 148-57 WTR/FUL RTN 16 AWG GXL X492 (2)
X492
CONN WIRE
POS COLOR
1 WHT 148-64 WTR/FUL SW 16 AWG GXL SN262 (1)
2 WHT 148-57 WTR/FUL RTN 16 AWG GXL SN262 (2)
3 WHT 48-96 FUEL PUMP 14 AWG GXL EC263+ (1)
4 BLK 000-48-1 ENG GND 14 AWG GXL EC263- (1)
EC263+
CONN WIRE
POS COLOR
EC263-
CONN WIRE
POS COLOR
1 BLK 000-48-1 ENG GND 14 AWG GXL X492 (4)
3121619 7-67
7-68
X457
X457 IP414
IP415 IP414
BT361+
IP415 BT361+
RL235-R
RL235-R IP379
X353 IP379
X353
RLRL235-Y_1-Y
RLRL235-Y_1-Y
IP90 S371 S239
IP90
IP91 S371 S239
IP91
RL360-85 X373
RL360-85 S07
X373 S07
RL360-86 X378
RL360-86
RL127-86 X378
X376 X159B
RL127-86
RL127-85 X376
X362 X159B
RL127-85
RL234-85 X362
X419
RL234-85 X419
X418
RL234-86 X418 S372
RL234-86 X377
X377
X375 S372
X375
X237
X237
RLRL236-Y_2-Y
RLRL236-Y_2-Y
RLRL236-R_2-R
RLRL236-R_2-R
IP90, IP91 DIODE DETAILS

IP90, IP91 DIODE DETAILS
X147A
X147A
PIN 1 = CATHODE PIN 2 = ANODE
PIN 1 = CATHODE PIN 2 = ANODE
X149A
X149A
X217A
X217A
1001149972-K
MAF08550K
X218A
X218A
MAF08550K
1001149972-K
Figure 7-38. Turntable Wiring Harness - Sheet 1 of 3
3121619
3121619
X84
X84
X06 MS148-3
TELEMATICS
MS148-2 X487A
X06 MS148-3
X81 TELEMATICS X327B
MS148-2 MS83
X487A
X81 X327B X468 CO02-J12
X341A MS83
SN123
CO02-J7
CO02-J12
X468
X341A X420
SN123
X412 CO02-J7
X420
X412 S469 X395
S89 S456
S469 X395
S89 S456
S11 IP85 CO02-J8
S09
S11 IP85 CO02-J8
LB417 S09
X440B X467
LB417
X440B X88 X467
CO02-J1
X88
MS82
CO02-J1
MS82
1001149972-K
MAF08560K
MAF08560K
1001149972-K
7-69
7-70
X395
X395 MS148-3
MS148-2
MS148-3 X06
MS148-2
X06
MS83
MS82 X487A
MS83
MS82 X487A
1001149972-K
MAF08570K
MAF08570K
1001149972-K
3121619
RL360-85 X378
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 55-35 AUX B+ DISC 18 AWG GXL CO02-J1 (2) 1 BLK 0-40 12 AWG GXL X81 (16)
RL360-86 X373
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-45 18 AWG GXL X373 (1) 1 BLK 0-21 18 AWG GXL RL234-85 (1)
1 BLK 0-45 18 AWG GXL RL360-86 (1)
RL127-86
CONN WIRE X419
POS COLOR CONN WIRE
1 WHT 53-3 AUX PMP 18 AWG GXL CO02-J1 (13) POS COLOR
1 BLK 0-50 16 AWG GXL S456 (1)
RL127-85
CONN WIRE X376
POS COLOR CONN WIRE
1 BLK 0-70 18 AWG GXL RL234-85 (1) POS COLOR
1 BLK 0-20 12 AWG GXL CO02-J8 (1)
RL234-85
CONN WIRE X362
POS COLOR CONN WIRE
1 BLK 0-21 18 AWG GXL X373 (1) POS COLOR
1 BLK 0-70 18 AWG GXL RL127-85 (1) 1 BLK 0-19 16 AWG GXL S239 (1)
RL234-86 X418
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED 1-4-2-1 18 AWG GXL IP91 (1) 1 BLK 00-11 10 AWG GXL X149A (2)
1 YEL 2-4-2-1 18 AWG GXL IP90 (1)
X377
X457 CONN WIRE
CONN WIRE POS COLOR
POS COLOR 1 BLK 0-41 12 AWG GXL X81 (18)
1 RED 1-15 18 AWG GXL IP414 (2)
X375
1 RED 1-5 16 AWG GXL IP415 (2)
CONN WIRE
RLRL236-Y_2-Y POS COLOR
CONN WIRE 1 BLK 0-22 14 AWG GXL X412 (1)
POS COLOR
X237
1 YEL 2-10 14 AWG GXL X412 (2)
CONN WIRE
1 YEL 2-11 12 AWG GXL CO02-J8 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
RLRL236-R_2-R 1 BLK 0-14 18 AWG GXL ()
CONN WIRE 1 BLK 0-16 18 AWG GXL LB417 (2)
POS COLOR
1 YEL 02-6 10 AWG GXL ()
3121619 7-71
RLRL235-Y_1-Y X147A
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-25 12 AWG GXL X81 (10) 1 WHT 27-3 JIB DN O/R 18 AWG GXL X81 (15)
1 YEL 2-26 12 AWG GXL X81 (12) 2 WHT 25-6 PLVL UP O/R 18 AWG GXL X81 (9)
3 WHT 25-5 PLVL DN O/R 18 AWG GXL X81 (7)
X353
4 WHT 50-2 PLTFM DUMP 18 AWG GXL X341A (4)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 5 WHT 50-3 JIB DUMP 18 AWG GXL X341A (3)
POS COLOR
1 YEL 2-12 18 AWG GXL X327B (5) 49-45 HYD OIL
6 WHT 18 AWG GXL CO02-J1 (35)
TEMP
1 YEL 2-17 18 AWG GXL LB417 (1)
7 BLK 0-31 18 AWG GXL CO02-J1 (27)
RL235-R 8
CONN WIRE 9
POS COLOR
10
1 YEL 2-1-99 IGNITION 12 AWG GXL S372 (1)
11 BLK 0-14 18 AWG GXL ()
1 YEL 2-13 16 AWG GXL X217A (5)
12 WHT 47-6 ALT EXC 18 AWG GXL S371 (2)
X147A
X217A
CONN WIRE
POS COLOR
1 YEL CAN HI 18 AWG J1939 CABLE MS148-2 (A)
2 GRN CAN LO 18 AWG J1939 CABLE MS148-2 (B)
2 BLK 0-17 16 AWG GXL CO02-J1 (8)
3 SHLD CAN SHLD 18 AWG J1939 CABLE MS148-2 (C)
3 WHT 52-9 GEN 18 AWG GXL CO02-J1 (22)
4
4 WHT 48-7 GLOW 18 AWG GXL CO02-J1 (12)
5
5 YEL 2-13 18 AWG GXL RL235-R (1)
6
6 BLK 0-18 18 AWG GXL CO02-J1 (9)
7 WHT 55-14 BRAKE 18 AWG GXL CO02-J1 (23)
7 WHT 48-8 SP 18 AWG GXL CO02-J1 (7)
8
8
9
10 X218A
11 CONN WIRE
POS COLOR
12
X149A 2 WHT 48-6 STRT 18 AWG GXL CO02-J1 (11)
CONN WIRE J1939
WIRE LABEL GAUGE JACKET TO 3 YEL CAN HI 20 AWG MS83 (1)
POS COLOR CABLE
1 YEL 02-6 10 AWG GXL RL236-R (1) J1939
4 GRN CAN LO 20 AWG MS83 (3)
1 YEL 00-11 10 AWG GXL X418 (1) CABLE
5 WHT 47-6-1 ALT EXC 18 AWG GXL S371 (2)
BT361+
J1939
CONN WIRE 6 SHLD CAN SHLD 20 AWG MS83 (5)
WIRE LABEL GAUGE JACKET TO CABLE
POS COLOR
1 RED 1-7 WK LT PWR 12 AWG GXL IP379 (1)
7-72 3121619
X06 X467
TELEMATICS CONN WIRE
CONN WIRE POS COLOR
POS COLOR 1 N/A UGM TO CHASSIS GND 4 AWG BRAID CO02-J8 (3)
1 RED 1-15-2 18 AWG GXL S07 (1)
X468
2 BLK 0-19-3 18 AWG GXL S239 (2)
CONN WIRE
3 YEL 2-11-1A 18 AWG GXL S09 (1) WIRE LABEL GAUGE JACKET TO
POS COLOR
4 RED 1-4-3A 18 AWG GXL S11 (1)
CAN SHIELD TO
1 N/A 10 AWG BRAID S469 (1)
X341A CHASSIS GND
CONN WIRE CO02-J8
POS COLOR
CONN WIRE
1 RED 1-7-2 WK LT PWR 16 AWG GXL IP379 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
2 RED 1-7-1 WK LT PWR 16 AWG GXL IP379 (2) 1 BLK 0-20 12 AWG GXL X376 (1)
3 WHT 50-3 JIB DUMP 16 AWG GXL X159B (5) 2 YEL 2-11 12 AWG GXL RLRL236-Y_2-Y (1)
4 WHT 50-2 PLTFM DUMP 16 AWG GXL X159B (4) UGM TO CHASSIS
3 N/A 4 AWG BRAID X467 (1)
GND
SN123
4
CONN WIRE
POS COLOR X395
1 RED B LNTH CBL 18 AWG CABLE CO02-J7 (35) CONN WIRE
2 BLK B LNTH CBL 18 AWG CABLE CO02-J7 (11) POS COLOR
3 1 WHT 49-64 TILT PWR 18 AWG GXL CO02-J7 (27)
4 WHT B LNTH CBL 18 AWG CABLE CO02-J7 (29) 2 BLK 0-60 18 AWG GXL CO02-J7 (25)
3 WHT 49-65 X AXIS 18 AWG GXL CO02-J7 (20)
X440B
4 WHT 49-66 Y AXIS 18 AWG GXL CO02-J7 (8)
CONN WIRE
POS COLOR LB417
1 WHT 55-30 LFT ENABLE 18 AWG GXL CO02-J1 (1) CONN WIRE
2 WHT 49-77 P C PWR 20 AWG GXL CO02-J7 (26) POS COLOR
3 WHT 49-76 P C GND 20 AWG GXL CO02-J7 (26) 1 YEL 2-17 18 AWG GXL X353 (1)
4 WHT 49-75 PRS CHK 20 AWG GXL CO02-J7 (7) 2 BLK 0-16 18 AWG GXL X237 (1)
5 WHT 49-73 L P PWR 20 AWG GXL CO02-J7 (16)
X420
6 WHT 49-74 L P GND 20 AWG GXL CO02-J7 (9)
CONN WIRE
7 WHT 49-72 LIFT PRS 20 AWG GXL CO02-J7 (4) WIRE LABEL GAUGE JACKET TO
POS COLOR
8 BLK 0-50-2 16 AWG GXL S456 (1) 1 BLK 0-50-1 16 AWG GXL S456 (2)
X487A MS148-3
CONN WIRE CONN WIRE
POS COLOR POS COLOR
A YEL CAN HI 18 AWG GXL MS83 (2) A YEL CAN HI 20 AWG J1939 CABLE MS82 (12)
B GRN CAN LO 18 AWG GXL MS83 (4) B GRN CAN LO 20 AWG J1939 CABLE MS82 (10)
C C SHLD CAN SHLD 20 AWG J1939 CABLE MS82 (7)
3121619 7-73
MS148-2 X81
CONN WIRE CONN WIRE
POS COLOR POS COLOR
A YEL CAN HI 18 AWG J1939 CABLE X147A (1) 1 SHLD CAN SHLD 20 AWG J1939 CABLE MS82 (5)
B GRN CAN LO 18 AWG J1939 CABLE X147A (2) 2 GRN CAN LO 20 AWG J1939 CABLE MS82 (9)
C SHLD CAN SHLD 18 AWG J1939 CABLE X147A (3) 3 YEL CAN HI 20 AWG J1939 CABLE MS82 (11)
4 YEL 2-4 18 AWG GXL S89 (1)
X412
5 RED 1-4-3 18 AWG GXL S11 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 6 YEL 2-15 18 AWG GXL CO02-J7 (15)
POS COLOR
1 BLK 0-22 14 AWG GXL X375 (1) 7 WHT 25-5 PLVL DN O/R 18 AWG GXL X159B (3)
2 YEL 2-10 14 AWG GXL RLRL236-Y_2-Y (1) 8
3 BLU CABLE 18 AWG CABLE CO02-J7 (12) 9 WHT 25-6 PLVL UP O/R 18 AWG GXL X159B (2)
4 BLK CABLE 18 AWG CABLE CO02-J7 (19) RLRL235-
10 YEL 2-25 12 AWG GXL
Y_1-Y (1)
5 RED CABLE 18 AWG CABLE CO02-J7 (32)
11 YEL 2-5 18 AWG GXL CO02-J7 (14)
BRKN CBL
6 SHIELD 18 AWG CABLE S469 (2) RLRL235-
PROX 12 YEL 2-26 12 AWG GXL
Y_1-Y (1)
MS83 13 WHT 27-6 J-UP O/R 18 AWG GXL CO02-J1 (3)
CONN WIRE 14
POS COLOR
15 WHT 27-3 JIB DN O/R 18 AWG GXL X159B (1)
1 YEL CAN HI 20 AWG J1939 CABLE X218A (3)
16 BLK 0-40 12 AWG GXL X378 (1)
2 YEL CAN HI 18 AWG GXL X487A (A)
17
3 GRN CAN LO 20 AWG J1939 CABLE X218A (4)
18 BLK 0-41 12 AWG GXL X377 (1)
4 GRN CAN LO 18 AWG GXL X487A (B)
19
5 SHLD CAN SHLD 20 AWG J1939 CABLE X218A (6)
6 SHLD CAN SHLD 20 AWG J1939 CABLE S469 (2) X84
7 SHLD CAN SHLD 20 AWG J1939 CABLE X84 (5) CONN WIRE
POS COLOR
8
A BLK 0-19-2 18 AWG GXL S239 (2)
9 GRN CAN LO 20 AWG J1939 CABLE X84 (4)
B RED 1-15-1 18 AWG GXL S07 (1)
10 GRN CAN LO 20 AWG J1939 CABLE CO02-J12 (4)
C YEL CAN HI 20 AWG J1939 CABLE MS83 (11)
11 YEL CAN HI 20 AWG J1939 CABLE X84 (3)
D GRN CAN LO 20 AWG J1939 CABLE MS83 (9)
E SHLD CAN SHLD 20 AWG J1939 CABLE MS83 (7)
F
G
H YEL 2-11-1B 18 AWG GXL S09 (1)
J
7-74 3121619
X327B CO02-J12
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED 1-5 16 AWG GXL IP415 (1) 1
2 RED 1-4-1 18 AWG GXL CO02-J7 (3) 2
3 RED 1-4-3B 18 AWG GXL S11 (1) 3 YEL CAN HI 20 AWG J1939 CABLE MS83 (12)
4 RED 1-4-2 18 AWG GXL IP91 (2) 4 GRN CAN LO 20 AWG J1939 CABLE MS83 (10)
5 YEL 2-12 18 AWG GXL X353 (1) 5 BLK 0-44 18 AWG GXL X327B (12)
6 BLK 0-19-1 18 AWG GXL S239 (2) 6 WHT JUMPER 18 AWG GXL CO02-J12 (7)
7 GRN CAN LO 20 AWG J1939 CABLE MS82 (3) 7 WHT JUMPER 18 AWG GXL CO02-J12 (6)
8 YEL CAN HI 20 AWG J1939 CABLE MS82 (1) 8 WHT 44-1 MSSO 18 AWG GXL X327B (11)
49-46 M
CNTRL
10
11 WHT 44-1 MSSO 18 AWG GXL CO02-J12 (8)
12 BLK 0-44 18 AWG GXL CO02-J12 (5)
MS82
CONN WIRE
POS COLOR
1 YEL CAN HI 20 AWG J1939 CABLE X327B (8)
3 GRN CAN LO 20 AWG J1939 CABLE X327B (7)
4 GRN CAN LO 20 AWG J1939 CABLE CO02-J7 (24)
5 SHLD CAN SHLD 20 AWG J1939 CABLE X81 (1)
6 SHLD CAN SHLD 20 AWG J1939 CABLE S469 (2)
7 SHLD CAN SHLD 20 AWG J1939 CABLE MS148-3 (C)
8
9 GRN CAN LO 20 AWG J1939 CABLE X81 (2)
10 GRN CAN LO 20 AWG J1939 CABLE MS148-3 (B)
X88
CONN WIRE
WIRE LABEL
1 WHT 49-34 A-PWR 18 AWG GXL CO02-J1 (28)
2 WHT 49-35 A-RX 18 AWG GXL CO02-J1 (29)
3 WHT 49-36 A-TX 18 AWG GXL CO02-J1 (30)
4 WHT 49-37 A-GND 18 AWG GXL CO02-J1 (31)
3121619 7-75
CO02-J1 CO02-J7
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 55-30 LFT ENABLE 18 AWG GXL X440B (1) 1 YEL 2-4-4 18 AWG GXL S89 (2)
2 WHT 55-35 AUX B+ DISC 18 AWG GXL RL360-85 (1) 2 YEL 2-4-3 18 AWG GXL S89 (2)
3 WHT 27-6 J-UP O/R 18 AWG GXL X81 (13) 3 RED 1-4-1 18 AWG GXL X327B (2)
4 4 WHT 49-72 LIFT PRS 20 AWG GXL X440B (7)
5 5
6 6
7 WHT 48-8 SP 18 AWG GXL X217A (7) 7 WHT 49-75 PRS CHK 20 AWG GXL X440B (4)
8 BLK 0-17 16 AWG GXL X217A (2) 8 WHT 49-66 Y AXIS 18 AWG GXL X395 (4)
9 BLK 0-18 18 AWG GXL X217A (6) 9 WHT 49-74 L P GND 20 AWG GXL X440B (6)
10 10 WHT 49-76 P C GND 20 AWG GXL X440B (3)
11 WHT 48-6 STRT 18 AWG GXL X218A (2) 11 BLK B LNTH CBL 18 AWG CABLE SN123 (2)
12 WHT 48-7 GLOW 18 AWG GXL X217A (4) 12 BLU CABLE 18 AWG CABLE X412 (3)
13 WHT 53-3 AUX PMP 18 AWG GXL RL127-86 (1) 13 YEL CAN HI 20 AWG J1939 CABLE MS82 (2)
14 14 YEL 2-5 18 AWG GXL X81 (11)
15 15 YEL 2-15 18 AWG GXL X81 (6)
16 16 WHT 49-73 L P PWR 20 AWG GXL X440B (5)
17 17
18 18
19 19 BLK CABLE 18 AWG CABLE X412 (4)
20 20 WHT 49-65 X AXIS 18 AWG GXL X395 (3)
21 21 WHT 49-46 M CNTRL 18 AWG GXL X327B (9)
22 WHT 52-9 GEN 18 AWG GXL X217A (3) 22
23 WHT 55-14 BRAKE 18 AWG GXL X147A (7) 23 WHT JUMPER3 18 AWG GXL CO02-J7 (30)
24 24 GRN CAN LO 20 AWG J1939 CABLE MS82 (4)
25 25 BLK 0-60 18 AWG GXL X395 (2)
26 26 WHT 49-77 P C PWR 20 AWG GXL X440B (2)
27 BLK 0-31 18 AWG GXL X159B (7) 27 WHT 49-64 TILT PWR 18 AWG GXL X395 (1)
28 WHT 49-34 A-PWR 18 AWG GXL X88 (1) 28
29 WHT 49-35 A-RX 18 AWG GXL X88 (2) 29 WHT B LNTH CBL 18 AWG CABLE SN123 (4)
30 WHT 49-36 A-TX 18 AWG GXL X88 (3) 30 WHT JUMPER3 18 AWG GXL CO02-J7 (23)
31 WHT 49-37 A-GND 18 AWG GXL X88 (4) 31
32 WHT 47-6-2 ALT EXC 18 AWG GXL S371 (1) 32 RED CABLE 18 AWG CABLE X412 (5)
33 33
34 34 YEL 2-11 18 AWG GXL IP85 (2)
49-45 HYD OIL 35 RED B LNTH CBL 18 AWG CABLE SN123 (1)
35 WHT 18 AWG GXL X159B (6)
TEMP
7-76 3121619
3121619 7-77
7-78
SW482-1
ENGINE REGENERATION
SW60 SW482-2
MAIN TELE
LB76
SW58 SW61 1000 CAP
TURNTABLE SWING JIB TELE
LB68
AXLE SET
X327 LB75
PLATF OVRLD
SW62 LB73
SW59 JIB LIFT MOMNT CNTRL
MAIN LIFT SW471-1
SW56-1 MSSO LB71
GND MODE LO OIL
SW471-2
SW56-3 LB72
PLATF MODE HRC-HEST/LRC-NO ALT
SW56-B ZIP TIE
CO02-J4 SW64 AS SHOWN
E-STOP B+ PLATF LVL
SW66-1
ZIP TIES ARE
SPACED 50mm APART MOMENT CONTROL
AND ARE FOR CAN CABLE
ROUTING ONLY.
SW66-2
X483 X77 LB70
HRC DISPLAY M.D.I. HRC-ENG WARN/ LRC-HI TEMP
X487B SW63 LB74
PLATF ROT BOOM CNTRL
SW55-2B SW55-1B LB69
E-STOP B+ BAT B+ GLOW PLUG
SW65 LB67
STRT/AUX 500 CAP
MAF08580F
1001149973-F
Figure 7-41. Ground Console Wiring Harness
3121619
CO02-J4 X327
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 39-4 AXLE 18 AWG GXL LB68 (1) 1 RED 1-5-1-1 16 AWG GXL SW55-1B (1B)
2 WHT 54-4 500# 18 AWG GXL LB67 (1) 1 YEL 2-12-1 18 AWG GXL ?
3 WHT 49-29 BCS 18 AWG GXL LB74 (1) 2 RED 1-4-1 18 AWG GXL SW56-3 (1)
4 WHT 48-4 STRT 18 AWG GXL SW65 (1) 3 RED 1-4-3 18 AWG GXL SW56-1 (1)
5 WHT 25-8 P-LVL DN 18 AWG GXL SW64 (3) 4 RED 1-4-2 18 AWG GXL SW56-3 (1)
6 WHT 23-6 P-ROT LFT 18 AWG GXL SW63 (3) 5 YEL 2-12 18 AWG GXL S31 (1)
7 WHT 13-5 TELE IN 18 AWG GXL SW60 (1) 6 BLK 0-19-1 18 AWG GXL S42 (1)
8 WHT 27-4 JIB DN 18 AWG GXL SW62 (1) 7 GRN 20 AWG J1939 CABLE X77 (3)
9 WHT 148-5 REGEN 18 AWG GXL SW482-1 (1) 8 YEL 20 AWG J1939 CABLE X77 (4)
10 9 WHT 49-46 M CNTRL 18 AWG GXL SW66-2 (1)
11 WHT 29-3 JIB IN 18 AWG GXL SW61 (1) 10 YEL 2-23 18 AWG GXL CO02-J4 (24)
12 11 WHT 44-1 MSSO 18 AWG GXL SW471-1 (1)
13 WHT 49-28 MNT CNTRL 18 AWG GXL LB73 (1) 12 BLK 0-44 18 AWG GXL SW471-2 (1)
14 WHT 49-30 OVERLOAD 18 AWG GXL LB75 (1)
X77
15 WHT 48-5 GLOW 18 AWG GXL LB69 (1)
CONN WIRE
16 WHT 53-2 AUX 18 AWG GXL SW65 (3) WIRE LABEL GAUGE JACKET TO
POS COLOR
17 WHT 25-7 P-LVL UP 18 AWG GXL SW64 (1) 1 YEL 2-12-1 18 AWG GXL S31 (2)
18 WHT 23-5 P-ROT RHT 18 AWG GXL SW63 (1) 2 BLK 0-19-3 18 AWG GXL S42 (2)
19 WHT 27-5 JIB UP 18 AWG GXL SW62 (3) 3 GRN 20 AWG J1939 CABLE X327 (7)
20 4 YEL 20 AWG J1939 CABLE X327 (8)
21 5
22 WHT 29-4 JIB OUT 18 AWG GXL SW61 (3) 6
23 WHT 3-3 LIFT UP 18 AWG GXL SW59 (1)
SW55-1B
24 YEL 2-23 18 AWG GXL X327 (10)
CONN WIRE
25 YEL 2-9 18 AWG GXL SW58 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
26 WHT HRC-HEST/ LRC-ALT 18 AWG GXL LB72 (1)
1B RED 1-5-1-1 16 AWG GXL X327 (1)
27 WHT 54-5 1000# 18 AWG GXL LB76 (1)
28 WHT HRC-WARN/ LRC-TEMP 18 AWG GXL LB70 (1) SW63
29 WHT 47-8 OIL PRS 18 AWG GXL LB71 (1) CONN WIRE
POS COLOR
30 WHT 13-6 TELE OUT 18 AWG GXL SW60 (3)
1 WHT 23-5 P-ROT RHT 18 AWG GXL CO02-J4 (18)
31 BLK 0-12 18 AWG GXL LB76 (2)
2 YEL 2-9-6 18 AWG GXL SW62 (2)
32
2 YEL 2-9-6 18 AWG GXL SW64 (2)
33 WHT 3-4 LIFT DN 18 AWG GXL SW59 (3)
3 WHT 23-6 P-ROT LFT 18 AWG GXL CO02-J4 (6)
34 WHT 21-3 SWG LFT 18 AWG GXL SW59 (3)
35 WHT 21-4 SWG RHT 18 AWG GXL SW59 (3) LB67
CONN WIRE
SW55-2B WIRE LABEL GAUGE JACKET TO
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 WHT 54-4 500# 18 AWG GXL CO02-J4 (2)
POS COLOR
2 BLK 0-12-9 18 AWG GXL LB68 (2)
2B RED 1-4 16 AWG GXL SW56-B (1)
3121619 7-79
LB69 LB73
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 48-5 GLOW 18 AWG GXL CO02-J4 (15) 49-28 MNT
2 BLK 0-12-7 18 AWG GXL LB70 (2) CNTRL
2 BLK 0-12-8 18 AWG GXL LB68 (2) 2 BLK 0-12-3 18 AWG GXL LB74 (2)
2 BLK 0-12-4 18 AWG GXL LB72 (2)
LB74
CONN WIRE LB75
POS COLOR CONN WIRE
1 WHT 49-29 BCS 18 AWG GXL CO02-J4 (3) POS COLOR
2 BLK 0-12-2 18 AWG GXL LB75 (2) 1 WHT 49-30 OVERLOAD 18 AWG GXL CO02-J4 (14)
2 BLK 0-12-2 18 AWG GXL LB74 (2)
LB70
CONN WIRE LB68
POS COLOR CONN WIRE
HRC-WARN/ POS COLOR
LRC-TEMP 1 WHT 39-4 AXLE 18 AWG GXL CO02-J4 (1)
SW66-2 LB76
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 49-46 M CNTRL 18 AWG GXL X327 (9) 1 WHT 54-5 1000# 18 AWG GXL CO02-J4 (27)
2 BLK 0-12 18 AWG GXL CO02-J4 (31)
SW66-1
2 BLK 0-12-1 18 AWG GXL LB75 (2)
CONN WIRE
POS COLOR SW64
1 YEL 2-9-3 18 AWG GXL SW60 (2) CONN WIRE
1 WHT 25-7 P-LVL UP 18 AWG GXL CO02-J4 (17)
LB72
2 YEL 2-9-8 18 AWG GXL SW63 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 YEL 2-9-9 18 AWG GXL SW65 (2)
POS COLOR
HRC-HEST/ LRC- 3 WHT 25-8 P-LVL DN 18 AWG GXL CO02-J4 (5)
ALT
SW56-1
2 BLK 0-12-4 18 AWG GXL LB73 (2)
CONN WIRE
2 BLK 0-12-5 18 AWG GXL LB71 (2) WIRE LABEL GAUGE JACKET TO
POS COLOR
LB71 1 RED 1-4-3 18 AWG GXL X327 (3)
CONN WIRE SW56-3
POS COLOR
CONN WIRE
1 WHT 47-8 OIL PRS 18 AWG GXL CO02-J4 (29) WIRE LABEL GAUGE JACKET TO
POS COLOR
2 BLK 0-12-5 18 AWG GXL LB72 (2) 1 RED 1-4-1 18 AWG GXL X327 (2)
2 BLK 0-12-6 18 AWG GXL LB70 (2) 1 RED 1-4-2 16 AWG GXL X327 (4)
7-80 3121619
SW56-B SW62
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED 1-4 16 AWG GXL SW55-2B (2B) 1 WHT 27-4 JIB DN 18 AWG GXL CO02-J4 (8)
2 YEL 2-9-5 18 AWG GXL SW61 (2)
SW58
2 YEL 2-9-6 18 AWG GXL SW63 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 3 WHT 27-5 JIB UP 18 AWG GXL CO02-J4 (19)
POS COLOR
1 WHT 21-3 SWG LFT 18 AWG GXL CO02-J4 (34) SW61
2 YEL 2-9 18 AWG GXL CO02-J4 (25) CONN WIRE
3 WHT 21-4 SWG RHT 18 AWG GXL CO02-J4 (35) 1 WHT 29-3 JIB IN 18 AWG GXL CO02-J4 (11)
2 YEL 2-9-4 18 AWG GXL SW66-1 (1)
SW482-1
2 YEL 2-9-5 18 AWG GXL SW62 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 3 WHT 29-4 JIB OUT 18 AWG GXL CO02-J4 (22)
POS COLOR
1 WHT 148-5 REGEN 18 AWG GXL CO02-J4 (9) SW60
SW482-2 CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 WHT 13-5 TELE IN 18 AWG GXL CO02-J4 (7)
POS COLOR
2 YEL 2-9-3 18 AWG GXL SW66-1 (1)
SW471-1
3 WHT 13-6 TELE OUT 18 AWG GXL CO02-J4 (30)
CONN WIRE
POS COLOR X487B
1 WHT 44-1 MSSO 18 AWG GXL X327 (11) CONN WIRE
POS COLOR
SW471-2
A YEL CAN HI 18 AWG GXL X483 (3)
CONN WIRE
WIRE LABEL GAUGE JACKET TO B GRN CAN LO 18 AWG GXL X483 (4)
POS COLOR
C
1 BLK 0-44 18 AWG GXL X327 (12)
X483
SW65
CONN WIRE
POS COLOR
1 BLK 0-19-2 18 AWG GXL S42 (2)
1 WHT 48-4 STRT 18 AWG GXL CO02-J4 (4)
2 YEL 2-12-2 18 AWG GXL S31 (2)
2 YEL 2-9-10 18 AWG GXL SW482-2 (1)
3 YEL CAN HI 18 AWG GXL X487B (A)
2 YEL 2-9-9 18 AWG GXL SW64 (2)
4 GRN CAN LO 18 AWG GXL X487B (B)
3 WHT 53-2 AUX 18 AWG GXL CO02-J4 (16)
SW59
CONN WIRE
POS COLOR
1 WHT 3-3 LIFT UP 18 AWG GXL CO02-J4 (23)
2 YEL 2-9-1 18 AWG GXL SW58 (2)
2 YEL 2-9-2 18 AWG GXL SW60 (2)
3 WHT 3-4 LIFT DN 18 AWG GXL CO02-J4 (33)
3121619 7-81
7-82
CO03-J1
CO03-J2
CO03-J3 MS244
X160
449B
SN243 S195
S424
X147B
CO03-J4 X425
CO03-J12 CO03-J7
S181
442A
445A
448B
HV178 HV179
TWO SPEED BRAKE
X338A
X340A
HV161 S167
S205 SN423
FRONT AXLE SWG EXT.
S203
HV170
RIGHT FRONT STR RHT
HV175
RIGHT REAR STR LFT
HV162
FRONT AXLE SWG RET.
HV171
RIGHT FRONT STR LFT
MS244
HV174
RIGHT REAR STR RHT
X337A
X339A
HV163 S204
REAR AXLE SWG EXT. S202
HV173 S168
LEFT FRONT STR LFT
HV176
LEFT REAR STR RHT
HV164
REAR AXLE SWG RET.
HV172
LEFT FRONT STR RHT
HV177
LEFT REAR STR LFT
MAF08320H
1001149975-H
Figure 7-42. Chassis Harness
3121619
S195 CO03-J7
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 00-8 18AWG GXL CO03-J1(9) 1
2 BLK 00-8-1 18AWG GXL X448B(3) 2
2 BLK 00-8-2 18AWG GXL X449B(3) 3 WHT 49-100 ENABLE 18AWG GXL CO03-J7(34)
4 BLU RHT FRNT STR 18AWG CABLE X340A(3)
CO03-J12
5 RED LFT REAR STR 18AWG CABLE X339A(2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 6 WHT 120OHM 18AWG GXL CO03-J7(17)
POS COLOR
1 7 BLU LFT FRNT STR 18AWG CABLE X337A(3)
2 WHT 55 - 18TTABLE ANG2 18AWG GXL SN243(C) 8 BLU LFT REAR STR 18AWG CABLE X339A(3)
3 9 BLK RHT FRNT STR 18AWG CABLE X340A(1)
4 10 BLK LFT FRNT STR 18AWG CABLE X337A(1)
5 11 WHT 55-17DOS 18AWG GXL X147B(11)
6 12 WHT 49-70HYD.OC 18AWG GXL SN423(2)
7 13 YEL CANHI 18AWG J1939CABLE X147B(1)
8 14
15 WHT 55-14BRAKE 18AWG GXL X147B(7)
X425
16 RED RHT FRNT STR 18AWG CABLE X340A(2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 17 WHT 120OHM 18AWG GXL CO03-J7(6)
POS COLOR
18 SHLD CANSHLD 18AWG J1939CABLE X147B(3)
1 BLK 00-12 16AWG GXL S424(1)
19
S424 20 BLU RHT REAR STR 18AWG CABLE X338A(3)
CONN WIRE 21
POS COLOR
22
1 BLK 00-12 16AWG GXL X425(1)
23
2 SHIELD SHLD 18AWG SHLD X337A(4)
24 GRN CANLOW 18AWG J1939CABLE X147B(2)
25 BLK RHT REAR STR 18AWG CABLE X338A(1)
26 RED LFT FRNT STR 18AWG CABLE X337A(2)
27 RED RHT REAR STR 18AWG CABLE X338A(2)
HV177 - LEFT REAR STR LFT 28 BLK LFT REAR STR 18AWG CABLE X339A(1)
CONN WIRE 29 YEL 02-4 18AWG GXL X147B(12)
POS COLOR 30
1 WHT 9-8 LREAR STRL 18AWG GXL CO03-J2(20) 31
2 BLK 00-6-2 18AWG GXL S204(2) 32 WHT 49-71 HYD.OCRTN 18AWG GXL SN423(1)
HV172 - LEFT FRONT STR RHT 33
CONN WIRE 34 WHT 49-100 ENABLE 18AWG GXL CO03-J7(3)

POS COLOR
1 WHT 9-2 LFRNT STRR 18AWG GXL CO03-J2(35)
2 BLK 00-4-1 18AWG GXL S202(2)
3121619 7-83
HV164 - REAR AXLE SWGRET. X339A

CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 38-6 RAXS RET 18AWG GXL CO03-J2(7) 1 BLK LFT REAR STR 18AWG CABLE CO03-J7(28)
2 WHT 60-5-2 RAXS RTN 18AWG GXL S168(2) 2 RED LFT REAR STR 18AWG CABLE CO03-J7(5)
3 BLU LFT REAR STR 18AWG CABLE CO03-J7(8)
HV176 - LEFT REAR STRRHT
4 SHIELD SHLD 18AWG SHLD S424(2)
CONN WIRE
POS COLOR
1 WHT 9-7 LREAR STRR 18AWG GXL CO03-J2(9) 6
2 BLK 00-6-1 18AWG GXL S204(2) X337A
HV173 - LEFT FRONT STRLFT CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 BLK LFTF RNT STR 18AWG CABLE CO03-J7(10)
POS COLOR
1 WHT 9-3 LFRNT STRL 18AWG GXL CO03-J2(34) 2 RED LFTF RNT STR 18AWG CABLE CO03-J7(26)
2 BLK 00-4-2 18AWG GXL S202(2) 3 BLU LFTF RNT STR 18AWG CABLE CO03-J7(7)
HV163 - REAR AXLE SWGEXT.
5
CONN WIRE
POS COLOR
1 WHT 38-4 RAXS EXT 18AWG GXL CO03-J2(5) X445A
2 WHT 60-5-1 RAXS RTN 18AWG GXL S168(2) CONN WIRE
POS COLOR
S168
1 WHT 61-1-25V 18AWG GXL MS244(8)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 WHT 38-1 RLFT ASWG 18AWG GXL CO03-J3(13)
POS COLOR
3 BLK 00-15 18AWG GXL CO03-J3(3)
1 WHT 60-5 RAXS RTN 18AWG GXL CO03-J3(2)
2 WHT 60-5-1 RAXS RTN 18AWG GXL HV163(2) X448B
2 WHT 60-5-2 RAXS RTN 18AWG GXL HV164(2) CONN WIRE
POS COLOR
S202
1 WHT 61-1-35V 18AWG GXL MS244(4)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 WHT 38-9 RAXS RHT 18AWG GXL CO03-J1(15)
POS COLOR
3 BLK 00-8-1 18AWG GXL S195(2)
1 BLK 00-4 18AWG GXL CO03-J2(28)
2 BLK 00-4-1 18AWG GXL HV172(2) HV174 - RIGHT REAR STRRHT
2 BLK 00-4-2 18AWG GXL HV173(2) CONN WIRE
POS COLOR
S204
1 WHT 9-5 RREAR STRR 18AWG GXL CO03-J2(8)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 BLK 00-5-1 18AWG GXL S203(2)
POS COLOR
1 BLK 00-6 18AWG GXL CO03-J2(30) HV170 - RIGHT FRONT STRRHT
1 WHT 60-4 FAXS RTN 18AWG GXL () CONN WIRE
2 BLK 00-6-1 18AWG GXL HV176(2) POS COLOR
2 BLK 00-6-2 18AWG GXL HV177(2) 1 WHT 9-4 RFRNT STRR 18AWG GXL CO03-J2(11)
2 BLK 00-3-1 18AWG GXL S205(2)
7-84 3121619
HV162 - FRONT AXLE SWGRET. X340A

CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 38-3FAXS RET 18AWG GXL CO03-J2(16) 1 BLK RHT FRNT STR 18AWG CABLE CO03-J7(9)
2 WHT 60-4-2 FAXS RTN 18AWG GXL S167(2) 2 RED RHT FRNT STR 18AWG CABLE CO03-J7(16)
3 BLU RHT FRNT STR 18AWG CABLE CO03-J7(4)
HV175 - RIGHT REAR STRLFT
CONN WIRE
POS COLOR
1 WHT 9-6 RREAR STRL 18AWG GXL CO03-J2(19) 6
2 BLK 00-5-2 18AWG GXL S203(2) X338A
HV171 - RIGHT FRONT STRLFT CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 BLK RHT REAR STR 18AWG CABLE CO03-J7(25)
POS COLOR
1 WHT 9-1 RFRNT STRL 18AWG GXL CO03-J2(22) 2 RED RHT REAR STR 18AWG CABLE CO03-J7(27)
2 BLK 00-3-2 18AWG GXL S205(2) 3 BLU RHT REAR STR 18AWG CABLE CO03-J7(20)
HV161 - FRONT AXLE SWGEXT.
5
CONN WIRE
POS COLOR
1 WHT 38-2FAXS EXT 18AWG GXL CO03-J2(4) X442A
2 WHT 60-4-1FAXS RTN 18AWG GXL S167(2) CONN WIRE
POS COLOR
S203
1 WHT 61-1-15V 18AWG GXL MS244(7)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 WHT 38-5 FAXS RHT 18AWG GXL CO03-J2(25)
POS COLOR
3 BLK 00-2 18AWG GXL CO03-J2(6)
1 BLK 00-5 18AWG GXL CO03-J2(18)
2 BLK 00-5-1 18AWG GXL HV174(2) HV178 - TWO SPEED
POS COLOR
S205
1 WHT 55-132 SPD 18AWG GXL CO03-J2(1)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 2 BLK 00-1-1 18AWG GXL S181(2)
POS COLOR
1 BLK 00-3 18AWG GXL CO03-J2(17) SN423
2 BLK 00-3-2 18AWG GXL HV171(2) POS COLOR
1 WHT 49-71 HYD.OCRTN 18AWG GXL CO03-J7(32)
S167
2 WHT 49-70 HYD.OC 18AWG GXL CO03-J7(12)
CONN WIRE
POS COLOR
1 WHT 60-4 FAXS RTN 18AWG GXL CO03-J3(1)
2 WHT 60-4-1 FAXS RTN 18AWG GXL HV161(2)
2 WHT 60-4-2 FAXSRTN 18AWG GXL HV162(2)
3121619 7-85
HV179 - BRAKE
CONN WIRE
POS COLOR
1 WHT 55-14 BRAKE 18AWG GXL CO03-J2(13)
2 BLK 00-1-2 18AWG GXL S181(2)
S181
CONN WIRE
POS COLOR
1 BLK 00-1 18AWG GXL CO03-J2(14)
2 BLK 00-1-1 18AWG GXL HV178(2)
2 BLK 00-1-2 18AWG GXL HV179(2)
X449B
CONN WIRE
POS COLOR
1 WHT 61-1-45V 18AWG GXL MS244(3)
2 WHT 38-10 FAXS LFT 18AWG GXL CO03-J1(14)
3 BLK 00-8-2 18AWG GXL S195(2)
7-86 3121619
3121619 7-87
7-88
BRN
SHLD RTN
SOLDER
BLU
SHLD
BRN
HV316 BLK LD
SH
WARM UP VLV BLU
BLK
HV108
TELE FLOW CNTRL SHIELD TERMINATION DIAGRAM
HV102 X158
LIFT FLOW CNTRL
AH318
HV348
SWG FLOW CNTRL
SN438
S156 CO02-J2
S154 S455
S157 S155 S153

X159A
HV314
X440A
CHASSIS ENABLE CO02-J3
HV104
MAIN DUMP
HV103
MAIN TELE OUT
SN114
HV106 FUEL LEVEL
MAIN LIFT UP
HV99
SWG RHT
HV105
LIFT DN AUX
HV107
LIFT PILOT
HV100
SWG LFT
HV101
MAIN LIFT DN HV315
LIFT ENABLE
HV109
MAIN TELE IN
SN416
HYD OIL TEMP SN439
MAF08640E
1001149974-E
Figure 7-43. Hydraulic Valve Bank Harness (Prior to SN 0300201023)
3121619
CO03-J7 CO02-J3
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 50-3 JIB DUMP 16 AWG GXL X159A (5) 1 WHT 60-1 LFCNTRL RTN 16 AWG GXL HV102 (2)
2 WHT 55-31 CHS ENABLE 18 AWG GXL HV314 (1) 2 WHT 60-2 TFCNTRL RTN 18 AWG GXL HV108 (2)
3 WHT 50-2 PLTFRM DUMP 16 AWG GXL X159A (4) 3
4 WHT 13-4 MTELE IN 18 AWG GXL HV109 (1) 4 WHT 60-3 SWG RTN 18 AWG GXL HV348 (2)
5 WHT 25-6 PLVL UP O/R 18 AWG GXL X159A (2) 5 WHT 60-6 WARM UP RTN 18 AWG GXL HV316 (2)
6 BLK 0-11 16 AWG GXL S156 (1) 6
7 WHT 25-5 PLVL DN O/R 18 AWG GXL X159A (3) 7 WHT 52-8 ALRM PWR 18 AWG GXL AH318 (A)
8 8
9 WHT 55-12 TELE FCNTRL 18 AWG GXL HV108 (1) 9 WHT 47-6 ALT EXC 18 AWG GXL X159A (12)
10 WHT 55-11 LFT PLT 18 AWG GXL HV107 (1) 10
11 WHT 3-2 MLIFT UP 18 AWG GXL HV106 (1) 11 BLK 0-46 18 AWG GXL CO02-J2 (29)
12 WHT 55-10 LFT DN AUX 18 AWG GXL HV105 (1) 12
13 WHT 50-1 MAIN DUMP 18 AWG GXL HV104 (1) 13
14 BLK 0-10 16 AWG GXL S154 (1) 14 WHT 60-7 LENABLE RTN 16 AWG GXL HV315 (2)
15 WHT 22-2 SWG LFT 18 AWG GXL HV100 (1)
HV315
16 WHT 13-3 MTELE OUT 18 AWG GXL HV103 (1) LIFT ENABLE
17 BLK 0-36 18 AWG GXL HV314 (2) CONN WIRE
18 BLK 0-30 18 AWG GXL S153 (1) POS COLOR
19 WHT 55-9 LFT FCNTRL 18 AWG GXL HV102 (1) 1 WHT 55-30 LFT ENABLE 18 AWG GXL X440A (1)
20 2 WHT 60-7 LENABLE RTN 18 AWG GXL CO02-J3 (14)
21
SN114
22 WHT 3-1 MLIFT DN 18 AWG GXL HV101 (1)
CONN WIRE
POS COLOR
24 1 WHT 47-10 FUL SEN 18 AWG GXL CO02-J2 (25)
25 WHT 47-10 FUL SEN 18 AWG GXL SN114 (1) 2 BLK 0-14-3 18 AWG GXL S157 (2)
26 WHT 52-7 H&T LT SIG 18 AWG GXL X158 (1)
HV314
27 WHT 52-6 MOT ALRM 18 AWG GXL AH318 (B)
CHASSIS ENABLE
28
CONN WIRE
29 BLK 0-46 18 AWG GXL CO02-J3 (11) WIRE LABEL GAUGE JACKET TO
POS COLOR
30 BLK 0-6 16 AWG GXL S155 (1) 1 WHT 55-31 CHS ENABLE 18 AWG GXL CO02-J2 (2)
31 WHT 27-3 JIB DN O/R 18 AWG GXL X159A (1) 2 BLK 0-36 18 AWG GXL CO02-J2 (17)
32 WHT 22-1 SWG RHT 18 AWG GXL HV99 (1)
HV104
33 WHT 55-33 WARM UP 18 AWG GXL HV316 (1)
MAIN DUMP
34
CONN WIRE
35 WHT 55-32 SWG F.C. 18 AWG GXL HV348 (1) WIRE LABEL GAUGE JACKET TO
POS COLOR
1 WHT 50-1 MAIN DUMP 18 AWG GXL CO02-J2 (13)
2 BLK 0-10-2 18 AWG GXL S154 (2)
3121619 7-89
HV100 HV107
SWG LFT LIFT PILOT
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 22-2 SWG LFT 18 AWG GXL CO02-J2 (15) 1 WHT 55-11 LFT PLT 18 AWG GXL CO02-J2 (10)
HV106 HV99
MAIN LIFT UP SWG RHT
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 3-2 MLIFT UP 18 AWG GXL CO02-J2 (11) 1 WHT 22-1 SWG RHT 18 AWG GXL CO02-J2 (32)
HV109 HV101
MAIN TELE IN MAIN LIFT DN
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 13-4 MTELE IN 18 AWG GXL CO02-J2 (4) 1 WHT 3-1 MLIFT DN 18 AWG GXL CO02-J2 (22)
HV108 HV103
TELE FLOW CNTRL MAIN TELE OUT
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 55-12 TELE FCNTRL 18 AWG GXL CO02-J2 (9) 1 WHT 13-3 MTELE OUT 18 AWG GXL CO02-J2 (16)
2 WHT 60-2 TFCNTRL RTN 18 AWG GXL CO02-J3 (2) 2 BLK 0-11-2 18 AWG GXL S156 (2)
X158 SN416
CONN WIRE HYD OIL TEMP
POS COLOR CONN WIRE
1 WHT 52-7 H&T LT SIG 18 AWG GXL CO02-J2 (26) POS COLOR
1 WHT 49-45 HYD OIL TEMP 18 AWG GXL X159A (6)
HV316
2 BLK 0-31 18 AWG GXL X159A (7)
WARM UP VLV
CONN WIRE AH318
POS COLOR CONN WIRE
1 WHT 55-33 WARM UP 18 AWG GXL CO02-J2 (33) POS COLOR
2 WHT 60-6 WARM UP RTN 18 AWG GXL CO02-J3 (5) A WHT 52-8 ALRM PWR 18 AWG GXL CO02-J3 (7)
B WHT 52-6 MOT ALRM 18 AWG GXL CO02-J2 (27)
HV105
LIFT DN AUX C BLK 0-14-2 18 AWG GXL S157 (2)
CONN WIRE SN438
POS COLOR
CONN WIRE
1 WHT 55-10 LFT DN AUX 18 AWG GXL CO02-J2 (12) WIRE LABEL GAUGE JACKET TO
POS COLOR
2 BLK 0-6-3 18 AWG GXL S155 (2) 1 BRN 49-77 P C PWR 20 AWG CABLE X440A (2)
2
3 BLU 49-75 PRS CHK 20 AWG CABLE X440A (4)
4 BLK 49-76 P C GND 20 AWG CABLE X440A (3)
SHLD SHLD P CHK SN 20 AWG CABLE S455 (2)
7-90 3121619
X440A X159A
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 55-30 LFT ENABLE 18 AWG GXL HV315 (1) 1 WHT 27-3 JIB DN O/R 18 AWG GXL CO02-J2 (31)
2 BRN 49-77 P C PWR 20 AWG CABLE SN438 (1) 2 WHT 25-6 PLVL UP O/R 18 AWG GXL CO02-J2 (5)
3 BLK 49-76 P C GND 20 AWG CABLE SN438 (4) 3 WHT 25-5 PLVL DN O/R 18 AWG GXL CO02-J2 (7)
4 BLK 49-75 PRS CHK 20 AWG CABLE SN438 (3) 4 WHT 50-2 PLTFRM DUMP 16 AWG GXL CO02-J2 (3)
5 BRN 49-73 L P PWR 20 AWG CABLE SN439 (1) 5 WHT 50-3 JIB DUMP 16 AWG GXL CO02-J2 (1)
6 BLK 49-74 L P GND 20 AWG CABLE SN439 (4) 6 WHT 49-45 HYD OIL TEMP 18 AWG GXL SN416 (1)
7 BLU 49-72 LIFT PRS 20 AWG CABLE SN439 (3) 7 BLK 0-31 18 AWG GXL SN416 (2)
8 SHLD RTN 20 AWG CABLE S455 (1) 8
9
SN439
10
CONN WIRE
WIRE LABEL GAUGE JACKET TO 11 BLK 0-14 16 AWG GXL S157 (1)
POS COLOR
1 BRN 49-73 L P PWR 20 AWG CABLE X440A (5) 12 WHT 47-6 ALT EXC 18 AWG GXL CO02-J3 (9)
2
3 BLU 49-72 LIFT PRS 20 AWG CABLE X440A (7)
4 BLK 49-74 L P GND 20 AWG CABLE X440A (6)
SHLD SHLD P LIFT SN 20 AWG CABLE S455 (2)
HV348
SWG FLOW CNTRL
CONN WIRE
POS COLOR
1 WHT 55-32 SWG F.C. 18 AWG GXL CO02-J2 (35)
2 WHT 60-3 SWG RTN 18 AWG GXL CO02-J3 (4)
HV102
LIFT FLOW CNTRL
CONN WIRE
POS COLOR
1 WHT 55-9 LFT FCNTRL 18 AWG GXL CO02-J2 (19)
2 WHT 60-1 LFCNTRL RTN 18 AWG GXL CO02-J3 (1)
3121619 7-91
7-92
SN439
LIFT ROD PRS
HV315
LIFT ENABLE
BRN
SHLD RTN
SOLDER
BLU
SHLD
BRN
BLK LD
SH
BLU
BLK
SHIELD TERMINATION DIAGRAM
HV99
SWG RHT SN114
HV109 FUEL SENDING UNIT
MAIN TELE IN HV106
MAIN LIFT UP
HV101
MAIN LIFT DN HV103
HV100 MAIN TELE OUT
SWG LFT HV314
CHASSIS ENABLE
HV107
LIFT PILOT HV104
MAIN DUMP
X05A
SN438
PRS CHK S156 S154
S153 S455
S155
SN416 X05B
HYD OIL TEMP HV105 X158
LIFT DN AUX HEAD & TAIL LIGHTS
X440A
AH318 CO02-J3
GROUND ALARM
HV316 CO02-J2
WARM UP VLV
HV108
TELE FLOW CNTRL
HV102 S157
LIFT FLOW CNTRL
HV348
SWG FLOW CNTRL
X159A
MAF08650B
1001197446-B
Figure 7-44. Hydraulic Valve Bank Harness (SN 0300201023 to Present)
3121619
X05B CO02-J3
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK 0-46 18 AWG GXL X05B (2) 1 WHT 60-1 LFCNTRL RTN 18 AWG GXL HV102 (2)
2 2 WHT 60-2 TFCNTRL RTN 18 AWG GXL HV108 (2)
3
X440A
4 WHT 60-3 SWG RTN 18 AWG GXL HV348 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 5 WHT 60-6 WARM UP RTN 18 AWG GXL HV316 (2)
POS COLOR
1 WHT 55-30 LFT ENABLE 18 AWG GXL HV315 (1) 6
2 BRN 49-77 P C PWR 20 AWG CABLE SN438 (1) 7 WHT 52-8 ALRM PWR 18 AWG GXL AH318 (A)
3 BLK 49-76 P C GND 20 AWG CABLE SN438 (4) 8
4 BLU 49-75 PRS CHK 20 AWG CABLE SN438 (3) 9 WHT 47-6 ALT EXC 18 AWG GXL X159A (12)
5 BRN 49-73 L P PWR 20 AWG CABLE SN439 (1) 10
6 BLK 49-74 L P GND 20 AWG CABLE SN439 (4) 11 BLK 0-46 18 AWG GXL X05A (2)
7 BLU 49-72 LIFT PRS 20 AWG CABLE SN439 (3) 12
8 SHLD RTN 20 AWG CABLE S455 (1) 13
14 WHT 60-7 LENABLE RTN 18 AWG GXL HV315 (2)
HV315
LIFT ENABLE SN416
CONN WIRE HYD OIL TEMP
POS COLOR CONN WIREC
1 WHT 55-30 LFT ENABLE 18 AWG GXL X440A (1) POS OLOR
2 WHT 60-7 LENABLE RTN 18 AWG CABLE CO02-J3 (14) 1 WHT 149-45 HYD OIL TEMP 18 AWG GXL X159A (6)
2 BLK 0-31 18 AWG GXL X159A (7)
SN439
CONN WIRE HV109
WIRE LABEL GAUGE JACKET TO MAIN TELE IN
POS COLOR
1 BRN 49-73 L P PWR 20 AWG CABLE X440A (5) CONN WIREC
POS OLOR
2
1 WHT 13-4 MTELE IN 18 AWG GXL CO02-J2 (4)
3 BLU 49-72 LIFT PRS 20 AWG CABLE X440A (7)
2 BLK 0-11-1 18 AWG GXL S156 (2)
4 BLK 49-74 L P GND 20 AWG CABLE X440A (6)
SHLD SHLD P LIFT SN 20 AWG CABLE S455 (2) HV101
MAIN LIFT DN
X05A
CONN WIREC
CONN WIRE WIRELABEL GAUGE JACKET TO
WIRE LABEL GAUGE JACKET TO POS OLOR
POS COLOR
1 WHT 3-1 MLIFT DN 18 AWG GXL CO02-J2 (22)
1 BLK 0-46 18 AWG GXL CO02-J2 (29)
2 BLK 0-6-2 18 AWG GXL S155 (2)
2 BLK 0-46 18 AWG GXL CO02-J3 (11)
HV100
SWG LFT
CONN WIREC
POS OLOR
1 WHT 22-2 SWG LFT 18 AWG GXL CO02-J2 (15)
2 BLK 0-30-1 18 AWG GXL S153 (2)
3121619 7-93
HV107 HV314
SWG LFT CHASSIS ENABLE
CONN WIREC CONN WIREC
WIRELABEL GAUGE JACKET TO WIRELABEL GAUGE JACKET TO
POS OLOR POS OLOR
1 WHT 55-11 LFT PLT 18 AWG GXL CO02-J2 (10) 1 WHT 55-31 CHS ENABLE 18 AWG GXL CO02-J2 (02)
2 BLK 0-10-1 18AWG GXL S154 (2) 2 BLK 0-36 18 AWG GXL CO02-J2 (17)
HV105 X158
LIFT DN AUX HEAD & TAIL LIGHTS
POS OLOR POS OLOR
1 WHT 55-10 LFT DN AUX 18 AWG GXL CO02-J2 (12) 1 WHT 52-7 H&T LT SIG 18 AWG GXL CO02-J2 (26)
2 BLK 0-6-3 18AWG GXL S155 (2)
SN114
SN438 FUEL SENDING UNIT
POS OLOR POS OLOR
1 BRN 49-77 P C PWR 20 AWG CABLE X440A (2) 1 WHT 47-10 FUL SEN 18 AWG GXL CO02-J2 (25)
2 2 BLK 0-14-3 18 AWG GXL S157 (2)
3 BLU 49-75 PRS CHK 20 AWG CABLE X440A (4) AH318
4 BLK 49-76 P C GND 20 AWG CABLE X440A (3) GROUND ALARM
SHLD SHLD P CHK SN 20 AWG CABLE S455 (2) CONN WIRE
POS COLOR
HV99
A WHT 52-8 ALRM PWR 18 AWG GXL CO02-J3 (7)
SWG RHT
B WHT 52-6 MOT ALRM 18 AWG GXL CO02-J2 (27)
CONN WIREC
WIRELABEL GAUGE JACKET TO C BLK 0-14-2 18 AWG GXL S157 (2)
POS OLOR
1 WHT 22-1 SWG RHT 18 AWG GXL CO02-J2 (32) HV316
2 BLK 0-30-2 18 AWG GXL S153 (2) WARM UP VLV
CONN WIRE
HV106 WIRE LABEL GAUGE JACKET TO
POS COLOR
MAIN LIFT UP
1 WHT 55-33 WARM UP 18 AWG GXL CO02-J2 (33)
CONN WIREC
WIRELABEL GAUGE JACKET TO 2 WHT 60-6 WARM UP RTN 18 AWG GXL CO02-J3 (5)
POS OLOR
1 WHT 3-2 MLIFT UP 18 AWG GXL CO02-J2 (32) HV348
2 BLK 0-6-1 18 AWG GXL S155 (2) SWG FLOW CNTRL
CONN WIRE
POS COLOR
MAIN TELE OUT
1 WHT 55-32 SWG F.C. 18 AWG GXL CO02-J2 (35)
CONN WIREC
WIRELABEL GAUGE JACKET TO 2 WHT 60-3 SWG RTN 18 AWG GXL CO02-J3 (4)
POS OLOR
1 WHT 13-3 MTELE OUT 18 AWG GXL CO02-J2 (16) HV108
2 BLK 0-11-2 18 AWG GXL S156 (2) TELE FLOW CNTRL
CONN WIRE
POS COLOR
MAIN DUMP
1 WHT 55-12 TELE FCNTRL 18 AWG GXL CO02-J2 (9)
CONN WIREC
WIRELABEL GAUGE JACKET TO 2 WHT 60-2 TFCNTRL RTN 18 AWG GXL CO02-J3 (2)
POS OLOR
1 WHT 50-1 MAIN DUMP 18 AWG GXL CO02-J2 (13)
2 BLK 0-10-2 18 AWG GXL S154 (2)
7-94 3121619
HV102 CO02-J2
LIFT FLOW CNTRL CONN WIRE
CONN WIRE POS COLOR
POS COLOR 1 WHT 50-3 JIB DUMP 16 AWG GXL X159A (5)
1 WHT 55-9 LFT FCNTRL 18 AWG GXL CO02-J2 (19) 2 WHT 55-31 CHS ENABLE 18 AWG GXL HV314 (1)
2 WHT 60-1 LFCNTRL RTN 18 AWG GXL CO02-J3 (1) 3 WHT 50-2 PLTFRM DUMP 16 AWG GXL X159A (4)
X159A 4 WHT 13-4 MTELE IN 18 AWG GXL HV109 (1)
CONN WIRE 5 WHT 25-6 PLVL UP O/R 18 AWG GXL X159A (2)
POS COLOR 6 BLK 0-11 16 AWG GXL S156 (1)
1 WHT 27-3 JIB DN O/R 18 AWG GXL CO02-J2 (31) 7 WHT 25-5 PLVL DN O/R 18 AWG GXL X159A (3)
2 WHT 25-6 PLVL UP O/R 18 AWG GXL CO02-J2 (5) 8
3 WHT 25-5 PLVL DN O/R 18 AWG GXL CO02-J2 (7) 9 WHT 55-12 TELE FCNTRL 18 AWG GXL HV108 (1)
4 WHT 50-2 PLTFRM DUMP 16 AWG GXL CO02-J2 (3) 10 WHT 55-11 LFT PLT 18 AWG GXL HV107 (1)
5 WHT 50-3 JIB DUMP 16 AWG GXL CO02-J2 (1) 11 WHT 3-2 MLIFT UP 18 AWG GXL HV106 (1)
6 WHT 49-45 HYD OIL TEMP 18 AWG GXL SN416 (1) 12 WHT 55-10 LFT DN AUX 18 AWG GXL HV105 (1)
7 BLK 0-31 18 AWG GXL SN416 (2) 13 WHT 50-1 MAIN DUMP 18 AWG GXL HV104 (1)
8 14 BLK 0-10 16 AWG GXL S154 (1)
9 15 WHT 22-2 SWG LFT 18 AWG GXL HV100 (1)
10 16 WHT 13-3 MTELE OUT 18 AWG GXL HV103 (1)
11 BLK 0-14 16 AWG GXL S157 (1) 17 BLK 0-36 18 AWG GXL HV314 (2)
12 WHT 47-6 ALT EXC 18 AWG GXL CO02-J3 (9) 18 BLK 0-30 18 AWG GXL S153 (1)
19 WHT 55-9 LFT FCNTRL 18 AWG GXL HV102 (1)
20
21
22 WHT 3-1 MLIFT DN 18 AWG GXL HV101 (1)
23
24
25 WHT 47-10 FUL SEN 18 AWG GXL SN114 (1)
26 WHT 52-7 H&T LT SIG 18 AWG GXL X158 (1)
27 WHT 52-6 MOT ALRM 18 AWG GXL AH318 (B)
28
29 BLK 0-46 18 AWG GXL X05A (1)
30 BLK 0-6 16 AWG GXL S155 (1)
31 WHT 27-3 JIB DN O/R 18 AWG GXL X159A (1)
32 WHT 22-1 SWG RHT 18 AWG GXL HV99 (1)
33 WHT 55-33 WARM UP 18 AWG GXL HV316 (1)
34
35 WHT 55-32 SWG F.C. 18 AWG GXL HV348 (1)
3121619 7-95
HV142
RHT DRV PUMP FWD
HV144
LFT DRV PUMP REV
001149970-B
X222A
S146
HV145
LFT DRV PUMP FWD HV143
RHT DRV PUMP REV
1001149970-B
MAF08660B
Figure 7-45. Drive Pump Harness
7-96 3121619
X222A
CONN WIRE
POS COLOR
1 WHT 7-4 RDRV PFWD 18 AWG GXL HV142 (1)
2 WHT 7-3 RDRV PREV 18 AWG GXL HV143 (1)
3 BLK 0-15 18 AWG GXL S146 (1)
4
5 WHT 7-2 LDRV PREV 18 AWG GXL HV144 (1)
6 WHT 7-1 LDRV PFWD 18 AWG GXL HV145 (1)
HV144 - LFT DRV PUMP REV

CONN WIRE
POS COLOR
1 WHT 7-2 LDRV PREV 18 AWG GXL X222A (5)
2 BLK 0-15-3 18 AWG GXL S146 (1)
HV143 - RHT DRV PUMP REV

CONN WIRE
POS COLOR
1 WHT 7-3 RDRV PREV 18 AWG GXL X222A (2)
2 BLK 0-15-2 18 AWG GXL S146 (2)
HV145 - LFT DRV PUMP FWD

CONN WIRE
POS COLOR
1 WHT 7-1 LDRV PFWD 18 AWG GXL X222A (6)
2 BLK 0-15-4 18 AWG GXL S146 (1)
HV142 - RHT DRV PUMP FWD

CONN WIRE
POS COLOR
1 WHT 7-4 RDRV PFWD 18 AWG GXL X222A (1)
2 BLK 0-15-1 18 AWG GXL S146 (2)
3121619 7-97
7-98
EC241-L
X218B
ATTACH MATING
CONNECTOR P/N 4460932
X941
MS999-1 MS1000-1
X1009 X217B
EIC S1011 S945 S944
S1008 MS1002-2
S946 ECM-J1
X950 MS1001-1
RL930
X1006
FC1004 ECM-J2
FC1003
RL930-2
T920
RL930-1
RL931-85 RL931-87
RL931-86
SN939
MAF08710F
1001149971-F
Figure 7-46. T4i Engine Harness
3121619
MS1001-1 X217B
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL CAN HIGH 0.75 mm² FLRYW ECM-J1 (54) 1 YEL 2-1-99 IGNITION 18 AWG GXL FC1004 (1)
2 GRN CAN LOW 0.75 mm² FLRYW ECM-J1 (76) 2
3
MS1000-1
4
CONN WIRE
POS COLOR
1 YEL CAN HIGH 0.75 mm² FLRYW ECM-J1 (75)
2 GRN CAN LOW 0.75 mm² FLRYW ECM-J1 (53)
X218B
CONN WIRE X950
WIRE LABEL
POS COLOR GAUGE JACKET TO CONN WIRE
1 POS COLOR
2 BLK 148-35-2 STRT REQ 0.75 mm² FLRYW S1011 (2) A YEL 2-48-2 IGNITION 18 AWG GXL S946 (2)
3 YEL CAN HIGH 20 AWG J1939 CABLE MS999-1 (A) B BLK 2-48-2 IGNITION 18 AWG GXL S1008 (2)
4 GRN CAN LOW 20 AWG J1939 CABLE MS999-1 (B) C
5 WHT 47-6-2 ALT EXC 18 AWG GXL EC241-L (1) D
6 SHLD SHIELD 20 AWG J1939 CABLE MS999-1 (C) E
F GRN CAN LOW 0.75 mm² FLRYW X1006 (2)
X941
G GRN CAN LOW 0.75 mm² FLRYW MS1002-2 (B)
CONN WIRE
WIRE LABEL GAUGE JACKET TO H YEL CAN HIGH 0.75 mm² FLRYW MS1002-2 (A)
POS COLOR
J
148-64 WATER IN
1 BLK 0.75 mm² FLRYW ECM-J1 (64) K
FUEL SW
148-57 WATER IN L
2 BLK 0.75 mm² FLRYW ECM-J1 (57)
FUEL SW RTN M YEL CAN HIGH 0.75 mm² FLRYW X1006 (1)
3 WHT 48-96 FUEL PUMP 14 AWG GXL RL930-1 (1) N.C
4 BLK 000-48-1 ENG GND 14 AWG GXL T920 (1) NC
MS1002-2 X1006
CONN WIRE CONN WIRE
POS COLOR POS COLOR
A YEL CAN HIGH 0.75 mm² FLRYW X950 (H) 1 YEL CAN HIGH 0.75 mm² FLRYW X950 (M)
B GRN CAN LOW 0.75 mm² FLRYW X950 (G) 2 GRN CAN LOW 0.75 mm² FLRYW X950 (F)
C 3 BLK 000-48-4 SHLD 18 AWG GXL S1008 (2)
RL931-86 RL930-2
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL 2-48-3 IGNITION 18 AWG GXL S946 (1) 1 RED 1-148-135 ECM PWR 8 AWG GXL S944 (1)
RL931-87 RL931-85
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 ORG 248-23-1 GLOW SENSE 18 AWG GXL FC1003 (2) 248-35G LOW RELAY
CONTROL GND
3121619 7-99
EC241-L ECM-J1
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 47-6-2 ALT EXC 18 AWG GXL X218B (5) 1 RED 148-1 ECM PWR 2.5 mm² FLRYW S944 (2)
2 BLK 148-2 ECM GND 2.5 mm² FLRYW S945 (2)
T920
3 RED 148-3 ECM PWR 2.5 mm² FLRYW S944 (2)
CONN WIRE
WIRE LABEL GAUGE JACKET TO 4 BLK 148-4 ECM GND 2.5 mm² FLRYW S945 (2)
POS COLOR
1 BLK 000-148-2 0.75 mm² FLRYW X1009 (1) 5 RED 148-5 ECM PWR 2.5 mm² FLRYW S944 (2)
1 BLK 000-148-246 ECM GND 8 AWG GXL S945 (1) 6 BLK 148-6 ECM GND 2.5 mm² FLRYW S945 (2)
1 BLK 000-48-1 ENG GND 14 AWG GXL X941 (4) 7
1 BLK 000-48-3 ENG GND 18 AWG GXL S1008 (1) 8
9
RL930-1
10
CONN WIRE
POS COLOR
12
148-13 COOLANT LEVEL
13 BLK 0.75 mm² FLRYW SN939 (3)
MS999-1 SIG
CONN WIRE 14
POS COLOR 15
A YEL CAN HIGH 20 AWG J1939 CABLE X218B (3) 16
B GRN CAN LOW 20 AWG J1939 CABLE X218B (4) 17
C SHLD SHIELD 20 AWG J1939 CABLE X218B (6) 18
SN939 19
CONN WIRE 20
POS COLOR
148-29 COOLANT 22
LEVEL PWR 23
148-87 COOLANT 24
LEVEL GND
25
148-13 COOLANT
3 BLK 0.75 mm² FLRYW ECM-J1 (13) 148-26F UEL PUMP
LEVEL SIG 26 BLK 0.75 mm² FLRYW RL930 (2)
RELAY CONTROL GND
4
27
RL930 28 BLK 148-70 STRT GND 0.75 mm² FLRYW EIC (2)
CONN WIRE 148-29 COOLANT LEVEL
WIRE LABEL GAUGE JACKET TO 29 BLK 0.75 mm² FLRYW SN939 (1)
POS COLOR PWR
1 YEL 2-48-4 IGNITION 18 AWG GXL S946 (1) 30
148-26F UEL PUMP 31
RELAY CONTROL GND 32
X1009 33
CONN WIRE 34
WIRE LABEL GAUGE JACKET TO 35 BLK 148-35-3 STRT REQ 0.75 mm² FLRYW S1011 (1)
POS COLOR
1 BLK 000-148-2 0.75 mm² FLRYW T920 (1) 36
2 BLK 148-35-4 STRT REQ 0.75 mm² FLRYW S1011 (2) 37
148-38 THROTTLE
38 BLK 0.75 mm² FLRYW EIC (52)
FLAP 4
7-100 3121619
39 MS1001-1
76 GRN CAN LOW 0.75 mm² FLRYW
40 (B)
41 77
42 78
43 79
148-44 E HXAUST GAS 80
RECIRCULATION 81
45 148-82 E HXAUST GAS
46 RECIRCULATION
47 83
48 84
49 148-85 E HXAUST GAS
RECIRCULATION
50
86
51
148-87 COOLANT LEVEL
52 87 BLK 0.75 mm² FLRYW SN939 (2)
GND
MS1000-1
53 GRN CAN LOW 0.75 mm² FLRYW 88 BLK 148-88 IGNITION 0.75 mm² FLRYW S946 (2)
(B)
89
MS1001-1
54 YEL CAN HIGH 0.75 mm² FLRYW 90
(A)
55 91
56 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW EIC (34) 92
148-57 WATER IN FUEL 93
57 BLK 0.75 mm² FLRYW X941 (2)
SW RTN 94
58
EIC
59
CONN WIRE
POS COLOR
148-61 F UEL LOW 248-38E NGINE SPEED
61 BLK 0.75 mm² FLRYW EIC (17) 1 SHLD 0.75 mm² SHLD ECM-J2 (38)
PRESSURE CRANKSHAFT
62 2 BLK 148-70 STRT GND 0.75 mm² FLRYW ECM-J1 (28)
63 3 BLK 148-71 STRT SIG 0.75 mm² FLRYW ECM-J1 (73)
148-64 WATER IN FUEL 4
64 BLK 0.75 mm² FLRYW X941 (1)
SW
5
65
6
66
7
67
8
148-15-68 CLUTCH
68 BLK 0.75 mm² FLRYW ECM-J1 (15) 248-53E NGINE SPEED
SWITCH 9 SHLD 0.75 mm² SHLD ECM-J2 (53)
CAMSHAFT
69
10
70
11
71
12
148-72 THROTTLE FLAP
72 BLK 0.75 mm² FLRYW EIC (49) 248-52E NGINE SPEED
3 13 BLK 0.75 mm² FLRYW ECM-J2 (52)
CAMSHAFT
73 BLK 148-71 STRT SIG 0.75 mm² FLRYW EIC (3)
248-37E NGINE SPEED
74 14 BLK 0.75 mm² FLRYW ECM-J2 (37)
CAMSHAFT
MS1000-1 248-39E NGINE SPEED
75 YEL CAN HIGH 0.75 mm² FLRYW 15 BLK 0.75 mm² FLRYW ECM-J2 (39)
(A) CRANKSHAFT
16
3121619 7-101
148-61 F UEL LOW 148-82 E HXAUST GAS

17 BLK 0.75 mm² FLRYW ECM-J1 (61) 51 BLK 0.75 mm² FLRYW ECM-J1 (82)
PRESSURE RECIRCULATION
18 148-38 THROTTLE FLAP
19 BLK 248-4M PROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (4) 4
20 BLK 248-5M PROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (5) 53
248-54E NGINE SPEED 54
CRANKSHAFT 55
248-24 BOOST PRESSURE 56
/ TEMP 57
23 BLK 248-43 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (43) 58
248-28C OOLING 59
TEMPERATURE
60
248-26 RAIL PRESSURE
25 BLK 0.75 mm² FLRYW ECM-J2 (26) 61 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW ECM-J2 (2)
FUEL
62 BLK 248-33 INJECTOR 1 1.5 mm² FLRYW ECM-J2 (33)
26 BLK 248-44 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (44)
27 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (29) ECM-J2
28 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW ECM-J2 (40) CONN WIRE
248-27 BOOST PRESSURE POS COLOR
/ TEMP 1
30 2 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW EIC (61)
248-25 RAIL PRESSURE 3 BLK 248-3 INJECTOR 2 1.5 mm² FLRYW EIC (41)
FUEL 248-4M PROP
248-7 RAIL PRESSURE ACTUATOR
FUEL 248-5M PROP
33 ACTUATOR
34 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW ECM-J1 (56) 6
35 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW ECM-J2 (16) 248-7 RAIL PRESSURE
36 FUEL
37 BLK 248-18 INJECTOR 4 1.5 mm² FLRYW ECM-J2 (18) 8
39 10
43 14
44 15
45 16 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW EIC (35)
148-85 E HXAUST GAS 17
RECIRCULATION 18 BLK 248-18 INJECTOR 4 1.5 mm² FLRYW EIC (37)
248-19 E HXAUST GAS 248-19 E HXAUST GAS
47 BLK 1.5 mm² FLRYW ECM-J2 (19) 19 BLK 1.5 mm² FLRYW EIC (47)
RECIRCULATION RECIRCULATION
248-20 E HXAUST GAS ECM-J2 (20) 248-20 E HXAUST GAS
48 BLK 1.5 mm² FLRYW 20 BLK 1.5 mm² FLRYW EIC (48)
RECIRCULATION 49 BLK RECIRCULATION
148-72 THROTTLE FLAP 21
3 22
148-44 E HXAUST GAS 23 BLK 248-23 GLOW SENSE 0.75 mm² FLRYW FC1003 (1)
RECIRCULATION
248-24 BOOST
PRESSURE / TEMP
7-102 3121619

FUEL
FUEL
248-27 BOOST
PRESSURE / TEMP
248-28C OOLING
TEMPERATURE
29 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW EIC (27)
30
31
32 BLK 248-32 INJECTOR 3 1.5 mm² FLRYW EIC (38)
34
248-35G LOW RELAY
35 BLK 0.75 mm² FLRYW RL931-85 (1)
CONTROL GND
36
248-37E NGINE SPEED
CAMSHAFT
248-38E NGINE SPEED
38 SHLD 0.75 mm² FLRYW EIC (1)
CRANKSHAFT
248-39E NGINE SPEED
CRANKSHAFT
248-40 AIR INLET
TEMP
41
42
45
47
49
50
51
248-52E NGINE SPEED
CAMSHAFT
248-53E NGINE SPEED
53 SHLD 0.75 mm² SHLD EIC (9)
CAMSHAFT
248-54E NGINE SPEED
CRANKSHAFT
55
56
57
58
59
60
3121619 7-103
7-104
MS999-2
MS999-2
X1005
X1005
MS1000-2
MS1000-2
MS1002-1
MS1002-1
MS1001-2
MS1001-2
MS999-3
MS999-3
1001156001-B
MAF08720B
MAF08720B
1001156001-B
Figure 7-47. CAN Engine Harness - Sheet 1 of 2
3121619
MS1000-2
MS1001-2
Figure 7-48. CAN Engine Harness - Sheet 2 of 2

X1005
MS1002-1
MS999-3
MS999-2
1001156001-B
MAF08730B
3121619 7-105
MS1002-1
CONN WIRE
POS COLOR
A YEL CAN HI 20 AWG J1939 CABLE MS1000-2 (A)
B GRN CAN LOW 20 AWG J1939 CABLE MS1000-2 (B)
C SHLD SHIELD 20 AWG J1939 CABLE MS1000-2 (C)
X1005
CONN WIRE
POS COLOR
2 GRN CAN LOW 20 AWG J1939 CABLE MS999-3 (B)
3 SHLD SHIELD 20 AWG J1939 CABLE MS999-3 (C)
MS999-2
CONN WIRE
POS COLOR
MS999-3
CONN WIRE
POS COLOR
2 GRN CAN LOW 20 AWG J1939 CABLE X1005 (2)
3 SHLD SHIELD 20 AWG J1939 CABLE X1005 (3)
MS1000-2
CONN WIRE
POS COLOR
MS1001-2
CONN WIRE
POS COLOR
7-106 3121619
3121619 7-107
7-108
XTERM1
XTERM1
X355
X355 XTERM3
XTERM3
XTERM2
XTERM2
FC356
FC356
1001156030-B
MAF08740B
MAF08740B
1001156030-B
Figure 7-49. Generator Enable Harness
3121619
X355
CONN WIRE
POS COLOR
1 YEL 2-13 18 AWG GXL FC356 (2)
2 WHT 52-9 GEN 18 AWG GXL XTERM2 (1)
3 BLK 0-18 18 AWG GXL XTERM3 (1)
FC356
CONN WIRE
POS COLOR
1 YEL 2-13 18 AWG GXL XTERM1 (1)
2 YEL 2-13 18 AWG GXL X355 (1)
XTERM3
CONN WIRE
POS COLOR
1 BLK 0-18 18 AWG GXL X355 (2)
XTERM2
CONN WIRE
POS COLOR
1 WHT 52-9 GEN 18 AWG GXL X355 (3)
XTERM1
CONN WIRE
POS COLOR
1 YEL 2-13 18 AWG GXL FC356 (1)
3121619 7-109
7-110
X942A
TO WTR IN FUEL/ FUEL PUMP HARNESS
X437A
TO UREA TANK HARNESS
X436A
X212 MS276 X213
DEUTZ D2.2 GROUND BUSS ENGINE CONNECTION
X211 FC248
DEUTZ D2.1 X218B RLY/FUSE PANEL
ENG CON #2 X229 SN239
X233 X217B CAN TERMINATOR AMBIENT AIR TEMP SNSR
CAN TERMINATOR ENG CON X241
#1
RL217-85
GLOW PLUG PWR
SN216
X568 EXHT GAS TEMP
MS567 SN240
X270 RL217-87 COOL LVL SNSR
ENG GND GLOW PLUG SIG EC246-D+
ALT EXCITE SN236
RL261 NOx SNSR AFTR SCR CAT
SN237
FUEL PUMP RLY NOx SNSR SCR CAT
RL217-86
GLOW PLUG RTN SN215
MS218 SCR EXH GAS TEMP V254
SN283 DOSING VLV
DEUTZ CAN BUSS DPF PRS
V267 MS259
UREA TANK HTR VLV BUSS BAR RLY PWR
X491
SYS B+
X260
SYS B+
MAF07320I
1001188922-I
Figure 7-50. T4F Engine Harness - Sheet 1 of 7
3121619
3121619
X211
X212
DEUTZ D2.2 DEUTZ D2.1
X233
X568
MS567
V267
UREA TANK HTR VLV
MAF07330I
1001188922-I
7-111
X436A
X437A
X942A
TO WTR IN FUEL/ FUEL PUMP HARNESS
X218B
ENG CON #2
X217B
ENG CON #1
X491
SYS B+
X260
SYS B+
1001188922-I
MAF07340I
7-112 3121619
3121619
FC248 X213
RLY/FUSE PANEL ENGINE CONNECTION
X229
CAN TERMINATOR
END LOOM HERE.
MS276
GROUND BUSS
X241
DEUTZ DIAGNOSTICS
RL217-85
GLOW PLUG PWR
X270
ENG GND
EC246-D+
ALT EXCITE
RL261
FUEL PUMP RLY RL217-87
GLOW PLUG SIG
RL217-86
MS259 GLOW PLUG RTN
BUSS BAR RLY PWR
MS218
DEUTZ CAN BUSS
MAF07350I
1001188922-I
7-113
35A
x5
30A
25A
5A
15A
5A
, 0.5W
RESISTOR
1001188922-I
MAF07360I
7-114 3121619
3121619
SN239
SN216 AMBIENT AIR TEMP SNSR
EXHT GAS TEMP
SN236 SN240
NOx SNSR AFTR SCR CAT COOL LVL SNSR
SN215
SCR EXH GAS TEMP
SN237
NOx SNSR SCR CAT
SN283
DPF PRS
V254
DOSING VLV
MAF07370I
1001188922-I
7-115

MS259
MS218
SN283
X233
X229
X568
MS567
1001188922-I
MAF07380I
7-116 3121619
42
X212 - DEUTZD 2.2 43 WHT 148-15CLUTCHSW 0.75mm² FLRYW X212(91)
CONN WIRE 44
POS COLOR 45
1 RED 1-20-1 2.5mm² FLRYW S280(2) 46
2 BLK 0-60-10-1 2.5mm² FLRYW S278(2) 47
3 RED 1-20-2 2.5mm² FLRYW S280(2) 48
4 BLK 0-60-10-2 2.5mm² FLRYW S278(2) 49
5 RED 1-20-3 2.5mm² FLRYW S280(2) 50 WHT 73-1ATEMPSNSR 0.75mm² FLRYW SN239(2)
6 BLK 0-60-10-3 2.5mm² FLRYW S278(2) 51
7 52
8 53
9 54
10 WHT 73-2ATEMPSNSR 0.75mm² FLRYW SN239(1) 55
11 56
12 57 WHT 72-1COOLLVLPWR 0.75mm² FLRYW SN240(1)
13 WHT 77-3DPFPRSSIG 0.75mm² FLRYW SN283(3) 58
14 59
15 60
16 61
17 62 WHT 72-2COOLLVLSIG 0.75mm² FLRYW SN240(3)
18 WHT 77-1DPFPRSPWR 0.75mm² FLRYW SN283(1) 63
19 64 WHT 148-35-3STRTREQ 0.75mm² FLRYW S285(1)
20 65
21 66
22 67 YEL 2-99-2 1mm² FLRYW S272(1)
23 WHT 48-95FULRLY86 0.75mm² FLRYW RL261(5) 68
24 69
25 70 WHT 148-64WTR/FULSW 0.75mm² FLRYW X942A(1)
26 WHT 148-57WTR/FULRTN 0.75mm² FLRYW X942A(2) 71
27 72
28 73
29 74 WHT 48-94FULRLY85 0.75mm² FLRYW RL261(2)
30 75
31 WHT 77-2DPFPRSRTN 0.75mm² FLRYW SN283(2) 76
32 77
33 78
34 79
35 80
36 81 WHT 72-3COOLLVLGND 0.75mm² FLRYW SN240(2)
37 82 GRN CNLCH2 0.75mm² FLRYW X241(H)
38 83 YEL CNHCH2 0.75mm² FLRYW X241(G)
39 84
40 85 YEL CNHCH2 0.75mm² FLRYW MS567(1)
41 86 GRN CNLCH2 0.75mm² FLRYW MS567(3)
3121619 7-117
87 37 WHT 103-2THRLEHTR 0.75mm² FLRYW FC248(B6)

88 38 WHT 38-49INTAKETHRTLE 0.75mm² FLRYW X213(49)
89 39
90 40
91 41 WHT 41-FC248RLYGND 0.75mm² FLRYW FC248(D9)
42
43
X211-DEUTZD2.1 44 WHT 44-38INJCTR 1.5mm² FLRYW X213(38)
CONN WIRE 45 WHT 45-40INJCTR 1.5mm² FLRYW X213(40)
POS COLOR
46 WHT 46-19MPROPRTN 1.5mm² FLRYW X213(19)
1
47 WHT 47-X254DOSEVLV 0.75mm² FLRYW V254(2)
2 WHT 2-47EXHGASREC 1.5mm² FLRYW X213(47)
48 WHT 48-SN215EXHTEMP 0.75mm² FLRYW SN215(1)
3 WHT 3-S265CNTRLPWR 1.5mm² FLRYW S265(1)
49
4 WHT 259RLYPWR 0.75mm² FLRYW MS259(5)
50
5 WHT 5-X253PURGVLV 0.75mm² FLRYW X437A(11)
51 WHT 51-6DELTAVNTRI 0.75mm² FLRYW X213(6)
6
52
7 WHT 7-52INTAKETHRTLE 0.75mm² FLRYW X213(52)
53
8 WHT 8-7EGRTEMP 0.75mm² FLRYW X213(7)
54 WHT 54-17FULLOWPRS 0.75mm² FLRYW X213(17)
9 WHT 9-SN216EXHGASTEMP 0.75mm² FLRYW SN216(2)
55 WHT 55-46EGASRECSIG 0.75mm² FLRYW X213(46)
10
56
11 WHT 11-29BSTPRSTEMP 0.75mm² FLRYW X213(29)
57 WHT 57-X253UREAPRS 0.75mm² FLRYW X437A(6)
12
58 WHT 58-RL217GLOWRLYSIG 0.75mm² FLRYW RL217-87(1)
13 WHT 13-24COOLTEMP 0.75mm² FLRYW X213(24)
59 WHT 59-X253UREAPUMP 0.75mm² FLRYW X437A(10)
14
60
15 WHT 15-SN215EXHTEMP 0.75mm² FLRYW SN215(2)
61 WHT 104-1PRSHTR 0.75mm² FLRYW FC248(B8)
16
62 WHT 101-2SUPMOD 0.75mm² FLRYW FC248(B2)
17 WHT 17-32RAILPRSFUL 0.75mm² FLRYW X213(32)
63 WHT 63-RL217GLOWRLY 0.75mm² FLRYW RL217-85(1)
18 WHT 18-505V 0.75mm² FLRYW X213(50)
64 WHT 64-35INJCTRRTN 1.5mm² FLRYW X213(35)
65
20
21 WHT 21-22PRSRTN 0.75mm² FLRYW X213(22)
67 WHT 67-48EXHGASREC 1.5mm² FLRYW X213(48)
22
68
69
25 WHT 25-20MPROP 1.5mm² FLRYW X213(20)
71
26 WHT 26-X254DOSEVLV 0.75mm² FLRYW V254(1)
72 WHT 72-26OILPRS 0.75mm² FLRYW X213(26)
27 WHT 27-SN216EXHGASTEMP 0.75mm² FLRYW SN216(1)
28
29
75 WHT 75-S214SHLDRTN 0.75mm² FLRYW S214(1)
30
76 WHT 76-51GNDRTN 0.75mm² FLRYW X213(51)
31
77 YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(6)
32
33
79
34
80 WHT 102-1STIONHTR 0.75mm² FLRYW FC248(B4)
35 WHT 35-27TEMP/PRSRTN 0.75mm² FLRYW X213(27)
81
7-118 3121619
82 WHT 82-X253PURGVLV 0.75mm² FLRYW X437A(12)

83 S280
84 CONN WIRE
85 WHT 85-62INJCTR 1.5mm² FLRYW X213(62) WIRE LABEL GAUGE JACKET TO
POS COLOR
86 1 RED 1-20 6mm² FLRYW IP481(1)
87 WHT 87-42INJCTR 1.5mm² FLRYW X213(42) 2 RED 1-20-1 2.5mm² FLRYW X212(1)
88 WHT 88-RL217GLOWRLYRTN 0.75mm² FLRYW RL217-86(1) 2 RED 1-20-2 2.5mm² FLRYW X212(3)
89 WHT 89-X253UREAPUMP 0.75mm² FLRYW X437A(9) 2 RED 1-20-3 2.5mm² FLRYW X212(5)
90
MS567
91
CONN WIRE
92 WHT 92-X267UREAHEATVLV 0.75mm² FLRYW V267(1) WIRE LABEL GAUGE JACKET TO
POS COLOR
93 1 YEL CNHCH2 0.75mm² FLRYW X212(85)
94 WHT 94-3STRTRTN 0.75mm² FLRYW X213(3) 2 YEL CNHCH2 0.75mm² FLRYW X568(A)
95 WHT 95-2STRTSIG 0.75mm² FLRYW X213(2) 3 GRN CNLCH2 0.75mm² FLRYW X212(86)
96 4 GRN CNLCH2 0.75mm² FLRYW X568(B)
97 5 GRN CNLCH2 0.75mm² FLRYW X241(F)
98 GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(10) 6 GRN CNLCH2 0.75mm² FLRYW X218B(4)
99 BLK 99-13CAMENGSPD 0.75mm² FLRYW X213(13) 7 YEL CNHCH2 0.75mm² FLRYW X241(M)
100 WHT 100-14CAMENGSPD 0.75mm² FLRYW X213(14) 8 YEL CNHCH2 0.75mm² FLRYW X218B(3)
101 BLK 101-21CRKENGSPD 0.75mm² FLRYW X213(21)
102 WHT 102-15CRKENGSPD 0.75mm² FLRYW X213(15) X568
103 CONN WIRE
POS COLOR
104
A YEL CNHCH2 0.75mm² FLRYW MS567(2)
105
B GRN CNLCH2 0.75mm² FLRYW MS567(4)
X233 C
CONN WIRE
WIRE LABEL GAUGE JACKET TO V267-UREA TANK HTR VLV
POS COLOR
A YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(5) CONN WIRE
POS COLOR
B GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(3)
1 WHT 92-X267UREAHEATVLV 0.75mm² FLRYW X211(92)
C
2
S278 3
CONN WIRE 4 YEL 2-60-2 0.75mm² FLRYW S271(1)
POS COLOR
1 BLK 0-60-10 6mm² FLRYW MS276(10) S485
2 BLK 0-60-10-1 2.5mm² FLRYW X212(2) CONN WIRE
POS COLOR
2 BLK 0-60-10-2 2.5mm² FLRYW X212(4)
1 RED 1-30-1 3mm² FLRYW FC248(AA1)
2 BLK 0-60-10-3 2.5mm² FLRYW X212(6)
FUSIBLE
2 16AWG X260(1)
LINK
3121619 7-119
S486 S273
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 RED 1-31-1 3mm² FLRYW FC248(A2) 1 YEL 2-100-1 1mm² FLRYW FC248(AA3)
FUSIBLE 1 YEL 2-100-2 1mm² FLRYW FC248(AA4)
2 16AWG X260(1)
LINK 1 YEL 2-100-3 1mm² FLRYW FC248(AA5)
S285 2 YEL 2-100 2mm² FLRYW X218B(1)
CONN WIRE 2 YEL 2-100-4 2mm² FLRYW X217B(8)
POS COLOR
S272
1 WHT 148-35-3STRTREQ 0.75mm² FLRYW X212(64)
CONN WIRE
2 WHT 148-35-2STRTREQ 0.75mm² FLRYW X218B(2) WIRE LABEL GAUGE JACKET TO
POS COLOR
2 WHT 148-35-4STRTREQ 0.75mm² FLRYW FC248(AA10) 1 YEL 2-99-2 1mm² FLRYW X212(67)
IP481 1 YEL 2-99-3 0.75mm² FLRYW X241(A)
30 AATO 2 YEL 2-99-1 1mm² FLRYW X217B(1)
CONN WIRE
WIRE LABEL GAUGE JACKET TO X217B
POS COLOR
ENGCON#1
1 RED 1-20 6mm² FLRYW S280(1)
CONN WIRE
2 RED 1-20 6mm² FLRYW X491(1) WIRE LABEL GAUGE JACKET TO
POS COLOR
X491SYSB+ 1 YEL 2-99-1 1mm² FLRYW S272(2)
CONN WIRE 2
POS COLOR 3
1 RED 1-20 6mm² FLRYW IP481(2) 4
5
X260
SYSB+ 6
CONN WIRE 7
POS COLOR 8 YEL 2-100-4 2mm² FLRYW S273(2)
1 16AWG FUSIBLELINK S486(2)
X218
1 16AWG FUSIBLELINK S485(2) BENGCON#2
S271 CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 YEL 2-100 2mm² FLRYW S273(2)
POS COLOR
1 YEL 2-60-1 1.5mm² FLRYW X437A(8) 2 WHT 148-35-2STRTREQ 0.75mm² FLRYW S285(2)
1 YEL 2-60-2 0.75mm² FLRYW V267(4) 3 YEL CNHCH2 0.75mm² FLRYW MS567(8)
1 YEL 2-60-3 2.5mm² FLRYW X436A(8) 4 GRN CNLCH2 0.75mm² FLRYW MS567(6)
2 YEL 2-60 3mm² FLRYW FC248(D10) EC246-
5 WHT 47-6-1ALTEXC 1mm² FLRYW
D+(1)
2 YEL 2-60-4 2.5mm² FLRYW X436A(6)
6
2 YEL 2-60-5 2.5mm² FLRYW X436A(4)
S265
CONN WIRE
POS COLOR
1 WHT 3-S265CNTRLPWR 1.5mm² FLRYW X211(3)
1 WHT 105-1CNTRLPWR 1.5mm² FLRYW X437A(1)
2 WHT 105-2CNTRLPWR 1.5mm² FLRYW FC248(B10)
7-120 3121619
X942A X270
TO WTR IN FUL/FUL PUMP HARNESS ENG GND
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 148-64WTR/FULSW 0.75mm² FLRYW X212(70) 1 BLK 0-60-1 3mm² FLRYW MS276(1)
2 WHT 148-57WTR/FULRTN 0.75mm² FLRYW X212(26) 1 BLK 0-60-2 3mm² FLRYW MS276(2)
3 WHT 48-96FUELPUMP 3mm² FLRYW RL261(4)
RL261
4 BLK 0-60-7-2 2.5mm² FLRYW S281(2) FUL PUMP RLY
X437A CONN WIRE
TO UREA TANK HARNESS POS COLOR
CONN WIRE 1 RED 1-31 3mm² FLRYW FC248(AA2)
POS COLOR 2 WHT 48-94FULRLY85 0.75mm² FLRYW X212(74)
1 WHT 105-1CNTRLPWR 1.5mm² FLRYW S265(1) 3
2 4 WHT 48-96FUELPUMP 3mm² FLRYW X942A(3)
3 WHT 101-1HTR1 0.75mm² FLRYW FC248(D2) 5 WHT 48-95FULRLY86 0.75mm² FLRYW X212(23)
4
MS259
5 WHT 19-X253UREAPRS 0.75mm² FLRYW X211(19) BUSS BAR RLY PWR
6 WHT 57-X253UREAPRS 0.75mm² FLRYW X211(57) CONN WIRE
7 WHT 70-X253UREAPRS 0.75mm² FLRYW X211(70) POS COLOR
8 YEL 2-60-1 1.5mm² FLRYW S271(1) 1 WHT 259-4RLYPWR 0.75mm² FLRYW FC248(D7)
9 WHT 89-X253UREAPUMP 0.75mm² FLRYW X211(89) 2 WHT 259-3RLYPWR 0.75mm² FLRYW FC248(D5)
10 WHT 59-X253UREAPUMP 0.75mm² FLRYW X211(59) 3 WHT 259-2RLYPWR 0.75mm² FLRYW FC248(D3)
11 WHT 5-X253PURGVLV 0.75mm² FLRYW X211(5) 4 WHT 259-1RLYPWR 0.75mm² FLRYW FC248(D1)
12 WHT 82-X253PURGVLV 0.75mm² FLRYW X211(82) 5 WHT 259RLYPWR 0.75mm² FLRYW X211(4)
6
X436A
TO UREA TANK HARNESS RL217-86
CONN WIRE GLOW PLUG RTN
POS COLOR CONN WIRE
1 POS COLOR
2 1 WHT 88-RL217GLOWRLYRTN 0.75mm² FLRYW X211(88)
3 WHT 104-2PRSHTR 2.5mm² FLRYW FC248(D8)
RL217-87
4 YEL 2-60-5 2.5mm² FLRYW S271(2) GLOW PLUG SIG
5 WHT 103-1THRLEHTR 2.5mm² FLRYW FC248(D6) CONN WIRE
6 YEL 2-60-4 2.5mm² FLRYW S271(2) POS COLOR
7 WHT 102-2STIONHTR 2.5mm² FLRYW FC248(D4) 1 WHT 58-RL217GLOWRLYSIG 0.75mm² FLRYW X211(58)
8 YEL 2-60-3 2.5mm² FLRYW S271(1)
9 YEL 2-100-1 1mm² FLRYW FC248(A3)
10 BLK 0-60-9-1 1mm² FLRYW S284(1)
11 YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(9)
12 GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(12)
3121619 7-121
MS218 X229
DEUTZ CAN BUSS CAN TERMINATOR
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 GRN CNL(DEUTZ) 0.75mm² FLRYW X229(B) A YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(4)
2 GRN CNL(DEUTZ) 0.75mm² FLRYW SN236(2) B GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(1)
3 GRN CNL(DEUTZ) 0.75mm² FLRYW X233(B) C
4 YEL CNH(DEUTZ) 0.75mm² FLRYW X229(A) X213
5 YEL CNH(DEUTZ) 0.75mm² FLRYW X233(A) ENGINECONNECTION
6 YEL CNH(DEUTZ) 0.75mm² FLRYW X211(77) CONN WIRE
7 YEL CNH(DEUTZ) 0.75mm² FLRYW SN236(1) POS COLOR
8 YEL CNH(DEUTZ) 0.75mm² FLRYW SN237(1) 1 SHLD S214-1 0.75mm² SHLD S214(2)
9 YEL CNH(DEUTZ) 0.75mm² FLRYW X436A(11) 2 WHT 95-2STRTSIG 0.75mm² FLRYW X211(95)
10 GRN CNL(DEUTZ) 0.75mm² FLRYW X211(98) 3 WHT 94-3STRTRTN 0.75mm² FLRYW X211(94)
11 GRN CNL(DEUTZ) 0.75mm² FLRYW SN237(2) 4
12 GRN CNL(DEUTZ) 0.75mm² FLRYW X436A(12) 5
6 WHT 51-6DELTAVNTRI 0.75mm² FLRYW X211(51)
EC246-D+ ALTEXCITE
7 WHT 8-7EGRTEMP 0.75mm² FLRYW X211(8)
CONN WIRE
POS COLOR
9 SHLD S214-9 0.75mm² SHLD S214(2)
1 WHT 47-6-1ALTEXC 1mm² FLRYW X218B(5)
10
RL217-85 11
GLOW PLUG PWR
12
CONN WIRE
WIRE LABEL GAUGE JACKET TO 13 BLK 99-13CAMENGSPD 0.75mm² FLRYW X211(99)
POS COLOR
14 WHT 100-14CAMENGSPD 0.75mm² FLRYW X211(100)
1 WHT 63-RL217GLOWRLY 0.75mm² FLRYW X211(63)
15 WHT 102-15CRKENGSPD 0.75mm² FLRYW X211(102)
S284 16
CONN WIRE 17 WHT 54-17FULLOWPRS 0.75mm² FLRYW X211(54)
POS COLOR
18
1 BLK 0-60-9 2.5mm² FLRYW MS276(9)
19 WHT 46-19MPROPRTN 1.5mm² FLRYW X211(46)
1 BLK 0-60-9-1 1mm² FLRYW X436A(10)
20 WHT 25-20MPROP 1.5mm² FLRYW X211(25)
2 BLK 0-60-9-2 1mm² FLRYW X213(60)
21 BLK 101-21CRKENGSPD 0.75mm² FLRYW X211(101)
S214 22 WHT 21-22PRSRTN 0.75mm² FLRYW X211(21)
CONN WIRE 23 WHT 73-23BSTPRSTEMP 0.75mm² FLRYW X211(73)
POS COLOR 24 WHT 13-24COOLTEMP 0.75mm² FLRYW X211(13)
1 WHT 75-S214SHLDRTN 0.75mm² FLRYW X211(75) 25 WHT 78-25RAILPRSFUL 0.75mm² FLRYW X211(78)
2 SHLD S214-1 0.75mm² SHLD X213(1) 26 WHT 72-26OILPRS 0.75mm² FLRYW X211(72)
2 SHLD S214-9 0.75mm² SHLD X213(9) 27 WHT 35-27TEMP/PRSRTN 0.75mm² FLRYW X211(35)
30
7-122 3121619
33 AA10 WHT 148-35-4STRTREQ 0.75mm² FLRYW S285(2)

34 AA2 RED 1-31 3mm² FLRYW RL261(1)
35 WHT 64-35INJCTRRTN 1.5mm² FLRYW X211(64) AA3 YEL 2-100-1 1mm² FLRYW S273(1)
36 AA4 YEL 2-100-2 1mm² FLRYW S273(1)
37 WHT 66-37INJCTRRTN 1.5mm² FLRYW X211(66) AA5 YEL 2-100-3 1mm² FLRYW S273(1)
38 WHT 44-38INJCTR 1.5mm² FLRYW X211(44) AA6
39 AA7
40 WHT 45-40INJCTR 1.5mm² FLRYW X211(45) AA8
41 WHT 24-41INJCTRRTN 1.5mm² FLRYW X211(24) AA9
42 WHT 87-42INJCTR 1.5mm² FLRYW X211(87) B1 BLK 0-60-6 2.5mm² FLRYW MS276(6)
43 B10 WHT 105-2CNTRLPWR 1.5mm² FLRYW S265(2)
44 B2 WHT 101-2SUPMOD 0.75mm² FLRYW X211(62)
45 B3 BLK 0-60-5 2.5mm² FLRYW MS276(5)
46 WHT 55-46EGASRECSIG 0.75mm² FLRYW X211(55) B4 WHT 102-1STIONHTR 0.75mm² FLRYW X211(80)
47 WHT 2-47EXHGASREC 1.5mm² FLRYW X211(2) B5 BLK 0-60-4 2.5mm² FLRYW MS276(4)
48 WHT 67-48EXHGASREC 1.5mm² FLRYW X211(67) B6 WHT 103-2THRLEHTR 0.75mm² FLRYW X211(37)
49 WHT 38-49INTAKETHRTLE 0.75mm² FLRYW X211(38) B7 BLK 0-60-3 2.5mm² FLRYW MS276(3)
50 WHT 18-505V 0.75mm² FLRYW X211(18) B8 WHT 104-1PRSHTR 0.75mm² FLRYW X211(61)
51 WHT 76-51GNDRTN 0.75mm² FLRYW X211(76) B9 RED 1-30 3mm² FLRYW FC248(A1)
52 WHT 7-52INTAKETHRTLE 0.75mm² FLRYW X211(7) C10
53 C2
54 C4
55 C6
56 C8
57 D1 WHT 259-1RLYPWR 0.75mm² FLRYW MS259(4)
58 D10 YEL 2-60 3mm² FLRYW S271(2)
59 YEL 2-100-3 1mm² FLRYW FC248(A5) D2 WHT 101-1HTR1 0.75mm² FLRYW X437A(3)
60 BLK 0-60-9-2 1mm² FLRYW S284(2) D3 WHT 259-2RLYPWR 0.75mm² FLRYW MS259(3)
61 WHT 23-61INJCTRRTN 1.5mm² FLRYW X211(23) D4 WHT 102-2STIONHTR 2.5mm² FLRYW X436A(7)
62 WHT 85-62INJCTR 1.5mm² FLRYW X211(85) D5 WHT 259-3RLYPWR 0.75mm² FLRYW MS259(2)
D6 WHT 103-1THRLEHTR 2.5mm² FLRYW X436A(5)
FC248
RLY/FUSEPANEL D7 WHT 259-4RLYPWR 0.75mm² FLRYW MS259(1)
CONN WIRE D8 WHT 104-2PRSHTR 2.5mm² FLRYW X436A(3)
POS COLOR D9 WHT 41-FC248RLYGND 0.75mm² FLRYW X211(41)
A1 RED 1-30 3mm² FLRYW FC248(B9)
A10 BLK 0-60-7-1 0.75mm² FLRYW S281(1)
A2 RED 1-31-1 3mm² FLRYW S486(1)
A3 YEL 2-100-1 1mm² FLRYW X436A(9)
A4 YEL 2-100-2 1mm² FLRYW S268(2)
A5 YEL 2-100-3 1mm² FLRYW X213(59)
A6
A7
A8
A9
AA1 RED 1-30-1 3mm² FLRYW S485(1)
3121619 7-123
X241 SN283
DEUTZ DIAGNOSTICS DPF PRS
CONN WIRE CONN WIRE
POS COLOR POS COLOR
A YEL 2-99-3 0.75mm² FLRYW S272(1) 1 WHT 77-1DPFPRSPWR 0.75mm² FLRYW X212(18)
B BLK 0-60-7-3 0.75mm² FLRYW S281(2) 2 WHT 77-2DPFPRSRTN 0.75mm² FLRYW X212(31)
C 3 WHT 77-3DPFPRSSIG 0.75mm² FLRYW X212(13)
D 4
E
V254
F GRN CNLCH2 0.75mm² FLRYW MS567(5) DOSING VLV
G YEL CNHCH2 0.75mm² FLRYW X212(83) CONN WIRE
H GRN CNLCH2 0.75mm² FLRYW X212(82) POS COLOR
J 1 WHT 26-X254DOSEVLV 0.75mm² FLRYW X211(26)
K 2 WHT 47-X254DOSEVLV 0.75mm² FLRYW X211(47)
L
SN236
M YEL CNHCH2 0.75mm² FLRYW MS567(7) NOx SNSR AFTR SCR CAT
S281 CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(7)
POS COLOR
1 BLK 0-60-7 3mm² FLRYW MS276(7) 2 GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(2)
1 BLK 0-60-7-1 0.75mm² FLRYW FC248(A10) 3 BLK 0-60-6-2 1mm² FLRYW S269(1)
2 BLK 0-60-7-2 2.5mm² FLRYW X942A(4) 4 YEL 2-100-2-2 1mm² FLRYW S268(1)
2 BLK 0-60-7-3 0.75mm² FLRYW X241(B) SN240
COOL LVL SNSR
SN216
EXHT GAS TEMP CONN WIRE
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET TO 1 WHT 72-1COOLLVLPWR 0.75mm² FLRYW X212(57)
POS COLOR
1 WHT 27-SN216EXHGASTEMP 0.75mm² FLRYW X211(27) 2 WHT 72-3COOLLVLGND 0.75mm² FLRYW X212(81)
2 WHT 9-SN216EXHGASTEMP 0.75mm² FLRYW X211(9) 3 WHT 72-2COOLLVLSIG 0.75mm² FLRYW X212(62)
4
SN237
NOxSNSRSCRCAT S268
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 YEL CNH(DEUTZ) 0.75mm² FLRYW MS218(8) 1 YEL 2-100-2-1 1mm² FLRYW SN237(4)
2 GRN CNL(DEUTZ) 0.75mm² FLRYW MS218(11) 1 YEL 2-100-2-2 1mm² FLRYW SN236(4)
3 BLK 0-60-6-1 1mm² FLRYW S269(1) 2 YEL 2-100-2 1mm² FLRYW FC248(A4)
4 YEL 2-100-2-1 1mm² FLRYW S268(1)
S269
SN215 CONN WIRE
SCR EXH GAS TEMP POS COLOR
CONN WIRE 1 BLK 0-60-6-1 1mm² FLRYW SN237(3)
POS COLOR 1 BLK 0-60-6-2 1mm² FLRYW SN236(3)
1 WHT 48-SN215EXHTEMP 0.75mm² FLRYW X211(48) 2 BLK 0-60-8 2.5mm² FLRYW MS276(8)
2 WHT 15-SN215EXHTEMP 0.75mm² FLRYW X211(15)
7-124 3121619
SN239
AMBIENT AIR TEMP SNSR
CONN WIRE
POS COLOR
1 WHT 73-2 ATEMP SNSR 0.75mm² FLRYW X212(10)
2 WHT 73-1 ATEMP SNSR 0.75mm² FLRYW X212(50)
3121619 7-125
7-126
X250
SUCTION HTR
X250
SUCTION HTR
X252 X251
PRS HTR THRTLE HTR
X252 X251
PRS HTR THRTLE HTR
X436B
TO ENG HARN
X436B
TO ENG HARN
X253
UREA SUP MOD
X253
UREA SUP MOD
SN238
UREA QUTY LVL TEMP
SN238
UREA QUTY LVL TEMP
X734B
TO ENG HARN
X734B
TO ENG HARN
1001191166-C
MAF08750C
MAF08750C
1001191166-C
Figure 7-57. Urea Tank/Supply Module Harness
3121619
X436B X253
TO ENG HARN UREA SUP MOD
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 1
2 2 WHT 19-X253 UREA PRS 0.75 mm² FLRYW X734B (5)
3 WHT 104-2 PRS HTR 2.5 mm² FLRYW X252 (2) 3 WHT 57-X253 UREA PRS 0.75 mm² FLRYW X734B (6)
4 YEL 2-60-5 2.5 mm² FLRYW X252 (1) 4 WHT 70-X253 UREA PRS 0.75 mm² FLRYW X734B (7)
5 WHT 103-1 THRLE HTR 2.5 mm² FLRYW X251 (2) 5 YEL 2-60-1 1.5 mm² FLRYW X734B (8)
6 YEL 2-60-4 2.5 mm² FLRYW X251 (1) 6 WHT 101-1 HTR1 0.75 mm² FLRYW X734B (3)
7 WHT 102-2 STION HTR 2.5 mm² FLRYW X250 (2) 7
8 YEL 2-60-3 2.5 mm² FLRYW X250 (1) 8 WHT 89-X253 UREA PUMP 0.75 mm² FLRYW X734B (9)
9 YEL 2-100-1 1 mm² FLRYW SN238 (4) 9 WHT 105-1 CNTRL PWR 0.75 mm² FLRYW X734B (1)
10 BLK 0-60-9-1 1 mm² FLRYW SN238 (3) 10 WHT 59-X253 UREA PUMP 0.75 mm² FLRYW X734B (10)
11 YEL CN H (DEUTZ) 0.75 mm² FLRYW SN238 (2) 11 WHT 5-X253 PURG VLV 0.75 mm² FLRYW X734B (11)
12 GRN CN L (DEUTZ) 0.75 mm² FLRYW SN238 (1) 12 WHT 82-X253 PURG VLV 0.75 mm² FLRYW X734B (12)
X734B X250
TO ENG HARN SUCTION HTR
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 WHT 105-1 CNTRL PWR 1.5 mm² FLRYW X253 (9) 1 YEL 2-60-3 2.5 mm² FLRYW X436B (8)
2 2 WHT 102-2 STION HTR 2.5 mm² FLRYW X436B (8)
3 WHT 101-1 HTR1 0.75 mm² FLRYW X253 (6)
X251
4 THRTLE HTR
5 WHT 19-X253 UREA PRS 0.75 mm² FLRYW X253 (2) CONN WIRE
6 WHT 57-X253 UREA PRS 0.75 mm² FLRYW X253 (3) POS COLOR
7 WHT 70-X253 UREA PRS 0.75 mm² FLRYW X253 (4) 1 YEL 2-60-4 2.5 mm² FLRYW X436B (6)
8 YEL 2-60-1 0.75 mm² FLRYW X253 (5) 2 WHT 103-1 THRLE HTR 2.5 mm² FLRYW X436B (5)
9 WHT 89-X253 UREA PUMP 0.75 mm² FLRYW X253 (8)
SN238
10 WHT 59-X253 UREA PUMP 0.75 mm² FLRYW X253 (10) UREA QUTY LVL TEMP
11 WHT 5-X253 PURG VLV 0.75 mm² FLRYW X253 (11) CONN WIRE
12 WHT 82-X253 PURG VLV 0.75 mm² FLRYW X253 (12) POS COLOR
1 GRN CN L (DEUTZ) 0.75 mm² FLRYW X436B (12)
X252
PRS HTR 2 YEL CN H (DEUTZ) 0.75 mm² FLRYW X436B (11)
CONN WIRE 3 BLK 0-60-9-1 1 mm² FLRYW X436B (10)
POS COLOR 4 YEL 2-100-1 1 mm² FLRYW X436B (9)
1 YEL 2-60-5 2.5 mm² FLRYW X436B (4)
2 WHT 104-2 PRS HTR 2.5 mm² FLRYW X436B (3)
3121619 7-127
X500
Figure 7-58. Platform Interface Harness

RL502
2X50
RL503
1001225580-D
X5B
MAF09950D
7-128 3121619
X5B - INTERFACE
CONN WIRE
POS COLOR
1 WHT P2 18 AWG GXL IP114 (1)
2 WHT P6 18 AWG GXL X500 (2)
3
4 WHT P1 18 AWG GXL RL503(87)
5 WHT P3 18 AWG GXL RL502 (87)
6
RL503 - SKYGUARD RELAY #1

CONN WIRE
POS COLOR
30 WHT P9-1 18 AWG GXL IP114 (1)
85 WHT P5-1 18 AWG GXL S191 (1)
86 WHT P4-1 18 AWG GXL S192 (1)
87 WHT P1 18 AWG GXL X5B(4)
87A
RL502 - SKYGUARD RELAY #2

CONN WIRE
POS COLOR
30 WHT P9-2 18 AWG GXL IP114 (1)
85 WHT P5-2 18 AWG GXL S191 (1)
86 WHT P4-2 18 AWG GXL S192 (1)
87 WHT P3 18 AWG GXL X5B (5)
87a
X500 - PLAT SENSOR

CONN WIRE
POS COLOR
1 WHT P10 18 AWG GXL IP114 (2)
2 WHT P6 18 AWG GXL X5B (2)
3 WHT P4 18 AWG GXL S192 (2)
4 WHT P5 18 AWG GXL S191 (2)
3121619 7-129
7-130
X878
WIRE WIRE LENGTH FROM TO

COLOR JACKET
NO GAUGE (mm) REFERENCE PIN REFERENCE PIN
CANH_5 YEL 18 TFFN 264 MS377-3 2 X878 9
CANH_6 YEL 18 TFFN 89 MS377-1 2 J7_13 1
CANL_7 GRN 18 TFFN 263 MS377-3 1 X878 10
CANL_8 GRN 18 TFFN 86 MS377-1 1 J7_24 1
J7_13
X878 MS377-1
CONN WIRE WIRE CONN WIRE WIRE
GAUGE JACKET TO GAUGE JACKET TO
POS COLOR LABEL POS COLOR LABEL
1 1 GRN CANL_8 18 AWG TFFN J7_24 (1)
2 2 YEL CANH_6 18 AWG TFFN J7_13 (1)
J7_24
3
4
5
J7_13
MS377-3 6
7 CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
8
1 YEL CANH_6 18 AWG TFFN MS377-1 (2)
9 YEL CANH_5 18 AWG TFFN MS377-3 (2)
10 GRN CANL_7 18 AWG TFFN MS377-3 (1)
MS377-1 11
12 J7_24
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 GRN CANL_8 18 AWG TFFN MS377-1 (1)
MS377-3
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 GRN CANL_7 18 AWG TFFN X878 (10)
MS377-2 2 CANH_5 18 AWG TFFN X878 (9)
YEL
MS377-2
X878
J7_13
MS377-3 MS377-1
J7_24
1001210632 A
Figure 7-59. Cribbing Module Harness - Sheet 1 of 2
3121619
3121619 7-131
J7_28
J7_33
X383
SW374
IP914
S371
S370
S369
Figure 7-60. Cribbing Harness - Sheet 2 of 2

LB373
SW374
X383
J7_33
J7_28
S370
S371 S369
IP914
LB373
1001210633-A
MAF12870A
7-132 3121619
LB373 X383
CONN WIRE CONN WIRE
POS COLOR POS COLOR
1 BLK/ORN 114 18 AWG TFFN X383 (7) 1 RED 103 18 AWG TFFN S370 (1)
2 BLK 113 18 AWG TFFN S369 (2) 2 BLK 102 18 AWG TFFN S369 (2)
3 RED/ORN 116 18 AWG TFFN SW374 (2)
J7_28
4
CONN WIRE
POS COLOR
1 BLK 117 18 AWG TFFN S369 (1) 6
7 BLK/ORN 114 18 AWG TFFN LB373 (1)
J7_33
8
CONN WIRE
POS COLOR
10
1 RED 118 18 AWG TFFN S371 (1)
11
S369 12
CONN WIRE
POS COLOR
1 BLK 117 18 AWG TFFN J7_28 (1)
2 BLK 102 18 AWG TFFN X383 (2)
3 BLK 113 18 AWG TFFN LB373 (2)
S370
CONN WIRE
POS COLOR
1 RED 103 18 AWG TFFN X383(1)
2 BLK 119_1 14 AWG TFFN IP914 (1)
S371
CONN WIRE
POS COLOR
1 RED 118 18 AWG TFFN J7_33 (1)
2 BLK 119_2 14 AWG TFFN IP914 (2)
IP914
CONN WIRE
POS COLOR
1 BLK 119_1 14 AWG TFFN S370 (1)
2 BLK 119_2 14 AWG TFFN S371 (2)
SW374
CONN WIRE
POS COLOR
1 RED 115 18 AWG TFFN S370 (2)
2 RED/ORN 116 18 AWG TFFN X383 (3)
3121619 7-133
CONNECTS TO BASE BOOM

SENSORS CABLE
X404B
CO128-J2
X406A
CONNECTS TO BASE BOOM
SENSORS CABLE
CO02-J8
CO128-J5
CO128-J1
CO02-J1
SN123
CONNECTS TO TRANSPORT
SWITCH CABLE
X81
CONNECTS TO
MAIN BOOM CABLE
CO02-J7
CO02-J12
X341A
CONNECTS TO
CO02-J4 16/4 MAIN
BOOM CABLE
MS148-3
MS148-2
X05B*
MS148-1 X05A* SN114
CO128-J3 X413
X420
*FOR MACHINES THAT REQUIRE MSSO FUNCTION, REMOVE CAP AND X421
CONNECT CONNECTORS X05A AND X05B 1001156522-O
MAF08350O
Figure 7-61. Electrical Installation - Sheet 1 of 10
7-134 3121619
SN416
HYD OIL TEMP
HV314
CHASSIS ENABLE
HV104
MAIN DUMP
HV316
WARM UP VLV
HV108
TELE FLOW CNTRL
HV109
MAIN TELE IN
HV103
MAIN TELE OUT
HV101
MAIN LIFT DN
HV102
HV100 LIFT FLOW CNTRL
SWG LFT
HV107
LIFT PILOT
HV348
SWG FLOW CNTRL
HV106
MAIN LIFT UP
X159A
HV99
SWG RHT HV105
LIFT DN AUX
SN438
1001156522-O
MAF08360O
3121619 7-135
RL234-85 RL234-86
RL127-85
RL127-86
RL360-85
RLRL236-R_2-R
RL360-86
X237
RLRL236-Y_2-Y X362
X373
X375
X376
RLRL235-Y_1-Y RL235-R X377
X378
X418
X353 X419
X406A X404B
X395 SN123
CONNECTS TO
TILT SENSOR X341A
X84
X467
X468
MS83 MS82 X412 1001156522-O

LB417
X411 SN959 MAF08370O
7-136 3121619
HI TEMP
LO OIL
MOMNT CNTRL LB70
LB71 NO ALT
LB73 LB72
BOOM CNTRL
LB74
GLOW PLUG
LB69
PLATF OVRLD
LB75
AXLE SET
LB68
SW66-2
500 CAP
LB67
SW66-1
1000 CAP
LB76 SW61
JIB TELE
SW60
MAIN TELE
SW63
PLATF ROT
SW62 SW58
JIB LIFT T U R N TA B L E
SWING
SW64
PLATF LVL
SW59
SW65 MAIN LIFT
STRT/AUX
GROUND PANEL
X77
M.D.I.
1001156522-O
MAF08380O
3121619 7-137
SW55-1B
BAT B+
SW55-2B
E-STOP B+ +
SW56-1
GND MODE
SW56-B
E-STOP B+
SW56-3
PLATF MODE
SPRAY TWO THIN COATS,
COVER TERMINALS COMPLETELY,
AVOID OVERSPRAY
EMERGENCY STOP AND KEY SWITCH
IP379
IP414
IP415
BATTERY AND RELAYS 1001156522-O

MAF08390O
7-138 3121619
X337A
X339A
CONNECTS TO STEER CABLE
CONNECTS TO STEER CABLE
4 OF 4
3 OF 4
449B
CONNECTS TO CONTROLLER
CONNECTS TO X147B
E
E 445A
HV179
X160
SN423
HV178
X147B
D D
448B
442A
CONNECTS TO LINEAR AXLE SENSOR
X340A X338A
CONNECTS TO STEER CABLE CONNECTS TO STEER CABLE
1 OF 4
2 OF 4
CHASIS WIRE ROUTING

BOTTOM PLATE NOT SHOWN FOR CLARITY
1001156522-O
MAF08400O
3121619 7-139
HV162 HV161
FRONT AXLE SWG RET. FRONT AXLE SWG EXT.
HV170
HV171 RIGHT FRONT STR RHT
RIGHT FRONT STR LFT
HV174 HV175
RIGHT REAR STR RHT RIGHT RIGHT STR LFT
SECTION E-E
HV176 HV177
LEFT REAR STR RHT
LEFT REAR STR LFT
HV173 HV172
LEFT FRONT STR LFT LEFT FRONT STR RHT
HV164
HV163
REAR AXLE SWG RET.
REAR AXLE SWG EXT.
SECTION D-D
X160 CO03-J7
CO03-J12
CO03-J1
CO03-J2
CO03-J3
CHASSIS MODULE
1001156522-O
MAF08410O
7-140 3121619
HV142
RHT DRV PUMP FWD
HV143
RHT DRV PUMP REV
HV144
LFT DRV PUMP REV
HV145
LFT DRV PUMP FWD
HV315
PUMP WIRING LIFT ENABLE
SN130
LIFT CYLINDER
X222A
X222B X941
X218B
X217B
X218A
X217A
ENGINE TRAY CONNECTIONS

1001156522-O
MAF08420O
3121619 7-141
1001156216-D
7-142 3121619
3121619
HV250
JIB SWG RHT
HV251
JIB TELE OUT
HV256
JIB LVL UP
HV248
JIB ENABLE HV255
JIB LVL DN
HV253
JIB LIFT DN
HV254
JIB LIFT UP
HV249
JIB SWG LFT
HV252
JIB TELE IN
1001156216-D
7-143
THIS MACHINE UTILIZES A 12-VOLT ELECTRICAL SYSTEM. TO PREVENT DAMAGE

WHEN JUMP-STARTING THE MACHINE, CONNECT THE JUMP-START EQUIPMENT
ONLY TO THE BATTERY SHOWN TO PREVENT DAMAGE TO THE MACHINE'S ELEC-
TRICAL SYSTEM.
Figure 7-71. Battery Jump-Start Hookup
7-144 3121619
Figure 7-72. Battery Installation - Sheet 1 of 2
3121619 7-145
87
86
AUXILIARY PUMP
RELAY 85
30
87
BATTERY DISCONNECT RELAY 86
(FOR DURING ENGINE CRANK) 85
3 3 30
IGNITION RELAY 87 2 5
86
85
30
1
4
+ - + -
PFM PFM SECONDARY PRIMARY
BATTERY BATTERY
1001158922-C
MAF08760C
Figure 7-73. Battery Installation - Sheet 2 of 2
7-146 3121619
Figure 7-74. Electrical Schematic (SN 0300224828 through SN 0300243454) - Sheet 1 of 21
3121619 7-147
7-148
SG #2 SG #1
RELAY RELAY
WHT 47-1 FUL 1/4

WHT 47-2 FUL 1/2
WHT 47-3 FUL 3/4
87a
87a
87
30
85
86
86
85
30
87
BLK 0-1
BLK 0-1-2
1001145974_3-[3,B]
[5,G]
87a
87a
87
30
85
86
86
85
30
87
WHT 47-4 FUL FULL
RL475
RL474
ANALYZER
BOTTOM OF CONSOLE BOX
WHT P3
WHT P5
WHT P4
WHT P9
WHT P1
WHT P1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P4-1
WHT P5-1
WHT P9-1
WHT 49-5 CREEP
1
2
3
4
YEL 2-2 ENABLE
X32
WHT 47-5 LOW FUL
BLK 0-2
WHT P5
4
WHT P4
3
WHT 49-7 TX
WHT 49-8 RX
BLK P6
2
WHT P10
1
WHT 49-6 ANALGND
WHT 49-9 ANALPWR

WHT 49-4 BCS
X476
WHT 39-1 AXL SET
WHT 55-1 DRV ORNT
WHT 54-2 1000LB MODE
WHT 49-3 BRKN CABLE
WHT 47-2 SYS FAIL
WHT P10
[4,G]
WHT 47-1 PLTFM LVL FAIL
WHT 52-1 GEN
IP477
WHT 49-2 OVERLOAD
WHT 54-1 500LB MODE
WHT 49-1 TILT
WHT 48-1 ENG PREHEAT
18 OHM WHT P2
[5,G]
[8,G]
[5,G]
[5,G]
[6,A]
DRIVE & STEER
ELECTRONIC JOYSTICK
LIFT & SWING
ELECTRONIC JOYSTICK WHT 48-1 ENG SPD
STEER
YEL 2-1-1
SWING LIFT
WHT 48-2 2 SPD
LEFT
YEL 2-1
WHT 55-6 DOS
RIGHT
WHT 59-6 JIB LOK
PIEZO ALARM
WHT 55-2 CRB STR
1
1
YEL 2-1-1
WHT 55-3 CRD STR
AH30-
AH30+
YEL 2-1-2
BLK 0-1
BLK 0-2
YEL 2-7
YEL 2-8
YEL 2-6
WHT 49-1 TILT
WHT 49-4 BCS

WHT 52-1 GEN
YEL 2-2 ENABLE

WHT 49-5 CREEP
WHT 47-1 FUL 1/4

WHT 47-2 FUL 1/2
WHT 47-3 FUL 3/4
WHT 39-1 AXL SET
WHT 47-2 SYS FAIL
WHT 47-5 LOW FUL
WHT 47-4 FUL FULL

WHT 55-1 DRV ORNT
WHT 49-2 OVERLOAD
WHT 55-6 DOS
WHT 54-1 500LB MODE
WHT 49-3 BRKN CABLE

WHT 49-21 SFTCH LT

WHT 59-2 JSWG LT
WHT 59-1 JSWG RT
BLK
BLK
BLU
BLU
RED
BRN
RED
BRN
GRN
WHT
BLK 0-5
WHT 25-1 PLVL UP
BLU/YEL
WHT/YEL
ORN/YEL
WHT/RED
WHT/GRN
1
YEL 2-1-2
2
WHT 49-26 ALARM

WHT 25-2 PLVL DN
3
YEL 2-1-3
4
5
6
GRN
GROUND
GROUND
BRN
SOFT TOUCH
RED WHT 39-2 AXL EXT
ANALYZER TX
ANALYZER RX
LIGHT SYSTEM
1
FAILURE LIGHT
LEVEL FAILURE
JIB LOCK LIGHT

JIB SWING LEFT
AXLE SET LIGHT

BLU YEL 2-1-3
ZONE B-1
LOW FUEL LIGHT
LIGHT TILT LIGHT
IGNITION POWER
IGNITION POWER
IGNITION POWER
JIB SWING RIGHT
LIGHT PLATFORM
OVERLOAD LIGHT
2
ENGIINE PREHEAT
ANALYZER POWER
SEE SHEET 3
LED PANEL POWER
500 LB MODE LIGHT
BLK WHT 39-3 AXL RET
ANALYZER GROUND
CREEP MODE LIGHT
DRIVE ORIENTATION
1000 LB MODE LIGHT

3
GENERATOR ENABLE
FUEL LEVEL 1/4 LIGHT

BROKEN CABLE LIGHT
BLU/YEL YEL 2-1-4
FUEL LEVEL FULL LIGHT

4
15 POS MATE-N-LOCK
ORN/YEL
DRIVE ORIENTATION LIGHT

5
TOGGLE SWITCH
WHT
6
CONNECTOR IN CONSOLE BOX

BOOM CONTROL SYSTEM LIGHT
AXLE EXTEND/RETRACT
SW18
X38B
BLU YEL 2-1-4
15 15
WHT P2 BLK YEL 2-1-5
14 14
WHT P9 BRN WHT 52-2 HORN
13 13
12 12
RED
11 11
WHT/GRN
10 10
YEL 2-8-1 WHT/RED

6 6
WHT 49-27 WHT/YEL
5 5
WHT 49-27 WHT 49-14 CREEP
4 4
YEL 2-8-1 YEL 2-1-5
9 9
YEL 2-8 BLK 0-5 WHT 48-1 ENG SPD WHT 55-4 POT REF
8 8 GROUND ENGINE SPEED
YEL 2-7 WHT 49-26 ALARM WHT 48-2 2 SPD BLK 0-3
2 2 ALARM TWO SPEED
WHT 49-25 FTSW OPEN WHT 49-25 FTSW OPEN YEL 2-1 WHT 55-5 PUMP POT
7 7 FOOT SWITCH OPEN IGNITION POWER
WHT 52-4 GEN WHT 52-4 GEN WHT 55-2 CRB STR YEL 2-1-7
1 1 GENERATOR CRAB STEER
WHT 49-24 SFTCH WHT 49-24 SFTCH WHT 55-3 CRD STR
3 3 SOFT TOUCH COORDINATED STEER
X38A WHT 25-1 PLVL UP
PLATFORM LEVEL UP
WHT 49-23 GND WHT 25-2 PLVL DN
GROUND PLATFORM LEVEL DOWN
BLK 0-4 WHT 39-2 AXL EXT GOLD PIN
GROUND AXLE EXTEND
WHT 55-25 JLOCK OUT WHT 39-3 AXL RET LB320+
JIB LOCK PIN OUT AXLE RETRACT
WHT 55-26 JLOCK IN WHT 52-2 HORN WHT 59-6 JIB LOK
JIB LOCK PIN IN HORN [2,D] 1
WHT 23-4 PROT RT WHT 49-14 CREEP
PLATFORM ROTATE RIGHT CREEP
LIGHT
WHT 23-3 PROT LT WHT 55-4 POT REF BLK 0-1-2-2

PLATFORM ROTATE LEFT REFERENCE VOLTAGE 1
JIB LOCK PIN
WHT 49-22 GND WHT 23-1 P ROT RT WHT 23-1 P ROT RT

GROUND PLATFORM ROTATE RIGHT LB320-
WHT 25-4 PLVL DN WHT 55-5 PUMP POT YEL 2-1-7
PLATFORM LEVEL DOWN PUMP POT
WHT 25-3 PLVL UP WHT 23-2 P ROT LT WHT 23-2 P ROT LT
PLATFORM LEVEL UP PLATFORM ROTATE LEFT
YEL 2-5
IGNITION GROUND
BLK 0-3 YEL 2-1-8 SILVER PIN
YEL 2-4 WHT 49-15 SFT TOUCH
IGNITION SOFT TOUCH
1
3
2
4
RED 1-4-3 PLTF MODE WHT 27-1 JIB UP
[7,E] PLATFORM MODE JIB UP
BRN 49-13 X44 PWR WHT 27-2 JIB DN
X392

M12 POWER JIB DOWN
WHT 52-3 HEAD/TAIL LT
HEAD & TAIL LIGHT
BRN 49-11 X43 PWR
PLATFORM CONTROL MODULE - 1600343
WHT 29-1 JTELE IN WHT 29-1 JTELE IN

M12 POWER JIB TELESCOPE IN
WHT 49-12 X44 GND M12 GROUND WHT P3 YEL 2-1-8
SKYGUARD INPUT #2
WHT 49-10 X43 GND WHT 29-2 JTELE OUT WHT 29-2 JTELE OUT
JIB TELESCOPE OUT
SHLD WHT 13-1 MTELE IN YEL 2-1-9
WORK/FLOOD
CAN SHIELD MAIN TELESCOPE IN
GRN CAN LOW MAIN TELESCOPE OUT WHT 13-2 MTELE OUT
LIGHT CONNECTION
YEL WHT 49-16 ENVLP
BLK 0-40-3 (16)

BLK 0-41-3 (16)
CAN HIGH ENVELOPE CONTROL
WHT 48-3 STRT
START
AUXILIARY POWER WHT 53-1 AUX
ORG 1-7-1 WK LT PWR(16)

MACHINE CAPACITY WHT 54-3 CPCITY SW BLK 0-1-2
[1,F]
PLATFORM LEVEL 2 SIGNAL WHT 49-17 PLVL 2
PLATFORM LEVEL 1 SIGNAL WHT 49-18 PLVL 1 WHT 49-21 SFTCH LT
[2,E]
MAIN PLATFORM POWER
MAIN PLATFORM GROUND
JIB TRANSPORT N.O. WHT 49-19 PROX NO

JIB TRANSPORT N.C. WHT 49-20 PROX NC
SKYGUARD GND
SHEET 2
3121619
BLK
BLU/YEL
ORN/YEL
WHT
X38B
3121619
BLU YEL 2-1-4
15 15
WHT P2 BLK YEL 2-1-5
14 14
WHT P9 BRN WHT 52-2 HORN
13 13
12 12
RED
11 11
WHT/GRN
10 10
YEL 2-8-1 WHT/RED
6 6
WHT 49-27 WHT/YEL
5 5
4 4
YEL 2-8-1 YEL 2-1-5
9 9
YEL 2-8 BLK 0-5 WHT 48-1 ENG SPD WHT 55-4 POT REF
8 8 GROUND ENGINE SPEED
YEL 2-7 WHT 49-26 ALARM WHT 48-2 2 SPD BLK 0-3
2 2 ALARM TWO SPEED
WHT 49-25 FTSW OPEN WHT 49-25 FTSW OPEN YEL 2-1 WHT 55-5 PUMP POT
7 7 FOOT SWITCH OPEN IGNITION POWER
WHT 52-4 GEN WHT 52-4 GEN WHT 55-2 CRB STR YEL 2-1-7
1 1 GENERATOR CRAB STEER
WHT 49-24 SFTCH WHT 49-24 SFTCH WHT 55-3 CRD STR
3 3 SOFT TOUCH COORDINATED STEER
WHT 25-1 PLVL UP
X38A PLATFORM LEVEL UP
WHT 49-23 GND WHT 25-2 PLVL DN
GROUND PLATFORM LEVEL DOWN
BLK 0-4 WHT 39-2 AXL EXT GOLD PIN
GROUND AXLE EXTEND
WHT 55-25 JLOCK OUT WHT 39-3 AXL RET
JIB LOCK PIN OUT AXLE RETRACT LB320+
WHT 55-26 JLOCK IN WHT 52-2 HORN WHT 59-6 JIB LOK
JIB LOCK PIN IN HORN [2,D] 1
WHT 23-4 PROT RT WHT 49-14 CREEP
PLATFORM ROTATE RIGHT CREEP
LIGHT
WHT 23-3 PROT LT WHT 55-4 POT REF BLK 0-1-2-2

PLATFORM ROTATE LEFT REFERENCE VOLTAGE 1
JIB LOCK PIN
WHT 49-22 GND WHT 23-1 P ROT RT WHT 23-1 P ROT RT

GROUND PLATFORM ROTATE RIGHT LB320-
WHT 25-4 PLVL DN WHT 55-5 PUMP POT YEL 2-1-7
PLATFORM LEVEL DOWN PUMP POT
WHT 25-3 PLVL UP WHT 23-2 P ROT LT WHT 23-2 P ROT LT
PLATFORM LEVEL UP PLATFORM ROTATE LEFT
YEL 2-5
IGNITION GROUND
BLK 0-3 YEL 2-1-8 SILVER PIN
YEL 2-4 WHT 49-15 SFT TOUCH
IGNITION SOFT TOUCH
1
3
2
4
RED 1-4-3 PLTF MODE WHT 27-1 JIB UP
[7,E] PLATFORM MODE JIB UP
BRN 49-13 X44 PWR WHT 27-2 JIB DN
X392
M12 POWER JIB DOWN
WHT 52-3 HEAD/TAIL LT
HEAD & TAIL LIGHT
BRN 49-11 X43 PWR
PLATFORM CONTROL MODULE - 1600343

WHT 29-1 JTELE IN WHT 29-1 JTELE IN
M12 POWER JIB TELESCOPE IN
WHT 49-12 X44 GND M12 GROUND WHT P3 YEL 2-1-8
SKYGUARD INPUT #2
WHT 49-10 X43 GND WHT 29-2 JTELE OUT WHT 29-2 JTELE OUT
JIB TELESCOPE OUT
SHLD WHT 13-1 MTELE IN YEL 2-1-9
WORK/FLOOD
CAN SHIELD MAIN TELESCOPE IN
GRN CAN LOW WHT 13-2 MTELE OUT
MAIN TELESCOPE OUT
LIGHT CONNECTION
YEL WHT 49-16 ENVLP
BLK 0-40-3 (16)

BLK 0-41-3 (16)
CAN HIGH ENVELOPE CONTROL
START WHT 48-3 STRT
AUXILIARY POWER WHT 53-1 AUX

MACHINE CAPACITY WHT 54-3 CPCITY SW BLK 0-1-2
[1,F]
PLATFORM LEVEL 2 SIGNAL WHT 49-17 PLVL 2
PLATFORM LEVEL 1 SIGNAL WHT 49-18 PLVL 1 WHT 49-21 SFTCH LT
[2,E]
MAIN PLATFORM POWER

MAIN PLATFORM GROUND
JIB TRANSPORT N.O. WHT 49-19 PROX NO WHT 59-1 JSWG RT
[2,E] 1
JIB TRANSPORT N.C. WHT 49-20 PROX NC YEL 2-1-9
SKYGUARD GND 2
WHT 59-2 JSWG LT
[2,E] 3
YEL 2-1-10
4
JIB SWING
MS41 5
TOGGLE SWITCH
YEL
1 6
YEL
2 SW19
BLU CAN HI
11 SW20-1
BLU CAN HI YEL 2-1-10
12 1
GRN YEL 2-1-11
3 SW20-2
GRN WHT 49-15 SFT TOUCH
4 1
BLK CAN LOW
CANBUS
TOGGLE SWITCH
3 x 4 Buss Bar
BLK CAN LOW
BLK 0-41-2 (12)

YEL 2-25-1 (12)
SOFT TOUCH OVERRIDE
10
SHLD WHT 27-1 JIB UP
5 1
SHLD YEL 2-25 (12) YEL 2-1-11
6 X387 2
GRY CAN SHIELD YEL 2-25-1 (12) WHT 27-2 JIB DN
7 1 1 3
GRY CAN SHIELD YEL 2-1-12
8 X386 X398 4
JIB LIFT
YEL 2-26 (12)

1 1 5
TOGGLE SWITCH
X399 6
[6,D]
[6,D]
X389
1 1 SW21
BLK 0-40-3 BLK P6
[6,A] X385 X400 SW22-1
BLK 0-41-3 YEL 2-1-12
[6,A] 1 1 1
YEL 2-1-13
X390 X397 SW22-2
BLK 0-41-2 (12) BLK 0-40 (12) WHT 52-3 HEAD/TAIL LT
1 1 1
W/ LINE TO LINE JUMPS

PUSH BUTTON
6-POSITION TERM.BLOCK
X384
HEAD/TAIL LIGHT
X388
YEL
GRN
SHLD
BLK 0-7 (16)
1 1
BLK 0-8 BLK 0-41 (12) WHT 13-1 MTELE IN
[2,D]
X391 1
YEL 2-1-13
2
WHT 13-2 MTELE OUT
WHT 25-3 PLVL UP

X472B
3
1
2
3
YEL 2-1-14
4
1
2
3
5
TOGGLE SWITCH
X472A
6
BRN 49-11 X43 PWR
BRN 49-13 X44 PWR

WHT 49-12 X44 GND
WHT 49-10 X43 GND
MAIN BOOM TELESCOPE
SW23
BLU CAN HI
BLU CAN HI
BLK CAN LOW

BLK CAN LOW
GRY CAN SHIELD

GRY CAN SHIELD
YEL 2-6
1
YEL 2-1-14
X44A
X43A
2
1
2
3
4
5
1
2
3
4
5
WHT 49-16 ENVLP
3
1
2
3
4
5
1
2
3
4
5
YEL 2-1-15
S45 WHT 25-4 PLVL DN

4
X44B
X43B
5
TOGGLE SWITCH
WHT 25-3-1 PLVL UP

WHT 25-6 PLVL UP O/R
6
YEL 2-6
BOOM CONTROL SELECT
1001145974_3-[1,A]
SW24
S46
WHT 48-3 STRT
1
YEL 2-1-15
2
S40
[5,B]
WHT 53-1 AUX

3
GRN
YEL 2-1-16
S481
S480
4
YEL
GRN
SHLD
5
TOGGLE SWITCH
WHT 25-4-1 PLVL DN

START/AUX POWER
WHT 25-5 PLVL DN O/R

6
SW25
YEL 2-6-2
YEL 2-6-1
1
YEL 2-1-16
2
WHT 54-3 CPCITY SW
3
YEL 2-1-17
4
BLK 0-4
YEL 2-6-2
YEL 2-6-1
5
BLK 0-7 (16)

TOGGLE SWITCH
CAPACITY SELECT
WHT 49-23 GND

WHT 49-22 GND
6
WHT 23-3 PROT LT

2-26 FUSIBLE LINK (12)
WHT 23-4 PROT RT

2-25 FUSIBLE LINK (12)
WHT 25-3-1 PLVL UP

WHT 25-4-1 PLVL DN
WHT 55-26 JLOCK IN

YEL 2-5
YEL 2-4
BLK 0-8
RED 1-4-3 PLTF MODE
WHT 55-25 JLOCK OUT

RED 1-4-3
SW26
WHT 50-2 P DUMP(16)

WHT 50-2 P DUMP(16)
BLK 0-41 (12)
BLK 0-40 (12)
GRN
WHT 49-20 PROX NC

WHT 49-19 PROX NO
WHT 55-6 DOS

RED 1-4-3
[2,E] 1
YEL 2-1-17
X36A
2
1
9
8
3
6
7
5
4
2
SW35-2B
SW35-2A
SW35-1A
SW35-1B
11
13
20
15
17
12
10
21
14
18
19
16
2B
2A
1A
1B
WHT 49-17 PLVL 2

WHT 49-18 PLVL 1
3
X33A
7
4
9
3
2
1
8
6
5
11
11
13
20
15
17
12
10
21
14
18
19
16
15
13
19
17
14
18
16
12
10
1
9
8
3
6
7
4
5
2
5
TOGGLE SWITCH
X36B
DRIVE ORIENTATION
11
15
13
19
17
14
18
16
12
10
7
4
9
3
2
1
8
6
5
SW27
X33B

EMS
SWITCH
ZONE C-1
SHEET 2
SEE SHEET 3
BOOM CABLE
CONNECTION
ZONE G&F-1
SEE SHEET 3
PLATFORM VALVE
BANK FUNCTIONS
7-149
JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN

SENSOR #2 (LH) SENSOR #1 (RH) ANGLE SENSOR
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR JIB LIFT
JIB LOCK JIB LOCK PLATF LVL PLATF LVL PLATF ROT PLATF ROT PLATFORM IGNITION/GROUND
PIN-IN PIN-OUT UP DOWN LEFT RIGHT DUMP 2x6 BUSS BAR
10
12
11
1
2
3
4
5
6
7
8
9
1
2
4
3
1
2
4
3
5
4
3
2
1
1
2
4
3
MS380
SN259
SN258
SN260
SN257
1
2
3
1
2
3
1
2
1
2
1
2
1
2
1
2
1
2
1
2
SN273
SN274
HV342
HV343
HV275
HV276
HV277
HV278
HV281
YEL 2-25 (12)

BLK 0-28 (14)
BLK 0-27-1
BLK 0-27
BLK 0-24
BLK 0-23
WHT 49-44 PROX 1NC
WHT 49-43 PROX 1NO
YEL 2-19
YEL 2-19
YEL 2-21
YEL 2-22
WHT 49-19 PROX NO
ORG CABLE
WHT 49-20 PROX NC
WHT 49-41 LOCK NO

WHT 49-42 LOCK NC
RED CABLE
BLK CABLE
BLU CABLE
BLK CABLE
YEL CABLE
BLK CAN LOW(20)

YEL 2-18 (14)
GRY SHIELD(20)
BLU CAN HI(20)

WHT 55-25 JLOCK OUT
BLK 0-4-5
BLK 0-4-6
BLK 0-4-1
BLK 0-4-2
BLK 0-4-3
BLK 0-4-4
WHT 25-5 PLTFRM DUMP (16)
WHT 0-29 (20)

BRN 2-20 (20)
BLK 0-41 (12)
BLK 0-40 (12)

WHT 55-26 JLOCK IN
BLK 0-40 (12)
YEL 2-25 (12)

YEL 2-26 (12)
WHT 25-4-2 PLVL DN
WHT 25-3-2 PLVL UP
WHT 23-4 PROT RT

WHT 23-3 PROT LT
BLK 0-7 (16)
YEL 2-26 (12)

BLK 0-41 (12)
S383 BLK 0-47 (16)
[8,G]
[4,C]
[4,D]
[4,D]
[4,C]
X36A
ORG CABLE
15 15
YEL CABLE
16 16
BLK CABLE
17 17
RED CABLE
1 1
BLU CABLE
2 2
BLK CABLE
3 3
WHT 55-26 JLOCK IN
10 10
WHT 55-25 JLOCK OUT
11 11
WHT 25-3-2 PLVL UP
7 7
WHT 25-4-2 PLVL DN
6 6
WHT 23-3 PROT LT
8 8
WHT 23-4 PROT RT
9 9 LSS MODULE
21 21 MOUNTED UNDER CONSOLE BOX
SHIELD SHIELD
5 5
BLK 0-4
12 12
18 18
BLK 0-4-2
BLK 0-4-1
BLK 0-4-3
BLK 0-4-4
BLK 0-4
BLK 0-7 (16)

19 19
BLK CABLE (16)
14 14
BLU CABLE (16)
4 4
ORG CABLE (16)
13 13
MS437
RED CABLE (16)

20 20
8
7
6
5
4
3
2
1
X36B
10
12
10
12
CO285-J1
CO285-J2
11
11
1
2
3
4
5
6
7
8
9
4
9
5
1
2
3
6
7
8
1 x 8 Buss Bar
VALVE GROUNDING
WHT
BRN
GRY
BLU
BLK
BLK CAN LOW(20)

GRY SHIELD(20)
BLU CAN HI(20)

X289
GRN CAN LOW

SHLD SHIELD
YEL CAN HI
1 1
WHT
BRN
GRY
BLU
BLK
2 2
3 3
4 4
X287
5 5
1
2
3
4
5
6 6
BRN
MS262-2
MS262-3
X43B 7 7
GRY
5 5 8 8
C
B
A
C
B
A
BLK BLK
4 4 9 9
BLU BLU
3 3 10 10
WHT WHT
2 2 11 11
BRN BRN
1 1 12 12
S291
X286 X290
MS262-1
C
A
B
X44A
BRN BRN
PLATFORM LEVEL
ANGLE SENSOR
1 1 1
WHT WHT
2 2 2
BLU BLU
3 3 3
BLK BLK
4 4 4
GRN CAN LOW

SHLD SHIELD
GRY GRY
YEL CAN HI
5 5 5
X44B SN292
ORN 12 AWG ORN 12 AWG BLK 0-40 (12)

16 [3,G]
BLK 12 AWG BLK 12 AWG YEL 2-25 (12)
10 [4,G]
RED 18 AWG RED 18 AWG YEL CAN HI
3
GRN CAN LOW
2
SHLD SHIELD
1
19
BLK/WHT 12 AWG BLK/WHT 12 AWG BLK 0-41 (12)
18 [3,G]
17
YEL/BLK 18 AWG YEL/BLK 18 AWG WHT 49-20 PROX NC
15
14
ORN/BLK 18 AWG ORN/BLK 18 AWG WHT 49-19 PROX NO
13
RED 12 AWG RED 12 AWG YEL 2-26 (12)
12 [4,G]
BLU/BLK 18 AWG BLU/BLK 18 AWG YEL 2-5
11
RED/BLK 18 AWG RED/BLK 18 AWG WHT 25-6 PLVL UP O/R
9
8
BRN 18 AWG BRN 18 AWG WHT 25-5 PLVL DN O/R
7
YEL 18 AWG YEL 18 AWG YEL 2-15
6
BLU 18 AWG BLU 18 AWG RED 1-4-3
5
ORN 18 AWG YEL 2-4
4
X228B
X365B
BLK CABLE (16)
4
BLU CABLE (16)
3
ORG CABLE (16)
2
RED CABLE (16)
1
WHT P1 WHT P1
1001145974_2-[1,C]
WHT P8
WHT P8
GRN
1001145974_2-[7,D]
GRN
7-150 3121619
JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING JIB
PROXIMITY SENSOR PROXIMITY SENSOR ANGLE SENSOR PROXIMITY SENSOR UP DOWN UP DOWN IN OUT RIGHT LEFT DUMP
JIB LIFT
1
2
1
2
1
2
2
1
1
2
1
2
1
2
1
2
1
2
HV256
HV255
HV254
HV253
HV252
HV251
HV250
HV248
HV249
WHT 55-20 JLVL UP
4
5
6
7
8
9
1
2
4
3
1
2
4
3
5
4
3
2
1
1
2
4
3
SN259
SN258
SN260
SN257
BLK 0-25-1
BLK 0-25-2
BLK 0-26-1
BLK 0-26-2
BLK 0-26-3
BLK 0-26-4
BLK 0-26-5
BLK 0-26-6
WHT 59-1-1 JSWG RT
WHT 29-4-1 JIB OUT
WHT 59-2-1 JSWG LT

WHT 55-19 JLVL DN
WHT 27-4-2 JIB DN

WHT 27-5-2 JIB UP
WHT 29-3-1 JIB IN
WHT 50-3 JIB DUMP(16)

BLK 0-47 (16)
YEL 2-25 (12)
BLK 0-27-1
BLK 0-24
BLK 0-23
WHT 49-44 PROX 1NC
WHT 49-43 PROX 1NO
YEL 2-19
YEL 2-19
YEL 2-21
YEL 2-22
WHT 49-19 PROX NO
WHT 49-20 PROX NC
WHT 49-41 LOCK NO

WHT 49-42 LOCK NC
BLK CAN LOW(20)
YEL 2-18 (14)
GRY SHIELD(20)
BLU CAN HI(20)

WHT 0-29 (20)
BRN 2-20 (20)
YEL 2-25 (12)
YEL 2-26 (12)
YEL 2-26 (12)
WHT 55-19 JLVL DN

WHT 27-3-1 JIB DN O/R
WHT 27-6-1 J-UP O/R
S383 BLK 0-47 (16)

[8,G]
CO245-J2
2 1
S264
1 2
WHT 29-3-1 JIB IN S265
12 5
BLK 0-25 WHT 29-4-1 JIB OUT
[4,G]
3 6
WHT 55-20 JLVL UP WHT 59-1-1 JSWG RT
11 3
WHT 49-41 LOCK NO WHT 59-2-1 JSWG LT
[4,D]
[4,C]
4 4
WHT 49-42 LOCK NC
5 7
WHT 49-43 PROX 1NO
6 8
WHT 49-44 PROX 1NC
7 9
8 10
9 11
BLK 0-26
10 12
CO245-J5
CO245-J4
BLK 0-23
2
YEL 2-22
LSS MODULE 1
MS347
SHLD SHIELD
MOUNTED UNDER CONSOLE BOX 5
9
8
7
6
5
4
3
2
1
12
10
11
GRN CAN LOW
4
YEL CAN HI
3
6
BLK 0-24
8
YEL 2-21 JIB VALVE
7
GND BUSS
SN246
CO245-J1
JIB SWING ANGLE SENSOR

BRN 2-20 (20) RED 5V PWR RED 5V PWR
DUAL OUTPUT ROTARY

11 10 B
WHT 0-29 (20) WHT SIGNAL WHT SIGNAL
12 11 D
10
12
10
12
CO285-J1
CO285-J2
11
11
WHT 27-6 J-UP O/R BLK GROUND BLK GROUND

9
4
9
5
1
2
3
6
7
8
2 12 A
WHT 27-3 JIB DN O/R ORG 5V PWR ORG 5V PWR
1 7 F
BLU SIGNAL BLU SIGNAL
3 8 C
YEL 2-18 (14) GRN GROUND GRN GROUND
5 9 E
BLK 0-28 (14) RED 5V PWR
4 4
GRY
BLU
BLK
YEL CAN HI WHT SIGNAL

6 5
GRN CAN LOW BLK GROUND
7 6
SHLD SHIELD ORG 5V PWR
8 1
BLU SIGNAL
9 2
JIB LEVEL ANGLE SENSOR

GRN GROUND RED 5V PWR
DUAL OUTPUT ROTARY

10 3 B
CO245-J3 WHT SIGNAL
D
BLK GROUND
A
ORG 5V PWR
F
BLU SIGNAL
C
GRN GROUND
BLK CAN LOW(20)
GRY SHIELD(20)
E
BLU CAN HI(20)
GRN CAN LOW

SHLD SHIELD
YEL CAN HI
1 SN247
2
3
4
5
6
MS262-2
MS262-3
7
8
C
B
A
C
B
A
9
10
11
12
X290
MS262-1
C
A
B
GRN CAN LOW
SHLD SHIELD
YEL CAN HI
X230A X231A
BLK 0-40 (12) BLK 12 AWG BLK 12 AWG
[3,G] 16 16 16 16
YEL 2-25 (12) ORN 12 AWG ORN 12 AWG
[4,G] 10 10 10 10
SHLD SHIELD SHIELD 18 AWG SHIELD 18 AWG
1 1 1 1
GRN CAN LOW BLK 18 AWG BLK 18 AWG
2 2 2 2
YEL CAN HI RED 18 AWG RED 18 AWG
3 3 3 3
19 19 19 19
BLK 0-41 (12) BLK/WHT 12 AWG BLK/WHT 12 AWG
[3,G] 18 18 18 18
17 17 17 17
WHT 27-3 JIB DN O/R YEL/BLK 18 AWG YEL/BLK 18 AWG
15 15 15 15
14 14 14 14
WHT 27-6 J-UP O/R ORN/BLK 18 AWG ORN/BLK 18 AWG
13 13 13 13
YEL 2-26 (12) RED 12 AWG RED 12 AWG
[4,G] 12 12 12 12
YEL 2-5 BLU/BLK 18 AWG BLU/BLK 18 AWG
11 11 11 11
WHT 25-6 PLVL UP O/R RED/BLK 18 AWG RED/BLK 18 AWG
9 9 9 9
8 8 8 8
WHT 25-5 PLVL DN O/R BRN 18 AWG BRN 18 AWG
7 7 7 7
YEL 2-15 YEL 18 AWG YEL 18 AWG
6 6 6 6
RED 1-4-3 BLU 18 AWG BLU 18 AWG
5 5 5 5
YEL 2-4 ORN 18 AWG ORN 18 AWG
4 4 4 4
X230B X81
X365B X364B
BLK CABLE (16) WHT 50-2 PLTFM DUMP(16) WHT 50-2 PLTFM DUMP(16) BLK (16)
4 4 4 4 1001145974_5-[8,B]
BLU CABLE (16) WHT 50-3 JIB DUMP(16) BLU (16)
3 3 3 3 1001145974_5-[8,B]
ORG CABLE (16) RED 1-7-1 WK LT PWR(16) RED 1-7-1 WK LT PWR(16) ORG (16)
2 2 2 2 1001145974_5-[8,B]
RED CABLE (16) RED 1-7-2 WK LT PWR(16) RED 1-7-2 WK LT PWR(16) RED (16)
1 1 1 1 1001145974_5-[8,B]
X365A X364A
3121619 7-151
7-152
1
1
1
SHIELD CABLE SHIELD SHIELD CABLE SHIELD
1
X422
X420
X421
X413
SHIELD
WHT 7-4 LDRV PFWD
6
WHT 7-3 LDRV PREV SHIELD CABLE SHIELD SHIELD CABLE SHIELD
5
BLK 0-50-1 (16)

SHIELD B LNGTH
4
BLK 0-15
3
WHT 7-1 RDRV PFWD
1
WHT 7-2 RDRV PREV
2
X222B
[6,C]
BLK 0-15
SHIELD B LNGTH
WHT 7-3 LDRV PREV

WHT 7-4 LDRV PFWD
YEL 1-10
X404B
BLK B LNGTH
BLU B LNGTH
RED B LNGTH
NC SN221
RED B LNGTH RED YEL BRN BRKN CBL PWR (22)
1 1 5 5 1
BLU B LNGTH BLU SHIELD
2 2 8 8 4
BLK B LNGTH BLK BRN BLU BRKN CBL GND1 (22)
3 3 7 7 3
RED/BLK ORG S410
BROKEN CABLE
4 4 6 6
SHIELD BRKN CBL PROX SHIELD RED/BLK
BLK PROX SIG (22)
PROXIMITY SENSOR #1
8 8 4 4
RED BRKN CBL PROX YEL RED
5 5 1 1
BLK BRKN CBL PROX BRN BLU
7 7 2 2
S409
ORG BLK
6 6 3 3
X404A X407A X407B
BLK BRKN CBL SIG (22)
BRN PROX PWR (22)
SN401
BLU BRKN CBL GND2 (22)
1
4
3
RED
BROKEN CABLE
BLU BRKN CBL PROX

PROXIMITY SENSOR #2
BLU
BLK
YEL 1-11
BLK 0-55
BLK 0-56
YEL 2-10 (14)
BLK 0-22 (14)
YEL CAN HIGH
GRN CAN LOW
WHT 7-2 RDRV PREV

WHT 7-1 RDRV PFWD
WHT 49-60 GRVTY SEN1

WHT 49-61 GRVTY SEN2
SHIELD
SHLD X406B
BLK CABLE BLK CABLE BLK 0-55
3 3 3
BLU CABLE BLU CABLE WHT 49-60 GRVTY SEN1
2 2
RED CABLE RED CABLE YEL 1-10
1 1
B
A
C
MS148-1
4 4
8 8
BRN CABLE BLK 0-56
7 7
ORG CABLE WHT 49-61 GRVTY SEN2
6 6 X147A
YEL CABLE YEL 1-11
5 5 4
C
C
A
B
A
B
SHLD X406A 5
BRN CABLE
3 6
MS148-2
MS148-3
ORG CABLE WHT 55-14 BRAKE WHT 55-14 BRAKE
2 1001145974_5-[7,D] 7
YEL CABLE SHLD CAN SHLD
1 3
#2 LEFT SIDE
GRN CAN LO
SN137 2
YEL
GRN
SHLD
YEL CAN HI
BOOM ANGLE SENSOR

1
9
10
11
12
8
X149A
YEL 02-6 (10)
1
BLK 00-11 (10)
2
BLK BRKN CBL PROX

BLU BRKN CBL PROX
RED BRKN CBL PROX

SHIELD BRKN CBL PROX
YEL 2-10 (14)
BLK 0-22 (14)
YEL
GRN
SHLD
X411
6
5
4
3
2
1
6
5
4
3
2
1
X412
BLK CABLE
BLU CABLE
RED CABLE
1001145974_5-[3,F]
1001145974_5-[3,F]
1001145974_5-[3,F]
BLK (1/0)
BLK (1/0)
YEL 2-10 (14)
BLK 0-22 (14)
RED (1/0)
SHIELD BRKN CBL PROX
RED (1/0) RED (1/0)

RED (1/0)
BLK 0-70
WHT 55-35 AUX B+ DISC

1 1001145974_5-[7,D]
WHT 53-3 AUX PMP WHT 53-3 AUX PMP
RL360-85 1001145974_5-[7,C]
BLK 0-45
1
RED (1/0)
RL360-86
RED (1/0)
1
SOLENOID
RED (1/0)
RL360-30
RED (1/0)
BATTERY DISCONNECT
1
RL360-87
IP379
RED 1-7-1 WK LT PWR(16) RED 1-7 WK LT PWR(12)
RED (1/0)
1001145974_5-[8,E]
RED 1-7-2 WK LT PWR(16)
1001145974_5-[8,E]
BLK (1/0)
BLK (1/0)
RED (1/0)
BT361-
1
1
BT361+
RED (1/0)
1001145974_5-[2,E]
1001145974_5-[3,A]
12 VOLT BATTERY
BLK (1/0)
SHEET 4
AUX POWER/ENGINE POWER
3121619
STROBE
LIGHT
2
1
LB417
RED (1/0)
RED (1/0)
BLK (1/0)
WHT 53-3 AUX PMP
WHT B LNTH CBL

RED B LNTH CBL
BLK B LNTH CBL
RED (1/0)
BLK 0-70
BLK 0-16
YEL 2-17
WHT 53-3 AUX PMP
WHT B LNTH CBL

1001145974_5-[3,C]
BLK B LNTH CBL
1001145974_5-[3,C]
RED B LNTH CBL
1001145974_5-[3,D]
1001145974_5-[7,C]
SHLD
1001145974_5-[3,F]
GRN
1001145974_5-[3,F]
YEL
1001145974_5-[3,F]
X411
BLK 0-22 (14) BLK 0-22 (14)
1 1
YEL 2-10 (14) YEL 2-10 (14)
2 2
BLU BRKN CBL PROX BLU CABLE BLU CABLE
3 3 1001145974_5-[3,D]
BLK BRKN CBL PROX BLK CABLE BLK CABLE
4 4 1001145974_5-[3,C]
RED BRKN CBL PROX RED CABLE RED CABLE
5 5 1001145974_5-[3,D]
SHIELD BRKN CBL PROX SHIELD BRKN CBL PROX SHIELD BRKN CBL PROX
6 6 1001145974_5-[3,E]
X412
RED 1-15 RED 1-15
1001145974_5-[2,C]
IP414
X457
RED 1-5 (16) RED 1-5 (16)
1001145974_5-[1,E] 1
IP415
YEL 02-6 (10)
1
YEL 2-10 (14)
??RL236-R_2-R
YEL 2-11 (12) YEL 2-11 (12)
1001145974_5-[4,B] 1
??RL236-Y_2-Y
BUSSBAR
1
??RL236-B+_2-B+
??RLGeneric power relay-B+_1-B+

BUSSBAR
1
RED 2/0 EPDM
YEL 2-25 (12)

1001145974_5-[4,A] ??RL235-Y_1-Y
YEL 2-26 (12)
1001145974_5-[4,A] 1
1001145974_5-[7,D]
RL235-R
YEL 2-1-99 IGNITION(12) YEL 2-1-99 IGNITION(12)
1001145974_5-[6,C] 1
YEL 2-13 (16) YEL 2-13 (16)
1001145974_5-[6,C] X353
YEL 2-12 YEL 2-12
1001145974_5-[2,E] 1
YEL 2-17
RL234-87
RED 2/0 EPDM
1
RL234-30
RED (1/0)
SOLENOID
1
IGNITION
IP90 RL234-86
YEL 2-4-2 YEL 2-4-2-1 YEL 2-4-2-1
1001145974_5-[3,A] 1
RED (1/0)
IP91
RED 1-4-2 RED 1-4-2-1 RED 1-4-2-1 RED 1-4-2-1
1001145974_5-[2,E] RL234-85
BLK 0-21
1
BLK 0-70
[1,E]
BLK 0-50-1 (16)
BLK (1/0)
1001145974_5-[8,D]
1001145974_5-[4,A]
1001145974_5-[4,A]
BLK (1/0)
1
BT361-
RED (1/0)
RED (1/0)
1
S456
BT361+
12 VOLT BATTERY BLK 0-50-2 (16)

RED 1-7 WK LT PWR(12)
1001145974_5-[2,B]
AUX POWER/ENGINE POWER
BLK 0-41 (12)
BLK 0-40 (12)

BLK 0-14
BLK 0-19 (16AWG)

1001145974_5-[2,A]
BLK 0-20 (12)

1001145974_5-[5,B]
RED (1/0)
RED (1/0)
BLK (1/0)
BLK 0-45
BLK 0-19 (16AWG)

BLK 00-11 (10)
BLK 0-22 (14)
BLK 0-50 (16)
BLK 0-20 (12)

RED (1/0)
RED (1/0)
RED (1/0)
BLK (1/0)
BLK (1/0)
IP379
BLK 0-45
BLK 0-21
BLK 0-16
BLK 0-14
RL360-86
RL360-30
RL360-87
RL360-85

1
X373
X374
X375
X237
X377
X378
X418
X419
X362
X376
1
BATTERY DISCONNECT
SOLENOID
1001145974_5-[8,E]
1001145974_5-[8,E]
3121619 7-153
SW55-1B
SW55-1A
7-154
2
1
4
3
RED 1-5-1-1 (16)
CAN CHANNEL #2 1B
X06
3 x 4 Buss Bar 1A
EMS
H
D
C
G
F
A
E
B
J
1
2
3
4
2A
EMERGENCY
X84
RED 1-4 (16)
X395
2B
SW55-2A
11
12
10
1
2
3
4
9
5
6
7
8
SW55-2B
MS83
BLK 0-19-2
YEL 2-11-1B
BLK 0-60
RED 1-4-3
BLK 0-19-3
SHLD CAN SHLD
RED 1-15-2
RED 1-15-1
RED 1-4-3A
YEL 2-11-1A
1
WHT 49-66 Y AXIS

WHT 49-65 X AXIS
SW56-1
YEL CAN HI
GRN CAN LO
RED 1-4 (16)
1
YEL CAN HI
YEL CAN HI
YEL CAN HI
GRN CAN LO
GRN CAN LO
GRN CAN LO
WHT 49-64 TILT PWR

S09
SHLD CAN SHLD
SHLD CAN SHLD
SW56-B
SHLD CAN SHLD

YEL CAN HI RED 1-4-1
[6,C] 1
GRN CAN LO RED 1-4-2
[6,C] SW56-3 KEY
SHLD CAN SHLD
SWITCH
YEL 2-11-1A
[6,C] 1
SW56-2
YEL 2-11-1
1
SW56-B1
RED 1-4-3A
1
SW56-4
X327B
RED 1-5 (16) RED 1-5-1-1 (16)
1001145974_4-[6,E] 1 1
RED 1-4-1 RED 1-4-1
2 2
S07
RED 1-4-3 RED 1-4-3B RED 1-4-3
[4,A] 3 3
RED 1-4-2 S11 RED 1-4-2 RED 1-4-2
IP85
1001145974_4-[5,C] 4 4 X77
YEL 2-12 YEL 2-12 YEL 2-12-1
1001145974_4-[7,C] 5 5 1
BLK 0-19-1 BLK 0-19-1 S31 BLK 0-19-3
5A
6 6 2
GRN CAN LO GRN (20) S42 GRN (20)
7 7 3
RED 1-15
YEL CAN HI YEL (20) YEL (20)
8 8 4
WHT 49-46 M CNTRL WHT 49-46 M CNTRL
9 9 5
10 10 6
WHT 44-1 MSSO WHT 44-1 MSSO
11 11
BLK 0-44 BLK 0-44
12 12
X327 SW471-1
WHT 44-1 MSSO
1
SW471-2
1001145974_4-[6,E]
MSSO
BLK 0-44
SWITCH
BLK 0-19-3
BLK 0-19 (16) S239 BLK 0-19-1
1001145974_4-[7,B] X483
BLK 0-19-2 BLK 0-19-2
X487A 1
YEL 2-12-2
C C 2
GRN CAN LO GRN CAN LO GRN CAN LO
B B 4
BLK 0-50-2 (16) YEL CAN HI YEL CAN HI YEL CAN HI
8 1001145974_4-[7,B] A A 3
WHT 49-72 LIFT PRS (20)
7 X487B 5
WHT 49-74 L P GND (20)
6 6
WHT 49-73 L P PWR (20)
5
WHT 49-75 PRS CHK (20)
4
WHT 49-76 P C GND (20)
1001145974_4-[7,G]
1001145974_4-[7,G]
1001145974_4-[7,E]
1001145974_4-[7,E]
1001145974_4-[7,E]
1001145974_4-[7,F]
3
WHT 49-77 P C PWR (20)
2 MS82
WHT 55-30 LFT ENABLE YEL CAN HI
1 1
YEL CAN HI
X440B 2
YEL CAN HI
11
YEL 2-4-2 YEL 2-4-2 YEL 2-4-4 YEL CAN HI YEL CAN HI
1001145974_4-[5,C] 1001145974_4-[4,E] 12
YEL 2-4 YEL 2-4-3 GRN CAN LO
3
BLK CABLE
BLU CABLE
RED CABLE
S89 GRN CAN LO
4
BLK B LNTH CBL

RED B LNTH CBL
WHT B LNTH CBL

GRN CAN LO
9
3 x 4 Buss Bar
GRN CAN LO GRN CAN LO

1001145974_4-[4,E] 10
CAN CHANNEL #1
SHLD CAN SHLD

5
SHLD CAN SHLD
6
SHLD CAN SHLD SHLD CAN SHLD
S469 X468 1001145974_4-[4,E] 7
SHLD CAN SHLD CAN SHIELD TO CHASSIS GND
1 8
SHLD CAN SHLD
1001145974_4-[7,E]
BLK 0-44
YEL CAN HI
YEL CAN HI
GRN CAN LO
GRN CAN LO
WHT 49-74 L P GND (20)
WHT 49-77 P C PWR (20)
BLK 0-60
WHT 44-1 MSSO
WHT 49-75 PRS CHK (20)

SW482-1
WHT 49-64 TILT PWR

WHT 49-46 M CNTRL
YEL 2-5
YEL 2-11
WHT 49-73 L P PWR (20)
YEL 2-15
WHT 49-76 P C GND (20)
WHT 148-5 REGEN
WHT 49-72 LIFT PRS (20)
YEL 2-4-3
YEL 2-4-4
RED 1-4-1
1
BLK B LNTH CBL

WHT B LNTH CBL
WHT 49-66 Y AXIS

WHT 49-65 X AXIS
WHT JUMPER
WHT JUMPER
BLK CABLE
BLU CABLE
RED CABLE
WHT JUMPER3
WHT JUMPER3
SW482-2
RED B LNTH CBL

YEL 2-9-10
ENGINE
WHT 55-30 LFT ENABLE

1
REGENERATION
1
12
WHT 21-3 SWG LFT WHT 21-3 SWG LFT
X467
34 1
YEL 2-9 YEL 2-9
25 2
WHT 21-4 SWG RHT WHT 21-4 SWG RHT
35 3
WHT 29-3 JIB IN YEL 2-9-1
1001145974_4-[7,D]
11 4
SWING
WHT 29-4 JIB OUT

TURNTABLE
22 5
WHT 27-4 JIB DN
8 6
WHT 27-5 JIB UP
19 SW58
WHT 23-5 P-ROT RHT
18
WHT 148-5 REGEN
UGM TO CHASSIS GND

9
20
YEL 2-11 (12)

WHT 23-6 P-ROT LFT
6
WHT 3-3 LIFT UP WHT 3-3 LIFT UP
23 1
WHT 25-7 P-LVL UP YEL 2-9-1
17 2
WHT 3-4 LIFT DN WHT 3-4 LIFT DN
33 3
WHT 25-8 P-LVL DN YEL 2-9-2
LIFT
1001145974_4-[7,D]
1001145974_4-[7,D]
1001145974_4-[6,B]
1001145974_4-[6,B]
MAIN
5 4
[2,E]
WHT 48-4 STRT
4 5
WHT 53-2 AUX
16 6
WHT 54-4 500#
2 SW59
WHT 39-4 AXLE
WHT 48-5 GLOW
CO02-J8 15
WHT 13-5 TELE IN WHT 13-5 TELE IN
RED 1-4-3
4 7 1
WHT HRC-WARN/ LRC-TEMP YEL 2-9-2
3 28 2
WHT 13-6 TELE OUT WHT 13-6 TELE OUT
2 30 3
YEL 2-26 (12)

YEL 2-25 (12)
BLK 0-41 (12)
BLK 0-40 (12)
WHT 47-8 OIL PRS YEL 2-9-3
MAIN
1 29 4
WHT HRC-HEST/ LRC-ALT
TELESCOPE
26 5
13 6
3 SW60
14 SW66-1
YEL 2-9-3
27 1
YEL 2-9-4
31 SW66-2
WHT 49-46 M CNTRL
32 1
PUSH BUTTON
MOMNT CNTRL
21
10
WHT 49-29 BCS
24
WHT 29-3 JIB IN
WHT 54-5 1000#
WHT 49-28 MNT CNTRL
12 1
YEL 2-9-4
WHT 49-30 OVERLOAD
10 2

WHT 29-4 JIB OUT
18 3
JIB
YEL 2-9-5
16 4
BLK 0-20 (12)

TELESCOPE
19 14 5
RED 1-4-3
5 13 6
17 12 SW61
14 11
8 10
SHLD CAN SHLD WHT 27-4 JIB DN
1 8 1
YEL CAN HI YEL 2-9-5
3 7 2
GRN CAN LO WHT 27-5 JIB UP
2 6 3
JIB
1001145974_4-[7,B]
YEL 2-4 YEL 2-9-6
LIFT
4 5 4
YEL 2-5
11 4 5
YEL 2-15
6 3 6
WHT 27-6 J-UP O/R
13 2 SW62
WHT 27-3 JIB DN O/R
15 1
9 9
WHT 25-5 PLVL DN O/R WHT 23-5 P-ROT RHT
7 CO02-J3 1
X81 YEL 2-9-6
2
WHT 23-6 P-ROT LFT
3
YEL 2-9-8
3121619
WHT 21-4 SWG RHT WHT 21-4 SWG RHT
35 3
WHT 29-3 JIB IN YEL 2-9-1
11 4
WHT 29-4 JIB OUT
SWING
22 5
WHT 27-4 JIB DN
TURNTABLE
8 6
WHT 27-5 JIB UP SW58
19
WHT 23-5 P-ROT RHT
18
WHT 148-5 REGEN
9
3121619
UGM TO CHASSIS GND
20
YEL 2-11 (12)

WHT 23-6 P-ROT LFT
6
WHT 3-3 LIFT UP WHT 3-3 LIFT UP
23 1
WHT 25-7 P-LVL UP YEL 2-9-1
17 2
WHT 3-4 LIFT DN WHT 3-4 LIFT DN
33 3
WHT 25-8 P-LVL DN YEL 2-9-2
LIFT
1001145974_4-[7,D]
1001145974_4-[7,D]
1001145974_4-[6,B]
1001145974_4-[6,B]
MAIN
5 4
[2,E]
WHT 48-4 STRT
4 5
WHT 53-2 AUX
16 6
WHT 54-4 500#
2 SW59
WHT 39-4 AXLE
WHT 48-5 GLOW
CO02-J8 15
WHT 13-5 TELE IN WHT 13-5 TELE IN
RED 1-4-3
4 7 1
WHT HRC-WARN/ LRC-TEMP YEL 2-9-2
3 28 2
WHT 13-6 TELE OUT WHT 13-6 TELE OUT
2 30 3
YEL 2-26 (12)

YEL 2-25 (12)
BLK 0-41 (12)
BLK 0-40 (12)
WHT 47-8 OIL PRS YEL 2-9-3
MAIN
1 29 4
TELESCOPE
26 5
13 6
3 SW60
14 SW66-1
YEL 2-9-3
27 1
YEL 2-9-4
31 SW66-2
WHT 49-46 M CNTRL
32 1
PUSH BUTTON
MOMNT CNTRL
21
10
WHT 49-29 BCS

24
WHT 29-3 JIB IN
WHT 54-5 1000#

WHT 49-28 MNT CNTRL
12 1
YEL 2-9-4
WHT 49-30 OVERLOAD

10 2
WHT 29-4 JIB OUT
18 3
JIB
YEL 2-9-5
16 4
BLK 0-20 (12)

TELESCOPE
19 14 5
RED 1-4-3
5 13 6
17 12 SW61
14 11
8 10
SHLD CAN SHLD WHT 27-4 JIB DN
1 8 1
YEL CAN HI YEL 2-9-5
3 7 2
GRN CAN LO WHT 27-5 JIB UP
2 6 3
JIB
1001145974_4-[7,B]
YEL 2-4 YEL 2-9-6
LIFT
4 5 4
YEL 2-5
11 4 5
YEL 2-15
6 3 6
WHT 27-6 J-UP O/R
13 2 SW62
WHT 27-3 JIB DN O/R
15 1
9 9
WHT 25-5 PLVL DN O/R WHT 23-5 P-ROT RHT
7 CO02-J3 1
YEL 2-9-6
X81 2
WHT 23-6 P-ROT LFT
3
YEL 2-9-8
4
ROTATE
PLATFORM
5
6
SW63
WHT 25-7 P-LVL UP

1
YEL 2-9-8
BLK 0-18
WHT 49-36 A-TX
WHT 49-35 A-RX
BLK 0-31
2
WHT 49-37 A-GND

WHT 49-34 A-PWR
WHT 27-6 J-UP O/R

WHT 48-8 SP
BLK 0-17 (16)
WHT 52-9 GEN
WHT 25-8 P-LVL DN
WHT 48-6 STRT
WHT 48-7 GLOW

3
WHT 55-14 BRAKE
WHT 53-3 AUX PMP
WHT 47-6-2 ALT EXC

YEL 2-9-9

LEVEL
WHT 49-45 HYD OIL TEMP

PLATFORM
1001145974_4-[7,D]
6
[1,D]
[1,D]
[1,D]
SW64
WHT 48-4 STRT

1
YEL 2-9-9
2
WHT 53-2 AUX
3
YEL CAN HI
S372
GRN CAN LO
YEL 2-9-10
S371
4
SHLD CAN SHLD

START/
AUX PWR
5
6
SW65
1001145974_4-[7,C]
WHT 47-6 ALT EXC
YEL 2-1-99 IGNITION (14)
WHT 54-4 500#
WHT 49-36 A-TX

WHT 49-35 A-RX
1
WHT 49-37 A-GND

WHT 49-34 A-PWR
LIGHT
BLK 0-12-9
WHT 48-6 STRT

500# CAP.
YEL 2-1-99 IGNITION (14)

2
WHT 47-6-1 ALT EXC

LB67
YEL CAN HI
YEL 2-13 (16)

GRN CAN LO
SHLD CAN SHLD

X88
4
3
2
1
WHT 39-4 AXLE
X218A
1
6
5
4
3
2
1
BLK 0-12-9
LIGHT
2
AXLE SET
BLK 0-12-8
LB68
WHT 48-5 GLOW

1
BLK 0-12-8
2
LIGHT
BLK 0-12-7 LB69

GLOW PLUG
BLK 0-18
WHT 48-8 SP
BLK 0-17 (16)
YEL 2-13 (16)

WHT 52-9 GEN
WHT 48-7 GLOW
WHT HRC-WARN/ LRC-TEMP
1
BLK 0-12-7
2
BLK 0-12-6
LB70
/ENG WARN LT
HIGH COOLANT
8
7
6
5
4
3
2
WHT 47-8 OIL PRS
1
1 X217A
BLK 0-12-6
2
BLK 0-12-5
LOW OIL
LB71
PRES. LIGHT
1001145974_4-[5,F]
1001145974_4-[5,C]
1001145974_4-[3,G]
1
BLK 0-12-5
2
BLK 0-12-4
/HEST LIGHT
X159B LB72
NO ALTERNATOR
WHT 47-6 ALT EXC

12
8
WHT 49-28 MNT CNTRL
9 1
BLK 0-12-4
10 2
WHT 27-3 JIB DN O/R BLK 0-12-3
1 LB73
TEST LIGHT

MOMENT CNTRL
2
3
BLK 0-14 BLK 0-14 WHT 49-29 BCS
1001145974_4-[6,B] 11 1

WHT 49-45 HYD OIL TEMP BLK 0-12-3
6 2
BLK 0-31 BLK 0-12-2 LB74
7
SYSTEM LIGHT
BOOM CONTROL
BLK (16) BLK (16) WHT 50-2 PLTFM DUMP (16) WHT 50-2 PLTFM DUMP (16)
1001145974_3-[8,C] 4 4 4
BLU (16) BLU (16) WHT 50-3 JIB DUMP (16) WHT 50-3 JIB DUMP (16)
1001145974_3-[8,B] 3 3 5
ORG (16) ORG (16) RED 1-7-1 WK LT PWR(16) WHT 49-30 OVERLOAD
1001145974_3-[8,B] 2 2 1001145974_4-[5,A] 1
LIGHT
RED (16) RED (16) RED 1-7-2 WK LT PWR(16) BLK 0-12-2

1001145974_3-[8,B] 1 1 1001145974_4-[5,A] 2
BLK 0-12-1
X341B X341A LB75
PLATFORM OVERLOAD
WHT 54-5 1000#

1
BLK 0-12-1
LIGHT
2
1000# CAP.
BLK 0-12
LB76
7-155
MTS LINEAR SENSOR

DEUTSCH REAR LFT AXLE SWG
1 x 8 Buss Bar
1
2
3
4
5
6
7
8
MS244
1
2
3
SN349
WHT 61-1-6 5V
WHT 61-1-5 5V
WHT 61-1-4 5V
WHT 61-1-3 5V
WHT 61-1-1 5V
WHT 61-1-2 5V
WHT 61-1 5V
BLU RETURN
BRN SUPPLY
WHT SIGNAL
X445B
1
2
3
X445A
WHT 38-1 RLFT ASWG

[6,C]
[6,C]
[6,C]
[7,C]
WHT 61-1 5V
BLK 00-15
WHT JUMPER
WHT JUMPER
WHT JUMPER
WHT JUMPER
GE TN
LTA G R RTN
F. VO SW G G D
RE AX SW SW GN
NT AX AX
FR EAR LF
T
R AR
RE
FRNT AXLE SWG EXT.
TWO SPEED
FRNT AXLE SWG RET.
REAR AXLE SWG EXT.

GND
BRAKE
FRNT RHT AXLE SWG
OPEN HYD. CIRCUIT GND
PRESSURE SENSOR REAR AXLE SWG RET.
1
3
2
SN423
GND
GND
GND
WHT 49-71 HYD. OC RTN
WHT 49-70 HYD. OC
WHT 55-18 TTABLE ANG2

GND
RHT FRNT STR LFT
TURNTABLE ANGLE 2 LFT FRNT STR RHT
LFT FRNT STR LFT
RHT FRNT STR RHT
RHT REAR STR RHT
RHT REAR STR LFT
LFT REAR STR RHT
LFT REAR STR LFT
WHT 120 OHM
WHT 120 OHM
WHT 55-14 BRAKE

ANALYZER GND
SHIELD SHLD
ANALYZER TX
NC X-CHASSIS SIDE
SHLD CAN SHLD
ANALYZER RX
6 6 6
GRN CAN LOW
ANALYZER PWR
5 5 5
LFT REAR
SHIELD SHLD SHIELD SHLD YEL CAN HI

STEER
4 4 4
RED STR PWR RED STR PWR RED LFT REAR STR RED LFT REAR STR
2 2 2
BLU STR SIG BLU STR SIG BLU LFT REAR STR BLU LFT REAR STR
3 3 3
BLK STR GND BLK STR GND BLK LFT REAR STR BLK LFT REAR STR
1 1 1
SN-SENSOR SIDE YEL 02-4
X339A
SHIELD SHLD WHT 55-17 DOS
NC X338B
6 6 6
5 5 5
RHT REAR\
SHIELD SHLD SHIELD SHLD

STEER
4 4 4
RED STR PWR RED STR PWR RED RHT REAR STR RED RHT REAR STR
2 2 2
BLU STR SIG BLU STR SIG BLU RHT REAR STR BLU RHT REAR STR
3 3 3
BLK STR GND BLK STR GND BLK RHT REAR STR BLK RHT REAR STR
1 1 1 RIGHT REAR AXLE SWG
SN330
SHIELD SHLD
X338A
WHT 49-70 HYD. OC
LFT FRNT AXLE SWG
NC X337B
WHT 49-71 HYD. OC RTN
6 6 6
5 5 5
LFT FRNT

STEER
4 4 4
RED STR PWR RED STR PWR RED LFT FRNT STR RED LFT FRNT STR
2
BLU STR SIG BLU STR SIG
2 2
BLU LFT FRNT STR BLU LFT FRNT STR
GND
3
BLK STR GND BLK STR GND
3 3
BLK LFT FRNT STR BLK LFT FRNT STR
TURNTABLE ANG
1 1 1
WHT 49-100 ENABLE
GND
SN331 X337A GND
WHT 49-100 ENABLE
X340B
BLK STR GND BLK STR GND BLK RHT FRNT STR BLK RHT FRNT STR
1 1 1
BLU STR SIG BLU STR SIG BLU RHT FRNT STR
3 3 3
RHT FRNT
RED STR PWR RED STR PWR RED RHT FRNT STR
STEER
2 2 2
4 4 4
5 5 5
1
6 6 6
X425
SHIELD SHLD
NC X340A
S424
SN332
BLK 00-12 (16)
BLK 00-11 (10)

YEL 02-6 (10)
BLK 00-12 (16)
WHT 55-14 BRAKE
SHLD CAN SHLD

GRN CAN LOW
WHT 55-17 DOS
YEL CAN HI
YEL 02-4
X147B
9
8
7
6
5
4
3
2
1
12
10
11
12
10
11
9
8
7
6
5
4
3
2
1
X309
BLK 00-11 (10)

YEL 02-6 (10)
ORG
GRN
BLK
YEL
ORIENTATION
SN312
BLK
DRIVE
1
BLK
2
X149B
X311
9
8
7
6
5
4
3
2
1
1
2
12
10
11
12
10
11
9
8
7
6
5
4
3
2
1
1
2
X147A
X149A
7-156 3121619
MTS LINEAR SENSOR MTS LINEAR SENSOR

DEUTSCH REAR LFT AXLE SWG FRNT RHT AXLE SWG
1 x 8 Buss Bar
1
2
3
4
5
6
7
8
MS244
1
2
3
1
2
3
SN349
SN350
WHT 61-1-6 5V
WHT 61-1-5 5V
WHT 61-1-4 5V
WHT 61-1-3 5V
WHT 61-1-1 5V
WHT 61-1-2 5V
WHT 61-1 5V
WHT 55-14 BRAKE

BLU RETURN
BLU RETURN
WHT SIGNAL
WHT SIGNAL
BRN SUPPLY
BRN SUPPLY
BLK 00-1-1
X445B
X442B
1
2
3
1
2
3
X445A
1
2
3
X442A
WHT 38-1 RLFT ASWG
[6,C]
[6,C]
[6,C]
[7,C]
WHT 38-5 FAXS RHT

WHT 61-1 5V
BLK 00-15
BLK 00-2
WHT JUMPER
WHT JUMPER
GE TN
TA G R RTN
OL SW G
F. V AX SW
G D
SW GN
RE NT R AX AX
R
F EA T
R LF
AR
RE
FRNT AXLE SWG EXT.
TWO SPEED
FRNT AXLE SWG RET.
REAR AXLE SWG EXT. BLK 00-1

GND WHT 55-14 BRAKE
BRAKE WHT 38-5 FAXS RHT
FRNT RHT AXLE SWG BLK 00-2
GND
REAR AXLE SWG RET.
BLK 00-3
GND BLK 00-4
GND BLK 00-5
GND
BLK 00-6
GND
RHT FRNT STR LFT
LFT FRNT STR RHT
LFT FRNT STR LFT
RHT FRNT STR RHT BLK 00-3 BLK 00-3-1
RHT REAR STR RHT S205
RHT REAR STR LFT
LFT REAR STR RHT
LFT REAR STR LFT BLK 00-3-2
BLK 00-4 BLK 00-4-1

ANALYZER GND S202
ANALYZER TX
ANALYZER RX
ANALYZER PWR BLK 00-4-2
BLK 00-5 BLK 00-5-1

S203
BLK 00-5-2
WHT 38-9 RAXS RHT

RIGHT REAR AXLE SWG WHT 38-10 FAXS LFT
LFT FRNT AXLE SWG
BLK 00-6 BLK 00-6-1

S204
BLK 00-8
GND BLK 00-9 S195
TURNTABLE ANG WHT 55-15 TTABLE ANG BLK 00-6-2
GND
[5,H]
BLK 00-14
GND WHT 61-1-3 5V
[5,H]
WHT 38-10 FAXS LFT
WHT 38-9 RAXS RHT

[5,H]
[5,H]
1
X425
WHT 61-1-4 5V
WHT 61-1-3 5V
BLK 00-8-2
BLK 00-8-1
WHT 61-1-6 5V
WHT 61-1-5 5V
BLK 00-12 (16)
BLK 00-11 (10)

YEL 02-6 (10)
X449B
X448B
3
2
1
3
2
1
3
2
1
3
2
1
X449A
X448A
WHT 55-18 TTABLE ANG2
WHT 55-15 TTABLE ANG
BLU RETURN
BRN SUPPLY
WHT SIGNAL
BLU RETURN
BRN SUPPLY
WHT SIGNAL
BLK 00-14
BLK 00-9
WHT 61-1-6 5V
WHT 61-1-5 5V
SN352
SN351
SN243
F
3
2
1
A
D
B
E
C
3
2
1
TURNTABLE
ANGLE SENSOR
MTS LINEAR SENSOR MTS LINEAR SENSOR

LFT FRNT AXLE SWG RHT REAR AXLE SWG
3121619 7-157
HYDRAULIC
OIL TEMP. WARM UP LIFT CHASSIS
VALVE ENABLE ENABLE
1
2
1
2
2
1
2
1
SN416
HV316
HV315
HV314
WHT 60-6 WARM UP RTN
WHT 55-31 CHS ENABLE

WHT 60-7 LENABLE RTN
BLK 0-31
WHT 55-33 WARM UP
BLK 0-36
WHT 7-4 RDRV PFWD
1
BLK 0-15-1 RIGHT DRV
2
PUMP FWD
HV142
WHT 7-4 RDRV PFWD

1
WHT 7-3 RDRV PREV WHT 7-3 RDRV PREV
2 1
BLK 0-15 BLK 0-15 BLK 0-15-2 BLK 0-15-2 RIGHT DRV
3 2
S146 PUMP REV
4 HV143
WHT 7-2 LDRV PREV
5
WHT 7-1 LDRV PFWD
6
X222A
WHT 7-2 LDRV PREV
1
BLK 0-15-3 LEFT DRV
2
PUMP REV
HV144
BLK 0-15-4
2
WHT 7-1 LDRV PFWD LEFT DRV
1
PUMP FWD
HV145
BLK 0-30
WHT 52-7 H&T LT SIG
1
X158
WHT 27-3 JIB DN O/R

1
2
3
4
WHT 50-3 JIB DUMP (16)
5
6
BLK 0-31
7
8
9
10
BLK 0-14
11
WHT 47-6 ALT EXC
12
X159A

1
BRN 49-77 P C PWR (20)
2
BLK 49-76 P C GND (20)
3
BLU 49-75 PRS CHK (20)
4
SHLD RTN (20) SHLD RTN (20)
8
BRN 49-73 L P PWR (20) S455
5
BLK 49-74 L P GND (20)
6
BLU 49-72 LIFT PRS (20)
7
SHLD P CHK SN (20)

SHLD P LIFT SN (20)
X440A
SN439
SN438
2
3
4
1
2
3
4
1
SHLD
SHLD
LIFT PRESSURE PRESSURE CHECK

SENSOR SENSOR
7-158 3121619
3121619
1
BLK 0-31
2
SN416
OIL TEMP.
HYDRAULIC
WHT 55-33 WARM UP

1
BLU 49-72 LIFT PRS (20)

2
VALVE
BLK 49-74 L P GND (20)

HV316
WARM UP
BRN 49-73 L P PWR (20)

BLU 49-75 PRS CHK (20)
BLK 49-76 P C GND (20)
BRN 49-77 P C PWR (20)
SHLD RTN (20)

BLK 0-30
S455
SHLD P LIFT SN (20)
SHLD
2
3
4
SENSOR
1
LIFT PRESSURE
SN439

2
1
LIFT
SHLD P CHK SN (20)

ENABLE
SHLD HV315
2
3
4
BLK 0-36
SENSOR
1 2
SN438 1
PRESSURE CHECK
ENABLE
CHASSIS
HV314
WHT 47-6 ALT EXC

WHT 52-8 ALRM PWR

WHT 60-3 SWG RTN
BLK 0-46
X05B
BLK 0-46 BLK 0-46
2 2
BLK 0-46 BLK 0-46
1 1
X05A
BLK 0-30
BLK 0-46
WHT 50-3 JIB DUMP (16)

WHT 27-3 JIB DN O/R
WHT 52-7 H&T LT SIG
WHT 55-33 WARM UP

BLK 0-36
WHT 55-32 SWG F.C. WHT 55-32 SWG F.C.

1
WHT 60-3 SWG RTN
2
SWING
HV348
FLOW CONTROL
WHT 52-6 MOT ALRM

WHT 47-10 FUL SEN

WHT 52-8 ALRM PWR
A
WHT 52-6 MOT ALRM
B
HORN
BLK 0-14 BLK 0-14-2 BLK 0-14-2

C
S157
MOTION ALARM/
AH318
WHT 47-10 FUL SEN

1
BLK 0-14-3
2
SN114
7-159
1 2 3 4 5
GLOW PLUG SENSOR IGNITION

FUSE FUSE
5A 10A
H BLK 148-70 STRT RTN
FC1003
FC1004
1
2
1
2
RED EPDM 2/0AWG

SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²
FUSIBLE LINK 12AWG

RED EPDM 2/0AWG
RED EPDM 2/0AWG
BLK 148-71 STRT SIG
SHLD SHIELD
MS999-1
A
B
C
MS999-2
MS999-3
C
C
B
A
B
A
GRN CAN LOW (J1939 CABLE 20)

SHLD SHIELD (J1939 CABLE 20)

YEL CAN HI (J1939 CABLE 20)

E
BLK 148-15-68 CLUTCH SWITCH
BLK 148-70 STRT RTN

BLK 148-35-3 STRT REQ
BLK 148-71 STRT SIG
MS1000-3
A
D B
120 OHM
C C
GRN CAN LOW GRN CAN LOW
B
YEL CAN HIGH YEL CAN HIGH YEL CAN HI (J1939 CABLE 20)
A A
MS1000-1 B
C
MS1000-2

C
MS1001-1 B
YEL CAN HIGH YEL CAN HIGH YEL CAN HI (J1939 CABLE 20)
A A
GRN CAN LOW GRN CAN LOW
B MS1001-2
C C
B
A
MS1001-3 120 OHM
C
BLK 148-15-68 CLUTCH SWITCH
1 2 3 4 5
7-160 3121619
4 5 6 7 8
GLOW
GLOW PLUG SENSOR IGNITION PLUGS
FUSE FUSE
5A 10A
FC1003
FC1004
1
2
1
2
RL931-87
EC1010
1
1
RED EPDM 2/0AWG
FUSIBLE LINK 12AWG
FUSIBLE LINK 12AWG

RED EPDM 2/0AWG
RED EPDM 2/0AWG
RED 4AWG
G
150 A
EC971-B+
DEUTZ CONTROLLED
RED EPDM 2/0AWG
STARTER MOTOR
1
EC971
1
EC971-B-
1
X1008
BLK 000-148-2 1.5 K OHM
1
BLK 148-35-4 STRT REQ
2
BLK 148-35-3 STRT REQ BLK 148-35-2 STRT REQ BLK 148-35-2 STRT REQ
S1007 YEL CAN HIGH
GRN CAN LOW
F
SHLD SHIELD
SHLD SHIELD
X217B
1
2
MS999-1
3
4
A
B
C
5
6
7
8
MS999-2
MS999-3
C
C
B
A
B
A


YEL 2-48-2 IGNITION

BLK 000-48-2 ENG GND
B
X1005 C
YEL CAN HI (J1939 CABLE 20) YEL CAN HIGH
MS1000-3 1 1 M
GRN CAN LOW (J1939 CABLE 20) GRN CAN LOW
A 2 2 F
B
120 OHM SHLD SHIELD (J1939 CABLE 20)
3 3 J
D
C C X1006 K
GRN CAN LOW
MS1002-1 B G
YEL CAN HI (J1939 CABLE 20) YEL CAN HI (J1939 CABLE 20) YEL CAN HIGH
A A A H
GRN CAN LOW (J1939 CABLE 20) GRN CAN LOW (J1939 CABLE 20)
B B MS1002-2 L
SHLD SHIELD (J1939 CABLE 20) SHLD SHIELD (J1939 CABLE 20)
C C C E
MS1000-2 B D
A
120 OHM
MS1002-3

C
B
A
MS1001-2
C
B
A
MS1001-3 120 OHM
C
WIF SWITCH
1
2
SN959
EC958+
FUEL PUMP
1
EC958-
1
BLK 000-148-2
BLK 000-48-2 ENG GND
4 5 6 7 8
3121619 7-161
7-162 3121619
3121619 7-163
DEUTZ EMR4 91 WAY CONNECTOR (D2.2)
TIER 4 FINAL
WHT 148-15 CLUTCH SW

WHT 148-15 CLUTCH SW
DEUTZ TD3.6L
CYLINDER 1
WHT 64-35 INJCTR RTN (1.5mm²)
INJECTOR
WHT 45-40 INJCTR (1.5mm²)
CYLINDER 2
INJECTOR
CYLINDER 3
INJECTOR
CYLINDER 4
INJECTOR
WHT 25-20 MPROP (1.5mm²)
ACTUATOR
WHT 46-19 MPROP RTN (1.5mm²)
MPROP
BLK 99-13 CAM ENG SPD
ENGINE SPEED
WHT 100-14 CAM ENG SPD
CAMSHAFT DPF PRESSURE
WHT 75-S214 SHLD RTN SHLD S214-9
WIRE SHIELD DS DPF
S214 SHLD S214-1 AMBIENT AIR
WIRE SHIELD COOLANT LEVEL
BLK 101-21 CRK ENG SPD TEMP. SENSOR
ENGINE SPEED SENSOR
WHT 102-15 CRK ENG SPD
CRANKSHAFT
WHT 67-48 EXH GAS REC (1.5mm²)
EXHAUST GAS
WHT 2-47 EXH GAS REC (1.5mm²)
RECIRCULATION
WHT 18-50 5V
5 VOLT SUPPLY
WHT 76-51 GND RTN
GROUND
WHT 55-46 E GAS REC SIG
EXHAUST GAS SIGNAL
WHT 36-31 RAIL PRS FUL
FUEL
RAIL
PRESSURE
WHT 13-24 COOL TEMP
COOLING TEMPERATURE
WHT 74-28 BST PRS TEMP
BOOST
PRESSURE
TEMPERATURE
WHT 21-22 PRS RTN
GROUND
WHT 72-26 OIL PRS
OIL PRESSURE
WHT 35-27 TEMP/PRS RTN
GROUND
WHT 54-17 FUL LOW PRS
LOW FUEL PRESSURE
WHT 95-2 STRT SIG
START SIGNAL
WHT 94-3 STRT RTN
START RETURN
WHT 8-7 EGR TEMP
EGR TEMPERATURE BEHIND VENTURI
BLK 0-60-7-3
WHT 7-52 INTAKE THRTLE
AIR INTAKE
WHT 38-49 INTAKE THRTLE
THROTTLE
WHT 51-6 DELTA VNTRI
DELTA p VENTURI
DEUTZ ENGINE 62 WAY
CONNECTOR (X17)
DEUTZ DIAGNOSTIC
CONNECTOR
PLUGS
GLOW
DEUTZ
CAN BUSS
BLK 0-60-9-2 (1mm²) GROUND

IGNITION
CAN HIGH (DEUTZ TERM)

CAN LOW (DEUTZ TERM)
CAN HIGH (DEUTZ)

CAN LOW (DEUTZ)
X233
C
GRN CN L (DEUTZ)
B
YEL CN H (DEUTZ)
A
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
SN237*
SN236
2
1
3
4
2
1
3
4
DOSING UREA TANK NOx SENSOR NOx SENSOR

VALVE
UREA TANK HARNESS AFTER SCR CAT SCR CAT UREA TANK HARNESS
HEATING
SHEET #11 SHEET #11
VALVE
ZONE H-2 ZONE H-2/3
SCR EXHAUST GAS EXHAUST GAS
TEMPERATURE TEMPERATURE
(BEFORE SCR) (BEFORE OXY CAT)
7-164 3121619
FUEL PUMP
AUXILIARY AUXILIARY
RELAY
RELAY PUMP
WHT 48-95 FUL RLY 86

WHT 148-35-3 STRT REQ
ENGINE/AUX PUMP
BATTERY
BATTERY ISOLATOR
140 AMP
FUEL
PUMP
DPF PRESSURE
AMBIENT AIR DS DPF
TEMP. SENSOR
WATER IN
FUEL SWITCH
EMR4 IGNITION
GROUND
GENERATOR ENABLE
GLOW
GENERATOR POWER
GENERATOR GROUND
PLUGGED
PLUGGED
S285* IGNITION
START REQUEST
CAN HIGH CHANNEL #2
CAN LOW CHANNEL #2
ALTERNATOR EXCITE
CAN SHIELD
BLK 0-60-7-3
DEUTZ
120 AMP
DEUTZ DIAGNOSTIC
CONNECTOR
RELAY
PLUGS
GLOW PLUG
GLOW
DEUTZ
CAN BUSS DEUTZ
STARTER
ENGINE POWER
DISTRIBUTION MODULE
PULL DOWN RESISTOR
AIR INTAKE THROTTLE POWER

5 AMP FUSE
NOx SENSORS POWER
15 AMP FUSE
UREA SENSOR POWER
5 AMP FUSE
FUEL PUMP RELAY
25 AMP FUSE
SCR CONTROL POWER
30 AMP FUSE
RELAY, SUPPLY
MODULE HEATER
RELAY, HEATER 1
SUCTION LINE
RELAY, HEATER 2
THROTTLE LINE
RELAY, HEATER 3
PRESSURE LINE
RELAY, SCR CONTROL

S284
SYSTEM B+ ON BATTERY ISOLATER

BLK 0-60-9 (2.5mm²)
GROUND STUD
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
SN237*
SN236
2
1
3
4
2
1
3
4
UREA TANK NOx SENSOR NOx SENSOR

AFTER SCR CAT SCR CAT UREA TANK HARNESS BUSS BAR BUSS BAR
ENGINE TIER 4 FINAL

HEATING
SHEET #11 RELAY POWER ENGINE GROUND
VALVE
ZONE H-2/3
3121619 7-165
ENGINE HARNESS ENGINE HARNESS

SHEET #10 SHEET #10
ZONE A-2/3 ZONE A-4/5
AFTERTREATMENT SECTION
UREA TANK/ SUPPLY MODULE
LOCATED ON LEFT SIDE OF MACHINE
UREA QUALITY, 1 3
N6 CONNECTION LEVEL AND TEMP. SUCTION LINE PRESSURELINE
2
UREA PUMP HEATER HEATER
UREA PURGE VALVE THROTTLE LINE
SUPPLY MODULE HEATER HEATER
UREA PRESSURE AFTER PUMP
IP914
BLK BLK
S371
5A
7-166 3121619
3121619
12
WHT - CAN SHIELD
11
BLK - CAN LOW
10
RED - CAN HIGH
9
8
7
6
5
4
3
2
1
X201
RED - CAN HIGH

1
BLK - CAN LOW
WHT - CAN SHIELD

RED - CAN HIGH
BLK - CAN LOW
WHT - CAN SHIELD
RED - CAN HIGH

BLK - CAN LOW
1
2
WHT - CAN SHIELD
RED - CAN HIGH

X207
12
BLK - CAN LOW
WHT - CAN SHIELD
WHT - IGNITION
BLK - GROUND
RED - BEACON PWR
WHT - CAN SHIELD

BLK - CAN LOW
RED - CAN HIGH

RED - BATTERY
BLK - GROUND
S208
WHT - CAN SHIELD
BLK - CAN LOW
RED - CAN HIGH

BLK - GROUND
WHT - IGNITION S209
WHT - CAN SHIELD
BLK - CAN LOW
RED - CAN HIGH

BLK - GROUND
RED - BEACON PWR
RED - BATTERY
BLK - GROUND S219

WHT - IGNITION
BLK - GROUND

UREA TANK MODULE & CRIBBING
7-167
7-168 3121619
1850SJ ELECTRICAL SCHEMATIC
SHEET 2: PLATFORM BOX SHEET 9: OPTIONS

HARNESS, CONTROL BOX HARNESS, GENERATOR ENABLE
ELECTRICAL ASSEMBLY, CONSOLE BOX HARNESS, HEAD AND TAIL LIGHTS
SHEET 3: PLATFORM AND JIB COMPONENTS SHEET 10: ENGINE TIER 4 FINAL
HARNESS, PLATFORM VALVE HARNESS, ENGINE T4F BOOM
HARNESS, JIB VALVE CABLE, TURNTABLE BATTERY KIT
CABLE, POSITIVE BAT TO ENGINE
SHEET 4: TURNTABLE AND BOOM CABLE, GLOW PLUG (100A FUSED)
HARNESS, BLAM
CABLE, ALTERNATOR 150 AMP
CABLE, LOAD SENSING PIN
CABLE, BASE BOOM SENSOR SHEET 11: UREA TANK/ SUPPLY MODULE
HARNESS, BASE BOOM CRIBBING OPTION
HARNESS, BECON/STROBE ALERT BEACON OPTION
HARNESS, FUEL PUMP and WIF GEN 2 PLAT INTERFACE
CABLE, TURNTABLE BATTERY KIT HARNESS, UREA TANK
CABLE, AUX POWER POSITIVE HARNESS, CRIBBING
CABLE, AUX POWER NEGATIVE HARNESS, GEN 2 PLAT INTERFACE
ELECTRICAL INSTALL
SHEET 5: GROUND CONTROLS (UGM)
HARNESS, TURNTABLE
HARNESS, GROUND CONTROL PANEL
SHEET 6: CHASSIS
HARNESS, CHASSIS
CABLE, STEER
CABLE, M12 MTS CONNECTION
SHEET 7: HYDRAULIC VALVES
HARNESS, HYDRAULIC VAVLE BANK
HARNESS, DRIVE PUMP
SHEET 8: ENGINE
HARNESS, ENGINE T4i
HARNESS, CAN ENGINE
CABLE, ALTERNATOR POWER
CABLE, POSITIVE BATTERY
CABLE, NEGATIVE BATTERY
WIRE, GLOW FUSE
CABLE, GLOW PLUG
1001145974-K
MAF09010K
Figure 7-95. Electrical Schematic (SN 0300243455 to Present) - Sheet 1 of 21
3121619 7-169
F
B
C
A
G
H
7-170
R
R
15 POS MATE-N-LOCK
BCS
CONNECTOR IN CONSOLE BOX
FAILURE
PLTF LEVEL
CONNECT TO X38A
GD04-J1
[7,D]
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
WHT 47-1 FUL 1/4 FUEL 1/4
1
X38B
G
G
2
3
BLK 0-1 FUEL GND
AXLE SET
4
GENERATOR
BLK 0-1-2 SPARE14
BLK
BLK
BLK
[5,G] 5
WHT
WHT
WHT
WHT 47-4 FUL FULL FUEL FULL
WHT P8
WHT P8
6
YEL 2-7-1
ANALYZER
R
1
1
WHT 52-5 GEN

6
DRIVE
BOTTOM OF CONSOLE BOX

5
OVERLOAD
ORIENTATION
4 GD04-J2
GRN WHT 49-5 CREEP CREEP
3 1
1
2
3
4
WHT YEL 2-2 ENABLE ENABLE
FOOT SWITCH
2 2
X32
BLK WHT 47-5 LOW FUL LOW FUEL
MNTD ON PLTF FLOOR

1 3
N/C
SW54 4
N/C
5
500# MODE
1000# MODE
BLK 0-2 GROUND
6
SN53
BLK
2
WHT
*
R
R
WHT 49-7 TX
WHT 49-8 RX
1
LIMIT SWITCH
TILT
RH SOFT TOUCH
LED BOARD
CABLE
BROKEN
GD04-J3
PLATFORM DISPLAY
WHT 49-9 ANALPWR

WHT 49-6 ANALGND
WHT 49-4 BCS BCS
1
WHT 39-1 AXL SET AXLE SET
2
WHT 55-1 DRV ORNT DRIVE ORIENTATION
3
WHT 54-2 1000LB MODE 1000# MODE
Y
Y
SN52 4
BLK WHT 49-3 BRKN CABLE BROKEN CABLE
2 5
FAULT
SYSTEM
ENGINE
WHT WHT 47-2 SYS FAIL SYSTEM FAULT

PREHEAT
1 6
LIMIT SWITCH
LH SOFT TOUCH
G
G
SW51
6 GD04-J4
CREEP
ENABLE
WHT 47-1 PLTFM LVL FAIL PLATF LEVEL FAILURE

5 1
WHT 52-1 GEN GENERATOR
2
2
4 2
YEL 2-7-1 WHT 49-2 OVERLOAD OVERLOAD
3 3
WHT 52-5 GEN WHT 54-1 500LB MODE 500# MODE
2 4
TOGGLE SWITCH
GENERATOR (OPT)
WHT 49-1 TILT TILT
G
1 5
WHT 48-1 ENG PREHEAT ENGINE PREHEAT
6 6
WHT P3 SKYG INPUT #2
SPARE14
LOW FUEL
5
BLK P6 SKYG GND
2
WHT P1 SKYG INPUT #1
4
Y
G
G
G
X5B
WHT P2 SKYG PWR
1
[4,G]
[5,G]
[8,G]
[5,G]
[5,G]
[6,A]
WHT 3-13 SOFTT SENSE
3
TO SHEET 11
FUEL GAUGE
X5A
DRIVE & STEER
ELECTRONIC JOYSTICK
DRIVE LIFT & SWING
ELECTRONIC JOYSTICK WHT 48-1 ENG SPD
STEER 1
YEL 2-1-1
SWING LIFT 2
YEL 2-8
WHT P2 SKYG PWR
WHT 48-2 2 SPD
3
LEFT
WHT 55-6 DOS
RIGHT
YEL 2-1
4
HIGH DRIVE
TOGGLE SWITCH
5
6
SW15
S296
WHT 55-2 CRB STR
1
YEL 2-1-1
2
WHT 55-3 CRD STR
3
YEL 2-1-2
4
STEER MODE
YEL 2-8-1
5
TOGGLE SWITCH
3
3
YEL 2-7
YEL 2-8
YEL 2-6
WHT 59-6 JIB LOK
WHT 47-1 FUL 1/4
WHT 47-2 FUL 1/2
WHT 47-3 FUL 3/4
BLK 0-1
WHT 47-4 FUL FULL
WHT 49-5 CREEP
YEL 2-2 ENABLE
WHT 47-5 LOW FUL
BLK 0-2
WHT 49-4 BCS
WHT 39-1 AXL SET
WHT 55-1 DRV ORNT
WHT 49-3 BRKN CABLE
WHT 47-2 SYS FAIL
WHT 52-1 GEN
WHT 49-2 OVERLOAD
WHT 54-1 500LB MODE
WHT 49-1 TILT
WHT 49-21 SFTCH LT
WHT 55-6 DOS
WHT 59-2 JSWG LT
WHT 59-1 JSWG RT
SW16
BLK
BLK
BLU
BLU
RED
RED
BRN
BRN
GRN
WHT
WHT 25-1 PLVL UP
BLU/YEL
ORN/YEL
WHT/YEL
WHT/RED
WHT/GRN
1
YEL 2-1-2
2
WHT 25-2 PLVL DN
3
9
7
8
6
5
4
2
1
CO01-J2
33
32
34
31
26
28
29
27
22
24
23
25
35
21
18
19
14
30
13
10
20
15
11
12
17
16
3
YEL 2-1-3
4
5
TOGGLE SWITCH
PLATF LVL OVERRIDE
6
CO01-J5 SW17
GRN
2
GROUND
GROUND
BRN
3
SOFT TOUCH
ANALYZER TX
ANALYZER RX
BLK P6 SKYG GND RED WHT 39-2 AXL EXT
LIGHT SYSTEM
LEVEL FAILURE
FAILURE LIGHT
JIB LOCK LIGHT

JIB SWING LEFT
1 1
AXLE SET LIGHT

JIB SWING RIGHT
LOW FUEL LIGHT

LIGHT TILT LIGHT
IGNITION POWER
IGNITION POWER
IGNITION POWER
BLK 0-5 BLU YEL 2-1-3
LIGHT PLATFORM
OVERLOAD LIGHT
ENGIINE PREHEAT
ANALYZER POWER
1 6 2
LED PANEL POWER

CREEP MODE LIGHT
500 LB MODE LIGHT
DRIVE ORIENTATION
ANALYZER GROUND
GENERATOR ENABLE
BLK WHT 39-3 AXL RET
1000 LB MODE LIGHT

BROKEN CABLE LIGHT

AH30- 7 3
FUEL LEVEL FULL LIGHT

WHT 49-26 ALARM BLU/YEL YEL 2-1-4
1 8 4
PIEZO ALARM
DRIVE ORIENTATION LIGHT
ORN/YEL
AH30+ 4 5
TOGGLE SWITCH
WHT
BOOM CONTROL SYSTEM LIGHT

AXLE EXTEND/RETRACT
5 6
SW18
CO01-J6 SW08-1
BLU YEL 2-1-4
15 2 1
BLK YEL 2-1-5
14 7 SW08-2
HORN
WHT 3-13 SOFTT SENSE BRN WHT 52-2 HORN

13 3 1
PUSH BUTTON
12 4
RED
11 1
WHT/GRN
10 5
4
4
YEL 2-8-1 WHT/RED

6 8 SW10
WHT 49-27 WHT/YEL
5 6 1
4 2
YEL 2-8-1 YEL 2-1-5
9 CO01-J7 3
YEL 2-8-1 BLK 0-5 WHT 48-1 ENG SPD WHT 55-4 POT REF
8

Service and Maintenance Manual: Model 1850SJ

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Service and Maintenance Manual: Model 1850SJ

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Service and Maintenance Manual

May 27, 2019 - Rev K

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 18, 2014

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION NO. TITLE PAGE NO.

SECTION NO. TITLE PAGE NO.

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FIGURE NO. TITLE PAGE NO.

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FIGURE NO. TITLE PAGE NO.

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TABLE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

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Horizontal Reach over end

Swing Gearbox 3 qt. (2.8 L)

Horizontal Reach from centerline of rota-

1.5 ENGINE DATA 1.7 HYDRAULIC OIL

Type Turbo-charged Diesel Hydraulic System

Components LBS. KG. SAE Grade 10W30

ISO Viscosity Grade #32 Density 0.92 g/cm3

Table 1-13. Mobil SHC 46 Specs

Table 1-10. Mobil EAL H 46 Specs Type Synthetic Biodegradable

Type Synthetic Biodegradable ISO Viscosity Grade 46

Table 1-11. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Figure 1-1. Maintenance and Lubrication Diagram

1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox

NOTE: The following numbers correspond to those in Figure 1-1.,

Table 1-14. Lubrication Specifications

Lube Point(s) - Fill Plug

Lube Point(s) - 3 Grease Fitting Lube Point(s) - Level/Fill Plug

4. Hydraulic Return Filter 6. Hydraulic Charge Filter

Lube Point(s) - Replaceable Element

5. Hydraulic Tank Breather

Lube Point(s) - Replaceable Element

8. Hydraulic Oil 10. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap

Lube Point(s) - Replaceable Element

11. Fuel Filter - Deutz 13. Air Filter

Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element